A30050-X6026-X-4-7618-rectifier GR60

Rectifier Modules GR60

48V/30A48V/40A60V/25A

Series 600

Description and Operating Instructions

A30050-X6026-X-4-7618

Rectifier Modules GR60Description and Operating Instructions 48V/30A 48V/40A 60V/25A

P

WARNING

During operation parts of this equipment carry hazardous voltage. Im-proper use can therefore result in severe or fatal injuries or propertydamage.

• The equipment must be maintained and operated by qualified per-sonnel only, e.g. an electrician as defined in EN 50110-1 or IEC60950.

• Before any work is carried out, a check must be made to ensurethat the equipment is isolated and grounded.

• Only spare parts approved by the manufacturer must be used.

!

Copyright (C) Siemens AG 1999 Technical modifications possible.

age 2 of 17 A30050-X6026-X-4-7618

A&D SE PS2Issued by the Automation and Drives GroupTelecommunication Power Supply SystemsMelscher Straße 7, 04299 Leipzig, GermanyTel.: ++49-341-210-5783Fax: ++49-341-210-5799

Technical specifications and features are bindingonly insofar as they are specifically and expresslyagreed upon in a written contact.

Rectifier Modules GR6048V/30A 48V/40A 60V/25A Description and Operating Instructions

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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.


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1 GeneralThe series 60 rectifier modules (known as GR) are used to supply telecommunications equipment withpower. Three types of modules are available: a 48V/30A module with extended input voltage range, amodule 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 a48V/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 connec-ted 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 densitywithout reducing the module’s life. The use of an active line filter to allow the GR to draw sinusoidalcurrent together with an inrush current limiting circuit ensure that the public supply company’s requi-rements as to radiated and conducted EMI are met. This also means that standby gensets can be loa-ded to 100% of nominal current.

The DC output of the GR is short proof. As a result of the high switching frequency, the output voltageis 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 toconstruct power supply systems with ratings between 60 and 400 A, for instance. The cabinets con-tain the central units required for control, signalling and monitoring as well as ventilation.

Figure 1: Block diagram

X2Load

output

X1AC input

Inputfilter

Rectifier

Regulationand

Monitoring

Inrushcurrentlimiting

Boostconverter

DC/DCconverter

Outputfilter

X3Controlinput

X3Signaloutput


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2 Technical Data

2.1 GR60 48V/30A – with Extended Input Voltage Range

2.1.1 Type and Ordering Designation

Type E48/30WBRUG-FG0 GR60

Ordering no. S31043-K1166-X

Block diagram A31043-X1165-X-*-7511

2.1.2 Electrical Data

DC output

Number of battery cells 24 1 25

Nominal output voltage 48V DC 48V DC

Max. output current 30A 30A

Characteristics

Direct supply mode 2.05V/C 51.0V DC 51.0V DC

Float charge mode 2.23V/C 2 53.5V DC 56.0V DC

Equalised charge mode 2.33V/C 56.0V DC 58.5V DC

For characteristic setting range see chapter 4.2

Tolerance 1%

Potentiometer setting range ±3V DC

Current limiting threshold 102%

Short circuit protection electronic

Noise voltage <1.0mV frequency weighted (ITU-T A-filter)

Superimposed AC voltage <15mV RMS

AC input

Nominal input voltage 1/N AC 230V -35%, +20%

Operating voltage range 150…275V AC

Nominal frequency 50/60Hz

Frequency range 47.5…63.0Hz

Displacement factor (cos ϕ) 3 ca. 0.99

Power factor (λ) 3 ca. 0.99

Input current 3 8.0A

Max. input current 12.0A

Max. power input 1.9kVA

Power dissipation 3 176W (measured value)

Efficiency 3 0.91

1 Factory setting2 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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2.2 GR60 48V/30A or 60V/25A – with Switchable Output Voltage


Type E48/30(60/25)WBRUG-FG0 GR60




DC output

Number of battery cells 24 1 25 30

Nominal output voltage 48V DC 48V DC 60V DC

Max. output current 30A 30A 25A

Characteristics

Direct supply mode 2.05V/C 51.0V DC 51.0V DC 62.0V DC

Float charge mode 2.23V/C 2 53.5V DC 56.0V DC 67.0V DC

Equalised Charge mode 2.33V/C 56.0V DC 58.5V DC 70.0V DC


Tolerance 1%






AC input

Nominal input voltage 1/N AC 230V –25%, +15%



Frequency range 47.5…63.0Hz



Input current 3 8.0A (24 cells) 8.0A (30 cells)

Max. input current 12.0A (24 cells) 11.0A (30 cells)

Max. power input 1.9kVA (24 cells) 2.0kVA (30 cells)


Efficiency 3 0.91

1 Factory Setting2 By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased



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2.3 GR60 48V/30A Battery Test Mode






DC Output



Output current preadjusted 2 22.5A 22.5A


Characteristics





Tolerance 1%






AC input




Frequency range 47.5…63Hz



Input current 4 8,0A




Efficiency 4 0.91

1 Factory setting2 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



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2.4 GR60 48V/40A






DC Output




Characteristics





Tolerance 1%






AC input




Frequency range 47.5…63Hz



Input current 3 10.7A



Power dissipation 3 205W

Efficiency 3 0.91

1 Factory setting2 By arrangement with leading battery manufacturers, the previous characteristic for Float Charge Mode has been increased



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2.5 Mechanical Data

Weight 6.8 kg

Dimensions (H x W x D) 240 x 106 x 330 mm

Type of connection

Mains (X1) Power connector as per DIN 49458, CEE 22

DC (X2) High current connector C31043-A1165-B24

Signals (X3) 25 pin SUB-D-cable (1:1/socket-to-socket)

2.6 General Data

Signalling Rectifier ON/OFF (RON)

Mains failure (GRMF)

Rectifier failure (GRF)

Signal outputs Potential-free relay contacts max. 80V DC, 100mA,max. 8W

Signal inputs Temperature-variable voltage Temp. Comp1/2

Switch to Direct Supply Mode (DSM)

Switch to Equalised Charge Mode (ECM)

Rectifier OFF

EMI suppression

Radiated EMI EN 50081-1, acc. to EN 55022 class B

Interference susceptibility EN 50082-2, acc. to industrial environment

Type of enclosure IP20 as per EN 60529 (IEC 529, VDE 0470 part 1)

Safety class I as per IEC 536 (VDE 0106, part 1)

Climatic conditions

S31043-K1160-X (60V/25A) -5…+55°C

S31043-K1166-X (48V/30A) -5…+55°C

S31043-K1169-X (48V/30A) -5…+55°C

S31043-K1168-X (48V/40A) -5…+45°C


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Cooling

Ordering no. Temperature range Type of cooling

S31043-K1160-X

(48V/30A))

-5°C...+30°C

+30°C...+45°C

+30°C...+45°C

+45°C...+55°C

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 35W/K power derating

S31043-K1160-X

(60V/25V))

-5°C...+32°C

+32°C...+45°C

+32°C...+45°C

+45°C...+55°C

Free convection



Forced ventilation with ≥1.0m/s with 23W/K power derating

S31043-K1166-X

(48V30A)

-5°C...+40°C

+40°C...+55°C

+40°C...+55°C

Free convection



S31043-K1169-X

(48V/30A)

-5°C...+40°C

+40°C...+45°C

+40°C...+55°C

Free convection



S31043-K1168-X

(48V/40A) 1-5°C...+40°C

+40°C...+55°C


Forced ventilation with ≥1.0m/s with power derating

Loudness <45dB (A)

Site altitude 2000m above sea level, above 2000m at reduced power

Climatic conditions

Operation ETS 300 019-1-3: 1992 Class 3.1E

Storage Class 1.2

Transport Class 2.2

Safety specifications (certified to:) EN 60950: 1992 +A1 +A2 +A3 +A4: 1997

CE-marking to Low-voltage- and EMC-directive

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

facturer.


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3 Connectors and Controls

3.1 Controls on the Front Panel

Figure 2: Front panel view

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

2.33V/C

S IEM ENS

2.23V/C

2.05V/C

FAULT

M AINS

ONOFF

2.33V/C2.23V/C

X3

(-)(+)

VIOUT

OUT

100m V=30A

Do not pu llunder load!

Before con-nectingswitch onrectifier!

N icht unterLast ziehen!

Vor demSteckenG leichrich tereinschalten!

A1(+)

A2(-)

X2

X1

GLEICHRICHTERM ODUL/RECTIFIER MODU LE

GR 60

48V/30AS31043-K1165-X

Test sockets

Connectors

IO UT test socket foroutput current 100m V=30A

V OUT test socket foroutput voltage

Controls

LED´s2.33V/Z (gn) Characteristic active

2.23V/Z 1(gn) Characteristic active

2.05V/Z (gn) Characteristic active

FAULT (rt) GR faulty

M AINS (gn) M ains present

DC-high current connectorS ignalling connector

M ains connector

ON/OFF On/O ff-switch

2.33V/Z Potentiom eter forsetting 2.33V/C-characteristic

2.23V/Z 1 Potentiom eter forsetting 2.23V/C-characteristic


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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 theconnecting 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 intoKS401(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 signallingunit.

An adapter, ordering no. S31043-Q314-B100, is required for installation of the 30A-rectifiers intoKS401(S) of the series 400.

Pin Function Pin Function13 [not used] 25 [not used]12 [not used] 24 [not used]11 [not used] 23 [without soldering terminal]10 [without soldering terminal] 22 Temp. Comp. 29 [not used] 21 DSM 2.05V/C 1

8 VOC (reference potential) 20 ECM 2.33V/C 1

7 Temp. Comp. 1 19 CSR (analogue current bus)6 Rectifier ON/OFF 18 [not used]5 RON_NO 17 RON_C4 RON_NC 16 GR Failure NO3 GR Failure C 15 GR Failure NC2 Mains Failure NO 14 Mains Failure C1 Mains Failure NC

1 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 batterymanufacturers, the previous characteristic for Float Charge Mode has been increased from2.23V/C to 2.24V/C.)

Figure 3: Top view of X3

14

1

1325


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Explanatory notes on signalling

Module fault (GRF)

X3:3 GR Failure C; common potential-free contact „C“

X3:16 GR Failure NO; connection to X3:3, if no fault is recognized and Uout iswithin limits

X3:15 GR Failure NC; connection to X3:3 in case of fault and/or Uout is outsidelimits and/or GR is completely disconnected from power

Mains fault (GRMF)

X3:14 Mains Failure C; common potential-free contact „C“

X3:2 Mains Failure NO; connection to X3:14, if mains voltage is within limits

X3:1 Mains Failure NC; connection to X3:14 in case of mains fault (mains over-voltage/undervoltage, mains failure) and/or GR is completely disconnectedfrom power

GR-state (position of GR-switch)

X3:17 RON_C; common potential-free contact „C“

X3:4 RON_NC; connection to X3:17, if GR is switched on

X3:5 RON_NO; connection to X3:17 if GR is switched off and mains and/oroutput voltage is present

GR-shutdown

X3:6 Rectifier ON/OFF; connection to X3:8 resulting from external release(switches GR off)

Signal inputs

X3:7/22 Potential-free input for temperature controlled voltage –5V DC...+5V DCcorresponds to an output voltage change (ECM) of –2,5V DC...+2,5V DC

X3:19 Analogue current bus between rectifiers

X3:20 Connection to X3:8 (VOC) switches rectifier to Equalised Charge Mode(ECM)

X3:21 Connection to X3:8 (VOC) switches rectifier to Direct Supply Mode (DSM)


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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.

Figure 4: Rectifier front view with cover removed

1 Function of S1 respectively S2 is enabled, when the other from each switches is in OFF-position.2 In non-switchable modules S3 is without any function, i.e. only 48V-operation is possible.

S1 1 Power reduction switchON = 75% (Idc max = 22.5A at 48V/30A

Idc max = 17.0A at 60V/25A Idc max = 30.0A at 48V/40A)

S2 1 Power reduction switchON = 50% (Idc max = 15.0A at 48V/30A

Idc max = 12.5A at 60V/25A Idc max = 20.0A at 48V/40A)

S3 2 Switch for 48V-/60V-operationOFF = 48V-operation; ON = 60V-operation

S4 Switch for overvoltage monitoringfor 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)

2.05V/C Potentiometer for setting 2.05V/C-caharacteristic

ON OFF


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4 Operating Instructions

4.1 Taking into Service

Note: To avoid unnecessary stress being placed on components and connectors throughcapacitive charges, do not insert DC connector X2 until after voltage is applied to themodule’s 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 breakerin the cabinet is in the OFF position. (The DC-output fuses at the output are not in place. This isonly 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 neces-sary, set the output voltage to the same value as the system voltage using the potentiometers. Atfirst adjust Equalised Charge Mode by using potentiometer 2.33V/C. Then adjust the voltages forFloat Charge Mode by using potentiometer 2.23V/C and then after removing the front cover adjustDirect Supply Mode by using potentiometer 2.05V/C. Changing subsequently the voltage of Equa-lised Charge Mode also results at the same time in a proportional voltage shift for Float ChargeMode 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 va-lid for the SVE630.)

8. Check at the test sockets IOUT to see whether the module delivers its share of the load; otherwisereadjust the output voltage as described in Section 5.

WARNING

During operation parts of this equipment carry hazardous voltage. Im-proper use can therefore result in severe or fatal injuries or propertydamage.

• The equipment must be maintained and operated by qualified per-sonnel only, e.g. an electrician as defined in EN 50110-1 or IEC60950.

• Before any work is carried out, a check must be made to ensure thatthe equipment is isolated and grounded.

• Only spare parts approved by the manufacturer must be used.

!


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4.2 Setting the Characteristics

Characteristic Nominal value / V DC Setting range / V DC

24 cells / 48V-system

Direct Supply Mode 2.05V/C 51.0 44.0 - 54.0

Float Charge Mode 2.23V/C 1 53.5 50.0 - 54.0

Equalised Charge Mode 2.33V/C 56.0 44.0 - 66.02



Float Charge Mode 2.23 V/C 1 56.0 52.5 - 56.5

Equalised Charge Mode 2.33 V/C 58.5 44.0 - 66.02



Float Charge Mode 2.23 V/C 1 67.0 63.0 - 68.0

Equalised Charge Mode 2.33 V/C 70.0 51.0 - 78.03

Changing the voltage of Equalised Charge Mode also results at the same time in a proportional voltageshift for Float Charge Mode and Direct Supply Mode.

Admissible number of battery cells

GR-type 24 cells 25 cells 30 cells

S31043-K1160-X X X X

S31043-K1166-X X X

S31043-K1169-X X X

S31043-K1168-X X X

1 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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4.3 Fault Removal

LED Signal Fault Removal

MAINS LED is off Mains voltage not present oroutside the tolerance.

Check the mains voltage, cabling, miniaturecircuit breakers and protective devices.

FAULT LED is lit GR output voltage (or systemvoltage) is to low (voltage fellbelow the DC-undervoltagedetection limit).E. g. GR or other GR in the sys-tem are overloaded.

Reduce GR load.One GR in the system has not been swit-ched on or has turned off becauseof a defect.Switch GR on or replace defective GR.

GR has turned off due to over-temperature.

GR starts automatically after cooling down.Check the fan; intake air is too hot; removethe cause of overtemperature!

GR has responded to an exter-nal DC overvoltage with main-tained shutdown.

Remove the cause of overvoltage.Reset the GR by means of switch ON-OFF.

GR has responded to an inter-nal overvoltage with maintainedshutdown.GR is internally defective.

Remove DC connector X2, reset the GR bymeans of switch ON-OFF.If, at restart, the GR responds again withmaintained shutdown, it must be replaced.

A30050-X6026-X-4-7618-rectifier GR60

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