ZXDU500 500A Combined Power Supply System User’s Manual

ZXDU500 500A Combined Power Supply System

User’s Manual

ZTE CORPORATION

© ZTE Corporation. 2002, Shenzhen, P. R. China

All rights reserved. No part of this publication may be excerpted, reproduced, translated, annotated or edited, in any form or by any means, without the prior written permission of the copyright owner.

ZXDU500 500A Combined Power Supply System User’s Manual

* * * *

3/F., A Wing, ZTE Plaza, Hi-Tech Industrial Park, Shenzhen, P. R. China

Tel: (0086) 755–26790192

Fax: (0086) 755–26790160

Post-code: 518057

* * * *

September 2002 First Edition

S.N.: SJZL2002588

Preface

ZXDU500 500A combined power supply system is the 50A series combined power

supply for communications, one of the latest version developed by ZTE Corporation.

The ZXDU500 500A combined power supply system uses two kinds of standard

cabinets with the heights of 2m and 1.6m. It is an intelligent, unattended, and combined

power supply system. This manual mainly introduces the overall architecture, system

features, main performance, working principles of the ZXDU500 500A combined

power supply system, and the equipment’s installation, debugging, maintenance and

management.

Chapter 1 - System Overview, describes system features and precautions.

Chapter 2 - System Structure & Working Principles, this chapter introduces the

architecture, working principles and configuration of the system. The working

principles, architecture, technical performance of each component are described in

detail. Then, the networking mode for monitoring is covered in the end.

Chapter 3 - Equipment Installation, this chapter mainly describes the basic requirement,

installation preparation of the system’s installation. The installation and electric

connection of each component are described in detail.

Chapter 4 - System Debugging, this chapter elaborates on power-on testing of the

system’s parts such as AC power distribution unit, rectifier, DC power distribution unit,

etc.; specific operation interfaces for the monitoring unit; system acceptance flow, and

so on.

Chapter 5 - System Usage, introduces the usage of the system, covering the rectifier’s

capacity expansion, load adding and processing of system alarms.

Chapter 6 - Maintenance & Management, describes major points of the daily

management and maintenance of the system, as well as the handling of emergencies.

Chapter 7 - Packaging, Transportation & Storage, describes the conditions and

precautions of the packaging, storage and transportation of the system.

Appendix A gives the threshold ranges specified for the power supply parameters,

including the ranges and default values of foreground parameters of the monitoring

unit, which can be used as a reference when users configure the system.

Appendix B lists documents and accessories supplied with the system.

Appendix C gives a principle block diagram about AC/DC power distribution, together

with the connection diagram of the AC/DC power distribution system to facilitate the

user’s maintenance and repairs.

Statement: The actual product may differ from what is described in this manual due to

frequent updates of ZTE products and fast development of technologies. Please accept

our apology for any inconvenience it may cause to you. Please contact our local

customer service centers for the updates of our products.

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Contents

1. SYSTEM OVERVIEW .............................................................................................................................1

1.1 INTRODUCTION .....................................................................................................................................1

1.2 PERFORMANCE & FEATURES ...............................................................................................................1

1.3 MAN-MACHINE INTERACTION ...............................................................................................................3

1.4 SYSTEM PERFORMANCE INDEXES .......................................................................................................3

1.5 CAUTIONS .............................................................................................................................................4

2. STRUCTURAL FEATURES & WORK PRINCIPLES ........................................................................5

2.1 OVERALL STRUCTURE AND CONFIGURATION ......................................................................................5

2.1.1 Overall structure..........................................................................................................................5

2.1.2 Basic configuration .....................................................................................................................8

2.2 INTRODUCTION TO SYSTEM PRINCIPLES..............................................................................................9

2.3 AC POWER DISTRIBUTION UNIT .........................................................................................................10

2.3.1 Working principles ....................................................................................................................10

2.3.2 Structure of AC power distribution unit ..................................................................................11

2.4 RECTIFIER...........................................................................................................................................14

2.5 DC POWER DISTRIBUTION UNIT .........................................................................................................17

2.5.1 Working principles ....................................................................................................................17

2.5.2 Structure of DC power distribution unit..................................................................................18

2.5.3 Functional characteristics ........................................................................................................20

2.6 SUPERVISION UNIT .............................................................................................................................21

2.6.1 Overview ....................................................................................................................................21

2.6.2 Structure.....................................................................................................................................22

2.6.3 Function of the monitoring unit ...............................................................................................33

2.6.4 Check precision.........................................................................................................................35

2.6.5 Alarm...........................................................................................................................................36

2.7 COMMUNICATIONS NETWORKING SCHEMES......................................................................................36

2.7.1 Simple RS232 serial port mode ..............................................................................................36

2.7.2 Dial-up mode (MODEM mode) ...............................................................................................37

2.7.3 ZXJ10 digital SPC switch mode .............................................................................................37

2.7.4 SCM mode .................................................................................................................................38

2.7.5 Access network mode ..............................................................................................................39

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2.7.6 CDMA mode.............................................................................................................................. 41

3. EQUIPMENT INSTALLATION ............................................................................................................ 43

3.1 INSTALLATION PROCEDURES ............................................................................................................. 43

3.2 BASIC REQUIREMENTS FOR POWER SUPPLY SYSTEM INSTALLATION............................................... 44

3.2.1 Environment requirements ...................................................................................................... 44

3.2.2 Power supply requirements .................................................................................................... 44

3.2.3 Safety and protection requirements....................................................................................... 45

3.3 PREPARATIONS BEFORE INSTALLATION ............................................................................................ 48

3.3.1 Safety check.............................................................................................................................. 48

3.3.2 Cooperation of the office party ............................................................................................... 48

3.3.3 A complete preparation for tools and instruments............................................................... 48

3.3.4 Preparations of technical documents .................................................................................... 49

3.4 WORK OF SUPPORTING FACILITIES OF THE POWER SUPPLY SYSTEM .............................................. 49

3.4.1 Battery installation .................................................................................................................... 49

3.4.2 Laying of power cables ............................................................................................................ 49

3.5 UNPACKING AND ACCEPTANCE.......................................................................................................... 50

3.5.1 Shipping ..................................................................................................................................... 50

3.5.2 Unpacking.................................................................................................................................. 50

3.5.3 Packing list ................................................................................................................................ 50

3.6 CABINET INSTALLATION ..................................................................................................................... 51

3.6.1 Cabinet installation requirements........................................................................................... 51

3.6.2 Cabinet installation procedure ................................................................................................ 52

3.7 OVERALL SYSTEM ASSEMBLY ............................................................................................................ 58

3.7.1 Assembling and fixing the monitoring unit ............................................................................ 59

3.7.2 Modem installation and fixing ................................................................................................. 60

3.7.3 Rectifier installation and fixing ................................................................................................ 61

3.8 ELECTRICAL CONNECTION ................................................................................................................. 62

3.8.1 Connection of AC input lines .................................................................................................. 63

3.8.2 Connection of DC load lines ................................................................................................... 64

3.8.3 Connection of battery cables .................................................................................................. 66

3.8.4 Connection of grounding cables............................................................................................. 67

3.8.5 Electrical connection of the rectifier ....................................................................................... 69

3.8.6 Electrical connection of the monitoring unit.......................................................................... 69

3.8.7 Binding cables........................................................................................................................... 73

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3.9 INSTALLATION CHECK .........................................................................................................................75

3.9.1 Cabinet check............................................................................................................................75

3.9.2 Check of electrical connection ................................................................................................76

4. SYSTEM DEBUGGING ........................................................................................................................77

4.1 STARTING UP AND SHUTTING DOWN THE SYSTEM ............................................................................77

4.1.1 Check before start-up...............................................................................................................77

4.1.2 Debugging procedures.............................................................................................................77

4.1.3 Startup procedures ...................................................................................................................78

4.1.4 Shutdown sequence.................................................................................................................79

4.2 TESTING THE AC DISTRIBUTION UNIT................................................................................................79

4.3 DEBUGGING THE RECTIFIER...............................................................................................................80

4.4 TESTING THE MONITORING UNIT ........................................................................................................81

4.4.1 Overview of the monitoring unit ..............................................................................................81

4.4.2 Powering on the monitoring unit .............................................................................................81

4.4.3 Enter system interface .............................................................................................................82

4.4.4 Real time data display..............................................................................................................83

4.4.5 Alarm data display ....................................................................................................................85

4.4.6 System parameter setting........................................................................................................86

4.4.7 “System maintenance & control” menu .................................................................................93

4.5 BACKGROUND MONITORING...............................................................................................................94

4.6 DC POWER DISTRIBUTION UNIT DEBUGGING AND BATTERY CONNECTION.......................................95

4.6.1 Connecting batteries ................................................................................................................96

4.6.2 Load the loading equipment....................................................................................................96

4.7 DEBUG THE WHOLE SYSTEM ..............................................................................................................97

4.7.1 Set system parameters ............................................................................................................97

4.7.2 Test data detection precision ..................................................................................................97

4.7.3 Test system function and alarm protection performance....................................................97

4.7.4 Test the current equalization characteristic of the system .................................................98

4.8 SYSTEM ACCEPTANCE........................................................................................................................98

4.8.1 Apply for preliminary test .........................................................................................................99

4.8.2 Installation acceptance ............................................................................................................99

4.8.3 Acceptance report of commissioning.....................................................................................99

4.8.4 Prepare relevant document .....................................................................................................99

4.8.5 Acceptance ................................................................................................................................99

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5. SYSTEM USAGE ................................................................................................................................ 101

5.1 SYSTEM POWER ON ......................................................................................................................... 101

5.1.1 System startup ........................................................................................................................ 101

5.1.2 System shut-down.................................................................................................................. 102

5.2 USE OF THE RECTIFIER .................................................................................................................... 102

5.2.1 Rectifier backup ...................................................................................................................... 102

5.2.2 Capacity expansion of the rectifier....................................................................................... 102

5.2.3 Replace the rectifier fan......................................................................................................... 103

5.3 BATTERY USAGE .............................................................................................................................. 103

5.3.1 Charge and discharge battery .............................................................................................. 103

5.3.2 Choice of battery .................................................................................................................... 104

5.3.3 Matters for attention during usage and maintenance of batteries................................... 105

5.4 ALARM DESCRIPTION AND HANDLING .............................................................................................. 105

5.4.1 Solutions to the alarms that affect the output of the system ............................................ 106

5.4.2 Alarms that do not affect the output of the system and their solutions .......................... 107

5.5 ADDING DC LOAD............................................................................................................................ 108

5.5.1 The use of fuse extractor....................................................................................................... 108

5.5.2 Adding DC Load ..................................................................................................................... 108

6. MAINTENANCE & MANAGEMENT................................................................................................. 110

6.1 EQUIPMENT ROOM MANAGEMENT ................................................................................................... 110

6.1.1 General requirements ............................................................................................................ 110

6.1.2 Management on unattended stations .................................................................................. 111

6.2 DAILY RECORDS ............................................................................................................................... 112

6.3 HANDLING SPECIAL CASES .............................................................................................................. 112

6.3.1 Blackout ................................................................................................................................... 112

6.3.2 AC over-voltage/under-voltage protection .......................................................................... 113

6.3.3 Disasters and accidents ........................................................................................................ 113

6.4 EQUIPMENT MAINTENANCE .............................................................................................................. 114

6.4.1 Major points for power supply maintenance....................................................................... 114

6.4.2 Troubleshooting for AC power distribution unit.................................................................. 114

6.4.3 Troubleshooting for DC power distribution unit.................................................................. 115

6.4.4 Handing of the rectifier failure............................................................................................... 116

6.4.5 Troubleshooting for the monitoring unit .............................................................................. 117

6.5 EMERGENCY HANDLING ................................................................................................................... 118

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6.5.1 Principle for emergency handling .........................................................................................118

6.5.2 Emergency handling for AC/DC power distribution unit....................................................118

6.5.3 Emergency handling for the monitoring unit .......................................................................118

6.5.4 Emergency handling of the rectifier failure .........................................................................119

7. PACKAGING, TRANSPORTATION & STORAGE ........................................................................120

7.1 PACKAGING.......................................................................................................................................120

7.2 TRANSPORTATION ............................................................................................................................120

7.3 STORAGE ..........................................................................................................................................120

APPENDIX A THRESHOLD RANGES OF POWER & ENVIRONMENT PARAMETERS ..........121

APPENDIX B DELIVERY ATTACHED PACKING ACCESSORIES ............................................123

APPENDIX C PRINCIPLE DIAGRAM OF AC/DC DISTRIBUTION..............................................124

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1. System Overview

1.1 Introduction The ZXDU500 500A combined power supply system is one of the products of the 50A

series combined power supply for communications, which is newly developed by ZTE

Corporation. As an intelligent, unattended power supply system, it employs the

internationally advanced rectifier conversion technology and can be widely applied to

various switching equipment, microwave communications, mobile base stations, and

optical fiber transmission systems.

ZXDU500 500A uses two kinds of standard cabinets with the heights of 2m and 1.6m.

The configurations and functions of the two kinds of cabinets are completely the same.

We take the cabinet of 2m as the example in this manual for illustrations.

1.2 Performance & features The performance and features of the ZXDU500 500A combined power supply system

are as follows:

1. Tracing the latest trends of communication power supply technologies developed

internationally, using the advanced power supply control technology and

components;

2. The advanced modularized design and automatic current equalizing technology

enable the system capacity to expand smoothly in the N+1 redundant mode;

3. With perfect electromagnetic compatibility, minimum electromagnetic radiation,

and minimum surge current at system startup;

4. The system is featured by the fully intelligent design, configured with centralized

monitoring unit, and designed with telemetry, telesignaling and telecontrol

functions. Besides, the computerized management enables unattended

management via communication with the remote central monitoring center. The

feature is in compliance with the demand of contemporary communication

technology development;

5. With the power supply control technology effectively combined with computer


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technology, various parameters of the rectifier and AC/DC power distribution

can be monitored and controlled in real time;

6. The system employs three-phase electric grid input or single-phase voltage input,

with a wide range of input voltages (80VAC ~ 300VAC), and is applicable to

regions with unstable power supply;

7. With mains input breakdown, the batteries will provide emergency power supply;

mains/generator automatic switching function is also provided;

8. Flexible configuration: up to ten rectifiers may be configured as required;

9. Automatic battery management: it powers communications equipment in

full-parallel float charging mode. The monitoring unit automatically measures

the battery charging/discharging current and controls the rectifier of

float/equalizing charging to the battery;

10. Two-stage power shutdown: when the system switches to battery power supply,

there will be audible and visible alarms; the loads are shifted off in two batches

according to their different degrees of importance. When the battery voltage is

lower than the first-stage power shut-down voltage, it gives audio and visual

alarms and cuts off one batch of loads; when the battery voltage is lower than

the second-stage power shut-down voltage, it gives audio and visual alarms and

cuts off another batch of loads, in this way, it is guaranteed that the most

important loads work a comparatively longer time;

11. The system adopts the multilevel lightning-proof technology, ensuring the high

reliability of the overall system;

12. Multiple AC auxiliary outputs are provided. Besides, DC emergency illumination

is supplied with AC power supply down;

13. When a fault occurs, the supervision module will give audio and visual alarms;

besides, it will send alarms to the remote central control room; at the same time,

it will call the pager number via the automatic station and leave messages;

14. The monitoring unit uses LCD to display the system information in

English/graphic mode. Meanwhile, it can detect multiple environmental

parameters such as the environment temperature, humidity, access control, and

flooding;

Chapter 1. System Overview

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15. Flexible power distribution mode: upward or downward drop line can be

configured as per customers’ demand;

16. It has a drawer structure, easy for transportation, installation, and maintenance;

17. The system has high reliability, with MTBF≥105h;

18. Brandnew architecture design, convenient for maintenance and capacity

expansion; ultra-small design for rectifier, with high power density.

1.3 Man-machine interaction 1. Provides users with information and operation interfaces using the LCD and

keyboard of the monitoring unit;

2. Connected via RS232 interface with near-end PCs, by whose monitoring software

the power supply system operation and maintenance can be performed;

3. Connected with remote computers via Modem or ZTE’s signal conversion

modules (SCM) for remote monitoring.

1.4 System performance indexes 1. AC input

(1) Voltage: 3-phase 5-wire system, the range of the input voltage is 80VAC ~

300VAC;

(2) Frequency: 45Hz~65Hz;

(3) Current: ≤100A;

(4) Power factor: ≥0.99;

(5) Lines of AC input: one or two. When there are two lines of input, they can be one

line of mains and one line of generator or two lines of mains. They can be

switched manually or automatically and have mechanic interlocking for manual

switchover, or electric and mechanic interlocking for automatic switchover; the

standard configuration is single air switch input;

(6) AC standby output: the standby output can be configured according to users’

demands. At most 16 air switch positions can be configured with the capacity

of 6A ~ 63A; no AC standby output tributary is configured for standard ones.


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2. DC output

(1) Voltage

The float charging voltage is 53.5V, and the equalized charging voltage is

56.4V (both can be directly adjusted via the monitoring unit or be fine tuned on

the rectifier panel);

(2) Current: 500A (configured with ten 50A rectifiers);

(3) Efficiency≥92%;

(4) Broadband psophometric noise

≤50mV (3.4kHz ~ 150kHz);

≤20mV (0.15MHz ~ 300MHz);

(5) Psophometrically weighted noise: < 2mV;

(6) System audible noise: <55dBa;

(7) Lines of load: maximum configuration is 15 fuses or 31 air switches;

(8) Lines of batteries: maximum configuration of 3 standby battery packs, with

capacity of 400A;

(9) Security specifications: in compliance with IEC950 standards;

3. Dimension: 2000mm (H)×600mm (W)×600mm (D) or 1600mm (H)×600mm

(W)×600mm (D).

4. Ambient conditions

(1) Temperature: -5℃~+40℃；

(2) Relative humidity: 10%-90%.

1.5 Cautions The ZXDU500 500A combined power supply system can be configured with three

lines of batteries at most, in which, the third line of battery is available only upon

user’s demand. Two lines of battery are the standard configuration.

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2. Structural Features & Work Principles

2.1 Overall structure and configuration

2.1.1 Overall structure

The ZXDU500 500A combined power supply system is composed of the AC power

distribution unit, rectifier unit, DC power distribution unit, monitoring unit, etc. Both

the rectifier and the monitoring unit employ the drawer structure, the outer appearance

of the cabinet is shown in Fig. 2-1.

Fig. 2-1 Appearance of cabinet for ZXDU500 500A combined power supply system

Monitoring unit

Rectifier

AC distribution unit

DC distributionunit


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Its structure without the front door of AC/DC distribution parts is shown in Fig. 2-2;

and that without the rear door is shown in Fig. 2-3.

Fig. 2-2 Front view of cabinet for ZXDU500 500A combined power supply system (without front

door)

Chapter 2. Structural Features & Work Principles

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Fig. 2-3 Back view of cabinet for ZXDU500 500A combined power supply system (without back

door)


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2.1.2 Basic configuration

The basic configurations of the ZXDU500 500A combined power supply system are

listed in Table 2-1.

Table 2-1 Basic system configuration

Unit I/O Configuration Remarks

AC input

Single air switch input, double air switch input, double contactor input etc. Input can be 1 line of mains and 1 line of generator or two lines of mains. The 2 lines of input can be switched manually or automatically.

Rated current: 95A;

Rated voltage: 380V;

Standard configuration: Single air switch input.

AC output Maximum configuration: 16P (16 air switch positions), with capacity of 6A ~ 63A.

The standby AC output shunt is configured on the user’s demand. It is unavailable in the standard configuration.

AC power distribution unit

Emergency lighting

The emergency lighting will be configured when required by users, and the configuration is an air switch of 6A~63A capacity.

No emergency lighting in the standard configuration.

Battery input

The system supports three lines of batteries, the third line of battery is configured on the user’s demand.

Standard configuration: 2 lines of 400A fuse protectors.

DC power distribution unit

DC output

The configuration is highly flexible, designed with three combinations of fuse, air switch and circuit-breaker+air switch. Max. config. of fuse breaker: 15 lines 6A to 160A shunt output; among them, the first-stage power shutdown: 5 lines maximally; Second-stage shutdown: 10 lines maximally.

The fuse protector combination under the standard configuration: 2 lines of 160A, 2 lines of 100A, 1 line of 63A, and 1 line of 32A.

Among them:

First-stage shutdown: 1 line of 160A, and 1 line of 100A;

Second-stage shutdown: 1 line of 160A, 100A, 63A and 32A respectively.

Rectifier

ZXD2400 (V3.0)

Input: AC 220V

Output:

DC 48V/50A

Full config: 10 modules Max. DC output capacity: 500A

Monitoring unit Provide the Modem with 12V power supply

1 ZXDU300 (V3.0) CSU monitoring unit


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2.2 Introduction to system principles The ZXDU500 500A combined power supply system is composed of AC power

distribution unit, rectifier unit, DC power distribution unit, monitoring unit, etc. The

rectifier model is ZXD2400 (V3.0) with the rated output of 48V/50A. With N+1

backup configuration of the rectifier, the system can be expanded smoothly from 100A

to 500A. The AC/DC power distribution unit of the system also provides multiple

AC/DC outputs to cater for users’ different demands.

The principle block diagram of the ZXDU500 500A combined power supply system is

shown in Figure 2-4.

Mains input

Disel generator

ZXD2400 (V3.0) rectifier

Battery pack I

Battery pack II

Load pack I

Load pack II

Wor

king

gro

und

Lightningprotectio

n unit

Monitoring unit

MODEM PSTN MODEM

Remote-end PC

Near-end PC

AC input

AC distribution AC/DCconversion

DC distribution

Centralizedsupervision

RS232

RS232

RS232

Phone line Phone line

Fig. 2-4 Principle block diagram of ZXDU500 500A combined power supply system

AC input is provided to the rectifier by way of the AC power distribution unit. With the

three-phase AC input for the system and single-phase input for the rectifier, it is

recommended that the rectifiers be evenly connected with the three-phase input voltage

to equalize the input load of the 3-phase AC input. For the phase sequence of the

rectifier within the cabinet, please refer to Fig. 3-12. Besides, when there is no

three-phase power supply, single-phase power supply may be employed, and the three

phases of input are to be connected in parallel.

The rectifier output works in the parallel mode. The output is collected via the copper

busbar first, and then enters the DC power distribution unit. Within the system, 2 to 10

rectifiers can be flexibly configured according to the user’s requirements.


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The DC power distribution unit provides at most three standby battery interfaces and

multiple DC output interfaces (tailored in a certain range of the interface quantity and

capacity according to the user’s requirements).

The ZXDU500 500A combined power supply system is controlled by the monitoring

unit, which will work according to the internally preset parameters or customized

parameters. The user command may be delivered via the keyboard of the monitoring

unit or the background PC; the system working status and parameters can be displayed

on either the LCD of the monitoring unit or the background PC. The combined power

supply system may be connected with the local near-end PC via serial ports to realize

local monitoring; or it may employ MODEM or other transmission channels (such as

auxiliary channels of the microwave equipment and optical transmission equipment) to

realize centralized monitoring. Meanwhile, the system may conveniently cooperate

with the environment and power monitoring systems of other manufacturers.

2.3 AC power distribution unit

2.3.1 Working principles

The working principle of the AC power distribution unit is shown in Fig. 2-5. Refer to

Appendix C for the electrical working principle.

AC

input switchover unit

Rectifier distribution unit

AC transmitter

N

PE

Mains II or diesel

generatorM

ains IMonitoring uit

Level Clightning

protection unitStandby AC

output

Fig. 2-5 Working principle of AC power distribution unit


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The AC power distribution unit performs the access and switching of the mains supply,

provides AC power supplies for rectifiers, furnishes the monitoring unit with sampling

output of AC voltage and current. Meanwhile, it possesses standby AC output and

lightening-proof functions.

2.3.2 Structure of AC power distribution unit

The AC power distribution unit is under the cabinet. At the front of the unit are AC

input switch, lightning arrester and switch, rectifier input switch, contactor protection

unit, AC transmitter, etc.; at the back of the unit are AC input line connection terminal,

zero line copper bus, grounding copper bus and AC standby input air switch; the output

of emergency lighting is 1 line of fuse located under the battery fuse at the back of the

cabinet.

The structure of AC power distribution unit is illustrated in Fig. 2-6.

Rectifier inputswitch

General switch forrectifier input

AC input air switch AC transmitter

Front baffle ofAC distribution unit

Level C lightningprotection unit

AC power distribution unit (front view)


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Rear baffle for ACdistribution Zero line busbarGrounding busbar

AC input connectionbusbar

AC power distribution unit (back view)

Fig. 2-6 Structure of AC power distribution unit

The AC input switching unit has three input modes: single air switch, dual air switch

and dual contactor.

1. Single air switch input: the system connects 1 line of mains supply, or the

conversion of 2 lines of mains supplies is fulfilled in the AC power distribution

board outside the system. The system AC input is configured with one air

switch.

2. Dual air switch input: supports 2 lines of AC input (users can use 2 lines of mains

supply or 1 line of mains supply and 1 line of diesel generator), the two lines of

AC input are handed over manually. The handover is performed with two air

switches with mechanically interlocking devices. When Mains 1 is normal,

Mains 1 powers the system on while Mains 2 (or the diesel generator) is

standby; when Mains 1 is cut off, you can switch to Mains 2 (or the generator)

manually. During the handover interval, the backup battery provides power

supplies for the system.

3. Dual contactor input: supports 2 lines of AC input (users can use 2 lines of mains

supply or 1 line of mains supply and 1 line of diesel generator according to the

actual needs), the 2 lines of AC input are handed over manually. During

handover, 2 AC contactors with mechanically interlocking devices and control

circuits perform the sampling and handover of 2 lines of input. When Mains 1


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is normal, it powers the system on while Mains 2 (or the generator) is standby;

when Mains 1 is cut off, the system can switch to Mains 2 (or the generator)

automatically.

Users may choose one of the three input modes in the purchase contract; if not

specified, the standard configuration is the single air switch input.

The standby AC output can be configured according to users’ demands. At most 16P

(16 monopole air switch positions) can be configured with the capacity of 6A ~ 63A.

If not specified by the user, the standard AC output shunt is not configured.

The emergency lighting will be configured when required by users, with the fuse of

6A~63A. The fuse is under the fuse of the battery pack at the back of the cabinet. No

emergency lighting shunt is available in the standard configuration.

The normal configuration of the ZXDU500 500A combined power supply system

employs the upper outlet mode. Of course, the lower outlet mode can be used on users’

demand. In lower wiring mode, at the upper part of the cabinet are AC power

distribution units; in upper wiring mode, at the lower part of the cabinet are DC power

distribution units. The upper outlet mode is adopted for the standard system

configuration.

When the system rectifiers are not fully configured, they shall be evenly connected

with the three-phase input, with basically the same number of rectifiers connected to

each phase to achieve the balance of the three-phase input.

The ZXDU500 500A combined communications power supply system has a high

lightning-proof capability. The lightning arrester has a display window. When the

window is green, it indicates that the arrester is normal; when the window is red, it

indicates that the arrester is out of service and needs replacing. The supervision unit

monitors the lightning arrester. When it is faulty, the supervision unit will alarm the

maintenance personnel to replace it. When doing so, the power of the arrester has not

to be cut off, directly plug-in/plug-out it instead.

Note: Check the lightning arresters carefully before and after the rainy season

every year and after each lightning.


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2.4 Rectifier The rectifier unit of the ZXDU500 500A combined power supply system employs the

ZXD2400 (V3.0) 50A switched rectifier. For detailed information, please refer to

ZXD2400 (V3.0) 50A Switched Rectifier User’s Manual.

The outer appearance of the rectifier is shown in Fig. 2-7.

Fig. 2-7 Outer appearance of ZXD2400 (V3.0) 50A rectifier

The front panel and rear panel of the rectifier are shown in Fig. 2-8.

Fig. 2-8 Front panel and rear panel of ZXD2400 (V3.0) 50A rectifier


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The description of the front panel and rear panel of the rectifier is listed in Table 2-2.

Table 2-2 Description of the front panel and rear panel of the rectifier

S.N. Part name Functionality description

1 Plastic panel

2 Mechanical locking switch Used to fix the rectifier, without electrical connection

function.

3 Pinch handle Used to load, unload and carry the rectifier.

4 Shutter Air inlet

5 Output current test hole

The signal measured here is the voltage signal, which has

the linear relationship with the current signal as 10A

corresponding to 1.5V

6 Output voltage test hole The tested signal here is the output voltage signal of the

rectifier, and no conversion is needed.

7 Input indicator Green indicates that the input is normal, no indication for

other cases.

8 Output indicator Green indicates that the output is normal, no indication for

other cases.

9 LED indicators to display the output

current Composed of 10 LEDs, each stands for output current of 5A.

10 Current-limiting indicator Yellow indicates that the rectifier is in the current-limiting

status, no indication for other cases.

11 Alarm indicator Red indicates that the rectifier is in the alarm status, no

indication for other cases.

12 Common ground for the output

voltage/current test

13 Fine adjustment potentiometer of the

output voltage

The output voltage of the rectifier decreases by the

clockwise adjustment, and increases by the counterclockwise

adjustment.

14 Rear panel

15 Ventilation holes To ensure the heat dissipation, no barriers can be placed in

front of ventilation holes.

16 Integrated input/output socket

The integrated input/output socket at the back panel of the rectifier as shown in Fig.

2-8 realizes AC input, DC output and control of the rectifier. The pins of the rectifier

socket are shown in Fig. 2-9.


----16----

Fig. 2-9 Interface of ZXD2400 (V3.0) 50A switched rectifier

Definition of pins of the integrated input/output socket is shown in Table 2-3.

Table 2-3 Definition of pins of the input/output interface of the rectifier

S.N. Signal Signal description

2 Protection earthing (PE) wire: Directly connected to the enclosure via conductor

7 AC input line N: corresponding to XJ2 of MAIN board

9 AC input line L: corresponding to XJ1 of MAIN board

22 REMOTE

Turn-off signal: the signal is mainly used in the remote ON/OFF control of the

switched rectifier by the system; when high level is inputted, the rectifier is turned

off (level of 5V); in case of input low level or high resistance, the rectifier is turned

on

23 ALARM

Low-resistance output: corresponds to the start-up process, internal faults or alarms,

and over-temperature statuses of the rectifier.

High-resistance output: corresponds to the normal working status

24 COM Monitors the system control ground

25 ON-LINE On-position signal for rectifier: directly connected to the COM signal on the MAIN

board

28 GND DC-DC control ground

29 PWM Input signal: requiring a pulse signal with amplitude of 5V

30 READY Input signal: the rectifier is started when short circuit happens between the input

signal and the GND. It is used to realize the hot swapping function.

31 SHARE-BUS Equalizing bus line: bi-directional signal

26 DC output charging pin of 48V+: corresponding to XJ4 of the MAIN board

34 DC output of 48V-: corresponding to XJ5 of MAIN board

35 DC output of 48V+: corresponding to XJ3 of MAIN board


----17----

2.5 DC power distribution unit The DC power distribution unit implements functions of DC load allocation, and

access of 2 lines of battery. (A third line can be connected on user’s demand.)

2.5.1 Working principles

The rectifier output employs parallel connection and enters the DC distribution unit via

the copper busbar.

The DC power distribution unit provides the access of two lines of battery (or

expanded to three lines) and no more than 31 lines of the DC load output (DC output

lines and capacities can be adjusted according to users’ demands). A 400A fuse is

configured in the battery’s return circuit to guard against the battery damage owing to

the short-circuit.

Each group of DC output is under the control of one DC contactor.

The whole system features the two-stage power-down, the load shunt in the front of the

cabinet is the load group of the second-stage power-down, and that in the back of the

cabinet is the load group of the first-stage power-down. The system will shift off the

loads in two stages according to the voltages set by the user and thus prolong the

working duration of important loads; meanwhile, it can switch off all loads when the

battery has been discharged to the maximum, so as to protect the battery. Both the load

and battery output ends are attached with fuses or air switches for protection.

The working principle of the DC power distribution unit is shown in Fig. 2-10. Refer to

Appendix C for the electrical working principles.


----18----

Output current sensor

Battery current sensor


DC contactor 1

DC contactor 2

Group 1 of load output (max. config. of 5 lines of fuses or 9lines of air switches)

Group 2 of load output (max. config. of 10 lines of fuses or22 lines of air switches)

Working ground -48V

Battery pack 2

Battery pack 3


Battery pack 1

Fig. 2-10 Principle diagram of DC power distribution unit

2.5.2 Structure of DC power distribution unit

At the upper front part of the cabinet, the DC power distribution unit has the DC output

load shunt, and has the DC output load shunt, battery fuse shunt and emergency

lighting fuse shunt at the upper rear part of the cabinet.

The DC output can be of three combination modes: fuses, air switches, and fuses plus

air switches. It can be configured according to users’ demands. If not specified,

standard configuration is employed, i.e., fuse combination.

The system’s DC power distribution features the two-stage power-down, the load shunt

in the front of the cabinet is the load shunt of the second-stage power-down, and that in

the back of the cabinet is the load shunt of the first-stage power-down.

1. Fuses combination

The load output shunts of the DC power distribution are all fuses. The fuse

combination is the standard configuration of the system, and the specific

configuration is listed in Table 2-4.


----19----

Table 2-4 The standard configuration of the DC load output

Standard configuration

160A 2 lines

100A 2 lines

63A 1 line DC load output

32A 1 line

For the first-stage shutdown: 1 line of 100A and 160A respectively;

Second-stage shutdown: 1 line of 160A, 100A, 63A and 32A respectively.

The fuse combination of DC power distribution is shown in Fig. 2-11.

Combination of second-stage power shutdown

Combination of first-stage power shutdown

Fig. 2-11 Fuse combination of DC power distribution

The capacity of the fuse combination may be chosen from 6A ~ 160A on users’

demands. Under the circumstances of no change of DC output structure, the

maximum configuration of the fuse combination can be expanded from 6 lines


----20----

to 15 lines of tributary output ranging from 6A to 160A; Second-stage

shutdown: 10 lines maximally; first-stage shutdown; 5 lines maximally (another

7 lines can be added by adding more structured components.)

The DC power distribution unit at the back of the cabinet has two battery shunts

(max. 3 shunts), each of which connects a 400A fuse. If the emergency lighting

shunt is configured, its fuse is in the DC power distribution unit at the back of

the cabinet.

2. Air switch combination

The DC load shunt outputs are all air switches.

According to the conditions of the structural parts, air switch combination can

be composed of 4, 8, 9, and 12 to 31 lines; the capacity can be selected between

6A-63A; second-stage shutdown: 22 lines maximally; first-stage shutdown: 9

lines maximally (another 18 lines can be added by adding more structural

parts.)

3. Mixed assembly of fuse and air switch

Some shunts of the DC output combination are fuses, while the others are air

switches. Various combinations of fuses and air switches can be configured

upon users’ demands.

The DC power distribution unit of the system can be configured flexibly; and

an optimal configuration can be made according to users’ requirement.

2.5.3 Functional characteristics

1. Protection function

(1) Battery loop, load output loop and emergency lighting loop are all under the

protection of fuses or air switches;

(2) There are alarms for system output over-/under-voltage; and alarms for broken

battery fuse, broken fuses for lines of loads or broken air switches as well;

(3) Battery over-discharge protection and second-stage shutdown function.

2. Others

(1) Two lines of battery can be connected and a third line too if necessary;


----21----

(2) Three lines of battery current and total load output current detection;

(3) One line of emergency lighting output (if requested by the user).

3. Grounding

There is a grounding busbar in the AC power distribution part at the back of the

cabinet, and a copper grounding bolt (no less than M8) at the base of the cabinet.

During installation, connect the grounding bolt to the user’s grounding busbar

with a copper wire.

2.6 Supervision unit

2.6.1 Overview

The supervision unit is responsible for the comprehensive management of AC power

distribution, DC power distribution, rectifier sets and battery of the system. The

supervision unit collects running data and monitors the working status of the system on

a real time basis. When the system fails, the supervision unit gives audible and visual

alarms and provides necessary protection measures. The profile of the supervision unit

is illustrated in Fig. 2-12.

Text

Fig. 2-12 Profile of supervision unit

The LCD and LED indicators on the panel of the supervision unit can display the

system’s output current, output voltage, battery current and all kinds of alarm

information. In addition, necessary parameters can be set through the keyboard on the

panel to fulfill necessary control. The running data and working status of the system,

instead of just being reflected locally, can also be reported to the upper-level

supervision unit through transmission of a certain mode.


----22----

The supervision unit also receives commands from the upper-level machine, so as to

query and control the system to realize the “3-tele” functions. The supervision unit

adopts English interfaces, and it can provide a visualized display of the working status

of each part of the power supply system. Indicators show the working status of each

part: power supply working status and alarm status.

When fault occurs to the system, both the alarm indicator and the buzzer generate

audible and visual alarm signals with the instructive alarm information displayed on

the LCD.

The power supply system can work without the supervision unit, in which case,

however, it will lose the “3-tele” function and the battery management function. Then,

in the system, the battery stays in the float charging status. Close attention must be paid

to the discharging of the battery.

2.6.2 Structure

The supervision unit is composed of seven boards connected with flat cables. The

seven boards are ZXDU150-CVT, ZXDU300-LED, ZXDU300-RLY,

ZXDU300-BACK, ZXDU45-PMS, ZXD-CSU-POWER and ZXDU300-EMB.

1. Front panel of the supervision unit

The front panel is composed of LCD, buttons and indicators. The schematic

diagram of the front panel is illustrated in Fig. 2-13, the indicators and buttons

are illustrated in Fig. 2-14, while the indicator instructions are shown in Table

2-5.

Fig. 2-13 Front panel of supervision unit


----23----

Power

Run

Alarm

Com

Reset

PgDn

EscPgUp

Enter

Fig. 2-14 Indicators and buttons on the front panel of the supervision unit

Table 2-5 Indicator instructions on the front panel of the supervision unit

Indicator Color Description

Power Green When the indicator is on, it means that the power

supply of the supervision unit is OK.

Run Green When the indicator flashes, it means that the

supervision unit is in the working status.

Alarm Red When the indicator is on, it means that alarms occur.

Com Yellow When the indicator flashes, it means that

communication is under way.

The “Reset” is a hidden button hole, in which is the Reset key. There are four

buttons in the communications unit: PgUp, PgDn, Esc and Enter, through which

information can be viewed and parameters can be set.

2. Back panel of the supervision unit

The schematic diagram of the back panel of the supervision unit is illustrated in

Fig. 2-15. There is description of the definition of each socket on the housing of

the device.

X11 X10

X6

X16

X17

X14

X12

X15

X19X8 X9 X7

X13 X5

FUSEPOWER

MODEM MODEM 48V

Fig. 2-15 Schematic diagram of the back panel of the supervision unit

Definition of each socket on the back panel of the supervision unit is shown in


----24----

Table 2-6.

Table 2-6 Definition of each socket on the back panel of the supervision unit

S.N. Socket No. Name Wire No. and the corresponding signal

Connector requirements

Remarks

1 X5: RS485/422 communications interface

1: B 485B line 2: A 485A line 3: Y 422Y line 4: Z 422Z line

4-pin 3.81 socket Communications port

2 X6 RS232 communications interface

1: 1: DCD data carrier detection 2: 2: RU receive data 3: 3: TU transmit data 4: 4: DTR data terminal ready5: GND1 communications signal ground 6: DSR data set ready 7: RTS request to send 8: CTS clear to send 9: RING ring

9-pin D-type socket Communications port

3 X7 Interface of battery temperature sensor 1

1: +12V 2: T1

2-pin 3.81 socket


1: +12V 2: T2

2-pin 3.81 socket


1: +12V 2: T3

2-pin 3.81 socket

6 X10 Relay output interface

1, 2： +5V power supply 3~10: signal lines of relays 1~8

10-pin flat cable socket

Make a connection from the BACK board to the relay output board

7 X11 Control alarm relay contact interface

1, 2： 1st stage power shutdown control alarm relay contact 3, 4 ： 2nd stage power shutdown control alarm relay contact 5, 6 ： emergency lighting control alarm relay contact 7，8，9: control relay 1’s NC, NO and COM 10, 11, 12: control relay 2’s NC, NO and COM 13, 14, 15: not defined

15-pin 3.81 socket Connect from the BACK board to the first-stage power-down contact, 2nd-stage power-down contactor or backup


----25----

Table 2-6 (Continued)

S.N. Socket No. Name Wire No. and the

corresponding signal

Connector

requirements

Remarks

8 X12 Environment

monitoring

interface

1: +12V power supply output 2: Input of smog detection

signal 3: Input of flooding detection

signal 4: Input of access control

detection signal 5: Input of access control

detection signal 6: Input of glass broken

detection signal 7: Input of ambient temperature

detection signal 8: Input of humidity detection

signal 9: -12V power supply output 10: -12V power supply output 11: Analog GNDA 12: not defined 13: Digital GND 14: +5V power supply output 15: not defined 16: not defined

16-pin flat cable

socket

Connect with EMB

board

9 X13 Input

interface of

alarm relay

contact

1: RLY1 input alarm relay

contact 1 2: Digital GND 3: RLY2 input alarm relay



contact 4 8: Digital GND

8-pin 3.81 socket Input interface of

alarm relay contact


----26----




Remarks

10 X14 Rectifier communications interface 1

1: EXT1 rectifier 1 in-position signal - U1~U25 2: ALARM1 rectifier 1 alarm signal - U1~U23 3: REMOTE1 rectifier 1 remote control signal - U1~U22 4: EXT2 rectifier 2 in-position signal – U2~U25 5: ALARM2 rectifier 2 alarm signal – U2~U23 6: REMOTE2 rectifier 2 remote control signal – U2~U22 7: EXT3 rectifier 3 in-position signal – U3~U25 8: ALARM3 rectifier 3 alarm signal – U3-U23 9: REMOTE3 rectifier 3 remote control signal – U3~U22 10: EXT4 rectifier 4 in-position signal – U4~U25 11: ALARM4 rectifier 4 alarm signal – U4~U23 12: REMOTE4 rectifier 4 remote control signal – U4~U22 13: EXT5 rectifier 5 in-position signal – U5~U25 14: ALARM5 rectifier 5 alarm signal – U5~U23 15: REMOTE5 rectifier 5 remote control signal – U5~U22 16: PWM signal – U1~U29 – U2~U29 – U3~U29 – U4~U29 – U5~U29 17: GND – U1~U24 –U2~U24 –U3~U24 – U4~U24 – U5~U24 18: GND idle

18-pin 2.54 socket to rectifier socket

Connect from the BACK board to the communications interface board of rectifiers 1~5


----27----




Remarks

11 X15 AC signal detection interface

1: Input of AC phase A current 2: AC transducer power supply GND 3: AC transducer -12V power supply 4: AC transducer +12V power supply 5: Input of AC phase A voltage 6: Input of AC phase B voltage 7: Input of AC phase C voltage 8: Input of the mains input switch status 9: Input of rectifier main switch status 10: Input of lightning-proof circuit status 11: Input of AC output switch status

11-pin 3181 socket Connect from the BACK board to AC transducer and AC distribution unit

12 X16 DC detection signal interface 1

1: Status of DC output fuse 15 2: Status of DC output fuse 14 3: Status of DC output fuse 13 4: Status of DC output fuse 12 5: Status of DC output fuse 11 6: Status of DC output fuse 10 7: Status of DC output fuse 9 8: Status of DC output fuse 8 9: Status of DC output fuse 7 10: Status of DC output fuse 6 11: Status of DC output fuse 5 12: Status of DC output fuse 4 13: Status of DC output fuse 3 14: Status of DC output fuse 2 15: Status of DC output fuse 1

15-pin 3.81 socket Connect from the BACK board to DC distribution

13 X17 DC detection signal interface 2

1: Status of DC output fuse 16 2: Status of DC output fuse 17 3: Status of DC output fuse 18 4: Status of DC output fuse 19 5: Status of DC output fuse 20 6: Voltage check of battery 1 7: Voltage check of battery 2 8: Voltage check of battery 3 9, 10： Battery 1 current divider +, - 11, 12： Battery 2 current divider +, - 13, 14： Battery 3 current divider +, - 15, 16： Load current divider +, -17, 18： monitoring power input terminals

18-pin 3.81 socket Connect from the BACK board to DC distribution


----28----




Remarks

14 X19 Rectifier communications interface 2

1: EXT6: Rectifier 6 in-position signal – U6~U25 2: ALARM6: Rectifier 6 alarm signal – U6~U23 3: REMOTE6: Rectifier 6 remote control signal – U6~U22 4: EXT7: Rectifier 7 in-position signal – U7~U25 5: ALARM7: Rectifier 7 alarm signal – U7~U23 6: REMOTE7: Rectifier 7 remote control signal – U7~U22 7: EXT8: Rectifier 8 in-position signal – U8~U25 8: ALARM8: Rectifier 8 alarm signal – U8~U23 9: REMOTE8: Rectifier 8 remote control signal – U8~U22 10: EXT9: Rectifier 9 in-position signal – U9~U25 11: ALARM9: Rectifier 9 alarm signal – U9~U23 12: REMOTE9: Rectifier 9 remote control signal – U9~U22 13: EXT10: Rectifier 10 in-position signal – U10~U25 14: ALARM10: Rectifier 10 alarm signal – U10~U23 15: REMOTE10: Rectifier 10 remote control signal – U10~U22 16: PWM signal: U6~U29—U7~U29—U8~U29—U9~U29—U10~U29 17: GND: U6~U24 – U7~U24 – U8~U24 – U9~U24 – U10~U24 18: GND idle

18-pin 2.54 socket to rectifier socket

Connect from the BACK board to the communication interfaces of rectifiers 6~10


----29----

3. Environment monitoring board ZXDU300-EMB

The environment monitoring board ZXDU300-EMB (EMB for short below) is

responsible for collecting multiple environmental parameters where the

combined power supply system is located, including ambient temperature,

ambient humidity, smog, door magnet, flooding, infrared (door control) and

glass broken. This board is optional and can be configured on the user’s

demand.

The schematic diagram of the electrical interface of EMB is illustrated in Fig.

2-16.

Temperature Accesscontrol Waterlogging Smog

X5 X6 X8

X9

X1

Envi

ronm

enta

l mon

itorin

g bo

ard

X7 X2 X3 X4

X10

Door magnetBreaking glass Ambienttemperature

Fig. 2-16 Position of the electrical interface of EMB


----30----

Pin definitions of sockets of EMB are shown in Table 2-7.

Table 2-7 Definitions of sockets of EMB

S.N. Line signal Name Leading wire No. and the corresponding signal

Connector requirements Remarks

1 EMB-X1 Input interface

Interconnect with X12 of the monitoring unit; for the pin definition, refer to the content related to X12 in Table 2-6

16-pin flat cable socket

Interconnect with X12 of the monitoring unit

2 EMB-X2 Infrared (access control) interface

1: +9V +9V power supply 2: GND Digital GND 3: DOOR access control pulse signal

3-pin 3.81 socket

3 EMB-X3 Flooding sensor interface

1: CTRL connect to resistance 2: VCC +5V power supply 3: GND Digital GND 4: Water flooding signal

4-pin 3.81 socket

4 EMB-X4 Smog sensor interface

1: +12V +12V power supply 2: SMOIN smog current signal

2-pin 3.81 socket

5 EMB-X5 Glass broken sensor interface

1: +12V +12V power supply 2: GND Digital GND 3: BOLI glass broken signal 4: GND Digital GND

4-pin 3.81 socket

6 EMB-X6 Door magnet interface 1: DOOR2 door magnet signal 2: GND Digital GND

2-pin 3.81 socket

7 EMB-X7 Ambient temperature sensor interface

1: +12V +12V power supply 2: T1 Temperature signal

2-pin 3.81 socket

8 EMB-X8 Environment humidity sensor interface

1: VCC +5V power supply 2: SHIDU humidity signal3: GND Digital GND

3-pin PCB socket

Directly inserted to PCB

9 EMB-X9 Short-circuit bar

X9 needs to be shorted while glass broken sensor is not connected.

10 EMB-X10 Short-circuit bar

X10 needs to be shorted while door magnetic sensor is not connected.


----31----

4. Monitoring unit relay output board ZXDU300-RLY

Alarm signals of the system can be converted to alarm relay contact signals

through the relay output board ZXDU300-RLY (RLY for short below) of the

monitoring unit. RLY provides eight alarm relay contact signals for the output

of alarm signals. The alarm signal of each alarm relay contact can be defined

through “System parameter setting” of the monitoring unit. The schematic

diagram of the alarm relay contact output interface position of the RLY board is

illustrated in Fig. 2-17.

ZXDU300 RLY

X1

X2 X3

X4 X5

K1 K2 K3 K4 - NO - K5 K6 K7 K8

K1 K2 K3 K4 - NC - K5 K6 K7 K8

Fig. 2-17 Interface position of RLY board

(1) Application cases

Instead of the full real-time data of the power supply, the user needs only to

know a few simple alarm parameters. Alarms of the power supply system can

be reported through other devices.

(2) Hardware architecture

The RLY board is composed of eight small relays, whose action is controlled by

the monitoring unit. The relays provide eight output contacts in the mode of

alarm relay contacts, each contact having a normally-on and a normally-closed

contact (respectively marked as NO and NC). The normally-on contact and

normally closed contact are of two different groups of the same relay, without

electrical connection between them. Each contact provides an alterable output


----32----

status to indicate the specific alarm information. Which contact is to be used is

up to the user.

(3) Hardware installation

The RLY board is on the top of the rack supervision unit. All that has to be done

is connect X10 of the monitoring unit BACK board with X1 of the RLY board

with a 10-core flat cable.

(4) Operations

After hardware installation, power-on and enable the monitoring unit to work

(see Section 4.4). Enter the submenu of “System parameter setting”, move the

cursor to the item “Alarm relay contact corresponding to failure category.”

Setting interface of this item is shown in Fig. 2-18.

Parametersetting

Alarm relay contact corresponding to fault tyupe

Alarm relaycontact 1

Help30

OKMain air switch for rectifier

Fig. 2-18 Wiring of the relay output board

Refer to Section 4.4.6 for the method of setting parameters. In the interface, the

“Main rectifier air switch off” is responsible for setting of alarm type, and there

are altogether 20 types of system alarms available for choice; “Alarm relay

contact 1” is the chosen position for the alarm relay contact, and there are

“Alarm relay contact 1” to “Alarm relay contact 9” for choice. Eight relay

interfaces are on the RLY board, while the remaining one is in the socket X11

of the monitoring unit’s rear panel. Press “OK” after the setting to determine

through which relay the corresponding alarm is to be output. When an alarm

occurs to a relay, the relay will react and the output status changes.

(5) Description of wiring

K1~K8 in Fig. 2-17 respectively correspond to eight relay positions, where NO

in the upper row corresponds to the relay’s normally-on contact while NC in the

lower row, the normally closed contact. For relays adopting two groups of

contacts, there is no electrical connection between the normally-on contact and

normally closed contact. For the wiring, lead out two normally-on signal lines


----33----

from the normally-on socket position in the upper row or two normally closed

signal lines from the normally closed socket position in the lower row. The

schematic diagram of wiring of the relay output board is illustrated in Fig. 2-19.

ZXDU300 RLY

X1

X2 X3

X4 X5

K1 K2 K3 K4 - NO - K5 K6 K7 K8

K1 K2 K3 K4 - NC - K5 K6 K7 K8

Drop-line socketfor normally-oncontact of relay

K1

Drop-line socketfor normally-off

contact of relay K1

Fig. 2-19 Wiring of the RLY board

2.6.3 Function of the monitoring unit

1. Man-machine interface

The man-machine interface is composed of LCD and buttons. The foreground

adopts English operation interface. Users can, on the man-machine interface,

set the parameters for the system, so as to display the running parameters of

various parts of the system.

2. Communications

The monitoring unit provides RS232 communications interface and can realize

centralized monitoring via Modem or in other modes. It reports on-site data and

status to the background PC and receives control instructions from the

background PC and executes them.

(1) Local supervision and control: provides the standard RS232 interface to connect

with a local PC.

(2) Remote supervision and control: provides the standard RS233 interface and

connects it to the centralized maintenance background via Modem.


----34----

(3) Communication with the rectifier is fulfilled in the analog mode.

(4) Communications with other monitoring systems: provides RS232 interface.

3. Data collecting and processing

The signals collected and processed are as follows:

(1) AC power distribution unit

The signals to be collected and processed by the AC power distribution unit

include: AC voltage U, V, W phases; AC phase U current; working status of AC

contactor; status of AC input air switch; working status of AC lightning arrester.

(2) DC power distribution unit

The signals to be collected and processed by the DC power distribution unit

include: DC output voltage; 3 lines of battery voltage; 3 lines of battery current;

1 line of general load current; load output fuse or air switch status; battery fuse

status; control of two lines of DC contactors.

(3) Rectifier part

The signals to be collected and processed by the rectifier include: alarm

information of the rectifier; switch control of the rectifier; equalized/floating

charge status control of the rectifier.

4. Alarm management and protective functions

It processes the real-time data according to the user’s configuration. When

anything abnormal happens, alarm will be reported automatically to the

background PC, and the existing faults will be recorded for saving. Users can

interrogate the alarms that happen most recently directly from the monitoring

unit. The monitoring unit can, when any alarm happens, automatically page the

maintenance personnel.

5. Battery management function

Battery management covers two parts:

(1) Battery charging management function

The monitoring unit manages the process of battery charging in two modes, i.e.,

cycled equalized charging, and power-on equalized charging again after power

failure. The cyclic equalized charging means that the system can automatically


----35----

perform equalized charging according to the cycles set by users. The power-on

equalized charging after power off means that the battery discharges after

power off, and automatically performs charging management to the battery

pack when the power is resumed.

(2) Battery protection

With mains supply’s breaking down, the loads will be powered by batteries;

when the battery voltage lowers to a certain degree (set by the user), alarm will

be given; when the battery further discharges till the battery voltage gets lower

than the first-stage power shut-down value set by users, a group of minor loads

can be cut off as per the user’s setup; when the battery further discharges to the

ultimate protective voltage (second-stage power shut-down voltage), cut off

another group of loads, so as to protect the battery from damage due to

over-discharge. Thus, a relatively longer duration is ensured for the major loads

after power failure and at the same time the batteries can be protected against

damages due to over discharge.

6. Control function

It is allowed to control, based on the foreground user’s operation or control

commands of the background PC, the ON/OFF and equalized charge/float

charge working status of the rectifier, as well as to control the rectifier output

voltage according to the user’s demand.

2.6.4 Check precision

1. AC

The check precision of AC voltage is ±3VAC, and that of AC current is ±2A.

2. DC

The check precision of DC current (rectifier output current, battery current and

load current) is ±3A; while the check precision of DC voltage (battery voltage

and output voltage) is ±0.3V.

3. Temperature/humidity

Temperature measurement precision ≤ +/-3°C

Humidity measurement precision ≤ +/-5%


----36----

4. Detection of switch parameters: the switch parameter check and alarm report must

be 100% accurate without false report or omission.

2.6.5 Alarm

1. Alarm setting

The user can set the upper and lower alarming limits of the detected power

supply system data according to real circumstances.

2. Alarm management

The system has perfect alarm judging conditions, which ensures that not only

the alarm judgment is reliable but also the alarms are reported in real time.

3. Alarm mode

The monitoring unit emits audible and visual alarm signals to prompt the

maintenance personnel, and at the same time, sends the alarm information to the

background PC via the RS232 communication interface. The maintenance

personnel can view and handle the alarm information and when he pushes a

button, the alarm sound disappears. At the same time, the alarm indicator still

suggests the alarm status. Only after the alarm status totally disappears will the

indicator light go out.

2.7 Communications networking schemes The ZXDU500 500A combined power supply system has flexible and diversified

communications and networking modes, which mainly cover the following.

2.7.1 Simple RS232 serial port mode

The monitoring unit and the background are connected directly via the serial port. This

is the most direct and convenient way of monitoring, but it is largely restricted by

practical conditions. Usually, it is required that the distance between the background

monitoring host and the power supply monitored should not be wider than 15 meters,

as illustrated in Fig. 2-20.


----37----

RS232

Power supplysystem

PC

Fig. 2-20 Connections of serial port monitoring

2.7.2 Dial-up mode (MODEM mode)

The monitoring background exchanges data with the monitoring unit in the dial-up

mode using a MODEM. This mode requires that the monitoring background be

connected with two Modems and the monitoring unit, with one Modem. Of the two

Modems connected to the monitoring background, one is responsible for data querying,

while the other, receiving the alarm data of the combined power supply system, as

illustrated in Fig. 2-21. This mode features the optimal versatility and is applicable to a

majority of networking modes.

Modem

Power supplysystem

PSTN

Modem

ModemModem

Modem

Power supplysystem

Power supplysystem

Fig. 2-21 Monitoring in the MODEM mode

2.7.3 ZXJ10 digital SPC switch mode

In this mode, networking is performed through the monitoring platform of ZXJ10

Digital SPC Switch (ZXJ10 for short below) developed by ZTE Corporation. The

networking and connections are illustrated in Fig. 2-22. For a single combined power

supply system, this mode is similar to the simple RS232 serial port mode.


----38----

Powersupply

monitoring

RS232ZXJ10 operation &

maintenance system

RS232 RS232 RS232 RS232

Power supplysystem

ZXJ10remote module

RSU

ZXJ10 central module

LAN

Power supplysystem

ZXJ10remote module

Power supplysystem

ZXJ10remote module

Power supplysystem

…

ZXJ10remote module

Fig. 2-22 Monitoring in ZXJ10 mode

The data under the power supply monitoring is transferred through the data channel of

ZXJ10. This mode is desirable for users using ZXJ10 as it can save the networking cost

(by sharing a set of monitoring hardware) and it is more reliable than the Modem mode

in terms of data transmission. The serial port of the power supply is connected to serial

port 2 of MP of ZXJ10, while the background may either share a computer with ZXJ10

maintenance platform or use a separate computer, which must be connected using the

network cable and run the NE2000 driver. The characteristics of the networking mode:

real-time, simple and economical networking.

2.7.4 SCM mode

The SCM signal conversion module is a set of intelligent equipment of proprietary

intellectual property by ZTE, which mainly applies to the centralized monitoring

networking of GSM base station. It is mainly used to join the point-to-point service

digital channels provided by microwave or optical fiber equipment into a network, to

perform centralized monitoring on the power supply, environment and other equipment

of the base station. Such an application is especially suitable for the networking in

other environments having the point-to-point service digital channel but without


----39----

enough telephone lines.

The SCM signal conversion module features high reliability and wide range of

applications. Besides, the equipment has several standard interfaces applicable to

RS232, RS422 and RS485.

The SCM mode can combine the power supplies to be monitored into a tree network,

and realize centralized monitoring on various power supply devices within this network

via the monitoring center. The SCM networking model is illustrated in Fig. 2-23.

Monitoring information of other

systems Microwave equiment

Centralized supervision sysetm Microwave

equiment

Microwave equiment

SCM RS232 /422

Other equipment Power supply

I/O

RS232

Microwave equiment

Microwave equiment

SCM RS232 /422


I/O

RS232

RS232

Microwave equiment

Microwave equiment

SCM RS232/422


I/O

RS232

The same as in the broken line

Fig. 2-23 SCM networking model

For the system running on the network, SCM is a remote transmission mode; for a

single combined power supply system, this mode is similar to the simple RS232 serial

port mode.

2.7.5 Access network mode

In addition to the above-mentioned four monitoring modes, there is the “Access

network communication and networking function” in the system. That is, connect serial

port X6 of the power supply system to the serial port of the ZTE access network

equipment, which has a special power supply monitoring software to monitor the

power supply system remotely. We shall introduce the system topology of the AN


----40----

networking mode.

In the remote user unit system, there exist the environment monitoring system and

integrated power supply monitoring system. Both are connected to the CSV board of

the access network system via the RS232 serial interface, and transmit the

bi-directional monitoring data to the remote monitoring and maintenance platform via

the CSV board. For the power supply monitoring system, there may exist two

possibilities which are described below respectively.

1. Both the power supply monitoring system and environment monitoring system

exist in the system, where Environment Monitoring Unit (EMU) and the CSV

board are directly connected, while the power supply monitoring system and

the Environment Monitoring Unit (EMU) are connected, as illustrated in Fig.

2-24.

Power supplymonitoring

systemCSV board

Environmentalmonitoring Unit

(EMU)RS232 RS232

Fig. 2-24 The mode of communication with connection between EMU and the power supply monitoring system as well as

between EMU and the CSV board

The power supply monitoring information is directly sent to the environment

monitoring unit, which then forwards the information to the CSV board.

2. If there is only the power supply monitoring in the system, the power supply

monitoring system will be directly connected to the CSV board, as illustrated in

Fig. 2-25.

CSV boardPower supplymonitoring system RS232

Fig. 2-25 The mode of communication with the power supply monitoring system directly connected to the access network

CSV board

Two points shall be emphasized for the two cases mentioned above: first,

environmental monitoring is completely transparent to the power supply


----41----

monitoring system, which does not know or care about its existence; Second, no

modification is necessary for the communications protocols of the power

monitoring system in any one of the situations mentioned above. In addition,

the power can also be monitored via the PPS board that connects with the

system, as shown in Figures 2-26 and 2-27.

Power supplymonitoring system PPS board

Environmentalmonitoring unit

(EMU)RS232 RS232

Fig. 2-26 The mode of communication with connection between EMU and the power supply monitoring system as well as

between EMU and the PPS board

PPS boardPower supplymonitoring system RS232

Fig. 2-27 The mode of communication with the power supply monitoring system directly connected to the PPS board

2.7.6 CDMA mode

For a single combined power supply system, this mode is similar to the simple RS232

mode.

Because there are many CDMA cell stations which are scattered, it is not practical and

economical for the combined power supply system itself to provide the data channel

for maintenance and monitoring. Therefore, communication can be done between the

power supply monitoring background and foreground via the CDMA internal

communication channel for daily maintenance and monitoring. The ZXDU500 500A

combined power supply system provides the CDMA networking mode.

First, the power supply foreground can be connected via serial lines with the CDMA

base transceiver station of the power supply, so as to realize data exchange; second, the

power supply monitoring background shall also communicate with CDMA background,

which will not only establish data channels between the foreground and the

background of the power supply, but also timely reflect the monitoring information to

the CDMA background operation and maintenance station. Communication between


----42----

the power supply background and CDMA background is realized through the

communication system running CDMA at the power supply monitoring background

and the corresponding TCP proxy program. The connection of the entire system is

illustrated in Fig. 2-28.

Ethernet

ZTE powersupply product

series

RS232

ZXC10-BTS

SAM boardR232 port

ZXC10-BSC

CDMAbackgroundserver

CDMAbackgroundclient terminal

ZTE powersupply

monitoringbackground

E1

Fig. 2-28 Connection in the CDMA networking mode

----43----

3. Equipment Installation

3.1 Installation procedures The work flow for installation, debugging, acceptance and commissioning is shown in

Fig. 3-1.

Project survey (including1st environment

acceptance

Project preparation

Start

2nd environmentacceptance

Unpacking &acceptance

System installation

System debugging

Test forpreliminaryacceptance

Handover

Cutover preparation &cutover

Final acceptance

Trialrunning

Finish

N

Y

N

Y

Inspection &power-on

Fig. 3-1 Procedures for installation and acceptance of combined power supply


----44----

3.2 Basic requirements for power supply system installation Before the installation of the power supply equipment, ZTE Corporation shall, together

with its local customer service center and user representatives, fulfill project and

environment survey, and, according to the actual situations of the site, fill in the Survey

Report on ZXDU Combined Power Supply System Project, and Acceptance Report on

ZXDU Combined Power Supply System Environment. If the conditions on the user site

fall under the minimum requirements on safe running of equipment as stipulated in the

survey report, the customer should be required to improve the site conditions

accordingly. The equipment installation shall resume only after the conditions are

compliant with the requirements of normal and safe running of the equipment.

3.2.1 Environment requirements

For environment requirements, please refer to the stipulations in Acceptance Report on

ZXDU Combined Power Supply System Environment.

3.2.2 Power supply requirements

1. General principles

The communications equipment should adopt mains supply as the primary

power supply. We should configure diesel generators and standby battery pack

according to the conditions of local power supply. The centralized power supply

is recommended for the AC power supply system consisting of mains and

self-contained diesel generators, while 3-phase 5-line system or single-phase

3-line system is recommended for low-voltage AC power supply system. The

self-contained diesel generators are preferably the automatic version.

When the load power factor falls under 0.7, the reactive power compensation

equipment should be installed to push the power factor up over 0.8.

The AC power cable should have copper cores and its sectional area should be

consistent with the load. When the wiring distance is less than 30m, the

cost-effective current density (with the value of 2.5A/mm2~4.0A/mm2) will be

used to calculate the sectional area. The outdoor power cable should be

directly buried or buried in tubing, and preferably laid away from signal cables.

2. Capacity requirements

(1) Power transformer

Chapter 3. Equipment Installation

----45----

The ZXDU500 500A combined power supply is a switching power supply,

which, for its special features, requires a larger redundancy in power supply. If

the power transformer capacity is small, other equipment so powered may fail

to work normally. If it is a special transformer, the capacity is calculated at full

configuration (500A) and should be higher than 65kVA. Besides, in

consideration of power consumption of AC standby output and air-conditioning

of the system, a higher capacity is recommended, and the selection should

follow the specifications upwards.

(2) Diesel generator set

If the load of the rectifier exceeds 30 percent of the capacity of the power set,

the voltage waveform will be seriously distorted when the high order harmonic

wave current generated by the rectifier passes the stator winding of the

synchronous power set, which will bring forward impacts of two aspects: on the

one hand, it will cause instable running and mechanical vibration; on the other

hand, the harmonic wave current will result in an overheated generator, and

speed up the insulation aging of the generator. It not only harms the generator,

but also affects the stable running of the power supply system, that is, the

vibration problem frequently encountered nowadays. As a result, the power

supply load shall not exceed 30% of the generator capacity, the load of the

power supply shall be calculated as per the existing power, and the simplified

calculation is as shown below: output voltage (calculated according to 60V) ×

output current (calculated according to the final configuration) × 2. The

selection of generators should also take their power factor and excitation into

consideration, while those with brushless fundamental wave excitation are not

recommended.

3.2.3 Safety and protection requirements

1. Lightningproof and surge protection requirements

Reliable lightning protection facilities must be installed for buildings with

communications equipment. In order to maintain normal performance of the

system, a lightning-proof device, or level B lightning-proof device, should

preferably be installed somewhere before the AC mains is introduced into the

power system. The level-B lightning arrester should be installed at the expense

of the user, and the recommended model is the ZXDU-LPU dedicated


----46----

lightning-protection unit produced by ZTE. If possible, the level B lightning

arrester should be installed somewhere 12m or more in front of the input end of

the power distribution cabinet. It is required that the cables from the level B

lightning-proof device installation site to the AC power distribution unit be

indoor cables, thus to ensure that the section of the cables is not directly

exposed to lightning strike. In the installation of the level B lightning-proof

device by users, attention should be paid to the cable diameter and length on the

lightning-proof device, and the lead sectional area should be no less than

16mm2, while the lead length is the shorter the better, so is the case for the

grounding cable of the lightning-proof unit.

The lightning-proof device and grounding cables installation are shown in Fig.

3-2.

3-phase ACdistribution

board

Level-C lightningarresterLevel-B

lightningarrester

Battery I Battery II

Com.equipment

Protectionground

Com.equipment

Protectionground

Equipment room grounding busbar (net)

N

AC input

No lessthan12m

Grounding body

System output -48

Working ground for system output

BA

C

PE A B C N

Fig. 3-2 AC incoming anti-lightning and grounding installation

2. Grounding requirements

The joint grounding mode is usually adopted for designing the grounding mode

of the communications equipment room, that is, the working ground, lightning

protection ground and protection ground share the same group of grounding


----47----

blocks, with the grounding resistance conforming to the specifications in Table

3-1.

The basic approach of joint grounding is to short the grounding busbar and DC

working ground of the power system with the user grounding busbar. As far as

those base stations without independent user grounding busbars are concerned,

the DC working ground access points (positive busbar or negative busbar) of

the power supply system can be regarded as the user grounding busbar. The

lightning ground and protection ground should be connected to the grounding

busbar of the power system in the vicinity, as shown in Fig. 3-2.

The multiple grounding of AC zero lines should not share the grounding busbar

or grounding grid of the equipment, and a separately buried grounding cable is

recommended for the multiple grounding of zero lines. The protective

grounding cables in the 3-phase/5-line system and the single-phase/3-line

system can be directly introduced into the grounding busbar of the power

supply system, or the protective ground connection terminal of the AC power

distribution cabinet.

Table 3-1 Grounding resistance requirements for communications stations

Grounding resistance Applicable scope Reference

<1Ω Buildings of general purposes, international telecom office, tandem exchange, SPC exchange over 10000 lines, toll exchange over 2000 lines

<3Ω SPC exchange of 2000—10000 lines, toll exchange under 2000 lines

<5Ω SPC exchange less than 2000 lines, optical cable terminal station, carrier repeater station, earth station, microwave hub station, mobile communication base station

YDJ20-88 “Provisional technical specifications on SPC telephone switch equipment installation and design”

<10Ω Microwave repeater station, optical cable repeater station, and small-sized earth station

<20Ω Passive microwave repeater station

YD2011-93 “Lightning-proof and grounding design specifications for microwave stations”

<10Ω Applicable for the lightning-proof grounding at the joint of the power cable and overhead power cable with unit earth resistance less than 100Ω×m

GBJ64-83 “Over-voltage protection design specifications on industrial and civil power equipment”

<15Ω Applicable for the lightning-proof grounding at the joint of the power cable and overhead power cable with unit earth resistance of 101Ω×m~500Ω×m

<20Ω Applicable for the lightning-proof grounding at the joint of the power cable and overhead power cable with unit earth resistance is 501Ω×m~1000Ω×m

GBJ64-83 “Over-voltage protection design specifications on industrial and civil power equipment”


----48----

3.3 Preparations before installation

3.3.1 Safety check

The following safety inspections must be carried out before installing the ZXDU500

500A combined power supply system:

1. Workable and effective fire-fighting devices must be made available in the

equipment room;

2. Different mains jacks in the equipment room must bear obvious marks;

3. No inflammables and explosives shall be placed in the equipment room;

4. Reserved holes and openings in floorslabs shall be covered for safety.

3.3.2 Cooperation of the office party

The installation of the equipment should be carried out jointly by the technical

personnel from both ZTE Corporation and the office party. To facilitate the normal

operation and maintenance of the equipment, the technical personnel of the office party

should learn the installation, structure, wiring and debugging steps actively.

3.3.3 A complete preparation for tools and instruments

1. ZTE shall provide the office party with a list of the tools and instruments, while

special instruments shall be taken to the site by ZTE technical personnel and

the universal ones purchased by the office party;

2. The instruments must be subject to rigorous calibration by relevant institutions,

and only qualified ones are allowed;

3. General-purpose tools and instruments mainly include the following items:

monkey wrench, socket wrench, Philips screw driver, flat-tip driver, antistatic

wrist strap, diagonal plier, long nose plier, vice, tweezer, impact drill, soldering

iron, ruler and tape measure, multimeter, MODEM, multi-serial-port card,

serial ports, MODEM connection line, etc.

4. Prior to the installation, the office party should prepare for the equipment room

and grounding cables and provide facilities required in the installation;

5. Installation shall be postponed if any inconsistence is found, and negotiation for

commencement will have to be performed.


----49----

3.3.4 Preparations of technical documents

1. Equipment room design documents and working drawings shall come from the

designers entrusted by the office party;

2. “ZXDU500 500A Combined Power Supply System User’s Manual” is provided by

ZTE Corporation.

3.4 Work of supporting facilities of the power supply system

3.4.1 Battery installation

The battery installation of the power supply system is to connect the battery into the

power supply system, which is usually the responsibility of the battery vendors.

The installation tools of battery pack have to undergo insulation treatment, in which the

plastic battery housing and output end should be kept intact. The batteries to be

installed layer by layer have to be connected by respective layers before inter-layer

connection. Leave the charging/discharging cable unconnected for the time being.

3.4.2 Laying of power cables

In the engineering design, the AC power cable and DC power cable should be laid

separately, to avoid the 3-phase AC power exerting electromagnetic interference on AC

output.

According to different load tributaries and polarities, each power cable of the battery

line and load line shall bear the line number and the marks for positive/negative pole,

and the marks shall be labeled on the cable for certain distance.

The positive polar cable of the battery and DC power distribution should be red or

black, the load cable should be blue, while the grounding cable should be yellow green.

The phases A, B, C and zero of the AC power cable should correspond to yellow, green,

red and light blue respectively.

When a uniform color is adopted for the power cables, black color shall be chosen,

however, cable marks shall be well presented, so as to avoid mixing.


----50----

3.5 Unpacking and acceptance

3.5.1 Shipping

The ZXDU500 500A combined power supply system is packed as required, bearing

waterproof and shockproof signs for shipping. When the equipment is delivered to

the office party, it should be handled with care and guarded against sunlight exposure

and rainwater.

1. The physical dimensions of the wooden case (cabinet) are

2200mm×760mm×870mm (L×W ×H). Proper handling tools and weight lifting

machinery (such as forklift) appropriate for such dimensions should be

provided.

2. As the wooden cases are large in size, the place for their unpacking has to be

determined beforehand (taking into consideration the route from the unpacking

place to that of installation, the shorter the better), and prepare the necessary

transport vehicles, such as hydraulic vehicle, cart, jack, ropes, piling machine

and iron bars.

3. Special care shall be paid to “bottlenecks” in the moving, such as turns, passage

elevators and slopes.

3.5.2 Unpacking

1. Check the appearance of the box to see if there is damage and indent, and take

photos and notify the supplier if necessary;

2. Unpacking shall proceed as shown in Fig. 3-3;

3. Remove all contents and fillings from inside;

4. Check whether the machine itself is damaged, deformed or rusted.

3.5.3 Packing list

Unpack the spare part box, and take out the packing list to check whether the contents

in the list are consistent with the parts. If any inconsistency if found with the

equipment part types or quantities, or any damaged in shipping, please do not hesitate

to contact ZTE Corporation.


----51----

1. Remove top cover 2. Remove front side board3. Remove side boards (2 ends) 4. Remove back side board

5. Remove foam board 6. Open dampproofplastic film

1 Top cover

3 Side board

5 Foam board

5 Foam board

5 Foam board

5 Foam board

3 Side board

6 Bottom frame

2 Front side board

Fig. 3-3 Unpacking procedures

3.6 Cabinet installation

3.6.1 Cabinet installation requirements

Determine the installation position of the cabinet according to the specific conditions

of the site. The installation position should be selected in view of reasonable line in/out

of the equipment and convenience of operation and maintenance. The installation

height shall be convenient for observing the monitoring display, taking into

consideration of the convenience in ventilation, heat dissipation, operation and


----52----

maintenance. The cabinet should be installed horizontally, with the cabinet vertical

inclination no more than 5°.

The installation modes for cabinet include the following: direct installation on the floor,

and fixed installation on the bracket.

3.6.2 Cabinet installation procedure

1. Determine the position for the cabinet to be installed

The ground position of cabinet should be specified according to factors such as

spatial position requirement, rationality of wire in/out of power supply system,

physical dimensions of the equipment, convenience of operation and

maintenance, size of equipment room, and specific environment conditions. The

requirement on the installation position of the cabinet is as shown in Figure 3-4.

600mm

600m

m

Front ofcabinet

Spacing betweenside and wallshall not be lessthan 0.8m

Spacing betweenback and wall shall

not be less than0.8m

Front path shall not be lessthan 1.5m

Fig. 3-4 Requirements for the position of the combined power supply cabinet to be installed

2. Specify cabinet installation mode

First decide whether a bracket is needed. When antistatic floor is available in

the user’s equipment room, the bracket should be installed under the cabinet.

Such factors as the heights of the floor and the ground, the exterior size of the

cabinet, the location of the fixing hole for the base, the bracket bearing etc. will

have to be considered in making the bracket. Where there is no antistatic floor


----53----

in the equipment room, the cabinet is usually installed by fixing it directly on

the ground with bolts.

3. Specify the hole site and fix the expansion bolts

1) Specify the installation hole position

After the position for installing the cabinet is specified, the position for the

installation holes should be specified according to the cabinet position and its

fixing holes, and the central point for the installation holes should be specified

as well. If a bracket is used in installation, the hole site should be specified

according to the installation hole dimensions of the bracket and that on the

ground.

The installation dimension of the cabinet is shown in Fig. 3-5.

Determine the position of the installation hole for the cabinet according to the

size of the fixing hole as shown in Fig. 3-5. After determination of the

installation hole location, use the impact drill to drill the installation hole. The

aperture for fixing the cabinet is 14mm. The fixing bolt is typically M10×80,

the drill bit isФ12, and the depth of the hole is about 70mm. During punching,

we shall try to prevent the vibration of the electric drill from resulting in

eccentricity, besides, the location of the hole shall keep vertical with the ground.


----54----

Ground baseinstallation hole

Anchoringbolt

installationhole

Fig. 3-5 Size for cabinet installation

2) Install expansion bolts

Add the gasket and the screw cap on the screw, insert it into the hole, and turn

the screw cap with the wrench clockwise, so as to fix the expansion bolt in the

hole, and take down the screw cap and the gasket afterwards.

After the expansion bolts are fixed, the part above the ground should be about

30mm.

The expansion bolt mounting procedure is shown in Fig. 3-6.


----55----

Fasten nut to fixexpansion bolt in hole

Nut

Spring washer

Flat washer

Underground partof expansion bolt

Bolt after installation

Fig. 3-6 Schematic diagram of expansion bolt mounting

4. Cabinet positioning

During cabinet installation, several persons are needed to lift the cabinet above

the ground, then settle it down after aiming precisely into position. When

possible, the cabinet can be hoisted using the hoisting ring on top of the rack

with a pulley block and put in position.

The position of the cabinet hoisted to is illustrated in Fig. 3-7.


----56----

Flat washer

Amplified part A

Bolt

Spring washer

Nut

Underground part of bolt

Nut after installation

Amplified part B

Cabinet

Fig. 3-7 Cabinet installation

The installation of the bracket is quite similar, first fix it on the expansion bolts,

as shown in Fig. 3-8.


----57----

Underground part of bolt

Expansion bolt after installation

Bracket

Fig. 3-8 Bracket installation

Then lift or hoist the cabinet onto the bracket, as shown in Fig. 3-9.


----58----

Bolt of fixed bracket

Bolt

Flat washer

Spring washer

Nut

Amplified figure

Cabinet

Fig. 3-9 Installation of cabinet with bracket

5. Cabinet fixing

After the cabinet is in position, it should be adjusted properly horizontally and

vertically. Generally speaking, insert an iron sheet under the lower edge or the

corner where the cabinet lands on the ground, making the vertical inclination of

the rack less than 5°, and put washers, spring washers and nuts on the expansion

bolt in the end to fix the rack properly. When the cabinet is installed on bracket,

fix the bracket and cabinet together with M10 screw of proper length, then

adjust the vertical inclination of the cabinet, making the vertical inclination

angle of the cabinet less than 5°.

3.7 Overall system assembly Assembling the integrated equipment refers to assembling the rectifiers that are


----59----

separately packed onto the cabinet.

3.7.1 Assembling and fixing the monitoring unit

The position of the monitoring unit on the cabinet is shown in Fig. 3-10. The

monitoring unit is delivered together with the cabinet as a whole package, so separate

installation of the monitoring unit is not required.

The monitoring unit and the rectifier module are hot-swappable. The system can still

run normally without the monitoring unit. In this case, the battery is in float-charging

status, and the current threshold of each rectifier should be adjusted to 20A.

When the system is running, the procedures for installation and removal of the

monitoring unit are as follows:

1. Assembling sequence

(1) Slowly insert the supervision plug-in box from the front;

(2) Secure the fastening screws on the front panel;

(3) Insert the power supply plug, monitoring plug, and communication wires on the

back panel;

(4) Turn on the power supply switch of the monitoring unit (the switch is on the upper

left of the back panel of the monitoring unit).

2. Disassembling sequence

(1) Switch off the power supply of the monitoring unit;

(2) Remove all the monitoring communications lines from the back panel of the

monitoring unit;

(3) Remove the fastening screws from the front panel;

(4) Slowly take out the monitoring plug-in box from the front.


----60----

Fig. 3-10 Installation of supervision box

3.7.2 Modem installation and fixing

For equipment with the modem for remote monitoring, the modem should be installed

to the upper right of the monitoring unit of the cabinet (front view), as shown in Fig.

3-11. To install the modem, unscrew the installation bracket of the modem, with the

modem connection port facing backward, insert and fasten the modem into the bracket,

and screw tight the bolt.

Bracket MODEM (indicator panel pointed forward)

Fig. 3-11 Modem installation


----61----

3.7.3 Rectifier installation and fixing

Specify the rectifier position according to the principles of balanced three phases and

conducive to cooling. The phase sequence distribution of the 3-phase AC input in the

rectifier module position in the system is shown in Fig. 3-12.

Phase A

(01)

Phase B

(02)

Phase C

(03)

Phase A

(04)

Phase B

(05)

Phase C

(06)

Phase A

(07)

Phase B

(08)

Phase C

(09)

Phase A

(10)

Fig. 3-12 Phase sequence distribution diagram of the rectifier slots of ZXDU500 500A combined

power supply system cabinet (front view)

Dissemble the packaging box for the rectifier, take out the rectifier, carefully examine

whether there is any damage, and contact the local customer office of ZTE Corporation

if any; if there is no any damage, install the rectifier on the bracket. The assembling

and disassembling of the rectifier are illustrated in Fig. 3-13.


----62----

Mechanicallock spanner

LOCKUNLOCK

Rectifier pushdirection

Moving direction formechanical lock

switch

Fig. 3-13 Installation of switched rectifier

To install the rectifier, seize the handle with one hand, and hold the rectifier with the

other, slowly push it into the rectifier slot, so that the integrated plug of the rectifier can

be correctly and reliably connected to the corresponding socket.

Before plugging the rectifier into the slot, the mechanic lock switch on the panel of the

rectifier should be set to the left side and then push the rectifier slowly in. When it can

no longer be pushed in, it means that the rectifier has reached the first limiting position.

At the time, it is necessary to move the mechanical switch to the rectifier on the right

before going on to insert the rectifier until the bottom, i.e., the second limiting position.

Move the mechanical switch to the position on the left, so that the rectifier is “locked”.

To uninstall the rectifier, move the mechanical switch to the right, slightly unplug the

rectifier outside for about 1cm, move the mechanical switch on the panel of the

rectifier to the left to extract the whole rectifier.

3.8 Electrical connection The internal lines of the combined power supply system have been connected prior to

leaving factory, and the electrical connections on the spot include the following:

connection of AC input lines, connection of DC load lines, connection of battery cables,

connection of battery temperature sampling lines, connection of grounding wires,

connection of communications lines with centralized monitoring function (users shall

provide telephone lines when centralized monitoring is performed via MODEM).

When upward wire routing is adopted for the system, the overhead wiring shall be

undertaken; when downward wire routing is adopted, hidden grooves shall be

employed for wiring. The principle for electrical connection is safety and reliability.


----63----

3.8.1 Connection of AC input lines

The wiring for AC power distribution unit includes the connection of AC input lines,

the connection of AC standby output, and the connection of emergency lighting lines.

The structure of the AC power distribution unit is shown in Fig. 3-14.

B

NW1V1U1

Y G R

NW2V2U2

BRGYAC input 1 AC input 2

Fig. 3-14 Line connection of AC 3-phase input

3-phase and 5-line input is employed for the system’s AC input lines, the leading in

ends of the input phase conductors are U1, V1 and W1 terminals of the AC input line

banks, with the colors of the connection lines corresponding to yellow, green and red;

the leading in end for the zero line is terminal N, and the connection line is blue; the

leading in end of the grounding line is the grounding busbar at the back of the cabinet,

and the color of the connection line corresponds to the yellow-green one.

If users use 2 lines of mains supply or 1 line of mains supply plus 1 line of oil engine,

connect the phase conductors of the first line of mains supply to U1, V1 and W1

terminals of the input connection busbar, and connect the phase conductors of the oil

engine or the other line of mains supply to U2, V2 and W2 terminals. The zero line is

connected to terminal N, and all the grounding cables to the grounding busbar.

The diameter of the lead-in line should be selected based on the actual load and battery


----64----

conditions. A typical choice is the copper-core soft cable with the sectional area

16mm2~35mm2. Remove the insulation layer from the connection ends of the input

phase line and the zero line that are connected with the cabinet, and insert them into the

corresponding terminals of the input busbar and tighten them.

The grounding cables are connected to the grounding copper busbar on the lower left

side of the cabinet back. During connection, the line ends should be crimped or welded

with copper connection terminals of proper sizes.

If the user only has a single phase AC power supply, then the connection terminals U,

V and W of the input 3-phase phase lines should be short-circuited, while the position

of the zero line connection remains unchanged, and now the AC input lines should be

thickened accordingly. Protection devices such as switches or fuses should be equipped

before the AC input lines are led into the equipment. Make sure the neutral lines are put

through and will not be short-circuited in any case. In the areas of frequent lightning

strikes, the line inlet of mains and equipment buildings should be fixed with good

multi-level lightning-proof system to maintain the normal and safe system operation.

The AC standby output phase lines are connected to the standby output air switch,

while the zero lines are connected to the zero line copper busbar on the lower right side

of the cabinet back. Screw the terminals of the phase lines onto the air switch after

stripping off the insulation layer, crimp or weld the zero line terminals with copper

terminals of proper sizes, and then screw them onto the zero line busbar, as shown in

Figure 3-14. The output fuse of emergency lighting is below the battery fuse of DC

power distribution unit. The negative and positive ends of emergency lighting lines

should be connected respectively to the emergency lighting fuse and working ground

copper busbar.

Note:

1. The AC drop lines are high-voltage active lines, be sure to power off the AC

input during operation, and add temporary prohibition signs to the

switches not allowed to be used during operation;

2. Fully insulate the AC line terminals, the contacts and other exposed positions;

there shall not be any joint between the lines.

3.8.2 Connection of DC load lines

Corresponding cross section areas of the DC output lines should be selected according


----65----

to the load current. To connect the fuse and the busbar, use connection copper lugs of

appropriate sizes crimped or welded at the line terminals for connection; strip the

insulation layer of the connection stubs for connection of the air switch.

The red DC load cables corresponds to the positive output (working ground), and the

blue to the negative output. The negative pole of DC output is connected to the

corresponding load output, and the positive pole is connected to the positive copper bus

bar (working ground) at the top of the cabinet in the back. The positions and method

for line connection are illustrated in Fig. 3-15 and Fig. 3-16.

负载电缆负极

负载电缆正极电池电缆负极

电池电缆正极

工作地母排

负载熔丝

蓄电池熔丝

Negative pole of battery cable Positive pole

of battery cable

Positive pole of load cable

Negative pole of load cable

Working ground busbar

Load fuseBattery fuse

Fig. 3-15 Locations of load cable connection

Load cable

Connection terminalfixed fast on copper

busbar

Copper lug

Flat washer

Spring washer

Nut

Bolt

Flat washer

Fig. 3-16 Locations of load cable connection


----66----

The installation flow of the DC load lines:

1. The selection and wiring of the load lines should meet the requirements of the

engineering design, and the connection terminals of load lines should be

prepared properly. Use connection terminals for the cables connected to the

fuse, and directly crimp the cables connecting to the breaker. Each load line

should bear corresponding signs.

2. Disconnect the corresponding load fuse or breaker.

3. Connect the load working grounding cable on the busbar of the power supply

working ground busbar.

4. Connect the load lines with the fuse base or the output ends of breaker.

Note:

1．．．． 1. To add DC loads with power on, prevent short-circuit accidents during

operation, and take corresponding measures for human body insulation;

2．．．． 2. As the system has the second-stage power shutdown function, make sure

to connect the secondary power supply equipment to the first-stage

shutdown group, and connect the main power supply equipment to

second-stage shutdown group. The DC load shunt at the cabinet front is

the second-stage power shutdown shunt.

3.8.3 Connection of battery cables

The copper lugs at the battery connection lines and joints are thicker and larger than the

load lines, and their colors should be identical with those of the DC load output lines. If

the system is configured with multiple battery sets, the conductors of each battery set

should be connected respectively.

The specific steps are as follows:

1. As per the given battery capacity and the maximum charging current, select the

appropriate wires (often with a cross sectional area of over 50mm2), correctly

mark the battery connection lines, the connection terminals and the positive and

negative poles;

2. Remove the battery fuse and place the battery connecting line properly;

3. Connect the positive busbar of the power system and the DC –48V on the battery


----67----

fuse respectively to the positive and negative poles of the battery, be careful not

to make a reverse connection;

4. Switch on 1 to 2 rectifiers after the system is powered on. After the output enters

into normal operation, use the fuse extractor to insert the battery fuse.

Note: when the rectifier is started up, the fuse can be inserted only after normal

input. This way, the voltage difference between two ends of the fuse will be too

small to cause sparks, otherwise it will.

3.8.4 Connection of grounding cables

It is advisable to lead out the protective grounding and working grounding cables

separately and connect them to different points on the grounding block, or they may be

led out separately and connected to the grounding busbar in concentration. The

grounding of the combined power supply system must be proper in compliance with

the grounding standards of the telecommunications equipment.

1. Connection of lightning protection ground

The connection has been completed before exworks, on the spot, multimeters

must be used to measure whether the PE terminals of lightning protection and

the grounding bolts of the lightning protection ground within the cabinet have

been short circuited. If yes, it means that the connection of lightning protection

ground has been completed; if not, it is necessary to perform installation of the

lightning protection ground. The copper-core cables with a cross section area of

over 16mm2 should be used as the lightning-protection ground cables, and

during wiring the cables should be separated from other working cables (not

grounding cables) as far as possible. When laying the lightning-protection

cables, be careful not to increase the line inductance caused by too many bends.

One end of the lightning-protection ground cable is connected to the grounding

busbar, while the other to the PE terminal of the lightning arrester. The line

connection of grounding bolts is illustrated in Fig. 3-17.


----68----

铜鼻子

螺栓

弹垫

平垫

Bolt

Spring washer

Flat washer

Copper lug

Fig. 3-17 Line connection of grounding bolts

2. Working ground connection

The wire diameter of the work ground connecting line is the same as the

sectional area of the load branch cables, and it is recommended that the

minimum sectional area be no less than 16mm2. One end of the working

ground is connected to the working ground busbar (positive busbar), while the

other end is connected to the user ground busbar via the connection terminal.

3. Protective ground connection

The protective ground and the lightning protection ground of the combined

power supply system have been connected together before equipment delivery.

The sectional area of the protective ground connecting line should be no less

than half of the sectional area of the AC input with the minimum sectional area

of 16mm2. Normally multi-core copper cables are used, both ends of which are

crimped with copper connection terminals of appropriate sizes, one end is

connected to the grounding busbar at the back of the cabinet, while the other

end is connected to the user grounding busbar.


----69----

铜鼻子

螺栓

平垫铜排

螺母

接用户地线排

工作地铜排

Copper lug

Copper busbar Flat washer

Nut

Working ground copper busbar

Bolt

Connected to user ground busbar

Fig. 3-18 Locations of connections lines of protective ground

3.8.5 Electrical connection of the rectifier

The rectifier module is hot-swappable, and completely connected with the system after

it is properly installed, without any further wiring.

3.8.6 Electrical connection of the monitoring unit

All the electrical connection sockets of the monitoring unit are plugged in the back

panel which is illustrated in Figure 2-15.

The definition of each socket on the back panel of the monitoring unit is shown in

Table 2-6.

The monitoring unit is packed and transported together with the cabinet, and the

electrical connections inside the monitoring unit are completed at the delivery time of

the equipment, so no further connections are necessary on site. The electrical

connection of the monitoring unit comprises the connection of 3 lines of battery

temperature detection, as well as the connection between communications cables and

power lines during networking, for detailed information, please refer to the content

below.

The environment detection board and the relay output board of the monitoring unit


----70----

should be connected if the two boards are equipped for the system. The installation

positions and connection methods of the respective devices and components are

described in section 2.6.2.

1. Electrical connection of the battery temperature sampling cable

The monitoring unit of the ZXDU500 500A combined power supply system is

configured with three sockets for the battery temperature sensors: X7, X8 and

X9, as shown in Fig. 2-15. In this way, the temperature of the three lines of

batteries can be detected.

The battery temperature sampling cables are delivered together with the

equipment, and placed in the common cartons. One end of the battery

temperature sampling cable is the battery temperature sensor of a round shape,

and a 2-pin plug is at the other end.

During installation, remove the outer paper of the sensor of the battery

temperature sampling cables, and stick the sensor onto the surface of the battery,

and press it tight. Then, insert the other end of the cable into the sensor sockets

of the monitoring unit: X7, X8 or X9. The first battery temperature sampling

cable is plugged into X7, the second into X8, and the third into X9.

Make sure they are plugged into the right sockets (X7, X8, X9) during

installation. Be careful not to plug the temperature sampling cable into the

power socket of the modem.

2. Electrical connection of the modem

The connection mode is applicable to the networking mode in section 2.7.2.

When remote monitoring is implemented in the modem networking mode, the

modem should be installed and electrically connected. The electrical connection

of the modem includes the power cord socket, telephone line, and

communications line socket.

There is a special Modem power cable in the packing box of the modem. Insert

one end of the Modem power cable into the power socket at the lower left back

panel of the monitoring unit, and the other end into the Modem power socket,

as shown in Figure 2-15. To connect the telephone line with a 4-pin crystal

head, insert one end into the “line” hole of the telephone jack of the modem,

and the other end into the telephone jack provided by the user. To connect the


----71----

communications lines, the cables delivered together with the modem should be

used. One end of this cable is a 25-pin male plug, which should be plugged into

the communications line socket of the modem, while the other end is a 9-pin

female connector and 24-core female connector, the 9-pin female connector

should be inserted into the 9-pin socket X6 on the back panel of the monitoring

unit (see Fig. 2-15). The connection of the modem communications cables is

shown in Fig. 3-19.

25-pin maleplug, connectedto MODEM

25-pinfemaleplug

9-pin femaleplug,connected tosupervisionunit X6

Fig. 3-19 Connection of modem communications cables

3. Connection of serial lines

The connection is applicable to the networking modes described in sections

2.7.1, 2.7.3 and 2.7.4.

Shielded cables shall be employed for the serial lines, and the shielded layer

shall be well grounded at the connection terminal, with its length less than 15m.

When the simplified RS232 serial port mode is adopted for communications,

this equipment provides two communications cables. One is a 9-pin cable with

a female connector at both ends, with a length of 10m. The other is a serial port

connection cable with a 9-pin male connector at one end, and 25-pin female

connector at the other end, this cable is 1m long. For serial port

communications of the system, the 9-pin female plug is connected to RS232

interface X6 of the monitoring unit, while the other end, via the 9-pin female

connector, is connected to the PC (or the far/near end module of ZXJ10, SCM

signal translation module). When a 25-pin female plug is needed for PC (or

remote/near end module of ZXJ10, SCM) connection, a serial transit cable can

be employed for connection. The foregoing two communications cables are

described in Table 3-2.


----72----

Table 3-2 List of serial port communications cables

S.N. Name Material

specifications

Connector

used

Length Quantity

(piece)

Remarks

1 Serial port

communications

cable

4-pin shielded

wire

9-pin female

connectors

(two)

Shielded

wire 10m

1 Self-made It can be

configured for users

demanding three

“tele”s

2 25-pin and 9-pin

serial port

transit cable

4-pin shielded

wire

One 9-pin male

plug and one

25-pin female

plug

1m 1 Self-made

Configured for

three “tele” users

and when the serial

port of the

computer is 25-pin

male connector.

The serial port communications cable 1 is shown in Fig. 3-20, and the

connection of the cables is shown in Fig. 3-3.

10m

9-pin female plug,connected to backgroundPC or SCM, ZXJ10,control module, etc

9-pin femaleplug,connected tosupervisionunit X6

Fig. 3-20 Connection of serial port communications cable 1

Table 3-3 Connection of pins of serial communications cable 1

Hole number for 9-pin female plug Hole number for 9-pin female plug

2 3

3 2

5 5


----73----

The serial port connection cable 2 is shown in Fig. 3-21, and the connection of the

cables is shown in Fig. 3-4.

1m

25-pin female plug, connectedto background PC or SCM,ZXJ10, near-end module, etc.

9-pin male plug, connected to 9-pin female plug of serial cable

Serial transit cable

Fig. 3-21 Connection of serial port transit cable 2

Fig. 3-4 Connection of serial transit cable of a 25-pin female connector with 9-pin female connector

Hole number for 25-pin female plug Hole No. for 9-pin male connector

2 3

3 2

7 5

Precautions for preparing the serial port cable:

1) Weld precisely, there should be no false welding, omitted welding or short circuit

of welding points;

2) Communication in the serial port mode is safe and stable in a distance of 15m, so

avoid the wiring from passing a longer distance and affecting the

communication quality.

3.8.7 Binding cables

Cable running and binding shall be taken into consideration for the combined power

supply system during electrical connection.

When cables run along the grooves of vertical shafts at both sides of the cabinet, the

cables nearby the plugs or connectors shall be bound as per the layout sequence. Cable

interleaving shall be avoided. The cables shall be straight and tidy, and vertical to the

ground after binding, as shown in Fig. 3-22.


----74----

Binding clip

Fig. 3-22 Binding by wire clips

In selecting wire clips, appropriate specifications shall be taken into consideration

according to specific circumstances. Wire clips shall not be joined together for

connection, thus avoiding decreased intensity after binding. The binding with√in the

figure is correct, while the one with×is wrong, the same in the following.

After binding, the excessive part shall be cut down smoothly, and there are shall not be

any spines at the joint, as shown in Fig. 3-23.

Pointedhead

Pointedhead

Cutsmoothly

Cutsmoothly

Fig. 3-23 Requirements on binding

The spacing between wire clips shall be 3 to 4 times of the diameter of the cable bundle,

as illustrated in Fig. 3-24.

d

3～4d

Fig. 3-24 Wire clips for bundles

When there is a sharp turn for the bundled cables, the wire clips shall be bound at both

sides of the turn, so as to avoid broken cores due to excessive force at the turn, as

shown in Fig. 3-25.


----75----

Wire clip for binding

Fig. 3-25 Turns for wire clips in a bundle

The cables within the cabinet shall be laid in a far-near sequence, i.e., the farthest

cables shall be laid first, placed at the bottom layer of the wiring area, and cable

interleaving shall be avoided during wire laying, as illustrated in Fig. 3-26.

Wire clip

Cable

Rack wiring area

Side Front

Rack wiring area

Wire clipWire clip

Cable Cable

Side Front

Fig. 3-26 Requirements for cable layout within the rack

3.9 Installation check

3.9.1 Cabinet check

After the installation of the cabinet, check the following items:

1. It should stand upright and firm, look nice and tidy;

2. The vertical inclination should be less than 5º;


----76----

3. The panels of the cabinet should lie on the same horizontal plane, without any

concave or convex;

4. Check whether all screws are tightened, whether any flat washer, spring washer are

missing or installed inversely;

5. Check the cabinet for any unnecessary materials, and clear them up if any;

6. Check for any damages or paint loss on the cabinet caused by knocking;

7. Check whether the cabinet is clean, and remove dust and stains if any;

8. Check whether it is easy to close or open the door of the cabinet, whether the lock

of the door fails.

3.9.2 Check of electrical connection

After the electrical connection of the combined power supply system is completed,

check the electrical connections against the following items:

1. Check on drop lines and power distribution: whether the chromatogram for AC

lines is standard, whether there is any loosening on the original wiring of the

cabinet, whether the safety identity for the power distribution unit is complete,

please refer to the manual for the wiring and using of AC lines;

2. Check the output, battery connection points, serial number, line sequence, polarity,

stability of the cable connection points, correctness and reliability of the mother

busbar connection, then recheck the polarity and sequence of battery

connection;

3. Check whether the lightning-proof grounding cable, work grounding cable and

chassis grounding cable are connected correctly and whether the contact is

reliable;

4. Check the module and monitoring lines of the monitoring unit, and check the input

and output lines of the rectifier;

5. Check whether the lightning protection switches are securely switched on, whether

other switches are disconnected;

5. Check whether the wiring is tidy, and whether cable binding conforms to the processing specifications;

6. Check whether the installation and wiring are conducive to future reform,

expansion and maintenance of the system.

----77----

4. System Debugging

4.1 Starting up and shutting down the system

4.1.1 Check before start-up

1. Confirm that the input switch outside the equipment is off.

2. Disconnect the mains input breaker, rectifier air switch of the distribution layer,

and air switch of the standby AC output, and then turn on the lightning

protection switch. Be sure that the power supply switch, battery, load fuse, and

load breaker on the back panel of the monitoring unit have been disconnected.

3. Check whether the AC drop lines, the grounding lines, and the distribution lines

inside the cabinet are correctly and reliably connected, and whether the bolts

are loosened.

4. Measure the resistance between the AC input and output phase lines, between the

phase lines and zero lines, and between the phase lines and ground of the AC

input breaker (or contactor), and be sure of no short circuit.

5. Use the multimeter to check if there is any short circuit between the output port of

the standby AC output breaker and the zero line.

6. Use the multimeter to check if the AC voltage of system power supply is within

the required range.

4.1.2 Debugging procedures

The cabinet, the rectifier and the monitoring unit are exposed to concussions to some

extent in long distance transportation and re-assembly. And after the power system is

reassembled, assembly or connection error may exist, so if the whole system is hastily

powered on and started, major accidents might occur, including damages of the whole

system. Therefore, after the assembly, the system should be carefully debugged, that is,

to debug the system step by step, so as to observe while debugging, power off the

system immediately on any abnormality, and go on with the debugging until after faults

are pinned down and cleared.


----78----

The testing flow is as follows: AC power distribution unit debugging-rectifier

debugging-monitoring unit debugging-battery connection for DC power distribution

unit-system test-powering on the communication equipment-adjusting the system to its

optimal running mode.

4.1.3 Startup procedures

1. Close the AC input switch of the external power supply system.

Close the external mains supply input switch and lead in the mains supply for

the power system. When contactor is employed for AC input of the system, and

the voltage of mains supply is within the normal voltage working range, the

contactor will be automatically closed, at the time, there have been mains

supplies for the AC input and AC standby output of the system; when the

voltage of the mains supply exceeds the working range of the system, the

contactor will not close (in the case of contactor for the AC input, the voltage

for the closing point of the contactor is 154VAC).

2. When the AC input is in the air switch mode, close the main switch and check

whether AC input voltage and each shunt voltage of the standby output are

normal.

3. Start up the rectifier.

Once the AC input voltage is confirmed to be normal, close the power switches

of respective rectifier modules on the AC power distribution layer to start up the

switch rectifier modules one by one. Observe whether each rectifier works

normally and measure the output voltage of each rectifier. Only after all are in

normal status, can the input switches of all the rectifiers be closed at the same

time. See Section 4.3 for starting up the rectifier.

4. Start up the monitoring unit.

Close the power supply switch on the backplane of the monitoring unit, and set

the working parameters of the system according to the correct method and

procedures. Refer to Section 4.4 for the method of relevant setting.

5. Load the loading equipment

Confirm that the system works normally and various parameters are up to

requirements, shut down the system by the sequence as described in 4.1.4,

Chapter 4. System Debugging

----79----

connect the load, start up the system, and connect the battery, so that the system

enters the normal working state. For adding load and connecting batteries,

please refer to Section 4.6.

4.1.4 Shutdown sequence

1. Disconnect the load and battery.

2. Switch off the power supply and rectifiers of the monitoring unit.

3. Disconnect the main AC input switch.

4. Disconnect the exterior AC input switch.

4.2 Testing the AC distribution unit 1. AC input switchover

If two lines of input are provided by the user, a switchover experiment of two

power supplies can be performed via the two air switches of the AC input or AC

contactors. To input the dual air switches, their switches should be manually

turned on/off to check whether the two input paths are normal. In the dual

contactor input mode, the system will automatically judge whether the first

mains supply is normal, if it isn’t, the system will switch to the second mains

supply or diesel generator.

2. Parameter and state test

Check each line of mains supply voltage and phase-A current in the monitoring

unit, which shall be in compliance with the actual values. If for the AC input

current, there is a rather large deviation between the displayed value and the

actual value (for specific deviation value, refer to the detection precision test of

Engineering Document of ZXDU500 500A Combined Power Supply System),

adjust the zero and slope of AC input current in system parameter setting of the

monitoring unit.

When the overall system works normally, disconnect the AC power supply, and

“Mains supply failure” will appear in the “Alarm data display” menu of the

monitoring unit.

3. AC phase loss, AC over-voltage and AC under-voltage alarms and automatic


----80----

protection

By debugging AC phase loss, AC over-/under-voltage alarms and automatic

protection, the system is tested on whether it can produce normal alarms and

react normally upon abnormal power supply. These items have undergone strict

test upon ex-factory, so debugging of these items may be skipped if no proper

condition is available on user’s site.

4.3 Debugging the rectifier 1. After the system passes the preliminary test on the AC power distribution unit and

works normally, it is time to power on the rectifier. Prior to powering on the

rectifier, disconnect all the air switches or fuses of DC load shunts, and turn off

the monitoring unit.

2. Prior to powering on the rectifier, make sure that there is no short circuit for the

input and output of the module, there is no loosening or damage on the

components within the rectifier, and the electrical connection is correct.

3. The AC input switch of the rectifier is at the AC distribution layer of the lower part

of the cabinet, and each rectifier corresponds to one AC input air switch.

Rectifiers should be started up one by one, so as to check whether each of them

works normally. After the power-on of the rectifier, there will be a delay of

startup to protect the rectifier. The green light will be lit during delayed startup,

and the red light will also flash for several seconds at the same time. After the

delayed startup completes, and the system works normally, the green light will

be lit, while the red light will be extinguished. Adjust the regulator

potentiometer on the panel of the rectifier and set the output voltage of each

rectifier to 53.5V.

4. After confirming that each rectifier is able to start up normally and the output

voltage becomes normal, close all AC input switches of the active rectifier so

the rectifiers of the system can work in the equalized current state. Observe the

change of the DC output voltage, and check whether there is any change in the

output voltage after the rectifier works in equalized current state. If there is

obvious output voltage drift, spot and fix the rectifier with poor current

equalization effect.


----81----

4.4 Testing the monitoring unit

4.4.1 Overview of the monitoring unit

The monitoring unit is responsible for the centralized management of AC distribution,

DC distribution, rectifier set and battery of the system. The monitoring unit collects the

running data of the system in real time and monitors the working status of the system.

When the system falls faulty, it gives out audible and visual alarms in addition to

proper protection measures.

The LCD and LED indicators on the panel of the supervision unit can display the

system’s output current, output voltage, battery current and all kinds of alarm

information. In addition, necessary parameters can be set through the keyboard on the

panel to fulfill necessary control.

The running data and working status of the system, instead of just being reflected

locally, can also be reported to the upper-level monitoring unit through transmission.

The supervision unit also receives commands from the upper-level machine, so as to

query and control the system to realize the “3-tele” functions.

The monitoring unit employs LCD, with English operation interface. The indicator

light on the front panel of the monitoring unit displays the current working status of the

system, please refer to Fig. 2-14 and Table 2-5. When there is any alarm, both the

buzzer and the alarm indicator light will give out audible and visual alarms, and display

the alarm information on LCD.

The reset button is located within the small hole below the communication indicator on

the panel of the monitoring unit, press this key to reset the monitoring unit. The system

can continue to work normally without the monitoring unit, however, the “3-tele”

functions will be disabled, with the standby battery pack being in the floating charge

status.

4.4.2 Powering on the monitoring unit

The monitoring unit examines the working state of various units in the combined

power supply system via the micro-processor and the interface circuit. Then it performs

analysis and processing, and delivers the information to the near-end monitoring

terminal or the remote monitoring center via the RS232 port, so as to fulfill the 3-teles

function and unattendedness.


----82----

The monitoring unit is of the drawer structure that is convenient for maintenance and

installation. The front panel serves as the operation and observation panel. On the back

panel are installed the testing cables, communications cables, working power supply

for the monitoring unit, and signal lines.

When there is rated DC voltage on the DC busbar of the rectifier cabinet, close the

power supply input switch on the back panel of the monitoring unit, therefore, the

monitoring unit is powered on and begins to work, and the main menu will be

displayed on the LCD, and operate the keyboard to observe the corresponding contents

of the display. If there is no normal display, it is necessary to check and maintain the

supervision unit.

Note: After installation of the system, we must perform correct settings for the

monitoring unit, so that the system can work normally. Refer to Section 4.4.6 for

the method for relevant setting.

4.4.3 Enter system interface

The monitoring unit of the ZXDU500 500A combined power supply system employs

V3.0 monitoring software. After the input switch of the monitoring unit is closed or the

monitoring unit is reset, the display will show in turn two start-up interfaces, as shown

in Fig. 4-1 and Fig. 4-2.

ZTE CORPORATION

Fig. 4-1 Start-up interface 1 of the monitoring unit

ZXDU500 V3.0

Software version: V3.0

Fig. 4-2 Start-up interface 2 of the monitoring unit

When the start-up interface is closed, the monitoring unit displays its main menu


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interface, as shown in Fig. 4-3.

Real-time data displayAlarm data displaySystem parameter settingSystem maintenance & control

Fig. 4-3 Main menu interface of the monitoring unit

4.4.4 Real time data display

Press PgUp or PgDn on the main menu interface of the monitoring unit, and move the

finger cursor to the real-time data-display menu items, press Enter, then the system

enters the real-time data displaying menu. There are totally eight interfaces in the

real-time data-displaying menu, they respectively display the system parameters such

as input, output, rectifier and environment. Interfaces for real-time data display can be

switched over via key operations of PgUp and PgDn. Press Esc to return to the main

menu.

The first screen of real-time data display is shown in Fig. 4-4.

System output voltage (V)Total system output current (A)

Next time of equalized charging: 2002-05-30Current time: 2002-02-20 17:55

53.526

Fig. 4-4 First screen of real-time data display

The second screen of real-time data display is shown in Fig. 4-5.

2313.8

AC phase A voltage (V) 230232

AC phase C voltage (V)AC phase B voltage (V)

AC phase A Current (A)

Fig. 4-5 Second screen of real-time data display

The third screen of real-time data display is shown in Fig. 4-6.


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Charging mode:Voltage of battery I (V)Charging current of battery I (A)Temperature of battery I (℃)

Float charging

33

53.5V0

Fig. 4-6 Third screen of real-time data display

The fourth screen of real-time data display is shown in Fig. 4-7.

Voltage of battery II (V)Charging current of battery II (A)Temperature of battery II (℃) 33

53.5V2

Fig. 4-7 Fourth screen of real-time data display

The fifth screen of real-time data display is shown in Fig. 4-8.

Voltage of battery III (V)Charging current of battery III (A)Temperature of battery III(℃) 25

53.5V0

Fig. 4-8 Fifth screen of real-time data display

The sixth screen of real-time data display is shown in Fig. 4-9.

Environment boardEnvironmental temperature (℃)

Environmental humidity (%)Status of input alarm relay contact:

Available2550

Fig. 4-9 Sixth screen of real-time data display

The seventh screen of real-time data display is shown in Fig. 4-10. For the rectifier

status item on this interface, the number of rectifiers displayed on the interface is the

same as the actual number of rectifiers of the system. If the rectifier at position 02 is


----85----

not installed, number “02” will be missing on the interface.

Rectifier status

Power supply mode:AC supporting output switch:

01Diesel generator

050403

Fig. 4-10 Seventh screen of real-time data display

The eighth screen of real-time data display is shown in Fig. 4-11.

Equipment type:Software version:Software date: 2001.12.05

V3.00ZXDU500V3.0

Fig. 4-11 Eighth screen of real-time data display

All the data above will be refreshed in real time. Press Return to return to the main

menu as shown in Fig. 4-3.

4.4.5 Alarm data display

As shown in Fig. 4-3, press PgUp or PgDn on the main menu interface of the

monitoring unit, and move the finger cursor to the “Alarm data display” menu items,

press Enter, then the system enters the “Alarm data display” menu. Each alarm

occupies a page, and if the alarm information exceeds one page, interfaces for real-time

data display can be switched over via key operations of PgUp and PgDn. Press Esc to

return to the main menu.

The interface for alarm data display is as shown in Fig. 4-12.


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Real-time alarm: 1Lightning arrester return circuit damaged

Start: 2002-01-22 15:05:046

1Historical alarm: 5

Fig. 4-12 Alarm data display interface 1

As an interface for real-time display, alarms displayed on this interface have only the

start, but not the end time. “1” in the upper right corner of the interface indicates that

this interface is the first one for alarm data display, and “6” in the lower right means

that there are totally six interfaces. Fig. 4-13 displays the contents of interface 2 for

history alarm data display.

Real-time alarm: 1Alarm of rectifier 04Start: 2002-02-22 15:21:04

6

2Historical alarm: 5

Finish: 2002-02-22 15:22:31

Fig. 4-13 Alarm data display interface 2

Other interfaces displaying the history alarm information are similar to interface 2 of

Fig. 4-13. What they display is the start and end time of the other four history alarms

and can be viewed by key operations of PgUp and PgDn. To return to the main menu,

press Esc.

4.4.6 System parameter setting


monitoring unit, and move the finger cursor to the “Setting system parameters” menu

items, press Enter, then the “Input Password” interface pops up, as shown in Fig. 4-14.

To enter “Setting system parameters”, the operation password must be input correctly,

then parameters can be modified and set.


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OK

Please enter password:

0 0 00

Fig. 4-14 Operation interface 1 for password inputting

In the monitoring unit operation of this system, for operations concerning the value

change, a symbol or will be shown in the upper right corner of the screen to

indicate whether the ongoing operation is about changing the option or value. See

in this interface. Among them, “ ” represents the option for the current operation. At

the time, press PgDn or PgUp to move the cursor between various functional areas, e.g.,

“0000” and “OK” functional keys as shown in Fig. 4-14; The symbol “ ” indicates

the current operation is about the parameters, now by pressing PgUp and PgDn the

number can be modified. As shown in Fig. 4-14, the cursor stays at the first number

and it is the symbol “ ” in the upper right corner, now the number may be changed by

pressing the PgUp and PgDn keys. After correct numbers are set, press Enter, the

interface as shown in Fig.4-15 will pop up. Note that in the narration of this article, the

“Enter” button is on the panel of the monitoring unit, while the “OK” refers to the

confirmation key in the monitoring interface.

OK


9 0 00


As shown in Fig. 4-15, move the cursor to the second number. To modify this number,

click “OK” to change the symbol “ ” to “ ”, then press PgUp or PgDn to change

this number into a desired one. Modify the four numbers in turn, then move the

cursor to OK, as shown in Fig. 4-16. Press “OK”, enter the parameter setting menu

when the input password is correct; if the input password is wrong, the system will

give prompt “Wrong input password”, and it is necessary to input the correct password

before entering the system parameter setting menu. The factory-set password of this

combined power supply equipment is 0000.


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9 9 9 9

OK


There are 31 items for setting system parameters, each with a separate setting interface.

Now let’s see the process of parameter setting with the first parameter setting item as

an example. The first parameter setting interface is shown in Fig. 4-17.

Parameter setting:

Alarm threshold for high AC voltage (V)

260

Help01

OK

Fig. 4-17 System parameter setting interface 1 for Item 01

Now the cursor stays at the location of number 01. To view or modify the parameters

of other setting items, press PgUp or PgDn, then the interface may switch among the

31 setting items. To modify the content of this item, click OK in the current state of Fig.

4-16, to pop up an interface as shown in Fig. 4-18.

Parameter setting:

Alarm threshold for AC high voltage (V) Help01

OK260


Let the cursor stay at the location of the high AC voltage threshold, the symbol at the

upper right corner for parameter setting is “ ”, whose meaning has been introduced in

the operation password input part in this section.

For operations concerning the value change, a symbol or will be shown in the

upper right corner of the screen to indicate whether the ongoing operation is about

changing the option or value.


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Of the two symbols, “ ” means that the current operation is about the option and at

this time, through PgUp and PgDn, the cursor may move between the function areas,

such as serial number “01”, number ”260”, “OK” and “HELP”.

When “ ” is displayed at the upper right corner of the interface, it means the current

operation is in the state of parameter modification, at the time, we can operate PgUp or

PgDn to increase or decrease the number pointed by the cursor.

To modify the number of the alarm in this interface, press the “OK” button to change

the symbol “ ” to “ ”, then press PgUp or PgDn to change this number into a

desired one.

After modifying the number, press the OK button and move the cursor to OK in this


Parameter setting:

Alarm threshold for high AC voltage (V) Help01

279 OK


In this interface, by pressing PgUp and PgDn, the cursor may be moved to HELP. Then

press OK to enter the HELP menu. The HELP menu gives description on the content or

scope of each setting item. The user may use the HELP menu to solve problems

encountered during parameter setting.

In the interface shown in Fig. 4-18, click OK to validate the modified content and the

system will automatically convert to the next setting item, as shown in Fig. 4-20.

Parameter setting:

Alarm threshold for AC low voltage (V) Help

180 OK

02

Fig. 4-20 System parameter setting interface for Item 02

In the “Setting system parameter” menu, if the user doesn’t press any key for 30s, the system will return to the main menu automatically. There are totally 31 items for


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parameter setting. For detailed setting contents and the text of the HELP menu, refer to Table 4-1.

Table 4-1 Setting of system parameters

S.N. Parameter Name Default value

Upper limit

Lower limit

Text of the “Help” menu

01 AC input high voltage alarm threshold (V)

260 300 240 Scope (240V~300V), higher than the AC high voltage alarm generated by the parameter

02 AC input low voltage alarm threshold (V)

180 200 160 Scope (160V~200V), lower than the AC low voltage alarm generated with the parameter

03 AC input high current alarm threshold (A)

60 80 50 Scope (50V~80V), higher than the AC high current alarm generated with the parameter

04 Output high voltage alarm threshold (V)

58.0 59.0 57.0 Scope (57V~59V), not lower than the equalized charging voltage by +1V, and higher than the high output voltage alarm generated with the parameter

05 Output low voltage alarm (V) 48.0 52.0 41.0 Scope (41V~52V), not higher than the equalized charging voltage by -1V, and lower than the low output voltage alarm generated with the parameter

06 Float-charging voltage (V) 53.5 58.0 42.0 Scope (42V~58V), not higher than the equalized charging voltage, not lower than the lower limit of output voltage alarm by +1V, and not lower than the alarm threshold for battery undervoltage by +1V, which will be set according to the actual conditions of the battery

07 Equalized-charging voltage (V)

56.4 58.0 42.0 Scope (42V~58V), not lower than the float charging voltage, and not higher than the alarm threshold for output voltage by –1V, which will be set according to the actual conditions of the battery

08 Test voltage (V) 46.0 48.0 42.0 Scope (42V~48V), place the battery in the discharging state when it is tested, so as to test the performance of the battery

09 Capacity of battery pack 1 (Ah)

100 2000 0 Scope (0AH~2000AH), set according to the actual conditions of the battery


100 2000 0 Scope (0AH~2000AH), set according to the actual conditions


0 2000 0 Scope (0AH~2000AH), set according to the actual conditions of the battery

12 Coefficient for battery charging current (A/Ah)

0.15 0.25 0.05 Scope (0.05A/AH~0.25A/AH), multiply the parameter with battery capacity, and you’ll get the maximum charging current for the battery

13 Battery temperature compensation coefficient (mv/℃/pc)

3 6 0 Scope (0mV/℃~6mV/℃), representing the temperature compensation coefficient for each battery, which will be set according to the actual conditions of the battery

14 Equalized-charging cycle of the battery

180 365 15 Scope (15 days~365 days), representing the designated time with the interval, and the battery shall be charged once for every cycle

15 Equalized-charging threshold capacity of the battery

0.85 0.95 0.6 Scope (0.6~0.95), means that if the ratio between the dynamic capacity and the rated capacity of the battery after power off is lower than the parameter, then equalized charge shall be performed after being powered on


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Upper limit

Lower limit


16 Battery under-voltage alarm threshold (V)

47.0 52.0 41.0 Scope (41V~52V), not higher than the float charging voltage by –1V, and not lower than the first-stage shutdown voltage by +1V. When it is lower than the parameter, low-voltage alarm of the battery will be given

17 First-stage shutdown voltage of the load (V)

46.0 47.0 40.0 Scope (40V~47V), not higher than battery undervoltage alarm threshold, and not lower than the second-stage power shut-down voltage, when it is lower than the parameter, the system will undergo first-stage shutdown

18 Second-stage shutdown voltage of the load (V)

45.0 47.0 40.0 Scope (40V~47V), not higher than first-stage shutdown voltage. When the DC voltage of the system is lower than the parameter, the system will undergo the second-stage power shutdown

19 Battery high temperature alarm threshold (℃)

40 55 30 Scope (30℃~55℃), when higher than the parameter, there will be alarm of high battery temperature

20 High ambient temperature alarm threshold (℃)

40 55 30 Scope (30℃~55℃), when higher than the parameter, there will be alarm of high ambient temperature

21 Low ambient temperature alarm threshold (℃)

-5 10 -20 Scope (-20℃~10℃), when lower than the parameter, there will be alarm of low ambient temperature

22 High ambient humidity alarm threshold (%)

90 100 80 Scope (80%~100%), when higher than the parameter, there will be alarm of high ambient humidity

23 Low ambient humidity alarm threshold (%)

20 40 10 Scope (10%~40%), when lower than the parameter, there will be alarm of low ambient humidity

24 Equipment address No. 1 254 1 Scope (1~254) 25 Baud rate (bps) 1200 9600 1200 Baud rate in case of RS232 communications,

1200 for the lowest, and 9600 for the highest26 Normal state of input alarm

relay contact 1 1 0 The parameter indicates the normal state of

the alarm relay contact. When the supervision alarm relay contact is abnormal, the system will give alarm

27 Alarming pager number The parameter is used to dial through the pager when the system detects any alarm. The symbol “,” means delay, while “.” means no value

28 Alarming phone number The parameter is used by the system to report detected alarms, “,” means time delay, while “.” Means no value

29 Menu password setting 0000 9999 To set menu password 30 Alarm relay contact

corresponding to the failure type

The menu is used to define the alarm type corresponding to each line of alarm relay contact

31 Time setting Used to set system date and time

The correct password has to be input before setting system parameters, so as to enter the hidden menu for parameter setting. In the hidden menu, more setting items are


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added except those mentioned above, as shown in Table 4-2. These items have already been adjusted to their optimal values based on the configuration of the equipment before delivery. So the user is freed of the trouble of readjusting the data in the hidden menu when using the equipment. But after the system capacity is expanded, or if the real-time data display has a serious deviation, zero and slope of relevant parameters then have to be readjusted.

Table 4-2 List of additional items and HELP menu of the hidden menu for system parameter setting


Upper limit

Lower limit


01 Input current zero adjustment (A)

0 10 -10 Scope (-10A~10A), used to adjust the zero point of AC current sensor

02 Input current slope adjustment (%)

1 1.2 0.8 Scope (0.3%~3%), used to adjust the slope of AC current sensor

03 Zero point adjustment for the temperature of battery 1 (℃)

0 10 -10 Scope (-10℃~10℃), used to adjust the zero point of battery temperature sensor

04 Zero point adjustment for temperature of battery 2 (℃)


05 Zero point adjustment for temperature of battery 3 (℃)


06 Load current zero adjustment (A)

0 10 -10 Scope (-10A~10A), used to adjust the zero point of load current sensor

07 Load current slope adjustment (%)

1 3 0.3 Scope (0.3%~3%), used to adjust the slope of load current sensor

08 Zero point adjustment for current of battery 1 (A)

0 10 -10 Scope (-10A~10A), used to adjust the zero point of battery current sensor





11 Slope adjustment for current of battery 1 (%)

1 3 0.3 Scope (0.3%~3%), used to adjust the slope of battery current sensor





14 Ambient temperature zero adjustment (℃)

0 10 -10 Scope (-10℃~10℃), used to adjust the zero point of ambient temperature sensor

15 Ambient humidity zero adjustment (%)

0 10 -10 Scope (-10%~10%), used to adjust the zero point of ambient humidity sensor

16 Total circuits of the load 20 20 0 Scope (0~20), representing the total load lines of the system, and users can set the parameter according to the specific line connection mode

17 First-stage power shut-down circuits

8 20 0 Scope (0~20), representing the load lines that can be disconnected during the first-stage shut-down, and users can set the parameter according to the specific line connection mode

18 Second-stage power shut-down circuits

12 20 0 Scope (0~20), representing the load lines that can be disconnected during the second-stage shut-down, and users can set the parameter according to the specific line connection mode


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4.4.7 “System maintenance & control” menu


monitoring unit, and move the finger cursor to the “System maintenance & control”

menu item, press the OK button, then the “Input Password” interface pops up, as

shown in Fig. 4-14. To enter “System maintenance & control”, the operation password

must be input correctly, then parameters can be modified and set. The factory-set

password of “System maintenance & control” is 0000. After the password is input

correctly, enter the submenu of “System maintenance & control”, as shown in Fig.

4-21.

System maintenance & control:

Battery charging mode

Float charging OK

01

Fig. 4-21 Submenu 01 of the “System maintenance & control” menu

The usage of the “System maintenance & control” menu is very similar to that of the

“System parameter setting” menu, so please refer to the related contents in the section

of “Setting system parameters”. The battery charging mode can be selected among the

“equalized charging”, “float charging” and “test”.

In the “System maintenance & control” menu, if the user doesn’t press any key for 30s,

the system will return to the main menu automatically.

Other submenus (from item 02 to item 11) of the “System maintenance & control”

menu are control menus for the states of 10 rectifiers in the system, as shown in Fig.

4-22 and Fig. 4-23.


Rectifier 01

Start up OK

02


The status of the rectifier can be selected between “Start-up” and “Shutdown”, after


----94----

selection, click OK to make the settings effective.

If a rectifier position (e.g., position 02) in the system is empty without any rectifier

inserted, the submenu of the “System maintenance & control” menu is shown in Fig.

4-22. Then the status of this rectifier cannot be changed.


Rectifier 02

Unavailable OK

03


Submenu 12 of the “System maintenance & control” menu is the language selection



Language

English OK

12


The interface language of the monitoring unit is “English”.

4.5 Background monitoring This power supply system can be monitored remotely through the “ZTE Centralized

Power Supply Monitoring System” via modem, or in the local background mode via

RS232. Through background monitoring, all key parameters of the power supply can

be detected and remotely controlled. The background monitoring system is realized

through the information exchange between the monitoring unit of the communication

equipment/power supply system and the background PC, and the connection is shown

in Fig. 4-25.


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Background PC Monitoring unitRS232

Modem or SCM,etc.

Fig. 4-25 Background monitoring

Working principle: the background computer sends commands to the monitoring unit

as per the regulations of the communications protocol, and the monitoring unit will

return the needed data to the background computer as per the commands it receives.

Through the above communication process, the background computer implements the

3-tele functions (telemetry, tele-control and tele-signaling), the centralized monitoring

and automation management services of the power system.

For the use of the “ZTE Centralized Power Supply Monitoring System”, please refer to

the User Manual of the background software for system configuration. The following

should be debugged for the remote monitoring:

1. Properly connect the monitoring unit with the background PC according to the

networking mode;

2. Check whether the monitoring unit can normally communicate with the

background PC;

3. Query the real-time display data of the power supply system from the background

PC, and the data should be in complete compliance with that displayed on the

LCD of the monitoring unit;

4. Check the alarm report function: extract a lightning protection chip, and alarm

information shall be reported;

5. On the background PC, control the start-up/shutdown of the rectifier of the power

supply system, and the conversion of the float charging and equalized charging.

The power supply system should be able to properly execute the above

commands coming from the background PC.

4.6 DC power distribution unit debugging and battery connection After the AC power distribution unit, rectifiers and monitoring unit are debugged

normally, the batteries can be connected and the DC power distribution unit can be

debugged.


----96----

4.6.1 Connecting batteries

1. Start up some rectifiers and the monitoring unit to let the system be in the float

charging status;

2. Use a multimeter to check whether the voltage polarity of the fuse of the two

battery packs is consistent with that of the busbar;

3. Measure the voltages of the two battery packs respectively, and use a fuse

extractor to press the fuse of the battery pack with a lower voltage into the fuse

base;

4. Use the power supply system to charge this battery pack. The system will

automatically charge up this battery pack to make its voltage transferred to the

voltage value of the other battery pack;

5. Measure the voltages of the two battery packs, and when the difference between

them is less than 0.5V, use a fuse extractor to press the fuse of the other battery

pack into its base.

If there is a third battery pack configured for the user, the method to connect the third

battery pack is similar to that for the second battery pack.

Note:

1. If there is only one pack of battery, it shall be connected to the fuse base of

battery 1.

2. If two packs of batteries are connected, be sure that the open-circuit voltage

of the two groups of batteries is almost the same, otherwise, the two lines of

batteries may charge each other, thus resulting in danger.

4.6.2 Load the loading equipment

Use a multimeter to check the system’s DC loading output port to see whether its

voltage is normal, whether the polarity is correct, whether it’s consistent with the label

of the cable, and whether the loading cable is shorted.

Under normal circumstances, use a load fuse handle to connect the corresponding load

fuse core into the fuse base of the corresponding tributary, or close the fuse switch of

the corresponding tributary, so as to put the communications equipment through. Then

check whether the input voltage at the two terminals of the communications equipment

is normal, if yes, turn on the equipment for operation.


----97----

Note: important loads can be only connected after qualified testing of the system.

4.7 Debug the whole system After all parts of the system prove to be normal after power on, the whole system

testing is used to perform comprehensive test and setting for the system, so as to check

whether various configurations of the system can run normally, whether the parameters

are correctly and appropriately set up, whether the monitoring unit can effectively and

reliably measure, control and communicate with various parts of the system, and

whether the monitoring background can perform remote monitoring on the system, etc.

Once the whole system is debugged and all parts of the system are working normally,

fill out the relevant test forms for acceptance by the user.

4.7.1 Set system parameters

After the system is powered on, operate the monitoring unit to check various

parameters of the system. Some parameters (e.g., the battery capacity, battery

charge/discharge management parameter, and rectifier current-limiting point) need to

be set over again with reference to the actual condition of the user and as required by

the user. When setting parameters, check them one by one with what listed in forms 4-1

and 4-2, and set those in need of re-set. Note to fill the relevant modified settings into

forms of the project document to save the data.

4.7.2 Test data detection precision

After the whole power supply system is powered on and begins to work, operate the

monitoring unit to enter the real-time data display menu to view whether each item

displayed is in compliance with the actual value. If the difference between the tested

data and the actual value exceeds the range stipulated, find the reason for further

improvement.

For the test contents and requirements, please refer to Engineering Document of

ZXDU500 500A Combined Power Supply.

4.7.3 Test system function and alarm protection performance

Check whether various functions of the system are normal, whether various protection

alarm functions of the monitoring system can timely and reliably work. If any function

fails, check the system and clear the fault.


----98----

For the test contents and requirements, please refer to Engineering Document of

ZXDU500 500A Combined Power Supply.

4.7.4 Test the current equalization characteristic of the system

While debugging a single rectifier, the system has to adjust the output voltage of each

rectifier as to be closely the same. Thereby, the system can automatically implement

the current equalization when all rectifiers are in service.

Observe the output current of each rectifier when the system has certain loads.

Segment indicators are used to display the system current. Totally ten segment LED

indicators are available, and each of them stands for a 5A current. If the difference

between the numbers of LED indicators for any two rectifiers is equal to or less than 1,

the current equalization of the system is qualified. That is to say, the difference

between the output currents of the two rectifiers is less than 5A. If the difference

between the number of segment indicators is larger than 1, the system needs to be

processed due to the insufficient current equalization.

If the current equalization deviation is not up to the requirement, adjust the

potentiometer on the panel of the corresponding rectifier until the current value falls

within the current equalization deviation range.

For testing of the system current equalization feature, the current value can also be

obtained through the current test hole on the rectifier panel. Testing method: use a

multimeter to test the voltage Vi between panel “I” and “COM”, and the relationship

between the output current of the rectifier and Vi is 10A corresponding to 1.5V. If the

difference between the output currents of any two rectifiers is less than 5A, the system

is OK in the current equalization. The current equalization index of the rectifier is

meaningful only when the load current of the system is larger than 20% of the system’s

rated output current. For the test contents and requirements, please refer to

Engineering Document of ZXDU500 500A Combined Power Supply.

4.8 System acceptance Test and accept the system according to the Standard YD5079-99 “Acceptance Method

of Posts and Telecommunications Project” after the project is completed.


----99----

4.8.1 Apply for preliminary test

After the ZXDU500 500A combined power supply system is completed in engineering

as per the construction drawing, we shall perform overall debugging and parameter

testing. If all kinds of functions and specifications prove to be qualified, the

construction unit shall apply to the owner for acceptance. Fill out the Preliminary Test

Application Report.

For the detailed contents of Preliminary Test Application Report, please refer to

Engineering Document of ZXDU Combined Power Supply System.

4.8.2 Installation acceptance

The personnel from ZTE Corporation will cooperate with those from the user for the

joint acceptance, for the contents of the installation acceptance, please refer to

Engineering Document of ZXDU500 500A Combined Power Supply System.

Check the contents in the project documents item by item, fill out the forms, and then

the two parties shall sign for confirmation.

4.8.3 Acceptance report of commissioning

Test respective indexes of the system with reference to the Engineering Document for

ZXDU500 500A Combined Power Supply System, as well as conditions on site and

actual configurations of the user, and then fill out the form with the actual test results.

4.8.4 Prepare relevant document

Prepare relevant documents to be accepted by the user, and save the acceptance record.

When ZTE Corporation asks the user to test and accept the power supply system, the

Engineering Document for ZXDU Combined Power Supply System should be filled out

carefully, and related acceptance personnel have to be asked to sign for confirmation

for those places needing signatures from various parties. One copy of the document is

to be kept by the user after the project is finished and necessary signatures are affixed.

4.8.5 Acceptance

The engineering construction personnel from both the user and ZTE Corporation shall

join hands to assess the preliminary acceptance and system running conditions, fill out

the “Certificate for Preliminary Engineering Acceptance” and the “Handover Report”


----100----

when they regard that the equipment is up to the requirements for the contract, and then

give a conclusion on the engineering. At the same time, the “Return Receipt for

Equipment Commissioning” needs to filled out and delivered to the local office of ZTE

Corporation. All done. Please refer to Engineering Document for ZXDU Combined

Power Supply System.

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5. System Usage

5.1 System power on After the installation and debugging of the power supply system, the equipment is

usually in standby status. When necessary, simple power-on operation can put the

equipment into operation.

5.1.1 System startup

Operate according to the following procedures in system startup to make sure that the

system starts and works smoothly:

1. Make sure the AC input switch of the rectifier is turned off so that the system can

start without load;

2. Close the main AC input switch;

3. Check whether the AC input is normal, and troubleshoot (if any fault) before the

following operations;

4. After the AC input is normal, turn on the input switches of respective rectifier

modules to start them one by one. Check whether all rectifier modules can start

normally;

5. Turn on the power switch of the monitoring unit and observe the LCD to see

whether the parameters of the system are normal. Set the system work

parameters as required when the system is in the normal state;

6. After the system is confirmed to operate normally and the various parameters have

been measured to meet the requirements, turn off the main AC input switch to

externally cut off AC power supply. Then connect the load, start up the system,

and connect the battery;

7. During the system operation, the maintenance personnel should keep an eye on the

system information supplied by the monitoring system, and process the alarms

as soon as they occur.


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5.1.2 System shut-down

System shutdown generally follows the procedures below:

1. Disconnect the load and battery;

2. Turn off respective rectifier modules and the input switch of the monitoring unit;

3. Turn off the AC mains switch of the system;

4. Turn off the input disconnector outside the system.

5.2 Use of the rectifier

5.2.1 Rectifier backup

Hot backup is recommended for the rectifier configured for the ZXDU500 500A

combined power supply system. That is, the rectifiers are not turned off when the

system output current load is low, so that all the rectifiers of the system are in the

working state. If the user prefers the cold backup mode, please remove the rectifier

from the system and keep it properly. If the AC input switch of the rectifier is turned

off without removing the rectifiers, the system will display “the rectifier alarm”. The

alarm buzzer of the system will sound and the alarm indicator will be lit on.

5.2.2 Capacity expansion of the rectifier

1. Dismantle blank panels. When the power supply system configuration is smaller

than the rated capacity, there are some idle installation slots on some rectifiers

of the cabinet, generally, blank panels are employed for decoration of the idle

slots in order not to affect the smart outlook of the whole system. In case of

system capacity expansion, it is necessary to dismantle the corresponding blank

panels, so as to facilitate inserting new rectifiers.

2. Set the AC input switch corresponding to the position where a module is to be

installed to the “OFF ” state.

3. Push the module into the slot slowly and fix it tight. Set the mechanical lock

switch on the rectifier panel correctly when inserting the rectifier.

4. Close the corresponding AC input switch of this rectifier to make it work normally.

5. Repeat the above steps and install all the modules.

Chapter 5. System Usage

----103----

6. Observe the current equalization effect of the system.

5.2.3 Replace the rectifier fan

If any fault occurs to the rectifier fan, it can also be replaced without dismounting the

rectifier. The replacing method of the fan is as follows:

1. Turn off the AC input switch of the rectifier whose fan is to be replaced;

2. Put your fingers into the small recess of the fan cover on the rectifier panel and

pull the fan cover outwards;

3. Remove the fan cover from the rectifier panel and take out the fan from its slot;

4. Unplug the power connector of the fan and take away the damaged fan;

5. Insert the power cable plug of the new fan into the power cable connector;

6. Push the fan into its slot, note not to make it face to the contrary direction;

7. Fix the fan cover and turn on the AC input switch of this rectifier.

5.3 Battery usage

5.3.1 Charge and discharge battery

Battery pack is an important power supply facility for uninterrupted power supply for

communications equipment. The battery pack is connected with the battery tributary of

the power supply system. When the mains supply is working normally, the power

supply system will perform float charging or equalized charging to the battery; In case

of blackout, the battery will supply power to the communications equipment connected

to the power supply system via the DC distribution unit of the power supply system.

The combined power supply system furnishes remote supervision for the

charging/discharging status, charging/discharging voltage, current and battery

temperature.

The battery pack for the 48V communications power comprises 24 serial batteries. The

nominal voltage for a single battery is 2V, the float charging voltage is 2.23V, the

equalized charging voltage is 2.35V. Generally speaking, the float charging voltage of

the battery pack is set at 53.5V (2.23V×24), while the equalized charging voltage is set

at 56.4V (2.35V×24). The float charging voltage and the equalized charging voltage

can be set in the monitoring unit of the combined power supply system, and the values


----104----

shall not deviate too much from the standard values mentioned above.

When the system undergoes charging, the “Charging current ratio” shall not be more

than 0.2C (C represents the rated capacity of the battery), i.e., the charging current shall

not exceed 20% of the total battery capacity.

The power supply system performs whole-process supervision on battery discharging.

When the battery voltage is lower than the “Low battery voltage alarm threshold”, the

monitoring unit will give alarms; the battery keeps discharging, when the battery

voltage is lower than the “Power shutdown voltage of the first group of loads”, the load

equipment of the first-stage shutdown group of the system will be disconnected; when

the battery voltage is lower than the “Power shut-down voltage of the second group of

loads”, all the load equipment of the system will be disconnected, so as to protect the

battery from being over-discharge.

5.3.2 Choice of battery

The choice of battery capacity is determined by 2 factors, i.e., the needed current and

the expected battery discharge time for the power consumption equipment of the power

supply system. For example, the total current of the load equipment of the power

supply system is 80A, the expected continuous power supply time of battery during AC

blackout is 10h, then the battery capacity required by the system=total current of load

equipment × continuous power supply time during AC blackout=800Ah. Then add an

additional quantity on the theoretical battery capacity to get the actually needed battery

capacity. Higher instead of lower battery capacities are preferred as a principle,

however, the deviation shall not exceed 20% of the capacity needed by the electric

equipment.

Batteries of different capacities cannot be used in series, and batteries of different

voltages cannot be used in parallel.

Please don’t use battery packs of different capacities (the different currents during

charging may result in asynchronous saturation of capacities due to different

resistances within the batteries, thus giving rise to 2 packs of batteries of over-charge

and under-discharge; besides, there is to be mutual discharge of the 2 packs of

batteries during discharge).


----105----

5.3.3 Matters for attention during usage and maintenance of batteries

1. When several battery packs are in parallel, the total capacity of the battery is the

sum of various packs of batteries. The power supply system can be connected

with 3 packs of batteries at the most. In calculating parameters such as the

current-limiting value of the rectifier, it is necessary to use the capacity of the

battery, and the battery capacity of the power supply system is the sum of the

capacities of various battery packs.

2. The temperature for using batteries is -10℃~ 45℃, the lifespan of the battery is in

the reverse ratio to the temperature of the battery, therefore, heat radiation shall

be taken into consideration in design when the battery is to be used in cases of

increased temperature, so as to avoid increased temperature of the battery

(when the battery temperature is on the increase, the polar plates will undergo

increased corrosion due to the sulphoric acid, thus reducing its lifespan). The

equipment rooms with available conditions shall be equipped with air

conditioning units, so as to lengthen the lifespan of the battery.

3. After the installation of the power supply system, the battery of the first time or out

of use for a long time shall be first charged before being used, for the battery is

subject to capacity loss due to long-time automatic discharge during storage,

and the performance cannot be resumed without charge first.

4. There shall be records for battery running, recording the voltage of a single battery,

the total voltage of the battery pack and the ambient temperature monthly. The

standard values shall be resumed in case of any deviation. The terminal voltage

of single battery packs shall be measured after equalized charging. The terminal

voltage of each battery shall be almost the same, which shall be higher than

1.8V. Those lower than 1.8V are called “Retarded battery”, which shall be

specially charged. If such batteries cannot recover in terms of performance,

new batteries of the same type and capacity shall be resorted to, thus avoiding

impact on the whole battery.

5. The battery pack shall be checked every year for its fixing connection wires etc. to

prevent accidents from happening, and it shall be fixed firmly periodically.

5.4 Alarm description and handling When the system fails, the monitoring unit will generate alarms according to the failure.


----106----

All kinds of failures will be prompted by audible and visible means as well as text

messages.

When an alarm occurs, the red alarming lamps on the monitoring module light up, the

buzzer gives out alarming sounds, and alarming information is sent to the remote

monitoring center.

The rectifiers and the monitoring unit of the system are designed with sufficient

internal protection, so the normal running of the system will not be affected if a single

module fails.

When any rectifier fails, it automatically exits from service; when the monitoring unit

fails, the rectifier keeps working in the float charging mode, so that the system can still

work normally.

The monitoring unit will immediately send out audio-visual alarm signals when an

alarm occurs to the system. The user can view the specific alarm information and alarm

start time through the displayed alarm data of the monitoring unit. The maintenance

personnel should check the corresponding equipment according to the alarming

information prompted by the monitoring unit, so as to determine the failure type and

location, and take the corresponding measures.

5.4.1 Solutions to the alarms that affect the output of the system

If a fault occurs that affects the system output, such as too low voltage of the

accumulator battery, over-voltage/under-voltage of the output load, abnormal output of

the rectifier module, the load fuse broken, etc., please handle them in accordance with

Table 5-1.

Table 5-1 Alarms that affect the output and solutions

Symptoms Solutions Battery voltage is too low Cut off the battery circuit to protect the battery from over-discharge (automatic) Load over-voltage, under-voltage

Check the output voltage of each rectifier module and the work status of the loading equipment, and check whether the monitoring unit is damaged

Battery circuit is disconnected

Check whether the DC contactor is damaged, whether the monitoring unit is damaged, and whether the data checked by the monitoring unit is normal

The whole system fails to start up

If a fault occurs to the control loop of the AC power distribution unit or the AC input contactor is damaged (when configuring the contractor), check the AC input circuit of the supervision system or replace the AC contactor.

The rectifier is abnormal or damaged Replace the corresponding rectifier module.

Load fuse is blown out Check whether there is any short circuit of the load equipment, whether the work current of the load equipment exceeds the capacity of the fuse. Replace with a spare fuse after making sure there are no other problems.


----107----

5.4.2 Alarms that do not affect the output of the system and their solutions

If a fault occurs that does not affect the power supply of the system, such as AC input

over/under voltage or lack (disconnection) of one phase, or the rectifier being

current-limited, the voltage of the accumulator battery pack being low (different from

too low voltage of the accumulator battery, when the system will cut off the loop of the

accumulator battery), or failure of the mains, the monitoring unit will also send the

corresponding alarm signals. The maintenance personnel shall, according to the prompt

information, check the equipment, determine the type and location of the fault, and

undertake the corresponding measures. Please refer to Table 5-2 for the failure

phenomena and remedies.

Table 5-2 Alarms that do not affect system output and their solutions

Symptoms Solutions

AC over and under

voltage

and phase loss

(disconnected )

First cut off the input, start the power generator set, or use the battery for supplying power till

the input gets normal. Check the input line and the external distribution screen,

input lines and external distribution board

The rectifier module

input is abnormal

or the output is

current-limited

Check the input switch of the rectifier module and monitor the output current of this module,

if faults occur to the internal parts of the rectifier module,

replace the module.

Mains supply outage Check if the power generator set is started, if not, start up the generator set

Low voltage of the

accumulator battery

Check whether the output voltage of the system is normal. If the power is cut off, start the

standby diesel generator.

The rectifier being

current limited

Check whether there is fault with the load, and judge whether the system is in the state of

charging. Check whether the rectifier fails,

if yes, replace it.

The monitoring unit is

abnormal Reset the monitoring unit, and remove for repair if the problem cannot be solved.

Without the monitoring unit the system can still work, but the failure information of the

system cannot be sent to the remote monitoring center, nor is there any indication of

monitored failure information at the local site.


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5.5 Adding DC Load

5.5.1 The use of fuse extractor

Usage of the handle of the fuse extractor is as follows:

1. Unplug the fuse

(1) Insert the bulge of the lower part of the fuse into the corresponding concave slot

under the fuse extractor according to the type of the fuse. Then insert the bulge

of the upper part of the fuse into the corresponding slot above the fuse

extractor;

(2) Slightly pull the fuse extractor upward, and integrate the fuse with the handle;

(3) Pull the handle of the fuse extractor outward with force, and the fuse will be

unplugged.

2. Plug the fuse

(1) First make the fuse and the handle become one according to the first steps of

“Unplug the fuse”;

(2) Pull the handle of the fuse extractor inward with force, and the fuse will be plugged

in place;

(3) Follow the following steps to separate the fuse and the handle.

3. Separate the fuse and handle

(1) Hold down the red button on the handle of the fuse extractor until the locking

spring tilts up;

(2) Pull the handle down to separate the handle and fuse.

Note: when installing fuse, users shall note that whether the fuse has been

installed to the designated position, and whether it is safe and fast.

5.5.2 Adding DC Load

During the initial installation and running period of the power supply equipment, often

not all the load is devoted for running, generally speaking, no power off is allowed

after load running, therefore, newly added load equipment must be operated with

power on. Install the new load equipment strictly according to the following procedure.

If there is any abnormality, check the cause and solve it immediately.


----109----

The procedure of adding the DC load is as follows:

1. Make the engineering design and choose the load fuse or the air switch for use.

Note to match the capacity of this tributary with the capacity to be used.

2. Process and lay out the load connection cables, number them and mark them with

their polarities.

3. The wiring of the cable begins with the load end. The grounding cable should be

connected first, followed by the –48V output fuse or air switch.

4. Check the power polarity carefully and ensure there is no error or short circuit.

5. Make sure that the power switch of the load equipment is cut off.

6. Insert the fuse of this tributary to the combined power system or close the air

switch of this load.

7. Check on the load equipment whether the power voltage and polarity conform

with the practical values and requirements.

8. Then, supply power can be provided to the load equipment.

Note: when adding DC load, the tools used must be insulated, and the

corresponding measures shall be undertaken aimed at the accidents that may

happen.

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6. Maintenance & Management

6.1 Equipment room management 6.1.1 General requirements

Equipment room management includes equipment room environment safety

management and equipment management.

The basic tasks for environmental security management are as follows: such elements

as equipment room environmental temperature, relative humidity, cleanness, static

interference, noise, and heavy-current electromagnetic interference etc. shall meet the

requirements, so as to ensure stable performance, reliable running and safe production

of the power supply equipment, and ensure the normal power supply of the

communications equipment.

For the requirements on the environmental security management on the

communications equipment room, please refer to the “General rules for environmental

security management on communications equipment room” promulgated by the

General Directorate of Telecoms.

The power unit consists of the AC transformer, DC power distribution unit, rectifier

module, battery, generator group, and so on. The basic requirements on equipment

management are as follows: guarantee sound equipment mechanical performance, the

equipment’s electrical performance shall meet the requirements of the related standards,

the equipment shall run stably and reliably, and the technical documents and original

records related to the equipment shall be complete.

For the requirements on the power supply equipment management of communications

offices and stations, please refer to the “Maintenance specifications on communications

power supply” promulgated by telecommunications departments.

Maintenance/test items in power and battery equipment room management are shown

in Table 6.1 (only for reference).

Chapter 6. Maintenance & Management

----111----

Table 6-1 Maintenance and test items concerning management on power battery equipment room

S.N. Maintenance/test item Period

1 Temperature and humidity check Day

2 Cleanness of the control room of the SPC equipment room and the common

communication equipment room.

Day

3 Indoors cleanness of the SPC equipment room Week

4 Surface cleaning of racks and desks in the equipment room Week

5 Temperature and humidity alarm performance check Week

6 Dusting or replacement of the filter (screen) of the air-conditioner Month

7 Resistance measurement of the anti-static workbench, floor, chair and strap Month

8 Lightning-proof device check (before the thunderstorm season) Year

9 Grounding cable check and grounding resistance test Year

10 Inflammable gas sensor check Year

11 Smoke and temperature sensors alarm check and fire auto-alarm device

check

Year

12 Gas fire device fixation Quarter

13 Equipment room dust particle content measurement

6.1.2 Management on unattended stations

The unattended equipment room includes the local telephone terminal exchange,

module exchange, transmission base station, relay station, power room and battery

room. General requirements of the management of the unattended station are as

follows:

1. There shall be people taking care of the stations (not on-site attendance), or tour

inspection by regions;

2. The unattended stations shall possess sound capabilities in fighting natural

disasters;

3. The unattended stations shall be sealed;

4. The temperature, humidity and cleanness and fire prevention measures of the

equipment room should meet requirements.

The requirements of unattended stations propose the following requirements on

equipment and power supply:

1. The power unit of the unattended equipment room should be stable and reliable,

the average no-failure interval of the rectifiers should be more than one year,


----112----

and the function of processing the environmental information and the channel

used to transmitting this information must be configured;

2. Both automatic and manual methods shall be available for control over the power

supply of the unattended stations, and the power supply system shall have such

remote management functions as telecontrol, telemetry, telesignaling, etc.;

3. The unattended stations shall be equipped with automatic start-up engines and air

conditioning equipment.

6.2 Daily records Contents of the power and battery equipment room duties or equipment room

management system records mainly consist of the environment information (such as

temperature and humidity), AC power supply information (such as power line voltage

and frequency), DC power supply information (such as output voltage, current and

battery and load status information). Table 6-2 is the power and battery daily record

from (only for reference). Generally the interval of the manual record is two hours, and

the period of acquisition and record of the automatic monitoring system is 30 minutes.

Table 6-2 Daily records for power battery

Time Temper

ature

Humidi

ty

VA VB VC VO IO I battery

1

I battery

2

Remark

s

Abnormality records

(Alarm records)

6.3 Handling special cases

6.3.1 Blackout

AC power-off is the most ordinary case in the power supply system running. If the

duration of power-off is not long, the battery will shoulder the DC power supply; on

the contrary, if there is no apparent cause of power-off or the duration of power-off is

extremely long, it is necessary to start the diesel generator for power generation. It is

recommended to wait for over two minutes after start-up of the diesel generator, then


----113----

switch it over to the power supply system, so as to reduce the possible impact on the

power supply equipment during start-up of the diesel generator.

Note: we will have to wait for the stabilization of the generator before using it to

supply power for the whole system.

6.3.2 AC over-voltage/under-voltage protection

The monitoring unit of the system will give the alarm information if the AC input

power exceeds the over-voltage alarm point or is below the under-voltage alarm point.

When the input AC voltage exceeds the over-voltage protection point or is below the

under-voltage protection point of the rectifier, the rectifier will shut down. In this case,

the system has no DC output and the battery will supply power to the load equipment.

A power system with double mains input is available for the AC input. When

over/under-voltage protection occurs, and if the double mains are input through the air

switch, it is necessary to manually switch the input to the AC supply loop with normal

voltage. If it is input through the contactor, the system will automatically switch to the

second mains (or the diesel generator) if the first mains voltage is abnormal. It is

normal that the AC power distribution unit cannot output AC power if the double AC

input of the AC power distribution unit exceeds the over-voltage point or is below the

under-voltage point. In this case, the battery will supply power to the load. Meanwhile,

closely follow up variation of the AC input, and if possible, start up the standby diesel

generator in time, lest communication is interrupted after the loop protection of the

battery is disabled.

6.3.3 Disasters and accidents

The disasters and accidents include such events as lightning strikes, flooding,

earthquake and fire accidents which will cause the failure of communications facilities.

For the disasters that may cause severe communications security problems, we should

emphasize on prevention. At the same time, communications stations and offices

should be equipped with corresponding manpower and material resources to deal with

the disasters, and the units should have emergency status administrative regulations and

severe accidents repairing rules.


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6.4 Equipment maintenance

6.4.1 Major points for power supply maintenance

As the telecom power supply features a modular design, usually partial or unit failures

will not lead to proliferation. Power supply failures can be divided into general failure

and emergent failure.

Minor failure refers to that not affecting communication security, including lightning

damage to the AC lightning arrester, system internal communications interruption, no

output of a single module, and damage to the monitoring unit, etc. Emergent failure

refers to the failure that will affect communication safety, such as AC power off due to

AC input and control damage, DC load power off due to DC sampling and control

circuit damage.

If the system generates the following alarms, it is normal: AC input over/under-voltage

alarm, battery under-voltage alarm, mains supply outage alarm, etc.

6.4.2 Troubleshooting for AC power distribution unit

1. Level C lightning-proof device damage

The lightning arrester is composed of 4 leaf-shaped lightning protection units, 3

of which have the status display function to display whether the lightning

protection unit is in the sound state. When the window of the lightning-proof

device is in green, it means that the lightning-proof device is in good status.

When the window of a certain unit is in red, it means that this lightning-proof

unit is damaged. Replace the lightning-proof unit as soon as possible or notify

the local office of ZTE Corporation for maintenance in this case.

2. AC input phase loss

When there is phase default for AC input, the AC power supply cannot be

resolved temporarily, and the system is required to work, emergency methods

can be employed: first cut off the AC power supply, get down the phase line

with phase default, wrap it with friction tape, then use a short line to connect

the normal phase line into the phase line cut off. Then send AC power.

3. AC input over/under-voltage

If AC power is normal but the AC over/under-voltage alarm occurs, usually the


----115----

AC sampling circuit of the monitoring system, AC transducer, or monitoring

unit becomes faulty.

4. AC contactor damage

The contactor does not close though the AC input voltage is within the normal

input range. Use a multimeter to check. If it is found in check that the AC

contactor coil has normal working voltage but does not close, it means that the

AC contactor is damaged and should be replaced.

5. AC contactor protection board (CEPU) damage

When the AC input voltage remains within the normal range while the contactor

does not close, check the contactor coil with a multimeter, and it is found that

there is no normal working voltage. In this case, it is probably that the CEPU

board of the AC input part is damaged. When CEPU board is damaged, the AC

input contactor cannot close. At the time, no AC power input will be available

for the system.

Handling method: when the system is powered by mains supply 1, extract plug

X11 on the CEPU board, and plug it into socket X31; when the system is

powered by mains supply 2 or the diesel generator, extract plug X21 on the

CEPU board, and plug it into socket X31. This handling method means that

CEPU board is skipped over.

6.4.3 Troubleshooting for DC power distribution unit

1. DC tributary failure

If the DC input terminal of the fuse or disconnector has voltage but the output

terminal has no voltage output, it means that the fuse or disconnector is not

connected or has been damaged. If the fuse or the breaker is normal, it may be

due to disconnection of DC tributary detection lines.

2. Battery management failure

If the monitoring unit cannot perform normal alarm and protection over the

battery, i.e., the battery voltage is lower than alarm and protection values, but

there is no alarm and protection signal output, which cannot correctly free the

battery. The causes for battery management fault are as follows: the

corresponding supervision sampling line is disconnected, the relevant part of


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the monitoring unit is damaged, the implementing part (DC contactor) is

damaged, or the cable for the implementation part is disconnected, and so on.

3. DC contactor failure

If there is normal working voltage at both ends of the contactor, but the

contactor cannot be disconnected, it means that the contactor is damaged, which

shall be replaced.

6.4.4 Handing of the rectifier failure

Common failures of the rectifier include the following: no output, over-heat failure, no

equalized current, no ideal equalized current, no display, etc.

1. Module no output

If the rectifier does not work, and no panel indicator lights up, then first check

whether there is AC input, secondly, check whether the input fuse of the module

is burnt out. Another case may be that there is failure with the module. If so, the

faulty module must be replaced.

2. Overheat

When the temperature on the main cooler inside the rectifier is over 85℃, the

module will stop output. In this case, the monitoring unit will display the alarm

information. Module overheat may be caused by blocking or serious aging of

the fan, or poor working of the internal circuits of the rectifier. In the first case,

replace the fan. In the second case, maintain and repair the power module.

3. No current equalization and poor current equalization

When no current equalization occurs in system utilization, check whether the

monitoring cable between the module and the monitoring is connected

appropriately and whether the monitoring cable itself is disconnected. If there is

current equalization but the effect is poor, adjust the output voltage of the

corresponding module with poor current equalization effect (adjust the

potentiometer on the rectifier panel), so that the difference of the output current

in the states of floating charge or the equalized charge is within the stipulated

scope, and equalized current will be obtained again.

4. Fan failure


----117----

The characteristic of fan failure is that it does not work when it is expected to. At the time, check whether the fan is blocked, if yes, clear the blocking materials; otherwise, it may be that the fan is damaged itself, or there is fault with the connection control part, it is necessary to dismantle the module for maintenance.

5. Over-current protection

The rectifier is capable of over-current protection. If the output is short-circuited, the module will retract for protection. And when the output voltage is lower than 20V, the rectifier will be switched off. In this case, the current limiting indicator on the panel will light up. After troubleshooting, the module will automatically resume working normally.

6.4.5 Troubleshooting for the monitoring unit

The monitoring unit features certain self-diagnosis function. When the monitoring unit

fails, we can handle the problems by referring to Table 6-3.

Table 6-3 Failure diagnosis of the monitoring unit

Symptoms Solutions

No working of the monitoring unit

First, check whether the power indicator is on. If not, check whether the power input of the monitoring box is normal, whether the fuse of the monitoring unit is normal and whether the power switch is turned on.

Display disorder on screen Press the Reset button to reset the monitoring unit

Communication disabled

Check whether the communication cable has been reliably connected to the 9-pin socket X6 of the backplane, and reset the monitoring unit is communication remains disabled. For Modem communication, check whether the Modem cable is connected reliably with the power cable.

Abnormal status detection and control of the rectifier

If rectifiers 1~5 are abnormal, check whether X14 on the backplane is connected reliably, and if rectifiers 6~10 are abnormal, check whether X19 on the backplane is connected reliably.

Abnormal AC data or status Check whether X15 on the backplane is plugged reliably.

Abnormal DC data or status Check whether X16 and X17 on the backplane are plugged reliably.

Abnormal battery temperature detection

Check whether the sensor sockets X7, X8 and X9 that detect the battery temperature are connected reliably on the back panel of the monitoring unit (never connect the battery temperature sensor to the power socket of Modem).

Error detection of the environment parameters

Check whether EMB board is well connected with the connection cable of socket X12 on the back panel of the monitoring unit and in good contact with the environment detection probe

Abnormal input detection of the alarm relay contact Check whether the socket X13 of the backplane is well connected.

Abnormal power-off control and emergency lighting control

Check whether the backplane X11 is well connected with the corresponding cable.

Abnormal dry contact output board of the system

Check whether RLY board is well connected with the connection cable of socket X10 on the back panel of the monitoring unit.

No flashing of the running indicator Please reset the monitoring box.


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6.5 Emergency handling

6.5.1 Principle for emergency handling

The basic principle for emergency handling of the power supply system fault is to keep

an uninterrupted DC power supply for the system.

The failures of the power supply system threatening communication security or

resulting in communications interruption mainly include the following: unrecoverable

damage to the AC power distribution circuit, short circuit of DC load or DC power

distribution unit, complete breakdown of the rectifier, shut-down accidents due to

monitoring unit out of control, and module blocking due to DC output over-voltage,

etc.

6.5.2 Emergency handling for AC/DC power distribution unit

The content of emergency handling of the AC power distribution unit failure is power

supply interruption, the way to handle is to directly introduce the single-phase AC into

the rectifier.

The emergency handling of DC power distribution unit is as follows:

1. Load part short-circuit

Separate the damaged load DC feeding fuse.

2. Power distribution short-circuit

DC power distribution short-circuit failure caused by human carelessness or

natural factors such as earthquake, will directly affect communication safety.

The processing method for the faults is as follows: cut off AC power supply;

separate the battery from the system by force; use battery or rectifier to directly

provide power supply for the load.

6.5.3 Emergency handling for the monitoring unit

If the monitoring unit failure affects DC power supply security, it is only necessary to

shut down the monitoring unit. At the same time, pay attention to management and

maintenance of the battery.


----119----

6.5.4 Emergency handling of the rectifier failure

1. Short circuit inside the module

When there is short circuit inside the module, it will automatically exit from the

system.

2. Partial module damage

After a part of the module is damaged, if the remaining parts can meet the

requirements of load power supply, it is sufficient to shut down the AC power

supply of the damaged module.

3. Module output over-voltage

When the load current is lower than the capacity of a single module, output

over-voltage of a module will lead to system over-voltage and over-voltage

protection of all modules and cannot be recovered automatically. Handling

method: turn off the AC input switches of all the modules, then turn on them

one by one; when a certain module is turned on and undergoes over-voltage

protection once more, turn off the module, and turn on other modules, then the

system can work normally.

----120----

7. Packaging, Transportation & Storage

7.1 Packaging The whole system is packed component by component. The monitoring unit and the

cabinet are packed together, and two rectifiers are packed in one carton. Fittings and

documents are packed in the general cartons. During packaging, we should pay special

attention to the requirements on the placement directions of various parts.

7.2 Transportation Packages should be handled with care during transportation, so as to prevent violent

impact on them. Besides, they should be placed strictly according to the direction

requirements marked on the packing boxes to prevent damaging devices due to shock.

7.3 Storage The system should be stored in dry warehouses and be kept from exposure to sunshine

or rainwater. The placing direction shall conform to the marks on packages. The

storage period is restricted to one year with a storage temperature in the range from -40

℃ to 70℃.

----121----

Appendix A Threshold Ranges of Power & Environment Parameters

Appendix A-1 Threshold ranges of power supply & environmental parameters

Parameter Name Default value

Upper limit

Lower limit

Remarks

AC input high voltage alarm threshold (V) 260 300 240 AC input low voltage alarm threshold (V) 180 200 160 AC input high current alarm threshold (A) 60 80 50 Output high voltage alarm threshold (V) 58.0 59.0 57.0 ≥ Equalized-charging voltage +1V Output low voltage alarm (V) 48.0 52.0 41.0 ≤ Float-charging voltage-1V Float-charging voltage (V) 53.5 58.0 42.0 ≤ Equalized-charging voltage

≥ Battery under-voltage alarm threshold +1 ≥ Low output voltage alarm threshold +1

Equalized-charging voltage (V) 56.4 58.0 42.0 ≥ Float-charging voltage ≤ high output voltage alarm threshold –1V

Test voltage (V) 46.0 48.0 42.0 Battery pack capacity (Ah) 100 2000 0 Battery charging coefficient 0.15 0.25 0.05 Battery temperature compensation coefficient (mv/℃/pcs)

3 6 0

Equalized-charging cycle of the battery 180 365 15 Equalized-charging threshold capacity of the battery

0.85 0.95 0.6

Battery under-voltage alarm threshold (V) 47.0 52.0 41.0 ≤ Float-charging voltage-1 ≥ First-stage power shutdown voltage +1

First-stage shutdown voltage of the load (V)

46.0 47.0 40.0 ≤ Battery under-voltage alarm threshold -1 ≥ Second-stage power shutdown voltage

Second-stage shutdown voltage of the load (V)

45.0 47.0 40.0 ≤ First-stage power shutdown voltage

Battery high temperature alarm threshold (℃)

40 55 30

High ambient temperature alarm threshold (℃)

40 55 30

Low ambient temperature alarm threshold (℃)

-5 10 -20

High ambient humidity alarm threshold (%)

90 100 80

Low ambient humidity alarm threshold (%)

20 40 10

Input current zero adjustment (A) 0 10 -10 Input current slope adjustment (%) 1 1.2 0.8 Battery temperature zero adjustment (℃) 0 10 -10 Load current zero adjustment (A) 0 10 -10 Load current slope adjustment (%) 1 3 0.3 Battery current zero adjustment (A) 0 10 -10


----122----

Continued Table A-1

Parameter Name Default

value

Upper

limit

Lower

limit

Remarks

Battery current slope adjustment

(%)

1 3 0.3

Ambient temperature zero adjustment (℃)

0 10 -10

Ambient humidity zero adjustment

(%)

0 10 -10

Total circuits of the load 20 20 0 ≥(First-stage power shut-down circuits

plus second-stage power shutdown

circuits)

First-stage power shut-down

circuits

8 20 0 ≤(Total circuits of the load minus the

second-stage power shutdown circuits)

Second-stage power shut-down

circuits

12 20 0 ≥(Total circuits of the load minus the

first-stage power shutdown circuits)

Equipment address No. 1 254 1

Baud rate 1200 9600 1200 Settings of four baud rates: 1200, 2400,

4800 and 9600

Menu password setting 0000 9999

Alarm relay contact corresponding

to the failure type

Language English Switchover between Chinese and

English

----123----

Appendix B Delivery Attached Packing Accessories

Table B-1 Delivery attached packing accessories

S.N. Part name Specifications Unit Qty Remarks 1 400A fuse 3NA3144-2C pc 1 Spare parts

2 6A ~ 200A fuse 3NA38**-2C Set 1

Spare parts, configured as required in the contract, or one piece for each type of fuse if there are no requirements in the contract.

3 Fuse extractor pc 1 4 Wire clip ≥145mm pc 30 5 Adhesive line clip base 20×20 pc 12 6 Nut M8 pc 4 7 Bolt M8×25 pc 4 8 Flat washer 8 pc 8 9 Spring washer 8 pc 4

10 Nut M10 pc 6 11 Bolt M10×35 pc 2 12 Flat washer 10 pc 8 13 Spring washer 10 pc 6 14 Expansion bolt M10*80 Set 4

15 Insulation tape Width 18mm Volume 3 One red, one blue and one black

16 Humidity sensor IH-3605-A pc 1 Configured as required in the contract

17 Smog sensor JTY-LZ-F901 pc 1 Configured as required in the contract

18 Infrared sensor AE1 PIR-9112 pc 1 Configured as required in the contract

19 Flooding sensor LL101101 pc 1 Configured as required in the contract

20 Cruciform round combination screw M4×12 nickel plating pc 4 No standard requirements

21 User’s Manual for Power Supply Background Monitoring Software (V3.0)

Copy 1 It can be configured for users demanding three “tele”s

22 “User’s manual of ZXDU500 500A Combined Power Supply System”

Copy 1

23 User’s Manual for ZXD2400 (V3.0) 50A Rectifier Copy 1

24 Certificate Copy 1

25 Serial port communication cable 4-pin shielded wire pc 1 Two 9-pin female plugs, 10m,

optionally configured

26 25-pin and 9-pin serial port transit cable 4-pin shielded wire pc 1 One 9-pin male plug and one 25-pin

female plug

27 Battery temperature sampling cable 4-pin shielded wire pc 2

----124----

Appendix C Principle Diagram of AC/DC Distribution

QF01(KM01)

QF02(KM02)TP1

QF0

F1

QF03

QF0n

QF1

QF2

QF3

QF4

QF5

QF6

U1 RS1

RS2

RS3

FU1

FU2

FU3

GB1

GB2

GB3

ST1

ST2

ST3

1FU11FU21FU31FU41FU5

2FU112FU122FU132FU142FU15

2FU12FU22FU32FU42FU52FU62FU72FU82FU9

2FU10

TA1

U6RS4

1KM1

2KM1

3KM1 3FU1

»úÐµ»¥Ëø

QF7

QF8

QF9

QF10 U10

U2

U3

U4

U5

U7

U8

U9

U1

V1

W1

U2

V2

W2

N

PE

U V WL+ L-+ -48V

X15-

2X1

5-3

X15-

4X1

5-5

X15-

6X1

5-7

X15-

1

X15-

10X15-8

X16-15X16-14X16-13X16-12X16-11

X16-10X16-9X16-8X16-7X16-6X16-5X16-4X16-3X16-2X16-1

X17-10 X17-9

X17-12 X17-11

X17-14 X17-13

X17-

16

X17-

15

X17-6

X17-7

X17-8

X7-2

X8-2

X9-2

X7-1

X8-1

X9-1

X11-2

X11-4

X11-6

1 2X7 1 2X8 1 2X9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X11

1 2 3 4 5 6 7 8 9 10 11

X15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15X161 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18X17

1 2 3 4X5

1 3

1 3

1 3

- +

- +

- +

+-

1 6 2 7 3 8 4 9 5

X61 2 3 4 5 6 7 8X13

RS485/422 RS232

B A Y Z

-48V

1KM

1-A1

2KM

1-A1

3KM

1-A1 CO

M1

NC1

NO1

COM

2

NO2

NC2

A1 A2

A1 A2

A1 A2

X10

X14 X19

ÕûÁ÷Æ÷½Ó¿Ú1 ÕûÁ÷Æ÷½Ó¿Ú2

2FU1

12F

U12

2FU1

32F

U14

2FU1

5FU

1FU

2FU

3RS

1+RS

1-RS

2+RS

2-RS

3+RS

3-RS

4+RS

4-L+ 2F

U10

2FU9

2FU8

2FU7

2FU6

2FU5

2FU4

2FU3

2FU2

2FU1

1FU5

1FU4

1FU3

1FU2

1FU1

VD1 IN4004

VD2 IN4004

VD3 IN4004

VD4 IN4004

-48V

ST1-

3ST

1-1

ST2-

3ST

2-1

ST3-

3ST

3-1

T1+1

2V T2+1

2V T3 +12V

TP1-

IaTP

1-GN

DTP

1-12

VTP

1+12

VTP

1-Va

TP1-

VbTP

1-Vc

QF01

QF0

F1

Ub

Ua

Uc N

Ia GN

D-1

2V+1

2VV

aV

bV

c

TA1-

1TA

1-2

Emergency Lighting

MAIN

GEN

BACK

~ =

~ =

~ =

~ =

~ =

~ =

~ =

~ =

~ =

~ =

1 2

MODEM POWER

12VDC

1 2

MODEM POWER

12VDC

1 2 3

48VDC- + - + L+

VD4-

PPE

¸É½ÓµãÊäÈë½Ó¿Ú

¸É½ÓµãÊä³ö½Ó¿Ú

X12

¸ºÔØÏÂµç½Ó¿Ú »·¾³°å½Ó¿Ú Ö±Á÷Åäµç½Ó¿Ú2 Ö±Á÷Åäµç½Ó¿Ú1

½»Á÷Åäµç½Ó¿Ú

µç³ØÎÂ¶È½Ó¿Ú

1C1

2C1

3C1

X17-1

X17-2

X17-3X17-4

X17-5

POWER-X1-3

GN

D

X15-9

X15-11

QF03

POWER

POWER-X2 POWER-X3 POWER-X1

Documents

ZXDU500 500A Combined Power Supply System User’s Manual