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Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center. Copyright 2006 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 accidents, please read the safety precautions carefully before operation. The Caution, Notice, Warning and Danger in this manual do not represent all the safety points to be observed, and are only used as supplement to various operation safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before operation. When operating Emerson products, the safety rules in the industry, the general safety points and special safety instructions specified in this manual must be strictly observed.
Electrical Safety
I. Hazardous voltage
Danger
Some components of the power system carry hazardous voltage in operation. Direct contact or indirect contact through moist objects with these components will result in fatal injury. Safety rules in the industry must be observed when installing the power 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, 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 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. II. Tools
Warning
In high voltage and AC operation, special tools must be used. No common or self-carried tools should 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
Note
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, wear ESD wrist strap to prevent body static from damaging the sensitive elements. The other end of the ESD wrist strap must be properly earthed. V. Shortcircuit
Danger
During operation, never short the positive and negative poles of the DC busbar or the non-earthing pole and the earth. The power system is constant voltage DC power equipment; short circuit will result in equipment burning and endanger human safety. Check carefully the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC power distribution unit is very tight, please carefully select the operation space. Remove watch, bracelet, bangle, ring, or other conductive objects before 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 the minimum.
Battery
Danger
Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery connection method. 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: Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. Use special insulated tools. Use eye protection device, and take preventive measures. Wear rubber gloves and apron to guard against electrolyte overflow. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted.
Installation Precautions
1. Only qualified technical person can perform the system installation and maintenance. 2. Avoid fire or body injuries. 3. Provide suitable AC mains supply to the system. 4. Earth the system according to the requirement. 5. Keep the environment of the system clean and dry. 6. Avoid touching the bare part of a circuit.
Others
I. Safety requirement
Notice
Always use the same model MCB to replace the old ones to comply with the safety requirement. II. Sharp object
Warning
When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object. III. Cable connection
Notice
Please verify the compliance of the cable and cable label with the actual installation prior to cable connection. IV. 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 Overview ............................................................................................................................................................ 1 1.1 Model Information ................................................................................................................................................. 1 1.2 Feature ................................................................................................................................................................. 1 1.3 Composition .......................................................................................................................................................... 2 1.4 Theory................................................................................................................................................................... 3 1.5 System Function ................................................................................................................................................... 3 1.5.1 Protective Function .................................................................................................................................... 3 1.5.2 Alarm Function .......................................................................................................................................... 4 1.5.3 Communication Function ........................................................................................................................... 5 Chapter 2 Installation Preparation....................................................................................................................................... 6 2.1 Site Selection ........................................................................................................................................................ 6 2.2 Laying Grounding Net ........................................................................................................................................... 7 2.3 Leading In Power .................................................................................................................................................. 7 2.4 Preparing Cable Tunnels ...................................................................................................................................... 7 2.5 Cable Requirements ............................................................................................................................................. 7 2.6 Requirements Of Laying Cables ........................................................................................................................... 8 Chapter 3 Installation .......................................................................................................................................................... 9 3.1 Installation Procedures ......................................................................................................................................... 9 3.2 Preparations ......................................................................................................................................................... 9 3.2.1 Inspecting Location.................................................................................................................................... 9 3.2.2 Unpacking.................................................................................................................................................. 9 3.2.3 Preparing Tools ....................................................................................................................................... 10 3.2.4 Clearances For Installing Cabinet............................................................................................................ 10 3.2.5 Opening The Cabinet Door...................................................................................................................... 11 3.3 Installing Cabinet ................................................................................................................................................ 12 3.3.1 Installing Cabinet On A Concrete Stand .................................................................................................. 12 3.3.2 Installing Cabinet On A Floorstand .......................................................................................................... 14 3.3.3 Installing Cabinet On Channel Beams ..................................................................................................... 15 3.4 Installing Rectifiers.............................................................................................................................................. 15 3.5 Connecting Cables.............................................................................................................................................. 16 3.5.1 Connecting Grounding Cable .................................................................................................................. 16 3.5.2 Connecting AC Power Cables And Load Cables..................................................................................... 17 3.5.3 Connecting Communication Cable Of The Monitoring Module ................................................................ 21 3.5.4 Sealing Cable Holes ................................................................................................................................ 21 3.6 Installing Batteries............................................................................................................................................... 21 3.7 Installation Inspection ......................................................................................................................................... 23 3.7.1 Cabinet Inspection................................................................................................................................... 23 3.7.2 Cable Connection Inspection................................................................................................................... 24 Chapter 4 Testing.............................................................................................................................................................. 25 4.1 Testing AC/ DC Distribution & Rectifiers............................................................................................................. 25 4.2 Testing Monitoring Module.................................................................................................................................. 26
4.2.1 Setting System Parameters ..................................................................................................................... 27 4.2.2 System Function Test .............................................................................................................................. 28 Chapter 5 Maintenance ..................................................................................................................................................... 29 5.1 Routine Maintenance .......................................................................................................................................... 29 5.2 Realtime Maintenance ........................................................................................................................................ 29 5.3 Alarm Handling ................................................................................................................................................... 30 5.4 Replacing Modules ............................................................................................................................................. 30 5.5 Replacing Rectifier Fan....................................................................................................................................... 31 5.6 Replacing Heat Exchanging Equipment.............................................................................................................. 32 5.7 Replacing External Fan....................................................................................................................................... 33 5.8 Replacing Heaters And Thermostats .................................................................................................................. 33 5.8.1 Replacing The Heater In Equipment Compartment ................................................................................. 34 5.8.2 Replacing The Heater In Battery Compartment....................................................................................... 35 5.8.3 Replacing Thermostats............................................................................................................................ 36 5.9 Replacing Door Status Sensor............................................................................................................................ 36 5.10 Replacing AC SPD............................................................................................................................................ 37 5.11 Replacing DC SPD Board................................................................................................................................. 38 5.12 Replacing Temperature Sensor ........................................................................................................................ 39 5.13 Replacing Monitoring Expansion Board ............................................................................................................ 40 5.14 Replacing Distribution Subrack ......................................................................................................................... 41 5.15 Battery Maintenance ......................................................................................................................................... 42 Appendix 1 Technical Data ............................................................................................................................................... 43 Appendix 2 Definitions Of Monitoring Expansion Board Interfaces ................................................................................... 45 Appendix 3 Common Problems......................................................................................................................................... 48 Appendix 4 Schematic Diagram ........................................................................................................................................ 49 Appendix 5 Wiring Diagram............................................................................................................................................... 51 Appendix 6 Spare Part List................................................................................................................................................ 52
Chapter 1 Overview
Chapter 1 Overview
APM100 outdoor power supply system can be used directly outdoors. It provides 48Vdc output power supply, 48V 100Ah battery standby power and four- unit height space for built- in equipment. It can supply as much as 60A electric current.
APM100 - 4860 S E
Emerson network power Co. Ltd S : south model; N: north model Output voltage: 48V; total current: 60A APM serial product name
Figure 1-1 Model information
1.2 Feature
Rectifier features Power factor up to 0.99, efficiency over 90%. Wide AC input voltage range from 90V to 290V. When the input voltage is between 90 ~ 175Vac, the rectifier starts power- limited output. The rectifier outputs as low as 37.5% of the rated power upon 90Vac input. Rectifiers are hot pluggable and the replacing time is less than 1min. System features Perfect battery management functions, including battery low voltage disconnection (BLVD) function, temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, and online battery test. Network design: providing multiple communication ports, which enables flexible networking and remote monitoring. Perfect lightning protection at both AC side and DC side. Complete fault protection and fault alarm functions. All system components are accessible from the front. The equipment compartment safety complies with IP55. The battery compartment safety complies with IP34. The system complies with GR487 waterproof requirement.
Chapter 1 Overview
1.3 Composition
The APM100 outdoor power supply consists of an equipment compartment and a battery compartment. The equipment compartment contains embedded power supply, heat exchanging equipment, external fan and distribution unit etc. The battery compartment has one layer, and a set of batteries that supplies backup power can be placed in the layer. In the north model system, two heaters are placed respectively in the equipment compartment and in the battery compartment. See Figure 1-2.
Door status sensor Heat exchanging unit External fan Monitoing expansion board Reserved space
Distribution unit
Figure 1-2
Embedded power supply The embedded power supply consists of three rectifiers, one monitoring module, one distribution subrack and one monitoring expansion board. It converts the 220V AC voltage into -48V DC voltage, and delivers the -48V DC voltage to the system distribution units and then to the load through the distribution subrack. Heat exchanging equipment and external fan The heat exchanging equipment dissipates the heat inside the cabinet with the external fan. It consists of an internal fan and a heat exchanger. The external fan aspirates the cold air outside and feeds it to the heat exchanger, while the internal fan expels the heat air inside the cabinet to the heat exchanger. The heat exchanger exchanges the heat between cold air and hot air in it to dissipate the heat. Distribution unit The distribution unit includes panel, AC/ DC SPD, connection terminals and MCBs. It is used to connect the AC input cables and load cables. Reserved space Reserved to place user devices. Heaters There are two heaters in the north model system; one is located behind the panel of the distribution unit in the equipment compartment and the other at the top of the battery compartment. The two heaters will start to work when the ambient temperature is below 5C (due to thermostat error, the actual temperature range of startup is 0C ~ 10C) to ensure the normal operation of the north model system segments in low temperature environment.
Chapter 1 Overview
1.4 Theory
The schematic diagram is shown in Figure 1-3. The detailed information is shown in Appendix 4 Schematic Diagram and Appendix 5 Wiring Diagram.
220Vac/110Vac Distribution unit Load 1 Load 11
220Vac/110Vac
-48Vdc
Figure 1-3
Schematic diagram
The embedded power system rectifies the 220V AC power into -48V DC power and delivers it to the distribution unit. It has functions of battery management, load low voltage disconnection (LLVD), BLVD, data acquisition, alarm, and communication with the host. The distribution unit connects the AC mains to the embedded power supply. It also outputs -48Vdc to the loads through different routes.
Chapter 1 Overview
180V
58V to 60V 1. The alarm return difference is 0.5V (1V above the 2. DC over- voltage alarm occurs when the busbar voltage is over 58V, and boost charging vanishes when the busbar voltage is below 57.5V voltage) 1. The alarm return difference is 0.5V 2. DC under- voltage alarm occurs when the busbar voltage is below 48.5V, and vanishes when the busbar voltage is over or equal to 49V 3. The lower limit voltage is LLVD voltage when load low- voltage disconnection is permitted 4. The lower limit voltage is BLVD voltage when load low- voltage disconnection is prohibited and BLVD is permitted 5. The lower limit voltage is 35V when both load low- voltage disconnection and BLVD are prohibited 1. The charging over- current alarm will occur when charging current is over the current- limit point for 5 minutes constantly 2. Alarm recovers when charging current is below the charging- limit point for 5 minutes constantly 1. If the function is activated (default alarm point: 65C) through the host and the ambient temperature is over the protection point for 30s constantly, the monitoring module will cut off the non- priority loads automatically. And the power will resume on automatically when the ambient temperature is lower by 10C than the protection point 2. The temperature sampling point is the external temperature sensor 3. The non- priority load over- temperature protection can be set controllable by the host. If controllable, the load over- temperature protection can be activated through the host command 1. If the function is activated (default alarm point: 53C) through the host and the circumambient temperature is over the over- temperature protection point for 30s constantly, the monitoring module will perform battery disconnection automatically. And the battery will resume power- on automatically when the ambient temperature is lower by 10C than the protection point 2. The temperature sampling point can be set to be battery temperature 1, and is subject to the temperature compensation value
DC undervoltage
48.5V
Inhibitive
50C to 70C
Inhibitive
40C to 70C
Ambient overtemperature
50C
The alarm return difference is 3C. The alarm point can be set respectively
Chapter 1 Overview
Alarm signals Default Setting range -50C to 0C (below the overtemperature alarm point) Description
Circumambience under0C temperature n# module failure n# module protection Battery loop disconnection BLVD 46.5V
The alarm return difference is 3C. The alarm point can be set respectively
Indicating n# module failure (output over- voltage, output shortage, fan failure) Indicating n# module protection (over- temperature, input over/ under- voltage protection) Battery loop disconnection (MCB, contactor or internal wiring disconnection) brings alarm 35V to LLVD voltage BLVD voltage to DC undervoltage alarm point
LLVD
Inhibitive
Low- voltage disconnection (LVD) activation and LVD voltage can be set through the host If LLVD is activated, the default voltage is 47.5V
Door status sensor SPD failure alarm Fan failure alarm Failure of batterycompartment heater Battery imbalance alarm
The dry contact is disconnected when alarm is raise Check the two- route SPDs. The dry contact disconnects when SPD exports alarms An alarm is raised when the fan stops running or the fan power cable disconnects When the mains is in normal state and the storage battery temperature is below -20C for an hour constantly, heater failure alarm of the storage battery compartment is raised When the battery is discharging, one battery imbalance alarm will generate if the following condition happens: Twice middle sampling voltage minus voltage between two ends of the battery string is above 0.6V for 30 seconds 1. Three routes altogether. The monitoring module supplies 24Vdc or 12Vdc operation power for the switch signal examination, disconnect the correlative low power level (0Vto 1V) and connect the correlative high power level (9to 24V) 2. 8/20s impulse current can endure 300A, without damage (bidirectional transient voltage suppressor with model of 1.5SMC39CA is recommended) 3. Alarm power level is adjustable
Note: If users need to activate Load over- temperature protection or other alarms that are inhibitive by default, they can reset alarm levels through the host
If the rated capacity of a MCB is much bigger than the actual output current, the MCB will not trip when overload happens. So the recommended MCB capacity is 1.5 to 2 times of the maximum load current (two times in the table above). Note The maximum output current that flows in the DC power cable is calculated according to the full load of the system. If the acceptable voltage drop is not 0.5V, determine the sectional area of the DC power cable according to the following expression. A= I%L/(KU) APM100 Outdoor Power Supply System User Manual
Chapter 2 Installation Preparation Where: Asectional area of a cable (m2) Itotal current that flows in the cable (A) Lcable length (m) U acceptable voltage drop in the cable (V) Kelectric conduction coefficient, here K Copper=57 Please choose the cable color according to local standards. It is recommended to use black cables as positive DC cables and blue as negative DC cables. 3. Grounding cables The sectional area of the grounding cable should be at least 16mm2. The green- yellow cables should be used as the grounding cables. Prepare the cables according to the cabling specification and quantity. Do not join two separate cables together to form one cable.
Plastic tubes do not have the lightning protective function. Steel tubes should be used.
Figure 2-2
Chapter 3 Installation
Chapter 3 Installation
3.1 Installation Procedures
The installation procedure diagram is shown in Figure 3-1.
Installation preparation
Installation
Installing cabinet
Installing rectifiers
Connecting cables
Installing batteries
No
Figure 3-1
3.2 Preparations
3.2.1 Inspecting Location
Before installation, please inspect: 1. Devices for laying cables, such as the cable tunnels. 2. Platforms for installation, such as the concrete standfloor. 3. Installation qualifications, such as AC power supply and the grounding connection.
3.2.2 Unpacking
Inspect the equipment carefully after unpacking to ensure successful installation. Unpack and inspect the equipment only after it arrives at the installation site. The user representative and the representative from Emerson Network Power Co., Ltd. shall inspect the equipment together. Open the case that contains the packing list first. Take out the packing list and check against it the customer name, customer address, machine No., quantity, case No., contract No. Check the goods one by one according to the packing list after unpacking. The procedures are as follows. Step 1: Check the quantity and serial number marked on the packing cases. Step 2: Check the correctness of the equipment packing. Step 3: Check the quantity and model of the accessories. Step 4: Check the correctness of equipment configuration. Step 5: Check the goods visually. For example, check if the cabinet or enclosure is distorted or affected with damp; shake gently the rectifier and the monitoring module to see if there is any loose component or connection caused by shipment. APM100 Outdoor Power Supply System User Manual
10
Chapter 3 Installation Step 6: The user representative signs the packing list. Do not unpack the components before installing them to avoid accessory loss.
Wire cutters Maximum 300mm2 Hydraulic- pressure compaction Maximum 300mm2 pincher Digital multimeter Impact electric drill Power socket Safety shoes Hammer Three and a half bit digital display With 14 or 12 impact aiguille With 5m cable To prevent puncture and for insulation -
Recommended clearances The recommended clearances for installing cabinet are shown in the following figure. 800mm clearance at the front 200mm clearance at the top 100mm clearance at the left 300mm clearance at the right
200 200
100
300
800
Figure 3-2
Minimum clearances The minimum clearances for installing cabinet are shown in the following figure. APM100 Outdoor Power Supply System User Manual
Chapter 3 Installation 650mm clearance at the front 100mm clearance at the top 100mm clearance at the left 250mm clearance at the right
100 100
11
100
250
650
Figure 3-3
Handle
Keyhole sheet
Figure 3-4
Unlock sequence
When you turn the key, lay your hand down to prevent being hit by the handle, as shown in Figure 3-5.
Figure 3-5
Unlock illustration
12
Chapter 3 Installation 2. Turn the handle counter clockwise to the position shown in Figure 3-6, and then open the door.
Handle
Figure 3-6
Handle position
3. Insert the door stay bar into the positioning pole to fix the door position, as shown in Figure 3-7.
Figure 3-7
4. To close the door, uplift the bar for 2mm- 3mm, place the handle to its original position, cover the keyhole with the keyhole sheet and undo the hexagon- socket- head- cap screw in the keyhole sheet clockwise with the hexagon key.
27 5
300~500
0
100
25
80 0
80
Ca
Figure 3-8
e bin
td
oo
Step 2: Mark the cabinet installation position Determine the center point positions of every installation hole on the stand according to the installation dimensions of the cabinet shown in Figure 3-9, and mark them with a pencil or an oil pen.
Chapter 3 Installation
60 400 4- 13 28
13
525
140
400
Front door
Figure 3-9 Installation dimensions of cabinet base (Unit: mm)
Step 3: Drill holes The size of the plastic expansion bolt delivered with the accessories is M10 55mm. Drill a 70mm-depth hole at each marked point by using a 14 impact drill bit. Be careful not to make the drill off-centered when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 3-10.
Expansion pipe
Power cabinet
70~75mm
14
Drill vertically
Figure 3-10
Step 4: Place cabinet in position Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the ground. Step 5: Open the cabinet door Take the key from the ring on the cabinet top, and open the cabinet door according to the method introduced in section 3.2.5 Opening The Cabinet Door. Step 6: Fix the cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Fasten the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 3-11.
Expansion bolt Cabinet Expansion bolt Expansion pipe Concrete stand Spring washer Concrete stand Spring washer Cabinet base Expansion pipe
Figure 3-11
Shake the cabinet in different directions after the installation to check for any loose component and loose installation of the cabinet.
14
Chapter 3 Installation
Front door
Figure 3-12 Installation dimensions of floorstand (Unit: mm)
Step 2: Drill holes The method is described in step 3 of 3.3.1 Step 3: Fix the floorstand Align the installation holes of the floorstand to those on the ground. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 3-13.
Cabinet Screw for fixing cabinet and floorstand Floorstand Expansion bolt Ground
Figure 3-13
Step 4: Place cabinet in position Place the cabinet on the floorstand. Align the installation holes of the cabinet to those of the floorstand. Step 5: Open the cabinet door Take the key from the ring on the cabinet top, and open the cabinet door according to the method introduced in 3.2.5 Opening The Cabinet Door.
Chapter 3 Installation
15
Front door
Figure 3-14 Dimensions of concrete stand (Unit: mm)
Step 2: Mark the cabinet installation position Determine the center point positions of every installation hole on the channel beams according to the installation dimensions of the cabinet shown in Figure 3-14, and mark them with a pencil or an oil pen. Step 3: Drill holes Drill a hole at each marked point by using a 12 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Step 4: Place cabinet in position Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the channel beams. Step 5: Fix the cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the expansion bolt with plain and spring washers into the expansion pipe with a 14# socket wrench, as shown in Figure 3-15.
Cabinet Screw
Floor stand
Channel beam
Figure 3-15
16
Chapter 3 Installation Step 1: Place the rectifier to the position shown in Figure 3-16. Step 2: Push the rectifier inward until it stops going forward. The rectifier will be fixed in the subrack by the locking devices.
Rectifier
Figure 3-16 Rectifier installation
Grounding cable
Figure 3-17
Because of the particularity of the outdoor equipment, the cabinet must be reliably grounded. The other end of the grounding cable must be connected to the metal base, as shown in Figure 3-18.
Chapter 3 Installation
17
The AC/ DC cables and the communication cable must be put into the metal pipe for protection. The metal pipe should be connected to the grounding busbar reliably. Considering the actual conditions, plastic coated metal hoses are recommended for protection, as shown in Figure 3-19.
Figure 3-19
AC power cord entrance Transmission fiber inlet/outlet 1 Transmission fiber inlet/outlet 2 -48Vdc DC power outlet 1 -48Vdc DC power outlet 2 -48Vdc DC power outlet 3 -48Vdc DC power outlet 4 -48Vdc DC power outlet 5 9 10 11 12 13 14 15 -48Vdc6 1 2 3 4 5 6
-48Vdc DC power outlet 6 User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet
1 2 3 4 5 6
Figure 3-20
Load distribution Arrange the load distribution before connecting power cables. The system can sustain 11 loads. The MCBs (LOAD1~LOAD6) of the distribution unit in the embedded power supply controls the 11 loads. The positions of the MCBs in the subrack are shown in Figure 3-21, and the relationship between these two levels of MCBs is shown in Figure 3-22. The specifications of the MCB and cables are shown in Table 3-3.
Table 3-3 Load MCB and load cable specifications
MCB cap. in distr. unit 16A 16A 16A 16A 32A 32A
Cable size in distr. unit 25mm2 25mm2 25mm2 25mm2 25mm2 25mm2
Remark Total output capacity of two loads should be no larger than 15A Total output capacity of two loads should be no larger than 15A Total output capacity of two loads should be no larger than 15A Total output capacity of three loads should be no larger than 15A Total load output capacity should be no larger than 30A Total load output capacity should be no larger than 30A
18
Chapter 3 Installation
Load MCB Battery MCB
Figure 3-21
LOAD1
LOAD2
LOAD3
LOAD4
LOAD5
LOAD6
Route 1 Route 2 Route 3 Route 4 Route 5 Route 6 Route 7 Route 8 Route 9 Route 10 Route 11
Figure 3-22
The embedded power supply system has LLVD and BLVD functions. When the battery voltage is less than 47.5V (default), the system will disconnect LOAD5 and LOAD6 automatically without interrupting LOAD1 ~ LOAD4. However, LOAD1 to LOAD4 will be disconnected automatically when the battery voltage is less than 46.5V (default) to avoid battery overdischarge. At this time, all loads are disconnected. The priority loads should be connected to the MCB of LOAD1 to LOAD4, that is Route1 to Route 9 in Figure 3-18. The non-priority loads should be connected to Route 10 and Route 11 in Figure 3-20. The load capacity should be no larger than the capacity of the MCB that is in the same route. Connecting AC power cables After confirming load distribution, you can connect AC power cables and load cables. The terminal and MCB positions are shown in Figure 3-23.
DC positive busbar
Socket
AC phase line(L)
Figure 3-23
The procedures of connecting AC power cables and load cables are given below. 1. Cable connection for system with 220V AC input
Chapter 3 Installation 1) Remove the panel of the distribution unit. The panel is shown in Figure 3-24.
19
Figure 3-24
2) Cut the protective cover over the cable hole with an electrician knife to lead in AC cables, as shown in Figure 3-25. 3) Put the AC cables through the cable holes at the right side of the cabinet bottom, as shown in Figure 3-25.
Protective cover
Figure 3-25
Leading in AC cables
4) Unscrew the tube cap, lead the AC cable through the tube, and finally screw the cap, as shown in Figure 3-26. Connect the neutral line to the N terminal at the bottom of the AC MCB. Connect the phase line to the L terminal at the bottom of the AC MCB.
AC MCB
Figure 3-26
5) Fix the AC cable to the cable frame with a nylon tie, as shown in Figure 3-26. Note 1. The grounding cable shall be connected first, then the neutral line and finally the phase lines. 2. The AC cables should be routed from the MCB in the external distribution equipment prepared by user. They should be connected to the MCB just before the system is powered on. The external distribution equipment should have some protection devices to fulfill the overcurrent, shortcircuit and lightning protection functions. 3. The AC phase line, neutral line and grounding cable should be identified with color labels. 4. The AC cables should be routed away from the DC cables. 5. It is recommended to use the 10m cable of the accessories as the AC cable. If users use their own cables as the AC cable, they should screw down the cap of the cable tunnel and use silicon sealant to seal the cable tunnels after connecting cables. If users use accessory cable as the AC cable, screw down the cap of the cable tunnel after connecting cables. 6) Place the protective cover over the cable hole after AC cable connection. 2. Cable connection for system with 110V AC input The AC transfer terminal of the systems with 110V AC input is different from that of the system with 220V AC input, as shown in Figure 3-27. 1) The procedures of step1 to step 3 are the same with those of 220V input cable connection.
20
Chapter 3 Installation 2) Connect the three cables labelled N, L1 and L2 to N terminal of the AC transfer terminals, and L1 and L2 terminals of the bottom of the AC MCB, as shown in Figure 3-27. 3) Fix the AC cable to the cable frame with a nylon tie.
AC transfer terminal
Figure 3-27
Connecting load cables 1. Cut the protective cover over the cable hole with an electrician knife and put the load cables through the cable holes at the left side of the cabinet bottom. Wrap the cable with two magnetic loops (model: DFK2528-13), one above the protective cover and one near the cable hole, as shown in Figure 3-28. Or put the load cable that is outside the cabinet through a steel tube or plastic coated metal hose. Fix the load cable to the cable frame at the battery compartment wall with a nylon tie.
Load cable
Figure 3-28
2. Unscrew the tube cap, lead the load cable through the cable tube, and then screw the cap. Connect the negative line to the underpart of the load terminals. Connect the positive line to the DC- output positive busbar, as shown in Figure 3-29.
Figure 3-29
AC cable connection
3. Fill the rubber plug in the unused cable tunnel and use silicon sealant to seal the used cable tunnels. Re-install the panel of the distribution unit. Place the protective cover over the cable hole. Note To avoid shortcircuit, the tools and body shall be insulated strictly before applying a load when the system is powered on.
Chapter 3 Installation
21
Figure 3-30
Figure 3-31
Figure 3-32
Terminal bolts
22
Chapter 3 Installation The installation procedures are as follows: 1. Switch off the AC input MCB and battery MCB. The MCB positions are in Figure 3-33.
Battery MCB
AC input MCB
Figure 3-33
MCB positions
2. Battery cables. The black cable is the cathode (-), the red cable is the anode (+) and the cable in the middle is mid- voltage sampling cable. The cable positions are illustrated in Figure 3-34.
Mid- voltage sam pling cable
Figure 3-34
Battery cables
3. Remove the four fixing screws of the battery baffle and take off the baffle. The fixing screws are shown in Figure 3-35.
Figure 3-35
4. Push the batteries into the battery compartment from right to left and make sure that the terminals are outside, as shown in Figure 3-36. The battery string should be near the right side and backside of the cabinet. The clearance between adjacent batteries should be 5mm ~ 10mm.
Figure 3-36
Chapter 3 Installation
23
5. Remove the cover of the battery terminals and connect the plate electrodes between the batteries. Note that the mid- voltage sampling cable should be connected to the plate electrode between the second and the third batteries, as shown in Figure 3-37.
Mid- voltage Plate electrode sampling cable
Figure 3-37
6. Connect the battery cables to the batteries. Attach the acid and alkali integration box (battery accessory) on the side panel of the cabinet. The black cable should be connected to the leftmost negative terminal and the red cable should be connected to the rightmost positive terminal, as shown in the Figure 3-38.
Negative cable
Positive cable
Figure 3-38
7. After installing the battery string, measure the voltage of the battery string. If the voltage value is correct, put the baffle back and fasten the screws, so that the battery string is blocked off, as shown in Figure 3-39.
Figure 3-39
Figure 3-40
24
Chapter 3 Installation 6. Check that the door can move freely, the lock is in good condition and the door stay bar is fixed. 7. Check that the dummies are installed at the reserved space where no customer device is installed. If the dummies are not installed, install them immediately.
Chapter 4 Testing
25
Chapter 4 Testing
The system must be tested strictly after it is installed. Conduct the test procedures carefully and observe the system in the mean time. Shut down the system in case of any abnormality and continue the test only after eliminating the fault.
RCCB
AC input MCB
Figure 4-1
MCB positions
3. Switch off the mains MCB, as shown in Figure 4-1. Remove the panel of the distribution unit and measure the resistance of the AC MCB input/ output terminals. Make sure that there is no shortcircuit between the following terminals, as shown in Figure 4-2 and Figure 4-3: 1) The AC MCB output terminals; 2) The AC MCB input terminals; 3) AC transfer terminal N and grounding busbar (220V input system), or AC transfer terminal L2 and grounding busbar (110V input system); 4) Heater MCB and grounding busbar.
AC transfer terminal N Measuring point of AC MCB output terminal
Grounding Measuring Measuring point of point of AC MCB input busbar heater MCB terminal
Figure 4-2
26
Chapter 4 Testing
Measuring point of AC MCB output terminal
AC transfer terminal L2
Grounding Measuring Measuring point of point of AC MCB input busbar heater MCB terminal
Figure 4-3
4. Supply AC power to the system. Turn the multimeter to the AC position and measure the voltage of the input terminal of AC MCB. If the voltage is abnormal, check the AC power. 5. Switch on the AC MCB. To protect the rectifiers, there will be a startup- delay, during which period the rectifiers green and red indicators will be on for a few seconds. After the startup- delay, the system runs normally. When there is no load, the rectifier fan may stop but the green indicator should still be on. If it turns out otherwise, check the distribution unit carefully. 5. Switch on the MCB in the external distribution equipment to power the system. Measure the voltages of the AC MCBs input terminals . Check the external distribution equipment if the voltages are abnormal. 6. Switch on the load MCB. Turn the multimeter to the DC position and measure the load voltage. Before testing, remove the panel of the distribution unit and measure the voltage between the load- connection terminal and DC positive busbar, which should be 53.5V 0.5 V. The measuring points are shown in Figure 4-4, and the load MCB is shown in Figure 4-5.
Load connection terminal DC positive busbar
Figure 4-4
Note If the load MCBs are switched off, there might be fake voltage when measuring load voltage, which is normal. 7. Switch on the battery MCB, which is shown in Figure 4-5.
Load MCB Battery MCB
Figure 4-5
Chapter 4 Testing
27
Range > 60V and lower than AC Over-Voltage Alarm Point Between AC Under-Voltage Alarm point and 300V 1. When LLVD enabled: LLVD Voltage DC Busbar Low Voltage Point 2. When LLVD disabled but BLVD enabled: BLVD voltage 3. When both LLVD and BLVD disabled: 35V Between DC Busbar Low Voltage Point and 2V below FC DC Busbar Under-Voltage Alarm Point voltage DC Busbar Over-Voltage Alarm Point 58V ~ 60V and 1V higher than BC voltage LLVD Status Disabled, Enabled Between BLVD voltage (when BLVD is disabled: >35V) * LLVD Voltage and DC Busbar Under-Voltage Alarm Point BLVD Status Disabled, Enabled BLVD Voltage* Ambient Temp Alarm Lower Limit Ambient Temp Alarm Upper Limit Standby Digital Signal Alarm Level System Control Mode FC/BC Status BC voltage FC voltage
35V but lower than LLVD voltage (when LLVD is disabled, lower than DC Busbar Under-Voltage Alarm Point)
Default value 180V 280V 47.5V/46.5V/35V (depending on the BLVD Status and LLVD Status) 48.5V 58V Disabled 47.5V Enabled 46.5V 0C 50C High level alarm 1 Auto FC 56.5V 53.5V
Capacity of Battery String 100Ah (unless specified) Coefficient of Charge Current Limiting 0.15 0.1 ~ 0.25 Point Scheduled BC Interval 30 days ~ 240 days 60 days Temp Compensation Coef. of Battery 0mV/C ~ 500mV/C 80mV/C String Battery Over-Temp Protection Point 40C ~ 70C 53C Note*: The LLVD voltage and BLVD voltage should be set according to the battery manufacturer instructions
-50C ~ 100C and lower than upper limit -50C ~ 100C and higher than lower limit High level alarm 1, low level alarm 0 Host Control, Auto BC, FC 43.2V ~ 57.6V, between FC voltage and 1V below DC Busbar Over-Voltage Alarm Point 43.2V ~ 57.6V, between BC voltage and 2V below DC Busbar Under-Voltage Alarm Point 30Ah ~ 100Ah
When setting system parameters through the host, please note that: 1. Make sure that the power system address set at the host is identical with the address set through the DIP switch, or the communication will fail. 2. Make sure that the rectifier number is set consistent with the actual condition. After a rectifier is added to or removed from the power system, the rectifier number parameter must be accordingly modified, or a rectifier alarm will be raised. 3. The battery string capacity setting is customized according to order requirement before delivery. If there is no specific capacity requirement in the order, the default battery string capacity is 100Ah. If the actual battery capacity is neither 100Ah nor 200Ah, reset it through the host to make the configuration consistent with the actual situation and prevent improper battery management. 4. If the battery string capacity is 100Ah or 200Ah, you can set the battery capacity by the DIP switch. The DIP switch is in the PCB board of the monitoring module, as shown in Figure 4-6. You need to pull out the monitoring module (hot pluggable) first before you can change the DIP switch settings. Refer to 5.4 Replacing Modules for the method of plugging monitoring module.
28
Chapter 4 Testing Description of DIP switch settings are given in Table 4-2.
Table 4-2 Description of DIP switch settings
Settings ON: 1; OFF: 0 ON: dry contact switched- off is normal; switched- on generates alarm. OFF: dry contact switched- on is normal, switchedoff generates alarm ON: battery capacity 200Ah; OFF: battery capacity 100Ah ON: GSM protocol; OFF: WCDMA protocol
Default setting
OFF
Battery capacity
100Ah
8 Communication protocol WCDMA protocol Note: Communication address setting uses 8421 code. DIP switch 4 corresponds to 8, DIP switch 3 corresponds to 4, DIP switch 2 corresponds to 2, DIP switch 1 corresponds to 1
DIP switch
Communication address
Figure 4-6
DIP switch
The DIP switch setting in Figure 4-5 is the setting of BBU (address: 9, communication protocol: WCDMA). The DIP switch setting of BTS 3002C (address: 3, communication protocol: GSM) is shown in Figure 4-7.
Figure 4-7
Chapter 5 Maintenance
29
Chapter 5 Maintenance
Inspect the outdoor power supply system periodically and shoot the trouble in time.
Frequency Once half a year Once half a year Once half a year Once half a year
Guide Step 6 of 4.1 Testing AC/ DC Distribution & Rectifiers 5.2 Realtime Maintenance
Rectifier appearance
Indicator Meaning Normal state Rectifier fan failure Protection alarm or faults occur
30
Chapter 5 Maintenance Monitoring module indicator The appearance of the monitoring module is shown in the following figure. There are two indicators on the panel: RUN (power indicator) and ALM (alarm indicator). Descriptions are as shown in Table 5-3.
Alarm indicator Run indicator
Indicator Meaning Normal No system alarm, communication interrupt System alarm, normal communication System alarm, communication interrupt
RUN indicator (green) Slow blinking (Once per second) Fast blinking (Once per 125ms) Slow blinking (Once per second) Fast blinking (Once per 125ms)
Rectifier handle
Figure 5-3
Chapter 5 Maintenance
31
To remove the monitoring module, first you need to remove the communication cable with a screwdriver and then pull out the signal cable, as shown in Figure 5-4. Otherwise you cannot pull out the monitoring module.
Interface of the signal cable Interface of the communication cable
Fixing screws
Handle
Figure 5-4
The procedures for removing/inserting the monitoring module are the same as those for the rectifiers. After plugging in the monitoring module, you should first connect the signal cable and then connect the communication cable. Note The rectifiers connecting part is a delicate device. Although the rectifiers are designed to be hot pluggable, the pull-out and plug-in operation should be gentle lest the connecting part should be damaged. Only professionals are allowed to conduct rectifier replacement.
Figure 5-5
5. Replace the fan with a new one. 6. Connect the power cable, and fix the fan with the screw on the top right corner. 7. Mount the baffle plate. Note 1. Only trained professionals are allowed to clean and replace the fan. 2. Do not touch any internal parts of the rectifier during fan maintenance.
32
Chapter 5 Maintenance
Cable connector
The internal fan speed is settable. The higher the temperature of the equipment compartment is, the larger the internal fan speed is. Replace the internal fan or adjust the fan position if it stops running or there is an abnormal noise in it. Clean the heat exchanger once half a year. The procedures are as follows. Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, as shown in Figure 5-6. Do not disconnect the cable frequently when power is on. Step 2: Remove the fixing screws shown in Figure 5-7 and then remove the heat exchanging equipment from the cabinet.
Fixing screws
Fixing screws
Figure 5-7
Step 3: Remove the nine screws that fix the cover and the internal fan baffle and then remove the cover and the baffle, as shown in Figure 5-8.
Fixing screws
Figure 5-8
Step 4: Remove the fixing screws of the internal fan shown in Figure 5-9. Adjust the fan position or replace the fan with a new one. Take out the heat exchanger to clean it if there is much dust on it.
Heat exchanger
Internal fan
Chapter 5 Maintenance Step 5: Follow step 5 to step 1 to install the new fan and the clean heat exchanger into the cabinet. Take care when installing the heat exchanger to avoid damaging the waterproof bar on it.
33
Step 2: Disconnect the cable connector of the external fan, as shown in Figure 5-10. Do not disconnect the cable frequently when power is on.
Step 3: Remove the fixing screw of the fan box shown in Figure 5-10 and then remove the fan box. Step 4: Remove the fixing screw of the external fan shown in Figure 5-11. Adjust the fan position or replace it with a new one.
External fan
Figure 5-11
Step 5: Reverse step 4 to step 1 to install the new fan into the cabinet. Install the heat exchanging equipment into the cabinet. Take care when installing the heat exchanging equipment to avoid damaging the waterproof bar on it.
34
Chapter 5 Maintenance
AC input MCB
Step 2: Remove the panel of the distribution unit and the four screws shown in Figure 5-13. Remove the right segment of the distribution unit. Pay attention to personnel safety.
Fixing screw
Fixing screw
Figure 5-13 Screw positions
Step 3: Unscrew the fixing screws of the heater cover and disconnect the cable connector from the thermostats. The thermostats are the two cables marked L and N in Figure 5-14. Remove the heater cover. The heater is fixed on the heater cover, as shown in Figure 5-15.
Figure 5-14
Thermostats
Step 4: Remove the two fixing screws of the heater cover. The heater is fixed below the heater cover, as shown in Figure 5-15.
Chapter 5 Maintenance
35
Step 5: Unscrew the four fixing screws of the heater, cut off the cable connector and then remove the damaged heater, as shown in Figure 5-16.
Fixing screws of the heater (four altogether)
Figure 5-16
Step 6: Weld the cable connector to the heater cable, as shown in Figure 5-17. Use the heat shrinkable tube to reinforce the welding point. Fix the new heater on the heater cover and mount the cover on the cabinet.
Figure 5-17
Step 7: Connect the cable connector to the thermostat. The position is shown in Figure 5-14. Finally, mount the distribution unit on the cabinet. Step 8: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater MCB after making sure every thing is OK.
Figure 5-18
Hold the heater when removing the fixing screws, as shown in Figure 5-19.
Figure 5-19
Step 4: Weld the cable connector to the heater cable, as shown in Figure 5-17. Install a new heater and fix it. Connect the cable connector to the thermostat. Move the battery string to its original position.
36
Chapter 5 Maintenance Step 5: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater MCB after making sure every thing is OK.
Figure 5-20
Figure 5-21
Replacement procedures: Step 1: Switch off the AC MCB, battery MCB and the heater MCB, as shown in Figure 5-12. Step 2: Take out the battery string on the lower floor of the battery compartment. Please refer to 3.6 Installing Batteries for the removing procedures. Step 3: Disconnect the cable connector of the thermostat and remove the screws. Step 4: Replace a new thermostat and connect the cable connector of the thermostat to its terminal. Step 5: Switch on the AC MCB, battery MCB and the heater MCB.
Chapter 5 Maintenance
37
Figure 5-22
AC SPD
Check the SPD indicator on the monitoring expansion board, as shown in Figure 5-23. The position of the monitoring expansion board is shown in Figure 1-2.
Figure 5-23
If the indicator on the right is on, the AC SPD must have failed and thus needs replacement. The replacement procedures of AC SPD are as follows: Step1: Switch off the AC MCB and the battery MCB. The position is shown in Figure 5-12. Step 2: Remove the panel of the distribution unit. The position is shown in Figure 5-12. Step 3: Remove the four screws shown in Figure 5-13, and remove the five cables connected to the AC SPD, as shown in Figure 5-24.
AC input cable
AC output cable
Figure 5-24
PE cable
38
Chapter 5 Maintenance Step 4: Remove the right segment of the distribution unit and pull out the SPD alarm interface, as shown in Figure 5-25. Be sure to pay attention to personnel safety.
Alarm interface
Figure 5-25
Step 5: Remove the four fixing screws of the SPD shown in Figure 5-26. Disconnect the cables connected to the SPD.
Figure 5-26
Step 6: Reverse previous steps 4 ~ 1 and replace the new SPD. Connect the cables, fix the screws and the SPD. Step 7: Fix the distribution unit onto the cabinet. Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and restart operation after making sure everything is OK.
Figure 5-27
The DC SPD board replacement procedures are as follows: Step 1: Switch off the AC MCB and the battery MCB. The position is shown in Figure 5-12. Step 2: Remove the panel of the distribution unit. The position is shown in Figure 5-12. Step 3: Remove the load cables, battery cables, positive DC output cable, and power cable of DC SPD board and monitoring expansion board, as shown in Figure 5-28. Refer to 5.14 Replacing Distribution Subrack for removing method. Remove the cables connected to the batteries before removing the battery cables. Refer to 3.6 Installing Batteries for removing method and to 5.15 Battery Maintenance for precautions.
Chapter 5 Maintenance
Battery cables
39
Step 4: Loosen the cable fixing screws of the SPD board. Do not take them off. Remove all the cables connected to the SPD board, as shown in Figure 5-29. Be sure to pay attention to personnel safety. Step 5: Take off the alarm cable connector and the power cable connector, as shown in Figure 5-29.
Step 6: Loosen the fixing screws of the DC SPD board. Take off the DC SPD, as shown in Figure 5-30.
After the replacement, reverse step 6 ~ step 1 to install the new SPD.
Figure 5-31
40
Chapter 5 Maintenance
Temperature sensor of battery compartment
Figure 5-32
If the temperature sensor is damaged and needs replacement, follow the procedures to replace it: 1. Unplug the damaged temperature sensor. 2. Plug the connector of the temperature sensor to the corresponding socket in the monitoring expansion board, as shown in Figure 5-33.
Figure 5-33
3. Lay the temperature sensor at the location shown in Figure 5-31 or Figure 5-32.
Fixing screws
Fixing screws
Figure 5-34
Chapter 5 Maintenance
41
3. Remove the nine cable interfaces connected to the monitoring expansion board. Remove the signal cable of the monitoring module with a screwdriver (please refer to 5.4 Replacing Modules), and take off the communication cable of the monitoring module. Then you can take off the monitoring expansion board, as shown in Figure 5-35.
Communication cable Interface 6
Figure 5-35
After the replacement, reverse the above procedures to install the new monitoring expansion board.
Grounding cable
Figure 5-36
5. Remove the load cables and other cables, as shown in Figure 5-37. Loosen the fixing screws and you can remove the load cables.
Fixing screw of load cable
Figure 5-37
42
Chapter 5 Maintenance Use a slotted screwdriver with proper length to remove cable- fixing screws, as shown in Figure 5-38.
Figure 5-38
6. Remove the four fixing screws shown in Figure 5-39 and you can remove the distribution subrack.
Figure 5-39
Fixing screws
Figure 5-40
When the number of the batteries that need replacement is smaller than four, the new batteries must be of the same model with the old ones.
43
Parameter Operating temperature Storage temperature Relative humidity Altitude Solar radiation
Technical data North model: -40C ~ 45C; South model: -5C ~ 45C -40 ~ 70 5%RH ~ 100%RH (40 2C) 2000m (The system should be derated where the altitude is higher than 2000m. The highest operating temperature should be reduced by 1C at every 200m higher) Direct radiation: 1120W/m2 Dispersion radiation: 224W/m2
Electrical parameters
Table 2 APM100 electrical parameters
Parameter type
AC input
Parameter AC input system Rated input voltage Input voltage range Input frequency range Rated frequency Maximum input current Output voltage Maximum output current
Technical data Single phase three wire 220Vac/ 110Vac 90Vac ~ 290Vac* 40Hz ~ 65Hz 50Hz/ 60Hz 25A (with no user connector- jack output)
-48Vdc
DC output
52A
Note*: When the input voltage is within 90Vac~176Vac, the rectifiers output is allowed of linear derating. When the voltage input is 90Vac, the minimum rectifier output power is 37.5% of rated power
Mechanical parameters
Table 3 APM100 mechanical parameters
Technical data 1130mm 600mm 600mm (without base); 1280mm 600mm 600mm (with base APM100 dimensions (H % W % D) and rings) Battery compartment dimensions (H % W % D) 270mm 475mm 520mm 300kg (Including four pieces of 12V 100Ah batteries) APM100 weight 90kg (Excluding batteries and rectifiers)
Parameter
Audible noise 65dB. Anti-erosive performance Coating: 1. Adhesion test satisfies ISO2409 Class 0. 2. The pencil rigidity test satisfies ASTM D3363 2H. 3. Shock test satisfies 50kg.cm according to ASTM D2794. 4. The coating is not changed after 500 hours salt-fog test according to ASTM B117. 5. The coating of the external surface of the cabinet is suitable at the -40C to +55C environmental temperature and 2 1120W/m solar radiation. The coating should not blister, flake or flaw after 250 hours test according to ASTM D822. But it is allowed to have slight pulverization, that is, a little paint particle is allowed to adhere when the coating is wiped at full tilt. The slight change of color is allowed, that is, it is acceptable if the color difference value (NBS) is less than 6.0.
44
Appendix 1 Technical Data Protection requirement 1. The cabinet of the equipment compartment satisfies GB4208 IP55. 2. The cabinet of the battery compartment satisfies GB4208 IP34. Lightning protection 1. The system has a Level B+C SPD on AC side. 2. The AC input can withstand the maximum strike through current capacity of 60kA, and the nominal through current capacity is 25kA. The simulated lightning strike is carried out in term of YD1235.1 and YD1235.2. 3. The test of which the DC side can withstand through current capacity of 15kA requires: -48V-RTN can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively 5 times, and the interval between every two tests is one minute; RTN-PE can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively 5 times, and the interval between every two tests is one minute.
45
Figure 1
Connector models of the monitoring expansion board terminals and recommended connection cables are in the following table.
Table 4 Connector models and recommended connection cables
Signal port Water logging Ambient temperature/ humidity Main distribution frame Smoke sensor Door status sensor Alarm dry contact Optical- coupler output Backup digital data input RS422 communication port Preset dry contact port
Screen print marks J_WATER TEM_HU J_WIRE J_SMOKE JTM1 JK1, JK2 JAC1, JAC2 J9 J8 J12
Socket- connector model P2500-4 P2500-4 P2500-2 P2500-2 P2500-2 P2500-2 P2500-2 MSTB2.5/2-ST-5.08 MSTB2.5/4-ST-5.08 MSTB2.5/2-ST-5.08
Recommended cable model (AWG) 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22
The functional definitions of port- pins of the monitoring expansion board are shown in the following table.
Table 5 Port- pin definitions of the monitoring expansion board
J_WATER
TEM_HU
BAT_WE
Optical- coupler1 controlling output port Optical- coupler2 controlling output port
JAC1 JAC2
Signal properties
Remark
+24V output Input of the signal cable +12V output Input of the signal cable Earth cable None +24V output Input of the temperature signal cable +24V output Humidity signal cable input Earth cable Check the batteryBattery- temperature signal cable input compartment temperature. +12V output Connected before delivery +12V output Optical- coupler1 controlling output Optical- coupler1 controlling output Optical- coupler2 controlling output Optical- coupler2 controlling output
46
EQU_WE
J4
Load MCB switch test port SPD failure test port on DC side SPD failure test port on AC side
J3 J5 J6
J_FAN
J8
J12 J2
Main distribution frame signal input +48V power output Door status sensor signal input +24V power output Smoke signal input +24V power output Dry contact1 output Dry contact1 output Dry contact2 output Dry contact2 output Earth cable Signal cable input of equipment compartment temperature +12V output +12V output BUS+ input BAT1 mid- voltage input BAT2 mid- voltage input BUS- input None None 7 Load MCB monitoring signal input -48V power output SPD failure of the DC side signal input Connected before delivery -48V power output SPD failure of the AC side signal input Connected before delivery Power output To internal fan. Connected Signal output of fan speed before delivery Signal input of fan failure Power- earth cable Power output To external fan. Connected Fan speed signal output before delivery Signal input of fan failure Power- earth cable TX+ TXRX+ RXRLn+, RLnBusbar+ Busbar-
Remark*: The descriptions of the dry contact port presetting is as follows: When the DIP switch 6 is switched to OFF, the dry contacts are closed when normal and are open upon alarms. When the DIP switch 6 is switched to ON, the dry contacts are open when normal and are closed upon alarms. The following description are given in case of DIP switch 6 switched to OFF. Dry contact 1: dry contact of AC/ DC SPD alarm are preset closed (normal state), and open upon AC/ DC SPD alarms. Dry contact 2: dry contact of mains failure alarm are preset closed (normal state), and open upon mains shortage, mains over/ under- voltage alarm occurs. Dry contact 3: dry contact of DC under- voltage alarm are preset closed (normal state), and open upon DC undervoltage alarm occurs.
47
Dry contact 4: dry contact of system power alarm are preset closed (normal state), and open upon rectifier failure, rectifier protection, rectifier communication abnormal, busbar output over/ under- voltage alarm, charging over- current alarm, battery string route disconnection or internal/ external fan fault alarm occur.
48
49
KT2
Thermostat
L AC Input
Lin
XS KT3
Thermostat Heater for bat. compartment
AC INPUT
KT4
Thermostat
AC/DC
Dry contact AC/DC AC/DC AC/DC Temperature sensor of equ. compartment Temperature sensor of bat. compartment
MONITOR
PSM
KM1
KM2
2QF1 16A
2QF2 16A
2QF3 16A
2QF4 16A
2QF5 32A
2QF6 32A
2QF7 63A
FAN1
FAN2
LOAD 1
LOAD 2
LOAD 3
LOAD 4
LOAD 5
LOAD 6
DC OUTPUT
F2
DC SPD Board
PE
Alarm
BATT.
XT2 1 2 3 4 5 6 7 8 9 10
-48V DC output
0V DC busbar
Figure 2
Schematic diagram of APM100 outdoor power supply system (with 220V AC input)
Note: the preceding schematic diagram is only used for the standard product.
50
Thermostat
L1 AC Input L2
Alarm SPD PE
XT1 Lout
1 N
1QF3
2 N
Nout
XS L N
PE
Thermostat
Thermostat
AC INPUT
N PE PE
EMI
AC/DC
48V
AC/DC
AC/DC
AC/DC
MONITOR
PSM
FL1 FL2
Temperature sensor for equipment compartment Temperature sensor for battery compartment
KM1
KM2
2QF1 16A
LOAD 1
2QF2 16A
LOAD 2
2QF3 16A
LOAD 3
2QF4 16A
LOAD 4
2QF5 32A
LOAD 5
2QF6 32A
LOAD 6 PE
2QF7 63A
FAN1
FAN2
F2
DC SPD Board
Alarm
DC OUTPUT
XT2 1
10 11
-48V DC output
Figure 3
Schematic diagram of APM100 outdoor power supply system (with 110V AC input)
Appendix 5
Wiring Diagram
51
W09 34 36
J12
J2
B1- B2-
B1+B2+
W11 43
09
10 W12 44
Equipment N 21 KT1 compartment L 21 heater
KT2
W02 W12 45
AC SPD
20 18 17 16 15
W05
W04
W10 41
W07 29 W06 26 25 19
W07
24
23
Door sensor
40 W03 13
W09 35
Heater of battery compartment
L N
Battery string
Figure 4
52
Bill of the spare part 02400495 02130518 19020099 02440018 03034342 03026682 32010108 11010118 02510016
Spare part Distribution subrack Rectifier AC SPD Monitoring module Monitoring expansion board DC SPD External/ internal fan Thermostat Heater