Tools Battery Cabinet

ZXDU68 W201 (V5.0) DC Power System 1

Quick Installation Guide 2

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3

ZTE CORPORATION
Customer support hotline: +86-755-26771900 Doc um ent Number:
Technical support website: http://support.zte.com.cn Doc um ent Ve rsion:
E-mail: support@zte.com.cn 1.Door magnet 3. Anti-theft barrier strips for the batteries
2.Lead-acid Batteries 4.TEC air conditioners

Power Distribution Chassis

Contents
This installation manual describes how to install the ZXDU68 W201(V5.0) DC power
System Structure
system. The foll owing figu res in th is document a re u sed to p rovi de i nstructions on eq uipment in stallation 6
onl y. If a figur e is i nco nsistent with the real obj ect, the r eal object prevail s.
Safety Precautions
Equipment installation requirements Overview and dimensions
 To avoid damages to the equipment, never place heavy objects on top of the cabinet. Dimensions of power cabinet:780(height)x600(width)x500(depth)
Electrical connection requirements Dimensions of battery cabinet:118(height)x650(width)x650(depth) 1
 Never install or remove cables while the equipment is powered on. 5
Power cabinet battery cabinet
 Remove conductive objects, including watches, bracelets, and rings, before the
operation. Wear special gloves for protection against electrostatic hazards. 4 2
 Always use insulated tools when making electrical connections and always ensure that
all connection terminals and metal parts exposed are fully insulated.
Battery requirements 3
 Battery packs must use cascaded batteries of the same brand, model, specifications,
and delivery time.
118
 Battery packs must not be short-circuited in any way during the operation.
780
Cable requirements
 The cross-sectional area of a cable should match the load capacity. 1.SIU 4.Rectifiers ZXD3000 V5.5
2.CSU501B 5.PE
 Cable color selection should comply with the engineering specification of the local
3.AC distribution unit 6.DC distribution unit
electric network. When using cables in non-standard colors, use black cables and
mark them by using heat-shrinkable tubes or insulated tapes in corresponding colors
to avoid errors. AC Distribution Unit
 At a corner of a cabling route, the turning radius should be 10 times equal to or greater 500 The AC distribution unit supports three-phase 110 V input, single/two-phase 110 V input and
650
than the cable diameter to avoid short circuits due to the cable tube damage caused single-phase 220 V input. A 63A/4P small-sized circuit breaker with an adaptor terminal in the
by the turning radius being too small. After cables are laid out, check the connection 650 650 front is used for AC type adaptation.
ends and bends to guarantee that the cables and insulated sleeves are not damaged.
 Cables must be connected securely to avoid any short circuit or open circuit. Unit: mm three-phase 110 V AC Input
Document Acquisition 50Hz/60Hz
Structural component
 You can query and download related documents from http://support.zte.com.cn. The ZXDU68 W201 supports a maximum of four ZXD3000 (V5.5) rectifiers as follow L2 L2 PE L1 L2 L3
 If your username cannot be registered for document downloading, you can send an
email to doc@zte.com.cn. Power cabinet
 You can add ztedoc in WeChat to obtain document information and propose
suggestions. 6
1 AC input
Contentions 5 AC breaker AC SPD
Danger: indicates an imminently hazardous situation. Failure to comply will result in 2
death or serious personal injury. Jumpers
Warning: indicates a potentially hazardous situation. Failure to comply can result in
death or serious personal injury.
3
Caution: indicates a potentially hazardous situation. Failure to comply can result in
1. Working ground connection
moderate or minor personal injury.
4 terminal
Notice: indicates equipment or environment safety information. Failure to comply can 2. 3U power distribution
result in equipment damage, data loss, equipment performance degradation, subrack
environmental contamination, or other unpredictable results. 3. Power distribution chassis
4. Dust-proof net
Note: provides additional information about a topic. 5. Fan
6. Door

1 2
 (Optional) Two/single-phase AC input 110 V 1 Installing the Cabinet Installing the Power Cabinet on the Battery Cabinet
50Hz/60Hz Steps:
1. Pile the device cabinet on the top of
The cabinet installation includes two parts: installing the battery cabinet to the the battery cabinet.
L1 L1 L2 L2
ground, and piling the power cabinet on the battery cabinet.
PE L1 L2

Installing the Battery Cabinet

AC input Steps
1. Mark installation holes according to the dimensions of the installation holes at the bottom of the
AC breaker AC SPD cabinet

Front view

Jumpers Space requirements for door opening

Ensure that there is no obstacle within
(Optional) Single-phase input 220 V the range of 120°for door opening.
4-Φ14
Installation

650
590
50Hz/60Hz hole

L L N N
PE L N

AC input 2. Install M10 x 80 expansion bolts through the installation holes. 2. Fix four M8 bolts on the left and right sides of the top of the battery cabinet.
AC breaker AC SPD Vacuum
cleaner The bolts on both sides are fixed in the same way. The following figure illustrates
Percussion the installation of bolts on the right side as an example.
drill
Jumpers
Expansion Plain Spring
bolt washer washer

DC Distribution Unit
3. Place the cabinet in position, and place the expansion bolts into the installation
holes of the cabinet.
4. Use a level ruler to verify that the cabinet is level.
5. Install flat washers, spring washers and nuts in sequence, and tighten the nuts.

The horizontal deviation of the cabinet must be less than 3 mm. If the cabinet is
not level, add U-shape washers under the cabinet to make the cabinet level.
BATT2
BATT1

DC
SPD LLVD1 BLVD

3U Power Distribution Subrack

3. Install the two front covers on the bottom of the device cabinet and the battery cabinet with four
M5 anti-theft bolts and four M5 stainless pan-head screws.

UK35
connection
terminal
DC output breakers

3 4 5
4. Install the two rear covers on the bottom of the device cabinet and the battery cabinet with four 2 Connecting Supervision Signal Cables 2.3 Connecting Communication Cables
M5 anti-theft bolts and four M5 stainless pan-head screws.
Steps
The SIB board provides communication interfaces, relay interfaces, and environmental Refer to the following table and connect communication cables to communication ports
variable detection interfaces, as shown in the following figure. Cables must be connected to according to the supervision networking requirements.
corresponding signal ports based on alarm and monitoring requirements.

2.4 (Optional) Connecting Sensor Cables

 The flu xga te sensor, flood se nsor, and temperature sensor are all optional componen ts.
 The batter y te mp erature se nso r is a standar d compon ent. For the de taile d i nstallation
proced ure, refer to the se ction 7.

5. Install two cable troughs on the rear side of the cabinet. Remove the cover of each trough, and
fix installation screws on the inner side. Tidy up the cables between the power cabinet and the
battery cabinet, bind the cables inside the cable trough, and then secure the cover.
3 Installing Batteries
Two battery packs can be installed inside the Batteries
battery cabinet. Each battery pack comprises
of four 12 V/150 Ah (or below) batteries in
4x12 V
series.

 The positive terminal and negative terminal must not be wrongly connected.
2.1 Connecting Alarm Output Relay Cables  When connecting the cables to the screw terminals, route the cables backwards.
Steps
 There are battery detection cables (with a red label) on the battery air circuit
1. Refer to the “Alarm List” section in the ZXDU CSU501B(SV1.13.01) Centralized Supervision breakers. If a detection cable is disconnected, reinstall it on the battery air circuit
Unit User Guide for default alarms of output relays
breaker to avoid abnormal battery management.
2. Connect cables to the corresponding output relay interfaces in accordance with the alarm
requirements and the interface descriptions in the following table. Route cab les Close the The detection cable
No fron t wiring
backwa rds cover must be co nnecte d.

Steps:
1. Remove the battery anti-thief plate.

Lea ve one pla te of e ach ba ttery p ack uninstalled, and conne ct the entire battery
pack in series after step 2 is a ccomplished

3. (Optional) To change the alarm correspondence for the output relay, refer to the Product
Description to configure the attributes of the output relay when commissioning the system.

2.2 Connecting Alarm Input Relay Cables

Steps:
Connect alarm cables to the input relay interfaces in accordance with the following table.

6 7 8
2. Install batteries into the battery racks, and install the connection plates. 5 Connecting the Temperature Sensor of the TEC 7 Connecting AC Input Cables
Air Conditioner
Step:  Supported AC inputs include three-phase 110 V input, single/two-
Install the temperature sensor of the TEC air conditioner on the wider edges of the second and phase 110 V input and single-phase 220 V input.
third batteries, see the following figure.
 The ZXUD68 W201 system is configured with a three-phase 110 V AC
Battery cabinet Sensor of the air Sensor probe input by default.
conditioner  Jumpers are used on different positions of the AC input terminals to
switch between three input modes.

Steps
1. Set the power switch on the equipment (in the AC power distribution unit) to the ON position.
2. Set the AC input circuit breaker in the equipment to the OFF position.
3. Connect the AC input Protective Earth (PE), live wires (L1\L2\L2\L3)

Wide side of Attach the sensor to the center of Three-phase AC input 110 V (default)
the battery the wide side between the
second and third Bank.
Steps Before attaching the sensor,
1 clean the corresponding position L2 L2 PE L1 L2 L3
1. Install battery packs layer by layer from the bottom. 2 3 4 on the battery to prevent the
2. Set battery circuit breakers to OFF, and install the cables for the battery packs in OFF
Battery pa ck
sensor from falling off.
accordance with the following figure.

6 Connecting PE Cable AC breaker AC SPD

Step Jumpers
OFF Connect the PE cables to the PE busbar on site. AC input
GND
Power cabinet
Single/two-phase AC input 110 V (optional)
BATT1

BATT2

L2 L2 L2 L2
PE L1 L2

- +- +- +- + OFF

AC breaker AC SPD

AC input
- +- +- +- +
Jumpers

Single-phase AC input 220 V (optional)

4 Connecting the Battery Temperature Sensor Battery cabinet
Install the battery temperature sensor for each channel of battery packs in accordance with the L L N N
following table. PE L N

OFF

AC breaker AC SPD

Attach the sensor to the center of AC input

This plu g i s co nnecte d to
X5/X6. No operation is
requ ired on si te.
the wide side between the Jumpers
second and third bank
. Before attaching the sensor,
1 clean the corresponding position
on the battery to prevent the
Remove the
protective pap er. sensor from falling off.
2 Wide side of
the battery

Battery
temperature
sensor 1 2 3 4
Battery pa ck
9 10 11
 8 Connecting Working Grounding Cables/DC Example Example:
This example uses an air circuit breaker of three-phase AC input to show how to This example uses a terminal of three-phase AC input to show how to detect the
Output Cables detect a short circuit between AC input terminal L1 and L3. voltage between AC input and L3-PE.

 The ca pacity of each load must not e xceed the cap acity l imit of the
DC output air circuit breaker. Certain fre e capa city must be retaine d. PEL1 L2 L3
 PEL1 L2 L3 AC input
The load air circu it brea ker has th e de tection ca ble (with a red lab el). Load OFF
When connecting a DC output cable, you need to re install the ca ble detection OFF Three-phase 110 V/127 V
back to the corre spo nding load circuit bre aker. Failure to comply ca n cable AC input 110 V, 50 Hz/60 Hz
affe ct the load mana gement. (marked with
50 Hz/60 Hz
the DC output
 The detection cable of the load ai r circuit bre aker is marke d with the
circuit
DC output circuit number number)
Switch the
multimeter to the Red AC SPD
Red Black AC SPD buzzer mode. probe(+) Black
Steps probe(+) probe (-) probe (-)
1. Set the circuit breaker of the load to the OFF position.
2. Select load air circuit breakers in accordance with load importance and capacity 9.2 Detecting a Short Circuit in the DC Output Circuit
requirements.
To avoid damage the multimeter, you should not perform a live short circuit check. Switch the
3. Connect the - 48 V cables for electrical load to air circuit breakers for electrical load (to multimeter to the
the ends with detection cables). AC voltage
Steps
4. Connect the RTN cables for the electrical load to the GND grounding bar. mode.
1. Switch the multimeter to the buzzer mode.
DC Output
(LLVD1/BLVD) GND 2. Detect the short circuit on the DC output circuit. 9.4 Detecting the Terminal Voltage of the Battery Pack
For the detection contacts and detection criteria, refer to the following table:
OFF Steps
OFF ...... 1. Switch the multimeter to the DC voltage mode.
OFF
 If th e b uzzer doe s not soun d, there is nO short circuit fault. 2. Use the multimeter to detect the terminal voltage for each battery pack in
The electri cal conne ction is qu alifi ed. the power fuse base, and record the detected values in the table.
 If th e b uzzer sounds, there is a short circuit fault. The excess
Detection Contacts and Detection Criteria
Cables tha t ca use the short circuit should be re mo ved.

DC load Example DC Output  If the detected value

(LLVD1/BLVD) is a positive value, the
...... GND
battery cable is
OFF
connected correctly.
OFF  If the detected value
Switch the is a negative value,
multimeter to the battery cable is
the buzzer reversely connected.
Black Red
mode.
probe (-) probe(+)
9 Checking Electrical Connections A polar ity con nection fault may ca use da ma ge to th e d evice. If th ere is a polar ity conn ection
fault, unin stall a con nectio n p late in the battery pack, and install battery cables correctly.
Electrical connection must be checked after the cables are connected, to avoid 9.3 Detecting the AC Input Voltage
equipment damage caused by cable connection errors. Steps Example:
1. Set the AC input air circuit breaker in the equipment to the OFF position. This example detects the terminal voltage of battery pack 1.
9.1 Detecting Short Circuits at the AC Input Circuit 2. Set the power switch on the equipment (in the AC power distribution unit) to the ON
position.
To avoid damage the multimeter, you should not perform a live short circuit check. 3. Switch the multimeter to the AC voltage mode.
GND
4. Measure the AC input voltage at the AC input circuit breaker of the equipment.
Steps 5. After detection, set the power switch on the equipment to the OFF position.
OFF
1. Set the power switch on the equipment (in the AC power distribution unit) to the OFF For the detection contacts and detection criteria, refer to the following table:
OFF
position.
2. Set the AC input circuit breaker in the equipment to the ON position.
3. Switch the multimeter to the buzzer mode.
4. Detect the short circuit at the AC input circuit breaker of the equipment.  The neutral-to-ground voltage must be lower Red
probe(+) Switch the
5. After detection, set the AC input circuit breaker in the equipment to the OFF position. than 5 V. If the criterion is not satisfied, you
multimeter to
need to upgrade the electrical grid to reduce

BATT1

BATT2
the DC voltage
For the detection contacts and detection criteria, refer to the following table: the neutral-to-ground voltage difference.
mode.
 The phase-to-neutral voltage is in the range
Black
of 80 V to 305 V. If the criterion is not
probe (-)
satisfied, it is recommended to start the oil
 If the buzzer does not sound, there is no short circuit fault. engine.
The electrical connection is qualified.
 If the buzzer sounds, there is a short circuit fault. Find out
the fault and re-connect cables.

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 Appendix Installing a Rectifier A. Installing or Removing a CSU
1 2
Loosen the bolts Lift the handles CSU model: CSU501B
A. Installing or Removing a Rectifier Removing The CSU
 Remove the films at the ven tila tion ho les or other obje cts that pr eve nt the rectifier
from coolin g to avoid damagin g the rectifier due to poor heat dissipa tio n. Loosen th e Lift th e
 In h ot plug of the rectifie r, slow action is req uired to avoid sparking. bolts handle
 Poo r contact of the recti fier can result in equ ipment da ma ge and even fire due to
serious heat g eneration after the rectifier is powered on. Thus, the rectifier must be
installed prop erly.
 When pushing a rectifie r into a slo t, to a void da ma ge to the equipmen t, never press
the disp lay screen, keys, or indicators.
3 4 Tighten the bolts
Lon g-distance transpor t may make the interna l compone nts of the equipmen t loose. If
Push in the rectifier
there is an y unusual sound in the rectifier durin g the insta llation, contact the suppl ier to
repa ir the rectifie r or chang e for another one.
Pull outwards
Rectifier Installation Requirements
Rectifiers must be installed in the corresponding slots in a sequence from small to large.
If rectifiers are not sequentially installed, they must be evenly distributed in phases (L1,
L2, and L3) to ensure the three-phase balance of the AC circuit and good equipment
ventilation.
Removing a Rectifier
Loosen the bolts Lift the handles
Installing the CSU
CSU model: CSU501B
A fa ulty CSU must be quic kly repla ced with a proper one.
If th e CSU is faulty or removed, the mo nito ring on the ZXDU68 W201 system is
unavaila ble.
The fau lt or removal of the CSU has the following impact on the batteri es:
 When the batterie s discharge, the CS U cannot i mp lement po wer-off protection.
 The rectifiers can ou tpu t only 53.5 V DC power to charg e the battery packs (through the
trickling charg ing).
Pull out the rectifier
Lift th e
handle Push inwards

Fasten the
bolts

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