Installation and SWAP guide for MTN Hybrid power system

Liu Feng

The topology of the Hybrid power system

Generator1 Power -48V 24V 220V

ATS Generator2

BAT 48V

RBS 24V

MW 48V

Content Install the hybrid power system Install the power and battery cabinet Install the battery Install the load cables Install power alarm cables Install ATS Make the labels The SWAP procedure

Content

Install the power and battery cabinet

Install the power and battery cabinet-fix the cabinet

Expand bolts(total 8 bolts for each cabinet) The RD engineer will design paper footprint of the power and battery cabinet to help the subcontractor to make hole.

Battery Cabinet with DC Air Conditioner

Dimension: 2100 mm 1050 mm 1110 mm (H W D)

Battery quantity : 24*2 V/1000 AH battery cells

Cabinet Weight: 250 kg approximately

Install the power and battery cabinet-install AC cable

This breaker to ZTE power

ZTE AC input breaker

ZTE AC input power The specification of AC cable is 4*10mm2 and it must be outdoor used

Install the power and battery cabinet-install battery

The breaker must be off Install the battery cable The biggest screw is for the battery cable.

Install the power and battery cabinet-install battery temp sensor

Battery temp sensor should be in the top of the battery cabinet( 2nd battery of top layer)

The other side of battery temp sensor should be installed here. You can see the terminal mark on the cover

Install the power and battery cabinet-install environment temp sensor

The environment temp sensor should be installed in the top of the power cabinet

Install the power and battery cabinet-install cable for battery cabinet cooling

the other side of the power cable should be in fuse F204 Power cable Alarm cable for Cooling The terminals should be covered with tap very well The alarm cable should be installed here

Install the power and battery cabinet-install door alarm cable for battery cabinet

The door alarm cable should be installed here

Content

Install battery

Battery Cabinet with DC Air Conditioner

Dimension: 2100 mm 1050 mm 1110 mm (H W D)

Battery quantity : 24*2 V/1000 AH battery cells

Cabinet Weight: 250 kg approximately

Install battery

The battery layout of top layer Battery voltage detect signal cable .each battery has Breaker one cable

The layout should strictly follow this When connect the battery to the Power ,the battery breaker must be off

The battery layout of bottom layer

Install battery

The battery cell voltage detect cable

Content

Install the load cables

Install load cable Load distribution

The load connection should strictly obey the following table F101-F114 means breaker of LLVD1 F201-F205 means breaker of LLVD2 INV : inverter MW : micro wave
Bre aker -48V F101 25A F102 25A F103 25A F104 25A F105 25A F106 25A F107 20A F108 25A F109 25A F110 25A F111 63A F112 63A F113 63A F114 63A F115 40A

Loa d Bre ake r 48V Loa d 24V

ZXD 2430-1

ZXD 2430-2

ZXD 2430-3

ZXD 2430-4

ZXD 2430-5

ZXD 2430-6

INV

Dc cooling

Spare

Spare

RBS1

RBS2

RBS3

RBS4

3G

F201 16A

F201 16A

F203 16A

F204 16A

F205 10A

F206 10A

MW1

MW2

MW3

Battery cooling

DC security light

AWL

NO1 100A
RBS1

NO2 100 A
RBS2

NO3 100A
RBS3

NO4 100A
RBS4

Install the load cables-RBS cable(+24V RBS

24V +(red 35mm2)

Make terminals and labels in RBS side

There are 4 pcs 24V breakers ,from left to right, RB1-RBS4

GNDblack 35mm2)

Install the load cables-microwave cable

-48V

GND

Make terminal in IDU side Make sure the -48V and GND are right

Content

Install alarm cable

Install alarm cable

Here 8 alarms, 16pcs signal cables.

relay
A1 A2 A3 A4 A5 A6 A7 A8

8 Alarms
Generator alarm Battery alarm Rectifiers alarm System alarm High temp alarm Battery discharge Air conditioner alarm reversed

Install alarm cable

16 cores twisted-pair as alarm cable
white/blue red/blue PIN white/orange red/orange Cable connection white/green red/green white/brown red/brown

X15

alarm definition

X16

X15

Pin 2white 3blue Pin 5: white 6: orange Pin 2white 3green Pin 5: white 6: brown Pin 2red Pin 5: red 3blue 6: orange

Generator alarm Battery alarm Rectifier alarm System alarm High temp alarm Battery discharge

X16

X17

X17

X18

Pin 2red Pin 5: red

3green 6: brown

Air conditioner alarm Reversed alarm

X18

Content

Install ATS

ATS

Dimension: 1200mm 890 mm 300 mm H W D) Weight: The whole machine < 130kg.

Install ATS-Signal cable (power-ATS)

Color Orange/white Cable connection EXB X3 Pin2 white Pin3 orange EXB X3 Pin 5 white Pin5 Green SIB X12 (pin1 brown (Pin3 white) Reserved Definition Start Generator1

Green/white

Start Generator2

Brown/white

Grid feedback

Blue/white

Reserved

Content

Make the labels

Make the labels

All the cable must have label ZTE will give the label template

Content

The SWAP procedure

Preparation work before SWAP-install and Debug ZTE power

Debug the power: Check whether the can work normally Set the parameters Check whether the generator can start when the battery charge current is 0.1C

Preparation work before SWAP-connect RBS cable

24V +

GND

Make terminals and labels in RBS side

Preparation work before SWAP-connect IDU cable

-48V

GND

Make terminal in IDU side Make sure the -48V and GND are right

SWAP procedure-SWAP RBS power cable

After start the generator , please call MTN staff about the SWAP

SWAP procedure-SWAP RBS power cable

24V battery +

Do not touch the breaker here

24V battery -

Take the battery + and battery cable from RBS. And it must be covered with insulation tap

SWAP procedure-SWAP RBS power cable

Install new 24v power cable from ZTE power Make sure the Positive and negative poles are right

SWAP procedure-SWAP RBS power cable

AC input of 24v power module 1.Switch on the breaker of the new power cable and check the power voltage (27V)

If every thing is ok, take off power alarm cable

2.Take off the A C input socket of 24V power module and check if the RF module can work

SWAP procedure-SWAP IDU power cable

Switch on the breaker of new IDU power cable, and check the power voltage

Take AC input power cable of IDU Insert the new DC power for IDU If the IDU can not work, rollback

After SWAP , call MTN engineer to check if every is OK

Tidy UP the side

1.Tidy the cable and make label 2.Clean up the site 3.If there is commercial power , turn off the generator

CONNECTION OF THE SIGNAL INTERFACE

X22 -------------------------- BMU 1 BACK 17 ------------------- VB1 DMS OUT ------------------- DMS IN X11 OUT -------------------- X11 IN BATT SENSOR ------------- SIB X6 X12 IN ---------------------- X 12 OUT ALM IN ---------------------------- ALM OUT

GEN to ATS SIGNAL CONNECTIVITY

BROWN BLUE BLACK BLUE BROWN BLACK BROWN +12 -12 START FUEL D+(NIL) HWT LOP 6 5 4 SOLENOID{33/3} DYNAMO 19(not terminated) TEMP SWITCH (16) OP(17)