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Power Supply System GDN.C.48.10 POS Instruction Manual

Document Number: BCG.00003 Rev: AA

Copyright © 1999-2009 Power-One, Inc. All Rights Reserved Restricted Rights Legend: Use, duplication, or disclosure by the Government is subject to restrictions as set forth in subparagraph © (1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 or subparagraphs © (1) and (2) of Commercial Computer Software Restricted Rights at 48 CFR 52.227-19, as applicable. For Contact Information, please go to http://www.power-one.com/contact/ Refer to the Power-One License Agreement in this package before installing or using this product. Unless specifically noted, all addresses, data characters and persons referenced herein, and all examples involving names of companies and products, are fictitious examples and are designed solely to illustrate the use of Power-One products. Product names, logos, brands, and other trademarks featured or referred to within this product manual are the property of their respective trademark holders. These trademark holders are not affiliated with Power-One, Inc. or our products. They do not sponsor or endorse our products. LIMITATIONS AND AUTHORIZATIONS FOR USE AND PERMITTED APPLICATIONS Power-One's products are not designed, intended for use in, or authorized for use as critical components in, human life support systems/equipment, equipment used in hazardous environments, or equipment used in nuclear control equipment or systems. Any such use requires the prior express written consent of an authorized executive officer of Power-One, Inc., which consent may be withheld by Power-One, Inc. in its sole discretion. Users assume all risk and liability for, and agree to indemnify and defend Power-One from and against any claims for personal injury (including death) or property damage resulting from any such use or application which is made in the absence of such prior express written consent. If you find errors or problems with this documentation, please notify Power-One. Power-One does not guarantee that this document is error-free. The information in this document is subject to change without notice. BCG.00003 June 2009

Contents Chapter 1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 1.1 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 Document Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.4 Feedback & Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.5 Layout, Numbering and Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1.6 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Chapter 2 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.4 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.4.1 System Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.4.2 Rectifier Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.4.3 Rectifier Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.4.4 PBDU 23” - Distribution module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.4.5 AC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.4.5.1 Low Voltage Disconnection (LVD) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2.4.5.2 Partial Load Disconnection (PLD) (Option) . . . . . . . . . . . . . . . . . . . . 2-9

Chapter 3 System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 3.1 Safety Warnings and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.1 System Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Safety Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.1.3 Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.1.4 Restricted Access Area Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3.1.5 Operating Temperature Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.6 Electrical Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.7 Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.1.8 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.1.8.1 Lead Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3.1.9 In Case of an Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.2 Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.2.1 Storage and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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iii

3.2.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 Handling Electrostatic Sensitive Devices . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.4 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.5 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.6 Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5 3-6 3-6 3-6 3-6

Chapter 4 Installation Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.3 Tools required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.4 Installation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.4.1 Cabinet Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.4.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.4.3 Cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4.4.4 Connection of Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.4.5 Alarm Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.4.6 Symmetry and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.5 Installation of Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.6 Battery Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.7 DC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Chapter 5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Test of output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Float charge (U1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2 Adjustment of Float Charge, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3 Boost Charging (U2) (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Battery Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Commissioning record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-2 5-2 5-2 5-2 5-2 5-4 5-4 5-4 5-4 5-5 5-5 5-6

Chapter 6 System Controller PCC . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.1 General - Product description PCC w/Display . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Technical specification:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Operation - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Starting the PCC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Adding modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Removing modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.4 PCC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.5 PCC Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6 PCC Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.1 Show voltage and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.2 Show alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.3 Show messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.4 Show data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.5 Controller failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6.6 Select / adjust U1 - U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv

6-1 6-2 6-2 6-3 6-4 6-4 6-4 6-5 6-6 6-7 6-7 6-7 6-7 6-8 6-8

GDN.C.48.10 POS Power Supply System Instruction Manual

6.3.6.7 Adjust limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 6.3.6.8 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 6.3.7 Connecting to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6.3.8 Connecting a Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.3.9 Boost charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 6.3.10 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 6.3.11 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 6.3.12 High load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Chapter 7 Product Description AC Distribution. . . . . . . . . . . . . . . . .7-1 7.1 Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.2 Cable cross section output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.4 Commissioning PBDU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Chapter 8 Maintenance & Troubleshooting. . . . . . . . . . . . . . . . . . . .8-1 8.1 Installing new Rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 8.4 Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

Appendix A Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1 Cabinet Layout GDN.C.48.10 POS - BCE.00028 - Rev.: AA . . . . . . . . . . . . . . . A-2 A.2 Installation Drawing GDN.C.48.10 POS - BCE.00029 - Rev.: AA . . . . . . . . . . . A-3 A.3 Block Diagram GDN.C.48.10 POS -044014 - Rev.: AB . . . . . . . . . . . . . . . . . . . A-4 A.4 Schematic Diagram 2xsubrack w/AC distr. - BCE.00030 - Rev.: AA . . . . . . . . . A-5 A.5 Schematic Diagram PBDU GDN.C.48.M24 - 043961 - Rev.: AB . . . . . . . . . . . . A-6

Appendix B Configuration PCC (C-000548) . . . . . . . . . . . . . . . . . . B-1 Appendix C Distribution GDN.C.48.10 POS . . . . . . . . . . . . . . . . . . C-1 Appendix D AC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Contents

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GDN.C.48.10 POS Power Supply System Instruction Manual

Chapter 1 About This Manual

This chapter contains an overview of the information that is presented in this Power System Manual. This includes information on objectives, the intended audience, and the organization of this manual. In addition, this chapter also defines the conventions used to indicate warnings, cautions and noteworthy information.

1.1 Objectives This manual describes the Power System, explains how to unpack and install the system, how to perform the initial power-up and operational system check. The information presented in this document is current as of the publication date.

1.2 Audience This manual is to be used by installers and technicians who are preparing the site for a new installation and installing the power system. This manual assumes that the technician has an understanding of power systems in general and understands safety procedures for working around AC and DC voltage. The user of this document should be familiar with electronic circuitry and wiring practices and have some expertise as an electronic, power, or electromechanical technician.

About This Manual Power-One Document Number: 039462.fm Rev. AF2

1-1

Document Key

1.3 Document Key This manual uses the following conventions: WARNING This symbol indicates a situation that could cause bodily injury. Always be aware of hazardous conditions when working in or around the power system.

This symbol indicates a situation that might result in equipment damage. The reader should be aware that their actions could result in equipment or data loss. CAUTION

This symbol is used to reference information either in this manual or in another document. NEED MORE INFORMATION?

This symbol means the reader should take note. Notes are helpful suggestions or reminders. NOTE

Table 1-1 Abbreviation

Description

P1 PPS PMP

Power One P1 Power Supply System

CMP FMP PCS PCU PCC ACC GMC PPR PBDU PBC PDU PPRD PPC PBF

1-2

Abbreviations

P1 Modular Power Convection-cooled Modular Power Fan-cooled Modular Power P1 Control and Supervision P1 Control Unit Prime Controller Card Advance Controller Card Galero Modular Controller P1 Power Rack P1 Battery Distribution Unit P1 Battery Cabinet P1 Distribution Unit P1 Power Rack with DC Distribution P1 Power Supply Cabinet P1 Battery Fuse Unit

Power Supply System Instruction Manual Power-One Document Number: 039462.fm Rev. AF2

Feedback & Support

PCB LVD PLD MCB MCCB XR DFC PODS BTS

Printed Circuit Board Low voltage disconnection Partial load disconnection Miniature circuit breaker Moulded case circuit breaker Xscend Rectifier Direct Fan Cooling P1 Outdoor System Base Transceiver Station

1.4 Feedback & Support For technical support or feedback, please visit http://www.power-one.com/contact/ Contact telephone numbers are: Region

Contact Number

Asia/Pacific

+ 65-6896-3363

Europe, Middle East, and Africa

+ 800-76937663

The Americas and Caribbean

+ 1-805-987-8742

1.5 Layout, Numbering and Printing This manual is intended for two-sided black and white printing. Some pages are intentionally left blank. The pages are numbered consecutively within each chapter, prefixed by the chapter number.

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

About This Manual Power-One Document Number: 039462.fm Rev. AF2

1-3

Disclaimer

1-4

Power Supply System Instruction Manual Power-One Document Number: 039462.fm Rev. AF2

Chapter 2 System Description

2.1 General The Guardian DC power cabinet system is designed to meet rigid telecom applications. This cabinet power solution provides rectification, system management and power distribution. The power system is based on fan-cooled, hot-swappable rectifier modules (FMP25.48 - air cooling) with output power available at 2500 W per module. System management is accomplished through messages and alarms displayed on the system controller’s LCD screen and can also be displayed remotely via the PC-based PowCom™1 software package. NOTE Rectifiers modules are normally shipped un-mounted, but in the same package as the equipment cabinet. In some particular cases rectifier modules may be shipped separately in their own packaging.

1. Communication program for remote control of the power system

System Description Power-One. Document Number: 046078 Rev. AA

2-1

General

Figure 2-1

System Overview

1

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C16

C16

C16

C16

C16

C16

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

230/400V 6000 3

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

I ON

i

3 4

1. Removable Top Lid 2. AC Distribution 3. Distribution with System Controller (PCC) 4. Rectifiers FMP 25.48

NOTE

2-2

System shown in 800 mm cabinet.

GDN.C.48.10 POS Power Supply System Instruction Manual Power-One. Document Number: 046078 Rev. AA

Technical Data

2.2 Technical Data Figure 2-2

Principle drawing

PCC DC distribution AC

FMP 25

F F

FMP 25

LVD

FB

BATT

Input:

Voltage: Current:

3x230 V AC