Quick Start Guide for Fpra

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Flexi Power Rectifier

Quick Start Guide

Emerson Network Power Co., Ltd. http://www. emersonnetworkpower.com.cn Manual Version: 01

Flexi Power Rectifier Quick Start Guide

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Manual Number: 03370500110 Manual Issue: 01 Manual Status: Standard Release Date: Sep 2008

Copyright © 2008 Emerson Network Power Co., Ltd. All rights reserved Published in China This document, and the information it contains, are the property of Emerson Network Power Co., Ltd, and are protected by law. Both must be held in strictest confidence at all times. Emerson Network Power 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. Emerson Network Power 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 Emerson Network Power with reasonable care and is believed to be accurate. However, Emerson Network Power shall not assume responsibility for losses or damages resulting from any omissions, inaccuracies, or errors contained herein.


History 3

History Date Version Author Change Note No./Notes 21/07/2008 01 David Cao First release


Table of contents 4

Table of contents History...................................................................................................................3 Table of contents ..................................................................................................4 List of figures ........................................................................................................4 List of tables..........................................................................................................4 List of terms ..........................................................................................................5 Preface .................................................................................................................7 Hardware Installation ............................................................................................9 Appendix – Tools and Torques ...........................................................................23

List of figures

Figure 1 – The FPRA before the installation................................................................ 9 Figure 2 – The PDA before the installation .................................................................. 9 Figure 3 – The cable gland configuration for typical use ......................................... 10 Figure 4 – Removing the drawer from the PDA ........................................................ 11 Figure 5 – Taking off the load (or battery) terminals short link and MCB switch

lever bar ................................................................................................................... 13 Figure 6 – DC terminal clamps distribution ................................................................ 14 Figure 7 – Connecting the DC cable ........................................................................... 14 Figure 8 – Putting the front panel back to the PDA .................................................. 15 Figure 9 – Connecting all the communication cables............................................... 17 Figure 10 - AC connection without the SPD – 3Y ..................................................... 19 Figure 11 – Installing the PDA into case .................................................................... 20 Figure 12 – Installing the rectifiers into case ............................................................. 20 Figure 13 – Installing the cable glands ....................................................................... 21 Figure 14 – Installing the front and back covers ....................................................... 21 Figure 15 – Cables exit from right of the FPRA ........................................................ 22

List of tables

Table 1 – Reference documents of the FPRA............................................................. 7 Table 2 – Three battery / load cables configurations ............................................... 12 Table 3 – Connection of the communication cables................................................. 16 Table 4 – Connection of the AC cable ........................................................................ 18 Table 5 – Tools and torques required for installation ............................................... 23


List of terms 5

List of terms

A Ampere

AC Alternative current

AWG American Wire Gauge

BAT Battery

BR Battery Return

BTS Base Transceiver Station

CB Circuit Breaker

CSA Cross Section Area

CU Control unit

DC Direct current

EMC Electromagnetic Compatibility

ESD Electrostatic Discharge

FPRA Flexi Power Rectifier

GND Ground

GUI Graphical User Interface

IE Internet Explorer

IP Ingress Protection

IP Internet Protocol

L Live cable from the AC mains

LAN Local Area Network

LED Light Emitting Diode

LVD Low Voltage Detection

MAC Media Access Control

MCB Micro Circuit Breaker


List of terms 6

N Neutral cable from the AC mains

PC Personal Computer

PCB Printed Circuit Board

PDA Power Distribution Assembly

PE Protective earth

PSU Power Supply Unit

SPD Surge Protect Discharge

V Volt

VPN Virtual Private Network

1Φ Single-phase AC type

3Y 3-phase star AC type

3∆ 3-phase delta AC type


Preface 7

Preface About this guide

This quick start guide is for quick installation or an overview of the FPRA. Thus only the typical configuration of the AC and DC cables is described in this guide. User shall refer to the main installation manual for more details about the other configurations.

FPRA Introduction

The FPRA is a 6kW output power AC rectifier package made up of three individual 2kW AC/DC power modules operating in a parallel mode configuration. It also includes a Power Distribution Assembly (PDA), which has a fully integrated battery protection LVD, load / battery circuit breakers, battery current shunt and alarm signals to the BTS EAC interface. The FPRA has a rated input voltage of 180~276VAC and provides an isolated –54VDC output (here referred to as V48N) that used for BTS power supply voltage as well as site battery charging. The maximum current of the system is up to 109.9A (at maximum 6kW output), and the ambient temperature is –40 ~ +55°C.

Reference documents

The reference documents of the FPRA contain:

Table 1 – Reference documents of the FPRA

Document Emerson Network Power File No.

Internal product specification – System / PDA 41970005110

Internal product specification – Rectifier 41970004980

Surge Protect Discharge for Flexi Power Rectifier – User Manual

03370500080

Flexi Power Rectifier - User Manual 03370500090


Preface 8

Table 1 – Reference documents of the FPRA

Flexi Power Rectifier - Installation Manual (Main installation manual)

03370500070

Surge Protect Discharge for Flexi Power Module – Quick Start Guide

03370500100

Flexi Power Rectifier – Quick Start Guide (This manual)

03370500110


Hardware Installation 9

Hardware Installation

Note: This FPRA quick start guide is for configuration with one battery string, one load string and three-phase star AC inputs.

B D

F A A B

CC

C

C

E AFigure 1 – The FPRA before the installation

(10) (8)(7)(6)

(5)(4)(3) (2)(1) (9)

(1) Rear 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

Figure 2 – The PDA before the installation



************************************ Follow the steps below to install the FPRA: ************************************

1. Detach the PDA from the case (refer to section 3.1 in the main installation manual). Loosen four screws ‘C’ to detach the two side cable glands; Loosen two thumbscrews ‘B’, nut ‘F’ and three cable restraints ‘A’ to pull out the PDA from the case (refer to Figure 1).

2. Puncture the waterproof on the cable gland and Insert the cable through the hole before installing it into the PDA (refer to section 3.1 in the main installation manual). Warning: The AC mains and battery blocks must be switched off firstly.

Note: (1) The cable gland configuration for typical use is for illustration herein (see Figure 3). (2) Refer to Appendix – Tools and Torques for detail tools and torques that required for each installation step.

Alarm

Alarm System earth cable

DC GND

RTN5

BAT2

Temperature cable

AC cable

Parallel cable

LOAD2

RTN2

Parallel cable

Figure 3 – The cable gland configuration for typical use



3. Loosen two screws ‘D’ in Figure 1 and remove the drawer from the PDA (see Figure 4).

1 2

Figure 4 – Removing the drawer from the PDA

4. Route the DC cables (refer to section 3.2 in the main installation manual): 4.1 Loosen six screws ‘D’ on the front panel and two screws ‘E’ on the

breaker window in Figure 1 to remove the front panel from the PDA. 4.2 Remove the sub cover (refer to Figure 2) from the PDA. 4.3 Take off the load / battery terminals short link and MCB switch lever

bar if required (refer to Table 2 and Figure 5).



Table 2 – Three battery / load cables configurations

Type Cable name CSA size (mm2)

Cable number

Recommended Installing sequence Breakers configuration

Load & return 35 2

Battery & return Up to 50 2 1

DC load grounding 35 1

→ RTN2 → LOAD2 → RTN5 → BAT2

Load MCB parallel & Battery MCB parallel

Load & Return 35 4

Battery & return 35 6 2


→ RTN1 → LOAD1 → RTN2 → LOAD2 → RTN3 →BAT1 → RTN4 → BAT2 →RTN5 → BAT3

No MCB parallel

Load & Return 35 2

Battery & return 16 6 3


→ RTN1 → LOAD2 → RTN3→ BAT1 → RTN4 → BAT2→ RTN5 → BAT3

Load MCB parallel



1

2

Figure 5 – Taking off the load (or battery) terminals short link and MCB switch lever bar

4.4 Puncture the waterproof on the DC grommet to insert the DC cable through the front panel (see Figure 7).

4.5 Insert the DC cables into the indicated DC terminal clamps and secure them respectively (see Table 2,

4.6 Figure 6 and Figure 7). Note: The DC configuration for typical use is for illustration herein.




Breaker LOAD2 BAT1 BAT2 MCB switch Lever bar

BAT3

LOAD1

InsulatorTerminals short link

RTN4

RTN5 LOADGND

RTN2 RTN3 RTN1

Figure 6 – DC terminal clamps distribution

Figure 7 – Connecting the DC cable


4.7 After connecting all the DC cables, Push the front panel back on the PDA and secure the six screws ‘D’ and two thumbscrews ‘E’ in Figure 1 (see Figure 8).

Figure 8 – Putting the front panel back to the PDA

4.8 Put the sub cover back to the PDA and secure it.

5. Route the communication cables (refer to section 3.3 in the main installation manual). 5.1 Connect the temperature cable to the drawer as per Table 3 (see

Figure 9). 5.2 Connect the parallel cable to the drawer if needed as per Table 3

(see Figure 9). 5.3 Connect the Alarm cable (may combines Alarm In and Alarm Out

together) as per Table 3, and fix the cable screen to position ‘A’ and ‘B’ on the sidewall of the drawer (see Figure 9).



Table 3 – Connection of the communication cables

Cable Pin name Pin number Name Color

7 TEM_GND Red

8 TEM SENSE_IN White

9 TEMP_VCC Black Temperature

cable

10 EARTH Cable screen

1 (4) RS422RD- Red

2 (5) RS422RD+ White

3 (6) SGND/F Black Parallel cable

J22

11 (12) EARTH Cable screen

1 ALARM IN (-) Alarm In cable

2 ALARM IN (+) Reference

3 ALARM_COM

4 MAINS 1

5 ALARM_COM

6 MAINS 2

7 ALARM_COM

8 MAINS 3

9 ALARM_COM

10 CRITICAL

11 ALARM_COM

12 MAJOR

13 ALARM_COM

Alarm Out cable

J11

14 MINOR

Reference

5.4 Assemble the temperature cable, parallel cable and alarm cable and fix them to position ‘C’ on the drawer with a cable-tie (see Figure 9).



5.5 Assemble the three RS485 cables and fix them to position ‘C’ on the drawer with a cable-tie (see Figure 9).

B A

Temperature cable

Parallel cable

C

Alarm cable

Figure 9 – Connecting all the communication cables

5.6 After connecting all the communication cables, put the drawer back into the PDA and tighten the two screws ‘D’ in Figure 1.

6. Route the AC cable without the SPD (refer to section 3.4 in the main

installation manual). Warning: the AC mains must be switched off before the installation.

6.1 Remove the rear cover from the PDA (refer to Figure 2). 6.2 Configure the AC terminal block for paralleling the corresponding

AC terminals with short links as per Table 4. 6.3 Puncture the waterproof marked “AC Inlet” on the front panel, and

insert the AC mains cable through the hole until it reaches the rear internal of the PDA.

6.4 Connect the 3-phase star AC mains into AC terminal block without the SPD as per Table 4 (see Figure 10).



Note: The connection of the 3-phase star AC mains is for illustration herein.

6.4.1 Connect the PE cable from the AC mains to the ground clamp on the chassis (see Figure 10).

6.4.2 Connect the live cables and neutral cable from the AC mains to the AC terminal block as per Table 4 (see Figure 10).

Table 4 – Connection of the AC cable

AC type Schematic diagram Configuration of AC terminal block

3Y 1 2 3 4 5 6

AC Terminal BlockL1 L2PE

AC mainsL3 N

Short terminals 1,2,3

3∆ 1 2 3 4 5 6

AC Terminal BlockL1 L2PE

AC mainsL3

Short terminals 1,2; 3,4; 5,6 respectively

1Φ

1 2 3 4 5 6

AC Terminal BlockL NPE

AC mains

Short terminals 1,2,3; 4,5,6 respectively



N

L3

PE of AC mains

L2

L1

Figure 10 - AC connection without the SPD – 3Y

6.5 Recover the rear cover to the PDA.

7. Install the PDA into case (refer to section 3.5 in the main installation manual). 7.1 Put the PDA back into the case; tighten the two screws ‘A’ (see

Figure 11). 7.2 Fix the PDA earth cable to position ‘B’ (see Figure 11). 7.3 Fix the system earth cable to position ‘C’ (see Figure 11).



A

B C

Figure 11 – Installing the PDA into case

8. Install the rectifiers into case (refer to section 3.6 in the main installation

manual). 8.1 Put the rectifiers into the case; tighten the thumbscrews ’A’ (see

Figure 12). 8.2 Plug the AC input connector; tighten the screws ‘B’ (see Figure 12). 8.3 Connect the RS485 cable and cover the connector seal on position

‘C’ (see Figure 12).

A

C

B

Figure 12 – Installing the rectifiers into case



9. Install the cables with cable glands to the case; tighten the screws ‘A’ and ‘B’; fix the PDA earth cable to position ‘C’ with cable tie (refer to section 3.7 in the main installation manual, see Figure 13).

C

1 2

A

B

A B

Figure 13 – Installing the cable glands

10. Install the front and back covers; tighten the screws ‘A’ and ‘B’ (see Figure 14).

A A B B

Figure 14 – Installing the front and back covers

11. Arrange the cables and fix them to the side cable plate with cable-ties (see Figure 15). Note: Cables can exit from right or left or both sides of the FPRA. The cable

running from right is for illustration herein.



Figure 15 – Cables exit from right of the FPRA


Appendix 23

Appendix – Tools and Torques ******************************************************************** Refer to the table below for the tools and torques required for each installation step:

********************************************************************

Table 5 – Tools and torques required for installation

Step Tool Usage Torque (N.m)

TORX screwdriver (T25) Loosen screw -- 1

Wrench (8mm) Loosen nut --

2 Awl (Φ2mm) Puncture the waterproof --

3 Cross screwdriver Loosen screw --

4.1 TORX screwdriver (T10) Loosen screw --


Flat screwdriver Loosen screw -- 4.3

Pliers Take off the short links --

4.4 Awl (Φ2mm) Puncture the waterproof --

4.5 Flat screwdriver Tighten screw 3

TORX screwdriver (T10) Tighten screw 0.8 4.6

Manual Tighten screw Fit

4.7 TORX screwdriver (T10) Tighten screw 0.8

Flat screwdriver For ‘push-fit’ connector Fit 5.1

Cable-tie Tie the cable screen Fit



- To be continued -


Appendix 24


Table 5 – Tools and torques required for installation

Step Tool Usage Torque (N.m)



5.4 Cable-tie Tie the cables Fit

5.5 Cross screwdriver Tighten screw 0.7~0.8


6.2 Flat screwdriver Tighten screw 0.8

6.3 Awl (diameter 2mm) Puncture the waterproof --

Flat screwdriver Tighten screw 1.5 6.4.1

TORX screwdriver (T25) Tighten screw 2

6.4.2 Flat screwdriver Tighten screw 1.5

6.5 TORX screwdriver (T10) Tighten screw 0.8

7.1 Cross screwdriver Tighten screw 1.2

7.2 Wrench (8mm) Tighten the nut 2.0

7.3 Wrench (8mm) Tighten the nut 2.0

8.1 Cross screwdriver Tighten screw 1.2

8.2 Flat screwdriver Tighten screw 0.8

8.3 Manual Clamp the connector seal Fit

9 TORX screwdriver (T25) Tighten screw 2.0

10 TORX screwdriver (T25) Tighten screw 2.0

11 Cable ties Fix the cables Fit

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Quick Start Guide for Fpra