Power One

POWER SUPPLY SYSTEM

PODS 16.48-16000 1940 HEX

Instruction Manual

Revision: B

Power-One, AS Kobbervikdalen 75 P.O.Box 1543 N-3007 Drammen

Unless specifically noted, all addresses, data, characters and persons referenced herein, and all exam-ples involving names of companies and products, are fictitious examexam-ples and are designed solely to il-lustrate the use of Power One products.

If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.

Power One logo is a registered trademark of Power One Corporation.

1-1

Document number: titlepage.fm Revision: B

Title page - Instruction Manual

Document Number:

039158

Revision:

B

Date:

11.05.2005

System:

PODS 16.48-16000 1940 HEX

Ouput Voltage:

48V

Publisher:

Power-One as

Postboks

1543

N-3007

Drammen

NORWAY

Amendment record:

Revision

(Issue)

Description

Author

Date

/ First issue Kai Morten Hennum 07.04.05

A Second issue Kai Morten Hennum 11.05.05

B Third issue Kai Morten Hennum 01.06.05

Originated Kai Morten

Hennum Date 07.04.05 Approved Hans André Dokka Date 01.06.05

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Document number: 039158TOC.fm Revision: B

Contents:

4 System description PODS 16.48-16000 1940 HEX . . . .4-1

4.1 General . . . .4-2 4.2 Technical Data . . . .4-4 4.3 Operation . . . .4-4 4.4 System Description - PPS 16 . . . .4-5 4.4.1 FMP 16- Rectifier Module . . . .4-5 4.4.2 PCS - Controller System . . . .4-5 4.4.3 PPR 16/10 23”- Subrack . . . .4-6 4.4.4 PBDU 23” - Distribution Module . . . .4-6 4.4.4.1 Low Voltage Disconnection (LVD) . . . .4-6 4.4.5 Cabinet Door With Heat Exchanger (HEX) . . . .4-6 4.4.6 BTS Breaker 50A 3-pole (Option) . . . .4-9 4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) . . . .4-9 4.4.8 FMP 16 Dummy Module (Option) . . . .4-9 4.4.9 Battery extension kit (Option) . . . .4-9

5 Safety . . . .5-1

5.1 Safety - Introduction . . . .5-2 5.2 Warnings . . . .5-2 5.2.1 Lethal voltages . . . .5-2 5.2.2 Grounding . . . .5-3 5.2.3 Precautions for lead acid batteries . . . .5-3 5.2.4 Weight . . . .5-3 5.2.5 High temperatures . . . .5-3 5.3 Cautions . . . .5-4 5.3.1 Storage and transportation . . . .5-4 5.3.2 Handling electrostatic sensitive devices . . . .5-4 5.3.3 Traceability . . . .5-4 5.3.4 Breakers . . . .5-4

6 Installation guide . . . .6-1

6.1 Site requirements . . . .6-2 6.1.1 AC Power source requirements . . . .6-2 6.2 Installation procedure . . . .6-2 6.2.1 Unpacking . . . .6-2 6.2.2 Tools and parts required . . . .6-2 6.2.3 Cabinet mounting . . . .6-4 6.2.4 Grounding . . . .6-7 6.2.5 Cable sizes / location of external connections . . . .6-7 6.2.5.1 Cable entry box . . . .6-7 6.2.6 Connection of Mains . . . .6-9 6.2.6.1 Mains Input Change . . . .6-10 6.2.7 Connection of Alarms . . . .6-10 6.2.8 Connection of Symmetry Measurement and Temperature Sensor . . . .6-11 6.2.9 Battery connection . . . .6-12 6.2.9.1 Battery tube routing. . . .6-13 6.2.10 DC connection . . . .6-13

7 Commissioning . . . .7-1

7.3 Preparation . . . 7-2 7.4 Commissioning procedure . . . 7-3 7.5 Test of output voltage . . . 7-4 7.5.1 Float charge (U1) . . . 7-4 7.5.2 Adjustment of float charge, U1 . . . 7-4 7.5.3 Boost charging (U2) (if applicable) . . . 7-4 7.6 Battery supervision . . . 7-5 7.7 Battery test . . . 7-5 7.8 Commissioning record . . . 7-6

8 Operation / Product description PCS 2 . . . 8-1

8.1 General - Product description PCS 2. . . 8-2 8.2 Technical specification: . . . 8-2 8.3 Operation - Introduction . . . 8-3 8.3.1 Starting the PCS 2 . . . 8-4 8.3.2 Adding modules . . . 8-4 8.3.3 Removing modules . . . 8-4 8.4 PCS 2 Control . . . 8-4 8.4.1 PCS 2 Menus . . . 8-5 8.4.1.1 Show voltage and currents . . . 8-5 8.4.1.2 Show alarms. . . 8-5 8.4.1.3 Show messages . . . 8-5 8.4.1.4 Show data. . . 8-5 8.4.1.5 Select / adjust U1 - U4 . . . 8-6 8.4.1.6 Adjust limits . . . 8-6 8.4.1.7 Miscellaneous. . . 8-7 8.4.2 Connecting to PC . . . 8-10 8.4.3 Boost charging . . . 8-11 8.4.4 Battery test . . . 8-12 8.4.5 Battery current limit . . . 8-13 8.4.6 Temperature compensation . . . 8-13 8.4.7 High load . . . 8-13

9 Product Description FMP 16 . . . 9-1

9.1 General - Product description FMP 16 . . . 9-2 9.2 Technical specification . . . 9-2 9.2.1 Mains input . . . 9-2 9.2.2 DC output . . . 9-2 9.2.2.1 Mains input 185-250VAC . . . 9-2 9.2.2.2 Mains input 95-185VAC . . . 9-2 9.2.3 Module dimensions . . . 9-2 9.2.4 Weight . . . 9-2 9.2.5 Other technical data . . . 9-3 9.3 Operation . . . 9-3 9.4 Environment . . . 9-4 9.4.1 Storage . . . 9-4 9.4.2 Transport . . . 9-4

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Document number: 039158TOC.fm Revision: B

9.4.3 Operation . . . .9-4 9.5 Safety . . . .9-4 9.6 EMC . . . .9-4

10 Product description PPR 16/10 23” Subrack . . . .10-1

10.1 General - Product description PPR 16/10 23” Subrack . . . .10-2 10.2 Connections and functions. . . .10-3 10.2.1 External connections . . . .10-3 10.2.2 Internal functions . . . .10-3 10.3 Connections between subracks . . . .10-4 10.4 Addressing module positions in subrack1, subrack2 etc. . . . .10-5

11 Product description PBDU 4U/23” . . . .11-1

11.1 General - Product description PBDU 4U/23” . . . .11-2 11.2 Technical specifications . . . .11-2 11.3 Construction and functions . . . .11-3 11.4 Cable cross section output connections . . . .11-3 11.5 Installation . . . .11-4 11.6 Commissioning PBDU . . . .11-4 11.7 Maintenance . . . .11-4

12 Product description PCS Alarm interface unit BM0685 . . . .12-1

12.1 General . . . .12-2 12.2 Technical data . . . .12-2 12.2.1 Pin Configuration of J20 and J21 . . . .12-2 12.3 Remote alarms, symmetry measurement and temperature sensor . . . .12-3 12.4 Maintenance . . . .12-3

13 Maintenance and Troubleshooting . . . .13-1

13.1 Installing new modules. . . .13-2 13.2 Troubleshooting . . . .13-2 13.3 Maintenance . . . .13-4 13.4 Torque table . . . .13-4

Appendix A: Drawings . . . A-1

A.1 Cabinet Layout - 039095 - Rev: / . . . A-2 A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: / . . . A-3 A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: / . . . A-4 A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 - Rev: / . . . A-5 A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: / . . . A-6 A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 - Rev: / . . . A-7 A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 - Rev: / . . . A-8 A.8 Footprint Outdoor Cabinet - 039423 - Rev:/ . . . A-9

Appendix B: Configuration c-000313 . . . B-1 Appendix C: Distribution . . . C-1

D.1 Scope and purpose . . . .D-5 D.2 Safety precautions . . . .D-5 D.3 AC Power source requirements . . . .D-6 D.4 Overview upgrade kit . . . .D-7 D.5 Mounting . . . .D-8 D.6 Installation . . . .D-9

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

- Installation procedure . . . E-1

E.1 Scope and purpose . . . E-5 E.2 Safety precautions . . . E-5 E.3 AC Power source requirements . . . E-6 E.4 Overview Surge arrestor kit . . . E-6 E.5 Installation and connection . . . E-7

Appendix F: Battery Extension Kit - Installation Procedure . . . F-1

F.1 Scope and purpose . . . F-5 F.2 Safety precautions. . . F-6 F.3 AC Power source requirements . . . F-6 F.4 Overview Battery Extension Kit . . . F-7 F.5 Installation and Connection . . . F-8 F.5.1 Installing the Battery Shelf . . . F-8 F.5.2 Installing the battery breaker . . . F-10 F.5.3 Installing the battery cables . . . F-13

Appendix G: FMP 16 Dummy Module - Installation procedure

G-1

G.1 Scope and purpose. . . .G-5 G.2 Safety precautions . . . .G-5 G.3 AC Power source requirements . . . .G-5 G.4 Overview dummy module . . . .G-6 G.5 Mounting . . . .G-7

Appendix H: 19” Adaptor Kit Installation Guide . . . .H-1

H.1 Scope and purpose . . . .H-5 H.2 Safety precautions . . . .H-6 H.3 AC Power source requirements . . . .H-6 H.4 Overview 19” adaptor kit . . . .H-7 H.4.1 Installation . . . .H-8

Appendix I: Battery Heater Kit

- Installation procedure . . . I-1

I.1 Scope and purpose. . . I-5 I.2 Safety precautions . . . I-5 I.3 AC Power source requirements . . . I-6 I.4 Overview Battery Heater Kit . . . I-6

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Document number: 039158TOC.fm Revision: B

I.5 Installation and connection . . . I-6

Appendix J: Customer AC service outlet

- Installation procedure . . . .J-1

J.1 Scope and purpose . . . J-5 J.2 Safety precautions . . . J-5 J.3 AC Power source requirements . . . J-6 J.4 Overview AC outlet . . . J-6 J.5 Installation and connection . . . J-6

Introduction to the manual 3-1

Document number: 028410.fm Revision: B

Introduction to the manual

Introduction to the manual

Objectives and audience

This manual provides the user with the necessary information to understand how the Power Supply System is made and functions, together with sufficient information to enable the user to safely install, commission, maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be used by professional and properly trained personnel selected by our customers. This manual assumes that the technician has an understanding of power systems in general and understands safety procedures for working around AC and DC voltage. The user of this document should be familiar with electronic circuitry and wiring practices and have some expertise as an electronic or electromechanical technician.

The information contained herein was applicable at the time the manual was ready for printing. Power One reserves the right to change specifications and designs without notice and without incurring obligation or liability.

This manual is the work product of Power One and embodies confidential proprietary data in which Power

One retains all rights, including exclusive right of use, reproduction, distribution and sale. It is submitted

under a confidential relationship for a specific purpose, and the recipient agrees by accepting this work product, not to supply or disclose any information regarding it to any unauthorized person.

Symbols and conventions

The following words and symbols found throughout this manual are meant to highlight particularly important matters regarding specific information concerning the personnel, equipment or the process.

Note! The text set off in this manner present an important piece of information that is essential to

highlight.

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

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

Abbreviations

The following abbreviations are used in this manual:

Disclaimer

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

Questionnaire for feed-back

We urge you to complete and return the questionnaire on our web page at the following address:

http://www.power-one.com/feedback.html. Let us know your remarks on and suggested improvements to this manual. We appreciate your comments in our achievement to improve our documentation.

If you have any problems with your system, e.g. you wonder how to install a new PMP rectifier or you have some questions regarding messages or alarms on the control module, please see the Troubleshooting section. If this does not solve your problem, please seek assistance at your local Power One office, or our head office in Norway. These also concern any indistinctness in the manual.

Abbreviation: Description:

PPS P1 Power Supply System

PODS P1 Outdoor System

PMP P1 Modular Power

CMP Convection-cooled Modular Power

FMP Fan-cooled Modular Power

PCS P1 Control and Supervision

PCU P1 Control Unit

PCC Prime Controller Card

BCC Base Controller Card

GMC Galero Modular Controller

XCS Xscend Control System

XR Xscend Rectifier Module

XS Xscend Subrack (Rectifier shelf)

PPR P1 Power Rack

PBDU P1 Battery Distribution Unit

PBC P1 Battery Cabinet

PDU P1 Distribution Unit

PPRD P1 Power Rack with DC Distribution

PPC P1 Power Supply Cabinet

PBF P1 Battery breaker Unit

PCB Printed Circuit Board

LVD Low voltage disconnection

PLD Partial load disconnection

MCB Miniature circuit breaker

System description PODS 16.48-16000 1940 HEX 4-1

Document number: 039159.fm Revision: A

System description PODS 16.48-16000 1940 HEX

4.1 General

PPS 16 modular DC power cabinet systems are designed to meet rigid telecom applications with very high reliability and flexibility for future expansion. This cabinet power solution provides rectification, system management and power distribution while maintaining high reliability and offering flexibility for future expansion. The PPS 16 Power Systems are based on hot-swappable rectifier modules (FMP 16.48) with output power available at 1600W per module. Systems are also based on fan cooling rectifiers and it is therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the air circulation.

System management is accomplished through messages and alarms displayed on the system controller’s (PCS) LCD screen and can also be displayed remotely via the PC-based PowCom™1 software package.

Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases

rectifier modules are shipped separately.

Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be

connected to the RS232 contact.

System description PODS 16.48-16000 1940 HEX 4-3

Document number: 039159.fm Revision: B

System description PODS 16.48-16000 1940 HEX

Figure 4-1 System drawing Outdoor cabinet

i IOIOI 1 2 3 4 multi 9 C120ND100MERLIN GERIN 415V10000 I ONI ONI ONI ON 1 2 3 4

multi 9C120ND100MERLIN GERIN

415V10000 I ONI ONI ONI ON 1 2 3 4

multi 9C120ND100MERLIN GERIN

415V10000 I ONI ONI ONI ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON power-one power-one FMP1648 power-one FMP1648 power-one power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648

4.2 Technical Data

Figure 4-2 Principle drawing

Input: -voltage: 1x230V AC, 3x230V AC, 3x230/400V AC -current: <10A per module

Output: -voltage: 48V DC nominal / 16000W -current: Max 32A per. module, 48V -power: Max 1600W pr. module. Weight: Rectifier: 2,2 kg

Cabinet dim.: Height: 1940 mm

Width: 800 mm

Depth: 850 mm

4.3 Operation

z The PODS 16.48-16000 HEX is capable of delivering up to 16000W/48V steady state power. The

system is based up on hot swappable 48V/1600W rectifier modules, which are working in parallel with automatic load sharing.

z The cabinet system is normally configured with N+1 redundancy, with N as the number of rectifier

modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier module. In normal operation the rectifier modules, FMP 16, are feeding the load and simultaneously maintain the batteries in a fully charged state.

z During a mains input power failure, the rectifiers are shut down and the batteries deliver the power

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

FB

BATT

LVD

F

F

DC distribution

AC

FMP 16

FMP 16

PCS

System description PODS 16.48-16000 1940 HEX 4-5

Document number: 039159.fm Revision: B

System description PODS 16.48-16000 1940 HEX

z The system performance is supervised and controlled from the supervisory unit, PCS. From this unit

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

z The alarm and threshold setting of the PPS 16 can be set locally by using the PCS push buttons and

menu guided operation or remotely, by using the PowComTM _software.

4.4 System Description - PPS 16

This system consists of the following components: Figure 4-3 Front view of PPS 16.48-16000

4.4.1 FMP 16- Rectifier Module

The Power-One FMP 16 rectifier provides extremely reliable DC power in the highest possible density. The module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification information to the controller.

Other features include 3xLED for rectifier status indication, thermal protection with de-rating and input over voltage disconnection with automatic reset. The rectifier units are hot swappable and can be quickly removed and replaced without disrupting the system or load.

See: 9 Product Description FMP 16 on page 9-1

4.4.2 PCS - Controller System

PCS - is a supervisory system with onboard software for monitoring and operation of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy of having one main controller supervision for the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus takes care of internal communication between the various units. RS232 is used for remote operation from a PC.

PowComTM _software

PowComTM _{is a communications software package that allows the remote control of the power supply}

system. The software uses a Windows based interface to allow access to the PCS. PowComTM _{is installed}

i IOIOI 1 2 3 4 multi 9 C120N D100 MERLIN GERIN 415V10000 I ON I ON I ONI ON 1 2 3 4 multi 9 C120N D100 MERLIN GERIN 415V10000 I ON I ON I ONI ON 1 2 3 4 multi 9 C120N D100 MERLIN GERIN 415V10000 I ON I ON I ONI ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16 230/400V 60003 MERLIN GERIN I ON I ON power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648 power-one power-one FMP1648

Battery breakers _{Load breakers} PCS

on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up modem.

Power-One Network interface (option)

The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with

PowComTM _{software either through a modem or Ethernet connection.} See: 8 Operation / Product description PCS 2 on page 8-1

4.4.3 PPR 16/10 23”- Subrack

PPR 16.48 is a subrack for modules in the FMP 16 series. The subrack has up to ten module positions (max. 10xFMP 16 rectifiers.) The subrack has a connection for AC in, DC out and RS485 for

communication.

Modules are “hot swappable” under full load conditions.

See: 10 Product description PPR 16/10 23” Subrack on page 10-1

4.4.4 PBDU 23” - Distribution Module

DC distribution module with battery breakers, load breakers, shunt for measurement of current, alarm for battery and load.

The distribution has no special operation other than switching the battery and load breakers on and off. All DC distribution breakers are supervised by measuring voltage drop across each breaker.

Breakers that are not connected to any load, will not cause breaker alarm even if they are left open.

Note! Due to a small leakage current (2,5-3 mA) through the alarm circuit the voltage measured with a

DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage.

If a battery breaker fault occurs or is simulated it may take from 2-10 minutes before the fault is indicated, depending on the battery condition.

The distribution module has common "+" and breakers in "-" leg. For more information see schematic drawing in Appendix A.

See: 7 Product description PBDU 23”

4.4.4.1 Low Voltage Disconnection (LVD)

The system is equipped with low voltage battery disconnection, which prevents the batteries from deep discharging, thus prolonging the battery life. A disconnection requires a detected mains failure at the supervision unit. Threshold for disconnection is available.

If disconnection occurs, the batteries will not supply power to the load until they have been recharged to set voltage level, which can be adjusted by the user.

If disconnection occurs, the batteries will be reconnected when mains supply return.

4.4.5 Cabinet Door With Heat Exchanger (HEX)

The Cabinet door is a lockable door meant to protect the battery compartment from access of unauthorised personnel. The system heat exchange unit is also mounted in the door.

System description PODS 16.48-16000 1940 HEX 4-7

Document number: 039159.fm Revision: B

System description PODS 16.48-16000 1940 HEX

Figure 4-4 Cabinet door with HEX, inside view

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

Air out

Air in

Fan out

Fan in

Figure 4-5 Heat Exchanger Airflow

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

Cabinet door

with HEX unit Rectifier shelf

Cabinet door with HEX unit

HEX unit ambient airflow

Heat Exchanger Element Principle Drawing

HEX Outside air HEX Inside air Inside of Cabinet

Ambient air

Cold ambient air in

Warm air out

Warm air from the cabinet into the HEX element

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

System description PODS 16.48-16000 1940 HEX 4-9

Document number: 039159.fm Revision: B

System description PODS 16.48-16000 1940 HEX

4.4.6 BTS Breaker 50A 3-pole (Option)

The BTS Breaker 50A 3-pole is an optional kit that allows extension of one extra load breaker. This breaker can be mounted with 50A, 100A or 150A load capacity.

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

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

The surge arrestor kit is an optional unit that protects the system against lightning and transient

overvoltage. Each surge arrestor kit consists of three over voltage protector units, a spark gap plugged in one holder and link cables.

Each surge arrestor unit has a display on the front that indicates if it is OK or has blown. Surge arrestor units with a red display have blown and must be replaced. When fitted, each surge arrestor kit is located below the mains input terminal blocks.

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

4.4.8 FMP 16 Dummy Module (Option)

The FMP 16 dummy module is an optional kit for covering empty module positions.

See: Appendix G: FMP 16 Dummy Module - Installation procedure

4.4.9 Battery extension kit (Option)

The battery extension is an optional kit that allows additional battery branches to be added to the power system (extension of hold up time). The power system allows maximum 4 battery branches. The kit includes one extra single pole battery breaker, battery shelf, battery cable, symmetry cable and signal cable harness.

Safety 5-1

Document number: 028580.fm Revision: A

Safety

5.1 Safety - Introduction

This document contains recommended safety guidelines for working with the equipment mentioned in this documentation.

The instructions in the Customer Documentation must be followed by properly trained and authorized personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the instructions may be dangerous to personnel and equipment. Although the purpose of safety devices, routines and regulations are meant to take care of the safety of the user, nobody is excused from using common sense at all times when operating or otherwise handling the equipment.

These above mentioned safety guidelines include Warnings, Cautions and Notes.

5.2 Warnings

5.2.1 Lethal voltages

All persons who perform any operations on this equipment should be advised of the potential dangers. Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems and equipment:

z Potentially lethal voltages are present within the system. Ensure that all power supplies are

completely isolated by setting all power switches to OFF, disconnecting all relevant connectors and removing all relevant breakers before attempting any maintenance work. Do not rely on switches alone to isolate a power supply.

z Potentially lethal voltages are present within this system. Ensure that high voltage safety

requirements are implemented before attempting to work on the system with power connected.

z Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly.

Ensure that all ground connections are secure.

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

WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES. THERE MUST BE NO DAMAGE OF ANY KIND TO THE INSULATION OF THE CABLES AND POINTS CARRYING LETHAL VOLTAGES SHOULD NOT BE EXPOSED. FOR SAFETY REASONS, MAKE SURE THE CABLES ARE NOT CONNECTED TO THE POWER SUPPLY WHEN ROUTING THEM.

Safety 5-3

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Safety

5.2.2 Grounding

5.2.3 Precautions for lead acid batteries

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

z Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes. z Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with

the corrosive fluid must be avoided.

z Neutralize any acid corrosion with copious amounts of a solution of baking soda and water, and then

wipe off all traces of soda.

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

to disposal.

z Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are

used when working with the batteries.

5.2.4 Weight

5.2.5 High temperatures

WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING

SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED.

WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A

CONDUCTOR SHOULD BE CONNECTED BETWEEN THE GROUNDING POINT IN THE POSITIVE DC BUSBAR TO THE CABINET. THIS CONDUCTOR IS

CONNECTED ON ITS OWN TO THE EARTH BAR AND NOT SHARED WITH OTHER SAFETY CONDUCTORS.

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

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

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

5.3 Cautions

5.3.1 Storage and transportation

5.3.2 Handling electrostatic sensitive devices

5.3.3 Traceability

5.3.4 Breakers

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

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

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

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

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Installation guide

6.1 Site requirements

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

6.1.1 AC Power source requirements

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

6.2 Installation procedure

6.2.1 Unpacking

Check that the equipment received is in accordance with the packing list. Ensure that the cabinet and the equipment have not been damaged during transportation.

Contact Power-One if any parts are missing or damaged, and correct any problems before continuing.

6.2.2 Tools and parts required

The following tools are required for a safe installation of the system:

z Anti-static hand strap z Socket wrench, insulated z Screwdriver set, flat, insulated z Screwdriver set, torx, insulated

z Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated z Torque spanner (for battery connection), insulated

z M12 bolts for cabinet base

WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY.

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

WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS INSTALLATION

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

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Installation guide

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

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

6.2.3 Cabinet mounting

The cabinet base needs to be fastened to the ground before lifting the cabinet into position.

WARNING! THE CABINET IS HEAVY AND MUST BE HANDLED WITH DUE CARE

1. Step 1 in Figure 6-1 shows the location of the mounting holes for the base. M12 bolts are not delivered with the cabinet and should be supplied by the customer.

2. Plinth directions: The sides of the plinth have a SIDE imprint. The SIDE imprint should face up from the ground. Measurements of the plinth needed to prepare the site for mounting can be found in

Appendix A: Drawings.

3. After secure fastening of the cabinet base, lift the cabinet into position on the cabinet base (Step 2 in

Figure 6-1).

4. Step 3 in Figure 6-1 shows location of mounting holes for fastening the cabinet to the cabinet base. Fasten the cabinet to the base with M10 bolts from inside the cabinet. M10 bolts are included.

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Installation guide

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

After mounting the cabinet base and cabinet, the four lifting brackets mounted on top of the system should be removed. The bolt holding the bracket should also be mounted in the opposite direction to tighten the holes and make the top spill-proof. Figure Figure 6-2 on page 6-6 shows the mounting of the brackets as delivered, and also how the parts should be assembled after removing the brackets.

Follow these steps to correctly remove and reassemble the parts: 1. Remove the top lid from the cabinet for easy access.

2. Loosen and remove the top nut, then remove the washer and lifting bracket. Keep these parts for possible future relocation of the cabinet.

Note! Only the nut and washer on top of the lifting bracket should be removed.

3. Enter the bolt in the opposite direction and fasten it from the inside with the remaining nut and washer as shown in Figure 6-2 on page 6-6.

Figure 6-2 Removal of lifting brackets

Lifting bracket as

deliv-ered

Location of

lift-ing brackets.

Lifting bracket

re-moved and bolt

fas-tened in opposite

direction.

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Installation guide

6.2.4 Grounding

Earth connection is essential BEFORE connecting supply. 1. Switch off all the breakers in the distribution panel.

2. Remove the roof by loosening the two screws at the front, which hold the top in position. Pull the top forward and lift it up.

3. Connect the grounding cable between the grounding connector in the positive DC busbar of the cabinet and the main grounding point at the back of the cabinet.

4. Check that the cables are secured tightly.

6.2.5 Cable sizes / location of external connections

Alarms: Max. 1,5 mm2 _(14AWG)

Load: Max. 16 mm2 _{/ 35 mm}2 _{(4AWG / 1AWG)}

Battery: Max. 35 mm2 _{(1AWG) (50mm}2 _{(0AWG) w / cable lug)}

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

6.2.5.1 Cable entry box

The cable entry box delivered with the system (or additional cable entry kit option) should be mounted before connecting mains and load. Remove or lift the cabinet top before installing the cable entry box. Once a cable entry side is selected (rear, left or right) the panel in the selected position is replaced with the panel

in Figure 6-3. Default cable entry side is to the right, so no panel is mounted in this position. Do not remove

the panel during cable installation. Follow steps 1 through 5 below to complete installation of the cable entry box.

Figure 6-3 Cable entry casing.(Shown without nipples)

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

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

Mains cable entry

Load/Battery/Signal cable entries

3. Attach the casing to the cabinet.

4. Mount the casing top and fasten with two M4 screws.

5. Cable entry box installation is now complete, lower the cabinet top. Figure 6-4 Mounting of Cable entry box

1 2

3

4 ₅

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6.2.6 Connection of Mains

1. Ensure that mains input is turned off before connecting.

2. Enter the mains supply cable into the cabinet through the mains cable entry in the cable entry box. 3. See 6.2.5 Cable sizes / location of external connections on page 6-7 for reference. Push the cable to

the terminal block. Fasten the cables with the mounting screws.

4. When connecting mains to terminal blocks remove as little insulation from the cable as possible before installing into terminal block, so that the jacket prevents a stranded conductor from coming loose and touch any secondary conductive parts on the backplane.

Note! The insulation on the cable must have a clearing of minimum 1mm in the terminal blocks

5. The mains input terminal blocks can be connected to: 1x230V AC, 3x230V or 3x230/400V AC. USA / Canada connections: 1x220V AC, 3x220V AC or 3x220/440V AC.

6. Use Torque table in the Maintenance and Troubleshooting chapter for the correct torque. Figure 6-5 Mains Input Types

Figure 6-6 Input Mains Terminal

Recommended mains fuse:

1x230V AC (USA/Canada 1x220V AC): Double pole 63A C-char (Mains 1) (USA/Canada: Double pole 70A C-char) 1x230V AC (USA/Canada 1x220V AC): Double pole 40A C-char (Mains 2) 3x230V AC (USA/Canada 3x220V AC): Triple pole 32A C-char (Mains 1)

(USA/Canada: Triple pole 40A C-char)

L1 PE 1 wire system TN-S 230V AC 1ph N L1 L2 L3 PEN 4 wire system TN-C/IT 230V AC 3ph L1 L2 L3 N PE 5 wire system TN-S/TT 230/400V AC 3ph VALVETRAB VAL-CP 350-ST VA LV ETRAB VA L-C P 350-ST VA LVETRAB VAL-C P 350-ST VA LVETRAB VAL-CP N/PE -350-ST L3 L3 L2 L1 L2 L1 N N Surge arrestor kit (Optional) PE 3 phase 400V AC PE PE N L1 L1 L2 L3 N N N N N L2 L3 1 2 5 5 6 7 2 3 3 4 4 6 7 1 1 PE 3x1 phase 230V AC PE PE N1 L1 L1 L2 L3 N1 N2 N2 N3 N3 L2 L3 1 2 5 5 6 7 2 3 3 4 4 6 7 1 1 PE 1x3 phase 230V AC PE PE L1 L2 L2 L3 L3 L1 L1 L1 L2 L2 L3 L3 1 2 5 5 6 7 2 3 3 4 4 6 7 1 1

Input mains terminals.

VALVETRAB VAL-CP 350-ST VALVETRAB VAL-C P 350-ST VA LVETRAB VAL-C P 350-ST VA LVETRAB VAL-CP N/PE -350-ST L3 L3 L2 L1 L2 L1 N N Surge arrestor kit (Optional) VALVETRAB VAL-CP 350-ST VALVETRAB VAL-C P 350-ST VA LVETRAB VAL-C P 350-ST VA LVETRAB VAL-CP N/PE -350-ST L3 L3 L2 L1 L2 L1 N N Surge arrestor kit (Optional)

3x230V AC (USA/Canada 3x220V AC): Triple pole 25A C-char (Mains 2) (USA/Canada: Triple pole 30A C-char) 3x400V AC (USA/Canada 3x440V AC): Triple pole 25A C-char (Mains 1) 3x400V AC (USA/Canada 3x440V AC): Triple pole 25A C-char (Mains 2)

(USA/Canada: Triple pole 30A C-char)

6.2.6.1 Mains Input Change

Attached to the cabinet behind the mains terminal blocks (the bags are attached to the cables between the terminal blocks and the subrack) there are two plastic bags containing fishplates, high voltage stickers (400VAC), labels for 3 phase 400 VAC and labels for 3 phase 230VAC for mains input change.

1. Connect according to Mains schematics in Appendix A 2. Attach labels accordingly on the cabinet chassis

6.2.7 Connection of Alarms

For remote supervision of the alarms, there are 4 potential free alarm contacts. Each alarm contact represents different alarm conditions. Potential free alarm contacts for remote signalling at PBDU interface are located in the right side of the distribution.

Note! Alarm contacts are shown in alarm position.

Figure 6-7 Connection of Alarms

i IOIOI 1 2 3 4

multi 9C120ND100MERLIN GERIN

415V10000 I ONI ONI ONI ON 1 2 3 4

multi 9C120ND100MERLIN GERIN

415V10000 I ONI ONI ONI ON 1 2 3 4

multi 9C120ND100MERLIN GERIN

415V10000 I ONI ONI ONI ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON multi 9 C60N C16230/400V 60003 MERLIN GERIN I ON I ON power-one power-one FMP1648 power-one FMP1648 power-one power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648 power-one FMP1648

Location of alarm connections

3 6 2 5 1 4 Batt. sym. 4/ ext. analog + Red T Green - Blue T 3 2 1 Temp. Probe 1 J2 3 6 2 5 1 4 J1 + Red T Green - Blue 6 5 4 Temp. Probe 2 + Red T Green - Blue 3 2 1 Temp. Probe 3 + Red T Green - Blue 6 5 4 Temp. Probe 4 J4 J5 J6 J7 J8 J9 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 3 2 1 2 1 Digital input (Door alarm) DI.1 DI.0 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1 Alarm contacts are shown in alarm position J10 4 3 2 Digital output 1 DO.0 DO.1 +12V 0V Batt. sym. J3

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Installation guide

Alarm cabling install:

The green connectors can be easily removed, if desired, for ease in installing the wires to the connector. 1. Remove the green plug from each connector.

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

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

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

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

6.2.8 Connection of Symmetry Measurement and Temperature Sensor

The controller can supervise the symmetry of up to 4 battery branches. The drawing in Figure 6-8 on

page 6-12 shows how to connect the symmetry cables for 1 battery branch. Symmetry and temp. sensor

contacts are located in the right side of the distribution.

Note! The number of battery branches to be supervised has to be set in the controller in order to

activate the symmetry measurement.

It is also possible to add four temperature probes to the system for temperature compensated charging of the battery bank. Fasten the temperature probe in the middle of the battery bank. The temperature probe will measure the ambient temperature of a battery bank and the controller will adjust the float charge according to the temperature compensation factor set in the controller. This factor must be set in the controller according to the battery manufacturer recommendation.

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

Installing the Symmetry cabling and the battery temperature sensor:

1. Remove the green plug from each connector.

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

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

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

6.2.9 Battery connection

The battery cables of the system are, if ordered, pre-connected to the systems battery breakers. The “+” cable of each battery string is connected to the positive bus bar of the system, and the “-“ cable to the negative battery breaker (separate for each string). Connect the other ends of the cables to the “-“ and “+” terminals of the batteries.

Note! Fasten the cable lugs pointing upwards, as there is not enough space in the cabinet for sideways

installation. -48V 0V -36V -24V -12V 3 6 2 5 1 4 Batt. sym. 3 Batt. sym. 4 + Red T Green - Blue

T

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Installation guide

6.2.9.1 Battery tube routing

The ventilation tube from the battery should be routed out of the cabinet through the cable entry casing as shown in Figure 6-9. Pull the tube through the cable entry casing from the inside, and attach a tube extension piece to avoid the tube sliding back inside the cabinet.

Note! Nipples on cable entry casing not shown in Figure 6-9.

Figure 6-9 Battery tube routing

6.2.10 DC connection

This section details how to connect external load to the DC load breakers. Check that all the MCB’s are in the OFF position.

1. Connect the negative (-) DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw. 2. Make sure the cable has the correct rating (i.e. thick enough) for the selected MCB.

3. Connect the positive (+) DC supply cable directly to the positive bus bar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the bus bar, and then tightening the screw.

4. Start connecting the loads to the bus bar from the first connector on the left. Make sure the cable is the correct rating (i.e. thick enough) for the load.

5. Check that all the cables are secured tightly to the connectors.

Commissioning 7-1

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Commissioning

7.1 Commissioning Overview

Before delivery the system was thoroughly inspected and tested. The following chapter is a guide to the set-up and operation of the control functions of the system.

Note! Before starting commissioning read the product description for the individual components.

If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a lower level.

7.2 Tools and Test Equipment

7.2.1 Tools List

The essential commissioning tools are listed below:

z A PC with PowCom installed (when controller is without LCD Display) z Anti-static hand strap

z Socket wrench, insulated z Screwdriver set, flat, insulated z Screwdriver set, torx, insulated

z Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated z Torque spanner (for battery connection), insulated

7.2.2 Test Equipment

z Multimeter (3 ½ Digit, 0 – 1% DC)

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

7.3 Preparation

Check the installation to ensure the following:

z Site is clean and safe

z Grounding: The equipment is correctly grounded. The grounding cable size, color and routing

conform to the requirements

z Power: The incoming mains AC power is available for this site. The site power switch and circuit

breakers are clearly labelled. The power cables are correctly terminated

WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

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Commissioning

7.4 Commissioning procedure

1. Remove the covers and check that all connections are made according to the installation drawing. Verify that all connections are properly tightened with sufficient torque.

2. Ensure load and battery MCB breakers are set to OFF position - ensuring the load and battery strings are connected.

3. Ensure all rectifier modules are removed. If not, remove each one in turn starting from the rightmost position.

4. Check the battery polarity with the Multimeter (3½ Digit, 0·1% dc). Place the positive lead of the meter to the plus-bus bar, and the negative lead to the battery breaker. The meter must now show a positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables to the batteries.

5. Turn on the AC mains voltage.

6. Measure the AC voltage on the AC terminal block, between phases and neutral. The correct value is approximately 230V. If the value is different, check the AC connection.

7. Plug in all rectifier modules, starting from the leftmost position. Make sure to fasten the rectifiers again. The rectifiers will turn on automatically.

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

9. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s) (Normally not more than 5V DC)

10. Green LED on controller should blink for approximately 20 sec. 11. Output voltage will increase slowly to U1.

12. Turn battery breaker to "1" ("on") position.

13. If any alarms are present, they should be reset in accordance with "Show alarms" in product description controller.

14. The system should now be without alarms.

15. Attach all the system covers in their correct places.

16. Check that all changes to drawings, if any have been completed. 17. Clean the site.

7.5 Test of output voltage

7.5.1 Float charge (U1)

Be sure that the controller is operating.

Connect load, approx. 50% of total capacity, to the system.

Check the voltage according to the battery manufactures requirements. If the batteries require other float charging voltage, adjust the output voltage from the controller. (See product description controller) If nothing else is required, use the following values:

7.5.2 Adjustment of float charge, U1

Output voltage is factory pre-set to: See Appendix B. The total voltage has to be in accordance to the number of battery cells.

Please verify number of cells and the battery manufacturers requirements. Adjust output voltage from the control unit.

Note! A sealing protects the potentiometer in the subrack. Do not break the seal.

7.5.3 Boost charging (U2) (if applicable)

Automatic boost charging - calculation of the time the battery voltage has been below certain levels. Automatic activating of boost charging for this calculated time multiplied by a (boost) factor.

Activate boost charging from the "Set/select U1-U4" menu in the control unit.

Return to float charge manually by selecting "U1", or automatically after a pre-set time.

Sealed lead-acid batteries.

Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be disabled.

Boost charging figures

Observe and write down all of the boost charging figures.

Parameters to be read/set/adjusted from control unit or PC with PowCom1 installed.

Battery type Float charge Boost charge

Open lead-acid batteries 2,23V/Cell 2,33V/Cell

Sealed lead-acid batteries 2,27V/Cell

-Table 7-1

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Commissioning

7.6 Battery supervision

For systems with symmetry cables supplied:

Set number of battery strings according to number of battery strings in the system. The settings are to be made in the control unit via a PC with PowCom installed or directly in the controller (if symmetry failure is indicated).

The symmetry fault alarm is to be simulated by pulling out one symmetry cable from battery string. Measure that setting to make sure that it is in accordance with battery manufacturer recommendations.

For systems with temp. probe cable supplied:

The temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that the compensation level is according to the battery manufacturers requirements. (If no compensation level is available from the battery manufacture, Power One recommends it to be set to 0,5V).

7.7 Battery test

The settings should be made according to the battery manufacturer requirements, but as a rule of thumb the following settings can be used for standard VR lead batteries:

No. of test pr. year = 2

U3 Test = 1,9 V/cell End voltage b.test = 1,94V/cell

Batt. test time = 40% of expected backup time Ah limit for test = 40% of nominal battery capacity

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

7.8 Commissioning record

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

Table 7-2 Commissioning record

Checked (D)

Result

1. Check that rack is levelled

2. Check that all breakers are turned to “off” position and that no rectifiers are mounted in the subrack(s).

3. Connect AC, and measure voltage on the mains input connections in the cabinet, Is to be 230V AC (Measure 230V from phase to N when 400V mains input is used)

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

4. Mount rest of the rectifiers

5. After connection of battery, verify right polarity by measuring the voltage drop across the battery breakers (normally not more than 5V DC).

6. Check float charge, U1, and boost charge, U2. Is to be adjusted according to the battery manufacture requirements.

U1:……..V DC U2:...V DC

7. Check temperature compensation. Is to be adjusted according to the battery manufacture requirements.

Check temperature read off compare to the room temperature.

Comp. :…….V/10oC

Read off:………o_C

8. Check symmetry measurement and set number of battery strings according to actually supervised battery strings in the system.

Number: …. Alarm limit:……

9. Check alarm transmission by running an alarm test.

Operation / Product description PCS 2 8-1

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Operation / Product description PCS 2

8.1 General - Product description PCS 2

PCS 2 - Power One Control System is a supervisory system particularly designed for supervision of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy that one main controller supervises the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus is used for internal communication between the various units. Very simple internal colour labelled signal wiring using only two cables with RJ45 plugs in each end. RS232 serial interface for remote control from a PC with PowCom1 software.

For more detailed project specific information regarding system settings see Appendix B, Configuration. This document specifies all available standard Power-One alarms, i.e. alarm 0 up to 23 and any customer specific alarms (available as alarm 24 up to 39).

Note! Some of the alarms have Power-One standard limits and some of them have customer specific

adjusted limits.

A complete supervisory system do always consist of the following units:

PCS 2 - Main Controller

Master unit in the system communicating with all distributed micro controllers. Has an LCD display, menu driven operation, visual alarm indication, RS232 contact for remote operation and RS 485 for internal communication with 128 addresses (64 rectifier modules - and 64 other remote micro controllers). Sockets for plug-in network interface. The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with PowComTM _{software either through a modem or Ethernet connection.}

PCS 2 - Alarm Interface board

The alarm interface board contains:

z Input for current reading

z Battery and load breaker monitoring

z Battery temperature and battery symmetry measurement z Output for operating two individual contactors (LVD and PLD)

z 6 potential free alarm contacts.

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

8.2 Technical specification:

Input voltage:18-72V DC Power consumption:Max 30W Output:+/- 12V

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

Operation / Product description PCS 2 8-3

Document number: 036777.fm Revision: B

Operation / Product description PCS 2

InstrumentationThree LED's, Green - OK, Yellow - Message, Red - Alarm 2 x 20 character alphanumeric LCD display with backlight. 5mm character height.

Interface:RS 232 for remote operation via PowCom. RS 485 for internal communication with 128 addresses (64 rectifier modules and 64 sub-controllers).

Basic functionsSimple manu-guided operation User-selectable alarm parameters

40 event data logging

Internal clock with battery backup Multiple language options

Temperature compensated charging Boost charging, manually and automatic Monthly data logging

LVD control of two contactors, voltage or time controlled Battery test, manual or automatic with symmetry measurement Alarm relay test

Adjustable battery current

Software controlled start up after mains outage and battery test Optional Ethernet interface

8.3 Operation - Introduction

The PCS 2 communicates through an alarm interface board and a backplane that connects to the rectifier modules. There may be up to 64 rectifier modules and 63 Units on one serial channel.

The following section contains basic PCS 2 functions including starting the PCS 2, adding modules and removing modules from the PCS 2 system.

Figure 8-1 PCS 2 LED's and control.

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

Power LED (Green)

Warning LED (Yellow)

Alarm LED (Red)

System Interface Controls

RS235 Interface Connection

8.3.1 Starting the PCS 2

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

8.3.2 Adding modules

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

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

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

8.3.3 Removing modules

Physically removing a module from the system appears as a communication error on the PCS 2. 1. To remove the error message use the Accept removed parts item on the Miscellaneous menu, or

press the reconfigure button in the Inventory window in PowCom.

2. Make sure that there are no communication faults caused by any failure before doing this as it will cause all not communicating modules and units to be removed from the inventory.

3. This will make all communication faults disappear, but it will not fix any problems so it must only be used if the communication fault is caused by the module or unit being intentionally removed.

8.4 PCS 2 Control

The control unit is equipped with four push buttons:

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

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

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

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

To adjust the alarm limits, use the arrow keys to select "adjust limits". Press RETURN to enter the sub menu, and RETURN once more to select "alarm limit". By using the arrow keys the various alarm limits can be checked. For adjusting a limit: select the correct limit and press RETURN. The correct password must be entered before a new value can be set.

The password is set to 1234 by default, but can be changed. Use the arrow keys to set and RETURN to confirm each digit. CANCEL can be used to correct a digit. For more information on setting the system password, see the section "Set New Password" in this chapter.