DUM-48/100B Power System

User Manual

Version: 1.0
Revision date: May 8, 2019

Beijing Dynamic Power Co., Ltd

All rights reserved. The contents in this document are subject to change
without notice.

Address: No.8 Xinghuo Rd., Science & Industry Park, Fengtai District
100070, Beijing China
Homepage: www.dpc.com.cn
E-mail: hwyx@dpc.com.cn
 Specification Update Record
Update time Version Contents updated Modified by
2019-05-05 1.0 New draft Xiao rong
 Safety Precautions 1

Safety Precautions

To reduce the chance of accident, please read the safety precautions very carefully before operation. The
"Caution, Note, Warning, Danger" in this book and on the product do not represent all the safety points to be
observed, and are only supplement to various safety points. So anybody who will install or operate the system
has to get strictly trained and master the correct ways and all the safety points before operation.
When operating DPC products, the personnel must observe the safety rules in the industry, the general safety
points and special safety instructions specified in this book.

Electrical Safety

I. Hazardous voltage

Some components of the Power System carry hazardous voltage in operation. Direct contact or indirect
contact through moist objects with these components will result in fatal injury.

Observe safety rules in the industry when installing the Power System. The installation and operation
personnel must be licensed to operate high voltage and AC power.
In operation or installation, any conductive objects, such as keys, tools, watches, bracelets, bangles and rings
are forbidden to be hung or ware.
When you spot the cabinet with water or moisture, turn off the power immediately. In moist environment,
precautions must be taken to keep moisture out of the Power System.
"Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during
installation.

High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in
compliance with the local rules and regulations. Only those who are licensed to operate high voltage and AC
power can perform high voltage operations.

II. Tools

In high voltage and AC operation, specialized tools must be used.

III. Thunderstorm

Never operate on high voltage, AC, iron tower or mast in the thunderstorm.

In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should
be well earthed in time to avoid damage by lightning strikes.

DUM-48/100B Power System User Manual

 Safety Precautions 2 Appendix 3 Wiring Diagram 23
IV. ESD

The static electricity generated by the human body will damage the static sensitive elements on PCBs, such
as large-scale ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to
prevent body static from damaging the sensitive components. The other end of the ESD wrist strap must be
well earthed.

V. Hotsurface

When the power converter is running in the environment of high temperature, the surface of the converter is
hot. Please be careful when you plug or extract the converter. At the same time, you may be injured by falling
converter.

VI. Fire

Please obey the standard operation rules when you connect any cable connectors and ensure reliable
connection to avoid an accident, such as fire and damage of equipment.
Please do the similarly operation when you connect AC cable, or it will make the SPD on fire or damage when
phase line and zero line are in wrong connection.

VII. Short circuit

During operation, never short the positive and negative poles of the DC distribution unit of the Power System
or the non-grounding pole and the earth. The Power System is a constant-voltage DC power device; short
circuit will result in equipment burning and endanger human safety.

Check the polarity of the cable and connection terminal when performing DC live operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Use insulated tools.
In live operation, keep the arm, wrist and hand tense, so that when the tool in operation slips, the movement of
the human body and tool is reduced to a minimum.

BLVD

The Power System has battery low voltage disconnection (BLVD) function. BLVD means when battery voltage
drops down to 42V, the Power System cuts the load off to prevent over-discharge.
BLVD is enabled before delivery, which means that if power outage lasts for a long time or the Power System
fails, there might be BLVD. Users should classify the loads and connect the priority loads to BLVD routes. For
vital loads, users can disable BLVD to ensure reliability of the power supply.

23
DUM-48/100B Power System User Manual
 Appendix 2 System Parameter Setting 22
Safety Precautions 3

Appendix 2 System Parameter Setting

The advantage of BLVD is protecting the batteries from over-discharge. The disadvantage of BLVD is that
when the battery voltage drops down to a certain value, all the loads (including non-priority loads and priority
Table 2 System basic parameters set value range and the default loads) will be cut off due to battery disconnection.
Item Name Range Default Description The advantage of disabling BLVD is prolonging the power supply of priority loads. The disadvantage is that
：
Auto Manage the system by the monitoring module 。 disabling cannot prevent unwanted power failure due to mis-operation or Power System failure.

1 Management mode
2 Battery shunt quantity
3 Battery capacitance
４ Shunt factor
： 。
Manually User can control the system But the battery
equalized Charging time and battery capacity are still
Auto/ Manually Auto
calculated automaticlly by monitoring module. And the mode Others
will be changed to auto mode when the DC low volt alarm
happens or there is no manual operation for a long time.
Please keep the battery shunt quantity set to “0” when there’s I. Safety
no battery on using or keep the battery shunt quantity set to
0-4 4 “1” when the battery pack is using, and when the battery pack
quantity is “1” we must set the battery capacitance as the sum
of all the battery pack capacity.
When replacing power input fuses of monitoring module and power distribution units, use the same type fuses
Please set value according to the right capacity,otherwise the to meet the safety requirement.
50 -5000Ah 4000Ah sysetme will work abnormal. Please set value according to
the item 2
II. Sharp object
，
0-2500A 25-75mV 2000A/50mV Has been set in manuafacture, not need to change.

５ Floating charge voltage 43.2V-58V 53.5V Has been set in manuafacture, not need to change.

6 LLVD Enabled/Disabled Disabled Please set the value to disabled when here is not LLVD. When moving equipment by hand, wear protective gloves to avoid injury by sharp object.

7 BLVD Enabled/Disabled Disabled Has been set in manuafacture, not need to change. III. Power cable
If no special requirement,Please don’t change it ,the
8 LVD method Voltage, tmie Disabled
parameter has been set up.
Battery protect voltage to
Please set the LLVD volt and the BLVD volt to the same
9 LLVD DC output under-voltage 44.0V Please verify the cable labels and the silkscreen of the power supply before connection.
value when there is not LLVD.
alarm point
10 BLVD 30V-LLVD voltage 43.2V
IV. Signal cables
Charging
11 0.1-0.25 0.1 Has been set in manuafacture, not need to change.
current-limiting value
Auto boost charging
12 Enabled/Disabled Enabled Has been set in manuafacture, not need to change.
enabled
To boost charging The signal cables should be routed at least 150mm away from power cables.
13 Available setting 0.060C Has been set in manuafacture, not need to change.
current
To boost charging
14 Available setting 80%
capacity
Constant charging
15 Available setting 0.010C Has been set in manuafacture, not need to change.
current
Constant current
16 Available setting 180min
charging time
Battery temperature
17 Enabled/Disabled Disabled
compensation enable
Temperature Has been set in manuafacture, not need to change before
18 Ambient1-4/battery1-4/No NO
parameter(temperature1) putting the temperature probe into the system
Emperature Has been set in manuafacture, not need to change.before
19 Ambient1-4/battery1-4/No NO
parameter(temperature2) putting the temperature probe into the system

20
System configuration 、
24V 48V-1 48V-2、 、 48V-3 This system is only allowed to run in the “48V-3” type.
type 48V-3

DUM-48/100B Power System User Manual

22
 Appendix 1 Technical Data 21
Contents Parameter
Parameter Description
category
Contents The rectifier provides over-voltage hardware and software protection. The
hardware protection point is between 59V and 60V, and it requires manual
resetting to restore operation. The software protection point is between 56V and
Chapter 1 Overview ..............................................................................................................................................1 59V, and can be set through the monitoring module.
There are two software protection modes, which can be selected through the
1.1 Model Description ...................................................................................................................................1 software at the host:
1.2 Composition and Configuration...............................................................................................................1 1. Lock out at the first over-voltage
Once the output voltage reaches protection point, the rectifier will shut off and
1.3 Features .................................................................................................................................................2
hold that state. It requires manual resetting to restore the operation.
1.4 Operating Principles ...............................................................................................................................3 Over-voltage protection 2. Lock out at the second over-voltage
When the output voltage reaches the software protection point and the current
1.5 Main Function .........................................................................................................................................3
is bigger than 5A, the rectifier will shutdown, and restart automatically after 5
1.5.1 Battery Management ...................................................................................................................3 seconds. If the over-voltage happens again within a set time (default: 5min.
1.5.2 Energy saving management (ECO) .............................................................................................5 Configurable through monitoring module), the rectifier will shut off and hold that
state. It requires manual resetting to restore the operation.
1.5.4 Rectifier Slot Management ..............................................................................................................6
If the rectifier output current is smaller than 5A, the rectifier will not shut down,
1.5.5 Alarm and Protection ......................................................................................................................7 no matter whether the software protection point is reached or not.
Manual resetting: Resetting can be done manually through the monitoring
Chapter 2 Installation Instruction ...........................................................................................................................8
module, or by removing the rectifier from system
2.1 Safety Regulations..................................................................................................................................8 -40°C -55°C, outputs full power
Temperature derating 55°C - 75°C, output linear derating power.
2.2 Preparation .............................................................................................................................................8
> 75°C, output power is 0W
2.3 Mechanical Installation ...........................................................................................................................9 • EN55022, class B
• IEC61000-4-2
2.4 Electrical Installation ...............................................................................................................................9
EMC • IEC61000-4-3
2.4.1 Connecting Power Cables ...........................................................................................................9 • IEC61000-4-4
• IEC61000-4-5
2.4.2 Connecting Signal Cables ......................................................................................................... 11 • IEC61000-4-6
Safety Acoustic noise ≤60dB (When the ambient temperature is 25°C)
2.4.3 Connecting RS485 Cable .......................................................................................................... 11
At temperature of 20°C - 30°C and relative humidity not bigger than 90%RH,
Chapter 3 Installation Testing ............................................................................................................................. 13 apply a test voltage of 500Vdc. The insulation resistances between AC circuit
Insulation resistance
and earth, DC circuit and earth, and AC and DC circuits are all not less than
3.1 Installation Check and Startup .............................................................................................................. 13 2MΩ
3.2 Basic Settings ....................................................................................................................................... 14 (Rectifiers and monitoring module from the system before the test.)
AC to DC circuits, 50Hz, 3000Vac (RMS).
3.2.1 Parameter setting ...................................................................................................................... 14
AC circuit to earth: 50Hz, 1500Vac (RMS).
3.2.2 Login & Password ..................................................................................................................... 14 DC circuit to earth: 50Hz, 500Vac (RMS).
Insulation strength
3.2.3 Other ......................................................................................................................................... 14 Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac
(RMS).
3.3 Alarm Check and System Operation Status ......................................................................................... 14
For all the three tests above, there should be no breakdown or flashover within
3.4 Final Steps ............................................................................................................................................ 15 1min, with leakage current not bigger than 10mA
Turn over Cabinet
Chapter 4 Alarm Handling ................................................................................................................................... 16 600×600×2000mm(W×D×H)
Size Cabinet
4.1 Alarms .................................................................................................................................................. 16 (mm) DC Cabinet 600×600×2000mm(W×D×H)

4.2 Handling Rectifier Fault ........................................................................................................................ 17 Rectifier module 108×415×86 mm (W×D×H)

System No more than 30 Kg (no rectifier)
Appendix 1 Technical Data ................................................................................................................................. 20 echanical AC Cabinet ≤120
Rectifier Cabinet 1 ≤120(no rectifier)
Appendix 2 System Parameter Setting ............................................................................................................... 22
Weight (kg) DC Cabinet 1 ≤260
DC Cabinet 2 ≤260
Rectifier Cabinet 2 ≤120(no rectifier)
Rectifier No more than 4.4 Kg

DUM-48/100B Power System User Manual

21
 Appendix 1 Technical Data 20

Appendix 1 Technical Data Chapter 1 Overview

Table 1 Technical data This chapter introduces model description, composition and configuration, and features of DUM-48/100B Power
Parameter System (abbreviated as ‘system’ here in after).
Parameter Description
category
Operating temperature -5°C - 40°C 1.1 Model Description
Storage temperature -40°C - 70°C
Relative humidity 5%RH - 90%RH DUM-48/100B
Environmental
Altitude ≤ 2000m (derating is necessary above 2000m)
Others No conductive dust or erosive gases. No danger of explosion 1.2 Composition and Configuration
Pollution level Level 2
Input line voltage 380Vac The appearance and the definition of connection is shown in Figure 1-1.
Input voltage range 208Vac - 530Vac
Input AC voltage frequency 45Hz - 65Hz
AC input
Max input current per rectifier 12A
Power factor ≥0.99
Overvoltage Category Ⅱ
Rated output voltage -53.5Vdc
Output DC voltage -42Vdc - -58Vdc
Output current ≤2000A
DC output Voltage set-point accuracy ≤ ±1%
Efficiency ≥ 95.5%
Noise (peak-peak) ≤ 200mV
Weighted noise ≤ 2mV
AC input over-voltage alarm point Default: 530, configurable through monitoring module
AC input over-voltage alarm
10Vac lower than the AC input over-voltage alarm point
recovery point
AC input under-voltage alarm point Default: 208, configurable through monitoring module
AC input under-voltage alarm
10Vac higher than the AC input under-voltage alarm point
recovery point
AC input
AC input over-voltage protection
alarm and Default: 530Vac
point
protection
AC input over-voltage protection
More than 5Vac lower than the AC input over-voltage protection point
recovery point
AC input under-voltage protection
Default: 208Vac
point
AC input under-voltage protection
More than 10Vac higher than the AC input under-voltage protection point
recovery point
DC output DC output over-voltage alarm point Default: 57.6Vdc, configurable through monitoring module
alarm and DC output over-voltage alarm
1Vdc lower than the over-voltage alarm point
protection recovery point
DC output under-voltage alarm
DC output Default: 45.0Vdc, configurable through monitoring module
point
alarm and Figure 1-1Appearance of system
DC output under-voltage alarm
protection 0.5Vdc higher than the under-voltage alarm point
recovery point The configuration of the system is listed in Table 1-1.
The imbalance is better than ± 5% rated output current. Test current range: 10%
- 50% rated current.
Table 1-1 Power system configuration table
Current sharing
The imbalance is better than ± 3% rated output current. Test current range: 50% DUM-48/100B
Rectifier - 100% rated current
Power System Name Model Number
Input voltage: 323ac - 530Vac, rectifier max. output power: full power,
Derated by input (45°C) Input voltage: 208Vac - 323Vac, rectifier output power: linear decreasing to 40% Turn over Cabinet DXZ-48/100B2 1
full power. DC Cabinet DPZ-48/100B2 1
Output voltage can rise slowly upon rectifier start up. The rise time is
Output delay
Rectifier configurable Total model of power system is DUM-48/100B. The number of each cabinet can be increased according to the
Fan speed Rectifier fan speed can be adjusted automatically needs of customers.
The configuration of each cabinet is as follows:

20 1
 Chapter 4 Alarm Handling 19

Table 1-2 Configuration of Turn over Cabinet

Turn over Cabinet DXZ-48/100B2

Name Model Number Note

AC Input MCCB NDM2-630L/3358-630A 2

AC SPD MCB NDB1C-63C 32/3P 1

AC SPD SPD385-40A-MH 1 In=20KA,Imax=40KA,8/20us

Current transformer YDBH0.66-40I 800/1 3
AC test board SC920 1
Indicator light AD16-16CF/g28 1

Table 1-3 Configuration of DC Cabinet

固定螺钉
DC Cabinet DPZ-48/100B2

Name Model Number Note

DC SPD MCB NDB1C-63C 32/1P 1 8038风扇
DC SPD M1C060-40 Ⅱ-1 1 In=15KA,Imax=30KA,8/20us 前面板
Indicator light AD16-16CF/g22 1
Figure 4-2 Disassembling the front panel
Indicator light AD16-16CF/r22 1
Buzzer AD16-30M/w22 1 Replacing rectifier

Controller SC501 1 1. Take a new rectifier and check it for any damage.

Controller SC520 1 2. Loosen the fixing screw of the handle of the rectifier with a Phillips screwdriver.

Expand DI Board 6DI+2Temp(SZ1091X2 PCBA) 1 3. Pull out the fault rectifier from the rack by grabbing its handle.

Expand DO Board 6DO(SZ1050X1 PCBA) 1 Be careful with the rectifier just pulled out from the system, as it could be very hot due to long-term operation.
Do not let it slip away and get damaged.
Status board SC340 1
4. Hold the rectifier handle, push the new rectifier into the slot and make sure the connection is good.
Current detecting SC310 1
After a brief delay, the rectifier RUN indicator will turn on and the fan will start running.
board
5. Check that the new rectifier works normally.
You should make sure that:
1) The monitoring module recognizes the new rectifier.
Note: The rectifiers DZY-48-100B2 HE can be used to this system as well.
2) The new rectifier shares current with other rectifiers.
But different types of rectifiers have different characteristics and efficiency. Users can choose any rectifier to
3) When this new rectifier is pulled out, there is a corresponding alarm and the monitoring module displays the
meet requirements.
alarm.
If the new rectifier passes all the above tests, the replacement is a success.
1.3 Features
6. Push the handle back into the front panel to lock the rectifier.
The rectifier uses the active Power Factor Compensation (PFC) technology, the power factor is up to
0.99.
The system has wide AC input phase voltage range: 208Vac - 530Vac.
The rectifier uses soft switching technology, the efficiency is up to 94%.
The rectifier is of high power density.
The rectifier is hot pluggable. It takes less than 1min to replace a rectifier.
The rectifier has two optional over-voltage protection methods: hardware protection and software
protection.
The controller will manage the system include battery charge and discharge, LLVD, BLVD,
temperature compensation, auto voltage regulation, current limitation, battery capacity calculation and
on-line battery test, alarms, and etc.

2 19
 Chapter 4 Alarm Handling 18
Monitoring
Symptom Causes Handling method
module alarms The controller can save up to 10000 historical alarm records and 10000 run information.
Check whether the rectifier communication is
RS485, Ethernet will be available for remote communication and controlling, relay outputs are
normal. If not, check whether the
available, too.
Current sharing imbalance communication cable is in normal connection.
If the communication is normal while the The system has complete fault protection and fault alarm functions.
Rect protect protection indicator is on, replace the rectifier

Yellow Power factor compensation low voltage or

Change the position of the faulty module with
1.4 Operating Principles
normal module. If the faulty module cannot
indicator on output external over voltage
work normally, replace it
The mains AC input will connect to the AC input MCB. All the rectifiers will work in parallel to one bus-bar to
AC input over-voltage Ensure AC input voltage normally
Rect Not Check whether the communication cable is in power the loads and charge the batteries. When mains fail, the batteries will discharge to power the loads
Rectifier communication interrupted
Respond normal connection automatically.
Output external Check whether the system or the load is short
Output external short circuit Two levels of LVDs are configured in the system for protect the battery from over-discharging. One is for
short circuit circuit.
Check whether the setting values of non-priority loads(LLVD) and another is for priority loads(BLVD). The batteries will discharge when mains fail, if the
Yellow Rect Output
Rect Output current limit current-limit parameters in the monitor are
indicator blinks current limit DC voltage drop to pre-set value of LLVD, LLVD will disconnect the non- priority loads; when the DC voltage drop to
right or keep the load-rate in the right range.
Reset the rectifier. If the protection is triggered the pre-set BLVD value, the priority loads will be disconnected.
Rect HVSD Rectifier over-voltage
again, replace the rectifier When the mains restore, rectifiers will restart. LLVD and BLVD will connect when the DC voltage is over 52.5V.
Power factor compensation over voltage
Change the position of the faulty module with (settable, 5V higher than active value).
One module no output
normal module. If the faulty module cannot
Multi modules no output When output MCB trips, “Load Branch1 Trip” or “Load Branch2 Trip” alarm will be generated by the controller.
work normally, replace it
Output inside short circuit or over load
Red indictor on Pull out the rectifier and after a period of time,
The controller SC520 will monitor and manage the system.
Rect Failure
Inside over temperature re-test when the temperature is normal, if the The system has the battery temperature compensation function. With the battery temperature
failure still exist, replace it.
increase/decrease, the system output voltage will be decrease/increase accordingly. This kind of output voltage
Hot plug( Position signal detection) Re-plug the rectifier in.
Two or more rectifiers have the same ID change is no less than 2V DC.
Contact DPC for maintenance
number
The controller has the RS485 port and the Ethernet port to monitor and manage the system remotely.
Rect Fan Fails Fan fault Replace the fan
The schematic diagram of the power system refers to < Appendix 3 Wiring Diagram>.
Replacing rectifier fan
If the rectifier fan is fault, it should be replaced. Refer to Figure 4-2, for the replacing procedures: 1.5 Main Function
1. Use a screwdriver to remove the two fixing screws and pull out the front panel.
The main functions of the power system as below:
2. Unplug the power cable of the fan and remove the fan.
3. Plug in the power cable of a new fan. AC/DC rectifiers management
4. Install the new fan, with fan blowing-direction inward. DC distribution
5. Restore the front panel. AC over voltage and under voltage alarm and protect
DC over voltage and under voltage alarm and protect
LLVD and BLVD
Battery management

Energy saving
Rectifier Slot Management
Fault alarm and protection
Monitor and management, remote communication and remote control function

1.5.1 Battery Management

The relationship between the floating and boosting as below 0 :

18 3
 Chapter 4 Alarm Handling 17
No. Alarm Meaning Fault handling Class
Check the relevant MCB
Charge-current is more than preset value state, insure the system
11 Bat Fuse1 trip Battery routes MCB/Fuse trip/blowout alarm CA
has not overload or short
circuit
Battery capacity is lower than preset value
Check the relevant MCB
Cyc-Boost Load Branch1 state, insure the system
12 Load MCB/Fuse trip/blowout alarm MA
trip has not overload or short

Floating

Boosting
Boosting by manual control
circuit
13 Rectifier fault Refer to Section 4.2 below. MA
Con-Boost time is over The temperature is abnormal and overrun alarm(system equipped Check the cooling system
14 Amb/Bat HT/LT OA
with environment sensor) and the temperature
The Boost limit time is over

All alarms could be set, such as class, sound, validity, related relay, and so on.
，
Specific alarm(mains failure Bat fuse
，
Trip Rectifier Communication failure)
4.2 Handling Rectifier Fault

Figure1-5 The transformation of floating and boosting Handling indicator fault

When the system configures battery management function, the specific parameters should be set as below. The symptoms of usual rectifier faults include: green indicator (run indicator) off, yellow indicator (protection
indicator) on, yellow indicator blink, red indicator (fault indicator) on and red indicator blink.
Charge Management The indicators are shown in Figure 4-1 and handling methods of the rectifier are given in Table 4-2.
The Charge-Manage’ parameter setting range, factory default value, and setting instructions see below
Table1-4.

Table 1-4 Charge-Manage Parameter Setting Instructions

Name Setting Range Default Setting Instructions
Float Volt 53.5V Output voltage of the Rectifier in floating.

Boost Volt
43.2V-58V
56.4V
Output voltage of the Rectifier in boosting, and the value must be set more than 故障指示灯
the “Float-Volt” value.
The battery group charge current is based on the setting value and less than the 保护指示灯
setting value.
Limit Rate 0.1-0.4C10 0.1C10
C10 -- The nominal capacity for lead-acid batteries. 运行指示灯
The suggestive value is 10-20% capacity of single battery group.
OCP means the Over Charge Current Point. An alarm should be triggered if the
OCP 0.1C10-0.35C10 0.3C10
charge current is more than the “OCP” setting value.
Auto-Boost EN EN: Function is available;
EN,DIS
Cyc-Boost DIS DIS: Function is unavailable.
Cyc-Boost Perd 1-360d 360d Cyc-Boost Perd: Time between twice Cyc-Boost.
When Cyc-Boost is running, the battery charge voltage is the setting value of
Cyc-Boost Time 0.5-24h 12h the “Boost Volt” and the charge time is the setting value of the “Cyc-Boost Figure 4-1 Rectifier indicator

Time”. Table 4-2 Handling methods of the rectifier

Auto-Boost Curr 0.05-0.08C10 0.06C10 In the auto-boost condition, the monitor should control the system running Monitoring
under boosting when the capacity of battery group is lower than the Symptom Causes Handling method
module alarms
Auto-Boost Cap 10％-95％ 80％ “Auto-Boost Cap” or when the charge current is more than the “Auto-Boost No input voltage Make sure there is input voltage
Curr”, at this moment, the battery charge voltage is “Boost Volt” setting value. Change the position of the faulty module with
Run indicator off No alarm
Con-Boost Curr 0.002-0.02C10 0.01C10 During the boosting, if the charge current is lower than the “Con-Boost Curr” Assistant power source of the rectifier fails normal module. If the faulty module cannot
and after a period of “Con-Boost Time” , then the system should start floating work normally, replace it
Con-Boost Time 0.5-24h 3h Run indicator The monitoring module performs operations
automatically. No alarm
blinks upon the rectifier
During the boosting, if the boosting time meets the “Boost Limit Time” setting
Boost Limit Time 0.5-48h 6h AC input voltage abnormal Make sure the AC input voltage is normal
value, at this moment, the system should start floating automatically.
Fan blocked Remove the object that blocks the fan
Over- Ventilation path blocked at
Yellow Remove the object at the inlet or vent
Rect over temp temperature the inlet or vent
indicator on
protection due Ambient temperature too
Decrease the ambient temperature or remove
to: high or the inlet too close to
the heat source
a heat source

4 17
 Chapter 4 Alarm Handling 16

1.5.2 Energy saving management (ECO)

Chapter 4 Alarm Handling
Operating principle:
The rectifier will get higher efficiency at 40% to 90% load rate. So we want to make the rectifier works
This chapter describes the handling of alarms, as well as the preventive maintenance of the system during
system daily operation. at a higher load rate condition to reduce the loose of the power.
The maintenance personnel must have adequate knowledge about the system. Energy-saving function is dedicated designed for this.
Note
When the load rate of the rectifiers is lower than the pre-set minimum value, the controller will turn off
1. The maintenance must be conducted under the guidance of related safety regulations.
some rectifiers to make the load rate at the preset range.
2. Only the trained personnel with adequate knowledge about the system can maintain the inner part of the
cabinet.
When the load rate of the rectifiers is higher than the pre-set maximum value, the controller will turn on
some rectifiers to make the load rate at the preset range.
4.1 Alarms The minimum and maximum value could be changed.
The monitoring module alarms are classified in two types: major alarm, observation. Sometimes the load rate is close to the pre-set value but lower than the minimum value or higher than
Major alarm (MA for short): this type of alarm has strong impacts on the system performance. Whenever these the maximum value, if we turn on or turn off the rectifiers, the system maybe become not stable. To avoid
alarms are generated, users are supposed to handle them immediately. The alarm indicators will be on and
audible indication will be given. this happen, the controller will calculate and control it. So the system will not always work in the pre-set
Observation alarm (OA for short): when this type of alarm is raised, the system maintains normal output for a range.
while. If the alarm occurs during watch time, it should be handled immediately. If the alarm occurs during non-
The energy saving function is not allowed when the battery is unavailable.
watch- time, handle it during watch time. The alarm indicators will be on when observation alarm occurs.
If alarms are set as ‘no alarm’ by the users, no visible or audible indication will be generated and the system The energy saving function will be interrupted when AC overvoltage/undervoltage, phase failure, DC
works normally. overvoltage/undervoltage, rectifiers fault, controller fault, boosting charge, battery test, and such as these
The meaning and degree of normal alarms are given in Table 4-1.
important things happen.
Table 4-1 System setting parameter description
No. Alarm Meaning Fault handling Class
All the rectifiers will work on shift type to get better reliability and lifetime. When the system shift the
AC input voltage is higher than the pre-set value. Check AC input voltage rectifier, it will turn on the rectifier that will be started then turn off the rectifier that will be turned off.
1 AC Overvoltage Alarm disappears when AC input reach to 10Vac lower than the OA
pre-set value. Setting Param-Energy Saving
AC input voltage is lower than the pre-set value. Check AC input voltage
AC Enter the “Sys Parameter Set” menu, choose and enter the “Param-Energy Save” menu, as below Figure
2 Alarm disappears when AC input reach to 10Vac higher than the OA
Undervoltage
pre-set value. 1-6,
3 AC Lost When AC lost or all rectifier turn off because of AC fail Check AC input voltage CA
Check SPD status, maybe
4 AC SPD When AC SPD faults MA
need replaced.
Param-
Param-Energy Save
DC voltage is higher than pre-set value. Check DC voltage P-Saving:
Saving: DIS
5 DC Overvoltage Alarm disappears when DC voltage reach to 0.5Vdc lower than the MA Rect Num:
Num: 01
Cyc Period:
Period: 168.
168.0h
pre-set value Rect On:
On: 90.
90.0%
DC voltage is lower than preset value. Check DC voltage Rect Off:
Off: 40.
40.0%
DC
6 Alarm disappears when DC voltage reach to 0.5Vdc higher than the MA
Undervoltage
pre-set value
Check AC input and Figure 1-6 Param-Energy Save Setting Menu
7 LLVD LLVD alarm CA
battery voltage Starting Condition
Check if all the routes are
disconnected. Otherwise it Set “P-Saving” to “EN”
8 LLVD Failure LLVD contactor misoperation CA
maybe need to replace the
Number of online rectifiers is more than the “Rect Num” setting value. (The “Rect Num” is the minimum
contactor1.
Check AC input and number of online rectifiers)
9 BLVD BLVD alarm CA
battery voltage
One battery group can be used at least (The number of the battery shunt should be set according to the
Check if all the routes are
disconnected. Otherwise it actual configuration), and the battery MCB must be switched on.
10 BLVD Failure BLVD contactor misoperation CA
maybe need to replace the
contactor2.

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 Chapter 3 Installation Testing 15
Check item OK Comments
Energy Saving Management Instruction measured battery current should be less than 1%
The energy saving function is not allowed when the number of the battery shunt is zero. Check the number of the rectifier through the controller. The number should be consistent with
the actual number
Set the “P-Saving” to “EN” when the number of the battery shunt is more than zero, and then set the specific parameter Check the voltage, current, current limiting factor of rectifiers through the controller.
such as “Rect Num”, “Cyc Period”, “Rect On”, “Rect Off”, etc. After that the Energy Saving function is running. For the system configured with temperature sensor, the controller should be able to display the
Some resting rectifiers should be awakened when the load rate is more than the “Rect On” setting value, and then the load battery/ambient temperature. Hold the probe of the temperature sensor with hand and watch
the monitoring module, which should display the change of temperature
rate should be recalculated, if the new load rate is less than the “Rect Off” setting value, some rectifiers should go to sleep.

3.4 Final Steps

1.5.4 Rectifier Slot Management
Check item OK Comments
Setting Parameter-Rct Make sure that materials irrelevant to the equipment have been all removed
Fill in the installation report and hand it over to the user
Enter the ‘Sys Parameter Set’ menu, choose the “Parameter-Rct” menu, and then find the “Posi-Ctrl” menu as Figure 1-7,
Fill in FAILURE REPORT if any question occurred
set the value from “DIS” to “EN” to allow the slot function.

When the “Posi-Ctrl” is “EN”, the rectifiers’ information and the orders in the system are according to the slot matching If any defect is found in this equipment, inform the personnel who is responsible for the contract.
setting values, or the rectifiers’ information and the orders in the system are according to the rectifiers’ ID numbers from small If repairing is needed, please fill in the FAILURE REPORT and send the report together with the defective unit
to large. to the Service center.

Note:

①When the “Posi-Ctrl” is “EN”, all the online rectifiers and slots should be matched correctly.

②If the number of the online rectifiers is very few, set the “Posi-Ctrl” value to “DIS” should be better.

Parameter-
Parameter-Rct Posi-Ctrl: DIS
Posi-Ctrl:
Rct-
Rct-Num : - - ClrSlotNum : 01
Rct-Volt：53.5V
Rct- Slot-Num : - -
Slot- ClrAllSee : OK
Rct-Lim ：120.0%
Rct- CurrSet : OK Slot-
Slot-Setting
AllSet : OK

Figure 1-7 Parameter-Rct Menu

Choose the right item and set the right parameter, then press the enter key to confirm. The Parameter-Rct setting range,
factory default value, and setting instructions see below table 1-4.

Table 1-4 The Parameter-Rct Setting Instructions

Name Setting Range Default Setting Instructions
Rct-Volt 43.2V-57.6V 53.5V Output voltage of the Rectifier.
Rct-Lim 10%-120% 120%
EN: Function is available;
Posi-Ctrl EN,DIS DIS
DIS: Function is unavailable.
Rct-Num
01-63 -- Set the right value according to the number of the online rectifiers.
Slot-Num
CurrSet OK OK Press the “OK” to confirm when one pair of rectifier and slot matched correctly.
AllSet OK OK Press the “OK” to confirm when all the rectifiers and slots matched correctly.
Select the number of slot which need to clear the matching information with the
ClrSlotNum 01-63 01
rectifier.
Press the “OK” to confirm and then “Doing” will replace the “OK” for a short
ClrAllSee OK/Doing OK
moment, after that, all the slots matching information with the rectifiers cleared.
Before matching, set the “SlotSt” values from “DIS” to “EN” which need to match with rectifier, refer to figure 1-8 and 63
slots can be suggested.

Two ways of matching can be choosing:

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 Chapter 3 Installation Testing 14
displayed value should be less than ±0.2V
Start and stop each rectifier of the system by inserting and unplugging the rectifier. Check their Way1: Firstly, choose and set the “Rct-Num” which rectifier you want to match, the green LED of the chose rectifier will
output voltages blink, then confirm.

Secondly, set the right “Slot-Num” which match the rectifier you chose in the last step, then choose the “CurrSet”, press
3.2 Basic Settings the “OK” to confirm.

Similarly, match the rest of rectifiers with the right slot.

3.2.1 Parameter setting
When the system starts to use, the parameters of system should be preset according to the actual system
configuration (refer to Appendix 2 ), such as battery number, battery charge factor and other functional
requirements, but the battery capacity should be set by user according to the actual situation.
Finally, choose the “AllSet”, press the “OK” to confirm, then all the matching settings are available.
Way2: Firstly, choose and set the “Slot-Num” which you want to match, then confirm.
Secondly, set the right “Rct-Num” which match the slot you chose in the last step, the green LED of the chose rectifier

We maybe update the controller for easy using, such as adjust the display interface, add new function, but this will blink, then choose the “CurrSet”, press the “OK” to confirm.
manual maybe not be updated. Similarly, match the rest of rectifiers with the right slot.

Finally, choose the “AllSet”, press the “OK” to confirm, then all the matching settings are available.

3.2.2 Login & Password Slot Rct SlotSt

01 - - DIS
For security, there are two default passwords in the monitoring module show as below, please reset the 02 - - DIS
03 - - DIS
passwords when using. Any operation for monitoring module must be qualified or you can only browse the 04 - - DIS
05 - - DIS
system information. 06 - - DIS
07 - - DIS
Project password (Low Authorized): 1031
Admin password (High Authorized): 170313
Figure 1-8 Slot-Setting Menu

All the matching information can be check in the “Slot-Setting” as figure 1-8. If one pair matching or more matching need

3.2.3 Other to be cleared, according to the instructions of the table 1-4 about “ClrSlotNum” and “ClrAllSee”.

For more information about SC520 controller, please refer to < SC520 USER MANUAL>.

1.5.5 Alarm and Protection

3.3 Alarm Check and System Operation Status
The system has perfect fault alarm and protection function. The working state of the load MCBs and the battery group
Alarm MCBs can be monitored. Users can set some alarm levels such as AC over voltage, AC under voltage, DC over voltage, DC
Check that all functional units can trigger alarms that can be displayed on the monitoring module. under voltage, MCBs’ state, floating, boosting, rectifier error and protection alarms, and etc., users can also set the alarm
Check item OK Comments modes of these alarm, such as sound alarm, light alarm, or both of them. Similarly, the alarm mode of the dry contact can be set
Pull out one rectifier. The ‘RecN lost’ alarm should be triggered. Insert the rectifier in. The alarm too
should disappear. Repeat the same procedures on other rectifiers
Switch off the battery fuse/MCB that has been connected to the battery. The ‘BatFuse N Trip’ alarm
should be triggered. Insert the battery fuse. The alarm should be cleared.
Switch off a load MCB that has been connected to the load. The alarm ‘Load Branch1 Trip’ should
be triggered. Switch on the MCB, and the alarm should be cleared. Repeat the same on the other load
MCBs
Keep the rectifiers in operation. Enter the system control menu at the controller. Set the operate
mode from “Auto” to ‘Manual’, then set BLVD ‘Disconnect’ and confirm it. The battery protection
contactor should be open, and the ‘BLVD’ alarm should be displayed at the monitoring module

System operation status

There should be no alarms during normal system operation. The system operation status check can be
conducted through the controller.
Check item OK Comments
The system setting is correct
The controller should display the correct AC voltage
The controller should be able to display the DC voltage. The difference between the displayed
voltage and that measured at the busbar with should be less than ±0.2V
The controller should display the battery current. The difference between the displayed and

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 Chapter 2 Installation Instruction 8 Chapter 3 Installation Testing 13

Chapter 2 Installation Instruction Chapter 3 Installation Testing

This chapter introduces installation and cable connection. Before installation, please read through safety This chapter introduces procedures of installation testing. The corresponding safety rules shall be obeyed by
precaution and safety regulations, and then follow this instruction to carry out the installation step by step. in the test.

2.1 Safety Regulations 3.1 Installation Check and Startup

Certain components in this system carry hazardous voltage and current. Please read the safety caution in the Before the test, inform the chief manufacturer representative. Only the trained electrical engineer can maintain
user manual and always follow the instructions below before do any operation or installation: and operate this equipment. In operation, the installation personnel are not allowed to wear conductive objects
1. Only the adequately trained personnel with satisfactory knowledge of the power system can carry out the such as watches, bracelets, bangles and rings.
installation. The most recent revision of these safety rules and local safety rules in force shall be adhered to During operation, parts of this equipment carry hazardous voltage. Any misoperation can result in severe or
during the installation. fatal injuries and property damage. Before the test, check the equipment to ensure the proper grounding.
2. All external circuits that are below -48V and connected to the power system must comply with the Installation check must be done before testing. Then the batteries can be charged for the first time.
requirements of SELV as defined in IEC 60950. Make sure that the AC input MCBs and load MCBs are switched off. Make sure that all the devices are
3. Make sure that the power (mains and battery) to the system is cut off before any operations can be carried properly installed.
out within the system cabinet. Installation check
4. The power cabinets shall be kept locked and placed in a locked room. The key keeper should be the one Check item OK Comments
who are responsible for the system.
Check all the MCBs are disconnected.
5. The wiring of the power distribution cables should be arranged carefully so that the cables are kept away
Check all the MCBs, fuse and cables.
from the maintenance personnel.
Check the input and output cable connection, and connection between the power
system and the system grounding
2.2 Preparation
Check if the number and connections of the batteries are correct. Check the polarity of
the battery string with a voltmeter
Unpacking inspection
Make sure all the connections are firm and reliable
The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall
Make sure all the communication cables and alarm cables are connected to the
be done by representatives of both the user and DPC Co., Ltd.
monitoring module. Check that the temperature sensor, if any, has been installed
To inspect the equipment, you should open the packing case, take out the packing list and check against the
packing list that the equipment is correct and complete. Make sure that the equipment is delivered intact. Startup preparations
Cables Check item OK Comments
The cable should be selected in accordance with relevant industry standards. Make sure that all the MCB are switched off and all the fuses are removed
Measure the AC input voltage. Make sure the input voltage is within the allowable range Umin=___V
The sectional area of DC cable depends on the current flowing through the cable, the allowable voltage drop,
load peak current, and the ambient. Check that the battery string circuit is not closed

℃
The cable rated temperature should be not more than 90 . Select the battery cable sectional area according
Connect the disconnected batteries to the battery string circuit
Measure with a voltmeter across the connection points of each battery and make sure that the
to Table 2-1. Select the load cable sectional area according to Table 2-2.
polarity is right. For a lead-acid battery with 24 cells, the voltmeter should be 2.0 - 2.1V/cell or 48 Umin=___V
Table 2-1 Battery cable CSA selection - 52.8V/battery. If the voltage of certain cell is lower than 2.0V, that cell must be replaced
Battery Max. Check with an ohmmeter that there is no short circuit between the positive & negative distribution
Max. Load Min. cable Screw Max. cable length (volt drop: 0.5V,
Fuse/MCB rated Battery bus-bars, or between the positive & negative battery poles
current CSA specification with max. CSA)
current current
(Note: Pull out all modules before the check and restore them after the check)
1000A 1000A 1000A 120 mm²*4 M16 OT 5.4m*4
Startup
Table 2-2 Load cable CSA selection
Load route rated
Check item OK Comments
Max. output Screw Max. cable length (volt drop: 0.5V,
Min. cable CSA Switch on the system AC input MCB and DC output MCB. Insert one rectifier. The monitoring
current（Fuse） current specification with min. CSA)
500A 500A 500 mm²*2 M12 OT 5.3 m*2 module will show the voltage and current
The green LED on the rectifier will be on and the fan will start running after a certain delay. The
monitoring module will show that the power supply voltage is 53.5V(Or float voltage setting value).
Consider the effects of ambient temperature, fuse installation, etc., the fuse of this product should be derated:
Set the battery capacity as same with the actual capacity. The capacity in this system is the sum of
1) If UL standard fuse is used, it should be derated to 75% of the rated value according to UL standard
capacity of all battery strings. Then turn on the battery MCBs.
( Referred to as the required value), and then consider the ambient temperature and thermal impact, again
When the battery voltage is lower, the bus-bar volt maybe under 53.5V because of current limit.
derate to 80% of the UL required value to ensure reliable power supply; 2) If the IEC standard fuse is selected,
Check the system voltage with a voltmeter. The voltage difference between the measured value and
it needs to be derated to 80% of the rated value to ensure The device is reliably powered.
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 Chapter 2 Installation Instruction 12 Chapter 2 Installation Instruction 9
The MCB of this system should be derated, it should be derated to rating of 80% to insure reliable power
Pin1 supply for different environment temperature or different way to install MCB.
Select the cable sectional area according to the table 3B of EN60950 《Safety of information technology
equipment 》.
Pin8 Usually, we use copper wire cable. If aluminum wire cable is replaced, please use the recommended value
correctly to prevent accidents for heating cables.
Figure2-5 The RS485 terminal definitions
Longer cable in the same sectional area can be used when more voltage drop is allowable.
2) The DB9 terminal pins and the RJ45 terminal pins matching Table 2-3 as below:
Farther transmission distance can be got when bigger sectional area cable is used.
Table 2-3 RJ45 terminal matching table

Definition 2.3 Mechanical Installation

Pin Illustration For system installation and maintenance please refer to < DUM-48/100B Fast Installation & Maintenance
1 -- -- Instructions>

2 -- --
2.4 Electrical Installation
3 -- --
4 485_3_A 485_3_A 2.4.1 Connecting Power Cables
5 485_3_B 485_3_B
6 -- -- Danger

7 485_4_A 485_4_A 1. Switch off all MCBs before the electrical connection.
2. Only the qualified personnel can do the power cable connection.
8 485_4_B 485_4_B 3. The batteries may have dangerous current. Before connecting battery cables, make sure that the battery
fuses at the battery side and battery MCBs at the system side are switched off. If there are no battery fuses at
the battery side, you should disconnect any one of the connectors between battery cells to avoid live state of
the system after installation.
Table 2-4 RJ45 terminal & Ethernet Port matching table
4. Be careful not to reversely connect the battery. Otherwise, both the battery and the system will be
Pin Signal Definition damaged!
5. AC cables must be connected according to the silkscreen of the back insulation cover plate and this
1 TX+ manual.
Transmission Data Cover board is installed above the cabinet to avoid foreign body falling and affecting the normal operation of
2 TX-
the system.
3 RX+
Receive Data
6 RX-

4 485_3_A 485_3_A

5 485_3_B 485_3_B

7 485_4_A 485_4_A

8 485_4_B 485_4_B

Figure 2-1 Wiring diagram of Turn over Cabinet

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 Chapter 2 Installation Instruction 10 Chapter 2 Installation Instruction 11

2.4.2 Connecting Signal Cables

The position of the DI/DO connection terminal is on the front panel of system, and the silkscreen shows as
below 0.

Figure2-3 DI/DO connection terminal

Connection method to signal terminals:

1, Peel one end of the signal cable. The maximum wiring range of the signal cable Is 1.5mm².
2, Use a screw driver or similar tool to press the white button.
3, Insert the cable into the black round hole of the DI/DO signal terminal and take away the tool.
4, Be sure the cable has a reliable connection.
5, There’s three temperature sensor connection terminals on the front panel. The length of the temperature
sensor is 3m, and the mounting hole is 9.5mm in diameter. The temperature sensor shows as 0, it’s optional.
Figure2-2 Wiring diagram of DC Cabinet
Note:
①　 The DI/DO signal cable and it’s terminal are not standard.
②　 The capacity of the dry contact is 30VDC/2A .

Figure2-4 The temperature sensor (Optional)

2.4.3 Connecting RS485 Cable

Customers can manufacture the cable by themselves according to the detail information as below;
1) For RS485 terminal, the definitions show as 0.

10 11