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NetSure 801 CAA Series Power Supply System
Instruction Manual
Version: V1.0
Revision date: August 16, 2018
BOM: 31013828
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Vertiv | NetSure 801 CAA Series Power Supply System Instruction Manual
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The information contained in this document is subject to change
without notice and may not be suitable for all applications. While
every precaution has been taken to ensure the accuracy and
completeness of this document, Vertiv Group Corporation
assumes no responsibility and disclaims all liability for damages
resulting from use of this information or for any errors or
omissions. Refer to other local practices or building codes as
applicable for the correct methods, tools, and materials to be
used in performing procedures not specifically described in this
document.
This document may contain confidential and/or proprietary
information of Vertiv Group Corporation, and its receipt or
possession does not convey any right to reproduce, disclose its
contents, or to manufacture or sell anything that it may describe.
Reproduction, disclosure, or use without specific authorization
from Vertiv Group Corporation is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered
trademarks of Vertiv Group Corporation. NetPerform™,
NetReach™, NetSure™ and NetXtend™ are trademarks of Vertiv
Energy Systems, Inc. All other trademarks are the property of
their respective owners.
© 2018 Vertiv Energy Systems, Inc. All rights reserved.
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TABLE OF CONTENTS
Safety Precautions .................................................................................. 5
Electrical Safety .................................................................................. 5
Battery ................................................................................................ 6
Others ................................................................................................. 7
OVERVIEW ............................................................................................... 8
Model Information ............................................................................. 8
Overview ............................................................................................ 8
Components ....................................................................................... 9
Rectifier ................................................................................................... 9
Controller .............................................................................................. 11
AC Distribution Cabinet ......................................................................... 11
DC Distribution Cabinet ........................................................................ 16
Rectifier Cabinet .................................................................................... 24
installation preparation ........................................................................ 29
Installation Requirements ................................................................ 29
Environmental Requirements ............................................................... 29
Layout Requirements of The Equipment Room .................................... 29
Power Supply ........................................................................................ 32
Safety Protection................................................................................... 33
Equipment Running Environment Checklist ......................................... 34
Storage Conditions ........................................................................... 36
Installation Preparation ................................................................... 36
Unpacking Inspection ....................................................................... 40
Installation ............................................................................................ 42
Cabinet Installation .......................................................................... 42
Cabinet Placement ................................................................................ 42
Mounting Large Side Door And Small Side Door .................................. 43
Installation on The Floor ....................................................................... 43
Installation on Supporting Rack ............................................................ 45
Parallel Connection Between Cabinets ................................................. 46
Parallel Connection with Copper Bars .................................................. 46
Connecting Power Cables................................................................. 49
Connecting Earth Cable ......................................................................... 50
Connecting Cables Between Rectifier Cabinet and AC
Distribution Cabinet .............................................................................. 52
Connecting AC Input Cables .................................................................. 55
Connecting DC Emergency Lighting Cables (Optional) ......................... 57
Connecting DC Load Cables ................................................................... 58
Connecting Battery Cables .................................................................... 59
Installation Checklist ........................................................................ 60
Installing Rectifier and Controller .................................................... 61
Installing Rectifier ................................................................................. 61
Installing Controller ............................................................................... 62
The Installation and Wiring of The Controller IB2 Extension
Board ..................................................................................................... 63
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Connecting Communication Cables and Auxiliary Power
Cable ................................................................................................. 66
Connecting Rectifier Cabinet Communication Cable ............................ 66
Connecting SPD Signal Parallel Connection Cable of Rectifier
Cabinet .................................................................................................. 68
Connecting Communication Cable of Distribution Cabinet .................. 69
Installing Options ............................................................................. 71
Installing Temperature Sensor .............................................................. 71
Testing ................................................................................................... 73
Note on Testing ................................................................................ 73
Power-on .......................................................................................... 73
Setting Basic Parameters ................................................................. 75
Setting DIP Switch ................................................................................. 75
Setting Basic Parameters for Controller................................................ 76
Checking Alarm and Operation Status ............................................. 82
Testing Controller .................................................................................. 82
Testing AC Distribution ......................................................................... 84
Testing DC Distribution ......................................................................... 85
Access Controller Through Web ........................................................... 86
Operation .............................................................................................. 94
Power Distribution LCD Operation................................................... 94
Controller Operation of Rectifier Cabinet ........................................ 96
System Alarm and Status ...................................................................... 96
Distribution Parameters Setting ........................................................... 96
Setting the Position Number of The Rectifier Manually .................. 96
Adding Load .................................................................................... 100
Adding Rectifier .............................................................................. 100
Maintenance ....................................................................................... 101
Maintenance Requirements .......................................................... 101
General ................................................................................................ 101
Maintenance Tools and Equipment .................................................... 101
Reference Technical Specification for Maintenance .......................... 102
Routine Maintenance Items ........................................................... 104
Routine Maintenance ..................................................................... 107
Basic Inspection .............................................................................. 108
Handling Controller Fault .................................................................... 108
Handling Rectifier Fault ....................................................................... 108
Replacing Rectifier ......................................................................... 110
Emergency Treatment .................................................................... 111
Appendix 1 Technical Parameters ..................................................... 113
Appendix 2 Alarm list ......................................................................... 116
Appendix 3 ENGINEERING DESIGN DIAGRAM ................................... 122
APPENDIX 4 WIRING DIAGRAM ......................................................... 138
Appendix 5 SPARE PARTS ................................................................... 156
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SAFETY PRECAUTIONS
To reduce the chance of accident, please read the safety precautions very carefully before
operation. The "Caution, Notice, Warning, Danger" in this book do not represent all the
safety points to be observed, and are only supplement to various safety points. Therefore,
the installation and operation personnel must be strictly trained and master the correct
operations and all the safety points before actual operation.
When operating Vertiv products, the safety rules in the industry, the general safety points
and special safety instructions specified in this book must be strictly observed.
Electrical Safety
I. Hazardous voltage
DANGER! 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.
When water or moisture is found on the Subrack, turn off the power immediately. In moist
environment, precautions must be taken to keep moisture out of the power system.
"Prohibit" warning label must be attached to the switches and buttons that are not
permitted to operate during installation.
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
II. Expected short-circuit current
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.
III. Dangerous energy
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.
IV. Multi-power input
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.
V. Power supply cable
NOTICE! Make sure the cable and cable labels are in accordance with actual installation
before cable connection.
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VI. Tools
WARNING! In high voltage and AC operation, special tools must be used. No common or self-
carried tools should not be used.
VII Thunderstorm
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.
VIII Static
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.
IX Short circuit
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.
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! Before any operation on battery, read carefully the safety precautions for battery
transportation and the correct battery connection method.
Non-standard operation on the battery will 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. Before any operation
on battery, pay attention to the following points:
Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.
Use special insulated tools.
Use eye protection device, and take preventive measures.
Wear rubber gloves and apron to guard against electrolyte overflow.
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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
I. Taking out rectifier
WARNING! When taking out the rectifier, you should replace with a new one or install a
dummy plate immediately.
II. Hoisting heavy objects
WARNING! Never walk under the crane arm or the hoisted objects when hoisting heavy
objects.
III. Sharp corners of the objects
WARNING! When moving equipment by hands, wear protective gloves to avoid injury by
sharp objects.
IV. Inserting and extracting boards
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.
V. Binding signal lines
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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OVERVIEW
The NetSure 801 CAA 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.
Model Information
The model information of the power supply system is shown in Figure 1.
Figure 1: Model information
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
A
Rectifier number in typical power supply system: 4. 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.
the rectifier: 5800W
Overview
The power supply system is composed of AC distribution cabinet, DC distribution cabinet, rectifier
cabinet, controller, rectifier and options.
The number of AC distribution cabinet, DC 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 2.
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Figure 2: Three-cabinet system structure
Rectifier Controller
AC distribution cabinet Rectifier cabinet DC distribution cabinet
See Appendix 1 Technical Parameters for the technical parameters of AC distribution cabinet, DC
distribution cabinet and rectifier cabinet.
Components
Rectifier
The system uses rectifier R48-5800A/R48-5800e, the frame structure of which mainly consists of
panel, enclosure, handle, and so on, as shown in Figure 3.
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Figure 3: Rectifier appearance
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 4, and functions of
indicators are given in Table 1.
Figure 4: Rectifier front panel
Slide switch
Handle
Fixing screw
Power indicator
Protection indicator
Fault indicator
Current indicators
Table 1: 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
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Controller
For the specific content of the controller, please refer to M831D Controller User Manual.
AC Distribution Cabinet
The AC distribution cabinet is available in four models: PD380/400AFH-A-Y1, PD380/630AFH-A-Y1,
PD380/630AFA-A-Y1 and PD380/630AFH-A-YF. The appearances of the AC distribution cabinets are
the same, as shown in Figure 5.
Figure 5: Appearance of AC distribution cabinet
Power distribution LCD
Indicator
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The internal structure of AC distribution cabinet PD380/400AFH-A-Y1 is shown in Figure 6.
Figure 6: PD380/400AFH-A-Y1 AC distribution cabinet
Knife-blade switch
AC output MCB
(a) Front view (front door open)
Neutral busbar
Earth busbar
(b) Rear view (rear door open)
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The internal structure of AC distribution cabinet PD380/630AFH-A-Y1 is shown in Figure 7.
Figure 7: PD380/630AFH-A-Y1 AC distribution cabinet
Knife-blade switch
SPD MCB
AC output MCB
Class C SPD
(a) Front view (front door open)
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Neutral busbar
Earth busbar
(b) Rear view (rear door open)
The internal structure of AC distribution cabinet PD380/630AFA-A-Y1 is shown in Figure 8.
Figure 8: PD380/630AFA-A-Y1 AC distribution cabinet
ATS
ATS controller
AC output MCB
(a) Front view (front door open)
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Neutral busbar
Earth busbar
(b) Rear view (rear door open)
The structure and configuration of PD380/630AFH-A-YF is determined by customer requirement.
See purchase order for description.
DC Distribution Cabinet
The DC distribution cabinet is available in seven models: PD48/1600DF-A-Y1, PD48/1600DF-A-Y2,
PD48/1600DF-A-YF, PD48/2500DF-A-Y1, PD48/2500DF-A-Y2, PD48/2500DF-A-Y3 and PD48/2500DFA-YF. The appearances of the DC distribution cabinets are the same, as shown in Figure 9.
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Figure 9: Appearance of DC distribution cabinet
Indicator
Power distribution LCD
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The internal structure of PD48/1600DF-A-Y1 DC distribution cabinet is shown in Figure 10.
Figure 10: PD48/1600DF-A-Y1 DC distribution cabinet
Battery fuse
Battery shunt
Output shunt
Output fuse
LCD
Power distribution
monitoring
(a) Front view (open front door)
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Total load current hall sensor
DC SPD
(b) Rear view (remove rear door)
The internal structure of DC distribution cabinet PD48/1600DF-A-Y2 is shown in Figure 11.
Figure 11: PD48/1600DF-A-Y2 DC distribution cabinet
Battery fuse
Power distribution
monitoring
LCD
Battery shunt
Output shunt
Output fuse
(a) Front view (open front door)
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Total load current hall sensor
DC SPD
(b) Rear view (remove rear door)
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The internal structure of DC distribution cabinet PD48/2500DF-A-Y1 is shown in Figure 12.
Figure 12: PD48/2500DF-A-Y1 DC distribution cabinet
LCD
Power distribution
monitoring
Output fuse
Output shunt
Battery shunt
Battery fuse
(a) Front view (open front door)
DC SPD
Total load current hall sensor
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(b) Rear view (remove rear door)
The internal structure of DC distribution cabinet PD48/2500DF-A-Y2 is shown in Figure 13.
Figure 13: PD48/2500DF-A-Y2 DC distribution cabinet
LCD
Power distribution
monitoring
Battery fuse
Battery shunt
Output shunt
Output fuse
(a) Front view (open front door)
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DC SPD
Total load current hall sensor
(b) Rear view (remove rear door)
The internal structure of DC distribution cabinet PD48/2500DF-A-Y3 is shown in Figure 14.
Figure 14: PD48/2500DF-A-Y3 DC distribution cabinet
Battery fuse
Battery shunt
Output shunt
Output fuse
LCD
Power distribution
monitoring
(a) Front view (open front door)
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Total load current hall sensor
DC SPD
(b) Rear view (remove rear door)
The structure and configuration of PD48/1600DF-A-YF and PD48/2500DF-A-YF are determined by
customer requirement. See purchase order for description.
Rectifier Cabinet
The structure of rectifier cabinet Rack1000-A is shown in Figure 15, the structure of rectifier cabinet
Rack1500-A is shown in Figure 16 and the structure of rectifier cabinet Rack2000-A is shown in
Figure 17.
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Figure 15: Rack1000-A rectifier cabinet
Rectifier input MCB
Controller
Rectifier
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Figure 16: Rack1500-A rectifier cabinet
Rectifier input MCB
Controller
Rectifier
Figure 17: Rack2000-A rectifier cabinet
Rectifier input MCB
Controller
Rectifier
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The name, function and use of the cabinet components are given in Table 2.
Table 2: 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
When the AC input 1 is available, HL1 illuminates; when
the AC input 2 is available, HL2 illuminates
Rectifier cabinet
When there is electricity in the busbar, the LED
illuminates
DC cabinet
Fault LED
When the distribution cabinet is in normal operation, it
is off; it illuminates otherwise
AC cabinet, DC cabinet
Display
Display the input voltage, current, frequency, running
mains input number, SPD state, output MCB state and
alarm information of the AC cabinet
AC cabinet
Display the busbar voltage, total load current, battery
voltage, battery current, load fuse status and alarm
information of the DC cabinet
DC cabinet
AEM02U11
monitoring
board
Measure the AC input voltage, phase-B current of the
running mains input, 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
HDU1U11
monitoring
board
Measure the busbar voltage, total load current, battery
voltage, battery current and load fuse status;
annunicate audible and visual alarms when the DC
cabinet malfunctions, and simultaneously transmit
relevant information to the display of the DC cabinet
and the controller
DC cabinet
SMPDU1X3
shunt
sampling
board
Sample the load branch current, load fuse status of the
DC cabinet, and send information to the controller
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
SPD MCB
It is used to protect the 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
AC 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
PD380/400AFH &
PD380/630AFH AC
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
PD380/630AFA AC cabinet
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NAME
FUNCTION
CABINET
Output MCB
Configured according to custermer requirement
AC cabinet
Output fuse
Configured according to custermer requirement
DC cabinet
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INSTALLATION PREPARATION
Installation Requirements
Environmental Requirements
The environmental conditions of the equipment room must meet the requirements listed in Table 3.
Table 3: Environmental conditions for the equipment room
ENVIRONMENTAL CONDITIONS
RECONMMENDED RANGE
Ambient temperature
-5°C to 40°C
Humidity
≤ 90%RH, no condensation
Dust density
≤ 1mg/m3
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.
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 is 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.
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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.
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 18 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.
Figure 18: Locating cabinet
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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
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 Installing
Cabinet); secondly, the system should be reinforced as shown in Figure 19 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.
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Figure 19: 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.
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-A-Y1 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-A-Y1 AC distribution cabinet and the transformer for
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short-circuit protection. PD380/630AFH-A-Y1 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-A-Y1 AC distribution cabinet and the
transformer for short-circuit 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.
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 20.
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 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.
Figure 20: Diagram of SPD mounting & system earthing
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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
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 4.
Table 4: 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
Equipment Running Environment Checklist
The equipment running environment checklist is given in Table 5.
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Table 5: 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 to 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
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
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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.
Installation 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 Maintenance Tools And Equipment 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 connection cables, battery load
connection cables, earth cables, and earth connection cables. The delivered cables and accessories
are given in Table 6 (only include cables and accessories between rectifier cabinet and AC cabinet,
and signal cables among AC cabinet, rectifier cabinet and DC cabinet).
Table 6: Delivered accessories
BOM
DESCRIPTION
LENGTH
NOTE
25030154
AC input cable of rectifier cabinet,
25mm2, black
10.5 ~
27m
Applicable for the power
connection between the AC
distribution cabinet and rectifier
cabinet
02300119
AC input cable of rectifier cabinet
3 ~ 6PCS
Applicable for crimping the AC
input cable of the rectifier cabinet.
1PCS for each 1000A rectifier
cabinet
04111498
W1PN5SL20-W1PN5Z cable suite
（RS485 signal cable connected
between AC ATS cabinet and
rectifier cabinet, and connected
between AC ATS cabinets-5.5m）
5.5m
Applicable for RS485 parallel cable
among the AC distribution cabinet,
rectifier cabinet and DC
distribution cabinet)
04112962
WA4AASL05-WA4AAZ cable suite
(48V auxiliary power source
cable)
5.5m
Applicable for the 48V auxiliary
power source cable of the AC
distribution cabinet
04116169
W64AASL09 cable suite (CAN bus)
2.8m
21241727
Parallel cabinets board
/
Used for locking the top parts of
two adjacent cabinets
02233399
Required for the AC cabinet and
rectifier cabinet
/
Include anchor screw used for
installing the cabinet and
engineering cable label
02233400
Required for the DC cabinet
/
Include anchor screw used for
installing the DC cabinet,
engineering cable label, one fuse
puller and one three-meter length
of temperature cable
21502330
Large side door of the rectifier
cabinet
/
Used for sealing the lower part of
rectifier cabinet side
21502332
Small side door of the rectifier
/
Used for sealing the upper part of
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BOM
DESCRIPTION
LENGTH
NOTE
cabinet
rectifier cabinet side
21502443
Large side door of the DC cabinet
/
Used for sealing the lower part of
DC cabinet side
21502444
Small side door of the DC cabinet
/
Used for sealing the upper part of
DC cabinet side
21505285
Parallel copper bar in Rectifier/DC
cabinet
/
Internal parallel copper bar
between Rectifier cabinet and DC
cabinet. Applicable for rectifier
cabinet – DC cabinet spaced
placement
21505286
Parallel copper bar in Rectifier
cabinet
/
Internal parallel copper bar
between Rectifier cabinets.
Applicable for rectifier cabinet –
DC cabinet
non-spaced placement
21170326
Parallel copper bar in DC cabinet
/
Internal parallel copper bar
between DC cabinets. Applicable
for rectifier cabinet – DC cabinet
non-spaced placement
21171348
4000A parallel copper bar
component in Rectifier cabinet
/
Used in rectifier cabinet,
overlapped on the internal copper
bar of rectifier cabinet for flowing
through 4000A current. Applicable
for rectifier cabinet – DC cabinet
non-spaced placement
21171316
4000A parallel copper bar
component in DC cabinet
/
Used in DC cabinet, overlapped on
the internal copper bar of DC
cabinet for flowing through 4000A
current. Applicable for rectifier
cabinet – DC cabinet non-spaced
placement
21170328
Internal parallel pad
/
For different cabinets, due to
increased stacking, the height of
the lap surface is inconsistent
21505287
Fixed piece assembly of parallel
bar
/
As an option when the system
adopts internal parallel
connection
02300119
Cabinets parallel copper bar
accessories
/
Used to fix the internal parallel
copper bar to the bottom of the
cabinet
21505235
External fixtures outside the
rectifier cabinet
/
Used to fix 21505274 and
21505277 copper bars, when the
rectifier cabinets are paralleling
externally
21505274
External parallel copper bar
component of the rectifier
cabinet
/
Used in rectifier cabinet, for
leading out the copper bar from
the top of the cabinet. Applicable
for external paralleling, no internal
paralleling and the rectifier
cabinet – DC cabinet spaced
placement
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BOM
DESCRIPTION
LENGTH
NOTE
21505277
Short copper bar component of
external parallel in rectifier
cabinet
/
Used in rectifier cabinet, for
leading out the copper bar from
the top of the cabinet. Applicable
for external paralleling and
internal paralleling (that is 6000A
non-spaced placement)
21171289
External parallel copper bar
component of the DC cabinet
/
Used in DC cabinet, for leading out
the copper bar from the top of the
cabinet
21170327
Connection bar component for
external parallel
/
Connection bar used for external
parallel, used to connect the
21505277 and 21171289
21505280
Expansion negative bar
component of rectifier cabinet
/
Used in rectifier cabinet, when
used in expansion of old cabinets,
convert the negative parallel port
into the switch copper bar of CA7
parallel port
21171294
Expansion negative bar
component of DC cabinet
/
Used in DC cabinet, when used in
expansion of old cabinets, convert
the negative parallel port into the
switch copper bar of CA7 parallel
port
Note:
When the AC distribution cabinet is not selected, then accessories of the rectifier cabinet will not
be delivered, because the distance from the superior cabinet to the rectifier cabinet cannot be
calculated
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 (mm2), 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. Kcopper=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 7. Select the load cable CSA according to the Table
8.
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Table 7: Battery cable CSA selection
DC
CABINET
RATED
CURRENT
BATTERY
FUSE RATED
CURRENT
MAX.
BATTERY
CURRENT
MIN. CABLE CSA
SPECS OF THE
CABLE CONNECTOR
MAX. CABLE
LENGTH
(ALLOWABLE
VOLTAGE DROP:
0.5V)
1600A
800A
800A
2 × 240mm2
OT cable connector
of M12 or M16 size
10m
2500A
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.
2. The battery cable should reach at least +90°C heat durability. It is recommended to use doubleinsulated copper-core flame retardant cable as battery cable
Table 8: Load cable CSA 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
The MCB/fuse capacity should be strictly limited so that it can function properly upon load overcurrent. The capacity of 100A and above MCB/fuse is required to be 1.5 ~ 2 times larger than the
load peak capacity, and the capacity of 63A and below MCB is twice of the peak load capacity. (If
the output MCB of AC cabinet is connected to other loads of the rectifier cabinet, it should be used
according to this principle.)
The CSA of grounding cable should be in accordance with that of the maximum power distribution
cable, but not less than 95mm2.
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 M8 OT - shape or pipe - shape cable connectors.
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The recommended CSA of AC input cables are shown in Table 9.
Table 9: AC input cable selection
CABINET
CONNECTOR
SPECS
REMARKS
CAPACITY
CONNECTOR SPECS
PD380/400AFHA-Y1
AC distribution
cabinet
AC input MCB
400A
Eight M12 bolts
(suggested cable
CSA 185mm2)
The live line and neutral
line of AC power supply
Grounding
busbar
One M16
bolt
suggested cable CSA
120mm2
The grounding bar of
the room
PD380/630AFHA-Y1
AC distribution
cabinet
AC input MCB
630A
Eight M16 bolts
(suggested cable
CSA 240mm2)
The live line and
neutral line of AC
power supply
Grounding
busbar
One M16
bolt
Suggested cable CSA
120mm2
The grounding bar of
the room
PD380/630AFAA-Y1
AC distribution
cabinet
AC input MCB
630A
Eight M12 bolts
(suggested cable
CSA 240mm2)
The live line and
neutral line of AC
power supply
Grounding
busbar
One M16
bolt
Suggested cable CSA
120mm2
The 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.
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.
2. Check against the packing label when delivering the equipment.
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:
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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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INSTALLATION
This chapter introduces the installation and connection of NetSure 801 CAA series power supply
system (power supply system for short).
Cabinet Installation
Cabinet Placement
Before installing and connecting the power system, make sure the layout of each cabinet in the
power system, especially the placement of DC cabinet and rectifier cabinet. Different placement
may directly impact the selection and installation of the parallel connection copper bars, there are
mainly two placement modes:
Rectifier cabinet – DC cabinet spaced placement
The NetSure 801 CAA 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-A rectifier cabinet, place one rectifier
cabinet or two rectifier cabinets as a unit. For a system composed of Rack2000-A, Rack1500-A
rectifier cabinet, place one rectifier cabinet as a unit.
Recommended arrangement of 6000A system using Rack1000-A rectifier cabinet.
AC cabinet AC cabi
net
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-A, Rack1500-A rectifier cabinet:
AC cabinet AC cabinet Rectifier cabinet
DC cabinet Rectifier cabinet
DC cabinet Rectifier cabinet DC cabinet AC cabinet AC cabinet
Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement
If the installation site does not permit the cabinet arrangement shown above, it is suggested to use
two parallel connection copper bars so that the current carrying capacity of single connection bar
does not exceed 2000A.
If ‘Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement’ is adopted,
the cabinet placement on the customer site must be stated or a schematic arrangement of the
cabinets must be provided when pre-purchasing the power system.
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NOTE! Upon DC parallel connection of the power system, it is recommended to use the
‘Rectifier cabinet – DC cabinet spaced placement’. If no statement about cabinet placement
was made when purchasing the power system, the default shipping status of the power
system is ‘Rectifier cabinet – DC cabinet spaced placement’.
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
21 According to distribution situation, cabinet placement and cabinet parallel connection, the side
doors are configured in various ways.
Before installing and connecting the cabinet, check as follows:
1. Make sure the sides of the first cabinet and the last one in a row of cabinets must be closed. The
rectifier cabinet need to install large side door and small side door. The AC distribution cabinet and
DC distribution cabinet need to install side doors.
2. Make sure the rectifier cabinets in the middle part of a row of cabinets are all installed with large
side door, so that they can isolate from the adjacent cabinets. Do not install small side doors, so
that interior parallel connection of cabinets and interior wiring can be easy performed.
3. Make sure the DC cabinets in the middle part of a row of cabinets are not installed with side
doors.
The large side doors and small side doors of the rectifier cabinet are interchangeable, users can
install the doors on the right side or the left side. The side doors of the DC distribution cabinet are
same with rectifier cabinet, users can exchange them on the spot.
Figure 21: Side doors
Small side door of
the rectifier cabinet
Large side door of
the rectifier cabinet
Large side door
of the DC cabinet
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 22) 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.
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Figure 22: Installation size of the cabinet base (unit: mm)
403.5
600
396
600
4-φ18
400
400
(a) Installation size of the AC distribution cabinet
530
600
409
600
4-φ14
(b) Installation size of the rectifier cabinet
603.5
800
396.5
600
4-φ18
600
400
(c) Installation size of the DC distribution cabinet
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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.
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.
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 23. The installation steps are the same as
the first three steps in Installation on The Floor.
Figure 23: Installing supporting rack
Floor
Expansive pipe
Bolt
Spring washer
Plain washer
Expansive pipe finshed
Floor
Bolt
Spring washer
Plain washer
Expansive pipe
Step 2: fix the cabinet
Install the power supply cabinet on the supporting rack, as shown in Figure 24.
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Figure 24: Installing power cabinet on supporting rack
Supporting rack
Cabinet base
Expansive pipe finished
Plain washer
Spring washer
Bolt
Spring washer
Plain
Plain washer
Cabinet base
Supporting rack
Bolt
Expansive pipe finshed
After the cabinet is installed, shake the cabinet from different directions. No obvious shake should
be felt.
Parallel Connection Between Cabinets
Users need to use connection straps to fix adjacent cabinets at the top, as shown in Figure 25. The
connection straps are accessories.
Figure 25: Parallel connection between cabinets (top view, unit: mm)
600
600
800
600
68.5
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. Upon parallel
connection of the power system, it is recommended to use the ‘Rectifier cabinet – DC cabinet
spaced placement’.
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. Install the parallel copper bar nut kit.
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3. Connect the DC positive bars and DC negative bars inside the rectifier cabinet and DC distribution
cabinet respectively by parallel copper bars, as shown in Figure 26.
4. If users use ‘Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement’,
they need to contact Vertiv for technical support.
Take parallel connections between a rectifier cabinet and a DC distribution cabinet for example, the
procedures for installing the parallel copper bar are as follows:
1). Install the nut kit on the parallel board V1 between the positive and negative cabinets adjacent
to one side of the external parallel connection port, as shown in Figure 26.
Figure 26: Parallel connection between cabinets (1)
Parallel board V1 between cabinets
External parallel connection port (reserved)
2). Install the nut kit on the main positive board V14 in DC cabinet (the nut kit has been installed on
the copper bar of the negative cabinet at factory, therefore the on-site installation is unnecessary),
as shown in Figure 27. Note that if only one side of the DC cabinet needs to be paralleled, just
install one side.
Figure 27: Parallel connection between cabinets (2)
Nut kit
Main positive board V14
in DC cabinet
3). Install the parallel board between cabinets, connect one side with nut kit (adjacent to the
external parallel connection port) to the parallel board in the rectifier cabinet, as shown in Figure
28.
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Figure 28: Parallel connection between cabinets (3)
Parallel positive board V12
in rectifier cabinet
Nut kit (install on site)
Parallel board V1 between cabinets
Parallel positive board V12
in rectifier cabinet
Parallel board V1 between cabinets
Parallel negative board V13
in DC cabinet
Parallel positive board V14
in DC cabinet
External parallel connection port (reserved)
Nut kit (install on site)
External parallel connection port (reserved)
Nut kit (install on site)
Nut kit (installed at factory)
4). The installed parallel board is shown in Figure 29. The nut kit of the rectifier cabinet should be
installed on the parallel board between the cabinets, that of the DC distribution cabinet should be
installed on the copper bar in the cabinet.
Figure 29: Parallel connection between cabinets (4)
Front View
Positive parallel board
in the rectifier cabinet
Nut kit
Negative parallel board
in the rectifier cabinet
Nut kit
Parallel board
between the cabinets
Positive parallel board in the DC cabinet
Parallel board between the cabinets
Negative parallel board in the DC cabinet
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Rear view
Positive parallel board
in the DC cabinet
Nut kit
Parallel board
between the cabinets
Nut kit
Positive parallel board in the rectifier cabinet
Negative parallel board
in the DC cabinet
Parallel board
between the cabinets
Negative parallel board in the rectifier cabinet
Top view
Positive parallel board in
the rectifier cabinet
Nut kit
Parallel board
between the cabinets
Negative parallel board in the rectifier cabinet
Nut kit
Parallel board between the cabinets
Positive parallel board in the DC cabinet
Negative parallel board in the DC cabinet
NOTE! The power system uses distributed monitoring mode, the DC cabinet can be placed
separately from the power system. Typical applications are placed in different load
concentration points, such as different floors for nearest power distribution. The separately
placed DC cabinet uses cable instead of copper bar for parallel connection with the power
system. The connection point is the mounting holes of the copper bar, so that the system can
correctly detect the load current.
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 10. Among which, 1 ~ 6 are power
cables between cabinets, 7 ~ 11 are communication cables between cabinets. The AC input cable,
battery cable and load cable should be prepared by user themselves.
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Table 10: Accessory cables used in cable connection
NO.
BOM
DESCRIPTION
LENGTH
NOTE
1
Usersupplied
Input cable of the AC distribution
cabinet
/
2
Usersupplied
User output cable of the AC
distribution cabinet (not for the
rectifier cabinet)
/
3
25030154
AC input cable of the rectifier
cabinet, 25mm2, black
10.5 ~
27m
4 02300119
AC input cable of the rectifier
cabinet
3 ~ 6PCS
5
Usersupplied
Battery input cable of the DC
distribution cabinet
/ 6
Usersupplied
Load cable of the DC distribution
cabinet
/ 7
Usersupplied
Grounding cable
/
8
04111498
W1PN5SL20-W1PN5Z cable suite
(RS485 signal cable connected
between AC ATS cabinet and
rectifier cabinet, and connected
between AC ATS cabinets-5.5m)
5.5m
Applicable for RS485
parallel cable among the
AC distribution cabinet,
rectifier cabinet and DC
distribution cabinet)
9
04112962
WA4AASL05-WA4AAZ cable suite
(48V auxiliary power source cable)
5.5m
Applicable for 48V
auxiliary power source
cable of the AC
distribution cabinet
10
04116169
W64AASL09 cable suite (CAN bus)
2.8m
Applicable for CAN loop
connection of two or
more rectifier cabinets
11
04113664
WA4AASL09-WA4AAZ cable suite
(SPD signal parallel connection
cable in rectifier cabinet)
5.5m
Applicable for SPD signal
loop connection of two or
more rectifier cabinets
Connecting Earth Cable
The power supply system uses common earth mode. The connection procedures are as follows.
1. Use the earth cable to connect the earth bolt at the rear lower part of the rectifier cabinet to the
earth bar of the AC distribution cabinet, see Figure 30 and Figure 31.
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Figure 30: Earth terminal of the rectifier cabinet (rear view)
Earth terminal
Figure 31: Earth bar of the AC distribution cabinet (rear view)
AC neutral bar
AC earth bar
2. Use the earth cable to connect the earth bolt of the DC distribution cabinet to the earth bar of
the AC distribution cabinet. The earth terminal of DC distribution cabinet is as shown in Figure 32.
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Figure 32: Earth terminal of the DC distribution cabinet (left view)
Earth terminal
3. 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 31 and Figure 32).
4. 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.
Connecting Cables Between Rectifier Cabinet and AC Distribution Cabinet
For Rack1000-A rectifier cabinet, choose one 160A MCB as AC input switch of the rectifier cabinet.
For Rack1500-A and Rack2000-A rectifier cabinets, choose two 160A MCBs 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. The cable
specification cannot greater than 50mm2. The wiring is shown in Figure 33.
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Figure 33: Connection of AC input cables of rectifier cabinet in AC distribution cabinet (front view)
2. Connect one end of the cable to the output terminal of the selected MCB in the AC distribution
cabinet (do not connect the neutral line). The AC input cable wiring is shown in Figure 34 and Figure
35.
Figure 34: AC input cable wiring (manually switch AC distribution cabinet, rear view)
Right view
Front view
Top view
Input cable wiring area
Output cable wiring area one
Output cable wiring area two
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Figure 35: AC input cable wiring (automatically switch AC distribution cabinet, rear view)
Right view
Front view
Output cable wiring area
Input cable wiring area
Top view
3. Connect the other end of the cable to the AC input terminal of the rectifier cabinet. The
connection of AC input cables in rectifier cabinet is shown in Figure 36.
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Figure 36: Connection of AC input cables in rectifier cabinet
1B 1C 2B 2C
NOTE! The Rack1500-A and Rack2000-A rectifier cabinet can work normally only when the
two routes of AC input are accessed in.
Connecting AC Input Cables
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:
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 37 and Figure 38.
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Figure 37: Mains input cable connection to AC distribution cabinet (manually switch AC distribution
cabinet, rear view)
1A 1B 1C 2A 2B 2C 1N 2N
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Figure 38: Mains input cable connection to AC distribution cabinet (automatically switch AC
distribution cabinet)
1A
1B
1C
1N
2A
2B
2C
2N
2N 2C 2B 2A
1N 1A 1B 1C
Rear view
Terminal of route one input cable
Terminal of route two input cable
Top view
Connecting DC 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 39. (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.
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 39.
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 39.
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Figure 39: Connection of emergency lighting cables in AC distribution cabinet
A
A amplified
Positive input cable
Negative input cable
Negative output cable
Positive output cable
Connecting DC Load Cables
The use of the DC distribution cabinet top cover is described below:
The cable entry holes of the DC distribution cabinet top cover are divided as load cable entry space
and battery cable entry holes, as shown in Figure 40. Lead the cables in or out the DC distribution
cabinet from the top cover sponge or epoxy board.
Figure 40: Cable entry hole for top cover
Load cable entry space (epoxy board)
Load cable / battery cable
entry space (sponge)
Reserved copper bar entry holes of external parallel cabinets
Sponge bar
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.
The DC load cables should be connected as follow:
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 41.
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Figure 41: Connecting load cable of the DC distribution cabinet
Negative load cable
Positive load cable
Right view
Positive load cable
Negative load cable
Rear view
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 two 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 42.
NOTE! The battery negative cables should be connected to the two battery fuses, not the
single one.
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Figure 42: Battery cable connection in DC cabinet
Negative cable of battery one
Negative cable of battery two
Front view
Positive cable of battery two
Positive cable of battery one
Rear view
Installation Checklist
After installation, security check should be conducted using the following checklist.
Table 11: 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
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NO
STANDARDS AND REQUIREMENTS
PASS
NOTES
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-A, check that 2-route AC input is
available.
Yes/No
Installing Rectifier and Controller
System assembly involves the installation of rectifier and controller.
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 43 (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 43 (b).
3. Tighten the bolts on the handle to fix the rectifier on the rack, as shown in Figure 43 (c) and
Figure 43 (d).
Figure 43: Installing rectifier
Fixing screw
Handle
Slide switch
(a) (b)
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(c) (d)
Installing Controller
The controller should be installed using the following procedures:
1. Unscrew the screws on the dummy plate, as shown in Figure 44.
Figure 44: Position of the dummy plate
Dummy panel
2. Unscrew the captive screw at the top of the handle of the controller, as shown in Figure 45.
Figure 45: Controller Panel diagram
Captive screw
Handle
Captive screw
Handle
3. Push the controller into the correct position, and then fix the screws on the panel, as shown in
Figure 46.
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Figure 46: Fixing the controller in the cabinet
Controller
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.
The Installation and Wiring of The Controller IB2 Extension Board
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 47.
Figure 47: IB2 extension board
Signal extension board
RS232 port
Cover plate
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NOTE! The IB2 extension board should be installing in the rectifier cabinet with the controller
when there are multiple rectifier cabinets in the system.
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 48.
Figure 48: IB2 board pin definition
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
Digital quantity
input port
DI 1
Alarm output dry contact, DC 15V~60V
DI 1
J9
J8
DO5
J7
DO3
DO7
J6
DO1
J5 J4 J3
8 7 6 5 4 3 2
DO8
DO6 DO4 DO2
8 7 6 5 4 3 2 1
Digital quantity
input port
SW1
Address DIP
I2C port
J12
J11
J2
5 3 1
5 3 1 5 3 1
5 3 1
5 3 1 5 3 1
5 3 1
6 4 2 6 4 2
6 4 2 6 4 2
6 4 2
6 4 2
6 4 2
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 12 for the dry contact terminal definition.
Table 12: Dry contact terminal definition
NAME OF DOUBLELAYER PORT
PIN NO.
PIN NAME
DEFINITION
J3
1
DI1-
Digital input 1-
2
DI1+
Digital input 1+
3
DI2-
Digital input 2-
4
DI2+
Digital input 2+
5
DI3-
Digital input 3-
6
DI3+
Digital input 3+
J4
1
DI4-
Digital input 4-
2
DI4+
Digital input 4+
3
DI5-
Digital input 5-
4
DI5+
Digital input 5+
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NAME OF DOUBLELAYER PORT
PIN NO.
PIN NAME
DEFINITION
5
DI6-
Digital input 6-
J4
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+
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
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
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 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 48 and the silkscreen, connect the signal cables to the corresponding terminals
DI1~8 on IB2 board. The connection in Figure 48 illustrates the connection of input terminal DI1.
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Connect I2C cable
Connect the I2C cable plug reserved on the cabinet to the J2 port on IB2 board.
Connect RS232 communication cable
The RS232 port position of the rectifier cabinet is shown in Figure 47. If you need to use it, lead the
RS232 cable from the secondary cable hole on the top of the rectifier cabinet and connect it to the
RS232 port on the left side of the controller. The interface specification is RS232 standard serial
port DB9 male connector. The pin definition of RS232 port is shown in Figure 49.
Figure 49: RS232 Pin definition
DCD232
RXD232
TXD232
DTR232
CGND
RTS232
5
9
8
1
6
Connecting Communication Cables and Auxiliary Power Cable
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 50.
Figure 50: Matched resistance
匹配电阻
CAN通信电缆
Matched resistanceCAN communication cable
CAN communication cable
Matched resistance
2) Connect the CAN communication cables between the rectifier cabinets.
2. Depending on your controller installation location in the Figure 51, Figure 52 and Figure 53,
connect CAN communication cable between the rectifiers and matching resistance. And install the
controller CAN communication and connection cables according to Figure 51.
When the controller mounted to the rectifier on the right, connect the CAN communication cable
between the rectifier cabinets as shown in Figure 51.
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Figure 51: Rectifier cabinet CAN communication cable connection diagram 1 (rear view)
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
CAN
CAN
Matching
resistance
When there
are only 2
rectifier
cabinets,
attach the
matching
resistance here
Matching resistance
Controller
Recti fi er
cabinet 1
Recti fi er
cabinet 2
Recti fi er
cabinet 3
When the controller mounted to the rectifier in the middle, connect the CAN communication cable
between the rectifier cabinets as shown in Figure 52.
Figure 52: Rectifier cabinet CAN communication cable connection diagram 2 (rear view)
CAN
CAN
Rectifier
cabinet 3
Rectifier
cabinet 2
Rectifier
cabinet 1
Matching resistance
Controller
Matching resistance
CAN
CAN
Matching resistance
controller
Matching resistance
Recti fi er
cabinet 3
Recti fi er
cabinet 2
Rect ifi er
cabinet 1
When the controller mounted to the rectifier on the left, connect the CAN communication cable
between the rectifier cabinets as shown in Figure 53.
Figure 53: Rectifier cabinet CAN communication cable connection diagram 3 (rear view)
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
CAN
CAN
Matching resistance
Controller
When there
are only 2
rectifier
cabinets,
attach the
matching
resistance
here
Recti fi er
cabinet 3
Rect ifi er
cabinet 2
Recti fi er
cabinet 1
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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 51, Figure 52 and Figure 53,
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.
Connecting SPD Signal Parallel Connection Cable of Rectifier Cabinet
If there are two or more rectifier cabinets in the power system, it is necessary to connect the SPD
signal cables between the rectifier cabinets. The specific steps are as follows.
1. Take off the shorting terminal of SPD signal cable from the rectifier cabinet (the shape is similar
to the CAN loop communication cable terminal, in which the CAN loop communication cable
terminal is a 2 PIN terminal, the SPD signal cable terminal is 4 PIN), and the position is similar to the
CAN matching resistor.
2. Connect the SPD parallel cables of the rectifier cabinet, the connections are shown in Figure 54
and Figure 55. Note that the main cabinet (the rectifier cabinet that installs the controller) can only
connect the parallel cable with one terminal, and the terminal cabinet should be connected to the
cabinet with shorting terminals.
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Figure 54: SPD signal cable connection diagram of two rectifier cabinets (rear view)
Monitor
SPD
SPD
Rectifier
cabinet 2
Rectifier
cabinet 1
Short connection terminal
Figure 55: SPD signal cable connection diagram of three rectifier cabinets (rear view)
Short connection terminal
Monitor
SPD SPD
SPD
Rectifier
cabinet 3
Rectifier
cabinet 2
Rectifier
cabinet 1
Connecting Communication Cable of Distribution Cabinet
Connecting RS485 communication cable
In the three-cabinet power system, RS485 communication cables are used to connect AC
distribution cabinet to DC distribution cabinet, and DC distribution cabinet to controller. The
connection relation is shown in Figure 56 and Figure 57.
For AC/DC distribution cabinet, reserved the 3 PIN plug-in connectors in the RS485 cables on the
rear top of the cabinet, through the 3 PIN plug-in connectors connected RS485 cables of the
distribution cabinets.
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In the RS485 port of the M831D controller, connect the RS485 communication cables from
distribution cabinet through 3 PIN SMR plug-in connectors.
Figure 56: Connection of communication cable in AC distribution cabinet (rear view)
RS485 port
RS485A
RS485B
PE
RS485A
RS485B
PE
RS485 port amplified
Figure 57: Connection of communication cable in DC distribution cabinet (front view)
RS485 port
RS485A
RS485B
PE
RS485A
RS485B
PE
RS485 port amplified
3. When the system has multiple AC cabinets or DC cabinets, connect the RS485 cables between
cabinets according to Figure 58. If the cabinet number is different from Figure 58, increase or
decrease the parallel cables between cabinets according to Figure 58. The connection of RS485
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cable should use bus type wiring, and the controller is always located at the first end or the end of
the circuit.
4. When the DC distribution cabinet is placed separately from the power system, you also need to
connect the DC cabinet to the RS485 communication cable of the power system. Otherwise, the
system cannot monitor the cabinet and battery state.
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 58.
Figure 58: Connection diagram of NetSure 801 CAA series power system communication cable and
48V DC auxiliary power source cable (front view)
SMPDUX3
Sampling
board
RS485 communication cable RS485 communication cable RS485 communication cable RS485 communication cable
Parallel CAN
communication cable
Parallel CAN
communication cable
0V
-48V
0V
-48V
0V
-48V
AEM02
Monitoring
board
AEM02
Monitoring
board
HDU1U 11
Monitoring
board
SMPDUX3
Sampl ing
board
HDU1U 11
Monitoring
board
SMPDUX3
Sampl ing
board
Monitor
HDU1U 11
Monitoring
board
SMPDUX3
Sampl ing
board
AC cabinet 1
AC cabinet 2
Rectifier
cabinet 1
DC cabinet 1
Rectifier
cabinet 2
DC cabinet 2
Rectifier
cabinet 3
DC cabinet 3
48V auxiliary power source
cable of AC cabinet
48V auxiliary power source cable of AC cabinet
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 J16 and
J17 sockets on the monitoring board of DC distribution cabinet (model: HDUL), as shown in Figure
59. J16 has temperature compensation function. J17 perform temperature display function but not
temperature compensation function. When there are multiple DC distribution cabinets, connect the
temperature sensor cable with temperature compensation function to J16 socket on the
monitoring board of DC distribution cabinet. For the setup method, refer to Setting DIP Switch.
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Figure 59: Connection of temperature sensor
+12
????
PGND
PGND
信号接口
+12
PGND
Signal port
+12
P101-3 socket
Temperature terminal J16
Temperature terminal J17
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 Setting DIP Switch.
4. The temperature probe should be placed in the battery room, which can reflect most of the
battery temperature. When fixing, do not connect the temperature probe with other heating
devices or metal conductors.
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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.
Note 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.
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.
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Preliminary test of controller
After the controller is powered on, it will do self-test without needing any operation. After about
50s, the M831D controller should start and display the following screen.
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.
Rect Cap Used: 22.3 %
100%
53.5 V
3600.0A
09:22:58
Power Supply
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
AC
View AC equipment 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.
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2. Turn on one rectifier, and set the rectifier voltage to a value with less than 0.5V 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 has already been connected to the
battery fuse as required in Connecting Battery Cables.
NOTE! 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).
Setting Basic Parameters
Setting DIP Switch
1. Setting AC distribution cabinet
Distribution cabinet address, temperature sensor selection and communication speed are set
through the DIP switches on the monitoring board. The DIP switch is shown in Figure 60.
Figure 60: DIP switch
ON
1 2 3 4
Position ‘ON’ represents ‘0’, and ‘OFF’ represents ‘1’. The setting explanation of bits 1 to 4 is given
in Table 13.
Table 13: Setting list of DIP switch
BIT
DEFINITION
SETTING EXPLANATION
1
Manual/Auto switch
ON: manual switch; OFF: Auto switch
2
Auto switch mode
ON: ATS switch; OFF: contactor + controller switch
3
Reserved
4 Reserved
NOTE! Address of the AC distribution cabinet is not set through the DIP switch, but set
through the software.
2. Setting DC distribution cabinet
Distribution cabinet address, temperature sensor selection and communication speed are set
through the DIP switches on the monitoring board. The DIP switch is shown in Figure 60.
Bits 1 to 4 are used to set the addresses of the AC distribution cabinet and DC distribution cabinet.
Position ‘ON’ represents ‘0’, and ‘OFF’ represents ‘1’. The setting explanation of bits 1 to 4 is given
in Table 14.
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Table 14: Setting DIP switches of DC distribution cabinet
BIT 1
BIT 2
BIT 3
BIT 4
CORRESPONDING
ADDRESS IN THE
CONTROLLER
0 0 0 0 72 1 0 0 0
73 0 1 0 0
74 1 1 0 0
75 0 0 1 0
76 1 0 1 0
77 0 1 1 0
78 1 1 1 0
79 0 0 0 1
80 1 0 0 1
81 0 1 0 1
82 1 1 0 1
83 0 0 1 1
84 1 0 1 1
85 0 1 1 1
86 1 1 1 1
87
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,…,87.
The setting explanation of bits 5 to 8 is given in Table 15.
Table 15: Setting list of DIP switch
BIT
DEFINITION
SETTING EXPLANATION
5
Reserved
Default: OFF
6
Reserved
Default: OFF
7
Reserved
Default: OFF
8
Reserved
Default: OFF
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 61.
2. check whether the ‘Address’ is within the range of 64 ~ 71. If the address is out of the range or
there are two or above AC screens set to the same address, then press and simultaneously at
the first screen to enter the parameter setting screen and reset the address, and press Enter to
confirm.
Figure 61: AC screen address
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Model: AEM02
CommAddr: 64
SW Ver: V1.00
2. At the default LCD screen of DC distribution cabinet, press ESC to enter the product information
screen. Check whether the ‘Address’ is within the range of Table 16. If the address is out of the
range in Table 16 or there are two or above DC screens set to the same address, then reset the
address according to Setting DIP Switch.
Figure 62: DC screen address
Model: HDUL
Syetem Type: X3
CommAddr: 72
SW Ver: 1.001
3. At the controller MAINMENU screen in DC cabinet, press ENT to enter the ‘Settings’ screen
(password: 1), enter ‘DC Settings’-->’Total Load Brh:’ -->’Total Load Curr’, set the branch number
(that is load branch number of the first layer in DC screen, the branches of the second layer and
third layer are not calculated) and the sampling component type of the total load current.
Figure 63: Setting load sampling type
Tot alLoadBrh:
8
Tot alLoadCurr:
Hall
Table 16: DC screen setting
PARAMETER NAME
DESCRIPTION
Total Load Brh
Total Load Curr
8
Hall
For PD48/2500DF-A-Y1
8
Hall
For PD48/2500DF-A-Y2
8
Hall
For PD48/2500DF-A-Y3
8
Hall
For PD48/1600DF-A-Y1
8
Hall
For PD48/1600DF-A-Y2
At the controller first screen in DC cabinet, press ENT to enter the ‘Settings’ screen (password: 1),
enter ‘Batt. Settings’-->’Shunt Qty:’, ‘Shunt Coef’ -->’Current’, set the battery shunt quantity and
battery shunt coefficient of the DC cabinet.
Figure 64: Setting battery shunt
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Shunt Qty: 1
Batt. String Qty: 2
Shunt Coef:
--Current: 1250A
2
Table 17: Battery shunt setting
PARAMETER NAME
DESCRIPTION
Shunt Qty
Shunt Coef-Curr
4
1250A
For PD48/2500DF-A-Y1
4
1250A
For PD48/2500DF-A-Y2
4
1250A
For PD48/2500DF-A-Y3
2
1250A
For PD48/1600DF-A-Y1
2
1250A
For PD48/1600DF-A-Y2
NOTE! Except the above four parameters, other parameters of the DC distribution cabinet
should be set in the M831D interface.
4. At the first screen of DC distribution cabinet, press ENT to enter ‘Settings’-->’System Parameters’
menu (password: 1), and confirm that the system type is ‘X3’.
Figure 65: Setting system type
ComDownLoad: N
LVD Enable: N
Syetem Type:
X3
5. 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.
6. 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, the
corresponding coefficient of PD380/400AFH would be 100. If any inconsistencies exist, set the
parameters as above.
Figure 66: AC settings
AC Distrib1
Curr Trans Coef:
160
Input Type:
3-Phase
Input Number:
2
AC Distrib1
Input Number:
2
Cur Measurement:
3-Phase
Output Number:
0
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Table 18: AC transformer setting
PARAMETER NAME
DEFAULT
SETTING
DESCRIPTION
AC Transformer
Coefficient
160
Used for PD380/630AFH, the corresponding coefficient is 800/5
100
Used for PD380/400AFH, the corresponding coefficient is 500/5
Current Measure Ty
Single phase
Set according to actual current transformer number, the default
setting is single phase
7. Back to the setting screen, enter ‘DC Settings’-->’DC Distrib 1’…… ’DC Distrib n’, check whether
the ‘Hall Coefficient’ is consistent with Table 19. If any inconsistencies exist, reset the parameters
according to Table 19.
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Figure 67: Load hall coefficient
DC Distrib1
Sensor Coeff:
4000
Numof Battery:
2
Temp Number:
1
Table 19: Setting DC hall sensor
Parameter
name
Default setting
Description
Hall Coefficient
3000
Used for PD48/2500DF-A-Y1/Y2/Y3
1500
Used for PD48/1600DF-A-Y1/Y2
8. Enter ‘DC Settings’-->’DC Distrib 1’…… ’DC Distrib n’, set the ‘Branch Curr Coeff’ and ‘Curr Output
Num’ according to actual situation.
Figure 68: Setting branch current coefficient and current output number
DC Distrib1
Temp Number:
1
Branch Curr Coeff:
500
CurrOutput Num:
0
Table 20: Setting branch current coefficient and current output number in DC screen
Parameter name
Default setting
Description
Branch Curr Coeff
500
Used for PD48/1600DF and PD48/2500DF
Curr Output Num
8
Used for PD48/1600DF-A-Y1
4
Used for PD48/1600DF-A-Y2
8
Used for PD48/2500DF-A-Y1
6
Used for PD48/2500DF-A-Y2
12
Used for PD48/2500DF-A-Y3
9. Enter ‘DC Settings’-->’DC Distrib 1’…… ’DC Distrib n’, set the ‘Num of Output’, the default value is
64. If the number of output is less than 64, then there is no need to set the ‘Num of Output’.
Figure 69: Setting number of output
DC Distrib1
Branch Curr Coeff:
500
CurrOutput Num:
0
Numof Output:
64
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10. 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.
Figure 70: Setting number of battery
DC Distrib1
Sensor Coeff:
4000
Numof Battery:
2
Temp Number:
1
11. 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.)
Figure 71: Setting battery nominal capacity
Charge
AutoEQ:
Yes
RatedCapacity:
500Ah
Reset BattCap:
Yes
Figure 72: Setting battery string sampling coefficient
Batt Settings
Charge >
Battery Test >
Temp Comp >
LargeDUBatt1 >
LargeDUBatt2 >
Batt Settings
Charge >
Battery Test >
Temp Comp >
LargeDUBatt1 >
LargeDUBatt2 >
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 73. (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 ~ 2 (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 74.
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Figure 73: Setting Temp Comp parameter
TempComp
TempCompSensor:
LDU1-Temp1
TempComp Center:
25deg. C
Temp Comp Coeff:
72mV/deg. C
Figure 74: Setting Temp Number
DC Distrib1
Sensor Coeff:
4000
Numof Battery:
2
Temp Number:
1
NOTE! ‘Ldu1 Temp1’ corresponds to the DC distribution screen that with the lowest address,
therefore the temperature cable used to set the battery compensation temperature must be
plugged into J16 terminal of the HDUL monitoring board with the lowest address. In DC
screen.
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 75. 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 75.
Figure 75: Setting float/EQ voltage
Charge
Float Voltage:
53.5V
EQ Voltage:
55.0V
Batt Curr Limit:
0.09C10
Checking Alarm and Operation Status
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.
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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 76.
Figure 76: Setting Auto/Man State
Maintenance
Auto/ManState:
Auto
EQ/FLTControl:
EQCharge
LVD1:
LVD 1 Reconnect
Maintenance
LVD2:
LVD2 Reconnect
BattTestControl:
Stop
Rect Curr Limit:
121%
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 76. 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 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 Setting Basic
Parameters for Controller, the rectifier voltage should be normally adjustable.
3. Under the condition that all the rectifier outputs are normal, observe and record the rectifier
current-sharing characteristics at different total loads.
System status query
When the system has an alarm, at the main page of the controller, press and to move the
cursor on , and press ENT to enter ‘Active Alarms’ screen, then you can view the active alarms;
enter ‘Alarm History’ to view all the history alarms.
Figure 77: Main page of the controller
Rect Cap Used: 22.3 %
100%
53.5 V
3600.0A
09:22:58
Power Supply
R: 380V
S: 380V
T: 380V
25/03/2014
电源
09:22:58
01/01/2008
0.0%
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Figure 78: Alarm page of the controller
Alarm
Active Alarms >
Alarm History >
At the main page of the controller, press and to move the cursor on , , , , and press
ENT to enter ‘AC’, ‘Module’, ‘DC’, ‘Battery’ submenus separately. Each submenu will respectively
display the status of equipment group and single equipment. Take ‘AC’ for example, you can query
the ‘AC DistGroup’ and ‘AC Distrib1 ~ X’ separately. Press ESC to return to the previous menu.
Figure 79: Querying system status
Rect Cap Used: 22.3 %
100%
53.5 V
3600.0A
09:22:58
Power Supply
R: 380V
S: 380V
T: 380V
25/03/2014
电源
09:22:58
01/01/2008
0.0%
AC DistGroup >
AC Distrib 1>
Testing AC Distribution
1. At the MAINMENU screen of the controller in AC cabinet, you can view the ‘AC Online’, ‘Status’,
‘Ctrl Mode’ and ‘SPD’, as shown in Figure 80.
Figure 80: MAINMENU screen
AC Online: 1
Status: Alarm
Ctrl Mode: Manaul
SPD: Failure
2. Open the SPD MCB, the ‘SPD’ will display ‘Failure’, and meanwhile the ‘AC output MCB off alarm’
should be triggered on the controller in rectifier cabinet. After closing the SPD MCB, the ‘SPD’
should resume to ‘Normal’.
Figure 81: SPD failure alarm
AC Online: 1
Status: Alarm
Ctrl Mode: Manaul
SPD: Failure
3. Press and to enter the second screen, and check that the AC input current is consistent with
actual input current.
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Figure 82: AC input current
Current：
Ia: 0.0A
Ib: 0.0A
Ic: 0.0A
4. In the case of accessing the battery, switch the two routes of AC input, the ‘AC Online’ should
correspondingly display ‘1’ or ‘2’. Press and to enter the third or fourth screen, the
corresponding AC1 should display ‘On’ or ‘Standby’.
Figure 83: AC online (1)
AC Online: 1
Status: Alarm
Ctrl Mode: Manaul
SPD: Failure
Figure 84: AC online (2)
AC 1：On 50Hz
-Uab：380V
-Ubc：380V
-Uca：380V
5. Press the ‘TEST’ button on any output circuit breaker panel, and press and to enter the fifth
screen, the ‘DI Status: On’ should be changed to ‘Off’, and meanwhile the ‘AC output MCB off
alarm’ should be triggered on the controller in rectifier cabinet. After switching on the circuit
breaker, the ‘DI Status: Off’ should resume to ‘On’, and the alarm will disappear. Check each output
circuit breaker in turn, and the results should meet the above description.
Figure 85: Output MCB off alarm
DI Status:
In: On Out: Off
Branch:
01: —— 02: ——
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 86. 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.
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Figure 86: Setting undervoltage alarm point
Over Voltage:
58.5V
45.0V
Under Voltage:
DC DistGroup
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 87. 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.
Figure 87: Setting overvoltage alarm point
Over Voltage:
58.5V
45.0V
Under Voltage:
DC DistGroup
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
88.
Figure 88: Setting Auto/Man State
Maintenance
Auto/ManState:
Auto
EQ/FLTControl:
EQCharge
LVD1:
LVD 1 Reconnect
By now, the system test is completed and the power supply system is in normal operation.
Access Controller Through Web
Login procedures are as follows:
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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 89.
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Figure 89: LAN setting (Step 1)
2. In the interface shown in Figure 89, click the LAN Settings button to pop up the interface shown
in Figure 90.
Figure 90: 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 91.
Figure 91: Internet options
4. Click on the Settings button. The following window opens, as shown in Figure 92. In the Settings
window, choose “Every time I visit the webpage” and click OK.
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Figure 92: Temporary internet files and history settings
5. In the “Internet Options” window, select the Security tab, as shown in Figure 93.
Figure 93: Security tab
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6. Click on Trusted sites. The following window opens, as shown in Figure 94.
Figure 94: Trusted sites
7. In the Trusted sites window, type or copy the address in the “Add this website to the zone:” box,
as shown in Figure 95.
Figure 95: Adding trusted sites (1)
NOTE! Please check that you are using an address that starts with ‘https’, if not, but an
address like http://10.39.3.200, then uncheck the ‘Require server verification (https:) for all
sites in the zone:’ box.
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8. In your browser, enter the controller’s IP address, User can view the IP address: Main menu
Settings (password:1) Communication Parameter, and then press the ENT key.
The following Web Interface Login window opens, as shown in Figure 96. Enter a valid User Name
and Password, and then click LOGIN.
By default, the “User Name” is "admin" and the “Password” is “1”.
Figure 96: Login the controller
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9. Check whether all parameters in Figure 97 are correct.
Figure 97: M831D Homepage
10. Control the boost/float and rectifier switch, check whether the control function is correct.
11. Simulate fault alarms on the power system, and then check whether corresponding alarms are
displayed in the homepage.
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OPERATION
This chapter introduces the operation of the power distribution LCD, procedures of adding loads
and rectifiers.
Power Distribution LCD Operation
1. LCD operation of 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.
The displayed contents vary depending upon the different distribution forms.
If left idle for a certain time, 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 in Table 21.
Table 21: Display contents in AC distribution LCD
NO.
DISPLAY CONTENT
1
Main menu
2
AC distribution phase A/B/C current or AC distribution current
3
Stat/ Freq /Volt of AC Distri 1
4
Stat/ Freq /Volt of AC Distri 2
5
AC input/output MCB state
The LCDs of DC distribution cabinet are shown in Table 22.
Table 22: Display contents in DC distribution LCD
NO.
DISPLAY CONTENT
1
Bus Volt/Bus Stat/Load Curt of DC Distri
2
DC Distri Batt 1 ~ 4 Curr
3
DC Distri Temp 1 ~ 2
4
Load total current/power/electric quantity
5~30
1~26 shunts current/load ratio/power/electric quantity
Note:
1. At the MAINMENU screen, press ▲ or ▼ to view display content 1 ~ 3.
2. At the MAINMENU screen, press ENT in the ‘DC distribution’ to view display content 4.
3. Press ◄ or ► in the ‘DC distribution’ to view display content 5 ~ 30.
4. Press ▲ or ▼ at any screen to adjust the cursor position
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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 98. Press ▲ or ▼, ◄ or ► to view the
information listed in Table 21 and Table 22.
Figure 98: First system information screen
AC Online: 1
Status: Alarm
Ctrl Mode: Manaul
SPD: Failure
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.
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 99.
Figure 99: Monitoring information screen
Model: AEM02
CommAddr: 64
SW Ver: V1.00
5. At the system information screen of AC screen, press and hold the ESC and ENT keys
simultaneously for several seconds, the controller will be reset, and then the system will restart (DC
screen dese not have this function).
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. The main menu screen is shown in Figure 100.
Figure 100: Main menu screen
AC Online: 1
Status: Alarm
Ctrl Mode: Manaul
SPD: Failure
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 higherlevel menu, and ultimately return to the main menu screen.
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Distribution parameter setting
All the distribution parameters are set on the LCD screen of the system main controller, except the
address of AC distribution screen, ‘Total load current branch’, ‘Total load current’, ‘Batt-Shunt Qty’
and ‘Shunt Coef-Curr’ of DC distribution screen. See Setting Basic Parameters for specific settings.
System Settings
The system settings screen is used to set the time, date and other parameters of the controller, the
setting method is as follows:
1. At the Settings screen, press ▲ or ▼ to select the ‘Sys set’ menu. Then press the ENT key to
confirm, as shown in Figure 101
Figure 101: System settings
Lang: English
CommAddr: 64
Baud: 19200bps
Parity: N
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.
Controller Operation of Rectifier Cabinet
System Alarm and Status
Please refer to Testing Controller for querying the system status.
Distribution Parameters Setting
All the distribution parameters are set on the LCD screen of the system main controller, except the
address of AC distribution screen, ‘Total load current branch’, ‘Total load current’, ‘Batt-Shunt Qty’
and ‘Shunt Coef-Curr’ of DC distribution screen. See Setting Basic Parameters for specific settings.
NOTE! The ‘System Type’ in the ‘System Settings’ screen of the DC distribution cabinet shall
not be changed arbitrarily. Otherwise, the system may not work normally.
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 Access Controller Through Web to enter the Web homepage window.
2. Select ‘Power System’ tab, as shown in Figure 102.
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Figure 102: 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 103.
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Figure 103: 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 104.
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Figure 104: 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 105.
Figure 105: Individual rectifier settings page
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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.
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 -48V
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 Connecting DC Load Cables for DC load cable
connection.
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.
2. Insert the new rectifier into position along the guide rail and fix it. See 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.
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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