NetSure 212 C23 user manual V1.0 20130617.pdf

NetSure 212 C23 插框电源系统

NetSure 212 C23 Subrack Power

用户手册

System User Manual

资料版本 V1.0 归档日期 2013-06-17 BOM 编码 31012878

艾默生网络能源有限公司为客户提供全方位的技术支持，用户可与就近的艾默生网络能源有限公司办事处或客户服务中心联系，也可直接

Version V1.0 Revision date June 17, 2013 BOM 31012878

Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.

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Copyright © 2013 by Emerson Network Power Co., Ltd.

不另行通知。

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

艾默生网络能源有限公司

Emerson Network Power Co., Ltd.

地址：深圳市南山区科技工业园科发路一号邮编：518057

Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China

公司网址：

Homepage: www.emersonnetworkpower.com.cn

www.emersonnetworkpower.com.cn

E-mail: [email protected]

客户服务热线：4008876510 E-mail：[email protected]

Safety Precautions To reduce the chance of accident, please read the safety precautions very carefully before operation. The 'Caution, Note, Warning, Danger' in this book and on the product do not represent all the safety points to be observed, and are only supplement to various safety points. Therefore, the installation and operation personnel must receive strict training and master the correct operations and all the safety points before operation. When operating Emerson products, the operation personnel must observe the safety rules in the industry, the general safety points and special safety instructions specified in this book.

Electrical Safety I. Hazardous voltage

Danger 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. Observe safety rules in the industry when installing the AC power devices. The installation personnel must be licensed to operate high voltage and AC power. In operation, the installation personnel are not allowed to wear conductive objects, such as watches, bracelets, bangles and rings. When you spot the cabinet with water or moisture, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power system. ‘Prohibit’ warning label must be attached to the switches and buttons that are not permitted to operate during installation.

Danger Danger High voltage operation may cause fire or 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. III. Thunderstorm

Danger Danger Never operate on high voltage, AC, iron tower or mast in the thunderstorm. In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be well earthed in time to avoid damage by lightning strikes.

IV. ESD

Note The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale ICs. Before touching any plug-in board, PCB or IC chip, ESD wrist strap must be worn to prevent body static from damaging the sensitive components. The other end of the ESD wrist strap must be well earthed. V. Short circuit

Danger Danger During operation, never short the positive and negative poles of the DC distribution unit of the power system or the non-grounding pole and the earth. The power system is a constant-voltage DC power device, short circuit will result in equipment burning and endanger human safety. Check the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC distribution unit is very tight, please carefully select the operation space. Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation. Use insulated tools. In live operation, keep the arm, wrist and hand tense, so that when the tool in operation slips, the movement of the human body and tool is reduced to a minimum. VI. Dangerous energy

Note More than 240VA system capacity, keep away from hazardous energy and avoid bridge connection.

Battery Danger Before any operation on the 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, take precautions to prevent battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs. Before any operation on battery, pay attention to the following points: Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. Use special insulated tools. Use eye protection device, and take preventive measures. Wear rubber gloves and apron to guard against electrolyte overflow. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted. Battery installation requires reliable grounding. And battery is connected before accessing the battery protection device.

BLVD The power system has battery low voltage disconnection (BLVD) function. BLVD means when battery voltage drops to 43.2V, the power system cuts the load off to prevent over-discharge. BLVD is enabled before delivery, which means that if power outage lasts for a long time or the power system fails, there might be BLVD. Users should classify the loads and connect the priority loads to BLVD routes. For vital loads, users can disable BLVD to ensure reliability of the power supply. The method of disabling BLVD is: Set ‘BLVD disabled’ parameter through the controller main menu  Settings (password: 1)  LVD  BLVD  ‘No’.

Note Noti Warn cein g The advantage of BLVD is protecting the batteries from over-discharge. The disadvantage of BLVD is that when the battery voltage drops 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 disabling BLVD is prolonging the power supply of priority loads. The disadvantage is that disabling cannot prevent unwanted power failure due to misoperation or power system failure.

Others I. Sharp object

Warning When moving equipment by hand, wear protective gloves to avoid injury by sharp object. II. Power cable

Note Noti Warn cein g Please verify the compliance of the cable and cable label with the actual installation prior to cable connection. III. Signal cables

Note Noti Warn cein g The signal cables should be routed separately from power cables, with binding interval of at least 150mm.

Contents Chapter 1 Overview ............................................................................................................................................................ 1 1.1 Composition And Configuration ............................................................................................................................ 1 1.2 Features ................................................................................................................................................................ 1 Chapter 2 Installation Instruction ......................................................................................................................................... 3 2.1 Safety Regulations ................................................................................................................................................ 3 2.2 Preparation ........................................................................................................................................................... 3 2.3 Mechanical Installation .......................................................................................................................................... 4 2.4 Cable Connection ................................................................................................................................................. 5 Chapter 3 Installation Testing.............................................................................................................................................. 7 3.1 Installation Check And Startup .............................................................................................................................. 7 3.2 Basic Settings ....................................................................................................................................................... 8 3.3 Alarm Check And System Operation Status Check .............................................................................................. 8 3.4 Final Steps ............................................................................................................................................................ 8 Chapter 4 Alarm Handling ................................................................................................................................................... 9 4.1 Handling Alarms.................................................................................................................................................... 9 4.2 Handling Rectifier Fault....................................................................................................................................... 10 4.3 Replacing Load Fuse .......................................................................................................................................... 12 4.4 Replacing DC Distribution Board ........................................................................................................................ 13 Appendix 1 Technical Data ............................................................................................................................................... 14 Appendix 2 Wiring Diagram............................................................................................................................................... 16 Appendix 3 Glossary ......................................................................................................................................................... 17

Chapter 1

Overview

1

Chapter 1 Overview This chapter introduces the composition and configuration, and features of NetSure 212 C23 subrack power system (‘power system’ for short).

1.1 Composition And Configuration The power system has two configurations: NetSure 212 C23-S1 and NetSure 212 C23-S2, and their appearances are shown in Figure 1-1 and Figure 1-2. Controller Dry contact RS232 port output

AC input socket

Rectifier

Temperature sensor and digital quantity input port

Battery input port

Load output

Figure 1-1 Appearance of the NetSure 212 C23-S1 Controller Dry contact RS232 port output

AC input port


Rectifier

Battery input port

Load output

Figure 1-2 Appearance of the NetSure 212 C23-S2

The configuration of the system is listed in Table 1-1. Table 1-1 Configuration of the system Component

Configuration

Rectifier

Model: R48-1000A or R48-500A Standard configuration: 2 pieces

Controller

Model: M225S Standard configuration: 1 piece

AC power distribution

AC input mode: L (L1) + N (L2) + PE/220V

DC power distribution

8 load fuses: 6 × 10A, 2 × 20A

Battery routes

One battery fuse: 1 × 30A

Others

Two digital quantity input ports, two dry contact output ports, one temperature sensor port

1.2 Features  The rectifier uses the active Power Factor Compensation (PFC) technology, raising the power factor to 0.99.  The system has wide AC input voltage range: 85Vac ~ 300Vac.  The rectifier uses soft switching technology, rated the efficiency to 91%.  The rectifier has ultra-low radiation. With advanced EMC design, the rectifier meets international standards such as CE and YD/T983. Both the conducted and radiated interference reach Class A.  The rectifier safety design complies with CE standards.  The rectifier is of high power density.  The rectifier is hot pluggable. It takes less than one minute to replace a rectifier. NetSure 212 C23 Subrack Power System

User Manual

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Chapter 1

Overview

 The rectifier has two over-voltage protection methods: hardware protection and software protection. The latter one also has two optional modes: lock-out at the first over-voltage and lock-out at the second over-voltage.  The controller has perfect battery management. The management functions include battery low voltage disconnection (BLVD), temperature compensation, auto voltage regulation, stepless current limiting, battery capacity calculation, on-line battery test, and so on.  The controller can save up to 200 pieces of historical alarm records, 512 pieces of historical events, and provide current alarm view.  The controller is of network design. With an RS232 port, two routes dry contacts and other communication ports provided, flexible networking is enabled to achieve remote monitoring and unattended operation.  The system has complete fault protection and fault alarm functions.

NetSure 212 C23 Subrack Power System

User Manual

Chapter 2

Installation

3

Chapter 2 Installation This chapter introduces the installation and cable connection. Before installation, please read through safety regulations, and then follow the instructions provided in this chapter to carry out the installation and cable connection.

2.1 Safety Regulations Certain components in this system carry hazardous voltage and current. Always follow the instructions below: 1. Only adequately trained personnel with satisfactory knowledge of the power system shall carry out the installation. The most recent revision of these safety regulations 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 defined in IEC 60950. 3. Make sure that the power (mains and battery) to the system is cut off before any operation can be carried out within the power system. 4. The equipment shall be kept locked and placed in a locked room. The key keeper should be the one responsible for the system. 5. The wiring of the power distribution cables should be arranged and protected carefully so that the cables are kept away from the maintenance personnel.

2.2 Preparation Installation spot Keep the installation position of the power system a sufficient distance away from the other inflammable materials. The system supports 19’/23’ rack or wall installation. 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 should be selected in accordance with relevant industry standards. It is recommended to use the RVVZ cables as AC cables. The cable should reach at least +70°C temperature durability. Select the AC cable Cross-Sectional Area (CSA) according to Table 2-1. Table 2-1 AC cable CSA selection System type

Connector

Specifications

AC cable CSA 2

NetSure 212 C23-S1

AC socket

Plug

1mm ~ 1.5mm2 three-core power cable

NetSure 212 C23-S2

3P AC terminal

UT1.5-3

1mm2 ~ 2mm2

The CSA of DC cable depends on the current flowing through the cable, the allowable voltage drop and load peak current. The recommended load peak current is 1/2 of load fuse capacity. Select the battery cable CSA according to Table 2-2. Select the load cable CSA according to Table 2-3. Table 2-2 Battery cable CSA selection Battery fuse rated Max. battery Min. cable Max. cable length (allowable Max. cable Max. cable length (volt drop: current current CSA voltage drop: 0.5V) CSA 0.5V, with max. CSA) 30A 20A 4mm2 5m 6mm2 8m Note: 1. The specs are applicable at ambient temperature of 25°C. 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


User Manual

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Chapter 2

Installation Table 2-3 Load cable CSA selection

Load route rated Max. output Min. cable Max. cable length (volt drop: Max. cable length (volt drop: Max. cable CSA current current CSA 0.5V, with min. CSA) 0.5V, with max. CSA) 10A 5A 2.5mm2 3m 4mm2 5m 20A 10A 2.5mm2 2m 4mm2 3m 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 2

Earth cable is the yellow-green cable which requires the CSA more than 1.5mm .

2.3 Mechanical Installation 1. Install brackets. Fix the brackets on the power subrack with screws. Users can choose proper installation holes according to actual instance.



Note

Before installation, remove the brackets which have been reversely fixed in the center of the subrack in factory. 2. Install the subrack. Fix the subrack on the rack with fixing screws through brackets. The installation dimensions are shown in Figure 2-1. Rack installation: Dimensions (mm) 27.3 (L) × 43 (H)

23’

78.1 (L) × 43 (H)

31.8

Model 19’

Accessories. Select either one

465

43.6

3.5

Note

428

289.5 29

Bracket: Either of the two positions is available for installation

482.6


User Manual

Chapter 2

Installation

5

Wall installation (Recommended installation direction is shown in Figure 2-1):

465

289.5

6.8×10.3 31.8

Figure 2-1 Installation dimensions (unit: mm)

2.4 Cable Connection Danger Danger Before electrical connection, ensure that protective MCBs of the AC power prestage distribution equipment are disconnected. It is recommended to use AC230/400V 20A bipolar C type-MCB (with two R48-1000A rectifiers for system), and AC230/400V 10A bipolar C type- MCB (with two R48-500A rectifiers for system). 

Note

1. Be careful not to reversely connect the battery. Otherwise, both the battery and the system will be damaged! 2. The connection terminals of the AC input cables must be wrapped with insulating UT/OT terminals, to avoid electric shock caused by contacting with bare metal parts of the connection terminals exposed to the plastic cover. 3. Before connecting battery cables, you should disconnect any one of the connectors between battery cells to avoid live state of the system after installation. 4. Never connect load at the battery port, otherwise the system will be damaged! Connect AC cables, battery cables, load cables and signal cables for on-site requirement, according to the ports layout in Figure 2-2 and ports definition in Table 2-2. The cable colligation holes are provided in front of the load cables and single cables, and the cables should be properly colligated after installation. AC input socket

RS232 port

Dry contact output



Battery input port

Load output

User Manual

Chapter 2

Installation AC input port

RS232 port

Dry contact output


Battery input port

Load output

Figure 2-2 Ports layout

Cable wiring and port position of the temperature sensor and digital quantity input port are shown in Figure 2-3. Monitoring board Temperature sensor port J 2

6

Digital quantity input port

To battery and user equipment

A

A amplified view

Figure 2-3 Temperature sensor and digital quantity input port

Table 2-4 Port definition Type AC input

Silkscreen L (L1) N (L2)

Definition

Note

AC input L(L1) AC input N(L2)

Direct connection for the input socket, with 16A standard AC power cable satisfied

AC input PE F1-, F2Load output

Battery input port RS232 communication port Dry contact Temperature sensor port

Digital quantity input port

F3- ~ F8F1+ ~ F8+ B+ B-

DC load output 1&2 (negative) DC load output 3~8 (negative) DC load output 1~8 (positive) 48V battery access (positive) 48V battery access (negative)

Equipped with 20A fuse protection Equipped with 10A fuse protection

Equipped with 30A fuse protection

RS-232 communication earthing Rx Tx DO1 DO2 J2

Dooralm SPDalm

RS-232 receives data RS-232 sends data Dry contact output 1 Dry contact output 2 Pin1-Power supply and signal output Pin2-Reference Pin3-Empty Brown-Access control alarm-input positive Black-Access control alarm-input negative Brown-SPD alarm-input positive Black-SPD alarm-input negative


NO (Normally open): closed upon an alarm while opened upon normal mode Port located on the monitoring board

Reserved

User Manual

Chapter 3

Testing

7

Chapter 3 Testing This chapter introduces procedures of system 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 shall conduct the system testing. Remove metal objects such as rings, watches, and so on that may cause short circuit. During operation, watch out for hazardous voltage, and avoid personnel injury and property damage. Before the test, ground the equipment properly. Installation check must be done before testing, then the batteries can be charged for the first time. Make sure that protective MCBs of the AC power prestage distribution equipment are disconnected. Make sure that all the devices are properly installed. Check the system according to the following items. Installation check Check item Check that the power subrack is horizontally, vertically and steadily fixed Check that the input, output and earth cables, and communication cables are connected properly and reliably Measure the resistance value between the positive terminal and negative terminal of the DC loop, and phase-to-phase resistance value in the AC loop. Make sure that there is no short circuit Check the AC input and distribution. Check that the color of the AC cables is normative, the cables are laid fast, and the safety labels are complete Check the connection point, line sequence and polarities of DC cables. Check the connection polarities of the batteries. Check that the connection points are fixed and the cable connections are correct and reliable Check the communication cables of the controller. Check that the rectifiers are fastened down

OK 

Comments

   

Startup preparations Check item Measure the AC input voltage. Make sure that the input voltage is within the allowable range Measure the battery string voltage with a voltmeter and the voltmeter should read in 48V/battery ~ 51V/battery Check with an ohmmeter that there is no short circuit between the positive & negative distribution busbars, or between the positive & negative battery poles (Note: Pull out all rectifiers before the check and restore them after the check)

OK

Comments



Umin＝V



Umin＝V



Startup Check item Switch on the client switch of the power system, then the controller should display the correct voltage and current values 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 output voltage is 53.5V Check the positive and negative of the DC output voltage with a voltmeter. The voltage difference between the measured value and displayed value should be less than ±0.3V


User Manual

OK   

Comments

8

Chapter 3

Testing

3.2 Basic Settings When the system is put into service for the first time, the parameters of the controller must be set based on the actual system configuration. Method for changing the parameter settings: Main→Settings (password: 1)→Bat. Settings. See M225S Controller User Manual. Check item Set the battery capacity according to the total capacity of all the batteries connected to the system. (Default: 100Ah). Default setting in this system is 40Ah.

OK

Comments



(The path to check and set the M225S controller: SettingsCapacity) Set ‘reply 2: LVD1’ (The path to check and set the M225S controller: Settings Relay 2) Set the controller according to the voltage suggested by the battery supplier. Float Charge (FC) voltage range: 42V ~ Boost Charge (BC) voltage. Default: 53.5V BC voltage range: FC voltage ~ 58V. Default: 56.4V BLVD: 40V ~ LLVD voltage，Default: 43.2V





(The path to check and set the M225S: SettingsFloat/Equalize), Settings Batt Pro） For batteries that do not need BC, set the BC voltage to FC voltage plus 0.1V Measure the battery voltage with a multimeter and record it



3.3 Alarm Check And System Operation Status Check System operation status check There should be no alarm during normal system operation. The system operation status check can be conducted through the controller. Check item

OK

Comments



The controller should display the correct AC voltage The controller should display the DC voltage. The difference between the displayed voltage and that measured should be less than ± 0.3V Hold the probe of the temperature sensor with hand and watch the controller, which should display the change of temperature.

 

3.4 Final Steps Check item Make sure that materials irrelevant to the equipment have been all removed Note down all the operations taken, including time of the operation and name of the operator

OK  

Comments

If any defect is found in this equipment, inform the personnel responsible for the contract. If repairing is needed, please fill in the FAILURE REPORT and send the report together with the defective unit to the repairing center for fault analysis.


User Manual

Chapter 4

Alarm Handling

9

Chapter 4 Alarm Handling This chapter describes the handling of alarms, as well as the routine maintenance of the system during system daily operation. 

Note

1. The maintenance must be conducted under the guidance of related safety regulations. 2. Only trained personnel with adequate knowledge about the system shall maintain the inner part of the system. 3. Hazardous voltage exists in the primary circuits. Disconnect power supply before servicing. 4. The output power taken from the supply must not exceed the rating given on the 'Power Supply'. The built-in monitoring unit is not intended to be repaired by service personnel in case of failure or component defect, failure unit should be sent back to the manufacture for repair.

4.1 Handling Controller Alarms Controller alarm handling The controller alarms are classified into three types: major alarm, observation alarm and no 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 red major alarm indicators will be on. 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 yellow observation alarm indicators will be on. No alarm: If alarms are set as ‘no alarm’ by the users, when these alarms occur, the green alarm indicators will be on and the system works normally. If an unnecessary alarm occurs during the operation of the controller, set it according to the following method. Take the alarm of ‘Rect Lost’ for example: The path to check and set through the M225S controller: MainSettingsClear. For the submenu of 'Clear', you can select 'Rect Lost' to clear corresponding alarm. The handling methods of normal alarms are given in Table 4-1. Table 4-1 Troubleshooting No.

Alarm

1

Mains Failure

2

AC Voltage High

3

AC Voltage Low

4

SPD alarm

5

DC Volt High

Handling method If the failure does not last long, the battery will power the load. If the cause is unknown or the failure lasts too long, a diesel generator is needed. Before using the generator power to supply the power system, it is suggested to run the generator at least five minutes to minimize the impact on the power system Check if the AC over-voltage value is too low. If yes, change the value. A mild over-voltage does not affect the system operation. However, the rectifiers will stop working when the mains voltage is more than 305V. If the mains voltage is above the AC over-voltage value, the mains grid should be improved Check if the AC Under- voltage point is too high. If yes, change the value. When the mains voltage is lower than 176V, the output power of the rectifiers will be derated. And if lower than 80V, the rectifiers will stop working. If the mains voltage is under the AC under-voltage value, the mains grid should be improved Check the SPD condition. If the SPD is damaged, replace it Check the DC over-voltage value through the controller. If the setting value is inappropriate, correct it. Otherwise, find out the rectifier that has caused the alarm: 1. Ensure that the batteries can operate normally. 2. Switch off the AC input of all rectifiers. 3. Power on the rectifiers one by one. 4. If the over-voltage protection is triggered when a certain rectifier is powered on, that rectifier is the faulty one. Replace it


User Manual

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Chapter 4 No.

6

7 8 9 10 11 12 13

Alarm Handling Alarm

Handling method 1. Check if the alarm is caused by mains failure, if yes, disconnect some loads to prolong the operation of the whole system. 2. Check the DC under-voltage value set through the controller. If the set value is inappropriate, correct it. DC Volt Low 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 Load Fuse Alarm, Check if the corresponding MCB is switched off. If the MCB is open, find out the fault and remove it. Batt Fuse Alarm Otherwise, the alarm circuit is faulty. Please contact Emerson 1. Check if there is mains failure, and the battery voltage is lower than the value of ‘LVD2’. LVD2 2. Check whether the battery is disconnected from the system manually The rectifier with the fault indicator (red) on is faulty. Rect Failure 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 305V or under 80V. If the mains voltage is under the AC 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 is Rect Fan Fails not obstructed or if the fault persists after cleaning, replace the rectifier Check if the communication cable is connected properly between rectifier and controller. If yes, restart the Rect Not Respond rectifier. If the alarm persists, replace the rectifier Check if the temperature of the temperature sensor is too high. If yes, find the causes and cool down the High temperature battery compartment

Controller fault handling The symptoms of usual rectifier faults include: green indicator (run indicator) off, screen does not display (If connecting to the host system, it may trigger an external alarm). Check whether the system bus voltage is normal. If not, check whether the terminal of the controller is in normal connection. If both are in normal, the controller is faulty, please see the following procedures to replace the controller: 1. Security preparation. Put one end of the effective grounding strap at the wrist and the other end attached to a suitable ground. 2. Loosen the captive screw of the controller. As shown in Figure 4-1. 3. Pull out the controller slowly until the J6, J7 and J2 (when configuring a temperature sensor in power system) terminals are completely exposed. Pull out the connected terminals from J6, J7 and J2 carefully. Then pull out the controller completely. Captive screw

Controller

Figure 4-1

Replacing controller

3. Push the new controller into the subrack, and tighten the captive screw of the controller. 4. Tighten the captive screws of the monitoring unit. 5. After controller startup, refer to 3.2

Basic Settings and actual configuration to set basic parameters.

4.2 Handling Rectifier Fault Handling indicator fault The symptoms of usual rectifier faults include: green indicator (run indicator) off, yellow indicator (protection indicator) on, yellow indicator blink, red indicator (fault indicator) on and red indicator blink. The indicators are shown in Figure 4-2 and handling methods of the rectifier faults are given in Table 4-2.


User Manual

Chapter 4

Alarm Handling

11

Run indicator Protection indicator Fault indicator

R48-1000 R48-1000A

Figure 4-2

Rectifier indicators

Table 4-2 Handling methods of the rectifier faults Symptom

Controller alarms

Green indicator off

No alarm

Green indicator blinks

No alarm

Yellow indicator on

Causes No input/output voltage Assistant power source of the rectifier fails

Rect over temp

The controller performs operations upon the rectifier AC input voltage abnormal Fan blocked OverVentilation path blocked at temperature the inlet or vent protection due Ambient temperature too to: high or the inlet too close to a heat source

Rect protect Power factor compensation internal under-voltage or over-voltage AC input over-voltage

Yellow indicator blinks

Rect Not Respond

Rectifier communication interrupted

Rect HVSD

Rectifier over-voltage

Red indicator blinks

Rect Fan Fails

Remove the object at the inlet or vent Decrease the ambient temperature or remove the heat source

Two or more rectifiers have the same ID number

Contact Emerson for maintenance

Serious current sharing imbalance (current imbalance > ± 3%)

Check whether the rectifier communication is normal. If not, check whether the communication cable is in normal connection. If the communication is normal while the protection indicator is on, replace the rectifier

Fan fault

Replace the fan

Red indictor on Rect Failure

Make sure the AC input voltage is normal Remove the object that blocks the fan

Check whether the rectifier communication is normal. If not, check whether the communication cable is in normal connection. If the communication is normal while the protection indicator is on, replace the rectifier Change the position of the faulty module with normal module. If the faulty module cannot work normally, replace it Ensure AC input voltage normally Check whether the communication cable is in normal connection Reset the rectifier. If the protection is triggered again, replace the rectifier

Current sharing imbalance Yellow indicator on

Handling methods Make sure that there is input/output voltage Change the position of the faulty module with normal module. If the faulty module cannot work normally, replace it

Replacing rectifier fan If the rectifier fan is faulty, it should be replaced. Refer to Figure 4-3 for the replacing procedures: 1. Use a cross head screwdriver to remove the two fixing screws and pull out the front panel. 2. Unplug the power cable of the fan and remove the fan. 3. Plug in a new fan. 4. Install the new fan, with fan blowing-direction inward. 5. Replace the front panel.


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Chapter 4

Alarm Handling

Fixing hole

Fan Fixing hole

Front panel

Figure 4-3

Disassembling the front panel

Replacing rectifier 1. Take a new rectifier and check it for any damage. 2. Loosen the fixing screws of the handle of the rectifier with a cross head screwdriver. 3. Press the rectifier handle to pop it out. 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. 4. Hold the rectifier handle, push the new rectifier into the slot and make sure the connection is good. After a brief delay, the rectifier RUN indicator will turn on and the fan will start running. 5. Check that the new rectifier works normally. You should make sure that: 1) The controller recognizes the new rectifier. 2) The new rectifier shares current with other rectifiers. 3) When this new rectifier is pulled out, there is a corresponding alarm and the controller displays the alarm. If the new rectifier passes all the above tests, the replacement is a success. 6. Push the handle back into the front panel to lock the rectifier. 7. Fix the fixing screws of the handle of the rectifier with a cross head screwdriver.

4.3 Replacing Load Fuse If load in short circuit or overload situations, the load fuses will be blowout, and you should replace the fuse of the same type and specification. Procedures for replacing the load fuse: 1. Loosen the fixing screws of the DC distribution board. 2. Pull out the DC distribution board 3. Remove the faulty fuse. Position of the fuse is shown in Figure 4-4. 4. Replace the fuse of the same type and specification.


User Manual

Chapter 4

Alarm Handling

Fuse

Figure 4-4 Schematic diagram of DC power distribution board

5. Push the DC distribution board into the subrack, and tighten the fixing screws, then the replacement is complete.

4.4 Replacing DC Distribution Board Procedures for replacing the DC distribution board: 1. Take a new DC distribution board and check it for any damage. 2. Power off all the MCBs of the AC power prestage distribution. 3. Loosen the fixing screws of the subrack top cover, controller and DC distribution board, as shown in Figure 4-5. Remove the top cover of subrack.

Top cover

Fixing screw

Fixing screw

Bus－ Bus＋

Fixing screw Reserved terminal

Figure 4-5

Replacing DC distribution board

4. Remove DC output load cables and the battery cables, and then perform insulation process.



Note

When connecting the cables, avoid short circuit caused by contacting with metal tools. 5. Pull off the cable connectors of J6. 6. Loosen the four fixing screws of the DC distribution board. 7. Replace a new DC distribution board. 8. After replacement, check that the system is operating properly, the load supplies power normally, and that the controller has no abnormal alarm.


User Manual

13

14

Appendix 1

Technical Data

Appendix 1 Technical Data Table 1 Technical data Parameter category

Environmental

AC input

Parameter Operating temperature Storage temperature Relative humidity Altitude Pollution level Others Input system Input voltage Input voltage range Input frequency Max input current Power factor Over-voltage level Rated output voltage Output voltage range Max output current

DC output

AC input alarm and protection

DC output alarm and protection

Total regulation Efficiency Noise (peak-peak) Weighted noise AC input over-voltage alarm point AC input over-voltage alarm recovery point AC input under-voltage alarm point AC input under-voltage alarm recovery point AC input over-voltage protection point AC input over-voltage protection recovery point AC input under-voltage protection point AC input under-voltage protection recovery point DC output over-voltage alarm point DC output over-voltage alarm recovery point DC output under-voltage alarm point DC output under-voltage alarm recovery point BLVD point

Description -5°C ~ 40°C (derating is necessary above 40°C) -40°C ~ 70°C 5%RH ~ 95%RH ≤ 2000m (derating is necessary above 2000m) II No conductive dust or erosive gases. No danger of explosion TN or TT, Single phase (L + N + PE) or dual live wires (L1 + L2 + PE) 220Vac 85Vac ~ 300Vac 45Hz ~ 65Hz Input current of each rectifier ≤ 7A ≥ 0.99 II -53.5Vdc -42.3Vdc ~ -57.6Vdc 40A (full configuration: two R48-1000A rectifiers for maximum); 20A (full configuration: two R48-500A rectifiers for maximum) ≤ ±1% ≥ 90% ≤ 200mV ≤ 2mV Default: 280Vac ± 10Vac 15Vac lower than the AC input over-voltage alarm point Default: 180Vac ± 10Vac 15Vac higher than the AC input under-voltage alarm point Default: 305Vac ± 5Vac 10Vac lower than the AC input over-voltage protection point Default: 80Vac ± 5Vac 15Vac higher than the AC input under-voltage protection point Default: 57.6Vdc ± 0.2Vdc 0.5Vdc lower than the over-voltage alarm point Default: 45.0Vdc ± 0.2Vdc 0.5Vdc higher than the under-voltage alarm point Default: 43.2Vdc ± 0.2Vdc, configurable through controller


User Manual

Appendix 1 Parameter category

Rectifier

Parameter

Current sharing

Derate by input (45°C)

Output delay Fan speed

Rectifier

Over-voltage protection

Temperature derating

CE RE Immunity to EFT Immunity to ESD Immunity to Surges

Class A

EN300386

≤ 3.2 (without rectifier）

Rectifier

≤ 1.2

ROHS

Weight (kg)

The imbalance is better than ± 5% rated output current. Test current range: 10% ~ 100% rated current; The imbalance is better than ± 3% rated output current. Test current range: 50% ~ 100% rated current 176Vac ~ 264Vac, system full load output 85Vac ~ 176Vac & 264Vac ~ 290Vac, System linearity and power limiting output (Vdc < 48V) 290Vac ~ 300Vac, system power limiting output Output voltage can rise slowly upon rectifier start up. The rise time is configurable Rectifier fan speed can be adjusted automatically The rectifier provides over-voltage hardware and software protection. The hardware protection point is between 59V and 60V, and manual resetting is required to restore operation. The software protection point is between 56V and 59V (required to be 0.5Vdc higher than the output voltage, default: 59Vdc), and can be set through the controller. There are two software protection modes, which can be selected through the software at the host: 1. Lock out at the first over-voltage Once the output voltage reaches protection point, the rectifier will shut down and hold that state. Manual resetting is required 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 5s. If the over-voltage happens again within a set time (default: 5min. Configurable through controller), the rectifier will shut down and hold that state. Manual resetting is required to restore the operation. Manual resetting: Resetting can be done manually through the controller, or by removing the rectifier from system According to figures below: - 40°C to +45°C with 1000W output; +45°C to +50°C with linearly derating to 800W; +50°C to +55°C with linearly derating to 600W; +55°C to +60°C with linearly derating to 200W; +60°C to +65°C with linearly derating to 0W

System

Insulation strength

Mechanical

Description

System Rectifier

Insulation resistance

Size (W × D × H) (mm)

15

Level 4 EN61000-4-4 Level 3 EN61000-4-2 Level 4 EN61000-4-5 ≤ 51dB (A) 25% load (When the ambient temperature is 25°C); ≤ 55dB (A) 50% load (When the ambient temperature is 25°C); ≤ 60dB (A) 100% load (When the ambient temperature is 25°C) At temperature of 20°C ~ 30°C and relative humidity not bigger than 90%RH, apply a test voltage of 500Vdc. The insulation resistances between AC circuit and earth, DC circuit and earth, and AC and DC circuits are all not less than 2MΩ ((Remove rectifiers and controller from the system before the test.) AC to DC circuits: 50Hz, 3000Vac (RMS); AC circuit to earth: 50Hz, 3000Vac (RMS); DC circuit to earth: 50Hz, 1500Vac (RMS); Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac (RMS); For all the three tests above, there should be no breakdown or flashover within 1min, with leakage current not bigger than 10mA Compliant with R5 standard 428 × 290 × 43 (without bracket) 86.5 × 241.1 × 40.8

Acoustic noise

EMC

Technical Data


User Manual

Appendix 2 Wiring Diagram

Appendix 2 Wiring Diagram

AC input scheme 2

2-J1-N

W03 can+ can-

J4

N

J5

Temperature sensor cable (Option)

2-DC-

2-DC+

W02

DC-

W03

W03

J6

4-J7-1 4-J7-4 4-J7-6 4-J7-5 4-J6-9 4-J6-11

1 2 3 4 5 6 7 8 9 10

J1

Bat_Cur-

W02

BATT-

DC+ J2

J4

Bat_Cur+ BUSBUS+ LVD_Ctrl+ LVD_CtrlBAT_Fuse Load_Fuse J3

OUTPUT-

BAT+ J7

OUTPUT+

3-J6-9

J3

M225SSL02W01

4-J6-8 4-J6-7

3-J6-2 3-J6-1 3-J6-8

J6

J6

J5

2 W4422X2

W03

Power-

W03 DC-

4-J 6-1

L

W02

DC+

J1

W03

1 Temp+ 2 Temp3 PE

1-L 1-N

3-DC+

W01

3-DC-

2 W4422X1

W03

J7

W01

W01

4-J 6-2

2-J1-L

2-J1-N

W01

4 M225S

Connected dry contact of access alarm input (Reserved)

Door alm

BAT-

J5

Figure 1 Wiring diagram of the system


User Manual

Can- 1 Can+ 2 3 4 5 6 BAT1_SH+ 7 BAT1_SH- 8 BATfuse1 9 10 Loadfuse1 11 12 13 14 15

PE

W03

W03

Connected dry contact of SPD input (Reserved)

SPDalm

2-J6-2 2-J6-1

PE N L

3-J6-5 3-J6-7 3-J6-6 2-J6-2 2-J6-1 2-J6-2 2-J6-1

AC Connector

N

W03

3-J6-4

L

W03

Back View

1

1 2 3 Power+ 4 Batt_com 5 Batt_off 6 SPD+ 7 SPD- 8 Door+ 9 Door10 11 12

Back View

1 AC connecter

2-J1-L

AC input scheme 1

16

Appendix 3

Appendix 3 Glossary Abbreviation Amb.Temp Batt BC BLVD Cap CommMode CurrLimit CycBC Con Alarm Voice Hist Alarm HVSD InitParam InitPWD LLVD LVD MCB Ph-A PWD Rect Shunt coeff SPD SW Version Sys Temp Temp Comp Volt

Full word Ambient Temperature Battery Boost Charging Battery Lower Voltage Disconnection Capacity Communication Mode Current Limit Cyclic Boost Charging Control Alarm Voice Historical alarm High Voltage Shutdown Initialize Parameters Initialize Password Load Low Voltage Disconnection Low Voltage Disconnection Miniature Circuit Breaker Phase A Password Rectifier Shunt Coefficient Surge Protection Device Software Version System Temperature Temperature Compensation Voltage


User Manual

Glossary

17

NetSure 212 C23 user manual V1.0 20130617.pdf

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