Professional Documents
Culture Documents
Manual Version: 05
Published in China
This document, and the information it contains, are the property of Emerson
Network Power Co., Ltd, and are protected by law. Both must be held in strictest
confidence at all times. Emerson Network Power grants no license or right to
copy, use or disclose either, expressly or by implication.
Disclaimer
This document and the information contained herein are provided on an "AS IS"
basis. Emerson Network Power may make improvements or changes in this
documentation, at any time and without notice and as it sees fit. The information
in this documentation was prepared by Emerson Network Power with reasonable
care and is believed to be accurate. However, Emerson Network Power shall not
assume responsibility for losses or damages resulting from any omissions,
inaccuracies, or errors contained herein.
History
Date Version Author Change Note No./Notes
02/09/2008 01 David Cao First release
20/10/2008 02 David Cao Correct Section 2.4 Table 13 Ethernet Cable
Emerson part number
Add note in section 3.4 for end user must have
disconnect device
Update caution in section 3.4 for size
requirements for L, N and PE cable from AC
mains
Add note in section 3.9 for parallel operation
supported CU firmware version
Update fig95, fig100 in section 3.9 to match
the actual parallel cable
Update fig105, fig109, fig110, fig112, fig113,
fig114, fig115, fig116 to match the newest
GUI
Table of contents
History................................................................................................................... 3
Table of contents .................................................................................................. 4
List of figures ........................................................................................................ 5
List of tables .......................................................................................................... 9
List of terms ........................................................................................................ 10
Preface ............................................................................................................... 12
Chapter 1 Product Introduction ......................................................................... 15
1.1 General Description ............................................................................... 15
1.2 The Power Distribution Assembly (PDA) ............................................... 22
1.3 The Rectifier .......................................................................................... 26
Chapter 2 Preparation ....................................................................................... 29
2.1 Safety Summary .................................................................................... 29
2.2 Installation site ....................................................................................... 31
2.3 Installation tools and test equipments.................................................... 32
2.4 Check list of the FPRA .......................................................................... 33
Chapter 3 Hardware Installation........................................................................ 38
3.1 Detach the PDA from the case .............................................................. 38
3.2 Route the DC cables ............................................................................. 46
3.3 Route the Communication cables .......................................................... 64
3.4 Route the AC cable without the SPD ..................................................... 80
3.5 Install the PDA into case ....................................................................... 98
3.6 Install the rectifiers............................................................................... 103
3.7 Installation of the cables with cable glands .......................................... 107
3.8 Install the front and back covers .......................................................... 114
3.9 Parallel installation of the FPRA .......................................................... 116
Chapter 4 Browser and Control Unit Setup ..................................................... 135
4.1 Set up the configuration environment .................................................. 136
4.2 Change the CU IP-address via the LCD .............................................. 137
4.3 Connect to the GUI in local Internet / Intranet ..................................... 137
4.4 Change the CU IP-address via the GUI............................................... 139
Chapter 5 Commissioning ............................................................................... 145
5.1 Set up a commissioning environment .................................................. 146
5.2 Battery input commissioning ................................................................ 147
5.3 Set up the system parameters ............................................................. 149
5.4 AC input commissioning ...................................................................... 151
Chapter 6 Maintenance ................................................................................... 152
Chapter 7 Troubleshooting ............................................................................. 153
List of figures
Figure 1 Output power-derating characteristic ................................................. 18
Figure 2 The schematic diagram of the FPRA ................................................. 21
Figure 3 General view of the FPRA ................................................................. 21
Figure 4 Back view of the FPRA ...................................................................... 22
Figure 5 General view of the PDA.................................................................... 24
Figure 6 The front panel of the PDA ................................................................ 25
Figure 7 General view of the rectifier ............................................................... 27
Figure 8 Product tree ....................................................................................... 33
Figure 9 The FPRA before the installation ....................................................... 38
Figure 10 Detaching the cable glands.............................................................. 39
Figure 11 Releasing the PDA earth cable ........................................................ 39
Figure 12 Releasing the RS485 cables ............................................................ 40
Figure 13 Detaching the PDA from the case .................................................... 40
Figure 14 Cable gland configuration option1 ................................................ 42
Figure 15 Cable gland configuration option2 ................................................ 43
Figure 16 Cable gland configuration option3 ................................................ 44
Figure 17 Inserting the cable through the cable gland ..................................... 46
Figure 18 Removing the drawer from the PDA ................................................ 47
Figure 19 Removing the front panel from the PDA .......................................... 47
Figure 20 Removing the sub cover from the PDA ............................................ 48
Figure 21 DC terminals distribution .................................................................. 49
Figure 22 DC inlet grommet ............................................................................. 49
Figure 23 Removing the load terminals short link and MCB switch lever bar .. 51
Figure 24 Removing the battery terminals short link and MCB switch lever bar
..................................................................................................................... 51
Figure 25 Inserting the DC load grounding cable through the front panel ........ 54
Figure 26 Securing the DC load grounding cable ............................................ 55
Figure 27 Connecting the DC cables configuration option1 (typical)............. 56
Figure 28 Connecting the DC cables configuration option2 .......................... 57
Figure 29 Connecting the DC cables configuration option3 .......................... 58
Figure 30 Putting the front panel back into the PDA ........................................ 59
Figure 31 Securing the front panel ................................................................... 60
Figure 32 Securing the window of the breakers ............................................... 61
Figure 33 Fixing the DC cables to the front panel ............................................ 62
Figure 34 Securing the sub cover .................................................................... 63
Figure 35 Drawer internal layout (old version) ................................................. 64
Figure 36 Drawer internal layout (updated version) ......................................... 65
Figure 37 Inserting the temperature cable into drawer (old version) ................ 66
Figure 38 Inserting the temperature cable into drawer (updated version) ........ 66
Figure 39 Connecting the temperature cable only (old version) ....................... 68
Figure 40 Connecting the temperature cable only (updated version)............... 68
Figure 41 Placing the temperature probe ......................................................... 69
Figure 42 Connecting the parallel cable only From PSU (old version) .......... 71
Figure 43 Connecting the parallel cable only From PSU (updated version) .. 71
Figure 44 Connecting the parallel cable only To PSU (old version) .............. 72
Figure 45 Connecting the parallel cable only To PSU (updated version) ...... 72
Figure 46 Connecting the Alarm In cable only (old version) ............................. 75
Figure 47 Connecting the Alarm In cable only (updated version) .................... 75
Figure 48 Connecting the Alarm Out cable only (old version) .......................... 76
Figure 49 Connecting the Alarm Out cable only (updated version) .................. 76
Figure 50 Fixing all the communication cables (old version) ............................ 77
Figure 51 Fixing all the communication cables (updated version) ................... 78
Figure 52 Putting the drawer back into the PDA .............................................. 79
Figure 53 Securing the drawer to the PDA ...................................................... 79
Figure 54 Removing the rear cover.................................................................. 80
Figure 55 The PDA rear internal chassis layout ............................................... 81
Figure 56 The AC cable connection chart ........................................................ 82
Figure 57 AC terminal block configuration 1 .............................................. 83
Figure 58 AC terminal block configuration 3 ............................................... 84
Figure 59 AC terminal block configuration 3Y ............................................... 85
Figure 60 Inserting the AC cable through the front panel................................. 86
Figure 61 Schematic diagram of AC connection without the SPD 3Y ........... 88
Figure 62 Detaching the Strain-relief from the chassis .................................... 88
Figure 63 Connecting the PE cable from the AC mains 3Y .......................... 89
Figure 64 Connecting the L and N line cables to the AC terminal block 3Y .. 90
Figure 65 Fixing the AC ground clamp back onto the chassis 3Y ................. 91
Figure 66 Fixing the AC terminal block back onto the chassis 3Y................. 92
Figure 67 Restraining the AC mains cable onto the chassis 3Y.................... 93
Figure 68 AC connection without the SPD 3Y............................................... 94
Figure 69 Schematic diagram of AC connection without the SPD 1........... 95
Figure 70 AC connection without the SPD 1 .............................................. 95
Figure 71 Schematic diagram of AC connection without the SPD 3 ........... 96
Figure 72 AC connection without the SPD 3............................................... 96
Figure 73 Securing the rear cover back to the PDA ......................................... 97
Figure 74 Putting the PDA back into the case ................................................. 98
Figure 75 Securing the PDA to the case .......................................................... 99
Figure 76 Connecting the PDA earth cable to the case ................................. 100
Figure 77 Connecting the system earth cable ................................................ 101
Figure 78 Connecting the Ethernet cable ....................................................... 102
Figure 79 Putting the rectifier into the first slot of the case ............................ 103
Figure 80 Securing the rectifier to the case ................................................... 104
List of tables
List of terms
A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
C Temperature in degrees Celsius
CSA Cross Section Area
CU Control unit
DC Direct current
EAC External Alarm and Control
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRA Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Ingress Protection
IP Internet Protocol
Preface
Symbol Description
Reference documents
The documents of the FPRA contain:
- To be continued -
1.1.1 Specification
Main specifications
Note: (1) The power supply unit is fully compliant with the operational and power output
requirements outlined within the Product Specification at the maximum ambient
temperature 55C (plus solar load).
(2) At -40C external ambient start up and after a period of 15minutes operation,
the FPRA is fully compliant with the operational and power output requirements
outlined within the Product Specification.
Battery is disconnected from the 48V power supply during the FPRA cold-start
at -40C.
AC input
The rated input voltage of the FPRA is 180~276VAC (200~230 VAC
10%/+20%). The rectifiers can be connected as single-phase 230 VAC
inputs or as 400 VAC (phase to phase) 3-phase Star or as 200 VAC
(phase to phase) 3-phase Delta.
Table 5 shows the various rated inputs that the FPRA are applicable
and allowed for.
Note: (1) Here indicates the 180 VAC has a 5 VAC tolerance.
(2) Yes / No means the PDA sends /not sends the EAC alarm. The illustration is
available for all same expressions in this table.
(3) Refer to Table 8 for the detailed EAC alarms.
DC output
The 54VDC output, here referred to as V48N, is with respects to
V48RTN (positive) which is grounded within the FPRA.
See Table 7 for more details about the DC output.
Note: (1). The values in the table shall be met for all input voltages and frequencies within the
rated and extended input ranges, and all valid output load conditions.
(2). Maximum output ripple voltage at -40C start up shall not be greater than 4% of the
FPRA output voltage factory set point 54.6V during the 15 minutes warming up period.
1.1.2 Properties
The FPRA has the following properties:
High-integrated power system.
The FPRA integrates the rectifiers, the AC and DC distribution, and
supervisor and communication functions.
Modularized design.
The modularized design of the FPRA leads to easier installation,
maintenance and troubleshooting.
Flexible applications.
The FPRA supplies the user with a varied output power of 2/4/6kW by
means of installing 1/2/3 rectifier modules. Also the 3 battery back-up
channels and 2 load channels of the FPRA provides the user with
flexible battery and load applications.
Variable AC power connections.
The FPRA can be used with different AC power types mentioned in
Table 5 by means of reconfiguring the internal AC terminal block.
Easy to control.
The user can control and supervise the operation of the FPRA via the
GUI after connecting the FPRA to a user PC.
IP54/55
The FPRA is IP54 rated and IP55 rated when fitted with front and rear
covers.
The FPRA comprises of one PDA and one to three identical 2kW rectifiers
working in a parallel mode. The schematic diagram of the FPRA is as
shown in Figure 2.
LOADs BATs
PDA
AC
AC DC
Distributor Distributor REC1
DC
Busbar
REC2
Display
MCU
REC3
RJ45 RS485
RS422
PC
FPRA
Figure 2 The schematic diagram of the FPRA
Figure 3 presents the general view of the FPRA with the cables breaking
out from the system right side. Depending on the field application, all the
cables can break out from left or right or both sides of the FPRA.
level to disconnect the batteries from the loads to under deep discharging
condition.
Supervisor of the FPRA.
The PDA has a built-in MCU to monitor the status of the rectifiers and
batteries such as voltage, current and temperature, etc., and display the
corresponding data through the LCD and LEDS.
The PDA also supplies 6 isolated and floating EAC alarms for the BTS.
Main phase #1 Mains phase failure indicates any single phase voltage of
the 3-phase FPRA power source configuration that is below
Main phase #2 85VAC
Main phase #3
(2)
(1)
(11)
(10)
(9)
(8)
The LEDS on the PDA front panel will have any of the status listed in Table 9.
Fault
F/MA
ON Major EAC alarm (refer to Table 8)
/ Red
Mains / phase failure (refer to Table 8)
Message
M/MA
ON
/ Yellow Minor EAC alarm (refer to Table 8)
SYSOK
ON System OK
/ Green
Turn on
simultaneously
All LEDS System initialization
and turn off after
about 20 seconds
RS485 interface. The rectifier can be connected to the PDA via the
internal RS485 interface. In this way, user can monitor and control three
rectifiers via the GUI.
The rectifier has a dimension of 81.8 X 383.7 X 100.0 (W X D X H) mm.
The general view of the rectifier is as shown in Figure 7.
(1)
(9)
(10)
(3)
(2) (4)
(1) Rectifier front panel (2) AC input connector (3) RS485 interface (4) connector clip
(5) 54V bus bar (6) BR bus bar (7) Case (8) Fan cover (9) Handle (10) LED
Figure 7 General view of the rectifier
Yellow (amber)
ON Minor EAC alarm (refer to Table 8)
/ Message
Rectifier failure
Fan failure
Red / Alarm ON
AC input phase voltage less than 80V
Low output voltage
Chapter 2 Preparation
Symbol Description
DC Voltage Hazard
DC Voltage Hazard:
There is DC voltage at the indicated position.
Hot surface:
To avoid being burnt, user shall not touch the product when it
is in operation.
ESD caution:
Means user should wear a well-grounded ESD wrist strap to
avoid product damage.
- To be continued -
Recycle:
User cannot dispose of this electronic product in the trash. To
protect the environment, please recycle.
Tool kit:
Allen key (hex key): 8 mm (0.31 in.)
Awl: diameter of 2mm
ESD wrist strap and cable
TORX screwdriver set: T10, T20, T25
Flat screwdriver
Cross screwdriver
Wrench 8 mm (5/16 inch)
Folding knife
Adjustable (monkey) wrench
Side cutters
Lint-free swab or wipe and 99% alcohol for cleaning optical connectors
Cable ties for routing cables
Tape measure
Flashlight, pocket lamp or torch
Hammer drill
Marker pen or comparable tool
Pliers
Wire-stripper
Test equipments
PC (optional)
Multi-meter: FLUKE 170 or equivalent
DC Current clamp: FLUKE I410 or equivalent
Customer
configuration
-------------------------
-------------------------
Flexi 3U ------------------------- -------------------------
Flexi Power
Mounting covers Rectifier Units Transient
Rectifier FPRA
Front/back 1/2/3 Protection Unit
(Chassis + PDA)
FMCA
One FPRA may adopt one or two or three rectifiers to meet the users
requirement.
The Transient Protection Unit is optional for the user, and is supplied
independently with the FPRA.
The part number listed in Table 13 is based on the present materials used,
and Emerson may change some materials and corresponding part
numbers in future. Therefore the user should contact Emerson for updated
information in time.
FPRA Global version has a separate PDA to use. The non-US version
FPRA has the same function as the US version FPRA except that the
GROUND bus-bar is connected to the chassis via a screw. (Refer to
Figure 8.A, Global version FPRA is by default shipped as US version)
M5 screw for (TEW) Fix the cable glands to shelf 4 41300000226 AA25020L/-A
AA27100L
Temperature cable The temperature sensor of 1
the FPRA 8087000695x
SPD
Surge Protection Discharge 1 10070000400
Rectifier
The AC/DC module 1/2/3 N/A AA25000L
A B C
Before inserting the cables through the cable gland, the AC mains and battery
blocks must be switched off.
If the cable gland was used, the AC mains cable, DC cables, temperature
cable and parallel cable are mandatory, however the Alarm In and Alarm Out
cables are optional to pass through the cable gland before installing them into
the PDA.
The two cable glands are usually used as cable entries or bases on which
the front cover of the FPRA are installed. The user decides either to use
the left, right or both cable glands referring to the placement of the FPRA
in field.
If two cable glands are used, the holes in the same position on the two
cable glands are used for the same cable. The use of the right cable gland
is for illustration herein.
The cable gland configuration shown herein is recommended for the user,
however the user can distribute the holes in field freely.
Do not strip the end insulator of the cables prior to inserting them through the
cable gland to prevent crisscross.
Alarm
System earth cable
BAT2
Parallel cable
Temperature
cable
LOAD2
AC cable
RTN2
DC GND
Alarm
LOAD2 LOAD1
Alarm
BAT2
Parallel cable
System earth cable
BAT1
Temperature
cable
BAT3 DC GND
AC cable
RTN5
RTN3
Parallel cable
RTN4
Alarm
RTN2 RTN1
Alarm LOAD2
BAT2
Parallel cable
System earth cable
BAT1
Temperature
cable
BAT3 DC GND
AC cable
RTN5
RTN3
Parallel cable
RTN4
Alarm RTN1
AC cable
DC GND
Puncture the waterproof of the cable gland with an awl (2mm), and insert
the corresponding cable through the hole (see Figure 17).
Take care not to break the waterproof of the cable gland while inserting the
cable.
2
1
The lower DC terminals and RTN1~5 are shorted together for the
positive earth connection and connected to the system earth
mechanically. The upper DC terminals are for the 48V connection.
Identify the DC terminals and the marks on the DC inlet grommet. The DC
terminals internal the PDA and the pre-exit holes on the DC inlet grommet
are in the one-to-one relationship (see Figure 21 and Figure 22).
The names in Figure 21 and Figure 22 are for illustration purpose only.
They are not printed on the DC inlet grommet.
The +/- in Figure 21, Figure 22 indicates the proper polarity of the load or
battery string to be connected.
In the event that the load in field has a protective earth cable, the user can
connect this grounding cable into any of the terminals in the lower row.
LOAD1(-)
Insulator
Terminals
short link
RTN4(+)
RTN5(+)
LOAD
GND
Fixing
pole
LOAD
GND
RTN5(-)
Make sure to switch off the battery blocks before configuring the DC cables.
The current passing through each MCB cannot exceed 63A in any DC
cables configuration.
When the Load / battery terminals are configured for different loads /
batteries, the short link for load / battery terminals and switch lever bar for
load / battery MCB must be removed.
If not needed, the short links for load / battery terminals and switch lever bar
for load / battery MCB must be removed:
Loosen the screws of the load / battery terminals with a flat screwdriver, and
then take off the short link for the terminals with a set of pliers (see Figure 23
and Figure 24).
Take off the switch lever bar for load / battery MCB with a set of pliers (see
Figure 23 and Figure 24).
There are three options for the battery and load cable configuration in field
(see Table 14).
Figure 23 Removing the load terminals short link and MCB switch lever bar
Figure 24 Removing the battery terminals short link and MCB switch lever bar
Note: (1) The user determines whether to use the DC load grounding cable referring to the battery and load conditions in field.
(2) It is easier to install the individual DC cable into the indicated DC terminal plug following the recommended sequence.
2
(3) The total CSA of the cables applied in one DC terminal plug cannot exceed 50 mm . The user is to choose the proper DC
cables in field.
Do not break the white insulators between the DC terminal blocks (see
Figure 21) while accessing the cables to prevent short circuit.
Check the polarity of the load or battery strings according Figure 21 so as
to connect to the right position.
Ensure the cables go through the side cable gland firstly.
During the installation of the DC cables, the associated breakers must
always be in the OFF position.
The typical DC cables configuration (option 1 in Table 14, however use CSA
35mm2 cables for battery and return) is for illustration in this manual.
Take care not to break the waterproof while inserting the DC cable through
the grommet.
Keep the front panel about 10cm away from the PDA, for easier access in the
following steps.
Figure 25 Inserting the DC load grounding cable through the front panel
Figure 28 and Figure 29 represent the final connections of the other two
DC cable configurations in Table 14.
1 1, 2, 3, 4, 5, 6 0.3~0.4
2 1, 2, 3, 4, 5, 6 0.5~0.6
2 4
1 1, 2, 3, 4 0.3~0.4
2 1, 2, 3, 4 0.5~0.6
1
Figure 34 Securing the sub cover
Wear an ESD wrist strap and make sure it has been well grounded before
accessing the drawer.
Here shows two drawers of old and updated versions, and different
installation methods as well.
Correctly grounding the cable shield is crucial to the electromagnetic
compatibility (EMC) of the entire system.
The drawer of updated version has no significant differences from the old
one, except for adding a punch on the drawer sidewall to fix the
communication cables (see Figure 35, Figure 36).
Gasket C A Connector
J11
J22
A
C
Gasket B
Connector
J11
D
J22
Take care not to break the waterproof of the gasket while inserting the
communication cable.
Runs the temperature cable under the three RS485 cables and connects
the core wires into terminal block J22 as per the one-to-one relationships
in Table 17 (see Figure 39, Figure 40).
J22 is a Push fit terminal block. Press the top button of each jack with a
flat screwdriver to insert the bare end of each wire entirely, and then
release the button to secure the wire.
The vendor has prepared the bare end of each wire.
For updated drawer installation, the temperature cable doesnt need to go
under the three RS485 cables (see Figure 40).
7 TEM_GND Red
9 TEMP_VCC Black
Put the temperature probe between the battery blocks where might has
the highest temperature (see Figure 41).
The parallel cable is used for the communication between the FPRA units
when they are configured in parallel.
The parallel cable is to be installed when the FPRA units are configured in
parallel. Otherwise it does not need to install the parallel cable.
Refer to section Parallel installation of the FPRA for more details about
parallel cable configuration.
For updated drawer installation, the parallel cable doesnt need to go under the
three RS485 cables (see Figure 43, Figure 45).
3 SGND/F Black
5 RS422TX+ White
6 SGND/F Black
Figure 42 Connecting the parallel cable only From PSU (old version)
Figure 43 Connecting the parallel cable only From PSU (updated version)
As the user provides its own Alarm In and Alarm Out cables,
The connections of the Alarm In and Alarm Out cables shown in this
manual are for illustration purpose only.
The colors selected to illustrate the Alarm In and Alarm Out wires do not
have significances and are only there to help distinguish the wires.
The user may use one Alarm cable, in which combined the Alarm In and
Alarm Out functional wires together. Connect each wire to the right pin as
connecting the Alarm In and Alarm Out cables separately. Two Alarm
cables are for illustration herein.
There are two holes on the drawer gasket for the alarm cable. Any one
can be use for Alarm In or Alarm Out cable.
Puncture the waterproof marked Alarm on the drawer gasket with an awl
(diameter of 2mm) to insert the Alarm cable like in Figure 37 or Figure 38.
Runs the Alarm cable under the three RS485 cables and connects the
Alarm cable into J11 as per the one-to-one relationships listed in Table 19
(See Figure 46, Figure 47).
Fix the Alarm In cable together with the bare cable screen to position A
on the drawer with a cable-tie, and make sure the cable screen firmly
touches the drawer sidewall (see Figure 46, Figure 47). This provides the
grounding of the cable screen.
User is permitted to detach the three RS 485 plugs to connect the Alarm
cables easily and then recover the RS 485 cables to the original position.
1 ALARM IN (-)
2 ALARM IN (+)
3 ALARM_COM
4 MAINS 1
5 ALARM_COM
6 MAINS 2
7 ALARM_COM
Reference
8 MAINS 3
9 ALARM_COM
10 CRITICAL
11 ALARM_COM
12 MAJOR
13 ALARM_COM
14 MINOR
Connect the Alarm Out cable into J11 as per the one-to-one relationships
listed in Table 19 (See Figure 48, Figure 49).
Fix the Alarm Out cable with the bare cable screen to position B on the
drawer in Figure 36 with a cable-tie, and make sure the cable screen firmly
touches the sidewall of the drawer (see Figure 48, Figure 49). This provides
the grounding of the cable screen.
For updated drawer, Assemble the Alarm cables and fix them to position
C, the temperature cable and parallel cables to position D in Figure 36
with a cable-tie (see Figure 51).
AC terminal block
E
D
Cable restraint
Verify the AC power system types in field, and make sure the corresponding
bridge configuration is used.
The AC terminal block has been already configured for 3-phase star AC
mains before the shipment. Therefore the user has to change the AC terminal
block configuration if required referring to the actual AC type in field.
There are three AC power system types (see Table 5), and thus three AC
configurations of the AC terminal block:
Single-phase (1) configuration
For Single- phase AC system, use two Phoenix 3-pole bridges to short
the terminals 1,2,3 and 4,5,6 respectively on the AC terminal block
(see Figure 57).
All the L, N and PE cables from the AC mains must be at least 12AWG for
three-phase star / delta AC connection, 8AWG for single-phase AC
connection.
The total CSA of AC mains cable should be less than 18mm; otherwise it
cannot pass through the cable gland or the PDA front panel.
Take care not to break the waterproof of the front panel while inserting the
AC cable.
Puncture the waterproof gasket marked AC INLET on the front panel with
an awl (diameter of 2mm), and then insert the AC cable through this hole
(see Figure 60).
The SPD (Surge Protect Discharge) is optional for the user. This manual
illustrates the AC connection without the SPD only.
Refer to the Surge Protect Discharge for Flexi Power Rectifier User Manual
(Emerson file NO.03370500080) for the detailed use of the SPD.
The colors of the AC mains in this manual are for illustration purpose only.
However, the user should verify the AC mains referring to the color-coding
in field.
Before the connection, prepare the AC mains cable as per Table 20. This
will provide easier installation in the following steps.
(Tolerance: 3mm)
AC type L1 L2 L3 N PE
Configure the AC terminal block as per Figure 59 firstly and then connect
the AC mains to the AC terminal block as per Figure 61.
1) Detach the adjustable Strain-relief from the chassis by loosening
the screw A (refer to Figure 55) with a TORX screwdriver (T25)
(see Figure 62).
L3
L1
L2
8) Fix the AC ground clamp with the PE cable from the AC mains back
onto its position on the chassis. Tighten the screw B in Figure 55
to 2.0Nm with a TORX screwdriver (T25) (see Figure 65).
9) Fix the AC terminal block back into its position on the chassis.
Tighten the screws D and E in Figure 55 to 2.0Nm with a TORX
screwdriver (T25) (see Figure 66).
L3
N
PE of AC mains
L2
L1
N
L
PE of AC mains
L3 L2
PE of AC mains L1
Secure the five captive screws following two steps listed in Table 21.
Tightening the screws orderly will avoid damage to the waterproof gasket at
the joint (see Figure 75).
1 1, 2, 3, 4, 5 0.3~0.4
2 1, 2, 3, 4, 5 0.5~0.6
5
1
4
1
2
The User is to decide whether to use an Ethernet cable. The IP rating of the
FPRA (IP54) is no longer guaranteed while an Ethernet cable is in place.
Remove the IP seal of the RJ45 interface and connect the Ethernet cable
(see Figure 78).
Start the installation of the rectifiers from the first slot on (on your left,
when facing the case):
When only one rectifier is needed, install it into the first slot.
When two rectifiers are needed, install them into the first and second slots.
Before the installation, take off the silicon caps of the rectifier DC bus bar and
save them for re-use.
Figure 79 Putting the rectifier into the first slot of the case
Before connection, take off the silicon caps of the AC input connector, the
RS485 cable connector and save them for re-use.
The three RS485 cables are of the different lengths and cannot be mixed.
The shortest one is for the left rectifier (face to the FPRA), the middle one
for the middle rectifier and the longest one for the right rectifier.
1
2
The cables can break out from left or right or both sides of the FPRA. The
cables exit from the right cable gland is described in detail.
The alarm cable (usually combines the Alarm In and Alarm Out cables
together) may exit from top of the case or through the cable gland. Herein
illustrates the alarm cable breaking out from the system top. In the latter
pictures, the alarm cable is defaulted to break out from the cable gland.
Take off the plastic cover on the case top surface and pull the alarm cable
out through the gap (see Figure 84).
Alarm cable
(2) Install the two cable glands with cables onto the case.
Secure the two cable glands back onto the case, tightening the screws A
and B to 2.0Nm with TORX screwdriver (T25) (see Figure 85 and 85.A).
1
2
B
A
It is optional for the end user to fix the cables to the side cable plate. However
the user is recommended to arrange the cables in the indicated way in this
step if required.
Some thin cables such as communication cables can be tied to the thicker
cables such as AC cable, DC cable, etc.
The AC cable can be fixed to the side cable plate with cable restraints.
Close the cable restraints with M3 screws A (supplied as accessories),
tightening to 0.6Nm (see Figure 87).
A A
A A
Fix the other cables to the side cable plate with cable-ties (see Figure 88).
All the cables may exit from right or left of the FPRA (see Figure 90, Figure
91).
The FPRA is IP54 rated and IP55 rated only when fitted with front and back
covers. The FPRA doesnt supply these.
A B
Figure 95, Figure 96 and Figure 97 show the general view of the FPRA after
completing all the installation items.
Figure 97 General view of the FPRA cables run from both sides
In the event that BTS site configuration exceeds the power rating of a
single FPRA unit, the user can configure up to a maximum of three FPRA
units in a parallel mode to share the battery blocks and support the
different loads.
In parallel configuration, two or three FPRA units can be stacked together
or positioned separately within 3 meters of each other. Only the stacked
configuration is illustrated in this manual.
FPRA #1
S/N: G7083770009
Master
FPRA #2 FPRA #3
S/N: G7081500036 S/N: G7074801770
Slave Slave
Figure 99 Master/slave definition of FPRA units in parallel
Figure 100 shows the current sharing between two battery blocks. The load /
battery switch lever bar and terminal short link should be removed when the
breakers supporting separate load / battery. Therefore each battery block will
be protected by MCBs from over current.
In Figure 100, the blue and green arrows indicate that the battery might
charge or discharge from different bus bars via the sharing cable
connecting the two or three FPRA systems. The red arrow indicates the
loop current that might happen between the battery blocks.
The current flow in Figure 100 represents all possibilities that will happen
in FPRA parallel configuration.
Bus bar
PDA
BAT sharing
BAT cable
PDA
Bus bar
Note: current flow path and direction
Figure 100 Current flow of two battery blocks in parallel
Figure 101 shows the two FPRA units parallel configuration with a single
battery block feed. The battery string requires a total CSA of 50mm 2 and
might be made of separate cables jointed in one clamp.
RJ45
PC
AC in
Load1
Load2
PDA #1
RS422
Load1
Load2
PDA #2
AC in
RJ45
Battery Cabinet
PC
AC in
Load1
Load2
PDA #1
RS422
RS422
Load1
Load2
PDA #2
AC in
Each BAT clamp of the PDA allows only one cable connection in order to
keep the waterproof function. Thus when configuring over 4 BAT strings
with separate cable runs per string for two FPRA systems, the end user
must use external terminal blocks to share current as shown in Figure
103.
As per Table 14, the battery strings in Figure 103 should be of CSA
16mm2 or 35mm2 for different load configurations.
The end user should prepare the external terminal block if needed.
External
Battery Cabinet Terminal Block
RJ45
PC
AC in
Load1
PDA #1
Load2
RS422
RS422
Load1
PDA #2
Load2
AC in
A A
A A
A Upper Lower
bottom A A top
A
B B
B
B
B
A
The two parallel cables should pass through the cable glands before installing
into the drawers.
J22 #1 J22 #2
11 12
1 4
Parallel cable #1
2 5
3 6
4 1
5 2
Parallel cable #2
6 3
12 11
Parallel
cable #1 Parallel
cable #1
Parallel
cable #2
Parallel
cable #2
2
Drawer #1 1 Drawer #2
Parallel
cable #2
Parallel
Parallel cable #2
cable #1
Parallel
cable #1
Drawer #1 1 Drawer #2 2
The FPRA units in parallel can share the same temperature cable,
Ethernet cable, Alarm In cable, and Alarm Out cable. Therefore anyone
drawer can be installed the parallel cable only while the other one is fully
installed with all the communication cables (refer to section Route the
Communication cables).
If the Ethernet cable is needed, installed it to the top FPRA.
The cables breaking out from system right is for illustration herein.
Parallel
cable #1
Parallel
cable #2
Parallel
cable #1
Parallel
cable #2
Figure 100 shows the current sharing between the two battery blocks. The
load / battery switch lever bar and terminal short link should be removed
when the breakers supporting separate load / battery. Therefore each
battery block will be protected by MCBs from over current.
Figure 112 shows the three FPRA units parallel configuration with a single
battery block feed. The battery string requires a total CSA of 50mm 2 and
might be made of separate cables jointed in one clamp.
RJ45
PC
AC in
Load1
PDA #1
Load2
RS422
Battery Cabinet
AC in
Load1
PDA #2
Load2
RS422
RS422
Load1
Load2
AC in
PDA #3
Battery Cabinet
RJ45
PC
AC in
Load1
PDA #1
Load2
RS422
AC in
Load1
PDA #2
Load2
RS422
RS422
Load1
Load2
AC in
PDA #3
Each BAT clamp of the PDA allows only one cable connection in order to
keep the waterproof function. Thus when configuring over 5 BAT strings
with separate cable runs per string for three FPRA parallel units, the end
user must use external terminal blocks to share the current as shown in
Figure 114.
As per Table 14, the battery strings in Figure 114 should be of CSA
16mm2 or 35mm2 for different load configurations.
The end user should prepare the external terminal block if needed.
External
Battery Cabinet Terminal Block
RJ45
PC
AC in
Load1
PDA #1
Load2
RS422
AC in
Load1
PDA #2
Load2
RS422
RS422
Load1
PDA #3 Load2
AC in
The parallel installation of three FPRA units is similar with that of the two
FPRA units, except the connection of the three parallel cables (see Figure
115, Figure 116, Figure 117).
J22 #1 J22 #2
11 12
1 4
Parallel cable #1
2 5
3 6
4 1
5 2
6 3
12 11
Parallel Parallel
cable #2 cable #3
J22 #3
11 1 2 3 4 5 6 12
Figure 115 Parallel cable configuration within the three drawers
3
1 2 Parallel
Parallel cable #2
Parallel cable #3
cable #1 Parallel
cable #1
Parallel
cable #3
Parallel
cable #2
Drawer #1 Drawer #2 Drawer #3
Parallel
Parallel Parallel cable #2
Parallel cable #1 cable #3
cable #1
Parallel
cable #3
Parallel
cable #2 1 2 3
Figure 118 shows the general view of the three FPRA units after completing all
the parallel installation items.
Parallel
cable #1
Parallel
cable #2
Parallel
cable #3
This chapter describes how to set up the FPRA Control Unit (CU) and the
Users PC, in order to be able to connect to the CU via the Web-based
Graphical User Interface (GUI).
The web-based GUI is optimized for a resolution of 1024 x 768 pixels or
higher.
Microsoft Internet Explorer and Mozilla Firefox browsers are both supported
and are available for download free of charge from their suppliers:
Microsoft Internet Explorer: www.microsoft.com
Mozilla Firefox: www.mozilla.com
The CU provides boundless connectivity within private intranets, which
includes connections via Virtual Private Network (VPN). It also supports direct
connection between the Users PC and the FPRA CU. Following the IEEE
rules, each CU has its own unique MAC address.
There are two ways to change the CU IP-address to connect to the users PC
in the local Internet / intranet.
For the browser and CU setup, the unit requires powered up.
Make sure all the protective earth terminals; extension cords, and devices
connected to the FPRA are well grounded. Any interruption in the protective
grounding will cause a potential shock hazard that might injure people.
There must be lightning protection if the setup is carried out outdoors.
The IP54 is no longer guaranteed if the Ethernet cable is connected to the
system. After finishing the web-GUI setup, The Ethernet cable should be
removed and the connecter seal should be replaced to the RJ45 hole to
provide IP54 protection.
User can use the end equipment in filed -- the BTS as the loads and battery
blocks as DC source for configuration as shown in Figure 119, but make sure:
All the breakers are in the OFF position before powering on the PDA.
The field battery blocks should have a voltage between 43V and 54V.
Verify the polarity of the battery leads and their connection before
connecting them to the PDA.
Verify that there are no shorts between the loads, batteries, and returns
strings. Use a multi-meter to ensure this at the DC cable terminals.
Login as the root user (key in the root / default) and enter the GUI home page
as shown in Figure 121.
Now the user can view all the information of the system by clicking the
submenu on the home page.
Follow the steps below to set up the IP-address of the users PC:
(1) Go to the Network-Settings and to the Properties menu of the active
TCP/IP connection (see also Figure 122).
(2) Chose the Internet Protocol (TCP/IP) menu and select the Properties
menu (see also Figure 123).
(3) Within the General menu chose the Use the following IP address
option. The IP-address must be in the same subnet as the IP-address of
the CU and the Subnet mask (e.g.: with the subnet mask
255.255.255.0).
Each FPRA unit has a same IP-address set in factory before shipment.
This IP-address is 142.120.72.172 with the subnet mask
255.255.255.0.
User has to change the users PC IP-address to 142.120.72.x (the last
digit x should be different with that of the CU IP-address) so as to
connect to the CU.
After disconnection from FPRA, the user shall restore his/her IP configuration
to the previous settings to maintain integrity of the PC for its regular use.
After changing the IP-address, the users PC may disconnect with the local
Internet / Intranet.
After changing the CU IP-address, the users PC may disconnect with the CU.
Chapter 5 Commissioning
All the commissioning data can also be read through LCD (refer to the Flexi
Power Rectifier User Manual, Emerson file No.03370500090) in the event that
the Ethernet cable is not applied.
User should check the battery voltage with a multi-meter before turn on the
battery switch or battery breakers. If the battery voltage is below 43V, it cannot
be connected to the FPRA directly.
Turn on the battery and load breakers to power the PDA and loads with
battery blocks.
Ensure the normally operation through the LED status of the PDA referring to
Table 9.
Assume the battery blocks have a voltage of -50V, and load current is -12A.
The GUI will display the battery status as shown in Figure 128, and these
values can also be read through the LCD.
Compare these values with those measured by a multi-meter to verify the
normal operation of the PDA.
The voltage and current measurement has been tested in factory before
shipment. Thus the user can only check the voltage test in field.
Turn on the AC power switch to power the rectifiers and the PDA through the
AC source in field.
Ensure the normally operation through the LED status of the PDA and the
rectifiers referring to Table 9 and Table 10.
Turn on the load breakers to power the load.
Assume the rectifiers have a voltage of -54V, and load current is -30A. The
GUI will display the rectifier status as shown in Figure 132, and these values
are also read through the LCD.
Compare these values with those measured by multi-meter to verify the
normal operation of the rectifier and PDA.
Chapter 6 Maintenance
The following describe issues that might occur during operation of the FPRA:
Checking the connector seals
Reset the connector seal if there is any looseness to ensure the IP rating.
Checking the cable connectors
Refit the cable connector if there is any looseness to ensure the normal
operation.
Checking screws
Re-fix the screws to ensure the stability of the whole FPRA system.
Cleaning rectifier fans
Clear the rectifier fans and the vents to ensure the cooling function.
Replace the SPD if required
Refer to section 3.2 of the Surge Protect Discharge for Flexi Power Rectifier
User Manual (Emerson file 03370500080) for the replacement of the SPD.
Update the system firmware if required
Refer to the section 2.3 of the Flexi Power Rectifier User Manual
(Emerson file No. 03370500090) for the upgrade of the system firmware.
Chapter 7 Troubleshooting
The end user is able to view the rectifier or system alarms via the GUI. Table
22 and Table 23 list these alarms and the recommended actions.
The alarm severities in Table 22 and Table 23 are defaulted, and user is
allowed to change them via the GUI (refer to the Flexi Power Rectifier User
Manual, Emerson file No.03370500090).
Besides the alarms indicated from GUI, some failures listed in Table 24 are
likely to happen.
The AC mains must be switched off prior to removing the PDA from the case.
The battery can be always switched on to support the load while accessing
the PDA.
Some alarms and failures listed in Table 22 through Table 24 may be
corrected by simple action of the end user. More in depth might be referred to
the Emerson Network Power service and support people.
The user is forbidden to open the PDA restricted area or rectifier in any case.
Only qualified person can carry out the troubleshooting.
Severity
Indeterminate
Rectifier
alarm Trigger condition Recommend action
Warning
configuration
Critical
Minor
Major
Off
General error X Rectifier internal error Uninstall the rectifier from system, and
then install the rectifier back again. If the
error appears again, change the rectifier
Input low X Set alarm when AC lower than 1705V, Check the AC input
(AC) clear when AC higher than 1755V
Temp High X Set when more than 75C, clear when Check there any block in the fan, check
lower than 70C the ambient temperature
Temp Low X Set when lower than 0C, clear when Check the ambient temperature
more than 5C
- To be continued -
Severity
Rectifier
Warning
alarm Trigger condition Recommend action
Indeter
Critical
minate
Minor
Major
configuration
Except Temp X Off Set when more than 90C, clear when Check there any block in the fan, check
High lower than 85C the ambient temperature
Except Temp X Set when low than -5C, clear when Check the ambient temperature
Low more than 0C
Input High X Set alarm when AC higher than Check the AC input
(AC) 282V5V, clear when AC lower than
276V5V
DC OVP X DC output higher than 58.5V1V, Remove the AC to the rectifier and re-
connect the AC to rectifier again
- To be continued -
Severity
Rectifier
Warning
alarm Trigger condition Recommend action
Indeter
Critical
minate
Minor
Major
configuration
DC UVP OffX Set when DC output lower than 40.5V, Check whether there is output short
clear when DC higher than 42.5V circuit
Over Temp X OTP when higher than 105C, recover Check there any block in the fan, check
Protect when lower than 84C the ambient temperature
Input Low X Set when AC lower than 150V, clear Check the AC input
Major when more than 151V
Input High X Set when AC more than 296V, clear Check the AC input
Major when lower than 295V
Fan Failure X Rectifier Fan fail Check the fan, if fan stop running, or
change the fan
Power Limit X Set when output current more than 1 Check the BTS system load
Amp of Power_max/52V, the Power_max
is decreased when power derating
occurs
Severity
System alarm
Warning
Trigger condition Recommend action
Indeter
Critical
minate
configuration Minor
Major
Off
General error X CU internal Errors Re-start the PDA, if error appear
again, change the PDA
Battery test fail X Battery discharge test fail Check whether the battery life time
reached
Date & Time not X Date and time is not set in the CU Set the date and time
set
- To be continued -
Severity
System alarm
Warning
Trigger condition Recommend action
Indeter
Critical
minate
configuration Minor
Major
Off
Circuit Breaker 3 X Circuit breaker 3 open Check whether the breaker
connects to battery or not. If no
load connected, no action required.
If battery connected, check whether
there is short circuit in the battery
and load, then close the breaker.
LVD X Low voltage load disconnected Check AC input and battery voltage
Bat. Temp. High X Battery temperature higher than the battery Check the battery temperature
temperature high set point
Bat. Discon. X Battery temperature higher than the battery Check the battery temperature
Temp. High temperature high disconnect set point
- To be continued -
Severity
System alarm
Warning
Trigger condition Recommend action
Indeter
Critical
minate
configuration Minor
Major
Off
Bat. Temp. Low X Battery temperature lower than the battery Check the battery temperature
temperature low set point
Bat. Discon. X Battery temperature lower than the battery Check the battery temperature
Temp. Low temperature low disconnect set point
Battery Low X Battery voltage lower than the battery low Check the battery voltage
Voltage voltage set point
Surge Protection X Surge protection device is not installed or If SPD installed, check the SPD fail
Device fail or not. If SPD not installed, no
action required
Failing to display the PDA LED or Maybe damages on the internal Refer to Emerson support people
LCD communication circuit
Large deviation between measured Maybe damages on the internal Refer to Emerson support people
and real data (Voltage / current, etc.) measurement circuit
Breaker failure, such as failing to turn Breakers maybe damaged Refer to Emerson support people
on / off, etc.
Failing to visit CU via the GUI Ethernet cable poor connection Check the net equipment, such as net
PDA card, Ethernet cable, etc.
Failing to display of the other FPRA Poor cable connection Check the proper connection of the
units via PDA LCD or GUI in parallel parallel cables in different drawers
configuration
Failing to display temperature or Poor cable connection Check the proper connection of the
alarms temperature or alarm cables
Rectifier Failing to display any LED AC power failure Check the AC power supply and the
connection to rectifier
- To be continued -
Rectifier abnormal operation, such as Maybe rectifier damaged Check AC input, load, environment, etc.
over voltage / current, etc
Failing to be shown via the PDA LCD Poor connection between Check whether the RS485 cable
or GUI rectifier and PDA properly connected
Alarm loss of rectifier Poor connection between Check the relevant data cable
Rectifier rectifier and PDA connection between the rectifier and
PDA
Rectifier over temperature Poor cooling or fan failure Check the fan normal movement or
replace the fan.
Refer to Emerson support people for fan
replacement if required.
Modules cannot be inserted into the Check for any foreign body within the
case respective module slot. Check all
module plug interfaces are clear and in
System good functional order. Check all
interfaces on the respective module are
correct and undamaged
Abnormal noise Maybe Fan failure Check for any obstruction on the fan