zxdupa-wr01(v4.0r02m02)&zxdupa-wr01(v4.0r02m03) dc power system installation guide

Installation Guide

Connecting the Primary and Secondary Cabinets

Safety precautions

ZTE Corporation Address NO. 55, Hi-tech Road South, ShenZhen, P.R.China Area code518057 Website http://ensupport.zte.com.cn [email protected] Document versionSJ-20101011152815-002/ 2010-11-16 R1.1

Cabinet dimensions: 2250 mm 750 mm 700 mm (H W D)Weight:

Approximately 100 kgRectifier: 3.8 kg/setMonitoring unit: 2.2 kg

Connecting AC Input Cables

1

Put warning signs in the equipment room, specifically the power distribution box.

Fully insulate the terminals, contacts and other exposed parts and wear protective gloves during installation/connection process.

Before connecting any electrical cable, turn OFF all the switches and breakers and turn OFF the protection breaker outside the system.

Connecting Grounding Cables

DC Outputbreakers

AC Input breaker

AC SPD BATT breakers 3 and 4

DC SPD

PE(Groung bolt)

Connect the grounding cables to the nearest grounding point. The PE length cannot exceed 30 m. The grounding cable should be laid as short and straight as possible.

1. Connect the PE cable between the grounding bolt and grounding busbar of the equipment room.

2. Connect the GND cable between the working ground busbar of ZXDU68 W201 and grounding busbar of the equipment room.

L1L2L3

Color codeL1: YellowL2: GreenL3: RedN: BlueN

1. Connect the grounding busbar of the secondary cabinet to that of the primary cabinet.

2. Connect one of the output breakers (secondary cabinet) to the 63 A DC output breaker of the primary cabinet.

Configuration AC input voltage MCB/TerminalsThree-phase five-w ire (L1/L2/L3/N/PE) 220 V (80-300 V) 1*63 A/3P MCB

Do not reverse the live wires and neutral wire.

Make sure that the AC input power is cut off during the operation to connect theAC input cables.

.3.3

22

4.4

Installing the Cabinet

Installed expansion bolt

Flat washerSpring washerNut

525

690

5

2

5

690

Cabinet Bottom

Installation hole

Drill

WrenchTools:

Cabinet front

Tape measure

Angle square

Expansion bolt

Unit: mm

1. Prepare four M12 X 100 expansion bolts.2. Drill four holes (70 mm deep) with the same dimensions as the cabinet holes at the bottom.3. Install the four M12 X 100 expansion bolts into the holes (leave 30 mm of the bolt above the ground).4. Mount the cabinet on the floor and into the expansion bolts.5. Fasten the bolts to fix the cabinet in place.

Limit the vertical inclination of the cabinet to 5o by inserting metal plates at the bottom

700

ZXDUFront of cabinet

1000

750

Unit: mmCabinet dimensions: 2250 x 750 x 700

Cabinet position

600

ZXD2400 Rectifiers Monitoring unit

Signal Interface Board (SIB)

DC Outputbreakers

DC Power Distribution (3U)Power supply unit (8U)

+/GND

PEPE PE

Protection ground busbar of installation site

Color codePE: Yellow greenGND: Black

DC Power distribution (3U)

ZXDU68 W201 V4.0R06M03&M04DC Power System

Secondary Cabinet(V4.0R06M04)

26U

1 2

DC Output

DC Output

+/GND(Primary cabinet)

+/GND(Secondary cabinet)

Primary cabinet

Secondary cabinet

63 A breaker

1. Turn off the AC input breaker of the AC distribution box that powers the ZXDU68 W201 system.

2. Turn off the AC input breaker of the ZXDU68 W201 system.

3. Connect the neutral cable (N) of the AC input.

4. Connect the phase wires of AC input (L1/L2/L3).

Connecting Battery Cables

.5.5

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Connect the negative cable first to ensure safety.

Do not connect positive and negative cables in reverse.

Tighten any loose detection cable after battery cable connection.

Cable colorBATT (+): RedBATT (-): Blue

BATT input 1 and 2+ +

Battery pack/rack Battery voltage MCB4*12 V battery cells 48 V 4*100 A MCB

Connecting plate1 3

1. Install the batteries into the cabinet.

2. Turn off the BATT breakers.

3. Connect the negative cables to the BATT breakers (battery packs of secondary cabinet connects to the battery breakers of primary cabinet power supply unit).

4. Connect the positive cables to the working ground busbars (GNDs of primary and secondary cabinets).

5. Install the connecting plates between battery cells.

6. Label with battery number and polarity. For example, mark battery 1 (+) on the positive cable and battery 1 (-) on the negative cable.

+/GND of the respectective cabinets

BATT 3 and 4 (Secondary cabinet)

2

1. Turn off the loads.

2. Turn off the DC output breakers.

3. Connect the negative terminal of a load to one of the DC output (-) breakers.

4. Connect the positive cable of a load to the working ground busbar (+/GND).

Color codeDC output (+):BlackDC output (-): Blue

DC Output

DC Power Distribution (Secondary Cabinet)

Power supply unit (Primary Cabinet)

The load current MUST NOT exceed the capacity of the breakers to avoid tripping of breakers and shutdown of loads.Tighten any loose detection cable after DC output cable connection.

-48 V

+/GND(Primary cabinet)

+/GND(Secondary cabinet)

Connecting DC Output Cables

DC Output

Load_ +

_ +Load

+ +BATT input 3 and 4

The negative cable is the first cable to be connected

Cabinet MCB DC voltage LLVD1: 1*6A + 3*20A LLVD2: 1*63A (Controls DCoutput of seondary cabinet)

Secondary cabinet LLVD2: 20*20A+2*10A

Primary cabinet

BATT 1 and 2 breakers (Primary cabinet)

Power supply unit (8U)

Communication equipment slots (21 U)

Primary Cabinet(V4.0R06M03

BATT breakers1 and 2

Performing Electrical Check

AC inputCheck both the AC distribution box and AC input breaker of the system.L1 N L1 - L2 L1 - PEL2 N L1 - L3 L2 - PEL3 N L2 - L3 L3 - PEBatteryCheck the positive and negative terminals of the battery pack for any short circuit.

DC outputCheck the Load (+) and Load (-) for any short circuit.

Checking for Short Circuit1Check the following cables for short circuit:

AC input cablesBattery cablesDC output cables

3 Checking Battery Voltage

2 Checking AC Input Voltage

If the the measured voltage is negative, the positive and negative terminals are reversely connected. Reconnect the cables.

The measured voltage must be positive and at least 43.2 V.

Measure the battery voltage between BATT (+) and BATT (-) through terminals of ZXDU68 W201.

.1.1

DO NOT install a faulty rectifier in the ZXDU68 W201 system. Make sure that no obstacle is blocked in the air vent of the rectifiers for good heat dissipation.

The following should be met for normal rectifier operationAC input voltage: 80 V300 VThe ZXD2400 V4.3 working status depends on the AC input voltage:

Installing the Monitoring Unit

The batteries and loads have not yet been connected to the system. As a result, the monitoring unit gives the DC Loop Break alarm and Bat Loop Break alarm.

Setting Output Relays

L1 L2

Multimeter

BATT breaker

Check in the ZXDU system

GND (+)

Black probeRed

probe

Installing the Rectifiers.2.2

2

Acceptance criteria

Before checking for short circuit, turn off the corresponding breaker. Locate any short circuit and eliminate it before proceeding to the next step.

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.3.3

Rectifiers

1 2 3

1. Turn off the power switch of the monitoring unit.

2. Insert the monitoring unit into the slot provided and fasten the screw.

3. Turn on the monitoring unit (RUN indicator should glow and the main menu is displayed on the screen).

Enter

1. Set Relays Out

AC-in Switch Off

Relay: A2

1.Setup Para

Enter

Ent

Esc

EntEsc

Modify value

Pass: 0000_Msg Alm Ctrl Rec

Ent

Main menu Initial password: 0000

Output relays can be modified through the following path: Ctrl1.Setup Para3. Alarm ParaSet Relays out

ZXDU68 W201 V4.0R06M03&M04DC Power System Installation Guide

Measure the AC input voltages by referring to the table.

If N-PE voltage is approximately equal to L-N voltage, N and L cables are inversely connected. Reconnect the cables L and N.

4

Monitoring unit

Rectifiers

1 2 3 4

Monitoring unit

The ZXDU68 W201 system can normally work without the monitoring unit. However, the system will have no communication functions and the batteries will be in the floating charge mode.

Setting System Parameters

1 Correct parameter setting is very important to ensure that the monitoring unit functions as expected. The default values of the parameter may not meet the requirements. Therefore, some parameters need to be set in the system commissioning.

The parameters can be modified through the 1. Setup Para interface under the Ctrl menu

EntModify valueSave setting

Esc Quit

System parameter list

Battery parameter list

HandleStop pin

C heck item C riteriaN-PE

S/N Alarm Level Relay S/N Alarm Level Relay

1 Total Alarm - A1 20 DCArrester Brk. Minor alarm A4

2 AC Aux SW Of f Minor alarm A2 21 DCBreaker Alarm Minor alarm A4

3 AC Main SW Of f Major alarm A2 22 Battery Fault Major alarm A4

4 AC Power Of f Major alarm A2 23 Bat Under-Temp Minor alarm A4

5 ACArrester Brk. Minor alarm A2 24 Bat.Temp.Void Minor alarm A4

6 AC Under-Vol Minor alarm A2 25 Bat.Discharge Minor alarm A4

7 AC Ov er-Vol Minor alarm A2 26 Env Under-Temp Minor alarm A5

8 AC Phase Lost Minor alarm A2 27 Env Ov er-Temp Minor alarm A5

9 AC Current Ov er Minor alarm A2 28 Env Under-Hum Minor alarm A5

10 SMR Alarm Minor alarm A3 29 Env Ov er-Hum Minor alarm A5

11 SMR Abnormal Minor alarm A3 30 Smoke Alarm Minor alarm A5

12 DC Under-Vol Minor alarm A4 31 Flood Alarm Minor alarm A5

13 DC Ov er-Vol Minor alarm A4 32 Intrusion Alarm Minor alarm A5

14 DC Loop Break Minor alarm A4 33 Door Magnet Alm Minor alarm A5

15 Bat Loop Break Minor alarm A4 34 Glass Broken Minor alarm A5

16 Bat Under-Vol Major alarm A4 35 Env Un.LostTouch Minor alarm A5

17 Bat Ov er-Temp Minor alarm A4 36 HeatExch.Alm Major alarm A5

18 1st Shut-Down Major alarm A4 37 Env .Temp.Void Minor alarm A5

19 2nd Shut-Down Major alarm A4 38 Start GEN - None

Charging the Batteries1. Before turning on the battery breaker, measure the voltage of the battery pack and keep a record.2. Set the floating charge voltage equal to the terminal voltage of the battery pack. Menu path: Ctrl 1.Setup Para Batt Para Float Vol..3. Turn on the BATT breaker.4. Reset the floating charge voltage to the default (53.5 V).5. Start the equalized (boost) charge mode in the monitoring unit. Menu path: Ctrl 2. OAM 4.EQUAL...]

.1.1

Connecting Loads to the System1. Turn off the load.2. Turn on the corresponding DC output breakers of the system.3. Measure the DC output voltage and make sure that the positive and negative load cables are properly connected.4. Turn on the load.

.2.2

Acceptance Criteria

Negative voltage means the cables are inversely connected. Reconnect the cables.

+ - 48V48V DC input

Red probeBlack probe

Check load

Appendix: System Shutdown and Startup

Shutdown

The ZXDU68 W201 shutdown will cause the loads to be shut down.

1. Turn off the loads.2. Turn off all DC Output breakers.3. Turn off the BATT breakers.4. Turn off the monitoring unit.5. Turn off the AC Input breaker of the system.6. Turn off the AC input breaker powering the system.

Startup1. Turn on the AC input breaker powering the system.2. Turn on the AC input of the system.3 Turn on the monitoring unit.4. Turn on the BATT breakers.5. Turn on all DC output breakers.

The measured voltage should be positive (+) and within the range of 42-58 V

Alarms and their default output relays

Avoid DC short circuit during operation.

A large difference between the voltage of the battery pack and the floating charge voltage of the system can cause sparks and could result in flames.

Follow the sequence to connect the battery packs: Connect a battery pack with lower voltage > Connect a battery pack with higher voltage.







12 11 14

VL+ VL-X2-1

RL1

C1

C2

X3-B6X3-C6 X10-1

X11-1

ACDC

LNPE

RMT ALM COM EX PWM SBCUT

282726

1711 12 13 14 15 16

1(2)

3(4)

M2

ACDC

LNPE


282726

1711 12 13 14 15 16

1(2)

3(4)

M3

ACDC

LNPE


282726

1711 12 13 14 15 16

1(2)

3(4)

M4

ACDC

LNPE


282726

1711 12 13 14 15 16

1(2)

3(4)

M1QFB1

100A

BATT 1

BATT 2

ST1

T1

+12V

ST2

T2

+12V

X3-C7X3-B7

1QFD1 6A

1QFD2 20A

1QFD3 20A

QFB3 100A

QFB4 100A

KMD1

KMD2

123456

X6

1

123456

X7

2

123456

X8

3

123456

X9

4

123

X10

123

X11

1 2 3

X1

1 2

X2

1A1B1C

32A32B32C

X3EX1

EX2

EX3

EX4

ALM1

ALM2

ALM3

ALM4

RMT1

RMT2

RMT3

RMT4

CUT1

CUT2

CUT3

CUT4

PWM

PWM

PWM

PWM

COM

COM

COM

COM

V

B

1

V

B

2

V

L

+

V

L

-

X3-C12X3-C9

48V-

12 11 14NL

-12VGND+12VVa

1

2

3

4

1

2

X1

X2

TRB

X1-1

X1-3

X4

BACK

Class B

DC SPD

Distribution

LLVD1 LLVD2

THUNDERACAIR0

1234567891011121314151617181920212223242526272829303132

X3A

1234567891011121314151617181920212223242526272829303132

X3B

1234567891011121314151617181920212223242526272829303132

X3C

RS6

IB2+IB1+

IB2-IB1-

IL+ IL-ACVa

RS1RS2RS3

RS4RS5

-12VFL-DC

+12VAGND AGND

AGND

PEN

AC Input380V 50Hz/60Hz

12

1X26-1X26-2 12

2

1QFD4 20A

X3-C11RS1

X3-B11RS2

X3-A9RS3

X3-C10RS4

X3-B10RS5

X3-A13

X3-B13

LLVD1

LLVD2

L1L2L3

11 14

QFA1 63A

L1' L2' L3' NX3-A15

X3-C14X3-B15X3-C15X3-A7

X2-2QFB2

100A

AC Input

AC SPD

AC Transducer

Rectifier

DC Bus Bar

Shunt and DC SPD

DC Contactor

AC Switch of Battery

DC Output

Battery

Battery ST

1 2

X4

1 2

X5

1 2

X12

12

X21RS485

AB

T

1

T

2

+

1

2

V

+

1

2

V

G

N

D

T

C

1 2

X24

1 2

X25

1 2 3 4

X23

1 2

X26

+

1

2

V

+

1

2

V

+

1

2

V

S

M

O

K

E

T

E

M

P

A

G

N

D

A

G

N

D

D

O

O

R

V

C

C

-

W

W

A

T

E

R

SIB X1

1 2 3 4 5 6

X17

1 2 3 4 5 6

X15

1 2 3 4 5 6

X16

1 2 3 4 5 6

X14

S

3

A

G

N

D

S

2

S

4

S

1

A

G

N

D

4

N

C

3

C

O

M

4

C

O

M

3

N

O

4

N

O

3

N

C

6

N

C

5

C

O

M

6

C

O

M

5

N

O

6

N

O

5

N

C

2

N

C

1

C

O

M

2

C

O

M

1

N

O

2

N

O

1

N

C

123456789

X22RS232

L+

L+2QFD 63A

BATT 3

BATT 4ZXDU68 W201(V4.0R06M04)

MV+

COMSIG

FAN2

MV+

COMSIG

FAN3

MV+

COMSIG

FAN1

LLVD2VL+

LLVD2VL+

LLVD2VL+

ZXDU68 W201(V4.0R06M04)3U

QFB3 100A

QFB4 100A

12

1X26-1X26-2 12

2

BATT 3

BATT 4ZXDU68 W201(V4.0R06M03)

1N5404

1N5404

1N5404

MV+

COMSIG

FAN2

MV+

COMSIG

FAN3

MV+

COMSIG

FAN1

1N5404LLVD2

VL+

LLVD2VL+

T1 40

T2 40

LLVD2VL+

T4 40

T3 30

RS62QFD1 20A

2QFD2 20A

VD3

VD4

2QFD3 20A

VD52QFD5 20A

2QFD6 20A

VD7

VD8

2QFD7 20A

2QFD8 20A

VD9

VD10

2QFD9 20A

VD11

2QFD10 20A

2QFD11 20A

VD12

VD13

2QFD12 20A

2QFD13 20A

VD14

VD15

2QFD14 20A

VD16

2QFD15 20A

2QFD16 20A

VD17

VD18

2QFD17 20A

2QFD18 20A

VD19

VD20

2QFD19 20A

VD21

2QFD4 20A

VD6

2QFD20 20A

2QFD21 10A

VD22

VD1

2QFD22 10A

VD2

L+

2QFD3 63ALLVD2

X3-A8

Electrical Connection Diagram of Secondary Cabinet (V4.0R06M04)

Electrical Connection Diagram of Primary Cabinet (V4.0R06M03)

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zxdupa-wr01(v4.0r02m02)&zxdupa-wr01(v4.0r02m03) dc power system installation guide

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