ZXDU68 G020(V5.0) DC Power System Quick User Guide

ZXDU68 G020 (V5.0)

DC Power System

Quick User Guide

Contents

Document number / version :

SJ-20111202092253-001 / 2012-06-15 (R1.0)

ZTE CORPORATION

No. 55, Hi-tech Road South, ShenZhen, P.R.China

Postcode: 518057

Tel: +86-755-26771900

Fax: +86-755-26770801

URL: http://ensupport.zte.com.cn

E-mail: [email protected]

Related Documentation§ ZXDU CSU500 (SV1.01) Centralized Supervision Unit Parameter and Alarm

Setting

This document describes the parameters that need to be set on site and the alarm information.

Record modified parameter values and alarm attributes in the document for future use.

§ System Introduction -------------1/7

System Structure

Technical Specifications

Heat Circulation of the Communications Equipment

§ Equipment Installation -----------2/7

Warnings/Cautions

Removing/Installing the CSU and Rectifiers

Step 1 Installing the Cabinet

Step 2 Connecting Grounding Cables

Step 3 Connecting AC Input Cables

Step 4 Connecting DC Output Cables

Step 5 Installing Batteries

Step 6 Installing Battery Temperature Sensors

Step 7 Connecting Signal Cables

§ System Commissioning ----------5/7

Step 1 Performing Electrical Check

Step 2 Checking and Starting Rectifiers

Step 3 Starting CSU

Step 4 Setting Rectifier Address

Step 5 Setting Parameters and Attributes of Input/Output Relays

Step 6 Connecting Batteries to the System

Step 7 Checking Battery Temperature Sensors

Step 8 Connecting Loads to the System

§ System Maintenance ----------6/7

CSU Troubleshooting

Rectifier Troubleshooting

Replacing the SPD

Querying System Information/Real-Time Alarms/History Records

Querying Real-Time Information of Rectifiers

Instructions for Removing/Installing a Rectifier Online

Normal Shutdown

Emergency Shutdown

Startup

Manually Re-connecting LLVD1/BLVD2 Branches When the CSU Is Faulty

A

B

C

D

E

F

G

H

I

J

ZXDU68 G020 (V5.0) DC Power System

System Structure

ZTE Corporation Address: No. 55, Hi-tech Road South, ShenZhen, P.R.China Postcode: 518057 Website: http://ensupport.zte.com.cn Email: [email protected]

System Introduction 1/7

Component Description

AC input MCBs Connects AC input cables (L1/L2/L3)

MCB: QF1 (L1/L2/L3)

AC SPD Provides class C surge protection for AC distribution unit

DC SPD Provides surge protection for DC distribution unit

Battery MCB Connects battery pack with overload protection

MCB: QFB

BLVD2 MCBs Connects primary loads with overload protection

MCBs: QFB-1 to QFB-5

LLVD1 MCBs Connects secondary loads with overload protection

MCBs: QFL-1 to QFL-4

LLVD1 ON button If the CSU cannot automatically re-connects the disconnected branch(es), press this button to close the LLVD1 contactor to connect the LLVD1 branch(es) and activate the LLVD1 loads.

BLVD2 ON button If the CSU cannot automatically re-connects the disconnected branch(es), press this button to close the BLVD2 contactor to connect the BLVD2 branch(es) and activate the BLVD2 loads.

Communications equipment can be fit

into the reserved 4U space.

The air circulates as follows:

§ The cabinet inhales the circulation

air from the bottom.

§ The air goes through the

communications equipment space

to cool down the equipment.

§ The cabinet exhales the air by fans

at the top.

Item Specification

AC input AC input mode: Three-phase five-wire (L1/L2/L3/N/PE) power supply

Rated AC input voltage: 220 V - 240 V (line voltage)

Input line voltage range: 85 V - 295 V

Frequency: 50 Hz/60 Hz

Rectifier ZXD3000 (V5.0), 3 set (maximum)

Maximum output power: 3 kW (when the input voltage is 176 V to 295 V and the operating temperature is -40 ℃ to +55 ℃)

DC output Rated output voltage: -53.5 V

Output voltage range: -42 V to -58 V

Rated output power: 9 kW (-48 V to -57.6 V)

Operating temperature 0 ℃ to +35 ℃ (+15 ℃ to +25 ℃, recommended)

Storage temperature -40 ℃ to +70 ℃

Relative humidity 10% to 90% (non-condensing); 40% to 60% recommended

Air pressure 80 kPa to 106 kPa

Altitude 0 - 2000 m: 100% output power

2000 m - 3000 m: The power derating percentage is 1% when the altitude increases by 100 m

System efficiency ≥ 93.5% (30% rated power)

≥ 95.5% (50% rated power)

≥ 95.5% (100% rated power)

Mean Time Between Failures (MTBF)

≥ 3.2 × 105 h

Protection degree IP44

Cabinet dimensions 850 mm × 650 mm × 500 mm (H×W×D, without consideration of thermoelectric coolor)

Cabinet weight Approximately 50 kg (excluding batteries, rectifiers and CSU)

Battery rack net 219 mm × 352 mm × 370 mm (H×W×D) for each level

Battery weight Approximately 21 kg per battery

Technical Specifications

Heat Circulation of the

Communications EquipmentDescriptions of the components of the power distribution unit are as follows:

Fans

Top

shield

Rectifiers

Base

CSU

Battery rackThermoelectric cooler

Battery MCBReserved 4U vertical space

(with 19 inch width)

PE boltsCabling holes

§ SIU: Signal Interface Unit

§ SIB: Signal Interface Board

§ CSU: Centralized Supervision Unit

§ TEC: Thermoelectric Cooler

AC input MCB AC SPD

DC SPD

BLVD2

MCBs

LLVD1

MCBs

SIU

Working ground busbar

LLVD1 ON & BLVD2 ON buttons

PE terminal

The rectifiers in the figure above refers to the ZXD3000 (V5.0) rectifiers.

L1L2L3

N PE

N terminal



Removing/Installing the CSU and Rectifiers

Removing the Rectifer Installing the Rectifer

Loosen the

captive screws. 2

1 Installing the Cabinet

Equipment Installation 2/7

Cabinet dimensions (without consideration of TEC): 850 mm × 650 mm × 500 mm (H × W × D)

Keep

vertical

Keep the cabinet vertical. The vertical

deviation should satisfy the requirement

specified in the engineering acceptance

document of ZTE Corporation.

1

No stacking

Long bolt

Pole (Diameter 80 mm to 120 mm)

Pole-installing assembly

(optional)

Use long bolts to secure the pole-installing assembly to the pole.2

b Tighten screws.

Pole-installing assembly

(secured in the pole)

a Hang the cabinet.

1

(Rear view)

Make sure the indicators are at the BOTTOM side of the rectifiers

Be aware of jamming!

Tighten the captive screws.

2

Locked

It is strongly recommended that the users should set the AC input

circuit breakers to OFF position prior to removing the rectifiers.

Remove the CSU and rectifers.1 3 Hang the cabinet onto the pole-mounting assembly, and tighten screws.

Tighten the captive screws.

Removing the CSU Installing the CSU

Loosen the captive screws.

1 2


2

Locked

1

Caution

≥800 mm

85

0 m

m

500 mm 650 mm

115 mm

§ Remove watches, bracelets, rings or other conductive objects before the operation. Wear special gloves for protection against electrostatic hazards. Failure to comply can result in damage to equipment.

§ Never set heavy objects on top of the cabinet. Failure to comply can result in damage to equipment.

§ Always use insulated tools when making electrical connections and always ensure that all connection terminals and unnecessarily exposed metal parts are fully insulated. Failure to comply can result in damage to equipment.

§ The system has high leakage current, thus it must be properly grounded before power-on. The grounding cable should be connected to the nearest grounding terminal, and the cable length cannot be greater than 30 m.

§ Battery requirements:

· Batteries used in the system should be of the same type. Old and new batteries must not be used together.

· Battery packs should not be short-circuited in any way during the operation.

§ Cable requirements:

· Cable diameter: The diameter of a cable should match the load capacity.

· Cable color: When using cables in non-standard colors, use black cables and mark them using heat-shrinkable tubing or insulated tape in corresponding colors to avoid errors. If local regulations have different requirements for cable colors, always follow the local regulations. Failure to comply can result in damage to equipment.

· Cable bending radius: At a corner of a cabling route, the turning radius should be 10 times equal to or greater than the cable diameter to avoid short circuits due to the cable tube damage caused by the turning radius being too small.

Warnings/Cautions

OFF OFF

LLVD1 MCBs(QFL-1 – QFL-4)

BLVD2 MCBs(QFB-1 – QFB-5)



3 Connecting AC Input Cables

The system supports the following AC input mode:

One three-phase five-wire (L1/L2/L3/N/PE) power supply.

4 Connecting DC Output Cables 5 Installing Batteries


Choose Proper DC Output Branches.

§ Choose circuit breakers of proper capacity.

The load capacity connected to each DC output branch cannot exceed the circuit

breaker capacity. Certain redundancy should be reserved to prevent interruption of

power supply to the loads due to the circuit breaker trip.

For example, if the capacity of a circuit breaker is 32 A, it can connect a load with the

peak capacity of no more than 25 A.

§ Divide loads into primary loads and secondary loads.

If mains fails, the batteries provide power supply. During the battery power supply,

the primary loads connected to the BLVD2 branch can work longer than the

secondary loads.

Disconnection Mode Load Configuration

LLVD1 Secondary loads 4 MCBs: 2*63 A, 2*40 A

BLVD2 Primary loads 5 MCBs: 40 A, 2*16 A, 2*5 A

(Remarks: Capacity of DC output circuit breakers is subject to the contract. Information in the table

above is for reference only.)

The system provides one battery circuit breaker.

One battery pack (two layers) can be installed inside the ZXDU68 G020 cabinet.

Battery Pack (in CSU) Circuit breaker

1 QFB

Connect DC Output Cables.

Battery space for each layer (H × W × D): 219 mm × 352 mm × 370 mm

To be continued

+-L

+

QFB

100 ABattery

GND

Primary load

DC load

Secondary load

DC load

- 48V (blue)

GND (black)

GND (black)

- 48V (blue)

OFF

2 Connecting Grounding Cables

Grounding cables of the system should be connected to the nearest grounding terminal, and the cable length cannot be greater than 30 m.

Caution

PE bolt

GND

Grounding busbar on site

GND (black)

PE (yellow-green)

The system uses the bottom cabling mode.

Caution

Battery Placement Requirements

§ Enough space should be reserved around each battery. Failure to

comply can result in short-circuit hazards.

§ If the spacing requirement (no less than 5 mm as shown) is satisfied,

the batteries should be placed on the right rear sides in the cabinet to

avoid short circuit caused by friction of the door lock.

§ Ensure that all circuit breakers are set to OFF position and that no power is

applied to the system prior to making any electrical connections. Failure to comply can result in death, personal injury or damage to equipment.

§ The live and neutral cables must not be reversed!

Caution:

AC power distribution box

AC output

circuit breaker

3P

OFF PE N L1 L2 L3

PE

1

2

L1 L2 L3

N

L1 (yellow)

L2 (green)

L3 (red)

PE

(yellow-green)

N (blue)

Stopping bar

When installing batteries, install the batteries on the right first. Refer to the steps on this section for detailed instructions.

L ≥ 5 mm

++

(Front view)

H

LL L

Near right rear corner

(Top view)Front

L

Cell

-

+

Cell

-

+

H ≥ 10 mm




5 Installing Batteries

§ Never perform operations with power applied! Set the battery input

circuit breaker to OFF position before the cable connection.

§ Do not reverse the positive and negative cables!

§ See the figure below for cable routing. Battery cables should be routed

backwards, not forwards.

Caution

Route the cable backwards.

Install the cover.

Do not route the

cable forwards!

Caution

3 Install the battery stopping bar onto the battery rack.

Remove the stopping bars of the battery rack.1

§ Connect the free side of Cable A to BATT1- terminal.

§ Connect one side of Cable B to BATT1+ terminal and put Cell 1 on the right

side of the upper layer.

§ Connect the other side of Cable B to BATT2- terminal and put Cell 2 on the

left side of the upper layer.

§ Connect the free side of Cable C to BATT4+ terminal.

§ Connect one side of Cable D to BATT4- terminal and put Cell 4 on the right

side of the lower layer.

§ Connect one side of Cable E to BATT3- terminal and put Cell 3 on the left

side of the lower layer.

§ Connect the other side of Cable E to BATT2+ terminal.

§ Connect the other side of Cable D to BATT3+ terminal.

2 Connect cables between batteries, circuit breaker and GND busbar by the

following steps.

Before the equipment delivery, one end of the battery temperature sensor is

connected with a dual-pin plug.

Temperature sensorDual-pin plug

6 Installing Battery Temperature Sensors

Insert the dual-pin plug into

the X6 interface on the SIB.3

Firmly paste the sensor onto the top

of Cell 4.2

Remove the paper cover of the

battery temperature sensor.1

-

+

-

+

Upper layer

Cell 3

-

+

-

+

Lower layer

Top View

Front

Cell 4

Cell 2 Cell 1

Preparation: Clean the top of

the Cell 4.

§ Do not pasting the sensor on the

hydrogen exhaust of the cell!

§ When pulling out the SIU, move

slowly to avoid disconnecting

cables connected to the SIB.

Caution

7 Connecting Signal CablesThe signal interfaces are located on the front panel of the Centralized Supervision Unit

(CSU) and in the Signal Interface Unit (SIU). Based on the actual requirements for

supervision and networking, connect signal cables to corresponding interfaces.

X1 (To BACK-X6)

X21 (To EIB-X11)

X12

RS

485(

inde

pent

)

RS

485A

0

RS

485B

0

1 2

X11

RS

232 1

9

5

6

X22

RS

232(

mul

tiple

xing

)R

XD

TX

D

GN

D_2

3 2 1

X14

Out

put r

elay

1,2

X16

Out

put r

elay

5,6

X17

Out

put r

elay

7,8

RO8-NC

RO8-NORO8-COM

RO7-NC

RO7-COMRO7-NO

X15

Out

put r

elay

3,4

61

23

45

RO2-NC

RO2-NORO1-NC

RO1-NO

61

23

45

RO1-COM

RO2-COM

RO4-NC

RO4-NORO3-NC

RO3-NO

61

23

45

RO3-COM

RO4-COM

RO6-NC

RO6-NORO5-NC

RO5-NO

61

23

45

RO5-COM

RO6-COM

ROW-COM

X3

Inpu

t rel

ay 1

,2

INRLY1INRLY2

48VP

X4

Inpu

t rel

ay 3

, 4X

5D

oor

alar

m

48VP

DOOR

X18

CS

U fa

ult

ROW-NC

ROW-NO

12

INRLY3

INRLY4

48VP

32

13

21

32

1

SIBThe SIB provides input & output

relays, communication interfaces,

battery temperature sampling

interfaces, and environmental

detection interfaces.

X13

RS

485(

mul

tiple

x)

RS

485A

1

RS

485B

1

1 2

+5V

VW

AGND

WATER

X6

Bat

t1 te

mp

+5V

TB_1

X7

Bat

t2 te

mp

X8

Bat

t3 te

mp

X9

Bat

t4 te

mp

X10

Env

. tem

p

TE

12

34

X2

Flo

od a

larm

12

+5V

TB_212

+5V

TB_312

+5V

TB_412

12 +5V

SIBSIU

Interface

designation

The RJ45 Ethernet interface rate is 10M/

100M adaptive Ethernet. The interface

supports multiple monitoring networking

modes via Telnet, HTTP, FTP and SNMP.

CSU

RJ45 Ethernet

interface

X11 and X13 cannot be used at the same time.

When pulling out the SIU, move slowly

to avoid disconnecting cables connected

to the SIB.

Caution

Output Relay Code in the CSU Alarm Designation

X14-R01 A1 Refer to the "Alarm Information" section in the

ZXDU CSU500 (SV1.01) Centralized Supervision

Unit User Guide for output relays for the alarms.

Users can set an output relay for an alarm in the

CSU.

X14-R02 A2

X15-R03 A3

X15-R04 A4

X16-R05 A5

X16-R06 A6

X17-R07 - Controls a diesel generator

X17-R08 - Controls emergency lighting

X18-R00 - Provides the CSU fault signal

Input Relay Name in the CSU Attributes

X3-INRLY1 In-Relay -1# Default state: close

Default level: mask

Default alarm name: In-Relay

Users can set attributes for an input relay in the

CSU.

X3-INRLY2 In-Relay -2#



SIB

X6

SIB

GND

Battery

connecting cable

GND

A

Cell 2

-

+

Cell 1

-

+

Upper layer

Cell 3

-

+

Cell 4

-

+

Lower layer

Top View

Front

B

C

D

EBATT MCB

BATT MCB

BATT- (blue)

BA

TT

+ (red)

OFF



System Commissioning 5/7

1 Performing Electrical Check

1.1 Checking AC Input for Short Circuit

1. Ensure that the AC output circuit breaker in the AC power distribution box and the AC

input circuit breaker in the ZXDU68 G020 cabinet are set to OFF position.

2. Turn the knob of the multimeter to the buzzer scale to check for short circuit.

Check items: L1-L2, L1-L3, L2-L3, L1-N, L2-N, L3-N, N-PE

Check Criterion: An alarm sound given by the multimeter indicates that there is a

short circuit! Locate any short circuit and eliminate it before proceeding to the next step.

Example:

Check for short circuit between

L1 and N.

Ensure that all power is removed

prior to performing the check.

Failure to comply can result in

damage to the multimeter.

Warning:L1 L2 L3 NN

OFF

Turn the knob to the buzzer scale

PE

Electrical check must be performed before system commissioning, to avoid

equipment damage caused by cable connection errors.Caution

1.2 Checking DC Output for Short Circuit

Steps

1. Set the AC output circuit breaker (in the AC power distribution box) to ON position.

2. Check rectifiers individually.

(1) Install rectifier 1 into the slot SMR 1.

(2) Set the AC input circuit breaker (in the ZXDU68 G020 cabinet) to ON position.

(3) Observe the rectifier indicators to ensure that the rectifier is operating properly.

(4) Set the AC input circuit breaker (in the ZXDU68 G020 cabinet) to OFF position.

(5) Pull the rectifier outward for about 30 mm to shut down the rectifier.

(6) Repeat the steps (1) - (5) to check the rectifiers (SMR 2 and SMR 3) and ensure

that the rectifiers are operating properly.

3. Push the rectifiers into the corresponding slots until well seated.

4. Set the AC input circuit breaker (in the ZXDU68 G020 cabinet) to ON position to power

all the rectifiers.Starting CSU3

Steps

1. Install the CSU.

2 Make sure that the CSU is operating normally by referring to “Status Indication”.

Status Indication:

After the CSU self-check and initialization, the LCD displays

the main menu screen. The DC output branches and battery

branches are open, so the CSU activates the following

alarms:

§ LLVD1 Loop Brk.

§ BLVD Loop Brk.

§ Batt.Loop Brk.

Alarm occurrence

Main Menu Screen

Real Msg

Operating normally Breaking down

Power Lit Lit Lit

Running Flashing -

Alarm Not lit - Flashing

Operating StatusIndicator

Lit/Not lit

Esc EntPower

Running

Alarm


Checking and Starting Rectifiers2

Check Criterion:

A rectifier is operating properly when its power

and running indicators are lit and its alarm and

fault indicators are not lit.

Remove the film (if any) from the

rectifier air inlet for heat dissipation!

Operating with

stable voltageCurrent

limitSleeping Communication

interruptionAlarm

occurrence

Fault

occurrence

Power Lit Lit Flashing Lit Lit Lit

Running Lit Flashing Not lit - - Not lit

Alarm - - - Flashing Lit -

Fault Not lit Not lit Not lit - - Lit

Operating Status

Indicator

Caution:

Relationship Between AC Input Voltage and Output Power

Prerequisite: the output voltage is within the range of 48 V - 59.5 V.

Max output power: 3000 W

Output voltage: 53.5 V (changes as the charge voltage in the CSU changes)

AC Input Voltage Output Power

≤ (85 ± 5) V 0 %

(85 V ± 5 V) to 110 V 40% to 55%

110 V to 176 V 55% to 100%

176 V to (295 V ± 5 V) 100%

>295V ± 5 V 0%

Output Power = Percentage of the Maximum Power

Query button (QUY)

Power

Running

Alarm

Fault

Slot Configuration


The “-” mark in the table means that the status of the corresponding indicator is not fixed.

SM

R 1

SM

R 2

SM

R 3

1.4 Checking Terminal Voltage of the Battery Pack

1. Turn the knob of the multimeter to the DC voltage scale.

2. Measure the terminal voltage of the battery pack and record the value in the table below.

A negative measured value indicates that the positive and negative battery cables are reversed. Re-connect the cables!

Check Criterion:1. The voltage of the battery pack should be

a positive value.

2. The voltage of the battery pack should not be lower than 43.2 V (the value is for reference only). If the voltage does not meet the requirement, verify correct

connection between batteries.

Touching Point Terminal Voltage

Red probe: GND busbar

Black probe: BATT- circuit breaker

Turn the knob to the DC

voltage scale.

Red probeBlack probe

BATT MCB

GNDWarning:

1.3 Checking AC Input Voltage

1. Set the AC output circuit breaker (in the AC power distribution box) to ON position.

Keep the AC input circuit breaker ( in the ZXDU68 G020 cabinet) in OFF position.

2. Turn the knob of the multimeter to the AC voltage scale and measure the AC voltage.

Check items: L1-N, L2-N, L3-N, N-PE

Check Criterion: 1. The N-PE voltage should be lower than 5 V. If the voltage does not meet the requirement,

it is recommended to improve AC input power supply.

2. The phase voltage should be within the range of 85 V - 295 V. If the voltage does not meet the requirement, it is recommended to start a diesel generator to power the ZXDU68

G020 system.

Check Criterion: An alarm sound given by the multimeter indicates that there is a

short circuit! Locate any short circuit and eliminate it before proceeding to the next step.

GND

LLVD1 MCBs

BLVD2 MCBs

The “-” mark in the table means that the status of the corresponding indicator is not fixed.

1. Turn the knob of the multimeter to the buzzer scale.

2. According to the figure above, choose one circuit breaker of LLVD1/BLVD2 to perform

the short circuit check.


System Commissioning 6/7

CSU TroubleshootingA

Rectifier TroubleshootingBSymptom Cause and Solution

Rectifier power-on

fails, and the power

indicator of the

rectifier is not lit

1. Ensure that the AC input circuit breaker is set to ON position.

2. Ensure that the AC input voltage is within the acceptable range.

3. Re-install the rectifier or install it in another slot.

4. If the symptom persists, contact maintenance personnel to troubleshoot the rectifier.

5. Install a new rectifier in the original slot and set the rectifier address.

The alarm indicator

is lit

The probable cause might be that the AC input voltage is too high or

too low, the temperature is too high, the load-sharing quality is poor,

or the addresses conflict. The alarm might not be caused by the

rectifier but by surrounding conditions or equipment.

Solution:

1. Check alarm information through the CSU to learn the cause.

2. Take appropriate measures according to the cause.

The fault indicator is

lit

The probable cause might be that the output voltage/current is too

high, the rectifier fan is faulty, or the output fuse has blown.

Solution:

1. Re-install the rectifier.

2. If the symptom persists, contact maintenance personnel to troubleshoot the rectifier.

3. Install a new rectifier in the original slot and set the rectifier address.

Application Scenario:

A red color window on the surge protection device (SPD) indicates that the SPD is

broken and should be replaced promptly.

Steps:

1. Grasp the damaged SPD and use force to

remove the SPD

2. Install a new SPD in position.

Status

window

(The image is for

reference only)SPD: Surge Protection Device

C Replacing the SPD

Symptom Cause and Solution

CSU power-on fails,

and the power

indicator of the CSU

is not lit

1. Re-install the CSU to restart it.

2. The positive and negative battery cables are reversely connected. Reconnect the cables.

3. Ensure that the battery circuit breakers are set to ON position.

Erratic LCD display 1. Re-install the CSU to restart it.

2. If the symptom persists, remove the CSU and contact maintenance personnel for troubleshooting.

3. Install a backup CSU and properly configure the new CSU.

Dropped connection

to the background

monitor

1. Ensure that the communication cable (serial port cable or network cable) is firmly connected to the correct port.

2. Ensure that the CSU is configured correctly according to the networking requirement.



Note: The communication parameters include the Port Baudrate,

Remote IP, Remote Port, and Device Addr. For specific parameter

values, consult the network administrator.

CSU crash 1. Re-install the CSU to restart the CSU.



The CSU activates

an alarm

Query the real-time alarm information and take appropriate actions.

System Maintenance ZXDU68 G020 (V5.0) DC Power System

Requirements for Setting the Address of a Rectifier

§ The default value is “1”. When a rectifier is installed in the slot SMR 2, change its

address to “2”, likewise the other rectifiers.

§ When rectifiers are not installed according to the slot sequence, re-allocate addresses

for these rectifiers. For example, when slots SMR 1 and SMR 3 are installed with

rectifiers while the slot SMR 2 is not, to avoid alarm errors, set the addresses of the

rectifiers in slots SMR1 and SMR3 to “1” and “2”.

Steps:

1. Press the QUY button of a rectifier and hold for five seconds to enter the main menu screen of the rectifier.

2. Set the address of the rectifier. For the operation procedure, see the image below.

Setting Rectifier Address4

SMR- 1#

Real Msg

Real Alm.

Para. Set

Ctrl.

Version

Press Esc to cancel

modification during

the operation.

Press ▼ to select Para.Set.

Ent

Initial password: 0000

Ent

Save

Password:

0000

Edit

SMR Addr.-1# 02

MAX: 40MIN: 1

§ Press ◄ or ► to move the cursor.

§ Press ▲ or ▼ to modify the value.

SMR- 2#

Real Msg

Real Alm.

Para. Set

Ctrl.

Version

Ent

Initial address of the rectifier

New address of the rectifier

1

2

3

Edit

Steps:

1. Set the float charge voltage as the terminal voltage of the battery pack.

§ Menu path: [Para.Set > Batt.Para. > Float Voltage]

§ The difference between float charge voltage and the terminal voltage of the battery

pack should be within the range of -0.1 V to 0.1 V.

2. Set the circuit breaker of the battery pack to ON position to connect the pack to the

system.

3. Reset the float charge voltage to the original value.

6 Connecting Batteries to the System

Steps:

1. Ensure that power switches of the load equipment are set to OFF position.

2. Set the DC output circuit breaker (LLVD1/BLVD2) connected to the load equipment

to ON position.

3. Use a multimeter to check DC power supply for one of the loads.

§ Red probe (+): Touching the DC Input (+) connection terminal of the load

§ Black probe (-): Touching the DC Input (-48 V) connection terminal of the load

4. Verify that the multimeter indicates a positive value within the range of 42 V to 58 V.

5. After the test has passed, set power switch of the load equipment to ON position.

_+

DC INPUT

DC LoadTurn the knob to the

DC voltage scale.

Black probe

Red probe

A negative measured value indicates that the positive and negative DC output

cables are reversed. Reconnect the DC output cables to the correct terminals.

Warning:

7 Checking Battery Temperature

Sensors

Check the battery temperature in the CSU to ensure that the battery temperature sensors

are properly installed.

When a valid battery temperature is not available on the LCD, check whether the battery

temperature sensor is faulty and make sure that the temperature sensor is properly

installed. Without a valid battery temperature, the alarms and functions related to battery

temperature are deactivated.

Querying Battery Information

Ent

Real Msg. Load

Power Source ACVolt. 56.4 VCurr. 99.2 A

Select Real Msg.

Ent

Select CSU Msg.

CSU Msg.

SMR Msg.

BMU Msg.

Real Msg.

Battery-1# 1/2

Volt. 54.3 VCurr. - 49.5ATemp. 26°C

Battery-2# 1/2

Volt. 54.3 VCurr. - 49.5ATemp. 26°C

“Invalid” indicates that the battery temperature

sensor is faulty or not properly installed.

§ Refer to the guide in ZXDU CSU500 (SV1.01) Centralized Supervision Unit Parameters and Alarm Setting to perform the following operations in the CSU.

§ Record the modified values in the manual for future use.

Steps:

1. Set system parameter, battery parameters and communication parameters.

When the system is used for the first time, the system and battery parameters must be

set properly according to the actual configuration on site.

2. (Optional) Set output relays and levels for alarms.

Users can set the output relay and level for each alarm and record the setting in the

“Alarm Information”.

3. (Optional) Set attributes for input relays.

Users can set the alarm name and alarm state for each input relay. The default alarm

state of each input relay is “Close”.

5 Setting Parameters and

Attributes of Input/Output Relays 8 Connecting Loads to the System



7/7System Maintenance

Querying Real-Time Information of

RectifiersEOverview of Querying Real-Time Information of Rectifiers

§ To query real-time information of multiple rectifiers, select [ Real Msg. > SMR

Msg.]. Refer to the “Querying System Information/Real-Time Alarms/History Records”

section for the operation procedure.

§ To query real-time information of a specified rectifier, follow the instructions below.

Querying Real-Time Information of a Specified Rectifier

1

Press the QUY button and hold for five seconds to enter

the main menu screen of the rectifier.

2

Querying System Information/Real-

Time Alarms/History RecordsDRefer to ZXDU CSU500 (SV1.01) Centralized Supervision Unit Parameters and Alarm

Setting for a description of the screens. Users can query the following data in the CSU:

§ System information: Select [ Real Msg. > CSU Msg.]. Refer to the “System

Information” section for further details about the screens.

§ Real-time alarms: Select [ Real Alm.]. Refer to the “Alarm Information” section

for further details about the screens.

§ History records: Select [ His.Record > …]. Refer to the “History Records”

section for further details about the screens.

Ent

Real Msg. Load

Power Source ACVolt. 56.4 VCurr. 99.2 A

CSU screen 1

Select Real Msg.

Ent

Select CSU Msg.

CSU Msg.

SMR Msg.

BMU Msg.

Real Msg.

CSU1/2

Batt.Mode Equal Mng.Batt.Chg.Dura. 31 MinWork Mode Auto NonSave Mode

CSU2/2

Batt.Total Curr. -99.0 ASet Volt. 56.4 VSet Curr.Limit 63.5 A

Example: Querying System Information

There are two pages and this is the first page.

Press ▲ or ▼ to turn pages.

CSU screen 2

The two icons indicate that users can press ► or ◄ to query other data.

Load screen

§ Press ► or ◄ to query

other data.

§ Press Esc to return.

Main menu screen

(Select Real Msg.)

SMR-1#

Real Msg.

Real Alm.

Para.Set

Ctrl.

Ent

SMR-1#

Out Volt. 56.4 VOut Curr. 3.8 AInternal Temp. 25 °C

§ Press ► or ◄ to query

other data.

§ Press Esc to return.

Follow the instructions below when removing or installing a rectifier:

§ Before installing or removing a rectifier, close its main information screen first

(press ESC). The rectifier whose main menu screen is being displayed cannot

compete with the other rectifiers for the communication address.

§ After removing a rectifier from the cabinet, manually enable the CSU to count

operating rectifiers. Failure to comply can result in the rectifier communication

failure. Operate menu [ Ctrl. → SMR Ctrl. → CAN Dev.Stat. ], following an

example shown below.

Instructions for Removing/Installing

a Rectifier OnlineF

Steps:

1. Set the AC output circuit breaker (in the AC power distribution box) to OFF

position to remove power from the system.

2. Set the battery circuit breaker to OFF position disconnect the battery pack.

The emergency shutdown should only be performed during an emergency.

Failure to comply can result in loss of traffic or damage to equipment.

Caution

Prerequisite:

Prior to startup, ensure that the system has been properly installed and

configured and all required tests has passed.

Steps:

1. Set the AC output circuit breaker (in the AC power distribution box) to ON

position to power the system.

2. Set the AC input circuit breaker of the ZXDU68 G020 system to ON position.

3. Wait for the rectifiers and CSU to start up automatically.

4. Set the battery circuit breaker to ON position.

5. Set the DC output circuit breakers to ON position to power the DC loads.

High current leakage exists during the system operation. The system must be

well grounded before power-on. Failure to comply can result in damage to

equipment or operation failure.

Caution

Ent Ent

Ctrl. Edit

Password:

0000

Initial password: 0000

Ctrl.

Batt.ManageSMR Ctrl. Save Ctrl.Alm.Ctrl.Dev.Stat.

Ent

Message

Succeed!

Press ▼ to select

Dev.Stat.

: to return to the

upper-level interface

Esc

SMR-1#

CAN Dev.Stat.

RS485 Dev.Stat.Ent

Normal ShutdownG

Emergency ShutdownH

StartupI

Steps:

1. To ensure that the system is free of loads, remove power from all loads or

switch the loads to another power supply system.

2. Set the DC output circuit breakers to OFF position.

3. Set the battery circuit breaker to OFF position.

4. Set the AC input circuit breaker of the ZXDU68 G020 system to OFF position.

5. Set the AC output circuit breaker (in the AC power distribution box) to OFF

position to remove power from the system.

The system shutdown will cause power supply interruption to the connected

loads. Do not shut down the system without permission. Failure to comply

can result in loss of traffic or damage to equipment.

Caution

JApplication Scenario:

When the system has disconnected the LLVD1 or BLVD2 branches, but the CSU is

faulty, the CSU cannot automatically re-connects the disconnected branch(es) after the

mains recover and the rectifiers output DC power. In this case, perform the following

steps to manually re-connect the disconnected branch(es).

Manually Re-connecting LLVD1/BLVD2

Branches When the CSU Is Faulty

Steps:

1. Remove the front panel of the power distribution unit and locate the LLVD1 ON button

and the BLVD2 ON button.

2. Press the LLVD1 ON button to connect the LLVD1 branch to the system and activate

the LLVD1 loads (secondary loads).

3. Calculate the number of rectifiers needed to provide sufficient power for the load and

the battery charge using the following calculation formula. (Note: Verify that the

numbers of operating rectifiers for three phases are equal to each other if possible.)

4. Pull the unnecessary rectifiers 30 mm out of the cabinet to avoid high charge current to

the batteries (because there is no CSU that can limit the output current of the rectifiers).

5. Press the BLVD2 ON button to connect the battery branch to the system and activate

the BLVD2 loads (primary loads).

6. When the CSU operates properly, activate the rectifiers that were deactivated in Step 4.

PB (power required for the battery charging) =

nominal voltage of the battery pack × rated battery charging current

For example, PB = 48 V × 0.15C10

PL (load power): marked on the nameplate of the load

Maximum output power of a single rectifier: 3000 W

Number of needed

rectifiers=

PB +PL

Maximum output power of a single rectifier+ 1

LLVD1 ON BLVD2 ON

If the CSU is operating properly,

the CSU can accordingly

disconnect the branch(es) that is

(are) manually connected through

the steps below.

Documents

ZXDU68 G020(V5.0) DC Power System Quick User Guide