ECM1500 Outdoor Cabinet
User Manual
Version
Revision date
BOM
V1.3
December 3, 2009
31012154
Emerson Network Power provides customers with technical support. Users may contact the nearest
Emerson local sales office or service center.
Copyright © 2009 by Emerson Network Power Co., Ltd.
All rights reserved. The contents in this document are subject to change without notice.
Safety Precautions
To reduce the chance of accident, please read the safety precautions very carefully before operation. The
"Caution, Note, Warning, Danger" in this book and on the product do not represent all the safety points to be
observed, and are only supplement to various safety points. Therefore, the installation and operation personnel
must receive strict training and master the correct operations and all the safety points before operation.
When operating Emerson products, the operation personnel must observe the safety rules in the industry, the
general safety points and special safety instructions specified in this book.
If you purchase an outdoor power supply without SPD, you should install an SPD at the front-end of AC input,
otherwise, the power supply system will generate over-voltage.
Electrical Safety
I. Hazardous voltage
Danger
Some components of the outdoor cabinet system carry hazardous voltage in operation. Direct contact or indirect contact
through moist objects with these components will result in fatal injury.
Observe safety rules in the industry when installing the power supply system. The installation personnel must be
licensed to operate high voltage and AC power.
In operation, the installation personnel are not allowed to wear conductive objects, such as watches, bracelets,
bangles and rings.
When you spot the cabinet with water or moisture, turn off the power immediately. In moist environment,
precautions must be taken to keep moisture out of the power supply system.
"Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during
installation.
Danger
High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance
with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high
voltage operations.
Danger
To avoid electric shock hazard for outdoor environment and outdoor equipment, the non-professionals are prohibited to
operate or maintain the outdoor power supply system.
II. Tools
Warning
In high voltage and AC operation, specialized tools must be used.
III. Thunderstorm
Danger
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 in time to avoid damage by lightning strikes.
IV. ESD
Note
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.
V. Short circuit
Danger
During operation, never short the positive and negative poles of the DC distribution unit of the outdoor cabinet system, or
the non-earth pole of the outdoor cabinet system and the earth. The power supply system is a constant-voltage DC power
device, short circuit will result in equipment burning and endanger human safety.
VI. Reverse connection
Warning
Never reverse-connect the AC input live line and neutral line, or else the system will be damaged.
Check the polarity of the cable and connection terminal when performing DC live operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation.
Use insulated tools.
In live operation, keep the arm, wrist and hand tense, so that when the tool in operation slips, the movement of
the human body and tool is reduced to a minimum.
Battery
Danger
Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery
connection method.
Warning
If customers prepare batteries themselves, the battery installation and maintenance should meet relevant safety standards.
Non-standard operation on the battery will cause danger. 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:
1. Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.
2. Use specialized insulated tools.
3. Use eye protection device, and take preventive measures.
4. Wear rubber gloves and apron to guard against electrolyte overflow.
5. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the
battery upside down or slanted.
Connection And Testing Of The Outdoor Cabinet
Before installing subrack power supply in the cabinet, you should finish the connection and testing of the
subrack power supply according to the corresponding subrack power supply user manual and then testing the
outdoor cabinet.
Others
I. Sharp object
Warning
When moving equipment by hand, wear protective gloves to avoid injury by sharp object.
II. Power cable
Note
Noti c
Please verify the cable labels before connection.
III. Signal cables
Note
Noti c
The signal cables should be routed at least 150mm away from power cables.
Contents
Chapter 1 Overview ............................................................................................................................................................ 1
1.1 Model Description ................................................................................................................................................. 1
1.2 Composition & Configuration ................................................................................................................................ 1
1.3 Operating Theory .................................................................................................................................................. 4
1.4 Features................................................................................................................................................................ 5
Chapter 2 Installation .......................................................................................................................................................... 6
2.1 Safety Regulations................................................................................................................................................ 6
2.2 Installation Preparation ......................................................................................................................................... 6
2.3 Mechanical Installation.......................................................................................................................................... 7
2.3.1 Installing The Outdoor Cabinet .................................................................................................................. 7
2.3.2 Opening And Closing Cabinet Door........................................................................................................... 8
2.4 Electrical Installation ............................................................................................................................................. 9
2.4.1 Connecting Power Cables ......................................................................................................................... 9
2.4.2 Connecting Signal Cables ....................................................................................................................... 11
2.4.3 Sealing The Entry Holes .......................................................................................................................... 11
2.5 Battery Installation .............................................................................................................................................. 11
2.6 Installation Check................................................................................................................................................ 12
Chapter 3 Testing.............................................................................................................................................................. 13
3.1 Startup ................................................................................................................................................................ 13
3.2 Alarm Check And System Operation Status Check ............................................................................................ 13
3.3 Final Steps .......................................................................................................................................................... 13
Chapter 4 Maintenance ..................................................................................................................................................... 14
4.1 Routine Maintenance .......................................................................................................................................... 14
4.2 Replacing Parts Of Forced Ventilation Model Outdoor Cabinet .......................................................................... 15
4.2.1 Replacing Heat Control Board ................................................................................................................. 15
4.2.2 Replacing Fans........................................................................................................................................ 16
4.2.3 Replacing Door Status Sensor ................................................................................................................ 18
4.3 Replacing Parts Of Heat Exchanger Model Outdoor Cabinet ............................................................................. 18
4.3.1 Replacing Environment Climate Control Unit........................................................................................... 18
4.3.2 Replacing Fans........................................................................................................................................ 20
4.3.3 Replacing Heater ..................................................................................................................................... 21
4.3.4 Replacing Door Status Sensor ................................................................................................................ 21
4.4 Replaciing Parts Of Air-condition Model Outdoor Cabinet .................................................................................. 22
4.4.1 Replacing air-conditioner ......................................................................................................................... 22
4.4.2 Replacing Emergent Ventilation Unit ....................................................................................................... 22
4.4.3 Replacing Door Status Sensor ................................................................................................................ 22
Appendix 1 Technical And Engineering Parameters ......................................................................................................... 23
Appendix 2 Wiring Diagram............................................................................................................................................... 24
Appendix 3 Schematic Diagram ........................................................................................................................................ 27
Chapter 1 Overview
1
Chapter 1 Overview
ECM1500 outdoor cabinet (outdoor cabinet for short) is a power supply system used outdoors. It provides outdoor
protection and operation environment. It contains thermal control units and AC power distribution units. The cabinet
can accommodate different Emerson subrack power supplies according to your requirement so as to form power
supply systems with different capacities.
This chapter introduces the model description, composition & configuration, operating theory and features of the
outdoor cabinet.
1.1 Model Description
The outdoor cabinet is available in three models, configured with different models of thermal control unit (forced
ventilation, heat exchanger and air-condition). Taking the forced ventilation model for example, the model description
of the outdoor cabinet is given in Figure 1-1.
EC
M
1500
F 1 - 48
300
Internal power capacity: 300A, 150A, 120A
Internal power voltage:48Vdc
Version No.
Thermal control method: F (forced ventilation), H (heat exchanger), A (air-condition)
Maximum heat productivity in cabinet:1500W
Application: mobile network integrated cabinet
Emerson outdoor cabinet
Figure 1-1
Model description
1.2 Composition & Configuration
Composition
The outdoor cabinet is composed of thermal control units, power distribution units and related structures. Three
models of thermal control units are available: forced ventilation, heat exchanger and air-condition.
Configuration
1. The configuration of the forced ventilation model outdoor cabinet is given in Table 1-1.
Table 1-1
Configuration list of the forced ventilation model outdoor cabinet
Component
Thermal control
unit
Power
distribution unit
Configuration
Fan
4 pieces
Heat control board
1 piece
Heat control extension
board
1 piece
AC power distribution
1 route 10A single-phase AC socket; one route 25A single-phase AC input MCB
DC power distribution
DC input terminals
Power and reserved space
Sharing space: 15U, you can adjust space according to requirement
Door status sensor
1 piece
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Chapter 1 Overview
The structure of the forced ventilation model outdoor cabinet is shown in Figure 1-2.
Figure 1-2
Structure of the forced ventilation model outdoor cabinet
2. The configuration of the heat exchanger model outdoor cabinet is given in Table 1-2.
Table 1-2
Configuration list of the heat exchanger model outdoor cabinet
Component
Thermal control
unit
Power
distribution unit
Configuration
Fan
4 pieces
Environment climate
control unit
1 piece
AC power distribution
1 route 10A single-phase AC socket; one route 25A single-phase AC input MCB
DC power distribution
DC input terminals
Power and reserved space
Sharing space: 15U, you can adjust space according to requirement
Door status sensor
1 piece
The structure of the heat exchanger model outdoor cabinet is shown in Figure 1-3.
Figure 1-3
Heat exchanger model outdoor cabinet
ECM1500 Outdoor Cabinet
User Manual
Chapter 1 Overview
The configuration of the air-condition model outdoor cabinet is given in Table 1-3.
Table 1-3
Configuration list of the air-condition model outdoor cabinet
Component
Thermal control
unit
Power
distribution unit
Configuration
Outdoor air-condition
1 piece
Emergent ventilation unit
1 set
AC power distribution
1 route 10A single-phase AC socket; 1 route 25A single-phase AC input MCB
DC power distribution
DC input terminals
Power and reserved space
Sharing space: 15U, you can adjust space according to requirement
Door status sensor
1 piece
The structure of the air-condition model outdoor cabinet is shown in Figure 1-4.
Figure 1-4
Air-condition model outdoor cabinet
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4
Chapter 1 Overview
1.3 Operating Theory
Heat dissipation theory for forced ventilation model outdoor cabinet
The cold air is sucked in through the front door air filter at the lower part of the outdoor cabinet. It passes through the
battery compartment, user equipment and subrack power supply in turn. Finally, the hot air is discharged by the fans
at the top of the outdoor cabinet. In this way, the equipment and power modules in the cabinet are cooled, as shown
in Figure 1-5.
Heat dissipation fan
Air outlet
Subrack power supply
Sharing space
Air inlet
Figure 1-5
Heat dissipation access for forced ventilation model outdoor cabinet
Heat dissipation theory for heat exchanger model outdoor cabinet
A heat exchanger is fitted on the door of the outdoor cabinet. It can exchange the heat between the cold air outside
the cabinet and the hot air inside the cabinet. In this way, the equipment and power modules in the cabinet are cooled,
as shown in Figure 1-6.
Internal circulation air
inlet of heat exchanger
Internal circulation air
outlet of heat exchanger
Figure 1-6
Heat dissipation theory for heat exchanger model outdoor cabinet
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User Manual
Chapter 1 Overview
5
Heat dissipation theory for air-condition model outdoor cabinet
An outdoor air-conditioner is fitted on the door of the outdoor cabinet to cool the cabinet. It is in this that the
equipment and power modules in the cabinet are cooled. In case of air-conditioner fault or AC mains failure, the
emergent ventilation units automatically startup to dissipate heat emergently, as shown in Figure 1-7.
Top emergent ventilation fan
Return air inlet of air-condition
Outdoor air-condition
Air outlet of air-condition
Figure 1-7
Heat dissipation theory for air-condition model outdoor cabinet
1.4 Features
z Variable subrack power supply: The outdoor cabinet can accommodate standard 19” and 23” subrack power
supply.
z Variable space: The power space, reserved space and the battery compartment space are interchangeable. You
can adjust the space according to the actual requirement.
z Thermal control unit: Three different models are available for your selection according to the local, environment
and requirement.
z Safety guideline: The equipment compartment satisfies IP*5 waterproof requirement and IP5* dustproof
requirement.
z Environment pollution level within the outdoor cabinets is 2.
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Chapter 2 Installation
Chapter 2 Installation
This chapter introduces installation and cable connection. Strictly follow the instructions provided in this chapter to
carry out the installation and cable connection.
2.1 Safety Regulations
Certain components in this power supply system have hazardous voltage and current. To ensure personnel safety,
always follow the instructions below:
1. Only the trained personnel with adequate knowledge of the outdoor cabinet shall carry out the installation. The
Safety Precautions listed before the Contents of this manual and local safety rules in force shall be adhered to during
installation.
2. All external circuits below -48V connected to the power supply system must comply with the SELV requirement
defined in IEC 60950.
3. To avoid electric shock, do not conduct any operation or maintenance within the outdoor cabinet under
thunderstorm or humid weather.
4. Make sure that the outdoor cabinet is powered off before any operations can be carried out within the cabinet.
5. The power cables should be routed and protected properly, so that the cables are kept away from the operation
and maintenance personnel.
2.2 Installation Preparation
Unpacking inspection
The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be done
by representatives of both the user and Emerson Network Power Co., Ltd.
To inspect the equipment, you should open the packing case, take out the packing list and check against the packing
list that the equipment is correct and complete. Make sure that the equipment is delivered intact.
Preparing tools
The installation tools are given in Table 2-1. The tools must be insulated and ESD-proof processed before they are
used.
Table 2-1
Tool
Installation tools
Specification
Tool
Combination wrench (hatch,
club)
Adjustable wrench
Electrician diagonal pliers
Electrician sharp nose pliers
Wrench set (10#, 13#, 16#,
18#, 21#)
200mm
150mm
150mm
Steel tape
5m
Electric knife
Normal type
Digital multimeter
Gradienter
Blinkers
Normal type
To prevent splash
Impact electric drill
Power socket
Fireproof mud
Configured in the accessories
Safety shoes
Specification
Box wrench
16mm
Cross screwdriver
Slotted screwdriver
Wire cutters
Hydraulic-pressure compaction
pincher
100mm, 200mm
100mm, 200mm
Maximum 300mm2
Hammer
ECM1500 Outdoor Cabinet
User Manual
Maximum 300mm2
Three and a half bit digital
display
With Φ14 impact aiguille
With 5m cable
To prevent puncture and for
insulation
Chapter 2 Installation
7
2.3 Mechanical Installation
2.3.1 Installing The Outdoor Cabinet
The outdoor cabinet must be installed directly onto the cement floor.
Step 1: Mark the specific installation position of the outdoor cabinet
It is recommended to determine the installation position in compliance with the clearance requirements given in Table
2-2.
Table 2-2
Clearances
Installation clearances
Front
Top
Left
Right
Back
750mm
700mm
100mm
100mm
100mm
Step 2: Install expansion bolts
480
657
For forced ventilation model outdoor cabinet, by referring to Figure 2-1; for heat exchanger model and air-condition
model outdoor cabinet, by referring to Figure 2-2, it is recommended to enlarge the installation size of the cabinet
base because of the existence of the anti-toppling device (see Figure 2-3), determine the exact central points of the
installation holes on the floor, and mark them with a pencil or oil pen. Use the electric drill (aiguille: Φ14) to dig holes
(depth: 70mm) at the marked points. Clean the drilled holes off dust. Put the expansion bolts into the holes and knock
them with a hammer till they are totally in.
88.5
650
700
Figure 2-1
Installation size 1 of the cabinet base (unit: mm)
1100
480±0.5
130
900
650±0.5
Expansion bolt
Front door
Figure 2-2
Installation size 2 of the cabinet base (unit: mm)
Step 3: Fix the cabinet
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Chapter 2 Installation
Move the cabinet to the installation position. Make the installation holes on the base coincide with those dug on the
floor. Screw the M10 anchor bolt down into the expansion pipe in the floor.
Pay attention to move the cabinet from the pallet in factory and install the anti-toppling device, as shown in Figure
2-3.
After installation, the cabinet should stand firmly no matter how it is shaken, then you can remove the anti-toppling
device from the inside of the cabinet.
Anti-toppling device
Figure 2-3
Anti-toppling device
2.3.2 Opening And Closing Cabinet Door
You need to open and close the cabinet door during the cabinet installation, operation and maintenance. Procedures
for opening and closing the cabinet door are as follows:
Step 1: Insert the key into the keyhole, and turn the key clockwise until the door handle pops out.
Step 2: Turn the handle counter-clockwise 90°, as shown in Figure 2-4. Pull the handle until the door opens.
90°
Figure 2-4
Turning the handle
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Chapter 2 Installation
9
Step 3: Adjust the door stay bar to the position shown in Figure 2-5 to prevent the door from closing automatically.
Door stay bar
Figure 2-5
Door stay bar
Step 4: Restore the door stay bar to its original position and close the door. Finally, turn the handle to its original
position and press it down until a click is heard.
2.4 Electrical Installation
All the cables must be put through metal pipes for protection. The metal pipe should be connected to the PE bar
reliably. Plastic coated metal hoses are recommended.
Earth cable and AC input cables enter the cabinet through the right side of the cabinet bottom. Signal cables, user
equipment cables and DC cables enter the cabinet through the left side of the cabinet bottom.
2.4.1 Connecting Power Cables
Connecting earth cable
Step 1: Cut the cable bushings covering the cabling holes (shown in Figure 2-6) on the bottom plate of the cabinet
with an electrician knife.
Step 2: Lead the earth cable into the cabinet through a cabling hole, and route it along the cable holders, as shown in
Figure 2-6.
Step 3: Connect one end of the earth cable to the earth terminal in the cabinet, and solder the other end to the earth
metal base reliably.
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Chapter 2 Installation
Step 4: Use nylon cable ties to tie the earth cable to the cable holders.
AC input MCB
Earth terminal
Cable holder
Cabling hole
Figure 2-6
Positions of earth terminal and cabling hole
Connecting AC input cables
If the outdoor cabinet has been installed Emerson matched subrack before delivery, the AC cable connection
between subrack and cabinet should have been done by Emerson. You only need to connect the AC input cables
according to the subrack user manual.
If the outdoor cabinet has not been installed Emerson matched subrack before delivery, you should connect 220V AC
power to the AC input MCB on the right side of the cabinet (shown in Figure 2-6), so as to ensure the cabinet
operation.
Connecting DC cables
If the outdoor cabinet has been installed Emerson matched subrack before delivery, the DC cable connection
between subrack and cabinet should have been done by Emerson. You only need to connect load cables according
to the subrack user manual.
If the outdoor cabinet has not been installed Emerson matched subrack before delivery, you should connect 48V DC
power to DC input terminal on the left side of the cabinet (shown in Figure 2-7), so as to ensure the cabinet operation.
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Chapter 2 Installation
11
2.4.2 Connecting Signal Cables
The cabinet provides four pairs of dry contacts for the user.
All the dry contacts must be connected to the signal output terminal block, which is fixed on the left side of the cabinet.
The position of the signal output terminal block is shown in Figure 2-7.
DC input terminal
Signal output terminal block
Figure 2-7
Position of signal output terminal block
Peel the signal cables and insert their ends into the corresponding terminals, then fasten the connection by tightening
the screws on the terminals.
The functions of the dry contact are given in Table 2-3.
Table 2-3
Port No.
1, 2
Dry contact functions
Definition
Remark
Over temperature alarm
Default value
3, 4
Thermal control unit failure
Default value
5, 6
Door alarm
Default value
7, 8
Spare
Configurable
2.4.3 Sealing The Entry Holes
After cable connection, use fireproof mud to seal the cabling holes (shown in Figure 2-6).
2.5 Battery Installation
The battery compartment can accommodate a battery string of capacity not higher than 50Ah. Batteries are classified
into front-terminal battery and general battery.
Note
1. The batteries may carry dangerous current. Before connecting the battery cables, make sure all the battery input MCBs are off.
2. Make sure that the battery cable polarities are correct. Otherwise, both the battery and the cabinet will be damaged!
3. Insulate the installation tools. Be careful not to damage the plastic battery case or the battery terminals during installation.
Check before installation
1. Check that the battery shells are in good condition.
2. Check that the polarities of the terminals are in accordance with the polarity marks on the battery shell.
3. Check that the terminal screws are fastened.
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Chapter 2 Installation
Installation procedures
Note
1. When installing two battery strings or more, install the lower battery string first. While removing them, remove the upper
battery string first.
2. This chapter is applicable to Emerson subrack and battery cables. It is a reference when you configure subrack and battery
cables for yourself.
Step 1: Open the battery MCBs and AC input MCBs.
Step 2: Place the batteries one by one in the battery compartment from right to left, with distance between adjacent
batteries at least 10mm.
Step 3: Remove the battery terminal covers, and connect the plate electrodes between the batteries in turn. Note that
the mid-voltage sampling cable should be connected to the plate electrode between the second and the third
batteries.
Step 4: Connect the positive battery cables (red) in the battery compartment to the battery positive terminals. Connect
the negative battery cables (black) in the battery compartment to the battery negative terminals. Attach the acid and
alkali integration box (battery accessory) to the internal side of the right panel of the cabinet.
Step 5: After installing the battery strings, use the 3M double-side adhesive tape pasted on the battery temperature
sensor to paste the sensor onto the center of the upper-layer battery string.
Step 6: Measure the battery string voltage. If the voltage value is correct, replace the battery terminal covers.
2.6 Installation Check
After installation, check the installation against the list given in Table 2-4.
Table 2-4
Check item
No.
1
2
3
Cabinet
installation
4
5
6
7
1
2
Electrical
connection
3
4
5
6
Installation check list
Description
Check that the cabinet is level, upright and steadily fixed
Check that all bolts are tightened, especially those in electrical connections, that all bolts have plain
washers and spring washers, and that the washers are not reversed
Check that there are no irrelevant materials in the cabinet, and clear them away if any
Check that the cabinet paint is intact. If there are scratches, paint them immediately with antirust paint to
prevent corrosion
Clean up the cabinet
Check that the door can move freely, the locks are in good condition and the door stay bar is fixed
Check that the dummy plates are installed at the reserved space where no customer device is installed.
Check that the burglarproof components (if configured) and battery baffles (if configured) are installed
Verify the specifications of all MCBs and cables
Check the correctness of bus bar connections, input and output cable connection, and connection
between the power system and the system grounding
Check the correctness of the batteries number and connection, and battery strings polarities
Make sure all the cable connections are firm and reliable
Check the connection point, line sequence and polarities of DC cables. Check the connection polarities of
the batteries. Check that the connection points are fixed and the cable connections are correct and
reliable
Check that the cables are tidy, and the cable binding is normative
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Chapter 3 Testing
13
Chapter 3 Testing
This chapter introduces the testing after installation. The corresponding safety rules shall be adhered to in the testing.
This testing should be done after the subracks in the cabinet are tested.
3.1 Startup
Note
Before the test, inform the chief manufacturer representative. Only the trained electrical engineer can maintain and operate this
equipment. In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles
and rings.
During operation, parts of this equipment carry hazardous voltage. Misoperation can result in severe or fatal injuries
and property damage. Before the test, check the equipment to ensure the proper earthing.
Make sure that the AC input and DC input are normal.
Forced ventilation check
After power-on, the heat control board enters self testing and the fans accelerate to full speed gradually. After a few
minutes, the fans stop. If the environmental temperature is about 35°C, the fans will operate at low speed.
Heat exchanger check
After power-on, the simple control unit enters self testing and the fans accelerate to full speed gradually. After a few
minutes, the fans stop. If the environmental temperature is about 35°C, the internal fans will operate at low speed and
the external fans will stop.
Air-condition check
After power-on, the air-condition starts to operate. If the environmental temperature is about 35°C, the internal fans of
the air-condition will operate at low speed and the compressors of the external fans will stop.
3.2 Alarm Check And System Operation Status Check
Alarm check
Disconnect the thermal control units, so as to check that if the thermal control units can trigger thermal control unit
alarm.
System operation status check
There should be no alarms during normal system operation.
3.3 Final Steps
Disconnect all test equipment from the outdoor cabinet and make sure that materials irrelevant to the
equipment have been all removed.
Restore the outdoor cabinet to its original condition and close the cabinet door.
Check and handover the equipment that the user has purchased.
Note down all the operations taken, including time of the operation and name of the operator.
OK
Comments
If any defect is found in this equipment, inform the personnel responsible for the contract.
If repairing is needed, please fill in the FAILURE REPORT and send the report together with the faulty unit to the
repairing center for fault analysis.
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Chapter 4 Maintenance
Chapter 4 Maintenance
This chapter describes the routine maintenance, alarm and fault handling, and part replacement of the power supply
system.
Note
1. The maintenance must be conducted in compliance with relevant safety rules.
2. Only the trained personnel with adequate knowledge about the outdoor cabinet shall work on the internal parts of the system.
4.1 Routine Maintenance
Inspect the power supply system periodically and shoot the troubles in time if any. The routine maintenance items are
given in Table 4-1.
Table 4-1
Item
Thermal control
unit
Paint and
galvanization layer
on the cabinet
Front door air filter
(for forced
ventilation model
and air-condition
model)
Period
Routine maintenance list
Inspection method
Guide
Check alarm and operation states. If the thermal control units
run abnormally, refer this chapter to replace relevant
components
Once half a year
Visual inspection
Once half a year
Visual inspection
If there is any paint peeling or scratches, mend the painting
immediately
Visual inspection
If dust accumulated on the front door air filter, loosen the fixing
screws of the air filter cover of the front door (shown in Figure
4-1). Then take off the air filter cover and brush off the dust. If
the air filter is damaged, replace it. Finally, replace the air filter
cover
Once half a year
Air filter
Fixing screw
of air filter
Air filter
Fixing screw
of air filter
Air-condition model outdoor cabinet
Forced ventilation model outdoor cabinet
Figure 4-1
Air filter
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Chapter 4 Maintenance
4.2 Replacing Parts Of Forced Ventilation Model Outdoor Cabinet
4.2.1 Replacing Heat Control Board
Replace the heat control board using the following procedures:
Step 1: Loosen the two fixing screws to remove the cover (shown in Figure 4-2), and then you can see the heat
control board. The appearance of the heat control board is shown in Figure 4-3.
Fixing screw of cover
Cover
Figure 4-2
Cover position
SW2
SW1
Alarm indicator
Figure 4-3
Appearance of the heat control board
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Chapter 4 Maintenance
Step 2: Disconnect J11, J12 and J2 terminals (shown in Figure 4-4) in sequence, and then disconnect the rest
connection terminals on the heat control board.
H1
J7
J6
SW1 SW2
ON
J2
J10
J12
J11
H2
J3
H4
H3
B
Figure 4-4
Heat control board terminals layout
Step 3: Loosen the fixing screws on the heat control board. Replace the heat control board with a new one.
Step 4: Reverse connection sequence in step 2 to connect terminals, so as to check that the indicators show correctly
when fan fails. In normal condition, no alarm indicators will be on.
Step 5: Set the SW2 switch according to Table 4-2.
Table 4-2
Name
Label on the
corresponding cover
Bit “1”
Bit “2”
Switch
Setting description of the SW2
Silk print on the
corresponding fan control
board
SW2 (shown in Figure 4-3)
Setting description
Put the switch to the ‘ON’ position (default), see Figure 4-3
Put the switch to the ‘OFF’ position (default), see Figure 4-3
Step 6: Press the SW1 self-test button (shown in Figure 4-3) to ensure that the fan can start normally.
Step 7: Replace the cover of the heat control board.
4.2.2 Replacing Fans
Fan alarm circuit
The fan-cooling unit of the outdoor cabinet is mainly composed of 2 ~ 4 axial flow fans. The fan alarm circuit is shown
in Figure 4-5, where the blue line is the alarm line.
VCC
(Red)
(Blue)
MOTOR
DRIVER IC
R
FG SIGNAL
VCE
(Black)
GROUND
(Yellow)
Figure 4-5
VFG
Ic
Illustration of the fan alarm circuit
ECM1500 Outdoor Cabinet
User Manual
Chapter 4 Maintenance
17
Fan alarm indicators
The position of the alarm indicators is shown in Figure 4-3.
The alarm indicators 1 ~ 4 on the heat control board correspond to fans 1 ~ 4 (alarm indicator 5 is the temperature
sensor alarm indicator).
Fan replacing procedures
If the fan is faulty, the corresponding indicator will be on. Follow the following procedures to replace the fan.
Step 1: Make sure that the fan-control terminals (J11 and J12 are hot pluggable) on the heat control board are
inserted firmly. The fan-control terminals are shown in Figure 4-4.
Step 2: Ensure that Bit 2 of SW2 switch is put to the “OFF” position.
Step 3: Press the SW1 self-test button (shown in Figure 4-3). If the fans do not work, make sure that the fan cables
are perfect.
Step 4: Loosen the fixing screws at the cabinet top cover to open the top cover. (Opening the top cover, pull it forward
and then lift up its front not more than 30°. Otherwise the top cover will be fallen.)
Step 5: Disconnect the fan power terminals at the top of the cabinet. Use a multimeter to measure the voltage
between the positive power cable and the negative power cable. Check if the voltage is close to the DC output
voltage (54.0V).
If the fan power voltage is normal, the fans are damaged. Carry out the next step.
Step 6: Loosen the fixing screws of the fans and replace the fans, as shown in Figure 4-6.
Fan
Figure 4-6
Fan position
Step 7: Reconnect the fan power terminals, and press SW1 self-test button (shown in Figure 4-3) to ensure that the
fan can startup normally.
Step 8: Replace the cabinet top cover.
ECM1500 Outdoor Cabinet
User Manual
18
Chapter 4 Maintenance
4.2.3 Replacing Door Status Sensor
There is a door status sensor installed in the cabinet for detecting the close or open status of the cabinet door. The
alarm will be eliminated only when the cabinet door is closed.
The door status sensor requires no particular maintenance; just replace it when it is damaged. If the door is closed,
while the door status sensor alarm occurs, the sensor must have been damaged. The position of the sensor is shown
in Figure 4-7.
Remove the sensor top cover and then the two screws. Replace the old sensor with a new one and finally fix the
sensor and the signal cables with the screws.
Door status sensor
Figure 4-7
Position of the door status sensor
4.3 Replacing Parts Of Heat Exchanger Model Outdoor Cabinet
4.3.1 Replacing Environment Climate Control Unit
Appearance and terminal layout
The appearance of the environment climate control unit is shown in Figure 4-8, and the terminal layout is shown in
Figure 4-9.
DIP switch
Earth nut
Figure 4-8
Environment climate control unit
ECM1500 Outdoor Cabinet
User Manual
Chapter 4 Maintenance
J3
FAN2
J8
J14
J4
FAN3
TEMP.
FAN4
J12
AC_OFF
ALMOUT
J5
SW101
J10
LED_FAULT
LED_ALM
LED_RUN
J6
RS232
J11
J9
SW100
CAN
J13
J7
J15
Figure 4-9
TEMP.&HUM.
J2
WATER
FAN1
POWER DOOR SMOKE INFRARED
J1
19
Terminal layout of the environment climate control unit
DIP switch description
DIP switch function description and setting method:
1. Bit 1 ~ 4 are used to set addresses of the environment climate control unit. OFF: 0, ON: 1. Default address: 16.
The setting method of the environment climate control unit (ECCU for short) is given in Table 4-3.
Table 4-3
Bit 4
0
0
0
…
1
Bit 3
0
0
0
…
1
Setting method of ECCU address
Bit 21
0
0
1
…
1
Bit 1
0
1
0
…
1
Address
16
1
2
…
15
Bit 1 ~ Bit 4 have been set in factory. You can change the settings according to your communication requirement.
2. The function description and setting method of Bit 5 ~ Bit 8 are given in Table 4-4.
Table 4-4
Bit No.
Function sescription and setting method of Bit 5 ~ 8
Function
Setting method
OFF: heat exchanger model
5
Choose cabinet model
ON: forced ventilation
OFF: normal when open; alarm when closed
6
Choose dry contact alarm mode
ON: normal when closed; alarm when open
OFF: serial port termperature & humidity sensor
7*
Choose sensor
ON: temperature sensor
Choose whether stopping fans
OFF: No
8
when AC mains fails
ON: Yes
Note*: When Bit 7 is placed to ON position, ECCU has no humidity acquisition function
Default value
OFF
ON
ON
OFF
Replacing procedures of the ECCU
Step 1: Loosen the two fixing screws to remove the cover, and then you can see the ECCU. The position of cover is
shown in Figure 4-10.
ECM1500 Outdoor Cabinet
User Manual
20
Chapter 4 Maintenance
Fixing screw of cover
Cover
Figure 4-10
Cover position
Step 2: Disconnect J15 terminal (shown in Figure 4-9), and then disconnect the rest connection terminals on the
ECCU.
Step 3: Loosen the fixing screws on the ECCU. Replace the ECCU with a new one.
Step 4: Reverse connection sequence in step 2 to connect terminals, so as to check that the LED_FAULT (shown in
Figure 4-9) indicator show correctly. Under normal instance, the LED_FAULT indicator is power-off.
Step 5: Place the DIP switch to the correct position according to Table 4-3 and Table 4-4.
Step 6: Press the SW1 self-test button (shown in Figure 4-9) to ensure that the fan can start normally.
Step 7: Replace the cover of the ECCU.
4.3.2 Replacing Fans
The heat exchanger of the outdoor cabinet is mainly composed of four centrifugal fans and a heat-exchanging core.
If the fan is faulty, follow the following procedures to replace the fan.
Step 1: Make sure that the fan-control terminals (J1, J2, J3 and J4 are hot pluggable) on the ECCU are inserted firmly.
The fan-control terminals are shown in Figure 4-9.
Step 2: Place the DIP switch to the correct position according to Table 4-3 and Table 4-4.
Step 3: Press the SW1 self-test button (shown in Figure 4-3). If the fans do not work, make sure that the fan cables
are perfect.
Step 4: Disconnect the fan power terminals on the right side of the cabinet. Use a multimeter to measure the voltage
between the positive power terminal and the negative power terminal. Check if the voltage is close to the DC output
voltage (54.0V).
If the fan power voltage is normal, the fans are damaged. Carry out the next step.
Step 5: Loosen the fixing screws to remove cover of heat exchanger (shown in Figure 4-11), and then you can see
the fans. Loosen the fixing screws of the fans to replace the fans.
Step 6: Reconnect the fan power terminals, and press SW101 self-test button (shown in Figure 4-9) to ensure that the
fan can startup normally.
Step 7: Replace the heat exchanger cover.
Fixing screw of heat
exchanger cover
Figure 4-11
Fixing screws of heat exchanger cover
ECM1500 Outdoor Cabinet
User Manual
Chapter 4 Maintenance
4.3.3 Replacing Heater
Step 1: Switch off the AC input MCB, as shown in Figure 4-12.
AC input MCB
Figure 4-12
AC input MCB
Step 2: Loosen the fixing screws of the heat exchanger cover to remove the cover.
Step 3: Loosen the fixing screws of the heater (shown in Figure 4-13). Disconnect all the cable connectors of the
heater to remove the heater.
Step 4: Replace the heater with a new one. Reverse the preceding steps to install the new heater.
Step 5: Check all the cable connection. If OK, power on the outdoor cabinet.
Heater
Figure 4-13
Heater position
4.3.4 Replacing Door Status Sensor
Refer to 4.2.3
Replacing Door Status Sensor.
ECM1500 Outdoor Cabinet
User Manual
21
22
Chapter 4 Maintenance
4.4 Replaciing Parts Of Air-condition Model Outdoor Cabinet
4.4.1 Replacing air-conditioner
Step 1: Switch off the AC input MCB, as shown in Figure 4-14. Disconnect all the cable connectors.
AC input MCB
Figure 4-14
AC input MCB position
Step 2: Loosen the fixing screws of air-condition to remove and replace air-condition.
4.4.2 Replacing Emergent Ventilation Unit
The emergent ventilation unit is composed of heat control board and fans. The replacing procedures of heat control
board and fans are the same as that of the forced ventilation model outdoor cabinet. You can refer to 4.2.1
Replacing Heat Control Board and 4.2.2 Replacing Fans.
4.4.3 Replacing Door Status Sensor
Refer to 4.2.3
Replacing Door Status Sensor.
ECM1500 Outdoor Cabinet
User Manual
Appendix 1
Technical And Engineering Parameters
23
Appendix 1 Technical And Engineering Parameters
Table 1
Parameter
category
Parameter
Operating temperature
Environmental
EMC
Technical parameters
Storage temperature
Relative humidity
Altitude
Others
Conducted emission
Radiated emission
Immunity to EFT
Immunity to ESD
Immunity to Surges
Immunity to radiation
Immunity to conduction
Safety regulation
Insulation resistance
Others
Insulation strength
MTBF
ROHS
Dimensions (mm)
Mechanical
Weight (kg)
Description
-10°C ~ +45°C (forced ventilation model), -40°C ~ +45°C (heat exchanger
model), -40°C ~ +50°C (air-condition model)
-40°C ~ +70°C
5%RH ~ 100%RH
≤ 2,000m (derating is required above 2,000m)
No conductive dust or erosive gases. No possibility of explosion
Class A
EN55022
Level 3
EN61000-4-4
Level 3
EN61000-4-2
Level 4
EN61000-4-5
Level 3
EN61000-4-3
Level 3
EN61000-4-6
Compliant with IEC60950-1, IEC60950-22
At temperature of 15°C ~ 35°C and relative humidity not bigger than 90%RH,
apply a test voltage of 500Vdc. The insulation resistances between AC circuit
and earth, DC circuit and earth, and AC and DC circuits are all not less than
10MΩ
(Remove the SPD, monitoring module and rectifiers from the system before the
test.)
AC circuit to earth: 50Hz, 2,500Vac
DC circuit to earth: 50Hz, 1,000Vac
Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac
AC to DC circuits: 50Hz, 3,000Vac
For all the three tests above, there should be no breakdown or flashover within
1min, with leakage current not bigger than 10mA
100,000hr
Compliant with R5 requirement
Cabinet
700 (W) × 700 (D) ×1800 (H)
Internal space of
613 (W) × 570 (D) × 350 (H)
battery compartment
Forced ventilation
≤ 125 (excluding subrack and battery string)
model cabinet
Heat exchanger
≤ 180 (excluding subrack and battery string)
model cabinet
Air-condition model
≤ 175 (excluding subrack and battery string)
cabinet
Table 2
Spart part list
Part
Specification or model
BOM
Fan
DC axial flow fan
32010191
Fan
DC centrifugal fan
32010261
ECM1500 Outdoor Cabinet
User Manual
Appendix 2
Wiring Diagram
24
Appendix 2 Wiring Diagram
AC Input
N
L
1
3
1
QFA1
2
Mains Input
4
9
10
11
12
FAN1
FAN2
FAN3
FAN4
W09
W01
Bottom cross control board door line
W01
PE
4
MS
PE Bar
2
L
3
4
N
19
XT
2
X1
5
6
FAN1
3
FAN2
FAN3
20
XT
FAN4
PE
1
W09
2
N
L
3
Bottom cross back door line
W02
4
NOTE:
W02_A for Europen standard socket.
W02_B for American standard socket.
W02_C for Chinese and British standard socket.
5
6
7
Blue Yellow Red Black
solder
Blue Yellow Red Black
W05
Blue Yellow Red Black
Blue Yellow Red Black
solder
Blue Yellow Red Black
solder
Blue Yellow Red Black
W05
17
XT
Blue Yellow Red Black
solder
Blue Yellow Red Black
18
XT
W09
DC Input
Bottom cross front door line
15
XT
W05
16
XT
3
4
1 2 3 4 5 6
1 2 3 4 5
J11
6
U1
J12
7
U2
8 7 6 5 4 3 2 1
W03
2 1
J2
W07
J3
W08
J10
W06
Temperature sensor I
7-J1
W04
P344309U1
J6
1 2 3
J7
P345314X1
7-J3-7
7-J3-8
7-J3-1
7-J3-2
8-1
8-2
1
3
5
7
9
11
13
15
17
19
21
23
2
4
6
8
10
12
14
16
18
20
22
24
14
X3
W04
Temperature sensor I
6-J6
-
W07
2
14-7
1
14-3
+
14-5
5
X2
14-1
PE BUS
1
13
T1
1 2
Door alarm
14-9
1
W07
J2
8 7 6 5 4 3 2 1
J3
1 2
6-J3
W06
6-J10
14-11
W06
7-J2
W06
Figure 1
Wiring diagram of forced ventilation model outdoor cabinet
ECM1500 Outdoor Cabinet
8
MJ
W08
8 7 6 5 4 3 2 1
W20
2
J1
User Manual
Appendix 2
Wiring Diagram
25
AC Input
N
L
1
3
2
4
1
QFA1
Mains Input
W09
W01
Bottom cross back door line
W01
PE
PE Bar
4
MS
1
2
L
3
4
N
5
6
Blue
Blue
3
Black
W03
1
PE
2
N
W09
22
H1
2
X1
1
2
1
2
Red
19
XT
Heater1
20
XT
W09
15
XT
W03
3
Black
21
KT1
4
W02
Blue
solder
Red
2
1
Black
18
XT
Bottom cross front door line
23
H2
W03
Black
L
Black
solder
17
XT
Bottom cross control board door line
16
XT
Heater2
5
10
FAN1
FAN2
FAN1
5
X2
+
1
2
-
11
12
FAN3
FAN4
4
FAN3
FAN4
Yellow Red Black
FAN2 Blue Yellow Red Black
FAN3 Blue Yellow Red Black
FAN4 Blue Yellow Red Black
solder
FAN1* Blue Yellow Red Black
solder
FAN2* Blue Yellow Red Black
solder
FAN3* Blue Yellow Red Black
solder
FAN4* Blue Yellow Red Black
FAN1 Blue
-
14-9
FAN2
3
Door alarm
PWM
ALARM
5-4
5-2
-
+
PWM
ALARM
5-4
5-2
-
+
PWM
ALARM
-
+
PWM
ALARM
5-4
5-2
+
6-J15-2
1
W04
2
6-J15-1
8
MJ
W08
14-11
W06
1 2 3 4
1 2 3 4 5
W05
1 2 3 4 5
5-4
1 2
1 2 3
6
U1
J5
W07
W08
ECCU11U1
J11
J13
W07
1
Figure 2
W07
2
J15
5-2
Temperature sensor I
J8
J14
J4
1 2 3 4
13
T1
1 2 3 4
J3
1 2
Temperature sensor I
J2
POWER
14-1
14-3
14-5
14-7
W05
W07
J1
W07
8 7 6 5 4 3 2 1
7
9
DC Input
6-J8
6
NOTE:
W02_A for Europen standard socket.
W02_B for American standard socket.
W02_C for Chinese and British standard socket.
5-4
5-2
W04
Wiring diagram of heat exchanger model outdoor cabinet
ECM1500 Outdoor Cabinet
User Manual
6-J5-1
6-J5-2
6-J5-3
6-J5-4
8-1
8-2
1
3
5
7
9
11
13
15
17
19
21
23
2
4
6
8
10
12
14
16
18
20
22
24
14
X3
Appendix 2
Wiring Diagram
26
W05
AC Input
6-J6
Temperature sensor I
N
L
1
3
2
4
13
T1
1
QFA1
14
X3
Mains Input
W06
W01
W17
W01
PE
4
MS
PE Bar
7-J3-7
7-J3-8
19-J2-9
19-J2-10
8-1
8-2
W08
1
2
L
3
4
N
5
6
2
X1
Door alarm
3
14-9
1
PE
1
2
N
2
2
4
6
8
10
12
14
16
18
20
22
24
1
3
5
7
9
11
13
15
17
19
21
23
FAN2
Blue Yellow Red Black
3
8
MJ
W17
10
FAN2
FAN1
L
4
5
6
NOTE: W02
W02_A for Europen standard socket.
W02_B for American standard socket.
W02_C for Chinese and British standard socket.
9
FAN1
solder
14-11
Blue Yellow Red Black
solder
W06
Blue Yellow Red Black
Blue Yellow Red Black
Temperature sensor II
19
XT
20
XT
L
N PE
1 2 3 4 5
J1
8 7 6 5 4 3 2 1
15 14 1312 11 10 9
J2
+
19
AC
J3
W06
5
X2
1
2
-
19-J2-7
19-J2-13
3
7
U2
4
1 2 3 4 5 6
1 2 3 4 5
J11
W08
6
U1
J12
2 1
18
XT
Air-condition
J3
J10
J2
Temperature sensor I
7-J1
W07
1 2
J7
16
XT
1 2 3
J6
Bottom cross front door line
J3
W07
7-J2
Wiring diagram of air-condition model outdoor cabinet
ECM1500 Outdoor Cabinet
User Manual
J2
8 7 6 5 4 3 2 1
W08
6-J3
8 7 6 5 4 3 2 1
Figure 3
P345314X1
W05
P344309U1
W08
15
XT
8 7 6 5 4 3 2 1
W04
Bottom cross back door line
17
XT
W08
Bottom cross control board door line
14-3
Cable from Air-condition
W09
14-1
W03
19-J2-8
19-J2-14
DC Input
14-7
14-5
FAN2
6-J12-3
FAN1
6-J12-3
7
W06
W07
J1
1 2
6-J10
W07
Appendix 3
Schematic Diagram
Appendix 3 Schematic Diagram
L
X1
QFA1
XS
Door Alarm
L
N
AC Input
N
to Dry Contact Terminal
PE
to PE bar
Dry Contact Terminal
Forced Ventilation Unit
Over Temperature
X2
C
……
V-
Fan
A
Climate unit fault
C
V+
-
CONTROL
+
-
-48V
ALARM
V+
CONTROL
A
+
V-
Fan
DC Input
ALARM
0V
Door Alarm
Spare
FCUX
FCU
X3
Figure 4
L
QFA1
X1
XS
AC Input
N
Schematic diagram of forced ventilation model outdoor cabinet
Door Alarm
L
N
to Dry Contact Terminal
PE
to PE bar
KT1
Dry Contact Terminal
Heat Exchanger Unit
A
C
-
V-
……
+
CONTROL
-48V
ALARM
V+
A
Climate unit fault
C
V+
-
DC Input
External fan
CONTROL
V-
+
Internal fan
ALARM
X2
0V
Over Temperature
AC
Heater
Door Alarm
Spare
ECCU
X3
Figure 5
Schematic diagram of heat exchanger model outdoor cabinet
ECM1500 Outdoor Cabinet
User Manual
27
28
Appendix 3 Schematic Diagram
L
QFA1
X1
N
XS
L
N
AC Input
PE
Door Alarm
to Dry Contact Terminal
to PE bar
Air-condition Unit
Dry Contact Terminal
Over Temperature
Alarm
Fan contral
Emergent Ventilation Unit
X2
0V
V+
Fan
DC Input
V-
Climate unit fault
Door Alarm
Spare
……
-48V
FCU
FCUX
X3
Figure 6
Schematic diagram of air-condition model outdoor cabinet
ECM1500 Outdoor Cabinet
User Manual