ACTURA Flex 48330 Power System

User Manual

Version: V1.0
Revision date: May 20, 2005
BOM: 31011084

Emerson Network Power provides customers with technical support.

Users may contact the nearest Emerson local sales office or service
center.

Copyright © 2005 by Emerson Network Power Co., Ltd.

All rights reserved. The contents in this document are subject to

change without notice.

Emerson Network Power Co., Ltd.

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District
518057, Shenzhen China

Homepage: www.emersonnetworkpower.com.cn

E-mail: [email protected]
Safety Precautions

To avoid accident, read the safety precautions very carefully before operation.
The "Caution, Notice, Warning, Danger" in this manual do not represent all the
safety points to be observed. Therefore, the installation and operation
personnel must be strictly trained and master the correct operations and all the
safety points before actual operation.

When operating Emerson products, the safety rules in the industry, the general
safety precautions and special safety instructions must be strictly observed.

Electrical Safety

1. Hazardous voltage

Some components of the power system carry hazardous voltage in operation,

direct contact or indirect contact through moist objects with these components
will result in fatal injury.

Safety rules in the industry must be observed when installing the power
system. The installation personnel must be licensed to operate high voltage
and AC power.

In operation, be sure to remove conductive objects, such as watch, bracelet,

ring, and so on.

When water or moisture is found on the cabinet, turn off the power immediately.
In moist environment, take precautions to keep moisture out of the power
system.

"Prohibit" warning label must be attached to the switches and buttons which
are not permitted to be operated on during installation.

High voltage operation may cause fire and electric shock. The connection and
wiring of AC cables must be in compliance with the local codes and
regulations. Only those who are licensed to operate high voltage and AC
power can perform high voltage operations.

2. Tools

In high voltage and AC operation, special tools must be used. No common or

homemade tools should be used.

3. Thunderstorm

Never operate on high voltage, AC, iron tower or mast on a day with
thunderstorm.
In thunderstorms, a strong electromagnetic field will be generated in the air.
Therefore the equipment should be well-earthed in time to avoid damage by
lightning strikes.

4. ESD

The static electricity generated by the human body will damage the static
sensitive elements on PCBs, such as large-scale ICs. Before touching any
plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body
static from damaging the sensitive elements. The other end of the ESD wrist
strap must be well earthed.

5 Short-circuit

During operation, never short the positive and negative terminals of the MFU
of the system or the non-earthing terminal and the earth. The power system is
a constant voltage DC power equipment, short circuit will result in equipment
burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when
performing DC live operations.

Never wear a watch, bracelet, ring, or other conductive objects during

operation.

Insulated tools must be used.

Battery

Before any operation on battery, read very carefully the safety precautions for
battery transportation and the correct battery connection method.

Non-standard operation on the battery will cause danger. In operation,

precautions should be taken to prevent battery short circuit and overflow of
electrolyte. The overflow of electrolyte will pose potential threat to the
equipment, it will erode the metal objects and PCBs, thus causing equipment
damage and short circuit of PCBs.

Before any operation on battery, pay attention to the following points:

Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.

Use special insulated tools.

Wear an eye protection device, and take preventive measures.

Wear rubber gloves and apron to guard against electrolyte overflow.

In battery transportation, the electrode of the battery should always be kept

facing upward. Never put the battery upside down or slanted.
Special Safe Requirements of This Equipment

The equipment has multi power inputs;

The equipment shall be installed on cement ground.

Others

1 Safety requirement

Please use the same model fuse to replace the fuse in the DC Power System.

2. Sharp object

When moving equipment by hand, wear protective gloves to avoid injury by

sharp object.

3. Cable connection

Please verify the compliance of the cable and cable label with the actual
installation prior to cable connection.

4. Binding the signal cables

The signal cables should be installed separately far away from heavy current
and high voltage cables, with distance at least 150mm.
 Contents

Chapter 1 System Description................................................................................................1

1.1 Abbreviation ..............................................................................................................1
1.2 Introduction ...............................................................................................................1
1.3 Features....................................................................................................................1
1.4 System Configuration................................................................................................2
1.5 Components..............................................................................................................4
1.5.1 Rectifier Shelf..................................................................................................4
1.5.2 Rectifier...........................................................................................................6
1.5.3 SCU ................................................................................................................7
1.5.4 Multi-Function Unit (MFU)...............................................................................9
1.5.5 Battery Connection Unit (BCU) .....................................................................10
1.5.6 System Cabinet.............................................................................................11

Chapter 2 Installation ........................................................................................................... 12

2.1 Installation Preparation ...........................................................................................12
2.1.1 Environmental Conditions .............................................................................12
2.1.2 Power Supply................................................................................................12
2.1.3 Site Survey ...................................................................................................13
2.1.4 Tools & Material ............................................................................................13
2.1.5 Unpacking.....................................................................................................14
2.2 Installation Procedures............................................................................................15
2.2.1 Cabinet Installation .......................................................................................15
2.3 External Electrical Connection Interface .................................................................17
2.3.1 Connection Of Input Cables ..........................................................................17
2.3.2 Connection Of Load Cables ..........................................................................20
2.3.3 Connection Of Communication Cables .........................................................21
2.3.4 Layout Of Connector Board S6415X2...........................................................22
2.3.5 Interface Definition Of Connector Board S6415X2........................................23
2.3.6 Connection Of Temperature Sensor Cables .................................................24
2.3.7 Connection With MODEM.............................................................................24
2.3.8 Connection With Dry Contacts ......................................................................25
2.4 Battery Installation And Cabling ..............................................................................25
2.4.1 Battery Installation ........................................................................................25
2.4.2 Battery Cable Connection .............................................................................26
2.5 Parallel Connection Of Cabinets .............................................................................29

Chapter 3 Startup................................................................................................................. 30
3.1 Checking Before Startup .........................................................................................30
3.2 Startup Process ......................................................................................................31
3.3 Parameters Configuration .......................................................................................31
Chapter 4 Testing................................................................................................................. 32
4.1 Testing MFU ...........................................................................................................32
4.2 Testing Rectifier ......................................................................................................32
4.3 Testing SCU............................................................................................................32
4.4 Battery Breaker Test ...............................................................................................33
4.5 BCU Test ................................................................................................................33
4.6 Load Breaker Test ..................................................................................................33

Chapter 5 Operating SCU ....................................................................................................34

5.1 Operation Panel ......................................................................................................34
5.2 Operation Procedures .............................................................................................35
5.3 Querying System Status .........................................................................................36
5.3.1 First Page Of System Information .................................................................36
5.3.2 Other System Information Screen.................................................................37
5.4 Querying Rectifier Status ........................................................................................39
5.5 Querying Alarms And Setting Alarm Plans..............................................................40
5.5.1 Querying Active Alarm ..................................................................................40
5.5.2 Query Alarm History......................................................................................41
5.5.3 Alarm Type Table..........................................................................................43
5.5.4 Changing Audible/Visual Alarm And Alarm Call Back Plan........................... 46
5.5.5 Changing Alarm Types Of Dry Contacts .......................................................46
5.5.6 Setting Alarm Type For Dry Contacts ...........................................................46
5.5.7 Set the Alarm Names Through PLC Function ............................................... 48
5.6 Maintenance ...........................................................................................................51
5.7 Setting System Parameters ....................................................................................53
5.7.1 Parameter Setting Method ............................................................................53
5.7.2 Batt. Selection...............................................................................................55
5.7.3 LVD Parameter Description ..........................................................................56
5.7.4 Charging Management Parameters ..............................................................57
5.7.5 Battery Test Parameters ...............................................................................60
5.7.6 Temperature Compensation Coefficient Parameters .................................... 62
5.7.7 AC Settings ...................................................................................................63
5.7.8 DC Setting ....................................................................................................64
5.7.9 Rect Settings ................................................................................................65
5.7.10 System Settings ..........................................................................................66
5.7.11 Alarm Settings.............................................................................................70

Chapter 6 Routine Maintenance...........................................................................................72

6.1 Maintenance Of Rectifier.........................................................................................72
6.2 Maintenance Of SCU ..............................................................................................72
6.3 Maintenance Of MFU ..............................................................................................72
6.4 Cover Plates ...........................................................................................................73
6.5 Battery Maintenance ...............................................................................................73
6.5.1 Storage And Supplementary .........................................................................73
 6.5.2 Daily Inspection.............................................................................................73
6.5.3 Replacement.................................................................................................74

Chapter 7 Troubleshooting...................................................................................................75
7.1 Troubleshooting Rectifier ........................................................................................75
7.2 Mains Failure ..........................................................................................................76
7.3 Disastrous Accidents ..............................................................................................76

Appendix 1 System Technical Parameters ..........................................................................77

Appendix 2 Engineering Design Diagram ............................................................................79

Appendix 2.1 Engineering Design Diagram For 2000mm%600mm%600mm Cabinet .. 79
Appendix 2.2 Engineering Design Diagram For 2000mm%600mm%400mm Cabinet .. 80
Appendix 2.3 Engineering Design Diagram For 700mm%600mm%400mm Cabinet .... 81
Appendix 2.4 System Input And Output Connector Specs............................................81

Appendix 3 System Circuit Diagram.....................................................................................82

Appendix 3.1 System Electric Schematic Diagram .......................................................82
Appendix 3.2 System Wiring Diagram ..........................................................................83
Appendix 3.3 MFU Electric Wiring Diagram ..................................................................84
Appendix 3.4 BCU Electric Wiring Diagram ..................................................................85

Appendix 4 Glossary ............................................................................................................ 86

 Table List

Table 1-1 Configurations of Actura Flex 48330 Power System ..............................................3

Table 1-2 Dimensions of rectifier shelf ...................................................................................5
Table 1-3 Function of indicators .............................................................................................7
Table 1-4 Authority and default password..............................................................................9
Table 1-5 Configuration of MFU ...........................................................................................10
Table 1-6 BCU configuration ................................................................................................11
Table 2-1 Environmental conditions in power room .............................................................12
Table 2-2 AC input modes ...................................................................................................17
Table 2-3 Configuration number of load MCBs and battery MCBs.......................................20
Table 2-4 Interface definition of connector board S6415X2 .................................................23
Table 3-1 System checklist before startup ...........................................................................30
Table 5-1 Functions of LED indicators .................................................................................34
Table 5-2 Functions of SCU keys.........................................................................................34
Table 5-3 Alarm type table ...................................................................................................43
Table 5-4 Changing audible/visual alarm and alarm call back plan......................................46
Table 5-5 Optional alarm types ............................................................................................47
Table 5-6 Logic matrix used for configuring 8 dry contacts .................................................. 49
Table 5-7 Example of PLC setting........................................................................................49
Table 5-8 PLC SN and Alarm...............................................................................................49
Table 5-9 Password levels and authorities...........................................................................54
Table 5-10 Value description of the basic battery parameters .............................................56
Table 5-11 Value description of the LVD parameters...........................................................57
Table 5-12 Charging management parameter value description..........................................59
Table 5-13 Value description of the battery test parameters................................................61
Table 5-14 Value description of temperature compensation coefficient ............................... 62
Table 5-15 Value description of AC settings ........................................................................63
Table 5-16 Value description of DC settings ........................................................................64
Table 5-17 Value description of rectifier settings..................................................................65
Table 5-18 Value description of system settings ..................................................................68
Table 5-19 Relationship between system model and system type....................................... 70
Table 5-20 Value description of alarm settings ....................................................................71
Table 7-1 Troubleshooting ...................................................................................................75
 Figure List
Figure 1-1 Outline ..................................................................................................................2
Figure 1-2 Rectifier shelf outline.............................................................................................4
Figure 1-3 Rectifier shelf with rectifiers and CU .....................................................................4
Figure 1-4 Dimensions ...........................................................................................................6
Figure 1-5 Outline of SCU ......................................................................................................7
Figure 1-6 Outline and components of MFU ..........................................................................9
Figure 1-7 Outline of battery connection unit (BCU).............................................................10
Figure 2-1 Installation dimensions of the cabinet base ........................................................15
Figure 2-2 Installing expansive pipe.....................................................................................16
Figure 2-3 Fixing cabinet with Tap .......................................................................................16
Figure 2-4 Cable mounted with H terminal...........................................................................17
Figure 2-5 Connection of input terminals .............................................................................18
Figure 2-6 Top cover............................................................................................................ 18
Figure 2-7 Connection of 3-phase AC power input ..............................................................18
Figure 2-8 Connection of single-phase AC power input .......................................................19
Figure 2-9 Connection of dual-phase AC power input.......................................................... 19
Figure 2-10 Connection of load cables.................................................................................20
Figure 2-11 Cable connection to MCB .................................................................................20
Figure 2-12 Connector board in rectifier shelf ......................................................................21
Figure 2-13 Layout of connector board S6415X2.................................................................22
Figure 2-14 Input/output interfaces of TD-5648DC MODEM................................................24
Figure 2-15 Cabinet with four battery strings installed .........................................................26
Figure 2-16 Connection of battery cables. ...........................................................................27
Figure 2-17 Positive and negative battery cables in each level............................................27
Figure 2-18 Negative battery cables connection in BCU......................................................28
Figure 2-19 Parallel connection of DC power system cabinet with battery cabinet .............. 29
Figure 5-1 SCU Front Panel.................................................................................................34
Figure 5-2 BC/FC switchover diagram .................................................................................59
Figure 5-3 Schematic diagram of the test function ...............................................................61
Figure 5-4 System model description...................................................................................69
 Chapter 1 System Description 1

Chapter 1 System Description

1.1 Abbreviation

AC Alternate Current

DC Direct Current

SCU Standard Controller Unit

BCU Battery Connection Unit

CSU Central Supervision Unit

HVSD High Voltage Shutdown

MCB Miniature Circuit Breaker

APFC Active Power Factor Correction

MFU Multi-Function Unit

1.2 Introduction

The ACTURA Flex 48330 Power system consists of 50A rectifiers, Control Unit,
Multi-Function Unit (MFU), rectifier shelf and BCU (optional).

The product is used in base station, small exchange station, satellite

communication, data communication, and so on, with a strong adaptability to power
network fluctuation.

This system is used as a power supply for telecom equipment with system nominal
voltage of -48V and positive terminal earthed.

1.3 Features

The DC power system is easy-to-operate, easy-to-install and easy-to-maintain. Its

main features are:

Rectifier uses APFC technology and therefore its PF is up to 0.99;

Wide AC input voltage range of 85~290V;

Rectifier efficiency is at least 90%;

Extra low EMI of rectifier and excellent EMC performance;

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2 Chapter 1 System Description

High power density of rectifier;

Rectifier has damage-free hot plugging/unplugging function, the replacement

time is less than 1min;

Rectifier has two kinds of over-voltage protection methods;

Perfect battery management with BLVD function;

Up to 200 PCS of historical alarms can be stored in SCU;

Provide RS232, Modem and dry contacts communication interfaces;

1.4 System Configuration

The outline of the DC Power System is illustrated in Figure 1-1:

Multi-function unit

Rectifier
Connector Board
Control unit
Rectifier shelf
Rectifier cover
Battery connection unit

Battery shelf

Door

Figure 1-1 Outline

There are three kinds of DC Power Systems, and their detail configurations are as
shown in Table 1-1:

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 Chapter 1 System Description 3

Table 1-1 Configurations of Actura Flex 48330 Power System

Cabinet dimension
Configuration 3
2.0 % 0.6 % 0.6 m 2.0 % 0.6 % 0.4 m3 0.7 % 0.6 % 0.4 m3
3P+N/380V AC input with SPD
3P+N/380V AC input without SPD
1P+N/220V AC input with SPD
1P+N/220V AC input without SPD
L1+L2/220V AC input with SPD
AC distribution
L1+L2/220V AC input without SPD
3P/220V AC input with SPD
3P/220V AC input without SPD
5 2P AC input MCBs
Individual AC cables with just terminals
DC distribution Up to 28 13mm-wide MCB, or 20 18mm-wide MCB
Rectifier Up to 5 rectifiers
Control unit 1 SCU
BCU 1 BCU with up to 5 battery circuit breakers

Telion 12V 165Ah FT: Hawker 12V82F:

16 Blocks 16 Blocks
Hawker 12V 155Ah FT: Hawker SBSC11 and
16 Blocks 3U space:
Battery Hawker 12V 105Ah FT: 16 Blocks No battery
20 Blocks EB4: 20 Blocks
Hawker 12V 105Ah FT Hawker 12V82F( no
and 6U space: BCU):
16 Blocks 20 Blocks
Dimensions
2000×600×600 2000×600×400 700×600×400
(H×W ×D) mm

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4 Chapter 1 System Description

1.5 Components

1.5.1 Rectifier Shelf

Outline

The outline of the Rectifier Shelf is illustrated in Figure 1-2:

Terminal connecting
50A Rectifier Connector Board
Chassis

Ear Bracket

(a) Actual appearance (front view)

Bus Bar

Back Board

(b) Actual appearance (rear view)

Figure 1-2 Rectifier shelf outline

The shelf can accommodate 5 rectifiers and a control unit as shown in Figure 1-3.
The user can mount the rectifier shelf into cabinets with widths of 600mm and
depths of 400mm. The rectifier shelf has a height of 3U (132.5mm).

Figure 1-3 Rectifier shelf with rectifiers and CU

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 Chapter 1 System Description 5

The Dimension of Rectifier Shelf are given in Table 1-2

Table 1-2 Dimensions of rectifier shelf

Manufacture type W(mm) ×D(mm) ×H(mm) Note
PSS485023/C 584.2×327×132.5 23’’ with controller

Backboard

The backboard has the functions below:

DC power source feed for controller and the connector board.

DC input filter and input fuse.

All the ingoing and outgoing signals of the controller

The backboard also contains system internal connectors below:

10 Distribution unit fuses alarm signal measurement input

4 battery fuse alarm signal measurement input

2 battery current shunt measurement inputs

1 load Current shunt measurement input

System bus-bar DC Voltage measurement input

Three-phase from two mains AC Voltage measurement inputs

CAN communication between rectifiers and controller

AC alarm module signals

System fault indicator drivers

LLVD & BLVD mono contactor driver outputs

The entire signal outgoing to the connector board

Connector board

Connector board is a user interface board and has the functions below:

8-channel relay outputs

8-channel digital inputs

One power source feed terminal (for digital inputs)

2-channel temperature sensor inputs

2-channel RS232 parallel connection outputs

LLVD & BLVD bistable contactor driver circuits and outputs

ACTURA Flex 48330 Power System User Manual

6 Chapter 1 System Description

One Ethernet output

One RS485 output

One console output for ECU debug

The connector board can be hot plug and has enough space for
accommodating all the interface cables.

The connector board should space the hollow to the SCU convection for air
flowing

The connector board is mounted in the room 1U×2U at the top of the SCU.

The shelf has a 1U×2U panel for the connector board.

One RS232 and Ethernet ports are located at the front of the connector board.

The shelf has two rails for supporting the connector board

1.5.2 Rectifier

Outline

The appearance and dimensions (unit: mm) of the rectifier are illustrated in the
following figure.

Figure 1-4 Dimensions

Weight: ≤3.5kg

Dimensions (H × W % D): 124.3mm % 84mm % 287mm

The functions of the indicators in front panel are listed in Table 1-3.

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 Chapter 1 System Description 7

Table 1-3 Function of indicators

LED Normal Abnormal Cause of abnormality
OFF No AC Mains Supply
Power indicator (green) ON
Blinking Rectifier is under control by SCU
AC input over/under voltage, PFC
Protection indicator ON
OFF over/under voltage and over temperature
(yellow)
Blinking Communication of rectifier with SCU failure
ON Output Over-voltage
Alarm indicator (red) OFF
Blinking Fan Failure

1.5.3 SCU

Outline

Figure 1-5 Outline of SCU

Dimension (H % W % D):132mm % 85mm % 287mm

Weight: 0.76kg

Multi-Communication mode

SCU communicates with MC (Main Computer) through the RS232/MODEM

communication port and 8 groups of alarm dry contacts on the Signal Junction
Board.

SCU supports both China Telecom Communication Protocol and EEM Protocol.
Make sure that the baud rates for receiving and transmitting are set to be
consistent when using SCU.

1. Communication through RS232

RS232 communication mode is mainly used for short-distance point-to-point

communication. The communication distance shall be less than 15m. If SCU
communicates with MC through RS232, just connect SCU RS232 port to the
RS232 port of MC.

2. Communication through MODEM or ES-MOD

ACTURA Flex 48330 Power System User Manual

8 Chapter 1 System Description

When SCU communicates with MC through MODEM or ES-MOD, it uses PSTN to

realize long-distance monitoring. Power supply cables and communication cables
shall be prepared for the communication through MODEM.

3. Dry Contacts Output

SCU has 8 dry-contact outputs. Every dry-contact output has NC (normally closed)
and NO (normally-open) contacts. Every dry-contact output shall be configured
before the alarm event occurs. Different dry-contact output can trigger different
alarms. Once the alarm event occurs, the dry-contact will close or open to generate
the alarm.

If the user has other intelligent equipment to be monitored by SCU, the user can
connect the dry contacts to the interface of the intelligent equipment, and control
the intelligent equipment through these dry contacts.

Capacity of dry contacts: 2A@30Vdc; 05A@125Vac;

Maximum power dissipation: 60W

Functions fulfilled by SCU and MC

In RS232 and MODEM communication modes, the MC can fulfill the following
functions through SCU:

1. Remote acquisition of analog and digital values: MC can acquire the real-time
analog and digital values of DC Power System through SCU;

2. Remote control functions: MC can shut down the rectifiers, change the boost
charge status to float charge status (or in reverse), silence the alarm and stop/start
the battery test through SCU.

Alarm category settings for dry contact output

1. Through setting the parameter of “Relate Relay”, the user can configure the
alarm category for every dry-contact output. Every dry-contact output has been
configured to correspond to an alarm category before SCU is delivered to
customer.

2. SCU has PLC functions in the alarm management. The PLC is to realize simple
logic operation, i.e. the "And", "Or" and "Not" operations. The PLC inputs are all the
possible alarm signals, and the PLC outputs can be used to select one of the 8 dry
contacts. The alarm categories can be configured flexibly for every dry-contact
output through MC. The PLC settings for every dry-contact have three alarm inputs,
and two relation flag. The SN of three alarm categories and the mutual logic
relationships need to be configured.

PLC can be set to “Disabled”. If PLC functions and alarm co-relation are enabled at
the same time, the dry contact will act to activate an alarm when any alarm event
occurs.

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 Chapter 1 System Description 9

Password protection for important operations

The users must input the correct password before they conduct “Maintenance” and
“Settings” operations. The password has 3 levels: user, operator or administrator.
The authorities of the 3 levels are the same while conducting “Maintenance”, but
different in conducting “Settings”. The operator can see 3 more pages than the user,
which are “resetting system”, “resetting password” and “modifying system type”.
The administrator can see 2 more pages than the operator, which are “modifying
password of all levels” and “controlling alarm sound volume”. In addition, the
administrator can browse the rectifier parameter serial No., software version and
the setting of internal switches. See the following table:

Table 1-4 Authority and default password

Level Authority Default password
User Configuration of general parameters 123456
User’s authority, plus resetting system, resetting
Operator 654321
password and modifying system type.
Operator’s authority, plus modifying password of all
Administrator levels, controling alarm sound volume, browsing system 640275
parameters that can be set only through the host

1.5.4 Multi-Function Unit (MFU)

Outline and components

The outline and the components of the MFU are illustrated in the following figure.
PE bus
OV DC bus
Bypass bar LLVD contactor SPD
Shunt

AC input terminals

BLVD contactor Rectifier AC input MCB

Battery MCB

Battery -48V bus

Low prior load bus
Load MCB
Prior load bus

Figure 1-6 Outline and components of MFU

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10 Chapter 1 System Description

Table 1-5 Configuration of MFU

No. Component Description
1 SPD Norminal Dischage Current(8/20μS) 20kA; Ue=385V
2 AC input terminals Rating Current 150A
3 Rectifier AC input MCB Rating Current 25A
4 BLVD contactor 200A or 400A optional
5 LLVD contactor 200A or 400A optional
6 Shunt 300A/75mV
7 Battery MCB 100A MCB (up to 5 battery MCBs can be selected to configure)
8 Load MCB Selected according to user’s requirement

The user can mount the distribution unit into cabinets with widths of 600mm and
depths of 400mm and 600mm. It has a height of 4.5U (200mm).

1.5.5 Battery Connection Unit (BCU)

Outline

The outline of the Battery Connection Unit (BCU) is illustrated in Figure1-7.

Enclosure

Battery MCB

-48V DC Bus

Figure 1-7 Outline of battery connection unit (BCU)

Physical size

Battery Connection Unit (BCU) can be installed in cabinets with widths of 600mm
and depths of 400mm and 600mm. BCU has a maximum height of 1.5U (67mm).

BCU contains 2 to 5 circuit breakers, each with ratings of 100A and 200A.

Alarm output

The BCU will generate an alarm if a battery circuit breaker is off. This alarm shall be
possible to connect to the connector board for display in the Controller. It shall be
possible to combine the alarms from 2 BCUs to generate a single alarm in the
controller. It shall also be possible to combine the alarm from the BCU with an

ACTURA Flex 48330 Power System User Manual

 Chapter 1 System Description 11

alarm generated from battery circuit breakers that are switched off in the BCU (for
example when using a BCU in an extension battery cabinet and battery circuit
breakers in the BCU in a main cabinet).

BCU configuration

The BCU configuration is as shown in Table 1-6:

Table 1-6 BCU configuration

Item Function unit Amount
100A CB for battery input 2/3/4/5
Battery connection unit
200A CB for battery input 2/3/4/5

1.5.6 System Cabinet

There are three kinds of cabinets. Their dimensions are 2.0m % 0.6m % 0.6m, 2.0m
% 0.6m % 0.4m and 0.7m % 0.6m % 0.4m respectively.

2.0m % 0.6m % 0.6m cabinet

This cabinet is installed with 1 % MFU, 1 % Rectifier Sub-rack, 1 % BCU and the
following combination of units:

16 Blocks of Telion 12V 165Ah FT batteries or 16 % Hawker 12V 155Ah FT

batteries

20 Blocks of Hawker 12V 105Ah FT batteries

16 Blocks of Telion 12V 100Ah FT batteries (20 blocks is preferred, if possible)

16 Blocks of Hawker 12V 105Ah Ft batteries and 6U of unspecified equipment

(such as DC/DC converters or similar)

2.0m % 0.6m % 0.4m cabinet

This cabinet accommodates 1 % MFU,1 % Rectifier Sub-rack, 1 % BCU and the

following combination of units:

16 Blocks of Hawker 12V82F batteries or 16 Blocks of Hawker SBSC11 and

3U available for additional equipment such as DC/DC converters

20 Blocks of EB4 batteries

20 blocks of Hawker 12V82F batteries (20 blocks and BCU is preferred, if possible)

0.7m % 0.6m % 0.4m cabinet

This cabinet accommodates 1 % MFU, 1 % Rectifier Sub-racks and 1 % BCU.

There shall be 3U available for the mounting of additional equipment such as
DC/DC converters. The cabinet should not be installed any battery.

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12 Chapter 2 Installation

Chapter 2 Installation

2.1 Installation Preparation

2.1.1 Environmental Conditions

Make sure the following environmental conditions are satisfied when selecting the
installation site:

Table 2-1 Environmental conditions in power room

Environmental conditions Recommended range
-5~50°C (If ambient temperature > 45°C, for the cabinet with
Ambient temperature 400mm depth, it should demount the front door of cabinet to
ensure the normal operation of the system.)
Humidity ≤90%RH, non-condensing
Dust ≤1mg/m3
Sunlight No direct sunlight
Corrosives No pollutants, such as salt, acid, and smoke, etc.
Shake ≤1.5m/s2
Insects, pests, and termites None
Mildew None
Moisture Water proof
Fire protection No flammable on the top/bottom of the cabient.

The DC Power system will be damaged if dust or sand accumulates in it. The
following measures are recommended for dusty environment:

1.The system should be installed in an airtight and air-conditioned power room. The
air-conditioner filter should be well serviced without being obstructed. To reduce the
dust in the power room, un-attendance in the power room is recommended.

2.The air filter should be cleaned periodically.

3.The product should be installed on a cement ground.

2.1.2 Power Supply

AC power supply for communication uses AC mains as its main power source.
Backup batteries and generator should be configured according to the actual power
supply situation. The AC power supply system composed of AC mains and
generator should adopt centralized power supply mode to supply power, while low

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voltage AC power supply system should adopt three-phase five-line or single-phase

three-line modes.

The AC power cable should adopt copper core cable, and the cable section should
suit the load. It is recommended that the power cable outside the power room be
buried directly under the ground or by means of cable pipe. Power cable should be
wired separately from signal line.

The AC mains voltage shall be within the range of the voltage input range of
rectifiers.

The DC power system has a circuit breaker that can cut the AC mains power to it.

2.1.3 Site Survey

The power room must be surveyed prior to installation, which should be focused
on:

1. Checking the wiring device, including cable chute, wiring rack, floor, wiring holes.

2. Checking the environmental conditions, including temperature, humidity, dust.

3. Checking the conditions for implementing the installation, including power supply
and lighting.

2.1.4 Tools & Material

1. Tools required for power equipment installation include electric drill, wire cutter,
wire presser, various wrenches, screwdriver, electrician knife, and steel saw. The
tools must be insulated and antistatic handled before they are used.

2. Power cables for electrical connection include AC cables, DC load cables,

battery cables, earth cables, earth bar and lighting connection cables. Their design
specifications should be in accordance with relevant specifications in the electrical
industry and the materials should be purchased according to the design material
list.

AC cables: this system uses 3-phase or single-phase AC power. Copper-core

flame-retardant PVC insulated cable and PVC sleeve soft cable, such as NH-BVR,
are recommended for the AC cables, whose sectional area should suit the load.
When the wiring distance is less than 30 meters, take 2.5A/mm2 of economical
current density to calculate the sectional area of the AC cables.

The sectional area of the DC load cables and battery cables should be calculated
using the following formula:

A=ΣI×L/K△U

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14 Chapter 2 Installation

In this formula: A is the sectional area of the lead (mm2), ΣI is the total current (A)
flowing through the lead, L is the length (m) of the lead loop, △U is the permitted
voltage drop on the lead, while K is the conductivity. Kcopper=57. For safety, the
voltage drop on the cables connecting battery and load cannot exceed 3.2V.

The sectional area of the lightning protection earth cable should not be less than
6mm2, and that of the DC operation earth cable, usually between 35-50mm2, is
determined by user. Take the greatest sectional area among the above 3 earth
cables as that of the cable connecting the user earth bar.

3. Purchase materials according to the materials list and inspect the materials, for
example, check the heat durability, moisture resistance, flame resistance, and
voltage resistance of the cable.

4. The auxiliary materials for power supply installation include expansive bolts,
binding strips, and insulating tape.

2.1.5 Unpacking

To ensure smooth installation, the power equipment must be carefully inspected

when it is unpacked.

The equipment unpacking and inspection are allowed only after it arrives the
installation site. The inspection is co-accomplished by the user representative and
representative from Emerson Network Power Co., Ltd.

When inspecting the equipment, first open the packing case with packing list put in
it, take out the packing list, and conduct inspection against the packing label,
including the customer name, customer address, machine No., total amount, case
No., contract No., etc.

Unpacking and inspection: after opening the packing case, check the goods one by
one according to the goods list on the packing label. The checking should include:

1. The number and serial number marked on the packing cases according to the
actual number of the packing cases.

2. The correctness of the equipment packing according to the packing list.

3. The number and model of the accessories according to the accessory list.

4. The completeness of the equipment set according to the system configuration.

5. The condition of the goods through visual inspection. For example, check if the
cabinet is damaged, if the cabinet has regained moisture; shake gently the rectifiers
and monitoring module to see if the parts and connections have been loosened
during delivery.

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2.2 Installation Procedures

2.2.1 Cabinet Installation

Installation on the floor

Step 1: mark the position where the power system is to be installed.

Determine the installation position of the power supply cabinet in the power room
according to the installation chart. Based on the mechanical specifications (see Fig.
2-1) of the installation holes of the power supply cabinet, determine the accurate
position of the center points of the installation holes on the floor, and mark them
with a pencil or oil pen.

(Applicable to the cabinet with 600mm depth)

(Applicable to the cabinet with 600mm depth)

Figure 2-1 Installation dimensions of the cabinet base

Step 2: drill reserve holes.

The expansive pipes delivered with the power system are M10%55mm, therefore,
use electric drill with drill bit Φ12 and depth 70mm to drill holes at the center points
of the installation holes marked on the ground. To avoid being off-center, be careful

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16 Chapter 2 Installation

not to shake the drill, and try to keep as vertical as possible to the ground, as
shown in Figure 2-2.

Step 3: install expansive pipes.

Clean the dust, and insert the expansive pipe into the reserve hole, knock it down
gently using a hammer until the top of the expansive pipe is level with the ground,
as shown in Figure 2-2.

Expansive Power
pipe cabinet

1) Drill vertically 2) Clean the dust 3) Knock it into place 4) Tighten the bolt

Figure 2-2 Installing expansive pipe

Step 4: place cabinet in position

Move the cabinet to the installation position aligning the installation holes of the
cabinet to the expansive pipe on the ground.

Step 5: fix the cabinet

After the cabinet is in position, make some horizontal and vertical adjustments.
Insert some iron pieces under the lower edge and corner of the cabinet to adjust
the vertical obliquity of the cabinet within 5 degrees. Finally, screw down the tap
bolt with plain washer and spring washer into the expansive pipe, and tighten it with
wrench. The cabinet fixation is illustrated in Figure 2-3.

Tap bolt
Plain washer
Spring washer Cabinet base

Ground

Expansive pipe

Figure 2-3 Fixing cabinet with Tap

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2.3 External Electrical Connection Interface

2.3.1 Connection Of Input Cables

The AC input terminals, SPD, rectifier AC input switch, PE bus and PE terminals
are illustrated in Figure 1-6. SPD is just adjacent to the AC input terminals and has
been connected in before delivery. PE bus is at the top of the MFU and is
connected to the DC Power Cabinet through screws. PE bus is connected PE
terminal through a cable.

Connection requirements

The AC mains is connected to the AC input terminals directly. There are 6 AC input
modes as shown in Table 2-2:

Table 2-2 AC input modes

Item Function unit Amount
3P+N/380V AC input
1P+N /220V AC input
L1+L2/220V AC input
AC distribution
3P/220V AC input
Terminals only - for individual rectifier AC feeds
2P MCB only - for individual rectifier AC feeds

Connection method

Strip the insulation layer of one end of the AC input cable, and then mounted the
cable end with an H terminal.

The cable mounted with an H terminal is shown in Figure 2-4.

H Terminal

AC Input Cable

Figure 2-4 Cable mounted with H terminal

After attaching the H terminal to the AC input cable, connect the AC input cable to
the AC input terminals as shown in Figure 2-5:

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AC input terminals

Figure 2-5 Connection of input terminals

The AC input cable is fed to the system through the top cover of the cabinet, as
shown in Figure 2-6:
AC input cable

Top cover
Cable bracket

Figure 2-6 Top cover

There is a cable bracket on the top cover. The input cables are bound to the cable
bracket with a cable tie.

Different cable connection modes

There are 4 AC input terminals. For 3-phase AC power input, just connect the AC
input cables as shown in Figure 2-7:
L1 L2 L3 N

AC input terminals

Figure 2-7 Connection of 3-phase AC power input

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 Chapter 2 Installation 19

For single-phase AC power input, connect the AC input cables as in Figure 2-8:
L N

AC Input Terminals

Figure 2-8 Connection of single-phase AC power input

If the AC input is single phase, the second and fourth terminals are not connected.

For dual-phase AC power input, connect the AC input cables as in Figure 2-9:
L1 L2

AC Input Terminals

Figure 2-9 Connection of dual-phase AC power input

If the AC input is dual-phase, the second and fourth terminals are not connected.

The yellow, green, red, and light blue AC cables correspond respectively to the AC
phase L1, L2, L3 and neutral lines. If the cables are the same color, they should be
identified with labels.

The AC cables should be laid separately from the DC cables.

No splice, damage, or scratch on the cables is permitted.

The rectifier AC input cables have already been connected in factory.

Note
1.To insure AC input cable has enough bearing current capability, the section area of the AC
input cable for 3-phase AC power input should not be less than 10mm2; and for single-phase
AC power input and dual-phase AC power, it should not be less than 25mm2. The section
area of input earth line should not be less than 35mm2.
2. The external AC input MCB of cabinet must be sure to disconnect all the AC input lines
(including live lines, zero line), but input earth line can not be disconnected by any breaking
device. It is recommended that the rated current of the AC input MCB is not less than 125A.

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2.3.2 Connection Of Load Cables

Loads are connected to the MCB with suitable capacity to avoid their failure to
function in the case of overload. The capacity of the MCBs is recommended to be
about 1.5 times of the peak value of the load capacity. The load circuit breakers are
shown in Figure 1-7. The circuit breakers can be ABB or CBI circuit breakers.

We take the CBI circuit breakers of 13mm for example to illustrate the load cable
connection, as shown in the Figure 2-10.

connected with
connected with high-priority load
low-priority load busbar
busbar

Low-priority
load busbar

Battery –48V busbar High-priority load busbar

Figure 2-10 Connection of load cables

Explanation: the load MCBs and battery MCBs can be configured flexible according
to the actual requirements. Their setting range is shown in the following table.

Table 2-3 Configuration number of load MCBs and battery MCBs

Busbar type Max. load number Note
Battery -48V busbar 0~5 Total number of the load should not
High-priority load busbar 0~19 exceed 20 with 18mm-width MCB or
Low-priority load busbar 0~28 not exceed 28 with 13mm-width MCB.

Cable connection to MCB: strip the power cable end, crimp-connect the copper
core to an H terminal, See Figure 2-4 for the cable mounted with a H terminal. After
attaching the H terminal to the cable, insert the cable into the wiring hole of the
MCB, then tighten the screw to fix the copper core, as shown in Figure 2-11:
Cable

H terminal

Figure 2-11 Cable connection to MCB

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 Chapter 2 Installation 21

Note
1. The cable should not be spliced. The load cable, signal cable and AC cables should be
wired separately as possible to avoid them affecting each other.
2. If the power supply system is in operation, switch off the DC output MCB before
connecting the cables.
3. The rated current of the output cable should be bigger than that of the corresponding
MCB connected with it.

DC output branch should match the load capacity. It is highly recommended to

connect priority load to BLVD branch, and normal load to LLVD branch.

2.3.3 Connection Of Communication Cables

There is a connector board in the rectifier shelf. The board is shown in Figure 2-12:

J10

J11

Ethernet Port

Figure 2-12 Connector board in rectifier shelf

There is an Ethernet port and a DB9 RS232 port on the front panel. For the
connection of communication cables, first connect the Ethernet port to the
transmission equipment, and then connect the DB9 RS232 port to the Main
Computer.

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2.3.4 Layout Of Connector Board S6415X2

Figure 2-13 Layout of connector board S6415X2

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2.3.5 Interface Definition Of Connector Board S6415X2

Table 2-4 Interface definition of connector board S6415X2

Connector Pin Signal name Mark number Logic relation
1 Relay output 1 normal close DO1_NC
2 Relay output 2 normal close DO2_NC
3 Relay output 1 common DO1_COM
J3
4 Relay output 2 common DO2_COM
5 Relay output 1 normal open DO1_NO
6 Relay output 2 normal open DO2_NO
1 Relay output 3 normal close DO3_NC
2 Relay output 4 normal close DO4_NC
3 Relay output 3 common DO3_COM
J4
4 Relay output 4 common DO4_COM
5 Relay output 3 normal open DO3_NO
6 Relay output 4 normal open DO4_NO
1 Relay output 5 normal close DO5_NC
2 Relay output 6 normal close DO6_NC
3 Relay output 5 common DO5_COM
J5
4 Relay output 6 common DO6_COM
5 Relay output 5 normal open DO5_NO
6 Relay output 6 normal open DO6_NO
1 Relay output 7 normal close DO7_NC
2 Relay output 8 normal close DO8_NC
3 Relay output 7 common DO7_COM
J6
4 Relay output 8 common DO8_COM
5 Relay output 7 normal open DO7_NO
6 Relay output 8 normal open DO8_NO
1 Digital circuits power +5V
J10 2 Temperature signal 1 input TEMP1 4~20mA
3 Analog ground GND
1 Digital circuits power +5V
J11 2 Temperature signal 2 input TEMP2 4~20mA
3 Analog ground GND
1 Data Carrier Detect DCD232
2 Receive Data RXD232
3 Transmit Data TXD232
4 Data Terminal Ready DTR232
J12, J18
5 Data Communication ground DGND
6 Empty
7 Request To Send RTS232
8,9 Empty
1 Ethernet TX+ NETTX+
2 Ethernet TX- NETTX-
3 Ethernet TR+ NETTR+
J13 4 Empty
5 Empty
6 Ethernet TR- NETTR-
7~12 Empty

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Connector Pin Signal name Mark number Logic relation

1 RS485 communication+ E485+
J14 2 RS485 communication- E485-
3 Protection ground PGNG
1 48V+ POWER+
J19
2 48V- POWER-

2.3.6 Connection Of Temperature Sensor Cables

There are two 3-pin terminals on the connector board in rectifier shelf. These two
terminals are J11 and J10 respectively. They are used to connect the temperature
sensors. The locations of J11 and J10 are as shown in Figure 2-12.

The user can connect the temperature sensor cables to J11 and J10.

2.3.7 Connection With MODEM

Take e-TEK TD-5648DC MODEM for example to illustrate the connection.

Power

Figure 2-14 Input/output interfaces of TD-5648DC MODEM

Conneting modem with M500D control unit

MODEM connects with M500D monitoring module through connector board

S6415X2:

1. Connect telephone line to the “LINE” port of MODEM.

2. Connect the 48V “POWER” terminal of MODEM with the J19 socket of connector
board S6415X2.

3. Connect “RS-232” (DB25 female) communication port of MODEM with the J12 or
J18 terminal (DB9 male) of connector board S6415X2 using a communication
cable.

Note
When the cabinet has a front door, before connecting the RS232 terminal, pull out the
S6415X2 board first, pass the RS232 terminal through the opening on the right side of the
rectifier subrack and connect it with the J18 terminal on the S6415X2 board, then insert the
S6415X2 board.

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2.3.8 Connection With Dry Contacts

The M500D monitoring module provides 8 sets of alarm dry contacts through the
J3-J6 sockets on the connector board S6415X2. Each set has a normally open
contact and a normally closed contact. Once the corresponding alarm event occurs,
the dry contact will act to report alarms under the control of M500D monitoring
module. Through the dry contact networking, the system can realize the level
isolation transmission of fault signals.

When delivery, each set of dry contacts is corresponding to one default alarm type,
and users can reset it as other alarm types.

Connecting method

After peeling the signal cable terminal, insert it into the dry contact terminal, then
tighten the hold-down bolt to compress the signal cable.

2.4 Battery Installation And Cabling

2.4.1 Battery Installation

The DC Power System with standard configuration has 4 battery strings. The DC
Power System with non-standard configuration can connect to up to 5 battery
strings. In the system cabinet, there are 5 levels and each battery string is installed
in one level. One battery string has four +12V battery blocks.

Procedures to install battery:

1. Install the batteries in the cabinet from low level to high level;

2. Place the battery on the level and push it inward until the battery is blocked;

3. Connect the positive and negative battery cable to the battery string.

The cabinet with four battery strings installed is shown in Figure 2-15:

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26 Chapter 2 Installation

Battery Connection Unit(BCU)

Battery(4 in a string)

Battery Shelf

Figure 2-15 Cabinet with four battery strings installed

Note
To satisfy the safety requirement of the whole equipment, the fire-retardant class of the
battery materials should not be lower than V-2.
Insure that the charge/discharge current of single battery group is not bigger than 100A, and
the total charge/discharge current of the all battery groups are not bigger than 200A.

2.4.2 Battery Cable Connection

The battery connection for the cabinet with standard configuration is different from
that of the cabinet with non-standard configuration.

Standard configuration

The DC Power System with standard configuration has no BCU. The system has
four battery strings. The negative battery cable is of blue color and the positive one
is of black color. There are two connection methods, one is for the cabinet of 600 %
400 % 700(mm), and another is for the cabinets of 600 % 400 % 2000(mm) and
600 % 600 % 2000(mm).

1) Batter Connection for Cabinet of 600 % 400 % 700(mm)

The four left-most circuit breakers in the MFU connect to the negative battery
cables (blue) respectively as shown in Figure 2-16. Another end of the negative

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 Chapter 2 Installation 27

battery cable is connected to the negative terminals of the battery string in each
level as shown in Figure 2-16:
Negative Battery Cables

4 Battery Circuit Breakers

Figure 2-16 Connection of battery cables.

2) Batter Connection for Cabinets of 600 % 400 % 2000(mm) and 600 % 600 %
2000(mm)

The connection is show in Figure 2-17:

Negative battery
cable
Positive battery
cable

Figure 2-17 Positive and negative battery cables in each level

One end of positive battery cable is connected to the neutral bus of the DC power
cabinet. Another end of the positive battery cable is connected to the positive
terminal of the battery string in each level as shown in Figure 2-17.

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Note
The actual number of battery circuit breakers in MFU may be 0~5 according to the user’s
need.

Non-standard configuration

The DC power system with non-standard configuration has a BCU. The connection
of positive cables is the same with that of the system with standard configuration.
The only difference is that there are five positive battery cables because the system
has five battery strings. One end of positive battery cable is connected to the
neutral bus of the DC power cabinet. Another end of the positive battery cable is
connected to the positive terminal of the battery string in each level as shown in
Figure 2-17.

One end of negative battery cable is connected to the negative terminal of the
battery string in each level as shown in Figure 2-17. Another end is connected to
the BCU as shown in Figure 2-18. The connection has already been done in
factory.

Negative Battery Cables(Blue)

Figure 2-18 Negative battery cables connection in BCU

Note
1. Before connecting the battery cables, the corresponding battery fuse or the battery switch
must be disconnected.
2. Be careful not to reverse connect the battery, otherwise, the battery and the power supply
system will be damaged!

Since the battery voltage decreases in discharge, hence the sectional area of the
cable connecting the battery and the MFU or BCU should be relatively big to keep
the voltage drop on the cable within 0.5V.

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2.5 Parallel Connection Of Cabinets

In order to prolong the backup time of battery, the battery capacity should be
increased. Another cabinet can be connected in parallel with the DC power system
cabinet. The expanded cabinet has no rectifier shelf and Multi-Function Unit. It is
only installed with battery strings and a BCU. So, it is actually the battery cabinet.
BCU in Extension Unit connects to Main Unit through cables. The parallel
connection of the DC power system cabinet with the battery cabinet is shown in
Figure 2-19:

Main cabinet Extension cabinet

BCU

Batteries

Figure 2-19 Parallel connection of DC power system cabinet with battery cabinet

DC/Parallel connections

The DC cables are connected to the output of the rectifier shelf in the MFU.

Up to two Battery Connection Units (BCUs) can be connected in the DC Power

System – up to one BCU in the main cabinet and up to one BCU in an extension
battery cabinet.

SCU can display the alarm signals from these two BCUs.

The user can connect the MFU to an additional extension MFU (only for additional
load circuit breakers) through suitably rated cables.

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Chapter 3 Startup

3.1 Checking Before Startup

Check the DC Power System according to Table 3-1 before startup.

Table 3-1 System checklist before startup

Comments (fill in
Item Action Result
“Ok” or not)
Check all the circuit breakers of the
1 They should be switched off.
shelf and BCU
Check the mains supply fuses/circuit
2 They should be removed/switched off.
breakers.
Check with an ohmmeter between
3 the positive and negative terminals of They must be no short circuit (>50ohms)
battery.
Check with an ohmmeter between
4 the battery terminals and shelf They must be no short circuit (>50ohms)
chassis.
Check the battery block voltage and The voltages shall correspond to the
5
total battery voltage. values given by battery manufacturer.
The voltage shall be within the rectifier
6 Check the mains phase voltage.
input voltage range (85Vac~290Vac).
The cables shall be connected to their
7 Check the connection of cables.
correct terminals firmly.

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3.2 Startup Process

Comments (Fill
Item Action Result
in “OK” or not)
The LEDs on the rectifiers and the
controller will emit light.
The rectifier fans will start.
Connect/switch on the mains supply
1 The LVD contactors will operate.
fuses/circuit breakers of the DC shelf.
The green LEDs of the rectifiers and
the controller will flash for about 10 s.
and then emit steady light.
The voltage should be close to what
has been set in the controller.
Check the DC voltage on the test outlet
2 If temperature compensated charging
marked U in the supervision unit.
is activated, the difference may be ±3
V from the set value.
If temperature compensated
charging is activated, warn the
3 The voltage should start to drop.
sensor on the battery with your hand
and observe the system voltage.
The battery voltage will increase and
reach the system voltage.
4 Switch on the battery circuit breakers.
(Might take hours, depending on the
charging state of the battery.)
5 Switch on the circuit breakers in MFU. The loads will get DC supply.
Only the green LEDs are On should
6 Check all the LEDs of the shelf.
emit light. No LED shall flash.

3.3 Parameters Configuration

After start up the DC Power System, following parameters need to be configured:

Password, AC parameters, DC parameters, rectifier parameters, battery

parameters, time and communication parameters.

Refer to Chapter 5 on how to configure the parameters.

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32 Chapter 4 Testing

Chapter 4 Testing

4.1 Testing MFU

Measure the L-N voltage at the input terminals with a multi-meter to check if it is
normal.

4.2 Testing Rectifier

1. Turn on one rectifier input MCB in the MFU to feed AC supply to the
corresponding rectifier, the rectifier should operate normally;

2. Turn off this MCB, and turn on the other rectifier input MCBs one by one to check
if all the other rectifiers operate normally.

If all of the rectifiers can operate normally, switch them on. In case of rectifier
malfunction, take the rectifier out and inspect it.

4.3 Testing SCU

When the rectifiers are operating normally, switch on the SCU, the SCU should
start and display the start screen. If the system self-test is normal, seconds later,
SCU displays Initial Screen with System Information:
2004-09-16
53.5V 300 A
System: Alarm
Auto /BC

There are default system parameter settings in the SCU, including the AC voltage
alarm points, DC voltage alarm points, battery management parameters, which are
available on the parameter card delivered with the system. If the battery capacity or
charging parameters set by user are different from those on the parameter card, or
if user has different BLVD management requirements, please reset the system
parameters according to the actual situation, and record the new settings on the
parameter card.

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4.4 Battery Breaker Test

1. Before turning on the battery circuit breaker, confirm with a multi-meter that the
battery is not reverse-connected.

2. When connecting the battery, be careful not to short the two battery terminals.

3. When connecting two batteries, be careful to avoid battery mutual charging due
to unequal terminal voltages of the two batteries.

4.5 BCU Test

The BCU can connect to a single battery via suitably sized cables from the
Distribution Unit.

The BCU can connect to up to five battery strings via suitably sized cables.

The user can route the battery cables via the left hand side and via the right hand
side of the BCU. A maximum of 7 cables can be routed via the left hand side of the
BCU and a maximum of 5 cables via the right hand side of the BCU.

The user can mount the BCU 15mm or more above a Front terminal battery. Care
shall be taken to connect the battery to the BCU via cables in this orientation.

The user can safely connect battery cables on a live system with only front access.
BCU can be partially slid out in order for this to be achieved.

The user can safely install or replace a battery circuit breaker on a live system with
only front access. BCU can be partially slid out in order for this to be achieved.

4.6 Load Breaker Test

Before connecting load to the system, check with a multi-meter if the connection
polarity of the load and the power system is correct and the voltage is normal.

1. Close the load MCB, DC power should be fed to the load;

2. Adjust the system parameters through the SCU, and make sure that the
information viewing and output control functions are normal.

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Chapter 5 Operating SCU

5.1 Operation Panel

SCU has a LCD with backlight, keys, LEDs and a latch, as shown in Figure 5-1:
运行指示灯
Run indicator

Alarm
告警指示灯 indicator

Critical
紧急告警指示灯 alarm indicator

LCD
液晶显示屏

ESC ENT 功能操作键 keys

Functional
M500D

Figure 5-1 SCU Front Panel

Functions of LED indicators are illustrated in Table 5-1

Table 5-1 Functions of LED indicators

Indicator Normal state Fault state Fault cause
RUN (Green) On Off No operation power supply
Alarm (Yellow) Off On There are observation alarms
Critical alarm (Red) Off On There are major or critical alarms

SCU controller uses a 128×64 dot-matrix LCD unit. It has 6 functional keys. Its
interface is easy-to-use and supports multi-language display. The panel of the
controller is easy-to-remove. The functions of these 6 keys are shown in Table 5-2:

Table 5-2 Functions of SCU keys

Key Function
ESC Return to the upper level menu.
Pressing ESC and ENT simultaneously
Enter the main menu or confirm the menu
ENT can reset the monitoring module
operation
“ ” and
Shift among parallel menus or parameters. To change a character string whose
“ ” digits needs setting separately, use
Change values at a value setting interface. “ “ and “ “ to move the curso left or
“ ” and
At the first page of system information, use right, or “ ” and “ ” to set each digit.
“ ”
these two keys to change LCD contrast.

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5.2 Operation Procedures

After the system is powered on for the first time, you should set the system type
according to the actual configuration. The monitoring module will restart after the
system type is changed. In that case, you should re-configure those parameters
whose default values are inconsistent with the actual situation. Only after that can
the monitoring module operate normally.

After configuring the system parameters, you can carry out various operations
directly without resetting the parameter values. As for those important parameters
related to battery management, such as BLVD, you should be fully aware of their
influence upon the system before you change their values.

Note
For the exact meanings of the abbreviations used in LCD displayer, see Appendix E
Glossary.

1. The LCD will prompt you to select a language once the monitoring module is
powered on.

英文
English

You can use “ ”, “ ”, “ ” or “ ” to select the language you want, and press
“ENT” to confirm.

2. The monitoring module will prompt you to wait, and start initialization.

Waiting……..

3. The first system information page appears

2004-09-16
53.5V 125 A
System: No alarm
Auto /BC

The system information is shown in many pages. You can repeatedly press “ ” to
view other system information pages in a cycle.

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4. At any system information page, press “ENT” to enter the “MAIN MENU” page,
which contains 3 sub-menus: “Status”, “Maintenance” and “Settings”.

Main Menu
Status
Maintenance
Settings

You can press “ ” or “ ” repeatedly to select a sub-menu, and press “ENT” to

enter the sub-menu. Press “ESC” to return to the menu of higher level.

1) Status

Including rectifier information, active alarm information and alarm history

information.

2) Maintenance

The maintenance operation can be conducted only when the battery management
mode is set to “Manual”. The maintenance includes battery FC, BC and test, load
power off/on, battery power off/on and rectifier voltage trimming, current limit,
switch control and resetting.

3) Settings

Including the setting of alarm parameter, battery parameter, AC/DC parameter,

rectifier parameter and system parameter.

5.3 Querying System Status

5.3.1 First Page Of System Information

1. At the main menu page, press “ESC” to return to the first system information
page.

2. If no operation is conducted on the monitoring module keypad for 8 minutes, the

LCD will return to the first system information page and shut down the backlight to
protect the screen. Pressing any key will turn on the back light.

The first system information page contains the major system operation information,
including date/time, busbar voltage, total load current, system operation state
(normal or alarm), battery management mode (AUTO or MANUAL) and battery
state.

Among which, the battery state include FC, temperature compensation, BC, Cyclic
Boost, test, short test and scheduled test. The current time are displayed in two
pages shifting at the interval of 2s. One page shows year, month and date, the

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 Chapter 5 Operating SCU 37

other shows hour, minute and second. The year is displayed with 4 digits; other
time units are in 2 digits.

10:09:16
53.5V 125 A
System: No alarm
Auto /BC

2004-09-16
53.5V 125 A
System: No alarm
Auto /BC

Note
1. At this page, you may use “ ” and “ " to adjust the LCD contrast (7-level).
2. If there has been no keypad operation for 8 minutes, the monitoring module will return to
the first system information page. The time of that return will be recorded automatically,
and can be queried through the host.

5.3.2 Other System Information Screen

The system information is shown in many pages. The default page of the
monitoring module after the system power on is the system information first page.
You can press “ ” or “ ” to scroll up or down to view more operation information,
as shown in the following page:

Battery information page

Batt1: 295 A
Actual: 99.1%
Batt2: 0 A
Remain: 0%

1. Battery 1, battery 2

They represent respectively the current of the battery that battery shunt 1 and shunt
2 is connected to. If the “Shunt Coeff” of a certain battery group is set to “No”, this
situation will be reflected at the battery information page by “Not connected”, and
no actual capacity will be displayed.

Note
There is only one current shunt in the system, that is “shunt 1”.

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2. Actual battery capacity

The monitoring module can approximately calculate the remaining battery capacity
in real time. Through configuration at the host, the remaining battery capacity can
be displayed in the mode of percentage, remaining Ah or remaining time, etc. The
default is the percentage.

During the normal BC/FC management, the monitoring module regards the rated
capacity as the capacity that each battery group can reach. When the battery
discharges, the monitoring module will calculate the battery remaining capacity
according to the discharge current, discharge time and the preset “battery
discharge curve”. When the battery is being charged, the monitoring module will
calculate the real-time battery capacity according to the detected charge current,
charge time and preset “battery charge efficiency”. If the calculated battery
remaining capacity is higher than the rated capacity, the monitoring module will
automatically change the calculated battery remaining capacity to the rated
capacity.

AC information page

There is no AC data acquisition board in ACTURA Flex 48330 Power System，so

the configuration of “AC Input” can only be set to “None”.

BC prompt and temperature information page

System Power:
23%
Cyc BC After:
55h

Bat. Temp:
25°C
Amb. Temp:
5°C

If the monitoring module bans BC and no temperature sensor is configured, this

page will not be displayed.

The first line of the information page displays the BC prompts, which will be
different with different systems, including:

1. Prompt the time of next Cyclic Boost according to the battery state

2. If BC is going on, the “Charging” will be prompted

3. If BC is disabled, this row will be empty

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The 2nd and 3rd rows of the page are the temperature information detected by the
temperature sensor. The display will vary with different parameter settings (see 4.7
for parameter setting). If the temperature sensor is not connected or is faulty,
system will prompt invalid. Meanwhile, the 4th row will display “Check Temp
Sensor”.

5.4 Querying Rectifier Status

The rectifier information includes the rectifier serial No., voltage, current, current
limit, mains situation, rectifier power limit and temperature power limit.

1. At any page of the system information, press “ENT” to enter the main menu.

2. Use “ ” or “ ” keys to select the “Status” sub-menu in the main menu, and
press “ENT” to confirm.

Status
Rectifiers
Active Alarm
Alarm History

3. Use “ ” or “ ” to select the “Rect Info” submenu, as shown in the above figure.
Press “ENT” to confirm.

Rect 1: 01234567
54.1V 30.2A
AC On DC on
AC Volt: 220V

Rect 1: 01234567
CurrLimit: 34%
AC Derated: Y
Temp Derated: N

The information of every rectifier is displayed in two pages. The information in the
first page includes: rectifier serial No., output voltage and current, AC/DC on/off
state and AC input voltage. The information in the second page includes: rectifier
serial No., current limit, the states of “AC Derated” and “Temp Derated”. Press “ ”
to scroll to the next page, or “ ” to return to the last.

4. Press “ ” or “ ” to query other rectifier’s information.

At most 48 pieces of rectifier’s information can be displayed. If the rectifier does not
exist, there will be no information. If the rectifier communication is interrupted, the
information will be displayed in high light.

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5. At any rectifier information page, press “ESC” repeatedly and you can return to
the higher-level menus.

5.5 Querying Alarms And Setting Alarm Plans

The monitoring module can locate and record the system fault according to the
collected data, as well as raise audible/visual alarms and output through dry
contact according to the preset alarm level. Meanwhile, it reports the alarms to the
host.

You can query historical alarms and active alarms through the LCD of the
monitoring module.

5.5.1 Querying Active Alarm

When a new alarm is raised, and there is no operation on monitoring module

keypad within 2 minutes, the LCD of the monitoring module will prompt
automatically the active alarm.

If there are multiple alarms in the current system, you can query alarms through the
following steps:

1. At any system information page, press “ENT” to enter the main menu

2. Use “ ” or “ ” to select the “Status” submenu in the main menu and press
“ENT” to confirm.

Status
Rectifiers
Active Alarm
Alarm History

3. Press “ ” or “ ” to select the “Active Alarm”, as shown in the above figure, and
press “ENT” to confirm.

1) If there is no active alarm, “Active Alarm: None” will be displayed

Active Alarm!
None

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 Chapter 5 Operating SCU 41

2) If there is any alarm, the display will be like the following:

Active Alarm!
3

1 Major Alarm
AC! Ph-A Failure
040412 12:30:23

The information in the active alarm information pages includes: alarm serial No.,
alarm level, alarm name and time (year, month, day, hour, minute and second). The
alarm raising time determines the sequence it is displayed, with the latest alarm
displayed first. Use “ ” or “ ” to view all active alarms.

While querying rectifier alarms, press “ ”, and the rectifier ID will be displayed,
and the “Run” indicator of the corresponding rectifier will blink.

Rect ID
02030405

In the case of battery test alarm or maintenance time alarm, press “ ” to display
the prompt information.

Notice:
Press ENT Clear
ESC Key Quit

In the prompt page, press “ENT” to confirm the alarm.

4. At any active alarm information page, press “ESC” repeatedly and you can return
to the higher-level menus.

5.5.2 Query Alarm History

1. At any system information page, press “ENT” to enter the main menu

2. Press “ ” or “ ” to select the “Status” submenu, and press “ENT” to confirm.

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42 Chapter 5 Operating SCU

Status
Rectifiers
Active Alarm
Alarm History

3. Use “ ” or “ ” to select the “Alarm History”, as shown in the above figure and
press “ENT” to confirm.

If there is no historical alarm, the prompt will be “Alarm History: None”.

ALARM HISTORY
None

The historical alarms of the monitoring module are stored in cyclic order. Up to 200
alarms will be recorded. Above that, the earliest alarm will be cleared automatically.

1Alarm
SPD Fault
040411 20:08:30
040411 22:08:30

At the monitoring module, the displayed historical alarm information includes: alarm
serial No., alarm name and alarm start/end time (year, month, day, hour, minute,
second).

If it is a rectifier that raised the alarm, the ID of that rectifier will be displayed.

4. At any Alarm History information page, press “ESC” repeatedly to return to the
higher-level menus.

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5.5.3 Alarm Type Table

Table 5-3 Alarm type table

Default
Serial Default Related parameter
Alarm Description related
No. alarm level configuration
relay
1 Input MCB Trip The system AC input MCB tripped Critical None Only in a system with
2 SPD Fault The SPD circuit is faulty Critical 8 AC sampling board
In a system with AC
The alarm name is user defined, not sampling board, you can
longer than 10 characters. The name 2 routes; in a
3 Digit Input Fault No alarm None
high/low level alarm can be set in the system without AC
alarm mode. sampling, you can name
8 routes
4 DC/DC Failure Including DC/DC converter fault Critical None
The system AC input voltage is
5 AC Over Volt higher than the set value of Critical None Over-voltage alarm
parameter “OverVolt”
The system AC input voltage is lower
6 Ph-X Volt Low than the set value of parameter Critical None Under-voltage alarm
“LowVolt”
The AC input voltage of the power
7 Phase failure Critical None
system is lower than 80V
In double-AC auto-switchover
system:
1. All AC voltage inputs are lower
than 80V.
2. Both AC inputs 1 and 2 are
8 Power Failure Major 1
broken.
In single AC input system or
double-AC manual-switchover
system, the AC voltage of all
rectifiers are lower than 80V
System DC output voltage is higher
9 DC Voltage High than the set value of parameter Critical 2 Over-voltage alarm
“Temp Threshold: Over”
System DC output voltage is lower
10 DC Under-volt than the set value of parameter Critical 2 Under-voltage alarm
“Temp Threshold: Under”
System DC output voltage is lower
11 DC Voltage Low than the set value of parameter Observation 2 Low-voltage alarm
“Temp Threshold: Low”
Battery temperature is higher than
Over-temperature alarm
12 Batt Overtemp the set value of parameter “Temp Major None
point
Threshold: Over Temp”
Battery temperature is higher than
High temperature alarm
13 Batt Temp High the set value of parameter “Temp Observation None
point
Threshold: High Temp”

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Default
Serial Default Related parameter
Alarm Description related
No. alarm level configuration
relay
Battery temperature is lower than the
Low temperature alarm
14 Batt Temp Low set value of parameter “Temp Observation None
point
Threshold: Low Temp”
Ambient temperature is higher than
15 Amb Temp High Observation None
the set alarm point
Ambient temperature is lower than
16 Amb Temp Low Observation None
the alarm point
Temperature sensor 1 has been set,
17 No TempSensor1 Critical None
but no sensor is actually connected
Temperature sensor 2 has been set,
18 No TempSensor2 Critical None
but no sensor is actually connected
TempSensor1 Temperature sensor 1 detected
19 Critical None
Err unreasonable temperature
Temperature sensor 2 detected
20 TempSensor2 Err Critical None
unreasonable temperature
1. Load disconnection
21 LLVD Critical 5 LLVD enabled
2. Manual load disconnection
1. When battery discharges till its
voltage is lower than the “BLVD
Volt”, or the discharge time is longer
22 BLVD Critical 4 BLVD enabled
than the “BLVD Time”, the BLVD
contactor will be open automatically
2. BLVD through manual operation
Over-load, short circuit, manual
23 Load 1 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
24 Load 2 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
25 Load 3 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
26 Load 4 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
27 Load 5 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
28 Load 6 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
29 Load 7 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
30 Load 8 Faiure Critical 6
disconnection or alarm circuit faulty
Over-load, short circuit, manual
31 Load 9 Faiure Critical 6
disconnection or alarm circuit faulty
32 Aux Load Fails The last route faulty Critical 6
Over-load, short circuit, manual
33 Batt1 Failure Critical None
disconnection or alarm circuit faulty
Over-load, short circuit, manual
34 Batt2 Failure Critical None
disconnection or alarm circuit faulty
Over-load, short circuit, manual
35 Batt3 Failure Critical None
disconnection or alarm circuit faulty

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 Chapter 5 Operating SCU 45

Default
Serial Default Related parameter
Alarm Description related
No. alarm level configuration
relay
Over-load, short circuit, manual
36 Batt4 Failure Critical None
disconnection or alarm circuit faulty
The charge current of battery group 1
37 Batt1 Over-curr is bigger than the set value of Observation None
parameter “Over”
The charge current of battery group 2
38 Batt2 Over-curr is bigger than the set value of Observation None
parameter “Over”
All AC voltages are lower than the
39 Rect Vac Err Major 3
AC low-volt point
Rectifier internal temperature higher
40 Rect Over Temp Observation None
than 90°C
Rectifier over-voltage, higher than
41 Rect Failure Critical 3
rectifier high threshold
AC over-voltage (ƒ295V) or
42 Rect Protect Observation 3
under-voltage ( 80V)
43 Rect Fan Fails Fan faulty Major 3
AC voltage lower than 176V, with
44 Rect PowerLimit rectifier internal higher than 85°C or Observation 3
temperature at inlet higher than 45°C
Rectifier and monitoring module
45 Rect Com Failure Major 3
communication interrupted
46 Multi Rect Fail More than 2 rectifiers raised alarms Critical None
Error is detected through hardware
47 Self-detect error No alarm None
self-detection
Battery management in the manual
48 Manual Mode No alarm None
state
Including auto-BC, Cyclic Boost,
49 Non-FC Status No alarm 7
constant current test and short test
50 Batt Discharge Battery being discharging No alarm None
In a system with load shunt, the
detected load current plus battery Not existent in this
51 Curr Imbalance No alarm None
current differs sharply from the power system series
rectifier output current
Battery discharge time unexpectedly
52 Batt Test Error Observation None
short
During the short test, the two
53 Short Test Fault batteries discharged more than the Observation None
set value
The maintenance FC voltage
different from the busbar voltage, or
54 Outvolt Fault Observation None
the reported data. The difference is
more than 1V
The pre-set system maintenance
55 System Maintain Observation None
time is due
Alarms sent to the host are blocked,
56 Alarm Block No alarm None
valid in EEM-M protocol

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Note
When the DC load 9 and its above (load 10, load 11 …) have circuit fault alarm, the
monitoring module all display “Load 9 Failure” or “Aux Load Fails”.

5.5.4 Changing Audible/Visual Alarm And Alarm Call Back Plan

There are different audible/visual alarms and call back modes for alarms of different
levels. For the products in China market, the alarming mode for major alarms and
critical alarms are the same.

Table 5-4 Changing audible/visual alarm and alarm call back plan
Red Yellow Alarm
Alarm level Call back Remark
indicator indicator horn
Critical ON / ON Y Callback No. can be set
Major ON / ON Y Callback No. can be set
Observation / ON OFF N
No alarm OFF OFF OFF N

Therefore, changing the alarm level of different alarms may change their
audible/visual alarm mode and call back plan too.

Pressing any key on the monitoring module can silence the alarm sound. The
sound will disappear and alarm indicator will be off when all alarms are cleared.

You can configure how long an alarm sound will last, or choose to make no alarm
sound. For details, see 5.7.11 Alarms Settings.

5.5.5 Changing Alarm Types Of Dry Contacts

As one of the alarm type parameter, “Related Relay” refers to the serial No. of the
dry contract corresponding to the alarm type, whose value is either 1 ~ 8 or “None”.
“None” means there is no corresponding dry contact. For details, see 4.7.11 Alarms
Settings.

5.5.6 Setting Alarm Type For Dry Contacts

The Programmable Logic Control (PLC) is configured through the host software.

The way to configure the PLC function is:

C = A (Status) * B (Status)

C: The dry contract serial No. of the corresponding output. Range: 1 ~ 8.

A, B: The input alarm type. Status: Whether the alarm has been raised.

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 Chapter 5 Operating SCU 47

*: The logic relationship between the two alarms. Options: “And”/”Or”.

The optional alarm types are listed in the following table:

Table 5-5 Optional alarm types

Alarm type Remark
Alarm Block
Load route 1
Load route 2
Load route 3
Load route 4
Load route 5
Load route 6
Load route 7
Load route 8
Load route 9
Auxiliary load route
SPD faulty
AC input MCB tripped
Valid in the double AC inputs auto-switchover
AC route 1 in operation
power system
AC route 2 in operation
DC/DC faulty
Digit Input (DI) 7
DI 8
DC voltage
Phase A of AC route 1
Phase B of AC route 1
Phase C of AC route 1 Valid in the double AC inputs auto-switchover
Phase A of AC route 2 power system
Phase B of AC route 2
Phase C of AC route 2
Load current Valid in the system with load shunt
Battery 1 current Valid in the system with battery shunt
Battery 2 current Valid in the system with battery shunt
Fuse of battery 1
Fuse of battery 2
Fuse of battery 3
Fuse of battery 4
Temperature detection 1
Temperature detection 2
Monitoring module in operation Used for monitoring module power off
Module self test
Manual mode
Non-FC state of battery
Battery discharge
Current imbalance
Battery short test
Battery test alarm
LLVD

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Alarm type Remark

BLVD
Output voltage abnormal
AC power off
Multiple rectifiers alarm
Time for system maintenance (replace the fan)
Any rectifier comm interrupted
Any rectifier AC power off
Any rectifier over-temperature
Any rctifier faulty
Any rectifier in protection
Any rectifier fan faulty
Any AC derated rectifier
Any temperature derated rectifier

For example: To make dry contact No.3 act when battery route 1 is broken but AC
power is still on, the PLC should be configured like this:

A: battery route 1, with “status” set as “Alarm”.

B: AC power off, with “status” set as “No alarm”.

C: Dry contact No.3

*: “AND”.

5.5.7 Set the Alarm Names Through PLC Function

Connect the serial port of MC to the RS-232 port of SCU, then configure the alarm
types that correspond to the dry contact outputs through MC.

An 8 (row) % 6 (column) logic matrix is used in configuring these 8 dry contacts.

Every row in the matrix corresponds to one dry contact. The setting of one dry
contact has 6 bytes.

Byte 0: The dry contact is disabled if byte 0 is set to 0, and enabled if byte0 is set to
1.

Bytes 1, 3 and 5 are the SN of the 3 alarms respectively. The range of SN is 0-56,
see section “5.5.3 Alarm List” for details.

Bytes 2 and 4 define the logic relationship between 3 alarms. The setting of byte 2
or 4 is 0-3. If the setting is 0, the logic is “AND”; If the setting is “1”, the logic is
“NOT”; If the setting is “2”, the logic is “OR”; and if the setting is “3”, the logic is
“AND”.

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Table 5-6 Logic matrix used for configuring 8 dry contacts

Setting 0,1 Alarm SN Logic Alarm SN Logic Alarm SN
Column(B)
0 1 2 3 4 5
Row(A)
Dry Contact 0 0
Dry Contact 1 1
Dry Contact 2 2
Dry Contact 3 3
Dry Contact 4 4
Dry Contact 5 5
Dry Contact 6 6
Dry Contact 7 7

The format of PLC setting is AlarmPLC[A][B]=C.

Where, “A” is the row No., and “B” is the column No., and “C” is the value of the
matrix element. An example is shown in the following table:

Table 5-7 Example of PLC setting

PLC byte Byte description Function
AlarmPLC[3][0]=1 Elemant value of Row 3 and Column 0 is 1. Use Dry Contact 3
AlarmPLC[3][1]=1 Elemant value of Row 3 and Column 1 is 1. Alarm SN of Fuse 1 Blow up
AlarmPLC[3][2]=3 Elemant value of Row 3 and Column 2 is 3. AND Logic
AlarmPLC[3][3]=2 Elemant value of Row 3 and Column 3 is 2. Alarm SN of Fuse 2 Blow up
AlarmPLC[3][4]=3 Elemant value of Row 3 and Column 4 is 3. OR Logic
AlarmPLC[3][5]=43 Elemant value of Row 3 and Column 5 is 43. Alarm SN of LLVD

For the above PLC setting: When alarms of “Fuse 1 Blow up” and “Fuse 2 Blow up”
occur at the same time, or LLVD occurs, dry contact 3 will output the alarm signal.

Relationship between PLC SN and Alarm:

Table 5-8 PLC SN and Alarm

PLC Alarm
Remark
SN description
0 Alarm Block Disabled for China Market, Enabled for rest of world
1 Load 1 Failure
2 Load 2 Failure
3 Load 3 Failure
4 Load 4 Failure
5 Load 5 Failure

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PLC Alarm
Remark
SN description
6 Load 6 Failure
7 Load 7 Failure
8 Load 8 Failure
9 Load 9 Failure
10 Aux Load Fails Load 10 is Auxiliary Load for China Market
11 SPD Fault Enabled when an AC Signal Acquisition Board is installed.
12 Input MCB Trip Enabled when an AC Signal Acquisition Board is installed.
Flag of Effective
13 Flag of Effective AC Input
AC Input
Flag of Effective
14 Flag of Effective AC Input
AC Input
15 DC/DC Failure Enabled when an AC Signal Acquisition Board is installed.
16 Digital Input 6
17 Digital Input 7
18 Digital Input 8
19 DC Voltage
20 Phase A of AC 1 Enabled when an AC Signal Acquisition Board is installed.
21 Phase B of AC 1 Enabled when an AC Signal Acquisition Board is installed.
22 Phase C of AC 1 Enabled when an AC Signal Acquisition Board is installed.
23 Phase A of AC 2 Enabled when an AC Signal Acquisition Board is installed.
24 Phase B of AC 2 Enabled when an AC Signal Acquisition Board is installed.
25 Phase C of AC 2 Enabled when an AC Signal Acquisition Board is installed.
26 Load Current Enabled when a load shunt is connected in DC Power System
27 Batt1 Curr Enabled when a battery shunt is connected in DC Power System
28 Batt2 Curr Enabled when a battery shunt is connected in DC Power System
29 Batt1 Fuse
30 Batt2 Fuse
31 Batt3 Fuse
32 Batt4 Fuse
33 Measured Temp1
34 Measured Temp2
35 SCU Working For LVD
36 Self-detect Error
37 Manual Mode
38 Non-FC Status
39 Batt Discharge
40 Curr Imbalance Only for China Market

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PLC Alarm
Remark
SN description
41 Short Test Error
42 BattTest Error
43 LLVD
44 BLVD
45 Outvolt Error
46 Power Failure
47 Multi-Rect Fails Disabled for China Market, Enabled for rest of world
48 Rect Fan Fails
49 Rect Com Failure
50 Rect Vac Err
51 Rect Over Temp
52 Rect Failure
53 Rect Protect
54 Rect Fan Fails
55 Rect PowerLimit
56 Derateby Temp

5.6 Maintenance

Note
1. This operation can be conducted only when the battery management is set to “Manual”.
2. Be careful! BLVD operations may result in power interruption.

Operation Procedures:

1. At any information page, press “ENT” to enter the main menu.

2. Press “ ” to select the “Maintenance” menu.

You cannot enter the system Maintenance menu if the “Battery Management” is set
to “Auto”.

3. Press “ENT” and input the correct operation password. Press “ENT” again to
enter the “Maintenance” menu.

Enter Password:
123456

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To input the password, use “ ” or “ ” to modify numbers, and use “ ” or “ ” to

move the cursor. After the input, press “ENT” to confirm.

If the password is incorrect, system will prompt “password incorrect”. If the

password is less than 6 digits, end it with a “#”.

Note
You can choose to enter the “Maintenance” menu by using either the user, operator or
administrator password, for in this menu, all users have the same authority.

4. Press “ ” or “ ” to scroll to the operation page you need.

There are two pages:

Maintenance
Start : BC
Batt: Reconnect
Load: Disconnect

RectTrim: 53.5V
CurrLimit: 110%
Rect 1: DC On
ID 01234567

5. Press " " and " " to select the needed action.

“Start”: The options include “FC”, “BC” and “Test”. If system is not configured with
any battery, the control would be invalid. If there is AC power off alarm, or the
busbar voltage is too low, the BC and battery test control will not be executed by
the system. No battery test control can be conducted when the rectifier
communication is interrupted. Finally, after the battery test, the battery management
mode will be changed from “Manual” to “Auto” automatically.

“Battery”: The options include “Reconnect” and “Disconnect”. If there is no battery,

or there is a battery alarm, the battery operations will be invalid.

“Load”: The options include “Reconnect” and “Disconnect”.

The following maintenance over the rectifier can be conducted only when the power
system is in the FC state.

”RectTrim”: Range: 42V ~ 58V. It can be used to improve the current sharing
among rectifiers. Note that the value of this parameter cannot exceed the
over-voltage alarm point, or the parameter will be invalid.

”RectLimit”: Range: 10% ~ 121%.

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The maintenance operations over a single rectifier include: “DC ON/OFF”, “AC
ON/OFF” and “Reset”. The operation method is:

① Use “ ” or ” ” to select the rectifier parameter, and “ ” or “ ” to change the

rectifier serial No. Then press “ENT” to confirm. The bottom line of the page
displays the rectifier ID.

② Use “ ” or “ ” to move the cursor to the maintenance operation area, and

“ ” or “ ” to select the value.

If the rectifier voltage is too high, you can select “Reset” to restore the output
voltage of that rectifier to normal.

6. There will be prompts as the confirmation of control commands. If the

maintenance operation is valid, system will prompt you press “ENT” to confirm and
execute the operation, or “ESC” to abort the operation. Otherwise, system will
prompt you the operation is invalid, and press “ESC” to quit.

Press ENT to Run

Other Key Quit

No Maintain!

ESC Quit

Press “ESC” to return to the menu of higher level.

5.7 Setting System Parameters

Battery parameters are very important, for they are related to the life of battery.
Before delivery, the battery parameters have been initialized. Without any special
needs, you only need to reset the battery group number and battery capacity, and
accept the defaults for other parameters.

5.7.1 Parameter Setting Method

1. At any system information page, press “ENT” to enter the main menu.

MAIN MENU
status
Maintenance
Settings

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2. Use “ ” or “ ” to select the submenu “Settings” and press “ENT” to confirm.

System will then prompt you to input the password.

Enter Password:
123456

3. Press " " or " " to select the number of password digits. Enter the password
digit by digit using “ ” or “ ”. Press “ENT” to confirm and enter the parameter
setting submenu.

Settings
Alarms Settings
Battery Settings
AC Settings

Parameter Set
DC Settings
Rect Settings
Sys Settings

Users with different password levels have different authorities. See the following
table:

Table 5-9 Password levels and authorities

Level Authority Default password
User Configuration of general parameters 123456
User’s authority, plus resetting system, resetting
Operator 654321
password and modifying system type.
Operator’s authority, plus modifying password of all
Administrator levels, controling alarm sound volume, browsing system 640275
parameters that can be set only through the host

4. There are two pages of “Settings”. Shift page by using “ ” or “ ”, and select
the parameter by using “ ” or “ ”. Press “ENT” to confirm.

As shown in the above figure, the monitoring module divides the parameters to be
set into 6 kinds: alarms parameter, battery parameter, AC parameter, DC parameter,
rectifier parameter and system parameter.

Among which, the battery parameters are divided into 5 kinds: basic, BLVD,
charging management, battery test, temperature coefficient, and they are displayed
in two pages, as shown below:

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Battery Setting
Batt. Selection
LVD Setting
Charge

Battery Setting
Batt. Test
Temp Comp

What follows is the description of the parameter functions and values by dividing
them into 5 small categories and 5 big categories.

5.7.2 Batt. Selection

1. The first page of the Batt. Selection is shown below:

Mode: Manual
Batt String: 1
Capacity: 300Ah
Batt Name: 1#

Use “ ” or “ ” to select the page and the parameter to be set, and “ ” or “ ” to

select the proper value for the parameter. Press “ENT” to confirm.

After setting the “Battery Type”, the following prompt will appear, asking you to
name a certain type of battery for the sake of identifying them:

Battery Name:
Batt1

To name a rectifier, you can use “ ” or “ ” to change the number, and “ ” or “ ”

to move the cursor left or right. Press “ENT” to confirm afterwards.

2. If setting parameter “System Type” does not require setting the battery shunt
coefficient, the second page of the basic battery settings is as follows:

Batt Shunt1:
Y
Batt Shunt2:
Y

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3. If setting parameter “System Type” requires setting the battery shunt coefficient,
the second page of the basic battery settings is as follows:

Batt Shunt1: Yes

Batt Shunt2: No
Shunt Coeff:
300A / 75mV

4. The value description of the basic battery parameters is listed below:

Table 5-10 Value description of the basic battery parameters

Parameter Range Defaults Value description
In normal situation, it should be in the “Auto” mode, which enables
the monitoring module manage the whole power system
automatically, including: Automatic FC/BC switchover, LLVD and
Mgmt Mode
BLVC. In the manual mode, you can do operations like BC, FC,
(Management Auto, Manual Auto
test and battery on/off, as well as enabling automatic battery BC
mode)
time protection and capacity calculation. Upon the system DC
under-voltage alarm, system can automatically switch to the “Auto”
mode, lest wrong manual operation should damage the system
Batt String You should set this parameter according to the actual battery
(number of 0~4 4 configuration. If “Batt Shunt” is set as “Y”, there should be batteries
battery strings) actually configured
Rated AH (rated The capacity of a single battery string. You should set this
50 ~ 5000Ah 300Ah
capacity) parameter according to the actual battery configuration.
BTT Name 1# ~ 11# 1#
Battery Name 10 characters Name different battery types to identify them
Batt Shunt1 Yes Select “Y” when a corresponding shunt is configured, otherwise,
Yes, No select “N”. Battery management aims at only the batteries
Batt Shunt2 No
connected to the shunt
Shunt Coeff In the system type setting, if the parameter “Shunt” is set to “Y”,
(shunt Dependent on system type this parameter will be displayed. Otherwise this parameter will take
coefficient) the default value, and is the same for both battery strings.

5.7.3 LVD Parameter Description

1. Function description

LLVD means the monitoring module opens the LLVD contactor, so that the
non-priority load will be powered off. In this way, the battery remaining capacity can
sustain the priority load longer.

BLVD means the monitoring module opens the BLVD contactor. In this way, the
battery will stop powering the load, preventing over-discharge.

2. There are 3 related pages, as shown below:

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LLVD Enable: Y
BLVD Enable: Y
LVD Mode:
Voltage

LVD Vlotage
LLVD: 44.0
BLVD: 43.2

LVD Time
LLVD: 300min
BLVD: 600min

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

Note
Generally you do not need to set the LVD parameters’ value. The defaults will do.

3. The value description of the LVD parameters is listed below.

Table 5-11 Value description of the LVD parameters

Parameter Range Default Value description
LLVD Enable Select “Y” to enable LLVD function
Y, N Y
BLVD Enable Select “Y” to disable the BLVD function
Time, Select “Voltage”, when the monitoring module detects that the battery
LLVD Mode Voltage
voltage voltage is lower than the prestet “LLVD Volt”, the load will be
LLVD Volt 44.0V disconnected, and so is the battery when the battery voltage is lower
40V ~ 60V
BLVD Volt 43.2V than the preset ‘BLVD Volt”.
LLVD Time 300min Select “Time”, when the discharge time reaches the preset “LLVD Time”,
3 ~ 1,000
the monitoring module will disconnect the load; when the discharge time
BLVD Time min 600min
reaches the preset “BLVD Time”, it will disconnect the battery

5.7.4 Charging Management Parameters

1. There are 6 related pages, as shown below:

Float: 53.5
Boost: 56.4
Limit: 0.100C10
Over: 0.300c10

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Automatic Boost
Y
Cyclic Boost:
Y

To Boost
Current: 80%
Capacity: 0.06C10

Constant Boost
Current: 0.01C10
Duration: 180min

Cyclic Boost
Interval: 400h
Duration: 300min

Boost Limit
Time: 300min

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

Note
Generally you do not need to set the management value. The defaults will do.

2. The charging management parameter value description is listed below:

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Table 5-12 Charging management parameter value description

Parameter Range Default Value description
In the FC state, all rectifiers output
Float 53.5V
voltage according to the set “Float” The “Boost” must be
42V ~ 58V
In the BC state, all rectifiers output higher than the “Float”
Boost 56.4V
voltage according to the set “Boost”
When the monitoring module detects that the battery charging
current is higher than the “Limit”, it will control the current of the
Limit (current
0.1 ~ 0.25C10 0.1C10 rectifiers, through which it can limit the battery charging current.
limit)
C10 is the battery rated capacity, generally set to 10 ~ 20% of the
rated capacity of one battery string.
When the monitoring module detects that the battery charging
Over (over current
0.3C10 ~ 1.0C10 0.300C10 current is higher than the “Over”, it will raise the battery charge
point)
over-current alarm.
Automatic Boost Select “Y”, and BC will be conducted when conditions allow
Yes, No Y
Cyclic Boost Select “Y”, and the monitoring module will control the system to
Cyclic Boost enter the Cyclic Boost when the FC time reaches the “Cyclic Boost
48 ~ 8760h 2400h
Interval Interval”. The battery charging voltage is the preset “Boost”, and
Cyclic Boost Time 30 ~ 2880min 720min the time is the preset “Cyclic Boost Time”
To Boost Current 0.50 ~ 0.80C10 0.06C10 The monitoring module will control the system enter the BC state
when the battery capacity decreases to the value of “To Boost
To Boost
0.1 ~ 0.95 0.80 Capacity”, or when the charge current reaches the “To Boost
Capacity
Current”. The charge voltage will be the “Boost”.
Constant BC Curr 0.02 ~ 0.99C10 0.01C10 The system in the BC state will enter the FC state when the charge
Duration (of current decreases to the “Constant BC Curr” and after the
30 ~ 1440min 180min
constant BC) “Duration”. The battery charge voltage then will be the “Float”.
To ensure safety, the monitoring module will forcefully control the
system to enter the FC state if during the BC state, the BC time
Boost Limit 60 ~ 2880min 1080min
reaches the “Boost Limit”, or abnormalities occur (such as AC
failure and battery route faulty, etc.).

3. The BC/FC switchover diagram is shown below:

FC time longer than "Scheduled BC Interval"

Battery charge current

bigger than "To BC Current"

Battery capacity smaller

than "To BC Capacity"
FC BC

Charge current
Constant BC smaller than
time-up "Constant BC
Constant
BC Curr"

BC time longer than

"BC LVD Time"

Abnormal situation

Figure 5-2 BC/FC switchover diagram

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5.7.5 Battery Test Parameters

1. There are 7 related pages, as shown below:

Battery Test
Voltage: 45.2
Time: 300min

Test End Cap:

0.700C10
Planned Test:
N

Planned Test1:
01.02 12Hr
Planned Test2:
04.02 12Hr

Planned Test3:
07.02 12Hr
Planned Test4:
07.02 12Hr

Short Test:
Enable: Y
Alarm Current
10A

Short Test:
Cyclye: 300h
Duration:
5min

Stable Test
Enable: Y
Current:
9999A

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

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2. The value description of the parameters is listed below:

Table 5-13 Value description of the battery test parameters
Parameter Range Default Value description
Battery test 43.1V ~ The monitoring module can do battery test, and record 10 sets of
45.2V
voltage 57.9V test data (accessible only through the host). The battery test has to
Battery test time 5 ~ 1440min 300min be started manually, then monitoring module will control the rectifier
output voltage, make it lower than the battery voltage, and the
battery discharge will begin. Monitoring module will stop the test if
the battery voltage reaches the “Battery test voltage”, or the
discharge time reaches “Battery test time”, or the battery capacity
reaches “Test End Cap”. Afterwards, it will restore the rectifier
Test End Cap 0.01C10 ~ output voltage to the normal FC voltage, begin the battery charge
0.7C10
(capacity) 0.95C10 and switch the system to battery auto-management. Meanwhile the
test start time/voltage and end time/voltage and battery remaining
capacity will be recorded. The records can be queried through the
host.
During the battery test, if abnormalities occur, the monitoring
module will stop the battery test automatically.
Scheduled Test Y, N Y
Planned Test 1 00:00, Jan. 1st When the parameter “Scheduled Test” is set to “Y”, the monitoring
Planned Test 2 Month,day, 00:00, April 1st module will test the battery according to the 4 sets of test time. You
Planned Test 3 hour 00:00, July 1st can set at most 12 sets of test time through the host.
Planned Test 4 00:00, Oct. 1st
Alarm Current 1A ~ 100A 10A If the battery have not discharged within the “ShortTest Cycle”, the
ShortTest Cycle 24h ~ 8,760h 720h monitoring module will start a short test, whose operation time is
set by the parameter “ShortTest Duration”. By the end of the test, if
the difference in the discharge currents of batteries is bigger than
ShortTest
1 ~ 60min 5min the “Alarm Current”, the battery discharge imbalance alarm will be
Duration
raised. This alarm will automatically end after 5min of delay. Also
you can end it by confirming it.
StableTest The stable test is conducted with constant battery current, whose
Y, N
Enable value is set through the parameter “StableTest Current”. If the
StableTest parameter “StableTest Enable” is set to “Y”, and the test will be
0 ~ 9999A 9999A
Current started once the battery satisfies the test condition

3. The schematic diagram of the test function is shown below:

"Test End Voltage"

Rectifier output is reached
voltage lower than
Manually start battery voltage Battery "Test End Cap" is
reached Battery
battery test discharges
Auto-management
Rectifier hot "Test End Time" is
standby reached

Figure 5-3 Schematic diagram of the test function

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5.7.6 Temperature Compensation Coefficient Parameters

1. The first page of the setting interface is shown below:

Temp 1:
Ambient
Temp 2:
Battery

2. If the “Temperature1” or “Temperature2” is set to “Battery Temp”, you need to set

the following parameters:

Center Temp:
25°C
Temp. Comp:
70mV / °C /Str

Batt Temp Alarm

Over: 70°C
High: 50°C
Low: 0°C

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

3. The value description of the parameters is listed below:

Table 5-14 Value description of temperature compensation coefficient

Parameter Range Default Value description
Temp 1 The “Ambient Temp” and “Battery Temp” refer to the
measurement of the ambient or battery temperature
sensor at the local power system. “None” means there is
Ambient Temp,
None no measurement input. You should set the parameter
Temp 2 None, Battery Temp
according to the actual situation. The temperature
measurement data will be displayed in the system
operation information screen.
Center Batteries are sensitive to temperature. To ensure
10°C ~40°C 25°C
Temp battery’s capacity and life, its FC voltage should change
together with the temperature: lower FC voltage for higher
When Temp 1 The default is temperature, and vice versa.
or Temp 2 is 72mV/°C for <FC = BattTemp – Center Temp % Temp Comp
set to “Battery Temp 0~ 48V system Upon alarms such as “Rect Com Failure”, “DC Under-volt”
Temp” Comp 500mV/°C and 36mV/°C and “DC Voltage High”, the monitoring module will not do
for 24V temperature compensation to the battery FC voltage.
system. Set this parameter according to the actual battery
technical parameters

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Parameter Range Default Value description

When Temp 1 When the detected battery temperature is
10 C ~
or Temp 2 is Over 50°C higher than the “Over”, the monitoring The “High”
100 C
set to “Battery module will raise an alarm must not be
Temp” When the detected battery temperature is higher than
10°C ~
High 50°C higher than the “High”, the monitoring the “Over”
100°C
module will raise an alarm
-40°C ~ The monitoring module will raise an alarm when the
Low 0°C
10°C detected battery temperature is lower than the “Low”

5.7.7 AC Settings

1. The configuration interface is shown below:

OverVolt: 240V
LowVolt: 210V
UnderVolt: 200V
AC Input: None

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

2. The value description of the parameters is listed below:

Table 5-15 Value description of AC settings

Parameter Range Default Value description
50V ~ The monitoring module will raise an alarm when The “OverVolt” must be
OverVolt 280V
300V the AC input voltage is higher than the “OverVolt” higher than the “LowVolt”.
To avoid alrm disorder, it
50V ~ The monitoring module will raise an alarm when
LowVolt 170V is suggested to use the
300V the AC input voltage is lower than the “LowVolt”.
default values
The monitoring module will raise an alarm when
the AC voltage of an operating route is lower than
50V ~ The “UnderVolt” must be
UnderVolt 80V the “UnderVolt”, but there will be no alarm when
300V lower than the “LowVolt”.
the AC voltage of the standby route is lower than
the “UnderVolt”
3-phase, Dependat
Set this parameter according to the actual situation. In a system with an AC
Single on
AC Input sampling board, you can only select “Single Phase” or “3-phase”; in a system
Phase, system
without an AC sampling board, you can select only “None”.
None type

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5.7.8 DC Setting

1. There are three related pages, as shown below:

DC Volt Alarm
Over: 58.5V
Low: 45.0V
Under: 45.0V

Amb. Temp Alarm

High: 25°C
Low: 0°C

Load Shunt
None
Shunt Coeff:
None

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

2. The value description of the parameters is listed below:

Table 5-16 Value description of DC settings

Parameter Range Default Value description
The “DC Over Voltage” alarm will be raised when
Over
58.5V the system DC output voltage is higher than the
(over-voltage)
value of “Over” The values of
The DC low voltage alarm will be raised when the these three
Low
40V ~ 60V 45.0V system DC output voltage is lower than the value parameters should
(low-voltage)
of “Low” be: Over > Low >
The DC under voltage alarm will be raised when Under
Under
45.0V the system DC output voltage is lower than the
(under-voltage)
value of “Under”
The high temperature alarm will be raised when
High (high 10°C ~ The value of
40°C the detected ambient temperature is higher than
temperature) 100°C parameter “High”
the value of “High”
must be higher
The low temperature alarm will be raised when
Low (low -40°C ~ than that of
-5°C the detected ambient temperature is lower than
temperature) 10°C parameter “Low”
the value of “Low”
Load shunt Y, None None Set according to the system actual situation
Dependent on system In the system with a load shunt, this parameter can be set only when
Shunt Coeff
type the parameter “Shunt” (as a system type) is set to “Set”.

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5.7.9 Rect Settings

1. There are three related pages, as shown below:

Rect Over Volt:

59.0V
Default Volt:
42.0V

Walk-in Enabled
N
Walk-in Time:
8s

Fan Speed
Full Speed
HVSD Time:
300s

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

2. The value description of the parameters is listed below:

Table 5-17 Value description of rectifier settings

Parameter Range Default Value description
The rectifier over voltage alarm will be
Rect Over Volt 56V ~ 59V 59V raised when the rectifier output voltage is The “Default Volt” must be
higher than the “Rect Over Volt” lower than the “Rect Over Volt”
Default Volt 48V ~ 58V 53.5V
Walkin Enabled Y, N N The output soft start function means the rectifier voltage will rise from 0V
Walkin Time 8s ~ 128s 10s to the “Default Volt” after the “Walkin Time”
When set to “Half Speed”, the rectifier will regulate the fan speed
Full Speed, Half
Fan Speed according to the temperature. When set to “Full Speed”, the fan will
Half Speed speed
operate at full speed
The rectifier will shut off automatically upon over-voltage, and restart after
a certain delay to see whether it is still over-voltage then. That delay is set
HVSD Time 50s ~ 300s 300s through the parameter “HVSD Time”. If the rectifier’s output voltage is
normal within the delay, the rectifier is regarded normal; otherwise, the
rectifier will be locked out and auto-restart function will be disabled

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5.7.10 System Settings

Users of different password levels have different authorities.

1. For the user level password (123456), there are 2 related pages, as shown
below:

Adress: 1
Text: Chinese
CommMode:Modem
Baud: 9600

Set Date:
2004-05-01
Set Time:
17:30:30

Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

When the “CommMode” is “modem” or “EEM-M”, the “CallBack Number” and

“CallBack Num” (how many times should callback be made) should be set.

Call back Num:

5
Call back Set
Code1

CallBack Number:
01234567901234
56789

Use “ ” or “ ” to change the number, and “ ” or “ ” to move the cursor left or

right. Press “ENT” to confirm.

2. For the operator level password (by default: 654321) or administrator level
password (by default: 640275), you can see the following pages, besides the pages
above, as shown below:

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System Type:
48V/50A/300/NONE
Serial No:
2004051025252

There will be a prompt when resetting the system:

Notice:
All Param Lost!
ENT Continue
ESC Quit

3. For administrator level password (by default: 640275), you can see the following
pages, besides all those above, as shown below:

Change Password:
Code
Con Alarm Voice:
1 Hour

Serial:
12345689101112
SW Ver: 1.00
Set Enable: Y

You can change the value of “Change Password” and press “ENT” to confirm.

Enter New PWD:

000000

Input Again!

Use “ ” or “ ” to change the number, and “ ” or “ ” to move the cursor left or

right. Press “ENT” to confirm. You should input the same number twice to complete
the setting.

4. The value description of the parameters is listed below:

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Table 5-18 Value description of system settings

Parameter Range Default Value description
Chinese, English and
Text Chinese Set according to your need
Spanish
The addresses of power systems that are at the
Address 1 ~ 254
same monitored office should be different
“MODEM”: Through modem and based on the
Telecom protocol.
modem, EEM-M, “EEM-M”: Through modem and based on the EES
CommMode
RS-232 protocol.
“RS-232”: Through a transparent serial port and
based on the Telecom protocol
1200bps, 2400bps, Make sure the baud rates of both the sending and
BaudRate
4800bps, 9600bps receiving parties are the same
When CallBack Set according to the actual need. In a extension
1 ~ 10 3
“CommMode Num. system, sometimes you need to put a “,” between the
” is set to main number and extension number. When the
CallBack
“MODEM” or 19 digits at most callback number is less than 19 digits, end it with a
Number
“EEM-M” “#”
Set Date 2,000 ~ 2,099 Set the time according to the current actual time,
Set Time Hour, min, sec regardless of whether it is a leap year or not

Initialize Selecting “Y” can reset the user level and

Y, N N
password administrator level passwords to the defaults
When the system parameters cannot be set normally,
Operator and the usual resetting methods do not work, you
level or Init Param
can set the “Init Param” to Y, and all the system
above (Initialize
Y, N N parameters will be restored to defaults. Alarms may
parameter
be raised for the defaults may fail to meet the actual
s)
situation. Set the parameters according to the actual
situation then.

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Parameter Range Default Value description

Operator 24V/75A/500/NONE
level or 24V/75A/500/MAN
above 24V/75A/500/AUTO
24V/50A/500/NONE
24V/50A/500/MAN
24V/50A/500/AUTO
48V/50A/500/NONE
48V/50A/500/MAN
48V/50A/500/AUTO
This parameter has been set according to the actual situation
48V/50A/300/NONE
upon delivery and needs not to be changed. However, when a
48V/50A/300/MAN
new monitoring module is used, its “System Type” should be
48V/50A/300/AUTO
set according to the actual situation.
System 48V/30A/300/NONE
After this parameter is changed, the monitoring module will
Type 48V/30A/300/MAN
restart automatically, and other parameters of the monitoring
48V/30A/300/AUTO
module will be changed to the defaults of the corresponding
48V/30A/100/NONE
system type. You should change some parameters according
48V/30A/100/MAN
to the actual situation.
48V/30A/100/AUTO
48V/15A/100/NONE
48V/15A/100/MAN
48V/15A/100/AUTO
48V/100A/SET/NON
48V/100A/SET/MAN
48V/100A/SET/AUT
48V/50A/SET/NONE
48V/30A/SET/NONE
Change The password can be 6 digits long at most. If it is shorte than 6
User, Operator, Admin
Password digits, end it with a “#”
Con Alarm 3min, 10min, 1h, 4h,
Contstant The period that an alarm sound will last
Voice constant
Serial The production serial No. of the monitoring module. This parameter cannot be changed
Administrator
SW Ver The software version No. of the monitoring module. This parameter cannot be changed
Reflecting the jumper status of a hardware switch within the monitoring module. If this
parameter is set to ”N”, you are not allowed to use the jumper, nor change any
Set Enable
parameter except the battery management mode. The maintenance over the monitoring
module will not be affected

5. The model description is shown below:

48V / 30A / 300 / NONE
No AC data acquisition
board

System shunt coefficient:

100/300/500/SET

Rectifier rated output current:

15A/30A/50A/75A/100A

Rectifier rated output

voltage: 48V/24V

Figure 5-4 System model description

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The relationship between the system model and system type is listed in the
following table:

Table 5-19 Relationship between system model and system type

Power system model System type
PS48400-3/2900, Single AC Input 48V/50A/300/NONE
PS48400-3/2900, Double AC Inputs, Manual Switchover 48V/50A/300/MAN
PS48400-3/2900, Double AC Inputs, Auto Switchover 48V/50A/300/AUTO
PS48600-3/2900, Single AC Input 48V/50A/500/NONE
PS48600-3/2900, Double AC Inputs, Manual Switchover 48V/50A/500/MAN
PS48600-3/2900, Double AC inputs, Auto Switchover 48V/50A/500/AUTO

Note
SCU can monitor multiple power systems made by Emerson. If the system type is not set
correctly, unpredictable faults may occur.

5.7.11 Alarm Settings

1. The first page of the setting interface is show below:

Alarm Settings
Alarm Type
Alarm Mode
Alarm Control

There are 3 submenus. Use “ ” or “ ” to select one, and use “ENT” to confirm.

2. The three submenus are shown below:

Alarm Type
Alarm Block
Level: Major
Relate Relay: 1

Alarm Mode
DI No: 1#
Mode: High
Set DI Name: 2#

Clear His. Alarm:

N
Block Alarm:
Y

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Use “ ” or “ ” to select one page or one of the parameters, and “ ” or “ ” to

select the parameter value. Press “ENT” to confirm and save.

3. After setting the “Set DI Name” and confirming it, the system will prompt you to
name the DI:

DI Name
Digital 1

Use “ ” or “ ” to change the number, and “ ” or “ ” to move the cursor left or

right. Press “ENT” to confirm.

4. The value description of the parameter is listed below:

Table 5-20 Value description of alarm settings

Parameter Range Default Value description
56 names of alarm Alarms of Select those alarm events whose levels and relate relays
Alarm Type
events different should be reset
Critical, Major, types have There are different audible/visual alarm modes and callback
Level
Observation, None different modes for alarm events of different levels
levels and “Empty”: The corresponding dry contact will not output alarm
different information upon an alarm event
Relate Relay Empty, No.1 ~ 8
Relate “No. 1 ~ 8”: There will be a dry contact in the range of No.1 ~
Relays 8 that outputs the alarm information upon an alarm event
The 8 corresponding connecting terminals,
DI No. No. 1 ~ 8 1 queued up in the order that the hardware
switches are put
“High”: alarm upon high level;
Alarm Mode High, Low Low “Low”: alarm upon low level.
Set according to the actual situation
Effective
Serial No. of the connecting terminal for DI
Set DI Name 1# ~ 8# 1# only to
input
self-defined
When there are DI alarms, this parameter
DI alarms
shows the alarm name you have actually
defined. In the system with an AC sampling
Figures or letters,
DI Name Digital board, you can define by yourself the DIs of
10 at most
routes No.7 and No.8.
In the system without an AC sampling board,
you can define all DIs
Clear His Alarm Y, N N “Y”: Delete historical alarms
“Y”: The active alarms will not be sent to the host (valid in
Block Alarm Y, N N
EEM protocol)

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72 Chapter 6 Routine Maintenance

Chapter 6 Routine Maintenance

6.1 Maintenance Of Rectifier

The fan of rectifier shall be maintained periodically.

The fan shall be replaced if it does not work due to faults.

Follow the procedures below to replace the fan:

1. Loosen the 3 screws on the baffle and remove the baffle.

2. Unplug the power cable of the fan and remove the fan.

3. Replace the fan.

4. Plug the fan power cable back into the corresponding socket.

5. Push back the fan (the side with the tag facing inward).

6. Mount the front baffle and fix it with screws.

6.2 Maintenance Of SCU

If any SCU fault affects the normal operation of DC power system, just turn off the
SCU.

6.3 Maintenance Of MFU

1. Short-circuit of load

If some of the loads have short circuit fault, just turn off the circuit breakers in the
MFU to disconnect the power to the loads.

2. MFU short-circuit

When MFU short-circuit occurs, disconnect the AC power supply, isolate the
batteries from the system, and then use battery or rectifier to directly supply power
to load.

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 Chapter 6 Routine Maintenance 73

6.4 Cover Plates

The Multi-Function Unit has a cover plate to protect the load and battery circuit
breakers and to create a neat finish. This cover plate is easy to open/remove in
order to switch on or off a circuit breaker, or to connect additional loads. The
cover plate can be opened or removed without the need of using special tools. The
DC section of the Distribution Unit is made safe for a “User” to access, which
follows the “Look and Feel” guidelines.

6.5 Battery Maintenance

6.5.1 Storage And Supplementary

During storage, the capacity of the battery decreases because of self-discharging.

When using a stored battery, always carry out supplementary charging before use.
Refer to the battery user manual or follow battery manufacturer’s advices to
perform supplementary charging.

Store the battery in a cool dry place.

6.5.2 Daily Inspection

1. Check the battery regularly. The battery needs to be replaced if any abnormal
condition occurs, such as:

Any voltage abnormalities;

Any physical defects (e.g., a cracked or deformed container cover);

Any electrolyte leakage;

Any abnormal heat generation.

2. Clean any dust contamination with a wet cloth. Never use organic solvents
(gasoline or thinners), otherwise the container or cover may crack.

3. Voltage checks.

Total voltage

The total voltage of the batteries should not deviate from the recommended 2.25 V
per cell (54V in a 48V DC power system at reference temperature). If it deviates,
check your system to see that the setting is correct and that the temperature
compensation is correct.

Unit voltage

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74 Chapter 6 Routine Maintenance

After one year of operation, all the units should be within the range of 13.50±0.48V.

6.5.3 Replacement

1) Replacing Criterion

Replace the battery if its capacity measured during the battery test is less than 80%
of the battery rated capacity. The capacity measured during the battery test shall be
evaluated at a discharge rate close to its actual use.

2) Replacement Interval

The battery is expendable, and has a certain life cycle. Considering the use
condition and ambient temperature, the new battery should replace the old battery
before it reaches its design life to ensure the normal and safety operation of the DC
power system. For instance, in an environment where the mean temperature is
35°C, it is necessary to replace the battery every 5-year operation.

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 Chapter 7 Troubleshooting 75

Chapter 7 Troubleshooting

7.1 Troubleshooting Rectifier

1. Troubleshoot Rectifier according to LED Indication

The usual fault symptoms of the rectifier include: power indicator (green) off,
protection indicator (yellow) on, protection indicator (yellow) blinking, alarm
indicator (red) on, and alarm indicator (red) blinking.

Table 7-1 Troubleshooting

Symptom Cause Suggestion
No input voltage Make sure there is input voltage

Power indicator (green) off Replace the fuse with a new one of the same
Input polarity reversed or input fuse
model or reconnect the input power with
blown
correct polarity.
AC input voltage outside the normal Ensure the AC input voltage remain within
range normal range
PFC over-voltage Replace the rectifier
Current sharing function is disabled Replace the rectifier
Rectifier over-temperature protection, which is caused by:
Protection indicator (yellow)
1. Fan blocked 1. Remove the obstacle that blocks the fan
on
2. Ventilation blocked: the inlet or 2. Remove the objects that blocks the inlet or
outlet blocked outlet
3. Ambient temperature too high or 3. Remove the heater, lower the ambient
rectifier inlet too close to an heater temperature
Rectifier not inserted into the slot
Insert the rectifier again properly
completely
Protection indicator (yellow)
Rectifier communication failure Check the communication cables
blinking
Remove the rectifier from the DC power
Alarm indicator (red) on Rectifier over-voltage system, restart the rectifier, and replace the
rectifier if over-voltage still occurs.
Alarm indicator (red) blinking Fan not running Replace the fan

2. Rectifier Current Sharing Unbalanced

When multiple rectifiers are in parallel connection and the unbalance of current
sharing among them is bigger than 3%, check if the communication cables are
correctly connected.

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76 Chapter 7 Troubleshooting

If the current sharing is still unsuccessful after the correction, replace the rectifier of
which the current sharing function is disabled.

7.2 Mains Failure

Mains failure often occurs in power system operation. Batteries will provide backup
DC power in case of short-period of mains failure. If the cause of mains failure
remains unknown or the failure lasts too long, the generator should be started to
provide mains supply to the system. It is suggested that the generator should
supply power to the power system at least 5 minutes after it is started so as to
reduce the effect of the start process on the power system.

7.3 Disastrous Accidents

Disastrous accidents such as lightning strike, flood, earthquake and fire lead to the
communication equipment faults. For the disasters that will severely affect the
safety of communications, efforts should be mainly made to prevention actions.
Meanwhile, communication stations should have adequate human and material
resources and work out effective countermeasures to cope with these disasters.
They should also have emergency management regulations and serious accidents
emergency plans.

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 Appendix 1 System Technical Parameters 77

Appendix 1 System Technical Parameters

Parameter category Note

AC input over-voltage
Default: 280 ! 5Vac, cofigurable through monitoring module
alarm point
AC input over-voltage Default: 270 ! 5Vac, 10Vac lower than the AC input
AC input alarm and recovery point over-voltage alarm point
protection AC input under-voltage
Default: 180 ! 5Vac, configurable through monitoring module
alarm point
AC input under-voltage Default: 190 ! 5Vac, 10Vac higher than the AC input
recovery point under-voltage alarm point
DC output over-voltage
Default: 59.0 ! 0.2Vdc
protection point
DC output over-voltage Default: 58.5 ! 0.2Vdc, configurable through monitoring
alarm point module
DC output over-voltage Default: 58 ! 0.2Vdc, 0.5Vdc lower than the over-voltage
recovery point alarm point
DC output under-voltage Default: 45.0 ! 0.2Vdc, configurable through monitoring
DC output alarm and alarm point module
protection DC output under-voltage Default: 45.5 ! 0.2Vdc, 0.5Vdc higher than the under-voltage
recovery point alarm point
LLVD Default: 44 ! 0.2Vdc, configurable through monitoring module
Default: 43.2 ! 0.2Vdc, configurable through monitoring
BLVD
module
Output voltage can rise slowly upon rectifier start up. The rise
Output delay
time is configurable
Fan speed adjustable Rectifier fan speed can be set to half or full speed.
CS
EN300386 2001, Class A
RS
EMC Immunity to EFT EN61000-4-4, Level 3
Immunity to ESD Air discharge: 8kV. Contact discharge: 4kV. EN61000-4-2
Immunity to Surges EN61000-4-5, Level 4

The AC input side can withstand 10/700μs simulated

lightning voltage 5kV for !5 times, or 8/20μs simulated
Lightning protection
At AC side lightning surge current 20kA for !5 times, or 8/20μs
features
simulated lightning surge current 40kA once. The test interval
is not smaller than 1 minute.

Acoustic noise 55dB (A)

At temperature of 15°C ~ 35°C and relative humidity not
higher than 90%RH, apply a test voltage of 500Vdc. The
Others Insulation resistance insulation resistances between AC circuit and earth, between
DC circuit and earth, or between AC and DC circuits are no
less than 10MΩ

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78 Appendix 1 System Technical Parameters

Parameter category Note

Others (Remove the SPD, monitoring module and rectifiers from the
system before the test.)
AC to DC circuits, AC circuit to earth: 50Hz, 3,000Vac (RMS).
DC circuit to earth: 50Hz, 1,000Vac (RMS).
Dielectric strength Assistant circuit (not directly connected to the host circuit):
50Hz, 500Vac (RMS).
For all the three tests above, there should be no breakdown
or flashover within 1min, with leakage current not bigger than
10mA.
MTBF 250,000hr
600 (W) % 600 (D) 600 (W) % 400 600 (W) % 400 (D)
Size (mm)
% 2000 (H) (D) % 2000 (H) % 700 (H)
Mechanica
<135kg (without <125kg (without <60kg (without
Weight
rectifiers) rectifiers) rectifiers)

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 Appendix 2 Engineering Design Diagram 79

Appendix 2 Engineering Design Diagram

Appendix 2.1 Engineering Design Diagram For

2000mm%600mm%600mm Cabinet

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80 Appendix 2 Engineering Design Diagram

Appendix 2.2 Engineering Design Diagram For

2000mm%600mm%400mm Cabinet

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 Appendix 2 Engineering Design Diagram 81

Appendix 2.3 Engineering Design Diagram For

700mm%600mm%400mm Cabinet

Appendix 2.4 System Input And Output Connector Specs

Connector Connector specs

AC input terminal H cable terminals, 2-4 pcs (cable section 35mm2)
AC Power
1 M8 bolt
distribution Grounding busbar
1 big wire connectors, (cable section 25mm2)
4 M8blots, 6 big wire connectors, (cable section 25mm2)
DC Power Positive bus bar
23 small wire connectors, (cable section 16mm2)
distribution
Output route MCB H cable terminals (cable section 25mm2)

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 Appendix 3 System Circuit Diagram 82

Appendix 3 System Circuit Diagram

Appendix 3.1 System Electric Schematic Diagram

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 Appendix 3 System Circuit Diagram 83

Appendix 3.2 System Wiring Diagram

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 Appendix 3 System Circuit Diagram 84

Appendix 3.3 MFU Electric Wiring Diagram

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 Appendix 3 System Circuit Diagram 85

Appendix 3.4 BCU Electric Wiring Diagram

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86 Appendix 4 Glossary

Appendix 4 Glossary

Abbreviation Full word

Amb.Temp Ambient Temperature
Batt Battery
BC Boost Charging
BLVD Battery Lower Voltage Disconnection
Cap Capacity
CommMode Communication Mode
CurrLimit Current Limit
CycBC Cyclic Boost Charging
Con Alarm Voice Control Alarm Voice
Hist Alarm Historical alarm
HVSD High Voltage Shutdown
InitParam Initialize Parameters
InitPWD Initialize Password
LLVD Load Low Voltage Disconnection
LVD Low Voltage Disconnection
Ph-A Phase A
PWD Password
Rect Rectifier
Shunt coeff Shunt Coefficient
SPD Surge Protection Device
SW Version Software Version
Sys System
Temp Temperature
Temp Comp Temperature Compensation
Volt Voltage

ACTURA Flex 48330 Power System User Manual