315ips-Odu Ds210rb2 User Manual- (Zte) Sep 7th, 2012

USER MANUAL

INTEGRATED POWER SYSTEM

315IPS-ODU

DS210R00

I

WARNING AND SAFETY PRECAUTIONS

Danger and Warning

High voltages can be present inside the unit at the AC Inlet/Outlet and

cable terminals.

The Equipment must be properly grounded.

Do not touch Electronic Circuit when system is turned on.

Safety Precautions

Install the unit in an area with adequate Air Flow.

Avoid blocking the Ventilation openings of the System

Do not place the System near Heat-Emitting Appliances such as Radiators or

Stoves.

If Installed near Generator then the unit should be at least one meter apart from

Generator.

The unit should be kept away from Generator / HVAC / Air Conditioner’s Exhaust and hot air flow.

Installation should be carried out by Trained Staff.

Note: Failure to undertake safety precautions and warnings under consideration can result in damage to equipment and injury to people.

II

Table of Contents

WARNING AND SAFETY PRECAUTIONS ............................................................................................. I

Table of Contents .................................................................................................................................... II

Chapter 1 General Information................................................................................................................ 4

1.1 Introduction ................................................................................................................................... 4

1.2 Snap Shots .................................................................................................................................... 4

1.3 Product Features ........................................................................................................................... 5

1.4 Line Diagram ................................................................................................................................. 6

1.5 Physical Layout ............................................................................................................................. 7

Chapter 2 Functional description .......................................................................................................... 12

2.1 Power Measurement and Management ...................................................................................... 12

2.1.1 Over Voltage Isolator ............................................................................................................ 12

2.1.2 OVI Bypass ........................................................................................................................... 12

2.1.3 Auto Mains Fail (AMF) .......................................................................................................... 12

2.1.4 Bypass (AMF) ....................................................................................................................... 13

2.1.5 Power Measuring Module (PMM) ......................................................................................... 13

2.2 Generator Management (GEM3) ................................................................................................ 14

2.3 DC Tower Light (TLC) ................................................................................................................. 14

Chapter 3 Operation and Configuration ................................................................................................ 15

3.1 Operation .................................................................................................................................... 15

3.1.1 Turning-on IPS ...................................................................................................................... 15

3.1.2 Emergency Stop ................................................................................................................... 16

3.1.3 LCD Displays ........................................................................................................................ 17

3.2 Configuration ............................................................................................................................... 20

3.3 Alarms ......................................................................................................................................... 22

3.4 References .................................................................................................................................. 23

Chapter 4 Technical Datasheet ............................................................................................................. 24

Chapter 5 Warranty ............................................................................................................................... 25

Chapter 6 Appendix ............................................................................................................................... 26

Appendix A: Schematic ..................................................................................................................... 26

Appendix B: Bill of Quantity (BOQ) ................................................................................................... 27

SalTec Powerlink DS210R00 Page 4 of 28 Sep 6

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Chapter 1 General Information

1.1 Introduction

Integrated Power System (IPS) is a High tech power solution specially designed for BTS Sites. It incorporates all Power Protection and Management devices into a single cabinet. The one unit

solution is easy to install, efficient, cost effective and easily manageable.

IPS is state of the art power conditioning and monitoring platform for BTS sites. Power fluctuations, phase failure, phase reversal are detected by the unit and immediately corrected to provide smooth operation for the BTS site.

This single cabinet solution is composed of the following devices integrated together in a modular form:

Generator Manager (GEM3)

Auto Mains Fail(AMF)

Power Measuring Module(PMM)

Over Voltage Isolator (OVI)

DC Tower Light (DCTLC)

IPS is specially designed to be installed at outdoor locations, and hence its cabinet is IP55 rated and constructed with stainless steel, dual coated with epoxy based zinc additive and polyester based powder paint, to ensure long life. Front mounted dual DC operated cooling fans provide forced cooling to support high power applications and maintain tolerable temperature for sensitive ancillary electronic equipment. The front and rear door are also equipped with locks for vandal protection. The equipment is designed to cater for the safety of the user, equipment and the environment, which includes compliance with IEC60950 – Safety standard for telecom equipment.

1.2 Snap Shots

Front Door Open Front View


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Rear Door Open Rear View

1.3 Product Features

IPS provides:

Digital (LCD) Metering of Input & Output Voltages, and Load Current

Extremely fast (<80mS) Over Voltage Isolator (OVI)

Under/Over voltage protection with instantaneous power cut-off

Over load protection (MCB)

Automatic Genset start and stop

Automatic Load Transfer to Mains/ Genset

Battery bank monitoring and management for efficient use of batteries and Genset, capable of

reducing Genset fuel consumption up to 50% or more (requires optional GEM3)


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1.4 Line Diagram

The basic functional overview and power flow of IPS is depicted in Figure 1 Integrated Power Solution

Line Diagram

Figure 1 Integrated Power Solution Line Diagram


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1.5 Physical Layout

Table 1 Front Door

Front View A (Front Door Closed)

A. Front Door –1

B. Front Door Lock

C. Vents

Front View B (Front Door –1 Open)

A. Output Power Indicators

B. PMM Display

C. Auto Mains Fail(AMF)

D. ATS By Pass Selector Switch

E. OVI By Pass Selector Switch

F. Source Selector Switch

A

B

C

Front Door - 2

A

C

D

B

E

F


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Table 2 Front View

Front View C (Inside Front Door –1)

A. Document Pocket

B. Dual DC Operated Cooling Fans

C. Air inlets with Air filters

Front View D (Panel inside Door - 2)

A. GEM3 Module

B. DC-TLC

C. DC-DC Power Supply UnitA

D. AC Distribution BreakerS Terminal Module

E. Power Measuring Module(PMM)

F. AC-DC Power Supply Unit

G. AMF Contactor

A

B

C

A B

C

G E

F

D


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Table 3 Rear View

Note: For detailed view of front and rear side terminals placement, refer to Table 4 Detailed View

Rear View A

A. Hazard warning

B. Door Lock

C. Access to Industrial Socket

Rear View B (Panel inside Rare Door)

A. Input MCB for Mains power input

B. Genset Input Terminals

C. AC Distribution Terminal

D. DIN rail terminals and Fuses

E. SPDs

F. Utility Socket

C

F

A

B

C

A

B

D

E


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Detailed View

GENSET BATTERY CHARGER AND AMF FUSES

DIN RAIL TERMINALS AND FUSES

BYPASS SELECTORS (Front View – B)

ATS BYPASS (S3) OVI BYPASS (S1) POWER SOURCE (S1)


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GENSET INPUT TERMINALS

AC DISTRIBUTION

Table 4 Detailed View


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Chapter 2 Functional description

IPS can be functionally classified into 2 distinct categories, namely Power Management and measurement and Generator Management. Details pertaining to each category are provided in subsequent sections.

2.1 Power Measurement and Management

The “Raw Mains” input to IPS is first conditioned and controlled by Over Voltage Isolator. High voltage surges are suppressed by Input Class B&C surge protectors. A bypass selector is provided to facilitate on-site maintenance. Next, the Conditioned Mains and Genset Lines are fed to the ATS Panel, which performs automatic load transfer between Conditioned Mains and Genset. Finally, the output of the ATS is distributed via numerous breakers in the AC Distribution. PMM provides IPS output voltages and load current measurement, along with energy and power consumption for performance analysis.

2.1.1 Over Voltage Isolator

Over Voltage Isolator is a protective device for AC system that shuts down the output power in case of under or over voltage. It’s a Micro-controller based intelligent system that protects against an accidental phase-neutral reversal, or neutral failure in the incoming power lines by isolating complete power to the equipment and automatically restores the power to the load upon restoration of safe input voltage. It has the capability to respond to input AC voltage variation within 3 to 4 cycles (<80ms) and protects the equipment from chronic brownouts and high voltages.

2.1.2 OVI Bypass

The bypass selector allows connection of ATS input to either OVI output or the raw mains, to facilitate maintenance and unexpected condition handling.

2.1.3 Auto Mains Fail (AMF)

Auto Mains Fail (AMF) is a low price / high-efficiency micro-controller device designed to operate the (Genset) automatically. The primary function of AMF is to ensure that load is powered up by either one of the power sources, Mains OR Genset, Mains being the preferred source and alert in case no source is available.

AMF performs multiple functions which includes efficient power monitoring and control, Auto / Manual Emergency Stop, AUTO Start / Stop and engine monitoring in a user friendly environment, comprising of 128 x 64 Graphical Liquid Crystal Display (LCD) with back-light and 8 x Push Buttons for menu settings / navigation.

AMF incorporates the following key features:

Three Modes Of Operation

1) AUTO 2) MANUAL 3) STOP

Over Voltage Isolator

AMF Module


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AUTO Mode: AMF monitors Mains voltages and controls the Genset Automatic Start and Stop and Transfers load to the Generator in case of either single Phase, double Phase or total Mains Failure. Unhealthy Mains voltages are also considered as Mains Fail (Under or Over Voltage).

MANUAL Mode: Facilitates manually generator start and stop, even if Mains is present.

STOP Mode: Used for emergency stop of the generator in both, MANUAL and AUTO modes.

Automatic Shutdown on fault condition

Once the generator is running, AMF monitors the internal protection and external faults inputs. The external fault inputs are listed below.

1) Low fuel 2) Low Oil Pressure 3) High Engine Temperature 4) Genset Over/Under Speed 5) Genset Over/Under Voltage

In case of any fault condition, the module shuts down the engine automatically and indicates the source of failure on the GLCD, activating the ALARM LED.

AMF as an Automatic Load Transfer Switch (ATS)

The AMF automatically transfers the Load to Genset, in case of Mains failure and transfers the Load back to Mains on Mains restoration. AMF performs this operation by controlling the MAINS and GENSET contactor.

Configurable Timers and Alarms

AMF has a unique Timer and Alarm configuration mode. This feature enables AMF compatibility with different types of engine controller, and allows it to cater to different BTS site conditions.

2.1.4 Bypass (AMF)

The two bypass selectors allow connection of Distribution input to either AMF output, mains, or directly to genset. This facilitates on-site AMF maintenance, without hampering the power flow to the IPS Load.

2.1.5 Power Measuring Module (PMM)

Power Measuring Module (SP305PMM) is a sophisticated micro-controller based Energy Monitoring device. It takes energy metering to a step further by introducing digital power-measurement techniques that are not only limited to monitoring Voltages and Currents but also Apparent and Real Power, Power Factor and Energy.

PMM measures the following parameters:

RMS AC Voltage

PMM measures RMS AC voltage within the range of 0-400V with an accuracy of 1%.

RMS AC Current

PMM measures RMS AC current within the range of 0-100A with an accuracy of 1%.

Apparent Power, Real Power and Power Factor

PMM measures Apparent Power, Real Power and Power Factor within the range of 0- 20kVA, 0-30kW and 0-1 respectively with an accuracy of 2%.

Frequency and Energy

PMM measures the Frequency and Energy of the power source with an accuracy of 10% and 2% respectively.

PMM Module


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2.2 Generator Management (GEM3)

Advanced Generator Manager (GEM3) is a micro-controller based, add-on module to the existing conventional AMF/ATS of standby Genset, used in the present telecom applications such as BTS & BSC sites of wireless operators. GEM3 controls the Genset switching by enabling or disabling (overriding Genset startup) the AMF on the basis of BTS system battery voltage and temperature of the room. The intelligence minimizes the Genset running hours, which leads towards the saving of fuel and subsequent wear and tear of Genset.

GEM3 has the following key features:

Genset Fuel Saving

GEM3 can monitor two battery banks of either 48V or 24V DC simultaneously. It disables Genset auto-start and allows BTS load to run on the battery bank power, until the battery bank is discharged to 30% of its total capacity, and starts Genset immediately afterwards.

GEM3 monitors the temperature of the BTS room as well, because during the Genset off period, air-conditioners are off. If room temperature rises, (and the MAINS is still absent) GEM3 starts the Genset so that air-conditioners can cool the room.

Genset Testing Capability in GEM3

GEM3 has Genset testing capability to ensure Genset’s operational readiness so that alarm can be sent to remote user in advance, in the case of malfunction. This reduces excessive downtime which could result if battery is fully discharged.

In case of a mains failure, generator must first be tested for its operational readiness before GEM3 can resume its normal operation so that any malfunction in Genset can be reported in advance. But constant start and stop of Genset on every mains fail can cause wear and tear of Genset. Hence, GEM3 is designed to trigger a Genset Test after a pre determined interval after first instant of mains failure.

GEM3 as Dual Genset Duty Cycle Controller

At Remote sites that do not have access to a mains supply, BTS load is run on two generators that work in tandem with each other. Effective management of these internal combustion generators is a tedious and expensive task. The GEM3 monitors and manages all parameters of these generators in a robust, accurate and efficient manner.

Genset Failure Sensing

GEM3 intelligently deals with critical errors namely if one Genset fails (Low battery condition persists for 5 minutes despite of enabling Genset). In such case, GEM3 passes control to next Genset, and escalates a Genset Fail Alarm. Second generator handles the load extensively stopping only for the minimum rest time and during its rest time, BTS load is shifted to battery bank. In case battery levels also drop low, the GEM3 automatically shifts whole BTS load on to the generator, halting its rest time.

2.3 DC Tower Light (TLC)

DC Tower light controller (TLC) is a module designed to control the tower light. A light detector mounted with the tower light enables the system to differentiate between day and night. This signal is used to switch the tower light on at night and blink during day time.

GEM3 Module

DCTLC


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Chapter 3 Operation and Configuration

3.1 Operation

3.1.1 Turning-on IPS

Instruction Snapshot

Switch “On” the Mains Breaker located at the Rear side of IPS (Refer Table 3 Marker A)

Move OVI Bypass Selector Switch to OVI(Refer Table 1 Marker E)

Move POWER SOURCE Selector Switch to MAINS(Refer Table 1 Marker F)

Move ATS BYPASS to AUTO(Refer Table 1 Marker D)

Table 5 Turning on IPS

OVI BY PASS

ATS BYPASS

MAINS OFF OVI

MAINS OFF GENSET

AUTO OFF MANUAL

MAINS

POWER SOURCE


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3.1.2 Emergency Stop

Instruction Snapshot

Move ATS BYPASS to OFF(Refer Table 1 Marker D)

Move POWER SOURCE Selector Switch to OFF(Refer Table 1 Marker F)

POWER SOURCE

Move System Bypass Selector to Zero Position i.e. disconnecting the Load(Refer Table 1 Marker E)

OVI BY PASS

Turn off the MAINS MCB located at the Rear Side(Refer Table 3 Marker A)

Table 6 Emergency Stop

ATS BYPASS

GENSET OFF MAINS

AUTO OFF MANUAL

MAINS OFF OVI

MAINS


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3.1.3 LCD Displays

The real time data pertaining to IPS operations is displayed over different LCDs within IPS. Detailed information regarding data enquiry of different parameters related to IPS is provided in Table 7 Data Query.

Parameter Instruction Snapshot

PMM LCD

Load Status Summary Default PMM screen

1 228v

02.4v

2 228v 02.4

v

3 228v 02.4

v

000000000KWh

Phase ONE Load Status

Press the “RIGHT OR LEFT “key to view these screens

227v P1

49.5 Hz

002.4A

00.5kW

0.89pf 0.000005kVA

00000000kWh

Phase Two Load Status

227v P2

49.5 Hz

002.4A

00.5kW

0.89pf 0.000005kVA

00000000kWh

Phase Three Load Status

227v P3

49.5 Hz

002.4A

00.5kW

0.89pf 0.000005kVA

00000000kWh

AMF LCD

Load Connected to MAINS

Default AMF screen

Transfer of Load between MAINS and GENSET

Load Connected to GENSET


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BT1 BT2 GN1 GN2

[+] [+] [0] [0]

GEM3 LCD

Rectifier Battery 1 Voltage

Default GEM3 screen (Press Cancel key to activate default screen if it’s not visible)

If Single battery is connected

If two batteries are connected

Rectifier Battery 2 Voltage

Ambient temperature

AMF Status EN=Enable; DS=Disable

Battery and Genset status summary [ - ] : Discharging [ + ] : Charging [ X ] : Disabled [ E ] : Enabled [ 1 ] : Running [ 1 ] : Stopped

Press the “DOWN” key on default screen

Rectifier Battery 1 current Press the “DOWN” key twice on default screen

T2 Temperature Press the “DOWN” key thrice on default screen

DG Battery Current Press the “DOWN” key four times on default screen

Table 7 Data Query

B1:51.0V 22.1°C

B2:53.5V AMF DS

B1 CURRENT

0150.0 A

B3

00.2V

B1:51.0V 22.1°C

AMF DS

B1:Lo Hi

AMF DS

B1:Hi Hi

B2:Lo AMF DS

BT1 BT2 GN1 GN2

[+] [+] [0] [0]

T2 16.2°C


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Other advanced parameters that can be monitored via GEM3 LCD are described along with their definitions in Table 8 Advanced GEM3 Parameters

Parameter Description

Battery 1 cycles Total charging cycles of Battery 1

Battery 1 low count The number of times battery 1 is drained to low threshold value

Battery 1 shift time Time for which the BTS(load) has been shifted on battery (HH:MM Format)

Battery 1 total time Total Time for which battery 1 supply power to the load with AMF Disabled

Battery 1 last charging Battery 1 voltage prior to most recent charging

Over-temperature count The number of times ambient temperature crossed high threshold value of temperature

Table 8 Advanced GEM3 Parameters

Note: All parameters mentioned in Table 8 for battery 1 are also available for battery 2


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3.2 Configuration

To configure the parameters indicated below, refer to instructions provided in Table 10 AMF Configuration Procedure.

Parameter Definition

REM Start It allows the user to Enable/Disable Remote Start Function

REM Stop It allows the user to Enable/Disable Remote Stop Function

Hi TEMP,LO OIL ,LO FUEL It determines the type of signal(Hi/Low) being generated by the Sensors for Monitoring Genset Temperature, Genset Oil and Genset Fuel

Life Count Displays total Running Hours for the Genset

Shift Time Displays Last / Current Running hours of the Genset

Stop Life It determines how long the Genset has been kept off when Mains was absent

Over Speed, Under Speed, Start Fail, Emergency Stop, Low Battery

Five Different Alarms can be activated. On the basis of the occurrence of any activated Alarm Genset’s operation will be hindered until the fault condition is restored to normal condition

Pre Heat Time to Pre-Heat the fuel before starting the Genset

Start Time of Crank to the Genset

Warm Up Time for Genset to warm-up before taking the load

Cooling Time for Genset to keep on running after the load has been shifted

Low Fuel The time for Genset to stop after the Low Fuel Alarm has been generated

Over Volts(Genset) Time to tolerate Overvoltage(Genset)

UnderVolts(Genset) Time to tolerate Under Voltage(Genset)

Over Volts(Mains) Time to tolerate Overvoltage(Mains)

UnderVolts(Mains) Time to tolerate Under Voltage(Mains)

Genset Output Voltage of the Genset acceptable to the Load

Battery Genset Battery Output Voltage acceptable for Genset operation

Frequency Genset Output Frequency that is acceptable to the Load

Under Voltage(Genset) It is the Minimum Voltage generated by the Genset that is acceptable to the Load

Over Voltage(Genset) It is the Maximum Voltage generated by the Genset that is acceptable to the Load.

Critical Phase(Mains)

The phase whose absence will cause the AMF to switch load from

MAINS to Genset is called Critical Phase. One, Two ,Three Phase

can be configured as Critical Phase

Table 9 AMF Configurable Parameters

Instructions AMF LCD Display

Press the “DOWNWARD” Key (AMF will go to SYSTEM CONFIG MENU)

Press “ENTER” Key to configure value

Use “LEFT” and “RIGHT” Key to change the parameter value

Use “UP” and “DOWN” Key to chose another parameter

Press “SAVE” Key to save and exit

Table 10 AMF Configuration Procedure


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To configure the parameters indicated below, refer to instructions provided in Table 12 GEM3 Configuration Procedure

Parameters Definition

Base voltage B1 Voltage of Battery 1 string (24V/48V)

Gensets Mode settings

Mode 1: Single Genset Mode 2: Dual Genset

Battery 1 settings Battery 1 Low and High voltage thresholds configuration which are used to decide battery health

Battery 2 settings Battery 2 Low and High voltage thresholds configuration which are used to decide battery health

Temperature settings

[EN] / [DS] : Enable/Disable temperature based action of GEM3 If Enabled, set the High and low temperature thresholds

Optional Settings B3 [EN] / [DS] : Enable/Disable Battery 3 monitoring T2 [EN] / [DS] : Enable/Disable Temperature 2 monitoring

Extended Run-time settings

Time for which AMF is kept enabled after the restoration of battery voltage or temperature. Both parameters are separately enabled/disabled and configured

Battery Calibration settings

Allows calibration of battery 1 or 2 or 3 voltages

Temperature Calibration

Allows calibration of temperature sensor 1 or 2

CT Zero Adjust Used to calibrate DC CT at the time of calibration

CT Range Maximum current that needs to be measured using DC CT

CT Zero current Limit

Current that is considered insignificant for the decision of charging/discharging state

Reset B1/B2 Reset all counters related to Battery 1 or 2

Factory reset Restores default factory settings of all parameters

Table 11 GEM3 Configurable Parameters

Instructions GEM3 LCD Display

Press “ENTER” on GEM3 Module (GEM3 will go to the setting mode)

Use arrow keys to Change value Press “Enter” to select next digit (Enter the Password)

Use arrow keys to select the parameter that needs configuration (e.g. Base voltage)

Press “Enter” Use “Up” or “Down” keys to change configuration

Press “Enter” to save and exit

Table 12 GEM3 Configuration Procedure

SETTING MODE

PSWD: [0]0 0 0

SETTING MODE

Access Granted

BASE VOLTAGE

BASE VOLTAGE

B1 [48V]

BASE VOLTAGE

[ENTER] to Save


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3.3 Alarms

Alarm/Indicator Description

AMF Module

Power On : AMF is powered up Off : AMF is not powered

Available MAINS On Load

On : MAINS is present Off : MAINS is absent

On : Load on MAINS Off : Load not on MAINS

Available Genset On Load

On : Genset is running Off : Genset is not running

On : Load on GENSET Off : Load not on GENSET

Auto On : AMF in AUTO MODE Off : AMF in MANUAL MODE

Alarm On : In case of fault condition Off : Normal behavior

GEM Module

Power LED On : GEM is powered up Off : GEM is not powered

Active LED On : Site is powered by battery bank (AMF Disabled

Alarm LED On : Alarming condition(GEM Critical alarm)

DCTLC

Power On: DCTLC is on Off: DCTLC is off

Lamp Fail On: Tower Light is not working Off: Normal Behavior

Sensor Fail On: Solar sensor is not working Off: Normal Behavior

External Alarms for NOC

GEM Active Site is powered by battery bank

GEM Critical Battery bank voltage is below threshold and GENSET failed to start in predefined time

GEM Fail GEM Failure

AMF Low Fuel Out Genset Fuel is Low

AMF Genset Fail Genset has Failed to Start

ATS Mains Fail Mains has Failed

ATS Genset Running Genset is running

Table 13 IPS Alarms/Indicators


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3.4 References

For further details on operations and configuration of different modules of IPS, refer to the following

manuals:

Doc# DS142 : GEM3 User Manual

Doc# DS205 : AMF User Manual

Doc# DS150 : PMM User Manual


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Chapter 4 Technical Datasheet

315IPS-ODU

Utility Input Phases Supply 3 + N

Utility Input Phases Utilized 3 + N

Power Rating 15KVA

Input Voltage Range 175-255 VAC

Input Current 18A per phase

Input Over Current Protection Yes (MCB)

Surge Protection Class C

OVI (Independent for Each Phase) 3

Rotary OVI Bypass Switch: Mains – OVI Yes

Rotary ATS Bypass Switch: Auto - Manual Yes

- Source Selector Switch (G-M) when ATS Manual Yes

AMF + Automatic Transfer Switch Yes ( Single Genset + Mains)

- Number of Gensets Direct Control 1

Mobile Genset Support (Manual Selector + Socket) Yes

AC DISTRIBUTION (ACDB)

BTS/ Rectifier MCBs 25A TP x 2

Spare MCBs 6A SP x 2; 25A TP x 1

SP MCBs for Guard Light 6A SP x 1

ELCB for Utility socket 25A DP 30mA; 6A SP x 1

OTHER FEATURES

Power Measurement Module (For IPS Load) Yes

DC Tower Light Controller (48VDC) Yes

Genset Battery Charger (SMPS) Yes

BTS Battery - Genset Cycling controller (GEM3) Yes

MECHANICAL / ENVIRONMENT

Dimensions (Outdoor Cabinet) 1579H x 735W x 562D

Weight (Net, Estimated) 125kg

Ingress Protection IP55

Cooling System DC Fan Cooled

Operating Temperature / Relative Humidity 0 to 55°C, 10 to 90 %RH

Cabinet Construction

iioMS CRC Sheet, thickness: Main Pillars 2 mm, Side angles 1.6mm, Wall 1.2mm, C-channel base 4mm. Dual Coated (Undercoat: Epoxy based Zinc additive, Overcoat: Polyester based Powder paint RAL7035)

SAFETY

Designed to IEC60950 Electrical Safety Standard Yes


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Chapter 5 Warranty

The Integrated Power System is warranted free from defects in materials and workmanship for period specified at sale, starting on receipt. This warranty is limited to repairing or replacing, at company’s option, any defective component, circuit board, or module contained within the product only when it is returned to company or to a company-designated repair facility. In all cases, the customer is responsible for shipping charges to and from company or the company-designated repair facility.

Limitations of Warranty

This limited warranty does not cover any losses or damage resulting from shipment to or from the customer, or from improper installation, inappropriate environment, abuse, modifications, adjustments, or unauthorized repair.

Life Support Policy

As a general policy, company does not recommend the use of any of its products in life support applications where failure or malfunction of the company product can be reasonably expected to cause failure of the life support device or to significantly affect its safety or effectiveness. Company does not recommend the use of any of its products in direct patient care. Company will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to company that (a) the risks of injury or damage have been minimized, (b) the customer assumes all such risks, and (c) the liability of company is adequately protected under the circumstances.


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.2

48V

DC

LA

MP

SU

NL

IGH

T

SEN

SO

RP

ow

er

Inp

ut

Tow

er

Lig

ht

Fail

OR

Sensor

Fail

DC

TL

C (

X6)

Fro

m R

ectifier

Battery

PO

WER

OU

TP

UT

MAINS FAIL

TB55 L

.

TB61 N

.

TB62 N

.

TB63 L

.

87

47

Not U

sed

7

48

Wire f

lexib

le 4

mm

sq(Y

ello

w)

Wire f

lexib

le 4

mm

sq(R

ed)

Wire f

lexib

le 6

mm

sq(B

lack)

Wire f

lexib

le 4

mm

sq(B

lue)

CH

AN

GES

: R

3B

2

83

85

84

Gre

en

I3

12

Yello

w

I2

12

Red

I1

12

F8

F9

F10

106

48

48

15

14

CRANK

RC

CB

Rem

oved

MC

B S

P 3

2A

MC

CB

4P 6

0A

Outp

ut N

eutr

al B

ar

Changed T

o E

art

h B

ar

Dis

trib

utio

n M

CB

SP R

atin

g C

hanged T

o 6

A

AM

F C

ontr

ol T

erm

inals

Repositi

on

10

10

TB18

CO

M .COM

94

94

TB43 L1

.

TB11

CO

M . 94

94

77

9 9C

LA

SS

CSP

D3

SP

D(C

lass C

)

L1

N2

29

CLA

SS

CSP

D2

SP

D(C

lass C

)

L1

N2

CLA

SS

CSP

D1

SP

D(C

lass C

)

L1

N2

TB29

HE

T .

TB30

LF

I .

P48V

75

9

45

MCB12

6A SP

. .

9

109

94

38

38

37

37

101

101

(X0)

100

100

99

99

102

102

94

CT2

.K1

.K2

F5

(X1)

RC

CB

1

25A

DP

30m

A

.1

.2

.3

.4

TB39

NO

.

GE

N.B

ATT.

NE

G

29

EARTH BAR

20

TB

69

45

11

11

107

88

P48V

4

74

PS

U1 L

INE

5

21

46

LO

AD

ME

TE

RIN

G

5655

60

58

57 50

49

53 48

59

CAT5 Cable

PM

M.C

T2+

PM

M

V S

EN

SE

I S

EN

SE

CO

M

IGLC

DR

J45

PO

WE

R I

N

PM

M

CT1 +

CT1 -

CT2 +

CT2 -

CT3 +

CT3 -

V1

V2

V3

N

RS

485 A

RS

485 B

24V

GN

D

PW

R TX

RX

GN

D

IGL

CD

GR

AP

HIC

AL

LC

D

GN

D TX

RX

PW

R

PM

M.C

T3-

PM

M.C

T3+

PM

M.C

T2-

12

12

45

PM

M.C

T1+

PM

M.V

3_sense

PM

M.V

2_sense

PM

M.V

1_sense

TB17

CO

M .

PM

M.C

T1-

N24V

P24V

PM

M.N

_sense

94

51

54

LOW OIL PRESSURE

GE

N.B

ATT.P

OS

TB16

-48

V.

7

28

96

GE

M

FA

IL

S1

32A

1-0

-2 /

4P

13

129

5

1

10

7

3

11

8

6

2

4

141516

76

46

74

FAN

+

FA

N2

1 2

20

74

F2

TB46 L1

.

27

TB48 L2

.

TB49 N

.

48

TB50 L3.

24

80

26

81

82

7

OV

I

BY

PA

SS

TO

MA

INS

35

98

9

49

LOW FUEL IN

L1

L2

L3

MC

B6

25A

3P

..

.

.

.

.

PS

U1

BA

TTE

RY

CH

AR

GE

R -

12V

DC

L1

N2

VD

C+

3

GN

D4

TB10

NE

G.

U

TIL

ITY

S

OC

KET

8

AU

TO

.

.

MA

NU

AL

Cab

ine

t 1

F3

MC

B2

32A

SP

. .

L1

L2

L3

MC

B7

25A

3P

..

.

.

.

.

TB44 L2.7

8

16mm sq Din Rail

Terminals

TB38 N

.

ST

AN

DB

Y G

EN

SE

T

TB36 L2.

TB37 L3.

TB35 L1

.

9

23

27

25

22 23

Wire flexible 4mm sq(Red)

Wire flexible 4mm sq(Blue)

Wire flexible 4mm sq(Yellow)

Wire flexible 6mm sq(Black)

REC

TIF

IER

BA

T2.N

EG

47

.

.

.

AT

S B

YP

AS

S

63 P

HA

SE

OV

I

L1out

L2out

L3out

Nout

L1in

L2in

L3in

Nin

F4

20

PO

WE

R W

IRIN

G D

IAG

RA

M 3

15

IPS

-OD

U

NEUBAR

TS

1

Therm

al S

W 4

5deg C

16

16

17

17

-V

MA

INS

IN

TA

KE

18

18

36

.

L1

L2

L3

N

MC

B63A

4P

..

.

.

..

.

.

19

19

HIGH ENGINE TEMPERATURE

28

F11

21

REMOTE START NO

50

NO

TE

:

24V

DC

120m

m

Fro

nt D

oor

Fan

FAN

+

FA

N1

1 2

0.5mm Wire Flexible (White)

47

L1

L2

L3

MC

B5

25A

3P

..

.

.

.

.

39

39

10

CH

AN

GES

: R

3B

3

110

3

COM

FU

SE T

AB

LE

Ref.

Rating

Description

FTA

BLE

1

86

SEN

SIN

G L

INE1,2

,3A

MF

2A

SEN

SIN

G L

INE1,2

,3 P

MM

30A

F2,F

3,F

42A

F1

51

2A

2A

IND

ICA

TO

R L

AM

PS

F5

53

2A

F7

PM

M.C

T3+

PM

M.C

T2-

PM

M.C

T2+

F8,9

,10

86

48

PM

M.C

T1-

PM

M.C

T1+

PM

M.V

2_sense

PM

M.V

1_sense

PM

M.V

3_sense

BA

T2 T

erm

inals

Rem

oved (

X5)

EX

T. TEM

P T

erm

inals

Rem

oved (

X8)

MC

B12 C

urr

ent R

atin

g C

orr

ecte

d

Term

inal A

dded in

DC

TLC

Sectio

n

Term

inal B

lock

Refe

rences U

pdate

d

BA

TT.P

OS

FU

SE T

AB

LE

Ref.

Rating

Description

FTA

BLE

2

PM

M.N

_sense

GEM

Fail

Ala

rm A

dded

6

48

GEN

SET L

INE1 A

MF

2A

S3

32A

1-0

-2 /

4P

13

12

951

1073

11862 4

14

15

16

58

33 35

TB42

CO

M .

4mm sq Din Rail Terminals

34

8

11

2

30

89

46

GE

NS

ET

A

LA

RM

S

2.5mm sq wire flexible

GENSET RUNNING

30

BATT. NEG

BATT. POS

AM

F/A

TS

L1 Mains

L2 Mains

L3 Gen1

N Gen1

L1

N

L2 Gen1

L1 Gen1

L2

L3

L3 Mains

N Mains

RE

MO

TE

STA

RT N

O

GN

D

CO

M

Charger 12V

Batt

. N

eg

Charger GND

MAINS FAIL

A

GENSET Fail NO

GENSET RUNNING

Batt

. P

os

12V

DC

LOW FUEL OUT

B

COM

FU

EL S

OLE

NO

ID

CR

AN

K S

OLE

NO

ID

LO

W O

IL P

RE

SS

UR

E

HIG

H E

NG

INE

TE

MP

ER

ATU

RE

LO

W F

UE

L I

N

COM

COM

COM

PM

M.C

T3-

1.5mm sq wire flexible

GE

NS

ET

CO

NT

RO

L (

X4)

76

MA

INS

DIS

TR

IBU

TIO

N

33

LOW FUEL OUT

25

F12,1

3,1

4

54 57

56

55

32

32

36

97

103

COM

Wire f

lexib

le 4

mm

sq(R

ed)

Wire f

lexib

le 4

mm

sq(B

lue)

Wire f

lexib

le 4

mm

sq(Y

ello

w)

16mm sq Din Rail Terminals

Wire f

lexib

le 6

mm

sq(B

lack)

MA

INS

OR

GE

NS

ET

SE

LE

CT

OR

31

MC

B11

6A

SP

. .

SE

CU

RIT

Y

L

IGH

T

TB41 L

.

No

te:

Ne

t co

lor

co

din

g:

1 =

L1 =

Re

d

2 =

L2 =

Ye

llo

w

3 =

L3 =

Blu

e

4 =

N =

Bla

ck

No

te:

All

Te

rmin

al

Blo

cks

Are

2.5

mm

sq

Un

less

Sp

ecif

ied

All

AC

Po

we

r W

irin

g (

L1,

L2,

L3)

Is D

on

e W

ith

4m

m s

q F

lex

ible

Wir

e w

hil

e N

ue

tra

l W

irin

g I

s D

on

e W

ith

6m

m s

q F

lex

ible

Wir

e,

Un

less

Sp

ecif

ied

TB60 N

.

TB7

M.F

.

TB1-V

.

TB5

G.R

.

TB2

CO

M .

TB4

LF

O .

MC

B10

6A

SP

.1

.2

TB47 N

.

TB3NO .

N48V

TB6GF

.

S2

32A

1-0

-2 /

4P

13

12

951

1073

11862 4

14

15

16

GENSET FAILURE

COM

22

F1

48

47

(X3) EARTH

BARTB

67

9

1

34

26

46

25

13

76

90

MC

B3

32A

SP

. .

62

CR

ITIC

AL

AC

TIV

E

23

23

TB20

GN

D .

CT3

.K1

.K2

BA

T1

71

(X5)

72

CT

IN

73

TB45 L3.

Exte

rnal C

T

79

48

27

28

22

21

26

TB24CS .

TB23

PW

R .

TB25

GN

D .

65

GEM

3 A

LA

RM

S

TB32

NO

.

TB34

CO

M .

Re

cti

fie

r

Batt

ery

TB33

NO

.

CT1

.K1

.K2

TB51 L1

.

TB52 L2.

TB53 N

.

TB54 L3.

Cab

ine

t 2

66

SP

48

D2

4

DC

48-D

C24

24V

GN

D

GN

D

-48

V

67

45

CT I

nT2

RS

485

Main

s F

ail

GE

M3

PW

R O

UT

GE

M A

CT

CR

ITIC

AL

GE

M F

AIL

AM

F 1

AM

F 2

T1

GE

M3

Bat 1 +Bat 1 -

Bat 2 +Bat 2 -

Bat 3 -Bat 3 +

+5VCS

GND

+5VSIG

GND

COMMF

AB

+V

GND

SIG+5V

NOCOM

NOCOM

NCCOM

NOCOMNC

NOCOMNC

COM

62

For

Inte

rnal te

mpera

ture

(Insid

e C

abin

et)

GE

M3

61

(X2)

(X7)

Chapter 6 Appendix

Appendix A: Schematic


th, 2012

Appendix B: Bill of Quantity (BOQ)

Item Code Sub-Assemblies/Accessories Qty per IPS Brand

Power Intake

1601-004 MCB SP 20A; 6kA 1 ABB / Schneider/LS or equiv.

1604-001 MCB 63A 4P C Curve 1 ABB / Schneider/LS or equiv.

2001-005 VAL - MS 400ST (Valuetrab Surge Arrestor Class C) 3 Phoenix Contact

2050-001 VAL - MS BE (Valutrab Base Element) 3 Phoenix Contact

2050-002 MPB 18/1 - 4 (Trabtech Wiring Bridge) 1 Phoenix Contact

2715-014 Panel Indicator LED Light Red 1 Klemsan

2715-015 Panel Indicator LED Light Yellow 1 Klemsan

2715-016 Panel Indicator LED Light Green 1 Klemsan

OVI (3 Ø)


9501-096 OVI, Over Voltage Isolator Module (SP110OVI) 3 SalTec Powerlink

2901-001 Changeover Switch 4 Pole 32A 1-0-2 1 Bretter or equiv

AMF / ATS

9403-006 AMF, Auto Mains Fail Module (SP205AMF) 1 SalTec Powerlink

2902-003 Magnetic Contactor 4-P 11kW 230Vac; 12A AC3, 25A AC1 2 ABB / Schneider/LS or equiv.


1508-010 Din Rail Terminal 16mm Blue AVK16 1 Klemsan

1508-011 Din Rail Terminal 16mm Grey AVK16 1 Klemsan

1508-012 Din Rail Terminal 16mm Red AVK16 1 Klemsan

1508-013 Din Rail Terminal 16mm Yellow AVK16 1 Klemsan

9721-002 Genset Battery Charger 12V (SP072SMPS) 1 Saltec Powerlink

Mobile Genset

1509-011 Industrial Plug & Socket Set 63A 5P IP67 1 China


PDB

2805-005 Current Transformer WJ706 20 (100)A/8(40)mA, Class 0.1, 2500:1 3 Wanjia

1508-001 Din Rail Terminal 2.5mm Blue AVK2.5 4 Klemsan

1508-003 Din Rail Terminal 2.5mm Grey AVK2.5 24 Klemsan

1508-004 Din Rail Terminal 2.5mm Red AVK2.5 9 Klemsan



1508-010 Din Rail Terminal 16mm Blue AVK16 3 Klemsan



1508-013 Din Rail Terminal 16mm Yellow AVK16 3 Klemsan


1603-002 MCB TP 25A; 6kA (for BTS / Rectifier) 3 ABB / Schneider/LS or equiv.

1605-001 RCCB DP 25A 30mA (for Utility Socket) 1 ABB / Schneider/LS or equiv.

9719-004 PMM, Power Measuring Module (SP305PMM) 1 SalTec Powerlink


th, 2012

9403-003 DC to DC Converter (48V to 24 V) (SP048DTD) 1 SalTec Powerlink

Tower Light (AWL) Section

9402-006 48VDC Tower Light Controller (with sun sensor) 1 SalTec Powerlink

On-Grid Hybrid Controller

9715-003 GEM3 (SP603) with DC-CT 1 Saltec Powerlink

IPS Cabinet

1420-004 OUTDOOR Cabinet IP55 1 Saltec Powerlink

9521-177 Fan Assembly (Dual Fans, 24VDC) 1 Saltec Powerlink

315ips-Odu Ds210rb2 User Manual- (Zte) Sep 7th, 2012

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