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Manufacturing PN: AA27540L


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Quick Start Guide Page 1 of 157


Manual Number: 970-009475-0000
Manual Version: AE
Manual Status: Standard
Release Date: Dec 20, 2014

Copyright © 2014 Artesyn Embedded Technologies. All rights reserved.


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Published in China
This document, and the information it contains, are the property of Artesyn Embedded
Technologies Co. and are protected by law. Both must be held in strictest confidence at all times.
Artesyn Embedded Technologies grants no license or right to copy, use or disclose either,
expressly or by implication.

Disclaimer

This document and the information contained herein are provided on an “AS IS” basis. Artesyn
Embedded Technologies may make improvements or changes in this documentation, at any time
and without notice and as it sees fit. The information in this documentation was prepared by
Artesyn Embedded Technologies with reasonable care and is believed to be accurate. However,
Artesyn Embedded Technologies shall not assume responsibility for losses or damages resulting
from any omissions, inaccuracies, or errors contained herein.

Quick Start Guide Page 2 of 157


History

History

Date Version Author Change Note No./Notes


June 30, 2013 AA Ferdinand Release for FPRB
Sisracon
November 30, 2013 AB Ferdinand Update to add caution during installation
Sisracon and Rectifier alarm indications
June 30, 2014 AC Alex Ding Change the brand from Emerson
Network Power to Artesyn
Embedded Technologies
Dec 20, 2014 AE JM Xu Change the torque set up from 55-
60kgf.cm to 4Nm(Figure16)

Quick Start Guide Page 3 of 157


Table of Contents

Table of Contents

Installation Manual ................................................................................................ 1


Flexi Power Rectifier ............................................................................................. 1
FPRB ..................................................................................................................... 1
Chapter 1 Product Introduction ......................................................................... 14
1.1 General Description ............................................................................... 14
1.2 The Power Distribution Assembly (PDA) ............................................... 23
1.3 The Rectifier........................................................................................... 27
Chapter 2 Preparation ....................................................................................... 31
2.1 Safety Summary .................................................................................... 31
2.2 Installation Site....................................................................................... 33
2.3 Installation tools and test equipments.................................................... 34
2.4 Check list of the FPRB........................................................................... 35
Chapter 3 Hardware Installation........................................................................ 45
3.1 Preparation of PDA ................................................................................ 50
3.2 Configure the AC terminal block. ........................................................... 58
3.3 Insert the AC cable through the front panel. .......................................... 61
3.4 Make AC connection without the SPD................................................... 62
3.5 Secure the back cover. .......................................................................... 72
3.6 Insert the cables through the cable gland if required............................. 73
3.7 Route the DC cables.............................................................................. 75
3.8 Route the Communication cables .......................................................... 88
3.9 Connect the temperature cable. ............................................................ 89
3.10 Connect the parallel cable. .................................................................... 92
3.11 Connect the Alarm cable........................................................................ 94
3.12 Fix the communication cables. .............................................................. 97
3.13 Secure the drawer to the PDA. .............................................................. 98
3.14 Install the PDA into shelf........................................................................ 99
3.15 Install the Rectifiers.............................................................................. 104
3.16 Install the front and back covers .......................................................... 115
3.17 Parallel installation of the FPRB .......................................................... 117
Chapter 4 Browser and Control Unit Setup ..................................................... 134
4.1 Set up the configuration environment .................................................. 134
4.2 Change the CU IP-address via the LCD .............................................. 135
4.3 Connect to the GUI in local Internet / Intranet ..................................... 135
4.4 Change the CU IP-address via the GUI............................................... 137
Chapter 5 Commissioning ............................................................................... 144
5.1 Set up a commissioning environment .................................................. 144
5.2 Battery input commissioning ................................................................ 146
5.3 Set up the system parameters ............................................................. 147
5.4 AC input commissioning ...................................................................... 149
Chapter 6 Maintenance ................................................................................... 150
Chapter 7 Troubleshooting.............................................................................. 151

Quick Start Guide Page 4 of 157


List of Figures

List of Figures

Figure 1 Output Power Derating Characteristic of 6kW Configuration of FPRB.. 17


Figure 2 Output Power Derating Characteristic of 9kW Configuration of FPRB.. 18
Figure 3 – The schematic diagram of the FPRB ....................................................... 22
Figure 4 – General view of the FPRB for reference ................................................. 22
Figure 5 – Back view of the FPRB for reference....................................................... 23
Figure 6 – General view of the PDA............................................................................ 25
Figure 7 – The front panel of the PDA ........................................................................ 26
Figure 8 2kW Rectifier Efficiency Curve ..................................................................... 28
Figure 9 3kW Rectifier Efficiency Curve ..................................................................... 28
Figure 10 – General view of the rectifier .................................................................... 29
Figure 11 2kW Rectifier (IP65 Version – Black handle) and 3kW Rectifier (IP65
Compliant – Gray handle) for Reference only ................................................... 30
Figure 12 6kW FPRB Product tree.............................................................................. 35
Figure 13 – 9kW FPRB Product tree .......................................................................... 36
Figure 14 Shelf Grounding Connection ...................................................................... 37
Figure 15 Torque Requirements for PDA Back Cover ............................................. 46
Figure 16 Torque Requirement for PDA Load, Battery Cables and Sub cover ... 46
Figure 17 Captive Screw Torque and Cable Size Requirement............................. 47
Figure 18 Alarm and Signal Cable Requirements .................................................... 47
Figure 19 – The FPRB before the installation ........................................................... 50
Figure 20 – Releasing the PDA earth cable .............................................................. 50
Figure 21 – Releasing the RS485 cables................................................................... 51
Figure 22 – Detaching the PDA from the case.......................................................... 52
Figure 23 Removing the Back and Sub Covers ........................................................ 53
Figure 24 – Removing the front DC Grommet from the PDA.................................. 54
Figure 25 Internal PDA Layout..................................................................................... 55
Figure 26 – AC input CB Rating for 3- Φ Star ........................................................... 56
Figure 27 – AC input CB Rating for 1- Φ.................................................................... 56
Figure 28 – AC input CB Rating for 3- Φ Delta ......................................................... 57
Figure 29 – AC input CB Rating for 2- Φ.................................................................... 57
Figure 30 – The AC cable connection chart .............................................................. 58
Figure 31 – AC terminal block configuration – 1Φ .................................................... 59
Figure 32 – AC terminal block configuration – 3Δ .................................................... 59
Figure 33 – AC terminal block configuration – 3Y .................................................... 60
Figure 34 – Inserting the AC cable through the front panel .................................... 61
Figure 35 – Schematic diagram of AC connection without the SPD – 3Y ............ 63
Figure 36 – Detaching the Strain-relief from the chassis......................................... 63

Installation Manual for FPRB Page 5 of 157


List of Figures

Figure 37 – Connecting the PE cable from the AC mains – 3Y.............................. 64


Figure 38 – Connecting the L and N line cables to the AC terminal block – 3Y .. 65
Figure 39 – Fixing the AC ground clamp back onto the chassis – 3Y................... 66
Figure 40 – Restraining the AC mains cable onto the chassis – 3Y...................... 67
Figure 41 – AC connection without the SPD – 3Y .................................................... 68
Figure 42 – Schematic diagram of AC connection without the SPD – 1Φ............ 69
Figure 43 – AC connection without the SPD – 1Φ ................................................... 69
Figure 44 – Schematic diagram of AC connection without the SPD – 3Δ ............ 70
Figure 45 – AC connection without the SPD – 3Δ .................................................... 70
Figure 46 – Schematic diagram of AC connection without the SPD – 2-phase... 71
Figure 47 –AC connection without the SPD – 2-phase............................................ 71
Figure 48 Secure the back cover................................................................................. 72
Figure 49 Cable Gland Configuration ......................................................................... 74
Figure 50 – Inserting the cable through the cable gland.......................................... 74
Figure 51 – Removing the drawer from the PDA ...................................................... 75
Figure 52 – DC terminals distribution.......................................................................... 76
Figure 53 – DC inlet grommet ...................................................................................... 77
Figure 54 – Inserting the DC load and battery cables through the DC front panel
cover......................................................................................................................... 80
Figure 55 Inserting the DC Cable and Battery cable - Back Panel Grommet ...... 81
Figure 56 Inserting the DC cables into the DC Grommet ........................................ 82
Figure 57 – Securing the DC load and battery cables ............................................. 83
Figure 58 – Securing the front panel........................................................................... 84
Figure 59 – Securing the window of the breakers .................................................... 85
Figure 60 – Fixing the DC cables to the front panel ................................................. 86
Figure 61 – Securing the sub cover ............................................................................ 87
Figure 62 – Drawer internal layout .............................................................................. 88
Figure 63 Slot Designator of the PDA Drawer........................................................... 89
Figure 64 – Inserting the temperature cable into drawer......................................... 90
Figure 65 – Connecting the temperature cable only (Reference Photo)............... 91
Figure 66 – Placing the temperature probe ............................................................... 92
Figure 67 – Connecting the parallel cable only – From PSU .................................. 93
Figure 68 – Connecting the parallel cable only – To PSU....................................... 94
Figure 69 – Connecting the Alarm In cable and the Genset signal Cable ............ 96
Figure 70 – Connecting the Alarm Out cable ............................................................ 97
Figure 71 – Fixing all the communication cables (Photo for Connection
Reference Only) ..................................................................................................... 97
Figure 72 – Putting the drawer back into the PDA.................................................... 98
Figure 73 – Putting the PDA back into the shelf ....................................................... 99
Figure 74 – Securing the PDA to the case............................................................... 100
Figure 75 – Connecting the PDA earth cable to the case ..................................... 101
Figure 76 – Connecting the system earth cable...................................................... 102
Figure 77 Connecting the Ethernet Cable................................................................ 103
Figure 78 Removing the silicon caps on the Rectifier DC terminal...................... 104
Figure 79 – Putting the rectifier into the first slot of the case ................................ 105
Figure 80 – Securing the rectifier to the case.......................................................... 106
Figure 81 – Connecting the AC power cable to the rectifier.................................. 107
Figure 82 – Installing the other rectifiers .................................................................. 108
Figure 83 – Alarm cable exits from top of the case (Reference only).................. 109

Installation Manual for FPRB Page 6 of 157


List of Figures

Figure 84 Installing the Cable Glands....................................................................... 110


Figure 85 – Fixing the cables to the cable gland .................................................... 111
Figure 86 – Fixing the AC cable to the side of the case ........................................ 112
Figure 87 – Fixing the cables to the case sidewall (Reference only) .................. 113
Figure 88 – Fixing the PDA earth cable.................................................................... 113
Figure 89 – Cables exit from right of the FPRB (Reference only for cable exit) 114
Figure 90 – Cables exit from left of the FPRB (Reference only for cable exit) .. 114
Figure 91 – Cables exit from both sides of the FPRB (Reference only for cable
exit) ......................................................................................................................... 114
Figure 92 – Installing the front cover to the FPRB.................................................. 115
Figure 93 – Installing the back cover to the FPRB ................................................. 115
Figure 94 – General view of the FPRB IP54 version – cables run from right
(Reference only for cable exit) ........................................................................... 116
Figure 95 – General view of the FPRB IP54 version – cables run from left
(Reference only for cable exit) ........................................................................... 116
Figure 96 – General view of the FPRB IP54 version – cables run from both sides
(Reference only for cable exit) ........................................................................... 116
Figure 97 – Serial number of the FPRB unit............................................................ 118
Figure 98 – Master/slave definition of FPRB units in parallel ............................... 118
Figure 99 – Current flow of two battery blocks in parallel...................................... 120
Figure 100 – Example of a parallel configuration – 2 FPRBs & 1 BAT ............... 121
Figure 101 – Example of a parallel configuration – 2 FPRBs & 4 BATs ............. 122
Figure 102 – Example of a parallel configuration – 2 FPRBs & 6 BATs ............. 123
Figure 103 – The locating points on the FPRB ....................................................... 124
Figure 104 – Stacking the two FPRB units .............................................................. 124
Figure 105 – Fixing the two FPRB units ................................................................... 125
Figure 106 – Parallel cable configuration within the two drawers ........................ 126
Figure 107 – Paralleling the two drawers (updated version)................................. 126
Figure 108 – Installing the two FPRB units.............................................................. 127
Figure 109 – General view of the two FPRB units in parallel................................ 128
Figure 110 – Example of a parallel configuration – 3 FPRBs & 1 BAT ............... 129
Figure 111 – Example of a parallel configuration – 3 FPRBs & 5 BATs ............. 130
Figure 112 – Example of a parallel configuration – 3 FPRBs & 9 BATs ............. 131
Figure 113 – Parallel cable configuration within the three drawers ..................... 132
Figure 114 – Paralleling the three drawers .............................................................. 133
Figure 115 – General view of the three FPRB units in parallel............................. 133
Figure 116 – Setting up the configuration environment ......................................... 135
Figure 117 – Login the GUI ........................................................................................ 136
Figure 118 – The GUI home page (1)....................................................................... 137
Figure 119 – Local Are Connection – Properties .................................................... 138
Figure 120 – Internet Protocol (TCP/IP) – Properties ............................................ 139
Figure 121 – Allocate secure IP-Address................................................................. 140
Figure 122 – The GUI home page............................................................................. 141
Figure 123 – Setting up the CU IP-address ............................................................. 142
Figure 124 – Commissioning configuration of the FPRB....................................... 145
Figure 125 – Commissioning of the battery input ................................................... 146
Figure 126 – Battery related settings via GUI.......................................................... 147
Figure 127 – System related settings via GUI......................................................... 147
Figure 128 Genset Related Settings ......................................................................... 148

Installation Manual for FPRB Page 7 of 157


List of Figures

Figure 129 – Time settings via GUI........................................................................... 148


Figure 130 – Commissioning of the AC input .......................................................... 149

Installation Manual for FPRB Page 8 of 157


List of tables

List of Tables

Table 1 – Contents of this manual............................................................................... 12


Table 2 – Symbols in the Installation Manual ............................................................ 12
Table 3 – Reference documents of the FPRB........................................................... 13
Table 4 – Main specifications of the 6kW Configuration of the FPRB................... 14
Table 5 – Main specifications of the 9kW Configuration of the FPRB................... 15
Table 6 – Applicable rated input voltage for all types of the FPRB........................ 16
Table 7 – Main voltages and the corresponding EAC alarms................................. 16
Table 8 AC Cable and Grounding Cable Maximum Allowable Diameter Size..... 17
Table 9 – Static data of the DC output for 6kW FPRB............................................. 18
Table 10 – Static data of the DC output for 9kW FPRB........................................... 19
Table 11 Output Cables Maximum Allowable Diameter Size .................................... 20
Table 12 – EAC alarm settings .................................................................................... 24
Table 13 – LEDS on the PDA front panel .................................................................. 27
Table 14 – LEDS on the rectifier front panel.............................................................. 30
Table 15 – Term and Symbols in this manual ........................................................... 32
Table 16 – Symbols on the FPRB ............................................................................ 32
Table 17– Delivery contents by FPRB .................................................................... 38
Table 18– Accessory Bag Contents by FPRB ...................................................... 41
Table 19– Delivery contents of the Optional SPD of FPRB .................................... 43
Table 20 Torque Summary ........................................................................................... 45
Table 21 Single System Configuration Matrix ........................................................... 48
Table 22 Parallel System Configuration Matrix ......................................................... 49
Table 23 – Recommended preparation for AC mains cable ................................... 62
Table 24 – Flow chart of securing the sub cover ...................................................... 72
Table 25 – Three typical battery / load cables configurations for Non Global
Version ..................................................................................................................... 78
Table 26 – Three typical battery / load cables configurations for Global Version 79
Table 27 DC Grommet layer Cutting Guide ............................................................... 81
Table 28 – Flow chart of securing the front panel..................................................... 84
Table 29 – Flow chart of securing the sub cover ...................................................... 87
Table 30 Drawer Grommet Cutting Guide.................................................................. 89
Table 31 – The connection of the temperature cable............................................... 91
Table 32 – The connection of the parallel cable ....................................................... 93
Table 33 – The connection of the Alarm cable.......................................................... 95
Table 34 – The connection of the ATS Signal and Genset Output ........................ 96
Table 35 – Rectifier alarm indications .................................................................. 152
Table 36 – System alarm indications.................................................................... 153
Table 37 – Failures likely to happen ..................................................................... 155
Table 38 Rectifier Vs Shelf Matrix.......................................................................... 157

Installation Manual for FPRB Page 9 of 157


List of Terms

List of Terms

A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
°C Temperature in degrees Celsius
CSA Cross Section Area
CU Control unit
DC Direct current
EAC External Alarm and Control
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRB Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Ingress Protection
TCP/IP Transmission Control Protocol (TCP) and Internet Protocol (IP) Internet
Protocol

L Live cable from the AC mains

LAN Local Area Network


LED Light Emitting Diode
LVD Low Voltage Disconnect
MAC Media Access Control
MCB Miniature Circuit Breaker
N Neutral cable from the AC mains
N/A Not applicable
PC Personal Computer
PCB Printed Circuit Board
PDA Power Distribution Assembly
PE Protective earth
PSU Power Supply Unit
RTN Return
S/N Serial Number
SNMP Simple Network Management Protocol

Installation Manual for FPRB Page 10 of 157


List of Terms

SPD Surge Protective Device


V Volt
VPN Virtual Private Network
1Φ Single-phase AC type
3Y 3-phase star AC type
3Δ 3-phase delta AC type

Installation Manual for FPRB Page 11 of 157


Preface

Preface

About this Manual


This manual guides the user on how to install the FPRB, including the hardware installation,
the browser and CU setup. The manual also introduces the FPRB as well as its
commissioning, maintenance and troubleshooting.
The contents of this manual are listed in Table 1.

Table 1 – Contents of this manual

Chapter Title Content

1 Product instruction Describes the specifications, properties,


mechanical data, etc. of the FPRB and the modules
it contains.

2 Preparation Describes the installation safety, site, and tools.

3 Hardware installation Describes how to install the AC cables, DC cables,


communication cables, parallel installation, etc. of
the FPRB.

4 Browser and CU setup Describes how to set the browser and CU, and
access the GUI.

5 Commissioning Describes how to commission the FPRB after the


installation.

6 Maintenance Describes how to maintain the FPRB.

7 Troubleshooting Describes how to solve the detected issues of the


FPRB.

Term and Symbols in this Manual


These terms and symbols in Table 2 might appear in the manual:

Table 2 – Symbols in the Installation Manual

Symbol Description

Safety symbol, see Safety summary

Safety symbol, see Safety summary

Provides hints to the user for easier installation,


maintenance and troubleshooting

The necessary supplementary of the article to let user


be clearer.

Installation Manual for FPRB Page 12 of 157


Preface

Reference Documents
The documents of the FPRB contain:

Table 3 – Reference documents of the FPRB

Artesyn Embedded
Document Technologies
File No.

Product Specification – FPRB 970-009025-0000

FPRB Installation Manual for SPD 970-009473-0000

FPRB User Manual 970-009474-0000

FPRB Installation Manual (This manual) 970-009475-0000

FPRB Quick Start Guide for SPD 970-009476-0000

FPRB Quick Start Guide 970-009477-0000

Installation Manual for FPRB Page 13 of 157


Product Introduction

Chapter 1 Product Introduction

1.1 General Description


The FPRB Flexi Power Rectifier System consists of a Power Shelf (AA27540L, NSN Code
CS7000030) with 6 to 9kW of output power using three individual 2kW AC/DC rectifier
modules (AA25000L/AA25000L-A, NSN Code CS7000001/CS7000021) or 3kW AC/DC
rectifier modules (AA27530L, NSN Code CS7000031) operating in a parallel mode
configuration.

The FPRB also includes a Power Distribution Assembly (PDA) with integrated battery
protection LVD, load/battery circuit breakers, battery current shunt and alarm signals to the
BTS EAC interface.

Although it has been proven that there will be no any damage in the event of accidental using
the Global FPRB on US application and Vice versa, it is still be a must for the installer to
check the correct version of the FPRB versus the customer requirement in the field. For
detailed shelf version conversion please refer to Figure 12 and Figure 13. For detailed Matrix
configurations please refer to Table 21 and Table 22.

1.1.1 Specification
 Main specifications

Table 4 – Main specifications of the 6kW Configuration of the FPRB

Parameter Specification Description

Min Nom Max

Rated AC input voltage (VAC) 180 -- 276 See Table 6

AC Input Iin (ADC) 3 0 -- 12.5 Per phase

Iin (ADC) 1 0 - 37.5 All L shorted


together

DC Nominal Vout -56 -54 -52 See Table 9


(VDC)
Output
Iout (ADC) 0 -- 109.9 Total load

(1)
Ambient -40 23 55 Max output 6kW
temperature
(2)
(°C) Start up -40 -- --

Storage -45 -- +45

Installation Manual Page 14 of 157


Product Introduction

Table 5 – Main specifications of the 9kW Configuration of the FPRB

Parameter Specification Description

Min Nom Max

Rated AC input voltage (VAC) 180 -- 276 See Table 6

AC Input Iin (ADC) 3 0 -- 18.5 Per phase

Iin (ADC) 1 0 - 55.5 All L shorted


together

DC Nominal Vout -56 -54 -52 See Table 9


(VDC)
Output
Iout (ADC) 0 -- 164.8 Total load

(3)
Ambient Operation -40 23 50 Max output 9kW
temperature
(2)
(°C) Start up -40 -- --

Storage -45 -- +45

Note:
(1) The 6kW configuration of the FPRB unit is fully compliant with the operational and power
output requirements outlined within the Product Specification at the maximum ambient
temperature 55°C (plus solar load).
(2) At -40°C external ambient start up and after a period of 15minutes operation, the FPRB is fully
compliant with the operational and power output requirements outlined within the
Product Specification.
3) The 9kW configuration of the FPRB unit is fully compliant with the operational and power
output. Requirements outlined within the Product Specification at the maximum
external ambient temperature of 50°C (+ solar load). An increase in external ambient
temperature above 50°C up to 60°C (abnormal operating temp) can result in the
system output power being derated.

Battery is disconnected by the LVD contactor from the –48V power supply during the
FPRB cold-start at -40°C.

Installation Manual Page 15 of 157


Product Introduction

 AC input
The rated input voltage of the FPRB is 180~276VAC (200~230 VAC –10%/+20%). The
rectifiers can be connected as single-phase 230 VAC inputs or as 400 VAC (phase to
phase) 3-phase Star or as 200 VAC (phase to phase) 3-phase Delta.
Table 6 shows the various rated inputs that the FPRB are applicable and allowed for.

Table 6 – Applicable rated input voltage for all types of the FPRB

VAC / V VAC / V Frequency / Hz Supply Network Type


(Nominal) (Range)

240 180 – 276 45 – 66 US Single phase; three-wire;


earthed midpoint of phase

230 180 – 276 45 – 66 Europe Single Phase

208 180 – 276 45 – 66 US 3-phase star; four wire;


Phase to Neutral earthed neutral

240 180 – 276 45 – 66 US 3-phase delta; four-wire;


Phase to Phase earthed midpoint of phase

202 180 – 276 45 – 66 Japanese 3-phase delta


Phase to Phase
230 180 – 276 45 – 66 European 3-phase star; four
Phase to Neutral wire; earthed neutral)

The FPRB is designed to operate with extended operation input main voltage, at the low
range between 90 ~180 VAC (with derated output power, see Figure 1 for 6kW FPRB and
Figure 2 for 9kW FPRB) and at upper range between 276~310 VAC.
The FPRB accepts, without damage, single phase AC input voltage of up to 350V AC at
frequency of 45~66Hz, for a duration of up to 60s.

Table 7 – Main voltages and the corresponding EAC alarms

Controller
VAC / V Status EAC Alarm
LED

Operational – Extended and low Yes


>85-170 (+/-5V)ac Amber
voltage range Minor

175- 276 (+/-5V)ac Rated operation No Green

Yes
281-310 (+/-5V)ac Operational – Extended range Amber
Minor

Over voltage – Rectifier Yes


315 (+/-5V)ac Red
Shutdown Major
Mains ph
<=80 (+/-5)Vac Low mains – Rectifier shutdown fail Red
1/2/3

Installation Manual Page 16 of 157


Product Introduction

Note:
(1) Here indicates the 180 VAC has a +/–5 VAC tolerance.
(2) “Yes” /”No” means that the PDA sends /not sends the EAC alarm. The illustration is available
for all same expressions in this table.
(3) Refer to Table 12 for the detailed EAC alarms.
(4) Please refer to Table 8 for the maximum allowable cables size for AC input and Grounding
cables.

Table 8 AC Cable and Grounding Cable Maximum Allowable Diameter Size

Diameter Tolerance Unit

AC Cable 17 ~ 18 ±0 mm

Grounding Cable 7.6 ± 0.4 mm

Figure 1 Output Power Derating Characteristic of 6kW Configuration of FPRB

Note: N+1 (failure) defines the condition that one of the three rectifiers has failures, and
only two rectifiers operate normally to support the load.

Installation Manual Page 17 of 157


Product Introduction

Figure 2 Output Power Derating Characteristic of 9kW Configuration of FPRB

 DC output
The –54VDC output, here referred to as V48N, is with respect to V48RTN (positive)
which is either grounded or isolated within the FPRB.
See Table 9 for 6kW and Table 10 for 9kW FPRB for more details about the DC
output.

Table 9 – Static data of the DC output for 6kW FPRB

Parameter Spec Description

(1)
-54± 2 Nominal output voltage
Output Voltage (VDC)
-57~-45 Output voltage range

Factory Output Voltage set point (VDC) -53.3±0.6 Factory default setting at +27°C

For a load from Minimum to Maximum


Line regulation <1%
at +27°C

For a load from Minimum to Maximum


Minimum Hold Up (ms) 20
(6kW FPRB)

Current Limit (ADC) +10% Based on the Battery Capacity Ah

OVP Limit (VDC) 58.5 ±1.0 Factory set

Output Low Voltage Alarm (VDC) 40±0.5 Factory set

Max output 6kW, -10~+55°C (plus


Ripple & noise (mV) 300 (2)
solar load)

Installation Manual Page 18 of 157


Product Introduction

Table 9 – Static data of the DC output for 6kW FPRB

Parameter Spec Description

(1)
-54± 2 Nominal output voltage
Output Voltage (VDC)
-57~-45 Output voltage range

6 -40°C ~+55°C (plus solar load)

Max Output power (kW) for 6kW 6kW derating to 4.5kW @


6 ~ 4.5
+55°C (plus solar load) → 65°C

Minimum Output power (kW) -- No minimum load limitation

Nominal AC input range, Table 6


>90%
Efficiency Max output 6kW

(3)
Nominal AC input range, Table 6
>95%
High Efficiency Rectifiers

Table 10 – Static data of the DC output for 9kW FPRB

Parameter Spec Description

(1)
-54± 2 Nominal output voltage
Output Voltage (VDC)
-57~-45 Output voltage range

Factory Output Voltage set point (VDC) -53.3±0.6 Factory default setting at +27°C

For a load from Minimum to Maximum


Line regulation <1%
at +27°C

For a load from Minimum to Maximum


Minimum Hold Up (ms) 10
(9kW FPRB)

Current Limit (ADC) +10% Based on the Battery Capacity Ah

OVP Limit (VDC) 58.5 ±1.0 Factory set

Output Low Voltage Alarm (VDC) 40±0.5 Factory set

Max output 9kW, -10~+55°C (plus


Ripple & noise (mV) 300 (2)
solar load)

Minimum Output power (kW) -- No minimum load limitation

Installation Manual Page 19 of 157


Product Introduction

Table 10 – Static data of the DC output for 9kW FPRB

Parameter Spec Description

(1)
-54± 2 Nominal output voltage
Output Voltage (VDC)
-57~-45 Output voltage range

9 -40°C ~+50°C (plus solar load)

Max Output power (kW) for 9kW


9kW derating to 7.5kW @
9 ~ 7.5
+50°C (plus solar load) → 65°C

Efficiency (4)
Nominal AC input range, Table 6
>95%
Max output 9kW

Note:
(1). The values in the table shall be met for all input voltages and frequencies within the rated and
extended input ranges, and all valid output load conditions.
(2). Maximum output ripple voltage at -40°C start up shall not be greater than 4% of the FPRB
output voltage factory set point -53.3Vdc during the 15 minutes warming up period.
(3). AA25000L-A (NSN Code CS7000021) can meet a typical 95% efficiency at 230Vac input
condition from 50% to 100% full load.
(4). AA27530L (NSN Code CS7000031) can meet a typical 95% efficiency at 230Vac input
condition from 50% to 100% full load.
(5) Refer to Table 11 for maximum allowable cable sizing for output cables.

Table 11 Output Cables Maximum Allowable Diameter Size

First Layer 8.5 ± 0.5 mm

Second Layer 11 ± 0.5 mm

Third Layer 14 ± 0.5 mm

Installation Manual Page 20 of 157


Product Introduction

1.1.2 Properties
The FPRB has the following properties:
 High-integrated power system.
The FPRB integrates the rectifiers, the AC and DC distribution, and supervisor and
communication functions.
 Modularized design.
The modularized design of the FPRB leads to easier installation, maintenance and
troubleshooting.
 Flexible applications.
The FPRB supplies the user with a varied output power of 2/4/6kW for 6kW FPRB
and 3/6/9kW for 9kW FPRB by means of installing 1/2/3 rectifier modules. Also the 3
battery back-up channels and 2 load channels of the FPRB provides the user with
flexible battery and load applications.
 Variable AC power connections.
The FPRB can be used with different AC power types mentioned in Table 6 by
means of reconfiguring the internal AC terminal block.
 Easy to control.
The user can control and supervise the operation of the FPRB via the GUI after
connecting the FPRB to a user PC.
 SNMP Function
It also provides SNMP for control and communication by the upstream system.
 Remote Genset Start function
The FPRB has an additional feature to control and monitor the starting and stopping
of the diesel generators as per battery charging needs.
 UV Compliant and UL Certified
The FPRB NSN PN: (CS7000030.XX) is UV compliant and UL certified product.
 IP65
The FPRB NSN PN: (CS7000030.XX) is an IP65 rated and designed to meet IP
class 65 rating without the fitment of front and rear covers and also IP class 65 once
front and rear covers are in place. The Ethernet interface cable from FPRB to BTS
System Module is also IP65 certified.
 Operation with or without Battery
The FPRB can also be operated without connecting any battery.
The FPRB comprises of one PDA and one to three identical 2kW rectifiers OR one PDA
and one to three identical 3kW rectifiers working in a parallel mode. The schematic
diagram of the FPRB is as shown in Figure 3.

Installation Manual Page 21 of 157


Product Introduction

LOADs BATs

PDA
AC
AC DC
Distributor Distributor REC1

DC
Busbar
REC2
Display
MCU
REC3

RJ45 RS485
RS422
PC
FPRA
FPRB

Figure 3 – The schematic diagram of the FPRB

Figure 4 presents the general view of the FPRB with the cables breaking out from the
system right side. Depending on the field application, all the cables can break out from
left or right or both sides of the FPRB.

Figure 4 – General view of the FPRB for reference

The FPRB has a dimension of 447 X 423.5 X 128.7 (W X D X H) mm. (Not including the
Cable Gland)

Installation Manual Page 22 of 157


Product Introduction

Figure 5 shows the back view of the FPRB after installing all the rectifiers.

Fan Guiding pole AC cable

Figure 5 – Back view of the FPRB for reference

1.2 The Power Distribution Assembly (PDA)


The Power Distribution Assembly (PDA) is the internal power distribution assembly of the
FPRB. It has the following properties:
 AC power distribution.
The PDA supplies the rectifiers with three AC input power system types, as listed in
Table 6 by using a different configuration of the internal AC terminal block connections.
 DC power distribution.
The rectifiers are all connected directly to a DC bus bar internal to the PDA.
The three battery back-up channels and two load channels are connected to the DC bus
bar through the internal miniature circuit breakers (MCB). Each battery breaker is rated to
63A and each load breaker is rated to 80A.
 Battery control function.
The PDA carries out an automatic battery test periodically by the control unit (CU), and
records the last 10 battery test data including the test date, discharge current and time,
test end voltage, battery temperature, discharged Ampere-hours, etc.
The batteries will stop discharging and disconnect from the loads once the battery
voltage is below the “LVD” set point.
The user can set the batteries charge voltage level to commensurate with the batteries in
field, and set the Low Voltage Disconnect (LVD) voltage level to disconnect the batteries
from the loads to under deep discharging condition.
 Supervisor of the FPRB.
The PDA has a built-in MCU to monitor the status of the rectifiers and batteries such as
voltage, current and temperature, etc., and display the corresponding data through the
LCD and LEDS.
The PDA also supplies 6 isolated and floating EAC alarms for the BTS.

Installation Manual Page 23 of 157


Product Introduction

 Genset Function.
The PDA has an added feature to control and monitor the starting and stopping of diesel
engine generators depending on the battery charging needs.
The GUI provides the customer interface function to monitor and set the data logging of
the power delivered by the FPRB to the customer system.
The PDA has a built-in potential free relay which provides the signal to turn On /Off the
diesel generators.
It has an Alarm input signal which will be coming from the ATS so that the FPRB can
detect if the power is fed through Grid or through Generator.
 Network connection based on LAN.
The PDA can be connected to a user PC via the internal RJ45 interface. The user can
monitor the whole system via a web-based GUI.
 SNMP for ease of managing equipments in the IP networks.
The PDA can configure / down load and Upload information from the FPRB locally or
remotely via an Ethernet / IP protocol, interface port & SNMP protocol. The SNMP
protocol allows users to access all alarms, counters and configuration data.

Table 12 – EAC alarm settings

EAC alarm Description

Main phase #1 Mains phase failure indicates any single phase voltage of the 3-phase
FPRB power source configuration that is below 85VAC
Main phase #2

Main phase #3

Critical  Battery low voltage


 PDA controller fail
 DC distribution failure (e.g. breaker failure)
 Generator Fail
 LVD Disconnect
 Rectifier Redundancy Fail
 Mixed System

Major  Battery failure


 Rectifier fail
 High float voltage
 Generator Time
 Element Loss
 Surge Protection Device Fail

Minor  Battery temperature High/Low


 Rectifier temperature High

Installation Manual Page 24 of 157


Product Introduction

 Rectifier over current


 Configuration change
 Extended and high mains voltage range (refer to Table 7)
 Extended and low mains voltage range (refer to Table 7)

Warning  ATS Open


 Battery Low Voltage Warning

Note: The alarm level also can be set by user.

The PDA has a dimension of 176.2 X 364.0 X 119.5 (W X D X H) mm. Figure 6 shows the
general view of the PDA before the installation.

(9)
(1)

(11)
(6)

(10) (8)
(7)

(1) Top cover (2) Sub cover (3) Restricted area (4) BR bus bar (5) –54V bus bar
(6) Front panel (7) Drawer (8) RS 485 cable (9) Window of the breakers (10) PE of the PDA (11)
Pressing Plate

Figure 6 – General view of the PDA

Installation Manual Page 25 of 157


Product Introduction

Figure 7 shows the front panel of the PDA.

(4) (6)
(3) (5) (7)

(2)

(1)

(10)

(9)

(8)

(15)
(13)
(14) (12)
(11)

(1) LCD (2) Red LED (3) Yellow LED (4) Green LED (5) Up button (6) Middle button
(7) Down button (8) AC cable inlet (9) Alarm Out (10) Alarm In (11) To PSU (12) From PSU
(13) Temperature (14) Ethernet interface (15) DC grommet

Figure 7 – The front panel of the PDA

Installation Manual Page 26 of 157


Product Introduction

The LEDS on the PDA front panel will have any of the status listed in Table 13.

Table 13 – LEDS on the PDA front panel

LED Mark Status Indication

 Fault
F/MA
ON  Major EAC alarm (refer to Table 12)
/ Red
 Mains / phase failure (refer to Table 12)

 Message
M/MA
ON
/ Yellow  Minor EAC alarm (refer to Table 12)

SYSOK
ON System OK
/ Green
Turn on
simultaneously and
All LEDS turn off after about System initialization
20 seconds

1.3 The Rectifier


The FPRB supports the operation of up to three rectifiers in parallel. Each rectifier is an
AC/DC module, which meets the specifications listed in Table 6 and Table 9. The rectifier has
the following properties:

 Efficiency. The rectifier has over 95% efficiency at the nominal AC input voltage.
Refer to below.
 AA25000L-A (NSN code: CS7000021can meet a typical 95% efficiency
at 230Vac input condition from 50% to 100% full load).
 AA27530L (NSN Code: CS7000031) can meet a typical 95% efficiency
at 230Vac input condition from 50% to 100% full load).
 Over current protection. The rectifier shuts down once an over current is detected,
and recovers automatically when the fault is no longer present.
 Over voltage protection. The rectifier shuts down once an over voltage is detected
for the first time, and recovers automatically when the fault is no longer present. If
the over voltage is detected for the second time, the rectifier will shuts down for
ever until the AC power supply re-powers up to restart the rectifier.
 Monitoring function. The rectifier monitors different parameters such as input
voltage, input power, output voltage, output power, etc., and sends out a
corresponding alarm signal in case it detects a fault.
 Self-cooling function. Each rectifier is forced convection cooled. The fan at its back
is replaceable.
 RS485 interface. The rectifier can be connected to the PDA via the internal RS485
interface. In this way, user can monitor and control three rectifiers via the GUI.

Installation Manual Page 27 of 157


Product Introduction

97.0%
96.5%
96.0%
95.5%
95.0%
94.5%
94.0%
93.5%
93.0%
20% 30% 40% 50% 60% 70% 80% 90% 100%
Percentage Loading

Figure 8 2kW Rectifier Efficiency Curve

3kW Rectifier Efficiency Curve


97.00%

96.00%

95.00%
Percentage Efficiency

94.00%

93.00%

92.00%

91.00%

90.00%

Percentage Loading

Figure 9 3kW Rectifier Efficiency Curve

Installation Manual Page 28 of 157


Product Introduction

The rectifier has a dimension of 81.8 X 383.7 X 100.0 (W X D X H) mm.


The general view of the rectifier is as shown in Figure 10

(8)

(5)
(6)

(1)

(9)

(10)
(7)

(3)

(2)
(4)

(1) Rectifier front panel (2) AC input connector (3) RS485 interface (4) connector screw
hole (5) –54V bus bar (6) BR bus bar (7) Case (8) Fan cover (9) Handle (10) LED

Figure 10 – General view of the rectifier

Installation Manual Page 29 of 157


Product Introduction

Table 14 lists the LED indications of the rectifier.

Table 14 – LEDS on the rectifier front panel

LED Mark Status Indication

Yellow (amber) /
ON Minor EAC alarm (refer to Table 12)
Message

 Rated mains voltage (refer to Table 6)


Green / Normal ON
 System OK

 Rectifier failure
 Fan failure
Red / Alarm ON
 AC input phase voltage less than 80V
 Low output voltage

Figure 11 2kW Rectifier (IP65 Version – Black handle) and 3kW Rectifier (IP65 Compliant –
Gray handle) for Reference only

Installation Manual Page 30 of 157


Product Introduction

Chapter 2 Preparation

2.1 Safety Summary


2.1.1 Injury and product damage precautions
The following precautions must be observed during all phases of servicing the product,
such as installation, maintenance or configuration. Any omission of the precautions might
cause injury and/or product damage.
 Do not service the product during a thunder / lightning storm to avoid electric shock.
 Turn off the AC power source before servicing or when accessing the AC
cables or the SPD to avoid electric shock.
 Make sure to turn off all the power and properly grounded the product before
servicing the product to avoid electric shock.
o Caution: In an event of any flash over caused by wrong installation, voltage,
current or temperature data reporting maybe affected which may lead to
undesired functions and generation of false alarms.
 The equipment must be installed in restricted access location
 The AC Outlet /Socket shall be installed at least 3m away from the FPRB.
 A “Risk of Electric Shock” symbol should be placed near the input and output
terminals.
 Do not install the product in an explosive atmosphere to avoid injury or fire hazard.
 An external Input Circuit Breaker with rating depending on the customer requirement
in a specified country where the equipment will be installed.
 AC power cords must be water resistant or outdoor type cables and must be marked
with “W” or “W-A”.
 Do not service the product if the environment cannot meet the requirements defined
in the product specification.
 Input and Output terminals should be covered to prevent accidental access during
operation.
 Do not place the product in an unstable rack, to avoid the product damage in case of
a fall.
 The equipment must be installed by trained and qualified service personnel.
o Service Personnel: Person having an appropriate technical training and
experience necessary to be aware of Hazards to which that person may be
exposed in performing a task and of measures to minimize the risk to that
person or other persons.
 Do not open the restricted area by unqualified personnel, to avoid damage to the
product.
 After unpacking, do not start the installation if you suspect any product damage
caused by shipment.
 Pay attention to the specific warning/caution terms and symbols in this manual.
 The protective earthing bond terminal marked with “ ” in PDA (Power Distribution
Assembly) must be reliably connected to Protective earth by end user

Installation Manual Page 31 of 157


Product Introduction

 The power supply system has no in-line fuse, For safety operation, an external UL
listed circuit breaker with adequate rating, max.70A must be employed as input line
protective device before Single-phase installation; an external UL listed circuit
breaker with adequate rating, max.25A must be employed as input line protective
device before 3-phase star(3Y) installation; and an external UL listed circuit breaker
with adequate rating, max.50A must be employed as input line protective device
before 3-phase delta(3Δ) installation
 The Output terminal should not be touched during operation.
 In case of failure, the power supply system must be returned to Astec
 Authorized Service Station for servicing to ensure compliance with safety
requirements.
 The surface of the power supply system should not be touched during it operating for
the high touch (leakage) current (exceed 3.5mA).

2.1.2 Safety Term and Symbols


These term and symbols listed in Table 15 may appear in this manual:

Table 15 – Term and Symbols in this manual

Term & Symbol Description

Warning statement identifies conditions or practices that could


result in bodily injury or loss of life.
It warns the reader to be extremely careful.

Caution statement identifies conditions or practices that could


result in damage to this product or devices connect to it.
It indicates that the reader must be careful.

These symbols listed in Table 16 may appear on the FPRB:

Table 16 – Symbols on the FPRB

Symbol Description

Risk of electric shock:


To avoid electric shock, user shall not touch the product.

DC Voltage Hazard
DC Voltage Hazard:
There is DC voltage at the indicated position.

Hot surface:
To avoid being burnt, user shall not touch the product when it is in
operation.

Installation Manual Page 32 of 157


Product Introduction

ESD caution:
Means user should wear a well-grounded ESD wrist strap to avoid product
damage.

Protective earth terminal:


Connect the protective earth cable in the indicated position.

System earth terminal:


Connect the system earth cable in the indicated position.

Recycle:
User cannot dispose of this electronic product in the trash. To protect the
environment, please recycle.

2.2 Installation Site


To ensure normal operation and long service life of the product, install it in an environment
that meets the following requirements:
 Temperature
The FPRB should be used and maintained in the temperature that defined in Table 4.
 Cleanness
Dust is a hazard to the operation to the device. The dust accumulated on the chassis
can be absorbed by static electricity and result in poor contact of metal connectors.
This not only shortens the service life of your device but may also cause
communication failures.
Besides dust, the harmful gases, containing salts, acids and sulfides, can accelerate
the corrosion and aging of metals.
 Ventilation
Each rectifier has an integrated fan for cooling. The airflow is from the rear to the
front of the rectifier unit. Consideration should be given to the amount of clearance
necessary to ensure FPRB cooling when configured within cabinets.
 Location
Installation site should be secured and restricted which can only be accessed by
authorized personnel.

Installation Manual Page 33 of 157


Product Introduction

2.3 Installation tools and test equipments

The installation tools and test equipments are prepared in field.

Tool kit:
 Allen key (hex key): 8 mm (0.31 in.)
 Awl: diameter of 2mm
 Hex Screwdriver 4mm
 ESD wrist strap and cable
 TORX screwdriver set: T10, T20, T25
 Flat screwdriver
 Cross screwdriver
 Wrench 8 mm (5/16 inch)
 Folding knife
 Adjustable (monkey) wrench
 Side cutters
 Lint-free swab or wipe and 99% alcohol for cleaning optical connectors
 Cable ties for routing cables
 Tape measure
 Flashlight, pocket lamp or torch
 Hammer drill
 Marker pen or comparable tool
 Pliers
 Wire-stripper
Test Equipment
 PC (optional)
 Multi-meter: FLUKE 170 or equivalent
 DC Current clamp: FLUKE I410 or equivalent

Installation Manual Page 34 of 157


Product Introduction

2.4 Check list of the FPRB


Figure 12 shows the product tree of the customer system with FPRB Shelf and 2kW
Rectifiers

Customer Configuration
IP65 - Flexi Power Rectifier
6kW FPRX
(Note 3)

2kW Rectifier Units


Flexi Power 1/2/3 Accessory Bag
Rectifier FPRX (Note 1) CS7000007.XX
(Chassis + PDA) CS7000001.XX or
CS7000032.XX plus CS7000021.XX
CS7000033.XX

Temperature Sensor AC OVP Kit Alarm PCB


CS7000005.XX (Optional) CS7000004.XX
Note 2
CS7000002.XX

Figure 12 6kW FPRB Product tree

Note:

1. All Rectifiers in the shelf must be 2kW (CS7000021.XX) or (CS7000001.XX)


2. SPD or AC OVP Kit is ordered separately depending on the customer requirement.
3. All Rectifiers must be IP65 compliant.

Refer to Table 17 lists the delivery contents by FPRB.

Installation Manual Page 35 of 157


Product Introduction

Figure 13 shows the product tree of the customer system with FPRB Shelf and 3kW
Rectifiers

Customer Configuration
IP65 - Flexi Power Rectifier
9kW FPRX

3kW Rectifier Units


Flexi Power
1/2/3 Accessory Bag
Rectifier FPRX
(Note 1) CS7000007.XX
(Chassis + PDA)
CS7000031.XX
CS7000032.XX plus
CS7000033.XX

AC OVP Kit Alarm PCB


Temperature Sensor
(Optional) CS7000004.XX
CS7000005.XX
Note 2
CS7000002.XX

Figure 13 – 9kW FPRB Product tree

Note:

1. All Rectifiers in the shelf must be 3kW (CS7000031.XX).


2. SPD or AC OVP Kit is ordered separately depending on the customer requirement.

Refer to Table 17 lists the delivery contents by FPRB.

Installation Manual Page 36 of 157


Product Introduction

 One FPRB may adopt one or two or three rectifiers to meet the user’s requirement.
 The Transient Protection Unit is optional for the user, and is supplied independently with
the FPRB.
 The part number listed in Table 17 is based on the present materials used, and Artesyn
may change some materials and corresponding part numbers in future. Therefore the
user should contact Artesyn for updated information in time.
 Since FPRB is a Global version, it can handle all kinds of PDA. The GROUND bus bar
can be configured to accommodate global applications. Default setting of the GROUND
bus bar is it has a rubber cover to isolate the -54V RTN to the Earth. Customer can
connect it to the chassis by removing the rubber cover then screw it to the chassis. (Refer
to Figure 14 Global version FPRB is by default shipped as US version)
 If by mistake Global one used in US and vice versa, there shall be no any damaged will
caused to the FPRB.

Note 1 Note 2

Figure 14 Shelf Grounding Connection

Note 1: US/ Global version with only sleeve attached, isolating the GND
connection. (Default configuration)
Note 2: Non-US version with M4 screw mounted.

Installation Manual Page 37 of 157


Preparation

Table 17– Delivery contents by FPRB

Name Figure Description Usage NSN Code Artesyn Artesyn


PN Model
Shelf plus The case of the CS7000030.XX NA AA27540L
PDA Non US FPRB with PDA 1 plus
and Global installed that CS7000033.XX
Version distributes the
AC to the
Rectifiers.

Temperature The 1 750-


cable temperature 006317-
sensor of the 000X
FPRB

Parallel cable The 750-


communication 1 006316-
cable for RS422 000X
interface

System earth Connects the 1 750-


cable FPRB to 006215-
system earth 000X

3-pole Bridge Used to 1 451-


configure the 005127-
AC terminal 0003
block

Quick Start Guide Page 38 of 157


Product Introduction

2-pole
pole Bridge Used to 3 451--
configure the 005128-
005128-
AC terminal 0002
block

Cable tie Used to tie the 50 499--


cables 000144-
000144-
0000
Cable Used to tie thick 2 601--
restraint cable, such as 000245-
000245-
AC cable 0000

M3 screw Used to fix the 4 602--


cable restraint 000683-
000683-
0000

M5 screw Used to fix the 2 602--


cases when 000681-
000681-
stacked for 0000
parallel
configuration
M4 screw Mounted when 1 602--
FPRB is 000986-
000986-
configured as 0000
non--US
US version

2kW Rectifier The AC/DC 1/2/ C


CS7000001
S7000001 NA AA25000L
IP54 Version module 3

Installation Manual Page 39 of 157


Product Introduction

2kW HE The AC/DC 1/2/ CS7000021 NA AA25000L-


Rectifier IP54 module 3 A
Version

3kW Rectifier The AC/DC 1/2/ CS7000031 NA AA27530L


module 3

Installation Manual Page 40 of 157


Product Introduction

Table 18– Accessory Bag Contents by FPRB

Name Figure Description Usage NSN Code Artesyn Artesyn


PN Model
M5 screw Fix the cable 4 602-000681-
glands to shelf 0000

System Earth Connects the 1 750-006215-


Cable FPRB to system 000X
earth

Cable tie Used to tie the 50 499-000144-


cables 0000

Cable Used to tie thick 2 601-000245-


restraint cable, such as 0000
AC cable

M3 screw Used to fix the 4 602-000683-


Cable Restraint 0000

Installation Manual Page 41 of 157


Product Introduction

M5x22 Torx Use to fix the 4 602-001115-


Captive Aluminum Heat 0000
Screw sink to the
Chassis

Heatsink Use to hold the 2 466-001812-


Aluminum faceplate cover 0000
99X20X8

Internal Internal Cable 2 499-000435-


Cable Tray Tray Entry 0000
Entry
AA27100L

Installation Manual Page 42 of 157


Product Introduction

Table 19– Delivery contents of the Optional SPD of FPRB

Part Figure Description Usage Artesyn Artesyn


Part Number Module
Number

SPD Surge Protective Device 1 pc 440-000700-


0000
Manufacturer p/n:VAL-MS
230IT/3+1-FM
Manufacturer: PHOENIX
CONTACT (SEA), PTE. LTD.

Surge Protective Device


Manufacturer p/n: ZGG40-
385(3+1)
Manufacturer: SICHUAN AA25130L
ZHONGGUANG LIGHTNING
PROTECTION
TECHNOLOGIES CO.,LTD.

SPD Jumper Short link for SPD terminals in 1 each 502-000496-


single-phase AC connection 000X/
500-001769-
000X

L line short link L1/L2/L3 between SPD and 1 750-006658-


input terminal block (AWG10) 000X

Installation Manual Page 43 of 157


Product Introduction

N line short N for three phase star, 1 438-000423-


link
N for single phase (10mm )
2 0000

SPD ground
SPD ground link to Chassis 1 750-000988-
link
000X

SPD sense
SPD signal cable connecting to 1 750-001004-
cable
the control board 000X

Installation Manual Page 44 of 157


Hardware Installation

Chapter 3 Hardware Installation

Before hardware installation, please note:


 All the precautions listed in the Safety summary. For further details please refer to
the printed Installation and Operating Instruction enclosed in the shipment.
 Mixing of CS7000001 (Standard 2kW Rectifier) or CS7000021 (High Efficiency
2kW Rectifier) with CS7000031 (3kW Rectifier) is not allowed. Please refer to
Table 21 (Single) and Table 22 (Parallel) Matrix of Configurations.
 The installation should be carried out only by qualified personnel and in
accordance with local electrical codes.
 Use an AC cord which must be UL listed and marked with “water resistant”,
“outdoor”, “W” or “W-A””.
 Sizes of cables to be used are summarized in Figure 16
 Torques to be used for each screws during installation are summarized in Table 20

The installation sequence summary of the various system modules described below is
mandatory for first time installation of the FPRB components. The detailed installation
procedure for each module can be found in the appropriate sections further on in this
document.

Torques Summary

Screw Size Torque Requirement (N.m) Torque Requirement (kgf-CM)

M3 0.588 ~ 0.784 6~8

M4 1.176 ~1.568 12 ~ 16

M5 1.96 ~ 2.45 20 ~ 25

M6 2.94 ~ 3.43 30 ~ 35

Table 20 Torque Summary

Installation Manual Page 45 of 157


Hardware Installation

Figure 15 Torque Requirements for PDA Back Cover

Figure 16 Torque Requirement for PDA Load, Battery Cables and Sub cover

Installation Manual Page 46 of 157


Hardware Installation

Figure 17 Captive Screw Torque and Cable Size Requirement

Figure 18 Alarm and Signal Cable Requirements

Installation Manual Page 47 of 157


Hardware Installation

Table 21 Single System Configuration Matrix

Installation Manual Page 48 of 157


Hardware Installation

Table 22 Parallel System Configuration Matrix

Installation Manual Page 49 of 157


Hardware Installation

3.1 Preparation of PDA


Figure 19 Illustrates the FPRB before the installation.

Figure 19 – The FPRB before the installation

3.1.1 Release the PDA earth cable.


Release the PDA earth cable by loosening the nut with a wrench (8mm) (see Figure 20).

Figure 20 – Releasing the PDA earth cable

Installation Manual Page 50 of 157


Hardware Installation

3.1.2 Release the RS485 cables.


Release the three RS485 cables by manually loosening the three cable ties originally (see
Figure 21

Figure 21 – Releasing the RS485 cables

Installation Manual Page 51 of 157


Hardware Installation

3.1.3 Detach the PDA from the case.


Loosen the two screws on the front panel of the PDA with a Cross screwdriver, and pull
the PDA out of the case horizontally along its guide rail on the bottom of the case (see
Figure 22).

Figure 22 – Detaching the PDA from the case

Installation Manual Page 52 of 157


Hardware Installation

3.1.4 Remove the back cover and the Sub cover


Remove the back and the sub covers with Torx T-10 screwdriver

Back Cover

Sub Cover

Figure 23 Removing the Back and Sub Covers

Installation Manual Page 53 of 157


Hardware Installation

3.1.5 Remove the DC Grommet panel from the PDA.


Loosen the four screws on the front panel and two screws on the window of the breakers
with a TORX screwdriver (T10), and detach the front panel from the PDA (see Figure 24)

Figure 24 – Removing the front DC Grommet from the PDA

Installation Manual Page 54 of 157


Hardware Installation

3.1.6 Overall view of the AC connections of the PDA


AC
SPD terminal
DIN Rail block

SPD ground
clamp B

AC ground
clamp A

PDA earth
cable

Strain-
relief

C SPD sensor
F
connection

Figure 25 Internal PDA Layout

The AC mains must be switched off prior to accessing the AC cable.


A disconnect device must be provided in system to ensure that all power conductors (including
all line and neutral conductors) can be disconnected simultaneously). Please refer to Figure 26
– AC input CB Rating for 3- Φ Star, Figure 27, Figure 28 – AC input CB Rating for
3- Φ Delta and Figure 29 – AC input CB Rating for 2- Φ for disconnect device rating.

Installation Manual Page 55 of 157


Hardware Installation

Figure 26 – AC input CB Rating for 3- Φ Star

Figure 27 – AC input CB Rating for 1- Φ

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Figure 28 – AC input CB Rating for 3- Φ Delta

Figure 29 – AC input CB Rating for 2- Φ

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SPD is an optional device and is not included in the original delivery of the FPRB.

It should be ordered separately as per customer requirement.


For the guide in installing the SPD, please refer to Surge Protective Device for Flexi
Power Rectifier – User Manual Artesyn PN: 970-009473-0000.

3.2 Configure the AC terminal block.

Verify the AC power system types in field, and make sure the corresponding bridge
configuration is used.

The AC terminal block has been already configured for 3-phase star AC mains before the
shipment. Therefore the user has to change the AC terminal block configuration if required
referring to the actual AC type in field.
2-phase do not included in below connection char, refer to Figure 46 and Figure 47 for
details.

Insert the short bridges and fasten the screws (provided as accessories) to the corresponding
slots on top of the AC terminal block referring to the AC CABLE CONNECTION CHART located
on the chassis (and reproduced in Figure 30).
Secure the screws with a flat screwdriver, tightening to 1.176 Nm.

Figure 30 – The AC cable connection chart


There are three AC power system types (see Table 6), and thus three AC configurations of the AC
terminal block:

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3.2.1 Single-phase (1Φ) configuration


For Single- phase AC system, use two 3-pole bridges to short the terminals 1, 2, 3 and 4, 5, 6
respectively on the AC terminal block (see Figure 31)

Figure 31 – AC terminal block configuration – 1Φ

3.2.2 2- phase configuration


For 2-phase AC system, use same configuration with Single-phase (1Φ) configuration.
Refer to Figure 31

3.2.3 3- phase delta (3Δ) configuration


For 3-phase delta AC system, use three 2-pole bridges to short the terminals 1, 2 and 3, 4
and 5, 6 respectively on the AC terminal block (see Figure 32 )

Figure 32 – AC terminal block configuration – 3Δ

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3.2.4 3- phase star (3Y) configuration


For 3-phase star AC system, use one 3-pole bridges to short the terminals 1, 2, 3 on the AC
terminal block (see Figure 33)

Figure 33 – AC terminal block configuration – 3Y

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3.3 Insert the AC cable through the front panel.

 All the L, N and PE cables from the AC mains must be at least 12AWG for three-phase
star / delta AC connection, 8AWG for single-phase AC connection.
 The total CSA of AC mains cable should be less than 18mm; otherwise it cannot pass
through the cable gland or the PDA front panel.
 Take care not to break the waterproof of the front panel while inserting the AC cable.

3.3.1 Insert the AC cable through this hole (see Figure 34)

Insert

Figure 34 – Inserting the AC cable through the front panel

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3.4 Make AC connection without the SPD.

 The SPD (Surge Protective Device) is optional for the user. This manual illustrates the
AC connection without the SPD only.
 Refer to the ‘Surge Protective Device for Flexi Power Rectifier – User Manual’ (Artesyn
file NO. 970-009473-0000) for the detailed use of the SPD.
 The colors of the AC mains in this manual are for illustration purpose only. However,
the user should verify the AC mains referring to the color-coding in field.

Before the connection, prepare the AC mains cable as per Table 23. This will provide easier
installation in the following steps.

Table 23 – Recommended preparation for AC mains cable

(Tolerance: 3mm)

AC type L1 L2 L3 N PE

A (mm) 140 115 85


Single-phase (1Φ)
B (mm) 10 20 20

A (mm) 140 85 --
2-phase
B (mm) 10 20 --

A (mm) 140 120 105 -- 85


3-phase delta (3Δ)
B (mm) 10 10 10 -- 20

A (mm) 150 140 125 100 85


3-phase star (3Y)
B (mm) 10 10 10 20 20

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Option 1 – 3-phase star (3Y) AC connection without the SPD

AC mains AC Terminal Block


PE L1 L2 L3 N 1 2 3 4 5 6

Figure 35 – Schematic diagram of AC connection without the SPD – 3Y

1) Configure the AC terminal block as per Figure 33 first and then connect the AC mains to the AC
terminal block as per Figure 35.
2) Detach the adjustable Strain-relief from the chassis by loosening the screw ‘C’ (refer to Figure 25)
with a TORX screwdriver (T25) (see Figure 36)

Figure 36 – Detaching the Strain-relief from the chassis

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3) Prepare the AC mains as per Table 23.


4) Detach the AC ground clamp from the chassis by loosening the screw ‘A’ (refer to Figure 25) with
a TORX screwdriver (T25) (see Figure 37)
5) Fit the PE cable from the AC mains into the AC ground clamp, tightening to 1.176Nm with a flat
screwdriver (see Figure 37)

Figure 37 – Connecting the PE cable from the AC mains – 3Y

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6) Fit the L1, L2 and L3 live cables from the AC mains into terminals ‘6’, ‘5’ and ‘4’ respectively on
the AC terminal block, tightening to 1.176Nm with a flat screwdriver (see Figure 38).
7) Fit the N cable from the AC mains into terminals ‘2’ on the AC terminal block, tightening to
1.176Nm with a flat screwdriver (see Figure 38)

L1

L2
N L3

Figure 38 – Connecting the L and N line cables to the AC terminal block – 3Y

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8) Fix the AC ground clamp with the PE cable from the AC mains back onto its position on the
chassis. Tighten the screw ‘A’ in Figure 25 to 2.0Nm with a TORX screwdriver (T25) (see Figure
39)

Figure 39 – Fixing the AC ground clamp back onto the chassis – 3Y

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9) Restrain the AC cable by fitting the adjustable Strain-relief on the cable socket and tightening the
screw ‘C’ in Figure 25 to 2.0Nm with a TORX screwdriver (T25) (see Figure 40).

Figure 40 – Restraining the AC mains cable onto the chassis – 3Y

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Figure 41 shows the final connection of the 3-phase star AC cable.

L1

L2

PE of AC mains L3

Figure 41 – AC connection without the SPD – 3Y

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 Option 2 – Single-phase (1Φ) AC connection without the SPD


1. Configure first the AC terminal block as per Figure 31)
2. Connect the single-phase AC mains cable in the similar way as connecting the 3-phase star
AC mains described in option 1.
3. Figure 42 and Figure 43 show the phase connection and final single-phase AC mains
connection.

AC mains AC Terminal Block


PE L N 1 2 3 4 5 6

Figure 42 – Schematic diagram of AC connection without the SPD – 1Φ

PE of
AC
mains

Figure 43 – AC connection without the SPD – 1Φ

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 Option 3 – 3-phase delta (3Δ) AC connection without the SPD


1. Configure the AC terminal block as per Figure 32
2. Connect the 3-phase delta AC cable in the similar way as connecting the 3-phase star AC
cable described in option 1. Figure 44 and Figure 45 show the phase connection and final 3-
phase delta AC mains connection.
3. Fit the L1, L2 and L3 live cables from the AC mains into terminals ‘5’, ‘3’ and ‘1’ respectively
on the AC terminal block, tightening to 1.5Nm with a flat screwdriver (see Figure 38)

AC mains AC Terminal Block


PE L1 L2 L3 1 2 3 4 5 6

Figure 44 – Schematic diagram of AC connection without the SPD – 3Δ

L3
L2

PE of AC
mains

L1

Figure 45 – AC connection without the SPD – 3Δ

Use DMM to measure L1-L2 voltage


Ensure L1-L2 voltage between 180VAC-276VAC

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Option 4 – 2-phase AC connection without the SPD


1. Configure the AC terminal block as per Figure 32
2. Connect the 2-phase AC cable in the similar way as connecting the 3-phase star AC cable
described in option 1.
3. Fit the L1 and L2 live cables from the AC mains into terminals ‘5’ and ‘2’ respectively on the
AC terminal block, tightening to 1.5Nm with a flat screwdriver (see Figure 38)
4. Figure 46 and Figure 47 show the phase connection and final 2-phase delta AC mains
connection.

AC mains AC Terminal Block


N PEL1 L L2 N 1 2 3 4 5 6

Figure 46 – Schematic diagram of AC connection without the SPD – 2-phase

L1

L2

N of AC mains

Figure 47 –AC connection without the SPD – 2-phase

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3.5 Secure the back cover.


Put the back cover back onto the PDA, and secure the four screws following two steps listed in
Table 24. Tightening the screws orderly will avoid damage to the waterproof gasket at the joint
(see Figure 48).

Table 24 – Flow chart of securing the sub cover

Step Sequence Torque (kgf-CM)

1 1, 2, 3, 4,5,6,7,8,9,10,11 6~8
Clockwise

Figure 48 Secure the back cover

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Before securing the rear cover,


Recheck the connection of the AC cables and make sure the protective earth terminals have
been correctly connected.
There should not be any loose parts, wires in the PDA.

3.6 Insert the cables through the cable gland if required.

Before inserting the cables through the cable gland, the AC mains and battery blocks must
be switched off.

If the cable gland was used, the AC mains cable, DC cables, temperature cable and parallel
cable are mandatory, however the Alarm In and Alarm Out cables are optional to pass
through the cable gland before installing them into the PDA.

The two cable glands are usually used as cable entries or bases on which the front cover of
the FPRB are installed. The user decides either to use the left, right or both cable glands
referring to the placement of the FPRB in field.

If two cable glands are used, the holes in the same position on the two cable glands are
used for the same cable. The use of the right cable gland is for illustration herein.
The cable gland configuration shown herein is recommended for the user; however the user
can distribute the holes in field freely.

Do not strip the end insulator of the cables prior to inserting them through the cable gland to
prevent crisscross.

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Figure 49 shows cable gland configuration

AC cable
Slot

DC GND
Slot

Figure 49 Cable Gland Configuration

Puncture the waterproof of the cable gland with an awl (Φ2mm), and insert the corresponding
cable through the hole (see Figure 50).

Take care not to break the waterproof of the cable gland while inserting the cable.

Figure 50 – Inserting the cable through the cable gland

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3.7 Route the DC cables


1 Detach the drawer from the PDA.
2 Loosen the two screws with a Cross screwdriver, and pull the drawer out of the PDA (see Figure
51)

Figure 51 – Removing the drawer from the PDA

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3 Identify the DC terminals.

The lower DC terminals and “RTN1~5” are shorted together for the positive earth connection
and connected to the system earth mechanically for Non-US Version. For the US or Global
Version, the positive is isolated from the Earth or Chassis. The upper DC terminals are for the –
48V connection.
Identify the DC terminals and the marks on the DC inlet grommet. The DC terminals internal the
PDA and the pre-exit holes on the DC inlet grommet are in the one-to-one relationship (see Figure
52 and Figure 53

The names in Figure 52 and Figure 53 are for illustration purpose only. They are not printed
on the DC inlet grommet.

The “+/-” in Figure 52 and Figure 53 indicates the proper polarity of the load or battery string
to be connected.

In the event that the load in field has a protective earth cable, the user can connect this
grounding cable into any of the terminals in the lower row.

LOAD2(-) BAT1(-) BAT2(-)

CB2 CB3
CB1 CB4 CB5 BAT3(-)

LOAD1(-)

Insulator

RTN4(+)

RTN5(+)
LOAD
GND

RTN1(+) RTN2(+) RTN3(+)

Figure 52 – DC terminals distribution

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LOAD2(-) BAT1(-) BAT2(-) BAT3(-)


LOAD1(-)

Fixing
pole
LOAD
GND

RTN5(-)

RTN1(-) RTN2(- RTN3(-) RTN4(-)

Figure 53 – DC inlet grommet

4 Configuration of the DC cables.

Make sure to switch off the battery strings before configuring the DC cables.

 In any DC cables configuration, the current passing through each MCB cannot
exceed 63A for Battery terminals and 80A for Load terminals.
 When the Load / battery terminals are configured for different loads / batteries, the
short link for load / battery terminals and switch lever bar for load / battery MCB must
be removed.

There are three options for the battery and load cable configuration in field (see Table 25) and
Table 26).

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Table 25 – Three typical battery / load cables configurations for Non Global Version

CSA size Cable Recommended Installing Breakers


Option Cable name 2 (2)
(mm ) number sequence configuration

Load & return 35 2 Load MCB


→ RTN2(+) → parallel
(3)
1 Battery & return 50 2 LOAD2(-) &
→ RTN5(+) → BAT2(-) Battery MCB
(1)
Load Grounding 35 1 parallel

Load & Return 35 4


→ RTN1(+) → LOAD1(-)
→ RTN2(+) → LOAD2(-) →
2 Battery & return 35 6 RTN3(+)→BAT1(-) → No MCB parallel
RTN4(+) → BAT2(-)
Load Grounding
(1)
35 1 →RTN5(+) → BAT3(-)

Load & Return 35 2


→ RTN1(+) → LOAD2(-)
→ RTN3(+)→ BAT1(-) → Load MCB
3 Battery & return 16 6
RTN4(+) → BAT2(-)→ parallel
(1) RTN5(+) → BAT3(-)
Load Grounding 35 1

Note:
1) The user determines whether to use the DC load grounding cable referring to the battery and
load conditions in field.
2) It is easier to install the individual DC cable into the indicated DC terminal plug following the
recommended sequence by installing the (lower connection) RTN cables first followed by the
Load and Battery main cables (upper connection)
3) The total CSA of the cables applied in one DC terminal plug cannot exceed 50 mm2. The user
is to choose the proper DC cables in field.

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Table 26 – Three typical battery / load cables configurations for Global Version

CSA size Cable Recommended Installing Breakers


Option Cable name 2 (2)
(mm ) number sequence configuration

Load & return 35 2 Load MCB


parallel
RTN2(+) → LOAD2(-)
1 &
→ RTN5(+) → BAT2(-)
Battery & return 50
(3)
2 Battery MCB
parallel

Load & Return 35 4 RTN1(+) → LOAD1(-)


→ RTN2(+) → LOAD2(-) →
No MCB
2 RTN3(+)→BAT1(-) →
parallel
RTN4(+) → BAT2(-)
Battery & return 35 6 →RTN5(+) → BAT3(-)

Load & Return 35 2 RTN1(+) → LOAD2(-)


→ RTN3(+)→ BAT1(-) → Load MCB
3
RTN4(+) → BAT2(-)→ parallel
RTN5(+) → BAT3(-)
Battery & return 16 6

Note:
1) The user determines whether to use the DC load grounding cable referring to the battery and
load conditions in field.
2) It is easier to install the individual DC cable into the indicated DC terminal plug following the
recommended sequence by installing the (lower connection) RTN cables first followed by the
Load and Battery main cables (upper connection)
3) The total CSA of the cables applied in one DC terminal plug cannot exceed 50 mm2. The user
is to choose the proper DC cables in field.

5 Connect the DC cables.


Install the DC cables following the recommended sequence in Table 25.
1) Insert the DC load grounding cable through the front panel. Not applicable for Global Version

 Do not break the white insulators between the DC terminal blocks (see Figure 52)
while accessing the cables to prevent short circuit.
 Check the polarity of the load or battery strings according Figure 52 so as to connect
to the right position.

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 Ensure the cables go through the side cable gland firstly.


 During the installation of the DC cables, the associated breakers must always be in
the OFF position.

2
The typical DC cables configuration (option 1 in Table 25, however use CSA 35mm
cables for battery and return) is for illustration in this manual.

Take care not to break the waterproofing rubber while inserting the DC cable through the
grommet.

Keep the front panel about 10cm away from the PDA, for easier access in the following
steps.

2) Cut the opening on the DC Grommet and insert the cable accordingly. Refer to for detailed
cable sizing and cutting of the DC Grommet.

Layer 1

Layer 2

Layer 3

Cut the layer of the


cone according to
the size of the cable
to be inserted.

Figure 54 – Inserting the DC load and battery cables through the DC front panel cover

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Layer 1

Layer 2

Cut the layer of the


cone according to
the size of the cable
to be inserted.

Figure 55 Inserting the DC Cable and Battery cable - Back Panel Grommet

Cable Size Diameter DC Grommet Layer DC Grommet Layer


(mm) (Front) (Back)

8.5 Cut layer 1 No need to cut

11 Cut layer 2 No need to cut

14 Cut layer 3 Cut layer 1

Table 27 DC Grommet layer Cutting Guide

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3) Insert the DC cables 15cm from the DC Grommet for easy installation on the terminal lug.

Figure 56 Inserting the DC cables into the DC Grommet

4) After the wire has been inserted, peel the end insulator of the cable with a wire-stripper, and
keep a bare end of about 15mm.

5) Insert the bare end of the cable to DC terminal (refer to Figure 52), and secure the cable
with a Hex screwdriver 4mm, tightening the according with Figure 16)

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Figure 57 – Securing the DC load and battery cables


6) Connect the other DC cables. Bottom first then the top.
7) Repeat the above two steps of connecting the DC load grounding cable; user shall install the
other DC cables one by one into the PDA.
8) The installation based on the indicated DC terminals and sequence in Table 25 is preferred.
9) Put the front panel back into the PDA. Push the front panel back into the PDA, while dragging
out the DC cables and keeping them in order to prevent crisscross.

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6 Secure the DC cover front panel.


Secure the four screws on the front panel following two steps listed in Table 28. Tightening
the screws orderly will avoid damage to the waterproof or distortion to the front panel (see
Figure 58).

Table 28 – Flow chart of securing the front panel

Step Sequence Torque (kgf-CM)

1 1, 2, 3, 4 6~8

3
1

4
2

Figure 58 – Securing the front panel

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7 Secure the window of the breakers.


Secure the two screws on the breaker window with a TORX screwdriver (T10), tightening to 6
~ 8 kgf-CM (see Figure 59)

Figure 59 – Securing the window of the breakers

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8 Fix the DC cables to the front panel.


Fix the DC cables to the corresponding side poles with cable ties (see Figure 60)

Figure 60 – Fixing the DC cables to the front panel

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9 Secure the sub cover.


Put the sub cover back onto the PDA, and secure the four screws following two steps listed in
Table 29. Tightening the screws orderly will avoid damage to the waterproof gasket at the joint
(see Figure 61).

Table 29 – Flow chart of securing the sub cover

Step Sequence Torque (kgf-CM)

1 1, 2, 3, 4 6~8

1 Figure 61 – Securing the sub cover

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3.8 Route the Communication cables

 Wear an ESD wrist strap and make sure it has been well grounded before accessing the
drawer.
 Here shows two drawers of old and updated versions, and different installation methods
as well.
 Correctly grounding the cable shield is crucial to the electromagnetic compatibility (EMC)
of the entire system.

The drawer of updated version has no significant differences from the old one, except for
adding a punch on the drawer sidewall to fix the communication cables (see Figure 62).

Gasket C A
B Connector

J11

J22

Figure 62 – Drawer internal layout

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From PSU
To Rect 1

To PSU
To Rect 2

Alarm In
To Rect 3

Alarm Out

Temp
Sensor

Figure 63 Slot Designator of the PDA Drawer

3.9 Connect the temperature cable.


Cut the cone of the waterproof gasket marked ‘TEMP’ on the drawer panel (see Figure 64 and
then insert the temperature cable through this hole)

Take care not to break the waterproof of the gasket while inserting the communication
cable.

Refer to for cutting the layer of the rubber cone on the Drawer front panel

Table 30 Drawer Grommet Cutting Guide

Cable Size Diameter (mm) Grommet Layer (Front) Grommet Layer (Back)

5.5 (Alarm Cables) Cut layer 1 No need to cut

4.3 (Signal Cables) Cut layer 1 No need to cut

14 (RS485 cables) Cut layer 1 No need to cut

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Cut silicone
rubber

Figure 64 – Inserting the temperature cable into drawer


Runs the temperature cable under the three RS485 cables and connects the core wires into
terminal block J22 as per the one-to-one relationships in Table 31 (see Figure 65).

 J22 is a “Push fit” terminal block. Press the top button of each jack with a flat
screwdriver to insert the bare end of each wire entirely, and then release the button
to secure the wire.
 The vendor has prepared the bare end of each wire.
 For updated drawer installation, the temperature cable doesn’t need to go under the
three RS485 cables (see Figure 62)

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Table 31 – The connection of the temperature cable

Pin of J22 Name Color

7 TEM_GND Red

8 TEM SENSE_IN White

9 TEMP_VCC Black

10 EARTH Cable screen

Figure 65 – Connecting the temperature cable only (Reference Photo)

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Put the temperature probe between the battery blocks where might has the highest temperature
(see Figure 66).

Figure 66 – Placing the temperature probe

3.10 Connect the parallel cable.

 The parallel cable is used for the communication between the FPRB units when they are
configured in parallel.
 The parallel cable is to be installed when the FPRB units are configured in parallel.
Otherwise it does not need to install the parallel cable.
 Refer to section Parallel installation of the FPRB for more details about parallel cable
configuration.
 Also refer to the Parallel System Configuration matrix in Table 22

Cut top most layer of the cone of the waterproof marked ‘From PSU’ or ‘To PSU’ on the drawer
gasket to insert the parallel cable like in Figure 64
For each parallel cable, it connects the “From PSU” pins in one drawer and “To PSU” pins in
another drawer (refer to Table 32) to parallel the two systems.
Runs the parallel cable under the three RS485 cables and connects the parallel cable to J22 as
per the one-to-one relationships listed in Table 32 (see, Figure 67, Figure 68).

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 For updated drawer installation, the parallel cable doesn’t need to go under the
three RS485 cables (see Figure 67, Figure 68).

Table 32 – The connection of the parallel cable

Option Pin of J22 Name Color

From PSU 1 RS422RD- Red

2 RS422RD+ White

3 SGND/F Black

11 EARTH Cable screen

To PSU 4 RS422TX- Red

5 RS422TX+ White

6 SGND/F Black

12 EARTH Cable screen

Figure 67 – Connecting the parallel cable only – From PSU

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Figure 68 – Connecting the parallel cable only – To PSU

3.11 Connect the Alarm cable.

As the user provides its own Alarm In and Alarm Out cables,
 The connections of the Alarm In and Alarm Out cables shown in this manual are for
illustration purpose only.
 The colors selected to illustrate the Alarm In and Alarm Out wires do not have
significances and are only there to help distinguish the wires.
 The user may use one Alarm cable, in which combined the Alarm In and Alarm Out
functional wires together. Connect each wire to the right pin as connecting the Alarm
In and Alarm Out cables separately. Two Alarm cables are for illustration herein.
 There are two holes on the drawer gasket for the alarm cable. Any terminal can be
use for Alarm In or Alarm Out cable. Refer to Figure 63

1. Cut the waterproof marked ‘Alarm’ on the drawer gasket with an awl (diameter of 2mm) to
insert the Alarm cable like in Figure 64
2. Runs the Alarm cable under the three RS485 cables and connects the Alarm cable into
J11 as per the one-to-one relationships listed in Table 33 (See Figure 69)

User is permitted to detach the three RS 485 plugs to connect the Alarm cables easily
and then recover the RS 485 cables to the original position.

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Table 33 – The connection of the Alarm cable

Pin of J11 Name Color

1 ALARM IN (-)

2 ALARM IN (+)

3 ALARM_COM

4 MAINS 1

5 ALARM_COM

6 MAINS 2

7 ALARM_COM
Reference
8 MAINS 3

9 ALARM_COM

10 CRITICAL

11 ALARM_COM

12 MAJOR

13 ALARM_COM

14 MINOR

Pin of J22 Name Color

13 RELAY_COM (Genset signal Out)

14 RELAY_NO (Genset signal Out)

3. Connect the Alarm In cable into J11 as per the one-to-one relationships listed in Table 33
(See Figure 69)
4. Connect the Genset signal out cable into J22 pin 13 and pin 14 as per Table 33. (See
Figure 69)

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5. Fix the Alarm In cable to position “A” and the Genset signal cable to position “B” on the
drawer. Fix the cable with cable tie as per “C” (see Figure 69)

A – From customer ATS signal

B – To customer Genset

Figure 69 – Connecting the Alarm In cable and the Genset signal Cable

Table 34 – The connection of the ATS Signal and Genset Output

Signal Pin of J11 Name Color

From 1 ALARM IN (-) White


Customer
ATS 2 ALARM IN (+) Black

Signal Pin of J22 Name Color

To Genset 13 RELAY_COM Cable Screen

14 RELAY_NO Red

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6. Connect the Alarm Out cable into J11 as per the one-to-one relationships listed in Table
33 (See Figure 70)
7. Fix the Alarm Out cable with the bare cable screen to position ‘B’ on the drawer in Figure
70 with a cable-tie, and make sure the cable screen firmly touches the sidewall of the
drawer (see Figure 70). This provides the grounding of the cable screen.

Figure 70 – Connecting the Alarm Out cable

3.12 Fix the communication cables.


After connecting all communication cables following the above steps:

For updated drawer, Assemble the Alarm cables and fix them to position ‘C’, the temperature
cable and parallel cables to position ‘D’ in Figure 71 with a cable-tie (see Figure 71).

Figure 71 – Fixing all the communication cables (Photo for Connection Reference Only)

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3.13 Secure the drawer to the PDA.

Push the drawer back into its slot horizontally until the drawer pin matches the internal connector
of the PDA (see Figure 72)

Figure 72 – Putting the drawer back into the PDA

Secure the two thumbscrews on the drawer panel by using a Cross screwdriver with a torque of
0.6~0.8 kgf-CM (see Figure 72.

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3.14 Install the PDA into shelf

3.14.1 Put the PDA back into the shelf.

Push the PDA horizontally along its bottom guide rail until it reaches the end of the shelf (see
Figure 73).

Figure 73 – Putting the PDA back into the shelf

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3.14.2 Secure the PDA.

Secure the two thumbscrews on the PDA front panel with a Cross screwdriver, tightening to 12-16
kgf-CM (see Figure 74).

Figure 74 – Securing the PDA to the case

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3.14.3 Connect the PDA earth cable to the case.


Secure the PDA earth cable from the PDA to the grounding pole ‘A’ on the case, tightening to
2.0Nm with a wrench (8 mm) (see Figure 75).

Figure 75 – Connecting the PDA earth cable to the case

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Hardware Installation

3.14.4 Connect the system earth cable.


Secure the system earth cable from the PDA to the ground pole ‘B’ on the case, tightening to
2.0Nm with a wrench (8 mm) (see Figure 76).

Figure 76 – Connecting the system earth cable

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Hardware Installation

3.14.5 Connect the Ethernet cable if required.

The FPRB is equipped with an Ethernet cable with built-in rubber sealing to meet IP65 protection
requirement.

Remove

Figure 77 Connecting the Ethernet Cable

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Hardware Installation

3.15 Install the Rectifiers

 Start the installation of the rectifiers from the first slot on (on your left, when facing the
case):
 When only one rectifier is needed, install it into the first slot.
 When two rectifiers are needed, install them into the first and second slots.

Before the installation, take off the silicon caps of the rectifier DC bus bar and save them for re-
use.

1
Remove

Figure 78 Removing the silicon caps on the Rectifier DC terminal

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Hardware Installation

3.15.1 Put the rectifier into the slot.


Push the rectifier horizontally into the first slot until it reaches the end of the case (see
Figure 79)

Figure 79 – Putting the rectifier into the first slot of the case

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Hardware Installation

3.15.2 Secure the rectifier.


Secure the two thumbscrews on the rectifier front panel with a Cross screwdriver,
tightening to 1.2Nm (see Figure 80).

Figure 80 – Securing the rectifier to the case

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Hardware Installation

3.15.3 Connect the RS485 cable to the rectifier.


Connect the RS485 cable to its interface on the rectifier and cover the connector
entirely with the waterproof gasket (see Figure 81).
Finally tighten the two screws to 0.8Nm with a Torx screwdriver to fix the RS485
connector (see Figure 81).

3.15.4 Connect the AC power cable to the rectifier.


Connect the AC input cable, and then tighten the two screws to 0.8Nm with a Flat
screwdriver (see Figure 81).

1
2

Figure 81 – Connecting the AC power cable to the rectifier

 Before connection, take off the silicon caps of the AC input connector, the RS485 cable

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Hardware Installation

connector and save them for re-use.


 The three RS485 cables are of the different lengths and cannot be mixed. The shortest
one is for the leftmost rectifier (face to the FPRB), the middle one for the middle rectifier
and the longest one for the rightmost rectifier.

The pressing plate of the RS485 cable should be properly fastened and installed to the
Rectifier to comply with IP65 requirement. However in some cases, non-IP65 Rectifiers
will be used or installed into the FPRB shelf, an extra pressing plate is included and will
be use when installed in an IP65 shelf. Refer to Table 38 for the correct configuration
between Rectifiers and Shelf.

3.15.5 Install the other rectifiers if required.


Install the other rectifiers in the same way as installing the first rectifier (See Figure
82).

Figure 82 – Installing the other rectifiers

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Hardware Installation

3.15.6 Installation of the cables with cable glands


The alarm cable exits from system top

The cables can break out from left or right or both sides of the FPRB. The cables exit from
the right cable gland is described in detail.

The alarm cable (usually combines the Alarm In and Alarm Out cables together) may exit
from top of the case or through the cable gland. Herein illustrates the alarm cable breaking
out from the system top. In the latter pictures, the alarm cable is defaulted to break out from
the cable gland.

Take off the plastic cover on the case top surface and pull the alarm cable out through
the gap (see Figure 83).

Alarm cable

Figure 83 – Alarm cable exits from top of the case (Reference only)

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Hardware Installation

3.15.7 Install the two cable glands into the case


Secure the two cable glands back onto the case, tightening the screws ‘A’ and ‘B’ to
2.0Nm with TORX screwdriver (T25) (see Figure 84).
84

B
A

A B

Figure 84 Installing the Cable Glands

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Hardware Installation

3.15.8 Fix the cables to the cable gland.

Fit the cables in the cable gland and fix them with cable ties (see Figure 85).

Figure 85 – Fixing the cables to the cable gland

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Hardware Installation

3.15.9 Fix the cables to the side of the case if required.

It is optional for the end user to fix the cables to the side cable plate. However the user is
recommended to arrange the cables in the indicated way in this step if required.

Some thin cables such as communication cables can be tied to the thicker cables such as AC
cable, DC cable, etc.

The AC cable can be fixed to the side cable plate with cable restraints. Close the cable restraints
with M3 screws ‘A’ (supplied as accessories), tightening to 0.6Nm (see Figure 86).

A A

A A

Figure 86 – Fixing the AC cable to the side of the case

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Hardware Installation

3.15.10 Fix the other cables to the side cable plate with cable-ties (see Figure 87).

Figure 87 – Fixing the cables to the case sidewall (Reference only)

3.15.11 Fix the PDA earth cable.


Fix the PDA earth cable to the cable gland on position ‘A’ with cable tie so as not to block the LCD
(see Figure 88).

Figure 88 – Fixing the PDA earth cable

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Hardware Installation

All the cables may exit from right or left of the FPRB (see Figure 89, Figure 90).

Figure 89 – Cables exit from right of the FPRB (Reference only for cable exit)

Figure 90 – Cables exit from left of the FPRB (Reference only for cable exit)

The cables can also exit from both sides of the FPRB. It is recommended that the AC cable and the
communication cables exit from right and the DC cables and system earth cable exit from left of the
FPRB (see Figure 91).

Figure 91 – Cables exit from both sides of the FPRB (Reference only for cable exit)

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Hardware Installation

3.16 Install the front and back covers

The FPRB is IP65 rated with or without front and back covers.

3.16.1 Install the front cover to the FPRB.


Put the front plastic cover in place, and fix the two screws to position ‘A’ and ‘B’ on the cable
glands, tightening to 2.0Nm with a TORX screwdriver (T25) (see Figure 92).

B
A

Figure 92 – Installing the front cover to the FPRB

3.16.2 Install the rear cover to the FPRB.


Put the back plastic cover in place, and fix the two screws to position ‘C’ and ‘D’ on back of the
FPRB, tightening to 2.0Nm with a TORX screwdriver (T25) (see Figure 93).

C D

Figure 93 – Installing the back cover to the FPRB

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Hardware Installation

Figure 94, Figure 95 and Figure 96 show the general view of the FPRB after completing all the
installation items.

Figure 94 – General view of the FPRB IP54 version – cables run from right (Reference only for
cable exit)

Figure 95 – General view of the FPRB IP54 version – cables run from left (Reference only for cable
exit)

Figure 96 – General view of the FPRB IP54 version – cables run from both sides (Reference only
for cable exit)

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Hardware Installation

3.17 Parallel installation of the FPRB

 In the event that BTS site configuration exceeds the power rating of a single FPRB unit, the
user can configure up to a maximum of three FPRB units in a parallel mode to share the
battery blocks and support the different loads.
 In parallel configuration, two or three FPRB units can be stacked together or positioned
separately within 3 meters of each other. Only the stacked configuration is illustrated in this
manual.

 FPRB parallel operation only support by CU firmware R1Bx or later. Parallel operation
is not supported by CU firmware PxAx, RxAx and other former CU firmware.
 When upgrade the CU firmware for the paralleled FPRB systems, each FPRB unit
needs to be updated and re-started after the upgrade.
 The S/N on the label is also the same of the internal CU.
 Mixing of 2kW (NSN Code CS7000001 or CS7000021) with 3kW (CS7000031) is
not allowed. Refer to Table 22

 The Master / Slave setup of the FPRB units in parallel


 The FPRB will be paralleled in a master / slave mode. User can control and review all the
FPRB units in the parallel system through the master FPRB, either via LCD or web GUI.
 After powering on each FPRB unit in a parallel system, the CU will detect the serial number
(S/N) of each FPRB, and the unit with the newest S/N is defaulted as the master.
 According to the S/N definition in Figure 97, a S/N number ‘G7083770009’ contains the
information: plant code ‘G7’, manufacture date ‘Year 2008, Week 37’, sequence number
‘70009’.
 For example in Figure 98, the ‘FPRB #1’ is defaulted as the master and the other two units as
the slaves since the S/N ‘G7083770009’ is newer than ‘G7081500036’ and ‘G7074801770’.
 Slave shelf or shelves are distinguished by blinking Green LEDs on the PDA.

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Hardware Installation

Figure 97 – Serial number of the FPRB unit

FPRB #1 #1
FPRA
S/N: G7083770009

Master

FPRA
FPRB #2 #2 FPRA
FPRB #3 #3
S/N: G7081500036 S/N: G7074801770

Slave Slave

Figure 98 – Master/slave definition of FPRB units in parallel

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Hardware Installation

 The parallel installation of the two FPRB units Figure 100, Figure 101 and Figure 102 show some
parallel configuration examples of the two FPRB units.
The user should choose a proper configuration referring to the actual battery/load conditions in
field.

Figure 99 shows the current sharing between two battery blocks. The load / battery
switch lever bar and terminal short link should be removed when the breakers
supporting separate load / battery. Therefore each battery block will be protected by
MCBs from over current.

 In Figure 99, the blue and green arrows indicate that the battery might charge or discharge
from different bus bars via the sharing cable connecting the two or three FPRB systems.
The red arrow indicates the loop current that might happen between the battery blocks.
 The current flow in Figure 99, represents all possibilities that will happen in FPRB parallel
configuration.
 6KW and 9KW systems cannot be mixed in parallel configurations.

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Hardware Installation

Bus bar

MCB MCB MCB

PDA

BAT sharing
BAT cable

PDA

MCB MCB MCB

Bus bar
Note: current flow path and direction

Figure 99 – Current flow of two battery blocks in parallel

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Hardware Installation

Figure 100 shows the two FPRB units parallel configuration with a single battery block
2
feed. The battery string requires a total CSA of 50mm and might be made of separate
cables jointed in one clamp.

RJ45
PC
AC in

Load1

Load2
PDA #1

RS422

Battery Cabinet RS422

Load1

Load2

PDA #2
AC in

Figure 100 – Example of a parallel configuration – 2 FPRBs & 1 BAT

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Hardware Installation

Figure 101 shows the two FPRB units parallel configuration with an individual battery block feed with
2
batteries connected in parallel. The battery string requires a total CSA of 50mm and might be made of
separate cables jointed in one clamp.

RJ45
Battery Cabinet
PC
AC in

Load1
Load2
PDA #1

RS422

RS422

Load1
Load2
PDA #2 AC in

Figure 101 – Example of a parallel configuration – 2 FPRBs & 4 BATs

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Hardware Installation

 Each BAT clamp of the PDA allows only one cable connection in order to keep the
waterproof function. Thus when configuring over 6 BAT strings with separate cable
runs per string for two FPRB systems, the end user must use external terminal blocks
to share current as shown in Figure 102.
2 2
 As per Table 25, the battery strings in Figure 102 should be of CSA 16mm or 35mm
for different load configurations.
 The end user should prepare the external terminal block if needed.

External
Battery Cabinet Terminal Block

RJ45
PC
AC in

Load1
PDA #1
Load2

RS422

RS422

Load1
PDA #2
Load2

AC in

Figure 102 – Example of a parallel configuration – 2 FPRBs & 6 BATs

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Hardware Installation

3.17.1 Stack the two FPRB units.


Stack the two FPRB units in place that ‘A’ and ‘B’ on the lower FPRB top surface match ‘A’’ and
‘B’’ on the upper FPRB bottom surface respectively (see Figure 103 and Figure 104)

A’ A
A A

A’ Upper Lower
bottom A A top
’ A

B
B’ B
’ B

Figure 103 – The locating points on the FPRB

Figure 104 – Stacking the two FPRB units

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Hardware Installation

3.17.2 Fix the two FPRB units.


Fix the two FPRB units in positions ‘A’ and ‘B’, tightening to 2.0Nm with a Torx screwdriver (T25)
(see Figure 105).

B
A

Figure 105 – Fixing the two FPRB units

3.17.3 Parallel the two FPRB units.


Connect the two FPRB units by configuring the two parallel cables within the two drawers (see
Figure 106, Figure 107).

The two parallel cables should pass through the cable glands before installing into the drawers.

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Hardware Installation

J22 #1 J22 #2
11 12
1 4
Parallel cable #1
2 5
3 6
4 1
5 2
Parallel cable #2
6 3
12 11

Figure 106 – Parallel cable configuration within the two drawers

Parallel
cable #2
Parallel
cable #2
Parallel
cable #1
Parallel
cable #1

Drawer #1 1 Drawer #2 2

Figure 107 – Paralleling the two drawers (updated version)

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Hardware Installation

3.17.4 Install the two FPRB units.

 The FPRB units in parallel can share the same temperature cable, Ethernet cable, Alarm
In cable, and Alarm Out cable. Therefore anyone drawer can be installed the parallel
cable only while the other one is fully installed with all the communication cables (refer to
section Route the Communication cables).
 If the Ethernet cable is needed, installed it to the top FPRB.
 The cables breaking out from system right is for illustration herein.

Parallel
cable #1

Parallel
cable #2

Figure 108 – Installing the two FPRB units

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Hardware Installation

(5) Install the front and rear covers.


Install the front and rear covers to each FPRB unit following the procedure in section 3.16.Figure
109 shows the general view of the two FPRB units after completing all the parallel installation
items.

Parallel
cable #1

Parallel
cable #2
Figure 109 – General view of the two FPRB units in parallel

 Parallel installation of the three FPRB units


Figure 108, Figure 111 and Figure 112 show some parallel examples of three FPRB units.
The user should choose a proper configuration referring to the actual battery/load conditions in
field.

Figure 99 shows the current sharing between the two battery blocks. The load / battery
switch lever bar and terminal short link should be removed when the breakers supporting
separate load / battery. Therefore each battery block will be protected by MCBs from
over current.

Figure 110 shows the three FPRB units parallel configuration with a single battery block feed. The
2
battery string requires a total CSA of 50mm and might be made of separate cables jointed in one
clamp.

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Hardware Installation

RJ45
PC
AC in

Load1
PDA #1
Load2

RS422

Battery Cabinet
AC in

Load1
PDA #2
Load2

RS422

RS422

Load1

Load2

AC in
PDA #3

Figure 110 – Example of a parallel configuration – 3 FPRBs & 1 BAT

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Hardware Installation

Battery Cabinet
RJ45
PC
AC in

Load1
PDA #1
Load2

RS422

AC in

Load1
PDA #2 Load2

RS422

RS422

Load1
Load2

AC in
PDA #3

Figure 111 – Example of a parallel configuration – 3 FPRBs & 5 BATs

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Hardware Installation

 Each BAT clamp of the PDA allows only one cable connection in order to keep the waterproof
function. Thus when configuring over 5 BAT strings with separate cable runs per string for
three FPRB parallel units, the end user must use external terminal blocks to share the current
as shown in Figure 112.
2 2
 As per Table 25, the battery strings in Figure 112 should be of CSA 16mm or 35mm for
different load configurations.
 The end user should prepare the external terminal block if needed.

External
Battery Cabinet Terminal Block

RJ45
PC
AC in

Load1
PDA #1
Load2

RS422

AC in

Load1
PDA #2
Load2

RS422

RS422

Load1
PDA #3 Load2

AC in

Figure 112 – Example of a parallel configuration – 3 FPRBs & 9 BATs

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Hardware Installation

The parallel installation of three FPRB units is similar with that of the two FPRB units, except the
connection of the three parallel cables (see Figure 113, Figure 114).

J22 #1 J22 #2
11 12
1 4
Parallel cable #1
2 5
3 6
4 1
5 2
6 3
12 11

Parallel Parallel
cable #2 cable #3

J22 #3
11 1 2 3 4 5 6 12
Figure 113 – Parallel cable configuration within the three drawers

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Hardware Installation

Parallel
Parallel Parallel Parallel cable #2
cable #1 cable #1 cable #3

Parallel
cable #3

Parallel 1 2 3
Drawer #3
cable #2
Drawer #1 Drawer #2 Drawer #3
Figure 114 – Paralleling the three drawers

Figure 115 shows the general view of the three FPRB units after completing all the parallel installation
items.

Parallel
cable #1

Parallel
cable #2

Parallel
cable #3
Figure 115 – General view of the three FPRB units in parallel

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Browser and Control Unit Setup

Chapter 4 Browser and Control Unit Setup

This chapter describes how to set up the FPRB Control Unit (CU) and the User’s PC, in order
to be able to connect to the CU via the Web-based Graphical User Interface (GUI).
The web-based GUI is optimized for a resolution of 1024 x 768 pixels or higher.
Microsoft Internet Explorer and Mozilla Firefox browsers are both supported and are available
for download free of charge from their suppliers:
 Microsoft Internet Explorer: www.microsoft.com
 Mozilla Firefox: www.mozilla.com
The CU provides boundless connectivity within private intranets, which includes connections
via Virtual Private Network (VPN). It also supports direct connection between the User’s PC
and the FPRB CU. Following the IEEE rules, each CU has its own unique MAC address.
There are two ways to change the CU IP-address to connect to the user’s PC in the local
Internet / intranet.

For the browser and CU setup, the unit requires powered up.
 Make sure all the protective earth terminals; extension cords, and devices connected to the
FPRB are well grounded. Any interruption in the protective grounding will cause a potential
shock hazard that might injure people.
 There must be lightning protection if the setup is carried out outdoors.
 FPRB is equipped with Ethernet cable with built-in connector rubber sealing to meet IP65
protection.

4.1 Set up the configuration environment


Set up the configuration environment was shown in Figure 116.

User can use the end equipment in filed -- the BTS as the loads and battery blocks as DC
source for configuration as shown in Figure 116, but make sure:
 All the breakers are in the OFF position before powering on the PDA.
 The field battery blocks should have a voltage between 43V and 54V.
 Verify the polarity of the battery leads and their connection before connecting them to the
PDA.
 Verify that there are no shorts between the loads, batteries, and returns strings. Use a
multi-meter to ensure this at the DC cable terminals.

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Browser an
andd Control Unit Setup

FPRB

Figure 116 – Setting up the configuration environment

Connect the FPRB to the user’s PC with an Ethernet cable.


Turn on the three battery circuit breakers to power up the PDA, and verify its normal
operation through the LED status on PDA front panel as per Table 13.
13

4.2 Change the CU IP


IP-address
address via the LCD
After normal power on, the user can view the information embedded in the CU via the LCD.
Refer to Appe
Appendix
ndix B of the ‘Flexi Power Rectifier – User Manual’ ((Artesyn
Artesyn file No. 970
970--
00947
009474--0000
0000)) for the detailed use of the PDA LCD.
The user can read and change some system information via the LCD, e.g. the battery
settings, the factory settings, alarm settings, e
etc.
tc.
Change the CU IP IP-address
address into the local IP IP--range.
range. E.g. if the local user’s PC former IP
IP-
address is “192.168.100.100”, the CU IP IP-address
address should be changed to “192.168.100.x” (the
last digit “x” should be different from that in the user’s PC IP
IP-address).
address).
In the parallel configuration, each CU should be changed the IP IP--address
address to “192.168.100.x”
(different last digit “x” for different CU and local user’s PC). In this way, the user’s PC can
access each CU in the local Internet / Intranet.
Now the user can link to the PDA CU with the Ethernet cable.

4.3 Connect to the GUI in local Internet / Intranet


Assume that the CU IP
IP--address
address is “192.168.100.101”. Open the browser and type the target
address in the address field “192.168.100.101” to connect the CU in the local Internet /
Intranet.
The GUI will ask for a “username” and “password” (see Figure 117
117.
The following users are supported:
 Root User: Full Access to all functionality of the FPRB System, released to the user.
o Username: “root”
o Password: “default” (this password can be changed as one of the functionalities
of the Root User)

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Browser and Control Unit Setup

 Admin User: This user is only applied for the service person, not released to the user.
 Calibration/Factory User: This User is only for internal use like calibration and
uploading factory data, not released to the user.

Figure 117 – Login the GUI

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Browser and Control Unit Setup

Login as the root user (key in the root / default) and enter the GUI home page as shown in
Figure 118.
Now the user can view all the information of the system by clicking the submenu on the home
page.

Figure 118 – The GUI home page (1)

4.4 Change the CU IP-address via the GUI


User can also change the PDA CU IP-address via the GUI. This need to change the IP-
address of the user’s PC and connects to the CU.
4.4.1 Set up the user’s PC
In order to connect to the FPRB CU, the IP-address of the user’s PC should be within the
same IP range of the CU.
Assume the CU IP-address is 142.120.72.172. User has to change the user’s PC IP-address
to 142.120.72.x (the last digit “x” should be different with that of the CU IP-address) so as to
connect to the CU.
Follow the steps below to set up the IP-address of the user’s PC:
(1) Go to the Network-Settings and to the “Properties” menu of the active TCP/IP connection
(see also Figure 119).

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Browser and Control Unit Setup

Figure 119 – Local Are Connection – Properties

(2) Chose the Internet Protocol (TCP/IP) menu and select the “Properties” menu (see also
Figure 120).

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Browser and Control Unit Setup

Figure 120 – Internet Protocol (TCP/IP) – Properties

(3) Within the “General” menu chose the “Use the following IP address” option. The IP-
address must be in the same subnet as the IP-address of the CU and the “Subnet mask”
(e.g.: with the subnet mask “255.255.255.0”).
Each FPRB unit has a same IP-address set in factory before shipment. This IP-address
is “142.120.72.172” with the subnet mask “255.255.255.0”.
User has to change the user’s PC IP-address to “142.120.72.x” (the last digit “x” should
be different with that of the CU IP-address) so as to connect to the CU.
See also Figure 121; change the user’s PC IP-address to “142.120.72.173”, the subnet
mask to “255.255.255.0” and leave the default gateway blank.

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Browser and Control Unit Setup

Figure 121 – Allocate secure IP-Address


With this setup, the PC is able to open a direct connection between the PC and the CU.
Note that it is not possible to establish other connections when the PC communicates
with the CU.

 After disconnection from FPRB, the user shall restore his/her IP configuration to the previous
settings to maintain integrity of the PC for its regular use.
 After changing the IP-address, the user’s PC may disconnect with the local Internet / Intranet.

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Browser and Control Unit Setup

4.4.2 Connect to the GUI


Open the browser and type the target address in the address field (e.g.: the CU address
”142.120.72.172”).
Login as the root user (key in root / default) and enter the GUI home page (see Figure 122)

Figure 122 – The GUI home page

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Browser and Control Unit Setup

4.4.3 Change the CU IP-address via the GUI


The user should change the CU IP-address into the local IP-range so as to be accessed by
the user’s PC in the local Internet / intranet.
Within the submenu “Access” (under main menu “Maintenance”), change the IP-address into
the local IP-range. E.g. if the local user’s PC former IP-address is “192.168.100.100”, the CU
IP-address should be changed to “192.168.100.x” (the last digit “x” should be different from
that in the user’s PC IP-address).
Assume change the CU IP-address to “192.168.100.101” and click “Update” (see Figure
123).

After changing the CU IP-address, the user’s PC may disconnect with the CU.

Figure 123 – Setting up the CU IP-address

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Browser and Control Unit Setup

4.4.4 Connect to the CU in local Internet / Intranet


Change the user’s PC IP-address back to the former “192.168.100.100”.
Open the browser and key in the CU IP-address “192.168.100.101” to connect the CU in the
local Internet / Intranet (see also Figure 118).
Now the user can view all the information embedded in the CU, e.g. the battery settings,
alarm settings, factory settings, etc.
In the parallel configuration, each CU should be changed the IP-address to “192.168.100.x”
(different last digit “x” for different CU and local user’s PC) via the GUI. In this way, the user’s
PC can access each CU in parallel / chained in the local Internet / Intranet.

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Commissioning

Chapter 5 Commissioning

Before turning on the FPRB system,


 Make sure all protective earth terminals, extension cords, and devices connected to the
FPRB are well grounded. Any interruption in the protective grounding is likely to cause a
potential shock hazard that might injure people.
 Make sure there is a lightning protection (especially for outdoor environment).
 Remove all metal materials such as watch and jewelry before power on.

Before turning on the FPRB system, make sure:


 The AC cables are connected correctly to avoid shorts between the L, N lines. User can use
a multi-meter to check this at the AC plugs.
 There are no shorts between the loads, batteries, and returns cables. User can use a multi-
meter to check this at the DC cable terminals.
 Note the environment requirements referring to the product specification (Artesyn file No.
970-009471-0000 and No. 970-009472-0000).
 See the User Guides of the test equipments to ensure the correct use.
 The IP65 is no longer guaranteed if the Ethernet cable is connected to the system. After
finishing the commissioning, The Ethernet cable should be removed and the connecter seal
should be replaced to the RJ45 hole to provide IP65 protection.

It is recommended to commission each FPRB individually, before putting it into the cabinet and
connecting it with the other devices to prevent problems or ease any required debugging.

All the commissioning data can also be read through LCD (refer to the ‘Flexi Power Rectifier –
User Manual’, Artesyn file No. 970-009474-0000) in the event that the Ethernet cable is not
applied.

5.1 Set up a commissioning environment


(1) Set up a commissioning configuration as shown in Figure 124.
Connect the BTS, battery blocks, AC power source and the user’s PC with the cables
that have been already installed.

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Commissioning

Before power on, make sure:


 All the breakers and AC power source switch are in the OFF position.
 The battery blocks have a voltage between 43V and 54V.
 The proper polarity of the battery leads before connecting it to the PDA.
 There are no shorts between the loads, batteries, and returns strings. User can use a multi-
meter to check this at the DC cables’ terminals.

FPRB

Figure 124 – Commissioning configuration of the FPRB


(2) Connect to the GUI
Connect the FPRB to the user’s PC with an Ethernet cable.
Connect to the GUI referring to Chapter 4 Browser and Control Unit Setup.

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Commissioning

5.2 Battery input commissioning

User should check the battery voltage with a multi-meter before turn on the battery switch or
battery breakers. If the battery voltage is below 43V, it cannot be connected to the FPRB directly.

Turn on the battery and load breakers to power the PDA and loads with battery blocks.
Ensure the normally operation through the LED status of the PDA referring to Table 13.
Assume the battery blocks have a voltage of -50V, and load current is -12A. The GUI will
display the battery status as shown in Figure 125, and these values can also be read through
the LCD.
Compare these values with those measured by a multi-meter to verify the normal operation of
the PDA.

The voltage and current measurement has been tested in factory before shipment. Thus the
user can only check the voltage test in field.

Figure 125 – Commissioning of the battery input

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Commissioning

5.3 Set up the system parameters


After entering the web-GUI, all the information internal the PDA CU can be read. The user
can also update some parameters in field, e.g. battery settings, system settings; time
settings, etc (see Figure 126, Figure 127 and Figure 129).
User should refer to the ‘Flexi Power Rectifier – User Manual’ (Artesyn file No. 970-009474-
0000) for more details about the system parameters setup.

Figure 126 – Battery related settings via GUI

Figure 127 – System related settings via GUI

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Commissioning

Figure 128 Genset Related Settings

Figure 129 – Time settings via GUI

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Commissioning

5.4 AC input commissioning

Before power on, make sure:


 All the breakers and AC power source switch are in the OFF position.
 Ensure that the AC voltage does not exceed the recommended AC input voltage range.

Turn on the AC power switch to power the rectifiers and the PDA through the AC source in
field.
Ensure the normally operation through the LED status of the PDA and the rectifiers referring
to Table 13 and Table 14.
Turn on the load breakers to power the load.
Assume the rectifiers have a voltage of -54V, and load current is -30A. The GUI will display
the rectifier status as shown in Figure 130, and these values are also read through the LCD.
Compare these values with those measured by multi-meter to verify the normal operation of
the rectifier and PDA.

Figure 130 – Commissioning of the AC input

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Maintenance

Chapter 6 Maintenance

 The maintenance should be taken periodically to ensure the normal operation and extend the
life of the FPRB.
 Only qualified personnel shall carry out the maintenance

The following describe issues that might occur during operation of the FPRB:
 Checking the connector seals
Reset the connector seal if there is any looseness to ensure the IP rating.
 Checking the cable connectors
Refit the cable connector if there is any looseness to ensure the normal operation.
 Checking screws
Re-fix the screws to ensure the stability of the whole FPRB system.
 Cleaning rectifier fans
Clear the rectifier fans and the vents to ensure the cooling function.
 Replace the SPD if required
Refer to section 3.2 of the ‘Surge Protective Device for Flexi Power Rectifier – User
Manual’ (Artesyn file 970-009473-0000) for the replacement of the SPD.
 Update the system firmware if required
Refer to the section 2.3 of the ‘Flexi Power Rectifier – User Manual’ (Artesyn file No. 970-
009474-0000) for the upgrade of the system firmware.

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Troubleshooting

Chapter 7 Troubleshooting

 The end user is able to view the rectifier or system alarms via the GUI. Table 35 and Table
36 list these alarms and the recommended actions.
 The alarm severities in Table 35 and Table 36 are defaulted, and user is allowed to change
them via the GUI (refer to the ‘Flexi Power Rectifier – User Manual’, Artesyn file No. 009474-
0000).
 Besides the alarms indicated from GUI, some failures listed in Table 37 are likely to happen.

 The AC mains must be switched off prior to removing the PDA from the case. The battery can
be always switched on to support the load while accessing the PDA.
 Some alarms and failures listed in Table 35 through Table 37 may be corrected by simple
action of the end user. More in depth might be referred to the Artesyn Embedded
Technologies service and support people.
 The user is forbidden to open the PDA restricted area or rectifier in any case.
 Only qualified person can carry out the troubleshooting.

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Troubleshooting

Table 35 – Rectifier alarm indications

Severity

Rectifier alarm
Trigger condition Recommend action
configuration

General error X Rectifier internal error Uninstall the rectifier from system, and then install
the rectifier back again. If the error appears again,
change the rectifier
Restart the system.

Input low (AC) X Set alarm when AC lower than 170±5V, clear Check the AC input
when AC higher than 175±5V

Temp Sensor X Temperature<-45°C or temperature>125°C Uninstalled the rectifier from system, and then
Fail installed the rectifier back again. If error appears
again, change the rectifier

Temp High X Set when more than 75°C, clear when lower than Check there any block in the fan, check the
70°C ambient temperature.

Temp Low X Set when lower than 0°C, clear when more than Check the ambient temperature
5°C
Except Temp X Set when more than 90°C, clear when lower than Check there any block in the fan, check the
High 85°C ambient temperature

Except Temp X Set when low than -5°C, clear when more than Check the ambient temperature
Low 0°C
Element X Communication failure Re-start the PDA and rectifier
Loss/Start
Input High (AC) X Set alarm when AC higher than 282V±5V, clear Check the AC input
when AC lower than 276V±5V
AC UVP X AC lower than 75V±5V Check the AC input
AC OVP X AC higher than 315V±5V Check the AC input
DC OVP X DC output higher than 58.5V±1V, Remove the AC to the rectifier and re-connect the
AC to rectifier again

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Troubleshooting

DC UVP X Set when DC output lower than 40.5V, clear Check whether there is output short circuit
when DC higher than 42.5V

Over Temp X OTP when higher than 105°C, recover when Check there any block in the fan, check the
Protect lower than 84°C (Artesyn model: AA25000L, ambient temperature
NSN code: CS7000001 and AA27530L, NSN
code CS7000031).
OTP when higher than 93°C, recover when lower Check there any block in the fan, check the
than 73°C (Artesyn model: AA25000L-A, NSN ambient temperature
code: CS7000021).
Input Low Major X Set when AC lower than 150V, clear when more Check the AC input
than 151V
Input High Major X Set when AC more than 296V, clear when lower Check the AC input
than 295V
Fan Failure X Rectifier Fan fail Check the fan, if fan stop running, or change the
fan
Power Limit X Set when output current more than 1 Amp of Check the BTS system load
Power_max /52V, the Power_max is decreased
when power derating occurs

Table 36 – System alarm indications

Severity

System alarm
Trigger condition Recommend action
configuration

General error X CU internal Errors Re-start the PDA, if error appear again,
change the PDA

Battery test fail X Battery discharge test fail Check whether the battery life time
reached

Date & Time not set X Date and time is not set in the CU Set the date and time

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Troubleshooting

Circuit Breaker 1 X Circuit breaker 1 open Check whether the breaker connects to
load or not. If no load connected, no action
required. If load connected, check whether
there is short circuit in the load, then close
the breaker

Circuit Breaker 2 X Circuit breaker 2 open (Same as above)

Circuit Breaker 3 X Circuit breaker 3 open Check whether the breaker connects to
battery or not. If no load connected, no
action required. If battery connected,
check whether there is short circuit in the
battery and load, then close the breaker.

Circuit Breaker 4 X Circuit breaker 4 open (Same as above)

Circuit Breaker 5 X Circuit breaker 5 open (Same as above)

LVD X Low voltage load disconnected Check AC input and battery voltage

Bat. Temp. High X Battery temperature higher than the battery Check the battery temperature
temperature high set point

Bat. Discon. Temp. X Battery temperature higher than the battery Check the battery temperature
High temperature high disconnect set point
Bat. Temp. Low X Battery temperature lower than the battery Check the battery temperature
temperature low set point

Bat. Discon. Temp. X Battery temperature lower than the battery Check the battery temperature
Low temperature low disconnect set point

Battery Low Voltage X Battery voltage lower than the battery low voltage set Check the battery voltage
point

Battery Low Voltage X Battery voltage lower than the battery low voltage Check the battery voltage
Warning warning set point

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Troubleshooting

Alarm In X Alarm in signal trigger Check the customer equipment for alarm
in

Surge Protective X Surge protective device is not installed or fail If SPD installed, check the SPD fail or not.
Device If SPD not installed, no action required

Rec. Redundancy X One or more rectifiers originally working in the Check the respective Rectifier/s
Fail system has shutdown Uninstall the Rectifier then re-install it back
Check the AC supply of the Rectifier.
Mixed System X A mix of 2kW and 3kW is detected by the system. Unplug the Rectifier supposed not to be
The PDA will shutdown all the 3kW Rectifiers leaving installed in the system.
only the 2kW Rectifiers working.
Generator Time X Alarm will activate when the Genset reached the Check the Generator time setting in the
Generator time set point. Generator Related Settings in the GUI.

ATS Open X ATS Open alarm will activate when the Power shift Check the ATS equipment status.
from Grid to generator. The signal input will come
from the ATS equipment
Generator On X Generator On alarm activates when the Generator Check the Genset signal wiring in the
signal is On or the Generator conditions are met Drawer board of the PDA.

Generator Fail X Generator fail alarm activates after the AC detection Check the ATS status
check has been done but no any AC applied into the Check the Genset signal wiring
Rectifier during the Generator mode. Check the Generator.
Element Loss X PDA communication error Re-start the PDA

Table 37 – Failures likely to happen


Category Trouble Analysis Troubleshooting

Failing to display the PDA LED or LCD Maybe damages on the internal Refer to Artesyn support people
communication circuit
PDA
Large deviation between measured and real Maybe damages on the internal Refer to Artesyn support people
data (Voltage / current, etc.) measurement circuit

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Troubleshooting

Breaker failure, such as failing to turn on / Breakers maybe damaged Refer to Artesyn support people
off, etc.
Failing to visit CU via the GUI Ethernet cable poor connection Check the net equipment, such as net card,
Ethernet cable, etc.
Setup error of the PC IP-address Refer to section Chapter 4 Browser and
Control Unit Setup
Failing to display of the other FPRB units via Poor cable connection Check the proper connection of the parallel
PDA LCD or GUI in parallel configuration cables in different drawers
Failing to display temperature or alarms Poor cable connection Check the proper connection of the temperature
or alarm cables
Rectifier Failing to display any LED AC power failure Check the AC power supply and the connection
to rectifier
Rectifier abnormal operation, such as over Maybe rectifier damaged Check AC input, load, environment, etc.
voltage / current, etc

Failing to be shown via the PDA LCD or GUI Poor connection between rectifier and Check whether the RS485 cable properly
PDA connected
Alarm loss of rectifier Poor connection between rectifier and Check the relevant data cable connection
PDA between the rectifier and PDA
Rectifier over temperature Poor cooling or fan failure Check the fan normal movement or replace the
fan.
Refer to Artesyn support people for fan
replacement if required.

Modules cannot be inserted into the case Check for any foreign body within the respective
module slot. Check all module plug interfaces
are clear and in good functional order. Check all
interfaces on the respective module are correct
and undamaged
System
Abnormal noise Maybe Fan failure Check for any obstruction on the fan
Genset not working ATS signal connection failure. Check if ATS signal connection is OK.
Genset connection failure. Check if the Genset output signal connection is
OK.
Generator Driving Functionality switch Check if the button is set to ON
button is OFF

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Troubleshooting

Table 38 Rectifier Vs Shelf Matrix


Types of Rectifiers
2Kw Rectifier IP54 2Kw Rectifier IP65 3Kw Rectifier
#
(CS7000001.02 / (CS7000001.03 / (CS7000031.00) (≥)
# #
CS7000021.00) (≤) CS7000021.01) (≥)
#
FPRA (CS7000000.07) (≤) with OK (System IP55) OK (System IP55) with Not Applicable
#
FMCA 470239A.206 (≤) Pressing Plate
#
FPRB (CS7000030.00) (≥) with OK (System IP55) with OK (System IP65) with OK (System IP65)
#
FMCA 470239A.207(≥) OPTIONAL Item Air Deflector Pressing Plate Waste
Plate NSN Code: 821480B
Existing pressing plate on
shelf is waste
#
FPRA (CS7000000.08) (≥) with OK (System IP55) With OK (System IP55) with Not Applicable
#
FMCA 470239A.207 (≥) Compulsory Addition of Pressing Plate
Deflector Plate NSN Code:
821480B with FPRA

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