Emerson 48330 User Manual

ACTURA Flex 48330 Power System
User Manual

Version: V1.0
Revision date: May 20, 2005
BOM: 31011084

Emerson Network Power provides customers with technical support.
Users may contact the nearest Emerson local sales office or service
center.

Copyright © 2005 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: [e-mail]

Safety Precautions

To avoid accident, read the safety precautions very carefully before operation.
The "Caution, Notice, Warning, Danger" in this manual do not represent all the
safety points to be observed. Therefore, the installation and operation
personnel must be strictly trained and master the correct operations and all the
safety points before actual operation.

When operating Emerson products, the safety rules in the industry, the general
safety precautions and special safety instructions must be strictly observed.

Electrical Safety

1. Hazardous voltage
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, be sure to remove conductive objects, such as watch, bracelet,
ring, and so on.

When water or moisture is found on the cabinet, turn off the power immediately.
In moist environment, take precautions to keep moisture out of the power
system.

"Prohibit" warning label must be attached to the switches and buttons which
are not permitted to be operated on during installation.

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

2. Tools
In high voltage and AC operation, special tools must be used. No common or

homemade tools should be used.

3. Thunderstorm
Never operate on high voltage, AC, iron tower or mast on a day with

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.

4. ESD
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, ESD wrist strap must be worn to prevent body
static from damaging the sensitive elements. The other end of the ESD wrist
strap must be well earthed.

5 Short-circuit
During operation, never short the positive and negative terminals of the MFU

of the system or the non-earthing terminal and the earth. The power system is
a 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.

Never wear a watch, bracelet, ring, or other conductive objects during
operation.

Insulated tools must be used.

Battery

Before any operation on battery, read very 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 pose potential threat to the
equipment, it 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.
Wear an 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.

Special Safe Requirements of This Equipment

The equipment has multi power inputs;
The equipment shall be installed on cement ground.

Others

1 Safety requirement
Please use the same model fuse to replace the fuse in the DC Power System.

2. Sharp object
When moving equipment by hand, wear protective gloves to avoid injury by

sharp object.

3. Cable connection
Please verify the compliance of the cable and cable label with the actual

installation prior to cable connection.

4. Binding the signal cables
The signal cables should be installed separately far away from heavy current

and high voltage cables, with distance at least 150mm.

Contents

Chapter 1 System Description................................................................................................1

1.1 Abbreviation..............................................................................................................1

1.2 Introduction...............................................................................................................1

1.3 Features....................................................................................................................1

1.4 Sy

1.5 Components..............................................................................................................4

Chapter 2 Installation...........................................................................................................12

2.1 Installation Preparation ...........................................................................................12

2.2 Installation Procedures............................................................................................15

2.3 External Electrical Connection

2.4 Battery Installation And Cabling

2.5 Parallel Connection Of Cabinets.............................................................................29

stem Configuration................................................................................................2

1.5.1 Rectif

1.5.2 Rectif

1.5.3 SCU................................................................................................................7

1.5.4 Multi-Function Unit (MFU)...............................................................................9

1.5.5 Battery Connection Unit (BCU).....................................................................10

1.5.6 Sy

2.1.1 Env

2.1.2 Power Supply................................................................................................12

2.1.3 Si

2.1.4 Tools & Material............................................................................................13

2.1.5 Unpacking.....................................................................................................14

2.2.1 Cabinet Installati

2.3.1 Connection Of Inpu

2.3.2 Connection Of Load Cables..........................................................................20

2.3.3 Connection

2.3.4 Layout Of Connector Board S6415X2...........................................................22

2.3.5 Interface Definition Of Connector Board S6415X2........................................23

2.3.6 Connection

2.3.7 Connection With MODEM.............................................................................24

2.3.8 Connection

2.4.1 Battery Installation ........................................................................................25

2.4.2 Battery Cable Connection.............................................................................26

ier Shelf..................................................................................................4

ier...........................................................................................................6

stem Cabinet.............................................................................................11

ironmental Conditions.............................................................................12

te Survey

...................................................................................................13

on .......................................................................................15

Interface .................................................................17

t Cables..........................................................................17

Of Communication Cables.........................................................21

Of Temperature Sensor Cables.................................................24

With Dry Contacts......................................................................25

..............................................................................25

Chapter 3

3.1 Checki

3.2 Startup Process

3.3 Parameters Configuration.......................................................................................31

Startup.................................................................................................................30

ng Before Startup.........................................................................................30

......................................................................................................31

Chapter 4 Testing.................................................................................................................32

4.1 Testing MFU ...........................................................................................................32

4.2 Testing Rectifier......................................................................................................32

4.3 Testing SCU............................................................................................................32

4.4 Battery

4.5 BCU Te

Breaker Test...............................................................................................33

st ................................................................................................................33

4.6 Load Breaker Test ..................................................................................................33

Chapter 5 Operating SC

U....................................................................................................34

5.1 Operation Panel......................................................................................................34

5.2 Operation Procedures.............................................................................................35

5.3 Query

5.3.1 First Page Of System Informatio

ing System Status .........................................................................................36

n.................................................................36

5.3.2 Other System Information Screen.................................................................37

5.4 Querying Rectifier Status........................................................................................39

5.5 Querying Alarms And Setting Alarm Plans

..............................................................40

5.5.1 Querying Active Alarm..................................................................................40

5.5.2 Query Alarm History

......................................................................................41

5.5.3 Alarm Type Table..........................................................................................43

5.5.4 Changing Audible/Visual Alarm And Alarm Call Back Pl

an...........................46

5.5.5 Changing Alarm Types Of Dry Contacts.......................................................46

5.5.6 Setting Alarm Type For Dry

Contacts ...........................................................46

5.5.7 Set the Alarm Names Through PLC Function...............................................48

5.6 Maintenance ...........................................................................................................51

5.7 Setting System Parameters ....................................................................................53

5.7.1 Parameter Setting

Method............................................................................53

5.7.2 Batt. Selection...............................................................................................55

5.7.3 LVD

Parameter Description..........................................................................56

5.7.4 Charging Management Parameters..............................................................57

5.7.5 Bat

tery Test Parameters...............................................................................60

5.7.6 Temperature Compensation Coefficient Parameters....................................62

5.7.7 AC Se

ttings...................................................................................................63

5.7.8 DC Setting ....................................................................................................64

5.7.9 Rect Settings ................................................................................................65

5.7.10 Sy

stem Settings..........................................................................................66

5.7.11 Alarm Settings.............................................................................................70

Chapter

6 Routine Maintenance...........................................................................................72

6.1 Mainte

nance Of Rectifier.........................................................................................72

6.2 Maintenance Of SCU..............................................................................................72

6.3 Mainte

nance Of MFU..............................................................................................72

6.4 Cover Plates ...........................................................................................................73

6.5 Battery Maint

6.5.1 Stora

enance...............................................................................................73

ge And Supplementary.........................................................................73

6.5.2 Daily Inspection.............................................................................................73

6.5.3 Replacement.................................................................................................74

Chapter 7 Troubleshooting...................................................................................................75

7.1 Troubleshooting Rectifier........................................................................................75

7.2 Mains Failure ..........................................................................................................76

7.3 Disastrous Accidents ..............................................................................................76

Appendix 1 System Technical Parameters ..........................................................................77

Appendi

x 2 Engineering Design Diagram ............................................................................79

Appendi

x 2.1 Engineering Design Diagram For 2000mm%600mm%600mm Cabinet
Appendix 2.2 Engineering Design Diagram For 2000mm%600mm%400mm Cabinet

Appendix 2.3 Engineering Design Diagram For 700mm%600mm%400mm Cabinet....81

Appendi

x 2.4 System Input And Output Connecto

Appendix 3 System Circ

uit Diagram.....................................................................................82

r Specs............................................81

Appendix 3.1 System Electric Schematic Diagram.......................................................82

Appendix 3.2 System Wiring Diagram

..........................................................................83

Appendix 3.3 MFU Electric Wiring Diagram..................................................................84

Appendix 3.4 BCU Electric Wiring Diagram..................................................................85

Appendi

x 4 Glossary............................................................................................................86

..79
..80

Table List

Table 1-1 Configurations of Actura Flex 48330 Power System..............................................3

Table 1-2 Dimensions of rectifier shelf...................................................................................5

1-3 Function of indicators.............................................................................................7

Table

Table 1-4 Authority and default password..............................................................................9

Table 1-5 Configuration of MFU...........................................................................................10

Table 1-6 BCU configuration................................................................................................11

2-1 Environmental conditions in power room .............................................................12

Table

Table 2-2 AC input modes ...................................................................................................17

Table 2-3 Configuration number of load MCBs and battery MCBs.......................................20

Table 2-4 Interface definition of connector board S6415X2.................................................23

3-1 System checklist before startup...........................................................................30

Table

Table 5-1 Functions of LED indicators.................................................................................34

Table 5-2 Functions of SCU keys.........................................................................................34

Table 5-3 Alarm type table

Table 5-4 Changing audible/visual alarm and alarm call back plan......................................46

Table 5-5 Optional alarm types............................................................................................47

Table 5-6 Logic matrix used for configuring 8 dry contacts..................................................49

Table 5-7 Example of PLC setting........................................................................................49

Table 5-8 PLC SN and Alarm...............................................................................................49

5-9 Password levels and authorities...........................................................................54

Table
Table 5-10

Table 5-11 Value description of the LVD parameters...........................................................57

Table

Table 5-13 Value description of the battery test parameters................................................61

Table 5-14 Value description of temperature compensation coefficient...............................62

Table 5-15 Value description of AC se
Table 5-16 Value description of DC se

Table 5-17 Value description of rectifier settings..................................................................65

Value description of the basic battery parameters .............................................56

5-12 Charging management parameter value description..........................................59

...................................................................................................43

ttings........................................................................63

ttings........................................................................64

Table 5-18 Value description of system settings

Table 5-19 Relationship between system model and system type.......................................70

Table 5-20 Value description of alarm settings ....................................................................71

Table 7-1 Troubleshooting ...................................................................................................75

..................................................................68

Figure List

Figure 1-1 Outline .................................................................................................................. 2

Figure 1-2 Rectifier shelf outline.............................................................................................

Figure 1-3 Rectifier shelf with rectifiers and CU.....................................................................4

Figure 1-4 Dimensions...........................................................................................................6

Figure 1-5 Outline of SCU......................................................................................................7

Figure 1-6 Outline and components of MFU..........................................................................9

Figure 1-7

Figure 2-1 Installation dimensions of the cabinet base ........................................................15

Figure 2-2 Installing expansive pipe.....................................................................................16

Figure 2-3 Fixing cabinet with Tap.......................................................................................16

Figure

Figure 2-5 Connection of input terminals .............................................................................18

Figure 2-6 Top cover............................................................................................................18

Figure 2-7 Connection of 3-phase AC power input ..............................................................18

Figure 2-8

Figure 2-9 Connection of dual-phase AC power input..........................................................19

Figure 2-10 Connection of load cables.................................................................................20

Figure 2-11 Cable connection to MCB

Outline of battery connection unit (BCU).............................................................10

2-4 Cable mounted with H terminal...........................................................................17

Connection of single-phase AC power input.......................................................19

.................................................................................20

4

Figure 2-12 Connector board in rectifier shelf......................................................................21

Figure 2-13 Layout of connector board S6415X2.................................................................22

Figure 2-14 Input/output interfaces of TD-5648DC MODEM................................................24

Figure 2-15

Figure 2-16 Connection of battery cables. ...........................................................................27

Figure 2-17 Positive and negative battery cables in each level............................................27

Figure 2-18 Negative battery cables connection in BCU......................................................28

Figure 2-19 Parallel connection of DC power system cabinet with battery cabinet..............29

Figure
Figure

Figure 5-3 Schematic diagram of the test function...............................................................61

Figure

Cabinet with four battery strings ins

5-1 SCU Front Panel.................................................................................................34

5-2 BC/FC switchover diagram.................................................................................59

5-4 System model description...................................................................................69

talled .........................................................26

Chapter 1 System Description

1.1 Abbreviation

AC Alternate Current
DC Direct Current
SCU Standard Controller Unit
BCU Battery Connection Unit
CSU Central Supervision Unit
HVSD High Voltage Shutdown
MCB Miniature Circuit Breaker

Chapter 1 System Description 1

APFC Active Power Factor Correction
MFU Multi-Function Unit

1.2 Introduction

The ACTURA Flex 48330 Power system consists of 50A rectifiers, Control Unit,
Multi-Function Unit (MFU), rectifier shelf and BCU (optional).

The product is used in base station, small exchange station, satellite
communication, data communication, and so on, with a strong adaptability to power
network fluctuation.

This system is used as a power supply for telecom equipment with system nominal
voltage of -48V and positive terminal earthed.

1.3 Features

The DC power system is easy-to-operate, easy-to-install and easy-to-maintain. Its
main features are:

 Rectifier uses APFC technology and therefore its PF is up to 0.99;
 Wide AC input voltage range of 85~290V;
 Rectifier efficiency is at least 90%;
 Extra low EMI of rectifier and excellent EMC performance;

ACTURA Flex 48330 Power System User Manual

2 Chapter 1 System Description

 High power density of rectifier;
 Rectifier has damage-free hot plugging/unplugging function, the replacement

time is less than 1min;

 Rectifier has two kinds of over-voltage protection methods;
 Perfect battery management with BLVD function;
 Up to 200 PCS of historical alarms can be stored in SCU;
 Provide RS232, Modem and dry contacts communication interfaces;

1.4 System Configuration

The outline of the DC Power System is illustrated in Figure 1-1:

Multi-function unit

Rectifier
Connector Board

Control unit

Rectifier shelf
Rectifier cover
Battery connection unit

Battery shelf

Door

Figure 1-1 Outline

There are three kinds of DC Power Systems, and their detail configurations are as
shown in Table 1-1:

ACTURA Flex 48330 Power System User Manual

Chapter 1 System Description 3

Table 1-1 Configurations of Actura Flex 48330 Power System

Configuration

Cabinet dimension

2.0 % 0.6 % 0.6 m3 2.0 % 0.6 % 0.4 m3 0.7 % 0.6 % 0.4 m3

3P+N/380V AC input with SPD
3P+N/380V AC input without SPD
1P+N/220V AC input with SPD
1P+N/220V AC input without SPD

AC distribution

DC distribution Up to 28 13mm-wide MCB, or 20 18mm-wide MCB
Rectifier Up to 5 rectifiers
Control unit 1 SCU
BCU 1 BCU with up to 5 battery circuit breakers

Battery

Dimensions
(H×W ×D) mm

L1+L2/220V AC input with SPD
L1+L2/220V AC input without SPD
3P/220V AC input with SPD
3P/220V AC input without SPD
5 2P AC input MCBs
Individual AC cables with just terminals

Telion 12V 165Ah FT:
16 Blocks

Hawker 12V 155Ah FT:
16 Blocks

Hawker 12V 105Ah FT:
20 Blocks

Hawker 12V 105Ah FT
and 6U space:

16 Blocks

2000×600×600 2000×600×400 700×600×400

Hawker 12V82F:
16 Blocks
Hawker SBSC11 and

3U space:
16 Blocks
EB4: 20 Blocks
Hawker 12V82F( no

BCU):
20 Blocks

No battery

ACTURA Flex 48330 Power System User Manual

4 Chapter 1 System Description

1.5 Components

1.5.1 Rectifier Shelf

Outline

The outline of the Rectifier Shelf is illustrated in Figure 1-2:

Chassis

Terminal connecting
50A Rectifier

Connector Board

Ear Bracket

(a) Actual appearance (front view)

Bus Bar

Back Board

(b) Actual appearance (rear view)

Figure 1-2 Rectifier shelf outline

The shelf can accommodate 5 rectifiers and a control unit as shown in Figure 1-3.
The user can mount the rectifier shelf into cabinets with widths of 600mm and
depths of 400mm. The rectifier shelf has a height of 3U (132.5mm).

Figure 1-3 Rectifier shelf with rectifiers and CU

ACTURA Flex 48330 Power System User Manual

Chapter 1 System Description 5

The Dimension of Rectifier Shelf are given in Table 1-2

Table 1-2 Dimensions of rectifier shelf

Manufacture type W(mm) ×D(mm) ×H(mm) Note

PSS485023/C 584.2×327×132.5 23’’ with controller

Backboard

The backboard has the functions below:

 DC power source feed for controller and the connector board.
 DC input filter and input fuse.
 All the ingoing and outgoing signals of the controller

The backboard also contains system internal connectors below:

 10 Distribution unit fuses alarm signal measurement input
 4 battery fuse alarm signal measurement input
 2 battery current shunt measurement inputs
 1 load Current shunt measurement input
 System bus-bar DC Voltage measurement input
 Three-phase from two mains AC Voltage measurement inputs
 CAN communication between rectifiers and controller
 AC alarm module signals
 System fault indicator drivers
 LLVD & BLVD mono contactor driver outputs
 The entire signal outgoing to the connector board

Connector board

Connector board is a user interface board and has the functions below:

 8-channel relay outputs
 8-channel digital inputs
 One power source feed terminal (for digital inputs)
 2-channel temperature sensor inputs
 2-channel RS232 parallel connection outputs
 LLVD & BLVD bistable contactor driver circuits and outputs

ACTURA Flex 48330 Power System User Manual

6 Chapter 1 System Description

 One Ethernet output
 One RS485 output
 One console output for ECU debug
 The connector board can be hot plug and has enough space for

accommodating all the interface cables.

 The connector board should space the hollow to the SCU convection for air

flowing

 The connector board is mounted in the room 1U×2U at the top of the SCU.
 The shelf has a 1U×2U panel for the connector board.
 One RS232 and Ethernet ports are located at the front of the connector board.
 The shelf has two rails for supporting the connector board

1.5.2 Rectifier

Outline

The appearance and dimensions (unit: mm) of the rectifier are illustrated in the
following figure.

Figure 1-4 Dimensions

Weight: ≤3.5kg
Dimensions (H × W % D): 124.3mm % 84mm % 287mm
The functions of the indicators in front panel are listed in Table 1-3.

ACTURA Flex 48330 Power System User Manual

1.5.3 SCU

LED Normal Abnormal Cause of abnormality

Power indicator (green) ON

Protection indicator
(yellow)

Alarm indicator (red) OFF

OFF

Outline

Chapter 1 System Description 7

Table 1-3 Function of indicators

OFF No AC Mains Supply
Blinking Rectifier is under control by SCU

ON
Blinking Communication of rectifier with SCU failure

ON Output Over-voltage
Blinking Fan Failure

AC input over/under voltage, PFC
over/under voltage and over temperature

Figure 1-5 Outline of SCU

Dimension (H % W % D):132mm % 85mm % 287mm
Weight: 0.76kg

Multi-Communication mode

SCU communicates with MC (Main Computer) through the RS232/MODEM
communication port and 8 groups of alarm dry contacts on the Signal Junction
Board.

SCU supports both China Telecom Communication Protocol and EEM Protocol.
Make sure that the baud rates for receiving and transmitting are set to be
consistent when using SCU.

1. Communication through RS232
RS232 communication mode is mainly used for short-distance point-to-point

communication. The communication distance shall be less than 15m. If SCU
communicates with MC through RS232, just connect SCU RS232 port to the
RS232 port of MC.

2. Communication through MODEM or ES-MOD

ACTURA Flex 48330 Power System User Manual

8 Chapter 1 System Description

When SCU communicates with MC through MODEM or ES-MOD, it uses PSTN to
realize long-distance monitoring. Power supply cables and communication cables
shall be prepared for the communication through MODEM.

3. Dry Contacts Output
SCU has 8 dry-contact outputs. Every dry-contact output has NC (normally closed)

and NO (normally-open) contacts. Every dry-contact output shall be configured
before the alarm event occurs. Different dry-contact output can trigger different
alarms. Once the alarm event occurs, the dry-contact will close or open to generate
the alarm.

If the user has other intelligent equipment to be monitored by SCU, the user can
connect the dry contacts to the interface of the intelligent equipment, and control
the intelligent equipment through these dry contacts.

Capacity of dry contacts: 2A@30Vdc; 05A@125Vac;
Maximum power dissipation: 60W

Functions fulfilled by SCU and MC

In RS232 and MODEM communication modes, the MC can fulfill the following
functions through SCU:

1. Remote acquisition of analog and digital values: MC can acquire the real-time
analog and digital values of DC Power System through SCU;

2. Remote control functions: MC can shut down the rectifiers, change the boost
charge status to float charge status (or in reverse), silence the alarm and stop/start
the battery test through SCU.

Alarm category settings for dry contact output

1. Through setting the parameter of “Relate Relay”, the user can configure the
alarm category for every dry-contact output. Every dry-contact output has been
configured to correspond to an alarm category before SCU is delivered to
customer.

2. SCU has PLC functions in the alarm management. The PLC is to realize simple
logic operation, i.e. the "And", "Or" and "Not" operations. The PLC inputs are all the
possible alarm signals, and the PLC outputs can be used to select one of the 8 dry
contacts. The alarm categories can be configured flexibly for every dry-contact
output through MC. The PLC settings for every dry-contact have three alarm inputs,
and two relation flag. The SN of three alarm categories and the mutual logic
relationships need to be configured.

PLC can be set to “Disabled”. If PLC functions and alarm co-relation are enabled at
the same time, the dry contact will act to activate an alarm when any alarm event
occurs.

ACTURA Flex 48330 Power System User Manual

Chapter 1 System Description 9

Password protection for important operations

The users must input the correct password before they conduct “Maintenance” and
“Settings” operations. The password has 3 levels: user, operator or administrator.
The authorities of the 3 levels are the same while conducting “Maintenance”, but
different in conducting “Settings”. The operator can see 3 more pages than the user,
which are “resetting system”, “resetting password” and “modifying system type”.
The administrator can see 2 more pages than the operator, which are “modifying
password of all levels” and “controlling alarm sound volume”. In addition, the
administrator can browse the rectifier parameter serial No., software version and
the setting of internal switches. See the following table:

Table 1-4 Authority and default password

Level Authority Default password

User Configuration of general parameters 123456
Operator

Administrator

User’s authority, plus resetting system, resetting
password and modifying system type.
Operator’s authority, plus modifying password of all
levels, controling alarm sound volume, browsing system
parameters that can be set only through the host

654321

640275

1.5.4 Multi-Function Unit (MFU)

Outline and components

The outline and the components of the MFU are illustrated in the following figure.

Bypass bar

BLVD contactor

Battery MCB

Battery -48V bus

Load MCB

OV DC bus

LLVD contactor

Shunt

Prior load bus

PE bus

SPD

AC input terminals

Rectifier AC input MCB

Low prior load bus

Figure 1-6 Outline and components of MFU

ACTURA Flex 48330 Power System User Manual

10 Chapter 1 System Description

Table 1-5 Configuration of MFU

No. Component Description

1 SPD
2 AC input terminals Rating Current 150A
3 Rectifier AC input MCB Rating Current 25A
4 BLVD contactor 200A or 400A optional
5 LLVD contacto r 200A or 400A optional
6 Shunt 300A/75mV
7 Battery MCB 100A MCB (up to 5 battery MCBs can be selected to configure)
8 Load MCB Selected according to user’s requirement

The user can mount the distribution unit into cabinets with widths of 600mm and
depths of 400mm and 600mm. It has a height of 4.5U (200mm).

1.5.5 Battery Connection Unit (BCU)

Outline

Norminal Dischage Current(8/20μS) 20kA; Ue=385V

The outline of the Battery Connection Unit (BCU) is illustrated in Figure1-7.

Enclosure

Battery MCB

-48V DC Bus

Figure 1-7 Outline of battery connection unit (BCU)

Physical size

Battery Connection Unit (BCU) can be installed in cabinets with widths of 600mm
and depths of 400mm and 600mm. BCU has a maximum height of 1.5U (67mm).

BCU contains 2 to 5 circuit breakers, each with ratings of 100A and 200A.

Alarm output

The BCU will generate an alarm if a battery circuit breaker is off. This alarm shall be
possible to connect to the connector board for display in the Controller. It shall be
possible to combine the alarms from 2 BCUs to generate a single alarm in the
controller. It shall also be possible to combine the alarm from the BCU with an

ACTURA Flex 48330 Power System User Manual

alarm generated from battery circuit breakers that are switched off in the BCU (for
example when using a BCU in an extension battery cabinet and battery circuit
breakers in the BCU in a main cabinet).

BCU configuration

The BCU configuration is as shown in Table 1-6:

Item Function unit Amount

Battery connection unit

1.5.6 System Cabinet

There are three kinds of cabinets. Their dimensions are 2.0m % 0.6m % 0.6m, 2.0m
% 0.6m % 0.4m and 0.7m % 0.6m % 0.4m respectively.

Chapter 1 System Description 11

Table 1-6 BCU configuration

100A CB for battery input 2/3/4/5
200A CB for battery input 2/3/4/5

2.0m % 0.6m % 0.6m cabinet

This cabinet is installed with 1 % MFU, 1 % Rectifier Sub-rack, 1 % BCU and the
following combination of units:

 16 Blocks of Telion 12V 165Ah FT batteries or 16 % Hawker 12V 155Ah FT

batteries

 20 Blocks of Hawker 12V 105Ah FT batteries
 16 Blocks of Telion 12V 100Ah FT batteries (20 blocks is preferred, if possible)
 16 Blocks of Hawker 12V 105Ah Ft batteries and 6U of unspecified equipment

(such as DC/DC converters or similar)

2.0m % 0.6m % 0.4m cabinet

This cabinet accommodates 1 % MFU,1 % Rectifier Sub-rack, 1 % BCU and the
following combination of units:

 16 Blocks of Hawker 12V82F batteries or 16 Blocks of Hawker SBSC11 and

3U available for additional equipment such as DC/DC converters
 20 Blocks of EB4 batteries
20 blocks of Hawker 12V82F batteries (20 blocks and BCU is preferred, if possible)

0.7m % 0.6m % 0.4m cabinet

This cabinet accommodates 1 % MFU, 1 % Rectifier Sub-racks and 1 % BCU.
There shall be 3U available for the mounting of additional equipment such as
DC/DC converters. The cabinet should not be installed any battery.

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12 Chapter 2 Installation

Chapter 2 Installation

2.1 Installation Preparation

2.1.1 Environmental Conditions

Make sure the following environmental conditions are satisfied when selecting the
installation site:

Table 2-1 Environmental conditions in power room

Environmental conditions Recommended range

Ambient temperature

Humidity ≤90%RH, non-condensing
Dust
Sunlight No direct sunlight
Corrosives No pollutants, such as salt, acid, and smoke, etc.
Shake
Insects, pests, and termites None
Mildew None
Moisture Water proof
Fire protection No flammable on the top/bottom of the cabient.

The DC Power system will be damaged if dust or sand accumulates in it. The
following measures are recommended for dusty environment:

-5~50°C (If ambient temperature > 45°C, for the cabinet with
400mm depth, it should demount the front door of cabinet to
ensure the normal operation of the system.)

3

≤1mg/m

≤1.5m/s

2

1.The system should be installed in an airtight and air-conditioned power room. The
air-conditioner filter should be well serviced without being obstructed. To reduce the
dust in the power room, un-attendance in the power room is recommended.

2.The air filter should be cleaned periodically.

3.The product should be installed on a cement ground.

2.1.2 Power Supply

AC power supply for communication uses AC mains as its main power source.
Backup batteries and generator should be configured according to the actual power
supply situation. The AC power supply system composed of AC mains and
generator should adopt centralized power supply mode to supply power, while low

ACTURA Flex 48330 Power System User Manual

voltage AC power supply system should adopt three-phase five-line or single-phase
three-line modes.

The AC power cable should adopt copper core cable, and the cable section should
suit the load. It is recommended that the power cable outside the power room be
buried directly under the ground or by means of cable pipe. Power cable should be
wired separately from signal line.

The AC mains voltage shall be within the range of the voltage input range of
rectifiers.

The DC power system has a circuit breaker that can cut the AC mains power to it.

2.1.3 Site Survey

The power room must be surveyed prior to installation, which should be focused
on:

1. Checking the wiring device, including cable chute, wiring rack, floor, wiring holes.

Chapter 2 Installation 13

2. Checking the environmental conditions, including temperature, humidity, dust.

3. Checking the conditions for implementing the installation, including power supply
and lighting.

2.1.4 Tools & Material

1. Tools required for power equipment installation include electric drill, wire cutter,
wire presser, various wrenches, screwdriver, electrician knife, and steel saw. The
tools must be insulated and antistatic handled before they are used.

2. Power cables for electrical connection include AC cables, DC load cables,
battery cables, earth cables, earth bar and lighting connection cables. Their design
specifications should be in accordance with relevant specifications in the electrical
industry and the materials should be purchased according to the design material
list.

AC cables: this system uses 3-phase or single-phase AC power. Copper-core
flame-retardant PVC insulated cable and PVC sleeve soft cable, such as NH-BVR,
are recommended for the AC cables, whose sectional area should suit the load.
When the wiring distance is less than 30 meters, take 2.5A/mm
current density to calculate the sectional area of the AC cables.

2

of economical

The sectional area of the DC load cables and battery cables should be calculated
using the following formula:

A=ΣI×L/K△U

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14 Chapter 2 Installation

In this formula: A is the sectional area of the lead (mm2), ΣI is the total current (A)
flowing through the lead, L is the length (m) of the lead loop, △U is the permitted
voltage drop on the lead, while K is the conductivity. Kcopper=57. For safety, the

voltage drop on the cables connecting battery and load cannot exceed 3.2V.
The sectional area of the lightning protection earth cable should not be less than

2

6mm

, and that of the DC operation earth cable, usually between 35-50mm2, is
determined by user. Take the greatest sectional area among the above 3 earth
cables as that of the cable connecting the user earth bar.

3. Purchase materials according to the materials list and inspect the materials, for
example, check the heat durability, moisture resistance, flame resistance, and
voltage resistance of the cable.

4. The auxiliary materials for power supply installation include expansive bolts,
binding strips, and insulating tape.

2.1.5 Unpacking

To ensure smooth installation, the power equipment must be carefully inspected
when it is unpacked.

The equipment unpacking and inspection are allowed only after it arrives the
installation site. The inspection is co-accomplished by the user representative and
representative from Emerson Network Power Co., Ltd.

When inspecting the equipment, first open the packing case with packing list put in
it, take out the packing list, and conduct inspection against the packing label,
including the customer name, customer address, machine No., total amount, case
No., contract No., etc.

Unpacking and inspection: after opening the packing case, check the goods one by
one according to the goods list on the packing label. The checking should include:

1. The number and serial number marked on the packing cases according to the
actual number of the packing cases.

2. The correctness of the equipment packing according to the packing list.

3. The number and model of the accessories according to the accessory list.

4. The completeness of the equipment set according to the system configuration.

5. The condition of the goods through visual inspection. For example, check if the
cabinet is damaged, if the cabinet has regained moisture; shake gently the rectifiers
and monitoring module to see if the parts and connections have been loosened
during delivery.

ACTURA Flex 48330 Power System User Manual

2.2 Installation Procedures

2.2.1 Cabinet Installation

Installation on the floor

Step 1: mark the position where the power system is to be installed.
Determine the installation position of the power supply cabinet in the power room

according to the installation chart. Based on the mechanical specifications (see Fig.
2-1) of the installation holes of the power supply cabinet, determine the accurate
position of the center points of the installation holes on the floor, and mark them
with a pencil or oil pen.

Chapter 2 Installation 15

(Applicable to the cabinet with 600mm depth)

(Applicable to the cabinet with 600mm depth)

Figure 2-1 Installation dimensions of the cabinet base

Step 2: drill reserve holes.
The expansive pipes delivered with the power system are M10%55mm, therefore,

use electric drill with drill bit Φ12 and depth 70mm to drill holes at the center points
of the installation holes marked on the ground. To avoid being off-center, be careful

ACTURA Flex 48330 Power System User Manual

16 Chapter 2 Installation

not to shake the drill, and try to keep as vertical as possible to the ground, as
shown in Figure 2-2.

Step 3: install expansive pipes.
Clean the dust, and insert the expansive pipe into the reserve hole, knock it down

gently using a hammer until the top of the expansive pipe is level with the ground,
as shown in Figure 2-2.

Power
cabinet

1) Drill vertically

Expansive
pipe

2) Clean the dust 4) Tighten the bolt

3) Knock it into place

Figure 2-2 Installing expansive pipe

Step 4: place cabinet in position
Move the cabinet to the installation position aligning the installation holes of the

cabinet to the expansive pipe on the ground.
Step 5: fix the cabinet
After the cabinet is in position, make some horizontal and vertical adjustments.

Insert some iron pieces under the lower edge and corner of the cabinet to adjust
the vertical obliquity of the cabinet within 5 degrees. Finally, screw down the tap
bolt with plain washer and spring washer into the expansive pipe, and tighten it with
wrench. The cabinet fixation is illustrated in Figure 2-3.

Tap bolt

Spring washer

Cabinet base
Ground

Expansive pipe

Figure 2-3 Fixing cabinet with Tap

ACTURA Flex 48330 Power System User Manual

Plain washer

2.3 External Electrical Connection Interface

2.3.1 Connection Of Input Cables

The AC input terminals, SPD, rectifier AC input switch, PE bus and PE terminals
are illustrated in Figure 1-6. SPD is just adjacent to the AC input terminals and has
been connected in before delivery. PE bus is at the top of the MFU and is
connected to the DC Power Cabinet through screws. PE bus is connected PE
terminal through a cable.

Connection requirements

The AC mains is connected to the AC input terminals directly. There are 6 AC input
modes as shown in Table 2-2:

Table 2-2 AC input modes

Item Function unit Amount

3P+N/380V AC input
1P+N /220V AC input

AC distribution

L1+L2/220V AC input
3P/220V AC input
Terminals only - for individual rectifier AC feeds
2P MCB only - for individual rectifier AC feeds

Chapter 2 Installation 17

Connection method

Strip the insulation layer of one end of the AC input cable, and then mounted the
cable end with an H terminal.

The cable mounted with an H terminal is shown in Figure 2-4.

H Terminal

AC Input Cable

Figure 2-4 Cable mounted with H terminal

After attaching the H terminal to the AC input cable, connect the AC input cable to
the AC input terminals as shown in Figure 2-5:

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18 Chapter 2 Installation

A

A

A

C input terminals

Figure 2-5 Connection of input terminals

The AC input cable is fed to the system through the top cover of the cabinet, as
shown in Figure 2-6:

C input cable

Cable bracket

Top cover

Figure 2-6 Top cover

There is a cable bracket on the top cover. The input cables are bound to the cable
bracket with a cable tie.

Different cable connection modes

There are 4 AC input terminals. For 3-phase AC power input, just connect the AC
input cables as shown in Figure 2-7:

L1 L2 L3 N

C input terminals

Figure 2-7 Connection of 3-phase AC power input

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Chapter 2 Installation 19

For single-phase AC power input, connect the AC input cables as in Figure 2-8:

L

N

AC Input Terminals

Figure 2-8 Connection of single-phase AC power input

If the AC input is single phase, the second and fourth terminals are not connected.
For dual-phase AC power input, connect the AC input cables as in Figure 2-9:

L1

L2

AC Input Terminals

Figure 2-9 Connection of dual-phase AC power input

If the AC input is dual-phase, the second and fourth terminals are not connected.
The yellow, green, red, and light blue AC cables correspond respectively to the AC

phase L1, L2, L3 and neutral lines. If the cables are the same color, they should be
identified with labels.

The AC cables should be laid separately from the DC cables.
No splice, damage, or scratch on the cables is permitted.
The rectifier AC input cables have already been connected in factory.

 Note

1.To insure AC input cable has enough bearing current capability, the section area of the AC
input cable for 3-phase AC power input should not be less than 10mm
AC power input and dual-phase AC power, it should not be less than 25mm
area of input earth line should not be less than 35mm

2

.

2. The external AC input MCB of cabinet must be sure to disconnect all the AC input lines
(including live lines, zero line), but input earth line can not be disconnected by any breaking
device. It is recommended that the rated current of the AC input MCB is not less than 125A.

2

; and for single-phase

2

. The section

ACTURA Flex 48330 Power System User Manual