100 amp 3000uc manual

8/13/2019 100 Amp 3000UC Manual

1/47

LARGE CAPACITY RACK

POWER SYSTEM

SYSTEM MANUAL

LARGE CAPACITY MODULAR RACK POWER SYSTEM BASED

ON

100ApfcSERIES SWITCHED MODE RECTIFIERS

(Compatible with VRLA Batteries only)

MODEL NO. HE-N*100ApfcLCRPSIIIAS PER TEC SPEC. No. GR/FLA/SMP 001/06/June. 2010

MFD BY: M/S EXICOM TELE-SYSTEMS LTD.(AN ISO 9001: 2008 COMPANY)

HEAD OFFICE WORKS:

8, Commercial Complex, Masjid Moth, Shed No. 1-8, Electronic Complex, Chambaghat,Greater Kailash II New Delhi-110048, India Solan (H.P.) - 173213

Tel: +91-11-3088 2624, +91-11-3068 2624 Phone: +91-1792- 230947, 230948, 231260

Fax: +91-11-3068 9013 Fax: +91-1792- 231255

E-mail:[email protected] E-mail:[email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

8/13/2019 100 Amp 3000UC Manual

2/47

CONTENTS

SECTION - 1 INSTALLATION AND COMMISSIONING MANUALINTRODUCTION

IMPORTANT

TECHNICAL DESCRIPTION

INITIAL CHECK ON RECEIEPT AT SITE

INSTALLATION & COMISSIONING OF POWER PLANT

COMMISSIONING THE POWER PLANT

LIGHTNING PROTECTION UNIT

INTERCONNECTING CABLE SET

SECTION - 2 RECTIFIER MANUALWARNING

IMPORTANT

QUICK REFERENCE CONTENTS


INITIAL CHECKS ON RECIPTS AT SITE

AC POWER QUALITY & EMI COMPATIBILITY

FAMILIARIZATION WITH THE RECTIFIERTESTING & ADJUSTMENT PROCEDURE

ROUTINE MAINTENANCE PROCEDURE

TROUBLESHOOTING

TECHNICAL SPECIFICATIONS

SECTION - 3 MONITORING AND CONTROL MODULE MANUALINTRODUCTIONCAUTION


INSTALLATION & COMMISSIONING

FRONT PANEL CONTROLS

STEP BY STEP COMMISSIONING OF A MCM FOR AN EXAMPLE SYSTEM

TROUBLESHOOTING

USER RESPONSE CARD

FAULT REPORT

WARRANTY CERTIFICATE

8/13/2019 100 Amp 3000UC Manual

3/47

SECTION - 1

INSTALLATION & COMMISSIONING MANUAL

INTRODUCTION

Exicom Large capacity Rack Power systems employ Exicomspfc series Switched Mode Rectifiers to provide upt

3000 Amps (max.) of regulated power for powering telecommunication equipments and also keep batteries floate

across the load in fully charged condition so that uninterrupted operation of vital communication network continue

even when AC mains fail.

Todays sensitive electronic loads and state of the art VRLA batteries require continuous electronic supervision an

features like Temperature Compensation, Battery path current limiting etc. A Micro-controller based Monitoring &

Control Module (MCM) carries out all these vital tasks.

For installation and periodic checking contactors are provided in each battery path. Ratings and the number o

contactors depend upon the particular installation, which is normally specified by the user.Every exchange design calls for different distribution of DC power typical to itself. When power plants are supplie

against any particular switch the DC distribution is configured accordingly.

All the above modules and sub-assemblies are housed in a rack. Because of the modularity of the whole architectur

the system is extremely flexible. A variety of combinations can be worked out to serve any kind of requirement an

provision for future expansion. Following sections contain further details on these modules and installation &

commissioning procedure.

Following abbreviations are used in the text for convenience.

MCM : Monitoring & Control Module.

SMR : Switched Mode Rectifier.

ACDB : AC Distribution Panel.LPU : Lightning protection module.

BI Panel : Battery Isolation Panel

RU : Rack Unit.

CB : Circuit Breaker.

8/13/2019 100 Amp 3000UC Manual

4/47

IMPORTANT

Please read this section carefully before attempting to install the system.

The equipment you are about to handle is a product of the latest in SMPS technology. The front end Active Powe

Factor Correction circuit develops very high DC voltages inside. This voltage may persist for some time even whe

the equipment has been switched off and disconnected from the input mains. No attempt should ever be made to ope

the equipment. It is stressed here that the equipment has no user serviceable part inside. In case of an

malfunction the matter should be brought to the notice of the manufacturer stating the description of the fault and th

serial number of the equipment.

Warranty stands void in case of any unauthorized tampering.

Caution:The equipment employs sensitive electronics that can be damaged if subjected to electrical and climati

environment other than those for which the product is designed. Such damages will not be entertained a

manufacturing defects.

It is strongly recommended that proper entry-level protection along with reliable earth connection be fir

installed before connecting the equipment to the AC mains.

The SMRs are power factor corrected. Hence no external capacitors are required.

Caution: In case external power factor correction capacitors are connected they should be removed befor

installing RPS as large spikes can be generated due to inductive switching in the proximity of the installation

which could damage the SMRs.

8/13/2019 100 Amp 3000UC Manual

5/47


The various sub-assemblies of the Rack Power System (Fig. 1.1) are discussed in this section.

RackAll the sub-assemblies are mounted in a rack750mm wide rack. These racks are of rigid steel structure fabricate

with CNC machines to provide the accuracy required to mount a verity of assemblies. A superior powder coatin

technology together with prepainting surface finishing provides total atmospheric protection.The height is 45RU

and the depth is 600mm. Provision for grouting these to the floor is also given. The contents of the rack are accessibl

from rear and front. Rectifiers are inserted or extracted from the front. No front door is provided. Rear door

removable.

Monitoring & Control ModuleThis module carries out all the supervisory and control of the power plant. The functions carried out by this modulare many and it is important to know these. For this reason a separate part inside the manual is supplied for MCM.

through study of this section is recommended before use.

Switched Mode RectifierEXICOMspfcseries SMRs convert AC mains to regulated DC for powering telecom installations. They are hig

efficiency converters with nearly unity power factor and draw near sinusoidal current from the mains. A separate pa

is available inside this manual for SMR.

A thorough study of this section is recommended before use.

ACDB (with inside SPU STAGE-II)

The incoming AC main is terminated in this panel. Circuit breakers have been provided for distribution of AC tevery rectifier. Terminal blocks have been provided for input terminations as well as for distribution to each SMR

SPU and Galvanic isolation contactor is part of this panel.

LPU (Stage-I)

To ensure total protection, entry-level protection is provided near the LT panel by the LPU. A Co-ordinatio

distance of 15 meters is to be maintained between LTP+SPU.

B.I PanelDepending on the rating and the number of MCBs or the particular rack power system configuration, the facility

housed in a rack along with SMRs. Due to the better flexibility a variety of configurations can be made

Arrangement is provided to monitor currents flowing in or flowing out of individual batteries. Audio and visual alarmis generated when any of the batteries are disconnected from the system. Adequate de-rating is done while selectin

the contactor size.

8/13/2019 100 Amp 3000UC Manual

6/47

Figure 1.1 3000A Rack Power System

HIMACHALEX ICOM COMMUNICATIONS LIMITED

CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL

HIMACHALEXI COM COMMUNICATIONS LIMITED

CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL

MONITOR

-

ON

+

OFF


OUTPUT


+MONITOR

OUTPUT

+MONITOR

0A

100A

CURRENT

RESETFAN FAIL

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOAD OV

-

0A

100A

CURRENT

OVERLOAD

FAN FAIL

RESET

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

-

COMM. FAIL

OVER TEMP.

OFF

ONRESET

FAN FAIL0A

ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOADOV

100A

CURRENT

FUSEFAIL

REC.DIS +

-MONITOR

OUTPUT

OFF

ONFAN FAIL

0A

100A

CURRENT

ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOAD OV

COMM. FAIL

OVER TEMP.


ON

OFF

OVERLOAD

FAN FAIL0A

RESET

ACOK/ABN

REC. OK/FAIL

LOADUV

LOADOV

100A

CURRENT

FUSEFAIL

REC.DIS

ON

+

-MONITOR

OUTPUT

OFF

ON

+MONITOR

OUTPUT

OFF

0A

OVERLOAD

FAN FAIL

100A

CURRENT

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV


COMM. FAIL

OVER TEMP.

ON

OFF

LOADUVCURRENT

OVERLOAD

FAN FAIL0A

RESET

ACOK/ABN

REC. OK/FAIL

LOADOV

100AFUSEFAIL

REC.DIS

-

ON

+MONITOR

OUTPUT

OFF

LOADUVCURRENT

0A

OVERLOAD

FAN FAIL

100AACOK/ABN

REC. OK/FAIL

LOAD OV

+MONITOR

OUTPUT



0A

CURRENT

100A

COMM. FAIL

OVERLOAD

LOADUV

FAN FAIL

-

RESET

FUSEFAIL

REC.DIS

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOAD OV

COMM. FAIL

OVER TEMP.


ON

OFF

OVERLOAD

LOADUV

FAN FAIL0A

CURRENT

RESET

ACOK/ABN

REC. OK/FAIL

LOADOV

100AFUSEFAIL

REC.DIS

MONITOR

-

ON

+OUTPUT

OFF

0A

CURRENT

OVERLOAD

LOADUV

FAN FAIL

100AACOK/ABN

CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0AFAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-

ON

+

OFF

OVER TEMP.

COMM. FAIL


OVERLOAD

0AFAN FAIL

100A

CURRENT

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

OFF

ONRESET

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

+

-MONITOR

OUTPUT

OFF

ONRESET

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

+

-MONITOR

OUTPUT





+MONITOR

OUTPUT



+MONITOR

OUTPUT

0A

100A

CURRENT

-OVERLOAD

FAN FAILRESET

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

CURRENT

0A

100A

-L O AD U V C O M M. FA I LOVERLOAD

FAN FAIL

RESET

FUSEFAIL

REC.DIS

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOAD OV


COMM. FAIL

OVER TEMP.

ON

OFF

OVERLOAD

FAN FAIL

0A

RESET

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

100A

CURRENT

FUSEFAIL

REC.DIS

-

REC. OK/FAIL

LOAD OV


OFF

ON

-

RESET

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

+MONITOR

OUTPUT

OFF

ON

-COMM. FAIL

RESET

FUSEFAIL

REC.DIS

OVER TEMP.

+MONITOR

OUTPUT

OFF

ON

MONITOR

RESET

COMM. FAIL -

FUSEFAIL

REC.DIS

OVER TEMP.

+OUTPUT

8/13/2019 100 Amp 3000UC Manual

7/47


Following sequence of action is recommended when the rectifier is received at site:

a) Although the equipment had left the factory properly packed instances of mishandling by the transporter are quit

common. Hence before taking delivery ensure that the packing is intact and free from any signs of damage o

improper handling. If any of these are suspected the manufacturer must be informed immediately for remedial actioand insurance.

b) Unpack the equipment carefully. Ensure that no force is applied in removing the packing, which could damage th

contents.

c) Never try to energies any equipment if any transit damage is suspected. Doing so irreparable damage may tak

place.

d) Tally the contents with the packing list. Report immediately if any anomaly is noticed.

e) Familiarize with the various sub-assemblies with the drawings enclosed. Call for assistance if required or in doubt

8/13/2019 100 Amp 3000UC Manual

8/47

INSTALLATION & COMISSIONING OF POWER PLANT

Note: Installation of this RPS involves handling 440 Volts AC and high AH capacity batteries, whic

could deliver, more than 1000 Amps when shorted. The job should be undertaken by qualified personne

at his or her own responsibility. Exicom takes no responsibility or liability in the event of any injur

inflicted on person or property due to improper use and practice.

Tools Requirement:The following tools are required to install and commission the RPS.

1) Spanner set.

2) Screw driver set.

3) Richest spanner set.

4) Cable cutter.

5) Cable crimping tool

6) Star headed screwdriver

7) Multimeter with test leads.

Step1: Rack Positioning (Figure 1.2)Front and rear access is required for installation and maintenance. Leave at least 1-meter space between the rear o

the rack and the wall, so that it can be easily accessible.

8/13/2019 100 Amp 3000UC Manual

9/47

Figure 1.2 Bare Rack

Step 2: Rectifier numberingRectifiers can be numbered 1,2,3... starting from the top most one as shown in Figure 1.5.

Step 3: Rack preparation (Figure 1.3)

1. Remove the rear cover of the rack.2. Place the rack in its position and grout the same to the floor.

8/13/2019 100 Amp 3000UC Manual

10/47

Figure 1.3

Step 4: Battery connections

1. Connect battery 1 +VE to B1+, battery 2 +VE to B2+ marked on battery termination bus bars and so on.2. Similarly, battery 1 -VE to marked B1-, battery 2 -VE to B2- marked on battery termination bus bars and so on.

3. Keep the circuit breakers of DC output CB panel in off condition before connecting the cable from the battery.

8/13/2019 100 Amp 3000UC Manual

11/47

8/13/2019 100 Amp 3000UC Manual

12/47

8/13/2019 100 Amp 3000UC Manual

13/47

Step 5: Installation of the ACDB (with inside SPU) (Figure 1.4)The ACDB (inside SPU) is to be mounted at its position as given in assembly drawing shown below.

AC Input to SMRs

Connect SMR AC Input Cable free ends to the terminal block for AC input to SMR on ACDB Panel. Route the cabl

thru the clamps provided.

Figure 1.4

Step 6: Mounting of MCM & SMRs (Figure 1.5)

The MCM is to be mounted above ACDB Panel at its position as shown in given drawing.SMRs are to be mounted below ACDB on the channels on the rack as shown in given drawing.

For all inter connection cables please refer to table-1

8/13/2019 100 Amp 3000UC Manual

14/47

L OA D UV C O MM . F AI LL OA D UV C O MM . F A IL -

HIMACHALEXICOM COMMUNICATIONSLIMITED

OUTPUT


+MONITOROUTPUT

+MONITOR

OVERLOAD

100A

CURRENT

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOAD OV

-

0A

RESETFAN FAIL

100A

CURRENT

FUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

-

0A

RESET

OVERLOAD

FAN FAIL

OVERLOADON

OVERLOADON


COMM. FAIL

OVER TEMP.

OFF ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOAD OV

100A

CURRENT

FUSEFAIL

REC.DIS

FAN FAIL0A

RESET

+

-MONITOR

OUTPUT

OFF 100A

CURRENT

ACOK/ABN

REC. OK/FAIL

OVERLOAD

LOADUV

LOAD OV

0AFAN FAIL


COMM. FAIL

OVER TEMP.

OFF ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

100A

CURRENT

FUSEFAIL

REC.DIS

ONOVERLOAD

FAN FAIL0A

RESET

+

-MONITOR

OUTPUT

OFF






LOAD OVOUTPUTL OA D O V O V ER TE M P.L OA D O V O V ER TE M P. OUTPUT

ONRESET

ONRESET

0AFAN FAIL FAN FAIL

0A 0AFAN FAIL

LOADUV-

100A

CURRENT

ACOK/ABN

REC. OK/FAIL

LOADUV

LOAD OV

ON

0A

OVERLOAD

FAN FAIL

MONITOR


+MONITOROUTPUT


+MONITOR

OUTPUT

-CURRENT

100A

CURRENT

FUSEFAIL

REC.DIS

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOAD OV

0A

RESET

COMM. FAIL

OVERLOAD

FAN FAIL

LOADUV

100AFUSEFAIL

REC.DIS

OVER TEMP.

ACOK/ABN

REC. OK/FAIL

LOAD OV

0A

CURRENTCOMM. FAIL

RESET

OVERLOAD

LOADUV

FAN FAIL

-

CURRENTMONITOR

-CURRENT


COMM. FAIL

OVER TEMP.

OFF ACOK/ABN

REC. OK/FAIL

LOAD OV

100A

CURRENT

FUSEFAIL

REC.DIS

ONOVERLOAD

FAN FAIL

LOADUV

0A

RESET

+MONITOR

OUTPUT

OFF 100A

CURRENT

ACOK/ABN

REC. OK/FAIL

LOAD OV

ON

0A

OVERLOAD

FAN FAIL

LOADUV

COMM. FAIL


OVER TEMP.

OFF ACOK/ABN

REC. OK/FAIL

LOAD OV

100AFUSEFAIL

REC.DIS

ONOVERLOAD

LOADUV

FAN FAIL0A

CURRENT

RESET

+OUTPUT

OFF 100A ACOK/ABN

REC. OK/FAIL

LOAD OV

-MONITOR

ON

CURRENT

0A

OVERLOAD

LOADUV

FAN FAIL

+


100AFUSEFAIL

REC.DIS

ACOK/ABN

REC. OK/FAIL


OFF ACOK/ABN

REC. OK/FAIL

100AFUSEFAIL

REC.DIS +

OFF 100A ACOK/ABN

REC. OK/FAIL

OUTPUTOVER TEMP.

RESETON

COMM. FAIL -

ON

OFFFUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

+

-MONITOR

OUTPUT

RESET

OFFFUSEFAIL

REC.DIS

COMM. FAIL

OVER TEMP.

+

-MONITOROUTPUT

ONRESET

MONITOR

-

OFFFUSEFAIL

REC.DIS

OVER TEMP.

+MONITOROUTPUT

ONRESET

COMM. FAIL

OFFFUSEFAIL

REC.DIS

OVER TEMP.

+OUTPUT

ONRESET

COMM. FAIL -MONITOR

OFFFUSEFAIL

REC.DIS +

Figure 1.5 MCM & SMRs

Step 7:MCM ConnectionsMake following connections to MCM as per details provided in MCM manual:

MCM to ACDB Connection (AC Supply)

MCM to SMRs (Alarm and Control Cable)

MCM to BI Rack (25 Way Ribbon Cable)

MCM to battery Chassis (Temp. Probe)

8/13/2019 100 Amp 3000UC Manual

15/47

Step 8: Connection of DC outputs from SMRs

Connect lugged end of SMRs output cables (RED/WHITE) at common bus bar & connect lugged

end of cables (BLACK/BROWN) at O/P.

Step 9: Connecting the remote alarm communication cable (Figure 1.6)

1. Connect the end connector on its mating connector in the MCM front panel.

2. Connect the daisy-chained connectors on the 15-pin receptacle on the front panel of each SMR.

Front view

Figure 1.6

Step 10: AC Input Connection to RPS (Figure 1.7)Copper cables for I/P + earth + neutral is needed. Connect this cable from LT panel to I/P terminal

block of ACDB.

Daisy chain remote alarm

communication cable

8/13/2019 100 Amp 3000UC Manual

16/47


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL

MONITOR

-ON

+

OFF

CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


CURRENT

0A FAN FAIL

LOAD OV

LOADUV

OVERLOAD

RESET

100A

REC. OK/FAIL

ACOK/ABN

REC.DIS

FUSEFAIL

OUTPUT

MONITOR

-ON

+

OFF

OVER TEMP.

COMM. FAIL


Figure 1.7 AC Input to RPS

Step 11: RPS Remote Alarm ConnectionsThe RPS alarms can be monitored remotely by connecting a cable at terminal block on the rear panel

of MCM. For location and pin out refer MCM Manual.

Step12: Power connection to SMRsGently insert the three pin round input connector on the back side of SMR & tight it properly.

Step 13: Power connection to exchangePower connection to the exchange is done by the DCDB (optional) which has been custom designed for the particula

switch and the installation.

8/13/2019 100 Amp 3000UC Manual

17/47

Step 14: Power connection to BatteriesEnsure that all the circuit breakers are in open position & the battery fuses located at the battery stand is removed

Battery terminations on the BI panel are to be connected to the batteries. Ensure correct polarity.

Step 15: Remote monitoring by RS 485 port

With this the installation of the system is over and it is ready for commissioning.

COMMISSIONING THE POWER PLANTAttention:

1. This activity is to be carried out by qualified and experienced personnel only.2. Check if any external Power Factor capacitors are connected to the mains. If yes, they must

be removed.

3. Check whether the mains is well within the range i.e. 320V to 480V phase to phase.

4. Check Earth & Neutral connections.

5. Ensure installation of Surge & Lightning protection modules.6. Ensure proper earth connection.

7. Check voltage between neutral & earth. It should not be more than 10 volts in any case.

8. Check AC earth connection between Master Rack & Slave Rack.

Step 1. Remove all AC, DC & communication connectors from the rectifiers.

Step 2. Turn on single-phase AC mains from the LT panel.

Step 3. Check the MCM. No alarm other than under voltage should glow.

Step 4. Read AC mains voltage on the MCM by the front panel controls.

Step 5. Connect AC connector on the SMR No.1.

Step 6. Turn on the corresponding MCB on the ACDB & DC MCB at the back of SMR.

Step 7. Press the Volt. select button on the rectifier front panel to read the voltage. This should be set at 54 Volt

This voltage can be adjusted (see Adjustment of Float Voltage in rectifier manual).

Step 8. Turn off the MCB for the SMR No.1 & Connect AC connector on the SMR No.2.

Step 9. Turn on the 2nd SMR and adjust the voltage.Step 10.Repeat this for all the SMRs.

Step 11.Connect test load to the output of the power plant. Ensure that the load doesnt exceed the capacity. It

better to connect somewhat less load when turning on initially. The load can be increased after adjusting th

current limiting.

Ensure that battery is not connected at this stage.

Step 12. Insert DC, AC & Communication connectors on all the SMRs.

Step 13. One by one turn on all the MCBs feeding the installed SMRs.

Step 14. On the MCM read the total load current.Step 15. Divide the current value by the number of SMRs installed.

Step 16. Identify the SMRs that are taking the maximum & minimum load.Step 17. Reduce the voltage by fine control switch for the SMRs taking more load and reverse

for the SMRs taking less load.

Step 18. Repeat the procedure till all the rectifiers are taking nearly equal current.

It is best to do the sharing on 70% loading.

Step 19. Increase the load and check sharing.

Now the Power Plant is commissioned, batteries and actual load can be connected.

8/13/2019 100 Amp 3000UC Manual

18/47

SECTION 2

RECTIFIER MANUAL

WARNING

There are dangerous voltages (440V AC phase to phase and 400V DC) within the

rectifiers units. They must only be opened and serviced by qualified personnel. Large

charged capacitors internal to the unit make it hazardous to open even when

disconnected from mains.

Unauthorized disassembly of any unit voids the warranty.

8/13/2019 100 Amp 3000UC Manual

19/47

IMPORTANT

Please read this section carefully before attempting to install the rectifier.

The equipment you are about to handle is a product of the latest in SMPS technology. The front end Activ

Power Factor Correction circuit develops very high DC voltages inside. This voltage may persist for som

time even when the equipment has been switched off and disconnected from the input mains. No attemp

should ever be made to open the equipment. It is stressed here that the equipment has no useserviceable part inside. In case of any malfunction the matter should be brought to the notice of th

manufacturer stating the description of the fault and the serial number of the equipment.

Warranty stands void in case of any unauthorized tampering.

Caution:The equipment employs sensitive electronics, which can be damaged if subjected to electrical an

climatic environment other than those for which the product is designed. Such damages will not b

entertained as manufacturing defects.

It is strongly recommended that proper entry- level protection along with reliable earth connection b

first installed before connecting the equipment to the AC mains.

EXICOMs High Voltage Disconnect along with Surge & Lightning Protector wall mounted modules whe

mounted near the LT panel ensure proper protection against erratic and noisy AC mains.

When the rectifier is energized out side the rack the AC input must be fed from a 3-Pole circuit breaker o

32 Amps with a breaking capacity of 10kAmps minimum.

The rectifier must be installed in a dust free atmosphere. Acid fumes and presence of corrosive gases in th

air will certainly have a detrimental effect on the equipment and hence care is required. Proper ventilation i

required. Remember that with 91% efficiency each rectifier will be dissipating 500W in heat. This heat mu

be removed from the room by ventilations. Although the rectifier is designed to operate at 50 deg.C

operation at lower ambient will certainly improve overall reliability.

The complete set of manuals must be thoroughly studied beforehand and in case of any doubt clarificatio

can easily be obtained by calling the numbers listed in the feedback format.Himachal Exicom Communications Limited in pursuit of excellence, innovation & improvement solicit

constructive suggestion from the user.

8/13/2019 100 Amp 3000UC Manual

20/47

QUICK REFERENCE CONTENTS

Familiarization with the rectifierRefer to fig. 2.1 for the front panel details and fig. 2.2 for the rear panel details.

With the aid of these drawings the various controls and indications on the front panel and the connections on the rea

panel can be better identified.

At the center of the front panel the LED display is situated. This display normally displays the current supplied by threctifier.

On the right of the display the alarm & status indicating LEDs are situated. Fault LEDs are red in colour. A 15 pin

D type connector is located here which is used to communicate with the MCM.

A red coloured push button is situated here by which latched fault indications can be resetted.

Having familiarized with the front panel turn to the rear panel. Both the AC input and DC output connectors are

located in the rear panel. The AC connector is three pole circular and the DC connector is two pole rectangular, can

be easily identified. The DC connector is specially crafted to cater for high DC current and positive snap in contacts

The front & rear panel features of the power modules are illustrated below, where information on each particular

feature is located.

Figure 2.1: Power Module Front Panel

8/13/2019 100 Amp 3000UC Manual

21/47

Figure 2.2: Power Module Rear Panel

Figure 2.3: AC input connecter for Power Module

Figure 2.4: DC output connector for Power Module

+VE (Common)

Brown / Red

--VE (Live) White / Black

8/13/2019 100 Amp 3000UC Manual

22/47

AC POWER QUALITY & EMI COMPATIBILITY

A) AC Power Quality

Reliability is of prime concern when designing an AC-DC power system for communication sites. Poor AC inputpower quality can seriously impede system reliability. In particular, transient disturbances on the power lines can

severely weaken or cause failure of semi-conductors in power supply and communication gear. It is important that

you know the input power quality when installing the system. Following is some basic information on the subject:

Causes

Transients are characterized as a voltage pulse of high energy and very short duration impressed upon the AC

waveform. These over voltage pulses can range from 1 to 100 times the normal AC voltage level and can last for a

fraction of a cycle to a few cycles. Transient disturbances can be placed into two categories:

- Lightning generated- Equipment generated

A direct lightning hit on a utility power line will cause a high-energy voltage transient to travel in both directions

along the power line. The disturbance can affect equipment hundreds of miles from the strike point.

Equipment generated transient sources include utility fault conditions and load switching as well as on site equipmen

such as pumps and air-conditioning loads, motors, phase control equipment.

Recommendations

All EXICOM power modules are designed to meet IEC 61000-4-5 requirements for surge immunity withstand

capability. The AC power source should confirm to this specification to ensure reliable power supply operation. If th

power supply source quality is suspect or unknown, it is recommended that an AC power quality survey to be

conducted before installation.

EMI (Electro-magnetic interference) considerations

The power modules employ switch mode technology to convert AC to DC. They are designed to produce minimal

EMI levels when operating [compliant to international standards IEC-CISPR 22 A (radiated) and IEC-CISPR 22

A (conducted)].

8/13/2019 100 Amp 3000UC Manual

23/47


The rectifier is based on the latest trend in SMPS technology and operates at frequency higher than 20kHz

This gives the rectifier its compact and lightweight size. There are 6 principal sub-assemblies inside. Thes

are discussed separately below.

1. Input Stage:

The AC input is fed from the circuit breakers in the ACDB module in the rack. The input connector i

located at the back of the equipment. The input is then fed to the EMI/RFI filters. Relays have been used in

each phase to disconnect AC input in the event of fault. The AC power is the fed to an in-rush preventio

circuit. The filters ensure that EMI generated by the high frequency power stage doesnt escape th

enclosure. The

Bi-directional nature of the filters also prevents EMI/RFI from out side to enter the rectifier. The in-rus

protection circuit keeps the in-rush current limited to a value, which is significantly, lowers than the full loa

value.

2. Active Power Factor Correction Stage:The filtered and conditioned AC mains is received by this stage and is the converted to high voltag

regulated DC of about 400 Volts. The conversion is carried out in such a manner that the input current i

shaped according to the Sinusoidal form of the input voltage maintaining near unity Power Factor (typicall

0.99). The control electronics feature EXICOMs proprietary technology, which results in low neutra

current while still providing input current harmonic distortion less than 10%. Operating temperature has n

effect at all on the Power Factor and distortion.

3. DC/DC Converter Stage:

The regulated HVDC produced by the previous stage is fed to this stage. This HVDC is switched at high

frequency and stepped down by high frequency transformers. The stepped down voltage is rectified by hig

efficiency and fast diodes and the fed to L-C filters which produces smooth DC output. The control is baseon Current-mode PWM technology. This technology offers the following benefits: -

a) Stable control loop.

b) Feed-forward feature for fast input transient correction.

c) Inherent short circuit protection.

The entire high frequency switching is done by state of the art MOS devices, which exhibit very low losses

The filter capacitors are of low ESR type. Low ESR results in better ripple figure along with lesse

dissipation in the capacitors while encountering high frequency ripple current.

4. Output Stage:

The regulated LVDC is fed to this stage. An additional filter is used in this section to remove any switchin

noise which might have escaped due to inter winding capacitances of the filter inductors and the ESL of thbulk filter capacitors. A shunt is installed to monitor the output current.

8/13/2019 100 Amp 3000UC Manual

24/47

5. Supervisory stage:

The complete supervisory electronics is housed on a single PCB fixed on the front panel of the rectifier. Th

C based circuit contains field proven modules using components which have been proven in SMP

rectifiers for over a decade. The LEDs, are mounted on this PCB. This stage caries out the followinfunctions: -

a) Generation of Under voltage alarm.

b) Generation of Over voltage alarm and shut down.

c) Generation of over voltage droop and shut down in case of excessive droop.

d) Generation of rectifier alarm.

e) Generation of AC available status.

f) Generation of fan failure alarm and shut down.

g) Indication of float/charge mode of operation.

h) Interaction with MCM for mode change.

i) Interaction with MCM for temperature compensation.

j) Interaction with MCM for shut down in case of abnormal AC mains and over voltage.k) Interaction with MCM for alarm extension.

Interaction with MCM is carried out via control cable that is terminated on this card on a 15 Pin D

type connector.

6. Fan speed controller stage:

In order to enlarge the life of the DC fans used in the equipment regulated DC voltage is fed to these. A

down converter used in this card steps down 48V to regulated 12V for the fans. Electronic circuits monito

the current drawn and the back EMF developed to detect either failure or malfunction of the fans. Th

information is sent to the supervisory stage for alarm generation and eventual shutdown of the equipment.

8/13/2019 100 Amp 3000UC Manual

25/47


Following sequence of action is recommended when the rectifier is received at site:

a) Although the equipment had left the factory properly packed, instances of mishandling by the transporte

are quite common. Hence before taking delivery ensure that the packing is intact and free from any signs o

damage or improper handling. If any of these are suspected the manufacturer must be informed immediately

for remedial action and insurance.b) Unpack the equipment carefully. Ensure that no force is applied in removing the packing which coul

damage the rectifier.

c) After unpacking keep the rectifier on its normal position and again check for any mechanical damage. D

not ever switch on a rectifier when a mechanical damage has been noticed. This may lead to irreparabl

damage of the rectifier and may also result in injury or shock hazards. Notify manufacturer immediately. D

not put any weight on the lid of the rectifier.

Note: The rectifier handles are only for guiding it in the shelf and not for lifting.

d) Gently shake the rectifier and if any sound suggesting presence of something loose is heard notify th

manufacturer and keep the equipment aside.

e) Check the packing for cables and accessories as per the packing list. If any anomaly is noticed the matte

should be reported to the manufacturer.

ROUTINE MAINTENANCE PROCEDURE

The rectifier is based on solid-state technology and engineered in such a fashion that practically n

maintenance is required. How ever the following procedure may be adopted to ensure trouble free operation

a) Every 15 days check for dust accumulation. Use a dry soft lint free cloth to gently brush off dust. Do no

scratch the window for the LCD display.

b) Check the input connector for proper tightness after switching off the unit.

d) Similarly check the output connector.

e) Check if the fans are moving freely and they are not producing any abnormal noise.

f) Press the Voltage selector button to check if voltage metering is OK.

8/13/2019 100 Amp 3000UC Manual

26/47

TROUBLE SHOOTING

The rectifier has been designed to offer reliable service through out its life. However a random failur

cannot be ruled out. As mentioned earlier high voltage surges in the AC lines can be damaging unless entry

level protection is provided near the LT panel.

It is once again stressed that the equipment is not user serviceable and no attempt should be made to open

the unit. The following table gives solutions to commonly occurring problems, which can be attended to bthe user.

S.No. Observation. Action to be taken. Remarks.

1. Unit not turning on. a) Check if any fault indication

is glowing.

b) Check input mains &

connection.

c) Check input connector

whether it is properly inserted

and screwed.

d) If mounted in the rackremove DC connector as well as

the control cable and retry.

a) The fault needs to be

attended first.

b) When connected to the

MCM the unit will shut

down in case of AC

abnormal. Check

indication on MCM.

d) If unit turns on connectthe control cable & try. If

unit doesnt come on the

MCM may be responsible.

2. Output voltage low. a) Remove DC connector &

control cable and retry.

b) Check voltage setting & retry.

a) Load could be more

than the capacity or the

MCM may be responsible.

b) Do not keep on trying if

there is no increase.

Report to factory.

3. Output voltage high. a) Remove DC connector &

control cable and retry.

b) Do voltage setting to check if

voltage is decreasing.

Report to factory.

4. Overload. a) Check the load it may be too

high.

b) Check the current limit

setting.

c) Check for short circuit in the

load path.

Do not retry without

carrying out thorough

checking.

8/13/2019 100 Amp 3000UC Manual

27/47

S.No. Observation Action to be taken. Remarks.

5. Fan fail. a) Check whether the fans are

really not moving.

b) Check whether the rotor is

jammed by some mechanical

deformity.

a) Detection ckt.

malfunction can

cause false alarm.

6. Unit not taking load. a) Check the load it may be too

high.

b) Check the current limit

setting.

In case the remedies suggested above dont yield desired results report the matter to the manufacturer givin

as detailed observations as possible so that quick diagnosis can be carried out. Always mention the seria

number of the unit.

Contact factory on telephone and feel free to discuss the problem observed with engineers who would guid

accordingly.

8/13/2019 100 Amp 3000UC Manual

28/47

TECHNICAL SPECIFICATIONS

The rectifier fully meets and surpasses the requirement of the latest TEC specifications. Following is th

brief technical specifications.

Input: 320 to 480 Volts phase-to-phase AC, 4 Wire, 48 to 52Hz.Output: 56 Volts at 100 Amps.

Power factor: 0.99 at full load and 400Volts AC input.

Current harmonic distortion: Less than 10% at full load and 400 Volts AC input.

Efficiency : 91% at full load and 400 Volts AC input.

Ripple & noise : 100mV peak-to-peak & less than 2mV psophometric.

Acoustic noise : Less than 45dBA.

Transient response : Limited to 5% & recovery within 10mSec.

Protections : Over voltage, Over load, Short circuit.

Indications : AC on, Under voltage, Over voltage, Over load, Fan fail,

Float mode, Charge mode, Rectifier fail.

Environmental : As per QM-333B2 of BSNL

Cooling : Fan cooled.

Dimensions : Height 266mm, Width 220mm, Depth 455mm.

8/13/2019 100 Amp 3000UC Manual

29/47

SECTION 3

MONITORING AND CONTROL

MODULE

Introduction

The Monitoring & Control Module (MCM) is a micro controller based system capable of monitoring, supervising &controlling a floated battery power plant. It packs all the features required for supporting state of the art SMF batterieIts menu driven program makes it extremely user friendly. Through front panel entry the module can be configured fopractically any capacity making it versatile. Large alphanumeric 16 characters 2 line front panel LCD display has beechosen for easy viewing from a distance. The construction is modular in nature making it easy to install. The user iadvised to read the manual carefully before attempting to install & operate.

Caution

1. The equipment is not user serviceable & hence no attempt is to be made to open or tamper the unit. Warrantstands void if opened or tampered.

2. Installing & commissioning requires handling of high voltage AC mains & very high capacity batteries. Henceonly suitably trained & qualified personnel should undertake installation & commissioning. The manufacturertakes no responsibility for loss of life & property caused by improper handling.

3. Proper understanding of the functioning & various connections are necessary. In case of any doubt themanufacturer is to be contacted for proper clarification.Warranty covers manufacturing defects only & not improper use.

8/13/2019 100 Amp 3000UC Manual

30/47

Front panel of MCM

MCM figure 1

Back panel of MCM

MCM figure 2

Alarms & Indicat ions :

Three 5mm bi-LEDs are provided for critical system status. LEDs are as follows-

a) System O.K/fail- green in case of system ok and red in case of system fail.b) AC OK/ABNORMAL- green in case of ac ok and red in case of ac abnormal.c) FLOAT/CHARGE- green in case of float mode and amber in case of charge.

Apart from these three LEDs, seven more alarm LED have been provided for immediate attention.

d) Ac available (green)e) Any rectifier fail-(red)f) Low voltage battery disconnect (lvd)- (red)g) MBD (mains on battery discharge) -(red)h) Any battery isolated.-(red)i) Battery periodic test fail.-(red)

j) SPU element fail-(red)

Connector Description:

A- 3 pin female connector for dc power supply.B- 15 way d type male connector from lvd card for dc contactor.C- 15 way d type male connector from ac interface card for ac sample information.D- 15 way d type female connector for v&I card for voltage and current info.E- 9 way female connector for rectifier communication.F- 25 way male connector for pfc contact extension.

54.0V / 3000A

System OK MENU ENTERUP

DOWN

Alarm

Reset

Audio

Reset

i

ii

iii

iv

v

vi

vii

viii

ix

x

8/13/2019 100 Amp 3000UC Manual

31/47

G- 9 way female connector for RS485 communication.H- 9 way male connector for RS232 communication.

Technical Description

This state of art design works for single phase as well as 3- phase application.

1. Specification:

Input: Single-phase AC mains 90V to 300V phase to neutral.DC 40 to 60 Volts.

Measurementa) Load voltageb) Individual battery voltagesc) Load currentd) Individual battery currentse) System currentf) Input AC voltages in RMS.g) Input AC frequencyh) Battery temperaturei) Remaining AH in percentage

j) Individual rectifier voltagek) Individual rectifier current.l) Individual rectifier status.m) Sharing deviation in percentage.n) Version of software.o) Checksum

Control functions:a) Battery temperature compensationb) Auto change over from float to charge & vice versa

c) Battery current limitingd) Rectifier disable in the event of abnormal input AC mains and over voltage.e) Automatic current sharing.f) Periodic battery test by discharging each battery by 20%of capacity.

Parametric settings:

a) MENU -This switch can be used for viewing various menu options.b) UP -This switch can be used for scrolling as well as for setting increment.c) Down -This switch can be used for scrolling as well as for setting decrement.d) ENTER -This switch can be in to sub menu as well as for registering the parameter changed.e) Alarm reset - this switch is used for clearing the latchable alarm.

f) Audio reset -this switch is used for audio cutoff.

Flow diagram of menus

Default screen

1. Read alarm.

8/13/2019 100 Amp 3000UC Manual

32/47

2. Read system data.

2.1. Read load voltage and load current.2.2. Read battery1 voltage and battery1 current and remaining ah in percentage.2.3. Read battery2 voltage and battery2 current and remaining ah in percentage.2.4. Read battery3 voltage and battery3 current and remaining ah in percentage.2.5. Read ac voltage2.6. Read ac current

2.7. Read ac frequency2.8. Read battery temperature.2.9. Read MCM and rectifier controller version and checksum information.

3. Read rectifiers data.

3.1. Read rectifier voltage and current with rectifier status.

4. Read battery data.

4.1. Not applicable.

5. User password.

5.1. Password =243.

6. Set system parameter.

6.1. Set over voltage6.2. Set under voltage6.3. Set lvd voltage6.4. Set lvd restore voltage6.5. Set system overload value.6.6. Set temperature compensation upper threshold.6.7. Set temperature compensation lower threshold

7. Set rectifier parameter.

7.1. Set rectifier float voltage globally.7.2. Set rectifier charge voltage globally.7.3. Set rectifier current limit globally.7.4. Set max no. of rectifier in system for current sharing.

8. Set battery parameter.

8.1. Set total no. of battery bank.8.2. Set battery capacity.8.3. Set load shunt.8.4. Set battery shunt.

9. Set relay configuration.

9.1. Configure individual relay for different alarms.

10. Test battery.10.1. Set battery 1 cuttoff voltage10.2. Set battery 1 period and time10.3. Set battery 2 cuttoff voltage10.4. Set battery 2 period and time10.5. Set battery 3 cuttoff voltage

8/13/2019 100 Amp 3000UC Manual

33/47

10.6. Set battery 3 period and time

11. System password.11.1. The user should not enter system password. This is required only for factory settings.

Detailed description of menus:

0 0 . 0 V / 0 0 0 0 As y s t e m o k

MCM normally displays the menu shown above. It gives the system voltage and system current information on the firsline. On the second line it shows the last alarm occurred or restored.

To view the various menus user should press the menu button once at a time. The Menu button allows theuser to choose Parameter reading or parameter & threshold settings. While in parameter reading mode press menubutton continuously to return to home screen.

Press menu once to get the read alarm screen.

1. Read alarm.

R E A D

A L A R M

When the LCD displays the menu shown above, press enter once to go into the sub menus of the read alarm menuNow the user can scroll the alarm using up and down key.

Sub menus of the read alarm menu are as follows.

M A J . = 1 1 / M I N . = 0 0

S Y S T E M O K

M A J . = 1 1 / M I N . = 0 0

A C A B N O R M A L

To leave the read alarm menu, press menu key once. The user will see the read system data menu.

2. Read system data.

R E A DS Y S T E M D A T A

When the LCD displays the menu shown above, press enter once to go into the sub menus of the read system datamenu. Now the user can scroll the system data using up and down key.

8/13/2019 100 Amp 3000UC Manual

34/47

Sub menus of the read system data menu are as follows.

L O A D

6 6 . 4 V / 0 0 . 0 A

B A T T E R Y - 1 1 0 0 %

5 4 . 0 V / 0 0 . 0 A

B A T T E R Y - 2 1 0 0 %

5 4 . 0 V / 0 0 . 0 A

B A T T E R Y - 3 1 0 0 %

5 4 . 0 V / 0 0 . 0 A

M A I N S V O L T A G E

4 0 0 V / 4 0 0 V / 4 0 0 V

M A I N S F R E Q U E N C Y

= 0 0 . 0 H Z

B A T T . T E M P R A T U R E

= 0 0 . 0 ' C

d s c a - v - x . x - x x x x

f r f c - v - x . x - x x x x

User can scroll these menus using up and down key.

To leave the read system data menu, press menu key once. The user will see the read rectifier data menu.

3. Read recti fiers data.

R E A D

R E C T I F I E R S D A T A

When the lcd displays the menu shown above, press enter once to go into the sub menus of the read rectifier datamenu. Now the user can scroll the rectifier data using up and down key.

Sub menus of the read rectifier data menu are as follows.

R E C # 0 1

5 4 . 0 V / 2 5 . 0 A / O K

R E C # 0 2

5 4 . 0 V / 2 5 . 0 A / O K

|

R E C # 0 8

5 4 . 0 V / 2 5 . 0 A / O K

8/13/2019 100 Amp 3000UC Manual

35/47

L O A D S H A R I N G D E V

= 1 %

User can scroll rectifier data using up and down key.

To leave the read rectifiers data menu, press menu key once. The user will see the read battery data menu.

4. Read battery data.

This menu will be active only if battery-monitoring equipment is connected.

5. User password

User password is 243.

U S E R P A S S W O R D

= 2 4 3

In this menu, cursor on the first digit blinks. User should press up key two times to increment first digit to value 2.Now the user should press enter once to register first digit password. Now cursor blinks on second digit. Similarly usecan enter the value 4 and value 3 for the second and third digit respectively.

At this point of time, if user press enter key, user can go through the set parameter option and menu on theLCD will be set system parameter

6. Set system parameter

S E T S Y S T E M

P A R A M E T E R

When the LCD displays the menu shown above, press enter once to go into the sub menus of the sesystem parameter menu. Now the user can scroll the system parameter entered previously using up and down key.

At any time if the user need to change the system setting, user can press the enter key once to go in to edmode. In the edit mode, cursor blinks on the value to be changed. User can now change the value using up and dowkey. To register the value Press enter key once, value will be stored in the non-volatile memory.

As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to vievarious set parameter.

Sub menus of the read system data menu are as follows.

D C O V E R V O L T A G E

= 5 7 . 0 V

D C U N D E R V O L T A G E

= 4 5 . 0 V

8/13/2019 100 Amp 3000UC Manual

36/47

L V D V O L T A G E

= 4 4 . 0 V

L V D R E S T . V O L T A G E

= 5 1 . 0 V

S Y S O V E R C U R R E N T

= 0 2 1 0 A

T E M P C O M P U - T H R D .

= 5 5 . 5 V

T E M P C O M P L - T H R D .

= 5 2 . 0 V

To leave the set system data menu, press menu key once. The user will see the set rectifiers data menu.

7. Set rectifiers parameter

S E T R E C T I F I E R

P A R A M E T E R

When the lcd displays the menu shown above, press enter once to go into the sub menus of the set rectifieparameter menu. Now the user can scroll the rectifier parameter entered previously using up and down key.

At any time if the user need to change the global rectifier setting, user can press the enter key once to go in edit mode. In the edit mode, cursor blinks on the value to be changed. User can now change the value using up andown key. To register the value Press enter key once, value will be stored in the non-volatile memory.

As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to viewvarious set parameter menu.

Sub menus of the set rectifiers parameter menu are as follows.

S E T F L O A T V O L T G

= 5 4 . 0 V

S E T C H A R G E V O L T G

= 5 5 . 2 V

S E T C U R R E N T L I M I T

= 2 5 . 0 A

R E C T I F I E R C O U N T

= 0 8

To leave the set rectifier parameter menu, press menu key once. The user will see the set battery parameter menu.

8. Set battery parameter

S E T B A T T E R Y

P A R A M E T E R

8/13/2019 100 Amp 3000UC Manual

37/47

When the LCD displays the menu shown above, press enter once to go into the sub menus of the set batter

parameter menu. Now the user can scroll the rectifier parameter entered previously using up and down key.

At any time if the user need to change the battery and system related settings, user can press the enter keonce to go in to edit mode. In the edit mode, cursor blinks on the value to be changed. User can now change the valuusing up and down key. To register the value Press enter key once, value will be stored in the non-volatile memory.

As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to vievarious set parameter menu.

Sub menus of the set battery parameter menu are as follows:8.1. Set total no. of battery bank.8.2. Set battery capacity.8.3. Set load shunt.8.4. Set battery shunt.

To leave the set rectifier parameter menu, press menu key once. The user will see the set relay configuration menu.

9. Set relay configu ration

S E T R E L A YC O N F I G U R A T I O N

When the LCD displays the menu shown above, press enter once to go into the sub menus of the set relaconfiguration menu. Now the user can scroll the various relay configured previously using up and down key.

At any time if the user need to change the relay configuration, user can press the enter key once to go in tedit mode. In the edit mode, cursor blinks on the alarms entered earlier. User can now change the alarm using up andown key. To register the alarm extension to that relay, Press enter key once, alarm to that relay will be stored in thnon-volatile memory and also extended.

As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to vievarious relay configurations.

Sub menus of the set battery parameter menu are as follows.

S E T R E L A Y 1

S Y S T E M O K

S E T R E L A Y 2

A C A B N O R M A L

|

S E T R E L A Y 7

L V D

To leave the relay configuration menu, press menu key once. The user will see the test battery menu.

10. Test battery

t e s t b a t t e r y

8/13/2019 100 Amp 3000UC Manual

38/47

When the LCD displays the menu shown above, press enter once to go into the sub menus of the tesbattery menu. Now the user can scroll the battery test configuration entered previously using up and down key.

At any time if the user need to change the cutoff voltage and period time of testing battery, user can press thenter key once to go in to edit mode. In the edit mode, cursor blinks on the value entered earlier. User can now changthe value using up and down key. To register the value, Press enter key once, value will be stored in the non-volati

memory.

As soon as the user press enter key, MCM comes out of edit mode. Now the user can scroll again to viebattery test setting.

Sub menus of the battery test settings are as follows.

10.1. Set battery 1 cuttoff voltage10.2. Set battery 1 period and time10.3. Set battery 2 cuttoff voltage10.4. Set battery 2 period and time10.5. Set battery 3 cuttoff voltage

10.6. Set battery 3 period and time

2. Sub- assemblies:

The MCM consists of the following:a) Control card.

This card contains all the electronic hardware. The heart of the electronics is the state of theart PIC processor. In set up mode the user can browse through various system parameters &thresholds. For status & alarm displays LEDs as well as LCDis used. A piezo-electric buzzer hasbeen provided which comes on when ever an alarm is detected. A push button for cutting off the audihas also been provided. The card also contains a set of push buttons. These buttons are markedMenu, Up, Down & Enter. The functions of these buttons are explained in the installation &commissioning chapter.

b) LCD:An alphanumeric LCD display of 16x2 is provided for display of various parameter viewing

and alarm display.

c) LED- LCD interface card:This card consists of 6 nos. of switches and three bi-LED for critical alarm and seven LEDs

for major and minor alarms. A piezo-electric buzzer has been provided which comes on when ever analarm is detected. A push button for cutting off the audio has also been provided. The card alsocontains a set of push buttons. These buttons are marked Menu, Up, Down & Enter. The functions ofthese buttons are explained in the installation & commissioning chapter.

d) RS232/RS485 interface card.This card receives input from control card and converts the serial data to either RS232 or RS485.

8/13/2019 100 Amp 3000UC Manual

39/47

INSTALLATION & COMMISSIONING

Caution:a) The equipment is a sensitive electronic system hence special care is required while installing the unit.b) Polarity is very important for the measurement electronics so this aspect must be kept in mind.c) The circuitry has CMOS integrated circuits which are sensitive to ESD & other discharges. The rack must be

properly earthed.

d) The packaging must be visually inspected for any possible damage during transit. Do not attempt to turn oneven slightly damaged unit . Report the matter to the manufacturer.

e) Only trained personnel should handle the equipment as 440 Volts AC and very high capacity batteries areconnected.

Step by step Commissioning of a MCM for an example system

System description:

SMR 100A modules

Ultimate capacity 3000A

No. of batteries 3

Battery AH 2000AHLoad path shunt 3000A/50mV

Each battery path shunt 1000A/50mV

Over voltage 56V

Under Voltage 45.5V

Temp. comp upper threshold 56.0V

Temp. comp lower threshold 51.5V

LVD threshold 44.4V

Over load 2800A

LVD Restore 52.0V

Step1:

Do not connect battery or load.

Connect plug coming from ACDB to socket coming from MCM Module. Do not connect the daisy- chained cable for rectifieMCM interface at this stage.

Step2:

Turn on the MCB for MCM on the ACDB. The MCM comes on & the controller begins checking displays & the LEDs.

Under voltage, & Temp. comp. fail alarm will come which is normal. Press the reset button & the audio cut-off button.

Thru Menu start reading parameters. All DC voltages & currents will read zero. Since the inputs for DC measurements are

floating some jittery display may bee seen while scrolling thru the DC parameters. Move on to AC input. Phase voltage can b

read.

Step3:

Switch off the MCB for MCM on the ACDB. Connect cable to 25 Pin

D-connector coming out from BI rack on the MCM back panel. Switch on the MCCB for MCM. After display check has

been completed & all alarms re-setted, turn on one or more rectifiers & connect some load to the exchange terminal. Do not

connect any voltage sensitive load at this stage. Go to Menu & start reading DC voltages & currents.

Step4:

Press the Menu button the display reads READ DATA

Press the Menu button once again the display reads SET PRAMETER

Press Enter the display reads OVER VOLTG = 56.0V

Press Enter the decimal digit blinks.

Use UP button to increase the threshold to 56V

Press Enter display reads SAVE Y/N

Press Enter to save the present value.

8/13/2019 100 Amp 3000UC Manual

40/47

Step5:

Press UP button to move to next setting the display reads

UNDER VOLTG = 44.4VPress Enter button the decimal digit blinks.

Use UP button to increase the threshold to 44.4V



Step6:


LVD VOLTG = 43.0V

Repeat process for increasing threshold to 43V.


OVER LOAD = 2800A

Press Enter the 1st

Press Enter again the 2

. digit blinksnd

Press Enter again the 3Digit blinks.

rd

Press enter again the 4th digit blinks. Press UP button till the display reads 02800A.

Digit blinks. Press DOWN button till the display reads 00100A

Press Enter 3 times. The display reads SAVE Y/N


Step7:

Press Enter the display reads TEMPCOMP _U = 56.0V

Press Enter button the decimal digit blinks.




Step8:Press Enter the display reads TEMPCOMP _L = 51.5V

Press Enter button the decimal digit blinks.




Step9:

Press UP the display reads BATT. BANK = 3

Press Enter 3 begins to blink

Press UP/DOWN button if it has to change.



Step10:Press UP display reads BATT. CAP = 2000AH

Press Enter 1st

Press Enter 2

. digit begins to blinknd

Use UP button to make it 2000AH

digit begins to blink

Press Enter, 3rd


digit begins to blink.


8/13/2019 100 Amp 3000UC Manual

41/47

Step11:

Press UP the display reads BATT.SHUNT = 1000A

Follow above for changing the value to 1000A



Step12:

Press UP the display reads LOAD.SHUNT = 3000A

Follow above for changing the value to 3000APress Enter display reads SAVE Y/N


Step13:

Press UP the display reads TEMPCOMP = E

Press Enter, blinking comes on E

To change settings press up / down button.


Press Enter.

Step14:

Press UP display reads LVD REST. = 51.6V

Press enter button the decimal digit blinks.Use UP button to increase the threshold to 52.0V

Press enter display reads save Y/N

Press enter to save the present values.

Step15:

Press MENU to come to default display i.e Load voltage & System current.

The system is now fully configured.

Step16:

Insert the daisy chained cable connector to the D connector on the front panel.

MCM Connections:

Following are the inputs to the unit:

a) Single- phase AC mains with neutral. This comes from the ACDB.A single phase CB is provided in the ACDB for this purpose.

b) Battery voltage. This signal comes in by a twisted wire cable from the battery feeder. This enters MCM via 25Pin D-connector with ferrule no. 1 as positive & ferrule no. 2 as negative.

c) Load voltage. This signal comes in by a twisted wire cable from the exchange feeder. This enters MCM via 25Pin D-connector with ferrule no. 1 as positive & ferrule no. 2 as negative.

d) Load current. This signal comes in by a twisted wire cable from the load shunt. This enters MCM via 25 Pin Dconnector with ferrule no. 3 as positive & ferrule no. 4 as negative.

e) Individual battery currents. The signal comes in by twisted wire cables from individual battery shunts. Thisenters MCM via 25 Pin D-connector with ferrule no. 5 as positive & ferrule no. 6 as negative for battery 1, with

ferrule no. 7 as positive and 8 as negative for battery 2 and with ferrule no. 9 as positive and no. 10 asnegative.f) Battery temperature. The temperature probe supplied with the unit is to be connected to terminal block as per

the fig. 2. The probe should be kept close to the batteries.g) Remote alarm extension. Potential free contacts have been provided. These are accessed through Terminal

block as per fig. 2.

h) 15 pin Connector on the front panel will be daisy chained to all the SMRs in the system and finally connectedwith MCMs 15 pin D-connector on the front panel.

8/13/2019 100 Amp 3000UC Manual

42/47

i) Signals for de-activating the battery contactors for LVD are available from 25 pin D- connector in the MCMback panel with ferrule no. 1 & 11.

j) Batter isolation signals are also available from 25 pin D-connector in the MCM back panel with ferrule no. 14for battery bank 1, with ferrule no. 15 for battery bank 2 and with ferrule no. 16 for battery bank 3, ferrule no.13 is common for all battery banks.

8/13/2019 100 Amp 3000UC Manual

43/47

Trouble shooting

Sl. No. Symptom Probable cause Action

1. MCM does not come ON

when the MCCB is turned

on.

a)ACDB to MCM cable not

connected.

b) Fuse F in the AC Monitoring &

Power supply card is blown

Connect cable

properly.Change fuse.

2. MCM does not come ON

when mains fail.

Fuse F in the AC Monitoring &

Power supply card is blown.

Battery is not connected

Replace fuse.

Connect battery.

3. Voltage or current display

erratic

Connector coming from BI rack is

not connected to MCM back

panel.

Insert connector

properly.

Check connections.

4. Temp. Comp fail alarm. Probe not connected.

Probe cable broken.

Connect probe.

Check cable for

damage.

5. MBD alarm. Total load exceeding capacity.

Current limit setting on SMRs too

low.

Check load & charging

current.

Check current limit

setting on all SMRs.6. AC abnormal alarm. AC mains out of range. Check mains voltages.

Rural & urban systems

have different ranges.

Check application.

7. Display not responding to

commands.

Front panel card malfunction. Call service engineer.

8. Battery current limiting

not working.

Error in system configuration.

Daisy chained cable not properly

inserted.

Check battery related

entries.

Check cable

connection.

9. Fault LEDs randomly

glowing.

Front panel card malfunction. Call service engineer.

--------------------X--------------------

8/13/2019 100 Amp 3000UC Manual

44/47

USER RESPONSE FORM

******EXICOM TELE-SYSTEMS LIMITED ********

8, Commercial Complex, Masjid Moth, Greater Kailash II

New Delhi-110048, India

Tel: +91-11-3088 2624, +91-11-3068 2624

Fax: +91-11-3068 9013

E-mail:[email protected]

NAME OF CUSTOMER:

SITE ADDRESS: .

Phone : Fax : ...

EQUIPMENT DESCRIPTION

Power Plant : Stand alone / Rack Power System

Power plant/ RACK serial No. : ( _______________ )

Module Rating: 12.5A/25A/50A/100A/200A SMR

No. of Modules : ( _____ )

Module serial Nos. :

SMR 1 SMR 2 SMR 3 SMR 4 SMR 5 SMR 6 SMR 7 SMR 8 SMR 9 SMR 10



Battery Capacity : Ah

No. of Battery Banks : (Fill the no. in numeric form)

Battery Make/Type :

( Page1)
mailto:[email protected]:[email protected]:[email protected]:[email protected]

8/13/2019 100 Amp 3000UC Manual

45/47

PLEASE COMMENT:

A. Any physical damage occurred to the equipment during transport (YES/NO)

If yes, describe:

B. Any problem faced during Installation and Commissioning:

C. Suggestions, if any:

PLEASE MAIL/FAX HERE:

Customer Support

EXICOM TELE-SYSTEMS LTD.

D-180, Mazenine Floor, Okhla Industrial Area Phase I,

New Delhi-110 020 (India)

Phone: 91-11-26810140/26810141/26810142 Fax: 91-11-26810137

Note: kindly fill the form and send to above no./ address as soon as power plant is commissioned. This willbe helpful for us to provide customer prompt service.

(Page2)

8/13/2019 100 Amp 3000UC Manual

46/47

Fault Report

******EXICOM TELE-SYSTEMS LIMITED ********

8, Commercial Complex, Masjid Moth, Greater Kailash II

New Delhi-110048, India

Tel: +91-11-3088 2624, +91-11-3068 2624Fax: +91-11-3068 9013

E-mail:[email protected]

NAME OF CUSTOMER :

SITE ADDRESS : .

Phone : Fax : ...

EQUIPMENT DESCRIPTION

Power Plant : Stand alone/Rack Power System

Module Rating : 12.5A/25A/50A/100A SMR

No. of Modules : (Fill the no. in numeric form)Any other Modules

Battery Capacity : Ah

No. of Battery Banks : (Fill the no. in numeric form)

Battery Make/Type :

INSTALLATION DETAILS

(Enclosed installation and commissioning report if available)

Is the equipment under warranty period - YES/NO

Fault Indication Report .

Date of occurrence of fault .

LED STATUS ON FAULT SMR

LED STATUS ON MCM

ANY OTHER SPECIFIC DETAILS WOULD YOU LIKE TO ADD

PRESENT STATUS OF POWER PLANT
mailto:[email protected]:[email protected]:[email protected]:[email protected]

8/13/2019 100 Amp 3000UC Manual

47/47

PLEASE MAIL/FAX HERE:

Customer Support

EXICOM TELE-SYSTEMS LTD.D-194, 2nd

New Delhi-110 020 (India)

Floor, Okhla Industrial Area Phase I,

Phone: 91-11-26810140/26810141/26810142 Fax: 91-11-26810137

100 amp 3000uc manual

Documents