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History
Table of contents
History ............................................................................................................................. 3
Table of contents............................................................................................................. 4
List of figures ................................................................................................................... 4
List of tables .................................................................................................................... 4
List of terms .................................................................................................................... 5
Preface............................................................................................................................ 6
SPD Installation............................................................................................................... 7
SPD Replacement ......................................................................................................... 28
Appendix – Tools and Torques ...................................................................................... 30
List of figures
List of tables
List of terms
A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
CB Circuit Breaker
CSA Cross Section Area
CU Control unit
DC Direct current
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRX Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Internet Protocol
Preface
General Description
The Flexi Power Rectifier (FPRX, Artesyn part number AA25020L/ CS7000013.XX
for 6kW and AA27540L/ CS7000030.XX for 9kW) is a 6kW or 9kW output power
AC rectifier package respectively. The Surge Protective Device (SPD, Artesyn part
number AA25130L/ CS7000002.XX) is used to prevent damage to the FPRX
caused by high input voltages or surge.
The SPD consists of three- equivalent OVP modules used between live cables and
neutral cable from the AC mains; one OVP module used between the neutral cable
from the AC mains and the earth; and one remote signaling contact.
The SPDs mentioned in this manual are applicable for both 6kW and 9kW system.
The SPD used is the same as the one we used in FPRA.
Reference documents
The reference document of the SPD contains:
SPD Installation
The AC power supply must be switched off prior to accessing the AC cable.
Note: The 3-phase star AC connection with SPD is for illustration herein.
Refer to Appendix – Tools and Torques for each installation step.
SPD
DIN Rail
SPD ground B
clamp
AC ground A
clamp
PDA earth
cable
Strain-
relief
F
SPD sensor
C connection
Note: (1) The short link names listed herein are in accordance with the actual labels on the short links.
(2) The AC terminal block should be configured before the AC connection. User shall refer to section 3.4 in
Flexi Power Rectifier – Installation Manual (Artesyn file No.970-009475-0000) for more details
(3) Refer to Table 3 for the corresponding clamps.
L1 L2 L3 N
3Y
PE L1 L2 L3 N
AC Mains
1Φ
PE L N
AC mains
L1 L2 L3 N
3∆
PE L1 L2 L3
AC mains
2-phase
Verify the AC power system types in field, and make sure the corresponding
bridge configuration is used.
The AC terminal block has been already configured for 3-phase star AC mains
before the shipment. Therefore the user has to change the AC terminal block
configuration if required referring to the actual AC type in field.
There are three AC power system types (see above Figure), and thus three AC
configurations of the AC terminal block.
For 3-phase delta AC system, use three 2-pole bridges to short the terminals
1, 2 and 3, 4 and 5, 6 respectively on the AC terminal block (see Figure 4 )
For 3-phase star AC system, use one 3-pole bridges to short the terminals 1,
2, 3 on the AC terminal block (see Figure 5)
AC Terminal Block
SPD 1 2 3 4 5 6
L1 L2 L3 N
PE L1 L2 L3 N
AC Mains
Figure 6 – Schematic diagram of AC connection with the SPD – 3Y
The terminal marks in Figure 6 are in accordance with the actual SPD and AC
terminal block.
Use the indicated L or N short link for the AC mains as shown in Figure 6 and
Table 2 referring to labels on the short links.
The terminals 1, 2, 3 on the AC terminal block should be shorted before the
connection. Refer to section 3.4 in Flexi Power Rectifier – Installation Manual
(Artesyn file No.970-009475-0000) for details.
3.1.2.1 Detach the cable strain-relief from the chassis by loosening the screw ‘C’
in Figure 1 with a TORX screwdriver (T20). Insert the AC mains cable on
the strain relief.
3.1.2.2 Detach the AC ground clamp and SPD ground clamp from the chassis by
loosening the screws ‘A’ and B ‘with a TORX screwdriver (T20).
3.1.2.3 Assemble the Link cables, the AC mains cable, the SPD sensor cable
and the SPD grounding cable into the SPD. Refer to Figure 7
L1 for
three-
phase
L2 for SPD
three- sense
phase cable
L3 for
three-
phase
N for
three-
phase SPD
star ground
cable
Insert the connector of the SPD sense cable into the left two contacts; otherwise it
will block the SPD from installing onto the chassis.
.
Figure 8 AC Ground wire
3.1.2.5 Secure the SPD into the SPD DIN rail. Connect the SPD sense cable to
the stand by mating connector. Connect the SPD grounding cable into the
terminal lug. Refer to Figure 9.
SPD
Grounding
SPD cable
3.1.2.6 Connect the AC link cables from SPD to the Terminal Block. Assemble
the SPD grounding cable and the AC grounding cable into the PDA
N link
cable
SPD
grounding
cable lug
L3 link
cable
AC L2 link
grounding cable
cable lug
L1 link
cable
1. Use the appropriate L and N short link referring to the label on the short links and
the indications in Figure 6 and Table 2.
2. Rotate the N link cable 90 degrees either clockwise or counter clockwise when
assembling the SPD on the FPRA due to the smaller slot of the terminal block.
Refer to Figure 11 - Special Instruction for N Link Cable Installation
It is recommended to clamp the AC wire and the corresponding short link with one
overlapping on another.
Below figure shows the PDA rear layout after completing the 3-phase star AC
connection with the SPD.
SPD ground
N cable
L3 N short link
L2 L1 short link
L1 L2 short link
L3 short link
PE of AC
mains
SPD sense cable
Figure 12 – AC connection with the SPD - 3Y
3.1.1.1 After finishing and checking the AC cable installation, re-install the PDA rear
cover referring to ‘Flexi Power Rectifier – Installation Manual’ (Artesyn
File No. 970-009475-0000).
After installation of the SPD kit has been completed, the installer should check the
installation against the steps outlined within this document, supported by a multi-
meter to check for wiring continuity.
It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
AC Terminal Block
SPD
L1 L2 L3 N 1 2 3 4 5 6
SPD
ground
clamp
The terminal marks in Figure 13 are in accordance with the actual SPD and AC
terminal block.
Use the indicated L or N short link for the AC mains as shown in Figure 13 and
Table 2 referring to labels on the short links.
The terminals 1,2,3 and 4,5,6 on the AC terminal block should be shorted
respectively before the connection. Refer to section 3.4 in Flexi Power Rectifier –
Installation Manual (Artesyn file No.970-009475-0000) for details.
3.1.2.1 Perform the same procedure in preparing the AC cables SPD grounding
cables and the SPD sense cables.
3.1.2.2 As indicated in Figure 13 and Table 2, the SPD terminals L1, L2 and L3 have
to be paralleled by the SPD jumper (see Figure 14).
The user should loosen the three terminal clamps of L1, L2 and L3, and hold the
SPD upside down. Thus the SPD jumper can be easily inserted into the parallel
clamps.
The jumper should be fixed in the SPD together with the live cables of the AC
mains and L line short links.
SPD jumper
3.1.2.3 Connect the live cable from the AC mains and L2 short link into terminal ‘L2’
on the SPD referring to Figure 13 and Table 2, tightening the top screw to
4.5Nm with a cross screwdriver (see Figure 15).
N for single
SPD
phase
ground
link
L3 for
three-
SPD
phase
ground
clamp
L2 for
three-
phase
AC ground
clamp
L1 for
three-
phase
3.1.2.4 After finishing and checking the AC cable installation, re-install the PDA rear
cover referring to section 3.4 in ‘Flexi Power Rectifier – Installation Manual’
(Artesyn File No. 970-009475-0000).
SPD ground
clamp
L3 for three-phase
AC ground
clamp L2 for three-phase
L1 for three-phase
3.1.3.1 Perform the same procedure in preparing the AC cables SPD grounding
cables and the SPD sense cables
3.1.3.2 As indicated in Figure 13 and Table 2, the SPD terminals L1, L2 and L3 have
to be paralleled by the SPD jumper (see Figure 14).
3.1.3.3 Connect the AC link cables and the AC cables to the SPD and to terminal
block. Refer to Figure 17)
SPD
ground N for single
link phase
L3 for
SPD three-
ground phase
clamp
L2 for
three-
AC ground phase
clamp
L1 for
three-
phase
After installation of the SPD kit has been completed, the installer should check
the installation against the steps outlined within this document, supported by a
multi-meter to check for wiring continuity.
It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
The terminal marks in Figure 16 are in accordance with the actual SPD and AC
terminal block.
Refer to Single-phase (1Φ) AC connection for details.
AC Terminal Block
SPD 1 2 3 4 5 6
L1 L2 L3 N
L3 for three-phase
L2 for three-phase
AC ground
clamp L1 for three-phase
PE L1 L2 L3
SPD ground
AC mains clamp
The terminal marks in Figure 18 are in accordance with the actual SPD and AC
terminal block.
Use the indicated L or N short link for the AC mains as shown in Figure 18 and
Table 2 referring to labels on the short links.
The terminals 1,2 and 3,4 and 5,6 on the AC terminal block should be shorted
respectively before the connection. Refer to section 3.4 in Flexi Power Rectifier –
Installation Manual (Artesyn file No.970-009475-0000) for details.
3.1.4.1 Perform the same procedure in preparing the AC cables SPD grounding
cables and the SPD sense cables
3.1.4.2 Configure the terminal block as per Figure 4
3.1.4.3 Assemble the AC cables, AC link cables into the SPD.
3.1.4.4 Assemble the AC link cables into the Terminal Block.
N connected to
Ground
3.1.4.5 Connect the L1, L2 and L3 short links to terminals ‘5’, ‘3’, ‘1’ on the AC
terminal block respectively referring to Figure 18 and Table 2, tightening the
top screws to 1.5Nm with a Cross screwdriver (see Figure 20).
L3 short
link
L2 short
link
L1 short
link
SPD
Sense
Cable
Figure 20 – Connecting the AC terminal block – 3Δ
3.1.4.6 Figure 21 shows the PDA rear internal layout after completing the 3-phase
delta AC connection with the SPD.
SPD
ground
link
L3 for
three-
SPD phase
ground
clamp
L2 for
three-
phase
AC ground
clamp
L1 for
three-
phase
3.1.4.7 After finishing and checking the AC cable installation, replace the PDA rear
cover referring to section 3.4 in ‘Flexi Power Rectifier – Installation Manual’
(Artesyn File No. 970-009475-0000).
After installation of the SPD kit has been completed, the installer should check
the installation against the steps outlined within this document, supported by a
multi-meter to check for wiring continuity.
It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
SPD Replacement
Warning: The AC power supply must be switched off prior to any access of the SPD.
The AC power supply must be switched off prior to accessing the SPD.
Ask Artesyn Embedded Technologies service people for help if any OVP module
has been damaged. Artesyn will provide the user with the individual OVP module
but not the whole SPD for replacement.
The user shall only replace the damaged OVP module of the SPD without
removing the whole SPD from the PDA chassis.
The user can verify which OVP module has been damaged Referring to section
Properties.
3.2.1 Hold the two sides of the damaged OVP module and pull it out from the
SPD base (see Figure 22)
3.2.2 The SPD base is designed such that the two kinds of OVP modules
cannot be mixed when installing onto it (see Figure 23).
3.2.3 Fit the new module into its position on the SPD base (see Figure 24).