DC Power Systems Handbook

Table of Contents
The DC Power System

1.1 DC Power Overview 1.2 Rectifier 1.3 Battery 1.4 Distribution 1.5 Battery Return Bus 1.6 Supervisory and System Control 1.7 Low Voltage Disconnect Contactor 1.8 CEMF Cell 1.9 Battery Temperature Compensation 1.10 DC - DC Converter System 1.11 DC Power System Integration 1.12 Inverters/UPS
1
1 7 16 27 31 33 40 43 45 51 54 58
4.5 Battery Installation 4.6 Cabling 4.7 Power Up Procedure 4.8 Battery Initial Charge and Discharge Test. 94 4.9 Documentation
86 89 92
95
Power System Commissioning Retrofit Installation

6.1 Precautions 6.2 Tools List 6.3 Distribution Circuit Addition 6.4 Common Ground Bus Addition 6.5 Distribution Panel Addition 6.6 Rectifier Addition 6.7 Shunt Replacement
97 99
99 100 100 100 101 103 103
Power System Sizing and Ordering

2.1 Calculations 2.2 Formulas 2.3 Power System Design Example 2.4 Ordering Information for Power Systems and Loose Items
62
62 65 66 67
Maintenance and Field Repair

7.1 Power System and System Controller 7.2 RST Rectifiers 7.3 RSM Rectifiers 7.4 Pathfinder 24-3kW, 48-3kW, and 4810kW Rectifiers 7.5 CS and CSM Converters 7.6 Vented Batteries 7.7 Valve Regulated Lead Acid (VRLA) Batteries 7.8 Battery Failure; Detection, Prevention and Corrective Action
105
105 107 109 112 114 116 118 119
Site Engineering for DC Power

3.1 Site Layout and Loading 3.2 Grounding Network 3.3 Surge Protection Devices (SPDs) 3.4 Wiring 3.5 Engineering Drawings
69
69 71 74 76 80
Initial Installation
4.1 Safety Precautions 4.2 Tools List 4.3 Inspection 4.4 Power System Assembly/Mounting
81
81 83 84 85
Troubleshooting
8.1 Power System and System Controller
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CHAPTER
The DC Power System

The DC power system is a vital part of the communications network.
Most communication equipment, including PBXs, telephone switches,

microwave transmission, fiber optic transmission, mobile radio, cellular, etc. are designed to operate from a DC input voltage. A DC source has the inherent benefit of higher reliability as compared to an AC source. This is because the battery, which is often used for backup, is directly connected to the load with no intermediate stage such as an inverter that may fail and disrupt power to the load. The basic power system consists of a rectifier and usually a battery, but may include various other components. The various components are discussed in detail later in this section.
1.1 DC Power Overview

1.1.1 Typical DC voltage and current requirements
The two most common input voltage requirements for communication equipment are +24V and -48V. The use of -48V is rapidly becoming the most predominate as this is the maximum safe working voltage according to both the National Electrical Code (NEC) and the Canadian Electrical Code (CEC) that has no current limiting requirements. The high voltage reduces the current requirements making fuses/circuit breakers/cables smaller.
+ 24V evolved from the mobile radio industry, where equipment

was designed to operate from either an automotive (+12V) charging system or a truck (+24V) charging system.
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- 48V evolved from the telephony world where 48 volts was

chosen because it was the maximum voltage that was considered safe as technicians had to make live connections. The negative polarity (positive ground, similar to the old British -6 VDC automotive charging system) was chosen as it reduced the galvanic corrosion that occurred when the lead sheathed telephone twisted pair cables were originally deployed and buried in the earth.
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Load
Battery
DC
DC
DC
Rectifier
AC
AC Power Off
AC Power On
Figure 1
Basic DC Power System Operation
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Load
Load
DCPSB01A
Load
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Application Mobile Radio Base Station Analog Cellular Base Station Microwave transmission station Mobile Radio Base Station Digital Cellular Base Station Digital Cellular Base Station Microwave transmission station Fiber optic transmission station Telephone switching center (pedestal) Telephone switching center (remote) Telephone switching center (large) PBX Pay phone coin control Fiber in the loop (FITL) Microwave transmission traveling wave tubes, etc
Voltage +12 VDC +24 VDC +24 VDC +24 VDC +24 VDC -48VDC -48VDC -48VDC -48VDC -48VDC
Current <50 Amps 200-800 Amps <400 Amps <50 Amps 100-600 Amps 100-400 Amps <600 Amps <100 Amps 20-100 Amps 50-200 Amps
Notes
-48VDC -48VDC +/- 130 VDC + 130 VDC -12, +130 & + 250 VDC
200-10 000 Amps <100 Amps < 5 amps 100 VA per circuit various
History History
Table A
Typical Telecom Equipment Voltage and Current Requirements
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Typical AC voltage sources

There are many different voltage sources around the world. Identify the source that you are using and watch the rectifiers to the source. See Table B.
Service 120/240V 1 PH 3W 120/208V 3PH 4W 277/480V 3PH 4W 347/600V 3PH 4W 208 V 3PH 3W 480 V 3 PH 3W 220/380 V 3PH 4W Configuration Single Phase Three Wye Three Wye Three Wye Three Delta Three Delta Three Wye Phase Phase Phase Phase Phase Phase LL Volts 240 VAC 208 VAC 480 VAC 600 VAC 208 VAC 480 VAC 380 VAC L-N Volts 120 VAC 120 VAC 277 VAC 347 VAC N/A N/A 220 VAC Where used? USA, Canada USA, Canada USA Canada USA, Canada USA Europe Asia South America Notes
Table B
Typical AC Commercial Voltage Sources
Figure 2
Single or Split Phase
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Figure 3
Three Phase Delta
Figure 4
Three Phase Wye or Star
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1.2
Rectifier
1.2.1 Description
The rectifier is a device that changes an AC (alternating current) input to a regulated and filtered DC (direct current) output. The DC output supplies power to the load (communication equipment) and charges a backup battery if required.
1.2.2
Connection
The rectifier is connected in parallel with both the load and the battery (if applicable). Multiple rectifiers may be connected together in parallel, with their corresponding (+) and (-) leads connected together.
1.2.3
Operation (Float charge mode)

The rectifiers are adjusted to the voltage requirement (float voltage) of the battery and to share the load or supply the same output current in systems with more than one rectifier.
AC-ON - The rectifier supplies current to the load and provides a
trickle charge current to the battery.

AC-OFF - The rectifier turns off and the battery will supply
current to the load until the battery is completely discharged.

AC-ON - The rectifier supplies current to the load, any extra
current available from the rectifier will be used to recharge the battery.
1.2.4
Sizing details
The rectifier size is chosen by determining the most cost-effective means of satisfying the total capacity requirements.
N+1 redundancy should always be considered. N is
the number of rectifiers required to satisfy the total capacity requirements of the load and the 1 is an extra rectifier added so that a failure of a rectifier in the system will not jeopardize system integrity.
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Correct choice of either positive ground (-48VDC) or negative ground (+24 VDC) is critical. The grounded potential is connected to a common point and the live cable is connected through either fuses or circuit breakers. Refer to power system design calculation section.
1.2.5
Features and selection criteria

Low output noise/ripple ensures that the load is unaffected by
the rectifier in both battery and more importantly battery-less operation. Note: the battery acts as a filter, but VRLA batteries will fail prematurely when connected to rectifiers with high output ripple voltage.
Tight voltage regulation (line and load) to ensure that the
battery is properly charged and the load does not receive fluctuating voltages.
Modular vs. monolithic configuration; modular rectifiers allow
for easy replacement and expansion.

Unity power factor (P.F.>.95) is becoming more important as
the utilities move toward increased monitoring of power factor. A poor power factor at your Telecom facility may result in the electrical utility adding a surcharge to your electrical bill. In Europe, unity power factor is a CE requirement for Residential and light commercial applications. North America may soon follow this trend. There are two types of power factor measurements displacement and true. The displacement component of power factor is the ratio of the active power of the fundamental wave (60 Hz), in watts, to the apparent power of the fundamental wave in volt-amperes. This is the value used by utilities to determine billing. True power factor is the ratio of the total power input, in watts, to the total volt ampere input, this includes the fundamental wave (60 Hz) and all the harmonics (120, 180, 240, 360, 480 Hz, etc. This value is used for efficiency calculations. Early Argus rectifiers utilize passive power factor correction to achieve reasonable power factor at low cost. The Pathfinder rectifiers offered by Argus have a true power factor of >.99.
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Figure 5
Power in an Inductive Circuit
Figure 6
Power Factor Triangle

Low THD (total harmonic distortion) and damaging harmonic currents to meet CE requirements and to eliminate
AC generator and transformer overheating and interaction problems. THD refers to the distortion of the incoming AC voltage or current waveform when the rectifier is connected and is expressed as a percentage.
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Three phase AC input - For higher power applications this
becomes more important to ensure even balancing of load on a three-phase AC source.

High efficiency as well as having the obvious power savings
benefit, reduces the size of the input feeder circuit breaker and input cabling.
Wide AC operating window for both frequency and voltage to
tolerate fluctuations without the rectifier shutting down. Argus rectifiers have a wide input tolerance range for both frequency and voltage. This allows uninterrupted operation and also allows universal operation for 208/240V 60Hz operation and 220V 50 Hz operation with no modification or reconfiguration required.
Pathfinder 48-3kW & 24-3kW rectifiers (208/240 VAC I/P) will continue to operate down to 90 VAC (with reduced output)!
Compact and lightweight helps reduce installation,
maintenance and shipping costs.

Balanced load sharing should be achieved between units of
the same design and with other types of rectifiers. Argus rectifiers accomplish this with a combination of forced sharing (master/slave) and/or adjustable slope regulation. Adjustable slope allows you to tailor the voltage regulation characteristics of different brands of rectifiers.
Forced sharing works by the rectifiers electing a
master unit (the rectifier with the highest output voltage). The other rectifiers are forced to adjust their output voltage to track the master and therefore share the load.
Slope Regulation (Output Voltage) allows the user
to drop the output voltage of the rectifier a small amount from no load to full load. This is done at a fixed rate. The slope in the voltage regulation of the rectifiers helps to allow the user to set the rectifiers to load share easily and also allows you to tailor the voltage regulation characteristics of different brands of rectifiers.
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Figure 7
Output Slope Voltage Regulation and Current Limit

Adjustable current limit restricting output current of the
rectifier, in either a discharged battery or overload condition. The rectifier can operate in this condition without damage.
Power limit allows the rectifier to supply greater output current
when the output voltage of the system is low. This reduces battery recharge time and also provides greater overload capabilities reducing the need for redundant rectifiers.
Figure 8
Current Output P 48/10 kW e/w Power Limit
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Figure 9
Power Limit (P 48-3kW) - Current Limit (RSM 48/50) Comparison

A float/equalize mode selector switch allowing selection of
two operating modes: 1. 2. Float mode for normal charging of the battery. Equalize mode for boost charging (at a higher charging voltage) of batteries when required. This boost charging eliminates any sulfation on the battery plates resulting in cell voltage imbalances and poor performance. This is an important feature for vented lead calcium batteries floated at reduced voltage levels. Typically not required with VRLA batteries under normal operating conditions.
Automatic high voltage shutdown (HVSD) or overvoltage protection (OVP) to switch the rectifier off in case of
a high output voltage condition, preventing damage to the batteries and load. An automatic restart feature should be included in the event that a site temporary abnormality surge as a ground surge resulted in the HVSD.
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Soft-start gradually steps each rectifier on-line at power up. This
eliminates start-up current surges associated with many rectifiers. The feeder breaker and feeder size requirements are decreased, reducing the installation costs of the rectifier.
Adjustable delay start allows staggered start-up of rectifiers
reducing stress on the AC generator and also allows the rectifiers to be started after the site air conditioner compressor (drawing high surge current) has started.
Alarms provide indication of rectifier failure and should be of
fail safe design. Local indication plus remote relay contacts are required.
Remote sensing leads are connected directly from the battery
to the rectifiers via a sense fuse distribution panel located in the supervisory panel. This allows the charger output voltage to be regulated at the battery improving voltage regulation at the battery. This is important with power systems that incorporate separate charge and discharge circuits or power systems where there may be a significant voltage drop in the battery cables. If this feature is not connected, the rectifiers automatically revert to internal sensing, regulating the rectifier output voltage to the rectifier output terminals.
Remote Control and Monitoring allows the rectifiers to be
remotely controlled and monitored from a central supervisory and control panel.
Model Pathfinder RSM 48/10 RSM
Voltage 24 VDC 48 VDC 24 VDC 48 VDC
Current 18, 50,100 A 10, 30, 50, 180 A 7.5, 50,100 A 15, 30, 50, 100 A
RST
12 VDC 24 VDC 48 VDC
50, 100 A 30, 50, 100 A 15, 30, 50, 100 A
Features Convection or fan cooled Modular design 200 kHz resonant converter design Convection or fan cooled Modular design 100 kHz forward converter design Passive power factor correction Convection cooled Monolithic Design 48 kHz forward converter design Passive power factor correction
Table C
Argus Technologies Solutions
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1.2.6
Theory of Operation RSM 24/50, 24/100,48/30 and 48/50

Please refer to the power circuit block diagram. The 184-264 VAC 50/60 Hz input is fed through a circuit breaker into a full wave rectifier, which provides a 120 Hz 340 V peak pulse train to an input filter circuit. The input filter provides a nominal 290 volts DC "raw supply" with approximately 30 V P-P 120 Hz ripple to the transistor switching circuit. The transistor switching circuit chops the raw supply into nominally 525V P-P , 100 kHz rectangular waveform with a nominal 66% duty cycle. This waveform is fed into a ferrite power transformer, which steps down and isolates the high frequency switching waveform. A rectifier circuit converts the power transformer output to a DC pulse train of nominally 136 V peak. A two-stage output filter averages and smoothes this pulse train down to provide the nominal 52 VDC output with low noise. A voltage error amplifier circuit senses the output voltage and compares it with the voltage reference to provide a voltage error signal. Similarly, a current error amplifier senses the output current using a shunt resistor and scaling amplifier to compare the output current to the desired maximum output current to provide a current error signal. These signals are fed into the pulse width modulator (PWM) via OR-ing circuitry so that either voltage or current regulation is achieved. The pulse width modulator controls the "ON" time of the switching transistors to vary the output as commanded by the error amplifiers. It also senses the switching transistor current on an instantaneous basis to provide cycle-by-cycle protection of the switching transistors. An auxiliary supply, powered via a small 50/60 Hz transformer, and a DC/DC converter power the control circuit and front panel circuitry. The PWM receives the ON/OFF command and clock signal from the front panel circuit and control circuitry.
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60Hz 290VDC 250V 525V 136V
120Hz
100kHz
+340V -340V
52V (48V Units) 0V
Figure 10
OV
P O W E R
Input 185-265VAC 50/60Hz
+
Input Rectifier Transistor Drive Isolation Boundary DC/DC Local Current Sense Auxiliary Supply Or Gate Pulse Width Modulator (PWM) Output Rectifier Transistor Switching Circuit
+
Output Filter
Output Shunt
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Input Filter & Storage Capacitors Output Current Sense Current Error Amplifier Voltage Error Amplifier
V AUX IN On/Off Command I Out
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RSM Block Diagram

Front Panel Circuit Micro Processor
H A N D B O O K
Output Voltage Sense
Remote Sense
Voltage Current V Out Reference Reference - Adjustments - Display - Monitoring

Communication
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1.3
Battery
1.3.1 Description
The battery is an electro-chemical means of energy storage. When AC power is interrupted to the rectifiers or when there is insufficient current available from the rectifiers to support the load requirements, the battery will automatically supply current to the load. The battery may be used in combination with a generator to provide back-up power for extended time periods to the load. A battery consists of a series connection of multiple cells. The number of cells in series is determined by the operating voltage of the system and the operating voltage of each cell.
1.3.2
Connection
The battery is connected in parallel with the rectifier and the load.
1.3.3
Operation
As detailed in the rectifier operation section. Some batteries may require periodic equalization. Equalization is where a higher boost voltage is applied to the battery to ensure the proper cell voltage balance and correct conditioning of the battery cells.
Parameter Nom. V Float V Equalize V End V Op. Win. V # cells
Valve Regulated Lead Acid Battery (VRLA) One Cell 24 V System 48 V System 2 24 48 2.25 27 54 2.30 27.6 55.2 1.75 21 42 1.75-2.30 21-27.6 42-55.2 1 12 24
Flooded or Vented Battery One Cell 24 V System 2 24 2.20 26.4 2.30 27.6 1.75 21 1.75-2.30 21-27.6 1 12
48 V System 48 52.8 55.2 42 42-55.2 24
Table D
1.3.4
Typical battery operating parameters
Sizing details
Determine your load profile (i.e. amps per hrs) and select the battery using the manufacturers sizing table (See: Table E). Batteries are rated using the following criteria:
Temperature (25 deg C in North America, 20 deg C
in Europe).
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End voltage (the lowest voltage that the cell is
discharged down to). The end voltage used in calculations is usually the minimum voltage that the battery can be discharged down to without damage. A more conservative end voltage will increase the life expectancy of the battery but reduce back up time.
Refer to IEEE battery sizing guidelines for calculating battery size for complex load profiles Evaluate battery charge rate for sizing intercell and inter-tier connectors
Apply temperature performance correction factor for average temperatures below 25 deg. C, (77 deg. F), if applicable (See: Table F). Ensure that the battery operating voltage coincides with the acceptable operating voltage window for the equipment connected. Apply the beginning and end of life de-rating factor. This factor is 20% and allows for: The battery shipped at less than 100% capacity, typically 90% (Full capacity is achieved after a short period of float service).
Cells that are tank formed ship at 100 % capacity.
Battery end of life considered as 80% of capacity (See: Figure 11).
Battery capacity is determined by the number & size of the plates, therefore the larger the battery the greater the capacity. Battery strings may be connected in parallel to obtain additional capacity. Strings should be equal in capacity and interconnecting cables should be of approx. the same size and length to obtain optimum charge and discharge characteristics. The maximum recommended number of parallel strings is three.
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Smaller applications commonly use mono-block batteries. Mono blocks are batteries that have more than one cell contained in the assembly (i.e. an automotive battery is a 6 cell 12 VDC monobloc).
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Average Cell Performance Data *

Discharge rates in amperes. 1.215 SP. GR. ELECTROLYTE AT 77 (25C), INCLUDING CELL CONNECTORS NOM. A.H. CAP. TO 1.50 VPC 1 MIN.
TYPE
72 HR.
24 HR.
12 HR.
8 HR.
5 HR.
4 HR.
3 HR.
2 HR.
1.5 HR.
1 HR.
30 MIN.
15 MIN.
1 MIN.
To 1.75 VPC Final EA-5 230 EA-7 EA-9 EA-11 EA-13 EA-15 EA-17 EA-19 EA-21 270 350 440 530 620 710 800 890
4.6 4.8 6.4 8.0 9.6 11.2 12.8 14.4 16.0
11.1 12.9 17.2 21.5 25.8 30.1 34.4 38.7 43.0
18.8 23.7 31.6 39.5 47.4 55.3 63.2 71.1 79.0
26.6 33.3 44.4 55.5 66.6 77.7 88.8 99.9 111
44.0 49.0 65.3 81.7 98.0 114 131 147 163
49.9 58.5 78.0 97.5 117 137 156 176 195
59 73 97 122 146 171 195 219 244
75 98 131 164 197 229 262 295 328
87 120 160 199 239 279 319 359 399
102 154 205 257 308 359 411 462 513
152 226 298 367 435 507 571 634 694
197 291 380 465 558 651 728 801 870
290 426 548 685 792 924 1010 1100 1190
530 790 1010 1270 1460 1700 1870 2030 2200
*Rates shown depict average values and are subject to IEEE-485
CONSTANT CURRENT DISCHARGE RATINGS AMPERES @ 77F

Operating Time To End Point Voltage
End Point Volts/ Cell
1.75
5 min.
15 min.
30 min.
60 min.
2 hr.
3 hr.
4 hr.
5 hr.
6 hr.
7 hr.
8 hr.
10 hr.
12 hr.
20 hr.
24 hr.
48 hr.
72 hr.
100 hr.
274
162
105
61.5
34.8
25.0
19.6
16.2
14.0
12.3
11.0
9.08
7.79
5.00
4.19
2.13
1.43
1.04
1.80
240
151
99.0
60.1
34.0
24.2
19.0
15.8
13.6
11.9
10.7
8.80
7.58
4.89
4.10
2.10
1.42
1.03
1.85
203
136
92.0
55.0
31.4
22.8
18.0
15.0
12.9
11.3
10.1
8.44
7.23
4.67
3.92
2.02
1.37
0.99
1.90
156
110
75.0
47.0
28.9
21.0
16.8
14.0
12.0
10.6
9.50
7.90
6.73
4.34
3.65
1.88
1.26
0.91
Table E
Typical Battery Performance Table
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Electrolyte C -3.9 -1.1 1.7 4.4 7.2 10.0 12.8 15.6 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.4 23.9 24.5 25.0 25.6 26.1 26.7 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.6 32.2 35.0 37.8 40.6 43.3 46.1 48.9
Temperature F 25 30 35 40 45 50 55 60 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 95 100 105 110 115 120
Cell size correction factor 1.520 1.430 1.350 1.300 1.250 1.190 1.150 1.110 1.080 1.072 1.064 1.056 1.048 1.040 1.034 1.029 1.023 1.017 1.011 1.006 1.000 0.994 0.987 0.980 0.976 0.972 0.968 0.964 0.960 0.956 0.952 0.948 0.944 0.940 0.930 0.910 0.890 0.880 0.870 0.860
Table F
Temperature Performance Correction Factor Table

This table is based on flooded lead-acid cells only.
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For further information, please refer to:

IEEE-485-199 - IEEE recommended practice for
sizing large lead-acid batteries for stationary applications.

IEEE-1184
- IEEE guide for the selection and sizing
of batteries for uninterruptible power systems.

IEEE-1689 - IEEE guide for the selection of valve-
regulated lead-acid (VRLA) batteries for stationary applications.
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Figure 11
Battery Performance vs. Time
1.3.5

There are three main types of lead acid batteries that are used in telecommunication applications. The three types, based on acid classification, are listed below.
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Acid Classification Flooded Technology
Description free liquid electrolyte, similar to an automotive battery
Advantages -proven technology -flat, tubular, plant options -best life expectancy of lead acid batteries at higher operating temperatures
Disadvantages -high maintenance -transportation restrictions
VRLA-AGM (Absorbed Glass Mat) Technology
a small quantity of liquid electrolyte is held in suspension in the fiberglass mat
-low maintenance -minimal vented gasses -easy installation in any position -easier shipping classification -will not freeze
-difficult to evaluate battery state of health -rapid reduction of life expectancy when operated at high temperatures (above 25 deg C)
VRLA-Gel Technology
fumed silica is added to gel the liquid electrolyte
-lasts longer than AGM at high operating temperatures
-performance (AH per kg) is less than AGM battery
Table G
Battery Type Comparison
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Figure 12
Battery Construction
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Cycling requirement - different cell plate alloys and plate
configuration affect the cycling (charge and discharge) performance of the battery. Determine the cycling requirement of your application (i.e. float with light cycling, float with heavy cycling and full cycle service) and choose the correct battery for the application.
Rate of discharge:
High < 15 minutes Medium 15 min. - 2 hr. Low 2 hr +

Maintenance requirements. Physical design parameters , ventilation, floor loading,
available space.
Cost including life expectancy. VRLA batteries of both AGM and gel type are usually the first
choice for backup. Some of the important features to look for in a VRLA battery are: Jar material with low water vapor diffusion rate i.e. polypropylene or PVC to prevent dry out. Flame retardant jar materials. Even compression of plates through a fixed method of jar compression to maintain, plate to microporous separator integrity (AGM). Designed to prevent strap corrosion and lug corrosion (AGM).
The Battery may be packaged on a traditional battery stand or be of bolt together self supporting construction. For smaller battery strings the use of relay rack shelves or cabinets is a consideration. There are also AGM batteries available from the manufactures prepackaged for easy installation into a relay rack.
1.3.6
Argus Technologies Solutions

Argus does not manufacture batteries, but will provide batteries as part of the integrated power system.
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Circuit Breaker Distribution
Charge (+)
Shunt Bar
Charge (-)
Rectifier #2
Figure 13
Basic System e/w Distribution
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Rectifier #1
Termination Panel
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Ground Bar
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Load
Load
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1.4
Distribution
1.4.1
Description
Fuses and circuit breakers are used to safely distribute the DC power from the rectifier and battery to the loads. These devices protect the loads and load cables from short circuits, overload conditions and allow easy manual shutoff . This helps to isolate faults between circuits. Circuit breakers and fuses are also used for protecting the battery and battery cables and to allow an easy means of disconnecting the battery from the system for safety, fire prevention and maintenance.
1.4.2
Connection
Primary Distribution
Load fuses or circuit breakers located at the power system are connected in series between the power system and the loads and/or between the power system and the battery.
Secondary Distribution
Large main fuses are installed in the power system to distribute dc power to remote BDFBs (Battery Distribution Fuse Boards) or BDCBBs (Battery Distribution Circuit Breaker Boards). From the BDFB power is distributed to the loads with smaller individual circuit breakers.
1.4.3
Operation
Fuse
Excessive current flowing through the fuse melts the internal link, disconnecting the load from the power system. A guard fuse is connected in parallel with the main fuse and will blow when the main fuse blows. The guard fuse provides a local indication and also will send an external alarm signal via a built-in contact.
Circuit breaker
Excessive current flowing through the circuit breaker causes excessive heat (thermal) or an excessive magnetic field (magnetic) to trip the circuit breaker to the off position. Alarm sending is via breaker auxiliary contacts or electronic trip detection circuitry.
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Electronic trip detection circuitry

A 10 000 ohm bypass resistor is connected across the circuit breaker (to limit current) and the output voltage of the circuit breaker is monitored. The benefit of the circuit is that an alarm is indicated only when a breaker is off with a load connected and no connection to the auxiliary contacts is needed.
Breaker ON with no load voltage on breaker
output is high no alarm .

Breaker ON with load voltage on breaker output is
high no alarm .
Breaker OFF with no load voltage on breaker
output is high (due to bypass resistor) no alarm .

Breaker OFF with load voltage on breaker output
is low (due to load forcing voltage down to zero V) alarm is indicated .
Voltage will be measured on the output of a circuit breaker even when the breaker is off, however current flow is limited to a few mA due to the 10,000 ohm resistor.
Sizing
Most communication equipment requires fuses or circuit breakers with short delay curves fast blow to provide proper protection Fuses with different curves may be utilized to match specific load requirements. Load fuses and circuit breakers should be sized 1.25 to 1.5 times the maximum continuous anticipated load on the circuit for reliable operation. Battery fuse/circuit breaker should be sized at 1.25 times the maximum current rating of all the rectifiers in the system (minimum). Ensure that the current capacity of the circuit breaker panels is not exceeded by the current draw of the connected loads.
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The interrupting capacity (highest fault current that the device is rated to safely interrupt) of the protection device should match the application. Battery protection devices require higher interrupting capacity due to the high short circuit current capability of a battery and the large cables (low impedance).

Remote alarm sending via guard fuse or remote
contacts on circuit breaker.

Alarm indicating lamp and an isolating relay.
Traditional bolt-in, plug-in or snap-in circuit breakers.

Guard bars to prevent accidental tripping of circuit
breakers. Electronic breaker trip detection circuitry. Various types of fuses and circuit breakers can be combined in different panels to meet load requirements.
Current monitoring via series shunts to ensure circuits
are not overloaded or power consumption monitoring for billing purposes.

Battery protection features :
EPO - Emergency Power Off control capability using contactor or shunt trip breaker for locations that require a mandatory emergency power shutdown to meet local fire codes. LVBD - Low Voltage Battery Disconnect control capability to automatically disconnect and reconnect the battery during an extended ac power outage. Manual battery disconnection - Single string disconnection for maintenance and fault isolation.
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Fuses or circuit breakers?

Fuse advantages - high interrupting capacity, cost, flexibility, fast speed. Circuit breaker advantages - can be reset, accuracy, low speed.
1.4.4
Argus solutions
Fuse blocks:
Type GMT 70 Type BAF Cartridge TPL Rating-Range (block size) 0-15A 1/2A used for indicating purposes 0-30A 0-30A, 31-60A, 61-100A, 101-200A 61-800A
Breakers:
Manufacturer Type Heinemann Heinemann Heinemann AM CD GJ Rating 5 - 100 A 5 - 100 A 100-700 A Interrupting Capacity 5 or 10kA 10,000A 25,000A Usage Load or battery Load or battery Load or battery
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1.5
Battery Return Bus

1.5.1 Description
The battery return bus (BRB), also referred to as the
common ground bus , provides a common return/reference
point for the connected loads and the power system. This common reference point is connected to the site ground to provide a low impedance path to ground for transients and noise.
1.5.2
Connection
The ground lead of all DC load inputs, batteries and rectifiers should be connected to this point. This bus must also be connected to the site ground grid (see grounding network section).
1.5.3
Sizing
Ground bars are sized according to load requirements.
1.5.4
Features
Allowances for termination of two-hole lugs of various sizes should be provided. Ground bars must be isolated from the relay rack through glastic insulators so that the power system can be integrated correctly into the site single point ground network. Provisions for small cable termination shall also be provided. Tin-plated copper construction for corrosion resistance .
1.5.5
Argus solutions
Various types are available from Argus including flat bars and U shaped bars for additional cable termination.
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Figure 14
Battery Circuit Breaker Distribution
P O W E R
+
Rectifier #2 Charge (-)
Charge (+)
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Rectifier #1 Shunt Bar
Power
A
Supervisory Panel
DCPSH03A
Basic System e/w Supervisory Panel
Termination Panel
Shunt
Ground Bar
Load
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1.6
Supervisory and System Control

1.6.1 Description
In most power systems it is desirable to have a central control and monitoring panel to provide local and remote indication of system operating parameters and alarms and also to provide system control.
1.6.2
Connection
Various connections are made to the supervisory panel from different components so that different parameters and levels may be monitored and controlled. Shunts can be installed in the grounded or live load, battery or system conductor.
1.6.3
Operation
The battery (charge) and load (discharge) voltage is monitored with a direct connection of the sense leads to the source; battery or load. The battery (charge) and load (discharge) current is monitored with an external shunt. Shunts are calibrated low resistance resistors designed to provide a specific voltage drop at a specific current (linear relationship). This voltage drop is measured by the ammeter. A typical shunt rating would be 200A, 50mV. Therefore 200 amps of current flowing through this shunt will cause a voltage drop of 50mV. Calculated values may also be displayed such as total rectifier output current (numerical addition of individual rectifier output currents). In systems where there is no battery shunt an estimation of battery current can be calculated by subtracting the discharge current from the rectifier total output current. Room and battery temperature can be monitored with temperature probes. Additional analog parameters can be monitored using available inputs.
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Events such as distribution fuse alarm, battery fuse alarm, rectifier failure, converter failure, etc. are monitored by the supervisory panels. Alarms are based on an analog or digital event. Each alarm has a two to five second delay before extending an alarm. The delay eliminates false triggering due to line transients or false alarms. Analog alarms usually incorporate a hysteresis into the trigger level to prevent oscillation of an alarm condition caused by a level fluctuating around the set point. Alarm functions provide both local (visual and audible (optional)) and remote (relay contact) indicators. Relay contacts may be configured as form A (NO), form B (NC), or form C (NO & NC). Control functions are extended from the supervisory panel to control various other power system components. Microprocessor based supervisory panels have direct communications with rectifiers for monitoring and single point control. Communications is via RS-485 connection. 1.6.4
Sizing
Shunts are sized according to load requirements and limit the initial capacity of the power system. Current flowing through a shunt must not exceed 80% of its nominal rating on a continuous basis.
1.6.5
Features (panel dependent)

Typical Alarms
high/low voltage (1 & 2) AC mains high/low/failure distribution fuse/breaker battery fuse/breaker control fuse trip rectifier failure alarm minor (one rectifier) rectifier failure alarm major (>one rectifier) converter failure alarm minor (one converter) converter failure alarm major (>one converter) auto-equalize
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high voltage shutdown low voltage disconnect CEMF (out) CEMF (fail) rectifier communication lost Power system minor alarm (logical or-ing of various non critical alarms) Power system major alarm (logical or-ing of various critical alarms) etc.
Controls
Control features are used to control power system devices such as rectifiers and contactors.
Manual equalize - Allows the user to initiate all the rectifiers
into the equalize mode with one common switch. Used for maintenance purposes with VRLA batteries, i.e. equalizing cell voltages in a battery string.
Auto-equalize - Common in applications where flooded batteries
are deployed. This function initiates the rectifiers into the equalize mode (boost charge) for a preprogrammed amount of time (duration). It is used with vented batteries floated at low voltages to prevent lead plate sulfation or where a quicker recharge of the battery is required after a power failure. Auto-equalize is initiated in one of three ways: 1. after power failure based on the voltage of the battery;
arm voltage (indicating that a long outage has
occurred, rectifiers are off and the batteries have been discharged) and activate voltage (indicating the battery is nearing full charge and the equalize mode is triggered, rectifiers are on) The rectifiers will remain in the equalize mode for the duration. 2. periodic equalize; where the batteries equalized at the interval programmed in days. are
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3.
manual initiation using the duration setting to return the rectifiers to float after the duration has expired.
HVSD/OVP - automatically shuts down all the rectifiers when an
output DC over-voltage condition is detected.

LVD - controls 1 or more contactors that automatically open when a low battery voltage condition is detected and close when the battery voltage returns to normal. See LVD section. LVD override control - switch for maintenance. Battery temperature compensation is used to adjust the
rectifier output voltage to ensure that the battery float voltage is correct for the operating temperature of the battery. See battery temperature compensation section.
Charge current control is used to limit the flow of current into
the battery when recharging commences after a power failure. It is programmed typically at C/5 (capacity of the battery/5). This ensures that the battery is not charged too quickly, resulting in excess heat generation and possible reduction in battery life. This can be very important for VRLA type batteries.
Battery diagnostics
Battery capacity estimation - the capacity of the
battery at the current point in time expressed as a percentage of the battery manufacturer's specification.
Battery state of health estimation - a continual
measurement of the batteries performance and state of health. It is expressed as a percentage of the manufacturer's specification. Alarm triggers can be set to alarm when the battery state of health falls below 80%.
Battery run time prediction - the algorithm
predicts the number of hours that the battery will last, before the battery will be fully discharged or a LVD will occur, at the present discharge rate.
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Rectifier group single point adjustment - allows the
operator to setup and adjust all the rectifiers at one central location.
CEMF (counter-electro-motive-force) controls 1 or more
contactors that automatically close when a high load voltage condition is detected and open when the load voltage returns to normal or is in a low voltage condition. See CEMF section.
1.6.6
Other Features
VAR (Visual alarm reset) - Is used to clear visual alarms. Lamp test - Illuminates all lamps to verify operation. Test - Combined with an external power supply, allows the user
to test and calibrate the power system while in service (SD series only).
ALCO (Alarm Cutoff) - Is provided to clear the relay contacts
and audible alarm associated with each alarm condition this allows extended alarms to be canceled while alarm condition is being resolved by local personnel.
1.6.7
Advanced features (SM series)

Remote access for control and monitoring, LocalRS232 Remotedial-in Remotedialback SNMP (Simple Network Management Protocol) alarm reporting over network LAN or WAN History and statistics Programmable alarm relays LCD display of alarms, parameters, etc.
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1.6.8
Argus Solutions
SM02
This microprocessor based supervisory panel combines a large LCD display and keypad with optional modem card to provide advanced power system monitoring and control features.
SM03
This microprocessor based supervisory panels provides many of the features of the SM02 (without the remote access) in a smaller, reduced cost package.
SD02 & 04
These discrete component supervisory panels provide comprehensive metering, control and alarm functionality.
SD03 & 05
These discrete component supervisory panels provide basic metering, control and alarm functionality.
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Figure 15
Battery Low Voltage Load Disconnect Circuit Breaker Distribution
P O W E R
+
Rectifier #2 Charge (-)
Charge (+)
H A N D B O O K
+
Rectifier #1 Shunt Bar
Power
DCPSH04A
Basic System e/w Load Disconnect
A
Supervisory Panel
Termination Panel
Shunt
Ground Bar
Load
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1.7
Low Voltage Disconnect Contactor

1.7.1 Description
The low voltage disconnect (LVD) contactor is used to disconnect either the load from the system (load disconnect) or the battery from the system (battery disconnect) when the battery has been completely discharged in a long duration power outage. There are three reasons for using a LVD: 1. Prevention of load damage due to an under voltage condition. Some communications equipment may be damaged when operated with an excessively low input voltage or draw excessive current that could trip a feeder circuit breaker. Prevention of damage to the battery due to overdischarge. Discharging a battery below the lowest recommended end voltage (see battery section) might permanently damage the battery. Load shedding - to disconnect specific loads in a prioritized sequence to maximize backup time for more critical loads (ex. up to three individually controlled contactors can be used with the SM02).
2.
3.
1.7.2
Connection
The low voltage disconnect can be connected in series with the load (load disconnect) or in series with the battery (battery disconnect). The LVD is controlled by the supervisory panel.
1.7.3
Operation
The supervisory panel continuously monitors system voltage. After an extended AC outage the batteries will discharge down to the disconnect point. The disconnect point is typically set to the lowest acceptable battery discharge voltage (end voltage). In a Telecom application the end voltage typically used is 1.75 volts per cell (21 VDC in a 24 VDC system and 42 VDC in a 48 VDC
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system). When the disconnect point is reached the load or battery will be disconnected from the system. The load or battery will remain disconnected until AC outage is over. On return of AC a load disconnect and a battery disconnect system function differently (see below).
Load disconnect The rectifiers will pre-charge the
batteries for a few minutes until the battery voltage reaches the reconnect point (typically 25 VDC or 50 VDC). When the reconnect point is reached, the load is connected on line at this voltage level.
Battery disconnect Immediately after the
reapplication of AC, the load will see a slowly increasing DC voltage (0-50 VDC over an 8-10 second period, due to the soft start feature in the rectifier). At the 50 VDC point the battery will be connected on line. A wide voltage differential between the in and out settings (i.e. out 42V, in 50 V in a 48V system) prevents the contactor from oscillation because the battery voltage will naturally rise after the load has been removed from it and reconnection without the rectifiers on-line would not be desirable.
Load vs. battery disconnect - In some cases battery, instead
of load, disconnection is desirable. The advantage of this system is that an accidental operation of the LVD will not disrupt power to the load unless the AC is also off. The disadvantage of the battery disconnect that the load will see a slowly increasing input voltage 0-50V as the rectifiers perform the soft start this may cause damage to the load or inadvertent fuse or circuit breaker tripping. Careful evaluation of the load specifications is required to verify that this method of disconnection will not affect the load. 1.7.4
Sizing
Low voltage disconnect contactors are available in various sizes. The rating of the LVD indicates its maximum current carrying/switching ability.
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1.7.5

Able to switch high current loads reliably.
1.7.6
Argus solutions
200A, 800A and 1200A available.
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1.8
CEMF Cell
1.8.1 Description
The CEMF cell is a diode array that is connected in series between the power system and the loads. A contactor is installed in parallel with the diodes. The diodes are used to reduce the voltage applied to the loads by a fixed value during normal operation or when the batteries are equalize charged. The contactor automatically bypasses the CEMF when the system is on battery to maintain maximum backup time for the loads. CEMF cells are rarely used in modern telecommunications systems as they introduce step voltage changes to the load voltage when switched in or out that may affect load operation. It also introduces another single point of failure. It was historically used with both step by step and crossbar telephone switching offices. A common alternative to the CEMF cell is to remove one battery cell from the string and lower the rectifier output voltage to reduce the operating voltage of the system; for example: 23 cell system with VRLA batteries 23 x 2.25 V per cell = 51.75V.
1.8.2
Connection
The CEMF cell is connected in series with the load. The supervisory panel controls the CEMF cell.
1.8.3
Operation
The supervisory panel continuously monitors system voltage. There are two scenarios for CEMF use: 1.
CEMF cell normally IN to reduce load voltage
in the float and equalize mode. The normal system float voltage is above the IN setting of the CEMF cell the CEMF contactor is opened so that current flow is through the CEMF diodes and the load voltage is reduced. When a power failure occurs
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and the voltage drops the contactor is closed to increase the voltage at the load to ensure maximum back up time. When power is restored the contactor will open when the voltage returns to normal diverting current through the diodes and reducing the load voltage. 2.
CEMF cell normally OUT to reduce load
voltage in the equalize mode only. In this system the IN setting of the CEMF is set higher than the float voltage and the contactor normally bypasses the diodes. When equalize mode is selected the voltage rises above the IN setting and the contactor is opened, current flows through the diodes and the voltage at the load is reduced. When the rectifiers are returned to float mode the voltage drops below the out setting and the diodes are again bypassed by the contactor and the load voltage returned to normal.
1.8.4
Sizing
Voltage drop required.
Current required by load.
1.8.5
Features
Monitoring of cell status.
Alarm on failure of cell. 1.8.6
Argus solutions
Cells and contactors in various sizes are available.
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1.9
Battery Temperature Compensation

1.9.1 Background
Battery performance and life expectancy is directly related to the battery ambient temperature. The optimum temperature for battery operation is 25 deg. C (77 deg. F). Above this temperature, battery life is compromised and below this temperature battery performance is reduced. VRLA batteries have a negative characteristic called thermal runaway. This occurs when the internal temperature of the battery rises due to overcharge, high ambient temperature or internal fault. The rise in internal ambient temperature causes the battery to draw more float current which in turn elevates the internal battery temperature. This cycle continues until the battery fails. The failure of the battery may be quite dramatic.
1.9.2
Description
Temperature compensation is the process of automatically reducing the charge voltage applied to the battery at high temperature (to increase life and prevent thermal runaway) and increasing the voltage applied to the battery at low temperatures (to increase the battery capacity and to ensure correct charging of the battery).
1.9.3
Connection
Connection is as follows: 1. Traditional rectifiers with non-SM supervisory panels use a temperature compensator module (TCM) connected in series with the rectifier remote sense line input and the battery that requires temperature compensation. Smaller rectifier systems (i.e. RSM 48/7.5 and 48/10) have this feature built in; there are no additional sense/battery connections required.
2.
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3.
RSM/Pathfinder rectifiers with SM supervisory panels, require no additional sense/battery connections.
Temperature probes (1-4) are mounted directly to either the same battery negative termination post or to multiple negative posts to monitor multiple battery strings.
1.9.4
Operation
Operation is as follows: 1. Non-SM based systems, the TCM adjusts the output sense voltage to the rectifiers based on ambient temperature detected at the battery. The rectifiers will adjust their output voltage according to the sense voltage level detected at their remote sense input. (See Table H & I) Small systems adjust the rectifier output voltage based on ambient temperature detected at the battery. (See Table H & I). SM based systems, the SM will automatically adjust the rectifier float voltage based on the battery temperature detected. It will repeat this process at the interval programmed. The rectifier RS 485 communications link is used for this purpose.
2.
3.
At 25 deg. C (77 deg. F) no voltage compensation will occur. At temperatures below 25 deg. C, the rectifier will increase its output at a fixed rate(ex. -2.5 mV per cell per deg. C change from 25 deg C reference). At temperatures above 25 deg. C, the rectifier will decrease its output at a fixed rate(ex. -2.5 mV per cell per deg. C change from 25 deg C reference). To prevent excessive voltage from damaging the load, the battery or causing a high voltage alarm condition; the battery voltage maximum compensation may be limited (lower break point) at a fixed temperature (ex. 0 deg C).
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To prevent excessively low voltage from undercharging the battery or discharging the battery; the battery voltage maximum compensation may be limited (upper break point) at a fixed temperature (ex. 50 deg C). 1.9.5
Sizing
Temperature compensation slope
Match the compensation slope to the recommendations of the battery manufacturer. Default to conservative 2.5 or 3.5 mV if this information is unavailable.
Breakpoint
The selection of the breakpoint is critical. This determines the maximum and minimum voltage that will be applied to the battery and the load. Match the breakpoints to the recommendations of the battery manufacture. Carefully select the lower breakpoint as this determines the maximum voltage applied to the load.
Check load acceptable input voltage operating window; for example: a 4.5 mV slope with a -40 deg C breakpoint in a 48V system will result in 61 volts applied to the load in a low temperature condition.
1.9.6

Fail detection circuitry. Redundant temperature probes for increased safety. Automatic turn off if a fault is detected and an alarm extended.
1.9.7
Argus solutions
TCM
This external temperature compensation module can be either relay rack or surface mounted. It will operate with RST (6 max.) and the larger remote sense input equipped RSM rectifiers (6 shelves max.). It will also operate with non-Argus remote sense input equipped rectifiers.
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TCM Internal
This feature is available built into Argus non-sense line equipped rectifiers, including RSM 48/7.5, RSM 24/15 and RSM 48/10.
SM System Controllers
Control larger RSM rectifiers and pathfinder rectifiers through the communications link.
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TEMPERATURE* C F
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25*** 30 35 40 45 50 55 60 65
-40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149
BFV**=27.00V @25C(77F) 2.5mV 3.5mV (volts) (volts) 28.95 29.73 28.80 29.52 28.65 29.31 28.50 29.10 28.35 28.89 28.20 28.68 28.05 28.47 27.90 28.26 27.75 28.05 27.60 27.84 27.45 27.63 27.30 27.42 27.15 27.21 27 27 26.85 26.79 26.70 26.58 26.55 26.37 26.40 26.16 26.25 25.95 26.10 25.74 25.95 25.53 25.80 25.32
4.5mV (volts) 30.51 30.24 29.97 29.70 29.43 29.16 28.89 28.62 28.35 28.08 27.81 27.54 27.27 27 26.73 26.46 26.19 25.92 25.65 25.38 25.11 24.84
BFV**=27.25V @25C(77F) 2.5mV 3.5mV (volts) (volts) 29.20 29.98 29.05 29.77 28.90 29.56 28.75 29.35 28.60 29.14 28.45 28.93 28.30 28.72 28.15 28.51 28.00 28.30 28.60 28.09 27.70 27.88 27.55 27.67 27.40 27.46 27.25 27.25 27.10 27.04 26.95 26.83 26.80 26.62 26.65 26.41 26.50 26.20 26.35 25.99 26.20 25.78 26.05 25.57
4.5mV (volts) 30.76 30.49 30.22 29.95 29.68 29.41 29.14 28.87 28.60 28.33 28.06 27.79 27.52 27.25 26.98 26.71 26.44 26.17 25.90 25.63 25.36 25.09
BFV**=27.50V @25C(77F) 2.5mV 3.5mV (volts) (volts) 29.45 30.23 29.30 30.02 29.15 29.81 29.00 29.60 28.85 29.39 28.70 29.18 28.55 28.97 28.40 28.76 28.25 28.55 28.10 28.34 27.95 28.13 27.80 27.92 27.65 27.71 27.5 27.5 27.35 27.29 27.20 27.08 27.05 26.87 26.90 26.66 26.75 26.45 26.60 26.24 26.45 26.03 26.30 25.82
4.5mV (volts) 31.01 30.74 30.47 30.20 29.93 29.66 29.39 29.12 28.85 28.58 28.31 28.04 27.77 27.5 27.23 26.96 26.69 26.42 26.15 25.88 25.61 25.34
Table H
24 Volt Temperature Compensated Battery Float Voltage
These tables are provided as a guideline only. If battery temperature falls between values on the above scale, estimate the voltage setting based on the closest numerical values.
* posts.
Refers to ambient temperature at the battery terminal
** BFV refers to Battery Float Voltage Check battery manufacturer's recommended settings. *** Refers to Nominal Battery Temperature. This is the optimum temperature for battery operation. No compensation occurs at this temperature (use as a reference point).
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TEMPERATURE* C F 2.5mV (volts) 57.90 57.60 57.30 57.00 56.70 56.40 56.10 55.80 55.50 55.20 54.90 54.60 54.30 54 53.70 53.40 53.10 52.80 52.50 52.20 51.90 51.60
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25*** 30 35 40 45 50 55 60 65
-40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95 104 113 122 131 140 149
BFV**=54.00V @25C(77F) 3.5mV (volts) 59.46 59.04 58.62 58.20 57.78 57.36 56.94 56.52 56.10 55.68 55.26 54.84 54.42 54 53.58 53.16 52.74 52.32 51.90 51.48 51.06 50.64
4.5mV (volts) 61.02 60.48 59.94 59.40 58.86 58.32 57.78 57.24 56.70 56.16 55.62 55.08 54.54 54 53.46 52.92 52.38 51.84 51.30 50.76 50.22 49.68
2.5mV (volts) 58.40 58.10 57.80 57.50 57.20 56.90 56.60 56.30 56.00 55.70 55.40 55.10 54.80 54.5 54.20 53.90 53.60 53.30 53.00 52.70 52.40 52.10
BFV**=54.50V @25C(77F) 3.5mV (volts) 59.96 59.54 59.12 58.70 58.28 57.86 57.44 57.02 56.60 56.18 55.76 55.34 54.92 54.5 54.08 53.66 53.24 52.82 52.40 51.98 51.56 51.14
4.5mV (volts) 61.52 60.98 60.44 59.90 59.36 58.82 58.28 57.74 57.20 56.66 56.12 55.58 55.04 54.5 53.96 53.42 52.88 52.34 51.80 51.26 50.72 50.18
2.5mV (volts) 58.90 58.60 58.30 58.00 57.70 57.40 57.10 56.80 56.50 56.20 55.90 55.60 55.30 55 54.70 54.40 54.10 53.80 53.50 53.20 52.90 52.60
BFV**=55.00V @25C(77F) 3.5mV (volts) 60.46 60.04 59.62 59.20 58.78 58.36 57.94 57.52 57.10 56.68 56.26 55.84 55.42 55 54.58 54.16 53.74 53.32 52.90 52.48 52.06 51.64
4.5mV (volts) 62.02 61.48 60.94 60.40 59.86 59.32 58.78 58.24 57.70 57.16 56.62 56.08 55.54 55 54.46 53.92 53.38 52.84 52.30 51.76 51.22 50.68
Table I
48 Volt Temperature Compensated Battery Float Voltage
These tables are provided as a guideline only. If battery temperature falls between values on the above scale, estimate the voltage setting based on the closest numerical values.
* posts.
Refers to ambient temperature at the battery terminal
** BFV refers to Battery Float Voltage Check battery manufacturer's recommended settings. *** Refers to Nominal Battery Temperature. This is the optimum temperature for battery operation. No compensation occurs at this temperature (use as a reference point).
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1.10 DC - DC Converter System

1.10.1 Description
A DC-DC converter system takes a DC input voltage and converts it to the same or a different output voltage. The converter system is utilized for any of the following reasons: Provide different voltage levels; i.e. -48V to +24V conversion. Ground swapping; i.e. +24V to -24V. Galvanic or ground isolation; i.e. +24V to +24V, floating ground. Voltage regulation for equipment, with a tight input voltage operating window, operated from a battery system.
1.10.2
Connection
The DC-DC converter system is connected in series between the main DC power system and the load. A converter system consists of single or multiple parallel DC-DC converters and may incorporate many of the features found in the main DC power system including distribution, common ground bus and supervisory. DC-DC Converters should have dedicated fuse/circuit breaker positions on the main DC power system for protection and isolation.
If converters are located in the same relay rack as the main DC power system, direct connection to the busswork on the input is permissible.
1.10.3
Operation
Since the converter system does not have a battery connected to its output adjustment of the output voltage is less critical and LVDs, temp comp, etc. are not required. The output voltage of the converters is adjusted to match the requirements of the load and to ensure correct load sharing between parallel converters.
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1.10.4
Sizing
The converter system should be sized to adequately supply the load under all conditions. There should be substantial converter redundancy built in to the converter system to account for fuse clearing and circuit breaker tripping. If this redundancy is not built in, the converters may not be able to clear a fault and current limiting will take effect and the output of the converter system may be affected. Always use fast acting fuses in converter system distribution circuits and do not use excessively high fuse ratings. DC - DC converter systems can add substantial load to the main power system, allowances should be made for this when sizing the main system.
1.10.5

Standardization of unit for ease of maintenance. Modular vs. monolithic configuration. Modular converters allow
for easy replacement and expansion. Supervisory and distribution may be incorporated into a modular converter system.
High efficiency
Physical constraints in most new facilities demand compact designs. Lightweight converters combined with space saving designs help reduce installation and shipping costs.
Balanced load sharing should be achieved between converters.
Argus converters accomplish this with output slope regulation it is adjustable on CS units to allow load sharing with other types of converters. CSM units utilize a fixed slope set at 1%.
Current limiting should be provided, Argus units are factory set
at 105% of rated output, to provide protection in a overload condition.

High voltage shutdown to switch converter off in case of high
output voltage condition, preventing damage to the load.
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Soft-start to gradually bring the converter on line from zero load
to the load requirement, eliminating high inrush currents surges. The feeder breaker and feeder size requirements are decreased, reducing the installation costs of the converter.
Alarms provide indication of converter failure and should be of
fail safe design. Local indication plus remote contacts are required.
1.10.6
Argus solutions
The converters are available in various input and output configurations including 24V and 48V input; 12V, 24V and 48V output. With current ratings from 5 Amps to 40 Amps. Specialized converters with 130 V /100VA output are available for powering FITL (fiber in the loop) applications.
CS series monolithic
Traditional converter packaging - each individual converter is a stand-alone unit.
CSM series modular

Modular construction - three or four individual modules are housed in a hardwired cabinet. Each converter is easily removed for maintenance purposes.
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1.11 DC Power System Integration

1.11.1 Description
The DC power system integrates and connects all the components mentioned in previous sections.
1.11.2
Connection
Intersystem
In a typical power system there should be provisions for easy termination of intersystem cables. Buswork should be copper; cables should meet electrical code requirements and utilize quality compression lugs. Lock washers or Belleville washers should be used on electrical/mechanical connections to ensure integrity under different temperature conditions, (high/low load). All terminations should have provisions for connection of standard 2 hole lugs (typically 3/8 hole, 1 spacing). Argus power systems include all these features and utilize tinplated copper buswork to eliminate oxidization. The intersystem wiring and buswork determines the ultimate capacity of the power system. The vertical discharge riser bus is used to connect the distribution panels to the charge/discharge termination in a traditional power system.
Battery
Separate charge/discharge configuration - This method of
connecting the battery was utilized in the past to reduce the rectifier ripple voltage at the load. The vented battery was used as a filter. With the advent of low ripple rectifiers this method of battery termination is generally not required.
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Two busses are provided for both negative and positive termination. Rectifier negative output cables are terminated to one bus (- charge bus) and a cable is run to the neg. battery terminal from this bus. A second cable is connected from the negative battery terminal back to the second bus (- discharge bus) and the neg. load feed is also connected to this bus. This is repeated for the positive side also. This method has the added benefit of better load regulation and a slightly reduced voltage level seen at the load.
Common charge/discharge configuration - This is the
current standard method of terminating the battery cables. One bus is provided for the negative connections and one for the positive connections. Rectifier output cables, battery cables and the load feed are connected directly to these bus.
1.11.3
Sizing
Power systems should be oversized by a factor of 20-25 %. To calculate the power system size multiple the maximum anticipated load by a factor of 1.2 - 1.25. This over-sizing factor will ensure that the shunt is not overloaded and that adequate capacity is available in the buswork and cables to accommodate both the load and battery recharge current.
1.11.4

Access requirements front only or front and rear. Open relay rack or box bay. Size restrictions.
1.11.5
Argus solutions
Traditional power systems
Traditional power system packaging is in either open relay rack or box frame. Choices of 19 and 23 rack widths. Access is required from both the front and the rear. Up to 10 000 amps.
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Front access power system

With less space available in many of the new communications facilities front access power systems have become popular. Argus front access power systems require some rear access upon initial installation. After initial installation the power system may be relocated closer to the wall, with allowances for ventilation of course. All maintenance and circuit termination may be performed from the front. Up to 1200 amps.
Miscellaneous power systems

Variations on the traditional packaging techniques include mounting the equipment in portable cabinets on castors or utilizing wall mount brackets. There would be obvious limitations for either of these methods, but they do provide solutions for specific applications and ensure flexibility of Argus equipment.
Ultra compact power systems RSM 48/10 and 24/18

These fully self contained power systems (except for battery), may be configured in various packages combining up to five rectifiers modules, distribution, supervisory, temperature compensation and low voltage disconnect. Packages are 17 wide, 12 deep and 5.25 high. RSM 48/7.5 and 24/15 These fully self contained power systems (except for battery), may be configured in various packages combining two or three rectifiers modules, distribution, supervisory, temperature compensation and low voltage disconnect. Packages are 17 wide, 12 deep and of various heights from 3.5 to 7.
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US Series Combine battery, rectifier and supervisory in a single package to provide either 5 Amps at 48V or 8 Amps at 24V backup time is approx. 2 hr. with internal battery. Extra extended backup battery cabinets may be added.
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1.12 Inverters/UPS
1.12.1 Description
The inverter or Uninterruptable Power System (UPS) is utilized to supply AC voltage to loads such as computers in the Telecom environment. These systems are often connected to the DC power system. There are a various options for providing uninterruptable AC for your loads including: 1.
On-line Inverter - DC input, AC output.
Connected directly to DC main power system. Has a standby AC line available (optional). 2.
Off-line Inverter - AC input, AC output. Has a
standby DC line connection available. The DC standby line is connected to the DC power system. 3.
Double conversion UPS - Dedicated rectifier,
battery and inverter, Traditional concept. 4.

Line Interactive UPS - Ferroresonant
transformer with small battery charger, battery, inverter and intelligent control. Normal operation is through a Ferro circuit. Ferro provides filtering and some energy storage. Inverter is switched online when required by the control. Battery charger charges the batteries only Type
1
Advantages
-simple -reliable -utilize main DC battery -may be paralleled for redundancy -compact -reliable -efficient -utilize main DC power system battery -rugged -good energy storage -compact -easy to install -efficient
Disadvantages
-inefficient -heavy DC system loading and inrush
3 4
-inefficient -large, heavy -internal battery
Table J
Inverter & UPS comparison
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Both inverter system designs (type1 &2) will be discussed in this section since they connect to and affect the operation and design of a DC power system.
1.12.2
Connection
On-line inverter - The inverter is connected in series with the
DC power system and the connected loads. A connection is made to a standby AC source for redundancy.
Off-line inverter - The inverter is connected in series with the
AC source and the connected loads. A connection is made to the DC power system for redundancy.
1.12.3
Operation
On-line inverter - In normal operation the inverter draws
current from the DC power system and coverts this to AC to power the connected load. If the inverter fails or the DC supply is interrupted there inverter automatically transfers to a connected AC stand-by source.
Off-line inverter - In normal operation the connected load is
powered from the AC source through the inverter. Upon loss of the AC source the load is transferred to the inverter. There may be a ferroresonant circuit to provide energy storage while the load is transferred to the inverter.
1.12.4
Sizing
Inverters/UPS should be sized such that the continuous load (VA) does not exceed 75% of the inverter rating (VA). Inverters often supply computers that incorporate switch mode power supplies and other non-linear loads. If loads with high crest factors (i.e. > 2.5) are connected, the UPS rating may have to be de-rated. See the manufacturer for further information. Neutral current should also be monitored after UPS installation to ensure it is within the limits of the conductor. Unbalanced loads and low power factor often generate substantial neutral currents. It is possible for these currents to overload the neutral conductor since there is no protection for the neutral conductor.
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If the on-line inverter is utilized both the DC power system battery and the rectifiers will have to be oversized to supply the additional load imposed by the inverter. If the off-line inverter is utilized only the DC power system battery need be oversized since the inverter is normally operating from the AC source and will only draw current from the DC power system when there is a failure of the AC source. Inverters may also draw substantial inrush current on start-up; breaker/ fuse curve coordination may be required.
1.12.5

Many UPS systems combine the battery in the UPS. These batteries rarely see proper maintenance and tend to be forgotten. These batteries never achieve proper ventilation due to the oftencramped compartments that they occupy. Many UPS systems utilize high DC voltage battery systems. Each of these many small cells is the potential weak link in the chain. Powering your AC loads from an inverter connected to the high quality, wellmaintained DC main system battery, reduces many of these problems.
1.12.6
Argus solutions
We will provide assistance in helping you chooses the right AC solution and integrating it into the DC power system.
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CHAPTER
Power System Sizing and Ordering

2.1 Calculations
2.1.1 Step 1 System load analysis
To determine your DC power system requirements evaluate your loads and the backup period required. Review all system components and determine: (A) Loads that require voltage conversion. (B) Loads that require battery backup. Dont forget AC loads i.e. computers that require backup. Determine the individual load currents for the different load voltages required. The voltage with the highest load is generally chosen as the main system voltage. (C) Battery details: Main system Secondary system 1 Secondary system 2 AC Secondary system Redundancy Battery discharge time Battery recharge time Battery end Voltage______ Voltage______ Voltage______ Voltage______ N+______ hrs.______ hrs.______ Voltage______ current_______________ current_______________ current_______________ Watts______ P.F.______
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Warning : Check and record the polarity requirement of your connected loads.
Which polarity is connected to the common ground? This is vital information to ensure functionality of the DC system and load.
2.1.2
Step 2 Converters
Determine the quantity and type of converters to meet each of the secondary DC voltage requirements (if applicable). Add redundant converters as required. Determine the total load that the converters will have on the main DC system. Use formula (i). Refer to converter sizing section for extra details.
2.1.3
Step 3 Inverters
Determine the size and type of inverter to meet the secondary AC voltage requirements (if applicable). Determine the load that the inverter will have on the main DC system. Use formula (ii). Refer to inverter sizing section for extra details.
2.1.4
Step 4 Total system load

Determine the total system load using formula (iii).
2.1.5
Step 5 Total rectifier capacity

Determine total rectifier capacity. Total rectifier capacity includes capacity to supply the load and recharge the discharged battery in the specified recharge interval. Use formula (iv). Determine the quantity and type of rectifiers required to meet the requirements of the total rectifier capacity. Add redundant rectifiers as required.
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2.1.6
Step 6 Battery
Using battery manufactures advertised literature select a battery that will meet the list of criteria established. Discharge hours Total system load End voltage Temperature performance
Refer to the battery sizing section for more details.
2.1.7
Step 7 Power system

Select a power system capacity that is at least 1.2-1.25 times larger than the maximum anticipated total system load . This will ensure that you dont overload the ammeter shunt and also have sufficient capacity in the intersystem buswork to charge the batteries. Include provisions for growth (growth factor) if required. Size load and battery fuses and circuit breakers as per fuse/CB sizing section. Size the LVD as per the LVD sizing section.
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2.2
Formulas
2.2.1 Power system design formulas
Formula (i) Converter load (amps)
= secondary load (amps) x (output voltage/input voltage) converter efficiency
Formula (ii) Inverter load (amps)

= load (watts) inverter efficiency x battery float voltage
Formula (iii) Total system load (amps)

= main load (amps) + converter load (amps) + inverter load (amps)
Formula (iv) Total rectifier capacity (amps)

= Total system load (1)+(R.F (2).x Dischg. hrs) x total system load) Rechg. hrs
If an off-line inverter is connected to the DC power system its load must be subtracted from the total system load (1) when calculating total rectifier capacity. Recharge factor is the recharge efficiency factor for the battery string. Typically 1.1 -1.2 for lead acid batteries.
2.2.2
Other useful power formulas

Formula (v) Rectifier and converter efficiency
=P(out) = V(out) x I(out) or V(out) x I(out) P(in) P(in) watts V(in) x I (in) x P.F.(true)
P.F. is not required in converter efficiency calculations.
Formula (vi) Apparent power (VA)

= Power (watts) P.F.
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Formula (vii) Crest factor calculation

= Peak input current R.M.S. input current ideal = 1.414 (sine wave)
Formula (viii) Temperature compensated battery voltage calculation

= (25 - bat. temp.)(#cells)(slope) + nominal bat. float v @ 25 deg.C
All calculations use deg. C as base units not deg. F.
2.3
Power System Design Example

Main system Secondary system 1 AC Secondary system Redundancy Battery discharge time Battery recharge time Battery end Voltage-48V Voltage+24V Voltage120V N+ hrs hrs 1 8 24 current 125A current 30A 240Watts P.F.75
Voltage 1.75V/cell
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2.4 Ordering Information for Power Systems and Loose Items

When individual components are ordered special consideration should be given to the following items: Relay rack width and mounting hole spacing. Mounting offsets; i.e. flush or specific depth. Physical size of equipment including depth. Environmental constraints including temperature, humidity, rain protection, dust, dirt, etc.; i.e. dont order a fan-cooled unit to be used in an extremely dusty environment. Access for maintenance, future distribution connection and most importantly airflow. Each rectifier or converter generates heat and the minimum ventilation requirements must be met for reliable operation. Custom engineering drawings are available from Argus to assist in the installation of system components.
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CHAPTER
Site Engineering for DC Power

3.1 Site Layout and Loading
3.1.1 Description
The floor loading and the physical space required for the power system and the battery is often overlooked. With the weight of a typical common battery exceeding several tons special arrangements may have to be made to deal with this extra weight.
3.1.2
Floor plan layout

The power system must be mounted in a clean and dry environment. Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the rectifiers utilized in the power system and to allow easy access to the power system components. The battery should be located in a temperature-controlled environment also. The temperature should be regulated at approx. 25 C (77 F). Significantly lower temperatures reduce performance and higher temperatures decrease life expectancy. Provide adequate ventilation for the battery.
VRLA batteries, though not requiring the special ventilation requirements of a flooded battery, should not be installed in an airtight enclosure. Hydrogen gas may be vented in a fault condition; i.e. failed battery.
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For large systems with secondary distributed power consider: Cable flow and congestion. Minimizing cable lengths (cost). Cable rack routing.
3.1.3
Cable Rack layout

The cable racking should be carefully laid out to minimize cable run lengths and voltage drop to keep installation cost to a minimum.
3.1.4
Floor loading
Raised computer floor
Power plant and battery may have to be suspended above the computer floor mounted on top of threaded rods extending through the floor tile. An arrangement of I beams may have to be bolted to the concrete floor and extend above the computer floor to provide a strong platform.
Concrete floor
The thickness of the concrete should be evaluated to ensure that its weight carrying capabilities meet the requirements. Steel plates may have to be installed on top of the concrete to reduce the point loading problems common with the base configuration with most VRLA batteries. I beams attached to the building pillars may have to be installed.
Wood floor
Steel plates I beams under the floor and steel plates Concrete pads. Check the placement of the floor trusses so that the weight is evenly distributed over as many floor trusses as possible.
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3.1.5
Rack loading
For installations where multiple large conductors are installed consideration should be given to the weight that these cables will be placing on the cable rack and the structure supporting the cables. For example 750 MCM cable weighs approx. 2.8 lbs. per foot.
3.2 Grounding Network

3.2.1 Description
The grounding network, though part of the site installation, is an integral part of the power system and greatly affects the performance of the DC power system and the connected loads. The site grounding system provides a low impedance path to ground for noise, lightning (high frequency), transients and surges. It also provides a common ground reference point for all equipment.
3.2.2
Connection
The North American standard for the grounding network of a communications installation dictates that a single point ground (SPG) philosophy is used See Figure 16. The first stage of the grounding system is the ground grid that usually consists of multiple driven ground rods interconnected in a ring configuration encircling the building to be protected. Metallic objects such as towers or lightning arrestors are connected into this ground grid. The second stage of the grounding network is the master ground bus (MGB). The connection sequence at the MGB is important. Surge producers (AC ground bond, frame ground bonds, metallic ground bonds, etc.) are separated from protected equipment (power system battery return reference) by the surge arrestor (connection to the ground grid. The third stage of the grounding network is the battery return bus (BRB) on the power system. This is where all the load ground connections are made. Typical communication systems also use this as the reference point for logic ground reference.
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Frame grounding is also very important for both safety and also to ensure proper operation of the rectifier surge divertor metal oxide varistors (MOV). Industry standard is a cable connection from each relay rack to the MGB.
3.2.3
Sizing
The cable from the BRB to the MGB should be sized to provide sufficient ampacity to clear the largest fuse or breaker on the power system, excluding the battery protection fuse or circuit breaker. This is the minimum requirement, other factors including length of cable and special grounding requirements of the load should also be factored in. The intention is to provide the lowest impedance path to ground for high frequency (lightning) transients see Table K.
System Ampacity < 30A 30-100A 100-400A 400-800A > 800A
Typical ground reference conductor size #10 #6-2 0000 350 MCM 750 MCM
Table K
Typical Ground Reference Conductor Selection
The connection between power system frame and the MGB should be #6 AWG (16 mm) minimum.
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3.2.4

Insulated cable should be used for grounding equipped with two hole crimp type lugs and should not have any tight bends or kinks. The use of welding cable should be avoided.
SPD
Frame Ground
#6 AWG (16mm) -48VPower System
L1 L1
L2 L2 N N AC Distribution Cabinet
Load (+) ()
BRB
(+)
() G G MGB
Denotes Isolation
Grounding Rod
Grounding Network
Figure 16
Typical Site Grounding and Surge Protection
3.2.5
Typical Requirements for Grounding Network

As specified by the electrical utilities, neutral and safety ground 10 ohms is required. For adequate facility lightning protection one to five ohms is required. For protecting sensitive telecom facilities less than one ohm is desirable.
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3.3 Surge Protection Devices (SPDs)

3.3.1 Description
To protect both rectifiers and connected loads from surges entering the site via the AC source surge protection devices are commonly installed at telecommunications sites see figure 17.
Stage one - This first stage of surge protection provides
increased protection for the power system rectifiers and other equipment in locations where lightning is prevalent. This stage is critical in high lightning activity areas to prevent damage to the rectifiers.
Stage two - This optional level of protection provides increased
protection over a level one and three combination. It is also useful in locations where there are large surges and transients generated within the site.
Stage three - This stage provides basic protection for each
rectifier.
3.3.2
Connection
Stage one - This first stage of the surge protection for any site is
located at the AC service entrance, usually connected either to the AC distribution service panel or directly to the main building disconnect switch.
Stage two - This optional level of protection can be located at
the DC power system rack. This will provide increased levels of protection for the rectifiers.
Stage three - This stage is built into the rectifiers. Short lead
lengths are critical to keep let through voltage low.
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AC
Stage 1
Stage 2
Stage 3
DC
AC Service Entrance
Power Rack
Rectifier
DCPSH08A
Figure 17
Staging of Surge Protection Components
3.3.3
Operation
Various types of protection devices are available. The most common technology used is a either silicon avalanche diode (SAD), metal oxide varistor (MOV) or a combination of both. These devices function as non-linear resistors. At voltages below their operating voltage they operate in the high impedance mode. At voltages above the operating voltage they operate in the low impedance mode. They are connected in parallel with the AC source either line to line or line to ground. Surges cause these devices to conduct, effectively clamping the surge voltage.
3.3.4
Sizing
Stage one and two - Minimum size should meet the
requirements of the ANSI/IEEE C62.41 category B3/C1 standard. Higher capacities should be used in areas where frequent violent lightning strikes are common.
Stage three - Minimum size should meet the requirement of the
ANSI/IEE C62.41 category B3 standard.
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3.3.5

SAD based SPDs offer low let through voltage and fast response
time but have limited capacity and are more expensive. SADs also do not degrade while in service.
MOV based SPDs offer reasonable cost and high capacity but are
slower to respond and have a higher let through voltage (up to 1200 volts for a 240 volt rated SPD). MOVs degrade with each surge absorbed by the MOV. Combination SPDs offering both SAD and MOV protection. Low pass filtering capability. Local and remote failure indication. Use devices that have no main fuse or circuit breaker protection to keep let through voltage as low as possible (preferred installation). Consult other users in your area to determine what units have the best track record. Easy to replace modules.
3.3.6
Argus solutions
Technical assistance in choosing the protection device. Stage two panel available.
3.4 Wiring
The cable chosen for use in power plant applications not only has to meet the requirements of the electrical code for ventilated cable tray installations, ampacity and cable type. The cable size must also be carefully selected to ensure minimum voltage drop across its length when fully loaded. Keeping the voltage drop to a minimum insures maximum back-up time and best performance when the system is operating on battery. The information below can be used to calculate the cable size using typical voltage drop recommendations for Telecom installations. Refer to Table L for more information.
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Calculating Wire Size Requirements CMA= A x LF x K AVD
Definitions CMA = Cross section of wire in circular MIL area A = Ultimate drain in amps LF = Conductor loop feet AVD = Allowable voltage drop K = 11.1 constant factor for commercial (TW type) copper wire
3.4.1
AC Cabling
Individual circuit breakers and circuits are recommended for each rectifier. Use conduit or liquid type cable matching the cable size to the ampacity of the circuit.
3.4.2
Rectifier Sensing
Recommended cable for sense circuit if used is 16 Ga.
3.4.3
Battery
Battery cables should be sized for a .25 V loop drop from battery to the distribution panel at full load including anticipated growth. The cables should also meet ampacity requirements of the protection breaker in the circuit.
3.4.4
Alarms
Recommended cable size is 16-24 Ga.; from the power system supervisory panel to the site alarm monitor.
3.4.5
Distribution
Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a .5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker.
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3.4.6
BDFB (Battery Distribution Fuse Board) or BDCBB
(Battery Distribution Circuit Breaker Board)

Circuits feeding BDFBs should be sized for .25 V loop voltage drop at maximum anticipated load (80 % of the BDFB rating). Cables must also meet the ampacity requirements of the protection fuse or circuit breaker.
Use lock washers on all DC connections to the power system
AWG
mm
Area Cir. Mils.
Current Rating (for ventilated cable rack installation) Amps 5 10 15 20 30 45 65 85 115 130 150 175 200 230 285 310 335 380 420 460 475 490
18 16 14 12 10 8 6 4 2 1 0 00 000 0000 250 MCM 300 MCM 350 MCM 400 MCM 500 MCM 600 MCM 700 MCM 750 MCM 800 MCM 900 MCM 1000 MCM 1,250 MCM 1,500 MCM 1,750 MCM 2,000 MCM
.75 1.5 2.5 4 6 10 16 25 35 50 70 95 120 150 185 240 300 400
500
1,620 2,580 4,110 6,530 10,380 16,510 26,240 41,740 66,360 83,690 105,600 133,100 167,800 211,600 250,000 300,000 350,000 400,000 500,000 600,000 700,000 750,000 800,000 900,000 1,000,000 1,250,000 1,500,000 1,750,000 2,000,000
Table L
Wire Gauge Table and Ampacity Ratings
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Load
Secondary Distribution
0.50 Volts
Main Power System
Negative (-)
Figure 18
Typical Power System Voltage Drop Diagram @-48Vdc
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Positive (+)
Battery
0.25 Volts
0.25 Volts
1.0 Volts
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3.5
Engineering Drawings
Complete engineering drawings should be completed to provide the necessary detail for the installer to install the power system.
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Initial Installation
This is a generic installation guide intended to be applicable for various types of Argus power systems, including front access and traditional power systems. For battery installation refer to the manufacturers guidelines for more specific information.
4.1 Safety Precautions

Hazardous voltages are present at the input of the rectifier systems. The DC output from the rectifiers and the battery system though not dangerous in voltage has a high short circuit current capacity that may cause severe burns and electrical arcing. Before working with any live battery or power system the following precautions should be followed: Removal of all metallic jewelry i.e. watches, rings, eyeglasses, necklaces, etc. Safety glasses with side shields must be worn at all times. Metallic tools must be properly insulated. Standard hand tools may be insulated using the following method: Apply one layer of half lapped rubber splicing tape. Cover the rubber spicing tape with two half lapped layers of vinyl tape.
Extra care is required when working with flooded battery systems. Protective clothing, eye protection and standard battery safety kits (as detailed on the next page) should be provided for installation personnel to deal with accidental spillage of acid. Avoid short
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circuits and arcing, which could cause explosion of any gases vented from the batteries. Follow battery manufactures safety recommendations when working around battery systems.
Warning : Do not smoke or present an open flame when batteries (especially
vented batteries) are on charge. Batteries vent hydrogen gas when on charge which creates an explosion hazard.
Installer should follow all applicable local rules and regulations for electrical and battery installations; i.e. CSA, UL, CEC. Batteries are hazardous to the environment and should be disposed of safely at a recycling facility. Consult the battery manufacturer for recommended local authorized recyclers.
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4.2
Tools List
Electric drill with hammer action 1/2 capacity Battery lifting apparatus (as required) Various crimpers and dies, to match lugs used in installation 4 1/2 digit digital voltmeter equipped with test leads Load bank of sufficient capacity to load largest rectifier into current limit 0-60 V test supply 0.5 amp capacity, equipped with 1/8 diameter banana plug test leads (SD equipped systems only) Cable cutters Torque wrench 0-150 in/lbs. (for battery post connections and intercell connectors) 0-100 ft/lbs (for power system connections) Laptop computer with Argus Insight software e/w DB9F to DB9-F null modem cable (SM02 equipped systems only) Insulating canvas as required (2 x 2, 1 x 1, 3 x 3, etc.) Various insulated hand tools, including: Combination wrenches Ratchet and socket set Fine tipped slot screwdriver tweaker Various screwdrivers Electricians knife, etc. Battery safety spill kit (required for wet cells only), including: Protective clothing Face shields Gloves Baking soda Eye wash equipment
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4.3
Inspection
All Argus products are shipped in rugged, double walled boxes and suspended via solid polyurethane foam inserts to minimize shock that may occur during transportation. Packaging assemblies and methods are tested to National Safe Transit Association standards. Power systems are custom packaged in heavy-duty plywood crates with an equipment inspection window. Power systems are also wrapped with a plastic sheet that is impregnated with CORTEX a corrosion inhibitor. Batteries are shipped on individual pallets and are packaged as per the manufacturer's guidelines. Prior to unpacking the batteries, power system or components, note any damage to the shipping container. Unpack the equipment and inspect the exterior for damage. If any damage is observed contact the carrier immediately. Continue the inspection for any internal damage. In the unlikely event of internal damage please inform the carrier and contact Argus Technologies for advice on the impact of any damage.
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4.4
Power System Assembly/Mounting

The power system must be mounted in a clean and dry environment. Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the rectifiers utilized in the power system and to allow easy access to the power system components. Front access systems that are to be positioned close to a wall should be installed at least 12 inches away from the wall to meet seismic requirements. Secure the power system to the floor utilizing either heavy duty concrete anchors 1/2 X 2 1/2 or for wooden floors, heavy duty screw type lags 5/8 X 2 1/2 and appropriate flat washers. It is recommended that the Relay Rack be secured to the overhead cable tray utilizing the brackets mounted on either side of the top of the relay rack. Mechanical details necessary for overhead support are not provided by Argus.
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4.5
Battery Installation
4.5.1 Preparation/Mounting
The battery should be located in a temperature-controlled environment. The temperature should be regulated at approx. 25 C (77 F). Significantly lower temperatures reduce performance and higher temperatures decrease life expectancy. Provide adequate ventilation for the battery.
VRLA batteries, though not requiring the special ventilation requirements of a flooded battery, should not be installed in an airtight enclosure. Hydrogen gas may be vented in a fault condition (i.e. failed battery).
Before assembly, clean cells as per the battery manufacturer's recommendations. First neutralize any acid with a baking soda and water solution. Then wipe the cells with clean water.
4.5.2
Installation of Battery in Argus Power System

Locate batteries on shelf or in cabinet provided, with a minimum of 1/2 between cells or mono-blocs if possible. Ensure that the battery output cables will reach the (+) and (-) termination cells of the series string and that the batteries are orientated correctly for easy installation of the inter-cell connectors. Remove any no-oxide A grease from battery terminals, burnish terminal posts with a non-metallic brush, polishing pad or 3M type scotch pad, apply a light coating of no-oxide A anti-corrosion grease to the terminal posts. If lead plated intercell connectors are used they should also be burnished and no-oxide A applied to the contact surfaces. Install all intercell connectors. After assembly, cells should be numbered and as received readings taken, including specific gravity, cell voltage and temperature. One cell will be designated as the pilot cell; this is usually the cell with either the lowest specific gravity or voltage. Refer to manufactures literature for guidelines (refer to Table M) .
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4.5.3
Installation of External Battery

Assemble battery rack (if required) and the cells or mono-blocks as per the installation instructions supplied with the batteries, with a minimum of 1/2 between cells if possible. Remove any no-oxide A grease from battery terminals, burnish terminal posts with a non-metallic brush, polishing pad or 3M type scotch pad, apply a light coating of no-oxide A to the terminal posts. Intercell connector contact surfaces should also be burnished and no-oxide A applied. Install all intercell and inter-tier connectors. After assembly, cells should be numbered and as received readings taken, including specific gravity, cell voltage and temperature. One cell will be designated as the pilot cell; this is usually the cell with either the lowest specific gravity or voltage. Refer to manufacturer's literature for guidelines (see Table M).
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TABLE M
Typical VRLA Battery Maintenance Report

Company_______________________________________________ Date:__________________________________________________ Address________________________________________________ Battery Location and/or Number________________________________________________ No. of cell ____________Type ___________ Date New_________ Date installed___________________________________________ Float Voltage __________________________________________ Ambient Temp._________________________________________________
Cell # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Serial #
Voltage
Specific Gravity
Ohms
Mhos
Observations
Cell Readings
Remarks and Recommendation ____________________________________________________________________ ____________________________________________________________________ _____________________________________ Readings taken by ____________________________________________________________________ ____________________________________________________________________ ___________________________________
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4.6 Cabling
4.6.1 AC Cabling
Shut off power to the AC distribution panel, if possible, before proceeding.
Cable and connect from the AC distribution panel to each rectifier, follow the connection information detailed in the rectifier manual. With the modular rectifiers it is recommended to pre-cable all rectifier positions to allow for easy addition of future rectifiers. If connection is to a 3-phase AC service, care should be taken to balance the load across the phases.
4.6.2
Rectifier Sensing
There are various methods of providing rectifier output voltage sensing.
SD equipped system:
Built in internal sensing. No connections required. Remote sensing referenced to battery, with no temperature compensation. (Note: Power system supervisory panel should be equipped with the rectifier remote sensing option.) Cable and connect leads from sense termination on the supervisory panel to the battery termination details.
Final connection to battery live should not be made, insulate and leave unconnected.
If the battery temperature compensation feature is ordered in addition to remote sensing, the rectifier sense leads from the batteries will be terminated at the temperature compensation unit.
SM equipped systems:
With a SM system the rectifier will regulate its voltage to the charge voltage displayed on the SM02.
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To regulate at the battery the charge input connection to the SM02 should be removed and the charge input connection should be directly to the battery.
4.6.3
Battery
Battery cables should be sized for a .25 V drop from battery to the distribution panel at full load including anticipated growth. The cables should also meet ampacity requirements. Cables terminating directly on battery posts or connection details should be secured so that there is no stress on the battery posts. Lead plated lugs and lead plated or stainless steel hardware should be used on all terminations with vented batteries to reduce corrosion. Cable and connect cables from power system to battery termination details. Terminating points should be burnished and no-oxide A grease applied.
Final connection to battery live should not be made. Insulate and leave disconnected .
4.6.4
Alarms
All applicable alarms should be connected to the local alarmsending unit from the power system. The deluxe supervisory panels provide a central point for all external alarm lead connections. The more basic panels provide for some alarm terminations such as low/high voltage but alarms such as rectifier or converter fail may have to be connected directly to the rectifier or converter. The type of alarm input required by the alarm sending unit determines how the alarm contacts are configured and wired; i.e. form A,B or C wired for ground sending, battery sending, loop closure, loop open, etc. Some supervisory panels require jumpers to be moved to configure the alarm contacts as form A or B.
4.6.5
Grounding
The isolated power system battery return bus (BRB) should be connected to the building master ground bus (MGB) or floor ground bus (FGB) in a larger building. This acts as a system reference and as a low impedance path to ground for surges, transients, noise, etc.
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The MGB or FGB should have a direct low impedance path to the building grounding system; i.e. the water main. The cable from the power system to the MGB or FGB should be sized to provide sufficient ampacity to clear the largest fuse or breaker on the power system, excluding the battery protection fuse or circuit breaker; this is the minimum requirement. Other factors including length of cable and special grounding requirements of the load should also be factored in. The insulated cable should be equipped with two-hole crimp type lugs and should not have any tight bends or kinks. The power system frame must also be connected to the MGB or FGB. This is done for personnel safety and to meet many telcogrounding requirements. Cable should be #6 AWG (16mm).
4.6.6
Distribution
Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a .5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker.
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4.7 Power Up Procedure

4.7.1 SD Based Power Systems
1. Ensure all input and output circuit breakers including rectifiers, converters, inverters, battery and distribution are in the off position. Remove all fuses including distribution, battery, rectifier sense and supervisory control panel fuses. Remove all modular rectifiers and converters. Double check polarity and make the final battery lead connection at the battery string. Check polarity at battery fuse/breaker before closing battery circuit breaker. Install battery fuse or close breaker. Check polarity at rectifier output termination, supervisory input, converter input and inverter input. Install rectifiers, converters, control fuses, etc. Apply AC feed to rectifiers. Verify AC levels at rectifiers if applicable. Turn on all power system components one at a time, beginning with the rectifiers. Follow the procedures outlined in the manuals supplied with the equipment.
2.
3.
4.
5. 6.
7.
4.7.2
SM Based Power Systems

1. Ensure all input and output circuit breakers including rectifiers, converters, inverters, battery and distribution are in the off position. Remove all fuses including distribution, battery, rectifier sense and supervisory control panel fuses. Remove all modular rectifiers and converters.
2.
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3.
Double check polarity and make the final battery lead connection at the battery string. Check polarity at battery fuse/breaker before closing battery circuit breaker. Install battery fuse or close breaker. Check polarity at rectifier output termination, supervisory input, converter input and inverter input. Install rectifiers, converters, control fuses etc. Apply AC feed to rectifiers. Verify AC levels at rectifiers if applicable. Turn on all power system components one at a time, beginning with the rectifiers. Follow the procedures outlined in the manuals supplied with the equipment. Perform an inventory update. Check the listing of rectifier serial numbers in the SM to ensure that the SM is communicating correctly with all the rectifiers. Check and adjust as necessary all the system and rectifier operating parameters. Download the rectifier settings to the rectifiers using the group download and save settings command in the rectifier menu.
4.
5. 6.
7.
8.
9.
10. Save the settings in the SM by exiting out of the menu and pressing F1. 11. Verify operation of the low voltage disconnects and alarm relays.
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4.8
Battery Initial Charge and Discharge Test

After installation of batteries it is usually necessary to initial charge the batteries to ensure proper operation and to eliminate plate sulfation. Follow guidelines supplied with the battery and record initial charge readings; i.e. specific gravity, cell voltage, charge current and temperature.
Battery warranty may be void if batteries are not initial charged following the manufacture's guidelines and proper records are kept.
Some VRLA batteries do not require initial charging if placed on charge within 3-6 months of manufacture, check with the manufacturer. After the equalization period battery voltage should be reduced to the recommended float level. Once the batteries have been initial charged it is suggested to perform a short duration-high rate discharge test on the batteries to verify the connections on the batteries and also to verify that there are no open or failed cells. Cell voltages should be monitored during this process. Discharge for 15 minutes at the C/8 rate. Record cell voltages every 5 minutes. Check for overheating connections.
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4.9
Documentation
Complete all necessary documentation; i.e. battery reports (Table M), DC wiring lists (refer to inserted drawings at rear of manual), AC distribution tables (Table N), floor plans, etc. Tag wires, fill out identification strips, and identify circuit breakers.
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Table N
AC Distribution Table
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Power System Commissioning

Please refer to Appendix B for the detailed procedure. All Argus power system components undergo thorough factory testing and all levels/alarms are set to factory default values, unless custom levels are specified. Good installation practice is to check the operation of all features and alarms and to set the power system levels as per the specific requirements of your system. The manuals supplied with the equipment detail the method to test and calibrate all system components.
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Retrofit Installation
This is a retrofit installation guide intended to be applicable for installation of power system components in live standard Argus power systems.
6.1
Precautions
When working on live power systems there are two very important criteria to be considered. 1.
Personnel safety - Follow guidelines in initial
installation section. 2.
System integrity - No interruption of DC
power can be tolerated during work on a power system. Every power system upgrade, addition, maintenance procedure can be completed while working live on a DC power system, without interrupting the load if the proper steps and precautions are followed.
It is highly recommended that only personnel with DC power experience and training perform operations on a live power system, including the operations detailed in this guide. Consult the factory before beginning any operation that you are unsure of.
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6.2
Tools List
Tool list as detailed in initial power system installation, plus the following: Bridging cables as required. Clamp-on ammeter. Ungrounded electric drill (as required).
6.3
Distribution Circuit Addition

1. Decide on cable size and where the conductors are to be terminated. Run cables in place, insulate at both ends. Temporarily wrap all live buswork on the power system with insulating canvas while work is being performed on the power system, use tape or tyraps to secure the canvas. Crimp lugs on cables, connect and secure cables at the power system and then at the load. Remove canvases. Fuse up circuit or close circuit breaker and test circuit. Tag wires with identification tags and identify fuse/circuit breaker positions as required.
2. 3.
4.
5. 6.
7.
6.4 Common Ground Bus Addition

1. Decide where the ground bus will be mounted (ground bus should be located in top of the relay rack as close as possible to initial power system). Protect equipment in relay rack with insulating canvas before proceeding. Secure ground bus to the top of relay rack and ensure that ground bus is fully isolated from the frame.
2.
3.
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4.
Decide where the ground bus will be connected to at the power distribution system. The new ground bus should be connected to the initial power system ground bus with a cable of sufficient capacity to carry the full anticipated load to be connected to the new ground bus. Temporarily wrap all live busswork on the power system with insulating canvas while work is being performed on the power system, use tape or tiewraps to secure the canvas. Crimp lugs on cables and connect at both ends. Remove canvas.
5.
6. 7.
6.5
Distribution Panel Addition

When adding new fuse panels and loads, care should be taken not to exceed the maximum current rating of the power system. Load current should not exceed 80% of shunt rating for continuous operation.
6.5.1
Pre-provisioned
1. Temporarily wrap all live buswork on the power system with insulating canvas while work is being performed on the power system, use tape or tiewraps to secure the canvas. Clean buswork to remove any oxidation of the copper buswork, with 3M scotch pads. Tin plated buswork does not generally require cleaning before using. Bolt new panel in place and connect to vertical distribution riser bus. Connect fuse fail alarm card into power system. Install protective cover on the rear of the fuse panel if required.
2.
3.
4. 5.
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6.
Remove insulating canvases.
6.5.2
Non-Pre-provisioned
Procedure is the same as for the pre-provisioned fuse panel addition except the following extra steps will have to be taken to connect the new fuse panel into the power system. Insulating canvases should be used to prevent short circuits between live buswork and chassis/load ground. If there is room to add fuse/circuit breaker below existing panels the vertical distribution riser bus may be replaced with a longer bus that will extend down to the new fuse/circuit breaker panel as follows: 1. Using bridging cable(s) (sufficiently sized to carry the load on the existing fuse/circuit breaker panel, check load with clamp on ammeter), bypass the vertical riser and connect directly from the power system charge battery (live) bus to the fuse panel distribution bus. Disassemble the vertical riser to fuse panel distribution bus connection and either replace riser with longer bus or extend riser with additional bus section to the new fuse/circuit breaker. panel. Clean buswork as required. Tighten connections and remove bridging cable(s). Install protective cover to cover the rear of the fuse panel (if ordered).
2.
3. 4.
If there is no room below existing fuse/circuit breaker panels, the new fuse panel will have to be cable connected to the existing power system as follows: 1. 2. Locate fuse/circuit breaker panel in position. Run appropriately sized cable (sized to carry max. anticipated load on fuse panel) in place. Connect cable to new fuse/circuit breaker panel termination buswork.
3.
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4.
Decide where connection will be made on vertical distribution riser on the power system. Mark hole spacing for cable lug on bus and drill hole with isolated drill (use canvas, plywood, etc. to protect equipment and to prevent short circuits). Bolt cable in place. Remove canvases, wood, etc.
5.
6. 7.
6.6 Rectifier Addition

1. Follow initial installation guide and manual for connection information. Utilize TECK 90 type cable for rectifier AC connections, this cable is equipped with a vinyl sheath that prevents short circuits when installations are being performed on live power systems. Utilize insulating canvas to prevent short circuits between battery and ground terminations.
2.
3.
6.7 Shunt Replacement

1. Shunts may be upgraded in power systems, up to the maximum rating of the buswork, intersystem cabling and contactor rating. Use bridging cables to maintain circuit continuity while the shunt is being replaced. Utilize insulating canvas to prevent short circuits.
2.
3.
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Maintenance and Field Repair

7.1.1 Annual Maintenance
Test and calibration of supervisory, and other misc. control circuits. Verify the operation of all alarm relays. Periodic removal of dust with compressed air is recommended, interval determined by environment. Check and record power system load and verify that system capacity meets the load requirements. Check and re-torque nuts and bolts securing cable lugs to buswork. Check and re-torque mechanical lug set screws (if applicable). Note: Caution should be used when performing field repair on power system supervisory components. If there is a low voltage disconnect in the power system precautions must be taken to ensure that the contactor is not accidentally tripped.
7.1.2
Supervisory Circuit Board Replacement

If the power system is equipped with a low voltage disconnect contactor, provisions should be made to bridge across the contactor to maintain power system integrity when the supervisory PCB (printed circuit board) or panel is replaced, follow procedure below:
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1.
Assemble bridging cable; size cable to carry the full load on the contactor and check with a clamp on ammeter. Temporarily insulate adjacent grounded metal work while installing bridging cable across the contactor. Install bridging cable across LVD contactor, effectively bypassing the contactor. If the power system is equipped with high voltage shutdown or remote sensing for the rectifiers, remove these leads at the rectifiers. The rectifiers will automatically revert to internal sensing. This will prevent problems occurring when the supervisory circuit board is being replaced. Identify wires terminating on the supervisory panel and tag wires to ensure wires are reinstalled in the correct position. Remove fuses in supervisory panel, disconnect and insulate leads.
2.
3.
4.
5.
6.
Use extreme care some leads will be live.
7.
Remove supervisory panel or PCB and install replacement board in position. Remove fuses in new PC board and reconnect leads in reverse order. Install fuses. Check all PC board functions and set levels (refer to manual for more detailed information).
8. 9.
10. Reconnect high voltage shutdown and remote sensing leads at rectifiers as required. 11. Remove temporary bridging cable across the low voltage disconnect contactor and remove insulating canvas.
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7.2
RST Rectifiers
Visually inspect the rectifier inside and out. Remove dust using compressed air. Replace fuses(s) F1 (and F2). Replace varistor(s) VR1 (VR2 & VR3) if in high lightning/surge activity area (located across input circuit breaker). Check meter calibration. Check and adjust levels; float voltage/equalize voltage at battery, load sharing, etc.
7.2.2
Five Year Maintenance

Replace varistor(s) VR1 (VR2 & VR3) if in low to moderate lightning surge area.
7.2.3
Ten Year Maintenance

Replace large input (electrolytic) surge capacitors (C11 & C12 for 48/50) and damper capacitor (C12 for 48/50). Consider sending unit to factory for full maintenance tune-up complete with 100 % unit performance testing.
7.2.4
Rectifier Replacement
1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Disconnect live lead from rectifier at the power system charge bus. Verify leads are dead at rectifier. Tag leads and remove input, output, alarm and control leads from rectifier and insulate. Remove rectifiers and install replacement rectifier in the same position.
2.
3. 4.
5.
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Reconnect all cables and make the live connection at the battery charge bus last. Power up and test rectifier as per the procedure outlined in the manual.
7.
7.2.5
Rectifier Front Panel Replacement

Many control, alarm, display problems may easily be solved by replacing the front control panel instead of sending the entire rectifier for repair. Replacement is as follows: 1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Open front panel, tag leads connected to front panel PC board, insulate and remove. Disconnect ribbon cable. Compress PC board retaining clips and remove PC board. Install new PC board, reconnect wires and ribbon cable. Power up and fully test rectifier as per the procedures detailed in the manual.
2.
3.
4.
5.
7.2.6
Rectifier MOV Replacement

1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Refer to RSM rectifier section for identifying and testing of MOV. Open front panel, disconnect and remove MOV from load side of the input circuit breaker. Install new MOV and close front panel. Power up and fully test rectifier as per the procedures detailed in the manual.
2.
3. 4.
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7.3 RSM Rectifiers

Visually inspect the rectifier inside and out. Remove dust using compressed air. Replace input varistors if in high lightning/surge activity area. Check meter calibration. Check and adjust levels.
7.3.2

Replace input varistors if in low to moderate lightning surge area (located across input circuit breaker, requires removal of front panel).
7.3.3

Consider sending unit to factory for full maintenance tune-up complete with 100 % unit performance testing.
7.3.4
1. 2. Open input/output breakers on rectifier. Loosen mounting screws and remove rectifier and install replacement rectifier in the same position, tighten mounting screws. Power up and test rectifier following the procedure outlined in the manual.
3.
7.3.5
Rectifier Addition
1. To add an additional rectifier either set the corresponding DIP slide switch (5KW & 7KW cabinets) or remove the module fail defeat plug (9KW & 12KW cabinets).
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2.
Verify that AC feed is in place for new rectifier position. Insert module, tighten mounting screws, power up and test following the procedures outlined in the manual.
3.
7.3.6
Fan Replacement
1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Loosen mounting screws and remove power module. With rectifier removed from the shelf, remove fan power leads and mounting screws. Install replacement fan and reconnect leads. Install power module, tighten screws, power up and test rectifier following the procedure outlined in the manual.
2.
3.
4. 5.
7.3.7
Rectifier MOV Check (RSM 48/50, 24/100, and 48/100)

1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Remove power module. Remove warranty void label and screws securing the front panel to the chassis. Identify MOVs; located usually on the load side of the input circuit breaker inside the rectifier cabinet (a small disc approximately the size of an U.S. 5 cent piece). Measure resistance of MOV. A short circuit or low resistance indicates a failed MOV. Replace if failed.
2. 3.
4.
5.
6.
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7.3.8
Rectifier MOV Replacement (RSM 48/50, 24/100, and 48/100)

1. Open AC input breaker at distribution panel. Open input/output breakers on rectifier. Remove power module. Remove warranty void label and screws securing the front panel to the chassis.
2. 3.
Warning : Removal of the warranty void label will void the warranty.
4.
Disconnect and remove MOV from load side of the input circuit breaker. Install new MOV and reinstall front panel. Install power module, tighten mounting screws, power up and fully test rectifier as per the procedures detailed in the manual.
5. 6.
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7.4 Pathfinder 24-3kW, 48-3kW, and 48-10kW Rectifiers

Visually inspect the rectifier inside and out. Remove dust using compressed air. Replace input varistors if in high lightning/surge activity area. Check meter calibration. Check and adjust levels.
7.4.2

Replace input varistors if in low to moderate lightning surge.
7.4.3

7.4.4
1. 2. Turn rectifier off and loosen mounting screws. Remove rectifier and install replacement rectifier in the same position, tighten mounting screws. Set up and test rectifier following the procedure outlined in the manual. If the system is SM equipped, perform an inventory update and then download all the rectifier settings from the SM to the rectifiers.
3.
7.4.5
Rectifier Addition
1. Verify that AC feed is in place for new rectifier position. Insert module, power up and test following the procedures outlined in the manual. If the system is SM equipped, perform an inventory update and then download all the rectifier settings from the SM to the rectifiers.
2.
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7.4.6
Fan Replacement
1. 2. 3. Turn rectifier off and loosen mounting screws. Remove power module. With rectifier removed from the shelf, remove fan power leads and mounting screws. Install replacement fan and reconnect leads. Install power module, power up and test rectifier following the procedure outlined in the manual.
4. 5.
7.4.7
Rectifier MOV (check and replace)

1. Open AC input breaker at distribution panel. Turn rectifier off and loosen mounting screws. Remove power module. Remove rear rectifier cover by removing three screws on each side of the rectifier module. Identify MOVs; located beside the AC input fuses. MOVs are small discs approximately the size of an U.S. 5 cent piece.
2. 3.
4.
3kW Pathfinders have 3 MOVs and 10kW Pathfinders have 9 MOVs.
5.
Measure resistance of MOV. A short circuit or low resistance indicates a failed MOV. Remove the MOVs if failed using side cutters to clip the MOV leads, clean printed circuit board of all metallic particles that may contaminate the PCB when the MOV fails. Plug in the replacement MOV pack on the PCB. Reinstall rectifier following the procedure in reverse sequence.
6.
7. 8.
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7.5 CS and CSM Converters

Visually inspect unit inside and out. Remove dust using compressed air. Check meter calibration. Check and adjust levels.
7.5.2

7.5.3
CS Series Converter Replacement

1. Open DC input breaker/fuse at DC distribution panel. If DC is not fused then the input live lead must be removed from the associated bus. Open input/output breakers on the converter. Disconnect live output lead from converter at the converter distribution bus. Ensure all leads are dead at converter. Tag leads and remove input, output, alarm and control leads from converter and insulate. Remove converter and install replacement converter in the same position. Reconnect all cables and make the live connections at appropriate bus last. Power up and test converter following the procedure outlined in the manual.
2.
3. 4.
5.
6.
7.
7.5.4
CSM Series Converter Replacement

1. Turn down the output voltage on the converter, so that the converter is not carrying any load.
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2.
Remove converter and install replacement converter in the same position. Power up and test converter following the procedure outlined in the manual.
3.
7.5.5
CSM Converter Addition

1. To add an additional converter set the corresponding jumpers on the converter shelf. Insert converter module, power up and test following the procedures outlined in the manual.
2.
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7.6 Vented Batteries

This is a generic maintenance schedule. Recommended maintenance for battery strings varies with each manufacturer and each type of battery. Refer to manufacturer for specific instructions for the battery string in question.
7.6.1
Monthly Maintenance
Visual inspection
General appearance, cleanliness -
neutralize with baking soda and water solution as necessary and wash cells with clean water.
Electrolyte levels - top up with approved water
as required.
Cracks in cells or electrolyte leakage -
report immediately.
Corrosion at terminals or connectors -
neutralize and clean as required. If corrosion is serious and threatens the integrity of the connection, the assembly will have to be disconnected, cleaned, greased with no-oxide A and reassembled. Verify battery voltage - adjust as necessary. Check and record ambient temperature and condition of ventilation equipment. Check and record pilot cell voltage, specific gravity and electrolyte temperature.
7.6.2
Quarterly Maintenance
In addition to the monthly items also check and record the following: Specific gravity for each cell. Voltage of each cell. Total battery voltage. Temperature of one cell on each row of the rack.
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Check 10 % of intercell connection resistances chosen at random, if resistance is high, all connection assemblies should be checked. Disassemble and clean as required.
7.6.3
Annual Maintenance
In addition to the quarterly items also: Visually inspect each cell. Check and re-torque all intercell connector bolts. Check connection resistance cell to cell and cell to terminal. Check integrity of rack. Conductance or impedance measurements of each cell.
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7.7 Valve Regulated Lead Acid (VRLA) Batteries

This is a generic maintenance schedule. Recommended maintenance of battery strings varies with each manufacturer and each type of battery. Refer to manufacturer for specific instructions for the battery string in question.
7.7.1
Monthly Maintenance
Check and record pilot cell voltage. Check and record ambient temperature.
7.7.2
Quarterly or Annual Maintenance

In addition to the monthly items also check and record the following: Voltage of each cell. Total battery voltage. Temperature of one cell. Visual inspection: General appearance cleanliness. Cracks in cells or electrolyte leakage. Corrosion. Check and re-torque all intercell connector bolts. Check connection resistance cell to cell and cell to terminal. Conductance or impedance measurements of each cell.
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7.8 Battery Failure; Detection, Prevention & Corrective Action

7.8.1 Performance/Integrity Checks
Real-time monitoring of battery performance using the SM02 power system control to chart battery performance. Measurements of voltage, specific gravity, conductance and impedance are useful in charting a cell state of health over time and to alert personnel to a problem cell or battery. Periodic evaluation of a battery system performance should also be completed. There are various methods of evaluating battery condition. Performance can be measured automatically with the SM02 or recorded manually. 1. 2. Short duration high rate discharge. Full discharge to 80% of capacity.
The battery end of life is determined when the capacity has dropped to 80% of nominal.
7.8.2
Alternatives for detecting battery problems

A real time midpoint cell voltage monitor such as the Argus SD08 can be used to detect cell voltage imbalances in the battery string during float, charge or discharge conditions. This can provide an early warning of a failing cell. 1. 2. 3. Splits the battery string voltage in half. Compares the two halves. When the difference exceeds a preset value an alarm is extended.
7.8.3
Corrective action
Report any serious problems to the manufacturer immediately.
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If any of the individual cell voltages fall out of range an equalizing charge will have to be applied. This may be applied by one of the following methods: On-line utilizing the power system rectifiers, to the voltage limits of the load. Alternatively the battery string may disconnected in a multiple string application, boost charged with an auxiliary charger and reconnected on line (see string/cell replacement section). On-line utilizing a single cell battery charger. The special single cell charger is connected across cell in question and the cell is boost charged while system is on-line.
7.8.4
String/Cell Replacement
1. Assemble temporary battery string if the power system is equipped with only one battery string. Match temporary battery string voltage to main power system voltage by either using an external charger to raise the voltage of the temporary string or by lowering the voltage on the power system to match the temporary string voltage (voltage should be within .5 volts). Connect temporary string on line. Disconnect battery string in question. Perform boost charging, cell replacement and/or maintenance on battery string. Match power system voltage to the voltage of the disconnected battery string. Connect battery string on line. Disconnect temporary string.
2.
3. 4. 5.
6.
7. 8.
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CHAPTER
Troubleshooting
To use the following troubleshooting guide, look for the specific symptom that you are experiencing. Then check the numbers in the left column to verify which power equipment it applies to, then check the solution in the right column. 1. 2. 3. 4. 5. 6. 7. 8. 9. RST rectifiers. RSM 48/100 rectifiers. RSM 48/50 and 24/100 rectifiers. RSM 48/30 and 24/50 rectifiers. RSM 48/10 rectifier systems. RSM 48/7.5 rectifier systems. SD 03 and 05 supervisory panels. SD 02 and 04 supervisory panels. SM 02 supervisory panel.
10. Temperature compensation panel. 11. Circuit breaker, fuse and distribution centers. 12. Battery back-up. 13. CS converters. 14. CSM converters. 15. Pathfinder 1.5, 3, 10 kW rectifiers. 16. SM 03 supervisory panel. See equipment manuals for additional details.
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Units 1-5, 15
Symptom Rectifier fail alarm indication.
Solution Check that the voltage on each rectifier is set to the same value. Check that there is a load on the system greater than 5% of the current capacity of a single rectifier in the system or that a battery is connected to the system. Perform a microprocessor reset, see rectifier manual.
2-4
Module not responding to commands. Alarm relay contacts not functional. Rectifiers not sharing current evenly > 10 % difference in current between modules.
3-4, 6
Check yellow alarm relay fuse located behind left module (3) or resistor style fuse behind SCI PCB (4). Check resistor style supervisory control fuses on backplane of rectifier cabinet (6). Set the slope on rectifier to the same value (0.5% preferred). Enable the forced sharing on each rectifier. Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off). Connect rectifier on line. Repeat with each rectifier in the system.
2-4
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Units 1, 5, 6 or a mixed model system.
Symptom Rectifiers/converters not sharing current evenly > 10 % difference in current between modules.
2-4,15 9,16.
Rectifiers not sharing current evenly > 10 % difference in current between modules. Systems. Rectifier fail and/or AC Mains fail alarm
1-6, 15.
2-4, 6, 15 1,13
Fan fail/speed error. Rectifier/converter control and/or alarm problem. No module fail alarm. Thermal shutdown/over temperature alarm.
Solution Systems not SM equipped Set the slope on rectifier/converter to the same value, 1% preferred (1,6,13) non-adjustable (5,14). Adjust the output voltage on each unit while monitoring the voltage at the batteries or load. Ensure that the battery or load voltage is correct and the load current is split evenly between the units. Repeat for the equalize voltage setting (1). Systems SM equipped Set the slope on rectifier to the same value (0.5% preferred). Enable the forced sharing on each rectifier. Adjust the float and equalize voltage on each rectifier to the same value off-line (output breaker off). Download the settings to the rectifiers. Check AC voltage level in the rectifier status display (2-4) or at rectifier input circuit breaker/termination (1,5,6,13,14). Check input feeder circuit breaker. Reset breaker as required. Check and replace rectifier input fuse (15) Check fan cable connection Replace fan assembly. Replace front panel control PCB, see maintenance and field repair section. Check module fail dip-switch (4), defeat plug (3) or jumpers (5,6,14). Check the cooling vents for obstruction or excessive dust build up. Clean as required. Reset unit. Turn off AC feeder circuit breaker. Turn on rectifier input circuit breaker (1-6). Turn on feeder breaker. If breaker trips again rectifier has been damaged, check and/or replace MOV in rectifier (1,2,3,6,15) or send for repair (1-6,15).
3, 4,5, 6,14 1-6, 13,14,1 5 1-6, 15
Input breaker/fuse trip/blow.
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Symptom OVP (over voltage protection) trip or HVSD (high voltage shutdown).
5,6,9,10, 16
OVP (over voltage protection) trip or HVSD (high voltage shutdown) at low temperature only.
1,2,3,4, 15 3,4,5,6, 15
6,7,8
5,6,7,8
AC on, no DC output after reset and LVA. New installation or rectifier addition rectifier not operational. Supervisory panel fail, LVD open or incorrect nonfunctional alarms. Supervisory panel fail, LVD open or incorrect nonfunctional alarms.
Solution Check that the OVP and float settings are correct. If module continues to trip off due to OVP, set OVP setting to the maximum setting and float voltage to the minimum setting i.e. manually adjust potentiometers (1,5,6) or adjust stored setting in the microprocessor with the input breaker off and a power source connected to the DC output (2,3,4). Turn rectifier on. Readjust settings to the correct value. Check that the temperature compensated float voltage does not exceed the OVP setting when maximum voltage boost is occurring i.e. at low temperatures. Check and adjust the OVP and/or float voltage settings as necessary, see battery temperature compensation section for more details. There should be at least 1 volt between the maximum float voltage and the OVP setting. Check start delay setting, rotary switch (1) or programmed setting (2,3,4). Wait for delay to elapse or reset delay to zero. Check that AC is actually connected and energized to module position.
Check power fuse for supervisory panel located on the front-GMT type (8), on the rear-GMT type (7) or on the backplane-resistor style(6).
Replace supervisory control PCB.
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Units 5,6,11
Symptom Load circuit breaker/fuse trip.
11
Circuit breaker alarm not functional.
5-9,12, 16
On power failure - no battery back up.
5-9,12, 16
On power failure - short battery back up.
Solution Check for fault condition. Reset circuit breaker or replace fuse. Check that load on circuit breaker does not exceed 75-80% of the fuse/c.b. rating using a clamp on ammeter. If load is within limits, monitor the situation and replace circuit breaker if there is a reoccurrence. If the load is exceeding limit upgrade the fuse/circuit breaker size and associated wiring if required. Check alarm signaling jumpers on rear of circuit breaker, ensuring continuity of alarm path. Check operation if possible by turning breaker off. Check that jumper setting on alarm PCB is correctly configured for voltage application. Check battery circuit for poor or missing connection. (12). Check battery for open cell (12). Check that the supervisory panel LVD control settings are correct. (5-9). Check battery circuit for poor or missing connection. (12). Check that battery is sized correctly for load and back-up time required (12). Check battery performance (12). Check that the supervisory panel LVD control settings are correct. (5-9).
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Units 15
Symptom Module fail & AC mains OK
15 15
15
Module fail & AC mains fail Module minor alarm (red LED flashing). Note: LED will flash when the rectifier is in current limit if the feature is enabled No display, no power up.
Solution Ensure that the rectifier is seated correctly and that the mounting screws are tight Verify rectifier settings and download (from SM02) Check AD and DC fuses Replace module Check AC feeder breaker and circuit Check AC input voltage Ensure that the rectifier is seated correctly and that the mounting screws are tight Verify rectifier settings and download (from SM02) Check and/or replace fan, connections, etc. Replace module If new rectifier module is installed in the early version of the pathfinder cabinets the module interlock jumper must be set correctly. This jumper is located below the DC output connectors on the module. It is the jumper on the left and it should be installed on the center and the left most pin if used in an older system (3kW only) Verify rectifier settings and download (from SM) to the rectifiers. Check cables Verify baud rate Enable remote access Verify that rectifier mounting screws are tight Calibrate analog channel Verify cable; must be null modem Verify communications speed If a baud rate change has been made the reset button must be depressed to activate the new communications speed. Enable remote access Reset SM02 Activate communications program from DOS to be sure that windows isnt taking control of the communications port.
9,16 9,16
Out of tolerance. Communications lost alarm
9,16 9
Measurement error RS 232 communications problems.
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Units 9
Symptom Modem communications problems.
Solution Same as above. Must use jumper configurable modem not plug and play Ensure that IRQ is set to 3, com port 4 Reset microprocessor. Depower SM controller and reapply power. Make sure rectifier mounting screws are tight. Check and/or replace RS 485 communications cable. Check that the RSM count is set to zero if using pathfinder type rectifiers. Set the count to the quantity of RSM type rectifiers in the system when using RSM type. Use left/right arrow keys in Normal operation mode to adjust the view angle. Depress visual alarm reset button (VAR) to clear. This message will appear on the SM02 if the rectifiers are equipped with local display/control and the keys in the rectifier have been depressed. Return to normal operation in the rectifier menu to clear this alarm. Ensure that remote access and remote adjust have been enables in all the rectifiers.
9 9
Function keys locked out. No rectifier ID aquistion.
9 9 9
Display hard to read Alarm messages on display with (clear). Rectifier Lockout message.
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Acronyms and Abbreviations

AC AGM AH alternating current absorbed glass mat (battery) ampere hour TCM THD UL UPF UPS VAR VRLA temperature compensator module total harmonic distortion Underwriters Laboratory unity power factor uninterruptable power supply visual alarm reset valve regulated lead acid (battery)
BDCBB battery distribution circuit breaker board BDFB BFV BRB CEC CEMF CMA CSA DC EPO FGB FITL HVA HVSD LCD LED LVA LVBD LVD LVLD MGB MOV NEC NSTA OVP PCB PWM SAD SNMP SPD SPG battery distribution fuse board battery float voltage battery return buss Canadian Electrical Code counter electro-motive force circular mil area Canadian Standards Association direct current emergency power off floor ground buss fiber in the loop high voltage alarm high voltage shutdown liquid crystal display light-emitting diode low voltage alarm low voltage battery disconnect low voltage disconnect low voltage load disconnect master ground buss metal oxide varistor National Electrical Code National Safe Transit Association over-voltage protection printed circuit board pulse-width modulation silicon avalanche diode simple network management protocol surge protection devices single point ground
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Power Plant Turn Up and Commissioning Report

1. Site Information Customer Name Site Address City Contact ______________________ ______________________ ______________________ Country______________________ ______________________ Phone _______________________
2. Pre-Turn Up Inspection 2.1. AC Panel/Protection Inspection 2.1.1. General AC Service ________V__PH__W Main Breaker ________A Panel rating __________A Surge Protection Model#___________ Type_________________ Rectifier feeder circuits _________A _______ Ga. or ________mm Circuit breakers labeled yes no Electrical connections ok yes no Measured AC Voltage ___________V 2.2. Power Plant Inspection 2.2.1. General Power Plant #_______________ Rectifiers labeled Converters labeled Distribution breakers labeled Serial numbers recorded 2.2.2. Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional) System bays bolted together Box bay shipping braces removed Verify busbar assembly
______V yes yes yes yes
Max________A no no n/a no no appendix _____
yes yes yes yes yes yes
no no no no no no
n/a n/a n/a n/a
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2.2.3. Electrical Rectifier output cables ____ Ga. Verify inter-bay cabling yes no Verify shunt lead installation yes no Verify comm's cable installation yes no Live buswork insulated adequately yes no Electrical connections ok yes no Grounding method Single Point Ground Frame ground each bay ____Ga. Green Power system battery return ground ____Ga. Green Battery return ground isolated yes no
Halo Black Black
2.3. BDFB (BDCCB) Inspection 2.3.1. BDFB ______________ 2.3.1.1. General BDFB Identification_____________________________________________ Power Plant #_________________ Source feed labeled yes no 2.3.1.2. Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional)
yes yes yes
no no no
2.3.1.3. Electrical Single feed ___________ MCM ___________A protection A+B ___________ MCM ___________A protection A,B,C+D ___________ MCM ___________A protection Frame ground each bay ____Ga. Green Black Live buswork insulated adequately yes no Electrical connections ok yes no
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2.4. Battery Inspection 2.4.1. Battery ________________________________________________ 2.4.1.1. General Battery Identification #________________________________________ Manufacturer______________________ Model____________________ Serial Number(s) _____________________ Visual inspection for cracks, leakage, etc ok As received battery voltage report attached yes no appendix _____ As received battery cond/imped. report attached yes no appendix _____ Anti-oxidation compound used yes no Cells labeled yes no Battery labeled yes no 2.4.1.2. Mechanical Seismic Zone 4 required System secure bottom (required) System secure top (optional) Battery assembled correctly Cable connections tight
yes yes yes yes yes
no no no no no
2.4.1.3. Electrical Battery cables __________________MCM/AWG Temperature probes installed yes no n/a Where installed?___________________________________________ 2.4.2. Battery Protection Manufacturer______________________ Model____________________ Serial Number _____________________ Max. Ampacity__________A Fuse/C.B. Rating __________A LVBD yes no EPO yes no 2.5. Torque Check Cable connections bolts (sample 1) Cable connections bolts (sample 2) Cable connections 3/8 bolts (sample 1) Cable connections 3/8 bolts (sample 2) Cable connections bolts (sample 1) Cable connections bolts (sample 2) Battery posts ________bolts (sample 1) Battery posts ________bolts (sample 2)
_____________ft/lbs torque (75 ft/lbs recd) _____________ft/lbs torque (75 ft/lbs recd) _____________ft/lbs torque (__ ft/lbs recd) _____________ft/lbs torque (__ ft/lbs recd) _____________ft/lbs torque (__ ft/lbs recd) _____________ft/lbs torque (__ ft/lbs recd) _____________in/lbs torque (__ft/lbs recd) _____________in/lbs torque (__ft/lbs recd)
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3. Turn Up procedure 3.1. Ensure all batteries are disconnected, rectifier modules are removed, fuses pulled and circuit breakers turned off. 3.2. Triple check the polarity of battery connections. 3.3. Install one rectifier. 3.4. Turn on the AC to the rectifier and allow it to start up. 3.5. Verify that the system starts up ok, controller turns on. 3.6. Check the battery polarity is correct and turn on the breakers, fuse or circuit breakers for the batteries. Note: If there is no means of disconnecting the battery then the rectifier output voltage should be reduced using the controller to match the rectifier voltage to the battery voltage to avoid sparks. 3.7. The single rectifier in the system will now begin charging the batteries, this is normal. Install the remaining rectifiers in the system. One at a time. Turning the AC on to each unit and verifying breaker position. 3.8. If the SM type of controllers are used a inventory update followed by a download of the system settings should be performed. 3.9. Install main fuse followed by the guard fuse for the BDFB (BDCCBs) if required. 4. Test 4.1. Power Plant 4.1.1. Verify Analog Measurements 4.1.2. Load test power plant 100A 4.1.3. Verify, adjust and download system settings 4.1.4. Verify output alarm relay function 4.1.5. Shunt multiplexer 4.2. Battery 4.2.1. Initial charge/report 4.2.2. Discharge test/report 4.3. Battery Disconnect 4.3.1. Verify LVLD Function 4.3.2. Verify EPO Function 4.3.3. Verify Alarm Reporting
complete complete complete complete complete
appendix____ n/a
complete complete
n/a appendix____ n/a appendix____
complete complete complete
n/a n/a n/a
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5. Notes: Note Action Details
CAR Corrective Action Required COM - Comment 6. Acceptance
REC Recommendation
______________________ Print Name ______________________ Company ______________________ Print Name
_______________________ ________________ Signature Date _______________________ Phone Number _______________________ ________________ Signature Date
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Power Plant Settings Report

Item Rectifiers Float voltage Equalize Voltage Force share enabled/disabled Slope Current limit Delay start High voltage shutdown or OVP High voltage alarm Low voltage alarm Security code Backlight time-out Temp display C or F Current Limit Alarm enabled/disabled Equalize time-out Remote access enabled/disabled Remote adjust enable/disabled Local access alarm enabled/disabled Default Check Reference/notes
DC-DC Converters Output voltage High voltage alarm Low voltage alarm High voltage shutdown or OVP Slope Current limit
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Item Supervisory High voltage alarm 1 High voltage alarm 2 Low voltage alarm 1 Low voltage alarm 2 Alarm hysterisis Discharge amps alarm Charge amps alarm AC Mains high AC Mains Low Rectifier minor trigger count Rectifier major trigger count User alarm 1 User alarm 2 User alarm 3 User alarm 4 User alarm 5 High voltage shutdown or OVP Low voltage disconnect 1 - in Low voltage disconnect 1 - out Low voltage disconnect 2 - in Low voltage disconnect 2 - out Low voltage disconnect 3 - in Low voltage disconnect 3 - out CEMF control - in CEMF control - out Auto-equalize duration Auto-equalize interval Temp comp enable/disable Temp comp slope Temp comp upper breakpoint Temp comp lower breakpoint Temp comp interval Temp comp sensor 1 enable Temp comp sensor 2 enable Temp comp sensor 3 enable Temp comp sensor 4 enable
Default
Check
Reference/notes
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Item Auto equalize enable Auto equalize duration Auto equalize interval Auto equalize high V threshold Auto equalize low V threshold Rectifier baud rate Terminal baud rate Remote access enable Dial back number 1 Dial back number 2 Dial back number 3 User access code Supervisor access code Alarm scroll rate Maximum RSM count SM02 Temperature scale
Default
Check
Reference/notes
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DC Power Systems Handbook

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DC Power Systems Handbook

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Table of Contents

The DC Power System

Power System Commissioning Retrofit Installation

Power System Sizing and Ordering

Maintenance and Field Repair

Site Engineering for DC Power

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The DC Power System

Most communication equipment, including PBXs, telephone switches,

1.1 DC Power Overview

+ 24V evolved from the mobile radio industry, where equipment

- 48V evolved from the telephony world where 48 volts was

Basic DC Power System Operation

Typical Telecom Equipment Voltage and Current Requirements

Typical AC voltage sources

Typical AC Commercial Voltage Sources

Single or Split Phase

Three Phase Delta

Three Phase Wye or Star

Operation (Float charge mode)

trickle charge current to the battery.

current to the load until the battery is completely discharged.

Features and selection criteria

for easy replacement and expansion.

Power in an Inductive Circuit

Power Factor Triangle

Three phase AC input - For higher power applications this

becomes more important to ensure even balancing of load on a three-phase AC source.

Compact and lightweight helps reduce installation,

maintenance and shipping costs.

Output Slope Voltage Regulation and Current Limit

Current Output P 48/10 kW e/w Power Limit

Power Limit (P 48-3kW) - Current Limit (RSM 48/50) Comparison

Soft-start gradually steps each rectifier on-line at power up. This

Model Pathfinder RSM 48/10 RSM

Voltage 24 VDC 48 VDC 24 VDC 48 VDC

12 VDC 24 VDC 48 VDC

50, 100 A 30, 50, 100 A 15, 30, 50, 100 A

Argus Technologies Solutions

Theory of Operation RSM 24/50, 24/100,48/30 and 48/50

60Hz 290VDC 250V 525V 136V

52V (48V Units) 0V

Input 185-265VAC 50/60Hz

RSM Block Diagram

Output Voltage Sense

Voltage Current V Out Reference Reference - Adjustments - Display - Monitoring

Parameter Nom. V Float V Equalize V End V Op. Win. V # cells

48 V System 48 52.8 55.2 42 42-55.2 24

Typical battery operating parameters

End voltage (the lowest voltage that the cell is

Cells that are tank formed ship at 100 % capacity.

Battery end of life considered as 80% of capacity (See: Figure 11).

Average Cell Performance Data *

4.6 4.8 6.4 8.0 9.6 11.2 12.8 14.4 16.0

11.1 12.9 17.2 21.5 25.8 30.1 34.4 38.7 43.0

18.8 23.7 31.6 39.5 47.4 55.3 63.2 71.1 79.0

26.6 33.3 44.4 55.5 66.6 77.7 88.8 99.9 111

44.0 49.0 65.3 81.7 98.0 114 131 147 163

49.9 58.5 78.0 97.5 117 137 156 176 195

59 73 97 122 146 171 195 219 244

75 98 131 164 197 229 262 295 328

87 120 160 199 239 279 319 359 399