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MCS48/600-TLUA5 Power System

User’s Manual

Version: 02
Issue date: 2007.6.25

Delta-CIMIC Electronics Co., Ltd.


All Rights Reserved

“Read this manual carefully before installation and operation”


Content
Content
Warranty
1 General
1.1 Using this Manual 1-1
1.2 Safety Regulation 1-1
1.3 Operating Environment 1-2
1.4 Product labels and instructions 1- 2

2 System Introduction And Characteristic


2.1 General 2-1
2.2 I ntroduction And Characteristic 2-1
2.3 C onstruction And Outlook 2-4
2.4 Application And Functionality 2-4
2.5 Electrical Characteristic 2-5
2.6 O peration Environment 2-5
2.7 Dry-Contact 2-7
2.8 Neutral Bus N 2-7

3 System Installations
3.1 General Requirements for Installation 3-1
3.2 Installation Preparation 3-4
3.3 System Installation 3-7
3.4 Preparations Before Commissioning 3-17

4 Start up System
4 . 1 Initial Start-Up Preparation 4-1
4 . 2 System Power-on 4-1
4 . 3 Setting Of System Parameters 4-1
4 . 4 System Functionality Check 4-2
4. 5 System Operation 4-2

5 System Operation And Parameter Setting


5.1 General 5-1
5.2 System Display 5-1
5.3 Front Panel Buttons 5-2
5.4 Status Lamps 5-2
5.5 Operation 5-4

6 Local And Remote Monitoring


6 . 1 Connection Method 6-1
Content

7 Rectifier Module
7.1 Profile And Structure 7-1
7.2 T echnical Data 7-1
7.3 Start-up Rectifier 7-4
7.4 Operation And Adjustment 7-4
7.5 SMR Operation Status Indicators 7- 4
7.6 S y s t e m Alarm And Troubleshooting 7-4
7.7 Block Diagram And Working Principle 7-4

8 Control And Supervisory Unit


8 . 1 General 8-1
8 . 2 Features And Specifications 8-1

9 DC Distributions
9.1 Distribution Voltage 9-1
9.2 LVDS 9-1
9.3 Battery Wire Connection 9-1
9.4 Temperature Sensor 9-1
9.5 Connecting Board 9-1

1 0 System Alarms And Troubleshooting


10.1 AC Input Failure Alarm 10-1
10.2 Output Voltage Alarm 10-1
10.3 F use Blows Up Alarm 10-1
10.4 O v e r Temperature Alarm 10-2
10.5 Microprocessor Failure Alarm 10-2
10.6 R ectifier Failure Alarm 10-3
10.7 SPD Failure Alarm 10-3

1 1 System Maintenance
1 1 . 1 Cleaning And Maintenance 11-1
1 1 . 2 Removing and Replacing a Rectifier module 11-1
1 1 . 3 Rectifier Fan Replacement 11-2

Accessory 1
Accessory 2
Warranty

Warranty

1. Factory guarantee
This MCS series high frequency switch-mode DC power system is through
rigorous production and quality control, accurate testing and calibration.
2. Warranty range
The duration of this warranty is twelve (12) months from the date of shipment from
the place of DCE factory. During this warranty time, it is free of charge for repairing and
is only applied for nature broken down under normal operation. It will be out of warranty
if any of following cases occurred:

(1) Repairing it without permission


(2) Arbitrarily adding or amending inside the system
(3) Improper operation or misuse

(4) Cleaning or maintenance without following relevant regulation in this manual


(5) Environment condition exceeds normal condition to cause the failure
(6) Man-made damage on purpose

(7) Damage from the force of the nature.

The standard warranty is set as above; it can be obeyed to the other agreement if
there is any other local issue.
General
1. General
1.1 Using this manual
This manual contains specifications and instructions, operation and adjustment of swich-mode
power supply system. We will introduce the rectifier, control and supervision unit, low voltage
disconnection switch, system alarms, troubleshooting, and system maintenance. It contains of
preparing to start up the system, start up steps, parameter selection, adjustment, confirmation, as
well as system monitoring, operations, and maintenance procedures, and method of deal with
unusual case.

The beginning of this manual is the operation safety and operation condition. It gives of list of
relative attentions when operating this system. Please follow it up.

The sequence: first of all, system introduction to let the user to understand the specifications and
characteristics of the power system. Second, system operation and adjustment, alarms and
troubleshooting will be introduced. Finally, system maintenance procedures are introduced.

System operation and adjustment are done mainly through rectifieras, as well as control and
supervision unit. The sequence also starts from their specifications and characteristics, then the
operation, adjustment, setting, display.

Please refer to chapter 10 to do the failure elimination if system alarms. Please record the alarm
details and contact with us if the failure still can not eliminated.

1.2 Safety regulation


Please follow following safety regulations in any condition such as operation, cleaning or
maintenance. DCE accepts no liability for personal injury or damage to property resulting from
negligent use.

Warning Warning
Make sure earth the system properly Before system operating, make sure the the input
to avoid electrical shock and voltage, frequency are correct .The MCBs or Fuses
personal injury or other condition is meet the specification of the
order

Warning
The rectifier in this system works in parallel with load or without load. Please turn the AC input and
DC output MCB of unused rectifiers, to avoid the rectifier always works in no load situation. If
rectifier needs to restarted, please turn on the AC input MCB and wait the output voltage stabilized
before turn on the DC output MCB.

Warning Warning
Must set a switch between system and
Please do not open the rectifers and touch
Mains,so that people can work off line when
components or parts inside it in any case
doing the installation and maintenance.

1-1
General

Warning Warning
For incresing the MCB lifetime of the AC For those parts which can be replaced by user
input and DC output, avoid to do “on” “off” if (such as fuses), if needed, please replace it
it is unnecessary. It is prohibited to turn the with same regulation to avoid happening
DC output MCB on if the rectifier is not unexpected event. It is total prohibited to do
started and no AC input in. any addition or modification to the system.

Warning
This product is advanced electronics product, dusty condition will lead to accumulation inside the
product so as to affect the product functionality because of its bad ventilation inside.Please install it
in a less dust condition and clean the filter regularly. Beside, it is better working with air conditioning.

Warning
Operating in the volatilization gas condition lead to
flammability is prohibited

1.3 Operating environment


(1) input voltage : 380Vac±30%; 3 phase 5 wire
(2) input Frequency : 45Hz~65Hz
(3) operation Temperature : -5~50℃(10℃~35℃ recommended)
(4) ambient humidity : 0~95%RH(no condense)
(5) altitude above the sea : -100m~3048m
(6) floor bear the weight : > 600kg/m2
(7) eanthing resistance : <4Ω or according local regulation
(8) illumination : 750 lx(equality intensity),or local regulation
(9) floor height : >3m (to be added if elevated floor is used)
front space: 800mm
rear space : 300mm
side space : 600mm
(10) basic lightning protection : primary side of high voltage transformer for mains should
have lightning protection device.

1.4 Product labels and instructions


According to Chinese requirements of <<management methods for control of pollution caused by
electronic information products>>, product labels and instructions are shown as follows:

1.4.1 Labels for control of pollution caused by products

1-2
General

The label for control of pollution caused by electronic information products in this system is
shown as follows:

Figure 1 Labels for control of pollution caused by products diagram

1.4.2 Hazardous substances or element marking (See the table 1)

Table 1 Hazardous substances or element name and content marking


Part name Cd Cr(VI) Hg Pb PBB PBDE
Rack main body ○ ○ ○ ○ ○ ○
Rectifier ○ ○ ○ ╳ ○ ○
Other electric circuit
board ○ ○ ○ ╳ ○ ○
Rack electric appliance ○ ○ ○ ○ ○ ○
Supplementary
material ○ ○ ○ ○ ○ ○
○:It means that the content of hazardous substances in all homogeneous materials of this part is
less than the value which SJ/T 11363-2006 requires.
╳:It means that the content of hazardous substances in some homogeneous materials of this
part is more than the value which SJ/T 11363-2006 requires at least.
Note: The content of lead in rectifier and other electric circuit board applies exemption provision
required for European Union <<Restriction of the Use of Certain Hazardous Substances in
Electrical and Electronic Equipment (RoHS) Directive>>.

1.4.3 Product instructions


Our company began to execute the European Union requirements << Restriction of the Use of
Certain Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive >>in 2005,
and all products will apply each target in related laws and regulations from now on.

1-3
System introduction and characteristic

2 System introduction and characteristic


2.1 General
2.1.1 MCS48/600-TLUA5 is a switch- mode DC power system by using 48V/50A paralleled
rectifier. It gives a stable and reliable DC power to telecom equipment.
2.1.2 This series products is designed according to IEEE、NEMA、ANSI, and Bellcore standard.

2.2 Introduction and characteristic


2.2.1 System characteristic
1. N+1 redundancy
2. wide AC input range (90Vac ~ 300Vac)
3. wide operating temperature (-5℃ ~ +50℃)
4. modular design, easy for expansion
5. hot-pluggable, easy replace the module without influence
6. light(rectifier weight 5 kg)
7. high power density
8. high power factor (PF >0.99)
9. high efficiency
10. temperature compensated float voltage control for battery
11. advanced load sharing technology
12. have intelligent remote control functionality via RS232,and in support of YD/T 1104-
2001 protocol.
13. low voltage disconnection switch(LVDS) is optional ,to protect the battery deep
discharged
14. compact DC distribution unit

2-1
System introduction and characteristic

2.2.2 System configuration (Figure 2-1)


This power system can gives out max of 600A current (48Vdc). It is 2.0m high. DC
distribution is designed at the top of the cabinet with optional LVDS
System distribution configuration (standard, can be changed by request):
AC input voltage: 380Vac±30%(3 phase)
Load disconnected branch: 3x 160A; 2x 100A;2x 63A; 3x 32A;2 x10A.
Battery protectd branch: 2 x63A;2 x32A;2 x10A
Battery breaker: 2x500A
Low voltage disconnection switch: load disconnection protect LLVD,
battery disconnection protect BLVD,
AC dual input switch : 2x100A(switchable manually)
AC breaker(for customer): 3x 16A(single phase); 2x 16A(3 phase)
Dimension and weight:
Dimension (mm): 600(width) × 600(depth) × 2000(height)
Weight (kg): about 131 kg (not include rectifiers)

Figure 2-1a System dimension drawing

2-2
System introduction and characteristic

2 11

12
3
13
14
4
15

5 16
6
17

7
18

19

8
20

9 21
10

1—DC bus (+) 2—Load disconnected output(-) 3—Battery connection (BAT-)


4—Battery current hall sensor 5—Fuse detect board 6—Rectifiers
7—Rectifier air breaker 8—Surge protection air breaker 9—AC surge protection device
10—Neutral input bus 11—Load disconnected output(-) 12—Battery protected Output(-)
13—CSU(include YD/T 1104- 14—DC output bus(-) 15—Battery disconnect
2001 protocol transform board) contactor
16—Load disconnect contactor 17—Communication and interface 18—Air breaker(for customer)
board include manual battery switch
19—AC input interlock air 20—Ground Bus 21—EMI board
breaker

Figure 2-1b System structure (front view)

2-3
System introduction and characteristic

2.3 Construction and outlook


1. The PC board can be switchable in new and old version, the CONNECTOR has protection
device.
2. Cabinet and fittings is designed and processed with precision. No roughness, shape
angles or joint scar, surface is smooth. It is applied the latest processing technology.
3. All materials and spare parts are brand new, easy replacement when repairing
4. Rectifier has self-protection when input is cut off or too low and gives out alarm.
5. Rectifier is designed for safety operation and front access. It will not affect the whole
system operation and stabilization when plug it in or take it out.
6. System configuration applies safety and neat. The capacitor for rectifying can bear high
voltage and air flowed. All the materials are not inflammable.

2.4. Application and functionality


2.4.1 Switch-mode rectifier (SMR)
(1) Operation display
a. AC OK : Green LED display(AC Input Normal)
b. DC OK : Green LED display(DC Output Normal)
c. RFA : Red LED display(Rectifier Fail)
d. I+,I- : Measure hole of current value (calculate:45A=>3V)
(2) Adjustment:
--float voltage: adjust through CSU
--current limitation: adjust through CSU

2.4.2 System control and supervisory unit (CSU)


CSU has following display and functionality
(1) Alarms when there is failure
(2) Display float voltage or equalizing voltage. Low voltage disconnection voltage
threshold settings, and gives alarms when voltage reach that voltage.
(3) When discharge voltage reach to low voltage disconnected voltage threshold settings
value, LVDS switch will act to cut the battery string off the system and give out a alarm.
(4) It will start to adjust the system voltage or turn to floating condition when battery
temperature sensor gives out a high temperature signal (when temperature is higher
than normal operating temperature
(5) Display total load current
(6) Battery charging /discharging current
(7) Automatically recharge the battery when AC mains is back
(8) Display fuse blow (or MCB turn to “off”)
(9) Display AC mains is off
(10) Control LVDS

2.4.3 Battery & load low voltage disconnection switch (LVDS)


System equipped LVDS on the side of the bigger load output and battery output to avoid the
batteries over discharge for the sake of plant room safety. When AC is cut off and battery
discharge to certain level, the system will disconnect the bigger load shunt from the system and
let the battery only give power to the rest of the loads. When discharge voltage drops to certain
setting level, the system will disconnect the battery string from the system and cut the entire load

2-4
System introduction and characteristic

off. When the output voltage of the SMR is back, it will automatically recover.

2.4.4 DC distribution unit


According to loads value, the system equips different fuses for it. DC distribution unit is
designed on the top of the cabinet.

2.5 Electrical characteristic


2.5.1 System capacity: 48V/600A

2.5.2 Characteristic
2.5.2.1 When rectifier works in parallel, it will gives out current to the load in the same percentage.
The current difference between it should gives out(I1) and the real current it gives out(I2) is within
±5% of its rated output current of the SMR. Load sharing imbalance is showed as follow:
I1 − I 2
≤±5%
I

2.5.2.2 Noise:
1m around the system, the measure meter is 1.5m above the ground, the noise is measured
≤ 55dB(A)

2.5.3 Block diagram of system (figure 2-2).

2.6 Operation environment


All parts in this system are tested in high/ low temperature and humidity, and passed.
(1) ambient temperature: -5℃~50℃
(2) relative humidity : 0~95%(no condense)
(3) altitude : -100m~3048m

2-5
System introduction and characteristic

Figure 2-2 Block Diagram of System

2-6
System introduction and characteristic

2.7 Dry-contact

Dry-Contact
Figure 2-3 Dry-Contact Diagram

2.8 Neutral bus N

Neutral Bus N

Figure 2-4 Neutral Bus N Diagram

2-7
System installation

3. System installation
System installation steps are as follows:
Site inspection

Preparation of mounting tools and power
lines

Preparation of system installation

Rack mounting

Module mounting

Inspection of internal wiring

Mounting instructions of rack top-cover

Connection of AC power lines

Connection of DC power lines

Installation of ground wire

Other wires

System commissioning

3.1 General requirements for installation


3.1.1 Ambient requirements for equipment Room
The equipment room used for the installation of this system shall meet the ambient requirements ,
refer to table 3-1.
Table 3-1 Ambient requirements for equipment room
Environment condition Range

Ambient temperature -5℃~50℃ (recommended: 10℃~35℃)

Ambient humidity 0~95%RH (not condensing)

Elevation -100m~3048m

Bearing capacity of floor > 600kg/m2

Lighting requirement 750 lx (even illumination) or as per local legal requirements

Floor height >3m (to be added if elevated floor is used)

Mildew No

Rainproof Yes

Mouse, insect, etc. No

Daylight No direct daylight


Concentration of dust particles with a diameter of >0.5μm: ≤18000 particles/liter
Concentration of dust particles
Concentration of dust particles with a diameter of >5μm: ≤300 particles/liter

3.1.2 Space requirements for equipment Room


3.1.2.1 Air exhaust and ventilation requirements:
3-1
System installation
When power supply system works, rectifier module will give off heat. Thus, air exhaust and
ventilation are very important. The ventilation form of power supply module is air in, front and air
out, rear. To ensure the front and rear ventilation, power supply system shall have enough wide
free space. There shall be no barrier or wind blocking device within 500m before the rack and
300mm behind the rack.

3.1.2.2 Space and structure requirements


The distance between the front of power supply equipment and the wall of equipment room shall
not be less than 1.5m; the width of the passage between the side of power supply equipment and
the wall of equipment room shall not be les than 0.8m; the width of the passage between the rear
of one equipment and the front of another equipment shall not be less than 1.5m; the width of the
passage between the rear of one equipment and the rear of another equipment shall not be less
than 1.2m; a maintenance passage between equipments shall be arranged, with a width of not less
than 2m, shown as figure 3-1:

Distance between
Distance between the side and wall is not
rear of rack and wall is less than 0.8m.
not less than 0.8m.

正面

Equipment can be 1.5m space needs to


close with other be reserved for
equipment in the front passage.
same row.

Figure 3-1 Space and Structure Requirements Diagram

3.1.3 Power requirements for equipment room

Communication power supply system had better use municipal power as mains supply and is also
equipped with house generator as auxiliary power supply. The AC power supply system composed
of municipal power and house generator had better adopt centralized power supply. Power supply
system shall adopt three-phase five-wire system.

Lead-in AC power line shall be protected with metal sheath and buried under the ground. The two
ends of metal sheath shall be grounded nearby. AC power line had better be led underground to
equipment room. AC power line, DC power line, signal line and ground wire shall be laid
separately.

When system I/O power lines are led in from rack top, equipment room shall be installed with
distribution frame. It is advised that distribution frame is more than 300mm higher than the rack
and the wiring of power lines inside the equipment room uses the distribution frame.

3-2
System installation

To prevent electric coupling, AC cables and DC cables shall be laid separately.

Warning

3.1.4 Lightning protection and grounding requirements

The lightning protection and grounding of communication equipment room/office/station shall be


designed according to the relevant state industry specifications. Different levels of lightning
arresters (SPD) shall be arranged in different protection areas for the multi-level discharge of
lightning strike current. Communication power supply system is already equipped with Level C
arrester (nominal discharging current is 20kA). To increase lightning protection effect, Level B
lightning arrester (nominal discharging current is not less than 60KA) shall be installed at the
lead-in side of AC municipal power.

When Level B lightning protection adopts switch SPD, the length of the cable from the side of AC
municipal power to communication power supply system shall be ≥10m; when Level B lightning
protection adopts voltage limiting SPD, the cable length shall be ≥5m. The section area of the
connecting wire of Level B SPD shall not be less than 16mm2 and the shorter, the better; the
section area of ground wire shall not be less than 16mm2, wire length shall be less than 1m (as
short as possible) and wire is grounded nearby. All levels of SPDs shall be regularly inspected. If it
is found that any SPD is damaged, it shall be replaced in time so as to ensure that lightning
protection performance is not affected.

(For lightning protection details, refer to YD 5098-2005 “Specifications for Engineering Design of
Lightning Over-Voltage Protection for Telecommunication Offices (Stations)”.)

Figure 3-2 System Grounding and Lightning Arrester Installation Diagram

Equipment room/office/station where communication power supply is mounted shall adopt joint
grounding. All parts inside the power supply system are already grounded. It is enough to connect
grounding bar with the grounding busbar of equipment room. The grounding resistances of
communication offices/stations shall meet the following requirements:

3-3
System installation

Table 3-2 Grounding Resistances of Joint Grounding Devices of Communication Offices/stations


Grounding resistance (Ω) Scope of application
<1 Comprehensive building, international telecommunication office, tandem office,
SPC exchange with more than 10,000 lines, long-distance call office with more than
2,000 lines.
<3 SPC exchange with more than 2,000 lines and less than 10,000 lines, long-distance
call office with less than 2,000 lines.
<5 SPC exchange, optical cable end station, carrier repeater station, earth station,
microwave hub station and mobile communication base station with less than 2,000
lines
<10 Microwave relay station, optical cable relay station, small earth station
<20 Microwave passive relay station
<10 Applicable for the lightning protection grounding at the interface of power cable and
overhead power line, with a earth resistivity of <100Ω·m.
<15 Applicable for the lightning protection grounding at the interface of power cable and
overhead power line, with a earth resistivity of 101~500Ω·m.
<20 Applicable for the lightning protection grounding at the interface of power cable and
overhead power line, with a earth resistivity of 501~1000Ω·m.

(For grounding details, refer to YD/T 1051-2000 “General Technical Requirements of Power
Supply System for Telecommunication Offices (stations)”.)

3.1.5 Fire protection requirements

Power supply system equipment room shall meet relevant fireproof regulations and be equipped
with gas fire extinguisher or fire extinguishing ball is hung at the ceiling. But the substance sprayed
from fire extinguishing equipment shall not be conductive so as to avoid danger. Smoke detector
and alarm device shall be installed inside the room so that an alarm is given off in case of fire.

3.1.6 Waterproof requirements

Necessary waterproof measures shall be taken inside power supply system equipment room.
Inside it, drain pipe shall be arranged so as to avoid water accumulation.

3.2 Installation preparation


3.2.1 Site Inspection

Before equipment installation, construction inspections shall be made on equipment room:


1) Whether the wiring and grounding devices required for equipment installation are completed or
not;
2) Whether the environment required for equipment installation meets the requirements or not;
3) Whether the power supply, illumination, etc at installation site are available or not.

3.2.2 Preparation of mounting tools and power lines


1) The tools required to install this system: electric drill, wire cutting pliers, wire clamping pliers,
spanner, screwdriver, electrician knife, multimeter, etc. Insulation and anti-static measures
shall be taken before their use.
2) Power lines used for installation. System installation requires AC cable, DC load cable, battery
connection cable, grounding cable, etc. Cable specifications shall meet relevant electric
industry specifications.

AC cable, DC load cable and battery connection cable shall meet the capacity of connected load
and the capacity after capacity expansion in future shall be taken into consideration.

3-4
System installation

3.2.3 Preparation of system installation


3.2.3.1 Unpacking inspection

Unpacking inspection shall be made only when goods are transported to installation site.
Unpacking steps shall follow figure3-3 “Unpacking Sketch” on the top of packing case (the
appearance of rack according to object). According to the “packing list” in the packing case, count
the goods inside the case, check the correctness of equipment as well as the quantity and types of
accessories. According to system configuration, inspect the integrity of equipment configuration. In
addition, inspect whether the rack is deformed and any components or connections are loose due
to transport.

3-5
System installation

Figure3-3 Unpacking Sketch


3.2.3.2 Mounting accessories
The accessories in the packing case used for rack mounting include: 6pcs of M12 expansion bolts,
dimension template of system mounting fixture, and cable ties.

3-6
System installation

3.3 System installation


3.3.1 Rack mounting
3.3.1.1 Rack is directly mounted on the floor.
Rack mounting size is as figure 3-4:

Rear

Front

Figure 3-4 Rack Mounting Size Diagram

The procedure for installation is as below:


Step 1: mark the mounting position of rack.
According to the mounting drawing of equipment room, determine the mounting position of power
supply rack in equipment room. Fix the mounting fixture (refer to Figure 3-1), determine the
positions of equipment on the floor of equipment room according to the centers of mounting holes
and mark them with pencil or ball pen. After marking, remove the mounting fixture.

Mark the centers of


holes. 机柜安装定位模板
Rack Mounting Fixture

机柜前门
FRONT DOOR

Figure 3-5 Template of Mounting Fixture

Step 2: Drill reserved holes.


Use the M12 expansion bolts in the accessories. Use an electric drill to drill mounting holes on the
mounting fixture(Diameter 16mm of drill bit, the hole depth is 100mm). At drilling, electric drill shall not

3-7
System installation
vibrate so as to prevent eccentricity and shall also be vertical to the ground.
Step 3: Mount expansion tubes.
Remove the dust on the surface of drilled holes, insert expansion tubes into reserved holes and
beat them with a hammer to make their tops level with the ground.

Step 4: Rack is in place.


Move the rack to mounting position and align the mounting holes on the rack with the reserved
holes inserted with expansion tubes on the ground.

Step 5: Fix the rack.


After rack is in place, make proper horizontal and vertical adjustments. Normally, use iron pieces at
the lower edge or angle of rack to make the vertical angle of rack less than 5 degrees. Finally, turn
the expansion bolts with flat washers and elastic washers into the expansion tubes and tighten the
bolts with the spanner. The fixing processes of rack refer to Figure 3-6.
Rack
M12 bolt

Flat washer

Elastic
washer

Expansion
tube Ground

Figure 3-6 Mounting Diagram of Expansion Bolts

3.3.1.2 Rack is mounted on anti-static support

When equipment room is laid with anti-static floor, rack needs to be mounted on an anti-static
support. The following is an example of Huawei anti-static support, which describes rack mounting
steps.

Step 1: anti-static support mounting. First to refer to the step 1 to step 3 of item 3.3.1.1 to mount
the anti-static support, the mounting hole at the anti-static support for cabinet mounting should be
suitable to the dimension of 520mm×400mm.

Step 2: rack is in place (same with item 3.3.1.1).

Step 3: fix the rack(same with item 3.3.1.1).

Details to refer to figure 3-7.

3-8
System installation

M12 Bolt
Spring washer
Plain washer

Base of cabinet

Anti-static support

Figure 3-7 Mounting Diagram

3.3.2 Module mounting

To reduce the weight of system during its transport, module adopts independent packing. It is
mounted into the system after rack is fixed. The method is as follows:

1) Turn the breaker of rectifier module to OFF state;


2) Tighten fixing screw after rectifier module is inserted into the position as figure 3-8.

Module is pushed along this direction.


Fixing screw

Figure 3-8 Rectifier Module Mounting Diagram

To ensure that no electric arc arises when rectifier module is pulled out of the
Warning power-on system, be sure to turn its breaker to OFF position when it is mounted
on or removed from the rack.

3-9
System installation
3.3.3 Inspection of Internal Wiring
All internal wires of the system are already connected when the system leaves the factory, but user
may inspect whether any wire is loose.

3.3.4 Mounting Instructions of Rack Top-cover


Before AC lead-in wires, load and battery wires are connected, first remove three rack top-covers
(as shown in Figure 3-9). After wiring, shear the corresponding positions of three rack top-covers
according to actual wiring. AC lead-in and lead-out positions are left after the area inside the broker
lines is sheared with angle pliers (the shearing of the positions of other lead-in and lead-out wires
is similar to this). Then, re-mount the top covers and tighten them with screws.

Battery and load (﹢)


wiring position

Battery (-) wiring


position AC wiring position

Rear
Load (-) wiring position

Front

Figure 3-9 Rack Top-cover Diagram

3.3.5 Connection of power lines

The DC output of this system is top lead-out and AC input meets top lead-in and bottom lead-in.
Before connecting power line, the copper core after power line is unsheathed shall be crimped on
the corresponding terminal. Connect power line to air switch or fuse, as shown figure3-10.
Note:
1) Fuse connection: bear down upon the fuse detecting wire to the outside of cable for
ensuring the good connection between cable and fuse block.

2) Air breaker connection: bear down upon the fuse detecting wire to the inside of cable for
ensuring the good connection between cable and fuse block.

3-10
System installation

Cable

Fuse detection line


Fuse detection line

Wiring hole

Fuse
Air breaker

Fuse holder

Figure 3-10 Connection Diagram of Power Line (AC air switch has no detection line)

3.3.5.1 Connection of AC power line


I. Preparations before connection:

1. The AC input cables of power supply system are led out from user’s AC distribution switch.
Before wiring, it shall be guaranteed that AC distribution switch is in OFF position.

2. AC input cables had better use colors for differentiation. Normally, AC phase wires use yellow,
green and red to correspond to phases A, B and C respectively, neutral wire (N) uses light
blue and ground wire (PE) must use yellow and green. In case of only one color, marks shall
be made for differentiation at the wire ends. Moreover, ensure the section area of AC input
cables shall not be more than 16mm2.

3. Make checks to ensure that cables are free of damage or scratch.

II. Connection steps:

1. Depending on actual situation at site, connect the AC input cables into the system above or
below power supply system.

2. Arrange the cables along the column (seen from the front) on the right side of rack and bind
the cables with cable ties at proper positions.

3. Wires go to the input terminals at AC distribution portion. Phase wires are connected to
terminal A, B and C positions, neutral wire is connected to N position and ground wire is
connected to ground bar. Wiring sequence is: first connect ground wire, then connect neutral
wire and finally connect phase wires.

3-11
System installation

AC wire Plug-in

Figure 3-11 AC Wire plug-in from the Top

3-12
System installation

AC wire Plug-in

Figure 3-12 AC Wiring plug-in from the Bottom

Air breaker for customer


Rectifier Breaker

Input line for AC1 Output cable for customer


AC Input Neutral Input line for AC2
Grounding bus (PE)
AC Surge Protection Device
Grounding line

Surge Protection
Neutral bus for
Air Breaker
customer

Neutral line for customer


Input Neutral terminal AC input air breaker

Figure 3 –13 Wiring Position Diagram

III. Dual AC input air breaker description


There is ‘Dual AC input air breaker’ available in this system, including ‘Mechanical Interlock’ as

3-13
System installation
well, shown as Figure 3-14a and Figure 3-14b (the position of this device in the system is as item
20 of Figure 2-1b). If you want to put ‘AC MAINS 1’ in service, move the ‘Mechanical Interlock’ to
the right, then turn on the ‘AC MAINS 1 Breaker’, shown as Figure3-14a; if ‘AC MAINS 2 ’ needed,
turn off the ‘AC MAINS 1 Breaker’ first, then move the ‘Mechanical Interlock’ to the left, turn on the
‘‘AC MAINS 2 Breaker’, shown as Figure3-14b.

AC1 AC2

Mechanical Interlock

AC1 Breaker AC2 Breaker

Figure 3-14a Dual AC Input Air Breaker (‘AC MAINS 1’ in service)

AC1 AC2

Mechanical Interlock

AC1 Breaker AC2 Breaker

Figure 3-14b Dual AC Input Air Breaker (‘AC MAINS 2’ in service)

VI. Wiring of the shunts used by the customer


When the shunts for customer need to be used, live wire is connected to the lower end of air switch
used by the customer, neutral line is connected to “neutral line input terminal block” and ground
wire is connected to “grounding bar” (as shown in Figure 3-13).

1. Before system start, confirm whether used voltage is correct.


2. Confirm that the air breaker of all rectifier modules are in OFF position.
Warning 3. The switch at AC power supply end shall be in OFF position.

3.3.5.2 Connection of DC power lines

3-14
System installation

When screws are used to fix load wire terminals, please note whether fuse
detection wire is locked and all screws are tightened. Otherwise, heat will be given
off due to improper contact.
Warning

I. Installation requirements
1. DC cables had better use colors for differentiation. In case of only one color, marks shall be
made for differentiation at wire ends.
2. Make checks to ensure that cables are free of damage or scratch.

II. Connection of DC load cables


1. DC cables had better use top lead-out, i.e. connect the rack over the system.
2. According to load capacity, select suitable fuse or air switch, fix the negative end of DC cable at
fuse holder or top of air switch and fix positive end at positive bar.

Load connection(-)
Load connection(-)

Load connection(-)
Battery connection(-)

Figure 3-15a DC Wiring Position Diagram

Battery connection(+)
Load connection(+)

Figure 3-15b DC Wiring Position Diagram

III. Connection of battery cables

1. Lead battery cable in above the system and connect the negative end of cable to the top of
battery fuse holder. Proceed according to the sequence of first line and second line. In case of
only one battery pack, only first line needs to be connected. Connect the positive end of cable
to the positive bar of system.

2. When the negative end of cable is fixed at fuse holder, first remove the screws at fuse holder

3-15
System installation
and the fuse detection wire fixed by screws; then, put the negative terminal of battery cable at
fuse holder and the fuse detection wire; finally, fasten and tighten two wires with screws.

1. Battery cables had better use colors for differentiation. In case of only one color,
marks shall be made for differentiation at wire end.
2. Before connecting battery cables, remove battery fuse so as to ensure that system is
Warning not powered on.
3. Make checks to ensure that cables are free of damage or scratch.

3.3.5.3 Installation of ground wire


This power supply system adopts joint grounding. When it leaves the factory, internal ground wire
is already connected to system grounding bar. It is enough to connect a wire from the grounding
bar in the rack to the grounding busbar in equipment room (the grounding connection position is
shown as figure 3-13). Refer to the description in Section 3.1.4.

Prohibit connecting the neutral line of AC power supply to this grounding end.

Warning

3.3.5.4 Other wires


I. Installation of temperature sensor cables:
The temperature detection wire at battery end is placed at the copper bar between battery poles,
and shall be apart from calorific equipments .The other end has been connected to system before
leave factory.

II. Connection of dry contact wires:


Output terminal is located over the rack and on the right side of DC distribution unit (refer to table
3-3 “Function Description of Relays”). It outputs from interface plate to terminal block. Terminal
block has numbers to be used by the user to connect other external alarm devices. When an alarm
occurs, corresponding contact acts, depending on the alarm it belongs to.

Table 3-3 Function Description of Relays


Relay No. Function Function description

Relay1 AC failure AC input failure alarm contact (AC Fail)

Relay2 DC under-voltage DC output low-voltage alarm contact (DC Low)

Relay3 Module failure Rectifier module failure alarm contact (SMR Fail)

Relay4 Battery protection Battery low-voltage isolation & trip alarm contact (Batt. LVD)

Note: each of relays 1-4 provides 3 contacts (as shown in Figure 3-15), which are common end
COM, normally open contact NO and normally close contact NC. The status between normally
open contact and common end is open if normal and close in case of alarm. The status between
normally close contact and common end is contrary.

3-16
System installation

Figure 3-16 Alarm Dry-Contact Diagram

The dry contact terminal bar of system is on the left side of the front of system. Part or all of dry
contact wires can be selected according to needs. Connected wires go upwards along rack column
and are firmly bundled with wire ties at proper positions, shown as figure 3-17.

Cable connect to dry contact for customer

Figure 3-17 Dry-Contact Wiring Diagram

3.4 Preparations before commissioning


After system installation, it is forbidden to start the whole system rashly. System shall be
commissioned in full accordance with commissioning steps so as to avoid accidents.

1. Before powering-on, check the parts and wiring inside the rack to ensure that parts are not
damaged, screws are not loose and wires are tightened.

2. Confirm that the wiring of AC cables is correct and there are no short-circuit and wrong wiring.
In particular, ensure that ground wire is connected correctly.

3. Confirm that DC cables are correctly connected and positive and negative polarities are not
inversed.

4. Confirm that all air switches at AC distribution portion are in OFF position. Disconnect all air
switches of DC input and pull out all DC fuses and battery fuses with the holder.

5. Confirm that breaker of each rectifier module is in OFF position.

6. Not touch or contact the live portion of system randomly during commissioning.

3-17
System installation
3.4.1 Battery connection:

1. After system works normally, adjust the difference between its voltage and battery voltage to
be within 0.5V.

2. Reinstall battery fuse with fuse holder. Installed fuse shall be firm.

3. Through monitoring unit, adjust system voltage to normal value.

3.4.2 Load connection:

1. Turn on the switches connected to the load by turns or reinstall load fuse with fuse holder.

2. At this time, loads end can be normally powered.

3-18
Start up system

4 Start up system
Start up system procedure:

Initial start-Up preparation



System power-on

System parameter setting

System functionality check

System operation

4.1 Initial start-Up preparation


Before start, make sure all the installations have done according to chapter 3.
(1) Confirm all polarity is correctly connected
(2) Confirm the operating voltage is within the range
(3) Ensure that the AC line is properly grounded
(4) Ensure all rectifier module is in working condition and the AC breaker of SMR is
switched to the “OFF” position

4.2 System power-on


1. Turn on the AC distribution switch installed on the site of customer. At this time, system input
end shall be live.

2. Measure the system input end with multimeter and see if AC voltage is normal.

3. After confirming that alternating current is normal, turn off the switch used by the system. At
this time, module input end is live.

4. Turn on the air breaker for rectifier. After about 1-2s, the RFA , AC OK and DC OK lamps on
the module are lit. After another 1s, only AC OK and DC OK LED is lit. This shows that
module is normally started. Measure with multimeter whether the voltages of positive and
negative bars are normal.

5. After module is normally started, the LCD screen of monitoring unit is automatically powered
and displays relevant information. For the operation of monitoring unit, refer to chapter 5
“SystemOperation and Parameter Setting”

Start remaining modules by turns. Confirm that each module works normally.

4.3 Setting of system parameters


Because most parameters are already set when this system leaves the factory, a general
description of the parameters that may be changed by the user is given here. For detailed
operations, refer to Chapter 5 “Adjustment of System Parameters”.

1. Floating/equalized charging voltage

4-1
Start up system
The voltage settings of floating/equalized charging are the values in ex-factory test report. If the
user needs to reset them, the voltage settings of floating/equalized charging shall be reset in the
CSU.

2. Total number of rectifier modules

Through monitoring unit, set the number of modules according to the number of modules actually
used by the system.

3. Confirmation of rectifier module positions

This system adopts fixed-number addressing, from left to right and from top to down.

Rectifier modules are numbered from left to right, from up to down. The sequence of the first row
(from left to right) is 1, 2, 3; the sequence of the second row is 4, 5, 6; The sequence of the third
row is 7, 8, 9; the sequence of the forth row is 10, 11, 12.

4. Setting of battery capacity

Battery capacity needs to be adjusted to the capacity of the batteries actually connected to the
system.

5. Current limiting setting of monitoring unit

Current limiting setting of battery include battery deeply discharge limit, battery float discharge
limit and battery equalised discharge limit.

4.4 System functionality check


After system start-up, basic functional verification should proceed as follows:

(1) Check the CSU display whether is in normal or not

(2) check LVDS (include load disconnection protect LVDS and battery disconnection protect
LBDS)functionality whether is in normal or not

Check system monitoring and alarm functionality .The checking items shows as below:
(1) system status display
To check all the voltage, current, temperature is in normal in the main screen,it should
match the real system statuses (see chapter 5.3).

(2) system alarms display

To check the alarms in the alarm display screen is match with present system functionality
(see chapter 5.4).

4.5 System operation


When finish all above setting and testing, the system should work normally.

4-2
System operation and parameter setting

5 System operation and parameter setting


5.1 General
This section gives a description of the display of system operation data and alarm screens as welll
as of how to set operation parameters in the system and guides the user to reset some specific
parameters. The other parameters are factory-set.

5.2 System display


When turned on, the system displays product series and version of monitoring software, as shown
below:

DELTA MCS3000H
V:1.3#1.1

Monitor module provides a 4-line, 16-character digital LCD display, which usually displays DC
voltage of system output, total load current and system state (floating charge or equalized charge).
The following is the main page by default.

200A 54.0 V
FL

Note: without alarm, if current screen is not on main page, display automatically returns to
main page if key is not pressed for more than 40s, main page and alarm prompt page are
displayed alternately.

5-1
System operation and parameter setting

5.3 Front panel buttons

The front panel of monitor module (CSU) has four buttons, which can be used to enter different
menus or move up and down in one menu. The positions and labels of buttons are shown in
Figure 5-1 below:

Green
绿灯 lamp
Yellow
黄灯 lamp
红灯
Red lamp

Bat Log

+ - SMR

Figure 5-1 Panel Diagram of Monitoring Unit

In the main page of monitor module or menu, there are the following 5 menu buttons, which
include the most parameters of the system. The user can directly enter relevant items through
these menus:
a) SMR menu, including all parameters related to rectification module, output current and
alarm contents of each module.
b) Bat menu (need to press the combination of keys: + key + - key). All battery-related
parameters are included.
c) Log menu (need to press the combination of keys: - key + key). Recent 100
alarm messages (including alarm data and time) are stored.
d) + key and - key, including all system parameter menus. For each setting, “+” and “-”
keys are used to change its value.
e) key, i.e. Enter key. For any parameter that can be changed, change is made only
after pressing Enter key. Besides, after change, press Enter key again to confirm.

5.4 Status lamps


Besides the menu contents of LCD display, there are the following three system status lamps:
System runs normally 9 Green lamp
Alarm/equalized charging ! Yellow lamp
Rectification module is shut down 2 Red lamp
If these three lamps are not lit, this means that system is shut down. The possible reasons are as
follows:
• Internal failure of monitor module
Yellow alarm lamp represents all alarm statuses, including those related to system and modules.
When alarm occurs, press Enter key to view alarm contents. If red alarm lamp is lit, this means
that one or several rectification modules are shut down.

5-2
System operation and parameter setting
5.4.1 Alarm items
All possible alarms in monitor module are shown below:
Alarm name Default Notes Lamp
SMR Alarm / One or several rectification modules are Yellow
giving an alarm.
SMR HVSD 59.5V Rectification module is shut down because Yellow + red
output voltage is higher than high-voltage
shutdown value.
SMR Comms Fail / Breaker of rectification module is off, RFA Yellow
alarm occurs or module communications
are poor.
No Load / The output current of rectification module Yellow
is less than 1A.
Current Lim. 30A Rectification module is at a state of current Yellow
limit.
EEPROM Error / Memory EEPROM fails (monitor module or Yellow
rectification module)
BLVD Trip 43.2V The low-voltage isolating switch of battery Yellow
is off.
LLVD Trip 44.0V The low-voltage isolating switch of load is Yellow
off.
AC Volt Fail 260V&200V AC voltage exceeds the set limit value,or Yellow
belows least value
Fuse Break / The fuse or CB of load shunt is off. Yellow
Voltage High 59.0V The output voltage of system is too high. Yellow
Voltage Low 49.0V The output voltage of system is too low. Yellow
Cell V High / The monitoring of battery condition monitor Yellow
module (BCM) shows that the voltage of
one or several batteries is too high (BCM
function is reserved).
Cell V Low / The monitoring of battery condition monitor Yellow
module (BCM) shows that the voltage of
one or several batteries is too low(BCM
function is reserved).
Cell %dev Hi / The monitoring of battery condition monitor Yellow
module (BCM) shows the too high
percentages of the voltages of one or
several batteries (compared with average
battery pack voltage)(BCM function is
reserved).
Cell %dev Lo / The monitoring of battery condition monitor Yellow
module (BCM) shows the too low
percentages of the voltages of one or
several batteries (compared with average
battery pack voltage) (BCM function is
reserved).
Batt. Disch / Battery is discharging. Yellow
BDT Fail / Battery discharge test fails. Yellow
Bat Dis Alm 47.0V During battery discharge, if system voltage Yellow
is lower than the preset discharge alarm
value, alarm signal will be given off.
SMR Urgent / Module is shut down due to high voltage. Yellow
Batt T Alm 40℃ Battery temperature is higher than set Yellow
value.
Temp Sen Alm / The detection line of battery temperature is Yellow
not connected or fails.

5-3
System operation and parameter setting

Equalize / System is at a state of equalized charging Yellow*


(when system has no alarm and is at a
state of equalized charging, yellow lamp
does not flash; when system is at a state
of equalized charging and has an alarm,
yellow lamp flashes).
Note: red = red lamp is lit. Yellow = yellow lamp flashes. *--- Not flash.

5.5 Operation

Press + key to select different parameters in the menu of the monitor module(refer to the
section 5.3 hereinafter).
Press - key to display the parameters in a reverse order. The last parameter will come to the
first. Thus, its parameters can be directly checked, saving the trouble to page down one by one.
To access the other menu parameters can be realized by pressing corresponding keys(SMR, Bat,
Log etc.). Please refer to the section 5.5.2, 5.5.3, 5.5.4 hereinafter to find the description for the
contents of corresponding menus.
Under any circumstance, return to the monitor module or main page can be realized by a single
press on the current menu button. For example, if the current menu is under Bat key, you can
press Bat key again to return to the default main page.
+ and - key are also used to increase or decrease the current value when a menu item is set.
For this purpose, first press key and the parameter value will flash. Then press + key to
increase the current value, or press - key to decrease it. Then press key to save the
desired value.

5.5.1 System menu


On the main page, press + key or - key and the system-related parameters will be
displayed as follows ( + Key for regular order and - key for reverse order),

1) Ambient Temperature(℃)
Cabinet Temp
If the ambient temperature detection line has not
Not Avail.
been connected,the “Not Avail.” will come up.

2) Single phase AC Voltage 1ph AC Volt


224 V

3) Single phase AC Current 1ph AC Curr


0A

4) Output Overvoltage Alarm Value Volts Hi Alm


59.0V

5) Output Undervoltage Alarm Value Volts Lo Alm


49.0V

5-4
System operation and parameter setting

6) Module current-limiting Minimum Value. This SMR CL Min value


item is set to ensure the minimum output current 30A
value when current-limiting takes place
automatically in a module. If the current-limiting
value figured out by the CSU is smaller than the
set value, the actual output current value of the
module will be equal to the set value. This is
performed to prevent misled deep current-limiting
and further system shutdown caused by the
damage of the Hall detection. If the output current
value of each module is smaller than this set value
under normal operation, the set value will have no
protection function during current-limiting.
Therefore, the set value should be based on the
actual load.

7) Password Setting.
Set Password
Press ENTER

8) Version Information Display. Press Enter key for


Lamp Test
software version information.
Press ENTER

9) RS-232 Communication Interface Baud Rate,


Baudrate
The default value is 9600 for this system.
9600

10) System standby Press “ENTER” key for


System
choosing UPS or standby.When the set value is
UPS
standby,the module won’t send alarm with on
load,but will be displayed this message. The
default value is “UPS” for this system.

11) Quantity of rectification modules in the system.


No.of SMRs
The value of this item must be entered; otherwise,
12
some rectification modules will be displayed as “no
response”. The default value is 12 for this system.

12) Select the hardware interface (interface board)


Interface
through which the system connects to the monitor
MUIB
modules. In accordance with different softwares,
options are available between the MUIB interface
board and MUIB2 interface board. The former is
selected for this system.

13) Quantity of the battery packs in the


Num Batt
system .The default value is 1 for this system.
1

5-5
System operation and parameter setting
14) Rated full scale rated value of battery current
FS Batt I
sensor, depending upon the rated value of Hall
480A
sensor. For example, if the rated value of a Hall
sensor is 600A/4V, the set value on the screen will
be 600. The rated value of Hall sensor can be set
based on a full range of 4V.
For example: if the rated value is 600A/5V, the set
value on the screen should be 480(600*4/5).

15) SMR no load alarm setting.


SMR No Load Alm
Off

16) Hall sensor test setting.


Hall Test
Off

17) A local address code with up to 7 bytes.


Access Code
If protocol transform board is used, the value
0000001
should be set “0000001”, otherwise”000000”.

18) Date format. Date format can be modified to


Date Format
DD/MM/YYYY, MM/DD/YYYY or YY/MM/DD.
YYYY /MM/ DD
(YYYY for year, MM for month, DD for date)

19) Clock setting. Monitor module clocks are set to


Date 2006/04/01
a specific date and time. Note: YYYY /DD/MM,
Time 00:21:58
hour, minute and second.

20) Alarm callback. Can be set to “On” mode and


Alarm Report
“Off” mode. When an alarm takes place under
On
“On” mode, the system will dial the first number in
the lower part the time setting screen.
If Phone 1 has no response, the system will
Alarm Report
automatically switch to Phone 2; If Phone 2 is not
Off
picked up, the system will automatically switch to
Phone 3; If Phone 3 is still not answered, a new
turn will start from Phone 1.

21) Daily report. Can be set to “On” mode and


Daily Report
“Off” mode. Under “On” mode, the system will
On
automatically dial the telephone number in the
lower part the time setting screen and download
the status of all the operating parameters.
Daily Report
Off

Daily report time display.


Daily Time
15:15

5-6
System operation and parameter setting
22) To switch on the Modem. When the Modem is
Modem
“On”, the front panel will have a normal display;
Off
when the Modem is “Off”, the front panel can not
be operated. When the Modem is under “On”
mode, a series of initiating orders will be issued via
remote ports to initialize the Modem.

Modem
The following contents will be displayed only when
On
the Modem is “On”.

Phone number 1. The first number to be


Phone 1
announced in case of an alarm. A number
58635678
contains at most 20 digits. Numbers with more
than 10 digits will be displayed in two screens.

The right chart demonstrates the case in which the


Phone 1 Cont
remnant part of a number with more than 10 digits
8239
is displayed in next screen.

Phone number 2. If phone number 1 has no


Phone 2
response, Phone 2 will be dialled.
58635678

The right chart demonstrates the case in which the


Phone 2 Cont
remnant part of a number with more than 10 digits
8238
is displayed in next screen.

Phone number 3. If phone number 2 is not


Phone 3
answered, Phone 2 will be dialled.
58635678

The right chart demonstrates the case in which the


Phone 3 Cont
remnant part of a number with more than 10 digits
8237
is displayed in next screen. If an extension exists,
58635678 is displayed as the host number, 8237
as the extension number automatically answered.
Note: If a local PC needs to receive alarm report or daily report, it should be set to “On” mode,
and the Modem should be set to “Off” mode.
23) To switch on audio alarm function. Can be set
Audio Alarm
to “On”, “Off” and “timing” mode. Under “On” and
On
“timing” mode, any alarm will be sent in audio
signal. The alarm will last unlimitedly under “On”
mode, in contrast with 2 minutes under “timing”
mode. An audio alarm will be suspended by the
Enter key, which is pressed to view the alarming
message. However, a new alarm can give rise to
the sound again.

24) To switch on the audio alarm function. Can be


Audio Alarm
set to “On”, “Off” and “timeout” mode. Under “On”
On
mode, any alarm will be sent in continuous audio
signal which can be stopped by pressing Enter
key.

5-7
System operation and parameter setting
“Off” mode, under which the alarm sound can be
Audio Alarm
silenced.
Off

“Timeout” mode, under which the alarm sound will


Audio Alarm
last 2 minutes. The default value is “Timeout” for
this system. Timeout

25) SPD Mode. This input can be set to


SPD Mode
“Used-N/O”, “Used-N/C” or “Not Used” Mode. If
Used-N/O
the brand of SPD is DELTA, set “Used-N/O “, and
set “Used-N/C” with brand of DOWIN.

26) Input interlocking contact for battery circuit


Bat Sw Input
breaker. It can be set to “Used-N/O”, “Used-N/C”
Not Used
or “Not Used” Mode. “Not Used” mode is set for
this system.

27) Input interlocking contact for low-voltage


division switch of battery. It can be set to
“Used-N/O”, “Used-N/C” or “Not Used” Mode. In
this system “Used-N/O” mode is set for the
normally-open contacts (when the contactor is not BLVD Input
energized) of the CSU sampling contactor. For the Used-N/O
normally-closed contacts (When the contactor is
not energized) of the sampling contactor, this item
should be set to “Used-N/C”.

28) Input interlocking contact for low-voltage


division switch of load. It can be set to “Used-N/O”, LLVD Input
“Used-N/C” or “Not Used” Mode. In this system Used-N/O
“Used-N/O” mode is set for the normally-open
contacts (when the contactor is not energized) of
the CSU sampling contactor. For the
normally-closed contacts (When the contactor is
not energized) of the sampling contactor, this item
should be set to “Used-N/C”.

29) Module grouping setting. When the SMRs are


Bank Setup
distributed on different positions in a system, the
Press ENTER
SMRs on continuous positions will be divided into
one group, and the vacant positions will be set as
a group. For example, if the system has altogether
2 SMRs on Position 1 and 3, then:

29-1) The last module number of the first group


Last SMR Bk1
will be 1;
1

29-2) The last module number of the second group


Last SMR Bk2
will be 2;
2

5-8
System operation and parameter setting
29-3) The last module number of the third group
Last SMR Bk3
will be 3;
3

29-4) The last module number of the fourth group


Last SMR Bk4
will be NotAvailable;
NotAvailable

30) Module Group 1 and Group 3 are set open,and


will alarm. Group 2 is set closed and will not Bank 1
alarm,Module Group 4 will not display again. A On
maximum of 4 groups is allowed. Module group 1.

Module Group 2 Bank 2


Off

Module Group 3 Bank 3


On

31) Auxiliary unit setting. As is shown in the right


Aux. Units
chart, auxiliary functions can be set by pressing
Press ENTER
Enter key.

32) Setting of the single-phase AC detection


1-ph AC Mon
switch (set to “On” mode in this system)
Press ENTER

32-1) Setting of the ingle-phase AC detection


1-ph AC Mon
switch (including mode “On” and mode “Off”)
On/Off

32-2) Alarm value for the single-phase AC high


1ph AC Vhi Alm
voltage, over which an alarm will be sent
260V

32-3) Alarm value for the single-phase AC low


1ph AC Vlo Alm
voltage, under which an alarm will be sent
200V

32-4) Single-phase AC full scale current


1p AC FS Cur
(unnecessary to be set in this system)
100A

33) Setting of the 3-phase AC detection switch (set


3-ph AC Mon
to “Off” mode in this system).
Off

34) Setting of the 3-phase AC detection #2 switch 3ph AC #2 Mon


Off

35) Setting of the battery detection board


Batt Monitor
(Unnecessary to be set in this system)
Off

5-9
System operation and parameter setting
36) Setting of the DC shunt detection #1 DC
Site Monitor#1
detection board, unnecessary to be set in this
Off
system.

37) Setting of the DC shunt detection #2 DC Site Monitor#2


detection board, unnecessary to be set in this Off
system.

38) Setting of the DC shunt detection #3 DC Site Monitor#3


detection board, unnecessary to be set in this Off
system.

39) Setting of the DC shunt detection #4 DC Site Monitor#4


detection board, unnecessary to be set in this Off
system.

5.5.2 Rectification module menu


Press the SMR key on the front panel of the monitor module to refer to all information related to
each rectification module. At any time, you can return to the main page of the monitor module by
pressing SMR key. If you want to access the rectification module menu again, press SMR key for
another time.

Communication failure will be presented on the


display if a rectification module has not been
connected to the system in a proper way, or the SMR 1
module switch is closed, or the module is No Response
inoperable.

Warning: In order to avoid false alarm, it is critical to input the exact number of the rectification
modules through the main page menus of the monitor modules
Note: The output current value is displayed in the lower part of the screen.
1) Press + key to display the output current of
SMR 2
the other modules. 21A

2) Float charging voltage. This parameter is


SMR Float
indirectly set in the battery menu, so it can not
54.0V
be modified in this screen.

3)
If you press key in the previous screen, SMR Float
the following information will come up.
NotAdjustable

4) Just as float charging, equalized charging


SMR Equalize
voltage parameters are also indirectly set from
56.4V
the battery menu and can not be modified in
this screen.

5)
If you press key in the previous screen, SMR Equalize
the following information will come up.
NotAdjustable

5-10
System operation and parameter setting

5.5.2.1 Screen of the editable parameters in the rectification module menu

Press key to modify the setting of the following parameters related to the rectification
modules (as shown in the screen). For the purpose of change, press + key or - key to
increase or decrease the set value. Press key to save the desired value.

1) High-voltage shutdown of the Rectification


SMR HVSD
module (HVSD),The default value is 59.6V in
59.6V
this system.

2) SMR current limit.


SMR I Limit
It means the rated value of output current for
50A
SMR.

3) High-voltage Shutdown Reset. A module may


HVSD Reset
be closed by a high-voltage shutdown order
Press ENTER
issued by the CSU. After the system voltage
recovers to the normal level, press key
and the undamaged module will undergo a
high-level shutdown reset and restart.

Note: Any parameter reset is valid among all the rectification modules.

5.5.3 Battery menu

Press the Bat key combination on the front panel of the monitor module to refer to all the
battery-related parameters. Press Bat key combination and you can return to the monitor module
main page at any time. Just as the other menus, an editable parameter can be increased or
decreased by + key and - key. Attempt to change an unmodifiable parameter will give rise
to a screen of “Not Adjustable”.
Press + key and the following screens will come up in sequence,
1) Current of Battery 1
Battery 1
12A

Current of Battery 2 Battery 2


12A

2) Battery temperature (if the battery temperature


Bat Temp
detection line has been connected). The
23 C
battery temperature is measured by
centigrade. The detection line should be
placed on the point with a higher temperature.

If the battery temperature detection line has


Bat Temp
not been connected and at the same time, the
Tmp Sen Fail
temperature sensor alarm switch is open, the
screen of “sensor failure” will come up.

5-11
System operation and parameter setting
3) The residual capacity of Battery 1. This screen
QEst Bat1
indicates the residual capacity of Battery 1.
500Ah

4) The residual capacity of Battery 2. This screen QEst Bat2


indicates the residual capacity of Battery 2. 500Ah

5) Battery discharging alarm value. With this


function, an alarm will be signalled when the
voltage of a discharging battery drops to a set Batt Dis Alm
value. The default value is 47.0V in this 47.0V
system.

5) Rated value of the battery (Ah). The rated A/H


value must be input in this screen. (depending Batt Rating
on the specifications of the battery) The default 500 Ah
value is 500 Ah in this system.

6) Battery string discharge current difference


alarm. Disch I Diff
This menu will not available until no. of 1%BatRate
batterys is more than 2 strings.

7) Battery temperature compensation function,


Bat Tmp Comp
set to “Off” mode in this system.
Off

8)
Press key to modify the mode to “On”, Bat Tmp Comp
and the battery temperature compensation
On
function will be activated.
(The formula to calculate the temperature
compensation value is as follows:
compensation value =(battery
temperature-compensation reference
temperature)*quantity of battery*BTC)

9) When the battery temperature compensation


BTC Coeff.
function is activated, the battery temperature
0 mV/C/_C
coefficient (BTC) (mV/℃)of each battery has
an allowed range of -0.1~-6 mV/C/_C. If the
current value is below 0.1, the screen will
indicate the “Off” mode.

10) Compensation reference temperature. This


BTC Nominal
screen will come up only when the battery
20 C
temperature compensation function is
activated. The temperature range is set from
18°C to 27°C.
Note: The compensation range is from 10°C to
35°C. The default value is 20°Cin this system.

11) Quantity of battery in the battery pack. This Number Cells


function is used to calculate and set 24
temperature compensation value based on the

5-12
System operation and parameter setting
actual quantity of battery in the battery pack.
The default value is 24 in this system.

12) Battery overheat alarm value. This item can be


Batt T Alrm
modified and adjusted by pressing + Key, -
40 C
Key and key, just as the
above-mentioned method. The default value is
40°C in this system.

13) Battery deeply discharging current-limiting


BILim Vb<Vdd
value.The limited value is the current when the
10% BatRate
voltage is lower than the deeply discharge
voltage.
The default value is 10% in this system.

14) Battery deeply discharging voltage threshold. Vdd Level


46.0V

15) Battery float current-limiting value.The limited


BILim Vb<Vdfl
value is higher than the deeply discharge
10% BatRate
current of battery uaually.
The default value is 10% in this system.

Notes:

a) The compensation function will fail if no temperature sensor has been connected to the system,
or the temperature compensation is set to 0. Under such circumstances, instead of FLC or
EQC, FL or EQ will be displayed as the status information on the monitor module main page.
b) If the battery temperature sensor has not been connected to the system, the measured value
provided by the ambient temperature sensor will be taken as the reference for the
compensation temperature.
c) If both the ambient and battery temperature sensor have been connected, the compensation
value is subject to the value provided by the battery temperature sensor.
d) If the temperature compensation function is activated, the voltage of the rectification module
will be automatically adjusted through the monitor module.

17) System float charging voltage. This parameter


Sys Float
specifies the system output voltage at the
54.0 V
output bus terminal.
The default value is 54.0V in this system.

18) Activate/deactivate the equalized charging


function. If the equalized charging function is Equalization
deactivated, the following screens will not On
come up.
The default value is ON in this system.

19) Battery equalized current-limiting value.The


limited value is the current when the voltage is
BILim Vb>Vfl
higher than the floated voltage. The default
10%
value is 10% in this system.

5-13
System operation and parameter setting
20) Equalized charging voltage. This setting can
Sys Equalize
achieve the maximum voltage during equalized
56.4V
charging of the battery.
The default value is 56.4V in this system.

21) The voltage start equalized charging function


V Eq Trig
is deactivated.
Off

22) The voltage start equalized charging function


V Start Eq
is deactivated.
Off

23) In the process of battery discharging,


V Eq Trig
equalized charging will take place when the
46.5 V
voltage drops to this set value.

24) The capacity start equalized function is


deactivated. The default value is ON in this Q Start Eq
system. On

25) The capacity start equalized function is


Q Start Eq
activated. Whether to start the equalized
On
charging or not depends on the quantity of
electricity the battery has provided for the
load.(measured by A/H)

26) Capacity setting of the battery which triggers


Q Loss Trig
equalized discharging. the calculate formular:
150Ah
equalized charge start capacity =30%*battery
rating capacity.When the discharging capacity
reaches the set value, equalized charging will
be automatically started. The default value is
500AH*30%=150Ah.

27) Equalized charging will be terminated if the


EQ End Curr
battery current is smaller than the set value.
5A
The default value is 5A.

28) If equalized charging is terminated


EQ End Curr
automatically, the set value here will decrease
Off
to under 5% of the rated A/H value of the
battery, and the status display is closed. “Off”
mode will deactivate this function.

29) When hitting the time limit here, equalized


EQ Duration
charging will terminate. If equalized charging
20 hours
termination depends exclusively on the
measured value derived from the A/H
discharging method, then this value should be
set to its maximum value, that is, 48 hours.
The default value is 20 hours.

5-14
System operation and parameter setting
30) To set the time interval of equalized
EQ Period
charging.The default value is 12 weeks.
12 week

31) The control page to manually terminate


Man Stop EQ
equalized charging (i.e.manual switch to float
Press ENTER
charging). When this display comes up,
equalized charging can be terminated
manually by pressing key. This display
only comes up under the equalized charging
mode. Equalized charging termination
depends on the equalized charging termination
current and equalized charging termination
time limit. Under given condition, either of them
may terminate equalized charging.

32) The control page to manually switch to


Man Start EQ
equalized charging. When this display comes
Press ENTER
up, equalized charging can be started
manually by pressing key. This display
only comes up under the float charging mode.
To switch to the equalized charging mode
manually, the equalized termination current
value should be modified against the equalized
charging termination condition, and then
equalized charging can be started manually.

33) When the battery discharges to a voltage lower


BLVD Trip
than the safe value set here in the wake of a
43.2V
long time AC interrupt, the low-voltage division
switch (LBDS) will act to completely divide the
battery from the load. The default value is 43.2
V.

34) Mode setting of the low-voltage division switch


BLVD Mode
(BLVD) of the battery. Under “Auto” mode,
Auto
when voltage drops to the set switch
disconnection value, BLVD will trip
automatically. After AC input recovers, the
system output voltage will climb due to the
operation of the rectification module, and then
the BLVD will close automatically. The default
value is Auto.

35)
Press key to operate the BLVD BLVD Mode
manually. Then press + key and - key, Closed
“Auto” and “Open” (or “Closed”) will flash
alternatively. Select “Open” and the switch will
be open; select “Closed” and the switch will be
closed. If it is desired to return to automatic
control, roll to “Auto” mode as above
mentioned.

5-15
System operation and parameter setting
36) Roll to the desired control mode and press
BLVD Mode
key to confirm. Open

37) When the battery discharges to a voltage lower


than the set safe value here in the wake of a
long time AC interrupt, the low-voltage division LLVD Trip
switch (LLVD) will act to divide a part of the 44.0V
load from the battery. The default value is 44.0
V.

38) Mode setting of the load LLVD. Under “Auto”


LLVD Mode
mode, when voltage drops to the set switch
Auto
disconnection value, LLVD will trip
automatically. The default value is Auto.
After AC input recovers, the system output
voltage will climb due to the operation of the
rectification module, and then the LLVD will
close automatically.

39)
Press key to operate the LLVD LLVD Mode
manually. Then press + and - , “Auto” and Closed
“Open” (or “Closed”) will flash alternatively.
Select “Open” and the switch will be open;
select “Closed” and the switch will be closed. If
it is desired to return to automatic control, roll
to “Auto” mode as above mentioned.

40) Roll to the desired control mode and press


LLVD Mode
key to confirm. Open

41) Under “On” mode, an alarm will be sent when


Temp Sen Alm
the battery temperature sensor is disconnected
Off
or damaged; Under “Off” mode, no alarm will
be sent. If the system contains no battery
temperature sensor, this item should be set to
“Off” mode.This item is set to “Off” mode.

5.5.3.1 Battery discharging test (to be performed in conjunction with hardware change)

As one of the functions of the monitor module, the battery discharging test can be performed on a
cycle and controlled battery discharging supply load. Though this test, the battery is discharged to
show its load-bearing capability.
To find the parameters of the battery discharging test function, access the battery menu and press
- key to show the following display,
1) During battery discharging test, the information
50A 49.2V
“Running BDT” will come up on the display. In
Running BDT
the monitor module, battery discharging, low
voltage, rectification module low voltage, and
low load alarm will be suppressed. However,
rectification module alarm will be displayed in
the rectification module.

5-16
System operation and parameter setting
2) The interval (measured by day) between
consecutive tests ranges from 0 to 365. When BDT Period
the set value is 0, the automatic operation 90 Day
function of the test will be deactivated (The
display will show “Off” mode) .This test can
also be started by the PC with remote
monitoring software. The previous menu only
comes up when the test function is activated.

3) Starting time of the test. In the program it is set


BDT Time
to the hour-minute format (24-hour format for 1
02:00
day).For example:The starting time of the test
is set at 02:00.

4) Battery discharging test duration. In the


program it is set to the hour-minute format
(from 5 minutes to 24 hours).The adjustment BDT Duration
range is 5 minutes. If the battery discharging 3:00
test duration is set to 3 hours,this test will be
end at 20:35.

5) The discharging current of the battery. It is


BDT Current
controlled by the monitor module within a
Curr = Load
setting range from 0A to 500A. In order to
ensure the proper operation of this function,
the load provided by the system during the test
should be at least bigger than 10% of the
desired value of the battery discharging
current. The monitor module will employ the
rectification module to bear the extra load, i.e.,
other user-defined load current provided by the
battery. If this parameter is set to 0, the control
function will be deactivated and the battery will
discharge under the load current.

6) Test termination voltage. If the battery voltage


BDT End V
drops to under this set value before the
46.0V
desired test duration expire, the test will be
automatically terminated. The monitor module
can recover the normal operation parameters
and recharge the battery. The test result will
display as “Failed”. The range of the set
voltage is subject to the system voltage.
Note: The set voltage should not be lower than
LLVD trip voltage; otherwise, the LLVD will trip.

7) The maximum capacity of the battery. The


BDT End Q
operation principle is the same as described
300Ah
above. The set range is from 25Ah to 9995Ah.
This item is set to 300AH.

8) To reset the test failure alarm. If the previous


BDT Fail Alarm
test failure is not reset, this information will
ENTER Reset
come up. Press key to ignore and

5-17
System operation and parameter setting
eliminate this alarm. This alarm can also be
reset through the operation of remote monitor
software.

9) To manually suspend the battery discharging


Running BDT
test. This display will not come up until the
ENT to Abort
battery discharging test starts.

5.5.3.2 Result of last battery discharging test

Below is the interpretation for the symbols of last battery discharging test that are stored in the
display,
1) Not available, no operation test.
Last BDT
Not Avail.

2) This display will come up in the following


Last BDT
scenario: during the test, the set value of the
Passed
discharging test duration is attained, and at the
same time, the set value of the “discharging
test termination voltage” or “discharging test
termination capacity” are not attained.

3) This display will come up in the following


Last BDT
scenario: during the test, the set value of the
Failed
discharging test duration is not attained, and at
the same time, the set value of the
“discharging test termination voltage” or
“discharging test termination capacity” are
attained.

4) The battery discharging test is suspended,


Last BDT
because the AC detection board can detect no
AC Lost
AC voltage, or all rectification modules shut
down and give rise to an AC input failure
alarm.

5) If the discharging voltage of a battery in the


Last BDT
battery pack is under the set limit, an alarm will
Cell V Low
be sent. This function is available only when
the battery condition monitor module (BCM) is
connected to the system and remains active.
At this time the battery discharging test is
terminated.

6) The test is suspended because it is beyond the


Last BDT
control of the rectification module. No alarm
No Control
will be sent.

7) The test fails because the load is too low to


Last BDT
control the discharging current. No alarm will
Low Load
be sent.

5-18
System operation and parameter setting
8) The test fails because the load is too high and
Last BDT
the controlled discharging current can not be
SMR Overload
borne. This happens when all the rectification
modules display the current-limiting mode,
maybe because of the rectification module
failure during the test. No alarm will be sent.

9) To suspend the test manually through the


Last BDT
monitor module front panel or remote
User Aborted
monitoring software.

Press key in this display and you will access a submenu containing all the results of the
last test. (If they are operated during the last test.) The test results are saved in an internal
storage device EEPROM. The details are as follows,

10) The date of last test


Last BDT
2006/04/01

11) The duration of last test


Last BDT
Dur 1h18min

12) Battery voltage at the end of the test


Last BDT
EndV 49.2V

13) The estimated residual capacity at the end of


Last BDT
the test. n—number of battery packs
EndQn 380Ah

In case of any of the following scenarios, the test will suspend for 100 hours,
a) The controller is closed. (e.g. The operating system of the controller need to be reinstalled.)
b) Records of AC interrupt
c) Records of low Electrolyte (when the sensors are properly installed and corresponding
softwares are operated.)
Under such circumstances, if an automatic test is preset, the battery discharging test will be put
off.

5.5.4 Alarm records

All the recent alarms are saved in the storage device of the monitor module. They can be referred
to at any time by pressing the key combination for alarm records.

5-19
System operation and parameter setting

1) Press the key combination for alarm records,


LOG 1…100
and the display will show the name of the latest
LLVD Open
alarm information.
Then press + key immediately, and the 3rd
and 4th alarm will be displayed. Press it again
and the 5th and 6th alarm will be displayed, and
so on.

2) If the key remains untouched for more than 2


2006/04/01
seconds, the alarm information and date/time
display will come up alternatively in sequence. 10:05:16

3)
To clear the alarm records, simply press DEC to Clear
key in the alarm record menu and you will enter
Log Entries
the following display. Press - key to delete
the records.

The menu is void with all the records cleared.


LOG
No Entries

5-20
Local and remote monitoring

6. Local and remote monitoring


This system fulfills the operation over monitored objects by connecting monitored objects to
PC through telephone line or RS-232 line.

6.1 Connection method


System monitoring unit is connected to PC’s serial input communication interface through
RS-232 connecting line and communication is enabled at PC with system monitoring unit
through user interface software, thus realizing local monitoring.

If monitoring unit is connected to Modem, remote monitoring (RMS) can be achieved by


communicating with remote PC through telephone network.

6.1.1 Connection to single system through serial port

RS-232
Computer
串口
Serial port 近端口
Line length not more than 15m
CSU

6.1.2 Connection to single or multiple systems through serial port (to RS-485)
Note: Power systems cannot have the same office code settings.

RS-232 to 485 RS-485to 232 RS-232


Computer CSU
Serial port

RS-485 line length is decided


RS-485to 232 RS-232
by the characteristics of
RS-232 to RS-485 converter. CSU
Usually not more than 2000m.

6-1
Local and remote monitoring

6.1.3 Connection to single or multiple systems through modem

Telecom system
Modem Modem RS-232
Telephone line Telephone line CSU
Computer
Serial port

6-2
Rectifier module

7 Rectifier module
This series switch-mode rectifier (SMR) is special designed for telecom equipment, industrial
purpose, IT, and office automation use. Each rectifier gives out 50A of DC current when its DC
voltage is 48V. Modular design provides the flexibility to configure and expand the system as the
load demand increase. Each rectifier unit is swappable with front access for ease of maintenance
without system shutdown, providing uninterrupted power to the load.

The rectifier unit has an active power factor correction of greater than 0.99 for maximum AC
utilization. Each module is equipped with a breaker located at the front of the module for easy
maintenance and taking out for service.

7.1 Profile and structure


There are the measure hole of current value(I+、I-)、rectifier alarm LED、AC power LED(AC OK)
and DC power LED(DC OK). The exact positon is shown as figure 7-1. For safety purpose the
protect net has been installed on the air-vent of rectifier and the cooling fan can be changed right
on site.

Figure 7-1 The sketch map of SMR

7.2 Technical data


7.2.1 Single rectifier character
(1) Working frequency: about 100 kHz
(2) Output Power: 3000W
(3) Efficiency: ≥90.5%
(4) AC Input
a) frequency : 45Hz~65Hz
b) voltage: 220Vac(1-ph)
176Vac~275Vac (full power)
90Vac~175Vac (50% of full power)

c) Power factor: >0.99 (full power ,rated input)


(5) DC output
a) Voltage :
Rated Voltage: -48V
Float voltage: the float voltage range is -42Vdc ~ -58Vdc(adjustable) when
rated voltage is -48Vdc and the factory preset value is -54.0V;

7-1
Rectifier module
Equalize voltage: according to the battery manufacturer’s request and the
effective on site to set the equalize voltage value. Normally
like below:
Rated voltage is at -48Vdc, the equalize voltage range is -
50Vdc~-61Vdc(adjustable), and the factory preset value is
-56.4Vdc;
b) Current: 50A (while a single recitifier’s output is -48V)
(6) Variety range of output voltage
Load regulation: ≤±5%( load 0-100%)

Line regulation : ≤±0.1%( load 0-100%)

Voltage accuracy: ≤±0.6%


Temperature coefficient: ≤±0.02%(1/℃)
(7) Current limitation
Every rectifier have the self-protection function of current limitation, depending on
output voltage & ambient temperature.
(8) Inrush current: 21A peak (at cold start)
(9) Soft start: >3second when the input current starts to rise to the rated value (not
include the delay time before input current increasing),.
(10) Noise(the condistion is rated input voltage,100% load,output voltage 54.0V)
(a) Audio band: ≤ 24dBmc (CCITT)
(b) Wide band : ≤ 20mVrmc (3.4kHz~100MHz)
(c) Peak ripple: ≤ 100mV(0~20MHz)
(d) Discrete band: ≤ 5mV(3.4kHz~150kHz)
≤ 3mV(150kHz~200kHz)
≤ 2mV(200kHz~500kHz)
≤ 1mV(0.5MHz~30MHz)
(11) EMI(Electro-Magnetic Interference): confirm CISPR22 Class A
(12) Dynamic response: ≤±5%(rated output voltage,load change90%~10%~90%)
recovery time<1ms, recover to≦±1% of rated output voltage

7.2.2 Inner Protection


(1) Input over-voltage protection
The SMR will automatically shutdown if the AC input voltage is over an inner
setting value and will auto recover if the AC input voltage is back to normal.
(2) Input under-voltage protection
The SMR will automatically limit and reduce the output current if the AC input
voltage is under the normal voltage range and will automatically shutdown if the
voltage continuously drops under the inner setting protection value. SMR will
auto recover if the AC input voltage is back to normal.
(3) Output Over-Voltage protection
The SMR will automatically shutdown and locked if the DC output voltage is over
an inner setting value. It needs manually re-start.
(4) Output short circuit protection

7-2
Rectifier module

The SMR will automatically limit the curren if the load is over the rated value,
and will auto recover if the short circuit has overcome.
(5) Output current limitation and power limitation
The output current can be controlled by CSU if the output current less than the
rating value (58V output voltage).The SMR will remain 3000W constant power if
the output current over the rating value while the output voltage is over 48V. The
SMR will remain constant current if the output voltage less then the rateg value
48V.The output power of SMR will automatically adapt to output voltage and
ambient temperature to remain constant power.
(6) Over temperature protection
The SMR will automatically shutdown if the inside temperature (radiator) is over
an inner setting value. It needs manually re-start if the temperature back to
normal.
(7) Fan failure
The fan failure shall cause the SMR to shut down and create an appropriate alarm to the
CSU, and a RFA red LED will light on the front panel.
(8) Electrical protection
The SMR has fuse and MCB at the input, also equipped fuse at output.

7.2.3 Operation display


a. AC OK: Green LED
b. DC OK: Green LED
c. RFA Red LED
c. I+,I- measure hole of current value (the transform
formular:45A=>3V)

7.2.4 Working environment


(1) ambient temperature: -5℃~50℃(full power)
(2) storage: -40℃~+70℃
(3) relative humidity: 0~95% (no condense)
(4) altitude: -100m~3048m
(5) Cooling: forced fan cooled

7.2.5 Safety and isolation


(1) Safty: confirm IEC 60950, EN 60950, and passed
UL/CUL60950,TUV/CE certificate.
(2) EMI: confirm CISPR22 CLASS A
(3) EMS: confirm IEC61000-4-3, LEVEL3
(4) EFT: confirm IEC61000-4-4, LEVEL4
(5) Inrush Current: confirm IEC61000-4-5, LEVEL4
(6) ESD: confirm IEC61000-4-2, LEVEL4

7.2.6 Reliability: MTBF >150000hrs

7.2.7 Dimension and weight

7-3
Rectifier module
(1) Height: 84.4 mm
(2) Width: 138.2 mm
(3) Depth: 374.7 mm
(4) Weight: 5kg

7.3 Start-up recrifier


Start up should accord to follow steps:
(1) Turn the rated breaker of the SMR to “off” position, and push it into the shelf along the
slide rail and fasten it;
(2) Turn the switch to “on “, the “RFA”, ”AC OK” LED and ”DC OK” will light up about 1-2
seconds later and only ”AC OK” LED will “on” about another seconds later

7.4 Operation and adjustment


7.4.1 Adjust rectifier when it installed on system
When the rectifier run on the system normally(that means CSU remains‘ON’and display the
rectifier status correctly), the fload/equalize voltage and the current limit value controlled by CSU,
meantime CSU will supervise and display the output corrent、alarms and current limit status.

7.5 SMR operation status indicators


SMR operation status and alarms can be shown at the front panel though LEDs (refer to figure
7-1). If the system equipped with CSU, then each rectifier’s out current can be read from the
CSU’s LCD
SMR front panel display:
AC OK: Indicate the AC is OK.
DC OK: Indicate the DC is OK.
RFA: full name is”RECTIFIER FAIL ALARM”
The possibly fail of the SMR may be:
Output over-voltage
DC output fuse blowed
Inside temperature is too high
Over current
Short circuit
Fan’s failure
7.6 System alarm and troubleshooting
Details about the ‘system alarm and troubleshooting’ described in chapter10.6.
If the SMR failure, the ‘RFA’ LED on the panel will light, meanwhile the corresponding alarm
information will be displayed on the CSU before shutdown.

7.7 Block diagram and working principle


7.7.1 SMR Block diagram

7-4
Rectifier module

Surge
L porotection
Vo+
EMI filter, PFC DC/DC
Rectifying Boost Converter
converter EMI
N Filter Vo-

FG
PFC control DC/DC
and Control
protection

Auxiliary Protect ing


Power circuit

Figure 7-2 SMR block diagram


7.7.2 Working principle
This series SMR block diagram shows in figure 7-2, its working principle is as following:
Connect single phase AC (220V) to the SMR, it will enter the EMI filter when passing the AC
switch and fuse. The functionality of the EMI filter is to prevent surge voltage destroying and to
reduce the diversity noise and common noise, in order to eliminate the high frequency noise from
the AC and to prevent the SMR’s noise feed back to the AC line.

Single phase AC been converted to DC by the bridge, and through PFC Boost Converter(active)
and PFC control circuit to achieve a high power factor(PF >0.99) and low distortion factor (THD
<5%). It generates about 400V DC to the DC-DC converter and also provides power to all control
circuit inside the SMR, it is called Auxiliary power.

The 400V DC power will enter the DC-DC converter and come out a stable DC voltage. This circuit
using full bridge phase-shift switching, convert the 400 DC to AC pulse wave by applying a 100
kHz switching frequency; through high frequency transformer to deduce the value of the AC pause
wave to a desire level. The AC pause wave on the secondary side through the diode and output
filter, then feed back to DC control, to come out a stable DC output. The stable DC go through the
output fuse and output EMI filter to filtrate the common noise before connected to the DC bus bar.
For the best protection to the SMR and the system, a protection circuit is applied include output
over-voltage/ under voltage, output over current, over temperature, and short circuit protection.
Beside, different color LEDs is applied to show the SMR status, it also has interface to the CSU to
provide full information for the CSU for proper monitoring and control.

7-5
Control and supervisory unit

8. Control and supervisory unit


8.1 General
An intelligent system CSU, which monitors system I/O, rectification module and battery pack,
battery temperature, discharge, floating charge voltage of battery, temperature compensation,
abnormality, warning and indication. CSU has RS-232 interfaces, has the functions of remote
signaling, telemetering and remote control and meets the needs of being unattended and
centralized monitoring. It can be connected with PC to transmit information, operated with
Chinese windows and used together with printer to provide word information. It also has pager
alarm function and informs the user of main alarms so that the user can get the latest information
of system at any time.
There is a signal line between CSU and rectifier module. It gathers the alarm signal and current
value transmitted from rectification module and sends such commands as shutdown and floating
charge/equalized charging control to rectification module.

RS-232 port

Front view of CSU Back view of CSU

Figure 8-1 Views of CSU

8.2 Features and specifications


8.2.1 Input voltage
-40Vdc~-60Vdc
8.2.2 Display
1. 4-line, 16-character digital LCD display
2. 4 inching buttons
3. Equalized charging is indicated by yellow LED.
4. Red lamp means that system is shut down.
5. Green lamp means that system runs normally.
8.2.3 Monitoring Functions
(1) Monitored items
a. Module data

8-1
Control and supervisory unit
b. Battery data
c. System status
d. Temperature (battery)
e. Total load current
f. AC input voltage, DC output voltage
(2) Controlled items
a. High-voltage shutdown
b. Floating/equalized charging conversion
c. Temperature compensation
d. Voltage compensation switch/upper and lower limits
e. Current limit mode
8.2.4 Communication interfaces
There is a RS-232 interface (Local and Remote) on the rear of Control and Supervisory Unit,
which provide two “remote” functions. Local monitoring is enabled by connecting RS-232
connection line between PC and CSU. Remote monitoring is enabled by connecting modem and
terminal (via telephone line) or using the Internet (network) to monitor the system.This system is
support of YD/T 1104-2001 protocol .

8.2.5 Battery charge/discharge control


(1) Floating/equalized charging voltage can be adjusted.
(2) Charging and discharge capacities are automatically calculated.
(3) Equalized charging optional for power failure and power resumption.
(4) Charging and discharge current detection.
(5) Automatic or manual equalized charging
(6) Temperature compensation for battery floating charging voltage optional
(7) Cyclic equalized charging optional

8.2.6 Low-voltage isolating switch


The system provides the low-voltage isolation protection function for battery and load:
Manual/automatic switch-off
Tripping/switch-on voltage adjustment
Switch-off of monitor module control
Alarm signal

8-2
DC distribution

9 DC distributions

9.1 Distribution voltage


The current system voltage is -48V.

9.2 Low voltage disconnection switch for battery BLVD and load LLVD
Low voltage disconnection switch has the function to protect the battery from deep discharge.
For deep discharge of battery avoiding, there is the battery/load LVDS installed separately on the
output port of battery and big capacity load shunt. The big capacity load will be cut off from the
system if the battery keep discharge and the voltage drop to the setting value of LLVD OPEN
because AC fail for a long time, the battery offer power only for the small capacity load, if the
voltage of BLVD OPEN continue dropping and to the setting value, the battery string will be cut off
from the system and meanwhile disconnected all the load and will reconnect automatically when
the AC power get retrieved.

9.3 Battery wire connection


Pay attention to the polarity of the battery and the system plus /minus bus bar when connecting
the battery. This system is a -48V system, so the plus terminal should connect to system “+” bus
bar and minus terminal should connect to system battery fuse.

9.4 Temperature sensor


(1) The battery temperature sensors is inside the packing.
(2) Connect those sensors to the connecting board.
(3) fixup the copper head of the sensor on the Rack.

9.5 Connecting board

9.5.1 Function
1. Collect the load and battery current signal to amplify and read it, then sent all the data
to CSU.
2. Detecting the fuse, fuse alarm will display on the CSU if the fuse blows up.
3. Detecting battery temperature, and feed back to CSU.
4. Detecting DC output voltage, and feed back to CSU.
5. Communicate with CSU to let the CSU to control LVDS trip/ recover.
6. System Relay alarms output

9-1
DC distribution
9.5.2 Definition of the pins of the signal transfer board
CN1 Power input
CN2 Alarm dry-contact output
CN3 BLVD connected to the battery
CN4 Sampling to the single phase AC voltage
CN5 Reserved
CN6 1# battery current detecting
CN7 Reserved
CN11 LLVD connected to the load
CN18 Battery temperature sensor
CN33 BLVD status of the battery
CN34 SPD alarm
CN44 Fuse alarm
CN45 LLVD status of the load

9-2
System Alarms And Troubleshooting

10 System Alarms And Troubleshooting


10.1 AC Input Failure Alarm
10.1.1 AC off-line, over voltage/under voltage alarm
(1) AC off-line: AC off -line alarm. Battery will be in discharge status.
Alarm will be off when AC comes back
(2) over voltage: It will alarms when input AC voltage is higher than “AC
voltage too high alarm” setting value and will goes off
when voltage drops to normal.
(3) under voltage: It will alarms when input AC voltage is lower than “AC
voltage too low alarm” setting value and will goes off
when voltage increase to normal.

10.1.2 AC off-line troubleshooting


(1) All rectifiers will stop working; CSU will be powered by battery. Pay attention to battery
discharge current and start the generator.
(2) When AC back, pay attention to battery charging current, keep the charging current in
a safe range and limit the charging current if necessary.

10.1.3 AC over voltage/under voltage failure elimination


(1) Check the AC voltage display value in the CSU and keep the system running if the
display voltage is within the specified range and let the maintenance people to handle
it.
(2) Turn the rectifier AC input switch to “off” if the voltage is higher than specified value to
protect the rectifier; turn rectifier AC switch “on” when voltage is back to normal.

10.2 Output Voltage Alarm


10.2.1 DC over voltage/under voltage alarm
(1) DC over voltage: It will alarms when output DC voltage is higher than “DC
voltage too high alarm” setting value and will goes off
when voltage drops to normal.
(2) DC under voltage: It will alarms when output DC voltage is lower than “DC
voltage too low alarm” setting value and will goes off
when voltage increase to normal.

When “DC voltage too low” alarms, pat attention to battery discharging to
protect the battery been damaged from deep discharging.
Caution

10.2.2 DC over voltage/under voltage troubleshooting


Tell the maintenance to handle it

10.3 Fuse Blows Up Alarm


10.3.1 Fuse detect board

10-1
System alarms and troubleshooting
CSU will alarm when any of battery fuse or distribution fuse is blow up. Press the alarm key to
check the details alarm, then to check the red LED on fuse detect board, if the LED lights, the
fuse fail(check the voltage on the fuse by electricity meter). The alarm will disappear when
fuse is replaced.

1. Should find out the reason causes the fuse blow. Can not just replace the
fuse blindly.
2. The fuse should be the same with the original specification.
Caution

10.3.2 Fuse blow up troubleshooting


(1) Check the load in this distribution route whether is too high or short circuit;
let load in this route within the range capacity.
(2) Disconnect the load in this route; replace it with the same specification fuse.
(3) Re-connect the load switch and tell the maintenance people to handle it if the fuse
blows up again

Disconnect the load from this route before replace the fuse and
reconnect the load after the fuse is replaced , otherwise the fuse
Caution connecting point is easy to damage.

10.4 Over Temperature Alarm


10.4.1 Battery over temperature alarm

CSU will alarm when battery temperature is higher than “battery temperature” setting value to
notice the maintenance people to handle it. The alarm will goes off when temperature is back
to normal

10.4.2 Battery over temperature troubleshooting


(1) Confirm whether the temperature is too high
(2) Check the charging current, to convert the charging mode from equalize to float if the
charging current is too high and check whether the current drops after the change
(3) Adjust the current limitation value to reduce the charging current if the charging
current is still too high
(4) Tell the maintenance people to handle it

10.5 Microprocessor Failure Alarm


10.5.1 Bad situation

When microprocessor in the CSU is out of function or the CSU fuse is blow, 198×128-lattice
LCD is out of function, the CSU will not function any more and all the text or LED alarms will not
show up.

10.5.2 Troubleshooting
(1) Check the CSU DC connecting terminal is loose or not;
(2) check the CSU fuse is abnormally blow up or not

10-2
System Alarms And Troubleshooting

(3) If yes, then replace a new one after find out the reason
(4) Tell the maintenance people if the CSU is still can not be recovered

10.6 Rectifier Failure Alarm


10.6.1 Rectifier alarm

When any of rectifiers in the system fail, the CSU will received a signal from this rectifier and
display the corresponding alarm information meanwhile the alarm LED will light.

10.6.2 Rectifier troubleshooting


(1) Check the fan failed or not (not working when other fans keep rotated), under a fan fail
condition the ‘RFA’ LED will light, to turn-off the AC power switch and restart rectifier,
check the ‘RFA’ LED light or not, if it doesn’t light, then replace a new one.
(2) If the failure is still there, then turn off this rectifier and withdraw this module from the
system and contact maintenance person.

10.7 SPD Failure Alarm


10.7.1 SPD failure alarm

The CSU will display the alarm information on condition that SPD in the system fails, or
monitor circuit fails, or establishment is unsuitable.

10.7.2 SPD troubleshooting


(1) Check the SPD failed or not, for failure condition the module failure window will display
red ,or replacing a new module for judgment.
(2) Check the connection of dry connect is correct or not, and the plug in interface board is
loose or not.
(3) Check the state of SPD dry connect is in accord with the establishment of panel or not.

10-3
System Maintenance

11. System Maintenance


11.1 Cleaning And Maintenance
11.1.1 General

The system can keep operating for a long term, special maintenance is not necessary for this
system.

The front panels and the cover of the DC distribution cabinet were treated with a special coating.
Do not use organic cleanser or volatile solvent because corrosion damage may occur. For
periodic cleaning, brush the dust from the cover and panel. If necessary, use a gentle
cleaner(soap) or clean water to remove any dirt or smudges (do not use spy, or with too wetly
cloth to prevent the water leak into the system to cause a short circuit).

11.1.2 Periodic maintenance


Visually check whether the DC distribution connecting terminal is color changed or not because of
the high temperature every two weeks (better check the temperature with proper thermometer).

11.2 Removing and Replacing a Rectifier module


11.2.1 Removing a Rectifier

(1) turn off the breaker of the SMR module

(2) check the status in the CSU for this module, it should shows “turn off”

(3) lose the screws which is locked the rectifier and pull it out.

(4) hold the handle and the other hand hold the other end of the rectifier slowly pull it out
from the shelf totally.

(5) check the CSU again, it will show this rectifier has been shutdown and take out.

11.2.2 Replacing a Rectifier

(1) turn off the breaker of the SMR module which is going to replace the other

(2) hold the handle and the other hand hold the other end of the rectifier, make sure the
rectifier is in the slot of the shelf, and slowly push the rectifier in with a steady speed.

(3) fasten the screws at the bottom of the rectifier to lock the SMR module

(4) turn on the AC Switch of the SMR module

It is best to adjust the rectifier before insert it in


Caution

(5) Check the CSU data if this rectifier is working properly and load sharing is in normal
condition

(6) Check the CSU data if this rectifier is joined in the operation

11-1
System Maintenance

11.3 Rectifier Fan Replacement


The fan life time may be reduced because of long time running. Replace the fan immediately if
there is a fan failure or abnormality situation occurred in order to keep the high performance.

The fan with the sticker should be face inside when replace the fan, can not be
Caution
wrong way

(1) Turn the rectifier (with failure fan) breaker to “off”

(2) Take the rectifier out of the shelf according to rectifier withdraw steps

(3) Loose the 4 screws which are located in the SMR front side for fixing the side panel.

(4) Take the side panel for fixing the fan out and replace the fan.

(5) Fasten the screws in order.

(6) Push back the rectifier into the shelf according to rectifier replacing steps. The fan
replacement is ceased.

11-2
Accessory1

MCS48/600-TLUA5 系统查检表/System Check List


交流电源查检表/AC Source Check List
项目/ Item 1st Rev Date Sign 2nd Rev Date Sign
N 不要虚接/ N Connect Well
G 不要虚接/ G Connect Well
N 与 G 连接正确/ N&G Connect Right
A-N 电压 220Vac / A- N 220Vac
B-N 电压 220Vac / B- N 220Vac
C-N 电压 220Vac / C- N 220Vac

电源系统参数设置表/Power System Parameter List


项目/ Item Factory Setting 1st Rev Date Sign 2nd Rev Date Sign
模块数量/ No. of SMRs
电池低压放电告警/ Batt Dis Alm 47.0V
电池总容量/ Batt Rating
系统浮充电压设定/ Sys Float 54.0V
系统均充电压设定/ Sys Equalize 56.4V
均充功能设定/ Equalization On
容量启动均充/ Q Start Eq On
BLVD 跳脱电压/ BLVD Trip 43.2V
LLVD 跳脱电压/ LLVD Trip 44.0V

1.模块台数,现场需要设定为实际使用的台数.
“No. of SMRs” should be set to the number of SMR in use when system power on.
Caution 2.电池组容量需设定为系统所接的电池的容量.
“Batt Rating” should be set to battery capacity that connected to the system.
Accessory 2
Accessory 2
Range of Parameter setting for MCS48/600-TLUA5(rev:01)
Parameter setting in CSU is shown as below:
Default
Parameter Description Range
Value
System Menu

Volts Hi Alm System output volts high threshold 58~60V 59.0V

Volts Lo Alm System output volts low threshold 35~55.4V 49.0V

SMR CL Min value Least value of SMR current limit 4~55A 30A

Baudrate Baudrate setting 1200;2400;4800;9600 9600

System Select system duty type Standby/UPS UPS

No. of SMRs Set number of SMRs in the system 0~15 12

Interface Panel type MUIB2/ MUIB MUIB

Num Bat Number of battery strings installed 1~2 1

Battery current transducer full scale


FS Batt I 10~2000A 480A
rating

SMR No Load Alm SMR no load alarm setting On/Off Off

Hall Test hall sensor test setting On/Off Off

Access Code CSU Access code (up to 7 digits) 0~9999999 0000001

Audio Alarm Alarm mode On/Off/Time out Timeout

Used-N/C; Used-N/O; (DELTA)Used-N/O


SPD Mode SPD alarm Mode
Not Used (DOWIN)Used-N/C

Input interlocking contact for battery Used-N/C; Used-N/O;


Bat Sw Input Not Used
circuit break Not Used

Input interlocking contact for Used-N/C; Used-N/O;


BLVD Input Used-N/O
low-voltage division switch of battery Not Used

Input interlocking contact for Used-N/C; Used-N/O;


LLVD Input Used-N/O
low-voltage division switch of load Not Used

Setting of the single-phase AC


1-ph AC Mon On/Off On
detection switch
Alarm value for the single-phase AC
1ph AC Vhi Alm 220~315V 260V
high voltage
Accessory 2
Alarm value for the single-phase AC
1ph AC Vlo Alm 140~270V 200V
low voltage

1p AC FS Cur Single-phase AC full scale current 10~600A 100A

Setting of the 3-phase AC detection


3-ph AC Mon On/Off Off
switch
Setting of the 3-phase AC detection #2
3ph AC #2 Mon On/Off Off
switch
Batt Monitor Setting of the battery detection board On/Off Off

Site Monitor#1 Setting of the DC shunt detection #1 On/Off Off

Site Monitor#2 Setting of the DC shunt detection #2 On/Off Off

Site Monitor#3 Setting of the DC shunt detection #3 On/Off Off

Site Monitor#4 Setting of the DC shunt detection #4 On/Off Off

SMR Menu

SMR HVSD SMR high volts shut down 58.6~66V 59.6V

SMR I Limit SMR current limit 4~55A 50A

Battery Menu

Batt Dis Alm Battery discharge alarm threshold 44~52V 47.0V

Batt Rating Ampere-hour rating of batteries 20~2000Ah 500Ah

Battery string discharge current


Disch I Diff 1~20%*BatRate 1% BatRate
difference alarm

Battery temperature compensated


Bat Tmp Comp On/Off Off
function setting

Battery temperature compensated


BTC Coeff. 0~-6 mV/C/-C Off
Coefficient

Battery temperature compensated


BTC Nominal 18~27℃ 20℃
benchmark

Number of chemical cells in battery


Number Cells 22~46 24
string

Battery over temperature alarm


Batt T Alrm 30~90℃ 40℃
threshold

Battery deeply discharging current


BILim Vb<Vdd 1~20%*BatRate 10% BatRate
limiting value for Vb < Vdd
Accessory 2
Battery deeply discharging voltage
Vdd Level 40~47V 46.0V
threshold

Battery charging current limit between


BILim Vb<Vfl 1~20%*BatRate 10% BatRate
Vdd and Vfl

Sys Float System float voltage (Vfl) 43.2~57.5V 54.0V

Equalization Enable/Disable EQ function On/Off On

Battery float charging current limit for


BILim Vb>Vfl 1~20%*BatRate 10% BatRate
Vdd < Vdfl

Sys Equalize System equalize voltage (Veq) 43.3~57.6V 56.4V

Enable/disable discharge voltage


V Start Eq On/Off Off
initiation of Eq

Discharge voltage threshold for Eq


V Eq Trig 44~50V 46.5V
charging

Q Start Eq Enable/disable battery charge trigger On/Off On

Charge depletion threshold for Eq


Q Loss Trig 30%*BatRate 150Ah
charging

Equalization termination for Ibat < EQ


EQ End Curr 1%*BatRate 5A
End

Maximum duration of Equalization


EQ Duration 3~48 hours 20 hours
charging

Time between periodic Equalization


EQ Period 0~52 week 12 week
charging

Man Start EQ/ Man Manual start/stop of Equalization


start/stop stop
Stop EQ charging

BLVD Mode Battery disconnected work mode Auto/Open/Closed Auto

Jump value for low-voltage division


BLVD Trip 35~55.3V 43.2V
switch of battery

Auto/Open/Closed/Hard
LLVD Mode Load disconnected work mode Auto
ware

Jump value for low-voltage division


LLVD Trip 35.1~55.3V 44.0V
switch of load

Temp Sen Alm Enable/Disable Temp. sensor failure On/Off Off


Accessory 2
alarm

Period between consecutive discharge


BDT Period 0~365 Day 90 Day
tests

BDT Time Time of day to begin BDT (hr:min) 00:00~23:59 02:00

BDT Duration Maximum duration of BDT 00:05~24:00 3:00

BDT Current Discharge test current 0~5000A 0(Curr=Load)

BDT End V Battery voltage limit to terminate BDT 36~48V 46.0V

BDT End Q Battery capacity limit to terminate BDT 25~9995Ah 300Ah


Delta-CIMIC Electronics Co., Ltd. YSHRPSC0224
No.238 Minxia Road Pudong New Area, Shanghai P.R.C.(201209)
Tel:021-58635678 Fax:021-58630003 Version: 02

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