Modular Rack Power System Manual

LARGE CAPACITY RACK POWER SYSTEM
SYSTEM MANUAL
LARGE CAPACITY MODULAR RACK POWER SYSTEM BASED ON 100A pfc SERIES SWITCHED MODE RECTIFIERS (Compatible with VRLA Batteries only)
MODEL NO. HE-N*100ApfcLCRPSIII

AS PER TEC SPEC. No. GR/FLA/SMP 001/06/June. 2010
MFD BY: M/S EXICOM TELE-SYSTEMS LTD.

(AN ISO 9001: 2008 COMPANY)
HEAD OFFICE
8, Commercial Complex, Masjid Moth, Greater Kailash II New Delhi-110048, India Tel: +91-11-3088 2624, +91-11-3068 2624 Fax: +91-11-3068 9013 E-mail: contact@exicom.in
WORKS:
Shed No. 1-8, Electronic Complex, Chambaghat, Solan (H.P.) - 173213 Phone: +91-1792- 230947, 230948, 231260 Fax: +91-1792- 231255 E-mail: factory.solan@exicom.in
CONTENTS
SECTION - 1
INSTALLATION AND COMMISSIONING MANUAL

INTRODUCTION IMPORTANT TECHNICAL DESCRIPTION INITIAL CHECK ON RECEIEPT AT SITE INSTALLATION & COMISSIONING OF POWER PLANT COMMISSIONING THE POWER PLANT LIGHTNING PROTECTION UNIT INTERCONNECTING CABLE SET
SECTION - 2
RECTIFIER MANUAL
WARNING IMPORTANT QUICK REFERENCE CONTENTS TECHNICAL DESCRIPTION INITIAL CHECKS ON RECIPTS AT SITE AC POWER QUALITY & EMI COMPATIBILITY FAMILIARIZATION WITH THE RECTIFIERTESTING & ADJUSTMENT PROCEDURE ROUTINE MAINTENANCE PROCEDURE TROUBLESHOOTING TECHNICAL SPECIFICATIONS
SECTION - 3
MONITORING AND CONTROL MODULE MANUAL

INTRODUCTION CAUTION TECHNICAL DESCRIPTION INSTALLATION & COMMISSIONING FRONT PANEL CONTROLS STEP BY STEP COMMISSIONING OF A MCM FOR AN EXAMPLE SYSTEM TROUBLESHOOTING USER RESPONSE CARD FAULT REPORT WARRANTY CERTIFICATE
SECTION - 1 INSTALLATION & COMMISSIONING MANUAL

INTRODUCTION
Exicom Large capacity Rack Power systems employ Exicoms pfc series Switched Mode Rectifiers to provide upto 3000 Amps (max.) of regulated power for powering telecommunication equipments and also keep batteries floated across the load in fully charged condition so that uninterrupted operation of vital communication network continues even when AC mains fail. Todays sensitive electronic loads and state of the art VRLA batteries require continuous electronic supervision and features like Temperature Compensation, Battery path current limiting etc. A Micro-controller based Monitoring & Control Module (MCM) carries out all these vital tasks. For installation and periodic checking contactors are provided in each battery path. Ratings and the number of contactors depend upon the particular installation, which is normally specified by the user. Every exchange design calls for different distribution of DC power typical to itself. When power plants are supplied against any particular switch the DC distribution is configured accordingly. All the above modules and sub-assemblies are housed in a rack. Because of the modularity of the whole architecture the system is extremely flexible. A variety of combinations can be worked out to serve any kind of requirement and provision for future expansion. Following sections contain further details on these modules and installation & commissioning procedure. Following abbreviations are used in the text for convenience. MCM SMR ACDB LPU BI Panel RU CB : Monitoring & Control Module. : Switched Mode Rectifier. : AC Distribution Panel. : Lightning protection module. : Battery Isolation Panel : Rack Unit. : Circuit Breaker.
IMPORTANT
Please read this section carefully before attempting to install the system. The equipment you are about to handle is a product of the latest in SMPS technology. The front end Active Power Factor Correction circuit develops very high DC voltages inside. This voltage may persist for some time even when the equipment has been switched off and disconnected from the input mains. No attempt should ever be made to open the equipment. It is stressed here that the equipment has no user serviceable part inside. In case of any malfunction the matter should be brought to the notice of the manufacturer stating the description of the fault and the serial number of the equipment. Warranty stands void in case of any unauthorized tampering. Caution: The equipment employs sensitive electronics that can be damaged if subjected to electrical and climatic environment other than those for which the product is designed. Such damages will not be entertained as manufacturing defects. It is strongly recommended that proper entry-level protection along with reliable earth connection be first installed before connecting the equipment to the AC mains. The SMRs are power factor corrected. Hence no external capacitors are required. Caution: In case external power factor correction capacitors are connected they should be removed before installing RPS as large spikes can be generated due to inductive switching in the proximity of the installations, which could damage the SMRs.
TECHNICAL DESCRIPTION
The various sub-assemblies of the Rack Power System (Fig. 1.1) are discussed in this section.
Rack
All the sub-assemblies are mounted in a rack 750mm wide rack. These racks are of rigid steel structure fabricated with CNC machines to provide the accuracy required to mount a verity of assemblies. A superior powder coating technology together with prepainting surface finishing provides total atmospheric protection. The height is 45RUs and the depth is 600mm. Provision for grouting these to the floor is also given. The contents of the rack are accessible from rear and front. Rectifiers are inserted or extracted from the front. No front door is provided. Rear door is removable.
Monitoring & Control Module

This module carries out all the supervisory and control of the power plant. The functions carried out by this module are many and it is important to know these. For this reason a separate part inside the manual is supplied for MCM. A through study of this section is recommended before use.
Switched Mode Rectifier

EXICOMs pfc series SMRs convert AC mains to regulated DC for powering telecom installations. They are high efficiency converters with nearly unity power factor and draw near sinusoidal current from the mains. A separate part is available inside this manual for SMR. A thorough study of this section is recommended before use.
ACDB (with inside SPU STAGE-II)

The incoming AC main is terminated in this panel. Circuit breakers have been provided for distribution of AC to every rectifier. Terminal blocks have been provided for input terminations as well as for distribution to each SMR. SPU and Galvanic isolation contactor is part of this panel.
LPU (Stage-I) To ensure total protection, entry-level protection is provided near the LT panel by the LPU. A Co-ordination distance of 15 meters is to be maintained between LTP+SPU. B.I Panel
Depending on the rating and the number of MCBs or the particular rack power system configuration, the facility is housed in a rack along with SMRs. Due to the better flexibility a variety of configurations can be made. Arrangement is provided to monitor currents flowing in or flowing out of individual batteries. Audio and visual alarm is generated when any of the batteries are disconnected from the system. Adequate de-rating is done while selecting the contactor size.
Figure 1.1
3000A Rack Power System
HIMACHAL EXICOM COMMUNICATIONS LIMITED
100A
AC OK/ABN REC. OK/FAIL LOAD OV
FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
INITIAL CHECK ON RECEIEPT AT SITE

Following sequence of action is recommended when the rectifier is received at site: a) Although the equipment had left the factory properly packed instances of mishandling by the transporter are quite common. Hence before taking delivery ensure that the packing is intact and free from any signs of damage or improper handling. If any of these are suspected the manufacturer must be informed immediately for remedial action and insurance. b) Unpack the equipment carefully. Ensure that no force is applied in removing the packing, which could damage the contents. c) Never try to energies any equipment if any transit damage is suspected. Doing so irreparable damage may take place. d) Tally the contents with the packing list. Report immediately if any anomaly is noticed. e) Familiarize with the various sub-assemblies with the drawings enclosed. Call for assistance if required or in doubt.
INSTALLATION & COMISSIONING OF POWER PLANT

Note: Installation of this RPS involves handling 440 Volts AC and high AH capacity batteries, which could deliver, more than 1000 Amps when shorted. The job should be undertaken by qualified personnel at his or her own responsibility. Exicom takes no responsibility or liability in the event of any injury inflicted on person or property due to improper use and practice. Tools Requirement:
The following tools are required to install and commission the RPS. 1) Spanner set. 2) Screw driver set. 3) Richest spanner set. 4) Cable cutter. 5) Cable crimping tool 6) Star headed screwdriver 7) Multimeter with test leads.
Step1: Rack Positioning (Figure 1.2)

Front and rear access is required for installation and maintenance. Leave at least 1-meter space between the rear of the rack and the wall, so that it can be easily accessible.
Figure 1.2
Bare Rack
Step 2: Rectifier numbering

Rectifiers can be numbered 1,2,3... starting from the top most one as shown in Figure 1.5.
Step 3: Rack preparation (Figure 1.3) 1. Remove the rear cover of the rack.
2. Place the rack in its position and grout the same to the floor.
Figure 1.3 Step 4: Battery connections 1. Connect battery 1 +VE to B1+, battery 2 +VE to B2+ marked on battery termination bus bars and so on.
2. Similarly, battery 1 -VE to marked B1-, battery 2 -VE to B2- marked on battery termination bus bars and so on. 3. Keep the circuit breakers of DC output CB panel in off condition before connecting the cable from the battery.
Step 5: Installation of the ACDB (with inside SPU) (Figure 1.4)

The ACDB (inside SPU) is to be mounted at its position as given in assembly drawing shown below. AC Input to SMRs Connect SMR AC Input Cable free ends to the terminal block for AC input to SMR on ACDB Panel. Route the cable thru the clamps provided.
Figure 1.4 Step 6: Mounting of MCM & SMRs (Figure 1.5)

The MCM is to be mounted above ACDB Panel at its position as shown in given drawing. SMRs are to be mounted below ACDB on the channels on the rack as shown in given drawing.
For all inter connection cables please refer to table-1
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
RESET
0A
FAN FAIL
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
RESET
0A
FAN FAIL
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
RESET
0A
FAN FAIL
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
RESET
0A
FAN FAIL
Figure 1.5 MCM & SMRs
Step 7: MCM Connections Make following connections to MCM as per details provided in MCM manual: MCM to ACDB Connection (AC Supply) MCM to SMRs (Alarm and Control Cable) MCM to BI Rack (25 Way Ribbon Cable) MCM to battery Chassis (Temp. Probe)
Step 8: Connection of DC outputs from SMRs Connect lugged end of SMRs output cables (RED/WHITE) at common bus bar & connect lugged end of cables (BLACK/BROWN) at O/P. Step 9: Connecting the remote alarm communication cable (Figure 1.6) 1. Connect the end connector on its mating connector in the MCM front panel. 2. Connect the daisy-chained connectors on the 15-pin receptacle on the front panel of each SMR.
Daisy chain remote alarm communication cable
Front view
Figure 1.6 Step 10: AC Input Connection to RPS (Figure 1.7) Copper cables for I/P + earth + neutral is needed. Connect this cable from LT panel to I/P terminal block of ACDB.
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
100A
OFF
100A
OFF
100A
OFF
+
OUTPUT MONITOR
+
OUTPUT MONITOR
+
OUTPUT MONITOR
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
CURRENT
LOAD UV OVER LOAD
ON
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
0A
FAN FAIL
RESET
Figure 1.7 Step 11: RPS Remote Alarm Connections
AC Input to RPS
The RPS alarms can be monitored remotely by connecting a cable at terminal block on the rear panel of MCM. For location and pin out refer MCM Manual.
Step12: Power connection to SMRs

Gently insert the three pin round input connector on the back side of SMR & tight it properly.
Step 13: Power connection to exchange

Power connection to the exchange is done by the DCDB (optional) which has been custom designed for the particular switch and the installation.
Step 14: Power connection to Batteries

Ensure that all the circuit breakers are in open position & the battery fuses located at the battery stand is removed. Battery terminations on the BI panel are to be connected to the batteries. Ensure correct polarity.
Step 15: Remote monitoring by RS 485 port With this the installation of the system is over and it is ready for commissioning.
COMMISSIONING THE POWER PLANT

Attention: 1. This activity is to be carried out by qualified and experienced personnel only.
2. Check if any external Power Factor capacitors are connected to the mains. If yes, they must be removed. 3. Check whether the mains is well within the range i.e. 320V to 480V phase to phase. 4. Check Earth & Neutral connections. 5. Ensure installation of Surge & Lightning protection modules. 6. Ensure proper earth connection. 7. Check voltage between neutral & earth. It should not be more than 10 volts in any case. 8. Check AC earth connection between Master Rack & Slave Rack. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Remove all AC, DC & communication connectors from the rectifiers. Turn on single-phase AC mains from the LT panel. Check the MCM. No alarm other than under voltage should glow. Read AC mains voltage on the MCM by the front panel controls. Connect AC connector on the SMR No.1. Turn on the corresponding MCB on the ACDB & DC MCB at the back of SMR. Press the Volt. select button on the rectifier front panel to read the voltage. This should be set at 54 Volts. This voltage can be adjusted (see Adjustment of Float Voltage in rectifier manual). Step 8. Turn off the MCB for the SMR No.1 & Connect AC connector on the SMR No.2. Step 9. Turn on the 2nd SMR and adjust the voltage. Step 10.Repeat this for all the SMRs. Step 11.Connect test load to the output of the power plant. Ensure that the load doesnt exceed the capacity. It is better to connect somewhat less load when turning on initially. The load can be increased after adjusting the current limiting. Ensure that battery is not connected at this stage. Step 12. Insert DC, AC & Communication connectors on all the SMRs. Step 13. One by one turn on all the MCBs feeding the installed SMRs. Step 14. On the MCM read the total load current. Step 15. Divide the current value by the number of SMRs installed. Step 16. Identify the SMRs that are taking the maximum & minimum load. Step 17. Reduce the voltage by fine control switch for the SMRs taking more load and reverse for the SMRs taking less load. Step 18. Repeat the procedure till all the rectifiers are taking nearly equal current. It is best to do the sharing on 70% loading. Step 19. Increase the load and check sharing. Now the Power Plant is commissioned, batteries and actual load can be connected.
SECTION 2 RECTIFIER MANUAL
WARNING
There are dangerous voltages (440V AC phase to phase and 400V DC) within the rectifiers units. They must only be opened and serviced by qualified personnel. Large charged capacitors internal to the unit make it hazardous to open even when disconnected from mains.
Unauthorized disassembly of any unit voids the warranty.
IMPORTANT
Please read this section carefully before attempting to install the rectifier. The equipment you are about to handle is a product of the latest in SMPS technology. The front end Active Power Factor Correction circuit develops very high DC voltages inside. This voltage may persist for some time even when the equipment has been switched off and disconnected from the input mains. No attempt should ever be made to open the equipment. It is stressed here that the equipment has no user serviceable part inside. In case of any malfunction the matter should be brought to the notice of the manufacturer stating the description of the fault and the serial number of the equipment. Warranty stands void in case of any unauthorized tampering. Caution: The equipment employs sensitive electronics, which can be damaged if subjected to electrical and climatic environment other than those for which the product is designed. Such damages will not be entertained as manufacturing defects. It is strongly recommended that proper entry- level protection along with reliable earth connection be first installed before connecting the equipment to the AC mains. EXICOMs High Voltage Disconnect along with Surge & Lightning Protector wall mounted modules when mounted near the LT panel ensure proper protection against erratic and noisy AC mains. When the rectifier is energized out side the rack the AC input must be fed from a 3-Pole circuit breaker of 32 Amps with a breaking capacity of 10kAmps minimum. The rectifier must be installed in a dust free atmosphere. Acid fumes and presence of corrosive gases in the air will certainly have a detrimental effect on the equipment and hence care is required. Proper ventilation is required. Remember that with 91% efficiency each rectifier will be dissipating 500W in heat. This heat must be removed from the room by ventilations. Although the rectifier is designed to operate at 50 deg.C, operation at lower ambient will certainly improve overall reliability. The complete set of manuals must be thoroughly studied beforehand and in case of any doubt clarification can easily be obtained by calling the numbers listed in the feedback format. Himachal Exicom Communications Limited in pursuit of excellence, innovation & improvement solicits constructive suggestion from the user.
QUICK REFERENCE CONTENTS

Familiarization with the rectifier Refer to fig. 2.1 for the front panel details and fig. 2.2 for the rear panel details. With the aid of these drawings the various controls and indications on the front panel and the connections on the rear panel can be better identified. At the center of the front panel the LED display is situated. This display normally displays the current supplied by the rectifier. On the right of the display the alarm & status indicating LEDs are situated. Fault LEDs are red in colour. A 15 pin D type connector is located here which is used to communicate with the MCM. A red coloured push button is situated here by which latched fault indications can be resetted. Having familiarized with the front panel turn to the rear panel. Both the AC input and DC output connectors are located in the rear panel. The AC connector is three pole circular and the DC connector is two pole rectangular, can be easily identified. The DC connector is specially crafted to cater for high DC current and positive snap in contacts. The front & rear panel features of the power modules are illustrated below, where information on each particular feature is located. Figure 2.1: Power Module Front Panel
Figure 2.2: Power Module Rear Panel
Figure 2.3: AC input connecter for Power Module
Figure 2.4: DC output connector for Power Module +VE (Common) Brown / Red
--VE (Live) White / Black
AC POWER QUALITY & EMI COMPATIBILITY

A) AC Power Quality Reliability is of prime concern when designing an AC-DC power system for communication sites. Poor AC input power quality can seriously impede system reliability. In particular, transient disturbances on the power lines can severely weaken or cause failure of semi-conductors in power supply and communication gear. It is important that you know the input power quality when installing the system. Following is some basic information on the subject: Causes Transients are characterized as a voltage pulse of high energy and very short duration impressed upon the AC waveform. These over voltage pulses can range from 1 to 100 times the normal AC voltage level and can last for a fraction of a cycle to a few cycles. Transient disturbances can be placed into two categories: - Lightning generated - Equipment generated A direct lightning hit on a utility power line will cause a high-energy voltage transient to travel in both directions along the power line. The disturbance can affect equipment hundreds of miles from the strike point. Equipment generated transient sources include utility fault conditions and load switching as well as on site equipment such as pumps and air-conditioning loads, motors, phase control equipment. Recommendations All EXICOM power modules are designed to meet IEC 61000-4-5 requirements for surge immunity withstand capability. The AC power source should confirm to this specification to ensure reliable power supply operation. If the power supply source quality is suspect or unknown, it is recommended that an AC power quality survey to be conducted before installation. EMI (Electro-magnetic interference) considerations The power modules employ switch mode technology to convert AC to DC. They are designed to produce minimal EMI levels when operating [compliant to international standards IEC-CISPR 22 A (radiated) and IEC-CISPR 22 A (conducted)].
TECHNICAL DESCRIPTION
The rectifier is based on the latest trend in SMPS technology and operates at frequency higher than 20kHz. This gives the rectifier its compact and lightweight size. There are 6 principal sub-assemblies inside. These are discussed separately below. 1. Input Stage: The AC input is fed from the circuit breakers in the ACDB module in the rack. The input connector is located at the back of the equipment. The input is then fed to the EMI/RFI filters. Relays have been used in each phase to disconnect AC input in the event of fault. The AC power is the fed to an in-rush prevention circuit. The filters ensure that EMI generated by the high frequency power stage doesnt escape the enclosure. The Bi-directional nature of the filters also prevents EMI/RFI from out side to enter the rectifier. The in-rush protection circuit keeps the in-rush current limited to a value, which is significantly, lowers than the full load value. 2. Active Power Factor Correction Stage: The filtered and conditioned AC mains is received by this stage and is the converted to high voltage regulated DC of about 400 Volts. The conversion is carried out in such a manner that the input current is shaped according to the Sinusoidal form of the input voltage maintaining near unity Power Factor (typically 0.99). The control electronics feature EXICOMs proprietary technology, which results in low neutral current while still providing input current harmonic distortion less than 10%. Operating temperature has no effect at all on the Power Factor and distortion. 3. DC/DC Converter Stage: The regulated HVDC produced by the previous stage is fed to this stage. This HVDC is switched at high frequency and stepped down by high frequency transformers. The stepped down voltage is rectified by high efficiency and fast diodes and the fed to L-C filters which produces smooth DC output. The control is based on Current-mode PWM technology. This technology offers the following benefits: a) Stable control loop. b) Feed-forward feature for fast input transient correction. c) Inherent short circuit protection. The entire high frequency switching is done by state of the art MOS devices, which exhibit very low losses. The filter capacitors are of low ESR type. Low ESR results in better ripple figure along with lesser dissipation in the capacitors while encountering high frequency ripple current. 4. Output Stage: The regulated LVDC is fed to this stage. An additional filter is used in this section to remove any switching noise which might have escaped due to inter winding capacitances of the filter inductors and the ESL of the bulk filter capacitors. A shunt is installed to monitor the output current.
5. Supervisory stage: The complete supervisory electronics is housed on a single PCB fixed on the front panel of the rectifier. The C based circuit contains field proven modules using components which have been proven in SMPS rectifiers for over a decade. The LEDs, are mounted on this PCB. This stage caries out the following functions: a) Generation of Under voltage alarm. b) Generation of Over voltage alarm and shut down. c) Generation of over voltage droop and shut down in case of excessive droop. d) Generation of rectifier alarm. e) Generation of AC available status. f) Generation of fan failure alarm and shut down. g) Indication of float/charge mode of operation. h) Interaction with MCM for mode change. i) Interaction with MCM for temperature compensation. j) Interaction with MCM for shut down in case of abnormal AC mains and over voltage. k) Interaction with MCM for alarm extension. Interaction with MCM is carried out via control cable that is terminated on this card on a 15 Pin D type connector. 6. Fan speed controller stage: In order to enlarge the life of the DC fans used in the equipment regulated DC voltage is fed to these. A down converter used in this card steps down 48V to regulated 12V for the fans. Electronic circuits monitor the current drawn and the back EMF developed to detect either failure or malfunction of the fans. The information is sent to the supervisory stage for alarm generation and eventual shutdown of the equipment.
INITIAL CHECK ON RECEIEPT AT SITE

Following sequence of action is recommended when the rectifier is received at site: a) Although the equipment had left the factory properly packed, instances of mishandling by the transporter are quite common. Hence before taking delivery ensure that the packing is intact and free from any signs of damage or improper handling. If any of these are suspected the manufacturer must be informed immediately for remedial action and insurance. b) Unpack the equipment carefully. Ensure that no force is applied in removing the packing which could damage the rectifier. c) After unpacking keep the rectifier on its normal position and again check for any mechanical damage. Do not ever switch on a rectifier when a mechanical damage has been noticed. This may lead to irreparable damage of the rectifier and may also result in injury or shock hazards. Notify manufacturer immediately. Do not put any weight on the lid of the rectifier. Note: The rectifier handles are only for guiding it in the shelf and not for lifting. d) Gently shake the rectifier and if any sound suggesting presence of something loose is heard notify the manufacturer and keep the equipment aside. e) Check the packing for cables and accessories as per the packing list. If any anomaly is noticed the matter should be reported to the manufacturer.
ROUTINE MAINTENANCE PROCEDURE

The rectifier is based on solid-state technology and engineered in such a fashion that practically no maintenance is required. How ever the following procedure may be adopted to ensure trouble free operation. a) Every 15 days check for dust accumulation. Use a dry soft lint free cloth to gently brush off dust. Do not scratch the window for the LCD display. b) Check the input connector for proper tightness after switching off the unit. d) Similarly check the output connector. e) Check if the fans are moving freely and they are not producing any abnormal noise. f) Press the Voltage selector button to check if voltage metering is OK.
TROUBLE SHOOTING
The rectifier has been designed to offer reliable service through out its life. However a random failure cannot be ruled out. As mentioned earlier high voltage surges in the AC lines can be damaging unless entrylevel protection is provided near the LT panel. It is once again stressed that the equipment is not user serviceable and no attempt should be made to open the unit. The following table gives solutions to commonly occurring problems, which can be attended to by the user. S.No. 1. Observation. Unit not turning on. Action to be taken. a) Check if any fault indication is glowing. b) Check input mains & connection. c) Check input connector whether it is properly inserted and screwed. d) If mounted in the rack remove DC connector as well as the control cable and retry. Remarks. a) The fault needs to be attended first. b) When connected to the MCM the unit will shut down in case of AC abnormal. Check indication on MCM. d) If unit turns on connect the control cable & try. If unit doesnt come on the MCM may be responsible. a) Remove DC connector & a) Load could be more control cable and retry. than the capacity or the b) Check voltage setting & retry. MCM may be responsible. b) Do not keep on trying if there is no increase. Report to factory. a) Remove DC connector & Report to factory. control cable and retry. b) Do voltage setting to check if voltage is decreasing. a) Check the load it may be too Do not retry without high. carrying out thorough b) Check the current limit checking. setting. c) Check for short circuit in the load path.
2.
Output voltage low.
3.
Output voltage high.
4.
Overload.
S.No. 5.
Observation Fan fail.
6.
Unit not taking load.
Action to be taken. a) Check whether the fans are really not moving. b) Check whether the rotor is jammed by some mechanical deformity. a) Check the load it may be too high. b) Check the current limit setting.
Remarks. a) Detection ckt. malfunction can cause false alarm.
In case the remedies suggested above dont yield desired results report the matter to the manufacturer giving as detailed observations as possible so that quick diagnosis can be carried out. Always mention the serial number of the unit. Contact factory on telephone and feel free to discuss the problem observed with engineers who would guide accordingly.
TECHNICAL SPECIFICATIONS
The rectifier fully meets and surpasses the requirement of the latest TEC specifications. Following is the brief technical specifications. Input: 320 to 480 Volts phase-to-phase AC, 4 Wire, 48 to 52Hz. Output: 56 Volts at 100 Amps. Power factor: 0.99 at full load and 400Volts AC input. Current harmonic distortion: Less than 10% at full load and 400 Volts AC input. Efficiency : 91% at full load and 400 Volts AC input. Ripple & noise : 100mV peak-to-peak & less than 2mV psophometric. Acoustic noise : Less than 45dBA. Transient response : Limited to 5% & recovery within 10mSec. Protections : Over voltage, Over load, Short circuit. Indications : AC on, Under voltage, Over voltage, Over load, Fan fail, Float mode, Charge mode, Rectifier fail. Environmental : As per QM-333B2 of BSNL Cooling : Fan cooled. Dimensions : Height 266mm, Width 220mm, Depth 455mm.
SECTION 3 MONITORING AND CONTROL MODULE
Introduction
The Monitoring & Control Module (MCM) is a micro controller based system capable of monitoring, supervising & controlling a floated battery power plant. It packs all the features required for supporting state of the art SMF batteries. Its menu driven program makes it extremely user friendly. Through front panel entry the module can be configured for practically any capacity making it versatile. Large alphanumeric 16 characters 2 line front panel LCD display has been chosen for easy viewing from a distance. The construction is modular in nature making it easy to install. The user is advised to read the manual carefully before attempting to install & operate.
Caution
1. The equipment is not user serviceable & hence no attempt is to be made to open or tamper the unit. Warranty stands void if opened or tampered. 2. Installing & commissioning requires handling of high voltage AC mains & very high capacity batteries. Hence only suitably trained & qualified personnel should undertake installation & commissioning. The manufacturer takes no responsibility for loss of life & property caused by improper handling. 3. Proper understanding of the functioning & various connections are necessary. In case of any doubt the manufacturer is to be contacted for proper clarification. Warranty covers manufacturing defects only & not improper use.
Front panel of MCM
54.0V / 3000A System OK
i UP MENU ENTER iii DOWN MCM figure 1 Audio Reset Alarm Reset ii
iv v vi vii viii ix x
Back panel of MCM
MCM figure 2
Alarms & Indications: Three 5mm bi-LEDs are provided for critical system status. LEDs are as followsa) System O.K/fail- green in case of system ok and red in case of system fail. b) AC OK/ABNORMAL- green in case of ac ok and red in case of ac abnormal. c) FLOAT/CHARGE- green in case of float mode and amber in case of charge.
Apart from these three LEDs, seven more alarm LED have been provided for immediate attention. d) e) f) g) h) i) j) Ac available (green) Any rectifier fail-(red) Low voltage battery disconnect (lvd)- (red) MBD (mains on battery discharge) -(red) Any battery isolated.-(red) Battery periodic test fail.-(red) SPU element fail-(red)
Connector Description: ABCDEF3 pin female connector for dc power supply. 15 way d type male connector from lvd card for dc contactor. 15 way d type male connector from ac interface card for ac sample information. 15 way d type female connector for v&I card for voltage and current info. 9 way female connector for rectifier communication. 25 way male connector for pfc contact extension.
GH-
9 way female connector for RS485 communication. 9 way male connector for RS232 communication.
Technical Description
This state of art design works for single phase as well as 3- phase application. 1. Specification: Input: Single-phase AC mains 90V to 300V phase to neutral. DC 40 to 60 Volts. Measurement a) Load voltage b) Individual battery voltages c) Load current d) Individual battery currents e) System current f) Input AC voltages in RMS. g) Input AC frequency h) Battery temperature i) Remaining AH in percentage j) Individual rectifier voltage k) Individual rectifier current. l) Individual rectifier status. m) Sharing deviation in percentage. n) Version of software. o) Checksum
Control functions: a) Battery temperature compensation b) Auto change over from float to charge & vice versa c) Battery current limiting d) Rectifier disable in the event of abnormal input AC mains and over voltage. e) Automatic current sharing. f) Periodic battery test by discharging each battery by 20%of capacity. Parametric settings:
a) b) c) d) e) f)
MENU -This switch can be used for viewing various menu options. UP -This switch can be used for scrolling as well as for setting increment. Down -This switch can be used for scrolling as well as for setting decrement. ENTER -This switch can be in to sub menu as well as for registering the parameter changed. Alarm reset - this switch is used for clearing the latchable alarm. Audio reset -this switch is used for audio cutoff.
Flow diagram of menus
Default screen 1. Read alarm.
2. Read system data. 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. Read load voltage and load current. Read battery1 voltage and battery1 current and remaining ah in percentage. Read battery2 voltage and battery2 current and remaining ah in percentage. Read battery3 voltage and battery3 current and remaining ah in percentage. Read ac voltage Read ac current Read ac frequency Read battery temperature. Read MCM and rectifier controller version and checksum information.
3. Read rectifiers data. 3.1. Read rectifier voltage and current with rectifier status. 4. Read battery data. 4.1. Not applicable. 5. User password. 5.1. Password =243. 6. Set system parameter. 6.1. 6.2. 6.3. 6.4. 6.5. 6.6. 6.7. Set over voltage Set under voltage Set lvd voltage Set lvd restore voltage Set system overload value. Set temperature compensation upper threshold. Set temperature compensation lower threshold
7. Set rectifier parameter. 7.1. 7.2. 7.3. 7.4. Set rectifier float voltage globally. Set rectifier charge voltage globally. Set rectifier current limit globally. Set max no. of rectifier in system for current sharing.
8. Set battery parameter. 8.1. 8.2. 8.3. 8.4. Set total no. of battery bank. Set battery capacity. Set load shunt. Set battery shunt.
9. Set relay configuration. 9.1. Configure individual relay for different alarms. 10. Test battery. 10.1. Set battery 1 cuttoff voltage 10.2. Set battery 1 period and time 10.3. Set battery 2 cuttoff voltage 10.4. Set battery 2 period and time 10.5. Set battery 3 cuttoff voltage
10.6.
Set battery 3 period and time
11. System password. 11.1. The user should not enter system password. This is required only for factory settings.
Detailed description of menus: 0 s 0 y . s 0 t V e / k 0 0 0 0 A
MCM normally displays the menu shown above. It gives the system voltage and system current information on the first line. On the second line it shows the last alarm occurred or restored. To view the various menus user should press the menu button once at a time. The Menu button allows the user to choose Parameter reading or parameter & threshold settings. While in parameter reading mode press menu button continuously to return to home screen. Press menu once to get the read alarm screen.
1. Read alarm.
R A
E L
A A
D R
When the LCD displays the menu shown above, press enter once to go into the sub menus of the read alarm menu. Now the user can scroll the alarm using up and down key. Sub menus of the read alarm menu are as follows.
M S
A Y
J S
. T
= E
1 M
1 O
/ K
M A
A C
. A
= B
1 N
1 O
/ M
M A
I L
To leave the read alarm menu, press menu key once. The user will see the read system data menu.
2. Read system data. R S E Y A S D T
When the LCD displays the menu shown above, press enter once to go into the sub menus of the read system data menu. Now the user can scroll the system data using up and down key.
Sub menus of the read system data menu are as follows.
L 6 B 5 B 5 B 5 M 4 M = B = d f
O 6 A 4 A 4 A 4 A 0 A 0 A 0 s r
A . T . T . T . I 0 I 0 T 0 c f
D 4 T 0 T 0 T 0 N V N . T . a c -
V E V E V E V S / S 0 . 0 v v R Y 1
0 1 0 1 0 1 0 G /
0 0 . 0 . 0 . E 4 N
A 0 0 0 0 0 0 % A % A % A
/ R Y 2 / R Y 3 / V 4 F Z T C x x E O 0 R L 0 E T V Q A
0 C
0 Y
'
. .
x x
x x
x x
x x
x x
User can scroll these menus using up and down key. To leave the read system data menu, press menu key once. The user will see the read rectifier data menu. 3. Read rectifiers data.
R R
E E
A C
D T
When the lcd displays the menu shown above, press enter once to go into the sub menus of the read rectifier data menu. Now the user can scroll the rectifier data using up and down key. Sub menus of the read rectifier data menu are as follows. R 5 R 5 E 4 E 4 C . C . # 0 # 0 0 V 0 V 1 / 2 /
2 |
R 5
E 4
C .
# 0
0 V
8 /
L =
O 1
A %
User can scroll rectifier data using up and down key. To leave the read rectifiers data menu, press menu key once. The user will see the read battery data menu.
4. Read battery data. This menu will be active only if battery-monitoring equipment is connected. 5. User password User password is 243. U = S 2 E 4 R 3 P A S S W O R D
In this menu, cursor on the first digit blinks. User should press up key two times to increment first digit to value 2. Now the user should press enter once to register first digit password. Now cursor blinks on second digit. Similarly user can enter the value 4 and value 3 for the second and third digit respectively. At this point of time, if user press enter key, user can go through the set parameter option and menu on the LCD will be set system parameter
6. Set system parameter
S P
E A
T R
S M
Y E
S T
T E
E R
When the LCD displays the menu shown above, press enter once to go into the sub menus of the set system parameter menu. Now the user can scroll the system parameter entered previously using up and down key. At any time if the user need to change the system setting, user can press the enter key once to go in to edit mode. In the edit mode, cursor blinks on the value to be changed. User can now change the value using up and down key. To register the value Press enter key once, value will be stored in the non-volatile memory. As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to view various set parameter.
Sub menus of the read system data menu are as follows.
D = D =
C 5 C 4
O . U .
V 0 N 0
E V D V
L = L = S = T = T =
V 4 V 5 Y 0 E 5 E 5
D 4 D 1 S 2 M 5 M 2
V 0 R 0 O 0 C 5 C 0
O V E V V A O V O V
1 P . P .
To leave the set system data menu, press menu key once. The user will see the set rectifiers data menu. 7. Set rectifiers parameter S P E A T R R M E E C T T E I R F I E R
When the lcd displays the menu shown above, press enter once to go into the sub menus of the set rectifier parameter menu. Now the user can scroll the rectifier parameter entered previously using up and down key. At any time if the user need to change the global rectifier setting, user can press the enter key once to go in to edit mode. In the edit mode, cursor blinks on the value to be changed. User can now change the value using up and down key. To register the value Press enter key once, value will be stored in the non-volatile memory. As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to view various set parameter menu. Sub menus of the set rectifiers parameter menu are as follows.
S = S = S = R =
E 5 E 5 E 2 E 0
T 4 T 5 T 5 C 8
F 0 C 2 C 0 I
L V H V U A F
. T
To leave the set rectifier parameter menu, press menu key once. The user will see the set battery parameter menu. 8. Set battery parameter
S P
E A
T R
B M
A E
T T
T E
E R
When the LCD displays the menu shown above, press enter once to go into the sub menus of the set battery parameter menu. Now the user can scroll the rectifier parameter entered previously using up and down key. At any time if the user need to change the battery and system related settings, user can press the enter key once to go in to edit mode. In the edit mode, cursor blinks on the value to be changed. User can now change the value using up and down key. To register the value Press enter key once, value will be stored in the non-volatile memory. As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to view various set parameter menu. Sub menus of the set battery parameter menu are as follows: 8.1. Set total no. of battery bank. 8.2. Set battery capacity. 8.3. Set load shunt. 8.4. Set battery shunt. To leave the set rectifier parameter menu, press menu key once. The user will see the set relay configuration menu. 9. Set relay configuration S C E O T N R I E G L U A R Y A
When the LCD displays the menu shown above, press enter once to go into the sub menus of the set relay configuration menu. Now the user can scroll the various relay configured previously using up and down key. At any time if the user need to change the relay configuration, user can press the enter key once to go in to edit mode. In the edit mode, cursor blinks on the alarms entered earlier. User can now change the alarm using up and down key. To register the alarm extension to that relay, Press enter key once, alarm to that relay will be stored in the non-volatile memory and also extended. As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to view various relay configurations. Sub menus of the set battery parameter menu are as follows. S S S A E Y E C T S T R E R B E M E N L L O A O A R Y K Y M 1 2 A
T A
S L
E V
T D
| L
To leave the relay configuration menu, press menu key once. The user will see the test battery menu.
10. Test battery
When the LCD displays the menu shown above, press enter once to go into the sub menus of the test battery menu. Now the user can scroll the battery test configuration entered previously using up and down key. At any time if the user need to change the cutoff voltage and period time of testing battery, user can press the enter key once to go in to edit mode. In the edit mode, cursor blinks on the value entered earlier. User can now change the value using up and down key. To register the value, Press enter key once, value will be stored in the non-volatile memory. As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to view battery test setting.
Sub menus of the battery test settings are as follows. 10.1. 10.2. 10.3. 10.4. 10.5. 10.6. Set battery 1 cuttoff voltage Set battery 1 period and time Set battery 2 cuttoff voltage Set battery 2 period and time Set battery 3 cuttoff voltage Set battery 3 period and time
2. Sub- assemblies: The MCM consists of the following: a) Control card. This card contains all the electronic hardware. The heart of the electronics is the state of the art PIC processor. In set up mode the user can browse through various system parameters & thresholds. For status & alarm displays LEDs as well as LCDis used. A piezo-electric buzzer has been provided which comes on when ever an alarm is detected. A push button for cutting off the audio has also been provided. The card also contains a set of push buttons. These buttons are marked Menu, Up, Down & Enter. The functions of these buttons are explained in the installation & commissioning chapter. b) LCD: An alphanumeric LCD display of 16x2 is provided for display of various parameter viewing and alarm display. c) LED- LCD interface card: This card consists of 6 nos. of switches and three bi-LED for critical alarm and seven LEDs for major and minor alarms. A piezo-electric buzzer has been provided which comes on when ever an alarm is detected. A push button for cutting off the audio has also been provided. The card also contains a set of push buttons. These buttons are marked Menu, Up, Down & Enter. The functions of these buttons are explained in the installation & commissioning chapter. d) RS232/RS485 interface card. This card receives input from control card and converts the serial data to either RS232 or RS485.
INSTALLATION & COMMISSIONING
Caution:
a) The equipment is a sensitive electronic system hence special care is required while installing the unit. b) Polarity is very important for the measurement electronics so this aspect must be kept in mind. c) The circuitry has CMOS integrated circuits which are sensitive to ESD & other discharges. The rack must be properly earthed. d) The packaging must be visually inspected for any possible damage during transit. Do not attempt to turn on even slightly damaged unit . Report the matter to the manufacturer. e) Only trained personnel should handle the equipment as 440 Volts AC and very high capacity batteries are connected.
Step by step Commissioning of a MCM for an example system

System description: SMR Ultimate capacity No. of batteries Battery AH Load path shunt Each battery path shunt Over voltage Under Voltage Temp. comp upper threshold Temp. comp lower threshold LVD threshold Over load LVD Restore 100A modules 3000A 3 2000AH 3000A/50mV 1000A/50mV 56V 45.5V 56.0V 51.5V 44.4V 2800A 52.0V
Step1: Do not connect battery or load. Connect plug coming from ACDB to socket coming from MCM Module. Do not connect the daisy- chained cable for rectifier MCM interface at this stage. Step2: Turn on the MCB for MCM on the ACDB. The MCM comes on & the controller begins checking displays & the LEDs. Under voltage, & Temp. comp. fail alarm will come which is normal. Press the reset button & the audio cut-off button. Thru Menu start reading parameters. All DC voltages & currents will read zero. Since the inputs for DC measurements are floating some jittery display may bee seen while scrolling thru the DC parameters. Move on to AC input. Phase voltage can be read. Step3: Switch off the MCB for MCM on the ACDB. Connect cable to 25 Pin D-connector coming out from BI rack on the MCM back panel. Switch on the MCCB for MCM. After display check has been completed & all alarms re-setted, turn on one or more rectifiers & connect some load to the exchange terminal. Do not connect any voltage sensitive load at this stage. Go to Menu & start reading DC voltages & currents. Step4: Press the Menu button the display reads READ DATA Press the Menu button once again the display reads SET PRAMETER Press Enter the display reads OVER VOLTG = 56.0V Press Enter the decimal digit blinks. Use UP button to increase the threshold to 56V Press Enter display reads SAVE Y/N Press Enter to save the present value.
Step5: Press UP button to move to next setting the display reads UNDER VOLTG = 44.4V Press Enter button the decimal digit blinks. Use UP button to increase the threshold to 44.4V Press Enter display reads SAVE Y/N Press Enter to save the present value. Step6: Press UP button to move to next setting the display reads LVD VOLTG = 43.0V Repeat process for increasing threshold to 43V. Press UP button to move to next setting the display reads OVER LOAD = 2800A Press Enter the 1st. digit blinks Press Enter again the 2nd Digit blinks. Press Enter again the 3rd Digit blinks. Press DOWN button till the display reads 00100A Press enter again the 4th digit blinks. Press UP button till the display reads 02800A. Press Enter 3 times. The display reads SAVE Y/N Press Enter to save the present value. Step7: Press Enter the display reads TEMPCOMP _U = 56.0V Press Enter button the decimal digit blinks. Use UP button to increase the threshold to 56.0V Press Enter display reads SAVE Y/N Press Enter to save the present value. Step8: Press Enter the display reads TEMPCOMP _L = 51.5V Press Enter button the decimal digit blinks. Use UP button to increase the threshold to 51.5V Press Enter display reads SAVE Y/N Press Enter to save the present value. Step9: Press UP the display reads BATT. BANK = 3 Press Enter 3 begins to blink Press UP/DOWN button if it has to change. Press Enter display reads SAVE Y/N Press Enter to save the present value. Step10: Press UP display reads BATT. CAP = 2000AH Press Enter 1st. digit begins to blink Press Enter 2nd digit begins to blink Use UP button to make it 2000AH Press Enter, 3rd digit begins to blink. Press Enter display reads SAVE Y/N Press Enter to save the present value.
Step11: Press UP the display reads BATT.SHUNT = 1000A Follow above for changing the value to 1000A Press Enter display reads SAVE Y/N Press Enter to save the present value. Step12: Press UP the display reads LOAD.SHUNT = 3000A Follow above for changing the value to 3000A Press Enter display reads SAVE Y/N Press Enter to save the present value. Step13: Press UP the display reads TEMPCOMP = E Press Enter, blinking comes on E To change settings press up / down button. Press Enter display reads SAVE Y/N Press Enter. Step14: Press UP display reads LVD REST. = 51.6V Press enter button the decimal digit blinks. Use UP button to increase the threshold to 52.0V Press enter display reads save Y/N Press enter to save the present values. Step15: Press MENU to come to default display i.e Load voltage & System current. The system is now fully configured. Step16: Insert the daisy chained cable connector to the D connector on the front panel. MCM Connections: Following are the inputs to the unit: a) Single- phase AC mains with neutral. This comes from the ACDB. A single phase CB is provided in the ACDB for this purpose. b) Battery voltage. This signal comes in by a twisted wire cable from the battery feeder. This enters MCM via 25 Pin D-connector with ferrule no. 1 as positive & ferrule no. 2 as negative. c) Load voltage. This signal comes in by a twisted wire cable from the exchange feeder. This enters MCM via 25 Pin D-connector with ferrule no. 1 as positive & ferrule no. 2 as negative. d) Load current. This signal comes in by a twisted wire cable from the load shunt. This enters MCM via 25 Pin Dconnector with ferrule no. 3 as positive & ferrule no. 4 as negative. e) Individual battery currents. The signal comes in by twisted wire cables from individual battery shunts. This enters MCM via 25 Pin D-connector with ferrule no. 5 as positive & ferrule no. 6 as negative for battery 1, with ferrule no. 7 as positive and 8 as negative for battery 2 and with ferrule no. 9 as positive and no. 10 as negative. f) Battery temperature. The temperature probe supplied with the unit is to be connected to terminal block as per the fig. 2. The probe should be kept close to the batteries. g) Remote alarm extension. Potential free contacts have been provided. These are accessed through Terminal block as per fig. 2. h) 15 pin Connector on the front panel will be daisy chained to all the SMRs in the system and finally connected with MCMs 15 pin D-connector on the front panel.
i) j)
Signals for de-activating the battery contactors for LVD are available from 25 pin D- connector in the MCM back panel with ferrule no. 1 & 11. Batter isolation signals are also available from 25 pin D-connector in the MCM back panel with ferrule no. 14 for battery bank 1, with ferrule no. 15 for battery bank 2 and with ferrule no. 16 for battery bank 3, ferrule no. 13 is common for all battery banks.
Trouble shooting
Sl. No. 1. Symptom MCM does not come ON when the MCCB is turned on. MCM does not come ON when mains fail. Voltage or current display erratic Temp. Comp fail alarm. Probable cause a)ACDB to MCM cable not connected. b) Fuse F in the AC Monitoring & Power supply card is blown Fuse F in the AC Monitoring & Power supply card is blown. Battery is not connected Connector coming from BI rack is not connected to MCM back panel. Probe not connected. Probe cable broken. Total load exceeding capacity. Current limit setting on SMRs too low. AC mains out of range. Action
Connect properly.
Change fuse. Replace fuse. Connect battery.
cable
2.
3.
4.
5.
MBD alarm.
6.
AC abnormal alarm.
7. 8.
Display not responding to commands. Battery current limiting not working.
Front panel card malfunction. Error in system configuration. Daisy chained cable not properly inserted. Front panel card malfunction.
Insert connector properly. Check connections. Connect probe. Check cable for damage. Check load & charging current. Check current limit setting on all SMRs. Check mains voltages. Rural & urban systems have different ranges. Check application. Call service engineer. Check battery related entries. Check cable connection. Call service engineer.
9.
Fault LEDs randomly glowing.
--------------------X--------------------
USER RESPONSE FORM
****** EXICOM TELE-SYSTEMS LIMITED ********

NAME OF CUSTOMER: SITE ADDRESS: . Phone : Fax : ...
EQUIPMENT DESCRIPTION Power Plant : Stand alone / Rack Power System ( _______________ )
Power plant/ RACK serial No. :
Module Rating: 12.5A/25A/50A/100A/200A SMR No. of Modules : Module serial Nos. : SMR 1 SMR 2 SMR 3 SMR 4 SMR 5 SMR 6 SMR 7 SMR 8 SMR 9 SMR 10 ( _____ )
SMR 11
SMR 12
SMR 13
SMR 14
SMR 15
SMR 16
SMR 17
SMR 18
SMR 19
SMR 20
SMR 21
SMR 22
SMR 23
SMR 24
SMR 25
SMR 26
SMR 27
SMR 28
SMR 29
SMR 30
Battery Capacity
Ah
No. of Battery Banks : (Fill the no. in numeric form) Battery Make/Type :
( Page1)
PLEASE COMMENT : A. Any physical damage occurred to the equipment during transport (YES/NO) If yes, describe: B. Any problem faced during Installation and Commissioning: C. Suggestions, if any:
PLEASE MAIL/FAX HERE: Customer Support EXICOM TELE-SYSTEMS LTD. D-180, Mazenine Floor, Okhla Industrial Area Phase I, New Delhi-110 020 (India)
Phone: 91-11-26810140/26810141/26810142 Fax: 91-11-26810137
Note:
kindly fill the form and send to above no./ address as soon as power plant is commissioned. This will be helpful for us to provide customer prompt service.
(Page2)
Fault Report
****** EXICOM TELE-SYSTEMS LIMITED ********
NAME OF CUSTOMER : SITE ADDRESS : . Phone : Fax : ... EQUIPMENT DESCRIPTION Power Plant : Stand alone/Rack Power System Module Rating : 12.5A/25A/50A/100A SMR No. of Modules : (Fill the no. in numeric form) Any other Modules Battery Capacity : Ah No. of Battery Banks : (Fill the no. in numeric form) Battery Make/Type : INSTALLATION DETAILS (Enclosed installation and commissioning report if available) Is the equipment under warranty period - YES/NO Fault Indication Report . Date of occurrence of fault . LED STATUS ON FAULT SMR LED STATUS ON MCM ANY OTHER SPECIFIC DETAILS WOULD YOU LIKE TO ADD
PRESENT STATUS OF POWER PLANT
PLEASE MAIL/FAX HERE : Customer Support EXICOM TELE-SYSTEMS LTD.

D-194, 2nd Floor, Okhla Industrial Area Phase I, New Delhi-110 020 (India) Phone: 91-11-26810140/26810141/26810142 Fax: 91-11-26810137

Modular Rack Power System Manual

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Modular Rack Power System Manual

Hochgeladen von

Copyright:

Verfügbare Formate

LARGE CAPACITY RACK POWER SYSTEM

MODEL NO. HE-N*100ApfcLCRPSIII

MFD BY: M/S EXICOM TELE-SYSTEMS LTD.

INSTALLATION AND COMMISSIONING MANUAL

MONITORING AND CONTROL MODULE MANUAL

SECTION - 1 INSTALLATION & COMMISSIONING MANUAL

Monitoring & Control Module

Switched Mode Rectifier

ACDB (with inside SPU STAGE-II)

3000A Rack Power System

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

AC OK/ABN REC. OK/FAIL LOAD OV

FUSE FAIL REC. DIS OVER TEMP. COMM. FAIL

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

LOAD UV OVER LOAD

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED

HIMACHAL EXICOM COMMUNICATIONS LIMITED