NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual Version Revision date BOM
V1.0 October 24, 2012 31012653
Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.
Copyright © 2012 by Emerson Network Power Co., Ltd. All rights reserved. The contents in this document are subject to change without notice.
Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China Homepage: www.emersonnetworkpower.com.cn E-mail:
[email protected]
Safety Precautions To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Caution, Notice, Warning, Danger" in this book 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 be strictly trained and master the correct operations and all the safety points before actual operation. When operating Emerson products, the safety rules in the industry, the general safety points and special safety instructions specified in this book must be strictly observed.
Electrical Safety I. Hazardous voltage
Danger Some components of the power system carry hazardous voltage in operation. Direct contact or indirect contact through moist objects with these components will result in fatal injury. Safety rules in the industry must be observed when installing the power 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, rings. When water or moisture is found on the Subrack, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power 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. II. Tools
Warning In high voltage and AC operation, special tools must be used. No common or self-carried tools should 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
Notice 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 system or the non-grounding pole and the earth. The power system is a constant voltage DC power equipment, short circuit will result in equipment burning and endanger human safety. Check carefully 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. Insulated tools must be used. In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of the human body and tool is reduced to a minimum. VI. Dangerous energy
Warning 240VA, hazardous energy, keep off, no bridge connection. This converter contains outputs exceed 240VA, when installing into end system care must be taken that the output and appropriate wire may not be touched.
Battery Danger Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery connection method. 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: Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. Use special insulated tools. Use eye protection device, and take preventive measures. Wear rubber gloves and apron to guard against electrolyte overflow. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted.
BLVD The system has battery low voltage disconnection (BLVD) function. BLVD means when the mains fail and batteries supply power, the controller cuts the load off when the battery voltage drops down to below 43.2V to prevent over-discharge. The BLVD voltage is settable. Refer to ACU+ User Manual for setting method. The factory setting is enabling BLVD, which means that if power outage lasts for a long time or the power system fails, there might be BLVD. Users should classify the loads and connect the priority loads to BLVD routes. For vital loads, users can disable BLVD of these loads to insure reliability of the power supply. The method of disabling BLVD is: Set “BLVD Enable” item of the controller to “N”. Refer to ACU+ User Manual for setting method.
Notice The advantage of enabling BLVD is protecting the batteries from over-discharge when the battery voltage is low. The disadvantage of enabling BLVD is that when the battery voltage drops down to a certain value, all the loads (including non-priority loads and priority loads) will be cut off due to battery disconnection. The advantage of software disabling BLVD is prolonging the power supply of priority loads. The disadvantage is that software disabling cannot prevent unwanted power failure due to misoperation or power system failure.
Others I. Sharp object
Warning When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object.
II. Cable connection
Notice Please verify the compliance of the cable and cable label with the actual installation prior to cable connection. III. Binding the signal lines
Notice The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least 150mm.
Contents Chapter 1 Overview ............................................................................................................................................................ 1 1.1 Model Information ................................................................................................................................................. 1 1.2 Composition And Configuration ............................................................................................................................ 1 1.3 Features ................................................................................................................................................................ 4 Chapter 2 Installation Instruction ......................................................................................................................................... 5 2.1 Safety Regulations ................................................................................................................................................ 5 2.2 Preparation ........................................................................................................................................................... 5 2.3 Mechanical Installation.......................................................................................................................................... 6 2.4 Electrical Installation ............................................................................................................................................. 9 2.4.1 Power System Cabling Method ................................................................................................................. 9 2.4.2 Connecting AC Input Cables ................................................................................................................... 10 2.4.3 Connecting Load Cables ......................................................................................................................... 11 2.4.4 Connecting Battery Cables ...................................................................................................................... 11 2.4.5 Connecting Signal Cables ....................................................................................................................... 12 Chapter 3 Installation Testing............................................................................................................................................ 16 3.1 Installation Check And Startup ............................................................................................................................ 16 3.2 Basic Settings ..................................................................................................................................................... 16 3.3 Alarm Check And System Operation Status Check ............................................................................................ 17 3.4 Final Steps .......................................................................................................................................................... 18 Chapter 4 Use Of Controller .............................................................................................................................................. 19 4.1 Control Keypad And Indicator ............................................................................................................................. 19 4.1.1 Front Panel .............................................................................................................................................. 19 4.1.2 Indicator Function .................................................................................................................................... 19 4.1.3 Control Keypad Function ......................................................................................................................... 19 4.2 LCD Menu Tree .................................................................................................................................................. 20 4.2.1 Status ...................................................................................................................................................... 20 4.2.2 Settings.................................................................................................................................................... 21 4.2.3 Manual ..................................................................................................................................................... 28 4.2.4 ECO ......................................................................................................................................................... 28 4.2.5 Quick Setting ........................................................................................................................................... 28 4.2.6 Controller Setting ..................................................................................................................................... 29 4.3 WEB Interface Operation .................................................................................................................................... 30 4.3.1 Setting Up The Internet Explorer Web Browser ....................................................................................... 30 4.3.2 Logging Into The Controller ..................................................................................................................... 31 4.3.3 Homepage Introduction ........................................................................................................................... 32
4.4 WEB Bootloader Interface Operation .................................................................................................................. 36 4.5 Serial Bootloader Interface Operation ................................................................................................................. 37 Chapter 5 Alarm Handling ................................................................................................................................................. 41 5.1 Handling Alarms.................................................................................................................................................. 41 5.2 Handling Rectifier Fault....................................................................................................................................... 42 Appendix 1 Technical And Engineering Data .................................................................................................................... 44 Appendix 2 Installation Instruction Of Battery Rack .......................................................................................................... 48 1. Installation Instruction Of Two-Layer And Four-Layer Battery Rack ..................................................................... 48 2. Installation Instruction Of Three-Layer Battery Rack............................................................................................. 50 3. Fixing The Battery Rack........................................................................................................................................ 51 Appendix 3 Wiring Diagram............................................................................................................................................... 52 Appendix 4 Shematic Diagram .......................................................................................................................................... 60 Appendix 5 Glossary ......................................................................................................................................................... 68
Chapter 1
Overview
1
Chapter 1 Overview This chapter introduces model description, composition and configuration, and features. The “power system” in this manual refers to the NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 series 19 inch subrack power system.
1.1 Model Information Take NetSure 501 A41-S1 power system as an example, the model description is given in Figure 1-1.
NetSure 501 A 4 1 S 1 Cabinet configuration Cabinet type: Subrack Version The number of the rectifier in the typical power supply system: 4, If the number ranges between 0 ~ 9, the character is represented by a number, If the number is larger than 9, the character isrepresented by a letter, for example: A represents the number 10, B represents the number 11, and so on Region A : Asia- Pacific region Output power of the rectifier. 501: 1740W ~2000W. 701: 2900W ~5000 W Brand name of the power supply system
Figure 1-1 Model information
1.2 Composition And Configuration System composition The system consists of power distribution parts, rectifiers and controller. The internal structures of the systems are shown in Figure 1-2 to Figure 1-6.
Figure 1-2
NetSure 501 A41- S1/S2 system structure
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Positive terminals
Battery MCB
AC input MCB
Load MCB Rectifier Monitoring module Controller Dummy panel
Figure 1-3
Figure 1-4
Figure 1-5
NetSure 501 A91-S1 system structure
NetSure 701 A41 –S2/S4 system structure
NetSure 701 A41-S1/S3/S5 system structure
Figure 1-6
NetSure 701 A41-S5 system structure
System configuration The configurations of the power system are described in Table 1-1.
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Table 1-1 Configuration of fixed- configuration system Item Contorller
Rectifier
NetSure 501 A41-S1
NetSure 501 A41-S2
NetSure 501 A91-S1 NetSure 701 A41-S1 NetSure 701 A41-S2 NetSure 701 A41-S3 NetSure 701 A41-S4 NetSure 701 A41-S5
Model：
Model：
Model：
Model：
Model：
Model：
Model：
Model：
M221S/M222S
M820B
M221S/M222S
M221S/M222S
M221S/M222S
M221S/M222S
M820B
M221S/M222S
Model：
Model：
Model：
Model：
Model：
Model：
Model：
Model：
R48-1800A/R48-2000/ R48-2000e Standard configuration：4 pieces
R48-1800A/R48-2000/ R48-2000e Standard configuration：4 pieces
R48-1800A/R48-2000 /R48-2000e Standard configuration：9
R48-2900U/R48-320 0e/R48-3200/R48-35 00e/R48-4000e Standard configuration：3
R48-2900U/ R48-3200e R48- 3200 R48-3500e R48-4000e Standard configuration：4
R48-2900U/ R48-3200e R48- 3200 R48-3500e R48-4000e Standard configuration：4
R48-2900U/ R48-3200e R48- 3200 R48-3500e R48-4000e Standard configuration：4
R48-2900U/ R48-3200e R48- 3200 R48-3500e R48-4000e Standard configuration：5
pieces
pieces
pieces
pieces
pieces
pieces
AC power distribution
DC power distribution
L＋N＋PE/ 220Vac
L＋N＋PE/220Vac
3P＋N＋PE/380Vac
3P＋N＋PE/380Vac
3P＋N＋PE/ 220Vac L＋N＋PE/380Vac
3P＋N＋PE/ 380Vac L＋N＋PE/ 220Vac
BLVD load route：
BLVD load route：
BLVD load route：
BLVD load route：
BLVD load route：
BLVD load route：
BLVD load route：
BLVD load route：
1 × 100A/1P; 1 × 16A/1P, MCB LLVD load route：
2 × 10A/1P, 2 × 32A/1PMCB LLVD load route：
5 × 63A/1P, 5 × 32A/1P, 8 × 10A/1P MCB LLVD load route：
1 × 10A/1P MCB LLVD load route：
4 × 63A/1P, 6 × 32A/1P, 2 × 10A/1P MCB LLVD load route：
2 × 32A/1P, 2 × 16A/1P MCB LLVD load route：
2 × 63A/1P 4 × 32A/1P, 4 × 10A/1P MCB LLVD load route：
2 × 32A/1P, 2 × 16A/1P MCB LLVD load route：
1 × 100A/1P, 1 × 63A/1P, 2 × 32A/1P MCB
2 × 63A/1P, 2 × 32A/1P MCB
Not configured
4 × 40A/1P MCB
Not configured
2 × 63A/1P, 4 × 32A/1P, 2 × 16A/1P MCB
AC output MCB 1 × 16A/1P Optional Optional Optional Optional 1 × 16A/1P Battery MCB 2 × 63A/1P 2 × 125A/1P 2 × 125A/1P 2 × 125A/1P 2 × 125A/1P 2 × 125A/1P AC SPD 1 piece Optional Optional Optional Optional 1 piece DC SPD 1 piece Optional Optional Optional Optional 1 piece Top cover Optional Optional Optional Optional Optional Optional Size (mm) 483 × 360 × 222 483 × 360 × 222 483 × 360 × 445 483 × 360 × 267 483 × 360 × 267 483 × 360 × 267 BLVD contorller Contorller power-off Contorller power-on Contorller power-on Contorller power-on Contorller power-on Contorller power-off mode Weight (without the ≤ 25kg ≤ 25kg ≤ 25kg ≤ 25kg ≤ 25kg ≤ 25kg rectifier and controller) Notes: 1. Temperature sensor and connected cables, remote monitoring unit, battery rack. 2. Battery MCB: The default system configuration is two sets of batteries, if not, please readjust the battery MCB configuration according to actual situation. 3. The way of outage for control is cutting off the battery, disconnecting the monitor and storage battery, monitor dropping out and communication broken up
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
2 × 63A/1P, 4 × 32A/1P MCB
2 × 100A/1P 2 × 63A/1P, 2 × 32A/1P MCB Optional 2 × 125A/1P Optional Optional Optional 483 × 360 × 400 Contorller power-on
1 × 16A/1P 2 × 125A/1P 1 piece 1 piece Optional 483 × 360 × 267 Contorller power-off
≤ 25kg
≤ 25kg
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1.3 Features The rectifier uses the active Power Factor Compensation (PFC) technology, raising the power factor to 0.99. Wide AC input voltage range: 85V ~ 290V (NetSure 701 A41) or 85Vac ~ 300Vac (NetSure 501 A41 & NetSure 501 A91). The rectifier uses soft switching technology, raising the system rated efficiency to 91%. Ultra-low radiation. With advanced EMC design, the rectifier meets international standards such as CE and NEBS. Both the conducted and radiated interference reach Class B. The rectifier safety design complies with UL, CE and NEBS standards. High power density. Rectifiers are hot pluggable. It takes less than 1min to replace a rectifier. Two over-voltage protection methods are optional: hardware protection and software protection. The latter one also has two optional modes: lock-out at the first over-voltage and lock-out at the second over-voltage. Perfect battery management: The management functions include the LLVD (optional), BLVD, temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation and on-line battery test, etc. M221S and M222S support historical alarm record up to 200 and historical record up to 1000. And M820B supports historical alarm record up to 3000 and historical record up to 60000 10 sets of battery test data records. Network design: Providing multiple communication ports (such as RS232, modem and dry contacts), which enables flexible networking and remote monitoring. M820B support the USB communication interface. Perfect lightning protection at AC side and DC side. Complete fault protection and fault alarm functions. NetSure 701 A41-S3, NetSure 701 A41-S5 and NetSure 501 A41-S1 adopt the way of outage for control, This way effectively prevents the storage battery from deeply discharging after system battery protection drops out and hence prevents the unattended outdoors and indoors server rooms from the damage due to the deep discharge.
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Chapter 2 Installation Instruction 2.1 Safety Regulations Certain components in this power system have hazardous voltage and current. Always follow the instructions below: 1. Only the adequately trained personnel with satisfactory knowledge of the power system can carry out the installation. The most recent revision of these safety rules and local safety rules in force shall be adhered to during the installation. 2. All external circuits that are below 48V and connected to the power system must comply with the requirements of SELV as defined in IEC 60950. 3. Make sure that the power (mains and battery) to the system is cut off before any operations can be carried out within the system subrack. 4. The power subracks shall be kept locked and placed in a locked room. The key keeper should be the one responsible for the power system. 5. The wiring of the power distribution cables should be arranged carefully so that the cables are kept away from the maintenance personnel.
2.2 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. Cables The cable design should meet relevant industry standards. It is recommended to use the RVVZ cables as AC cables. The cable should reach at least +70°C temperature durability. With cable length shorter than 30 meters, the Cross-Sectional Area (CSA) calculation should be based on 2 the current density of 3.5A/mm . The suggested CSA value is no less than the Table 2-1. Table 2-1 Load cable CSA selection AC MCB rated current 125A 100A 63A
Max. battery current 105A 80A 50A
Min. cable CSA 35mm2 25mm2 16mm2
Max. cable length 50mm2 50mm2 25mm2
The CSA of DC cable depends on the current flowing through the cable and the allowable voltage drop. To select the battery cable CSA, see Table 2-2. Select the DC load cable CSA according to the Table 2-3. Table 2-2 Battery cable CSA selection Battery MCB rated current Max. battery current Min. cable CSA Max. cable length (volt drop: 0.5V, with max. CSA) 125A 105A 35mm2 6m 63A 50A 16 mm2 5m Note: 1. The specs are applicable at ambient temperature of 25°C. If the temperature is higher or lower than this, the CSA of the cable should be increased. 2. The battery cable should reach at least +90°C heat durability. It is recommended to use double-insulated copper-core flame retardant cable as battery cable
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Installation Instruction Table 2-3 DC load cable selection
Load route rated Max. output Min. cable Max. cable length (volt drop: Max. cable length (volt drop: Max. cable CSA current current CSA 0.5V, with min. CSA) 0.5V, with max. CSA) 100A 80A 25mm2 14m 50mm2 20m 63A 50A 16mm2 9m 25mm2 14m 32A 25A 10mm2 11m 25mm2 29m 16A 12A 6mm2 14m 25mm2 48m 10A 8A 6mm2 23m 25mm2 98m Note: The specs are applicable at ambient temperature of 25°C. If the temperature is higher than this, the CSA of the cable should be increased
To prevent the air switching capacity is too large, the load overload does not work. Recommended the capacity of the air switching is up to 1.5 ~ 2 times of the load peak. The CSA of the system grounding cables should be consistent with the largest power distribution cables. The CSA 2 value is no less than 25mm . AC and DC power distribution interface definition see Table 2-4. Table 2-4 AC and DC power distribution interface definition Connector name
AC power distribution
DC power distribution
Connector specifications
Wiring instructions
AC input MCB
H type terminal, max. cable CSA 35mm2 (Single-phase power input) H type terminal, max. cable CSA 25mm2 (Three -phase power input)
AC power line
Grounding busbar
One M8 bolt, OT type wiring terminal, max. cable CSA 35mm2
Connected to the grounding bar of the equipment room
Battery output MCB
H type terminal, max. cable CSA 25mm2 (63A and below) H type terminal, max. cable CSA 50mm2 (capacity above 63A)
Connected to the battery port
Negative output MCB
H type terminal, max. cable CSA 25mm2 (63A and below) H type terminal, max. cable CSA 50mm2 (capacity above 63A)
Connected to the users load port
Positive busbar
Terminal subrack terminal: cable CSA ≤ 50mm2
Connected to the users load port
2.3 Mechanical Installation
Note
1. The cabinet or rack the subrack power supply system installed in must provide fireproof and electric protection casing, or install in cement or other difficult to burn, at the same time and other combustible materials to keep enough distance. 2. For the convenience of maintenance, users should maintain a clearance of 800mm at the front of the power supply system. 3. Subrack cannot be installed against the wall, it must leave enough space for heat dissipation. Installed on battery bracket 1. Fix the subrack power system to the battery bracket through the connectors with M6 bolts, as shown in Figure 2-1.
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Subrack power system
M6 screw M6 screw
Connector
Connector
Battery bracket
Figure 2-1
Cabinet and rack installation
Installed in cabient Insert the subrack power system to the matching cabinet, as shown in Figure 2-2.
Subrack power 电源插框 system
Figure 2-2 Installed in the cabinet system
The engineering graphics of the subrack power system as shown in Figure 2-3 to Figure 2-8.
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Figure 2-3 Installation size of NetSure 501 A41 (unit: mm)
445
Figure 2-4 Installation size of NetSure 501 A91 (unit: mm)
Figure 2-5 Installation size of NetSure 701 A41-S1 (unit: mm)
Figure 2-6 Installation size of NetSure 701 A41-S2/S3 (unit: mm)
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Figure 2-7 Installation size of NetSure 701 A41- S4 (unit: mm)
265.0
438.5 482.6
Figure 2-8 Installation size of NetSure 701 A41-S5 (unit: mm)
Note
1. Tighten the captive screw of the MFU and DU Panel by the cross head screwdriver when there is no operation. 2. Also tighten the handle of the 501 modules by the cross head screwdriver. 3. Please plug in the new modules or installing a new panel after removing the rectifier module.
2.4 Electrical Installation 2.4.1 Power System Cabling Method Cabling from the top of the power system DU unit and MFU unit are available for the system top cover cabling. For DU unit cabling: Cabling from the cable outlet area and then fixed to the cable-bundling plate and the top edge. As shown in Figure 2-9.
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Cable outlet area
Cable-bundling plate Cable outlet area
Figure 2-9
Cable entry Illustration of the DU unit
The MFU unit cabling is shown in 2-10.
Figure 2-10
Cable entry Illustration of the MFU unit
Cabling from side of the power system Use a cross head screwdriver to remove two screws which fix the cabling panel at side of cabling area, then the cable can be led out from the cabling area, as shown in Figure 2-11. 螺钉
出线板 （出线空间）
Figure 2-11 Side cable cabling Illustration
2.4.2 Connecting AC Input Cables
Danger 1. Switch off all MCBs before the electrical connection. 2. Only the qualified personnel can do the mains cable connection. Take the NetSure 701 A41 power supply system as an example, the position of the terminals are shown in Figure 2-12.
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Figure 2-12 Illustration of the connection terminal
Note
If the user selects the subrack with AC input terminal, no overcurrent or short circuit protection function, then configuration of the overcurrent and grounding protection device is required for the subrack upstream. For selection of the detailed protection device specification, please contact the Emerson local technical support center.
2.4.3 Connecting Load Cables Connect the negative cable of the load to the upper terminal of load MCB. Connect the positive cable of the load to the DC positive busbar, as shown in Figure 2-13.
Figure 2-13 Illustration of the load cable connection terminal
2.4.4 Connecting Battery Cables
Note
1. The batteries may have dangerous current. Before connecting the battery cables, the corresponding battery input MCBs or the battery cell connector must be disconnected to avoid live state of the power system after installation. 2. Be careful not to reverse connect the battery. Otherwise, both the battery and the power system will be damaged! 1. Connect one end of the negative battery cable to the upper terminal of battery MCBs. Connect one end of the positive battery cable to the DC positive bus bar. 2. Connect copper lugs to the other end of the battery cables. Bind the connecting parts with insulating tape, and put them beside the battery. Connect the cables to the battery when the DC distribution unit is to be tested. As shown in Figure 2-14. Positive terminal Battery MCB
Figure 2-14 Illustration of the battery connection terminal
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2.4.5 Connecting Signal Cables There are two user interface board of the power system can optional, respectively the W2453X1 user interface board and IB2 user interface board. The W2453X1 user interface board is used together with the M221S monitoring unit or M222S monitoring unit only; and the IB2 user interface board is used together with the M820B monitoring unit only. W2453X1 user interface board cable connection Take the NetSure 501 A41 power supply system as an example, the position of the user connector board (W2453X1) is shown in Figure 2-15.
Figure 2-15 W2453X1 user interface board Illustration
At most two user connector boards are allowed in the power supply system. Standard cabinet is only configured with one user connector board. With one user connector board configured, the power supply system provides three external digital signal input interfaces: DI2, DI3, DI4 (DI1 is used for DC SPD alarm. If no DC SPD is configured in the power supply system, DI1 is available) and four dry contact alarm output interfaces: DO1, DO2, DO3, DO4. With two user connector boards configured, the power supply system provides additional four dry contact alarm output interfaces: DO5, DO6, DO7, and DO8.
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The functions of the interfaces are shown in Table 2-5. Table 2-5 nterface functions Type Dry contact 1 Dry contact 2 Dry contact 3 Dry contact 4 Dry contact 5 Dry contact 6 Dry contact 7 Dry contact 8
Default alarm AC power failure DC overvoltage or DC undervoltage Rectifier alarm Priority LLVD Non-priority LLVD / / /
Description / Four-level DC voltage alarms Except rectifier lost and multi-rectifier alarm / / / / /
With default settings, when the preceding alarms are generated, the contactors of the corresponding dry contacts should change their status, that is, the normally-open contactors close, and the normally-closed contactors open. All the status changes should be verified by a multimeter. After the alarms are removed, the dry contacts should resume. The default settings of the dry contact alarms can be changed through the controller. The interfaces of the user connector board are shown in Figure 2-16.
Figure 2-16 W2453X1 user connector board interface
IB2 user interface board The external input and output signals are all connected to the IB2 user interface board. For the ports on the IB2 user interface board, see Figure 2-17.
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Figure 2-17 IB2 user interface board definition
Note
1. J11 and J12 are temperature sensor ports. They are not used here. 2. J2 is I2C interface, and provides the power. See Table 2-6 for the dry contact terminal definition. Table 2-6 Dry contact terminal definition Name of double-layer port
J3
J4
J5
J6
J7
Pin No. 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5
Pin name DI1DI1+ DI2DI2+ DI3DI3+ DI4DI4+ DI5DI5+ DI6DI6+ DI7DI7+ DI8DI8+ NA NA DO1_NC DO2_NC DO1_COM DO2_COM DO1_NO
Definition Digital input 1Digital input 1+ Digital input 2Digital input 2+ Digital input 3Digital input 3+ Digital input 4Digital input 4+ Digital input 5Digital input 5+ Digital input 6Digital input 6+ Digital input 7Digital input 7+ Digital input 8Digital input 8+ / / NC contact of relay 1 NC contact of relay 2 Common contact of relay 1 Common contact of relay 2 NO contact of relay 1
6
DO2_NO
NO contact of relay 2
1 2 3
DO3_NC DO4_NC DO3_COM
NC contact of relay 3 NC contact of relay 4 Common contact of relay 3
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J8
J9
Pin No. 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
Pin name DO4_COM DO3_NO DO4_NO DO5_NC DO6_NC DO5_COM DO6_COM DO5_NO DO6_NO DO7_NC DO8_NC DO7_COM DO8_COM DO7_NO DO8_NO
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Definition Common contact of relay 4 NO contact of relay 3 NO contact of relay 4 NC contact of relay 5 NC contact of relay 6 Common contact of relay 5 Common contact of relay 6 NO contact of relay 5 NO contact of relay 6 NC contact of relay 7 NC contact of relay 8 Common contact of relay 7 Common contact of relay 8 NO contact of relay 7 NO contact of relay 8
The definition of dry contact function can be set through controller or WEB browser. The specifications of the dry contact ports are as follows: Digital inputs: 8-route, opto-isolation, the alarm and high/low level are definable (high level: 20V ~ 60V, low level: less than 1V). Digital output: 8-route, relay isolation, maximum: 30Vdc 1A, 125Vac 0.5A; 60W; minimum: 10uA @ 10Vdc, alarm is definable. Connecting Communication Signal Cable The communication port of the M221S controller is shown in Figure 2-18. The M222S only provides the RS232 communication serial port, whereas the Ethernet port is not provided.
Figure 2-18 M221S controller communication port
The communication port of the M820B controller is shown in Figure 2-19.
Figure 2-19 M820B controller communication port
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Chapter 3
Installation Testing
Chapter 3 Installation Testing This chapter introduces procedures of installation testing. The corresponding safety rules shall be adhered to in the test.
3.1 Installation Check And Startup Before the test, inform the chief manufacturer representative. Only 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. Installation check must be done before testing. Then the batteries can be charged for the first time. Make sure that the AC input MCBs, battery MCBs and load MCBs are switched off. Make sure that all the devices are properly installed. Installation check Check all the MCBs and cables. Are their models correct? Check the bus bar connections, input and output cable connection, and connection between the power system and the system grounding. Check the if the number and connections of the batteris are correct. Check the polarity of the battery string with a voltmeter. Make sure all the cable connections are firm and reliable.
OK
Comments
Startup preparations Make sure that all the MCB are switched off. Measure the AC input voltage. Make sure the input voltage is within the allowable range. Check that the communication and alarm cables are connected to the signal transfer board. Check that the temperature sensor, if any, has been installed. Check that the battery string circuit is not closed. Connect the disconnected batteries to the battery string circuit Switch off unconnected battery MCBs. Check that the battery signal cables are connected to battery MCBs reliably, not loosened or suspended Measure with a voltmeter across the connection points of each battery and make sure that the polarity is right. For a lead-acid battery with 24 cells, the voltmeter should read 2.0-2.1V/cell or 48-51V/battery. If the voltage of certain cell is lower than 2.0V, that cell must be replaced. Check with an ohmmeter that there is no short circuit between the positive & negative distribution bus bars, or between the positive & negative battery poles (Note: Pull out all modules before the check and restore them after the check)
OK
Comments Umin=___V
Umin=___V
Startup Switch on the system AC input MCB. The green LED on the rectifier will be on and the fan will start running after a certain delay. The controller will show that the power supply voltage is 53.5V. Check the system voltage and busbar polarity with a voltmeter. The voltage difference between the measured value and displayed value should be less than ± 0.2V. Start and stop each rectifier of the system by unplugging and inserting each rectifier. Check their output voltages.
OK
Comments
3.2 Basic Settings When the system is put into service for the first time, the parameters of controller must be set based on the actual system configuration, such as battery number, capacity, user’s charge current limit and other functional requirements. Only after that can the controller display system operation information and control the output.
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Installation Testing OK
Comments
The system model has been set correctly in factory before delivery, check that the setting agrees with the actual system: NetSure 701 A41-S1：48V/SET；Set the battery shunt coefficient for：175A/25mV； NetSure 701 A41-S2～S5：48V/SET；Set the battery shunt coefficient for：300A/25mV；
NetSure 501 A41-S1：48V/SET；Set the battery shunt coefficient for：175A/25mV； NetSure 501 A41-S2：48V/SET；Set the battery shunt coefficient for：300A/25mV； NetSure 501 A91-S1：48V/SET；Set the battery shunt coefficient for：300A/25mV The DC over-voltage alarm point has been set correctly in factory before delivery, check that the setting agrees with the actual system: Set DC over-voltage alarm: 58V Check that the parameter Setting→Alarm Settings→Alarm mode, check that the mode is set to “High” The battery string number set at the controller should be the same as the number actually connected. (By default: 2) Set the battery capacity according to the actual capacity of the battery connected to the system. Default: 300Ah Configure the temperature coefficient according to the battery manufacturer’s requirement. Setting range: 0-500mV/°C. By default: 72mV/°C. (if no temperature sensor is installed, do not set this parameter) Set the charge current limit according to your needs. Setting range: 0.1~0.25C10. (By default: 0.1C10) Set the controller according to the voltage suggested by the battery supplier. Floating Charge (FC) voltage range: 42V ~ Boost Charge (BC) voltage. Default: 53.5V. BC voltage range: FC voltage ~ 58V. By default: 56.4V. For batteries that do not need BC, set the BC voltage to FC voltage plus 0.1V Put through the battery MCBs and connect the batteries
3.3 Alarm Check And System Operation Status Check Alarm check Check that all functional units can trigger alarms that can be displayed on the controller. Pull out one rectifier. The “Rect N Com Failure” alarm should be triggered. Insert the rectifier in. The alarm should disappear. Repeat the same procedures on other rectifiers. Remove battery MCB 1. The “Batt1 Failure” alarm should be triggered. Put on the MCB. The alarm should be cleared. Repeat the same on battery MCB 2. Switch off a load MCB connected to a load route. The alarm “Load N Failure” should be triggered. Switch on the MCB, and the alarm should be cleared. Repeat the same on the other load MCBs. Remove all the battery input MCBs. Keep only one rectifier in operation. Through the controller, adjust the rectifier FC voltage to make it lower than the alarm point. The alarm “DC Voltage Low” should be triggered. Keep the rectifiers in operation. Set through the controller the battery management parameter to “Manual”. Enter the maintenance menu at the controller. Select “Disconnect” and confirm it. The battery protection contactor should be open, and the “BLVD” alarm should be displayed at the controller. Note: when the preceding alarms are generated, the controller will give alarms after approximately 3s.
OK
Comments
System operation status check There should be no alarms during normal system operation. The system operation status check can be conducted through the controller. Check that the system type agrees with the actual system when the system operates The controller should display the correct AC voltage. The controller should be able to display the DC voltage. The difference between the displayed voltage and that measured at the bus bar should be less than 1%. The controller should display the battery current. The difference between the displayed and measured battery current should be less than 1%. Check the number of the rectifier through the controller. The number should be consistent with the actual number. Check the voltage, current, current limiting point of rectifiers through the controller. They should agree
OK
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Installation Testing OK
with the actual parameters. For the system configured with temperature sensor, the controller should be able to display the battery ambient temperature. Hold the probe of the temperature sensor with hand and watch the controller, which should diplay the change of temperature.
Comments
3.4 Final Steps Disconnect all test equipment from the system and make sure that materials irrelevant to the equipment have been all removed. Restore the equipment 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 defective unit to the repairing center for fault analysis.
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Chapter 4
Use Of Controller
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Chapter 4 Use Of Controller The controller modules of this power system are M221S, M222S and M820B. The M820B control module for details please refer to the ACU+ User Manual. This chapter introduces the front panel and functional keys briefly, and expounds screen contents, access method, system controlling, information querying and parameter setting. After the controller is powered on, the language selection screen will pop up, and the controller is initialized. The default language is Chinese. After the initialization, the first system information page will appear.
4.1 Control Keypad And Indicator 4.1.1 Front Panel There are backlit LCD display, functional keypad, indicators and positioning pin on the front panel of M500D controller, as shown in figure 4-1.
Figure 4-1 Front panel of M500D controller
4.1.2 Indicator Function The function of the indicators is shown in table 4-1. Table 4-1 Functions of Indicators Indicator
Normal State
Fault State
Fault Cause
Status (green)
On
Off
If this LED is on, this means the system is operating normally
Observation Alarm (yellow)
Off
On
The power system has one or more active observation alarms. Alarm conditions are programmable. Refer to Table 3-3 for defaults
Major Alarm (red)*
Off
On
The power system has one or more active major alarms (Major and Critical Alarms). Alarm conditions are programmable. Refer to Table 3-3 for defaults
Note: A Major Alarm initiates an alarm report if alarm report is enabled
4.1.3 Control Keypad Function The function of the control keypad is shown in table 4-2. Table 4-2 Function of Keys on the Panel Key Symbol
Key Name
ENT
Enter
▲
Up
▼
Down
ESC
Escape
Function Confirm or Execute Move Up Cursor or Select the Previous Screen Move Down Cursor or Select the Next Screen Escape or Cancel
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4.2 LCD Menu Tree The overall menu structure is shown in Figure 3-5. 09:20:20 Float 53.4V 404A Manual Normal 08 -11 - 03 Float 53.4V 404A Manual Normal
ENT MAIN MENU Status Settings Manual ECO Quick Settings
ENT
STATUS Active Alarm Rectifiers History Alarm
SETTINGS Alarm Battery AC DC Rectifier Controller Communication
MANUAL Sys Mode: Auto ▼ In Manual
ECO Disable CycPeriod: 168h RectWork: 80% Rect Limit: 1 System Type: 48V / set Capacity: 300Ah LCD Rotation: On
Figure 4-2 Main menu screen
4.2.1 Status In the screen of MAINMENU, when cursor is at ‘Status’, press ‘ENT’ to go to the status screen: Status Active Alarm Rectifiers History Alarm
ALARM: 2/2 ALARM: 1/2 ENT Batt Volt Low ENT Batt Discharge Critical Alarm Observation Alarm Start Time: Start Time: 081104 15:52:55 081104 15:52:53 RECTIFIER 1/3 ID: 02070801232 R48800B00 DC Volt: 53.4V DC Curr : 0.0A Curr Limit: 109% AC Volt: 201V AC Status: On DC Status: On AC Derated : N Temp Derated : N
ALARM 001 ENT SPD Fault 08- 07 -10 11:35:22 08- 07 - 10 12:35:22
ALARM 002 DC Volt Low 08 - 07-10 11:35:25 08 - 07-10 12:35:25
Figure 4-3 Status screen
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In the status screen, you can move the cursor to ‘Active Alarm’, ‘Rectifiers’, and ‘History Alarm’ respectively and press ‘ENT’ to check the information of active alarm, rectifiers, and history alarm. The rectifier screen shows the information of first rectifier, if you want see the information of next rectifier, just press ‘ENT’. In screen of ‘Active Alarm’, ‘Alarm 1/2’, ‘1/2’ means there are 2 active alarms and this screen is displaying the first active alarm. The alarm level and alarm start time are displayed in the screen In the screen of ‘History Alarm’, the ‘ALARM 001’ means this screen is displaying the first history alarm. The alarm start time and end time are displayed in the screen.
4.2.2 Settings In the Main Menu screen, move the cursor to the item of ‘Setting’ and press ‘ENT’ to enter the Setting menus. Before you access the Setting menu, the system will require you to enter the password first. Method of entering password: For example, to enter the password of ‘640275’: Press ‘ENT’, and the bit will be highlighted, now you can press ▲ or ▼ continuously to enter the numbers from 0 to 9, or enter the letters from ‘a’ to ‘z’ or from capital letter ‘A’ to ‘Z’. After entering ‘6’, press ‘ENT’ and the cursor will move to the next bit, and in the same way, press ▲ or ▼ continuously to enter ‘4’, and you can enter the rest bits ‘0275’ in the same way. ALARM Alarm Level Alarm Control DI Setting
AC Over Volt: 280V Under Volt: 180V PH Fail: 80V AC Input: N AC PH: 3-PH
SETTINGS Alarm Battery AC DC Rectifier Controller Communication
RECTIFIER Position: Disabl R -Posi: 1-1 HVSD: 59.0V Default V: 53.5V Walk-in On: N Walk-in T: 8s Interval T: 0s AC OverV On: N ACCurrLim : 30A CONTROLLER Lang: English Tzone: GMT + 08:00 Date: 2009-03 -23 Time: 22:17:18 System Type: 48V/1000A DownloadMode:N Reset PWD: N Reset Para: N Oper1PWD: ****** Oper2PWD: ****** AdminPWD: ******
BATTERY Basic LVD Charge Test Temp Comp DC Over Volt2: 58.2V Over Volt1: 58.5V Under V1: 45.0V Under V2: 45.0V Amb High: 40C Amb Low: - 5C
COMMUNICATION Address: 1 CommMode : RS232 Protocol: YDN23 BaudRate: 9600 IP/Subnet/Gate: 10.163.210.91 255.255.255.0 10.163.210.1 CallbackTime: 3 PhoneNumber: 86010677 86010808
Figure 4-4 Settings screen
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In the Setting menu, there are 7 items that are ‘Alarm’, ‘Rectifier’, ‘LVD’, ‘AC’, ‘DC’, ‘Controller’ and ‘Communication’ respectively. Move the cursor to ‘Rectifier’ and press ENT, you can configure the following rectifier parameters: Position: Enable or disable the shelf setting. R-Posi: rectifier position in shelf. HVSD: high voltage shut down, rectifier will shut down when its output voltage exceeds this HVSD point. Default V: rectifier default output voltage. Walk-in ON: rectifier walk-in function (soft start) is enabled. Walk-in T: rectifier walk-in time (soft start time). Interval T: rectifier sequential startup interval. AC OverV on: rectifier will shutdown when AC input exceeds AC over voltage point. ACCurrLim: rectifier current limiting value during startup process. Move the cursor to ‘AC’ and press ENT, you can configure the following AC parameters: Over Volt: set the over voltage protection point. Under Volt: set the under voltage protection point. PH Fail: set the phase failure voltage point. AC PH: can set the AC input to 3-phase or single phase (‘1-PH’). Move the cursor to ‘DC’ and press ENT, you can configure the following DC parameters: Over Volt2: set the over voltage protection point2. Over Volt1: set the over voltage protection point1. Under V1: set the DC output under voltage point 1. Under V2: set the DC output under voltage point 2. AmbHigh: set the high ambient temperature. AmbLow: set the low ambient temperature. Move the cursor to ‘Controller’ and press ENT, you can configure the following controller parameters: Lang: set the display language of LCD, you can select English or your local language. Tzone: set the time zone. Date: set the current date. Time: set the current time. System Type: set the system type. DownloadMode: enter the download mode through serial port. Reset PWD: Reset the password to default. Reset Para: Reset parameters to default. Oper1PWD: set the password of operator 1. Oper2PWD: set the password of operator 2. AdminPWD: set the password of administrator. There are three levels password. Default passwords: 1 for operator1, 2 for operator2, and 640275 for administrator. Only administrator can transfer to serial and web download mode and reset the password. Operator2 can change the system type and reset the parameters. Move the cursor to ‘Alarm’ and press ENT, you can enter the alarm menus:
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Chapter 4 Alarm Alarm Level Alarm Control DI Setting
ENT
ALARM LEVEL ENT ALARM LEVEL Alarm Block SPD fault Severity: Severity: Observation Alarm Major Alarm Out Relay: 0 Out Relay: 0
Use Of Controller
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ENT ALARM LEVEL LFuse Alarm Severity: Critical Alarm Out Relay: 6
ALARM CONTROL Alm Voice: Open Clear: History
DI SETTINGS DI NO.: 1 Digital1 Alarm Active: High
Figure 4-5 Alarm screen
Alarm level setting In the submenu of alarm level setting, move cursor before ‘Alarm Block’, press ‘ENT’, then you can set the alarm levels of other alarms such as ‘SPD fault’, ‘LFuse Alarm’, ‘Digital3 Alarm’, etc. In the submenu of alarm level setting, you can set the alarm level of each alarm to observe alarm, major alarm, or critical alarm. You can also set the output relay number that outputs the alarm signal. The characteristics of 4 alarm categories are given in the following table: Table 4-3 characteristics of 4 alarm categories
Alarm levels
Red alarm indicator of controller and system
Yellow alarm indicator of controller and system
Alarm buzzer
Alarm report
Remark
CA (critical alarm)
On
On
Yes
Alarm report is enabled
MA (major alarm)
On
On
Yes
Alarm report is enabled
On
Off
No
Off
Off
No
OA (observation alarm) No alarm
Off
Note: 1. The alarm levels of temperature sensor disconnected alarm and temperature sensor failure alarm, and the corresponding relay output cannot be set through the LCD. The alarm levels of these two alarms and the corresponding relay are the same with those of the high temperature alarm setting. 2. If the analog alarm has two levels of alarm thresholds, and if these two alarm thresholds are set to the same value, then the second level will be cancelled and the first level of the alarm will be displayed in LCD. For example: If the alarm threshold of ‘high temperature 1’ is set to the same with the threshold of ‘high temperature 2’, and if this threshold is set to 40 deg C, then when the temperature exceeds 40 deg C, the system will only issue ‘high temperature 1 alarm’, and will not issue the ‘high temperature 2 alarm’. In the alarm level setting submenu, you can also set the output relay no. for the corresponding alarm. Alarm control menu For the submenu of ‘AlmVoice’ of alarm control menu, you can set it to ‘Open’(audible alarm is enabled) or ‘Close’ (no audible alarm), and you can also set the time of audible alarm and the time can be ‘3min’, ‘10min’, ‘1h’ and ‘4h’. For the submenu of ‘Block Alarm’, you can set ‘Y’ or ‘N’ to select whether the alarm should be blocked or not. For the submenu of ‘Clear’, you can select ‘History’, ‘ECOFail’, ‘Maintain’, ‘ShortTest’, ‘TestFail’ ,’Rect Lost’ ‘Rect Commb’ and ‘Rect Not respond’ to clear corresponding alarm.
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DI SETTINGS All the alarms can be configured with No.1 to No.8 alarm contacts. ‘0’ means no alarm dry contacts. All the alarm dry contacts provide NC (normally closed) or NO (normally opened) output and the default alarm dry contacts are given in the following table. Table 4-4 Default alarm dry contact setting Dry contact No.
Default alarm
Dry contact 1
Mains Failure
Dry contact 2
DC Under Volt or DC Over Volt
Dry contact 3
Rectifier alarm
Dry contact 4
LVD2
Dry contact 5
LVD1
Dry contact 6
None
Dry contact 7
None
Dry contact 8
None
Table 3-5 lists the alarms that you can scroll through in the ALARM SETTINGS/ALARM LEVEL menu, and also shows their factory default ‘Alarm Level’ and ‘Mapped Output Relay’ settings. Table 4-5 Controller Alarms and Factory Default Settings Alarm name Alarm Block Batt Imbalance
Alarm description
Condition
Default alarm level
Alarm Block
Alarms are blocked by the LCU+
Observation
Batt Imbalance
Battery middle voltage out of the range of ( bus voltage /2) ± 0.6
Major
Into and out of save power status for 5 times in one hour
Major
SavePowerF SavePowerFault ault
Default mapped output relay
Save Power
Save Power Function System is in save power status
Observation
AC High
AC Voltage High
Input phase voltage higher than AC High point
Observation
AC Low
AC Voltage Low
Input phase voltage lower than AC Low point
Observation
AC PH Fail
AC Phase Fail
Input phase fails
Observation
Temp High2
Temperature High 2
Ambient/ Battery temperature higher than Temperature High 2
Major
Temp High1
Temperature High1
Ambient/ Battery temperature higher than normal operation range
Major
Temp Low
Temperature Low
Ambient/ Battery temperature lower than normal operation range
Observation
Batt Over Chg
Battery Over Charge
The charging current over the maximum value
Observation
DC Volt High+
DC Voltage High+
System output voltage much higher than float charge voltage
Critical
2
DC Volt High DC Voltage High
System output voltage higher than float charge voltage
Critical
2
DC Volt Low
System output voltage slightly lower than float charge voltage
Critical
2
DC Volt Low- DC Voltage Low-
System output voltage is much lower than float charge voltage
Critical
2
Rect HVSD
Rectifier HVSD
Rectifier HVSD circuit activated
Major
3
Rectifier LoadShare
The difference between rectifier output current and average output current larger than 8A (+/-4A), and the load of the rectifier greater than 10% of its capacity
Observation
3
Rect Derated Rectifier Derated
The output power of at least one rectifier is derated because of AC undervoltage or overtemperature
Observation
3
Rect Fan Fails
Rectifier Fan Fails
Fan of at least one rectifier fails
Major
3
Rect Protect
Rectifier Protect
AC input voltage out of the range of 85Vac to 295Vac results in at least one rectifier protected
Observation
3
Rect LoadShare
DC Voltage Low
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Chapter 4 Alarm name
Alarm description
Condition
Use Of Controller
Default alarm level
25
Default mapped output relay
Rect Failure
Rectifier Failure
Serious load sharing alarm (the output current of the rectifier is lower than 1A, and the average load is Critical greater than 10% of the total rectifier capacity)
Rect TempHigh
Rectifier Temperature High
High temperature protection activated in at least one Major rectifier
3
Rect AC Fail
Rectifier AC Fail
AC input voltage lower than 80Vac
Major
3
Rect Comm Fail
Rectifier Communication Fail
Rectifier(s) unable to communicate with LCU+
Major
3
MultiRect Alarm
Multi rectifier Alarm
Two or more rectifiers have alarms
Critical
System Maintain
System Maintain
System has not been maintained within preset maintenance time
None
Rect Lost
Rectifier Lost
Rectifier reduction detected
Critical
Rect OverLoad
Rectifier OverLoad
Total load current greater than the High Load value
Observation
Mains Failure
Mains Failure
AC input voltage lower than 80Vac
Major
1
LVD2
LVD2
LVD contactor 2 open due to low battery voltage
Critical
4
LVD1
LVD1
LVD contactor 1 open due to low battery voltage
Critical
5
Batt Test Fail Battery Test Fail
Battery discharge test failure (battery voltage is Observation lower than setting value before test time is reached)
DC Volt Fail
DC Voltage Fail
The difference between bus voltage and the set output voltage larger than the set value
Observation
Curr Imbalance
Current Imbalance
The total output current not equal to the sum of the battery current and the load current
Observation
Batt Discharge
Battery Discharge
Batteries are discharging
Observation
Batt Test
Battery Test
The batteries are testing
None
Boost Charge
Boost Charge
The batteries are in boost charge state
None
Manual Mode
Manual Mode
The system is in manual mode
Observation
SelfDetect Fail
SelfDetect Fail
LCU+ detects error in hardware self test
Observation
LVD2Ctrl Fail LVD2 Control Fail
After battery disconnection/ connection signal is sent out, the feedback signal of the contactor is false
Critical
BattFuse Fail
Battery Fuse Fail
Battery fuse(s) or circuit breaker(s) open
Critical
LoadFuse Fail
Load Fuse Fail
Distribution (load) fuse(s) or circuit breaker(s) open
Critical
Digital4
Digital4
User programmable
Major
Digital3
Digital3
User programmable
Major
Digital2
Digital2
User programmable
Major
Digital1
Digital1
User programmable
Major
SPD
SPD
SPD signal interrupted
Major
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Move the cursor to ‘Battery’ to set the battery parameters: Sys Mode: Auto BattFuse : 2 Capacity: 600Ah Bat. Shunt: Y Shunt Coeff -Current: 500A -Volt: 25mV
BATTERY Basic LVD Charge Test Temp Comp
ENT
LVD1: Enbl LVD2: Enbl LVD1 Volt: 44.0V LVD2 Volt: 43.2V
Center Temp: 25C Coeff : 72mV / C Temp1: N Temp2: N Batt T H2: 50C Batt T H1: 50C Batt T L1: 0C
Float: 51.8V Boost: 57.6V Limit: 0.100C Over: 0.300C Auto Boost: - Enable -Current: 0.060C - Capacity: 80.0% Const Boost: - Curr: 0.01C - Time: 180min Cyc Boost: - Enable - Period: 2400h -Time: 720min Boost Limit Time: 1080min
End Test - Volt: 45.2V - Time: 300min - Capacity: 0.70C Cyc Test: Disabl Cyc Test Time: 01 - 01 00:00 04 - 01 00:00 07 - 01 00:00 10 - 01 00:00 Short Test: - Enable: No - Alarm 10A - Period: 1h - Time: 1min ConCurr Test: - Enable: No - Current: 9999A
Figure 4-6 Battery screen
Move cursor to ‘Basic’, you can configure the following parameters: Sys Mode: set the system mode from ‘Auto’ to ‘Manual’ or from ‘Manual’ to ‘Auto’. Method of changing ‘Auto’ to ‘Manual’: As shown in screen of ‘Basic’, in the item of ‘Sys Mode’, press ‘ENT’ to highlight ‘Auto’, and then press ▲ or ▼ to change it into ‘Manual’, and then press ‘ENT’ again to validate the change. BattFuse: set the number of battery fuses. Capacity: Set the battery capacities. Bat. Shunt: set if battery shunt is configured. Shunt Coeff: set current and voltage coefficients. Move cursor to ‘LVD’, you can configure the following parameters: LVD1: Enable or disable LVD1. LVD2: Enable or disable LVD2. LVD1 Volt: set the voltage point at which the LVD1 contactor disconnects. LVD2 Volt: set the voltage point at which the LVD2 contactor disconnects. Move cursor to ‘Charge’, you can configure the following parameters: Float: set the float charging voltage. Boost: set the boost charging voltage.
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Limit: set the charging current limit. This is the maximum charging current that should be allowed into the battery at any time, as regards to the nominal capacity of the battery. For example, a value of 0.150C10 means that the charging current is limited to 15% of the battery’s nominal capacity. Over: set the over boost charging current. This is the charging current, as regards to the nominal capacity of the battery, at which an over current alarm will be initiated if this current is reached. For example, a value of 0.300C10 means that when the charging current reaches 30% of the battery’s nominal capacity, an alarm will be extended. AutoBoost: An Automatic Boost is started when one of the following conditions is reached. -Enable: Use this submenu to enable or disable auto boost charging. -Curr: This is the battery discharge current, as regards to the nominal capacity of the battery, above which an Automatic Boost is started, when the Automatic Boost function is enabled. For example, a value of 0.060C10 means that an Automatic Boost is started if the battery current is greater than 6% of the battery’s nominal capacity. -Cap: This is the remaining battery capacity under which (less than) an Automatic Boost is started when the Automatic Boost function is enabled. CycBoost -Enable: Use this submenu to enable or disable cyclic boost charging. -Period: Use this submenu to set cyclic boost charging period. This is the interval, in hours, between the boost cycles. -Time: Use this submenu to set cyclic boost charging time. This is the duration of each cycle for the Cyclic Boost when this function is enabled. Const Boost -Curr: Use this submenu to set constant boost charging current. -Time: Use this submenu to set constant boost charging time. BoostLimitTime: Use this submenu to set boost charging time limit beyond which boost charge will be stopped. Move cursor to ‘Test’, you can configure the following parameters: End Test: A Battery Test is interrupted when one of the following conditions is reached. -Volt: This is the ‘end of test voltage level’ for each battery test. -Time: This is the maximum duration, in minutes, for each battery test. -Cap: This is the remaining battery capacity, as regards to the nominal capacity of the battery, at which a Battery Test will be interrupted. For example, a value of 0.700C10 means that when the charging current reaches 70% of the battery’s nominal capacity, the battery test is interrupted. Cyc Test: Displays whether the time (on specific dates) battery test function is enabled (Y) or not (N). During a Timed Battery Test, the output voltage of the rectifiers is reduced so that the batteries power the load. If the batteries fail, the rectifiers power the load. Short Test: A short test is a short duration battery discharge test used to verify that parallel batteries are discharging equally. If the discharge current difference between the two batteries exceeds a preset level (default is 10 A), a Short Test Fault alarm is generated. -Enable: Displays whether the short (at specific intervals) battery test function is enabled (Y) or not (N). -Alarm: Displays the battery current difference at which an alarm will be extended. -Time: Displays the interval, in hours, between short battery tests. -Duration: Displays the duration, in minutes, of each short battery test. ConCurr Test: A Constant Current test is a battery discharge test done at constant current. The controller will automatically adjust the rectifiers to maintain the battery discharge current at the preset value. -Enable: Displays whether the constant current battery test function is enabled (Y) or not (N). -Current: Displays the stable test current. Move cursor to ‘TEMP COMP’, you can configure the following parameters: Center Temp: Displays the temperature, in °C, at which the system operates at normal voltage levels. Temp 1: Displays whether a temperature probe on MB is installed and enabled (Battery or Ambient) or not (None) in position No. 1, and if there is one, whether it is used for battery or ambient temperature measurements.
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Temp 2: Displays whether a temperature probe on MB is installed and enabled (Battery or Ambient) or not (None) in position No. 2, and if there is one, whether it is used for battery or ambient temperature measurements. Coeff: Displays the temperature compensation slope or rate of change per °C above or below the normal operation level selected in the second line. This value is expressed in millivolt per °C per string (mV/°C/str). For example, for a rate of change of 72mV/°C/str in a 24-cell, 48 V nominal, battery string, the rate of change is 3 mV per cell.
4.2.3 Manual In the Main Menu, move the cursor to ‘Manual’ and press ENT to enter Manual control menu: Change to 'Manual' from 'Auto' MANUAL Start: Float LVD1: Reconn LVD2: Reconn RectTrim : 53.5V RectLimit : 121%
MAIN MENU Status Settings Manual ECO Quick Settings
MANUAL ENT Sys Mode: Auto ▼ In Manual
Figure 4-7 Manual screen
In the manual screen, you can perform the following manual control operations: Start: To start float or boost charging or battery test. LVD1: To reconnect or disconnect LVD1 contactor. LVD2: To reconnect or disconnect LVD2 contactor. RectTrim: To adjust the rectifier output voltage. RectLimit: To adjust the rectifier current limiting point.
4.2.4 ECO In the Main Menu, move the cursor to ‘ECO’ and press ENT to enter ECO menu: MAIN MENU Status Settings Manual ECO Quick Settings
ENT
ECO Disable Cyc Period: 168h Rect Work: 80% Rect Limit: 1
Figure 4-8 ECO screen
The following parameters can be configured: ECO: To disable or enable ECO function. Cyc Period: Rectifier redundancy cycle. Rect Work: Optimum operating load point of rectifier. Rect Limit: In ECO mode, the minimum number of rectifiers required.
4.2.5 Quick Setting In the Main Menu, move the cursor to ‘Quick Setting’ and press ENT to enter Quick Setting menu: MAIN MENU Status Settings Manual ECO Quick Settings
Figure 4-9
ENT
System Type: 48V / 1000A Capacity: 300Ah LCD Rotation: On
Quick Settings screen
In the Quick Setting screen, you set the system type and system capacity, as well as the parameters (current, voltage) of load shunts and battery shunts.
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4.2.6 Controller Setting Table 4-6 summarizes all the settings of the controller. Table 4-6 Controller Settings
DI alarm mode HVSD point Default voltage Restart time upon over voltage Soft-start time with load Soft-start with load enabled Startup upon AC over voltage System ECO enabled Sequencial start interval Input current limiting Rectifier slot setting enabled Rectifier slot setting Number of fuses Nominal capacity Shunt
Available Settings Low limit High limit High / low 56 59 48 58 0 300 8 128 Enabled/Disabled Enabled/Disabled Enabled/Disabled 0 10 1 50 Enabled/Disabled 1 30 0 5 20 5000 Yes / No
Shunt current
1
Shunt voltage Temperature 1 Temperature 2 Float charging voltage Boost charging voltage Charging current limiting Auto boost charging enabled Constant charging current Constant current charging time To boost charging current To boost charging capacity Scheduled boost charging enabled Boost charging protection time Scheduled boost charging cycle Scheduled boost charging time Battery test end time Battery test end voltage Battery test end capacity Scheduled test enabled Constant current test enabled Constant battery test current Short test enabled Short test alarm point Short test cycle Short test time Temperature compensation central point Battery compensation coefficient Battery over temperature point Battery high temperature point Battery low temperature point Over voltage 1 Under voltage 1 Under voltage 2 High ambient temperature Low ambient temperature
Components Alarm
Rectifier
Basic battery parameters
Battery
Battery charge parameters
Battery charge parameters
Battery test parameters
Battery temp compensation coefficient
DC unit
Name
Default setting High 59 53.5 300 8 Disabled Disabled Disabled 0 30 Disabled 1-1/2-2… 2 600
Unit / V s s / / / s / / Ah
1 500 None/Battery/Ambient None/Battery/Ambient 42 58 42 58 0.1 0.25 Yes / No 0.002 0.02 5 1440 0.04 0.08 10 99 Yes / No 60 2880 2 8760 30 2880 5 1440 43.1 57.9 0 1 Yes Yes / No 1 9999 Yes / No 1 100 24 8760 1 60
According to system type 25 Disabled Disabled 53.5 56.4 0.1 Yes 0.01 180 0.06 80 Yes 1080 2400 720 300 45.2 0.7 No No 9999 No 10 720 5
mV / / V V C10 / C10 Min C10 % / H h Min Min Min C10 / / A / A h min
10
40
25
deg.C
0 10 10 -40 40 40 40 10 -40
500 100 100 10 60 60 60 100 10
72 50 50 0 58.5 45 45 40 -5
mv/deg.C deg.C deg.C deg.C V V V deg.C deg.C
2000
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Components
Name Load shunt LVD1 Enabled LVD2 enabled
LVD
LVD1 voltage LVD2 voltage AC unit
Communication parameters
Controller parameters
Available Settings Low limit High limit Yes / No Disabled / Enabled Disabled Disabled /Enabled 40 60 40 60
Default setting No Disabled
Unit / /
/ 43.2 43.2
V V
Over voltage alarm point
0
500（866）
280（485）
V
Under voltage alarm point
0
500（866）
180（304）
V
Phase failure alarm point
0
500（866）
80（255）
%
IP address Subnet code Default gateway Local address Port type Baud rate Protocol Alarm call-back enabled Call back times Call back number 1 Call back number 2 Call back number 3 Language Display time zone System date System time Restore default configurations Set rotating screens
0-255 0-255 0-255 1 RS232/Modem/ETH 1200/2400/4800/9600 YDN23/EEM/RSOC/SOCTPE Yes / No 0 10
192.168.1.2 255.255.255.0 192.168.1.1 255 1 RS232 9600 YDN23 No 3
/ / / / /
English / Chinese
English GMT+08:00
Yes / No Horizontal/Vertical 48V/set, 48V/1000A, 48V/500A, 48V/300A, 48V/100A, 24V/set, 24V/1000A, 24V/500A, 24V/300A and 24V/100A
No Horizontal
System type
/ /
48V/set
4.3 WEB Interface Operation Through the WEB Interface, a remote user can: View real-time operating information. Send control commands. Set programmable parameters. Set which new alarms are displayed in a pop-up WEB window. Download and upload configuration files.
4.3.1 Setting Up The Internet Explorer Web Browser Procedure
Note
This procedure needs to be performed only when the controller is connected to an Internet and the User has set that the access to the Internet needs to be made through proxy. If the controller is connected Internet and the user computer is connected to the Internet, the user cannot disable the proxy, otherwise he will have no access to the controller. 1. Launch Internet Explorer.
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Chapter 4 2. Select Internet Options from the Tools menu. The ‘Internet Options’ window opens. window, select the Connections tab.
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In the ‘Internet Options’
Figure 4-10 Internet options window
3. Click on the LAN Settings... button. box and click OK.
The following window opens. In the LAN Settings window, uncheck the proxy
Figure 4-11
LAN settings window
4.3.2 Logging Into The Controller Procedure In Internet Explorer, enter the IP address programmed into the controller and press ENTER. The following WEB Interface window opens. Enter a valid User Name and Password, and then click OK. By default, there are two ‘User Name’ and ‘Password’ combinations, one is ‘admin’ and ‘640275’, the other is ‘operator’ and ‘1’. The username of ‘admin’ has the highest authority and the username ‘operator’ has no authority for uploading and downloading configuration files.
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Figure 4-12 Access to controller
4.3.3 Homepage Introduction After entering a valid User Name and Password, and clicking OK; the homepage window opens. The homepage window is divided into three areas: System Information, Parameter Settings and Control Functions, and Upload/Download Files.
Figure 4-13
Homepage window
System information At the top of homepage, System Information is displayed, such as System Voltage, System Load, MA/CA Number, OA Number, Battery Mode, Site Name, HW Version, and SW Version. Parameter and control function You can set the following parameters and control functions: Battery Temp Comp: To disable or enable the battery temperature compensation function. NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
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Battery Test: To disable or enable the periodical battery test function. This setting has no effect on the short test. Current Limitation: To disable or enable the battery charging current limitation function. Boost Charge: To disable or enable the periodical battery boost charging function. This setting has no effect on auto boost charging. LVD1 Level, LVD2 Level: To set the low voltage disconnection point. Under Voltage Level 1, Under Voltage Level 2: To set the under voltage point. System Volt: To set the system voltage. Boost Volt: To set the battery boost charging voltage. NMS1 IP, NMS2 IP: To set the IP address of SNMP Remote1 IP, Remote2 IP: To set the IP address of EEM protocol. TCP IP address: To set the IP address of TCP IP protocol. Upload/download files 1. Procedure 1) To upload a configuration file, click the Upload button. The following window opens. Click the Save button.
Figure 4-14
Uploading the configuration file
2) The following window opens. Navigate to where you want the file to be saved. Click the Save button.
Figure 4-15 Save as window
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After the upload is completed, the system will pop up a window to prompt the user that the upload is successful:
Figure 4-16
Upload successful
3) Users can also upload up to 80 active alarms or history alarms. 4) To download a file, click the Browse button. Navigate to and select the configuration file to be downloaded:
Figure 4-17 Selecting the configuration file
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Then click Open:
Figure 4-18 Access to the homepage
Then click Download button, the system will pop up a window requiring you to confirm:
Figure 4-19
Confirmation window
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Click OK, the system will prompt you that the download is successful:
Figure 4-20
Download successful
In the above screen, you can click ‘Back to the Homepage’ to return to the Homepage. Administrator can click ‘Go to Firmware Download Mode’ to enter Bootloader download interface.
4.4 WEB Bootloader Interface Operation Below is the web download webpage. In this webpage administrator can update the firmware. Please ensure that the file name of the firmware is M221S.bin.
Figure 4-21 WEB webpage
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4.5 Serial Bootloader Interface Operation Serial COM PORT can be used to download and upload files through the following procedure: 1. Connect Serial line to the computer and LCU+. Connect the DB9 terminal to computer, while connect the RJ45 terminal to the port assigned with ‘IOIO’ on LCU+. 2. Open the software of HyperTerminal on the computer, set the parameters according to the following method, here we use COM1, however, other COM PORT is optional dependent on your computer.
Figure 4-22
Choose the COM port
Figure 4-23 Set the parameters of COM port
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Figure 4-24 Main menu of download/upload
Here we can see there are 4 options, choose ‘1’ to download the application program, choose ‘2’ to download the configuration data, choose ‘3’ to upload the data configuration file, choose ‘4’ to execute the application program. 1. Method of downloading the application program: 1) Press ‘1’ on the keyboard, enter the surface of download; 2) Choose Transfer->Send File…, select the .bin file you want to download;
Figure 4-25
Choose the file
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Pay attention that the protocol is Ymodem
Figure 4-26
Choose Ymodem as protocol
3) Press ‘Send’, ‘.bin’ file is transmitted from computer to LCU+;
Figure 4-27 The process of downloading file
4) After the file downloading is completed successfully, the following interface pops up:
Figure 4-28
Downloading file successfully
2. Method of downloading the configuration data: Similar to the download of application program, will not be introduced here; 3. Method of uploading the data configuration file: 1) Press ‘3’ on the keyboard, enter the interface of uploading files:
Figure 4-29
Uploading the file
2) Choose Transfer->Receive File… to select the position in which you save the file
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Figure 4-30 Select the position in which you save the file
Pay attention that the protocol is Ymodem.
Figure 4-31
Choose Ymodem as protocol
3) Press Receive, the file is transmitted from LCU+ to computer.
Figure 4-32 The process of uploading file
4) After the file downloading is completed successfully, the following interface pops up.
Figure 4-33
Uploading file successfully
You can also press "4" on the keyboard to execute the application.
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Alarm Handling
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Chapter 5 Alarm Handling This chapter describes the handling of alarms, as well as the preventive maintenance of the system during system daily operation. The maintenance personnel must have adequate knowledge about the power system.
Note
1. The maintenance must be conducted under the guidance of related safety regulations. 2. Only the trained personnel with adequate knowledge about the power system can maintain the inner part of the subrack.
5.1 Handling Alarms The controller alarms are classified in four types: critical alarm, major alarm, observation and no alarm. Critical alarm, major alarm: these two types of alarms have strong impacts on the system performance. Whenever these alarms are generated, users are supposed to handle them immediately. The alarm indicators will be on and audible indication will be given. Observation: when this type of alarm is raised, the system maintains normal output for a while. If the alarm occurs during watch time, it should be handled immediately. If the alarm occurs during non- watch- time, handle it during watch time. The alarm indicators will be on when observation alarm occurs. No alarm: if alarms are set as ‘no alarm’ by the users, when these alarms occur, no visible or audible indication will be generated and the system works normally. The handling methods of normal alarms are given in Table 5-1. Table 5-1 System setting parameter description No.
Alarm
1
Mains Failure
2
AC Voltage High
3
AC Voltage Low
4
SPD failure
5
DC Volt High
6
DC Volt Low
7
Load Fuse Alarm, Batt Fuse Alarm
Handling method If the failure does not last long, the battery will power the load. If the cause is unknown or the failure lasts too long, a diesel generator is needed. Before using the generator power to supply the power system, it is suggested to run the generator five minutes to minimize the impact on the power system Check if the AC over-voltage value is too low. If yes, change the value. A mild over-voltage does not affect the system operation. However, the rectifier will stop operation when the mains voltage is more than 530V. If the mains voltage is above the AC over-voltage value, the mains grid should be improved Check if the AC Under- voltage point is too high. If yes, change the value. When the mains voltage is lower than 304V, the output power of the rectifiers will be derated. And if lower than 260V, the rectifiers will stop working. If the mains voltage is under the AC under-voltage value, the mains grid should be improved Check the SPD condition. If the SPD is damaged, replace it Check the DC over-vlotage value through the controller. If the set value is inappropriate, correct it. Otherwise, find out the rectifier that has caused the alarm: 1. Ensure that the batteries can operate normally. 2. Switch off the AC input of all rectifiers. 3. Power on the rectifiers one by one. 4. If the over-voltage protection is triggered when a certain rectifier is powered on, that rectifier is the faulty one. Replace it 1. Check if the alarm is caused by mains failure, if yes, disconnect some loads to prolong the operation of the whole system. 2. Check the DC under-voltage value set through the controller. If the set value is inappropriate, correct it. 3. Check if any rectifier is inoperative, or has no output current. If yes, replace it. 4. Check if the total load current exceeds the total rectifier current during float charge. If yes, disconnect some loads or add more rectifiers to make the total rectifier current bigger than 120% of the total load current with one redundant rectifier Check if the corresponding MCB is switched off. If the MCB is open, find out the fault and remove it. Otherwise, the alarm circuit is faulty. Please contact Emerson
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Chapter 6 No.
Alarm Handling Alarm
8
LVD2
9
Rect Failure
10 Rect Protect 11 Rect Fan Fails 12 Rect Not Respond 13 Batt Over Temp
Handling method 1. Check if there is mains failure, and the battery voltage is lower than the value of ‘LVD2’. 2. Check whether the battery is disconnected from the system manually The rectifier with the fault indicator (red) on is faulty. Power off the rectifier, and then power it on after a while. If the alarm persists, replace the rectifier Check if the mains voltage is above 530V or under 260V. If the mains voltage is under the AC under-voltage value or above the AC over-voltage value, the mains grid should be improved Pull out the rectifier to check if the fan is obstructed. If yes, clean it and push the rectifier back. If the fan is not obstructed or if the fault persists after cleaning, replace the fan Check if the communication cable is connected properly between rectifier and controller. If yes, restart the rectifier. If the alarm persists, replace the rectifier 1. Check if the battery compartment temperature is too high. If yes, cool down the battery compartment. 2. Check if there is battery internal fault. If yes, replace the faulty battery
5.2 Handling Rectifier Fault The indicator description, fan and handling methods of all the rectifiers on the system are the same, take R48-1800A and R48-3200 as an example. Handling indicator fault The symptoms of usual rectifier faults include: Run indicator (green) off, Protection indicator (yellow) on, Protection indicator blink, Fault indicator (red) on and Fault indicator blink, as shown in Figure 5-1.
Run indicator Protection indicator Fault indicator
Run indicator Protection indicator R48-3200
R48-1800
Figure 5-1
Fault indicator
Rectifier indicator
The indicators are shown in Table 5-2. Table 5-2 Indicator fault description Symptom
Monitoring module alarms
Run indicator off (green)
No alarm
Run indicator blinks(green)
No alarm Rect Protect
Rect Protect Protection indicator on (yellow)
Causes No input/output voltage Assistant power source of the rectifier fails The monitoing module performs operations upon the rectifier AC input voltage abnormal Fan blocked Ventilation path blocked at the inlet or vent Ambient temperature too high or the inlet too close to a heat source
Load share Alarm
Current sharing imbalance
Rect Protect
Power factor compensation internal under voltage or over voltage
Handling method Make sure there is input/output voltage Replace the recitifier No actions need to be taken Make sure the AC input voltage is normal Remove the object that blocks the fan Remove the object at the inlet or vent Decrease the ambient temperature or remove the heat source Check whether the rectifier communication is normal. If not, check whether the communication cable is in normal connection. If the communication is normal while the protection indicator is on, replace the rectifier Replace the rectifier
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Chapter 5 Symptom Protection indicator blinks(yellow)
Monitoring module alarms
43
Handling method
Rect Not Respond
Rectifier communication interrupted
Check whether the communication cable is in normal connection
Rect HVSD
Rectifier over-voltage
Reset the rectifier. If the protection is triggered again, replace the rectifier
Rect Failure
Two or more recitifiers have the same ID number
Contact Emerson for maintenance
Rect Failure
Check whether the rectifier communication is Serious current sharing imbalance, normal. If not, check whether the 501 series modle: current imbalance > ± 3%; communication cable is in normal connection. 701 series modle: current imbalance > ± 5% If the communication is normal while the protection indicator is on, replace the rectifier
Rect Fan Fails
Fan fault
Fault indictor on (red)
Fault indicator blinks (red)
Causes
Alarm Handling
Replace the fan
Replacing rectifier fan If the rectifier fan is faulty and does not work, it should be replaced. Take the R48-1800 rectifiers as an example, the replacement procedures are as follows: 1. Use a cross screwdriver to remove the 3 screws from the fixing holes and pull out the front panel. 2. Unplug the power cable of the fan and remove the fan. Install a new fan. 3. Plug the fan power cable. Put the front panel back and fasten it with the 3 screws, as shown in Figure 5-2.
Fixing screw of the fan Fan Front panel
Fixing screw of the panel
. Figure 5-2
Disassembling the front panel
Replacing rectifier Except replacing the fan, it is recommended not to repair any other part of the module. When faulty, the module should be replaced, not repaired. See the following procedures to replace the rectifier. 1. Take a new rectifier and check it for any damage from transport. 2. Loosen the fixing screw of the handle of the R48-1800A rectifier with a Phillips screwdriver. Pull out the faulty rectifier from the rack by grabbing its handle. Be careful with the rectifier just pulled out from the system, as it could be very hot due to long-term operation. Do not let it slip away and get damaged. 3. By holding the rectifier handle, push the new rectifier into the slot just vacated and make sure the connection is good. After a brief delay, the rectifier run indicator will turn on and the fan will start running. 4. Check whether the new rectifier works normally. You should make sure that: 1) The controller recognizes the new rectifier. 2) The new rectifier shares current with other rectifiers. 3) When this new rectifier is pulled out, there is a corresponding alarm and the controller displays the alarm. If the new rectifier passes all the above tests, the replacement is a success. 5. Push the handle back into the front panel to fix the rectifier with the positioning pin. Fix the fixing screw of the handle of the R48-1800 rectifier with a Phillips screwdriver.
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Appendix 1
Technical And Engineering Data
Appendix 1 Technical And Engineering Data Table 1 Technical data Parameter category
Environmental
Parameter Operating temperature Storage temperature Relative humidity Altitude Polution level Others
Description -5°C ~ +40°C -40°C ~ +70°C 5%RH ~ 95%RH ≤ 2,000m (derating is necessary above 2,000m) Level 2 No conductive dust or erosive gases. No possibility of explosion NetSure 701 A41-S3/S5, NetSure 501 A41-S1/S2：L＋N＋
AC input system AC input type Input voltage range AC input
Input AC voltage frequency
PE/220Vac. Others: 3P + N + PE/ 380Vac TN-C, TN-S, TN-C-S, TT NetSure 701 A41：85 Vac～290Vac； NetSure 501 A41, NetSure 501 A91：85Vac～300Vac 45Hz ~ 65Hz NetSure 701 A41-S1≤25A; NetSure 701 A41-S2/S4≤45A;
Max input current
NetSure 701 A41-S3≤90A;NetSure 701 A41-S5≤90A; NetSure 501 A91-S1≤37A;NetSure 501 A41-S2≤50A; NetSure 501 A41-S1≤50A
Power factor Over-voltage level Standard output DC voltage Rated output DC voltage Output DC voltage
Maximum output current DC output Voltage set-point accuracy
≥ 0.99 Level II -48Vdc -53.5Vdc -42.3Vdc ~ -57.6Vdc NetSure 701 A41 ≤ 275A, load current ≤ 225A, battery charge current ≤ 50A NetSure 501 A41≤150A, load current≤ 120A, battery charge current ≤ 30A NetSure 501 A91≤275A, load current≤ 225A, battery charge current ≤ 50A ≤ 1% R48-1800A/R48-2000≥89％;
Efficiency
R48-2000e/R48-3200e/R48-3500e≥94.5％;
Noise (peak-peak) Weighted noise AC input over-voltage alarm point AC input over-voltage alarm recovery point AC input under-voltage alarm point AC input under-voltage alarm recovery point
≤ 200mV (0 ~ 20MHz) ≤ 2mV (300 ~ 3400Hz) Default: 280 ± 5Vac, cofigurable through controller Default: 270 ± 5Vac, 10Vac lower than the AC input over-voltage alarm point Default: 180 ± 5Vac, configurable through controller Default: 190 ± 5Vac, 10Vac higher than the AC input under-voltage alarm point NetSure 501 A41, NetSure 501 A91: 305 ± 5Vac by default, cofigurable through controller NetSure 701 A41: 295 ± 5Vac by default, cofigurable through controller NetSure 501 A41, NetSure 501 A91: 295 ± 5Vac by default, 10Vac lower than the AC input over-voltage alarm point NetSure 701 A41: 285 ± 5Vac by default, 10Vac lower than the AC input over-voltage alarm point
R48-2900U≥90％; R48-4000e≥90％
AC input alarm and protection
AC input over-voltage protection point
AC input over-voltage protection recovery point
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Appendix 1 Parameter category AC input alarm and protection
DC output alarm and protection
DC output alarm and protection
Parameter
Technical And Engineering Data
45
Description
AC input under-voltage protection point AC input under-voltage protection recovery point DC output over-voltage alarm point
Default: 80 ± 5Vac, configurable through controller Default: 95 ± 5Vac, 10Vac higher than the AC input under-voltage alarm point Default: -58.0 ± 0.2Vdc, configurable through controller Default: -57.5 ± 0.2Vdc, 0.5Vdc lower than the over-voltage alarm DC output over-voltage recovery point point DC output under-voltage alarm point Default: -45.0 ± 0.2Vdc, configurable through controller Default: -45.5 ± 0.2Vdc, 0.5Vdc higher than the under-voltage alarm DC output under-voltage recovery point point DC output over-voltage proteciton point Default: -59.0 ± 0.2Vdc, configurable through controller LLVD Default: -44.0 ± 0.2Vdc, configurable through controller BLVD Default: -43.2 ± 0.2Vdc, configurable through controller The rectifiers can work in parallel and share the current. The Current sharing unbalanceness is better than ± 5% R48-1800A、R48-2000、R48-2000e: 176Vac input, The rectifier outputs max.power: 100% 85Vac input, The rectifier outputs max. power: 40% 80Vac input, The rectifier low pressure power off R48-3200、R48-2900U、R48-3500e、R48-3200e：
Derate by input (at 45°C)
Output delay Fan speed adjustable
176Vac input, The rectifier outputs 100% power 120Vac input, The rectifier outputs 50% power 85Vac input, The rectifier outputs 18.75% power 80Vac input, The rectifier low pressure power off R48-4000e: 207Vac input, The rectifier outputs 100% power 120Vac input, The rectifier outputs 2200W power 85Vac input, The rectifier outputs 1500W power 80Vac input, The rectifier low pressure power off Output voltage can rise slowly upon rectifier start up. The rise time is configurable Rectifier fan speed can be set to half or full speed
Rectifier
Over-voltage protection
The rectifier provides over-voltage hardware and software protection. The hardware protection point is 59.5V ± 0.5V, and it requires manual resetting to restore operation. The software protection point is between 56V and 59V (0.5V above output voltage, 59V by default), and can be set through the controller There are two software protection modes, which can be selected through the software at the host: 1. Lock out at the first over-voltage Once the output voltage reaches protection point, the rectifier will shut off and hold that state. It requires manual resetting to restore the operation 2. Lock out at the second over-voltage When the output voltage reaches the software protection point, the rectifier will shutdown, and restart automatically after 5 seconds. If the over-voltage happens again within a set time (default: 5min. Configurable through controller), the rectifier will shut off and hold that state. It requires manual resetting to restore the operation Manual resetting: Resetting can be done manually through the controller, or by removing the rectifier from system
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
46
Appendix 1 Parameter category
Technical And Engineering Data Parameter
Description
R48-1800A: Temperature below 45°C, outputs full power Temperature above 45°C, there will be linear derating, that is: At 55°C, output power is 1,600W At 65°C, output power is 1,500W At 75°C, output power is 800W At 80°C, output power is 0 R48-2000、R48-2000e:
Rectifier
Temperature derating
EMC
Conducted emission Radiated emission Voltage fluctuation and flash Immunity to EFT Immunity to ESD Immunity to surges Immunity to radiation Immunity to conduction
Starts at -40°C; Temperature below 45°C, outputs full power Temperature above 45°C, there will be linear derating, that is: At 55°C, output power is 1,750W At 65°C, output power is 1,600W At 70°C, output power is 800W At 75°C, output power is 0 R48-3200e: At the ambient temperature of: Below 45°C, outputs full power: 3,000W Above 45°C, there will be linear derating, that is: At 55°C, output power ≥ 2,400W At 60°C, output power ≥ 1,500W At 65°C, output power: 0 R48-3200: Starts at -40°C; Temperature below 45°C, outputs power is 3200W. Temperature above 45°C, there will be linear derating, that is: At 65°C, output power is 2,320W At 70°C, output power is 1,450W At 75°C, output power is 0 R48-2900U: Starts at -40°C; Temperature below 45°C, outputs power is 2900W. Temperature above 45°C, there will be linear derating, that is: At 55°C, output power is 2,320W At 60°C, output power is 1,450W At 65°C, output power is 0 R48-3500e: Starts at -40°C; Temperature below 45°C, outputs power is 3500W. Temperature above 45°C, there will be linear derating, that is: At 50°C, output power is 3200W; At 55°C, output power is 2900W; At 65°C, output power is 2320W; At 70°C, output power is 1450W. At 75°C, output power is 0 R48-4000e: Starts at -40°C; Temperature below 50°C, outputs power is 4000W. Temperature above 45°C, there will be linear derating, that is: At 55°C, output power is 3500W; At 65°C, output power is 3000W; At 75°C, output power is 2400W
Class A
EN55022
Class A Level 4 Level 3 Level 4 Level 2 Level 2
EN61000-3-11 EN/IEC 61000-4-4 EN/IEC 61000-4-2 EN/IEC 61000-4-5 EN/IEC 61000-4-3 EN/IEC 61000-4-6
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
Appendix 1 Parameter category
Lightning protection features
Parameter
Safety regulation
Insulation resistance
Others Insulation strength
MTBF ROHS Maximum dimensions of the subracks
Weight (kg)
Description
≤ 60db (A) (When the ambient temperature is lower than25℃)
Acoustic noise
Mechanical
47
The AC input side can withstand five times of simulated lightning voltage of 5Kv at 10/700µs, for the positive and negative polarities respectively. It can withstand five times of simulated lightning surge current of 20Ka at 8/20µs, for the positive and negative polarities respectively. The test interval is not smaller than 1 minute. It can also withstand one event of simulated lightning surge current of 40Ka at 8/20µs IEC60950-1:2001
At AC side
Dimensions (mm)(W×D×H)
Technical And Engineering Data
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, controller and rectifiers from the system before the test.) AC loop to DC loop can withstand 50Hz. DC circuit to earth: 50Hz, 2,500Vac; or 3535Vdc; AC to DC circuits: 50Hz, 1,000Vac; or 1414Vdc; Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac For all the three tests above, there should be no breakdown or flashover within 1min, with leakage current not bigger than 10Ma; > 200,000hr Compliant with R5 requirement NetSure 501 A41-S1/S2: 483 × 360 × 223 NetSure 501 A91-S1: 483 × 360 × 445 NetSure 701 A41-S1/S2/S3/S5: 483 × 360 × 267 NetSure 701 A41-S4: 483 × 360 × 400.5
Monitoring module M501D/ M500D
85 × 85 × 287
Rectifier
R48-1800A, R48-2000, R48-2000e: 87.9× 85.3× 272 R48-3200e, R48-3200, R48-2900U, R48-3500e: 132.3 × 88× 294 R48-4000e:132.3 × 88 × 294
Subrack (without rectifiers and controller) Monitoring module M501D/M500D Rectifier
≤ 25
< 0.8 R48-1800A, R48-2000, R48-2000e ≤ 2.0 R48-3200, R48-2900U, R48-3200, R48-3500e, R48-4000e ≤ 3.5
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
48
Appendix 2
Installation Instruction Of Battery Rack
Appendix 2 Installation Instruction Of Battery Rack 1. Installation Instruction Of Two-Layer And Four-Layer Battery Rack Packing list
Accessory 1
Accessory 2
Accessory 3
Accessory 4
Accessory 5
Figure 1 Accessory Table 2 Packing list of the battery rack Battery rack
Two-layer battery rack
Accessory
Four-layer battery rack
Accessory 1
2
4
Accessory 2
8
14
Accessory 3
2
4
Accessory 4
2
2
Accessory 5
0
2
Expansion bolt
4 pieces
4 pieces
Fastener
1 set
1 set
Installation procedures 1. Installation procedures of two-layer battery rack 1) Install accessory 1 and accessory 2 according to Figure 2 (a). 2) Install accessory 3 according to Figure 2 (b).
Accessory 1 Accessory 3 Accessory 2
(a)
(b)
Figure 2 Installation procedure of accessory 1 ~ accessory 3
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
Appendix 2
Installation Instruction Of Battery Rack
3) Install accessory 2 and accessory 4 according to Figure 3. Accessory 4 Accessory 2
Figure 3 Installation procedure of accessory 2 and accessory 4
2. Installation procedures of four-layer battery rack 1) Install accessory 1, accessory 2 and accessory 3 according to Figure 2 (a) and Figure 2 (b). 2) Install accessory 5 according to Figure 4 (a). 3) Install accessory 2 and accessory 4 according to Figure 4 (b).
Accessory 4 Accessory 2
(a)
(b)
Figure 4 Installation procedure of accessory 2, accessory 4 and accessory 5
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
49
50
Appendix 2
Installation Instruction Of Battery Rack
2. Installation Instruction Of Three-Layer Battery Rack Packing list
Accessory 1
Accessory 2
Accessory 3
Accessory 4
Figure 5 Accessory Table 3 Packing list of the battery rack Accessory Accessory 1 Accessory 2 Accessory 3 Accessory 4 Expansion bolt Fastener
Accessory number 2 6 3 2 4 pieces 1 set
Installation procedures 1. Install accessory 1 and accessory 2 according to Figure 6 (a). 2. Install accessory 3 according to Figure 6 (b).
Accessory 2 Accessory 1
Accessory 3
(a)
(b)
Figure 6 Installation procedure of accessory 1 ~ accessory 3 NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
Appendix 2
Installation Instruction Of Battery Rack
3. Install accessory 2 and accessory 4 according to Figure 7. Accessory 2 Accessory 4
Figure 7 Installation procedure of accessory 2 and accessory 4
3. Fixing The Battery Rack 1. Fix the battery rack to the ground according to the installation dimensions shown in Figure 8. The fixing bolts are accessories. 575
480
600
600 Figure 8 Installation dimensions (unit: mm)
2. Fix the subrack power system onto the top of the battery rack. Refer to 2.3
Mechanical Installation.
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
51
Appendix 3 Wiring Diagram
Appendix 3 Wiring Diagram
Rear view
DU power unit
17 DU
0V To MFU positive expansion busbar
W81+W82 1
8-QF17
8-QF18
7-29
2
1 2 Three-phase AC input
PL
1 QFA
B TO MFU unit PL busbar
1
2
3 9-2
1 2
2
7-35/7-47/7-49/7-50 X5-1/X6-1 W80
9-BUS+-1
TO MFU unit PL busbar To the positive busbar of the MFU 24 H4
23 H3
10 RB
N
PE
P
1
8-B-
W80
2
1 2
22 H2
PE
P
W01
L
W02
N
W04
21 H1
W01
L
W02
N
W04
PE
P
W01
L
W02
W02
N
W04
PE
P
X3-1
7-2 W05
7-4
W04
12 J6 J8
2
1
3 4
2
1 5
3
4
5
6
12 J7
2
1
3 4
2
1 5
3
4
6
5
6
6
W80 29 H9
28 H8
1
27 H7
26 H6
25 H5
L
W01
L
W01
L
W01
L
W01
N
W02
N
W02
N
W02
N
W02
PE
2
W04
3 4
1 5
PE
P
2 4
6
W04
3
1 5
PE
P
2
3 4
6
W04
1 5
PE
P
2 4
5
1 2
1
W80
Figure 9 NetSure 501 A91-S1 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
W02
N
PE
P
1
6
W01
L
W04
3
7-22
2
15-J7 2
To the Negative Busbar
QFB2
W80
7-20
7-41 1
7-39
12 KM2
W80
W01
L
W80
7-44
W05
Rear view
P
PL
7-31 PL 7-46 1
W80
8
6 Shelf 1
To the positive Busbar
2
TO DU unit PL bar
W80
W80
1
0V
7-28
QFD1
1 2
5-3 W07
W80+W81+W82 7-29 1 1
QFD2
QFD3
QFD16
2
Module subrack
W2453X1
7-30
2
13
4- 4+ 2- 2+ DO4 DO2 J4 J3
9 BUS+
4
1
8-B--1
Rear top view
5 PE
TO the user protective earth
1
User interface board 1
3- 3+ 1- 1+ DO3 DO1
8 MFU
QFB1
MFU DC power wiring diagram
W80 W80
W80
W80
W80
8-PL-1
W80 W80
8-QFB1-1
10-2 10-1
8-QFB2-1
X3-2
W01 W01W01
W2453X1
13-J8-4 13-J8-6 13-J8-7 13-J7-2 13-J8-8
24-CAN-
24-CAN+
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
23-L/26-L/29-L
11-1
W80 W80
22-L/25-L/28-L
21-L/24-L/27-L
W80
11-2
X5-1
9-BUS+-1W80
8-PL-1
8-NPL-QFD
13-J7-1
13-J8-1
13-J8-2 13-J8-3 13-J8-5
X6-1
2 4 6 8
MFU door connected ground
W80 X7-2
9-BUS+-2 W80
2 4
6
W04
3 5 6
21-N/22-N/23-N/24-N
Front view
7 M221S
W80
8-PL-QFD
Controller motherboard switch
W02
25-N/26-N/27-N/228-N/29-N
L1 L2 L3 N 1 3 5 7
52
Appendix 3 Wiring Diagram
18 M34C3C1
W06
15
13-J3-1-
1 2 3
M2433X2
7-39 7-41
1 2
13-J3-1+
DCSPD
J1
J2
J3 J1 J2 J5 J6
J4
v-
v+
5-2
9-2
PE
W06 W06 Controller motherboard switch
J7 8-PL-2
12-1 12-2 8-PL-1
W06
Front view
7 M221S
9-BUS+-1 W80
11-1
1
8
J8
J6 12
1 3
J7
2 4
W80 8 MFU
TO the user protective earth
1
PE
L
2 4
W03
3-2 Conneted earthing terminal
W80
Module subrack Rear view TO MFU unit PL busbar
6 Shelf 1
W80 7-29
24 H4
W01
W80
QFD2
QFD3
QFD4
2 W80
1 NPL
10 RB
PE
P
W01
L
W02
N
W04
W02
N
W04
PE
P
1 2
1
2
3 4
1 5
2
3 4
6
1 5
2
3 4
6
1 5
2
X3-1 W04
3 4
6
1 2
1 8-B-
2
1 7-20
1
To the Negative Busbar
QFB2
W84 12 KM2 W80
2
PE
P
7-22
PL
W 02
N
W04
21 H1
W01
L
NPL
18-J2-1
15-J7 2
2
PE
P
22 H2
W01
L
W02
N
7-24
W06
2
1
7-26
2
2
1
QFB1
18-J2-3 7-31 7-46 W80 7-35 1
1
9-BUS+-1
PL
W80
7-45
7-43
W80
18-J2-2
2
11 KM1
1
QFD1
L
1
To the positive busbar of the MFU
23 H3
W80
Figure 10 NetSure 501 A41-S1 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
5 6
7-4
W03
2-N
W03
W01
0V
W80 7-27
2
N
2
W06 15-J6 7-47/7-49/7-50 2 3 9-2 5-3 W07 1 12-1 W84 2-PE W03 To the positive Busbar
1
L N 1 3
23-L 22-L 21-L/24-L
9 BUS+
5 PE
15-J5
QFD6
W06
W03 W03
Rear top view
QFD5
MFU DC power wiring diagram
1 QFA
W03 W03 X10-1
LO NO
3-4
12
2 SPD1
7-2 W05
21-N/24-N 22-N 23-N
W80
Single-phase AC input(SPD) 3 QFA2
1-4
W80
W80
W06 15-J4-1 W06 15-J4-2
W2453X1
1-2 2-N
X10-2 W80
9-BUS+-1
8-PL-1
8-QFB4-2
8-QFB3-2
8-QFB2-2
10-2
10-1 8-QFB1-2
13-J8-8
13-J8-7
13-J7-2
13-J8-4
13-J8-6
24-CAN-
24-CAN+
W80 W80
User interface board 1
4- 4+ 2- 2+ DO4 DO2 J4 J3
W2453X1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
X3-2 W80
13
User interface board 1
3- 3+ 1- 1+ DO3 DO1
11-2
9-BUS+-1
13-J7-1
W80 W80 W80 W80
18-J1-2
W80
W80 W80 X7-2
18-J1-1
X5-1
8-PL-1
13-J8-3
X6-1
13-J8-5
13-J8-1
13-J8-2
W80
W02
53
Appendix 3 Wiring Diagram
Door connected ground
X12-2
W80 W80
11-1 11-2
W80
8-PL-QFD
8-QFB1-1
7 M820B
8-NPL-QFD
W80
Controller motherboard switch
12-1 12-2 X5-1
8-PL-1
13 IB2
W80 W80
W80
W80
Rear top view
8 MFU
2
1 2 3
5-3 W07
7-35/7-47/7-49/7-50 X5-1/X6-1 W80
2
2
QFD1
2
QFD2
2
QFD3
QFD4
1
TO MFU unit PL busbar 24 H4
NPL
W01 W02 PE
N P
7-55
7-56 10 RB
P
W02 PE
N
W04
1
2
3 4
1 5
7-44
8-B-
W80
2
2
3 4
P
1 5
1 2
1
2
W80
Figure 11 NetSure 501 A41-S2 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
2
W01
L
W02 PE
N
W04
3 4
6
7-22
2
1
QFB1
QFB2
W80
1 To the Negative Busbar
W02 PE
N
W04
21 H1
W01
L
P
X3-1 W04
W80
7-82 1
22 H2
W01
L
6
W80
To the positive busbar of the MFU
23 H3
L
12 KM2
W02
Rear top view
6 S helf 1
2
NPL
2
Module subrack
W82+W81+W80 7-60 1 1 1
1
1 PL
2 4
W01
7-20
7-31 7-46
W80
7-80
W80 W80
2
W80 7-79
PL
11 KM1
1
7-81
2
QFD5
2
QFD6
QFD7
QFD8
2
1
L N 1 3
J11 J12
W80
To the positive Busbar
1
1
0V
W82+W81+W80 7-59 1
3
W80
9 BUS+
5 PE 至用户保护地 1 2 3 9-2 4
J2 4 2
1 QFA
23-L 22-L 21-L/24-L
MFU DC power wiring diagram
J3 J4 J5
W80 W80
Single-phase AC input
9-BUS+-1
8-B--1 8-PL-1
X3-2
10-2 10-1
13-J2-2
24-CAN-
24-CAN+
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
21-N/24-N 22-N 23-N
13-J2-3
J6 J7 J8 J9
W80
13-J2-1
X6-1
User interface board 1
W80 W80 9-BUS+-1 W80
9-BUS+-2 W80
X9
W80
13-J2-4
8-QFB2-1
51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100
User Manual
1 5
2
3 4
6
5 6
7-4
7-2 W05
54
Appendix 3 Wiring Diagram
Three-phases AC input 1 QFA
L1 L2 L3 N 1 3 5 7 MFU Door connected ground
2 4 6 8
W80
W01 W01 W01
11-1
12-1 11-2
W80 W80 W80W80
12-2
8-PL-QFD
8-NPL-QFD
X5-1
8-PL-1
X6-1
13-J7-1
13-J8-1
13-J8-2 13-J8-3 13-J8-5
W80
21-L 22-L 23-L
X7-2 W80 9-BUS+-1 W80 9-BUS+-2 W80
8 MFU
1 2 3
5-3 W07
QFD4
1
2
2
1
2 8-B-
7-44
To the Negative Busbar
QFB2
10 RB
1
W80
10
10
2
12 J8
J6 12
PE N
J7
L
W04 W02 W01
7-30
1
1
2
2
-48V 7-2
1 7-22
PL
12 KM2 W80
7-20
W80
10
W80
QFB1
1 2
1
2
NPL
21 H1
1
W80+W81+W82 7-27 1
1
7-39
7-31 7-46
2
22 H2
1
To the positive Busbar
NPL
1
7-41
W80 W80
2
1
To the positive busbar of the MFU
23 H3
W80
7-28
PL
7-45
QFD5
W80+W81+W82 7-29 11 1 KM1 W80 W80 2
TO MFU unit PL busbar
6 Shelf 1
0V
7-35/7-47/7-49/7-50 X5-1/X6-1 W80
QFD1
2
QFD2
1 2 4 3 9-2
8
W2453X1
W80
9 BUS+
5 PE
QFD3
TO the user protective earth
1
Rear top view
7-43
MFU DC power wiring diagram
4- 4+ 2- 2+ DO4 DO2 J4 J3
W80
3- 3+ 1- 1+ DO3 DO1
9-BUS+-1
8-PL-1
W80 W80
W80
W80
W80
8-B--1
8-QFB1-1
8-QFB2-1
10-2 10-1
13-J8-4 13-J8-6 13-J8-7 13-J7-2 13-J8-8
24-CAN-
24-CAN+
X3-2
W80W80
Module subrack
13 W2453X1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
21-N/22-N/23-N
Front view
7 Controller motherboard switch M221S
W80
Figure 12 NetSure 701 A41-S1 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
PE N L
W04 W02 W01
PE N L
0V
W04
W02 W01
X3-1
7-4 W05
W02
55
Appendix 3 Wiring Diagram
MFU Door connected ground
Front view 9-BUS+-1 W80 W80
W80 W80
11-1
Three-phases AC input
1 QFA
TO the user protective earth
2
5-3 W07
2 3
W80+W81+W82 7-29 1 1 2
QFD1
2
1
QFD2
1
1
8
J6 12 J8 J7 W80
0V
2
2 4 3 9-2
7-35/7-47/7-49/7-50 X5-1/X6-1 W80
W80
W01 W01W01
Module subrack 6 Shelf 1
PE N
2 8-B-
7-44
1
To the Negative Busbar
QFB2
10 RB
W80
1 2
7-30 QFB1
7-28 1
21 H1
1
1
1
10
10
10
10
L
W04 W02
PE
W01
L
N
W04 W02 W01
1 2
1
2
7-22
PL
12 KM2 W80
7-20
W80
7-39
1 2
22 H2
1
-48V
7-2
W80
7-31 7-46
To the positive busbar of the MFU
23 H3
To the positive Busbar
PL W80 W80
TO MFU unit PL busbar 24 H4
2
7-41
QFD12
9 BUS+
5 PE
1
1
12
W80
Figure 13 NetSure 701 A41-S2 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
PE N L
W04 W02
PE
W01
L
N
0V
W04 W02 W01
X3-1
7-4 W05
21-N/22-N/23-N/24-N
Rear top view
8 MFU
QFD3
MFU DC power wiring diagram
2 4 6 8 21-L/24/L
W80
L1 L2 L3 N 1 3 5 7
W2453X1
J4 J3
W80 W80
3- 3+ 1- 1+ DO3 DO1
W80
9-BUS+-1
8-B--1
W80 W80
W80
8-PL-1
8-QFB1-1
8-QFB2-1
10-2 10-1
13-J8-4 13-J8-6 13-J8-7 13-J7-2 13-J8-8
24-CAN-
24-CAN+
X3-2 W80
13 W2453X1
22-L 23-L
User interface board 1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
4- 4+ 2- 2+ DO4 DO2
W80 X7-2
11-2
X5-1
8-NPL-QFD
13-J7-1
13-J8-1 13-J8-2 13-J8-3 13-J8-5
X6-1
8-PL-1
9-BUS+-2 W80 W80
8-PL-QFD
7 Controller motherboard switch M221 S
W02
56
Appendix 3 Wiring Diagram
18 M34C3C1
7-39 7-41 W84
1 2
W06
DCSPD
15 M2433X2
J1 J5
J3
J6
J2
J4
W06 W06 User interface board 1
J7
v-
v+
9-2
5-2
PE
13-J3-1+
1 2 3
13-J3-1-
8-PL-1
J1
J2
8-PL-2
12-1 W84 12-2
W06
13
3 QFA2
PE
1-2 2-N
9-BUS+-1
8-PL-1
8-QFB2-1
10-2 10-1
8 MFU
W80
L
2 4
W03
5-4
W03W03
3-2
W03
W80
24 H4
1
2 W06 15-J6 2 5-3 W07 4 3 9-2 2-PE W03
1 2 3
7-35/7-47/7-49/7-50 X5-1/X6-1 W80 12-1 W84 1 2
N L
10
10
10
10
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
NPL 7-28
7-30
W80
W84 W84
12 W84 KM2
1
10 RB
2 8-B-
1 2
1 2
1
2 7-20
1
To the Negative Busbar
QFB2
PL
1
7-22
2
PE
1
NPL 1
1
2
1
18-J2-2
W06 15-J7
2
18-J2-1
18-J2-3 W80 7-31 W80 7-46
1 2
21 H1
22 H2
1
-48V
7-2 X3-1
To the positive Busbar
QFB1
PL W84
1 2
QFD1
11 KM1 W80
7-43
W80
QFD3
1 2
QFD8
1 2
7-45
1 2
QFD10
QFD12
QFD11
1 2
23 H3
1
W80
W80 7-27
W80 7-29
QFD2
15-J6
To the positive busbar of the MFU
TO MFU unit PL busbar
6 Shelf 1
0V
W80
Figure 14 NetSure 701 A41-S3 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
N
0V
W04 W02 W01
2-N
W02
Module subrack
9 BUS+
5 PE
W03
W01
Rear top view
TO the user protective earth
W06
X10-2 W80
W80
9-BUS+-3
MFU DC power wiring diagram
8-QFB1-1
2 4 W80 W80
L N 1 3
N
7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
QFD9
X3-2 W80
5 6
13-J8-4 13-J8-6 13-J8-7 13-J7-2 13-J8-8
24-CAN-
24-CAN+
3 4
W03 W03 X10-1
LO NO 1 3
W80 1 2
1 QFA
2 SPD1
21-N/24-N 22-N 23-N
J6 12 8 J8 J7
23-L 22-L 21-L/24-L
1
Single-phase AC input
12
1-4 3-4
W80
11-1
18-J1-2 11-2
W84 W84 W80W80
W2453X1
J4 J3
W06 15-J4-1 W06 15-J4-2
9-BUS+-1 W80
3- 3+ 1- 1+ DO3 DO1
W80 X7-2
18-J1-1
X5-1
8-NPL-QFD
13-J7-1
13-J8-2 13-J8-3 13-J8-5
X6-1
8-PL-1
9-BUS+-2 W80 W80
13-J8-1
Door connected ground
Front view
7 M221S
8-PL-QFD
Controller motherboard switch
4- 4+ 2- 2+ DO4 DO2
W2453X1
7-4 W05
57
Appendix 3 Wiring Diagram
DU 配电单元
后视图
17 DU
0V
至 MFU 正极扩展排
W81+W82
PL
12-1 12-1
User interface board 1
13 IB2
W01 W01 W01
1 2 3
J11 J12
8-QF3
Module subrack 6 Shelf 1
1
0V
PE
2
1
QFD1
2
10
10
10
10
N L
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
2
7-82
QFB2
W80
10 RB
2 8-B-
7-44
1 至模块负极排
1
W80
2
1 2
1 2
1 7-22
1
PL
21 H1
1
W80
7-80
2
22 H2
NPL
7-20
12 KM2
W80
To the positive busbar of the MFU
1
W80 7-60 1
NPL 7-31 7-46 1
23 H3
1
7-56 7-55
W80
1
QFB1
至 DU单元 PL 排
至 DU单元 NPL排
11 KM1
W80
QFD2
至模块正极排
7-79
2
PL
TO MFU unit PL busbar 24 H4
W80
7-35/7-47/7-49/7-50 W80 X5-1/X6-1 W80
1
7-81
2
3
2
QFD9
2
QFD10
1
9 BUS+
5-3 W07 W80 7-59
1
J2 4 2
W02
-48V
7-2 X3-1
Rear top view
5 PE 1 2 4 3 9-2
J3 J4 J5
9-BUS+-1
8-B--1 8-PL-1
10-2 10-1
13-J2-2
W80W80
2 4 6 8
23-L 21-N 22-N 23-N 24-N
W80
22-L
X5-1
8-PL-1
13-J2-1
13-J2-3
13-J2-4
X4-2
9-BUS+-1 W80
W80
QFD11
8-QF4
1 QFA
L1 L2 L3 N 1 3 5 7
21-L/24-L
9-BUS+-2 W80
W80W80
8 MFU
QFD18
8-QF5
Three-phases AC input
J6 J7 J8 J9
8-QFB2-1 24-CAN-
24-CAN+
X3-2 W80
W80 W80
2
To the positive busbar of the MFU
TO MFU unit PL busbar
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
2
1
W80 W80
W80
1
1 2
W80 W80
X9
TO the user protective earth
2
NPL
51 53 55 57 59 61 63 65 67 69 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100
MFU DC power wiring diagram
1
MFU Door connected ground
Front view
X12
1 2
11-1 11-2
W80
8-PL-QFD
8-QFB1-1
M820B
8-NPL-QFD
W80
Controller motherboard switch7
1
2
8-QF6
8-QF8
1 2
8-QF7
7-60
W80
Figure 15 NetSure 701 A41-S4 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
N
0V
W04 W02 W01
7-4 W05
58
Appendix 3 Wiring Diagram
18 M34C3C1
15 M2433X2
J3
J1 J5
J6
5-2
PE
J2
13-J3-1+
W06
DCSPD
13-J3-1-
7-39 7-41 W84
1 2
J4
v-
v+
W06 W06 User interface board 1
J7 8-PL-2
8-PL-1
1 2 3
9-2
12-1 W84 12-2
J1
J2
W06
13
1
12
单相交流输入带防雷
J6 12 8 J8 J7
3 QFA2
W80
1-2 2-N
L
PE
5-4
3-2
W03
W03 W03
W80
W07 W01 8 MFU
2-N
W02W07
Rear top view
1 2 3
7-35/7-47/7-49/7-50 X5-1/X6-1 W80 12-1 W84 QFD1
1 2
QFD2
QFD6
1 2
1
1
10
10
10
10
N L
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
N
W04 W02
PE
W01
L
N
W04 W01
7-30
7-28
2
2
1 2
QFB1
W84 10 RB
0V
W02
W80
1 B-
To the Negative Busbar
PE
QFB2
PL
12 KM2
-48V
1
25 H5
W08
1
7-2 X3-1
1
1
W84
W84
21 H1
1
1 2
1 7-22
1 2
22 H2
1
To the positive Busbar
2
NPL
15-J7
To the positive busbar of the MFU
23 H3
NPL
7-20
W06
2
1 2
18-J2-2
18-J2-3 7-31 7-46
W80 W80
9-BUS+-1 18-J2-1
W84
1 11 2 W80 KM1 W80
7-43
PL
TO MFU unit PL busbar
W80
W80 7-27
7-45
1 2
QFD7
1 2
QFD8
QFD9
QFD10
1
6 Shelf 1
0V
24 H4
W80 7-29
2
Module subrack
9 BUS+
5 PE 1 2 W06 15-J6 W06 15-J6 2 5-3 W07 4 3 9-2 2-PEW03
TO the user protective earth
QFD3
MFU DC power wiring diagram
2 4 W03
W03
25-L 23-L 22-L 21-L/24-L
W80
W80
L N 1 3
N
2 4
9-BUS+-1
8-PL-1
W80 W80
8-QFB1-1
8-QFB2-1
10-2 10-1
13-J8-4 13-J8-6 13-J8-7 13-J7-2 13-J8-8
24-CAN-
24-CAN+
X3-2 W80
X10-2 W80
W03 W03 X10-1
LO NO 1 3
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
1 QFA
2 SPD1
21-N/24-N 22-N 23-N 25-N
11-1
18-J1-2 11-2
8-PL-QFD
8-NPL-QFD
W80
1-4 3-4
W06 15-J4-1 W06 15-J4-2
W84 W84 W80 W80
W2453X1
J4 J3
W80 X7-2
X5-1
18-J1-1
X6-1
13-J7-1
13-J8-1
13-J8-2 13-J8-3 13-J8-5
W80
9-BUS+-1 W80
3- 3+ 1- 1+ DO3 DO1
门接地
Front view 9-BUS+-2 W80
8-PL-1
Controller motherboard switch
7 M221S
4- 4+ 2- 2+ DO4 DO2
W2453X1
W80
Figure 16 NetSure 701 A41-S5 wiring diagram
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
10
W08 PE N L
W04 W02 W01
7-4
W05
59
Appendix 4
Appendix 4 Shematic Diagram
PD1
User interface board
W2453X1
ST1
User-defined AC Output Class C SPD SPD1
QFA2
MB
Temperature Sensor
No Lo
Controller
QFD1
M221S or M222S
ST2
NPL
Temperature Sensor
Optional
QFD6 KMD1
H1
LLVD Contactor Mains Input
QFD7 H2
QFA1 N L
PL
W34C3C1
QFD10
PD2
H3 PE KMD2
BLVD Contactor
H4 RS1 H5
QFB1 QFB2
Battery 1 Positive Busbar
Battery 2
CAN
DC SPD SPD2 M2433X2
AC Distribution Unit
DC Distribution Unit 1
-48V 0V
Figure 17 Schematic diagram of NetSure 501 A91
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
Shematic Diagram
60
Appendix 4
用户交流输出 User-defined AC Output
用户接口板 W2453X1
PD1
ST1 温度传感器 C 级防雷器 Class C SPD SPD1
MB 监控单元 M221S or M222S
Temperature Sensor
No Lo QFA2
Shematic Diagram
选配 Optional
ST2 温度传感器
QFD1
NPL 非重要负载
Temperature Sensor
QFD4 KMD1
H1
负载下电接触器 市电输入 Mains Input
LLVD Contactor QFD5 H2 重要负载 PL
QFA1 N L
W34C3C1
QFD6
H3
PE
KMD2 电池下电接触器 BLVD Contactor
H4
RS1 CAN
QFB1 QFB2
电池组 1 Battery 1 电池组 2 Battery 2
正排 Positive Busbar
直流防雷 DC SPD SPD2 M2433X2
交流配电单元 AC Distribution Unit
直流配电单元 1
-48V 0V
Figure 18 Schematic diagram of NetSure 501 A41（1）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
DC Distribution Unit 1
61
Appendix 4
PD1
Shematic Diagram
User interface board
M A4 C5U3 1
ST1 Temperature Sensor
ST2
MB Contoller M820B
QFD1
Tem perature Sensor
NPL
Op tional
QFD4 KMD1
H1
LLVD Contactor Mains Input
QFD5 H2
QFA1
PL
N L
QFD8 H3
PE BLVD Contactor
KMD2 H4 RS1 CAN
QFB1 QFB2
Battery 1 Battery 2
AC Distribution Unit
Positive Busbar
DC Distribution Unit 1
Figure 19 Schematic diagram of NetSure 501 A41（2）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
62
Appendix 4
Shematic Diagram
User interface board
PD1
W2453X1 ST1 Temperature Sensor
ST2 选配 Optional
MB Controller
QFD1
M221S or M222S
NPL
Temperature Sensor
QFD4 KMD1
H1
LLVD Contactor
Mains Input H2
QFD5
QFA1
PL
N W V U
H3
PE
KMD2
BLVD Contactor
CAN RS1 QFB1 QFB2
Battery 1 Battery 2
AC Distribution Unit
Positive Busbar
DC Distribution Unit 1
Figure 20 Schematic diagram of NetSure 701 A41（1）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
63
Appendix 4
PD1
Shematic Diagram
User interface board
W2453X1 ST1 Temperature Sensor
ST2 Optional
MB Controller
M221S or M222S
Temperature Sensor
H1
Mains Input
QFD1 H2
QFA1 N W V U
PL QFD12 H3
PE
KMD2
BLVD Contactor
H4 RS1 CAN
QFB1 QFB2
Battery 1 Battery 2
AC Distribution Unit
Positive Busbar
DC Distribution Unit 1
Figure 21 Schematic diagram of NetSure 701 A41（2）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
64
Appendix 4
PD1 User-defined AC Output
User interface board
W2453X1 ST1
MB Controller
Temperature Sensor
Class C SPD SPD1
Shematic Diagram
No Lo QFA2
QFD1
M221S or M222S
ST2
NPL
Temperature Sensor
Optional
QFD8 KMD1
H1
LLVD Contactor
Mains Input
QFD9 H2
QFA1 N L
PL
W34C3C1
QFD12
PD2
H3 PE KMD2 H4
BLVD Contactor
RS1 CAN
QFB1 QFB2
Battery 1 Battery 2
Positive Busbar
DC SPD SPD2 M2433X2
AC Distribution Unit
DC Distribution Unit 1
-48V 0V
Figure 22 Schematic diagram of NetSure 701 A41（3）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
65
Appendix 4
PD1
Shematic Diagram
User interface board
MA4C5U31
ST1 Temperature Sensor
ST2 Optional
MB Controller
QFD11
QFD1
M820B
NPL
NPL
Temperature Sensor
QFD14
QFD4 KMD1
H1
LLVD Contactor Mains Input
QFD5
QFD15
H2 QFA1 PL
N W V U
QFD10
PL QFD18
H3
PE
KMD2
BLVD Contactor
H4 RS1 CAN
QFB1 QFB2
AC Distribution Unit
Battery 1 Positive Busbar
Battery 2
DC Distribution Unit 1
Figure 23 Schematic diagram of NetSure 701 A41（4）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
Positive Busbar
DC Distribution Unit 2
66
Appendix 4
PD1
User interface board
W2453X1
ST1
User-defined AC Output Class C SPD SPD1
QFA2
Shematic Diagram
MB
Temperature Sensor
No Lo
Controller
QFD1
M221S or M222S
ST2
NPL
Temperature Sensor
Optional
QFD6 KMD1
H1
LLVD Contactor Mains Input
QFD7 H2
QFA1 N L
PL
W34C3C1
QFD10
PD2
H3 PE
BLVD Contactor
KMD2 H4 RS1 H5
QFB1 QFB2
Battery 1 Battery 2
Positive Busbar
CAN
DC SPD SPD2 M2433X2
AC Distribution Unit
DC Distribution Unit 1
-48V 0V
Figure 24 Schematic diagram of NetSure 701 A41（5）
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual
67
68
Appendix 5
Glossary
Appendix 5 Glossary Abbreviation Amb.Temp Batt BC BLVD Cap CommMode CurrLimit CycBC Con Alarm Voice Hist Alarm HVSD InitParam InitPWD LLVD LVD MCB Ph-A PWD Rect Shunt coeff SM SPD SW Version Sys Temp Temp Comp Volt
Full word Ambient Temperature Battery Boost Charging Battery Lower Voltage Disconnection Capacity Communication Mode Current Limit Cyclic Boost Charging Control Alarm Voice Historical alarm High Voltage Shutdown Initialize Parameters Initialize Password Load Low Voltage Disconnection Low Voltage Disconnection Miniature Circuit Breaker Phase A Password Rectifier Shunt Coefficient Supervision module (controller) Surge Protection Device Software Version System Temperature Temperature Compensation Voltage
NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system
User Manual
