emerson manual

1

NETSURE 702IC4 MANUAL

NetsureTM 702 IC4 DC Power System

User Manual

Emerson part No. Revision Revision Date

744802500600 00 Jan 3rd 2013

Copyright © 2009 by Emerson Network Power India Pvt. Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Homepage: www.emersonnetworkpower.com

Head Office:

EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED

Plot No. C-20, Road No. 19,

Wagle Industrial Estate

Thane – 400 604, Maharashtra, INDIA

Phone: (00 91 22) 33154400

Fax: (00 91 22) 25800829 / 25828358

http://www.emersonnetworkpower.com/

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Dear Customer,

Please accept our thanks for giving us the privilege to serve you by choosing Emerson make

‘702IC4 DCPS’.

If this is your first Emerson 702IC4 DCPS, we hope it is the beginning of a long relationship

which delivers value to your organization. If you already own and use Emerson Product, we

are doubly honored by your decision of continuing this relationship.

It is our constant endeavor to partner you for the growth and success of your Business. This

philosophy is reflected in our Mission statement “To deliver value through Air & Power Quality

solutions to achieve customer delight”. Please do give us feedback to help us realize our

Mission.

Emerson Network Power (India) Private Limited

3


IMPORTANT

This manual contains information concerning the installation, operation and Maintenance of the DC Power

System.

All relevant parts of the manual should be read prior to commencing installation.

The DCPS must be commissioned by an engineer approved by the manufacturer (or his agent) before being put into service. Failure to observe this condition will invalidate any implied warranty.

The DCPS has been designed for Telecom use only.

The DCPS has not been designed for direct use in any life support application. If you encounter any problem

with the procedures contained in this manual you should seek immediate assistance from Emerson Network

Power (India) Pvt. Ltd. Sales Office from whom the equipment was purchased. Alternatively contact the

Emerson Network Power (India) Pvt. Ltd Customer Service & Support department at the address shown

below:

EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED

Plot No. C-20, Road No. 19,

Wagle Industrial Estate

Thane (West) – 400 604,

Maharashtra, INDIA

Phone: (00 91 22) 33154400

Customer Care / Service Helpline Number:

Toll Free: 1800 209 6070

Chargeable: +91-22-66231200

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Safety Precautions

To reduce the chance of accident, please read the safety precautions very carefully before

operation. The "Caution, Notice, Warning, Danger" in this manual do not represent all the

safety points to be observed, and are only used as supplement to various operation safety

points. Therefore, the installation and operation personnel must be strictly trained and master

the correct operations and all the safety points before actual operation.

When operating Emerson products, the safety rules in the industry, the general safety points

and special safety instructions specified in this manual must be strictly observed.

Electrical Safety

I. Hazardous voltage

Some components of the power system carry hazardous voltage in operation; direct contact or

indirect contact through moist objects with these components will result in fatal injury.

Safety rules in the industry must be observed when installing the power system. The

installation personnel must be licensed to operate high voltage and AC power.In operation,

conductive objects such as watch, bracelet, bangle, ring, etc. are not allowed to be worn.

When water or moisture is found on the cabinet, turn off the power immediately. In moist

environment, precautions must be taken to keep moisture out of the power system.

"Prohibit" warning label must be attached to the switches and buttons which are not permitted

to be operated on during installation.

High voltage operation may cause fire and electric shock. The connection and wiring of AC

Cables must be in compliance with the local rules and regulations. Only those who are licensed

to operate high voltage and AC power can perform high voltage operations.

II. Tools

In high voltage and AC operation, special tools must be used. No common or self-carried tools

should be used.

Danger

Danger

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III. Thunderstorm

Never operate on high voltage, AC, iron tower or mast on a day with thunderstorm. In

thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the

equipment should be well earthed in time to avoid damage by lightning strikes.

IV. ESD

The static electricity generated by the human body will damage the static sensitive elements on

PCBs, such as large-scale ICs, etc. Before touching any plug-in board, PCB or IC chip, ESD

wrist strap must be worn to prevent body static from damaging the sensitive elements. The

other end of the ESD wrist strap must be well earthed.

V. Short-circuit

During operation, never short the positive and negative poles of the DC distribution unit of the

system or the non-earthing pole and the earth. The power system is constant voltage DC power

equipment; short circuit will result in equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when performing DC live

operations.

As the operation space in the DC distribution unit is very tight, please carefully select the

operation space.

Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.

Insulated tools must be used.

In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free

journey of the human body and tool is reduced to a minimum

Danger

Notice

Danger

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Revision history details of 744802500600_00- “User Manual

For- Netsure 702 IC4”

[Following is the reference revision history summary of all the revisions made in User Manual

for- Netsure 702 IC4 Power System].

Revision

No.

Revision

Description

Prepared by

Reviewed By

Approved

by

Date

00 Initial Engg TJ DD 03-01-2013

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Contents

Chapter 1 Introduction 8

1.1 Features 8

1.2 Operation Theory 8

Chapter 2 System Configuration 10

2.1 System Configuration 10

Chapter 3 Units in the System 15

3.1 R48-4000e Rectifier 15

3.2 SCU M523S CONTROLLER 18

3.3 Operation Panel of the Controller 19

Chapter- 4 Battery Reverse Protection & Discharge Alarm Board 33

Chapter 5 PAU Protocol Converter 38

Chapter 6 System Specifications & general Requirements 42

6.1 Technical Specifications 42

6.2 Guideline for earthing Earthing 43

6.3 System Input And Output Recomanded Connections 43

6.4 Recommanded Torque 43

6.5 List of Recommanded Spares 43

Chapter 7 Installation Preparation 44

7.1Installation Requirements 44

7.2 Layout Requirements Of The Equipment Room 44

Power Supply 46

7.3 Safety Protection 46

Figure 5-4 Diagram of SPD mounting & system earthing 47

7.4 Equipment Running Environment Checklist 47

Table 5-3 (Equipment running environment checklist) 47

7.5 Storage Conditions 48

Chapter 8 Electrical Schematic 49

8.2 Flow Chart For M523S 56

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Chapter 1 Introduction

NETSURE 702 IC4 Power system consists of R48-4000W rectifiers, Standard Controller Unit (M523S) ,AC distribution and DC distribution, which consist of distribution unit for load and battery. The Load distribution and Battery Distribution units can be designed as per users requirement.

This system is used as a power supply for telecom equipment with system nominal voltage of -48V and positive terminal earthed.

1.1 Features

The power system is easy-to-operate/install/maintain. Its main features are:

Rectifier uses APFC technology and therefore its power factor is up to 0.99;

Wide AC input voltage range of 85~290V;

Rectifier efficiency is >94% at the peak

Rectifiers compliant with UL, CE and NEBS standards;

True hot pluggable, the replacement time is less than 1min;

Perfect battery management with BLVD function;

Up to 200 nos of historical alarms;

Provide RS232, Modem and dry contacts communication interfaces.

1.2 Operation Theory

The basic operating theory of power system is shown in the following figure:

Figure 1-1 Basic operation theory diagram

AC mains inputs rectifiers through AC input terminals and rectifiers breakers. (The rectifiers output to the priority load or to non-priority load through a LLVD, and output terminals of rectifiers connect with batteries). Batteries connect to the loads through BLVD contactor.

The monitoring unit collects the working states of each part of the system and generates alarm to alert users.

AC Input Terminals

C Class SPD

Rectifier AC Breakers

Rectifiers

Back Board Control Unit

Prior Load

LLVD

(Optional)

Non Prior Load

BLVD

Battery 1

Battery n

Power cable

Signal cable

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1.2.1 Lightning Protection

Netsure 702 IC4 Power System has perfect lightning protection on input side, as shown in the following figure:

Figure 1-2 AC lightning protection

A built-in II/C Surge Protection Devices (SPDs) is installed in the system, while each rectifier is

designed with perfect lightning protection circuits. The whole system can withstand 8/20 s

surge current 20kA for 5 times, or 8/20 s surge current 40kA once. To further protect the system, Class I/B SPD which comes as optional item (with through current capacity of at least 50kA) can be installed close to the main AC distribution board.

1.2.2 LLVD and BLVD

Batteries will start discharging to power loads once the AC mains fails. When the battery voltage reaches to 45V (low voltage point, adjustable), the system will raise audible/visual alarms. When the battery voltage continues dropping to 44.0V (LLVD point, adjustable), the LLVD contactor will act to cut off power supply to non-priority loads (such as local exchange) so as to ensure power supply to priority loads (such as transmission equipment).

As the discharge goes on, when the battery voltage drops to 43.2V (BLVD point, adjustable), the BLVD contactor will act to cut off the connection between the batteries and the system, stopping the power output and protecting the batteries. When AC mains recover, rectifiers will resume outputs, LLVD & BLVD contactors will close automatically, and the system will restore to normal operation.

1.2.3 Alarm And Protection

Based on the real-time data collected by the monitoring module, the system can detect the states of output breakers, battery breakers and class II/C SPD. User can set the severity level of faults such as AC input over/under-voltage, DC output over/under-voltage, etc. so as to raise audible/visual alarms upon designated faults. User can also set alarm types of alarm dry contacts.

AC Input

Rectifier

Rectifier

Rectifier

AC power distribution

unit

DC power distribution

unit

Monitoring unit

Battery group

1/2

I/B SPD

DC SPDII/C

SPD

MODEM

RJ11 SPD

£ 48V Output

RS232

RJ11

5~10m

PSTN

Remote monitoring host

Note:

I, II, III are based on IEC standard

B, C, D are based on German VDE standard

DINVED0675-6: 1989-11 (draft)

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Chapter 2 System Configuration

2.1 System Configuration

The typical outline of Cabinet of NETSURE 702 IC4 is illustrated in Figure 2-1:

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12


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14


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Chapter 3 Units in the System

3.1 R48-4000e Rectifier

R 48 – 4000 e

Figure 1-1: Model Number

3.1.1 Form and Interface

There are 3 indicators on the front panel. The location of the indicators is

shown in Figure 1-3.

Figure 1-3: Front Panel

The functions of the indicators are listed in Table 1-1.

Table 1-1: Function of Indicators

Indicator Normal state Fault state Fault cause

Power indicator

(Green) On

Off No input and output

Flashing The rectifier is being operated through the host.

Protection indicator

(Yellow) Off

On

AC input under/over-voltage, rectifier PFC output

under/over-voltage, high-temperature, or current

sharing imbalance

Flashing Rectifier communication failure

Fault indicator

(Red) Off

On Output over-voltage, output fuse blown, or rectifier

addresses contradictory

Flashing Faulty fan

3.1.2 Main Functions and Features

1. Hot Swappable

The rectifier is designed to be plug-and-play. There will be no arcing and the terminals will not be damaged when inserting/removing the rectifier from a live DC power system. A rectifier can be replaced in less than 1 minute and the inrush current will be no larger than 150% of the rated input steady-state peak value.

When the rectifier is plugged into the system, the system output voltage will not be affected.

HIGH EFFICIENCY

4000 W OUTPUT POWER

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2. Active Load Sharing The rectifier uses advanced digital active load sharing technology that maintains

balancing to within 2A.

3. Output Characteristics

The relationship between output voltage and current is summarized in below table and depicted graphically in Figure 1-9.

Output Power Output Current Output Voltage

4000 W 69 A 58Vdc

4000 W 83.34A 48Vdc

Figure 1-9: Output Characteristics

4. Current Limit Function

The rectifier has current limit function. The current limit point can be set between the range of 6 to 72.9A. The setting is done using the SCU.The current limit accuracy is

≤ 2A when the output voltage ranges from 42 to 58.5 V, and 3A for output voltages

ranges from 30 to 42 V, 5A for output voltages below 30V.

5. Adjustable Output Voltage

The output voltage can be set through the SCU within the range of 42 V to 58V. The

accuracy is 0.1V.

6. Fan Control

When the input voltage is within a normal range, the built-in processor adjusts the fan’s speed according to the rectifier’s internal temperature and Load. For example, a

higher temperature and load will increase the fan speed. Above 45 C with full load, the fan will be operating at full speed.

When the input voltage is abnormal, such as very low or high input voltage, the fan will turn off.

7. Input Over/Under Voltage Protection

The rectifier will shut down and its protection indicator (yellow) will light up when the input voltage is lower than 85Vac or higher than 300Vac. This condition will be reported to the SCU and the SCU will process the alarms accordingly.

8. Output over Voltage Protection (HVSD)

There are two kinds of HVSD:

a. The fixed hardware HVSD is 59.5V (within the range of 59 to 60V), In case of hardware HVSD; the rectifier has to be restarted manually.

0

10

20

30

40

50

60

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85

Ou

tpu

t V

olt

ag

e (

V)

For R48-4000e Output Current (A)

R48-4000e Output voltage v.s. Output current at max. Power 4000W

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b. The software HVSD is settable; its level (from controller) is from 56V to 59V.

The rectifier will shut down when its output voltage is higher than HVSD set point. Note that the HVSD set point can be modified through the SCU and the permissible range is from 56 V to 59 V. The occurrence of a HVSD condition will cause the rectifier’s alarm indicator (red) to light up. The failure information will be reported to the SCU and the SCU will process the failure accordingly. Note also that the rectifier can only be restarted manually should a HVSD condition occur twice within a 5-minute interval.

The rectifier also has two additional software settings that can be configured using the SCU:

Manual restart and Automatic restart attempt should be within 5 seconds of a HVSD condition.

9. High Temperature Protection

The rectifier will shut down and its protection indicator(yellow) will light up when its

internal temperature becomes higher than 90 C. The causes for the high temperature condition may be that the ventilation openings are obstructed, the ambient temperature is too high, or the rectifier fan has failed.The failure information will be reported to the CSU and the CSU will process the failure accordingly. The high temperature alarm will clear and the rectifier restored to normal operation when its

internal temperature returns to normal values (hysteresis is between 5 to10 C).

10. Communication Failure

The rectifier’s protection indicator (yellow) will flash should it experience a communication failure. The failure information will be reported to the SCU and the SCU will process the failure accordingly. During a communication failure, in order to protect the battery, the rectifier output voltage will automatically adjust to 53.5 V (this is a default value which can be modified using the SCU). The rectifier will revert to normal operation once normal communication is restored.

11. Fan Fault Protection

An alarm will be generated upon a fan fault. In such cases, the fault indicator (red) on the rectifier front panel will flash and the rectifier will also inhibit its output. Auto-recovery is enabled upon the clearing of the corresponding fault.

12. Unbalance of Rectifier Output Current

When the output current of the rectifiers in a DC power system is unbalanced, the rectifier whose output current is unbalanced will be identified automatically and its protection indicator (yellow) will light up. The failure information will be reported to the SCU and the SCU will process the failure accordingly.

3.1.3 Specifications

1. Environmental Operating temperature: -40 to 75 C

Full rated output power of 4000 W for temperatures -20 to 50 C.

Power limitation for temperatures higher than 45 C.

Relative humidity: up to 90% RH

Elevation: 2000 m (power limited for heights above 2000 m)

2. Input

Input voltage: 85 to 300 Vac, single-phase three-wire

Maximum non-destructive input voltage when rectifier is not operating: 415 Vac

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Rated input voltage: 207 to 250 Vac

Input current: <22A @ 4000 W, and at an input voltage of 176 Vac

Inrush current: less than150% of the rated input steady-state peak value

Allowable input power frequency: 45-65 Hz

Rated input power frequency: 50/60 Hz

3. Output

Output voltage: 42 to 58 V

Output DC current: 0 to 73 A

Voltage regulation: ≤ 1%

Load regulation: ≤ 0.5%

Line regulation: ≤ 0.1%

Overshoot at startup: ≤ 1%

Power factor >0.98 (50% to 100% load)

Efficiency > 95%(50% load at Nominal Voltage)

Ripple ≤200mV at 0-20MHZ

Acostic Nosie 50db

4. Dimensions

132.5 mm (Height) X 88 mm (Width) X 293 mm (Depth)

5. Weight

Under 3.5 kg

3.2 SCU M523S CONTROLLER

3.2.1 Dimensions and Structure

The appearance of the Controller M523S is shown as Figure 1-1,

Figure 1-1 Appearance of M523S Controller 3.2.2 Main Functions

3.2.2.1 Different Authorities Protected by Different Password Levels

The Controller has 2 passwords of different operation authority: user level

password and engineer level password. The two passwords have the same

authority for “control output”. But during the setting of “system parameters”

under “parameter setting”, the parameters for the setting and the operation

functions are different. The engineer level password will have more operation

authorities than the user level password, including “reset system, reset

password, change system type”.

ESC

ENT

Run indicator

Alarm indicator

Critical alarm indicator

Functional keys

LCD

19


The passwords and the relevant authorities are listed as follows

3.3 Operation Panel of the Controller

There are backlit LCD display, functional keypad, indicators and positioning pin on

the front panel of M523S monitoring module, as shown in the following figure:

Figure 2-1 Front Panel of M523S Controller

The description of the LED indicators on the front panel is shown as the following

table.

Indicator Normal Status Abnormal Status Abnormal cause

Running indicator

(green) On Off

The power system has no power

supply.

Alarm indicator

(yellow) Off On

The power system has an

observation alarm.

Critical alarm

indicator (yellow) Off On

The power system has a major

alarm or critical alarm.

The M523S Controller uses a 128×64 LCD unit and has 6 functional keys. The

Functions of the 6 functional keys of the Controller are shown in the following table.

Key Function

ESC Return to the upper level menu

ENT Enter the main menu or confirm the menu operation

“▲” and “▼” Shift among parallel menus. For a character string, these 2 keys can be

used to shift among different options

““ and

““

Change values at a value setting interface. For a character string, these 2

keys can move the cursor left or right

ESC

ENT

Run indicator

Alarm indicator

Critical alarm indicator

Functional keys

LCD

Password level Operation authority Default password

User Configuration of general parameters 123456

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3.3.1 Power-on Sequence

After the system is powered on for the first time, you should set the system type

according to the actual configuration. The monitoring module will restart after the

system type is changed. In that case, you should re-configure those parameters

whose default values are inconsistent with the actual situation. Only after that can the

monitoring module operate normally.

After configuring the system parameters, you can carry out various operations directly

without resetting the parameter values. As for those important parameters related to

battery management, such as BLVD, you should be fully aware of their influence upon

the system before you change their values.

1. The LCD will prompt you to select a language once the monitoring module

is powered on.

You can use “◄”, “►”, “▲” or “▼” to select the language you want, and press

“ENT” to confirm.

2. The monitoring module will prompt you to wait, and start initialization.

3. The first system information page appears

The system information is shown in many pages. You can repeatedly press

“▼” to view other system information pages in a cycle.

4. At any system information page, press “ESC” to enter the help page, which

displays software version (SW), product code (PC), product reversion (PR)

and serial number (SS).

English

English

▼

自动均充

Waiting…

▼

2004-5-12

53.5V 125A

System:No Alarm

Auto /BC ▼

自动均充

SW: V1.20

PC: 1M502D

PR: A00

SS: 01051200012

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5. At any system information page, press “ENT” to enter the “MAIN MENU”

page, which contains 3 sub-menus: “Status”, “Maintenance” and “Settings”.

You can press “▲” or “▼” repeatedly to select a sub-menu, and press “ENT”

to enter the sub-menu. Press “ESC” to return to the menu of higher level.

1)

Status Including rectifier information, active alarm information and alarm history information

2) Maintenance The maintenance operation can be conducted only when the battery management

mode is set to “Manual”. The maintenance includes battery FC, BC and test, load power

off/on, battery power off/on and rectifier voltage trimming, current limit, switch control

and resetting

3) Settings Includes the setting of alarm parameter, battery parameter, AC/DC parameter, rectifier

parameter, system parameter and communication settings

4) Energy

Saving Includes the setting of cyc period, rectifier work and rectifier limit

when the save option is enabled.

Display

The root screen displays the system voltage, load

current, alarm status and system mode of

operation. Press “▼” or “ ” to view other rectifier

information

The other information consist of battery voltage,

battery capacity, battery current, save status,

rectifier o/p power, batt. Cyc boost charge after, AC

voltage, percentage load, battery temperature &

ambient temperature

Main Menu – Press “ENT” to go to main Menu

Status Displays the rectifier information, active alarm

information and alarm history information

Rectifier

Rectifier information like serial number of the

rectifier, the output voltage, output current, the

AC/DC switch status, the AC input voltage. Current

limiting threshold, the AC-limited power status, the

temperature-limited power status.

Active Alarm

Press “ENT”, use the “ ▼” or “ ” key to select the

“active alarm” and press the “ENT” screen to

confirm and run the active alarm information

MAINMENU

Status

Settings

Maintenance

Energy Saving

Fast settings

22


screen.

If there is no alarm, the screen will display “no

active alarm”.

The alarm sequence number, the alarm level, the

alarm name and the alarm time (including the year,

month, day, hour, minute, and second).

The display sequence will follow the sequence of

the occurring time of the alarms. The latest alarm

will be displayed as the first one. The user can use

the “ ▼” or “ ” key to view all the active alarm

information

Alarm History

Press “ENT”, use the “▼” or “ ” key to select the

“alarm history” and press the “ENT” screen to

confirm and run the alarm history information

screen.

If there is no alarm history, the system cannot enter

the lower level menu

Up to 200 pieces of alarm records can be stored. If

there are more than 200 pieces of records, the

earliest records will be cleared automatically.

On the Controller, only the following information

about the alarm history will be displayed: alarm

sequence number, alarm name, alarm occurrence

and ending time (including year, month, day, hour,

minute and second).

Maintenance

When the system battery management adopts the

auto mode, no control output operation can be

conducted

When the system battery management adopts the

manual mode, the user can conduct control output

operation, including battery boost charge, float

charge and test, LLVD power on/off, BLVD power

on/off and rectifier voltage adjustment, current

limiting and DC on/off, AC on/off and reset control

Press the “ENT” key to select the “Maintenance”

menu.

When the “battery management” is set as “manual”,

the user can manually control the battery under the

system control output menu. If the system “battery

management” is in “auto” state, the user cannot

enter into the system control output menu

Press the “ENT” key, input the correct operation

password on the pop up display screen

Press “ENT” key again, and then the user can enter

into the “control output” menu

When inputting the password, user “▼” or “ ” key

to modify the number and

23


“ “Or “ “to shift left or right. After the modification,

press “ENT” key to confirm

Settings

Includes the setting of the alarm, battery, AC/DC,

rectifier, system and communication parameter

Press “ENT”, Use the “▼” or “ ” key to select the

parameter “setting” and press “ENT” to confirm.

The system prompts to enter password.

Press the “▼” or “ ” key to input the correct

password number for each digit, press the “ENT”

key to confirm and enter into the parameter setting

submenu screen.

Alarm Setting

No. Alarm Description Alarm level Related relay

Related

parameter

1 SPD Fault SPD failure Major None -

2

DI

Defined the alarm

name by user, at

most 10 letters. In

this system, eight

DIs can be defined.

Among which, the

first DI is defined as

SPD Fault, the

remained seven DI

can be defined freely

No alarm None -

3 AC Voltage High AC input voltage

higher than the

setting of ‘AC input

over- voltage alarm

point’

Major None Over- voltage

alarm

4 Over- voltage alarm AC input voltage

lower than the

setting of ‘AC input

under- voltage alarm

point’

Major None Low- voltage

alarm

5 Mains Failure All the AC input

voltages from the

rectifier are less than

80V

Critical 1 -

6 DC Volt High DC Volt High Major 2 Over- voltage

alarm

7 DC Volt Low DC output voltage

lower than the

setting of ‘DC output

low- voltage alarm

point’

Major 2 Low- voltage

alarm

8 DC Volt Under DC output voltage

lower than the

setting of ‘DC output

under- voltage alarm

point’

No alarm None Under- voltage

alarm

24


9 Batt Over Temp Battery temperature

higher than the

setting of Temp

Critical None Over Temp alarm

point

10 Batt Temp High Alarm Battery temperature

higher than the

setting of Temp

Observation None High Temp alarm

point

11 Batt Temp Low Alarm Battery temperature

lower than the

setting of Temp

Observation None Low Temp alarm

point

12 Ambient Temp High

Alarm

Ambient

temperature higher

than the setting of

Temp

Observation None High Temp alarm

point

13 Ambient Temp Low

Alarm

Ambient

temperature lower

than the setting of

Temp

Observation None Low Temp alarm

point

14

T1 No Probe

Configured with

temperature sensor

1 but not connected Major None -

15

T2 No Probe

Configured with

temperature sensor

2 but not connected Major None -

16

Sensor 1 Fault

Temperature sensor

1 measures

unreasonable

temperature Major None -

17

Sensor 2 Fault

Temperature sensor

2 measures

unreasonable

temperature Major None -

18 LLVD enabled Load low voltage

disconnects Major 5 LLVD enabled

19 LVD 2

Battery low voltage

disconnects Major 4 BLVD enabled

20

Load Fuse Alarm 1 ~ 9

Load failure caused

by overload, short

circuit, manual

disconnect, and

alarm circuit failure Major None -

21 Aux Load Fails

The last load fuse

failure Major None -

22

Batt Fuse Alarm 1 ~ 4

Battery failure

caused by overload,

short circuit, manual

disconnect, and

alarm circuit failure Major None -

23

Batt 1 Curr High

Charging current of

battery string 1

higher than the

setting of ‘Over’

(Charging over Observation None

Over (over

current point)

25


current limit)

24

Batt 2 Curr High

Battery failure

caused by overload,

short circuit, manual

disconnect, and

alarm circuit failure Observation None

Over (over

current point)

25

Rect AC Fail

AC input voltage of

this rectifier lower

than low- voltage

alarm point Critical 3 -

26

Rect Over Temp

The internal

temperature of the

rectifier is higher

than 90° Observation 3 -

27

Rect Failure

The rectifier voltage

is higher than upper

limit voltage Major 3 -

28

Rect Protect

Rectifier performs

self- protection and

has no output Observation 3 -

29 Rect Fan Fails Rectifier fan fails Critical 3 -

30 Rect Derated

Rectifier limits its

output power Observation 3 -

31

Rect Not Respond

Rectifier does not

communicate with

the monitoring

module Critical 3 -

32 HVSD

Rectifier shut down

under high voltage 3 -

33 Multi-Rect Alarm

More than two

rectifiers alarm Major None -

34 Self-detect Err

Hardware Self-

detect Error No alarm None -

35

Manual Mode

Battery management

is in manual control

mode No alarm None -

36 Non Float Status

Battery is not under

float status No alarm None -

37 Batt Discharge

Battery is

discharging No alarm None -

38

Load share Alarm

In the system with

load current shunt,

the sampled load

current plus battery

current differs

greatly from rectifier

current No alarm 3 -

39

Batt Test Fail

Battery discharging

time shorter than

expected Observation None -

40 Short Test Fail

In short test, battery

discharging capacity Observation None -

26


is bigger than setting

value

41

Volt Discrepancy

Actual output

voltage is different

from both the

measured DC bus

voltage and different

from the voltage

reported by the

rectifier to

monitoring module.

The error is bigger

than 1V Observation None -

42 Maintain Alarm

Time to maintain

system Observation None -

43

Save Power

The system is

running under

energy saving status No alarm None

44

DCEM fail

Communication

failure with the

DCEM PCB Major 6

45 Batt Symm Fail

Failure of battery

symmetry function Major 2

Alarm Mode

Parameter Name Setting Range Default Value Value Description

Alarm Type 44 names of alarm

events

Alarms of different

types have different

levels and different

Relate Relays

Select those alarm

events whose levels

and relate relays

should be reset

Alarm Type Level

Level Critical, Major,

Observation, None

There are different

audible/visual alarm

modes and callback

modes for alarm

events of different

levels

Relay

Related Relay

Empty, No.1 ~ 6 “Empty”: The

corresponding dry

contact will not

output alarm

information upon an

alarm event

No. 1 ~ 6”: There will

be a dry contact in

the range of No.1 ~ 6

that outputs the

alarm information

upon an alarm event DI No

DI No. No. 1 ~ 2 1 The 8 corresponding

connecting

terminals, queued up

in the order that the

hardware switches

27


are put

Alarm Mode High, Low Low

“High”: alarm upon

high level;

Alarm Mode “Low”: alarm upon

low level.

Set according to the

actual situation

DI Name

Figures or letters, 10

at most

SPD When there are DI

alarms, this

parameter shows the

alarm name you

have actually defined

DI Name

Alarm Control


Voice sign open, off, 3 minutes,

10 minutes, 1 hour, 4

hours

Normally on Launch alarm

beeping duration

control

Clear alarm history Yes, No No When the value

“yes” is selected,

clear the alarm

history information

Battery Settings


Mgmt Mode

Auto, Manual Auto

In the Auto mode, you can

manage the system

through the monitoring

module

(Management mode) In the Manual mode, you

can manage the system

manually, as well as

calculate battery BC time

protection and capacity

automatically. Upon the

system DC under-voltage

alarm, system can

automatically switch to the

Auto mode

Batt String (number of

battery strings)

0 ~ 4 2

Rated AH (rated capacity) 50 ~ 5000Ah 600Ah The capacity of a single

battery string. You should

set this parameter

according to the actual

battery configuration

Batt Shunt1 Yes, No Yes You can set the shunt

parameters when the

“system type” is SET.

Batt Shunt2 Yes, No No

Shunt co-eff current 1-5000A 300A

Shunt co-eff Volt 1-500mV 50mV

LVD

28



LVD1 Enable

Y, N Y

Select “Y” to enable LLVD

function

LVD2 Enable Select “Y” to disable the

BLVD function

LVD1 Volt

40V ~ 60V

44.0V If selecting the “According

to voltage”, then the LVD

contactor shall operate

according to the voltage

LVD2 Volt 43.2V If selecting the “According

to time”, then the LVD

contactor shall operate

according to time.

Charge


Float

42V ~ 58V

53.5V In the FC state, all

rectifiers output

voltage according to

the set “Float”

The “Boost” must be

higher than the

“Float”

Boost 56.4V In the BC state, all

rectifiers output

voltage according to

the set “Boost”

Limit (current limit) 0.1 ~ 0.25C10

0.1C10

When the monitoring module detects that the

battery charging current is higher than the

“Limit”, it will control the current of the

rectifiers, through which it can limit the

battery charging current

Over (over current

point)

0.3C10 ~ 1.0C10 0.3C10 C10 is the battery rated capacity, generally

set to 10 ~ 20% of the rated capacity of one

battery string

Automatic Boost

Enable Y, N Y Select ‘Y’ to enable this function

Select ‘N’ to disable this function

Automatic Boost

Current 0.050C10 ~ 0.080C10 0.06C10

The monitoring module will control the

system enter the BC state when the battery

capacity decreases to the value of To Boost

Capacity, or when the charge current

reaches the To Boost Current. The charge

voltage will be the Boost

Automatic Boost Cap 10% ~ 99% 80%

Const Boost Current 0.002C10 ~ 0.02C10 0.01C10 The system in the BC state will enter the FC

state when the charge current decreases to

the Constant BC Curr and after the Duration.

The battery charge voltage then will be the

Float

Const Boost Time 30min ~ 1440min 180min

Cyclic Boost Enable Y, N Y Select ‘Y’ to enable this function

Select ‘N’ to disable this function

Cyclic Boost Period 48h ~ 8760h 2400h Select ‘Y’, and the monitoring module will control the system to enter the Cyclic Boost when the FC time reaches the Cyclic Boost Interval. The battery charging voltage is the preset Boost, and the time is the preset

Cyclic Boost Time 30min ~ 2880min 720min

29


Cyclic Boost Time

Boost Limit Time 60min ~ 2880min 1080min

To ensure safety, the monitoring module will

forcefully control the system to enter the FC

state if during the BC state, the BC time

reaches the Boost Limit, or abnormalities

occur (such as AC failure, battery route

faulty, and rectifier communication failure)

Battery Test Parameters

Parameter Range Factory setting Value description

End Test Volt 43.1V ~ 57.9V 45.2V The monitoring module will stop the test and

change to FC if the battery voltage reaches

the Battery Test Voltage, or the discharge

time reaches Battery Test Time, or the

battery capacity reaches Test End Cap

End Test Time 5min ~ 1440min 300min

End Test Cap 0.01C10 ~ 0.95C10 0.7C10

Cyc Test En Y, N Y Select ‘Y’ to enable this function

Cyc Test Time Month, day, time

01-01-00:00 When the parameter Cyc Test En is set to Y,

the monitoring module will test the battery

according to the 4 sets of test time

04-01-00:00

07-01-00:00

10-01-00:00

Short Test Enable Y, N Y Whether using Short Test function

Short Test Alarm 1A ~ 100A 10A

If the battery is not discharged within the ShortTest Cycle, the monitoring module will start a short test, whose operation time is set by the parameter ShortTest Duration. By the end of the test, if the difference in the discharge currents of batteries is bigger than the Alarm Current, the battery discharge imbalance alarm will be raised. This alarm will automatically end after 5min of delay. Also you can end it by confirming it

Stable Test Current 0 ~ 9999A 9999A

Temperature Compensation Co-efficient parameters


Center Temp 10°C ~ 40°C 25°C

Coeff 0 ~ 500mV/°C 72mV/°C/str (48Vdc)

36mV/°C/str (24V dc)

Upon alarms such as Rect Not Respond, DC

Volt High, DC Volt Low and Batt Fuse Alarm,

the monitoring module will not do

temperature compensation to the battery FC

voltage

Temp1

Ambient Temp,

None, Battery Temp None

Ambient Temp refer to the measurement of

the ambient temperature sensor at the local

power system.

Temp2 Battery Temp refer to the measurement of

the battery temperature sensor at the local

power system.

None means there is no measurement input

Batt T H1 -40°C ~ 100°C 50°C When the detected battery temperature is

higher than Batt T H1, the monitoring module

will raise an alarm

Batt T L1 -40°C ~ 100°C 0°C The monitoring module will raise an alarm

when the detected battery temperature is

lower than Batt T L1

AC Settings

30



Over Volt 50V ~ 300V 280V The monitoring module will raise an alarm

when the AC input voltage is higher than the

Over Volt

Low Volt 50V ~ 300V 170V The monitoring module will raise an alarm

when the AC input voltage is lower than the

Low Volt. The value of the Low Volt must

lower than that of the Over Volt

Under Volt 50V ~ 300V 80V Setting according to actual requirement

AC In Auto, No, Manual No Setting according to the AC input mode of AC

sampling board. Choose ‘No’ if the AC

sampling board is not configured

AC PH 1-PH, 3-PH

3-PH

Setting according to the actual configuration.

Choose ‘1-PH’ and ‘3-PH’ if the AC sampling

board is configured

DC Settings


Over Volt

40V ~ 60V

58.5V The DC Over

Voltage alarm will be

raised when the

system DC output

voltage is higher

than the value of

Over Volt

The values of these

three parameters

should be: Over Volt

> Low Volt 1 > Low

Volt 2

Low Volt 1 45.0V The DC low voltage

alarm will be raised

when the system DC

output voltage is

lower than the value

of Low Volt 1

Low Volt 2 45.0V The DC under

voltage alarm will be

raised when the

system DC output

voltage is lower than

the value of Low Volt

2

L-Shunt Y, N N Setting according to the actual instance

Shunt Coeff Current 1A ~ 5000A 500A They can be reset when the shunt options are ‘SET’ in the system with load shunt. Shunt Coeff Volt 1mV ~ 500mV 75mV

Rectifier Parameters Parameter Range Factory setting Value description

Position En Y, N Y

‘Y’: The monitoring module will prompt you to set rectifier position before the rectifier and monitoring module are powered on. ‘N’: You need not to set rectifier position

R-Posi 1 ~ 30 -

R-Posi: represented in two figures, the first figure represents the rectifier number, the next figure reprents position number. Press ENT to select the rectifier, press ◄ or ► to change position number. When the monitoring module communicates with the rectifier, the green indicator on the corresponding rectifier will blink

HVSD 56V ~ 59V 59V The rectifier over voltage alarm will be raised

31


when the rectifier output voltage is higher than the HVSD voltage

Default V 48V ~ 58V 53.5V Default output voltage when communication interrupted. Must be lower than the HVSD voltage

Walk-in On Y, N N The output soft start function means the rectifier voltage will rise from 0V to the Default Volt after the Walk-in time

Walk-in 8s ~ 128s 8s

Interval T 0s ~ 10s 0s The monitoring module can set the DCDC Interval Start of the modules. Start time = module address * interval time

AC OverV On Y, N N

The monitoring module can set the rectifier to OverVolt Enable, meanwhile, the rectifier can start forcibly. The monitoring module will set automatically the rectifier with least address to have this function. If the rectifier always exceeds the normal voltage for 60s, the function will be canceled automatically

ACCurrLim 1A ~ 50A 30A The monitoring module limits the input current of the rectifier in the AC current limiting.

Communication Parameter Parameter Range Factory setting Value description

Address 1 ~ 254

1 The addresses of power systems that are at the same monitored office should be different

Comm Mode MODEM RS232 The system only supports RS232 mode communication

BaudRate 1200bps ~ 9600bps 9600bps Make sure the baud rates of both the sending and receiving parties are the same

IP/Subnet/Gate - -

Set according to actual instance CallbackTime - -

Phone Number - -

System Setting Parameter


Lang Chinese, English Chinese Set according to your need

Tzone - - Set according to actual instance

Date 2000-2009 - Set the time according to the current actual time, regardless of whether it is a leap year or not

System Type

24V/100

24V/300

48V/500

The system type of the monitoring module has been set according to the actual instance before the monitoring module is delivered with power supply system. You need not to change the value except that the monitoring module is replaced with a new one.

After changing the type, the monitoring module will restart and the other parameters will resume the default. You need to reset and change some parameters according to the battery and equipment configured with system

ComDownLoad Y, N N -

Reset PWD Y, N N Whether resetting the password to the default

Reset Para - - Whether resetting the parameters to the defaults

Op1 PWD - - The password can be 6 digits long at most. If it is shorter than 6 digits, end it with a #. Use ▲ or ▼ to change the number, and ◄ or ► to move the cursor left or right. Press ENT to confirm. You should input the same number twice to complete the setting

Op2 PWD - -

Adm PWD - -

32


Energy Saving Settings


Save enable Y/ N Y Energy saving function enable or disable

Cycle period 10-8760Hrs 48Hr Energy save frequency

Rectifier work 30-100% 100% rectifier o/p percentage

Rectifier Limit 30-Jan 1 Number of rectifiers that will go into energy save mode

Battery Symmetry Setting


Batt symm No, Option1-4 Option1 Battery symmetry function mode

Symm alarm 0.2-1V 0.5V Symm alarm setting DCEM Settings


DCEM1

SH1 Current 1-2000A 200A load shunt channel1 current setting SH1 Volt 1-500mV 50mV load shunt channel1 voltage setting SH2 Current 1-2000A 200A load shunt channel2 current setting SH2 Volt 1-500mV 50mV load shunt channel2 voltage setting SH3 Current 1-2000A 200A load shunt channel3 current setting SH3 Volt 1-500mV 50mV load shunt channel3 voltage setting SH4 Current 1-2000A 200A load shunt channel4 current setting SH4 Volt 1-500mV 50mV load shunt channel4 voltage setting DCEM2

SH1 Current 1-2000A 200A load shunt channel1 current setting

SH1 Volt 1-500mV 50mV load shunt channel1 voltage setting SH2 Current 1-2000A 200A load shunt channel1 voltage setting SH2 Volt 1-500mV 50mV load shunt channel1 voltage setting SH3 Current 1-2000A 200A load shunt channel3 current setting SH3 Volt 1-500mV 50mV load shunt channel3 voltage setting SH4 Current 1-2000A 200A load shunt channel4 current setting SH4 Volt 1-500mV 50mV load shunt channel4 voltage setting

DCEM Ctrl Nor/clr1/2/3/4 To reset the energy reading of the load channels

Dis1/2/3/4 To disable any load channel

The SCU will generate “rectifier lost” alarm incase SCU misses out any rectifier during CAN initialization. The

alarm can be reseted as follows

Prompt:

The Rectifier Lost alarm can be cleared: on the alarm screen, press right key, then press ENT twice after a prompt to clear

off the rectifier lost alarm is displayed on the screen. The SYSTEM MAINT alarm can be cleared off in the similar way.

33


Chapter- 4 Battery Reverse Protection & Discharge Alarm Board

Introduction

4.1 Scope

The Battery Reverse Protection & Discharge Alarm Board (BRPDAB) is a part of a 48 Volt DC

Telecom Power System. This board is optional. This board is used to sense battery discharge

condition and to protect the system from battery reverse polarity condition.

4.2 Features

The Battery Reverse Protection & Discharge Alarm Board has two features. 1) Battery Discharge

Alarm unit monitors the polarity across the battery shunt, when battery goes in discharge mode the

unit generates alarm by using potential free relay contact. 2) Battery Reverse Protection Unit will

activate only in battery reverse condition mode and it protects the system by discharging the LVD

(Contactor).

4.3 Operating Principle

1. Battery Dis-charge Alarm Unit Operating Principales:-

I) Battery In Charging Mode:-

Source Load

Figure 1 shows Shunt will not sense any potential

Load

SH1 SH2

Batt1 Batt2

34


II) Battery In Discharging Mode:-

Source Load

Figure 2 Polarity across the battery shunt changes during discharge mode.

Shunt will generate some potential in mille-volt range.

Figure 3 shows block diagram of the Battery Discharge Unit

SH1

SH2

BATTERY

REVERSE

PROTECTIO

N AND

DISCHARGE

ALARM

BOARD

Potential

Free

Contact

SH1 SH2

Batt1 Batt2

35


2. Battery Reverse Protection Unit Operating Principales:-

I) Same Polarity Condition

Same Polarity + +

-

LVD

Contactor

+ _

Battery De-activated

Control Signal

Figure 4 shows LVD Is Not Activated

I) Reverse Polarity Condition

Reverse Polarity + + +

-

LVD

Contactor

_ +

Battery

Activated

Control Signal

Figure 5 shows LVD Is Activated

+

BATTERY

REVERSE

PROTECTIO

N AND

DISCHARGE

ALARM

BOARD

CONTROL

+

BATTERY

REVERSE

PROTECTIO

N AND

DISCHARGE

ALARM

BOARD

CONTROL

SCU

SCU

36


4.4 Specifications

# Parameters Values / Range

1.0 Input Parameters

Operating Voltage 40 V to 60V(48V Typical)

Reverce Polarity Protection Required

Sensitivity of Shunt Signal 2.5mV

2.0 Output

LLVD Signal Through Isolated C/O contact & diode in series

LLVD Alarm Through Isolated C/O contact & diode in series

BLVD Signal Through Isolated C/O contact & diode in series

BLVD Alarm Through Isolated C/O contact & diode in series

Contact Rating Should be rated for 2A

O/P Settable Range 42V to 58.5V

LLVD Stability 46V to 43V,The tripping should be within +/- 5% of the

set value

BLVD Stability 44.5V to 41V,The tripping should be within +/- 5% of

the set value

Setting Accuracy 0.1V

Reconnection Through Hysteresis at 52V

3.0 Indications

Shunt 1 Discharge Red LED

Shunt 1 Discharge Red LED

Power Red LED

4.0 Environmental

Temperature Range -10 OC to 55

OC

Altitude 3000 meters

Humidity >90%

5.0 MTR Mean Time to Replace should be maintained as

minimum as possible.

6.0 MTBF Professional grade components should be used to

ensure high MTBF figures

7.0 Dispatch Unit to be housed in a box

37


4.5 Connections

SNO. Connector PIN Description Type

1 CN1.1 -48V (GND) Input

CN1.2 -48V (GND) Input

CN1.3 +48V Input

2 CN2.1 SHUNT2 -VE Input

CN2.2 SHUNT2 +VE Input

CN2.3 SHUNT1 -VE Input

CN2.4 SHUNT1 +VE Input

3 CN3.1 NC Contact of Relay 1 Output

CN3.2 Pole of Relay 1 Output

CN3.3 NO Contact of Relay 1 Output

4 CN4.1 NC Contact of Relay 2 Output

CN4.2 Pole of Relay 2 Output

CN4.3 NO Contact of Relay 2 Output

5 CN5.1 LLVD1+ve Output

CN5.2 LLVD1-ve Output

CN5.3 From Controller BoardLLVD+Ve Input

CN5.4 From Controller BoardLLVD-Ve Input

6 CN6.1 LVD2+ve Output

CN6.2 LVD2-ve Output

CN6.3 From Controller BoardBLVD+Ve Input

CN6.4 From Controller BoardBLVD-Ve Input

7 J1 Jumper to Short Shunt1+ and Shunt2+ Input

8 J2 Jumper to short CN1.1 and CN1.2 Input

38


Chapter 5 PAU Protocol Converter

PAU Protocol Converter

User Manual

1 Introduction Configured with different application programs, the PAU protocol converter (converter for short) performs

communication protocol conversions among RS485 - CAN, RS232 - Ethernet, RS232/485 - RS232/485, RS485

- Ethernet, and is used for -48V and 24V power system.

2 Appearance The appearance of the converter is shown in Figure 1.

Figure 1 Appearance

3 Installation The converter is installed in the cabinet, and two installation modes are available:

Screw installation: Through installation holes (see Figure 2), use two M5 screws to fix the converter on the

corresponding position.

Double-sided adhesive installation: Paste two double-sided adhesives at the back of the converter, and remove

the surface stickers, and then press the converter until its back is tightly pasted on the corresponding position.

Figure 2 Installation holes

4 Electrical Connection On both sides of the converter, there are five ports used for external electrical connection, including: Power

port, RS232/485/CAN port, RS232/485 port, Ethernet port and Console port. The schematic diagram of the

ports is shown in Figure 3.

Indicators

PortsPorts

Installation

hole (2 pcs)

39


Figure 3 Schematic diagram of the ports

5.1 Port Definition

The definition of the ports is listed in Table 1 to Table 5.

Table 1 Definition of Power port

No. Signal Description Specification

1 VBUS+ Power input port, positive 19V ~ 60V, power

2 VBUS- Power input port, negative GND

Table 2 Definition of RS232/485/CAN port


1 RS4851_T+ RS485 sends positive pulse Standard RS485 level

2 RS4851_T- RS485 sends negative pulse Standard RS485 level

3 U0_TXD RS232 sending Standard RS232 level

4 GND Communication GND GND


6 U0_RXD RS232 receiving Standard RS232 level

7 CAN_H CAN positive pulse Standard CAN level

8 CAN_L CAN negative pulse Standard CAN level

Table 3 Definition of RS232/485 port


1 RS4852_T+ RS485 sends positive pulse Standard RS485 level

2 RS4852_T- RS485 sends negative pulse Standard RS485 level



5 U1_DTR RS232 DSR Standard RS232 level


7 U1_DCD RS232 carrier detecting Standard RS232 level

8 U1_RTS RS232 requests sending Standard RS232 level

Table 4 Definition of Ethernet port


1 TX+ Sends signal+ Differential signal

2 TX- Sends signal- Differential signal

3 RX+ Receives signal+ Differential signal

4 NC NC

5 NC NC

6 RX- Receives signal- Differential signal

7 NC NC

8 NC NC

Table 5 Definition of Console port


1 NC NC

2 NC NC





40


7 NC NC

8 NC NC

5.2 RJ45 Connection

See Figure 4 for the converter connection with RJ45 crystal head.

Pins of port

RJ45 crystal head

Figure 4 RJ45 connection

5 Indicators The indicators are shown in Figure 1, and their functions are as follows:

1. Run indicator (silkscreen: RUN): It is a bicolor indicator. The indicator will be green when the system is

normal, and the indicator will be red when the system is faulty or has hardware fault.

2. Left status indicator (silkscreen: L): It is a bicolor indicator. The indicator will be green when the

RS232/485/CAN port communication is normal, otherwise the indicator will be red.

3. Right status indicator (silkscreen: R): It is a bicolor indicator. The indicator will be green when the RS232/485

port or Ethernet port communication is normal, otherwise the indicator will be red.

Note

This converter does not support functions of Console port or Ethernet port currently.

6 Performance Index

Environmental requirements

Operating temperature: -40°C ~ +75°C

Operating humidity: ≤ 95%

Atmospheric pressure: 86kPa ~ 106kPa

Power input and voltage sampling

Rated voltage: 48Vdc

Voltage range: 19Vdc ~ 60Vdc

Operating current: 150mA ~ 60mA

1 8

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

12345678

41


Insulation capability

At temperature of 25°C ± 5°C and relative humidity of 90%, the insulation resistance between DC terminal and

enclosure is bigger than 2MΩ after applying a test voltage of 500Vdc.

At temperature of 25°C ± 5°C and relative humidity of 90%, the DC terminal to enclosure can withstand 707Vdc

voltage, and there should be no breakdown or flashover within one minute, with leakage current not bigger than

30mA.

Noise

Lower than 50dB at 1.5 meter position.

Mechanical parameters

Dimensions: 115mm (L) × 70mm (W) × 25mm (H)

Weight: < 0.5kg

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: [email protected]

Copyright © 2011 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Version V1.2

Revision date April, 12, 2012BOM

42


Chapter 6 System Specifications & general Requirements

6.1 Technical Specifications

Input Recommended Range

Operating Voltage 156V to 502V for three phase

Power Consumption 12.76KW

THD < 5%

Power Factor > 0.99

Output Recommended Range

Output Voltage 42V to 58V by rectifier,

Output Power 12.0 KW and 5KW by converter

O/P Current 250A @ 48V Constant Power,

Efficiency >94%

Ripple <100mV p-p

Environmental

Conditions Recommended Range

Ambient temperature -5~45°C

Humidity ≤90%RH, non-condensing

Dust ≤1mg/m3

Sunlight No direct sunlight

Corrosives No pollutants, such as salt, acid, and smoke, etc.

Shake ≤1.5m/s2

Insects, pests, and

termites None

Mildew None

Moisture Water proof

Fire protection No flammable on the top/bottom of the cabient.

Component Dimensions Weight

Monitoring module 1U(H) × 2U(W) 0.15 kg

Rectifier 124.3 mm(H) × 84 mm(W) × 287 mm(D) 3.5 kg

System 630 mm(H) × 335 mm(W) × 402 mm(D) Approx 35 kg

43


6.2 Guideline for earthing Earthing

Equi-potential earthing should be provided, refer table 5-2 for earthing resistance.

Table 5-2 Requirements on earth resistance of communication station Earth

resistance Applications range

<1Ω Comprehensive building, international telecom bureau, tandem office, SPC switching office above 10000 lines, toll office above 2000 routes

<3Ω SPC switching office above 2000 lines and below 10000 lines, toll office below 2000 lines

<5Ω SPC switching office below 2000 lines, opto-terminal station, microwave tandem station, mobile station.

<10Ω Microwave relay, optical cable relay, small size earth station.

The protective earth of mains input should be directly connected to the user earth bar in the power room

6.3 System Input And Output Recomanded Connections Connection Specs

AC Power distribution

L & N 4 core 25 sq mm for 3 phase Copper Flexible Cable with Pin type Lugs

AC Earth PE Single Core 16 sq mm Copper Flexible Cable

DC Power distribution

+ve busbar Connection with RING Type Lugs with holes suitable for M6 or M8 hardware

Load –ve Suitably rated cable with Pin type lugs for MCB and Ring type lugs for Fuses

Battery –ve Max 50 sq mm single core copper flexible cable with RING type lug

Earth Telecom Ground

Single Core 216 sq mm Copper Flexible Cable with RING type lug suitable for M8 or M6 hardware

6.4 Recommanded Torque

The torque mentioned below is applicable only for sheet metal or busbar tightening.

Torque Settings for Hardware Metric

Screw Size Torque (N·m) Torque (in·lbs) Screw Size Torque (N·m) Torque (in·lbs)

M2 0.24 2 M5 4 35

M2.5 0.48 4 M6 7 62

M3 0.9 8 M8 18 145

M3.5 1.4 12 M10 34 300

M4 2 18 M12 58 513

6.5 List of Recommanded Spares

SR.NO. Item Description ENPI Ordering Code

1. Rectifier Module R48-4000W 273902130706

2. Controller SCU M523S 000003034706

3. MCB 32A 1P 280200326110

4. Temp Sensor 278292000000

5. 48V DC Contactor 200A 281702001110

44


Chapter 7 Installation Preparation

This chapter introduces installation requirements, storage conditions, installation preparation

and unpacking inspection.

7.1Installation Requirements

Environmental Requirements:The environmental conditions listed in Table 5-1 must be met

when locating the equipment.

Table 5-1 ( Environmental conditions for the equipment room)

Environmental conditions Recommended range

Ambient temperature -10°C j; to 55°C (derating from 40°C)

Humidity ≤ 90%RH, no condensation

Dust density ≤ 1mg/m3

Sunlight No direct sunlight

Corrosive materials No pollutants, such as salt, corrosive materials, and

smoke

Vibration ≤ 1.5m/s²

Harmful organisms None

Mould None

Dampness The shelter should be waterproof

The equipment may be prematurely damaged if dust or sand accumulates in it. The following

measures are recommended for dirty environment:

1. The equipment should be installed in an airtight and air-conditioned room. The air

conditioner filter should be adequately maintained without being obstructed. To reduce the

dust in the equipment room, unattended equipment room is recommended.

2. Clean the air filter periodically to provide clean air.

7.2 Layout Requirements Of The Equipment Room

Air exhaust and ventilation

When the power supply is working, the main exothermic part is the rectifier. To ensure free

airflow around the power supply system, an 800mm clearance must be kept in front of the

system.

Cabling

If top cabling is used, wiring rack should be provided in the equipment room. It is

recommended that the wiring rack be at least 300mm above the equipment. For bottom

45


cabling system, cable trough should be provided in the equipment room, which should be no

wider than the spacing between the equipment mounting holes.

Note

To prevent electric coupling, AC cables should be laid separately from DC cables and signal cables.

Antistatic

As for antistatic requirement, the absolute value of the static voltage of the equipment, wall

and people to the ground should be less than 200V. Raised floor or antistatic ceramic tile is

highly recommended for the equipment room. The antistatic earth resistance should be no

greater than 10Ω. Care should be taken regarding antistatic during equipment unpacking,

transportation and operation.

Lighting

Lighting in equipment room may be classified into general lighting and partial lighting.

General lighting provides light for the whole room, while partial lighting is installed above the

equipment cabinet or workstation to provide light for a restricted area. It is recommended to

provide both lightings in the equipment room.

Clearance

No less than 1.5m of clearance should be kept between the front of the power system

cabinet and the wall. No less than 0.8m of clearance should be kept the sides of the power

system cabinet and the wall. No less than 1.5m of clearance should be kept between the

back of the power system cabinet and the front of another piece of equipment. The back of

the power system cabinet can be installed against another piece of equipment. Maintenance

passage should be kept between equipment, which should not be less than 2m wide. Refer

to Figure 5-2 for the above requirements:

No less than 0.2m of clearance should be kept between the battery and the wall, and no less

than 0.8m of clearance should be kept between batteries.

Figure 5-2 Locating cabinet

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Weight capacity and shockproof

When installing the power system in areas subject to frequent earthquakes, shockproof

measures should be taken. Firstly, expansive bolts should be used to fix the system;

secondly, the system should be reinforced as shown in Figure 5-3 to enhance its shockproof

ability. Because the power supply system is relatively heavy, the weight capacity of the

equipment room should meet relative requirements and is determined based on the

equipment configuration.

Figure 5-3 Reinforcing the cabinet for shockproof purpose

Fire protection facility

The equipment room should comply with relevant fire protection regulations and

requirements for power distribution, and provide adequate fire protection facility, such as dry-

chemical extinguisher and automatically explosive fire protection ball.

Power Supply

General

Mains power should be used as the main AC source; backup batteries and generator should

be provided according to the actual power source conditions. AC source composed of mains

power and user-provided generator should use centralized power supply mode to supply

power, and low voltage AC power supply system should use three-phase five-line (the

neutral line is invalid) mode.

The AC power cables should be copper core cable and sized to suit for the load. It is

recommended that the power cables outside the equipment room should be buried directly

under the ground or by means of cable pipe. Power cables should be laid separately from

signal cables.

7.3 Safety Protection

Lightning protection & surge protection

The lightning protection and earthing system of telecom stations should comply with relevant

standards.

The power supply system has Class-C SPD. The preceding AC input equipment should be

equipped with a Class-B SPD. To achieve better surge protection, it is recommended to

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mount Class-B SPD before the AC mains is connected to the system. The mounting of

Class-B SPD is shown in Fig 5-4.

Class-B should be purchased and mounted by the user. If condition permits, it is

recommended that the cable length between the Class-B SPD and the AC distribution unit of

the power supply system range between 5 ~ 10m. And this section of cable should be routed

indoors to avoid direct lightning strike. When mounting the Class-B SPD, attention should be

paid to the sectional area and length of the cable connecting the Class-B SPD: the sectional

area should be no less than 25mm2, the cable should be as short as possible, and so is the

earth cable of the Class-B SPD. The SPDs should be inspected periodically to ensure their

normal operation.

Figure 5-4 Diagram of SPD mounting & system earthing

7.4 Equipment Running Environment Checklist

The equipment running environment checklist is given in Table 5-3.

Table 5-3 (Equipment running environment checklist)

No. Item Index Pass

1 Ambient temperature in equipment room -10°C to +55°C Yes/No

2 Humidity in equipment room ≤ 95% Yes/No

3 Lighting in equipment room 70 to 200Lux Yes/No

4 Height of equipment room ≥ 3m Yes/No

5 Static electricity in equipment room Lay antistatic floor or antistatic rubber Yes/No

6 Weight capacity and quakeproof ability Accord with Level 8 quakeproof, and safety

must be ensured Yes/No

7 Radiation No blockage in equipment radiation

passage Yes/No

48VDC

+

-

ABCN

PE

5~10m

Class-B

SPD

DC earth

Protective earth cable

User earth bar

System earth bar

Protective earth

Powersupply

system

SPD

earth

DC earth cable

Class-C

SPD

SPD

earth

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8 Damp proof No mildew breeding conditions Yes/No

9 Dust-proof No conductive dust and gas which

deteriorate insulation Yes/No

10 Fire protection Fire fighting equipment such as fire

extinguisher Yes/No

11 Earth resistance In accordance with relevant standards Yes/No

12 Sectional area of SPD earth cable Not less than 25mm2，the shorter the better Yes/No

13 Colour of protective earth cable Greenyellow Yes/No

14 Earth connection Via suitable Copper Cable Yes/No

15 Tablet, symbol, tag of customer equipment Complete and clear Yes/No

16 Violent vibration and shock None Yes/No

17 Sectional area of AC distribution cables According to design specifications Yes/No

18 Fluctuation range of AC input voltage According to equipment input specifications Yes/No

19 Frequency fluctuation range 45Hz to 65Hz Yes/No

20 Voltage of neutral line to ground Less than 10V Yes/No

21 Power of backup power source Twice the actual capacity Yes/No

22 Pollution or interference in power network None Yes/No

23 Colour code of AC bus Should be marked with identifier Yes/No

24 Capacity of the customer AC distribution

cabinet Meet equipment requirements Yes/No

25 Wiring of AC distribution cables According to standard specifications Yes/No

26 Colour code of DC load cables According to standard specifications Yes/No

27 Sectional area of DC distribution cables According to requirements Yes/No

28 Earth wiring According to specifications Yes/No

7.5 Storage Conditions

The product should be kept in the packing box prior to use. The warehouse ambient

temperature should range between -40°C and 70°C, and the relative humidity should not be

higher than 95%. Toxic gas, flammables, explosives, corrosives, severe vibration, shock and

strong magnetic field are not permitted in the warehouse.

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Chapter 8 Electrical Schematic

8.1 702 IC4 Schematic

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8.2 Flow Chart For M523S

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emerson manual

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