Vertiv Tech NetSure 731 A41-S1, NetSure 731 A41-S2, NetSure 731 A41-S8 User Manual

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NetSure 731 A41 插框电源系统用户手册

NetSure 731 A41 Subrack Power System User Manual

资料版本 V1.1 归档日期 2017-12-31

BOM 编码 31013139

Version V1.1 Revision date December 31, 2017 BOM 31013139

维谛技术有限公司为客户提供全方位的技术支持，用户可与就近的维谛技术有限公司办事处或客户服务中心联系，也可直接与公司总部联

系。

维谛技术有限公司

不另行通知。

维谛技术有限公司地址：深圳市南山区学苑大道 1001 号南山智园

B2 栋邮编：518055 公司网址：www.vertivco.com 客户服务热线：4008876510

E-mail：[email protected]

Vertiv Tech provides customers with technical support. Users may contact the nearest Vertiv local sales office or service center.

are subject to change without notice.

Vertiv Tech Co., Ltd. Address: Block B2, Nanshan I Park, No.1001

Xueyuan Road, Nanshan District, Shenzhen, 518055, P.R.China

Homepage: www.vertivco.com E-mail: [email protected]

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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

Some components of the power system carry hazardous voltage in operation. Direct contact or indirect contact through moist objects with these components will result in fatal injury.

Safety rules in the industry must be observed when installing the power system. The installation personnel must be licensed to operate high voltage and AC power.

In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles, rings.

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.

Danger

High voltage operation may cause fire and electric shock. The connection and wiring of AC cables must be in compliance with the local rules and regulations. Only those who are licensed to operate high voltage and AC power can perform high voltage operations.

II. Tools

Warning

In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used.

III. Thunderstorm

Danger

Never operate on high voltage, AC, iron tower or mast in the thunderstorm.

In thunderstorms, a strong electromagnetic field will be generated in the air. Therefore the equipment should be well earthed in time to avoid damage by lightning strikes.

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IV. ESD

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.

V. Short circuit

Danger

During operation, never short the positive and negative poles of the DC distribution unit of the system or the non-grounding pole and the earth. The power system is a constant voltage DC power equipment, short circuit will result in equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminal when performing DC live operations. As the operation space in the DC distribution unit is very tight, please carefully select the operation space. Never wear a watch, bracelet, bangle, ring, or other conductive objects during operation. Insulated tools must be used. In live operation, keep the arm muscle tense, so that when tool connection is loosened, the free movement of

the human body and tool is reduced to a minimum.

VI. Dangerous energy

Warning

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

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 cause danger. In operation, precautions should be taken to prevent battery short circuit and overflow of electrolyte. The overflow of electrolyte will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs.

Before any operation on battery, pay attention to the following points: Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist. Use special insulated tools. Use eye protection device, and take preventive measures. Wear rubber gloves and apron to guard against electrolyte overflow. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery

upside down or slanted.

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Battery installation requires reliable grounding. And battery is connected before accessing the battery protection device.

Others

I. Sharp object

Warning

When moving equipment by hand, protective gloves should be worn to avoid injury by sharp object.

II. Cable connection

Notice

Please verify the compliance of the cable and cable label with the actual installation prior to cable connection.

III. Binding the signal lines

Notice

The signal lines should be bound separately from heavy current and high voltage lines, with binding interval of at least 150mm.

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Contents

Chapter 1 Overview ............................................................................................................................................................ 1

1.1 Composition and Configuration ............................................................................................................................. 1

Chapter 2 Installation Instruction ......................................................................................................................................... 3

2.1 Safety Regulation .................................................................................................................................................. 3

2.2 Preparation ........................................................................................................................................................... 3

2.3 Mechanical Installation .......................................................................................................................................... 4

2.4 Electrical Installation ............................................................................................................................................. 6

2.4.1 Power System Cabling Method ................................................................................................................. 6

2.4.2 Connecting AC Cables .............................................................................................................................. 7

2.4.3 Connecting Load Cables ........................................................................................................................... 7

2.4.4 Connecting Battery Cables ........................................................................................................................ 8

2.4.5 Connecting Signal Cables ......................................................................................................................... 8

Chapter 3 Commissioning ................................................................................................................................ ................. 15

3.1 Installation Check and Startup ............................................................................................................................ 15

3.2 Basic Settings ..................................................................................................................................................... 16

3.3 Alarm Check And System Operation Status Check ............................................................................................ 17

3.4 Final Steps .......................................................................................................................................................... 18

Chapter 4 Troubleshooting ................................................................................................................................................ 19

4.1 Controller Alarms And Fault Handling ................................................................................................................. 19

4.2 Rectifier Fault Handling ....................................................................................................................................... 22

4.2.2 Rectifier Fan Replacement ...................................................................................................................... 24

Appendix 1 Technical And Engineering Data .................................................................................................................... 26

Appendix 2 Installation Instruction Of Battery Rack .......................................................................................................... 29

1. Installation Instruction Of Two-Layer And Four-Layer Battery Rack ..................................................................... 29

2. Installation Instruction Of Three-Layer Battery Rack ............................................................................................. 31

3. Fixing The Battery Rack ........................................................................................................................................ 32

Appendix 3 Wiring Diagram ............................................................................................................................................... 33

Appendix 4 Schematic Diagram ........................................................................................................................................ 35

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Chapter 1 Overview 1

NetSure 731 A41 Subrack Power System User Manual

Chapter 1 Overview

This chapter introduces model composition and configuration and features of NetSure 731A41-S1 and NerSure 731A41-S2 (abbreviated as 'power system' hereinafter).

1.1 Composition and Configuration

Composition

The power system is composed of power distribution、rectifier modules and controller module. Take NetSure731A41-S1 for example, the internal structure is shown as Figure 1-1.

Positive terminal

Battery MCB

Controller

Rectifier

AC input terminal N AC input terminal L

Earthing screw

AC output terminal L

AC output terminal N

Non-prority load

Prority load

Figure 1-1 NetSure 731 A41- S1/S2 system instruction

The internal structure of NetSure731A41-S8 is as shown in Figure 1-3.

监控模块

电池空开

正接线端子

重要负载(PL) 非重要负载(NPL)

接地螺钉

整流模块

交流输入N 交流输入L

Prority load

Non-proity load

Positive terminal

Battery MCB

Controller

Earthing screw

AC input terminal N AC input terminal L

Rectifier

Figure 1-1 NetSure 731 A41- S8 system instruction

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2 Chapter 1 Overview

NetSure 731 A41 Subrack Power System User Manual

Configuration

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

Table 1-1 Configuration of power system

Item

NetSure 731 A41-S1

NetSure 731 A41-S2

NetSure 731 A41-S8

Controller

Model：M225S

Model：M221S/M222S

Model：M830B

Rectifier

Model： R48-3000e3 or R48-3000A3 Maximum configuration：4 pieces

Model： R48-3000e3 or R48-3000A3 or R48-3500e3 Maximum configuration：4 pieces

AC power distribution

L＋N＋PE/220Vac

DC power distribution

PL： 32A/1P×2;16A/1P×2 MCB NPL： 63A/1P×2;32A/1P×4;16A/1P×2 MCB

PL： 32A/1P×2;16A/1P×2 MCB NPL： 63A/1P×2; 32A/1P×4;16A/1P×2 MCB

AC output MCB

1×16A/1P

Battery MCB

2×125A/1P

AC SPD

1 piece

1piece

DC SPD

1piece

Cover

Optional

BLVD controller control mode

Controller power-losing mode

Main Features

 The rectifier uses the active Power Factor Compensation(PFC) technology and the power factor is up to 0.99.  The power system has wide AC input voltage: 85Vac～300Vac.  The rectifier uses soft switching technology, raising the efficiency above 95.5％.  The rectifier has Ultra-low radiation. With advanced EMC design, the rectifier meets international standards such

as CE、NEBS and YD/T983.Both the conducted and radiated interference reach Class B.

 The rectifier safety design complies UL，CE and NEBS.  The rectifier is of high power density.  The rectifier is hot pluggable. It takes less than1 min to replace a rectifier.  The rectifier has two optional over-voltage protection methods: hardware protection and software protection. The

latter one also has two optional modes: lock-out at the first over-voltage and lock-out at the second over-voltage.

 The controller module has perfect battery management. The management functions includes BLVD,

temperature compensation, auto voltage regulation , stepless current limiting ,battery capacity calculation and on-line battery test, etc.

 History alarm records：M221S/M222S controller supports 200 history alarms and 1000 history data records,

M225S controller supports 200 history alarms and 512 history data records. And M820B/M830B supports historical alarm record up to 3000 pcs and historical record up to 60000 pcs.

 Battery test data: can record up to 10 sets of battery test data.  The power system is of network design. Providing multiple communication ports (such as RS232, modem and

dry contacts), which enables flexible networking and remote monitoring.

 The power system has perfect lighting protection at both AC side and DC side.  The power system has complete fault protection and fault alarm functions.  The power system uses " controller power-losing " control mode . In the indoor or outdoor equipment room

without guard and maintenance, the " controller power- losing mode" can protect the battery from deep discharge.

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Chapter 2 Installation Instruction 3

NetSure 731 A41 Subrack Power System User Manual

Chapter 2 Installation Instruction

2.1 Safety Regulation

Certain components in this power system carry hazardous voltage and current. Always following the instructions below：

1．Only the adequately trained personnel with satisfactory knowledge of the power system can carry out the installation. The most recent revision of these safety rules and local safety rules in force shall be adhered to during the installation.

2．All external circuits that are below 48V and connected to the power system must comply with the requirements of SELV as defined in IEC 60950.

3．Make sure that the power (mains and battery) to the system is cut off before any operations can be carried out within the system cabinet.

4．The power cabinets shall be kept locked and placed in a locked room. The key keeper should be the one responsible for the power system.

5．The wiring of the power distribution cables should be arranged carefully so that the cables are kept away from the maintenance personnel.

2.2 Preparation

Unpacking inspection

The equipment should be unpacked and inspected after it arrives at the installation site. The inspection shall be done by representatives of both the user and Vertiv Tech Co., Ltd.

To inspect the equipment, you should open the packing case, take out the packing list and check against the packing list that the equipment is correct and complete. Make sure that the equipment is delivered intact.

Cables

The cable should be selected in accordance with relevant industry standards. It is recommended to use the RVVZ cables as AC cables. The cable should reach at least +70°C temperature

durability. With cable length shorter than 30 meters, the Cross-Sectional Area (CSA) calculation should be based on the current density of 3.5A/mm2. The suggested CSA value is no less than the Table 2-1.

Table 2-1 AC cable CSA selection

AC MCB rated current

Max. AC input current

Min cable CSA

Max cable CSA

125A

74A

25mm2

50mm2

The CSA of DC cable depends on the current flowing through the cable and the allowable voltage drop. To select the battery cable CSA, see Table 2-2,select the DC load cable CSA according to the Table 2-3.

Table 2-2 Battery cable CSA selection

Battery MCB rated current

Max. battery current

Min cable CSA

Max cable length( volt drop:

0.5V with max. CSA)

125A

105A

35mm2

Note:

1. The specs are applicable at ambient temperature of 25°C.

2. The battery cable should reach at least +90°C heat durability. It is recommended to use double-insulated copper-core flame retardant cable as battery cable.

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NetSure 731 A41 Subrack Power System User Manual

Table 2-3 DC 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)

63A

50A

16mm2

25mm2

14m

32A

25A

10mm2

11m

25mm2

29m

16A

12A

6 mm2

14m

25mm2

48m

Note: The specs are applicable at ambient temperature of 25°C. If the temperature is higher than this, the CSA of the cable should be increased.

To prevent the air switching capacity is too large, the load doesn't work when overload. Recommended the capacity of the air switching is up to 1.5~2 times of the load peak.

The CSA of the system grounding cables should be consistent with the largest power distribution cables. The CSA value is no less than 25mm2.

AC distribution、DC distribution interface definition see Table 2-4.

Table 2-4 AC distribution、DC distribution interface definition

Connector name

Connector specifications

Wiring instruction

AC power distribution AC input MCB

H type terminal, max. cable CSA 50mm2

AC power line

Grounding busbar

One M8 bolt, OT type wiring terminal, max. cable CSA 35mm2

Connected to the grounding bar of the building

DC power distribution

Battery output MCB

H type terminal, max. cable CSA 50mm2

Connected to the battery port

Negative output MCB

H type terminal, max. cable CSA 25mm2

Connected to the users negative load port

Positive busbar

Terminal subrack terminal：cable CSA ≤ 50mm2

Connected to the users positive load port

2.3 Mechanical Installation

 Note

1. The cabinet or rack that installed in the subrack must provide fireproof and electric protection casing, or install in cement or other difficult to burn, at the same time keep enough distance to other combustible material.

2. For the convenience of maintenance, users should maintain a clearance of 800mm at the front of the power system.

3. Subrack cannot be installed against the wall, it must leave enough space for heat dissipation.

Installed on the battery rack

Fix the subrack power system to the battery rack through the connectors with M6 bolts, as show in Figure 2-1.

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Chapter 2 Installation Instruction 5

NetSure 731 A41 Subrack Power System User Manual

Connector

M6 screw

Subrack power system

Connector

M6 screw

Battery bracket

Battery rack

Power system

Figure 2-1 Cabinet and rack installation

Installed in cabinet

Insert the subrack power system to the matching cabinet, as shown in Figure 2-2.

电源插框

Power subrack

Figure 2-2 Installed in the cabinet system

The engineering graphics of the subrack power system as shown in Figure 2-3.

101.6

177.0

37.7

465.1

482.6

7.0

R3.5

10.0

Figure 2-3 Installation size of NetSure 731 A41（unit:：mm）

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 Note

1. Tighten the captive screw of the MFU Panel by the cross head screwdriver when there is no operation.

2. Also tighten the handle by the cross head screwdriver.

3. Please plug in the new modules or installing a new panel after removing the rectifier module.

2.4 Electrical Installation

2.4.1 Power System Cabling Method

Cabling from the top of the power system

Epoxy board top cover and rubber ring top cover are optional for this system.

 Note

If the user requires the system to meet the CE certification, install the epoxy board top cover to be installed at a distance of 1.8 meters high above the ground.

Epoxy board top cover for MFU unit cabling. As shown in the Figure 2-4.

Cable outlet area

Cable-bundling plate

Signal cable

outlet holes

Cable outlet area

Square unit

Figure 2-4 Cable entry illustration of the MFU unit

Rubber ring top cover for MFU unit cabling as shown in Figure 2-5.

Cable outlet area

Latex unit

Figure 2-5 Cable entry illustration of the MFU unit

Cabling from side of the power system

Use a cross head screwdriver to remove two screws which fix the cabling panel at side of cabling area, then the cable can be led out from the cabling area, as shown in Figure 2-6.

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Chapter 2 Installation Instruction 7

NetSure 731 A41 Subrack Power System User Manual

Screw

Cable-bunding plate (cabling area)

Figure 2-6 Side cabling illustration

2.4.2 Connecting AC Cables

Danger

1. Switch off all MCBs and fuses before the electrical connection.

2. Only the qualified personnel shall do the power cable connection.

Take the NetSure 731 A41-S1power system for example, the position of the connection terminals are shown in Figure 2-7.

AC output terminal N

Earthing screw

AC output terminalL

AC output terminal N

Figure 2-7 Illustration of the connection terminal

 Note

1. Recommended tightening torque of user grounding screw is 10.78N*M.

2. In case system earthing cable lessen, please add another fixing point except for the earthing screw.

2.4.3 Connecting Load Cables

Connect the negative load cable to the upper terminal of load MCB and then connect the positive load cable to positive terminal. As shown in Figure 2-8.

Positive terminal

Load MCB

Figure 2-8 Illustration of the load connection terminal

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2.4.4 Connecting Battery Cables

 Note

1. The batteries may have dangerous current. Before connecting battery cables, make sure that the battery MCBs at the battery side are switched off.

2. If there are no battery MCBs at the battery side, users should disconnect any one of the connectors between battery cells to avoid live state of the system after installation.

3.Be careful not to reversely connect the battery. Otherwise, both the battery and the system will be damaged.

4.It's forbidden to disassemble battery cables in the up of the battery MCB when the battery input port is still connected.

1. Connect one end of the negative battery cable to the upper terminal of battery MCBs. Connect one end of the positive battery cable to the DC positive bus bar.

2. Connect copper lugs to the other end of the battery cables. Bind the connecting parts with insulating tape, and put them beside the battery. Connect the cables to the battery when the DC distribution unit is to be tested. As shown in Figure 2-9.

Positive terminal

Battery MCB

Figure 2-9 Illustration of the battery connection terminal

2.4.5 Connecting Signal Cables

Connecting NetSure 731 A41-S1 Signal Cables

The standard configuration of the system is M225S controller. The M225S1X1 user interface board is used for M225S.M225S controller and M225S1X user interface board cable connection is show in the following:

Interface board

Figure 2-10 NetSure 731 A41-S1 user interface board position illustration

M225S controller provides two dry contact alarm output ports: DO1 and DO2. DO2 is for LLVD in subrack system. If LLVD is selected, it can't be used for dry contact and should be sealed by white tape when out of the factory . If LLVD

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Chapter 2 Installation Instruction 9

NetSure 731 A41 Subrack Power System User Manual

is not selected, It can be used for dry contact. NetSure 731 A41-S1 provides four extended dry contacts: DO3、DO4、 DO5 and DO6，the illustration is as shown in the following:

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Figure 2-11 M225S1X1usr interface board illustration

Digital output dry contact specification of M225S controller and M225S1X1user interface board is as following: Digital output：relay isolation，max：30Vdc 1A，125Vac 0.5A，60W；Min：10uA@10Vdc. The dry contacts definition of M225S controller and M225S1X1 user interface board is shown in Table 2-5.

Table 2-5 Dry contact definition

Type

Default alarm

Description

DO1

Major alarm

DO2

Load disconnection control

LLVD control, user can't use it when LLVD is selected.

DO3

AC failure.

DO4

DC overvoltage or DC undervoltage

DO5

Rectifier alarm

Except rectifier lost and multi-rectifier alarm.

DO6

Battery protection and load disconnection alarm.

In the controller normal state, the alarm contacts are always open, when system issues above alarms, related contacts will be closed. All the status changes should be verified by a multimeter. After the alarms are removed, the dry contacts (DO) should back to the open state.

Connecting NetSure 731 A41-S2 Signal Cables

W2453X1 user interface board provides dry contacts for NetSure 731 A41-S2.W2453X1 user interface board position and signal cabling as shown in Figure 2-12.

信号电缆

用户接口板

（柔性配置）

Signal cable

User interface board

(Flexible configuration)

Figure 2-12 NetSure 731 A41-S2 user interface board illustration

At most two W2453X1 user interface boards are allowed in the power system. Standard cabinet is only configured with one user interface board.

With one W2453X1 user interface board configured, the power system provides four external digital input ports: DI1， DI2，DI3，DI4 and four dry contact alarm output ports

With two user interface boards configured, the power system provides additional four dry contact alarm output interfaces: DO5，DO6，DO7，DO8.

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NetSure 731 A41 Subrack Power System User Manual

The digital input ports of W2453X1 user interface board needs to connect active dry contact. Dry contact spec as following:

Digital output: relay isolation, Max.:30Vdc/1A, 125Vac/0.5A, 60W; Min.: 10uA@10Vdc, alarm is definable. The functions of the interfaces are shown in Table 2-6.

Table 2-6 Dry contacts definition

Type

Default alarm

Description

Dry contact 1

AC power failure

Dry contact 2

DC overvoltage or DC undervoltage

Four-level DC voltage alarms

Dry contact 3

Rectifier alarm

Except rectifier lost and multi-rectifier alarm

Dry contact 4

Priority LLVD

Dry contact 5

Non-priority LLVD

Exist when the second user interface board is installed

Dry contact 6

Exist when the second user interface board is installed

Dry contact 7

Exist when the second user interface board is installed

Dry contact 8

Exist when the second user interface board is installed

With default settings, when the preceding alarms are generated, the contactors of the corresponding dry contacts should change their status. That is, the normally-open contactors close, and the normally-closed contactors open. All the status changes should be verified by a multimeter. After the alarms are removed, the dry contacts (Do) should back to the original state.

Dry contact definition is settable in the controller, please refer to M221S Controller User Manual. The user interface board illustration is as shown in the following:

Figure 2-13 W2453X1 user interface board illustration

Connecting NetSure 731 A41-S8 Signal Cables

The communication port of the M830B controller is shown in Figure 2-18.

用户接口板 (DI/DO板 )

信号线缆

RS485端子

User interface board

(DI/DO board)

RS485 terminal

Figure 1-2 Communication port of M830B controller

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NetSure 731 A41 Subrack Power System User Manual

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 2-15.

J9 J8 J7 J6 J5 J4

J12

J11

Digital inputs 1~ 8,

20V ~ 60V

I C port

SW1

Address DIP

Alarm output dry contact

Figure 1-1 IB2 extension board port definition

 Note

1. J11 and J12 are temperature sensor ports. They are not used here.

2. J2 is I2C interface, and provides the power.

See Table 2-6 for the dry contact terminal definition.

Table 1-1 Dry contact terminal definition

Name of double-layer port

Pin No.

Pin name

Definition

DI1-

Digital input 1-

DI1+

Digital input 1+

DI2-

Digital input 2-

DI2+

Digital input 2+

DI3-

Digital input 3-

DI3+

Digital input 3+

DI4-

Digital input 4-

DI4+

Digital input 4+

DI5-

Digital input 5-

DI5+

Digital input 5+

DI6-

Digital input 6-

DI6+

Digital input 6+

DI7-

Digital input 7-

DI7+

Digital input 7+

DI8-

Digital input 8-

DI8+

Digital input 8+

NA / 6

DO1_NC

NC contact of relay 1

DO2_NC

NC contact of relay 2

DO1_COM

Common contact of relay 1

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NetSure 731 A41 Subrack Power System User Manual

Name of double-layer port

Pin No.

Pin name

Definition

DO2_COM

Common contact of relay 2

DO1_NO

NO contact of relay 1

DO2_NO

NO contact of relay 2

DO3_NC

NC contact of relay 3

DO4_NC

NC contact of relay 4

DO3_COM

Common contact of relay 3

DO4_COM

Common contact of relay 4

DO3_NO

NO contact of relay 3

DO4_NO

NO contact of relay 4

DO5_NC

NC contact of relay 5

DO6_NC

NC contact of relay 6

DO5_COM

Common contact of relay 5

DO6_COM

Common contact of relay 6

DO5_NO

NO contact of relay 5

DO6_NO

NO contact of relay 6

DO7_NC

NC contact of relay 7

DO8_NC

NC contact of relay 8

DO7_COM

Common contact of relay 7

DO8_COM

Common contact of relay 8

DO7_NO

NO contact of relay 7

DO8_NO

NO contact of relay 8

The definition of dry contact function can be set through controller or the WEB browser. The specifications of the dry contact ports are as follows: Digital inputs: 8-route, opto-isolation, the alarm and high/low level are definable (high level: 20V ~ 60V, low level: less

than 1V). Digital output: 8-route, relay isolation, maximum: 30Vdc 1A, 125Vac 0.5A; 60W; minimum: 10uA @ 10Vdc, alarm is

definable.

Connecting Communication Signal Cable

The RS232 communication port of M225S controller is shown in Figure 2-14.

RS232 communication

serial port

Dry contact output

Figure 2-14 M225S controller communication port

The communication port of the M221S controller is shown in Figure 2-15.M222S only provides the RS232 communication serial port, whereas the Ethernet port is not provided.

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以太网口

RS232通讯串口

RS232 communication

serial port

Ethernet port

Figure 2-15 M221S controller communication port

The communication port of the M830B controller is shown in Figure 2-16.

Figure 2-16 M830B controller communication port

Please refer to Figure 2-17 to make communication signal cables.

X1 X2

接线表

X2X1 颜色 X1.2 X1.3

X1.5

X2.3 X2.6

X2.5

白/绿

绿

白/蓝

Wiring table

X1.2 X1.3 X1.5

X2.3 X2.6 X2.5

Colour

White/blue

Green

White/green

9 6

5 1

Figure 2-17 Communication signal cable

2.4.6 Connecting temperature compensation cable

If the optional temperature compensation cable is not connected to the subrack, take down the preassembled Temp terminal from the left side of the subrack, connect the temperature compensation cable with Temp terminal and put the probe on the other side onto the battery. The Temp terminal is as shown in Figure 2-18

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Temp terminal

Figure 2-18 The position of temp terminal

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Chapter 3 Commissioning

The controllers can be used in the power system are M221S、M222S , M225S and M830B. The detail instructions of the controllers please refer to the user manuals. This section introduces commissioning after installation. During installation test, the corresponding safety rules should be adhered to. The system has been tested before out of the factory, user doesn't need to test on site.

3.1 Installation Check and Startup

Before the test, inform the chief manufacturer representative. Only trained electrical engineer can maintain and operate this equipment. In operation, the installation personnel are not allowed to wear conductive objects such as watches, bracelets, bangles and rings.

During operation, parts of this equipment carry hazardous voltage. Misoperation may result in severe or fatal injuries and property damage. Before the test, check the equipment to ensure the proper earthing. Installation check must be done before testing. Then the batteries can be charged for the first time.

Make sure that the AC input MCBs, battery MCBs and load MCBs are switched off. Make sure that all the devices are properly installed.

Installation check

Comments

Check all the fuse and cables. Are the models correct?



Check the busbar connections, input and output cable connection, and connection between the power system and the system grounding.



Check if the number and connections of the batteries are correct. Check the polarity of the battery string with a voltmeter.



Make sure all the communication cables and alarm cables are connected to the controller module. Check that the temperature sensor, if any, has been installed.



Startup preparations

Comments

Make sure that all the MCB are switched off and all the fuses are removed.



Measure the AC input voltage. Make sure the input voltage is within the allowable range.



Umin＝ V

Check that communication and alarm cables are connected to the signal transfer board.



Check that the temperature sensor, if any, has been installed.



Check that the battery string circuit is not closed.



Connect the disconnected batteries to the battery string circuit.



Make sure that the MCB disconnected to the battery cables are switched off. Check the battery signal cables connection and MCB cables connection.



Measure with a voltmeter across the connection points of each battery and make sure that the polarity is right. For a lead-acid battery with 24 cells, the voltmeter should read 2.0 ~ 2.1V/cell or 48 ~ 51V/battery. If the voltage of certain cell is lower than 2.0V, that cell must be replaced.



Umin＝ V

Check with an ohmmeter that there is no short circuit between the positive & negative distribution bus bars, or between the positive & negative battery poles (Note: Pull out all modules before the check and restore them after the check).



Startup

Comments

Switch on the system AC input MCB. Insert one rectifier. The green LED on the rectifier will be on and the fan will start running after a certain delay. The controller module will show that the power supply voltage is

53.5V( when it used for outdoor, the output voltage is 54V).



Check the system voltage and busbar polarity with a voltmeter. The voltage difference between the measured value and displayed value should be less than±0.2V.



Start and stop each rectifier of the system by inserting and unplugging the rectifier. Check their output voltages.



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3.2 Basic Settings

When the system is put into service for the first time, the parameters of controller module must be set based on the actual system configuration, such as battery number, capacity, user’s charge current limit and other functional requirements. Only after that can the controller module display system operation information and control the output.

(M221S,M222S controller password is 2; M225S controller password is1 )

Comments

The system model has been set correctly in factory before delivery, check that the setting agrees with the actual system. (The path to check and set of the M221S\M222S controller：SettingsBat. SettingsBasic Settings）

NetSure 731 A41-S1：48V/SET；battery shunt coefficient：300A/25mV； (The path to check and set of the M225Scontroller：Settings Shunt A） NetSure 731 A41-S2：battery shunt coefficient：300A/25mV



Setting controller according to number of battery groups connected. Default: two groups. (The path to check and set of the M221S\M222S controller：SettingsBat. SettingsBasic Settings

Bat.Fuse）（No such settings for M225S controller）



Setting controller according to the capacity of battery groups connected. Default: 300Ah

（The path to check and set of the M221S\M222S controller：SettingsBat. SettingsBasic Settings Capacity）（The path to check and set of the M225S controller：Settings Capacity）



Setting LVD1: default:44V（If the subrack system is used for outdoor, default setting:46.6V）

（The path to check and set of the M221S\M222S controller：SettingsBat. SettingsLVD Settings LVD1 Volt）（The path to check and set of the M225Scontroller：SettingsLVD1，default setting:Yes

Relay 2 settings“SettingsRelay 2”,default setting “LVD1”） Setting LVD2: default:43.2V（If the subrack system is used for outdoor, default setting:45.6V）

（The path to check and set of the M221S\M222S controller：SettingsBat. SettingsLVD Settings LVD2 Volt

（The path to check and set of the M225Scontroller：SettingsLVD2，） Setting AC input type. Default value: 1-PH

（The path to check and set of the M221S\M222S controller：SettingsInput SettingsAC PH）（No such settings for M225S controller） Walk-in T setting: default：8S （The path to check and set of the M221S\M222S controller：SettingsRect SettingsWalk-in on，

default“Y” (SettingsRect SettingsWalk-in T，default“8S”）（The path to check and set of the M225Scontroller：Settings Walk-in T，default“8S“） Setting controller according to the battery factory.Temperature compensation range:0～500mV/℃. Default： 72mV/℃.

（The path to check and set of the M221S\M222S controller：SettingsBat.settingsTemp.Comp）（No such settings for M225S controller）



Set the charge current limit according to your needs. Setting range: 0.1 C10～0.25C10。Default：0.1C10

（The path to check and set of the M221S\M222S controller：Settings Bat. SettingsCharge）（No such settings for M225S controller）



Set the controller according to the voltage suggested by the battery supplier. Float charge voltage：42V～Boost charge(BC)，default：53.5V(If the subrack system is used for outdoor, default voltage:54V)； Boost chare voltage：Float charge(FC)～58V，default：56.4V

（The path to check and set of the M221S\M222S controller：Settings Bat. SettingsCharge）（The path to check and set of the M225Scontroller：SettingsFloat/Boost）

SettingsFloat/Boost



Set the boost charge voltage higher 0.1V than float charge voltage for the free boost charge battery. Close the battery MCBs and connect the battery.



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The User and password of the M830B controller is set by web, see NetSure™ Control Unit (NCU) User Manual Tabe 3-3 M830B

controller paremeter settings

Parameter

Path

Default settings

Rated Capacity

LCD/ SettingsBatt SettingsChargeBatt1 Settings Rated Capacity

300Ah LVD1

LCD/ Settings—LVD Settings—LVD1

Enabled

LVD2

LCD/ Settings—LVD Settings—LVD2

Enabled

LVD1 Voltage

LCD/ Settings—LVD Settings—LVD1Voltage

44.0V

LVD2 Voltage

LCD/ Settings—LVD Settings—LVD2Voltage

43.2V

AC Fail Required

Web/Settings—System—LVDGroup—AC Fail Required

Enabled

Num Batt Shunts

LCD/ Settings—Batt Settings—Basic Settings—Num Batt Shunts

Shunt Current/ Shunt Voltage

LCD/ Settings—Batt Settings—Basic Settings—Batt1 Settings—Shunt Current/Shunt Voltage

300A/25mV LVD Contactor Type

Web /Settings—LVD—LVD Contactor Type

Bistable

Walk-In

LCD/ Settings—Rect Settings—Walk-In

Enabled

Walk-In Time

LCD/ Settings—Rect Settings—Walk-In Time

128S

Note: The LVD2 voltage settings should follow battery factory's requirement and the battery capacity settings should based on the actual configuration settings.

3.3 Alarm Check And System Operation Status Check

Alarm check

Check that all functional unit can trigger alarms that can be displayed on the controller.

Comment

Pull out one rectifier. The ‘Rect N Com Failure’ alarm should be triggered. Insert the rectifier in. The alarm

should disappear. Repeat the same procedures on other rectifiers



Switch off battery MCB 1. The ‘Batt1 Failure’ alarm should be triggered. Switch on the MCB. The alarm

should be cleared. Repeat the same on battery MCB 2



Switch off a load MCB connected to a load route. The alarm ‘Load Fuse N Failure’ should be triggered. Switch on the MCB, and the alarm should be cleared. Repeat the same on the other load MCBs



Remove all the battery MCBs. Keep only one rectifier in operation. Through the controller module, adjust the rectifier FC voltage to make it lower than the alarm point. The alarm ‘DC Voltage Low’ should be triggered



Keep the rectifiers in operation. Set through the controller module the battery management parameter to

‘Manual’. Enter the maintenance menu at the controller module. Select ‘Disconnect’ and confirm it. The battery protection contactor should be open, and the ‘BLVD’ alarm should be displayed at the controller

module



Note: when the preceding alarms are generated, the controller module will give alarms after approximately 3s.

System operation status check

There should be no alarms during normal system operation. The system operation status can be conducted through the controller module.

Comments

The system model is correct.



The controller should display the correct AC voltage



The controller should be able to display the DC voltage. The difference between the displayed voltage and that measured at the busbar should be less than 1％



The controller should diaplay the battery current. The difference between the displayed and measured battery current should be less than 1％



Check the number of the rectifier through the controller . The number should be consistent with the actual number.



Check the voltage, current, current limiting point of rectifiers through the controller. They should agree with the actual parameter.



For the system configured with temperature sensor, the controller should be able to diaplay the battery



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ambient temperature. Hold the probe of the temperature sensor with hand and watch the controller which should display the change of temperature.

3.4 Final Steps

Comments

Make sure that materials irrelevants to the equipment have been all removed.



Rehabilitate the power equipment and close the cabinet door.



Fill in the installation report and hand it over to the user.



Record all the operations in the file , including operation time and operator name.



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

repairing center for fault analysis.

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Chapter 4 Troubleshooting

This chapter describes the handling of alarms, as well as the routine maintenance of the system during system daily operation.

The maintenance personnel must have adequate knowledge about the subrack power system.

 Note

1. The maintenance must be conducted under the guidance of related safety regulations.

2. Only trained personnel with adequate knowledge about the subrack power system shall maintain the inner part of the subrack.

4.1 Controller Alarms And Fault Handling

The controller alarms are classified into three types: major alarm, observation alarm and no alarm. Major alarm: This type of alarms have strong impacts on the system performance. Whenever these alarms are

generated, users are supposed to handle them immediately. The red major alarm indicators will be on. Observation: When this type of alarm is raised, the system maintains normal output for a while. If the alarm occurs

during watch time, it should be handled immediately. If the alarm occurs during non- watch- time, handle it during watch time. The yellow observation alarm indicators will be on.

No alarm: If alarms are set as ‘no alarm’ by the users, when these alarms occur, the green alarm indicators will be on and the system works normally.

If an unnecessary alarm occurs during the operation of the controller, set it according to the following method. Take the alarm of ‘Rect Lost’ for example: For M221S/M222S controller: MAIN MENU —> Settings —> Alarm—> Alarm Control—> Clear—> For the submenu

of "Clear", you can select "Rect Lost" to clear corresponding alarm. For M225S controller: SettingsClear. For the submenu of ‘Clear’, you can select ‘Rect Lost’ to clear corresponding

alarm. The handling methods of normal alarms are given in Table 4-1.

Table 4-1 Alarm description and action to correct

Index

Alarm

Handling method

Mains Failure

If the failure does not last long, the battery will power the load. If the cause is unknown or the failure lasts too long, a diesel generator is needed. Before using the generator power to supply the subrack power system, it is suggested to run the generator at least five minutes to minimize the impact on the subrack power system

AC Voltage High

Check if the AC over-voltage value is too low. If yes, change the value. A mild over-voltage does not affect the system operation. However, the rectifiers will stop working operation when the mains voltage is more than 305V. If the mains voltage is above the AC over-voltage value, the mains grid should be improved

AC Voltage Low

Check if the AC Under- voltage point is too high. If yes, change the value. When the mains voltage is lower than 176V, the output power of the rectifiers will be derated. And if lower than 80V, the rectifiers will stop working. If the mains voltage is under the AC under-voltage value, the mains grid should be improved

SPD alarm

Check the SPD condition. If the SPD is damaged, replace it

DC Volt High

Check the DC over-voltage value through the controller. If the setting value is inappropriate, correct it. Otherwise, find out the rectifier that has caused the alarm:

1. Ensure that the batteries can operate normally.

2. Switch off the AC input of all rectifiers.

3. Power on the rectifiers one by one.

4. If the over-voltage protection is triggered when a certain rectifier is powered on, that rectifier is the faulty one. Replace it

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Index

Alarm

Handling method

DC Volt Low

1. Check if the alarm is caused by mains failure, if yes, disconnect some loads to prolong the operation of the whole system.

2. Check the DC under-voltage value set through the controller. If the set value is inappropriate, correct it.

3. Check if any rectifier is inoperative, or has no output current. If yes, replace it.

4. Check if the total load current exceeds the total rectifier current during float charge. If yes, disconnect some loads or add more rectifiers to make the total rectifier current bigger than 120% of the total load current with one redundant rectifier.

Load Fuse Alarm, Batt Fuse Alarm

Check if the corresponding MCB is switched off. If the MCB is open, find out the fault and remove it. Otherwise, the alarm circuit is faulty. Please contact Vertiv.

LVD2

1. Check if there is mains failure, and the battery voltage is lower than the value of ‘LVD2’.

2. Check whether the battery is disconnected from the system manually.

Rect Failure

The rectifier with the fault indicator (red) on is faulty. Power off the rectifier, and then power it on after a while. If the alarm persists, replace the rectifier.

Rect Protect

Check if the mains voltage is above 305V or under 80V. If the mains voltage is under the AC under-voltage value or above the AC over-voltage value, the mains grid should be improved.

Rect Fan Fails

Pull out the rectifier to check if the fan is obstructed. If yes, clean it and push the rectifier back. If the fan is not obstructed or if the fault persists after cleaning, replace the rectifier.

Rect Not Respond

Check if the communication cable is connected properly between rectifier and controller. If yes, restart the rectifier. If the alarm persists, replace the rectifier.

High temperature

Check if the temperature of the temperature sensor is too high. If yes, find the causes and cool down the battery compartment.

Controller fault handling

The symptoms of usual controller faults include：power indicator(green) off. LCD doesn't display( if connected to the host system, it may cause an external alarm). Check whether the system bus voltage is normal. If not, check whether

the terminal of the controller is in normal connection. If both are in normal, the controller is faulty, please see the following procedures to replace the controller.

M221S/M222S replacement: 1．Check the new controller for damage.

2．Loosen the captive screw of the controller, as shown in Figure 4-1

以太网口

RS232通讯串口

RS232 communication

serial port

Ethernet port

Figure 4-1 M221S/M222S Controller replacement

3．Push the new controller into the system and tighten the captive screw of the controller 4．After controller startup, refer to 3.2 Basic Settings M225S controller replacement：

1. Security preparation Put one end of the effective grounding strap at the wrist and the other end attached to a suitable ground.

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2. Loosen the captive screw of the controller, as shown in Figure 4-2.

Captive screw

Figure 4-2 M225S Controller replacement (1)

3. Pull out the controller unit slowly until the J2 terminal is completely exposed, and pull out the connected terminals fromJ2,J6,J7 carefully and do insulation respectively.( as shown in Figure 4-3 ).

Figure 4-3 M225S Controller replacement (2)

4. Push the new controller into the system and insert connection terminals to the corresponding J2, J6 and J7 respectively. Make sure that the connections are fastened, then push the controller into the system.

5. Tighten the captive screw of the controller.

6. After controller startup, refer to 3.2 Basic Settings

Replacement of the M830B controller

The procedures for replacing M830B controller are as follows:

1. Check the new controller for damage.

2. Loosen the captive screw of the controller, as shown in Figure 4-4.

USB接口

以太网口

松不脱螺钉

Ethernet port

USB port

Captive screw

Figure 4-4 M221S/M222S Controller replacement

3. Push the new controller into the system and tighten the captive screw of the controller

4. After controller startup, refer to 3.2 Basic Settings

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4.2 Rectifier Fault Handling

Alarm handling

The symptoms of usual rectifier faults include: power indicator ( green ) off, protection indicator ( yellow) on, protection indicator blink , fault indicator (red) on and fault indicator blink, the indicator locations as shown:

Figure 4-5 Local Indicator Locations

Table 4-2 Rectifier Troubleshooting

Symptom

Related alarm

Possible cause(s)

Suggested action(s)

Power Indicator (Green) Off

No alarm 1．No input/output voltage.

Make sure that there is input/output voltage

2．Internal input fuse open.

Replace the rectifier

Power Indicator (Green) flashing

No alarm

The rectifier is being identified by the controller

Protection（yellow）

Rect protection

AC input voltage abnormal

Make sure the AC input voltage is normal

Rect over temperature

1. Fan blocked

1. Remove the object that blocks the fan

2. Ventilation path blocked at the inlet or vent

2. Remove the object at the inlet or vent

3. Ambient temperature too high or the inlet too close to a heat source

3. Decrease the ambient temperature or remove the heat source

Rect protection

Current sharing imbalance

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

Rect protection

Power factor compensation internal under voltage or over voltage

Replace the rectifier

Protection indicator flash (yellow)

Rect communication fail

Rectifier communication fail

Check whether the communication cable is in normal connection

Fault indicator on(red)

Rect HVSD

Rectifier over-voltage

Reset the rectifier. If the protection is triggered again, replace the rectifier

Rect fail

Rectifier module addresses contradictory.

Replace the rectifier module.

Severe load sharing imbalance.

positive and negative deviations of average current ≤ 2.5A

Fault indicator flash (red)

Rect Fan Fails

Fan fault

Replace the fan.

R48-3000e3, R48-3000A3, R48-3500e3 Replacement

Rectifier modules can be inserted or removed with power applied (hot swappable).

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 Note:

Each rectifier module locks into a module mounting shelf by means of a latch located on the bottom of the module. The latch and rectifier module handle are interactive. Pushing the handle up into the module’s front panel causes the latch to extend to the locking position; pulling the handle down out from the module’s front panel causes the latch to retract.

Danger

DANGER!

Take care when removing a rectifier module that was in operation, as rectifier module surfaces could be very hot.

Warning

WARNING!

To prevent damage to the latching mechanism, ensure the handle is in the open position when installing or removing a rectifier module. NEVER hold the handle in the closed position when installing a rectifier module into a shelf.

Procedure

Refer to Figure 4-6 as this procedure is performed.

1. Performing this procedure may activate external alarms. Do one of the following. If possible, disable these alarms. If these alarms cannot be easily disabled, notify the appropriate personnel to disregard any alarms associated with this system while this procedure is performed.

2. Loosen the captive screw on the module’s handle. Pull the handle down out from the module’s front panel (this will also retract the latch mechanism).

3. Grasp the handle and pull firmly to remove the module from the shelf.

4. Place the replacement rectifier module into the mounting position without sliding it in completely.

5. Loosen the captive screw on the module’s handle. Pull the handle down out from the module’s front panel (this will also retract the latch mechanism).

6. Push the module completely into the shelf.

7. Push the handle up into the module’s front panel. This will lock the module securely to the shelf. Tighten the captive screw on the handle.

8. Certain functions (i.e. rectifier current limit, rectifier addressing) may require adjustment when adding or replacing a rectifier module.

9. After the rectifier modules are physically installed in the mounting shelf(s), they are ready for operation immediately after power is supplied to them. Verify that the rectifiers are operating normally.

10. Enable the external alarms, or notify appropriate personnel that this procedure is finished.

11. Ensure that there are no local or remote alarms active on the system.

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Figure 4-6 Installing Rectifier

4.2.2 Rectifier Fan Replacement

Each Rectifier uses a fan (P/N:32010485) for cooling. If fan replacement should become necessary, perform the following procedure.

Refer to Figure 4-6 as this procedure is performed.

Warning

WARNING!

In a system with NO redundant Rectifier, battery must have sufficient reserve to power the load(s) while the Rectifier is removed for fan replacement.

 Note:

When performing any step in this procedure that requires removal of existing hardware, retain all hardware for use in subsequent steps.

Procedure

2. Remove the Rectifier from the shelf. Refer to a previous procedure for step-by-step instructions.

3. On this Rectifier; remove the front panel by removing the screws securing the front panel to the chassis, and by unplugging the fan from the printed circuit card.

4. For proper orientation of the new fan, observe the location of the fan wires and the air flow arrows on the old fan.

5. Remove the old fan from the front panel by removing the two screws and clips securing the fan.

6. Install the new fan onto the front panel using the two screws and clips previously removed. Ensure the fan wires and air flow arrows match the orientation of the old fan.

7. Install the front panel with the new fan onto the chassis by plugging the fan cable into the printed circuit card, and securing the front panel with the screws previously removed.

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8. Replace the Rectifier into the shelf. Refer to the previous procedure for step-by-step instructions.

9. Enable the external alarms, or notify appropriate personnel that this procedure is finished.

10.Ensure that there are no local or remote alarms active on the system.

Figure 4-7 Fan replacement

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Appendix 1 Technical And Engineering Data

Table 1 Technical data

Parameter category

Parameter

Description

Environmental

Operating temperature

－5℃～＋40℃(derating is necessary above 40°C)

Storage temperature

－40℃～＋70℃

Relative humidity

5％RH～95％RH

Altitude

≤2000m(derating is necessary above 2,000m)

Polution level

Level 2

Others

No conductive dust or erosive gases. No possibility of explosion

AC input

AC input system

L＋N＋PE/220Vac； AC input type

TN，TT

Input voltage range

85Vac～300Vac

Input AC voltage frequency

45Hz～65Hz

Maximum input current

≤74A（including 10A AC output current）； ≤84A（using R48-3500e3 modules）

Power factor

≥0.99

Overvoltage level

Level Ⅱ

DC output

Nominal output voltage

－48Vdc

Rated output voltage

－53.5Vdc（If it is used for outdoor，the rated voltage is-54V）

Output DC voltage

－43.2～－57.6Vdc

Maximum output current

DC load output ≤150A (R48-3000e3/R48-3000A3) DC load output ≤185A (R48-3500e3) battery charging current≤56A Note: in 45℃, full load output, above 45℃, the power derating 2% per ℃.

Voltage set-point accuracy

≤1％ Maximum efficiency

≥94.5％

Noise (peak-peak) (rated output)

≤200mV（0～20MHz）

Weighted noise (rated output)

≤2mV（300～3400Hz）

AC input alarm and protection

AC input over-voltage alarm point

Default: 280 ± 5Vac, configurable through controller

AC input over-voltage alarm recovery point

Default: 270 ± 5Vac, 10Vac lower than the AC input over-voltage alarm point

AC input under-voltage alarm point

Default: 180 ± 5Vac, configurable through controller

AC input under-voltage alarm recovery point

Default: 190 ± 5Vac, 10Vac higher than the AC input under-voltage alarm point

AC input over-voltage protection point

305 ± 5Vac by default, configurable through controller

AC input over-voltage protection recovery point

295 ± 5Vac by default, 10Vac lower than the AC input over-voltage alarm point

AC input under-voltage protection point

Default: 80 ± 5Vac, configurable through controller

AC input under-voltage protection recovery point

Default: 95 ± 5Vac, 10Vac higher than the AC input under-voltage alarm point

DC output alarm and protection

DC output over-voltage alarm point

Default: -58.0 ± 0.2Vdc, configurable through controller

DC output over-voltage recovery point

Default: -57.5 ± 0.2Vdc, 0.5Vdc lower than the over-voltage alarm point DC output under-voltage

Default: -45.0 ± 0.2Vdc, configurable through controller

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Parameter category

Parameter

Description

alarm point

DC output alarm and protection

DC output under-voltage recovery point

Default: -45.5 ± 0.2Vdc, 0.5Vdc higher than the under-voltage alarm point

DC output over-voltage protection point

Default: -59.0 ± 0.2Vdc, configurable through controller

LLVD

Default: -44.0 ± 0.2Vdc, configurable through controller（If it is used for outdoor， the default is-－46.6±0.2Vdc）

BLVD

Default: -43.2 ± 0.2Vdc, configurable through controller

Rectifier

Current sharing

The rectifiers can work in parallel and share the current. The unbalanceness is better than ± 5%.

Derate by input (at 45°C)

176Vac input, The rectifier output is 100% power 154Vac~176Vac input，the rectifier output power increased from 2900W to 3000W. 85Vac~154Vacinput，the rectifier output power increased from 1500W to 2900W. Below 80Vac，the rectifier low pressure power off.

Walk-in

The output voltage can rise slowly when the rectifier start up. The walk in time is configurable through the controller.

Fan speed adjustable

Rectifier fan speed can be set to auto or full speed.

Over-voltage protection

The rectifier provides over-voltage hardware and software protection. The hardware protection point is 59.5V ± 0.5V, and it requires manual resetting to restore operation. The software protection point is between 56V and 59V (0.5V above output voltage, 59V by default), and can be set through the controller There are two software protection modes, which can be selected through the software at the host:

1. Lock out at the first over-voltage Once the output voltage reaches protection point, the rectifier will shut off and hold that state. It requires manual resetting to restore the operation

2. Lock out at the second over-voltage When the output voltage reaches the software protection point, the rectifier will shutdown, and restart automatically after 5 seconds. If the over-voltage happens again within a set time (default: 5min. Configurable through controller), the rectifier will shut off and hold that state. It requires manual resetting to restore the operation Manual resetting: Resetting can be done manually through the controller, or by removing the rectifier from system

Temperature power limiting

The rectifiercan start in -40℃; Below 45℃, the rectifier with full power (3000 W) output. From 45℃~55℃, the rectifier with linearly derating to 2900W. From 55℃~65℃, the rectifier with linearly derating to 2250W. From 65℃~70℃, the rectifier with linearly derating to 0W.

EMC

Conducted emission

Class A EN55022 Radiated emission

Harmonic current emission

Class A EN61000-3-12

Voltage fluctuation and flash

EN61000-3-11 EFT

Level 4 EN/IEC 61000-4-4

ESD

Level 3 EN/IEC 61000-4-2

Surges

Level 4 EN/IEC 61000-4-5

Radiation

Level 3 EN/IEC 61000-4-3

Conduction

Level 2 EN/IEC61000-4-6

Lightning protection features

At AC side

The AC input side can withstand five times of simulated lightning voltage of 5Kv at 10/700µs, for the positive and negative polarities respectively. It can withstand five times of simulated lightning surge current of 20Ka at 8/20µs, for the positive and negative polarities respectively. The test interval is not smaller than 1 minute. It can also withstand one event of simulated lightning surge current of 40kA at 8/20µs.

Page 36

28 Appendix 1 Technical And Engineering Data

NetSure 731 A41 Subrack Power System User Manual

Parameter category

Parameter

Description

Others

Safety regulation

Conform to IEC60950-1 standards

Acoustic noise

≤ 60db (A) (When the ambient temperature is lower than25°C )

Insulation resistance

At temperature of 15°C ~ 35°C and relative humidity not bigger than 90%RH, apply a test voltage of 500Vdc. The insulation resistances between AC circuit and earth, DC circuit and earth, and AC and DC circuits are all not less than 2MΩ

Insulation strength

(Remove the SPD, controller and rectifiers from the system before the test.) AC loop to DC loop can withstand 50Hz. AC to DC circuits: 3,000Vac; or 4,242Vdc for one minute, leak curren≤10mA , without puncturing and electric arcing; AC circuit to earth: 50Hz, 2,500Vac; or 3,535Vdc for one minute, leak curren≤10mA , without puncturing and electric arcing ; DC circuit to earth: 50Hz, 1,000Vac; or 1,414Vdc for one minute, leak curren≤10mA , without puncturing and electric arcing ; Auxiliary circuit without connecting to the main circuit directly: 50Hz,500Vac; or 707Vdc for one minute, leak curren≤10mA , without puncturing and electric arcing ;

MTBF

> 200,000hr

ROHS

Compliant with R5 requirement

Mechanical

Dimensions (mm) Standard dimensions of the

subracks:

483 mm×390 mm×178 mm

Controller:

M221S\M222S\M830B：87×212×42 M225S：43.6×212×42

Rectifier:

85.1×330×43.6

Weight (kg) Subrack (package,rectifier

and controller are all included)

≤25;

Subrack (without package,rectifier and controller included)

≤15;

Page 37

Appendix 2 Installation Instruction Of Battery Rack 29

NetSure 731 A41 Subrack Power System User Manual

Appendix 2 Installation Instruction Of Battery Rack

1. Installation Instruction Of Two-Layer And Four-Layer Battery Rack

Packing list

Accessory 1 Accessory 2 Accessory 3 Accessory 4 Accessory 5

Figure 1 Accessory

Table 2 Packing list of the battery rack

Battery rack

Accessory

Two-layer battery rack

Four-layer battery rack

Accessory 1

Accessory 2

Accessory 3

Accessory 4

Accessory 5

Expansion bolt

4 pieces

Fastener

1 set

Installation procedures

1. Installation procedures of two-layer battery rack

1) Install accessory 1 and accessory 2 according to Figure 2 (a).

2) Install accessory 3 according to Figure 2 (b).

Accessory 1

Accessory 2

Accessory 3

(a) (b)

Figure 2 Installation procedure of accessory 1 ~ accessory 3

Page 38

30 Appendix 2 Installation Instruction Of Battery Rack

NetSure 731 A41 Subrack Power System User Manual

3) Install accessory 2 and accessory 4 according to Figure 3.

Accessory 4 Accessory 2

Figure 3 Installation procedure of accessory 2 and accessory 4

2. Installation procedures of four-layer battery rack

1) Install accessory 1, accessory 2 and accessory 3 according to Figure 2 (a) and Figure 2 (b).

2) Install accessory 5 according to Figure 4 (a).

3) Install accessory 2 and accessory 4 according to Figure 4 (b).

Accessory 4 Accessory 2

(a) (b)

Figure 4 Installation procedure of accessory 2, accessory 4 and accessory 5

Page 39

Appendix 2 Installation Instruction Of Battery Rack 31

NetSure 731 A41 Subrack Power System User Manual

2. Installation Instruction Of Three-Layer Battery Rack

Packing list

Accessory 1 Accessory 2 Accessory 3 Accessory 4

Figure 5 Accessory

Table 3 Packing list of the battery rack

Accessory

Accessory number

Accessory 1

Accessory 2

Accessory 3

Accessory 4

Expansion bolt

4 pieces

Fastener

1 set

Installation procedures

1. Install accessory 1 and accessory 2 according to Figure 6 (a).

2. Install accessory 3 according to Figure 6 (b).

Accessory 1

Accessory 2

Accessory 3

(a) (b)

Figure 6 Installation procedure of accessory 1 ~ accessory 3

Page 40

32 Appendix 2 Installation Instruction Of Battery Rack

NetSure 731 A41 Subrack Power System User Manual

3. Install accessory 2 and accessory 4 according to Figure 7.

Accessory 4

Accessory 2

Figure 7 Installation procedure of accessory 2 and accessory 4

3. Fixing The Battery Rack

1. Fix the battery rack to the ground according to the installation dimensions shown in Figure 8. The fixing bolts are accessories.

600

575

480

Figure 8 Installation dimensions (unit: mm)

2. Fix the subrack subrack power system onto the top of the battery rack. Refer to2.3 Mechanical Installation

Page 41

Appendix 3 Wiring Diagram 33

NetSure 731 A41 Subrack Power System User Manual

Appendix 3 Wiring Diagram

MFU DC wiring diagram

MFU

Rear top view

M225S1X1

User interface board 1

monitor motherboard

M225S

M34C3C1

Subrack

5-2

W07

2 1

121

7-J6-9

QFB1

QFB2

7-J6-10

7-J6-8

7-J6-7

18-J2-1

18-J2-2

W80

7-J7-11

8-PL-2

NPL

8-B-

121

QFD1

QFD2

1 2

QFD3

QFD8

NPL

121

QFD9

QFD12

To the positive busbar of the module

BUS+

KM1

KM2

9-2

W80

7-J6-11

W84

W80

W84

W80

7-J7-4/7-J7-12

9-BUS+-2

12--KM2-1

W84

W80

Single AC input (wi th AC SPD)

Front view

11-KM1-2

W80

7-J7-1

W80

Right view

DC-

L N

L N L N

L N

J4J3

J13

J11

H3 H4

DC+

U1 U2DC+DC-J12 U3

DC+

DC-

J14

U11 U12

U13

U14

DC-

DC+

1-2

2-N-1

1-2

J41

CAN+CAN-

J42

CAN+CAN-

W01

Front top view of the back plat (with the controller and rectifier)

1-2

W80

8-PL

QFA

SPD1

1 3

2 4

N-1

COM

W80

7-J7-7

7-J7-8

W01

31-J1-L/31-J2-L/31-J3-L/31-J4-L/3-2

2-N-2

W01

N-2

31-J1-N/31-J2 -N/32-J3-N/32-J 4-N

1-4/3-4

W2493ZX1

7-J7-5

7-J7-6

12-KM2-1

12-KM2-2

8-PL-1

W84

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 2 3 4 5 6 7 8

9 10 11 12

X4-1

CAN-

CAN+

13-J1-1

10-RB-1 10-RB-2 8-QFB1-1

8-QFD 13-J1-5

8-PL-1

9-BUS+-1 18-J1-1

2-COM 2-NC

11-KM1-1 9-BUS+-1

DO3

DO4

DO5

DO6

W80

13-J1-2 13-J1-3 13-J1-4

13-J1-6 13-J1-7 13-J1-8

W80

8-QFB2-1

W80

18-J2-3

18-J1-2

W84

W80

To subrack PE bar

To SPD PE bar

This diode cintai ns in the W80 cable

N L

2-L

3 4

W01W01

2-N-2

QFA2

W80

7-J6-2

7-J6-1

31-J42-CAN31-J42-CAN+

8-PL-2

M2433X2

J7J5

J1 J2 J4

5-4

W06

DCSPD

15-J6

W06

15-J7

W06

8-QFD

W80

door

W80 W80

W80

W01

2-N-1

31-H5

W07

5-4

W07

W06

socket

Top view

Note: Connet X4-1 and the cable of the temperature sensor.

To the negative busbar of the module

Pull out the controller

Figure 9 NetSure 731 A41-S1 wiring diagram

Page 42

Appendix 3 Wiring Diagram 34

NetSure 731 A41 Subrack Power System User Manual

MFU

W2453X1

1+ 1-

2+ 2-

LCU+ controller busbar s ocket

W80

1 2

12345678910111213141516171819202122232425262728293031323334353637383940414243444546474849

13-J8-1

31-J42-CAN-

M221S

18-J1-1

11-2

11-1

31-J42-CAN+

13-J7-1

13-J7-2

13-J8-2

13-J8-3

13-J8-5

13-J8-4

13-J8-6

13-J8-7

13-J8-8

8-QFB2-1

8-QFB1-1

10-2

10-1

W80

W84

W80

9-BUS+-2

X6-1

X5-1

8-PL-1

W80

9-BUS+-1

W80

8-PL-1

M34C3C1

18-J1-2

W80

3+ 3-

4+ 4-

DO3

DO4

DO1

DO2

2 3

5-2

W07

121

7-30

QFB1

QFB2

7-28

7-20

7-22

18-J2-1

18-J2-2

W80

7-45

7-43

NPL

8-B-

121

QFD1

QFD2

1 2

QFD3

1 2

QFD8

NPL

1 2

QFD9

QFD12

BUS+

KM1

KM2

9-2

7-29

W84

W80

W84

W80

7-35/7-49/7-50

9-BUS+-2

12-1

W84

W80

9-BUS+-1

X5-1

W80

8-QFD

Front view

15-J7

W80

W06

7-31/7-46

18-J2-3

W84

W80

Front top view (open the panel)

7-39

7-41

12-1

12-2

8-PL-1

W84

8-PL

QFA

SPD1

QFA2

N-1

N L

2-L

3 4

W01W01

COM

W80

7-42

7-40

W01

2-N-2

31-J1-L/31-J2-L/31-J3-L/31 -J4-L/3-2

2-N-2

W01

N-2

31-J1-N/31-J2-N/32-J3-N /32-J4-N

3-4/1-4

8-PL-2

W06

M2433X2

J1 J2 J4

5-4

W06

DCSPD

15-J6

W06

31-H5

W07

2-NC

2-COM

DC-

L N

N L N

L N

J13

J11

H3 H4

DC+

U1 U2

DC+DC-

J12 U3

DC+

DC-

J14

U11

U12

U13

U14

DC-

DC+

1-2

2-N-1

1-2

J41

CAN+CAN-

J42

CAN+ CAN-

W01

1-2

W80

W2493ZX1

W80

7-4

7-2

W01

2-N-1

5-4

W07

Front view

MFU DC wiring diagram

Rear top view

To SPD PE bar

To the positive busbar of the module

To the negative busbar of the module

Note: Connet X5-1 to the X6-1 and the cable of the temperature sensor.

User interface board 1

Single-phase AC input with the SPD

Subrack

Front top view of the back plat (with the controller and rectifier)

Figure 10 NetSure 731 A41-S2 wiring diagram

Page 43

Appendix 4 Schematic Diagram 35

NetSure 731 A41 Subrack Power System User Manual

Appendix 4 Schematic Diagram

Battery 1

Battery 2

QFB2

RS1

QFD12

Class C SPD

KMD1

LLVD Contactor

NPL

KMD2

Main input

QFA1

AC Distribtion Unit

BLVD Contactor

SPD1

COM

DC-

L N

L N L N

J4J3

J13

J11

H3 H4

DC+ U1 U2 DC+

DC-J12

DC+

DCJ14

U11

U12

U13 U14

DC-

DC+

J41

CAN+

CAN-

J42

CAN+

CAN-

CANCAN+

Controller M225S

Positive Busbar

QFB1

QFD9

QFD8

QFD3

QFD2

QFD1

DC+

DC-

TEMP

1 2 3 4 5 6 7 8

9 10 11

12 13 14 15

1 2 3 4 5 6 7 8

9 10 11 12

W34C3C1

1 2 3

X4-1

PD1

PD2

PD3

ST1

OC1+ OC1OC2+ OC2-

BAT1_SH+ BAT1_SHBAT_FUSE1 BAT_FUSE2 LOAD_FUSE

GND CREALY3 CREALY4 +5V

POWERPOWER-

POWER+ BLVD_CTRL-

BLVD_CTRL+ DI_SPD+ DI_SPDDI_DOOR+ DI_DOORD02M DO2

M3_AVREF

V_TEMP

M225S1X1

1 8

DO3 DO4

DO5

DO6

J3 J2

QFA2

J7J5

J1 J2 J4

DCSPD

Optional

AC output

Terminal

1D1

1D2

1D3

1D8

1D9

1D12

DC Distribtion Unit

Figure 11 Schematic diagram of NetSure 731 A41-S1

Page 44

Appendix 4 Schematic Diagram 36

NetSure 731 A41 Subrack Power System User Manual

QFB2

RS1

QFD12

KMD1

NPL

KMD2

QFA1

QFA2

SPD1

COM

Terminal

DC-

L N

J13

J11

DC+ U1

U2 DC+

DC-J12

DC+

DCJ14

U11

U12

U13

U14

DC-

DC+

J41

CAN+

CAN-

J42

CAN+

CAN-

12345678910111213141516171819202122232425262728293031323334353637383940414243444546474849

CAN-

CAN+

X5-1

J1 J2 J4

DCSPD

QFB1

X6-1

W2453X1

1+ 1-

4+ 4-

DO3

DO4

DO1

DO2

QFD9

QFD8

QFD3

QFD2

QFD1

DC+

DC-

W34C3C1

PD2

1D1

1D2

1D3

1D8

1D9

1D12

AC output

Class C SPD

Main input

AC Distribtion Unit

DC Distribtion Unit

LLVD Contactor

BLVD Contactor

Battery 1

Battery 2

Positive Busbar

Controller M221S

Figure 12 Schematic diagram of NetSure 731 A41-S2