DONGAH ELECOMM VPRS-4175E, Operation Manual

Page 1: ...220V AC 1Phase Input 54 5VDC Output 175Amps per Shelf 35Amps per Module VPRS 4175E POWER SUPPLY SYSTEM OPERATION MANUAL ...

Page 2: ...N MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 2 31 CONTENTS 1 SYSTEM SPECIFICATIONS 12 1 1 ELECTRIC CHARACTERISTICS 12 1 1 1 Input Characteristics 12 1 1 2 Output Characteristics 12 1 2 SAFETY SPECIFICATIONS 13 ...

Page 3: ...ension 14 1 4 2 Weight 15 2 RECTIFIER SYSTEM CONFIGURATION 15 2 1 CONFIGURATION 15 2 2 FRONT VIEW 15 2 3 FUNCTIONS 15 2 4 RECTIFIER SYSTEM BLOCK DIAGRAM 18 3 INITIALIZATION CHECK POINTS 19 3 1 INSTALLATION CHECK LIST 19 3 2 RECTIFIER MODULE INSERTION DELETION 20 3 2 1 Rectifier Module Insertion 20 3 2 2 Rectifier Module Deletion 20 3 3 NORMAL OPERATION 20 3 4 ABNORMAL ACTIONS CORRECTIVE MEASURES 2...

Page 4: ...GE FL CHAGE MODE SELECT TEMP OFF 30 7 5 OUTPUT VOLTAGE EQ CHARGE MODE SELECT TEMP OFF 31 7 6 RECTIFIER MODULE RESTART 32 7 6 1 When Module is Shut Down by Over Voltage 32 7 6 2 Rectifier Unit Thermal Shut Down 32 7 7 BATTERY CHARGE CURRENT LIMITATION 32 7 8 CONTROL PANEL POWER DROP 32 8 CONTROL PANEL SETUP MEASUREMENT 32 8 1 CONTROL PANEL SETUP FUNCTIONS 33 8 1 1 Float voltage setting 33 8 1 2 Equ...

Page 5: ...ement 34 8 2 2 Output voltage current measurement 34 8 2 3 Battery charge discharge current measurement 34 8 2 4 Current measurement per unit 34 8 2 5 Rectifier system alarm monitoring 34 9 RECTIFIER TEST MAINTENANCE 34 9 1 OVERVIEW 34 9 2 PERIODIC INSPECTION 34 9 3 ADDING RECTIFIER MODULE 35 10 PROBLEM SOLVING FAULT FIXING 36 10 1 PROBLEM SOLVING 37 10 2 REPLACING PARTS 37 10 3 ORDER OF REPLACEME...

Page 6: ...tion test and repair work please read carefully al of the directions specified in this manual for your safe operation of the system This product has been manufactured under strict quality management If there are any potential damages to human life or assets please contact Dongahelecomm This document deals with safety directions with the following symbols ...

Page 7: ...system without observing this symbol it may cause an injury or damage to assets Check of Contained Materials Make sure that the delivered product is the same one that you ordered Check first the quantity of the delivered articles as specified in the enclosed sheet Thene make sure that there are any missing parts deformation damage peeled out paints unscrews or damage of cables Directions in Storag...

Page 8: ...nd vibrations Violating the environmental requirements may cause an electric shock or fire Before connecting the battery wire load and gronding wire pay attention not to reverse the polarity of them Polarity reversal may cause fire While the system is on do not touch the battery wire load or grounding wire ports It may cause an electric shock or short circuit Pay attention not to reverse polarity ...

Page 9: ...battery wire load and grounding wire are taken apart from NFB and fuses Connect the battery wire load and grounding wire while the load side has been unloaded External transmission signal should be used at 60V or lower of input voltage and 0 5A or lower of circuit current Before you take apart or insert the RS232C and RS485 ports of the control module turn off the control module switch When you ta...

Page 10: ...VPRS 4175E OPERATION MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 10 31 ...

Page 11: ...perience should repair this product Violating this direction may cause an electrtic shock or fire As AC input and DC voltage are applied take particular attention not to have electric shock or short circuit when the system is tested or repaired Even when the system is turned on while commercial power is failed AC input may be fed to the system Take particular attention to test and repair work of t...

Page 12: ...stics 1 1 1 Input Characteristics 1 Rated input voltage 1Φ 3W 220Vac 2 Input voltage 90V 280V 3 Input frequency 45Hz 65Hz 4 Input rush current 50Apeak or less per rectifier module 5 Efficiency 90 or greater at 10 100 load 6 Power factor 98 or greater at 10 100 load 1 1 2 Output Characteristics 1 Rated output voltage 54 5V 0 545V ...

Page 13: ... 2 L5 8 DC 20A 4PORT 54 5V Load voltage supply 5 8 3 L9 10 DC 10A 2PORT 54 5V Load voltage supply 9 10 4 BATTERY 1 DC 150A 1PORT 1 Battery power supply 5 BATTERY 2 DC 150A 1PORT 48V 2 Battery power supply 5 Stability of input and load 0 5 0 27V or less 6 Output current limitation at 105 130 40 during derating 7 Output over voltage protection Suspend rectifier module at 59 0V 60 0V 8 Battery over d...

Page 14: ...9 5dB or lower 1 2 2 Surge Voltage of Power Cable Î Voltage 6kV 1 2 50 Current 3kA 8 20 1 2 3 Leaked Current Î 10mA or lower 1 3 Environmental Characteristics 1 3 1 Operating Temperature Humidity 10 55 10 95 1 3 2 Storage Temperature Humidity 40 80 5 95 1 4 Physical Specifications 1 4 1 Dimension VPRS 4175E Rectifier Shelf 310 3 H X 482 6 W X 421 7 D mm VPRM5435 Rectifier Module 122 5 H X 85 W X 4...

Page 15: ...lf top DC distribution frame contains 10 circuits for load supply and 2 circuit for battery connection This rectifier has been designed to charge the battery with positive ground and can be used for the system without any battery installed or connected Rectifier capacity can easily be built up by adding modules 2 2 Front View Figures 1 shows the exterior view of the rectifier 2 3 Functions Table 2...

Page 16: ...TION MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 16 31 DC distribution frame 1 Distributes output power and connects battery Figure 1 Exterior View of VPRS 4175E Rectifier Module Part Rectifier Controler Part ...

Page 17: ...VPRS 4175E OPERATION MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 17 31 ...

Page 18: ...VPRS 4175E OPERATION MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 18 31 2 4 Rectifier System Block Diagram ...

Page 19: ... has been connected to the main ground busbar 7 Check if the AC input ground has been connected to the main ground busbar 8 Check if the I O cable has been correctly connected 9 Check if the rectifier modules have been fully inserted Once all of the cabling and installation procedures are finished initialize the system and carry out the function test in the following order 1 Check if all of the po...

Page 20: ...n tighten the captive screws at the front panel and turn on the power switch Keep the switch ON while the rectifier is in operation 3 2 2 Rectifier Module Deletion Turn off the power switch of the module Then loosen the captive screws on it Pull out the module seizing the handle on it Before starting the action wait for about 1 minute until the LED is turned off Caution Turn off power switch when ...

Page 21: ...Normal 3 4 Abnormal Actions Corrective Measures If FAIL LED is turned on while the rectifier system is driven that means the rectifier system is abnormal in operation Alarm status is displayed on the LCD window of the control panel Check the alarm status and take proper actions Normal LED ON Error Message Display Fail LED ON RED ...

Page 22: ...OV DCUV Check default setting of output voltage Check output UV and OV alarm settings ACUV ACOV Measure actual input voltage using DVM LVD Check if the battery disconnector switch is in Normal Check if the battery has been normally connected B NFB Check if battery 1 2 C B OFF Position OCA Check the input voltage and check if the output is open See How to Operate Control Unit If the listed problem ...

Page 23: ...ating Switch During the operation the module should be in Operating Mode If the switch is in Standby mode output is not fed Caution Even though the switch is in Standby mode AC power will be fed to the module and the STB LED on the rectifier module will be turned on 4 2 POWER ON LED This LED is turned on green when the module is normal Standby Operate Button ...

Page 24: ...RM LED In one of the following conditions ALARM LED RED will be turned on When AC power excceds UV OV limits UV limit 90V OV limit 280V When the module is shut down due to output OV protection circuit driving When the module is shut down due to internal high temperature protection circuit driving When the voltage falls below UV limit due to current limit circuit driving When internal fan is failed...

Page 25: ...e left to decrease voltage Output voltage has been set to 54 5V It is recommended not to touch the setting Load sharing deviation among units may be adjusted 5 Control Panel Operation 5 1 DISPLAY Figure 6 Control Panel Front View 5 2 Control Panel Functions See Control Panel Operation Manual Table 5 Adjustments Menu Defaults ...

Page 26: ... Battery Charge Current 10A 200A 50A Battery Charge End Current 2A 100A 5A Temp Mode ON OFF ON Battery Charge Slect Auto Manual FL MODE EQ MODE Auto Battery Emergency Voltage 42 0V 48 0V 44 0V 5 3 Control Panel Operation See Control Panel Operation Manual 6 Manual Battery Disconnect Manual BATTERY DISCONNECT switch C B Circuit Breker type located at the rear side of the front panel When the C B is...

Page 27: ...ANUAL 27 31 Figure 7 Battery Disconnect 7 Rectifier System Operation Stop Operation 7 1 Rectifier System Operation Turn on the AC power switches at the rectifier unit top Yellow LED on each rectifier unit will be turned on Turn on the switch of each rectifier unit O OFF ...

Page 28: ...rectifier unit is turned on Turn off the main breaker at the distribution panel Turn off the power switch of the control unit 7 3 Battery Temperature Compensation BTC mode in TEMP ON As shown in the Rectifier Installation Manual install the Battery Temperature Compensating Probe near the battery Shelf Once the temperature probe is connected and set to BTC mode the system will operate in temperatur...

Page 29: ... 31 FL Charge Mode 5 6 4 V 5 2 8 V 0 5 3 2 T e m p Vo u t 1 0 A c tu a l T e m p e ra tu re C o rre c te d Vo lta g e 2 2 0 V C e ll 2 2 4 V C e ll 2 3 0 V C e ll 2 3 5 V C e ll 3 2 9 0 Ｆ o r a b o v e 2 5 7 7 Ｆ 1 5 5 9 Ｆ 5 4 0 Ｆ o r b e lo w Figure 8 BTC FL MODE EQ Charge Mode ...

Page 30: ... 2 T e m p Vo u t 1 0 A c tu a l T e m p e ra tu re C o rre c te d Vo lta g e 2 2 0 V C e ll 2 2 4 V C e ll 2 3 0 V C e ll 2 3 5 V C e ll 5 2 1 2 6 Ｆ o r a b o v e 4 5 1 1 3 Ｆ 3 5 9 5 Ｆ 2 5 7 7 Ｆ o r b e lo w Figure 9 BTC EQ MODE 7 4 Output Voltage FL Chage Mode Select TEMP OFF Default is AUTO FLOAT MODE ...

Page 31: ...ifier is initialized it will operate up to 32 hours at AUTO EQ mode automatically That is because the battery may have been discharged in the storage process If AUTO EQ is selected EQ charge is started and auto EQ mode is maintained until 10 minutes pass after current falls below battery end current limit EQ state is maintained for up to 32 hours after EQ charge gets started If EQ charge period ex...

Page 32: ...hut down by its protection circuit To restore the module push the switch at the rectifier unit front to OFF and then push the switch again to ON manually 7 7 Battery Charge Current Limitation This function enables user to set ON or OFF Default is OFF In that case the maximum value of charge current equals the output current limit of rectifier which means max current limit of the installed rectifie...

Page 33: ...t UV alarm setting 8 1 5 New password setting 8 1 6 Battery charge current limitation setting 8 1 7 Battery charge end current setting 8 1 8 Battery charge start current setting 8 1 9 Temp ON OFF setting 8 1 10 Battery charge mode setting 8 1 11 Battery emergency voltage setting 8 1 12 Alarm History Clerar 8 1 13 Alarm Sound Setting See Control Panel Operation Manual 8 2 Control Panel Measurement ...

Page 34: ...l state Enough amounts of spare parts must be prepared to repair fault units Even though the fault location and reason are detected under the guidelines of this Manual if field repair work is not possible or long period of time is needed for repair the fault units should be replaced with spare ones reserved Then the fault units can be repaired with enough amount of time Note As this rectifier uses...

Page 35: ...eck if the Standby Operate switch of the module is set to Standby 2 Insert a rectifier module to a corresponding slot and tighten the captive screw on it 3 Set Standby Operate switch of the module to Operate 4 Control panel will automatically set current limit of rectifier As current limit is set to 50 or 110 current limitation is made considering the number of rectifier modules within this range ...

Page 36: ...uld be necessarily carried out by experienced workers observing safety directions Jobs should be carried out in due order Workers should not wear rings watches or metallic accessories If non insulated conductors are used check using DVM if voltage is fed to them Battery capacity may not be enough to complete the maintenance work of the system Circuits and boards should be protected from EMI 1 5 ...

Page 37: ...eplacement of Rectifier Module VPRM5435 1 When a rectifier module is replaced alarm will be driven Turn off the rectifier module from the control panel or notify this fact to the person in charge 2 Set the switch of the rectifier module to STB 3 Turn the captive screw of the module counter clockwise Then take out the module from the shelf seizing the handle on it 4 Check if the switch of the new m...

Page 38: ...nnector of the separated front panel and power switch connector from the rectifier module 6 Loosen the 4 nuts fixing the front panel to the fan 7 Separate the fan front panel and fan grill 8 Replace the fan and then take the opposite direction from 7 to 4 For fan assembly make the arrow mark on the fan facing inner side of the module Fan connector cable should face downward and then assemble it 9 ...

Page 39: ...rotector Get rid of the rear cover from the rectifier system rear Pull out with a hand the part to be replaced from the SURGE PROTECTOR at the rear Insert the new part in the opposite order Caution As power is directly applied to the surge protector while input power is fed particular care must be paid 11 Acronyms GSM Global Standard System for Mobile ...

Page 40: ...VPRS 4175E OPERATION MANUAL Issue 2009 03 ED 1 VPRS 4175E OPERATION MANUAL 40 31 NFB No Fuse Breaker C B Circuit Breaker S W Switch RMS Root Mean Square LVD LOW VOLTAGE DISCONNECT ...

Page 41: ...FIER OPERATION MANUAL 2009 Dongahelecomm Corp All rights reserved Information in this document is proprietary to dongahelecomm No information contained here may be copied translated transcribed or duplicated by any form without the prior written consent of Dongahelecomm http www Dongahelecomm co kr ...