Beruflich Dokumente
Kultur Dokumente
Revision: B
Document number: 039158
039158
Revision:
Date:
11.05.2005
System:
Ouput Voltage:
48V
Publisher:
Power-One as
Postboks 1543
N-3007 Drammen
NORWAY
Amendment record:
Revision
(Issue)
Description
Author
/
A
B
First issue
Second issue
Third issue
Date 07.04.05
Date
Date 01.06.05
Signed
1-1
Document number: titlepage.fm
Revision: B
1-2
Contents:
4 System description PODS 16.48-16000 1940 HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 System Description - PPS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.1 FMP 16- Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.2 PCS - Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.3 PPR 16/10 23- Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.4 PBDU 23 - Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.4.1 Low Voltage Disconnection (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.5 Cabinet Door With Heat Exchanger (HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.6 BTS Breaker 50A 3-pole (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.8 FMP 16 Dummy Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.9 Battery extension kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Lethal voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.5 High temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6 Installation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Tools and parts required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.3 Cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5 Cable sizes / location of external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5.1 Cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.6 Connection of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.2.6.1 Mains Input Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.2.7 Connection of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.2.8 Connection of Symmetry Measurement and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .6-11
6.2.9 Battery connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6.2.9.1 Battery tube routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6.2.10 DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
2-1
Document number: 039158TOC.fm
Revision: B
2-2
2-3
Document number: 039158TOC.fm
Revision: B
2-4
2-5
Document number: 039158TOC.fm
Revision: B
2-6
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
3-1
Abbreviations
The following abbreviations are used in this manual:
Abbreviation:
PPS
PODS
PMP
CMP
FMP
PCS
PCU
PCC
BCC
GMC
XCS
XR
XS
PPR
PBDU
PBC
PDU
PPRD
PPC
PBF
PCB
LVD
PLD
MCB
MCCB
Description:
Disclaimer
Power One is not responsible for system problems that are the result of installation or modification of the
instructions provided in this manual.
3-2
4-1
4.1 General
PPS 16 modular DC power cabinet systems are designed to meet rigid telecom applications with very high
reliability and flexibility for future expansion. This cabinet power solution provides rectification, system
management and power distribution while maintaining high reliability and offering flexibility for future
expansion. The PPS 16 Power Systems are based on hot-swappable rectifier modules (FMP 16.48) with
output power available at 1600W per module. Systems are also based on fan cooling rectifiers and it is
therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the
air circulation.
System management is accomplished through messages and alarms displayed on the system controllers
(PCS) LCD screen and can also be displayed remotely via the PC-based PowCom1 software package.
Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases
rectifier modules are shipped separately.
Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be
connected to the RS232 contact.
1.
4-2
IOIOI
Figure 4-1
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
C120N
D100
C120N
multi 9
1
D100
415V
10000
I ON
C120N
D100
415V
10000
I ON
415V
10000
I ON
I ON
I ON
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
4-3
Principle drawing
PCS
DC distribution
FMP 16
AC
F
F
FMP 16
LVD
FB
BATT
Input:
Output:
Weight:
Cabinet dim.:
-voltage:
-current:
-voltage:
-current:
-power:
Rectifier:
Height:
Width:
Depth:
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.
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.
During a mains input power failure, the rectifiers are shut down and the batteries deliver the power
required by the load, for a certain backup time. If the battery voltage drops below the pre-set level,
the low voltage disconnection circuit (LVD) disconnects the batteries automatically to prevent battery
deep discharge prolonging the battery life. When the mains input power is restored, the rectifiers
start up automatically feeding the load, closes the LVD circuit and begin to recharge the batteries.
4-4
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.
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.
PCS
i
IOIOI
MERLIN GERIN
multi 9
MERLIN GERIN
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
C120N
D100
415V
10000
C120N
D100
I ON
C120N
D100
415V
10000
I ON
I ON
I ON
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
I ON
I ON
Battery breakers
multi 9
C60N
C16
multi 9
415V
10000
I ON
MERLIN GERIN
C60N
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
I ON
I ON
I ON
I ON
I ON
Load breakers
power-one
power-one
FMP1648
FMP1648
FMP 16
4-5
on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up
modem.
Power-One Network interface (option)
The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely
accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and
enables the system to be accessed from any location. The protocol uses simple commands to configure
and control the system and relay the system status to the operator. Using this monitoring ability allows the
alarm messages to be transmitted to any location. The PNI also can be used in conjunction with
PowComTM software either through a modem or Ethernet connection.
See: 8 Operation / Product description PCS 2 on page 8-1
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.
4-6
Figure 4-4
Air out
Air in
Fan out
Fan in
The principle of the Heat Exchanger unit is to use cool ambient air to cool down the warm air inside the
cabinet, without any ambient air being pulled into the cabinet itself. Two fans pull outside and inside air
respectively through each side of the heat exchanger element. The fan speed is monitored by the controller
and is decided by a temperature sensor positioned by the internal air inlet (see Figure 4-4). Figure 4-5 on
page 4-8 shows external air flow, internal air flow and a principle drawing of the heat exchanger element.
4-7
Figure 4-5
HEX airflow internal. Seen from the side with side plate removed.
Cabinet door
with HEX unit
Rectifier shelf
Ambient air
Inside of Cabinet
4-8
4-9
4-10
Safety
5 Safety
Safety
Document number: 028580.fm
Revision: A
5-1
Safety
5.2 Warnings
5.2.1 Lethal voltages
WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE
ATTEMPTING TO WORK ON THE SYSTEM WITH THE POWER CONNECTED.
POTENTIALLY LETHAL VOLTAGES ARE PRESENT WITHIN THIS SYSTEM.
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.
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.
Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly.
Ensure that all ground connections are secure.
5-2
Safety
5.2.2 Grounding
WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING
SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF
SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED.
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.
Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with
the corrosive fluid must be avoided.
Neutralize any acid corrosion with copious amounts of a solution of baking soda and water, and then
wipe off all traces of soda.
If the lead acid battery is removed from the equipment, any exposed contact must be insulated prior
to disposal.
Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are
used when working with the batteries.
5.2.4 Weight
WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS
SUFFICIENTLY HEAVY TO REQUIRE HANDLING BY TWO OR MORE PEOPLE, OR
BY SPECIALISED LIFTING EQUIPMENT.
Safety
Document number: 028580.fm
Revision: B
5-3
Safety
5.3 Cautions
5.3.1 Storage and transportation
CAUTION! During storage and transportation, the units must remain in their
original packages in order to avoid mechanical damage, maintain tracability, and
protect the units against electrostatic discharge.
5.3.3 Traceability
CAUTION! Units are labelled with permanently attached product identification
labels. The labels are designed to be indelible throughout the life span of the
equipment, unless mistreated. Make sure that the product identification labels are
present on the equipment and are not subjected to unusual wear or mistreatment.
5.3.4 Breakers
CAUTION! Breakers should always be replaced with the same type in order to
avoid damage to system components.
5-4
Installation guide
6 Installation guide
Installation guide
Document number: 039160.fm
Revision: A
6-1
Installation guide
Note! This product is also designed for IT power distribution system with phase-to-phase voltage 230V.
6-2
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.
Installation guide
Document number: 039160.fm
Revision: A
6-3
Installation guide
1. Step 1 in Figure 6-1 shows the location of the mounting holes for the base. M12 bolts are not
delivered with the cabinet and should be supplied by the customer.
2. Plinth directions: The sides of the plinth have a SIDE imprint. The SIDE imprint should face up from
the ground. Measurements of the plinth needed to prepare the site for mounting can be found in
Appendix A: Drawings.
3. After secure fastening of the cabinet base, lift the cabinet into position on the cabinet base (Step 2 in
Figure 6-1).
4. Step 3 in Figure 6-1 shows location of mounting holes for fastening the cabinet to the cabinet base.
Fasten the cabinet to the base with M10 bolts from inside the cabinet. M10 bolts are included.
6-4
Installation guide
After mounting the cabinet base and cabinet, the four lifting brackets mounted on top of the system should
be removed. The bolt holding the bracket should also be mounted in the opposite direction to tighten the
holes and make the top spill-proof. Figure Figure 6-2 on page 6-6 shows the mounting of the brackets as
delivered, and also how the parts should be assembled after removing the brackets.
Follow these steps to correctly remove and reassemble the parts:
1. Remove the top lid from the cabinet for easy access.
2. Loosen and remove the top nut, then remove the washer and lifting bracket. Keep these parts for
possible future relocation of the cabinet.
Note! Only the nut and washer on top of the lifting bracket should be removed.
3. Enter the bolt in the opposite direction and fasten it from the inside with the remaining nut and
washer as shown in Figure 6-2 on page 6-6.
4. Slide the top lid back into position on top of the cabinet.
Installation guide
Document number: 039160.fm
Revision: A
6-5
Installation guide
6-6
Installation guide
6.2.4 Grounding
Earth connection is essential BEFORE connecting supply.
1. Switch off all the breakers in the distribution panel.
2. Remove the roof by loosening the two screws at the front, which hold the top in position. Pull the top
forward and lift it up.
3. Connect the grounding cable between the grounding connector in the positive DC busbar of the
cabinet and the main grounding point at the back of the cabinet.
4. Check that the cables are secured tightly.
Mains:
Alarms:
Load:
Battery:
Alarm connections are located at the top right side of the system.
6.2.5.1
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
Load/Battery/Signal
cable entries
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.
Installation guide
Document number: 039160.fm
Revision: A
6-7
Installation guide
3.
4.
5.
Cable entry box installation is now complete, lower the cabinet top.
6-8
Installation guide
L1
L2
L3
PEN
L1
N
PE
1 wire system
TN-S
230V AC 1ph
4 wire system
TN-C/IT
230V AC 3ph
5 wire system
TN-S/TT
230/400V AC 3ph
Figure 6-6 Input Mains Terminal
N2
L1
N2
L1
N3
L2
4
5
N
L1
4
5
N3
L1
4
5
L2
L2
L1
L1
L2
L2
L2
L3
L2
L2
L3
L3
L3
L3
L3
L3
L3
L3
L2
L1
L1
Installation guide
L2
L3
L1
L3
L2
L1
L1
L1
2
2
N1
N1
2
2
L3
N
N
L2
PE
2
2
L1
PE
PE
PE
L3
PE
L2
PE
L1
PE
PE
PE
L2
L3
3 phase 400V AC
6-9
Installation guide
6.2.6.1
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
IOIOI
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
C120N
D100
C120N
multi 9
1
D100
415V
10000
I ON
C120N
D100
415V
10000
I ON
415V
10000
I ON
I ON
I ON
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
I ON
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
power-one
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
+
T
+
T
-
DI.1
DI.0
Red
Green
Blue
Red
Green
Blue
+
T
+
T
-
Red
Green
Blue
Red
Green
Blue
Alarm contacts
are shown in
alarm position
0V
+12V
DO.1
DO.0
6-10
6
5
4
3
2
1
6
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
J2
Batt. sym. 4/
ext. analog
J1
Batt. sym.
J3
Digital input
(Door alarm)
Temp. Probe 4
J5
Temp. Probe 3
Temp. Probe 2
J4
Temp. Probe 1
Alarm 6
J9
Alarm 5
6
5
4
3
2
1
J8
3
2
1
J7
Alarm 2
3
2
1
J6
Alarm 1
4
3
2
1
J10
Digital output
Alarm 4
Alarm 3
Installation guide
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.
Installation guide
Document number: 039160.fm
Revision: A
6-11
Installation guide
0V
-12V
-24V
-24V
-36V
-48V
-24V
0V
-12V
-24V
-24V
-36V
-48V
+
T
+
T
-
Red
Green
Blue
Red
Green
Blue
+
T
+
T
-
Red
Green
Blue
Red
Green
Blue
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
Batt. sym. 4
J2
Batt. sym. 3
Batt. sym. 2
J1
Batt. sym. 1
Temp. Probe 4
J5
Temp. Probe 3
Temp. Probe 2
J4
Temp. Probe 1
T
Installing the Symmetry cabling and the battery temperature sensor:
1.
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.
6-12
Installation guide
6.2.9.1
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 MCBs are in the OFF position.
1. Connect the negative (-) DC supply cable to the appropriate negative DC distribution MCB by
inserting the stripped cable in the opening on top of the MCB and tightening the screw.
2. Make sure the cable has the correct rating (i.e. thick enough) for the selected MCB.
3. Connect the positive (+) DC supply cable directly to the positive bus bar by inserting the stripped
cable to the hole on top of the screw connector so that the cable is behind the bus bar, and then
tightening the screw.
4. Start connecting the loads to the bus bar from the first connector on the left. Make sure the cable is
the correct rating (i.e. thick enough) for the load.
5. Check that all the cables are secured tightly to the connectors.
Use Table 13-1 in the Maintenance and troubleshooting chapter for the correct torque.
Installation guide
Document number: 039160.fm
Revision: A
6-13
Installation guide
6-14
Commissioning
7 Commissioning
Commissioning
Document number: 036285.fm
Revision: A
7-1
Commissioning
7.3 Preparation
Check the installation to ensure the following:
z
Grounding: The equipment is correctly grounded. The grounding cable size, color and routing
conform to the requirements
Power: The incoming mains AC power is available for this site. The site power switch and circuit
breakers are clearly labelled. The power cables are correctly terminated
7-2
Commissioning
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.
9. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s)
(Normally not more than 5V DC)
10. Green LED on controller should blink for approximately 20 sec.
11. Output voltage will increase slowly to U1.
12. Turn battery breaker to "1" ("on") position.
13. If any alarms are present, they should be reset in accordance with "Show alarms" in product
description controller.
14. The system should now be without alarms.
15. Attach all the system covers in their correct places.
16. Check that all changes to drawings, if any have been completed.
17. Clean the site.
18. Fill in the commissioning record (see end of chapter).
Commissioning
Document number: 036285.fm
Revision: B
7-3
Commissioning
Float charge
Boost charge
2,23V/Cell
2,33V/Cell
2,27V/Cell
Table 7-1
1.
7-4
Commissioning
=
=
=
=
=
2
1,9 V/cell
1,94V/cell
40% of expected backup time
40% of nominal battery capacity
Parameters to be set/adjusted from the controller (Battery test menu) or "Supervision - Set parameters
menu in PowCom.
Commissioning
Document number: 036285.fm
Revision: B
7-5
Commissioning
Result
(D)
1. Check that rack is levelled
2. Check that all breakers are turned to off
position and that no rectifiers are mounted in the
subrack(s).
3. Connect AC, and measure voltage on the
mains input connections in the cabinet, Is to be
230V AC (Measure 230V from phase to N when
400V mains input is used)
4. Mount rest of the rectifiers
5. After connection of battery, verify right polarity
by measuring the voltage drop across the battery
breakers (normally not more than 5V DC).
6. Check float charge, U1, and boost charge,
U2. Is to be adjusted according to the battery
manufacture requirements.
7. Check temperature compensation. Is to be
adjusted according to the battery manufacture
requirements.
Check temperature read off compare to the room
temperature.
8. Check symmetry measurement and set
number of battery strings according to actually
supervised battery strings in the system.
L1-N:..V AC
L2-N:...............V AC
L3-N:...............V AC
U1:..V DC
U2:.........V DC
Comp. :.V/10oC
Read off:oC
Number: .
Alarm limit:
7-6
Commissioning record
8-1
Three analogue and two digital inputs for supervision of miscellaneous signals (ventilation, door
open or other).
8-2
PowCom is a communications software package that allows the remote control of the system. The software uses a Windows
based interface to allow access to the PCS. PowCom is installed on a remote PC and can access the system by either direct
connection, a LAN, or through a dial-up modem.
8-3
8.3.1
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.
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.
CANCEL - Used to go cancel the current selection on the menu hierarchy. When pressed the menu
will return to the previous screen.
UP ARROW - Used to go up in the menu hierarchy. select options and to adjust limits.
DOWN ARROW - Used to go down in the menu hierarchy. select options and to adjust limits.
RETURN - Used to select and confirm an option or to go down a level in the PCS 2 software
hierarchy.
To adjust the alarm limits, use the arrow keys to select "adjust limits". Press RETURN to enter the sub
menu, and RETURN once more to select "alarm limit". By using the arrow keys the various alarm limits can
be checked. For adjusting a limit: select the correct limit and press RETURN. The correct password must
be entered before a new value can be set.
The password is set to 1234 by default, but can be changed. Use the arrow keys to set and RETURN to
confirm each digit. CANCEL can be used to correct a digit. For more information on setting the system
password, see the section "Set New Password" in this chapter.
8-4
Adjust mode is indicated by a: (colon) in front of the value and a steady cursor behind. Use the arrow keys
to adjust the alarm limit and press RETURN to confirm the value or CANCEL to revert to the previous
value.
To return to main menu, press the CANCEL button. If the PCS 2 is left unattended the display will return to
main menu automatically after 2 minutes. The backlight will be turned off. after 2 minutes without any key
pressed. It will be turned back on by pressing any key.
The default PCS 2 screen displays system voltage and battery current. Pressing the down arrow will
display system voltage and distribution current, pressing down once more will display system voltage and
rectifier current.
8.4.1.2
Show alarms
Displays the current alarm status. If there are several alarms use the arrow keys to scroll through the
alarms. Any new alarms or alarms that disappear will be added or taken off of the menu immediately.
Battery failure and symmetry failure alarms need to be reset manually by pressing RETURN at the show
alarms display.
8.4.1.3
Show messages
This item displays any messages. If there are several messages use the arrow keys to view the various
messages. New or disappearing messages will be updated immediately on the menu.
8.4.1.4
Show data
This menu displays information about: modules, units, temperature, and symmetry voltage. Information on
each of these menus is in the following section:
Module Data
This menu displays information from each rectifier module. Use the arrow keys to select the module
number.
Note! Rectifier modules are numbered from the top to bottom, and left to right.
Once the rectifier is selected on screen, Pressing RETURN will display a new menu with the following
information: communication status, module current, mean current, module temperature, module measured
voltage, Module OVP limit, alarm information, serial number and module software version number.
Module alarms are indicated by 3 letter flags. The meanings of these are as follows.
z
FAN - Fan failure, will cause the module turn off (depending on type of module.)
8-5
CUR - Current sharing fault. Current deviates too much from average
Unit Data
This menu shows information from the individual units. Units are I/O parts of the system like alarm interface
cards and distribution cards. The information available is communication status, serial number and unit
software version number.
Temperature
This menu displays the battery temperature.
Symmetry Voltage
The symmetry voltage for each battery branch is displayed.
8.4.1.5
Select / adjust U1 - U4
This menu is used to select one of the references for the 4 charge modes, U1 - float voltage, U2 - boost
voltage, U3 - battery test voltage, U4 - spare, and to adjust these references.
CAUTION! Always consult the battery user's guide before attempting to boost.
Improper settings can damage batteries.
The voltage references can be adjusted in steps of 0,1V.
U1 Normal. The U1 reference is shown, press RETURN to change U1 (The float charge voltage) and use
the arrow keys to adjust to the proper voltage.
U2 Boost. The U2 reference is shown, press RETURN to change U2 (The boost charge voltage).
U3 Test. The U3 reference is shown, press RETURN to change U3 (The Battery test voltage).
U4 Spare. The U4 reference is shown, press RETURN to change U4 (The spare voltage). The U4 setting is
normally not used in this system.
8.4.1.6
Adjust limits
The Adjust Limits menu allows the user to change and add limits to the system. The menu has the following
options: alarm limits, boost parameters, battery test, temperature compensation, battery current limit,
system specific limits and distribution current limits. Parameters can be set and adjusted by selecting the
different sub-menus.
Alarm limits.
This menu allows the following alarm limits to be changed:
z
High voltage
Low voltage
8-6
Change these limits using the arrow keys and RETURN to select. See Appendix B, Configuration for
default settings.
Boost parameters.
This menu contains the limits for boost charging control. See section "Boost charging" for more information.
Battery test.
This menu contains the limits for battery test. See section "Battery test" for more information.
Temperature comp.
This menu turn the temperature compensation on and off, and is used to set the compensation factor.
System specific limits
Only available for specific systems. For more information see Appendix B, Configuration
Batt. Cur. Limit.
This menu is used to toggle the battery current limiting on and off, and to set the current limit.
Dist. Current limits
This menu is used to toggle each distribution high current alarm limit on and off, and to set the current limit.
Note! Current limiting is not available on all systems.
8.4.1.7
Miscellaneous
The miscellaneous menu is used to set the date and time, change password, view version information,
initialize modem, show symmetry voltages and temperature.
Set time
The clock is shown. Press RETURN to adjust the clock. The clock has a battery back-up and will keep the
time even if the PCS 2 is turned off.
Relay test
Press RETURN to check the alarm relays. Use the arrow keys to select the relay to be activated.
Alarm blocking
Use Alarm Blocking to disable the relays during service. One alarm relay will normally be active as long as
the alarms are blocked.
Version
Show the PCS 2 software version, configuration number and serial number.
Set new password
Choose "set new password" from the "miscellaneous" menu. Press RETURN, enter the old password and
press RETURN. Enter the new password and confirm by pressing RETURN. To avoid mistyping the new
password has to be entered once more. Confirm by pressing RETURN.
Note! Be sure to note the new password. If the password is not known or access is denied, contact
Power-One technical support for assistance
Shunt A
Displays the current rating of the battery shunt. I.e. this parameter shows the value of current in the current/
voltage ratio of the shunt.
8-7
Shunt mV
Displays the voltage drop of the battery shunt at rated current. I.e. this parameter shows the value of
voltage in the current/voltage ratio of the shunt.
Network address
Displays the network address for each module. Several PCS 2's may be connected together in a multidrop
RS232 network. The modules require a unique address between 2 and 255. This address may be set here.
Baud rate
Select the baud rate for the RS232 serial port of the PCS 2. Either 2400 or 9600.
Init modem
Press RETURN to send a string to initiate a modem. See the modem instructions to see if it requires
additional initialization to operate.
Accept removed parts
Removing a module or unit will appear to the PCS 2 as a communication error. If the module or unit is
intentionally removed then the PCS 2 will need to be informed. Select "YES" in the Accept Removed Parts
menu to inform the system that the module was removed.
Note! Do not accept removed parts if the there is an alarm on a module that has not been removed.
Reset to defaults
This command will reset the system to default values without deleting logged data or system information. It
is recommended to try this in stead of Master Reset if a reset is needed. After a reset always check all limits
and adjust them to the desired level.
Master reset
Will completely reset the PCS 2, deleting all stored data. If possible backup the data to a PC before doing a
master reset. After a reset always check all limits and adjust them to the desired level.
CAUTION! A Master Reset will delete all information from the system. Use the
master reset feature only as a last resort.
Language
This menu is used to choose the language used in the PCS 2 menus. Selecting a different language will
immediately change the menu language. The language menu is in English by default.
8-8
Figure 8-2
Menu tree
Show voltage/
Batt. current
Show voltage/
Distr. current
Show voltage/
Rect. current
Show alarms
Show alarms
Show messages
Show messages
Show data
Module data
Unit data
Symmetry
voltage 5
Temperature
Symmetry
voltage 6
Ext.
measurements
Symmetry
voltage 7
U1 normal voltage
Distr. current
Select/adjust
U1-U4
Symmetry
voltage 8
U2 boost voltage
Symmetry
voltage 1
Symmetry
voltage 9
U3 test voltage
Symmetry
voltage 2
Symmetry
voltage 10
U4 spare voltage
Symmetry
voltage 3
Symmetry
voltage 11
Reference
Symmetry
voltage 4
Adjust limits
Symmetry
voltage 12
Alarm limits
Low voltage
Boost parameters
set time
Miscellaneous
Relay test
Battery test
Temperature
comp.
Alarm blocking
Batt. current limit
Menu language
Version
Syst. specific
limits
Set new password
Shunt current
Shunt voltage
Network address
Symmetry limit
Enable temp.
comp.
Enable current
limit
Batt. current
limit
Comp. factor
Test end
voltage
Test duration
Ah- limit
Time of test
Distr. current lim.
No of tests/year
Boost time
High voltage
Boost interval
Overvolt.
Shutdown
Boost factor
Load/battery
disconnect
Boost t1
Partial
disconnect
Boost t2
Load/battery
reconnect
Autoboost
enable
High load
Temperature
alarm
No of batteries
Battery type
Baud rate
Init modem
Accept removed
parts
Reset to defaults
Master reset
8-9
8.4.2 Connecting to PC
The PCS 2 to PC connection requires a RS232 cable to connect to the PCS 2 and to the PC serial port
connection.
Cable
The PC to PCS 2 connection is made using a modem, or directly with a null-modem cable (Figure 8-3
PCS 2 to PC cable). P1 and P2 are both 9-pin female D-sub plugs. P1 is to be connected to the PCS 2.
Figure 8-3
PCS 2 to PC cable
1
P1
Pin
P1
P2
Receive
Transmit
Transmit
Receive
0V (Ground)
0V (Ground)
Table 8-1
P2
1.
To connect the PCS 2 to the PC, locate the RS232 interface connector on the front of the PCS 2.
2.
3.
Route the cable to the rear of the PC (the PC should be powered "Off").
4.
5.
6.
Choose "Communications" from the PowCom menu, and select "Port Setup" (Figure 8-4).
8-10
Figure 8-4
7.
Communications menu
Select "9600" baud rate from the Port Setup menu (Figure 8-5).
Figure 8-5
8.
Select "OK"
9.
8-11
Figure 8-6
Boost charging
Voltage (V)
Level t2
U1 (Float Charge)
Level t1
t1
Mains
Interrupt
t2=K x t1
Time (hour
Mains
Returns
8-12
Parameter Settings.
The parameter settings feature allows for the partial discharge of the batteries (approx. 30-40% of the
capacity) in order to test the batteries for errors. The settings should be done according the battery
manufacturer requirements, however, the following settings can be used for standard VR lead batteries:
U3 = 1,9 V/cell
End voltage = 1,94V/cell
Time = 100% of expected backup time
Ah = 40% of nominal battery capacity
Parameters to be set/adjusted from the "battery test" menu or PC with PowCom installed.
Battery test voltage:U3
Symmetry limit:
Test end voltage:
Test duration:
Ah limit:
Time of test:
No of test/year:
No of batteries:
Battery type:
0- 100 Volts
0.0 - 4.0 Volts
0-100 Volts
0- 20 hours
0- 50000 Ah
0 - 23 (0=midnight)
0-4
0 - 12
4 blocks, 23 cell-, 23 cell+, 3 blocks or 2 blocks
Number of batteries must be equal to number of symmetry measurements. If symmetry cables are not in
use, number of batteries must be set to 0 (zero).
8-13
8-14
9-1
9.2.2 DC output
9.2.2.1
Voltage:45V DC - 56 V DC nominal
Current limit:32A
Power:1600W
Efficiency:>93%, typical 93,5% (at 40-90% load)
9.2.2.2
Voltage:45V DC - 56 V DC nominal
Current limit:27A
Power:675W
Efficiency:>88,5%, typical 90% (at 40-90% load)
9.2.4 Weight
Approximately 2,2 kg
9-2
9.3 Operation
FMP 16 has status indicators that is located on the front panel of the module. The output voltage is
adjusted from the controller.
There are three LEDs situated on the rectifier's front panel, which indicate the operating condition of the
rectifier.
Figure 9-1
9-3
9.4 Environment
The FMP 16 rectifiers meet the Environmental Standard requirements of:
ETS 300 019-1-3 class 3.2 / 3M1 for Operating (Stationary In-Use)
Temperature Range: -40C to +65C (up to 2000m) and -40C to +55C (above 2000m)
9.4.1 Storage
ETS 300 019-2-1 Class 1.2.
9.4.2 Transport
ETS 300 019-2-2 Class 2.3.
9.4.3 Operation
ETS 300 019-2-3 Class 3.2.
9.5 Safety
The FMP 16 rectifiers fulfil those international and national safety standards for these systems according to
grounding, fire protection and other safety matters as specified in the following standards:
EN60950 / IEC 60950
UL60950
CSA C22-2 No. 950
9.6 EMC
The rectifiers' EMC meets the requirements of:
EN61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4 and FCC Part 15 Class B
9-4
10-1
10-2
Function
RS 485 interface
Current share with other PPR 16/10
Input mains
DC output
PL12
PL11
PL14
PL13
PL4 PL6
(Com)
PL16
PL15
PL18
PL17
PL20
PL19
PL3 PL5
(Curr)
PE
N
L
Input mains
10-3
Subrack 1
PL4 PL6
PL3 PL5
Subrack 2
PL4 PL6
PL3 PL5
Subrack 3
PL4 PL6
PL3 PL5
Communication signal
from alarm interface unit
Use cable marked with Brown 1 between PL6 in subrack 1 to PL4 in subrack 2.
Use cable marked with Orange 3 between PL5 in subrack 1 to PL3 in subrack 2.
Use cable marked with Brown 1 between PL6 in subrack 2 to PL4 in subrack 3.
Use cable marked with Orange 3 between PL5 in subrack 2 to PL3 in subrack 3.
Note! If the system consist of more subracks connect after the same method between subracks as
described over.
10-4
Module
position
Connection
Dip switch ON
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
All off
1
2
1+2
3
1+3
2+3
1+2+3
4
1+4
2+4
1+2+4
3+4
1+3+4
2+3+4
1+2+3+4
5
1+5
2+5
1+2+5
3+5
1+3+5
2+3+5
1+2+3+5
4+5
1+4+5
2+4+5
1+2+4+5
3+4+5
1+3+4+5
2+3+4+5
1+2+3+4+5
6
1+6
2+6
1+2+6
3+6
1+3+6
2+3+6
1+2+3+6
4+6
1+4+6
2+4+6
1+2+4+6
3+4+6
1+3+4+6
2+3+4+6
1+2+3+4+6
5+6
1+5+6
10-5
6
6
6
6
6
6
6
6
6
6
7
7
7
7
51
52
53
54
55
56
57
58
59
60
61
62
63
64
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
2+5+6
1+2+5+6
3+5+6
1+3+5+6
2+3+5+6
1+2+3+5+6
4+5+6
1+4+5+6
2+4+5+6
1+2+4+5+6
3+4+5+6
1+3+4+5+6
2+3+4+5+6
1+2+3+4+5+6
10-6
11-1
PBDU 4U/23
The Power-One PBDU 4U/23 includes a complete system controller plus battery and load distribution in a
4U unit. The Compact Distribution is compatible with various types of Power-One subracks/rectifier
shelves, and may be configured for a variety of battery and load breaker selections.
The distribution unit is designed for switching the battery and load on and off. All DC distribution breakers
are supervised by measuring voltage drop across each breaker. MCB's (breakers), which are not
connected to any load, will not cause breaker alarm even if they are left open.
Due to small leakage current (2,5 - 3 mA) through the alarm circuit the voltage measured with a DVM
(Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage. If a battery
breaker fault occurs or is simulated it might take from 2 - 10 minutes before the fault is indicated, depending
on the battery condition.
11-2
0V Battery/Load
- Battery/Load
Figure 11-3
+ Battery/Load
Connections
- Battery/load
Connections
11-3
11.5 Installation
This section details how to connect the -48 V DC supply to the DC load.
Check that all the MCB breakers and the AC mains supply are in the OFF position.
Unscrew the cabinet's four top fixing screws and slide top-cover forward before lifting it up. Enter each load
cable in to the cabinet trough the inlet at the back of the cabinet.
Connect the negative (-) load DC supply cable to the appropriate negative DC distribution MCB by inserting
the stripped cable in the opening on top of the MCB and tightening the screw. Make sure the cable is the
correct rating (i.e. thick enough) for the selected MCB.
Connect the positive (+) load DC supply cable directly to the positive busbar by inserting the stripped cable
to the hole on top of the screw connector so that the cable is behind the busbar, and then tightening the
screw. Start connecting the loads to the busbar from the first connector on the left. Make sure, the cable is
the correct rating (i.e. thick enough) for the load.
Check, that all the cables are secured tightly to the connectors. Use Torque Table in the Maintenance and
troubleshooting chapter for the correct torque.
11.7 Maintenance
The distribution does not need any special maintenance except for ordinary cleaning.
11-4
12-1
12.1 General
PCS alarm interface unit consist of BM0685, which is an alarm board for Power One systems. The unit is
located on the right hand side of the distribution and is accessed from the top of the cabinet.
Control signal for individual operating LVD and PLD. (J20, J21)
4 x input for symmetry measurement. (J1, J2). Optionally symmetry input 4 may be used as 3 x
analogue inputs. (J2 pin 4-6).
RS485 interface for communication with plant controller PCS. (J24 and J25)
Pin
1
2
3
4
5
6
A
RECONN1
DISCONN1
DF/BFM1
BATTFUSE1
SHUNT1+
SHUNT1-
B
RECONN1
DISCONN1
DISTFUSE1
BATTFUSE2
SHUNT2+
SHUNT2-
Plug J20
Pin
1
2
3
4
5
6
A
RECONN1
DISCONN2
DF/BFM2
BATTFUSE3
SHUNT1+
SHUNT1-
B
RECONN1
DISCONN2
DISTFUSE1
BATTFUSE4
SHUNT2+
SHUNT2-
12-2
J7 J6
12 3 12 3
12 3 12 3
456 456
J3
J2 J1
J5 J4
12 12 3 12 3
456 456
Figure 12-1
+
T
+
T
-
DI.1
DI.0
Red
Green
Blue
Red
Green
Blue
+
T
+
T
-
Red
Green
Blue
Red
Green
Blue
12 34 12 3 12 3
J10
J9 J8
456 456
Alarm contacts
are shown in
alarm position
0V
+12V
DO.1
DO.0
6
5
4
3
2
1
6
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
J2
Batt. sym. 4/
ext. analog
J1
Batt. sym.
J3
Digital input
(Door alarm)
Temp. Probe 4
J5
Temp. Probe 3
Temp. Probe 2
J4
Temp. Probe 1
Alarm 6
J9
Alarm 5
6
5
4
3
2
1
J8
3
2
1
J7
Alarm 2
3
2
1
J6
Alarm 1
4
3
2
1
J10
Digital output
Alarm 4
Alarm 3
12.4 Maintenance
The PCS alarm interface unit does not need any special maintenance.
12-3
12-4
13-1
13.2 Troubleshooting
This guide is a step-by-step recommendation of what to do if problems occur. If first step of
recommendation do not solve the problem continue to the next one. If the problem cannot be solved please
call your local Power - One office for assistance.
Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be
connected to the RS232 contact (Only applies when a controller without LCD display is in use).
Low system voltage:
z
Load/battery disconnected:
z
If breaker blows once more, there is either a too high load or short circuit at the system
Mains error:
z
13-2
Check the equipment that is connected to the blown breaker (there may be a reason for this breaker
to blow) and reconnect it.
Battery failure:
z
Module failure:
z
Pull it out.
Wait for 30 sec. and reinstall it according to 13.1 Installing new modules.
Check ventilation.
Symmetry fault:
z
Check batteries.
High load:
z
Communication failure:
z
13-3
13.3 Maintenance
The connections on the terminal blocks and circuit breakers must be checked according to the 13.4 Torque
table minimum once a year.
Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed
to see any deviations.
In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air
inlets and outlets free from dust or other materials, which may prevent free air circulation through the
cubical.
MODEL / DESCRIPTION:
TORQUE
(Nm):
TORQUE
(Inch LB):
AKG 16mm2
2,5 Nm
22
AKG 35mm2
3,5 Nm
31
WDU 4mm
0,6 Nm
WDU 10mm
2,0 Nm
18
WDU 16mm
3,0 Nm
27
Siemens
2,5 Nm
22
Merlin G
3,5 Nm
31
ABB
2,0 Nm
18
CBI HY-MAG
3,0 Nm
27
ABB 160A - S2
5,0 Nm
45
9,0 Nm
80
ABB 630A - S6
9,0 Nm
80
Terasaki - XS125CJ
9,0 Nm
80
13-4
Drawings
Appendix A: Drawings
Date:
17.02.05
Designer:
Scale:
SK
Cabinet layout
PODS 16.48-16000 1940 HEX
Drawings
Document number: Appendix A.fm
Revision: B
Page 01 of 01
ref:
039095
Rev:
A-1
Drawings
Date:
17.02.05
Designer:
Scale:
SK
Cabinet layout
PODS 16.48-16000 1940 HEX
A-2
Page 01 of 01
ref:
039095
Rev:
Drawings
BM0685
Connection of alarms and signals in the right hand side of the distribution
Table below shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet)
Note: Check that symmetry and temp cables are correctly mounted
*Battery type: 2 blocks, ext sym
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
0V
-24V
6
5
4
3
2
1
6
5
4
3
2
1
J2
J1
Batt. sym. 4
/ext. analog
J2
(-)16V
(-)32V
Batt. sym. 3
(-)16V
(-)32V
Batt. sym. 2
J1
(-)16V
(-)32V
0V
Batt. sym. 1
(-)16V
(-)32V
-16V
-32V
-48V
6
5
4
3
2
1
6
5
4
3
2
1
J2
Batt. sym. 3
Batt. sym. 2
J1
0V
-12V
Batt. sym. 1
-24V
-36V
IOIOI
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
MERLIN GERIN
multi 9
1
D100
C120N
multi 9
1
D100
415V
10000
I ON
C120N
D100
415V
10000
I ON
415V
10000
I ON
I ON
I ON
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
MERLIN GERIN
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
multi 9
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C60N
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
C16
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
230/400V
6000
3
I ON
I ON
power-one
MERLIN GERIN
multi 9
C60N
power-one
I ON
power-one
I ON
I ON
I ON
power-one
I ON
I ON
I ON
power-one
I ON
I ON
power-one
I ON
I ON
I ON
power-one
I ON
I ON
I ON
power-one
I ON
I ON
power-one
I ON
I ON
I ON
power-one
+
T
+
T
-
DI.1
DI.0
Red
Green
Blue
Red
Green
Blue
+
T
+
T
-
Red
Green
Blue
Red
Green
Blue
T
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
FMP1648
Alarm contacts
are shown in
alarm position
0V
+12V
DO.1
DO.0
3 phase 400V AC
* Extended symmetry:
Check extended symmetry flag in config wizard - page 1
6
5
4
3
2
1
6
5
4
3
2
1
Batt. sym. 4
/ext. analog
J2
Batt. sym. 3
Batt. sym. 2
J1
Batt. sym. 1
-48V
-48V
C120N
(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V
Batt. sym. 4
/ext. analog
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1
Digital input
Temp. Probe 4
J5
Temp. Probe 3
Temp. Probe 2
J4
Temp. Probe 1
Alarm 6
J9
Alarm 5
6
5
4
3
2
1
J8
3
2
1
J7
Alarm 2
3
2
1
J6
Alarm 1
4
3
2
1
J10
Digital output
Alarm 4
Alarm 3
PE
PE
PE
PE
PE
PE
PE
PE
PE
2
2
N
N
2
2
N1
N1
2
2
L1
L1
N2
L1
N2
L1
N3
L2
4
5
N
L1
4
5
N3
L1
4
5
L2
L2
L1
L1
L2
L2
L2
L3
L2
L2
L3
L3
L3
L3
L3
L3
L3
17.02.05
Designer:
Scale:
SK
Installation drawing
PODS 16.48-16000 1940 HEX
Drawings
Document number: Appendix A.fm
Revision: B
Page 01 of 01
ref:
039096
Rev:
A-3
Drawings
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
BM0666
Subrack
PL4 COM
8
PL6 COM
8
PL3 Current share
8
PL5 Current share
Subrack for
10xFMP 16
PCS
control unit
J1 Com 1
BM0686
RS 232
J7 Com PCS
J9 Ethernet
1
2
3
+12V
Sys. voltage J8 Internal power
-12V
1
2
+ J2 Power
-
Optional plugable
PNI board
8
9
ETHERNET
MODEM/PC
Display board
PB2002B-P9
Distribution
0V
See schematic
diagram for
more details
LVD
- Battery 1
Fuse alarm
board
- Battery n
- Load 1
- Load n
BM0685
6
5
4
3
2
1
Batt. Sym./
Ext. analog
PTC 2
J2
Batt. sym
PTC 1
J1
Batt. sym
J3
Digital input
6
5
4
3
2
1
Temp. 4
J25 Com.
J5
J24 Com.
Temp. 3
1 0V
2 System voltage
J 23
1 +12V
2 0V
3 -12V
J 22 Electronic
J4
power
Temp. 2
Temp. 1
DI.1
DI.0
2
1
+12V
Sense
0V
+12V
Sense
0V
6
5
4
3
2
1
+12V
Sense
0V
+12V
Sense
0V
6
5
4
3
2
1
6
5
4
3
2
1
Alarm 6
Alarm 5
BM0708
Pulse
Pulse
Fan 2 J3
+
AN Out 1
1 Pulse
2 Pulse
Fan 1 J2
3 +
4 AN Out 0
1 0V
2 Sense Temp 2 J5
3 +12V
1 0V
2 Sense Temp 1 J4
3 +12V
Heat exchanger
(HEX)
In
Blue
White
Red
Yellow
J8
J7
J6
Alarm 3
6
5
4
3
2
1
Alarm 2
3
2
1
Alarm 4
3
2
1
Alarm 1
J 10 Digital out
0V
+12V
DO.1
DO.0
4
3
2
1
Cabinet
Com.
NC
NO
Door switch
Out
Blue
White
Red
Yellow
Designer:
Date:
07.03.05
Scale:
KMH
Page 1 of 1
ref:
Rev:
039097
A-4
Drawings
A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 Rev: /
0V Battery
0V Load
LVD
- Battery 1
Black
Red
+
- Battery n
- Load 1
- Load n
BM0700
J1
J3
B1-1
B2-1
B3-1
B4-1
B5-1
B6-1
MH1
F1-1
F2-1
MH7
Fn-1
Fn-1
1
2
3
4
J2
1
2
J4
BM0685
J2
6
5
4
3
2
1
Batt. Sym/
Ext. analog
Batt. sym
J1
Batt. sym
J3
Digital input
Temp. 4
J25 Com.
J5
J24 Com.
Temp. 3
1 0V
2 System voltage
J 23
1 +12V
2 0V
3 -12V
J 22 Electronic
J4
power
Temp. 2
Temp. 1
6
5
4
3
2
1
DI.1
DI.0
2
1
+12V
Sense
0V
+12V
Sense
0V
6
5
4
3
2
1
+12V
Sense
0V
+12V
Sense
0V
6
5
4
3
2
1
6
5
4
3
2
1
Alarm 6
Alarm 5
BM0708
1
2
3
4
Pulse
Pulse
Fan 2 J3
+
AN Out 1
1
2
3
4
Pulse
Pulse
Fan 1 J2
+
AN Out 0
J8
J7
1 0V
2 Sense Temp 2 J5
3 +12V
J6
1 0V
2 Sense Temp 1 J4
3 +12V
Date:
Connect according
to Block diagram
07.03.05
Designer:
Alarm 3
6
5
4
3
2
1
Alarm 2
3
2
1
Alarm 1
3
2
1
Alarm 4
J 10 Digital out
KMH
Page 1 of 1
Powec ref:
ref:
Rev:
039098
4
3
2
1
Scale:
Drawings
0V
+12V
DO.1
DO.0
A-5
A-6
COM
PL4
L
N
PE
COM
PL6
L
N
PE
L
N
CURR
PL3
CURR
PL5
L
N
PE
L
N
PE
L
N
PE
Optional Battery
heater
PE
Optional AC outlet
L
N
PE
PE
PE
BM0666
L
N
PE
L
N
Designer:
SK
Scale:
Mains input
terminal blocks
18.02.05
Date:
Optional Over
Voltage Protection
PE
Powec
ref: ref:
039109
Page 1 of 1
Rev:
Drawings
COM
PL4
Drawings
L
N
PE
COM
PL6
L
N
PE
L
N
CURR
PL3
CURR
PL5
L
N
PE
L
N
PE
L
N
PE
Optional Battery
heater
PE
Optional AC outlet
L
N
PE
PE
PE
BM0666
L
N
PE
L
N
Designer:
SK
Mains input
terminal blocks
Scale:
18.02.05
Date:
Optional Over
Voltage Protection
PE
Powec
ref: ref:
039110
Page 1 of 1
Rev:
Drawings
A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 Rev: /
A-7
A-8
COM
PL4
L
N
PE
COM
PL6
L
N
PE
L
N
CURR
PL3
Optional Battery
heater
PE
Optional AC outlet
L
N
PE
PE
PE
CURR
PL5
L
N
PE
L
N
PE
L
N
PE
BM0666
L
N
PE
L
N
Designer:
SK
Scale:
Mains input
terminal blocks
18.02.05
Date:
Optional Over
Voltage Protection
PE
Powec
ref: ref:
039111
Page 1 of 1
Rev:
Drawings
A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 Rev: /
Drawings
Drawings
Document number: Appendix A.fm
Revision: B
A-9
Drawings
A-10
Configuration c-000313
Configuration c-000313
Document number: 039418.fm
Revision: A
B-1
Configuration c-000313
B-2
Configuration c-000313
Configuration c-000313
Document number: 039418.fm
Revision: B
B-3
Configuration c-000313
B-4
Distribution
Appendix C: Distribution
C.1 Distribution PBDU 23" 1xMCB/10xMCB
Breaker 6A
FB1
FB2
FB3
FB4
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
X
X
X
X
X
X
X
X
X
X
Distribution
Document number: 039099.fm
Revision: A
PLD
Type of equipment
Battery 1
C
C
C
C
C
C
C
C
C
C
C-1
Distribution
+Connection
to chassis
0V, LOAD
0V, BATTERY
0V
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
Power-one
C-2
F1
Power-one
-LOAD
- Batt. 1
FB1
0V
F10
D-1
D-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
D-3
Amendment record:
Revision
(Issue)
Description
Author
Date
/
A
B
C
First issue
New revision
New revision
New revision
rjan Skauge
Hans A Dokka
Kai Morten Hennum
Hans A Dokka
06.10.04
12.05.05
13.05.05
18.05.05
D-4
Date 18.05.05
Date 19.05.05
WARNING! THE READER MUST READ AND UNDERSTAND THE WARNINGS AND CAUTIONS
IN THIS MANUAL BEFORE STARTING.
Insulated tools.
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
D-5
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
D-6
Overview
1.
2.
3.
4.
5.
6.
D-7
D.5 Mounting
Figure D-3
1.
2.
D-8
D.6 Installation
Figure D-4
1.
Remove 3 dummy breakers by releasing the catch on top of the dummy breaker using a screw
driver.
Figure D-5
D-9
2.
Figure D-6
3.
4. Install the new load breaker in the open breaker slots. Tighten the lower screws in the breaker to a
torque of 3,5 Nm.
D-10
Figure D-7
5.
Mount the alarm cable harness to the fuse alarm board as shown in Figure D-7.
Figure D-8
6.
Mount the front terminal for copper cables to the common rail as shown in above figure.
7.
Tighten the front terminal for copper cables to the AKG with a torque of 3,5 Nm.
8.
Cables mounted to the front terminal for copper cables to be mounted with a torque of 7 Nm.
D-11
D-12
E-1
E-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
E-3
Amendment record:
Revision
(Issue)
Description
Author
/
A
First issue
New Revision
Date 21.03.05
Date
Date 13.05.05
Hennum
Signed
E-4
Signed
The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
WARNING!
Figure E-1
Insulated tools.
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
E-5
E-6
2.
Remove the end-stop piece mounted on the DIN rail below the mains terminal blocks.
3. Mount the Surge arrestor kit for mains input 1 by snapping the surge arrestor holder on the DIN rail
next to the mains input terminal blocks on the left hand side. Mount the end stop below the Surge arrestor
kit in order to prevent the Surge arrestor kit from sliding on the DIN rail.
Figure E-2
4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in
Appendix A: Drawings.
Note! Do not use Figure 2 as connection reference. It is important to always connect according to
Appendix A: Drawings schematics.
5.
6.
After checking the Surge arrestor kit connections, the mains input can be reconnected.
7. Each Surge arrestor module has a display on the front that indicates if it is OK or has blown. Red
displayed surge arrestors are blown and has to be replaced.
E-7
E-8
F-1
F-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
F-3
Amendment record:
Revision
(Issue)
Description
Author
/
A
First issue
Second issue
Date 21.03.05
Date
Date 13.05.05
Hennum
Signed
F-4
Signed
The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
WARNING!
Figure F-1
Insulated tools.
F-5
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
F-6
2.
3.
4.
5. Antistatic bag, signal cable harness, plugable fuse alarm and 4xscrew M6.0 x 12 Taptite pan elzn
TT3.
F-7
Note! Front plate removal is only necessary when installing battery extension kit 4. However, removal of
the lower plate is recommended for easy access when installing batteries in the lower shelf.
Mount the battery shelf by sliding it into the punch outs on the back walls. The spacing between two battery
shelves should be 8U. This is measured from the mounting hole of the lower shelf to the mounting hole on
the shelf above. The shelves in Figure F-2 are shown transparent so that the mounting holes are visible.
Figure F-2
1
8
7
6
5
4
3
2
1
F-8
Fasten the battery shelf using the supplied screws in mounting holes on the battery shelf. Torque 3,5 Nm.
F-9
F-10
Figure F-4
Figure F-5
F-11
2. Mount the signal cable harness by sliding the cable lug onto the fuse alarm board in the position for
battery breakers. Battery breaker positions are labelled with a B on the print board.
Figure F-6
F-12
2. Mount the negative battery cable directly on top of the new battery breaker.
3. Make sure the signal cable harness is mounted to the battery breaker together with the battery
cable. Torque 3,5Nm.
F-13
Figure F-8
4. Strip the battery cables to the sheet metal bracket as shown in Figure F-9. Strip the rest of the
battery cables using the original battery cables as reference.
Figure F-9
5. Mount the supplied symmetry cable to the Alarm interface board located in the upper right corner of
the cabinet. Torque 0,6Nm.See Installation drawing in Appendix A for reference.
6. Strip the new symmetry cable using the original symmetry cable as reference.
F-14
Figure F-10
F-15
F-16
G-1
G-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
G-3
Amendment record:
Revision
(Issue)
Description
Author
Date
First issue
rjan Skauge
05.11.04
G-4
Date 11.11.04
Date 11.11.04
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
G-5
Overview
1.
G-6
G.5 Mounting
Figure G-2
Fix the dummy module FMP 16 with the screw in bottom left corner. See Figure G-2
2.
G-7
G-8
H-1
H-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Overview 19 adaptor kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
G.5.Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
G.5.1.Installing the battery shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
G.5.2.Installing the battery breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
G.5.3.Installing the battery cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11
H-3
Amendment record:
Revision
(Issue)
Description
Author
/
A
First issue
Second issue
Date 06.04.05
Date
Date 13.05.05
Hennum
Signed
H-4
Signed
The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
Note! Use insulated tools.
Figure H-1
Insulated tools.
H-5
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
H-6
2.
3.
Figure H-2
19 adaptor kit
H-7
H.4.1 Installation
First enter the two adaptor pieces on each side of the cabinet as shown in Figure H-3 using the 8 screws.
Torque: 6 Nm.
Figure H-3
H-8
Use the isolation pieces where cable feed-through is wanted to avoid damaging cables.
Figure H-4
H-9
H-10
I-1
I-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6
Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6
I-3
Amendment record:
Revision
(Issue)
Description
Author
First issue
Date 10.06.05
Date
Date 10.06.05
Hennum
Signed
I-4
Signed
I.1
The purpose of this document is to give a clear instruction in the connection of a Battery Heater Kit for
PODS 16.48-16000 1940 cabinets.
To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT
The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.
WARNING!
Figure I-1
I.2
Insulated tools.
Safety precautions
WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
I-5
I.3
I.4
The battery heater kit is designed to heat the batteries installed in the Power-One outdoor cabinets to avoid
batteries from freezing when operating in a cold environment.
I.5
1.
Locate the position for heater kit installation at the bottom right of the cabinet.
3.
Remove the lower three screws used to fasten the panel and battery shelf.
4.
Position the heater fan and fasten the shelf, panel and fan with three screws. (Torque: 6 Nm)
5. The heater fan is now mounted. Ensure that the heater thermostat is set to the 5 degrees default
value.
6. Mount the heater cable as shown. Insert the four strip fasteners into the holes along the shown cable
path, and use the four strips to fasten the cable.
Note! Some early versions of the outdoor cabinets do not have the cable entry opening shown in part 6
of Figure I-2 on page I-7. Alternative cable routing down and under the bracket is shown in
Figure I-3 on page I-8. In this case the easiest installation is to pull the cable through before
mounting the heater fan.
I-6
Figure I-2
3. Removal of screws
2. Heater Fan location
6. Cable Path
I-7
Figure I-3
7.
Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.
Note! If a Surge arrestor kit is installed or is being installed, mount the battery heater circuit breakers
and ground terminal block below the surge arrestor as shown in Figure I-4.
8. Mount the circuit breaker and the ground terminal block by snapping them on the DIN rail below the
mains input terminal blocks or below the surge arrestor kit if installed (Torque: 1,5 Nm). Mount the end stop
below the kit in order to prevent the parts from sliding on the DIN rail (Torque: 1,5 Nm)..
I-8
Figure I-4
9.
I-9
I-10
J-1
J-2
Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Overview AC outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
J-3
Amendment record:
Revision
(Issue)
Description
Author
/
A
B
First issue
New Revision
New Revision
Date 21.03.05
Date
Date 30.05.05
Hennum
Signed
J-4
Signed
The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.
WARNING!
Figure J-1
Insulated tools.
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.
J-5
2.
Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.
3. Mount the AC service outlet by snapping the holder on the DIN rail below the mains input terminal
blocks. Mount the end stop below the AC outlet kit in order to prevent the parts from sliding on the DIN rail.
Note! If Surge arrestor kit or battery heater kit is installed, mount the AC outlet below the surge arrestor
and battery heater breakers as shown in Figure J-2.
J-6
Figure J-2
4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in
Appendix A.
5.
6.
After checking the AC outlet kit connections the mains input can be reconnected.
J-7
J-8