APM200 Outdoor Power Supply System User Manual-20060628-B-1.0

APM200 Outdoor Power Supply System User Manual
Version: Revision date: BOM: V1.0 December 16, 2005 31011189
Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center. Copyright 2005 by Emerson Network Power Co., Ltd. All rights reserved. The contents in this document are subject to change without notice. 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: support@emersonnetwork.com.cn
Safety Precautions
To reduce the chance of accidents, please read the safety precautions carefully before operation. The Caution, Notice, Warning and 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. 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.
Notice
II. Shortcircuit
During operation, never short the positive and negative poles of the DC busbar or the non-earthing pole and the earth. The power system is a constant voltage DC power equipment, short circuit will result in equipment burning and endanger human safety.
Danger
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 movement of the human body and tool is reduced to the minimum.
Others
I. Safety requirement
Notice
II. Sharp object
Please use the same model MCB to replace the MCB.
Waring
When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object.
III. Cable connection
Notice
Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.
IV. Binding the signal lines
Notice
The signal lines should be bound separately from heavy current and high voltage lines, with minimum 150mm binding interval.
Contents
Chapter 1 Overview ...............................................................................................................1 1.1 Theory.......................................................................................................................1 1.2 System Features.......................................................................................................1 1.3 System Function .......................................................................................................2 1.3.1 Protective Function .........................................................................................2 1.3.2 Alarm Function................................................................................................3 1.3.3 Communication Function ................................................................................5 1.4 System Composition .................................................................................................5 1.4.1 Embedded Power Supply ...............................................................................6 1.4.2 Heat Exchanging Equipment And External Fan ..............................................6 1.4.3 Heaters ...........................................................................................................6 Chapter 2 Installation .............................................................................................................7 2.1 Precautions ...............................................................................................................7 2.2 Preparations..............................................................................................................7 2.2.1 Inspecting Location .........................................................................................7 2.2.2 Distributing Goods ..........................................................................................7 2.2.3 Unpacking.......................................................................................................7 2.2.4 Preparing Tools...............................................................................................8 2.2.5 Preparing Cables ............................................................................................8 2.2.6 Opening The Cabinet Door ........................................................................... 10 2.3 Installing Cabinet .................................................................................................... 11 2.3.1 Installing Cabinet On A Concrete Stand ....................................................... 11 2.3.2 Installing Cabinet On A Floorstand ............................................................... 13 2.4 Installing Battery .....................................................................................................14 2.5 Installing Rectifiers.................................................................................................. 15 2.6 Connecting Cables.................................................................................................. 15 2.6.1 Precautions ................................................................................................... 15 2.6.2 Cable Tube ................................................................................................... 16 2.6.3 Connecting Power Cables ............................................................................ 16 2.6.4 Connecting Battery Cables ........................................................................... 19 Chapter 3 Testing................................................................................................................. 21 3.1 Introduction ............................................................................................................. 21 3.2 Testing AC Distribution ........................................................................................... 21 3.3 Testing Rectifier ...................................................................................................... 22 3.4 Testing Monitoring Module...................................................................................... 22 3.4.1 Setting System Parameters .......................................................................... 22 3.4.2 System Function Test ................................................................................... 25 Chapter 4 Maintenance........................................................................................................ 27 4.1 Embedded Power Supply System Maintenance ..................................................... 27 4.1.1 System Operation ......................................................................................... 27
4.2 4.3 4.4 4.5
4.6 4.7
4.1.2 Indicator Description ..................................................................................... 27 4.1.3 Routine Maintenance .................................................................................... 29 4.1.4 Handling Of Common Faults......................................................................... 31 Battery Maintenance ............................................................................................... 31 Heat Exchanging Equipment................................................................................... 31 External Fan Maintenance ...................................................................................... 32 Replace Heaters And Relays .................................................................................. 33 4.5.1 Replace The Heater In Equipment Compartment ......................................... 34 4.5.2 Replace The Heater In Battery Compartment ............................................... 35 4.5.3 Replace Heater Relays ................................................................................. 36 Replace Door Status Sensors................................................................................. 37 SPD Maintenance ................................................................................................... 37 Technical Data .................................................................................................. 40 Definitions Of The Monitoring Expansion Board Interface................................. 42 System Schematic Diagram .............................................................................. 45 System Wiring Diagram..................................................................................... 46
Appendix 1 Appendix 2 Appendix 3 Appendix 4
Chapter 1 Overview
Chapter 1
Overview
APM200 outdoor power supply system can be used directly outdoors. It can supply as much as 60A electric current. There are two models of this system: North model and South model. North model has an extra heating unit compared with the South model.
1.1
Theory
The simplified theoretical block diagram is shown in Figure 1-1. The detailed theoretical diagram is shown in Appendix 3 and 4.
Load 1 220Vac Distribution unit Load 11
220Vac
-48Vdc
Embedded power supply
Figure 1-1
Simplified theoretical block diagram
The embedded power system rectifies the 220V AC power into -48V DC power and exports the DC power to the distribution unit. It has functions of battery management, LLVD (load low voltage disconnection), BLVD (battery low voltage disconnection), data acquisition, alarm, and communication with the host. The distribution unit connects to AC mains and feeds the AC power to the embedded power supply. In addition, it has routes of -48V DC output for the loads.
1.2
System Features
Power factor of the rectifier can reach 0.99. The efficiency is higher than 90%. Wide AC input voltage range from 90V to 290V. When the input voltage is between 90~175Vac, the rectifier exports power- limited output. When the input voltage is 90Vac, the minimum output power of the rectifier is 37.5% of the rated power. Perfect battery management. The system has BLVD function, and can perform functions such as temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, and online battery test etc. Rectifiers are hot pluggable. It takes less than 1min to replace a rectifier.
Chapter 1 Overview
Network design: Providing multiple communication ports, which enables flexible networking and remote monitoring. Perfect lightning protection at both AC side and DC side. Complete fault protection and fault alarm functions. All system components are accessible from the front. The safety guideline satisfies IP55, and satisfies GR487 waterproof requirement.
1.3
1.3.1
System Function
Protective Function
LLVD and BLVD When mains failure occurs, the battery will supply power. When the battery voltage drops to 47.5V (by default, adjustable), the monitoring module will cut off the nonpriority loads. When the battery voltage drops to the BLVD voltage (default: 46.5V), the monitoring module will cut off all the loads to avoid battery overdischarge. When the mains resumes, the power system will go back to normal state. Over- temperature protection If the temperature of the equipment compartment remains over the protection point (55C by default) for 30 seconds constantly, the monitoring module will cut off the nonpriority loads until the ambient temperature drops below 45C. If AC side failure occurs, all the loads will be cut off. This function is inhibitive by default, though the user can activate or prohibit it through the host command. Input under-voltage protections When the AC input voltage is over 290Vac or below 90Vac, the rectifier will perform self- protection. It can recover automatically, and the return difference is more than 5Vac. Output over-voltage protections When the DC output voltage is over 60V, the rectifier will stop exporting voltage or current. This protection cannot recover automatically. Output current- limit protection The APM200 system can perform current- limited protection. Output shortcircuit protection The APM200 system can perform shortcircuit protection. It can short circuit for a long while and recover automatically.
Chapter 1 Overview
1.3.2
Alarm Function
The system provides alarm functions. It annunciates alarm in the event of mains failure, mains over/ under- voltage, DC output over/ under- voltage, charging overcurrent, load over- temperature protection, ambient over- temperature, module failure, module protection, as shown in table 1-1. Table 1-1 Alarm functions Description
Remotecommunication values
Mains shortage
Alarm is raised when mains is below 50V, and resumes when mains is above 60V. 1. Setting range: between the under- voltage alarm point and 300V. The mains over- voltage alarm point must be set above the AC over- voltage alarm point, and the mains over- voltage alarm point is 280V by default. 2. Alarm recovery conditions: Mains over- voltage When the mains is below the alarm point minus 3V for 10 minutes constantly, the alarm recovers. 3. The mains over- voltage alarm point can be set through the host. AC over/ under- voltage alarm and module alarm are shielded when mains shortage. 1. Setting range: between 60V and the over- voltage alarm point. The mains under- voltage alarm occurs when mains is below the under- voltage alarm point, and the default mains undervoltage alarm point is 180V. 2. Alarm recovery conditions: Mains underWhen the mains is above the alarm point plus 3V for 10 minutes constantly. voltage , the alarm recovers. 3. The mains over- voltage alarm point can be set through the host. Mains under- voltage alarm is shielded when mains shortage. 1. The alarm point is settable. The setting range is 58V~60V, and the alarm point must be above the boost charging voltage plus 1V. The alarm return difference is 0.5V. DC over- voltage 2.Default: 58V. DC over- voltage alarm occurs when the busbar voltage is over 58V, and vanishes when the busbar voltage is below 57.5V. 1. The alarm point is settable. The setting range isbetween the low- voltage disconnection point and float charging voltage minus 2V. The alarm return difference is 0.5V. 2.Default: 48.5V. DC under- voltage alarm occurs when the busbar voltage is below 48.5V, and vanishes when the busbar voltage is over or equal to 49V. DC under- voltage 3. The lower limit voltage is LLVD voltage when load low- voltage disconnection is permitted. 4. The lower limit voltage is BLVD voltage when load low- voltage disconnection is prohibited and BLVD is permitted. 5. The lower limit voltage is 35V when both load low- voltage disconnection and BLVD are prohibited. 1. The charging overcurrent alarm will plus 5A when charging current is over the current- limit Charging overpoint for 5 minutes constantly.. current 2. Alarm recovers when charging current is below the current- limit point for 5 minutes constantly.
Chapter 1 Overview
Description
1.The nonpriority load over- temperature protection can be set activated or not through the host settings. It is prohibited by default. 2. If the function is activated and the circumambient temperature is over the over- temperature protection point for 30s constantly, the monitoring module will cut off the nonpriority loads Load overautomatically. And the power will resume on automatically when the circumambient temperature is lower by 10C than the protection point. temperature 3. Setting range: 50C ~70C. The protection point is 65C by default. protection 4. The temperature sampling point is the external temperature sensor. 5. The nonpriority load over- temperature protection can be set controllable by the host. If controllable, the load over- temperature protection can be activated through the host command. 1.The battery over- temperature protection can be set activated or not through the host settings. It is prohibited by default. 2. If the function is activated and the circumambient temperature is over the over- temperature Battery overprotection point for 30s constantly, the monitoring module will perform battery disconnection temperature automatically. And the battery will resume power- on automatically when the circumambient protection temperature is lower by 10C than the protection point. 3. Setting range: 40C ~70C. The protection point is 53C by default. 4. The temperature sampling point can be set to be battery temperature 1, and is subject to the temperature compensation value. Circumambience The available setting range is -50~100C. When over the over- temperature alarm point, the over- temperature alarm return difference is 3C. The alarm point can be set respectively, and is 50C by default. Circumambience The available setting range is -50~0C. When under the over- temperature alarm point, the under- temperature alarm return difference is 3C. The alarm point can be set respectively, and is 0C by default. n# module failure Stand for n# module failure (output over- voltage, output shortage, fan failure) n# module Stand for n# module protection (over- temperature, intput over/ under- voltageprotection). protection 1. One battery- string loop alarms. 2. Battery loop disconnection (MCB/ fuse, contactor or internal wiring disconnection) brings Battery loop disconnection alarm. 3. The battery loop is the path between the battery string MCB and the battery string contactor. 1. Low- voltage disconnection (LVD) activation and LVD voltage can be set through the host. LLVD is inhibited by default, and BLVD is activated by default. BLVD 2. The available setting range of BLVD voltage is between 35V and LLVD voltage, and BLVD voltage is 46.5V by default. 3. The available setting range of LLVD voltage is between BLVD voltage and DC undervoltage alarm point, and BLVD voltage is 47.5V by default. 4. LVD criterion LLVD 1) The system has either following setting cannot perform LVD control: the number of system and power module is set zero or battery string capability is set zero. 2) LVD is activated in accordance with LVD conditions and the host command. Door status sensor The dry contact is disconnected when alarm. SPD failure alarm Check the two- route SPDs. The dry contact disconnects when SPD exports alarms. If the fan rev. is measurable and the fan rev. is set to be maximum, the virtual fan rev. is less than 80% of the normal rev., fan failure alarm should be raised. Fan failure alarm If the fan rev. is un measurable, fan failure alarm performs in accordance with failure description by fan manufacturer.
Chapter 1 Overview
Description
Heater failure alarm of the storage When the mains is in normal state and the storage battery temperature is below 5C for an battery hour constantly, heater failure alarm of the storage battery compartment is raised. compartment 1. 3 routes altogether. The monitoring module supplies 24Vdc or 12Vdc operation power for the switchable signal examination, disconnect the correlative low power level (0V~1V) and connect the correlative high power level (9~24V). Test on backup 2. 8/20s impulse current can endure 300A, without damage (bio- transient digital data
suppressor with model of 1.5SMC39CA is commeded). 3. Alarm power level is adjustable.
Note:
Alarm levels can be set through the host. The alarm levels are divided as critical alarm, observation alarm, and inhibit alarm. Alarms that may cause load power interruption are defined as critical alarm by default, and the rests are observation alarms. Door status sensor alarms, humidity alarms and backup equipment alarms can be set as non- alarm and be shielded, while the other alarms cannot. Except exposited ones, the alarm affirmance time is 10 seconds.
1.3.3
Communication Function
The system can communicate with the user host through communication port RS232 or RS485, and report sampling data and alarm data to the host. The APM200 system can report some alarms information to the host through the 4 couples of dry contacts.
1.4
System Composition
The APM200 outdoor power supply is constructed by an equipment compartment and a battery compartment. The equipment compartment consists of embedded power supply, heat exchanging equipment, external fan and distribution unit etc. The battery compartment has two layers, and a set of batteries that supplies backup power can be placed in each layer. Each heater is placed in the equipment compartment and in the battery compartment in the North model system. See Figure 1-2.
Chapter 1 Overview
Heat exchanging equipment
Rings(4 pieces)
External fan
Equipment compartment door
Monitoring expansion board Reserved Embedded power supply Distribution unit Heater in equipment compartment (behind distribution unit)
Battery string I Heater in battery compartment (under the plate)
Battery compartment door
Battery string II
Floorstand
Figure 1-2
Structure of APM200 outdoor power supply system
1.4.1
Embedded Power Supply

The embedded power supply consists of 3 rectifiers, one monitoring module, one distribution subrack and one monitoring expansion board. It switches the 220V AC voltage to -48V DC voltage, and delivers the -48V DC voltage to the distribution units of the system and then to the loads through its distribution subrack.
1.4.2
Heat Exchanging Equipment And External Fan

The heat exchanging equipment dissipates the heat inside the cabinet with the external fan. It consists of an internal fan and a heat exchanger. The external fan aspirates the cold air outside and feeds it to the heat exchanger, while the internal fan expels the heat air inside the cabinet to the heat exchanger. The heat exchanger exchanges the heat between cold air and hot air in it to dissipate the heat.
1.4.3
Heaters
The two heaters will start to work when the environment temperature is below 5C5C to ensure the normal operation of the North model system segments in low temperature environment.
Chapter 2 Installation
Chapter 2
2.1 Precautions
Installation
1. Only qualified technical person can do the system installation and maintenance. 2. Avoid fire or body injuries. 3. Provide suitable AC mains supply to the system. 4. Earth the system according to the requirement. 5. Keep the environment of the system clean and dry. 6. Avoid touching the bare part of a circuit. 7. Switch off the circuit breakers in case of system failure.
2.2
2.2.1
Preparations
Inspecting Location
Before installation, please inspect: 1. the cable routing such as cable tunnel and so on. 2. the conditions required for the normal operation of the system, such as AC mains supply, earth cable and so on.
2.2.2
Distributing Goods
The user needs to distribute the goods if several systems with same model are purchased at the same time. Every system has been tested and gone through the burn-in test strictly before delivery. In order to ensure the optimized operation and track the product quality conveniently, the components should be installed in their corresponding cabinet, even though these components can be installed in other systems. Ensure that all components in the same system have the same No. that is marked on the packing case.
2.2.3
Unpacking
Inspect the equipment strictly after unpacking to ensure successful installation. Unpack and inspect the equipment only after it arrives at the installation site. The user representative and the representative from Emerson Network Power Co., Ltd. shall inspect the equipment together.
Open the packing case with a packing list in it first, take out the packing list, and inspect according to the packing list, including customer name, customer address, machine No., quantity, case No., contract No., and others. Check the goods one by one according to the packing list after unpacking. The procedures are as follows. Step 1: Check the quantity and serial number marked on the packing cases according to the actual quantity of the packing cases. Step 2: Check the correctness of the equipment packing according to the packing list. Step 3: Check the quantity and model of the accessories according to the packing list. Step 4: Check the correctness of equipment configuration according to the system configuration. Step 5: Check the goods visually. For example, check if the cabinet or enclosure is distorted or affected with damp; shake gently the rectifier and the monitoring module to see if there is any loose component or connection caused by shipment. Step 6: The user representative signs the packing list. Do not unpack the components before installing them to avoid accessory loss.
2.2.4
Preparing Tools
The installation tools include electric drill, wire cutters, crimping tools, wrench set, screwdriver, and electric knife. The tools must be insulation and ESD-proof processed before they are used.
2.2.5
Preparing Cables
The cables to be installed include AC power cables, DC power cable and grounding cable. RVVZ cables such as flame retardant PVC insulation or jacket soft cable with copper conductors are recommended. The cables should be able to withstand at least +70C temperature. The colors of AC phase cable, neutral cable and grounding cable shall be red, Cambridge blue and green and yellow respectively. If the cables have the same color, they should be identified with IDs or color labels. The sectional area of the AC power cable depends on the current, temperature rise, voltage drop and mechanical strength of the cable. The 2.5A/mm2 current density is recommended to estimate the sectional area of the AC power cables and the cable with less than 10mm2 sectional area is not recommended. The sectional area of the DC power cable is shown in Table 2-1.
Table 2-1 Rated current

32 A 20 A 16 A 10 A
Sectional area of the DC power cable Min. sect. area

16 mm2 10 mm2 6 mm2 4 mm2
Max. output current

16 A 10 A 8A 5A
Max. cable l. with 0.5V voltage drop and Min. sect. area
14 m 14 m 11 m 11 m
If the rated capacity of a MCB is much bigger than the actual output current, the MCB will not trip when overload happens. So the recommended MCB capacity is 1.5 to 2 times of the maximum load current (it is two times in the table above).
Note
The maximum output current that flows in the DC power cable is calculated according to the full load of the system. If the acceptable voltage drop is not 0.5V, determine the sectional area of the DC power cable according to the following expression. A= I%L/(KU) Where: Asectional area of a cable (m2) Itotal current that flows in the cable (A) Lcable length (m) U acceptable voltage drop in the cable (V) Kelectric conduction coefficient, here K Copper=57 Recommended color labels for the positive and negative DC power cables: Positive cable black Negative cable blue The sectional area of the grounding cable should be at least 16mm2. A green and yellow cable should be used as the grounding cable. Prepare the cables according to the cabling specification and quantity. Do not join two separate cables together to form one cable. The blue and black cables should be used as DC power cables. If the cables are routed outside, they should be inserted into a corrugation sleeve.
10
2.2.6
Opening The Cabinet Door

The equipment or battery compartment door needs to be opened during system installation or maintenance. The two doors can be opened with same method, and the procedures are follows: Step 1: Undo the hexagon socket head cap screw in the keyhole sheet with the hexagon key widdershins. Remove the keyhole sheet. Insert another key into the keyhole and turn the key clockwise until it cannot be turned any more, as shown in Figure 2-1.
Handle
Keyhole sheet
Figure 2-1
Unlock sequence
Step 2: Turn the handle about 120 counter clockwise, and then pull the door, as shown in Figure 2-2.
Handle
Figure 2-2
Handle position
Step 3: Use the position pole to fix the position of the door to prevent the door from being closed automatically, as shown in Figure 2-3.
Position pole
Figure 2-3
Position Pole
11
Step 4: Place the pole to its original position before closing the door.
Note
Different cabinets have the same key. If different key is needed, notify Emerson in advance.
2.3
Installing Cabinet
The APM200 outdoor power supply system uses bottom cabling mode. Make a concrete stand or a floorstand first, and then place the cabinet on the concrete stand or the floorstand. The detailed installation procedures are follows.
2.3.1
Installing Cabinet On A Concrete Stand

Step 1: Make a concrete stand The dimensions of the stand are shown in Figure 2-4.
100
800 250
Cable tunnel
800 300~500
Cabinet door
Figure 2-4
Dimensions of concrete stand (Unit: mm)
Step 2: Mark the cabinet installation position Determine the center point positions of every installation hole on the stand according to the installation dimensions of the cabinet shown in Figure 2-5, and mark them with a pencil or an oil pen.
480 800 Cabinet door
Figure 2-5
Installation dimensions of cabinet base
530
800
12
Step 3: Drill holes The size of the expansion bolt delivered with the accessories is M1055mm. Drill a 70mm-depth hole at each marked point by using a 14 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 2-6.
Expansion pipe
Power cabinet
70~75mm
14
Drill vertically
Clean the dust
Knock it Tighten into place the bolt
Figure 2-6
Drilling holes and Installing expansion pipe and bolt
Step 4: Place cabinet in position Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the ground. Step 5: Open the battery compartment door Take the key from the ring on the cabinet top, and open the battery compartment door according to the method introduced in section 2.2.6. Step 6: Fix the cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 2-7.
Battery compartment
Expansion bolt
Spring washer Concrete stand
Spring washer Cabinet base Expansion pipe
Expansion bolt Expansion pipe Concrete stand
Figure 2-7
Screwing an expansion bolt
Shake the cabinet in different directions after the installation to check for any loose component and loose installation of the cabinet.
13
2.3.2
Installing Cabinet On A Floorstand

Step 1: Mark the floorstand installation position Determine the center point positions of the floorstand on the ground and mark them with a pencil or an oil pen, as shown in Figure 2-8.
Cabinet door
14
400
Figure 2-8 Step 2: Drill holes
Installation dimensions of floorstand
The size of the expansion bolt delivered with the accessories is M1055mm. Drill a 70mm-depth hole at each marked point by using a 14 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 2-4. Step 3: Fix the floorstand Align the installation holes of the floorstand to those on the ground. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 2-9.
Battery compartment
Screw for fixing cabinet and floorstand Floorstand Expansion bolt Ground
Figure 2-9
Installing the cabinet and floorstand
Step 4: Place cabinet in position Place the cabinet on the floorstand. Align the installation holes of the cabinet to those of the floorstand.
450
14
Step 5: Open battery compartment door Take the key from the ring on the top of the cabinet, and open the battery compartment door according to the method described in section 2.2.6. Step 6: Fix cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner of the cabinet that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the screws supplied with the accessories to fix the cabinet on the floorstand with a wrench, as shown in Figure 2-7. Shake the cabinet in different directions after the installationto check for any loose component and loose installation of the cabinet.
2.4
Installing Battery
Open the battery compartment door according to the method introduced in Section 2.2.6. The battery compartment has two floors. Each floor can be placed with one battery string that has four cells. Install the battery cells according to the battery user manual delivered with the battery. The battery cells should be installed as close to the right side and rear side of the cabinet as possible. Attach the acid and alkali integration box on the side panel of the cabinet. Loosen the two baffles in the front of the battery compartment after installing the battery cells, and then move the baffles vertically about 10mm and screw the screws solidly to block the battery cells, as shown in Figure 2-8. The installation tools must be insulation processed. Do not damage the plastic cover of the battery cells and their output terminals during the installation.
Battery compartment Battery string I Baffle
Battery string II
Baffle
Figure 2-10
Installing battery strings
15
2.5
Installing Rectifiers
The subrack of the embedded power supply has been installed in the cabinet of the outdoor power supply system. While the rectifiers of the embedded power supply are packed and delivered separately and need to be installed on spot. Rectifiers should be installed in the three left slots of the subrack. Install the rectifiers from left to right when there are less than three rectifiers to be installed and mount dummy plate at the remaining position. The installation procedures are as follows. Step 1: Place the rectifier to the position shown in Figure 2-11.
Rectifier
Handle
Figure2-11
Positions of the rectifier and the handle
Step 2: Push the handle into the panel. Step 3: Push the rectifier inward until it stops going forward. The rectifier is fixed in the subrack. Step 4: The procedures to unplug the rectifier-move the latch to Unlock position first, and pull out the rectifier then.
2.6
2.6.1
Connecting Cables
Precautions
1. When doing engineering design, AC cables and DC cables should be installed separately to avoid interfering with DC output caused by AC power.
Note
At the point where the DC output cable is led out of the cabinet, drill the cable through a steel tube longer than one meter and then connect it to the load to prevent radiant disturbance. 2. AC cables and DC cables should be identified with cable labels and polarity markings. The markings should be attached on the cables at a fixed distance. 3. The cables should be identified with different colors, as shown below: Positive DC cable black Negative DC cable blue
16
Grounding cable green and yellow AC phase line red Neutral line Cambridge blue or black If the cables have the same color, black cable is preferred and they should be identified with IDs. 4. The cables to be connected are AC power cables, DC power cables and battery cables. 5. Safety and reliability are most significant factors in electrical connection. 6. The AC and DC power cables and grounding cable should be routed through the cable tunnel, the battery compartment and the cable tubes between the two compartments, and should finally be connected to the distribution unit. 7. The cables shall not have joint, damage or scratch.
2.6.2 Cable Tube

This system is configured of 15 cable tubes with different sizes. The appearance of the tube is shown in Figure 2-10. The cable tubes are located on the separating plate between the equipment compartment and the battery compartment, as shown in Figure 2-11. User can select the suitable tube to route the cable according to the cable size. Unscrew the tube cap, then lead the cable through the tube, and finally screw the cap.
Distribution unit
Cable tube
Figure 2-12
Position of cable tube
2.6.3
Connecting Power Cables

Step 1: Remove the panel of the distribution unit The panel is shown in Figure 2-13.
17
The panel of the distribution unit
Figure 2-13 Step 2: Load Distribution
Panel of the distribution unit
The system can supply 11 routes of loads, as shown in Figure 2-16. The MCBs (LOAD1~LOAD6) of the distribution unit in the embedded power supply controls the 11 loads. The positions of the MCBs in the subrack are shown in Figure 2-14, and the relationship between these two levels of MCBs is shown in Figure 2-15. The specifications of the MCBs are shown in Table 2-2. Table 2-2 MCB in subrack
LOAD 1 LOAD 2 LOAD 3 LOAD 4 LOAD 5 LOAD 6
MCB Specifications Cable size in distr. unit

25mm2 25mm2 25mm2 25mm2 25mm2 25mm2
MCB in distr. unit

1, 2 3, 4 5, 6 7, 8, 9 10 11
MCB cap. in distr. unit

16A 16A 16A 16A 32A 32A
Remark
Total output of two MCBs should be less than 15A Total output of two MCBs should be less than 15A Total output of two MCBs should be less than 15A Total output of three MCBs should be less than 15A Total output of the MCB should be less than 30A Total output of the MCB should be less than 30A
Load MCB Battery MCB Battery force- on button
Figure 2-14
MCBs in subrack of embedded power supply system
18
LOAD1
LOAD2
LOAD3
LOAD4
LOAD5
LOAD6
Route1
Route 2
Route 3
Route 4
Route 5
Route 6
Route7
Route 8
Route 9
Route 10
Route11
Figure 2-15
Relationship between two levels of MCBs
The embedded power supply system has LLVD and BLVD functions. When the battery voltage is less than 47.5V (default), the embedded power supply system will disconnect the load connected to the MCBs of LOAD5 and LOAD6 automatically without interrupting the power to the load connected to the MCB of LOAD1~LOAD4. LOAD1~LOAD4 will be disconnected automatically when the battery voltage is less than 46.5V (default) to avoid battery overdischarge. At this time, all loads are disconnected. So the priority loads should be connected to the MCB of LOAD1~LOAD4, that is the Route1 to Route 9 in Figure 2-16. The normal loads should be connected to the Route 10 to Route 11 in Figure 2-16. Step 3: Connect loads As shown in Figure 2-15, connect the negative polarity of every load to the lower terminal of the MCB with a negative cable, and connect the positive polarity of the load to the bolt on the positive busbar that has one M6 bolt and seven M4 bolts.
Note
The tools and body shall be insulated strictly before applying a load when the system is powered on to avoid shortcircuit.
Terminal for connecting load
Positive busbar Grounding bar AC phase line (L) Neutral line (N)
Figure 2-16
Terminals for connecting load and AC power
19
Note:
The L & N terminals above are divisional interface of AC SPD and power subracks instead of AC input terminals. Step 4: Connect AC power cables Connect the AC input grounding cable to the grounding bar shown in Figure 2-16 or the grounding bar outside the battery compartment of the cabinet. Connect the AC input neutral line to the wiring point below the MCB N shown in Figure 2-16. Connect the AC input phase line to the wiring point below the MCB L shown in Figure 2-16.
Note
1. The grounding cable shall be connected first, then the neutral line and finally the phase lines. 2. The AC cables should be routed from the MCB in the external distribution equipment prepared by user. They should be connected to the MCB just before the system is powered on. The external distribution equipment should have some protection devices to fulfill the overcurrent, shortcircuit and lightning protection functions. 3. The AC cables should be identified with color labels to identify the phase line, neutral line and grounding cable. 4. The AC cables should be routed away from the DC cables. Step 5: Re-install the cover Re-install the cover to the distribution unit after completing the connection.
2.6.4 Connecting Battery Cables

Step 1: Switch on the AC input MCB and battery MCB The positions of the AC input MCB and the battery MCB are shown in Figure 2-17.
Battery MCB
AC input MCB
Figure 2-17
Position of AC input MCB and battery MCB
20
Step 2: Check if the polarities of the battery cables are correct Check the polarities of the battery cables in the battery compartment with a multimeter. The black cable should be negative pole and the red cable should be positive pole. The cable in the middle is middle voltage sampling cable of the battery, as shown in Figure 2-18. If the polarity is incorrect, please contact Emerson.
Negative battery cable Middle voltage sampling cable of the battery
Positive battery cable
Negative battery cable
Middle voltage sampling cable of the battery
Figure 2-18 Step 3: Connect battery cells
Battery cables
Switch off the battery MCB and AC input MCB. Connect the battery cells with the cables delivered with the battery according to the battery user manual. Step 4: Connect the battery string to the cabinet Connect the blue and black cables in the battery compartment respectively to the negative and positive terminals of the battery string. Connect the voltage sampling cable to the middle voltage terminal of the battery. Step 5: Recheck if the polarities of the battery cables are correct Check the polarities of the battery cables again after completing the connection. Make sure that the blue cable in the battery compartment is negative and the black cable is positive. If the cable polarity is incorrect, repeat Step 4.
Chapter 3 Testing
21
Chapter 3
3.1 Introduction
Testing
The cabinet, rectifiers and monitoring module are subject to vibrations during shipment. More over, mistakes might be made during system installation. If the system is powered on in haste, a fatal accident may occur and the whole power supply system may be damaged. Therefore, the system must be tested strictly after it is installed. Conduct the test procedures carefully and observe the system in the mean time. Shut down the system in case of any abnormal phenomenon and continue the test after the fault is eliminated.
3.2
Testing AC Distribution
Step 1: Check if the PE cables are reliably connected and the AC cables are correctly connected to the system according to the system schematic diagram (refer to Appendix 3), and if the screws are loose before powering on the system. Step 2: Switch on the residual current operated circuit breaker (RCCB). Switch off all MCBs (put the handles down) in the subrack and the distribution unit. Switch on the SPD MCBs, as shown in Figure 3-1.
RCCB
Figure 3-1
MCB positions
Step 3: Make sure that there is no short circuit in the input and output terminals of the AC Step 4: Switch on the MCB in the external distribution equipment to power the system. Measure the voltages of the input terminals of the AC MCBs. Check the external distribution equipment if the voltages are abnormal. Step 6: Switch on the battery MCB. Step 5: Switch on the AC MCBs and the operation indicators (green) on the rectifier panels should turn on. Otherwise, check the distribution unit carefully.
22
Chapter 3 Testing
3.3
Testing Rectifier
Step 1: Make sure that there is no short circuit in the input and output terminals of the rectifier and there is no loose or damaged component inside the rectifier. Step 2: Switch on the AC MCBs. The green indicator on the rectifier panel turns on and the red indicator is on for several seconds. The rectifier starts after a start delay and then operates normally. At this time, only the green indicator is on and the fan will stop several minutes later if no load is applied to the system. Step 3: Measure the DC output voltage of the system with a multimeter. It should be 53.5V0.5V.
Note
Only the engineers from Emerson can adjust the output voltage of the rectifier. After the system test is completed, the output voltage needs not to be adjusted any more unless the rectifier is replaced with a new one.
3.4
Testing Monitoring Module

The monitoring module must be tested with a host.
3.4.1
Setting System Parameters

Upon delivery, the default parameters of the monitoring module may be inconsistent with the actual situation or your needs. In that case, you should configure the system parameters through the host before the system testing. According to the communication protocol, the parameters that you can query through the host are listed in the following table. Table 3-1 Parameters that can be queried
Remotely Acquired Analog Signal Remote-Control Parameters 1) AC Input Voltage 2) DC Busbar Voltage 3) Rectifier Total Output Current 4) Battery String Current 5) Ambient Temperature/Humidity 6) Battery Temperature 1) AC Mains On/Off 2) AC Mains Status 3) DC Bus Voltage Status 4) Load MCB Status 5) System Current-Limiting Status 6) Load Connection/Disconnection Status 7) Battery Connection/Disconnection Status 8) Battery MCB Status 9) Ambient Temperature/Humidity Status 10) Door Status Sensor 11) Water Sensor Status 12) Smoke Sensor Status 13) Rectifiers Operation Status 14) System Control Mode and Battery BC/FC Status 15) 7 Standby Digital Signal Status 16) 2 Digital Signal Output Status 17) Battery Discharge Test Phase Status 18) Battery Charge Over-Current Status
Remotely Acquired Alarm/Digital Signal
1) Rectifier On/off Control 2) BLVD & LLVD 3) FC/BC Status Control 4) Start/End Battery Capacity Test
Chapter 3 Testing
23
According to the communication protocol, the parameters that you can configure through the host are listed in the following table. Table 3-2 Parameter
AC Input Under-Voltage Alarm Point
Configurable parameters Range Default value

180V 280V 46.5V/47.5V/35V (depending on the BLVD Status and LLVD Status) 48.5V 58V Disabled 47.5V Enabled 46.5V 0C 50C 10%RH 80%RH High level alarm 1 (3, 1, 2, 3) Auto FC 56.5V
> 60V and lower than AC Over-Voltage Alarm Point Between AC Under-Voltage Alarm point AC Input Over-Voltage Alarm Point and 300V 1, When LLVD enabled: LLVD Voltage 2, When LLVD disabled but BLVD DC Busbar Low Voltage Point enabled: BLVD voltage 3, When both LLVD and BLVD disabled: 35V DC Busbar Under-Voltage Alarm Between DC Busbar Low Voltage Point Point and 2V below FC voltage DC Busbar Over-Voltage Alarm 58V ~ 60V and 1V higher than BC voltage Point LLVD Status Disabled, Enabled Between BLVD voltage (when BLVD is LLVD Voltage disabled: >35V) and DC Busbar Under-Voltage Alarm Point BLVD Status Disabled, Enabled 35V but lower than LLVD voltage (when BLVD Voltage LLVD is disabled, lower than DC Busbar Under-Voltage Alarm Point) Ambient Temp Alarm Lower Limit -50C ~ 100C and lower than upper limit -50C ~ 100C and higher than lower Ambient Temp Alarm Upper Limit limit Ambient Humidity Alarm Lower 0%RH ~ 100%RH and lower than upper Limit limit Ambient Humidity Alarm Upper 0%RH ~ 100%RH and higher than lower Limit limit Standby Digital Signal Alarm Level High level alarm 1, low level alarm 0 Number and Addresses of (1, 1), (2, 1, 2), (3, 1, 2, 3) Rectifiers System Control Mode Host Control, Auto FC/BC Status BC, FC 43.2V ~ 57.6V, between FC voltage and BC voltage 1V below DC Busbar Over-Voltage Alarm Point 43.2V ~ 57.6V, between BC voltage and FC voltage 2V below DC Busbar Under-Voltage Alarm Point Number of Battery Strings 0~1
53.5V 1 100Ah (when no specific requirement is made)
Capacity of Battery String
30Ah ~ 600Ah
24
Chapter 3 Testing
Parameter
Coefficient of Charge Current Limiting Point Scheduled BC Interval Temp Compensation Coef. of Battery String Temp Measurement Lower Limit Temp Measurement Upper Limit 0.1 ~ 0.25
Range
Default value
0.15 60 days 80mV/C -50C 50 C 0%RH 100%RH
30 days ~ 240 days 0mV/C ~ 500mV/C
-50C ~ 0C 0 C ~ 100 C 0%RH ~ 100%RH and lower than Upper Humidity Measurement Lower Limit Limit 0%RH ~ 100%RH and higher than Lower Humidity Measurement Upper Limit Limit Power Distribution Analog Signal Not configurable by the user Calibration Coefficient Battery Over-Temp Protection 40C ~ 70C Point
53C
When setting system parameters through the host, please note that: 1. Make sure that the power system address set at the host is identical with the address set through the DIP switch, or the communication will fail. 2. Make sure that the rectifier number is set consistent with the actual condition. After a rectifier is added to or removed from the power system, the rectifier number parameter must be accordingly modified, or a rectifier alarm will be raised. 3. The battery string capacity is set to customer required specific capacity according to order requirement before delivery. If there is no specific capacity of the battery strings required in the order, the default battery string capacity is 100AH. If the actual battery capacity is different from that, reset the configuration through the host to make the configuration consistent with the actual situation and prevent improper battery management. (Note: the 200Ah and 100Ah capacities are set through DIP switch. You can only set other capacities through the host.) 4. The management over the battery strings is realized through a common BLVD and a shunt, and the battery current measured by the monitoring module is actually the total current of the two. Therefore, at the host, the battery string number should be set to 1, and the battery capacity be set to the sum of the two strings. 5. The DIP switch is in the PCB board of the monitoring module. Pull out the monitoring module (hot pluggable) before changing the DIP switch settings. Then you can change the DIP switch settings Description of DIP switch settings: DIP switch 1~4: Address DIP switch. ON acts 1, OFF acts 0. DIP switch 7: ON denotes that the battery string capacity is 200Ah; OFF denotes that the battery string capacity is 100Ah. As shown in Figure 3-2.
Chapter 3 Testing
25
DIP switch7 ON
DIP switch7 OFF
Figure 3-2
DIP switches
3.4.2
System Function Test

After setting the system parameters, you can go on to carry out the system function test. For the requirements of the test on system AC over/under-voltage alarm and protection are rather strict, you do not need to do them. After all, the system has passed strict tests before delivery. Battery Auto-Management Test Cut off AC mains supply and power the load with the battery for above 15 minutes (!1 minute), then recover the AC mains, all rectifiers will be in current-limiting BC status. During the current-limiting BC status, it is normal that the rectifier output voltage is sometimes below 53.5V. For the test of battery auto-management has strict requirements for the system, it is not necessary to carry out this test if your test conditions are limited. Rectifier On/Off Test Set the control mode to background control through the host software and try turning on/off each module. The corresponding module should act correctly. Note to change the control mode to automatic control after the test is finished. Under-voltage Alarm And LLVD/BLVD Test Cut off the AC power and power the load with batteries. Set the DC under-voltage alarm point, LLVD and BLVD voltage to higher values to shorten the test duration. Then observe the battery under-voltage alarm, LLVD and BLVD situation. The monitoring module should send out the corresponding alarms one by one. The red indicator on the front panel of monitoring module should be on, and the dry contact controlling the external audible/visual alarm equipment should output alarm signal. Recover the AC power, restore the settings of under voltage alarm point, LLVD and BLVD voltage, and the above alarms should disappear. Rectifier On Position Test Set the power system address and rectifier number correctly, insert and pull out the rectifiers one by one, and the host should display the communication state of corresponding rectifiers correctly.
26
Chapter 3 Testing
Battery MCB Off Alarm Test Connect the battery to the system, and switch off its MCB. There should be a corresponding battery MCB off alarm raised at the host. The alarm will disappear when the MCB is turned on. Load MCB Off Alarm Test Connect a load to the system and switch off its MCB. There should be a corresponding load MCB off alarm raised at the host. The alarm will disappear when the MCB is turned on.
Note
1. If the terminal of corresponding load and battery route is not connected with load or battery during the test, but is suspended, the MCB Off Alarm for corresponding load or battery may not be reported accurately. 2. Make sure that system configurations are restored to normal status after the test. Viewing Operation Information After the system power on, you can get simple operation information through the indicators on the monitoring module front panel. For detailed information, you must query through the host. Canceling Battery Protection If you think it more important powering the loads than protecting the battery, thus do not want the battery protection in the case of mains failure, you can set the LLVD and BLVD status to Disabled through the host.
Note
When the battery is discharged to the BLVD voltage, the battery backup time is very short. It is impossible to obtain long time operation of loads by sacrificing the battery.
Chapter 4 Maintenance
27
Chapter 4
Maintenance
Inspect the outdoor power supply system periodically and shoot the trouble in time.
4.1
4.1.1
Embedded Power Supply System Maintenance

System Operation
After installation and testing, the system is ready for use. When necessary, it can be put into normal operation just by switching on the corresponding MCB. During the operation, the following issues may call your attention: Fan speed control technology The fan may run for a second and stop when the rectifier is powered on for the first time. If load is connected to the system, the inner temperature of the rectifier will increase after operation for a period of time, and the fan will begin running and speed up with the increase of inner temperature. That phenomenon is due to the fan speed adjusting technology, and thus absolutely normal. Over temperature protection A rectifiers inner temperature may be high during operation. If you reset it by turning it off and on at that time, you may observe that the rectifier has no output but the fan is running. That is because the OTP circuit within is working. The output will recover after the temperature decreases 1 minute later. If the fan does not run, and the rectifier has no output for more than 5 minutes, the rectifier may have been damaged. Please replace the faulty rectifier or contact Emerson local service center.
4.1.2
Indicator Description
Indicator description of the rectifier The appearance of the rectifier is shown in Figure 4-1. There are 3 indicators on the panel: ALM (alarm indicator), FAN-ALM (indicator of fan faulty alarm) and RUN (power indicator)
28
Figure 4-1
Rectifier appearance
When the rectifier runs in normal condition, the power indicator RUN is on, and the other two indicators are off. When fan failure occurs, FAN- ALM indicator is on and RUN indicator is off. When other faults or protection alarm occur, ALM indicator is on and RUN indicator is off. The operation state of the rectifier should be estimated according to the indicator state when maintenance. Indicator description of the monitoring module The appearance of the monitoring module is shown in the following figure. There are 2 indicators on the panel: RUN (power indicator) and ALM (alarm indicator). Descriptions are as shown in Table 4-1.
Figure 4-2
Appearance of monitoring module
29
Table 4-1 Meaning

Normal No system alarm, with abnormal communication System alarm, with normal communication System alarm, with abnormal communication
Monitoring module indicator description RUN indicator (green)

Slow blinking (Once per second) Fast blinking (Once per 120ms) Slow blinking (Once per second) Fast blinking (Once per 120ms)
Indicator
ALM indicator (red)

Off Off On On
4.1.3
Routine Maintenance
Fan Maintenance Dust will accumulate on the baffle plate if the rectifier works in a dusty and windy environment. To ensure long-term reliable and smooth operation of the rectifier, it is necessary to clean the fan regularly (once 6 months). In addition, the fan performance will deteriorate after long-term operation. You need to replace the fan regularly (once every 3-5 years). Fan replacing method: 1. Remove the fan baffle plate 2. Remove the screws on the top right corner of the fan 3. Pull out the power cable 4. Replace the fan with a new one 5. Connect the power cable, and fix the fan with the screw on the top right corner 6. Mount the baffle plate back The fan structure is shown below:
30
Figure 4-3
Fan of the rectifier
Note
1. Only trained professionals are allowed to clean and replace the fan. 2. Do not touch any internal parts of the rectifier during fan maintenance. Rectifier Pull-Out & Plug-in Upon abnormities, the rectifier may need to be pulled out and plugged in. The rectifiers and monitoring modules are all hot swappable. To pull out the rectifier, you should first draw out the handle at rectifier front panel to detach the latch at rectifier bottom from the distribution frame. Then you can pull the rectifier out by the handle. The handle position is shown in Figure 4-4. When replacing new monitoring modules, communication cable and signal cable shoule be connected as well. See Figure 4-4.
Signal cable to the expanding board Monitoring module Rectifier
Communication cable to the expanding board
Handle of the monitoring module
Handle of the rectifier
Figure 4-4
Handle of the modules
31
Note
The rectifiers connecting part is a delicate device. Although the rectifiers are designed to be hot swappable, the pull-out and plug-in operation should be gentle lest the connecting part should be damaged. Non-professionals are not allowed to replace the rectifier on-line.
4.1.4
Handling Of Common Faults

Fault Symptom1: The rectifier quits operation automatically and a corresponding alarm is raised at the host. Solution: replace the faulty rectifier. Fault Symptom2: Rectifier(s) is/are shut down upon over-voltage and the corresponding alarm is raised at the host. Solution: 1) Upon single rectifier shutdown: Switch off the faulty rectifier. Wait till its indicators are off, and switch it on again. If the over-voltage still exists, the rectifier may have been damaged and need replacing. 2) Upon multiple-rectifier shutdown: Pull output all rectifiers and insert them one by one to find out the real faulty one. Replace the faulty rectifier after confirmation.
4.2
Battery Maintenance
Refer to the battery user manual supplied with the battery. (Note: It is recommended to use T12V100SEF/A battery within this system. If you choose to use battery of other models, please consult with Emerson to prevent improper configuration.)
4.3
Heat Exchanging Equipment

The heat exchanging equipment consists of an internal fan and a heat exchanger. Its position is shown in Figure 4-5.
Cable connector
Heat exchange equipment
Fixing screws
Figure 4-5
Position of heat exchanging equipment
The internal fan rev is settable. The higher the temperature of the equipment compartment is, the larger the internal fan rev is.
32
Replace the internal fan or adjust the fan position if it stops running or there is an abnormal noise in it. And clean the heat exchanger if there is much dust on it. The procedures are as follows. Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, as shown in Figure 4-5. Do not disconnect when power is on. Step 2: Remove the fixing screws shown in Figure 4-5 and then remove the heat exchanging equipment from the cabinet. Step 3: Remove the screws that fix the cover and the internal fan baffle and then remove the cover and the baffle, as shown in Figure 4-6.
Cover Screws for fixing the cover (4 pieces) Fan baffle
Screws for fixing the baffle (3 pieces)
Figure 4-6
Remove the cover and baffle
Step 4: Remove the fixing screws of the internal fan shown in Figure 4-7. Adjust the fan position or replace the fan with a new one. Take out the heat exchanger to clean it if there is much dust on it.
Heat exchanger
Internal fan position
Fan screws (4 pieces)
Figure 4-7
Remove internal fan and heat exchanger
Step 5: Follow step 5 to step 1 to install the new fan and the clean heat exchanger into the cabinet. Take care when installing the heat exchanger to avoid damaging the waterproof bar on it.
4.4
External Fan Maintenance

The external fan rev is settable. The higher the temperature of the equipment compartment is, the larger the external fan rev is. Replace the external fan or adjust the fan position if it stops running or there is an abnormal noise in it. The procedures are as follows.
33
Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, and disconnect the fan cables from the terminals, as shown in Figure 4-8. Do not disconnect when power is on.
Cable connector of the heat exchange equipment External fan Cable connector of the external fan Fixing screws
Heat exchange equipment
Fixing screws
Figure 4-8
Positions of heat exchanger and external fan
Step 2: Remove the fixing screws of the heat exchanging equipment shown in Figure 4-8, and then remove the equipment. Step 3: Remove the fixing screw of the fan box shown in Figure 4-4 and then remove the fan box. Step 4: Remove the fixing screw of the external fan shown in Figure 4-9. Adjust the fan position or replace it with a new one.
Fixing screws of external fan (4 pieces)
External fan
Figure 4-9
Remove the external fan
Step 5: Follow step 4 to step 1 to install the new fan into the cabinet. Install the heat exchanging equipment into the cabinet. Take care when installing the heat exchanging equipment to avoid damaging the waterproof bar on it.
4.5
Replace Heaters And Relays

The two heaters of the system do not need to be repaired. Be sure to pay attention to their operation status. The heaters will heat when the environment temperature is below 5C5C, and stop heating above 15C5C. If they operate abnormally, check the heater relays (refer to section 4.6.3). If the relays operate abnormally, replace them. Otherwise, replace the heaters.
34
4.5.1
Replace The Heater In Equipment Compartment

Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-10.
Panel of distribution unit
Heater MCB
AC input MCB
Figure 4-10
Position of AC MCB and heater MCB
Step 2: Remove the panel of the distribution unit, as shown in Figure 4-11. The position is shown in Figure 4-10.
Figure 4-11
Remove the panel of the distribution unit
Step 3: Unscrew the 4 pieces of screws on the panel of the distribution unit and then remove the right segment of the distribution unit. Do not disconnect its components and cables and be sure to pay attention to personnel safety.
Screw 2 Screw 3
Screw 1
Screw 4
Figure 4-12
Screw positions
Step 4: Unscrew the fixing screws of the heater cover and disconnect the cable connector from the heater relays. The heater relays are the two cables marked L
35
and N in Figure 4-14. Remove the heater cover. The heater is fixed on the heater cover, as shown in Figure 4-13.
Heater cover
Screws Heater
Heater of the equipment compartment
Figure 4-13
Disassembly of the equipment compartment heater
Cable connector of the heater
Cable connector of the heater
Figure 4-14
Heater relays
Step 5: Unscrew the fixing screws of the heater on the heater cover and then remove the damaged heater, as shown in Figure 4-12. Step 6: Fix the new heater on the heater cover and mount the cover on the cabinet. Connect the cable connector to the heater relay. Finally, mount the distribution unit on the cabinet. Step 7: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse after making sure every thing is OK.
4.5.2
Replace The Heater In Battery Compartment

Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-10. Step 2: Take out the battery string on the lower floor of the battery compartment. Step 3: Disconnect the cable connector from the heater relay. Remove the heater cover after removing the screws on the cover, as shown in Figure 4-15.
36
Heater of the battery compartment
Figure 4-15
Position of the heater in battery compartment
Step 4: Replace a new heater and fix it. Connect the cable connector to the heater relay. Move the battery string to its original position. Step 5: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse after making sure every thing is OK.
4.5.3 Replace Heater Relays

There are two heater relays in one heater circuit. When the environment temperature is below 5C5C, the relay contacts are closed to switch on the heater circuit. When the environment temperature is above 15C5C, the relay contacts are opened to switch off the heater circuit. Replace the relay if its contact cannot be closed or opened normally. Every compartment has two heater relays that are connected in series in the phase line and the neutral line separately, as shown in Appendix 3. The position of the heater relay in equipment compartment is shown in Figure 4-14, and that of the heater relay in battery compartment is shown in Figure 4-16.
Heater relay of the battery compartment
Figure 4-16
Position of the heater relay in battery compartment
Replacement processes: Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-7. Step 2: Disconnect the cable connector of the relay and remove the screws.
37
Step 3: Replace a new relay and connect the cable connector of the relay to its terminal. Step 4: Switch on the AC MCB and the heater fuse.
4.6
Replace Door Status Sensors

There is one door status sensors installed in the equipment compartment and the battery compartment separately for detecting the close or open status of the compartment doors. The two sensors are connected in series, so the monitoring module will generate an alarm when one of the doors is open. The alarm will be eliminated only when both doors are closed. The door status sensors are not intended for service or repair, just replace them when they are damaged. If the doors are closed, when the door status sensor alarm occurs, the sensors must have been damaged. The positions of the sensors are shown in Figure 4-17. Remove the sensor cap and then the two pieces of screws. Replace the old sensor with a new one and finally fix the sensor and the signal cables with the screws.
Door status sensor A in equipment compartment Door status sensor B in equipment compartment
Door status sensor A in battery compartment
Door status sensor B in battery compartment
Figure 4-17
Replace door status sensor
4.7
SPD Maintenance
The AC SPD is behind the distribution unit. The appearance is shown in Figure 4-18.
Figure 4-18
AC SPD
38
Check the SPD indicator on the monitoring expansion board, as shown in Figure 4-19. The position of the monitoring expansion board is shown in Figure 1-2.
Alarm indicator of DC SPD Alarm indicator of AC SPD
Figure 4-19
AC/ DC SPD indicator
If the indicator on the left is on, the DC SPD fails and needs replacement. The replacement procedures of the DC SPD are easy to take and not expatiated on here. If the indicator on the right is on, the AC SPD fails and needs replacement. The replacement procedures of AC SPD are as follows: Step1: Switch off the AC MCB. The position is shown in Figure 4-10. Step 2: Remove the cover of the distribution unit. The position is shown in Figure 4-10. Step 3: Remove the 4 screws shown in Figure 4-12, pull out the SPD alarm interface and remove the right segment of the distribution unit, as shown in Figure 4-20, Figure 4-21, Figure 4-22. Be sure to pay attention to personnel safety.
SPD alarm interface
Figure 4-20
Pull out the SPD alarm interface
Figure 4-21
Take out SPD and heater
39
Figure 4-22
SPD and heater
Step 4: Remove the 4 fixing screws of the SPD shown in Figure 4-21, and screw4 and screw2 are on the cross. Disconnect the connection cables of the SPD.
Figure 4-23
Remove the fixing screws of SPD
Step 5: Reverse previous steps 4~1 and replace the new SPD. Connect the cables, fix the screws and the SPD. Step 6: Fix the distribution unit to the cabinet. Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and restart operation after making sure everything is OK.
40
Appendix 1 Technical Data
Appendix 1
Environmental parameters 1. Operating temperature:
Technical Data
North model: -40C to +45C; South model: -5C to +45C; 2. Storage temperature: -40C to +70C 3. Relative humidity: 5% to 100%, no condensing 4. Altitude: 0 to 2000m. The system should be derated where the altitude is higher than 2000m. The highest operating temperature should be reduced by 1C at every 200m higher. And the highest altitude is 4800m. 5. Solar radiation Direct radiation: 1120W/m2 Electrical parameters 1. Rated input voltage: 220Vac 2. Input voltage range: 90Vac to 290Vac, single phase three wire. When the voltage input is between 90Vac~176Vac, the rectifiers output is allowed of linear derating. When the voltage input is 90Vac, the minimum rectifier output power is 37.5% of rated power. 3. Maximum input current of the system: 25A (with no user connector- jack output) 4. Maximum output current of standard configuration: 60A 5. Rated frequency: 50Hz 6. Input frequency range: 40Hz to 65Hz Mechanical parameters Dimensions (H%W%D): 1600mm%600mm%600mm (without base) Weight: 450kg Audible noise 61dB. Anti-erosive performance Coating: 1. Adhesion test satisfies ISO2409 Class 0. 2. The pencil rigidity test satisfies ASTM D3363 2H. 3. Shock test satisfies 50kg.cm according to ASTM D2794. 4. The coating is not changed after 500 hours salt-fog test according to ASTM B117. Dispersion radiation: 224W/m2
Appendix 1
Technical Data
41
5. The coating of the external surface of the cabinet is suitable at the -40C to +55C environmental temperature and 1120W/m2 solar radiation. The coating should not blister, flake or flaw after 250 hours test according to ASTM D822. But it is allowed to have slight pulverization, that is, a little paint particle is allowed to adhere when the coating is wiped at full tilt. The slight change of color is allowed, that is, it is acceptable if the color difference value (NBS) is less than 6.0. Protection requirement 1. The cabinet of the equipment compartment satisfies GB4208 IP55. 2. The cabinet of the battery compartment satisfies GB4208 IP23. Lightning protection 1. The system has a Level B+C SPD on AC side. 2. The AC input can withstand the maximum strike through current capacity of 60kA, and the nominal through current capacity is 25kA. The simulated lightning strike is carried out in term of YD1235.1 and YD1235.2. 3. The test of which the DC side can withstand through current capacity of 15kA requires: -48V-RTN can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively of 10/700s 5 times, for positive and negative polarity respectively, and the interval between every two tests is one minute; RTN-PE can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively of 10/700s 5 times, for positive and negative polarity respectively, and the interval between every two tests is one minute
42
Appendix 2 Definitions Of The Monitoring Expansion Board Interface
Appendix 2
Definitions Of The Monitoring
Expansion Board Interface

All the sensors are connected to the monitoring expansion board. The screen print diagram of the wiring port of the monitoring expansion board is as follows.
Screen print of Monitoring expansion board socket
Figure 1
Screen print diagram of the monitoring expansion board
Connector models of the monitoring expansion board terminals and recommended connection cables are in the following table. Table 1 Connector models and recommended connection cables Screen print Socket- connector model marks
J_WATER TEM_HU J_WIRE J_SMOKE JTM1 JK1,JK2 JAC1,JAC2 J9 J8 J12 P2500-4 P2500-4 P2500-2 P2500-2 P2500-2 P2500-2 P2500-2 MSTB2.5/2-ST-5.08 MSTB2.5/4-ST-5.08 MSTB2.5/2-ST-5.08
Signal port
Waterlogging Circumambient temperature/ humidity main distribution frame Smoke sensor Door status sensor Alarm dry contact Optical- coupler output Backup digital data input RS422 communication port Preset dry contact port
commended cables(AWG)
26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22
The functional definitions of port- pins of the monitoring expansion board are shown in the following table. Table 2 Port name
Backup digital value
Port- pin definitions of the monitoring expansion board Signal properties

+24V output Input of the signal cable
Screen Correlative print marks pins

J9 1,3,5 2,4,6
Remark
Appendix 2
Definitions Of The Monitoring Expansion Board Interface
43
Port name
Waterlogging sensor port

J_WATER 1 2 3 4 1 2 3 4 1 BAT_WE 2 3 4 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 5 6 1~7
Signal properties
+12V output Input of the signal cable Earth cable None +24V output Input of the temperature signal cable +24V output Humidity signal cable input Earth cable Battery- temperature signal cable input +12V output +12V output Optical- coupler1 controlling output Optical- coupler1 controlling output Optical- coupler2 controlling output Optical- coupler2 controlling output main distribution frame signal input +48V power output Door status sensor signal input +24V power output Smoke signal inout +24V power output dry contact1 output dry contact1 output dry contact2 output dry contact2 output Earth cable Signal cable input of equipment compartment temperature +12V output +12V output BUS+ input BAT1 mid- voltage input BAT2 mid- voltage input BUS- input None None 7 Load MCB monitoring signal input
Remark
Port of the circumambient temperature/ Humidity sensor
TEM_HU
Batterytemperature sensor port
Check the batterycompartment temperature. Connected before delivery.
Optical- coupler1 controlling output JAC1 port Optical- coupler2 controlling output JAC2 port Port of mains distribution frame J_WIRE sensor Door status sensor port Smoke sensor port JTM1 J_SMOKE
Alarm dry contact JK1 port Alarm dry contact JK2 port Port of the Equipmentcompartment temperature Sensor
EQU_WE
Battery- balance test port
J4
Load MCB switchable test port
J3
44
Appendix 2 Definitions Of The Monitoring Expansion Board Interface
Port name
SPD failure test port on DC side SPD failure test port on AC side

1 J5 2 1 J6 2 1 2 3 4 5 6 7 8 1 2 3 4 1~8 1 J2 2
Signal properties
-48V power output SPD failure of the DC side signal input -48V power output SPD failure of the AC side signal input Power output Signal output of fan speed Signal input of fan failure Power- earth cable Power output Fan speed signal output Signal input of fan failure Power- earth cable TX+ TXRX+ RXRLn+,RLnBusbar Busbar
Remark
Connected before delivery Connected before delivery To internal fan. Connected before delivery
Fan- control port
J_FAN
To external fan. Connected before delivery
RS422 communication port
J8
Preset dry contact J12 port Expansion board power input port
Remark: The descriptions of the preset dry contact ports are as follows: Dry contact 1: dry contact of AC/ DC SPD alarm are preset switched- on (normal state), and gets switched- off when AC/ DC SPD alarms. Dry contact 2: dry contact of mains failure alarm are preset switched- on (normal state), and gets switched- off when mains shortage, mains over/ under- voltage alarm occurs. Dry contact 3: dry contact of DC over/ under- voltage alarm are preset switched- on (normal state), and gets switched- off when DC over/ under- voltage alarm occurs. Dry contact 4: dry contact of system power alarm are preset switched- on (normal state), and gets switched- off when module failure, module protection, module communication abnormal, busbar output over/ under- voltage alarm, charging overcurrent alarm, battery string route disconnection or internal/ external fan fault alarm occur.
Appendix 3
System Schematic Diagram
45
Appendix 3
System Schematic Diagram
Heater for equipment box Temperature relay
Temperature relay
L AC input N PE
Lin
Alarm
Lout
SPD
Nin Nout
Heater for battery box Temperature relay
Temperature relay
Heating unit for North model cabinet
Standby value input port RS485 communication port Dry contact Temperature sensor for equipment box Monitor transfer board Temperature sensor for battery box
External fan Internal fan
LOAD 1
LOAD 2
LOAD 3
LOAD 4
LOAD 5
LOAD 6
Door status sensor for equipment box
-48V DC output
Alarm
Door status sensor for battery box
PE
0V DC busbar
PE busbar for inside cabinet
PE busbar for outside cabinet
Figure 2
Schematic diagram of APM200 outdoor power supply system
46
Appendix 4 System Wiring Diagram
Appendix 4
System Wiring Diagram
LOAD1- LOAD2- LOAD3-
LOAD4- LOAD5-
LOAD6-
BATT.(-)
SPD- LOAD+
BATT.(+)
Heater of the equipment compartment
Battery Temperature compensation
AC outleading wire of the subrack
Temperature check of the equipment compartment

PE bus
Up access control
Cross- cable (up/ down)
Down access control
Battery string 1
Heater of the battery compartment PE bus outside the cabinet
Equipotential cable
Battery string 2
Figure 3
Wiring diagram of APM200 outdoor power supply system

APM200 Outdoor Power Supply System User Manual-20060628-B-1.0

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APM200 Outdoor Power Supply System User Manual

Version: Revision date: BOM: V1.0 December 16, 2005 31011189

Please use the same model MCB to replace the MCB.

III. Cable connection

IV. Binding the signal lines

4.2 4.3 4.4 4.5

Appendix 1 Appendix 2 Appendix 3 Appendix 4

Embedded power supply

Simplified theoretical block diagram