valere smps gs150a[1]

User Manual

DC Power System – VP GS150A-480 1016

(Sample System)

Installation, Operation & Maintenance Guide

24 x 7 Installation and Technical Support

US: +1-866-240-6614 Singapore: +63 9209149514

India: +91 9899661113

Notice: The information, specifications, and procedures given in this manual are subject to change without notice and manufacturer assumes no responsibility for any errors that may appear in this document.

Document Reference: VPAP-TD1016 Revision 00 May 18, 2006

The Power to Innovate


www.valerepower.com Document Reference: VPAP-TD1016 Revision 00 May 18, 2006

2

Index

Sl. No. Description Page No.

1. Read This First 05 1.1. Welcome 05 1.2. About This Manual 05 1.3. Safety and Recommended Practice 05 1.4. FCC Compliance 06

1.4.1. Note 06 1.4.2. Warning 06

1.5. Terms & Abbreviation 06 2. User’s Comments 07

2.1 General 07 2.2 Feedback Report on SMPS Power Plant 07 2.3 Evaluation of Manual 07

3 System Description 09

3.1 Introduction 09 3.2 AC Distribution 09 3.3 DC System Voltage 10 3.4 DC Output Distribution 10 3.5 Rectifier Shelf 11 3.6 System Features 12 3.7 General Arrangement/Cabinet Size 13 3.8 System Cables/Wires 13

3.8.1 AC Input Wiring 13 3.8.2 DC Output Wiring 13

3.8.2.1 Grounding 13 3.8.2.2 Wire Sizing 13

4 Installation Guide 15

4.1 Warning 16 4.2 Introduction 17 4.3 Recommended Tools for Installation 17 4.4 Un-Packing of System 18 4.5 Mechanical Installation 18 4.6 Earth connection 19 4.7 AC Mains connections 19 4.8 Battery connection 20 4.9 Load connection 20 4.10 Alarm connection 21 4.11 Temperature Probe connection 21 4.12 Installation of SMPS Rectifier Module 22

5 Start up & Commissioning of System 25 5.1 Introduction 25 5.2 Recommended Tools for Commissioning. 25 5.3 Commissioning/Site Acceptance Test 26



3

5.3.1 Pre Start / Initial Checks. 26 5.3.2 System Start up. 26

6 Alarm Controller - Operation Guide 27 6.1 Controller Setup 28 6.2 Table – Controller Setup 29 6.3 Controller Menu Tree – Main Menu 31 6.4 Remote Signal’s PFC connector details 32

7 V Series Wide Range Rectifiers 33 7.1 The Valere Difference 33 7.2 Features 33

8 Replacement of Items 34

8.1 Alarm Controller replacement 34 8.2 Rectifier module replacement 34

9 Troubleshooting 35 Figures Figure-1 AC Distribution 10 Figure-2 DC Distribution 11 Figure-3 Rectifier shelf with rectifier modules 11 Figure-4 Rectifier shelf without rectifier modules 12 Figure-5 Alarm controller connections 22 Figure-6 Rectifier Module insertion 23 Figure-7 Alarm Controller 27 Figure-8 Controller display 28 Figure-9 V Series Rectifier Module 33 Figure-10 Alarm Controller Replacement 34 Figure-11 Rectifier Module Replacement 34

Annexure Annexure-A Feedback Report on SMPS Power Plant Annexure-B Evaluation of User’s Manual Annexure-C System Configuration - Customer Specific Annexure-D System Drawings (Not provided with sample / demo system)



4

1 Read This First

1.1 Welcome

Welcome to Valere Power’s manufactured DC Power System Model No. ‘VP GS150A-480 1016’. GS150 means Global System 150 Ampere plus redundancy - A Modular Power Supply System designed for use with Telecommunications, Industrial automation and all applications requiring high efficiency and uninterrupted standby DC Power.

1.2 About This Manual This User Manual has been written to provide you with all information about the rectifier system and modules incorporated. The next three parts of this documentation contain information that covers all aspects of GS150A-480-1016, related to installation & commissioning.

Details of operation described in the Operation Guide of Alarm Controller. The System Drawings are specific to your system.

1.3 Safety and Recommended Practices

General practices Suitable for mounting on 19” rack. The integrated system accepts an AC Voltage range of 150 to 275Vac, single phase and produces 42 – 56VDC at nominal up to 150 Amperes plus redundancy in an ambient max. operating temperature range of -40ºC to +50ºC.

HAZARDOUS VOLTAGE AND ENERGY LEVELS ARE PRESENT WHICH CAN PRODUCE SERIOUS SHOCKS AND BURNS.

Only authorized, qualified, and trained personnel should attempt to work on this equipment. Refer to the Product datasheets/drawings for full product specifications / understanding.

NOTE: ALL RECTIFIERS EMPLOY INTERNAL DOUBLE POLE/NEUTRAL FUSING Use single/double hole, good quality copper lugs for all DC connections to prevent inadvertent contact with other circuits. Copper wire is recommended for all DC connections.



5

All AC and DC power terminations are rated for 90ºC operation. Minimum wire sizes, based on capacity, are shown in Wire Sizing Para no. 3.8.2.2. of this manual. In practice, loop voltage drop considerations will usually dictate larger than minimum safe wire size. Alarm contacts are not fused internally; therefore current limiting protection for these contacts must be provided by external circuits. The alarm contacts are rated for a maximum voltage of 60 V, SELV (Safety Extra Low Voltage) and a maximum continuous current of 0.5A.Connection. Valere does not recommend shipping the power shelf with the rectifiers installed. Rectifiers should be shipped in separate boxes provided by Valere Power.

1.4 FCC Compliance Statement

1.4.1 Note This device complies with Part 15 of FCC (Federal Communications Commission, Columbia) Rules. Operation is subject to the following two conditions:

i. This device may not cause harmful interference, and

ii. This device must accept any interference received, including interference that may cause undesired operation.

1.4.2 Warning Changes or modifications to this unit not expressly approved by the party responsible for the compliance could void the user's authority to operate this equipment.

1.5 Terms & Abbreviation

List of Abbreviations, used in the Valere Power Product Manuals:

Abbreviations Description A Ampere AC Alternating Current AMPACITY Ampere Capacity C.O. Common Output DC Direct Current ESD Electro Static Discharge FCC Federal Communications Commission of Columbia LED Light Emitting Diode LVD Low Voltage Battery Disconnect MCB Miniature Circuit Breaker PCB Printed Circuit Board PR Power Rack PFC Potential Free Contacts SELV Safety Extra Low Voltage SMPS Switch Mode Power Supply V Volt R Redundancy



6

2. User Comments

2.1 General It is the policy of Valere Power that we shall work actively to ensure that our products are

in accordance with our customer's expectations and requirements. In order to achieve this goal at any part of time, we wish to follow up our products throughout their lifetime. We therefore request your kind assistance.

2.2 Product Report

If you have any technical comments with respect to product specification, performance, maintenance or service, we would appreciate if you would fill in these comments on a copy of the form ‘Product Report’ format provided in this manual (Please refer Appendix-A for Product Report) and return it to us. You may as well contact us by telephone, fax or Electronic mail. We will confirm receipt of all comments received and inform you of changes as a result of your comments and suggestions.

2.3 Evaluation of Manual

We are continually looking for ways to make our products and our manuals as easy to use as possible, you can help us by sharing your comments and suggestions about how our manuals could be made more useful and about any inaccuracies or information gap they might contain. You can submit your comments either by making a copy and filling out the form Evaluation of User's Manual format provided in this manual (Please refer Appendix-B for Evaluation of User’s Manual) or by writing to us via E-Mail or otherwise. We sincerely appreciate your comments about our products.



7

System Description

GS150A-480-1016

Standby DC Power System



8

3. System Description 3.1 Introduction The GS150A-480-1016 DC Power System is developed to support -48 volt telecommunications, industrial automation and similar applications as powering solutions for Global markets. The GS150A-480-1016 combines 50 ampere, fan cooled, switch mode rectifiers modules, microprocessor control technologies, battery disconnect/re-connect options, and a comprehensive line of fuse & circuit breaker for dc distribution options in a modular front-access design. This modularity insures easy access, simplified installation and maintenance, and allows the system to expand in capacity and features as power needs grow. The main emphasis of this manual is to provide a general product description that will familiarize the user with the main components of the system and to provide guidelines for the basic maintenance of this GS150A-480-1016 Power System. The Power System comprise of Switch Mode Plug-in Rectifiers (SMPS), Micro processor Alarm & Control Module, Interface connectors with potential free contacts and AC & DC distribution. All SMPS rectifier modules provide active load current sharing. Shunts are used to measure DC current to/from the batteries. Please refer Annexure-C for shunt rating used in your system. All Load fuses/MCBs of the DC distribution have a common alarm circuitry through Load Breaker Open Sensing Card and Battery fuses/MCBs have the common alarm circuitry through Battery Breaker Open Sense Card. The system provides a high quality standby DC Power and automatic battery charging. The Micro processor Alarm Controller is a plug-in type module, which facilitates Potential Free Contacts (Form-C) for remote monitoring of Alarms. All alarms are potential free and may be connected to external displays/equipment as closed circuit when alarm is reported. Alarm Controller also has the optional feature of Temperature Probe integration, which controls output voltage according to environmental temperature for battery safety/protection. 3.2 AC Distribution This single shelf AC distribution comprises of one external (Optional) Class-B input lightening protection, which is then connected to the AC mains input terminal. Further, connected to mains UV/OV contactor, one (Optional) class ‘C’ input surge protection, and rectifier input MCBs, which are inside the system. The UV/OV controller card is mounted on left side wall of the distribution and visible after opening the front door. All electrical items are fitted as per system ultimate power requirements.



9

You can make the AC mains connections to left side mounted terminal/MCBs (Cable entry).

Fig - 1 AC Distribution with open door front view 3.3 DC System Voltage DC Power System GS150A-480-1016 (Your Power System output DC Voltage) -54Vdc

3.4 DC Output Distribution All electrical items are fitted as per system ultimate power requirements. The single shelf distribution comprises of one LVBD contactor. The number of load breakers/fuse and battery breakers/fuse along with rating of LVBD are as per Appendix-C. The LVD controller is available on right side wall after opening the front opening.

AC Main & Alarm Cable entry holes

Class-‘C’ Protection

Individual Rectifier

input MCBsAC Input Terminals

AC UV/OV

Contactor



10

The return bus bar (+ve) is available above the load and battery breakers profited with clinch nuts. The Micro Processor Alarm Controller is mounted on front left hand side. The display is visible from the front. You can operate the controller through keypad available at display.

Fig – 2 DC Distribution with open door front view

Please refer the following: • Annexure-C for details of the ratings • Annexure-D for details of Schematics, General arrangement drawings.

DC Load & Battery Cable

entry hole

-Ve Bus Bar

+ve Bus Bar

Load & Battery MCBs & Fuses

LVBD Contactor & Shunt



11

3.5 Rectifier Shelf This rectifier shelf comprises four rectifier slots. In full capacity (200A-48V) all the slots are pre wired. The system power can be increased by just adding the rectifiers. There is no need to put extra wiring and controller. The blank slots may be covered by dummy plates/rectifiers.

Fig – 3 Rectifier Shelf with V series rectifiers

Fig-4 Rectifier Shelf without rectifiers

Rectifier Modules

Rectifier shelf

Rectifier Back Plane

Micro Processor Alarm Controller

Temperature Probe

connector

PFC Connector

Rectifier Shelf

Rectifier AC input connector

Rectifier Slot

Rectifier DC output connector



12

3.6 System Features The following features have been provided in your system. ♦ LVD (Low Voltage Disconnect)

To prevent the battery (ies) from deep discharge, DC contactor is used in battery path. This also has been

incorporated with one by-pass switch for force mode operation.

♦ Battery Current Limiting (BCL)

When Battery is in deep discharge condition and the charging resumes, it may take more current than safer value. To avoid this, Battery Current Limit circuitry has been provided, which monitors battery-charging current and limits it, in case, it tries to exceed specified limit i.e. 5% to 20% of Battery AH capacity. This is a likely if battery is connected. You may set the BCL limits, as required.

♦ AC Over Voltage Cut off

System is protected for any damage from AC over voltage beyond 275V±2%.

♦ AC Lower Voltage Cut Off

Lower voltage protection to system for AC low voltage at 150V±2%.

♦ Input Surge Suppressor

In addition to the build in class ‘D’ protection at each rectifier module, system is incorporated with Class ‘C’ input surge protection at System level. These are provided in line- neutral & neutral- earth paths.

♦ Temperature Sensor

During charging of battery (ies), output voltage is controlled in accordance to out side temperature have better battery (ies) life.

♦ Audible buzzer

Buzzer integrated to have alarm audible with option of its ON/OFF switch.



13

3.7 General Arrangement/Cabinet Size.

The cabinet size of GS150A-480-1016 DC Power System is: Mechanical dimension: 480(W) x 350(D) x 350(H) mm for 19” rack mount system. Please refer Annexure ‘D’ for details of Schematics, General arrangement drawings. 3.8 System Cabling/Wiring

3.8.1 AC Input Wiring The single phase AC main supply is connected through Class-C input surge arrestor (should be installed by customer out side DCPP & at AMF panel) to AC mains input terminal (Phase, N & E). AC power is fed internally to rectifier modules through pre-wired AC mains input terminal, rectifier input MCBs, UV/OV contactor and Class ‘C’ protection provided in the system. 3.8.2 DC output wiring 3.8.2.1 Grounding System polarity is determined by the system grounding. For a positive ground system (i.e. -48V system) the positive output of the system must be grounded to the C.O. (Common Output) ground. 3.8.2.2 Wire Sizing There are two main considerations for sizing DC wire, Ampacity and voltage drop. Ampacity refers to a safe current carrying level as specified by non-profit organizations such as Underwriters Laboratories and the National Fire Prevention Association, which publishes the National Electric Code. Voltage drop is simply the amount of voltage loss in a length of wire due to ohmic resistance of the conductor. DC wire may be sized for either ampacity or voltage drop depending on branch load loop length and conductor heating. In general, ampacity considerations will drive wire selection for short loop lengths (less than 50 feet) and voltage drop will drive wire selection for long loop lengths (greater than 50 feet). ALWAYS FOLLOW THE ELECTRICITY REGULATIONS VALID FOR THE INSTALLAION AREA AND YOUR LOCAL COMPANY PRACTICES WHEN MAKING FINAL SELECTIONS FOR AC & DC WIRING AND PROTECTION. ACCORDING TO THE NEC RULES WHICH ARE APPLICABLE FOR NORTH AMERICA, THESE RULES MAY BE USED AS GUIDENCE FOR INSTALLATION IN OTHER AREAS.



14

All Valere power plants are rated for usage with 90ºC wires. Below Table shows MINIMUM recommended wire sizes for various current ratings.

Current Protector Rating (A) Wire & Lug Gauge (AWG) using 90° C

wire (NEC Table 310.16) 1 18* 5 18*

10 16* 15 14 20 12 30 10 40 8 50 8 75 6 100 2 125 2 150 1 AWG 175 2/0 AWG 200 3/0 AWG 225 3/0 AWG 250 4/0 AWG 300 (1) 300 MCM or (2) 1 AWG 400 (1) 500 MCM or (2) 3/0 AWG 450 (1) 600 MCM or (2) 3/0 AWG 500 (1) 700 MCM or (2) 4/0 AWG 600 (2) 300 MCM or (3) 4/0 AWG 700 (2) 350 MCM or (3) 4/0 AWG 800 (2) 500 MCM or (4) 4/0 AWG

* - For wire sizes less than 15 A not covered in NEC Table 310.16 use Table 3B - Sizes of Conductors, UL60950, "Safety of Information Technology Equipment", Dec., 2000 for non-building wiring.

Table - Recommended DC AWG for 90° C Cabling

NOTE: For lugs and cable size, please refer Annexure ‘D’



15

4. Installation Guide

GS150A-480-1016




16

4.1 Warning

Warning

Valere Power’s personnel must only work with the equipment described in

this manual or Personnel who have attended a suitable Valere Power’s training course. The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warrantee. There are hazardous voltages inside the power system. The rectifier units include large charged capacitors; therefore it is dangerous to work inside the system even if the mains supply is disconnected. Ensure that system is connected with proper Protective Earthing and Chassis Grounding. Grounding resistance should not be more then 10 Ohm. Ensure that surrounding area to the system is free from all environmental hazards such as dust, inflammable & explosive materials. Also, ensure that system is mounted at a solid concrete plinth which is sufficiently high to take care of cooling air passage from its bottom. Lightening/Surge Protection Box is to be installed outside the system. Before making any connection to System, please ensures that lightening protection is installed & wired properly. If lightening protection is not installed, manufacturer will not be responsible for any damage due to Lightening & Surge. Manufacturer will not be responsible for any damage occurred in the system or to individual due to any of the above mentioned points, in case requested care is not taken. Please read the User Manual Carefully before using the equipment.



17

4.2 Introduction This chapter guides you step by step through: Unpacking Mechanical Installation Battery Installation All cable connections Installation of Modules

Whenever a drawing is needed to support an installation step, you will find the referred drawing in the Annexure -D Ensure all AC and DC power sources are off and disconnected. To the extent possible ensure a clean (free of debris, dust, foreign material, etc.) work environment.

Have all tools, wire, cables, hardware, etc., within easy reach.

The Valere power’s power system employs bottom to top airflow via self contained fans. Care should be taken when mounting the system at locations that present an airflow blockage on the bottom surface of the system. Allow at least 1.75” (44.52mm) of unrestricted clearance for proper airflow, if any blockages are present. For maintenance purposes, only the front of the cabinets needs to be accessible at most of the time. Please check cabinet mounting detail provided in Annexure ‘C’ & ‘D’. 4.3 Recommended tools for Installation Valere Power’s systems are designed to be installed with a minimum number of commonly used standard equipment/Authorized electrician available tools. • #1 & #2 Phillips Screwdrivers • #1 & #2 Flat Head Screwdrivers • Set of Box Wrenches, Ratchet Set, or Nut Drivers • Wire and Cable Strippers suitable for the wire size selected • Wire and Cable Crimpers suitable for the wire size selected • Pliers (Flat & Long Nose) • Digital Multimeter Note: Use insulated tools when working on a live system!



18

4.4 Unpacking of System Contact Valere Power’s sales or technical support immediately if any damage is observed.

Some of the cabinets/parts may weight in excess of 50 KG. If required, the appropriate lifting equipment should be used and care must be taken whilst handling these units.

# Installation Step Comments OK 1 Remove Packaging The system is covered with polythene sheet,

extended PE foam sheet on all sides of system and packed in a wooden/corrugated box. These must be removed before the cabinet is removed. Check that the received equipment is according to packing list provided within system documents envelop. Inspect all the equipment’s parts for any transport damage.

2 Mount the system in the required 19” cabinet.

Please refer System mounting type at Annexure ‘C’

4.5 Mechanical Installation

The System must not be located in an explosive atmosphere i.e. flammable gases and fumes. There must be suitable ventilation for the batteries.

# Installation Steps Comments OK

1 Remove the cabinet front/top cover/panel(s) on the upper portion.

Necessary for accessing the connection terminals.

2 Rack mounting. (Verify, if system is designed for Rack mounting?)

Use proper size mechanical channels to match the Rack frame holes and system grouting holes.

3 For Wall mounting (Verify, if system is designed for Wall mounting?)

Ensure that wall is of concrete and should be able to sustain the load of system. Make appropriate holes in the wall by concrete drill machine as per system holes. (Refer the system mounting drawing attached at Appendix ‘D’). Put the grouting bolts into the holes, mount



19

the system and fasten the grouting bolts with proper size of washers and secure the cabinet to the wall.

4 External Cables Cable entry for Earth (PE & Telecom), AC Mains, DC loads, Battery (ies), Alarm PFCs and (Optional) Temperature Probe cables.

4.6 Earth Connections

# Installation Steps Comments OK 1 Chassis Earth To prevent electric

shock, the rectifier and battery cabinet chassis must be connected to a protective Earth.

2 Protective Earth The incoming mains to the System must contain a Main's safety earth and should be connected to protective earth terminal provided in system.

3 Telecom Grounding The System has been configured for Negative distribution. +Ve Common Terminal can be connected to Telecom earth, if desired.

4.7 AC Main Connections Connect the System to a suitable rated MCB of your ACDB Panel. Please refer Annexure ‘C’ for AC Mains input configuration

Always Switch OFF the External AC Mains supply before the Mains cable is connected to the Mains terminals. The Cabinet earth terminal is located along with the mains terminal on the right side.



20

# Installation Steps Comments OK 1 AC Main connection Connect the Mains input

to the system. Open the front of AC distribution and see the AC mains input terminals/MCB at left side of front mounting plate. Connect LINE, NEUTRAL and EARTH to terminals/MCB as marked.

4.7 Battery Connection

Before connecting batteries: remove all metallic object like rings, watches etc. from your hands for safety reasons. Remove Battery HRC Fuse/Switch OFF Battery MCB before making battery connection with DC Power system.

The batteries are to be installed as recommended by the battery manufacturer. For battery connections in your system, you may make the following color coding on the battery cables:

Battery connections

Blue (-) Negative terminal

Black (+) common Positive terminal

# Installation Steps Comments OK 1 Battery Connection Up to one string of battery may be

connected via the battery connection Fuse. Connections are made with proper size ring tongue lug or line lugs

4.9 Load Connections DC connections are accomplished via the Load breakers and Battery fuses/MCB. Common return bus bar is available for load and battery return connections. The max tongue width of lugs allowed for standard landings is 0.83”. Any tongue width larger than that max value will require special landings that will reduce the number of connections points



21

# Installation Steps Comments OK 1 Connect the Load(s) to the blade

fuses First Only applicable if load HRC fuse is available and the load current is in excess of the Load MCB ratings.

Connect Positives to the Common terminals.

2 Connect Load(s) to the MCB(s) Connect Load circuits as per the rating of the MCB. Connect Positive to the Common terminals.

4.10 Alarm Connections (See figure-5) Three form ‘C’ Dry relay contacts are available through a controller connector. Multi core cable having self mating connector on one end and bare tinned pre-defined color coded wires on other end is provided along with the system for extending various alarms generated by DC Power System. Alarm Contacts of different Alarms may also be used in parallel in locations where alarm transport capacity is limited.

# Installation Steps Comments OK 1 Potential Free Connection.

(Please refer Para 6.4 for PFC Details)

Connect the required PFC connections. PFC Connected (to be filled-in by User): 1. _____________________________

2. _____________________________

3. _____________________________

4. _____________________________

5. _____________________________

6. _____________________________

4.11 Temperature Probes (Optional) (See figure-5) Battery temperature probe having one ring terminal on one end of Shielded cable and self mated connector on the other end is provided as an Optional along with DC Power System for activation of battery temperature compensation charging. Attach the ring terminal of this shielded cable to a battery post and insert the self mated connector to the connector available on Alarm Controller. You may



22

extend the temperature alarm through the pre-defined alarm cable provided along with the system and discussed at Para no. 4.10 above. The controller will automatically detect a contact closure and set a minor alarm. (Please refer Annexure ‘D’)

Fig – 5 Alarm controller connections

# Installation Steps Comments OK 1 Temperature Probe connection Connect temperature probe one end terminal

as shown in figure 5 above and connect second end with battery bank.

4.12 Installation of SMPS Modules (See figure-6)

# Installation Steps Comments OK 1 Plug in the new SMPS Rectifier

module

Install each rectifier module sequentially by sliding and latching each rectifier into a shelf position. The rectifier latches must be open for installation. Attempting to install the rectifiers with the latches closed will result in mechanical damage to the rectifiers and the shelf.

2 Lock the SMPS handle Refer the figure-6

Temperature Probe Connector

Buzzer Connector

Alarm Cable Connector



23

Fig – 6 Rectifier modules Insertion



24

System Start up and Commissioning

GS150A-480-1016




25

5. System Start up and Commissioning 5.1 Introduction The Commissioning / Site Acceptance Procedure verifies that the system is correctly installed and operating satisfactory. The procedure should be completed by the commissioning/site Engineer and signed by him and a customer representative. Please consult the operation Guide for the Alarm Module in case any of the system parameters needs to be changed. 5.2 Recommended tools • Standard equipment for an Authorized electrician. • Digital Multi meter Note: All tools should be insulated.



26

5.3 Commissioning / Site Acceptance Procedure 5.3.1 Pre Start / Initial Checks

Check Following OK

1. System Installation is completed. Check that the System installation has been correctly performed. (Refer Installation Guide Para no. 4 of this manual).

2 Battery and load are disconnected. Verify that the battery and Load fuses are not connected and load MCB’s are in off position.

3. Rectifier Modules are connected. Verity that all rectifier Modules are plugged in and the latched.

4. Rectifier System connected to Mains supply and protective Earth. Check that the system mains cable is connected to the mains supply through Class ‘B’ protection. Also ensure that system is provided with protective earth.

5. Mains MCB’s are connected to the system Verify that the mains circuit breakers are in OFF position.

6. Rectifier Module Individual input MCB Ensure that all input MCBs of all the rectifier modules are kept at OFF position

5.3.2 System Start Up

Check Following OK

1. Connect Battery to System. Insert HRC battery fuse or switch ON Battery MCB (as applicable)

2. Turn the System ON Turn ON the MAINS circuit breaker.

3 Read the AC Main Voltage Note the AC main voltage through the Digital Display Meter

Vac

4. Power up the rectifier module After 30 – 60 sec, AC Contactor will get energized. Power up one rectifier module by switching ON the respective input MCB.

5 Read output voltage Wait for about 1 min. and read the output voltage on the alarm module’s display

Vdc

6 Measure output voltage Use a Digital Voltmeter to verify that the output is in accordance with the system's Voltage.

Vdc

7. Read the AC Main Voltage Power up rest all rectifier modules by respective MCBs

8 Rectifier Modules are ON and without fault alarms Verify that the SMPS modules are in normal mode of operation (not reportingany Alarms).

8 Connect the loads : Turn on load MCB’s to put Load on the System.



27

6 Alarm Controller – Operation Guide

Fig – 7 Alarm Controller



28

6.1 Controller set up The controller is equipped with factory settings shown at Para 6.2 to assure safe power up operation. Fig-8 below shows the controller front display and three button keypad. Refer Para 6.3 for complete menu tree for the controller. The UP and DN buttons are used to scroll through the functions and the MENU button is used to select and/or drop down into a sub-menu.

Figure 8 - Controller Display

There are three controller menu levels, Basic, Main, and Log-IN. When the controller displays “System Float”, the controller is at the Basic menu level. The UP/DN buttons can be used to sequentially view basic plant parameters such as float voltage and plant current, temperature compensation state, battery temperature (N.C. if not connected), and internal plant temperature. By holding the MENU button down for 5 seconds, the Main level is accessed. All plant parameters can be viewed from this level by scrolling to and selecting “Review.” Follow the menu tree for exact navigation directions. By scrolling to and selecting “Log In”, the Administrator level is accessed. The default password is “5001”. This level allows you to make changes to all the plant settings



29

6.2 Table - Controller Settings

Parameter Description 48 Volt Nominal

Float Voltage The voltage to which the rectifiers will regulate the plant during float mode 54 Vdc

Fallback

Rectifier float voltage will revert to nominal value in the event of a controller failure or removal. If disabled the rectifier will stay at last float voltage setting Disabled

Fallback V Safe rectifier voltage 48 Vdc Batt CL Enable* Enables the battery current limit feature Disabled

Batt CL Setpoint* The controller will limit the current to the batteries at this setpoint 600 A

Rect CL Enable Enables the system current limit feature Disabled Rect CL Setpont The controller will limit the current of the rectifiers to the value 200 A

HVSD Setpoint The controller will shut down the rectifiers if the plant voltage exceeds this setpoint 58 Vdc

HVA Setpoint The controller will issue a High Voltage Alarm if the plant voltage exceeds this setpoint 57 Vdc

BD Alarm The controller will issue a Battery-On-Discharge alarm if the plant voltage falls below this setpoint 48 Vdc

Capacity Alarm A minor alarm is set if the number of installed rectifiers will not support N+1 redundancy required by the load. Disabled

I Share Alarm A minor alarm is set if the output current of any rectifier exceeds current sharing tolerances Enabled

Com Alarm

A minor alarm is set if any rectifier either stops communicating or is removed from the shelf. User action is required to clear the alarm Disabled

Boost Enables or Disables the equalize/boost charge tests Disabled Boost Voltage The voltage at which the equalize/boost charge test will begin 58 Vdc Boost Time The time at which the equalize/boost charge test will end 12 hours TComp Enable Enables thermal compensation Disabled Hi Temp Thermal Comp Start Temp

The controller begins to reduce the float voltage when the highest measured battery temperature reaches this value 35 °C

Hi Temp Thermal Slope

If battery temperature is above the start temperature, the controller will linearly reduce the plant voltage by this slope 72 mV/°C

Hi Temp Thermal Comp Stop Voltage

The minimum voltage to which the controller will reduce plant voltage for thermal compensation 50.5 Vdc

Lo Temp Thermal Comp Start Temp

The controller begins to increase the float voltage when the lowest measured battery temperature reaches this value -20 °C

Lo Temp Thermal Slope

If battery temperature is below the start temperature, the controller will linearly increase the plant voltage by this slope 0 mV/°C

Lo Temp Thermal Comp Stop Voltage

The maximum voltage to which the controller will increase plant voltage for thermal compensation 56 Vdc

Thermal Runaway Clamp Temp

The temperature at which the controller will reduce the Float Voltage to Runaway Clamp Voltage 60°C

Thermal Runaway Clamp Voltage

The Float Voltage to which the controller will reduce for temperatures above Runaway Clamp Voltage 50 Vdc



30

Parameter Description 48 Volt Nominal

Thermal Sense

Selects temperature sensing device to use for battery temperature compensation; Internal sensor or External temp probes. Auto senses when external probe is attached and automatically adjusts value to external. External

Temp. Units Selects the units the temperature readings are given in. Either Celsius or Fahrenheit Celsius

LVD Warning** The controller will issue a Low Voltage Disconnect Warning if the plant voltage falls below this setpoint 44 Vdc

LVD 1 Open** The system LVD contactor will open if the plant voltage falls below this setpoint 42 Vdc

LVD 1 Reconnect**

The system LVD contactor will reconnect if the plant voltage exceeds this setpoint 50 Vdc

LVD 1 Reconnect Delay Time**

The amount of time that the plant voltage must exceed the LVD reconnect setpoint prior to reconnecting the LVD contactor 20 Sec

LVD 2 Open** The 2nd system LVD contactor will open if the plant voltage falls below this setpoint 42 Vdc

LVD 2 Reconnect**

The 2nd system LVD contactor will reconnect if the plant voltage exceeds this setpoint 50 Vdc

LVD 2 Reconnect Delay Time**

The amount of time that the plant voltage must exceed the 2nd LVD reconnect setpoint prior to reconnecting the 2nd LVD contactor 20 Sec

Batt Test* Enables or Disables the battery test Disabled BD Time* Sets the length of time (minutes) that the battery test will run. 30 min

BDT Alarm* Sets the voltage at which an alarm will be generated if the battery voltage falls below it during the Bat Test 52 Vdc

BDT Abort*

The voltage at which the battery discharge test will abort at when the system voltage drop below this point. This is a user settable value that should be at least 2V below BDT Alarm. LVD1 Open

BD Test Constant*

Sets the alarm constant for the Bat Test. 0 will disable Thermal Compensation effects during BD Test. 1 will take Thermal Compensation effects into account during test 0

RLY Test Enables or Disables the relay test Disabled Ringer Frq*** Frequency of the ringer (17 Hz - 50 Hz) 20 Hz Ringer RMS*** The root mean square of the ringer voltage (85 V - 105 V) 86 Vac Ringer DC Offset***

The DC value at which the Ringer RMS value is offset. The value should be the same value as the float voltage. -Vfloat

Ringer Select*** Selects Ringer A/B A Password Administrator/User 5001/1001 * - Requires LVD and/or proper Shunt ** - Requires LVD *** - Requires Ringer



31

6.3 Controller’s Operation Menu Tree



32

6.4 REMOTE SIGNAL’S PFC CONNECTOR DETAILS Single Core wires of 0.25 to 0.5 Sq. mm size can be connected to Connector/WIRE and your radio communication equipment for remote alarms through potential free contacts as per following PIN/WIRE Connection description:

Relay Name Alarm Name Wire Color Code SIGNAL DESCRIPTION

Orange Common Contact Orange-Black Normally Open Contact Relay ‘A’ Power Major Orange-White Normally Close Contact Red Common Contact Red-Black Normally Open Contact Relay ‘B’ Power Minor Red-White Normally Close Contact Green Common Contact Green-Black Normally Open Contact Relay ‘C’ AC Fail Green-White Normally Close Contact Yellow Common Contact Yellow-Black Normally Open Contact Relay ‘D’ Battery on

Discharge Yellow-White Normally Close Contact Blue Common Contact Blue-Black Normally Open Contact Relay ‘E’ LVD Open Blue-White Normally Close Contact Brown Common Contact Brown-Black Normally Open Contact Relay ‘F’ Common

Alarm Brown-White Normally Close Contact

IMPORTANT NOTE CONTACT RATING OF POTENTIAL FREE CONTACTS IS 0.5AMP, 48VDC. PFC CABLE IS TO BE CONNECTED FROM FRONT IN THE ALARM BACK PLANE. Conditions under which Major, Minor & Common alarms shall appear:

Major Alarm Minor Alarm Common

AC Fail Redundant Capacity Any of the available High Voltage Warning Current Share alarms High Voltage Shut Down Auxiliary Alarm Battery on Discharge High Temperature Any LVD Warning Any LVD Open Distribution Open Single Rectifier Fail Multiple Rectifier Fail System Communication

Optimization – Valere Power rectifiers are optimized for

the demanding power needs of wireless communica-

tions, enterprise and broadband access equipment.

SMALL SIZE, BIG POWER – At only 2RU, these compact

rectifiers can provide up to 2800 Watts of power. The

small size can free up space to reduce system size or

incorporate additional electronics.

Industry Leading Efficiency – An industry leading 92%

efficiency reduces the thermal load thus improving the over-

all reliability and availability of the system.

Flexibility – These rectifiers are designed to operate as

an integral component in Valere’s Compact, Integrated,

Modular or Enterprise DC Power Systems. They are

extremely flexible and can be operated either with a

system controller or as a stand-alone module in telecom-

munication and enterprise applications.

7 . V S E S I R E S W I D E R A N G E R E C T I F I E R S

Valere rectifier modules provide unprecedented

power density and power levels in a true plug and

play format. With a wide range of available

voltages, power ratings, and form factors, the

rectifiers allow optimal system design and cost

effective deployment from initial install through

future upgrades.

• 150VAC to 300VAC Input

• Up to 92% efficiency

• Power Factor Correction

• Hot Pluggable

• Front panel LED indicators

• I2C Serial Communications bus

• AC Fail Alarm

• DC Fail Alarm

• Over-temperature Alarm

• Meets General Requirements

7.2 FEATURES

7.1 THE VALERE DIFFERENCE

Toshiba

Installation, Operation & Maintenance Manual

Toshiba

www.valerepower.com Document Reference: VPAP-TD1016 Revision 00

Toshiba

May 18. 2006

Toshiba

Fig-9 V Series Rectifier Module

Toshiba

33



34

8 Replacement Items 8.1 Alarm Controller Replacement In the event of a controller failure, the system will remain at the last known settings until a new controller is installed. To replace the controller, remove the display by unlatching the wire harness connector and releasing the spring latch. Loosen the controller set screw and slide the controller out of the shelf. Insert new controller and reattach display. Follow the controller set-up procedure of the Operation Guide to re-initialize the system.

Fig-10 Alarm Controller Replacement

8.2 Rectifier Module Replacement In the event of a rectifier module failure, the system will continue to run with other rectifier modules until a new rectifier module is installed. Switch-off the respective input MCB of rectifier. Remove the rectifier module by pressing the small press button and pulling the lever as shown in the figure below. Insert the new rectifier module and lock it with the front lever. Switch ON its respective input MCB.

Fig-11 Rectifier Module replacement

Remove the Display by unlocking its front.

Remove the PFC Ribbon cable & Temperature Probe

Open the mounting screw.

Slide out the module.

Press the knob of failed module

Pull the lever out.

Slide out the module

Slide in new module

Close the lever



35

9 Trouble Shooting The modular, plug-n-play nature of this plant makes diagnostics and repair very easy. For all conditions listed in the alarm matrix, the controller will display the indicated alarm. The corresponding Form C relay will also toggle to the alarm state.



36

Make sure that all rectifiers are properly seated and latched into their respective slots. Make sure that all power and signal connectors are properly mated. Table below lists problems and potential solutions.

Alarm Problem Solutions Minor Alarm Rectifier Current Share, System

Redundant Capacity Alarm, Auxiliary Alarm, System Over Temperature

Replace bad rectifier or ringer unit.

Major Alarm Single Rectifier Failure, Multiple rectifier failure, single rectifier failure leaving only one rectifier left working, Battery on Discharge, AC Mains Fail, LVD Warning, LVD Open, Distribution Alarm, System Communication alarm, High Voltage Alarm, or High Voltage Shut Alarm

Replace rectifier unit(s) in alarm. Adjust BD and LVD settings.

AC Fail Commercial power has been lost. Reset commercial circuit breaker to the dedicated AC circuit that feeds system. Seek alternative power source until power is restored.

BD Alarm The system voltage has fallen below the BD (batteries on discharge) alarm level.

Consider replacing batteries in the near future before they are depleted.

LVD Alarm The battery voltage has fallen below the LVD Alarm value. The LVD is very close to opening.

Connect more batteries or find alternative power source before LVD opens.

LVD Open The battery voltage has fallen below the LVD OPEN value and the batteries have been disconnected from the system.

Replace batteries or find alternative power source.

Dist. Alarm Fuse open or circuit breaker tripped. Circuit breaker is turned off.

Reset circuit breaker or replace the fuse. Turn circuit breaker on.

Temp. Comp. Active

Plant Voltage drops with increasing temperature

Temperature compensation is in effect reducing the output to the batteries. This is adjustable and may be disabled.

Thermal Runaway

Temperature of batteries has exceeded the Thermal Runaway temperature.

Float voltage has automatically been lowered in an attempt to lower the temperature. If this has not solved the problem, disconnect batteries from the system

Comm. Alarm Controller has lost communication with one or more rectifiers or ringers

Replace the removed module(s) in the same shelf slot (s). This alarm can also be cleared when display indicates “ HIT MENU TO CLEAR”



37

I SHARE Alarm One or more rectifier(s) is not sharing the total system load equally.

Review the current output of the module(s) in the Review: Module menu. Replace the faulty rectifier(s).

Capacity Alarm The total load current has exceeded the summed current capacity of “N” number of rectifiers in an “N+1” redundant system.

Add more rectifiers or reduce system load to maintain redundancy. This can often occur on an initial system turn up when new, completely discharged batteries are charging. Simply wait till the batteries are charged.

Auxiliary Alarm Indicates a contact closure at the AUX INPUT on Temperature Probe

Check the input contact closure you attached to this Auxiliary Alarm.

BD Test Fail Battery voltage dropped below BDT Alarm value during battery discharge test.

Batteries are nearing end of life. Consider replacing the batteries.

High V System voltage has exceeded the High Voltage Alarm value. Indicates a problem with a rectifier or controller.

Check float voltage settings versus High V alarm value. Float voltage value should be lower than High V alarm. If values OK, replace faulty rectifier or controller.

HVSD System voltage has exceeded the High Voltage Shutdown value.

Replace faulty rectifier or controller.

Temp Alarm External or Internal temperature has exceeded the maximum temperature values

Lower the temperature in the cabinet. If temperature is within acceptable levels, your Temperature values may be too low. These values can be adjusted through the LAN or modem interface only.



38

Product Report Date:

Company Name:

Site Name:

Site Address:

Report Originator’s Name & Designation:

Phone No.: Fax No.:

Mobile No.: Email: Product Name: System Serial No. Description Please give as detailed information as possible. This will simplify our analysis & corrective action.

Please forward this product report to:

Email: [email protected]

To be filled by Valere Power Received, Name & sign. Date Action taken by & sign Date

Feedback Report No. Date Checked By Approved by

Remarks

Annexure -A



39

EVALUATION OF USER'S MANUAL

Date: ο Customer (Operator) ο Valere Power Authorized Service Provider ο Telecom Equipment Supplier ο Other, please specify

Company Name:

Site Name:

Site Address:

Evaluation Person Name & Designation:

Phone No.: Fax No.:

Mobile No.: Email:

Evaluation of User Manual : Low High

Rating From 1 to 6 1 2 3 4 5 6 1. Contents of Information in the text 2. Contents of drawings and illustration 3. Use of Language, Symbols 4. Logical build up 5. Layout 6. Paper format, binding 7. Ease of use 8. Comparison with other Companies Manuals 9. Others, please specify: 10. Remarks, if any:

Please, forward this evaluation report to following address:

+91(124) 4102268 Tel. +91(124) 4102269

Fax +91(124) 4102257

VALERE POWER INDIA PVT. LTD. #405, Galleria Tower, DLF City, Phase-IV, Gurgaon-122 002 (Haryana) India Email [email protected]

ERRORS IN USER'S MANUAL Please, specify all printing errors, drawing errors, faulty specification, references, etc. Please, also specify on that what page(s) the errors occur, or send some examples.

Annexure – B



40

SYSTEM CONFIGURATION: CUSTOMER SPECIFIC

CUSTOMER NAME: TD Vietnam System: GS 150A-480-1016 (Sample / Demo)

S. No.

Description Provided/ Not Provided

Rating/Remarks

System Configuration

1 Input AC Voltage 230Vac 50Hzs Single Phase 2 System Output -54Vdc 3 System Mounting 19’’ Rack Mounting 4 Rectifier Rack Capacity 4 150A+R 5 No. of rectifiers Modules Provided Qty-04 in System Type 150A+R

AC Input configuration

6 Line & Neutral Provided UIK 16 7 Protected Earth Provided USL 10 8 Individual Rect. Mod MCB Provided 32 A SP Qty. 4 Nos 9 AC Contactor Provided 3 pole 25A/230Vac

DC Output Configuration

10 Battery HRC Fuse 125A Provided Qty-01 11 Battery Contactor 100A/54 Provided Qty-01 12 Battery Com Shunt Provided 150A/50mV 13 Load MCB 63A Provided Qty-05 14 Load MCB 16A Not provided 15 Load MCB 6A Not provided 16 Load MCB 32 A Not provided

Optional Parts

17 Lightening Protection Class ‘B’

Not provided

18 Surge Protection Class ‘C’ Provided Single Phase (L-N and N-PE)

19 Temperature Probe Provided 01 each

Annexure -C



41

SYSTEM DRAWING: CUSTOMER SEPCIFIC

S.NO. DESCRIPTION

1 System Isometric view with all covers

2 System isometric view without top covers

3 Detail ‘A’ - AC Distribution

4 Detail ‘B’ - DC Distribution

5 Wiring Diagram

6 Drawing System in Packed condition

7 Drawing System Un-packing steps

8 Site Cable Details

9 System Mounting on Rack

Note: Drawings not provided with sample / demo system.

Annexure -D

Documents

valere smps gs150a[1]