Vertiv R48-1000C User Manual

NetSure™ IPE Series Rectifier

Installation and User Manual

Specification Number: 561664, 561665, 561666 Model Number: R48-1000C

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

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 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.

The products covered by this instruction manual are manufactured and/or sold by Vertiv. This document is the property of Vertiv and contains confidential and proprietary information owned by Vertiv. Any copying, use or disclosure of it without the written permission of Vertiv is strictly prohibited.

Names of companies and products are trademarks or registered trademarks of the respective companies. Any questions regarding usage of trademark names should be directed to the original manufacturer.

Technical Support Site

If you encounter any installation or operational issues with your product, check the pertinent section of this manual to see if the issue can be resolved by following outlined procedures.

Visit https://www.vertiv.com/en-us/support/ for additional assistance.

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

iii

TABLE OF CONTENTS

Admonishments Used in this Document .......................................................................................................................... v

Important Safety Instructions ............................................................................................................................................ vi

Static Warning ....................................................................................................................................................................... viii

1 Introduction ......................................................................................................................................................................... 1

1.1 Ordering Structure ........................................................................................................................................................................................................................................................ 1

1.1.1 Configurations ............................................................................................................................................................................................................................................ 1

1.1.2 Circuit breaker option ......................................................................................................................................................................................................................... 1

1.1.3 GMT fuse option ....................................................................................................................................................................................................................................... 1

1.1.4 What is in the box ................................................................................................................................................................................................................................... 2

1.1.5 Replacement components ............................................................................................................................................................................................................. 3

1.2 Rectifier Overview ........................................................................................................................................................................................................................................................ 4

1.3 Rectifier Specifications ............................................................................................................................................................................................................................................ 4

1.3.1 DC output ratings ................................................................................................................................................................................................................................... 4

1.3.2 AC input ratings ....................................................................................................................................................................................................................................... 6

1.3.3 Environmental ratings ..................................................................................................................................................................................................................... 10

1.3.4 Compliance information

1.3.5 Standard features ................................................................................................................................................................................................................................. 11

1.3.6 Mechanical specifications ............................................................................................................................................................................................................ 12

2 Installation ......................................................................................................................................................................... 14

2.1 General Requirements ........................................................................................................................................................................................................................................... 14

2.2 Tools and Test Equipment Required for Installation ................................................................................................................................................................ 14

2.3 Installing the Rectifier .............................................................................................................................................................................................................................................15

2.3.1 General ...........................................................................................................................................................................................................................................................15

2.3.2 Front door ....................................................................................................................................................................................................................................................15

2.3.3

Pole installation

2.3.4 Wall installation procedure

2.4 Installing GMT Fuses (P/N 561666 [R48-1000C-6] Only) ................................................................................................................................................. 20

3 Making Electrical Connections ................................................................................................................................... 20

3.1 Important Safety Instructions ........................................................................................................................................................................................................................ 20

3.2 Wiring Considerations........................................................................................................................................................................................................................................... 20

3.3 Frame Ground Connection ............................................................................................................................................................................................................................... 20

3.4 Customer Wiring to the Mating Connectors ..................................................................................................................................................................................... 21

3.5 Electrical Connections Diagrams ................................................................................................................................................................................................................26

3.6 External Alarm and Control Connections ........................................................................................................................................................................................... 30

3.6.1 General ......................................................................................................................................................................................................................................................... 30

3.6.2 Alarm and Control Connections ........................................................................................................................................................................................... 30

3.6.3 Changing the Alarm Relay Configuration for the Rectifier Fail Alarm and AC Fail Alarm ................................................ 31

3.7 Nominal 120 VAC / 208 VAC / 220 VAC / 230 VAC / 240 VAC Input and AC Input Equipment Grounding

Connections .................................................................................................................................................................................................................................................................... 32

3.8 -48 VDC Output Connections ........................................................................................................................................................................................................................ 32

3.9 -48 VDC Input Connections ............................................................................................................................................................................................................................. 32

3.10 Paralleling Rectifiers ................................................................................................................................................................................................................................................ 32

............................................................................................................................................................................................................... 10

proc

edure

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

3.10.1 Two Paralleled Rectifiers or One Plus One with Redundancy ................................................................................................................... 32

3.10.2 Three Paralleled Rectifiers or Two Plus One with Redundancy ............................................................................................................. 34

3.11 Final Step ........................................................................................................................................................................................................................................................................... 35

4 Initially Starting and Checking Rectifier Operation ............................................................................................. 36

4.1 Initially Starting the Rectifier .......................................................................................................................................................................................................................... 36

4.2 Checking System Status .................................................................................................................................................................................................................................... 36

5 Operation ........................................................................................................................................................................... 37

5.1 Local Indicators ........................................................................................................................................................................................................................................................... 37

5.2 Rectifier High Voltage Shutdown and Lockout Restart ........................................................................................................................................................ 37

6 Troubleshooting and Repair ........................................................................................................................................ 38

6.1 Contact Information .................................................................................................................................................................................................................................................38

6.2 Troubleshooting ..........................................................................................................................................................................................................................................................38

6.3 Repair ...............................................................................................................................................................................................................................................................................38

7 DC Power, Outdoor Enclosure & Service Contacts ............................................................................................. 40

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

DANGER!

in death or serious injury if not avoided. (ANSI, OSHA)

WARNING!

result in death or serious injury if not avoided. This admonition is not used for situations that pose a risk only to equipment, software, data, or service. (ANSI)

CAUTION!

result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not used for situations that pose a risk only to equipment, data, or service, even if such use appears to

ALERT!

equipment, software, data, or service. (ISO)

ALERT!

equipment damage, software corruption, data loss, or service interruption. (ISO)

FIRE SAFETY!

or policies, or of the locations of fire

SAFETY!

policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)

Admonishments Used in this Document

Warns of a hazard the reader

Warns of a potential hazard the reader

be permitted in some of the applicable standards. (OSHA)

Alerts the reader to an action that

will

be exposed to that will

may

be exposed to that

may

be exposed to that

must be avoided

likely

result

could

in order to protect

Alerts the reader to an action that

Informs the reader of fire safety information, reminders, precautions,

Informs the reader of general safety information, reminders, precautions, or

-fighting and fire-safety equipment. (ISO)

must be performed

in order to prevent

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

Important Safety Instructions

Safety Admonishments Definitions

Definitions of the safety admonishments used in this document are listed under “Admonishments Used in this Document” on page v.

General Safety

DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.

Performing the following procedures may expose you to hazards. These procedures should be performed by qualified

technicians familiar with the hazards associated with this type of equipment. These hazards may include shock, energy,

and/or burns. To avoid these hazards:

a) The tasks should be performed in the order indicated.

b) Remove watches, rings, and other metal objects.

c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage or the expected

voltage is present. Check for voltage with both AC and DC voltmeters prior to making contact.

d) Wear eye protection.

e) Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for the work to be

performed.

Voltages

AC Input Voltages

DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. AC input power must be

completely disconnected from the branch circuits wiring used to provide power to the system before any AC electrical

connections are made. Follow local lockout/tagout procedures to ensure upstream branch circuit breakers remain de-

energized during installation. DO NOT apply AC input power to the system until all electrical connections have been

completed and checked.

DC Output and Battery Voltages

DANGER! This system produces DC power and may have a battery source connected to it. Although the DC voltage is not

hazardously high, the rectifiers and/or battery can deliver large amounts of current. Exercise extreme caution not to

inadvertently contact or have any tool inadvertently contact an output terminal or battery terminal or exposed wire

connected to an output terminal or battery terminal. NEVER allow a metal object, such as a tool, to contact more than one

termination or battery terminal at a time, or to simultaneously contact a termination or battery terminal and a grounded

object. Even a momentary short circuit can cause sparking, explosion, and injury.

DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices remain de-energized

during installation at loads, as required.

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

vii

Personal Protective Equipment (PPE)

DANGER! ARC FLASH AND SHOCK HAZARD.

Appropriate PPE and tools required when working on this equipment. An appropriate flash protection boundary analysis

should be done to determine the “hazard/risk” category, and to select proper PPE.

Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain the equipment.

Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work Permits as required

by the local authority, per NFPA 70E “Standard for Electrical Safety in the Workplace”.

Hazardous Voltage

DANGER! HAZARD OF ELECTRICAL SHOCK.

More than one disconnect may be required to de-energize the system before servicing.

Handling Equipment Containing Static Sensitive Components

ALERT! Installation or removal of equipment containing static sensitive components requires careful handling. Before

handling any equipment containing static sensitive components, read and follow the instructions contained on the Static

Warning Page.

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

viii

Static Warning

This equipment contains static sensitive components. The warnings listed below must be observed to prevent damage to

these components. Disregarding any of these warnings may result in personal injury or damage to the equipment.

1. Strictly adhere to the procedures provided in this document.

2. Before touching any equipment containing static sensitive components, discharge all static electricity from yourself by

wearing a wrist strap grounded through a one megohm resistor. Some wrist straps have a built-in one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s instructions outlining use of a specific wrist strap.

3. Do not touch traces or components on equipment containing static sensitive components. Handle equipment

containing static sensitive components only by the edges that do not have connector pads.

4. After removing equipment containing static sensitive components, place the equipment only on static dissipative

surfaces such as conductive foam or ESD bag. Do not use ordinary Styrofoam or ordinary plastic.

5. Store and ship equipment containing static sensitive components only in static shielding containers.

6. If necessary to repair equipment containing static sensitive components, wear an appropriately grounded wrist strap,

work on a conductive surface, use a grounded soldering iron, and use grounded test equipment.

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

1 Introduction

The NetSure IPE SERIES provides a rectifier mounted inside an environmentally protective enclosure. The NetSure IPE SERIES rectifier can be wall or pole mounted.

1.1 Ordering Structure

1.1.1 Configurations

The NetSure IPE SERIES rectifier can be provided in three (3) configurations.

• Bulk Output: Spec. No. 561664 (R48-1000C-4).

• Output Fed through an Internal 30 A Circuit Breaker:

Spec. No. 561665 (R48-1000C-5).

• Output Fed through an Internal 6-Position GMT Fuse Block: Spec. No. 561666 (R48-1000C-6).

1.1.2 Circuit breaker option

Spec. No. 561665 (R48-1000C-5): A 30 A internal circuit breaker is provided.

1.1.3 GMT fuse option

Spec. No. 561666 (R48-1000C-6): An internal 6-position GMT fuse block is provided. Specify fuses from Table 1-1.

• Maximum GMT fuse size is 10 A.

• At +65 °C (+149 °F), a space is required between GMT fuses greater than 5 A.

• When used for power distribution, load should not exceed 80% of device rating, except 10 A fuses, for which load should not

exceed 70% of device rating.

Table 1-1: GMT Fuses

Ampere Rating Part Number Fuse Color

1/4 248610200 Violet

1/2 248610300 Red

3/4 248610500 Brown

1-1/3 248610700 White

2 248610800 Orange

3 248610900 Blue

5 248611000 Green

7-1/2 248611300 Black-White

10 248611200 Red-White

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

1.1.4 What is in the box

Refer to Table 1-2.

Table 1-2:

Item

(1) 21503878 Mounting Bracket Kit X X X

(2) 632404V1 Mounting Bracket (Big) X X X

(1) 632404V2 Mounting Bracket (Small) X X X

(2) 21101742 Sealing Cable Adapter (Single Large) (DC Input, Bulk DC Output, 30 A Breaker Output, AC Input)

(1) 21101743 Sealing Cable Adapter (Single Small) (AC Input) X X X

(3) 21101744 Sealing Cable Adapter (Three Cables) (Alarm, GMT Output) X X X

(1) 63126350 Door Hardware Tool X X X

(2) 26011153 M8 Bolts w/ Flat Washer and Lock Washer X X X

(4) 26011018 M5 Bolts w/ Flat Washer and Lock Washer X X X

(2) 26011356 M5 Flat Head Screws X X X

(2) 63126330 Pole Mount Band X X X

(1) 14190607 AC Input Connector (Customer Side) X X X

(2) 14190609 DC Output Connector for GMT Fuse Option (Customer Side)

(1) 14190611 Alarm Connector (Customer Side) X X X

(1) 14190615 DC Input Connector (Customer Side) X X X

(1) 14190623 DC Output Connector for Bulk Output or Internal Circuit Breaker Option (Customer Side)

(6) 21101745 Sealing Pin for Unused Holes in Sealing Cable Adapters X X X

(1) UM1R481000CNA Installation and User Manual X X X

P/N 561664

(R48-1000C-4)

X X X

-- -- X

X X --

P/N 561665

(R48-1000C-5)

P/N 561666

(R48-1000C-6)

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

1.1.5 Replacement components

The input/output terminations are connectorized. For a replacement mating connector, order from Table 1-3. Refer also to Table 1-3 for other replacement components.

Table 1-3: Replacement Components

Part Number Description

14190607 AC Input Connector (Customer Side)

14190609 DC Output Connector for GMT Fuse Option (Customer Side)

14190611 Alarm Connector (Customer Side)

14190615 DC Input Connector (Customer Side)

14190623 DC Output Connector for Bulk Output or Internal Circuit Breaker Option (Customer Side)

63126330 Pole Mount Band

21101742 Sealing Cable Adapter (Single Large) (DC Input, Bulk DC Output, 30 A Breaker Output, AC Input)

21101743 Sealing Cable Adapter (Single Small) (AC Input)

21101744 Sealing Cable Adapter (Three Cables) (Alarm, GMT Output)

21101745 Sealing Pin for Unused Holes in Sealing Cable Adapters

21101755 Door Gasket

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

Output Voltage (V)

Output Current (A)

1.2 Rectifier Overview

The rectifier provides load power during normal operating conditions. The rectifier is a constant power design. The rectifier is rated at its maximum output power. This means that, within the normal operating ambient temperature range and input voltage range, the maximum available output power is a constant 1000 W. Within these ranges, the rectifier operates in one of three modes, depending upon load demands. Transition between modes is completely automatic. If ambient temperature rises above or input voltage falls below acceptable values, the rectifier continues to operate but at derated output power levels.

• Constant Voltage Mode: For any initial output voltage setting from -42 VDC to -58 VDC (factory set at -54 VDC), output

voltage remains constant regardless of load. This is the normal operating condition, in which loads are being supplied. The rectifier operates in the Constant Voltage Mode unless load increases to the point where the product of load current and output voltage is approximately 1000 W.

• Constant Power Mode: As load increases above approximately 1000 W (non-adjustable), output current continues to

increase, but output voltage decreases as required to maintain constant output power. The rectifier operates in the Constant Power Mode unless load continues to increase to the point where the current limit setting is reached.

• Constant Current Mode: If load increases to the current limit setting, output voltage decreases linearly to maintain output

current at the current limit setting.

1.3 Rectifier Specifications

The specifications are for a single unit only, unless otherwise noted.

1.3.1 DC output ratings

1. Voltage: -42 VDC to -58 VDC, positive ground. Output voltage is factory set at -54 VDC.

2. Output Power and Current:

a) 1000 W (20.83 A) @ 200 VAC to 250 VAC input and -48 VDC output.

b) 700 W (14.58 A) @ 120 VAC input and -48 VDC output.

3. Output Characteristics: Refer to Figure 1-1 for a graph of output voltage vs. output current.

Figure 1-1: Output Voltage vs. Output Current

Output Voltage vs. Output Current

at Maximum Power 1000 W

60 50 40 30 20 10

0 2 4 6 8 10 12 14 16 18 20 22 24

4. Power Derating Based on Input Voltage: The rectifier power varies with changes in input voltage. It uses an advanced power

limitation method. The lower input threshold is 85 VAC. The rectifier can provide its maximum rated power (1000 W) as long as the input voltage is within the range of 176 VAC to 300 VAC. Below 176 VAC, and down to 85 VAC, the rectifier will continue to operate normally but will be in a power derating mode. The relationship between the output power and input voltage is illustrated in Figure 1-2.

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

% of Output Power

Input Voltage (Vac)

% of Output Power

Temperature (℃)

Figure 1-2: Power Derating Based on Input Voltage

Output Power vs. Input Voltage

and Vo >48 V at Temp ≤55℃

120.0%

100.0%

80.0%

60.0%

40.0%

20.0%

0.0% 0 50 100 150 200 250 300 350

5. Power Derating Based on Temperature: The rectifier delivers full power when operating at an ambient temperature of +55 °C

(+131 °F) or below. The rectifier continuously monitors the ambient temperature surrounding the power conversion circuit. If this temperature for any reason (such as a high ambient temperature) increases above approximately +55 °C (+131 °F), the rectifier will not shut down. Rather, the rectifier limits its maximum output power to maintain the temperature of the power conversion circuit within design parameters. Operation between +55 °C (+131 °C) and +75 °C (+167 °F) will result in output power being decreased. Full power capability is restored when the temperature decreases to below approximately +55 °C (+131 °F). Refer to Figure 1-3 to view the relationship between the output power and the ambient temperature.

WARNING! The module is rated for continuous operation at full output power up to +55 °C (+131 °F). Operation between

+55 °C (+131 °F) and +75 °C (+167 °F) will result in output power decrease. Operation above +75 °C (+167 °F) is considered

abnormal and should be used on a temporary

Temporary Operation at Abnormal Temperature: Temporary operation is defined as a period of not more than eight

basis only.

consecutive hours per day, and a total of not more than 15 days in a year. (This refers to a total of 120 hours in any given year, but no more than 15 occurrences in that one-year period.)

Other power rating values are as follows (refer to Figure 1-3):

a) At an ambient temperature of +65 °C (+149 °F), the power delivered by the rectifier is 500 W.

b) At an ambient temperature of +75 °C (+167 °F), the power delivered by the rectifier is 0 W.

NOTE!

If used outdoors under full solar radiation, in an ambient of 46 °C the product is rated for 561 W per Telcordia GR-

487-CORE.

Figure 1-3: Power Derating Based on Temperature

Output Power vs. Temperature

at 290 Vac ≥ Vin ≥ 176 Vac 120 100

80 60 40 20

-40 -20 0 20 40 60 80 100

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

6. Regulation:

a) Static: Steady state regulation is ±0.6% as controlled within the rectifier for any and all combinations of load from no

load to full load, input voltage, and input frequency at a constant ambient temperature.

b) Dynamic: Response time ≤200 us and overshoot ≤5% for load changes at 50% - 25% - 50%

and 50% - 75% - 50% at rated output current.

For any step load change within the range of 10% to 90% of full load within 50 us, per Telcordia GR-947-CORE, the maximum voltage transient will not exceed 5% of the initial steady state voltage within 50±10 us. Recovery to within 1% of the initial steady state voltage does not exceed 1 milliseconds.

7. Filtering:

a) Voice Band Noise: Peak-peak voltage is ≤200 mV at 0 MHZ to 20 MHZ and normal output voltage.

b) Wide Band Noise: Wideband noise voltage is ≤50 mV at 3.4 kHz to 150 kHz and ≤20 mV at 0.15 MHz to 30 MHz.

c) Discrete Noise Voltage: Discrete noise voltage is ≤5 mV at 3.4 kHz to 150 kHz, ≤3 mV at 150 kHz to 200 kHz, ≤2 mV at

200 kHz to 500 kHz, and ≤1 mV at 500 kHz to 30000 kHz.

d) Psophometric Noise: Psophometric noise is ≤2 mV typical at 220 VAC input, 53.5 VDC output, and 30% to 90% of rated

load for more than one rectifier.

1.3.2 AC input ratings

1. Voltage: Nominal 120 VAC / 208 VAC / 220 VAC / 230 VAC / 240 VAC, single phase, 3-wire, 50 Hz / 60 Hz, with an operating

range of 85 VAC to 300 VAC. Acceptable input frequency range is 45 Hz to 65 Hz.

Permitted Variation: 85 VAC to 300 VAC.

2. Harmonic Content (THD): Meets EN61000-3-2. ≤5% from 50% to 100% of rated output current at 220 VAC.

3. Inrush Current: Peak does not exceed 1.5 times of the peak value of the maximum steady-state input current at full load, 220

VAC input voltage, and for any duration of AC input interrupts. Under the above conditions, standard AC distribution circuit breakers will not trip.

4. Typical Input Data: 50 Hz input.

a) Refer to Table 1-4.

b) Maximum Input Current: Refer to Table 1-5.

c) Efficiency Curve: Refer to Figure 1-4.

5. Typical Input Data: 60 Hz input.

a) Refer to Table 1-6.

b) Maximum Input Current: Refer to Table 1-7.

c) Efficiency Curve: Refer to Figure 1-5 and Figure 1-6.

Table 1-4: Typical Input Data with 50 Hz Input

Vertiv™ NetSure™ IPE Series Rectifier Installation and User Manual

Nominal

Input Voltage

208

240

Note:

System output is initially adjusted to 54 volts DC as measured at the system sense point at 50% of full load

Percent

of Full Load

0 0.286 55.84 4.73 0.10023 -- 16.137

25 1.26 258.754 245.374 0.9 48 57 90.79 77.1101

50 2.34 485.81 479.1 4 0.98624 94.33 92.6646

75 3.489 725.77 721.56 0.99407 94.81 127.7476

100 4.66 970. 24 967.15 0.99682 94.76 172.9354

110 5.01 1041.68 1038.95 0.99725 94.70 187.9968

0 0.33 73.4 4.908 0.06636 -- 16.745

25 1.12 265.36 244.52 0.92218 91.16 73.7573

50 2.02 482.99 477.956 0.9897 7 94.59 88.2566

75 3.015 724.2 719.46 0.99357 95.10 120.301

100 4.033 969.3 966.68 0.99727 95.09 161.8856

110 4.32 1037.32 103 5.1 0.99778 95.05 174.7991

Input Current

(Amperes)

and nominal input. “Percent of Full Load” refers to percent of 17.24 amperes.

Table 1-5: Maximum Input Current with 50 Hz Input

Nominal Input

Voltage

Input

Voltage

Input Current

(Amperes)

Input

Watts

Power Factor

Efficiency

Heat Dissipation

BTU/Hr

208/240 176 7.5

Note:

At 100% of full load with output adjusted to 58 volts DC as

measured at the output terminals.

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Specifications and Main Features

Frequently Asked Questions

User Manual