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NetSure 801 CA7 Power Supply System (New Skelecton)
User Manual
Version
V1.1
Revision date
BOM
December 21, 2018
31013510
Vertiv Tech provides customers with technical support. Users may contact the nearest Vertiv local sales
office or service center.
Copyright © 2018 by Vertiv Tech Co., Ltd.
All rights reserved. The contents in this document are subject to change without notice.
Vertiv Tech Co., Ltd.
Address: Block B2, Nanshan I Park ,No.1001 Xueyuan Road, Nanshan District, Shenzhen, 518055, PR
China
Homepage: www.vertivco.com
E-mail: overseas.support@vertivco.com
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Safety Precautions
To prevent unexpected problems, please read the operation instructions and safety precautions very carefully
before installation operation. The “Caution, Notice, Warning, Danger” in this manual do not represent all of the
safety points that should be observed, and are only used as supplementary to the operation safety. Therefore,
the personnel responsible for the installation and operation of Vertiv products must be strictly trained to master
the correct operations and all the safety points before actual operation.
When working on Vertiv products, relevant industry safety rules and special safety instructions provided by Vertiv
must be observed.
Electrical Safety
High voltage
Danger
Danger
High voltage power supply provides power for equipment operation, any direct contact or indirect contact through moist
objects with high voltage or AC mains will result in fatal injury.
Relevant industry safety regulations must be observed during the installation of AC power supply
equipment. The people who do the AC standard installation must be licensed to operate high voltage and
AC power.
During operation, metal objects such as watches, bracelets, bangles, rings, etc. must be removed.
In case water or moisture is found on the cabinet, turn off the power immediately. In moist environments,
take strict precautions to prevent water from entering the equipment.
“Prohibit” warning label must be attached to the switches and buttons which are not permitted to be
operated on during installation.
Danger
Danger
Nonstandard or incorrect high voltage operation can present risk of electric shock or burn. The connection and wiring of AC
cables must be in compliance with local rules and regulations. Only those who are licensed to operate high voltage and AC
power can perform high voltage operations.
Expected short-circuit current
Notice
Notice
The short-circuit breaking capacity of the rectifier AC input MCB is 6kA. If the expected short-circuit current of AC input
loop exceeds 6kA, please contact Vertiv technical support.
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Dangerous energy
Danger
Warning
The power system contains output exceeds 240VA, when installing into end system care must be taken that the output and
appropriate wire may not be touched.
Multi-power input
Danger
Warning
Prevent electric shock and dangerous energy. Even if the AC input power is cut off, there is still dangerous conductive parts
fed by battery existing.
Power supply cable
Notice
Notice
Make sure the cable and cable labels are in accordance with actual installation before cable connection.
Tools
Warning
Warning
In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used.
Thunderstorm
Danger
Danger
Never perform high voltage, AC, iron tower, or mast operations on a day with thunderstorms about.
In thunderstorms, strong electromagnetic field will be generated in the air. Therefore the equipment should be solidly
earthed in time to avoid damage by lightning strikes.
Static
Notice
Notice
The static electricity generated by the human body will damage the static sensitive elements on circuit board, such as
large-scale ICs, etc. Before touching any plug-in board, circuit board and IC chip, ESD wrist strap must be worn to prevent
body static from damaging the sensitive elements. The other end of the antistatic wrist strap must be solidly earthed.
Short circuit
Danger
Danger
During operation, never short-circuit the positive and negative poles of the DC distribution unit of the system or the
non-earthing pole and the earth. The power supply equipment is a constant voltage DC power supply. Short circuit will
result in equipment burning and endanger human safety.
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Check carefully the polarity of the cable and connection terminals when performing live DC 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 in operation.
Insulated tools must be used.
In live operations, keep the arm muscle in tense state so that when tool connection is loosened, the free
journey between the human body and tool is reduced to the minimum.
Battery
Danger
Danger
Before working on the battery, read very carefully the safety precautions for battery transportation and the correct battery
connection method.
Non-standard operation on the battery will result in danger. In operation, pay close attention to prevent battery
short circuit and spill of the electrolyte. The spill of the electrolyte will pose potential threat to the equipment and
erode the metal objects and circuit board, thus causing damage to the equipment and short circuit of the circuit
board.
For safety reasons, before working on the battery, pay attention to the following points:
Remove the watch, bracelet, bangle, ring, and other metal objects.
Use insulated tools.
Wear eye protection and take preventive measures.
Wear rubber gloves and apron to guard against spilt electrolyte.
In battery transportation, the electrode of the battery should always be kept facing upward. Never put the
battery upside down or slanted.
After battery installation, check carefully that the battery cable polarity is correct and the connections are solid.
After battery connections are made and before the system is switched on, the battery fuse must be in open state
in case the battery is damaged due to overdischarge in this period.
Others
Taking out rectifier
Notice
Warning
When taking out the rectifier, you should replace with a new one or install a dummy plate immediately.
Hoisting heavy objects
Notice
Warning
Never walk under the crane arm or the hoisted objects when hoisting heavy objects.
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Sharp corners of the objects
Notice
Warning
When moving equipment by hands, wear protective gloves to avoid injury by sharp objects.
Inserting and extracting boards
Notice
Notice
Do not use too much force in inserting single boards to prevent the contact pins on the motherboard to be twisted. Insert the
boards along the slots to avoid short circuit resulting from the contact of circuit boards. Never touch the connectors of the
boards when holding the boards.
Binding signal lines
Notice
Notice
Signal lines should be bound separately from heavy current and high voltage lines, with binding interval no less than
150mm.
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Contents
Chapter 1 Introduction ................................................................................................................................................. 1
1.1 Model Information .......................................................................................................................................... 1
1.2 Overview ....................................................................................................................................................... 2
1.3 Components .................................................................................................................................................. 4
1.3.1 Rectifier ................................................................................................................................ .............. 4
1.3.2 Controller ............................................................................................................................................ 5
1.3.3 AC Distribution Cabinet ................................ ....................................................................................... 6
1.3.4 DC Distribution Cabinet ......................................................................................................................10
1.3.5 Rectifier Cabinet ................................................................................................................................15
Chapter 2 Installation Preparation ................................ ...............................................................................................18
2.1 Installation Requirements ..............................................................................................................................18
2.1.1 Environmental Requirements ..............................................................................................................18
2.1.2 Layout Requirements Of The Equipment Room ...................................................................................18
2.1.3 Power Supply .....................................................................................................................................20
2.1.4 Safety Protection ................................................................................................................................20
2.1.5 Equipment Running Environment Checklist .........................................................................................21
2.2 Storage Conditions .......................................................................................................................................22
2.3 Installation Preparation..................................................................................................................................22
2.3.1 Field Check ........................................................................................................................................22
2.3.2 Tools And Materials Preparation .........................................................................................................22
2.4 Unpacking Inspection ....................................................................................................................................24
Chapter 3 Installation ..................................................................................................................................................26
3.1 Installing Cabinet ................................................................ ..........................................................................26
3.1.1 Installation On The Floor ....................................................................................................................26
3.1.2 Installation On Supporting Rack ..........................................................................................................27
3.1.3 Parallel Connection Between Cabinets ...............................................................................................28
3.1.4 Parallel Connection With Copper Bars ................................................................ ................................29
3.1.5 Installation Of System Above 2000A ...................................................................................................30
3.1.6 Mounting Large Side Door And Small Side Door .................................................................................30
3.1.7 Placing DC Cabinet Separate From System ........................................................................................31
3.2 Connecting Power Cables .............................................................................................................................31
3.2.1 Connecting Earth Cable .....................................................................................................................32
3.2.2 Connecting Cables Between Rectifier Cabinet And AC Distribution Cabinet .........................................33
3.2.3 Connecting AC Input Cables ...............................................................................................................35
3.2.4 Connecting Emergency Lighting Cables (Optional) ..............................................................................36
3.2.5 Connecting DC Load Cables ..............................................................................................................37
3.2.6 Connecting Battery Cables .................................................................................................................39
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3.3 Installation Checklist .....................................................................................................................................40
3.4 Installing Rectifier And Controller ...................................................................................................................40
3.4.1 Installing Rectifier ...............................................................................................................................40
3.4.2 Installing Controller ............................................................................................................................41
3.4.3 The Installation And Wiring Of The Controller IB2 Extension Board ......................................................42
3.5 Connecting Communication Cables And Auxiliary Power Cable ......................................................................44
3.5.1 Connecting Rectifier Cabinet Communication Cable ............................................................................44
3.5.2 Connecting Communication Cable Of Distribution Cabinet ...................................................................46
3.6 Installing Options ..........................................................................................................................................48
Chapter 4 Testing .......................................................................................................................................................50
4.1 Notes On Testing ..........................................................................................................................................50
4.2 Power-on ......................................................................................................................................................50
4.3 Setting Basic Parameters ..............................................................................................................................51
4.3.1 Setting DIP Switch .............................................................................................................................51
4.3.2 Setting Basic Parameters For Controller .............................................................................................53
4.4 Checking Alarm And Operation Status ................................................................................................ ...........56
4.4.1 Testing Controller ...............................................................................................................................56
4.4.2 Testing DC Distribution .......................................................................................................................57
4.4.3 Access Controller Through Web .........................................................................................................58
Chapter 5 Operation ...................................................................................................................................................63
5.1 Power Distribution LCD Operation .................................................................................................................63
5.2 Setting The Position Number Of The Rectifier Manually .................................................................................69
5.3 Adding Load .................................................................................................................................................71
5.4 Adding Rectifier ............................................................................................................................................71
Chapter 6 Maintenance ...............................................................................................................................................73
6.1 Maintenance Requirements ...........................................................................................................................73
6.1.1 General..............................................................................................................................................73
6.1.2 Maintenance Tools And Equipments ...................................................................................................73
6.1.3 Reference Technical Specification For Maintenance ............................................................................74
6.2 Routine Maintenance Items ...........................................................................................................................75
6.3 Routine Maintenance ....................................................................................................................................77
6.4 Basic Inspection............................................................................................................................................77
6.4.1 Handling Controller Fault ....................................................................................................................77
6.4.2 Handling Rectifier Fault ................................ ......................................................................................78
6.5 Replacing Rectifier ........................................................................................................................................79
6.6 Emergency Treatment ...................................................................................................................................80
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Appendix 1 Technical Parameter .................................................................................................................................82
Appendix 2 Alarm List ................................................................................................ .................................................87
Appendix 3 Terminologies ...........................................................................................................................................91
Appendix 4 Engineering Design Diagram.....................................................................................................................93
Appendix 5 Spare Part List........................................................................................................................................ 108
Appendix 6 Wiring Diagram ....................................................................................................................................... 109
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Chapter 1 Introduction 1
NetSure 801 Series Power Supply System User Manual
Chapter 1 Introduction
The NetSure 801 CA7 series power supply system (power supply system for short) is a new generation of telecom
power supply with exceptional reliability and performance. It is designed by Vertiv incorporating years of experience in
development and equipment operation on power network.
This chapter introduces the model information, overview and components.
1.1 Model Information
Take NetSure 801 CA7 power supply system for example, the model information of the NetSure 801 series power
supply system is shown in Figure 1-1.
NetSure 801 C A
The number of the rectifier in the typical power supply system. If the number
ranges between 0 ~ 9, the character is represented by a number. If the number
is larger than 9, the character is represented by a letter, for example, A represents
the number 10, B represents the number 11, and so on. A: 10.
Region. C: China.
Output power of the rectifier. The output power of R48-5800: 5800W.
Brand name of the power supply system.
7
Version number
Figure 1-1 Model information
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NetSure 801 Series Power Supply System User Manual
1.2 Overview
The power supply system is composed of AC distribution cabinet, DC distribution cabinet, AC/DC integrated
distribution cabinet, rectifier cabinet, controller, rectifier and options.
The number of AC distribution cabinet, DC distribution cabinet, AC/DC integrated distribution cabinet and rectifier
cabinet can be configured according to customer requirement. The capacity of the system can be expanded to 6000A
at most. The system composed of one AC distribution cabinet, one DC distribution cabinet and one rectifier cabinet is
shown in Figure 1-2.
DC distribution cabinet
AC distribution cabinet
Rectifier cabinet
ControllerRectifier
Figure 1-2 Three-cabinet system structure
The technical parameter of the rectifier cabinet is given in Table 1-1.
Table 1-1 Technical parameter of rectifier cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
AC input
Input system
3- phase 4-wire and 3- phase 5-wire
Iined voltage
380Vac
Voltage range
260Vac ~ 530Vac (errors: 5Vac)
Frequency
45Hz ~ 65Hz
Max. current
≤ 130A (304V input)
Power factor
≥ 0.98
DC output
Voltage range
53.5Vdc
Nominal voltage
48Vdc
Output DC voltage
42Vac ~ 57.6Vac
Max. current
Rack1000-7: 1000A
Rack2000-7: 2000A
Voltage stabilizing precision
≤ 1%
Efficiency
≥ 90%
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Parameter
Description
Mechanical
Dimensions
mm (H × W
× D)
Recitifier cabinet
2000mm × 600mm × 600mm
Controller(M831D)
42mm × 86.60mm × 211.5mm
Recitifier (R48-5800A、
R48-5800e)
88mm × 244mm × 372mm
Weight (kg)
Recitifier cabinet (not include
the rectifier)
Rack1000-7 ≤ 140；Rack2000-7 ≤ 180
Controller(M831D)
≤ 2
Recitifier (R48-5800A、
R48-5800e)
≤ 8
The technical parameter of the AC distribution cabinet is given in Table 1-2.
Table 1-2 Technical parameter of AC distribution cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C ;
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
AC input
Input system
TN-C, TN-S, TN-C-S, TT, 3- phase 4-wire and 3- phase 5-wire network
forms
Rated line voltage
380Vac
Voltage range
260Vac ~ 530Vac (errors: 5Vac)
Frequency
45Hz ~ 65Hz
45Hz ~ 55Hz (Configuring PD380/630AFA-7-Y1)
AC output
Distribution parameter
PD380/400AFH-7-Y2:
6 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 400A:
160A/3P × 4, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7-Y3:
8 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 630A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7/YF: Configured according to customer requirement (IF
the input switch using MCB, shall not exceed the total capacity of the
Cabinet input of MCB 80%)
AC output
Distribution parameter
PD380/630AFA-7/Y4:
8 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 600A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
Mechanical
Dimensions mm (W × D × H)
2000mm × 800mm × 600mm
Weight (kg)
PD380/400AFH-7-Y2, PD380/630AFH-7-Y3 ≤ 240,
PD380/630AFA-7-Y4 ≤ 250, PD380/630AFH-7/YF ≤ 270
The technical parameter of the DC distribution cabinet is given in Table 1-3.
Table 1-3 Technical parameter of DC distribution cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C ;
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
DC input
Rated voltage
48Vac
Voltage range
42Vac ~ 57.6Vac (errors: 0.3Vac)
Rated input current
PD48/1600DF-7-Y3: 1600A; PD48/1600DF-7-Y4: 1600A;
PD48/2500DF-7-Y3: 2500A; PD48/2500DF-7-Y4: 2500A
DC output
Load current
PD48/1600DF-7-Y3: ≤ 1200A; PD48/1600DF-7-Y4: ≤ 1200A;
PD48/2500DF-7-Y3: ≤ 2000A; PD48/2500DF-7-Y4: ≤ 2000A
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NetSure 801 Series Power Supply System User Manual
Parameter
Description
DC output
Battery charging current
PD48/1600DF-7-Y3: ≤ 400A; PD48/1600DF-7-Y4: ≤ 400A;
PD48/2500DF-7-Y3: ≤ 500A; PD48/2500DF-7-Y4: ≤ 500A
Distribution parameter
PD48/1600DF-7-Y3, 22 routes load output:
500A (NT3) × 6, 200A (NT2) × 2, 100A (NT00) × 8, 63A (NT00) × 6
PD48/1600DF-7-Y4, 24 routes load output:
400A (NT3) × 12, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 6
PD48/2500DF-7-Y3，30 routes load output:
630A (NT3) × 8, 400A (NT2) × 4, 200A (NT2) × 4, 100A (NT00) × 8, 63A
(NT00）× 6
PD48/2500DF-7-Y4，26 routes load output:
500A (NT3) × 16, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 4
DC output
Distribution parameter
PD48/1600DF-7/YF: Configured according to customer requirement
PD48/2500DF-7/YF: Configured according to customer requirement
Mechanical
Dimensions mm (W × D × H)
2000mm × 800mm × 600mm
Weight (kg)
PD48/1600DF-7-Y3 ≤ 280; PD48/1600DF-7-Y4 ≤ 280;
PD48/2500DF-7-Y3 ≤ 290; PD48/2500DF-7-Y4 ≤ 290;
PD48/2500DF-7/YF, PD48/1600DF-7/YF ≤ 290
1.3 Components
1.3.1 Rectifier
The system uses rectifier R48-5800A, the frame structure of which mainly consists of panel, enclosure, handle, and
so on, as shown in Figure 1-3.
Figure 1-3 Rectifier appearance
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There are LEDs, slide switch and handle on the front panel, and AC input socket, DC output socket and
communication port on the rear panel. The front panel is shown in Figure 1-4, and functions of indicators are given in
Table 1-4.
Slide switch
Handle
Fixing screw
Power indicator
Protection indicator
Fault indicator
Current indicators
Figure 1-4 Rectifier front panel
Table 1-4 Function of indicators
Indicator
Normal state
Fault state
Fault cause
Power indicator
(Green)
On
Off
No input and output
Flashing
The rectifier is being operated through the host
Protection indicator
(Yellow)
Off
On
AC input under/overvoltage,
rectifier PFC output under/overvoltage, high-temperature, or current sharing
imbalance
Flashing
Rectifier communication failure
Fault indicator
(Red)
Off
On
Output overvoltage, output fuse blown, or rectifier addresses contradictory
Flashing
Faulty fan
Current indicators
on
Shows the output current, each LED represents 10A. If the rectifier is in
current limiting state (output current > 100A), the tenth LED will blink. If the
output current of the rectifier is smaller than 2A, no current indicator will be
on
1.3.2 Controller
The controller specific content see the M831D Controller User Manual .
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1.3.3 AC Distribution Cabinet
The AC distribution cabinet is available in four models: PD380/400AFH-7-Y2, PD380/630AFH-7-Y3,
PD380/630AFA-7-Y4 and PD380/630AFH-7/YF. The appearances of the AC distribution cabinets are the same, as
shown in Figure 1-5.
AC mains indicator
Failure indicator
Power distribution
LCD
Figure 1-5 Appearance of AC distribution cabinet
The internal structure of AC distribution cabinet PD380/400AFH-7-Y2 is shown in Figure 1-6.
Knife-blade switch
Class C SPD
SPD MCB
AC output MCB
Buzzer
Buzzer control switch
Monitoring board
Signal transfer board
AC sampling board
(a) Front view (door open)
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Chapter 1 Introduction 7
NetSure 801 Series Power Supply System User Manual
Earth busbar
Neutral busbar
Cover plate
(b) Rear view (door open)
Figure 1-6 PD380/400AFH-7-Y2 AC distribution cabinet
The internal structure of AC distribution cabinet PD380/630AFH-7-Y3 is shown in Figure 1-7.
Class C SPD
SPD MCB
Buzzer
Buzzer control switch
Monitoring board
Signal transfer board
AC sampling board
AC output MCB
Knife-blade switch
(a) Front view (door open)
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NetSure 801 Series Power Supply System User Manual
Earth busbar
Neutral busbar
Cover plate
(b) Rear view (door open)
Figure 1-7 PD380/630AFH-7-Y3 AC distribution cabinet
ATS controller
ATS
Monitoring board
AC sampling board
AC output MCB
(a) Front view (door open)
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Neutral busbar
Earth busbar
SPD MCB
SPD
(b) Rear view (door open)
Figure 1-8 PD380/630AFA-7-Y4 AC distribution cabinet
The structure and configuration of PD380/630AFH-7/YF is determined by customer requirement. See purchase order
for description.
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1.3.4 DC Distribution Cabinet
The DC distribution cabinet is available in six models: PD48/1600DF-7-Y3, PD48/1600DF-7-Y4, PD48/1600DF-7/YF,
PD48/2500DF-7-Y3, PD48/2500DF-7-Y4 and PD48/2500DF-7/YF. The appearances of the DC distribution cabinets
are the same, as shown in Figure 1-9.
Power indicator
Failure indicator
Power distribution
LCD
Figure 1-9 Appearance of DC distribution cabinet
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The internal structure of DC distribution cabinet PD48/1600DF-7-Y3 is shown in Figure 1-10.
Battery II fuseBattery I fuse
Buzzer
Buzzer control switch
Fault silencer
Controller LCD
Control board
Load fuse
(a) Front view (open front door)
DC positive busbar
(b) Rear view (open front door and remove rear door)
Figure 1-10 PD48/1600DF-7-Y3 DC distribution cabinet
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NetSure 801 Series Power Supply System User Manual
The internal structure of DC distribution cabinet PD48/1600DF-7-Y4 is shown in Figure 1-11.
Battery I fuse
Buzzer
Buzzer control switch
Fault silencer
Controller LCD
Control board
Battery II fuse
Load fuse
(a) Front view (open front door)
DC positive busbar
(b) Rear view (open front door and remove rear door)
Figure 1-11 PD48/1600DF-7-Y4 DC distribution cabinet
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The internal structure of DC distribution cabinet PD48/2500DF-7-Y3 is shown in Figure 1-12.
Battery II fuse
Load fuse
Battery I fuse
Buzzer
Buzzer control switch
Fault silencer
Controller LCD
Control board
(a) Front view (open front door)
DC positive busbar
(b) Rear view (open front door and remove rear door)
Figure 1-12 PD48/1600DF-7-Y3 DC distribution cabinet
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The internal structure of DC distribution cabinet PD48/2500DF-7-Y4 is shown in Figure 1-13.
Battery I fuse
Buzzer
Buzzer control switch
Fault silencer
Controller LCD
Control board
Load fuse
Battery II fuse
(a) Front view (open front door)
DC positive busbar
(b) Rear view (open front door and remove rear door)
Figure 1-13 PD48/2500DF-7-Y4 DC distribution cabinet
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The structure and configuration of PD48/1600DF-7/YFand PD48/2500DF-7/YF are determined by customer
requirement. See purchase order for description.
1.3.5 Rectifier Cabinet
Rectifier cabinets Rack 1000-7 and Rack 2000-7 are shown in Figure 1-14 and Figure 1-15 respectively.
Rectifier
Controller
Rectifier input switch
Figure 1-14 Rectifier cabinet Rack1000-7
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NetSure 801 Series Power Supply System User Manual
Rectifier
Controller
Rectifier input switch
Figure 1-15 Rectifier cabinet Rack2000-7
The name, function and use of the cabinet components are given in Table 1-5.
Table 1-5 Part name, function and use
Name
Function
Cabinet
Power LED
When the mains input 1 is available, HL1 illuminates; when the mains
input 2 is available, HL2 illuminates
AC cabinet, AC/DC cabinet
When the AC input 1 is available, HL1 illuminates; when the AC input
2 is available, HL2 illuminates
Rectifier cabinet, AC/DC cabinet
When there is electricity in the busbar, the LED illuminates
DC cabinet, AC/DC cabinet
Fault LED
When the distribution cabinet is in normal operation, it is off; it
illuminates otherwise
AC cabinet, DC cabinet, AC/DC
cabinet
JYG-12864J9G
(R)-YS6L2-VB
Display
Display the input voltage, current, frequency, running mains input
number, SPD state, output MCB state (AC/DC cabinets have none)
and alarm information of the AC cabinet
AC cabinet, AC/DC cabinet
Display the busbar voltage, total load current, battery voltage, battery
current, load fuse status and alarm information
DC cabinet, AC/DC cabinet
A6V6FU11
monitoring board
Measure the AC input voltage, main switch state, output MCB state,
surge protection device (SPD) state; control the position of the main
switch, generator start signal output; annunicate audible and visual
alarms when the AC cabinet malfunctions, and simultaneously transmit
relevant information to the display of the AC cabinet and the controller
PD380/400AFH & PD380/630AFH AC
cabinet, AC/DC cabinet
Measure the busbar voltage, total load current, battery voltage, battery
current and load fuse status; annunicate audible and visual alarms
when the AC cabinet malfunctions, and simultaneously transmit
relevant information to the display of the DC cabinet and the controller
DC cabinet, AC/DC cabinet
A2V6FX1 signal
transfer board
Transfer the input/output signals of the monitoring board of the AC
cabinet
PD380/400AFH & PD380/630AFH AC
cabinet, AC/DC cabinet
Transfer the input/output signals of the monitoring board of the DC
cabinet
DC cabinet, AC/DC cabinet
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Name
Function
Cabinet
A6V6FA1 AC
sampling board
Sample the phase voltage of both mains inputs and the phase-B
current of the running mains input
AC cabinet, AC/DC cabinet
HDU1U11
monitoring board
Measure the AC input voltage, main switch state, output MCB state,
surge protection device (SPD) state; control the position of the main
switch, generator start signal output; annunicate audible and visual
alarms when the AC cabinet malfunctions, and simultaneously transmit
relevant information to the display of the AC cabinet and the controller
PD380/400AFH & PD380/630AFH AC
cabinet, DC cabinet, AC/DC cabinet
A1V8FA1 AC
sampling board
Sample the phase voltage of one main inputs or the phase-B current of
the running mains input
PD380/400AFH AC cabinet
Buzzer
It does not beep when the AC cabinet is in normal operation, and
beeps when the AC cabinet malfunctions
PD380/400AFH & PD380/630AFH AC
cabinet, DC cabinet, AC/DC cabinet
Buzzer control
switch
K1 can be placed in 2 positions: fault alarm and alarm silencing;
K2 can be placed in 2 positions: buzzer ON, and buzzer OFF.
Normally, K1 is placed in the “fault alarm” position,and K2 in “buzzer
ON” position.
When AC cabinet fault occurs, the buzzer will beep; if alarm silencing
is needed, place K1 in the “alarm silencing” position; when the fault is
removed, the buzzer will beep again, then place K1 to the “fault alarm”
position, the buzzer will stop beeping.
K2 is buzzer switch: when K2 is placed to the “buzzer ON” position,
the buzzer beeping is subject to the control of the monitoring board;
when placed to the “buzzer OFF” position, the buzzer will not beep,
and is not controlled by the monitoring board
PD380/400AFH & PD380/630AFH AC
cabinet, DC cabinet, AC/DC cabinet
Class-C SPD
Discharge lightning strike current. The SPD indicator is green when
the SPD operates normally, and turns red when it malfunctions. In this
case, it must be replaced
AC cabinet, AC/DC cabinet
SPD MCB
It is used to protect SPD, and is closed when the SPD operates
normally. When it trips, the SPD should be checked for damage. It is
damaged, it must be replaced immediately, and the MCB should be
closed; if the SPD is not damaged, close the MCB timely
PD380/400AFH & PD380/630AFH AC
cabinet, AC/DC cabinet
Knife- blade
switch or air
breaker
It is used to control the switchover between the 2 mains inputs. This
switch can be placed in 2 positions: “I” and “II”, respectively
representing mains input 1 and mains input 2
AC cabinet, AC/DC cabinet
ATS
It is used to control the switchover automatic between the 2 mains
inputs. This switch can be placed in 2 positions: “I” and “II”,
respectively representing mains input 1 and mains input 2
PD380/630AFH AC cabinet
Output MCB
Configured according to custermer requirement
AC cabinet, AC/DC cabinet
Output fuse
Configured according to custermer requirement
DC cabinet, AC/DC cabinet
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Chapter 2 Installation Preparation
This chapter introduces installation requirements, storage conditions, installation preparation and unpacking
inspection.
2.1 Installation Requirements
2.1.1 Environmental Requirements
The environmental conditions of the equipment room must meet the requirements listed in Table 2-1.
Table 2-1 Environmental conditions for the equipment room
Environmental conditions
Recommended range
Ambient temperature
-5°C to 40°C
Humidity
≤ 90%RH, no condensation
Dust density
≤ 1mg/m
3
Sunlight
No direct sunlight
Corrosive materials
No pollutants, such as salt, corrosive materials, and smoke.
Vibration
≤ 1.5m/s²
Harmful organisms
None
Mould
None
Dampness
Waterproof
The equipment may be prematurely damaged if dust or sand accumulates in it. The following measures are
recommended for dirty environment:
1. The equipment should be installed in an airtight and air-conditioned room. The air conditioner filter should be
adequately maintained without being obstructed. To reduce the dust in the equipment room, unattended equipment
room is recommended.
2. Clean the air filter periodically to provide clean air.
2.1.2 Layout Requirements Of The Equipment Room
Air exhaust and ventilation
When the power supply is working, the main exothermic part is the rectifier. To ensure free airflow around the power
supply system, an 800mm clearance must be kept in front of the system and 800mm behind.
Cabling
The top cable entry system are all introduced from the top of the cabinet, therefore wiring rack should be provided in
the equipment room for top cable entry system, which is recommended to be at least 300mm above the equipment.
For bottom cable entry system, cable trough should be provided in the equipment room, which should be no wider
than the spacing between the equipment mounting holes.
Note
To prevent electric coupling, AC cables should be run separate from DC cables and signal cables.
Installation surface
The installation surface is supposed to be cement floor or incombustible metal subrack.
Antistatic requirement
As for antistatic requirement, the absolute value of the static voltage of the equipment, wall and people to the ground
should be less than 200V. Raised floor is highly recommended for the equipment room. The antistatic earth
resistance should be not greater than 10Ω. Care should be taken regarding antistatic during equipment unpacking,
transportation and operation.
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Lighting
Lighting in equipment room may be classified into general lighting and partial lighting. General lighting provides light
for the whole room, while partial lighting is installed above the equipment cabinet or workstation to provide light for a
restricted area. It is recommended to provide both lightings in the equipment room.
Clearance
1. At least 1.5m of clearance should be kept between the front of the power system cabinet and the wall.
2. At least 0.8m of clearance should be kept between the back of the power system cabinet and the wall.
3. At least 0.8m of clearance should be kept the sides of the power system cabinet and the wall.
4. At least 1.5m of clearance should be kept between the back of the power system cabinet and the front of another
piece of equipment.
5. At least 1.2m of clearance should be kept between the back of the power system cabinet and the back of another
piece of equipment.
6. Maintenance passage should be kept between equipment, which should not be less than 2m wide.
Refer to Figure 2-1 for the above requirements. No less than 0.2m of clearance should be kept between the battery
and the wall, and no less than 0.8m of clearance should be kept between batteries.
Front of the
cabinet
Clearance
≥ 1.5m
Clearance
between
cabinet side
and the wall ≥
0.8m
Clearance
between
cabinet back
and the wall ≥
0.8m
Figure 2-1 Locating cabinet
Weight capacity and shockproof requirements
When installing the power system in areas subject to frequent earthquakes, shockproof measures should be taken.
Firstly, expansive bolts should be used to fix the system (refer to 3.1 Installing Cabinet); secondly, the system
should be reinforced as shown in Figure 2-2 to enhance its shockproof ability. Because the power supply system is
relatively heavy, the weight capacity of the equipment room should meet relative requirements and is determined
based on the equipment configuration.
Figure 2-2 Reinforcing the cabinet for shockproof purpose
Fire protection facility
The equipment room should comply with relevant fire protection regulations and requirements for power distribution,
and provide adequate fire protection facility, such as dry-chemical extinguisher and automatically explosive fire
protection ball.
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2.1.3 Power Supply
General
Mains power should be used as the main AC source in communication field; backup batteries and generator should
be provided according to the actual power source conditions. AC source composed of mains power and
user-provided generator should use centralized power supply mode to supply power, and low voltage AC power
supply system should use three-phase five-line mode.
The AC power cables should be copper core cable and sized to suit for the load. It is recommended that the power
cables outside the equipment room should be buried directly under the ground or by means of cable pipe. Power
cables should be run separate from signal cables.
Power supply adaptability
The power supply system is adaptable to various mains formats, including TN-C, TN-S, TN-C-S and TT formats with
three-phase four-wire or three-phase five- wire styles. If the power supply system uses IT mains format, users need
to have the system made to order.
Capacity requirements
1. Power transformer
Because of the particularity of switch-mode power supply system, the power supply should provide relatively large
redundancy. If the capacity of the power transformer is small, operation of other electric equipment may be affected.
Calculated based on full configuration of the power supply system, the capacity of a dedicated transformer should
exceed 1.25 times of the total capacity of the system. So, considering other electric equipment such as air conditioner,
the capacity of the transformer should be even larger, and the upper capacity level should be selected according to
the specifications.
PD380/400AFH-7-Y2 AC distribution cabinet is not supposed to be directly connected to the secondary side of a
transformer with capacity greater than 800kVA. An extra distribution cabinet should be used between
PD380/400AFH-7-Y2 AC distribution cabinet and the transformer for shortcircuit protection. PD380/630AFH-7-Y3 AC
distribution cabinet is not supposed to be directly connected to the secondary side of a transformer with capacity
greater than 1000kVA. An extra distribution cabinet should be used between PD380/630AFH-7-Y3 AC distribution
cabinet and the transformer for shortcircuit protection.
2. Generator
If the load of the power supply system is more than 50% of the generator capacity, when the higher harmonic current
generated by the rectifiers passes the stator winding of the synchronous generator, the voltage waveform will be
severely distorted, which will have two effects. One is, it will cause unstable running and mechanical vibration of the
generator; and the other is, the harmonic current will make the generator overheat, thus accelerating the insulation
ageing of the generator. This is not only harmful to the generator, but also affects the stable running of the power
supply system. Therefore, the load of the power supply system should not exceed 50% of the generator capacity. It
should be calculated based on the apparent power. A simple calculation of the generator capacity is: output voltage
(taken as 60V) × output current (take the final configuration) × 2.
The power factor and excitation model of the generator should also be taken into consideration when selecting a
generator. Brushless generator of fundamental wave excitation model should be used with caution.
2.1.4 Safety Protection
Lightning protection & surge protection
The lightning protection and earthing system of telecom stations should comply with relevant standards.
The power supply system is equipped with a Class- C SPD. To achieve better surge protection, it is recommended to
mount Class-B SPD before the AC mains is connected to the system. The mounting of Class-B SPD is shown in
Figure 2-3.
Class-B SPD should be purchased and mounted by the user. If condition permits, it is recommended that the cable
length between the Class-B SPD and the AC distribution unit of the power supply system range between 5 ~ 10m.
And this section of cable should be routed indoors to avoid direct lightning strike. When mounting the Class-B SPD,
attention should be paid to the sectional area and length of the cable connecting the Class-B SPD: the sectional area
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should be no less than 25mm2, the cable should be as short as possible, and so is the earth cable of the Class-B
SPD. The SPDs should be inspected periodically to ensure their normal operation.
48VDC
+
-
A
B
C
N
PE
5~10m
Class-B SPD
SPD
DC earth
Protective earth cable
User earth bar
System earth bar
Protective earth
Power
supply
system
SPD earth
SPD earth
DC earth cable
Figure 2-3 Diagram of SPD mounting & system earthing
Earthing requirement
The earthing system in the communication equipment room is generally designed on the principle of common earth,
that is, DC operation earth, SPD earth and protective earth sharing the same earth. The earth resistance should be in
accordance with the specifications listed in Table 2-2.
Table 2-2 Earth resistance requirements for communication station
Earth resistance
Application range
<1Ω
Integrated building, international telecom bureau, tandem station, SPC switching office above 10000 lines,
toll office above 2000 lines
<3Ω
SPC switching office above 2000 lines and below 10000 lines, toll office below 2000 routes
<5Ω
SPC switching office with less than 2000 lines, optical cable terminal station, carrier wave repeating station,
earth station, microwave junction center, mobile communication machine station
10Ω
Microwave relay station, optical cable relay station, small-sized earth station
<20Ω
Microwave passive relay station
<10Ω
Suitable for those whose earth resistance rate is less than 100Ω·m, SPD earth in the interface between
electric cable and aerial electric line
<15Ω
Suitable for those whose earth resistance rate is 100-500Ω·m, SPD earth in the interface between electric
cable and aerial electric line
<20Ω
Suitable for those whose earth resistance rate is 501-1000Ω·m, SPD earth in the interface between electric
cable and aerial electric line
Note: the content in the table is adapted from Installation Design Specifications for Communication Power Supply Equipment
2.1.5 Equipment Running Environment Checklist
The equipment running environment checklist is given in Table 2-3.
Table 2-3 Equipment running environment checklist
No.
Item
Index
Pass
1
Ambient temperature in equipment room
-5°C to +40°C
Yes/No
2
Humidity in equipment room
≤ 95%
Yes/No
3
Lighting in equipment room
70 ~ 200Lux
Yes/No
4
Height of equipment room
≥ 3m
Yes/No
5
Static electricity in equipment room
Lay antistatic floor or antistatic rubber
Yes/No
6
Weight capacity and quakeproof ability
Accord with Level 8 quakeproof, and safety must be ensured
Yes/No
7
Radiation
No blockage in equipment radiation passage
Yes/No
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No.
Item
Index
Pass
8
Damp proof
No mildew breeding conditions
Yes/No
9
Dust-proof
No conductive dust and gas which deteriorate insulation
Yes/No
10
Fire protection
Fire fighting equipment such as fire extinguisher
Yes/No
11
Earth resistance
In accordance with relevant standards
Yes/No
12
Sectional area of SPD earth cable
Not less than 25mm2，the shorter the better
Yes/No
13
Colour of protective earth cable
Greenyellow
Yes/No
14
Earth nut
Copper, no less than M8
Yes/No
15
Tablet, symbol, tag of customer equipment
Complete and clear
Yes/No
16
Violent vibration and shock
None
Yes/No
17
Sectional area of AC distribution cables
According to design specifications
Yes/No
18
Fluctuation range of AC input voltage
According to equipment input specifications
Yes/No
19
Frequency fluctuation range
45Hz to 65Hz
Yes/No
20
Voltage of neutral line to ground
Less than 10V
Yes/No
21
Power of backup power source
Twice larger than the actual capacity
Yes/No
22
Pollution or interference in power network
None
Yes/No
23
Colour code of AC bus
Yellow, green, red, light blue or marked with identifier
Yes/No
24
Capacity of the customer AC distribution
cabinet
Meet equipment requirements
Yes/No
25
Wiring of AC distribution cables
According to specifications
Yes/No
26
Colour code of DC load cables
According to specifications
Yes/No
27
Sectional area of DC distribution cables
According to requirements
Yes/No
28
Earth wiring
According to specifications
Yes/No
2.2 Storage Conditions
The product should be kept in the packing box prior to use. The warehouse ambient temperature should range
between -40°C and 70°C and the relative humidity should not be higher than 95%. Toxic gas, flammables, explosives,
corrosives, severe vibration, shock and strong magnetic field are not permitted in the warehouse.
2.3 Installation Preparation
2.3.1 Field Check
Construction survey must be conducted to the equipment room before equipment installation, which should be
focused on:
1. Checking the wiring devices, such as cable trenching, wiring rack, floor, and cabling holes.
2. Checking the environmental conditions, such as temperature, humidity, and dust density.
3. Checking the conditions for installation construction, such as power supply and lighting.
2.3.2 Tools And Materials Preparation
1. Tools required for power supply equipment installation include electric drill, wire cutter, wire presser, various
wrenches, screwdriver, electrician knife, tinning furnace, staircase and steel saw. See 6.1.2 Maintenance Tools And
Equipments for the specifications of the tools. The tools must be well insulated and antistatic handled before they are
used.
2. Materials for electrical connection include AC cables, DC load cables, battery cables, earth cables, and earth
connection cables. The cables accessories are given in Table 2-4. Other cables should be prepared by users in
accordance with relevant specifications in the electrical industry.
Table 2-4 Accessory cables used in cable connection
BOM
Description
Length
Note
04110145
(optional)
W74AASL03 cable suite (AC input cable of the
rectifier cabinet-3.5m)
3.5m
No DC cabinet between AC cabinet and rectifier
cabinet. Internal cabling (≤ 2000A), When the AC
output EMR1 series MCCB for Vertiv
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BOM
Description
Length
Note
04116219
(optional)
W64AASL03 cable suite (AC input cable of the
rectifier cabinet-3.5m)
3.5m
No DC cabinet between AC cabinet and rectifier
cabinet. Internal cabling (≤ 2000A), When the AC
output S series of the ABB MCCB
04110146
(optional)
W74AASL11 cable suite (AC input cable of the
rectifier cabinet-7m)
7m
No DC cabinet between AC cabinet and rectifier
cabinet. Internal cabling (≤ 2000A), When the AC
output EMR1 series MCCB for Vertiv
04116341
(optional)
W64AASL11 cable suite (AC input cable of the
rectifier cabinet-7m)
7m
One DC cabinet between AC cabinet and rectifier
cabinet. External cabling, When the AC output T
series of the ABB MCCB
041163475
(optional)
W64AASL12 cable suite (AC input cable of the
rectifier cabinet-9m)
9m
More than one DC cabinet between AC cabinet
and rectifier cabinet. External cabling (> 4000A),
When the AC output EMR1 series MCCB for Vertiv
04116345
W64AASL12 cable suite (AC input cable of the
rectifier cabinet-9m)
9m
More than one DC cabinet between AC cabinet
and rectifier cabinet. External cabling (> 4000A),
When the AC output T series of the ABB MCCB
04119128
W1PK2SL10 cable suite (RS485 signal cable
connected to M821D controller)
5.5m
04116221
W64AASL05 cable suite (RS485 signal cable
connected between AC distribution cabinet and
DC distribution cabinet)
4.0m
PD380/400AFH & PD380/630AFH AC cabinet and
rectifier cabinet
04111498
W1PN5SL20-W1PN5Z cable suite （RS485
signal cable connected between AC ATS
cabinet and rectifier cabinet, and connected
between AC ATS cabinet）
5.5
RS485 signal cable connected between
PD380/630AFA AC cabinet and rectifier cabinet, or
between the PD380/630AFA AC cabinet
04116222
W64AASL06 cable suite (power cable of
A6V6FU11 monitoring board)
4.3m
04116169
W64AASL09 cable suite (CAN bus)
2.8m
3. Preparing 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
the current density of 2.5A/mm2.
The sectional area of the DC load cables and battery cables should be computed with the following formula:
A=ΣI × L / K△U
In this formula: A is the sectional area of the lead (mm
2
), ΣI is the total current (A) passing through the lead, L is the
length (m) of the lead loop, △U is the permitted voltage drop in the lead, while K is the conductivity factor. K
copper
=57.
For the sake of distribution safety, the voltage drop on the cables should be compliant with corresponding rules.
The sectional area of the earth cables (including DC earth cable) shall exceed 95mm2.
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 2-5. Select the DC load cable CSA according to the Table 2-5.
Table 2-5 Battery cable CSA selection
Battery fuse rated current
Max. battery current
Min. cable CSA
Specs of the cable
connector
Max. cable length (allowable
voltage drop: 0.5V)
1000A
1000A
2 × 240mm2
OT cable connector of
M12 or M16 size
10m
Note:
1. The specs are applicable at ambient temperature of 25°C. If the temperature is higher or lower than this, the CSA of the cable
should be increased.
2. The battery cable should reach at least +90°C heat durability. It is recommended to use double-insulated copper-core flame
retardant cable as battery cable
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Table 2-6 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)
630A
630A
240mm2
10m
300mm2
13m
500A
500A
240mm2
13m
300mm2
17m
400A
400A
185mm2
13m
300mm2
21m
300A
300A
120mm2
11m
240mm2
22m
250A
250A
95mm2
10m
185mm2
21m
160A
160A
70mm2
12m
95mm2
16m
100A
100A
50mm2
14m
95mm2
27m
50A
50A
25mm2
14m
50mm2
25m
32A
32A
16mm2
7m
25mm2
11m
Note:
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
The MCB/fuse capacity should be strictly limited so that it can function properly upon load over-current. The
recommended MCB/fuse capacity is 1.5 ~ 2 times larger than the load peak capacity.
The load fuses with capacity over 160A use M12 or M16 OT- shape cable connectors. The load fuses with capacity
equal to or under 160A use M8 OT- shape cable connectors. The load MCBs uses the H- shape cable connectors.
The recommended CSA of AC input cables are shown in Table 2-7.
Table 2-7 AC input cable selection
Cabinet
Connector
Specs
Remarks
Capacity
Connector specs
PD380/400AFH-7-Y2
AC distribution cabinet
AC input MCB
400A
Eight M12 bolts (suggested cable
CSA 185mm2)
The live line of AC power supply
Grounding
busbar
One M16 bolt
suggested cable CSA 120mm2
The grounding bar of the room
PD380/630AFH-7-Y3
AC distribution
cabinet
AC input MCB
630A
Eight M16 bolts (suggested cable
CSA 240mm2)
The live line of AC power
supply
Grounding
busbar
One M16 bolt
Suggested cable CSA 120mm2
The grounding bar of the room
PD380/630AFA-7-Y4
AC distribution
cabinet
AC input MCB
(ATS)
630A
Eight M12 bolts (suggested cable
CSA 240mm2)
The N line of AC power supply
Grounding
busbar
One M16 bolt
Suggested cable CSA 120mm2
he grounding bar of the room
Note
Generally, in design the total current passing through the lead is calculated based on full load configuration.
4. Purchase materials according to the construction materials list and inspect the materials. For example, check the
heat durability, moisture resistance, flame resistance, and pressure resistance of the cables.
5. For the materials that need to be processed by other factories, the materials and the processing drawings should
be provided in advance for processing.
6. The auxiliary materials for power supply installation include expansive bolts, cable lugs, cable ties, and insulating
tape.
2.4 Unpacking Inspection
Explanation on packing
One suit of power system is packed up separately in many packing cases and delivered in suit. There is a printed
packing label on the surface of each packing case. In the case which is pasted a 16mo red label on the surface, there
is the packing list of the power system marked with “packing list storage case”. To inspect the equipment, you should:
1. Open the packing case and take out the packing list.
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2. Check against the packing label when delivering the equipments.
3. Check the goods one by one according to the packing label after they arrive at the site.
4. Check the goods according to the packing list and equipment configuration and technical requirements.
Unpacking inspection
To ensure smooth installation, the equipment must be carefully inspected when it is unpacked. The checking should
include:
1. The number and serial number of the packing cases according to the system packing case number.
2. The correctness of the equipment packing according to the packing list.
3. The number and type of the accessories according to the accessory list.
4. The completeness of the equipment configuration according to the system configuration.
5. The conditions of the goods through visual inspection. For example, check if the cabinet and case are damaged, if
the cabinet and case have regained moisture; shake gently the rectifiers and controller to check if the parts and
connections have been loosened during transportation.
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Chapter 3 Installation
This chapter introduces installation and cable connection.
3.1 Installing Cabinet
3.1.1 Installation On The Floor
Step 1: mark the installation position
Determine the installation position of the power supply cabinet in the equipment room according to the installation
drawing. Based on the mechanical parameters (see Figure 3-1) of the installation holes of the power supply cabinet,
determine the exact position of the center points of the installation holes on the floor, and mark them with a pencil or
oil pen.
370
600
600
436
4- 18
600
400
600
4-Ф18
800
(a) Installation size of the rectifier cabinet (b) Installation size of the AC/DC distribution cabinet
Figure 3-1 Installation size of the cabinet base (unit: mm)
Step 2: drill reserve holes
The expansive pipes delivered along with the system are generally M10 × 65mm. Therefore, use electric drill with drill
bit Φ14 to drill holes at the center points of the installation holes marked on the floor, and the depth of the holes
should be 70mm. To avoid being off-center, be careful not to shake the drill, and try to keep it as vertical as possible
to the floor.
Step 3: install expansive pipes
Clean the dust, and insert the expansive pipe into the reserve hole, knock it down gently using a hammer until the top
of the expansive pipe is level with the ground.
Step 4: place cabinet in position
Move the cabinet to the installation position aligning the installation holes of the cabinet with the reserve holes on the
ground.
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Step 5: fix the cabinet
After the cabinet is in position, make some horizontal and vertical adjustments. Insert some iron pieces under the
lower edge and corner of the cabinet to adjust the vertical obliquity of the cabinet within 5 degrees. Finally, screw
down the tap bolt with plain washer and spring washer into the expansive pipe, and tighten it with wrench. The
cabinet fixation is illustrated in Figure 3-2.
Tap bolt
Plain washer
Cabinet base
Ground
Spring washer
Expansive pipe
Figure 3-2 Fixing cabinet with tap bolt
3.1.2 Installation On Supporting Rack
If antistatic floor is laid in the equipment room, a supporting rack should be made according to the height of the
antistatic floor.
Step 1: place cabinet in position
Install the supporting rack on the floor as shown in Figure 3-3. The installation steps are the same as the first three
steps in 3.1.1 Installation On The Floor.
Expansive pipe finished
Floor
Expansive pipe
Bolt
Spring washer
Plain washer
Figure 3-3 Installing supporting rack
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Step 2: fix the cabinet
Install the power supply cabinet on the supporting rack, as shown in Figure 3-4.
Supporting rack
Cabinet base
Expansive pipe finished
Plain washer
Spring washer
Bolt
Figure 3-4 Installing power cabinet on supporting rack
After the cabinet is installed, shake the cabinet from different directions. No obvious shake should be felt.
3.1.3 Parallel Connection Between Cabinets
Users need to use connection straps to fix adjacent cabinets at the top, as shown in Figure 3-5. The connection
straps are accessories.
600
600
600
280 80
80
40
Rectifier cabinet
Rectifier cabinet
800
600
Rectifier cabinet
16.5
54
16.5
54
2-M12× 30 bolt
2-M6× 16 screw
600
AC cabinet/DC cabinet
Make sure that the front door header of the rectifier cabinet aligns
horizontally with that of the AC/DC cabinet during parallel connection.
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800
800
525
68
4-M12
×
30 bolt
AC cabinet/DC cabinet
Make sure that the front door header of the cabinet
aligns horizontally during parallel connection.
600
AC cabinet/DC cabinet
Figure 3-5 Parallel connection between cabinets (top view, unit: mm)
3.1.4 Parallel Connection With Copper Bars
AC distribution cabinet and rectifier cabinet are connected by cables, while parallel connections between rectifier
cabinets, between rectifier cabinet and DC distribution cabinet and between DC distribution cabinets are all achieved
by means of parallel connection copper bars. The AC/DC integrated distribution cabinet and rectifier cabinet are
connected by both cables and copper bars.
Take parallel connections between a rectifier cabinet and a DC distribution cabinet for example, the connection
procedures are as follows:
1. Remove the upper side doors between the rectifier cabinet and the DC distribution cabinet.
2. Connect the positive bars and negative bars inside the cabinet respectively by copper bars and screws, as shown
in Figure 3-6.
If users need to parallel connect the rectifier cabinets or the DC distribution cabinets, they need to contact Vertiv for
technical support.
A
DC positive busbar
DC negative busbar
A amplification
Bolt
Plain washer
Spring washer
Nut
Copper bar
Plain washer
Figure 3-6 Parallel connection inside cabinet
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3.1.5 Installation Of System Above 2000A
The NetSure 801 CA7 power supply system can be expanded up to 6000A. As the max current carrying capacity of
single parallel connection bar is 2000A, when the system capacity exceeds 2000A, the system cabinets should be
arranged in the way that the max current carrying capacity of one parallel connection bar does not exceed 2000A.
It is recommended to place the cabinets in the way of “Rectifier cabinet- DC cabinet- Rectifier cabinet- DC cabinet”.
For a system composed of Rack1000-7 rectifier cabinet, place one rectifier cabinet or two rectifier cabinets as a unit.
For a system composed of Rack2000-7 rectifier cabinet, place one rectifier cabinet as a unit.
Recommended arrangement of 6000A system using Rack1000-7 rectifier cabinet:
AC cabinet AC cabinet
Rectifier
cabinet
Rectifier
cabinet
DC cabinet
Rectifier
cabinet
Rectifier
cabinet
DC cabinet
Rectifier
cabinet
Rectifier
cabinet
DC cabinet
AC cabinet AC cabinet
Recommended arrangement of 6000A system using Rack2000-7 rectifier cabinet:
AC cabinet AC cabinet
Rectifier
cabinet
DC cabinet
Rectifier
cabinet
DC cabinet
Rectifier
cabinet
DC cabinet
AC cabinet AC cabinet
If the installation site does not permit the cabinet arrangement shown above, it is suggested to use 2 parallel
connection copper bars so that the current carrying capacity of single connection bar does not exceed 2000A. When
using 2 connection bars, only external parallel connection can be used and the connection bars must be specially
made.
3.1.6 Mounting Large Side Door And Small Side Door
The rectifier cabinet and distribution cabinet have two side doors on both sides, as shown in Figure 3-7. According to
distribution situation, cabinet placement and cabinet parallel connection, the side doors are configured in various
ways.
Prior to cabinet parallel connection, check that there is at least one large side door between adjacent cabinets. The
large side doors of the rectifier cabinet and the distribution cabinet are interchangeable. Users can exchange them on
the spot.
Small side door
Large side door
Cabinet
Small side door
Large side door
Figure 3-7 Side doors
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3.1.7 Placing DC Cabinet Separate From System
The NetSure 801 power supply system uses integrated monitoring, the DC distribution cabinet can be placed
separate from the system, and typically where loads are grouped, for example, on different floors. When connecting
the DC distribution cabinet to the system, use cable to connect between the parallel connection bars. Pay attention to
the following points:
Use cable rather than copper bar to connect between the parallel connection copper bars of the DC distribution
cabinet and the system to ensure accurate measurement of load current. The connecting points are the
installation holes for parallel connection copper bar.
Communication inside the system uses RS485 mode.
3.2 Connecting Power Cables
Note
Before electrical connection, turn off all the switches and fuses.
The accessory cables used in cable connection are given in Table 3-1.
Table 3-1 Accessory cables used in cable connection
BOM
Description
Length
Note
04110145
(optional)
W74AASL03 cable suite (AC input cable of the rectifier
cabinet-3.5m)
3.5m
No DC cabinet between AC cabinet
and rectifier cabinet. Internal cabling (≤
2000A), When the AC output EMR1
series MCCB for Vertiv
04116219
(optional)
W64AASL03 cable suite (AC input cable of the rectifier
cabinet-3.5m)
3.5m
No DC cabinet between AC cabinet
and rectifier cabinet. Internal cabling (≤
2000A), When the AC output S series
of the ABB MCCB for Vertiv
04110146
(optional)
W74AASL11 cable suite (AC input cable of the rectifier
cabinet-7m)
7m
No DC cabinet between AC cabinet
and rectifier cabinet. Internal cabling (≤
2000A), When the AC output EMR1
series MCCB for Vertiv
04116341
(optional)
W64AASL11 cable suite (AC input cable of the rectifier
cabinet-7m)
7m
One DC cabinet between AC cabinet
and rectifier cabinet. External cabling,
When the AC output S series of the
ABB MCCB for Vertiv
041163475
(optional)
W64AASL12 cable suite (AC input cable of the rectifier
cabinet-9m)
9m
More than one DC cabinet between AC
cabinet and rectifier cabinet. External
cabling (> 4000A), When the AC output
EMR1 series MCCB for Vertiv
04116345
W64AASL12 cable suite (AC input cable of the rectifier
cabinet-9m)
9m
More than one DC cabinet between AC
cabinet and rectifier cabinet. External
cabling (> 4000A), When the AC output
S series of the ABB MCCB for Vertiv
04119128
W1PK2SL10 cable suite (RS485 signal cable connected to
M821D controller)
5.5m
04116221
W64AASL05 cable suite (RS485 signal cable connected
between AC distribution cabinet and DC distribution cabinet)
4.0m
PD380/400AFH & PD380/630AFH AC
cabinet and rectifier cabinet
04111498
W1PN5SL20-W1PN5Z cable suite (RS485 signal cable
connected between AC ATS cabinet and rectifier cabinet, and
connected between AC ATS cabinet）
5.5
RS485 signal cable connected
between PD380/630AFA AC cabinet
and rectifier cabinet, or between the
PD380/630AFA AC cabinet
04116222
W64AASL06 cable suite (power cable of A6V6FU11
monitoring board)
4.3m
04116169
W64AASL09 cable suite (CAN bus)
2.8m
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3.2.1 Connecting Earth Cable
The power supply system uses common earth. The connection procedures are as follows.
1. Use the earth cable to connect the earth bolt at the rear lower (or rear upper) part of the rectifier cabinet to the
earth bar of the AC distribution cabinet, see Figure 3-8 to Figure 3-10.
Earth terminal
Earth terminal
Figure 3-8 Earth terminal of the rectifier cabinet
Earth busbar
A
Earth bar
To earth terminal of rectifier rack
Bolt
Spring washer
To earth terminal of DC cabinet
To earth copper bar
of equipment room
Plain washer
A amplication
Figure 3-9 Earth bar of the AC distribution cabinet
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Earth terminal
Earth terminal
Figure 3-10 Earth bar of the DC cabinet
2. Connect one end of the earth cable to the user earth bar, and the other end to the earth bar in the AC distribution
cabinet (See Figure 3-9 and Figure 3-10).
3. Lead out the DC earth cable from the positive busbar of the DC distribution cabinet, and connect it to the copper
earth bar in the equipment room. The sectional area of the DC earth cable increases with system capacity, and
should be at least 95mm2.
3.2.2 Connecting Cables Between Rectifier Cabinet And AC Distribution Cabinet
For Rack1000-7 rectifier cabinet, choose one 160A MCB inside PD380/400AFH-7-Y2 or PD380/630AFH-7-Y3 or
PD380/630AFA-7-Y4 cabinet as AC input switch of the rectifier cabinet.
For Rack2000-7 rectifier cabinet, choose two 160A MCBs inside PD380/400AFH-7-Y2 or PD380/630AFH-7-Y3 or
PD380/630AFA-7-Y4 cabinet as AC input switches of the rectifier cabinet.
Follow the steps below to install the AC input cables of the rectifier cabinet.
1. If the AC input cables of the rectifier cabinet are routed inside the cabinets, users can use the accessory cables as
the AC input cables. Otherwise users need to prepare armored cables by themselves. If the system capacity exceeds
2000A, users need to prepare extra cables.
2. Add cable lugs to both ends of the cables.
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3. Connect one end of the cable to the output terminal of the selected MCB in the AC distribution cabinet, as shown in
Figure 3-11 and Figure 3-12.
A处
Phase A line (yellow)
Phase B line (green)
A amplification
Phase C line (red)
Bolt
Spring washer
Plain washer
Figure 3-11 Connection of AC input cables (phase line) of rectifier cabinet in AC distribution cabinet
A
Neutral busbar
A amplification
Neutral line (light blue)
Spring washer
Plain washer
Bolt
Figure 3-12 Connection of AC input cables (neutral line) of rectifier cabinet in AC distribution cabinet
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4. Connect the other end of the cable to the AC input terminal of the rectifier cabinet. The AC input cable wiring is
shown in Figure 3-13. The connection of AC input cables in rectifier cabinet is shown in Figure 3-14.
AC input
cable 1
AC input
cable 2
Figure 3-13 AC input cable wiring
A处
Phase A line (yellow)
Phase B line (green)
Phase C line (red)
Neutral line (light blue)
A amplification
Figure 3-14 Connection of AC input cables in rectifier cabinet
3.2.3 Connecting AC Input Cables
Connection requirements
1. The AC in cables are wired from the distribution switch, and connected to the output terminal when the power is to
be switched on. The AC input is fitted with overcurrent, short circuit and lightning protection devices. The capacity of
the distribution switch should be no less than 1.5 ~ 2 times of the load capacity.
2. The yellow, green, red, and light blue AC cables correspond respectively to the AC phase A, B, C and neutral lines.
If the cables are the same color, they should be numbered or identified with insulating tape of different colors at both
cable ends.
3. The AC cables should be run separate from the DC cables, with separation exceeding 150mm.
4. No splice, damage, or scratch on the cables is permitted.
Connection
The AC cables can enter the system from either the cabinet top from wiring rack or the cabinet bottom from cable
trenching.
For AC distribution cabinet:
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After the AC input cables are fed into the cabinet, connect them to the knife-blade switch or air breaker or ATS of the
AC distribution cabinet, as shown in Figure 3-15.
A处
A amplification
AC input neutral line
(light blue cable)
AC input phase C line (red cable)
AC input phase B line (green cable)
AC input phase A line
(yellow cable)
Figure 3-15 AC input cable connection to AC distribution cabinet
3.2.4 Connecting Emergency Lighting Cables (Optional)
Connection of AC distribution cabinet and DC distribution cabinet
The DC emergency lighting contactor is an optional part that locates at the bottom part of the AC distribution cabinet,
as shown in Figure 3-17 (removing the panel). In the event of AC mains failure, the AC monitoring circuit closes the
DC emergency lighting contactor, and then 48V voltage is available at its output terminal.
Choose a 100A load fuse in the DC distribution cabinet to supply DC power for emergency lighting, and then connect
this fuse to the DC contactor by means of cable (which should be sized for the emergency lighting power).
Follow the steps below to connect the emergency lighting cables.
1. Determine the cable length according to the actual wiring route.
2. Add cable lugs to both ends of the cables.
3. Connect one end of the positive cable (cable 2) to the positive busbar of the DC distribution cabinet, and one end
of the negative cable (cable 1) to the load fuse in the DC distribution cabinet, as shown in Figure 3-16.
4. Connect the other end of the positive cable (cable 2) to the positive emergency lighting busbar, and the other end
of the negative cable (cable 1) to the DC contactor, as shown in Figure 3-17.
5. Connect one end of the positive emergency lighting cable to the positive emergency lighting busbar, and the other
end to the positive terminal of the emergency lighting. Connect one end of the negative emergency lighting cable to
the bottom terminal of the emergency lighting MCB, and the other end to the negative terminal of the emergency
lighting, as shown in Figure 3-17.
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A
A amplification
B
B amplification
To input terminal of emergency lighting
contactor in AC distribution cabinet (cable 1)
To emergency lighting busbar (+) in AC
distribution cabinet (cable 2)
Figure 3-16 Connection of emergency lighting cables in DC distribution cabinet
A
To emergency
lighting (-)
To fuse in DC distribution
cabinet (cable 1)
To busbar (+) in DC
distribution cabinet (cable 2)
To emergency
lighting (+)
Emergency lighting contactor
Emergency
lighting busbar (+)
A amplification
Emergency lighting
MCB
Figure 3-17 Connection of emergency lighting cables in AC distribution cabinet
3.2.5 Connecting DC Load Cables
The use of the top cover and the connection of DC load cables are the same with DC distribution cabinet. Taking the
DC distribution cabinet as an example, the cable connection is described below.
The use of the DC distribution cabinet top cover is described below:
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The cable entry holes of the DC distribution cabinet top cover are divided as load cable entry space, communication
cable and dry contact output entry hole, and battery cable entry holes, as shown in Figure 3-18. Users need to use an
electrician knife to cut the protective cover in the cable entry holes to lead in cables.
Load cable entry space
Battery cable entry space
Dry contact signal cable entry space
Figure 3-18 Cable entry hole for top cover
The DC load cables should be connected using the following procedures:
1. Select the cable length and section according to the actual wiring route and load capacity. The positive and
negative cables of the load should be obviously distinguished with different colors. Generally, the positive cable is
black and the negative cable is blue. If the cables are the same color, they should be numbered or identified with
insulating tape of different colors at both cable ends.
2. Add cable lugs to both ends of the cables.
3. Select the DC output branch that matches the load capacity.
Load should be connected to the MCB/fuse of suitable capacity to avoid their failure to function in the case of
overload. The capacity of the MCB/fuse is recommended to be about 1.5 ~ 2 times of the peak value of the load
capacity.
Note
1. The power supply line should not be spliced. It is highly recommended that the load cables, signal lines and customer cables be
run separate to prevent them from affecting each other.
2. Before connecting, pull out the DC output fuse with fuse puller or turn off the MCB.
4. Connect one end of the negative cable to the output terminal of the fuse, and the other end of the positive cable to
the positive copper bar of the DC distribution cabinet, as shown in Figure 3-19 and Figure 3-20 .
A
Bolt
Plain washer
Nut
Spring washer
Plain washer
Negative load cable
A amplification
Figure 3-19 Connecting negative load cable
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A
DC positive busbar
Positive load cable
Spring washer
Plain washer
A amplification
Bolt
Figure 3-20 Connecting positive load cable
3.2.6 Connecting Battery Cables
The connection of battery cables in DC distribution cabinet is described below.
The procedures of connecting battery cables are as follows:
1. Route and number the cables of the 2 batteries and mark their polarities.
2. Connect one end of the negative cable to the output terminal of the battery fuse and one end of the positive cable
to the positive copper bar of the DC distribution cabinet. Add cable lugs to the other end of the positive and negative
cables, bind the cable lugs with insulating tape, and put them beside the battery. Connect the cables to the battery
when the DC distribution is to be initially tested, as shown in Figure 3-21.
Note
The battery negative cables should be connected to the two battery fuses, not the single one.
电池熔断器
电池负极电缆电池负极电缆
Negative
battery cable
Negative
battery cable
Battery fuse
Battery input cable
Bolt
Plain washer
Spring washer
Nut
Battery busbar (-)
Cable connection finished
Figure 3-21 Battery cable connection in DC cabinet
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3.3 Installation Checklist
Aft er installation, security check should be conducted using the checklist shown in Table 3-2.
Table 3-2 Installation checklist
No
Standards and requirements
Pass
Notes
1
Constructed according to the design plan
Yes/No
2 The system cabinets are fixed with expansive screws
Yes/No
3 The cabinets are aligned
Yes/No
4 The installation equipment is clean
Yes/No
5 The installation equipment facilitates wiring
Yes/No
6 Cable wiring is covert
Yes/No
7 Cable is wired with consideration of the wiring of other systems
Yes/No
8 Cable pipe is laid in cable trenching
Yes/No
9 Cable labels are clear and accurate
Yes/No
10
Connector coat peeling is tidy and consistent
Yes/No
11
Type O or U terminal is used for the connection of signal lines
Yes/No
12
Cable lug is reasonably used in cable connection
Yes/No
13
SPD earth, DC power earth and protective earth are connected correctly
Yes/No
14
Leeway is left for the length of connection cable and the cable wiring is covert
Yes/No
15
The cable lugs and cable connectors are well connected
Yes/No
16
The screws in all cable connection points are firmly fixed
Yes/No
17
The original environment is restored which has been destroyed due to the construction
Yes/No
18
Scratch traces by marking pencils are left on the equipment
Yes/No
19
The busbar connection on the rack top for connection of parallel cabinets is up to requirements
Yes/No
20
The cables and cable trenching are level horizontally or vertically.
Yes/No
21
Distances between line cable ties are equal and consistent
Yes/No
22
Leeway is left in cable trenching
Yes/No
23
Separation measures are taken in cross wiring
Yes/No
24
Wiring is far from high temperature equipment and corrosive liquid pipe
Yes/No
25
Wiring on wiring rack is in accordance with the original wiring style
Yes/No
26
DC distribution branches and fuses are properly selected according to the corresponding loads
Yes/No
27
Surplus parts of the cable ties are left uncut
Yes/No
28
The placement of the equipment facilitates cabinet expansion and maintenance
Yes/No
29
The cabinet assembly is well-fixed and quakeproof-handled
Yes/No
30
Paint and galvanized layer on the cabinet are not peeled
Yes/No
31
No crumple or crack at the turning points of bus
Yes/No
32
For rectifier cabinet Rack2000-7, check that 2-route AC input is available.
Yes/No
3.4 Installing Rectifier And Controller
System assembly involves the installation of rectifier and controller.
3.4.1 Installing Rectifier
The installation steps of rectifier are as following:
1. Place up the slide switch of the rectifier, and push the rectifier into the corresponding position in the rectifier cabinet
(do not push it inward completely), as shown in Figure 3-22 (a).
2. Place down the slide switch, and then push the rectifier to the back until the rectifier panel is level with the rectifier
cabinet panel, as shown in Figure 3-22 (b).
3. Tighten the bolts on the handle to fix the rectifier on the rack, as shown in Figure 3-22 (c) and Figure 3-22 (d).
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（a） （b）
（c） （d）
Figure 3-22 Installing rectifier
Note
The rectifier is relatively big and heavy, please hold it carefully when mounting and dismounting it.
3.4.2 Installing Controller
The controller should be installed using the following procedures:
1. Unscrew the screws on the dummy plate, as shown in Figure 3-23.
假面板
螺钉
Screw
Dummy panel
Figure 3-23 Fixing the controller on the slideway
2. Unscrew the captive screw at the top of the hand of the controller, as shown in Figure 3-24.
Captive screw
Handle
Figure 3-24 Controller Panel diagram
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3. Push the controller into the correct position, and then fix the screws on the panel, as shown in Figure 3-25.
监控模块
Controller
Figure 3-25 Fixing the controller in the cabinet
Note
There should be only one controller in the system even there are multiple rectifier cabinets. The controller should be installed on
the right side of the rectifier cabinet. The dummy plate inside the rectifier cabinet without controller should be retained.
3.4.3 The Installation And Wiring Of The Controller IB2 Extension Board
Notice
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.
The Installation of the IB2 extension board
IB2 extension board of the rectifier is optional with the monitor. The installation steps are as follows：
Unscrew the fixing bolts on the cover plate of the IB2 extension board, disassemble the cover plate of the IB2
expansion board. Use four screws IB2 extension board fix the installation components, as shown in Figure 3-26.
IB2扩展板
I2C电缆接口
监控模块
RS232接口
IB2扩展板盖
板固定螺钉
IB2 extension board
I2C cable port
Controller RS232 port
Fixing bolts on the
cover plate of the IB2
extension board
Figure 3-26 IB2 extension board
Once the signal cable is connected, cover the IB2 extension board on the cover, and tighten the captive screws.
Note
The IB2 extension board should be installing in the rectifier cabinet with the controller when there are multiple rectifier cabinets
in the system.
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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 3-27.
SW1
J1
J2
J11
J12
J3J4
J5
J6
J7
J8
1
35
6 4 2
+
+
+
+
+
8
7
56 4 3
数字输入量接口
+
+2+
+
I2C接口
1
35
1
35
1
35
1
35
1
35
1
35
6 4 2 6 4 26 4 26 4 26 4 26 4 2
J9
DO1
DO3
DO5DO7
- - - - - - -
DI1
-
DO8 DO6 DO4
DO2
1
8
7 56
4
3 2
外部设备的告警点，DC 15V～60V
J5 J4 J3
Alarm output dry contact,DC 15V~60V
I2C port
Address DIP
Digital quantity
input port
DI 1
Figure 3-27 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 3-3 for the dry contact terminal definition.
Table 3-3 Dry contact terminal definition
Name of double-layer port
Pin No.
Pin name
Definition
J3
1
DI1-
Digital input 1-
2
DI1+
Digital input 1+
J3
3
DI2-
Digital input 2-
4
DI2+
Digital input 2+
5
DI3-
Digital input 3-
6
DI3+
Digital input 3+
J4
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+
J5
1
DI7-
Digital input 7-
2
DI7+
Digital input 7+
3
DI8-
Digital input 8-
4
DI8+
Digital input 8+
J5
5
NA
/
6
NA
/
J6
1
DO1_NC
NC contact of relay 1
2
DO2_NC
NC contact of relay 2
3
DO1_COM
Common contact of relay 1
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Name of double-layer port
Pin No.
Pin name
Definition
J6
4
DO2_COM
Common contact of relay 2
5
DO1_NO
NO contact of relay 1
6
DO2_NO
NO contact of relay 2
J7
1
DO3_NC
NC contact of relay 3
2
DO4_NC
NC contact of relay 4
J7
3
DO3_COM
Common contact of relay 3
4
DO4_COM
Common contact of relay 4
5
DO3_NO
NO contact of relay 3
6
DO4_NO
NO contact of relay 4
J8
1
DO5_NC
NC contact of relay 5
2
DO6_NC
NC contact of relay 6
3
DO5_COM
Common contact of relay 5
4
DO6_COM
Common contact of relay 6
5
DO5_NO
NO contact of relay 5
6
DO6_NO
NO contact of relay 6
J9
1
DO7_NC
NC contact of relay 7
2
DO8_NC
NC contact of relay 8
3
DO7_COM
Common contact of relay 7
4
DO8_COM
Common contact of relay 8
5
DO7_NO
NO contact of relay 7
6
DO8_NO
NO contact of relay 8
Connect alarm relay output
Connected the alarm output cables to the terminals DO1~8 (silkscreen) on IB2 board.
Note
Alarm relay contact capacity: Max. 1A@60Vdc and 60W; Min. 10uA@10Vdc.
Connect digital quantity input
The digital input uses 15Vdc~60Vdc active signal, which can configure the digital input functions through the
controller and WEB interface.
According to Figure 3-27 and the silkscreen, connect the signal cables to the corresponding terminals DI1~8 on IB2
board. The connection in Figure 3-27 illustrates the connection of input terminal DI1.
Connect I2C cable
Connect the I2C cable plug reserved on the cabinet to the J2 port on IB2 board.
3.5 Connecting Communication Cables And Auxiliary Power Cable
3.5.1 Connecting Rectifier Cabinet Communication Cable
The steps of connecting CAN communication cables among multi rectifier cabinets are as follows:
1) Remove the matched resistance located on the back of rectifier cabinet, as shown in Figure 3-28.
匹配电阻
CAN通信电缆
Matched resistanceCAN communication cable
Figure 3-28 Matched resistance
2) Connect the CAN communication cables between the rectifier cabinets.
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2. Depending on your controller installation location in the Figure 3-29, Figure 3-30 and Figure 3-31, connect CAN
communication cable between the rectifiers and matching resistance. And install the controller CAN communication
and connection cables according to Figure 3-29. (The controller needs to be placed in the rightmost rectifiers)
When the controller mounted to the rectifier on the right, connect the CAN communication cable between the rectifier
cabinets as shown in Figure 3-29.
CAN CAN
Matching
resistance
Controller
Rectifier
cabinet 3
Matching resistance
Rectifier
cabinet 2
Rectifier
cabinet 1
When there
are only 2
rectifier
cabinets,
attach the
matching
resistance
here
Figure 3-29 Rectifier cabinet CAN communication cable connection diagram 1 (rear view)
When the controller mounted to the rectifier in the middle, connect the CAN communication cable between the
rectifier cabinets as shown in Figure 3-30.
CAN
CAN
Rectifier
cabinet 3
Rectifier
cabinet 2
Rectifier
cabinet 1
Matching resistance
Controller
Matching resistance
Figure 3-30 Rectifier cabinet CAN communication cable connection diagram 2 (rear view)
When the controller mounted to the rectifier on the left, connect the CAN communication cable between the rectifier
cabinets as shown in Figure 3-31.
CAN CAN
监控
模块
When there
are only 2
rectifier
cabinets,
attach the
matching
resistance
here
Rectifier
cabinet 3
Rectifier
cabinet 2
Rectifier
cabinet 1
Matching resistance
Figure 3-31 Rectifier cabinet CAN communication cable connection diagram 3 (rear view)
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3．If there are more than three rectifier cabinets, please increase the number of the CAN parallel configuration
communications cable, and connect as shown in Figure 3-29, Figure 3-30 and Figure 3-31, according to the controller
of the location. CAN cable should use total style wiring, which makes the controller is always located at the beginning
and the end of circuit. Retain the match resistance in the controller, and access a second match resistance on the
other end of the circuit.
Note
As the CAN parallel connection should be operated at the rear of the cabinet, therefore the cabinet arrangement shown in Figure
3-29, Figure 3-30 and Figure 3-31 is from the front view of rear cabinet.
3.5.2 Connecting Communication Cable Of Distribution Cabinet
Connecting RS485 communication cable
The distribution cabinets communicate with controller by RS485 communication cables whose connector is DB9.
In the three-cabinet power system, RS485 communication cables are used to connect PD380/400AFH &
PD380/630AFH AC distribution cabinet to DC distribution cabinet, and DC distribution cabinet to controller. The
connection relation is shown in Figure 3-32 and Figure 3-33.
The communication cables between the distribution cabinets and the controller are connected by means of DB9
connectors with pin 1 connecting to pin 1 and pin 2 connecting to pin 2.
For PD380/630AFA AC distribution cabinet, reserved the 3 PIN plug-in connectors in the RS485 cables on the rear
top of the cabinet, though the 3 PIN plug-in connectors connected RS485 cables of the PD380/630AFA AC
distribution cabinet.
In the RS485 port of the M831D controller, connect the RS485 communication cables from distribution cabinet
through 3 PIN plug-in connectors.
A处
A
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A amplication
Monitoring board
To monitoring module
in rectifier rack
(To monitoring ports of
other distribution cabinets)
Figure 3-32 Connection of communication cable in AC distribution cabinet
A
A amplication
Monitoring board
To monitoring module
in rectifier rack
(To monitoring ports of
other distribution cabinets)
Figure 3-33 Connection of communication cable in DC distribution cabinet
3. When the system has multiple AC cabinets or DC cabinets, connect the RS485 cables between cabinets according
to Figure 3-34. If the cabinet number is different from Figure 3-34, increase or decrease the parallel cables between
cabinets according to Figure 3-34. The connection of RS485 cable should use bus type wiring, and the controller is
always located at the first end or the end of the circuit.
Connecting 48V DC auxiliary power source cable of monitoring board in AC cabinet
Connect one end of the power cable in the accessories to the terminal with “AC cabinet -48V” label on the AC cabinet.
And connect the other end to the terminal with “AC cabinet -48V” label on the DC cabinet. Pay attention to the two
poles of power and the cable color which must be corresponded (black to black, brown to brown). Each AC cabinet
corresponds to a DC cabinet, as shown in Figure 3-34.
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RS485 communication cable
AC cabinet 1
Rectifier cabinet
1
DC cabinet
1
AC cabinet 48V power cable
0V
-48V
0V
-48V
0V
-48V
A2V4FA1
A6V6FU11
Monitor
RS485 communication cable
AC cabinet 48V power cable
RS485 communication cable
AC cabinet 2
Rectifier cabinet
2
Rectifier cabinet
3
DC cabinet
2
DC cabinet
3
Sampling transfer
board of AC
Monitoring
board
A2V6FX1
A2V4FA1
Sampling transfer
board of AC
Signal transfer
board
A6V6FU11
A2V6FX1
Monitoring
board
Signal transfer
board
A6V6FU11
A2V6FX1
Monitoring
board
Signal transfer
board
A6V6FU11
A2V6FX1
Monitoring
board
Signal transfer
board
A6V6FU11
A2V6FX1
Monitoring
board
Signal transfer
board
Configuring PD380/400AFH & PD380/400AFH AC distribution cabinet
HDU1U11
Monitoring
board
A1V8FA1
电流采样板
HDU1U11
Monitoring
board
A1V8FA1
电流采样板
AC cabinet 1
AC cabinet 2
Rectifier
cabinet 1
Rectifier
cabinet 2
Rectifier
cabinet 3
DC cabinet 1 DC cabinet 2
DC cabinet 3
Monitor
0V
-48V
0V
-48V
0V
-48V
A6V6FU11
Monitoring
board
A2V6FX1
Signal transfer
board
RS485communication cable
RS485communication cable
AC cabinet 48V power cable
AC cabinet 48V power cable
RS485communication cable
A6V6FU11
Monitoring
board
A6V6FU11
Monitoring
board
A2V6FX1
Signal transfer
board
A2V6FX1
Signal transfer
board
Current sampling
board
Current sampling
board
Configuring PD380/630AFA AC distribution cabinet
Figure 3-34 Connection diagram of power system communication cable and 48V DC auxiliary power source cable(front view)
3.6 Installing Options
Installing temperature sensor
AD592BN temperature sensor is an option. And the wiring steps are shown as follows:
1. Make cable connection to the temperature sensor. Pay attention to the cable definition and color.
2. Connect P101-3 socket which is connected to 3-core cable of the temperature sensor to J4, J5 and J6 sockets on
the monitoring board of DC distribution cabinet (model: A6V6FU11), as shown in Figure 3-35. J4 has temperature
compensation function. J5 and J6 perform temperature display function but not temperature compensation function.
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JP2 JP1
1J1
1J3
1J2
J0
J1
J2
J
3
J4
J5
J6
J8
J9
J10
J7
+12
Signal output
PGND
1
2
3
+12
PGND
1
2
3
+12
PGND
1
2
3
J11
J12
J13
1
8
+12
PGND
P101-3 socket
A6V6FU11 board
Signal output
Signal output
Signal output
Figure 3-35 Connection of temperature sensor
3. AD592BN is current type temperature sensor. Ensure that the sixth position (temperature sensor selection position)
of the DIP switch on the DC distribution cabinet has been set “OFF”. For the setup method, refer to 4.3.1 Setting
DIP Switch.
4. The temperature probe should be put in the battery room where it can best incarnate the battery temperature.
When fixing it, do not connect it to any other exothermic equipment or metal conductor.
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Chapter 4 Testing
This chapter mainly introduces the notes on testing, system power-on, parameter setting, inquiry of alarm and
operation information. For detailed using of M831D controller, please refer to M831D Controller User Manual.
4.1 Notes On Testing
Before putting the system into operation, testing must be conducted strictly following the testing steps. The following
safety precautions must be observed in testing
The system test requires extensive technical knowledge; therefore the test engineers must have had relevant
technical training. Be sure the test is conducted in accordance with the instructions in this manual.
The system test involves working with live wires, therefore, during the test, stand on dry insulated objects, use
insulated tools, and do not wear watch, necklace or any other metal objects.
Avoid touching two live objects with different potentials.
Before the switch-on operation, check whether the conditions of appropriate parts are normal.
During operation, a warning sign “No switch-on, in operation” should be posted on the equipment to prevent
inadvertent operation.
Close observation is required during test. The system should be turned off immediately when any malfunction
occurs. The cause of the malfunction must be found out before resuming the operation.
4.2 Power-on
Inspection before power-on
The inspection steps as below:
1. Check that the earth cables of the cabinets are connected reliably and that the wiring and screws in the cabinet are
fastened.
2. Open all the MCBs in the AC distribution cabinet, and then feed the mains supply to the system, measure the
phase voltage of the three phases with a multimeter to confirm the mains condition. If everything is normal, proceed
with the next step.
3. Turn on the knife-blade switch or input air breaker of the AC distribution cabinet, the running indicator of the AC
distribution cabinet should illuminate.
4. Close the input MCB of the rectifier cabinet in the AC distribution cabinet, the power indicator of the rectifier cabinet
should illuminate.
Preliminary test of rectifier
After introducing the AC mains, turn on one certain MCB of rectifier in the upper part of the rectifier cabinet. The
power indicator of the corresponding rectifier should be on and the fan begins to run. After a while, the controller will
display 53.5V rectifier output voltage and then turn off the MCB of this rectifier. Check the other rectifiers one by one
through turning on and off the rectifier MCBs and see if they can work normally.
Preliminary test of controller
After the controller is powered on, it will do self test without needing any operation. After about 50s, the M831D
should start and display the following screen.
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The first screen of M831D is the language selection screen. You can press ▲ or ▼ to select English or other local
language. Then press “ENT” to enter default interface. It will enter fault interface directly after 30s without any
operation, as the following figure.
In the default main screen:
Press ▲+ ▼to select different menu;
Press the ENT key to enter the selected menu.
Icon
Name
Description
Alarm
View the active alarm and history alarm
Setting
Enter the setting menu
Power Supply
View power supply information
Module
View rectifier and inverter module information
DC
View DC equipment information
Battery
View battery information
Preliminary test of DC distribution and battery connection
Please connect the battery to the system according to the following steps.
1. Measure the battery voltage with multimeter and keep a record.
2. Turn on one rectifier, and set the rectifier voltage to a value with less than 0.5 V difference from the battery voltage
through the controller.
3. Use insulated tools, and connects the battery cables to the batteries according to the instructions of the battery
manufacturer. The other end of the battery cables have already been connected to the battery fuse as required in
3.2.6 Connecting Battery Cables.
Danger
Danger
Before access the battery, check with a multimeter that the battery polarities are correct. When connecting the battery, careful
attention is required to prevent short circuit of the positive and negative poles of the battery. If two batteries are connected at one
time, battery mutual charging due to unequal terminal voltages of the two batteries should be avoided.
4. Set the power supply voltage to the required battery float voltage through the controller (in this case, the rectifier
should not be in current limiting state).
4.3 Setting Basic Parameters
4.3.1 Setting DIP Switch
Setting dIP switches of PD380/400AFH and PD380/630AFH AC distribution cabinet
Bits 1 to 5 are used to set the addresses of the AC distribution cabinets. Position ‘ON’ represents ‘0’, and ‘OFF’
represents ‘1’. The setting explanation of bits 1 to 5 is given in Figure 4-1 to Table 4-1.
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1
2 3 4
5
6
7
8
OFF
ON
Figure 4-1 DIP switch
Table 4-1 Setting list of DIP switch for AC distribution cabinet address
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Corresponding address in the controller
0 0 0 0 0
64
1 0 0 0 0
65
0 1 0 0 0
66
1 1 0 0 0
67
0 0 1 0 0
68
1 0 1 0 0
69
0 1 1 0 0
70
1 1 1 0 0
71
Note
Address of the AC distribution cabinet default setting from factory is 64, if there are multiple AC screens, set the cabinets address
to 64, 65,…,71.
The setting explanation of bits 6 to 8 is given in Table 4-2.
Table 4-2 Setting list of DIP switch
Bit
Definition
Default
Setting explanation
6
Temperature sensor type
ON
ON: voltage type temperature sensor; OFF: current type temperature sensor;
AC distribution cabinet can ignore this item
7
Buad rate
OFF
ON: 9600bps; OFF: 19200bps; AC distribution cabinet if OFF by default
8
Reserved
ON
ON
Setting DIP switches of PD380/630AFA AC distribution cabinet
The setting dip switch of AC distribution cabinet is shown in Figure 4-2.
1 2 3 4 5 6 7 8
RS485 address
ON
Reserved Reserved
1 2 3 4 5 6 7 8
Figure 4-2 DIP switch
Position ‘ON’ represents ‘1’, and ‘OFF’ represents ‘0’. See Table 4-3 for details.
Table 4-3 Setting DIP switches of DC distribution cabinet
Bit
Definition
Setting explanation
1 ~ 4
Communication
address
Bits 1 is low, Bits 4 is high
AC distribution cabinet address: 00000~11100 (controller address: 64 ~ 71):
1
2 3
4 1
2
3 4
5
Reserved
Set it to ‘OFF’ during test
6
Reserved
Set it to ‘OFF’ during test
7
Reserved
Set it to ‘OFF’ during test
8
Reserved
Set it to ‘OFF’ during test
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Note
The defaults parameter in controller of the system is: ‘LDU mode: NO’, not to change it.
Setting DIP switches of DC distribution cabinet
Distribution cabinet address, communication speed and temperature sensor selection select the desired set by dip
switches on the monitor panel. DIP switch is shown in Figure 4-1.
Bits 1 to 5 are used to set the addresses of the AC distribution cabinets. Position ‘ON’ represents ‘0’, and ‘OFF’
represents ‘1’. The setting explanation of bits 1 to 5 is given in Table 4-4.
Table 4-4 Setting DIP switches of DC distribution cabinet
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Corresponding address in the controller
0 0 0 1 0
72
1 0 0 1 0
73
0 1 0 1 0
74
1 1 0 1 0
75
0 0 1 1 0
76
1 0 1 1 0
77
0 1 1 1 0
78
1 1 1 1 0
79
0 0 0 1 1
88
1 0 0 1 1
89
0 1 0 1 1
90
1 1 0 1 1
91
Note
Address of the AC distribution cabinet default setting from factory is 72, if there are multiple AC screens, set the cabinets address
to 72, 73,…,91.
The setting explanation of bits 6 to 8 is given in Table 4-2.
4.3.2 Setting Basic Parameters For Controller
To put the system into service, system setting must be done through the controller, battery group number, battery
nominal capacity, charge current limit and other function requirements according to the actual system configuration.
Otherwise, the system information display and output control cannot function normally.
1. At the default LCD screen (if stay in other screen, press ESC will exit to the default screen) of the controller in AC
distribution cabinet, press ESC to enter the product information screen, as shown in Figure 4-3, check whether the
‘Address’ is within the range of Table 4-1. If the address is out of the range in Table 4-1 or there are two or above AC
screens set to the same address, then reset the address according to 4.3.1 Setting DIP Switch.
Model: LargeDU
Software version:
V1.08
Address: 64
Figure 4-3 AC screen address
2. At the default LCD screen of DC distribution cabinet, press ESC to enter the product information screen (see
Figure 4-4). Check whether the ‘Address’ is within the range of Table 4-4. If the address is out of the range in Table
4-4 or there are two or above AC screens set to the same address, then reset the address according to 4.3.1 Setting
DIP Switch.
Model: LargeDU
Software version:
V1.08
Address: 72
Figure 4-4 DC screen address
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3. At the controller MAINMENU screen in rectifier cabinet, press or to move the cursor to the setting icon
.
Click the setting icon and input user name (‘admin’) and password (‘1’) to enter the setting screen.
4. Enter ‘AC Settings’-->’AC Distrib 1’…… ’AC Distrib n’, check the PD380/400AFH&PD380/630AFH AC coefficients
of transformer, the corresponding coefficient of PD380/630AFH would be 160 (800/5), the corresponding coefficient
of PD380/400AFH would be 100 (that is 500/5). If any inconsistencies exist, set the parameters as above.
5. Back to the setting screen, enter ‘DC Settings’-->’DC Distrib 1’…… ’DC Distrib n’, check whether the ‘Hall
Coefficient’ and ‘Load Measure Ty’ are consistent with Table 4-5. If any inconsistencies exist, reset the parameters
according to Table 4-5.
Over Voltage:
58.5V
45.0V
Under Voltage:
Num of Battery:
2
Temp Number:
0
Branch CurrCoeff:
Curr Output Num:
Load Measure Ty:
Hall
Hall Coefficient:
32
3000
500
DC DistGroup
DC Distrib1
Figure 4-5 DC Distrib 1 screen
Table 4-5 Setting DC hall sensor
Parameter name
Default setting
Description
Hall Coefficient
3000
Used for PD48/2500DF
1500
Used for PD48/1600DF
Load Measure Ty
Hall
Set to Hall by default
6. Back to ‘DC Settings’-->’DC Distrib 1’…… ’DC Distrib n’, set the ‘Num of Battery’ of each DC distribution screen
according to actual connected battery strings.
Over Voltage:
58.5V
45.0V
Under Voltage:
Num of Battery:
2
Temp Number:
0
Branch CurrCoeff:
500
DC DistGroup
DC Distrib1
Figure 4-6 Setting number of battery
7. Set battery parameters as follows:
Back to ‘Settings’ screen, enter ‘Batt Settings’-->’Charge’, set the actual connected battery string capacity, then click
‘Reset Batt Cap’, select ‘Yes’ and press ENT to confirm. Back to the ‘Batt Settings’ screen, enter the ‘LargeDU’ screen
to set the battery current sampling coefficient. (The battery string index is related with the connected DC cabinet
address and battery string number, if the DIP of DC Distrib 1 is set to 72, and the the DIP of DC Distrib 2 is set to 73,
and the battery string number is set to 2, then the battery current coefficient of battery string1 and battery string 2 is
the shunt coefficient of two battery ports in DC Distrib 1, and the current coefficient of battery string 3 and battery
string 4 is the shunt coefficient of two battery ports in DC Distrib 2.)
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Charge
Yes
Auto EQ
0.30C10
Over Curr Lmt:
0.10C10
Batt Curr Limit:
56.4V
EQ Voltage:
53.5V
Float Voltage:
Figure 4-7 Setting battery charge parameters
Charge
Battery Test
Yes
Constant Curr Test:
Temp Comp
LargeDU
Large DUBatt1
2000
2000
Large DUBatt2
70%
EndTestCapacity:
180min
End Test Time:
No
TempComp Sensor:
None
TempComp Center:
25deg.C
72mV/deg.C
Temp Comp Coeff:
45.2V
End Test Voltage:
Auto EQ
0.30C10
Over Curr Lmt:
0.10C10
Batt Curr Limit:
56.4V
EQ Voltage:
53.5V
Float Voltage:
Figure 4-8 Battery current coefficient
Back to ‘Batt Settings’ screen, enter ‘Temp Comp’ screen, set the ‘Temp Comp Coeff’ according to battery factory
requirement. The default value is 72mV/°C (If no temperature sensor is configured, ignore this item), and set the
‘TempComp Sensor’ to ‘Ldu1 Temp1’, as shown in Figure 4-9. (If no temperature sensor is configured or the
temperature compensation function needs to be canceled, then set the ‘TempComp Sensor’ to ‘None’). Meanwhile,
set ‘DC Settings’’DC Distrib 1’Temp Number’ to 1 ~ 3 ( if no temperature sensor is configured or the temperature
compensation function needs to be canceled, then set the ‘Temp Number’ to ‘0’), as shown in Figure 4-10.
Charge
Battery Test
Yes
Constant Curr Test:
Temp Comp
70%
EndTestCapacity:
180min
End Test Time:
No
TempComp Sensor:
None
TempComp Center:
25deg.C
72mV/deg.C
Temp Comp Coeff:
45.2V
End Test Voltage:
Auto EQ
0.30C10
Over Curr Lmt:
0.10C10
Batt Curr Limit:
56.4V
EQ Voltage:
53.5V
Float Voltage:
Figure 4-9 Setting Temp Comp parameter
Over Voltage:
58.5V
45.0V
Under Voltage:
Num of Battery:
2
Temp Number:
0
Branch CurrCoeff:
500
DC DistGroup
DC Distrib1
Figure 4-10 Setting Temp Number
Note
‘DC Distrib 1’ corresponds to the DC distribution screen that with the lowest address.
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Back to ‘Batt Settings’ screen, and enter the ‘Charge’ screen, set the ‘Float Voltage’ (default value: 53.5V) and ‘EQ
Voltage’ (default value: 56.4V) according to the recommended value of the battery supplier, as shown in Figure 4-11.
For free EQ charge battery, the EQ voltage can be set 0.1V higher than the float voltage. Set the battery current limit
according to Figure 4-11.
Charge
Yes
Auto EQ
0.30C10
Over Curr Lmt:
0.10C10
Batt Curr Limit:
56.4V
EQ Voltage:
53.5V
Float Voltage:
Figure 4-11 Setting float/EQ voltage
4.4 Checking Alarm And Operation Status
4.4.1 Testing Controller
The controller can be tested after the parameter setting is completed based on the actual system configuration and
battery management requirements.
Communication test
When the system is in normal operation, disconnecting the communication cable of any unit (AC distribution cabinet,
DC distribution cabinet and controller) will interrupt the communication between the controller and this unit as well as
other units in serial connection with this unit, and cause the controller to generate communication failure alarm. Real
time data will be displayed in contrast with the background in LCD. By reconnecting the communication cable, the
system will recover automatically.
Boost charge and float charge changeover
Click the setting icon, input user name (‘admin’) and password (‘1’) to enter the ‘Settings’ ‘Maintenance’ screen, set
the ‘Auto/Man State’ to ‘Manual’, as shown in Figure 4-12.
Maintenance
Auto/Man State:
Auto
EQ/FLT Control:
Float Charge
BattTestControl:
Stop
Rect Curr Limit:
121%
Figure 4-12 Setting Auto/Man State
When the system is in float charge state, click the setting icon, input user name (‘admin’) and password (‘1’) to enter
the ‘Settings’ ‘Maintenance’ screen, change the ‘EQ/FLT Control’ to ‘EQ charge’, as shown in Figure 4-12. The
system will enter into EQ charge state, and the rectifiers will output EQ charge voltage. Change it back to ‘Float
charge’ and the system will return to float charge state.
Rectifier adjustment
1. Refer to 5.2 Setting The Position Number Of The Rectifier Manually to enter the rectifier setting interface. Test the
switching-on/off of the rectifier, the rectifier switching-on/off should be under control and normal.
2. Set the system float/EQ voltage in the LCD of the controller according to 4.3.2 Setting Basic Parameters For
Controller, the rectifier voltage should be normally adjustable.
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3. Under the condition that all the rectifier outputs are normal, observe and record the rectifier current-sharing
characteristics at different total loads.
4.4.2 Testing DC Distribution
Connect some loads to the system and test the battery protection characteristics using the following steps.
1. At the MAINMENU screen of the controller in rectifier cabinet, press and to move the cursor on the setting
icon , click this icon to enter the setting screen.
2. Input user name (‘admin’) and password (‘1’) to enter ‘DC Settings’’DC DistGroup’, change the ‘Under Voltage’ to
52V, as shown in Figure 4-13. Then reduce the load, and open the AC input MCB of the rectifier, the battery will
discharge to the load, and the output voltage will decrease. When the battery output voltage drops below the
undervoltage alarm point, the controller will generate battery undervoltage alarm.
Over Voltage:
58.5V
45.0V
Under Voltage:
DC DistGroup
Figure 4-13 Setting undervoltage alarm point
3. Close the rectifier AC input MCB. When the entire rectifiers begin to work normally, the rectifier startup process can
be observed. The time for rectifier output current reaching a steady state varies depending on the battery capacity,
rectifier quantity and load capacity. By that time, the mains failure alarm will disappear automatically. With the output
voltage rising to exceed the undervoltage alarm recovery point, the battery undervoltage alarm will disappear
automatically.
4. After finishing the test, restore the system under-voltage alarm point to the original value.
5. Entering ‘DC Settings’’DC DistGroup’ screen to lower the system overvoltage alarm point (for example, 52V), as
shown in Figure 4-14. When the output voltage of the module exceeds the overvoltage alarm point, the controller
should generate audio and visual output overvoltage alarms. Restore the system overvoltage alarm point to its
original value and the output overvoltage alarm should automatically disappear.
Over Voltage:
58.5V
45.0V
Under Voltage:
DC DistGroup
Figure 4-14 Setting overvoltage alarm point
6. Connect a small load between the output terminal of a fuse link and the positive busbar (10kΩ resistance
recommend), and pull out this fuse link, the controller should display ‘Output ** disconnect’ alarm. Plug in the fuse link
again, and the system will resume normal.
7. Click the setting icon to enter the setting screen, input user name (‘admin’) and password (‘1’) to enter the
‘Settings’ ‘Maintenance’ screen, set the ‘Auto/Man State’ to ‘Auto’, as shown in Figure 4-15.
Maintenance
Auto/Man State:
Auto
EQ/FLT Control:
Float Charge
BattTestControl:
Stop
Rect Curr Limit:
121%
Figure 4-15 Setting Auto/Man State
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By now, the system test is completed and the power supply system is in normal operation.
4.4.3 Access Controller Through Web
Login procedures are as follows:
1. To log in the controller, double-click the icon of IE to run the software, click the menus of Tools -> Internet Options
and then click the Connections button to pop up the interface shown in Figure 4-16.
Figure 4-16 LAN setting (Step 1)
2. In the interface shown in Figure 4-16, click the LAN Settings button to pop up the interface shown in Figure 4-17.
Figure 4-17 LAN setting (Step 2)
In the above interface, uncheck the proxy option and click OK to finish the LAN setting.
Note
The user only needs to do the above settings when the controller is connected to an intranet and the user has set that the access to
the intranet needs to be made through proxy. If the controller is connected to Internet and the user computer is connected to the
intranet, the user cannot disable the proxy, otherwise you will have no access to the controller.
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3. Select Internet Options from the Tools menu. The “Internet Options” window opens. In the “Internet Options”
window, select the General tab, as shown in Figure 4-18.
Figure 4-18 Internet options
4. Click on the Settings button. The following window opens, as shown in Figure 4-19. In the Settings window,
choose “Every time I visit the webpage” and click OK.
Figure 4-19 Temporary internet files and history settings
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5. In the “Internet Options” window, select the Security tab, as shown in Figure 4-20.
Figure 4-20 Security tab
6. Click on Trusted sites. With “Trusted sites” selected, click “Sites”. The following window opens, as shown in
Figure 4-21. Uncheck the “Require server verification (https:) for all sites in the zone:” box if https is not being used.
Figure 4-21 Trusted sites
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7. In the Trusted sites window, type or copy the NCU URL in the “Add this website to the zone:” box, as shown in
Figure 4-22.
Figure 4-22 Adding trusted sites (1)
8. Click Add. The NCU URL is listed in the Websites: box. Click Close, as shown in Figure 4-23.
Figure 4-23 Adding trusted sites (2)
9. In your browser, enter http:// and the controller’s IP address and press ENTER. If your site requires secure HTTP
and you were furnished with an M831D configuration with secure HTTP, enter https:// and the controller’s IP address
and press ENTER. The following Web Interface Login window opens, as shown in Figure 4-24 . Enter a valid User
Name and Password, and then click LOGIN.
By default, the “User Name” is "admin" and the “Password” is “1”.
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User can view the IP address: Main menu——>Settings (password:1)——>Communication Parameter, and then
press the ENT key.
Figure 4-24 Login the controller
10. In the Web Interface, after entering a valid User Name and Password and clicking LOGIN, the "Homepage"
window opens, as shown in Figure 4-25.
Figure 4-25 M831D Homepage
11. Check whether all parameters in Figure 4-25 are correct.
12. Control the boost/float and rectifier switch, check whether the control function is correct.
13. Simulate fault alarms on the power system, and then check whether corresponding alarms are displayed in the
homepage.
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Chapter 5 Operation
This chapter introduces the operation of the power distribution LCD, procedures of adding loads and rectifiers.
5.1 Power Distribution LCD Operation
LCD Operation Of PD380/400AFH and PD380/630AFH AC distribution cabinet and DC distribution cabinet
The power distribution LCDs can display AC/DC power distribution data of communication power supply system.
They are mounted on the front door of AC and DC distribution cabinet.
Six keys are positioned below the LCD.
▲, ▼: Scroll the screen.
◄, ►: Adjust the display brightness.
ESC: Exit language switch interface without changing the language.
ENT: confirm the language switch.
There are 20 levels of display brightness for adjustment and the displayed contents vary depending upon the different
distribution forms.
If left idle for about 8mins, the backlight will be off and the display will switch to the original screen. When you set
parameters for the power distribution cabinet through the controller, the display will switch to the original screen if the
currently displayed parameters are changed.
The LCDs of AC distribution cabinet are shown below:
Screen 1:
ESC to Quit
To Chinese
ENT to Run
Screen 2:
AC Distri 1
Stat: Run Normal
Ctrl Mode: Manual
Light Stat: On
The possible state of AC Distri 1: run/backup, normal/power failure/imbalance
The possible indications of Ctrl Mode: manual/automatic
The possible indications of Light Stat: off/on
Screen 3:
AC Distri 1
Ua: 380V
Ub: 402V Over
Uc: 180V Under
or
AC Distri 1
Uab: 380V
Ubc: 402V Over
Uca: 180V Under
or
AC Distri 1
Volt: 90V Under
The possible indications of AC 1 voltage: 3-phase line voltage, 3-phase phase voltage or 1-phase phase voltage
The possible indications of AC voltage corresponding state: over/under/phase loss
When the LCD displays 3-phase or 1-phase phase voltage, the AC voltage alarm corresponds to the displayed phase
voltage. When the LCD displays 3-phase line voltage, if the Ua voltage exists phase loss there will display phase loss
at the back of Uab voltage; if the Ub voltage exists phase loss there will display phase loss at the back of Ubc voltage;
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if the Uc voltage exists phase loss there will display phase loss at the back of Uca voltage. The overvoltage alarm at
this time takes place at line voltage.
Screen 4 to screen 6:
The AC 2 and AC 3 information of the screen 4 to screen 6 are similar with AC 1 information.
Screen 7:
AC Distri
A Curt: 35.3A
A Curt: 12.8A
A Curt: 9.9A
or
AC Distri
Curt: 12.5A
Indications of AC current depend on the current measurement methods set through the controller: 3-phase
current/1-phase current/no display.
Screen 8:
AC Distri
AC Freq: 50.1Hz
Freq Stat: Normal
Arrester Stat: Normal
Possible indications of operation Freq: normal/over Freq/under Freq
Possible indications of SPD state: normal/abnormal
Screen 9 and screen 10:
AC Distri MCCB
In: On Out: On
Output Stat
01: On 02: On
AC Distri MCCB
03 On 04: On
06: On 07: On
05: On 06: On
Indications of AC input MCCB/output MCCB state: on/off
The AC output state will be displayed according to the AC output MCCB number set in the controller (≤8 routes) and
their actual state.
Screen 11:
DC Distri
Bus Volt: 53.5V
Bus Stat: Normal
Load Curt: 2390.6A
Possible indications of busbar voltage state: normal/overvoltage/undervoltage.
Note
To facilitate the replacement and maintenance, the total load current sampling components of DC distribution cabinet use open
type Hall sensors with measurement accuracy of 2%. Taking into account the general error of the measuring circuit, the displayed
total load current on the controller LCD of DC distribution cabinet may have certain difference (0 ~ 60A) with the displayed
value on the controller in rectifier cabinet.
Screen 12:
DC Distri Batt1
53.5V Normal
Batt1 Fuse: On
30A Normal
Indications of batteries are depended on the battery number set in the controller: two groups/one group or display any
information about battery.
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Possible indications of battery voltage state: overvoltage/undervoltage/normal
Possible indications of battery current state: overcurrent/normal
Possible indications of battery fuse state: on/off
Screen 13 to screen 15:
The battery 2 and battery 4 information of the screen 13 to screen 15 are similar with battery 1 information.
Screen 16 to screen 26:
DC Distri Fuse
01 On 02: On
05: On 06: On
03: On 04: On
The branch fuse state will be displayed according to the DC fuse number in the controller (≤ 64 routes) and their
actual state.
Screen 27 to screen 29:
DC Distri
BranchCur 1: 25A
BranchCur 2: 25A
BranchCur 3: 25A
The branch battery current will be displayed according to the current branch number set in the controller (≤ 6 routes)
and their actual value. When the three branches’ currents in one screen are not set, this screen will not be displayed.
Screen 30:
DC Distri
Temp 1: 25℃
Temp 2: 25℃
Temp 3: 25℃
Indications of temperature will be displayed according to the temperature circuit number set in the controller (≤ 3
routes) and their actual value.
When the number is 0, this screen will not be displayed. While setting the temperature measurement and
disconnecting temperature sensor or the sensor is damaged, it will display 27°C .
LCD Operation Of PD380/800AFA AC Distribution Cabinet
First, you need to ensure that monitoring system is ‘ATS communication system’. Set the system type to ‘ATS
communication system’ in the main menu: Parameter settings –system parameter—system style, Change the style to
the ’ATS AC system’.
System information screen
When the controller is powered on, the language selection interface will appear, and the default language is Chinese.
If you need English interface, press ▲ or ▼ for language selection and then press the ENT key to confirm. Then the
inside of the controller is initialized. After the initialization, the first system information page will appear in Figure 5-1.
2009-01-03
System：Normal
SPD State：Normal
Light State：Off
Figure 5-1 First system information screen
1. The first row displays the date and time alternately.
2. At the main menu screen, press the ESC key to return to the first system information screen.
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3. If no operation is conducted on the controller keypad for 8 minutes, the LCD screen will automatically return to the
first system information screen. The time of that return will be recorded automatically, and can be queried through the
host.
4. At the system information screen, press the ESC key to display monitoring information screen. As shown in Figure
5-2.
Model：HDU-ATS
Comm Addr：190
SW Ver：1.09
64
Figure 5-2 Monitoring information screen
5. At the system information screen, press and hold the ESC and ENT keys simultaneously for several seconds, the
controller will be reset, and then the system will restart.
Password confirmation screen
During the operation, some monitoring units will prompt you to input password, as shown in Figure 5-3.
Only the correct password allows you to enter the screen you need to operate.
Login：
Password：
Figure 5-3 Password confirmation screen
1. When inputting the password, use the ENT key to get into editing state, use ▲ or ▼ to modify numbers, and use
◄ or ► to move the cursor. After the input, press ENT to confirm.
2. If the password is correct, the next screen will appear. Otherwise, the system will prompt ‘Password incorrect’.
3. During the operation, press the ESC key will return to the main menu screen.
The monitoring unit has three password levels: user level password (default: 1), engineer level password (default: 2)
and administrator level password (default: 640275). See Table 5-1.
Table 5-1 Password levels and operation authorities
Password level
Operation authority
Default password
User level
The authority to change general parameters
1
Engineer level
All the user’s authorities, plus ‘resetting system, resetting password, changing
system work mode’ operation authorities
2
Administrator
level
All the engineer’s authorities, plus ‘changing password, controlling alarm volume,
browsering parameters set through host’ operation authorities
640275
Once you input the correct password, you never need to input the password again during the operation. If the interval
for adjacent operation is more than four minutes, the system will prompt you to input the password again. If you want
to operate senior settings, you need to input higher level password after four minutes (note that within this four
minutes, you cannot do any key operation). If the password of the higher level and lower level is the same, then
controller will display senior setting menu.
Main menu screen
The main menu is the highest-level menu of the monitoring unit. At the sub-menus of this screen, you can query the
alarms information, distribution, insulation, and parameter settings of the system. There are two screens, as shown in
Figure 5-4.
MAIN MENU
Active Alarm
Branch Info
History Alarm
MAIN MENU
Branch Info
History Alarm
Settings
Figure 5-4 Main menu screen
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1. At any one of the system information screen, press the ENT key to enter the main menu screen.
2. At any sub-menu of the main menu screen, press the ESC key repeatedly to return to the higher-level menu, and
ultimately return to the main menu screen.
Active alarm
When a new alarm is generated, and there is no operation on controller keypad for two minutes, the LCD of the
controller will prompt the active alarm screen automatically. If there are multiple alarms in the current system, you can
query alarms through the following steps.
At screen in Figure 5-4, press ▲ or ▼ to select ‘Active Alarm’, then press the ENT key to confirm.
If there is an active alarm, the display shown in Figure 5-5 will appear.
Alarm：1/3
Self-detect Err
Important Alarm
111214 19:49:53
Figure 5-5 Active alarm screen
The previous screen includes the alarm serial No./alarm total number, alarm name, alarm level and alarm time. The
alarm generating time determines the sequence it is displayed, with the latest alarm displayed first. Press ▲ or ▼ to
view all active alarms.
Branch information
Branch information menu shows the branch currents and load rate. As shown in Figure 5-6.
Branch： 1/8
-Curr：0.0A
-LoadRate：0%
Figure 5-6 Branch information screen
History alarm screen
At the screen shown in Figure 3-8, press ▲ or ▼ to select the ‘History Alarm’ menu, then press the ENT key to
confirm.
1) If there is no history alarm, the system cannot access the history alarm screen.
2) If there is an alarm, the display shown in Figure 5-7 will appear.
Alarm：1/3
Self-detect Err
111214 19:49:53
111214 19:56:30
Figure 5-7 History alarm screen
The history alarms of the controller are stored in cyclic order. At most 200 alarms will be recorded, above that, the
earliest alarm will be cleared automatically.
2. Press ▲ or ▼ to view other history alarms.
3. At any history alarm screen, press the ESC key repeatedly to return to the higher-level menu, and ultimately return
to the first system information screen.
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Settings screen
Displayed in many screens, the settings screen is a sub-menu of the main menu. It is used to set system parameters.
The settings screen has password protection, only the correct password allows you to enter it. See Figure 5-8 for the
settings screen.
Settings
AC set
System setting
Figure 5-8 Settings screen
1. At the main menu screen, press ▲ or ▼ to select the ‘Settings’ menu, and press the ENT key to display the
password confirmation screen.
2. Input the correct password and press the ENT key to enter the settings screen. Press ▲ or ▼ to enter the
operation screen you need.
There are three parameters for setting: DC setting, insulation setting, and system setting. Setting methods are as
follows:
AC distribution
1. At the screen shown in Figure 5-9, press ▲ or ▼ to select the ‘AC Dis’ menu, then press the ENT key to confirm.
AC Input：
-Current： Hall
-HallCoef： 230A
Branch： 1
2307A
Figure 5-9 AC distribution screen
2. Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value. Then press the
ENT key to confirm. The controller will automatically save the setting value. See Table 5-2 for parameters of AC
distribution settings.
Table 5-2 Description of the AC parameter setting
Parameter name
Setting range
Default
Description
AC input-Curr
None/Hall
Nonel
Set it according to the actual sensor used by the power system
AC input-HallCoef
1A～5000A
600A
Set it according to the actual sensor used by the power system
Branch
1～8
1
Set it according to the actual number of the test load current circuits
Branch-Curr
None/Hall
Nonel
Set it according to the sensor used by the load. Each branch needs to be set
Branch-HallCoef
1A～5000A
50A
Set it according to the actual sensor used by the power system
Branch-SW
1A ~ 5000A
50A
Set it according to the MCB capacity used by load
Brh HighLoad
50% ~ 100%
60%
Set it according to the user requirements. High load alarm is generated when
load current reaches setting value*load capacity
Brh OverLoad
50% ~ 100%
90%
Set it according to the user requirements. Overload alarm is generated when
load current reaches setting value*load capacity
Note
PD380/800AFA use the 800/1 current transformer, the hall coefficient of the AC input is set to 2307A.
System Settings
1. At the Settings screen, press ▲ or ▼ to select the ‘Sys set’ menu. Then press the ENT key to confirm, as shown in
Figure 5-10.
Lang: English
Date: 2009-08-08
Time: 16:26:16
Tzone: GMT+08:00
Figure 5-10 System settings
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2. Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value. Then press the
ENT key to confirm. The controller will automatically save the setting value. See Table 5-3 for parameters of system
settings.
Table 5-3 Description of the system parameter setting
Main
menu
Main
menu
Lang
Chinese, English
Chinese
Set it according to your requirements
Tzone - -
Set it according to the actual instance
Date
2000 ~ 2038
-
Set the time according to the current actual time, regardless of whether it
is a leap year or not
Time - -
Set the time according to the current actual time
485 Baud
38400
19200
9600
4800
2400
1200
19200
Set it according to your requirements
232 Baud
38400
19200
9600
4800
2400
1200
9600
Set it according to your requirements
232 Addr
1 ~ 254
1
Set it according to your requirements
Reset Paras
Y, N N Whether resetting the parameter to the default
User PWD
-
-
The password can be 6 digits long at most. If it is shorter than 6 digits,
end it with space key
ComDownLoad
Y, N
N
When the serial port is needed to upgrade the program or configure files,
enter serial port download mode first
System types
240V DC system
336V DC system
380V AC system
ATS AC system
240V DC
system
Set it according to your requirements
Empty
History alarm
History
alarm
Press the’Enter’ two times will empty the historical alarms
LDU modle
Y, N N If you need to communicate with M820D/M831D, set ‘Yes’
5.2 Setting The Position Number Of The Rectifier Manually
When the power supply system is in operation, each rectifier is given a position number by the controller. This
position number is assigned automatically, and may change when the rectifier is repowered on. Then users need to
set the position number of the rectifier manually though the Web control interface in the controller.
1. Refer to 4.4.3 Access Controller Through Web to enter the Web homepage window.
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2. Select ‘Power System’ tab, as shown in Figure 5-11.
Figure 5-11 Power system status tab
The Power System Status tab displays power system status in a graphical block diagram format. This includes status
of the input power, modules (i.e. rectifiers, converters), DC equipment, and battery.
3. Click on the ‘Rectifier’ icon to access the following window, as shown in Figure 5-12.
Figure 5-12 Rectifier status web page
Displayed on the Rectifier Device Group status page are the individual rectifiers installed in the system.
4. Click an individual rectifier icon to display its status such as "Current Limit", "Valid Rated Current", etc., as shown in
Figure 5-13.
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Figure 5-13 Individual rectifier status page
5. Hover the mouse pointer on an individual rectifier icon , this icon changes to . Click to set the
individual rectifier information and set the rectifier position number to actual position number, then click the ‘Set’ to
confirm.
6. Click to go back to the individual rectifier status page, as shown in Figure 5-14.
Figure 5-14 Individual rectifier settings page
Note
During the setting, you can set the ‘LED Control’ to ‘LED Control’ to make sure the power indicator of the corresponding
module flash, so as to make sure the actual position of that module.
5.3 Adding Load
Generally, the power system is not fully loaded at the initial operation stage. Power interrupt is not allowed once the
priority load is put into operation. Therefore, new load adding must be a live operation.
Before adding DC load, a good construction design must be worked out. Select the load fuse or MCB, process and
lay the load cables, and attach serial number and polarity labels to the cables. Cable connection should start from the
load end. Connect the earth cable first, and then the 240V output fuse or the MCB. The tools used must be insulated
and preventive measures against possible accidents must be worked out in advance. Refer to 3.2.5 Connecting DC
Load Cables for DC load cable connection.
5.4 Adding Rectifier
1. Remove dummy plates.
Some rectifier guide rails are idle and covered with dummy plates when the power supply system is not fully
configured. Before adding rectifier, these dummy plates must be removed so that new rectifiers can be mounted.
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2. Insert the new rectifier into position along the guide rail and fix it. See 3.4.1 Installing Rectifier.
3. Set the address in the controller of the corresponding rectifier.
4. Close the corresponding AC input switch to feed AC power to this rectifier.
5. Repeat steps 1 to 4 to add all rectifiers.
6. Reset parameters for controller.
Notice
Note
Connection and disconnection of rectifier’s external input cables should be done by maintenance personnel, and the cables must
be connected before switching on the rectifier, and disconnected after switching off the rectifier. The rated current of the rectifier
input MCB is 20A, and its breaking capacity is 6kA.
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Chapter 6 Maintenance
This chapter introduces basic maintenance requirements, routine maintenance items, maintenance operations, basic
fixing methods and emergency treatment.
6.1 Maintenance Requirements
6.1.1 General
To ensure quality power supply and guarantee stable and reliable operation of the communication system, operation
management and maintenance are necessary to the power supply system. Basic requirements for maintenance of
power supply system include:
1. Guarantee uninterrupted quality power supply to the communication equipment.
2. Carry out periodic inspection and overhaul to ensure stable and reliable operation of the power supply system and
prolong its operational life span.
3. Conduct effective troubleshooting to reduce the loss caused by faults.
4. Keep the equipment and environment clean to ensure that the environment in the equipment room conforms to the
basic requirements of equipment operation.
5. Use new technologies and improve maintenance methods to achieve centralized monitoring, little or even no
attendance.
To sum up, the power supply system maintenance includes routine maintenance, periodic inspection and
technological reform. And the maintenance must be carried out in compliance with applicable industry standards and
local regulations.
6.1.2 Maintenance Tools And Equipments
The common tools and instruments used in maintenance of power supply system are separately listed in Table 6-1
and Table 6-2.
Table 6-1 Common tools for power equipments maintenance
Name
Quantity
Applications
Joint pliers
1 piece
Shape and coil the naked pins and help to weld and assemble the surface of
intensive device
Diagonal cutting pliers
1 piece
Cut extra leads, pins of welding surface, and nylon binding clips
Tweezers
1 piece
Help to weld and clean, pick up mini components, and coil tiny leads
Blade screwdriver
1 set
Drive and remove plain screws and open boxes
Cross screwdriver
1 set
Drive and remove cross screws
Wrench (double end wrench or
fork wrench)
1 set
Wrench 6-angle or 4-angle bolts and nuts
Socket wrench
1 set
A kind of spinning tool used when there is no space for operation on the screw
surface
Adjustable wrench
1 set
Wrench 6-angle or 4-angle bolts and nuts. Note: when in use, the adjustable
tongue shall turn to the inside of the spinning direction.
Electric soldering iron
1 piece
Weld components
Wash brush
1 piece
Clean the equipment and dust inside boxes
Handsaw
1 piece
Saw the bus and cables. Note: The saw blade shall not turn to the handle.
Electrician knife
1 piece
Peel off the skin of cables, etc.
Electrician rubber mallet
1 piece
Rectify cables or equipment location
Auxiliary materials (non-spare
parts)
Commonly-used auxiliary materials include insulating tape, self-adhesive label, soldering tin,
nylon bandage, etc.
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Table 6-2 Common instruments for power equipments maintenance
Name
Quantity
Applications
Remark
Multimeter
2 to 3 pieces
Measure AC/DC voltage, current and resistance
Those instruments
marked with * may be
configured or not to
those relatively
less-equipped
equipment room
according to actual
requirements
Earth resistance tester
1 piece
Measure the earth resistance
Megommeter (500V and
1000V withstand voltage)
1 piece/each
Dielectric strength test
AC/DC clamp-on amper meter
1 piece
Measure current
Contact Thermometer
1 piece
Measure the temperature of the surface and
junction points of equipment
High/low-frequency noise
tester
1 piece
Measure noise
*Ampere-hour meter
1 piece
Measure battery capacity
AC/DC load meter
1 piece
Measure and test the load capacity of power net,
rectifier and batteries
Note*: testing devices that can be omitted
6.1.3 Reference Technical Specification For Maintenance
The power supply system consists of AC power supply, DC power supply and earthing system. To ensure
communication quality and power supply security, the power supply quality must conform to some basic quality
standards. Reference standards for AC, DC and earth resistance are shown in Table 6-3, Table 6-4 and Table 6-5.
Table 6-3 Quality standards for DC power supply
Standard
voltage (V)
Voltage variation range
at the receiving end of
telecom equipment (V)
Noise voltage (mV)
Maximum permissible
voltage drop of power
supply circuit (V)
Psophometrically
weighted noise
Peak-peak
value noise
Wide frequency noise
(effective value)
-48
-40 to -57
≤ 2mV
≤ 200mV
0 to 20Mhz
≤ 50mV
@3.4kHz to 150kHz
≤ 20mV
@150kHz to 30Mhz
3
24
19.8 to 28.2
≤ 2.4mV
1.8
Note: The voltage drop at the connectors of DC power supply circuit (including the fuse of the feed line output from the
discharging busbar, and battery connectors) shall be in conformity with the following requirements or the temperature rise shall
not exceed the permissible value: 1. If under 1000A, every hundred ampere≤5mv; 2. If above 1000A, every hundred
ampere≤3mv.
Table 6-4 Quality standards for AC power supply
Nominal
voltage (V)
Voltage variation
range at the
receiving end (V)
Nominal
frequency
(Hz)
Variation range
of frequency
(Hz)
Power factor
Remark
Below
100kVA
Above
100kVA
The voltage
imbalance of
three-phase power
supply shall not
exceed 4%
220
187 ~ 242
50
± 2.5
≥ 0.85
≥ 0.9
380
323 ~ 418
50
± 2.5
≥ 0.85
≥ 0.9
Table 6-5 Earth resistance reference standards for communication station
Name of the communication station
Earth resistance (Ω)
Comprehensive building, international telecom administration, tandem office, program
control exchange with over 10 thousand lines, and toll exchange with over 2,000 lines.
< 1
Program control exchange with more than 2,000 lines but less than 10 thousand lines, and
toll exchange with less than 2,000 lines.
< 3
Program control exchange with less than 2,000 lines, fiber terminal station, carrier repeater
station, ground satellite station, and microwave junction station
< 5
Microwave relay station, fiber relay station
< 10
Microwave passive relay station
< 20 (may be up to 30 in the
case of high soil resistivity)
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6.2 Routine Maintenance Items
This chapter introduces routine maintenance items for power supply system and maintenance operation methods.
The power supply system maintenance items are list in Table 6-6.
Table 6-6 Maintenance items for power supply system
No.
Item
Test standard
Test tools
Test method
1
System current
sharing
After each rectifier is over half load, the
output current imblance between
rectifiers should be less than ±3%
Calculate the imblance based on the
output current of each rectifier displayed
on on the controller; or the rectifier
output current displayed on each rectifier
2
Display of voltage /
current
The difference between the the rectifier
voltage, busbar voltage and various
output voltages displayed on the
controller shall be less than 0.2V; the
difference between the sum of the
displayed currents of all rectifiers and
the sum of charge current and total load
current shall be within the specified error
range
Read the voltage and current values
displayed on the controller and rectifiers,
and make judgement according to the
above standards
3
Parameter setting
Conduct compliance check according to
the record of the previously setting
parameters (parameter table)
Reset those parameters not in
conformity with the specified
requirements. The operation method of
parameter setting can refer to the
Device user manual
4
Communication
function
The communication between each
system unit and the controller shall be
normal and there shall be no record of
frequent communication interrupt
between one certain unit and the
controller in the shistorical alarm record
5
Alarm function
Alarm should be given out in case of
fault
Check the testable items on the spot.
Testable items include AC mains failure,
damage to SPDs (SPDs with alarm
indicator or alarm contact), module
failure and DC fuse blowout (test shall
be conducted on unload fuse)
6
Protection function
Conduct compliance check according to
factory parameters or parameters set
through the controller
This item is generally not easy to test
when the system is in the operation. It is
usually conducted when the prptection
function of the power supply is abnormal
due to frequent occurrence of AC or DC
protection. Test methods including
testing the AC under/overvoltage
protection function through external
voltage regulator and testing the DC
under/overvoltage protection function by
forced discharge
7
Management
function
The calculation, storage and battery
auto-management functions performed
by the controller. The historical alarm
record can be queried, and the battery
auto-management function is testable
1. Storage function: simulate an alarm,
the controller will record the alarm
information.
2. Battery auto-management: the battery
charge mode and charge current can be
adjusted and various protections can be
implemented through the moniotoring
module according to the data set by the
user
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No.
Item
Test standard
Test tools
Test method
8
Noise index
Psophometrically weigthed noise ≤ 2mV;
peak – peak noise ≤ 200mV
Noise meter,
oscillograph
During noise measurement, the batteries
should be separated from the power
equipment. However, for the sake of
safety of power supply, the batteries
cannot be disconnected during field
operation. Therefore, this test should
only be done when the communication
quality of the exchange is poor and the
power supply quality of the power
equipment is considered not in
conformity with requirements. The
psophometrically weigthed noise, input
through through the positive and
negative busbar, can be measured by a
noise meter, which shall be geared to
“telephone noise” measurement scale.
The peak – peak noise can be
measured by an oscillograph. For test
method refer to the equipment operation
instructions
9
Internal connection
The socket shall be well connected; the
cables shall be well laid out and fixed;
there shall be no cables that have been
squeezed out of shaped by metal
components; and there shall be no
partial overheat or aging of connection
cables
10
Vent duct and dust
deposit
There shall be no blockage or dust
deposit in the vent ducts of rectifier fans
or vent ducts in the cabinets
Hairbrushes,
leather bellows,
etch
Remove, clean and wash the guard
boards of the vent ducts and the fan;
replace them after they have been dried
11
DC cables
The permissible voltage drop determined
in circuit design is generally less than
0.5V (low impendance distribution)
Note down the maximum current flowing
through the cables, look up the sectional
area and wiring length of the cable in the
design plan, calculate the voltage drop
and check whether it meets the design
requirements
12
Configuration of
DC circuit breakers
The rated current of the DC circuit
breaker should not be more than twice of
the maximum load current. The rated
current of the circuit breaker in each
special equipment room should not more
than 1.5 times of the maximum load
current
Check the adaptability of the circuit
breakers according to the recorded
maximum current of each load
13
Voltage drop and
temperature rise of
nodes
If below 1000A, the voltage drop should
be ≤ 5mV for every hundred ampere; if
above 1000A, the voltage drop should
be ≤ 3mV; and the temperature rise of
node should not exceed 70°C
Multimeter,
semiconductor
thermometer
Use multimeter to measure the voltage
drop between the buses and cables at
the two terminals of the node; and judge
the rationality of the voltage drop of the
node based on the current flowing
through the node. Use the
semiconductor thermometer to measure
the temperature rise of the node. The
measurement results should meet the
temperature rise limitation and voltage
drop limitation requirements
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No.
Item
Test standard
Test tools
Test method
14
Basic requirements
(standards issued
by the Ministry of
Information
Industry)
1. The power supply shall be installed in
a dry and well-ventilated room with no
corrosive gas, and the temperature
inside the room is less than 30°C.
2. The input AC voltage should range
from -15% to +10% of the rated value. In
case of big voltage fluctuation, automatic
voltage stabilizing or regulating device
should be installed.
3. The operating current should either go
beyond the rated value or below 10% of
the rated value for a long period. Various
automatic, alarm and protection
functions shall be normal.
4. It shall operate under the stabilized
voltage and load share mode.
5. The wiring shall be kept neat, various
parts such as switches, fuse breakers,
connectors and connection terminals
should be well connected, and there
shall be no electric corrosion.
6. The cabinets of the power equipment
shall be well earthed
6.3 Routine Maintenance
Routine maintenance of power equipment mainly involves management of the equipment room environment and
inquiry of the equipment running status. The basic requirements for the management of the equipment room
environment have been presented in detail in the previous section. Inquiry of the equipment running status is a part of
the routine logs, generally including the following items:
1. The inquiry of the operating status of the power supply equipment can be completed through the controller. The
status parameters that can be inquired include mains voltage, mains frequency, DC output voltage, boost charge/float
charge status, charge/discharge current, total load current, voltage and current of each rectifier, historical alarm
record, etc. For inquiry methods, refer to M831D Controller User Manual.
2. Streamlined logs of the power supply status. The power equipment can measure mains voltage and record mains
failure alarms, but cannot complete statistical work. To conduct statistical analysis of the operating status of the power
grid, there shall be a detailed streamlined log of the status of the power net. In general, the status of the power grid
shall be recorded once about every 2 hours, including the voltage and current of each phase of the power grid, the
start and recovery time of mains failure, and the startup time and break time of the generator, etc.
3. Streamlined logs of the DC power supply status. The requirements for the streamlined logs of the DC power supply
status are similar to those for the streamlined logs of the AC power supply status. Log items include DC output
voltage, current of main loads, charge/discharge voltage and current, total load current, etc.
4. Faults maintenance. Overhaul and maintenance of other equipment shall be conducted in accordance with the
requirements and methods provided by the manufacturer. But, during the routine maintenance, be sure to write down
the fault causes and the maintenance results in the “equipment calendar”. An equipment calendar shall be kept for
each piece of equipment in the equipment room.
6.4 Basic Inspection
6.4.1 Handling Controller Fault
When the faults of the controller affect the DC power supply, turn off the controller.
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6.4.2 Handling Rectifier Fault
Note
If a rectifier is pulled out or there is faulty rectifier, users should reset the controller. Or else the batteries cannot be boost
charged.
Fault phenomenon and handling method
Rectifier faults include power indicator off (green), protection indicator on (yellow), protection indicator flashing
(yellow), fault indicator on (red) and fault indicator flashing (red).
The indicators positions are shown in Figure 6-1.
Power indicator
Protection indicator
Fault indicator
Figure 6-1 Rectifier indicator position
Change the position of the abnormal and normal rectifiers upon abnormity. If the abnormal rectifier still cannot work
normally, refer to Table 6-7 to dispose the faults.
Table 6-7 Disposal methods for rectifier faults
Fault
Related alarm
Fault cause
Proposal
Power indicator off
(green)
No alarm
No input or output voltage
Ensure having input and output voltage
Protection indicator on
(yellow)
Rectifier over
temperature
Main
causes of
overheat
protection
for
rectifier
Fan is blocked
Remove the object which blocks the
fan operation
The vent duct is expedite: there
are some blockages at air intake
or air outlet
Remove the blockage at air intake and
air outlet
High temperature or pyrotoxin is
near to the air intake of rectifier
Decrease ambient temperature or
remove the pyrotoxin
The rectifier isn’t absolutely
inserted into the frame
Reinsert rectifier
Rectifier
protection
No current sharing
Check the rectifier communication
whether nomal or not. If not, continue
to check the connection of
communication lines. Replace the fault
rectifier when it works normally
PFC output overvoltage protection
Change the position of the abnormal
and normal rectifiers. Replace the
abnormal rectifier if it cannot work
normally all the same
AC input voltage exceeding the normal range
Ensure the AC input voltage whether in
normal range or not
Protection indicator
flashing (yellow)
Rectifier
communication
failure
Rectifier communication failure
Check the communication lines
connection whether well or not
Fault indicator on (red)
Rectifier failure
Overvoltage
Remove the abnormal rectifier and
restart. Replace the rectifier if it occurs
overvoltage again
Fault indicator flashing
(red)
Rectifier fan
fault
Fan fault
Replace new fan
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Fault description
1．Internal short-circuit of rectifier
The rectifier will automatically exit the system in case of internal short-circuit.
2．Damage to partial rectifier
In case of damage to partial rectifiers, if the remaining undamaged rectifiers are able to meet the power supply
requirements of loads, just turn off the AC input switches of the damaged rectifiers.
3．Rectifier output overvoltage
The overvoltage of a single rectifier will not cause the overvoltage protection of all rectifiers. However, if overvoltage
protection occurs to all rectifiers, the system cannot recover automatically.
Treatment: turn off the AC input switches of all rectifiers and remover the rectifier to disconnect it. At this time, the
system voltage should be below 56.4V. Then insert rectifier one by one and turn on the AC input switches to observe
the output current of it. When the AC input MCB of a certain rectifier is switched on, its output current is obviously
bigger than that of the others. When the system voltage is higher than 56.4V, the rectifier with bigger output must be
faulty Replace it. If all the rectifiers show the same symptom, you must turn off the monitoring and rectifiers and then
restart the rectifiers.
Note
During the treatment of rectifier fault, delete the address code of the closed rectifier in the rectifier parameters setting through the
controller. Refer to M831D Controller User Manual for deleting method.
6.5 Replacing Rectifier
Note
Rectifier surface temperature may be high, be careful when you pull out the rectifier.
When rectifier is faulty, see the following procedures to replace:
1. Check the new rectifier to see whether there is any damage.
2. Disconnect the AC input MCB of the rectifier and loosen the fixing screw on the panel of the rectifier. See Figure
6-2.
Figure 6-2 Rectifier position slide switch
3．Grasp the handles, pull the module out of the cabinet slowly until it stops, and put the slide switch on position.
Then pull out the rectifier completely. Observe whether there is a appropriate controller alarm.
4．Disconnect the rectifier switch, put the slide switch on position, grasp the handles, and push the rectifier into
cabinet slowly, until it stops, as shown in Figure 6-3.
Figure 6-3 Replacing rectifier (1)
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5．Put the slide switch on position. And then push the rectifier to the bottom until the rectifier panel is on the same
level as the rectifier rack panel, as shown in Figure 6-4.
Figure 6-4 Replacing rectifier (2)
6．Push the handle to the front panel, as shown in Figure 6-5.
Figure 6-5 Replacing rectifier (3)
7．Tighten the fixing screw on the handle to fix the rectifier on the rack, as shown in Figure 6-6.
Figure 6-6 Replacing rectifier (4)
8．Close the AC input MCB of rectifier.
The power indicator of rectifier will light up after a short delay, and then the fan operates. The alarm stops.
9．Check the following items, including: the controller can identify the new rectifier; the new one has the same current
sharing with the others; the controller will generate alarm when pulling out the new one. If all the checks are
accordant, the new one operates normally.
6.6 Emergency Treatment
In order to keep uninterrupted DC power supply of the power supply system, some emergency measures shall be
taken to cope with the faults that threaten DC power supply.
Faults that may occur in the power supply system and cause output interrupt mainly include unrecoverable damage
to AC distribution circuit, short circuit of DC load or DC distribution, system shutdown due to breakdown of the
controller, and blockage of rectifier due to DC output overvoltage, etc.
Emergency treatment of AC distribution
In case of failure of AC power supply to rectifier due to AC distribution fault, the AC mains can be directly introduced
into the input switch of the rectifier.
Emergency treatment of DC distribution
1．Partial short-circuit of load
Disconnect the branch fuse that corresponds to the damaged loads. Replace the faulty fuse. If the fuse link is
replaced for other reasons, it must make clear whether the load circuit where the fuse link is located permits power
disconnection.
2．Distribution short circuit
When this fault occurs, it shall be treated as follows: disconnect the AC power supply; isolate the batteries from the
system; and then use batteries and rectifiers to directly supply power to load.
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Power failure
AC power failure is the general case in the operation of power supply system. If the continuous time is not long, the
batteries are feed to DC. However, if the power failure is not clear or the continuous time is too long, restart the
generator to power. And then transfer to feed the power supply system after 5min in order to reduce the effects to the
power supply equipments during the process from starting to transition for generator.
Disastrous accidents
Disastrous accidents refer to communication equipment faults arising from disasters such as lightning strike, flood,
earthquake and fire. For those disasters that may severely affect the safety of communications, emphasis shall be
mainly laid on pervention. Meanwhile, communication exchanges shall have adequate human and material resources
and work out effective countermeasures to deal with these disasters. They shall also prepare emergency
management regulations and grave accidents rush-repair rules.
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Appendix 1 Technical Parameter
Table 1 Technical parameters of rectifier cabinet
Parameter
Category
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C
Storage temperature
-40°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2000m (derating is necessary above 2000m)
Other
No conductive dust or erosive gases. No possibility of explosion
AC input
AC input system
3-phase 4-wire and 3-phase 5-wire
Rated input line voltage
380Vac
Input voltage range
260Vac ~ 530Vac (error: 5Vac)
Input AC voltage
frequency
45Hz ~ 65Hz
Max input current
≤ 130A (304V input)
Power factor
≥ 0.98
DC output
Rated voltage
53.5Vdc
Nominal voltage
48Vdc
Output DC voltage
42Vdc ~ 57.6Vdc
Max output current
Rack1000-7: 1000A
Rack2000-7: 2000A
Total regulation
≤ 1%
Efficiency
≥ 90%
Noise voltage
(peak-peak
≤ 200mV (0 ~ 20MHz)
Telephone
psophometrically
weighted noise voltage
≤ 2mV (300Hz ~ 3400Hz)
Wide frequency noise
voltage
≤ 100mV (3.4kHz ~ 150kHz); ≤ 30mV (150kHz ~ 30MHz)
Discrete noise
≤ 5mV (3.4kHz ~ 150kHz); ≤ 3mV (150kHz ~ 200kHz); ≤ 2mV (200kHz ~ 500kHz);
≤ 1mV (0.5MHz ~ 30MHz)
AC input alarm
and protection
AC input overvoltage
alram point
Default: 485 ± 10Vac (line voltage), configurable through controller, hysteresis is 10Vac
AC input overvoltage
alarm recovery point
Default: 475 ± 10Vac (line voltage), 10Vac lower than AC input overvoltage alarm point
AC input undervoltage
alarm point
Default: 310 ± 10Vac (line voltage), configurable through controller, hysteresis is 10Vac
AC input undervoltage
alarm recovery point
Default: 320 ± 10Vac (line voltage), 10Vac higher than AC input undervoltage alarm
point
AC input overvoltage
protection point
Default: 535 ± 10Vac (line voltage), not configurable through controller, hysteresis is
more than 10Vac
AC input undervoltage
protection point
Default: 255 ± 10Vac (line voltage), not configurable through controller, hysteresis is
more than 15Vac
AC input phase loss
alarm point
Default: 120 ± 10Vac (phase voltage), configurable through controller, hysteresis is
10Vac
DC output
alarm and
protection
DC output overvoltage
alarm point
Default: -58.5 ± 0.3Vdc, configurable through controller
DC output overvoltage
alarm recovery point
Default: -58.0 ± 0.3Vdc, 0.5Vdc lower than overvoltage alarm point
DC output undervoltage
alarm point
Default: -45.0 ± 0.3Vdc, configurable through controller
DC output undervoltage
alarm recovery point
Default: -45.5 ± 0.3Vdc, 0.5Vdc lower than undervoltage alarm point
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Parameter
Category
Parameter
Description
Rectifier
Current sharing
Rectifiers can work in parallel and share the current. The unblanceness is better than
±3% rated current. Test current range: 10% ~ 100% rated current
Derate by input (45°C)
The rectifier can output max. power of 5,800W with input voltage of 304Vac ~ 530Vac.
The output power will drop to 50% rated power when the input volatage fall to 304Vac ~
260Vac
Output delay startup
The startup time is configurable through controller. The time is 8s at 90% rated load, and
90s at 100% rated load
Fan controlling
Rectifier fan speed can be increased when the rectifier temperature and output current is
raising. The fan speed will reach full speed when ambient temperature is more than 45°C
or full loads output. If the PFC bus voltage exceeds the normal range, for example in the
case of low bus voltage, the fan will stop to work
Overvoltage protection
mode
The rectifier provides overvoltage 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, and can be set through the
controller
When the output voltage of rectifier is higher the overvoltage protection point, the rectifier
will shutdown. The overvoltage protection point is between 56V and 59V, and can be set
through the controller. The alarm indicator (red) will be on when rectifier occurs
overvoltage protection. The protection event will be set to the controller which will deal
with this alarm. If the rectifier happens four times overvoltage in 5min, it requires manual
resetting to restore the operation
There are two software setting modes through the controller on rectifier:
1. Restart by hand
2. Restart automatically after overvoltage protection in 5s
Temperature derating
Temperature below 45°C , outputs full power: 5,800W
Temperature above 45°C , outputs power as following::
At 50°C , output power is 5,400W
At 65°C , output power is 4,640W
EMC
Conducted emission
Class A EN300386
Radiated emission
Immunity to ESD
Level 3 EN/IEC 61000-4-2
Immunity to EFT
Level 4 EN/IEC 61000-4-4
Surge
Level 4 EN/IEC 61000-4-5
Immunity to radiation
Class A EN/IEC 61000-4-3
Immunity to conduction
Class A EN/IEC61000-4-6
Lightning
protection
featires
At AC side
The AC input side can withstand five times of simulated lightning voltage of 5kV at
10/700µs, for the positive and negative polarities respectively. It can withstand five times
of simulated lightning surge current of 20kA at 8/20µs, for the positive and negative
polarities respectively. The test interval is not smaller than 1 minute. It can also withstand
one event of simulated lightning surge current of 40kA at 8/20µs (test with AC cabinet)
At DC side
The DC side can withstand one time of simulated lightning current of 10kA at 8/20μs
Other
Safety regulation
Compliant with IEC60950
Noise
The noise is not more than 60dB (A) when ambient temperature is 25°C
Protection level
IP20
Insulation resistance
At temperature of 15°C ~ 35°C and relative humidity not bigger than 90%RH, apply a
test voltage of 500Vdc. The insulation resistances between AC circuit and earth, DC
circuit and earth, and AC and DC circuits are all not less than 10MΩ
Insulation strength
Remove the SPD, controller and rectifiers from the system before the test
AC circuit to earth: 50Hz, 2,500Vac
AC circuit to DC circuit: 50Hz, 3,000Vac
DC circuit to earth: 50Hz, 1,000Vac
Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac
For all the four 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
Mechnical
Dimension (mm)
Rectifier cabinet
2000 (H) × 600 (W) × 600 (D)
Controller M831D
42 (H) × 86.6(W) × 211.5 (D)
Rectifier R48-5800A, R48-5800e
88 (H) × 244 (W) × 372 (D)
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Parameter
Category
Parameter
Description
Mechnical
Weight (kg)
Rectifier cabinet (not including rectifier)
Rack1000-7 ≤ 140
Rack2000-7 ≤ 180
Controller M831D
≤ 2
Rectifier R48-5800A, R48-5800e
≤ 8
Table 2 Technical parameters of AC distribution c abinet
Parameter
Category
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C
Storage temperature
-40°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2000m (derating is necessary above 2000m)
Other
No conductive dust or erosive gases. No possibility of explosion
AC input
AC input system
TN-C, TN-S, TN-C-S and TT formats with three- phase four- wire or three- phase fivewire styles
Rated input phase
voltage
380Vac
Input voltage range
260Vac ~ 530Vac (error is 5Vac)
Input AC voltage
frequency
45Hz ~ 65Hz
45Hz ~ 55Hz (PD380/630AFA-7-Y4)
AC output
Distribution parameters
PD380/400AFH-7-Y2:
6-route 3-phase output, 6-route single phase output, output total capacity not exceeding
400A:
160A/3P × 4, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7-Y3:
8-route 3-phase output, 6-route single phase output, output total capacity not exceeding
630A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFA-7-Y4:
8-route 3-phase output, 6-route single phase output, output total capacity not exceeding
600A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7/YF: configuration in accordance with customer requirement （If the
input switch using MCB, shall not exceed the total capacity of the Cabinet input of MCB
80%)
AC input alarm
and protection
AC input overfrequency
alarm point
Default: 55Hz, configurable through controller
AC input underfrequency
alarm point
Default: 45Hz, configurable through controller
AC input overvoltage
alarm point
Default: 535Vac ± 10Vac (line voltage), not configurable through controller, 10Vac
hysteresis
AC input undervoltage
alarm point
Default: 485Vac ± 10Vac (line voltage), configurable through controller, 10Vac hysteresis
ACinput undervoltage
protection point
Default: 255Vac ± 10Vac (line voltage), not configurable through controller, 15Vac
hysteresis
AC input phase loss
alarm point
Default: 120 ± 10Vac (phase voltage), configurable through controller, 10Vac hysteresis
Overtemperature alarm
point
Default: 50°C, configurable through controller, 2°C hysteresis
EMC
Conducted emission
Class A EN300386
Radiated emission
Immunity to ESD
Level 3 EN/IEC 61000-4-2
Immunity to EFT
Level 4 EN/IEC 61000-4-4
Surge
Level 4 EN/IEC 61000-4-5
Immunity to radiation
Level 2 EN/IEC 61000-4-3
Immunity to conduction
Level 2 EN/IEC61000-4-6
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Parameter
Category
Parameter
Description
Other
Lightning protection
feature
The AC input side can withstand five times of simulated lightning voltage of 5kV at
10/700µs, for the positive and negative polarities respectively. It can withstand five times
of simulated lightning surge current of 20kA at 8/20µs, for the positive and negative
polarities respectively. The test interval is not smaller than 1 minute. It can also withstand
one event of simulated lightning surge current of 40kA at 8/20µs
Safety regulation
Compliant with IEC60950
Overvoltage type
II class device
Noise
The noise is not more than 60dB (A) when ambient temperature is 30°C
Protection level
IP20
Insulation resistance
At temperature of 15°C ~ 35°C and relative humidity not bigger than 90%RH, apply a
test voltage of 500Vdc. The insulation resistances between AC circuit and earth, DC
circuit and earth, and AC and DC circuits are all not less than 10MΩ
Insulation strength
Remove the SPD, controller and rectifiers from the system before the test
AC circuit to DC circuit: 50Hz, 3,000Vac
AC circuit to earth: 50Hz, 2,500Vac
DC circuit to earth: 50Hz, 1,000Vac
Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac
For all the four tests above, there should be no breakdown or flashover within 1min, with
leakage current not bigger than 10mA
MTBF
200000hr
ROHS
Compliant with R5 requirement
Mechnical
parameters
Dimension (mm)
2000 (H) × 800 (W) × 600 (D)
Weight (kg)
PD380/400AFH-7-Y2, PD380/630AFH-7-Y3 ≤ 240, PD380/630AFA-7-Y4 ≤ 250,
PD380/630AFH-7/YF ≤ 270
Table 3 Technical parameters of DC distribution cabinet
Parameter
Category
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C
Storage temperature
-40°C ~ 70°C
Relative humidity
5RH ~ 95%RH
Altitude
≤ 2000m (derating is necessary above 2000m)
Other
No conductive dust or erosive gases. No possibility of explosion
DC input
Rated input voltage
48Vdc
Input voltage range
42Vdc ~ 57.6Vdc (error: 0.3Vdc)
Rated input current
PD48/1600DF-7-Y3: 1600A；PD48/1600DF-7-Y4: 1600A；
PD48/2500DF-7-Y3: 2500A；PD48/2500DF-7-Y4: 2500A
DC output
Load current
PD48/1600DF-7-Y3:≤ 1200A；PD48/1600DF-7-Y4:≤ 1200A；
PD48/2500DF-7-Y3:≤ 2000A；PD48/2500DF-7-Y4:≤ 2000A
Battery charge current
PD48/1600DF-7-Y3: ≤ 400A；PD48/1600DF-7-Y4: ≤ 400A；
PD48/2500DF-7-Y3: ≤ 500A；PD48/2500DF-7-Y4: ≤ 500A
Distribution parameters
PD48/1600DF-7-Y3, 22 routes load output:
500A (NT3) × 6, 200A (NT2) × 2, 100A (NT00) × 8, 63A (NT00) × 6
PD48/1600DF-7-Y4，24 routes load output:
400A (NT3) × 12, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 6
PD48/2500DF-7-Y3，30 routes load output:
630A (NT3) × 8, 400A (NT2) × 4, 200A (NT2) × 4, 100A (NT00) × 8, 63A
(NT00）× 6
PD48/2500DF-7-Y4，26 routes load output:
500A (NT3) × 16, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 4
PD48/1600DF-7/YF: Configured according to customer requirement
PD48/2500DF-7/YF: Configured according to customer requirement
Alarm
parameters
Busbar overvoltage alarm point
Default 58Vdc, configurable through controller, 0.5Vdc hysteresis
Busbar undervoltage alarm point
Default 45Vdc, configurable through controller, 0.5Vdc hysteresis
Battery 1 overvoltage alarm point
Default 58Vdc, configurable through controller, 0.5Vdc hysteresis
Battery 1 undervoltage alarm point
Default 58Vdc, configurable through controller, 0.5Vdc hysteresis
Battery 1 overcurrent alarm point
Default 100A, configurable through controller, 0.5A hysteresis
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Parameter
Category
Parameter
Description
Alarm
parameters
Battery 2 overvoltage alarm point
Default 58Vdc, configurable through controller, 0.5Vdc hysteresis
Battery 2 undervoltage alarm point
Default 58Vdc, configurable through controller, 0.5Vdc hysteresis
Battery 2 overcurrent alarm point
Default 100A, configurable through controller, 0.5A hysteresis
Overtemperature alarm point
Default 50°C, configurable through controller, 2°C hysteresis
EMC
Conducted emission
Class A EN300386
Radiated emission
Immunity to ESD
Level 3 EN/IEC 61000-4-2
Immunity to EFT
Level 4 EN/IEC 61000-4-4
Surge
Level 4 EN/IEC 61000-4-5
Immunity to radiation
Level 2 EN/IEC 61000-4-3
Immunity to conduction
Level 2 EN/IEC61000-4-6
Other
Lightning protection feature
The DC side can withstand one time of simulated lightning current of 10kA at
8/20μs
safety regulation
Compliant with IEC60950
Noise
The noise is not more than 50dB (A) when ambient temperature is 30°C
Protection level
IP20
Insulation resistance
At temperature of 15°C ~ 35°C and relative humidity not bigger than 90%RH,
apply a test voltage of 500Vdc. The insulation resistances between AC circuit
and earth, DC circuit and earth, and AC and DC circuits are all not less than
10MΩ
Insulation strength
Remove the SPD, controller and rectifiers from the system before the test
DC circuit to earth: 50Hz, 1,000Vac
Assistant circuit (not directly connected to the host circuit): 50Hz, 500Vac
For all the two 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
Mechnical
parameters
Dimension (mm)
2000 (H) × 800 (W) × 600 (D)
Weight (kg)
PD48/1600DF-7-Y3 ≤ 280, PD48/1600DF-7-Y4 ≤ 280
PD48/2500DF-7-Y3 ≤ 290, PD48/2500DF-7-Y4 ≤ 290
PD48/2500DF-7/YF, PD48/1600DF-7/YF ≤ 290
Page 97
Appendix 2 Alarm List 87
NetSure 801 CA7 Power Supply System (New Skelecton) User Manual
Appendix 2 Alarm List
Table 4 Alarm list
SN
Alarm
device
Alarm name
Alarm category
Related
relay
Alarm description
1
M831D
system
SelfDetect Fail
Observation
None
Controller hardware failure
2
CAN Com fail
Observation
None
No recitifer is able to comminucate.
3
Config Error 1
Observation
None
This alarm occurs when configuration file
has error.
4
Config Error 2
Observation
None
This alarm occurs when backup
configuration file has error.
5
Imbalance Curr
Critical
Relay 1
The rectifier output current is not equal to
sum of the load current detected by the
DC distribution unit and the battery
current. The alarm reasons are as
follows:
1. Battery shunt coefficient is wrongly set;
2. Part of the rectifiers are not monitored
by the controller; 3. Wiring of DC
distribution unit is wrong.
Judging method:
1. When there are more than 2 rectifiers,
if the absolute value of the sum of
rectifier output current, load current of DC
distribution unit and battery current is
bigger than the 2.5 X number of rectifiers
(current of each rectifier is 2.5A), then the
current is unbalanced.
2. When there are less than 2 rectifiers, if
the absolute value of the sum of rectifier
output current, load current of DC
distribution unit and battery current is
bigger than the 5 X number of rectifiers
(current of each rectifier is 5A), then the
current is unbalanced.
If the alarm condition is met, there is a
50s delay.
An exception:
If the system has a LVD alarm, ‘System
current unbalance’ alarm does not occur
6
Over Load
Observation
7
EStop/EShutdown
Critical
8
DHCP Failure
Observation
9
PLC Config Err
Observation
10
485 Comm Fail
Critical
11
Over Voltage 1
Critical
12
Over Voltage 2
Critical
13
Under Voltage 1
Critical
14
Under Voltage 2
Critical
16
DG Run OverTemp
Observation
17
DG1 is Running
Observation
18
DG1 is Running
Observation
19
DG1 Failure
Observation
20
DG1 Failure
Observation
Page 98
88 Appendix 2 Alarm List
NetSure 801 CA7 Power Supply System (New Skelecton) User Manual
SN
Alarm
device
Alarm name
Alarm category
Related
relay
Alarm description
21
M831D
system
Grid is on
Observation
22
Hi Ambient Temp
Observation
23
Lo Ambient Temp
Observation
24
Sensor Fault
Observation
25
DI1 Alarm
Critical
26
DI2 Alarm
Critical
27
DI3 Alarm
Critical
28
DI4 Alarm
Critical
29
DI5 Alarm
Critical
30
DI6 Alarm
Critical
31
DI7 Alarm
Critical
32
DI8 Alarm
Critical
33
IB Comm Fail
Critical
34
Rect Group
Multi-Rect Fail
Critical
Relay 4
This alarm happens when rectifier AC
power fails.
35
Rectifier Lost
Major
Relay 4
The controller can memorize the number
of rectifiers. If the number of detected
rectifiers is less than the number
memorized by the controller, then this
alarm occurs. This alarm can only be
ceased manually
36
ECO Active
Observation
37
AllRectCommFail
Major
38
ECO Cycle Alarm
Observation
39
Rectifier
AC Failure
Major
Relay 4
This alarm happens when rectifier AC
power fails
40
Rect Temp High
Observation
None
This alarm happens when rectifier has
over temperature fault
41
Rect Fault
Major
Relay 4
This alarm happens when rectifier fails
42
Over Voltage
Major
Relay 4
This alarm happens when DC output
over voltage occurs
43
Rect Protected
Observation
None
This alarm happens when rectifier is
under protection
44
Fan Failure
Major
Relay 4
This alarm happens when rectifier fan
fails.
45
Current limit
Observation
None
This alarm happens when rectifier limits
its output current
46
Rect Comm Fail
Major
Relay 4
This alarm happens when rectifier
communication fails
47
Derated
Observation
The alarm happens when rectifier power
limit occurs
48
Curr Shara Alm
Observation
The alarm happens when rectifier current
unbalance occurs
49
Low AC Protect
Major
50
Battery
Group
ShortBatTestRun
Observation
The alarm happens during short test
51
EQ for Test
Observation
The alarm happens during pre-boost
charging
52
Manual Test
Observation
The alarm happens during manual
battery test
53
Planned Test
Observation
The alarm happens during planed battery
test
54
AC Fail Test
Observation
The alarm happens during AC power
failure test
Page 99
Appendix 2 Alarm List 89
NetSure 801 CA7 Power Supply System (New Skelecton) User Manual
SN
Alarm
device
Alarm name
Alarm category
Related
relay
Alarm description
55
Battery
Group
Manual EQ
Observation
The alarm happens during manual
battery test
56
Auto EQ
Observation
The alarm happens during auto boost
charging
57
Cyclic EQ
Observation
The alarm happens during timed boost
charging
58
Dsch Curr Imb
Observation
The alarm happens when discharging
current is unbalanced
59
Abnl Batt Curr
Observation
When the boost charging time is longer
than “boost charging protection time”,
then system changes to float charging, at
this time, the controller checks if the
battery current meets the conditions for
transfering to boost charging condition,
and this alarm happens if this condition is
satisfied 3 times
60
TempComp Active
Observation
The alarm happens when temperature
compensation is enabled
61
Battery Disch
Observation
The alarm happens during current
limitation process
62
Battery TestFail
Major
The alarm happens if the battery test is
ended because the voltage is reduced to
“Voltage of end of battery test”
63
VHi Batt Temp
Observation
64
High Batt Temp
Observation
65
Low Batt Temp
Observation
66
TempSensorFail
Observation
67
Large DU
Batt
Batt Fuse Fail
Critical
Relay 3
The alarm happens if battery charging
curren is bigger than “battery current
limiting point”
68
Batt Over Volt
Critical
Relay 3
69
Batt Under Volt
Critical
Relay 3
70
Batt Over Curr
Critical
Relay 3
71
Large DU
AC Dist
Mains Failure
Major
Relay 2
72
AC
distribution
cabinet
Mains 1 Fail
Critical
Relay 2
73
Mains 2 Fail
Critical
Relay 2
74
Mains 3 Fail
Critical
Relay 2
75
M1 Uab/Ua Fail
Critical
Relay 2
76
M1 Ubc/Ub Fail
Critical
Relay 2
77
M1 Uca/Uc Fail
Critical
Relay 2
78
M2 Uab/Ua Fail
Critical
Relay 2
79
M2 Ubc/Ub Fail
Critical
Relay 2
80
M2 Uca/Uc Fail
Critical
Relay 2
81
M3 Uab/Ua Fail
Critical
Relay 2
82
M3 Ubc/Ub Fail
Critical
Relay 2
83
M3 Uca/Uc Fail
Critical
Relay 2
84
Over Frequency
Observation
None 85
Under Frequency
Observation
None 86
M1 Uab/Ua OverV
Observation
Relay 2
87
M1 Ubc/Ub OverV
Observation
Relay 2
88
M1 Uca/Uc OverV
Observation
Relay 2
89
M2 Uab/Ua OverV
Observation
Relay 2
90
M2 Ubc/Ub OverV
Observation
Relay 2
91
M2 Uca/Uc OverV
Observation
Relay 2
92
M3 Uab/Ua OverV
Observation
Relay 2
93
M3 Ubc/Ub OverV
Observation
Relay 2
94
M3 Uca/Uc OverV
Observation
Relay 2
Page 100
90 Appendix 2 Alarm List
NetSure 801 CA7 Power Supply System (New Skelecton) User Manual
SN
Alarm
device
Alarm name
Alarm category
Related
relay
Alarm description
95
AC
distribution
cabinet
M1 Uab/Ua UnderV
Observation
Relay 2
97
M1 Ubc/Ub UnderV
Observation
Relay 2
98
M1 Uca/Uc UnderV
Observation
Relay 2
99
M2 Uab/Ua UnderV
Observation
Relay 2
100
M2 Ubc/Ub UnderV
Observation
Relay 2
101
M2 Uca/Uc UnderV
Observation
Relay 2
102
M3 Uab/Ua UnderV
Observation
Relay 2
103
M3 Ubc/Ub UnderV
Observation
Relay 2
105
M3 Uca/Uc UnderV
Observation
Relay 2
106
Input MCCB Trip
Critical
Relay 2
107
Output MCCB Trip
Critical
Relay 2
108
SPD Trip
Critical
Relay 2
109
Comm Fail
Critical
Relay 2
110
DC
distribution
cabinet
DC Over Volt
Critical
Relay 3
111
DC Under Volt
Critical
Relay 3
112
Output1~64 Discon
Critical
Relay 3
113
Comm Fail
Critical
Relay 3
114
T1 Over Temp
Critical
Relay 3
115
T2 Over Temp
Critical
Relay 3
116
T3 Over Temp
Critical
Relay 3
117
T1 Under Temp
Major
Relay 3
118
T2 Under Temp
Major
Relay 3
119
T3 Under Temp
Major
Relay 3
120
T1 Sensor Fail
Observation
None
121
T2 Sensor Fail
Observation
None
122
T3 Sensor Fail
Observation
None
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