Introduction to Hybrid Power Supply

System of Telecom Station

Catalogue

1 System Introduction

2 Controller

3 FSU(Field Superation Unit)

4 Installation and Commissioning

5 O&M
System Introduction

The hybrid power supply system converts the mains / DG into a stable -48VDC
through the rectifier module, and the module outputs -48VDC to supply the load
and charge the battery at the same time;
The hybrid power supply system converts the DC power generated by the solar
battery pack into a stable -48VDC through the PV module, and the module outputs
-48VDC to power the load and charge the battery at the same time;
Mains, DG, PV,and battery complement supply power ; unified management
through platform and controller to achieve PV priority power supply and provide
stable and reliable -48VDC for the load;
When the battery pack supplies power to the load, when the battery voltage
drops to LVD1, the Controller issues an instruction to cut off the power supply of
the primary load circuit; when the battery voltage drops to LVD2, the Controller
issues an instruction. Cut off the power supply of the secondary load circuit;
  Intelligent devices such as controllers, combiners, and energy meters, as well
as door sensors, smoke, flood, temperature, and humidity are uploaded to RMS
center through FSU.

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System wiring diagram

4
Structure drawing

5
System Configuration

Item Configuration
Input branches Mains*1+DG*1 Manual ,CB 125/3P

AC Input AC SPD Class B+C

1p,detect the phase voltage, current, power, power consuption
Energy Meter
etc. of the mains / DG

Rectifier Module：DUM-48/50HI Rated Output：-48VDC

Input branches 6 ,DC CB*6

PV Input
PV Input SPD 6,Class C
PV Module Module：POSI-48/2900 Rated Output：-48VDC
Monitoring Unit DKD51 Controller
Battery Max 4 battery bank
LVD1：
CB 100A/1P*2、63A/1P*4；32A/1P*4、16A/1P*2；
LVD2：
DC Output
DCDB CB 63A/1P*2、32A/1P*2、16A/1P*2。
(Output shunt can be flexibly configured according to user
requirements)
DC SPD Class C
Combiner DB48400-4T
Intelligent access: Energy meter, controller, combiner, RS485;
IBSU-4E
FSU Environmental : door magnet, flood, smoke, temperature and
humidity of power cabinet and battery cabinet.

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 AC Input

Socket
Earth
Mains DG SPD Meter

Mains：U、V、W、N；
DG：U、V、W、N；
SPD：Class B+C，The green terminal is a dry node in SPD state, and 4 sets of
dry nodes are connected in seriesEnergy
Meter：Current detection：CT(curremt transformer)，Factory connected;
voltage detection: U, V, W, N; can detect voltage, current, active power,
reactive power, active power, reactive power of each phase; total
voltage, current, power, power consumption;
Communication : 485 to FSU (IBSU-4E).

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AC input Basic diagram

8
 PV Input

CB SPD *2 *3
*6

CB：Bipolar，Below is marked with + and-on the CB of the photovoltaic

input access terminal, indicating the direction of the current (the positive
electrode of the photovoltaic is connected to +, and the negative electrode
is connected to-);

SPD：Class C，The green terminal is a dry node in the SPD state, and the
PV input SPD dry nodes are connected in series;

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AC input Basic diagram

P
V

10
 DCDB

LVD2 LVD1 LVD2 LVD1

DC output branch FUSE FUSE SPD

Notes：
q LVD1 contactor：NO；
q LVD2 contactor：NO；
q Battery access：Fuse，Access via
combiner.
q DC SPD：Class C；
q Fuse state detection: the voltage
difference between the upper and lower ends
of the fuse is greater than 0.5V, and the
DCDB diagram controller reports a fuse failure 11
 Battery Combiner

电池合路器（电池共用管理器）

Notes：
Switch connector Battery connector RS485
q The wiring from the combiner to the switching power
supply and the FSU is connected at the factory;
q The combiner has been debugged at the factory；
q It is necessary to connect the battery to the combiner at
the site. Only the negative battery wire is connected, and the
positive battery wire is connected to the Positive of the
cabinet.

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● Independently set the boost and floating charge voltage
value of each battery pack ;
● Independently set the charging and discharging current
coefficient of each battery pack;
● Independently set the relevant technical parameters of
each battery pack;
● Real-time measure the operating parameters like SOC /
SOH / DOD of each battery pack;
● Dynamically store the operating data of a certain number
of equipment and battery packs;；
● Support battery packs of different periods, capacities, and
brands;
● Support the sharing of lead-acid battery pack, lithium
battery pack and echelon battery pack;
● Support lithium battery / echelon battery priority discharge,
lead-acid battery backup option;
● Support over-voltage, under-voltage, over-current, over-
temperature cut-off protection for lithium battery / echelon
battery cells;
● RS485 Northbound Interface southbound interface
connected to echelon battery;
Schematic diagram of battery connection
● Connect FSU and monitoring center for two-way data
communication through northbound communication;

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 Power Switch and Monitoring Unit

Monitoring unit (controller) Note：

q Monitoring unit：DKD51 controller；

q Rectifier：DUM-48/50HI，AC/DC，Gray panel;
Rectifier q PV module:POSI-48/2900，DC/DC；Green panel;
q Physical address: See the picture above.
q Rectifier and PV module have the same shape and
interface shape;
PV Module q Rectifier and PV module are not interchangeable.

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 Controller

LVD control Dry contact control

Monitoring uint

Composition：

q Controller；
q DC power board, shunt detection board, dry contact
board;
q LVD control board;

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 Controller function, interface

Detect system battery status, fault status, AC power supply status, module status and DC output
information
Parameters, battery parameters, system parameters, energy saving parameters, environmental
parameters
System control, module control, dry contact control, sub-cabinet configuration
Control the failure alarm records in the running state
Perform system configuration operations before leaving the factory according to the technical
requirements of the order, please do not operate

a.Detection and control of each unit(Such as: AC power distribution status, rectifier status, battery status, DC
shunt status are all detected or controlled by the controller).
b.It can be connected with the monitoring center to realize four remote functions (with intelligent
communication port (RS232 / RS485, network port, etc.),
   Realize telemetry, remote signaling, remote control and remote adjustment functions with the monitoring
center, and upload the power supply running status to the tower monitoring center in real time)
c.Support dry contact alarm output, simple and convenient.
 FSU(IBSU-4E)

North
bound
on/off Com Port AI DI
interface

q COM port：controller, combiner, energy meter; wiring has been completed.

q AI：The temperature and humidity sensor of the power cabinet, the wiring has been completed
q DI：The wiring of the flood and smoke senser in the power cabinet has been completed at the
factory; the battery cabinet's flood and smoke senser shall be connected on site
q The WEB system configuration has been configured at the factory and no operation is required on
site;
q Upload communication:Depends on the background platform system.
FSU wiring diagram

Wiring diagram
 Construction tools

Name Specification Qty. Remark Name Specificatio Qty. Remark

DG
3000W 1 Provide construction 60W lamp or LED 1
AC power Emergency light
flashlight
1500W 1 Heat shrinkable tube
Hot air gun
shrink processing
Socket 1
1500W 1 Drill Φ6mm-20mm- 12# 1 Maximum
Impact drill 20mm Adjustable wrench opening diameter
Accuracy requires 4 1/2 1 36mm
Multimeter
digits Diagonal pliers 1
Clamp ammeter
Accuracy requires 4 1/2 1 1
digits Ratchet bolt cutter
Suitable for 6-25mm2 1
Crimping Tool
wire
Needle-nose pliers 1
Suitable for 6-25mm2 1 Utility knife 1
Hydraulic clamp
wire Hammer 1
Electric iron 50W 1 Portable ladder 1
Socket wrench 1 Sleeve Φ6mm-24mm Strip level 1
Open-end wrench 17x19mm 1 Bellows
Open-end wrench 14x17mm 1
Open-end wrench 12x14mm 1
laptop
Open-end wrench 8x10mm 1 Serial to 485
Phillips screwdriver 4x100mm 1 converter
Phillips screwdriver 6x100mm 1 Network pliers
Slotted screwdriver 6x100mm 1 Labeling 1
Slotted screwdriver 2x100mm 1
machines

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 Common construction materials

Material Specification Table

No. Name Specification Qty. Unit Remark
1 AC cable U, V, W, N four-core cable is recommended to tbd m n line with the engineering design requirements,
be no less than 10mm2 it is recommended that the U, V, W, and N wires
be yellow, green, red, and light blue, respectively.
2 singal cable 2*0.5mm2 tbd m Two banks of battery temperature sampling
cables; battery cabinet flood, door magnetic;
already configured
3 singal cable 4*0.3mm2 tbd m Battery cabinet smoke sampling cable,already
configured
4 PV input cable PV+、 4mm ^ 2 is recommended for each photovoltaic tbd m
PV- input wire, the positive is brown, and the
negative is blue.
5 Battery and load The mounting holes in the positive are threaded tbd m The battery-to-power cabinet positive and
cable holes. Select the corresponding wires and negative cables are factory-configured
terminals according to the specifications of
circuit breakers and fuses。

6 PE cable Two，≥16mm2 tbd m Copper yellow-green two-color wire

7 Cold pressed Wire diameter specifications are consistent tbd p
solder
8 Expansion bolt 4*N p Equipment installation accessories, N represents
the number of equipment
9 Thermal casing Yellow green red blue black tbd m Meet the cable diameter requirements
10 Insulation Tape Red blue black 3 p
11 Cable tie 4*200 1 p
12 Net cable RS485，pin 4（Blue）A、pin 8 （brown）B tbd p
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 Secondary transportation, unpacking inspection, installation location

1. Design drawings (the basis for determining the installation location)

2. Secondary transportation: The construction unit provides transportation means to transport the
equipment to the construction site. The equipment should be kept in good packaging during
transportation to prevent equipment damage during transportation.
3. Construction site protection: Fences should be set up on the construction site, and obvious reminder
signs should be set to prevent people unrelated to the construction from entering the site by mistake.
4. Unpacking inspection of equipment: unpacking inspection after the equipment arrives on site, the
contents of unpacking inspection are as follows:
4.1. In the inspection of equipment packaging, the packaging should be checked for damage, water stains
and deformation.
4.2. Appearance inspection of equipment, including: cabinet color, whether there is damage and
deformation, whether internal components are off, whether internal structure is damaged or deformed,
and whether equipment is rusted.
4.3. Examination of auxiliary materials should be checked against the list of auxiliary materials of equipment to check whether the
types and quantities of auxiliary materials are missing or whether the auxiliary materials themselves are defective.

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 Secondary transportation, unpacking inspection, installation location

4.4. For data inspection, check the inventory data against the equipment data list, and check the accuracy and
completeness of the data.
4.5. Processing of unpacking inspection results
a. Start by checking the project preparation form and fill in the inspection results in the form.
b. The results of the abnormal inspection should be attached with photos and necessary textual
explanations.
c. Prepare a written report for the abnormal situation of inspection and send it to the relevant
department for processing through the feedback channel.
5. Determine the installation location
5.1. The installation position of the equipment conforms to the requirements of the equipment layout design
drawings of the station. It is strictly forbidden to change the installation position of the equipment.
Equipment installation position error ≤10mm.
5.2. After the calibration of the installation location of the equipment, the accuracy of the location of the
design drawings should be checked. If there is a deviation, the design department should be contacted
for correction.

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 Rack fixing

1. Rack fixing
1.1. Fix the cabinet after the installation position is determined. The
size of the cabinet installation holes is shown in Figure 4-2. During
installation, first measure and mark the drilling position on the
ground (equipment base). Hole, install M12 * 95 expansion bolts;
remove the access panel in the cabinet and the baffle at the rear of
the cabinet, and then fix the cabinet at the designed installation
position.
Claim:
a. The vertical error of the equipment does not exceed 0.1% of the
height of the equipment. The front of the equipment is arranged
straight and should be in a straight line. The deviation per meter is
≤3mm, and the deviation of the entire column is ≤15mm.
b. Keep the drill bit vertical to the ground when drilling, and the
drilling depth should be greater than the length of the expansion tube
of the expansion bolt 20mm to ensure that the expansion tube of the
expansion bolt can fully contact the wall of the installation hole.
c. When installing the expansion bolt, the nut should be tightened to
fix the expansion tube of the expansion bolt, and then a nut should
be screwed in, so as not to expose the bolt: (as shown in Figure 4-1).
d. The bolts are installed in the order of flat washer, spring yellow
washer and nut.
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 Main circuit connection

W
AC input
V
U
N

+
PV input --

To the nearest PE
ground point

Working earth
Battery 2 +
Battery 1+
Battery 2-
Battery1-

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Controller connection

Interface Defination Description

The power cabinet
has been
Door magnet connected, and the
DI5 battery cabinet is
connected on site
(parallel)

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 FSU

North
bound
on/off Com Port AI DI
interface

q COM port：DKD51 controller, combiner, energy meter; wiring has been completed.
q AI：The temperature and humidity sensor of the power cabinet, the wiring has been
completed
q DI：The wiring of the flood and smoke senser in the power cabinet has been completed at
the factory; the battery cabinet's flood and smoke senser shall be connected on site
q The WEB system configuration has been configured at the factory and no operation is
required on site;
q Upload communication:Depends on the background platform system.
FSU connection with power cabinet

FSU connection with power cabinet(Wiring is complete, no operation required)

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FSU connection with battery cabinet

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Parameter Setting

When the system is operating for the first time, the system time of the
monitoring unit needs to be set to the local time, otherwise it will affect the
energy measurement ,set the controller parameters according to the on-site
battery manufacturer information, otherwise it will affect the battery
management and accelerate the aging of the battery. The parameter names are
shown in the table below.
Parameter Name Setting Range

DG Parameter DC Parameter

Battery Parameter LVD Parameter

Please refer to the
appendix for the setting
Environment System Parameter
range.The device has been
set up at the factory
PV Battery Combiner Parameter

Energy Meter FSU

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 Power on Test

(1) Choose a time with good lighting conditions for debugging. Turn on the PV input MCB and observe whether the module
is turned on normally.
(2) Use a multimeter to measure the positive and negative bus voltages, and slowly increase to the default float voltage value,
and turn off the photovoltaic input.
(3) Turn on the DH input MCB, and set the DG switch to on in the system control settings through the controller parameter
settings. Start the DG and observe whether the module is normally power on. Use a multimeter to measure the positive and
negative bus voltage values. to the default value of float charge voltage, set the DG switch to off, turn off the DG input, omit
this step when DG is not available.
(4) When there is mains in the system, turn on the AC input MCB and observe whether the rectifier module is normally
power on. Use a multimeter to measure the positive and negative bus voltage values. Slowly increase to the default float
voltage value and close the mains input.
(5) Observe whether the system parameters are abnormal through the LCD screen, and set the system working parameters
according to the correct operation method and steps.
(6) After confirming that the system is working properly and that the measured parameters meet the requirements, close
the photovoltaic input and AC input switches, connect the load, turn on the system, close the battery fuse, and the system
enters the normal working state.
(7) Turn on the FSU switch, observe the status of the FSU indicator, and wait for 2 minutes to log in to the monitoring
platform.
(8) After starting, the system must be closely monitored for 20 minutes, pay attention to the monitoring information
provided by the system, and the alarms should be processed in time. If the situation is serious or the system needs to be
shut down for testing, the shutdown sequence is as follows:
1) Disconnect the load and battery; 2) Disconnect the photovoltaic input and AC input switches;

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Switching power supply

Shunt Contactor

u Function: DC current detection u DC input：DC48V

u Type：50/75mv u Contactor type: normally open MZJ, normally
u Detect battery current closed BZJ
u Function: battery protection, LVD1 and LVD2
actuator
 AC overvoltage, power outage, phase loss

Socket
Earth Mains DG SPD Meter

Ø"AC overvoltage and undervoltage" alarm

Alarm condition: AC voltage exceeds the setting range
        Upper range: 210 ~ 286V
        Lower range: 154 ~ 230V
Ø“Power outage”alarm
Alarm condition：The controller detects the AC three-phase voltage which is lower than 50V.
Ø“Phase loss”alarm
Alarm condition：The controller shows that one or two of the three-phase AC is less than 50V
Approach：
a.Mains problems
b.Check whether the AC input terminal has a virtual connection
c.Rectifier failure or no communication.
d.It can be taken in an emergency, and the method of parallel connection at the AC input terminal is temporarily
handled.
（For example: Phase A is normal, Phase B is normal, and Phase C is missing. The C-phase input can be
disconnected and insulated, and the higher of the A and B phases can be selected in parallel with the C-phase input）
 SPD failure

Ø “SPD failure”alarm
Alarm condition：AC SPD fault alarm is displayed in the controller;；

ØJudgment and processing steps

a.Check whether the SPD module is invalid
b.The color change of the display window indicates
that the SPD is damaged.
Dry contact
      Replace the corresponding single-chip SPD
module or the whole set 
c. The display window is normal, you can re-insert
the SPD module, if the fault is eliminated, the SPD
module is loose, just tighten it.
d.The green terminal (dry contact) of the SPD is
loose or comes off. Note that each block has a green
terminal and is connected in series.
 “LVD1 、LVD2（BLVD）”Alarm

Ø“LVD1 、LVD2（BLVD）”Alarm
Alarm condition：“When the "system protection mode" is the "LVD" mode, the primary DC contactor
is opened.

ØJudgment and processing steps

a.Confirm whether it is LVDt
b.After the LVD has been performed, it can
be analyzed and confirmed according to the LVD2 LVD1
historical information, current information,
LVD parameters and other information of the
controller to determine whether it is normal
LVD
c.Normal LVD requires timely power
generation
d. Abnormal LVD requires emergency short-
circuit contactor for processing.
 “Fuse failure”Alarm

Ø“Fuse”Alarm：
Alarm condition：When the voltage difference between the upper end of the battery fuse and
the negative is greater than 0.5V;

ØJudgment and processing steps

1.Check if the fuse is not inserted
a. If yes, it is necessary to measure the voltage on both
sides of the fuse and connect it to the fuse at the same
potential. LVD2 LVD1
2.Check whether the voltage across the fuse is greater
than 0.5V
a.If yes, the fuse is damaged. If there is a fuse damage,
you need to first confirm that there is no short circuit in
the battery circuit.,then replace the fuse.
3.Check whether the detection wire at the upper end of Fuse Fuse SPD
the fuse is not connected.
a.If yes, you need to restore the fuse detection line
 “DC shunt fault”Alarm

Ø“DC shunt fault”Alarm

Alarm condition: customer load is connected and DC shunt switch or fuse is
disconnected

ØJudgment and processing steps

a.Check whether the corresponding customer
branch has a load connected and disconnected (as
long as a certain output circuit breaker is
LVD2 LVD1
connected to the load line, the system
automatically monitors)
b.It is necessary to judge whether the
corresponding DC shunt load is artificially
disconnected
DC output shunt
c .The load does not have the power-on condition
and does not need to be handled if it is not closed.
d.If it is not artificially disconnected, it is necessary
to determine whether the corresponding DC shunt
load has short circuit or overcurrent protection
 “Module communication”or“PV module
communication”Alarm

Ø“Module communication”Alarm
Alarm condition: the communication between the rectifier (including photovoltaic
module) and the controller fails;

ØJudgment and processing steps

a. Check whether the alarm module is operating
normally.
b. Whether the module communicates normally.
c. You can judge whether the original module is
faulty by swapping the position with the normal
module.
Judgment and processing steps
a.The rectifier module does not work, the indicators are off
Main reason: AC power failure, rectifier circuit breaker not open or module
failure.
b.The rectifier module does not work, and the three indicators flash in turn.
Main reason: the virtual connection of the AC power (focus on checking the
virtual connection of the zero line).
c.The rectifier module does not work, the indicator light is red (FLT light)
Main reason: AC overvoltage, module temperature is too high or module
failure, module is not inserted in place, etc.
Module yellow light alarm

Alarm conditions: AC input undervoltage, module current limit, communication failure,

etc.

Judgment and processing steps

1. Check whether the AC input voltage of the rectifier module is too low.
a. If yes, you need to deal with the problem of AC supply
b. In an emergency, the module can be changed to a higher phase voltage slot.
2. Check whether the rectifier is in the controller current limit state (charging current
limit).
a. At this time, the yellow light of the rectifier is normal and does not need to be
processed.
3. Check if the communication of the rectifier is interrupted.
a. You can refer to the processing method of the module communication fault for
processing.
b. If the rectifier fails, the rectifier can be replaced.
 Module red light alarm

Module red light alarm：

Alarm conditions: AC input overvoltage, input frequency overrun, zero line false connection, zero ground
connection reverse, module overtemperature, DC output overvoltage, abnormal in-position identification circuit,
etc

Judgment and processing steps

1. Check whether the rectifier module is not installed in place.
a. If yes, install the module in place and tighten its screws.
2. Check whether the AC input voltage of the rectifier is too high, whether the input frequency exceeds the limit,
whether the zero line is virtually connected, and whether the zero ground is reversed.
a. If yes, relevant adjustments are required.
3. Check if the temperature of the rectifier is too high.
a. If yes, first check whether the ambient temperature is too high.
b. When the ambient temperature is normal and the module temperature is too high, the rectifier needs to be
replaced after removing the abnormal fan and long-term high current or full load operation.
4. Check if the rectifier DC output voltage is too high.
a. If yes, you need to troubleshoot the module.
b. Troubleshooting can be done by turning on the rectifier individually one by one.
 Common failures of mains

ØNeutral wire virtual connection

Common phenomenon: All modules turn on red light alternately, one after another, turn on
and off, and occasionally the green light may flash. Use a multimeter to measure the voltage of
the three-phase to neutral wire at the input end of the switching power supply. Two phases
are too high (above 300V) and one phase is too low (below 100V).
ØLive wire virtual connection：
The voltage of one phase associated with the virtual connection phase is low, the module
cannot work normally, or it cannot be output at full load. Use a multimeter to measure the
relative phase voltage to neutral line which is a too low.
ØNeutral and live reverse：
Due to the risk of burning modules when the neutral and live wire is reversed, it is necessary
to strengthen the management of engineering construction.
ØNeutral and Earth reverse：
The rectifier module of single-phase power distribution often fails to start normally. Generally,
the fan of the module starts and stops, and continuous measurement of neutral and earth
voltage may fluctuate.
Controller Replacement

42
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