Emerson NetSure 4015 DC Application Guide

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SYSTEM OVERVIEW

Description: 400V DC Output @ up to 30kW Power System

The NetSure™ 4015, 30kW DC Power System is a complete integrated power system
containing rectifiers, intelligent control, metering, monitoring, and distribution. The
individual system sub-racks can be factory integrated into a standard 19” IT rack or
provided separately for customer integration into an existing IT rack.

This power system is capable of operating either with or without batteries online.
This system consists of the following components.

Power and Control Sub-Rack (List 11, 12)

SAG584000300

System Application Guide

NetSure™ 4015 30kW 400V DC Power System

Spec. No. 584000300 (Model 4015-X003)

Issue AB, April 5, 2013

The system contains one (1) “power and control sub-rack”, which houses up to two
(2) rectifiers and the system control and monitoring components.

Rectifier(s)

The system contains one (1) or two (2) rectifiers, which provide load power,
battery float current, and battery recharge current during normal operating
conditions. Refer to the rectifier instructions (UM1R40015000e) for more
information.

Controls

ACU+ (Advanced Control Unit Plus) Controller
The system controller provides power system control, rectifier control (including a

charge control function), metering functions, monitoring functions, and
local/remote alarm functions. Power system control includes battery low voltage
disconnect (BLVD) functionality to remotely trip battery circuit breakers which
protects batteries against over-discharge. The system can also be equipped with
one (1) or two (2) temperature probe(s). Any combination of the two (2)
temperature probes can be programmed to monitor ambient air temperature
and/or battery temperature. A temperature probe set to monitor battery
temperature can also be used for the rectifier battery charge temperature
compensation feature and/or BTRM (battery thermal runaway management)
feature. The controller also provides data acquisition, system alarm
management, and advanced battery and energy management. The controller
contains an LCD display and keypad for local access. The controller provides
Ethernet connection and supports
software upgrade via its USB port. It also
comes with a comprehensive web page
and SNMP capability for remote system
management. Refer to the ACU+
controller instructions (UM1M820NNB-1)
for more information.

System Shutdown

A “System Shutdown” pushbutton is

located on the front of the power and
control sub-rack. When momentarily

depressed, the rectifier’s AC input circuit

breakers and the Emerson provided

battery trays’ battery disconnect circuit

breakers are tripped open to isolate the
system from all electrical sources.
Manual intervention is required to restart
the system.

Page 1 of 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

SAG584000300 System Application Guide

Home

Complete Solution

(components factory installed

in an Emerson Network

Power DCM IT Rack)

Individual Components

Issue AB, April 5, 2013 NetSure™ 4015 30kW 400V DC Power System
Spec. No. 584000300 (Model 4015-X003)

Load Distribution Sub-Rack(s) (List 21-24)

The system may contain up to two (2) “load distribution sub-racks”, which provide DC
distribution through circuit breakers. Optional main row breaker required for UL
applications. Distribution can also be bulk with no “distribution sub-rack”.

Battery Tray(s) (List 91, 92)

The system may contain up to five (5) battery trays, each housing one (1) 400V
battery string consisting of twenty-eight (28) 12V battery blocks (336V nominal).
Customer supplied external battery strings can be connected to the system. The
total number of internal and external battery strings cannot exceed five (5).

IT Rack Integration (List R1, R2)

Choice of 24U or 42U rack, also includes factory installation, integration, and testing
of all selected components.

Available Grounding Configurations

HRMG (High Resistance Midpoint Ground) Configuration (+/- 200V DC)
The HRMG configuration provides system voltages to ground at half of the output

system voltage, for additional personnel safety. That is, the HRMG version of
400V DC produces +/-200V DC to ground potentials. This configuration is used in
applications where an internal high resistance path is required between the positive
output busbar and site ground and also the negative output busbar and site ground.

The DC bus is continuously monitored for ground fault conditions. If the insulation
resistance between the +BUS or -BUS to ground goes below a set value, a ground
fault alarm is generated. (Refer to UM584000300 [Operation Instructions] for
additional information on this topic.)

NPG (Negative Pole Ground) Configuration (+400V, -0V DC)
This configuration is used in applications where the negative output busbar is

required to be connected to site ground.

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 2 of 32

System Application Guide SAG584000300

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NetSure™ 4015 30kW 400V DC Power System Issue AB, April 5, 2013
Spec. No. 584000300 (Model 4015-X003)

General Specifications
Family: NetSure™
System Spec. No.: 584000300
System Model: 4015-X003
System AC Input Voltage Nominal 380/400/480 volts AC, three phase, 50/60 Hz, with an

operating range of 260 to 530 volts. Acceptable input frequency
range is 45 to 65 Hz. A single 4-wire (no neutral) AC input feed

supplies both rectifiers.
System Output Voltage (max.): 400V DC
Output Capacity:

System: 89A, 30kW (maximum)
Rectifier: 44.6A @ 336V DC to 37.5A @ 400V DC, 15kW (maximum)

System Agency Approval: UL Listed per UL60950-1 (cUL for Canada). CE Marking per low

voltage directive (EN60950) and the EMC directive.

(See “1.5.1 Safety Compliance” on page 27.)
EMI: EN 300 386, Class A and FCC Part 15, Class A
Framework Type: Rack Mounting in an IT Rack (EIA-310-D Compliant)
Mounting Width: 19 Inches (483mm), nominal
Mounting Depth:

Power and Control Sub-Rack: 724mm (28.5 inches)
Load Distribution Sub-Rack: 257mm (10 inches), HRMG Configuration

317mm (12.5 inches), NPG Configuration

Battery Tray: 838mm (33 inches)
24U Rack Dimensions: 1194mmH x 600mmW x 1000mmD (47"H x 24"W x 40"D)
42U Rack Dimensions: 2000mmH x 600mmW x 1000mmD (79"H x 24"W x 40"D)
Access: Front and rear for installation and maintenance.

Front for operation.
Control: Microprocessor
Color: Black
Environment: -5°C to +45°C (+23°F to +113°F).

Full Rating: -5°C to +35°C (+23°F to +95°F).

Note: Battery manufacturers recommend an operating temperature

of 25°C (77°F). Ambient temperatures higher than this reduce

battery life; temperatures lower than this reduce battery capacity.

For optimal battery performance and service life, battery temperature

should be maintained between +20°C to +25°C (+68°F to +77°F).

See detailed specifications on page 26.
Customer Supplied IT Rack Guidelines

If you plan to assemble / configure your own system, note that the NetSure 4000 Series components
(power and control sub-rack / load distribution sub-rack / battery tray) were evaluated as a UL Listed
system in an Emerson Network Power DCM IT Rack in an ambient of +35°C (95°F), with a front and rear
door free area ratio of 83%.

Page 3 of 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

SAG584000300 System Application Guide
Issue AB, April 5, 2013 NetSure™ 4015 30kW 400V DC Power System
Spec. No. 584000300 (Model 4015-X003)

TABLE OF CONTENTS

SYSTEM OVERVIEW................................................................................................................................................. 1

TABLE OF CONTENTS ............................................................................................................................................. 4

MAIN COMPONENTS ILLUSTRATIONS .................................................................................................................. 6

Factory System Integration – Lists R1 and R2 (Assembled System) ............................................................ 6

Customer System Integration – Installed in Customer IT Rack ..................................................................... 6

Power and Control Sub-Rack - Lists 11 (HRMG) and List 12 (NPG) .............................................................. 7

Load Distribution Sub-Rack – List 21-24 .......................................................................................................... 8

Battery Tray - List 91 (HRMG) and List 92 (NPG) ............................................................................................. 9

LIST DESCRIPTIONS .............................................................................................................................................. 10

Power and Control Sub-Rack ........................................................................................................................... 11

List 11: Power and Control Sub-Rack – HRMG (High Resistance Midpoint Grounded) Systems ............... 11

List 12: Power and Control Sub-Rack – NPG (Negative Pole Grounded) Systems ..................................... 11

Load Distribution Sub-Rack ............................................................................................................................. 12

List 21: Load Distribution Sub-Rack with Row Breaker – HRMG (High Resistance Midpoint

Grounded) Systems ....................................................................................................................................... 12

List 22: Load Distribution Sub-Rack with Row Breaker – NPG (Negative Pole Grounded) Systems .......... 12

List 23: Load Distribution Sub-Rack without Row Breaker – HRMG (High Resistance Midpoint

Grounded) Systems ....................................................................................................................................... 13

List 24: Load Distribution Sub-Rack without Row Breaker – NPG (Negative Pole Grounded)

Systems .......................................................................................................................................................... 13

Battery Tray ........................................................................................................................................................ 14

List 91: Battery Tray – HRMG (High Resistance Midpoint Grounded) Systems .......................................... 14

List 92: Battery Tray – NPG (Negative Pole Grounded) Systems ................................................................ 14

Temperature Probes ......................................................................................................................................... 15

List 98: Temperature Probe, 12 Feet (4m) Total Cable Length ..................................................................... 15

List 99: Temperature Probe, 33 Feet (10m) Total Cable Length ................................................................... 15

Rack Integration (Factory Integrated System) ............................................................................................... 16

List R1: 24U, 19” ........................................................................................................................................... 16

List R2: 42U, 19” ........................................................................................................................................... 16

ACCESSORY DESCRIPTIONS ............................................................................................................................... 17

DC Load Distribution Devices .......................................................................................................................... 17

DIN-Rail Type Load Circuit Breakers ............................................................................................................. 17

Load Circuit Breaker Lockout/Tagout Assembly ............................................................................................ 18

User Replaceable Components ....................................................................................................................... 19

ONE LINE DIAGRAM............................................................................................................................................... 20

RECOMMENDED WIRING SIZES, BRANCH CIRCUIT PROTECTION, AND CRIMP LUGS ............................... 21

Equipment Grounding ...................................................................................................................................... 21

Factory Furnished IT Rack Frame Grounding ............................................................................................... 21

Sub-Rack Frame Grounding (for systems installed in a customer furnished IT rack) ................................... 21

Return Busbar (-Bus) Grounding (NPG Configurations Only) ....................................................................... 22

AC Input (Power and Control Sub-Rack) ........................................................................................................ 23

DC Load Distribution (Distribution Sub-Rack) ............................................................................................... 24

DC Load Distribution (Bulk Output from Power and Control Sub-Rack) .................................................... 25

External Controller Interface (Distribution Sub-Rack)................................................................................... 25

Battery (Power and Control Sub-Rack) ........................................................................................................... 25

SPECIFICATIONS .................................................................................................................................................... 26

1. System ........................................................................................................................................................... 26

1.1 System DC Output Ratings...................................................................................................................... 26

1.2 System AC Input Ratings......................................................................................................................... 26

1.3 System Environmental Ratings ............................................................................................................... 26

Page 4 of 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

System Application Guide SAG584000300
NetSure™ 4015 30kW 400V DC Power System Issue AB, April 5, 2013
Spec. No. 584000300 (Model 4015-X003)

1.4 Physical.................................................................................................................................................... 26

1.5 System Compliance Information .............................................................................................................. 27

2. Rectifier .......................................................................................................................................................... 27

3. ACU+ Controller ............................................................................................................................................ 27

MECHANICAL SPECIFICATIONS .......................................................................................................................... 28

Rack Integrated System (24U) (List R1) .......................................................................................................... 28

Rack Integrated System (42U) (List R2) .......................................................................................................... 28

Dimensions and Weights .................................................................................................................................. 29

RELATED DOCUMENTATION ................................................................................................................................ 31

BATTERY MANUFACTURER INFORMATION ...................................................................................................... 31

Page 5 of 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

SAG584000300 System Application Guide

Home

Complete Solution

(components factory installed

in Emerson Network Power

DCM 24U IT rack)

Complete Solution
(components factory installed
in Emerson Network Power
DCM 42U IT rack)

Doors/Sides Removed
in Illustration for Clarity

Load Distribution Sub-Rack(s)
(6U each)

Power and Control Sub-Rack
(6U)

Optional Battery Tray(s)
(4U each)

(List 21, 22, 23, 24)

(List 11 and 12)

(List 91 and 92)

List R1:

List R2:

Issue AB, April 5, 2013 NetSure™ 4015 30kW 400V DC Power System
Spec. No. 584000300 (Model 4015-X003)

MAIN COMPONENTS ILLUSTRATIONS
Factory System Integration – Lists R1 and R2 (Assembled System)

Note: Also order individual sub-racks List 11, 12, 21, 22, 23, 24, 91, 92;

not to exceed 24U for List R1 and 42U for List R2.
See List Descriptions on page 10.

Customer System Integration – Installed in Customer IT Rack

Note: Order List 11, 12, 21, 22, 23, 24, 91, 92.

See List Descriptions on page 10.

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 6 of 32

System Application Guide SAG584000300

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Front

Rectifier Module
AC Input Circuit Breakers
(40A, 380V/400V/480V AC)

ACU+ Interface Board (IB2)

(behind cover)

ACU+ Controller

Rectifier Modules

Adjustable
Rear Mounting
Brackets

Front Mounting Flanges

System Shutdown Button

AC Input Leads Opening
for 25mm (1”) Conduit

Alarm Leads Opening
for 25mm (1”) Conduit

DC Output Leads Openings

for 32mm (1.25”) Conduit

Battery Leads Openings for

19mm (0.75”) Conduit

(top and bottom)

AC Surge

Protectors

Removable Panels

(for installation)

Battery

Shunt

Battery Terminals
(5 sets of studs
for double hole
lugs, each polarity)

External and Internal
Battery Tray Control/Alarm
Connectors

Sub-Rack Grounding Stud

DC Output Terminals
(2 sets of studs
for double hole
lugs, each polarity)

AC Input

Terminals

Rear

HRMG Ground Connection
(HRMG Configurations Only)
(MUST BE PROPERLY
CONNECTED TO GROUND)

NetSure™ 4015 30kW 400V DC Power System Issue AB, April 5, 2013
Spec. No. 584000300 (Model 4015-X003)

Power and Control Sub-Rack - Lists 11 (HRMG) and List 12 (NPG)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 7 of 32

SAG584000300 System Application Guide

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Rear

HRMG Configuration NPG Configuration

Sub-Rack
Grounding Stud

Sub-Rack

Grounding Stud

DC Distribution Leads Openings

for 25mm (1”) Conduit

(snap bushings are furnished

for use without conduit)

Removable
Panel

Rear

Return Bar

Grounding Point

(opening for 19mm [0.75"]

conduit provided)

Front

Front

Conduit Grounding Points
(opposite side also)
(both HRMG and NPG)

Distribution Blocks hold factory wiring
in unused breaker locations for ease
of adding future circuit breakers.
(both HRMG and NPG)

Customer
Load Connections
to DC Distribution
Circuit Breakers

Removable Panel
(for installation)
(both HRMG and NPG)

Customer

Load Connections

to DC Distribution

Circuit Breakers

Customer
Load Return
Connections
to Return Bar

List Row Breaker HRMG NPG

21 X X
22 X X
23 X
24 X

Front

DC Distribution
Circuit Breakers - 9 positions
(4A, 6A, 8A, 10A, 16A, 20A,
25A, 32A, 40A, 50A, 63A)

Future Circuit
Breaker Mounting
Positions

Optional (List 21, 22)

Row DC Distribution

Circuit Breaker (125A)

DC Distribution

Input Leads

(from Power and

Control Sub-Rack)

Front
Mounting
Flanges

Issue AB, April 5, 2013 NetSure™ 4015 30kW 400V DC Power System
Spec. No. 584000300 (Model 4015-X003)

Load Distribution Sub-Rack – List 21-24

Page 8 of 32

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

System Application Guide SAG584000300

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Six (6) Removable Battery Sub-Trays
Four (4) trays equipped with five (5) 12V DC battery blocks.
Two(2) trays equipped with four (4) 12V DC battery blocks.
Battery blocks in each tray are factory wired.

Battery Breaker (40A)

Front

Rear

Adjustable
Rear Mounting
Brackets

Front
Mounting
Flanges

Tray Grounding Stud

Battery Sub-Trays

Battery Tray

View of Individual
Battery Sub-Tray

Battery Retaining Bracket

(shipped installed, remove to

install battery sub-trays)

Battery Sub-Tray Connector

Battery wiring connectorized
for easy installation.

Battery Tray Connector

Battery Tray
Power Cables

Battery Tray
Control/Alarm
Harness

NetSure™ 4015 30kW 400V DC Power System Issue AB, April 5, 2013
Spec. No. 584000300 (Model 4015-X003)

Battery Tray - List 91 (HRMG) and List 92 (NPG)

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 9 of 32

SAG584000300 System Application Guide

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List

Number

Part

Number

Description

Rack Unit

Height

11

58400030011

Power and Control Sub-Rack – HRMG
(High Resistance Midpoint Grounded) Systems

6U

12

58400030012

Power and Control Sub-Rack – NPG
(Negative Pole Grounded) Systems

6U

21

58400030021

Load Distribution Sub-Rack with Row Breaker – HRMG
(High Resistance Midpoint Grounded) Systems

6U

22

58400030022

Load Distribution Sub-Rack with Row Breaker – NPG
(Negative Pole Grounded) Systems

6U

23

58400030023

Load Distribution Sub-Rack without Row Breaker – HRMG
(High Resistance Midpoint Grounded) Systems

6U

24

58400030024

Load Distribution Sub-Rack without Row Breaker – NPG
(Negative Pole Grounded) Systems

6U

91

58400030091

Battery Tray – HRMG
(High Resistance Midpoint Grounded) Systems

4U

92

58400030092

Battery Tray – NPG
(Negative Pole Grounded) Systems

4U

R1

584000300R1

Rack Integration (Factory Integrated System)
24U, 19”

24U

R2

584000300R2

Rack Integration (Factory Integrated System)
42U, 19”

42U

98

58400030093

Temperature Probe, 12 Feet (4m)

--

99

58400030094

Temperature Probe, 33 Feet (10m)

--

Issue AB, April 5, 2013 NetSure™ 4015 30kW 400V DC Power System
Spec. No. 584000300 (Model 4015-X003)

LIST DESCRIPTIONS

This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy

Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.

Page 10 of 32