sjzl20092663-ZXDU68T301 (V4.1R01M01) Installation Manual PDF

ZXDU68 T301
DC Power System
Installation Manual
Version 4.1R01M01
ZTE CORPORATION
ZTE Plaza, Keji Road South,
Hi-Tech Industrial Park,
Nanshan District, Shenzhen,
P. R. China
518057
Tel: (86) 755 26771900
Fax: (86) 755 26770801
URL: http://ensupport.zte.com.cn
E-mail: support@zte.com.cn
LEGAL INFORMATION
Copyright © 2006 ZTE CORPORATION.
The contents of this document are protected by copyright laws and international treaties. Any reproduction or distribution of
this document or any portion of this document, in any form by any means, without the prior written consent of ZTE CORPO-
RATION is prohibited. Additionally, the contents of this document are protected by contractual confidentiality obligations.
All company, brand and product names are trade or service marks, or registered trade or service marks, of ZTE CORPORATION
or of their respective owners.
This document is provided “as is”, and all express, implied, or statutory warranties, representations or conditions are dis-
claimed, including without limitation any implied warranty of merchantability, fitness for a particular purpose, title or non-in-
fringement. ZTE CORPORATION and its licensors shall not be liable for damages resulting from the use of or reliance on the
information contained herein.
ZTE CORPORATION or its licensors may have current or pending intellectual property rights or applications covering the subject
matter of this document. Except as expressly provided in any written license between ZTE CORPORATION and its licensee,
the user of this document shall not acquire any license to the subject matter herein.
ZTE CORPORATION reserves the right to upgrade or make technical change to this product without further notice.
Users may visit ZTE technical support website http://ensupport.zte.com.cn to inquire related information.
The ultimate right to interpret this product resides in ZTE CORPORATION.
Revision History
Revision No. Revision Date Revision Reason

1.1 2009–07–21 1. Produce update
2. First edition
Serial Number: sjzl20092663

Contents
About this Manual .............................................. i

Safety Instructions............................................1
Safety Signs .................................................................. 1
Safety Precautions.......................................................... 2
Installation Overview ........................................5
Installation Introduction .................................................. 5
Installation Flow ............................................................. 5
Installation Precautions ................................................... 6
Cabinet Dimensions and Weight........................................ 7
Components Location...................................................... 8
Installation Slots Configuration ........................................12
Installation Preparation .................................. 13
Installation Preparation Flow ...........................................13
Documentation Preparation.............................................13
Trained Professionals......................................................14
Tools Preparation ...........................................................14
Installation Site Inspection .............................................17
Equipment Installation .................................... 21
Equipment Installation Flow ............................................21
Installing the Cabinet on Floor.........................................22
Installing Top Cap..........................................................26
Installing Dust Cap ........................................................29
Installing the Monitoring Unit ..........................................31
Installing the Rectifiers...................................................31
Installation Check..........................................................33
Electrical Connection ....................................... 35
Electrical Connection Flow...............................................35
Precautions in Electrical Connection .................................36
Connecting Cables .........................................................38
Common Methods of Cable Connection .........................38
Circuit Breaker Connection .................................38
Copper Busbar Connection .................................38
Fuse Connection ...............................................39
Connecting Grounding Cable .......................................40
Connecting AC Input Cables ........................................42
Connecting AC Output Cables ......................................45
Connecting DC Output Cables......................................47
Connecting Battery Cables ..........................................48
Connecting Signal Cables............................................50
Requirements for Bundling Cables....................................53
Electrical Connection Check ............................................55
System Commissioning and Debugging ........... 57
Commissioning and Debugging Flow.................................57
Check Before System Startup..........................................58
Check Flow Before System Startup...............................58
AC Distribution Unit Check ..........................................59
Rectifiers Check.........................................................60
Monitoring Unit Check ................................................60
DC Distribution Unit Check..........................................60
Batteries Check .........................................................61
System Commissioning ..................................................61
Batteries Input ..............................................................62
System Debugging ........................................................63
Parameters Setting in Commissioning...........................63
Rectifiers Load Sharing Quality Check...........................64
System Shutdown with Fault ...........................................66
Operation of Fuse Extractor ............................ 67
Electrical Connection Diagram......................... 69
Figures ............................................................ 73
Tables ............................................................. 75
About this Manual
Purpose of this ZXDU68 T301 (V4.1R01M01) DC power system has a -48VDC out-
Manual put. The system adopts three-phase five-wire AC input. When
configured to full capacity, it can be equipped with six ZXD2400
50A switching mode rectifiers, forming a power supply system of
300A output capacity.
This document is one of the following manuals for the equipment:
� ZXDU68 T301 (V4.1R01M01) DC Power System Installation
Manual
This manual provides the information to install the equipment.
This manual is intended for the installation personnel.
� ZXDU68 T301 (V4.1R01M01) DC Power System User Manual
This manual describes the application, features, technical spec-
ifications, appearance and structure, operating principles, net-
working mode and the monitoring unit operation instructions,
operation and maintenance. This manual is applicable to every
user.
What is in this This manual contains the following chapters and appendixes:
Manual
Chapter/Appendix Summary
Describes the safety instructions and

Chapter 1 Safety
precaution for the installation, maintenance
Instructions
and operation of the system.
Chapter 2 Installation Describes the system installation flow and

Overview precautions.
Describes the installation requirements,

Chapter 3 Installation
installation preparations and unpacking
Preparation
acceptance for the system.
Describes the procedure and method to install

Chapter 4 Equipment
the cabinet, monitoring unit, rectifier and
Installation
battery of the system.
Chapter 5 Electrical Describes the process and method of

Connection connecting the external cables of the system.
Chapter 6 System
Describes the process and method of
Commissioning and
debugging the system.
Debugging
Appendix A Operation
Describes how to use a fuse extractor.
of Fuse Extractor
Appendix B Electrical Provides the diagram of the electrical

Connection Diagram connections.
Confidential and Proprietary Information of ZTE CORPORATION i

ZXDU68 T301 Installation Manual
This page is intentionally blank.
ii Confidential and Proprietary Information of ZTE CORPORATION

Chapter 1
Safety Instructions
Table of Contents
Safety Signs ...................................................................... 1
Safety Precautions.............................................................. 2
Safety Signs
TABLE 1 SAFETY SIGNS
Safety Signs Meaning
Danger: Indicates an imminently hazardous

situation, which if not avoided, will result in death
or serious injury. This signal word should be
limited to only extreme situations.
Warning: Indicates a potentially hazardous

situation, which if not avoided, could result in
death or serious injury.
Caution: Indicates a potentially hazardous

situation, which if not avoided, could result in
minor or moderate injury. It may also be used to
alert against unsafe practices.
Note: Indicates a potentially hazardous situation,

which if not avoided, could result in injuries,
equipment damage or interruption of services.
Erosion: Beware of erosion.
Electric shock: There is a risk of electric shock.
Electrostatic: The device may be sensitive to

static electricity.
Microwave: Beware of strong electromagnetic

field.
Confidential and Proprietary Information of ZTE CORPORATION 1

Safety Signs Meaning
Laser: Beware of strong laser beam.
No flammables: No flammables can be stored.
No touching: Do not touch.
No smoking: Smoking is forbidden.
Safety Precautions
This chapter describes safety precautions for the installation,
maintenance and operation of the system.
Read the safety instructions before any operation of the equip-
ment. The safety precautions mentioned in this manual only serve
as a supplement to the local safety codes.
Only trained professionals are allowed to install, operate and main-
tain the equipment. ZTE bears no liability to the consequences in-
curred by violation of the general safety operation requirements,
or violation of the safety standards for designing, manufacturing
and using the equipment.
The precautions for operating the power supply products are listed
in Table 2.
TABLE 2 SAFETY PRECAUTIONS
S/N Precautions Requirement Possible Danger
� Observe the
local safety
codes during
the equipment
installation.
The installation
personnel must Direct contact or
be qualified for indirect contact with
high voltage high voltage and
1 High voltage and AC power mains through damp
operations. object will endanger
� Never wear the operator’s life.
any conductive
object, such as
watch, hand
chain, bracelet
or ring during
the operation on
the equipment.
2 Confidential and Proprietary Information of ZTE CORPORATION

Chapter 1 Safety Instructions

� Prevent any
moisture from
entering the
equipment
during
operations
ZXDU68 T301
system is a power DC short circuit can
DC short supply product of cause fatal danger
2
circuit constant DC voltage. and damage to the
DC short circuit must equipment.
be avoided.
� Switch OFF
the power
supply before
connecting or Performing power
disconnecting a cable operation
Connecting or power cable. with power ON will
3 disconnecting � Before cause fatal danger to
power cable connecting a operation personnel
cable, make and damage to the
sure that the equipment.
cable and its
label are in
accordance with
the requirement.
When operating
high-voltage Tools-caused short
equipment, tools circuit can cause
4 Tools safety safety must be fatal danger to
considered. Insulate operation personnel
the tools to prevent and equipment.
short circuit.
Insulate the Static electricity

Electrostatic uncovered metals generated by human
5
damage to prevent short body may damage
circuit. components.
In the case of
environment
over-temperature,
Over-temperature
improve the
will affect normal
Temperature ventilation of
6 operation and service
effect the equipment
life of the power
to keep the
product.
suitable operating
environment for the
system.

� Before
performing any
operation on
battery, read � The electrolyte
the safety leakage of battery
precautions can corrupt PCB
on the battery and cause short
manual. circuit.
� Perform battery � When the
cable connection environment
according to temperature is
instructions. below 20℃, the
Operation on
7 Avoid short efficiency and
battery
circuit and performance of
electrolyte the battery will
leakage. be affected; when
� The the environment
recommended temperature is
operation over 25℃, the
environment battery service life
temperature for will be affected.
battery ranges
from 20℃ to
25℃.

Chapter 2
Installation Overview
Table of Contents
Installation Introduction ...................................................... 5
Installation Flow ................................................................. 5
Installation Precautions ....................................................... 6
Cabinet Dimensions and Weight............................................ 7
Components Location.......................................................... 8
Installation Slots Configuration ............................................12
Installation Introduction
ZXDU68 T301 system installation consists of the equipment instal-
lation and cables connection.
� Equipment installation
� Equipment cabinet installation
� Monitoring unit installation
� Rectifiers installation
� Installation check
� Cables connection
� Grounding cables
� AC input cables
� AC output cables
� DC output cables
� Batteries cables
� External signals cables
Installation Flow
The installation flow is shown in Figure 1.

FIGURE 1 INSTALLATION FLOW
Refer to Table 3 for the description of the steps involved in the

system installation.
TABLE 3 STEPS DESCRIPTION
Step Title Task
1 Installation � Preparing installation site

preparation � Perming safety inspection
� Preparing Tools and documents
� Unpacking for inspection
2 System installation � Install the cabinet, the monitoring unit, rectifiers and
batteries.
� Check the installation
3 Electrical � Connect the grounding cable, AC input cables, AC output

connection cables, DC output cables, battery cables and signal cables.
� Check the electrical connection.
4 System System check before startup ,startup and commissioning, joint

commissioning commissioning , system shutdown.
Installation Precautions
The installation methods of all parts and cables have been de-
scribed in detail in this manual, but the practical installation may
vary with the difference in installation sites and equipment. It is
desirable if the installation personnel can follow the methods in

Chapter 2 Installation Overview
this manual and flexibly use them by considering the real site sit-
uations.
During installation, the installation personnel should follow the re-
lated operating rules and ensure safe operation.
Cabinet Dimensions and

Weight
The cabinet has 1.6 m height (An optional top cap with 0.4 m
in height can be added). Figure 2 shows the dimensions of the
ZXDU68 T301 cabinet.
FIGURE 2 ZXDU68 T301 CABINET APPEARANCE
The top cap of the ZXDU68 T301 system is shown in Figure 3.

FIGURE 3 TOP CAP APPEARANCE
The dimensions and Weight of the ZXDU68 T301 system are shown
in Table 4.
TABLE 4 ZXDU68 T301 SYSTEM DIMENSIONS AND WEIGHT
System Dimensions (Height × Width × Weight

Depth)
ZXDU68 T301cabinet 1600 mm × 600 mm × 400 mm 78 kg (excluding the

rectifiers and the
monitoring unit)
Top cap 400 mm × 598 mm × 400 mm 9.5 kg
Components Location
ZXDU68 T301 components are as shown in Figure 4.

FIGURE 4 CABINET STRUCTURE
1. Top cap
2. Power indicator
3. Alarm indicator
4. Cabinet a foot (adjustable)
5. DC distribution unit
6. Monitoring unit connecting boards
box
7. Rectifiers
8. AC distribution unit
9. DC surge arrester
10. LLVD control device
11. Monitoring unit
12. Fuse extractor holder

Components of DC The structure of the DC distribution unit is as shown in Figure 5.

Distribution Unit
FIGURE 5 DC DISTRIBUTION UNIT STRUCTURE
1. Working ground busbar (+48 V) 4. LLVD control device

2. LLVD1 load air switches and fuses 5. DC surge arrester
3. LLVD2 load air switches 6. Battery fuses
Components of AC The module structure is based on the user requirement.

Distribution Unit
� AC input mode 1– Single air switch (standard configuration) :
The AC input has no auxiliary output and the input switch is
configured with a single 3 phase air switch.
� AC input mode 2– Single air switch (optional configuration) :
The AC input has an auxiliary output and the input switch is
configured with a single 3 phase air switch.
Note:
In the aforementioned two modes, the AC distribution unit
structure is as shown in Figure 6.
� AC input mode- Double air switch (optional configuration) : In

this case, the AC input can have an auxiliary output and the
input switch is configured with two 3 phase air switches. The
AC distribution unit structure is as shown in Figure 7.

FIGURE 6 AC DISTRIBUTION UNIT STRUCTURE (SINGLE AIR SWITCH)
1. Rectifiers air switches 4. Protection ground busbar (PE)

2. AC lightning arrester (AC SPD) 5. Neutral cable terminal (N)
3. AC Transducer 6. AC input single air switch
FIGURE 7 AC DISTRIBUTION UNIT STRUCTURE (DOUBLE AIR SWITCH)
1. Rectifiers air switches

2. AC lightning arrester (AC SPD)
3. AC Transducer
4. Protection ground busbar (PE)
5. Neutral cable terminal (N)
6. AC input double air switch
7. AC auxiliary output air switch

Note:
For AC input double air switch, only one of the air switches should
be turned on /off at a time.
Installation Slots
Configuration
The number of rectifiers for each of the three phases L1, L2 and
L3 should be basically identical in order to maintain phase balance
and favor a good radiation.
The distribution of the slots and phases of the rectifiers is shown
in Figure 8.
FIGURE 8 INSTALLATION SLOTS CONFIGURATION

Chapter 3
Installation Preparation
Table of Contents
Installation Preparation Flow ...............................................13
Documentation Preparation.................................................13
Trained Professionals..........................................................14
Tools Preparation...............................................................14
Installation Site Inspection .................................................17
Installation Preparation Flow

Before system installation, preparations should be made by refer-
ring to Figure 9.
FIGURE 9 INSTALLATION PREPARATION FLOW
Documentation Preparation
Prepare the installation design, the construction details and the
delivery-attached documentation.

Trained Professionals
Only trained professionals are allowed to perform installations.
Please query the user manual or contact the local office of ZTE
for any question during operation. Operations without security
confirmation should be avoided.
Tools Preparation
TABLE 5 DESCRIPTION OF TOOLS AND INSTRUMENTS
Picture Name Function
Philips screwdriver Used to fix screws
Straight Used to fix screws

screwdriver
Wrench Used to fix screws
Torque wrench Used to fasten expansion

bolts
Nail hammer Used to install expansion

bolts

Chapter 3 Installation Preparation
Cutter Used to prune cable ties
Cable crimper Used to crimp network cables
Cable peeler Used to peel off the cable

skins
Liquid pressure Used to bond flat lugs

crimper

Percussion drill Used to drill holes
Tape Used to measure distance
Angle square Used to measure distance
Horizontal ruler Used to check horizontal

deviation
Plumb calibrator Used to check vertical

deviation
Multimeter Used to measure resistance

and voltages, and check
continuity relationship and
so on

Cable tie Used to bind cables
Gloves Wear them during installation
Installation Site Inspection

Before installation, make sure that the installation site complies
with the following requirements:
Environment The environment requirements for the installation are as below:
requirements
� The construction of the equipment room shall be completed,
and the indoor walls shall be dry.
� The height and width of the doors of the equipment room
should not obstruct the equipment transportation.
� The equipment room should be neat and clean.
� If the equipment room has antistatic moveable floor, the
floor should be laid firmly, the support of floor should be
well grounded and the grounding resistance and antistatic
measures should meet the requirements.
� The grounding wire should be laid according to the require-
ments .
� Air conditioners used in the equipment room should be installed
and have desirable performances.
The temperature/humidity and air pressure meet the requirements
stated in Table 6.
TABLE 6 ENVIRONMENT REQUIREMENTS
Item Requirement
Temperature Operating temperature: -5°C to +45°C

(+ 15°C to +25°C recommended). Air
conditioners are required to control the
temperature of the equipment room.
Storage temperature:–40°C to +70°C

Item Requirement
Humidity Relative humidity: 10% to 90% (40% to

60% recommended). Air conditioners are
required to control the temperature of the
equipment room.
Air pressure 70 kPa to 106 kPa
Grounding � Joint grounding

requirements
Joint grounding is used in telecommunication buildings. Work-
ing ground, lightning protection ground and protection ground
share the same grounding electrode. They are connected to
the grounding busbar of the equipment room.
The basic principle of common bonding network is to short-cir-
cuit the grounding copper bus-bar and DC power ground of the
system with the equipment room grounding bus-bar. The light-
ning protection ground and the protection ground of the power
system should be connected to a nearby grounding copper bus-
bar of the power system.
The AC neutral wires should be grounded separately and should
not be connected to the grounding busbar or grounding net-
work of the power equipment. In three-phase five-wire mode
and single-phase three-wire mode, the protection grounding
(PE) cable can be directly connected to the grounding busbar
of the power system.
� Grounding resistance
The grounding resistance of the equipment room should com-
ply with the requirements in Table 7.
TABLE 7 REQUIREMENTS FOR GROUNDING RESISTANCE IN

COMMUNICATION STATIONS
Scope of Application Grounding Resistance
Integrated building, international <1 Ω

telecom bureau, tandem exchange,
SPC exchange (10,000 lines or more)
and toll exchange (2,000 lines or
more)
SPC exchanges of 2000 to 10,000 <3 Ω

lines, and toll exchanges of no more
than 2000 lines
SPC exchange of less than 2,000 lines, <5 Ω

fiber terminal station, carrier repeater
station, earth station, microwave
junction center station, and mobile
communication base station
Microwave relay stations, fiber relay <10 Ω

stations, and small-sized earth
stations
Passive microwave relay stations <20 Ω

Scope of Application Grounding Resistance
Applicable to the lightning-proof <10 Ω

grounding at the joint of the power
cable and overhead power cable with
the earth resistance less than 100 Ωm

the earth resistance of 101 Ωm to
500 Ωm

the earth resistance of 501 Ωm to
1000 Ωm
Power source It is recommended to use mains as the active AC power supply

requirements of ZXDU68 T301 system. A diesel generator and storage batteries
should be prepared according to actual situation of the local mains.
If the power factor of the load is lower than 0.7, reactive power
compensation device must be installed to ensure that the power
factor exceeds 0.8.
Take reliable lighting protection measures before leading AC mains
into the equipment. The outdoor power cable of AC lead-in should
be buried directly or with tube.
Safety The following should be checked:
requirements
� The equipment room should be equipped with applicable and
effective fire fighting apparatus and the alarm detection device
(if any) should be in good condition.
� Various power sockets in the equipment room should be iden-
tified with obvious marks.
� Never store any flammable or explosive materials in the equip-
ment room.
Installation site Before the equipment installation, check the installation site as
requirements follows:
� Check the ground groove, floor, and wiring hole for the equip-
ment installation.
� Check the environment for the equipment installation.
� Check the conditions required for installation and construction,
for example, the power supply and lighting.
� Check the conditions for the working of the equipment, includ-
ing AC power supply and grounding cables.
Lightning In a lightning-prone area, reliable multi-class lightning protection
protection system should be configured at the place of introducing the mains
requirements and the equipment building. Lightning protection requirements
are listed in Table 8.

TABLE 8 LIGHTNING PROTECTION REQUIREMENTS
Item Description
Class B arrester Class B lightning arrester is purchased and

installed by the user.
The lightning discharging current of the class

B arrester should be greater than 60 kA.
It is required that the cables between the

class B lightning arrester and the AC power
distribution unit of the equipment room
should be located indoors, thus to prevent
the cables from being exposed directly to
lightning strike.
The cables, especially the grounding wire of

the lightning arrester, should be as short as
possible.
Class C arrester The class C lightning arrester is installed at

the input port of the AC distribution unit of
ZXDU68 T301 system.
DC lightning box The DC lightning box is installed at the input

port of the DC distribution unit of ZXDU68
T301 system.

Chapter 4
Equipment Installation
Table of Contents
Equipment Installation Flow ................................................21
Installing the Cabinet on Floor.............................................22
Installing Top Cap..............................................................26
Installing Dust Cap ............................................................29
Installing the Monitoring Unit ..............................................31
Installing the Rectifiers.......................................................31
Installation Check..............................................................33
Equipment Installation Flow

Figure 10 shows the equipment installation flow.

FIGURE 10 EQUIPMENT INSTALLATION FLOW
Installing the Cabinet on

Floor
Context Install the cabinet if the floor of the equipment room is not anti-
static. The installation flow is shown in Figure 11.

Chapter 4 Equipment Installation
FIGURE 11 INSTALLATION FLOW
Steps 1. Select the position to install the cabinet.

The basic requirement for the installation position is sufficient
space, as shown in Figure 12. In addition, the installation posi-
tion should be convenient for cable leading-in and leading-out,
convenient for operation & maintenance and have good venti-
lation.
� The gradient should be less than 5°.
� The space in front of the cabinet should be greater than or
equal to 1.5 m.
� Provide enough space at the cabinet rear side, for good
ventilation and operation/maintenance purposes.

FIGURE 12 REQUIREMENTS FOR THE POSITION OF THE CABINET
2. Determine the position for the expansion bolts on the floor.

Determine the positions to install the expansion bolts according
to the cabinet orientation and the holes at the cabinet bottom.
Mark the center of the holes on the floor.
Note:
When installing the cabinet on floor, the position of the holes
to install the expansion bolts on the floor should match the
position of the holes on the cabinet bottom.
FIGURE 13 HOLES POSITION
3. Drill holes and install the expansion bolts.

i. Drill holes with an electric drill.

Select the Ф14 electric drill, with the aperture of 14 mm

and hole depth of 70 mm. When drilling holes, avoid any
deviation caused by the vibration of the drill. Make sure
that the holes are vertical to the floor. The drilling operation
is shown in Figure 14.
FIGURE 14 DRILLING HOLES
ii. Fix expansion bolts.

Insert the expansion bolt into the hole and put a flat washer,
spring washer and nut on the bolt in turn. Screw down the
nut clockwise with a spanner to fix the expansion bolt in the
hole and keep 30 mm of expansion bolt above the ground,
as shown in Figure 15. After installing the expansion bolts,
take off the nut, spring washer and flat washer.
FIGURE 15 INSTALLING EXPANSION BOLTS
1. Nut 4. Installed expansion bolt

2. Spring washer 5. Part of the expansion bolt
3. Flat washer inside the floor
4. Place the cabinet.

i. Unscrew and remove the four feet of the cabinet.
ii. Place the cabinet with the expansion bolts inserted inside
the holes at the bottom of the cabinet, as shown in Figure
16.

FIGURE 16 PLACING THE CABINET
5. Adjust the position and gradient of the cabinet and fix it.
i. Adjust the gradient less than 5° by inserting an iron plate
under the lower side of the cabinet.
ii. Put flat washer, spring washer and nuts to the expansion
bolt, and tighten the nuts one by one.
END OF STEPS
Installing Top Cap

Prerequisites A 400 mm height top cap can be installed on top of the 1600 mm
height cabinet.
Context The top cap has the following characteristics:
� Weight: 9.5 kg
� External dimensions: 400 mm x 598 mm x 400 mm (H x W x
D).
� The structure is composed of two side plates, one front plate
and one rear plate, as shown in Figure 17.
� The installation sequence is the following: Side plates installa-
tion®Front and rear plates installation.

FIGURE 17 TOP CAP STRUCTURE
The top cap appearance is as shown in Figure 18.
FIGURE 18 TOP CAP APPEARANCE
Caution:
� Prevent the top cap from falling during installation.
� Use an insulated cross screwdriver to fix the bolts.
Steps 1. Fix the side plates of the top cap with M5 x12 bolts, as shown
in the following figure.
2. Install the front plate
Make sure that the strip is in the same alignment with stop
hole.

3. Fix the front plate with M5 x12 bolts and install the flat head
screw cover to cover the bolts.
4. Open the cabinet front door to fix the M5 x12 bolt on the lower
side of the front plate.

5. Use the same procedure as mentioned above to install the rear

plate.
END OF STEPS
Installing Dust Cap

Prerequisites Install a dust cap on cabinet top to protect the cabinet against
dust. It is an optional component.
Context Dust cap is composed of many dust cap units. The two sides are
provided with fire protection sponges and both extremities are pro-
vided with oval holes.
FIGURE 19 DUST CAP APPEARANCE
The number of dust caps, as shown in Figure 20, is evaluated

according to the lead out cables requirements on the top of the
cabnet. A maximum of five dust caps can be installed on ZXDU68
T301 system.

FIGURE 20 DUST CAPS ON CABINET TOP
Note:
� Strip off both sides or a single side of the dust cap unit to adjust
the lead-out cable spacing.
� The installation sequence of dust caps is from the most front
end of the cabinet top to the rear end.
� After installing all the dust caps, make sure that there is no
spacing in between them.
Steps 1. Install the first dust cap.

2. Use M5 x 12 bolt to fix the dust cap unit, as shown below.
3. Use the same procedure to install the other dust caps. The
overall structure is as shown below.
END OF STEPS

Installing the Monitoring Unit

Context Refer to the section “Installation Slots Configuration” for the loca-
tion of the monitoring unit.
Steps 1. Grasp the handle with one hand. Hold the monitoring unit with
another hand and push it slowly into the monitoring unit slot
of the cabinet with equal force.
2. Screw the fastening bolt to connect the monitoring unit firmly.
END OF STEPS
Installing the Rectifiers

Context � The quantity of rectifiers for each phase L1/L2 /L3 should be
the same if possible to ensure a three-phase balance and a
good ventilation.
� Each rectifier should be installed in a slot, as shown in the
section “Installation Slots Configuration”.
� After the rectifier is inserted properly, electrical connection be-
tween the rectifier and the system is established and no more
connection cable is required.

Caution:
Do not touch the interfaces at the back of the rectifier, especially
the input/output integrated socket. The internal circuit of recti-
fiers has large capacitors, so there may be electricity on these
interfaces.
Steps 1. Fix the rectifier 1 in slot 1 of the cabinet

i. Use one hand to grasp the handle of the rectifier and the
other hand to hold the rectifier. Push the rectifier slowly to
slot 1 of the cabinet with even force.
ii. The rectifier is in the proper position when the stop pin is
locked (we can hear a “click” noise).
2. Repeat step 1 to fix other rectifiers to their corresponding slots.

END OF STEPS

Installation Check
Check each item listed in Table 9 . The installation is not acceptable
unless the check result of each item is checked as Y.
TABLE 9 INSTALLATION CHECK LIST
No. Requirements Check Result
1 The installed cabinet stands firmly upright, Y□N□

looking nice and tidy.
2 The vertical inclination of the installed cabinet Y□N□

is less than 5°.
3 All the screws are tightened securely, and the Y□N□

necessary flat washers and spring washers
are complete and installed correctly.
4 There is no needless material on the cabinet. Y□N□
5 The cabinet is free from any scratches, Y□N□

damages from shocks, or paint coming off.
6 The cabinet is clean, without dust or dirt. Y□N□
7 The door of the cabinet closes and opens Y□N□

easily, and the lock of the door is normal and
operational.
8 The rectifiers are firmly installed. Y□N□
9 The monitoring unit is firmly installed. Y□N□


Chapter 5
Electrical Connection
Table of Contents
Electrical Connection Flow...................................................35
Precautions in Electrical Connection .....................................36
Connecting Cables .............................................................38
Requirements for Bundling Cables........................................53
Electrical Connection Check ................................................55
Electrical Connection Flow

Figure 21 shows the flow of connecting the electrical cables.

FIGURE 21 ELECTRICAL CONNECTION FLOW
Precautions in Electrical
Connection
Danger:
High voltages are present in the installation of ZXDU68 T301 sys-
tem. Direct contact with or indirect contact through wet objects
with high voltages or mains supply may result in deadly danger.
Before any connection, make sure that all the breakers/switches
of the equipment are turned off.

Chapter 5 Electrical Connection
1. Cables requirements
� Select the cables colors according to Table 10.
TABLE 10 REQUIREMENTS FOR CABLES COLORS
Cable Color
AC cable Three-phase live wire (L1) Yellow
Three-phase live wire (L2) Green
Three-phase live wire (L3) Red
Single-phase live wire (L) Red
Neutral wire (N) Blue
PE cable Yellow/green
DC cable (+) cable Red
(-) cable Blue
Note:
To use AC cables of the same color, please select black
cables. Mark the cables clearly to avoid confusion.
The requirements for cable color may vary in countries.
Please observe the local rules for cable color.
� It is recommended to use AC cables with copper core. And

the cross-sectional area of cables should match the load.
The recommended current density ranges from 2.5 A/mm2
to 4.0 A/mm2 to calculate the cross-sectional area of a ca-
ble.
� The grounding cable should be a stranded copper core wire,
whose cross-sectional area is half of the input phase wire.
� There should be no joints in the middle of any cable.
2. Cabling requirements
� In the top cabling mode, distribute cables overhead. Keep
the distance between the cabling rack and the top of the
cabinet more than 300 mm.
� In the bottom cabling mode, distribute cables along troughs
with the width less than the distance between two adjacent
installation holes of the cabinet.
� Lay out the DC cables, AC cables and the signal cables
separately. Don’t tie them to the same bundle. In case
that the three kinds of cables have to be laid in the same
cable trough, make the distance between them at least 200
mm.
3. Connection requirements

� The electrical connections should be safe and reliable and

meet the specifications. Make sure that all the switches of
the equipment are OFF before wiring.
� Make sure that the neutral wire is always properly con-
nected and will not be open in any case.
� Fully insulate the connection terminals, contacts and other
exposed parts.
� The grounding cable should be as short and straight as
possible.
Connecting Cables
Common Methods of Cable
Connection
Circuit Breaker Connection

Context Figure 22 shows the circuit breaker connection.
FIGURE 22 CIRCUIT BREAKER CONNECTION
1. Cable 3. Screwdriver
2. Air switch
Steps 1. Strip away the insulation material from the ends of the cable.
2. Connect this cable to the breaker and tighten it.
END OF STEPS
Copper Busbar Connection

Context Figure 23 shows the copper busbar connection.

FIGURE 23 COPPER BUSBAR CONNECTION
1. cable 4. Nut
2. Copper lug 5. Bolt
3. Flat washer 6. Copper busbar
Steps 1. Use the hydraulic tongs to crimp a cable to a proper-sized cop-

per lug.
2. Connect the copper lug to the copper busbar and tighten it.
END OF STEPS
Fuse Connection
Context Figure 24 illustrates how to connect the fuse.
FIGURE 24 CONNECTING THE FUSE
1. Cable 5. Nut
2. Copper lug 6. Bolt + Flat washer
3. Flat washer 7. Fuse
4. Spring washer

Steps 1. Use hydraulic tongs to crimp a cable to a proper-sized copper

lug.
2. Connect the copper lug to a fuse and tighten it.
END OF STEPS
Connecting Grounding Cable

Context Connecting the grounding cables involves connecting the PE cable
and connecting the working ground cable.
Caution:
To ensure the equipment safety, the PE cable should be connected
firstly and the connection should be reliable.
Steps 1. Connect the PE cable to the PE busbar and the grounding bus-
bar of the equipment room, as shown in Figure 25.
Note:
The grounding busbar of the equipment room is located at the
rear side of the cabinet . It is advised that the PE cable passes
underneath the cabinet.

FIGURE 25 CONNECTING PE CABLE
TABLE 11 PE CABLE CONNECTION DESCRIPTION
Cable name Color End A End B
PE cable Yellow-green PE busbar of the Grounding busbar of

cabinet the equipment room
2. Connect the working ground cable to the grounding busbar

of the equipment room and to the working ground busbar
(GND/+48 V), as shown in Figure 26.
Note:
It is suggested that the cable passes over the cabinet.

FIGURE 26 WORKING GROUND CABLE CONNECTION
TABLE 12 WORKING GROUND CABLE CONNECTION DESCRIPTION
Cable Name Color End A End B
Working ground cable Red/ black Working ground Grounding busbar of

busbar (GND/ +48 the equipment room
V)
END OF STEPS
Connecting AC Input Cables

Context ZXDU68 T301 system is equipped with two AC input modes (refer
to ZXDU68 T301 DC Power System (V4.1R01M01) User Manual for
more details ). This section shows how to connect the AC input
cables for each mode.

Warning:
� The AC input cables have high voltage. Make sure the AC input
will not be subjected to power failure during operation.
� Bind cables according to their related specifications.
� Lay the AC input cables separately.
� The neutral wire should not be connected to any air switch
/fuse. The terminals of the neutral and the phase should be
connected reliably, to avoid any damage.
� To ensure the system safety, it is recommended to connect first
the PE cable and make sure the connection is reliable.
Steps 1. Turn off the AC protection air switch outside the system. Turn
off the corresponding AC output air switches in the AC distri-
bution box.
2. Turn off the AC input air switch.
3. Connect the AC input cables
The AC input mode is based on user requirement. When the AC
input mode with single air switch is chosen, then the connection
is as shown in Figure 27.

FIGURE 27 CONNECTING AC INPUT CABLES (AC INPUT MODE WITH SINGLE AIR SWITCH)
TABLE 13 CONNECTION DESCRIPTION (AC INPUT MODE WITH SINGLE AIR SWITCH)
cable name Color End A End B
AC input L1 Yellow AC input air switch- AC distribution

L1 box-AC output L1
terminal
AC input L2 Green AC input air switch- AC distribution box-

L2 AC output L2 terminal
AC input L3 Red AC input air switch- AC distribution box-

AC input N Blue Neutral N AC distribution box-

AC output N terminal
For the AC input mode with double air switch the connection is
as shown in Figure 28.

FIGURE 28 CONNECTING AC INPUT CABLES (AC INPUT MODE WITH DOUBLE AIR SWITCH)
TABLE 14 CONNECTION DESCRIPTION (AC INPUT MODE WITH DOUBLE AIR SWITCH)
AC input L1 Yellow AC input air switch- AC distribution box-

AC input L2 Green AC input air switch- AC distribution box-

AC input L3 Red AC input air switch- AC distribution box-

AC input N Blue Neutral N AC distribution box-

AC output N terminal
END OF STEPS
Connecting AC Output Cables

Prerequisites � ZXDU68 T301 cabinet is configured with an AC auxiliary output
branch.

� The equipment has AC auxiliary output air switch.

Context When the AC auxiliary output power supply is needed, the AC aux-
iliary output cable is connected to the AC input terminal of the load.
Steps 1. Turn off the AC auxiliary output air switch of the cabinet.
2. Make sure that the Power switch of the AC load is turned off.
3. Connect the AC auxiliary cables:
FIGURE 29 AC AUXILIARY OUTPUT CABLES CONNECTION
TABLE 15 CONNECTION DESCRIPTION
AC auxiliary output phase ( L) Red AC auxiliary output AC input L

air switch- L terminal of AC
terminal load
AC auxiliary output neutral (N ) Blue N terminal N terminal of AC

load
Load protection earth cable (PE) Yellow-green PE terminal of AC Grounding busbar

load of the equipment
room
END OF STEPS

Connecting DC Output Cables

Context � The ZXDU68 T301 system supports several DC load output
branches. The negative pole of the DC output branch (DC Out-
put -48 V) uses fuses and air switches for connection.
� These fuses and air switches are located in the front side of the
cabinet. Their number is based on the user requirement.
� Furthermore, the LLVD1/LLVD2 configuration is also based
on the user requirement. The fuses/air switches under the
LLVD1/LLVD2 label, represent the DC output terminals of each
label.
Caution:
In order to extend the equipment (important load) operating time,
the DC output branch of the system falls into LLVD1 and LLVD2.
Therefore be careful when connecting load cables. Important loads
(such as transmission equipment) are connected to the LLVD2
branch and the less important loads are connected to the LLDV1
branch.
Note:
LLVD1: First low-level voltage disconnection. When the battery
voltage falls to a limit, the system will shut down less important
loads, which is called LLVD1. LLVD1 is to ensure that important
loads are powered for a longer time.
LLVD2: Second low-level voltage disconnection. When the battery
voltage falls to a lower limit, the system will shut down all the
loads, which is called LLVD2. LLVD2 is to protect battery from
over-discharge.
Steps 1. Make sure that the power switch of the DC load is off.
2. Remove the DC output fuse (or turn off the DC output air
switch). Cut off the DC output branch.
3. Connect the DC output Cables (+) and (-).

FIGURE 30 CONNECTING DC OUTPUT CABLES
TABLE 16 CONNECTION DESCRIPTION
Less important load n (+) Red Working ground DC load n1 (+)

busbar of the cabinet
Less important load n (-) Blue LLVD1 load fuses/ air DC load n1 (-)
switches
Important load n (+) Red Working ground DC load n2 (+)

busbar of the cabinet
Important load n (-) Blue LLVD2 load fuses/ air DC load n2 (-)
switches
END OF STEPS
Connecting Battery Cables

Prerequisites For each battery pack, disconnect one battery, to avoid electric
shock during the connection process.
Context The ZXDU68 T301 system supports two battery input branches.

Steps 1. Remove the battery fuses with a fuse extractor to disconnect

the battery branches.
2. Connect the battery cables:
i. Connect BATT1 cables
For safety , first connect one terminal of the battery cable
in the cabinet, and then connect the other terminal to the
output terminal of the battery pack BATT1.
FIGURE 31 BATT1 CONNECTION
TABLE 17 BATT1 CONNECTION DESCRIPTION
BATT1 (+) Red Cabinet’s working ground BATT1 (+) terminal

busbar
BATT1 (-) Blue Battery fuse 1 terminal BATT1 (-) terminal
ii. Connect BATT2 cables

For safety , first connect one terminal of the battery cable
in the cabinet, and then connect the other terminal to the
output terminal of the battery pack BATT2.

FIGURE 32 BATT2 CONNECTION
TABLE 18 BATT2 CONNECTION DESCRIPTION
BATT2 (+) Red Working ground busbar BATT2 (+) terminal

of the cabinet
BATT2 (-) Blue Battery fuse 2 terminal BATT2 (-) terminal
3. Connect the batteries that were disconnected in each battery

pack.
END OF STEPS
Postrequisite Measure the voltage of each battery pack terminal to make sure
that the terminals are not reversely connected .
Connecting Signal Cables

The following signal cables are involved:
� Battery temperature sampling cables.
� Environment parameters signal cables.

� Alarm output relay signal cables.

� Background monitoring cable.
Connecting One end of the battery temperature sampling cable is a tempera-
Battery ture sensor, and the other end is a two-pin plug.
Temperature
Sampling Cables The connection of battery temperature sampling cables is shown
in Figure 33.
FIGURE 33 BATTERY TEMPERATURE SAMPLING CABLES
TABLE 19 TEMPERATURE SAMPLING CABLES CONNECTION DESCRIPTION
Cable End A End B
BATT1 temperature Remove the paper X2 on SIB borad

sampling cable cover of the sensor,
and paste the sensor
onto BATT1
BATT2 temperature Remove the paper X3 on SIB board

sampling cable cover of the sensor,
and paste the sensor
onto BATT2
Connecting The environment parameters signal cable board collects the envi-
Environment ronment parameters and transmits them to the monitoring unit.
Parameters Signal Please refer to ZXDU68 T301 DC Power System (V4.1R01M01)
Cable User Manual for more details about the SIB board.
The connection method is described as follow:
� Select the environment parameters interface on the SIB board.
� Connect the environment parameters signal cable to the se-
lected interface.

Connecting Alarm The ZXDU68 T301 system has totally five alarm output relay inter-
Output Relay faces: X14, X15, X16, X17 and X18, all located on the SIB board,
Signal Cable as shown in Figure 34.
FIGURE 34 CONNECTING OUTPUT RELAY CABLES
The connection method is as follows:

� Select an alarm output relay interface on the SIB board.
� Connect the relay signal cable to the selected interface.
� Follow the procedure in the section “Setting Output Relays” of
ZXDU68 T301 DC Power System (V4.1R01M01) User Manual
to set each alarm to its corresponding output relay.
Connecting the Use a shielded cable as RS232 serial port cable for the connection.
Background The length of the cable should be less than or equal to 15 m.
Monitoring Cable
The connection procedure is described in Table 20.
TABLE 20 BACKGROUND MONITORING CABLE CONNECTION
Cable End A End B
RS232 serial X21 on SIB board (refer to PC (or remote/local

port cable Figure 35). ZXJ10 module or
SCM signal conversion
module) serial port.

FIGURE 35 CONNECTING BACKGROUND MONITORING CABLE
Requirements for Bundling

Cables
The ties to bundle the cables should comply with related specifi-
cations. Do not use connected cable ties to bundle the cables.
The specific requirements of bundling cables are:
� The cables should be routed in the grooves on the standing post
of the cabinet. Lay down the cables, which are connected to
sockets/connectors in such a way that the farthest cable comes
at the bottom in the cable bundle. Try to avoid interleaving of
cables, as shown in Figure 36.

FIGURE 36 CABLE LAYOUT REQUIREMENTS
� Do not twist the cables. Keep them level and straight. Bundle
the cables on both sides of a corner but not at the corner to
prevent the core from being broken due to stress at the corner,
as shown in Figure 37.
FIGURE 37 BUNDLING OF CABLES
� The space between the cable ties should be three to four times
of the diameter of the bundle, as shown in Figure 38.
FIGURE 38 DISTANCE BETWEEN CABLE TIES
� After bundling, cut the redundant parts of the cable ties neatly
from the root, without leaving any sharp cut, as shown in Fig-
ure 39.

FIGURE 39 CUTTING REQUIREMENT OF CABLE TIES
Electrical Connection Check

Check each item listed in Table 21 . The electrical connection is
not acceptable unless the check result of every item is “Y”.
TABLE 21 ELECTRICAL CONNECTION CHECK ITEMS
No. Requirements Check result
1 The color of the cables complies with the Y□ N□

related specifications.
2 The cross-sectional area, material and Y□ N□

insulation strength of the cables comply
with related specifications.
3 All the existing cables of the cabinet are Y□ N□

firm.
4 The grounding cable is properly and firmly Y□ N□

connected.
5 The cables are routed neatly and bundled in Y□ N□

accordance with the related specification.
6 All labels are correct, clear and complete. Y□ N□
7 The installation and cabling are conducive Y□ N□

to future reconfiguration, expansion and
maintenance of the system.
8 The quantity of installed batteries meets Y□ N□

the requirement.
9 The cables among the batteries are correctly Y□ N□

connected.
10 The positive and the negative battery cables Y□ N□

are correctly to the DC distribution unit.


Chapter 6
System Commissioning
and Debugging
Table of Contents
Commissioning and Debugging Flow.....................................57
Check Before System Startup..............................................58
System Commissioning ......................................................61
Batteries Input..................................................................62
System Debugging ............................................................63
System Shutdown with Fault ...............................................66
Commissioning and
Debugging Flow
Figure 40 shows the commissioning and debugging flow.
FIGURE 40 COMMISSIONING AND DEBUGGING FLOW

Warning:
Debug the system carefully and observe it while in operation. Ma-
jor accidents and/or entire damage to the equipment may result if
the user starts up the system rashly. Immediately shut down the
system if any abnormality occurs, and proceed with the debugging
after the abnormality is troubleshot.
Table 22 describes the commissioning and debugging task.
TABLE 22 COMMISSIONING AND DEBUGGING FLOW
Step No. Step Title Main Task
1 Check before system � Check AC unit

startup � Check rectifiers
� Check monitoring unit
� Check DC unit
� Check batteries
2 Startup and commissioning -
3 Batteries input -
4 Overall debugging � Set basic parameters

� Test equalized charge
Check Before System

Startup
Check Flow Before System Startup
The check flow is shown in Figure 41.

Chapter 6 System Commissioning and Debugging
FIGURE 41 CHECK FLOW BEFORE STARTUP
For equipment installation check , refer to the section Installation

Check.
For electrical connection check, refer to the section Electrical Con-
nection Check.
AC Distribution Unit Check

The check items of the AC distribution unit are listed in Table 23.
TABLE 23 AC DISTRIBUTION UNIT CHECK
Check item Check result
AC protection air switch (outside ZXDU68 T301 Y □ N □

system) is OFF.
AC input air switch is OFF. Y □ N □
Air switch of level C lightning arrester is ON. Y □ N □
All connections are proper; all bolts and screws Y □ N □

are tight.

No short circuit occurs for AC input air switch Y □ N □

(or AC contactor).
AC input voltage is in the required range: 80 Y □ N □

V to 300 V. (If the voltage is not in the range,
the system cannot be normally started.)
Rectifiers Check
The check items of the rectifiers are listed in Table 24.
TABLE 24 RECTIFIERS CHECK
All air switches of the rectifiers are OFF. Y □ N □
The rectifiers are properly installed inside the Y □ N □

equipment cabinet.
Monitoring Unit Check

Perform the following check before the monitoring unit is started
up:
1. Make sure that the monitoring unit is properly installed in the
cabinet of the system.
2. Make sure that the external signal cables are firmly connected
to the SIB board.
DC Distribution Unit Check

The check items of the DC distribution unit are listed in Table 25.
TABLE 25 DC DISTRIBUTION UNIT CHECK
Check item Requirement Check result
DC output fuse Unplugged Y □ N □
Battery fuse Unplugged Y □ N □
DC output air switch OFF Y □ N □
Battery air switch OFF Y □ N □

Batteries Check
The check items of the batteries are listed in Table 26.
TABLE 26 BATTERIES CHECK
Check Item and Requirement Check result
If temperature sensor is required, make sure Y □ N □

that it is properly installed.
The quantity of installed batteries meets the Y □ N □

requirement.
Connections among batteries are proper. Y □ N □
Battery cables are properly connected to the Y □ N □

DC distribution unit. (Do not confuse positive
polarity with negative polarity).
No short circuit between positive polarity and Y □ N □

negative polarity of battery.
System Commissioning
Context ZXDU68 T301 system commissioning is performed as follows:
Steps 1. Turn on the AC protection air switch outside the system.
Caution:
Make sure there is nothing wrong such as burns or sparks.
Be cautious to avoid electric shock. When the AC protection air
switch of the equipment is turned on, dangerous high voltage
is already present in the cabinet although the system has no
output.
2. Connect the AC input switch of the cabinet.

3. Turn on the rectifiers
i. Turn on the switch of rectifier 1 to start it.
The IN indicator glows. If the ALM indicator glows, the rec-
tifier 1 may be not properly installed; in this case, unplug
and re-plug the rectifier with power on. If the ALM indica-
tor still glows after the rectifier is properly installed, please
seek help from the maintenance personnel.
ii. Turn off the switch of rectifier 1, turn on the switch of rec-
tifier 2 and check if it works normally.
iii. Use the above substeps to start the remaining rectifiers.
iv. Turn on the rectifiers’ air switches after making sure that
all rectifiers work normally (Turn on one switch at a time).

4. Observe the running status of the monitoring unit.

Once the rectifiers are started, the monitoring unit starts self-
test with its indicator flashing. After about 10 seconds, the unit
starts working normally. Then PWR, RUN and ALM indicators
glow, and the LCD displays Dc Out Fn0m Fault and Bat.n
Loop Break alarms (Please refer to the section “Alarm list” of
ZXDU68 T301 DC Power System (V4.1R01M01) User Manual
for the more details).
END OF STEPS
Batteries Input
Prerequisites Connect battery cables by referring to the contents in Connecting
Battery Cables.
Connect the batteries input cables when the rectifiers and moni-
toring unit start operating normally.
Context The ZXDU68 T301 system has two battery packs, BATT1 and
BATT2. Battery fuses are located on the DC distribution unit of
the system, as shown in Figure 42.
FIGURE 42 BATTERY FUSE LOCATION
Steps 1. Connect the battery pack with lower voltage.

i. Set the floating voltage : [Ctrl ®1. Setup Para ®1. Float
Vol.].
ii. Connect the battery pack to its corresponding fuse, and the
system starts floating charge of the battery.
2. Refer to step 1 to connect the battery pack with higher voltage.
3. Restore the floating voltage to its default value (53.5 V) by
performing step 1.i.
The floating voltage value could be changed, if requested.
END OF STEPS

System Debugging
Parameters Setting in Commissioning
After initial system commissioning, check each system parameter
value against the following tables and check the parameters as
required. Record the changed values in the “Changed Value” col-
umn.
Setting System Table 27 lists the system parameters that need to be checked and
Parameters changed at field. The access path is Ctrl > 1. Setup Para > 1.
Sys Para.
TABLE 27 DESCRIPTION OF SYSTEM PARAMETERS TO BE SET AT FIELD
S/N Parameter Name Default Changed Remarks

Value Value
1 Bat1 Cap. (Ah) 300 Set this parameter according to the actual
battery capacity to ensure normal battery
2 Bat2 Cap. (Ah) 0 management. Since ZXDU68 T301 is config-
ured with only two battery packs, Bat3 Cap.
3 Bat3 Cap. (Ah) 0 and Bat4 Cap. must be 0.
4 Bat4 Cap. (Ah) 0
5 COM1 Bauds (bps) 9600 Set these parameters as required. Set the
TXD baud rate equal to the RXD baud rate;
6 COM1 Bauds (bps) 9600 otherwise, communication will fail.
7 COM1 Bauds (bps) 9600
8 Device No. 1 Set this parameter as required. For the devi-

ces monitored by the same background mon-
itoring computer, the number of each device
should be unique; otherwise a communica-
tion error will occur.
9 Password 0000 It is recommended to change the initial pass-

word and keep the new one in mind.
10 Language Chinese
11 Buzz Switch On
12 AuxSwitch Set No If the system is configured with AC auxiliary

switch, set this parameter to Yes.
13 Auto Alarm Enable
14 SMR Pulled Alm Enable
15 Current Date - Change this parameter so that it is consistent

with the local time; otherwise the information
related to system date will be incorrect.
16 Current Time - Change this parameter so that it is consistent

with the local time; otherwise the information
related to system time will be incorrect.

Setting Battery Table 28 lists the battery parameters that need to be checked and
Parameters changed at field. The access path is Ctrl > 1. Setup Para > 2.
Batt Para.
TABLE 28 DESCRIPTION OF BATTERY PARAMETERS TO BE SET AT FIELD
S/N Parameter Name Default Changed Value Remarks

Value
1 Work Mode Safe Mode
2 Float Vol. (V) 53.5
3 Equal Vol. (V) 56.4
4 Test Vol. (V) 46
5 Cur. Limited (C) 0.125
6 Equal Func. Enable
7 Equal Period (Day) 90
8 BatVol Min. (V) 47
9 1-Shut Vol. (V) 45
10 2-Shut Vol. (V) 44
11 Auto Test Disable If it is required to enable

auto test, set this param-
eter to Enable.
12 Test Period (Day) 30
13 Test StartTime 10:00
Rectifiers Load Sharing Quality

Check
Warning:
Set the floating charge voltage equal to the battery voltage be-
fore turning on the battery breaker of the power distribution unit.
Sparks may occur if the difference between the battery voltage and
the floating charge voltage of the system is too high. For example,
if the battery voltage is 50.0 V, set the floating charge voltage to
50.0 V.
Caution:

Make sure that the batteries are connected to the system and they
can power the loads. Otherwise, the load might be shut down
when a rectifier module is unplugged.
Unplug one rectifier module at a time during the operation to im-
prove the current equalization quality.
TABLE 29 RECTIFIERS LOAD SHARING QUALITY CHECK
Maintenance Item Description
Prerequisite When various rectifiers work with over 10% of rated load, the output
current difference among the rectifiers is lower than 1.5 A.
Check Criteria Observe the output current displayed on the front panel of the CSU.
Check Methods If the difference between the current is greater than 1, the load
sharing quality is undesirable. In this case, follow the steps
below to improve the load sharing quality.
Before performing the following steps, make sure that the batteries are
connected to the system and they can power the loads. Otherwise, the
load might be shut down when a rectifier module is unplugged.
Only one rectifier can be unplugged at a time, during the operation,
to improve the current equalization quality.
1. Unplug the rectifier 1, and then observe the output current on the
front panel of the other rectifiers to check the rectifiers load sharing
quality.
– A good load sharing quality indicates that the rectifier 1 is faulty.
In this case, replace it with a new one.
– Proceed to the next step if the load sharing quality is not good.
2. Re-install the rectifier 1 in the slot 1 and unplug the rectifier 2. Then
observe the output current displayed on the front panel of the CSU
o check the load sharing quality.
– A good load sharing quality indicates that the rectifier 2 is faulty.
In this case, replace it with a new one.
– If the load sharing quality is not good then proceed to the next
step.
3. Find the faulty rectifier by repeating the step 2.
4. Replace the faulty rectifier.
Note:
� The current equalization index of the rectifier is meaningful
only when the load current of the system is greater than 20%
of the rated output current of the system.
� After the battery is connected to the system, set the floating
charge voltage of the system. The floating charge voltage is
53.5 V by default.

System Shutdown with Fault

Context Generally, power interruption is not allowed after system debug-
ging and on-load running. However, if any fault occurs or the sys-
tem should be shut down during the test, system shutdown can
be performed by following the procedure below.
Steps 1. Remove the DC output and battery fuses (or turn off the air
switches).
2. Turn off the rectifiers air switches. Then the monitoring unit is
automatically shut down.
3. Turn off the AC input air switches.
4. Turn off the system’s external AC switch.
END OF STEPS

Appendix A
Operation of Fuse
Extractor
Steps 1. Align extractor holes with the outer parts of the fuse.
2. When the outer parts of the fuse are completely inserted into
extractor holes, lift the extractor. The extractor and the fuse
are combined and one can hear a "click" sound.
3. Pull out the extractor and the fuse is pulled out of the fuse
base.

4. Keep pressing the extractor button and lift the extractor up-
wards. Then the fuse is taken out of the extractor.
END OF STEPS

Appendix B
Electrical Connection
Diagram
Figure 43 shows the electrical connection of ZXDU68 T301 system.

FIGURE 43 ELECTRICAL CONNECTION DIAGRAM

Appendix B Electrical Connection Diagram


Figures
Figure 1 Installation Flow..................................................... 6

Figure 2 ZXDU68 T301 Cabinet Appearance ........................... 7
Figure 3 Top Cap Appearance ............................................... 8
Figure 4 Cabinet Structure ................................................... 9
Figure 5 DC Distribution Unit Structure.................................10
Figure 6 AC Distribution Unit Structure (Single Air Switch) ......11
Figure 7 AC Distribution Unit Structure (Double Air Switch) .....11
Figure 8 Installation Slots Configuration................................12
Figure 9 Installation Preparation Flow...................................13
Figure 10 Equipment Installation Flow ..................................22
Figure 11 Installation Flow ..................................................23
Figure 12 Requirements for the Position of the Cabinet ...........24
Figure 13 Holes Position .....................................................24
Figure 14 Drilling Holes ......................................................25
Figure 15 Installing Expansion Bolts .....................................25
Figure 16 Placing the Cabinet ..............................................26
Figure 17 Top Cap Structure................................................27
Figure 18 Top Cap Appearance ............................................27
Figure 19 Dust Cap Appearance ..........................................29
Figure 20 Dust Caps on Cabinet Top ....................................30
Figure 21 Electrical Connection Flow.....................................36
Figure 22 Circuit Breaker Connection....................................38
Figure 23 Copper Busbar Connection....................................39
Figure 24 Connecting the Fuse ............................................39
Figure 25 Connecting PE Cable ............................................41
Figure 26 Working Ground Cable Connection .........................42
Figure 27 Connecting AC Input Cables (AC Input Mode with
Single Air Switch) ..............................................44
Figure 28 Connecting AC Input Cables (AC Input Mode with
Double Air Switch) .............................................45
Figure 29 AC Auxiliary Output Cables Connection ...................46
Figure 30 Connecting DC Output Cables................................48
Figure 31 BATT1 Connection ...............................................49
Figure 32 BATT2 Connection ...............................................50

Figure 33 Battery Temperature Sampling Cables ....................51

Figure 34 Connecting Output Relay Cables ............................52
Figure 35 Connecting Background Monitoring Cable................53
Figure 36 Cable Layout Requirements...................................54
Figure 37 Bundling of Cables ...............................................54
Figure 38 Distance Between Cable Ties.................................54
Figure 39 Cutting Requirement of Cable Ties .........................55
Figure 40 Commissioning and Debugging Flow ......................57
Figure 41 Check flow before startup .....................................59
Figure 42 Battery Fuse Location ..........................................62
Figure 43 Electrical Connection Diagram ...............................70

Tables
Table 1 Safety Signs ........................................................... 1

Table 2 Safety Precautions ................................................... 2
Table 3 Steps Description .................................................... 6
Table 4 ZXDU68 T301 System Dimensions and Weight............. 8
Table 5 Description of Tools and Instruments .........................14
Table 6 Environment requirements .......................................17
Table 7 Requirements for Grounding Resistance in
Communication Stations .....................................18
Table 8 Lightning protection requirements.............................20
Table 9 Installation check list ..............................................33
Table 10 Requirements for Cables Colors ..............................37
Table 11 PE Cable Connection Description .............................41
Table 12 Working Ground Cable Connection Description ..........42
Table 13 Connection Description (AC Input Mode with Single
Air Switch) .......................................................44
Table 14 Connection Description (AC Input Mode with Double
Air Switch) .......................................................45
Table 15 Connection Description ..........................................46
Table 16 Connection Description ..........................................48
Table 17 BATT1 Connection Description ................................49
Table 18 BATT2 Connection Description ................................50
Table 19 Temperature Sampling Cables Connection
Description .......................................................51
Table 20 Background Monitoring Cable Connection .................52
Table 21 Electrical connection check items ............................55
Table 22 Commissioning and Debugging Flow ........................58
Table 23 AC distribution unit check ......................................59
Table 24 Rectifiers check ....................................................60
Table 25 DC distribution unit check ......................................60
Table 26 Batteries check .....................................................61
Table 27 Description of System Parameters to be Set at Field...63
Table 28 Description of Battery Parameters to be Set at Field...64
Table 29 Rectifiers Load Sharing Quality Check ......................65

sjzl20092663-ZXDU68T301 (V4.1R01M01) Installation Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

sjzl20092663-ZXDU68T301 (V4.1R01M01) Installation Manual PDF

Uploaded by

Copyright:

Available Formats

ZXDU68 T301

Copyright © 2006 ZTE CORPORATION.

The ultimate right to interpret this product resides in ZTE CORPORATION.

Revision No. Revision Date Revision Reason

Serial Number: sjzl20092663

About this Manual .............................................. i

Describes the safety instructions and

Chapter 2 Installation Describes the system installation flow and

Describes the installation requirements,

Describes the procedure and method to install

Chapter 5 Electrical Describes the process and method of

Appendix B Electrical Provides the diagram of the electrical

Confidential and Proprietary Information of ZTE CORPORATION i

This page is intentionally blank.

ii Confidential and Proprietary Information of ZTE CORPORATION

Safety Signs Meaning

Danger: Indicates an imminently hazardous

Warning: Indicates a potentially hazardous

Caution: Indicates a potentially hazardous

Note: Indicates a potentially hazardous situation,

Erosion: Beware of erosion.

Electric shock: There is a risk of electric shock.

Electrostatic: The device may be sensitive to

Microwave: Beware of strong electromagnetic

Confidential and Proprietary Information of ZTE CORPORATION 1

Safety Signs Meaning

Laser: Beware of strong laser beam.

No flammables: No flammables can be stored.

No touching: Do not touch.

No smoking: Smoking is forbidden.

TABLE 2 SAFETY PRECAUTIONS

S/N Precautions Requirement Possible Danger

2 Confidential and Proprietary Information of ZTE CORPORATION

S/N Precautions Requirement Possible Danger

Insulate the Static electricity

Confidential and Proprietary Information of ZTE CORPORATION 3

S/N Precautions Requirement Possible Danger

4 Confidential and Proprietary Information of ZTE CORPORATION

Confidential and Proprietary Information of ZTE CORPORATION 5

FIGURE 1 INSTALLATION FLOW

Refer to Table 3 for the description of the steps involved in the

TABLE 3 STEPS DESCRIPTION

Step Title Task

1 Installation � Preparing installation site

3 Electrical � Connect the grounding cable, AC input cables, AC output

4 System System check before startup ,startup and commissioning, joint

6 Confidential and Proprietary Information of ZTE CORPORATION

Cabinet Dimensions and

FIGURE 2 ZXDU68 T301 CABINET APPEARANCE

The top cap of the ZXDU68 T301 system is shown in Figure 3.

Confidential and Proprietary Information of ZTE CORPORATION 7

FIGURE 3 TOP CAP APPEARANCE

TABLE 4 ZXDU68 T301 SYSTEM DIMENSIONS AND WEIGHT

System Dimensions (Height × Width × Weight

ZXDU68 T301cabinet 1600 mm × 600 mm × 400 mm 78 kg (excluding the

Top cap 400 mm × 598 mm × 400 mm 9.5 kg

8 Confidential and Proprietary Information of ZTE CORPORATION

FIGURE 4 CABINET STRUCTURE

Confidential and Proprietary Information of ZTE CORPORATION 9

Components of DC The structure of the DC distribution unit is as shown in Figure 5.

1. Working ground busbar (+48 V) 4. LLVD control device

Components of AC The module structure is based on the user requirement.

� AC input mode- Double air switch (optional configuration) : In