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APM200 Outdoor Power Supply System

User Manual
Version
Revision date
BOM

V1.2
Sept 17, 2007
31011189

Emerson Network Power provides customers with technical support. Users may contact the nearest
Emerson local sales office or service center.
Copyright 2005 by Emerson Network Power Co., Ltd.
All rights reserved. The contents in this document are subject to change without notice.
Emerson Network Power Co., Ltd.
Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China
Homepage: www.emersonnetworkpower.com.cn
E-mail: support@emersonnetwork.com.cn

Safety Precautions
To reduce the chance of accidents, please read the safety precautions carefully before operation. The Caution,
Notice, Warning and Danger in this manual do not represent all the safety points to be observed, and are only
used as supplement to various operation safety points. Therefore, the installation and operation personnel must
be strictly trained and master the correct operations and all the safety points before actual operation.
When operating Emerson products, the safety rules in the industry, the general safety points and special safety
instructions specified in this manual must be strictly observed.

Electrical Safety
I. ESD

Notice

The static electricity generated by the human body will damage the static sensitive elements
on PCBs, such as large-scale ICs, etc. Before touching any plug-in board, PCB or IC chip,
ESD wrist strap must be worn to prevent body static from damaging the sensitive elements.
The other end of the ESD wrist strap must be well earthed.

II. Shortcircuit

Danger

During operation, never short the positive and negative poles of the DC busbar or the
non-earthing pole and the earth. The power system is a constant voltage DC power
equipment, short circuit will result in equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when performing DC live operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Insulated tools must be used.
In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of the
human body and tool is reduced to the minimum.

Others
I. Safety requirement

Notice

Please use the same model MCB to replace the MCB.

II. Sharp object

Waring

When moving equipment by hand, protective gloves should be worn to avoid injury by sharp
object.

III. Cable connection

Notice

Please verify the compliance of the cable and cable label with the actual installation prior to
cable connection.

IV. Binding the signal lines

Notice

The signal lines should be bound separately from heavy current and high voltage lines, with
minimum 150mm binding interval.

Contents
Chapter 1 Overview ............................................................................................................................................................ 1
1.1 Theory................................................................................................................................................................... 1
1.2 System Features................................................................................................................................................... 1
1.3 System Function ................................................................................................................................................... 1
1.3.1 Protective Function .................................................................................................................................... 1
1.3.2 Alarm Function .......................................................................................................................................... 2
1.3.3 Communication Function ........................................................................................................................... 4
1.4 System Composition ............................................................................................................................................. 4
1.4.1 Embedded Power Supply .......................................................................................................................... 4
1.4.2 Heat Exchanging Equipment And External Fan......................................................................................... 4
1.4.3 Heaters ...................................................................................................................................................... 4
Chapter 2 Installation .......................................................................................................................................................... 5
2.1 Precautions ........................................................................................................................................................... 5
2.2 Preparations ......................................................................................................................................................... 5
2.2.1 Inspecting Location.................................................................................................................................... 5
2.2.2 Distributing Goods ..................................................................................................................................... 5
2.2.3 Unpacking.................................................................................................................................................. 5
2.2.4 Preparing Tools ......................................................................................................................................... 5
2.2.5 Preparing Cables ....................................................................................................................................... 6
2.2.6 Opening The Cabinet Door........................................................................................................................ 6
2.3 Installing Cabinet .................................................................................................................................................. 7
2.4 Installing Battery ................................................................................................................................................... 9
2.5 Installing Rectifiers................................................................................................................................................ 9
2.6 Connecting Cables.............................................................................................................................................. 10
2.6.1 Precautions.............................................................................................................................................. 10
2.6.2 Cable Tube .............................................................................................................................................. 10
2.6.3 Connecting Power Cables ....................................................................................................................... 11
2.6.4 Connecting Battery Cables ...................................................................................................................... 13
2.7 Installation Inspection ......................................................................................................................................... 13
2.7.1 Cabinet Inspection................................................................................................................................... 13
2.7.2 Cable Connection Inspection................................................................................................................... 14
Chapter 3 Testing.............................................................................................................................................................. 15
3.1 Introduction ......................................................................................................................................................... 15
3.2 Testing AC Distribution ....................................................................................................................................... 15
3.3 Testing Rectifier .................................................................................................................................................. 15
3.4 Testing Monitoring Module.................................................................................................................................. 15
3.4.1 Setting System Parameters ..................................................................................................................... 16
3.4.2 System Function Test .............................................................................................................................. 18
Chapter 4 Maintenance ..................................................................................................................................................... 19
4.1 Embedded Power Supply System Maintenance ................................................................................................. 19
4.1.1 System Operation.................................................................................................................................... 19
4.1.2 Indicator Description ................................................................................................................................ 19

4.1.3 Routine Maintenance............................................................................................................................... 20


4.1.4 Common Faults Handling ........................................................................................................................ 22
4.2 Battery Maintenance ........................................................................................................................................... 22
4.3 Heat Exchanging Equipment .............................................................................................................................. 22
4.4 External Fan Maintenance .................................................................................................................................. 23
4.5 Replace Heaters And Relays .............................................................................................................................. 24
4.5.1 Replace The Heater In Equipment Compartment.................................................................................... 24
4.5.2 Replace The Heater In Battery Compartment.......................................................................................... 25
4.5.3 Replace Heater Relays............................................................................................................................ 26
4.6 Replace Door Status Sensors............................................................................................................................. 26
4.7 SPD Maintenance ............................................................................................................................................... 27
Appendix 1 Technical Data ............................................................................................................................................... 29
Appendix 2 Definitions Of The Monitoring Expansion ....................................................................................................... 31
Appendix 3 Schematic Diagram ........................................................................................................................................ 34
Appendix 4 Wiring Diagram............................................................................................................................................... 35

Chapter 1 Overview

Chapter 1 Overview
APM200 outdoor power supply system can be used directly outdoors. It can supply as much as 60A electric current.
There are two models: north model and south model. North model has an extra heating unit.

1.1 Theory
The simplified theoretical block diagram is shown in Figure 1-1. The detailed theoretical diagram is shown in
Schematic Diagram and Wiring Diagram.
Load 1
220Vac

Distribution unit

220Vac

Load 11

-48Vdc

Embedded power
supply

Figure 1-1

Simplified theoretical block diagram

The embedded power system rectifies the 220V AC power into -48V DC power and exports the DC power to the
distribution unit. It has functions of battery management, LLVD (load low voltage disconnection), BLVD (battery low
voltage disconnection), data acquisition, alarm, and communication with the host.
The distribution unit connects to AC mains and feeds the AC power to the embedded power supply. In addition, it has
routes of -48V DC output for the loads.

1.2 System Features


Power factor of the rectifier can reach 0.99. The efficiency is higher than 90%.
Wide AC input voltage range from 90V to 290V. When the input voltage is between 90~175Vac, the rectifier
exports power- limited output. When the input voltage is 90Vac, the minimum output power of the rectifier is
37.5% of the rated power.
Perfect battery management. The system has BLVD function, and can perform functions such as temperature
compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, and online battery
test etc.
Rectifiers are hot pluggable. It takes less than 1min to replace a rectifier.
Network design: Providing multiple communication ports, which enables flexible networking and remote
monitoring.
Perfect lightning protection at both AC side and DC side.
Complete fault protection and fault alarm functions.
All system components are accessible from the front.
The safety guideline satisfies IP55, and satisfies GR487 waterproof requirement.

1.3 System Function


1.3.1 Protective Function
LLVD and BLVD
When mains failure occurs, the battery will supply power. When the battery voltage drops to 47.5V (by default,
adjustable), the monitoring module will cut off the non- priority loads. When the battery voltage drops to the BLVD
voltage (default: 46.5V), the monitoring module will cut off all the loads to avoid battery over- discharge. When the
mains resumes, the power system will go back to normal state.
APM200 Outdoor Power Supply System User Manual

Chapter 1 Overview
Over- temperature protection
If the temperature of the equipment compartment remains over the protection point (55C by default) for 30 seconds
constantly, the monitoring module will cut off the non- priority loads until the ambient temperature drops below 45C. If
AC side failure occurs, all the loads will be cut off.
This function is inhibitive by default, though the user can activate or prohibit it through the host command.
Input under-voltage protections
When the AC input voltage is over 290Vac or below 90Vac, the rectifier will perform self- protection. It can recover
automatically, and the return difference is more than 5Vac.
Output over-voltage protections
When the DC output voltage is over 60V, the rectifier will stop exporting voltage or current. This protection cannot
recover automatically.
Output current- limit protection
The APM200 system can perform current- limited protection.
Output short- circuit protection
The APM200 system can perform short- circuit protection. It can short circuit for a long while and recover
automatically.

1.3.2 Alarm Function


The system provides alarm functions. It annunciates alarm in the event of mains failure, mains over/ under- voltage,
DC output over/ under- voltage, charging over- current, load over- temperature protection, ambient over- temperature,
module failure, module protection, as shown in table 1-1.
Table 1-1
Remote communication values

Alarm functions
Description

Mains shortage

Alarm is raised when mains is below 50V, and resumes when mains is above 60V

Mains over- voltage

1. Setting range: between the under- voltage alarm point and 300V. The mains over- voltage alarm
point must be set above the AC over- voltage alarm point, and the mains over- voltage alarm point
is 280V by default.
2. Alarm recovery conditions:
When the mains is below the alarm point minus 3V for 10 minutes constantly, the alarm recovers.
3. The mains over- voltage alarm point can be set through the host. AC over/ under- voltage alarm
and module alarm are shielded when mains shortage

Mains under- voltage

1. Setting range: between 60V and the over- voltage alarm point. The mains under- voltage alarm
occurs when mains is below the under- voltage alarm point, and the default mains under- voltage
alarm point is 180V.
2. Alarm recovery conditions:
When the mains is above the alarm point plus 3V for 10 minutes constantly.
, the alarm recovers.
3. The mains over- voltage alarm point can be set through the host. Mains under- voltage alarm is
shielded when mains shortage

DC over- voltage

1. The alarm point is settable. The setting range is 58V~60V, and the alarm point must be above
the boost charging voltage plus 1V. The alarm return difference is 0.5V.
2.Default: 58V. DC over- voltage alarm occurs when the busbar voltage is over 58V, and vanishes
when the busbar voltage is below 57.5V

DC under- voltage

1. The alarm point is settable. The setting range isbetween the low- voltage disconnection point
and float charging voltage minus 2V. The alarm return difference is 0.5V.
2.Default: 48.5V. DC under- voltage alarm occurs when the busbar voltage is below 48.5V, and
vanishes when the busbar voltage is over or equal to 49V.
3. The lower limit voltage is LLVD voltage when load low- voltage disconnection is permitted.
4. The lower limit voltage is BLVD voltage when load low- voltage disconnection is prohibited and
BLVD is permitted.
5. The lower limit voltage is 35V when both load low- voltage disconnection and BLVD are
prohibited

Charging over- current

1. The charging over- current alarm will plus 5A when charging current is over the current- limit
point for 5 minutes constantly..
2. Alarm recovers when charging current is below the current- limit point for 5 minutes constantly

APM200 Outdoor Power Supply System User Manual

Chapter 1 Overview
Remote communication values

Description

Load over- temperature


protection

1.The non- priority load over- temperature protection can be set activated or not through the host
settings. It is prohibited by default.
2. If the function is activated and the circumambient temperature is over the over- temperature
protection point for 30s constantly, the monitoring module will cut off the non- priority loads
automatically. And the power will resume on automatically when the circumambient temperature is
lower by 10C than the protection point.
3. Setting range: 50C ~70C. The protection point is 65C by default.
4. The temperature sampling point is the external temperature sensor.
5. The non- priority load over- temperature protection can be set controllable by the host. If
controllable, the load over- temperature protection can be activated through the host command

Battery over- temperature


protection

1.The battery over- temperature protection can be set activated or not through the host settings. It
is prohibited by default.
2. If the function is activated and the circumambient temperature is over the over- temperature
protection point for 30s constantly, the monitoring module will perform battery disconnection
automatically. And the battery will resume power- on automatically when the circumambient
temperature is lower by 10C than the protection point.
3. Setting range: 40C ~70C. The protection point is 53C by default.
4. The temperature sampling point can be set to be battery temperature 1, and is subject to the
temperature compensation value

Circumambience overtemperature

The available setting range is -50~100C. When over the over- temperature alarm point, the alarm
return difference is 3C. The alarm point can be set respectively, and is 50C by default

Circumambience undertemperature

The available setting range is -50~0C. When under the over- temperature alarm point, the alarm
return difference is 3C. The alarm point can be set respectively, and is 0C by default

n# rectifier failure

n# rectifier failure (output over- voltage, output shortage, fan failure)

n# rectifier protection

n# rectifier protection (over- temperature, intput over/ under- voltageprotection)

Battery loop disconnection

1. One battery- string loop alarms.


2. Battery loop disconnection (MCB/ fuse, contactor or internal wiring disconnection) brings alarm.
3. The battery loop is the path between the battery string MCB and the battery string contactor
1. Low- voltage disconnection (LVD) activation and LVD voltage can be set through the host. LLVD
is inhibited by default, and BLVD is activated by default.
2. The available setting range of BLVD voltage is between 35V and LLVD voltage, and BLVD
voltage is 46.5V by default.
3. The available setting range of LLVD voltage is between BLVD voltage and DC under- voltage
alarm point, and BLVD voltage is 47.5V by default.
4. LVD criterion
1) The system has either following setting cannot perform LVD control: the number of system and
power module is set zero or battery string capability is set zero.
2) LVD is activated in accordance with LVD conditions and the host command

BLVD

LLVD

Door status sensor

The dry contact is disconnected upon alarm

SPD failure alarm

Check the two- route SPDs. The dry contact disconnects when SPD exports alarms

Fan failure alarm

If the fan rev. is measurable and the fan rev. is set to be maximum, the virtual fan rev. is less than
80% of the normal rev., fan failure alarm should be raised.
If the fan rev. is un measurable, fan failure alarm performs in accordance with failure description by
fan manufacturer

Heater failure alarm of the


storage battery compartment

When the mains is in normal state and the storage battery temperature is below 5C for an hour
constantly, heater failure alarm of the storage battery compartment is raised

Test on backup digital data

1. 3 routes altogether. The monitoring module supplies 24Vdc or 12Vdc operation power for the
switchable signal examination, disconnect the correlative low power level (0V ~ 1V) and connect
the correlative high power level (9V ~ 24V).
2. 8/20s impulse current can endure 300A, without damage (bio- transient suppressor with model
of 1.5SMC39CA is commeded).
3. Alarm power level is adjustable

Note
Alarm levels can be set through the host. The alarm levels are divided as critical alarm, observation alarm, and inhibit alarm.
Alarms that may cause load power interruption are defined as critical alarm by default, and the rests are observation alarms. Door
status sensor alarms, humidity alarms and backup equipment alarms can be set as non- alarm and be shielded, while the other
alarms cannot. Except exposited ones, the alarm affirmance time is 10 seconds.

APM200 Outdoor Power Supply System User Manual

Chapter 1 Overview

1.3.3 Communication Function


The system can communicate with the user host through communication port RS232 or RS485, and report sampling
data and alarm data to the host. The APM200 system can report some alarms information to the host through the 4
couples of dry contacts.

1.4 System Composition


The APM200 outdoor power supply is constructed by an equipment compartment and a battery compartment. The
equipment compartment consists of embedded power supply, heat exchanging equipment, external fan and
distribution unit etc. The battery compartment has two layers, and a set of batteries that supplies backup power can be
placed in each layer. Each heater is placed in the equipment compartment and in the battery compartment in the North
model system. See Figure 1-2.
Heat exchanging equipment

Rings(4 pieces)

External fan

Equipment
compartment
door

Monitoring expansion board


Reserved
Embedded power supply
Distribution unit
Heater in equipment
compartment (behind
distribution unit)

Battery string I
Heater in battery
compartment (under
the plate)

Battery
compartment
door

Battery string II

Floorstand

Figure 1-2

Structure of APM200 outdoor power supply system

1.4.1 Embedded Power Supply


The embedded power supply consists of three rectifiers, one monitoring module, one distribution subrack and one
monitoring expansion board. It switches the 220V AC voltage to -48V DC voltage, and delivers the -48V DC voltage to
the distribution units of the system and then to the loads through its distribution subrack.

1.4.2 Heat Exchanging Equipment And External Fan


The heat exchanging equipment dissipates the heat inside the cabinet with the external fan. It consists of an internal
fan and a heat exchanger. The external fan aspirates the cold air outside and feeds it to the heat exchanger, while the
internal fan expels the heat air inside the cabinet to the heat exchanger. The heat exchanger exchanges the heat
between cold air and hot air in it to dissipate the heat.

1.4.3 Heaters
The two heaters will start to work when the environment temperature is below 5C 5C to ensure the normal
operation of the North model system segments in low temperature environment.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

Chapter 2 Installation
2.1 Precautions
1. Only qualified technical person can do the system installation and maintenance.
2. Avoid fire or body injuries.
3. Provide suitable AC mains supply to the system.
4. Earth the system according to the requirement.
5. Keep the environment of the system clean and dry.
6. Avoid touching the bare part of a circuit.
7. Switch off the circuit breakers in case of system failure.

2.2 Preparations
2.2.1 Inspecting Location
Before installation, please inspect:
1. The cable routing such as cable tunnel and so on.
2. The conditions required for the normal operation of the system, such as AC mains supply, earth cable and so on.

2.2.2 Distributing Goods


The user needs to distribute the goods if several systems with same model are purchased at the same time. Every
system has been tested and gone through the burn-in test strictly before delivery. In order to ensure the optimized
operation and track the product quality conveniently, the components should be installed in their corresponding cabinet,
even though these components can be installed in other systems.
Ensure that all components in the same system have the same No. that is marked on the packing case.

2.2.3 Unpacking
Inspect the equipment strictly after unpacking to ensure successful installation.
Unpack and inspect the equipment only after it arrives at the installation site. The user representative and the
representative from Emerson Network Power Co., Ltd. shall inspect the equipment together.
Open the packing case with a packing list in it first, take out the packing list, and inspect according to the packing list,
including customer name, customer address, machine No., quantity, case No., contract No., and others.
Check the goods one by one according to the packing list after unpacking. The procedures are as follows.
Step 1: Check the quantity and serial number marked on the packing cases according to the actual quantity of the
packing cases.
Step 2: Check the correctness of the equipment packing according to the packing list.
Step 3: Check the quantity and model of the accessories according to the packing list.
Step 4: Check the correctness of equipment configuration according to the system configuration.
Step 5: Check the goods visually. For example, check if the cabinet or enclosure is distorted or affected with damp;
shake gently the rectifier and the monitoring module to see if there is any loose component or connection caused by
shipment.
Step 6: The user representative signs the packing list.
Do not unpack the components before installing them to avoid accessory loss.

2.2.4 Preparing Tools


The installation tools include electric drill, wire cutters, crimping tools, wrench set, screwdriver, and electric knife. The
tools must be insulation and ESD-proof processed before they are used.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

2.2.5 Preparing Cables


The cables to be installed include AC power cables, DC power cable and grounding cable.
RVVZ cables such as flame retardant PVC insulation or jacket soft cable with copper conductors are recommended.
The cables should be able to withstand at least +70C temperature. The colors of AC phase cable, neutral cable and
grounding cable shall be red, Cambridge blue and green and yellow respectively. If the cables have the same color,
they should be identified with IDs or color labels.
The sectional area of the AC power cable depends on the current, temperature rise, voltage drop and mechanical
2
strength of the cable. The 2.5A/mm current density is recommended to estimate the sectional area of the AC power
cables and the cable with less than 10mm2 sectional area is not recommended.
The sectional area of the DC power cable is shown in Table 2-1.
Table 2-1

Sectional area of the DC power cable

Rated current

Max. output current

Min. sect. area

50 A

50 A

2 10 mm2

Max. cable l. with 0.5V voltage drop and Min. sect. area
14 m

40 A

40 A

10 mm2

14 m

25 A

12.5 A

6 mm2

11 m

16 A

8A

4 mm2

11 m

If the rated capacity of a MCB is much bigger than the actual output current, the MCB will not trip when overload
happens. So the recommended MCB capacity is 1.5 to 2 times of the maximum load current.
Note
The maximum output current that flows in the DC power cable is calculated according to the full load of the system.
If the acceptable voltage drop is not 0.5V, determine the sectional area of the DC power cable according to the
following expression.
A= I L/(KU)
Where:
Asectional area of a cable (m2)
Itotal current that flows in the cable (A)
Lcable length (m)
U acceptable voltage drop in the cable (V)
Kelectric conduction coefficient, here K Copper=57
Recommended color labels for the positive and negative DC power cables:
Positive cable black
Negative cable blue
2
The sectional area of the grounding cable should be at least 16mm . A green and yellow cable should be used as the
grounding cable.

Prepare the cables according to the cabling specification and quantity. Do not join two separate cables together to
form one cable. The blue and black cables should be used as DC power cables. If the cables are routed outside, they
should be inserted into a corrugation sleeve.

2.2.6 Opening The Cabinet Door


The user needs to open the cabinet door when carrying out system installation or maintenance. The opening
procedures are follows:
1. Undo the hexagon- socket- head- cap screw in the keyhole sheet widdershins with the hexagon key. Remove the
keyhole sheet. Insert another key into the keyhole and turn the key clockwise until the handle pops out, as shown in
Figure 2-1.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

Handle

Keyhole
sheet

Figure 2-1

Unlock sequence

When you turn the key, lay your hand down to prevent being hit by the handle, as shown in Figure 2-2.

Figure 2-2

Unlock illustration

2. Turn the handle counter clockwise to the position shown in Figure 2-3, and then open the door.

Handle

Figure 2-3

Handle position

3. Insert the door stay bar into the positioning pole to fix the door position, as shown in Figure 2-4.

Door stay bar


Figure 2-4

Door stay bar

4. To close the door, uplift the bar for 2mm- 3mm, place the handle to its original position, cover the keyhole with the
keyhole sheet and undo the hexagon- socket- head- cap screw in the keyhole sheet clockwise with the hexagon key.

2.3 Installing Cabinet


The APM200 outdoor power supply system uses bottom cabling method. The cabinet should be installed on the
floorstand (accessory). The installation procedures are as follows.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation
Step 1: Mark the floorstand installation position
Determine the center point positions of the floorstand on the ground and mark them with a pencil or an oil pen, as
shown in Figure 2-5.

Cabinet door

14

450

400
Figure 2-5

Installation dimensions of floorstand

Step 2: Drill holes


The size of the expansion bolt delivered with the accessories is M10 55mm. Drill a 70mm-depth hole at each marked
point by using a 14 drill bit. Be careful not to make the drill be off-center when drilling and keep the drilling vertical.
Clean the dust from the hole. Insert an expansion pipe into it, and knock the pipe gently until its head is in the same
level with the floor.
Step 3: Fix the floorstand
Align the installation holes of the floorstand to those on the ground. Screw the expansion bolt with plain and spring
washers into the expansion pipe with a wrench, as shown in Figure 2-6.

Battery
compartment

Screw for fixing cabinet


and floorstand
Floorstand
Expansion bolt
Ground

Figure 2-6

Installing the cabinet and floorstand

Step 4: Place cabinet in position


Place the cabinet on the floorstand. Align the installation holes of the cabinet to those of the floorstand.
Step 5: Open battery compartment door
Take the key from the ring on the top of the cabinet, and open the battery compartment door according to the method
described in Opening The Cabinet Door.
Step 6: Fix cabinet
Adjust the cabinet horizontally and vertically. Insert an iron flake underneath the lower edge or the corner of the cabinet
that is closer to the ground to adjust the vertical tilt to be within 5 degrees. Screw the screws supplied with the
accessories to fix the cabinet on the floorstand with a wrench, as shown in Figure 2-6.
Shake the cabinet in different directions after the installation to check for any loose component and loose installation of
the cabinet.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

2.4 Installing Battery


Open the battery compartment door according to the method introduced in Opening The Cabinet Door.
The battery compartment has two floors. Each floor can be placed with one battery string that has four cells. Install the
battery cells according to the battery user manual delivered with the battery.
The battery cells should be installed as close to the right side and rear side of the cabinet as possible. Attach the acid
and alkali integration box on the side panel of the cabinet.
Loosen the two baffles in the front of the battery compartment after installing the battery cells, and then move the
baffles vertically about 10mm and screw the screws solidly to block the battery cells, as shown in Figure 2-7.
The installation tools must be insulation processed. Do not damage the plastic cover of the battery cells and their
output terminals during the installation.

Battery
compartment
Battery string I
Baffle

Battery string II

Baffle
Figure 2-7

Installing battery strings

2.5 Installing Rectifiers


The subrack of the embedded power supply has been installed in the cabinet of the outdoor power supply system.
While the rectifiers of the embedded power supply are packed and delivered separately and need to be installed on
spot.
Rectifiers should be installed in the three left slots of the subrack. Install the rectifiers from left to right when there are
less than three rectifiers to be installed and mount dummy plate at the remaining position. The installation procedures
are as follows.
Step 1: Place the rectifier to the position shown in Figure 2-8.
Rectifier

Handle
Figure 2-8

Positions of the rectifier and the handle

Step 2: Push the handle into the panel.


Step 3: Push the rectifier inward until it stops going forward. The rectifier is fixed in the subrack.
Step 4: The procedures to unplug the rectifier-move the latch to Unlock position first, and pull out the rectifier then.

APM200 Outdoor Power Supply System User Manual

10

Chapter 2 Installation

2.6 Connecting Cables


2.6.1 Precautions
1. When doing engineering design, AC cables and DC cables should be installed separately to avoid interfering with
DC output caused by AC power.
Note
At the point where the DC output cable is led out of the cabinet, drill the cable through a steel tube longer than one meter and
then connect it to the load to prevent radiant disturbance.
2. AC cables and DC cables should be identified with cable labels and polarity markings. The markings should be
attached on the cables at a fixed distance.
3. The cables should be identified with different colors, as shown below:
Positive DC cable black
Negative DC cable blue
Grounding cable green and yellow
AC phase line red
Neutral line Cambridge blue or black
If the cables have the same color, black cable is preferred and they should be identified with IDs.
4. The cables to be connected are AC power cables, DC power cables and battery cables.
5. Safety and reliability are most significant factors in electrical connection.
6. The AC and DC power cables and grounding cable should be routed through the cable tunnel, the battery
compartment and the cable tubes between the two compartments, and should finally be connected to the distribution
unit.
7. The cables shall not have joint, damage or scratch.

2.6.2 Cable Tube


This system is configured with 15 cable tubes of different sizes. The cable tubes are located on the separating plate
between the equipment compartment and the battery compartment, as shown in Figure 2-9. Among these tubes, two
are for optical fiber transmission cables (cable diameter range: 13mm~18mm), the remaining 13 are for other cables
(cable diameter range: 10mm~14mm). Users can select the suitable tube to route the cable according to the cable size.
Unscrew the tube cap, then lead the cable through the tube, and finally screw the cap.

Distribution unit

Cable tube

Figure 2-9

Position of cable tube

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

11

2.6.3 Connecting Power Cables


Step 1: Remove the panel of the distribution unit
The panel is shown in Figure 2-10.

The panel of the distribution unit

Figure 2-10

Panel of the distribution unit

Step 2: Load Distribution


The system can supply 11 routes of loads. The MCBs (LOAD1 ~ LOAD6) of the distribution unit in the embedded
power supply controls the 11 loads. The positions of the MCBs in the subrack are shown in Figure 2-11, and the
relationship between these two levels of MCBs is shown in Figure 2-12. The specifications of the MCBs are shown in
Table 2-2.
Table 2-2

MCB in subrack
LOAD 1
LOAD 2
LOAD 3
LOAD 4
LOAD 5
LOAD 6

MCB in distr.
unit
1, 2, 3
4, 5
6, 7
8, 9
10
11

MCB cap. in
distr. unit
16A
25A
25A
25A
40A
50A

MCB Specifications

Cable size in
distr. unit
25mm2
25mm2
25mm2
25mm2
25mm2
25mm2

Remark
Total output of three MCBs should be less than 16A
Total output of two MCBs should be less than 25A
Total output of two MCBs should be less than 25A
Total output of two MCBs should be less than 25A
Total output of the MCB should be less than 40A
Total output of the MCB should be less than 50A

Load MCB Battery MCB Battery force- on button

Figure 2-11

MCBs in subrack of embedded power supply system

LOAD1

Route 1

Route 2

LOAD3

LOAD2

Route 3

Route 4

Figure 2-12

Route 5

Route 6

Route 7

LOAD4

Route 8

Route 9

Relationship between two levels of MCBs

APM200 Outdoor Power Supply System User Manual

LOAD5

Route 10

LOAD6

Route 11

12

Chapter 2 Installation
The embedded power supply system has LLVD and BLVD functions. When the battery voltage is less than 47.5V
(default), the embedded power supply system will disconnect the load connected to the LOAD2 ~ LOAD6 MCBs
automatically without interrupting the power to the load connected to the LOAD1 MCB. LOAD1 will be disconnected
automatically when the battery voltage is less than 46.5V (default) to avoid battery overdischarge. At this time, all
loads are disconnected.
So the priority loads should be connected to the MCB of LOAD1, that is the Route1 to Route 3 in Figure 2-12. The
normal loads should be connected to the Route 4 to Route 11 in Figure 2-12.
Step 3: Connect loads
As shown in Figure 2-13, connect the negative polarity of every load to the lower terminal of the MCB with a negative
cable, and connect the positive polarity of the load to the bolt on the positive busbar that has one M6 bolt and seven
M4 bolts.
Note
The tools and body shall be insulated strictly before applying a load when the system is powered on to avoid shortcircuit.

Terminal for
connecting load

Positive busbar Grounding bar AC phase line (L) Neutral line (N)

Figure 2-13

Terminals for connecting load and AC power

Note
The L & N terminals above are divisional interface of AC SPD and power subracks instead of AC input terminals.
Step 4: Connect AC power cables
Connect the AC input grounding cable to the grounding bar shown in Figure 2-13 or the grounding bar outside the
battery compartment of the cabinet.
Connect the AC input neutral line to the wiring point below the MCB N shown in Figure 2-13.
Connect the AC input phase line to the wiring point below the MCB L shown in Figure 2-13.
Note
1. The grounding cable shall be connected first, then the neutral line and finally the phase lines.
2. The AC cables should be routed from the MCB in the external distribution equipment prepared by user. They should be
connected to the MCB just before the system is powered on. The external distribution equipment should have some protection
devices to fulfill the overcurrent, shortcircuit and lightning protection functions.
3. The AC cables should be identified with color labels to identify the phase line, neutral line and grounding cable.
4. The AC cables should be routed away from the DC cables.
Step 5: Re-install the cover
Re-install the cover to the distribution unit after completing the connection.

APM200 Outdoor Power Supply System User Manual

Chapter 2 Installation

13

2.6.4 Connecting Battery Cables


Step 1: Switch on the AC input MCB and battery MCB
The positions of the AC input MCB and the battery MCB are shown in Figure 2-14.

Battery MCB

AC input MCB

Figure 2-14

Position of AC input MCB and battery MCB

Step 2: Check if the polarities of the battery cables are correct


Check the polarities of the battery cables in the battery compartment with a multimeter. The black cable should be
negative pole and the red cable should be positive pole. The cable in the middle is middle voltage sampling cable of
the battery, as shown in Figure 2-15. If the polarity is incorrect, please contact Emerson.
Negative battery cable

Middle voltage sampling cable of the battery

Positive battery cable

Negative battery cable

Middle voltage sampling cable of the battery

Figure 2-15

Battery cables

Step 3: Connect battery cells


Switch off the battery MCB and AC input MCB. Connect the battery cells with the cables delivered with the battery
according to the battery user manual.
Step 4: Connect the battery string to the cabinet
Connect the blue and black cables in the battery compartment respectively to the negative and positive terminals of
the battery string. Connect the voltage sampling cable to the middle voltage terminal of the battery.
Step 5: Recheck if the polarities of the battery cables are correct
Check the polarities of the battery cables again after completing the connection. Make sure that the blue cable in the
battery compartment is negative and the black cable is positive. If the cable polarity is incorrect, repeat Step 4.

2.7 Installation Inspection


After installation, the following inspection procedures should be taken.

2.7.1 Cabinet Inspection


1. Check the fixing of the cabinet on the floor. Check if the cabinet is horizontally, vertically and steadily fixed.
APM200 Outdoor Power Supply System User Manual

14

Chapter 2 Installation
2. Check if all the screws are screwed down, especially the screws in electrical connections. Check if all the bolts have
plain washers and spring washers and if the bolts are reversely fastened.
3. Check if there are unwanted materials inside the cabinet. Clear up the unwanted materials.
4. Check if the cabinet is collided to injury and if the paint is intact (If there is injury, repaint it immediately to prevent
corrosion).
5. Clean up the cabinet. Remove dust and feculence in time.
6. Check if the door is unjamming, if the lock is in good condition and if the door stay bar is fixed.
7. Check if the dummies are installed at the reserved space where no customer device is installed. If the dummies are
not installed, install them immediately.

2.7.2 Cable Connection Inspection


1. Measure the resistance value between the positive terminal and negative terminal and phase- to - phase resistance
value in the AC loop. Make sure there is no shortcircuit.
2. Check the AC input and distribution. Check if the AC cable color is normative, if the cables are made fast, and if the
safety labels are complete. Please refer to Appendix 4 Wiring Diagram and check the AC cable connection.
3. Check if the connection point, line sequence and polarities of DC and battery cables. Check if the connection points
are fixed and the cable connections are correct and reliable.
4. Check if the SPD PE cable and grounding cable are correctly connected and if the contacts are reliable.
5. Check the communication cables of the monitoring module. Check if the rectifiers are fastened down.
6. Check if the SPD MCB is switched on and other MCBs are switched off.
7. Check if the cables are tidy, and if the cable binding is normative.

APM200 Outdoor Power Supply System User Manual

Chapter 3 Testing

15

Chapter 3 Testing
3.1 Introduction
The cabinet, rectifiers and monitoring module are subject to vibrations during shipment. More over, mistakes might be
made during system installation. If the system is powered on in haste, a fatal accident may occur and the whole power
supply system may be damaged. Therefore, the system must be tested strictly after it is installed.
Conduct the test procedures carefully and observe the system in the mean time. Shut down the system in case of any
abnormal phenomenon and continue the test after the fault is eliminated.

3.2 Testing AC Distribution


Step 1: Check if the PE cables are reliably connected and the AC cables are correctly connected to the system
according to the system schematic diagram (refer to Schematic Diagram), and if the screws are loose before powering
on the system.
Step 2: Switch on the residual current operated circuit breaker (RCCB). Switch off all MCBs (put the handles down) in
the subrack and the distribution unit. Switch on the SPD MCBs, as shown in Figure 3-1.

RCCB

Figure 3-1

MCB positions

Step 3: Make sure that there is no short circuit in the input and output terminals of the AC
Step 4: Switch on the MCB in the external distribution equipment to power the system. Measure the voltages of the
input terminals of the AC MCBs. Check the external distribution equipment if the voltages are abnormal.
Step 6: Switch on the battery MCB.
Step 5: Switch on the AC MCBs and the operation indicators (green) on the rectifier panels should turn on. Otherwise,
check the distribution unit carefully.

3.3 Testing Rectifier


Step 1: Make sure that there is no short circuit in the input and output terminals of the rectifier and there is no loose or
damaged component inside the rectifier.
Step 2: Switch on the AC MCBs. The green indicator on the rectifier panel turns on and the red indicator is on for
several seconds. The rectifier starts after a start delay and then operates normally. At this time, only the green indicator
is on and the fan will stop several minutes later if no load is applied to the system.
Step 3: Measure the DC output voltage of the system with a multimeter. It should be 53.5V0.5V.
Note
Only the engineers from Emerson can adjust the output voltage of the rectifier. After the system test is completed, the output
voltage needs not to be adjusted any more unless the rectifier is replaced with a new one.

3.4 Testing Monitoring Module


The monitoring module must be tested with a host.
APM200 Outdoor Power Supply System User Manual

16

Chapter 3 Testing

3.4.1 Setting System Parameters


Upon delivery, the default parameters of the monitoring module may be inconsistent with the actual situation or your
needs. In that case, you should configure the system parameters through the host before the system testing.
According to the communication protocol, the parameters that you can query through the host are listed in the
following table.

Remotely acquired alarm/digital signal

1) AC Mains On/Off
2) AC Mains Status
3) DC Bus Voltage Status
4) Load MCB Status
5) System Current-Limiting Status
6) Load Connection/Disconnection Status
7) Battery Connection/Disconnection Status
8) Battery MCB Status
9) Ambient Temperature/Humidity Status
10) Door Status Sensor
11) Water Sensor Status
12) Smoke Sensor Status
13) Rectifiers Operation Status
14) System Control Mode and Battery BC/FC Status

Remotely acquired analog signal

1) AC Input Voltage
2) DC Busbar Voltage
3) Rectifier Total Output Current
4) Battery String Current
5) Ambient Temperature/Humidity
6) Battery Temperature

15) 7 Standby Digital Signal Status


16) 2 Digital Signal Output Status
17) Battery Discharge Test Phase Status
18) Battery Charge Over-Current Status

Remote-control parameters

Parameters that can be queried

Remotely acquired alarm/digital signal

Table 3-1

1) Rectifier On/off Control


2) BLVD & LLVD
3) FC/BC Status Control
4) Start/End Battery Capacity Test

According to the communication protocol, the parameters that you can configure through the host are listed in the
following table.
Table 3-2

Parameter
AC Input Under-Voltage Alarm Point
AC Input Over-Voltage Alarm Point
DC Busbar Low Voltage Point

DC Busbar Under-Voltage Alarm Point


DC Busbar Over-Voltage Alarm Point
LLVD Status
LLVD Voltage*
BLVD Status

Configurable parameters

Range
> 60V and lower than AC Over-Voltage Alarm Point
Between AC Under-Voltage Alarm point and 300V
1, When LLVD enabled: LLVD Voltage
2, When LLVD disabled but BLVD enabled: BLVD voltage
3, When both LLVD and BLVD disabled: 35V
Between DC Busbar Low Voltage Point and 2V below FC
voltage
58V ~ 60V and 1V higher than BC voltage
Disabled, Enabled
Between BLVD voltage (when BLVD is disabled: >35V) and
DC Busbar Under-Voltage Alarm Point
Disabled, Enabled

Default value
180V
280V
46.5V/47.5V/35V
(depending on the BLVD
Status and LLVD Status)
48.5V
58V
Disabled
47.5V
Enabled

BLVD Voltage*

35V but lower than LLVD voltage (when LLVD is disabled,


lower than DC Busbar Under-Voltage Alarm Point)

46.5V

Ambient Temp Alarm Lower Limit


Ambient Temp Alarm Upper Limit
Ambient Humidity Alarm Lower Limit
Ambient Humidity Alarm Upper Limit
Standby Digital Signal Alarm Level
Number and Addresses of Rectifiers
System Control Mode

-50C ~ 100C and lower than upper limit


-50C ~ 100C and higher than lower limit
0%RH ~ 100%RH and lower than upper limit
0%RH ~ 100%RH and higher than lower limit
High level alarm 1, low level alarm 0
(1, 1), (2, 1, 2), (3, 1, 2, 3)
Host Control, Auto

0C
50C
10%RH
80%RH
High level alarm 1
(3, 1, 2, 3)
Auto

APM200 Outdoor Power Supply System User Manual

Chapter 3 Testing
Parameter

Number of Battery Strings

Range
BC, FC
43.2V ~ 57.6V, between FC voltage and 1V below DC Busbar
Over-Voltage Alarm Point
43.2V ~ 57.6V, between BC voltage and 2V below DC Busbar
Under-Voltage Alarm Point
0~1

Capacity of Battery String

30Ah ~ 600Ah

FC/BC Status
BC voltage
FC voltage

Coefficient of Charge Current Limiting


0.1 ~ 0.25
Point
Scheduled BC Interval
30 days ~ 240 days
Temp Compensation Coef. of Battery
0mV/C ~ 500mV/C
String
Temp Measurement Lower Limit
-50C ~ 0C
Temp Measurement Upper Limit
0 C ~ 100 C
Humidity Measurement Lower Limit
0%RH ~ 100%RH and lower than Upper Limit
Humidity Measurement Upper Limit
0%RH ~ 100%RH and higher than Lower Limit
Power Distribution Analog Signal
Not configurable by the user
Calibration Coefficient
Battery Over-Temp Protection Point
40C ~ 70C
Note*: The LLVD voltage and BLVD voltage should be set according to battery manufacturer instructions

17

Default value
FC
56.5V
53.5V
1
100Ah (when no specific
requirement is made)
0.15
60 days
80mV/C
-50C
50 C
0%RH
100%RH

53C

When setting system parameters through the host, please note that:
1. Make sure that the power system address set at the host is identical with the address set through the DIP switch, or
the communication will fail.
2. Make sure that the rectifier number is set consistent with the actual condition. After a rectifier is added to or removed
from the power system, the rectifier number parameter must be accordingly modified, or a rectifier alarm will be raised.
3. The battery string capacity setting is customized according to order requirement before delivery. If there is no
specific capacity requirement in the order, the default battery string capacity is 100Ah. If the actual battery capacity is
different from that, reset it through the host to make the configuration consistent with the actual situation and prevent
improper battery management. Note: the battery string capacity (200Ah and 100Ah) can be set by DIP switch.
4. The DIP switch is in the PCB board of the monitoring module, as shown in Figure 3-2. Pull out the monitoring
module (hot pluggable) before changing the DIP switch settings. Then you can change the DIP switch settings.
Description of DIP switch settings are given in Table 3-3.
Table 3-3

DIP switch
1~4
5

Description
Communication address
Reserved

Dry contact status

7
8

Battery capacity
Communication protocol

Description of DIP switch settings

Settings

Default setting

ON: 1; OFF: 0
ON: dry contact switched- off is normal; switched- on
generates alarm. OFF: dry contact switched- on is normal, OFF
switched- off generates alarm
ON: battery capacity 200Ah; OFF: battery capacity 100Ah 100Ah
ON: GSM protocol; OFF: WCDMA protocol
WCDMA protocol

Note:
Communication address setting uses 8421 code. DIP switch 4 corresponds to 8, DIP switch 3 corresponds to 4, DIP switch 2
corresponds to 2, DIP switch 1 corresponds to 1

DIP switch

Communication
address

Figure 3-2

DIP switch

APM200 Outdoor Power Supply System User Manual

Communication protocol
Battery capacity
Dry contact status
Reserved

18

Chapter 3 Testing

3.4.2 System Function Test


After setting the system parameters, you can go on to carry out the system function test.
For the requirements of the test on system AC over/under-voltage alarm and protection are rather strict, you do not
need to do them. After all, the system has passed strict tests before delivery.
Battery auto-management test
Cut off AC mains supply and power the load with the battery for above 15 minutes ( 1 minute), then recover the AC
mains, all rectifiers will be in current-limiting BC status.
During the current-limiting BC status, it is normal that the rectifier output voltage is sometimes below 53.5V.
For the test of battery auto-management has strict requirements for the system, it is not necessary to carry out this test
if your test conditions are limited.
Rectifier on/off test
Set the control mode to background control through the host software and try turning on/off each module. The
corresponding module should act correctly.
Note to change the control mode to automatic control after the test is finished.
Under-voltage alarm and LLVD/BLVD test
Cut off the AC power and power the load with batteries. Set the DC under-voltage alarm point, LLVD and BLVD voltage
to higher values to shorten the test duration. Then observe the battery under-voltage alarm, LLVD and BLVD situation.
The monitoring module should send out the corresponding alarms one by one. The red indicator on the front panel of
monitoring module should be on, and the dry contact controlling the external audible/visual alarm equipment should
output alarm signal.
Recover the AC power, restore the settings of under voltage alarm point, LLVD and BLVD voltage, and the above
alarms should disappear.
Rectifier on position test
Set the power system address and rectifier number correctly, insert and pull out the rectifiers one by one, and the host
should display the communication state of corresponding rectifiers correctly.
Battery MCB off alarm test
Connect the battery to the system, and switch off its MCB. There should be a corresponding battery MCB off alarm
raised at the host. The alarm will disappear when the MCB is turned on.
Load MCB off alarm test
Connect a load to the system and switch off its MCB. There should be a corresponding load MCB off alarm raised at
the host. The alarm will disappear when the MCB is turned on.
Note
1. If the terminal of corresponding load and battery route is not connected with load or battery during the test, but is suspended,
the MCB Off Alarm for corresponding load or battery may not be reported accurately.
2. Make sure that system configurations are restored to normal status after the test.
Viewing operation information
After the system power on, you can get simple operation information through the indicators on the monitoring module
front panel. For detailed information, you must query through the host.
Canceling battery protection
If you think it more important powering the loads than protecting the battery, thus do not want the battery protection in
the case of mains failure, you can set the LLVD and BLVD status to Disabled through the host.
Note
When the battery is discharged to the BLVD voltage, the battery backup time is very short. It is impossible to obtain long time
operation of loads by sacrificing the battery.

APM200 Outdoor Power Supply System User Manual

Chapter 4 Maintenance

19

Chapter 4 Maintenance
Inspect the outdoor power supply system periodically and shoot the trouble in time.

4.1 Embedded Power Supply System Maintenance


4.1.1 System Operation
After installation and testing, the system is ready for use. When necessary, it can be put into normal operation just by
switching on the corresponding MCB. During the operation, the following issues may call your attention:
Fan speed control technology
The fan may run for a second and stop when the rectifier is powered on for the first time. If load is connected to the
system, the inner temperature of the rectifier will increase after operation for a period of time, and the fan will begin
running and speed up with the increase of inner temperature. That phenomenon is due to the fan speed adjusting
technology, and thus absolutely normal.
Over temperature protection
A rectifiers inner temperature may be high during operation. If you reset it by turning it off and on at that time, you may
observe that the rectifier has no output but the fan is running. That is because the OTP circuit within is working. The
output will recover after the temperature decreases 1 minute later.
If the fan does not run, and the rectifier has no output for more than 5 minutes, the rectifier may have been damaged.
Please replace the faulty rectifier or contact Emerson local service center.

4.1.2 Indicator Description


Indicator description of the rectifier
The appearance of the rectifier is shown in Figure 4-1. There are 3 indicators on the panel: ALM (alarm indicator),
FAN-ALM (indicator of fan faulty alarm) and RUN (power indicator)

Figure 4-1

Rectifier appearance

When the rectifier runs in normal condition, the power indicator RUN is on, and the other two indicators are off. When
fan failure occurs, FAN- ALM indicator is on and RUN indicator is off. When other faults or protection alarm occur, ALM
indicator is on and RUN indicator is off. The operation state of the rectifier should be estimated according to the
indicator state when maintenance.

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20

Chapter 4 Maintenance
Indicator description of the monitoring module
The appearance of the monitoring module is shown in the following figure. There are 2 indicators on the panel: RUN
(power indicator) and ALM (alarm indicator). Descriptions are as shown in Table 4-1.

Figure 4-2
Table 4-1

Indicator
Meaning
Normal
No system alarm, with abnormal communication
System alarm, with normal communication
System alarm, with abnormal communication

Appearance of monitoring module

Monitoring module indicator description

RUN indicator (green)

ALM indicator (red)

Slow blinking (Once per second)


Fast blinking (Once per 120ms)
Slow blinking (Once per second)
Fast blinking (Once per 120ms)

Off
Off
On
On

4.1.3 Routine Maintenance


Fan maintenance
Dust will accumulate on the baffle plate if the rectifier works in a dusty and windy environment. To ensure long-term
reliable and smooth operation of the rectifier, it is necessary to clean the fan regularly (once 6 months).
In addition, the fan performance will deteriorate after long-term operation. You need to replace the fan regularly (once
every 3-5 years).
Fan replacing method:
1. Remove the fan baffle plate
2. Remove the screws on the top right corner of the fan
3. Pull out the power cable
4. Replace the fan with a new one
5. Connect the power cable, and fix the fan with the screw on the top right corner
6. Mount the baffle plate back

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Chapter 4 Maintenance

21

The fan structure is shown below:

Figure 4-3

Fan of the rectifier

Note
1. Only trained professionals are allowed to clean and replace the fan.
2. Do not touch any internal parts of the rectifier during fan maintenance.
Rectifier pull-out & plug-in
Upon abnormities, the rectifier may need to be pulled out and plugged in. The rectifiers and monitoring modules are all
hot swappable.
To pull out the rectifier, you should first draw out the handle at rectifier front panel to detach the latch at rectifier bottom
from the distribution frame. Then you can pull the rectifier out by the handle. The handle position is shown in Figure
4-4.
When replacing new monitoring modules, communication cable and signal cable shoule be connected as well. See
Figure 4-4.
Signal cable to the
expanding board

Communication
cable to the
expanding board
Figure 4-4

Monitoring
module

Rectifier

Handle of the
monitoring
module

Handle of the
rectifier

Handle of the modules

Note
The rectifiers connecting part is a delicate device. Although the rectifiers are designed to be hot swappable, the pull-out and
plug-in operation should be gentle lest the connecting part should be damaged. Non-professionals are not allowed to replace the
rectifier on-line.

APM200 Outdoor Power Supply System User Manual

22

Chapter 4 Maintenance

4.1.4 Common Faults Handling


Fault Symptom1:
The rectifier quits operation automatically and a corresponding alarm is raised at the host.
Solution: replace the faulty rectifier.
Fault Symptom2:
Rectifier(s) is/are shut down upon over-voltage and the corresponding alarm is raised at the host.
Solution: 1) Upon single rectifier shutdown: Switch off the faulty rectifier. Wait till its indicators are off, and switch it on
again. If the over-voltage still exists, the rectifier may have been damaged and need replacing. 2) Upon
multiple-rectifier shutdown: Pull output all rectifiers and insert them one by one to find out the real faulty one. Replace
the faulty rectifier after confirmation.

4.2 Battery Maintenance


Refer to the battery user manual supplied with the battery. (Note: It is recommended to use T12V100SEF/A battery
within this system. If you choose to use battery of other models, please consult with Emerson to prevent improper
configuration.)

4.3 Heat Exchanging Equipment


The heat exchanging equipment consists of an internal fan and a heat exchanger. Its position is shown in Figure 4-5.

Cable
connector

Heat
exchange
equipment

Fixing
screws

Figure 4-5

Position of heat exchanging equipment

The internal fan rev is settable. The higher the temperature of the equipment compartment is, the larger the internal
fan rev is.
Replace the internal fan or adjust the fan position if it stops running or there is an abnormal noise in it. And clean the
heat exchanger if there is much dust on it. The procedures are as follows.
Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, as shown in Figure 4-5. Do
not disconnect when power is on.
Step 2: Remove the fixing screws shown in Figure 4-5 and then remove the heat exchanging equipment from the
cabinet.
Step 3: Remove the screws that fix the cover and the internal fan baffle and then remove the cover and the baffle, as
shown in Figure 4-6.
Cover
Screws for fixing the
cover (4 pieces)
Fan baffle

Screws for fixing the


baffle (3 pieces)
Figure 4-6

Remove the cover and baffle

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Chapter 4 Maintenance

23

Step 4: Remove the fixing screws of the internal fan shown in Figure 4-7. Adjust the fan position or replace the fan with
a new one. Take out the heat exchanger to clean it if there is much dust on it.
Heat exchanger

Fan screws
(4 pieces)

Internal fan
position

Figure 4-7

Remove internal fan and heat exchanger

Step 5: Follow step 5 to step 1 to install the new fan and the clean heat exchanger into the cabinet. Take care when
installing the heat exchanger to avoid damaging the waterproof bar on it.

4.4 External Fan Maintenance


The external fan rev is settable. The higher the temperature of the equipment compartment is, the larger the external
fan rev is. Replace the external fan or adjust the fan position if it stops running or there is an abnormal noise in it. The
procedures are as follows.
Step 1: Disconnect the cable connector at the left side of the heat exchanging equipment, and disconnect the fan
cables from the terminals, as shown in Figure 4-8. Do not disconnect when power is on.
Cable connector of the
heat exchange
equipment

Heat exchange
equipment

External fan
Cable connector of the
external fan

Fixing
screws

Fixing
screws
Figure 4-8

Positions of heat exchanger and external fan

Step 2: Remove the fixing screws of the heat exchanging equipment shown in Figure 4-8, and then remove the
equipment.
Step 3: Remove the fixing screw of the fan box shown in Figure 4-4 and then remove the fan box.
Step 4: Remove the fixing screw of the external fan shown in Figure 4-9. Adjust the fan position or replace it with a new
one.

Fixing screws
of external
fan (4 pieces)

Figure 4-9

External fan

Remove the external fan

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Chapter 4 Maintenance
Step 5: Follow step 4 to step 1 to install the new fan into the cabinet. Install the heat exchanging equipment into the
cabinet. Take care when installing the heat exchanging equipment to avoid damaging the waterproof bar on it.

4.5 Replace Heaters And Relays


The two heaters of the system do not need to be repaired. Be sure to pay attention to their operation status. The
heaters will heat when the environment temperature is below 5C5C, and stop heating above 15C5C. If they
operate abnormally, check the heater relays (refer to section 4.6.3). If the relays operate abnormally, replace them.
Otherwise, replace the heaters.

4.5.1 Replace The Heater In Equipment Compartment


Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-10.

Panel of distribution unit


Figure 4-10

Heater MCB

AC input MCB

Position of AC MCB and heater MCB

Step 2: Remove the panel of the distribution unit, as shown in Figure 4-11. The position is shown in Figure 4-10.

Figure 4-11

Remove the panel of the distribution unit

Step 3: Unscrew the 4 pieces of screws on the panel of the distribution unit and then remove the right segment of the
distribution unit. Do not disconnect its components and cables and be sure to pay attention to personnel safety.
Screw 2

Screw 1
Figure 4-12

Screw 3

Screw 4

Screw positions

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Chapter 4 Maintenance

25

Step 4: Unscrew the fixing screws of the heater cover and disconnect the cable connector from the heater relays. The
heater relays are the two cables marked L and N in Figure 4-14. Remove the heater cover. The heater is fixed on the
heater cover, as shown in Figure 4-13.
Heater cover

Screws
Heater

Heater of the equipment


compartment
Figure 4-13

Disassembly of the equipment compartment heater

Cable connector of
the heater

Cable connector of
the heater

Figure 4-14

Heater relays

Step 5: Unscrew the fixing screws of the heater on the heater cover and then remove the damaged heater, as shown in
Figure 4-12.
Step 6: Fix the new heater on the heater cover and mount the cover on the cabinet. Connect the cable connector to the
heater relay. Finally, mount the distribution unit on the cabinet.
Step 7: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse
after making sure every thing is OK.

4.5.2 Replace The Heater In Battery Compartment


Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-10.
Step 2: Take out the battery string on the lower floor of the battery compartment.
Step 3: Disconnect the cable connector from the heater relay. Remove the heater cover after removing the screws on
the cover, as shown in Figure 4-15.

Heater of the battery


compartment

Figure 4-15

Position of the heater in battery compartment

Step 4: Replace a new heater and fix it. Connect the cable connector to the heater relay. Move the battery string to its
original position.

APM200 Outdoor Power Supply System User Manual

26

Chapter 4 Maintenance
Step 5: Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and heater fuse
after making sure every thing is OK.

4.5.3 Replace Heater Relays


There are two heater relays in one heater circuit. When the environment temperature is below 5C 5C, the relay
contacts are closed to switch on the heater circuit. When the environment temperature is above 15C 5C, the relay
contacts are opened to switch off the heater circuit. Replace the relay if its contact cannot be closed or opened
normally. Every compartment has two heater relays that are connected in series in the phase line and the neutral line
separately, as shown in Schematic Diagram.
The position of the heater relay in equipment compartment is shown in Figure 4-14, and that of the heater relay in
battery compartment is shown in Figure 4-16.

Heater relay of the


battery compartment

Figure 4-16

Position of the heater relay in battery compartment

Replacement processes:
Step 1: Switch off the AC MCB and the heater fuse, as shown in Figure 4-7.
Step 2: Disconnect the cable connector of the relay and remove the screws.
Step 3: Replace a new relay and connect the cable connector of the relay to its terminal.
Step 4: Switch on the AC MCB and the heater fuse.

4.6 Replace Door Status Sensors


There is one door status sensors installed in the equipment compartment and the battery compartment separately for
detecting the close or open status of the compartment doors. The two sensors are connected in series, so the
monitoring module will generate an alarm when one of the doors is open. The alarm will be eliminated only when both
doors are closed.
The door status sensors are not intended for service or repair, just replace them when they are damaged. If the doors
are closed, when the door status sensor alarm occurs, the sensors must have been damaged. The positions of the
sensors are shown in Figure 4-17.
Remove the sensor cap and then the two pieces of screws. Replace the old sensor with a new one and finally fix the
sensor and the signal cables with the screws.

APM200 Outdoor Power Supply System User Manual

Chapter 4 Maintenance

Door status
sensor A in
equipment
compartment

27

Door status
sensor B in
equipment
compartment

Door status
sensor B in
battery
compartment

Door status
sensor A in
battery
compartment

Figure 4-17

Replace door status sensor

4.7 SPD Maintenance


The AC SPD is behind the distribution unit. The appearance is shown in Figure 4-18.

Figure 4-18

AC SPD

Check the SPD indicator on the monitoring expansion board, as shown in Figure 4-19. The position of the monitoring
expansion board is shown in Figure 1-2.

Alarm indicator of DC SPD


Alarm indicator of AC SPD

Figure 4-19

AC/ DC SPD indicator

If the indicator on the left is on, the DC SPD fails and needs replacement. The replacement procedures of the DC SPD
are easy to take and not expatiated on here. If the indicator on the right is on, the AC SPD fails and needs
replacement.
The replacement procedures of AC SPD are as follows:
Step1: Switch off the AC MCB. The position is shown in Figure 4-10.
Step 2: Remove the cover of the distribution unit. The position is shown in Figure 4-10.

APM200 Outdoor Power Supply System User Manual

28

Chapter 4 Maintenance
Step 3: Remove the 4 screws shown in Figure 4-12, pull out the SPD alarm interface and remove the right segment of
the distribution unit, as shown in Figure 4-20.

Alarm interface

Figure 4-20

Pull out the SPD alarm interface

Step 4: Remove the four fixing screws of the SPD shown in Figure 4-21. Disconnect the cables connected to the SPD.

SPD fixing screws

Figure 4-21

SPD and heater

Step 5: Reverse previous steps 4~1 and replace the new SPD. Connect the cables; fix the screws and the SPD.
Step 6: Fix the distribution unit to the cabinet.
Check if each cable connector is tight and the connection is reliable. Switch on the AC MCB and restart operation after
making sure everything is OK.

APM200 Outdoor Power Supply System User Manual

Appendix 1

Technical Data

29

Appendix 1 Technical Data


Environmental parameters
1. Operating temperature:
North model: -40C to +45C; South model: -5C to +45C;
2. Storage temperature: -40C to +70C
3. Relative humidity: 5% to 100%, no condensing
4. Altitude: 0 to 2000m. The system should be derated where the altitude is higher than 2000m. The highest operating
temperature should be reduced by 1C at every 200m higher. And the highest altitude is 4800m.
5. Solar radiation
2

Direct radiation: 1120W/m

Dispersion radiation: 224W/m2

Electrical parameters
1. Rated input voltage: 220Vac
2. Input voltage range: 90Vac to 290Vac, single phase three wire. When the voltage input is between 90Vac~176Vac,
the rectifiers output is allowed of linear derating. When the voltage input is 90Vac, the minimum rectifier output power
is 37.5% of rated power.
3. Maximum input current of the system: 25A (with no user connector- jack output)
4. Maximum output current of standard configuration: 60A
5. Rated frequency: 50Hz
6. Input frequency range: 40Hz to 65Hz
Mechanical parameters
APM200 dimensions (H W D): 1600mm 600mm 600mm (without base)
APM200 weight: 450kg
Battery compartment dimensions (H W D): 280mm 490mm 520mm
Audible noise
65dB.
Anti-erosive performance
Coating:
1. Adhesion test satisfies ISO2409 Class 0.
2. The pencil rigidity test satisfies ASTM D3363 2H.
3. Shock test satisfies 50kg.cm according to ASTM D2794.
4. The coating is not changed after 500 hours salt-fog test according to ASTM B117.
5. The coating of the external surface of the cabinet is suitable at the -40C to +55C environmental temperature and
2
1120W/m solar radiation. The coating should not blister, flake or flaw after 250 hours test according to ASTM D822.
But it is allowed to have slight pulverization, that is, a little paint particle is allowed to adhere when the coating is wiped
at full tilt. The slight change of color is allowed, that is, it is acceptable if the color difference value (NBS) is less than
6.0.
Protection requirement
1. The cabinet of the equipment compartment satisfies GB4208 IP55.
2. The cabinet of the battery compartment satisfies GB4208 IP34.
Lightning protection
1. The system has a Level B+C SPD on AC side.
2. The AC input can withstand the maximum strike through current capacity of 60kA, and the nominal through current
capacity is 25kA. The simulated lightning strike is carried out in term of YD1235.1 and YD1235.2.
3. The test of which the DC side can withstand through current capacity of 10kA requires: -48V-RTN can withstand the
strike of 10kV with the waveform 8/20s 5 times, for positive and negative polarity respectively 5 times, and the
APM200 Outdoor Power Supply System User Manual

30

Appendix 1 Technical Data


interval between every two tests is one minute; RTN-PE can withstand the strike of 10kV with the waveform 8/20s 5
times, for positive and negative polarity respectively 5 times, and the interval between every two tests is one minute.

APM200 Outdoor Power Supply System User Manual

Appendix 2

Definitions Of The Monitoring Expansion Board Interface

31

Appendix 2 Definitions Of The Monitoring Expansion


Board Interface
All the sensors are connected to the monitoring expansion board. The screen print diagram of the wiring port of the
monitoring expansion board is as follows.

Screen print of Monitoring expansion board socket

Figure 1

Screen print diagram of the monitoring expansion board

Connector models of the monitoring expansion board terminals and recommended connection cables are in the
following table.
Table 1

Connector models and recommended connection cables

Signal port

Screen print marks

Socket- connector model

commended cables(AWG)

Waterlogging
Circumambient temperature/ humidity
main distribution frame
Smoke sensor
Door status sensor
Alarm dry contact
Optical- coupler output
Backup digital data input
RS422 communication port
Preset dry contact port

J_WATER
TEM_HU
J_WIRE
J_SMOKE
JTM1
JK1,JK2
JAC1,JAC2
J9
J8
J12

P2500-4
P2500-4
P2500-2
P2500-2
P2500-2
P2500-2
P2500-2
MSTB2.5/2-ST-5.08
MSTB2.5/4-ST-5.08
MSTB2.5/2-ST-5.08

26~22
26~22
26~22
26~22
26~22
26~22
26~22
26~22
26~22
26~22

The functional definitions of port- pins of the monitoring expansion board are shown in the following table.
Table 2

Port name

Screen print marks

Backup digital value

J9

Waterlogging sensor port

J_WATER

Port of the circumambient


temperature/ Humidity
TEM_HU
sensor

Battery- temperature
sensor port

Optical- coupler1
controlling output port

Port- pin definitions of the monitoring expansion board

BAT_WE

JAC1

Correlative pins
1,3,5
2,4,6
1
2
3
4
1
2
3
4
1
2
3

Signal properties
+24V output
Input of the signal cable
+12V output
Input of the signal cable
Earth cable
None
+24V output
Input of the temperature signal cable
+24V output
Humidity signal cable input
Earth cable
Battery- temperature signal cable input
+12V output

+12V output

1
2

Optical- coupler1 controlling output


Optical- coupler1 controlling output

APM200 Outdoor Power Supply System User Manual

Remark

Check the batterycompartment


temperature.
Connected before
delivery.

32

Appendix 2 Definitions Of The Monitoring Expansion Board Interface


Port name
Optical- coupler2
controlling output port

Screen print marks


JAC2

Port of mains distribution


frame sensor

J_WIRE

Door status sensor port

JTM1

Smoke sensor port

J_SMOKE

Alarm dry contact port

JK1

Alarm dry contact port

JK2

Port of the Equipmentcompartment temperature EQU_WE


Sensor

Battery- balance test port

J4

Load MCB switchable test


J3
port
SPD failure test port on
DC side

J5

SPD failure test port on AC


J6
side

Fan- control port

J_FAN

RS422 communication
port
Preset dry contact port

Expansion board power


input port

J8

Correlative pins
1
2
1
2
1
2
1
2
1
2
1
2
1

3
4
1
2
3
4
5
6

Signal properties
Optical- coupler2 controlling output
Optical- coupler2 controlling output
main distribution frame signal input
+48V power output
Door status sensor signal input
+24V power output
Smoke signal inout
+24V power output
dry contact1 output
dry contact1 output
dry contact2 output
dry contact2 output
Earth cable
Signal cable input of equipment
compartment temperature
+12V output
+12V output
BUS+ input
BAT1 mid- voltage input
BAT2 mid- voltage input
BUS- input
None
None

1~7

7 Load MCB monitoring signal input

-48V power output

SPD failure of the DC side signal input

-48V power output

SPD failure of the AC side signal input

Power output

Signal output of fan speed

3
4
5

Signal input of fan failure


Power- earth cable
Power output

Fan speed signal output

7
8
1
2
3
4

Signal input of fan failure


Power- earth cable
TX+
TXRX+
RX-

J12

1~8

J2

1
2

Remark

Connected before
delivery
Connected before
delivery
To internal fan.
Connected before
delivery

To external fan.
Connected before
delivery

RLn+,RLnBusbar+
Busbar-

Remark:
The descriptions of the dry contact port presetting is as follows:
When the DIP switch 6 is switched to OFF, the dry contacts are closed when normal and are open upon alarms.
When the DIP switch 6 is switched to ON, the dry contacts are open when normal and are closed upon alarms. The
following description are given in case of DIP switch 6 switched to OFF.
Dry contact 1: dry contact of AC/ DC SPD alarm are preset closed (normal state), and open upon AC/ DC SPD alarms.

APM200 Outdoor Power Supply System User Manual

Appendix 2

Definitions Of The Monitoring Expansion Board Interface

33

Dry contact 2: dry contact of mains failure alarm are preset closed (normal state), and open upon mains shortage,
mains over/ under- voltage alarm occurs.
Dry contact 3: dry contact of DC under- voltage alarm are preset closed (normal state), and open upon DC undervoltage alarm occurs.
Dry contact 4: dry contact of system power alarm are preset closed (normal state), and open upon rectifier failure,
rectifier protection, rectifier communication abnormal, busbar output over/ under- voltage alarm, charging over- current
alarm, battery string route disconnection or internal/ external fan fault alarm occur.

APM200 Outdoor Power Supply System User Manual

34

Appendix 3 Schmatic Diagram

Appendix 3 Schematic Diagram

AC
INPUT

AC input
L

F1

1QF1
2

Lin

Alarm

Thermostat

Nin

L
N

Nout

PE

HEATER 1

Heater of the
equipment
compartment

KT2

Thermostat

XS

SPD

KT1
2

1QF3

XT1

Lout

1QF2

HEATER 2
PE

KT3

Thermostat

PE

Heater of the
battery
compartment

KT4

Thermostat

PE

EMI

Standby digital value


RS485 port

AC/DC
AC/DC

MONITOR

AC/DC

Dry contact

AC/DC

+
48V
-

PSM
FL1

FL2

KM1

2QF1
16A

2QF2
25A

2QF3
25A

LOAD 1 LOAD 2 LOAD 3

OUTPUT

KM2

2QF4
25A

2QF5
40A

2QF6
50A

LOAD 4

LOAD 5

LOAD 6

FAN1

2QF7
80A

External fan

XT2 1

-48V output

0V busbar

Figure 2

FAN2

Internal fan

Door sensor of the


equipment compartment

BATT.1 BATT.2

DC

Temperature sensor of the


equipment compartment
Temperature sensor of the
battery compartment

Monitoring
transfer
board

9 10 11
F2

0V -48V
SPD11DZ
Alarm

Door sensor of the battery compartment

PE busbar inside the cabinet

Schematic diagram of APM200 outdoor power supply system

APM200 Outdoor Power Supply System User Manual

PE busbar outside the cabinet

Appendix 4

Wiring Diagram

Appendix 4 Wiring Diagram

21
FAN

20
PCB

W08 37

W8

39

FAN1
c
c
+

FAN2
c
c
+

J2

J12

J8

W07

34

36

33

35

J11
J3

Screen print of the


monitoring expansion
board socket

01
PD

22
PSM

PSM-BB

J4
J_FAN

W12

B1- B2-

W11 47

B1+ B2+

JK1

JAC1

JAC2

J_SMOKE

TEM_HU JK2

J_WIRE

BAT_WE

J_WATER

RS485

J5 J6

W10

EQU_WE
JTM1

W09

J7

W08
W10

J9

LOAD1-

LOAD2- LOAD3-

LOAD4-

LOAD5-

LOAD6-

BATT.(-)

SPD- LOAD+

BATT.(+)

J1

W13 50

W11 47
01

02

03

04

05

06

08

10

41

40

11A 11B
W02

W02

W01
10
SPD1

W12 48

Standby
temperature
measurement of
equipment
compartment

12
KT1

11
HEATER

Heater of the N
equipment
compartment L

SPD1

27 22 21 19 18

W05

39

W10 45A

W06 31

W06 30

02
-48V

1 2

3 4 5 6

7 8

9 10 11

04
SPD2

20

28

0V -48V

W10 45

W04

To AC output cable of the subrack

W08

Temperature
measurement of
equipment
compartment

SPD2

06
LCB

05
SOCKET

07
TEM.

08
MCB

09
MCB

25

PE Alarm
W02 07 09
Battery temperature
compensation

13
KT2

KT2
KT1

32

W12 49
03
0V

W03

W06

0VDC BUS
W03
-48VDC OUTPUT

W10 46

23

29

18
MJ

17
W03

14

AC INPUT

17
PE

24

42

PE busbar

Bottom door 44
sensor

W09

12,13

Cross-door cable
(up and down)

Upper door
sensor 26

W03

15

43
W08 38

16
HEATER

19
BAT.

Heater of the L
battery
compartment N

14
KT3

15
KT4

KT3
KT4

PE busbar outside the cabinet

1# Battery

W03

16

Equipotential cable

W08 38

2# Battery

Figure 3

Wiring diagram of APM200 outdoor power supply system

APM200 Outdoor Power Supply System User Manual

35