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POWER SUPPLY SYSTEM

PODS 16.48-16000 1940 HEX


Instruction Manual

Revision: B
Document number: 039158

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples involving names of companies and products, are fictitious examples and are designed solely to illustrate the use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not
guarantee that this document is error-free. The information in this document is subject to change without
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All other trademarks or product names mentioned herein are trademarks of their respective owners.

Title page - Instruction Manual


Document Number:

039158

Revision:

Date:

11.05.2005

System:

PODS 16.48-16000 1940 HEX

Ouput Voltage:

48V

Publisher:

Power-One as
Postboks 1543
N-3007 Drammen
NORWAY

Amendment record:
Revision
(Issue)

Description

Author

/
A
B

First issue
Second issue
Third issue

Kai Morten Hennum 07.04.05


Kai Morten Hennum 11.05.05
Kai Morten Hennum 01.06.05

Originated Kai Morten


Hennum
Signed

Date 07.04.05

Approved Hans Andr Dokka

Date

Date 01.06.05

Signed

1-1
Document number: titlepage.fm
Revision: B

1-2

PODS 16.48-16000 1940 HEX


Document number: titlepage.fm
Revision: B

Contents:
4 System description PODS 16.48-16000 1940 HEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 System Description - PPS 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.1 FMP 16- Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.2 PCS - Controller System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4.3 PPR 16/10 23- Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.4 PBDU 23 - Distribution Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.4.1 Low Voltage Disconnection (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.5 Cabinet Door With Heat Exchanger (HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.6 BTS Breaker 50A 3-pole (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.8 FMP 16 Dummy Module (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4.9 Battery extension kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 Lethal voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.2.5 High temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
6 Installation guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Tools and parts required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.3 Cabinet mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.4 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5 Cable sizes / location of external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5.1 Cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.6 Connection of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.2.6.1 Mains Input Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.2.7 Connection of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.2.8 Connection of Symmetry Measurement and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .6-11
6.2.9 Battery connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
6.2.9.1 Battery tube routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6.2.10 DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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Document number: 039158TOC.fm
Revision: B

7.2 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2


7.2.1 Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.2 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.4 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.5 Test of output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5.1 Float charge (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5.2 Adjustment of float charge, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.5.3 Boost charging (U2) (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.6 Battery supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.7 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.8 Commissioning record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
8 Operation / Product description PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 General - Product description PCS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Technical specification: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Operation - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.3.1 Starting the PCS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3.2 Adding modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.3.3 Removing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4 PCS 2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 PCS 2 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1.1 Show voltage and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1.2 Show alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1.3 Show messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1.4 Show data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.1.5 Select / adjust U1 - U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.4.1.6 Adjust limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8.4.1.7 Miscellaneous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8.4.2 Connecting to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.4.3 Boost charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
8.4.4 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
8.4.5 Battery current limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.6 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4.7 High load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
9 Product Description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 General - Product description FMP 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.1 Mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.2 DC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.2.1 Mains input 185-250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.2.2 Mains input 95-185VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.3 Module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2.5 Other technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

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PODS 16.48-16000 1940 HEX


Document number: 039158TOC.fm
Revision: B

9.4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4


9.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.6 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
10 Product description PPR 16/10 23 Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.1 General - Product description PPR 16/10 23 Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.2 Connections and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
10.2.1 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
10.2.2 Internal functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.3 Connections between subracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4
10.4 Addressing module positions in subrack1, subrack2 etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5
11 Product description PBDU 4U/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.1 General - Product description PBDU 4U/23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
11.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
11.3 Construction and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.4 Cable cross section output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
11.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
11.6 Commissioning PBDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
11.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4
12 Product description PCS Alarm interface unit BM0685 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1
12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
12.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
12.2.1 Pin Configuration of J20 and J21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
12.3 Remote alarms, symmetry measurement and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . .12-3
12.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3
13 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1
13.1 Installing new modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2
13.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2
13.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
13.4 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4
Appendix A: Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Cabinet Layout - 039095 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: / . . . . . . . . . . . . . . . . . . . . . . A-3
A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 - Rev: / . . . . . . . . . . . . . . . . . . A-5
A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev: / . . . . . . . . . . . . . . . . . . . . A-6
A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 - Rev: / . . . . . . . . . . . . . . . . . . A-7
A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 - Rev: / . . . . . . . . . . . . . . . . . . . A-8
A.8 Footprint Outdoor Cabinet - 039423 - Rev:/ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Appendix B: Configuration c-000313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C: Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
C.1 Distribution PBDU 23" 1xMCB/10xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

2-3
Document number: 039158TOC.fm
Revision: B

Appendix D: BTS Breaker 50A 3-pole - Installation procedure


D-1
D.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
D.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
D.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
D.4 Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
D.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
D.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9
Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1)
- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
E.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
E.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
E.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
E.4 Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
E.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Appendix F: Battery Extension Kit - Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
F.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
F.2 Safety precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
F.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
F.4 Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
F.5 Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
F.5.1 Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
F.5.2 Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
F.5.3 Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Appendix G: FMP 16 Dummy Module - Installation procedure
G-1
G.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
G.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
G.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
G.4 Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6
G.5 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Appendix H: 19 Adaptor Kit Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-1
H.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-5
H.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6
H.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-6
H.4 Overview 19 adaptor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-7
H.4.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H-8
Appendix I: Battery Heater Kit
- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
I.1 Scope and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
I.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
I.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6
I.4 Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6

2-4

PODS 16.48-16000 1940 HEX


Document number: 039158TOC.fm
Revision: B

I.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6


Appendix J: Customer AC service outlet
- Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
J.1 Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
J.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
J.3 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
J.4 Overview AC outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
J.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6

2-5
Document number: 039158TOC.fm
Revision: B

2-6

PODS 16.48-16000 1940 HEX


Document number: 039158TOC.fm
Revision: B

Introduction to the manual

Introduction to the manual


Objectives and audience
This manual provides the user with the necessary information to understand how the Power Supply System
is made and functions, together with sufficient information to enable the user to safely install, commission,
maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be
used by professional and properly trained personnel selected by our customers. This manual assumes that
the technician has an understanding of power systems in general and understands safety procedures for
working around AC and DC voltage. The user of this document should be familiar with electronic circuitry
and wiring practices and have some expertise as an electronic or electromechanical technician.
The information contained herein was applicable at the time the manual was ready for printing. Power One
reserves the right to change specifications and designs without notice and without incurring obligation or
liability.
This manual is the work product of Power One and embodies confidential proprietary data in which Power
One retains all rights, including exclusive right of use, reproduction, distribution and sale. It is submitted
under a confidential relationship for a specific purpose, and the recipient agrees by accepting this work
product, not to supply or disclose any information regarding it to any unauthorized person.

Symbols and conventions


The following words and symbols found throughout this manual are meant to highlight particularly important
matters regarding specific information concerning the personnel, equipment or the process.
Note! The text set off in this manner present an important piece of information that is essential to
highlight.

CAUTION! The text set off in this manner provides warning notice that failure to
follow these directions can result in damage to equipment.

WARNING! THE TEXT SET OFF IN THIS MANNER PROVIDES WARNING NOTICE
THAT FAILURE TO FOLLOW THESE DIRECTIONS CAN RESULT IN BODILY HARM
OR LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO EQUIPMENT

Introduction to the manual


Document number: 028410.fm
Revision: B

3-1

Introduction to the manual

Abbreviations
The following abbreviations are used in this manual:
Abbreviation:
PPS
PODS
PMP
CMP
FMP
PCS
PCU
PCC
BCC
GMC
XCS
XR
XS
PPR
PBDU
PBC
PDU
PPRD
PPC
PBF
PCB
LVD
PLD
MCB
MCCB

Description:

P1 Power Supply System


P1 Outdoor System
P1 Modular Power
Convection-cooled Modular Power
Fan-cooled Modular Power
P1 Control and Supervision
P1 Control Unit
Prime Controller Card
Base Controller Card
Galero Modular Controller
Xscend Control System
Xscend Rectifier Module
Xscend Subrack (Rectifier shelf)
P1 Power Rack
P1 Battery Distribution Unit
P1 Battery Cabinet
P1 Distribution Unit
P1 Power Rack with DC Distribution
P1 Power Supply Cabinet
P1 Battery breaker Unit
Printed Circuit Board
Low voltage disconnection
Partial load disconnection
Miniature circuit breaker
Moulded case circuit breaker

Disclaimer
Power One is not responsible for system problems that are the result of installation or modification of the
instructions provided in this manual.

Questionnaire for feed-back


We urge you to complete and return the questionnaire on our web page at the following address:
http://www.power-one.com/feedback.html. Let us know your remarks on and suggested improvements to
this manual. We appreciate your comments in our achievement to improve our documentation.
If you have any problems with your system, e.g. you wonder how to install a new PMP rectifier or you have
some questions regarding messages or alarms on the control module, please see the Troubleshooting
section. If this does not solve your problem, please seek assistance at your local Power One office, or our
head office in Norway. These also concern any indistinctness in the manual.

3-2

PODS 16.48-16000 1940 HEX


Document number: 028410.fm
Revision: B

System description PODS 16.48-16000 1940 HEX

4 System description PODS 16.48-16000 1940 HEX

System description PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: A

4-1

System description PODS 16.48-16000 1940 HEX

4.1 General
PPS 16 modular DC power cabinet systems are designed to meet rigid telecom applications with very high
reliability and flexibility for future expansion. This cabinet power solution provides rectification, system
management and power distribution while maintaining high reliability and offering flexibility for future
expansion. The PPS 16 Power Systems are based on hot-swappable rectifier modules (FMP 16.48) with
output power available at 1600W per module. Systems are also based on fan cooling rectifiers and it is
therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the
air circulation.
System management is accomplished through messages and alarms displayed on the system controllers
(PCS) LCD screen and can also be displayed remotely via the PC-based PowCom1 software package.
Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases
rectifier modules are shipped separately.

Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be
connected to the RS232 contact.

1.

4-2

Communication program for remote control of the power supply system

PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

System description PODS 16.48-16000 1940 HEX

System drawing Outdoor cabinet

IOIOI

Figure 4-1

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N

D100

C120N

multi 9
1

D100

415V
10000

I ON

C120N

D100

415V
10000

I ON

415V
10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

System description PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

4-3

System description PODS 16.48-16000 1940 HEX

4.2 Technical Data


Figure 4-2

Principle drawing

PCS
DC distribution
FMP 16

AC

F
F

FMP 16

LVD

FB

BATT
Input:
Output:

Weight:
Cabinet dim.:

-voltage:
-current:
-voltage:
-current:
-power:
Rectifier:
Height:
Width:
Depth:

1x230V AC, 3x230V AC, 3x230/400V AC


<10A per module
48V DC nominal / 16000W
Max 32A per. module, 48V
Max 1600W pr. module.
2,2 kg
1940 mm
800 mm
850 mm

4.3 Operation
z

The PODS 16.48-16000 HEX is capable of delivering up to 16000W/48V steady state power. The
system is based up on hot swappable 48V/1600W rectifier modules, which are working in parallel
with automatic load sharing.

The cabinet system is normally configured with N+1 redundancy, with N as the number of rectifier
modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier
module. In normal operation the rectifier modules, FMP 16, are feeding the load and simultaneously
maintain the batteries in a fully charged state.

During a mains input power failure, the rectifiers are shut down and the batteries deliver the power
required by the load, for a certain backup time. If the battery voltage drops below the pre-set level,
the low voltage disconnection circuit (LVD) disconnects the batteries automatically to prevent battery
deep discharge prolonging the battery life. When the mains input power is restored, the rectifiers
start up automatically feeding the load, closes the LVD circuit and begin to recharge the batteries.

4-4

PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

System description PODS 16.48-16000 1940 HEX

The system performance is supervised and controlled from the supervisory unit, PCS. From this unit
output DC voltage is set, alarm thresholds, LVD circuit operation, temperature compensated battery
charging and battery testing. Any malfunction will be indicated by LED, text in the display and
operation of dry contacts. However, PCS is not a single point of failure. In the event of malfunction in
the PCS, basic tasks like feeding the load and charging batteries, will be maintained by the rectifier
modules directly at preset default values.

The alarm and threshold setting of the PPS 16 can be set locally by using the PCS push buttons and
menu guided operation or remotely, by using the PowComTM software.

4.4 System Description - PPS 16


This system consists of the following components:
Figure 4-3

Front view of PPS 16.48-16000

PCS
i

IOIOI
MERLIN GERIN

multi 9

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N
D100

415V
10000

C120N
D100

I ON

C120N
D100

415V
10000

I ON

I ON

I ON

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

I ON

I ON

Battery breakers

multi 9

C60N

C16

multi 9

415V
10000

I ON

MERLIN GERIN

C60N

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

I ON

I ON

I ON

I ON

I ON

Load breakers
power-one

power-one

FMP1648

FMP1648

FMP 16

4.4.1 FMP 16- Rectifier Module


The Power-One FMP 16 rectifier provides extremely reliable DC power in the highest possible density. The
module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up
to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load
sharing among rectifiers, and providing status and identification information to the controller.
Other features include 3xLED for rectifier status indication, thermal protection with de-rating and input over
voltage disconnection with automatic reset. The rectifier units are hot swappable and can be quickly
removed and replaced without disrupting the system or load.
See: 9 Product Description FMP 16 on page 9-1

4.4.2 PCS - Controller System


PCS - is a supervisory system with onboard software for monitoring and operation of power supply systems
based up on Power One rectifier modules. The design is based up on the philosophy of having one main
controller supervision for the entire power supply system, and use of distributed intelligence by local micro
controllers. A RS485 data bus takes care of internal communication between the various units. RS232 is
used for remote operation from a PC.
PowComTM software
PowComTM is a communications software package that allows the remote control of the power supply
system. The software uses a Windows based interface to allow access to the PCS. PowComTM is installed

System description PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

4-5

System description PODS 16.48-16000 1940 HEX

on a remote PC and can access the system by either direct connection, a LAN, or through a dial-up
modem.
Power-One Network interface (option)
The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely
accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and
enables the system to be accessed from any location. The protocol uses simple commands to configure
and control the system and relay the system status to the operator. Using this monitoring ability allows the
alarm messages to be transmitted to any location. The PNI also can be used in conjunction with
PowComTM software either through a modem or Ethernet connection.
See: 8 Operation / Product description PCS 2 on page 8-1

4.4.3 PPR 16/10 23- Subrack


PPR 16.48 is a subrack for modules in the FMP 16 series. The subrack has up to ten module positions
(max. 10xFMP 16 rectifiers.) The subrack has a connection for AC in, DC out and RS485 for
communication.
Modules are hot swappable under full load conditions.
See: 10 Product description PPR 16/10 23 Subrack on page 10-1

4.4.4 PBDU 23 - Distribution Module


DC distribution module with battery breakers, load breakers, shunt for measurement of current, alarm for
battery and load.
The distribution has no special operation other than switching the battery and load breakers on and off. All
DC distribution breakers are supervised by measuring voltage drop across each breaker.
Breakers that are not connected to any load, will not cause breaker alarm even if they are left open.
Note! Due to a small leakage current (2,5-3 mA) through the alarm circuit the voltage measured with a
DVM (Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier
voltage.
If a battery breaker fault occurs or is simulated it may take from 2-10 minutes before the fault is indicated,
depending on the battery condition.
The distribution module has common "+" and breakers in "-" leg. For more information see schematic
drawing in Appendix A.
See: 7 Product description PBDU 23
4.4.4.1

Low Voltage Disconnection (LVD)

The system is equipped with low voltage battery disconnection, which prevents the batteries from deep
discharging, thus prolonging the battery life. A disconnection requires a detected mains failure at the
supervision unit. Threshold for disconnection is available.
If disconnection occurs, the batteries will not supply power to the load until they have been recharged to set
voltage level, which can be adjusted by the user.
If disconnection occurs, the batteries will be reconnected when mains supply return.

4.4.5 Cabinet Door With Heat Exchanger (HEX)


The Cabinet door is a lockable door meant to protect the battery compartment from access of unauthorised
personnel. The system heat exchange unit is also mounted in the door.

4-6

PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

System description PODS 16.48-16000 1940 HEX

Figure 4-4

Cabinet door with HEX, inside view

Air out

Air in

Fan out

Fan in

Door Locking mechanism

The principle of the Heat Exchanger unit is to use cool ambient air to cool down the warm air inside the
cabinet, without any ambient air being pulled into the cabinet itself. Two fans pull outside and inside air
respectively through each side of the heat exchanger element. The fan speed is monitored by the controller
and is decided by a temperature sensor positioned by the internal air inlet (see Figure 4-4). Figure 4-5 on
page 4-8 shows external air flow, internal air flow and a principle drawing of the heat exchanger element.

System description PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

4-7

System description PODS 16.48-16000 1940 HEX

Figure 4-5

Heat Exchanger Airflow

HEX airflow internal. Seen from the side with side plate removed.

HEX unit ambient airflow

Cabinet door
with HEX unit

Rectifier shelf

Cabinet door with


HEX unit

Heat Exchanger Element Principle Drawing

Ambient air

HEX Outside air

HEX Inside air

Inside of Cabinet

Cold ambient air in


Warm air from the cabinet
into the HEX element

Warm air out

Cooled air back to the


cabinet
Heat energy from internal air to
external air through the HEX
element

4-8

PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

System description PODS 16.48-16000 1940 HEX

4.4.6 BTS Breaker 50A 3-pole (Option)


The BTS Breaker 50A 3-pole is an optional kit that allows extension of one extra load breaker. This breaker
can be mounted with 50A, 100A or 150A load capacity.
See: Appendix D: BTS Breaker 50A 3-pole - Installation procedure

4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option)


The surge arrestor kit is an optional unit that protects the system against lightning and transient
overvoltage. Each surge arrestor kit consists of three over voltage protector units, a spark gap plugged in
one holder and link cables.
Each surge arrestor unit has a display on the front that indicates if it is OK or has blown. Surge arrestor
units with a red display have blown and must be replaced. When fitted, each surge arrestor kit is located
below the mains input terminal blocks.
See: Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure

4.4.8 FMP 16 Dummy Module (Option)


The FMP 16 dummy module is an optional kit for covering empty module positions.
See: Appendix G: FMP 16 Dummy Module - Installation procedure

4.4.9 Battery extension kit (Option)


The battery extension is an optional kit that allows additional battery branches to be added to the power
system (extension of hold up time). The power system allows maximum 4 battery branches. The kit
includes one extra single pole battery breaker, battery shelf, battery cable, symmetry cable and signal cable
harness.
See: Appendix F: Battery Extension Kit - Installation Procedure

System description PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

4-9

System description PODS 16.48-16000 1940 HEX

4-10

PODS 16.48-16000 1940 HEX


Document number: 039159.fm
Revision: B

Safety

5 Safety

Safety
Document number: 028580.fm
Revision: A

5-1

Safety

5.1 Safety - Introduction


This document contains recommended safety guidelines for working with the equipment mentioned in this
documentation.
The instructions in the Customer Documentation must be followed by properly trained and authorized
personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the
instructions may be dangerous to personnel and equipment. Although the purpose of safety devices,
routines and regulations are meant to take care of the safety of the user, nobody is excused from using
common sense at all times when operating or otherwise handling the equipment.
These above mentioned safety guidelines include Warnings, Cautions and Notes.

5.2 Warnings
5.2.1 Lethal voltages
WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE
ATTEMPTING TO WORK ON THE SYSTEM WITH THE POWER CONNECTED.
POTENTIALLY LETHAL VOLTAGES ARE PRESENT WITHIN THIS SYSTEM.

WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES.


THERE MUST BE NO DAMAGE OF ANY KIND TO THE INSULATION OF THE
CABLES AND POINTS CARRYING LETHAL VOLTAGES SHOULD NOT BE
EXPOSED. FOR SAFETY REASONS, MAKE SURE THE CABLES ARE NOT
CONNECTED TO THE POWER SUPPLY WHEN ROUTING THEM.
All persons who perform any operations on this equipment should be advised of the potential dangers.
Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems
and equipment:
z

Potentially lethal voltages are present within the system. Ensure that all power supplies are
completely isolated by setting all power switches to OFF, disconnecting all relevant connectors and
removing all relevant breakers before attempting any maintenance work. Do not rely on switches
alone to isolate a power supply.

Potentially lethal voltages are present within this system. Ensure that high voltage safety
requirements are implemented before attempting to work on the system with power connected.

Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly.
Ensure that all ground connections are secure.

5-2

PODS 16.48-16000 1940 HEX


Document number: 028580.fm
Revision: B

Safety

5.2.2 Grounding
WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING
SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF
SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED.

WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A


CONDUCTOR SHOULD BE CONNECTED BETWEEN THE GROUNDING POINT IN
THE POSITIVE DC BUSBAR TO THE CABINET. THIS CONDUCTOR IS
CONNECTED ON ITS OWN TO THE EARTH BAR AND NOT SHARED WITH OTHER
SAFETY CONDUCTORS.

5.2.3 Precautions for lead acid batteries


WARNING! THIS EQUIPMENT USES LEAD ACID BATTERIES. WHEN HANDLING
THE BATTERIES FOLLOW THE INSTRUCTIONS DELIVERED WITH THE BATTERY
SET, AS THE FLUIDS CONTAINED WITHIN THESE BATTERIES ARE KNOWN TO
BE A HEALTH HAZARD. THE DISPOSAL OF LEAD ACID BATTERIES IS SUBJECT
TO LEGAL REQUIREMENTS FOR HAZARDOUS WASTE, THEREFORE DISPOSAL
LOCALLY MUST BE UNDERTAKEN SAFELY AND ACCORDING TO LOCAL
GUIDELINES.

Ensure the following guidelines are observed when dealing with equipment that may contain lead acid
batteries:
z

Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes.

Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with
the corrosive fluid must be avoided.

Neutralize any acid corrosion with copious amounts of a solution of baking soda and water, and then
wipe off all traces of soda.

If the lead acid battery is removed from the equipment, any exposed contact must be insulated prior
to disposal.

Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are
used when working with the batteries.

5.2.4 Weight
WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS
SUFFICIENTLY HEAVY TO REQUIRE HANDLING BY TWO OR MORE PEOPLE, OR
BY SPECIALISED LIFTING EQUIPMENT.

5.2.5 High temperatures


WARNING! CARE MUST BE TAKEN WHEN HANDLING THE EQUIPMENT AS
SOME OF IT MAY REACH HIGH TEMPERATURES.

Safety
Document number: 028580.fm
Revision: B

5-3

Safety

5.3 Cautions
5.3.1 Storage and transportation
CAUTION! During storage and transportation, the units must remain in their
original packages in order to avoid mechanical damage, maintain tracability, and
protect the units against electrostatic discharge.

5.3.2 Handling electrostatic sensitive devices


CAUTION! An electrostatic sensitive device is an electronic component that
may be permanently damaged by the discharge of electrostatic charges
encountered in routine handling, testing and transportation.

5.3.3 Traceability
CAUTION! Units are labelled with permanently attached product identification
labels. The labels are designed to be indelible throughout the life span of the
equipment, unless mistreated. Make sure that the product identification labels are
present on the equipment and are not subjected to unusual wear or mistreatment.

5.3.4 Breakers
CAUTION! Breakers should always be replaced with the same type in order to
avoid damage to system components.

5-4

PODS 16.48-16000 1940 HEX


Document number: 028580.fm
Revision: B

Installation guide

6 Installation guide

Installation guide
Document number: 039160.fm
Revision: A

6-1

Installation guide

6.1 Site requirements


The site should be suitable and ready for the power supply. If it is not or you are unsure about this, contact
your supervisor before continuing. Check, using a spirit level, that the site is level.

6.1.1 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY.

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

Note! This product is also designed for IT power distribution system with phase-to-phase voltage 230V.

WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS


INSTALLATION

6.2 Installation procedure


6.2.1 Unpacking
Check that the equipment received is in accordance with the packing list. Ensure that the cabinet and the
equipment have not been damaged during transportation.
Contact Power-One if any parts are missing or damaged, and correct any problems before continuing.

6.2.2 Tools and parts required


The following tools are required for a safe installation of the system:
z

Anti-static hand strap

Socket wrench, insulated

Screwdriver set, flat, insulated

Screwdriver set, torx, insulated

Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated

Torque spanner (for battery connection), insulated

M12 bolts for cabinet base


WARNING! USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS: SHAFTS
OF SCREWDRIVERS ETC.; SHOULD BE INSULATED.

6-2

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.

CAUTION! Installation in USA / Canada must conform with NEC/CEC


requirements.

Installation guide
Document number: 039160.fm
Revision: A

6-3

Installation guide

6.2.3 Cabinet mounting


The cabinet base needs to be fastened to the ground before lifting the cabinet into position.
WARNING!

THE CABINET IS HEAVY AND MUST BE HANDLED WITH DUE CARE

1. Step 1 in Figure 6-1 shows the location of the mounting holes for the base. M12 bolts are not
delivered with the cabinet and should be supplied by the customer.
2. Plinth directions: The sides of the plinth have a SIDE imprint. The SIDE imprint should face up from
the ground. Measurements of the plinth needed to prepare the site for mounting can be found in
Appendix A: Drawings.
3. After secure fastening of the cabinet base, lift the cabinet into position on the cabinet base (Step 2 in
Figure 6-1).
4. Step 3 in Figure 6-1 shows location of mounting holes for fastening the cabinet to the cabinet base.
Fasten the cabinet to the base with M10 bolts from inside the cabinet. M10 bolts are included.

6-4

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

Figure 6-1 Base and cabinet mounting (empty cabinet shown)

After mounting the cabinet base and cabinet, the four lifting brackets mounted on top of the system should
be removed. The bolt holding the bracket should also be mounted in the opposite direction to tighten the
holes and make the top spill-proof. Figure Figure 6-2 on page 6-6 shows the mounting of the brackets as
delivered, and also how the parts should be assembled after removing the brackets.
Follow these steps to correctly remove and reassemble the parts:
1. Remove the top lid from the cabinet for easy access.
2. Loosen and remove the top nut, then remove the washer and lifting bracket. Keep these parts for
possible future relocation of the cabinet.
Note! Only the nut and washer on top of the lifting bracket should be removed.
3. Enter the bolt in the opposite direction and fasten it from the inside with the remaining nut and
washer as shown in Figure 6-2 on page 6-6.
4. Slide the top lid back into position on top of the cabinet.

Installation guide
Document number: 039160.fm
Revision: A

6-5

Installation guide

Figure 6-2 Removal of lifting brackets

Lifting bracket as delivered

Location of lifting brackets.

Lifting bracket removed and bolt fastened in opposite


direction.

6-6

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

6.2.4 Grounding
Earth connection is essential BEFORE connecting supply.
1. Switch off all the breakers in the distribution panel.
2. Remove the roof by loosening the two screws at the front, which hold the top in position. Pull the top
forward and lift it up.
3. Connect the grounding cable between the grounding connector in the positive DC busbar of the
cabinet and the main grounding point at the back of the cabinet.
4. Check that the cables are secured tightly.

6.2.5 Cable sizes / location of external connections


Max. 16 mm2 (4AWG)
Max. 1,5 mm2 (14AWG)
Max. 16 mm2 / 35 mm2 (4AWG / 1AWG)
Max. 35 mm2 (1AWG) (50mm2 (0AWG) w / cable lug)

Mains:
Alarms:
Load:
Battery:

Alarm connections are located at the top right side of the system.
6.2.5.1

Cable entry box

The cable entry box delivered with the system (or additional cable entry kit option) should be mounted
before connecting mains and load. Remove or lift the cabinet top before installing the cable entry box. Once
a cable entry side is selected (rear, left or right) the panel in the selected position is replaced with the panel
in Figure 6-3. Default cable entry side is to the right, so no panel is mounted in this position. Do not remove
the panel during cable installation. Follow steps 1 through 5 below to complete installation of the cable entry
box.
Figure 6-3

Cable entry casing.(Shown without nipples)

Battery tube entry

Load/Battery/Signal
cable entries

Mains cable entry


1.

Select cable entry side and remove the cover where mounted. If rear or left cable entry is wanted,
the cover mounted here can be moved to the right side.

2.

Fasten the cable entry casing to the cabinet with three M4 screws.

Installation guide
Document number: 039160.fm
Revision: A

6-7

Installation guide

3.

Attach the casing to the cabinet.

4.

Mount the casing top and fasten with two M4 screws.

5.

Cable entry box installation is now complete, lower the cabinet top.

Figure 6-4 Mounting of Cable entry box


2

(Feed-through plate shown without nipples)


3

6-8

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

6.2.6 Connection of Mains


1. Ensure that mains input is turned off before connecting.
2. Enter the mains supply cable into the cabinet through the mains cable entry in the cable entry box.
3. See 6.2.5 Cable sizes / location of external connections on page 6-7 for reference. Push the cable to
the terminal block. Fasten the cables with the mounting screws.
4. When connecting mains to terminal blocks remove as little insulation from the cable as possible
before installing into terminal block, so that the jacket prevents a stranded conductor from coming
loose and touch any secondary conductive parts on the backplane.
Note! The insulation on the cable must have a clearing of minimum 1mm in the terminal blocks
5. The mains input terminal blocks can be connected to: 1x230V AC, 3x230V or 3x230/400V AC.
USA / Canada connections: 1x220V AC, 3x220V AC or 3x220/440V AC.
6. Use Torque table in the Maintenance and Troubleshooting chapter for the correct torque.
Figure 6-5 Mains Input Types
L1
L2
L3
N
PE

L1
L2
L3
PEN

L1
N
PE
1 wire system
TN-S
230V AC 1ph

4 wire system
TN-C/IT
230V AC 3ph

5 wire system
TN-S/TT
230/400V AC 3ph
Figure 6-6 Input Mains Terminal

1x3 phase 230V AC

N2

L1

N2

L1

N3

L2

4
5

N
L1

4
5

N3
L1

4
5

L2
L2

L1

L1

L2

L2

L2

L3

L2

L2

L3

L3

L3

L3

L3

L3

L3
L3
L2
L1

Document number: 039160.fm


Revision: A

L1

Installation guide

L2

1x230V AC (USA/Canada 1x220V AC):


3x230V AC (USA/Canada 3x220V AC):

L3

L1

Recommended mains fuse:


1x230V AC (USA/Canada 1x220V AC):

L3

L2

L1

VALVETRAB VALVETRAB VALVETRAB VALVETRAB


VAL-CP
VAL-CP
VAL-CP
VAL-CP
350-ST
350-ST
N/PE-350-ST 350-ST

L1
L1

2
2

N1
N1

Surge arrestor kit


(Optional)

2
2

L3

N
N

L2

PE

2
2

L1

VALVETRAB VALVETRAB VALVETRAB VALVETRAB


VAL-CP
VAL-CP
VAL-CP
VAL-CP
350-ST
350-ST
N/PE-350-ST 350-ST

PE

PE

Surge arrestor kit


(Optional)

PE

L3

PE

L2

PE

L1

PE

VALVETRAB VALVETRAB VALVETRAB VALVETRAB


VAL-CP
VAL-CP
VAL-CP
VAL-CP
350-ST
350-ST
N/PE-350-ST 350-ST

PE

PE

L2

Input mains terminals.


3x1 phase 230V AC

L3

Surge arrestor kit


(Optional)

3 phase 400V AC

Double pole 63A C-char (Mains 1)


(USA/Canada: Double pole 70A C-char)
Double pole 40A C-char (Mains 2)
Triple pole 32A C-char (Mains 1)
(USA/Canada: Triple pole 40A C-char)

6-9

Installation guide

3x230V AC (USA/Canada 3x220V AC):


3x400V AC (USA/Canada 3x440V AC):
3x400V AC (USA/Canada 3x440V AC):

6.2.6.1

Triple pole 25A C-char (Mains 2)


(USA/Canada: Triple pole 30A C-char)
Triple pole 25A C-char (Mains 1)
Triple pole 25A C-char (Mains 2)
(USA/Canada: Triple pole 30A C-char)

Mains Input Change

Attached to the cabinet behind the mains terminal blocks (the bags are attached to the cables between the
terminal blocks and the subrack) there are two plastic bags containing fishplates, high voltage stickers
(400VAC), labels for 3 phase 400 VAC and labels for 3 phase 230VAC for mains input change.
1. Connect according to Mains schematics in Appendix A
2. Attach labels accordingly on the cabinet chassis

6.2.7 Connection of Alarms


For remote supervision of the alarms, there are 4 potential free alarm contacts. Each alarm contact
represents different alarm conditions. Potential free alarm contacts for remote signalling at PBDU interface
are located in the right side of the distribution.
Note! Alarm contacts are shown in alarm position.
Figure 6-7 Connection of Alarms

IOIOI
MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9

C120N

D100

C120N

multi 9
1

D100

415V
10000

I ON

C120N

D100

415V
10000

I ON

415V
10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

Location of alarm connections

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

power-one

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

+
T
+
T
-

DI.1
DI.0
Red
Green
Blue
Red
Green
Blue

+
T
+
T
-

Red
Green
Blue
Red
Green
Blue

Alarm contacts
are shown in
alarm position

0V
+12V
DO.1
DO.0

6-10

6
5
4
3
2
1
6
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1

J2

Batt. sym. 4/
ext. analog

J1

Batt. sym.

J3

Digital input
(Door alarm)
Temp. Probe 4

J5
Temp. Probe 3

Temp. Probe 2

J4
Temp. Probe 1

Alarm 6

J9
Alarm 5

6
5
4
3
2
1

J8

3
2
1

J7

Alarm 2

3
2
1

J6

Alarm 1

4
3
2
1

J10

Digital output

Alarm 4

Alarm 3

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

Alarm cabling install:


The green connectors can be easily removed, if desired, for ease in installing the wires to the connector.
1.

Remove the green plug from each connector.

2.

Determine whether to reference normally closed or normally open with reference to common for
each alarm contact.

3.

Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper
ferrule if desired.

4.

Insert wire into the correct positions in the green connector and tighten screw to clamp wire into
connector.

5.

Route the wires through the cable area at the top left of the cabinet.

6.2.8 Connection of Symmetry Measurement and Temperature Sensor


The controller can supervise the symmetry of up to 4 battery branches. The drawing in Figure 6-8 on
page 6-12 shows how to connect the symmetry cables for 1 battery branch. Symmetry and temp. sensor
contacts are located in the right side of the distribution.
Note! The number of battery branches to be supervised has to be set in the controller in order to
activate the symmetry measurement.
It is also possible to add four temperature probes to the system for temperature compensated charging of
the battery bank. Fasten the temperature probe in the middle of the battery bank. The temperature probe
will measure the ambient temperature of a battery bank and the controller will adjust the float charge
according to the temperature compensation factor set in the controller. This factor must be set in the
controller according to the battery manufacturer recommendation.

Installation guide
Document number: 039160.fm
Revision: A

6-11

Installation guide

Figure 6-8 Connection of Symmetry (2 Block Measurement) and Temp. Sensor


-24V

0V
-12V

-24V

-24V
-36V
-48V

-24V

0V
-12V

-24V

-24V
-36V
-48V

+
T
+
T
-

Red
Green
Blue
Red
Green
Blue

+
T
+
T
-

Red
Green
Blue
Red
Green
Blue

6
5
4
3
2
1
6
5
4
3
2
1

6
5
4
3
2
1
6
5
4
3
2
1

Batt. sym. 4
J2

Batt. sym. 3

Batt. sym. 2
J1

Batt. sym. 1

Temp. Probe 4

J5
Temp. Probe 3

Temp. Probe 2

J4
Temp. Probe 1

T
Installing the Symmetry cabling and the battery temperature sensor:
1.

Remove the green plug from each connector.

2.

Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper
ferrule if desired.

3.

Insert wire into the correct positions in the green connector and tighten screw to clamp wire into
connector.

4.

The wires are wound up and pre-routed with fastener strips on the cabinet sidewall. The cables must
be unwound and connected to the battery pole according to the Figure 6-8 on page 6-12.

6.2.9 Battery connection


The battery cables of the system are, if ordered, pre-connected to the systems battery breakers. The +
cable of each battery string is connected to the positive bus bar of the system, and the - cable to the
negative battery breaker (separate for each string). Connect the other ends of the cables to the - and +
terminals of the batteries.
Note! Fasten the cable lugs pointing upwards, as there is not enough space in the cabinet for sideways
installation.

6-12

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Installation guide

6.2.9.1

Battery tube routing

The ventilation tube from the battery should be routed out of the cabinet through the cable entry casing as
shown in Figure 6-9. Pull the tube through the cable entry casing from the inside, and attach a tube
extension piece to avoid the tube sliding back inside the cabinet.
Note! Nipples on cable entry casing not shown in Figure 6-9.
Figure 6-9 Battery tube routing

6.2.10 DC connection
This section details how to connect external load to the DC load breakers.
Check that all the MCBs are in the OFF position.
1. Connect the negative (-) DC supply cable to the appropriate negative DC distribution MCB by
inserting the stripped cable in the opening on top of the MCB and tightening the screw.
2. Make sure the cable has the correct rating (i.e. thick enough) for the selected MCB.
3. Connect the positive (+) DC supply cable directly to the positive bus bar by inserting the stripped
cable to the hole on top of the screw connector so that the cable is behind the bus bar, and then
tightening the screw.
4. Start connecting the loads to the bus bar from the first connector on the left. Make sure the cable is
the correct rating (i.e. thick enough) for the load.
5. Check that all the cables are secured tightly to the connectors.
Use Table 13-1 in the Maintenance and troubleshooting chapter for the correct torque.

Installation guide
Document number: 039160.fm
Revision: A

6-13

Installation guide

6-14

PODS 16.48-16000 1940 HEX


Document number: 039160.fm
Revision: A

Commissioning

7 Commissioning

Commissioning
Document number: 036285.fm
Revision: A

7-1

Commissioning

7.1 Commissioning Overview


Before delivery the system was thoroughly inspected and tested. The following chapter is a guide to the
set-up and operation of the control functions of the system.
Note! Before starting commissioning read the product description for the individual components.

WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE


AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING. IT IS IMPORTANT
TO FOLLOW ALL SAFETY REGULATIONS.
If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a
lower level.

7.2 Tools and Test Equipment


7.2.1 Tools List
The essential commissioning tools are listed below:
z

A PC with PowCom installed (when controller is without LCD Display)

Anti-static hand strap

Socket wrench, insulated

Screwdriver set, flat, insulated

Screwdriver set, torx, insulated

Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated

Torque spanner (for battery connection), insulated

7.2.2 Test Equipment


z

Multimeter (3 Digit, 0 1% DC)

Load resistance, to connect 0-100% of total capacity to the system

7.3 Preparation
Check the installation to ensure the following:
z

Site is clean and safe

Grounding: The equipment is correctly grounded. The grounding cable size, color and routing
conform to the requirements

Power: The incoming mains AC power is available for this site. The site power switch and circuit
breakers are clearly labelled. The power cables are correctly terminated

7-2

PODS 16.48-16000 1940 HEX


Document number: 036285.fm
Revision: B

Commissioning

7.4 Commissioning procedure


1. Remove the covers and check that all connections are made according to the installation drawing.
Verify that all connections are properly tightened with sufficient torque.
2. Ensure load and battery MCB breakers are set to OFF position - ensuring the load and battery
strings are connected.
3. Ensure all rectifier modules are removed. If not, remove each one in turn starting from the rightmost
position.
4. Check the battery polarity with the Multimeter (3 Digit, 01% dc). Place the positive lead of the
meter to the plus-bus bar, and the negative lead to the battery breaker. The meter must now show a
positive voltage. If the voltage is negative, change over the connection of the blue and black battery cables
to the batteries.
5.

Turn on the AC mains voltage.

6. Measure the AC voltage on the AC terminal block, between phases and neutral. The correct value is
approximately 230V. If the value is different, check the AC connection.
7. Plug in all rectifier modules, starting from the leftmost position. Make sure to fasten the rectifiers
again. The rectifiers will turn on automatically.
8.

Set load breakers into "1" (ON) position.

9. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s)
(Normally not more than 5V DC)
10. Green LED on controller should blink for approximately 20 sec.
11. Output voltage will increase slowly to U1.
12. Turn battery breaker to "1" ("on") position.
13. If any alarms are present, they should be reset in accordance with "Show alarms" in product
description controller.
14. The system should now be without alarms.
15. Attach all the system covers in their correct places.
16. Check that all changes to drawings, if any have been completed.
17. Clean the site.
18. Fill in the commissioning record (see end of chapter).

Commissioning
Document number: 036285.fm
Revision: B

7-3

Commissioning

7.5 Test of output voltage


7.5.1 Float charge (U1)
Be sure that the controller is operating.
Connect load, approx. 50% of total capacity, to the system.
Check the voltage according to the battery manufactures requirements. If the batteries require other float
charging voltage, adjust the output voltage from the controller. (See product description controller)
If nothing else is required, use the following values:
Battery type

Float charge

Boost charge

Open lead-acid batteries

2,23V/Cell

2,33V/Cell

Sealed lead-acid batteries

2,27V/Cell

Table 7-1

7.5.2 Adjustment of float charge, U1


Output voltage is factory pre-set to: See Appendix B. The total voltage has to be in accordance to the
number of battery cells.
Please verify number of cells and the battery manufacturers requirements.
Adjust output voltage from the control unit.
Note! A sealing protects the potentiometer in the subrack. Do not break the seal.

7.5.3 Boost charging (U2) (if applicable)


Open lead-acid batteries.
Automatic boost charging - calculation of the time the battery voltage has been below certain levels.
Automatic activating of boost charging for this calculated time multiplied by a (boost) factor.
Activate boost charging from the "Set/select U1-U4" menu in the control unit.
Return to float charge manually by selecting "U1", or automatically after a pre-set time.
Sealed lead-acid batteries.
Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this type of
battery is used, the boost function should be disabled.
Boost charging figures
Observe and write down all of the boost charging figures.
Parameters to be read/set/adjusted from control unit or PC with PowCom1 installed.

1.

7-4

Communication program for remote control of the power supply system.

PODS 16.48-16000 1940 HEX


Document number: 036285.fm
Revision: B

Commissioning

7.6 Battery supervision


For systems with symmetry cables supplied:
Set number of battery strings according to number of battery strings in the system. The settings are to be
made in the control unit via a PC with PowCom installed or directly in the controller (if symmetry failure is
indicated).
The symmetry fault alarm is to be simulated by pulling out one symmetry cable from battery string. Measure
that setting to make sure that it is in accordance with battery manufacturer recommendations.
For systems with temp. probe cable supplied:
The temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that
the compensation level is according to the battery manufacturers requirements. (If no compensation level is
available from the battery manufacture, Power One recommends it to be set to 0,5V).

7.7 Battery test


The settings should be made according to the battery manufacturer requirements, but as a rule of thumb
the following settings can be used for standard VR lead batteries:
No. of test pr. year
U3 Test
End voltage b.test
Batt. test time
Ah limit for test

=
=
=
=
=

2
1,9 V/cell
1,94V/cell
40% of expected backup time
40% of nominal battery capacity

Parameters to be set/adjusted from the controller (Battery test menu) or "Supervision - Set parameters
menu in PowCom.

Commissioning
Document number: 036285.fm
Revision: B

7-5

Commissioning

7.8 Commissioning record


This is a step-by-step commissioning record for easy commissioning of Power-One Supply Systems. Do
not continue if any faults occur during this commissioning. The checkpoints are to be considered as a
minimum for commissioning of the system.
Checked

Result

(D)
1. Check that rack is levelled
2. Check that all breakers are turned to off
position and that no rectifiers are mounted in the
subrack(s).
3. Connect AC, and measure voltage on the
mains input connections in the cabinet, Is to be
230V AC (Measure 230V from phase to N when
400V mains input is used)
4. Mount rest of the rectifiers
5. After connection of battery, verify right polarity
by measuring the voltage drop across the battery
breakers (normally not more than 5V DC).
6. Check float charge, U1, and boost charge,
U2. Is to be adjusted according to the battery
manufacture requirements.
7. Check temperature compensation. Is to be
adjusted according to the battery manufacture
requirements.
Check temperature read off compare to the room
temperature.
8. Check symmetry measurement and set
number of battery strings according to actually
supervised battery strings in the system.

L1-N:..V AC
L2-N:...............V AC
L3-N:...............V AC

U1:..V DC
U2:.........V DC
Comp. :.V/10oC
Read off:oC

Number: .
Alarm limit:

9. Check alarm transmission by running an


alarm test.
Table 7-2

7-6

Commissioning record

PODS 16.48-16000 1940 HEX


Document number: 036285.fm
Revision: B

Operation / Product description PCS 2

8 Operation / Product description PCS 2

Operation / Product description PCS 2


Document number: 036777.fm
Revision: A

8-1

Operation / Product description PCS 2

8.1 General - Product description PCS 2


PCS 2 - Power One Control System is a supervisory system particularly designed for supervision of power
supply systems based up on Power One rectifier modules. The design is based up on the philosophy that
one main controller supervises the entire power supply system, and use of distributed intelligence by local
micro controllers. A RS485 data bus is used for internal communication between the various units. Very
simple internal colour labelled signal wiring using only two cables with RJ45 plugs in each end. RS232
serial interface for remote control from a PC with PowCom1 software.
For more detailed project specific information regarding system settings see Appendix B, Configuration.
This document specifies all available standard Power-One alarms, i.e. alarm 0 up to 23 and any customer
specific alarms (available as alarm 24 up to 39).
Note! Some of the alarms have Power-One standard limits and some of them have customer specific
adjusted limits.
A complete supervisory system do always consist of the following units:
PCS 2 - Main Controller
Master unit in the system communicating with all distributed micro controllers. Has an LCD display, menu
driven operation, visual alarm indication, RS232 contact for remote operation and RS 485 for internal
communication with 128 addresses (64 rectifier modules - and 64 other remote micro controllers).
Sockets for plug-in network interface. The Power-One Network Interface (PNI) is an optional component,
that allows the PCS unit to be remotely accessed via Ethernet and SNMP. The SNMP protocol allows
enhanced managing capabilities and enables the system to be accessed from any location. The protocol
uses simple commands to configure and control the system and relay the system status to the operator.
Using this monitoring ability allows the alarm messages to be transmitted to any location. The PNI also can
be used in conjunction with PowComTM software either through a modem or Ethernet connection.
PCS 2 - Alarm Interface board
The alarm interface board contains:
z

Input for current reading

Battery and load breaker monitoring

Battery temperature and battery symmetry measurement

Output for operating two individual contactors (LVD and PLD)

6 potential free alarm contacts.

Three analogue and two digital inputs for supervision of miscellaneous signals (ventilation, door
open or other).

8.2 Technical specification:


Input voltage:18-72V DC
Power consumption:Max 30W
Output:+/- 12V
1.

8-2

PowCom is a communications software package that allows the remote control of the system. The software uses a Windows
based interface to allow access to the PCS. PowCom is installed on a remote PC and can access the system by either direct
connection, a LAN, or through a dial-up modem.

PODS 16.48-16000 1940 HEX


Document number: 036777.fm
Revision: B

Operation / Product description PCS 2

InstrumentationThree LED's, Green - OK, Yellow - Message, Red - Alarm 2 x 20 character


alphanumeric LCD display with backlight. 5mm character height.
Interface:RS 232 for remote operation via PowCom. RS 485 for internal communication with
128 addresses (64 rectifier modules and 64 sub-controllers).
Basic functionsSimple manu-guided operation
User-selectable alarm parameters
40 event data logging
Internal clock with battery backup
Multiple language options
Temperature compensated charging
Boost charging, manually and automatic
Monthly data logging
LVD control of two contactors, voltage or time controlled
Battery test, manual or automatic with symmetry measurement
Alarm relay test
Adjustable battery current
Software controlled start up after mains outage and battery test
Optional Ethernet interface

WARNING! RISK OF EXPLOSION IF LITHIUM BATTERY IS REPLACED BY AN


INCORRECT TYPE. DISPOSE OF USED BATTERIES ACCORDING TO THE
MANUFACTURERS INSTRUCTIONS.

8.3 Operation - Introduction


The PCS 2 communicates through an alarm interface board and a backplane that connects to the rectifier
modules. There may be up to 64 rectifier modules and 63 Units on one serial channel.
The following section contains basic PCS 2 functions including starting the PCS 2, adding modules and
removing modules from the PCS 2 system.
Figure 8-1

PCS 2 LED's and control.

RS235 Interface Connection

Power LED (Green)


Warning LED (Yellow)
System Interface Controls
Alarm LED (Red)

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-3

Operation / Product description PCS 2

8.3.1

Starting the PCS 2

When power is applied to the PCS 2:


The PCS 2 will spend 20 seconds analyzing the system and testing all addresses for connected modules
and units. The green LED on the PCS 2 will blink (Figure 8-1). No alarms will be given during this period.
When the PCS 2 finds a module or a unit it will add it to the inventory. The module will remain in system
memory until a master reset or a reconfiguration is done.

8.3.2 Adding modules


When a rectifier is added to the system it will remain off until the PCS 2 detects it.
1.

The PCS 2 constantly scan for new modules and units, but it may take up to 5 minutes from a
module is inserted until it is registered. During this time the yellow warning LED on the module will
blink.

2. The PCS 2 will locate the module and the LED will stop blinking. The new module will give a current
sharing fault until its output voltage has been adjusted to the correct voltage. This may take additional time.
3. To shorten the time that is needed to find new modules the PCS 2 can be powered down and then
powered up. This will cause the system to search for new modules faster. This is only recommended as a
solution if it is important to shorten the time required for searching for new modules.

8.3.3 Removing modules


Physically removing a module from the system appears as a communication error on the PCS 2.
1.

To remove the error message use the Accept removed parts item on the Miscellaneous menu, or
press the reconfigure button in the Inventory window in PowCom.

2. Make sure that there are no communication faults caused by any failure before doing this as it will
cause all not communicating modules and units to be removed from the inventory.
3. This will make all communication faults disappear, but it will not fix any problems so it must only be
used if the communication fault is caused by the module or unit being intentionally removed.

8.4 PCS 2 Control


The control unit is equipped with four push buttons:
z

CANCEL - Used to go cancel the current selection on the menu hierarchy. When pressed the menu
will return to the previous screen.

UP ARROW - Used to go up in the menu hierarchy. select options and to adjust limits.

DOWN ARROW - Used to go down in the menu hierarchy. select options and to adjust limits.

RETURN - Used to select and confirm an option or to go down a level in the PCS 2 software
hierarchy.

To adjust the alarm limits, use the arrow keys to select "adjust limits". Press RETURN to enter the sub
menu, and RETURN once more to select "alarm limit". By using the arrow keys the various alarm limits can
be checked. For adjusting a limit: select the correct limit and press RETURN. The correct password must
be entered before a new value can be set.
The password is set to 1234 by default, but can be changed. Use the arrow keys to set and RETURN to
confirm each digit. CANCEL can be used to correct a digit. For more information on setting the system
password, see the section "Set New Password" in this chapter.

8-4

PODS 16.48-16000 1940 HEX


Document number: 036777.fm
Revision: B

Operation / Product description PCS 2

Adjust mode is indicated by a: (colon) in front of the value and a steady cursor behind. Use the arrow keys
to adjust the alarm limit and press RETURN to confirm the value or CANCEL to revert to the previous
value.
To return to main menu, press the CANCEL button. If the PCS 2 is left unattended the display will return to
main menu automatically after 2 minutes. The backlight will be turned off. after 2 minutes without any key
pressed. It will be turned back on by pressing any key.

8.4.1 PCS 2 Menus


The PCS 2 menu is divided into nine sections. Some of these sections are further divided into more menu
options. Figure 8-2 Menu tree shows the hierarchy tree. The following section contains descriptions of each
menu option.
8.4.1.1

Show voltage and currents

The default PCS 2 screen displays system voltage and battery current. Pressing the down arrow will
display system voltage and distribution current, pressing down once more will display system voltage and
rectifier current.
8.4.1.2

Show alarms

Displays the current alarm status. If there are several alarms use the arrow keys to scroll through the
alarms. Any new alarms or alarms that disappear will be added or taken off of the menu immediately.
Battery failure and symmetry failure alarms need to be reset manually by pressing RETURN at the show
alarms display.
8.4.1.3

Show messages

This item displays any messages. If there are several messages use the arrow keys to view the various
messages. New or disappearing messages will be updated immediately on the menu.
8.4.1.4

Show data

This menu displays information about: modules, units, temperature, and symmetry voltage. Information on
each of these menus is in the following section:
Module Data
This menu displays information from each rectifier module. Use the arrow keys to select the module
number.
Note! Rectifier modules are numbered from the top to bottom, and left to right.
Once the rectifier is selected on screen, Pressing RETURN will display a new menu with the following
information: communication status, module current, mean current, module temperature, module measured
voltage, Module OVP limit, alarm information, serial number and module software version number.
Module alarms are indicated by 3 letter flags. The meanings of these are as follows.
z

MNS - No input mains.

LOW - Input voltage low

OFF - No operation, caused by no mains or other failure

OVS - Overvoltage shutdown

FAN - Fan failure, will cause the module turn off (depending on type of module.)

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-5

Operation / Product description PCS 2

CUR - Current sharing fault. Current deviates too much from average

TMP - Temperature is high. This alarm must be reset manually

Unit Data
This menu shows information from the individual units. Units are I/O parts of the system like alarm interface
cards and distribution cards. The information available is communication status, serial number and unit
software version number.
Temperature
This menu displays the battery temperature.
Symmetry Voltage
The symmetry voltage for each battery branch is displayed.
8.4.1.5

Select / adjust U1 - U4

This menu is used to select one of the references for the 4 charge modes, U1 - float voltage, U2 - boost
voltage, U3 - battery test voltage, U4 - spare, and to adjust these references.

CAUTION! Always consult the battery user's guide before attempting to boost.
Improper settings can damage batteries.
The voltage references can be adjusted in steps of 0,1V.
U1 Normal. The U1 reference is shown, press RETURN to change U1 (The float charge voltage) and use
the arrow keys to adjust to the proper voltage.
U2 Boost. The U2 reference is shown, press RETURN to change U2 (The boost charge voltage).
U3 Test. The U3 reference is shown, press RETURN to change U3 (The Battery test voltage).
U4 Spare. The U4 reference is shown, press RETURN to change U4 (The spare voltage). The U4 setting is
normally not used in this system.
8.4.1.6

Adjust limits

The Adjust Limits menu allows the user to change and add limits to the system. The menu has the following
options: alarm limits, boost parameters, battery test, temperature compensation, battery current limit,
system specific limits and distribution current limits. Parameters can be set and adjusted by selecting the
different sub-menus.
Alarm limits.
This menu allows the following alarm limits to be changed:
z

High voltage

Low voltage

Over voltage shutdown limit

Low voltage disconnect

Partial low voltage disconnect limits

Load reconnect limit

High load limit

8-6

PODS 16.48-16000 1940 HEX


Document number: 036777.fm
Revision: B

Operation / Product description PCS 2

High temperature limit.

Change these limits using the arrow keys and RETURN to select. See Appendix B, Configuration for
default settings.
Boost parameters.
This menu contains the limits for boost charging control. See section "Boost charging" for more information.
Battery test.
This menu contains the limits for battery test. See section "Battery test" for more information.
Temperature comp.
This menu turn the temperature compensation on and off, and is used to set the compensation factor.
System specific limits
Only available for specific systems. For more information see Appendix B, Configuration
Batt. Cur. Limit.
This menu is used to toggle the battery current limiting on and off, and to set the current limit.
Dist. Current limits
This menu is used to toggle each distribution high current alarm limit on and off, and to set the current limit.
Note! Current limiting is not available on all systems.

8.4.1.7

Miscellaneous

The miscellaneous menu is used to set the date and time, change password, view version information,
initialize modem, show symmetry voltages and temperature.
Set time
The clock is shown. Press RETURN to adjust the clock. The clock has a battery back-up and will keep the
time even if the PCS 2 is turned off.
Relay test
Press RETURN to check the alarm relays. Use the arrow keys to select the relay to be activated.
Alarm blocking
Use Alarm Blocking to disable the relays during service. One alarm relay will normally be active as long as
the alarms are blocked.
Version
Show the PCS 2 software version, configuration number and serial number.
Set new password
Choose "set new password" from the "miscellaneous" menu. Press RETURN, enter the old password and
press RETURN. Enter the new password and confirm by pressing RETURN. To avoid mistyping the new
password has to be entered once more. Confirm by pressing RETURN.
Note! Be sure to note the new password. If the password is not known or access is denied, contact
Power-One technical support for assistance
Shunt A
Displays the current rating of the battery shunt. I.e. this parameter shows the value of current in the current/
voltage ratio of the shunt.

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-7

Operation / Product description PCS 2

Shunt mV
Displays the voltage drop of the battery shunt at rated current. I.e. this parameter shows the value of
voltage in the current/voltage ratio of the shunt.
Network address
Displays the network address for each module. Several PCS 2's may be connected together in a multidrop
RS232 network. The modules require a unique address between 2 and 255. This address may be set here.
Baud rate
Select the baud rate for the RS232 serial port of the PCS 2. Either 2400 or 9600.
Init modem
Press RETURN to send a string to initiate a modem. See the modem instructions to see if it requires
additional initialization to operate.
Accept removed parts
Removing a module or unit will appear to the PCS 2 as a communication error. If the module or unit is
intentionally removed then the PCS 2 will need to be informed. Select "YES" in the Accept Removed Parts
menu to inform the system that the module was removed.
Note! Do not accept removed parts if the there is an alarm on a module that has not been removed.
Reset to defaults
This command will reset the system to default values without deleting logged data or system information. It
is recommended to try this in stead of Master Reset if a reset is needed. After a reset always check all limits
and adjust them to the desired level.
Master reset
Will completely reset the PCS 2, deleting all stored data. If possible backup the data to a PC before doing a
master reset. After a reset always check all limits and adjust them to the desired level.

CAUTION! A Master Reset will delete all information from the system. Use the
master reset feature only as a last resort.
Language
This menu is used to choose the language used in the PCS 2 menus. Selecting a different language will
immediately change the menu language. The language menu is in English by default.

8-8

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Revision: B

Operation / Product description PCS 2

Figure 8-2

Menu tree

Show voltage/
Batt. current

Show voltage/
Distr. current

Show voltage/
Rect. current

Show alarms

Show alarms

Show messages

Show messages

Show data

Module data

Unit data

Symmetry
voltage 5

Temperature

Symmetry
voltage 6

Ext.
measurements

Symmetry
voltage 7

U1 normal voltage
Distr. current
Select/adjust
U1-U4

Symmetry
voltage 8

U2 boost voltage
Symmetry
voltage 1

Symmetry
voltage 9

U3 test voltage
Symmetry
voltage 2

Symmetry
voltage 10

U4 spare voltage
Symmetry
voltage 3

Symmetry
voltage 11

Reference
Symmetry
voltage 4

Adjust limits

Symmetry
voltage 12

Alarm limits

Low voltage

Boost parameters

set time

Miscellaneous

Relay test

Battery test

Temperature
comp.

Alarm blocking
Batt. current limit

Menu language
Version

Syst. specific
limits
Set new password

Shunt current

Shunt voltage

Network address

Symmetry limit

Enable temp.
comp.

Enable current
limit
Batt. current
limit

Comp. factor

Test end
voltage

Test duration

Ah- limit

Time of test
Distr. current lim.
No of tests/year

Boost time

High voltage

Boost interval

Overvolt.
Shutdown

Boost factor

Load/battery
disconnect

Boost t1

Partial
disconnect

Boost t2

Load/battery
reconnect

Autoboost
enable

High load

Temperature
alarm

No of batteries

Battery type

Baud rate

Init modem

Accept removed
parts

Reset to defaults

Master reset

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-9

Operation / Product description PCS 2

8.4.2 Connecting to PC
The PCS 2 to PC connection requires a RS232 cable to connect to the PCS 2 and to the PC serial port
connection.
Cable
The PC to PCS 2 connection is made using a modem, or directly with a null-modem cable (Figure 8-3
PCS 2 to PC cable). P1 and P2 are both 9-pin female D-sub plugs. P1 is to be connected to the PCS 2.
Figure 8-3

PCS 2 to PC cable
1

P1
Pin

P1

P2

Receive

Transmit

Transmit

Receive

0V (Ground)

0V (Ground)

Table 8-1

P2

RS232 Cable Pin Outs

1.

To connect the PCS 2 to the PC, locate the RS232 interface connector on the front of the PCS 2.

2.

Connect one end of the RS232 cable to the interface connection.

3.

Route the cable to the rear of the PC (the PC should be powered "Off").

4.

Connect the RS232 cable to the #1 serialport on the PC.

5.

Power up the PC and start the PowCom software.

6.

Choose "Communications" from the PowCom menu, and select "Port Setup" (Figure 8-4).

8-10

PODS 16.48-16000 1940 HEX


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Revision: B

Operation / Product description PCS 2

Figure 8-4

7.

Communications menu

Select "9600" baud rate from the Port Setup menu (Figure 8-5).

Figure 8-5

Port Setup Menu

8.

Select "OK"

9.

Choose "Direct Communication" from the Communications menu.

10. Enter Password (1234 by default).


11. See "Product description PowCom 3.17" for more information about using PowCom software

8.4.3 Boost charging


Open the "Select/Adjust" menu on the PCS 2.
Boost charging can be activated by three methods:
Manual boost charging - Choose "U2" in the reference menu for activating boost charging. (Return to
float charge manually by choosing "U1", or automatically after a pre-set time.)
Periodic boost charging - after a pre-set period boost charge will be automatically activated for a pre-set
time. Interval and boost time to be programmed (for example 4 hours every 3rd week).
Automatic boost charging - when during a mains failure the battery voltage falls below LEVEL t1 value, a
timer is started. When the mains return, the system will start an automatic boost. This will last a certain time
after the battery voltage reach LEVEL t2. This time will be multiplied with a factor, K. LEVEL t1, LEVEL t2
and the factor can all be set.

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-11

Operation / Product description PCS 2

Figure 8-6

Boost charging

Voltage (V)
Level t2

U1 (Float Charge)
Level t1

t1

Mains
Interrupt

t2=K x t1

Time (hour

Mains
Returns

The following values are adjustable for boost charging:


Boost voltage40 - 60 Volts
Boost time0 - 200 hours
Boost interval3 - 16 weeks
Boost factor1.0 - 16
Boost t140 - 60 Volts
Boost t240 - 60 Volts
Auto boost enablePassive - Active
Disabling Automatic Boost Charge:
Select "Boost parameters" in the "Adjust limits" menu. Push RETURN, up arrow and RETURN / then select
disable.
Note! Most manufactures of sealed lead acid batteries do not recommend boost charging. If this type of
battery is used, the boost function should be totally disabled by settings as follows:
Boost time = 0; U2= U1

8.4.4 Battery test


The following section contains the procedure for testing the batteries in the system.
Battery testing is activated by selecting U3 (in the "Choose reference" menu.)
Once selected the rectifier voltage will decrease to a pre-set value (U3, adjustable). The system will begin
logging battery voltage, battery current and Ah.
The battery test will automatically be interrupted and output rectifier voltage will raise to U1 level, if
programmed time, Ah or end voltage is reached during the test.
The test is considered as accepted if time or Ah causes the interruption.
If the battery voltage reaches programmed end voltage, the battery is considered as faulty, and an alarm
will be indicated and further automatic testing is interrupted.
Battery tests can also be set to activate automatically 1-4 times a year. In the "Choose Reference" menu,
select "Select no. of tests". The measurement will automatically be started at mains interruption but will not
be saved if duration of mains outage is less than 30 min.

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Operation / Product description PCS 2

Parameter Settings.
The parameter settings feature allows for the partial discharge of the batteries (approx. 30-40% of the
capacity) in order to test the batteries for errors. The settings should be done according the battery
manufacturer requirements, however, the following settings can be used for standard VR lead batteries:
U3 = 1,9 V/cell
End voltage = 1,94V/cell
Time = 100% of expected backup time
Ah = 40% of nominal battery capacity
Parameters to be set/adjusted from the "battery test" menu or PC with PowCom installed.
Battery test voltage:U3
Symmetry limit:
Test end voltage:
Test duration:
Ah limit:
Time of test:
No of test/year:
No of batteries:
Battery type:

0- 100 Volts
0.0 - 4.0 Volts
0-100 Volts
0- 20 hours
0- 50000 Ah
0 - 23 (0=midnight)
0-4
0 - 12
4 blocks, 23 cell-, 23 cell+, 3 blocks or 2 blocks

Number of batteries must be equal to number of symmetry measurements. If symmetry cables are not in
use, number of batteries must be set to 0 (zero).

8.4.5 Battery current limit


Battery current can be controlled by the PCS 2. The PCS 2 will adjust the rectifier current limit so that the
total rectifier current may not exceed "load current + desired battery current". Rapid changes in load current
will lead to changes in battery current, due to this variation the current can be above the limit for a limited
time.
In the PCS 2 you can set the battery current limit from 5A to 3000A.
There is also a function to enable or disable the function all together.

8.4.6 Temperature compensation


The supervisory module can adjust the charging voltage to compensate for temperatures above or below
20oC. T > 20oC lower charging voltage. T < 20oC higher charging voltage.
The temperature compensation function can be enabled and disabled and the level of compensation is
adjustable.

8.4.7 High load


The "High Load" alarm is activated when the load current exceeds the capacity of the installed modules
multiplied by the high load limit. This is an indication that the system requires increased rectifier capacity.

Operation / Product description PCS 2


Document number: 036777.fm
Revision: B

8-13

Operation / Product description PCS 2

8-14

PODS 16.48-16000 1940 HEX


Document number: 036777.fm
Revision: B

Product Description FMP 16

9 Product Description FMP 16

Product Description FMP 16


Document number: 036972.fm
Revision: A

9-1

Product Description FMP 16

9.1 General - Product description FMP 16


The FMP 16 rectifier module is a modular power supply designed for parallel operation and plug-in
installation in the PPS 16 systems. The rectifiers provides extremely reliable DC power in the highest
possible density. The module incorporates the latest in power monitoring solutions through an internal
microprocessor, giving up to the second updates to the system controller and adjacent rectifiers,
guaranteeing tightly controlled load sharing among rectifiers, and providing status and identification
information to the controller.
There is no cabling at the front of the unit. The AC input, DC output and signal cables are connected using
a backplane integral to the cabinet frame. A rectifier module can be plugged into, or unplugged from, the
support frame with no impact upon the other modules.
The rectifiers operate on the principle of active load sharing and can operate in parallel. They incorporate
"soft start" at the input and at the output, which avoids high incoming and outgoing currents. The output
voltage of the rectifier is automatically adjusted to the required voltage at installation by the controller.
The rectifiers in the system are controlled by the controller, see chapter 8, Operation / Product description
PCS 2.

9.2 Technical specification


9.2.1 Mains input
Input voltage:100-240V AC +/-15% single phase
Input current:<10A
Frequency:44-66 Hz
Power factor:> 0,98 typical

9.2.2 DC output
9.2.2.1

Mains input 185-250VAC

Voltage:45V DC - 56 V DC nominal
Current limit:32A
Power:1600W
Efficiency:>93%, typical 93,5% (at 40-90% load)
9.2.2.2

Mains input 95-185VAC

Voltage:45V DC - 56 V DC nominal
Current limit:27A
Power:675W
Efficiency:>88,5%, typical 90% (at 40-90% load)

9.2.3 Module dimensions


Height:177 mm
Width:51 mm
Depth:280 mm

9.2.4 Weight
Approximately 2,2 kg

9-2

PODS 16.48-16000 1940 HEX


Document number: 036972.fm
Revision: B

Product Description FMP 16

9.2.5 Other technical data


Protection:Short circuit proof
Automatic current limiting
Selective shut down of modules at excess output voltage
Thermal protection reduces the output power at environmental temp. above
maximum level. Shut down at >app 75oC with an automatic restart
Input over-voltage disconnection at >275VAC with automatic reset at <260VAC
Alarms:High output voltage / shut down
Low voltage / module failure
Each alarm has a common LED indicator on the front panel
Enclosure:IP 20
Storage:-60 to +85C
Cooling:Fan cooled (front to back), speed controlled and alarmed

9.3 Operation
FMP 16 has status indicators that is located on the front panel of the module. The output voltage is
adjusted from the controller.
There are three LEDs situated on the rectifier's front panel, which indicate the operating condition of the
rectifier.
Figure 9-1

Front view of FMP 16

FMP 16 has LED indicators as follows:


GREEN
Power ON
YELLOW
Thermal protection. Communication failure (flashing).
RED
Module failure / high output voltage / shutdown.

Product Description FMP 16


Document number: 036972.fm
Revision: B

9-3

Product Description FMP 16

9.4 Environment
The FMP 16 rectifiers meet the Environmental Standard requirements of:
ETS 300 019-1-3 class 3.2 / 3M1 for Operating (Stationary In-Use)
Temperature Range: -40C to +65C (up to 2000m) and -40C to +55C (above 2000m)

9.4.1 Storage
ETS 300 019-2-1 Class 1.2.

9.4.2 Transport
ETS 300 019-2-2 Class 2.3.

9.4.3 Operation
ETS 300 019-2-3 Class 3.2.

9.5 Safety
The FMP 16 rectifiers fulfil those international and national safety standards for these systems according to
grounding, fire protection and other safety matters as specified in the following standards:
EN60950 / IEC 60950
UL60950
CSA C22-2 No. 950

9.6 EMC
The rectifiers' EMC meets the requirements of:
EN61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4 and FCC Part 15 Class B

9-4

PODS 16.48-16000 1940 HEX


Document number: 036972.fm
Revision: B

Product description PPR 16/10 23 Subrack

10 Product description PPR 16/10 23 Subrack

Product description PPR 16/10 23 Subrack


Document number: 037680.fm
Revision: A

10-1

Product description PPR 16/10 23 Subrack

10.1 General - Product description PPR 16/10 23 Subrack


PPR 16/10 is a subrack/rectifier shelf for interconnecting of FMP 16 modules. Each subrack/rectifier shelf
has 10 module positions. Module positions are numbered from left to right viewed from the front.
Each subrack/rectifier shelf may be equipped according to present power requirements, and later be
completed with additional FMP 16 modules.
For high power requirements several subracks may be paralleled.
Figure 10-1

10-2

Front view of subrack / rectifier shelf

PODS 16.48-16000 1940 HEX


Document number: 037680.fm
Revision: B

Product description PPR 16/10 23 Subrack

10.2 Connections and functions


10.2.1 External connections
Description
PL4, PL6
PL3, PL5
PL12, PL11, PL14, PL13, PL16,
PL15, PL18, PL17, PL20, PL19
Bus bar connections

Function
RS 485 interface
Current share with other PPR 16/10
Input mains
DC output

10.2.2 Internal functions


DescriptionFunction
Dip switchesDip switches S12, S11, S14, S13, S16, S15, S18, S17, S20 and S19 are used for
addressing module positions and has to be set for controller supervision to function
properly. The switches can each address six bit binary addresses, which means
up to 64 modules on one COM channel (total 128 modules if both COM channels
are used). Addressing is performed by setting each of the six bits on each switch in
either an ON or OFF position. See Table 10-1 Addressing module positions.
Figure 10-2

PL12

Front and back view of the subrack

PL11

PL14

PL13

PL4 PL6
(Com)

PL16

PL15

PL18

PL17

PL20

PL19

PL3 PL5
(Curr)

Dip switch (S12 for module pos 1)

Negative (DC output)


Positive (DC output)

PE
N
L

Product description PPR 16/10 23 Subrack


Document number: 037680.fm
Revision: B

Input mains

10-3

Product description PPR 16/10 23 Subrack

10.3 Connections between subracks


Figure 10-3

Example shows three subracks connected together

Subrack 1

PL4 PL6

PL3 PL5

Subrack 2

PL4 PL6

PL3 PL5

Subrack 3

PL4 PL6

PL3 PL5

Curr. share signal between subracks


Com.signal between subracks

Communication signal
from alarm interface unit

Use cable marked with Brown 1 between PL6 in subrack 1 to PL4 in subrack 2.

Use cable marked with Orange 3 between PL5 in subrack 1 to PL3 in subrack 2.

Use cable marked with Brown 1 between PL6 in subrack 2 to PL4 in subrack 3.

Use cable marked with Orange 3 between PL5 in subrack 2 to PL3 in subrack 3.

Note! If the system consist of more subracks connect after the same method between subracks as
described over.

10-4

PODS 16.48-16000 1940 HEX


Document number: 037680.fm
Revision: B

Product description PPR 16/10 23 Subrack

10.4 Addressing module positions in subrack1, subrack2 etc.


Subrack no = Number of subrack
Module position= Numbered from bottom left position
Connection= Dip switch 1-6
Dip Switch = Indicates which dip switch to be turned ON.
Subrack no.

Module
position

Connection

Dip switch ON

1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5
5

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6

All off
1
2
1+2
3
1+3
2+3
1+2+3
4
1+4
2+4
1+2+4
3+4
1+3+4
2+3+4
1+2+3+4
5
1+5
2+5
1+2+5
3+5
1+3+5
2+3+5
1+2+3+5
4+5
1+4+5
2+4+5
1+2+4+5
3+4+5
1+3+4+5
2+3+4+5
1+2+3+4+5
6
1+6
2+6
1+2+6
3+6
1+3+6
2+3+6
1+2+3+6
4+6
1+4+6
2+4+6
1+2+4+6
3+4+6
1+3+4+6
2+3+4+6
1+2+3+4+6
5+6
1+5+6

Table 10-1 Addressing module positions

Product description PPR 16/10 23 Subrack


Document number: 037680.fm
Revision: B

10-5

Product description PPR 16/10 23 Subrack

6
6
6
6
6
6
6
6
6
6
7
7
7
7

51
52
53
54
55
56
57
58
59
60
61
62
63
64

1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6
1-6

2+5+6
1+2+5+6
3+5+6
1+3+5+6
2+3+5+6
1+2+3+5+6
4+5+6
1+4+5+6
2+4+5+6
1+2+4+5+6
3+4+5+6
1+3+4+5+6
2+3+4+5+6
1+2+3+4+5+6

Table 10-1 Addressing module positions

10-6

PODS 16.48-16000 1940 HEX


Document number: 037680.fm
Revision: B

Product description PBDU 4U/23

11 Product description PBDU 4U/23

Product description PBDU 4U/23


Document number: 038222.fm
Revision: A

11-1

Product description PBDU 4U/23

11.1 General - Product description PBDU 4U/23


Figure 11-1

PBDU 4U/23

The Power-One PBDU 4U/23 includes a complete system controller plus battery and load distribution in a
4U unit. The Compact Distribution is compatible with various types of Power-One subracks/rectifier
shelves, and may be configured for a variety of battery and load breaker selections.
The distribution unit is designed for switching the battery and load on and off. All DC distribution breakers
are supervised by measuring voltage drop across each breaker. MCB's (breakers), which are not
connected to any load, will not cause breaker alarm even if they are left open.
Due to small leakage current (2,5 - 3 mA) through the alarm circuit the voltage measured with a DVM
(Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage. If a battery
breaker fault occurs or is simulated it might take from 2 - 10 minutes before the fault is indicated, depending
on the battery condition.

11.2 Technical specifications


Voltage:48V DC nominal
Load breaker capacity: Max 20-26 x 18mm MG-breakers C-60N, low-ohmic connections
Battery breaker capacity: Max 2-6 x 27mm 1-pole MG-breakers
Dimensions:23/4U

11-2

PODS 16.48-16000 1940 HEX


Document number: 038222.fm
Revision: B

Product description PBDU 4U/23

11.3 Construction and functions


The distribution module has common "+" and all the MCB's connected in the "-" branch.
Figure 11-2

Typical distribution (Front view, controller unit removed)

0V Battery/Load

- Battery/Load
Figure 11-3

Distribution (Top view)


Protective Earth

+ Battery/Load
Connections

- Battery/load
Connections

11.4 Cable cross section output connections


Load connections:Cable area max. 16 mm2 / 35 mm2

Product description PBDU 4U/23


Document number: 038222.fm
Revision: B

11-3

Product description PBDU 4U/23

11.5 Installation
This section details how to connect the -48 V DC supply to the DC load.
Check that all the MCB breakers and the AC mains supply are in the OFF position.
Unscrew the cabinet's four top fixing screws and slide top-cover forward before lifting it up. Enter each load
cable in to the cabinet trough the inlet at the back of the cabinet.
Connect the negative (-) load DC supply cable to the appropriate negative DC distribution MCB by inserting
the stripped cable in the opening on top of the MCB and tightening the screw. Make sure the cable is the
correct rating (i.e. thick enough) for the selected MCB.
Connect the positive (+) load DC supply cable directly to the positive busbar by inserting the stripped cable
to the hole on top of the screw connector so that the cable is behind the busbar, and then tightening the
screw. Start connecting the loads to the busbar from the first connector on the left. Make sure, the cable is
the correct rating (i.e. thick enough) for the load.
Check, that all the cables are secured tightly to the connectors. Use Torque Table in the Maintenance and
troubleshooting chapter for the correct torque.

11.6 Commissioning PBDU


1. Switch on all MCB's in the distribution units.
2. Turn off one of the breakers and verify breaker alarm at controller.
3. Verify disappearing of alarm when turning the breaker on again.
4. Repeat the two above-mentioned steps for one MCB in each distribution module.

11.7 Maintenance
The distribution does not need any special maintenance except for ordinary cleaning.

11-4

PODS 16.48-16000 1940 HEX


Document number: 038222.fm
Revision: B

Product description PCS Alarm interface unit BM0685

12 Product description PCS Alarm interface unit BM0685

Product description PCS Alarm interface unit BM0685


Document number: 037901.fm
Revision: A

12-1

Product description PCS Alarm interface unit BM0685

12.1 General
PCS alarm interface unit consist of BM0685, which is an alarm board for Power One systems. The unit is
located on the right hand side of the distribution and is accessed from the top of the cabinet.

12.2 Technical data


Connection:Plugable terminal blocks max. 1,5mm2
z

2x input for battery current reading (common + or -). (J20, J21)

Breaker monitoring, battery and load. (J20, J21)

Control signal for individual operating LVD and PLD. (J20, J21)

6 x potential free change over contacts. (J6, J7, J8, J9)

4 x input for symmetry measurement. (J1, J2). Optionally symmetry input 4 may be used as 3 x
analogue inputs. (J2 pin 4-6).

4 x battery temp sensor. (J4, J5)

2 x digital inputs. (J3)

2 x digital output (J10)

RS485 interface for communication with plant controller PCS. (J24 and J25)

Up to four units per system.

12.2.1 Pin Configuration of J20 and J21


Plug J21

Pin
1
2
3
4
5
6

A
RECONN1
DISCONN1
DF/BFM1
BATTFUSE1
SHUNT1+
SHUNT1-

B
RECONN1
DISCONN1
DISTFUSE1
BATTFUSE2
SHUNT2+
SHUNT2-

Plug J20

Pin
1
2
3
4
5
6

A
RECONN1
DISCONN2
DF/BFM2
BATTFUSE3
SHUNT1+
SHUNT1-

B
RECONN1
DISCONN2
DISTFUSE1
BATTFUSE4
SHUNT2+
SHUNT2-

12-2

PODS 16.48-16000 1940 HEX


Document number: 037901.fm
Revision: B

Product description PCS Alarm interface unit BM0685

12.3 Remote alarms, symmetry measurement and temperature sensor


Alarms:Six dry alarm contacts for remote signalling (J6, J7, J8, J9).
Symmetry:Four separate inputs, each supervising battery branch symmetry voltage (J1, J2).
Temperature:Four connection points for connection of Power- One temperature sensor (J4, J5).

J7 J6

12 3 12 3
12 3 12 3

456 456

J3

J2 J1
J5 J4

12 12 3 12 3

BM0685 alarm board

456 456

Figure 12-1

+
T
+
T
-

DI.1
DI.0
Red
Green
Blue
Red
Green
Blue

+
T
+
T
-

Red
Green
Blue
Red
Green
Blue

12 34 12 3 12 3

J10

J9 J8

456 456

Alarm contacts
are shown in
alarm position

0V
+12V
DO.1
DO.0

6
5
4
3
2
1
6
5
4
3
2
1
2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1

J2

Batt. sym. 4/
ext. analog

J1

Batt. sym.

J3

Digital input
(Door alarm)
Temp. Probe 4

J5
Temp. Probe 3

Temp. Probe 2

J4
Temp. Probe 1

Alarm 6

J9
Alarm 5

6
5
4
3
2
1

J8

3
2
1

J7

Alarm 2

3
2
1

J6

Alarm 1

4
3
2
1

J10

Digital output

Alarm 4

Alarm 3

12.4 Maintenance
The PCS alarm interface unit does not need any special maintenance.

Product description PCS Alarm interface unit BM0685


Document number: 037901.fm
Revision: B

12-3

Product description PCS Alarm interface unit BM0685

12-4

PODS 16.48-16000 1940 HEX


Document number: 037901.fm
Revision: B

Maintenance and Troubleshooting

13 Maintenance and Troubleshooting

Maintenance and Troubleshooting


Document number: 037043.fm
Revision: A

13-1

Maintenance and Troubleshooting

13.1 Installing new modules


Install new modules according to following steps:
1.Plug in module
2.Ignore the module alarm caused current sharing
3.Wait. After 1 minute the yellow LED will start blinking. Wait for max. 4 min
4.Verify that yellow LED stops blinking
5.The alarm should now disappear
6.Tighten front screw

13.2 Troubleshooting
This guide is a step-by-step recommendation of what to do if problems occur. If first step of
recommendation do not solve the problem continue to the next one. If the problem cannot be solved please
call your local Power - One office for assistance.
Note! Before Commissioning and Maintenance are carried out a PC with PowCom installed must be
connected to the RS232 contact (Only applies when a controller without LCD display is in use).
Low system voltage:
z

Check the batteries with a voltmeter.

Check "low volt alarm" limit in controller / PowCom.

Check that the system is not in battery "test mode".

Check modules, mains and load situation compared to rectifier capacity.

High system voltage:


z

Check the batteries with a voltmeter.

Check "High volt alarm" limit in controller / PowCom.

Check that the system is not in "boost/Charge mode".

Load/battery disconnected:
z

Verify that input mains is present

Check system DC voltage with voltmeter

Compare system DC voltage with disconnected thresholds in controller / Powcom.

If breaker blows once more, there is either a too high load or short circuit at the system

Mains error:
z

Check mains breakers.

Check mains voltage.

Distribution breaker failure:


z

13-2

Localise the blown breaker.

PODS 16.48-16000 1940 HEX


Document number: 037043.fm
Revision: B

Maintenance and Troubleshooting

Check the equipment that is connected to the blown breaker (there may be a reason for this breaker
to blow) and reconnect it.

Battery failure:
z

Check the batteries.

Check the "battery test" parameters in controller / Powcom.

Module failure:
z

Localise the module.

Pull it out.

Wait for 30 sec. and reinstall it according to 13.1 Installing new modules.

Battery temp alarm:


z

Check the batteries.

Check ventilation.

Check reading in controller / Powcom.

Symmetry fault:
z

Reset the alarm.

Check connections according to number of batteries in controller / Powcom.

Check batteries.

Battery breaker failure:


z

Localise the breaker.

Check the batteries.

Reconnect the breaker.

High load:
z

Check load situation according to capacity of the system.

Increase number of modules.

Urgent module failure:


z

See "Module failure".

Communication failure:
z

Check if there is a module in current position.

See "module failure".

Temp probe failure:


z

Check connection on temp probe.

Replace temp probe.

Alarms are blocked (only with LCD display):


z

Check " miscellaneous" menu in controller.

Maintenance and Troubleshooting


Document number: 037043.fm
Revision: B

13-3

Maintenance and Troubleshooting

13.3 Maintenance
The connections on the terminal blocks and circuit breakers must be checked according to the 13.4 Torque
table minimum once a year.
Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed
to see any deviations.
In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air
inlets and outlets free from dust or other materials, which may prevent free air circulation through the
cubical.

13.4 Torque table


TYPE:

MODEL / DESCRIPTION:

TORQUE
(Nm):

TORQUE
(Inch LB):

Terminal block for rail

AKG 16mm2

2,5 Nm

22

Terminal block for rail

AKG 35mm2

3,5 Nm

31

Terminal block Weidemullers

WDU 4mm

0,6 Nm

Terminal block Weidemullers

WDU 10mm

2,0 Nm

18

Terminal block Weidemullers

WDU 16mm

3,0 Nm

27

Miniature circuit breaker

Siemens

2,5 Nm

22

Miniature circuit breaker

Merlin G

3,5 Nm

31

Miniature circuit breaker

ABB

2,0 Nm

18

Miniature circuit breaker

CBI HY-MAG

3,0 Nm

27

Moulded case circuit breaker

ABB 160A - S2

5,0 Nm

45

Moulded case circuit breaker

ABB 160A/250A - S3/S4

9,0 Nm

80

Moulded case circuit breaker

ABB 630A - S6

9,0 Nm

80

Moulded case circuit breaker

Terasaki - XS125CJ

9,0 Nm

80

Table 13-1 Torque

13-4

PODS 16.48-16000 1940 HEX


Document number: 037043.fm
Revision: B

Drawings

Appendix A: Drawings

Cabinet size: 800x850x1940mm (WxDxH)

Date:

17.02.05

Designer:

Scale:

SK

Cabinet layout
PODS 16.48-16000 1940 HEX

Drawings
Document number: Appendix A.fm
Revision: B

Page 01 of 01
ref:

039095

Rev:

A-1

Drawings

A.1 Cabinet Layout - 039095 - Rev: /

Cabinet size: 800x850x1940mm (WxDxH)

Date:

17.02.05

Designer:

Scale:

SK

Cabinet layout
PODS 16.48-16000 1940 HEX

A-2

Page 01 of 01
ref:

039095

Rev:

PODS 16.48-16000 1940 HEX


Document number: Appendix A.fm
Revision: B

Drawings

A.2 Installation drawing PODS 16.48-16000 1940 HEX - 039096 - Rev: /

BM0685
Connection of alarms and signals in the right hand side of the distribution
Table below shows different ways of battery symmetry cable connections depending on actual software (see controller software sheet)
Note: Check that symmetry and temp cables are correctly mounted
*Battery type: 2 blocks, ext sym
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V
(-)24V

0V
-24V

6
5
4
3
2
1
6
5
4
3
2
1

*Battery type: 2 blocks


(-)24V 6
5
4
(-)24V 3
2
1
(-)24V 6
5
4
(-)24V 3
2
1

Batt. sym. 12/ext. Analog


Batt. sym. 11/ext. Analog
Batt. sym. 10/ext. Analog
Batt. sym. 9
Batt. sym. 8
Batt. sym. 7
Batt. sym. 6
0V
Batt. sym. 5
-12V
Batt. sym. 4
-24V
Batt. sym. 3
Batt. sym. 2
-36V
Batt. sym. 1
-48V

J2

J1

Battery type: 3 blocks

Batt. sym. 4
/ext. analog
J2

(-)16V
(-)32V

Batt. sym. 3

(-)16V
(-)32V

Batt. sym. 2
J1

(-)16V
(-)32V
0V

Batt. sym. 1

(-)16V
(-)32V

-16V
-32V

-48V

6
5
4
3
2
1
6
5
4
3
2
1

Battery type: 4 blocks

J2
Batt. sym. 3

Batt. sym. 2
J1

0V
-12V

Batt. sym. 1

-24V
-36V

IOIOI
MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

MERLIN GERIN

multi 9
1

D100

C120N

multi 9
1

D100

415V
10000

I ON

C120N

D100

415V
10000

I ON

415V
10000

I ON

I ON

I ON

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

MERLIN GERIN

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

multi 9

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C60N

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

C16

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

230/400V
6000
3

I ON

I ON

power-one

MERLIN GERIN

multi 9

C60N

power-one

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

I ON

power-one

I ON

I ON

power-one

I ON

I ON

I ON

power-one

+
T
+
T
-

DI.1
DI.0
Red
Green
Blue
Red
Green
Blue

+
T
+
T
-

Red
Green
Blue
Red
Green
Blue

T
FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

FMP1648

Alarm contacts
are shown in
alarm position

0V
+12V
DO.1
DO.0

3 phase 400V AC

* Extended symmetry:
Check extended symmetry flag in config wizard - page 1

6
5
4
3
2
1
6
5
4
3
2
1

Batt. sym. 4
/ext. analog
J2
Batt. sym. 3

Batt. sym. 2
J1
Batt. sym. 1

-48V

-48V

C120N

(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V
(-)12V
(-)24V
(-)36V

Batt. sym. 4
/ext. analog

2
1
6
5
4
3
2
1
6
5
4
3
2
1
6
5
4
3
2
1

Digital input
Temp. Probe 4

J5
Temp. Probe 3

Temp. Probe 2

J4
Temp. Probe 1

Alarm 6

J9
Alarm 5

6
5
4
3
2
1

J8

3
2
1

J7

Alarm 2

3
2
1

J6

Alarm 1

4
3
2
1

J10

Digital output

Alarm 4

Alarm 3

Input mains terminals.


3x1 phase 230V AC 1x3 phase 230V AC

PE

PE

PE

PE

PE

PE

PE

PE

PE

2
2

N
N

2
2

N1
N1

2
2

L1
L1

N2

L1

N2

L1

N3

L2

4
5

N
L1

4
5

N3
L1

4
5

L2
L2

L1

L1

L2

L2

L2

L3

L2

L2

L3

L3

L3

L3

L3

L3

L3

Terminal blocks located in front on the right hand side


Date:

17.02.05

Designer:

Scale:

SK

Installation drawing
PODS 16.48-16000 1940 HEX

Drawings
Document number: Appendix A.fm
Revision: B

Page 01 of 01
ref:

039096

Rev:

A-3

Drawings

A.3 Block diagram PODS 16.48-16000 1940 HEX - 039097 - Rev: /


+
-

L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE

BM0666

Subrack

PL4 COM
8
PL6 COM
8
PL3 Current share
8
PL5 Current share

Subrack for
10xFMP 16

PCS
control unit

J1 Com 1

BM0686

RS 232

J7 Com PCS

J9 Ethernet

J4 Com PCS modem

1
2
3

+12V
Sys. voltage J8 Internal power
-12V

1
2

+ J2 Power
-

Optional plugable
PNI board

8
9

ETHERNET
MODEM/PC

Display board
PB2002B-P9

Distribution
0V

See schematic
diagram for
more details

LVD

- Battery 1

Fuse alarm
board

- Battery n

- Load 1
- Load n

BM0685

6
5
4
3
2
1

Batt. Sym./
Ext. analog

PTC 2

J2
Batt. sym

PTC 1

J1

Batt. sym

J3

Digital input

6
5
4
3
2
1

Temp. 4

J25 Com.

J5

J24 Com.

Temp. 3

1 0V
2 System voltage

J 23

1 +12V
2 0V
3 -12V

J 22 Electronic
J4
power

Temp. 2
Temp. 1

J21A Sh1 Dis1

J21B Sh2 Dis1


J9

J20A Sh1 Dis2

DI.1
DI.0

2
1

+12V
Sense
0V
+12V
Sense
0V

6
5
4
3
2
1

+12V
Sense
0V
+12V
Sense
0V

6
5
4
3
2
1
6
5
4
3
2
1

Alarm 6
Alarm 5

J20B Sh2 Dis2


1
2
3
4

BM0708

Pulse
Pulse
Fan 2 J3
+
AN Out 1

1 Pulse
2 Pulse
Fan 1 J2
3 +
4 AN Out 0
1 0V
2 Sense Temp 2 J5
3 +12V
1 0V
2 Sense Temp 1 J4
3 +12V

Heat exchanger
(HEX)
In

Blue
White
Red
Yellow

J8

J7

J6

Alarm 3

6
5
4
3
2
1

Alarm 2

3
2
1

Alarm 4

3
2
1

Alarm 1

J 10 Digital out

0V
+12V
DO.1
DO.0

4
3
2
1

Cabinet

Com.

NC
NO

Door switch

Out
Blue
White
Red
Yellow

Designer:

Date:

07.03.05

Scale:

KMH

Block diagram PODS 16.48-16000


1940 HEX

Page 1 of 1
ref:

Rev:

039097

A-4

PODS 16.48-16000 1940 HEX


Document number: Appendix A.fm
Revision: B

Drawings

A.4 Schematic diagram PBDU POD 16.48-16000 1940 HEX - 039098 Rev: /
0V Battery
0V Load
LVD

- Battery 1

Black

Red

+
- Battery n

- Load 1

- Load n

BM0700

J1

J3

B1-1
B2-1
B3-1
B4-1
B5-1
B6-1

MH1

F1-1
F2-1

MH7

Fn-1
Fn-1

1
2
3
4

J2

1
2

J4

BM0685
J2

6
5
4
3
2
1

Batt. Sym/
Ext. analog
Batt. sym

J1

Batt. sym

J3

Digital input

Temp. 4

J25 Com.

J5

J24 Com.

Temp. 3

1 0V
2 System voltage

J 23

1 +12V
2 0V
3 -12V

J 22 Electronic
J4
power

Temp. 2
Temp. 1

J21A Sh1 Dis1

J21B Sh2 Dis1


J9

J20A Sh1 Dis2

6
5
4
3
2
1
DI.1
DI.0

2
1

+12V
Sense
0V
+12V
Sense
0V

6
5
4
3
2
1

+12V
Sense
0V
+12V
Sense
0V

6
5
4
3
2
1
6
5
4
3
2
1

Alarm 6
Alarm 5

J20B Sh2 Dis2

BM0708

1
2
3
4

Pulse
Pulse
Fan 2 J3
+
AN Out 1

1
2
3
4

Pulse
Pulse
Fan 1 J2
+
AN Out 0

J8

J7

1 0V
2 Sense Temp 2 J5
3 +12V

J6

1 0V
2 Sense Temp 1 J4
3 +12V

Date:

Connect according
to Block diagram

07.03.05

Designer:

Alarm 3

6
5
4
3
2
1

Alarm 2

3
2
1

Alarm 1

3
2
1

Alarm 4

J 10 Digital out

KMH
Page 1 of 1
Powec ref:
ref:

Rev:

039098

Document number: Appendix A.fm


Revision: B

4
3
2
1

Scale:

Schematic diagram PBDU POD 16.4816000 1940 HEX

Drawings

0V
+12V
DO.1
DO.0

A-5

A-6

COM
PL4

L
N
PE

COM
PL6

L
N
PE

L
N

CURR
PL3

CURR
PL5

L
N
PE

L
N
PE

L
N
PE

Optional Battery
heater

PE

Optional AC outlet

L
N
PE

PE

PE

Main Subrack PPR 16 48/10

BM0666

L
N
PE

L
N

Designer:

SK

Scale:

Mains input
terminal blocks

Schematic diagram PPR 16.48/10


3 phase 400V AC

18.02.05

Date:

Optional Over
Voltage Protection

PE

Powec
ref: ref:

039109

Page 1 of 1

Rev:

Drawings

A.5 Schematic diagram PPR 16.48/10 3 Phase 400V AC - 039109 - Rev:


/

PODS 16.48-16000 1940 HEX

Document number: Appendix A.fm


Revision: B

COM
PL4

Drawings

Document number: Appendix A.fm


Revision: B

L
N
PE

COM
PL6

L
N
PE

L
N

CURR
PL3

CURR
PL5

L
N
PE

L
N
PE

L
N
PE

Optional Battery
heater

PE

Optional AC outlet

L
N
PE

PE

PE

Main Subrack PPR 16 48/10

BM0666

L
N
PE

L
N

Designer:

SK

Mains input
terminal blocks

Scale:

Schematic diagram PPR 16.48/10


1x3 phase 230V AC

18.02.05

Date:

Optional Over
Voltage Protection

PE

Powec
ref: ref:

039110

Page 1 of 1

Rev:

Drawings

A.6 Schematic diagram PPR 16.48/10 1x3 phase 230 V AC - 039110 Rev: /

A-7

A-8

COM
PL4

L
N
PE

COM
PL6

L
N
PE

L
N

CURR
PL3

Optional Battery
heater

PE

Optional AC outlet

L
N
PE

PE

PE

CURR
PL5

L
N
PE

L
N
PE

L
N
PE

Main Subrack PPR 16 48/10

BM0666

L
N
PE

L
N

Designer:

SK

Scale:

Mains input
terminal blocks

Schematic diagram PPR 16.48/10


3x1 phase 230V AC

18.02.05

Date:

Optional Over
Voltage Protection

PE

Powec
ref: ref:

039111

Page 1 of 1

Rev:

Drawings

A.7 Schematic diagram PPR 16.48/10 3x1 phase 230V AC - 039111 Rev: /

PODS 16.48-16000 1940 HEX

Document number: Appendix A.fm


Revision: B

Drawings

A.8 Footprint Outdoor Cabinet - 039423 - Rev:/

Drawings
Document number: Appendix A.fm
Revision: B

A-9

Drawings

A-10

PODS 16.48-16000 1940 HEX


Document number: Appendix A.fm
Revision: B

Configuration c-000313

Appendix B: Configuration c-000313

Configuration c-000313
Document number: 039418.fm
Revision: A

B-1

Configuration c-000313

B-2

PODS 16.48-16000 1940 HEX


Document number: 039418.fm
Revision: B

Configuration c-000313

Configuration c-000313
Document number: 039418.fm
Revision: B

B-3

Configuration c-000313

B-4

PODS 16.48-16000 1940 HEX


Document number: 039418.fm
Revision: B

Distribution

Appendix C: Distribution
C.1 Distribution PBDU 23" 1xMCB/10xMCB
Breaker 6A
FB1
FB2
FB3
FB4
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17

10A 16A 25A 32A 100A 150A Char.


X

X
X
X
X
X
X
X
X
X
X

Distribution
Document number: 039099.fm
Revision: A

PLD

Type of equipment
Battery 1

C
C
C
C
C
C
C
C
C
C

C-1

Distribution

+Connection
to chassis

0V, LOAD

0V, BATTERY

0V

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one

Power-one
Power-one

Power-one
Power-one

Power-one
Power-one

C-2

F1

Power-one

-LOAD

- Batt. 1

FB1

0V

F10

PODS 16.48-16000 1940 HEX


Document number: 039099.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

Appendix D: BTS Breaker 50A 3-pole - Installation procedure

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: A

D-1

BTS Breaker 50A 3-pole - Installation procedure

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

D-2

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Overview upgrade kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: B

D-3

BTS Breaker 50A 3-pole - Installation procedure

Amendment record:
Revision
(Issue)

Description

Author

Date

/
A
B
C

First issue
New revision
New revision
New revision

rjan Skauge
Hans A Dokka
Kai Morten Hennum
Hans A Dokka

06.10.04
12.05.05
13.05.05
18.05.05

Originated Hans A Dokka


Signed

D-4

Date 18.05.05

Approved Bjrn K Lindberg


Signed

Date 19.05.05

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

D.1 Scope and purpose


The purpose of this document is to give a clear instruction in the mounting of the 50A 3-pole load breaker
(upgrade kit) in the PPS 16.48-16000.
This breaker can be mounted with 50A, 100A or 150A load capacity.
WARNING! MAKE SURE THAT THE POWER TO THE SYSTEM IS
DISCONNECTED BEFORE STARTING THE INSTALLATION.

WARNING! THE READER MUST READ AND UNDERSTAND THE WARNINGS AND CAUTIONS
IN THIS MANUAL BEFORE STARTING.

Note! Use insulated tools with torque control.


Bits needed: Flat 0,8x4x150, 13mm metric socket and PZ2.
Figure D-1

Insulated tools.

D.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: B

D-5

BTS Breaker 50A 3-pole - Installation procedure

It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

D.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

D-6

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

D.4 Overview upgrade kit


Figure D-2

Overview

1.

MCB 3 pole C 50 C60N

2.

Connector 3 x MCB (150A) for front terminal

3.

Connector 2 x MCB (100A) for front terminal

4.

Connector 2xAKG for front terminal

5.

Front terminal for copper cables - FC Cu T2 95mm2 (2 pieces)

6.

Signal cable harness Plugable fuse alarm CD

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: B

D-7

BTS Breaker 50A 3-pole - Installation procedure

D.5 Mounting
Figure D-3

1.

Mounted 50A 3-pole breaker with 150A capacity

Mount the kit according to Figure D-3


1.For 50A load breaker capacity mount the "end case" side of the signal cable harness on the middle
position on top of the breaker. Mount the negative load cable to the same slot on the breaker.
2.For 100A load breaker capacity mount the Connector 2xMCB (100A) for front terminal on top of the
breaker. Mount the "end case" side of the signal cable harness on the left most position on top of
the breaker. Mount the negative load cable to the front terminal for copper cables.
3.For 150A load breaker capacity mount the Connector 3xMCB (150A) for front terminal on top of the
breaker. Mount the "end case" side of the signal cable harness on the left most position on top of
the breaker. Mount the negative load cable to the front terminal for copper cables.

2.

D-8

Tighten the upper screws on the breaker to a torque of 3,5 Nm.

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

D.6 Installation
Figure D-4

1.

Remove dummy breakers

Remove 3 dummy breakers by releasing the catch on top of the dummy breaker using a screw
driver.

Figure D-5

Dummy breaker removed

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: B

D-9

BTS Breaker 50A 3-pole - Installation procedure

2.

Dummy breakers removed.

Figure D-6

3.

Install new breaker

Unscrew the three lower screws to end positions.

4. Install the new load breaker in the open breaker slots. Tighten the lower screws in the breaker to a
torque of 3,5 Nm.

D-10

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

BTS Breaker 50A 3-pole - Installation procedure

Figure D-7

5.

Signal cable harness

Mount the alarm cable harness to the fuse alarm board as shown in Figure D-7.

Figure D-8

Front terminal for copper cables

6.

Mount the front terminal for copper cables to the common rail as shown in above figure.

7.

Tighten the front terminal for copper cables to the AKG with a torque of 3,5 Nm.

8.

Cables mounted to the front terminal for copper cables to be mounted with a torque of 7 Nm.

The installation procedure is now complete.

BTS Breaker 50A 3-pole - Installation procedure


Document number: 038316.fm
Revision: B

D-11

BTS Breaker 50A 3-pole - Installation procedure

D-12

PODS 16.48-16000 1940 HEX


Document number: 038316.fm
Revision: B

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Appendix E: Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1)


- Installation procedure

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure


Document number: 039247.fm
Revision: A

E-1

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

E-2

PODS 16.48-16000 1940 HEX


Document number: 039247.fm
Revision: B

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Overview Surge arrestor kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure


Document number: 039247.fm
Revision: B

E-3

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Amendment record:
Revision
(Issue)

Description

Author

/
A

First issue
New Revision

Kai Morten Hennum 21.03.05


Kai Morten Hennum 13.03.05

Originated Kai Morten

Date 21.03.05

Approved Tony Starr

Date

Date 13.05.05

Hennum
Signed

E-4

Signed

PODS 16.48-16000 1940 HEX


Document number: 039247.fm
Revision: B

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

E.1 Scope and purpose


The purpose of this document is to give clear instructions on the connection of the Surge arrestor kit for the
PODS 16.48-16000 1940 HEX.
To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
WARNING!

Figure E-1

USE INSULATED TOOLS.

Insulated tools.

E.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure


Document number: 039247.fm
Revision: B

E-5

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

E.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

E.4 Overview Surge arrestor kit


The surge arrestor kit protects the system against lightning and transient over voltage. Each surge arrestor
kit consists of a holder containing three over voltage protector units, one spark gap and a cable harness.

E-6

PODS 16.48-16000 1940 HEX


Document number: 039247.fm
Revision: B

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

E.5 Installation and connection


1.

Turn off the mains input voltage.

2.

Remove the end-stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the Surge arrestor kit for mains input 1 by snapping the surge arrestor holder on the DIN rail
next to the mains input terminal blocks on the left hand side. Mount the end stop below the Surge arrestor
kit in order to prevent the Surge arrestor kit from sliding on the DIN rail.
Figure E-2

Surge arrestor kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in
Appendix A: Drawings.
Note! Do not use Figure 2 as connection reference. It is important to always connect according to
Appendix A: Drawings schematics.
5.

Check the connections with a Digital Multi Meter.

6.

After checking the Surge arrestor kit connections, the mains input can be reconnected.

7. Each Surge arrestor module has a display on the front that indicates if it is OK or has blown. Red
displayed surge arrestors are blown and has to be replaced.

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) - Installation procedure


Document number: 039247.fm
Revision: B

E-7

Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) -

Installation procedure is now complete.

E-8

PODS 16.48-16000 1940 HEX


Document number: 039247.fm
Revision: B

Battery Extension Kit - Installation Procedure

Appendix F: Battery Extension Kit - Installation Procedure

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: A

F-1

Battery Extension Kit - Installation Procedure

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

F-2

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Overview Battery Extension Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-7
Installation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Installing the Battery Shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-8
Installing the battery breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Installing the battery cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-3

Battery Extension Kit - Installation Procedure

Amendment record:
Revision
(Issue)

Description

Author

/
A

First issue
Second issue

Kai Morten Hennum 21.03.05


Kai Morten Hennum 13.05.05

Originated Kai Morten

Date 21.03.05

Approved Tony Starr

Date

Date 13.05.05

Hennum
Signed

F-4

Signed

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

F.1 Scope and purpose


The purpose of this document is to give a clear instruction in the connection of the battery extension kit for
PODS 16.48-16000 1940 HEX.
To ensure the continues supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
WARNING!

Figure F-1

USE INSULATED TOOLS.

Insulated tools.

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-5

Battery Extension Kit - Installation Procedure

F.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

F.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

F-6

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

F.4 Overview Battery Extension Kit


The Battery Extension Kit allows you to install additional battery strings. Each Battery extension kit consists
of
1.

Battery shelf ODU.

2.

Battery cable 35mm2/M8/250cm STD.

3.

Magnetic C.B. 1 pole D100 C120N.

4.

Symmetry cable 260xm middle point measurement

5. Antistatic bag, signal cable harness, plugable fuse alarm and 4xscrew M6.0 x 12 Taptite pan elzn
TT3.

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-7

Battery Extension Kit - Installation Procedure

F.5 Installation and Connection


F.5.1 Installing the Battery Shelf
WARNING! THE TWO FRONT PLATES ARE MOUNTED FOR CABINET STABILITY. IF THESE
HAVE TO BE REMOVED DURING INSTALLATION, DO NOT REMOVE BOTH PLATES AT THE
SAME TIME.

Note! Front plate removal is only necessary when installing battery extension kit 4. However, removal of
the lower plate is recommended for easy access when installing batteries in the lower shelf.
Mount the battery shelf by sliding it into the punch outs on the back walls. The spacing between two battery
shelves should be 8U. This is measured from the mounting hole of the lower shelf to the mounting hole on
the shelf above. The shelves in Figure F-2 are shown transparent so that the mounting holes are visible.
Figure F-2

Additional Battery shelves

1
8
7
6
5
4
3
2
1

F-8

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

Fasten the battery shelf using the supplied screws in mounting holes on the battery shelf. Torque 3,5 Nm.

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-9

Battery Extension Kit - Installation Procedure

F.5.2 Installing the battery breaker


1. Remove two dummy breakers by releasing the catch on top of the dummy breaker by using a screw
driver.
Figure F-3

F-10

Remove dummy breakers

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

Figure F-4

Dummy breakers removed

Figure F-5

Replace the dummy breakers with supplied battery breaker

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-11

Battery Extension Kit - Installation Procedure

2. Mount the signal cable harness by sliding the cable lug onto the fuse alarm board in the position for
battery breakers. Battery breaker positions are labelled with a B on the print board.
Figure F-6

F-12

Signal cable harness mounted

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

F.5.3 Installing the battery cables


1. Mount the positive battery cable on the positive copper connection bar. Torque 13,5Nm.
Figure F-7

Positive battery cable mounted

2. Mount the negative battery cable directly on top of the new battery breaker.
3. Make sure the signal cable harness is mounted to the battery breaker together with the battery
cable. Torque 3,5Nm.

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-13

Battery Extension Kit - Installation Procedure

Figure F-8

Negative battery cable mounted

4. Strip the battery cables to the sheet metal bracket as shown in Figure F-9. Strip the rest of the
battery cables using the original battery cables as reference.
Figure F-9

5. Mount the supplied symmetry cable to the Alarm interface board located in the upper right corner of
the cabinet. Torque 0,6Nm.See Installation drawing in Appendix A for reference.
6. Strip the new symmetry cable using the original symmetry cable as reference.

F-14

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

Battery Extension Kit - Installation Procedure

Figure F-10

7. Check the connections with a Digital Multi Meter.


The installation procedure is now complete.

Battery Extension Kit - Installation Procedure


Document number: 039249.fm
Revision: B

F-15

Battery Extension Kit - Installation Procedure

F-16

PODS 16.48-16000 1940 HEX


Document number: 039249.fm
Revision: B

FMP 16 Dummy Module - Installation procedure

Appendix G: FMP 16 Dummy Module - Installation procedure

FMP 16 Dummy Module - Installation procedure


Document number: 038471.fm
Revision: A

G-1

FMP 16 Dummy Module - Installation procedure

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

G-2

PODS 16.48-16000 1940 HEX


Document number: 038471.fm
Revision: B

FMP 16 Dummy Module - Installation procedure

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Overview dummy module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

FMP 16 Dummy Module - Installation procedure


Document number: 038471.fm
Revision: B

G-3

FMP 16 Dummy Module - Installation procedure

Amendment record:
Revision
(Issue)

Description

Author

Date

First issue

rjan Skauge

05.11.04

Originated rjan Skauge


Signed

G-4

Date 11.11.04

Approved Erlend Breivik


Signed

Date 11.11.04

PODS 16.48-16000 1940 HEX


Document number: 038471.fm
Revision: B

FMP 16 Dummy Module - Installation procedure

G.1 Scope and purpose


The purpose of this document is to give a clear instruction in the mounting of the FMP 16 dummy module in
the PPS 16.48 system.
Note! Use insulated tools with torque control.
Bits needed: Philips 2.

G.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

G.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

FMP 16 Dummy Module - Installation procedure


Document number: 038471.fm
Revision: B

G-5

FMP 16 Dummy Module - Installation procedure

G.4 Overview dummy module


Figure G-1

Overview

1.

G-6

Dummy module FMP 16

PODS 16.48-16000 1940 HEX


Document number: 038471.fm
Revision: B

FMP 16 Dummy Module - Installation procedure

G.5 Mounting
Figure G-2

Mounting of dummy module

Remove all packaging supplied with the dummy module FMP 16


1.

Fix the dummy module FMP 16 with the screw in bottom left corner. See Figure G-2

2.

Installation procedure is now complete.

FMP 16 Dummy Module - Installation procedure


Document number: 038471.fm
Revision: B

G-7

FMP 16 Dummy Module - Installation procedure

G-8

PODS 16.48-16000 1940 HEX


Document number: 038471.fm
Revision: B

19 Adaptor Kit Installation Guide

Appendix H: 19 Adaptor Kit Installation Guide

19 Adaptor Kit Installation Guide


Document number: 039273.fm
Revision: A

H-1

19 Adaptor Kit Installation Guide

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

H-2

PODS 16.48-16000 1940 HEX


Document number: 039273.fm
Revision: B

19 Adaptor Kit Installation Guide

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Overview 19 adaptor kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
G.5.Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
G.5.1.Installing the battery shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8
G.5.2.Installing the battery breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9
G.5.3.Installing the battery cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

19 Adaptor Kit Installation Guide


Document number: 039273.fm
Revision: B

H-3

19 Adaptor Kit Installation Guide

Amendment record:
Revision
(Issue)

Description

Author

/
A

First issue
Second issue

Kai Morten Hennum 06.04.05


Kai Morten Hennum 13.05.05

Originated Kai Morten

Date 06.04.05

Approved Tony Starr

Date

Date 13.05.05

Hennum
Signed

H-4

Signed

PODS 16.48-16000 1940 HEX


Document number: 039273.fm
Revision: B

19 Adaptor Kit Installation Guide

H.1 Scope and purpose


The purpose of this document is to give a clear instruction in the connection of the 19 adaptor 8U kit for
PODS 16.48-16000 1940 HEX.
To ensure the continued supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT

The reader must READ AND UNDERSTAND all warnings and cautions in this manual before starting.
Note! Use insulated tools.

Figure H-1

Insulated tools.

19 Adaptor Kit Installation Guide


Document number: 039273.fm
Revision: B

H-5

19 Adaptor Kit Installation Guide

H.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

H.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

H-6

PODS 16.48-16000 1940 HEX


Document number: 039273.fm
Revision: B

19 Adaptor Kit Installation Guide

H.4 Overview 19 adaptor kit


The 19 adaptor 8U kit allows you to install up 8U of 19 equipment into the cabinet. The kit consists of
1.

2pcs Adaptor 8U 23 to 19 inch.

2.

2pcs Isolation for oval feed-through holes.

3.

8pcs Screw M6.0x12 mm Taptite pan elzn TT3.

Figure H-2

19 adaptor kit

19 Adaptor Kit Installation Guide


Document number: 039273.fm
Revision: B

H-7

19 Adaptor Kit Installation Guide

H.4.1 Installation
First enter the two adaptor pieces on each side of the cabinet as shown in Figure H-3 using the 8 screws.
Torque: 6 Nm.
Figure H-3

H-8

Mounted Adaptor pieces

PODS 16.48-16000 1940 HEX


Document number: 039273.fm
Revision: B

19 Adaptor Kit Installation Guide

Use the isolation pieces where cable feed-through is wanted to avoid damaging cables.
Figure H-4

Example of use of isolation

The installation procedure is now complete and 19 equipment can be mounted.

19 Adaptor Kit Installation Guide


Document number: 039273.fm
Revision: B

H-9

19 Adaptor Kit Installation Guide

H-10

PODS 16.48-16000 1940 HEX


Document number: 039273.fm
Revision: B

Battery Heater Kit - Installation procedure

Appendix I: Battery Heater Kit


- Installation procedure

Battery Heater Kit - Installation procedure


Document number: 039448.fm
Revision: A

I-1

Battery Heater Kit - Installation procedure

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

I-2

PODS 16.48-16000 1940 HEX


Document number: 039448.fm
Revision: B

Battery Heater Kit - Installation procedure

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6
Overview Battery Heater Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-6

Battery Heater Kit - Installation procedure


Document number: 039448.fm
Revision: B

I-3

Battery Heater Kit - Installation procedure

Amendment record:
Revision
(Issue)

Description

Author

First issue

Kai Morten Hennum 10.06.05

Originated Kai Morten

Date 10.06.05

Approved Lars Helge Stlen

Date

Date 10.06.05

Hennum
Signed

I-4

Signed

PODS 16.48-16000 1940 HEX


Document number: 039448.fm
Revision: B

Battery Heater Kit - Installation procedure

I.1

Scope and purpose

The purpose of this document is to give a clear instruction in the connection of a Battery Heater Kit for
PODS 16.48-16000 1940 cabinets.
To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT

The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.
WARNING!

Figure I-1

I.2

USE INSULATED TOOLS.

Insulated tools.

Safety precautions
WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

Battery Heater Kit - Installation procedure


Document number: 039448.fm
Revision: B

I-5

Battery Heater Kit - Installation procedure

I.3

AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

I.4

Overview Battery Heater Kit

The battery heater kit is designed to heat the batteries installed in the Power-One outdoor cabinets to avoid
batteries from freezing when operating in a cold environment.

I.5
1.

Installation and connection


Turn off the mains input voltage.

Note! Steps 2 to 6 below are described in Figure I-2 on page I-7.


2.

Locate the position for heater kit installation at the bottom right of the cabinet.

3.

Remove the lower three screws used to fasten the panel and battery shelf.

4.

Position the heater fan and fasten the shelf, panel and fan with three screws. (Torque: 6 Nm)

5. The heater fan is now mounted. Ensure that the heater thermostat is set to the 5 degrees default
value.
6. Mount the heater cable as shown. Insert the four strip fasteners into the holes along the shown cable
path, and use the four strips to fasten the cable.
Note! Some early versions of the outdoor cabinets do not have the cable entry opening shown in part 6
of Figure I-2 on page I-7. Alternative cable routing down and under the bracket is shown in
Figure I-3 on page I-8. In this case the easiest installation is to pull the cable through before
mounting the heater fan.

I-6

PODS 16.48-16000 1940 HEX


Document number: 039448.fm
Revision: B

Battery Heater Kit - Installation procedure

Figure I-2

Battery heater mounting

3. Removal of screws
2. Heater Fan location

4. Mounting Heater Fan

5. Heater Fan Mounted

Battery Heater Kit - Installation procedure


Document number: 039448.fm
Revision: B

6. Cable Path

I-7

Battery Heater Kit - Installation procedure

Figure I-3

7.

Alternative Cable Path

Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

Note! If a Surge arrestor kit is installed or is being installed, mount the battery heater circuit breakers
and ground terminal block below the surge arrestor as shown in Figure I-4.
8. Mount the circuit breaker and the ground terminal block by snapping them on the DIN rail below the
mains input terminal blocks or below the surge arrestor kit if installed (Torque: 1,5 Nm). Mount the end stop
below the kit in order to prevent the parts from sliding on the DIN rail (Torque: 1,5 Nm)..

I-8

PODS 16.48-16000 1940 HEX


Document number: 039448.fm
Revision: B

Battery Heater Kit - Installation procedure

Figure I-4

9.

Heater kit din rail parts mounted in the cabinet

Connect attached cables according to Schematic diagram PPR 16.48/10 in Appendix A.

10. Check the connections with a Digital Multi Meter.


11. After checking the battery heater kit connections the mains input can be reconnected.

Installation procedure is now complete.

Battery Heater Kit - Installation procedure


Document number: 039448.fm
Revision: B

I-9

Battery Heater Kit - Installation procedure

I-10

PODS 16.48-16000 1940 HEX


Document number: 039448.fm
Revision: B

Customer AC service outlet - Installation procedure

Appendix J: Customer AC service outlet


- Installation procedure

Customer AC service outlet - Installation procedure


Document number: 039248.fm
Revision: A

J-1

Customer AC service outlet - Installation procedure

Copyright Power One AS.


All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all examples
involving names of companies and products, are fictitious examples and are designed solely to illustrate the
use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not guarantee that this document is error-free. The information in this document is subject to change without notice.
Power One logo is a registered trademark of Power One Corporation.
All other trademarks or product names mentioned herein are trademarks of their respective owners.

J-2

PODS 16.48-16000 1940 HEX


Document number: 039248.fm
Revision: B

Customer AC service outlet - Installation procedure

Contents:
Scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Overview AC outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6

Customer AC service outlet - Installation procedure


Document number: 039248.fm
Revision: B

J-3

Customer AC service outlet - Installation procedure

Amendment record:
Revision
(Issue)

Description

Author

/
A
B

First issue
New Revision
New Revision

Kai Morten Hennum 21.03.05


Kai Morten Hennum 13.05.05
Kai Morten Hennum 30.05.05

Originated Kai Morten

Date 21.03.05

Approved Tony Starr

Date

Date 30.05.05

Hennum
Signed

J-4

Signed

PODS 16.48-16000 1940 HEX


Document number: 039248.fm
Revision: B

Customer AC service outlet - Installation procedure

J.1 Scope and purpose


The purpose of this document is to give a clear instruction in the connection of an AC service outlet for
PODS 16.48-16000 1940 HEX.
To ensure the continous supply of the loads from batteries, it is of vital importance to follow this procedure
closely.
WARNING! IF ONLINE ADJUSTMENTS HAS TO BE MADE, USE EXTREME
CAUTION AND RESPECT

The reader must READ AND UNDERSTAND allwarnings and cautions in this manual before starting.
WARNING!

Figure J-1

USE INSULATED TOOLS.

Insulated tools.

J.2 Safety precautions


WARNING! ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE
AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, WHO HAVE COMPLETED THE APPROVED TRAINING TO
THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION. IT IS
IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.

CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
It is possible to mechanically damage the units. To avoid this you must follow the approved assembly and
installation methods described in the relevant sections.

Customer AC service outlet - Installation procedure


Document number: 039248.fm
Revision: B

J-5

Customer AC service outlet - Installation procedure

J.3 AC Power source requirements


WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED
BEFORE CONNECTING MAINS SUPPLY

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE


SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.

WARNING! ONLY A QUALIFIED ELECTRICIAN MAY CARRY OUT THE


INSTALLATION.
Failure to observe the above warning may result in hazardous conditions on the system that may cause
injury to personnel.

J.4 Overview AC outlet


The AC service outlet is not provided by Power-One, but may be installed by the customer following these
instructions.

J.5 Installation and connection


1.

Turn off the mains input voltage.

2.

Remove the end stop piece mounted on the DIN rail below the mains terminal blocks.

3. Mount the AC service outlet by snapping the holder on the DIN rail below the mains input terminal
blocks. Mount the end stop below the AC outlet kit in order to prevent the parts from sliding on the DIN rail.
Note! If Surge arrestor kit or battery heater kit is installed, mount the AC outlet below the surge arrestor
and battery heater breakers as shown in Figure J-2.

J-6

PODS 16.48-16000 1940 HEX


Document number: 039248.fm
Revision: B

Customer AC service outlet - Installation procedure

Figure J-2

AC outlet kit mounted in the cabinet

4. Connect attached cables according to schematic diagram. See Schematic diagram PPR 16.48/10 in
Appendix A.
5.

Check the connections with a Digital Multi Meter.

6.

After checking the AC outlet kit connections the mains input can be reconnected.

Installation procedure is now complete.

Customer AC service outlet - Installation procedure


Document number: 039248.fm
Revision: B

J-7

Customer AC service outlet - Installation procedure

J-8

PODS 16.48-16000 1940 HEX


Document number: 039248.fm
Revision: B