1

Flexi Power Rectifier

Quick Start Guide

Emerson Network Power Co., Ltd.

http://www. emersonnetworkpower.com.cn

Manual Version: 01

Flexi Power Rectifier Quick Start Guide

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Manual Number: 03370500110

Manual Issue: 01
Manual Status: Standard
Release Date: Sep 2008

Copyright 2008 Emerson Network Power Co., Ltd.

All rights reserved

Published in China
This document, and the information it contains, are the property of Emerson
Network Power Co., Ltd, and are protected by law. Both must be held in strictest
confidence at all times. Emerson Network Power grants no license or right to
copy, use or disclose either, expressly or by implication.

Disclaimer

This document and the information contained herein are provided on an "AS
IS" basis. Emerson Network Power may make improvements or changes in
this documentation, at any time and without notice and as it sees fit. The
information in this documentation was prepared by Emerson Network Power
with reasonable care and is believed to be accurate. However, Emerson
Network Power shall not assume responsibility for losses or damages
resulting from any omissions, inaccuracies, or errors contained herein.

Flexi Power Rectifier Quick Start Guide

 History 3

History

Date Version Author Change Note No./Notes

21/07/2008 01 David Cao First release

Flexi Power Rectifier Quick Start Guide

 Table of contents 4

Table of contents
History...................................................................................................................3
Table of contents ..................................................................................................4
List of figures ........................................................................................................4
List of tables..........................................................................................................4
List of terms ..........................................................................................................5
Preface .................................................................................................................7
Hardware Installation ............................................................................................9
Appendix Tools and Torques ...........................................................................23

List of figures
Figure 1 The FPRA before the installation................................................................ 9
Figure 2 The PDA before the installation .................................................................. 9
Figure 3 The cable gland configuration for typical use ......................................... 10
Figure 4 Removing the drawer from the PDA ........................................................ 11
Figure 5 Taking off the load (or battery) terminals short link and MCB switch
lever bar ................................................................................................................... 13
Figure 6 DC terminal clamps distribution ................................................................ 14
Figure 7 Connecting the DC cable ........................................................................... 14
Figure 8 Putting the front panel back to the PDA .................................................. 15
Figure 9 Connecting all the communication cables............................................... 17
Figure 10 - AC connection without the SPD 3Y..................................................... 19
Figure 11 Installing the PDA into case .................................................................... 20
Figure 12 Installing the rectifiers into case ............................................................. 20
Figure 13 Installing the cable glands ....................................................................... 21
Figure 14 Installing the front and back covers ....................................................... 21
Figure 15 Cables exit from right of the FPRA ........................................................ 22

List of tables
Table 1 Reference documents of the FPRA............................................................. 7
Table 2 Three battery / load cables configurations ............................................... 12
Table 3 Connection of the communication cables................................................. 16
Table 4 Connection of the AC cable ........................................................................ 18
Table 5 Tools and torques required for installation ............................................... 23

Flexi Power Rectifier Quick Start Guide

 List of terms 5

List of terms

A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
CB Circuit Breaker
CSA Cross Section Area
CU Control unit
DC Direct current
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRA Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Ingress Protection
IP Internet Protocol

L Live cable from the AC mains

LAN Local Area Network

LED Light Emitting Diode
LVD Low Voltage Detection
MAC Media Access Control
MCB Micro Circuit Breaker

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 List of terms 6

N Neutral cable from the AC mains

PC Personal Computer
PCB Printed Circuit Board
PDA Power Distribution Assembly
PE Protective earth
PSU Power Supply Unit
SPD Surge Protect Discharge
V Volt
VPN Virtual Private Network
1 Single-phase AC type
3Y 3-phase star AC type
3 3-phase delta AC type

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 Preface 7

Preface

About this guide

This quick start guide is for quick installation or an overview of the FPRA.
Thus only the typical configuration of the AC and DC cables is described in
this guide. User shall refer to the main installation manual for more details
about the other configurations.

FPRA Introduction
The FPRA is a 6kW output power AC rectifier package made up of three
individual 2kW AC/DC power modules operating in a parallel mode
configuration. It also includes a Power Distribution Assembly (PDA), which
has a fully integrated battery protection LVD, load / battery circuit breakers,
battery current shunt and alarm signals to the BTS EAC interface.
The FPRA has a rated input voltage of 180~276VAC and provides an isolated
54VDC output (here referred to as V48N) that used for BTS power supply
voltage as well as site battery charging. The maximum current of the system
is up to 109.9A (at maximum 6kW output), and the ambient temperature is
40 ~ +55C.

Reference documents
The reference documents of the FPRA contain:

Table 1 Reference documents of the FPRA

Document Emerson Network Power File No.

Internal product specification System / PDA 41970005110

Internal product specification Rectifier 41970004980

Surge Protect Discharge for Flexi Power Rectifier

03370500080
User Manual

Flexi Power Rectifier - User Manual 03370500090

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 Preface 8

Table 1 Reference documents of the FPRA

Flexi Power Rectifier - Installation Manual

03370500070
(Main installation manual)

Surge Protect Discharge for Flexi Power Module

03370500100
Quick Start Guide

Flexi Power Rectifier Quick Start Guide

03370500110
(This manual)

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 Hardware Installation 9

Hardware Installation

Note: This FPRA quick start guide is for configuration with one battery
string, one load string and three-phase star AC inputs.

F B D A A
B

C
C

E A
Figure 1 The FPRA before the installation

(1) (3) (4) (5) (2) (9)

(6) (10) (7) (8)

(1) Rear cover (2) Sub cover (3) Restricted area (4) BR bus bar (5) 54V bus bar
(6) Front panel (7) Drawer (8) RS 485 cable (9) Window of the breakers (10) PE of the PDA
Figure 2 The PDA before the installation

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 Hardware Installation 10

************************************
Follow the steps below to install the FPRA:
************************************

1. Detach the PDA from the case (refer to section 3.1 in the main installation
manual).
Loosen four screws C to detach the two side cable glands; Loosen two
thumbscrews B, nut F and three cable restraints A to pull out the PDA
from the case (refer to Figure 1).
2. Puncture the waterproof on the cable gland and Insert the cable through
the hole before installing it into the PDA (refer to section 3.1 in the main
installation manual).
Warning: The AC mains and battery blocks must be switched off firstly.
Note: (1) The cable gland configuration for typical use is for illustration herein (see
Figure 3). (2) Refer to Appendix Tools and Torques for detail tools and
torques that required for each installation step.

Alarm
System earth cable

BAT2
Parallel cable

Temperature
cable

LOAD2

AC cable

RTN2

RTN5 Parallel cable

DC GND
Alarm
Figure 3 The cable gland configuration for typical use

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 Hardware Installation 11

3. Loosen two screws D in Figure 1 and remove the drawer from the PDA
(see Figure 4).

1
2

Figure 4 Removing the drawer from the PDA

4. Route the DC cables (refer to section 3.2 in the main installation manual):
4.1 Loosen six screws D on the front panel and two screws E on the
breaker window in Figure 1 to remove the front panel from the PDA.
4.2 Remove the sub cover (refer to Figure 2) from the PDA.
4.3 Take off the load / battery terminals short link and MCB switch lever
bar if required (refer to Table 2 and Figure 5).

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 Hardware Installation 12

Table 2 Three battery / load cables configurations

CSA size Cable Recommended Installing

Type Cable name Breakers configuration
(mm2) number sequence

Load & return 35 2

Load MCB parallel
Battery & return Up to 50 2 RTN2 LOAD2
1 &
RTN5 BAT2
DC load Battery MCB parallel
35 1
grounding

Load & Return 35 4

RTN1 LOAD1

2 Battery & return 35 6 RTN2 LOAD2 RTN3 No MCB parallel

DC load BAT1 RTN4 BAT2
35 1 RTN5 BAT3
grounding

Load & Return 35 2

RTN1 LOAD2
Battery & return 16 6
3 RTN3 BAT1 RTN4 Load MCB parallel
DC load BAT2 RTN5 BAT3
35 1
grounding

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 Hardware Installation 13

Figure 5 Taking off the load (or battery) terminals short link and MCB switch lever bar

4.4 Puncture the waterproof on the DC grommet to insert the DC cable

through the front panel (see Figure 7).
4.5 Insert the DC cables into the indicated DC terminal clamps and
secure them respectively (see Table 2,
4.6 Figure 6 and Figure 7).
Note: The DC configuration for typical use is for illustration herein.

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 Hardware Installation 14

Breaker LOAD2 BAT1 BAT2

MCB switch
Lever bar
BAT3

LOAD1

Insulator
Terminals
short link
RTN4

RTN5
LOAD
GND

RTN1 RTN2 RTN3

Figure 6 DC terminal clamps distribution

Figure 7 Connecting the DC cable

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4.7 After connecting all the DC cables, Push the front panel back on
the PDA and secure the six screws D and two thumbscrews E in
Figure 1 (see Figure 8).

Figure 8 Putting the front panel back to the PDA

4.8 Put the sub cover back to the PDA and secure it.

5. Route the communication cables (refer to section 3.3 in the main installation
manual).
5.1 Connect the temperature cable to the drawer as per Table 3 (see
Figure 9).
5.2 Connect the parallel cable to the drawer if needed as per Table 3
(see Figure 9).
5.3 Connect the Alarm cable (may combines Alarm In and Alarm Out
together) as per Table 3, and fix the cable screen to position A and
B on the sidewall of the drawer (see Figure 9).

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 Hardware Installation 16

Table 3 Connection of the communication cables

Cable Pin name Pin number Name Color

7 TEM_GND Red
Temperature 8 TEM SENSE_IN White
cable 9 TEMP_VCC Black
10 EARTH Cable screen
J22 1 (4) RS422RD- Red
2 (5) RS422RD+ White
Parallel cable 3 (6) SGND/F Black
11 (12) EARTH Cable screen

1 ALARM IN (-)
Alarm In cable Reference
2 ALARM IN (+)
3 ALARM_COM
4 MAINS 1
5 ALARM_COM
6 MAINS 2

J11 7 ALARM_COM
8 MAINS 3
Alarm Out cable Reference
9 ALARM_COM
10 CRITICAL
11 ALARM_COM
12 MAJOR
13 ALARM_COM
14 MINOR
5.4 Assemble the temperature cable, parallel cable and alarm cable
and fix them to position C on the drawer with a cable-tie (see
Figure 9).

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5.5 Assemble the three RS485 cables and fix them to position C on
the drawer with a cable-tie (see Figure 9).

A B
Parallel cable

Alarm
cable

Temperature cable
Figure 9 Connecting all the communication cables
5.6 After connecting all the communication cables, put the drawer back
into the PDA and tighten the two screws D in Figure 1.

6. Route the AC cable without the SPD (refer to section 3.4 in the main
installation manual).
Warning: the AC mains must be switched off before the installation.
6.1 Remove the rear cover from the PDA (refer to Figure 2).
6.2 Configure the AC terminal block for paralleling the corresponding
AC terminals with short links as per Table 4.
6.3 Puncture the waterproof marked AC Inlet on the front panel, and
insert the AC mains cable through the hole until it reaches the rear
internal of the PDA.
6.4 Connect the 3-phase star AC mains into AC terminal block without
the SPD as per Table 4 (see Figure 10).

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 Hardware Installation 18

Note: The connection of the 3-phase star AC mains is for illustration herein.
6.4.1 Connect the PE cable from the AC mains to the ground
clamp on the chassis (see Figure 10).
6.4.2 Connect the live cables and neutral cable from the AC mains
to the AC terminal block as per Table 4 (see Figure 10).

Table 4 Connection of the AC cable

AC type Schematic diagram Configuration of

AC terminal block

3Y AC mains AC Terminal Block

Short terminals
PE L1 L2 L3 N 1 2 3 4 5 6
1,2,3

3 AC mains AC Terminal Block

Short terminals
PE L1 L2 L3 1 2 3 4 5 6
1,2; 3,4; 5,6
respectively

1 Short terminals
AC mains AC Terminal Block 1,2,3; 4,5,6
PE L N 1 2 3 4 5 6 respectively

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 Hardware Installation 19

L3

N
PE of AC mains

L2

L1

Figure 10 - AC connection without the SPD 3Y

6.5 Recover the rear cover to the PDA.

7. Install the PDA into case (refer to section 3.5 in the main installation manual).
7.1 Put the PDA back into the case; tighten the two screws A (see
Figure 11).
7.2 Fix the PDA earth cable to position B (see Figure 11).
7.3 Fix the system earth cable to position C (see Figure 11).

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 Hardware Installation 20

A B C

Figure 11 Installing the PDA into case

8. Install the rectifiers into case (refer to section 3.6 in the main installation
manual).
8.1 Put the rectifiers into the case; tighten the thumbscrews A (see
Figure 12).
8.2 Plug the AC input connector; tighten the screws B (see Figure 12).
8.3 Connect the RS485 cable and cover the connector seal on position
C (see Figure 12).
A

Figure 12 Installing the rectifiers into case

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 Hardware Installation 21

9. Install the cables with cable glands to the case; tighten the screws A and
B; fix the PDA earth cable to position C with cable tie (refer to section
3.7 in the main installation manual, see Figure 13).

C
A

1
2

A B

Figure 13 Installing the cable glands

10. Install the front and back covers; tighten the screws A and B (see Figure
14).

A A B B

Figure 14 Installing the front and back covers

11. Arrange the cables and fix them to the side cable plate with cable-ties (see
Figure 15).
Note: Cables can exit from right or left or both sides of the FPRA. The cable
running from right is for illustration herein.

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 Hardware Installation 22

Figure 15 Cables exit from right of the FPRA

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 Appendix 23

Appendix Tools and Torques

********************************************************************
Refer to the table below for the tools and torques required for each installation step:
********************************************************************

Table 5 Tools and torques required for installation

Step Tool Usage Torque (N.m)

1 TORX screwdriver (T25) Loosen screw --

Wrench (8mm) Loosen nut --

2 Awl (2mm) Puncture the waterproof --

3 Cross screwdriver Loosen screw --

4.1 TORX screwdriver (T10) Loosen screw --

4.2 TORX screwdriver (T10) Loosen screw --

4.3 Flat screwdriver Loosen screw --

Pliers Take off the short links --

4.4 Awl (2mm) Puncture the waterproof --

4.5 Flat screwdriver Tighten screw 3

4.6 TORX screwdriver (T10) Tighten screw 0.8

Manual Tighten screw Fit

4.7 TORX screwdriver (T10) Tighten screw 0.8

5.1 Flat screwdriver For push-fit connector Fit

Cable-tie Tie the cable screen Fit

5.2 Flat screwdriver For push-fit connector Fit

Cable-tie Tie the cable screen Fit

- To be continued -

Flexi Power Rectifier Quick Start Guide

 Appendix 24

Table 5 Tools and torques required for installation

Step Tool Usage Torque (N.m)

5.3 Flat screwdriver For push-fit connector Fit

Cable-tie Tie the cable screen Fit

5.4 Cable-tie Tie the cables Fit

5.5 Cross screwdriver Tighten screw 0.7~0.8

6.1 TORX screwdriver (T10) Loosen screw --

6.2 Flat screwdriver Tighten screw 0.8

6.3 Awl (diameter 2mm) Puncture the waterproof --

6.4.1 Flat screwdriver Tighten screw 1.5

TORX screwdriver (T25) Tighten screw 2

6.4.2 Flat screwdriver Tighten screw 1.5

6.5 TORX screwdriver (T10) Tighten screw 0.8

7.1 Cross screwdriver Tighten screw 1.2

7.2 Wrench (8mm) Tighten the nut 2.0

7.3 Wrench (8mm) Tighten the nut 2.0

8.1 Cross screwdriver Tighten screw 1.2

8.2 Flat screwdriver Tighten screw 0.8

8.3 Manual Clamp the connector seal Fit

9 TORX screwdriver (T25) Tighten screw 2.0

10 TORX screwdriver (T25) Tighten screw 2.0

11 Cable ties Fix the cables Fit

Flexi Power Rectifier Quick Start Guide