PS481000-2/100 System

Shelby Wey, Customer Trainer 86-755-6812363 w.xiaobin@avansys.com

Nomenclature
PS481000-2/100 Rectifiers Rated Output Current (100A) Serial No. (2) Maximum System Output Current (1000A) Rated System Output Voltage (48V) Power Supply System

PS481000-2/100 System

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

Be able to extend to 6000A (60 rectifiers)

PS481000-2/100 System
AC Distribution Cabinet Remote Monitoring Center

RS485

RS232

Monitor DC Distribution Cabinet RS485 RS485

Rectifier Cabinet

PS481000-2/100 System
AC distribution
Rectifiers DC distribution Telecom equipment

AC mains I AC mains II

AC

... ~ ~ ~ -

-48 VDC

-48 VDC

Battery

...

RS-485 RS-485 RS-2 32 RS-232

PSTN
Monitoring module
MODEM MODEM

Monitoring center

Background computer

System Principle of PS481000-2/100

48V +

switch

Content

Nomenclature & system principle AC distribution DC distribution

Rectifier
Monitor

Maintenance & emergency handling

AC Distribution Cabinet

AC Input

AC I AC II

AC Distribution Principle
Mains I Switch

Mains

QF1

QF2

QF3

QF4

QF5

QF6

QF7

QF8

C-Level Lightning Arrester

PE

QF9

QF10

QF11

QF12

Rack
QF13 QF14 QF15 QF16

Neutral Bar

Grounding Bar

Lightning Arrester

C Level

D Level

Lightning Arrester (C Level)

C Level

Lightning Arrester (D Level)

D Level

Lightning Arrester
Varistors + Discharge tube Varistor: voltage sensitive resistor

C Level
Green window, good; Red window, bad.

D Level
Indicators on, good;

Indicators off, bad.

Lightning proof breaker

C Level ---- air breaker D Level ---- fuse

Protect the wire from firing when varistors are broken (short) for lighting strike. Do keep the air breaker on

Buzzer Control

Muting control

Buzzer switch

Emergency Light Control

-48V

-48V

AC Distribution Monitoring Boards

AC Distribution Monitoring Boards

4V 8 J 0 V P w r s p ly 1 2 o e up 12 J 13 J R45 S8 tomn r gmd le o itoin o u R 4 5D S8 tod tr u r d p y is ib to is la

Ad - p a a r u ioo tic l lam

J 1

J 2

B4 3 1 1 CU
A /D d t ib t r C C isr uo u it dmn oin n e o it r g C Ub a d P or 11 J

J2 P

J1 P

A a g es n l n lo u ig a

s itc s n l w h ig a

J2 P

J1 P J 7 B ttey a c r e t a r /lo d ur n ma ue e t e s r mn B sb r a r u - a/b ttey v lta e o g ma ue e t e s r mn L a /b ttey od a r be k r s tu r a e ta s

Ad - p a u ioo tic l a r lam

J1 1

J5 1 J ,4 3 ,5

E eg n y mr e c lig t c n o h o tr l 3 te p r tue mea r s no es r ( p n l) o tio a

AV F 1 26X
S n l bid in b ad ig a r g g o r

D DSRBTO C ITIUIN SGA INL

J 1 J 2 J5 2 J 9 J 8 A min C a s v lta e e u n y o g /fr q e c s mlin a p g 1 VC .5 A top 1 in 0 L h in ar s r s tu ig tn g r e te ta s &a r s itc lam w h 20 A 2VC Fe u n y r qec in u pt J 8 20 A 2VC A min C a s v lta ein u o g pt 8

E eg n y mr e c lig t c n o h o tr l

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

1 7 /3 0 .6 V 0 A c re t ur n ma ue e t e s r mn

J 9 1 A c re t C ur n ma ue e t e s r mn J 6
1

A M Bs tu C C ta s

WV U N WV U N 2 2 2 1 1 1

AV F 1 2 4A
A min s mlin b ad C a s a p g or J 5
N X I X W V U WV U 2 2 2 1 1 1

A DSRBTO C ITIUIN SGA INL

1 0

J 4

Board Functions

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

Diagnosis of B14C3U1

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

Notice when replacing B14C3U1

Port J2 should be plug out first, plug in last.

Question

The AC distribution cabinet alarms.It shows that mains I lacks one phase. Whats the cause?

Content

Nomenclature & system principle AC distribution DC distribution

Rectifier
Monitor

Maintenance & emergency handling

DC Distribution Cabinet

Free cable access mode

DC Distribution Principle
-V 4 8 B 1ty a t yB 2 t e a r t e r
BF a u t ye t es r S h u n t S h u n t

LF ou as de

switch

Shunt
Precision resistor

Measure the current

1KA75mv Shunt coefficient (the relation between current and voltage)

DC Distribution Monitoring Boards

DC Distribution Monitoring Boards

4 8 V J 0 peul 1 or p 2 w p V s y J 1 Ao t aa u- i lam do i p lr c J 2 1 J 2 1 J 3

B3 1 U 4 1 C
A C tb r C dr u / Di i t s o ue oog nd nr i m i t i n t Cb d Po Ua r

R5 S 4 8 t m r gol ooo me ni i n d t u

R5 S4D 8 1 J 1 t dr u dl y osb r i p it t s i o a

J P 2

J P 1

A gs a n u in a egl l o

S hgl wsa ic i n t

-V 4 8 A - ta uo l dp i oi c am lr a
tpJ f or 1 o o t J 1 4 A3 1 X An g 4 1 Cl u C aoe a s aw i n sth gl ic , sa in gl

J 2

J 1

B3 1 X 4 1 C
Sar g b d in i ig a g b no l d r

J 6 J 7 J 8

3 tm tr e eu p e r a ss eo nr (pn ool t a i )

J 1 J 3 1 2

J 1 0

J 9

J 1 1

JJ 43

ADTBI CIRUO SITN SN IA GL

B L V D LD L V Erey mn e c g l hoo i t nl gct r

Bbbe u aar sr t y - / t va m rm og eu e l e aen t s t B r l a un a y dr t t / cr t o e e m rm eu e a en s t Do c c C t tr o ca no i l Ld t r o/a y a t be b k su rar tts ee a

DDTBI CIRUO SITN SN IA GL

Board Functions

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

Diagnosis of B14C3U1

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

Notice when replacing B14C3U1

Port J2 should be plug out first, plug in last.

Question

DC distribution communication fault. Whats the cause?

Content

Nomenclature & system principle AC distribution DC distribution

Rectifier
Monitor

Maintenance & emergency handling

Name

HD 48 100-2
Serial No.(2) Rated output current (100A) Rated output voltage (48V)

HD48100-2
Wide input voltage range from 304~ 456Vac 3- phase AC input (3 -phase and 3 lines) Efficiency92% PF0.92

Rear View

Front View

Front View (zoomed)

Power

Protection

Fault

Address

Indicators

Power Indicator (green) With AC input for the rectifier, the indicator will be on.

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

Address Setting Binary

MSB 0 1 0 1 1 LSB

Decimal 11

Question

How to judge whether the rectifier is normal or not?

How to replace the failed rectifier?

Replacing Rectifier Procedure

1 2

Replacing procedure
1. Insert AC input plug 2. Start the rectifier 3. Insert DC output plug

Principle
Equal electric potential, so as not to sparkle

Content

Nomenclature & system principle AC distribution DC distribution

Rectifier
Monitor

Maintenance & emergency handling

Monitor PSM-A

386 industry computer 100 historical alarm records Help on-line

Users password: 123456

Maintainers password: 640275
PSM-A Monitoring Module

Front Maintenance

Front & Rear View

Line-up (3 cabinet)
To other distribution cabinet COM5 COM4 To other distribution cabinet

PSM-A
1J3
1J2 1J1 B14C3U1 COM7 1J3 1J2 1J1 B14C3U1

HD48100-2 HD48100-2
COM6

HD48100-2 HD48100-2
RS485

AC Distribution

Rectifier Rack

DC Distribution

Line-up (2 cabinet)
COM5 To other distribution cabinet COM4

PSM-A
1J3 1J2 1J1 B14C3U1 COM7

HD48100-2 HD48100-2
COM6

HD48100-2 HD48100-2

AC/DC Distribution

RS485

Rectifier Rack

Monitor

RS485
Rec1 Rec2 Rec3 0

AC 64

RS485
DC 72 ADC 80

1
2

CPU board

B14C3U1 B14C3U1

Distribution signal (analogue and switch signal)

Connection of Rectifier Module

Address of Rectifier module

Determined by selector switch of rectifier module

1 2 3 4 5 6 7 8

MSB 0 1 0 1 1

LSB

Address Setting for Distribute Cabinet

AC: 64= All ON
H
L

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

Address Setting
S1 Binary digit Corresponding Range of PSM-A communication communication address address Application

xxx00xx0

0~7

64~71

AC distribution cabinet

H
xxx10xx0 8~15 72~79 DC distribution cabinet AC&DC combined distribution cabinet

xxxx1xx0

16~31

80~95

Base address=64

Key Parameter setting

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;

Key Parameter setting

Conditions to Equalize Charge-----empty?

TO EQU CAP RATIO: 80%; TO EQU CUR: 0.01C10;

Conditions to Float-----full?
STABLE TIME: 1080 MIN & STABLE CUR: 0.01C10 MIN;

EQU TIMEOUT: 18 hours;

Battery Test----- discharge!

TEST END VOLT: 45V TEST END TIME: XXX MIN

Internal Construction

Power Board

CPU Board

Board Functions

CPU Board (M14C3U1)

process all the signals

Power Board (M14C3R1)

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

Diagnosis for Monitor

Phenomenon
AC/DC distribution or rectifier communication fault

Cause
Address, communication port number, CPU Board

no power display without backlight

Fuse, Power Board Power Board

Question

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?

Content

Nomenclature & system principle AC distribution DC distribution

Rectifier
Monitor

Maintenance & emergency handling

Maintenance

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.

Handling Failure Procedure

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

Emergency Handling

Principle: maintain the DC power for telecom equipment Handling Emergency Cases
1. AC Distribution Failure
2. DC Distribution Failure
Load short circuit Distribution short

1. Connect AC directly to rectifiers 2. Get rid of short

Cut off the fuse/breaker for the load

Cut off AC, then separate the battery from the system, and then power loads with battery or rectifiers directly

3. Monitor impacts DC 4. Rectifier failure

Inside short
Many rectifiers fail Output over-voltage

3. Turn off monitor, manage battery manually

4. Turn off the failed rectifiers

Automatically turn off Turn off, ensure enough normal rectifiers Turn off all, then turn on one by one except the failed one.

Summary

Summary
signal flow, board functions, important parts checkup of key boards

failure analysis and handling

Homework: Next class:

Thank you very much!

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