PS481000-5/100 System

Training CenterJianbo Gong

Tel86-0755-26862543
Email:[email protected]

Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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Name
PS481000-5/100
Rectifiers Rated Output Current (100A)
Version No. (5)
Maximum System Output Current
(1000A)
Rated System Output Voltage (48V)
Power Supply System

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PS481000
-5/100 System
PS481000-5/100

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Extra wide input voltage range: 304V~456Vac;

Be able to extend to 6000A (60 rectifiers)

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PS481000
-5/100 System
PS481000-5/100
AC
Distribution
Cabinet

Remote
Monitorin
g Center
RS48
5

RS23
2

Monitor
DC
Distributio
n Cabinet

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RS48
5

RS48
5
Rectifier
Cabinet

PS481000
-5/100 System
PS481000-5/100
... ~
~
~
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AC

AC mains I
AC mains II

DC distribution

Rectifiers

AC distribution

Telecom equipment

-48 VDC

-48 VDC

...

Battery

RS-485
RS-232

RS-485

PSTN

RS-2
32

Background
computer

Monitoring
center

Monitoring
module

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MODEM

MODEM

System Principle

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Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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AC Distribution Cabinet

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AC Input

AC I
AC II

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AC Distribution Principle
Switch

Mains I

Mains

QF1

C-Level Lightning
Arrester

QF2

QF3

QF4

QF5

QF6

QF7

PE

QF9

QF10

QF11

QF12

QF13

QF14

QF15

QF16

Rack

Neutral Bar

Grounding Bar

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QF8

Lightning Arrester

C Level

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D Level

Lightning Arrester (C Level)

C Level

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Lightning Arrester (D Level)

D Level

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Lightning Arrester
Varistors + Gap
Varistor: voltage sensitive resistor
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C Level
Green window, good;
Red window, bad.

D Level
Indicators on, good;
Indicators off, bad.

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Lightning proof breaker

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C Level ---- circuit breaker

D Level ---- fuse
Protect the wire from firing when varistors are
broken (short) for lighting strike.
Do keep the circuit breaker on

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Buzzer Control

Muting control

Buzzer switch

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Emergency Light Control

-48V

-48V
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AC Distribution Monitoring Boards

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AC Distribution Monitoring Boards

48V

J0

12V Power supply

Audio-optical alarm

1J2
1J3

J1

B14C3U1

J2

AC/DC distributor
united monitoring
CPU board

JP2

RS485-D
to distributor display

1J1

JP1

switch signal

Analogue signal

JP2

Audio-optical
alarm

RS485
to monitoring module

JP1

J11

J7

Battery/load current
measurement

J15

Bus-bar/battery
voltage
measurement

J3,4,5

Emergency
light control

Load/battery
breaker status

A2V6FX1
Signal bridging board

3
temperature
sensor
(optional)

DC DISTRIBUTION
SIGNAL
J1

Emergency
light control

J9

J25

J2

1.67V/300A
current
measurement

BLVD (optional)
LLVD (optional)

Lightning arrester status

& alarm switch

J8
AC mains
voltage/frequency
sampling
1.5VAC
to pin 10
220VAC
AC mains
voltage input

220VAC
Frequency
input

AC MCB status

J8

W2 V2 U2 N

J9
W1 V1 U1 N

1
AC current
measurement

A2V4FA1

J6

AC mains sampling board

J5

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AC DISTRIBUTION
SIGNAL

N X

X W2 V2 U2 W1 V1 U1

10

J4

AC Distribution Monitoring Boards

J9
1.67V/300A
current
measurem ent

rrester status
itch

J8
AC m ains
voltage/frequency
sam pling
1.5VAC
to pin 10
220VAC
AC mains
voltage input

220VAC
Frequency
input

J8

W 2 V2 U2 N

J9
W 1 V1 U1 N

AC current
m easurement

A2V4FA1

J6

AC m ains sam pling board

J5

IBUTION
AL
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W 2 V2 U2 W 1 V1 U1

10

J4

AC Distribution Monitoring Boards

JP2

JP1

s w it c h s ig n a l

A n a lo g u e s ig n a l

JP1

JP2

A u d io - o p tic a l
a la r m

J7

J 11

J15
J 3 ,4 ,5

E m e rg e n c y
lig h t c o n tr o l

A2V6FX1
S ig n a l b r id g in g b o a r d

3
te m p e ra tu re
sensor
( o p t io n a l)

J1

E m e rg e n c y
lig h t c o n tr o l

J9

J25

J2

1 .6 7 V /3 0 0 A
c u rre n t
m e a s u re m e n t

B L V D ( o p tio n a l)
L L V D ( o p tio n a l)

L ig h tn in g a r r e s t e r s t a t u s
& a la r m s w it c h

J8
A C m a in s
v o lt a g e /f r e q u e n c y
s a m p lin g
1 .5 V A C
to p in 1 0

220VAC
F re q u e n c y
in p u t

A C M C B s ta tu s

J8

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v
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AC Distribution Monitoring Boards

48V

J0

12V Power supply

Audio-optical alarm

1J2
1J3

J1

B14C3U1

J2

AC/DC distributor
united monitoring
CPU board

JP2

Analogue signal

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JP1

switch signal

1J1

RS485
to monitoring module
RS485-D
to distributor display

Board Functions
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Distribution CPU Board B14C3U1

Process all the signals from AC distribution

Alarm
LVD control
Report to monitor (communication)

AC Sampling Board A2V4FA1

Make mains voltage step-down to 1.5Vac

Signal Bridging Board B14C3X1

Bridge all the signals

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Diagnosis of B14C3U1
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3 indicators on board:
LED1, Receive (green, normally flashing)
LED2, Send (red, normally flashing)
LED3, power (green, normally on)

Failure: wrongly alarm or not be able to alarm,

communication failure

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CPU Board B14C3U1

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Question
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The AC distribution cabinet alarms.It shows that

mains I lacks one phase. Whats the cause?

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Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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DC Distribution Cabinet

Free cable
access
mode

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DC Distribution Principle
-48V

Battery 1 Battery 2
Battery Fuse
Shunt

Shunt

switch
Load Fuse

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Shunt
Precision resistor
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Measure the current

Shunt coefficient :
the relation between current
and voltage

1000A75mv
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DC Distribution Monitoring Boards

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DC Distribution Monitoring Boards

48V
J0
12V power supply

Audio-optical alarm

1J2
1J3

J1

B14C3U1
J2

AC/DC distributor
united monitoring
CPU board

JP2

to port J1 of
A14C3X1

AC analogue
signal, switch
signal

AC DISTRIBUTION
SIGNAL

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BLVD
LLVD
Emergency
light control

Switch signal

J2

J1
J6
J7
J8

B14C3X1

J14

J13

RS485-D
to distributor display

1J1

JP1

Analogue signal

-48V
Audio-optical
alarm

RS485
to monitoring module

Signal bridging board

J12

J10

Battery/load current
measurement

J9

J11

J4 J3

Bus-bar/battery
voltage measurement
Load/battery
breaker status

DC contactor coil

DC DISTRIBUTION
SIGNAL

3
temperature
sensor
(optional)

DC Distribution Monitoring Boards

Analogue signal

J2

-48V
Audio-optical
alarm
to port J1 of
A14C3X1 AC analogue
signal, switch
signal

BUTION
AL

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J1
J6
J7
J8

B14C3X1

J14

J13

BLVD
LLVD
Emergency
light control

Switch signal

Signal bridging board

J12

J10

Battery/load current
measurement

J9

J11

J4 J3

Bus-bar/battery
voltage measurement

DC contactor coil

Load/battery
breaker status

3
temperature
sensor
(optional)

DC Distribution Monitoring Boards

48V

J0

12V power supply

Audio-optical alarm

J1

B14C3U1
J2

AC/DC distributor
united monitoring
CPU board

JP2

Analogue signal

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1J2
1J3

JP1

Switch signal

1J1

RS485
to monitoring module
RS485-D
to distributor display

Board Functions
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Distribution CPU Board B14C3U1

Process all the signals from DC distribution

Alarm
LVD control
Report to monitor (communication)

Signal Bridging Board B14C3X1

Bridge all the signals

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Question
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DC distribution communication fault. Whats the

cause?

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Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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Name

HD 48 100-5
Serial No.(5)
Rated output current (100A)
Rated output voltage (48V)

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HD48100
-5
HD48100-5

Wide input voltage range from 304~ 456Vac

3- phase AC input (3 -phase and 3 lines)
Efficiency92%
PF0.94
Hot-plug

When lacking 1 phase, output up to 50% of rated current

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Front/Rear View

Front panel

Rear panel
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Indicators
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Power Indicator (green, 2)

With AC input for the rectifier, the indicator will be on.

Protection Indicator (yellow, 3)

In case of AC over-voltage (protect at 460 10V, recover at 450
10V ), AC under-voltage (protect at 300 5V, recover at
324V), Over-temperature (protect at 95, recover at 85), the
protection indicator turns on. Meanwhile the rectifier halts to
protect itself until the case disappears.

Fault Indicator (red, 4)

turn on for output over-voltage or IGBT over-current ( the rectifier
will keep halt and not recover automatically).

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Address Setting
Binary
MSB

LSB
0

Decimal 11

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Question
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How to judge whether the rectifier is normal or

not?
How to replace the failed rectifier?

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HD48100
-5
HD48100-5

Easy to replace fans

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Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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Monitor PSM
-A
PSM-A
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386 industry computer

100 historical alarm records
Help on-line
Users password: 123456
Maintainers password: 640275

PSM-A Monitoring Module

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Front Maintenance

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Front & Rear View

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Line
-up (3 cabinet)
Line-up
To other distribution cabinet

COM5

To other distribution
cabinet

COM4

PSM-A
1J3

1J3

1J2

1J2

1J1
B14C3U1

COM7

1J1

HD48100-5

B14C3U1

HD48100-5
COM6

HD48100-5
HD48100-5

AC Distribution
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RS485

Rectifier Rack

DC Distribution

Line
-up (2 cabinet)
Line-up
To other distribution cabinet

COM5

COM4

PSM-A
1J3
1J2
1J1
B14C3U1

COM7

HD48100-5
HD48100-5
COM6

HD48100-5
HD48100-5

AC/DC Distribution
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RS485

Rectifier Rack

Monitor

RS485
Rec1

AC 64
0

Rec2

Rec3

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CPU
board

RS485

B14C3U1
B14C3U1

Distribution signal
(analogue and switch signal)

DC 72
ADC 80

Address of Rectifier
Determined by DIP switch of rectifier

MSB

LSB
0

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1
2
3
4
5
6
7
8

Address Setting for Distribute Cabinet

AC:
64= All ON
H
L

DC:
72=4OFF
AC/DC:
80=5OFF

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Address Setting
S1

Binary digit

xxx00xx0

Corresponding
Range of
PSM-A
communication
communication
address
address

0~7

Application

64~71

AC
distribution
cabinet

72~79

DC
distribution
cabinet

80~95

AC&DC
combined
distribution
cabinet

H
xxx10xx0

xxxx1xx0

Base address=64

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8~15

16~31

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Others

1/F2
2/F2 3/F2

Float voltage

6
Remote
Communication

U/F2

1/F2 2/F2 3/F2

4/F2

Telephone
number

6/F2

Baud rate

5/F2

Local address

User level

M/F2

Control

User level

5
System
management

Equalize voltage

U/F2 U/F2

Battery
management

2/F2 3/F2 4/F2

Maintenance
level

4/F2

Equlalize charge
pemitted or not

U/F2

4 Alarm level setup

4
Alarm
parameters

System
configulation

U/F2 M/F2 U/F2

1/F2

User level

3/F2

3 Alarm history clearing

3/F2

User level

3
Rectifier
parameters

2 Alarm history

2/F2

1 Active alarm

1/F2

3 Control

2/F2

User level

3/F2

2 Setting

2
DC
parameters

User level

U/F2

1 Real time data

2/F2

Maintenance
level

M/F2

3 Control

1/F2

User level

1/F2

Charging
efficiency

U/F2

2 Setting

1 Real time data

2/F2 3/F2

User level

U/F2

Maintenance
level

1
AC
parameters

Nominal
capacity

Battery
number

M/F2

3 Control

2 Setting

1 Real time data

1/F2

User level

User level

Maintenance
level

Main menu

7/F2

7
Others

U/F2

The parameters needn't be set

if no remote com.exists.

Key Parameter setting

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EQU VOLT: 56.4V;

FLO VOLT: 53.5V;
OVER CHRG( Charge over-current threshold): 0.3C10;
CHRG CUR LIM(Battery charge current limit): 0.1C10;
LOAD LVD : 44V;
BATT LVD : 43.2V;

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Key Parameter setting

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Conditions to Equalize Charge-----empty?

TO EQU CAP RATIO: 80%;
TO EQU CUR: 0.06C10;
Conditions to Float-----full?
STABLE TIME: 180 MIN & STABLE CUR: 0.01C10
EQU TIMEOUT: 18 hours;
Battery Test----- discharge!
TEST END VOLT: 47V
TEST END TIME: XXX MIN

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Internal Construction

Power
Board

CPU
Board

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Board Functions
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CPU Board (M14C3U1)

process all the signals

Power Board (M14C3R1)

Convert 48Vdc to 12Vdc, 5Vdc, 9Vdc and 500Vac

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Diagnosis for Monitor

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Phenomenon

Cause

AC/DC distribution or
rectifier communication
fault

Address,
communication port
number, CPU Board

no power
display without backlight

Fuse, Power Board

Power Board

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Question
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The monitor prompts that AC Distribution, DC

Distribution and all rectifiers communication fault.
What is the cause?
Suppose the monitor fails, how to maintain the
system without monitor?

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Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

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Maintenance
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Special Phenomena
1. With small output current, the rectifiers fan may not
rotate, or rotate very slowly.
2. With small load current, rectifiers may not share the load
current equally.
3. The rectifiers may output only 52V due to limiting charge
current though they are in equalizing charge state.
4. Alarm information will not be displayed if the alarm is
disabled in Monitor PSM-A.
5. The system does not alarm though some of the fuses or
circuit breakers are off.

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Handling Failure Procedure

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Handling Failure Procedure

1. Make the system mute
2. Check and record the alarm indicators and information
3. Classify the failure ( of AC distribution, DC distribution,
Rectifier or Monitor)
4. Analyze ( guess all of the possible causes)
5. Test and then locate the failure ( verify the guessing)
6. Handle ( caution: safety first, mark the plugs)
7. Confirm

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Emergency Handling
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Principle: ensure the DC power for telecom equipment

Emergency Cases z Handling
1. AC Distribution Failure

1. Connect AC directly to rectifiers

2. DC Distribution Failure

2. Get rid of short

Load short circuit

Cut off the fuse/breaker for the load

Distribution short

Cut off AC, then separate the battery from

the system, and then power loads with
battery or rectifiers directly

3. Monitor failure

3. Turn off monitor, manage battery manually

4. Rectifier failure

4. Turn off the failed rectifiers

Inside short

Automatically turn off

Many rectifiers fail

Turn off, ensure enough normal rectifiers

Output over-voltage

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Turn off all, then turn on one by one except

the failed one.

Case 1Mains voltage detection abnormal

Phenomena: The voltage value displayed is much
different to the actual value.
Failure analysis: Possible reasons
1.AC mains sampling board A2V4FA1 fails;
2.Distribution CPU board B14C3U1 fails.
Treatment: Check sampling board A2V4FA1, Replace

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Case 2Failure of SPD

Phenomena
The monitor activates the alarm SPD fault.
Analysis
1.C-level SPD fails;
2.SPD MCB(circuit breaker) trips;
3.Detection cable for SPD is not connected well or has
breakpoints;
4.AC distribution CPU board B14C3U1 fails.

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Case 3Battery parameter can not be set up

Phenomenasetting battery capacity parameter
through the monitor is unsuccessful.
Analysis
Communication break
Treatment

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Case 44-Voltage
-Voltage doesn
t conform with float voltage
doesnt
PhenomenaThe float voltage of PS481000-2/100 power
system is set to 53.5 V, but the actual output value is about
55.5V.
Analysis
1.System is in equalize charge state
2.Rectifier is out of control
3.Temperature compensation
Treatment

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Case 5LCD of AC cabinet can not be

paged down/up
PhenomenaLCD of AC (DC or AC/DC combined)
distribution cabinet always stays in one page. Pressing the
keyboard can not make it page down/up.
Analysis
1.Failure of keyboard;
2.Breaking of the communication between LCD and
distribution CPU board B14C3U1;
3.Failure of LCD hardware.
Treatment

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Case 6Monitor does not respond to

keyboard operation
PhenomenaAfter a period of system running, the monitor
does not respond to keyboard operation.
Analysis
1.Monitor failure or breakdown.
2.Keyboard malfunction.
Treatment

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Case 7Load sharing imbalance between

rectifiers
PhenomenaIn the power system configured with 4
rectifiers, the respective output current of rectifier 1, 2, 4 is
about 30A, while that of rectifier 3 is zero, and the system
gives no alarm.
Analysis
1.Failure of load sharing circuit of rectifier 3
2.Considerably low output voltage of rectifier 3
3.Rectifier 3 output fuse blowout
4.Rectifier 3 output socket failure
5.No output due to other failures inside rectifier 3
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End

Thank You

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Summary
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance

75 Emerson Confidential