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OPERATING AND MAINTENANCE MANUAL

OPERATING AND MAINTENANCE MANUAL


Document No. : S5073XU04 REV 1

FAN CONTROLLER FSC0348 SERIES

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OPERATING AND MAINTENANCE MANUAL

SECTION 1 _______________________________________________________________ 3
EXPLANATION OF HAZARD INFORMATION-------------------------------------------------------------------------------------- 3 HEALTH AND SAFETY PRECAUTIONS--------------------------------------------------------------------------------------------- 4 FIRST AID IN CASE OF ELECTRIC SHOCK --------------------------------------------------------------------------------------- 5 RESUSCITATION USING EXPIRED AIR METHOD ------------------------------------------------------------------------- 5 TREATMENT FOR BURNS -------------------------------------------------------------------------------------------------------- 5

SECTION 2 _______________________________________________________________ 6
INTRODUCTION --------------------------------------------------------------------------------------------------------------------------- 6

SECTION 3 _______________________________________________________________ 7
ELECTRICAL SPECIFICATION -------------------------------------------------------------------------------------------------------- 7 INPUT RATINGS---------------------------------------------------------------------------------------------------------------------- 7 MAINS INPUT-------------------------------------------------------------------------------------------------------------------------- 7 DC INPUT------------------------------------------------------------------------------------------------------------------------------- 7 OUTPUT RATINGS------------------------------------------------------------------------------------------------------------------- 7 OUTPUT CONNECTORS: CON1 (FAN 1) AND CON2 (FAN 2) ---------------------------------------------------------- 8 SIGNAL CONNECTOR: CON3 ---------------------------------------------------------------------------------------------------- 8 FAN SELECTION JUMPER: CON7 ---------------------------------------------------------------------------------------------- 9

SECTION 4 _______________________________________________________________ 10
INSTALLTION------------------------------------------------------------------------------------------------------------------------------- 10 LOCATION------------------------------------------------------------------------------------------------------------------------------ 10 VENTILATION ------------------------------------------------------------------------------------------------------------------------- 10 WALL MOUNTING-------------------------------------------------------------------------------------------------------------------- 10 COMPLIANCE WITH SAFETY STANDARDS --------------------------------------------------------------------------------- 10 ISOLATION----------------------------------------------------------------------------------------------------------------------------- 11

SECTION 5 _______________________________________________________________ 12
COMMISSIONING ------------------------------------------------------------------------------------------------------------------------- 12 FRONT PANEL CONTROLS------------------------------------------------------------------------------------------------------- 12 ADJUSTING FAN THRESHOLDS ------------------------------------------------------------------------------------------------ 13

SECTION 6 _______________________________________________________________ 15
FUNCTIONAL DESCRIPTION---------------------------------------------------------------------------------------------------------- 15 BLOCK DIAGRAM -------------------------------------------------------------------------------------------------------------------- 15

SECTION 7 _______________________________________________________________ 16
MAINTENANCE INSTRUCTIONS ----------------------------------------------------------------------------------------------------- 16

SECTION 8 _______________________________________________________________ 17
FAULT FINDING --------------------------------------------------------------------------------------------------------------------------- 17

SECTION 9 _______________________________________________________________ 18
DRAWING FILE ---------------------------------------------------------------------------------------------------------------------------- 18

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OPERATING AND MAINTENANCE MANUAL

SECTION 1

EXPLANATION OF HAZARD INFORMATION


To clarify certain points within this manual to ensure proper and safe operation of the equipment, the following emphasis is used.

NOTE:-

Highlights an essential element of a procedure to ensure correctness.

NOTE:CAUTION:-

Highlights an essential element of a procedure for installation or maintenance to ensure correctness. Indicates a procedure or practice which, if not strictly observed, could result in damage or destruction of equipment. Indicates a procedure or practice which could result in injury to personnel or loss of life if not followed correctly. Erskine Systems own the copyright to this manual, which cannot be copied, reproduced or disclosed to a third party without prior written permission.

WARNING:-

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OPERATING AND MAINTENANCE MANUAL

HEALTH AND SAFETY PRECAUTIONS


Installation, testing, fault location and repair should only be attempted by an authorised, qualified technician. This equipment carries dangerous voltages and stored electrical energy. Removal of shrouding can reveal dangerous voltages and/or high temperatures. Erskine Systems Ltd accepts no responsibility for the safety of personnel and property due to any actions after their removal. Before touching, or bringing metal objects, e.g. tools, metal bracelets, rings or necklaces into contact with items carrying electricity, carry out the following instructions: The above instructions must always be followed before making any adjustments, and also before making any electrical connections to any part of the equipment for the purpose of servicing. Such connections should always be checked for safety before reconnecting power. The above instructions must also be followed before any such connection is modified or renewed. NOTE:- Adjustments should only be carried out with non-conducting tools, taking care not to touch any item carrying electricity whilst doing so. Reference should also be made to any installation and fault-finding procedures in the equipment manual before installing and making external connections.

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OPERATING AND MAINTENANCE MANUAL

FIRST AID IN CASE OF ELECTRIC SHOCK


DO NOT TOUCH VICTIM WITH BARE HANDS IF HE IS STILL IN CONTACT WITH THE ELECTRICAL SUPPLY. IF THE ELECTRICAL SUPPLY CANNOT BE ISOLATED USE A DRY INSULATING MATERIAL E.G. A SCARF, TO PULL THE VICTIM CLEAR. 1 2 3 4

RESUSCITATION USING EXPIRED AIR METHOD (Approved by the Royal Life Saving Society) Lay the patient on his back with arms to his sides, ensuring that the stomach is lower than the chest if laid on a slope. Kneeling to one side and level with the head of the patient, place one hand under his neck and the other on top of his head (FIG 1). Raise the neck and tilt the head as far back as possible (FIG 2). Keeping the patient's head tilted use one hand to seal either the patient's nose or mouth. Open your mouth wide and inflate the victims' lungs by blowing air into his mouth or nose (FIG 3). Do not exceed 12 breaths per minute. As you blow observe the rise of the patient's chest. Then between each breath remove your mouth and allow air to escape from the patients' lungs (FIG 4). When there are signs of natural respiration adjust the resuscitary breathing rate to coincide with that of the victim. Continue resuscitation until the patient revives or a doctor certifies death. Resuscitation must commence immediately. Every second counts. If possible start oral resuscitation even before, and while, laying the patient down. If facial injuries have occurred it may be necessary to use a manual form of artificial respiration (Holger Nielson for instance). TREATMENT FOR BURNS If breathing has stopped, the victim must be resuscitated before treating for burns. Do not attempt to remove clothing adhering to the burn. Do not break blisters. Use dry sterile dressing using pad of cotton wool, bandage lightly over blisters or firmly over non-blistered wounds. Oil or grease in any form should not be applied.

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OPERATING AND MAINTENANCE MANUAL

SECTION 2

INTRODUCTION
The Erskine FSC0348 Fan Controller is intended to operate one or two 48Vdc cooling fans, type EBM R3G-355. Input power is from 230Vac utility supply, or in the event of failure of the utility supply, power is taken from a local 24V or 48V DC battery system. The controller is provided with a thermistor temperature sensor input, allowing the fan speed to be controlled as a function of temperature. Listed below are some of the main features of the FSC0348 series. Power Supply for large DC cooling fans NTC thermistor probe for temperature input Operates from both AC mains and Telecom DC systems to maintain 0-10V control output to fans availability of cooling under all Fault alarm circumstances Convection cooled Redundant Design, two separate Each fan has its own AC/DC supply PSUs in one box Quick change of controller in the Temperature control of fan speed unlikely event of failure (<2 minutes) Monitoring of fan performance Terminal cover interlocked with mains AC input 198-264Vrms connector DC input 20-56V LED Temperature display DC outputs 2 X 56V-6A for full fan power Cable Entry Terminal Cover

Control Switch

LED Indicators

Temperature Display

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OPERATING AND MAINTENANCE MANUAL

SECTION 3

ELECTRICAL SPECIFICATION
INPUT RATINGS Input Voltage, AC Input Current, AC Frequency Input Voltage, DC Input Current, DC MAINS INPUT A Standard IEC 320 mains inlet is provided for connection of the utility mains supply. This must be unplugged in order to remove the Terminal Cover. Note: The Terminal Cover must be refitted BEFORE applying mains power. DC INPUT Two M6 male studs are provided for the DC input. An external MCB must be fitted to the DC supply, see below for recommended rating and cable sizing. DC SYSTEM VOLTAGE 24V 48V CABLE SIZE 10mm 2 6mm
2

230Vac 4A max 45 65Hz 24/48V 32/18A max

BREAKER 40A Type B 20A Type B

CAUTION: Observe polarity as marked on the PCB. Ensure the flat and spring washers are located between the nut and cable crimp. Take care not to drop washers or nuts into the Controller. NOTE: The Controller does not incorporate any battery charging facilities, it is assumed that charging is incorporated elsewhere within the DC power system. OUTPUT RATINGS OUTPUT FAN 1 FAN 2 VOLTAGE (D.C.) 56 Volts 56 Volts CURRENT 6 Amps 6 Amps POWER 340W 340W

WARNING - ENERGY HAZARD - Output Power greater than 240VA The output is classed as unearthed SELV hazardous and must therefore not be accessible to operators. Ratings are for a maximum ambient temperature of 50C WIRING - All wiring to the unit must be in accordance with local Wiring Regulations and Codes of Practice.

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OPERATING AND MAINTENANCE MANUAL

OUTPUT CONNECTORS: CON1 (FAN 1) AND CON2 (FAN 2) Two fan outputs are provided with plug-in terminal blocks. Recommended cable size is 2 2 2 1.5mm , or for runs exceeding 3m, 2.5mm . Control and tacho signals may use 0.5mm if required. PIN NO. 1 2 3 4 FUNCTION +56V output 0V Control Output Tacho Input COMMENTS Permanent power connection to the fan. Power and Signal ground for the fan 0 10V speed control signal to the fan 0/5V tacho signal from the fan

CAUTION: The output voltage of 56Vdc will be present if either AC or DC supplies are live, regardless of the status of any other input or controls. SIGNAL CONNECTOR: CON3 PIN NO. 1 2 3 4 5 6 7 8 FUNCTION Fault Alarm N/C Fault Alarm Common Fault Alarm N/O Not used Thermistor Thermistor Return Enable Enable Return COMMENTS Closed to common under fault conditions Common, Volt free alarm contacts, 1A 30Vdc max. Closed to common when operating Connect a NTC thermistor temperature probe (Erskine Part No. RT10KPROBE/A) Link pin 7 to 8 to enable speed control signal to the fan, e.g. can be used for external enable switch.

The temperature probe lead must not exceed 3m in length. Generally the probe should be mounted high up in the hottest area being cooled. In, for example, cabin cooling applications, it may be necessary to have an externally accessible enable switch, otherwise if may be difficult to open the cabin door against the pressure drop created by the fan(s). NOTE: Pin 7 and pin 8 of must be linked together if no external switch is used.

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Case fixing screw Fan 2 CON2 41 Fan 1 CON1 41 Alarms CON3 81

DC Input

AC Mains In CON8

+
CON7

FAN SELECTION JUMPER: CON7 If only one fan is to be connected to the controller, then the use the FAN 1 output, and place the jumper link on CON7 in the 1 position (i.e. over the two pins nearest DC input terminals). This disables the second convertor to eliminate unnecessary quiescent power dissipation.

FAN 1 ONLY

FANS 1 & 2

FAN SELECTION VIA CON7 NOTE: A fault alarm will be initiated if either: CON7 is set to position 2 and only one fan 1 is fitted. Fan 1 is selected but connected to the Fan 2 output.

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CON7 CON7 2 2

OPERATING AND MAINTENANCE MANUAL

SECTION 4

INSTALLTION
LOCATION WARNING : The location chosen for the Controller must be accessible to authorised personnel only (i.e. Service Access Area) and must be installed in an environment that prevents user or operator access so as to (a) avoid access to the interior and (b) protect from items entering the unit. VENTILATION CAUTION : The Controller is intended for wall mounting only, and must be installed vertically, with the terminal cover either at the top or bottom. Adequate free ventilation must be provided around the Controller. A minimum of 200mm free space should be provided above and below the Controller. WALL MOUNTING To install the Controller:1. Remove the terminal cover and remove the screw from the chassis located directly below the negative DC input stud (see picture terminal layout above for location). 2. Slide the main body of the Controller upward and forward to detach it from the wall mounting plate. 3. Use the base as a template to mark the wall and secure through the 4 off dimpled fixing holes using suitable fasteners (Keyhole slot to top). 4. The Controller may be mounted onto the wall plate, with the terminals at either the top or bottom depending upon variant supplied. 5. Refit the screw to lock the Controller to the mounting plate. COMPLIANCE WITH SAFETY STANDARDS These units are designed to meet a wide variety of National and International Safety Standards; UL 60950, EN60950 and EN41003. No account has been taken of possible violations with the requirements of these standards due to the method of installation in host equipment. Installation of the Controller into the equipment must comply with the following requirements as applicable:The external wiring of the controller terminals is part of the fixed wiring of the equipment. Base plate orientation

Removing the controller from the base

4 off fixing holes in base plate (controller removed)

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OPERATING AND MAINTENANCE MANUAL

A 6A type C (IEC898)(EN 60898) circuit breaker should be fitted between the AC input of the rectifier and the mains supply. A 20A (-48V PSU) or 40A (+24V PSU) type B (IEC898, EN 60898) circuit breaker should be fitted between the DC input of the controller and the DC power system or battery. ISOLATION A 4 pole 10A isolator can be fitted between the controller output and the fan if required. NOTE: Isolation of the Fan whilst running will initiate a fault alarm.

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OPERATING AND MAINTENANCE MANUAL

SECTION 5

COMMISSIONING
After testing the wiring, refit the terminal cover, ensuring the plastic cable bushes supplied are used to anchor the cables in the appropriate chassis slots. CAUTION: 56Vdc is always present at the output of the controller if either AC or DC supplies are energised. The enable link, temperature sensor and front panel selector switch, have no influence on the output voltage! Operational control of the fans is purely by means of the control signal on pin 3 of the output connectors. 1. 2. 3. 4. 5. 6. Set the front panel switch of the controller to 100%. Close any fan isolators fitted. Switch on AC power and check the fan(s) run without excessive noise or vibration. Switch on the DC supply. Isolate the AC supply and ensure the fan(s) continue to run. Switch the controller to AUTO. If the fans stop warm the temperature sensor to ensure they come on at 30C. 7. Switch on the AC supply and cool the sensor to < 20C and ensure that the fans stop. NOTE: Default factory settings for the fan speed control is as below. SUPPLY MODE AC DC FRONT PANEL CONTROLS A two-digit LED display indicates the temperature as sensed by the thermistor probe. An indication of indicates that the probe is not connected or is open circuit. A switch is provided on the front panel to set the operating mode of the controller. 100% Off Auto Fan speed demand is set to maximum Fan speed demand is set to zero Fan speed demand is controlled by the temperature sensed by the temperature probe. FAN START 20C 30C FAN AT MAXIMUM 28C 38C

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Typical Installation, adjacent to fan

ADJUSTING FAN THRESHOLDS If required, the fan speed control characteristics can be adjusted by means of six potentiometers accessible on the main PCB of the controller. Three separate setting are provided for each fan output : AC Start : The temperature at which the fans will start with AC mains present DC Start : The temperature at which the fan will start with AC failure, i.e. running on DC. Slope : The temperature span over which the fans will reach full speed, the same setting being applicable to both AC and DC operation. In order to accurately adjust the settings, it is necessary to temporarily replace the usual temperature sense probe with a selection of fixed resistors equivalent to the expected temperature probe resistance at the desired set point. The table below gives the required resistance for temperatures over the range 10 to 40 C. Temp / C 10 12 14 16 18 20 22 24 Rprobe / Ohms 20010 18170 16510 15030 13700 12500 11420 10450 Temp / C 26 28 30 32 34 36 38 40 Rprobe / Ohms 9572 8777 8058 7405 6814 6276 5787 5341

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OPERATING AND MAINTENANCE MANUAL

Choose the four required calibration temperatures, AC start, DC start, AC maximum, DC maximum, where AC maximum = AC start + slope DC maximum = DC start + slope, and select the required resistor values from the table. It is recommended that the required resistor values are then assembled into a switch selector box, henceforth referred as a thermistor simulator. The adjustment method is as follows. 1. Connect the thermistor simulator to CON3 pins 5 & 6. 2. Initial setting for VR3 & VR6 at 50% (pointing towards CON3). 3. Front panel switch to Auto. 4. FAN 1 Set-up: Connector a DVM across pin 3 (+ve) and pin 2 (-ve) on FAN 1 output (CON1). Set the thermistor simulator to AC start and switch on the AC and DC power. Adjust VR1 so the DVM reads 1.0V ( 0.2V). Set thermistor simulator to AC maximum, adjust VR3 for 10.0V (0.2V). Switch off the AC mains (i.e. run the unit off DC power). Set thermistor simulator to DC start. Adjust VR2 so the DVM reads 1.0V (0.2V). Set thermistor simulator to DC maximum, check the DVM reads 10.0V 0.5V. 5. FAN 2 Set-up: Connector a DVM across pin 3 (+ve) and pin 2 (-ve) on FAN 2 output (CON2) Set the thermistor simulator to AC start and switch on the AC and DC power. Adjust VR4 so the DVM reads 1.0V ( 0.2V) Set thermistor simulator to AC maximum, adjust VR6 for 10.0V (0.2V) Switch off the AC mains (i.e. run the unit off DC power) Set thermistor simulator to DC start. Adjust VR5 so the DVM reads 1.0V (0.2V) Set thermistor simulator to DC maximum, check the DVM reads 10.0V 0.5V

VR1

VR2

VR3

VR4

VR5

VR6

Location & identification of fan control pots (viewed with terminals at bottom)

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SECTION 6

FUNCTIONAL DESCRIPTION
BLOCK DIAGRAM The FSC0348 consists of a number of functional blocks as shown below. Key power conversion stages are duplicated, with separate converters for each channel to provide a degree of redundancy.

AC-DC PFC FLYBACK CONVERTER AC IN AC FILTER AC-DC PFC FLYBACK CONVERTER DC IN DC FILTER

OUTPUT FILTER & FUSE

POWER CONTROL TACHO

OUTPUT FILTER & FUSE

POWER CONTROL TACHO

BOOST CONVERTER DC INRUSH LIMITER BOOST CONVERTER

ENABLE INPUT

AUTO / OFF / 100% FRONT-PANEL SWITCH

TEMP. SENSOR

ANALOGUE TEMPERATURE > FAN DEMAND CCT

PIC MICRO

TEMP DISPLAY

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SECTION 7

MAINTENANCE INSTRUCTIONS
1. As a general principle, it is better not to interfere with the control of this type of equipment, provided that the equipment is functioning satisfactory. It is recommended that routine maintenance is limited to simple cleaning and checking that the ventilation paths, etc. are free from obstruction. 2. The equipment should be checked and cleaned of dust, etc. at periods depending upon the operating climate. 3. In the event of faulty operation it is recommended that the fault finding procedures outlined be carried out and/or consult the Customer Services Manager at Erskine Systems Ltd.

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SECTION 8

FAULT FINDING
FAULT Temperature display shows - - No fault LED but fans will not start. Fans run slowly. POSSIBLE CAUSE Thermistor not fitted Thermistor failed Temperature < -9C Temperature below start set point.(20C for AC only, 30C for DC only). Enable link (Con 8 pins 7&8) not linked. Control switch set to OFF. Temperature just above set point. Temperature below DC on threshold (normally 30C). Control switch set to 100%. Only Fan 1 fitted but CON7 in position 2. Fan isolator open. Fan 1 connected to Fan 2 output with CON7 in position 1. Fan connections faulty. Faulty fan. DC input MCB open. No DC available. DC available but not present at controller input. Faulty controller. AC input MCB open. AC supply failed. AC supply healthy but not present at controller input. Faulty controller. ACTION Fit thermistor Replace thermistor No fault Check display. Fit link. If inhibit switch is fitted is this open? Reset to AUTO. Check display. The higher the temperature the faster the fans will run. No fault. Reset to AUTO if required. Move CON7 to position 1. Close isolator. Reconnect to Fan 1 output. Check fan connections Replace fan. Check circuit and close. Check supply. Check wiring and connections Replace controller. Check circuit and close. Check supply. Check wiring and connections Replace controller

Fans run ok on AC but stop on DC. Temperature below set point but fan runs continuously. Fault LED on, fan running. Fault LED on, fan not running.

Fan does not run on DC only.

Fan does not run on DC only, DC supply healthy. Fan does not run on AC only, AC Supply LED off.

Fan does not run on AC only, AC Supply LED on.

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SECTION 9

DRAWING FILE
48V CONNECTION DIAGRAM - S5073XC01 24V CONNECTION DIAGRAM - S5073XC02 ARRANGEMENT - S5073XDA2

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