EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply

System
User Manual

Version V1.1
Revision date January 14, 2009
BOM 31011973

Emerson Network Power provides customers with technical support. Users may contact the nearest
Emerson local sales office or service center.

Copyright © 2008 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China
Homepage: www.emersonnetworkpower.com.cn
E-mail: support@emersonnetwork.com.cn
Safety Precautions

To reduce the chance of accident, please read the safety precautions very carefully before operation. The
"Caution, Note, Warning, Danger" in this book and on the product do not represent all the safety points to be
observed, and are only supplement to various safety points. Therefore, the installation and operation personnel
must receive strict training and master the correct operations and all the safety points before operation.
When operating Emerson products, the operation personnel must observe the safety rules in the industry, the
general safety points and special safety instructions specified in this book.
If you purchase the outdoor cabinet without SPD, you should add a SPD at the AC input terminal to prevent risk
of over-voltage.

Electrical Safety

I. Hazardous voltage

Danger

Some components of the power supply system carry hazardous voltage in operation. Direct contact or indirect contact
through moist objects with these components will result in fatal injury.

Observe safety rules in the industry when installing the power supply system. The installation personnel must be
licensed to operate high voltage and AC power.
In operation, the installation personnel are not allowed to wear conductive objects, such as watches, bracelets,
bangles and rings.
When water or moisture is found on the cabinet, turn off the power immediately. In moist environment,
precautions must be taken to keep moisture out of the power supply system.
"Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during
installation.

Danger

High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance
with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high
voltage operations.

Danger

To avoid electric shock hazard for outdoor environment and outdoor equipments, the non-professionals are prohibited to
operate or maintain the outdoor power supply system.

II. Tools

Warning

In high voltage and AC operation, specialized tools must be used.

 III. Thunderstorm

Danger

Never operate on high voltage, AC, iron tower or mast in the thunderstorm.

In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be
well earthed in time to avoid damage by lightning strikes.
IV. ESD

Notice

The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale
ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from
damaging the sensitive components. The other end of the ESD wrist strap must be well earthed.

V. Short circuit

Danger

During operation, never short the positive and negative poles of the DC distribution unit of the power supply system or the
non-grounding pole and the earth. The power supply system is a constant-voltage DC power device; short circuit will result
in equipment burning and endanger human safety.

VI. Reverse connection

Warning

Never connect reversely live line and neutral line of the AC input cables, or else the system will be damaged.

Check the polarity of the cable and connection terminal when performing DC live operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Use insulated tools.
In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of
the human body and tool is reduced to a minimum.

Battery

Danger

Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery
connection method.

Warning

If customers prepare batteries themselves, the batteries installation and maintenance should meet relevant safety standards.
 Non-standard operation on the battery will cause danger. In operation, precautions should be taken to prevent
battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs,
thus causing equipment damage and short circuit of PCBs.
Before any operation on battery, pay attention to the following points:
1. Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.
2. Use specialized insulated tools.
3. Use eye protection device, and take preventive measures.
4. Wear rubber gloves and apron to guard against electrolyte overflow.
5. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the
battery upside down or slanted.

Connection And Testing Of The Outdoor Cabinet

Before installing subrack power supply in the cabinet, you should finish the connection and testing of the
subrack power supply according to the corresponding subrack power supply user manual and then testing the
outdoor cabinet.

Others

I. Sharp object

Warning

When moving equipment by hand, wear protective gloves to avoid injury by sharp object.

II. Power cable

Notice

Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.

III. Binding the signal lines

Notice

The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least
150mm.
 Contents

Chapter 1 Product Introduction .....................................................................................................................................1

1.1 Overview ........................................................................................................................................................1

1.2 Model Description ...........................................................................................................................................1
1.3 Composition And Configuration .......................................................................................................................1
1.4 Parameters.....................................................................................................................................................3
1.5 Heat Dissipation Theory ..................................................................................................................................3
1.6 Features.........................................................................................................................................................3
Chapter 2 Installation ....................................................................................................................................................4

2.1 Safety Regulations..........................................................................................................................................4

2.2 Preparation.....................................................................................................................................................4
2.3 Mechanical Installation....................................................................................................................................5
2.3.1 Installing The Outdoor Cabinet .............................................................................................................5
2.3.2 Opening And Closing Cabinet Door ......................................................................................................6
2.4 Electrical Installation .......................................................................................................................................7
2.4.1 Connecting Grounding Cables ..............................................................................................................7
2.4.2 Connecting Signal Cables ....................................................................................................................8
2.4.3 Connecting Fan Control Board Power Cables .......................................................................................9
2.4.4 Connecting Other Cables .....................................................................................................................9
2.4.5 Sealing The Entry Holes .......................................................................................................................9
2.5 Battery Installation ..........................................................................................................................................9
2.6 Installation Inspection ................................................................................................................................... 10
Chapter 3 Testing ....................................................................................................................................................... 11

3.1 Startup ......................................................................................................................................................... 11

3.2 Alarm Check And System Operation Status Check ........................................................................................ 11
3.3 Final Steps ................................................................................................................................................... 11

Chapter 4 Maintenance .............................................................................................................................................. 12

4.1 Routine Maintenance .................................................................................................................................... 12
4.2 Handling Alarms And Faults .......................................................................................................................... 13
4.3 Replacing Parts ............................................................................................................................................ 13
4.3.1 Replacing Fan Control Board.............................................................................................................. 13
4.3.2 Replacing Fan control extension Board............................................................................................... 14
4.3.3 Replacing Fans .................................................................................................................................. 14
Appendix 1 Spare Part List ......................................................................................................................................... 16

Appendix 2 Wiring Diagram ........................................................................................................................................ 17

Appendix 3 Schematic Diagram .................................................................................................................................. 20

 Chapter 1 Product Introduction 1

Chapter 1 Product Introduction

This chapter introduces the model description, composition & configuration, parameters, heat dissipation theory and
features of Aluminum Flexi EPC48150/1800-FA1 & EPC48300/3200-FA1 outdoor power supply system (outdoor
cabinet for short).

1.1 Overview
The outdoor cabinet is dedicated to providing protection and operation environment for outdoor power supply system
and user equipment. The cabinet can accommodate different Emerson subrack power supplies according to your
requirement so as to form power supply systems with different capacities.

1.2 Model Description

An EPC48150/1800-FA1 outdoor cabinet contains five 30A rectifiers and an EPC48300/3200-FA1 outdoor cabinet
contains five 50A rectifiers. Their model descriptions are given in Figure 1-1 and Figure 1-2.
EPC 48 150 / 1800 - FA 1
Version No.
Thermal control method: forced fan cooling
Power of the rectifier: 1800W
Max. output current: 150A
Output voltage: 48V
Emerson outdoor power cabinet
Figure 1-1 Model description of EPC48150/1800-FA1 outdoor cabinet

EPC 48 300 / 3200 - FA 1

Version No.
Thermal control method: forced fan cooling
Power of the rectifier: 3200W
Max. output current: 300A
Output voltage: 48V
Emerson outdoor power cabinet
Figure 1-2 Model description of EPC48300/3200-FA1outdoor cabinet

1.3 Composition And Configuration

Composition
The outdoor cabinet is composed of a fan-cooling unit, an equipment compartment and a battery compartment. The
fan-cooling unit consists of fan, fan control board and fan control extension board. The equipment compartment
consists of subrack power supply and reserved space for user equipment. The power distribution unit is located in the
subrack power supply and consists of AC sockets and AC power distribution MCBs. The battery compartment is used
to accommodate battery strings.
The outdoor cabinet has four types of dimensions, as given in Table 1-1. You can select one according to your actual
requirement.
Table 1-1 Dimensions of the outdoor cabinet
Type Dimensions (W×D×H) (mm) Shell Battery layer
1 650×650×1000 Partially double skin 1
2 700×650×1600 Partially double skin 2
3 700×650×1600 Fully double skin 2
4 650×650×2000 Partially double skin 3

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2 Chapter 1 Product Introduction

The four types of outdoor cabinets have the same structure, except for dimensions, shell and battery layer (see Table
1-1). Take the 1600mm (height) partially double skin outdoor cabinet for example, the structure is shown in Figure
1-3.

Fan-cooling unit

Subrack power supply

Equipment
compartment

Reserved space

Battery bracket

Battery
compartment

Figure 1-3 Structure of the outdoor cabinet

Configuration
The configuration list of the outdoor cabinet is given in Table 1-2.
Table 1-2 Configuration list
Component Configuration
Fan 2 ~ 4, optional
Fan control board 1 piece
Fan-cooling
0 ~ 1, optional. Select this board when you need fan fault alarm. While you select 120A
unit Fan control extension
subrack power supply, you need not select this board (because the 120A subrack power
board
supply has fan alarm function)
One 10A/1P MCB or one
One 10A AC socket, single-phase, four standards optional
AC power AC socket 10A/2P leakage MCB is
(Chinese, British, American and German standards)
distribution mandatory
unit AC power distribution
One 10A/1P MCB, optional
MCB
Reserved space and battery Sharing space. You can adjust space by removing or adjusting the position of the battery
compartment space bracket (see Figure 1-3)
Others Door status sensor: 1

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 Chapter 1 Product Introduction 3

1.4 Parameters
The parameters of the outdoor cabinet are given in Table 1-3.
Table 1-3 Parameters of the outdoor cabinet
Param eter category Parameter Description
Operating temperature -10°C ~ +45°C
Storage temperature -45°C ~ +70°C
Environmental Relative humidity 5%RH ~ 100%RH
Altitude ≤ 2,000m (derating is necessary when above 2,000m)
Others No conductive dust or erosive gases. No risk of explosion
Reserved space Sharing space with the battery compartment, adjustable
Dimensions Space of each layer of the
Adjustable height: 240mm, 280mm, 320mm
battery compartment
Cabinet (height: 1000mm) 40kg
Mechanical Cabinet (height: 1600mm,
70kg
Weight partially double skin shell)
Cabinet (height: 1600mm,
75kg
fully double skin shell)
Cabinet (height: 2000mm) 80kg
Note: For param eters of AC input, DC output and subrack power supply, refer to the corresponding subrack power supply user
manual

1.5 Heat Dissipation Theory

The cold air is sucked in through the front door air filter at the lower part of the outdoor cabinet. It passes through the
battery compartment, user equipment and subrack power supply in turn. Finally, the resulting hot air is discharged by
the fans at the top of the outdoor cabinet. It is in this way that the equipment in the outdoor cabinet is cooled.

1.6 Features
l Material: The structural material of the outdoor cabinet is aluminium, making the cabinet lighter than iron cabinet
of the same dimensions.
l Variable subrack power supply: The outdoor cabinet can accommodate standard 19” and 23” subrack power
supply.
l Variable space: The reserved space and the battery compartment space are interchangeable. You can adjust
the space according to the actual requirements.
l Dimensions: Four types of dimensions. You can select one according to the field conditions, environmental
conditions and your requirements.
l Structure shape: partially double skin shell and fully double skin shell.
l Safety guideline: The equipment compartment satisfies IP*5 waterproof requirements and IP4* dustproof
requirements.
l Environment pollution level within the cabinet: 3.

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4 Chapter 2 Installation

Chapter 2 Installation

This chapter introduces installation and cable connection. Before the installation, read through the safety regulations,
and then follow the instructions in this chapter to carry out the installation and cable connection.

2.1 Safety Regulations

Certain components in this outdoor cabinet carry hazardous voltage and current. Always follow the instructions
below:
1. Only the adequately trained personnel with adequate knowledge of the outdoor cabinet shall carry out the
installation. The Safety Precautions listed before the contents of this manual and local safety rules in force shall be
adhered to during the installation.
2. All external circuits that are below -48V and connected to the outdoor cabinet must comply with the requirements of
SELV defined in IEC 60950. The voltage at the DC side exceeds 30V, posing electric shock hazard.
3. To avoid electric shock hazard, do not perform any operation or maintenance within the system under stormy or
humid weather conditions.
4. Make sure that the power (mains and battery) to the system is cut off before any operations can be carried out
within the outdoor cabinet.
5. The wiring of the power distribution cables should be arranged carefully so that the cables are kept away from the
maintenance personnel.

2.2 Preparation
Unpacking inspection
The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be done
by representatives of both the user and Emerson Network Power Co., Ltd.
To inspect the equipment, you should open the packing case, take out the packing list and check against the packing
list that the equipment is correct and complete. Make sure that the equipment is delivered intact.
Preparing tools
The installation tools are given in Table 2-1. The tools must be insulated and ESD-proof processed before they are
used.
Table 2-1 Installation tools
Tool Specification Tool Specification
Combination wrench (hatch, Wrench set (10#, 13#, 16#,
Cross screwdriver 100mm, 200mm
club) 18#, 21#)
Adjustable wrench 200mm Slotted screwdriver 100mm, 200mm
Electrician diagonal pliers 150mm Wire cutters Maximum 300mm2
Hydraulic-pressure compaction
Electrician sharp nose pliers 150mm Maximum 300mm2
pincher
Three and a half bit digital
Steel tape 5m Digital multimeter
display
Electric knife Normal type Impact electric drill With Φ14 impact aiguille
Gradienter Normal type Power socket With 5m cable
To prevent puncture and for
Blinkers To prevent splash Safety shoes
insulation
Fireproof mud Configured in the accessories Hammer
Box wrench 16mm

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 Chapter 2 Installation 5

2.3 Mechanical Installation

2.3.1 Installing The Outdoor Cabinet

The outdoor cabinet must be installed directly onto the cement floor. Follow the steps below to install it:
Step 1: Mark the specific installation position of the outdoor cabinet
It is recommended to determine the installation position in compliance with the clearance requirements given in Table
2-2.
Table 2-2 Installation clearances
Front Top Left Right Back
Clearances 750mm 700mm 100mm 100mm 100mm

Step 2: Install expansion pipes

By referring to Figure 2-1 and Figure 2-2, determine the exact central points of the installation holes on the floor, and
mark them with a pencil or oil pen. Use the electric drill (aiguille: Φ14) to dig holes (depth: 70mm) at the marked
points. Clean the drilled holes off dust. Put the expansion pipes into the installation holes.
447
80

642

Figure 2-1 Installation size of the cabinet base (height: 1600mm, unit: mm)

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6 Chapter 2 Installation

447
80

592
Figure 2-2 Installation size of the cabinet base (height: 1000mm and 2000mm, unit: mm)

Step 3: Fix the cabinet

Move the cabinet to the installation position. Make the installation holes on the base coincide with those dug on the
floor. Screw the M10 anchor bolt down into the expansion pipe in the floor.
After installation, the cabinet should stand firmly no matter how it is shaken.

2.3.2 Opening And Closing Cabinet Door

You need to open and close the cabinet door during the cabinet installation, operation and maintenance. Procedures
for opening and closing the cabinet door are as follows:
Step 1: Insert the key into the keyhole, and turn the key clockwise until the door handle pops out.
Step 2: Turn the handle counter-clockwise 90°, as shown in Figure 2-3. Pull the handle until the door opens.

90°

Figure 2-3 Turning the handle

Step 3: Adjust the door stay bar to the position shown in Figure 2-4 to prevent the door from closing automatically.
Door stay bar

Figure 2-4 Door stay bar

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 Chapter 2 Installation 7

Step 4: To close the door, restore the door stay bar to its original position and close the door. Finally, turn the handle
to its original position and press it down until a click is heard.

2.4 Electrical Installation

All the cables must be put through metal pipes for protection. The metal pipe should be connected to the PE bar
reliably. Plastic coated metal hoses are recommended.

& Note
1. Grounding cables and AC input cables enter the cabinet through the left side of the cabinet bottom.
2. Signal cables and load cables enter the cabinet through either side of the cabinet bottom.

2.4.1 Connecting Grounding Cables

The procedures of connecting grounding cables are as follows:

Step 1: Open the cabinet door, and you can see cable frames and PE bar on the left side of the cabinet and entry
holes on the cabinet bottom. Their positions are shown in Figure 2-5.

Cable frame

PE bar

Entry hole

Figure 2-5 Position of the cable frame, PE bar and entry hole

Step 2: Cut the cable bushing over the entry hole with an electrician knife to lead in cables.
Step 3: Lead the grounding cable into the cabinet through the entry hole on the cabinet bottom. Route the cable along
the cable frames.
Step 4: Connect one end of the grounding cable to the PE bar and solder the other end to the metal base outside of
the outdoor cabinet reliably.
Step 5: Fix the grounding cable to the cable frame with nylon ties.
If the outdoor cabinet is not configured with a subrack power supply, then a green yellow earth cable has been
connected to the PE bar in factory. When you purchase a subrack power supply separately, please connect the other
end of this earth cable to the earth terminal of the subrack power supply. For the position of the earth terminal of the
subrack power supply, please refer to the corresponding subrack power supply user manual.

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8 Chapter 2 Installation

2.4.2 Connecting Signal Cables

Dry contacts
The cabinet provides one signal output terminal block, which provides four pairs of dry contacts for the user, as
shown in Figure 2-6. The definitions of the dry contacts are given in Table 2-3.

Signal output
terminal block

Figure 2-6 Position of the signal output terminal block

Table 2-3 Dry contact definitions

Port No. Silk print Definition Remark
1, 2 Door alarm Door alarm Default value. Reconfigurable
3, 4 Over temperature alarm Over temperature alarm Default value. Reconfigurable
Default value. Reconfigurable (the function is
5, 6 Fan fault alarm Fan fault alarm enabled when the outdoor cabinet is configured
with a fan control extension board)
7, 8 Spare Spare Configurable

Connecting dry contacts

1. Internal connection
If the outdoor cabinet is configured with a subrack power supply, the internal connections of the four dry contacts
have been made in factory. If the outdoor cabinet is not configured with a subrack power supply, then except that the
other end of the over temperature alarm cable connected to ports 3 and 4 is left unconnected, other internal
connections have been made in factory. In the latter case, if you purchase a subrack power supply separately, you
need to connect the other end of this over temperature alarm cable to the over temperature alarm dry contact output
terminal of the subrack power supply. For the position of this terminal, please refer to the corresponding subrack
power supply user manual.
2. External connection
you need to connect the four pairs of dry contacts to the user’s signal input terminals.
When make connection, peel the signal cables and insert their ends into the corresponding terminals, then fasten the
connection by tightening the screws on the terminals.

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 Chapter 2 Installation 9

2.4.3 Connecting Fan Control Board Power Cables

& Note
1. If the outdoor cabinet is configured with a 120A subrack power supply, you can skip 2.4.3 Connecting Fan Control Board
Power Cables.
2. For the sake of safety, follow the labels on the cables to carry out the cable connection.

Step 1: By referring to the corresponding subrack power supply user manual, find out the priority 10A (or 16A) load
MCB in the subrack power supply.
Step 2: Unfasten the double-core power cable of the fan control board in the cabinet, and connect the black cable to
the priority load MCB (namely: -48V output MCB) in the subrack power supply and connect the brown cable to the 0V
busbar.
Step 3: If the 0V busbar is fixed with screws, you should press an OT terminal onto the -48V terminal cable before
connection.
Note: Follow the previous steps you can make a power input MCB for the fan control board.

2.4.4 Connecting Other Cables

Other cables include AC input cables and load cables. For their connection methods, see the corresponding subrack
power supply user manual.

2.4.5 Sealing The Entry Holes

After finishing the cable connections, seal the entry holes (see Figure 2-5) with fireproof mud.

2.5 Battery Installation

& Note
1. The batteries may carry dangerous current. Before connecting the battery cables, make sure all the battery input MCBs (their
positions are shown in the corresponding subrack power supply user manual) are off.
2. Be careful not to reverse connect the battery. Otherwise, both the battery and the outdoor cabinet system will be damaged!
3. The installation tools must be insulated. Do not damage the battery plastic cover or battery terminals during the installation.

The battery compartment can accommodate two battery strings.

Installation check
1. Check that the battery shells are in good condition.
2. Check that the polarities of the terminals are in accordance with the polarity marks on the battery shell.
3. Check that the terminal screws are fastened.
Installation procedures

& Note
When installing two battery strings or more, install the lower battery string first. While removing them, remove the upper battery
string first.

Step 1: Switch off the battery MCBs and AC input MCBs. For their positions, refer to the corresponding subrack
power supply user manual.
Step 2: Push the batteries into the battery compartment from right to left. The clearance between adjacent batteries
should be at least 10mm.
Step 3: Remove the cover of the battery terminals and connect the plate electrodes between the batteries.
Step 4: Connect the positive battery cables (red) to the positive pole of the batteries in the battery compartment.
Connect the negative battery cables (black) to the negative pole of the batteries. Attach the acid and alkali integration
box (battery accessory) on the right side panel of the cabinet.

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10 Chapter 2 Installation

Step 5: After installing the battery strings, use the 3M double-side adhesive tape to affix the temperature sensor to
the center of the upper-layer battery string.
Step 6: Measure the voltage of the battery strings. If the voltage value is correct, replace the battery cover.

2.6 Installation Inspection

After installation, you should carry out the inspection procedures given in Table 2-4.
Table 2-4 Installation inspection list
Check item No. Check content
1 Check that the cabinet is level, upright and steadily fixed
Check that if all the screws are tightened, especially those in electrical connections. Check that the bolts
2
have plain washers and spring washers and are not reversed
Cabinet
3 Check that there are no unwanted materials inside the cabinet and clear up the unwanted materials
installation
Check that the cabinet paint is intact. If there are scratches, paint them immediately with antirust paint to
4
prevent corrosion
5 Clean up the cabinet
6 Check that the door can move freely, the lock is in good condition and the door stay bar is fixed
Cabinet
installation 7 Check that the dummy plates are installed at the reserved space where no customer device is installed

1 Check the correctness of all the MCBs and cables specifications

Check the correctness of bus bar connections, input and output cable connection, and connection
2
between the power system and the system grounding
3 Check the correctness of the batteries number and connection, and battery strings polarities
Electrical
4 Make sure all the cable connections are firm and reliable
connection
Check the connection point, line sequence and polarities of DC cables. Check the connection polarities of
5 the batteries. Check that the connection points are fixed and the cable connections are correct and
reliable
6 Check that the cables are tidy, and the cable binding is normative

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 Chapter 3 Testing 11

Chapter 3 Testing

This chapter introduces procedures of testing. The corresponding safety rules shall be adhered to in the testing.

& Note
After testing the subrack power supply, you can test the outdoor cabinet.

3.1 Startup

& Note
Before the test, inform the chief manufacturer representative. Only the trained electrical engineer can maintain and operate this
equipment. In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles
and rings.

During operation, parts of this equipment carry hazardous voltage. Misoperation can result in severe or fatal injuries
and property damage. Before the test, check the equipment to ensure the proper earthing. Installation inspection (see
Table 2-4) must be done before testing. Then you can do the following operation.
Switch on the power input MCB of the fan control board (For the position, refer to 2.4.3 Connecting Fan Control
Board Power Cables.) to power on the fan control board. When the outdoor cabinet is configured with 120A subrack
power supply, the power input MCB is not available; you just need to power on 120A subrack power supply to power
on the fan control board. At this point, the fan control board enters self testing and the fans accelerate to full speed
gradually. After a few minutes, the fans stop. If the environmental temperature is about 35°C, the fans will operate at
low speed, until the environmental temperature reaches 25°C, then the fans will stop.

3.2 Alarm Check And System Operation Status Check

Alarm check
If the outdoor cabinet is configured with a fan control board, you can disconnect the J11 and J12 terminals (see
Figure 4-2) on the fan control board when the fan is operating. So as to check that if the fan control board can trigger
fan alarm.
System operation status check
There should be no alarms during normal system operation.

3.3 Final Steps

OK Comments
Disconnect all test equipment from the system and make sure that materials irrelevant to the 
equipment have been all removed.
Restore the outdoor cabinet to its original condition and close the cabinet door. 
Check and handover the equipment that the user has purchased. 
Note down all the operations taken, including time of the operation and name of the operator. 

If any defect is found in this equipment, inform the personnel responsible for the contract.
If repairing is needed, please fill in the FAILURE REPORT and send the report together with the faulty unit to the
repairing center for fault analysis.

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12 Chapter 4 Maintenance

Chapter 4 Maintenance

This chapter describes the routine maintenance, alarm and fault handling, and replacing of the outdoor cabinet parts.

& Note
1. The maintenance must be conducted under the guidance of the related safety regulations.
2. Only the trained personnel with adequate knowledge about the outdoor cabinet shall maintain the inner part of the cabinet.

4.1 Routine Maintenance

Inspect the outdoor cabinet periodically and shoot the trouble in time. The routine maintenance items are given in
Table 4-1.
Table 4-1 Routine maintenance items
Maintenance item Frequency Inspecting method Guide
The check method is given in 3.1 Startup. If the fans run
Fans Once half a year Visual inspection abnormally, refer to 4.3.3 Replacing Fans to maintain or
replace the fan
Paint, galvanization layer Once half a year Visual inspection If there are scratches, paint them immediately
If dust accumulated on the front door air filter (shown in
Figure 4-1), loosen the four fixing screws of the air filter
cover of the front door (shown in Figure 4-1). Then take off
the air filter cover and clean the air filter with water from
Front door air filter Once three months Visual inspection
inside to outside (wire fence is inside of the air filter). Each
air filter can not be cleaned for over two times. Otherwise,
the air filter must be replaced. If the air filter is damaged,
replace it. Finally, replace the air filter cover

Front door air filter

Fixing screw of the air
filter cover of the front
door (4 pieces)

Figure 4-1 Front door air filter

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 Chapter 4 Maintenance 13

4.2 Handling Alarms And Faults

The normal alarms and faults of the outdoor cabinet are the alarms and faults of the fan. For inspection and
maintenance of the fan, refer to 4.3.3 Replacing Fans.

4.3 Replacing Parts

4.3.1 Replacing Fan Control Board

Fan control board and its terminals layout are shown in Figure 4-2.

H1 H2

J11

J12
J10
J2
SW2

ON
SW1 SW2
SW1

J6
J7
H4

J3
B
H3
Alarm indicators
Figure 4-2 Fan control board and its terminal layout

Setting description of the fan control board

The setting description of the fan control board is listed in Table 4-2.
Table 4-2 Setting description of the fan control board
Label on the Silk print on the
Nam e corresponding corresponding fan control Setting description
cover board
Bit “1”
Switch SW2 (shown in Figure 4-2) Put SW2 switch to the ‘OFF’ position (default), see Figure 4-3
Bit “2”
Self-test button Button SW1 (shown in Figure 4-2) Press the button to test the fan
Remark: The position of the cover is shown in Figure 4-4. The fan control board is located under the cover
SW2

Figure 4-3 Amplified SW2

Replacing procedures of the fan control board

The procedures of replacing the fan control board are as follows.
Step 1: Loosen the two fixing screws to remove the cover, and then you can see the fan control board. The position of
the cover is shown in Figure 4-4.

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

14 Chapter 4 Maintenance

Fixing screw of the cover Cover Fixing screw of the cover

Figure 4-4 Plastic cover position

Step 2: Disconnect J11, J12 and J2 terminals (shown in Figure 4-2) in sequence, and then disconnect the rest
connection terminals on the fan control board.
Step 3: Loosen the fixing screws on the fan control board. Replace the fan control board with a new one.
Step 4: Reverse connection sequence of previous step 2 to connect terminals, so as to check that the indicators show
correctly when fan fails.
Step 5: Ensure that Bit 2 of SW2 switch is put to the position shown in Figure 4-3.
Step 6: Replace the cover of the fan control board. Press the SW1 self-test button (shown in Figure 4-2) to ensure
that the fan can start normally.

4.3.2 Replacing Fan Control Extension Board

The procedures of replacing the fan control extension board are as follows.
Step 1: Loosen the two fixing screws to remove the cover, and then you can see the fan control extension board. The
position of the cover is shown in Figure 4-4.
Step 2: Loosen the four fixing screws to remove the fan control extension board. Replace the fan control extension
with a new one.
Step 3: Replace the cover.

4.3.3 Replacing Fans

Fan alarm circuit

The fan-cooling unit of the outdoor cabinet is mainly composed of 2 ~ 4 axial flow fans. The illustration of the fan
alarm circuit is shown in Figure 4-5, where the blue line is the alarm line.
VCC

(Red) Ic VFG

(Blue)
R
MOTOR FG SIGNAL
DRIVER IC VCE

(Black) GROUND
(Yellow)
Figure 4-5 Illustration of the fan alarm circuit

Fan alarm indicators

The position of the alarm indicators is shown in Figure 4-2.
If the system is configured with four fans, the alarm indicators 1 ~ 4 on the fan control board correspond to fans 1 ~ 4.
If the system is configured with three fans, the alarm indicator 1 on the fan control board corresponds to fan 1; alarm

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

 Chapter 4 Maintenance 15

indictor 2 corresponds to fan 2, and alarm indicators 3 and 4 correspond to fan 3. If the system is configured with two
fans, alarm indicators 1 and 2 correspond to fan 1, and alarm indicators 3 and 4 correspond to fan 2.
Fan replacing procedures
If the fan is faulty, the corresponding indicator will be on. Follow the following procedures to replace the fan.
Step 1: Make sure that the fan-control terminals (J11 and J12 are hot pluggable) on the fan control board are inserted
firmly. The fan-control terminals are shown in Figure 4-2.
Step 2: Ensure that Bit 2 of SW2 switch is put to the position shown in Figure 4-3.
Step 3: Press the SW1 self-test button (shown in Figure 4-2). If the fans do not work, make sure that the fan cables
are perfect.
Step 4: Loosen the fixing screws at the cabinet top cover to open the top cover. (Opening the top cover, pull it forward
and then lift up its front not more than 30°. Otherwise the top cover will be fallen.)
Step 5: Disconnect the fan power terminals at the top of the cabinet. Use a multimeter to measure the voltage
between the positive power cable and the negative power cable. Check if the voltage is close to the DC output
voltage (54.0V).
If the fan power voltage is normal, the fans are damaged. Carry out the next step.
Step 6: Loosen the four fixing screws of the fans and replace the fans, as shown in Figure 4-6.
Fixing screw of the fan (4 pieces)
Fan

Figure 4-6 Replacing the fan

Step 7: Reconnect the fan power terminals, and press SW1 self-test button (shown in Figure 4-2) to ensure that the
fan can startup normally.

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

16 Appendix 1 Spare Part List

Appendix 1 Spare Part List

Table 1 Spare part list

Component Description BOM
Fan DC axial flow fan 32010191
Power supply cable for fan P345314SL31 04118331 (with two fans)
Power supply cable for fan P345314SL32 04118332 (with three fans)
Power supply cable for fan P345314SL33 04118333 (with four fans)
Air filter 430mm×320mm×46mm 02560009
Fan control board P344309U1 03034609

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

 Appendix 2 Wiring Diagram 17

Appendix 2 Wiring Diagram

8 9
XT XT
W02 L=270mm

Back cross door line

W02 L=320mm

Front cross door line

Battery MCB
43 44
QFDI QFDII

W03 W07 W07

26-BATT1-V-

26-BATT2-V-
1 3 5 7 9 11
3 L1 L2 L3 N N
JX 2 4 6 8 10 11
1 1
QFDI QFDII
63A 63A
2 2 15
Note 4
Project 1 Project 2 W03 1 2
Bus-
2 2
W03 N
W 03_A/B/C
W03 PE
W 03_A/B/C
PE
4 N 4
5 1 5 1
B
QFA2 QFA2
MS N L MS N L 1 2 3 4 5 6 7 8 9 10 11 12
10A
10A 0V bar
W03

26-BATT1-V+
26-BATT2-V+

26-BATT3-V+

26-BATT4-V+
W03
W03 W03 25
Note: Bus+
W03_A for Europen and British standard.
W03_B for American standard socket.
W03_C for Chinese standard socket. W07

7 W07 W07
PE BUS
1 2 3 4 5 6

43-1

25-2

44-1

25-3
W02 Subrack power supply PE bar
1
2 - + - +
3
4 45 1# BATT 2# BATT
5 PE BUS

6
PE bar in cabinet

26
BATT

Note：
1. Because 3# and 4# BATT cables have no battery MCBs, you can bind the cables to the corresponding positions along the cable frames in the cabinet.
2. AC socket conection: according to project 1 or project 2.
3. Connect cables according to actual configuration.
4. When leakage MCB is available, QFA2 MCB is reserved for user and not connected.
Figure 1 Wiring diagram (1)

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

 Appendix 2 Wiring Diagram 18

6
MJ
120A Door sensor
X1-J_DOOR1-1
J_TEMP 31
1 2
P144309X1 J_Z X1

1
2
W17

3
2
X1-J_DOOR1-2

1
1
6

4 3 2 1
J_232 J_BMV

8
9

7
5
W17

2
J_X J_I
J_DOOR1

1
4
6-2
1

2 1
J_RLY 6-1

3 2 1
30 50
J_MFAIL

2
28 29
FAN3 FAN4
FAN2

1
FAN1
W01 46-1 46-2 W01
W01 46-3 Fan 3 Fan 4

2 1
46-4 Fan 1 Fan 2
6
W01

8 7 6 5 4 3 2 1
U1-J3-7
J_FAULT
5
U1-J3-8
W01 46-5 46-6 W01 4 U1-J3-5
U1-J3-6

5 4 3 2 1
3

J_CTRL
15

16

U1-J3-1 FAN1 FAN2 FAN3 FAN4

39
40
U1-J3-2
1

B W20

W23
W23
32
X2
1 2 3 4 5 6 7 8

J_X
W22 33
U1
W22

36-TEMP
36-GND
FCU Temperature sensor II

U1-J6
36-+
36
W20 T2
P144309X2 1 2 3 1 2

J6 J7

1 2 3 45 6
SW2 SW1 X1-J_FAULT-2
J_M

6 5 4 3 2 1
X1-J_FAULT-1

J_PWR J12
1
2

J_CAN J3 X1-J_FAULT-6
X1-J_FAULT-5
X1-J_FAULT-8
U1-J2-2

8 7
X1-J_FAULT-7
U1-J2-1
J10

1 2 3 45
J11
W11
2 1
J2
8 7 6 5 4 3 21
J_Z

X2-J_PWR-4
X2-J_PWR-3
9
0
3
4

W11

46
XT2
W01 Dry contact output terminal block
31-J-RLY-10

31-J-RLY-13

31-J-RLY-14
31-J-RLY-7

31-J-RLY-8

31-J-RLY-9

Note:
1 2 3 4 5 6 7 8 1. Configure W23 cables according to actual configuration.
2. Connect cables according to actual configuration

Figure 2 Wiring diagram (2)

Note: FCU is fan control board.

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

 Appendix 2 Wiring Diagram 19

26-BATT3-+
150A subrack 6

26-BATT4-+

26-BATT1-+

26-BATT2-+
8 9
MJ XT
DU power distribution unit Front view XT
33-J2-1 W 12 Door sensor
2 0V W02
DU 46-1 L=270mm

26-BATT1--

26-BATT2--
1 2
Back cross door line

33-J2-2
W 12 W 17 W02
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 L=320mm

8- Q F 10

8-QF12
1 1 1

8- Q F 11

8 -Q F 13
46-2

8- Q F 14

8- Q F 15

8- Q F 18

8- Q F 19

8 -Q F 20

8 -Q F 21

8 -Q F 22
8-QF16

8-QF17
1

8- Q F 6
8 -Q F 1

8 -Q F 2

8 -Q F 3

8 -Q F 4

8 -Q F 5

8 -Q F 7

8- Q F 8

8 -Q F 9
2 2 2 2

Front cross door line

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2

W27/W28 /W29
2

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29

W27/W28/W29
PL PL NPL
28 29
30 50
FAN1 FAN2
AC project 2 for 3p+N+PE/380V AC input
User port board FAN3 FAN4
1 3
ACIN
W24C3 W 12
X1

46-3

46-4
L1 L2 L3 N
1 3 5 7

QF1 1 2 3
PE bar 2
5-PE

2 4 6 8
J2
N Bar
5-N Fan 1 Fan 2 Fan 3 Fan 4
W03
5-L W 03

Dry contact output terminal block

W23
W 03
46 W23
XT2
W 02
1-PE

W17 W 17 W12 W12 W03 W03

W22
3-J2-2-2

3-J2-2-3
PE

49-J3-1

49-J3-2
Temperature sensor II
6-1

6-2

U1-J6
5
MS
N L W22 33 49
AC socket 1 2 3 4 5 6 7 8 U1 T2
FCUX
1-N

1-6

FCU

36-TEMP
49

36-GND
U2

36-+
Note: NO
W03_A for Europen and British standard. 1 2 3 1 2
W02
W03_B for American standard socket. J6 J7

1 2 3456
W03_C for Chinese standard socket. SW2SW1

8 7 65 43 2 1

8 7 6 5 43 2 1
J12

876 5 4321
1
J3 J2 J3
2 46-6
3
J10 46-5

1 234 5
4 45 J11
W01
PE bar in cabinet

21
PE BUS
5 J1 W03
6
12
J2

2--48V
26

2-0V
BATT

W 12 W 12 W 12 W 12 W11
2-QB1

2-QB2
2-OV

2-OV

1# BATT 2# BATT

Note:
1. Find out the PL label or 10A MCB between PL and PL, then follow the figure to connect power cables of the FCU.
2. Connect cables according to actual corfiguration.

Figure 3 Wiring diagram (3)

Note: FCU is fan control board. FCUX is fan control extension board.

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual

20 Appendix 3 Schematic Diagram

Appendix 3 Schematic Diagram

Fan-cooling unit

Project 1 FCU+4 Fan

QF
BLVD
1 2 3
FCU

CO NT R O L

CO NT R O L
C O NT R O L

C O NT R O L
AL AR M

A LA R M
A LA R M

A LA R M
Project 2 FCU+FCUX+4 Fan
Fan fault alarm
FCUX
QF
BLVD 1 2 3
FCU
C O N TR O L

C O N TR O L
C O N TR O L

C O N TR O L
A L A RM

AL AR M
A LA R M

A LA R M
Note:
Fan number: 2 ~ 4, optional.

Figure 4 Fan-cooling unit schematic diagram

Note: FCU is fan control board. FCUX is fan control extension board.

AC power distribution unit

Project 1

QFA2 QFA3 XS

L
PE
N

Project 2

QFA2 QFA3 XS

L
PE
N

Note:
1. QF3 in the project 1 is a leakage MCB.
2. QF3 in the project 2 is a general MCB.
3. XS mainterance socket: four standards, optional.

Figure 5 AC power distribution unit schematic diagram

EPC48150/1800-FA1 & EPC48300/3200-FA1 Outdoor Power Supply System User Manual