Installation and SWAP guide for MTN Hybrid power system
Liu Feng
The topology of the Hybrid power system
Generator1 Power -48V 24V 220V
ATS Generator2
BAT 48V
RBS 24V
MW 48V
Content Install the hybrid power system Install the power and battery cabinet Install the battery Install the load cables Install power alarm cables Install ATS Make the labels The SWAP procedure
Content
Install the power and battery cabinet
Install the power and battery cabinet-fix the cabinet
Expand bolts(total 8 bolts for each cabinet) The RD engineer will design paper footprint of the power and battery cabinet to help the subcontractor to make hole.
Battery Cabinet with DC Air Conditioner
Dimension: 2100 mm 1050 mm 1110 mm (H W D)
Battery quantity : 24*2 V/1000 AH battery cells
Cabinet Weight: 250 kg approximately
Install the power and battery cabinet-install AC cable
This breaker to ZTE power
ZTE AC input breaker
ZTE AC input power The specification of AC cable is 4*10mm2 and it must be outdoor used
Install the power and battery cabinet-install battery
The breaker must be off Install the battery cable The biggest screw is for the battery cable.
Install the power and battery cabinet-install battery temp sensor
Battery temp sensor should be in the top of the battery cabinet( 2nd battery of top layer)
The other side of battery temp sensor should be installed here. You can see the terminal mark on the cover
Install the power and battery cabinet-install environment temp sensor
The environment temp sensor should be installed in the top of the power cabinet
Install the power and battery cabinet-install cable for battery cabinet cooling
the other side of the power cable should be in fuse F204 Power cable Alarm cable for Cooling The terminals should be covered with tap very well The alarm cable should be installed here
Install the power and battery cabinet-install door alarm cable for battery cabinet
The door alarm cable should be installed here
Content
Install battery
Battery Cabinet with DC Air Conditioner
Dimension: 2100 mm 1050 mm 1110 mm (H W D)
Battery quantity : 24*2 V/1000 AH battery cells
Cabinet Weight: 250 kg approximately
Install battery
The battery layout of top layer Battery voltage detect signal cable .each battery has Breaker one cable
The layout should strictly follow this When connect the battery to the Power ,the battery breaker must be off
The battery layout of bottom layer
Install battery
The battery cell voltage detect cable
Content
Install the load cables
Install load cable Load distribution
The load connection should strictly obey the following table F101-F114 means breaker of LLVD1 F201-F205 means breaker of LLVD2 INV : inverter MW : micro wave
Bre aker -48V F101 25A F102 25A F103 25A F104 25A F105 25A F106 25A F107 20A F108 25A F109 25A F110 25A F111 63A F112 63A F113 63A F114 63A F115 40A
Loa d Bre ake r 48V Loa d 24V
ZXD 2430-1
ZXD 2430-2
ZXD 2430-3
ZXD 2430-4
ZXD 2430-5
ZXD 2430-6
INV
Dc cooling
Spare
Spare
RBS1
RBS2
RBS3
RBS4
3G
F201 16A
F201 16A
F203 16A
F204 16A
F205 10A
F206 10A
MW1
MW2
MW3
Battery cooling
DC security light
AWL
NO1 100A
RBS1
NO2 100 A
RBS2
NO3 100A
RBS3
NO4 100A
RBS4
Install the load cables-RBS cable(+24V RBS
24V +(red 35mm2)
Make terminals and labels in RBS side
There are 4 pcs 24V breakers ,from left to right, RB1-RBS4
GNDblack 35mm2)
Install the load cables-microwave cable
-48V
GND
Make terminal in IDU side Make sure the -48V and GND are right
Content
Install alarm cable
Install alarm cable
Here 8 alarms, 16pcs signal cables.
relay
A1 A2 A3 A4 A5 A6 A7 A8
8 Alarms
Generator alarm Battery alarm Rectifiers alarm System alarm High temp alarm Battery discharge Air conditioner alarm reversed
Install alarm cable
16 cores twisted-pair as alarm cable
white/blue red/blue PIN white/orange red/orange Cable connection white/green red/green white/brown red/brown
X15
alarm definition
X16
X15
Pin 2white 3blue Pin 5: white 6: orange Pin 2white 3green Pin 5: white 6: brown Pin 2red Pin 5: red 3blue 6: orange
Generator alarm Battery alarm Rectifier alarm System alarm High temp alarm Battery discharge
X16
X17
X17
X18
Pin 2red Pin 5: red
3green 6: brown
Air conditioner alarm Reversed alarm
X18
Content
Install ATS
ATS
Dimension: 1200mm 890 mm 300 mm H W D) Weight: The whole machine < 130kg.
Install ATS-Signal cable (power-ATS)
Color Orange/white Cable connection EXB X3 Pin2 white Pin3 orange EXB X3 Pin 5 white Pin5 Green SIB X12 (pin1 brown (Pin3 white) Reserved Definition Start Generator1
Green/white
Start Generator2
Brown/white
Grid feedback
Blue/white
Reserved
Content
Make the labels
Make the labels
All the cable must have label ZTE will give the label template
Content
The SWAP procedure
Preparation work before SWAP-install and Debug ZTE power
Debug the power: Check whether the can work normally Set the parameters Check whether the generator can start when the battery charge current is 0.1C
Preparation work before SWAP-connect RBS cable
24V +
GND
Make terminals and labels in RBS side
Preparation work before SWAP-connect IDU cable
-48V
GND
Make terminal in IDU side Make sure the -48V and GND are right
SWAP procedure-SWAP RBS power cable
After start the generator , please call MTN staff about the SWAP
SWAP procedure-SWAP RBS power cable
24V battery +
Do not touch the breaker here
24V battery -
Take the battery + and battery cable from RBS. And it must be covered with insulation tap
SWAP procedure-SWAP RBS power cable
Install new 24v power cable from ZTE power Make sure the Positive and negative poles are right
SWAP procedure-SWAP RBS power cable
AC input of 24v power module 1.Switch on the breaker of the new power cable and check the power voltage (27V)
If every thing is ok, take off power alarm cable
2.Take off the A C input socket of 24V power module and check if the RF module can work
SWAP procedure-SWAP IDU power cable
Switch on the breaker of new IDU power cable, and check the power voltage
Take AC input power cable of IDU Insert the new DC power for IDU If the IDU can not work, rollback
After SWAP , call MTN engineer to check if every is OK
Tidy UP the side
1.Tidy the cable and make label 2.Clean up the site 3.If there is commercial power , turn off the generator
CONNECTION OF THE SIGNAL INTERFACE
X22 -------------------------- BMU 1 BACK 17 ------------------- VB1 DMS OUT ------------------- DMS IN X11 OUT -------------------- X11 IN BATT SENSOR ------------- SIB X6 X12 IN ---------------------- X 12 OUT ALM IN ---------------------------- ALM OUT
GEN to ATS SIGNAL CONNECTIVITY
BROWN BLUE BLACK BLUE BROWN BLACK BROWN +12 -12 START FUEL D+(NIL) HWT LOP 6 5 4 SOLENOID{33/3} DYNAMO 19(not terminated) TEMP SWITCH (16) OP(17)
