Installaton Manual For FPRA PDF

1
Flexi Power Rectifier

Installation Manual
Emerson Network Power Co., Ltd.

http://www. emersonnetworkpower.com.cn
Manual Version: 03
Flexi Power Rectifier Installation Manual

2
Manual Number: 03370500070

Manual Issue: 03
Manual Status: Standard
Release Date: Mar 2009
Copyright © 2009 Emerson Network Power Co., Ltd.

All rights reserved
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 3
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
18/03/2009 03 David Update all the pictures in section 3.3 to show

the latest drawer design
Update the parallel configuration with more
details in section 3.9
Add a new paragraph to show setup of master/
slave FPRA unit in a parallel system
Add fig101, fig112 to show single battery in
parallel configuration
Add table22 and table23 of rectifier and
system alarm indications
Add string polarity marks in fig21 and fig22

Table of contents 4
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........................................................................37
3.1 Detach the PDA from the case ..............................................................37
3.2 Route the DC cables .............................................................................44
3.3 Route the Communication cables..........................................................62
3.4 Route the AC cable without the SPD.....................................................78
3.5 Install the PDA into case .......................................................................96
3.6 Install the rectifiers...............................................................................101
3.7 Installation of the cables with cable glands..........................................105
3.8 Install the front and back covers ..........................................................110
3.9 Parallel installation of the FPRA ..........................................................112
Chapter 4 Browser and Control Unit Setup.....................................................131
4.1 Set up the configuration environment ..................................................132
4.2 Change the CU IP-address via the LCD..............................................133
4.3 Connect to the GUI in local Internet / Intranet .....................................133
4.4 Change the CU IP-address via the GUI...............................................135
Chapter 5 Commissioning...............................................................................141
5.1 Set up a commissioning environment..................................................142
5.2 Battery input commissioning................................................................143
5.3 Set up the system parameters.............................................................145
5.4 AC input commissioning ......................................................................147
Chapter 6 Maintenance...................................................................................148
Chapter 7 Troubleshooting .............................................................................149

List of figures 5
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 .......................................................37
Figure 10 – Detaching the cable glands..............................................................38
Figure 11 – Releasing the PDA earth cable........................................................38
Figure 12 – Releasing the RS485 cables............................................................39
Figure 13 – Detaching the PDA from the case....................................................39
Figure 14 – Cable gland configuration – option1 ................................................41
Figure 17 – Inserting the cable through the cable gland .....................................44
Figure 18 – Removing the drawer from the PDA ................................................45
Figure 19 – Removing the front panel from the PDA ..........................................45
Figure 20 – Removing the sub cover from the PDA............................................46
Figure 21 – DC terminals distribution..................................................................47
Figure 22 – DC inlet grommet.............................................................................47
Figure 23 – Removing the load terminals short link and MCB switch lever bar ..49
Figure 24 – Removing the battery terminals short link and MCB switch lever bar
.....................................................................................................................49
Figure 25 – Inserting the DC load grounding cable through the front panel........52
Figure 26 – Securing the DC load grounding cable ............................................53
Figure 27 – Connecting the DC cables – configuration option1 (typical).............54
Figure 28 – Connecting the DC cables – configuration option2 ..........................55
Figure 29 – Connecting the DC cables – configuration option3 ..........................56
Figure 30 – Putting the front panel back into the PDA ........................................57
Figure 31 – Securing the front panel...................................................................58
Figure 32 – Securing the window of the breakers ...............................................59
Figure 33 – Fixing the DC cables to the front panel ............................................60
Figure 34 – Securing the sub cover ....................................................................61
Figure 35 – Drawer internal layout (old version) .................................................62
Figure 36 – Drawer internal layout (updated version) .........................................63
Figure 37 – Inserting the temperature cable into drawer (old version) ................64

List of figures 6
Figure 38 – Inserting the temperature cable into drawer (updated version)........64

Figure 39 – Connecting the temperature cable only (old version).......................66
Figure 40 – Connecting the temperature cable only (updated version)...............66
Figure 41 – Placing the temperature probe.........................................................67
Figure 42 – Connecting the parallel cable only – From PSU (old version)..........69
Figure 43 – Connecting the parallel cable only – From PSU (updated version)..69
Figure 44 – Connecting the parallel cable only – To PSU (old version) ..............70
Figure 45 – Connecting the parallel cable only – To PSU (updated version)......70
Figure 46 – Connecting the Alarm In cable only (old version).............................73
Figure 47 – Connecting the Alarm In cable only (updated version) ....................73
Figure 48 – Connecting the Alarm Out cable only (old version)..........................74
Figure 49 – Connecting the Alarm Out cable only (updated version)..................74
Figure 50 – Fixing all the communication cables (old version)............................75
Figure 51 – Fixing all the communication cables (updated version) ...................76
Figure 52 – Putting the drawer back into the PDA ..............................................77
Figure 53 – Securing the drawer to the PDA ......................................................77
Figure 54 – Removing the rear cover..................................................................78
Figure 55 – The PDA rear internal chassis layout...............................................79
Figure 56 – The AC cable connection chart........................................................80
Figure 57 – AC terminal block configuration – 1Φ ..............................................81
Figure 58 – AC terminal block configuration – 3Δ ...............................................82
Figure 59 – AC terminal block configuration – 3Y ...............................................83
Figure 60 – Inserting the AC cable through the front panel.................................84
Figure 61 – Schematic diagram of AC connection without the SPD – 3Y ...........86
Figure 62 – Detaching the Strain-relief from the chassis ....................................86
Figure 63 – Connecting the PE cable from the AC mains – 3Y ..........................87
Figure 64 – Connecting the L and N line cables to the AC terminal block – 3Y ..88
Figure 65 – Fixing the AC ground clamp back onto the chassis – 3Y .................89
Figure 66 – Fixing the AC terminal block back onto the chassis – 3Y.................90
Figure 67 – Restraining the AC mains cable onto the chassis – 3Y....................91
Figure 68 – AC connection without the SPD – 3Y...............................................92
Figure 69 – Schematic diagram of AC connection without the SPD – 1Φ...........93
Figure 70 – AC connection without the SPD – 1Φ ..............................................93
Figure 71 – Schematic diagram of AC connection without the SPD – 3Δ ...........94
Figure 72 – AC connection without the SPD – 3Δ...............................................94
Figure 73 – Securing the rear cover back to the PDA.........................................95
Figure 74 – Putting the PDA back into the case .................................................96
Figure 75 – Securing the PDA to the case..........................................................97
Figure 76 – Connecting the PDA earth cable to the case ...................................98
Figure 77 – Connecting the system earth cable..................................................99
Figure 78 – Connecting the Ethernet cable.......................................................100
Figure 79 – Putting the rectifier into the first slot of the case ............................101
Figure 80 – Securing the rectifier to the case ...................................................102

List of figures 7
Figure 81 – Connecting the AC power cable to the rectifier..............................103

Figure 82 – Connecting the RS485 cables to the rectifier.................................104
Figure 83 – Installing the other rectifiers ...........................................................104
Figure 84 – Alarm cable exits from top of the case ...........................................105
Figure 85 – Installing the two cable glands .......................................................106
Figure 86 – Fixing the cables to the cable gland...............................................106
Figure 87 – Fixing the AC cable to the side of the case....................................107
Figure 88 – Fixing the cables to the case sidewall............................................108
Figure 89 – Fixing the PDA earth cable ............................................................108
Figure 90 – Cables exit from right of the FPRA ................................................109
Figure 91 – Cables exit from left of the FPRA...................................................109
Figure 92 – Cables exit from both sides of the FPRA .......................................109
Figure 93 – Installing the front cover to the FPRA ............................................110
Figure 94 – Installing the back cover to the FPRA ............................................110
Figure 95 – General view of the FPRA – cables run from right.........................111
Figure 96 – General view of the FPRA – cables run from left ...........................111
Figure 97 – General view of the FPRA – cables run from both sides................111
Figure 98 – Serial number of the FPRA unit .....................................................113
Figure 99 – Master/slave definition of FPRA units in parallel............................113
Figure 100 – Current flow of two battery blocks in parallel................................115
Figure 101 – Example of a parallel configuration – 2 FPRAs & 1 BAT .............116
Figure 102 – Example of a parallel configuration – 2 FPRAs & 4 BATs............117
Figure 104 – The locating points on the FPRA .................................................119
Figure 105 – Stacking the two FPRA units .......................................................120
Figure 106 – Fixing the two FPRA units............................................................120
Figure 107 – Parallel cable configuration within the two drawers .....................121
Figure 108 – Paralleling the two drawers (old version) .....................................122
Figure 109 – Paralleling the two drawers (updated version) .............................122
Figure 110 – Installing the two FPRA units .......................................................123
Figure 111 – General view of the two FPRA units in parallel ............................124
Figure 112 – Example of a parallel configuration – 3 FPRAs & 1 BAT .............125
Figure 115 – Parallel cable configuration within the three drawers ...................128
Figure 116 – Paralleling the three drawers (old version)...................................129
Figure 117 – Paralleling the three drawers (updated version) ..........................129
Figure 118 – General view of the three FPRA units in parallel .........................130
Figure 119 – Setting up the configuration environment.....................................132
Figure 120 – Login the GUI...............................................................................134
Figure 121 – The GUI home page (1) ...............................................................135
Figure 122 – Local Are Connection – Properties ..............................................136
Figure 123 – Internet Protocol (TCP/IP) – Properties .......................................137

List of figures 8
Figure 124 – Allocate secure IP-Address..........................................................138

Figure 125 – The GUI home page (2) ...............................................................139
Figure 126 – Setting up the CU IP-address ......................................................140
Figure 127 – Commissioning configuration of the FPRA ..................................143
Figure 128 – Commissioning of the battery input..............................................144
Figure 129 – Battery related settings via GUI ...................................................145
Figure 130 – System related settings via GUI...................................................146
Figure 131 – Time settings via GUI...................................................................146
Figure 132 – Commissioning of the AC input....................................................147

List of tables 9
List of tables
Table 1 – Contents of this manual ......................................................................12

Table 2 – Symbols in the Installation Manual......................................................13
Table 3 – Reference documents of the FPRA ....................................................13
Table 4 – Main specifications of the FPRA .........................................................15
Table 5 – Applicable rated input voltage types of the FPRA ...............................16
Table 6 – Main voltages and the corresponding EAC alarms .............................17
Table 7 – Static data of the DC output ................................................................19
Table 8 – EAC alarm settings .............................................................................23
Table 9 – LEDS on the PDA front panel .............................................................26
Table 10 – LEDS on the rectifier front panel .......................................................28
Table 11 – Term and Symbols in this manual.....................................................30
Table 12 – Symbols on the FPRA.......................................................................30
Table 13 – Delivery contents by FPRA ...............................................................34
Table 14 – Three typical battery / load cables configurations .............................50
Table 15 – Flow chart of securing the front panel ...............................................58
Table 16 – Flow chart of securing the sub cover.................................................60
Table 17 – The connection of the temperature cable..........................................65
Table 18 – The connection of the parallel cable .................................................68
Table 19 – The connection of the Alarm cable....................................................72
Table 20 – Recommended preparation for AC mains cable ...............................85
Table 21 – Flow chart of securing the rear cover ................................................95
Table 22 – Rectifier alarm indications ...............................................................150
Table 23 – System alarm indications ................................................................153
Table 24 – Failures likely to happen .................................................................156

List of terms 10
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
L Live cable from the AC mains
LAN Local Area Network

LED Light Emitting Diode
LVD Low Voltage Detection
MAC Media Access Control
MCB Micro Circuit Breaker

List of terms 11
N Neutral cable from the AC mains

N/A Not applicable
PC Personal Computer
PCB Printed Circuit Board
PDA Power Distribution Assembly
PE Protective earth
PSU Power Supply Unit
RTN Return
S/N Serial Number
SPD Surge Protect Discharge
V Volt
VPN Virtual Private Network
1Φ Single-phase AC type
3Y 3-phase star AC type
3Δ 3-phase delta AC type

Preface 12
Preface
About this manual

This manual guides the user on how to install the FPRA, including the
hardware installation, the browser and CU setup. The manual also introduces
the FPRA as well as its commissioning, maintenance and troubleshooting.
The contents of this manual are listed in Table 1.
Table 1 – Contents of this manual
Chapter Title Content
1 Product instruction Describes the specifications, properties,

mechanical data, etc. of the FPRA and the
modules it contains.
2 Preparation Describes the installation safety, site, and

tools.
3 Hardware installation Describes how to install the AC cables, DC

cables, communication cables, parallel
installation, etc. of the FPRA.
4 Browser and CU Describes how to set the browser and CU,

setup and access the GUI.
5 Commissioning Describes how to commission the FPRA

after the installation.
6 Maintenance Describes how to maintain the FPRA.
7 Troubleshooting Describes how to solve the detected

issues of the FPRA.

Preface 13
Term and Symbols in this manual

These term and symbols in Table 2 might appear in the manual:
Table 2 – Symbols in the Installation Manual
Symbol Description
Safety symbol, see Safety summary
Safety symbol, see Safety summary
Provides hints to the user for easier

installation, maintenance and troubleshooting
The necessary supplementary of the article
to let user be clearer.
Reference documents
The documents of the FPRA contain:
Table 3 – Reference documents of the FPRA
Emerson Network Power

Document
File No.
Internal product specification – System / PDA 41970005110
Internal product specification – Rectifier 41970004980
Surge Protect Discharge for Flexi Power Rectifier –

03370500080
User Manual
Flexi Power Rectifier - User Manual 03370500090
Flexi Power Rectifier - Installation Manual

03370500070
(This manual)
- To be continued -

Preface 14
Table 3 – Reference documents of the FPRA
Surge Protect Discharge for Flexi Power Rectifier –

03370500100
Quick Start Guide
Flexi Power Rectifier – Quick Start Guide 03370500110

Product Introduction 15
Chapter 1 Product Introduction
1.1 General Description

The FPRA is a 6kW output power AC rectifier package made up of three
individual 2kW AC/DC power modules operating in a parallel mode
configuration. The FPRA outputs a positive earthed –54VDC (V48N) as a
respective BTS operational supply voltage rail and for site battery charging. It
also includes a Power Distribution Assembly (PDA), which has a fully
integrated battery protection LVD, load / battery circuit breakers, battery
current shunt and alarm signals to the BTS EAC interface.
1.1.1 Specification
 Main specifications
Table 4 – Main specifications of the FPRA
Parameter Specification Description
Min Nom Max
Rated AC input voltage 180 -- 276 See Table 5

(VAC)
DC Nominal Vout -56 -54 -52 See Table 7

(VDC)
Output
Iout (ADC) 0 -- 109.9 See Table 7
Ambient Operation -40 23 55 (1) Max output 6kW

temperature
Storage -45 -- +45
(°C)
Start up -40 (2) -- -- Max output 6kW
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 55°C (plus solar load).

(2) At -40°C 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 -40°C.
 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.
Table 5 – Applicable rated input voltage types of the FPRA
VAC / V VAC / V Frequency / Hz Supply Network Type

(Nominal) (Range)
240 180 – 276 45 – 66 US Single phase; three-
wire; earthed mid point of
phase
230 180 – 276 45 – 66 Europe Single Phase
208 180 – 276 45 – 66 US 3-phase star; four

Phase to Neutral wire; earthed neutral
240 180 – 276 45 – 66 US 3-phase delta; four-
Phase to Phase wire; earthed mid point of
phase
202 180 – 276 45 – 66 Japanese 3-phase delta
Phase to Phase
230 180 – 276 45 – 66 European 3-phase star;
Phase to Neutral four wire; earthed neutral)
The FPRA is designed to operate with extended operation input main

voltage, at the low range between 90 ~180 VAC (with derated output
power, see Figure 1) and at upper range between 276~310 VAC.
The FPRA accepts, without damage, single phase AC input voltage of
up to 350VAC at frequency of 45~66Hz, for a duration of up to 60s.

Table 6 – Main voltages and the corresponding EAC alarms
VAC / V Status EAC alarm
<85 Low mains voltage – Yes (2)

Rectifier shutdown Mains phase failure (3)
#1 / #2 / #3
90 ~ 180 (-5) (1) Operational – extended and Yes

low mains voltage range Minor (3)
180 ~ 276 Rated operation No (2)

Refer to Table 5
277 (+5) ~ 310 Operational – extended and Yes

high mains voltage range Minor (3)
>315 (±5) Over mains voltage Yes

– Rectifier Shutdown Major (3)
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.

Figure 1 – Output power-derating characteristic

Note: N+1 (failure) defines the condition that one of the three rectifiers has failures, and
only two rectifiers operate normally to support the load.
 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.

Table 7 – Static data of the DC output
Parameter Spec Description
-54± 2(1) Nominal output voltage

Output Voltage (VDC)
-57~-45 Output voltage range
Factory Output Voltage set point

-53.3±0.6 Factory default setting at +27°C
(VDC)
For a load from Minimum to

Line regulation <1%
Maximum at +27°C
For a load from Minimum to

Minimum Hold Up (ms) 20
Maximum
Current Limit (ADC) +10% @ Maximum output 6kW
OVP Limit (VDC) 58.5 ±1.0 Factory set
Output Low Voltage Alarm (VDC) 40±0.5 Factory set
Max output 6kW,

Ripple & noise (mV) 300
-10~+55°C (plus solar load) (2)
6 -40°C ~+55°C (plus solar load)

Max Output power (kW) 6kW derating to 4.5kW @
6 ~ 4.5
+55°C (plus solar load) → 65°C
Minimum Output power (kW) -- No minimum load limitation
Nominal AC input range,

Efficiency >90%
Max output 6kW
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 -40°C 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.
Figure 3 – General view of the FPRA

The FPRA has a dimension of 475.0 X 504.0 X 128.7 (W X D X H) mm.
Figure 4 shows the back view of the FPRA after installing all the rectifiers.

Fan Guiding pole AC cable
Figure 4 – Back view of the FPRA
1.2 The Power Distribution Assembly (PDA)

The Power Distribution Assembly (PDA) is the internal power distribution
assembly of the FPRA. It has the following properties:
 AC power distribution.
The PDA supplies the rectifiers with three AC input power system types,
as listed in Table 5 by using a different configuration of the internal AC
terminal block connections.
 DC power distribution.
The rectifiers are all connected directly to a DC bus bar internal to the
PDA.
The three battery back-up channels and two load channels are connected
to the DC bus bar through the internal micro circuit breakers (MCB). Each
breaker is rated to 63A.
 Battery control function.
The PDA carries out an automatic battery test periodically by the control
unit (CU), and records the last 10 battery test data including the test date,
discharge current and time, test end voltage, battery temperature,
discharged Ampere-hours, etc.
The batteries will stop discharging and disconnect from the loads once the
battery voltage is below the “LVD” set point.
The user can set the batteries charge voltage level to commensurate with
the batteries in field, and set the Low Voltage Detection (LVD) voltage

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.
Table 8 – EAC alarm settings
EAC alarm Description
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
Critical Battery low voltage

PDA controller fail
DC distribution failure (e.g. breaker failure)
Major Battery failure

Rectifier fail
High float voltage
Minor Battery temperature High/Low

Rectifier temperature High
Rectifier over current
Configuration change
Extended and high mains voltage range (refer to Table 6)
Extended and low mains voltage range (refer to Table 6)
 Network connection based on LAN.

The PDA can be connected to a user PC via the internal RJ45 interface.
The user can monitor the whole system via a web-based GUI.

The PDA has a dimension of 176.2 X 364.0 X 102.0 (W X D X H) mm.

Figure 5 shows the general view of the PDA before the installation.
(1) (3) (4) (5) (2) (9)
(6) (10) (7) (8)

(1) Rear cover (2) Sub cover (3) Restricted area (4) BR bus bar (5) –54V bus bar
(6) Front panel (7) Drawer (8) RS 485 cable (9) Window of the breakers (10) PE of the PDA
Figure 5 – General view of the PDA

Figure 6 shows the front panel of the PDA.

(3) (4) (5) (6) (7)
(2)
(1)
(11)
(10)
(9)
(8)
(13) (14) (12) (15)

(1) LCD (2) Red LED (3) Yellow LED (4) Green LED (5) Up button (6) Middle button
(7) Down button (8) AC cable inlet (9) Alarm Out (10) Alarm In (11) To PSU (12) From PSU
(13) Temperature (14) Ethernet interface (15) DC grommet
Figure 6 – The front panel of the PDA

The LEDS on the PDA front panel will have any of the status listed in Table 9.
Table 9 – LEDS on the PDA front panel
LED Mark Status Indication
Fault
F/MA
ON Major EAC alarm (refer to Table 8)
/ Red
Mains / phase failure (refer to Table 8)
M/MA Message
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
1.3 The Rectifier

The FPRA supports the operation of up to three rectifiers in parallel. Each
rectifier is an AC/DC module, which meets the specifications listed in Table 5
and Table 7. The rectifier has the following properties:
 High efficiency. The rectifier has an over 90% efficiency at the nominal AC
input voltage.
 Over current protection. The rectifier shuts down once an over current is
detected, and recovers automatically when the fault is no longer present.
 Over voltage protection. The rectifier shuts down once an over voltage is
detected for the first time, and recovers automatically when the fault is no
longer present. If the over voltage is detected for the second time, the
rectifier will shuts down for ever until the AC power supply re-powers up to
restart the rectifier.
 Monitoring function. The rectifier monitors different parameters such as
input voltage, output voltage, etc., and sends out a corresponding alarm
signal in case it detects a fault.
 Self-cooling function. Each rectifier is forced convection cooled. The fan at
its back is replaceable.

 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.
(8) (7) (6) (5)
(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

Table 10 lists the LED indications of the rectifier.
Table 10 – LEDS on the rectifier front panel
LED Mark Status Indication
Yellow (amber)
ON Minor EAC alarm (refer to Table 8)
/ Message
Rated mains voltage (refer to Table 5)

Green / Normal ON
System OK
Rectifier failure
Fan failure
Red / Alarm ON
AC input phase voltage less than 80V
Low output voltage

Preparation 29
Chapter 2 Preparation
2.1 Safety Summary

2.1.1 Injury and product damage precautions
The following precautions must be observed during all phases of servicing
the product, such as installation, maintenance or configuration. Any
omission of the precautions might cause injury and/or product damage.
 Do not service the product during a thunder / lightning storm to avoid
electric shock.
 Turn off the AC power source when accessing the AC cables or the
SPD to avoid electric shock.
 Make sure the product is well grounded before servicing the product to
avoid electric shock.
 Do not install the product in an explosive atmosphere to avoid injury or
fire hazard.
 Do not service the product if the environment cannot meet the
requirements defined in the product specification.
 Do not place the product in an unstable rack, to avoid the product
damage in case of a fall.
 Do not open the restricted area by unqualified personnel, to avoid
damage to the product.
 After unpacking, do not start the installation if you suspect any product
damage caused by shipment.
 Pay attention to the specific warning/caution terms and symbols in this
manual.
2.1.2 Safety Term and Symbols

These term and symbols listed in Table 11 may appear in this manual:

Preparation 30
Table 11 – Term and Symbols in this manual
Term & Symbol Description
Warning statement identifies conditions or practices

that could result in bodily injury or loss of life.
It warns the reader to be extremely careful.
Caution statement identifies conditions or practices

that could result in damage to this product or
devices connect to it.
It indicates that the reader must be careful.
These symbols listed in Table 12 may appear on the FPRA:
Table 12 – Symbols on the FPRA
Symbol Description
Risk of electric shock:

To avoid electric shock, user shall not touch the product.
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 -

Preparation 31
Table 12 – Symbols on the FPRA
Protective earth terminal:

Connect the protective earth cable in the indicated position.
System earth terminal:

Connect the system earth cable in the indicated position.
Recycle:
User cannot dispose of this electronic product in the trash. To
protect the environment, please recycle.
2.2 Installation site

To ensure normal operation and long service life of the product, install it in an
environment that meets the following requirements:
 Temperature
The FPRA should be used and maintained in the temperature that
defined in Table 4.
 Cleanness
Dust is a hazard to the operation to the device. The dust accumulated
on the chassis can be absorbed by static electricity and result in poor
contact of metal connectors. This not only shortens the service life of
your device but may also cause communication failures.
Besides dust, the harmful gases, containing salts, acids and sulfides,
can accelerate the corrosion and aging of metals.
 Ventilation
Each rectifier has an integrated fan for cooling. The airflow is from the
rear to the front of the rectifier unit. Consideration should be given to
the amount of clearance necessary to ensure FPRA cooling when
configured within cabinets.

Preparation 32
2.3 Installation tools and test equipments
The installation tools and test equipments are prepared in field.
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

Preparation 33
2.4 Check list of the FPRA

Figure 8 shows the product tree of the iPSU in which the FPRA is
included.
Customer configuration
AA25020L AA25000L AA25130L

Flexi 3U
Flexi Power
mounting covers Rectifier Unit Transient
Rectifier 6000
front/back 1/2/3 Protection Unit
FPRA
FMCA
Figure 8 – Product tree
Table 13 lists the delivery contents by FPRA.
One FPRA (AA25020L) may adopt one or two or three rectifiers

(AA25000L) to meet the user’s requirement.
The Transient Protection Unit (AA25130L) is optional for the user, and is
supplied independently with the FPRA (AA25000L).
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.

Preparation 34
Table 13 – Delivery contents by FPRA
Name Figure Description Usage Emerson Emerson

Part Number Module Number
Case The case of the FPRA, in N/A

which the PDA and rectifiers 1
are installed.
PDA The distribution of AC input 85570602630

and DC output 1
Cable gland Cable entry of the FPRA 2 18370104780
Temperature cable The temperature sensor of the 1

FPRA 8087000695x
AA25020L
Parallel cable The communication cable for 8087000694x
RS422 interface 1
Ethernet cable Ethernet cable compliant with 1

T568A/B 8087000897x
System earth cable Connects the FPRA to system 1

earth 8087000987x

Preparation 35
Phoenix Used to configure the AC 1 40570002800

terminal block
3-pole Bridge
Phoenix Used to configure the AC 3 40570002790

terminal block
2-pole Bridge
Cable tie Used to tie the cables 50 18870001600

AA25020L
Cable restraint Used to tie thick cable, such 2 18370104720
as AC cable
M3 screw Used to fix the cable restraint 4 41300000208
M5 screw Used to fix the cases when 2 41300000181

stacked for parallel
configuration

Preparation 36
SPD Surge Protection Discharge 1 10070000400
SPD jumper Short link for SPD terminals in 1 18370102980/

single-phase AC connection 40370110040
L line short link L1/L2/L3 for three phase, 1 8087000880x

AA25130L
L for single phase (AWG12)
N line short link N for three phase star, 1 8087000879x

N for single phase (AWG 8)
SPD ground link SPD ground link 1 8087000902x
SPD Sense Cable SPD signal cable connecting 1 8087000925x

to the MCU
Rectifier The AC/DC module 1/2/3 AA25000L
AA25000L

Hardware Installation 37
Chapter 3 Hardware Installation
Before hardware installation, please note:

All the precautions listed in the Safety summary.
The installation should be carried out only by qualified personnel and in
accordance with local electrical codes.
The installation sequence summary of the various system modules

described below is mandatory for first time installation of the FPRA
components. The detailed installation procedure for each module can be
found in the appropriate sections further on in this document.
3.1 Detach the PDA from the case

Figure 9 presents the FPRA before the installation.
A B C
Figure 9 – The FPRA before the installation

(1) Remove the two cable glands from the case.

Loosen the four screws with a TORX screwdriver (T25), and remove the
cable glands from the case (see Figure 10).
Figure 10 – Detaching the cable glands

(2) Release the PDA earth cable.
Release the PDA earth cable by loosening the nut with a wrench (8mm)
(see Figure 11).
Figure 11 – Releasing the PDA earth cable

(3) Release the RS485 cables.

Release the three RS485 cables by manually loosening the three cable
ties originally (see Figure 12).
Figure 12 – Releasing the RS485 cables

(4) Detach the PDA from the case.
Loosen the two screws on the front panel of the PDA with a Cross
screwdriver, and pull the PDA out of the case horizontally along its guide
rail on the bottom of the case (see Figure 13).
Figure 13 – Detaching the PDA from the case

(5) Insert the cables through the cable gland if required.
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.

There are three types of DC cables configuration (refer to Figure 21 and

Table 14), thus corresponding three types of recommended configuration
of the cable glands (see Figure 14, Figure 15 and Figure 16).
Alarm
System earth cable
BAT2
Parallel cable
Temperature
cable
LOAD2
AC cable
RTN2
RTN5 Parallel cable
DC GND
Alarm
Figure 14 – Cable gland configuration – option1

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

Puncture the waterproof of the cable gland with an awl (Φ2mm), 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.
Figure 17 – Inserting the cable through the cable gland
3.2 Route the DC cables

(1) Detach the drawer from the PDA.
Loosen the two screws with a Cross screwdriver, and pull the drawer out
of the PDA (see Figure 18).

2
1
Figure 18 – Removing the drawer from the PDA

(2) Remove the front panel from the PDA.
Loosen the six screws on the front panel and two screws on the window of
the breakers with a TORX screwdriver (T10), and detach the front panel
from the PDA (see Figure 19).
Figure 19 – Removing the front panel from the PDA

(3) Remove the sub cover from the PDA.

Loosen the four screws on the sub cover with a screwdriver (Torx10), and
remove the sub cover from the PDA (see Figure 20).
Figure 20 – Removing the sub cover from the PDA

(4) Identify the DC terminals.
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.

LOAD2(-) BAT1(-) BAT2(-)

MCB switch
Lever bar
CB1 CB2 CB3 CB4 CB5 BAT3(-)
LOAD1(-)
Insulator
Terminals
short link
RTN4(+)
RTN5(+)
LOAD
GND
RTN1(+) RTN2(+) RTN3(+)

Figure 21 – DC terminals distribution
LOAD2(-) BAT1(-) BAT2(-) BAT3(-)

LOAD1(-)
Fixing
pole
LOAD
GND
RTN5(+)
RTN1(+) RTN2(+) RTN3(+) RTN4(+)

Figure 22 – DC inlet grommet

(5) Configuration of the DC cables.
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

Table 14 – Three typical battery / load cables configurations
CSA size Cable Recommended Installing

Option Cable name Breakers configuration
(mm2) number sequence (2)
Load & return 35 2

Load MCB parallel
1 Battery & return 50 (3) 2 → RTN2(+) → LOAD2(-) &
→ RTN5(+) → BAT2(-) Battery MCB parallel
Load
35 1
Grounding (1)
Load & Return 35 4
→ RTN1(+) → LOAD1(-)
Battery & return 35 6 → RTN2(+) → LOAD2(-) →
2 RTN3(+)→BAT1(-) → RTN4(+) No MCB parallel
Load → BAT2(-) →RTN5(+) →
35 1 BAT3(-)
Grounding (1)
Load & Return 35 2

→ RTN1(+) → LOAD2(-)
3
Battery & return 16 6 → RTN3(+)→ BAT1(-) → Load MCB parallel
RTN4(+) → BAT2(-)→ RTN5(+)
Load → BAT3(-)
35 1
Grounding (1)
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.

(6) Connect the DC cables.
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.
Install the DC cables following the recommended sequence in Table 14.

1) Insert the DC load grounding cable through the front panel.
Puncture the waterproof of the front panel marked (see Figure 25

with an awl (Φ2mm), and then insert the load grounding cable through
the hole (see Figure 25).
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

2) Connect the DC load grounding cable.

After the wire has been inserted, peel the end insulator of the cable
with a wire-stripper, and keep a bare end of about 15mm.
Insert the bare end of the cable to DC terminal (refer to

Figure 21), and secure the cable with a flat screwdriver, tightening the
clamp to 3.0Nm (see Figure 26).
Figure 26 – Securing the DC load grounding cable

3) Connect the other DC cables.

Repeat the above two steps of connecting the DC load grounding
cable, user shall install the other DC cables one by one into the PDA.
The installation based on the indicated DC terminals and sequence in
Table 14 is preferred.
Figure 27 shows the final connection after the above assembly.
Figure 27 – Connecting the DC cables – configuration option1 (typical)

Note: The terminals short links and MCB switch lever bars for load and battery are all
reserved for this configuration.

Figure 28 and Figure 29 represent the final connections of the other two
DC cable configurations in Table 14.
Figure 28 – Connecting the DC cables – configuration option2

Note: The terminals short link and MCB switch lever bar for load and battery are all
removed for this configuration.

Figure 29 – Connecting the DC cables – configuration option3

Note: The terminals short link and MCB switch lever bar for battery are removed for this
configuration.

(7) Put the front panel back into the PDA.

Push the front panel back into the PDA, while dragging out the DC cables
and keeping them in order to prevent crisscross (see Figure 30).
Figure 30 – Putting the front panel back into the PDA

(8) Secure the front panel.

Secure the six screws on the front panel following two steps listed in Table
15. Tightening the screws orderly will avoid damage to the waterproof or
distortion to the front panel (see Figure 31).
Table 15 – Flow chart of securing the front panel
Step Sequence Torque (Nm)
1 1, 2, 3, 4, 5, 6 0.3~0.4
2 1, 2, 3, 4, 5, 6 0.5~0.6
2 4
Figure 31 – Securing the front panel

(9) Secure the window of the breakers.

Secure the two screws on the breaker window with a TORX screwdriver
(T10), tightening to 0.6~0.7Nm (see Figure 32).
Figure 32 – Securing the window of the breakers

(10) Fix the DC cables to the front panel.

Fix the DC cables to the corresponding side poles with cable ties (see
Figure 33).
Figure 33 – Fixing the DC cables to the front panel
(11) Secure the sub cover.

Put the sub cover back onto the PDA, and secure the four screws
following two steps listed in Table 16. Tightening the screws orderly will
avoid damage to the waterproof gasket at the joint (see Figure 34).
Table 16 – Flow chart of securing the sub cover
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

3.3 Route the Communication cables
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 B A Connector
J11
J22
Figure 35 – Drawer internal layout (old version)

Gasket C B A
Connector
J11
D J22
Figure 36 – Drawer internal layout (updated version)
(1) Connect the temperature cable.

Puncture the waterproof gasket marked ‘TEMP’ on the drawer panel with
an awl (diameter of 2mm) (see Figure 37, Figure 38), and then insert the
temperature cable through this hole.
Take care not to break the waterproof of the gasket while inserting the
communication cable.

Figure 37 – Inserting the temperature cable into drawer (old version)
Figure 38 – Inserting the temperature cable into drawer (updated version)

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 doesn’t need to go
under the three RS485 cables (see Figure 40).
Table 17 – The connection of the temperature cable
Pin of J22 Name Color
7 TEM_GND Red
8 TEM SENSE_IN White
9 TEMP_VCC Black
10 EARTH Cable screen

Figure 39 – Connecting the temperature cable only (old version)
Figure 40 – Connecting the temperature cable only (updated version)

Put the temperature probe between the battery blocks where might has
the highest temperature (see Figure 41).
Figure 41 – Placing the temperature probe
(2) Connect the parallel cable.
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.

Puncture the waterproof marked ‘From PSU’ or ‘To PSU’ on the drawer
gasket with an awl (diameter of 2mm) to insert the parallel cable like in
Figure 37 or Figure 38.
For each parallel cable, it connects the “From PSU” pins in one drawer
and “To PSU” pins in another drawer (refer to Table 18) to parallel the two
systems.
Runs the parallel cable under the three RS485 cables and connects the
parallel cable to J22 as per the one-to-one relationships listed in Table 18
(see Figure 42, Figure 43, Figure 44, Figure 45).
For updated drawer installation, the parallel cable doesn’t need to go under the
three RS485 cables (see Figure 43, Figure 45).
Table 18 – The connection of the parallel cable
Option Pin of J22 Name Color
From 1 RS422RD- Red

PSU
2 RS422RD+ White
3 SGND/F Black
To PSU 4 RS422TX- Red
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)

Figure 44 – Connecting the parallel cable only – To PSU (old version)
Figure 45 – Connecting the parallel cable only – To PSU (updated version)

(3) Connect the Alarm cable.
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.

Table 19 – The connection of the Alarm cable
Pin of J11 Name Color
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

Figure 46 – Connecting the Alarm In cable only (old version)
Figure 47 – Connecting the Alarm In cable only (updated version)

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.
Figure 48 – Connecting the Alarm Out cable only (old version)
Figure 49 – Connecting the Alarm Out cable only (updated version)

(4) Fix the communication cables.

After connecting all communication cables following the above steps:
For old drawer, Assemble the alarm cable, temperature cable and parallel
cable and fix them to position ‘C’ in Figure 35 with a cable-tie (see Figure
50).
Figure 50 – Fixing all the communication cables (old version)

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).
Figure 51 – Fixing all the communication cables (updated version)

(5) Put the drawer back into the PDA.

Push the drawer back into its slot horizontally until the drawer pin matches
the internal connector of the PDA (see Figure 52).
Figure 52 – Putting the drawer back into the PDA

(6) Secure the drawer to the PDA.
Secure the two thumbscrews on the drawer panel by using a Cross
screwdriver with a torque of 0.6~0.7Nm (see Figure 53).
Figure 53 – Securing the drawer to the PDA

3.4 Route the AC cable without the SPD
The AC mains must be switched off prior to accessing the AC cable.

A disconnect device must be provided in system to ensure that all power
conductors (including all line and neutral conductors) can be disconnected
simultaneously
(1) Remove the rear cover from the PDA.

Loosen the five captive screws on the rear cover using a TORX
screwdriver (T10), and remove it from the PDA (see Figure 54).
Figure 54 – Removing the rear cover

Figure 55 shows the PDA rear internal chassis layout.
PDA rear cover
SPD DIN Rail
AC terminal block
E
D
SPD ground clamp

SPD sensor
PDA earth cable connector
AC ground clamp
C
Rear cover
Retention
A B
cable
Cable restraint
Figure 55 – The PDA rear internal chassis layout

(2) Configure the AC terminal block.
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.
Insert the Phoenix bridges and screws (provided as accessories) to the

corresponding slots on top of the AC terminal block referring to the AC
CABLE CONNECTION CHART located on the chassis (and reproduced in
Figure 56).
Secure the screws with a flat screwdriver, tightening to 0.8Nm.
Figure 56 – The AC cable connection chart

There are three AC power system types (see Table 5), and thus three AC
configurations of the AC terminal block:
 Single-phase (1Φ) 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).
Figure 57 – AC terminal block configuration – 1Φ

 3- phase delta (3Δ) configuration

For 3-phase delta AC system, use three Phoenix 2-pole bridges to
short the terminals 1,2 and 3,4 and 5,6 respectively on the AC terminal
block (see Figure 58).
Figure 58 – AC terminal block configuration – 3Δ

 3- phase star (3Y) configuration

For 3-phase star AC system, use one Phoenix 3-pole bridges to short
the terminals 1,2,3 on the AC terminal block (see Figure 59).
Figure 59 – AC terminal block configuration – 3Y

(3) Insert the AC cable through the front panel.
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).
Figure 60 – Inserting the AC cable through the front panel

(4) Make AC connection without the SPD.
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.
Table 20 – Recommended preparation for AC mains cable
(Tolerance: 3mm)
AC type L1 L2 L3 N PE
Single- A (mm) 140 115 85

phase
(1Φ) B (mm) 10 20 20
3-phase A (mm) 140 120 105 -- 85

delta
(3Δ) B (mm) 10 10 10 -- 20
3-phase A (mm) 150 140 125 100 85

star
(3Y) B (mm) 10 10 10 20 20

 Option 1 – 3-phase star (3Y) AC connection without the SPD
AC mains AC Terminal Block

PE L1 L2 L3 N 1 2 3 4 5 6
Figure 61 – Schematic diagram of AC connection without the SPD – 3Y
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).
Figure 62 – Detaching the Strain-relief from the chassis

2) Prepare the AC mains as per Table 20.

3) Detach the AC ground clamp from the chassis by loosening the
screw ‘B’ (refer to Figure 55) with a TORX screwdriver (T25) (see
Figure 63).
4) Fit the PE cable from the AC mains into the AC ground clamp,
tightening to 1.5Nm with a flat screwdriver (see Figure 63).
Figure 63 – Connecting the PE cable from the AC mains – 3Y

5) If required, detach the AC terminal block from the chassis by

loosening screws ‘D’ and ‘E’ (refer to Figure 55). This will provide a
better view of the AC terminal block connections (see Figure 64).
6) Fit the L1, L2 and L3 live cables from the AC mains into terminals
‘6’, ‘5’ and ‘4’ respectively on the AC terminal block, tightening to
1.5Nm with a flat screwdriver (see Figure 64).
7) Fit the N cable from the AC mains into terminals ‘2’ on the AC
terminal block, tightening to 1.5Nm with a flat screwdriver (see
Figure 64).
L3
L1
L2
Figure 64 – Connecting the L and N line cables to the AC terminal block – 3Y

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).
Figure 65 – Fixing the AC ground clamp back onto the chassis – 3Y

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).
Figure 66 – Fixing the AC terminal block back onto the chassis – 3Y

10)Restrain the AC cable by fitting the adjustable Strain-relief on the

cable socket and tightening the screw ‘A’ in Figure 55 to 2.0Nm
with a TORX screwdriver (T25) (see Figure 67).
Figure 67 – Restraining the AC mains cable onto the chassis – 3Y

Figure 68 shows the final connection of the 3-phase star AC cable.
L3
N
PE of AC mains
L2
L1
Figure 68 – AC connection without the SPD – 3Y

 Option 2 – Single-phase (1Φ) AC connection without the SPD

Configure the AC terminal block as per Figure 57 firstly.
Connect the single-phase AC mains cable in the similar way as
connecting the 3-phase star AC mains described in option 1.
Figure 69 and Figure 70 show the phase connection and final single-
phase AC mains connection.

PE L N 1 2 3 4 5 6
Figure 69 – Schematic diagram of AC connection without the SPD – 1Φ
N
L
PE of AC mains
Figure 70 – AC connection without the SPD – 1Φ

 Option 3 – 3-phase delta (3Δ) AC connection without the SPD

Configure the AC terminal block as per Figure 58 firstly.
Connect the 3-phase delta AC cable in the similar way as connecting
the 3-phase star AC cable described in option 1.
Figure 71 and Figure 72 show the phase connection and final 3-phase
delta AC mains connection.

PE L1 L2 L3 1 2 3 4 5 6
Figure 71 – Schematic diagram of AC connection without the SPD – 3Δ
L3 L2
PE of AC mains L1
Figure 72 – AC connection without the SPD – 3Δ

(5) Secure the rear cover back to the PDA.
Before securing the rear cover,

Recheck the connection of the AC cables and make sure the protective earth
terminals have been correctly connected.
There should not be any loose parts, wires in the PDA.
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).
Table 21 – Flow chart of securing the rear cover
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
Figure 73 – Securing the rear cover back to the PDA

3.5 Install the PDA into case

(1) Put the PDA back into the case.
Push the PDA horizontally along its bottom guide rail until it reaches the
end of the case (see Figure 74).
Figure 74 – Putting the PDA back into the case

(2) Secure the PDA.

Secure the two thumbscrews on the PDA front panel with a Cross
screwdriver, tightening to 1.2Nm (see Figure 75).
Figure 75 – Securing the PDA to the case

(3) Connect the PDA earth cable to the case.

Secure the PDA earth cable from the PDA to the grounding pole ‘A’ on the
case, tightening to 2.0Nm with a wrench (8 mm) (see Figure 76).
Figure 76 – Connecting the PDA earth cable to the case

(4) Connect the system earth cable.

Secure the system earth cable from the PDA to the ground pole ‘B’ on the
case, tightening to 2.0Nm with a wrench (8 mm) (see Figure 77).
Figure 77 – Connecting the system earth cable

(5) Connect the Ethernet cable if required.
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).
Figure 78 – Connecting the Ethernet cable

3.6 Install the rectifiers

(1) Install a rectifier into the first slot of the case.
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.
1) Put the rectifier into the slot.

Push the rectifier horizontally into the first slot until it reaches the end
of the case (see Figure 79).
Figure 79 – Putting the rectifier into the first slot of the case

2) Secure the rectifier.

Secure the two thumbscrews on the rectifier front panel with a Cross
screwdriver, tightening to 1.2Nm (see Figure 80).
Figure 80 – Securing the rectifier to the case

3) Connect the AC power cable to the rectifier.

Connect the AC input cable, and then tighten the two screws to 0.8Nm
with a flat screwdriver (see Figure 81).
Figure 81 – Connecting the AC power cable to the rectifier

4) Connect the RS485 cable to the rectifier.
First release the clip by pressing its both sides (see Figure 82).
Second connect the RS485 cable to its interface on the rectifier and
cover the connector entirely with the waterproof gasket (see Figure
82).
Finally refit the clip to fix the RS485 connector (see Figure 82).
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
Figure 82 – Connecting the RS485 cables to the rectifier
(2) Install the other rectifiers if required.

Install the other rectifiers in the same way as installing the first rectifier
(See Figure 83).
Figure 83 – Installing the other rectifiers

3.7 Installation of the cables with cable glands
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.
(1) The alarm cable exits from system top if required.
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
Figure 84 – Alarm cable exits from top of the case

(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 a TORX screwdriver (T25) (see Figure 85).
1
2
B
A
Figure 85 – Installing the two cable glands

(3) Fix the cables to the cable gland.
Fit the cables in the cable gland and fix them with cable ties (see Figure
86).
Figure 86 – Fixing the cables to the cable gland

(4) Fix the cables to the side of the case if required.
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
Figure 87 – Fixing the AC cable to the side of the case

Fix the other cables to the side cable plate with cable-ties (see Figure 88).
Figure 88 – Fixing the cables to the case sidewall

(5) Fix the PDA earth cable.
Fix the PDA earth cable to the cable gland on position ‘A’ with cable tie so
as not to block the LCD (see Figure 89).
Figure 89 – Fixing the PDA earth cable

All the cables may exit from right or left of the FPRA (see Figure 90, Figure
91).
Figure 90 – Cables exit from right of the FPRA
Figure 91 – Cables exit from left of the FPRA

The cables can also exit from both sides of the FPRA. It is recommended that
the AC cable and the communication cables exit from right and the DC cables
and system earth cable exit from left of the FPRA (see Figure 92).
Figure 92 – Cables exit from both sides of the FPRA

3.8 Install the front and back covers
The FPRA is IP54 rated and IP55 rated only when fitted with front and back
covers. The FPRA doesn’t supply these.
(1) Install the front cover to the FPRA.

Put the front plastic cover in place, and fix the two screws to position ‘A’
and ‘B’ on the cable glands, tightening to 2.0Nm with a TORX screwdriver
(T25) (see Figure 93).
A B
Figure 93 – Installing the front cover to the FPRA

(2) Install the rear cover to the FPRA.
Put the back plastic cover in place, and fix the two screws to position ‘C’
and ‘D’ on back of the FPRA, tightening to 2.0Nm with a TORX
screwdriver (T25) (see Figure 94).
C D
Figure 94 – Installing the back cover to the FPRA

Figure 95, Figure 96 and Figure 97 show the general view of the FPRA after
completing all the installation items.
Figure 95 – General view of the FPRA – cables run from right
Figure 96 – General view of the FPRA – cables run from left
Figure 97 – General view of the FPRA – cables run from both sides

3.9 Parallel installation of the FPRA
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 parallel operation only support by CU firmware R1Bx or later.

Parallel operation is not supported by CU firmware PxAx, RxAx and other
former CU firmware.
When upgrade the CU firmware for the paralleled FPRA systems, each
FPRA unit needs to be updated and re-started after the upgrade.
The S/N on the label is also the same of the internal CU.
 The Master / Slave setup of the FPRA units in parallel

The FPRA will be paralleled in a master / slave mode. User can control and
review all the FRPA units in the parallel system through the master FPRA,
either via LCD or web GUI.
After powering on each FPRA unit in a parallel system, the CU will detect the
serial number (S/N) of each FPRA, and the unit with the newest S/N is
defaulted as the master.
According to the S/N definition in Figure 98, a S/N number ‘G7083770009’
contains the information: plant code ‘G7’, manufacture date ‘Year 2008, Week
37’, sequence number ‘70009’.
For example in Figure 99, the ‘FPRA #1’ is defaulted as the master and the
other two units as the slaves since the S/N ‘G7083770009’ is newer than
‘G7081500036’ and ‘G7074801770’.

Figure 98 – Serial number of the FPRA unit
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

 The parallel installation of the two FPRA units

Figure 101, Figure 102 and Figure 103 show some parallel configuration
examples of the two FPRA units.
The user should choose a proper configuration referring to the actual
battery/load conditions in field.
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
MCB MCB MCB
PDA
BAT sharing
BAT cable
PDA
MCB MCB MCB
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 50mm2 and
might be made of separate cables jointed in one clamp.
RJ45
PC
AC in
Load1
Load2
PDA #1
RS422
Battery Cabinet RS422
Load1
Load2
PDA #2
AC in
Figure 101 – Example of a parallel configuration – 2 FPRAs & 1 BAT

RJ45
Battery Cabinet
PC
AC in
Load1
Load2
PDA #1
RS422
RS422
Load1
Load2
PDA #2 AC in
Figure 102 – Example of a parallel configuration – 2 FPRAs & 4 BATs

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

(1) Stack the two FPRA units.

Stack the two FPRA units in place that ‘A’ and ‘B’ on the lower FPRA top
surface match ‘A’’ and ‘B’’ on the upper FPRA bottom surface respectively
(see Figure 104 and Figure 105).
A’ A’
A A
A’ Upper Lower
bottom A’ A top A
B
B’ B’
B
Figure 104 – The locating points on the FPRA

Figure 105 – Stacking the two FPRA units

(2) Fix the two FPRA units.
Fix the two FPRA units in positions ‘A’ and ‘B’, tightening to 2.0Nm with a
Torx screwdriver (T25) (see Figure 106).
B
A
Figure 106 – Fixing the two FPRA units

(3) Parallel the two FPRA units.

Connect the two FPRA units by configuring the two parallel cables within
the two drawers (see Figure 107, Figure 108, Figure 109).
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
Figure 107 – Parallel cable configuration within the two drawers

Parallel
cable #1 Parallel
cable #1
Parallel
cable #2
Parallel
cable #2
2
Drawer #1 1 Drawer #2
Figure 108 – Paralleling the two drawers (old version)
Parallel
cable #2
Parallel
Parallel cable #2
cable #1
Parallel
cable #1
Drawer #1 1 Drawer #2 2
Figure 109 – Paralleling the two drawers (updated version)

(4) Install the two FPRA units.

Install the two FPRA units individually following the procedures in sections
3.1 ~ 3.7 (see Figure 110).
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
Figure 110 – Installing the two FPRA units

(5) Install the front and rear covers.
Install the front and rear covers to each FPRA unit following the procedure
in section 3.8.
Figure 111 shows the general view of the two FPRA units after completing
all the parallel installation items.

Parallel
cable #1
Parallel
cable #2
Figure 111 – General view of the two FPRA units in parallel
 Parallel installation of the three FPRA units

Figure 112, Figure 113 and Figure 114 show some parallel examples of
three FPRA units.
The user should choose a proper configuration referring to the actual
battery/load conditions in field.
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 50mm2 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
Figure 112 – Example of a parallel configuration – 3 FPRAs & 1 BAT

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
Figure 116 – Paralleling the three drawers (old version)
Parallel
Parallel Parallel cable #2
Parallel cable #1 cable #3
cable #1
Parallel
cable #3
Parallel
cable #2 1 2 3
Drawer #1 Drawer #2 Drawer #3
Figure 117 – Paralleling the three drawers (updated version)

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
Figure 118 – General view of the three FPRA units in parallel

Browser and Control Unit Setup 131
Chapter 4 Browser and Control Unit Setup
This chapter describes how to set up the FPRA Control Unit (CU) and the
User’s 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 User’s 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 user’s 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.

4.1 Set up the configuration environment

Set up the configuration environment was shown in Figure 119.
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.
Figure 119 – Setting up the configuration environment
Connect the FPRA to the user’s PC with an Ethernet cable.

Turn on the three battery circuit breakers to power up the PDA, and verify its
normal operation through the LED status on PDA front panel as per Table 9.

4.2 Change the CU IP-address via the LCD

After normal power on, the user can view the information embedded in the
CU via the LCD.
Refer to Appendix B of the ‘Flexi Power Rectifier – User Manual’ (Emerson file
No. 03370500090) for the detailed use of the PDA LCD.
The user can read and change some system information via the LCD, e.g. the
battery settings, the factory settings, alarm settings, etc.
Change the CU IP-address into the local IP-range. E.g. if the local user’s PC
former IP-address is “192.168.100.100”, the CU IP-address should be
changed to “192.168.100.x” (the last digit “x” should be different from that in
the user’s PC IP-address).
In the parallel configuration, each CU should be changed the IP-address to
“192.168.100.x” (different last digit “x” for different CU and local user’s PC). In
this way, the user’s PC can access each CU in the local Internet / Intranet.
Now the user can link to the PDA CU with the Ethernet cable.
4.3 Connect to the GUI in local Internet / Intranet

Assume that the CU IP-address is “192.168.100.101”. Open the browser and
type the target address in the address field “192.168.100.101” to connect the
CU in the local Internet / Intranet.
The GUI will ask for a “username” and “password” (see Figure 120).
The following users are supported:
 Root User: Full Access to all functionality of the FPRA System,
released to the user.
o Username: “root”
o Password: “default” (this password can be changed as one of the
functionalities of the Root User)
 Admin User: This user is only applied for the service person, not
released to the user.
 Calibration/Factory User: This User is only for internal use like
calibration and uploading factory data, not released to the user.

Figure 120 – Login the GUI

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.
Figure 121 – The GUI home page (1)
4.4 Change the CU IP-address via the GUI

User can also change the PDA CU IP-address via the GUI. This needs to
change the IP-address of the user’s PC and connects to the CU.
4.4.1 Set up the user’s PC
In order to connect to the FPRA CU, the IP-address of the user’s PC should
be within the same IP range of the CU.
Assume the CU IP-address is 142.120.72.172. User has to change the user’s
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.

Follow the steps below to set up the IP-address of the user’s PC:
(1) Go to the Network-Settings and to the “Properties” menu of the active
TCP/IP connection (see also Figure 122).
Figure 122 – Local Are Connection – Properties

(2) Chose the Internet Protocol (TCP/IP) menu and select the “Properties”
menu (see also Figure 123).
Figure 123 – Internet Protocol (TCP/IP) – Properties
(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 user’s 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.

See also Figure 124; change the user’s PC IP-address to

“142.120.72.173”, the subnet mask to “255.255.255.0” and leave the
default gateway blank.
Figure 124 – Allocate secure IP-Address

With this setup, the PC is able to open a direct connection between the
PC and the CU. Note that it is not possible to establish other connections
when the PC communicates with 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 user’s PC may disconnect with the local
Internet / Intranet.

4.4.2 Connect to the GUI

Open the browser and type the target address in the address field (e.g.: the
CU address ”142.120.72.172”).
Login as the root user (key in root / default) and enter the GUI home page
(see Figure 125)
Figure 125 – The GUI home page (2)
4.4.3 Change the CU IP-address via the GUI

The user should change the CU IP-address into the local IP-range so as to be
accessed by the user’s PC in the local Internet / intranet.
Within the submenu “Access” (under main menu “Maintenance”), change the
IP-address into the local IP-range. E.g. if the local user’s PC former IP-
address is “192.168.100.100”, the CU IP-address should be changed to
“192.168.100.x” (the last digit “x” should be different from that in the user’s PC
IP-address).
Assume change the CU IP-address to “192.168.100.101” and click “Update”
(see Figure 126).

After changing the CU IP-address, the user’s PC may disconnect with the CU.
Figure 126 – Setting up the CU IP-address
4.4.4 Connect to the CU in local Internet / Intranet

Change the user’s PC IP-address back to the former “192.168.100.100”.
Open the browser and key in the CU IP-address “192.168.100.101” to
connect the CU in the local Internet / Intranet (see also Figure 121).
Now the user can view all the information embedded in the CU, e.g. the
battery settings, alarm settings, factory settings, etc.
In the parallel configuration, each CU should be changed the IP-address to
“192.168.100.x” (different last digit “x” for different CU and local user’s PC) via
the GUI. In this way, the user’s PC can access each CU in parallel / chained
in the local Internet / Intranet.

Commissioning 141
Chapter 5 Commissioning
Before turning on the FPRA system,

Make sure all protective earth terminals, extension cords, and devices
connected to the FPRA are well grounded. Any interruption in the protective
grounding is likely to cause a potential shock hazard that might injure people.
Make sure there is a lightning protection (especially for outdoor environment).
Remove all metal materials such as watch and jewelry before power on.
Before turning on the FPRA system, make sure:

The AC cables are connected correctly to avoid shorts between the L, N lines.
User can use a multi-meter to check this at the AC plugs.
There are no shorts between the loads, batteries, and returns cables. User
can use a multi-meter to check this at the DC cable terminals.
Note the environment requirements referring to the product specification
(Emerson file No.41970005110 and No.41970004980).
See the User Guides of the test equipments to ensure the correct use.
The IP54 is no longer guaranteed if the Ethernet cable is connected to the
system. After finishing the commissioning, The Ethernet cable should be
removed and the connecter seal should be replaced to the RJ45 hole to
provide IP54 protection.

Commissioning 142
It is recommended to commission each FPRA individually, before putting it into

the cabinet and connecting it with the other devices to prevent problems or ease
any required debugging.
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.
5.1 Set up a commissioning environment

(1) Set up a commissioning configuration as shown in Figure 127.
Connect the BTS, battery blocks, AC power source and the user’s PC with
the cables that have been already installed.
Before power on, make sure:

All the breakers and AC power source switch are in the OFF position.
The battery blocks have a voltage between 43V and 54V.
The proper polarity of the battery leads before connecting it to the PDA.
There are no shorts between the loads, batteries, and returns strings. User
can use a multi-meter to check this at the DC cables’ terminals.

Commissioning 143
Figure 127 – Commissioning configuration of the FPRA

(2) Connect to the GUI
Connect the FPRA to the user’s PC with an Ethernet cable.
Connect to the GUI referring to Chapter 4 Browser and Control Unit
Setup.
5.2 Battery input commissioning
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.

Commissioning 144
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.
Figure 128 – Commissioning of the battery input

Commissioning 145
5.3 Set up the system parameters

After entering the web-GUI, all the information internal the PDA CU can be
read. The user can also update some parameters in field, e.g. battery
settings, system settings, time settings, etc (see Figure 129, Figure 130 and
Figure 131).
User should refer to the ‘Flexi Power Rectifier – User Manual’ (Emerson file No.
03370500090) for more details about the system parameters setup.
Figure 129 – Battery related settings via GUI

Commissioning 146
Figure 130 – System related settings via GUI
Figure 131 – Time settings via GUI

Commissioning 147
5.4 AC input commissioning
Before power on, make sure:

All the breakers and AC power source switch are in the OFF position.
Ensure that the AC voltage does not exceed the recommended AC input
voltage range.
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.
Figure 132 – Commissioning of the AC input

Maintenance 148
Chapter 6 Maintenance
The maintenance should be taken periodically to ensure the normal operation

and extend the life of the FPRA.
Only qualified personnel shall carry out the 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.

Troubleshooting 149
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.

Troubleshooting 150
Table 22 – Rectifier alarm indications
Severity
Indeterminate
Rectifier
alarm Trigger condition Recommend action
Warning
configuration
Critical
Major
Minor
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 170±5V, Check the AC input
(AC) clear when AC higher than 175±5V
Temp Sensor X Temperature<-45°C or Uninstalled the rectifier from system, and

Fail temperature>125°C then installed the rectifier back again. If
error appears again, change the rectifier
Temp High X Set when more than 75°C, clear when Check there any block in the fan, check
lower than 70°C the ambient temperature
Temp Low X Set when lower than 0°C, clear when Check the ambient temperature
more than 5°C
- To be continued -

Troubleshooting 151
Severity
Rectifier
Warning
Indeter
Critical
minate
Major
Minor
configuration
Except Temp X Off Set when more than 90°C, clear when Check there any block in the fan, check
High lower than 85°C the ambient temperature
Except Temp X Set when low than -5°C, clear when Check the ambient temperature
Low more than 0°C
Element X Communication failure Re-start the PDA and rectifier

Loss/Start
Input High X Set alarm when AC higher than Check the AC input
(AC) 282V±5V, clear when AC lower than
276V±5V
AC UVP X AC lower than 75V±5V Check the AC input
AC OVP X AC higher than 315V±5V Check the AC input
DC OVP X DC output higher than 58.5V±1V, Remove the AC to the rectifier and re-
connect the AC to rectifier again
- To be continued -

Troubleshooting 152
Severity
Rectifier
Warning
Indeter
Critical
minate
Major
Minor
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 105°C, recover Check there any block in the fan, check
Protect when lower than 84°C 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

Troubleshooting 153
Table 23 – System alarm indications
Severity
System alarm
Warning
Trigger condition Recommend action
Indeter
Critical
minate
configuration
Major
Minor
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
Circuit Breaker 1 X Circuit breaker 1 open Check whether the breaker

connects to load or not. If no load
connected, no action required. If
load connected, check whether
there is short circuit in the load,
then close the breaker
Circuit Breaker 2 X Circuit breaker 2 open (Same as above)
- To be continued -

Troubleshooting 154
Severity
System alarm
Warning
Indeter
Critical
minate
configuration
Major
Minor
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 -

Troubleshooting 155
Severity
System alarm
Warning
Indeter
Critical
minate
configuration
Major
Minor
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
Alarm In X Alarm in signal trigger Check the customer equipment for

alarm in
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
Element Loss X PDA communication error Re-start the PDA

Troubleshooting 156
Table 24 – Failures likely to happen
Category Trouble Analysis Troubleshooting
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.
Setup error of the PC IP-address Refer to section Chapter 4 Browser

and Control Unit Setup
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 -

Troubleshooting 157
Table 24 – Failures likely to happen
Category Trouble Analysis Troubleshooting
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

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Flexi Power Rectifier

Emerson Network Power Co., Ltd.

Flexi Power Rectifier Installation Manual

Manual Number: 03370500070

Copyright © 2009 Emerson Network Power Co., Ltd.

Flexi Power Rectifier Installation Manual

18/03/2009 03 David Update all the pictures in section 3.3 to show

Flexi Power Rectifier Installation Manual

Flexi Power Rectifier Installation Manual

Flexi Power Rectifier Installation Manual

Figure 38 – Inserting the temperature cable into drawer (updated version)........64

Flexi Power Rectifier Installation Manual

Figure 81 – Connecting the AC power cable to the rectifier..............................103

Flexi Power Rectifier Installation Manual

Figure 124 – Allocate secure IP-Address..........................................................138

Flexi Power Rectifier Installation Manual

Table 1 – Contents of this manual ......................................................................12

Flexi Power Rectifier Installation Manual

L Live cable from the AC mains

LAN Local Area Network

Flexi Power Rectifier Installation Manual

N Neutral cable from the AC mains

Flexi Power Rectifier Installation Manual

About this manual

Table 1 – Contents of this manual

Chapter Title Content

1 Product instruction Describes the specifications, properties,

2 Preparation Describes the installation safety, site, and

3 Hardware installation Describes how to install the AC cables, DC

4 Browser and CU Describes how to set the browser and CU,

5 Commissioning Describes how to commission the FPRA

6 Maintenance Describes how to maintain the FPRA.

7 Troubleshooting Describes how to solve the detected

Flexi Power Rectifier Installation Manual

Term and Symbols in this manual

Table 2 – Symbols in the Installation Manual

Safety symbol, see Safety summary

Safety symbol, see Safety summary

Provides hints to the user for easier

Table 3 – Reference documents of the FPRA

Emerson Network Power

Internal product specification – System / PDA 41970005110

Internal product specification – Rectifier 41970004980

Surge Protect Discharge for Flexi Power Rectifier –

Flexi Power Rectifier - User Manual 03370500090

Flexi Power Rectifier - Installation Manual

Flexi Power Rectifier Installation Manual

Table 3 – Reference documents of the FPRA

Surge Protect Discharge for Flexi Power Rectifier –

Flexi Power Rectifier – Quick Start Guide 03370500110

Flexi Power Rectifier Installation Manual

Chapter 1 Product Introduction

1.1 General Description

Table 4 – Main specifications of the FPRA

Parameter Specification Description

Min Nom Max

Rated AC input voltage 180 -- 276 See Table 5

DC Nominal Vout -56 -54 -52 See Table 7

Ambient Operation -40 23 55 (1) Max output 6kW

Flexi Power Rectifier Installation Manual

Table 5 – Applicable rated input voltage types of the FPRA

VAC / V VAC / V Frequency / Hz Supply Network Type