The installation of GZDW (high-frequency switching DC power supply system) needs to be strictly carried out in accordance with the power industry standards and technical specifications provided by the equipment manufacturer to ensure safety and reliability. The following are detailed installation steps and precautions:
Preparation before installation
Site survey
Confirm whether the installation location (such as distribution room, battery room) meets the requirements:
Ambient temperature: -10℃～+40℃ (battery room recommended 15℃～25℃).
Humidity ≤90% (no condensation).
Avoid direct sunlight, dust, and corrosive gases.
Check the ground load (battery pack is heavy, ≥600kg/m²).
Tools and materials
Multimeter, insulation resistance tester, hydraulic pliers, level, cable (cross-sectional area according to design drawings).
Bolts, brackets, insulating rubber pads (anti-vibration and anti-slip).
Safety measures
Disconnect all input power and hang a "no closing" sign.
Wear insulating gloves, goggles and other protective equipment.
Installation steps
1. Cabinet installation
Fix the cabinet
Use expansion bolts to fix the cabinet on the horizontal ground, and the vertical deviation of the cabinet is ≤1.5mm/m.
Cabinet grounding: grounding wire cross-sectional area ≥25mm² (copper cable), grounding resistance ≤4Ω.
2. Cable connection
AC input cable
Connect to the AC power distribution unit (L1/L2/L3, N, PE) according to the design drawings, tighten the terminals and insulate.
It is recommended to install a lightning protection module (SPD).
DC output cable
The positive and negative poles are connected to the DC power distribution unit busbar respectively, and the polarity must be checked correctly (red positive and black negative).
Multiple loads need to be evenly distributed to avoid single-line overload.
Battery group connection
When connecting batteries in series, first connect the batteries in the group (such as 24 2V batteries in series for a 48V system), and then connect to the system.
The bolt tightening torque is in accordance with the manufacturer's requirements (such as lead-acid batteries are usually 8~10N·m).
3. Module installation
Rectifier module
Insert the rectifier module into the slot, make sure it is plugged in place, and tighten the screws.
The number of modules is configured as N+1 redundancy (such as 4 modules for main use and 1 module for standby use).
Monitoring module
After installation, power on and initialize, set parameters (such as floating charge voltage and equalization charge cycle).
4. System grounding
Multi-point grounding requirements
The cabinet housing, battery rack, and cable shielding layer must be grounded independently to avoid circulation interference.
Debugging and testing
Check before power-on
Check that all wiring is correct and the insulation resistance is ≥10MΩ (tested with a 1000V megohmmeter).
Is the open circuit voltage of the battery normal (e.g., 12V battery should be 12.6~12.8V).
Power on step by step
First close the AC input switch and observe the indicator light of the rectifier module (normally green).
Then close the DC output switch and monitor the output voltage (e.g., 220V±1%).
Function test
Equalized floating charge switching: simulate the mains power outage to verify that the battery is automatically put into use.
Alarm function: manually trigger overvoltage, undervoltage, and high temperature alarms to confirm the response of the monitoring system.
Precautions
Battery safety
Short circuit and reverse connection are prohibited. Use insulating tools when handling.
Lead-acid batteries need ventilation (risk of hydrogen accumulation), and lithium batteries need fire prevention measures.
Anti-interference measures
Signal lines and power cables are routed separately, with a spacing of ≥30cm.
Document records
Save installation drawings, commissioning reports, and battery factory test data.
After the installation is completed, a load operation test is required for at least 24 hours to confirm that the system is stable before it can be put into formal use.
Contact Us
If you have further requirements for the installation, selection, operation and maintenance or other technical details of GZDW (high-frequency switching DC power supply system), please feel free to contact us：pannie@hdswitchgear.com. Or please leave your specific requirements or contact information, and we will contact you as soon as possible!
