Installaton Manual For FPRA

1
Flexi Power Rectifier

Installation Manual
Emerson Network Power Co., Ltd. http://www. emersonnetworkpower.com.cn Manual Version: 03
Installation Manual
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.
Installation Manual
History 3
History
Date Version Author David Cao David Cao Change Note No./Notes First release 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 02/09/2008 01 20/10/2008 02
Installation Manual
Table of contents
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
Installation Manual
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 15 Cable gland configuration option2 ................................................42 Figure 16 Cable gland configuration option3 ................................................43 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
Installation Manual
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 1 ..............................................81 Figure 58 AC terminal block configuration 3 ...............................................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 1...........93 Figure 70 AC connection without the SPD 1 ..............................................93 Figure 71 Schematic diagram of AC connection without the SPD 3 ...........94 Figure 72 AC connection without the SPD 3...............................................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
Installation Manual
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 103 Example of a parallel configuration 2 FPRAs & 6 BATs............118 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 113 Example of a parallel configuration 3 FPRAs & 5 BATs............126 Figure 114 Example of a parallel configuration 3 FPRAs & 9 BATs............127 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
Installation Manual
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
Installation Manual
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
Installation Manual
List of terms 10
List of terms
A AC AWG BAT BR BTS C CSA CU DC EAC EMC ESD FPRA GND GUI IE IP IP L LAN LED LVD MAC MCB Ampere Alternative current American Wire Gauge Battery Battery Return Base Transceiver Station Temperature in degrees Celsius Cross Section Area Control unit Direct current External Alarm and Control Electromagnetic Compatibility Electrostatic Discharge Flexi Power Rectifier Ground Graphical User Interface Internet Explorer Ingress Protection Internet Protocol Live cable from the AC mains Local Area Network Light Emitting Diode Low Voltage Detection Media Access Control Micro Circuit Breaker
Installation Manual
List of terms 11 N N/A PC PCB PDA PE PSU RTN S/N SPD V VPN 1 3Y 3 Neutral cable from the AC mains Not applicable Personal Computer Printed Circuit Board Power Distribution Assembly Protective earth Power Supply Unit Return Serial Number Surge Protect Discharge Volt Virtual Private Network Single-phase AC type 3-phase star AC type 3-phase delta AC type
Installation Manual
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 1
Title Product instruction
Content Describes the specifications, properties, mechanical data, etc. of the FPRA and the modules it contains. Describes the installation safety, site, and tools. Describes how to install the AC cables, DC cables, communication cables, parallel installation, etc. of the FPRA. Describes how to set the browser and CU, and access the GUI. Describes how to commission the FPRA after the installation. Describes how to maintain the FPRA. Describes how to solve the detected issues of the FPRA.
2 3
Preparation Hardware installation
4 5 6 7
Browser and CU setup Commissioning Maintenance Troubleshooting
Installation Manual
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
Document Internal product specification System / PDA Internal product specification Rectifier Surge Protect Discharge for Flexi Power Rectifier User Manual Flexi Power Rectifier - User Manual Flexi Power Rectifier - Installation Manual (This manual)
- To be continued -
Emerson Network Power File No. 41970005110 41970004980 03370500080 03370500090 03370500070
Installation Manual
Preface 14
Table 3 Reference documents of the FPRA
Surge Protect Discharge for Flexi Power Rectifier Quick Start Guide Flexi Power Rectifier Quick Start Guide
03370500100 03370500110
Installation Manual
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 Min Nom -Max 276
Description
Rated AC input voltage (VAC) DC Output Nominal Vout (VDC) Iout (ADC) Ambient temperature (C) Operation Storage Start up
180
See Table 5
-56 0 -40 -45 -40 (2)
-54 -23 ---
-52 109.9 55 (1) +45 --
See Table 7 See Table 7 Max output 6kW
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 55C (plus solar load).
Installation Manual
(2) At -40C 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 -40C.
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 (Nominal) 240
VAC / V (Range) 180 276
Frequency / Hz 45 66
Supply Network Type US Single phase; threewire; earthed mid point of phase Europe Single Phase US 3-phase star; four wire; earthed neutral US 3-phase delta; fourwire; earthed mid point of phase Japanese 3-phase delta European 3-phase star; four wire; earthed neutral)
230 208 Phase to Neutral 240 Phase to Phase 202 Phase to Phase 230 Phase to Neutral
180 276 180 276 180 276
45 66 45 66 45 66
180 276 180 276
45 66 45 66
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.
Installation Manual
Table 6 Main voltages and the corresponding EAC alarms
VAC / V <85
Status Low mains voltage Rectifier shutdown
EAC alarm Yes (2) Mains phase failure (3) #1 / #2 / #3 Yes Minor (3) No (2) Refer to Table 5
90 ~ 180 (-5) (1)
Operational extended and low mains voltage range Rated operation
180 ~ 276
277 (+5) ~ 310
Operational extended and Yes high mains voltage range Minor (3) Over mains voltage Rectifier Shutdown Yes Major (3)
>315 (5)
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.
Installation Manual
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.
Installation Manual
Table 7 Static data of the DC output
Parameter Output Voltage (VDC)
Spec -54 2(1) -57~-45
Description Nominal output voltage Output voltage range
Factory Output Voltage set point (VDC) Line regulation Minimum Hold Up (ms) Current Limit (ADC) OVP Limit (VDC) Output Low Voltage Alarm (VDC) Ripple & noise (mV)
-53.30.6 Factory default setting at +27C <1% 20 +10% For a load from Minimum to Maximum at +27C For a load from Minimum to Maximum @ Maximum output 6kW
58.5 1.0 Factory set 400.5 300 6 Factory set Max output 6kW, -10~+55C (plus solar load) (2) -40C ~+55C (plus solar load) 6kW derating to 4.5kW @ +55C (plus solar load) 65C No minimum load limitation Nominal AC input range, Max output 6kW
Max Output power (kW) 6 ~ 4.5 Minimum Output power (kW) Efficiency ->90%
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 -40C 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.
Installation Manual
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.
Installation Manual
LOADs
BATs
PDA
AC
AC Distributor DC Distributor DC Busbar
REC1 REC2 REC3
Display
MCU
RS485 RS422
RJ45
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.
Installation Manual
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
Installation Manual
Product Introduction 23 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 Main phase #1 Main phase #2 Main phase #3 Critical
Description Mains phase failure indicates any single phase voltage of the 3-phase FPRA power source configuration that is below 85VAC
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.
Installation Manual
Product Introduction 24 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
Installation Manual
Product Introduction 25 Figure 6 shows the front panel of the PDA. (3) (2) (1) (4) (5) (6) (7)
(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
Installation Manual
Product Introduction 26 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 F/MA / Red M/MA / Yellow SYSOK / Green All LEDS
Status
Indication Fault
ON
Major EAC alarm (refer to Table 8) Mains / phase failure (refer to Table 8) Message
ON ON Turn on simultaneously and turn off after about 20 seconds
Minor EAC alarm (refer to Table 8) System OK
System initialization
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.
Installation Manual
Product Introduction 27 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)
(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
(4)
Installation Manual
Product Introduction 28 Table 10 lists the LED indications of the rectifier.

Table 10 LEDS on the rectifier front panel
LED Mark Yellow (amber) / Message
Status ON
Indication Minor EAC alarm (refer to Table 8) Rated mains voltage (refer to Table 5) System OK Rectifier failure Fan failure AC input phase voltage less than 80V Low output voltage
Green / Normal
ON
Red / Alarm
ON
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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:
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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 -
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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.
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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
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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 Flexi 3U mounting covers front/back FMCA Flexi Power Rectifier 6000 FPRA
AA25000L Rectifier Unit 1/2/3
AA25130L Transient Protection Unit
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 users 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.
Installation Manual
Preparation 34
Table 13 Delivery contents by FPRA
Name
Figure
Description
Usage
Emerson Part Number
Emerson Module Number
Case
The case of the FPRA, in which the PDA and rectifiers are installed. The distribution of AC input and DC output Cable entry of the FPRA The temperature sensor of the FPRA The communication cable for RS422 interface Ethernet cable compliant with T568A/B
N/A
PDA Cable gland Temperature cable
85570602630 1 2 1 8087000695x AA25020L 8087000694x 1 1 8087000897x 18370104780
Parallel cable
Ethernet cable
System earth cable
Connects the FPRA to system earth
8087000987x
Installation Manual
Preparation 35 Phoenix 3-pole Bridge Used to configure the AC terminal block 1 40570002800
Phoenix 2-pole Bridge
Used to configure the AC terminal block
40570002790
Cable tie Cable restraint
Used to tie the cables Used to tie thick cable, such as AC cable
50 2
18870001600 18370104720
AA25020L
M3 screw
Used to fix the cable restraint
41300000208
M5 screw
Used to fix the cases when stacked for parallel configuration
41300000181
Installation Manual
Preparation 36 SPD Surge Protection Discharge 1 10070000400
SPD jumper
Short link for SPD terminals in single-phase AC connection
18370102980/ 40370110040
L line short link
L1/L2/L3 for three phase, L for single phase (AWG12)
8087000880x AA25130L
N line short link
N for three phase star, N for single phase (AWG 8)
8087000879x
SPD ground link
SPD ground link
8087000902x
SPD Sense Cable
SPD signal cable connecting to the MCU The AC/DC module
8087000925x
Rectifier
1/2/3
AA25000L AA25000L
Installation Manual
Hardware Installation 37
Chapter 3 Hardware Installation
Before hardware installation, please note: the precautions listed in the Safety summary. All 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
Installation Manual
Hardware Installation 38 (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
Installation Manual
Hardware Installation 39 (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
Installation Manual
Hardware Installation 40 (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. two cable glands are used, the holes in the same position on the two If 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.
Installation Manual
Hardware Installation 41 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). System earth cable BAT2 Alarm
Parallel cable
Temperature cable LOAD2 AC cable
RTN2 RTN5 DC GND Parallel cable
Alarm
Figure 14 Cable gland configuration option1
Installation Manual
Alarm BAT2 System earth cable
LOAD2
LOAD1
Parallel cable BAT1
Temperature cable BAT3 AC cable RTN5 RTN3 Parallel cable Alarm RTN2 RTN1 DC GND
RTN4
Installation Manual
Alarm BAT2 System earth cable
LOAD2
Parallel cable
Temperature cable BAT3 AC cable RTN5 RTN3
BAT1
DC GND
RTN4 Alarm RTN1
Parallel cable
Installation Manual
Hardware Installation 44 Puncture the waterproof of the cable gland with an awl (2mm), 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).
Installation Manual
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
Installation Manual
Hardware Installation 46 (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. the event that the load in field has a protective earth cable, the user can In connect this grounding cable into any of the terminals in the lower row.
Installation Manual
Hardware Installation 47 MCB switch Lever bar LOAD2(-) BAT1(-) BAT2(-)
CB1 LOAD1(-)
CB2
CB3
CB4
CB5
BAT3(-)
Terminals short link
Insulator RTN4(+) RTN5(+)
LOAD GND
RTN1(+)
RTN2(+)
Figure 21 DC terminals distribution
RTN3(+)
LOAD1(-)
LOAD2(-)
BAT1(-)
BAT2(-)
BAT3(-)
Fixing pole LOAD GND RTN5(+)
RTN1(+)
RTN2(+)
Figure 22 DC inlet grommet
RTN3(+)
RTN4(+)
Installation Manual
(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).
Installation Manual
Figure 23 Removing the load terminals short link and MCB switch lever bar
1
Figure 24 Removing the battery terminals short link and MCB switch lever bar
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Table 14 Three typical battery / load cables configurations
Option
Cable name Load & return
CSA size (mm2) 35
Cable number 2 2 1 4 6 1 2 6 1
Recommended Installing sequence (2)
Breakers configuration
Battery & return 50 (3) Load Grounding (1) Load & Return 35 35
RTN2(+) LOAD2(-) RTN5(+) BAT2(-)
Load MCB parallel & Battery MCB parallel
Battery & return 35 Load Grounding (1) Load & Return 35 35
RTN1(+) LOAD1(-) RTN2(+) LOAD2(-) RTN3(+)BAT1(-) RTN4(+) BAT2(-) RTN5(+) BAT3(-)
No MCB parallel
Battery & return 16 Load Grounding (1) 35
RTN1(+) LOAD2(-) RTN3(+) BAT1(-) RTN4(+) BAT2(-) RTN5(+) BAT3(-)
Load MCB parallel
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. (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.
2
Installation Manual
Hardware Installation 51 (6) Connect the DC cables.
not break the white insulators between the DC terminal blocks (see Do 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 (2mm), 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.
Installation Manual
Keep the front panel about 10cm away from the PDA, for easier access in the following steps.
1 2
Figure 25 Inserting the DC load grounding cable through the front panel
Installation Manual
Hardware Installation 53 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
Installation Manual
Hardware Installation 54 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.
Installation Manual
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.
Installation Manual
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.
Installation Manual
Hardware Installation 57 (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
Installation Manual
Hardware Installation 58 (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 1 2
Sequence 1, 2, 3, 4, 5, 6 1, 2, 3, 4, 5, 6
Torque (Nm) 0.3~0.4 0.5~0.6
1 5
6 2
Figure 31 Securing the front panel
Installation Manual
Hardware Installation 59 (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
Installation Manual
Hardware Installation 60 (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
Step 1 2
Sequence 1, 2, 3, 4 1, 2, 3, 4
Torque (Nm) 0.3~0.4 0.5~0.6
Installation Manual
Hardware Installation 61 3 2
1
Figure 34 Securing the sub cover
Installation Manual
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
Connector
J11
J22
Figure 35 Drawer internal layout (old version)
Installation Manual
Gasket
Connector
J11
D
Figure 36 Drawer internal layout (updated version)
J22
(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.
Installation Manual
Figure 37 Inserting the temperature cable into drawer (old version)
Figure 38 Inserting the temperature cable into drawer (updated version)
Installation Manual
Hardware Installation 65 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 doesnt need to go under the three RS485 cables (see Figure 40).
Table 17 The connection of the temperature cable
Pin of J22 7 8 9 10
Name TEM_GND TEM SENSE_IN TEMP_VCC EARTH
Color Red White Black Cable screen
Installation Manual
Figure 39 Connecting the temperature cable only (old version)
Figure 40 Connecting the temperature cable only (updated version)
Installation Manual
Hardware Installation 67 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.
Installation Manual
Hardware Installation 68 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 doesnt need to go under the three RS485 cables (see Figure 43, Figure 45).
Table 18 The connection of the parallel cable
Option From PSU
Pin of J22 1 2 3 11
Name RS422RDRS422RD+ SGND/F EARTH RS422TXRS422TX+ SGND/F EARTH
Color Red White Black Cable screen Red White Black Cable screen
To PSU
4 5 6 12
Installation Manual
Figure 42 Connecting the parallel cable only From PSU (old version)
Figure 43 Connecting the parallel cable only From PSU (updated version)
Installation Manual
Figure 44 Connecting the parallel cable only To PSU (old version)
Figure 45 Connecting the parallel cable only To PSU (updated version)
Installation Manual
Hardware Installation 71 (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.
Installation Manual
Table 19 The connection of the Alarm cable
Pin of J11 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Name ALARM IN (-) ALARM IN (+) ALARM_COM MAINS 1 ALARM_COM MAINS 2 ALARM_COM
Color
Reference MAINS 3 ALARM_COM CRITICAL ALARM_COM MAJOR ALARM_COM MINOR
Installation Manual
Figure 46 Connecting the Alarm In cable only (old version)
Figure 47 Connecting the Alarm In cable only (updated version)
Installation Manual
Hardware Installation 74 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. B
Figure 48 Connecting the Alarm Out cable only (old version)
Figure 49 Connecting the Alarm Out cable only (updated version)
Installation Manual
(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)
Installation Manual
Hardware Installation 76 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)
Installation Manual
Hardware Installation 77 (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
Installation Manual
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
Installation Manual
Hardware Installation 79 Figure 55 shows the PDA rear internal chassis layout. PDA rear cover
SPD DIN Rail
AC terminal block E D SPD ground clamp PDA earth cable SPD sensor connector AC ground clamp C B Rear cover Retention cable
Cable restraint F
Figure 55 The PDA rear internal chassis layout
Installation Manual
(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
Installation Manual
Hardware Installation 81 There are three AC power system types (see Table 5), and thus three AC configurations of the AC terminal block: Single-phase (1) 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 1
Installation Manual
Hardware Installation 82 3- phase delta (3) 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 3
Installation Manual
Hardware Installation 83 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
Installation Manual
(3) Insert the AC cable through the front panel.
the L, N and PE cables from the AC mains must be at least 12AWG for All 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
Installation Manual
(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 Singlephase (1) 3-phase delta (3) 3-phase star (3Y) A (mm) B (mm) A (mm) B (mm) A (mm) B (mm) 140 10 150 10 L1 L2 140 10 120 10 140 10 105 10 125 10 L3 N 115 20 --100 20 PE 85 20 85 20 85 20
Installation Manual
Hardware Installation 86 Option 1 3-phase star (3Y) AC connection without the SPD
AC mains
PE L1 L2 L3 N
AC Terminal Block
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
Installation Manual
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
Installation Manual
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
Installation Manual
Hardware Installation 89 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
Installation Manual
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
Installation Manual
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
Installation Manual
Hardware Installation 92 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
Installation Manual
Hardware Installation 93 Option 2 Single-phase (1) 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 singlephase AC mains connection.
AC mains
PE L N
AC Terminal Block
1 2 3 4 5 6
Figure 69 Schematic diagram of AC connection without the SPD 1
N L
PE of AC mains
Figure 70 AC connection without the SPD 1
Installation Manual
Hardware Installation 94 Option 3 3-phase delta (3) 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.
AC mains
PE L1 L2 L3
AC Terminal Block
1 2 3 4 5 6
Figure 71 Schematic diagram of AC connection without the SPD 3
L3
L2
PE of AC mains
L1
Figure 72 AC connection without the SPD 3
Installation Manual
Hardware Installation 95 (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
Step 1 2
Sequence 1, 2, 3, 4, 5 1, 2, 3, 4, 5
Torque (Nm) 0.3~0.4 0.5~0.6 5 1 4
2 2 3
Figure 73 Securing the rear cover back to the PDA
Installation Manual
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
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Hardware Installation 97 (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
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(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
Installation Manual
(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
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Hardware Installation 100 (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
Installation Manual
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).
2
Figure 79 Putting the rectifier into the first slot of the case
Installation Manual
Hardware Installation 102 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
Installation Manual
Hardware Installation 103 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.
Installation Manual
1 2
3
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
Installation Manual
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
Installation Manual
Hardware Installation 106 (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). A B
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
Installation Manual
Hardware Installation 107 (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).
Figure 87 Fixing the AC cable to the side of the case
Installation Manual
Hardware Installation 108 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
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Hardware Installation 109 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
Installation Manual
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 doesnt 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
Installation Manual
Hardware Installation 111 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
Installation Manual
3.9 Parallel installation of the FPRA
the event that BTS site configuration exceeds the power rating of a In 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. parallel configuration, two or three FPRA units can be stacked together In 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.
Installation Manual
Figure 98 Serial number of the FPRA unit
FPRA #1 S/N: G7083770009
Master
FPRA #2 S/N: G7081500036
FPRA #3 S/N: G7074801770
Slave
Slave
Figure 99 Master/slave definition of FPRA units in parallel
Installation Manual
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.
Figure 100, the blue and green arrows indicate that the battery might In 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.
Installation Manual
Bus bar
MCB
MCB PDA
MCB
BAT BAT PDA MCB MCB
sharing cable
MCB
Bus bar
Note: current flow path and direction Figure 100 Current flow of two battery blocks in parallel
Installation Manual
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 PDA #1 Load2
RS422
Battery Cabinet
RS422
Load1 Load2 PDA #2 AC in
Figure 101 Example of a parallel configuration 2 FPRAs & 1 BAT
Installation Manual
Battery Cabinet
RJ45 PC AC in Load1 PDA #1 Load2
RS422
RS422
Load1 Load2 PDA #2 AC in
Figure 102 Example of a parallel configuration 2 FPRAs & 4 BATs
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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. per Table 14, the battery strings in Figure 103 should be of CSA As 16mm2 or 35mm2 for different load configurations. The end user should prepare the external terminal block if needed.
External Terminal Block RJ45 PC AC in Load1 PDA #1 RS422 Load2
Battery Cabinet
RS422 Load1 PDA #2 Load2 AC in
Installation Manual
(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 Upper bottom
A A B B Lower top
Figure 104 The locating points on the FPRA
Installation Manual
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).
Figure 106 Fixing the two FPRA units
Installation Manual
(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 11 1 2 3 4 5 6 12 Parallel cable #2 Parallel cable #1
J22 #2 12 4 5 6 1 2 3 11
Figure 107 Parallel cable configuration within the two drawers
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Parallel cable #1 Parallel cable #2
Parallel cable #1
Parallel cable #2
Drawer #1
Drawer #2
Figure 108 Paralleling the two drawers (old version)
Parallel cable #2 Parallel cable #2
Parallel cable #1
Parallel cable #1
Drawer #1
Drawer #2
Figure 109 Paralleling the two drawers (updated version)
Installation Manual
(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). the Ethernet cable is needed, installed it to the top FPRA. If 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.
Installation Manual
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.
Installation Manual
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 RS422 Load2
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
Installation Manual
Battery Cabinet RJ45 PC AC in
Load1 PDA #1 Load2 RS422
AC in Load1 PDA #2 RS422 Load2
RS422 Load1 Load2 AC in PDA #3

Installation Manual
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. per Table 14, the battery strings in Figure 114 should be of CSA As 16mm2 or 35mm2 for different load configurations. The end user should prepare the external terminal block if needed.
External Terminal Block RJ45 PC AC in Load1 PDA #1 RS422 Load2
Battery Cabinet
AC in
PDA #2
Load1 Load2 RS422
RS422 Load1 PDA #3 AC in Load2
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Hardware Installation 128 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 11 1 2 3 4 5 6 12
Parallel cable #1
J22 #2 12 4 5 6 1 2 3 11
Parallel cable #2
Parallel cable #3
J22 #3
11 1 2 3
6 12
Figure 115 Parallel cable configuration within the three drawers
Installation Manual
1 Parallel cable #1 Parallel cable #1
2 Parallel cable #3
Parallel cable #2
Parallel cable #3 Parallel cable #2 Drawer #1 Drawer #2 Drawer #3
Figure 116 Paralleling the three drawers (old version)
Parallel cable #1
Parallel cable #1
Parallel cable #3
Parallel cable #2
Parallel cable #3 Parallel cable #2 1 Drawer #1 Drawer #2 2 Drawer #3 3
Figure 117 Paralleling the three drawers (updated version)
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Hardware Installation 130 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
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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 Users 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 Users 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 users 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.
Installation Manual
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: the breakers are in the OFF position before powering on the PDA. All 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 users 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.
Installation Manual
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 users 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 users 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 users PC). In this way, the users 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.
Installation Manual
Figure 120 Login the GUI
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Browser and Control Unit Setup 135 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 users PC and connects to the CU.
4.4.1 Set up the users PC

In order to connect to the FPRA CU, the IP-address of the users 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 users 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.
Installation Manual
Browser and Control Unit Setup 136 Follow the steps below to set up the IP-address of the users 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
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Browser and Control Unit Setup 137 (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 users 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.
Installation Manual
Browser and Control Unit Setup 138 See also Figure 124; change the users 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 users PC may disconnect with the local Internet / Intranet.
Installation Manual
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 users 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 users PC former IPaddress 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 users PC IP-address). Assume change the CU IP-address to 192.168.100.101 and click Update (see Figure 126).
Installation Manual
After changing the CU IP-address, the users 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 users 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 users PC) via the GUI. In this way, the users PC can access each CU in parallel / chained in the local Internet / Intranet.
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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.
Installation Manual
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 users PC with the cables that have been already installed.
Before power on, make sure: the breakers and AC power source switch are in the OFF position. All 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.
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Commissioning 143
Figure 127 Commissioning configuration of the FPRA
(2) Connect to the GUI Connect the FPRA to the users PC with an Ethernet cable. Connect to the GUI referring to Chapter 4 Setup. Browser and Control Unit
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.
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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
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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
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Commissioning 146
Figure 130 System related settings via GUI
Figure 131 Time settings via GUI
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Commissioning 147
5.4 AC input commissioning
Before power on, make sure: the breakers and AC power source switch are in the OFF position. All 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
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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.
Installation Manual
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.
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Troubleshooting 150
Table 22 Rectifier alarm indications
Severity Rectifier alarm configuration

Indeterminate
Trigger condition
Off
Recommend action
General error
Warning
Critical
Major
Minor
Rectifier internal error
Uninstall the rectifier from system, and then install the rectifier back again. If the error appears again, change the rectifier Check the AC input Uninstalled the rectifier from system, and then installed the rectifier back again. If error appears again, change the rectifier Check there any block in the fan, check the ambient temperature Check the ambient temperature
Input low (AC) Temp Sensor Fail Temp High Temp Low
X X
Set alarm when AC lower than 1705V, clear when AC higher than 1755V Temperature<-45C or temperature>125C Set when more than 75C, clear when lower than 70C Set when lower than 0C, clear when more than 5C
- To be continued -
X X
Installation Manual
Troubleshooting 151
Severity
Warning Indeter minate Off Critical Major Minor
Rectifier alarm configuration
Trigger condition
Recommend action
Except Temp High Except Temp Low Element Loss/Start Input High (AC) AC UVP AC OVP DC OVP X
X X X X
Set when more than 90C, clear when lower than 85C Set when low than -5C, clear when more than 0C Communication failure Set alarm when AC higher than 282V5V, clear when AC lower than 276V5V AC lower than 75V5V
Check there any block in the fan, check the ambient temperature Check the ambient temperature Re-start the PDA and rectifier Check the AC input
Check the AC input Check the AC input Remove the AC to the rectifier and reconnect the AC to rectifier again
X X
AC higher than 315V5V DC output higher than 58.5V1V,

- To be continued -
Installation Manual
Troubleshooting 152
Severity
Rectifier alarm configuration
Trigger condition
Recommend action
DC UVP Over Temp Protect Input Low Major Input High Major Fan Failure Power Limit X X X
Set when DC output lower than 40.5V, clear when DC higher than 42.5V OTP when higher than 105C, recover when lower than 84C
Check whether there is output short circuit Check there any block in the fan, check the ambient temperature Check the AC input Check the AC input Check the fan, if fan stop running, or change the fan
X X
Set when AC lower than 150V, clear when more than 151V Set when AC more than 296V, clear when lower than 295V Rectifier Fan fail
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
Installation Manual
Troubleshooting 153
Table 23 System alarm indications
Severity
System alarm configuration
Trigger condition
Recommend action
General error Battery test fail Date & Time not set Circuit Breaker 1 X
X X X
CU internal Errors Battery discharge test fail Date and time is not set in the CU Circuit breaker 1 open
Re-start the PDA, if error appear again, change the PDA Check whether the battery life time reached Set the date and time 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 (Same as above)
Circuit Breaker 2
Circuit breaker 2 open

- To be continued -
Installation Manual
Troubleshooting 154
Severity
Trigger condition
Recommend action
Circuit Breaker 3
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. (Same as above) (Same as above) Check AC input and battery voltage Check the battery temperature
Circuit Breaker 4 Circuit Breaker 5 LVD Bat. Temp. High
X X X X
Circuit breaker 4 open Circuit breaker 5 open Low voltage load disconnected Battery temperature higher than the battery temperature high set point Battery temperature higher than the battery temperature high disconnect set point
- To be continued -
Bat. Discon. Temp. High
Check the battery temperature
Installation Manual
Troubleshooting 155
Severity
Trigger condition
Recommend action
Bat. Temp. Low Bat. Discon. Temp. Low Battery Low Voltage Alarm In Surge Protection Device Element Loss X X X
Battery temperature lower than the battery temperature low set point Battery temperature lower than the battery temperature low disconnect set point Battery voltage lower than the battery low voltage set point
Check the battery temperature Check the battery temperature Check the battery voltage Check the customer equipment for alarm in If SPD installed, check the SPD fail or not. If SPD not installed, no action required Re-start the PDA
Alarm in signal trigger Surge protection device is not installed or fail PDA communication error
Installation Manual
Troubleshooting 156
Table 24 Failures likely to happen
Category Trouble Failing to display the PDA LED or LCD Large deviation between measured and real data (Voltage / current, etc.) Breaker failure, such as failing to turn on / off, etc. Failing to visit CU via the GUI PDA
Analysis Maybe damages on the internal communication circuit Maybe damages on the internal measurement circuit Breakers maybe damaged Ethernet cable poor connection
Troubleshooting Refer to Emerson support people Refer to Emerson support people Refer to Emerson support people Check the net equipment, such as net 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 units via PDA LCD or GUI in parallel configuration Failing to display temperature or alarms Rectifier Failing to display any LED Poor cable connection Check the proper connection of the parallel cables in different drawers Check the proper connection of the temperature or alarm cables Check the AC power supply and the connection to rectifier
Poor cable connection AC power failure

- To be continued -
Installation Manual
Troubleshooting 157
Table 24 Failures likely to happen
Category Trouble Rectifier abnormal operation, such as over voltage / current, etc Failing to be shown via the PDA LCD or GUI Rectifier Alarm loss of rectifier
Analysis Maybe rectifier damaged Poor connection between rectifier and PDA Poor connection between rectifier and PDA Poor cooling or fan failure
Troubleshooting Check AC input, load, environment, etc. Check whether the RS485 cable properly connected Check the relevant data cable connection between the rectifier and PDA Check the fan normal movement or replace the fan. Refer to Emerson support people for fan replacement if required.
Rectifier over temperature
Modules cannot be inserted into the case System
Check for any foreign body within the respective module slot. Check all module plug interfaces are clear and in good functional order. Check all interfaces on the respective module are correct and undamaged Maybe Fan failure Check for any obstruction on the fan
Abnormal noise
Installation Manual

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Flexi Power Rectifier

Emerson Network Power Co., Ltd. http://www. emersonnetworkpower.com.cn Manual Version: 03

Flexi Power Rectifier

Copyright 2009 Emerson Network Power Co., Ltd.

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Flexi Power Rectifier

Title Product instruction

Preparation Hardware installation

Browser and CU setup Commissioning Maintenance Troubleshooting

Flexi Power Rectifier

Term and Symbols in this manual

Flexi Power Rectifier

Table 3 Reference documents of the FPRA

Flexi Power Rectifier

Chapter 1 Product Introduction

Specification Min Nom -Max 276

-56 0 -40 -45 -40 (2)

-54 -23 ---

-52 109.9 55 (1) +45 --

See Table 7 See Table 7 Max output 6kW

Max output 6kW

Flexi Power Rectifier

VAC / V (Nominal) 240

VAC / V (Range) 180 276

180 276 180 276 180 276

180 276 180 276

Flexi Power Rectifier

Table 6 Main voltages and the corresponding EAC alarms

Status Low mains voltage Rectifier shutdown

90 ~ 180 (-5) (1)

Operational extended and low mains voltage range Rated operation

277 (+5) ~ 310

Flexi Power Rectifier

Flexi Power Rectifier

Table 7 Static data of the DC output

Parameter Output Voltage (VDC)

Spec -54 2(1) -57~-45

Description Nominal output voltage Output voltage range

Flexi Power Rectifier

Flexi Power Rectifier

REC1 REC2 REC3

Figure 3 General view of the FPRA

Flexi Power Rectifier

Figure 4 Back view of the FPRA

1.2 The Power Distribution Assembly (PDA)

Flexi Power Rectifier

EAC alarm Main phase #1 Main phase #2 Main phase #3 Critical

Battery failure Rectifier fail High float voltage

Flexi Power Rectifier

Flexi Power Rectifier

(11) (10) (9)

Flexi Power Rectifier

ON ON Turn on simultaneously and turn off after about 20 seconds

Minor EAC alarm (refer to Table 8) System OK