319788645-31012653-NetSure-701-A41-NetSure-501-A41-NetSure-501-A91-1.pdf

NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system User Manual

Version

V1.0

Revision date

October 24, 2012

BOM

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. reserved. The contents contents in this document document are subject to change without without notice.

Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Science Science & Industry Park, Park, Nanshan District District 518057, Shenzhen Shenzhen China Homepage: www.emersonnetworkpower.com.cn E-mail: support@emersonnetwo [email protected] rk.com.cn

Safety Precautions To reduce the chance o f 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, 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 f ound on the Subrack, turn off t he power immediately. immediately. In moist environment, precautions must be taken to keep moisture out o f 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 operate on high voltage, voltage, AC, iron tower tower or mast in the thunderstorm 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.

Safety Precautions To reduce the chance o f 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, 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 f ound on the Subrack, turn off t he power immediately. immediately. In moist environment, precautions must be taken to keep moisture out o f 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 operate on high voltage, voltage, AC, iron tower tower or mast in the thunderstorm 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 voltage DC power power equipment, equipment, short circuit will result in equipment equipment burning and and endanger endanger human safety safety..

Check carefully the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC DC distribution unit is very tight, please carefully select the operation space. 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 o f PCBs. Before any operation on battery, 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 l asts 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 ~5000W Brand name of the power supply system

Figure 1-1

Model information

1.2 Composition And Configuration System composition The system consists of power di stribution 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


2

Chapter 1

Overview

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.

NetSure 701 A41, NetSure 501 A41, NetSure 501 A91 Subrack Power system

User Manual

4

Chapter 1

Overview

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 p luggable. It takes less than 1min to replace a rectifier.

 Two

over-voltage protection methods are optional: hardware protection and software protection. The la tter 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 a nd historical record up to 1 000. 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.

4

Chapter 1

Overview

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 p luggable. It takes less than 1min to replace a rectifier.

 Two

over-voltage protection methods are optional: hardware protection and software protection. The la tter 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 a nd historical record up to 1 000. 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  NetSure

fault protection and fault alarm functions.

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.


User Manual

Chapter 2

Installation Instruction

5

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

Max. battery current

Min. cable CSA

Max. cable length

125A

105A

35mm2

50mm2

100A

80A

25mm2

50mm2

63A

50A

16mm2

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 MCB rated current

Max. battery current

Battery cable CSA selection Min. cable CSA 2

Max. cable length (volt drop: 0.5V, with max. CSA)

125A

105A

35mm

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


6

Chapter 2

Installation Instruction Table 2-3

DC load cable selection

Load route rated current

Max. output current

Min. cable CSA

Max. cable length (volt drop: 0.5V, with min. CSA)

Max. cable CSA

Max. cable length (volt drop: 0.5V, with max. CSA)

100A

80A

25mm

14m

50mm

20m

63A

2

50A

16mm

9m

2

2

14m

2

25mm

32A

25A

10mm

11m

25mm

29m

16A

12A

6mm2

14m

25mm2

48m

10A

2

8A

6mm

2

23m

25mm

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 input MCB AC power distribution

Grounding busbar Battery output

DC power distribution

Connector specifications

Wiring instructions

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 Connected to the

One M8 bolt, OT type wiring terminal, max. cable CSA 35mm

2

grounding bar of the equipment room

2

Connected to the battery

2

H type terminal, max. cable CSA 25mm (63A and below)

MCB

H type terminal, max. cable CSA 50mm (capacity above 63A)

port

Negative

H type terminal, max. cable CSA 25mm2 (63A and below)

Connected to the users load

output MCB Positive busbar

2

H type terminal, max. cable CSA 50mm (capacity above 63A) Terminal subrack terminal: cable CSA ≤ 50mm2

port 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.


User Manual

Chapter 2


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.


7

8

Chapter 2


Figure 2-3

Installation size of NetSure 501 A41 (unit: mm)

445

Figure 2-4

Figure 2-5

Installation size of NetSure 501 A91 (unit: mm)

Installation size of NetSure 701 A41-S1 (unit: mm)

Figure 2-6 Installation size of NetSure 701 A41-S2/S3 (unit: mm)


User Manual

Chapter 2


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 s ystem 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.


9

10

Chapter 2


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 s ystem 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 e xample, the position of the t erminals are shown in Figure 2-12.


User Manual

Chapter 2

Figure 2-12 


11

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 b attery 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


12

Chapter 2


2.4.5 Connecting Signal Cables There are two user i nterface 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 i s used together with the M820B monitoring unit only. W2453X1 user interface board cable connection Take the NetSure 501 A41 power supply system as an e xample, 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 u sed for DC SPD alarm. If no DC SPD is configured in the p ower 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.


User Manual

Chapter 2


13

The functions of the interfaces are shown in Table 2-5. Table 2-5 Type

nterface functions

Default alarm

Description

Dry contact 1

AC power failure

/

Dry contact 2

DC overvoltage or DC undervoltage

Four-level DC voltage alarms

Dry contact 3

Rectifier alarm

Except rectifier lost and multi-rectifier alarm

Dry contact 4

Priority LLVD

/

Dry contact 5

Non-priority LLVD

/

Dry contact 6

/

/

Dry contact 7

/

/

Dry contact 8

/

/

With default settings, when the preceding alarms are generated, the contactors of the corresponding dry contacts should change their status, that is, t he 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 Figu re 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.


14

Chapter 2


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 Name of double-layer port

J3

J4

J5

J6

J7

Pin No.

Dry contact terminal definition Pin name

Definition

1

DI1-

Digital input 1-

2

DI1+

Digital input 1+

3

DI2-

Digital input 2-

4

DI2+

Digital input 2+

5

DI3-

Digital input 3-

6

DI3+

Digital input 3+

1

DI4-

Digital input 4-

2

DI4+

Digital input 4+

3

DI5-

Digital input 5-

4

DI5+

Digital input 5+

5

DI6-

Digital input 6-

6

DI6+

Digital input 6+

1

DI7-

Digital input 7-

2

DI7+

Digital input 7+

3

DI8-

Digital input 8-

4

DI8+

Digital input 8+

5

NA

/

6

NA

/

1

DO1_NC

NC contact of relay 1

2

DO2_NC


3

DO1_COM

Common contact of relay 1

4

DO2_COM


5

DO1_NO

NO contact of relay 1

6

DO2_NO


1

DO3_NC


2

DO4_NC


3

DO3_COM



User Manual

Chapter 2 Name of double-layer port J7

J8

J9

Pin No.

Pin name


15

Definition

4

DO4_COM


5

DO3_NO


6

DO4_NO


1

DO5_NC


2

DO6_NC


3

DO5_COM


4

DO6_COM


5

DO5_NO


6

DO6_NO


1

DO7_NC


2

DO8_NC


3

DO7_COM


4

DO8_COM


5

DO7_NO


6

DO8_NO


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 an d 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 i s 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 i s shown in Figure 2-19.

Figure 2-19

M820B controller communication port


16

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 no t 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 de vices are properly installed. Installation check OK

Comments



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.



 

Startup preparations OK 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



Comments Umin=___V

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



Umin=___V

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)

Startup OK

Comments



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.

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.


User Manual

Chapter 3

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. OK Pull out one rectifier. The “Rect N Com Failure” alarm should be triggered. Insert the rectifier in. The

Comments



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.

System operation status check There should be no alarms during normal system operation. The system operation status check can be conducted through the controller. OK 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 t he 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




Comments

17

18

Chapter 3

Installation Testing OK

Comments

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.

3.4 Final Steps OK Disconnect all test equipment from the system and make sure that materials irrelevant to the equipment

Comments



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.



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.


User Manual

Chapter 4

Use Of Controller

19

Chapter 4 Use Of Controller The controller modules of this po wer 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 o f 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 Indicator

Functions of Indicators

Normal State

Fault State

Status (green)

On

Off

Observation Alarm (yellow)

Off

On

Fault Cause If this LED is on, this means the system is operating normally The power system has one or more active observation alarms. Alarm conditions are programmable. Refer to Table 3-3 for defaults The power system has one or more active major alarms (Major and

Major Alarm (red)*

Off

On

Critical Alarms). Alarm conditions are programmable. 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

Function

ENT

Enter

▲

Up

Move Up Cursor or Select the Previous Screen

▼

Down

Move Down Cursor or Select the Next Screen

ESC

Escape

Confirm or Execute

Escape or Cancel


Refer to

20

Chapter 4 Use Of Controller

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

ENT MAIN MENU Status Settings

ENT

Manual ECO Quick Settings

STATUS Active Alarm Rectifiers History Alarm

SETTINGS Alarm Battery AC DC Rectifier Controller Communication

Float 53.4V 404A Manual Normal

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: 1/2 ENT Batt Discharge Observation Alarm Start Time: 081104 15:52:53

ALARM: 2/2 ENT Batt Volt Low Critical Alarm Start Time: 081104 15:52:55

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 SPD Fault

ENT

08- 07 -10 11:35:22 08- 07 - 10 12:35:22

Figure 4-3

ALARM 002 DC Volt Low 08 - 07-10 11:35:25 08 - 07-10 12:35:25

Status screen


User Manual

Chapter 4

Use Of Controller

21

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 al arm. 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 th e 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 bi t, 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: ******

Figure 4-4

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

Settings screen


22

Chapter 4 Use Of Controller 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 la nguage 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:


User Manual

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

23

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 fa ult’, ‘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

Alarm levels

characterist ics of 4 alarm categories

Red alarm

Yellow alarm

indicator of

indicator of

controller and system

controller and system

CA (critical alarm) MA (major alarm)

Alarm buzzer

Alarm report

On

On

Yes

On

On

Yes

On

Off

No

Off

Off

No

OA (observation alarm) No alarm

Off

Remark

Alarm report is enabled Alarm report is enabled

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) o r ‘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.


24

Chapter 4 Use Of Controller 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 SavePowerF ault Save Power

Alarm description Alarm Block Batt Imbalance SavePowerFault Save Power Function

Condition Alarms are blocked by the LCU+ Battery middle voltage out of the range of ( bus voltage /2) ± 0.6 Into and out of save power status for 5 times in one hour

Default alarm level Observation Major Major

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

Temp High1

Temperature High1

Temp Low

Temperature Low

Batt Over Chg DC Volt

Battery Over Charge DC Voltage High+

High+

DC Volt High DC Voltage High DC Volt Low

DC Voltage Low

DC Volt Low- DC Voltage LowRect HVSD

Rectifier HVSD

Ambient/ Battery temperature higher than Temperature High 2 Ambient/ Battery temperature higher than normal operation range Ambient/ Battery temperature lower than normal operation range The charging current over the maximum value System output voltage much higher than float charge voltage System output voltage higher than float charge voltage System output voltage slightly lower than float charge voltage System output voltage is much lower than float charge voltage Rectifier HVSD circuit activated

Default mapped output relay

Major Major Observation Observation Critical

2

Critical

2

Critical

2

Critical

2

Major

3

Observation

3

Observation

3

Major

3

Observation

3

The difference between rectifier output current and Rect LoadShare

Rectifier LoadShare

average output current larger than 8A (+/-4A), and the load of the rectifier greater than 10% of its capacity

Rect Derated Rectifier Derated Rect Fan Fails Rect Protect

Rectifier Fan Fails Rectifier Protect

The output power of at least one rectifier is derated because of AC undervoltage or overtemperature Fan of at least one rectifier fails AC input voltage out of the range of 85Vac to 295Vac results in at least one rectifier protected


User Manual

Chapter 4 Alarm name

Rect Failure

Alarm description

Rectifier Failure

Condition

Use Of Controller

Default alarm level

25

Default mapped output relay

Serious load sharing alarm (the output current of the rectifier is lower than 1A, and the average load is Critical

3

greater than 10% of the total rectifier capacity) Rect

Rectifier

High temperature protection activated in at least one

TempHigh

Temperature High

rectifier

Rect AC Fail

Rectifier AC Fail

Rect Comm

Rectifier

Fail

Communication Fail

MultiRect Alarm System

Multi rectifier Alarm System Maintain

Maintain Rect Lost

Major

3

AC input voltage lower than 80Vac

Major

3

Rectifier(s) unable to communicate with LCU+

Major

3

Two or more rectifiers have alarms

Critical

System has not been maintained within preset maintenance time

None

Rectifier Lost

Rectifier reduction detected

Critical

Rectifier OverLoad

Total load current greater than the High Load value

Observation

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

Rect OverLoad Mains Failure

Batt Test Fail Battery Test Fail DC Volt Fail Curr Imbalance Batt Discharge Batt Test Boost Charge Manual Mode SelfDetect Fail

DC Voltage Fail Current Imbalance

Battery discharge test failure (battery voltage is lower than setting value before test time is reached) The difference between bus voltage and the set output voltage larger than the set value The total output current not equal to the sum of the battery current and the load current

Observation Observation Observation

Battery Discharge

Batteries are discharging

Observation

Battery Test

The batteries are testing

None

Boost Charge

The batteries are in boost charge state

None

Manual Mode

The system is in manual mode

Observation

SelfDetect Fail

LCU+ detects error in hardware self test

Observation

After battery disconnection/ connection signal is sent out, the feedback signal of the contactor is

Critical

LVD2Ctrl Fail LVD2 Control Fail

false BattFuse Fail

Battery Fuse Fail

Battery fuse(s) or circuit breaker(s) open

Critical

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

LoadFuse Fail


26

Chapter 4 Use Of Controller 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.


User Manual

Chapter 4

Use Of Controller

27

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 0.1 50C10 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 ini tiated 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 no minal 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 in terval, in hours, between the b oost 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 le vel (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 h ours, 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 i s 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.


28

Chapter 4 Use Of Controller Temp 2: Displays 2: Displays whether a temperature probe on MB is installed and enabled (Battery (Battery or or Ambient) Ambient) or not (None (None)) in position No. 2, and if there is one, whether it is used for battery or ambient temperature measurements. Coeff: Displays 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: Chang Change e to'Manual to'Manual'' from from 'Auto' 'Auto' MAIN MENU Status Settings

ENT

MANUAL Sys Mode: Auto ▼ In Manual

Manual ECO Quick Settings Figure 4-7

MANUAL Start: Float LVD1 LVD1:: Reco Reconn nn LVD2 LVD2:: Reco Reconn nn RectTrim RectTrim : 53.5V RectLimit RectLimit : 121%

Manual screen

In the manual screen, you can perform the following manual control operations: Start: T Start: To o start float or boost charging or battery test. LVD1: To LVD1: To reconnect or disconnect LVD1 contactor. LVD2: To LVD2: To reconnect or disconnect LVD2 contactor. RectTrim: T RectTrim: To o adjust the rectifier output voltage. RectLimit: T RectLimit: To o 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 Figure 4-8

ECO ENT

Disable Cyc Period: 168h Rect Work: 80% Rect Limit: 1

ECO screen

The following parameters can be configured: ECO: T ECO: To o disable or enable ECO function. Cyc Period: Rectifier Period: Rectifier redundancy cycle. Rect Work: Optimum Work: Optimum operating load point of rectifier. Rect Limit: In 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

ENT

System Type: 48V / 1000A Capacity: 300Ah LCD Rotation: On

Quick Settings

Figure 4-9

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 batte ry shunts.

NetSure 701 A41, A41, NetSure 501 A41, NetSure NetSure 501 A91 A91 Subrack Power system system

User Manual Manual

Chapter 4

Use Use Of Controller

29

4.2.6 Controller Setting Table 4-6 summarizes all the settings of the controller. Table 4-6 Components Alarm

Rectifier

Basic battery parameters

Available Settings Settings

Name

Low limit

DI alarm mode

High / low

HVSD point

56

Default voltage

Default setting

High limit

Unit

High

/

59

59

V

48

58

53.5

Restart time upon over voltage

0

300

300

s

Soft-start time with load

8

128

8

s

Soft-start with load enabled

Enabled/Disabled Enabled/Disabled

Disabled

/

Startup upon AC over voltage


Disabled

/

System ECO enabled


Disabled

/

Sequencial start interval

0

10

0

s

Input current limiting

1

50

30

Rectifier slot setting enabled


Rectifier slot setting

1

Number of fuses

Disabled

/

30

1-1/2-2…

/

0

5

2

Nominal capacity

20

5000

600

Shunt

Yes / No

Shunt current

1

2000 500

According to system system type

Ah

A

Shunt voltage

1

25

mV

Temperature 1

None/Battery/Ambient None/Battery/Ambient

Disabled

/

Temperature 2

None/Battery/Ambient None/Battery/Ambient

Disabled

/

Float charging voltage

42

53.5

V

58

Battery

Boost charging voltage

42

58

56.4

V

charge

Charging current limiting

0.1

0.25

0.1

C10

Yes

/

parameters

y r e t t a B

Controller Settings

Auto boost charging charging enabled

Yes / No

Constant charging current

0.002

0.02

0.01

C10

Constant current charging time

5

1440

180

Min

To boost charging current

0.04

0.08

0.06

C10

Battery

To boost charging capacity

10

99

80

%

charge

Scheduled boost charging enabled

Yes / No

Yes

/

parameters

Boost charging protection time

60

2880

1080

H

Scheduled boost charging cycle

2

8760

2400

h

Scheduled boost charging time

30

2880

720

Min

Battery test end time

5

1440

300

Min

Battery test end voltage

43.1

57.9

45.2

Min

Battery test end capacity

0

1

0.7

C10

Scheduled test enabled

Yes

No

/

Battery test

Constant current test enabled

Yes / No

No

/

parameters

Constant battery test current

1

9999

A

Short test enabled

Yes / No

No

/

Short test alarm point

1

100

10

A

Short test cycle

24

8760

720

h

Short test time

1

60

5

min

Temperature compensation central point

10

40

25

deg.C

Battery temp compensation coefficient

DC unit

9999

Battery compensation coefficient

0

500

72

mv/deg.C

Battery over temperature point

10

100

50

deg.C

Battery high temperature point

10

100

50

deg.C

Battery low temperature point

-40

10

0

deg.C

Over voltage 1

40

60

58.5

V

Under voltage 1

40

60

45

V

Under voltage 2

40

60

45

V

High ambient temperature

10

100

40

deg.C

Low ambient temperature

-40

10

-5

deg.C


30

Chapter 4 Use Of Controller Components Load shunt

LVD

AC unit

Available Settings Settings

Name

Low limit

Default setting

High limit

Unit

Yes / No

No

/

LVD1 Enabled

Disabled / Enabled

Disabled

/

LVD2 enabled

Disabled /Enabled

Disabled

/

LVD1 voltage

40

60

43.2

V

LVD2 voltage

40

43.2

V

Over voltage alarm point

0

500（ 500（866） 866）

280（ 280（485） 485）

V

Under voltage alarm point

0

500（ 500（866） 866）

180（ 180（304） 304）

V

Phase failure alarm point

0

500（ 500（866） 866）

80（ 80（255） 255）

%

IP address

0-255

192.168.1.2

/

Subnet code

0-255

255.255.255.0

/

60

Default gateway

0-255

192.168.1.1

Local address

1

255

Port type

RS232/Modem/ETH RS232/Modem/ETH

RS232

Communication

Baud rate

1200/2400/4800/9600

9600

parameters

Protocol

YDN23/EEM/RS OC/SOCTPE

YDN23

/

No

/

Alarm call-back call-back enabled

Yes / No

Call back times

0

10

/ 1

/ /

3

Call back number 1 Call back number 2 Call back number 3 Language

English / Chinese

Display time zone

English GMT+08:00

System date System time Controller parameters

Restore default configurations

Yes / No

No

Set rotating screens

Horizontal/Vertical Horizontal/Vertical

Horizontal

48V/set, 48V/1000A, 48V/500A, 48V/300A, System type

48V/100A, 24V/set,

48V/set

24V/1000A, 24V/500A, 24V/300A and 24V/100A

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 al arms are displayed in a pop-up W EB window. window.

 Download

and upload configuration files.

4.3.1 Setting Up The Internet Explorer Web Browser 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. proxy. If the controller is connected Internet and the user computer is connected to the Internet, the user cannot disable the proxy, proxy, otherwise he will have no access to the controller. 1. Launch In ternet Explorer.

NetSure 701 A41, A41, NetSure 501 A41, NetSure NetSure 501 A91 A91 Subrack Power system system

User Manual Manual

Chapter 4 2. Select Internet Options from the Tools menu. The ‘Internet Options’ window opens. window, select the Connections tab.

Figure 4-10

3. Click on the LAN Settings... button.

Use Of Controller

31

In the ‘Internet Options’

Internet options window

The following window opens. In the LAN Settings window, uncheck the proxy

box and click OK.

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 pressENTER. 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.


32


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

User Manual

Chapter 4 

Use Of Controller

33

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


34

Chapter 4 Use Of Controller 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


User Manual

Chapter 4

Use Of Controller

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


35

36

Chapter 4 Use Of Controller 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 do wnload 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


User Manual

Chapter 4

Use Of Controller

37

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 fo llowing 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


38


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 e xecute 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


User Manual

Chapter 4

Use Of Controller

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 fil es:

Figure 4-29

Uploading the file

2) Choose Transfer->Receive File… to select the position in which you save the file


39

40


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.


User Manual

Chapter 5

Alarm Handling

41

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 No.

System setting parameter description

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

1

Mains Failure

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 t he value.

2

AC Voltage High

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.

3

AC Voltage Low

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

4

SPD failure

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.

5

DC Volt High

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

6

DC Volt Low

the whole system. 2. Check the DC under-voltage value set t hrough 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

7

Load Fuse Alarm, Batt Fuse Alarm

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


42

Chapter 6 No.

Alarm Handling Alarm

Handling method 1. Check if there is mains failure, and the battery voltage is lower than the value of ‘LVD2’.

8

LVD2

9

Rect Failure

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 m ains voltage is under the AC

10 Rect Protect

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

11 Rect Fan Fails

is not obstructed or if the fault persists after cleaning, replace the f an

12 Rect Not Respond 13

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

Batt Over Temp

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 Symptom Run indicator off (green) Run indicator blinks(green)

Monitoring module

Causes

alarms No alarm No alarm Rect Protect

Rect Protect

Indicator fault description

No input/output voltage Assistant power source of the rectifier fails The monitoing module performs operations upon the rectifier

Make sure there is input/output voltage Replace the recitifier No actions need to be taken

AC input voltage abnormal

Make sure the AC input voltage is normal

Fan blocked

Remove the object that blocks the fan

Ventilation path blocked at the inlet or vent

Remove the object at the inlet or vent

Ambient temperature too high or the inlet too Decrease the ambient temperature or remove close to a heat source

Protection indicator on (yellow)

Handling method

the heat source Check whether the rectifier communication is

Load share Alarm

Current sharing imbalance

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

Rect Protect

Power factor compensation internal under voltage or over voltage

Replace the rectifier


User Manual

Chapter 5 Symptom

Monitoring module

Causes

alarms

Protection indicator

Rect Not Respond

Rectifier communication interrupted

Rect HVSD

Rectifier over-voltage

blinks(yellow)

Two or more recitifiers have the same ID

Rect Failure

number

Fault indictor on (red)

Serious current sharing imbalance, Rect Failure

Fault indicator blinks (red)

Alarm Handling

43

Handling method Check whether the communication cable is in normal connection Reset the rectifier. If the protection is triggered again, replace the rectifier Contact Emerson for maintenance Check whether the rectifier communication is normal. If not, check whether the

501 series modle: current imbalance > ± 3%; communication cable is in normal connection.

Rect Fan Fails

701 series modle: current imbalance > ± 5%

If the communication is normal while the protection indicator is on, replace the rectifier

Fan fault

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 fi xing 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 t he 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.


44

Appendix 1

Technical And Engineering Data

Appendix 1 Technical And Engineering Data Table 1 Technical data Parameter

Parameter

category

Environmental

Description

Operating temperature

-5°C ~ +40°C

Storage temperature

-40°C ~ +70°C

Relative humidity

5%RH ~ 95%RH

Altitude

≤ 2,000m (derating is necessary above 2,000m)

Polution level

Level 2

Others

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

PE/220Vac. Others: 3P + N + PE/ 380Vac

AC input type Input voltage range AC input

Input AC voltage frequency

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

≥ 0.99

Over-voltage level

Level II

Standard output DC voltage

-48Vdc

Rated output DC voltage

-53.5Vdc

Output DC voltage

-42.3Vdc ~ -57.6Vdc NetSure 701 A41 ≤ 275A, load current ≤ 225A, battery charge current ≤ 50A

Maximum output current

NetSure 501 A41≤150A, load current≤ 120A, battery charge current ≤ 30A NetSure 501 A91≤275A, load current≤ 225A, battery charge

DC output

current ≤ 50A Voltage set-point accuracy

≤ 1% R48-1800A/R48-2000 ≥89％;

Efficiency

R48-2000e/R48-3200e/R48-3500e≥94.5％; R48-2900U≥90％; R48-4000e≥90％

Noise (peak-peak)

≤ 200mV (0 ~ 20MHz)

Weighted noise

≤ 2mV (300 ~ 3400Hz)

AC input over-voltage alarm point

Default: 280 ± 5Vac, cofigurable through controller

AC input over-voltage alarm recovery

Default: 270 ± 5Vac, 10Vac lower than the AC input over-voltage

point

alarm point

AC input under-voltage alarm point

Default: 180 ± 5Vac, configurable through controller

AC input under-voltage alarm recovery

Default: 190 ± 5Vac, 10Vac higher than the AC input under-voltage

point

alarm point

AC input alarm and protection

AC input over-voltage protection point

NetSure 501 A41, NetSure 501 A91: 305 ± 5Vac by default, cofigurable through controller NetSure 701 A41: 295 ± 5Vac by default, cofigurable through controller

AC input over-voltage protection

NetSure 501 A41, NetSure 501 A91: 295 ± 5Vac by default, 10Vac lower than the AC input over-voltage alarm point

recovery point

NetSure 701 A41: 285 ± 5Vac by default, 10Vac lower than the AC input over-voltage alarm point


User Manual

Appendix 1 Parameter

Parameter

category AC input alarm and protection

DC output alarm and protection

Default: 80 ± 5Vac, configurable through controller

AC input under-voltage protection

Default: 95 ± 5Vac, 10Vac higher than the AC input under-voltage

recovery point

alarm point

DC output over-voltage alarm point

Default: -58.0 ± 0.2Vdc, configurable through controller

DC output over-voltage recovery point

DC output under-voltage recovery point and protection

45

Description

AC input under-voltage protection point

DC output under-voltage alarm point

DC output alarm


Default: -57.5 ± 0.2Vdc, 0.5Vdc lower than the over-voltage alarm point Default: -45.0 ± 0.2Vdc, configurable through controller Default: -45.5 ± 0.2Vdc, 0.5Vdc higher than the under-voltage alarm point

DC output over-voltage proteciton point Default: -59.0 ± 0.2Vdc, configurable through controller LLVD


BLVD


Current sharing

The rectifiers can work in parallel and share t he current. The 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)

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 delay Fan speed adjustable

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 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 Over-voltage protection

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


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: 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. Rectifier

Temperature derating

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

Conducted emission

Class A

EN55022

Voltage fluctuation and flash

Class A

EN61000-3-11

Immunity to EFT

Level 4

EN/IEC 61000-4-4

Immunity to ESD

Level 3

EN/IEC 61000-4-2

Immunity to surges

Level 4

EN/IEC 61000-4-5

Immunity to radiation

Level 2

EN/IEC 61000-4-3

Immunity to conduction

Level 2

EN/IEC 61000-4-6

Radiated emission

EMC


User Manual

Appendix 1 Parameter

Parameter

category


47

Description The AC input side can withstand five times of simulated lightning voltage of 5Kv at 10/700µs, for the positive and negative polarities

Lightning protection

respectively. It can withstand five times of simulated lightning surge At AC side

current of 20Ka at 8/20µs, for the positive and negative polarities

features

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 Safety regulation

IEC60950-1:2001

Acoustic noise

≤ 60db (A) (When t he ambient temperature is lower than25℃) At temperature of 15°C ~ 35°C and relative humidity not bigger than

Insulation resistance

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 t o DC loop can withstand 50Hz.

Others Insulation strength

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;

MTBF

> 200,000hr

ROHS

Compliant with R5 requirement NetSure 501 A41-S1/S2: 483 × 360 × 223

Dimensions (mm)(W×D×H)

Maximum dimensions

NetSure 501 A91-S1: 483 × 360 × 445

of the subracks

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 R48-1800A, R48-2000, R48-2000e: 87.9× 85.3× 272

Rectifier

Mechanical

R48-3200e, R48-3200, R48-2900U, R48-3500e: 132.3 × 88× 294 R48-4000e:132.3 × 88 × 294

Subrack (without rectifiers and

≤ 25

controller) Weight (kg)

Monitoring module M501D/M500D Rectifier

< 0.8 R48-1800A, R48-2000, R48-2000e ≤ 2.0 R48-3200, R48-2900U, R48-3200, R48-3500e, R48-4000e ≤ 3.5


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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

Four-layer battery rack

Accessory 1

2

4

Accessory 2

8

14

Accessory 3

2

4

Accessory 4

2

2

Accessory

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


User Manual

Appendix 2


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


49

50

Appendix 2


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 number

Accessory 1

2

Accessory 2

6

Accessory 3

3

Accessory 4

2

Expansion bolt

4 pieces

Fastener

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


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.


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319788645-31012653-NetSure-701-A41-NetSure-501-A41-NetSure-501-A91-1.pdf

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