Power One

POWER SUPPLY SYSTEMPODS 16.48-16000 1940 HEX

Instruction Manual

Revision: BDocument number: 039158

Copyright © Power One AS. All Rights Reserved.

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

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

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Title page - Instruction Manual

Document Number: 039158

Revision: B

Date: 11.05.2005

System: PODS 16.48-16000 1940 HEX

Ouput Voltage: 48V

Publisher: Power-One as

Postboks 1543

N-3007 Drammen

NORWAYAmendment record:Revision(Issue)

Description Author Date

/ First issue Kai Morten Hennum 07.04.05A Second issue Kai Morten Hennum 11.05.05B Third issue Kai Morten Hennum 01.06.05

Originated Kai Morten Hennum

Date 07.04.05 Approved Hans André Dokka Date 01.06.05

Signed Signed

1-1Document number: titlepage.fmRevision: B

1-2 PODS 16.48-16000 1940 HEXDocument number: titlepage.fm

Revision: B

Contents:4 System description PODS 16.48-16000 1940 HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44.4 System Description - PPS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.4.1 FMP 16- Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54.4.2 PCS - Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54.4.3 PPR 16/10 23”- Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64.4.4 PBDU 23” - Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.4.4.1 Low Voltage Disconnection (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64.4.5 Cabinet Door With Heat Exchanger (HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64.4.6 BTS Breaker 50A 3-pole (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94.4.8 FMP 16 Dummy Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94.4.9 Battery extension kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.2.1 Lethal voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25.2.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35.2.5 High temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-45.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

6 Installation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26.1.1 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.2 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26.2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26.2.2 Tools and parts required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26.2.3 Cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46.2.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-76.2.5 Cable sizes / location of external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.2.5.1 Cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-76.2.6 Connection of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6.2.6.1 Mains Input Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-106.2.7 Connection of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-106.2.8 Connection of Symmetry Measurement and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .6-116.2.9 Battery connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6.2.9.1 Battery tube routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-136.2.10 DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

2-1Document number: 039158TOC.fmRevision: B

7.2 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27.2.1 Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27.2.2 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27.4 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37.5 Test of output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.5.1 Float charge (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47.5.2 Adjustment of float charge, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47.5.3 Boost charging (U2) (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.6 Battery supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57.7 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57.8 Commissioning record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

8 Operation / Product description PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 General - Product description PCS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.2 Technical specification: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28.3 Operation - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.3.1 Starting the PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.3.2 Adding modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.3.3 Removing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

8.4 PCS 2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48.4.1 PCS 2 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

8.4.1.1 Show voltage and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.4.1.2 Show alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.4.1.3 Show messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.4.1.4 Show data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.4.1.5 Select / adjust U1 - U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68.4.1.6 Adjust limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-68.4.1.7 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

8.4.2 Connecting to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-108.4.3 Boost charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-118.4.4 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-128.4.5 Battery current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-138.4.6 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-138.4.7 High load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

9 Product Description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 General - Product description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29.2 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2.1 Mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29.2.2 DC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2.2.1 Mains input 185-250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29.2.2.2 Mains input 95-185VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.2.3 Module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29.2.5 Other technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.4.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49.4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

2-2 PODS 16.48-16000 1940 HEXDocument number: 039158TOC.fm

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9.4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-49.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-49.6 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4

10 Product description PPR 16/10 23” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

10.1 General - Product description PPR 16/10 23” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-210.2 Connections and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

10.2.1 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-310.2.2 Internal functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

10.3 Connections between subracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-410.4 Addressing module positions in subrack1, subrack2 etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5

11 Product description PBDU 4U/23” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

11.1 General - Product description PBDU 4U/23” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-211.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-211.3 Construction and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-311.4 Cable cross section output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-311.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-411.6 Commissioning PBDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-411.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4

12 Product description PCS Alarm interface unit BM0685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-212.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2

12.2.1 Pin Configuration of J20 and J21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-212.3 Remote alarms, symmetry measurement and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . .12-312.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3

13 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1

13.1 Installing new modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-213.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-213.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-413.4 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4

Appendix A: Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A.1 Cabinet Layout - 039095 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: / . . . . . . . . . . . . . . . . . . . . . . A-3A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 - Rev: / . . . . . . . . . . . . . . . . . . A-5A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: / . . . . . . . . . . . . . . . . . . . . A-6A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 - Rev: / . . . . . . . . . . . . . . . . . . A-7A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 - Rev: / . . . . . . . . . . . . . . . . . . . A-8A.8 Footprint Outdoor Cabinet - 039423 - Rev:/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Appendix B: Configuration c-000313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Appendix C: Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

C.1 Distribution PBDU 23" 1xMCB/10xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1


Appendix D: BTS Breaker 50A 3-pole - Installation procedure D-1

D.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5D.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5D.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6D.4 Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7D.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8D.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9

Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1)- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

E.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5E.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5E.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6E.4 Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6E.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7

Appendix F: Battery Extension Kit - Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

F.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5F.2 Safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6F.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6F.4 Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7F.5 Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8

F.5.1 Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8F.5.2 Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10F.5.3 Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Appendix G: FMP 16 Dummy Module - Installation procedure G-1

G.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5G.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5G.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5G.4 Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6G.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

Appendix H: 19” Adaptor Kit Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-1

H.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-5H.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6H.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6H.4 Overview 19” adaptor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-7

H.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-8

Appendix I: Battery Heater Kit- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

I.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5I.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5I.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6I.4 Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6


Revision: B

I.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6

Appendix J: Customer AC service outlet- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J-1

J.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5J.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5J.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6J.4 Overview AC outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6J.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6



Revision: B

Introduction to the manual


Objectives and audienceThis manual provides the user with the necessary information to understand how the Power Supply System is made and functions, together with sufficient information to enable the user to safely install, commission, maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be used by professional and properly trained personnel selected by our customers. This manual assumes that the technician has an understanding of power systems in general and understands safety procedures for working around AC and DC voltage. The user of this document should be familiar with electronic circuitry and wiring practices and have some expertise as an electronic or electromechanical technician.

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

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

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

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

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

WARNING! THE TEXT SET OFF IN THIS MANNER PROVIDES WARNING NOTICE THAT FAILURE TO FOLLOW THESE DIRECTIONS CAN RESULT IN BODILY HARM OR LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO EQUIPMENT

Introduction to the manual 3-1Document number: 028410.fmRevision: B


AbbreviationsThe following abbreviations are used in this manual:

DisclaimerPower One is not responsible for system problems that are the result of installation or modification of the instructions provided in this manual.

Questionnaire for feed-backWe urge you to complete and return the questionnaire on our web page at the following address: http://www.power-one.com/feedback.html. Let us know your remarks on and suggested improvements to this manual. We appreciate your comments in our achievement to improve our documentation.

If you have any problems with your system, e.g. you wonder how to install a new PMP rectifier or you have some questions regarding messages or alarms on the control module, please see the Troubleshooting section. If this does not solve your problem, please seek assistance at your local Power One office, or our head office in Norway. These also concern any indistinctness in the manual.

Abbreviation: Description:PPS P1 Power Supply SystemPODS P1 Outdoor SystemPMP P1 Modular PowerCMP Convection-cooled Modular PowerFMP Fan-cooled Modular PowerPCS P1 Control and SupervisionPCU P1 Control UnitPCC Prime Controller CardBCC Base Controller CardGMC Galero Modular ControllerXCS Xscend Control SystemXR Xscend Rectifier ModuleXS Xscend Subrack (Rectifier shelf)PPR P1 Power RackPBDU P1 Battery Distribution UnitPBC P1 Battery CabinetPDU P1 Distribution UnitPPRD P1 Power Rack with DC DistributionPPC P1 Power Supply CabinetPBF P1 Battery breaker UnitPCB Printed Circuit BoardLVD Low voltage disconnectionPLD Partial load disconnectionMCB Miniature circuit breakerMCCB Moulded case circuit breaker

3-2 PODS 16.48-16000 1940 HEXDocument number: 028410.fm

Revision: B

System description PODS 16.48-16000 1940 HEX

4 System description PODS 16.48-16000 1940 HEX

System description PODS 16.48-16000 1940 HEX 4-1Document number: 039159.fmRevision: A


4.1 GeneralPPS 16 modular DC power cabinet systems are designed to meet rigid telecom applications with very high reliability and flexibility for future expansion. This cabinet power solution provides rectification, system management and power distribution while maintaining high reliability and offering flexibility for future expansion. The PPS 16 Power Systems are based on hot-swappable rectifier modules (FMP 16.48) with output power available at 1600W per module. Systems are also based on fan cooling rectifiers and it is therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the air circulation.System management is accomplished through messages and alarms displayed on the system controller’s (PCS) LCD screen and can also be displayed remotely via the PC-based PowCom™1 software package.

Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases rectifier modules are shipped separately.

Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be connected to the RS232 contact.

1. Communication program for remote control of the power supply system


Revision: B


Figure 4-1 System drawing Outdoor cabinet

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System description PODS 16.48-16000 1940 HEX 4-3Document number: 039159.fmRevision: B


4.2 Technical Data

Figure 4-2 Principle drawing

Input: -voltage: 1x230V AC, 3x230V AC, 3x230/400V AC-current: <10A per module

Output: -voltage: 48V DC nominal / 16000W-current: Max 32A per. module, 48V-power: Max 1600W pr. module.

Weight: Rectifier: 2,2 kgCabinet dim.: Height: 1940 mm

Width: 800 mmDepth: 850 mm

4.3 OperationThe PODS 16.48-16000 HEX is capable of delivering up to 16000W/48V steady state power. The system is based up on hot swappable 48V/1600W rectifier modules, which are working in parallel with automatic load sharing.

The cabinet system is normally configured with N+1 redundancy, with N as the number of rectifier modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier module. In normal operation the rectifier modules, FMP 16, are feeding the load and simultaneously maintain the batteries in a fully charged state.

During a mains input power failure, the rectifiers are shut down and the batteries deliver the power required by the load, for a certain backup time. If the battery voltage drops below the pre-set level, the low voltage disconnection circuit (LVD) disconnects the batteries automatically to prevent battery deep discharge prolonging the battery life. When the mains input power is restored, the rectifiers start up automatically feeding the load, closes the LVD circuit and begin to recharge the batteries.

FB

BATT

LVD

F

F

DC distribution

AC FMP 16

FMP 16

PCS


Revision: B


The system performance is supervised and controlled from the supervisory unit, PCS. From this unit output DC voltage is set, alarm thresholds, LVD circuit operation, temperature compensated battery charging and battery testing. Any malfunction will be indicated by LED, text in the display and operation of dry contacts. However, PCS is not a single point of failure. In the event of malfunction in the PCS, basic tasks like feeding the load and charging batteries, will be maintained by the rectifier modules directly at preset default values.

The alarm and threshold setting of the PPS 16 can be set locally by using the PCS push buttons and menu guided operation or remotely, by using the PowComTM software.

4.4 System Description - PPS 16This system consists of the following components:

Figure 4-3 Front view of PPS 16.48-16000

4.4.1 FMP 16- Rectifier ModuleThe Power-One FMP 16 rectifier provides extremely reliable DC power in the highest possible density. The module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification information to the controller.Other features include 3xLED for rectifier status indication, thermal protection with de-rating and input over voltage disconnection with automatic reset. The rectifier units are hot swappable and can be quickly removed and replaced without disrupting the system or load.See: 9 Product Description FMP 16 on page 9-1

4.4.2 PCS - Controller SystemPCS - is a supervisory system with onboard software for monitoring and operation of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy of having one main controller supervision for the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus takes care of internal communication between the various units. RS232 is used for remote operation from a PC.PowComTM softwarePowComTM is a communications software package that allows the remote control of the power supply system. The software uses a Windows based interface to allow access to the PCS. PowComTM is installed

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multi 9

C120N

D100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

1

2

3

4

multi 9

C120N

D100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

Battery breakers Load breakers

PCS

FMP 16



on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up modem.Power-One Network interface (option)The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with PowComTM software either through a modem or Ethernet connection.See: 8 Operation / Product description PCS 2 on page 8-1

4.4.3 PPR 16/10 23”- SubrackPPR 16.48 is a subrack for modules in the FMP 16 series. The subrack has up to ten module positions (max. 10xFMP 16 rectifiers.) The subrack has a connection for AC in, DC out and RS485 for communication.Modules are “hot swappable” under full load conditions. See: 10 Product description PPR 16/10 23” Subrack on page 10-1

4.4.4 PBDU 23” - Distribution ModuleDC distribution module with battery breakers, load breakers, shunt for measurement of current, alarm for battery and load.

The distribution has no special operation other than switching the battery and load breakers on and off. All DC distribution breakers are supervised by measuring voltage drop across each breaker.

Breakers that are not connected to any load, will not cause breaker alarm even if they are left open.

Note! Due to a small leakage current (2,5-3 mA) through the alarm circuit the voltage measured with a DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage.

If a battery breaker fault occurs or is simulated it may take from 2-10 minutes before the fault is indicated, depending on the battery condition.

The distribution module has common "+" and breakers in "-" leg. For more information see schematic drawing in Appendix A.

See: 7 Product description PBDU 23”

4.4.4.1 Low Voltage Disconnection (LVD)The system is equipped with low voltage battery disconnection, which prevents the batteries from deep discharging, thus prolonging the battery life. A disconnection requires a detected mains failure at the supervision unit. Threshold for disconnection is available.If disconnection occurs, the batteries will not supply power to the load until they have been recharged to set voltage level, which can be adjusted by the user.If disconnection occurs, the batteries will be reconnected when mains supply return.

4.4.5 Cabinet Door With Heat Exchanger (HEX)The Cabinet door is a lockable door meant to protect the battery compartment from access of unauthorised personnel. The system heat exchange unit is also mounted in the door.


Revision: B


Figure 4-4 Cabinet door with HEX, inside view

The principle of the Heat Exchanger unit is to use cool ambient air to cool down the warm air inside the cabinet, without any ambient air being pulled into the cabinet itself. Two fans pull outside and inside air respectively through each side of the heat exchanger element. The fan speed is monitored by the controller and is decided by a temperature sensor positioned by the internal air inlet (see Figure 4-4). Figure 4-5 on page 4-8 shows external air flow, internal air flow and a principle drawing of the heat exchanger element.

Air out

Air in

Fan out

Fan in

Door Locking mechanism



Figure 4-5 Heat Exchanger Airflow

HEX airflow internal. Seen from the side with side plate removed.

Cabinet door

with HEX unitRectifier shelf

Cabinet door with

HEX unit

HEX unit ambient airflow

Heat Exchanger Element Principle Drawing

HEX Outside air HEX Inside air Inside of CabinetAmbient air

Cold ambient air in

Warm air out

Warm air from the cabinet

into the HEX element

Cooled air back to the

cabinet

Heat energy from internal air to

external air through the HEX

element


Revision: B


4.4.6 BTS Breaker 50A 3-pole (Option)The BTS Breaker 50A 3-pole is an optional kit that allows extension of one extra load breaker. This breaker can be mounted with 50A, 100A or 150A load capacity.

See: Appendix D: BTS Breaker 50A 3-pole - Installation procedure

4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option)The surge arrestor kit is an optional unit that protects the system against lightning and transient overvoltage. Each surge arrestor kit consists of three over voltage protector units, a spark gap plugged in one holder and link cables.

Each surge arrestor unit has a display on the front that indicates if it is OK or has blown. Surge arrestor units with a red display have blown and must be replaced. When fitted, each surge arrestor kit is located below the mains input terminal blocks.

See: Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure

4.4.8 FMP 16 Dummy Module (Option)The FMP 16 dummy module is an optional kit for covering empty module positions.

See: Appendix G: FMP 16 Dummy Module - Installation procedure

4.4.9 Battery extension kit (Option)The battery extension is an optional kit that allows additional battery branches to be added to the power system (extension of hold up time). The power system allows maximum 4 battery branches. The kit includes one extra single pole battery breaker, battery shelf, battery cable, symmetry cable and signal cable harness.

See: Appendix F: Battery Extension Kit - Installation Procedure




Revision: B

Safety

5 Safety

Safety 5-1Document number: 028580.fmRevision: A

Safety

5.1 Safety - IntroductionThis document contains recommended safety guidelines for working with the equipment mentioned in this documentation.

The instructions in the Customer Documentation must be followed by properly trained and authorized personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the instructions may be dangerous to personnel and equipment. Although the purpose of safety devices, routines and regulations are meant to take care of the safety of the user, nobody is excused from using common sense at all times when operating or otherwise handling the equipment.

These above mentioned safety guidelines include Warnings, Cautions and Notes.

5.2 Warnings

5.2.1 Lethal voltages

All persons who perform any operations on this equipment should be advised of the potential dangers. Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems and equipment:

Potentially lethal voltages are present within the system. Ensure that all power supplies are completely isolated by setting all power switches to OFF, disconnecting all relevant connectors and removing all relevant breakers before attempting any maintenance work. Do not rely on switches alone to isolate a power supply.

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

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

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

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


Revision: B

Safety

5.2.2 Grounding

5.2.3 Precautions for lead acid batteries

Ensure the following guidelines are observed when dealing with equipment that may contain lead acid batteries:

Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes.

Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with the corrosive fluid must be avoided.

Neutralize any acid corrosion with copious amounts of a solution of baking soda and water, and then wipe off all traces of soda.

If the lead acid battery is removed from the equipment, any exposed contact must be insulated prior to disposal.

Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are used when working with the batteries.

5.2.4 Weight

5.2.5 High temperatures

WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED.

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

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

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

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

Safety 5-3Document number: 028580.fmRevision: B

Safety

5.3 Cautions

5.3.1 Storage and transportation

5.3.2 Handling electrostatic sensitive devices

5.3.3 Traceability

5.3.4 Breakers

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

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

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

CAUTION! Breakers should always be replaced with the same type in order to avoid damage to system components.


Revision: B

Installation guide

6 Installation guide

Installation guide 6-1Document number: 039160.fmRevision: A

Installation guide

6.1 Site requirementsThe site should be suitable and ready for the power supply. If it is not or you are unsure about this, contact your supervisor before continuing. Check, using a spirit level, that the site is level.

6.1.1 AC Power source requirements

Note! This product is also designed for IT power distribution system with phase-to-phase voltage 230V.

6.2 Installation procedure

6.2.1 UnpackingCheck that the equipment received is in accordance with the packing list. Ensure that the cabinet and the equipment have not been damaged during transportation.

Contact Power-One if any parts are missing or damaged, and correct any problems before continuing.

6.2.2 Tools and parts requiredThe following tools are required for a safe installation of the system:

Anti-static hand strapSocket wrench, insulatedScrewdriver set, flat, insulatedScrewdriver set, torx, insulatedScrewdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulatedTorque spanner (for battery connection), insulatedM12 bolts for cabinet base

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

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

WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS INSTALLATION

WARNING! USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS: SHAFTS OF SCREWDRIVERS ETC.; SHOULD BE INSULATED.


Revision: A

Installation guide

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

CAUTION! Installation in USA / Canada must conform with NEC/CEC requirements.


Installation guide

6.2.3 Cabinet mountingThe cabinet base needs to be fastened to the ground before lifting the cabinet into position.

WARNING! THE CABINET IS HEAVY AND MUST BE HANDLED WITH DUE CARE

1. Step 1 in Figure 6-1 shows the location of the mounting holes for the base. M12 bolts are not delivered with the cabinet and should be supplied by the customer.

2. Plinth directions: The sides of the plinth have a SIDE imprint. The SIDE imprint should face up from the ground. Measurements of the plinth needed to prepare the site for mounting can be found in Appendix A: Drawings.

3. After secure fastening of the cabinet base, lift the cabinet into position on the cabinet base (Step 2 in Figure 6-1).

4. Step 3 in Figure 6-1 shows location of mounting holes for fastening the cabinet to the cabinet base. Fasten the cabinet to the base with M10 bolts from inside the cabinet. M10 bolts are included.


Revision: A

Installation guide

Figure 6-1 Base and cabinet mounting (empty cabinet shown)

After mounting the cabinet base and cabinet, the four lifting brackets mounted on top of the system should be removed. The bolt holding the bracket should also be mounted in the opposite direction to tighten the holes and make the top spill-proof. Figure Figure 6-2 on page 6-6 shows the mounting of the brackets as delivered, and also how the parts should be assembled after removing the brackets.

Follow these steps to correctly remove and reassemble the parts:

1. Remove the top lid from the cabinet for easy access.

2. Loosen and remove the top nut, then remove the washer and lifting bracket. Keep these parts for possible future relocation of the cabinet.

Note! Only the nut and washer on top of the lifting bracket should be removed.

3. Enter the bolt in the opposite direction and fasten it from the inside with the remaining nut and washer as shown in Figure 6-2 on page 6-6.

4. Slide the top lid back into position on top of the cabinet.


Installation guide

Figure 6-2 Removal of lifting brackets

Lifting bracket as deliv-ered

Location of lift-ing brackets.

Lifting bracket re-moved and bolt fas-tened in oppositedirection.


Revision: A

Installation guide

6.2.4 GroundingEarth connection is essential BEFORE connecting supply.

1. Switch off all the breakers in the distribution panel.

2. Remove the roof by loosening the two screws at the front, which hold the top in position. Pull the top forward and lift it up.

3. Connect the grounding cable between the grounding connector in the positive DC busbar of the cabinet and the main grounding point at the back of the cabinet.

4. Check that the cables are secured tightly.

6.2.5 Cable sizes / location of external connectionsMains: Max. 16 mm2 (4AWG)Alarms: Max. 1,5 mm2 (14AWG)Load: Max. 16 mm2 / 35 mm2 (4AWG / 1AWG)Battery: Max. 35 mm2 (1AWG) (50mm2 (0AWG) w / cable lug)

Alarm connections are located at the top right side of the system.

6.2.5.1 Cable entry boxThe cable entry box delivered with the system (or additional cable entry kit option) should be mounted before connecting mains and load. Remove or lift the cabinet top before installing the cable entry box. Once a cable entry side is selected (rear, left or right) the panel in the selected position is replaced with the panel in Figure 6-3. Default cable entry side is to the right, so no panel is mounted in this position. Do not remove the panel during cable installation. Follow steps 1 through 5 below to complete installation of the cable entry box.

Figure 6-3 Cable entry casing.(Shown without nipples)

1. Select cable entry side and remove the cover where mounted. If rear or left cable entry is wanted, the cover mounted here can be moved to the right side.

2. Fasten the cable entry casing to the cabinet with three M4 screws.

Mains cable entry

Load/Battery/Signal cable entriesBattery tube entry


Installation guide

3. Attach the casing to the cabinet.

4. Mount the casing top and fasten with two M4 screws.

5. Cable entry box installation is now complete, lower the cabinet top.

Figure 6-4 Mounting of Cable entry box

1 2

3

4 5

(Feed-through plate shown without nipples)


Revision: A

Installation guide

6.2.6 Connection of Mains1. Ensure that mains input is turned off before connecting.

2. Enter the mains supply cable into the cabinet through the mains cable entry in the cable entry box.

3. See 6.2.5 Cable sizes / location of external connections on page 6-7 for reference. Push the cable to the terminal block. Fasten the cables with the mounting screws.

4. When connecting mains to terminal blocks remove as little insulation from the cable as possible before installing into terminal block, so that the jacket prevents a stranded conductor from coming loose and touch any secondary conductive parts on the backplane.

Note! The insulation on the cable must have a clearing of minimum 1mm in the terminal blocks

5. The mains input terminal blocks can be connected to: 1x230V AC, 3x230V or 3x230/400V AC.USA / Canada connections: 1x220V AC, 3x220V AC or 3x220/440V AC.

6. Use Torque table in the Maintenance and Troubleshooting chapter for the correct torque.

Figure 6-5 Mains Input Types

Figure 6-6 Input Mains Terminal

Recommended mains fuse:1x230V AC (USA/Canada 1x220V AC): Double pole 63A C-char (Mains 1)

(USA/Canada: Double pole 70A C-char)1x230V AC (USA/Canada 1x220V AC): Double pole 40A C-char (Mains 2)3x230V AC (USA/Canada 3x220V AC): Triple pole 32A C-char (Mains 1)

(USA/Canada: Triple pole 40A C-char)

L1

PE

1 wire system

TN-S

230V AC 1ph

N

L1

L2

L3

PEN

4 wire system

TN-C/IT

230V AC 3ph

L1

L2

L3

N

PE

5 wire system

TN-S/TT

230/400V AC 3ph

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

N/P

E-3

50

-ST

L3

L3

L2

L1

L2

L1

N N

Surg

earr

esto

rkit

(Optional)

PE

3 phase 400V AC

PE

PE

N

L1

L1

L2

L3

N

N

N

N

N

L2

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

PE

3x1 phase 230V AC

PE

PE

N1

L1

L1

L2

L3

N1

N2

N2

N3

N3

L2

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

PE

1x3 phase 230V AC

PE

PE

L1

L2

L2

L3

L3

L1

L1

L1

L2

L2

L3

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

Input mains terminals.

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

N/P

E-3

50

-ST

L3

L3

L2

L1

L2

L1

N N

Surg

earr

esto

rkit

(Optional)

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

35

0-S

T

VA

LVETR

AB

VA

L-C

P

N/P

E-3

50

-ST

L3

L3

L2

L1

L2

L1

N N

Surg

earr

esto

rkit

(Optional)


Installation guide

3x230V AC (USA/Canada 3x220V AC): Triple pole 25A C-char (Mains 2)(USA/Canada: Triple pole 30A C-char)

3x400V AC (USA/Canada 3x440V AC): Triple pole 25A C-char (Mains 1)3x400V AC (USA/Canada 3x440V AC): Triple pole 25A C-char (Mains 2)

(USA/Canada: Triple pole 30A C-char)

6.2.6.1 Mains Input ChangeAttached to the cabinet behind the mains terminal blocks (the bags are attached to the cables between the terminal blocks and the subrack) there are two plastic bags containing fishplates, high voltage stickers (400VAC), labels for 3 phase 400 VAC and labels for 3 phase 230VAC for mains input change.

1. Connect according to Mains schematics in Appendix A

2. Attach labels accordingly on the cabinet chassis

6.2.7 Connection of AlarmsFor remote supervision of the alarms, there are 4 potential free alarm contacts. Each alarm contact represents different alarm conditions. Potential free alarm contacts for remote signalling at PBDU interface are located in the right side of the distribution.

Note! Alarm contacts are shown in alarm position.

Figure 6-7 Connection of Alarms

i

IOIO

I

1

2

3

4

multi 9

C120N

D100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

1

2

3

4

multi 9

C120N

D100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

1

2

3

4

multi 9

C120N

D100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

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C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

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3

MERLIN GERIN

I ONI ON

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C60NC16230/400V

6000

3

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I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

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C60NC16230/400V

6000

3

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multi 9

C60NC16230/400V

6000

3

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I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

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I ONI ON

multi 9

C60NC16230/400V

6000

3

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I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

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I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V

6000

3

MERLIN GERIN

I ONI ON

power-onepower-one

FMP1648

power-one

FMP1648

power-onepower-one

FMP1648

power-one

FMP1648

power-one

FMP1648

power-one

FMP1648

power-one

FMP1648

power-one

FMP1648

power-one

FMP1648

power-one

FMP1648

Location of alarm connections

3

6

2

5

1

4 Batt. sym. 4/

ext. analog

+ Red

T Green

- Blue

T

3

2

1

Temp. Probe 1

J2

3

6

2

5

1

4J1

+ Red

T Green

- Blue

6

5

4

Temp. Probe 2

+ Red

T Green

- Blue

3

2

1

Temp. Probe 3

+ Red

T Green

- Blue

6

5

4

Temp. Probe 4

J4

J5

J6

J7

J8

J9321

6

5

4

3

21

6

5

4

3

21

3

2

1

2

1Digital input

(Door alarm)

DI.1

DI.0

Alarm 6

Alarm 5

Alarm 4

Alarm 3

Alarm 2

Alarm 1

Alarm contacts

are shown in

alarm position

J10

4

3

2Digital output

1DO.0DO.1

+12V0V

Batt. sym.

J3


Revision: A

Installation guide

Alarm cabling install:

The green connectors can be easily removed, if desired, for ease in installing the wires to the connector.

1. Remove the green plug from each connector.

2. Determine whether to reference normally closed or normally open with reference to common for each alarm contact.

3. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper ferrule if desired.

4. Insert wire into the correct positions in the green connector and tighten screw to clamp wire into connector.

5. Route the wires through the cable area at the top left of the cabinet.

6.2.8 Connection of Symmetry Measurement and Temperature SensorThe controller can supervise the symmetry of up to 4 battery branches. The drawing in Figure 6-8 on page 6-12 shows how to connect the symmetry cables for 1 battery branch. Symmetry and temp. sensor contacts are located in the right side of the distribution.

Note! The number of battery branches to be supervised has to be set in the controller in order to activate the symmetry measurement.

It is also possible to add four temperature probes to the system for temperature compensated charging of the battery bank. Fasten the temperature probe in the middle of the battery bank. The temperature probe will measure the ambient temperature of a battery bank and the controller will adjust the float charge according to the temperature compensation factor set in the controller. This factor must be set in the controller according to the battery manufacturer recommendation.


Installation guide

Figure 6-8 Connection of Symmetry (2 Block Measurement) and Temp. Sensor

Installing the Symmetry cabling and the battery temperature sensor:

1. Remove the green plug from each connector.

2. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper ferrule if desired.

3. Insert wire into the correct positions in the green connector and tighten screw to clamp wire into connector.

4. The wires are wound up and pre-routed with fastener strips on the cabinet sidewall. The cables must be unwound and connected to the battery pole according to the Figure 6-8 on page 6-12.

6.2.9 Battery connectionThe battery cables of the system are, if ordered, pre-connected to the systems battery breakers. The “+” cable of each battery string is connected to the positive bus bar of the system, and the “-“ cable to the negative battery breaker (separate for each string). Connect the other ends of the cables to the “-“ and “+” terminals of the batteries.

Note! Fasten the cable lugs pointing upwards, as there is not enough space in the cabinet for sideways installation.

-48V

0V

-36V

-24V

-12V

3

6

2

5

1

4

Batt. sym. 3

Batt. sym. 4

+ Red

T Green

- Blue

T

3

2

1

Temp. Probe 1

J2

-24V3

6

2

5

1

4

Batt. sym. 1

Batt. sym. 2

J1

+ Red

T Green

- Blue

6

5

4

Temp. Probe 2

+ Red

T Green

- Blue

3

2

1

Temp. Probe 3

+ Red

T Green

- Blue

6

5

4

Temp. Probe 4

J4

J5

-24V

-24V

-24V

-48V

0V

-36V

-24V

-12V


Revision: A

Installation guide

6.2.9.1 Battery tube routingThe ventilation tube from the battery should be routed out of the cabinet through the cable entry casing as shown in Figure 6-9. Pull the tube through the cable entry casing from the inside, and attach a tube extension piece to avoid the tube sliding back inside the cabinet.

Note! Nipples on cable entry casing not shown in Figure 6-9.

Figure 6-9 Battery tube routing

6.2.10 DC connectionThis section details how to connect external load to the DC load breakers.

Check that all the MCB’s are in the OFF position.

1. Connect the negative (-) DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw.

2. Make sure the cable has the correct rating (i.e. thick enough) for the selected MCB.

3. Connect the positive (+) DC supply cable directly to the positive bus bar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the bus bar, and then tightening the screw.

4. Start connecting the loads to the bus bar from the first connector on the left. Make sure the cable is the correct rating (i.e. thick enough) for the load.

5. Check that all the cables are secured tightly to the connectors.

Use Table 13-1 in the Maintenance and troubleshooting chapter for the correct torque.


Installation guide


Revision: A

Commissioning

7 Commissioning

Commissioning 7-1Document number: 036285.fmRevision: A

Commissioning

7.1 Commissioning OverviewBefore delivery the system was thoroughly inspected and tested. The following chapter is a guide to the set-up and operation of the control functions of the system.

Note! Before starting commissioning read the product description for the individual components.

If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a lower level.

7.2 Tools and Test Equipment

7.2.1 Tools ListThe essential commissioning tools are listed below:

A PC with PowCom installed (when controller is without LCD Display)

Anti-static hand strap

Socket wrench, insulated

Screwdriver set, flat, insulated

Screwdriver set, torx, insulated

Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated

Torque spanner (for battery connection), insulated

7.2.2 Test EquipmentMultimeter (3 ½ Digit, 0 – 1% DC)

Load resistance, to connect 0-100% of total capacity to the system

7.3 PreparationCheck the installation to ensure the following:

Site is clean and safe

Grounding: The equipment is correctly grounded. The grounding cable size, color and routing conform to the requirements

Power: The incoming mains AC power is available for this site. The site power switch and circuit breakers are clearly labelled. The power cables are correctly terminated

WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.


Revision: B

Commissioning

7.4 Commissioning procedure1. Remove the covers and check that all connections are made according to the installation drawing.

Verify that all connections are properly tightened with sufficient torque.

2. Ensure load and battery MCB breakers are set to OFF position - ensuring the load and battery strings are connected.

3. Ensure all rectifier modules are removed. If not, remove each one in turn starting from the rightmost position.

4. Check the battery polarity with the Multimeter (3½ Digit, 0·1% dc). Place the positive lead of the meter to the plus-bus bar, and the negative lead to the battery breaker. The meter must now show a positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables to the batteries.

5. Turn on the AC mains voltage.

6. Measure the AC voltage on the AC terminal block, between phases and neutral. The correct value is approximately 230V. If the value is different, check the AC connection.

7. Plug in all rectifier modules, starting from the leftmost position. Make sure to fasten the rectifiers again. The rectifiers will turn on automatically.

8. Set load breakers into "1" (ON) position.

9. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s) (Normally not more than 5V DC)

10. Green LED on controller should blink for approximately 20 sec.

11. Output voltage will increase slowly to U1.

12. Turn battery breaker to "1" ("on") position.

13. If any alarms are present, they should be reset in accordance with "Show alarms" in product description controller.

14. The system should now be without alarms.

15. Attach all the system covers in their correct places.

16. Check that all changes to drawings, if any have been completed.

17. Clean the site.

18. Fill in the commissioning record (see end of chapter).

Commissioning 7-3Document number: 036285.fmRevision: B

Commissioning

7.5 Test of output voltage

7.5.1 Float charge (U1)Be sure that the controller is operating.Connect load, approx. 50% of total capacity, to the system.Check the voltage according to the battery manufactures requirements. If the batteries require other float charging voltage, adjust the output voltage from the controller. (See product description controller)

If nothing else is required, use the following values:

7.5.2 Adjustment of float charge, U1Output voltage is factory pre-set to: See Appendix B. The total voltage has to be in accordance to the number of battery cells.Please verify number of cells and the battery manufacturers requirements.Adjust output voltage from the control unit.

Note! A sealing protects the potentiometer in the subrack. Do not break the seal.

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

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

Activate boost charging from the "Set/select U1-U4" menu in the control unit.

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

Sealed lead-acid batteries.

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

Boost charging figures

Observe and write down all of the boost charging figures.Parameters to be read/set/adjusted from control unit or PC with PowCom1 installed.

Battery type Float charge Boost charge

Open lead-acid batteries 2,23V/Cell 2,33V/Cell

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

Table 7-1

1. Communication program for remote control of the power supply system.


Revision: B

Commissioning

7.6 Battery supervisionFor systems with symmetry cables supplied:

Set number of battery strings according to number of battery strings in the system. The settings are to be made in the control unit via a PC with PowCom installed or directly in the controller (if symmetry failure is indicated).

The symmetry fault alarm is to be simulated by pulling out one symmetry cable from battery string. Measure that setting to make sure that it is in accordance with battery manufacturer recommendations.

For systems with temp. probe cable supplied:

The temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that the compensation level is according to the battery manufacturers requirements. (If no compensation level is available from the battery manufacture, Power One recommends it to be set to 0,5V).

7.7 Battery testThe settings should be made according to the battery manufacturer requirements, but as a rule of thumb the following settings can be used for standard VR lead batteries:

No. of test pr. year = 2U3 Test = 1,9 V/cellEnd voltage b.test = 1,94V/cellBatt. test time = 40% of expected backup timeAh limit for test = 40% of nominal battery capacity

Parameters to be set/adjusted from the controller (Battery test menu) or "Supervision - Set parameters” menu in PowCom.

Commissioning 7-5Document number: 036285.fmRevision: B

Commissioning

7.8 Commissioning recordThis is a step-by-step commissioning record for easy commissioning of Power-One Supply Systems. Do not continue if any faults occur during this commissioning. The checkpoints are to be considered as a minimum for commissioning of the system.

Table 7-2 Commissioning record

Checked

( )

Result

1. Check that rack is levelled2. Check that all breakers are turned to “off”

position and that no rectifiers are mounted in the subrack(s).

3. Connect AC, and measure voltage on the mains input connections in the cabinet, Is to be 230V AC (Measure 230V from phase to N when 400V mains input is used)

L1-N:………..V ACL2-N:...............V ACL3-N:...............V AC

4. Mount rest of the rectifiers5. After connection of battery, verify right polarity

by measuring the voltage drop across the battery breakers (normally not more than 5V DC).

6. Check float charge, U1, and boost charge, U2. Is to be adjusted according to the battery manufacture requirements.

U1:……..V DCU2:.........V DC

7. Check temperature compensation. Is to be adjusted according to the battery manufacture requirements.Check temperature read off compare to the room temperature.

Comp. :…….V/10oC

Read off:………oC

8. Check symmetry measurement and set number of battery strings according to actually supervised battery strings in the system.

Number: ….

Alarm limit:……9. Check alarm transmission by running an

alarm test.


Revision: B

Operation / Product description PCS 2

8 Operation / Product description PCS 2

Operation / Product description PCS 2 8-1Document number: 036777.fmRevision: A


8.1 General - Product description PCS 2PCS 2 - Power One Control System is a supervisory system particularly designed for supervision of power supply systems based up on Power One rectifier modules. The design is based up on the philosophy that one main controller supervises the entire power supply system, and use of distributed intelligence by local micro controllers. A RS485 data bus is used for internal communication between the various units. Very simple internal colour labelled signal wiring using only two cables with RJ45 plugs in each end. RS232 serial interface for remote control from a PC with PowCom1 software.

For more detailed project specific information regarding system settings see Appendix B, Configuration. This document specifies all available standard Power-One alarms, i.e. alarm 0 up to 23 and any customer specific alarms (available as alarm 24 up to 39).

Note! Some of the alarms have Power-One standard limits and some of them have customer specific adjusted limits.

A complete supervisory system do always consist of the following units:

PCS 2 - Main Controller

Master unit in the system communicating with all distributed micro controllers. Has an LCD display, menu driven operation, visual alarm indication, RS232 contact for remote operation and RS 485 for internal communication with 128 addresses (64 rectifier modules - and 64 other remote micro controllers). Sockets for plug-in network interface. The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and enables the system to be accessed from any location. The protocol uses simple commands to configure and control the system and relay the system status to the operator. Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can be used in conjunction with PowComTM software either through a modem or Ethernet connection.

PCS 2 - Alarm Interface board

The alarm interface board contains:

Input for current reading

Battery and load breaker monitoring

Battery temperature and battery symmetry measurement

Output for operating two individual contactors (LVD and PLD)

6 potential free alarm contacts.

Three analogue and two digital inputs for supervision of miscellaneous signals (ventilation, door open or other).

8.2 Technical specification:Input voltage:18-72V DC

Power consumption:Max 30W

Output:+/- 12V

1. PowCom is a communications software package that allows the remote control of the system. The software uses a Windows based interface to allow access to the PCS. PowCom is installed on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up modem.


Revision: B


InstrumentationThree LED's, Green - OK, Yellow - Message, Red - Alarm 2 x 20 character alphanumeric LCD display with backlight. 5mm character height.

Interface:RS 232 for remote operation via PowCom. RS 485 for internal communication with128 addresses (64 rectifier modules and 64 sub-controllers).

Basic functionsSimple manu-guided operationUser-selectable alarm parameters40 event data loggingInternal clock with battery backupMultiple language optionsTemperature compensated chargingBoost charging, manually and automaticMonthly data loggingLVD control of two contactors, voltage or time controlledBattery test, manual or automatic with symmetry measurementAlarm relay testAdjustable battery currentSoftware controlled start up after mains outage and battery testOptional Ethernet interface

8.3 Operation - IntroductionThe PCS 2 communicates through an alarm interface board and a backplane that connects to the rectifier modules. There may be up to 64 rectifier modules and 63 Units on one serial channel.

The following section contains basic PCS 2 functions including starting the PCS 2, adding modules and removing modules from the PCS 2 system.

Figure 8-1 PCS 2 LED's and control.

WARNING! RISK OF EXPLOSION IF LITHIUM BATTERY IS REPLACED BY AN INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS.

Power LED (Green)

Warning LED (Yellow)

Alarm LED (Red)

System Interface Controls

RS235 Interface Connection

Operation / Product description PCS 2 8-3Document number: 036777.fmRevision: B


8.3.1 Starting the PCS 2When power is applied to the PCS 2:The PCS 2 will spend 20 seconds analyzing the system and testing all addresses for connected modules and units. The green LED on the PCS 2 will blink (Figure 8-1). No alarms will be given during this period.When the PCS 2 finds a module or a unit it will add it to the inventory. The module will remain in system memory until a master reset or a reconfiguration is done.

8.3.2 Adding modulesWhen a rectifier is added to the system it will remain off until the PCS 2 detects it.

1. The PCS 2 constantly scan for new modules and units, but it may take up to 5 minutes from a module is inserted until it is registered. During this time the yellow warning LED on the module will blink.

2. The PCS 2 will locate the module and the LED will stop blinking. The new module will give a current sharing fault until its output voltage has been adjusted to the correct voltage. This may take additional time.

3. To shorten the time that is needed to find new modules the PCS 2 can be powered down and then powered up. This will cause the system to search for new modules faster. This is only recommended as a solution if it is important to shorten the time required for searching for new modules.

8.3.3 Removing modulesPhysically removing a module from the system appears as a communication error on the PCS 2.

1. To remove the error message use the Accept removed parts item on the Miscellaneous menu, or press the reconfigure button in the Inventory window in PowCom.

2. Make sure that there are no communication faults caused by any failure before doing this as it will cause all not communicating modules and units to be removed from the inventory.

3. This will make all communication faults disappear, but it will not fix any problems so it must only be used if the communication fault is caused by the module or unit being intentionally removed.

8.4 PCS 2 ControlThe control unit is equipped with four push buttons:

CANCEL - Used to go cancel the current selection on the menu hierarchy. When pressed the menu will return to the previous screen.

UP ARROW - Used to go up in the menu hierarchy. select options and to adjust limits.

DOWN ARROW - Used to go down in the menu hierarchy. select options and to adjust limits.

RETURN - Used to select and confirm an option or to go down a level in the PCS 2 software hierarchy.

To adjust the alarm limits, use the arrow keys to select "adjust limits". Press RETURN to enter the sub menu, and RETURN once more to select "alarm limit". By using the arrow keys the various alarm limits can be checked. For adjusting a limit: select the correct limit and press RETURN. The correct password must be entered before a new value can be set.

The password is set to 1234 by default, but can be changed. Use the arrow keys to set and RETURN to confirm each digit. CANCEL can be used to correct a digit. For more information on setting the system password, see the section "Set New Password" in this chapter.


Revision: B


Adjust mode is indicated by a: (colon) in front of the value and a steady cursor behind. Use the arrow keys to adjust the alarm limit and press RETURN to confirm the value or CANCEL to revert to the previous value.

To return to main menu, press the CANCEL button. If the PCS 2 is left unattended the display will return to main menu automatically after 2 minutes. The backlight will be turned off. after 2 minutes without any key pressed. It will be turned back on by pressing any key.

8.4.1 PCS 2 MenusThe PCS 2 menu is divided into nine sections. Some of these sections are further divided into more menu options. Figure 8-2 Menu tree shows the hierarchy tree. The following section contains descriptions of each menu option.

8.4.1.1 Show voltage and currentsThe default PCS 2 screen displays system voltage and battery current. Pressing the down arrow will display system voltage and distribution current, pressing down once more will display system voltage and rectifier current.

8.4.1.2 Show alarmsDisplays the current alarm status. If there are several alarms use the arrow keys to scroll through the alarms. Any new alarms or alarms that disappear will be added or taken off of the menu immediately. Battery failure and symmetry failure alarms need to be reset manually by pressing RETURN at the show alarms display.

8.4.1.3 Show messagesThis item displays any messages. If there are several messages use the arrow keys to view the various messages. New or disappearing messages will be updated immediately on the menu.

8.4.1.4 Show dataThis menu displays information about: modules, units, temperature, and symmetry voltage. Information on each of these menus is in the following section:

Module DataThis menu displays information from each rectifier module. Use the arrow keys to select the module number.

Note! Rectifier modules are numbered from the top to bottom, and left to right.

Once the rectifier is selected on screen, Pressing RETURN will display a new menu with the following information: communication status, module current, mean current, module temperature, module measured voltage, Module OVP limit, alarm information, serial number and module software version number.

Module alarms are indicated by 3 letter flags. The meanings of these are as follows.

MNS - No input mains.

LOW - Input voltage low

OFF - No operation, caused by no mains or other failure

OVS - Overvoltage shutdown

FAN - Fan failure, will cause the module turn off (depending on type of module.)



CUR - Current sharing fault. Current deviates too much from average

TMP - Temperature is high. This alarm must be reset manually

Unit DataThis menu shows information from the individual units. Units are I/O parts of the system like alarm interface cards and distribution cards. The information available is communication status, serial number and unit software version number.

TemperatureThis menu displays the battery temperature.

Symmetry VoltageThe symmetry voltage for each battery branch is displayed.

8.4.1.5 Select / adjust U1 - U4This menu is used to select one of the references for the 4 charge modes, U1 - float voltage, U2 - boost voltage, U3 - battery test voltage, U4 - spare, and to adjust these references.

The voltage references can be adjusted in steps of 0,1V.

U1 Normal. The U1 reference is shown, press RETURN to change U1 (The float charge voltage) and use the arrow keys to adjust to the proper voltage.

U2 Boost. The U2 reference is shown, press RETURN to change U2 (The boost charge voltage).

U3 Test. The U3 reference is shown, press RETURN to change U3 (The Battery test voltage).

U4 Spare. The U4 reference is shown, press RETURN to change U4 (The spare voltage). The U4 setting is normally not used in this system.

8.4.1.6 Adjust limitsThe Adjust Limits menu allows the user to change and add limits to the system. The menu has the following options: alarm limits, boost parameters, battery test, temperature compensation, battery current limit, system specific limits and distribution current limits. Parameters can be set and adjusted by selecting the different sub-menus.

Alarm limits.This menu allows the following alarm limits to be changed:

High voltage

Low voltage

Over voltage shutdown limit

Low voltage disconnect

Partial low voltage disconnect limits

Load reconnect limit

High load limit

CAUTION! Always consult the battery user's guide before attempting to boost. Improper settings can damage batteries.


Revision: B


High temperature limit.

Change these limits using the arrow keys and RETURN to select. See Appendix B, Configuration for default settings.

Boost parameters.This menu contains the limits for boost charging control. See section "Boost charging" for more information.

Battery test.This menu contains the limits for battery test. See section "Battery test" for more information.

Temperature comp.This menu turn the temperature compensation on and off, and is used to set the compensation factor.

System specific limitsOnly available for specific systems. For more information see Appendix B, Configuration

Batt. Cur. Limit.This menu is used to toggle the battery current limiting on and off, and to set the current limit.

Dist. Current limitsThis menu is used to toggle each distribution high current alarm limit on and off, and to set the current limit.

Note! Current limiting is not available on all systems.

8.4.1.7 MiscellaneousThe miscellaneous menu is used to set the date and time, change password, view version information, initialize modem, show symmetry voltages and temperature.

Set timeThe clock is shown. Press RETURN to adjust the clock. The clock has a battery back-up and will keep the time even if the PCS 2 is turned off.

Relay testPress RETURN to check the alarm relays. Use the arrow keys to select the relay to be activated.

Alarm blockingUse Alarm Blocking to disable the relays during service. One alarm relay will normally be active as long as the alarms are blocked.

VersionShow the PCS 2 software version, configuration number and serial number.

Set new passwordChoose "set new password" from the "miscellaneous" menu. Press RETURN, enter the old password and press RETURN. Enter the new password and confirm by pressing RETURN. To avoid mistyping the new password has to be entered once more. Confirm by pressing RETURN.

Note! Be sure to note the new password. If the password is not known or access is denied, contact Power-One technical support for assistance

Shunt ADisplays the current rating of the battery shunt. I.e. this parameter shows the value of current in the current/voltage ratio of the shunt.



Shunt mVDisplays the voltage drop of the battery shunt at rated current. I.e. this parameter shows the value of voltage in the current/voltage ratio of the shunt.

Network addressDisplays the network address for each module. Several PCS 2's may be connected together in a multidrop RS232 network. The modules require a unique address between 2 and 255. This address may be set here.

Baud rateSelect the baud rate for the RS232 serial port of the PCS 2. Either 2400 or 9600.

Init modemPress RETURN to send a string to initiate a modem. See the modem instructions to see if it requires additional initialization to operate.

Accept removed partsRemoving a module or unit will appear to the PCS 2 as a communication error. If the module or unit is intentionally removed then the PCS 2 will need to be informed. Select "YES" in the Accept Removed Parts menu to inform the system that the module was removed.

Note! Do not accept removed parts if the there is an alarm on a module that has not been removed.

Reset to defaultsThis command will reset the system to default values without deleting logged data or system information. It is recommended to try this in stead of Master Reset if a reset is needed. After a reset always check all limits and adjust them to the desired level.

Master resetWill completely reset the PCS 2, deleting all stored data. If possible backup the data to a PC before doing a master reset. After a reset always check all limits and adjust them to the desired level.

LanguageThis menu is used to choose the language used in the PCS 2 menus. Selecting a different language will immediately change the menu language. The language menu is in English by default.

CAUTION! A Master Reset will delete all information from the system. Use the master reset feature only as a last resort.


Revision: B


Figure 8-2 Menu tree

Show voltage/

Batt. current

Show voltage/

Distr. current

Show voltage/

Rect. current

Show alarms

Show messages

Show data

Select/adjust

U1-U4

Adjust limits

Miscellaneous

set time

Relay test

Alarm blocking

Version

Set new password

Shunt current

Shunt voltage

Network address

Baud rate

Init modem

Accept removed

parts

Reset to defaults

Master reset

Alarm limits

Battery test

Boost parameters

Temperature

comp.

Batt. current limit

Low voltage

High voltageBoost time

Symmetry limit

Enable temp.

comp.

Enable current

limit

Batt. current

limit

Comp. factor

Test end

voltage

Test duration

Ah- limit

Time of test

No of tests/year

No of batteries

Battery type

Boost interval

Boost factor

Boost t1

Boost t2

Autoboost

enable

Overvolt.

Shutdown

Load/battery

disconnect

Partial

disconnect

Load/battery

reconnect

High load

Temperature

alarm

U1 normal voltage

U2 boost voltage

U3 test voltage

U4 spare voltage

Reference

Module data

Unit data

Temperature

Symmetry

voltage 1

Symmetry

voltage 2

Symmetry

voltage 3

Symmetry

voltage 5

Symmetry

voltage 6

Symmetry

voltage 7

Symmetry

voltage 8

Symmetry

voltage 9

Symmetry

voltage 10

Symmetry

voltage 11

Symmetry

voltage 4Symmetry

voltage 12

Show messages

Show alarms

Menu language

Syst. specific

limits

Distr. current lim.

Ext.

measurements

Distr. current



8.4.2 Connecting to PC The PCS 2 to PC connection requires a RS232 cable to connect to the PCS 2 and to the PC serial port connection.

CableThe PC to PCS 2 connection is made using a modem, or directly with a null-modem cable (Figure 8-3 PCS 2 to PC cable). P1 and P2 are both 9-pin female D-sub plugs. P1 is to be connected to the PCS 2.

Figure 8-3 PCS 2 to PC cable

1. To connect the PCS 2 to the PC, locate the RS232 interface connector on the front of the PCS 2.

2. Connect one end of the RS232 cable to the interface connection.

3. Route the cable to the rear of the PC (the PC should be powered "Off").

4. Connect the RS232 cable to the #1 serialport on the PC.

5. Power up the PC and start the PowCom software.

6. Choose "Communications" from the PowCom menu, and select "Port Setup" (Figure 8-4).

Pin P1 P2

2 Receive Transmit

3 Transmit Receive

5 0V (Ground) 0V (Ground)

Table 8-1 RS232 Cable Pin Outs

1

5

6

9 1

5

6

9

P1 P2


Revision: B


Figure 8-4 Communications menu

7. Select "9600" baud rate from the Port Setup menu (Figure 8-5).

Figure 8-5 Port Setup Menu

8. Select "OK"

9. Choose "Direct Communication" from the Communications menu.

10. Enter Password (1234 by default).

11. See "Product description PowCom 3.17" for more information about using PowCom software

8.4.3 Boost chargingOpen the "Select/Adjust" menu on the PCS 2.

Boost charging can be activated by three methods:

Manual boost charging - Choose "U2" in the reference menu for activating boost charging. (Return to float charge manually by choosing "U1", or automatically after a pre-set time.)

Periodic boost charging - after a pre-set period boost charge will be automatically activated for a pre-set time. Interval and boost time to be programmed (for example 4 hours every 3rd week).

Automatic boost charging - when during a mains failure the battery voltage falls below LEVEL t1 value, a timer is started. When the mains return, the system will start an automatic boost. This will last a certain time after the battery voltage reach LEVEL t2. This time will be multiplied with a factor, K. LEVEL t1, LEVEL t2 and the factor can all be set.



Figure 8-6 Boost charging

The following values are adjustable for boost charging:

Boost voltage40 - 60 VoltsBoost time0 - 200 hoursBoost interval3 - 16 weeksBoost factor1.0 - 16

Boost t140 - 60 VoltsBoost t240 - 60 VoltsAuto boost enablePassive - Active

Disabling Automatic Boost Charge:Select "Boost parameters" in the "Adjust limits" menu. Push RETURN, up arrow and RETURN / then select disable.

Note! Most manufactures of sealed lead acid batteries do not recommend boost charging. If this type of battery is used, the boost function should be totally disabled by settings as follows: Boost time = 0; U2= U1

8.4.4 Battery testThe following section contains the procedure for testing the batteries in the system.

Battery testing is activated by selecting U3 (in the "Choose reference" menu.)

Once selected the rectifier voltage will decrease to a pre-set value (U3, adjustable). The system will begin logging battery voltage, battery current and Ah.

The battery test will automatically be interrupted and output rectifier voltage will raise to U1 level, if programmed time, Ah or end voltage is reached during the test.

The test is considered as accepted if time or Ah causes the interruption.

If the battery voltage reaches programmed end voltage, the battery is considered as faulty, and an alarm will be indicated and further automatic testing is interrupted.

Battery tests can also be set to activate automatically 1-4 times a year. In the "Choose Reference" menu, select "Select no. of tests". The measurement will automatically be started at mains interruption but will not be saved if duration of mains outage is less than 30 min.

Voltage (V)Level t2

Level t1

U1 (Float Charge)

MainsInterrupt

MainsReturns

t1 t2=K x t1 Time (hour


Revision: B


Parameter Settings.The parameter settings feature allows for the partial discharge of the batteries (approx. 30-40% of the capacity) in order to test the batteries for errors. The settings should be done according the battery manufacturer requirements, however, the following settings can be used for standard VR lead batteries:

U3 = 1,9 V/cellEnd voltage = 1,94V/cellTime = 100% of expected backup timeAh = 40% of nominal battery capacity

Parameters to be set/adjusted from the "battery test" menu or PC with PowCom installed.

Battery test voltage:U3 0- 100 VoltsSymmetry limit: 0.0 - 4.0 VoltsTest end voltage: 0-100 VoltsTest duration: 0- 20 hoursAh limit: 0- 50000 AhTime of test: 0 - 23 (0=midnight)No of test/year: 0 - 4No of batteries: 0 - 12Battery type: 4 blocks, 23 cell-, 23 cell+, 3 blocks or 2 blocks

Number of batteries must be equal to number of symmetry measurements. If symmetry cables are not in use, number of batteries must be set to 0 (zero).

8.4.5 Battery current limitBattery current can be controlled by the PCS 2. The PCS 2 will adjust the rectifier current limit so that the total rectifier current may not exceed "load current + desired battery current". Rapid changes in load current will lead to changes in battery current, due to this variation the current can be above the limit for a limited time.

In the PCS 2 you can set the battery current limit from 5A to 3000A.

There is also a function to enable or disable the function all together.

8.4.6 Temperature compensationThe supervisory module can adjust the charging voltage to compensate for temperatures above or below 20oC. T > 20oC lower charging voltage. T < 20oC higher charging voltage.

The temperature compensation function can be enabled and disabled and the level of compensation is adjustable.

8.4.7 High loadThe "High Load" alarm is activated when the load current exceeds the capacity of the installed modules multiplied by the high load limit. This is an indication that the system requires increased rectifier capacity.




Revision: B

Product Description FMP 16

9 Product Description FMP 16

Product Description FMP 16 9-1Document number: 036972.fmRevision: A


9.1 General - Product description FMP 16The FMP 16 rectifier module is a modular power supply designed for parallel operation and plug-in installation in the PPS 16 systems. The rectifiers provides extremely reliable DC power in the highest possible density. The module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification information to the controller.

There is no cabling at the front of the unit. The AC input, DC output and signal cables are connected using a backplane integral to the cabinet frame. A rectifier module can be plugged into, or unplugged from, the support frame with no impact upon the other modules.

The rectifiers operate on the principle of active load sharing and can operate in parallel. They incorporate "soft start" at the input and at the output, which avoids high incoming and outgoing currents. The output voltage of the rectifier is automatically adjusted to the required voltage at installation by the controller.

The rectifiers in the system are controlled by the controller, see chapter 8, Operation / Product description PCS 2.

9.2 Technical specification

9.2.1 Mains inputInput voltage:100-240V AC +/-15% single phaseInput current:<10A Frequency:44-66 HzPower factor:> 0,98 typical

9.2.2 DC output

9.2.2.1 Mains input 185-250VACVoltage:45V DC - 56 V DC nominalCurrent limit:32APower:1600WEfficiency:>93%, typical 93,5% (at 40-90% load)

9.2.2.2 Mains input 95-185VACVoltage:45V DC - 56 V DC nominalCurrent limit:27APower:675WEfficiency:>88,5%, typical 90% (at 40-90% load)

9.2.3 Module dimensionsHeight:177 mmWidth:51 mmDepth:280 mm

9.2.4 WeightApproximately 2,2 kg


Revision: B


9.2.5 Other technical dataProtection:Short circuit proofAutomatic current limitingSelective shut down of modules at excess output voltageThermal protection reduces the output power at environmental temp. abovemaximum level. Shut down at >app 75oC with an automatic restartInput over-voltage disconnection at >275VAC with automatic reset at <260VAC

Alarms:High output voltage / shut downLow voltage / module failureEach alarm has a common LED indicator on the front panel

Enclosure:IP 20

Storage:-60 to +85°C

Cooling:Fan cooled (front to back), speed controlled and alarmed

9.3 OperationFMP 16 has status indicators that is located on the front panel of the module. The output voltage is adjusted from the controller.

There are three LEDs situated on the rectifier's front panel, which indicate the operating condition of the rectifier.

Figure 9-1 Front view of FMP 16

FMP 16 has LED indicators as follows:

GREENPower ON

YELLOWThermal protection. Communication failure (flashing).

REDModule failure / high output voltage / shutdown.

Product Description FMP 16 9-3Document number: 036972.fmRevision: B


9.4 EnvironmentThe FMP 16 rectifiers meet the Environmental Standard requirements of:ETS 300 019-1-3 class 3.2 / 3M1 for Operating (Stationary In-Use)Temperature Range: -40°C to +65°C (up to 2000m) and -40°C to +55°C (above 2000m)

9.4.1 StorageETS 300 019-2-1 Class 1.2.

9.4.2 TransportETS 300 019-2-2 Class 2.3.

9.4.3 OperationETS 300 019-2-3 Class 3.2.

9.5 SafetyThe FMP 16 rectifiers fulfil those international and national safety standards for these systems according to grounding, fire protection and other safety matters as specified in the following standards:

EN60950 / IEC 60950UL60950CSA C22-2 No. 950

9.6 EMCThe rectifiers' EMC meets the requirements of:

EN61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4 and FCC Part 15 Class B


Revision: B

Product description PPR 16/10 23” Subrack

10 Product description PPR 16/10 23” Subrack

Product description PPR 16/10 23” Subrack 10-1Document number: 037680.fmRevision: A


10.1 General - Product description PPR 16/10 23” SubrackPPR 16/10 is a subrack/rectifier shelf for interconnecting of FMP 16 modules. Each subrack/rectifier shelf has 10 module positions. Module positions are numbered from left to right viewed from the front.

Each subrack/rectifier shelf may be equipped according to present power requirements, and later be completed with additional FMP 16 modules.

For high power requirements several subracks may be paralleled.

Figure 10-1 Front view of subrack / rectifier shelf


Revision: B


10.2 Connections and functions

10.2.1 External connectionsDescription FunctionPL4, PL6 RS 485 interfacePL3, PL5 Current share with other PPR 16/10PL12, PL11, PL14, PL13, PL16,PL15, PL18, PL17, PL20, PL19 Input mains Bus bar connections DC output

10.2.2 Internal functionsDescriptionFunctionDip switchesDip switches S12, S11, S14, S13, S16, S15, S18, S17, S20 and S19 are used for addressing module positions and has to be set for controller supervision to functionproperly. The switches can each address six bit binary addresses, which meansup to 64 modules on one COM channel (total 128 modules if both COM channelsare used). Addressing is performed by setting each of the six bits on each switch ineither an ON or OFF position. See Table 10-1 Addressing module positions.

Figure 10-2 Front and back view of the subrack

PL14PL11 PL16 PL15 PL18 PL17 PL20PL13

PL3 PL5(Curr)

PENL

Negative (DC output)

Input mains

PL12 PL19

PL4PL6(Com)

Positive (DC output)

Dip switch (S12 for module pos 1)

Product description PPR 16/10 23” Subrack 10-3Document number: 037680.fmRevision: B


10.3 Connections between subracks

Figure 10-3 Example shows three subracks connected together

Use cable marked with Brown 1 between PL6 in subrack 1 to PL4 in subrack 2.

Use cable marked with Orange 3 between PL5 in subrack 1 to PL3 in subrack 2.

Use cable marked with Brown 1 between PL6 in subrack 2 to PL4 in subrack 3.

Use cable marked with Orange 3 between PL5 in subrack 2 to PL3 in subrack 3.

Note! If the system consist of more subracks connect after the same method between subracks as described over.

PL3 PL5PL4 PL6

Subrack 2Subrack 1 Subrack 3

PL3 PL5PL4 PL6 PL3 PL5PL4 PL6

Communication signal

from alarm interface unit

Curr. share signal between subracks

Com.signal between subracks


Revision: B


10.4 Addressing module positions in subrack1, subrack2 etc.Subrack no = Number of subrackModule position= Numbered from bottom left positionConnection= Dip switch 1-6Dip Switch = Indicates which dip switch to be turned ON.

Subrack no. Module position Connection Dip switch ON

1 1 1-6 All off1 2 1-6 11 3 1-6 21 4 1-6 1+21 5 1-6 31 6 1-6 1+31 7 1-6 2+31 8 1-6 1+2+31 9 1-6 41 10 1-6 1+42 11 1-6 2+42 12 1-6 1+2+42 13 1-6 3+42 14 1-6 1+3+42 15 1-6 2+3+42 16 1-6 1+2+3+42 17 1-6 52 18 1-6 1+52 19 1-6 2+52 20 1-6 1+2+53 21 1-6 3+53 22 1-6 1+3+53 23 1-6 2+3+53 24 1-6 1+2+3+53 25 1-6 4+53 26 1-6 1+4+53 27 1-6 2+4+53 28 1-6 1+2+4+53 29 1-6 3+4+53 30 1-6 1+3+4+54 31 1-6 2+3+4+54 32 1-6 1+2+3+4+54 33 1-6 64 34 1-6 1+64 35 1-6 2+64 36 1-6 1+2+64 37 1-6 3+64 38 1-6 1+3+64 39 1-6 2+3+64 40 1-6 1+2+3+65 41 1-6 4+65 42 1-6 1+4+65 43 1-6 2+4+65 44 1-6 1+2+4+65 45 1-6 3+4+65 46 1-6 1+3+4+65 47 1-6 2+3+4+65 48 1-6 1+2+3+4+65 49 1-6 5+65 50 1-6 1+5+6

Table 10-1 Addressing module positions

Product description PPR 16/10 23” Subrack 10-5Document number: 037680.fmRevision: B


6 51 1-6 2+5+66 52 1-6 1+2+5+66 53 1-6 3+5+66 54 1-6 1+3+5+66 55 1-6 2+3+5+66 56 1-6 1+2+3+5+66 57 1-6 4+5+66 58 1-6 1+4+5+66 59 1-6 2+4+5+66 60 1-6 1+2+4+5+67 61 1-6 3+4+5+67 62 1-6 1+3+4+5+67 63 1-6 2+3+4+5+67 64 1-6 1+2+3+4+5+6

Table 10-1 Addressing module positions


Revision: B

Product description PBDU 4U/23”

11 Product description PBDU 4U/23”

Product description PBDU 4U/23” 11-1Document number: 038222.fmRevision: A


11.1 General - Product description PBDU 4U/23”

Figure 11-1 PBDU 4U/23”

The Power-One PBDU 4U/23” includes a complete system controller plus battery and load distribution in a 4U unit. The Compact Distribution is compatible with various types of Power-One subracks/rectifier shelves, and may be configured for a variety of battery and load breaker selections.

The distribution unit is designed for switching the battery and load on and off. All DC distribution breakers are supervised by measuring voltage drop across each breaker. MCB's (breakers), which are not connected to any load, will not cause breaker alarm even if they are left open.

Due to small leakage current (2,5 - 3 mA) through the alarm circuit the voltage measured with a DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage. If a battery breaker fault occurs or is simulated it might take from 2 - 10 minutes before the fault is indicated, depending on the battery condition.

11.2 Technical specificationsVoltage:48V DC nominalLoad breaker capacity: Max 20-26 x 18mm MG-breakers C-60N, low-ohmic connectionsBattery breaker capacity: Max 2-6 x 27mm 1-pole MG-breakersDimensions:23”/4U


Revision: B


11.3 Construction and functionsThe distribution module has common "+" and all the MCB's connected in the "-" branch.

Figure 11-2 Typical distribution (Front view, controller unit removed)

Figure 11-3 Distribution (Top view)

11.4 Cable cross section output connectionsLoad connections:Cable area max. 16 mm2 / 35 mm2

0V Battery/Load

- Battery/Load

- Battery/loadConnections

+ Battery/LoadConnections

Protective Earth

Product description PBDU 4U/23” 11-3Document number: 038222.fmRevision: B


11.5 InstallationThis section details how to connect the -48 V DC supply to the DC load.

Check that all the MCB breakers and the AC mains supply are in the OFF position.

Unscrew the cabinet's four top fixing screws and slide top-cover forward before lifting it up. Enter each load cable in to the cabinet trough the inlet at the back of the cabinet.

Connect the negative (-) load DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw. Make sure the cable is the correct rating (i.e. thick enough) for the selected MCB.

Connect the positive (+) load DC supply cable directly to the positive busbar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the busbar, and then tightening the screw. Start connecting the loads to the busbar from the first connector on the left. Make sure, the cable is the correct rating (i.e. thick enough) for the load.

Check, that all the cables are secured tightly to the connectors. Use Torque Table in the Maintenance and troubleshooting chapter for the correct torque.

11.6 Commissioning PBDU1. Switch on all MCB's in the distribution units.

2. Turn off one of the breakers and verify breaker alarm at controller.

3. Verify disappearing of alarm when turning the breaker on again.

4. Repeat the two above-mentioned steps for one MCB in each distribution module.

11.7 MaintenanceThe distribution does not need any special maintenance except for ordinary cleaning.


Revision: B

Product description PCS Alarm interface unit BM0685

12 Product description PCS Alarm interface unit BM0685

Product description PCS Alarm interface unit BM0685 12-1Document number: 037901.fmRevision: A


12.1 General PCS alarm interface unit consist of BM0685, which is an alarm board for Power One systems. The unit is located on the right hand side of the distribution and is accessed from the top of the cabinet.

12.2 Technical dataConnection:Plugable terminal blocks max. 1,5mm2

2x input for battery current reading (common + or -). (J20, J21)

Breaker monitoring, battery and load. (J20, J21)

Control signal for individual operating LVD and PLD. (J20, J21)

6 x potential free change over contacts. (J6, J7, J8, J9)

4 x input for symmetry measurement. (J1, J2). Optionally symmetry input 4 may be used as 3 x analogue inputs. (J2 pin 4-6).

4 x battery temp sensor. (J4, J5)

2 x digital inputs. (J3)

2 x digital output (J10)

RS485 interface for communication with plant controller PCS. (J24 and J25)

Up to four units per system.

12.2.1 Pin Configuration of J20 and J21Plug J21 Pin A B

1 RECONN1 RECONN12 DISCONN1 DISCONN13 DF/BFM1 DISTFUSE14 BATTFUSE1 BATTFUSE25 SHUNT1+ SHUNT2+6 SHUNT1- SHUNT2-

Plug J20 Pin A B1 RECONN1 RECONN12 DISCONN2 DISCONN23 DF/BFM2 DISTFUSE14 BATTFUSE3 BATTFUSE45 SHUNT1+ SHUNT2+6 SHUNT1- SHUNT2-


Revision: B


12.3 Remote alarms, symmetry measurement and temperature sensorAlarms:Six dry alarm contacts for remote signalling (J6, J7, J8, J9).Symmetry:Four separate inputs, each supervising battery branch symmetry voltage (J1, J2).Temperature:Four connection points for connection of Power- One temperature sensor (J4, J5).

Figure 12-1 BM0685 alarm board

12.4 MaintenanceThe PCS alarm interface unit does not need any special maintenance.

3

6

2

5

1

4 Batt. sym. 4/

ext. analog

+ Red

T Green

- Blue

T

3

2

1

Temp. Probe 1

J2

3

6

2

5

1

4J1

+ Red

T Green

- Blue

6

5

4

Temp. Probe 2

+ Red

T Green

- Blue

3

2

1

Temp. Probe 3

+ Red

T Green

- Blue

6

5

4

Temp. Probe 4

J4

J5

J6

J7

J8

J9321

6

5

4

3

21

6

5

4

3

21

3

2

1

2

1Digital input

(Door alarm)

DI.1

DI.0

Alarm 6

Alarm 5

Alarm 4

Alarm 3

Alarm 2

Alarm 1

Alarm contacts

are shown in

alarm position

J10

4

3

2Digital output

1DO.0DO.1

+12V0V

Batt. sym.

J3

J1

J2

J3

J4

J5

J7

J6

J8

J9

J1

0

32

1

65

4

32

1

65

4

32

1

65

4

32

1

65

4

32

1

65

4

32

1

65

4

32

13

21

21

32

14

Product description PCS Alarm interface unit BM0685 12-3Document number: 037901.fmRevision: B



Revision: B

Maintenance and Troubleshooting

13 Maintenance and Troubleshooting

Maintenance and Troubleshooting 13-1Document number: 037043.fmRevision: A


13.1 Installing new modulesInstall new modules according to following steps:

1.Plug in module

2.Ignore the module alarm caused current sharing

3.Wait. After 1 minute the yellow LED will start blinking. Wait for max. 4 min

4.Verify that yellow LED stops blinking

5.The alarm should now disappear

6.Tighten front screw

13.2 TroubleshootingThis guide is a step-by-step recommendation of what to do if problems occur. If first step of recommendation do not solve the problem continue to the next one. If the problem cannot be solved please call your local Power - One office for assistance.

Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be connected to the RS232 contact (Only applies when a controller without LCD display is in use).

Low system voltage:

Check the batteries with a voltmeter.

Check "low volt alarm" limit in controller / PowCom.

Check that the system is not in battery "test mode".

Check modules, mains and load situation compared to rectifier capacity.

High system voltage:

Check the batteries with a voltmeter.

Check "High volt alarm" limit in controller / PowCom.

Check that the system is not in "boost/Charge mode".

Load/battery disconnected:

Verify that input mains is present

Check system DC voltage with voltmeter

Compare system DC voltage with disconnected thresholds in controller / Powcom.

If breaker blows once more, there is either a too high load or short circuit at the system

Mains error:

Check mains breakers.

Check mains voltage.

Distribution breaker failure:

Localise the blown breaker.


Revision: B


Check the equipment that is connected to the blown breaker (there may be a reason for this breaker to blow) and reconnect it.

Battery failure:

Check the batteries.

Check the "battery test" parameters in controller / Powcom.

Module failure:

Localise the module.

Pull it out.

Wait for 30 sec. and reinstall it according to 13.1 Installing new modules.

Battery temp alarm:


Check ventilation.

Check reading in controller / Powcom.

Symmetry fault:

Reset the alarm.

Check connections according to number of batteries in controller / Powcom.

Check batteries.

Battery breaker failure:

Localise the breaker.


Reconnect the breaker.

High load:

Check load situation according to capacity of the system.

Increase number of modules.

Urgent module failure:

See "Module failure".

Communication failure:

Check if there is a module in current position.

See "module failure".

Temp probe failure:

Check connection on temp probe.

Replace temp probe.

Alarms are blocked (only with LCD display):

Check " miscellaneous" menu in controller.

Maintenance and Troubleshooting 13-3Document number: 037043.fmRevision: B


13.3 MaintenanceThe connections on the terminal blocks and circuit breakers must be checked according to the 13.4 Torque table minimum once a year.

Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed to see any deviations.

In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air inlets and outlets free from dust or other materials, which may prevent free air circulation through the cubical.

13.4 Torque table

TYPE: MODEL / DESCRIPTION:TORQUE (Nm):

TORQUE (Inch LB):

Terminal block for rail AKG 16mm2 2,5 Nm 22

Terminal block for rail AKG 35mm2 3,5 Nm 31

Terminal block Weidemullers WDU 4mm 0,6 Nm 5



Miniature circuit breaker Siemens 2,5 Nm 22

Miniature circuit breaker Merlin G 3,5 Nm 31

Miniature circuit breaker ABB 2,0 Nm 18

Miniature circuit breaker CBI HY-MAG 3,0 Nm 27

Moulded case circuit breaker ABB 160A - S2 5,0 Nm 45

Moulded case circuit breaker ABB 160A/250A - S3/S4 9,0 Nm 80

Moulded case circuit breaker ABB 630A - S6 9,0 Nm 80

Moulded case circuit breaker Terasaki - XS125CJ 9,0 Nm 80

Table 13-1 Torque


Revision: B

Drawings

17.02.05 ØSK

039095

Page 01 of 01Cabinet layout

PODS 16.48-16000 1940 HEX/

Cabinet size: 800x850x1940mm (WxDxH)

Date: Designer: Scale:

ref: Rev:

Appendix A: Drawings

Drawings A-1Document number: Appendix A.fmRevision: B

Drawings

17.02.05 ØSK

039095

Page 01 of 01Cabinet layout

PODS 16.48-16000 1940 HEX/

Cabinet size: 800x850x1940mm (WxDxH)


ref: Rev:

A.1 Cabinet Layout - 039095 - Rev: /

A-2 PODS 16.48-16000 1940 HEXDocument number: Appendix A.fm

Revision: B

Drawings

17.02.05 ØSK

039096

Page 01 of 01Installation drawingPODS 16.48-16000 1940 HEX

/

i

IOIO

I

1

2

3

4

multi 9

C120ND100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

1

2

3

4

multi 9

C120ND100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

1

2

3

4

multi 9

C120ND100

MERLIN GERIN

415V

10000

I ONI ON I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

multi 9

C60NC16230/400V6000

3

MERLIN GERIN

I ONI ON

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

power-onepower-one

FMP1648

PE

3 phase 400V AC

PE

PE

N

L1

L1

L2

L3

N

N

N

N

N

L2

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

PE

3x1 phase 230V AC

PE

PE

N1

L1

L1

L2

L3

N1

N2

N2

N3

N3

L2

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

PE

1x3 phase 230V AC

PE

PE

L1

L2

L2

L3

L3

L1

L1

L1

L2

L2

L3

L3

1

2

5

5

6

7

2

3

3

4

4

6

7

1

1

Input mains terminals.

Terminal blocks located in front on the right hand side

BM0685Connection of alarms and signals in the right hand side of the distribution

Table below shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet)Note: Check that symmetry and temp cables are correctly mounted

3

6

2

5

1

4

+ Red

T Green

- Blue

T

3

2

1

Temp. Probe 1

J2

3

6

2

5

1

4J1

+ Red

T Green

- Blue

6

5

4

Temp. Probe 2

+ Red

T Green

- Blue

3

2

1

Temp. Probe 3

+ Red

T Green

- Blue

6

5

4

Temp. Probe 4

J4

J5

J6

J7

J8

J9321

6

5

4

3

21

6

5

4

3

21

3

2

1

2

1Digital input

DI.1

DI.0

Alarm 6

Alarm 5

Alarm 4

Alarm 3

Alarm 2

Alarm 1

Alarm contacts

are shown in

alarm position

J10

4

3

2Digital output

1DO.0DO.1

+12V0V

-48V

0V

Batt. sym. 3

Batt. sym. 4

/ext. analog

Batt. sym. 1

Batt. sym. 2

(-)24V

-36V

-24V

-12V

3

6

2

5

1

4J2

3

6

2

5

1

4J1

Batt. sym. 3

Batt. sym. 4

/ext. analog

Batt. sym. 1

Batt. sym. 2

-48V

0V

-36V

-24V

-12V

(-)12V

(-)24V

(-)36V

(-)12V

(-)24V

(-)36V

(-)12V

(-)24V

(-)36V

(-)12V

(-)24V

(-)36V

3

6

2

5

1

4J2

3

6

2

5

1

4J1

Batt. sym. 3

Batt. sym. 4

/ext. analog

Batt. sym. 1

Batt. sym. 2

-48V

0V

-32V

-16V(-)16V

(-)32V

(-)16V

(-)32V

(-)16V

(-)32V

(-)16V

(-)32V

3

6

2

5

1

4J2

3

6

2

5

1

4J1

Batt. sym. 3

Batt. sym. 4

Batt. sym. 1

Batt. sym. 2

-48V

0V

-24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

(-)24V

Batt. sym. 7

Batt. sym. 8

Batt. sym. 5

Batt. sym. 6

Batt. sym. 11/ext. AnalogBatt. sym. 12/ext. Analog

Batt. sym. 9

Batt. sym. 10/ext. Analog

*Battery type: 2 blocks, ext sym Battery type: 3 blocks Battery type: 4 blocks*Battery type: 2 blocks

(-)24V

(-)24V

(-)24V

* Extended symmetry:Check “extended symmetry” flag in config wizard - page 1


ref: Rev:

A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: /


Drawings

07.03.05

Date: Designer:

KMH

Page 1 of 1

Scale:

039097

ref: Rev:

/

Block diagram PODS 16.48-16000

1940 HEX

Fuse a

larm

bo

ard

-- Battery 1

- Battery n

0V

- Load 1

- Load n

PCS

control unit

Distribution

Subrack

LVD

Subrack for

10xFMP 16

+

-

8

BM0666

PL5 Current share

8

PL4 COM

PL3 Current share

8

PL6 COM

8

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

L

PE

N

J25 Com.

+12V

0V

Sense

Batt. sym

8

8

J24 Com.

BM0685 Batt. Sym./

Ext. analog

1 +12V

2 0V

3 -12V

J 22 Electronic

power

1 0V

2 System voltage

6

5

4

3

2

1

6

5

4

3

2

1

J 2

J 1

2

1Digital inputJ 3

6

5

4

J 5 +12V

0V

Sense

3

2

1

Temp. 4

Temp. 3

+12V

0V

Sense

6

5

4

J 4 +12V

0V

Sense

3

2

1

Temp. 2

Temp. 1

6

5

4Alarm 6

3

2

1Alarm 5

J 9

6

5

4Alarm 4

3

2

1Alarm 3

J 8

3

2

1Alarm 2

3

2

1Alarm 1

J 7

J 6

4

3

2

1

J 10 Digital out

J 23

J21A Sh1 Dis16

6

J21B Sh2 Dis1

6

6J20A Sh1 Dis2

J20B Sh2 Dis2

0V

+12V

DO.0

DO.1

DI.1

DI.0

RS 232

ETHERNET

MODEM/PC

BM06869

J7 Com PCS

J4 Com PCS modem

8

8J1 Com 1

J9 Ethernet8

1

2 J2 Power

1

2J8 Internal power

3

+-

+12VSys. voltage

-12V

Optional plugable

PNI board 8

9

Display board

PB2002B-P9

See schematic

diagram for

more details

Heat exchanger

(HEX)

Out

In

Cabinet

Door switch

NC

NOCom.

White

Blue

Yellow

Red

PT

C 2

BM0708

1 0V

2 Sense

3 +12V

Temp 1 J4

1 0V

2 Sense

3 +12V

Temp 2 J5

1 Pulse

2 Pulse

3 +

4 AN Out 1

Fan 1 J2

Fan 2 J3

1 Pulse

2 Pulse

3 +

4 AN Out 0

White

Blue

Yellow

Red

PT

C 1

Batt. sym

A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: /


Revision: B

Drawings

07.03.05

Date: Designer:

KMH

Page 1 of 1

Scale:

Powec ref:

039098

ref: Rev:

/

Schematic diagram PBDU POD 16.48-

16000 1940 HEX

0V Load

0V Battery

- Load 1

- Battery n

- Load n

- Battery 1

+-

LVD

Black Red

Connect according

to Block diagram

B1-1

B2-1

B3-1

B4-1

B5-1

B6-1

F1-1

F2-1

Fn-1

6

6J1

J3

J2

J4

BM0700

MH1

MH7

1

2

3

4

1

2

Fn-1

J25 Com.

+12V

0V

Sense

Batt. sym

Batt. sym

8

8

J24 Com.

BM0685 Batt. Sym/

Ext. analog

1 +12V

2 0V

3 -12V

J 22 Electronic

power

1 0V

2 System voltage

6

5

4

3

2

1

6

5

4

3

2

1

J 2

J 1

2

1Digital inputJ 3

6

5

4

J 5 +12V

0V

Sense

3

2

1

Temp. 4

Temp. 3

+12V

0V

Sense

6

5

4

J 4 +12V

0V

Sense

3

2

1

Temp. 2

Temp. 1

6

5

4Alarm 6

3

2

1Alarm 5

J 9

6

5

4Alarm 4

3

2

1Alarm 3

J 8

3

2

1Alarm 2

3

2

1Alarm 1

J 7

J 6

4

3

2

1

J 10 Digital out

J 23

J21A Sh1 Dis16

6

J21B Sh2 Dis1

6

6J20A Sh1 Dis2

J20B Sh2 Dis2

0V

+12V

DO.0

DO.1

DI.1

DI.0

BM0708

1 0V

2 Sense

3 +12V

Temp 1 J4

1 0V

2 Sense

3 +12V

Temp 2 J5

1 Pulse

2 Pulse

3 +

4 AN Out 1

Fan 1 J2

Fan 2 J3

1 Pulse

2 Pulse

3 +

4 AN Out 0

A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 - Rev: /


Drawings

18

.02.0

5

Da

te:

De

sig

ne

r:

ØS

K

Pag

e 1

of

1

Sca

le:

Pow

ec r

ef:

039109

re

f:R

ev: /

Sch

em

atic d

iag

ram

PP

R 1

6.4

8/1

0

3 p

ha

se

40

0V

AC

Main

Subra

ck P

PR

16 4

8/1

0

CO

M

PL

4

BM

06

66

CO

M

PL

6

CU

RR

PL

3

CU

RR

PL

5

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

88

88

123567 4

Ma

ins inp

ut

term

ina

l b

locks

1 1234567

Optional O

ver

Voltage P

rote

ction

Optional A

C o

utlet

PENL

LN

LN

Optional B

attery

heate

r

0T

A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: /


Revision: B

Drawings

18

.02.0

5

Da

te:

De

sig

ne

r:

ØS

K

Pag

e 1

of

1

Sca

le:

Pow

ec r

ef:

039110

re

f:R

ev: /

Sch

em

atic d

iag

ram

PP

R 1

6.4

8/1

0

1x3

ph

ase

23

0V

AC

Main

Subra

ck P

PR

16 4

8/1

0

CO

M

PL

4

BM

06

66

CO

M

PL6

CU

RR

PL

3

CU

RR

PL

5

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

88

88

123567 4

Ma

ins inp

ut

term

ina

l b

locks

1 1234567

Optional O

ver

Voltage P

rote

ction

Optional A

C o

utlet

PENL

LN

LN

Optional B

attery

heate

r

0T

A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 - Rev: /


Drawings

18

.02.0

5

Da

te:

De

sig

ne

r:

ØS

K

Pag

e 1

of

1

Sca

le:

Pow

ec r

ef:

039111

re

f:R

ev: /

Sch

em

atic d

iag

ram

PP

R 1

6.4

8/1

0

3x1

ph

ase

23

0V

AC

Ma

in S

ub

rack P

PR

16

48

/10

CO

M

PL4

BM

06

66

CO

M

PL

6

CU

RR

PL3

CU

RR

PL5

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

L N PE

88

88

123567 4

Ma

ins in

pu

t

term

ina

l b

locks

1 1234567

Optional O

ver

Voltage P

rote

ction

Optional A

C o

utlet

PENL

LN

LN

Op

tio

na

l B

att

ery

he

ate

r

0T

A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 - Rev: /


Revision: B

Drawings

A.8 Footprint Outdoor Cabinet - 039423 - Rev:/


Drawings


Revision: B

Configuration c-000313

Appendix B: Configuration c-000313

Configuration c-000313 B-1Document number: 039418.fmRevision: A


B-2 PODS 16.48-16000 1940 HEXDocument number: 039418.fm

Revision: B


Configuration c-000313 B-3Document number: 039418.fmRevision: B


B-4 PODS 16.48-16000 1940 HEXDocument number: 039418.fm

Revision: B

Distribution

Appendix C: Distribution C.1 Distribution PBDU 23" 1xMCB/10xMCB

Breaker 6A 10A 16A 25A 32A 100A 150A Char. PLD Type of equipmentFB1 X D Battery 1FB2FB3FB4F1 X CF2 X CF3 X CF4 X CF5 X CF6 X CF7 X CF8 X CF9 X CF10 X CF11F12F13F14F15F16F17

Distribution C-1Document number: 039099.fmRevision: A

Distribution

0V, LOAD

F1

-LOAD

0V, BATTERY

FB1

- Batt. 1

0V

F10

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

Pow

er-o

ne

0V

+Connectionto chassis

Pow

er-o

neP

ower

-one

Pow

er-o

neP

ower

-one

Pow

er-o

neP

ower

-one

C-2 PODS 16.48-16000 1940 HEXDocument number: 039099.fm

Revision: B

BTS Breaker 50A 3-pole - Installation procedure

Appendix D: BTS Breaker 50A 3-pole - Installation procedure

BTS Breaker 50A 3-pole - Installation procedure D-1Document number: 038316.fmRevision: A




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


D-2 PODS 16.48-16000 1940 HEXDocument number: 038316.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9

BTS Breaker 50A 3-pole - Installation procedure D-3Document number: 038316.fmRevision: B


Amendment record:Revision(Issue)


/ First issue Ørjan Skauge 06.10.04A New revision Hans A Dokka 12.05.05B New revision Kai Morten Hennum 13.05.05C New revision Hans A Dokka 18.05.05

Originated Hans A Dokka Date 18.05.05 Approved Bjørn K Lindberg Date 19.05.05Signed Signed


Revision: B


D.1 Scope and purposeThe purpose of this document is to give a clear instruction in the mounting of the 50A 3-pole load breaker (upgrade kit) in the PPS 16.48-16000.

This breaker can be mounted with 50A, 100A or 150A load capacity.

WARNING! THE READER MUST READ AND UNDERSTAND THE WARNINGS AND CAUTIONS IN THIS MANUAL BEFORE STARTING.

Note! Use insulated tools with torque control.

Bits needed: Flat 0,8x4x150, 13mm metric socket and PZ2.

Figure D-1 Insulated tools.

D.2 Safety precautions

WARNING! MAKE SURE THAT THE POWER TO THE SYSTEM IS DISCONNECTED BEFORE STARTING THE INSTALLATION.

WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.




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

D.3 AC Power source requirements

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

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


WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE INSTALLATION.


Revision: B


D.4 Overview upgrade kit

Figure D-2 Overview

1. MCB 3 pole C 50 C60N

2. Connector 3 x MCB (150A) for front terminal

3. Connector 2 x MCB (100A) for front terminal

4. Connector 2xAKG for front terminal

5. Front terminal for copper cables - FC Cu T2 95mm2 (2 pieces)

6. Signal cable harness Plugable fuse alarm CD

2

13

5

4

6



D.5 Mounting

Figure D-3 Mounted 50A 3-pole breaker with 150A capacity

1. Mount the kit according to Figure D-3

1.For 50A load breaker capacity mount the "end case" side of the signal cable harness on the middle position on top of the breaker. Mount the negative load cable to the same slot on the breaker.

2.For 100A load breaker capacity mount the Connector 2xMCB (100A) for front terminal on top of the breaker. Mount the "end case" side of the signal cable harness on the left most position on top of the breaker. Mount the negative load cable to the front terminal for copper cables.

3.For 150A load breaker capacity mount the Connector 3xMCB (150A) for front terminal on top of the breaker. Mount the "end case" side of the signal cable harness on the left most position on top of the breaker. Mount the negative load cable to the front terminal for copper cables.

2. Tighten the upper screws on the breaker to a torque of 3,5 Nm.


Revision: B


D.6 Installation

Figure D-4 Remove dummy breakers

1. Remove 3 dummy breakers by releasing the catch on top of the dummy breaker using a screw driver.

Figure D-5 Dummy breaker removed



2. Dummy breakers removed.

Figure D-6 Install new breaker

3. Unscrew the three lower screws to end positions.

4. Install the new load breaker in the open breaker slots. Tighten the lower screws in the breaker to a torque of 3,5 Nm.


Revision: B


Figure D-7 Signal cable harness

5. Mount the alarm cable harness to the fuse alarm board as shown in Figure D-7.

Figure D-8 Front terminal for copper cables

6. Mount the front terminal for copper cables to the common rail as shown in above figure.

7. Tighten the front terminal for copper cables to the AKG with a torque of 3,5 Nm.

8. Cables mounted to the front terminal for copper cables to be mounted with a torque of 7 Nm.

The installation procedure is now complete.




Revision: B

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1)- Installation procedure

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure E-1Document number: 039247.fmRevision: A






E-2 PODS 16.48-16000 1940 HEXDocument number: 039247.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure E-3Document number: 039247.fmRevision: B




/ First issue Kai Morten Hennum 21.03.05A New Revision Kai Morten Hennum 13.03.05


Date 21.03.05 Approved Tony Starr Date 13.05.05

Signed Signed


Revision: B


E.1 Scope and purposeThe purpose of this document is to give clear instructions on the connection of the Surge arrestor kit for the PODS 16.48-16000 1940 HEX.

To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure closely.

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.

WARNING! USE INSULATED TOOLS.

Figure E-1 Insulated tools.

E.2 Safety precautions


WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME CAUTION AND RESPECT





E.3 AC Power source requirements


E.4 Overview Surge arrestor kitThe surge arrestor kit protects the system against lightning and transient over voltage. Each surge arrestor kit consists of a holder containing three over voltage protector units, one spark gap and a cable harness.





Revision: B


E.5 Installation and connection1. Turn off the mains input voltage.

2. Remove the end-stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the Surge arrestor kit for mains input 1 by snapping the surge arrestor holder on the DIN rail next to the mains input terminal blocks on the left hand side. Mount the end stop below the Surge arrestor kit in order to prevent the Surge arrestor kit from sliding on the DIN rail.

Figure E-2 Surge arrestor kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in Appendix A: Drawings.

Note! Do not use Figure 2 as connection reference. It is important to always connect according to Appendix A: Drawings schematics.

5. Check the connections with a Digital Multi Meter.

6. After checking the Surge arrestor kit connections, the mains input can be reconnected.

7. Each Surge arrestor module has a display on the front that indicates if it is OK or has blown. Red displayed surge arrestors are blown and has to be replaced.



Installation procedure is now complete.


Revision: B

Battery Extension Kit - Installation Procedure

Appendix F: Battery Extension Kit - Installation Procedure

Battery Extension Kit - Installation Procedure F-1Document number: 039249.fmRevision: A






F-2 PODS 16.48-16000 1940 HEXDocument number: 039249.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Battery Extension Kit - Installation Procedure F-3Document number: 039249.fmRevision: B




/ First issue Kai Morten Hennum 21.03.05A Second issue Kai Morten Hennum 13.05.05



Signed Signed


Revision: B


F.1 Scope and purposeThe purpose of this document is to give a clear instruction in the connection of the battery extension kit for PODS 16.48-16000 1940 HEX.

To ensure the continues supply of the loads from batteries, it is of vital importance to follow this procedure closely.



Figure F-1 Insulated tools.




F.2 Safety precautions


F.3 AC Power source requirements








Revision: B


F.4 Overview Battery Extension KitThe Battery Extension Kit allows you to install additional battery strings. Each Battery extension kit consists of

1. Battery shelf ODU.

2. Battery cable 35mm2/M8/250cm STD.

3. Magnetic C.B. 1 pole D100 C120N.

4. Symmetry cable 260xm middle point measurement

5. Antistatic bag, signal cable harness, plugable fuse alarm and 4xscrew M6.0 x 12 Taptite pan elzn TT3.



F.5 Installation and Connection

F.5.1 Installing the Battery Shelf

WARNING! THE TWO FRONT PLATES ARE MOUNTED FOR CABINET STABILITY. IF THESE HAVE TO BE REMOVED DURING INSTALLATION, DO NOT REMOVE BOTH PLATES AT THE SAME TIME.

Note! Front plate removal is only necessary when installing battery extension kit 4. However, removal of the lower plate is recommended for easy access when installing batteries in the lower shelf.

Mount the battery shelf by sliding it into the punch outs on the back walls. The spacing between two battery shelves should be 8U. This is measured from the mounting hole of the lower shelf to the mounting hole on the shelf above. The shelves in Figure F-2 are shown transparent so that the mounting holes are visible.

Figure F-2 Additional Battery shelves

1

2

3

4

5

6

7

8

1


Revision: B


Fasten the battery shelf using the supplied screws in mounting holes on the battery shelf. Torque 3,5 Nm.



F.5.2 Installing the battery breaker1. Remove two dummy breakers by releasing the catch on top of the dummy breaker by using a screw

driver.

Figure F-3 Remove dummy breakers


Revision: B


Figure F-4 Dummy breakers removed

Figure F-5 Replace the dummy breakers with supplied battery breaker



2. Mount the signal cable harness by sliding the cable lug onto the fuse alarm board in the position for battery breakers. Battery breaker positions are labelled with a “B” on the print board.

Figure F-6 Signal cable harness mounted


Revision: B


F.5.3 Installing the battery cables1. Mount the positive battery cable on the positive copper connection bar. Torque 13,5Nm.

Figure F-7 Positive battery cable mounted

2. Mount the negative battery cable directly on top of the new battery breaker.

3. Make sure the signal cable harness is mounted to the battery breaker together with the battery cable. Torque 3,5Nm.



Figure F-8 Negative battery cable mounted

4. Strip the battery cables to the sheet metal bracket as shown in Figure F-9. Strip the rest of the battery cables using the original battery cables as reference.

Figure F-9

5. Mount the supplied symmetry cable to the Alarm interface board located in the upper right corner of the cabinet. Torque 0,6Nm.See Installation drawing in Appendix A for reference.

6. Strip the new symmetry cable using the original symmetry cable as reference.


Revision: B


Figure F-10


The installation procedure is now complete.




Revision: B

FMP 16 Dummy Module - Installation procedure

Appendix G: FMP 16 Dummy Module - Installation procedure

FMP 16 Dummy Module - Installation procedure G-1Document number: 038471.fmRevision: A






G-2 PODS 16.48-16000 1940 HEXDocument number: 038471.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

FMP 16 Dummy Module - Installation procedure G-3Document number: 038471.fmRevision: B




/ First issue Ørjan Skauge 05.11.04

Originated Ørjan Skauge Date 11.11.04 Approved Erlend Breivik Date 11.11.04Signed Signed


Revision: B


G.1 Scope and purposeThe purpose of this document is to give a clear instruction in the mounting of the FMP 16 dummy module in the PPS 16.48 system.

Note! Use insulated tools with torque control.

Bits needed: Philips 2.

G.2 Safety precautions


G.3 AC Power source requirements









G.4 Overview dummy module

Figure G-1 Overview

1. Dummy module FMP 16

1


Revision: B


G.5 Mounting

Figure G-2 Mounting of dummy module

Remove all packaging supplied with the dummy module FMP 16

1. Fix the dummy module FMP 16 with the screw in bottom left corner. See Figure G-2

2. Installation procedure is now complete.




Revision: B

19” Adaptor Kit Installation Guide

Appendix H: 19” Adaptor Kit Installation Guide

19” Adaptor Kit Installation Guide H-1Document number: 039273.fmRevision: A






H-2 PODS 16.48-16000 1940 HEXDocument number: 039273.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6Overview 19” adaptor kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7G.5.Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8G.5.1.Installing the battery shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8G.5.2.Installing the battery breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9G.5.3.Installing the battery cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

19” Adaptor Kit Installation Guide H-3Document number: 039273.fmRevision: B




/ First issue Kai Morten Hennum 06.04.05A Second issue Kai Morten Hennum 13.05.05



Signed Signed


Revision: B


H.1 Scope and purposeThe purpose of this document is to give a clear instruction in the connection of the 19” adaptor 8U kit for PODS 16.48-16000 1940 HEX.

To ensure the continued supply of the loads from batteries, it is of vital importance to follow this procedure closely.


Note! Use insulated tools.

Figure H-1 Insulated tools.




H.2 Safety precautions


H.3 AC Power source requirements








Revision: B


H.4 Overview 19” adaptor kitThe 19” adaptor 8U kit allows you to install up 8U of 19” equipment into the cabinet. The kit consists of

1. 2pcs Adaptor 8U 23 to 19 inch.

2. 2pcs Isolation for oval feed-through holes.

3. 8pcs Screw M6.0x12 mm Taptite pan elzn TT3.

Figure H-2 19” adaptor kit



H.4.1 InstallationFirst enter the two adaptor pieces on each side of the cabinet as shown in Figure H-3 using the 8 screws. Torque: 6 Nm.

Figure H-3 Mounted Adaptor pieces


Revision: B


Use the isolation pieces where cable feed-through is wanted to avoid damaging cables.

Figure H-4 Example of use of isolation

The installation procedure is now complete and 19” equipment can be mounted.




Revision: B

Battery Heater Kit - Installation procedure

Appendix I: Battery Heater Kit- Installation procedure

Battery Heater Kit - Installation procedure I-1Document number: 039448.fmRevision: A






I-2 PODS 16.48-16000 1940 HEXDocument number: 039448.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Battery Heater Kit - Installation procedure I-3Document number: 039448.fmRevision: B




/ First issue Kai Morten Hennum 10.06.05


Date 10.06.05 Approved Lars Helge Stølen Date 10.06.05

Signed Signed


Revision: B


I.1 Scope and purposeThe purpose of this document is to give a clear instruction in the connection of a Battery Heater Kit for PODS 16.48-16000 1940 cabinets.


The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.


Figure I-1 Insulated tools.

I.2 Safety precautions







I.3 AC Power source requirements


I.4 Overview Battery Heater KitThe battery heater kit is designed to heat the batteries installed in the Power-One outdoor cabinets to avoid batteries from freezing when operating in a cold environment.

I.5 Installation and connection1. Turn off the mains input voltage.

Note! Steps 2 to 6 below are described in Figure I-2 on page I-7.

2. Locate the position for heater kit installation at the bottom right of the cabinet.

3. Remove the lower three screws used to fasten the panel and battery shelf.

4. Position the heater fan and fasten the shelf, panel and fan with three screws. (Torque: 6 Nm)

5. The heater fan is now mounted. Ensure that the heater thermostat is set to the 5 degrees default value.

6. Mount the heater cable as shown. Insert the four strip fasteners into the holes along the shown cable path, and use the four strips to fasten the cable.

Note! Some early versions of the outdoor cabinets do not have the cable entry opening shown in part 6 of Figure I-2 on page I-7. Alternative cable routing down and under the bracket is shown in Figure I-3 on page I-8. In this case the easiest installation is to pull the cable through before mounting the heater fan.





Revision: B


Figure I-2 Battery heater mounting

2. Heater location Fan 3. Removal of screws

4. Mounting Heater Fan

5. Heater Mounted Fan 6. Cable Path



Figure I-3 Alternative Cable Path

7. Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

Note! If a Surge arrestor kit is installed or is being installed, mount the battery heater circuit breakers and ground terminal block below the surge arrestor as shown in Figure I-4.

8. Mount the circuit breaker and the ground terminal block by snapping them on the DIN rail below the mains input terminal blocks or below the surge arrestor kit if installed (Torque: 1,5 Nm). Mount the end stop below the kit in order to prevent the parts from sliding on the DIN rail (Torque: 1,5 Nm)..


Revision: B


Figure I-4 Heater kit din rail parts mounted in the cabinet

9. Connect attached cables according to Schematic diagram PPR 16.48/10 in Appendix A.


11. After checking the battery heater kit connections the mains input can be reconnected.





Revision: B

Customer AC service outlet - Installation procedure

Appendix J: Customer AC service outlet- Installation procedure

Customer AC service outlet - Installation procedure J-1Document number: 039248.fmRevision: A






J-2 PODS 16.48-16000 1940 HEXDocument number: 039248.fm

Revision: B


Contents:Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6Overview AC outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6

Customer AC service outlet - Installation procedure J-3Document number: 039248.fmRevision: B




/ First issue Kai Morten Hennum 21.03.05A New Revision Kai Morten Hennum 13.05.05B New Revision Kai Morten Hennum 30.05.05



Signed Signed


Revision: B


J.1 Scope and purposeThe purpose of this document is to give a clear instruction in the connection of an AC service outlet for PODS 16.48-16000 1940 HEX.


The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.


Figure J-1 Insulated tools.

J.2 Safety precautions







J.3 AC Power source requirements


J.4 Overview AC outletThe AC service outlet is not provided by Power-One, but may be installed by the customer following these instructions.

J.5 Installation and connection1. Turn off the mains input voltage.

2. Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the AC service outlet by snapping the holder on the DIN rail below the mains input terminal blocks. Mount the end stop below the AC outlet kit in order to prevent the parts from sliding on the DIN rail.

Note! If Surge arrestor kit or battery heater kit is installed, mount the AC outlet below the surge arrestor and battery heater breakers as shown in Figure J-2.





Revision: B


Figure J-2 AC outlet kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in Appendix A.


6. After checking the AC outlet kit connections the mains input can be reconnected.





Revision: B

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