ARCON RDI INVERTER SYSTEM

RDI - 40 kVA Inverter System

(Cabinet Modular System)

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Table of Contents
1. INTRODUCTION............................................................................................................................................ 3
1.1 SCOPE ........................................................................................................................................................ 3
1.2 SAFE WORK PRACTICE ............................................................................................................................... 3
1.3 HIGH VOLTAGES........................................................................................................................................ 3
2. GENERAL ........................................................................................................................................................ 3

3. SYSTEM DESCRIPTION............................................................................................................................... 4
3.1 MODULES DESCRIPTION :........................................................................................................................... 5
3.1.1 ARCON RDI 4000VA........................................................................................................................... 5
3.1.2 ARCON STM150.................................................................................................................................. 5
3.1.3 ARCON SYS3000 ................................................................................................................................. 6
4. CABINET ASSEMBLY : ................................................................................................................................ 7

5. TECHNICAL DESCRIPTION..................................................................................................................... 11
5.1 EMC ....................................................................................................................................................... 11
5.2 SAFETY .................................................................................................................................................. 11
5.3 COMMERCIAL POWER INTERFACE ..................................................................................................... 11
5.4 AC INPUT .............................................................................................................................................. 11
5.5 DC INPUT .............................................................................................................................................. 11
5.6 DC DISTRIBUTION ................................................................................................................................ 11
5.7 AC OUTPUT DISTRIBUTION ................................................................................................................. 12
5.8 SYSTEM DIMENSIONS & WEIGHT ....................................................................................................... 12
5.9 ENVIRONMENT ..................................................................................................................................... 12
6. CABINET INSTALLATION ........................................................................................................................ 13
6.1 MECHANICAL INSTALLATION .................................................................................................................. 13
6.1.1 Common DC input connection........................................................................................................... 13
6.1.2 Indicidual DC input connection......................................................................................................... 14
6.1.3 AC input / AC output connection ....................................................................................................... 14
6.1.4 Procedure to install new DIN rail breaker ........................................................................................ 16
6.1.5 Alarms&Signalling ............................................................................................................................ 17
6.1.6 Module connection............................................................................................................................. 18
6.1.7 Static switch connection..................................................................................................................... 18
7. COMMISSIONING ....................................................................................................................................... 19
7.1 OPERATION MODES .................................................................................................................................. 19
7.1.1 On-line ............................................................................................................................................... 19
7.1.2 Off-line ............................................................................................................................................... 19
7.2 START UP ................................................................................................................................................. 20
8. TROUBLESHOOTING AND MAINTENANCE ....................................................................................... 21
8.1 TROUBLESHOOTING ................................................................................................................................. 21
8.2 MAINTENANCE ........................................................................................................................................ 21
8.2.1 1) General Aspect .............................................................................................................................. 21
8.2.2 Inverter Module ................................................................................................................................. 22
8.2.3 Manual Bypass................................................................................................................................... 22
9. APPENDIX - INSTALLATION AND COMMISSIONING CERTIFICATE ......................................... 24
9.1 INSTALLATION ......................................................................................................................................... 24
9.2 COMMISSIONING ...................................................................................................................................... 24
9.2.1 Verification ........................................................................................................................................ 24
9.2.2 Connect the DC voltage to the System ............................................................................................... 25
9.2.3 Alarms Test ........................................................................................................................................ 25

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1. Introduction
1.1 Scope
This document is a product description for the ARCON - RDI (Stackable Rack System) Inverter
Systems. It describes the electrical and mechanical installation. Cabinets using our modular rack
Systems must be build according to the techniques and recomandations described in this
manual.

1.2 Safe work practice

The procedures described are only to be performed by personnel who are qualified by reason of
training and/or experience in the installation, commissioning and service of electrical/electronic
equipment. No attempts are to be made to service any Systems without taking adequate
precautions to assure personal safety.

General safe work practices commonly associated with use of tools, test sets, wire, etc. need to
be exercised when performing service functions.

1.3 High Voltages

Special care must be exercised in servicing any Systems because high voltage can be present.
Even when the main AC power to the unit has been disconnected, potential harm still exists
from the inverter module taking power from the external battery.

2. General
The ARCON Inverter supplies uninterrupted and disturbance-free ac power to
telecommunication site loads.
There are two operating modes, ON LINE and OFF LINE. In the ON LINE mode the inverter is
being powered by the dc power System and is providing ac power to the loads. Each inverter
has a build-in LVD (low voltage disconnect) that will disconnect the inverter from the dc power
System if the pre-set dc minimum input voltage level is reached. This feature protects batteries
in the dc power System from being discharged too deeply.
In the OFF LINE mode the inverter are in standby and commercial ac powers the loads. If the
power fails the static bypass switches the load to the inverter which will take power from the dc
power System.

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3. System description
The System consists of : cabinet made with stackable rack, inverter modules, static switch,
maintenance bypass, dc and ac distribution units and control System.

AC output distribution
customized

Manual By-Pass

Static Switch

Inverter module 1

Inverter module n

All the racks are inter-connected during cabinet mounting. Once this installation is done, all the
modules can be plugged / unplugged without any wiring.

The rack System is modular, different combination are possible, depending on the required
amount of power.

The inverter modules can be replaced without interrupting the operation of the power supply.
The STM static switch can be replaced AFTER manual by-pass operation.

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3.1 Modules description :

3.1.1 ARCON RDI 4000VA

The RDI inverter module is a high-frequency switchmode inverter, which can be paralleled in
order to offer modular power System to the end user.

RDI inverter module

1. Handles for module manipulation and plugging.

2. DC polarity indicator (Green OK, RED DC connection reversed)
3. Fan air entrance for proper cooling
4. LCD display for measurements and module status
5. Inverter OFF push button / Down key in parameter mode
6. Inverter ON push button / Up key in parameter mode
7. Scrolling menu push button to move through different menu
8. Green LED : module in operation
9. Red LED : module faulty

Inverter module is designed to offer:

• maximum utilization of the energy source
• affective utilization of commercial power cabling
• low losses
• lower total weight
• Hot-swappable capabilities

The inverter is based on switchmode technology that provides:

• low RFI
• high efficiency
• limited chance of ac output disturbances
• lower weight
• compact module

The inverter has an intelligent overload and current limit mode process as well as a selective
disconnection capability in case of module failure.

User interface and module installation or replacement is described in RDI Inverter Module
manual. Please refer to this manual for more detail.

3.1.2 ARCON STM150

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1. Inverter System switch on/off 8. Connector for DCI bus (X13) (With DCI only)
2. Connector RJ45 for RDI bus (X10) 9. Down key (in parametric mode)
3. Connector RJ45 to download a new software version (X8) 10. Up key (in parametric mode)
4. LEDs to indicate voltage presence on AC terminals 11. LCD display for measure and module status
5. Scrolling menu push button 12. output trigger terminal
6. Green LED indicating the RDI bus is active 13. AC + Alarms connection (behind panel)
7. Red LED for alarm status 14. 19” mounting brackets

3.1.3 ARCON SYS3000

The controller is a monitoring unit LOCATED just below the STM150

It will control and monitor the following:

• Individual inverter module individually
• Static switch
• ac output distribution
• Manual bypass for maintenance

The controller has two LCDs and five LEDs to display System status locally and remotely to:
• free potential contact
• local PC through ISM software
• remotely through modem link

The controller user interface contains:

• keyboard
• local LED
• measurements display
• status display

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Measures Status &Menu

Escape

UP

DOWN

ENTER

RS232 RECORD BACKSPACE

ARCON SYS3000 Controller front plate

4. Cabinet assembly :

The electrical drawing is presented in figure 1

The cabinet drawing is presented in figure 2

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Figure 1

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Figure 2

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1. Grounding :

The cradles have to be grounded to the cabinet. For

this, screw the ground cable to the cabinet with an
appropriate bolt.

2. Module plugging :

Once all the mechanical installation is done, you

simply have to plug the modules inside the cradles,
inserting them firmly into the spaces.

Proceed the same way for the static switch.

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5. Technical description
5.1 EMC
The inverter fulfill the following standards:

EN50081/ IEC 61000-6-3 Generic emission standard

EN50082 / IEC 61000-6-1 Generic immunity standard
CISPR 22 class B Limits and methods of measurements of radio interference
characteristics of information technology equipment.

5.2 Safety

IEC 950 Safety of information technology equipment.

The power supply System fulfills those international and national safety standard that are made
for these Systems according to earthing, fire protection and other safety matters. It’has designed
to be installed in a retricted access location only and over a concrete or non-combustible
ground.

It uses 90°C copper conductors only.

5.3 Commercial power interface

ETS 300 132-1 Power supply interface at the input to telecommunications equipment.

5.4 AC input

AC input type single phase

AC Input voltage 230 Vac rms + 10%
AC input current Max 175 A rms permanent
Frequency 60Hz + 5%

5.5 DC input

DC input voltage 48 Vdc or 60 Vdc nominal (min 40 Vdc max 60 Vdc)

DC input current 600 A max. at 21000W Vin = 40VDC
1200 A during 5 seconds overload 42000 W
Inrush current max In/2

5.6 DC distribution

Each inverter has an input DC fuses 100 A, C curve one pole

The DC input fuse is in the negative pole.
See cabinet arrangement for detail

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5.7 AC output distribution

Load ac distribution consist of maximum 20 Ullisted breaker QOU type – rating up to 70A – 2
pole
See cabinet arrangement for detail

5.8 System dimensions & weight

Height 2100 mm / 83.0 inches

Width 600 mm / 23.62 inches
Depth 600 mm / 23.62 inches

Weight 190 kg / 420 lbs. Without modules

5.9 Environment

Ambient operation temperature: 0 °C to +40 °C / 32 °F to 113 °F

Storage Temperature: -40 °C to +85 °C / -40 °F to 185 °F
Vibration: IEC 721-3-3
Shock: IEC 721-3-2
Cooling: Forced convection
Audible noise: < 55 dB(A)

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6. Cabinet installation
6.1 Mechanical Installation

The inverter System must be placed in a proper site location. It is a top or bottom cable access
system.

1) Place the cabinet on a non-combustible floor and check the mechanical stability.

NB: The insulation cover of connecting cables must meet the international standards and the
cross section related to the upstream protections. (Use only 90°C copper conductors)
Do not cover the top of the rack with any equipment that could block the airflow.

2) Unscrew the screws in order to remove the rear panel of the cabinet.

6.1.1 Common DC input connection

• Place both bus bar-one per pole - to group each inverter DC terminal + and -
• To protect the DC input lines, use an input circuit breaker of 600A in your DC source before
cables departure.
• Verify that each DC pole + and - coming from external PDU has a minimum cross section of
2×240mm² (2x 500MCM cable) and are minimum 90°C temperature rated. Each DC cable
must be ended with a double 2 holes lugs suitable for 240mm² (500MCM). Use lug types
listed below :

- YA34L-2TC38 BURNDY
- YA34L-2TC38-45 BURNDY

• Connect DC cables to the appropriate bus bar. Positive on + and negative on -. The
tightening torque is 40 Nm.

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6.1.2 Indicidual DC input connection

1. The individual DC input consist of one DC input per cradle (2 modules in each cradles).
You will need to prepare each individual DC input as the number of cradle installed
inyour system. (10 modules = 5 DC input )

2. Use only 90°C copper conductor with a cross section of 2/0AWG (70mm²). All cable
must be ended with double hole lug YA26L-2TC38 BURNDY for UL requirement. The
tightening torque is 20 Nm.

6.1.3 AC input / AC output connection

For all connection for AC INPUT (L/N/PE), use only 90°C copper conductor with a cross
section of 2/0AWG (70mm²). All
cable must be ended with double
hole lug YA26L-2TC38 BURNDY
for UL requirement. The tightening
torque is 20 Nm.

- Remove earth bond bridge

before connecting AC input
cable. The purpose of that
bridge is to connect Neutral to
earth PE in case no AC input
cable is connected to the
System. The tightening
torque is 20 Nm.

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- Connect AC GROUND on PE plated busbar on top of frame. Cable must be ended with
suitable listed lug ( type YA26L-2TC38-90 BURNDY)

- Connect the commercial power input L / N to the appropriated terminal COMMERCIAL

POWER X2. L (and N if not grounded) must be connected with a 200A (min 10,000A
interrupting capacity) circuit breaker as disconnect device for AC input. Terminal X2 is
located in the middle of the rack and can receive up to 95-mm² cable per phase.
The minimum cable section for AC input is 75 mm² (2/0 AWG). Cable terminal must be
ended with a listed M10 lug ( type YA26L-2TC38 BURNDY). The tightening torque is 20.3
Nm.

AC output distribution is connected to distribution breaker for L, and N and common bus bar
for PE. See table below for wire minimal cross-section and tightening torque details:

BREAKER PHASE MINIMAL WIRE LUG∅ (MM) TIGHTENING Lug

RATING (A) SECTION MM² TORQUE
(AWG) (Nm)
15A PE 1.5 (14) M10 8.5 YAV102TC38-45
N BURNDY
L According breaker instructions
20A PE 2.5 (12) M10 8.5 YAV102TC38-45
N BURNDY
L According breaker instructions
30A PE 4 (10) M10 8.5 YAV102TC38-45
N BURNDY
L According breaker instructions
40A PE 4 (10) M10 8,5 YAV102TC38-45
N BURNDY
L According breaker instructions

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6.1.4 Procedure to install new DIN rail breaker

Breaker must be DIN rail mountable please follow instruction to install breakers:
0. Remove front panel covering the breaker
1. Plug In the DIN rail breaker to be installed closed to the first free position
2. Wire the breaker 2 poles L to Brown terminal and N to neutral terminal. Use the wire
prepared for wiring (see figure 3)
a. Insert wire into breaker first
b. Then insert wire to the terminal closed to the breaker
3. Be sure the breaker is in OFF position
4. Connect the cable from the load to the breaker

Note: For personnel safety and protection of Equipment this unit must be properly
grounded (DC ground connected on plate area, soldered on frame).

Figure 3 AC output brekaer 2 poles

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6.1.5 Alarms&Signalling

Alarms are reported locally through LED and LCD displays and remotely through two potential
free contacts and ISM software.
Free potential contact are reported on terminal X3 (see block figure 1 page 8).
Systems send an alarm in following failure:

- AC input voltage failure MINOR in ON LINE

MAJOR in OFF LINE
- AC input frequency out of range MINOR
- Module failure MINOR
- More then one module faulty MAJOR
- DC input voltage out of range MAJOR in ON LINE
MINOR in OFF LINE
- static by-pass engaged MAJOR
- Overload (please note that this alarm is MINOR
adjustable in % of nominal power in control unit)
- AC output breaker tripped MAJOR

MAJOR Alarm is connected on PIN 1-2 closed in case of alarm.

MINOR alarm is connected between PIN 3-4 closed in case of alarm.

Relay characteristics:
CAUTION: The relay contacts may only be connected to SELV circuits (max 60 Vdc or
42.4 Vpeak).
In this context, following relay characteristics are given for info only:
DC AC
• Nominal voltage: 24 Vdc 120 Vac
• Nominal current: 1A à 24 Vdc 0.5A à 120 Vac
• Max commutation current 2A 2A
• Max commutation power
with resistive load 30 W 60 VA

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6.1.6 Module connection

Plug each inverter module in the provided space and

secure them to the frame cabinet with the 4 previewed
screws.

- Install each inverter module in the provided space and secure them to the frame cabinet.

6.1.7 Static switch connection

Please refer to the ARCON STM 150 Static Switch Manual for detail.

Now the System is ready to be commissioned. Please refer to section 7 commissioning.

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7. Commissioning
7.1 Operation modes

There are two operating modes, ON LINE and OFF LINE.

7.1.1 On-line
In the ON LINE mode the inverter is being powered by the dc power System and is providing ac
power to the loads. When the commercial power is present, the static switch keeps the inverter
synchronized and in frequency and phase with the commercial power.
Each inverter has a built-in LVD (Low Voltage Disconnect) that will disconnect the unit from the
dc power System if the pre-set dc minimum input voltage is reached. This feature protects
batteries in the dc power System from being discharged too deeply.
In case of total inverter module failure, the static switch will transfer the load to the ac power
supply connected to the System.

See ARCON STM 150 Static Switch manual for more detail.

7.1.2 Off-line

In the OFF LINE mode the inverters are in standby and the commercial ac power source powers
the load. If commercial power fails, the static switch will automatically switch to the dc power
System as its input voltage and begin powering the loads.

Note: Selection to work ON LINE or OFF LINE can be done through the static
switch configuration menu. Please refer to static switch manual.

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7.2 Start up

Before connecting any power DC or AC to the System:

• Make sure you have followed the instruction for Installation.
• Make sure the manual bypass is not ENGAGED (see section 8.4).
Wrong manipulation may damage the inverter.

1) Set the static switch ON/OFF switch in position OFF

2) Switch OFF all AC output breakers

3) Apply the DC power to the System

The Inverter will display:
OFF RDI REM
0% 100%

4) Start the module one by one BEFORE CONNECTING THE LOAD

Switch ON the inverter by pressing one button ON

Switch ON the static switch ON/OFF switch in position ON
Verify that each module display:
Vout:127Vac
0% 100%
These values depends on factory setting and load condition

Switch OFF the inverter by pressing the button OFF

Repeat this process until you have tested all units

5) Set static switch ON/OFF switch in position OFF

6) Switch ON all module locally by pressing the button ON

Each module displays:
OFF REM
0% 100%

7) Set the static switch ON/OFF switch on position ON

All modules will start.

8) Switch OFF all modules through static switch

9) Connect the commercial power to the System.

Static Switch displays Module OFF
Load supplied by Commercial power

10) Start the inverter through the static switch ON/OFF switch
Inverter will start and synchronised with commercial power ac

11) Switch ON the LOAD breaker

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8. Troubleshooting and maintenance

8.1 Troubleshooting

Alarms are reported locally through LED and LCD displays and remotely through two potential
free contacts and ISM software.
Free potential contact are reported on terminal X3 (see block diagram page 5).
Systems send an alarm in following failure:

- AC input voltage failure MINOR in ON LINE

MAJOR in OFF LINE
- AC input frequency out of range MINOR
- Module failure MINOR
- More then one module faulty MAJOR
- DC input voltage out of range MAJOR in ON LINE
MINOR in OFF LINE
- static by-pass engaged MAJOR
- Overload (please note that this alarm is MINOR
adjustable in % of nominal power in control unit)
- AC output breaker tripped MAJOR

MAJOR Alarm is connected on PIN 1-2 closed in case of alarm.

MINOR alarm is connected between PIN 3-4 closed in case of alarm.

Due to the modularity concept, it is very easy to replace one inverter. The replacement can
be done while the System is under operation “hot-swappable solution”. See inverter manual
for more details.

8.2 Maintenance

Maintenance as to be done by trained personnel only

The purpose of the maintenance is to check the proper operation of the System.

8.2.1 1) General Aspect

Care must be taken to prevent dust, which can damage electronic components, by reducing
the ESD distances. If necessary, remove dust by using industrial tools such as industrial
vacuum cleaner.

DO NOT use any cleaning equipment using any liquid or insert metallic tools inside the
equipment.

If necessary engage the manual bypass (see section 8.4) and remove each unit from the
System to clean it properly.

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8.2.2 Inverter Module

The System is based on modular concept. Thus we will check each individual unit and verify
that they operating all at the same level of load and conditions.

Please refer to inverter controller manual and static switch manual for more detail
Check that all inverter modules are operating by looking on the LCD display and scrolling the
menu:

• the ac output voltage on the LCD display

• the ac output current of each individual module are correctly balanced

This balance can be calculated by reading the total current given all module and divide
by the number of module

Each inverter should give this value within 10% tolerance

- Verify the T° of the heatsink and all units should be in the same range with a
maximum of 10 degrees Centigrade deviation.

The T° can be read on the LCD display by scrolling the menu

- Static switch in the System

- check that output voltage and current is in accordance with the load
- verify that no alarms is present

8.2.3 Manual Bypass

The Manual Bypass switch is shown below. It will allow the user to insulate the inverter and
static switch from the load when some service has to be done on the System.

BY PASS

ON

OFF

In normal operation, the manual by-pass is not engaged and is in the OFF position.
In case of necessity the manual by-pass can be engaged to insulate the System from the load.
When the manual by-pass is engaged it is in the ON position.

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WARNING! ! ! The Manual Bypass must be operated by qualified and trained personnel.
An error in the procedure may result in power outage to the load and damage the inverter.

Procedure to engage the Manual Bypass

1. Stop the inverter or transfer the load on COMMERCIAL POWER

2. Set the switch on position “Transfer” and wait 10 seconds
3. Set the switch to position ON
Procedure to disable the Manual Bypass

1. Set the switch to position “TRANSFER” and wait 10 seconds

2. Set the switch to position OFF
3. Start the inverter

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9. APPENDIX - Installation and Commissioning certificate

The scope of this document is to provide a general guide for the contractor personnel
that install and commissions a CMS inverter System. Please refer to the operation manual
for more details.

9.1 Installation

Cabinet are properly placed and stable

Cables support are properly fixed
Positive bus bar connection « + » connected to DC input + terminal
Negative bus bar connection « - » connected to DC input – terminal
AC input and output cables installation AC
AC input connection properly done (L + N + PE) on terminal X2
AC output connection properly done (L + N ) on output terminal
PE connection properly done
Inverter module are correctly installed and fixed in the rack
DC, AC and Digital bus cable are correctly connected to each inverter
module
Inverter module are correctly inserted and fixed
Inverter cabinet is correctly connected to EARTH
Neutral N is connected to EARTH (If required!)

9.2 Commissioning

9.2.1 Verification

All Cable DC and AC are connected

All EARTH connection are done (cabinet and AC output)

Controller – version …. Serial Number ….

Inverter module type: 48 V /……. KVA
Serial N° ………………………………………………………………………………….
Digital bus connected between inverter, static switch and control unit
Inverter labelling
dc input, commercial power ac input, LOAD ac output labelling
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9.2.2 Connect the DC voltage to the System

SYS3000 configuration (see menu 10. Configuration)

SYS3000 password if required
Start All inverter module through STM150 if present or through module ON/OFF
Current Load sharing between inverter (see on inverter current LCD display)

Apply AC voltage to the System if required

Apply commercial power ac input measure ac voltage on terminal X2

If STM150 is present verify synchronism on STM150 LCD display

9.2.3 Alarms Test

DEFAUT UA NUA OK
One Inverter module OFF X
More than one inverter OFF X
Ac output MCB tripped X
Ac input failure (commercial power failure) X

Contractor :

Date : Contact : Visa :

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