DONGAH ELECOMM VPRS-430 User manual

220V AC 1Phase Input
-54.5VDC Output
30Amps per Shelf
15Amps per Module
VPRS-430
POWER SUPPLY SYSTEM
OPERATION MANUAL

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- CONTENTS -
1. SYSTEM SPECIFICATIONS.....................................................................................................10
1.1 ELECTRIC CHARACTERISTICS ...............................................................................................10
1.1.1 Input Characteristics ...................................................................................................10
1.1.2 Output Characteristics................................................................................................10
1.2 SAFETY SPECIFICATIONS ......................................................................................................11
1.2.1 Electro Magnetic Interference (EMI).........................................................................11
1.2.2 Surge Voltage of Power Cable..................................................................................11
1.2.3 Leaked Current............................................................................................................11
1.3 ENVIRONMENTAL CHARACTERISTICS ...................................................................................11
1.3.1 Operating Temperature & Humidity..........................................................................11
1.3.2 Storage Temperature & Humidity ..............................................................................11
1.4 PHYSICAL SPECIFICATIONS...................................................................................................11
1.4.1 Dimension.....................................................................................................................11
1.4.2 Weight ...........................................................................................................................11
2 RECTIFIER SYSTEM CONFIGURATION ..............................................................................12
2.1 CONFIGURATION ....................................................................................................................12
2.2 FRONT VIEW ..........................................................................................................................12
2.3 FUNCTIONS ............................................................................................................................12
2.4 RECTIFIER SYSTEM BLOCK DIAGRAM ..................................................................................14
3 INITIALIZATION & CHECK POINTS.......................................................................................15
3.1 INSTALLATION CHECK LIST ...................................................................................................15
3.2 RECTIFIER MODULE INSERTION &DELETION ......................................................................15

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3.2.1 Rectifier Module Insertion...........................................................................................16
3.2.2 Rectifier Module Deletion ...........................................................................................16
3.3 NORMAL OPERATION.............................................................................................................16
3.4 ABNORMAL ACTIONS/CORRECTIVE MEASURES ..................................................................17
4 RECTIFIER MODULE CONFIGURATION..............................................................................18
4.1 STANDBY/OPERATING SWITCH.............................................................................................18
4.2 POWER ON LED .................................................................................................................18
4.3 STB LED ...............................................................................................................................18
4.4 ALARM LED .........................................................................................................................19
4.5 ADJUSTMENT VR...............................................................................................................19
5 CONTROL PANEL OPERATION .............................................................................................20
5.1 DISPLAY...............................................................................................................................20
5.2 CONTROL PANEL FUNCTIONS...............................................................................................20
5.3 CONTROL PANEL OPERATION...............................................................................................21
6 MANUAL BATTERY DISCONNECT........................................................................................21
7 RECTIFIER SYSTEM OPERATION & STOP OPERATION................................................22
7.1 RECTIFIER SYSTEM OPERATION...........................................................................................22
7.2 RECTIFIER SYSTEM STOPPING (LOCAL) ............................................................................22
7.3 BATTERY TEMPERATURE COMPENSATION (BTC MODE IN TEMP ON) .............................22
7.4 OUTPUT VOLTAGE FL CHAGE MODE SELECT (TEMP OFF)..............................................23
7.5 OUTPUT VOLTAGE EQ CHARGE MODE SELECT (TEMP OFF) ..........................................24
7.6 RECTIFIER MODULE RESTART ..............................................................................................24
7.6.1 When Module is Shut Down by Over Voltage.........................................................25
7.6.2 Rectifier Unit Thermal Shut Down.............................................................................25

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7.7 BATTERY CHARGE CURRENT LIMITATION............................................................................25
7.8 CONTROL PANEL POWER DROP...........................................................................................25
8 CONTROL PANEL SETUP & MEASUREMENT...................................................................25
8.1 CONTROL PANEL SETUP &FUNCTIONS ...............................................................................25
8.1.1 Float voltage setting....................................................................................................26
8.1.2 Equalize voltage setting..............................................................................................26
8.1.3 Output OV alarm setting.............................................................................................26
8.1.4 Output UV alarm setting.............................................................................................26
8.1.5 New password setting.................................................................................................26
8.1.6 Battery charge current limitation setting...................................................................26
8.1.7 Battery charge end current setting............................................................................26
8.1.8 Battery charge start current setting...........................................................................26
8.1.9 Temp ON/OFF setting.................................................................................................26
8.1.10 Battery charge mode setting......................................................................................26
8.1.11 Battery emergency voltage setting............................................................................26
8.1.12 Alarm History Clerar....................................................................................................26
8.1.13 Alarm Sound Setting..................................................................................................26
8.2 CONTROL PANEL MEASUREMENT ........................................................................................26
8.2.1 Input voltage measurement .......................................................................................26
8.2.2 Output voltage/current measurement.......................................................................26
8.2.3 Battery charge/discharge current measurement ....................................................26
8.2.4 Current measurement per unit...................................................................................26
8.2.5 Rectifier system alarm monitoring.............................................................................26
9 RECTIFIER TEST & MAINTENANCE.....................................................................................26
9.1 OVERVIEW..............................................................................................................................26
9.2 PERIODIC INSPECTION ..........................................................................................................27
9.3 ADDING RECTIFIER MODULE ................................................................................................27
10 PROBLEM SOLVING & FAULT FIXING............................................................................28
10.1 PROBLEM SOLVING ...............................................................................................................29
10.2 REPLACING PARTS ................................................................................................................29
10.3 ORDER OF REPLACEMENT ....................................................................................................29

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10.3.1 Replacement of Rectifier Module (VPRM5415)......................................................29
10.3.2 FAN Replacement of Rectifier Module.....................................................................29
10.3.3 Replacement of Surge Protector...............................................................................31
11 ACRONYMS.............................................................................................................................31
Safety Tips
For Your Safe Operation…
- Before starting the installation, operation, test and repair work, please read carefully al of
the directions specified in this manual for your safe operation of the system.
- This product has been manufactured under strict quality management. If there are any
potential damages to human life or assets, please contact Dongahelecomm.
- This document deals with safety directions with the following symbols.

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If you deal with this system without observing this symbol, it may cause
death or critical injury.
If you deal with this system without observing this symbol, it may cause an injury or damage
to assets.
《Check of Contained Materials》
●Make sure that the delivered product is the same one that you
ordered.
●Check first the quantity of the delivered articles as specified in the
enclosed sheet. Thene, make sure that there are any missing parts,
deformation, damage, peeled out paints, unscrews or damage of
cables.
《Directions in Storage》
●Do not put this product package in a place where water or rain
drops, there are any harmful gas or liquids or direct lay of light
reaches.
●Do not store this product under high temperature and humidity
conditions.

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《Directions in Operation》
Injury, Electric Shock, Fire
●Do not run this system in a place with flammable or corrosive gases,
dewdrops or humidity. (It may cause an electric shock or fire.)
●Do not try to modify this product. (It may cause an electric burn or
fire.)
●Operate this system under the environmental conditions specified in
this manual. Take particular attention to voltage, frequency,
temperature, humidity and vibrations. (Violating the environmental
requirements may cause an electric shock or fire.)
●Before connecting the battery wire, load and gronding wire, pay
attention not to reverse the polarity of them. (Polarity reversal may
cause fire.)
●While the system is on, do not touch the battery wire, load or
grounding wire ports. It may cause an electric shock or short circuit.
●Pay attention not to reverse polarity of signaling cables and detection
cables when connected. (It may cause a fire.)
●Do not leave alien materials such as sheathes of electric wires,
screws and so on inside the product. (It may cause an electric shock
or fire.)
●DC output is connected to the battery before the system starts to be
driven. Pay close attention not to cause an electric shock or short
circuit.
●When the rectifier units are added, pay close attention as AC input
voltage is fed to the Connector in the Shelf side. (It may cause an
electric shock.)
●When you take apart or insert a rectifier unit from/to the Shelf, pay
close attention not to have a burn as the part has been heated. (It
may cause an injury.)
●Do not put your finger or other things to the ractifier unit fan. (It may
cause an injury.)
●When you extend units, pay close attention not to arise an accident
of short circuit. (It may cause an electric shock.)

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●When cables are connected, battery should be separated from the
rectifier system except one point of the conductor at each cell.
●Start operation after the connections of battery wire, load, and
grounding wire are taken apart from NFB and fuses.
●Connect the battery wire, load and grounding wire while the load side
has been unloaded.
●External transmission signal should be used at 60V or lower of input
voltage and 0.5A or lower of circuit current.
●Before you take apart or insert the RS232C and RS485 ports of the
control module, turn off the control module switch.
●When you take apart or insert the rectifier unit from/to the rectifier
system, turn off the rectifier unit switch.
●Rectifier unit should be inserted and taken apart in line with the guide
rail of the rectifier system.
●Tightly join the unit fixing screws, and then, turn on the input switch
of the rectifier unit.
●As AC input may be fed to turned on system while power is failed,
special care should be paid to check and maintain the AC input.

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《Test & Repair》
Electric Shock, Fire
●Qualified labor should perform test and repair work periodically with
designated methods. (Violating this direction may cause an electric
shock or fire.)
●Only qualified labor with due knowledge and experience should
repair this product. (Violating this direction may cause an electrtic
shock or fire.)
●As AC input and DC voltage are applied, take particular attention
not to have electric shock or short circuit when the system is tested
or repaired.
●Even when the system is turned on while commercial power is
failed, AC input may be fed to the system. Take particular attention
to test and repair work of the AC input.
《Disposal》
●This product should be disposed under the ordinary industrial
wastes disposition procedure.

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1. System Specifications
1.1 Electric Characteristics
1.1.1 Input Characteristics
1) Rated input voltage : 1Φ3W 220Vac
2) Input voltage : 90V ~ 280V
3) Input frequency : 45Hz ~ 65Hz
4) Input rush current : 15Apeak or less (per rectifier module)
5) Efficiency : 90% or greater (at 10% ∼100% load)
6) Power factor : 98% or greater (at 10% ∼100% load)
1.1.2 Output Characteristics
1) Rated output voltage : -54.5V ±0.545V
2) Operating voltage : -40.0V ∼-59.0V
3) Output current : max. 10A (15A ×2 Modules:N+1)
4) Output distribution circuit : Refer to Table 1)
Table 1) Output Distribution
NO Output Port Class Cap. Volt. Description
1 L1~2 DC 10A : 2PORT -54.5V Load voltage supply
#1 ~#2
2 L3~4 DC 6A : 2PORT -54.5V Load voltage supply
#3 ~#4
3 BATTERY#1 DC 20A : 1PORT #1 Battery power supply
4 BATTERY#2 DC 20A : 1PORT
-48V
#2 Battery power supply
5)Stability of input and load : ±0.5% (±0.27V) or less
6)Output current limitation : at 105％∼130％(40% during derating)

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7)Output over voltage protection : Suspend rectifier module at 59.0V ∼
60.0V.
8)Battery over discharge protection : Suspend battery at 42.0V ±0.2V.
9)Output Ripple / Noise : 100mV or less at peat point
1.2 Safety Specifications
1.2.1 Electro Magnetic Interference (EMI)
ÎFCC PART 15 SUBPART B, CLASS A
- 450kHz≤f≤1.6MHz : 1mV (60dB ㎶) or lower
- 1.6MHz≤f≤30MHz : 3mV (69.5dB ㎶) or lower
1.2.2 Surge Voltage of Power Cable
ÎVoltage →6kV (1.2 ×50 ㎲), Current →3kA (8 ×20 ㎲)
1.2.3 Leaked Current
Î10mA or lower
1.3 Environmental Characteristics
1.3.1 Operating Temperature & Humidity
-10℃∼+55℃, 10% ∼95%
1.3.2 Storage Temperature & Humidity
-40℃∼+80℃, 5% ∼95%
1.4 Physical Specifications
1.4.1 Dimension
VPRS-430 Rectifier Shelf ⇒132.5(H) X 482.6(W) X 396.2(D) ( mm )
VPRM5415 Rectifier Module ⇒130(H) X 65(W) X 331(D) ( mm )
1.4.2 Weight
VPRS-430 Shelf ⇒11 Kg (w/o 2 rectifier modules)

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VPRM5415 Rectifier Module ⇒2.6 Kg
2 Rectifier System Configuration
2.1 Configuration
The VPRS-430 rectifier system accommodates max. 2 rectifier units
(VPRM5415). The rectifier system contains control panel (VPRC-30E) and DC
distribution panel. (See Figure 1 Exterior View). The control panel is located at
the front panel of the distribution frame at the rectifier Shelf top. DC distribution
frame contains 4 circuits for load supply and 2 circuit for battery connection.
This rectifier has been designed to charge the battery with positive ground, and
can be used for the system without any battery installed or connected. Rectifier
capacity can easily be built up by adding modules.
2.2 Front View
Figures 1 shows the exterior view of the rectifier.
2.3 Functions
Table 2) Rectifier System Functions
Classification No. of
Modules Function Remark
Rectifier Module
[VPRM5415] 2 Receives AC 110V/220VAC, and feeds DC-48V to load and charges the battery.
Control Panel
[VPRC-30E] 1 Controls up to 2 rectifiers, sends out alarms.
AC distribution
frame 1 Receives 1Φ3W 220Vac.
DC distribution
frame 1 Distributes output power, and connects
battery.

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(Front Panel Closed View)
(Front Panel Open View)
(Rear Panel Open View)
Figure 1. Exterior View of VPRS-430
Rectifier
Module Part
Rectifier
Controler Part
Battery C/B(#1,#2) Output +27V C/B(L1~L4) Output GND
AC INPUT C/B9(16A) SURGE PROTECTOR

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2.4 Rectifier System Block Diagram
Figure 2. VPRS-430 Block Diagram

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3 Initialization & Check Points
3.1 Installation Check List
To check installation of the system, take the following procedure:
1) Check if the Shelf has been fixed to the floor.
2) Check if the battery charge temperature compensation probe has been fixed.
3) Check if NFB has been installed in the DC distribution frame.
4) Check if the battery has been correctly connected.
If the battery polarity is reversed, relay will not work when power is fed.
5) Check if the battery C/B is in the ON Position.
6) Check if the Shelf frame ground has been connected to the main ground
busbar.
7) Check if the AC input ground has been connected to the main ground busbar.
8) Check if the I/O cable has been correctly connected.
9) Check if the rectifier modules have been fully inserted.
Once all of the cabling and installation procedures are finished, initialize the system
and carry out the function test in the following order.
1) Check if all of the power switches have been turned off, and check polarity and
cable connection status of batteries using DVM.
2) Check if the input power has been correctly connected and check the input
voltage using DVM.
3) Check if the output cables have been correctly connected, and check polarity.
4) Turn on the AC power switch at the right side of each shelf.
5) Check if the STB LED at the rectifier module is turned to yellow. Then, turn on
the module switch.
6) Check if the POWER LED at the rectifier module is green. Then, turn on the
power switch of the control panel, and check error status on the display window.
3.2 Rectifier Module Insertion & Deletion

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3.2.1 Rectifier Module Insertion
Rectifier module should be inserted from the left top side of the Shelf. So
insertion should made from left to right and from top to bottom. Turn off the
power switch of each module. Then, insert it until it reaches the end of the Shelf.
Then, tighten the captive screws at the front panel and turn on the power switch.
Keep the switch ON while the rectifier is in operation.
3.2.2 Rectifier Module Deletion
Turn off the power switch of the module. Then, loosen the captive screws on it.
Pull out the module seizing the handle on it.
Before starting the action, wait for about 1 minute until the LED is turned off.
Caution : Turn off power switch when taking apart a module.
3.3 Normal Operation
Default setting of the output voltage of this rectifier is BTC-FL MODE. NORMAL
LED and DCV LED at the control panel are turned on. The LCD window provides
information on the rectifier. Using the push button switches [F1(▼), F2(EDIT),
F3(ENT), F4(▲)] at the LCD window, user may query or modify setup values. (See
Figure 3.)

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Figure 3. Control Panel Front Status Indication (Normal)
3.4 Abnormal Actions/Corrective Measures
If FAIL LED is turned on while the rectifier system is driven, that means the
rectifier system is abnormal in operation. Alarm status is displayed on the LCD
window of the control panel. Check the alarm status and take proper actions.
Figure 4. Control Panel Front Status Indication (Error)
Normal LED ON
Error Message Display
Fail LED ON (RED)

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Table 4) Corrective Actions per Alarm
Alarm Corrective Actions
MF
If rectifier unit communication is failed,
⇒Insert the module to the rectifier system until it reaches the end.
If rectifier unit is off,
⇒Turn on the power switch of the unit.
DCOV, DCUV Check default setting of output voltage.
Check output UV and OV alarm settings.
ACUV, ACOV Measure actual input voltage using DVM.
LVD Check if the battery disconnector switch is in Normal.
Check if the battery has been normally connected.
B-NFB Check if battery(#1,#2) C/B OFF Position.
OCA Check the input voltage, and check if the output is open.
(See How to Operate Control Unit.)
☞
If the listed problem is not solved after the recommended actions are taken,
or if other problems occur, contact A/S center.
4Rectifier Module Configuration
4.1 Standby/Operating Switch
During the operation, the module should be in Operating Mode.
If the switch is in Standby mode, output is not fed.
Caution : Even though the switch is in Standby mode, AC power will be fed to the
module, and the STB LED on the rectifier module will be turned on..
4.2 POWER ON LED
This LED is turned on (green) when the module is normal.
4.3 STB LED
The rectifier module is in standby mode, and does not feed output.

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Caution: Even though the STB LED is turned on (yellow), AC power will be fed to
the module.
☞While AC power is input, rectifier unit turns on POWER ON LED. When
communication with the control panel is failed or when rectifier module output OC
alarm (OCA) is driven, STB LED (yellow) and POWER ON LED are turned on
simultaneously.
4.4 ALARM LED
In one of the following conditions, ALARM LED(RED) will be turned on:
* When AC power excceds UV/OV limits (UV limit : 90V, OV limit: 290V);
* When the module is shut down due to output OV protection circuit driving;
* When the module is shut down due to internal high temperature protection circuit
driving;
* When the voltage falls below UV limit due to current limit circuit driving;
* When internal fan is failed;
* When the module is shut down due to an external signal (Green, yellow and red
LEDs are blinking.)
* When output is not made due to other problems, or when the voltage falls below
UV limit.
4.5 ADJUSTMENT VR
This function enables to calibrate output voltage of the rectifier module. Turn the
VR to the right to add voltage. Turn it to the left to decrease voltage. Output voltage
has been set to 54.5V. It is recommended not to touch the setting. Load sharing
deviation among units may be adjusted.
Voltage Adjustment Resistor
Power on LED
Standby LED
Alarm LED

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Figure 5. Front View of Rectifier Module
5Control Panel Operation
5.1 DISPLAY
Figure 6. Control Panel Front View
5.2 Control Panel Functions
See Control Panel Operation Manual.
Table 5) Adjustments Menu Defaults
Standby/Operate
Button