Eagle Eye Power Solutions Calidad 1U User manual

DCPS-SHELF-6KW Operation Manual | Copyright © 2016 | All Rights Reserved
220VAC Input (1Phase 3Wire)
-48VDC Output
111A per Shelf
37A per Rectifier Module
Maintenance & Operation Manual
DCPS-SHELF-6KW SYSTEM
This document is the property of Eagle Eye Power Solutions, contains proprietary information, and is
not for disclosure or use in any form or fashion without express written permission from Eagle Eye
Elecomm.
WWW.EEPOWERSOLUTIONS.COM

DCPS-SHELF-6KW
Maintenance & Operation Manual Issue 2.0 Sept-2016
DCPS-6K Maintenance & Operation Manual 2 /23
- CONTENTS -
1 SYSTEM SPECIFICATIONS ..................................................................................................................... 9
1.1 ELECTRIC CHARACTERISTICS ............................................................................................................... 9
1.1.1 Input Characteristics ....................................................................................................................... 9
1.1.2 Output Characteristics .................................................................................................................... 9
1.2 SAFETY REQUIREMENTS ..................................................................................................................... 10
1.2.1 Electro Magnetic Interference (EMI) .......................................................................................... 10
1.2.2 Surge Voltage of Power Cable ................................................................................................... 10
1.2.3 Leakage Current ........................................................................................................................... 10
1.2.4 Withstand Voltage ......................................................................................................................... 10
1.3 ENVIRONMENTAL CHARACTERISTICS .................................................................................................. 10
1.4 PHYSICAL SPECIFICATIONS ................................................................................................................. 10
1.4.1 Dimensions .................................................................................................................................... 10
2 INSTALLATION & CABLING .................................................................................................................. 11
2.1 PREPARATION FOR RACK INSTALLATION ............................................................................................ 11
2.2 CABLING ............................................................................................................................................... 11
2.2.1 AC Input Connection .................................................................................................................... 11
2.2.2 DC Output Connection ................................................................................................................. 12
2.2.3 Communication Cable Connection ............................................................................................. 13
3 INITIALIZATION & CHECK POINTS ..................................................................................................... 14
3.1 INSTALLATION CHECK LIST .................................................................................................................. 14
3.2 RECTIFIER MODULE INSERTION & REMOVAL ...................................................................................... 14
3.2.1 Rectifier Module Installation ........................................................................................................ 14
3.2.2 Rectifier Module Removal ........................................................................................................... 15
3.3 NORMAL OPERATION ........................................................................................................................... 15
3.3.1 Initial Operation Status Check .................................................................................................... 15
3.4 ABNORMAL ACTIONS/CORRECTIVE MEASURES ................................................................................. 16
4 RECTIFIER MODULE (NESPACE-48/2K) CONFIGURATION ......................................................... 17
4.1 ON LED (GREEN) ............................................................................................................................. 17
4.2 FAIL LED (RED) ................................................................................................................................ 17

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5 RECTIFIER SYSTEM OPERATION ....................................................................................................... 17
5.1 RECTIFIER SYSTEM OPERATION ......................................................................................................... 17
5.2 RECTIFIER REMOVAL / REPLACEMENT ................................................................................................ 18
5.3 RECTIFIER MODULE RESTART ............................................................................................................ 18
6 RECTIFIER MAINTENANCE................................................................................................................... 18
6.1 OVERVIEW ........................................................................................................................................... 18
6.2 PERIODIC INSPECTION ......................................................................................................................... 19
6.3 ADDING RECTIFIER MODULE ............................................................................................................... 19
7 PROBLEM SOLVING & FAULT FIXING ............................................................................................... 19
7.1 PROBLEM SOLVING .............................................................................................................................. 20
7.2 REPLACING PARTS .............................................................................................................................. 20
7.3 ORDER OF REPLACEMENT .................................................................................................................. 20
7.3.1 Replacement of Rectifier Module ............................................................................................... 20
FIGURE
FIGURE 2-1 FRONT VIEW ............................................................................................................................... 11
FIGURE 2-2 AC INPUT & FG CABLE CONNECTION ................................................................................. 12
FIGURE 2-3 OUTPUT CABLE CONNECTION ............................................................................................. 12
FIGURE 2-4 COMMUNICATION CONNECTION PORTS ........................................................................... 12
FIGURE 3-1 FRONT VIEW OF RECTIFIER UNIT ........................................................................................ 15
FIGURE 3-2 CONTROL UNIT FRONT ........................................................................................................... 16
TABLE
TABLE 2-1 OUTPUT CABLE & LUG ............................................................................................................... 12
TABLE 2-2 COMMUNICATION PIN TABLE ................................................................................................ 123
TABLE 3-1 CORRECTIVE ACTIONS PER ALARM ..................................................................................... 16

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Safety Tips
SAFETY FIRST… at ALL TIMES !
- Before starting installation, operation, test. or repair work, carefully read and follow all directions
specified in this manual for safe operation of the system and to minimize risk to the operator.
- This product has been manufactured under strict quality management. If any potentially
hazardous procedure cannot be performed safely with regard to life or connected equipment,
contact EAGLE EYE POWER SOLUTIONS immediately.
- Pay special attention to sections throughout this manual that are highlighted with the following
WARNING or CAUTION symbols:
This WARNING symbol indicates a high risk that may cause death
or critical injury to the operator if proper procedures and safety
precautions are not used.
This CAUTION symbol indicates a serious risk that may cause injury
to the operator or damage to connected equipment if proper
procedures and safety precautions are not used. .

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《Check of Contained Materials》
《Directions in Storage》
● Secure and store this product package away from water, rain, direct
sunlight, and any potentially harmful gas or liquid.
● Store this product within the specified temperature (-40°C to +85°C)
and humidity (5% to 95%, non-condensing) conditions.
● Ensure that the product type and quantity received is the product
type and quantity that you ordered. Use the enclosed shipping
documents to verify all contents.
● Ensure that all parts and hardware are accounted for and with no
deformation, damage, peeling or scratched paints, or cable damage.

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《Directions in Operation》
Injury, Electric Shock, Fire
● Do not run this system in a place with flammable or corrosive gases,
dew or humidity. (It may cause an electric shock or fire.)
● Do not try to modify this product. (It may cause an electric shock,
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 connections, load and gruonding wires,
pay attention not to reverse the polarity of them. (Polarity reversal
may cause fire.)
● While the system is connected, do not touch any battery wire, load or
grounding wire ports. It may cause an electric shock or death.
● Pay attention not to reverse the polarity of signaling cables and
detection cables when connected. (It may cause a fire.)
● Do not leave excess or foreign materials (such as sheathes of
electric wires or hardware) on top of or inside the product. It may
cause an electric shock or fire.
● The DC outputs are 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 inserted into the shelf,
be aware that the
live AC input voltage is fed to the Connector in the rack side. (It may
cause an electric shock.)
● When you insert or remove a rectifier unit from or into the shelf, be
aware of the unit mey be hot enough to cause a burn injury.
● Do not insert an object or finger into the ractifier unit fan. (It may
cause an injury.)
● When handling rectifier units, pay close attention not to touch any
open connector pins. (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 all connections (battery, load, and grounding
wires/cables) are made but Circuit Breakers are OFF.
● Connect the battery wire, load and grounding wire while the load side
has been unloaded and Circuit Breakers are OFF.
● External transmission signal should be ≤ 60V level and ≤ 0.5A.
● Rectifier unit should be inserted and removed using the guide rail of
the rectifier system, to engage connectors without damage.
● ● Use caution during an AC failure event as the AC power may be
restored at any time. Use special care to lockout/tagout the AC
whenever necessary, check the presence of, and maintain the AC
input to the power shelf, as needed.

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《Test & Repair》
Electric Shock, Fire
● Trained and qualified personnel should perform test and repair work
periodically with designated methods. (Violating this directive is a
risk to life and limb and may cause an electric shock or fire.)
● Only qualified labor with due knowledge and experience should
repair this product. (Violating this directive is a risk to life and limb
and may cause an electric shock or fire.)
● Whenever the AC input, DC output, and/or Battery voltage(s) are
applied or present, use precautions to avoid electric shock or short
circuit when the system is tested or repaired.
● Even when the system is turned on while commercial power has
failed, AC input may be fed to the system. Take particular attention
of the live AC input voltages present during test and repair work.
《Disposal》
● This product should be disposed under the ordinary industrial
wastes disposition procedure. Be aware that there may be industrial
waste management policies that need to be followed at the local,
state, and national levels.

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1 - System Specifications
1.1 Electrical Characteristics
1.1.1 Input Characteristics
1) Rated input voltage : 1 Φ 3W 220Vac
2) Input voltage range: 85Vac ~ 296Vac (Nominal:176VAC ~ 296VAC)
3) Input frequency : 47 ~ 63Hz
4) Efficiency : typical 96% (at 40% ~ 60% load)
5) Power factor : ≥ 0.99 (at 50% ~ 100% load)
1.1.2 Output Characteristics
1) Rated output voltage : -54.0V ±0.27V (at 50% load)
2) Operating voltage : -43.5V ~ -58.0V
3) Output current : 111A (37A × 3 Modules)
4) Output port : Single-point (Bus-bar)
5) Line Regulation : ±0.5% (±0.27V)
6) Load Regulation : ±0.5% (±0.27V)
7) Current Limit : at 101％ ~ 120％
8) Over- Volltage Protection: -58.5V~-59.5V (Recycle to reset)
9) Output Ripple / Noise: 250mVp-p (max)

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1.2 Safety Requirements
1.2.1 Electro Magnetic Interference (EMI)
EN55022/EN61204-3 Class A
1.2.2 Input Surge Voltage
Voltage →6kV (1.2 ×50 ㎲), Current →3kA (8 × 20 ㎲)
1.2.3 Leakage Current
≤ 10mA
1.2.4 Withstand Voltage
1) Input to Output: 3.0kVac (1 minute) or 4242Vdc (1 minute)
2) Input to Chassis : 1.5kVac (1 minute) or 2121Vdc (1 minute)
1.3 Environmental Characteristics
Operating Temperature: -10℃ ∼ +75℃ (Derating above +55℃)
Operating Humidity : 5% ∼ 95%
1.4 Physical Specifications
1.4.1 Dimensions (W x D x H):
446mm x 408mm x 44.4mm

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2 - Installation & Cabling
DCPS-6K (SHELF)
Figure 2-1 Front View
2.1 Preparation for Rack Installation
This rectifier is required to be installed using an indoor cabinet/rack in a clean, dry location, with
at least 50cm spacing at the front and rear of the shelf to allow for unrestricted air flow.
2.2 Cabling
● Pay particular attention to safety procedures while installing
rectifiers.
● Before cable installation, use a DVM to verify AC and DC
voltages are not present. Use tagout/lockout, as needed.
● Before starting any operation, carefully read the following
directions.
Input/output of the DCPS-6K rectifier is connected through terminals, connectors, and bus-
bars. Pay attention to AC input Line/Load/GND and DC output connection polarities.
2.2.1 AC Input Connection
The AC input includes a lightning surge arrestor (10kA). The AC input cabls should be
physically separated from DC output cables as much as possible to minimize EMI.
The AC 1ø3W input cable may be connected after voltage of it is verified to be off and
locked-out..
* INPUT & FG cables should be as sized peoperly, at a minimum of:
AC Line (ACL) and AC Neutral (CAN) terminals : min. 6SQ (10AWG)
AC Ground (PE) : min. 8SQ (8AWG)

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Frame Ground (FG) : min. 8SQ (8AWG) / 1 or 2 HOLE LUG (5Øx15mm)
Figure 2-2. AC Input & FG Cable Connection
2.2.2 DC Output Connection
DC output cable should be connected referring to Table 2-1 and Figure 2-3. Connect each
of the output cables to corresponding port.
Table 2-1 Output Cable & LUG
LOAD (-48V) RTN (RETURN GROUND)
55A: 1HOLE LUG  25SQ or greater
110A: 1HOLE LUG  50SQ or greater
55A: 1HOLE LUG  25SQ or greater
110A: 1HOLE LUG  50SQ or greater
AC Ground
(PE)
PE
ACL
ACN
Frame Ground
(FG)
ACL (L1)
ACN (L2)

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Figure 2-3 Output Cable Connection
2.2.3 Communication Cable Connection
Rectifier alarm and operation status are sent out over Debug and Ethernet ports.
Pins are assigned as follows:
Figure 2-4. Communication Connection Ports
Table 2-2. Communication Pinout Table
> Ethernet (TCP/IP)
Pin NO Name Description Comments
1 TX+ Transmit Data+ CONNECTOR: RJ45
2 TX- Transmit Data-
3
RX+
Receive Data+
4 Not Used
5
Not Used
6 RX- Receive Data-
7 Not Used
8
Not Used
Ethernet (TCP/IP)
Debug
Digital Input
Alarm (4ports)
Dry contact
Alarm (6ports)
Battery Temp
Sensor

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3 - Initialization & Check Points
Once all of the cabling and installation procedures are finished, initialize
the system and perform the functional test in the following order.
Check carefully if there are any service failures or alarms during the test.
1) Check that all of the power switches have been turned off, and check polarity and
cable connection status using DVM.
2) Check that the input power has been correctly connected using DVM.
3) Check that the DC Output cables have been correctly connected, and check polarity.
4) Turn on the AC main Circuit Breaker.
5) Check that each installed Rectifier Module front panel LED is green, and verify that the
DC output voltage is correct.
3.1 Installation Check List
To check installation of the system, use the following procedure:
1) Check that the equipmment rack has been properly and firmly mounted to the floor.
2) Check that the dry contact alarms cable (optional) of the Control unit is connected.
3) Check if CIRCUIT BREAKER has been installed in the distribution frame of the
system.
4) Check if audible alarm switch of the control panel is ON.
5) Verify that the rack Frame Ground has been connected to the main ground busbar.
6) Check if the AC power ground is connected to the surge protector ground.
7) Check if the I/O cable has been correctly connected.
8) Verify that all installed rectifier modules have been fully inserted.
3.2 Rectifier Module Insertion & Removal
3.2.1 Rectifier Module Installation
Each Rectifier Module should be inserted into the shelf from the front. Insert each
module until it reaches the mating connector then push in the ejector to fully seat the
connectors. The ejector will easily lock into place when inserted and seated.

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EJECTOR
Figure 3-1. Rectifier Unit Front View
3.2.2 Rectifier Module Removal
Remove the Rectifier Module by pushing in on the top front portion of the ejector
then pull the ejector handle to slide the module out from the shelf assembly.
3.3 Normal Operation
Status data is displayed on the LCD window of the Control unit. Use the push button
switches on the front panel to edit or display setup values.
3.3.1 Initial Operation Status Check
1) Rectifier Module (NESPACE-48/2K)
Check that the ON LED is illuminated.
Check that ALARM LED is turned off.
If the FAIL LED is ON, the Rectifier Module is not operating normally. In that case,
check the unit status on the LCD window of the Control unit.
Check that the Rectifier Module fan operates normally (pulls air in from front to
rear).
2) Controller (NESPACE-KA)
Check that the status indicator “ FAIL” LED (red) is off.
Check that the audible alarm is not activated (it should remain quiet).
Check that alarms are not shown (as activated) on the LCD display and that the
LCD displays the present status correctly.

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LCD
WINDOW
LED
INDICATOR
SELECTION
BUTTON
Figure 3-2. Control Unit Front View
3.4 Abnormal Actions / Corrective Measures
If the FAIL LED (red) is on while the Rectifier System is powered ON, the alarm status
will be displayed on the LCD window of the control panel and the audible alarm will
sound. Check the alarm satus and take corrective measures.
Table 3-1 Corrective Actions per Alarm (optional, user defined)
No ALARM CORRECTIVE MEASURES Default (List)
Port1 AC input
AC High & Low voltage
Measure actual input voltage using the digital volt
meter. Verify input voltage UV, OV alarm settings.
AC UV : Under 174Vac
AC OV : Over 276Vac
Port2 Output
voltage
Verify default setting of output voltage.
Verify output voltage UV,OV alarm settings.
Verify individual current of unit and check if load
sharing is working correctly (only for the case of
Under voltage fail).
DC OV : Over 58Vdc
DC UV : Under 47.5Vdc
Port3 Rectifier
module
If an inserted rectifier module inserted has any
problem, remove and reinsert it. If it fails again,
replace the module.
UNIT FAIL
(Default.#1~#2, Max #3)
Port4 Environment
(Etc)
Check details using a PC and the Debug port to
check the actual status of the alarm.
Rack. High Temp (80℃)
Rack. Sensor fail (open)
Port5 Ext Alarm Check details using a PC and the Debug port to Digital input Alarm fail

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check the actual status of the alarm. Check the
Digital input (Ext) Alarm cable
(Default: Normally open)
Port6 Control
If Control Unit has any problems, power the AC off
to the Shelf then remove and reinsert it. If it fails
again, replace the Control Unit.
* Type can be set arbitrarily (Normal open / Normal closed)
4 4 - Rectifier Module (NESPACE_48/2K) Configuration
4.1 ON LED (GREEN)
The ON LED is lit (GREEN) when the Rectifier Module is in normal operation.
If internal communication with the Control Unit fails, the ON LED slowly blinks.
4.2 FAIL LED (RED)
The FAIL LED is lit (RED) under one of the following conditions:
* When system is shut down due to the DC OV (OverVoltage) protection circuit.
* When system is shut down due to the OT (OverTemperature) protection circuit.
* When system is in a DC UV (UnderVoltage) due to an over- current limit condition.
* When the internal FAN has failed – FanFail (FF).
* When system shuts down due to the AC OV or AC UV exceeding rated spec limit.
* When output is not functioning or voltage falls below DC UV limit (for any reason).
5 5 - Rectifier System (RM) Operation
5.1 Rectifier System Operation
①Check that each RM ON LED is illuminated (GREEN) for normal operation.
If the RM FAIL LED is on (RED), check module error status then remove
and reinsert the RM to check the status again.
②Verify that the RM ON LED is illuminated (GREEN) for normal operation.
If the FAIL LED is still on (RED), check the alarm displayed on the Control Unit LCD.

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If any error on the rectifier system is not solved under the direction of above Table 3-1,
contact a Sales Representative or the headquarters of Dongahelecomm.
5.2 Rectifier Removal / Replacement
①The Rectifier Modules are hot-swappable so can be replaced with AC power applied.
(Note that if any external battery has been connected, the Control Unit still operates.)
②
The Control Umnit is not hot-swappable so replacement requires that the AC input
voltage be turned off and all external batteries be disconnected (BATT circuit
breakers OFF). Then the Control Unit can be replaced and the system power
restored.
5.3 Rectifier Module Restart
If a Rectifier Module output voltage is suspended due to a DC OverVoltage (OV) or
Fan Failure (FF), manually turn off the main AC Circuit Breaker. Then, when the
module is fully discharged (LED off), turn on the AC Circuit Breaker to see if the
event was isolated or recurring. If the OV/FF is still indicating the failure, replace the
Rectifier Module and repeat this restart process to check thast the replacement
module clears the alarm.
6 - Rectifier Maintenance
6.1 Overview
The purpose of this document is to provide guidelines to test the rectifier and setup
measures to restore the rectifier to normal operation within a shortest possible time
when any fault occurs to the system. Enough field-replaceable spare parts must be
maintained on-hand to prepare for replacement of units or components that may fail in
the field. Even though the fault location and reason are detected under the guidelines of
this Manual, if field repair work is not possible, or a ong period of time is needed for
repair, the faulty units should be replaced with a spare one held in reserve. This allows

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the system alarm to be cleared quickly and efficiently to minimize technician time and
maximize system up-time.
Note : As this rectifier uses AC voltage, it may cause electric shock. As battery voltage
is fed to the system, safety measures should be taken to repair and maintain the
rectifier.
6.2 Periodic Inspection
To guarantee effective operation of the system, periodic inspection is required.
Periodic inspection should be carried out one time per 6 months.
1) Take care not to block the air ventilation holes with dust, dirt, or other debris.
2) Check the cable connections and tighten as necessary.
3) Check if internal temperature of the site is maintained at the rated levels.
4) Visually check all rectifier operation states and alarm states.
5) Check the equipment rack floor mount is maintained and ensure there is not
water leakage at or near the installation site for the rectifier system.
6.3 Adding Rectifier Module
To expand the system capacity, rectifier modules are hot-swappable so may be inserted
to vacant slots while the Rectifier Shelf is powered up normally.
1) Insert a rectifier module to the vacant slot until it reaches the mating connector then
push in the ejector to fully seat the connectors. The ejector will easily lock into place
when inserted and seated.
2) Confirm the Rectifier Module ON LED is illuminated GREEN.
3) On the Control Unit, check operation status of the newly inserted module for no
active alarms.
7 – Problem Solving & Fault Fixing
Repairing or problem fixing of the rectifier should be necessarily carried out by
experienced workers observing safety directions.
* Jobs should be carried out in due order.

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* Workers should not wear rings, watches or metallic accessories.
* If non-insulated conductors are used, check using a power meter if voltage is fed to
them.
- Circuits and boards should be protected from EMI.
7.1 Problem Solving
This rectifier has been designed for users to solve problems easily. The meter window of
the control panel displays details of faults.
7.2 Replacing Parts
If a fault is suspected on a particular point, circuit board of that point should be replaced.
Replacing or replacement of individual circuits should not be made in fields.
7.3 Order of Replacement
7.3.1 Replacement of Rectifier Module
1) When a rectifier module is replaced, an alarm will be activated. Turn off the rectifier
module from the control panel, or notify this fact to the person in charge.
2) Push in on a the ejector on the Rectifier Module, and then pull the ejector handle to
remove the module.
3) Slide in a new Rectifier Module along the mechanical guides until it reaches the
backplane connector.
4) Carefully push in the ejector handle to lock the mating connectors. The ejector
handle easily should snap in place and lock into the Rectifier Module front panel.
5) Check that the module operates normally and that no alarms are activated.