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Power One PODS 16.48-16000 1940 HEX Instruction Manual Download Page 5

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Document number: 039158TOC.fm
Revision: B

Contents:

4 System description PODS 16.48-16000 1940 HEX   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1 General  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.2 Technical Data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.3 Operation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.4 System Description - PPS 16  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.4.1 FMP 16- Rectifier Module   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.4.2 PCS - Controller System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.4.3 PPR 16/10 23”- Subrack   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.4.4 PBDU 23” - Distribution Module  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.4.4.1 Low Voltage Disconnection (LVD)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.4.5 Cabinet Door With Heat Exchanger (HEX)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.4.6 BTS Breaker 50A 3-pole (Option)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.4.7 Surge arrestor kit, 3-phase (VAL-CP-3S-350/3+1) (Option)   . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.4.8 FMP 16 Dummy Module (Option)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4.4.9 Battery extension kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

5 Safety   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.2 Warnings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.2.1 Lethal voltages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.2.2 Grounding   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.4 Weight   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5.2.5 High temperatures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.3 Cautions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

5.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

6 Installation guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.1.1 AC Power source requirements  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.2 Installation procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.2.1 Unpacking   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2.2 Tools and parts required   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6.2.3 Cabinet mounting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
6.2.4 Grounding   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
6.2.5 Cable sizes / location of external connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.2.5.1 Cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6.2.6 Connection of Mains   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6.2.6.1 Mains Input Change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6.2.7 Connection of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6.2.8 Connection of Symmetry Measurement and Temperature Sensor  . . . . . . . . . . . . . . . . . . . . . .6-11
6.2.9 Battery connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

6.2.9.1 Battery tube routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

6.2.10 DC connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

7 Commissioning   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1 Commissioning Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Summary of Contents for PODS 16.48-16000 1940 HEX

Page 1: ...POWER SUPPLY SYSTEM PODS 16 48 16000 1940 HEX Instruction Manual Revision B Document number 039158...

Page 2: ...tious examples and are designed solely to il lustrate the use of Power One products If you find errors or problems with this documentation please notify Power One Power One does not guarantee that thi...

Page 3: ...EX Ouput Voltage 48V Publisher Power One as Postboks 1543 N 3007 Drammen NORWAY Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 07 04 05 A Second issue Kai Morten...

Page 4: ...1 2 PODS 16 48 16000 1940 HEX Document number titlepage fm Revision B...

Page 5: ...es 5 2 5 2 2 Grounding 5 3 5 2 3 Precautions for lead acid batteries 5 3 5 2 4 Weight 5 3 5 2 5 High temperatures 5 3 5 3 Cautions 5 4 5 3 1 Storage and transportation 5 4 5 3 2 Handling electrostatic...

Page 6: ...les 8 4 8 3 3 Removing modules 8 4 8 4 PCS 2 Control 8 4 8 4 1 PCS 2 Menus 8 5 8 4 1 1 Show voltage and currents 8 5 8 4 1 2 Show alarms 8 5 8 4 1 3 Show messages 8 5 8 4 1 4 Show data 8 5 8 4 1 5 Sel...

Page 7: ...85 12 1 12 1 General 12 2 12 2 Technical data 12 2 12 2 1 Pin Configuration of J20 and J21 12 2 12 3 Remote alarms symmetry measurement and temperature sensor 12 3 12 4 Maintenance 12 3 13 Maintenance...

Page 8: ...ety precautions F 6 F 3 AC Power source requirements F 6 F 4 Overview Battery Extension Kit F 7 F 5 Installation and Connection F 8 F 5 1 Installing the Battery Shelf F 8 F 5 2 Installing the battery...

Page 9: ...nstallation and connection I 6 Appendix J Customer AC service outlet Installation procedure J 1 J 1 Scope and purpose J 5 J 2 Safety precautions J 5 J 3 AC Power source requirements J 6 J 4 Overview A...

Page 10: ...2 6 PODS 16 48 16000 1940 HEX Document number 039158TOC fm Revision B...

Page 11: ...rves the right to change specifications and designs without notice and without incurring obligation or liability This manual is the work product of Power One and embodies confidential proprietary data...

Page 12: ...arms on the control module please see the Troubleshooting section If this does not solve your problem please seek assistance at your local Power One office or our head office in Norway These also conc...

Page 13: ...System description PODS 16 48 16000 1940 HEX 4 1 Document number 039159 fm Revision A System description PODS 16 48 16000 1940 HEX 4 System description PODS 16 48 16000 1940 HEX...

Page 14: ...r available at 1600W per module Systems are also based on fan cooling rectifiers and it is therefore important that the ventilation panels are kept free from dust and obstructions that may prevent the...

Page 15: ...multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000...

Page 16: ...ly configured with N 1 redundancy with N as the number of rectifier modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier module In normal operation the rect...

Page 17: ...on for the entire power supply system and use of distributed intelligence by local micro controllers A RS485 data bus takes care of internal communication between the various units RS232 is used for r...

Page 18: ...d load The distribution has no special operation other than switching the battery and load breakers on and off All DC distribution breakers are supervised by measuring voltage drop across each breaker...

Page 19: ...he cabinet without any ambient air being pulled into the cabinet itself Two fans pull outside and inside air respectively through each side of the heat exchanger element The fan speed is monitored by...

Page 20: ...e plate removed Cabinet door with HEX unit Rectifier shelf Cabinet door with HEX unit HEX unit ambient airflow Heat Exchanger Element Principle Drawing HEX Outside air HEX Inside air Inside of Cabinet...

Page 21: ...tor unit has a display on the front that indicates if it is OK or has blown Surge arrestor units with a red display have blown and must be replaced When fitted each surge arrestor kit is located below...

Page 22: ...4 10 PODS 16 48 16000 1940 HEX Document number 039159 fm Revision B System description PODS 16 48 16000 1940 HEX...

Page 23: ...Safety 5 1 Document number 028580 fm Revision A Safety 5 Safety...

Page 24: ...ved when dealing with high voltage systems and equipment z Potentially lethal voltages are present within the system Ensure that all power supplies are completely isolated by setting all power switche...

Page 25: ...ratures WARNING THE SYSTEM SHOULD BE HARD WIRED TO THE INCOMING SAFETY EARTH A SOLID HIGH CURRENT GROUND CONNECTION CAPABLE OF SINKING THE MAXIMUM SYSTEM CURRENT IS REQUIRED WARNING DUE TO HIGH LEAKAG...

Page 26: ...electrostatic sensitive device is an electronic component that may be permanently damaged by the discharge of electrostatic charges encountered in routine handling testing and transportation CAUTION U...

Page 27: ...Installation guide 6 1 Document number 039160 fm Revision A Installation guide 6 Installation guide...

Page 28: ...sportation Contact Power One if any parts are missing or damaged and correct any problems before continuing 6 2 2 Tools and parts required The following tools are required for a safe installation of t...

Page 29: ...guide CAUTION Care must be taken when installing this system The units can be damaged and can cause damage if not handled with care Pay particular attention to the order in which units are installed C...

Page 30: ...he cabinet and should be supplied by the customer 2 Plinth directions The sides of the plinth have a SIDE imprint The SIDE imprint should face up from the ground Measurements of the plinth needed to p...

Page 31: ...the brackets as delivered and also how the parts should be assembled after removing the brackets Follow these steps to correctly remove and reassemble the parts 1 Remove the top lid from the cabinet f...

Page 32: ...HEX Document number 039160 fm Revision A Installation guide Figure 6 2 Removal of lifting brackets Lifting bracket as deliv ered Location of lift ing brackets Lifting bracket re moved and bolt fas te...

Page 33: ...the top right side of the system 6 2 5 1 Cable entry box The cable entry box delivered with the system or additional cable entry kit option should be mounted before connecting mains and load Remove o...

Page 34: ...Installation guide 3 Attach the casing to the cabinet 4 Mount the casing top and fasten with two M4 screws 5 Cable entry box installation is now complete lower the cabinet top Figure 6 4 Mounting of...

Page 35: ...gure 6 5 Mains Input Types Figure 6 6 Input Mains Terminal Recommended mains fuse 1x230V AC USA Canada 1x220V AC Double pole 63A C char Mains 1 USA Canada Double pole 70A C char 1x230V AC USA Canada 1...

Page 36: ...ERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C60N C16 230 400V 6000 3 MERLIN GERIN I ON I ON multi 9 C6...

Page 37: ...surement and Temperature Sensor The controller can supervise the symmetry of up to 4 battery branches The drawing in Figure 6 8 on page 6 12 shows how to connect the symmetry cables for 1 battery bran...

Page 38: ...nnected to the battery pole according to the Figure 6 8 on page 6 12 6 2 9 Battery connection The battery cables of the system are if ordered pre connected to the systems battery breakers The cable of...

Page 39: ...n the OFF position 1 Connect the negative DC supply cable to the appropriate negative DC distribution MCB by inserting the stripped cable in the opening on top of the MCB and tightening the screw 2 Ma...

Page 40: ...6 14 PODS 16 48 16000 1940 HEX Document number 039160 fm Revision A Installation guide...

Page 41: ...Commissioning 7 1 Document number 036285 fm Revision A Commissioning 7 Commissioning...

Page 42: ...ulated z Screwdriver set flat insulated z Screwdriver set torx insulated z Screwdrivers pozidrive cross head sizes 1 2 and 3 insulated z Torque spanner for battery connection insulated 7 2 2 Test Equi...

Page 43: ...rn on the AC mains voltage 6 Measure the AC voltage on the AC terminal block between phases and neutral The correct value is approximately 230V If the value is different check the AC connection 7 Plug...

Page 44: ...in the subrack Do not break the seal 7 5 3 Boost charging U2 if applicable Open lead acid batteries Automatic boost charging calculation of the time the battery voltage has been below certain levels A...

Page 45: ...temp probe cable supplied The temperature compensation is factory pre set Check that the temp probe is activated and verify that the compensation level is according to the battery manufacturers requi...

Page 46: ...e cabinet Is to be 230V AC Measure 230V from phase to N when 400V mains input is used L1 N V AC L2 N V AC L3 N V AC 4 Mount rest of the rectifiers 5 After connection of battery verify right polarity b...

Page 47: ...Operation Product description PCS 2 8 1 Document number 036777 fm Revision A Operation Product description PCS 2 8 Operation Product description PCS 2...

Page 48: ...ation RS232 contact for remote operation and RS 485 for internal communication with 128 addresses 64 rectifier modules and 64 other remote micro controllers Sockets for plug in network interface The P...

Page 49: ...ntactors voltage or time controlled Battery test manual or automatic with symmetry measurement Alarm relay test Adjustable battery current Software controlled start up after mains outage and battery t...

Page 50: ...on error on the PCS 2 1 To remove the error message use the Accept removed parts item on the Miscellaneous menu or press the reconfigure button in the Inventory window in PowCom 2 Make sure that there...

Page 51: ...keys to scroll through the alarms Any new alarms or alarms that disappear will be added or taken off of the menu immediately Battery failure and symmetry failure alarms need to be reset manually by p...

Page 52: ...RETURN to change U1 The float charge voltage and use the arrow keys to adjust to the proper voltage U2 Boost The U2 reference is shown press RETURN to change U2 The boost charge voltage U3 Test The U3...

Page 53: ...4 1 7 Miscellaneous The miscellaneous menu is used to set the date and time change password view version information initialize modem show symmetry voltages and temperature Set time The clock is show...

Page 54: ...ntentionally removed then the PCS 2 will need to be informed Select YES in the Accept Removed Parts menu to inform the system that the module was removed Note Do not accept removed parts if the there...

Page 55: ...mit Enable temp comp Enable current limit Batt current limit Comp factor Test end voltage Test duration Ah limit Time of test No of tests year No of batteries Battery type Boost interval Boost factor...

Page 56: ...s P1 is to be connected to the PCS 2 Figure 8 3 PCS 2 to PC cable 1 To connect the PCS 2 to the PC locate the RS232 interface connector on the front of the PCS 2 2 Connect one end of the RS232 cable t...

Page 57: ...by three methods Manual boost charging Choose U2 in the reference menu for activating boost charging Return to float charge manually by choosing U1 or automatically after a pre set time Periodic boost...

Page 58: ...attery testing is activated by selecting U3 in the Choose reference menu Once selected the rectifier voltage will decrease to a pre set value U3 adjustable The system will begin logging battery voltag...

Page 59: ...of symmetry measurements If symmetry cables are not in use number of batteries must be set to 0 zero 8 4 5 Battery current limit Battery current can be controlled by the PCS 2 The PCS 2 will adjust t...

Page 60: ...8 14 PODS 16 48 16000 1940 HEX Document number 036777 fm Revision B Operation Product description PCS 2...

Page 61: ...Product Description FMP 16 9 1 Document number 036972 fm Revision A Product Description FMP 16 9 Product Description FMP 16...

Page 62: ...ged into or unplugged from the support frame with no impact upon the other modules The rectifiers operate on the principle of active load sharing and can operate in parallel They incorporate soft star...

Page 63: ...output voltage shut down Low voltage module failure Each alarm has a common LED indicator on the front panel Enclosure IP 20 Storage 60 to 85 C Cooling Fan cooled front to back speed controlled and a...

Page 64: ...00m 9 4 1 Storage ETS 300 019 2 1 Class 1 2 9 4 2 Transport ETS 300 019 2 2 Class 2 3 9 4 3 Operation ETS 300 019 2 3 Class 3 2 9 5 Safety The FMP 16 rectifiers fulfil those international and national...

Page 65: ...Product description PPR 16 10 23 Subrack 10 1 Document number 037680 fm Revision A Product description PPR 16 10 23 Subrack 10 Product description PPR 16 10 23 Subrack...

Page 66: ...terconnecting of FMP 16 modules Each subrack rectifier shelf has 10 module positions Module positions are numbered from left to right viewed from the front Each subrack rectifier shelf may be equipped...

Page 67: ...S13 S16 S15 S18 S17 S20 and S19 are used for addressing module positions and has to be set for controller supervision to function properly The switches can each address six bit binary addresses which...

Page 68: ...range 3 between PL5 in subrack 1 to PL3 in subrack 2 z Use cable marked with Brown 1 between PL6 in subrack 2 to PL4 in subrack 3 z Use cable marked with Orange 3 between PL5 in subrack 2 to PL3 in su...

Page 69: ...3 1 8 1 6 1 2 3 1 9 1 6 4 1 10 1 6 1 4 2 11 1 6 2 4 2 12 1 6 1 2 4 2 13 1 6 3 4 2 14 1 6 1 3 4 2 15 1 6 2 3 4 2 16 1 6 1 2 3 4 2 17 1 6 5 2 18 1 6 1 5 2 19 1 6 2 5 2 20 1 6 1 2 5 3 21 1 6 3 5 3 22 1 6...

Page 70: ...0 23 Subrack 6 51 1 6 2 5 6 6 52 1 6 1 2 5 6 6 53 1 6 3 5 6 6 54 1 6 1 3 5 6 6 55 1 6 2 3 5 6 6 56 1 6 1 2 3 5 6 6 57 1 6 4 5 6 6 58 1 6 1 4 5 6 6 59 1 6 2 4 5 6 6 60 1 6 1 2 4 5 6 7 61 1 6 3 4 5 6 7...

Page 71: ...Product description PBDU 4U 23 11 1 Document number 038222 fm Revision A Product description PBDU 4U 23 11 Product description PBDU 4U 23...

Page 72: ...distribution breakers are supervised by measuring voltage drop across each breaker MCB s breakers which are not connected to any load will not cause breaker alarm even if they are left open Due to sm...

Page 73: ...on module has common and all the MCB s connected in the branch Figure 11 2 Typical distribution Front view controller unit removed Figure 11 3 Distribution Top view 11 4 Cable cross section output con...

Page 74: ...Connect the positive load DC supply cable directly to the positive busbar by inserting the stripped cable to the hole on top of the screw connector so that the cable is behind the busbar and then tigh...

Page 75: ...Product description PCS Alarm interface unit BM0685 12 1 Document number 037901 fm Revision A Product description PCS Alarm interface unit BM0685 12 Product description PCS Alarm interface unit BM0685...

Page 76: ...l signal for individual operating LVD and PLD J20 J21 z 6 x potential free change over contacts J6 J7 J8 J9 z 4 x input for symmetry measurement J1 J2 Optionally symmetry input 4 may be used as 3 x an...

Page 77: ...5 alarm board 12 4 Maintenance The PCS alarm interface unit does not need any special maintenance 3 6 2 5 1 4 Batt sym 4 ext analog Red T Green Blue T 3 2 1 Temp Probe 1 J2 3 6 2 5 1 4 J1 Red T Green...

Page 78: ...12 4 PODS 16 48 16000 1940 HEX Document number 037901 fm Revision B Product description PCS Alarm interface unit BM0685...

Page 79: ...Maintenance and Troubleshooting 13 1 Document number 037043 fm Revision A Maintenance and Troubleshooting 13 Maintenance and Troubleshooting...

Page 80: ...e carried out a PC with PowCom installed must be connected to the RS232 contact Only applies when a controller without LCD display is in use Low system voltage z Check the batteries with a voltmeter z...

Page 81: ...k the batteries z Check ventilation z Check reading in controller Powcom Symmetry fault z Reset the alarm z Check connections according to number of batteries in controller Powcom z Check batteries Ba...

Page 82: ...prevent free air circulation through the cubical 13 4 Torque table TYPE MODEL DESCRIPTION TORQUE Nm TORQUE Inch LB Terminal block for rail AKG 16mm2 2 5 Nm 22 Terminal block for rail AKG 35mm2 3 5 Nm...

Page 83: ...A 1 Document number Appendix A fm Revision B Drawings 17 02 05 SK 039095 Page 01 of 01 Cabinet layout PODS 16 48 16000 1940 HEX Cabinet size 800x850x1940mm WxDxH Date Designer Scale ref Rev Appendix A...

Page 84: ...40 HEX Document number Appendix A fm Revision B Drawings 17 02 05 SK 039095 Page 01 of 01 Cabinet layout PODS 16 48 16000 1940 HEX Cabinet size 800x850x1940mm WxDxH Date Designer Scale ref Rev A 1 Cab...

Page 85: ...power one power one FMP1648 power one power one FMP1648 PE 3 phase 400V AC PE PE N L1 L1 L2 L3 N N N N N L2 L3 1 2 5 5 6 7 2 3 3 4 4 6 7 1 1 PE 3x1 phase 230V AC PE PE N1 L1 L1 L2 L3 N1 N2 N2 N3 N3 L...

Page 86: ...emp 4 Temp 3 12V 0V Sense 6 5 4 J 4 12V 0V Sense 3 2 1 Temp 2 Temp 1 6 5 4 Alarm 6 3 2 1 Alarm 5 J 9 6 5 4 Alarm 4 3 2 1 Alarm 3 J 8 3 2 1 Alarm 2 3 2 1 Alarm 1 J 7 J 6 4 3 2 1 J 10 Digital out J 23 J...

Page 87: ...analog 1 12V 2 0V 3 12V J 22 Electronic power 1 0V 2 System voltage 6 5 4 3 2 1 6 5 4 3 2 1 J 2 J 1 2 1 Digital input J 3 6 5 4 J 5 12V 0V Sense 3 2 1 Temp 4 Temp 3 12V 0V Sense 6 5 4 J 4 12V 0V Sens...

Page 88: ...0 3 phase 400V AC Main Subrack PPR 16 48 10 COM PL4 BM0666 COM PL6 CURR PL3 CURR PL5 L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE 8 8 8 8 1 2 3 5 6 7 4 Mains input terminal bl...

Page 89: ...230V AC Main Subrack PPR 16 48 10 COM PL4 BM0666 COM PL6 CURR PL3 CURR PL5 L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE 8 8 8 8 1 2 3 5 6 7 4 Mains input terminal blocks 1 1...

Page 90: ...3x1 phase 230V AC Main Subrack PPR 16 48 10 COM PL4 BM0666 COM PL6 CURR PL3 CURR PL5 L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE L N PE 8 8 8 8 1 2 3 5 6 7 4 Mains input terminal bl...

Page 91: ...Drawings A 9 Document number Appendix A fm Revision B Drawings A 8 Footprint Outdoor Cabinet 039423 Rev...

Page 92: ...A 10 PODS 16 48 16000 1940 HEX Document number Appendix A fm Revision B Drawings...

Page 93: ...Configuration c 000313 B 1 Document number 039418 fm Revision A Configuration c 000313 Appendix B Configuration c 000313...

Page 94: ...B 2 PODS 16 48 16000 1940 HEX Document number 039418 fm Revision B Configuration c 000313...

Page 95: ...Configuration c 000313 B 3 Document number 039418 fm Revision B Configuration c 000313...

Page 96: ...B 4 PODS 16 48 16000 1940 HEX Document number 039418 fm Revision B Configuration c 000313...

Page 97: ...ution Appendix C Distribution C 1 Distribution PBDU 23 1xMCB 10xMCB Breaker 6A 10A 16A 25A 32A 100A 150A Char PLD Type of equipment FB1 X D Battery 1 FB2 FB3 FB4 F1 X C F2 X C F3 X C F4 X C F5 X C F6...

Page 98: ...99 fm Revision B Distribution 0V LOAD F1 LOAD 0V BATTERY FB1 Batt 1 0V F10 Power one Power one Power one Power one Power one Power one Power one Power one Power one 0V Connection to chassis Power one...

Page 99: ...BTS Breaker 50A 3 pole Installation procedure D 1 Document number 038316 fm Revision A BTS Breaker 50A 3 pole Installation procedure Appendix D BTS Breaker 50A 3 pole Installation procedure...

Page 100: ...ples involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please...

Page 101: ...rocedure D 3 Document number 038316 fm Revision B BTS Breaker 50A 3 pole Installation procedure Contents Scope and purpose D 5 Safety precautions D 5 AC Power source requirements D 6 Overview upgrade...

Page 102: ...ocedure Amendment record Revision Issue Description Author Date First issue rjan Skauge 06 10 04 A New revision Hans A Dokka 12 05 05 B New revision Kai Morten Hennum 13 05 05 C New revision Hans A Do...

Page 103: ...rque control Bits needed Flat 0 8x4x150 13mm metric socket and PZ2 Figure D 1 Insulated tools D 2 Safety precautions WARNING MAKE SURE THAT THE POWER TO THE SYSTEM IS DISCONNECTED BEFORE STARTING THE...

Page 104: ...ribed in the relevant sections D 3 AC Power source requirements Failure to observe the above warning may result in hazardous conditions on the system that may cause injury to personnel WARNING HIGH LE...

Page 105: ...n procedure D 4 Overview upgrade kit Figure D 2 Overview 1 MCB 3 pole C 50 C60N 2 Connector 3 x MCB 150A for front terminal 3 Connector 2 x MCB 100A for front terminal 4 Connector 2xAKG for front term...

Page 106: ...2 For 100A load breaker capacity mount the Connector 2xMCB 100A for front terminal on top of the breaker Mount the end case side of the signal cable harness on the left most position on top of the bre...

Page 107: ...t number 038316 fm Revision B BTS Breaker 50A 3 pole Installation procedure D 6 Installation Figure D 4 Remove dummy breakers 1 Remove 3 dummy breakers by releasing the catch on top of the dummy break...

Page 108: ...TS Breaker 50A 3 pole Installation procedure 2 Dummy breakers removed Figure D 6 Install new breaker 3 Unscrew the three lower screws to end positions 4 Install the new load breaker in the open breake...

Page 109: ...to the fuse alarm board as shown in Figure D 7 Figure D 8 Front terminal for copper cables 6 Mount the front terminal for copper cables to the common rail as shown in above figure 7 Tighten the front...

Page 110: ...D 12 PODS 16 48 16000 1940 HEX Document number 038316 fm Revision B BTS Breaker 50A 3 pole Installation procedure...

Page 111: ...it 3 phase VAL CP 3S 350 3 1 Installation procedure E 1 Document number 039247 fm Revision A Surge arrestor kit 3 phase VAL CP 3S 350 3 1 Appendix E Surge arrestor kit 3 phase VAL CP 3S 350 3 1 Instal...

Page 112: ...ples involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please...

Page 113: ...ation procedure E 3 Document number 039247 fm Revision B Surge arrestor kit 3 phase VAL CP 3S 350 3 1 Contents Scope and purpose E 5 Safety precautions E 5 AC Power source requirements E 6 Overview Su...

Page 114: ...ge arrestor kit 3 phase VAL CP 3S 350 3 1 Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 21 03 05 A New Revision Kai Morten Hennum 13 03 05 Originated Kai Morten...

Page 115: ...1 Insulated tools E 2 Safety precautions It is possible to mechanically damage the units To avoid this you must follow the approved assembly and installation methods described in the relevant section...

Page 116: ...arrestor kit The surge arrestor kit protects the system against lightning and transient over voltage Each surge arrestor kit consists of a holder containing three over voltage protector units one spa...

Page 117: ...low the Surge arrestor kit in order to prevent the Surge arrestor kit from sliding on the DIN rail Figure E 2 Surge arrestor kit mounted in the cabinet 4 Connect attached cables according to schematic...

Page 118: ...E 8 PODS 16 48 16000 1940 HEX Document number 039247 fm Revision B Surge arrestor kit 3 phase VAL CP 3S 350 3 1 Installation procedure is now complete...

Page 119: ...Battery Extension Kit Installation Procedure F 1 Document number 039249 fm Revision A Battery Extension Kit Installation Procedure Appendix F Battery Extension Kit Installation Procedure...

Page 120: ...ples involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please...

Page 121: ...Extension Kit Installation Procedure Contents Scope and purpose F 5 Safety precautions F 6 AC Power source requirements F 6 Overview Battery Extension Kit F 7 Installation and Connection F 8 Installin...

Page 122: ...tery Extension Kit Installation Procedure Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 21 03 05 A Second issue Kai Morten Hennum 13 05 05 Originated Kai Morten...

Page 123: ...the connection of the battery extension kit for PODS 16 48 16000 1940 HEX To ensure the continues supply of the loads from batteries it is of vital importance to follow this procedure closely The read...

Page 124: ...RY EXPERIENCE AND KNOWLEDGE WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION IT IS...

Page 125: ...ion Kit The Battery Extension Kit allows you to install additional battery strings Each Battery extension kit consists of 1 Battery shelf ODU 2 Battery cable 35mm2 M8 250cm STD 3 Magnetic C B 1 pole D...

Page 126: ...removal is only necessary when installing battery extension kit 4 However removal of the lower plate is recommended for easy access when installing batteries in the lower shelf Mount the battery shel...

Page 127: ...Kit Installation Procedure F 9 Document number 039249 fm Revision B Battery Extension Kit Installation Procedure Fasten the battery shelf using the supplied screws in mounting holes on the battery sh...

Page 128: ...ber 039249 fm Revision B Battery Extension Kit Installation Procedure F 5 2 Installing the battery breaker 1 Remove two dummy breakers by releasing the catch on top of the dummy breaker by using a scr...

Page 129: ...Kit Installation Procedure F 11 Document number 039249 fm Revision B Battery Extension Kit Installation Procedure Figure F 4 Dummy breakers removed Figure F 5 Replace the dummy breakers with supplied...

Page 130: ...ttery Extension Kit Installation Procedure 2 Mount the signal cable harness by sliding the cable lug onto the fuse alarm board in the position for battery breakers Battery breaker positions are labell...

Page 131: ...ing the battery cables 1 Mount the positive battery cable on the positive copper connection bar Torque 13 5Nm Figure F 7 Positive battery cable mounted 2 Mount the negative battery cable directly on t...

Page 132: ...et metal bracket as shown in Figure F 9 Strip the rest of the battery cables using the original battery cables as reference Figure F 9 5 Mount the supplied symmetry cable to the Alarm interface board...

Page 133: ...it Installation Procedure F 15 Document number 039249 fm Revision B Battery Extension Kit Installation Procedure Figure F 10 7 Check the connections with a Digital Multi Meter The installation procedu...

Page 134: ...F 16 PODS 16 48 16000 1940 HEX Document number 039249 fm Revision B Battery Extension Kit Installation Procedure...

Page 135: ...FMP 16 Dummy Module Installation procedure G 1 Document number 038471 fm Revision A FMP 16 Dummy Module Installation procedure Appendix G FMP 16 Dummy Module Installation procedure...

Page 136: ...les involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please...

Page 137: ...lation procedure G 3 Document number 038471 fm Revision B FMP 16 Dummy Module Installation procedure Contents Scope and purpose G 5 Safety precautions G 5 AC Power source requirements G 5 Overview dum...

Page 138: ...r 038471 fm Revision B FMP 16 Dummy Module Installation procedure Amendment record Revision Issue Description Author Date First issue rjan Skauge 05 11 04 Originated rjan Skauge Date 11 11 04 Approved...

Page 139: ...hazardous conditions on the system that may cause injury to personnel WARNING ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE AND KNOWLEDGE WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS B...

Page 140: ...G 6 PODS 16 48 16000 1940 HEX Document number 038471 fm Revision B FMP 16 Dummy Module Installation procedure G 4 Overview dummy module Figure G 1 Overview 1 Dummy module FMP 16 1...

Page 141: ...on B FMP 16 Dummy Module Installation procedure G 5 Mounting Figure G 2 Mounting of dummy module Remove all packaging supplied with the dummy module FMP 16 1 Fix the dummy module FMP 16 with the screw...

Page 142: ...G 8 PODS 16 48 16000 1940 HEX Document number 038471 fm Revision B FMP 16 Dummy Module Installation procedure...

Page 143: ...19 Adaptor Kit Installation Guide H 1 Document number 039273 fm Revision A 19 Adaptor Kit Installation Guide Appendix H 19 Adaptor Kit Installation Guide...

Page 144: ...nvolving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please notif...

Page 145: ...Installation Guide Contents Scope and purpose H 5 Safety precautions H 6 AC Power source requirements H 6 Overview 19 adaptor kit H 7 G 5 Installation and connection G 8 G 5 1 Installing the battery s...

Page 146: ...B 19 Adaptor Kit Installation Guide Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 06 04 05 A Second issue Kai Morten Hennum 13 05 05 Originated Kai Morten Henn...

Page 147: ...ection of the 19 adaptor 8U kit for PODS 16 48 16000 1940 HEX To ensure the continued supply of the loads from batteries it is of vital importance to follow this procedure closely The reader must READ...

Page 148: ...PERIENCE AND KNOWLEDGE WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM AND ITS BATTERIES WHO HAVE COMPLETED THE APPROVED TRAINING TO THIS SYSTEM INSTALLATION MAY CARRY OUT THIS INSTALLATION IT IS IMPOR...

Page 149: ...allation Guide H 4 Overview 19 adaptor kit The 19 adaptor 8U kit allows you to install up 8U of 19 equipment into the cabinet The kit consists of 1 2pcs Adaptor 8U 23 to 19 inch 2 2pcs Isolation for o...

Page 150: ...ent number 039273 fm Revision B 19 Adaptor Kit Installation Guide H 4 1 Installation First enter the two adaptor pieces on each side of the cabinet as shown in Figure H 3 using the 8 screws Torque 6 N...

Page 151: ...039273 fm Revision B 19 Adaptor Kit Installation Guide Use the isolation pieces where cable feed through is wanted to avoid damaging cables Figure H 4 Example of use of isolation The installation proc...

Page 152: ...H 10 PODS 16 48 16000 1940 HEX Document number 039273 fm Revision B 19 Adaptor Kit Installation Guide...

Page 153: ...Battery Heater Kit Installation procedure I 1 Document number 039448 fm Revision A Battery Heater Kit Installation procedure Appendix I Battery Heater Kit Installation procedure...

Page 154: ...es involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation please n...

Page 155: ...ure I 3 Document number 039448 fm Revision B Battery Heater Kit Installation procedure Contents Scope and purpose I 5 Safety precautions I 5 AC Power source requirements I 6 Overview Battery Heater Ki...

Page 156: ...8 fm Revision B Battery Heater Kit Installation procedure Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 10 06 05 Originated Kai Morten Hennum Date 10 06 05 Appr...

Page 157: ...ols I 2 Safety precautions It is possible to mechanically damage the units To avoid this you must follow the approved assembly and installation methods described in the relevant sections WARNING IF ON...

Page 158: ...l and battery shelf 4 Position the heater fan and fasten the shelf panel and fan with three screws Torque 6 Nm 5 The heater fan is now mounted Ensure that the heater thermostat is set to the 5 degrees...

Page 159: ...on procedure I 7 Document number 039448 fm Revision B Battery Heater Kit Installation procedure Figure I 2 Battery heater mounting 2 Heater location Fan 3 Removal of screws 4 Mounting Heater Fan 5 Hea...

Page 160: ...r kit is installed or is being installed mount the battery heater circuit breakers and ground terminal block below the surge arrestor as shown in Figure I 4 8 Mount the circuit breaker and the ground...

Page 161: ...Figure I 4 Heater kit din rail parts mounted in the cabinet 9 Connect attached cables according to Schematic diagram PPR 16 48 10 in Appendix A 10 Check the connections with a Digital Multi Meter 11...

Page 162: ...I 10 PODS 16 48 16000 1940 HEX Document number 039448 fm Revision B Battery Heater Kit Installation procedure...

Page 163: ...ustomer AC service outlet Installation procedure J 1 Document number 039248 fm Revision A Customer AC service outlet Installation procedure Appendix J Customer AC service outlet Installation procedure...

Page 164: ...amples involving names of companies and products are fictitious examples and are designed solely to illustrate the use of Power One products If you find errors or problems with this documentation plea...

Page 165: ...rocedure J 3 Document number 039248 fm Revision B Customer AC service outlet Installation procedure Contents Scope and purpose J 5 Safety precautions J 5 AC Power source requirements J 6 Overview AC o...

Page 166: ...Installation procedure Amendment record Revision Issue Description Author Date First issue Kai Morten Hennum 21 03 05 A New Revision Kai Morten Hennum 13 05 05 B New Revision Kai Morten Hennum 30 05...

Page 167: ...ted tools J 2 Safety precautions It is possible to mechanically damage the units To avoid this you must follow the approved assembly and installation methods described in the relevant sections WARNING...

Page 168: ...d stop piece mounted on the DIN rail below the mains terminal blocks 3 Mount the AC service outlet by snapping the holder on the DIN rail below the mains input terminal blocks Mount the end stop below...

Page 169: ...ocedure Figure J 2 AC outlet kit mounted in the cabinet 4 Connect attached cables according to schematic diagram See Schematic diagram PPR 16 48 10 in Appendix A 5 Check the connections with a Digital...

Page 170: ...J 8 PODS 16 48 16000 1940 HEX Document number 039248 fm Revision B Customer AC service outlet Installation procedure...

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