PS481000 5 100 System 040808

PS481000-5/100 System
Training CenterJianbo Gong

Tel86-0755-26862543
Email:[email protected]
Content
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System principle
AC distribution Cabinet
DC distribution Cabinet
Rectifier
Monitor
Maintenance
2 Emerson Confidential
Name
PS481000-5/100
Rectifiers Rated Output Current (100A)
Version No. (5)
Maximum System Output Current
(1000A)
Rated System Output Voltage (48V)
Power Supply System
PS481000
-5/100 System
PS481000-5/100
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Extra wide input voltage range: 304V~456Vac;

Be able to extend to 6000A (60 rectifiers)
PS481000
-5/100 System
PS481000-5/100
AC
Distribution
Cabinet
Remote
Monitorin
g Center
RS48
5
RS23
2
Monitor
DC
Distributio
n Cabinet
RS48
5
RS48
5
Rectifier
Cabinet
PS481000
-5/100 System
PS481000-5/100
... ~
~
~
-
AC
AC mains I
AC mains II
DC distribution
Rectifiers
AC distribution
Telecom equipment
-48 VDC
-48 VDC
...
Battery
RS-485
RS-232
RS-485
PSTN
RS-2
32
Background
computer
Monitoring
center
Monitoring
module
MODEM
MODEM
System Principle
Content
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System principle
Rectifier
Monitor
Maintenance
AC Distribution Cabinet
AC Input
AC I
AC II
AC Distribution Principle
Switch
Mains I
Mains
QF1
C-Level Lightning
Arrester
QF2
QF3
QF4
QF5
QF6
QF7
PE
QF9
QF10
QF11
QF12
QF13
QF14
QF15
QF16
Rack
Neutral Bar
Grounding Bar
QF8
Lightning Arrester
C Level
D Level
Lightning Arrester (C Level)
C Level
Lightning Arrester (D Level)
D Level
Lightning Arrester
Varistors + Gap
Varistor: voltage sensitive resistor
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C Level
Green window, good;
Red window, bad.
D Level
Indicators on, good;
Indicators off, bad.
Lightning proof breaker

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C Level ---- circuit breaker

D Level ---- fuse
Protect the wire from firing when varistors are
broken (short) for lighting strike.
Do keep the circuit breaker on
Buzzer Control
Muting control
Buzzer switch
Emergency Light Control

-48V
-48V
AC Distribution Monitoring Boards

48V
J0
12V Power supply
Audio-optical alarm
1J2
1J3
J1
B14C3U1
J2
AC/DC distributor
united monitoring
CPU board
JP2
RS485-D
to distributor display
1J1
JP1
switch signal
Analogue signal
JP2
Audio-optical
alarm
RS485
to monitoring module
JP1
J11
J7
Battery/load current
measurement
J15
Bus-bar/battery
voltage
measurement
J3,4,5
Emergency
light control
Load/battery
breaker status
A2V6FX1
Signal bridging board
3
temperature
sensor
(optional)
DC DISTRIBUTION
SIGNAL
J1
Emergency
light control
J9
J25
J2
1.67V/300A
current
measurement
BLVD (optional)
LLVD (optional)
Lightning arrester status

& alarm switch
J8
AC mains
voltage/frequency
sampling
1.5VAC
to pin 10
220VAC
AC mains
voltage input
220VAC
Frequency
input
AC MCB status
J8
W2 V2 U2 N
J9
W1 V1 U1 N
1
AC current
measurement
A2V4FA1
J6
AC mains sampling board

J5
AC DISTRIBUTION
SIGNAL
N X
X W2 V2 U2 W1 V1 U1
10
J4

J9
1.67V/300A
current
measurem ent
rrester status
itch
J8
AC m ains
voltage/frequency
sam pling
1.5VAC
to pin 10
220VAC
AC mains
voltage input
220VAC
Frequency
input
J8
W 2 V2 U2 N
J9
W 1 V1 U1 N
AC current
m easurement
A2V4FA1
J6
AC m ains sam pling board
J5
IBUTION
AL
W 2 V2 U2 W 1 V1 U1
10
J4

JP2
JP1
s w it c h s ig n a l
A n a lo g u e s ig n a l
JP1
JP2
A u d io - o p tic a l
a la r m
J7
J 11
J15
J 3 ,4 ,5
E m e rg e n c y
lig h t c o n tr o l
A2V6FX1
S ig n a l b r id g in g b o a r d
3
te m p e ra tu re
sensor
( o p t io n a l)
J1
E m e rg e n c y
lig h t c o n tr o l
J9
J25
J2
1 .6 7 V /3 0 0 A
c u rre n t
m e a s u re m e n t
B L V D ( o p tio n a l)
L L V D ( o p tio n a l)
L ig h tn in g a r r e s t e r s t a t u s
& a la r m s w it c h
J8
A C m a in s
v o lt a g e /f r e q u e n c y
s a m p lin g
1 .5 V A C
to p in 1 0
220VAC
F re q u e n c y
in p u t
A C M C B s ta tu s
J8
v
8

48V
J0
12V Power supply
Audio-optical alarm
1J2
1J3
J1
B14C3U1
J2
AC/DC distributor
united monitoring
CPU board
JP2
Analogue signal
JP1
switch signal
1J1
RS485
RS485-D
Board Functions
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Distribution CPU Board B14C3U1
Process all the signals from AC distribution

Alarm
LVD control
Report to monitor (communication)
AC Sampling Board A2V4FA1

Make mains voltage step-down to 1.5Vac
Signal Bridging Board B14C3X1

Bridge all the signals
Diagnosis of B14C3U1
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3 indicators on board:
LED1, Receive (green, normally flashing)
LED2, Send (red, normally flashing)
LED3, power (green, normally on)
Failure: wrongly alarm or not be able to alarm,

communication failure
CPU Board B14C3U1
Question
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The AC distribution cabinet alarms.It shows that

mains I lacks one phase. Whats the cause?
Content
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System principle
Rectifier
Monitor
Maintenance
DC Distribution Cabinet
Free cable
access
mode
DC Distribution Principle
-48V
Battery 1 Battery 2
Battery Fuse
Shunt
Shunt
switch
Load Fuse
Shunt
Precision resistor
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Measure the current

Shunt coefficient :
the relation between current
and voltage
1000A75mv
DC Distribution Monitoring Boards

48V
J0
12V power supply
Audio-optical alarm
1J2
1J3
J1
B14C3U1
J2
AC/DC distributor
united monitoring
CPU board
JP2
to port J1 of
A14C3X1
AC analogue
signal, switch
signal
AC DISTRIBUTION
SIGNAL
BLVD
LLVD
Emergency
light control
Switch signal
J2
J1
J6
J7
J8
B14C3X1
J14
J13
RS485-D
1J1
JP1
Analogue signal
-48V
Audio-optical
alarm
RS485
J12
J10
measurement
J9
J11
J4 J3
Bus-bar/battery
voltage measurement
Load/battery
breaker status
DC contactor coil
DC DISTRIBUTION
SIGNAL
3
temperature
sensor
(optional)

Analogue signal
J2
-48V
Audio-optical
alarm
to port J1 of
A14C3X1 AC analogue
signal, switch
signal
BUTION
AL
J1
J6
J7
J8
B14C3X1
J14
J13
BLVD
LLVD
Emergency
light control
Switch signal
J12
J10
measurement
J9
J11
J4 J3
Bus-bar/battery
voltage measurement
DC contactor coil
Load/battery
breaker status
3
temperature
sensor
(optional)

48V
J0
12V power supply
Audio-optical alarm
J1
B14C3U1
J2
AC/DC distributor
united monitoring
CPU board
JP2
Analogue signal
1J2
1J3
JP1
Switch signal
1J1
RS485
RS485-D
Board Functions
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Distribution CPU Board B14C3U1
Process all the signals from DC distribution

Alarm
LVD control
Report to monitor (communication)
Signal Bridging Board B14C3X1

Bridge all the signals
Question
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DC distribution communication fault. Whats the

cause?
Content
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System principle
Rectifier
Monitor
Maintenance
Name
HD 48 100-5
Serial No.(5)
Rated output current (100A)
Rated output voltage (48V)
HD48100
-5
HD48100-5
Wide input voltage range from 304~ 456Vac

3- phase AC input (3 -phase and 3 lines)
Efficiency92%
PF0.94
Hot-plug
When lacking 1 phase, output up to 50% of rated current
Front/Rear View
Front panel
Rear panel
Indicators
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Power Indicator (green, 2)

With AC input for the rectifier, the indicator will be on.
Protection Indicator (yellow, 3)

In case of AC over-voltage (protect at 460 10V, recover at 450
10V ), AC under-voltage (protect at 300 5V, recover at
324V), Over-temperature (protect at 95, recover at 85), the
protection indicator turns on. Meanwhile the rectifier halts to
protect itself until the case disappears.
Fault Indicator (red, 4)

turn on for output over-voltage or IGBT over-current ( the rectifier
will keep halt and not recover automatically).
Address Setting
Binary
MSB
LSB
0
Decimal 11
Question
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How to judge whether the rectifier is normal or

not?
How to replace the failed rectifier?
HD48100
-5
HD48100-5
Easy to replace fans
Content
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System principle
Rectifier
Monitor
Maintenance
Monitor PSM
-A
PSM-A
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386 industry computer

100 historical alarm records
Help on-line
Users password: 123456
Maintainers password: 640275
PSM-A Monitoring Module
Front Maintenance
Front & Rear View
Line
-up (3 cabinet)
Line-up
To other distribution cabinet
COM5
To other distribution
cabinet
COM4
PSM-A
1J3
1J3
1J2
1J2
1J1
B14C3U1
COM7
1J1
HD48100-5
B14C3U1
HD48100-5
COM6
HD48100-5
HD48100-5
AC Distribution
RS485
Rectifier Rack
DC Distribution
Line
-up (2 cabinet)
Line-up
To other distribution cabinet
COM5
COM4
PSM-A
1J3
1J2
1J1
B14C3U1
COM7
HD48100-5
HD48100-5
COM6
HD48100-5
HD48100-5
AC/DC Distribution
RS485
Rectifier Rack
Monitor
RS485
Rec1
AC 64
0
Rec2
Rec3
CPU
board
RS485
B14C3U1
B14C3U1
Distribution signal
(analogue and switch signal)
DC 72
ADC 80
Address of Rectifier
Determined by DIP switch of rectifier
MSB
LSB
0
1
2
3
4
5
6
7
8
Address Setting for Distribute Cabinet

AC:
64= All ON
H
L
DC:
72=4OFF
AC/DC:
80=5OFF
Address Setting
S1
Binary digit
xxx00xx0
Corresponding
Range of
PSM-A
communication
communication
address
address
0~7
Application
64~71
AC
distribution
cabinet
72~79
DC
distribution
cabinet
80~95
AC&DC
combined
distribution
cabinet
H
xxx10xx0
xxxx1xx0
Base address=64
8~15
16~31
Others
1/F2
2/F2 3/F2
Float voltage
6
Remote
Communication
U/F2
1/F2 2/F2 3/F2
4/F2
Telephone
number
6/F2
Baud rate
5/F2
Local address
User level
M/F2
Control
User level
5
System
management
Equalize voltage
U/F2 U/F2
Battery
management
2/F2 3/F2 4/F2
Maintenance
level
4/F2
Equlalize charge
pemitted or not
U/F2
4 Alarm level setup
4
Alarm
parameters
System
configulation
U/F2 M/F2 U/F2
1/F2
User level
3/F2
3 Alarm history clearing
3/F2
User level
3
Rectifier
parameters
2 Alarm history
2/F2
1 Active alarm
1/F2
3 Control
2/F2
User level
3/F2
2 Setting
2
DC
parameters
User level
U/F2
1 Real time data
2/F2
Maintenance
level
M/F2
3 Control
1/F2
User level
1/F2
Charging
efficiency
U/F2
2 Setting
1 Real time data
2/F2 3/F2
User level
U/F2
Maintenance
level
1
AC
parameters
Nominal
capacity
Battery
number
M/F2
3 Control
2 Setting
1 Real time data

1/F2
User level
User level
Maintenance
level
Main menu
7/F2
7
Others
U/F2
The parameters needn't be set

if no remote com.exists.
Key Parameter setting

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EQU VOLT: 56.4V;

FLO VOLT: 53.5V;
OVER CHRG( Charge over-current threshold): 0.3C10;
CHRG CUR LIM(Battery charge current limit): 0.1C10;
LOAD LVD : 44V;
BATT LVD : 43.2V;
Key Parameter setting

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Conditions to Equalize Charge-----empty?

TO EQU CAP RATIO: 80%;
TO EQU CUR: 0.06C10;
Conditions to Float-----full?
STABLE TIME: 180 MIN & STABLE CUR: 0.01C10
EQU TIMEOUT: 18 hours;
Battery Test----- discharge!
TEST END VOLT: 47V
TEST END TIME: XXX MIN
Internal Construction
Power
Board
CPU
Board
Board Functions
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CPU Board (M14C3U1)

process all the signals
Power Board (M14C3R1)

Convert 48Vdc to 12Vdc, 5Vdc, 9Vdc and 500Vac
Diagnosis for Monitor

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Phenomenon
Cause
AC/DC distribution or
rectifier communication
fault
Address,
communication port
number, CPU Board
no power
display without backlight
Fuse, Power Board

Power Board
Question
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The monitor prompts that AC Distribution, DC

Distribution and all rectifiers communication fault.
What is the cause?
Suppose the monitor fails, how to maintain the
system without monitor?
Content
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System principle
Rectifier
Monitor
Maintenance
Maintenance
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Special Phenomena
1. With small output current, the rectifiers fan may not
rotate, or rotate very slowly.
2. With small load current, rectifiers may not share the load
current equally.
3. The rectifiers may output only 52V due to limiting charge
current though they are in equalizing charge state.
4. Alarm information will not be displayed if the alarm is
disabled in Monitor PSM-A.
5. The system does not alarm though some of the fuses or
circuit breakers are off.
Handling Failure Procedure

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Handling Failure Procedure

1. Make the system mute
2. Check and record the alarm indicators and information
3. Classify the failure ( of AC distribution, DC distribution,
Rectifier or Monitor)
4. Analyze ( guess all of the possible causes)
5. Test and then locate the failure ( verify the guessing)
6. Handle ( caution: safety first, mark the plugs)
7. Confirm
Emergency Handling
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Principle: ensure the DC power for telecom equipment

Emergency Cases z Handling
1. AC Distribution Failure
1. Connect AC directly to rectifiers
2. DC Distribution Failure
2. Get rid of short
Load short circuit
Cut off the fuse/breaker for the load
Distribution short
Cut off AC, then separate the battery from

the system, and then power loads with
battery or rectifiers directly
3. Monitor failure
3. Turn off monitor, manage battery manually
4. Rectifier failure
4. Turn off the failed rectifiers
Inside short
Automatically turn off
Many rectifiers fail
Turn off, ensure enough normal rectifiers
Output over-voltage
Turn off all, then turn on one by one except

the failed one.
Case 1Mains voltage detection abnormal

Phenomena: The voltage value displayed is much
different to the actual value.
Failure analysis: Possible reasons
1.AC mains sampling board A2V4FA1 fails;
2.Distribution CPU board B14C3U1 fails.
Treatment: Check sampling board A2V4FA1, Replace
Case 2Failure of SPD

Phenomena
The monitor activates the alarm SPD fault.
Analysis
1.C-level SPD fails;
2.SPD MCB(circuit breaker) trips;
3.Detection cable for SPD is not connected well or has
breakpoints;
4.AC distribution CPU board B14C3U1 fails.
Case 3Battery parameter can not be set up

Phenomenasetting battery capacity parameter
through the monitor is unsuccessful.
Analysis
Communication break
Treatment
Case 44-Voltage
-Voltage doesn
t conform with float voltage
doesnt
PhenomenaThe float voltage of PS481000-2/100 power
system is set to 53.5 V, but the actual output value is about
55.5V.
Analysis
1.System is in equalize charge state
2.Rectifier is out of control
3.Temperature compensation
Treatment
Case 5LCD of AC cabinet can not be

paged down/up
PhenomenaLCD of AC (DC or AC/DC combined)
distribution cabinet always stays in one page. Pressing the
keyboard can not make it page down/up.
Analysis
1.Failure of keyboard;
2.Breaking of the communication between LCD and
distribution CPU board B14C3U1;
3.Failure of LCD hardware.
Treatment
Case 6Monitor does not respond to

keyboard operation
PhenomenaAfter a period of system running, the monitor
does not respond to keyboard operation.
Analysis
1.Monitor failure or breakdown.
2.Keyboard malfunction.
Treatment
Case 7Load sharing imbalance between

rectifiers
PhenomenaIn the power system configured with 4
rectifiers, the respective output current of rectifier 1, 2, 4 is
about 30A, while that of rectifier 3 is zero, and the system
gives no alarm.
Analysis
1.Failure of load sharing circuit of rectifier 3
2.Considerably low output voltage of rectifier 3
3.Rectifier 3 output fuse blowout
4.Rectifier 3 output socket failure
5.No output due to other failures inside rectifier 3
End
Thank You
Summary
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System principle
Rectifier
Monitor
Maintenance

PS481000 5 100 System 040808

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What are the main components of the power supply system?

What are the main components of the power supply system?

What are the functions of the AC distribution cabinet?

What are the functions of the AC distribution cabinet?

PS481000-5/100 System

Training CenterJianbo Gong

Extra wide input voltage range: 304V~456Vac;

Lightning Arrester (C Level)

Lightning Arrester (D Level)

Lightning proof breaker

C Level ---- circuit breaker

Emergency Light Control

AC Distribution Monitoring Boards

AC Distribution Monitoring Boards

12V Power supply

Lightning arrester status

AC mains sampling board

AC Distribution Monitoring Boards

AC m ains sam pling board

AC Distribution Monitoring Boards

AC Distribution Monitoring Boards

12V Power supply

Distribution CPU Board B14C3U1

Process all the signals from AC distribution

AC Sampling Board A2V4FA1

Signal Bridging Board B14C3X1

Failure: wrongly alarm or not be able to alarm,

CPU Board B14C3U1

The AC distribution cabinet alarms.It shows that

Measure the current

DC Distribution Monitoring Boards

DC Distribution Monitoring Boards

Signal bridging board

DC Distribution Monitoring Boards

Signal bridging board

DC Distribution Monitoring Boards

12V power supply

Distribution CPU Board B14C3U1

Process all the signals from DC distribution

Signal Bridging Board B14C3X1

DC distribution communication fault. Whats the

Wide input voltage range from 304~ 456Vac

When lacking 1 phase, output up to 50% of rated current

Power Indicator (green, 2)

Protection Indicator (yellow, 3)

Fault Indicator (red, 4)

How to judge whether the rectifier is normal or

Easy to replace fans

386 industry computer

PSM-A Monitoring Module

Front & Rear View

Address Setting for Distribute Cabinet

1/F2 2/F2 3/F2

2/F2 3/F2 4/F2

4 Alarm level setup

U/F2 M/F2 U/F2

3 Alarm history clearing

1 Real time data