Valere Smps Gs150a

The Power to Innovate
User Manual
DC Power System VP GS150A-480 1016
(Sample System)
Installation, Operation & Maintenance Guide
24 x 7 Installation and Technical Support US: +1-866-240-6614 Singapore: +63 9209149514 India: +91 9899661113
Notice:
The information, specifications, and procedures given in this manual are subject to change without notice and manufacturer assumes no responsibility for any errors that may appear in this document.
Document Reference: VPAP-TD1016 Revision 00 May 18, 2006
Index
Sl. No. Description Page No. 05 05 05 05 06 06 06 06 07 07 07 07 09 09 09 10 10 11 12 13 13 13 13 13 13 15 16 17 17 18 18 19 19 20 20 21 21 22 25 25 25 26
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1. Read This First 1.1. Welcome 1.2. About This Manual 1.3. Safety and Recommended Practice 1.4. FCC Compliance 1.4.1. Note 1.4.2. Warning 1.5. Terms & Abbreviation 2. Users Comments 2.1 General 2.2 Feedback Report on SMPS Power Plant 2.3 Evaluation of Manual 3 System Description 3.1 Introduction 3.2 AC Distribution 3.3 DC System Voltage 3.4 DC Output Distribution 3.5 Rectifier Shelf 3.6 System Features 3.7 General Arrangement/Cabinet Size 3.8 System Cables/Wires 3.8.1 AC Input Wiring 3.8.2 DC Output Wiring 3.8.2.1 Grounding 3.8.2.2 Wire Sizing Installation Guide 4.1 Warning 4.2 Introduction 4.3 Recommended Tools for Installation 4.4 Un-Packing of System 4.5 Mechanical Installation 4.6 Earth connection 4.7 AC Mains connections 4.8 Battery connection 4.9 Load connection 4.10 Alarm connection 4.11 Temperature Probe connection 4.12 Installation of SMPS Rectifier Module Start up & Commissioning of System 5.1 Introduction 5.2 Recommended Tools for Commissioning. 5.3 Commissioning/Site Acceptance Test
5.3.1 5.3.2 6
Pre Start / Initial Checks. System Start up.
26 26 27 28 29 31 32 33 33 33 34 34 34 35 10 11 11 12 22 23 27 28 33 34 34
Alarm Controller - Operation Guide 6.1 Controller Setup 6.2 Table Controller Setup 6.3 Controller Menu Tree Main Menu 6.4 Remote Signals PFC connector details V Series Wide Range Rectifiers 7.1 The Valere Difference 7.2 Features Replacement of Items 8.1 Alarm Controller replacement 8.2 Rectifier module replacement Troubleshooting AC Distribution DC Distribution Rectifier shelf with rectifier modules Rectifier shelf without rectifier modules Alarm controller connections Rectifier Module insertion Alarm Controller Controller display V Series Rectifier Module Alarm Controller Replacement Rectifier Module Replacement
Figures Figure-1 Figure-2 Figure-3 Figure-4 Figure-5 Figure-6 Figure-7 Figure-8 Figure-9 Figure-10 Figure-11 Annexure Annexure-A Annexure-B Annexure-C Annexure-D
Feedback Report on SMPS Power Plant Evaluation of Users Manual System Configuration - Customer Specific System Drawings (Not provided with sample / demo system)
1 1.1
Read This First

Welcome
Welcome to Valere Powers manufactured DC Power System Model No. VP GS150A-480 1016. GS150 means Global System 150 Ampere plus redundancy - A Modular Power Supply System designed for use with Telecommunications, Industrial automation and all applications requiring high efficiency and uninterrupted standby DC Power.
1.2
About This Manual

This User Manual has been written to provide you with all information about the rectifier system and modules incorporated. The next three parts of this documentation contain information that covers all aspects of GS150A-480-1016, related to installation & commissioning. Details of operation described in the Operation Guide of Alarm Controller. The System Drawings are specific to your system.
1.3
Safety and Recommended Practices

General practices Suitable for mounting on 19 rack. The integrated system accepts an AC Voltage range of 150 to 275Vac, single phase and produces 42 56VDC at nominal up to 150 Amperes plus redundancy in an ambient max. operating temperature range of -40C to +50C. HAZARDOUS VOLTAGE AND ENERGY LEVELS ARE PRESENT WHICH CAN PRODUCE SERIOUS SHOCKS AND BURNS. Only authorized, qualified, and trained personnel should attempt to work on this equipment. Refer to the Product datasheets/drawings for full product specifications / understanding. NOTE: ALL RECTIFIERS EMPLOY INTERNAL DOUBLE POLE/NEUTRAL FUSING Use single/double hole, good quality copper lugs for all DC connections to prevent inadvertent contact with other circuits. Copper wire is recommended for all DC connections.
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All AC and DC power terminations are rated for 90C operation. Minimum wire sizes, based on capacity, are shown in Wire Sizing Para no. 3.8.2.2. of this manual. In practice, loop voltage drop considerations will usually dictate larger than minimum safe wire size. Alarm contacts are not fused internally; therefore current limiting protection for these contacts must be provided by external circuits. The alarm contacts are rated for a maximum voltage of 60 V, SELV (Safety Extra Low Voltage) and a maximum continuous current of 0.5A.Connection. Valere does not recommend shipping the power shelf with the rectifiers installed. Rectifiers should be shipped in separate boxes provided by Valere Power. 1.4 1.4.1
FCC Compliance Statement Note

This device complies with Part 15 of FCC (Federal Communications Commission, Columbia) Rules. Operation is subject to the following two conditions: i. This device may not cause harmful interference, and ii. This device must accept any interference received, including interference that may cause undesired operation.
1.4.2
Warning
Changes or modifications to this unit not expressly approved by the party responsible for the compliance could void the user's authority to operate this equipment.
1.5
Terms & Abbreviation

List of Abbreviations, used in the Valere Power Product Manuals: Abbreviations
A AC AMPACITY C.O. DC ESD FCC LED LVD MCB PCB PR PFC SELV SMPS V R
Description
Ampere Alternating Current Ampere Capacity Common Output Direct Current Electro Static Discharge Federal Communications Commission of Columbia Light Emitting Diode Low Voltage Battery Disconnect Miniature Circuit Breaker Printed Circuit Board Power Rack Potential Free Contacts Safety Extra Low Voltage Switch Mode Power Supply Volt Redundancy
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2.
2.1
User Comments
General
It is the policy of Valere Power that we shall work actively to ensure that our products are in accordance with our customer's expectations and requirements. In order to achieve this goal at any part of time, we wish to follow up our products throughout their lifetime. We therefore request your kind assistance.
2.2
Product Report
If you have any technical comments with respect to product specification, performance, maintenance or service, we would appreciate if you would fill in these comments on a copy of the form Product Report format provided in this manual (Please refer Appendix-A for Product Report) and return it to us. You may as well contact us by telephone, fax or Electronic mail. We will confirm receipt of all comments received and inform you of changes as a result of your comments and suggestions.
2.3
Evaluation of Manual
We are continually looking for ways to make our products and our manuals as easy to use as possible, you can help us by sharing your comments and suggestions about how our manuals could be made more useful and about any inaccuracies or information gap they might contain. You can submit your comments either by making a copy and filling out the form Evaluation of User's Manual format provided in this manual (Please refer Appendix-B for Evaluation of Users Manual) or by writing to us via E-Mail or otherwise. We sincerely appreciate your comments about our products.
System Description
GS150A-480-1016 Standby DC Power System
3. 3.1
System Description
Introduction
The GS150A-480-1016 DC Power System is developed to support -48 volt telecommunications, industrial automation and similar applications as powering solutions for Global markets. The GS150A-480-1016 combines 50 ampere, fan cooled, switch mode rectifiers modules, microprocessor control technologies, battery disconnect/re-connect options, and a comprehensive line of fuse & circuit breaker for dc distribution options in a modular front-access design. This modularity insures easy access, simplified installation and maintenance, and allows the system to expand in capacity and features as power needs grow. The main emphasis of this manual is to provide a general product description that will familiarize the user with the main components of the system and to provide guidelines for the basic maintenance of this GS150A-480-1016 Power System. The Power System comprise of Switch Mode Plug-in Rectifiers (SMPS), Micro processor Alarm & Control Module, Interface connectors with potential free contacts and AC & DC distribution. All SMPS rectifier modules provide active load current sharing. Shunts are used to measure DC current to/from the batteries. Please refer Annexure-C for shunt rating used in your system. All Load fuses/MCBs of the DC distribution have a common alarm circuitry through Load Breaker Open Sensing Card and Battery fuses/MCBs have the common alarm circuitry through Battery Breaker Open Sense Card. The system provides a high quality standby DC Power and automatic battery charging. The Micro processor Alarm Controller is a plug-in type module, which facilitates Potential Free Contacts (Form-C) for remote monitoring of Alarms. All alarms are potential free and may be connected to external displays/equipment as closed circuit when alarm is reported. Alarm Controller also has the optional feature of Temperature Probe integration, which controls output voltage according to environmental temperature for battery safety/protection.
3.2
AC Distribution
This single shelf AC distribution comprises of one external (Optional) Class-B input lightening protection, which is then connected to the AC mains input terminal. Further, connected to mains UV/OV contactor, one (Optional) class C input surge protection, and rectifier input MCBs, which are inside the system. The UV/OV controller card is mounted on left side wall of the distribution and visible after opening the front door. All electrical items are fitted as per system ultimate power requirements.
You can make the AC mains connections to left side mounted terminal/MCBs (Cable entry).
AC Main & Alarm Cable entry holes
Class-C Protection
AC Input Terminals
Individual Rectifier input MCBs
AC UV/OV Contactor
Fig - 1 AC Distribution with open door front view
3.3
DC System Voltage
-54Vdc
DC Power System GS150A-480-1016 (Your Power System output DC Voltage)
3.4
DC Output Distribution
All electrical items are fitted as per system ultimate power requirements. The single shelf distribution comprises of one LVBD contactor. The number of load breakers/fuse and battery breakers/fuse along with rating of LVBD are as per Appendix-C. The LVD controller is available on right side wall after opening the front opening.
The return bus bar (+ve) is available above the load and battery breakers profited with clinch nuts. The Micro Processor Alarm Controller is mounted on front left hand side. The display is visible from the front. You can operate the controller through keypad available at display. DC Load & Battery Cable entry hole
Load & Battery MCBs & Fuses
+ve Bus Bar
LVBD Contactor & Shunt
-Ve Bus Bar
Fig 2 DC Distribution with open door front view Please refer the following: Annexure-C for details of the ratings Annexure-D for details of Schematics, General arrangement drawings.
3.5
Rectifier Shelf
This rectifier shelf comprises four rectifier slots. In full capacity (200A-48V) all the slots are pre wired. The system power can be increased by just adding the rectifiers. There is no need to put extra wiring and controller. The blank slots may be covered by dummy plates/rectifiers. Micro Processor Alarm Controller
Rectifier Back Plane
Rectifier shelf
Temperature Probe connector Rectifier Modules
PFC Connector Fig 3 Rectifier Shelf with V series rectifiers
Rectifier AC input connector
Rectifier DC output connector Rectifier Slot
Rectifier Shelf
Fig-4 Rectifier Shelf without rectifiers
3.6
System Features
The following features have been provided in your system. LVD (Low Voltage Disconnect) To prevent the battery (ies) from deep discharge, DC contactor is used in battery path. This also has been incorporated with one by-pass switch for force mode operation. Battery Current Limiting (BCL) When Battery is in deep discharge condition and the charging resumes, it may take more current than safer value. To avoid this, Battery Current Limit circuitry has been provided, which monitors battery-charging current and limits it, in case, it tries to exceed specified limit i.e. 5% to 20% of Battery AH capacity. This is a likely if battery is connected. You may set the BCL limits, as required. AC Over Voltage Cut off System is protected for any damage from AC over voltage beyond 275V2%. AC Lower Voltage Cut Off Lower voltage protection to system for AC low voltage at 150V2%. Input Surge Suppressor In addition to the build in class D protection at each rectifier module, system is incorporated with Class C input surge protection at System level. These are provided in line- neutral & neutral- earth paths. Temperature Sensor During charging of battery (ies), output voltage is controlled in accordance to out side temperature have better battery (ies) life. Audible buzzer Buzzer integrated to have alarm audible with option of its ON/OFF switch.
3.7
General Arrangement/Cabinet Size.
The cabinet size of GS150A-480-1016 DC Power System is: Mechanical dimension: 480(W) x 350(D) x 350(H) mm for 19 rack mount system. Please refer Annexure D for details of Schematics, General arrangement drawings. 3.8 3.8.1
System Cabling/Wiring
AC Input Wiring
The single phase AC main supply is connected through Class-C input surge arrestor (should be installed by customer out side DCPP & at AMF panel) to AC mains input terminal (Phase, N & E). AC power is fed internally to rectifier modules through pre-wired AC mains input terminal, rectifier input MCBs, UV/OV contactor and Class C protection provided in the system. 3.8.2 DC output wiring
3.8.2.1 Grounding System polarity is determined by the system grounding. For a positive ground system (i.e. -48V system) the positive output of the system must be grounded to the C.O. (Common Output) ground. 3.8.2.2 Wire Sizing There are two main considerations for sizing DC wire, Ampacity and voltage drop. Ampacity refers to a safe current carrying level as specified by non-profit organizations such as Underwriters Laboratories and the National Fire Prevention Association, which publishes the National Electric Code. Voltage drop is simply the amount of voltage loss in a length of wire due to ohmic resistance of the conductor. DC wire may be sized for either ampacity or voltage drop depending on branch load loop length and conductor heating. In general, ampacity considerations will drive wire selection for short loop lengths (less than 50 feet) and voltage drop will drive wire selection for long loop lengths (greater than 50 feet). ALWAYS FOLLOW THE ELECTRICITY REGULATIONS VALID FOR THE INSTALLAION AREA AND YOUR LOCAL COMPANY PRACTICES WHEN MAKING FINAL SELECTIONS FOR AC & DC WIRING AND PROTECTION. ACCORDING TO THE NEC RULES WHICH ARE APPLICABLE FOR NORTH AMERICA, THESE RULES MAY BE USED AS GUIDENCE FOR INSTALLATION IN OTHER AREAS.
All Valere power plants are rated for usage with 90C wires. Below Table shows MINIMUM recommended wire sizes for various current ratings.
Current Protector Rating (A)
Wire & Lug Gauge (AWG) using 90 C wire (NEC Table 310.16) 1 18* 5 18* 10 16* 15 14 20 12 30 10 40 8 50 8 75 6 100 2 125 2 150 1 AWG 175 2/0 AWG 200 3/0 AWG 225 3/0 AWG 250 4/0 AWG 300 (1) 300 MCM or (2) 1 AWG 400 (1) 500 MCM or (2) 3/0 AWG 450 (1) 600 MCM or (2) 3/0 AWG 500 (1) 700 MCM or (2) 4/0 AWG 600 (2) 300 MCM or (3) 4/0 AWG 700 (2) 350 MCM or (3) 4/0 AWG 800 (2) 500 MCM or (4) 4/0 AWG * - For wire sizes less than 15 A not covered in NEC Table 310.16 use Table 3B - Sizes of Conductors, UL60950, "Safety of Information Technology Equipment", Dec., 2000 for non-building wiring. Table - Recommended DC AWG for 90 C Cabling
NOTE: For lugs and cable size, please refer Annexure D
4.
Installation Guide
GS150A-480-1016
Standby DC Power System
4.1
Warning
Warning
Valere Powers personnel must only work with the equipment described in this manual or Personnel who have attended a suitable Valere Powers training course. The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warrantee. There are hazardous voltages inside the power system. The rectifier units include large charged capacitors; therefore it is dangerous to work inside the system even if the mains supply is disconnected. Ensure that system is connected with proper Protective Earthing and Chassis Grounding. Grounding resistance should not be more then 10 Ohm. Ensure that surrounding area to the system is free from all environmental hazards such as dust, inflammable & explosive materials. Also, ensure that system is mounted at a solid concrete plinth which is sufficiently high to take care of cooling air passage from its bottom. Lightening/Surge Protection Box is to be installed outside the system. Before making any connection to System, please ensures that lightening protection is installed & wired properly. If lightening protection is not installed, manufacturer will not be responsible for any damage due to Lightening & Surge. Manufacturer will not be responsible for any damage occurred in the system or to individual due to any of the above mentioned points, in case requested care is not taken. Please read the User Manual Carefully before using the equipment.
4.2
Introduction
This chapter guides you step by step through: Unpacking Mechanical Installation Battery Installation All cable connections Installation of Modules Whenever a drawing is needed to support an installation step, you will find the referred drawing in the Annexure -D Ensure all AC and DC power sources are off and disconnected. To the extent possible ensure a clean (free of debris, dust, foreign material, etc.) work environment. Have all tools, wire, cables, hardware, etc., within easy reach. The Valere powers power system employs bottom to top airflow via self contained fans. Care should be taken when mounting the system at locations that present an airflow blockage on the bottom surface of the system. Allow at least 1.75 (44.52mm) of unrestricted clearance for proper airflow, if any blockages are present. For maintenance purposes, only the front of the cabinets needs to be accessible at most of the time. Please check cabinet mounting detail provided in Annexure C & D. 4.3
Recommended tools for Installation
Valere Powers systems are designed to be installed with a minimum number of commonly used standard equipment/Authorized electrician available tools. #1 & #2 Phillips Screwdrivers #1 & #2 Flat Head Screwdrivers Set of Box Wrenches, Ratchet Set, or Nut Drivers Wire and Cable Strippers suitable for the wire size selected Wire and Cable Crimpers suitable for the wire size selected Pliers (Flat & Long Nose) Digital Multimeter Note: Use insulated tools when working on a live system!
4.4
Unpacking of System
Some of the cabinets/parts may weight in excess of 50 KG. If required, the appropriate lifting equipment should be used and care must be taken whilst handling these units.
Contact Valere Powers sales or technical support immediately if any damage is observed.
# 1
Installation Step Remove Packaging
Comments The system is covered with polythene sheet, extended PE foam sheet on all sides of system and packed in a wooden/corrugated box. These must be removed before the cabinet is removed. Check that the received equipment is according to packing list provided within system documents envelop.
OK
Inspect all the equipments parts for any transport damage. Mount the system in the required Please refer System mounting type at Annexure C 19 cabinet.
4.5
Mechanical Installation
The System must not be located in an explosive atmosphere i.e. flammable gases and fumes. There must be suitable ventilation for the batteries.
# 1
Installation Steps Remove the cabinet front/top cover/panel(s) on the upper portion. Rack mounting. (Verify, if system is designed for Rack mounting?) For Wall mounting (Verify, if system is designed for Wall mounting?)
Comments Necessary for accessing the connection terminals. Use proper size mechanical channels to match the Rack frame holes and system grouting holes. Ensure that wall is of concrete and should be able to sustain the load of system. Make appropriate holes in the wall by concrete drill machine as per system holes. (Refer the system mounting drawing attached at Appendix D). Put the grouting bolts into the holes, mount
OK
External Cables
the system and fasten the grouting bolts with proper size of washers and secure the cabinet to the wall. Cable entry for Earth (PE & Telecom), AC Mains, DC loads, Battery (ies), Alarm PFCs and (Optional) Temperature Probe cables.
4.6
# 1
Earth Connections
Installation Steps Chassis Earth Comments To prevent electric shock, the rectifier and battery cabinet chassis must be connected to a protective Earth. The incoming mains to the System must contain a Main's safety earth and should be connected to protective earth terminal provided in system. The System has been configured for Negative distribution. +Ve Common Terminal can be connected to Telecom earth, if desired. OK
Protective Earth
Telecom Grounding
4.7
AC Main Connections
Connect the System to a suitable rated MCB of your ACDB Panel. Please refer Annexure C for AC Mains input configuration Always Switch OFF the External AC Mains supply before the Mains cable is connected to the Mains terminals. The Cabinet earth terminal is located along with the mains terminal on the right side.
# 1
Installation Steps AC Main connection
Comments Connect the Mains input to the system. Open the front of AC distribution and see the AC mains input terminals/MCB at left side of front mounting plate. Connect LINE, NEUTRAL and terminals/MCB as marked.
OK
EARTH
to
4.7
Battery Connection
Before connecting batteries: remove all metallic object like rings, watches etc. from your hands for safety reasons. Remove Battery HRC Fuse/Switch OFF Battery MCB before making battery connection with DC Power system.
The batteries are to be installed as recommended by the battery manufacturer. For battery connections in your system, you may make the following color coding on the battery cables: Battery connections Blue (-) Negative terminal Black (+) common Positive terminal # 1 Installation Steps Battery Connection Comments Up to one string of battery may be connected via the battery connection Fuse. Connections are made with proper size ring tongue lug or line lugs OK
4.9
Load Connections
DC connections are accomplished via the Load breakers and Battery fuses/MCB. Common return bus bar is available for load and battery return connections. The max tongue width of lugs allowed for standard landings is 0.83. Any tongue width larger than that max value will require special landings that will reduce the number of connections points
# 1
Installation Steps Connect the Load(s) to the blade fuses First
Comments Only applicable if load HRC fuse is available and the load current is in excess of the Load MCB ratings.
OK
Connect Load(s) to the MCB(s)
Connect Positives to the Common terminals. Connect Load circuits as per the rating of the MCB. Connect Positive to the Common terminals.
4.10 Alarm Connections (See figure-5)

Three form C Dry relay contacts are available through a controller connector. Multi core cable having self mating connector on one end and bare tinned pre-defined color coded wires on other end is provided along with the system for extending various alarms generated by DC Power System. Alarm Contacts of different Alarms may also be used in parallel in locations where alarm transport capacity is limited. # 1 Installation Steps Potential Free Connection. (Please refer Para 6.4 for PFC Details) Comments Connect the required PFC connections. PFC Connected (to be filled-in by User): 1. _____________________________ 2. _____________________________ 3. _____________________________ 4. _____________________________ 5. _____________________________ 6. _____________________________ OK
4.11 Temperature Probes (Optional) (See figure-5)

Battery temperature probe having one ring terminal on one end of Shielded cable and self mated connector on the other end is provided as an Optional along with DC Power System for activation of battery temperature compensation charging. Attach the ring terminal of this shielded cable to a battery post and insert the self mated connector to the connector available on Alarm Controller. You may
extend the temperature alarm through the pre-defined alarm cable provided along with the system and discussed at Para no. 4.10 above. The controller will automatically detect a contact closure and set a minor alarm. (Please refer Annexure D) Temperature Probe Connector
Buzzer Connector
Alarm Cable Connector # 1 Installation Steps
Fig 5 Alarm controller connections Comments Connect temperature probe one end terminal as shown in figure 5 above and connect second end with battery bank. OK
Temperature Probe connection
4.12 Installation of SMPS Modules (See figure-6)

# 1 Installation Steps Plug in the new SMPS Rectifier module Comments Install each rectifier module sequentially by sliding and latching each rectifier into a shelf position. The rectifier latches must be open for installation. Attempting to install the rectifiers with the latches closed will result in mechanical damage to the rectifiers and the shelf. 2 Lock the SMPS handle Refer the figure-6 OK
Fig 6 Rectifier modules Insertion
System Start up and Commissioning
GS150A-480-1016 Standby DC Power System
5. 5.1
System Start up and Commissioning

Introduction
The Commissioning / Site Acceptance Procedure verifies that the system is correctly installed and operating satisfactory. The procedure should be completed by the commissioning/site Engineer and signed by him and a customer representative. Please consult the operation Guide for the Alarm Module in case any of the system parameters needs to be changed. 5.2
Recommended tools
Standard equipment for an Authorized electrician. Digital Multi meter
Note: All tools should be insulated.
5.3 5.3.1 1. 2 3. 4.
Commissioning / Site Acceptance Procedure

Pre Start / Initial Checks Check Following System Installation is completed. Check that the System installation has been correctly performed. (Refer Installation Guide Para no. 4 of this manual). Battery and load are disconnected. Verify that the battery and Load fuses are not connected and load MCBs are in off position. Rectifier Modules are connected. Verity that all rectifier Modules are plugged in and the latched. Rectifier System connected to Mains supply and protective Earth. Check that the system mains cable is connected to the mains supply through Class B protection. Also ensure that system is provided with protective earth. Mains MCBs are connected to the system Verify that the mains circuit breakers are in OFF position. Rectifier Module Individual input MCB Ensure that all input MCBs of all the rectifier modules are kept at OFF position System Start Up Check Following OK OK
5. 6.
5.3.2
1. 2. 3 4. 5 6 7. 8 8
Connect Battery to System. Insert HRC battery fuse or switch ON Battery MCB (as applicable) Turn the System ON Turn ON the MAINS circuit breaker. Read the AC Main Voltage Note the AC main voltage through the Digital Display Meter Power up the rectifier module After 30 60 sec, AC Contactor will get energized. Power up one rectifier module by switching ON the respective input MCB. Read output voltage Wait for about 1 min. and read the output voltage on the alarm modules display Measure output voltage Use a Digital Voltmeter to verify that the output is in accordance with the system's Voltage. Read the AC Main Voltage Power up rest all rectifier modules by respective MCBs Rectifier Modules are ON and without fault alarms Verify that the SMPS modules are in normal mode of operation (not reporting any Alarms). Connect the loads : Turn on load MCBs to put Load on the System.
Vac
Vdc Vdc
Alarm Controller Operation Guide
Fig 7 Alarm Controller
6.1
Controller set up
The controller is equipped with factory settings shown at Para 6.2 to assure safe power up operation. Fig-8 below shows the controller front display and three button keypad. Refer Para 6.3 for complete menu tree for the controller. The UP and DN buttons are used to scroll through the functions and the MENU button is used to select and/or drop down into a sub-menu.
Figure 8 - Controller Display There are three controller menu levels, Basic, Main, and Log-IN. When the controller displays System Float, the controller is at the Basic menu level. The UP/DN buttons can be used to sequentially view basic plant parameters such as float voltage and plant current, temperature compensation state, battery temperature (N.C. if not connected), and internal plant temperature. By holding the MENU button down for 5 seconds, the Main level is accessed. All plant parameters can be viewed from this level by scrolling to and selecting Review. Follow the menu tree for exact navigation directions. By scrolling to and selecting Log In, the Administrator level is accessed. The default password is 5001. This level allows you to make changes to all the plant settings
6.2
Table - Controller Settings

48 Volt Nominal
Parameter
Description The voltage to which the rectifiers will regulate the plant during Float Voltage float mode Rectifier float voltage will revert to nominal value in the event of a controller failure or removal. If disabled the rectifier will stay Fallback at last float voltage setting Fallback V Safe rectifier voltage Batt CL Enable* Enables the battery current limit feature The controller will limit the current to the batteries at this Batt CL Setpoint* setpoint Rect CL Enable Enables the system current limit feature Rect CL Setpont The controller will limit the current of the rectifiers to the value The controller will shut down the rectifiers if the plant voltage HVSD Setpoint exceeds this setpoint The controller will issue a High Voltage Alarm if the plant HVA Setpoint voltage exceeds this setpoint The controller will issue a Battery-On-Discharge alarm if the BD Alarm plant voltage falls below this setpoint A minor alarm is set if the number of installed rectifiers will not Capacity Alarm support N+1 redundancy required by the load. A minor alarm is set if the output current of any rectifier I Share Alarm exceeds current sharing tolerances A minor alarm is set if any rectifier either stops communicating or is removed from the shelf. User action is required to clear the alarm Com Alarm Boost Enables or Disables the equalize/boost charge tests Boost Voltage The voltage at which the equalize/boost charge test will begin Boost Time The time at which the equalize/boost charge test will end TComp Enable Enables thermal compensation Hi Temp Thermal The controller begins to reduce the float voltage when the Comp Start Temp highest measured battery temperature reaches this value Hi Temp Thermal If battery temperature is above the start temperature, the Slope controller will linearly reduce the plant voltage by this slope Hi Temp Thermal The minimum voltage to which the controller will reduce plant Comp Stop Voltage voltage for thermal compensation Lo Temp Thermal The controller begins to increase the float voltage when the Comp Start Temp lowest measured battery temperature reaches this value Lo Temp Thermal If battery temperature is below the start temperature, the Slope controller will linearly increase the plant voltage by this slope Lo Temp Thermal The maximum voltage to which the controller will increase plant Comp Stop Voltage voltage for thermal compensation Thermal Runaway The temperature at which the controller will reduce the Float Clamp Temp Voltage to Runaway Clamp Voltage Thermal Runaway The Float Voltage to which the controller will reduce for Clamp Voltage temperatures above Runaway Clamp Voltage
54 Vdc Disabled 48 Vdc Disabled 600 A Disabled 200 A 58 Vdc 57 Vdc 48 Vdc Disabled Enabled Disabled Disabled 58 Vdc 12 hours Disabled 35 C 72 mV/C 50.5 Vdc -20 C 0 mV/C 56 Vdc 60C 50 Vdc
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Parameter
Description Selects temperature sensing device to use for battery temperature compensation; Internal sensor or External temp probes. Auto senses when external probe is attached and Thermal Sense automatically adjusts value to external. Selects the units the temperature readings are given in. Either Temp. Units Celsius or Fahrenheit The controller will issue a Low Voltage Disconnect Warning if LVD Warning** the plant voltage falls below this setpoint The system LVD contactor will open if the plant voltage falls LVD 1 Open** below this setpoint LVD 1 The system LVD contactor will reconnect if the plant voltage Reconnect** exceeds this setpoint LVD 1 Reconnect The amount of time that the plant voltage must exceed the LVD Delay Time** reconnect setpoint prior to reconnecting the LVD contactor The 2nd system LVD contactor will open if the plant voltage LVD 2 Open** falls below this setpoint LVD 2 The 2nd system LVD contactor will reconnect if the plant Reconnect** voltage exceeds this setpoint The amount of time that the plant voltage must exceed the 2nd LVD 2 Reconnect LVD reconnect setpoint prior to reconnecting the 2nd LVD Delay Time** contactor Batt Test* Enables or Disables the battery test BD Time* Sets the length of time (minutes) that the battery test will run. Sets the voltage at which an alarm will be generated if the battery BDT Alarm* voltage falls below it during the Bat Test The voltage at which the battery discharge test will abort at when the system voltage drop below this point. This is a user BDT Abort* settable value that should be at least 2V below BDT Alarm. Sets the alarm constant for the Bat Test. 0 will disable Thermal Compensation effects during BD Test. 1 will take Thermal BD Test Constant* Compensation effects into account during test RLY Test Enables or Disables the relay test Ringer Frq*** Frequency of the ringer (17 Hz - 50 Hz) Ringer RMS*** The root mean square of the ringer voltage (85 V - 105 V) Ringer DC The DC value at which the Ringer RMS value is offset. The Offset*** value should be the same value as the float voltage. Ringer Select*** Selects Ringer A/B Password Administrator/User * - Requires LVD and/or proper Shunt ** - Requires LVD *** - Requires Ringer
48 Volt Nominal
External Celsius 44 Vdc 42 Vdc 50 Vdc 20 Sec 42 Vdc 50 Vdc 20 Sec Disabled 30 min 52 Vdc LVD1 Open 0 Disabled 20 Hz 86 Vac -Vfloat A 5001/1001
6.3
Controllers Operation Menu Tree
6.4
REMOTE SIGNALS PFC CONNECTOR DETAILS
Single Core wires of 0.25 to 0.5 Sq. mm size can be connected to Connector/WIRE and your radio communication equipment for remote alarms through potential free contacts as per following PIN/WIRE Connection description: Relay Name Relay A Alarm Name Power Major Wire Color Code Orange Orange-Black Orange-White Red Red-Black Red-White Green Green-Black Green-White Yellow Yellow-Black Yellow-White Blue Blue-Black Blue-White Brown Brown-Black Brown-White SIGNAL DESCRIPTION Common Contact Normally Open Contact Normally Close Contact Common Contact Normally Open Contact Normally Close Contact Common Contact Normally Open Contact Normally Close Contact Common Contact Normally Open Contact Normally Close Contact Common Contact Normally Open Contact Normally Close Contact Common Contact Normally Open Contact Normally Close Contact
Relay B
Power Minor
Relay C
AC Fail Battery on Discharge LVD Open Common Alarm
Relay D
Relay E
Relay F
IMPORTANT NOTE CONTACT RATING OF POTENTIAL FREE CONTACTS IS 0.5AMP, 48VDC. PFC CABLE IS TO BE CONNECTED FROM FRONT IN THE ALARM BACK PLANE. Conditions under which Major, Minor & Common alarms shall appear:
Major Alarm AC Fail High Voltage Warning High Voltage Shut Down Battery on Discharge Any LVD Warning Any LVD Open Distribution Open Single Rectifier Fail Multiple Rectifier Fail System Communication Minor Alarm Redundant Capacity Current Share Auxiliary Alarm High Temperature Common Any of the available alarms
Installation, Operation & Maintenance Manual
7.
V SESIRES WIDE RANGE RECTIFIERS
Valere rectifier modules provide unprecedented power density and power levels in a true plug and play format. With a wide range of available voltages, power ratings, and form factors, the rectifiers allow optimal system design and cost effective deployment from initial install through
Fig-9 V Series Rectifier Module
future upgrades.
7.1
T H E VA L E R E D I F F E R E N C E Industry Leading Efficiency An industry leading 92% efficiency reduces the thermal load thus improving the overall reliability and availability of the system. Flexibility These rectifiers are designed to operate as an integral component in Valeres Compact, Integrated, Modular or Enterprise DC Power Systems. They are extremely flexible and can be operated either with a system controller or as a stand-alone module in telecommunication and enterprise applications.
Optimization Valere Power rectifiers are optimized for the demanding power needs of wireless communications, enterprise and broadband access equipment. SMALL SIZE, BIG POWER At only 2RU, these compact rectifiers can provide up to 2800 Watts of power. The small size can free up space to reduce system size or incorporate additional electronics.
7.2
F E AT U R E S AC Fail Alarm DC Fail Alarm Over-temperature Alarm Meets General Requirements
150VAC to 300VAC Input Up to 92% efficiency Power Factor Correction Hot Pluggable Front panel LED indicators I2C Serial Communications bus
33
www.valerepower.com
Document Reference: VPAP-TD1016 Revision 00 May 18. 2006
8 8.1
Replacement Items
Alarm Controller Replacement
In the event of a controller failure, the system will remain at the last known settings until a new controller is installed. To replace the controller, remove the display by unlatching the wire harness connector and releasing the spring latch. Loosen the controller set screw and slide the controller out of the shelf. Insert new controller and reattach display. Follow the controller set-up procedure of the Operation Guide to re-initialize the system. Remove the Display by unlocking its front. Open the mounting screw. Remove the PFC Ribbon cable & Temperature Probe Slide out the module.
Fig-10 Alarm Controller Replacement
8.2
Rectifier Module Replacement
In the event of a rectifier module failure, the system will continue to run with other rectifier modules until a new rectifier module is installed. Switch-off the respective input MCB of rectifier. Remove the rectifier module by pressing the small press button and pulling the lever as shown in the figure below. Insert the new rectifier module and lock it with the front lever. Switch ON its respective input MCB. Slide in new module
Press the knob of failed module Pull the lever out.
Close the lever
Slide out the module

Fig-11 Rectifier Module replacement
Trouble Shooting
The modular, plug-n-play nature of this plant makes diagnostics and repair very easy. For all conditions listed in the alarm matrix, the controller will display the indicated alarm. The corresponding Form C relay will also toggle to the alarm state.
Make sure that all rectifiers are properly seated and latched into their respective slots. Make sure that all power and signal connectors are properly mated. Table below lists problems and potential solutions. Alarm Minor Alarm Problem Rectifier Current Share, System Redundant Capacity Alarm, Auxiliary Alarm, System Over Temperature Single Rectifier Failure, Multiple rectifier failure, single rectifier failure leaving only one rectifier left working, Battery on Discharge, AC Mains Fail, LVD Warning, LVD Open, Distribution Alarm, System Communication alarm, High Voltage Alarm, or High Voltage Shut Alarm Commercial power has been lost. Solutions Replace bad rectifier or ringer unit.
Major Alarm
Replace rectifier unit(s) in alarm. Adjust BD and LVD settings.
AC Fail
Reset commercial circuit breaker to the dedicated AC circuit that feeds system. Seek alternative power source until power is restored. BD Alarm The system voltage has fallen below Consider replacing batteries in the the BD (batteries on discharge) near future before they are depleted. alarm level. LVD Alarm The battery voltage has fallen below Connect more batteries or find the LVD Alarm value. The LVD is alternative power source before LVD opens. very close to opening. LVD Open The battery voltage has fallen below Replace batteries or find alternative the LVD OPEN value and the power source. batteries have been disconnected from the system. Dist. Alarm Fuse open or circuit breaker Reset circuit breaker or replace the tripped. Circuit breaker is turned fuse. Turn circuit breaker on. off. Temp. Comp. Plant Voltage drops with increasing Temperature compensation is in Active temperature effect reducing the output to the batteries. This is adjustable and may be disabled. Thermal Temperature of batteries has Float voltage has automatically been Runaway exceeded the Thermal Runaway lowered in an attempt to lower the temperature. temperature. If this has not solved the problem, disconnect batteries from the system Comm. Alarm Controller has lost communication Replace the removed module(s) in with one or more rectifiers or the same shelf slot (s). This alarm ringers can also be cleared when display indicates HIT MENU TO CLEAR
I SHARE Alarm
Capacity Alarm
Auxiliary Alarm BD Test Fail High V
HVSD Temp Alarm
One or more rectifier(s) is not Review the current output of the sharing the total system load module(s) in the Review: Module equally. menu. Replace the faulty rectifier(s). The total load current has exceeded Add more rectifiers or reduce the summed current capacity of system load to maintain N number of rectifiers in an redundancy. This can often occur N+1 redundant system. on an initial system turn up when new, completely discharged batteries are charging. Simply wait till the batteries are charged. Indicates a contact closure at the Check the input contact closure you AUX INPUT on Temperature attached to this Auxiliary Alarm. Probe Battery voltage dropped below Batteries are nearing end of life. BDT Alarm value during battery Consider replacing the batteries. discharge test. System voltage has exceeded the Check float voltage settings versus High Voltage Alarm value. Indicates High V alarm value. Float voltage a problem with a rectifier or value should be lower than High V controller. alarm. If values OK, replace faulty rectifier or controller. System voltage has exceeded the Replace faulty rectifier or controller. High Voltage Shutdown value. External or Internal temperature Lower the temperature in the has exceeded the maximum cabinet. If temperature is within temperature values acceptable levels, your Temperature values may be too low. These values can be adjusted through the LAN or modem interface only.
Annexure -A
Product Report
Date: Company Name: Site Name: Site Address: Report Originators Name & Designation: Phone No.: Mobile No.: Product Name: Description Fax No.: Email: System Serial No.
Please give as detailed information as possible. This will simplify our analysis & corrective action. Please forward this product report to:
Email: apcustomercare@valerepower.com
To be filled by Valere Power Received, Name & sign. Feedback Report No. Remarks
Date Date
Action taken by & sign Checked By
Date Approved by
Annexure B
EVALUATION OF USER'S MANUAL

Date:
Customer (Operator) Telecom Equipment Supplier Valere Power Authorized Service Provider Other, please specify
Company Name: Site Name: Site Address: Evaluation Person Name & Designation: Phone No.: Mobile No.: Evaluation of User Manual : Rating From 1 to 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Contents of Information in the text Contents of drawings and illustration Use of Language, Symbols Logical build up Layout Paper format, binding Ease of use Comparison with other Companies Manuals Others, please specify: Remarks, if any:
Fax No.: Email:
Low 2
High 5
Please, forward this evaluation report to following address: VALERE POWER INDIA PVT. LTD. #405, Galleria Tower, DLF City, Phase-IV, Gurgaon-122 002 (Haryana) India Tel. Fax Email +91(124) 4102268 +91(124) 4102269 +91(124) 4102257 apcustomercare@valerepower.com
ERRORS IN USER'S MANUAL Please, specify all printing errors, drawing errors, faulty specification, references, etc. Please, also specify on that what page(s) the errors occur, or send some examples.
Annexure -C
SYSTEM CONFIGURATION: CUSTOMER SPECIFIC

CUSTOMER NAME: TD Vietnam S. Description No. System Configuration 1 2 3 4 5 Input AC Voltage System Output System Mounting Rectifier Rack Capacity No. of rectifiers Modules 230Vac 50Hzs Single Phase -54Vdc 19 Rack Mounting 150A+R Qty-04 in System Type 150A+R System: GS 150A-480-1016 (Sample / Demo) Rating/Remarks Provided/ Not Provided
4 Provided
AC Input configuration 6 7 8 9 Line & Neutral Protected Earth Individual Rect. Mod MCB AC Contactor Provided Provided Provided Provided UIK 16 USL 10 32 A SP Qty. 4 Nos 3 pole 25A/230Vac
DC Output Configuration 10 11 12 13 14 15 16 Battery HRC Fuse 125A Battery Contactor 100A/54 Battery Com Shunt Load MCB 63A Load MCB 16A Load MCB 6A Load MCB 32 A Provided Provided Provided Provided Not provided Not provided Not provided Qty-01 Qty-01 150A/50mV Qty-05
Optional Parts 17 18 19 Lightening Protection Class B Surge Protection Class C Temperature Probe Not provided Provided Provided Single Phase (L-N and N-PE) 01 each
Annexure -D
SYSTEM DRAWING: CUSTOMER SEPCIFIC

S.NO. 1 DESCRIPTION System Isometric view with all covers
System isometric view without top covers
Detail A - AC Distribution
Detail B - DC Distribution
Wiring Diagram
Drawing System in Packed condition
Drawing System Un-packing steps
Site Cable Details
System Mounting on Rack
Note: Drawings not provided with sample / demo system.

Valere Smps Gs150a

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The Power to Innovate

DC Power System VP GS150A-480 1016

Installation, Operation & Maintenance Guide

Document Reference: VPAP-TD1016 Revision 00 May 18, 2006

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

Pre Start / Initial Checks. System Start up.

Installation, Operation & Maintenance Guide

Read This First

About This Manual

Safety and Recommended Practices

Document Reference: VPAP-TD1016 Revision 00 May 18, 2006

Installation, Operation & Maintenance Guide

FCC Compliance Statement Note

Terms & Abbreviation

Document Reference: VPAP-TD1016 Revision 00 May 18, 2006

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

GS150A-480-1016 Standby DC Power System

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

AC Main & Alarm Cable entry holes

Individual Rectifier input MCBs

Fig - 1 AC Distribution with open door front view

DC Power System GS150A-480-1016 (Your Power System output DC Voltage)

Installation, Operation & Maintenance Guide

Load & Battery MCBs & Fuses

+ve Bus Bar

LVBD Contactor & Shunt

-Ve Bus Bar

Installation, Operation & Maintenance Guide

Rectifier Back Plane

Temperature Probe connector Rectifier Modules

PFC Connector Fig 3 Rectifier Shelf with V series rectifiers

Rectifier AC input connector

Rectifier DC output connector Rectifier Slot

Fig-4 Rectifier Shelf without rectifiers

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

General Arrangement/Cabinet Size.

Installation, Operation & Maintenance Guide

Current Protector Rating (A)

NOTE: For lugs and cable size, please refer Annexure D

Installation, Operation & Maintenance Guide

Standby DC Power System

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

Recommended tools for Installation

Installation, Operation & Maintenance Guide

Installation Step Remove Packaging

Installation, Operation & Maintenance Guide

Installation, Operation & Maintenance Guide

Installation Steps AC Main connection

Installation, Operation & Maintenance Guide

Installation Steps Connect the Load(s) to the blade fuses First

Connect Load(s) to the MCB(s)

4.10 Alarm Connections (See figure-5)

4.11 Temperature Probes (Optional) (See figure-5)

Installation, Operation & Maintenance Guide

Alarm Cable Connector # 1 Installation Steps

Temperature Probe connection

4.12 Installation of SMPS Modules (See figure-6)