You are on page 1of 58

APM100 Outdoor Power Supply System User Manual

Version Revision date BOM V1.3 Spet 11, 2007 31011252

Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center. Copyright 2006 by Emerson Network Power Co., Ltd. All rights reserved. The contents in this document are subject to change without notice. Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China Homepage: www.emersonnetworkpower.com.cn E-mail: support@emersonnetwork.com.cn

Safety Precautions
To reduce the chance of accidents, please read the safety precautions carefully before operation. The Caution, Notice, Warning and Danger in this manual do not represent all the safety points to be observed, and are only used as supplement to various operation safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before operation. When operating Emerson products, the safety rules in the industry, the general safety points and special safety instructions specified in this manual must be strictly observed.

Electrical Safety
I. Hazardous voltage

Danger
Some components of the power system carry hazardous voltage in operation. Direct contact or indirect contact through moist objects with these components will result in fatal injury. Safety rules in the industry must be observed when installing the power system. The installation personnel must be licensed to operate high voltage and AC power. In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles, rings. When water or moisture is found on the cabinet, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power system. "Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during installation.

Danger
High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high voltage operations. II. Tools

Warning
In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used. III. Thunderstorm

Danger
Never operate on high voltage, AC, iron tower or mast in the thunderstorm. In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be well earthed in time to avoid damage by lightning strikes.

IV. ESD

Note
The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale ICs. Before touching any plug-in board, PCB or IC chip, wear ESD wrist strap to prevent body static from damaging the sensitive elements. The other end of the ESD wrist strap must be properly earthed. V. Shortcircuit

Danger
During operation, never short the positive and negative poles of the DC busbar or the non-earthing pole and the earth. The power system is constant voltage DC power equipment; short circuit will result in equipment burning and endanger human safety. Check carefully the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC power distribution unit is very tight, please carefully select the operation space. Remove watch, bracelet, bangle, ring, or other conductive objects before operation. Use insulated tools. In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of the human body and tool is reduced to the minimum.

Battery

Danger
Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery connection method. Non-standard operation on the battery will cause danger. In operation, precautions should be taken to prevent battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs. Before any operation on battery, pay attention to the following points: Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. Use special insulated tools. Use eye protection device, and take preventive measures. Wear rubber gloves and apron to guard against electrolyte overflow. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted.

Installation Precautions
1. Only qualified technical person can perform the system installation and maintenance. 2. Avoid fire or body injuries. 3. Provide suitable AC mains supply to the system. 4. Earth the system according to the requirement. 5. Keep the environment of the system clean and dry. 6. Avoid touching the bare part of a circuit.

7. Switch off the circuit breakers in case of system failure.

Others
I. Safety requirement

Notice
Always use the same model MCB to replace the old ones to comply with the safety requirement. II. Sharp object

Warning
When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object. III. Cable connection

Notice
Please verify the compliance of the cable and cable label with the actual installation prior to cable connection. IV. Binding the signal lines

Notice
The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least 150mm.

Contents
Chapter 1 Overview ............................................................................................................................................................ 1 1.1 Model Information ................................................................................................................................................. 1 1.2 Feature ................................................................................................................................................................. 1 1.3 Composition .......................................................................................................................................................... 2 1.4 Theory................................................................................................................................................................... 3 1.5 System Function ................................................................................................................................................... 3 1.5.1 Protective Function .................................................................................................................................... 3 1.5.2 Alarm Function .......................................................................................................................................... 4 1.5.3 Communication Function ........................................................................................................................... 5 Chapter 2 Installation Preparation....................................................................................................................................... 6 2.1 Site Selection ........................................................................................................................................................ 6 2.2 Laying Grounding Net ........................................................................................................................................... 7 2.3 Leading In Power .................................................................................................................................................. 7 2.4 Preparing Cable Tunnels ...................................................................................................................................... 7 2.5 Cable Requirements ............................................................................................................................................. 7 2.6 Requirements Of Laying Cables ........................................................................................................................... 8 Chapter 3 Installation .......................................................................................................................................................... 9 3.1 Installation Procedures ......................................................................................................................................... 9 3.2 Preparations ......................................................................................................................................................... 9 3.2.1 Inspecting Location.................................................................................................................................... 9 3.2.2 Unpacking.................................................................................................................................................. 9 3.2.3 Preparing Tools ....................................................................................................................................... 10 3.2.4 Clearances For Installing Cabinet............................................................................................................ 10 3.2.5 Opening The Cabinet Door...................................................................................................................... 11 3.3 Installing Cabinet ................................................................................................................................................ 12 3.3.1 Installing Cabinet On A Concrete Stand .................................................................................................. 12 3.3.2 Installing Cabinet On A Floorstand .......................................................................................................... 14 3.3.3 Installing Cabinet On Channel Beams ..................................................................................................... 15 3.4 Installing Rectifiers.............................................................................................................................................. 15 3.5 Connecting Cables.............................................................................................................................................. 16 3.5.1 Connecting Grounding Cable .................................................................................................................. 16 3.5.2 Connecting AC Power Cables And Load Cables..................................................................................... 17 3.5.3 Connecting Communication Cable Of The Monitoring Module ................................................................ 21 3.5.4 Sealing Cable Holes ................................................................................................................................ 21 3.6 Installing Batteries............................................................................................................................................... 21 3.7 Installation Inspection ......................................................................................................................................... 23 3.7.1 Cabinet Inspection................................................................................................................................... 23 3.7.2 Cable Connection Inspection................................................................................................................... 24 Chapter 4 Testing.............................................................................................................................................................. 25 4.1 Testing AC/ DC Distribution & Rectifiers............................................................................................................. 25 4.2 Testing Monitoring Module.................................................................................................................................. 26

4.2.1 Setting System Parameters ..................................................................................................................... 27 4.2.2 System Function Test .............................................................................................................................. 28 Chapter 5 Maintenance ..................................................................................................................................................... 29 5.1 Routine Maintenance .......................................................................................................................................... 29 5.2 Realtime Maintenance ........................................................................................................................................ 29 5.3 Alarm Handling ................................................................................................................................................... 30 5.4 Replacing Modules ............................................................................................................................................. 30 5.5 Replacing Rectifier Fan....................................................................................................................................... 31 5.6 Replacing Heat Exchanging Equipment.............................................................................................................. 32 5.7 Replacing External Fan....................................................................................................................................... 33 5.8 Replacing Heaters And Thermostats .................................................................................................................. 33 5.8.1 Replacing The Heater In Equipment Compartment ................................................................................. 34 5.8.2 Replacing The Heater In Battery Compartment....................................................................................... 35 5.8.3 Replacing Thermostats............................................................................................................................ 36 5.9 Replacing Door Status Sensor............................................................................................................................ 36 5.10 Replacing AC SPD............................................................................................................................................ 37 5.11 Replacing DC SPD Board................................................................................................................................. 38 5.12 Replacing Temperature Sensor ........................................................................................................................ 39 5.13 Replacing Monitoring Expansion Board ............................................................................................................ 40 5.14 Replacing Distribution Subrack ......................................................................................................................... 41 5.15 Battery Maintenance ......................................................................................................................................... 42 Appendix 1 Technical Data ............................................................................................................................................... 43 Appendix 2 Definitions Of Monitoring Expansion Board Interfaces ................................................................................... 45 Appendix 3 Common Problems......................................................................................................................................... 48 Appendix 4 Schematic Diagram ........................................................................................................................................ 49 Appendix 5 Wiring Diagram............................................................................................................................................... 51 Appendix 6 Spare Part List................................................................................................................................................ 52

Chapter 1 Overview

Chapter 1 Overview
APM100 outdoor power supply system can be used directly outdoors. It provides 48Vdc output power supply, 48V 100Ah battery standby power and four- unit height space for built- in equipment. It can supply as much as 60A electric current.

1.1 Model Information


The model information of APM100 is shown in Figure 1-1.

APM100 - 4860 S E
Emerson network power Co. Ltd S : south model; N: north model Output voltage: 48V; total current: 60A APM serial product name
Figure 1-1 Model information

1.2 Feature
Rectifier features Power factor up to 0.99, efficiency over 90%. Wide AC input voltage range from 90V to 290V. When the input voltage is between 90 ~ 175Vac, the rectifier starts power- limited output. The rectifier outputs as low as 37.5% of the rated power upon 90Vac input. Rectifiers are hot pluggable and the replacing time is less than 1min. System features Perfect battery management functions, including battery low voltage disconnection (BLVD) function, temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, and online battery test. Network design: providing multiple communication ports, which enables flexible networking and remote monitoring. Perfect lightning protection at both AC side and DC side. Complete fault protection and fault alarm functions. All system components are accessible from the front. The equipment compartment safety complies with IP55. The battery compartment safety complies with IP34. The system complies with GR487 waterproof requirement.

APM100 Outdoor Power Supply System User Manual

Chapter 1 Overview

1.3 Composition
The APM100 outdoor power supply consists of an equipment compartment and a battery compartment. The equipment compartment contains embedded power supply, heat exchanging equipment, external fan and distribution unit etc. The battery compartment has one layer, and a set of batteries that supplies backup power can be placed in the layer. In the north model system, two heaters are placed respectively in the equipment compartment and in the battery compartment. See Figure 1-2.

Door status sensor Heat exchanging unit External fan Monitoing expansion board Reserved space

Door status sensor

Embedded power supply

Distribution unit

Figure 1-2

Composition of APM100 outdoor power supply system

Embedded power supply The embedded power supply consists of three rectifiers, one monitoring module, one distribution subrack and one monitoring expansion board. It converts the 220V AC voltage into -48V DC voltage, and delivers the -48V DC voltage to the system distribution units and then to the load through the distribution subrack. Heat exchanging equipment and external fan The heat exchanging equipment dissipates the heat inside the cabinet with the external fan. It consists of an internal fan and a heat exchanger. The external fan aspirates the cold air outside and feeds it to the heat exchanger, while the internal fan expels the heat air inside the cabinet to the heat exchanger. The heat exchanger exchanges the heat between cold air and hot air in it to dissipate the heat. Distribution unit The distribution unit includes panel, AC/ DC SPD, connection terminals and MCBs. It is used to connect the AC input cables and load cables. Reserved space Reserved to place user devices. Heaters There are two heaters in the north model system; one is located behind the panel of the distribution unit in the equipment compartment and the other at the top of the battery compartment. The two heaters will start to work when the ambient temperature is below 5C (due to thermostat error, the actual temperature range of startup is 0C ~ 10C) to ensure the normal operation of the north model system segments in low temperature environment.

APM100 Outdoor Power Supply System User Manual

Chapter 1 Overview

1.4 Theory
The schematic diagram is shown in Figure 1-3. The detailed information is shown in Appendix 4 Schematic Diagram and Appendix 5 Wiring Diagram.
220Vac/110Vac Distribution unit Load 1 Load 11

220Vac/110Vac

-48Vdc

Embedded power supply

Figure 1-3

Schematic diagram

The embedded power system rectifies the 220V AC power into -48V DC power and delivers it to the distribution unit. It has functions of battery management, load low voltage disconnection (LLVD), BLVD, data acquisition, alarm, and communication with the host. The distribution unit connects the AC mains to the embedded power supply. It also outputs -48Vdc to the loads through different routes.

1.5 System Function


1.5.1 Protective Function
LLVD and BLVD When mains failure occurs, the battery will supply power. When the battery voltage drops to 47.5V (default, adjustable), the monitoring module will cut off the non- priority loads. When the battery voltage drops to the BLVD voltage (46.5V by default), the monitoring module will cut off all the loads to avoid battery over- discharge. When the mains resumes, the power system will go back to normal state. Over- temperature protection If the temperature of the equipment compartment exceeds the protection point (65C by default) for 30 seconds, the monitoring module will cut off the non- priority loads until the ambient temperature drops below 45C. If the temperature of the battery compartment remains over the protection point (53C by default) for 30 seconds, the monitoring module will cut off the connection between system and batteries until the ambient temperature drops below 45C. Under this condition, if AC side failure occurs, all the loads will be cut off. This function is inhibited by default, though the user can activate it through the host. Input under-voltage protection When the AC input voltage is over 290Vac or below 90Vac, the rectifier will perform self- protection. It can recover automatically, and the return difference is more than 5Vac. Output over-voltage protection When the DC output voltage is over 60.5V, the rectifier will stop exporting voltage or current. This protection cannot recover automatically. Output current- limiting protection The APM100 system can perform current- limiting protection. The current- limiting protection point is 61.5A 1.5A. Output short- circuit protection The APM100 system can perform short- circuit protection. It can be shorted for a long while and recover automatically. The short- circuit protection current is 6A.

APM100 Outdoor Power Supply System User Manual

Chapter 1 Overview

1.5.2 Alarm Function


The system raises alarm on the following occasions: mains failure, mains over/ under- voltage, DC output over/ undervoltage, charging over- current, load over- temperature protection, ambient over- temperature, module failure, module protection. The alarm levels are divided as critical alarm, observation alarm, and inhibitive alarm. Alarms that may cause load power interruption are defined as critical alarm by default, and the rest are observation alarms. Only door status sensor alarms, humidity alarms and backup equipment alarms can be set as non- alarm and be shielded. Unless otherwise stated (Battery charging over- current: 5 minutes; Failure of battery- compartment heater: 1 hour; Battery imbalance alarm: 30 seconds), the confirm time of the alarm is ten seconds. See Table 1-1.
Table 1-1 Alarm signals Mains failure Mains overvoltage Mains undervoltage 280V Default Setting range Alarm functions Description Alarm is raised when mains is below 50V, and resumes when mains is above 60V Under- voltage Alarm recovery conditions alarm point to When the mains is 3V below the alarm point for 10 minutes, the alarm recovers 300V 60V to overvoltage alarm point Alarm recovery conditions When the mains is 3V above the alarm point for 10 minutes, the alarm recovers

180V

DC over- voltage 58V

58V to 60V 1. The alarm return difference is 0.5V (1V above the 2. DC over- voltage alarm occurs when the busbar voltage is over 58V, and boost charging vanishes when the busbar voltage is below 57.5V voltage) 1. The alarm return difference is 0.5V 2. DC under- voltage alarm occurs when the busbar voltage is below 48.5V, and vanishes when the busbar voltage is over or equal to 49V 3. The lower limit voltage is LLVD voltage when load low- voltage disconnection is permitted 4. The lower limit voltage is BLVD voltage when load low- voltage disconnection is prohibited and BLVD is permitted 5. The lower limit voltage is 35V when both load low- voltage disconnection and BLVD are prohibited 1. The charging over- current alarm will occur when charging current is over the current- limit point for 5 minutes constantly 2. Alarm recovers when charging current is below the charging- limit point for 5 minutes constantly 1. If the function is activated (default alarm point: 65C) through the host and the ambient temperature is over the protection point for 30s constantly, the monitoring module will cut off the non- priority loads automatically. And the power will resume on automatically when the ambient temperature is lower by 10C than the protection point 2. The temperature sampling point is the external temperature sensor 3. The non- priority load over- temperature protection can be set controllable by the host. If controllable, the load over- temperature protection can be activated through the host command 1. If the function is activated (default alarm point: 53C) through the host and the circumambient temperature is over the over- temperature protection point for 30s constantly, the monitoring module will perform battery disconnection automatically. And the battery will resume power- on automatically when the ambient temperature is lower by 10C than the protection point 2. The temperature sampling point can be set to be battery temperature 1, and is subject to the temperature compensation value

DC undervoltage

48.5V

Low- voltage disconnection point to 2V below float charging voltage

Battery charging over- current

5A above charging limit point

Load overtemperature protection

Inhibitive

50C to 70C

Battery overtemperature protection

Inhibitive

40C to 70C

Ambient overtemperature

50C

-50C to 100C (above the overtemperature alarm point)

The alarm return difference is 3C. The alarm point can be set respectively

APM100 Outdoor Power Supply System User Manual

Chapter 1 Overview
Alarm signals Default Setting range -50C to 0C (below the overtemperature alarm point) Description

Circumambience under0C temperature n# module failure n# module protection Battery loop disconnection BLVD 46.5V

The alarm return difference is 3C. The alarm point can be set respectively

Indicating n# module failure (output over- voltage, output shortage, fan failure) Indicating n# module protection (over- temperature, input over/ under- voltage protection) Battery loop disconnection (MCB, contactor or internal wiring disconnection) brings alarm 35V to LLVD voltage BLVD voltage to DC undervoltage alarm point

LLVD

Inhibitive

Low- voltage disconnection (LVD) activation and LVD voltage can be set through the host If LLVD is activated, the default voltage is 47.5V

Door status sensor SPD failure alarm Fan failure alarm Failure of batterycompartment heater Battery imbalance alarm

The dry contact is disconnected when alarm is raise Check the two- route SPDs. The dry contact disconnects when SPD exports alarms An alarm is raised when the fan stops running or the fan power cable disconnects When the mains is in normal state and the storage battery temperature is below -20C for an hour constantly, heater failure alarm of the storage battery compartment is raised When the battery is discharging, one battery imbalance alarm will generate if the following condition happens: Twice middle sampling voltage minus voltage between two ends of the battery string is above 0.6V for 30 seconds 1. Three routes altogether. The monitoring module supplies 24Vdc or 12Vdc operation power for the switch signal examination, disconnect the correlative low power level (0Vto 1V) and connect the correlative high power level (9to 24V) 2. 8/20s impulse current can endure 300A, without damage (bidirectional transient voltage suppressor with model of 1.5SMC39CA is recommended) 3. Alarm power level is adjustable

Test on standby digital data

Note: If users need to activate Load over- temperature protection or other alarms that are inhibitive by default, they can reset alarm levels through the host

1.5.3 Communication Function


The system can communicate with the user host through communication port RS485, and report sampling data and alarm data to the host. The APM100 system can report some alarms information to the host through the 4 couples of dry contacts.

APM100 Outdoor Power Supply System User Manual

Chapter 2 Installation Preparation

Chapter 2 Installation Preparation


2.1 Site Selection
To ensure the long and stable operation of the power supply system, both the mains and the environmental conditions of the installation site should be considered. The main requirements are given below: Open and easy- rented location. Convenient traffic, available mains, safe environment. There should be no combustible around the perimeter. The examples of site selection and installation modes are illustrated in the following figures.

(a) Installed at the lower platform of the iron tower

b Installed inside the outdoor room

c Installed inside the pole- holding platform


Figure 2-1

d Installed at the roof

Examples of site selection and installation mode

APM100 Outdoor Power Supply System User Manual

Chapter 2 Installation Preparation

2.2 Laying Grounding Net


To ensure the safe and reliable operation of the power supply system, the grounding devices must be installed before the cabinet installation. Requirements of the grounding equipment: Vertical grounding equipment: 50mm galvanized steel tube, 2m long; Horizontal grounding equipment: 40 4mm galvanized flat steel, length as demanded; Galvanized angle steel: 50 50 5mm, 2m long; Grounding leading -in: 40 4mm galvanized flat steel, length as demanded.

2.3 Leading In Power


The power supply of the APM100 cabinet is 220Vac/ 110Vac. The AC power is usually led in on the stilts, from the secondary side of the nearby transformer through an AC MCB with capacity over 63A. The power cable of the lattermost level should be no longer than 10m and shielded by metal layer. Both ends of the metal layer should be grounded. The endurable voltage of the power cable should be larger than 300Vac and the endurable frequency should range between 40Hz to 65Hz.

2.4 Preparing Cable Tunnels


All the outside cables should be equipped with cable tube or cable tunnels for protection. Lay the cables at the cable tunnels and take moisture-proof, mouse-proof and fireproof measures.

2.5 Cable Requirements


The cables to be installed include AC power cables, DC power cable and grounding cable. The cables should be able to withstand the temperature of at least +70C. The descriptions of different cables are as follows: 1. AC cables Temperature rise, voltage drop and mechanical strength should be comprehensively considered when selecting the sectional areas of the AC cables. If the AC cable is shorter than 15m, it is recommended to use cables with sectional area larger than 4mm2 (larger than 12AGW cable). If the AC cable is longer than 15m, please choose the cable size according to site operation. Note: The cabinet is furnished with one piece of 10m two- core cable (212AWG) with jacket as accessory. 2. DC cables The sectional area of the DC power cable is shown in Table 2-1.
Table 2-1 Rated current 32 A 20 A 16 A 10 A Max. output current 16 A 10 A 8A 5A Sectional area of the DC power cable Max. dual- cable length with 0.5V volt. drop and Min. sect. area 7m 7m 5.5 m 5.5 m Min. sect. area 16 mm2 10 mm2 6 mm2 4 mm2

If the rated capacity of a MCB is much bigger than the actual output current, the MCB will not trip when overload happens. So the recommended MCB capacity is 1.5 to 2 times of the maximum load current (two times in the table above). Note The maximum output current that flows in the DC power cable is calculated according to the full load of the system. If the acceptable voltage drop is not 0.5V, determine the sectional area of the DC power cable according to the following expression. A= I%L/(KU) APM100 Outdoor Power Supply System User Manual

Chapter 2 Installation Preparation Where: Asectional area of a cable (m2) Itotal current that flows in the cable (A) Lcable length (m) U acceptable voltage drop in the cable (V) Kelectric conduction coefficient, here K Copper=57 Please choose the cable color according to local standards. It is recommended to use black cables as positive DC cables and blue as negative DC cables. 3. Grounding cables The sectional area of the grounding cable should be at least 16mm2. The green- yellow cables should be used as the grounding cables. Prepare the cables according to the cabling specification and quantity. Do not join two separate cables together to form one cable.

2.6 Requirements Of Laying Cables


1. Tag the AC cables and load cables should with numbers and polarities. Tag the cables at both ends. 2. The cables should be intact and have no flaw. 3. If the cables are routed outdoors, they should be put into plastic coated metal hoses or steel tubes, as shown in Figure 2-2.

Plastic tubes do not have the lightning protective function. Steel tubes should be used.

Figure 2-2

Requirements of laying cables

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation

Chapter 3 Installation
3.1 Installation Procedures
The installation procedure diagram is shown in Figure 3-1.
Installation preparation

Installation

Installing cabinet

Installing rectifiers

Connecting cables

Installing batteries

Passing the installation inspection? Yes Installation accomplished

No

Re-installing disqualified components

Figure 3-1

Installation procedure diagram

3.2 Preparations
3.2.1 Inspecting Location
Before installation, please inspect: 1. Devices for laying cables, such as the cable tunnels. 2. Platforms for installation, such as the concrete standfloor. 3. Installation qualifications, such as AC power supply and the grounding connection.

3.2.2 Unpacking
Inspect the equipment carefully after unpacking to ensure successful installation. Unpack and inspect the equipment only after it arrives at the installation site. The user representative and the representative from Emerson Network Power Co., Ltd. shall inspect the equipment together. Open the case that contains the packing list first. Take out the packing list and check against it the customer name, customer address, machine No., quantity, case No., contract No. Check the goods one by one according to the packing list after unpacking. The procedures are as follows. Step 1: Check the quantity and serial number marked on the packing cases. Step 2: Check the correctness of the equipment packing. Step 3: Check the quantity and model of the accessories. Step 4: Check the correctness of equipment configuration. Step 5: Check the goods visually. For example, check if the cabinet or enclosure is distorted or affected with damp; shake gently the rectifier and the monitoring module to see if there is any loose component or connection caused by shipment. APM100 Outdoor Power Supply System User Manual

10

Chapter 3 Installation Step 6: The user representative signs the packing list. Do not unpack the components before installing them to avoid accessory loss.

3.2.3 Preparing Tools


The installation tools are given in Table 3-1. The tools must be insulated and ESD-proof processed before they are used.
Table 3-1 Tool Double- function wrench Adjustable wrench Electrician diagonal pliers Electrician sharp nose pliers Steel tape Electric knife Gradienter Blinkers Fireproofing mud Box wrench Specs Wrench set (10#, 13#, 16#, 18#, 21#) 200mm 150mm 150mm 5m Normal type Normal type To prevent splash Prepared by users 16mm Tools for installation Tool Cross point screwdriver Slotted screwdriver Slotted screwdriver Specs 100mm, 200mm 100mm, 200mm Slot width 4mm

Wire cutters Maximum 300mm2 Hydraulic- pressure compaction Maximum 300mm2 pincher Digital multimeter Impact electric drill Power socket Safety shoes Hammer Three and a half bit digital display With 14 or 12 impact aiguille With 5m cable To prevent puncture and for insulation -

3.2.4 Clearances For Installing Cabinet


Mechanical parameters
Table 3-2 Parameter Dimensions (H % W % D) Weight Mechanical parameters of APM100 Technical data 1130mm 600mm 600mm (without base); 1280mm 600mm 600mm (with base and rings) 300kg (Including four pieces of 12V 100Ah batteries) 90kg (Excluding batteries and rectifiers)

Recommended clearances The recommended clearances for installing cabinet are shown in the following figure. 800mm clearance at the front 200mm clearance at the top 100mm clearance at the left 300mm clearance at the right
200 200

100

300

800

Figure 3-2

Recommended clearances for installation (unit: mm)

Minimum clearances The minimum clearances for installing cabinet are shown in the following figure. APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation 650mm clearance at the front 100mm clearance at the top 100mm clearance at the left 250mm clearance at the right
100 100

11

100

250

650

Figure 3-3

Minimum clearances for installation (unit: mm)

3.2.5 Opening The Cabinet Door


The user needs to open the cabinet door when carrying out system installation or maintenance. The opening procedures are follows: 1. Undo the hexagon- socket- head- cap screw in the keyhole sheet widdershins with the hexagon key. Remove the keyhole sheet. Insert another key into the keyhole and turn the key clockwise until the handle pops out, as shown in Figure 3-4.

Handle

Keyhole sheet

Figure 3-4

Unlock sequence

When you turn the key, lay your hand down to prevent being hit by the handle, as shown in Figure 3-5.

Figure 3-5

Unlock illustration

APM100 Outdoor Power Supply System User Manual

12

Chapter 3 Installation 2. Turn the handle counter clockwise to the position shown in Figure 3-6, and then open the door.

Handle

Figure 3-6

Handle position

3. Insert the door stay bar into the positioning pole to fix the door position, as shown in Figure 3-7.

Door stay bar

Figure 3-7

Door stay bar

4. To close the door, uplift the bar for 2mm- 3mm, place the handle to its original position, cover the keyhole with the keyhole sheet and undo the hexagon- socket- head- cap screw in the keyhole sheet clockwise with the hexagon key.

3.3 Installing Cabinet


The APM100 outdoor power supply system is bottom cabling. Make a concrete stand or a floorstand first, and then place the cabinet on the concrete stand or the floorstand, or other nonflammable flat surface. The detailed installation procedures are as follows.

3.3.1 Installing Cabinet On A Concrete Stand


Step 1: Make a concrete stand The dimensions of the stand are shown in Figure 3-8.

27 5

300~500
0

100

25

80 0

80

Ca
Figure 3-8

e bin

td

oo

Dimensions of concrete stand (Unit: mm)

Step 2: Mark the cabinet installation position Determine the center point positions of every installation hole on the stand according to the installation dimensions of the cabinet shown in Figure 3-9, and mark them with a pencil or an oil pen.

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation
60 400 4- 13 28

13

525

140

400

Front door
Figure 3-9 Installation dimensions of cabinet base (Unit: mm)

Step 3: Drill holes The size of the plastic expansion bolt delivered with the accessories is M10 55mm. Drill a 70mm-depth hole at each marked point by using a 14 impact drill bit. Be careful not to make the drill off-centered when drilling and keep the drilling vertical. Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same level with the floor, as shown in Figure 3-10.

Expansion pipe

Power cabinet

70~75mm

14

Drill vertically
Figure 3-10

Clean the dust

Knock it Tighten into place the bolt

Drilling holes and Installing expansion pipe and bolt

Step 4: Place cabinet in position Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the ground. Step 5: Open the cabinet door Take the key from the ring on the cabinet top, and open the cabinet door according to the method introduced in section 3.2.5 Opening The Cabinet Door. Step 6: Fix the cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Fasten the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 3-11.
Expansion bolt Cabinet Expansion bolt Expansion pipe Concrete stand Spring washer Concrete stand Spring washer Cabinet base Expansion pipe

Figure 3-11

Screwing an expansion bolt

Shake the cabinet in different directions after the installation to check for any loose component and loose installation of the cabinet.

APM100 Outdoor Power Supply System User Manual

14

Chapter 3 Installation

3.3.2 Installing Cabinet On A Floorstand


Step 1: Mark the floorstand installation position Determine the center point positions of the floorstand on the ground and mark them with a pencil or an oil pen, as shown in Figure 3-12.

Front door
Figure 3-12 Installation dimensions of floorstand (Unit: mm)

Step 2: Drill holes The method is described in step 3 of 3.3.1 Step 3: Fix the floorstand Align the installation holes of the floorstand to those on the ground. Screw the expansion bolt with plain and spring washers into the expansion pipe with a wrench, as shown in Figure 3-13.
Cabinet Screw for fixing cabinet and floorstand Floorstand Expansion bolt Ground

Installing Cabinet On A Concrete Stand.

Figure 3-13

Installing the cabinet and floorstand

Step 4: Place cabinet in position Place the cabinet on the floorstand. Align the installation holes of the cabinet to those of the floorstand. Step 5: Open the cabinet door Take the key from the ring on the cabinet top, and open the cabinet door according to the method introduced in 3.2.5 Opening The Cabinet Door.

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation

15

3.3.3 Installing Cabinet On Channel Beams


Step 1: Prepare channel beams Prepare four M10 20mm bolts and two parallel channel beams according to the installation dimensions of the cabinet, as shown in Figure 3-14.

Front door
Figure 3-14 Dimensions of concrete stand (Unit: mm)

Step 2: Mark the cabinet installation position Determine the center point positions of every installation hole on the channel beams according to the installation dimensions of the cabinet shown in Figure 3-14, and mark them with a pencil or an oil pen. Step 3: Drill holes Drill a hole at each marked point by using a 12 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical. Step 4: Place cabinet in position Move the cabinet to the installation position, and align the installation holes of the cabinet to those on the channel beams. Step 5: Fix the cabinet Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the expansion bolt with plain and spring washers into the expansion pipe with a 14# socket wrench, as shown in Figure 3-15.
Cabinet Screw

Floor stand

Channel beam

Figure 3-15

Installing on the channel beams

3.4 Installing Rectifiers


The subrack of the embedded power supply has been installed in the cabinet of the outdoor power supply system, while the rectifiers are packed and delivered separately and need to be installed on the spot. Rectifiers should be installed in the three left slots of the subrack. Install the rectifiers from left to right when there are less than three rectifiers to be installed and mount dummy plate at the remaining position. The installation procedures are as follows.

APM100 Outdoor Power Supply System User Manual

16

Chapter 3 Installation Step 1: Place the rectifier to the position shown in Figure 3-16. Step 2: Push the rectifier inward until it stops going forward. The rectifier will be fixed in the subrack by the locking devices.

Rectifier
Figure 3-16 Rectifier installation

3.5 Connecting Cables


It is recommended to connect cables in the following sequence: 1. connecting grounding cable 2. connecting AC power cable and load cables 3. connecting communication cable 4. sealing cable hole

3.5.1 Connecting Grounding Cable


The grounding busbar of the cabinet is located within the grounding busbar plate outside the cabinet. Remove the fixing screws of the plate before installation. Connect one end of the grounding cable to the busbar reliably, as shown in the left figure of Figure 3-17. Re-install the plate, and connect the other end of the cable to the grounding device reliably, as shown in the right figure of Figure 3-17.
Fixing screws

Grounding busbar plate

Grounding cable

Figure 3-17

Grounding busbar position

Because of the particularity of the outdoor equipment, the cabinet must be reliably grounded. The other end of the grounding cable must be connected to the metal base, as shown in Figure 3-18.

The gounding screw must be welded to the metal base reliably


Figure 3-18 Grounding cable connected to the metal base

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation

17

The AC/ DC cables and the communication cable must be put into the metal pipe for protection. The metal pipe should be connected to the grounding busbar reliably. Considering the actual conditions, plastic coated metal hoses are recommended for protection, as shown in Figure 3-19.

Plastic coated metal hose


Connected to the cabinet reliably

Aluminum alloy joint

Plastic coated metal hose

Figure 3-19

Metal pipe connection

3.5.2 Connecting AC Power Cables And Load Cables


AC power cables and load cables are connected to power distribution unit. The following text will introduce cable tube information, load distribution and detailed cable- connection procedures. Cable tube This system is configured of 15 cable tubes with different sizes, which locate at the separating plate between the equipment compartment and the battery compartment. Lead the cables through corresponding cable tubes according to the labels. There are two pieces of transmission fiber cable tubes (diameter of the cable: 13mm ~ 18mm) and thirteen pieces of other cable tubes (diameter of the cable: 5mm ~ 10mm), as shown in Figure 3-20. To use the cable tubes, you should unscrew the tube cap, then lead the cable through the tube, and finally screw the cap.
1 2 3 4 5 6 7 8 1 2 -48Vdc1 -48Vdc2 -48Vdc3 -48Vdc4 -48Vdc5
10 11 12 15 13 2 14 3 4 7 5 8 6 9

AC power cord entrance Transmission fiber inlet/outlet 1 Transmission fiber inlet/outlet 2 -48Vdc DC power outlet 1 -48Vdc DC power outlet 2 -48Vdc DC power outlet 3 -48Vdc DC power outlet 4 -48Vdc DC power outlet 5 9 10 11 12 13 14 15 -48Vdc6 1 2 3 4 5 6

-48Vdc DC power outlet 6 User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet User equipment fiber inlet/outlet

1 2 3 4 5 6

Figure 3-20

Silk-print of cable tubes

Load distribution Arrange the load distribution before connecting power cables. The system can sustain 11 loads. The MCBs (LOAD1~LOAD6) of the distribution unit in the embedded power supply controls the 11 loads. The positions of the MCBs in the subrack are shown in Figure 3-21, and the relationship between these two levels of MCBs is shown in Figure 3-22. The specifications of the MCB and cables are shown in Table 3-3.
Table 3-3 Load MCB and load cable specifications

MCB in subrack LOAD 1 LOAD 2 LOAD 3 LOAD 4 LOAD 5 LOAD 6

MCB in distr. unit 1, 2 3, 4 5, 6 7, 8, 9 10 11

MCB cap. in distr. unit 16A 16A 16A 16A 32A 32A

Cable size in distr. unit 25mm2 25mm2 25mm2 25mm2 25mm2 25mm2

Remark Total output capacity of two loads should be no larger than 15A Total output capacity of two loads should be no larger than 15A Total output capacity of two loads should be no larger than 15A Total output capacity of three loads should be no larger than 15A Total load output capacity should be no larger than 30A Total load output capacity should be no larger than 30A

APM100 Outdoor Power Supply System User Manual

18

Chapter 3 Installation
Load MCB Battery MCB

Figure 3-21

MCBs in subrack of embedded power supply system

LOAD1

LOAD2

LOAD3

LOAD4

LOAD5

LOAD6

Route 1 Route 2 Route 3 Route 4 Route 5 Route 6 Route 7 Route 8 Route 9 Route 10 Route 11

Figure 3-22

Relationship between two levels of MCBs

The embedded power supply system has LLVD and BLVD functions. When the battery voltage is less than 47.5V (default), the system will disconnect LOAD5 and LOAD6 automatically without interrupting LOAD1 ~ LOAD4. However, LOAD1 to LOAD4 will be disconnected automatically when the battery voltage is less than 46.5V (default) to avoid battery overdischarge. At this time, all loads are disconnected. The priority loads should be connected to the MCB of LOAD1 to LOAD4, that is Route1 to Route 9 in Figure 3-18. The non-priority loads should be connected to Route 10 and Route 11 in Figure 3-20. The load capacity should be no larger than the capacity of the MCB that is in the same route. Connecting AC power cables After confirming load distribution, you can connect AC power cables and load cables. The terminal and MCB positions are shown in Figure 3-23.

Terminal for connecting load

DC positive busbar

Socket

AC phase line(L)

Grounding busbar (inside the cabinet)


Terminal & MCB positions

AC neutral line (N)

Figure 3-23

Note: The sockets are different according to different local standards.

The procedures of connecting AC power cables and load cables are given below. 1. Cable connection for system with 220V AC input

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation 1) Remove the panel of the distribution unit. The panel is shown in Figure 3-24.

19

Fixing screws of the panel (four altogether)

Panel of the distribution unit

Figure 3-24

Panel of the distribution unit

2) Cut the protective cover over the cable hole with an electrician knife to lead in AC cables, as shown in Figure 3-25. 3) Put the AC cables through the cable holes at the right side of the cabinet bottom, as shown in Figure 3-25.

AC cable Cable hole

Protective cover

Figure 3-25

Leading in AC cables

4) Unscrew the tube cap, lead the AC cable through the tube, and finally screw the cap, as shown in Figure 3-26. Connect the neutral line to the N terminal at the bottom of the AC MCB. Connect the phase line to the L terminal at the bottom of the AC MCB.
AC MCB

AC input phase line (L)

AC input neutral line (N)

Cable tube Frame

Figure 3-26

AC cable connection system with 220Vac input

5) Fix the AC cable to the cable frame with a nylon tie, as shown in Figure 3-26. Note 1. The grounding cable shall be connected first, then the neutral line and finally the phase lines. 2. The AC cables should be routed from the MCB in the external distribution equipment prepared by user. They should be connected to the MCB just before the system is powered on. The external distribution equipment should have some protection devices to fulfill the overcurrent, shortcircuit and lightning protection functions. 3. The AC phase line, neutral line and grounding cable should be identified with color labels. 4. The AC cables should be routed away from the DC cables. 5. It is recommended to use the 10m cable of the accessories as the AC cable. If users use their own cables as the AC cable, they should screw down the cap of the cable tunnel and use silicon sealant to seal the cable tunnels after connecting cables. If users use accessory cable as the AC cable, screw down the cap of the cable tunnel after connecting cables. 6) Place the protective cover over the cable hole after AC cable connection. 2. Cable connection for system with 110V AC input The AC transfer terminal of the systems with 110V AC input is different from that of the system with 220V AC input, as shown in Figure 3-27. 1) The procedures of step1 to step 3 are the same with those of 220V input cable connection.

APM100 Outdoor Power Supply System User Manual

20

Chapter 3 Installation 2) Connect the three cables labelled N, L1 and L2 to N terminal of the AC transfer terminals, and L1 and L2 terminals of the bottom of the AC MCB, as shown in Figure 3-27. 3) Fix the AC cable to the cable frame with a nylon tie.

AC transfer terminal

Figure 3-27

AC cable connection system with 110Vac input

Connecting load cables 1. Cut the protective cover over the cable hole with an electrician knife and put the load cables through the cable holes at the left side of the cabinet bottom. Wrap the cable with two magnetic loops (model: DFK2528-13), one above the protective cover and one near the cable hole, as shown in Figure 3-28. Or put the load cable that is outside the cabinet through a steel tube or plastic coated metal hose. Fix the load cable to the cable frame at the battery compartment wall with a nylon tie.

Load cable

Magnetic loop Magnetic loop Protective cover

Figure 3-28

Load cables connection

2. Unscrew the tube cap, lead the load cable through the cable tube, and then screw the cap. Connect the negative line to the underpart of the load terminals. Connect the positive line to the DC- output positive busbar, as shown in Figure 3-29.

Negative load cable

Positive load cable

Figure 3-29

AC cable connection

3. Fill the rubber plug in the unused cable tunnel and use silicon sealant to seal the used cable tunnels. Re-install the panel of the distribution unit. Place the protective cover over the cable hole. Note To avoid shortcircuit, the tools and body shall be insulated strictly before applying a load when the system is powered on.

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation

21

3.5.3 Connecting Communication Cable Of The Monitoring Module


When connecting the communication cable, wrap the communication cable with a magnetic loop (model: ZCAT2235-1030) at the end, and insert the same end of the cable to the RS 485 interface at the top of the monitoring expansion board, as shown in Figure 3-30. Connect the other end of the cable to the host computer interface.
Interface of the communication cable Magnetic loop

Communication cable Expansion board

Figure 3-30

Connecting communication cable

3.5.4 Sealing Cable Holes


After cable connections, the cable holes must be sealed with fireproofing mud. Other vacant cable holes must be sealed as well, as shown in Figure 3-31.
Seal the cable hole with fireproofing mud

Figure 3-31

Sealing cable holes

3.6 Installing Batteries


The battery compartment can be placed with one battery string that has four cells. Install the battery cells according to the battery user manual delivered with the battery. The installation tools must be insulation processed. Do not damage the plastic cover of the battery cells and their output terminals during the installation. Before installation, check that: 1. The battery shells are in good condition. 2. The polarities of the terminals are in accordance with the polarity marks on the battery shell. 3. The terminal bolts are fastened. The terminal bolts are shown in Figure 3-32.
Terminal bolts

Figure 3-32

Terminal bolts

APM100 Outdoor Power Supply System User Manual

22

Chapter 3 Installation The installation procedures are as follows: 1. Switch off the AC input MCB and battery MCB. The MCB positions are in Figure 3-33.
Battery MCB

AC input MCB

Figure 3-33

MCB positions

2. Battery cables. The black cable is the cathode (-), the red cable is the anode (+) and the cable in the middle is mid- voltage sampling cable. The cable positions are illustrated in Figure 3-34.
Mid- voltage sam pling cable

Anode cable C athode cable

Figure 3-34

Battery cables

3. Remove the four fixing screws of the battery baffle and take off the baffle. The fixing screws are shown in Figure 3-35.

Fixing screw of battery baffle

Figure 3-35

Fixing screws of battery baffle

4. Push the batteries into the battery compartment from right to left and make sure that the terminals are outside, as shown in Figure 3-36. The battery string should be near the right side and backside of the cabinet. The clearance between adjacent batteries should be 5mm ~ 10mm.

Figure 3-36

Pushing in the batteries in turn

APM100 Outdoor Power Supply System User Manual

Chapter 3 Installation

23

5. Remove the cover of the battery terminals and connect the plate electrodes between the batteries. Note that the mid- voltage sampling cable should be connected to the plate electrode between the second and the third batteries, as shown in Figure 3-37.
Mid- voltage Plate electrode sampling cable

Figure 3-37

Connecting plate electrodes

6. Connect the battery cables to the batteries. Attach the acid and alkali integration box (battery accessory) on the side panel of the cabinet. The black cable should be connected to the leftmost negative terminal and the red cable should be connected to the rightmost positive terminal, as shown in the Figure 3-38.

Negative cable

Positive cable

Figure 3-38

Battery cable connections

7. After installing the battery string, measure the voltage of the battery string. If the voltage value is correct, put the baffle back and fasten the screws, so that the battery string is blocked off, as shown in Figure 3-39.

Figure 3-39

Installing the baffle

8. Re-install the battery covers, as shown in Figure 3-40.


Battery cover

Figure 3-40

Re-installing the battery covers

3.7 Installation Inspection


After installation, the following inspection procedures should be taken.

3.7.1 Cabinet Inspection


1. Check that the cabinet is horizontally, vertically and steadily fixed. 2. Check if all the screws are tightened, especially those in electrical connections. Check that the bolts have plain washers and spring washers and are not reversed. 3. Check that there are no unwanted materials inside the cabinet. If yes, clear up the unwanted materials. 4. Check that the cabinet paint is intact. If there are scratches, paint them immediately to prevent corrosion. 5. Clean up the cabinet. Remove dust and feculence in time.

APM100 Outdoor Power Supply System User Manual

24

Chapter 3 Installation 6. Check that the door can move freely, the lock is in good condition and the door stay bar is fixed. 7. Check that the dummies are installed at the reserved space where no customer device is installed. If the dummies are not installed, install them immediately.

3.7.2 Cable Connection Inspection


1. Measure the resistance value between the positive terminal and negative terminal and phase- to - phase resistance value in the AC loop. Make sure there is no shortcircuit. 2. Check the AC input and distribution. Check that the AC cable color is normative, the cables are laid fast, and the safety labels are complete. Refer to Appendix 4 Schematic Diagram for the AC cable connection information. 3. Check the connection point, line sequence and polarities of DC and battery cables. Check that the connection points are fixed and the cable connections are correct and reliable. 4. Check that the SPD PE cable and grounding cable are correctly connected and the contacts are reliable. 5. Check the communication cables of the monitoring module. Check that the rectifiers are fastened down. 6. Check that the SPD MCB is switched on and other MCBs are switched off. 7. Check that the cables are tidy, and the cable binding is normative.

APM100 Outdoor Power Supply System User Manual

Chapter 4 Testing

25

Chapter 4 Testing
The system must be tested strictly after it is installed. Conduct the test procedures carefully and observe the system in the mean time. Shut down the system in case of any abnormality and continue the test only after eliminating the fault.

4.1 Testing AC/ DC Distribution & Rectifiers


1. Before powering on the system, check whether the PE cables are reliably connected, the AC cables are correctly connected to the system according to the system schematic diagram (see Appendix 4 Schematic Diagram), and the screws are tightened. Ensure that there is no shortcircuit in the input/ output circuit and that the internal components of the rectifier are in good condition. 2. Switch on the residual current operated circuit breaker (RCCB), as shown in Figure 4-1. Switch off all MCBs (put the handles down) in the subrack and the distribution unit.
Load MCB Battery MCB

RCCB

AC input MCB

Figure 4-1

MCB positions

3. Switch off the mains MCB, as shown in Figure 4-1. Remove the panel of the distribution unit and measure the resistance of the AC MCB input/ output terminals. Make sure that there is no shortcircuit between the following terminals, as shown in Figure 4-2 and Figure 4-3: 1) The AC MCB output terminals; 2) The AC MCB input terminals; 3) AC transfer terminal N and grounding busbar (220V input system), or AC transfer terminal L2 and grounding busbar (110V input system); 4) Heater MCB and grounding busbar.
AC transfer terminal N Measuring point of AC MCB output terminal

Grounding Measuring Measuring point of point of AC MCB input busbar heater MCB terminal

Figure 4-2

Measuring points for shortcircuit check (220V input system)

APM100 Outdoor Power Supply System User Manual

26

Chapter 4 Testing
Measuring point of AC MCB output terminal

AC transfer terminal L2

Grounding Measuring Measuring point of point of AC MCB input busbar heater MCB terminal

Figure 4-3

Measuring points for shortcircuit check (110V input system)

4. Supply AC power to the system. Turn the multimeter to the AC position and measure the voltage of the input terminal of AC MCB. If the voltage is abnormal, check the AC power. 5. Switch on the AC MCB. To protect the rectifiers, there will be a startup- delay, during which period the rectifiers green and red indicators will be on for a few seconds. After the startup- delay, the system runs normally. When there is no load, the rectifier fan may stop but the green indicator should still be on. If it turns out otherwise, check the distribution unit carefully. 5. Switch on the MCB in the external distribution equipment to power the system. Measure the voltages of the AC MCBs input terminals . Check the external distribution equipment if the voltages are abnormal. 6. Switch on the load MCB. Turn the multimeter to the DC position and measure the load voltage. Before testing, remove the panel of the distribution unit and measure the voltage between the load- connection terminal and DC positive busbar, which should be 53.5V 0.5 V. The measuring points are shown in Figure 4-4, and the load MCB is shown in Figure 4-5.
Load connection terminal DC positive busbar

Figure 4-4

Measuring load voltage

Note If the load MCBs are switched off, there might be fake voltage when measuring load voltage, which is normal. 7. Switch on the battery MCB, which is shown in Figure 4-5.
Load MCB Battery MCB

Figure 4-5

Battery MCB position

4.2 Testing Monitoring Module


The monitoring module should be tested from the host. Please refer to 3.5.3 Connecting Communication Cable Of The Monitoring Module for communication- cable connection.

APM100 Outdoor Power Supply System User Manual

Chapter 4 Testing

27

4.2.1 Setting System Parameters


Upon delivery, the default parameters of the monitoring module may be inconsistent with the actual situation or your needs. In that case, you should configure the system parameters through the host before the system testing. According to the communication protocol, the parameters that you can configure through the host are listed in the following table.
Table 4-1 Configurable parameters

Parameter AC Input Under-Voltage Alarm Point AC Input Over-Voltage Alarm Point

Range > 60V and lower than AC Over-Voltage Alarm Point Between AC Under-Voltage Alarm point and 300V 1. When LLVD enabled: LLVD Voltage DC Busbar Low Voltage Point 2. When LLVD disabled but BLVD enabled: BLVD voltage 3. When both LLVD and BLVD disabled: 35V Between DC Busbar Low Voltage Point and 2V below FC DC Busbar Under-Voltage Alarm Point voltage DC Busbar Over-Voltage Alarm Point 58V ~ 60V and 1V higher than BC voltage LLVD Status Disabled, Enabled Between BLVD voltage (when BLVD is disabled: >35V) * LLVD Voltage and DC Busbar Under-Voltage Alarm Point BLVD Status Disabled, Enabled BLVD Voltage* Ambient Temp Alarm Lower Limit Ambient Temp Alarm Upper Limit Standby Digital Signal Alarm Level System Control Mode FC/BC Status BC voltage FC voltage
35V but lower than LLVD voltage (when LLVD is disabled, lower than DC Busbar Under-Voltage Alarm Point)

Default value 180V 280V 47.5V/46.5V/35V (depending on the BLVD Status and LLVD Status) 48.5V 58V Disabled 47.5V Enabled 46.5V 0C 50C High level alarm 1 Auto FC 56.5V 53.5V

Capacity of Battery String 100Ah (unless specified) Coefficient of Charge Current Limiting 0.15 0.1 ~ 0.25 Point Scheduled BC Interval 30 days ~ 240 days 60 days Temp Compensation Coef. of Battery 0mV/C ~ 500mV/C 80mV/C String Battery Over-Temp Protection Point 40C ~ 70C 53C Note*: The LLVD voltage and BLVD voltage should be set according to the battery manufacturer instructions

-50C ~ 100C and lower than upper limit -50C ~ 100C and higher than lower limit High level alarm 1, low level alarm 0 Host Control, Auto BC, FC 43.2V ~ 57.6V, between FC voltage and 1V below DC Busbar Over-Voltage Alarm Point 43.2V ~ 57.6V, between BC voltage and 2V below DC Busbar Under-Voltage Alarm Point 30Ah ~ 100Ah

When setting system parameters through the host, please note that: 1. Make sure that the power system address set at the host is identical with the address set through the DIP switch, or the communication will fail. 2. Make sure that the rectifier number is set consistent with the actual condition. After a rectifier is added to or removed from the power system, the rectifier number parameter must be accordingly modified, or a rectifier alarm will be raised. 3. The battery string capacity setting is customized according to order requirement before delivery. If there is no specific capacity requirement in the order, the default battery string capacity is 100Ah. If the actual battery capacity is neither 100Ah nor 200Ah, reset it through the host to make the configuration consistent with the actual situation and prevent improper battery management. 4. If the battery string capacity is 100Ah or 200Ah, you can set the battery capacity by the DIP switch. The DIP switch is in the PCB board of the monitoring module, as shown in Figure 4-6. You need to pull out the monitoring module (hot pluggable) first before you can change the DIP switch settings. Refer to 5.4 Replacing Modules for the method of plugging monitoring module.

APM100 Outdoor Power Supply System User Manual

28

Chapter 4 Testing Description of DIP switch settings are given in Table 4-2.
Table 4-2 Description of DIP switch settings

DIP switch 1~4 5

Description Communication address Reserved

Settings ON: 1; OFF: 0 ON: dry contact switched- off is normal; switched- on generates alarm. OFF: dry contact switched- on is normal, switchedoff generates alarm ON: battery capacity 200Ah; OFF: battery capacity 100Ah ON: GSM protocol; OFF: WCDMA protocol

Default setting

Dry contact status

OFF

Battery capacity

100Ah

8 Communication protocol WCDMA protocol Note: Communication address setting uses 8421 code. DIP switch 4 corresponds to 8, DIP switch 3 corresponds to 4, DIP switch 2 corresponds to 2, DIP switch 1 corresponds to 1

DIP switch

Communication address

Communication protocol Battery capacity Dry contact status Reserved

Figure 4-6

DIP switch

The DIP switch setting in Figure 4-5 is the setting of BBU (address: 9, communication protocol: WCDMA). The DIP switch setting of BTS 3002C (address: 3, communication protocol: GSM) is shown in Figure 4-7.

Figure 4-7

Example of DIP switch setting

4.2.2 System Function Test


The system has been tested before delivery. You do not need to carry out system function test.

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance

29

Chapter 5 Maintenance
Inspect the outdoor power supply system periodically and shoot the trouble in time.

5.1 Routine Maintenance


The routine maintenance items are in the following table.
Table 5-1 Routine maintenance items

Maintenance items DC output Rectifier fan Indicators Paint, galvanization layer

Frequency Once half a year Once half a year Once half a year Once half a year

Inspecting method Multimeter Visual inspection Visual inspection Visual inspection

Guide Step 6 of 4.1 Testing AC/ DC Distribution & Rectifiers 5.2 Realtime Maintenance

5.2 Realtime Maintenance


The realtime operation state is indicated by rectifier indicators and monitoring module indicators. Rectifier indicator The appearance of the rectifier is shown in Figure 5-1. There are three indicators on the panel: ALM (alarm indicator), FAN-ALM (fan fault indicator) and RUN (power indicator). The indicator descriptions are in Table 5-2.

Alarm indicator Fan alarm indicator Run indicator

Figure 5-1 Table 5-2

Rectifier appearance

Description of rectifier indicators

Indicator Meaning Normal state Rectifier fan failure Protection alarm or faults occur

RUN indicator On Off Off

FAN-ALM indicator Off On Off

ALM indicator Off Off On

APM100 Outdoor Power Supply System User Manual

30

Chapter 5 Maintenance Monitoring module indicator The appearance of the monitoring module is shown in the following figure. There are two indicators on the panel: RUN (power indicator) and ALM (alarm indicator). Descriptions are as shown in Table 5-3.
Alarm indicator Run indicator

Figure 5-2 Table 5-3

Appearance of monitoring module

Monitoring module indicator description

Indicator Meaning Normal No system alarm, communication interrupt System alarm, normal communication System alarm, communication interrupt

RUN indicator (green) Slow blinking (Once per second) Fast blinking (Once per 125ms) Slow blinking (Once per second) Fast blinking (Once per 125ms)

ALM indicator (red) Off Off On On

5.3 Alarm Handling


Fault 1: The rectifier quits operation automatically and a corresponding alarm is raised at the host. Solution: replace the faulty rectifier. Fault 2: Rectifier(s) is/are shut down upon over-voltage and the corresponding alarm is raised at the host. Solution: 1. Upon single rectifier shutdown: Switch off the faulty rectifier. Wait till its indicators are off, and switch it on again. If the over-voltage still exists, the rectifier may have been damaged and need replacing. 2. Upon multiple-rectifier shutdown: Pull output all rectifiers and insert them one by one to find out the faulty one. Replace the faulty rectifier after confirmation.

5.4 Replacing Modules


Upon abnormities, the rectifier may need to be pulled out and plugged in. The rectifiers and monitoring modules are all hot swappable. Do not touch the back board of the rectifier subrack. To pull out the rectifier, first you should draw out the handle at rectifier front panel to detach the latch at rectifier bottom from the distribution frame. Then you can pull the rectifier out by the handle. The handle position is shown in Figure 5-3.

Rectifier handle

Figure 5-3

Pulling out rectifier handle

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance

31

To remove the monitoring module, first you need to remove the communication cable with a screwdriver and then pull out the signal cable, as shown in Figure 5-4. Otherwise you cannot pull out the monitoring module.
Interface of the signal cable Interface of the communication cable

Fixing screws

Handle

Figure 5-4

Pulling out monitoring module

The procedures for removing/inserting the monitoring module are the same as those for the rectifiers. After plugging in the monitoring module, you should first connect the signal cable and then connect the communication cable. Note The rectifiers connecting part is a delicate device. Although the rectifiers are designed to be hot pluggable, the pull-out and plug-in operation should be gentle lest the connecting part should be damaged. Only professionals are allowed to conduct rectifier replacement.

5.5 Replacing Rectifier Fan


Dust will accumulate on the baffle plate if the rectifier works in a dusty and windy environment. To ensure long-term reliable and smooth operation of the rectifier, it is necessary to clean the fan regularly (once half a year). In addition, the fan performance will deteriorate after long-term operation. You need to replace the fan regularly. Procedures of replacing rectifier fan are described as follows. 1. Pull out the rectifier. 2. Remove the fan baffle plate. 3. Remove the screws on the down right corner of the fan, as shown in Figure 5-5. 4. Pull out the power cable of the fan, as shown in Figure 5-5.

Power cable terminal Fixing screw of the fan

Figure 5-5

Removing the rectifier fan

5. Replace the fan with a new one. 6. Connect the power cable, and fix the fan with the screw on the top right corner. 7. Mount the baffle plate. Note 1. Only trained professionals are allowed to clean and replace the fan. 2. Do not touch any internal parts of the rectifier during fan maintenance.

APM100 Outdoor Power Supply System User Manual

32

Chapter 5 Maintenance

5.6 Replacing Heat Exchanging Equipment


The heat exchanging equipment consists of an internal fan and a heat exchanger. Its position is shown in Figure 5-6.

Cable connector

Heat exchanging equipment


Figure 5-6 Position of heat exchanging equipment

The internal fan speed is settable. The higher the temperature of the equipment compartment is, the larger the internal fan speed is. Replace the internal fan or adjust the fan position if it stops running or there is an abnormal noise in it. Clean the heat exchanger once half a year. The procedures are as follows. Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, as shown in Figure 5-6. Do not disconnect the cable frequently when power is on. Step 2: Remove the fixing screws shown in Figure 5-7 and then remove the heat exchanging equipment from the cabinet.

Fixing screws

Fixing screws

Figure 5-7

Fixing screws of the heat exchanging equipment

Step 3: Remove the nine screws that fix the cover and the internal fan baffle and then remove the cover and the baffle, as shown in Figure 5-8.

Fixing screws

Figure 5-8

Remove the cover and baffle

Step 4: Remove the fixing screws of the internal fan shown in Figure 5-9. Adjust the fan position or replace the fan with a new one. Take out the heat exchanger to clean it if there is much dust on it.

Heat exchanger

Internal fan

Fixing screws of the internal fan


Figure 5-9 Remove internal fan and heat exchanger

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance Step 5: Follow step 5 to step 1 to install the new fan and the clean heat exchanger into the cabinet. Take care when installing the heat exchanger to avoid damaging the waterproof bar on it.

33

5.7 Replacing External Fan


The external fan speed is settable. The higher the temperature of the equipment compartment is, the larger the external fan speed is. Replace the external fan or adjust the fan position if it stops running or there is an abnormal noise in it. The procedures are as follows. Step 1: Remove the heat exchanging equipment according to the procedures in 5.6 Equipment. Replacing Heat Exchanging

Step 2: Disconnect the cable connector of the external fan, as shown in Figure 5-10. Do not disconnect the cable frequently when power is on.

Handle External fan Cable connector Fixing screw


Figure 5-10 Positions of heat exchanger and external fan

Step 3: Remove the fixing screw of the fan box shown in Figure 5-10 and then remove the fan box. Step 4: Remove the fixing screw of the external fan shown in Figure 5-11. Adjust the fan position or replace it with a new one.

Fixing screws of external fan (4 pieces)

External fan

Figure 5-11

Remove the external fan

Step 5: Reverse step 4 to step 1 to install the new fan into the cabinet. Install the heat exchanging equipment into the cabinet. Take care when installing the heat exchanging equipment to avoid damaging the waterproof bar on it.

5.8 Replacing Heaters And Thermostats


The two heaters of the system do not need repairing. Pay attention to their operation status. The heaters will heat when the ambient temperature is below 5C 5C, and stop heating above 15C 5C. If they operate abnormally, check the thermostats (refer to 5.8.3 Replacing Thermostats). If the thermostats operate abnormally, replace them. Otherwise, replace the heaters. Note If the heaters are working before replacement, do not touch them until they are cool.

APM100 Outdoor Power Supply System User Manual

34

Chapter 5 Maintenance

5.8.1 Replacing The Heater In Equipment Compartment


Step 1: Switch off the AC MCB and the heater MCB, as shown in Figure 5-12.
Battery MCB

Panel of Heater MCB distribution unit


Figure 5-12

AC input MCB

Position of AC MCB and heater MCB

Step 2: Remove the panel of the distribution unit and the four screws shown in Figure 5-13. Remove the right segment of the distribution unit. Pay attention to personnel safety.
Fixing screw

Fixing screw
Figure 5-13 Screw positions

Step 3: Unscrew the fixing screws of the heater cover and disconnect the cable connector from the thermostats. The thermostats are the two cables marked L and N in Figure 5-14. Remove the heater cover. The heater is fixed on the heater cover, as shown in Figure 5-15.

Cable connector of the heater

Figure 5-14

Thermostats

Step 4: Remove the two fixing screws of the heater cover. The heater is fixed below the heater cover, as shown in Figure 5-15.

Heater cover Heater Fixing screws of the heater cover


Figure 5-15 Removing the heater cover

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance

35

Step 5: Unscrew the four fixing screws of the heater, cut off the cable connector and then remove the damaged heater, as shown in Figure 5-16.
Fixing screws of the heater (four altogether)

Figure 5-16

Removing the heater

Step 6: Weld the cable connector to the heater cable, as shown in Figure 5-17. Use the heat shrinkable tube to reinforce the welding point. Fix the new heater on the heater cover and mount the cover on the cabinet.

Cable Heat shrinkable connector tube

Figure 5-17

Welding the cable connector

Step 7: Connect the cable connector to the thermostat. The position is shown in Figure 5-14. Finally, mount the distribution unit on the cabinet. Step 8: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater MCB after making sure every thing is OK.

5.8.2 Replacing The Heater In Battery Compartment


Step 1: Switch off the AC MCB, battery MCB and the heater MCB, as shown in Figure 5-12. Step 2: Take out the battery string. Please refer to 3.6 Installing Batteries for removing procedures. Step 3: Disconnect the cable connector from the thermostat. Remove the heater cover after removing the screws on the cover, as shown in Figure 5-18.
Heater of battery Fixing screws of the heater compartment (two altogether)

Figure 5-18

Removing heater of battery compartment

Hold the heater when removing the fixing screws, as shown in Figure 5-19.

Figure 5-19

Removing heater of battery compartment

Step 4: Weld the cable connector to the heater cable, as shown in Figure 5-17. Install a new heater and fix it. Connect the cable connector to the thermostat. Move the battery string to its original position.

APM100 Outdoor Power Supply System User Manual

36

Chapter 5 Maintenance Step 5: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater MCB after making sure every thing is OK.

5.8.3 Replacing Thermostats


There are two thermostats in one heater circuit. When the ambient temperature is below 5C 5C, the thermostat contacts are closed to switch on the heater circuit. When the ambient temperature is above 15C 5C, the thermostat contacts are opened to switch off the heater circuit. Replace the thermostat if its contact cannot be closed or opened normally. Every compartment has two thermostats that are connected in series in the phase line and the neutral line separately, as shown in Appendix 5 Wiring Diagram. The position of the thermostat in equipment compartment is shown in Figure 5-20, and that of the thermostat in battery compartment is shown in Figure 5-21.

Thermostat of equipment compartment

Figure 5-20

Thermostat of equipment compartment

Thermostat of battery compartment

Figure 5-21

Position of the heater/ thermostat in battery compartment

Replacement procedures: Step 1: Switch off the AC MCB, battery MCB and the heater MCB, as shown in Figure 5-12. Step 2: Take out the battery string on the lower floor of the battery compartment. Please refer to 3.6 Installing Batteries for the removing procedures. Step 3: Disconnect the cable connector of the thermostat and remove the screws. Step 4: Replace a new thermostat and connect the cable connector of the thermostat to its terminal. Step 5: Switch on the AC MCB, battery MCB and the heater MCB.

5.9 Replacing Door Status Sensor


There is a door status sensor installed in cabinet for detecting the close or open status of the compartment door. The monitoring module will generate an alarm when the door is opened. The door status sensor is not intended for service or repair, just replace it when they are damaged. If an alarm is generated when the door is closed the sensor must have been damaged. The position of the sensor is shown in Figure 1-2. Remove the sensor cap and then the two screws. Replace the old sensor with a new one and finally fix the sensor and the signal cables with the screws.

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance

37

5.10 Replacing AC SPD


The AC SPD is behind the distribution unit. The appearance is shown in Figure 5-22.

Figure 5-22

AC SPD

Check the SPD indicator on the monitoring expansion board, as shown in Figure 5-23. The position of the monitoring expansion board is shown in Figure 1-2.

Alarm i ndicator of DC SPD

Alarm i ndicator of AC SPD

Figure 5-23

AC/ DC SPD indicator

If the indicator on the right is on, the AC SPD must have failed and thus needs replacement. The replacement procedures of AC SPD are as follows: Step1: Switch off the AC MCB and the battery MCB. The position is shown in Figure 5-12. Step 2: Remove the panel of the distribution unit. The position is shown in Figure 5-12. Step 3: Remove the four screws shown in Figure 5-13, and remove the five cables connected to the AC SPD, as shown in Figure 5-24.
AC input cable

AC output cable
Figure 5-24

PE cable

Cables connected to AC SPD

APM100 Outdoor Power Supply System User Manual

38

Chapter 5 Maintenance Step 4: Remove the right segment of the distribution unit and pull out the SPD alarm interface, as shown in Figure 5-25. Be sure to pay attention to personnel safety.

Alarm interface

Figure 5-25

Pull out the SPD alarm interface

Step 5: Remove the four fixing screws of the SPD shown in Figure 5-26. Disconnect the cables connected to the SPD.

SPD fixing screws

Figure 5-26

Remove the fixing screws of SPD

Step 6: Reverse previous steps 4 ~ 1 and replace the new SPD. Connect the cables, fix the screws and the SPD. Step 7: Fix the distribution unit onto the cabinet. Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and restart operation after making sure everything is OK.

5.11 Replacing DC SPD Board


If the DC SPD indicator on the monitoring expansion board is on, the DC SPD board must have failed and thus needs replacement. The DC SPD board locates behind the distribution panel, as shown in Figure 5-27.
DC SPD board

Figure 5-27

Position of DC SPD board (unwired)

The DC SPD board replacement procedures are as follows: Step 1: Switch off the AC MCB and the battery MCB. The position is shown in Figure 5-12. Step 2: Remove the panel of the distribution unit. The position is shown in Figure 5-12. Step 3: Remove the load cables, battery cables, positive DC output cable, and power cable of DC SPD board and monitoring expansion board, as shown in Figure 5-28. Refer to 5.14 Replacing Distribution Subrack for removing method. Remove the cables connected to the batteries before removing the battery cables. Refer to 3.6 Installing Batteries for removing method and to 5.15 Battery Maintenance for precautions.

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance
Battery cables

39

Fixing screw of load cable

Positive DC output cable


Figure 5-28

Power cable of DC SPD board and monitoring expansion board

Removing cables of the distribution subrack

Step 4: Loosen the cable fixing screws of the SPD board. Do not take them off. Remove all the cables connected to the SPD board, as shown in Figure 5-29. Be sure to pay attention to personnel safety. Step 5: Take off the alarm cable connector and the power cable connector, as shown in Figure 5-29.

Power cable of the SPD

Cable fixing srew


Figure 5-29

Alarm cable connector

Removing DC SPD board cables

Step 6: Loosen the fixing screws of the DC SPD board. Take off the DC SPD, as shown in Figure 5-30.

Fixing screws of the SPD board


Figure 5-30 Removing DC SPD board

After the replacement, reverse step 6 ~ step 1 to install the new SPD.

5.12 Replacing Temperature Sensor


The locations of the equipment compartment temperature sensor and battery compartment temperature sensor are shown in Figure 5-31 and Figure 5-32.

Temperature sensor of equipment compartment

Figure 5-31

Temperature sensor of equipment compartment

APM100 Outdoor Power Supply System User Manual

40

Chapter 5 Maintenance
Temperature sensor of battery compartment

Figure 5-32

Temperature sensor of battery compartment

If the temperature sensor is damaged and needs replacement, follow the procedures to replace it: 1. Unplug the damaged temperature sensor. 2. Plug the connector of the temperature sensor to the corresponding socket in the monitoring expansion board, as shown in Figure 5-33.

Screen print of Monitoring expansion board socket

Socket of battery- compartment Socket of equipmenttemperature sensor compartment temperature sensor

Figure 5-33

Temperature sensor socket

3. Lay the temperature sensor at the location shown in Figure 5-31 or Figure 5-32.

5.13 Replacing Monitoring Expansion Board


The monitoring expansion board locates at the left side within the cabinet. The replacement procedures are as follows. 1. Switch off the AC MCB and battery MCB, as shown in Figure 5-12. 2. Remove the four fixing screws of the monitoring expansion board, and you can remove the cover of the monitoring expansion board, as shown in Figure 5-34.

Fixing screws

Fixing screws

Figure 5-34

Removing cover plate of the monitoring expansion board

APM100 Outdoor Power Supply System User Manual

Chapter 5 Maintenance

41

3. Remove the nine cable interfaces connected to the monitoring expansion board. Remove the signal cable of the monitoring module with a screwdriver (please refer to 5.4 Replacing Modules), and take off the communication cable of the monitoring module. Then you can take off the monitoring expansion board, as shown in Figure 5-35.
Communication cable Interface 6

Interface 1 Interface 2 Interface 3 Interface 4 Interface 5

Interface 7 Interface 8 Interface 9 Signal cable

Figure 5-35

Cable interfaces of the monitoring expansion board

After the replacement, reverse the above procedures to install the new monitoring expansion board.

5.14 Replacing Distribution Subrack


The procedures of replacing distribution subrack are as follows: 1. Switch off the AC MCB, battery MCB and the heater MCB, as shown in Figure 5-12. 2. Remove the cables connected to batteries. Please refer to 3.6 Installing Batteries for removing procedures and 5.15 Battery Maintenance for precautions. 3. Remove the rectifiers and the monitoring module. Refer to 5.4 Replacing Modules for removing procedures. 4. Remove the AC input cables. Remove the phase line first, and then the neutral line. Remove the grounding cable, as shown in Figure 5-36.
Load cables Battery cables (six altogether) (two altogether) AC input cables

Grounding cable

Figure 5-36

Removing distribution subrack

5. Remove the load cables and other cables, as shown in Figure 5-37. Loosen the fixing screws and you can remove the load cables.
Fixing screw of load cable

Figure 5-37

Removing load cables

APM100 Outdoor Power Supply System User Manual

42

Chapter 5 Maintenance Use a slotted screwdriver with proper length to remove cable- fixing screws, as shown in Figure 5-38.

Cable fixing screw

Figure 5-38

Removing other cables

6. Remove the four fixing screws shown in Figure 5-39 and you can remove the distribution subrack.

Fixing screws of the distribution unit

Fixing screws of the distribution unit

Figure 5-39

Fixing screws

5.15 Battery Maintenance


Refer to the battery user manual supplied with the battery. (Note: It is recommended to use T12V100SEF/A battery within this system. If you use batteries of other models, please consult with Emerson to prevent improper configuration.) When replacing the batteries, you should remove the battery cables firstly. See 3.6 Installing Batteries for the removing method. Please note that the battery cables must be jacketed with the heat shrinkable tube, as shown in Figure 5-40.
Battery cable Heat shrinkable tube

Figure 5-40

Battery cable shielded with heat shrinkable tube

When the number of the batteries that need replacement is smaller than four, the new batteries must be of the same model with the old ones.

APM100 Outdoor Power Supply System User Manual

Appendix 1 Technical Data

43

Appendix 1 Technical Data


Environmental parameters
Table 1 APM100 environmental parameters

Parameter Operating temperature Storage temperature Relative humidity Altitude Solar radiation

Technical data North model: -40C ~ 45C; South model: -5C ~ 45C -40 ~ 70 5%RH ~ 100%RH (40 2C) 2000m (The system should be derated where the altitude is higher than 2000m. The highest operating temperature should be reduced by 1C at every 200m higher) Direct radiation: 1120W/m2 Dispersion radiation: 224W/m2

Electrical parameters
Table 2 APM100 electrical parameters

Parameter type

AC input

Parameter AC input system Rated input voltage Input voltage range Input frequency range Rated frequency Maximum input current Output voltage Maximum output current

Technical data Single phase three wire 220Vac/ 110Vac 90Vac ~ 290Vac* 40Hz ~ 65Hz 50Hz/ 60Hz 25A (with no user connector- jack output)
-48Vdc

DC output

52A

Note*: When the input voltage is within 90Vac~176Vac, the rectifiers output is allowed of linear derating. When the voltage input is 90Vac, the minimum rectifier output power is 37.5% of rated power

Mechanical parameters
Table 3 APM100 mechanical parameters

Technical data 1130mm 600mm 600mm (without base); 1280mm 600mm 600mm (with base APM100 dimensions (H % W % D) and rings) Battery compartment dimensions (H % W % D) 270mm 475mm 520mm 300kg (Including four pieces of 12V 100Ah batteries) APM100 weight 90kg (Excluding batteries and rectifiers)

Parameter

Audible noise 65dB. Anti-erosive performance Coating: 1. Adhesion test satisfies ISO2409 Class 0. 2. The pencil rigidity test satisfies ASTM D3363 2H. 3. Shock test satisfies 50kg.cm according to ASTM D2794. 4. The coating is not changed after 500 hours salt-fog test according to ASTM B117. 5. The coating of the external surface of the cabinet is suitable at the -40C to +55C environmental temperature and 2 1120W/m solar radiation. The coating should not blister, flake or flaw after 250 hours test according to ASTM D822. But it is allowed to have slight pulverization, that is, a little paint particle is allowed to adhere when the coating is wiped at full tilt. The slight change of color is allowed, that is, it is acceptable if the color difference value (NBS) is less than 6.0.

APM100 Outdoor Power Supply System User Manual

44

Appendix 1 Technical Data Protection requirement 1. The cabinet of the equipment compartment satisfies GB4208 IP55. 2. The cabinet of the battery compartment satisfies GB4208 IP34. Lightning protection 1. The system has a Level B+C SPD on AC side. 2. The AC input can withstand the maximum strike through current capacity of 60kA, and the nominal through current capacity is 25kA. The simulated lightning strike is carried out in term of YD1235.1 and YD1235.2. 3. The test of which the DC side can withstand through current capacity of 15kA requires: -48V-RTN can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively 5 times, and the interval between every two tests is one minute; RTN-PE can withstand the strike of 15kV with the waveform 8/20s 5 times, for positive and negative polarity respectively 5 times, and the interval between every two tests is one minute.

APM100 Outdoor Power Supply System User Manual

Appendix 2 Definitions Of Monitoring Expansion Board Interfaces

45

Appendix 2 Definitions Of Monitoring Expansion Board Interfaces


All the sensors are connected to the monitoring expansion board. The screen print diagram of the wiring port of the monitoring expansion board is as follows.

Screen print of Monitoring expansion board socket

Figure 1

Screen print diagram of the monitoring expansion board

Connector models of the monitoring expansion board terminals and recommended connection cables are in the following table.
Table 4 Connector models and recommended connection cables

Signal port Water logging Ambient temperature/ humidity Main distribution frame Smoke sensor Door status sensor Alarm dry contact Optical- coupler output Backup digital data input RS422 communication port Preset dry contact port

Screen print marks J_WATER TEM_HU J_WIRE J_SMOKE JTM1 JK1, JK2 JAC1, JAC2 J9 J8 J12

Socket- connector model P2500-4 P2500-4 P2500-2 P2500-2 P2500-2 P2500-2 P2500-2 MSTB2.5/2-ST-5.08 MSTB2.5/4-ST-5.08 MSTB2.5/2-ST-5.08

Recommended cable model (AWG) 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22 26~22

The functional definitions of port- pins of the monitoring expansion board are shown in the following table.
Table 5 Port- pin definitions of the monitoring expansion board

Port name Backup digital value

Screen print marks J9

Water logging sensor port

J_WATER

Port of the ambient temperature/ humidity sensor

TEM_HU

Battery- temperature sensor port

BAT_WE

Optical- coupler1 controlling output port Optical- coupler2 controlling output port

JAC1 JAC2

Correlative pins 1,3,5 2,4,6 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2

Signal properties

Remark

+24V output Input of the signal cable +12V output Input of the signal cable Earth cable None +24V output Input of the temperature signal cable +24V output Humidity signal cable input Earth cable Check the batteryBattery- temperature signal cable input compartment temperature. +12V output Connected before delivery +12V output Optical- coupler1 controlling output Optical- coupler1 controlling output Optical- coupler2 controlling output Optical- coupler2 controlling output

APM100 Outdoor Power Supply System User Manual

46

Appendix 2 Definitions Of Monitoring Expansion Board Interfaces


Port name Port of mains distribution frame sensor Door status sensor port Smoke sensor port Alarm dry contact port Alarm dry contact port Screen print marks J_WIRE JTM1 J_SMOKE JK1 JK2 Correlative pins 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 5 6 1~7 1 2 1 2 1 2 3 4 5 6 7 8 1 2 3 4 1~8 1 2 Signal properties Remark

Port of the Equipmentcompartment temperature Sensor

EQU_WE

Battery- balance test port

J4

Load MCB switch test port SPD failure test port on DC side SPD failure test port on AC side

J3 J5 J6

Fan- control port

J_FAN

RS422 communication port


*

J8

Preset dry contact port

J12 J2

Expansion board power input port

Main distribution frame signal input +48V power output Door status sensor signal input +24V power output Smoke signal input +24V power output Dry contact1 output Dry contact1 output Dry contact2 output Dry contact2 output Earth cable Signal cable input of equipment compartment temperature +12V output +12V output BUS+ input BAT1 mid- voltage input BAT2 mid- voltage input BUS- input None None 7 Load MCB monitoring signal input -48V power output SPD failure of the DC side signal input Connected before delivery -48V power output SPD failure of the AC side signal input Connected before delivery Power output To internal fan. Connected Signal output of fan speed before delivery Signal input of fan failure Power- earth cable Power output To external fan. Connected Fan speed signal output before delivery Signal input of fan failure Power- earth cable TX+ TXRX+ RXRLn+, RLnBusbar+ Busbar-

Remark*: The descriptions of the dry contact port presetting is as follows: When the DIP switch 6 is switched to OFF, the dry contacts are closed when normal and are open upon alarms. When the DIP switch 6 is switched to ON, the dry contacts are open when normal and are closed upon alarms. The following description are given in case of DIP switch 6 switched to OFF. Dry contact 1: dry contact of AC/ DC SPD alarm are preset closed (normal state), and open upon AC/ DC SPD alarms. Dry contact 2: dry contact of mains failure alarm are preset closed (normal state), and open upon mains shortage, mains over/ under- voltage alarm occurs. Dry contact 3: dry contact of DC under- voltage alarm are preset closed (normal state), and open upon DC undervoltage alarm occurs.

APM100 Outdoor Power Supply System User Manual

Appendix 2 Definitions Of Monitoring Expansion Board Interfaces

47

Dry contact 4: dry contact of system power alarm are preset closed (normal state), and open upon rectifier failure, rectifier protection, rectifier communication abnormal, busbar output over/ under- voltage alarm, charging over- current alarm, battery string route disconnection or internal/ external fan fault alarm occur.

APM100 Outdoor Power Supply System User Manual

48

Appendix 3 Common Problems

Appendix 3 Common Problems


After installation and testing, the system is ready for use. When necessary, it can be put into normal operation just by switching on the corresponding MCB. During the operation, the following issues may call your attention: Fan speed control technology The fan may run for a second and stop when the rectifier is powered on for the first time. If load is connected to the system, the inner temperature of the rectifier will increase after operation for a period of time, and the fan will begin running and speed up with the increase of inner temperature. That phenomenon is due to the fan speed adjusting technology, and thus absolutely normal. Over temperature protection A rectifiers inner temperature may be high during operation. If you reset it by turning it off and on at that time, you may observe that the rectifier has no output but the fan is running. That is because the over temperature protection circuit within is working. The output will recover after the temperature decreases one minute later. If the fan does not run, and the rectifier has no output for more than five minutes, the rectifier may have been damaged. Please replace the faulty rectifier or contact Emerson local service center.

APM100 Outdoor Power Supply System User Manual

Appendix 4 Schematic Diagram

49

Appendix 4 Schematic Diagram


1QF2 1 2 1QF1 2 1 4 3 Alarm SPD Nin PE Nout PE XT1 Lout 1QF3 KT1
Thermostat Heater for equ. compartment

KT2
Thermostat

L AC Input

Lin

XS KT3
Thermostat Heater for bat. compartment

AC INPUT

KT4
Thermostat

Heater Subassembly For North Model Cabinet PE PE

EMI Standby value input port RS485 communication port

AC/DC

Dry contact AC/DC AC/DC AC/DC Temperature sensor of equ. compartment Temperature sensor of bat. compartment

MONITOR

48V FL1 FL2

PSM

Monitoring expansion board

KM1

KM2

2QF1 16A

2QF2 16A

2QF3 16A

2QF4 16A

2QF5 32A

2QF6 32A

2QF7 63A

FAN1

FAN2

LOAD 1

LOAD 2

LOAD 3

LOAD 4

LOAD 5

LOAD 6

DC OUTPUT

F2

DC SPD Board

PE

Alarm

BATT.
XT2 1 2 3 4 5 6 7 8 9 10

Door status sensor

-48V DC output

0V DC busbar

PE busbar for inside cabinet

PE busbar for outside cabinet

Figure 2

Schematic diagram of APM100 outdoor power supply system (with 220V AC input)

Note: the preceding schematic diagram is only used for the standard product.

APM100 Outdoor Power Supply System User Manual

50

Appendix 4 Schematic Diagram


1QF2 1 2 1QF1 2 1 4 3 F1 Lin Nin
Thermostat

Heater for equ. box

Thermostat

L1 AC Input L2

Alarm SPD PE

XT1 Lout

1 N

1QF3

2 N

Nout

XS L N

PE
Thermostat

Heater for bat. box

Thermostat

AC INPUT

N PE PE

Heater Subassembly For North Model Cabinet

EMI

Standby value input port RS485 communication port Dry contact

AC/DC
48V

AC/DC

AC/DC

AC/DC

MONITOR

PSM
FL1 FL2

Monitoring transfer board

Temperature sensor for equipment compartment Temperature sensor for battery compartment

KM1

KM2

2QF1 16A
LOAD 1

2QF2 16A
LOAD 2

2QF3 16A
LOAD 3

2QF4 16A
LOAD 4

2QF5 32A
LOAD 5

2QF6 32A
LOAD 6 PE

2QF7 63A

FAN1

FAN2

External fan Internal fan

F2

DC SPD Board

Alarm

BATT. Door status sensor

DC OUTPUT

XT2 1

10 11

-48V DC output

PE busbar for outside cabinet 0V DC busbar PE busbar for inside cabinet

Figure 3

Schematic diagram of APM100 outdoor power supply system (with 110V AC input)

APM100 Outdoor Power Supply System User Manual

Appendix 5

Wiring Diagram

51

Appendix 5 Wiring Diagram

W09 34 36

J12

J2

Screen print of Monitoring expansion board socket

B1- B2-

B1+B2+

LOAD1- LOAD2- LOAD3- LOAD4- LOAD5- LOAD6- BATT.(-)

SPD- LOAD+ BATT.(+)

W11 43

09

10 W12 44
Equipment N 21 KT1 compartment L 21 heater

KT2

W02 W12 45

AC SPD

20 18 17 16 15

Temperature detection of equipment compartment


To AC outleading cable of the subrack

W05

W04

W10 41
W07 29 W06 26 25 19

W10 41A Standby temperature detection of equipment compartment


L(L1)

Battery temperature compensation W10 42

0VDC BUS -48VDC OUTPUT

W07

24

23
Door sensor

W03 11 AC INPUT PE busbar


39 W09

40 W03 13

W09 35
Heater of battery compartment

L N

22 22 PE busbar outside cabinet


W03 14

Battery string

Cross door cable

Figure 4

Wiring diagram of APM100 outdoor power supply system

APM100 Outdoor Power Supply System User Manual

52

Appendix 6 Spare Part List

Appendix 6 Spare Part List


The common spare parts of APM100 are listed in the following table.
Table 6 Spare part list

Bill of the spare part 02400495 02130518 19020099 02440018 03034342 03026682 32010108 11010118 02510016

Spare part Distribution subrack Rectifier AC SPD Monitoring module Monitoring expansion board DC SPD External/ internal fan Thermostat Heater

APM100 Outdoor Power Supply System User Manual