Rectifier Modules GR 60 4 8 V / 30 A 48V / 4 0 A 60 V / 25 A Series 600

Description and Operating Instructions

A30050-X6026-X-4-7618

Description and Operating Instructions

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

WARNING

During operation parts of this equipment carry hazardous voltage. Improper use can therefore result in severe or fatal injuries or property damage.

The equipment must be maintained and operated by qualified personnel only, e.g. an electrician as defined in EN 50110-1 or IEC 60950. Before any work is carried out, a check must be made to ensure that the equipment is isolated and grounded. Only spare parts approved by the manufacturer must be used.

Copyright (C) Siemens AG 1999 A&D SE PS2 Issued by the Automation and Drives Group Telecommunication Power Supply Systems Melscher Strae 7, 04299 Leipzig, Germany Tel.: ++49-341-210-5783 Fax: ++49-341-210-5799

Technical modifications possible. Technical specifications and features are binding only insofar as they are specifically and expressly agreed upon in a written contact.

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

Table of Contents
1 General .................................................................................................................. 4 2 Technical Data ...................................................................................................... 5 2.1 GR60 48V/30A with Extended Input Voltage Range.......................................... 5 2.2 GR60 48V/30A or 60V/25A with Switchable Output Voltage............................. 6 2.3 GR60 48V/30A Battery Test Mode....................................................................... 7 2.4 GR60 48V/40A ..................................................................................................... 8 2.5 Mechanical Data................................................................................................... 9 2.6 General Data ........................................................................................................ 9 3 Connectors and Controls................................................................................... 11 3.1 Controls on the Front Panel................................................................................ 11 3.2 Connectors......................................................................................................... 12 3.3 Controls on the Module (behind front panel) ...................................................... 14 4 Operating Instructions....................................................................................... 15 4.1 Taking into Service ............................................................................................. 15 4.2 Setting the Characteristics ................................................................................. 16 4.3 Fault Removal .................................................................................................... 17

This document consists of a total of 17 pages. All pages are issue 4. A30050-X6026-X-4-7618 Page 3 of 17

Description and Operating Instructions

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

1 General
The series 60 rectifier modules (known as GR) are used to supply telecommunications equipment with power. Three types of modules are available: a 48V/30A module with extended input voltage range, a module that is switchable from 48V/30A to 60V/25A and a 48V/30A module with battery test mode. Depending on the site of installation the modules do not require forced ventilation. Furthermore a 48V/40A module is available which requires forced ventilation all time. The units are designed to operate in standby parallel mode, ie, the GR, batteries and loads are connected in parallel in all operating states. It is also possible to operate either module in direct supply mode. The safe electrical isolation between AC and DC circuits allows the GR to be used for supplying TNV (telecommunications network voltage) circuits with power. The switch mode technology and latest state components used in the GR enable high power density without reducing the modules life. The use of an active line filter to allow the GR to draw sinusoidal current together with an inrush current limiting circuit ensure that the public supply companys requirements as to radiated and conducted EMI are met. This also means that standby gensets can be loaded to 100% of nominal current. The DC output of the GR is short proof. As a result of the high switching frequency, the output voltage is very stable, even during step load changes. The GR is designed as a slide-in module, with pluggable connectors X1 (for AC), X2 (for DC) and X3 (for control and signals) on the front panel. With paralleled modules installed in specially for the modules designed cabinets it is possible to construct power supply systems with ratings between 60 and 400 A, for instance. The cabinets contain the central units required for control, signalling and monitoring as well as ventilation.

X1 AC input

Rectifier

Inrush current limiting

Boost converter

DC/DC converter

X2 Load output Output filter

Input filter Regulation and Monitoring

X3 Control input

X3 Signal output

Figure 1: Block diagram

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

2 Technical Data
2.1 GR60 48V/30A with Extended Input Voltage Range
2.1.1 Type and Ordering Designation
Type Ordering no. Block diagram E48/30WBRUG-FG0 GR60 S31043-K1166-X A31043-X1165-X-*-7511

2.1.2 Electrical Data

DC output Number of battery cells Nominal output voltage Max. output current Characteristics Direct supply mode Float charge mode Equalised charge mode Tolerance Potentiometer setting range Current limiting threshold Short circuit protection Noise voltage Superimposed AC voltage AC input Nominal input voltage Operating voltage range Nominal frequency Frequency range Displacement factor (cos ) 3 Power factor () Input current
3 3

24 1 48V DC 30A 2.05V/C 2.23V/C 2.33V/C

2

25 48V DC 30A 51.0V DC 56.0V DC 58.5V DC

51.0V DC 53.5V DC 56.0V DC 1% 3V DC 102% electronic

For characteristic setting range see chapter 4.2

<1.0mV frequency weighted (ITU-T A-filter) <15mV RMS

1/N AC 230V -35%, +20% 150275V AC 50/60Hz 47.563.0Hz ca. 0.99 ca. 0.99 8.0A 12.0A 1.9kVA

Max. input current Max. power input Power dissipation Efficiency

3 3

176W (measured value) 0.91

1 2

Factory setting By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C. 3 Measured under Umains = 230V AC, Uout = 56V DC, Iout = 30A

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Description and Operating Instructions

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

2.2 GR60 48V/30A or 60V/25A with Switchable Output Voltage

2.2.1 Type and Ordering Designation
Type Ordering no. Block diagram E48/30(60/25)WBRUG-FG0 GR60 S31043-K1160-X A31043-X1165-X-*-7511

2.2.2 Electrical Data

DC output Number of battery cells Nominal output voltage Max. output current Characteristics Direct supply mode Float charge mode Equalised Charge mode Tolerance Potentiometer setting range Current limiting threshold Short circuit protection Noise voltage Superimposed AC voltage AC input Nominal input voltage Operating voltage range Nominal frequency Frequency range Displacement factor (cos ) Power factor () Input current
3 3 3

24 1 48V DC 30A 2.05V/C 2.23V/C 2.33V/C

2

25 48V DC 30A 51.0V DC 56.0V DC 58.5V DC

30 60V DC 25A 62.0V DC 67.0V DC 70.0V DC

51.0V DC 53.5V DC 56.0V DC 1% 3V DC 102% electronic

For characteristic setting range see chapter 4.2

<1.0mV frequency weighted (ITU-T A-filter) <15mV RMS

1/N AC 230V 25%, +15% 172264V AC 50/60Hz 47.563.0Hz ca. 0.99 ca. 0.99 8.0A (24 cells) 8.0A (30 cells) 12.0A (24 cells) 1.9kVA (24 cells) 166W (measured value) 0.91 11.0A (30 cells) 2.0kVA (30 cells)

Max. input current Max. power input Power dissipation 3 Efficiency 3

1 2

Factory Setting By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C. 3 Measured under Umains = 230V AC, Uout = 56V DC, Iout = 30A

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A30050-X6026-X-4-7618

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

2.3 GR60 48V/30A Battery Test Mode

2.3.1 Type and Ordering Designation
Type Ordering no. Block diagram E48/30WBRUG-FG0 GR60 S31043-K1169-X A31043-X1165-X-*-7511

2.3.2 Electrical Data

DC Output Number of battery cells Nominal output voltage Output current preadjusted Max. output current Characteristics Direct supply mode Float charge mode Equalised charge mode Tolerance Potentiometer setting range Current limiting threshold Short circuit protection Noise voltage Superimposed AC voltage AC input Nominal input voltage Operating voltage range Nominal frequency Frequency range Displacement factor (cos ) Power factor () Input current
4 4 4 2

24 1 48V DC 22.5A 30A 2.05V/C 2.23V/C 2.33V/C

3

25 48V DC 22.5A 30A 45.0V DC 56.0V DC 58.5V DC

45.0V DC 54.0V DC 56.0V DC 1% 3V DC 102% electronic

For characteristic setting range see chapter 4.2

<1.0mV frequency weighted (ITU-T A-filter) <15mV RMS

1/N AC 230V -35%, +20% 150275V AC 50/60Hz 47.563Hz ca. 0.99 ca. 0.99 8,0A 12.0A 1.9kVA

Max. input current Max. power input Power dissipation Efficiency

4 4

176W (measured value) 0.91

1 2

Factory setting The preadjusted power limitation can be inactivated as described in chapter 3.3. 3 By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C. 4 Measured under Umains = 230V AC, Uout = 56V DC, Iout = 30A

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Description and Operating Instructions

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

2.4 GR60 48V/40A

2.4.1 Type and Ordering Designation
Type Ordering no. Block diagram E48/30WBRUG-FG0 GR60 S31043-K1168-X A31043-X1168-X-*-7511

2.4.2 Electrical Data

DC Output Number of battery cells Nominal output voltage Max. output current Characteristics Direct supply mode Float charge mode Equalised charge mode Tolerance Potentiometer setting range Current limiting threshold Short circuit protection Noise voltage Superimposed AC voltage AC input Nominal input voltage Operating voltage range Nominal frequency Frequency range Displacement factor (cos ) Power factor () Input current
3 3 3

24 1 48V DC 40A 2.05V/C 2.23V/C 2.33V/C

2

25 48V DC 40A 51.0V DC 56.0V DC 58.5V DC

51.0V DC 53.5V DC 56.0V DC 1% 3V DC 102% electronic

For characteristic setting range see chapter 4.2

<1.0mV frequency weighted (ITU-T A-filter) <15mV RMS

1/N AC 230V -25%, +15% 172264V AC 50/60Hz 47.563Hz ca. 0.99 ca. 0.99 10.7A 14.3A 2.56kVA 205W 0.91

Max. input current Max. power input Power dissipation 3 Efficiency

3

1 2

Factory setting By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C. 3 Measured under Umains = 230V AC, Uout = 56V DC, Iout = 40A

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

2.5 Mechanical Data

Weight Dimensions (H x W x D) Type of connection Mains (X1) DC (X2) Signals (X3) Power connector as per DIN 49458, CEE 22 High current connector C31043-A1165-B24 25 pin SUB-D-cable (1:1/socket-to-socket) 6.8 kg 240 x 106 x 330 mm

2.6 General Data

Signalling Rectifier ON/OFF (RON) Mains failure (GRMF) Rectifier failure (GRF) Signal outputs Signal inputs Potential-free relay contacts max. 80V DC, 100mA, max. 8W Temperature-variable voltage Temp. Comp1/2 Switch to Direct Supply Mode (DSM) Switch to Equalised Charge Mode (ECM) Rectifier OFF EMI suppression Radiated EMI Interference susceptibility Type of enclosure Safety class Climatic conditions S31043-K1160-X (60V/25A) S31043-K1166-X (48V/30A) S31043-K1169-X (48V/30A) S31043-K1168-X (48V/40A) -5+55C -5+55C -5+55C -5+45C EN 50081-1, acc. to EN 55022 class B EN 50082-2, acc. to industrial environment IP20 as per EN 60529 (IEC 529, VDE 0470 part 1) I as per IEC 536 (VDE 0106, part 1)

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Description and Operating Instructions Cooling Ordering no. S31043-K1160-X (48V/30A)) Temperature range Type of cooling -5C...+30C +30C...+45C +30C...+45C +45C...+55C S31043-K1160-X (60V/25V)) -5C...+32C +32C...+45C +32C...+45C +45C...+55C S31043-K1166-X (48V30A) S31043-K1169-X (48V/30A) S31043-K1168-X (48V/40A) 1 Loudness Site altitude Climatic conditions Operation Storage Transport Safety specifications (certified to:) CE-marking to -5C...+40C +40C...+55C +40C...+55C -5C...+40C +40C...+45C +40C...+55C -5C...+40C +40C...+55C Free convection

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Free convection with power derating 16W/K Forced ventilation with 1.0m/s without power derating Forced ventilation with 1.0m/s with 35W/K power derating Free convection Free convection with power derating 16W/K Forced ventilation with 1.0m/s without power derating Forced ventilation with 1.0m/s with 23W/K power derating Free convection Free convection with power derating 20W/K Forced ventilation with 0.5m/s without power derating Free convection Free convection with power derating 20W/K Forced ventilation with 0.5m/s without power derating Forced ventilation with 1.0m/s without power derating Forced ventilation with 1.0m/s with power derating <45dB (A) 2000m above sea level, above 2000m at reduced power ETS 300 019-1-3: 1992 Class 3.1E Class 1.2 Class 2.2 EN 60950: 1992 +A1 +A2 +A3 +A4: 1997 Low-voltage- and EMC-directive

Only when mounted in power supply units KSB631 or KS631W. Under other mechanical conditions please contact the manufacturer.

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

3 Connectors and Controls

3.1 Controls on the Front Panel

S IE M E N S
L E D s
2.33 V /Z (gn ) C ha ra c te ris tic a ctiv e 2.3 3V /C 2 .23 V /C 2.05 V /C 2 .23 V /Z 1 (g n) C h ara cte ris tic ac tive 2 .05 V /Z (gn ) C h a ra cte ris tic a ctive F A U LT (rt) M A IN S (gn ) G R fau lty M ain s p re s en t

T e s t s o c k e ts
I O U T te st s oc ke t fo r ou tp u t c urren t 1 0 0m V = 3 0A IO U T VO U T V O U T tes t s o ck et for ou tpu t v olta ge
D o n ot pu ll un de r lo ad ! B e fo re co nne cting sw itch o n re ctifier! N icht un te r La st zie he n! V o r d em S te cken G leichrich ter einsch alte n! 10 0m V =3 0A

FA U LT M A IN S (-)(+) ON OFF 2.3 3V /C 2.2 3V /C

C o n tro ls
O N /O F F O n/O ff-s w itch 2 .3 3V /Z P ote ntio m ete r fo r s etting 2 .33 V /C c ha ra c te ris tic
1

2 .2 3V /Z X2 A 1(+ ) X3

P ote ntio m ete r fo r s etting 2 .23 V /C c ha ra c te ris tic

A 2(-)

C o n n e c to rs
D C -hig h c urren t c o nn ec tor S ig na llin g c o nn ec tor M a ins co n ne cto r X1

G L E IC H R IC H T E R M O D U L /R E C T IF IE R M O D U LE

GR 60 48 V /30 A S 31 04 3 -K 1 16 5-X

Figure 2: Front panel view

By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C.

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Description and Operating Instructions

Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

3.2 Connectors
3.2.1 Connector X1
Connector X1 (power connector to DIN 49458, CEE 22) is used to connect the GR to AC power.

3.2.2 Connector X2
Connector X2, ordering no. C31043-A1165-B24, is used to connect the GR to the DC distributor via the connecting cable provided and a female connector, ordering no. C39316-A98-B190. An adapter, ordering no. S31043-Q314-B100, is required for installation of the 30A-rectifiers into KS401(S) of the series 400.

3.2.3 Connector X3
Connector X3 (25 pin SUB-D connector), is used to connect the GR to the central control and signalling unit. An adapter, ordering no. S31043-Q314-B100, is required for installation of the 30A-rectifiers into KS401(S) of the series 400. 13 25

Pin 13 12 11 10 9 8 7 6 5 4 3 2 1

Function [not used] [not used] [not used] [without soldering terminal] [not used] VOC (reference potential) Temp. Comp. 1 Rectifier ON/OFF RON_NO RON_NC GR Failure C Mains Failure NO Mains Failure NC

Pin 25 24 23 22 21 20 19 18 17 16 15 14

Function [not used] [not used] [without soldering terminal] Temp. Comp. 2 DSM 2.05V/C 1 ECM 2.33V/C 1 CSR (analogue current bus) [not used] RON_C GR Failure NO GR Failure NC Mains Failure C

14 1

Figure 3: Top view of X3

When in contact with pin 8 characteristic is activated. With connector X3 removed GR the GR operates in Float Charge Mode (FCM) 2,23V/C. (By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C.)

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A Explanatory notes on signalling Module fault (GRF) X3:3 X3:16 X3:15 Mains fault (GRMF) X3:14 X3:2 X3:1

Description and Operating Instructions

GR Failure C; common potential-free contact C GR Failure NO; connection to X3:3, if no fault is recognized and Uout is within limits GR Failure NC; connection to X3:3 in case of fault and/or Uout is outside limits and/or GR is completely disconnected from power Mains Failure C; common potential-free contact C Mains Failure NO; connection to X3:14, if mains voltage is within limits Mains Failure NC; connection to X3:14 in case of mains fault (mains overvoltage/undervoltage, mains failure) and/or GR is completely disconnected from power RON_C; common potential-free contact C RON_NC; connection to X3:17, if GR is switched on RON_NO; connection to X3:17 if GR is switched off and mains and/or output voltage is present Rectifier ON/OFF; connection to X3:8 resulting from external release (switches GR off)

GR-state (position of GR-switch) X3:17 X3:4 X3:5 GR-shutdown X3:6

Signal inputs X3:7/22 X3:19 X3:20 X3:21 Potential-free input for temperature controlled voltage 5V DC...+5V DC corresponds to an output voltage change (ECM) of 2,5V DC...+2,5V DC Analogue current bus between rectifiers Connection to X3:8 (VOC) switches rectifier to Equalised Charge Mode (ECM) Connection to X3:8 (VOC) switches rectifier to Direct Supply Mode (DSM)

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Description and Operating Instructions

Rectifier Modules GR60 24V/30A 48V/30A 60V/25A

3.3 Controls on the Module (behind front panel)

The controls for setting the basic values are situated behind the front panel. Undo the ten Torx screws (4mm in diameter) to remove the front panel.

2.05V/C S1 1

Potentiometer for setting 2.05V/C-caharacteristic Power reduction switch ON = 75% (Idc max = 22.5A at 48V/30A Idc max = 17.0A at 60V/25A Idc max = 30.0A at 48V/40A) Power reduction switch ON = 50% (Idc max = 15.0A at 48V/30A Idc max = 12.5A at 60V/25A Idc max = 20.0A at 48V/40A) Switch for 48V-/60V-operation OFF = 48V-operation; ON = 60V-operation Switch for overvoltage monitoring for 48V: ON = B (58.5V fast) OFF = A (62V slow and 67V fast) for 60V: ON = B (69V fast) OFF = A (73V slow and 79V fast)

ON

OFF

S2 1

S3 2 S4

Figure 4: Rectifier front view with cover removed

1 2

Function of S1 respectively S2 is enabled, when the other from each switches is in OFF-position. In non-switchable modules S3 is without any function, i.e. only 48V-operation is possible.

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

4 Operating Instructions

WARNING

During operation parts of this equipment carry hazardous voltage. Improper use can therefore result in severe or fatal injuries or property damage.

The equipment must be maintained and operated by qualified personnel only, e.g. an electrician as defined in EN 50110-1 or IEC 60950. Before any work is carried out, a check must be made to ensure that the equipment is isolated and grounded. Only spare parts approved by the manufacturer must be used.

4.1 Taking into Service

Note:
To avoid unnecessary stress being placed on components and connectors through capacitive charges, do not insert DC connector X2 until after voltage is applied to the modules output.

1. In 60V systems, remove the front panel from the GR and set switch S3 to ON (48V = factory setting). This action is not possible for non-switchable modules. 2. Before sliding the module into its equipment mount, make sure the assigned mains circuit breaker in the cabinet is in the OFF position. (The DC-output fuses at the output are not in place. This is only valid for SVE630.) 3. At first insert mains connector X1 afterwards switch the miniature circuit breaker on. 4. Switch the GR on by means of switch ON-OFF. 5. Measure the GR output voltage across test sockets VOUT (above X2) (see factory setting). If necessary, set the output voltage to the same value as the system voltage using the potentiometers. At first adjust Equalised Charge Mode by using potentiometer 2.33V/C. Then adjust the voltages for Float Charge Mode by using potentiometer 2.23V/C and then after removing the front cover adjust Direct Supply Mode by using potentiometer 2.05V/C. Changing subsequently the voltage of Equalised Charge Mode also results at the same time in a proportional voltage shift for Float Charge Mode and Direct Supply Mode. 6. Insert connector X3 and tighten the screws. 7. Insert connector X2 in one go and tighten the screws. (Insert the DC-output fuses. This is only valid for the SVE630.) 8. Check at the test sockets IOUT to see whether the module delivers its share of the load; otherwise readjust the output voltage as described in Section 5.

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Description and Operating Instructions

Rectifier Modules GR60 24V/30A 48V/30A 60V/25A

4.2 Setting the Characteristics

Characteristic 24 cells / 48V-system Direct Supply Mode Float Charge Mode Equalised Charge Mode 25 cells / 48V-system Direct Supply Mode Float Charge Mode Equalised Charge Mode 30 cells / 60V-system Direct Supply Mode Float Charge Mode Equalised Charge Mode 2.05V/C 2.23 V/C 2.33 V/C
1

Nominal value / V DC 2.05V/C 2.23V/C 2.33V/C 2.05V/C 2.23 V/C 2.33 V/C
1 1

Setting range / V DC 44.0 - 54.0 50.0 - 54.0 44.0 - 66.02 46.0 - 56.0 52.5 - 56.5 44.0 - 66.02 55.0 - 67.0 63.0 - 68.0 51.0 - 78.03

51.0 53.5 56.0 51.0 56.0 58.5 62.0 67.0 70.0

Changing the voltage of Equalised Charge Mode also results at the same time in a proportional voltage shift for Float Charge Mode and Direct Supply Mode. Admissible number of battery cells GR-type S31043-K1160-X S31043-K1166-X S31043-K1169-X S31043-K1168-X 24 cells X X X X 25 cells X X X X 30 cells X

By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased from 2.23V/C to 2.24V/C. 2 Above 62V DC the maximum output current is 24A. Above 24A the rectifier switches itself automatically off. 3 Above 73V DC the maximum output current is 20A. Above 20A the rectifier switches itself automatically off.

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Rectifier Modules GR60 48V/30A 48V/40A 60V/25A

Description and Operating Instructions

4.3 Fault Removal

LED MAINS FAULT Signal LED is off LED is lit Fault Mains voltage not present or outside the tolerance. GR output voltage (or system voltage) is to low (voltage fell below the DC-undervoltage detection limit). E. g. GR or other GR in the system are overloaded. GR has turned off due to overtemperature. GR has responded to an external DC overvoltage with maintained shutdown. GR has responded to an internal overvoltage with maintained shutdown. GR is internally defective. Removal Check the mains voltage, cabling, miniature circuit breakers and protective devices. Reduce GR load. One GR in the system has not been switched on or has turned off because of a defect. Switch GR on or replace defective GR. GR starts automatically after cooling down. Check the fan; intake air is too hot; remove the cause of overtemperature! Remove the cause of overvoltage. Reset the GR by means of switch ON-OFF. Remove DC connector X2, reset the GR by means of switch ON-OFF. If, at restart, the GR responds again with maintained shutdown, it must be replaced.

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