Manual Instrucciones Power One Forza 48 25600pdf

POWER SUPPLY SYSTEM
Forza 48-25600 PPC

Instruction Manual
Revision: /
Document number: 037879
Copyright © Power One AS.
All Rights Reserved.
Power-One, AS
Kobbervikdalen 75
P.O.Box 1543
N-3007 Drammen
Unless specifically noted, all addresses, data, characters and persons referenced herein, and all exam-
ples involving names of companies and products, are fictitious examples and are designed solely to il-
lustrate the use of Power One products.
If you find errors or problems with this documentation, please notify Power One. Power One does not
guarantee that this document is error-free. The information in this document is subject to change without
notice.
Power One logo is a registered trademark of Power One Corporation.

All other trademarks or product names mentioned herein are trademarks of their respective owners.
Title page - Instruction Manual
Document Number: 037879
Revision: /
Date: 08.07.2004
System: Forza 48-25600 PPC
Ouput Voltage: 48V
Publisher: Power-One as
Postboks 1543
N-3007 Drammen
NORWAY
Amendment record:
Revision Description Author Date
(Issue)
/ First issue Hans Andre Dokka 23.07.04
Originated Hans Andre Dokka Date 23.07.04 Approved Roar Fagerhus Date 23.07.04
Signed Signed
Introduction to the manual
Objectives and audience

This manual provides the user with the necessary information to understand how the Power Supply System
is made and functions, together with sufficient information to enable the user to safely install, commission,
maintain and operate the equipment in a safe and efficient manner. This manual has been prepared to be
used by professional and properly trained personnel selected by our customers. This manual assumes that
the technician has an understanding of power systems in general and understands safety procedures for
working around AC and DC voltage. The user of this document should be familiar with electronic circuitry
and wiring practices and have some expertise as an electronic or electromechanical technician.
The information contained herein was applicable at the time the manual was ready for printing. Power One
reserves the right to change specifications and designs without notice and without incurring obligation or
liability.
This manual is the work product of Power One and embodies confidential proprietary data in which Power
One retains all rights, including exclusive right of use, reproduction, distribution and sale. It is submitted
under a confidential relationship for a specific purpose, and the recipient agrees by accepting this work
product, not to supply or disclose any information regarding it to any unauthorized person.
Symbols and conventions

The following words and symbols found throughout this manual are meant to highlight particularly important
matters regarding specific information concerning the personnel, equipment or the process.
Note! The text set off in this manner present an important piece of information that is essential to
highlight.
CAUTION The text set off in this manner provides warning notice that failure to
follow these directions can result in damage to equipment.
WARNING THE TEXT SET OFF IN THIS MANNER PROVIDES WARNING NOTICE
THAT FAILURE TO FOLLOW THESE DIRECTIONS CAN RESULT IN BODILY
HARM OR LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO EQUIPMENT
Introduction to the manual v

Document number: 028410.fm
Revision: B
Abbreviations
The following abbreviations are used in this manual:
Abbreviation: Description:
PPS P1 Power Supply System
PMP P1 Modular Power
CMP Convection-cooled Modular Power
FMP Fan-cooled Modular Power
PCS P1 Control and Supervision
PCU P1 Control Unit
GMC Galero Modular Controller
PPR P1 Power Rack
PBDU P1 Battery Distribution Unit
PBC P1 Battery Cabinet
PDU P1 Distribution Unit
PPRD P1 Power Rack with DC Distribution
PPC P1 Power Supply Cabinet
PBF P1 Battery Fuse Unit
PCB Printed Circuit Board
LVD Low voltage disconnection
PLD Partial load disconnection
MCB Miniature circuit breaker
MCCB Moulded case circuit breaker
Disclaimer
Power One is not responsible for system problems that are the result of installation or modification of the
instructions provided in this manual.
Questionnaire for feed-back

We urge you to complete and return the questionnaire on our web page at the following address:
http://www.power-one.com/feedback.html. Let us know your remarks on and suggested improvements to
this manual. We appreciate your comments in our achievement to improve our documentation.
If you have any problems with your system, e.g. you wonder how to install a new PMP rectifier or you have
some questions regarding messages or alarms on the control module, please see the Troubleshooting
section. If this does not solve your problem, please seek assistance at your local Power One office, or our
head office in Norway. These also concern any indistinctness in the manual.
vi Forza 48-25600 PPC

Revision: B
Table of contents
Contents:
1 System description Forza PPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 System description - Forza . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.1 FMP 32 - Rectifier module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.2 PCS - Controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.3 PPR 32/4 19"- Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4.4 PBDU, PBF and PDU - Distribution modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4.4.1 Low voltage disconnection (LVD) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4.4.2 Partial load disconnection (PLD) (Option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.1 Lethal voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.3 Precautions for lead acid batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.5 High temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.1 Storage and transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Handling electrostatic sensitive devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.3 Traceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.4 Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3 Installation guide Forza PPC guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 AC Power source requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.2 Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.3.1 Connection of mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.3.2 DC connections from top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4.3.3 Connection of Common positive (+) DC cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.3.4 DC connection from bottom (Only for special made cabinets) . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4.3.5 Connection of live DC cables (- 48V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3.6 Connection of communication and current share signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3.7 Connection of expansion cabinet(s) with copper bars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.4.3.8 Connection of expansion cabinet(s) cable to copper rail under floor level . . . . . . . . . . . . . .3-10
3.4.3.9 Connections of fuse alarms between cabinets.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3.4.4 Connection of alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3.4.5 Connection of symmetry measurement and temperature sensor . . . . . . . . . . . . . . . . . . . . . . .3-13
4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Commissioning overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Table of contents vii

Table of contents
4.2 Tools and test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1 Tools list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 Test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Test of output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5.1 Float charge (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5.2 Adjustment of float charge, U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.5.3 Boost charging (U2) (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 Battery supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.7 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.8 Commissioning record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
5 Product description PCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 General - Product description PCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Technical specification: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Operation - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 Starting the PCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 Adding modules to the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.3 Removing / replacing modules in the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4 Operation - Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.5 Connecting to PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6.1 Show voltage and currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6.2 Show alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6.3 Show messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6.4 Show data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6.5 Select/adjust U1-U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.6 Adjust limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.7 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.7 Boost charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.8 Battery test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9.1 Temperature compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9.2 Battery current limit (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.9.3 High load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
6 Product description FMP 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 General - Product description FMP 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 Mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 DC output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2.1 Mains input 190-240VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2.2 Mains input 85-185VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.3 Module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.5 Other technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
viii Forza 48-25600 PPC

Table of contents
6.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.4.1 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4.3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.6 EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
7 Product description PPR 32/4 19” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 General - Product description PPR 32/4 19” Subrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2 Construction and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2.1 External connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2.2 Internal functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Connections between subrack / rectifier shelf’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.4 Connections main / extension cab. Subracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Addressing module positions in subrack1, subrack2 etc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
8 Product description PBDU 25-50/3xNH1-3/2xNH1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 General - Product description PBDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Cable area output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.5 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Product description PDU 25-50/24xMCB (300A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 General – Product description PDU 25 24xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3 Construction and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.4 Cable area output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.6 High ohmic distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
10 Product description PDU 25-50 16xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
10.1 General – Product description PDU 25-50 16xMCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.3 Construction and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.4 Cable area remote distribution connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2
10.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
10.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
10.7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3
11 Product description PCS Alarm interface unit BM0546 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
11.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2
11.3 Remote alarms, symmetry measurement and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . .11-3
Table of contents ix
Table of contents
11.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

12 Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 Installing new modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.4 Torque table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Appendix A: Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
A.1 Menu tree PCS - 017438 - Rev: C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.2 Cabinet layout Forza 48 - 037810 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.3 General connection drawing Forza - 037396 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.4 General block diagram Forza main cabinet - 037397 - Rev: B . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
A.5 General block diagram Forza extension cabinet - 037398 - Rev: A . . . . . . . . . . . . . . . . . . . . . . . . . A-6
A.6 Schematic diagram PCS + Power Forza - 037400 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
A.7 Schematic diagram PCS Alarm interface unit PBDU NH1-3 - 037811 Rev: / . . . . . . . . . . . . . . . . . A-8
A.8 Schematic diagram PBDU 25 - 032566 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
A.9 Schematic diagram PDU 25 w/LED - 037822- Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
A.10 Schematic diagram PDU 25-max16xMCB - 024499 - Rev: / . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
A.11 Schematic diagram PPR 32/4pos Forza (Part 1 of 2) - 037407 - Rev: / . . . . . . . . . . . . . . . . . . . A-12
A.12 Schematic diagram PPR 32/4pos Forza (Part 2 of 2) - 037407 - Rev: / . . . . . . . . . . . . . . . . . . . A-13
Appendix B: Configuration Forza (c-000262.pcg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Appendix C: Distribution PBDU 5xNH1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
C.1 Main cabinet PBDU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Appendix D: Distribution PDU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
D.1 Main cabinet PDU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
D.4 Extension Cabinet PDU 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
x Forza 48-25600 PPC

System description Forza PPC
1 System description Forza PPC
System description Forza PPC 1-1

Revision: /
1.1 General
Forza modular DC power cabinet systems are designed to meet rigid telecom applications with very high
reliability and flexibility for future expansion. This cabinet power solutions provide rectification, system
management and power distribution while maintaining high reliability and offering flexibility for future
expansion. The Forza Power Systems are based on hot-swappable rectifier modules (FMP 32.48) output
power available at 3200W per module.
System management is accomplished through messages and alarms displayed on the system controller’s
(PCS) LCD screen and can also be displayed remotely via the PC-based PowCom™1 software package.
Highly scalable PPC range with vertical raiser bars for hot live expansion or rectifier shelf’s and DC
distribution.
Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases
rectifier modules are shipped separately.
Figure 1-1 Typical system drawing
POWER ON
MESSAGE
ALARM
POWER ON
MESSAGE CANCEL
CANCEL RS232
ALARM
PBDU 1
PDU 1
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
1. Communication program for remote control of the power suplly system
1-2 Forza 48-25600 PPC

Revision: /
1.2 Technical data
Figure 1-2 Principle drawing
PCS
DC distribution
FMP 32
AC F
F
FMP 32
LVD
FB
BATT
Input: -voltage: 230/400 V 3-phase (site configurable)
-current: <2x10A per module
Output: -voltage: 48V DC nominal / 64000W pr cabinet
-current: Max 64A per. module, 48V
-power: Max 3200W pr. module.
Weight: Rectifier: 4,2 kg
Cabinet dim.: Height: 2150 mm
Width: 600 mm
Depth: 600 mm
1.3 Operation
z The Forza 48-64000 is a floor cabinet solution with a built in DC-bus that enables the plug-in
connection of rectifier subracks and battery / load breaker shelves. This system can accommodate
up to 20 rectifier modules, a supervision module (PCS) and DC distribution with a wide range of
plug-in DC load distributions (low and high ohmic). Up to 64000W/48V steady state power per
cabinet. The system is based up on hot swappable 48V/3200W rectifier modules, which are working
in parallel with automatic load sharing.
z The cabinet system is normally configured with N+1 redundancy, with N as the number of rectifier
modules necessary for feeding the load and charging the battery and 1 as the redundant rectifier
module. In normal operation the rectifier modules, FMP 32, are feeding the load and simultaneously
maintain the batteries in a fully charged state.
z During a mains input power failure, the rectifiers are shut down and the batteries deliver the power
required by the load, for a certain backup time. If the battery voltage drops below the pre-set level,
the low voltage disconnection circuit, LVD disconnects the batteries automatically to prevent battery

Revision: /
deep discharge and thus prolong the battery life. When the mains input power is restored, the
rectifiers start up automatically feeding the load, closes LVD circuit and are starting recharge the
batteries.
z The system performance is supervised and controlled from the supervisory unit, PCS. From this unit
output DC voltage is set, alarm thresholds, LVD circuit operation, temperature compensated battery
charging, etc. Any malfunction will be indicated by LED, text in the display and operation of dry
contacts. How ever, PCS is not a single point of failure. In the event of malfunction in the PCS, basic
tasks like feeding the load and charging batteries, will be maintained by the rectifier modules directly
at preset default values.
z The alarm and threshold setting of the Forza can be set locally by use of the PCS push buttons and
menu guided operation or remotely, by use of the PowComTM program.
1.4 System description - Forza

This system consists of the following modules;
1.4.1 FMP 32 - Rectifier module

The Power-One FMP 32 rectifier provides extremely reliable DC power in the highest possible density. The
module incorporates the latest in power monitoring solutions through an internal microprocessor, giving up
to the second updates to the system controller and adjacent rectifiers, guaranteeing tightly controlled load
sharing among rectifiers, and providing status and identification information to the controller.
Other features include 3xLED for rectifier status indication, thermal protection with de-rating and input over
voltage disconnection with automatic reset. The rectifier units are hot swappable and can be quickly
removed and replaced without disrupting the system or load.
See: Product description FMP 32
1.4.2 PCS - Controller system

PCS - is a supervisory system with onboard software for monitoring and operation of power supply systems
based up on Power One rectifier modules. The design is based up on the philosophy of having one main
controller supervision for the entire power supply system, and use of distributed intelligence by local micro
controllers. A RS485 data bus takes care of internal communication between the various units. RS232 for
remote operation from PC.
PowComTM software
PowComTM is a communications software package that allows the remote control of the Forza system. The
software uses a Windows based interface to allow access to the PCS. PowComTM is installed on a remote
PC and can access the system by either direct connection, a LAN, or through a dial-up modem.
Network interface
The Power-One Network Interface (PNI) is an optional component, that allows the PCS unit to be remotely
accessed via Ethernet and SNMP. The SNMP protocol allows enhanced managing capabilities and
enables the system to be accessed from any location. The protocol uses simple commands to configure
and control the system and relay the system status to the operator. Using this monitoring ability allows the
alarm messages to be transmitted to any location. The PNI also can be used in conjunction with
PowComTM software either through a modem or Ethernet connection.
See: Product description PCS 2
1.4.3 PPR 32/4 19"- Subrack

PPR 32/4 19” is a subrack for interconnecting of modules in the FMP 32 series, and requires no operation.
The subrack has up to four module positions (4xFMP 32 rectifiers.) Each subrack may be euipped
according to present power requirements, and later be completed with additional FMP 32 modules.
The subrack has a connection for AC in, DC out and RS485 for communication.
Modules are “hot swappable” under full load conditions.
1-4 Forza 48-25600 PPC

Revision: /
1.4.4 PBDU, PBF and PDU - Distribution modules

DC distribution modules with battery breakers, load breakers, shunt for measurement of current, alarm for
battery and load.
Load outputs:
Several available load breaker modules based on:
MCCB’s: 1x1500A, 2x600A, 2x384A and 4x384A
MCB’s: 24x2-63A, 16x80-100A, 24x216A High ohmic.
Knife fuses: 5xNH1-3 and 9xNH00
Battery outputs:
Several available battery breaker modules based on:
MCCB’s: 1x1500A, 2x600A and 4x384A
MCB’s: 12x100A.
Knife fuses: 5xNH1-3
See product description PBDU, PBF and PDU for detailed information about the actual module.
The distribution has no special operation other than switching the battery and load breakers on and off. All
DC distribution breakers are supervised by measuring voltage drop across each breaker.
Breakers which are not connected to any load, will not cause breaker alarm even if they are left open.
Due to a small leakage current (2,5-3 mA) through the alarm circuit the voltage measured with a DVM
(Digital Volt Meter) on an open breaker output, will be nearly equal to output rectifier voltage.
If a battery breaker fault occurs or is simulated it might take from 2-10 minutes before the fault is indicated,
depending on the battery condition.
The distribution module has common "+" and breakers in "-" leg. For more information see schematic
drawing in Appendix A.
1.4.4.1 Low voltage disconnection (LVD) (Option)

The system can be equipped with low voltage battery disconnection, which prevents the batteries from
deep discharging, thus prolonging the battery life. A disconnection requires a detected mains failure at the
supervision unit. Threshold for disconnection is available.
If disconnection occurs, the batteries will not supply power to the load until they have been recharged to set
voltage level, which can be adjusted by the user.
If disconnection occurs, the batteries will be reconnected when mains supply return.
1.4.4.2 Partial load disconnection (PLD) (Option)

Partial load disconnection is voltage or time dependent (has to be specified when ordering).
At a mains outage, PCS will open the PLD contactor when batteries has discharged down to a certain
voltage, or the battery voltage has been under a certain voltage for a predetermined time. The
disconnecting has to be set according to the present load and battery manufacturers discharge tables or
requirements.
The distribution module has common "+" and breakers in "-" leg. For more information see schematic
drawing in Appendix A.

Revision: /
1-6 Forza 48-25600 PPC

Revision: /
Safety
2 Safety
Safety 2-1
Revision: A
Safety
2.1 Safety - Introduction

This document contains recommended safety guidelines for working with the equipment mentioned in this
documentation.
The instructions in the Customer Documentation must be followed by properly trained and authorized
personnel when installing, operating, commissioning or maintaining this equipment. Neglecting the
instructions may be dangerous to personnel and equipment. Although the purpose of safety devices,
routines and regulations are meant to take care of the safety of the user, nobody is excused from using
common sense at all times when operating or otherwise handling the equipment.
These above mentioned safety guidelines include Warnings, Cautions and Notes.
2.2 Warnings
2.2.1 Lethal voltages
WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE

ATTEMPTING TO WORK ON THE SYSTEM WITH THE POWER CONNECTED.
POTENTIALLY LETHAL VOLTAGES ARE PRESENT WITHIN THIS SYSTEM.
WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES.

THERE MUST BE NO DAMAGE OF ANY KIND TO THE INSULATION OF THE
CABLES AND POINTS CARRYING LETHAL VOLTAGES SHOULD NOT BE
EXPOSED. FOR SAFETY REASONS, MAKE SURE THE CABLES ARE NOT
CONNECTED TO THE POWER SUPPLY WHEN ROUTING THEM.
All persons who perform any operations on this equipment should be advised of the potential dangers.
Ensure that the following guidelines and cautions are observed, when dealing with high voltage systems
and equipment:
z Potentially lethal voltages are present within the system. Ensure that all power supplies are
completely isolated by setting all power switches to OFF, disconnecting all relevant connectors and
removing all relevant breakers before attempting any maintenance work. Do not rely on switches
alone to isolate a power supply.
z Potentially lethal voltages are present within this system. Ensure that high voltage safety
requirements are implemented before attempting to work on the system with power connected.
z Potentially lethal voltages can be induced if the equipment is not grounded (earthed) correctly.
Ensure that all ground connections are secure.
2-2 Forza 48-25600 PPC

Revision: A
Safety
2.2.2 Grounding
WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING

SAFETY EARTH. A SOLID HIGH CURRENT GROUND CONNECTION, CAPABLE
OF SINKING THE MAXIMUM SYSTEM CURRENT, IS REQUIRED.
WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A

CONDUCTOR SHOULD BE CONNECTED BETWEEN THE GROUNDING POINT IN
THE POSITIVE DC BUSBAR TO THE CABINET. THIS CONDUCTOR IS
CONNECTED ON ITS OWN TO THE EARTH BAR AND NOT SHARED WITH OTHER
SAFETY CONDUCTORS.
2.2.3 Precautions for lead acid batteries
WARNING! THIS EQUIPMENT USES LEAD ACID BATTERIES. WHEN HANDLING

THE BATTERIES FOLLOW THE INSTRUCTIONS DELIVERED WITH THE BATTERY
SET, AS THE FLUIDS CONTAINED WITHIN THESE BATTERIES ARE KNOWN TO
BE A HEALTH HAZARD. THE DISPOSAL OF LEAD ACID BATTERIES IS SUBJECT
TO LEGAL REQUIREMENTS FOR HAZARDOUS WASTE, THEREFORE DISPOSAL
LOCALLY MUST BE UNDERTAKEN SAFELY AND WITH DUE CARE.
Ensure the following guidelines are observed when dealing with equipment that may contain lead acid
batteries:
z Any attempt to burn these batteries may result in an explosion and the generation of toxic fumes.
z Should a lead acid battery suffer damage, it must be moved into a well-ventilated area. Contact with
the corrosive fluid must be avoided.
z Neutralize any acid corrosion with copious amounts of a solution of baking soda and water. Wipe of
all traces of soda.
z If the lead acid battery is removed from the equipment to which it is fitted, any exposed contact must
be insulated prior to disposal.
z Ensure that protective full-face shields, rubber gloves and aprons are worn and insulated tools are
used when working with the batteries.
2.2.4 Weight
WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS

SUFFICIENTLY HEAVY TO REQUIRE HANDLING BY TWO OR MORE PEOPLE, OR
BY SPECIALISED LIFTING EQUIPMENT.
2.2.5 High temperatures
WARNING! CARE MUST BE TAKEN WHEN HANDLING THE EQUIPMENT AS

SOME OF IT MAY REACH HIGH TEMPERATURES.
Safety 2-3
Revision: A
Safety
2.3 Cautions
2.3.1 Storage and transportation
CAUTION! During storage and transportation, the units must remain in their
original packages in order to avoid mechanical damage, maintain tracability, and
protect the units against electrostatic discharge.
2.3.2 Handling electrostatic sensitive devices
CAUTION! An electrostatic sensitive device is an electronic component that

may be permanently damaged by the discharge of electrostatic charges
encountered in routine handling, testing and transportation.
2.3.3 Traceability
CAUTION! Units are labelled with permanently attached product identification

labels. The labels are designed to be indelible throughout the life span of the
equipment, unless mistreated. Make sure that the product identification labels are
present on the equipment and are not subjected to unusual wear or mistreatment.
2.3.4 Breakers
CAUTION! When replacing breakers, it must be to the same types.
2-4 Forza 48-25600 PPC

Revision: A
Installation guide Forza PPC guide
3 Installation guide Forza PPC guide
Installation guide Forza PPC guide 3-1

Revision: /
3.1 Site requirements

The site should be suitable and ready for the Power supply. If it is not or you are unsure about this, contact
your supervisor before continuing. Check, using a spirit level, that the site is level.
3.2 AC Power source requirements
WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED

BEFORE CONNECTING MAINS SUPPLY.
WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE

SYSTEM IS ISOLATED FROM ALL AC MAINS SUPPLIES.
WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS

INSTALLATION
3.3 Technical data

Input voltage: 230V AC 3-phase (3 wire system) or
230V/400V AC 3-phase (5 wire system)
Current: Max 20A/ 230V single phase per module.
3.4 Installation procedure

The power supply systems are delivered completely assembled in crates and are ready to be installed
without any pre-assembly.
Note! Normally rectifier modules are installed in the cabinet at shipment, but in some particular cases
rectifier modules are shipped separately.
3.4.1 Unpacking
Check that the received equipment is in accordance with the packing list. Ensure that the cabinet and the
equipment have not been damaged during transportation.
You must report any parts that are damaged, missing or incorrect. If possible, correct the problem before
continuing.
3.4.2 Tools required

The following tools are required for a safe installation of the Forza system:
z Anti-static hand strap
z Socket wrench, insulated
z Screwdriver set, flat, insulated
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z Screwdriver set, torx, insulated
z Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated
z Torque spanner (for battery connection), insulated
WARNING! USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS: SHAFTS OF

SCREWDRIVERS ETC.; SHOULD BE INSULATED.
CAUTION! Care must be taken when installing this system. The units can be
damaged and can cause damage if not handled with care. Pay particular attention
to the order in which units are installed.
CAUTION! Installation in USA / Canada must conform with the requirements in

NEC/CEC.
1. Pull out all rectifier modules in order to lower the overall weight.
2. Move cabinet to the right place and rise into on upright position.
3. Use a water leveller making sure that cabinet is levelled. Adjust cabinet legs if necessary.
4. If necessary the cabinet can be fixed to the floor through the plinth or towards the wall.
Figure 3-1 Plinth

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Figure 3-2
Wall bracket
Tapties
M6 Torx 30
Loose the wall bracket located on the upper part on left and right side by unscrewing the two tapties. Drag
the wall bracket up and fasten it to the cabinet again (see Figure 3-2). The cabinet is now ready to be fixed
to the wall.
3.4.3 Connections
See also: Product description PBF
Product description PDU
Product description PBDU
Make input and output connections as described below.
3.4.3.1 Connection of mains

The power supply system has connections for up to four input mains at the terminal blocks located in the
upper/lower left side of the cabinet. Number of input mains depends on number of subracks in the cabinet.
Input mains cables to be tread through the plastic tube from top (only mains located in the top of the cab.).
Connection of three-phase input mains according to the label located beside the terminal blocks
Mains cable area:Max. 16 mm2 pr input.
When connecting mains to terminal blocks use, depending on type of cable, either:
z use a cable tie around conductors as close to the terminal block as possible, to prevent a stranded
conductor to come loose and touch any secondary conductive parts on the backplane or,
z remove as little insulation on cable as possible before entering into terminal block, so that the jacket
prevent a stranded conductor to come loose and touch any secondary conductive parts on the
backplane (Note! The insulation on the cable must have a clearing of minimum 1mm in the terminal
blocks).
Figure 3-3 Connection of mains
Plastic tubes
Terminal blocks Mains label
Mains 1 Mains 2
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Mains 1: is supplying subrack 1, position 1, 2, 3 and 4, and subrack 2, position 5 and 6
Mains 2 is supplying subrack 2, position 7 and 8, and subrack 3 position 9, 10, 11 and 12
Mains 3: is supplying subrack 4, position 13, 14, 15 and 16, and subrack 5, position 17 and 18
Mains 4 is supplying subrack 5, position 19 and 20, and subrack 6 position 21, 22, 23 and 24
Figure 3-4
Recommended mains fuse:
3 x 230V AC feed 3 pole 63A – C char, per mains.

3 x 400V AC feed 3 pole 40A – D char, per mains.
3.4.3.2 DC connections from top

The cabinet has got a special designed cable gland at the top for entrance of larger cables, 50mm2 up to
240mm2 . For cables ≤ 50mm2 the left hand vertical cable duct can be used
The following description describes how to install 50 to 240mm2 cables.
1. Remove cabinet top cover.
2. Remove the horizontal sheet metal, which is mounted in front of the cable glands. (Fixed from top
with 2xM4 screws)

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Figure 3-5 Front view
M4 screws
Horizontal sheet Horizontal sheet

metal metal removee.8596.242 611.2400.0017 Tc
3. Remove all the cable bushings located over the positive copper bus bar except from the one half of
the inner row.
Note! It is important to select the input cable positions systematically, using the inner row first, in order
to take care of future expansion of cables
Figure 3-6 Front view
4. Remove the "knock out" of the bushing by a hammer and screwdriver or similar tool. Fit the two
bushing parts around the cable and if necessary clamp it with the attached screws.
Figure 3-7
5. If the opening is too big compared to size of cable, wind some scotch tape around the cable.
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6. When all cable bushings are fitted and mounted, replace all the unused bushings. Secure the
bushings by fitting the sheet horizontal metal and fix it by enclosed M8 washers and nuts.
3.4.3.3 Connection of Common positive (+) DC cables

Where the entrance should be will vary due to cable properties (size and flexibility). The cable duct (located
on the left side of the cabinet) is only accessible for up to 50mm2 cables. Bigger cables are to be tread
trough the cable gland on top of the cabinet. Note that some systems will only have the possibility to
connect 1-6 cables
Connect cables according to Figure 3-8, request torque 30 Nm
Figure 3-8 Connection of common positive DC cables
Connection points when Connection points when

you need 11-12 cables you need 5 or 6 cables


3.4.3.4 DC connection from bottom (Only for special made cabinets)

Cable entry from the bottom, use cable duct located on the left hand side for cables ≤ 50 mm2. For larger
cables use bottom entrance of cabinet.
Connect common positive (+) DC cables according to Figure 3-9, request torque 30 Nm.
Note! Some cabinets will only have the possibility to connect 1-6 cables.
Figure 3-9

you need 7 or 8 cables you need 1 or 2 cables

Bottom entrance of cabinet
7. Grounding of power cabinets.
The system is made common positive, 0V positive and –48V negative. A grounding terminal, meant for
central earth, is located on the top of the cabinet. Internal grounding of the system may easily be removed
in case a “floating” output voltage is requested. Unscrew the two torx screws shown in and remove the

Revision: /
copper plate. When the output is “floating”, the positive block in the system may be used for grounding.
This way, a grounding cable of max. 240mm2 may be connected to the positive block.
Figure 3-10
2 x Torx
Copper plate
Common positive (+) connected to
the chassis of the cabinet
3.4.3.5 Connection of live DC cables (- 48V)

See product description of individual unit.
3.4.3.6 Connection of communication and current share signals.
Note! Only applicable if system consist of more than one cabinet
See: Product description PPR 32/4 19” Subrack/rectifier shelf.
3.4.3.7 Connection of expansion cabinet(s) with copper bars.

Only if the system consists of more than one cabinet.
Technical data
Double U-shaped copper bars, 1000 sqmm.
Removable top side panels with punch outs for paralleling.
Expansion cabinet to be placed towards right or left.
Live expansion by isolated copper bars.
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Figure 3-11
Screw Washers Copper bar
Taptites
Connection • M6
point • Torx 30
Nut Washers Copper bars
Mounting of parallel copper bars
1. Remove top, top side panels and front panels in that order.
2. Knock out the punch outs for paralleling. (Located on the top side panels).
3. Use attached screws, nuts and washers for mounting of the copper bars. Required torque: 30 Nm.
Note! Do not use spring washer against copper.
The copper bars is to be mounted on top of the connection points (see Figure 3-11 and Figure 3-12) With
two (double) copper bars (see Figure 3-13)

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Figure 3-12
Figure 3-13
3.4.3.8 Connection of expansion cabinet(s) cable to copper rail under floor level
Only for special made cabinets and if the system consist of more than one cabinet.
Technical data
Double U-shaped copper bars, 1000 sqmm.
Cable from U-shaped copper bars to copper rail section under floor level.
Expansion cabinet to be placed towards right or left.
Live expansion by cables from power cab. to copper rail section.
Mounting of cable between cabinet and copper rail
Mount cables from rail section in power cabinets on to rail section under floor level.
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Figure 3-14
Floor level
+ Copper rail
- Copper rail
3.4.3.9 Connections of fuse alarms between cabinets.

For alarm monitoring of the fuses there is one common (serial) distribution fuse alarm signal from each
distribution unit, in each cabinet. This serial signal is terminated at the top/bottom of each cabinet.
Figure 3-15
Termination point for serial

fuse alarm signal
Previous cabinet
Fuse alarm signal
Next cabinet /
Main cabinet
If the system consists of more than one cabinet, the cabinets fuse alarm must be connected together using
the fuse alarm contact. For this purpose use max a 1.5mm2 cable.
When all cabinets fuse alarm is connected together, connect one cable from cabinet 1 to main cabinet.
Figure 3-16
Main cabinet Ext. cab. 1 Ext. cab. n

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3.4.4 Connection of alarms

For remote supervision of the alarms, there are 6 potential free alarm contacts. Each alarm contact
represents different alarm conditions. See “Appendix B - Configuration” for an alarm overview. Potential
free alarm contacts for remote signalling at PBDU interface are located on the back of the distribution.
Note! Alarm contacts are shown in alarm position.
Figure 3-17 Connection of alarms
ALARM 6 18
17
16
ALARM 5 15
14
13
ALARM 4 12
11
10
J13 ALARM 3 9
8
7
ALARM 2 6
5
4
ALARM 1 3
2
1
Alarm cabling install:
The green connectors can be easily removed, if desired, for ease in installing the wires to the connector.
Power-One recommends using 22 AWG wires to connect alarms to the alarm output terminals.
1. Remove the green plug from each connector.
2. Determine whether to reference normally closed or normally open with reference to common for
each alarm contact.
3. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper
ferrule if desired.
4. Insert wire into the correct positions in the green connector and tighten screw to clamp wire into
connector.
5. Route the wires through the cable area at the top left of the cabinet.
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3.4.5 Connection of symmetry measurement and temperature sensor

The PCS can supervise the symmetry of up to 4 battery branches. The drawing shows how to connect the
symmetry cables for 1 battery branch.
Note! The number of battery branches to be supervised has to be set in the PCS in order to activate the
symmetry measurement.
It is also possible to add a temperature probe to the system for temperature compensated charging of the
battery bank. Fasten the temperature probe in the middle of the topmost battery bank. The temperature
probe will measure the ambient temperature of a battery bank and the PCS will adjust the float charge
according to the temperature compensation factor set in the PCS. This factor must be set in the PCS
according to the battery manufacturer recommendation.
Figure 3-18 Connection of symmetry measurement and temp. sensor
- Blue 1
T Green 2 J11 Temp. probe
+ Red 3
T -36V Blue 1
-24V Green 1 J4 Batt. sym. 1
-12V Red 3
-36V Blue 4
-12V Red 6
-36V Blue 7
-12V Red
-48V 9
-36V -36V Blue 10
-24V -24V Green 11 J4 Batt. sym. 4
-12V Red 12
-12V
0V
Installing the Symmetry cabling and the battery temperature sensor:
1. Remove the green plug from each connector.
2. Strip the wires back approximately 10mm. Stranded wire may be soldered or covered with copper
ferrule if desired.
3. Insert wire into the correct positions in the green connector and tighten screw to clamp wire into
connector.
The wires are pre-routed with fastener strips on the cabinet sidewall and down to the battery bank.

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Commissioning
4 Commissioning
Commissioning 4-1
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Commissioning
4.1 Commissioning overview

Before the system was delivered, it has been thoroughly inspected and tested. The following chapter is a
guide to the set-up and operation of the control functions of the system.
Note! Before starting commissioning read the product description for the individual modules.
WARNING ONLY TECHNICAL STAFF WITH THE NECESSARY EXPERIENCE

AND KNOWLEDGE, WITH REGARD TO THE POWER SUPPLY SUPPORT SYSTEM
AND ITS BATTERIES, MAY PERFORM THE COMMISSIONING.
IT IS IMPORTANT TO FOLLOW ALL SAFETY REGULATIONS.
If there are any difficulties in increasing the voltage to alarm level, the alarm level can be adjusted to a
lower level.
4.2 Tools and test equipment
4.2.1 Tools list

The essential commissioning tools are listed below:
z Anti-static hand strap
z Socket wrench, insulated
z Screwdriver set, flat, insulated
z Screwdriver set, torx, insulated
z Screwdrivers, pozidrive (cross head), sizes 1, 2, and 3, insulated
z Torque spanner (for battery connection), insulated
4.2.2 Test equipment

z Multimeter (3 ½ Digit, 0 – 1% DC)
z Load resistance, to connect 0-100% of total capacity to the system.
4.3 Preparation
Check the installation to ensure the following:
z Site is clean and safe
z Grounding: The equipment is correctly grounded. The grounding cable size, color and routing
conform to the requirements.
z Power: The incoming mains AC power is available for this site. The site power switch and circuit
breakers are clearly labelled. The power cables are correctly terminated.
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Commissioning
4.4 Commissioning procedure

1. Verify cabinet levelled vertically.
2. Remove covers and check that all connections are made according to the installation drawing. Verify
that all connections are properly tightened with a sufficient torque.
(See Torque table in the Maintenance and troubleshooting chapter)
3. Make sure that all rectifier modules are unplugged.
4. Verify correct mains voltage on input mains terminals in cabinet by measuring each individual phase
voltage towards neutral. Turn off mains voltage after verifying.
5. Set battery breaker(s) in "off" position.
6. Install all FMP 32 modules.
7. Set load breakers into "on" position.
8. Switch on mains voltage.
9. The yellow LED on the rectifiers should blink
10. Green LED on PCS (control unit) should blink for approximately 20 sec.
11. Yellow LED on rectifiers should turn off.
12. Output voltage will increase slowly to U1.
13. Verify right polarity on battery connection by measuring the voltage drop across battery breaker(s)
(Normally not more than 5V DC)
14. Turn battery breaker to "on" position.
15. If any alarms are present they should be reset in accordance with “Show alarms” in product
description PCS. No alarms should be present.
16. If the system shows any communication failure from a rectifier position without any rectifier installed.
Select "Accept removed parts" from the Miscellaneous menu on PCS. (For more information see
product description PCS.)
17. Attach all the system covers in their correct places.
18. Clean the site.
19. Fill in the commissioning record (see end of chapter).
Commissioning 4-3
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Commissioning
4.5 Test of output voltage
4.5.1 Float charge (U1)

Be sure that the PCS is operating.
Connect load, approx. 50% of total capacity, to the system.
Check the voltage according to the battery manufactures requirements. If the batteries require other float
charging voltage, adjust the output voltage from the PCS. (See product description PCS)
If nothing else is required, use the following values:
Battery type Float charge Boost charge

Open lead-acid batteries 2,23V/Cell 2,33V/Cell
Sealed lead-acid batteries 2,27V/Cell -

Table 4-1
4.5.2 Adjustment of float charge, U1

Output voltage is factory pre-set to: See Appendix B. The total voltage has to be in accordance to the
number of battery cells.
Please verify number of cells and the battery manufacturers requirements.
Adjust output voltage from the PCS (control unit).
Note! A sealing protects the potentiometer in the subrack. Do not break the seal.
4.5.3 Boost charging (U2) (if applicable)

Open lead-acid batteries.
Automatic boost charging - calculation of the time the battery voltage has been below certain levels.
Automatic activating of boost charging for this calculated time multiplied by a (boost) factor.
Activate boost charging from the "Set/select U1-U4" menu in the PCS.
Return to float charge manually by selecting "U1", or automatically after a pre-set time.
Sealed lead-acid batteries.
Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this type of
battery is used, the boost function should be disabled.
Boost charging figures
Observe and write down all of the boost charging figures.
Parameters to be read/set/adjusted from PCS or PC with PowCom1 installed.
1. Communication program for remote control of the power supply system.
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Commissioning
4.6 Battery supervision

For systems with symmetry cables supplied:
Set number of battery strings according to number of battery strings in the system. The settings are to be
done in the control unit via a PC with PowCom installed or directly in the PCS. (if symmetry failure is
indicated)
The symmetry fault alarm is to be simulated by pulling out one symmetry cable from battery string. Measure
that setting is in accordance with battery manufacturer recommendations.
For systems with temp. probe cable supplied:
The temperature compensation is factory pre-set. Check that the temp. probe is activated and verify that
the compensation level is according to the battery manufacturers requirements. (If no compensation level is
available from the battery manufacture, Power One recommends it to be set to 0,5V).
4.7 Battery test

The settings should be done according to the battery manufacturer requirements, but as a rule of thumb the
following settings can be used for standard VR lead batteries:
No. of test pr. year = 2
U3 Test = 1,9 V/cell
End voltage b.test = 1,94V/cell
Batt. test time = 40% of expected backup time
Ah limit for test = 40% of nominal battery capacity
Parameters to be set/adjusted from the PCS (Battery test menu) or "Supervision - Set parameters” menu in
PowCom.
Commissioning 4-5
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Commissioning
4.8 Commissioning record

This is a step-by-step commissioning record for easy commissioning of Power-One Supply Systems. Do
not continue if any faults occur during this commissioning. The checkpoints are to be considered as a
minimum for commissioning of the system.
Checked Result
(D)
1. Check that rack is levelled
2. Check that all breakers are turned to “off”
position and that no rectifiers are mounted in
the subrack(s).
3. Connect AC, and measure voltage on the L1-N:………..V AC
mains input connections in the cabinet, Is to L2-N:...............V AC
be 230V AC (Measure 230V from phase to N L3-N:...............V AC
when 400V mains input is used)
4. Mount rest of the rectifiers
5. After connection of battery, verify right
polarity by measuring the voltage drop across
the battery breakers (normally not more than
5V DC).
6. Check float charge, U1, and boost charge,
U2. Is to be adjusted according to the battery U1:……..V DC
manufacture requirements. U2:.........V DC
7. Check temperature compensation. Is to be
adjusted according to the battery Comp. :…….V/10oC
manufacture requirements.
Check temperature read off compare to the Read off:………oC
room temperature.
8. Check symmetry measurement and set
number of battery strings according to Number: ….
actually supervised battery strings in the
Alarm limit:……
system.
9. Check alarm transmission by running an
alarm test.
Table 4-2 Commissioning record
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Product description PCS
5 Product description PCS
Product description PCS 5-1

Revision: F
5.1 General - Product description PCS

PCS - Power One Control System is a supervisory system particularly designed for supervision of Power
One power supply systems based up on PMP 25 and FMP 32 rectifier modules. The design is based up on
the philosophy of having one main controller supervision for the entire power supply system, and use of
distributed intelligence by local micro controllers. A RS485 data bus takes care of internal communication
between the various units. Visual notification of alarm and warning conditions are indicated by front panel
LED’s while descriptions of the alarms are provided through RS232 D-sub connector using PC-based
PowComTM1 software package.
WARNING! WHEN EXTERNAL EARTHED EQUIPMENT IS CONNECTED TO THE

PCS CONTROL UNIT, THE EXTERNAL UNIT MUST BE CONNECTED TO SAME
EARTH AS THE PCS CONTROL UNIT.
A complete supervisory system do always consist of the following units:
Main Controller
Master unit in the system communicating with all distributed micro controllers. Has LCD display, menu
driven operation, visual alarm indication, RS232 contact for remote operation and RS 485 for internal
communication with 128 addresses. (64 rectifiers and 64 other remote micro controllers).
Internal Power
DC/DC converter providing galvanic isolated DC power to the control system
Alarm Interface
Input for current reading, battery and load breaker monitoring, battery temperature, battery symmetry
measurement. Output for operating two individual contactors (LVD and PLD), 6 potential free alarm
contacts. Five analogue or digital inputs for supervision of miscellaneous signals (ventilation, door open,
etc)
Figure 5-1 Basic block diagram

PCS- -Main
PCS MainController
Controller
RS 232
PCS- -Internal
PCS InternalPower
Power
Optional
(BM0500)
(BM0500) RS 485 or
RS 232 (via converter )
PCS- -Alarm
PCS AlarmInterface
Interface
(BM0494)
(BM0494)
RS
485
PMPController
PMP Controller
(PMP 25/50)
(PMP 25 / FMP 32)
In addition PMP 25 and FMP 32 has an internal micro controller communicating with the other units.
1. PowCom - Communication program for remote control (by modem or zero-modem cable) of the power supply system.
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5.2 Technical specification:

z Input voltage: 18-72V DC
z Power consumption: Approx. 30W
z Output: 12V/500mA for modem
z Instrumentation: Three LED's, green - OK, yellow - Message, red - Alarm 2 x 20

character alphanumeric LCD display with backlight. 5mm character
height (Optional)
z Interface: RS 232 for remote operation via PowCom. RS 485 for internal
communication with 128 addresses (64 rectifiers and 64 sub-
controllers). Optional RS 485 for communication with additional 128
addresses. Overall max. capability is 128 rectifiers and 128
sub-controllers.
z Basic functions: Menu driven operation
Up to 24 pre-defined alarms
16 programmable alarms
Internal clock with battery backup
Multiple language choice
Temperature compensated charging
Boost charging, manually and automatic
LVD control of two contactors, voltage or time controlled
Battery test, manual or automatic with symmetry measurement.
Alarm relay test
Adjustable battery current
Software controlled start up after mains outage and battery test
Enhanced battery monitoring
CAUTION Risk of explosion if lithium battery is replaced by an incorrect type.

Dispose of used batteries according to the manufacturer’s instructions.
5.3 Operation - Introduction

The PCS communicates on a RS485 serial network with the rectifiers modules (called Modules) and one or
many I/O units (called Units). There may be up to 64 Modules and 63 Units on one serial channel. There
are two RS485 serial channels available and if more than 64 modules or more than 63 units are needed in
a system both channels will be used.
5.3.1 Starting the PCS

When the PCS is started it will spend approx. 20 seconds analysing the system and testing all addresses
for connected modules and units. During this period the green LED on the PCS will blink. No alarms will be
given during this period. When the PCS finds a module or a unit it will add it to the inventory. It will
remember this until a master reset, or a reconfiguring is done, even if it is turned off.
5.3.2 Adding modules to the system

When a rectifier is added to the system it will remain off until the PCS detects it. The PCS constantly scans
for new modules and units, but it may take up to 5 minutes from the time a module is inserted until it is
registered. During this time the yellow warning LED of the module will blink. When the PCS locates the
module, the LED will stop blinking. The new module will give a current sharing fault until its output voltage
has been adjusted. This may take additional time. If the PCS is turned off and on again it will reanalyse the
system and find the new module faster. This is only recommended as a solution if it is important to cut short
the time used to find new modules.

Revision: F
5.3.3 Removing / replacing modules in the system

Since the PCS communicates with the modules and units by a serial link, removing a module or unit will
appear to the PCS as a communication failure. This will cause an error message. To remove the error
message use the Accept removed parts item on the Miscellaneous menu, or press the reconfigure button in
the Inventory window in PowCom. Make sure that there are no valid communication faults caused by any
failure before doing this, as it will cause all not communicating modules and units to be removed from the
inventory. This will make all communication faults disappear, but it will not fix any problems so it must only
be used if the communication fault is caused by the module or unit being intentionally removed.
5.4 Operation - Control unit

Figure 5-2 Front view of control unit
System LED’s
RS232 Interface
The control unit is equipped with four push buttons: CANCEL, , , and (ENTER).
The arrow keys are used to go up and down in the menu hierarchy, to adjust limits and to select options.
The key is used to go one level deeper to the menu system and to confirm adjustments. The CANCEL
key takes you one level up in the menu hierarchy in addition to cancel the adjustments.
To adjust the alarm limits, use the arrow keys to select "adjust limits". Press to enter the sub menu, and
once more to select "alarm limit". By using the and keys the various alarm limits can be checked. To
adjust a limit: select the correct limit and press . The correct password must be entered before a new
value can be set.
The password is set to 1234 by default, but can be changed. Use the keys to set and to confirm each
digit. CANCEL can be used to correct a digit. When the correct password is entered it stays active for
approximately 2 minutes.
The adjust mode is indicated by a : (colon) in front of the value and a steady cursor behind. Use the
keys to adjust the alarm limit and press to confirm the value or CANCEL to revert to the previous value.
To return to main menu, press the CANCEL button. If the PCS is left unattended the display will return to
main menu automatically after 2 minutes. The backlight will be turned off after 2 minutes without any key
pressed. Pressing any key will turn it back on.
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5.5 Connecting to PC
Connect to a PC with PowComTM installed. The BAUD rate in the PowComTM COM port settings must be
set to the same as the PCS is set to (9600 is the default baud rate of the PCS). If modem is to be used,
connect modem before initiation. Push INIT MODEM in the miscellaneous menu.
Pin out of the RS 232 connector:
Pin Function
2 Receive
3 Transmit
5 0V (ground)
5.6 Menus
5.6.1 Show voltage and currents
The control module normally shows system voltage and battery current. Pressing the arrow will show
system voltage and distribution current, pressing once more will show system voltage and rectifier
current.
5.6.2 Show alarms

This item displays the current alarm status. If there are several alarms use the keys to scroll through the
various alarms. New alarms or disappearing alarms will be updated immediately on the menu. Some
alarms have to be reset manually, by pressing at the show alarms display.
The alarms to be reset are: Battery failure and symmetry failure.
5.6.3 Show messages

This item displays any messages. If there are several messages use the keys to view the various
messages. New or disappearing messages will be updated immediately on the menu.
5.6.4 Show data

This menu is used to display various measurements.
Module data
This menu shows information from the individual rectifier modules. Use the keys to select the module
number. Press enter to view another page of information. Four pages of information are available for each
module. The information available is communication status, module current, mean current, module
temperature, module measured voltage, Module OVP limit, alarm information, Serial number and module
software version number. Module alarms are indicated by 3 letter flags. The meanings of these are as
follows.
MNS - No input mains.
LOW - Output voltage low
OFF - No operation, caused by no mains or other failure
OVS - Overvoltage shutdown.
FAN - Fan failure, will cause the module to go off and OFF to be set.
CUR - Current sharing fault. Current deviates too much from average.
TMP - Temperature is high, will eventually cause the module to go off and off to be set.
Unit data
This menu shows information from the individual units. Units are I/O parts of the system like alarm interface
cards, distribution cards etc. The information available is communication status, serial number and unit
software version number. The menu is operated as the module data menu.
Temperature
The battery temperature is shown.

Revision: F
Ext. measurements
Up to 8 "external measurements" can be shown. These measurements are not standard measurements.
Both text and inputs are system specific and are defined in the configuration. If there are not configured any
measurements NA will be shown when enter is pressed.
Dist. current
Show the distribution current from individual distributions. Up to 64 distributions can be shown. Require
distributions with Distribution interface (PDU-IF). If no such distributions are available NA will be shown
when enter is pressed.
Symmetry voltage
The symmetry voltage for each battery branch is shown.
5.6.5 Select/adjust U1-U4

This menu is used to select one of the references for the 4 charge modes, U1 - float voltage, U2 - boost
voltage, U3 - battery test voltage, U4 - spare. Also use to adjust these references. The voltage references
can be adjusted in steps of 0,1V.
z U1 Normal. The U1 reference is shown, press to change U1 (The float charge voltage)
z U2 Boost. The U2 reference is shown, press to change U2 (The boost charge voltage)
z U3 Test. The U3 reference is shown, press to change U3 (The Battery test voltage)
z U4 Spare. The U4 reference is shown, press to change U4 (The spare voltage) (Not normally used)
5.6.6 Adjust limits

The menu has the following items: alarm limits, boost parameters, battery test and temperature
compensation. Parameters can be set/adjusted by entering the different sub-menus.
Alarm limits.
This menu contains High voltage, low voltage, Over voltage shutdown limit, low voltage disconnect, partial
low voltage disconnect limits, load reconnect limit, high load limit, high temperature limit.
Boost parameters.
This menu contains the limits for boost charging control. See section 5.7 Boost charging
Battery test.
This menu contains the limits for battery test. See section 5.8 Battery test
Temperature comp.
This menu turns the temperature compensation on and off, and set the compensation factor.
Batt. Cur. Limit

This menu turn the battery current limiting on and off, and set the limit.
Note! Current limiting is not available on all systems.
Sys. specific limits

This menu show up to 8 system specific limits. These are limits that are non-standard limits that are defined
in the configuration. The description and function of these limits are defined in the system configuration. If
there are not configured any limits NA will be shown when enter is pressed.
Dist. current lim.

This menu allows the setting of current limits for individual distributions. Limits for up to 64 distributions can
be set. If the load current of a distribution gets higher than the limit a high distribution current alarm will be
given. Require distributions with Distribution interface (PDU-IF). If no such distributions are available NA
will be shown when enter is pressed.
5-6 Forza 48-25600 PPC

Revision: F
5.6.7 Miscellaneous
The miscellaneous menu makes it possible to set the date and time, change password, view version
information, initialise modem, and show symmetry voltages and temperature.
Set time
The clock is shown. Press to adjust the clock. The clock is battery backed and will keep the time even if
the PCS is turned off.
Relay test
Press to check the alarm relays. The relays will be activated one and one. Use the keys to select
witch relay should be activated.
Alarm blocking
Allows the alarm relays to be disabled during maintenance. One alarm relay will normally be active as long
as the alarms are blocked.
Version
Show the PCS software version, configuration number and serial number.
Set new password

Choose "set new password" from the "miscellaneous" menu. Press , enter the old password and press .
Enter the new password and confirm by pressing . To avoid mistyping the new password has to be
entered once more. Confirm by pressing .
Shunt A
The nominal current of the battery shunts.
Shunt mV
The nominal voltage of the battery shunts.
Network address
Several PCS's may be connected together in a multidrop RS232 network. Each module then needs to have
a unique address between 2 and 255. The address may be set here.
Baud rate
Select the baud rate for the RS232 serial port of the PCS. Either 2400 or 9600.
Init modem
Press enter to send a string to init a modem. Additional initiation may be required in beforehand depending
on the modem.
Accept removed parts

Since the PCS communicates with the modules and units by a serial link, removing a module or unit will
appear to the PCS as a communication failure. This will cause an error message. If the module or unit is
intentionally removed the PCS must be told that it is OK that the module or unit is gone. Selecting this
menu and reply YES to the question will cause the PCS to assume that all not communicating modules and
units are removed purposely.
Note! Do not do this if there is an actual communication alarm caused by a fault in a module or unit.
Reset to defaults
Will reset alarm limits etc. to the default value without deleting logged data or system information. It is
recommended to try this instead of Master Reset if a reset is needed. In some cases it might still be
necessary to do a master reset. After a reset always check all limits and adjust them to the desired level.
Master reset
Will completely reset the PCS deleting all stored data. If possible download the data to a PC before doing
this. Use this only if absolutely necessary. After a reset always check all limits and adjust them to the
desired level.

Revision: F
5.7 Boost charging

Boost charging can be activated by three methods in the PCS:
Manually boost charging - Choose U2 boost in the referance menu for activating boost charging. (Return to
float charge manually by choosing "U1", or automatically after a pre-set time.)
Periodic boost charging - after a pre-set period boost charge will be automatically activated for a pre-set
time. Interval and boost time to be programmed (for example 4 hours every 3rd week).
Automatic boost charging - when during a mains failure the battery voltage falls below t1 limit value, a timer
is started. When the mains return, the system will start an automatic boost. This will last a certain time after
the battery voltage reach the t2 limit. This time will be multiplied with a boost factor; K. t1 limit, t2 limit and
the factor can all be set.
Figure 5-3 Boost charging
Adjustable values:
Boost (voltage) 40 - 60 Volts

Boost time 0 - 200 hours
Boost interval 3 - 16 weeks
Boost factor 1.0 - 16
Boost t1 limit 40 - 60 Volts
Boost t2 limit 40 - 60 Volts
Automatic boost Passive - Active
Disabling of automatic boost charge:

Choose "Boost parameters" in the "Adjust limits" menu. Push , and then select disable.
Note! Most of the manufactures of sealed lead acid batteries do not recommend boost charging. If this
type of battery is used, the boost function should be totally disabled by settings as follows:
Boost time = 0
U2 boost = U1 normal
5-8 Forza 48-25600 PPC

Revision: F
5.8 Battery test

Battery test may be activated manually by selecting U3 (in the "Choose reference" menu or by PC with
PowCom installed. Rectifier voltage will decrease to pre-set value (U3, adjustable), and logging of battery
voltage, battery current and Ah starts. The battery test will automatically be interrupted and output rectifier
voltage will rise to U1 level, if programmed time, Ah or end voltage is reached during the test. The test is
considered as accepted if time or Ah causes the interruption. If the battery voltage reaches programmed
end voltage, the battery is considered as faulty, an alarm will be indicated and further automatic testing is
interrupted.
Battery test can also be activated automatically 0-4 times a year. Select no. of tests. The measurement will
automatically be started at mains interruption but will not be saved if duration of mains outage is less than
30 min.
Parameter settings.
The idea of this feature is to make partial discharges of the battery, approx. 30-40% of the capacity, in order
to discover faults before it actually becomes a problem. The settings should be done according to the
battery manufacturer requirements, but as a rule of thumb the following settings can be used for standard
VR lead batteries:
U3 Test = 1,9 V/cell
End voltage b.test = 1,94V/cell
Batt. test time = 40% of expected backup time
Ah limit for test = 40% of nominal battery capacity
Parameters to be set/adjusted from the "battery test" menu or PC with PowCom installed.
Adjustable values:
Battery test voltage, (U3) 0 - 100 Volts
Symmetry limit 0,0 - 4,0 Volts
End voltage battery test 0 - 100 Volts
Test duration 0 - 20 hours
Ah limit for test 0 - 50000 Ah
Time for test 0 - 23
No of test/year 0-4
No of batteries branches 0 - 12
Battery type 4 blocks, 23 cell-, 23 cell+, 3 blocks or 2 blocks
Number of batteries must be equal to number of symmetry measurements. If symmetry cables are not in
use, number of batteries must be set to 0 (zero).
5.9 Other functions

5.9.1 Temperature compensation
The supervisory module can adjust the charging voltage to compensate for temperatures above or below
20oC. T > 20oC lower charging voltage. T < 20oC higher charging voltage.
The temperature compensation function can be enabled and disabled and the level of compensation is
adjustable.
5.9.2 Battery current limit (option)

Battery current can be controlled by the PCS. The PCS will adjust the rectifier current limit so that the total
rectifier current may not exceed "load current + desired battery current". Rapid changes in load current will
lead to changes in battery current, due to this variation the current can be above the limit for a limited time.
5.9.3 High load

The "High load" alarm is activated when the load current exceeds the capacity of the installed modules
multiplied by the high load limit. This is an indication that you should install more rectifier capacity.

Revision: F
5-10 Forza 48-25600 PPC

Revision: F
Product description FMP 32
6 Product description FMP 32
Product description FMP 32 6-1

Revision: /
6.1 General - Product description FMP 32
6-2 Forza 48-25600 PPC

Revision: /
6.2.5 Other technical data

Protection: Short circuit proof.
Automatic current limiting.
Selective shut down of modules at excess output voltage.
Thermal protection reduces the output power at environmental temp. above
maximum level. Shut down at >app 75oC with an automatic restart.
Input over-voltage disconnection at >275VAC with automatic reset at <260VAC.
Alarms: High output voltage / shut down.

Low voltage / module failure.
Each alarm has a common LED indicator on the front panel and a common
potential free contact for external signalling.
Enclosure: IP 20
Storage: -60 to +85°C
Cooling: Fan cooled, speed controlled and alarmed.
6.3 Operation
FMP 32 has status indicators that is located on the front panel of the module. The output voltage is
adjusted from the Controller.
There are three LEDs situated on the rectifier's front panel, which indicate the operating condition of the
rectifier.
Figure 6-1 Front view of FMP 32
FMP 32 has LED indicators as follows:
GREEN
Power ON
YELLOW
Current Limit / Thermal protection. Communication
failure (flashing).
RED
Module failure / high output voltage / shutdown.
Product description FMP 32 6-3

Revision: /
6.4 Environment
The FMP 32 rectifiers meet the Environmental Standard requirements of:
ETS 300 019-1-3 class 3.1 / 3M1 for Operating (Stationary In-Use)
Temperature Range: -40°C to +65°C (up to 2000m) and -40°C to +55°C (above 2000m)
6.4.1 Storage
ETS 300 019-2-1 Class 1.2.
6.4.2 Transport
ETS 300 019-2-2 Class 2.3.
6.4.3 Operation
ETS 300 019-2-3 Class 3.2.
6.5 Safety
The FMP 32rectifiers fulfil those international and national safety standards for these systems according to
grounding, fire protection and other safety matters as specified in the following standards:
EN60950 / IEC 60950

UL1950
CSA C22-2 No. 950
6.6 EMC
The rectifiers' EMC meets the requirements of:
EN61000-6-1, EN 61000-6-2, EN 61000-6-3 and FCC Part 15 Class B
6-4 Forza 48-25600 PPC

Revision: /
Product description PPR 32/4 19” Subrack
7 Product description PPR 32/4 19” Subrack
Product description PPR 32/4 19” Subrack 7-1

Revision: /
7.1 General - Product description PPR 32/4 19” Subrack
Note! All examples, pictures and drawings in this documentation are based on cabinets with 4 x PPR.
PPR 32/4 is a subrack/rectifier shelf for interconnecting of FMP 32 modules. Each subrack/rectifier shelf
has 4 module positions.
Each subrack/rectifier shelf may be equipped according to present power requirements, and later be
completed with additional FMP 32 modules.
For high power requirements several subracks may be paralleled.
Figure 7-1 Front view of subrack / rectifier shelf
7-2 Forza 48-25600 PPC

Revision: /
7.2 Construction and function

7.2.1 External connections
Description Function
PL4, PL6 RS 485 interface.
PL3, PL5 Current share with other PPR 32/4
PL2, PL1, PL12, PL11,
PL22, PL21, PL32, PL31 Input mains
Bus bar connections DC output.
7.2.2 Internal functions

Description Function
Dip swich 1-6 Dip switch setting for programming the address of each module position, has to be
set if PCS is used for supervision. See Table 7-1 Addressing module positions
Each module position has two dip switches 1-6 that are parallel connected.
Figure 7-2 Front and back view of the subrack
PL4 (COM)
PL6 (COM)
PL3 (CUR)
PL5 (CUR)
PL2 PL1 PL12 PL11 PL22 PL21 PL32 PL31
Dip switches
Negative (DC output)

PL4
Positive (DC output) PL6
PL3
PL5
PE
N
L Input mains
Note! You can only address 64 modules in one com. channel. If more than 64 modules are used,
module position 65 will have address 0 (Dip switch off). This will also be com. channel 2, new
com. cable from main cabinet.

Revision: /
7.3 Connections between subrack / rectifier shelf’s

Figure 7-3 Example shows a cabinet with 3 x PPR
FMP 32.48 FMP 32.48
PL4
PL6
PL3
PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL4
PL6
PL3
PL5 FMP 32.48 FMP 32.48 FMP 32.48
z Use cable marked with Brown 1 between PL6 in subrack/rectifier shelf 1 to PL4 in subrack/rectifier
shelf 2.
z Use cable marked with Orange 3 between PL5 in subrack/rectifier shelf 1 to PL3 in subrack/rectifier
shelf 2.
z Use cable marked with Brown 1 between PL6 in subrack/rectifier shelf 2 to PL4 in subrack/rectifier
shelf 3.
z Use cable marked with Orange 3 between PL5 in subrack/rectifier shelf 2 to PL3 in subrack/rectifier
shelf 3.
Note! If the system consist of more subracks connect after the same method between subracks as
described above.
7-4 Forza 48-25600 PPC

Revision: /
F M P 3 2 2 . 8
7.4 Connections main / extension cab. Subracks

Figure 7-4
Mains cabinet Extension cabinet 1 Extension cabinet 2
PL4 PL4 PL4
PL6 PL6 PL6
PL3 PL3 PL3
PL5 FMP 32.48 FMP 32.48 FMP 32.48

PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL4 PL4 PL4
PL6 PL6 PL6
PL3 PL3 PL3
PL5 FMP 32.48 FMP 32.48 FMP 32.48

PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL4 PL4 PL4
PL6 PL6 PL6
PL3 PL3 PL3
PL5 FMP 32.48 FMP 32.48 FMP 32.48

PL5 FMP 32.48 FMP 32.48 FMP 32.48
PL5 FMP 32.48 FMP 32.48 FMP 32.48
z Use cable marked with Brown 1 between PL6 in main cabinet to PL4 in extension cabinet1.
z Use cable marked with Orange 3 between PL5 in main cabinet to PL3 in extension cabinet1.
z Use cable marked with Brown 1 between PL6 in extension cabinet1 to PL4 in extension cabinet2.
z Use cable marked with Orange 3 between PL5 in extension cabinet1 to PL3 in extension cabinet2.
Note! If the system consist of more extension cabinets connect after the same method between
cabinets as described above.

Revision: /
7.5 Addressing module positions in subrack1, subrack2 etc

Subrack Com. Module
no. channel position Connection Dip switch on/off
1 1 1 1-6 Off
1 1 1 1-6 Off
1 1 2 1-6 1
1 1 2 1-6 1
1 1 3 1-6 2
1 1 3 1-6 2
1 1 4 1-6 1+2
1 1 4 1-6 1+2
2 1 5 1-6 3
2 1 5 1-6 3
2 1 6 1-6 1+3
2 1 6 1-6 1+3
2 1 7 1-6 2+3
2 1 7 1-6 2+3
2 1 8 1-6 1+2+3
2 1 8 1-6 1+2+3
3 1 9 1-6 4
3 1 9 1-6 4
3 1 10 1-6 1+4
3 1 10 1-6 1+4
3 1 11 1-6 2+4
3 1 11 1-6 2+4
3 1 12 1-6 1+2+4
3 1 12 1-6 1+2+4
4 1 13 1-6 3+4
4 1 13 1-6 3+4
4 1 14 1-6 1+3+4
4 1 14 1-6 1+3+4
4 1 15 1-6 2+3+4
4 1 15 1-6 2+3+4
4 1 16 1-6 1+2+3+4
4 1 16 1-6 1+2+3+4
5 1 17 1-6 5
5 1 17 1-6 5
5 1 18 1-6 1+5
5 1 18 1-6 1+5
5 1 19 1-6 2+5
5 1 19 1-6 2+5
5 1 20 1-6 1+2+5
5 1 20 1-6 1+2+5
6 1 21 1-6 3+5
6 1 21 1-6 3+5
6 1 22 1-6 1+3+5
6 1 22 1-6 1+3+5
6 1 23 1-6 2+3+5
6 1 23 1-6 2+3+5
6 1 24 1-6 1+2+3+5
6 1 24 1-6 1+2+3+5
7 1 25 1-6 4+5
7 1 25 1-6 4+5
7 1 26 1-6 1+4+5
7 1 26 1-6 1+4+5
7 1 27 1-6 2+4+5
7 1 27 1-6 2+4+5
7 1 28 1-6 1+2+4+5
Table 7-1 Addressing module positions
7-6 Forza 48-25600 PPC

Revision: /
7 1 28 1-6 1+2+4+5
8 1 29 1-6 3+4+5
8 1 29 1-6 3+4+5
8 1 30 1-6 1+3+4+5
8 1 30 1-6 1+3+4+5
8 1 31 1-6 2+3+4+5
8 1 31 1-6 2+3+4+5
8 1 32 1-6 1+2+3+4+5
8 1 32 1-6 1+2+3+4+5
9 1 33 1-6 6
9 1 33 1-6 6
9 1 34 1-6 1+6
9 1 34 1-6 1+6
9 1 35 1-6 2+6
9 1 35 1-6 2+6
9 1 36 1-6 1+2+6
9 1 36 1-6 1+2+6
10 1 37 1-6 3+6
10 1 37 1-6 3+6
10 1 38 1-6 1+3+6
10 1 38 1-6 1+3+6
10 1 39 1-6 2+3+6
10 1 39 1-6 2+3+6
10 1 40 1-6 1+2+3+6
10 1 40 1-6 1+2+3+6
11 1 41 1-6 4+6
11 1 41 1-6 4+6
11 1 42 1-6 1+4+6
11 1 42 1-6 1+4+6
11 1 43 1-6 2+4+6
11 1 43 1-6 2+4+6
11 1 44 1-6 1+2+4+6
11 1 44 1-6 1+2+4+6
12 1 45 1-6 3+4+6
12 1 45 1-6 3+4+6
12 1 46 1-6 1+3+4+6
12 1 46 1-6 1+3+4+6
12 1 47 1-6 2+3+4+6
12 1 47 1-6 2+3+4+6
12 1 48 1-6 1+2+3+4+6
12 1 48 1-6 1+2+3+4+6
13 1 49 1-6 5+6
13 1 49 1-6 5+6
13 1 50 1-6 1+5+6
13 1 50 1-6 1+5+6
13 1 51 1-6 2+5+6
13 1 51 1-6 2+5+6
13 1 52 1-6 1+2+5+6
13 1 52 1-6 1+2+5+6
14 1 53 1-6 3+5+6
14 1 53 1-6 3+5+6
14 1 54 1-6 1+3+5+6
14 1 54 1-6 1+3+5+6
14 1 55 1-6 2+3+5+6
14 1 55 1-6 2+3+5+6
14 1 56 1-6 1+2+3+5+6
14 1 56 1-6 1+2+3+5+6
15 1 57 1-6 4+5+6
15 1 57 1-6 4+5+6

Revision: /
15 1 58 1-6 1+4+5+6
15 1 58 1-6 1+4+5+6
15 1 59 1-6 2+4+5+6
15 1 59 1-6 2+4+5+6
15 1 60 1-6 1+2+4+5+6
15 1 60 1-6 1+2+4+5+6
16 1 61 1-6 3+4+5+6
16 1 61 1-6 3+4+5+6
16 1 62 1-6 1+3+4+5+6
16 1 62 1-6 1+3+4+5+6
16 1 63 1-6 2+3+4+5+6
16 1 63 1-6 2+3+4+5+6
16 1 64 1-6 1+2+3+4+5+6
16 1 64 1-6 1+2+3+4+5+6
17 2 65 1-6 Off
17 2 65 1-6 Off
17 2 66 1-6 1
17 2 66 1-6 1
17 2 67 1-6 2
17 2 67 1-6 2
17 2 68 1-6 1+2
17 2 68 1-6 1+2
18 2 69 1-6 3
18 2 69 1-6 3
18 2 70 1-6 1+3
18 2 70 1-6 1+3
18 2 71 1-6 2+3
18 2 71 1-6 2+3
18 2 72 1-6 1+2+3
18 2 72 1-6 1+2+3
19 2 73 1-6 4
19 2 73 1-6 4
19 2 74 1-6 1+4
19 2 74 1-6 1+4
19 2 75 1-6 2+4
19 2 75 1-6 2+4
19 2 76 1-6 1+2+4
19 2 76 1-6 1+2+4
20 2 77 1-6 3+4
20 2 77 1-6 3+4
20 2 78 1-6 1+3+4
20 2 78 1-6 1+3+4
20 2 79 1-6 2+3+4
20 2 79 1-6 2+3+4
20 2 80 1-6 1+2+3+4
20 2 80 1-6 1+2+3+4
21 2 81 1-6 5
21 2 81 1-6 5
21 2 82 1-6 1+5
21 2 82 1-6 1+5
21 2 83 1-6 2+5
21 2 83 1-6 2+5
21 2 84 1-6 1+2+5
21 2 84 1-6 1+2+5
22 2 85 1-6 3+5
22 2 85 1-6 3+5
22 2 86 1-6 1+3+5
22 2 86 1-6 1+3+5
22 2 87 1-6 2+3+5
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Revision: /
22 2 87 1-6 2+3+5
22 2 88 1-6 1+2+3+5
22 2 88 1-6 1+2+3+5
23 2 89 1-6 4+5
23 2 89 1-6 4+5
23 2 90 1-6 1+4+5
23 2 90 1-6 1+4+5
23 2 91 1-6 2+4+5
23 2 91 1-6 2+4+5
23 2 92 1-6 1+2+4+5
23 2 92 1-6 1+2+4+5
24 2 93 1-6 3+4+5
24 2 93 1-6 3+4+5
24 2 94 1-6 1+3+4+5
24 2 94 1-6 1+3+4+5
24 2 95 1-6 2+3+4+5
24 2 95 1-6 2+3+4+5
24 2 96 1-6 1+2+3+4+5
24 2 96 1-6 1+2+3+4+5
25 2 97 1-6 6
25 2 97 1-6 6
25 2 98 1-6 1+6
25 2 98 1-6 1+6
25 2 99 1-6 2+6
25 2 99 1-6 2+6
25 2 100 1-6 1+2+6
25 2 100 1-6 1+2+6
26 2 101 1-6 3+6
26 2 101 1-6 3+6
26 2 102 1-6 1+3+6
26 2 102 1-6 1+3+6
26 2 103 1-6 2+3+6
26 2 103 1-6 2+3+6
26 2 104 1-6 1+2+3+6
26 2 104 1-6 1+2+3+6
27 2 105 1-6 4+6
27 2 105 1-6 4+6
27 2 106 1-6 1+4+6
27 2 106 1-6 1+4+6
27 2 107 1-6 2+4+6
27 2 107 1-6 2+4+6
27 2 108 1-6 1+2+4+6
27 2 108 1-6 1+2+4+6
28 2 109 1-6 3+4+6
28 2 109 1-6 3+4+6
28 2 110 1-6 1+3+4+6
28 2 110 1-6 1+3+4+6
28 2 111 1-6 2+3+4+6
28 2 111 1-6 2+3+4+6
28 2 112 1-6 1+2+3+4+6
28 2 112 1-6 1+2+3+4+6
29 2 113 1-6 5+6
29 2 113 1-6 5+6
29 2 114 1-6 1+5+6
29 2 114 1-6 1+5+6
29 2 115 1-6 2+5+6
29 2 115 1-6 2+5+6
29 2 116 1-6 1+2+5+6
29 2 116 1-6 1+2+5+6

Revision: /
30 2 117 1-6 3+5+6

30 2 117 1-6 3+5+6
30 2 118 1-6 1+3+5+6
30 2 118 1-6 1+3+5+6
30 2 119 1-6 2+3+5+6
30 2 119 1-6 2+3+5+6
30 2 120 1-6 1+2+3+5+6
30 2 120 1-6 1+2+3+5+6
31 2 121 1-6 4+5+6
31 2 121 1-6 4+5+6
31 2 122 1-6 1+4+5+6
31 2 122 1-6 1+4+5+6
31 2 123 1-6 2+4+5+6
31 2 123 1-6 2+4+5+6
31 2 124 1-6 1+2+4+5+6
31 2 124 1-6 1+2+4+5+6
32 2 125 1-6 3+4+5+6
32 2 125 1-6 3+4+5+6
32 2 126 1-6 1+3+4+5+6
32 2 126 1-6 1+3+4+5+6
32 2 127 1-6 2+3+4+5+6
32 2 127 1-6 2+3+4+5+6
32 2 128 1-6 1+2+3+4+5+6
32 2 128 1-6 1+2+3+4+5+6
7-10 Forza 48-25600 PPC

Revision: /
Product description PBDU 25-50/3xNH1-3/2xNH1-3
8 Product description PBDU 25-50/3xNH1-3/2xNH1-3
Product description PBDU 25-50/3xNH1-3/2xNH1-3 8-1

Revision: /
8.1 General - Product description PBDU

The battery and distribution unit is designed for breaking three battery branches and distribution of 48V DC
to telecommunication equipment.
8.2 Technical specifications

Voltage: 48V nominal.
Number of breakers: Max 5 x NH1-3 (3 for Battery and 2 for Load)
Size of breakers: Has to be specified when ordering (50A-630A, NH1-3)
Dimensions: 19"/7U (H=311mm)
8.3 Installation
Cable entry from top of cabinet:
The battery and distribution module is a "plugable" module that connects directly to the systems rail
section. Decide where on the top of cabinet you want the entrance of the negative (-) cables for battery
breaker and distribution breakers (knives 5xNH1-3). Entrance will vary due to cable properties (size and
flexibility). The cable duct (located on the left side of the cabinet) is only accessible for up to 50mm2 cables.
The negative (-) connection is to be done directly on the breakers. (see Figure below)
Cable entry from bottom of cabinet (only for special made cabinets):
The battery and distribution module is a "plugable" module that connects directly to the systems rail
section. Decide where from the bottom of the cabinet you want the entrance of the negative (-) cables for
battery and distribution breakers (knives 5xNH1-3). Entrance will vary due to cable properties (size and
flexibility). The cable duct (located on the left side of the cabinet) is only accessible for up to 50mm2 cables.
The negative (-) connection is to be done directly on the breakers. (see Figure below)
Figure 8-1
Connection of negative Connection of negative

“-” cables for load “-” cables for battery
8.4 Cable area output connections

Load connections: Cable area max. 240mm2
8-2 Forza 48-25600 PPC

Revision: /
8.5 Commissioning
1. Measure voltage drop across battery breaker to make sure battery is correctly polarised. (Normally
not more than 5V DC)
2. Insert breakers to the battery and distribution unit.
3. Pull out one of the battery breakers and verify battery breaker alarm in the controller
4. Verify disappearing of alarm when the breaker is inserted again.
5. Pull out one of the load breakers and verify breaker alarm in the controller
6. Verify disappearing of alarm when the breaker is inserted again.
7. Repeat the above mentioned steps for each battery and distribution module.
8.6 Maintenance
The module does not need any special maintenance except for ordinary cleaning.
Product description PBDU 25-50/3xNH1-3/2xNH1-3 8-3

Revision: /
8-4 Forza 48-25600 PPC

Revision: /
Product description PDU 25-50/24xMCB (300A)
9 Product description PDU 25-50/24xMCB (300A)
Product description PDU 25-50/24xMCB (300A) 9-1

Document number: 025153B.fm
Revision: B
9.1 General – Product description PDU 25 24xMCB

The distribution is designed for distribution of 48V DC to telecommunication equipment.
WARNING! MAX CURRENT 300A
Voltage: 48V DC nominal.

Number of breakers: Max. 24 x MCB's
Size of breakers: Has to be specified when ordering (1-63A).
Dimensions: 19”/5U (H=222mm)
9.3 Construction and functions

The distribution module has common "+" and all the MCB’s connected in the "-" branch.
Figure 9-1
Common “+” connection. Output
connection positive cables
MCB’s connected to the “-” branch

Output connection. Negative cables
On the top of the distribution there is a horizontal cable duct for fixing output cabling.
Figure 9-2 Cable duct seen from top of distribution
9-2 Forza 48-25600 PPC

Revision: B
9.4 Cable area output connections

Load connections: Cable area max. 16 mm2
9.5 Installation
The distribution module is a “plug able” module that connects directly to the systems rail section. Use cable
duct located on the left side of the cabinet for guiding of cables to the distribution. Positive cables are to be
connected in terminal blocks at the common "+" bar, and negative cables are to be connected directly to
the MCB's. Use torque 2,5 – 3,5 Nm on these connections.
9.6 High ohmic distribution
WARNING! INFLAMMABLE. CARE MUST BE TAKEN WHEN HANDLING THE

EQUIPMENT AS SOME OF IT MAY REACH VERY HIGH TEMPERATURES.
The distribution unit may be delivered with high ohmic resistance wires mounted on the MCB breakers. A
maximum of 6W loss in each wire gives the following:
Resistance (mΩ) Max continuous current (A)

120 7
60 10
30 14
15 20
Table 9-1
Longer output cables can be used, if more resistance is needed.
2,5mm2 – 7,2 mΩ/m

6mm2 – 3 mΩ/m
10mm2 – 1,8 mΩ/m
16mm2 – 1,1 mΩ/m
9.7 Commissioning
1. Switch on all MCB's in the distribution units.
2. Turn off one of the fuses and verify fuse alarm at PCS
3. Verify disappearing of alarm when turning the fuse on again.
4. Repeat the two above-mentioned steps for one MCB in each distribution module.
9.8 Maintenance
The distribution does not need any special maintenance except for ordinary cleaning.
Product description PDU 25-50/24xMCB (300A) 9-3

Revision: B
9-4 Forza 48-25600 PPC

Revision: B
Product description PDU 25-50 16xMCB
10 Product description PDU 25-50 16xMCB
Product description PDU 25-50 16xMCB 10-1

Revision: A
10.1 General – Product description PDU 25-50 16xMCB

The distribution is designed for distribution of 48V DC to remote distribution cabinet(s).

Voltage: 48V DC nominal.
Number of breakers: Max. 16 x MCB
Size of breakers: 384A (3 x 160A in parallel)
Dimensions: 19”/5U (H=222mm)
10.3 Construction and functions

The distribution module has common "+" and all the MCB’s connected in the "-" branch.
Figure 10-1

connection positive cables
MCB’s connected to the “-” branch Output connection. Negative cables
Figure 10-2

connection positive cables. Seen
from top of cabinet
10.4 Cable area remote distribution connections

Remote distribution cables: Cable area max. 35 mm2
10-2 Forza 48-25600 PPC

Revision: A
10.5 Installation
The distribution module is a "plugable" module that connects directly to the systems rail section. Use cable
duct located on the left side of the cabinet for guiding of cables to the distribution. Positive cables to be
connected to the terminals at the common “+” bar and negative cables to be connected directly to the
MCB’s.
10.6 Commissioning
1. Switch on all MCB's in the distribution unit.
2. Turn off one of the breakers and verify breaker alarm at PCS
3. Verify disappearing of alarm when turning the breaker on again.
4. Repeat the above mentioned steps for one MCB in each distribution module.
10.7 Maintenance
The distribution does not need any special maintenance except for ordinary cleaning.
Product description PDU 25-50 16xMCB 10-3

Revision: A
10-4 Forza 48-25600 PPC

Revision: A
Product description PCS Alarm interface unit BM0546
11 Product description PCS Alarm interface unit BM0546
Product description PCS Alarm interface unit BM0546 11-1

Revision: A
11.1 General
PCS alarm interface unit consist of PCB0546, which is an alarm board for Power One systems. The unit is
located on the left or backside of the distribution. Access from top of the cabinet.
11.2 Technical data

Connection: Plugable terminal blocks max. 1,5mm2
z 2x input for current reading (common + or -). (J2 and J12)
z Breaker monitoring, battery and load. (J5 and J6)
z Control signal for individual operating LVD and PLD. (J1)
z 6 x potential free change over contacts. (J13)
z 4 x input for symmetry measurement. (J4)
z Battery temp sensor. (J11)
z 3 x analogue inputs. (J4 pin 10-12) (Pin 12 = Analog 1, Pin 11 = Analog 2 and Pin 10 = Analog 3)
z 2 x digital inputs (fire, door open, etc). (J3)
z 2 x digital output (J10)
z RS485 interface for communication with plant controller PCS. (J7 and J16)
z Up to four units per system.
11-2 Forza 48-25600 PPC

Revision: A
11.3 Remote alarms, symmetry measurement and temperature sensor

Alarms: Six dry alarm contacts for remote signalling (J13).
Symmetry: Four separate inputs, each supervising battery branch symmetry voltage (J4).
Temperature: One connection point for connection of Power- One temperature sensor (J11).
Figure 11-1 BM0546 alarm board

Alarm contacts are shown in alarm position
1
Alarm 1 2
3 NO 9
4 Disconnect 1 NC 8
Alarm 2 5 C 7
6 6
NO
7 J1 Disconnect 2 NC 5
Alarm 3 8 C 4
9 3
J13 NO
10 Reconnect NC 2
Alarm 4 11 C 1
12
System voltage 2
13 J14 0V 1
Alarm 5 14
Battfuse alarm 4 4
15
J6 Battfuse alarm 3 3
16 Battfuse alarm 2 2
Alarm 6 17 Battfuse alarm 1 1
18 +12V 3
12V
J9 Ext. transfoshunt 2
3 -12V 1
2 J10 Digital output
1
Distrfuse alarm 2
- Blue 1 J5 Battfuse manual 1
+ Red 2
3
J3 Digital input
1
T -36V Blue 1
-24V Green -Shunt 2 2
-12V Red
2 J4 Batt. sym. 1 J12 +Shunt 2 1
3
-36V Blue -Shunt 1 2
-24V Green
4 J2 +Shunt 1 1
5 J4 Batt. sym. 2
-12V Red 6 8
-36V Blue 7 J16 Comm. RJ45
-24V Green 8 J4 1
Batt. sym. 3
-12V Red
-48V 9 8
-36V -36V Blue 10 J7 Comm. RJ45
-24V -24V Green 11 J4 Batt. sym. 4 1
-12V Red 12
-12V
0V
11.4 Maintenance
The PCS alarm interface unit does not need any special maintenance.
Product description PCS Alarm interface unit BM0546 11-3

Revision: A
11-4 Forza 48-25600 PPC

Revision: A
Maintenance and Troubleshooting
12 Maintenance and Troubleshooting
Maintenance and Troubleshooting 12-1

Revision: /
12.1 Installing new modules

Install new modules according to following statements.
1. Plug in module.
2. Ignore the module alarm caused current sharing.
3. Wait. After 1 minute the yellow LED will start blinking. Wait for max. 4 min.
4. Verify that yellow LED stops blinking.
5. The alarm should now disappear.
12.2 Troubleshooting
This guide is a step-by-step recommendation of what to do if problems occur. If first step of
recommendation do not solve the problem continue to the next one. If the problem cannot be solved please
call your local Power - One office for assistance.
Low system voltage:
z Check the batteries with a voltmeter.
z Check "low volt alarm" limit in controller / PowCom.
z Check that the system is not in battery "test mode".
z Check modules, mains and load situation compared to rectifier capacity.
High system voltage:
z Check the batteries with a voltmeter.
z Check "High volt alarm" limit in controller / PowCom.
z Check that the system is not in "boost/Charge mode".
Load/battery disconnected:
z Verify that input mains is present
z Check system DC voltage with voltmeter
z Compare system DC voltage with disconnected thresholds in controller / Powcom.
z If breaker blows once more, there is either a too high load or short circuit at the system
Mains error:
z Check mains fuses.
z Check mains voltage.
Distribution fuse failure:
z Localise the blown fuse.
z Check the equipment that is connected to the blown fuse (there may be a reason for this fuse to
blow) and reconnect it.
12-2 Forza 48-25600 PPC

Revision: /
Battery failure:
z Check the batteries.
z Check the "battery test" parameters in controller / Powcom.
Module failure:
z Localise the module.
z Pull it out.
z Wait for 30 sec. and reinstall it according to 12.1 Installing new modules.
Battery temp alarm:
z Check ventilation.
z Check reading in controller / Powcom.
Symmetry fault:
z Reset the alarm.
z Check connections according to number of batteries in controller / Powcom.
z Check batteries.
Battery fuse failure:
z Localise the breaker.
z Reconnect the breaker.
High load:
z Check load situation according to capacity of the system.
z Increase number of modules.
Urgent module failure:
z See "Module failure".
Communication failure:
z Check if there is a module in current position.
z See "module failure".
Temp probe failure:
z Check connection on temp probe.
z Replace temp probe.
Alarms are blocked (only with LCD display):
z Check " miscellaneous" menu in controller.
Maintenance and Troubleshooting 12-3

Revision: /
12.3 Maintenance
The connections on the terminal blocks and circuit breakers must be checked according to the 12.4 Torque
table minimum once a year.
Minimum once a year output voltage should be verified to be within limits. Result of the test should be filed
to see any deviations.
In addition the system needs normal cleaning and verifying of right operation. It is very important to keep air
inlets and outlets free from dust or other materials, which may prevent free air circulation through the
cubical.
12.4 Torque table
TYPE: MODEL / DESCRIPTION: TORQUE:

Terminal block for rail AKG 16mm2 2,5 Nm
2
Terminal block for rail AKG 35mm 3,5 Nm
Terminal block Weidemullers WDU 4mm 0,6 Nm
Miniature circuit breaker Siemens 2,5 Nm
Miniature circuit breaker Merlin G 3,5 Nm
Miniature circuit breaker ABB 2,0 Nm
Miniature circuit breaker CBI HY-MAG 3,0 Nm
Moulded case circuit breaker ABB 160A - S2 5,0 Nm
Moulded case circuit breaker ABB 160A/250A - S3/S4 9,0 Nm
Moulded case circuit breaker ABB 630A - S6 9,0 Nm
Moulded case circuit breaker Terasaki - XS125CJ 9,0 Nm

Table 12-1 Torque
12-4 Forza 48-25600 PPC

Revision: /
Appendix A: Drawings
Document number: Appendix A.fm A-1

A.1 Menu tree PCS - 017438 - Rev: C
Show voltage/
Batt. current
Show voltage/
Distr. current
Show voltage/
Rect. current
Show alarms Show alarms
Show messages Show messages
Show data Module data
Unit data Symmetry

voltage 5
Temperature Symmetry
voltage 6
Ext.
measurements Symmetry
voltage 7
U1 normal voltage
Distr. current Symmetry
voltage 8
Select/adjust
U1-U4 U2 boost voltage
Symmetry
Symmetry
voltage 1
voltage 9
U3 test voltage
Symmetry
Symmetry
voltage 2
voltage 10
U4 spare voltage
Symmetry
Symmetry
voltage 3
voltage 11
Reference
Symmetry
Symmetry
voltage 4
voltage 12
Adjust limits Alarm limits Low voltage
Boost parameters Boost time High voltage
Overvolt.
Boost interval
Battery test Symmetry limit Shutdown
set time
Load/battery
Miscellaneous Test end Boost factor disconnect
Relay test Temperature Enable temp. voltage
comp. comp.
Partial
Boost t1
Alarm blocking Test duration disconnect
Enable current Comp. factor
Batt. current limit
Menu language limit
Load/battery
Boost t2
Version Ah- limit reconnect
Batt. current
Syst. specific limit
limits Autoboost
Set new password High load
Time of test enable
Distr. current lim. Temperature

Shunt current alarm
No of tests/year
Shunt voltage
No of batteries
Network address
Battery type
Baud rate
Init modem
Accept removed
Date: Designer: Control: Approved: Scale:
parts
05.09.2002 ØSK
Reset to defaults Replacement for: Replaced by:
Menu tree
Master reset
Page 1 of 1
PCS ref: Rev:
C:\Documents and Settings\orjans\Skrivebord\017438.vsd 017438 C

A.2 Cabinet layout Forza 48 - 037810 - Rev: /
45
40
POWER ON
MESSAGE
ALARM
POWER ON
MESSAGE CANCEL
CANCEL RS232
ALARM
35
PBDU 1
PDU 1
30
25 PDU 1 PDU 2
20
PDU 2 PDU 3
15
PDU 3 PDU 4
10
5
FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
0 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48
WxHxD=600x2150x600mm WxHxD=600x2150x600mm
Date: Designer: Scale:
12.07.04 ØSK 1:10
Page 01 of 01
Cabinet layout
Forza 48-25600 ref: Rev:
037810 /

Input mains terminal located in top of the cabinet Connection point for
Mains 1 Mains 2 Mains 3 Mains 4 distribution fuse alarm signal
(near front of cab.) (behind mains 1) (behind mains 2) (behind mains 3) Optional 6 extra
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 positive output 6 positive output
connections connections
400Vac
3 phase
PE N N N L1 L2 L3 PE N N N L1 L2 L3 PE N N N L1 L2 L3 PE N N N L1 L2 L3
1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
Document number: Appendix A.fm

230Vac
3 phase
PE L1 L1 L2 L2 L3 L3 PE L1 L1 L2 L2 L3 L3 PE L1 L1 L2 L2 L3 L3 PE L1 L1 L2 L2 L3 L3
For systems with more than 3 rectifier shelves PCS CANCEL
POWER ON
control unit MESSAGE RS232

ALARM
Distribution units with negative

terminals only. Distribution units with negative
Positive connections in top and positive terminals.
of the cabinet
PCS alarm interface unit PCS alarm interface unit

BM0546 BM0546
Connection of alarms and signals Connection of alarms and signals
from cable duct. from cable duct.
-12V Red 9 -12V Red

-24V Green 8 J4 Batt. Sym. 3 -24V Green
-36V Blue -36V Blue
7
-12V Red -12V Red
6
-24V Green 5 J4 -24V Green
Batt. Sym.2
-36V Blue 4 -36V Blue
0V 0V
-12V -12V Red 3 -12V -12V Red . 1 8 6 l 1 8 i 3 . 5 8 2 l 3 0 5 . 8 5 2 3 8 . 1 8 6 l 3 9 5 1 2 . 0 0 c - 0 l 3 9 5 1 3 r e c - 0 l c 1 9 8 . 2 7 4 2 0 c - 0 l 3 9 . 5 8 2 2 3 8 . 1 8

-24V -24V Green 2 J4 Batt. sym. 1 -24V -24V Green
-36V -36V Blue -36V -36V Blue
1
A.3 General connection drawing Forza - 037396 - Rev: /
-48V -48V
+ Red 3
- Blue
1
T
18
Alarm 6 17 J13
16
15
Alarm 5 14 J13
13
12
Alarm 4 11 J13
10
9
Alarm 3 8 J13
7
6
5 10.05.04 ØSK 1:10
Alarm 2 J13
4
3 Page 01 of 01
Alarm 1 2 J13
General connection drawing
1
Forza 48 Top entry caninet
Alarm contacts are shown in alarm position Alarm contacts are shown in alarm position 037396 /
A-4
A.4 General block diagram Forza main cabinet - 037397 - Rev: B
1
+ Output
1
- Output Quantity of subracks
will vary due to the
actual order
+ BM0635
L
N
8
- PE
L
PL4 COM N
8 PE
OPTION:
8
PL6 COM Subrack for L
N
8 Current share exten.cab.
8
PL3 Current share 4xFMP 32 PE
L
subrack 1
PL5 Current share
N BM0635 PL5
PE
Sub Rack n
OPTION:
8
Communication exten. cab.
subrack 1
BM00635 PL6
PCS - Control unit
8
J6 Com Modem 9
BM0479
with power
8
J7 Com PCS RS 232
J3 Com system 1
8
J4 Com system 2
8
J8 Power PCS
8
8
J8 Power
8
J5 Com 2 BM0500
8
J4 Com 2
8
J2 Com 1
J3 Com1
Main cabinet
1 1
PBF/PBDU 2 2 J1
PL1, Pin1 and 2
PCS 8
J7 Com
BM0546
alarm interface unit J16 Com
For more details, see

connection drawing
PDU 25 0V
Quantity and type of
- Load 1 distributions will vary
due to the actual
- Load n
order
PDU 25 0V
w/PLD
- Load 1
- Load n
PDU 25 - Load 1
- Load n
PBDU 25
- Load 1
- Load n
- Batt. 1
- Batt. n
PBF 25 - Batt. 1
- Batt. n
12.07.04 ØSK
General block diagram Page 1 of 1

Forza Main cabinet ref: Rev:
037397 B

A.5 General block diagram Forza extension cabinet - 037398 - Rev: A
1
+ Output
1
Communication - Output Quantity of subracks
from prev. cab. 8
Last subrack + L will vary due to the

- BM0635 N
BM00635 PL4 8
PE
L
actual order
PL4 COM N
8 PE
8
N
Current share
8 8
L
from prev. cab. PL5 Current share
N
PE
Last subrack Sub Rack 1
BM0635 PL3
+ BM0635
L
N
8
- PE
L
PL4 COM N
8 PE
8
N
8
L
N
PL5 Current share PE
Sub Rack 2
+ BM0635
L
N
8
- PE
L
PL4 COM N
8 PE
8
N
8
L
N
PL5 Current share PE
Sub Rack n OPTION:
8 Current share exten.cab.
subrack 1
BM0635 PL5
OPTION:
8
Communication exten. cab.
subrack 1
BM00635 PL6
8
J7 Com
PCS 8
J16 Com
BM0546
alarm interface unit For more details, see

connection drawing
PDU 25 0V
Quantity and type of
- Load 1 distributions will vary
due to the actual
- Load n
order
PDU 25 0V
w/PLD
- Load 1
- Load n
PDU 25 - Load 1
- Load n
PBDU 25
- Load 1
- Load n
- Batt. 1
- Batt. n
PBF 25 - Batt. 1
- Batt. n
08.07.04 ØSK
General block diagram Page 1 of 1

Forza Extension cabinet ref: Rev:
037398 A

A.6 Schematic diagram PCS + Power Forza - 037400 - Rev: /
8
J6 Com Modem 9
8 BM0479 J7 Com PCS
J3 Com system 1
8
J4 Com system 2
8
J8 Power PCS
8
* 8
8
J8 Power
8
J5 Com 2 BM0500
8
J4 Com 2
8
J2 Com 1
J3 Com 1
1
J1
* 2
Connect according Date: Designer: Scale:

to Block diagram
10.05.04 ØSK
Schematic diagram Page 1 of 1

PCS + Power Forza Powec ref:
ref: Rev:
037400 /

A.7 Schematic diagram PCS Alarm interface unit PBDU NH1-3 - 037811 Rev: /
8 8
J7 Com. BM0546
* 8 8
J16 Com. For more details, see
1 + connection drawing
2 - J2 Shunt 1
1 +
Distr. breaker 2 - J12 Shunt 2
alarm signal 1 Distribution fuse
J5
2 Batt. fuse manual
Located in top of
the cabinet
1
12 2
3 J6 Batt. fuse
4
Signal 1 0V
PDU 2 Sys. voltage J14
PL 1
1 J1 Disconnect 1
2
3
1
4 J1 Disconnect 2
5
6
Reconnect 7 J1 Reconnect
6
Signal Disconnect 8
9
PDU w/PLD
PL 1
Quantity and 1
type of 1
2
Digital input 0 J3
Digital input 1
distributions
will vary due to 6
Signal
the actual PDU
order PL 1 1
12
Batt. fuse alarm

Signal and power Batt. fuse alarm
Batt. fuse alarm
PBF PL 1 Distr. fuse alarm
Shunt 1 +
Shunt 1 -
Sys voltage
1 0V
Connect according 12.07.04 ØSK

to Block diagram
Schematic diagram PCS alarm
Page 1 of 1
interface unit Forza PBDU
Powec ref:
ref: Rev:
NH1-3 - 3xbatt/2xload fuses 037811 /

A.8 Schematic diagram PBDU 25 - 032566 - Rev: /
0V
- batt 1
- batt 2
- batt 3
- Load 1
- Load n
12
batt. fuse al.

PBDU batt. fuse al.
batt. fuse al.
PL 1 distr. fuse al.
shunt 1 +
shunt 1 -
sys voltage
0V
1
Date: Designer: Control: Approved: Scale:
27.03.2003 RFA
Replacement for: Replaced by:
Schematic diagram
Page 1 of 1
http://esmtier.power.one:7777/files/
PBDU 25 Powec ref:
ref: Rev:
content/MyWorkspaces/ES Documents/ 032566 /

cc/tg/vsd/25/032566.vsd

A.9 Schematic diagram PDU 25 w/LED - 037822- Rev: /
0V
- Load 1
- Load n
BM0660
X1
6 X2
X3
PDU 24xMCB X4
X5
PL1 LED board
1
BM0554
13.07.04 ØSK
Page 1 of 1
Schematic diagram PDU 25 w/LED
Powec ref:
ref: Rev:
037822 /

A.10 Schematic diagram PDU 25-max16xMCB - 024499 - Rev: /
0V
- Load 1
- Load n
6
PDU 25-max16xMCB
PL1
1
Date: Designer: Approved: Scale:

14.01.200
RFA
0 Replacement for: Replaced by:
Schematic diagram PDU 25-

Page 1 of 1
max16xMCB powec
Powec ref: ref: Rev:
024499
G:\cc\tg\vsd\25\ 024499.vsd /

A.11 Schematic diagram PPR 32/4pos Forza (Part 1 of 2) - 037407 - Rev: /
8
PL4
BM0635
PL6
8 PL3
Subrack 1
8 PL5
L
L
+
N
N 1
PE
PE
-
L
L
N
N
PE
2
PE
L
L
N
N
PE
3
PE
L
L
N
7
N
PE
4
PE
6
Mains 1 4
8 PL4
3
8
BM0635
PL6
2
8 PL3
Subrack 2
1 8 PL5
1
L
L
+
N
N 5
PE
PE
-
L
L
N
N
PE
6
PE
L
L
N
N
PE
7
PE
L
L
N
N
PE
8
7
PE
6
Mains 2 4
8 PL4
3
8 PL6
BM0635
2 8 PL3 Subrack 3
1 8 PL5
1 L
L
+
N
N 9
PE
PE
-
L
L
N
N
PE
10
PE
L
L
N
N
PE
11
PE
L
L
N
N
PE
12
PE
10.05.04 ØSK
Schematic diagram PPR 32/4pos. Page 1 of 2

Forza ref: Rev:
037407 /

A.12 Schematic diagram PPR 32/4pos Forza (Part 2 of 2) - 037407 - Rev: /
8
PL4
BM0635
PL6
8 PL3
Subrack 4
8 PL5
L
L
+
N
N 13
PE
PE
-
L
L
N
N
PE
14
PE
L
L
N
N
PE
15
PE
L
L
N
7
N
PE
16
PE
6
Mains 3 4
8 PL4
3
8
BM0635
PL6
2
8 PL3
Subrack 5
1 8 PL5
1
L
L
+
N
N 17
PE
PE
-
L
L
N
N
PE
18
PE
L
L
N
N
PE
19
PE
L
L
N
N
PE
20
7
PE
6
Mains 4 4
10.05.04 ØSK
Schematic diagram PPR 32/4pos. Page 2 of 2

Forza ref: Rev:
037407 /

Configuration Forza (c-000262.pcg)
Appendix B: Configuration Forza (c-000262.pcg)
Configuration Forza (c-000262.pcg) B-1

Revision: /
B-2 Forza 48-25600 PPC

Revision: /
Configuration Forza (c-000262.pcg) B-3

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B-4 Forza 48-25600 PPC

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Distribution PBDU 5xNH1-3
Appendix C: Distribution PBDU 5xNH1-3
C.1 Main cabinet PBDU 1

Breaker 160A 200A 250A 300A 630A Char. Type of equipment
F1 X NH1-3
F2 X NH1-3
FB1 X NH1-3 Battery 1
-Battery 1
-Battery 2
-Battery 3
- Load
F1 F2 FB1 FB2 FB3
Distribution PBDU 5xNH1-3 C-1

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Distribution PBDU 5xNH1-3
C-2 Forza 48-25600 PPC

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Distribution PDU
Appendix D: Distribution PDU
D.1 Main cabinet PDU 1
Fuse 6A 10A 16A 20A 25A 32A 40A 50A 200A Char. PLD Type of equipment
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
-Load
Distribution PDU D-1

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Distribution PDU
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
-Load
D-2 Forza 48-25600 PPC

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Distribution PDU
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
-Load

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Distribution PDU
D.4 Extension Cabinet PDU 1

F1 X C
F2 X C
+ LOAD
F1 F2

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Distribution PDU
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
0V 0V
-Load

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Distribution PDU
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
-Load

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Distribution PDU
F1 X C
F2 X C
F3 X C
F4 X C
F5 X C
F6 X C
F7 X C
F8 X C
F9 X C
F10 X C
F11 X C
F12 X C
F13 X C
F14 X C
F15 X C
F16 X C
F17 X C
F18 X C
F19 X C
F20 X C
F21 X C
F22 X C
F23 X C
F24 X C
+0V Load
-Load

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Distribution PDU

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Manual Instrucciones Power One Forza 48 25600pdf

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Manual Instrucciones Power One Forza 48 25600pdf

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POWER SUPPLY SYSTEM

Forza 48-25600 PPC

Power One logo is a registered trademark of Power One Corporation.

Introduction to the manual

Objectives and audience

Symbols and conventions

Introduction to the manual v

Questionnaire for feed-back

vi Forza 48-25600 PPC

Table of contents vii

4.2 Tools and test equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

viii Forza 48-25600 PPC

6.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

11.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

x Forza 48-25600 PPC

1 System description Forza PPC

System description Forza PPC 1-1

Figure 1-1 Typical system drawing

FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48

FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48

FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48

FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48

FMP 32.48 FMP 32.48 FMP 32.48 FMP 32.48

1. Communication program for remote control of the power suplly system

1-2 Forza 48-25600 PPC

1.2 Technical data

Figure 1-2 Principle drawing

System description Forza PPC 1-3

1.4 System description - Forza

1.4.1 FMP 32 - Rectifier module

1.4.2 PCS - Controller system

1.4.3 PPR 32/4 19"- Subrack

1-4 Forza 48-25600 PPC

1.4.4 PBDU, PBF and PDU - Distribution modules

1.4.4.1 Low voltage disconnection (LVD) (Option)

1.4.4.2 Partial load disconnection (PLD) (Option)

System description Forza PPC 1-5

1-6 Forza 48-25600 PPC

2.1 Safety - Introduction

2.2.1 Lethal voltages

WARNING! OBSERVE HIGH VOLTAGE SAFETY PRECAUTIONS BEFORE

WARNING! CARE MUST BE TAKEN WHEN HANDLING ALL POWER CABLES.

2-2 Forza 48-25600 PPC

WARNING! THE SYSTEM SHOULD BE HARD-WIRED TO THE INCOMING

WARNING! DUE TO HIGH LEAKAGE CURRENT IN THIS SYSTEM, A

2.2.3 Precautions for lead acid batteries

WARNING! THIS EQUIPMENT USES LEAD ACID BATTERIES. WHEN HANDLING

WARNING! MUCH OF THE HARDWARE THAT COMPRISES THIS EQUIPMENT IS

2.2.5 High temperatures

WARNING! CARE MUST BE TAKEN WHEN HANDLING THE EQUIPMENT AS

2.3.1 Storage and transportation

2.3.2 Handling electrostatic sensitive devices

CAUTION! An electrostatic sensitive device is an electronic component that

CAUTION! Units are labelled with permanently attached product identification

CAUTION! When replacing breakers, it must be to the same types.

2-4 Forza 48-25600 PPC

3 Installation guide Forza PPC guide

Installation guide Forza PPC guide 3-1

3.1 Site requirements

3.2 AC Power source requirements

WARNING! HIGH LEAKAGE CURRENT. ENSURE EARTH IS CONNECTED

WARNING! PRIOR TO INSTALLING MAINS CABLING, ENSURE THAT THE

WARNING! ONLY QUALIFIED ELECTRICIAN MAY CARRY OUT THE MAINS

3.3 Technical data