EXICOM POWER SOLUTIONS 84000 Series User manual

1
48V DC POWER SYSTEM
LARGE POWER SYSTEMS - 84000 Series
Indoor Power Plant
User Manual

Copyright © 2019 by Exicom Tele-Systems. The contents of the document are to change as per the latest design updates in the systems
Contact Exicom Tele-Systems for latest copy of the document.
EXICOM Tele-System Limited incepted in 1994, is a leading Telecom Power Solution Provider in India, with its
corporate office in Gurgaon (Near to New Delhi) and manufacturing facilities at Solan (Himachal Pradesh) and
Gurgaon (Haryana).
Corporate Office:
PLOT NO. 77A, IFFCO ROAD, SECTOR - 18,
GURGAON –122015 HARYANA, INDIA
Tel: [phone]
Fax: [phone]
EXICOM TELE-SYSTEM (SINGAPORE).
7500A, BEACH ROAD, #12-318-9, THE PLAZA,
SINGAPORE 199591.
HORIZON TELE-SYSTEM SDN BHD (MALAYSIA)
47, JALAN ASTAKA U8/48A,
BUKIT JELUTONG, 40150
SHAH ALAM, SELANGOR
Tel: [phone]
Fax: [phone]
EXICOM’s power plants are equipped with in-house produced Switched Mode Rectifiers (SMR). We have power
plants configurations with ampere ultimate capacity ranging from 100A up to 4000A (for instance 100A, 200A,
400A, 800A, 1000A, 2000A, 2500A, 3000A etc.), which provide regulated power to telecommunication equipment
and also keep batteries floated across the load in fully charged condition so that uninterrupted operation of vital
communication network continues even when AC mains fail.
Today’s sensitive electronic loads and state of the art VRLA batteries require continuous electronic supervision
and features like Temperature Compensation, Battery path current limiting etc. A micro -controller based
Monitoring and Control Unit (M2000) carries out all these vital functions.
All the above modules and sub-assemblies are housed in a rack. Because of the modularity of the whole
architecture the system is extremely flexible. A variety of combinations can be worked out to serve any kind of
requirement and provision for future expansion.
CUSTOMER SUPPORT
PROJECT MANAGER : [phone] EN WAN MALEK
TECHNICAL : [phone] EN ZAIRUL
WARRANTY : [phone] EN KHAIRY
HELP LINE : [phone]

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Table of Contents
User Manual-Power Plant
(ID)
Core Power
EXICOM TELE-SYSTEMS
i
Empowering Innovation
Safety Instructions and Symbols Used................................................................................................ iii
Abbreviations.......................................................................................................................................vi
Introduction .......................................................................................................................................viii
Unpacking Instructions ........................................................................................................................ 1
Power Plant Unpacking Procedure ................................................................................................. 1
Rectifier Unpacking Procedure ....................................................................................................... 2
Product Description ............................................................................................................................. 3
Dimensional Information ............................................................................................................... 3
System Architecture........................................................................................................................ 4
Technical Specification.................................................................................................................... 5
Rectifier Introduction........................................................................................................................... 6
Technical Specification –SMR 3000W............................................................................................ 7
Controller (M2000) .............................................................................................................................. 9
Technical Specification.................................................................................................................. 10
M2000 Physical Overview............................................................................................................. 12
Home Screen Information............................................................................................................. 13
Navigation Keys............................................................................................................................. 14
Installation ......................................................................................................................................... 15
Commissioning................................................................................................................................... 19
Troubleshooting................................................................................................................................. 21
Preventive Maintenance.................................................................................................................... 22
Safety Precautions ............................................................................................................................. 23

User Manual-Power
Plant
EXICOM TELE-SYSTEMS
ii
Empowering Innovation
RECORDS OF REVISION
REVISION
RELEASE DATE
AUTHOR
REVIEWED BY
APPROVED BY
Initial Issue
04. 09. 23
NP
RICHARD
AZLAN

3
Safety Instructions and Symbols Used
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
iii
Empowering Innovation
Please read the safety instructions very carefully before operation to avoid harm to the personnel or the system.
The special instructions laid in this book does not include all the safety points to be observed, and are only
supplement to various safety points. Therefore, the installation and commissioning personnel must be strictly
trained to correctly and cautiously operate the system.
Warns of a hazard the system operator will be exposed to, that will likely result in death
or serious injury if not avoided.
Warns of a potential hazard the system operator may be exposed to, if not avoided, that
may result in equipment damage or performance loss.
Notifies an action to the reader that must be avoided or performed in order to protect
equipment, software, data, or service.
Hazardous Voltage
Some components of the power system carry hazardous voltage in operation. Direct or indirect
contact through moist objects with these components will result in fatal injury.
Safety rules in the industry must be observed when installing the power system. The
installation personnel must be strictly trained to operate high voltage and AC power.
In operation, the installation personnel are not allowed to wear conductive objects such as
watches, bracelets, bangles, rings etc.
When water or moisture is found on the Sub-rack, turn off the power immediately. In moist
environment, precautions must be taken to keep moisture out of the power system.
Tools
In high voltage and AC operation, special tools must be used. No common or self-carried tools
should be used.
Thunderstorm
Never operate on high voltage, AC, iron tower or mast in the thunderstorm.
In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the
equipment should be well earthed to avoid damage by lightning strikes.
ESD LOGO
The static electricity generated by the human body will damage the static sensitive elements
on PCBs, such as large-scale ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist
strap must be worn to prevent body static from damaging the sensitive components. The other
end of the ESD wrist strap must be well earthed.

Safety Instructions and Symbols Used
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
iv
Empowering Innovation
Short Circuit
During operation, never short the positive and negative poles of the DC distribution unit of the
system or the non-grounding pole and the earth. The power system is a constant voltage DC
power equipment, short circuit will result in equipment burning and endanger human safety.
Check carefully the polarity of the cable and connection terminal when performing DC live
operations.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Insulated tools must be used.
Battery
Before any operation on battery, read carefully the safety precautions for battery handling and
the correct battery connection method.
Non-standard operation on the battery will deteriorate battery efficiency and may cause
danger to battery or operating personnel.
In operation, precautions should be taken to prevent battery short circuit and overflow of
electrolyte. The overflow of electrolyte will erode the metal objects and PCBs, thus causing
equipment damage and short circuit of PCBs.
Before any operation on battery, pay attention to the following points:
Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.
Use special insulated tools.
Use eye protection device, and take preventive measures.
Wear rubber gloves and apron to guard against electrolyte overflow.
In battery transportation, the electrode of the battery should always be kept facing
upward. Never put the battery upside down or slanted.
BLVD
The system has battery low voltage disconnection (BLVD) function. BLVD means when the mains
fail and batteries supply power, the monitoring module cuts the load off when the battery
voltage drops down to below 44.4V to prevent over-discharge. The BLVD voltage is settable
through controller (M1000).
The factory setting is enabling BLVD, which means that if power outage lasts for a long time or
the power supply system fails, there might be BLVD. Users should classify the loads and connect
the priority loads to BLVD routes.
For vital loads, users can disable BLVD of these loads to insure reliability of the power supply.
The advantage of enabling BLVD is protecting the batteries from over-discharge when the
battery voltage is low. The disadvantage of enabling BLVD is that when the battery voltage
drops down to a certain value, all the loads (including non-priority loads and priority loads) will
be cut off due to battery disconnection.
The advantage of software disabling BLVD is prolonging the power supply of priority loads. The
disadvantage is that software disabling cannot prevent unwanted power failure due to mis-
operation or power supply system failure.

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Safety Instructions and Symbols Used
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
Sharp Objects
When moving equipment by hand, protective gloves should be worn to avoid injury by sharp
object.
Cable Connection
Please verify the compliance of the cable and cable label with the actual installation prior to
cable connection.
Binding the signal lines
The signal lines should be bound separately from heavy current and high voltage lines, with
binding separation of at least 150mm.
General Safety
A Good Earth. Typical earth resistance should be less than 1 ohm, for lightening protection;
earth resistance should be periodically verified (once in three months).
In case of DG set supply, adequately rated DG set to cater for minimum 1.25 times of Power
Plant load and maximum of other loads (e.g. starting load of AC). In case of three phase DG set,
load on DG set should be balanced on three phases within +/-10%.
The Power plant has unity power factor and does not require external PF correction. Use of
switched capacitor bank at input results in switching transients which may damage the Power
plant and is to be avoided.
Without LPU installation/integration with SMPS/PP, do not Switch ON the Power Plant.

Abbreviations
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
ABBREVIATION
DESCRIPTION
A
Ampere
AC
Alternating Current
ACDB
AC Distribution Board (Panel)
Ah
Ampere Hour
AUC
Ultimate Capacity
Batt.
Battery
BHMS
Battery Health Monitoring System
BLVD
Battery Low Voltage Disconnect
CAN
Controller Area Network
CB
Circuit Breaker
CC
Constant Current
CV
Constant Voltage
Comm.
Communication
Comp.
Compensation
Config.
Configuration
DC
Direct Current
DCEM
DC Energy Meter
DG
Diesel Generator
DisChrg.
Discharge
DSP
Digital Signal Processing
EB
Electrical Board
HES
Hall Effect Sensor
HVLV
High Voltage Low Voltage
Hz
Hertz (unit of frequency)
Indiv.
Individual
I/F
Interface
KAH
Kilo Ampere Hour
KWH
Kilo Watt Hour
LED
Light Emitting Diode
LLVD
Load Low Voltage Disconnect
LVD
Low Voltage Differential
MCB
Main Circuit Board
MCM
Monitoring and Control Module
mm
Millimeter
MOV
Metal Oxide Varistor
PCA
Printed Circuit Assembly
pfc
Power Factor Correction
PFC
Potential Free Contacts

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Abbreviations
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
ABBREVIATION
DESCRIPTION
PN
Phase Neutral
PP
Power Plant
RH
Relative Humidity
SMPS
Switched Mode Power Supply
SMR
Switched Mode Rectifiers
SOC
State of Charge
Std.
Standard
Temp.
Temperature
USB
Universal Serial Bus
VRLA
Valve-Regulated Lead-Acid

Introduction
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
viii
Empowering Innovation
The Manual helps the personnel understand system, and take advantage of its capability.
It includes the following information:
A brief description of the unit supplied, and all its components;
Operations, maintenance and repair rules, necessary for maintaining the correct operational condition of the
unit;
Installation and commissioning procedures;
Information for locating and identifying all spares of the systems.
The power plant information is divided into following ten chapters as briefed below:
SECTION 1 - UNPACKING INSTRUCTIONS
This section contains instructions to unpack the power plant and the rectifiers.
SECTION 2 - PRODUCT DESCRIPTION
This section provides information about the power plant physical dimensions, functionality and its technical
specifications. It briefs about its components and their significance in the system. It contains block diagram to
explain the system internal interfaces and gives a schematic into system functionality.
SECTION 3 - RECTIFIER INTRODUCTION
This section describes key features and benefits of the switched mode rectifiers installed on the system. It
tabulates its technical specifications and also gives a physical overview to its front and rear panel provisions and
alarm indications.
SECTION 4 –CONTROLLER M1000
This section provides information about the M1000 technical capabilities and its functionality in the system. A
physical overview to its front and rear panel provisions and alarm indications is also provided.
An introduction to the M1000 menu system, through menu tree and parameter configuration tables is provided.
Each parameter is briefed with its primary settings, default values and extended settings (if applicable).
SECTION 5 - INSTALLATION
This section contains stepwise procedures to install and commission the power plant.
SECTION 6 - COMMISSIONING
This section contains stepwise procedures to install and commission the power plant.
SECTION 7 –TROUBLESHOOTING
This section contains basic user level troubleshooting procedures. The table details fault, its cause and corrective
action required.
SECTION 8 - PREVENTIVE MAINTENANCE
This section contains the scheduled maintenance procedures, which shall be periodically carriedout on the system
to maintain correct operation and the performance within specification limits.

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Introduction
User Manual-Power Plant
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EXICOM TELE-SYSTEMS
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Empowering Innovation
Page Intentionally Left Blank

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Unpacking Instructions
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
1
Empowering Innovation
Upon delivery, examine the consignment for possible damage caused in transit. In case the packing material or
the contents inside indicates rough handling, obtain pictures of the damaged area and report it to your Exicom
representative.
Once the external review is completed carefully remove the protective packing cover and check the consignment
content against the order list. Report any short shipment to your Exicom representative.
Power Plant Unpacking Procedure
PROCEDURE:
1. Power Plant, as you receive.
2. Remove the shrink wrap.
3. Cut the nylon strap, using scissors.
4. Remove the nylon strap and the edge boards.
5. Remove the corrugate cover.
6. Remove the corner thermocol.
7. Remove all the four fasteners, to detach the power plant unit from palette.

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Unpacking Instructions
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
Rectifier Unpacking Procedure
PROCEDURE:
1. Packing of four
rectifiers.
2. Open the
corrugated box.
3. Carefully, take out
each rectifier.
PROCEDURE:
1. Packing of four rectifiers.
2. Open the corrugated box.
3. Carefully, take out each rectifier.

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Product Description
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
This section introduces all subassemblies of the power plant to user. It also gives a brief about the system
functionality and its working.
Dimensional Information
FIGURE 2.1 - POWER PLANT OVERALL DIMENSIONS

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Product Description
User Manual-Power Plant
(ID)
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Empowering Innovation
System Architecture
FRONT VIEW WITHOUT FRONT DOOR

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Product Description
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
Technical Specification
TABLE 2.1 - POWER PLANT TECHNICAL SPECIFICATION
PARAMETERS
SPECIFICATIONS
System Capacity
-48VDC/84kW
AC Input Voltage
415VAC, Three phase/5wire (Y connection)
Input Frequency
45Hz to 66Hz
Output Voltage
42Vdc to 58Vdc
Type of Rectifier
Serenity SMR 3kW
Input distribution
415VAC, Three phase/5wire (Y connection)
Surge Protection
SPD Class C
DC Distribution
Copper Bus-bars for Positive
Copper Bus-bars riser for load distribution
2 x Load Fuse Range (500A-1000A)
1 x Load Fuse Range (500A-1000A) (Optional)
Controller
M2000
Battery Termination
2 x Range (500A - 1000A) Fuse
Mechanical dimensions
2000mm(H)x600mm(W)x600mm(D)
Cable Entry/Service
Top/Bottom Entry
Mounting arrangement
Floor mount
Degree of Protection
IP-20
Potential Free Contacts
8 nos. configurable
Operating Temperature
-40°C to +75°C, Linear derating from 40°C onwards
Operating RH
0% to 95% Non-Condensing
Cooling /SMR Cooling
Natural cooling for System/ Forced cooling for
rectifiers
Environmental
As per QM333, Cat-B

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Rectifier Serenity 3000W
User Manual-Power Plant
(ID)
EXICOM TELE-SYSTEMS
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Empowering Innovation
Serenity SMR 3000W
Telecom operators and infrastructure companies look for reliable, high quality, high efficiencycost effective power
solutions. Exicom is proud to introduce one of the first commercially available bridgeless, dynamically and digitally
controlled ultra-high efficiency rectifiers, the Serenity 3.0kW.
FEATURES AND BENEFITS
High efficiency
Extensive use of DSP controls, managing a dynamically optimized topology that yields veryhigh efficiency.
Peak efficiency achieved is 96%
Ultra-high power density
The single phase, hot pluggable fan cooled rectifier provides outstanding power densitywhile its intelligent &
advanced protection features allow users to deploy it in any kind of environment –urban / rural / poor grid etc.
Active Load Sharing
The rectifier uses advanced digital active load sharing technology. The output current of each rectifier is
<±5% of the average current of all rectifiers from 10% to 100% load.
Hot Swappable
The rectifier is designed to be plug-and play. It can be inserted or removed from a live DC power system with
no damage. When the rectifier is plugged into the system, the system output voltage willnot be affected.
Paralleling
This rectifier may be connected in parallel with any other SERENITY 3000W rectifier. M1000/2000 cansupport
up to 120 rectifiers.
Wide input voltage range Operational: 90V 300V; self-protection up to 400V; auto restart
Intermittent, HV grid conditions are a norm in the developing nations and even in the developed ones. Rugged,
high reliability, robust protection is designed into all SERENITY products, to combat abnormalAC Input.
Specifications
AC INPUT
Voltage
90 –300 VAC
Frequency
45Hz-66Hz
Current
18A
THD
<5%
Power Factor
> 0.99 for more than 50% load

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Rectifier Serenity 3000W
User Manual-Power Plant
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EXICOM TELE-SYSTEMS
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Protection
Internal fuse
MOV
GDT
DC OUTPUT
Voltage
42 - 58V DC
Output Power
3000 W above 185Vac
Max. Current
62.5 A at 48V DC
Current Sharing
± 5% of max. current above 10% Load
Static Voltage
Regulation
0.5% from 10% - 100% load
Ripple and Noise
<300mV peak to peak
30MHz bandwidth
<2mV rms Psophometric
Output Protection
Overvoltage shutdown
Output Fuse Protection
Hot-plug Inrush Current limiting
Overload fold back
Over temp. shut-off
Short Circuit
OTHER SPECIFICATIONS
Operating Temp.
-10⁰C to +75⁰C linear de-rating from +45⁰C
Storage Temp.
-40⁰C to +85⁰C
Humidity
5% to 95% RH non-condensing
Efficiency
Peak 96%
Acoustic Noise
<55dBA
MTBF
> 255,736 hrs.
Alarms
AC input abnormal
AC over/under voltage
Rectifier OK/Fail
Communication fail
Fan Fail
Temp. Shut-off
Output over/under
voltage
Cooling
Forced Cooling
APPLICABLE STANDARDS
Electrical Safety
EN 60950
EN 300 019-2-1/2-2/2-3
EMC
EN 61000 –6-1/6-2/6-3/6-4
EN 61000 –3 –2
Environment
RoHS Compliance

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Rectifier Serenity 3000W
User Manual-Power Plant
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EXICOM TELE-SYSTEMS
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1. LED Indications
LED INDICATION
DESCRIPTION
Green
OFF –AC Fail
ON –AC OK
Flash –SMR Comm. OK, Sleep
Mode (Slow Flash)
Yellow
OFF –Normal
ON –AC Low/High Cut-Off, I/P AC
Derating, Temp. Derating, O/P
Derating
Flash –SMR Comm. Fail
Red
OFF –Normal
ON –High Temp. Shutdown, O/P
Over /Under Volt, AC Low/High Cut-
Off
Flash –SMR Fan Fail