quick start guide for fpra
TRANSCRIPT
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Flexi Power Rectifier
Quick Start Guide
Emerson Network Power Co., Ltd. http://www. emersonnetworkpower.com.cn Manual Version: 01
Flexi Power Rectifier Quick Start Guide
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Manual Number: 03370500110 Manual Issue: 01 Manual Status: Standard Release Date: Sep 2008
Copyright © 2008 Emerson Network Power Co., Ltd. All rights reserved Published in China This document, and the information it contains, are the property of Emerson Network Power Co., Ltd, and are protected by law. Both must be held in strictest confidence at all times. Emerson Network Power grants no license or right to copy, use or disclose either, expressly or by implication.
Disclaimer
This document and the information contained herein are provided on an "AS IS" basis. Emerson Network Power may make improvements or changes in this documentation, at any time and without notice and as it sees fit. The information in this documentation was prepared by Emerson Network Power with reasonable care and is believed to be accurate. However, Emerson Network Power shall not assume responsibility for losses or damages resulting from any omissions, inaccuracies, or errors contained herein.
Flexi Power Rectifier Quick Start Guide
History 3
History Date Version Author Change Note No./Notes 21/07/2008 01 David Cao First release
Flexi Power Rectifier Quick Start Guide
Table of contents 4
Table of contents History...................................................................................................................3 Table of contents ..................................................................................................4 List of figures ........................................................................................................4 List of tables..........................................................................................................4 List of terms ..........................................................................................................5 Preface .................................................................................................................7 Hardware Installation ............................................................................................9 Appendix – Tools and Torques ...........................................................................23
List of figures
Figure 1 – The FPRA before the installation................................................................ 9 Figure 2 – The PDA before the installation .................................................................. 9 Figure 3 – The cable gland configuration for typical use ......................................... 10 Figure 4 – Removing the drawer from the PDA ........................................................ 11 Figure 5 – Taking off the load (or battery) terminals short link and MCB switch
lever bar ................................................................................................................... 13 Figure 6 – DC terminal clamps distribution ................................................................ 14 Figure 7 – Connecting the DC cable ........................................................................... 14 Figure 8 – Putting the front panel back to the PDA .................................................. 15 Figure 9 – Connecting all the communication cables............................................... 17 Figure 10 - AC connection without the SPD – 3Y ..................................................... 19 Figure 11 – Installing the PDA into case .................................................................... 20 Figure 12 – Installing the rectifiers into case ............................................................. 20 Figure 13 – Installing the cable glands ....................................................................... 21 Figure 14 – Installing the front and back covers ....................................................... 21 Figure 15 – Cables exit from right of the FPRA ........................................................ 22
List of tables
Table 1 – Reference documents of the FPRA............................................................. 7 Table 2 – Three battery / load cables configurations ............................................... 12 Table 3 – Connection of the communication cables................................................. 16 Table 4 – Connection of the AC cable ........................................................................ 18 Table 5 – Tools and torques required for installation ............................................... 23
Flexi Power Rectifier Quick Start Guide
List of terms 5
List of terms
A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
CB Circuit Breaker
CSA Cross Section Area
CU Control unit
DC Direct current
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRA Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Ingress Protection
IP Internet Protocol
L Live cable from the AC mains
LAN Local Area Network
LED Light Emitting Diode
LVD Low Voltage Detection
MAC Media Access Control
MCB Micro Circuit Breaker
Flexi Power Rectifier Quick Start Guide
List of terms 6
N Neutral cable from the AC mains
PC Personal Computer
PCB Printed Circuit Board
PDA Power Distribution Assembly
PE Protective earth
PSU Power Supply Unit
SPD Surge Protect Discharge
V Volt
VPN Virtual Private Network
1Φ Single-phase AC type
3Y 3-phase star AC type
3∆ 3-phase delta AC type
Flexi Power Rectifier Quick Start Guide
Preface 7
Preface About this guide
This quick start guide is for quick installation or an overview of the FPRA. Thus only the typical configuration of the AC and DC cables is described in this guide. User shall refer to the main installation manual for more details about the other configurations.
FPRA Introduction
The FPRA is a 6kW output power AC rectifier package made up of three individual 2kW AC/DC power modules operating in a parallel mode configuration. It also includes a Power Distribution Assembly (PDA), which has a fully integrated battery protection LVD, load / battery circuit breakers, battery current shunt and alarm signals to the BTS EAC interface. The FPRA has a rated input voltage of 180~276VAC and provides an isolated –54VDC output (here referred to as V48N) that used for BTS power supply voltage as well as site battery charging. The maximum current of the system is up to 109.9A (at maximum 6kW output), and the ambient temperature is –40 ~ +55°C.
Reference documents
The reference documents of the FPRA contain:
Table 1 – Reference documents of the FPRA
Document Emerson Network Power File No.
Internal product specification – System / PDA 41970005110
Internal product specification – Rectifier 41970004980
Surge Protect Discharge for Flexi Power Rectifier – User Manual
03370500080
Flexi Power Rectifier - User Manual 03370500090
Flexi Power Rectifier Quick Start Guide
Preface 8
Table 1 – Reference documents of the FPRA
Flexi Power Rectifier - Installation Manual (Main installation manual)
03370500070
Surge Protect Discharge for Flexi Power Module – Quick Start Guide
03370500100
Flexi Power Rectifier – Quick Start Guide (This manual)
03370500110
Flexi Power Rectifier Quick Start Guide
Hardware Installation 9
Hardware Installation
Note: This FPRA quick start guide is for configuration with one battery string, one load string and three-phase star AC inputs.
B D
F A A B
CC
C
C
E AFigure 1 – The FPRA before the installation
(10) (8)(7)(6)
(5)(4)(3) (2)(1) (9)
(1) Rear cover (2) Sub cover (3) Restricted area (4) BR bus bar (5) –54V bus bar (6) Front panel (7) Drawer (8) RS 485 cable (9) Window of the breakers (10) PE of the PDA
Figure 2 – The PDA before the installation
Flexi Power Rectifier Quick Start Guide
Hardware Installation 10
************************************ Follow the steps below to install the FPRA: ************************************
1. Detach the PDA from the case (refer to section 3.1 in the main installation manual). Loosen four screws ‘C’ to detach the two side cable glands; Loosen two thumbscrews ‘B’, nut ‘F’ and three cable restraints ‘A’ to pull out the PDA from the case (refer to Figure 1).
2. Puncture the waterproof on the cable gland and Insert the cable through the hole before installing it into the PDA (refer to section 3.1 in the main installation manual). Warning: The AC mains and battery blocks must be switched off firstly.
Note: (1) The cable gland configuration for typical use is for illustration herein (see Figure 3). (2) Refer to Appendix – Tools and Torques for detail tools and torques that required for each installation step.
Alarm
Alarm System earth cable
DC GND
RTN5
BAT2
Temperature cable
AC cable
Parallel cable
LOAD2
RTN2
Parallel cable
Figure 3 – The cable gland configuration for typical use
Flexi Power Rectifier Quick Start Guide
Hardware Installation 11
3. Loosen two screws ‘D’ in Figure 1 and remove the drawer from the PDA (see Figure 4).
1 2
Figure 4 – Removing the drawer from the PDA
4. Route the DC cables (refer to section 3.2 in the main installation manual): 4.1 Loosen six screws ‘D’ on the front panel and two screws ‘E’ on the
breaker window in Figure 1 to remove the front panel from the PDA. 4.2 Remove the sub cover (refer to Figure 2) from the PDA. 4.3 Take off the load / battery terminals short link and MCB switch lever
bar if required (refer to Table 2 and Figure 5).
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Hardware Installation 12
Table 2 – Three battery / load cables configurations
Type Cable name CSA size (mm2)
Cable number
Recommended Installing sequence Breakers configuration
Load & return 35 2
Battery & return Up to 50 2 1
DC load grounding 35 1
→ RTN2 → LOAD2 → RTN5 → BAT2
Load MCB parallel & Battery MCB parallel
Load & Return 35 4
Battery & return 35 6 2
DC load grounding 35 1
→ RTN1 → LOAD1 → RTN2 → LOAD2 → RTN3 →BAT1 → RTN4 → BAT2 →RTN5 → BAT3
No MCB parallel
Load & Return 35 2
Battery & return 16 6 3
DC load grounding 35 1
→ RTN1 → LOAD2 → RTN3→ BAT1 → RTN4 → BAT2→ RTN5 → BAT3
Load MCB parallel
Flexi Power Rectifier Quick Start Guide
Hardware Installation 13
1
2
Figure 5 – Taking off the load (or battery) terminals short link and MCB switch lever bar
4.4 Puncture the waterproof on the DC grommet to insert the DC cable through the front panel (see Figure 7).
4.5 Insert the DC cables into the indicated DC terminal clamps and secure them respectively (see Table 2,
4.6 Figure 6 and Figure 7). Note: The DC configuration for typical use is for illustration herein.
Flexi Power Rectifier Quick Start Guide
Hardware Installation 14
Flexi Power Rectifier Quick Start Guide
Breaker LOAD2 BAT1 BAT2 MCB switch Lever bar
BAT3
LOAD1
InsulatorTerminals short link
RTN4
RTN5 LOADGND
RTN2 RTN3 RTN1
Figure 6 – DC terminal clamps distribution
Figure 7 – Connecting the DC cable
Hardware Installation 15
4.7 After connecting all the DC cables, Push the front panel back on the PDA and secure the six screws ‘D’ and two thumbscrews ‘E’ in Figure 1 (see Figure 8).
Figure 8 – Putting the front panel back to the PDA
4.8 Put the sub cover back to the PDA and secure it.
5. Route the communication cables (refer to section 3.3 in the main installation manual). 5.1 Connect the temperature cable to the drawer as per Table 3 (see
Figure 9). 5.2 Connect the parallel cable to the drawer if needed as per Table 3
(see Figure 9). 5.3 Connect the Alarm cable (may combines Alarm In and Alarm Out
together) as per Table 3, and fix the cable screen to position ‘A’ and ‘B’ on the sidewall of the drawer (see Figure 9).
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Hardware Installation 16
Table 3 – Connection of the communication cables
Cable Pin name Pin number Name Color
7 TEM_GND Red
8 TEM SENSE_IN White
9 TEMP_VCC Black Temperature
cable
10 EARTH Cable screen
1 (4) RS422RD- Red
2 (5) RS422RD+ White
3 (6) SGND/F Black Parallel cable
J22
11 (12) EARTH Cable screen
1 ALARM IN (-) Alarm In cable
2 ALARM IN (+) Reference
3 ALARM_COM
4 MAINS 1
5 ALARM_COM
6 MAINS 2
7 ALARM_COM
8 MAINS 3
9 ALARM_COM
10 CRITICAL
11 ALARM_COM
12 MAJOR
13 ALARM_COM
Alarm Out cable
J11
14 MINOR
Reference
5.4 Assemble the temperature cable, parallel cable and alarm cable and fix them to position ‘C’ on the drawer with a cable-tie (see Figure 9).
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Hardware Installation 17
5.5 Assemble the three RS485 cables and fix them to position ‘C’ on the drawer with a cable-tie (see Figure 9).
B A
Temperature cable
Parallel cable
C
Alarm cable
Figure 9 – Connecting all the communication cables
5.6 After connecting all the communication cables, put the drawer back into the PDA and tighten the two screws ‘D’ in Figure 1.
6. Route the AC cable without the SPD (refer to section 3.4 in the main
installation manual). Warning: the AC mains must be switched off before the installation.
6.1 Remove the rear cover from the PDA (refer to Figure 2). 6.2 Configure the AC terminal block for paralleling the corresponding
AC terminals with short links as per Table 4. 6.3 Puncture the waterproof marked “AC Inlet” on the front panel, and
insert the AC mains cable through the hole until it reaches the rear internal of the PDA.
6.4 Connect the 3-phase star AC mains into AC terminal block without the SPD as per Table 4 (see Figure 10).
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Hardware Installation 18
Note: The connection of the 3-phase star AC mains is for illustration herein.
6.4.1 Connect the PE cable from the AC mains to the ground clamp on the chassis (see Figure 10).
6.4.2 Connect the live cables and neutral cable from the AC mains to the AC terminal block as per Table 4 (see Figure 10).
Table 4 – Connection of the AC cable
AC type Schematic diagram Configuration of AC terminal block
3Y 1 2 3 4 5 6
AC Terminal BlockL1 L2PE
AC mainsL3 N
Short terminals 1,2,3
3∆ 1 2 3 4 5 6
AC Terminal BlockL1 L2PE
AC mainsL3
Short terminals 1,2; 3,4; 5,6 respectively
1Φ
1 2 3 4 5 6
AC Terminal BlockL NPE
AC mains
Short terminals 1,2,3; 4,5,6 respectively
Flexi Power Rectifier Quick Start Guide
Hardware Installation 19
N
L3
PE of AC mains
L2
L1
Figure 10 - AC connection without the SPD – 3Y
6.5 Recover the rear cover to the PDA.
7. Install the PDA into case (refer to section 3.5 in the main installation manual). 7.1 Put the PDA back into the case; tighten the two screws ‘A’ (see
Figure 11). 7.2 Fix the PDA earth cable to position ‘B’ (see Figure 11). 7.3 Fix the system earth cable to position ‘C’ (see Figure 11).
Flexi Power Rectifier Quick Start Guide
Hardware Installation 20
A
B C
Figure 11 – Installing the PDA into case
8. Install the rectifiers into case (refer to section 3.6 in the main installation
manual). 8.1 Put the rectifiers into the case; tighten the thumbscrews ’A’ (see
Figure 12). 8.2 Plug the AC input connector; tighten the screws ‘B’ (see Figure 12). 8.3 Connect the RS485 cable and cover the connector seal on position
‘C’ (see Figure 12).
A
C
B
Figure 12 – Installing the rectifiers into case
Flexi Power Rectifier Quick Start Guide
Hardware Installation 21
9. Install the cables with cable glands to the case; tighten the screws ‘A’ and ‘B’; fix the PDA earth cable to position ‘C’ with cable tie (refer to section 3.7 in the main installation manual, see Figure 13).
C
1 2
A
B
A B
Figure 13 – Installing the cable glands
10. Install the front and back covers; tighten the screws ‘A’ and ‘B’ (see Figure 14).
A A B B
Figure 14 – Installing the front and back covers
11. Arrange the cables and fix them to the side cable plate with cable-ties (see Figure 15). Note: Cables can exit from right or left or both sides of the FPRA. The cable
running from right is for illustration herein.
Flexi Power Rectifier Quick Start Guide
Hardware Installation 22
Figure 15 – Cables exit from right of the FPRA
Flexi Power Rectifier Quick Start Guide
Appendix 23
Appendix – Tools and Torques ******************************************************************** Refer to the table below for the tools and torques required for each installation step:
********************************************************************
Table 5 – Tools and torques required for installation
Step Tool Usage Torque (N.m)
TORX screwdriver (T25) Loosen screw -- 1
Wrench (8mm) Loosen nut --
2 Awl (Φ2mm) Puncture the waterproof --
3 Cross screwdriver Loosen screw --
4.1 TORX screwdriver (T10) Loosen screw --
4.2 TORX screwdriver (T10) Loosen screw --
Flat screwdriver Loosen screw -- 4.3
Pliers Take off the short links --
4.4 Awl (Φ2mm) Puncture the waterproof --
4.5 Flat screwdriver Tighten screw 3
TORX screwdriver (T10) Tighten screw 0.8 4.6
Manual Tighten screw Fit
4.7 TORX screwdriver (T10) Tighten screw 0.8
Flat screwdriver For ‘push-fit’ connector Fit 5.1
Cable-tie Tie the cable screen Fit
Flat screwdriver For ‘push-fit’ connector Fit 5.2
Cable-tie Tie the cable screen Fit
- To be continued -
Flexi Power Rectifier Quick Start Guide
Appendix 24
Flexi Power Rectifier Quick Start Guide
Table 5 – Tools and torques required for installation
Step Tool Usage Torque (N.m)
Flat screwdriver For ‘push-fit’ connector Fit 5.3
Cable-tie Tie the cable screen Fit
5.4 Cable-tie Tie the cables Fit
5.5 Cross screwdriver Tighten screw 0.7~0.8
6.1 TORX screwdriver (T10) Loosen screw --
6.2 Flat screwdriver Tighten screw 0.8
6.3 Awl (diameter 2mm) Puncture the waterproof --
Flat screwdriver Tighten screw 1.5 6.4.1
TORX screwdriver (T25) Tighten screw 2
6.4.2 Flat screwdriver Tighten screw 1.5
6.5 TORX screwdriver (T10) Tighten screw 0.8
7.1 Cross screwdriver Tighten screw 1.2
7.2 Wrench (8mm) Tighten the nut 2.0
7.3 Wrench (8mm) Tighten the nut 2.0
8.1 Cross screwdriver Tighten screw 1.2
8.2 Flat screwdriver Tighten screw 0.8
8.3 Manual Clamp the connector seal Fit
9 TORX screwdriver (T25) Tighten screw 2.0
10 TORX screwdriver (T25) Tighten screw 2.0
11 Cable ties Fix the cables Fit