Eagle Eye DCPS-SHELF-9KW User manual
1
DCPS-SHELF-9KW Rectifier Shelf
Operation Manual
•AC Input: 1Phase 3Wire (range: 90V~285V); Individual AC for each Rectifier Module position
•DC Output: 54V @ 166.6A; Hot-swappable Rectifiers & Control Module; TCP/IP, SNMPv3, Web Browser
•2RU height; 19-inch wide; configurable bullet-style circuit breaker positions (2 Battery, 10 Load)
Components of the DCPS-SHELF-9KW Rectifier
Shelf
NESPACE-KA
Control Module NESPACE-48/3K
Rectifier Module
Accepts Bullet-style
1RU Breakers for
flexibility, scalability
The Appendix within this User Manual contains supporting documents including
datasheets for the DCPS-SHELF-9KW Rectifier Shelf, modules, and other useful reference
material
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Rectifier Modules (3 positions)
Each: 3KW (54VDC @ 55.5A)
Control Module
DC Load Breakers (10 positions)
(Configurable Up To 50A each)
Battery Breakers , 2 positions,
(Configurable Up To 100A each)
This Operation Manual supports the DCPS-SHELF-9KW Rectifier Shelf
Section 1. DCPS-SHELF-9KW Overview
The DCPS-SHELF-9KW Rectifier Shelf is a 19-inch wide, rack-mountable, 2RU height, intelligently-
controlled -54V DC Output Rectifier Shelf. The NESPACE-KA Control Module interfaces with up to
(3) hot-swappable, active current-sharing 3KW Rectifier Modules. The Shelf delivers up to 9KW
(166.5A) bulk power or 6KW (111A) in an N+1 redundant configuration and includes individual AC
inputs for each rectifier module, configurable circuit breakers for DC load and battery back-up, on
the rear terminal block.
Each NESPACE-48/3K Rectifier Module provides a regulated +-54Vdc output with up to 55.5A
current (see Figure 2 for derating below 176Vac). The Rectifier Modules actively current-share
with other NESPACE-48/3K modules, support N+1 Redundancy, and are hot-swappable. Mid-load
range efficiency is 96% and a flat efficiency curve maintains excellent efficient operation from
light-to-full load conditions. The DCPS-SHELF-9KW Shelf supports external battery back-up and
provides (2) configurable bullet-style battery breaker positions (up to 100A each) with battery
Low Voltage Disconnect (LVD) protection.
Figure 1. DCPS-SHELF-9KW Rectifier Shelf
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Section 1. DCPS-SHELF-9KW Overview
Operating Deratings: The DCPS-SHELF-9KW Rectifier Shelf is designed to operate with the AC
input voltage between 85V to 285V and in conditions with an ambient temperature of -40°C to
+75°C (maximum). However, the output power is derated when the AC input < 176V (see Figure
2) and when the operating ambient temperature > +45°C (See Figure3).
AC Input Voltage Derating: The DCPS-SHELF-9KW Rectifier Shelf is designed to operate in
conditions with the applied AC input voltage between 85Vac to 285Vac. Each Rectifier Module is
capable of providing full DC Output power when the AC input voltage is 176V or higher. Each
Rectifier Module’s DC output power derates when the AC input voltage is below 176V, as shown
below.
Figure 2. 3KW Rectifier Module Output Power Derating vs. AC Input Voltage
Temperature Derating: The DCPS-SHELF-9KW Rectifier Shelf is designed to operate at full power
with no temperature derating up to +45°C. In a > +45°C to +75°C (max) ambient temperature
environment, the Rectifier Modules power derate as shown below.
Figure 3. 3KW Rectifier Module Output Power Derating vs. Ambient Temperature
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Section 2. DCPS-SHELF-9KW Shelf Specifications
2.1 AC Input Characteristics
1) Rated input voltage: 1 Phase 3Wire 220Vac
2) Input voltage range: 93Vac ~ 275Vac (Nominal:176VAC ~ 264VAC)
3) Input frequency: 45Hz ~ 66Hz
4) Efficiency: 95.0% max (100% load)
5) Power factor: ≥ 0.98 (50% load or higher)
2.2 DC Output Characteristics
1) Rated output DC voltage : 54.0V ±0.54V
2) Operating DC voltage : 42.0V ∼58.0V
3) Output current max. 166.5 (55.5A × 3 Modules)
4) Output distribution ports : 10 LOAD ports. (Battery: 2 ports)
5) Line Regulation over entire load range: ±0.5% (±0.27V)
6) Load Regulation over entire line range: ±1.0%(±0.54V)
7) Output current-limit inception at 101％∼110％of full load
8) Output over voltage protection: Module OVP (shutdown) at > 59.0Vdc(±0.5V)
9) Battery Low Voltage protection: LVD preset to 45.0V ±0.5V(user-configurable)
10) Output Ripple & Noise : ≤ 300mVpeak (using 3KW modules)
# of Terminal
Connections
Class
Maximum
Capacity
Voltage
Description
10
DC (Loads)
50A each
-54V
LOAD
2
DC (Battery -)
100A
-54V
Battery String
13
DC GND.
100A each
GND
10-LOAD Rtn, 2-Batt +, 1-F.G.
Table 1. DC Output Terminal Block assignments
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Section 2. DCPS-SHELF-9KW Shelf Specifications (continued)
2.3 Safety Requirements
2.3.1 Electro Magnetic Interference (EMI)
➢EN61204/EN55022 Class A/
2.3.2 Surge Voltage of Power Cable
➢Voltage → 6kV (1.2 ×50㎲), Current →3kA (8 × 20㎲)
2.3.3 Leakage Current
➢≤30mA
2.3.4 Withstand Voltage
➢1) between input port and output port : 1.5kVac, 1 min. or 2121Vdc, 1min.
➢2) between input port and chassis : 1.0kVac, 1 min. or 1414Vdc, 1 min.
2.4 Environmental Characteristics
➢Operating Temperature & Humidity: -10℃ ∼ +65℃ (max); de-rates above 50 ℃
➢Operating Humidity: 0% ∼ 95%, non-condensing
2.5 Mechanical Dimensions
➢Rectifier Shelf ⇒ 177mm (H) X 482.6mm (W) X 469.1mm (D)
⇒6.97in. (H) X 19.0in. (W) X 18.47in. (D)
➢Rectifier Module ⇒ 122.5mm (H) X 85mm (W) X 405.5mm (D)
⇒4.82in. (H) X 3.34in. (W) X 15.97in. (D)
➢Control Module ⇒ 122.5mm (H) X 83mm (W) X 405.5 (D)
⇒4.82in. (H) X 3.27in. (W) X 15.97in. (D)
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Section 3. Installation & Cabling
Preparation for Rack Installation
The installation location should be clean and
dry. The Rectifier Shelf requires a 50cm (20 inches)
Figure 4. Front View of Rectifier System
minimum clearance at the front and sides. The Rectifier Modules each have a fan that pulls air in
from the front so it should be clear of any obstructions to allow for adequate airflow.
Installation (Pre-Installation, Protective Earthing, AC Input, DC Output)
A) Elevated Operating Ambient: If installed in a closed or multi-unit rack, the operating ambient
of the rack may be greater than room ambient. Therefore, consideration should be given to the
Maximum Operating Ambient Temperature. See the Product Safety Label on the DCPS-SHELF-9KW
and Power Derating vs. Temperature graph in Figure3.
B) Reduced airflow: Installation of the equipment in a rack should ensure that the amount of
airflow required for safe operation is not compromised. Installation should allow unrestricted
airflow at the front and rear of the DCPS-SHELF-9KW and NESPACE Rectifier Modules in the shelf.
C) Mechanical Loading: Mounting of the equipment in a rack should ensure thata hazardous
condition is not achieved due to uneven loading of therack.
D) Circuit Overloading: Consideration should be given to the connection of the equipment to the
supply circuit and the effect of the overloading of circuits could have on over-current protection
and supply wiring. Appropriate consideration of equipment nameplate ratings should be used
when addressing this concern. See Product Safety Label onShelf.
E) Reliable Earthing: Reliable earthing or rack-mounted equipment should be maintained.
Particular attention should be given to the supply connections other than direct connections to
the branch (e.g, the use of power strips).
F) Installation, maintenance, and repair of the DCPS-SHELF-9KW Rectifier Shelf, and components
within, must be carried out by qualified electricalpersonnel.
For safety reasons, installing cables for AC input, DC Loads, and/or Battery Backup requires that
no AC input voltage and no Battery (DC) voltage is applied to any of the terminal block positions
until all cables are installed. Proper lockout/tagout procedures should be followed at all times to
ensure safety to any persons in close contact with the DCPS-SHELF-9KWShelf.
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Section 3. Installation & Cabling (continued)
AC Input Protection
The end-customer shall ensure that the appropriately sized and rated AC input protection devices
(such as fuses or circuit breakers) and properly sized cables are installed by trained personnel.
Section 3.1 AC Input Cable Connections
AC Input Terminal Blocks
Located on the rear of the Shelf, each of the 3 AC Input terminal blocks are dedicated to one of
the three Rectifier Module positions.
➢AC Terminal Block #1 is dedicated to Rectifier Module position #1 only
➢AC Terminal Block #2 is dedicated to Rectifier Module position #2 only
➢AC Terminal Block #3 is dedicated to Rectifier Module position #3 only
Figure 5. AC Input Terminal Block Assignments
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Minimum Wire Size for AC Terminal Blocks is AWG 12
Use single wire lug for
Protective Earth
Ground. Minimum
Wire Size is AWG 8.
AC Input terminal blocks
#3 #2 #1
Section 3.1 AC Input Cable Connections (continued)
Figure 6. Wire Size for AC Input TerminalBlocks
Each of the Shelf’s 3 AC Input terminal blocks can require up to 18.5A continuous current.
See Figure 6 for the minimum wire size for each of the AC cables, which is:
▪
N1, N2, N3 (AC-Neutral): 2.5mm2 (AWG 12)
▪
L1, L2, L3 (AC-Line): 2.5mm2 (AWG 12)
▪
P.E. (Frame Ground): 2.5mm2 (AWG 12)
▪
Protective Earth Ground: 8mm2 (AWG8)
Strip, insert and tighten the proper sized wires (N, L, and P.E.) into the AC Input terminal block
that physically supports the dedicated Rectifier Module (RM) for that position. For example, if
only RM position #1 is configured within the Shelf, then do not wire AC Terminal Blocks #2 and #3.
Also, attach the single lugged cable to the Protective Earth Ground mounting location (to the left
of the AC terminal blocks).
Note: Any Rectifier Module position that is not filled with a Rectifier Module should have a
Rectifier Module Blank (filler) inserted into that position.
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Section 3. Installation & Cabling(continued)
L10-L1
terminals
Batt1, Batt2
terminals
3.2 DC Output Cable Connections
Ensure that AC power to the shelf is off. If Batt1 or Batt2 circuit breakers are installed, turn them
to the OFF position. Remove the rear cover to gain access to the DC terminal block
Each L1-L10, Batt 1, Batt 2, and GND/Return
cable connection should match the silkscreen
If there are cables installed at either Batt1
or Batt2 terminals, use extreme caution as
these are live (direct connections) from the
external Battery string(s) for BBU, ifequipped.
The minimum wire size for each of the
DC Output and Batt1, Batt2 cables is:
▪
L1 ~ L10 (-54V Output): 25mm2 (AWG4)
Figure 6. DC Output & Battery Terminal Block
(top view with cover removed)
▪
DC Output GND (Return for L1 ~ L10): 25mm2 (AWG 4)
▪
Batt1, Batt2 (-54V): 35mm2 (AWG 2)
▪
Batt1 GND, Batt2 GND: 35mm2 (AWG 2)
Connect DC (-54V) cables with the straight-barrel 2-hole lugs to the breaker-protected L1-L10
(Load) and Batt 1, Batt 2 (Battery) nodes. Also, all of the Load Return and Batt Return cables
should include straight-barrel 2-hole lugs to connect to the common GND terminal block.
Replace the rear cover and secure it in place with the mounting hardware.
Note that the L1 ~ L10 DC bus positions are designed to carry 100A continuous current. However, this section
limits DC breakers up to 50A maximum due to existing availability. Currently, no 1RU breakers are available
with ratings > 50A but, if they become available in same form, fit and function, this section will be edited to
include higher rated breakers up to 100A, if possible.
GND (Return)
terminals
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Section 3. Installation & Cabling(continued)
Right-Side
View
“ON”
Front
View
“ON”
Left-Side
View
“ON”
3.2.1 DC Circuit Breakers (L1 ~ L10) -Overview
There are 10 DC Load circuit breaker positions (L1 through L10) that each directly interface with
the DC Output Terminal Block positions L1 ~ L10. Each of the 10 circuit breaker positions are
configurable as each can accept removable, replaceable bullet-style 1RU-height breakers with
current ratings up to 100A. However, despite the L1 ~ L10 load positions designed for up to 100A
each, the existing 1RU circuit breakers on the market are only rated up to 50A maximum. At least
2 vendors have similar form factor 1RU bullet-style breakers, including Heinemann and Airpax
(see Figure 6a).
Note: Any breaker position that is not filled with a circuit breaker should have a Breaker Blank
Cover installed over that position.
Figure 6a. Airpax 1RU Bullet-style 50A Circuit Breaker
3.2.1.1 DC Load Front Access Panel
Unscrew the (4) captive thumb screws
from the corners of the Access Panel
then pull it forward to remove it from
the Shelf. This provides full access to
the DC Load breakers (L1~L10) and to
the BATT 1 and BATT 2 breakers.
Figure 6b. Front Access Panel removed
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Section 3. Installation & Cabling (continued)
3.2.2 Installing and Configuring CircuitBreakers
Figure 6c shows the DCPS-SHELF-9KW Shelf with the Front Access Panel removed, providing
access to:
1. BATT1 and BATT2 Breakers- Reserved for 1 or 2 external Battery Backup (BBU) strings. Circuit
breakers are removable, replaceable bullet style with current ratings up to 100A each.
Configuration settings for 0, 1, or 2 Battery Strings are in the Web Browser interface.
See Section 3.2.1 Note regarding unfilled circuit breaker positions.
1. L1 ~ L10 LOAD Breakers- Reserved for up to 10 DC Loads, L1~L10 circuit breakers are
removable, replaceable bullet style. Each breaker position can accept DC current up to 100A
but existing suppliers limit the 1RU style breaker current to 50A (maximum). Configuration
settings are in the Web Browser interface and EDPS9K-MAIN board DIP Switch settings (see
Item #3 below).
2. EDPS9K MAIN board- (see Figures 6d) - Each switch on the
10-position DIP Switch links specifically to one of the 10 DC
LOAD Breaker positions (see Table 2). Any L1 ~ L10 breaker
position with a circuit breaker installed requires the linked
DIP Switch position set to OFF. Any empty L1 ~ L10 breaker
position requires the DIP Switch position set to ON, which .
disables breaker-related alarms for that position.
Example: If L1~L9 breakers are installed but the L10 breaker
position is left empty, then DIP Switch positions 1~9 will be set
OFF and DIP Switch position 10 will be set ON).
Table 2. DIP Switch Settings
Figure 6c. Configurable Breakers
for Batt1, Batt2, Loads
Figure 6d. (Top View) Close-up of DIP Switch on
EDPS9K-MAIN Board (Shelf Top Cover removed)
L1 ~ L10 LOAD
Breakers
(Switch UP = ON)
BATT1 & BATT2
Breakers
(Switch LEFT = ON)
MAIN
Board
DIP
Switch
OFF
Front of Shelf
ON
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Section 3. Installation & Cabling (continued)
3.3 Temperature Sensors (Batt Temp and Rack Tempcables)
The NESPACE-KA Control Module measures and reports ambient temperatures measured within
the Rectifier Rack and Battery Shelf areas. The Rack Temp sensor measures the Shelf ambient
temperature and should always be connected. The Batt Temp sensor specifically measures the
Battery String ambient temperature and is used for battery temperature compensation. When no
external Battery String is connected, remove the Batt Temp sensor cable from the Shelf and
ensure the Batt Temp sensor alarm is configured properly to disable the alarm. By default, alarms
will occur if either Temp sensor cable in not inserted properly into the Shelf connectors.
Each temperature sensor is located at the
cable end (within the heat-shrink tubing)
so the mounting location is important:
The Batt Temp sensor needs to measure the
ambient temperature near the Battery String,
so mount the Batt Temp sensor near the middle
busbar on the Battery String. Secure the Temp
Sensor with a cable tie or other suitable method. Batt
Temp
Rack
Temp
If possible: Figure 7. Temperature Sensor connectors
▪Avoid placing the Batt Temp sensor directly on top of the battery housing.
▪Avoid exposing either Temp sensor to direct sunlight, drafts from the AC system, or open windows.
▪Do not route either Temp sensor adjacent to powercables.
▪Do not allow either Temp sensor to physically contact power cables.
The Rack Temp sensor needs to measure the ambient temperature near the front of the DCPS-
SHELF-9KW Rectifier Shelf., so secure the Rack Temp sensor to any convenient location at the
Shelf front but away from direct airflow (fans). If the Rectifier Shelf is mounted inside a closed
cabinet, ensure the Rack Temp cable is unobstructed when the cabinet door is closed.
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Section 3. Installation & Cabling (continued)
3.4 Battery String Symmetry (BATT CELLcable)
The NESPACE-KA Control Module monitors and reports battery string voltages for 1 or 2 external
Battery Strings. Each Battery String consists of (4) series-connected 12V batteries and a typical
float-charged VRLA string will measure -54.0Vdc. Monitoring for Battery Symmetry is achieved by
connecting the Batt Cell cable to the 2-pin CELL connector on the Shelf rear. The other cable end
has 2 ring terminals (CELL 1 and CELL 2) that have heat-shrink tubing over each ring terminal.
Remove the heat-shrink to expose the ring terminals, as needed, to connect to the middle busbar
on each Battery String. This battery string midpoint connection essentially allows monitoring of a
“Left 2-string” (-27V) and a “Right 2-String” that can be used for Equalization and determining
battery health/status.
If only one Battery String is used, remove
the heat-shrink only from the CELL 1 ring
terminal; the CELL 2 ring terminal should
remain insulated with heat-shrink tubing,
cable-tied to prevent interferenceissues.
If no external Battery Strings are used, do
not connect the BATT CELL ring terminals,
but bundle and tie them together to allow
a possible later re-configuration that may
require Battery Strings.
BATT CELL
Figure 8. BATT CELL 2-pin connector
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Section 3. Installation & Cabling(continued)
BATT CELL
3.5 Dry Relay Alarm Contacts (H/W.ALARM terminalblock)
The NESPACE-KA Control Module monitors and reports the real-time status (Normal or Alarm)
in the Status Information-Alarm page for up to 6 Dry Relay contact alarms.
Refer to Section 4.34 (Contact Output Used Set) to configure each Dry Relay contact position
using the dropdown menu (choices are: Unused, Normally Closed or Normally Open. In that same
page, click the Alarm Set button to view alarms assigned to specific Dry Relays and to assign or
delete alarms assigned to each Dry Relay.
Physical connections are made at the 12-position
H/W.ALARM terminal block (one pair of wires per
Relay) for up to 6 Dry Relay contact alarms. The
quick-connect, spring-lock terminal block allows
for fast installation by simply pressing the solid
wire into the connector terminal until it locks. To
remove a wired connection, push the release tab
above the wired position and pull the wire out.
Figure 8a. H/W.ALARM terminal block wiring
Figure 8b. Dry Relay Alarm #1 wired connection
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Section 3. Installation & Cabling(continued)
BATT CELL
3.6 Digital Input Alarm Contacts (EXT.ALARM terminalblock)
The NESPACE-KA Control Module monitors and reports real-time status (Normal or Alarm) in the
Status Information-Alarm page for up to 6 Digital Input alarms. There alarms are externally
generated alarms and are switched contacts (open or closed, such as a relay or FET as a switch).
Refer to Section 4.31 (Alarm Set- Digital Inputs Used Set) to configure each Digital Input position
using the dropdown menu (choices are: Unused, Normally Closed or Normally Open). Also, the 6
Digital Input alarm items can individually given a name, up to 12 characters long, in Section 4.35
(Digital Inputs Name Set) page.
Physical connections are made at the 12-position
EXT.ALARM terminal block (one pair of wires per
Relay) for up to 6 Digital Input alarms. The
quick-connect, spring-lock terminal block allows
for fast installation by simply pressing the solid
wire into the connector terminal until it locks. To
remove a wired connection, push the release tab
above the wired position and pull the wire out. Figure 8a. EXT.ALARM terminal block wiring
Figure 8b. Digital Input Alarm #1 wired connection
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Section 4. Mastering the Web ServerInterface
▪Login/Access to the Rectifier Shelf using the Web Server Interface
▪GUI (Main Page) elements
▪Alarm Manager
▪Rectifier Manager
▪SystemOperation
▪Controller Manager
▪System Configuration
▪Measurement Set
▪Date/Time Set
▪Controller Set
▪Factory Initalization
▪Alarm Log, Data Log, and Event Log
▪Exiting the Web Server Interface
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Section 4. Web Server Interface
4.1 Login Instructions –Preparing the IP settings for Network Connection
The Web Server interface allows interaction with the DCPS-SHELF-9KW Rectifier Shelf for
configuration, alarm and event management, status and real-time event monitoring, stored
event history, remote multi-user management via SNMPv3, other tools and user-configurable
features.
The 1st step is to edit PC settings so a direct
connection is established with the Shelf:
1. Connect a network interface cable from
the PC/laptop directly toi the Shelf's Thernet port
2. On the Control Module panel, press ‘ ’ (ENTER) several times to view the Shelf IP address.
on the LCD screen. The PC network settings will need to match this IP address to connect.
3. Go to the PC/laptop’s ‘Network Properties’ to temporarily edit the
laptop’s IP address. (Example: if Shelf IP address is 192.168.0.102 then
the laptop’s IP address must be set to 192.168.0.xxx (such as 192.168.0.100),
with Subnet Mask 255.255.255.0 and Gateway192.68.0.1).
Note: the direct connection is established between Shelf and PC.
The 2nd step is to use the direct connection to edit the Shelf IP Settings
so an active LAN connection is established with the Shelf:
4. Open a browser (such as Firefox or Chrome) and, in the address
bar, enter the numerical Shelf IP address. The User Login page
will open; enter the Username and Password then clickLOGIN.
5. The Web Browser Interface will open to the Rectifier-Home
(Status Information-Measure) page. Click on the Configuration-
Remote IP Set page (see Figure9). In the Network Configuration
Setting section, edit the IP Address then click the associated
Setting button (to save the new value). Edit the Gateway then
click Setting, and edit the Subnet Mask then click
Setting, as needed for the desired LAN settings.
When each item has been edited in this section,
click the IP Set –Setting button to save all edits
to the Network Configuration Setting section.
Note: the DCPS-SHELF-9KW Shelf IP settings are now reset to
match your local network (LAN) of choice.
Figure 9. Configuration –Remote IP Set pag
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Section 4. Web Server Interface
4.2 Login Instructions –Ethernet Access
This section assumes the Shelf IP settings and the PC/laptop network settings are configured to
allow access to a common active local (LAN) network. Refer to Section 4.1, as needed.
1. Connect an RJ45 network interface cable from the Shelf’s Ethernet port to an active LAN
port.
2. Connect a network interface cable from the PC/laptop to a separate port on the same LAN.
3. On the Control Module panel, press ‘↵’(ENTER) several times toview the Shelf IP address.
on the LCD screen. The PCnetwork settings will need to match this IP address toconnect.
4. Open a browser (such as Firefox or Chrome) and, in the address bar, enter thenumerical
Shelf IP address. The User Login page will open (see Figure 10).
5. Enter the Username and Password then click LOGIN to open the Web Browser Interface.
The Web Browser Interface will open to the Rectifier-Home page, which is the
Status Information-Measure page.
Figure 10. User Login page
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Section 4. Web Server Interface
4.3 Login Instructions –LOGIN failure or success
This section assumes the Shelf IP settings and the PC/laptop network settings are configured to
allow access to a common active local (LAN) network. Refer to Section 4.1, as needed.
1.
A failed LOGIN will result in a
browser time-out and should
provide a time-out message,
such as:
2. A successful LOGIN will open to the Web Browser Interface to the Rectifier-Home page,
which defaults to the Status Information-Measure page (see Figure11a).
This page shows real-time measured values for AC Input Voltage, DC Output Voltage and
Load Current, Rack Temperature, Battery Temperatures, and Battery Cell Voltages.
Figure 11a. Status Information- Measure page
Table of contents
