VNP 52000425

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PS250164 Revision / Page 1 of 2

POWER SUPPLY SYSTEM PPS32.48

INSTRUCTION MANUAL

CONTENTS: DOCUMENT: CHAPTER TITLE: REVISION:

PS250164 Title page Rev: / PS100080 Introduction to the manual Rev: D PS100088 Safety Rev: C PS160130 (039340.fm) Technical Product Description – PCC Concept Rev: / PS160131 (038793.fm) Technical Product Description – PCC Rev: / PS160132 (039367.fm) Technical Product Description – PCC Interface Boards Rev: / PS160263 Installation Guide PPS16.48/32.48 - PCC+FMP Rev: A PS160134 Commissioning PPS/PPRD16.48/32.48 - PCC Rev: A PS160023 Maintenance and Troubleshooting Rev: / ENCLOSED DRAWINGS

PS160198 Menu Tree, PCC Controller with Display Rev: / PS250162 Cabinet Layout for PPS32.48-PCC+5xFMP/20U/23" Rev: / PS160135 Schematic Diagram PPRD16/32 - PCC LVD only Rev: / PS160133 PCC - Connection of Alarms, Sym and Temp Sensing Rev: / PS160336 PCC Configuration Table Rev: / PS250163 Distribution 3x Batt MCB / 18x Load MCB Rev: / CHECKLISTS

PS100546 Installation Checklist Rev: A PS100547 System Commissioning Checklist Rev: A PS100548 Battery Commissioning Checklist Rev: A PS100549 Maintenance Checklist Rev: A

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Instruction Manual

Document Number: PS250164

Revision: /

Date of Issue: 29.05.07

System: PPS32.48 – PCC + 5xFMP32/23”/20U

Output voltage: 48V

Publisher: Power-One Pte Ltd

27 International Business Park

Primefield-Landmark Building, #03-02

Singapore 609924

Website: www.power-one.com

Amendment record:

Revision (Issue)

Description Author Date

/ First Issue Raymond Hoe 29.05.07

Originated Raymond Hoe Date 29.05.07 Approved Teo Kim Huat Date 29.05.07

INTRODUCTION TO THE MANUAL ___________________________________________________________________________________________

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PS100080 Revision D Page 1 of 3

INTRODUCTION TO THE MANUAL

This manual provides the user with the necessary information to understand how the Power Supply System is made and functions, together with sufficient information to enable the user to safely install, commission, maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be used by professional and properly trained personnel selected by our customers.

The information contained herein was applicable at the time the manual was ready for printing. Power-One reserves the right to change specifications and designs without notice and without incurring obligation or liability.

This manual is the work product of Power-One and embodies confidential proprietary data in which Power-One retains all rights, including exclusive right of use, reproduction, distribution and sale. It is submitted under a confidential relationship for a specific purpose, and the recipient agrees by accepting this work product, not to supply or disclose any information regarding it to any unauthorized person.

Page 5 of 14

Page Numbering The pages are numbered consecutively within each chapter, prefixed by the current page and the total numbers of pages, as illustrated below. The grey area is an illustration of a page footer.

Current page

Total pages in chapter

The pages are numbered consecutively within each chapter

Document # and Revision #

Symbols and conventions The following words and symbols found throughout this manual are meant to highlight particularly important matters regarding specific information concerning the personnel, equipment or the process.

NOTE! The text set off in this manner present an important piece of information that is essential to highlight.

Caution! The text set off in this manner provides warning notice that failure to follow these directions can result in damage to equipment.

WARNING! The text set off in this manner provides warning notice that failure to follow these directions can result in bodily harm or loss of life and/or extensive damage to equipment


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Abbreviations The following abbreviations are used in this manual:

Abbreviation: Description: PPS Power-one Power System OPS Outdoor Power System PMP Power-One Modular Power PCS Power-One Control and Supervision PPR Power-One Power Rack PBDU Power-One Battery Distribution Unit PBC Power-One Battery Cabinet PCU Power-One Control Unit PDU Power-One Distribution Unit PPRD Power-One Power Rack with DC Distribution PPC Power-One Power Supply Cabinet PBF Power-One Battery Fuse Unit PCB Printed Circuit Board LVD Low voltage disconnection PLD Partial load disconnection MCB Miniature circuit breaker MCCB Moulded case circuit breaker

This marking shows that the product should not be disposed with other wastes at the end of its working life. To prevent possible harm to the environment or human health from uncontrolled waste disposal, please separate this product from other types of wastes and recycle it responsibly to promote the sustainable reuse of material resources.

Users should contact their supplier and check the terms and conditions of the purchase contract. This product should not be mixed with other commercial wastes for disposal.

Questionnaire for feed-back

We urge you to complete and return the questionnaire on the next page to Power-One. Let us know your remarks on and suggested improvements to this manual. We appreciate your comments in our achievement to improve our documentation. If you have any problems with your system, e.g. you wonder how to install a new PMP/RM rectifier or you have some questions regarding messages or alarms on the PCS control module, please see the Troubleshooting section. If this does not solve your problem, please seek assistance at your local Power-One office, or our head office in Norway. These also concern any indistinctness in the manual.


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Power-One Pte Ltd Name: 27 International Business Park Company: Primefield-Landmark Building Job title: #03-02 Address: Singapore 609924 Fax: (+65) 6869 3353 Country: E-mail: [email protected] Name of product: Your opinion is of interest to us!

Please use this form and let us have your comments:

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Is it easy to find what you are looking for in the manual

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Comments:

Safety ___________________________________________________________________________________________

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PS100088 Revision C Page 1 of 5

SAFETY

Safety ___________________________________________________________________________________________

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Amendment record:

Revision (Issue)


/ First issue Tan Kian Leong 01.02.02

A Change of company logo Tan Kian Leong 27.02.02

B Change of company logo Lim Siew May 26.06.03

C Realignment of Paragraph Teo Kian Sen 10.11.04

Originated Teo Kian Sen Date 10.11.04 Approved Teo Kim Huat Date 10.11.04

Safety ___________________________________________________________________________________________

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1.1 Safety - Introduction This document contains recommended safety guidelines for working with the equipment mentioned in this documentation. The instructions in the Customer Documentation must be followed by properly trained and authorized personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the instructions may be dangerous to personnel and equipment. Although the purpose of safety devices, routines and regulations are meant to take care of the safety of the user, nobody is excused from using common sense at all times when operating or otherwise handling the equipment. These above mentioned safety guidelines include Warnings, Cautions and Notes.

1.2 Warnings

1.2.1 Lethal voltages

WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE ATTEMPTING TO WORK ON THE SYSTEM WITH THE POWER CONNECTED. POTENTIALLY LETHAL VOLTAGES ARE PRESENT WITHIN THIS SYSTEM.

WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES. THERE MUST BE NO DAMAGE OF ANY KIND TO THE INSULATION OF THE CABLES AND POINTS CARRYING LETHAL VOLTAGES SHOULD NOT BE EXPOSED. FOR SAFETY REASONS, MAKE SURE THE CABLES ARE NOT CONNECTED TO THE POWER SUPPLY WHEN ROUTING THEM.

All persons who perform any operations on this equipment should be advised of the potential dangers. Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems and equipment: • Potentially lethal voltages are present within the system. Ensure that all power supplies are completely

isolated by setting all power switches to OFF, disconnecting all relevant connectors and removing all relevant fuses before attempting any maintenance work. Do not rely on switches alone to isolate a power supply.

• Potentially lethal voltages are present within this system. Ensure that high voltage safety requirements are implemented before attempting to work on the system with power connected.

• Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly. Ensure that all ground connections are secure.

Safety ___________________________________________________________________________________________

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1.2.2 Grounding

WARNING! THIS SYSTEM SHOULD ONLY BE CONNECTED TO TN OR TT POWER SYSTEMS AS DEFINED IN EN 60950 (IEC950). THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION, CAPABLE OF SINKING A 13K AMPERE CURRENT, IS REQUIRED.

WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A CONDUCTOR SHOULD BE CONNECTED BETWEEN THE GROUNDING POINT IN THE POSITIVE DC BUSBAR TO THE CABINET. THIS CONDUCTOR IS CONNECTED ON ITS OWN TO THE EARTH BAR AND NOT SHARED WITH OTHER SAFETY CONDUCTORS.

1.2.3 Precautions for lead acid batteries

WARNING! THIS EQUIPMENT USES LEAD ACID BATTERIES. WHEN HANDLING THE BATTERIES FOLLOW THE INSTRUCTIONS DELIVERED WITH THE BATTERY SET, AS THE FLUIDS CONTAINED WITHIN THESE BATTERIES ARE KNOWN TO BE A HEALTH HAZARD. THE DISPOSAL OF LEAD ACID BATTERIES IS SUBJECT TO LEGAL REQUIREMENTS FOR HAZARDOUS WASTE, THEREFORE DISPOSAL LOCALLY MUST BE UNDERTAKEN SAFELY AND WITH DUE CARE.

Ensure the following guidelines are observed when dealing with equipment that may contain lead acid batteries: • Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes. • Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with the

corrosive fluid must be avoided. • Neutralize any acid corrosion with copious amounts of a solution of baking soda and water. Wipe of all

traces of soda. • If the lead acid battery is removed from the equipment to which it is fitted, any exposed contact must be

insulated prior to disposal. • Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are used

when working with the batteries.

Safety ___________________________________________________________________________________________

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1.2.4 Weight

WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS SUFFICIENTLY HEAVY TO REQUIRE HANDLING BY TWO OR MORE PEOPLE, OR BY SPECIALISED LIFTING EQUIPMENT.

1.2.5 High temperatures

WARNING! CARE MUST BE TAKEN WHEN HANDLING THE EQUIPMENT AS SOME OF IT MAY REACH HIGH TEMPERATURES.

1.3 Cautions

1.3.1 Storage and transportation

Caution! During storage and transportation, the units must remain in their original packages in order to avoid mechanical damage, maintain tracability, and protect the units against electrostatic discharge.

1.3.2 Handling electrostatic sensitive devices

Caution! An electrostatic sensitive device is an electronic component that may be permanently damaged by the discharge of electrostatic charges encountered in routine handling, testing and transportation.

1.3.3 Traceability

Caution! Units are labelled with permanently attached product identification labels. The labels are designed to be indelible throughout the life span of the equipment, unless mistreated. Make sure that the product identification labels are present on the equipment and are not subjected to unusual wear or mistreatment.

1.3.4 Fuses

Caution! When replacing fuses, it must be to the same types.

Technical Product Description PCC concept 1-1Document number: 039340.fmRevision: /

Technical Product Description PCC concept

1 Technical Product Description PCC concept

1-2 Technical Product Description PCC conceptDocument number: 039340.fm

Revision: /


Copyright © Power One AS. All Rights Reserved.

Power-One, ASKobbervikdalen 75P.O.Box 1543N-3007 DrammenNORWAY

Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples involving names of companies and products, are fictitious examples and are designed solely to illustrate the use of Power One products.If you find errors or problems with this documentation, please notify Power One. Power One does not guar-antee that this document is error-free. The information in this document is subject to change without notice.

Power One logo is a registered trademark of Power One Corporation.All other trademarks or product names mentioned herein are trademarks of their respective owners.



Amendment record:Revision(Issue)


/ First issue Kai Morten Hennum 06.06.05

Originated Kai Morten Hennum Date 06.06.05 Approved Arild Sagebø Date 06.06.05Signed Signed


Revision: /


1.1 General - Product description PCC ConceptThe Power-One Prime Controller Card (PCC) is a pluggable microprocessor controller that provides monitoring and control for a broad range of Power-One single subrack or cabinet DC power systems. The PCC monitors all system parameters including DC voltage, rectifier current, rectifier temperature, system capacity, battery parameters, and circuit breaker status.

Alarm and warning notifications are indicated by front panel LED’s, and through potential free alarm contacts that allow remote signaling. External monitoring of alarms is accomplished through through an RS232 port and is accessed using PC-based PowCom™ software. Front panel and interface boards are positioning-flexible for easy fitting into different system solutions.

To meet individual site requirements, the PCC contains a Programmable Logic Unit that can be used to monitor and control specified requirements. This allows individual alarm routing and logic operations to be set as actions, alarms to be triggered, and outputs to be activated based on internal and external signal monitoring, comparing, and processing.

Figure 1 Basic block diagram

Internal databus

Main unit, PCC

I/O signal connection strip

Rectifiermodule 1

Rectifiermodule N

Serial interface

PC, PDAmodem oroptional

PNI

Minimum configuration

OptionalLCD/

OperationunitPCC



1.2 FeaturesUser controls and interfaces:

• User-selectable alarm parameters• Password controlled environment• RS232 Interface and Form “C” dry alarm contacts• Programmable alarm routing, logic unit and analog inputs• Optional LCD display• Optional Ethernet interface box (PNI)

Intelligent battery management:

• Temperature compensation with programmable compensation factor• Programmable boost charging• Automatic and manual battery capacity testing• Battery symmetry voltage monitoring• Low voltage disconnect, LVD• Load shedding (PLD)

1.2.1 Standards

1.2.1.1 Environment• Storage: EN 300 019-2-1• Transport: EN 300 019-2-2• Operation: EN 300 019-2-3

1.2.1.2 Safety• EN 60950• UL 60950

1.2.1.3 EMC• EN 61000-6-2• EN 61000-6-3• EN 300 386-2


Revision: /


1.3 Controller boards and interface boardsA typical PCC configuration consists of a controller board, a front panel solution, an internal interface board and a external (customer) interface board. This document contains a technical description of each of the boards included in the PCC concept.

The PCC controller board is available in a 48V and 24V versions, with or without Ethernet support.

Figure 2 Controller board (not all parts mounted on model)

User interface is available through the front panel, including LEDs, serial plug for communication with PC, ethernet plug and optional display with buttons.

Figure 3 Front panel (not all parts mounted on models)

For internal system signaling a separate interface board is used. This is plugged directly into the controller board.



Figure 4 Internal signaling interface board. (not all parts mounted on model)

A separate card connected to the internal interface allows external (customer) signaling such as alarms and symmetry measurement.

Figure 5 External interface board (not all parts mounted on model)

1.4 Mechanical covers and insulation platesAs part of the PCC design a selection of insulation and mechanical covers are designed to shield the electronic equipment. When mounting the PCC parts into a system this should be considered. The controller board and the internal interface board have thin insulation film underneath them that are mounted on the mechanics below.

The PCC controller board also has a mechanical part shielding the top. PCC with mounted cover is shown in Figure 6 on page 1-8.


Revision: /


Figure 6 PCC With Cover

Technical Product Description PCC 1-1Document number: 038793.fmRevision: A

Technical Product Description PCC

1 Technical Product Description PCC

1-2 Technical Product Description PCCDocument number: 038793.fm

Revision: A










/ First issue Kai Morten Hennum 21/12/04A New revision Kai Morten Hennum 06/06/05

Originated Kai Morten Hennum Date 21/12/04 Approved Arild Sagebø Date 06/06/05Signed Signed


Revision: A


1.1 Details• Input voltage:18-60V DC• Current: <200mA at 48V • Measures

Width 15mm (0.6in)

Height 80mm (3.1in)

Depth 175mm (6.9in)

• WeightApproximately 0.2kg (0.44lbs)

1.2 ConnectionsFigure 1 points to all the plugs, jumpers and fuses on the controller board. The functionality of these are explained in the chapters below.

Figure 1 PCC Component reference

1 2

3

4 5

6



1.2.1 Controller Programming (1 in Figure 1)J32 is used for controller programming.

Table 1-1 J32 Pin Configuration

1.2.2 Display Option (2 in Figure 1) The controller board is connected to the optional display unit either via the J3 plug as described in 1.2.3 Main interface plug (3 in Figure 1), or via the J12 plug. J12 pin configuration is shown in Table 1-2.


Pin Signal1 Vpp2 +5V3 GND4 PGD5 PGC

Pin Signal1 +5V2 Relays_Ser/LCD_Data3 Relays_SCLK/LCD_CLK4 LCD_CS5 Key_16 Key_27 Key_38 Key_49 GND10 LCD_ID


Revision: A


1.2.3 Main interface plug (3 in Figure 1)J3 is the main interface plug and is configured as in Table 1-3.

Table 1-3 J3 Pin configuration (empty cells are Not In Use)

1.2.4 Jumpers (4 in Figure 1)• J55 can to be inserted to force bootloading of controller firmware via RS232. Boot loader can normally be

activated by the programming software, if a non-working program has been loaded this jumper can force the PCC back into boot load mode.

• J56 Not In Use.• J57 Not In Use.

J3 A B C D1 GND 5V_485 +Vo2 GND RS485_A -Vo3 GND RS485_B RS232 TX4 GND LED Green (OK) RS232 RX5 GND LED Yellow (Warning) RS232 GND6 Alarm1 C LED Red (Alarm) RS232 V+7 Alarm1 NO Battery breaker8 Alarm1 NC OutputDC LCD CS9 Alarm2 C Load Breaker LCD CLK10 Alarm2 NO Multi Purpose 1 LCD Data11 Alarm2 NC Multi Purpose 2 Key_112 Alarm3 C Multi Purpose 3 Key_213 Alarm3 NO Multi Purpose 4 LVD Disconnect C Key_314 Alarm3 NC Multi Purpose 5 LVD Disconnect NO Key_415 Alarm4 C Multi Purpose 6 LVD Disconnect NC LCD_ID16 Alarm4 NO low-side current shunt (+) LVD Reconnect C +5V17 Alarm4 NC low-side current shunt (-) LVD Reconnect NO TTL RS_TX18 GND Temp sense LVD Reconnect NC TTL RS_RX19 GND high-side current shunt (+) PLD C Vpp20 GND high-side current shunt (-) PLD NO PGD21 GND PLD NC PGC22 GND2324



1.2.5 J1 (5 in Figure 1)The J1 plug is for connection to the controller front, including RS232 communication, LED signals and Ethernet communication.

Table 1-4 J1 Pin configuration

1.2.6 Fuses (6 in Figure 1)Two ceramic fuses, F1 and F2, are mounted on the DC input. Each is 2A.

Pins Signal (J3 corr.)1 LED1 Green OK2 LED2 Yellow Warning3 LED3 Red Alarm4 GND5 Not in use6 Not in use7 Not in use8 Not in use9 ET-RDN10 ET-RDP11 ET-TDN12 ET-TDP13 Not in use14 Not in use15 Not in use16 Not in use17 V+ (J3-D6)18 TX (J3-D3)19 RX (J3-D4)20 GND (J3-D5)

Technical Product Description PCC Interface Boards 1-1Document number: 039367.fmRevision: /

Technical Product Description PCC Interface Boards

1 Technical Product Description PCC Interface Boards

1-2 Technical Product Description PCC Interface BoardsDocument number: 039367.fm

Revision: /










/ First issue Kai Morten Hennum 07/06/05

Originated Kai Morten Hennum Date 07/06/05 Approved Arild Sagebø Date 07/06/05Signed Signed


Revision: /


1.1 PCC Front Panel

1.1.1 Details• Measures (front mechanics included)

Width 2U

Height 1U

Depth 33mm

• WeightApproximately 0.2kg

1.1.2 ConnectionsFigure 1 points to all the plugs on the controller front. The functionality of these are explained in the chapters below.

Figure 1 PCC Front panel (rear view)

1.1.2.1 Ethernet connection (1 in Figure 1)

J1 is used for ethernet communication and is only available for the ethernet compatible versions of the controller boards.


Pin Signal (PL9 ref.)1 ET-TDP (PL1-12)2 ET-TDN (PL1-11)3 ET-RDP (PL1-104 Not in use

1 2

3

4



1.1.2.2 J2 RS232 communication (2 in Figure 1)

The J2 plug is used for RS232 communication. The pin configuration is shown in Table 1-8.


1.1.2.3 PL1 (3 in Figure 1)

The PL1 plug is for connection to the controller board, including RS232 communication, LED signals and Ethernet communication.

Table 1-3 PL1 Pin Configuration

5 Not in use6 ET-RDN (PL1-9)7 Not in Use8 Not in Use

Pin Signal (PL1 ref.)1 Not in Use2 RS232_RX (PL1-19)3 RS232_TX (PL1-18)4 RS232_V+ (PL1-17)5 RS232_GND (PL1-20)6 Not in Use7 RS232_V+ (PL1-17)8 Not in Use

Pins Signal (J3 corr.)1 LED1 Green OK2 LED2 Yellow Warning3 LED3 Red Alarm4 GNDa

a. GND in this context refers to system minus. This is NOT chassis ground.

5 Not in use6 Not in use7 Not in use8 Not in use9 ET-RDN10 ET-RDP11 ET-TDN12 ET-TDP13 Not in use14 Not in use15 Not in use16 Not in use17 V+ (J3-D6)18 TX (J3-D3)19 RX (J3-D4)20 GNDa (J3-D5)

Pin Signal (PL9 ref.)


Revision: /


1.1.2.4 Display plug (4 in Figure 1)

The PCC controller board is connected to the optional display unit with a ribbon cable. The pin configuration for the display board plug corresponds directly to the J12 pin configuration on the controller board. J12 pin configuration is shown in Table 1-2.


1.2 Internal Signaling Interface Board (BM0724)


Width 80mm

Height 90mm

Depth 25mm


1.2.2 ConnectionsFigure 2 points to all plugs and jumpers on the internal signaling interface board. The functionality of these are explained in the chapters below.

Pin Signal1 +5V2 Relays_Ser/LCD_Data3 Relays_SCLK/LCD_CLK4 LCD_CS5 Key_16 Key_27 Key_38 Key_49 GNDa

a.GND in this context refers to systemminus. This is NOT chassis ground.

10 LCD_ID



Figure 2 BM0724 Component Reference

1.2.2.1 J1 System Voltage Out (1 in Figure 2)This output is used for sourcing system voltage to other devices.

J1-1 Minus.

J1-2 GND.

1.2.2.2 J24 RS485 Communication (2 in Figure 2)The J24 plug is for RS485 communication with subracks. The pin configuration is shown in Figure 1-5


1.2.2.3 J10 for External Interface Board (3 in Figure 2)The J10 plug is for signaling to the external interface board. The signaling here is configurable but is usually used for alarm outputs, symmetry measurements and temperature measurements. The pin configuration for J10 is shown in Table 1-6 on page 1-8.

Pin Signal (J3 ref.)1 5V 485 (J3-1B)2 GNDa


3 RS485 B (J3-3B)4 RS485 A (J3-2B)5 GNDa6 5V 485 (J3-1B)7 Not in Use8 Not in Use

1

2

3

4

5

6

7

9 81011


Revision: /



1.2.2.4 J20 Distribution Surveillance (4 in Figure 2)The J20 plug is used for distribution signaling and supervision. Pin configuration is shown in Table 1-7


Pins Signal (J3 corr.)1 Multi Purpose 3 (J3-12B)2 Multi Purpose 2 (J3-11B)3 Multi Purpose 1 (J3-10B)4 Multi Purpose 6 (J3-15B)5 Multi Purpose 5 (J3-14B)6 Multi Purpose 4 (J3-13B)7 Not in use8 Not in use9 Temperature plus10 Temperature (J3-18B)11 GNDa


12 Not in use13 Not in use14 Not in use15 ALARM1 NO1 (J3-7A)16 ALARM1 NC2 (J3-8A)17 ALARM1 C1 (J3-6A)18 ALARM2 NO2 (J3-10A)19 ALARM2 NC2 (J3-11A)20 ALARM2 C2 (J3-9A)21 ALARM3 NO3 (J3-13A)22 ALARM3 NC3 (J3-14A)23 ALARM3 C3 (J3-12A)24 ALARM4 NO4 (J3-16A)25 ALARM4 NC4 (J3-17A)26 ALARM4 C4 (J3-15A)

Pin Signal (J3 ref.)A1 LVD Reconnect C (J3-16C)A2 LVD Disconnect C (J3-13C)A3 Load Breaker (J3-9B)A4 Battery Breaker (J3-7B)

A5 Low-side current shunt (+) (J3-16B and J3-20B)

A6 Low-side current shunt (-) (J3-17B and J3-19B)

B1 LVD Reconnect C (J3-16C)B2 PLD Disconnect C (J3-19C)B3 Load Breaker (J3-9B)B4 Battery Breaker (J3-7B)

B5 Low-side current shunt (+) (J3-16B and J3-20B)

B6 Low-side current shunt (-) (J3-17B and J3-19B)



1.2.2.5 J23 System Voltage In (5 in Figure 2)J23-1 Plus (0VR).

J23-2 Minus.

1.2.2.6 J5 RS232 Communication (6 in Figure 2)The J5 plug is used for RS232 communication. The pin configuration is shown in Table 1-8.


1.2.2.7 J3 for Controller Communication (7 in Figure 2)The J3 plug is for communication with the PCC controller board. The pin configuration corresponds directly to the J3 plug on the controller board.

Table 1-9 J3 Pin Configuration (empty cells are Not In Use)

GND in Table 1-9 context refers to system minus. This is NOT chassis ground.

Pin Signal (J3 ref.)1 Not in Use2 RS232_RX (J3-4D)3 RS232_TX (J3-3D)4 RS232_V+ (J3-6D)5 RS232_GND (J3-5D)6 Not in Use7 RS232_V+ (J3-6D)8 Not in Use

J3 A B C D1 GND 5V_485 +Vo2 GND RS485_A -Vo3 GND RS485_B RS232 TX4 GND LED Green (OK) RS232 RX5 GND LED Yellow (Warning) RS232 GND6 Alarm1 C LED Red (Alarm) RS232 V+7 Alarm1 NO Battery breaker8 Alarm1 NC OutputDC LCD CS9 Alarm2 C Load Breaker LCD CLK10 Alarm2 NO Multi Purpose 1 LCD Data11 Alarm2 NC Multi Purpose 2 Key_112 Alarm3 C Multi Purpose 3 Key_213 Alarm3 NO Multi Purpose 4 LVD Disconnect C Key_314 Alarm3 NC Multi Purpose 5 LVD Disconnect NO Key_415 Alarm4 C Multi Purpose 6 LVD Disconnect NC LCD_ID16 Alarm4 NO low-side current shunt (+) LVD Reconnect C +5V17 Alarm4 NC low-side current shunt (-) LVD Reconnect NO TTL RS_TX18 GND Temp sense LVD Reconnect NC TTL RS_RX19 GND high-side current shunt (+) PLD C Vpp20 GND high-side current shunt (-) PLD NO PGD21 GND PLD NC PGC22 GND2324


Revision: /


1.2.2.8 J2 for Door Alarm (8 in Figure 2)When activated (see 1, Jumpers (10 and 11 in Figure 2)) J2 is used for door alarm. The door alarm should be configured to be closed on alarm (closed when the door is open).

1.2.2.9 J4 for Surge Arrestor Alarm (9 in Figure 2)When activated (see 1, Jumpers (10 and 11 in Figure 2)) J4 is used for surge arrestor alarm.

1.2.2.10 Alarm signals for J2 and J4The surge arrestor alarm and the door open alarm are both sent to the same analog input on the controller board. The different alarm situations will cause different voltage levels as shown in Figure 3.



Figure 3 Door alarm and Surge Arrestor alarm signals

1.2.2.11 Jumpers (10 and 11 in Figure 2)Jumper 1 (JP1, 10 in Figure 2) is used to activate or deactivate Multipurpose 6 on the J10 plug. The jumper set between pins 1 and 2 activates Multipurpose 1, while jumper set between pins 2 and 3 activates Door alarm/surge arrestor.

Jumpers 5 to 10 (JP5 to JP10) mounted on the 724 board are used to set 0V reference for either Normally Open or Normally Closed for the LVD and PLD contactors. Default on Bill of materials is that all jumpers are mounted. Reference for the jumpers is shown in Table 1-10.

To J3-15B

+48V

R5

R6

J4

J2

No active alarms (no signal)

To J3-15B

+48V

R5

R6

J4

J2

Door alarm active

To J3-15B

+48V

R5

R6

J4

J2

Surge Arrestor alarm active

To J3-15B

+48V

R5

R6

J4

J2

Both alarms active


Revision: /


Table 1-10 0724 Jumper Reference

1.3 External Signaling Interface Board (BM0723)


Width 115mm

Height 60mm

Depth 11mm


1.3.2 ConnectionsThe external interface board is a very simple board, with only one plug for connection to the internal interface board and seven alarm, temperature or symmetry connections. Schematics for the board is shown in Figure 4

Figure 4 0723 Schematics

JP Signal (J3 ref.)5 LVD Reconnect NC (J3-18C)6 LVD Reconnect NO (J3-17C)7 PLD NO (J3-21C)8 PLD NC (J3-20C)9 LVD Disconnect NO (J3-15C)

10 LVD Disconnect NC (J3-14C)

Installation Guide PPS16.48/PPS32.48 – PCC + FMP

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PS160263 Revision A Page 1 of 13

INSTALLATION GUIDE PPS16.48/PPS32.48 – PCC + FMP


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Amendment record: Revision (Issue)


/ First issue Raymond Hoe 28.09.06

A Insertion of reference to PPS32.48 Raymond Hoe 29.05.07


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1 Scope and purpose This document is a complete installation description for the PPS16.48/PPS32.48-PCC+FMP indoor cabinet. The purpose of this document is to give clear instructions to assist in the installation of the PPS16.48/PPS32.48-PCC+FMP indoor cabinet. Following these instructions will:

• Ensure the installation is completed correctly, efficiently and safely. The following chapters give purpose and definition to the main work phases.

Tip To minimise costs, the installation and commissioning tasks should be carried out during the same site visit whenever possible.

2 Site installation requirements This section deals with the site requirements for the PPS16.48/PPS32.48-PCC+FMP indoor power system. It lists the power feed requirements and weights of the system.

2.1 AC Power source requirements

WARNING

HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED BEFORE CONNECTING MAINS SUPPLY

WARNING

PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING

ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS INSTALLATION.

The AC mains supply shall conform to the following requirements:

• Rated Voltage: 205 - 250 Volts AC (RMS) • Rated Frequency: 44 - 66 Hz

The PPS16.48/PPS32.48-PCC+FMP AC mains shall be supplied via a wall-mounted distribution unit, which is capable of isolating the system from the AC mains supply. The disconnection device shall disconnect all the phases of the incoming AC supply voltage.


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2.2 Grounding This system should only be connected to TN or TT power systems as defined in EN60950 (IEC950). The system should be hard-wired to the incoming safety earth. A solid high current ground connection, capable of sinking a 13K Ampere current, is required. Grounding should be a Single-Point connection CAD welded to the main earth grounding point.

WARNING

Due to HIGH LEAKAGE current in this system, a conductor size of 16-mm2 minimum (Green/Yellow) is connected between the Earthing point in the positive DC busbar and the cabinet.

This conductor is to be connected on its own to the Earth bar and NOT shared with other safety conductors.

Failure to observe the above warning may result in hazardous conditions on the system that may cause injury to personnel.

Note

All dimensions and weights are approximate

2.3 Outdoor cabinet mechanical specification

2.3.1 Weight Empty: approx. 40kg Fully loaded (6 rectifiers): approx. 43.2kg (6 x 2.2kg = 13.2kg)

2.3.2 Dimensions Height: Varies (To refer to the Drawing for Height) Width: 600 mm (per cabinet) Depth: 600 mm (per cabinet)

2.4 Environmental specifications

2.4.1 Temperature • ETS 300 019 -1-3 Class 3.2/3M5

-5°C to +65°C up to 2000m

2.4.2 Humidity • <95% (non condensing)


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3 Installation procedure This chapter details the installation of the PPS16.48/PPS32.48-PCC+FMP indoor cabinet.

WARNING

Only technical staff with the necessary experience and knowledge, with regard to the power supply support system and its batteries, may carry out this installation.

It is important to follow all safety regulations.

Check your work after completing each stage and checkmark the bracketed area [ ] corresponding to that stage of installation.

Record the results in the checklist at the end of this document. You must read and understand the warnings and cautions in this manual before starting work.

Note The bracketed numbers [ ] in following chapters refer to corresponding numbers in the figures.

Caution Care must be taken when installing this system. The units can be damaged and can cause damage if not handled with care. Pay particular attention to the order in which units are installed.

It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and installation methods described in the relevant sections.

3.1 Preliminaries The site should be suitable and ready for the cabinet. If it is not or you are unsure about this, contact your supervisor before continuing. [ ] Check, using a spirit level, that the site (or mounting frame) is level. [ ]

3.2 Unpacking the power supply system Check that the received equipment is in accordance with the packing list. [ ] Ensure that the cabinet and the equipment have not been damaged during transportation. [ ] You must report any parts that are damaged, missing or incorrect. If possible, correct the problem before continuing. [ ]


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3.3 Installation Place the cabinet to the desired location. Make sure that the cabinet is facing the right way. [ ]

Figure 1 System connections

Note

For permanently connected equipment, a readily accessible disconnect device shall be incorporated in the fixing wiring.

Battery MCBs [13] Distribution MCBs

DC common busbar

Positive Ground Connection

AC Input terminal


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For pluggable equipment, the socket outlet shall be near the equipment and shall be easily accessible.

An appropriate device will be provided as part of the building installation.

WARNING

HIGH LEAKAGE CURRENT Earth connection essential BEFORE connecting supply.

3.4 Grounding Open the distribution panel of the outdoor cabinet, Figure 1. [ ] Switch off all the fuses in the distribution panel, Figure 1. [ ] Connect the grounding cable between the grounding connector, Figure 1, in the positive DC busbar of the Outdoor cabinet and the main grounding point at the back of the cabinet. Check that the cables are secured tightly. [ ]

3.5 Connection of mains

WARNING

Lethal voltages.

Read the voltage warning section at the start of this manual. Make sure that the mains supply is turned OFF in the mains distribution for the system. [ ] If fitted, remove all the rectifiers, by opening the two screws on each rectifier and pulling the rectifier out of its location. [ ] Open the top hat by removing the 2 screws on the front. [ ] Insert the mains input cable, using a cable gland, through the back cable entry at the top of the cabinet. Use cables which are rated according to the supplying AC fuse [ ] The system is prepared for 3 x AC single phase (or 230V AC single phase) input. Connect the mains input cable according to the label located on the mains input terminal blocks positioned near the top of the cabinet on the right hand side. [ ]


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Tip The following mains fuses are recommended:

• 3 x (Single phase 230V AC) 3 x 63A,1P or 3 x 63A,2P

3.6 Battery installation Ensure the battery terminals are clean and corrosion free before installing the batteries. If necessary, gently clean the contact surface with a brass-suede brush, 3M Scotch-brite scouring pad or 00 grade sandpaper. Apply a thin layer of NO-OXIDE grease to clean the terminal surfaces. Follow the installation sequence and orientation. Start by placing the batteries on the lower shelf and, if necessary, continue to the middle shelf and finally the top shelf, Use the battery handle(s) if fitted/supplied to help with the installation of the batteries. Leave supplied handle(s) in the cabinet after use. For battery installation, there is a separate checklist to be completed. These checks consist of visual checks and mechanical checks. The checks to be completed are described in the following section.

Tip The mechanical checks on the batteries have to be performed in disconnect mode. Switch off battery circuit breaker first.

If a battery is found to be defective it must be disposed of and replaced with a new battery. The following guidance procedures show how to perform these checks.

3.7 Visual checks This section requires any externally recognisable damage to the batteries and accessories to be recorded.

3.7.1 Cabinet and battery temperature sensor Are the cabinet and battery temperature sensors in the correct position? Tick off the box in the checklist.

Cabinet and battery temperature sensor position ok or not ok.

3.7.2 External damage Is there any visible damage to the batteries or the accessories? Tick off the box in the checklist.

No visible damage to batteries ok or not ok.

3.7.3 Pressure spots Are there any visible pressure spots on the battery case? Tick off the box in the checklist.

No visible pressure spots on batteries ok or not ok.


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3.7.4 Deformities Are there any visible deformities such as swelling of the battery bodies? Tick off the box in the checklist.

No visible deformities ok or not ok.

3.7.5 Corrosion of battery terminals Is there any visible corrosion on the battery terminals? Tick off the box in the checklist.

No corrosion on battery terminals ok or not ok.

3.7.6 Acid escape Is there any visible acid escape from the batteries? Tick off the box in the checklist.

No acid escape from batteries ok or not ok.

3.7.7 Accessories kit check In addition to checking for the correct number and type of batteries, the check of the accessories kit includes checking that the following parts were correctly installed:

• Two (2) pole screws and washers per battery. • The connection cable set consisting of three (3) cable bridges equipped with

ring tags to ensure that all the batteries are connected together. • Sufficient rubber terminal caps to ensure that all the terminals are covered.

After checking the list of accessories, tick off the box in the checklist.

Battery accessories kit complete yes or no.

3.8 Mechanical checks The mechanical checks are carried out to ensure safe mechanical and electrical connection of the batteries.

WARNING

The mechanical checks of the batteries have to be performed in disconnect mode. Switch off the battery circuit breaker first.

Working on the batteries requires insulated tools. The torque spanner must also be an insulated type. Avoid any short circuits.


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3.8.1 Terminal screws torque check It is important to tighten the battery contact screws to the correct torque to ensure safe electrical connection and avoid damage to the screws or threads. Check the torque is set correctly by loosening the screws one half-turn, adjusting the torque spanner to the required torque for the type of battery in use and tightening the screws again.

Caution Do not over tighten the screws by exceeding the given torque value. If the required torque value cannot be reached, check the screw or battery terminal thread for damage.

Tick off the box in the checklist.

Terminal screws torque checked ok or not ok.

3.8.2 Battery terminal grease To ensure good electrical contact with minimum resistance and to protect from corrosion, the contact area between the battery terminal and the ring tag of the cable should be coated with contact terminal grease. If there is no grease on the terminals or the battery terminals are soiled, loosen the contact screws, clean the contact areas with a cloth, apply grease to the described places and tighten the screws again to the required torque. Tick off the box in the checklist.

Battery terminals greased yes or no.


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3.9 Battery connection

Red-24V,

Green-36V,Blue

-12V, -

+ + + +

-Batt.1

(Blue)

T+

+ Batt.1(Black)

19

Located on onebattery block

Batteries seen from top

-36V, Blue-24V, Green-12V, Red

-36V, Blue

12 J13

Batt. 1

-24V, Green-12V, Red

4J2

6Batt. 2

-, BlueT, Green+, Red

12 J4

3Temp. probe

PCC External Interface Card

Batteries, Symmetry measurement and Temperature probe.

20

21

22

Figure 2. Connection of the batteries, the symmetry measurement and temperature probe.

Make sure that all the MCB fuses, Figure 1, are in the OFF position. [ ] Use the enclosed cables to make the internal series connection to the batteries according to [22] Figure 2. At the same time connect the symmetry measurement cables to the battery poles according to [20] Figure 2. When connecting the cables remember to install the protective covers for the battery poles to the cables. [ ]


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Secure the connections by fastening the nuts, to the appropriate torque for the type of batteries in use, using a calibrated and correctly adjusted torque wrench. [ ] The battery cables of the system are pre-connected on the system side. The "+" cable of each battery string is connected to the positive busbar of the system, and the "-" cable to the negative battery fuse (separate for each string). Connect the other ends of the cables to the "-" and "+" terminals of the batteries according to [21] Figure , as follows:

• First connect the blue battery cable to the negative "-" terminal of the battery string (battery number 1)

• Then connect the black battery cable to the Positive "+" terminal of the battery string (battery number 4)

• Repeat this for other battery strings, if more than one battery string is used. [ ]

Tip

The battery fuse for the string referred as "String 1" is the leftmost battery fuse in the DC distribution. The fuse for "String 2" is the second battery fuse from left.

A temperature probe, [21] Figure 2, which measures the battery temperature, is connected to the power supply support system. Remove the protective sticker from the probe. Place the probe between the 2nd and 3rd battery block and attach it to the side of one of the battery blocks. [ ]

3.10 Power connections to the dc load This section details how to connect the -48 V DC supply to the DC load (normally a BTS).

WARNING

Lethal voltages.

Read the voltage and grounding warnings in Section 0 at the start of this manual.

Check that all the MCB are in the OFF position. [ ] Remove the top front panel and the side panels of the cabinet, if necessary. [ ] Connect the load and battery negative DC supply cable to the negative common busbar located at the back of the cabinet. Make sure the cable is of correct rating (i.e. thick enough) for the load and batteries. [ ] Connect the load positive DC supply cable directly to the load positive busbar and the battery positive DC supply cable to the battery positive busbar. Make sure the cable is of correct rating (i.e. thick enough) for the load and batteries. [ ]


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Tip The cable diameter depends on the selected load MCB. Each load should be connected to a separate MCB and busbar-connector. The MCB, which is used for the connection of each load, depends on the load’s power requirement.

Check, that all the cables are secured tightly to the connectors. [ ]

3.12 Installation completion Re-fit the top fan tray back into place and tighten the screws. [ ] Re-fit the top hat back into place. [ ] Ensure that all the cables are installed properly and according to this manual. [ ] Re-install the rectifiers inserting each rectifier into its location and secure by tightening the two screws on each rectifier. [ ] Ensure that all the MCBs, Figure 1, and the AC supply are in the OFF-position. [ ]

Commissioning PPS/PPRD16.48-PCC & PPS/PPRD32.48-PCC

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COMMISSIONING

PPS/PPRD16.48-PCC &

PPS/PPRD32.48-PCC


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/ First issue Raymond Hoe 06.01.06

A Incorporate PPS/PPRD32 system Raymond Hoe 28.05.07



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1.1 Commissioning

1.1.1 General Before the power supply system is delivered, it has been thoroughly inspected and tested. The following chapter is a guidance to control all functions of the system.

Caution! Before starting commissioning read the product description for the individual modules.

Technical staff with necessary experience and knowledge must accomplish the commissioning regarding the power supply system and the batteries. It is important to follow all safety regulations. If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a lower level.

NOTE! The measurements and observations must be noted in the Commissioning Record (point 2).

1.1.2 Test equipment Digital voltmeter. Load resistance, to connect 0-100% of total capacity to the system.

1.1.3 Commissioning • Verify cabinet levelled vertically. • Verify all connections tighten properly with sufficient torque. • Make sure that all rectifier modules are unplugged. • Verify correct mains voltage on input mains terminals in cabinet by measuring each individual phase voltage towards neutral. Turn off mains voltage after verifying. • Set battery breaker(s) in “off” position. • Install all FMP16.48 or FMP32.48 modules. • Set load fuses into "on" position. • Turn on mains voltage. • The yellow LED on the rectifiers should blink • Green LED on Controller should blink for approximately 20 sec. • Yellow LED on rectifiers should turn off.

• Output voltage will increase slowly to U1. • Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s)

(Normally not more than 5V DC)


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• Turn battery fuse to “on” position. • If any alarms are present they should be reset in accordance with chapter 3.1.1 show alarms in product

description PCC. The system should now be without alarms. • If the system shows any communication failure from a rectifier position without any rectifier installed.

Select “Accept removed parts” from the Miscellaneous menu on PCC. (For more information see product description PCC)

1.2 Test of output voltage

1.2.1 Float charge (U1) • Connect load, approx. 50 % of total capacity, to the system.

• Check the voltage according to the battery manufactures requirements. If the batteries require other float

charging voltage, adjust by operating the PCC. (See product description PCC)

• If nothing else is required, use the following values:

Battery type Float charge Boost charge Open lead-acid batteries 2,23V/Cell 2,33V/Cell

Sealed lead-acid batteries 2,27V/Cell -

1.2.2 Adjustment of float charge, U1 • Output voltage is factory pre-set to: (See Configuration sheet.)

• The total voltage has to be in accordance to the number of battery cells.

Please verify number of cells and the battery manufacturer requirements.

• Adjust output voltage from PCC (Control Unit).

1.2.3 Boost charging (U2) (if applicable) • Open lead-acid batteries.

Automatic boost charging - calculation of the time the battery voltage has been below certain levels. Automatic activating of boost charging for this calculated time multiplied by a (boost) factor.

Activate boost charging from the “set/select U1-U4” menu on PCC.

Return to float charge manually by selecting "U1", or automatically after a pre-set time.

• Sealed lead-acid batteries.

Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be disabled.

• Boost charging figures

Observe and write down the entire boost charging figures. Parameters to be read/set/adjusted from PCC with PowCom installed. PowCom: Communication program for remote control of the power supply system.


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1.3 Commissioning record General

Approved Yes No NA

Batteries:

Power supply system:

Commissioning Yes

Mains voltage connected

Control module turned on. Green LED will illuminate.

Voltage drop across battery fuse(s) < 5V DC Battery fuse in on-position

Test of output voltage

Default float charge (U1) ..........V

Float charge (U1) adjusted to: ..........V

Alarms

Pre-set on

factory New value Alarm

Low voltage alarm 46,3 V

High voltage alarm 57,5 V

Low voltage disconnect 39,5V

Over voltage shutdown 60,0V

Mains failure, input mains < 160V AC -

Distribution fuse failure - -

Battery fuse failure - -

Module failure - -


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1.4 Maintenance The system does not require any special maintenance, except for normal cleaning and verification of correct operation. It is very important to keep air inlets and outlets free from dust or other materials, which may prevent free air circulation through the cubical. At least once a year output voltage should be verified to be within limits. Result of the test should be recorded to see any deviations.

Maintenance and troubleshooting

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MAINTENANCE AND TROUBLESHOOTING


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/ First issue Ørjan Skauge 24.05.04

Originated Ørjan Skauge Date 24.05.04 Approved Roar Fagerhus Date 24.05.04

Signed Signed


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1.1 Chapter information This chapter contains information about replacing individual components in the PPS system, and a troubleshooting guide that should be consulted in the event of a system malfunction.

1.2 Replacing modules This section contains information on how to remove and install modules from an active system. 1. Locate the module that is to be removed. 2. Grasp the handle and gently pull the module out and away from the shelf. 3. Continue to pull the unit until it is halfway out of the shelf. Grasp the bottom of the unit with one hand and

continue using the other hand to pull the unit out. 4. Pull the module out of the shelf. The system will generate a communication error, see “Adding modules”

in Product description PCS/PCC for more information. 5. Insert and slide the new rectifier module into the open rectifier slot. 6. Tighten the two screws on top and bottom of the rectifier module. 7. The generated communication error will disappear.

1.3 Alarm warnings The following is a list of potential problems and resolutions. If the first recommendation does not solve the problem, continue on to the next.

WARNING! SYSTEM TROUBLESHOOTING SHOULD ONLY BE PERFORMED BY A QUALIFIED TECHNICIAN TO AVOID POTENTIAL SYSTEM DAMAGE AND PERSONAL INJURY.

Low System Voltage If the system gives a “Low System Voltage” warning do the following: 1. Check the batteries with the PCS/PCC or a digital voltmeter to see if the voltage is low. 2. Check "low volt alarm" limit in PCS/PCC, reset alarm limit if it is too high. 3. Check that the system is not in battery "test mode." 4. Check modules, mains and load situation compared to rectifier capacity. 5. The alarm will clear automatically when the plant returns to acceptable limits. High System Voltage 1. Check the batteries with a voltmeter to determine if the voltage is too high. 2. Check "High volt alarm" limit in PCS/PCC, reset the alarm limit if it is too low. 3. Check that the system is not in "Boost/Charge” mode. 4. The alarm will clear automatically when the plant returns to acceptable limits. Load/Battery Disconnected 1. Verify that AC input voltage is present 2. Check system DC voltage with voltmeter 3. If a LVD contactor is open, compare system DC voltage with disconnected thresholds in PCS/PCC, if the

voltage is above the disconnect threshold, check the re-connect threshold. 4. If a battery or load breaker is open use a volt meter to check for a short. If no short is indicated re-set the

breakers. If breaker opens once more, there is either a too high load or short circuit at the system. 5. The alarm will clear automatically when the plant returns to acceptable limits.


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Battery Failure 1. Check the batteries for obvious signs of damage or wear. 2. Check the "battery test" parameters in PCS/PCC. Most battery failure alarms indicate the battery voltage

dropped below the defined voltage before the defined test time expired. Verify that the parameters of the test are applicable to the systems current capacity.

3. This alarm must be manually cleared by hitting the RETURN button when “battery failure” is displayed in the list of alarms.

Battery Temp Alarm 1. Check the batteries. 2. Check the ventilation around the system area. Make sure that nothing is obstructing airflow through the

battery area. 3. Check reading in PCS/PCC of the measured temperature, and of the alarm set point. Change alarm set

point if necessary. 4. Replace probe if reading is outside the temperature probe reading. 5. Alarm will clear automatically when temperature goes below alarm set point. Symmetry Fault 1. Check batteries using a voltmeter to verify each cell/battery voltage is correct. 2. Check connection: They should match the number of batteries in the PCS/PCC. Adjust if necessary. 3. Check cell readings in the PCS/PCC. If readings are significantly out of order (i.e. -12, 0 +24) then the

cables are not connected in the correct sequence to the batteries. 4. This alarm must be manually cleared by hitting the ø button when “battery failure” is displayed in the list

of alarms. Battery Fuse Failure 1. Localize the breaker. 2. Check the batteries. 3. Reconnect the breaker. If the breaker trips again, the current from the battery is exceeding the breaker

rating, or a short exists in the battery. Replace battery or breaker as necessary. 4. The alarm will clear automatically when the breaker is turned on or removed. Mains Error 1. Check the AC input fuses/circuit breakers for voltage. 2. Check the AC input voltage on the terminals. 3. The alarm will clear automatically when the breaker is turned on or removed. Distribution Fuse Failure 1. Locate the tripped circuit breaker 2. Check the equipment and cabling that is connected to the tripped breaker to look for shorts or damaged

equipment/ cabling. 3. If the equipment appears ok, reset the breaker. If the breaker trips again, a problem exists with the

breaker or customer equipment. Note! Due to proprietary alarm wiring, a load will appear across the breaker. This is not an energy hazard. 4. The alarm will clear automatically when the breaker is turned on or removed. Module Failure 1. Localize the module. 2. Remove the module. 3. Wait for 30 sec. and reinstall the module. 4. Wait up to four minutes for the controller to re-establish communication with the rectifier. If the module

fails, LED is still illuminated, return unit to Power-One for repair. Replace with a new module, or follow instructions for “Communications Failure” (below) if the space is to be left empty.


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High Load 1. Check load amps versus capacity amps for the system. 2. Alarm will be generated when load output reaches 80% of rectifier capacity. Clear alarm by increasing

rectifier capacity, reducing load, or changing alarm threshold to a higher percentage. Urgent Module Failure 1. See "Module failure". Urgent Module Failure indicates more than one rectifier is reporting a module

failure. Communications Failure 1. Check if there is a module in indicated position. 2. Communication Failure will be indicated whenever a module loses communication with the controller

either through defect within the rectifier, or removal of a rectifier from the system. 3. If a replacement module is to be inserted, install unit, and alarm will clear within 1-2 minutes. If the

removed module is not immediately replaced, see manually clearing of the alarm below. If no modules have been removed recently, and no rectifiers show RED LED's on the front and the alarm is still present, determine which rectifier position is generating the alarm by viewing the "show alarms" on the controller display, or by reviewing the display on the PowCom software package.

4. If a rectifier is in that position, briefly remove the module, and re-insert. If the alarm does not clear, return the unit for repair service, and replace unit or manually clear the alarm. To manually clear the alarm, go to the "miscellaneous" menu on the panel controller, scroll down until "Accept removed parts" is displayed, and push "ENTER" to complete the entry.

Temp Probe Failure 1. Check connection on temperature probe. 2. Replace temperature probe. Alarms are blocked 1. Check "miscellaneous" menu in PCS/PCC. 2. This feature is used to be able to test alarm conditions within the system, without sending alarm signals

out via the form C relays. 3. When "Alarms are blocked" is activated, alarms will be indicated on the LED's and will show on the

panel display, but will not trigger a change in state of the alarm relays. 4. To unblock the alarms, find "Alarm Blocking" under the "Miscellaneous" menu on the controller and

change the status from "Active" to "Passive" by using the up arrow until "Passive" is displayed, and then hit the "Enter” button.


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1.4 Maintenance The connections on the terminal blocks and circuit breakers must be checked according to the Torque table below minimum once a year. Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed to see any deviations. In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air inlets and outlets free from dust or other materials, which may prevent free air circulation through the cubical.

1.5 Torque table TYPE: MODEL / DESCRIPTION: TORQUE: Terminal block for rail AKG 16mm2 2,5 Nm Terminal block for rail AKG 35mm2 3,5 Nm Terminal block Weidemullers WDU 4mm 0,6 Nm Terminal block Weidemullers WDU 10mm 2,0 Nm Terminal block Weidemullers WDU 16mm 3,0 Nm Miniature circuit breaker Siemens 2,5 Nm Miniature circuit breaker Merlin G 3,5 Nm Miniature circuit breaker ABB 2,0 Nm Miniature circuit breaker CBI HY-MAG 3,0 Nm Moulded case circuit breaker ABB 160A - S2 5,0 Nm Moulded case circuit breaker ABB 160A/250A - S3/S4 9,0 Nm Moulded case circuit breaker ABB 630A - S6 9,0 Nm Moulded case circuit breaker Terasaki - XS125CJ 9,0 Nm

Approved:

26.05.2006

Date: Designer:

RAYReplacement for:

Page 1 of 1

Scale:

PS160198ref: Rev:

/

Menu TreePCC Controller with Display

Replaced by:

Control:

Batcurr: xxxx ADistcurr: xxxx ARectcurr: xxxx A

Show alarms

Show messages

Show data

Select/adjustU1-U4

Adjust limits

Miscellaneous

Set time:hh:mm:ss

dd.mm.yyyy

Relay test

Alarm blockingoff

Version

Set newpassword

Shunt currentxxxx A

Shunt voltagexxx mV

Network address

Baud ratexxxx

Init modem

Accept removedparts

Reset to defaults

Master reset

Alarm limits

Battery test

Boost parameters

Temperaturecompensation

Low voltage:xx.x V

High voltage:xx.x V

Boost time:xxx.x Hours

Enable temp.compensation:

Off

Test endvoltage:xx.x V

Test duration:xxx Min

Time of test:x x

No of tests peryear:

x x

Boost interval:xx Weeks

Boost factor:xx.x

Boost t1:xx.x V

Boost t2:xx.x V

Autoboostenable:

Off

Overvoltageshutdown:

xx.x V

Load/batterydisconnect:

xx.x V

Partialdisconnect:

xx.x V

Load/batteryreconnect:

xx.x V

High load:xxx %

U1Normal voltage:

xx.x V

U2Boost voltage:

xx.x V

U3Test voltage:

xx.x V

U4Spare voltage:

xx.x V

Reference:XX

Show moduledata

Symmetrymeasurements

Symmetry:1:xx.xx 2:xx.xx3:xx.xx 4:xx.xx

Messages:Message nMessage n+1

Alarms:Alarm n..Alarm n+1..

Syst. specificlimits

Externalmeasurements

External meas: xText string

xx.xx

M.no:xx Com:OKI=xxx.xAU=xx.xV

Im=xxx.xA

Temperaturealarm:

Low: xxx C

Temperaturealarm:

High: xxx C

M.no:xx xx COVP=xx.xVCurr limit=xxx%

Temperature:xx C

Ext Limit X:Text stringxxxxx

Testing relay:x

PCC V.xx.xxSno: 16777216Cfg:xxxxxxxx

TCP/IP adr:xxx.xxx.xxx.xxx

Default gateway:xxx.xxx.xxx.xxx

PowCom adr:xxx

+-

LCD:

Netmask:xxx.xxx.xxx.xxx

Comp. Factor:x.x V/10 C

Battery Settings Symmetry limit:xx.x V

No of batteries:x x

Battery type:4 blocks

Batterycapacity

xxxxx Ah

M.no:xx AlarmsMNS CUR TMPOVS

Approved:

28/05/07Date: Designer:

RAY

Page 1 of 1

Scale:

Powec ref:

Ps250162.vsdpower-one ref: Rev:

Cabinet Layout for PPS32.48-PCC+5xFMP/20U/

23" System

Replaced by:Replacement for:

/Ps250162.vsd

Battery Distribution3 x Batt MCB (27mm)

DC Load Distribution18 x Load MCB (18mm)

Dimension of Cabinet : H980 x W600 x D600 mm

Subrack for max. 5 x FMP32.48

Note : PPS32.48-PCC+5xFMP/20U/23" in max. configuration

PCC Controller w/ DisplayInternal Int card, BM0724 External Int card, BM0723

5U

11U

17U

3-Phase AC InputPCC Controller with DisplayBM0723 & BM07241x PPR32/5pos Subrack (P/No. 1-138110G)1x LVD, 400A1x Shunt, 400A3x Batt MCB, 100A, 1P, CQCLoad MCB, 6x 63A, 6x 32A, 6x 16A, 1P, CQC1x 8U Blank Panel1x 2U Top Hat1x Temp Cable, L=3mBattery Kit, N/RSurge Arrestor, N/RSym Cable, N/R

06/01/06

Date: Designer:

RAY

Page 1 of 1

Scale:

Powec ref:

PS160135ref: Rev:

/

Schematic Diagram PPRD16/32-PCC/LVD only

0V Load0V Battery

- Load 1

- Battery n

- Load n

- Battery 1+-

LVD

Black Red

*

B1-1B2-1B3-1B4-1B5-1B6-1

F1-1F2-1

Fn-1

BM0215

Fn-1

- Load 1

- Load n

8

J24 Com.

BM0724

1 +2 -

J 23 System Voltage

J20 Distribution Surveillance6

6

6

J07 Controller Communication

J10 Connect to BM 0723

8

Connect to BM 0724

BM0723

Symmetry

Alarm 1

Temperature

123123

123

123123123123

J 2

J 1

J 4

J 7

J 6

J 9

J 8

Alarm 2

Alarm 3

Alarm 4

Shunt

Note:Shunt & Contactor may be taken out when required

1 - Black2 - Red3 - White4 - White5 - Green/Yellow6 - Yellow

Approved:

06/01/06Date: Designer:

RAYReplacement for:

Page 1 of 1

Scale:

Powec ref:

PS160053powec ref: Rev:

/

PCC - Connection of alarms,symmetry and temp sensing

Replaced by:

Sym Connection

TempSensing

Connection Alarm Relays3333

2222

1111

Contacts inalarm position

PCC Configuration Table, PPRD16.48 with LVD Contactor


Note: Number of Battery Branches & Battery Type to be modified accordingly as required. Battery Current Limit to be modified accordingly as required

(Normally tabbed to 7-10% of total system rectifier current, unless otherwise stated)





Distribution PDU - 3x Batt MCB / 18x Load MCB

___________________________________________________________________________ PS250163 Revision / Page 1 of 1

Fuse 10A 16A 32A 63A 80A 100A Char. Address Type of Equipment

FB01 X D Battery 1 Battery, 1P FB02 X D Battery 2 Battery, 1P FB03 X D Battery 3 Battery, 1P F01 X C Load LVD Load F02 X C Load LVD Load F03 X C Load LVD Load F04 X C Load LVD Load F05 X C Load LVD Load F06 X C Load LVD Load F07 X C Load LVD Load F08 X C Load LVD Load F09 X C Load LVD Load F10 X C Load LVD Load F11 X C Load LVD Load F12 X C Load LVD Load F13 X C Load LVD Load F14 X C Load LVD Load F15 X C Load LVD Load F16 X C Load LVD Load F17 X C Load LVD Load F18 X C Load LVD Load

Required fuses in the system: Type of equipment F-Mains fuse in each module (5x20mm) 4 x F12.5A Rectifier module (FMP 32) F-230V AC to mains supervision (5x20mm) T0,5A Mains supervision

Installation Checklist


No. Unpacking Completed

1 The site should be suitable and ready for the cabinet. !

2 Check that all the material, tools and documents are available and the work can start.

!

3 Check carefully for possible damage during transportation. !

Installation Completed

1 Install power supply cabinet. !

2 Earth rectifier cabinet to the main grounding busbar. !

3 Check the connection between positive busbar and the cabinet. !

4 Connect the AC mains power cables to AC supply terminals. !

Single phase in use ! Three phase in use !

5 Remove all rectifiers, if fitted. !

Accessories Checklist

1 No external damage to batteries ! Ok ! Not Ok

2 No pressure spots on batteries ! Ok ! Not Ok

3 No deformities to batteries ! Ok ! Not Ok

4 No corrosion of battery terminals ! Ok ! Not Ok

5 No acid escape from batteries ! Ok ! Not Ok

6 Battery accessories kit complete ! Ok ! Not Ok

7 Terminal screws torque checked ! Ok ! Not Ok

8 Battery terminals greased ! Ok ! Not Ok

9 Battery type: !

Number of battery strings 1 ! 2 ! 3 !

10 Install battery cables. !

11 Place the battery temperature sensor between batteries. !

12 Connect the symmetry measurement cables to the battery. !

13 Connect the DC distribution cables. !

14 Connect the remote alarm cable to alarms PCB. !

15 Re-install the rectifiers. !

Remarks:

Name:__________________ Company: ___________________ Sign: _______________

System Commissioning Checklist


No. Starting up the system Completed

1 Check that all connections are made according to the installation drawing.

2 Check that DC distribution and battery circuit breakers are in OFF position.

3 Ensure all rectifier modules are removed.

4 Check the battery polarity.

5 Turn on the AC mains voltage.

Checking the function of the rectifiers Completed

1 Measure the AC voltage on the AC Input MCBs

2 Plug in all rectifier modules starting from the leftmost position.

3 Set load fuses to "ON" position - having the load connected - and set battery fuses to "ON" position - having the battery string connected.

Check that the rectifiers are able to deliver current.

4 Check, that no alarms have activated and only green LEDs illuminate on the rectifiers and the control panel.

Checking the control and alarm system Completed

1 Check the following settings:

Alarm Limits

System Voltage

Temp Comp

Battery Test

Adjust

Note: The system voltage and temperature compensation settings are pre-set according to the battery used. If battery type used is different from the type the pre-set values were adjusted for, the values MUST be changed according to the battery type.

2 Run the alarm test.

3 Check the fuse monitoring.

4 Check the rectifier failure alarm.

5 Test the mains failure alarm.

Finishing Completed

1 Fill in Installation and Commissioning Certificate of Completion.

2 Leave this manual in an appropriate place

Remarks:

Name: _____________________ Company: __________________ Sign:____________

Battery Commissioning Checklist


No. Battery commissioning checklist

1 Battery temperature sensor position Acceptable Not Acceptable

2 External damage Acceptable Not Acceptable

3 Pressure spots Acceptable Not Acceptable

4 Deformities Acceptable Not Acceptable

5 Corrosion of battery terminals Acceptable Not Acceptable

6 Acid escape Acceptable Not Acceptable

7 Accessories complete Acceptable Not Acceptable

8 Terminal screws torque checked Acceptable Not Acceptable

9 Battery terminals greased Acceptable Not Acceptable

10 Battery compartment temperature _______C°

Remarks:

11 Battery idle voltage

Battery 1 _______ V Battery 2 _______ V Battery 3 _______ V Battery 4 _______ V


Battery 9 _______ V Battery 10_______ V Battery 11_______ V Battery 12_______ V

Battery 13_______ V Battery 14_______ V Battery 15_______ V Battery 16_______ V



12 Entire float charge voltage: _______V

13 Single float charge voltages:



Battery 9 _______ V Battery 10_______ V Battery 11_______ V Battery 12_______ V




14 Battery Backup Unit ok. Yes No

Remarks:

Name: ____________________ Company: _____________________ Sign: _________________

Maintenance Checklist


No. Maintenance Check

1 Cabinet exterior cleaned Ok Not Ok

2 Cabinet paint checked Ok Not Ok

3 Hinges lubricated (if necessary) Ok Not Ok

4 No humidity inside the cabinets Ok Not Ok

5 Ventilation filter check Ok Not Ok

6 No external damage to batteries Ok Not Ok

7 No pressure spots on batteries Ok Not Ok

8 No deformities to batteries Ok Not Ok

9 No corrosion of battery terminals Ok Not Ok

10 No acid escape from batteries Ok Not Ok

11 Battery accessories complete Ok Not Ok

12 Terminal screws torque checked Ok Not Ok

13 Battery terminals greased Ok Not Ok

14 Battery compartment temperature: ______C°

15 Battery idle voltage (No battery load, Battery circuit breaker "OFF")

Battery 1 ______V Battery 2_______V Battery 3 _______V Battery 4_______V

Battery 5 ______V Battery 6_______V Battery 7 _______V Battery 8_______V

Battery 9 ______V Battery 10______V Battery 11 ______V Battery 12______V

Battery 13______V Battery 14______V Battery 15 ______V Battery 16______V



16 Entire float charge voltage: ______V

17 Battery single float charge voltage

Battery 1 ______ V Battery 2_______V Battery 3 _______V Battery 4_______V

Battery Backup Unit: Ok Not Ok

Remarks:

Name: ______________________ Company: _____________________ Sign: _______________

Documents

VNP 52000425