Vertiv Tech NetSure 731 C62 Series, NetSure 731 C62-X2, NetSure 731 C62-X1, NetSure 731 CC2-X4, NetSure 731 C62-X3 User Manual

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NetSure 731 CC2、NetSure 731 C62 系列电源系统用户手册

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

资料版本 V2.0 归档时间 2017-12-31

BOM 编码 31013521

Version V2.0 Revision date December 31, 2017 BOM 31013521

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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Declaration

This is a Class A UPS product. In a residential environment, this product may nevertheless cause radio interference, in which case, the user is required to take additional measures to reduce the interference.

Safety Precautions

To reduce the chance of accident, please read the safety precautions very carefully before operation. The 'Caution, Note, Warning, Danger' in this book and on the product 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 receive strict training and master the correct operations and all the safety points before operation.

When operating Vertiv products, the operation personnel must observe the safety rules in the industry, the general safety points and special safety instructions provided by Vertiv.

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.

Observe safety rules in the industry 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 and rings.

When you spot the cabinet with water or moisture, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power system.

’Prohibit’ warning label m ust be attached to the switches and buttons that are not permi tted to operate during installation.

Danger

High voltage operation may cause fire and electric shock. The connection and w iring 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, specialized tools must 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.

IV. ESD

Note

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 w rist strap must be worn to prevent body static from damaging the sensitive components. The other end of the ESD w rist strap must be w ell earthed.

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V. Short circuit

Danger

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

Check 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. Use insulated tools. In live operation, keep the arm, wrist and hand tense, so that when the tool in operation slips, the movement of

the human body and tool is reduced to a minimum.

Battery

Danger

Before any operation on battery, read carefully the safety precautions for battery transportation and the correct battery connection method.

Note

If the power system does not connect with mains power for a long time, to prevent battery over-discharge, users should cut batteries off from the pow er system thoroughly, for example, pulling out battery fuses or switching off battery MCBs. Before putting the power system into operation, insert all the battery fuses or switch on all the battery MCBs.

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:

1. Remove the watch, bracelet, bangle, ring, and other metal objects on the wrist.

2. Use specialized insulated tools.

3. Use eye protection device, and take preventive measures.

4. Wear rubber gloves and apron to guard against electrolyte overflow.

5. In battery transportation, the electrode of the battery should always be kept facing upward. Never put the battery upside down or slanted.

LLVD And BLVD

The power system has battery low voltage disconnection (BLVD) function and load low voltage disconnection (LLVD) function. LLVD means that the mains fail and batteries supply power, the controller cuts the non-priority load off when the battery voltage drops down to below 44V. In this way, the battery remaining capacity can sustain the priority load longer. BLVD means that the controller cuts the load off when the battery voltage drops down to 43.2V to prevent over-discharge.

The factory setting is enabling LLVD and BLVD, which means that if power outage lasts for a long time or the power system fails, there might be LLVD and BLVD. Users should classify the loads and connect the nonpriority loads to LLVD routes, and connect the priority loads to BLVD routes. For vital loads, users can disable BLVD of these loads to insure reliability of the power supply.

The method of disabling BLVD is:

1. Hardware disabling: unplug the signal cable in J10 interface of the controller. Tag the BLVD-disabled label. The position of the controller and the interface description are given in 2.4.2 Connecting Signal Cables.

2. Software disabling: set ‘BLVD Enable’ item of the controller to ‘N’.

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Note

The advantage of enabling BLVD is protecting the batteries from over-discharge when the battery voltage is low. The disadvantage of enabling BLVD is that when the battery voltage drops down to a certain value, all the loads (including non-priority loads and priority loads) will be cut off due to battery disconnection. The advantage of software disabling BLVD is prolonging the power supply of priority loads. The disadvantage is that software disabling cannot prevent unwanted power failure due to misoperation or power system failure. The advantage of hardware disabling BLVD is preventing unwanted power failure due to misoperation or power system failure, and ensuring the continuity of vital loads’ power supply.

Others

I. Sharp object

Warning

When moving equipment by hand, wear protective gloves to avoid injury by sharp object.

II. Power cable

Note

Please verify the cable labels before connection.

III. Signal cables

Note

The signal cables should be routed at least 150mm aw ay from power cables.

Note

To preserve the environment, the busbar of the power system may use tinning technique or passivation technique. The busbar may become dark due to long-term operation, w hich does not influence the performance or use of the power system.

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Contents

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

1.1 Model Description ...................................................................................................................................................................1

1.2 Composition And Configuration ............................................................................................................................................1

1.3 Features....................................................................................................................................................................................6

1.4 Operating Principle .................................................................................................................................................................6

1.5 Functions ..................................................................................................................................................................................6

1.5.1 Lightning And Surge Protection ...............................................................................................................................6

1.5.2 LLVD And BLVD .........................................................................................................................................................8

1.5.3 Fault Alarm And Protection .......................................................................................................................................8

1.5.4 AC And DC Distribution .............................................................................................................................................8

1.5.5 Earthing Design ..........................................................................................................................................................9

Chapter 2 Installation Instruction ....................................................................................................................................................... 10

2.1 Safety Regulations............................................................................................................................................................... 10

2.2 Preparation............................................................................................................................................................................ 10

2.3 Mechanical Installation ........................................................................................................................................................ 11

2.3.1 Installing Power Cabinet......................................................................................................................................... 11

2.3.2 Installing Rectifiers .................................................................................................................................................. 12

2.4 Electrical Installation ............................................................................................................................................................ 12

2.4.1 Connecting Power Cables ..................................................................................................................................... 12

2.4.2 Connecting Signal Cables...................................................................................................................................... 14

2.4.3 Bottom Cabling Cabinet ......................................................................................................................................... 17

Chapter 3 Testing................................................................................................................................................................................. 19

3.1 Installation Check And Startup .......................................................................................................................................... 19

3.2 Basic Settings ....................................................................................................................................................................... 20

3.3 Alarm Check And System Operation Status Check ....................................................................................................... 20

3.4 Final Steps ............................................................................................................................................................................ 21

Chapter 4 Use Of The Controller....................................................................................................................................................... 22

4.1 Operation Panel ................................................................................................................................................................... 22

4.2 Main LCD Screens............................................................................................................................................................... 22

4.2.1 System Information Screen ................................................................................................................................... 22

4.2.2 Password Confirmation Screen............................................................................................................................. 23

4.2.3 MAINMENU Screen ................................................................................................................................................ 23

4.2.4 STATUS Screen ...................................................................................................................................................... 24

4.2.5 Settings Screen ....................................................................................................................................................... 24

4.2.6 Maintenance Screen ............................................................................................................................................... 24

4.2.7 Energy Saving Screen ............................................................................................................................................ 25

4.2.8 Fast Settings Screen............................................................................................................................................... 25

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4.3 Querying System Main Information................................................................................................................................... 25

4.4 Querying Rectifier Status .................................................................................................................................................... 27

4.5 Querying Alarm Information ............................................................................................................................................... 27

4.5.1 Querying Active Alarm ............................................................................................................................................ 27

4.5.2 Querying History Alarm .......................................................................................................................................... 29

4.6 Maintenance ......................................................................................................................................................................... 29

4.7 Setting Parameters .............................................................................................................................................................. 30

4.7.1 Alarm Settings.......................................................................................................................................................... 30

4.7.2 Battery Settings ....................................................................................................................................................... 32

4.7.3 AC Settings............................................................................................................................................................... 37

4.7.4 DC Settings .............................................................................................................................................................. 37

4.7.5 Rectifier Settings ..................................................................................................................................................... 38

4.7.6 System Settings....................................................................................................................................................... 39

4.7.7 Communication Settings ........................................................................................................................................ 39

4.8 Energy Saving Settings....................................................................................................................................................... 40

4.9 Fast Settings ......................................................................................................................................................................... 41

Chapter 5 Technical Parameters of Rectifier .................................................................................................................................. 42

5.1 Appearance and Structure.................................................................................................................................................. 42

5.2 Functions And Features ...................................................................................................................................................... 43

5.3 Technical Parameters ......................................................................................................................................................... 46

Chapter 6 Troubleshooting ................................................................................................................................................................. 48

6.1 Handling Alarms ................................................................................................................................................................... 48

6.2 Handling Rectifier Fault....................................................................................................................................................... 49

6.3 Handling Controller Fault .................................................................................................................................................... 51

Appendix 1 Technical Data................................................................................................................................................................. 54

Appendix 2 Engineering Diagram...................................................................................................................................................... 57

Appendix 3 Parameter Setting Of The Controller ........................................................................................................................... 61

Appendix 4 Menu Structure Of The Controller ................................................................................................................................ 65

Appendix 5 Schematic Diagram ........................................................................................................................................................ 67

Appendix 6 Wiring Diagram................................................................................................................................................................ 69

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Chapter 1 Overview 1

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Chapter 1 Overview

This chapter introduces the model description, composition and configuration, features, operating principle and functions of the NetSure 731 CC2 and NetSure 731 C62 series power system (power system for short).

1.1 Model Description

Taking NetSure 731 CC2 power system as an example, the model description is given in Figure1-1.

Power system brand

Rectifier specification: G3 50A

Region: China

Max number of the rectifier: 12

Cabinet configuration type

System version: 2

NetSure

731

Figure 1-1 Model description

1.2 Composition And Configuration

Composition

The NetSure 731 CC2 power system has four models: NetSure 731 CC2-X1, NetSure 731 CC2-X2, NetSure 731 CC2-X3 and NetSure 731 CC2-X4. Figure 1-2 to Figure 1-5 illustrate the structure of the four models. NetSure 731 C62 has three models: NetSure 731 C62-X1, NetSure 731 C62-X2 and NetSure 731 C62-X3, the structure of this model are shown in Figure 1-6 and Figure1-8.

Battery fuse

Priority load MCB Non- priority load fuse

DC output positive busbar

Rectifier

AC input MCB

controller

Non- priority load MCB

Rectifier MCB

Non- priority load fuse

AC output MCB

Figure 1-2 NetSure 731 CC2-X1 power system structure

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NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Priority load MCB Non- priority load fuse

Battery fuse

controller

Non- priority load MCB

Rectifier MCB

DC output positive busbar

Rectifier

AC input MCB

Non- priority load fuse

AC output MCB

Figure 1-3 NetSure 731 CC2-X2 power system structure

Battery fuse

Controller

Priority load MCB

Non-priority load fuse

Non-priority load MCB

Rectifier

Rectifier MCB

AC output MCB

AC input MCB

DC output positive busbar Non-priority load MCB

Figure 1-4 NetSure 731 CC2-X3 power system structure

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Chapter 1 Overview 3

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Battery fuse

Controller

Priority load MCB

Non-priority load fuse

DC output positive busbar

Non-priority load MCB

Rectifier

Non-priority load MCB Rectifier MCB

AC output MCB

AC input MCB

Figure 1-5 NetSure 731 CC2-X4 power system structure

Priority load MCB Non- priority load fuse

Battery fuse

DC output positive busbar

Controller

Non- priority load MCB

Rectifier MCB

Rectifier

AC input MCB

AC output MCB

Figure 1-6 NetSure 731 C62-X1 power system structure

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NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Battery fuse

Priority load MCB Non- priority load fuse

DC output positive busbar

Controller

Non- priority load MCB

Rectifier MCB

AC input MCB Rectifier

AC output MCB

Figure 1-7 NetSure 731 C62-X2 power system structure

Priority load MCB

Battery fuse

controller

Non- priority load MCB

DC output positive busbar

AC input MCB

Non- priority load fuse

AC output MCB

Module MCB

Rectifier MCB

Figure 1-8 NetSure 731 C62-X3 power system structure

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Chapter 1 Overview 5

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Configuration

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

Table 1-1 Power system configuration

Component

Configuration

NetSure 731 C62

NetSure 731 CC2

Rectifier

Model: R48-3000e3 Standard: 6 pcs Optional: 2 ~ 6 pcs

Model: R48-3000e3 Standard: 12 pcs Optional: 2 ~ 12 pcs

Controller

Model: M522S; Standard: 1 pcs

AC distribution AC input:

NetSure 731 C62-X1, X2, X3: 1 × 63A/3P MCB

AC input: NetSure 731 CC2-X1, X3, X4: 1 × 100A/3P MCB NetSure 731 CC2-X2: 2 × 100A/3P MCB

AC output: NetSure 731 C62-X1, X2: 1 × 16A/1P MCB NetSure 731 C62-X3: 1 × 16A/1P MCB, 1 × 16A/3P MCB

AC output: NetSure 731 CC2- X1, X2: 1 × 16A/1P MCB NetSure 731 CC2- X3, X4: 1 × 16A/3P MCB, 1 × 16A/1P MCB

DC ditribution

Priority load output: NetSure 731 C62-X1: 2 × 32A/1P MCB, 2 × 10A/1P MCB NetSure 731 C62-X2: 2 × 32A/1P MCB, 2 × 10A/1P MCB NetSure 731 C62-X3: 2 × 32A/1P MCB, 2 × 16A/1P MCB

Priority load output: NetSure 731 CC2-X1/X2: 2 × 32A/1P MCB, 4 × 10A/1P MCB NetSure 731 CC2-X3: 4 × 16A/1P MCB NetSure 731 CC2-X4: 2 × 63A/1P MCB, 2 × 32A/1P MCB, 2 × 10A/1P MCB

Non-priority load output: NetSure 731 C62-X1: 4 × 100A fuse, 4 × 63A/1P fuse, 4 × 32A/1P MCB, 2 × 10A/1P MCB NetSure 731 C62-X2: 4 × 100A fuse, 4 × 63A fuse, 4 × 32A/1P MCB, 2 × 10A/1P MCB NetSure 731 C62-X3: 4 × 100A fuse, 4 × 63A/1P MCB, 6 × 32A/1P MCB

Non-priority load output: NetSure 731 CC2-X1/X2: 6 × 100A fuse, 6 × 63A fuse, 6 × 32A/1P MCB, 4 × 16A/1P MCB NetSure 731 CC2-X3: 4 × 100A fuse, 4 × 63A/1P MCB, 6 × 32A/1P MCB NetSure 731 CC2-X4: 4 × 100A fuse, 6 × 63A fuse, 2 × 32A/1P MCB, 2 × 16A/1P MCB

Battery branch circuit: NetSure 731 C62-X1: 2 × 250A fuse NetSure 731 C62-X2: 2 × 250A fuse NetSure 731 C62-X3: 2 × 250A fuse

Battery branch circuit: 2 × 500A fuse

Optional parts

Top cover, temperature sensor and modem, front and back cover plate (NetSure 731 C62-X2), Battery cable (NetSure 731 C62-X2)

(2) NetSure 731 C62-X2 power system is configured with two layers of battery rack, the battery compartment space is shown in Figure 1-9.

Figure 1-9 Battery compartment structure

330mm

570mm

535mm

Tw o layers

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6 Chapter 1 Overview

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

1.3 Features

 The rectifier uses the active Power Factor Compensation (PFC) technology, raising the power factor to 0.99  The power supply system has wide AC input voltage range: 90Vac ~ 300Vac  The rectifier uses soft switching technology, raising the efficiency up to 95%  The rectifier is of High power density  The rectifier is hot pluggable. It takes less than 1min 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 power system has perfect battery management function. The management functions include BLVD, LLVD,

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

 The power system can save up to 200 pieces of historical alarm records, and 10 sets of battery test data records  The power system is of network design. Providing multiple communication ports (such as RS232, modem and

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

 The power supply system has perfect lightning protection at both AC side and DC side  The power supply system has complete fault protection and fault alarm functions

1.4 Operating Principle

The AC mains comes out from the AC distribution unit and is distributed to each rectifier. After rectification, the -48V DC current from each rectifier flows to the DC distribution unit through busbar, and then multiple outputs of the DC distribution unit provide power for communication equipment. Normally, the system operates in parallel float charge state, that is, the rectifiers, load and batteries work in parallel; besides powering the communication equipment, the rectifiers provide float charge for the batteries. In case of mains failure, the rectifiers will stop working, and the batteries begin to supply power to communication equipment. When the AC mains recovers, the rectifiers will resume supplying power to communication equipment and charging the batteries.

Using centralized monitoring mode, the controller module manages the AC distribution unit and DC distribution unit. It also receives the operating data of the rectifiers and controls them accordingly through CAN mode. The controller can be connected to a local computer using the RS232 port. The power system can be connected to the monitoring center through connecting a modem or other transmission resources (such as PSTN and so on) to achieve remote monitoring.

For the detailed schematic diagram of the power system, see Appendix 5 Schematic Diagram.

1.5 Functions

Main functions of the power system include: Lightning and surge protection. LLVD and BLVD. Fault alarm and protection. AC and DC distribution. Perfect earthing design.

1.5.1 Lightning And Surge Protection

The power system is equipped with lightning protection at both the AC side and the DC side. The lightning protection system is shown in Figure 1-10.

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Chapter 1 Overview 7

NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

交流输入

整流模块

交流配电单元

直流配电单元

监控模块

电池组

1、2

I/B

防雷器

Modem

RJ11

防雷器

－48V输出

RS232

RJ11

5m～10m

PSTN

远程后台监控

注：I，II，III级是IEC标准的分类方法

B，C，D级是德国VDE标准的分类方法

II/C

防雷器

AC input

5m ~ 10m

I/B SPD

II/C SPD

distribution

unit

Rectifier

Controller

RS232

Modem

RJ11

SPD

distributi

on unit

SPD

Battery string 1, 2

PSTN

Remote host

- 48V output

Note:Classes I,II,III are IEC atandard, classes B, C, D are VDE Geman standards.

Figure 1-10 Lightning protection system

The power system is equipped with a Class II/C SPD. Meanwhile, each module of the system has perfect lightning protection circuit. The system can withstand simulated lightning surge currents of 20kA at 8/20μs five times, and 40kA at 8/20μs once. To prevent higher lightning strikes from damaging the equipment, it is recommended to install a higher protective Class I/B SPD in the cable inlet of the equipment room (lightning surge current is at least 60kA, refer to YD/T5098-2001 Signal station lightning overvoltage protection engineering design standard).

To prevent lightning strikes at the DC side from damaging the equipment, an effective lightning protection device is provided, which can withstand simulated lightning surge currents of 10kA and 15kA at 8/20μs once respectively. To prevent conductive lightning strike from damaging the modem port of the controller, the power system provides lightning protection (optional) for the modem port. The SPD can withstand a 5kA lightning surge current at 8/20s and a 4kV lightning surge voltage at 10/700s.

The power system has perfect lighting protection at both AC side and DC side. The power system is equipped with a Class II/C SPD at AC side and SPD at DC side. To achieve better lightning protection at AC side, it is recommended to mount a Class I/B SPD, lightning surge current is at least 60kA. The Class I/B SPD should be purchased by the user. Refer to YD/T5098-2001 Signal station lightning overvoltage protection engineering design standard for the detailed technical rules. The Class I/B SPD installation is shown in Figure 1-11.

48Vdc

A B

C N

5m ~ 10m

Class-B

SPD

DC earth

Protective earth cable

User earth bar

System earth bar

Protective earth

Power supply

system

SPD earth

DC earth cable

240Vdc

Class-C

SPD

240Vdc

First

Class-B

SPD

Power system

-48Vdc

lever 1 SPD

(Class B)

Lever

Class

Lever 1

(Class B)

SPD

Lever 2

(Class C)

SPD

Level 1

Level 2

Figure 1-11 Diagram of Class I/B SPD mounting & system earthing

The Class I/B SPD should be purchased and mounted by the user. If condition permits, it is recommended that the cable length between the Class I/B SPD and the power system meet the following rules: if a voltage limiting type SPD

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NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

is used, then the cable length should be longer or equal than 5m; if a switching type SPD is used, then the cable length should be longer or equal than 10m. The cable between the Class I/B SPD and the input terminals of the AC distribution unit of the power system should be routed indoors to avoid direct lightning strike. The output cable CSA of the Class I/B SPD and the grounding cable CSA should not be less than 16mm2. For the cable length, the shorter the better.

The power system has lighting protection at DC side, which can meet YD/T5098 requirements. There’s no need to design lighting protection at DC side.

1.5.2 LLVD And BLVD

In case of mains failure, the rectifiers will stop working and the batteries will begin to discharge and power the load. When the battery voltage falls to the low voltage alarm point 45.0V (adjustable), the system will give audible/visual alarm. When the battery voltage continues to fall and reaches the LLVD point 44.0V (adjustable), the LLVD contactor will open, cutting off the power supply for the non-priority loads connected to the LLVD output branches thus the power supply to priority load can be prolonged. As the batteries discharge, the battery voltage continues to fall. When it reaches the BLVD point 43.2V (adjustable), the BLVD contactor will open, and the battery discharge will come to an end. Thus the power supply to all loads is stopped, protecting the battery from being damaged due to over-discharge. When the mains recovers and the rectifier output resumes normal functioning, the LLVD and BLVD contactors will automatically close, and the system will resume normal operation.

1.5.3 Fault Alarm And Protection

The power system provides perfect fault alarm and protection functions. The system operating data can be collected and the states of the load MCBs, load fuses, battery fuses and Level 2 (class C) SPD can be detected by the controller. The alarm level can be set and audible/visual alarms can be selected for the system alarms, such as AC input over/under voltage, DC output over/under voltage, fuse alarm, float charge and equalized charge status, rectifier fault and protection alarm. The alarm type can be configured to correspond to dry contact relay output.

1.5.4 AC And DC Distribution

The functions of AC distribution are as follows:

The AC input uses 3-pole MCB, and has short circuit and over-current protection. The AC input has overvoltage and undervoltage protection.

See Table 1-2 for the functions of the AC input and output interfaces of the power system.

Table 1-2 Functions of AC input and output interfaces

Interface

Functions

AC input MCB

To AC power supply; switchable

AC output MCB

Provides phase line terminal of AC; used to power other AC equipment

AC input neutral line busbar

To the neutral line of the 3-phase AC input

Earth terminal

The junctions of the protection earth, SPD earth, operation earth of the power system; need connect to the earth bar of the equipment room

The functions of DC distribution are as follows:

Output load branch has short circuit and over-current protections, and branch capacity can be adjusted

according to user requirements.

Battery input uses fuse which has functions like short circuit, over-current protection, alarm and fault status

detection.

Battery current detection. DC output overvoltage, undervoltage alarm functions.

See Table 1-3 for the functions of the DC input and output interfaces of the power system.

Table 1-3 Functions of DC input and output interface functions

Interface

Functions

Battery 1 fuse

To negative terminal of the battery string 1

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NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Interface

Functions

Battery 2 fuse

To negative terminal of the battery string 2

DC output positive busbar

To positive terminal of battery string 1 and 2, and load output positive terminal

Priority load MCB

Negative terminal of 48V supply for priority load. Cut off the priority load output when the battery voltage drops to the BLVD point

1.5.5 Earthing Design

Protective earth, SPD earth, and DC operation earth of the power system have been connected to the earth bar before it is delivered. During the installation, user should connect the grounding terminal to the user earth bar of the equipment room, as shown in Figure 1-11.

The protective earth cable of 3-phase 5-line system can be directly connected to the earth bar of the equipment room. The earth resistance should be in accordance with the specifications listed in Table 1-4.

Table 1-4 Earth resistance requirements for communication station

Earth

resistance

Application range

Basis

< 1Ω

Integrated building, international telecom bureau, tandem station, SPC sw itching office above 10000 lines, toll office above 2000 lines

YDJ20-88 Provisional technical regulations of computerized telephone sw itching equipment installation and design

< 3Ω

SPC switching office above 2000 lines and below 10000 lines, toll office below 2000 routes

< 5Ω

SPC switching office with less than 2000 lines, optical cable terminal station, carrier w ave repeating station, earth station, microwave junction center, mobile communication machine station

< 10Ω

Microwave relay station, optical cable relay station, small-sized earth station

YD2011-93 Microwave station lightning protection and grounding design specifications

< 20Ω

Microwave passive relay station

< 10Ω

Suitable for those w hose earth resistance rate is less than 100Ω·m, SPD earth in the interface between electric cable and aerial electric line

GBJ64-83 Industrial and civil electrical device overvoltage protection design specification

< 15Ω

Suitable for those whose earth resistance rate is 100-500Ω·m, SPD earth in the interface between electric cable and aerial electric line

< 20Ω

Suitable for those whose earth resistance rate is 501-1000Ω·m, SPD earth in the interface between electric cable and aerial electric line

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Chapter 2 Installation Instruction

This chapter introduces installation and cable connection. Before installation, please read through the safety regulations, and then follow the instructions in this chapter to carry out the installation and connection.

2.1 Safety Regulations

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

1. Only adequately trained personnel with satisfactory knowledge of the power supply system can carry out the installation. The Safety Precautions listed before the Contents of this manual 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 defined in IEC 60950.

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

4. The power system 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.

 Note

1. When delivered with the cabinet, the rectifier should be placed at the bottom of the cabinet subrack.

2. If the system need to configure fuse extractor, it should be strapped at the he bottom of the cabinet subrack.

Cable Preparation

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. Select the AC cable CSA according to Table 2-1.

Table 2-1 AC cable CSA selection

Connector

Specifications

AC cable CSA

AC input MCB

1 × 63A/3P MCB, 3 H-shape tubal terminals

≤ 35mm2

AC input neutral busbar

1 M8 tubal OT terminal

≤ 25mm2

AC output MCB

1 × 16A/1P MCB, one H-shape tubal terminal (CC2-X1/X2, C62-X1/X2)

≤ 10mm2

1 × 16A/3P MCB and 1 × 16A/1P MCB, 4 H-shape tubal terminals (CC2-X3/X4, C62-X3)

AC output neutral busbar

2 M6 screws

Note: With cable length shorter than 30m, the CSA calculation should be based on the current density of 2.5A/mm2. The suggested CSA value is not smaller than 15mm2

The CSA of DC cable depends on the current flowing through the cable, the allowable voltage drop and load peak current. The recommended load peak current is 1/2 to 2/3 as large as the MCB or fuse capacity.

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Select the battery cable CSA according to Table 2-2. Select the load cable CSA according to Table 2-3.

Table 2-2 Battery cable CSA selection

Battery fuse

rated current

Max. battery

current

Min. CSA

Max. cable

length (voltage

drop: 0.5V)

Max. cable

CSA

Max. cable length (volt

drop: 0.5V, with max.

CSA)

500A

400A

95mm2 (two) or 185mm2

14m

240mm2

20m

300A

200A

70mm2

120mm2

15m

250A

160A

70mm2

10m

120mm2

15m

Note:

1. The specs are applicable at ambient temperature of 25°C. If the temperature is too high, the CSA should be increased.

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

Table 2-3 Load cable CSA selection

Load route

rated current

Max. output

current

Min. CSA

Max. cable length (volt

drop: 0.5V, with min.

CSA)

Max. CSA

Max. cable length (volt

drop: 0.5V, with max.

CSA)

160A

120A

50mm2

95mm2

17m

100A

50A

25mm2

14m

50mm2

25m

63A

32A

16mm2

25mm2

11m

32A

16A

16mm2

14m

25mm2

22m

10A

6mm2

17m

25mm2

71m

Note: The specs are applicable at ambient temperature of 25°C. If the temperature is too high, the CSA should be increased

The CSA of the system grounding cable should be the same as that of the largest power distribution cable and not less than 35mm2. The grounding terminal of the grounding busbar is M10 screw.

2.3 Mechanical Installation

2.3.1 Installing Power Cabinet

The power cabinet must be installed directly onto the cement floor, and kept far away from combustible materials.

1. Mark the specific installation position of the cabinet Determine the installation position of the power cabinet in the equipment room according to Figure 2-1. (the depth of

NetSure 731 C62-X2 cabinet is 600mm)

Figure 2-1 Locating power cabinet

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2. Install expansion pipe According to Figure 2-2, determine the exact central points of the installation holes on the floor, and mark them with a

pencil or oil pen. Use the electric drill (aiguille: Φ14) to drill holes (depth: 70mm) at the marked points. Clean the drilled hole of dust. Put the expansion pipe into the hole and knock it with a hammer till it is totally in.

436

400 300

600

NetSure 731 CC2 & NetSure 731 C62-X1/X3 NetSure 731 C62-X2

Figure 2-2 Installation size of the cabinet base (unit: mm)

3. Fix the cabinet Move the cabinet to the installation position. Align the installation holes on the cabinet with the expansion pipes in the

floor. Secure the cabinet with bolts.

2.3.2 Installing Rectifiers

 Note

1. In the non-full-configuration, install dummy plates at empty slots.

2. When installing the rectifier, hold the handle and push the rectifier into the slot gently, otherwise the slot may be damaged.

The procedures for installing rectifiers are as follows:

1. After loosing the fixing screw of the handle on the front panel of the rectifier, press the handle (see Figure 2-3) to pop it up.

Handle

Fixing screw

Figure 2-3 Handle of the rectifier

2. Put the rectifiers in the slot. Push the rectifier completely into the cabinet. Close the handle and tighten the fixing screw to lock the rectifiers onto the cabinet.

2.4 Electrical Installation

2.4.1 Connecting Power Cables

Danger

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

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

The power systems uses top cabling, and all the cables should be introduced in or led out along the cable binding

beam in the side wall of the cabinet.

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Connecting grounding cable

Connect one end of the grounding cable to the user earth bar of the equipment room, and the other end to the grounding terminal of the power system. Put the cable through the fixing holes at the top of the cabinet. Use the cable ties to fix the modem on the top of the cabinet, as shown in Figure 2-8. Taking NetSure 731 CC2-X3/X4 and NetSure 731 C62-X1 power system as an example, the grounding terminal is shown in Figure 2-4. The grounding terminal and neutral busbar of the NetSure 731 CC2-X1、X2 power system are located under the rectifier subrack. The grounding

terminal position of NetSure 731 C62- X2 and NetSure 731 C62-X1/X3 is same as that of the neutral line busbar.

接地端子

零线母排

Neutral line busbar

Earth terminal

Figure 2-4 Connection terminals (rear view, rear plate removed)

Connecting AC cables

1. Connect the AC input phase cables to the AC input MCBs, as shown in Figure 2-5. The figure shows the two routes of mains input MCB configuration. NetSure 731 CC2-X3, X4 and NetSure 731

C62-X1, X2, X3 power system only configure one route of mains input MCB, the AC input MCB is shown in Figure 2-5. The AC input MCB, AC output MCB and rectifier MCB of the NetSure 731 CC2-X1, X2 power system are located in the distribution room below the rectifier subrack.

非重要负载熔断器

重要负载空开

直流输出正母排

电池熔断器

交流输出空开

交流输入空开

非重要负载空开

Priority load MCB

Non-priority load fuse

DC output positive busbar

Non-priority load MCB

AC input MCB

AC output MCB

Battery fuse

Figure 2-5 Connection terminals (front view)

2. If the power system is configured with AC output MCB, connect the AC out cables to the AC output MCB, and connect the AC out neutral line to the neutral busbar, as shown in Figure 2-4 and Figure 2-5.

Connecting load cables  Note

The total capacity of the priority loads should not exceed 100A.

Connect the negative load cable to the upper terminal of the load MCB or load fuse. Connect the positive load cable to the DC positive busbar, as shown in Figure 2-5. The specifications of the positive busbar connection screw are ￠

8mm and ￠6mm. Please connect the load cable according to the priority load and non-priority load labels.

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Connecting battery cables  Note

1. The batteries may have dangerous current. Before connecting battery cables, make sure that the battery fuses at the system side and the battery MCBs at the battery side are switched off. 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 power system after installation.

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

3. When the load capacity exceeds 200A, it is recommended to connect two routes of batteries.

1. Connect one end of the negative battery cable to the upper terminal of the battery fuse. Connect one end of the positive battery cable to the DC positive busbar. The positions of the connection terminals are shown in Figure 2 -5. The specifications of the positive busbar connection screw is ￠10mm.

2. Connect OT lugs to the other end of the two battery cables. Wrap all the bare parts with insulating tape, and put them beside the battery. Do not connect the cables to the battery until the DC distribution unit is to be tested.

3. The wiring path of battery cable configured in NetSure 731 C62-X2 is shown in Figure 2-6.

Figure 2-6 Battery cable wiring path of NetSure 731 C62-X2

2.4.2 Connecting Signal Cables

All the signal cables are connected to the controller. The position of the controller is shown in Figure 1-2 and Figure 1-3.

The interfaces of the controller are shown in Figure 2-7. The functions of the interfaces are listed in Table 2-4.

Battery negative cable

Battery positive cable

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J1 J2

J4 J5

J10

J12J11

emp

RS232

M522S

Figure 2-7 Interfaces of the controller

Table 2-4 Interface functions

Interface

Definition

Connection

J1 ~ J5

Dry contact output

To signal cables

RS232 port

To modem or host

Battery temperature sensor interface

Connected before delivery

Pow er interface of the controller

Connected before delivery

J9_1 and J9_2

CAN interface

Connected before delivery

J10_1 and J10_2

LLVD normally-closed contact

The signal terminal has been connected to the PCB before delivery LLVD normally-closed contact, when this interface is connected, the LLVD contactor is controlled by the controller. Refer to 4.7.2 Battery Settings for the method of controlling LLVD contactor

J10_3 and J10_4

BLVD normally-closed contact

The signal terminal has been connected to the PCB before delivery BLVD normally-closed contact, w hen this interface is connected, the LLVD contactor is controlled by the controller. Refer to 4.7.2 Battery Settings for the method of controlling BLVD contactor

J11 and J12

Detect and alarm interface

To battery shunt sampling, battery fuse and alarm cables of output routes

Procedures for connecting signal terminal J1 ~ J5： Step 1: Unplug the signal terminal connector from the monitoring board;

Step 2: Use a slotted screwdriver, press the raised part of the terminal hardly, and push it out from the shell. Step3: Peel off the insulation outer layer (about 3mm), as shown in Figure 2-8. Then press the naked wire and

insulation out layer. Step 4: The well-compacted terminal is shown in Figure 2-8. Step 5: Plug the terminal into the terminal shell, as shown in Figure 2-8.

Press insulation out layer

Press naked wire

Figure 2-8 Connecting J1-J5 signal terminal

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Connecting temperature sensor

The temperature sensor is an optional accessory. Probe operating voltage: 12V. Measurement range: -5°C ~ +100°C. Measurement precision: ± 2°C. When installing the temperature sensor, put the temperature probe in the battery room that best represents the

battery temperature, far away from other heat-generating equipment. When the batteries are placed outside the cabinet, the temperature probe shall not be placed inside the cabinet.

Installing modem

Modem is an optional accessory, suitable for those who have purchased the modem remote monitoring system. The following expounds the modem installation and connection, taking e-TEK TD-5648DCII modem for example.

1. Fix the modem Put the cable ties through the fixing holes at the top of the cabinet. Use the cable ties to fix the modem on the top of

the cabinet, as shown in Figure 2-9.

Modem

Cable tie

Figure 2-9 Position for placing modem

2. Connect modem with the controller The input and output interfaces of the modem are shown in Figure 2-10.

RS-232

LINE

PHONE

POWER

Figure 2-10 Input & output interfaces of TD-5648DCII Modem

1) Connect a telephone line to the ‘LINE’ interface on the modem.

2) Use a power cable to connect the positive and negative power terminals (screenprint: POWER) of the modem to the DC positive busbar and negative busbar (below the battery fuse) of the power system respectively.

3) Use a communication cable to connect the communication interface of the modem (DB25 female, screenprint: RS-232) to the J6 interface (DB9 male) of the controller.

 Note

During system testing, set the parameter ‘M odem’ of the controller to ‘Y’.

Connecting dry contacts

The controller provides five pairs of dry contacts, which are J1 ~ J5 interfaces shown in Figure 2-7. Peel one end of the signal cable (optional) and insert it into the J1 ~ J5 sockets. The functions of the dry contacts are given in Table 2-5.

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Table 2-5 Dry contact functions

Interface

Function

Interface

Function

AC mains failure

LLVD

DC over/undervoltage

BLVD

Rectifier failure

Note: The above functions are default settings. Users can change them through the controller

2.4.3 Bottom Cabling Cabinet

If the cabinet must use bottom cabling method, a rear cover plate should be installed at the rear of the cabinet. User should follow the procedures below to install the cover plate. (Note: The bottom cabling method is not applicable to NetSure 731 C62-X2.)

1. Remove the original rear cover plate of the cabinet, and then install the new rear cover plate (100mm thickness) in the main frame of the cabinet. First install one screw on both of the right and left vertical pole of the new rear cover plate respectively. Then fix the upper and lower beam, and the cable binding beam in the middle of the cabinet.

Finally, install the other screws on both of the right and left vertical pole, as shown in Figure 2-11.

Beam

screw on the left and right column

Cable bindong beam

Beam

Figure 2-11 Rear cover plate installation for bottom cabling method (1)

2. Install the original rear cover plate on the outside of the new one, as shown in Figure 2-12.

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后盖板

Back cover

Figure 2-12 Rear cover plate installation for bottom cabling method (2)

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Chapter 3 Testing

This chapter introduces the testing procedures after installation. The corresponding safety rules shall be adhered to in the test.

3.1 Installation Check And Startup

Before the test, inform the chief manufacturer representative. Only trained electrical engineers shall maintain and operate the power system. In operation, the installation personnel are not allowed to wear conductive objects such as watches, and rings.

During operation, parts of this power system carry hazardous voltage. Misoperation can result in personnel injury and property loss. 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, rectifier MCBs and load MCBs are switched off. Make sure that all the devices are properly installed.

Check the power system step by step according to the following listed items.

Installation check

Check item

Comments

Check all the models of MCBs, fuses and cables are correct



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



Check whether the number and connections of the batteries are correct; check the polarity of the battery string are correct



Make sure all the connections are solid and reliable



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



Startup preparations

Check item

Comments

Make sure that all the MCBs are sw itched 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 at least one short-circuit copper bar in battery string circuit is not connected before installation, prevent short-circuit caused by positive and negative short-connect



Connect the disconnected batteries to the battery string circuit



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 2.0V ~ 2.1V/cell or 48V ~ 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 busbars, or between the positive & negative battery poles (Note: Pull out all the rectifiers before the check and restore them after the check)



Startup

Check item

Comments

Switch on the AC input MCB. Switch on one rectifier MCB. The green LED on the rectifier w ill be on and the fan w ill start running after a certain delay. The controller will show that the pow er supply voltage is 53.5V



Check the voltage and busbar polarity with a voltmeter. The voltage difference between the measured value and displayed value should be less than ±0.3V



Start and stop each rectifier of the power system by switching on and sw itching off the rectifier MCBs. Check their output voltages



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3.2 Basic Settings

When the power system is put into service for the first time, the parameters of controller must be set based on the actual system configuration, such as battery string number, capacity, user’s charge current limi t and other functional requirements. Only after that can the controller display system operation information and control the output.

Select the main menu  Settings (password: 1)  Battery Settings  Basic Settings. Set the ‘Mode’ parameter to ‘Manual’. Return to the Settings menu to set the parameters in relative submenus. Refer to 4.7 Setting Parameters.

Check item

Comments

The power supply system model has been set correctly in factory before delivery, check that the setting agrees with the actual situation. (The system models are: NetSure 731 C62: 48V/300; NetSure 731 CC2: 48V/500)



The battery string number set at the controller should be the same as the number actually connected. By default: 2



Set the battery capacity at the controller according to the actual capacity of the battery connected to the power supply system. By default: 300Ah



Configure the temperature compensation coefficient at the monitoring module according to the battery manufacturer’s requirement. Setting range: 0 ~ 500mV/°C. By default: 72mV/°C. (if no temperature sensor is installed, do not set this parameter)



Set the charge current limiting point. Setting range: 0.1C10 ~ 0.25C10. By default: 0.1C10



Set the monitoring module according to the voltage suggested by the battery supplier. Floating Charge (FC) voltage range: 42V ~ Boost Charge (BC) voltage. By default: 53.5V. BC voltage range: FC voltage ~ 58V. By default: 56.4V. For batteries that do not need BC, set the BC voltage to FC voltage plus 0.1V



Measure the battery voltage w ith a multimeter and record it. Enter Main menu  Maintenance (password: 1)  RectTrim submenu. Set the output voltage of the rectifier to the value of the battery voltage. Insert the battery fuse. Set the output voltage of the rectifier to 53.5V



Enter the Basic Parameters submenu. Set the ‘Mode’ parameter to ‘Auto’



3.3 Alarm Check And System Operation Status Check

Alarm check

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

Check item

Comments

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



Remove battery fuse 1. The ‘Batt1 Failure’ alarm should be triggered. Put on the fuse. The alarm should be cleared. Repeat the same on battery fuse 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 input fuses. Keep only one rectifier in operation. Through the controller, adjust the rectifier FC voltage to make it lower than the alarm point. The alarm ‘DC Voltage Low ’ should be triggered



Pull out the varistor of the AC SPD. The ‘SPD fault’ alarm should be triggered. Insert the varistor, the alarm should be cleared



Note: When the preceding alarms are generated, the controller will give alarms after approximately 3s. For querying the alarm information in the controller, please refer to 4.5 Quering Alarm Information

System operation status check

There’s no alarm if the system works normally. User can check whether the system runs normally through the controller. For querying the controller parameters, please refer to 4.3 Querying System Main Information and 4.4 Querying Rectifier Status.

Check item

Comments

The system models are NetSure 731 C62: 48V/300; NetSure 731 CC2: 48V/500



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 with should be less than ± 0.3V



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Check item

Comments

The controller should display 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 settings and actual values



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



For the power system configured with temperature sensor, the battery and ambient temperature displayed by the controller should be normal. Hold the probe of the temperatures sensor and the displayed temperatures should change



3.4 Final Steps

Check item

Comments

Make sure that materials irrelevant to the equipment have been all removed



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



Fill in the parameter table at the cabinet door



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 Use Of The Controller

This chapter introduces the operation panel indicators and functional keys of the controller briefly, and expounds the main screen contents, access method, system controlling, information querying and parameter setting.

When the controller is powered on, the language selection screen will appear. The default language is Chinese, and you do not need to do any operation. Then the controller will be initialized. After the initialization, the first system information screen will appear.

4.1 Operation Panel

The operation panel of the controller provides the backlit LCD, functional keys and indicators, as shown in Figure 4-1.

ESC

ENT

运行指示灯

告警指示灯

紧急告警指示灯

操作键

液晶显示屏

操作面板

监控单元前面板

Functional keys

LCD

Run indicator

Alarm indicator

Critical alarm indicator

Figure 4-1 Operation panel of the controller

Description of the indicators on the operation panel is given in Table 4-1.

Table 4-1 Description of the controller indicators

Indicator

Color

Normal state

Fault state

Fault cause

Run indicator

Green

Off

No operation power supply

Alarm indicator

Yellow

Off

There are observation alarms

Critical alarm indicator

Red

Off

There are major or critical alarms

The controller uses a 128 × 64 LCD unit, and a keypad with six functional keys. The interface language is Chinese/English optional (8 × 4 Chinese characters can be displayed). Table 4-2 shows the description of the controller functional keys.

Table 4-2 Description of the controller functional keys

Screenprint

Name

Function

ESC

Escape

Return to the upper level menu. When the audible alarm is generated, press this key to cancel it

ENT

Enter the lower level menu or confirm the menu operation. When changing or inputting parameters, press this key to get into editing state. After any change is made, press this key to validate the change

▲

Shift among parallel menus. For a character string, these two keys can be used to change values

▼

Down



Left

In value setting interface, these two keys can be used to change values. These two keys can move the cursor, only w hen one LCD screen requires character string to be input



Right

4.2 Main LCD Screens

The following LCD screens will be mentioned in this chapter for many times. This section is a centralized introduction about the contents and access methods of these LCD screens.

4.2.1 System Information Screen

When the controller is powered on, the language selection screen will appear. The default language is English, and you do not need to do any operation. Then the controller will be initialized. After the initialization, the first system information screen will appear.

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The system information screen shows the main information, which is displayed on five pages. You can press ▲ or ▼ repeatedly to select different system information screens. The first system information screen has 7-level contrast, you can press ◄ or ► to adjust the LCD contrast. The first system information screen is shown in Figure 4-2.

2009-3-23

53.5V 125A



Float

NormalAuto



Figure 4-2 First system information screen

1. The first row displays the date and time alternately.

2. At the main menu screen, press the ESC key to return to the first system information screen.

3. If no operation is conducted on the controller keypad for eight minutes, the LCD screen will return to the first system information screen. The time of that return will be recorded, and can be queried through the host.

4. At any one of the system information screen, press the ESC key to display the serial No., software version and runtime of the controller.

5. At the system information screen, pressing and holding the ESC and ENT keys simultaneously for several seconds, resets the controller, and restarts the system.

4.2.2 Password Confirmation Screen

During operation, some controllers will prompt you to enter password, as shown in Figure 4-3. Only the correct password allows you to enter the screen you need to operate.

Password:

Figure 4-3 Password confirmation screen

When inputting the password, use the ENT key to get into editing state, use ▲ or ▼ to modify numbers, and use ◄ or ► to move the cursor. After the input, press the ENT key to confirm. If the password is correct, the next screen will appear. Otherwise, the system will prompt ‘Password incorrect’. During this operation, pressing the ESC key returns to the main menu screen.

The controller has three password levels: user level password (default: 1), engineer level password (default: 2)and administrator level password (default: 640275).

Once you enter the correct password, you never need to enter the password again during the operation. If the interval between adjacent operations is more than four minutes, the system will prompt you to input the password again. Therefore, if you want to enter senior setting screens, you need to wait four minutes and cannot do any operation during waiting, and then the system will enter the senior setting screens after you input the higher level password. If the two level passwords are the same, the controller will display the senior menus after you enter the password.

4.2.3 MAINMENU Screen

The main menu is the highest-level menu of the controller. At the sub-menus of this screen, you can query the settings, controls, rectifiers and alarms information of the power system. The main menu screen is shown in Figure 4-4.

MAINMENU



Status



Settings Maintenance

Energy Saving Fast Settings





Figure 4-4 MAINMENU screen

1. At any one of the system information screen, press the ENT key to enter the MAINMENU screen.

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2. At any sub-menu of the MAINMENU screen, press the ESC key repeatedly to return to the higher-level menu, and ultimately to the MAINMENU screen.

4.2.4 STATUS Screen

The STATUS screen is a sub-menu of the main menu. It contains rectifiers, active alarm and history alarm. The STATUS screen is shown in Figure 4-5.

STATUS

Rectifiers

Active Alarm History Alarm

Figure 4-5 STATUS screen

1. At the MAINMENU screen, press ▲ or ▼ to select the ‘STATUS’ m enu, and press the ENT key to enter the STATUS screen.

2. At any sub-menu of the STATUS screen, press the ESC key repeatedly to return to the higher-level menu, and ultimately to the STATUS screen.

4.2.5 Settings Screen

Displayed in two screens, the Settings screen is a sub-menu of the main menu. It is used to set all the parameters of the power system. The Settings screen has password protection, only the correct password allows you to enter it. See Figure 4-6 for the Settings screen.

Settings



Alarm Setting



Bat. Settings AC Settings

DC Settings



Rect Settings



Sys Settings Comm Settings

Figure 4-6 Settings screen

1. At the MAINMENU screen, press ▲ or ▼ to select the ‘Settings’ menu, and press the ENT key to enter the password confirmation screen.

2. Input the correct password and press the ENT key to enter the Settings screen. Press ▲ or ▼ to enter the screen you need.

In the settings screen, each password level has different authority. See Table 4-3 for the operation authorities.

Table 4-3 Password levels and operation authorities

Passw ord level

Operation authority

Default password

User

General parameter settings

Engineer

All the user’s authorities, plus operation authorities such as resetting system, resetting password and changing system type

Administrator

All the engineer’s authorities, plus operation authorities such as modifying passwords, controlling alarm volume and browsing system parameters set by host

640275

4.2.6 Maintenance Screen

Displayed in two screens, the Maintenance screen is a sub-menu of the main menu. It is used to control the system in real time. The Maintenance screen has password protection, only the correct password allows you to enter it. For this screen, the user level password, engineer level password and administrator level password all have the same authority. The Maintenance screen is shown in Figure 4-7.

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Maintenance



Start: FC Batt: ReConnect Load: DisConn



RectTrim: 53.5V RectLimit: 121%





Figure 4-7 Maintenance screen

1. At the MAINMENU screen, press ▲ or ▼ to select the ‘Maintenance’ menu, and press the ENT key to confirm. The system will prompt you to input the password if the ‘Sys Mode’ is set to ‘Manual’ (see 4.7.2 Battery Settings for setting method).

2. Input the correct password and press the ENT key to enter the Maintenance screen. Press ▲ or ▼ to enter the screen you need.

4.2.7 Energy Saving Screen

The Energy Saving screen is a sub-menu of the main menu, as shown in Figure 4-8. It is used to set the relevant parameters for energy saving.

Save Enable: Y Cyc Period: 168h Rect Work: 80% Rect Limit: 1

Figure 4-8 Energy saving screen

1. At the MAINMENU screen, press ▲ or ▼ to select the ‘Energy Saving’ menu, and press the ENT key to display the password confirmation screen.

2. Input the correct password and press the ENT key to enter the Energy Saving screen. Press ▲ or ▼ to select the parameters you need.

4.2.8 Fast Settings Screen

The Fast Settings screen is a sub-menu of the main menu, as shown in Figure 4-9. It is used to set the system type and battery capacity.

System Type:

48V/SET Capacity: 300Ah

600Ah

Figure 4-9 Fast settings screen

1. At the MAINMENU screen, press ▲ or ▼ to select the ‘Fast Settings’ screen, and press the ENT key to display the password confirmation screen.

2. Input the correct password and press the ENT key to enter the Fast Settings screen. Press ▲ or ▼ to select the parameters you need.

4.3 Querying System Main Information

DC, system state, battery state and energy management mode information

At any one of the system information screen, press ▲ or ▼ repeatedly to enter the first system information screen. At other screens, press the ESC key repeatedly to return to the first system information screen. DC voltage and current, system state, battery state and energy management mode information are all displayed in the first system information screen, as shown in Figure 4-10.

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2009-3-23

53.5V 125A



Float

NormalAuto



Figure 4-10 First system information screen

The date and time are alternately displayed every two seconds. The system state contains Normal and Alarm. The energy management mode includes Auto and Manual. The battery state includes Float, Temp Comp, Boost, Cyclic Boost, Batt. Test, ShortTest and TimeTest.

Save state, rectifier output power and cyclic BC after information

At the first system information screen, press ▼ to enter the screen shown in Figure 4-11.

Save Stat: Y



Sys Used: 80.0%



Cyc BC After:

2400h

Figure 4-11 Save state, output power and cyclic BC after information screen

The first row displays the save state. The second row displays the percentage ratio of the rectifier output power to the rectifier rated power. The last two rows display the boost charge prompt information, they will be different for different states of the power system, including:

1. Prompt the time of the next cyclic BC according to the battery state.

2. If BC is going on or prohibited, ‘---’ will be prompted.

Battery and remain information

At the screen shown in Figure 4-11, press ▼ to view the battery information shown in Figure 4-12.

Batt1: 0A



Remain: 100%



Batt2: 0A Remain: 100%

Figure 4-12 Battery information screen

‘Batt1’ and ‘Batt2’ in the preceding screen represent respectively the current that flowed through battery shunt 1 and battery shunt 2. If several battery strings are connected to one shunt, the displayed current is their total current; if the ‘Shunt Coeff’ of one battery string is set to ‘N’, the corresponding battery information will display ‘None’, and the remaining capacity will not be displayed.

The remaining battery capacity can be displayed in percentage (default), remaining ampere hours and remaining time.

AC voltage information

At the battery information screen, press ▼ to display the AC information page. The system will display AC voltage of the A, B and C phases, as shown in Figure 4-13.

AC 1 Volt



Phase A: 0V



Phase B: 0V Phase C: 0V

AC 2 Volt



Phase A: 0V



Phase B: 0V Phase C: 0V

Figure 4-13 AC information screen

System temperature information

At the AC information screen, if a temperature sensor is configured, pressing ▼ displays the screen shown in Figure 4-14.

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Bat.Temp:



25°C



Figure 4-14 Battery temperature screen

If the temperature sensor is not connected or is faulty, the system will prompt ‘---’. Meanwhile, the alarm information screen will be displayed. If the controller bans BC and no temperature sensor is configured, this screen will not be displayed.

4.4 Querying Rectifier Status

 Note

If the controller has not detected rectifiers, you cannot query the rectifier information.

The rectifier information includes the serial No., output voltage, output current, current limit, input voltage, AC and DC states, AC power limit and temperature power limit of each rectifier.

At the STATUS screen (see Figure 4-5), press ▲ or ▼ to select the ‘Rectifiers’, and press the ENT key to enter the screen shown in Figure 4-15.

Rect 1: ID: 01060700584



Out Volt: 53.5V Out Curr: 38.5A



Curr Limit: 110%



In Volt: 220V

AC State: On

DC State: On



AC Derated: N



Temp Derated: Y



Figure 4-15 Rectifier information screen

The information of every rectifier is displayed in three screens. Press ▲ or ▼ to scroll to the three information screens. Press ◄ or ► to query other rectifiers ’ information. At most 24 pieces of rectifier information can be displayed in the controller. When selecting one rectifier, the green indicator of the rectifier will blink. If the rectifier communication is interrupted, the information will be displayed in high light.

4.5 Querying Alarm Information

You can query the active alarms and history alarms through the LCD of the controller. The query methods are given in the following sections.

4.5.1 Querying Active Alarm

When a new alarm is generated, and there is no operation on controller keypad for two minutes, the LCD of the controller will prompt an active alarm screen automatically. If there are multiple alarms in the current system, you can query alarms through the following steps.

At the STATUS screen (see Figure 4-5), press ▲ or ▼ to select the ‘Active Alarm’, and press the ENT key to enter it.

1. If there is no active alarm, the alarm prompt will not appear; if there is an active alarm, after entering the active alarm screen, the alarm will disappear and ‘Active alarm: None’ will appear.

2. If there is an active alarm, the screen shown in Figure 4-16 will appear.

Alarm 1/5

071213 14:27:50

Manual Mode Observation

Figure 4-16 Active alarm screen

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The Figure 4-16 screen includes alarm serial No./ alarm total number, alarm name, alarm level and alarm time. The alarm generating time determines the sequence it is displayed, with the latest alarm displayed first. Use ▲ or ▼ to view all active alarms.

When querying the rectifier alarms, pres s ► to display the rectifier ID, and the green indicator of the rectifier will blink. In case of battery test alarm or maintenance time alarm, press ► to display the prompt information screen, then

press the ENT key to confirm that the alarm is cleared. The active alarms in the controller are given in Table 4-4.

Table 4-4 Active alarm of the controller

No.

Alarm type

Alarm

Description

Rectifier alarm

Rect AC Fail

Press ► to browse the serial No. of the faulty rectifier

Rect Over Temp

Rect Fault

Rectifier alarm

Rect Protect

Press ► to browse the serial No. of the faulty rectifier

Rect Fan Fails

Rect Derated

Rect Not Respond

Multi-Rect Alarm

9 Rectifier Lost

You can clear this alarm manually

AC alarm

SPD Fault

SPD fault is the alarm of Digital 1

Digital Alarm

AC High

AC Low 5

AC PH Fail

Mains Failure

DC alarm

DC Volt High+

2 DC Volt Low

3 DC Volt Low-

Batt Over Temp

Batt Temp High Alarm

6 Batt Temp Low Alarm

7 Ambient Temp High Alarm

8 Ambient Temp Low Alarm

T No Probe

Sensor Fault

LVD

BLVD 13

Load Fuse Alarm 1

Load Fuse Alarm 2

Load Fuse Alarm 3

Load Fuse Alarm 4

Load Fuse Alarm 5

Load Fuse Alarm 6

Aux Load Fails

Batt Fuse Alarm 1

Batt Fuse Alarm 2

Batt 1 Curr High

Battery management alarm

Non Float Status

Batt Discharge

Load Share Alarm

Batt Test Fail

Press ► to prompt you to clear this alarm

Short Test Fail

Save Pow er

7 Save Pow er Fault

Controller self-detect alarm

SelfDetect Fail

2 Manual Mode

Volt Discrepancy

Maintain Alarm

5 Alarm Block

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4.5.2 Querying History Alarm

1. At the STATUS screen (see Figure 4-5), press ▲ or ▼ to select the ‘History Alarm’, and press the ENT key to enter it.

1) If there is no history alarm, the system cannot access the lower level menu.

2) If there is an active alarm, the screen shown in Figure 4-17 will appear.

199 ID2067000584

071213 17:30:05

Rect1 Fault 071213 14:27:50

Figure 4-17 History alarm screen

If the alarm is a rectifier alarm, the first row in Figure 4-17 will display the latter 10 digits of the rectifier ID. The history alarms of the controller are stored in cyclic order. At most 200 alarms will be recorded, above that, the

earliest alarm will be cleared automatically.

2. Use ▲ or ▼ to view other history alarms.

3. At any History Alarm screen, press the ESC key repeatedly to return to the higher-level menu, and ultimately to the first system information screen.

4.6 Maintenance

 Note

Be careful! BLVD operations may result in load power interruption.

1. From the battery basic parameters, you can change the ‘Sys Mode’ from ‘Auto’ to ‘Manual’, and then press the ENT key to confirm. For the detailed procedures, see Basic parameters in 4.7.2 Battery Settings.

2. At the MAINMENU screen, pres s ▲ or ▼ to select the ‘Maintenance’ menu. Press the ENT key, the system will prompt you to input the password.

3. Input the password and press the ENT key to enter the Maintenance screen (displayed in two screens), as shown in Figure 4-18.

Maintenance



Start: FC



RectTrim: 53.5V RectLimit: 121%





Rect 1: DC On Rect 1: AC On Rect 1: Reset

Figure 4-18 Maintenance screen

4. Press ◄ or ► to select the needed operation, and press the ENT key to confirm. The screen pops up the corresponding prompt. If the system satisfies control situation, press the ENT key to make the control valid, otherwise, the controller will prompt you that the control is disabled. Press the ESC key to cancel. The control contents are given below.

1) Start: The option includes FC, BC and Test. Press ◄ or ► to select the needed action. After selecting the Start option, press ◄ or ► to select the needed operation. If there is an AC power-off alarm, or the busbar undervoltage, the boost charge and battery test control will not be executed by the system. No battery test control can be conducted when the rectifier communication is interrupted. After the battery test, the management mode will be changed from ‘Manual’ to ‘Auto’ autom atically.

2) RectTrim: Range: 42V ~ 58V. The control voltage value of this parameter cannot exceed the overvoltage alarm point, otherwise, the parameter will be invalid.

3) RectLimit: Range: 10% ~ 121%.

4) Rect: The operations for a single rectifier include: DC On/Off, AC On/Off and Reset. Operation method:

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Use ▲ or ▼ to select the rectifier parameter, and use ◄ or ► to change the rectifier serial No.. Then press the ENT key to confirm. The bottom row of the screen displays the rectifier ID automatically. Us e ▲ or ▼ to move the cursor to the operation area (that is, ‘DC On’ in Figure 4-18), and use ◄ or ► to select the value , and then press the ENT key to confirm.

If a rectifier shuts down due to over-voltage, you can select the Reset order to reset the rectifier once. If the overvoltage fault disappears afterwards, this rectifier will resume normal operation; otherwise, the rectifier will shut down again. The control orders of RectTrim, RectLimit and single rectifier can be executed only when the system is in float charge state.

5. Press the ESC key to return to the MAINMENU screen, and change the management mode from ‘Manual’ to ‘Auto’. Then press the ESC key to return to the system information screen.

4.7 Setting Parameters

The power system parameters are divided into seven kinds: alarm, battery, AC, DC, rectifier, system and communication parameters. Without any special needs, you only need to reset the battery string and battery capacity according to system configuration and battery actual instance, and accept the factory settings for other parameters. The setting methods of parameters are given in the following sections.

4.7.1 Alarm Settings

At the Settings screen, press ▲ or ▼ to select the ‘Alarm Settings’ menu, then press the ENT key to enter the Alarm Settings screen, as shown in Figure 4-19.

Alarm Settings

Alarm Level Alarm Control DI Settings

Figure 4-19 Alarm settings screen

There are three sub-menus shown as follows.

Setting alarm level

At the Alarm Settings screen, press ▲ or ▼ to select the ‘Alarm Level’ menu. Then press the ENT key to enter the Alarm Level screen, as shown in Figure 4-20.

Alarm Type:

Load Fuse Alarm Level: Critical Out Relay: N

Figure 4-20 Alarm level screen

Press ▲ or ▼ to move the cursor to the needed option. Press ◄ or ► to select the corresponding content and press the ENT key to confirm.

The controller alarms are classified into four types: critical alarm, major alarm, observation and no alarm. Critical alarm, major alarm: These two types of alarms have strong impacts on the power system performance.

Whenever these alarms are generated, you are supposed to handle them immediately. The alarm indicators will be on and audible alarm will be generated.

Observation alarm: When this type of alarm is generated, the power system maintains normal DC 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 alarm indicators will be on when observation alarm occurs.

No alarm: No visual or audible alarm. The alarm and its default value of the controller are listed in Table 4-5.

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Table 4-5 Description of alarm setting parameter

No.

Alarm

Description

Alarm level

Related relay

parameter

SPD Fault

Lighting protection circuit failure

Critical

None

The alarm name is user-defined, at most 10 letters. In this system, eight DIs can be defined. Among which, the first DI is defined as ‘SPD Fault’, the other seven DIs can be defined by the user

No alarm

None

AC Voltage High

The AC input voltage is higher than the setting of AC input over-voltage alarm point

Critical

None

Over-voltage alarm

AC Voltage Low

The AC input voltage is lower than the setting of AC input under-voltage alarm point

Critical

None

Low-voltage alarm

Mains Failure

All the AC input voltages from the rectifier are less than 80V

Major

DC Volt High

The DC output voltage is higher than the setting of DC output over-voltage alarm point

Critical

Over-voltage alarm

DC Volt Low

The DC output voltage is low er than the setting of DC output under-voltage alarm point

Critical

Low-voltage alarm

DC Volt Under

DC output voltage lower than the setting of ‘DC output under- voltage alarm point’

Observation

None

Under-voltage alarm

Batt Over Temp

The battery temperature is higher than the setting of over-temperature point

Critical

None

Over Temp alarm point

Batt Temp High Alarm

The battery temperature is higher than the setting of high temperature point

Observation

None

High Temp alarm point

Batt Temp Low Alarm

The battery temperature is lower than the setting of low temperature point

Observation

None

Low Temp alarm point

Ambient Temp High Alarm

The ambient temperature is higher than the setting of high temperature point

Observation

None

High Temp alarm point

Ambient Temp Low Alarm

The ambient temperature is lower than the setting of low temperature point

Observation

None

Low Temp alarm point

T No Probe

Configured with temperature sensor, but not connected

Critical

None

Sensor Fault

The temperature sensor measures unreasonable temperature

Critical

None

LVD 1

Load low voltage disconnects manually

Critical

LLVD enabled

LVD 2

Battery low voltage disconnects manually

Critical

BLVD enabled

Load Fuse Alarm 1 ~ 6

Load failure caused by overload, short circuit, manual disconnect, or alarm circuit failure

Critical

None

Aux Load Fails

The last load fuse fails

Critical

None

Batt Fuse Alarm 1 ~ 2

Battery failure caused by overload, short circuit, manual disconnect, and alarm circuit failure

Critical

None 21

Batt 1 Curr High

The charging current of battery string 1 is higher than the setting of charging over current limit

Observation

None

Over current point

Batt 2 Curr High

The charging current of battery string 2 is higher than the setting of charging over current limit

Observation

None

Over current point

Rect AC Fail

The AC input voltage of this rectifier is lower than under-voltage alarm point

Major

Rect Over Temp

The internal temperature of the rectifier is higher than 90°

Observation

Rect Failure

The rectifier voltage is higher than upper limit voltage

Critical

Rect Protect

The rectifier performs self-protection and has no output

Observation

Rect Fan Fails

Rectifier fan failure

Major

Rect Derated

The rectifier limits its output power

Observation

Rect Not Respond

The rectifier does not communicate w ith the monitoring unit

Major

HVSD

The rectifier shuts down under high voltage

Major

Multi-Rect Alarm

More than two rectifiers alarm

Critical

None

Self-detect Err

Hardware self-detect error

No alarm

None 33

Manual Mode

The battery management is in ‘Manual’ mode

No alarm

None 34

Non Float Status

The battery is not under float charge status

No alarm

None 35

Batt Discharge

The battery is discharging

Observation

None

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No.

Alarm

Description

Alarm level

Related relay

parameter

Load Share Alarm

In the system with load current shunt, the sampled load current plus battery current differs greatly from rectifier current

No alarm

Batt Test Fail

The battery discharging time is shorter than expected time

Observation

None 38

Short Test Fail

In short test, the battery discharging capacity is bigger than setting value

Observation

None

Volt Discrepancy

The actual output voltage is different from both the measured DC bus voltage and the voltage reported by the rectifier to monitoring unit. The error is bigger than 1V

Observation

None

Maintain Alarm

Time to maintain the system

Observation

None

Rectifier Lost

The monitoring unit has detected a reduction in the number of running rectifiers

Critical

None

Save Pow er

The system is running under energy saving status

No alarm

None

Setting alarm control

At the Alarm Settings screen, press ▲ or ▼ to select the ‘Alarm Control’ menu. Then press the ENT key to enter the Alarm Control screen, as shown in Figure 4-21.

Alarm Control

Voice Sign: Open Clear: Hist Alarm

Figure 4-21 Alarm control screen

‘Voice Sign’ option includes: open, off, 3min, 10min, 1h, 4h. You can set it according to your requirements. ‘Clear: Hist Alarm’ option includes: Hist Alarm, Rect Lost, TestFail, ShortTest, ESaveFail and Maintain. If you press

the ENT key, the corresponding alarm information saved in the controller will be cleared.

DI settings

DI settings only have an impact on user-defined DI alarm. At the Alarm Settings screen, press ▲ or ▼ to select the ‘Active: High’ menu, then press the ENT key to enter the DI Settings screen, as shown in Figure 4-22.

Digital 1 Alarm

DI Settings

Active: High

DI No.: 1

Digital 1 Alarm Active: High

Figure 4-22 DI settings screen

Press ▲ or ▼ to select the needed option. Press ◄ or ► to select the parameter value and press the ENT key to confirm. Press ▲ or ▼ to modify the number and letter of DI name on the third row after pressing the ENT key to confirm, and press ◄ or ► to move the cursor left or right, and then input ‘#’ to end. Finally, press the ENT key to confirm.The value description of the alarm setting parameter is listed in Table 4-6.

Table 4-6 Description of the alarm parameter setting

Parameter

Range

Factory setting

Value description

DI No.

1 ~ 8

The eight corresponding connecting terminals, queued up in the order that the hardware switches are put

DI Name

Figures or letters, 10 at most

SPD

When there are DI alarms, this parameter shows the alarm name you have defined

Alarm Mode

High, Low

Low

High: alarm upon high level; low: alarm upon low level

4.7.2 Battery Settings

Battery parameters are important, because they are related to the life of battery.

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At the Settings screen (see Figure 4-6), press ▲ or ▼ to select the ‘Bat. Settings’ menu, then press the ENT key to enter the BAT Settings screen, as shown in Figure 4-23.

BAT Settings



Basic Setting



LVD Settings

Charge

Battery Test

Temp. Comp





Figure 4-23 BAT settings screen

The battery parameters include: ‘Basic Setting’, ‘LVD Setting’, ‘Charge’, ‘Battery Test’ and ‘Temp. Comp’. The setting methods of the battery parameters are given as follows.

Basic parameters

1. At the BAT Settings screen, press ▲ or ▼ to select the ‘Basic Setting’ menu, then press the ENT key to enter the basic battery parameter setting screen, as shown in Figure 4-24.

Sys Mode: Auto



Bat. Fuse: 2



Capacity: 300Ah Bat. Shunt 1: Y

Bat. Shunt 2: Y



Shunt Coeff:



-Current: 300A

-Volt: 25mV

Figure 4-24 Basic battery parameter setting screen

2. Press ▲ or ▼ to select one screen or one of the parameters, and press ◄ or ► to select the parameter value. Then press the ENT key to confirm, and the controller will automatically save the setting value.

The value description of the basic battery parameters is listed in Table 4-7.

Table 4-7 Description of the basic battery parameter setting

Parameter

Range

Factory setting

Value description

Sys Mode

Auto, Manual

Auto

In the Auto mode, you can manage the system through the controller. In the Manual mode, you can manage the system manually, and the controller calculates the battery boost charge time protection and capacity automatically. When the system has DC undervoltage alarm, the parameter can automatically sw itch to the ‘Auto’ mode

Bat. Fuse

0 ~ 2

You should set this parameter according to the actual battery fuse configuration

Capacity

50Ah ~ 5000Ah

300Ah

The capacity sum of the total battery strings connected with each shunt. You should set this parameter according to the actual battery configuration

Bat. Shunt1

Y, N

You can set the shunt parameters only when the system type is SET

Bat. Shunt2

Y, N

Shunt Coeff

-Current

1A ~ 5000A

500A Shunt Coeff -Volt

1mV ~ 500mV

25mV

LVD parameters

At the BAT Settings screen, press ▲ or ▼ to select the ‘LVD Settings’ menu. Then press the ENT key to enter the LVD Settings screen, as shown in Figure 4-25.

LVD1 Enable: Y



LVD2 Enable: Y



LVD1 Volt: 44.0V LVD2 Volt: 43.2V

Figure 4-25 LVD settings screen

Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value. Then press the ENT key to confirm.

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LVD1 means the controller receives power supply from the battery upon AC power-off, so the non-priority load will be powered off automatically. In this way, the battery remaining capacity can sustain the priority load longer.

LVD2 means the controller receives power supply from the battery upon AC power-off, so the battery will be powered off automatically. In this way, the battery over-discharge can be avoided.

The value description of the LVD parameters is listed in Table 4-8.

Table 4-8 Description of the LVD parameter setting

Parameter

Range

Factory setting

Value description

LVD1 Enable

Y, N

Select ‘Y’ to enable the LVD1/LVD2 function; Select ‘N’ to disable the LVD1/LVD2 function

LVD2 Enable

LVD1 Volt

40V ~ 60V

44.0V

Select the battery voltage, when the battery voltage is low er than the preset LVD1 Volt, the load w ill be disconnected, and so does the battery when the battery voltage is low er than the preset LVD2 Volt

LVD2 Volt

43.2V

Charge management parameters

At the BAT Settings screen, press ▲ or ▼ to select the ‘Charge’ menu, then press the ENT key to confirm. There are five screens, as shown in Figure 4-26.

Float: 53.5V



Boost: 56.4V



Limit: 0.100C10 Over: 0.300C10

Auto Boost:



-Enable: Y



-Current: 0.060C10

-Cap: 80.0%

Const Boost:



-Current: 0.010C10



-Time: 180min

Cyc Boost:



-Enable: Yes



-Period: 2400h

-Time: 720min

Boost Limit Time:





1080min

Figure 4-26 Charge management settings screen

Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value. Then press the ENT key to confirm.

The value description of the charge parameters is listed in Table 4-9.

Table 4-9 Description of the charge parameter setting

Parameter

Range

Factory setting

Value description

Float

42V ~ 58V

53.5V

The rectifier output voltage in FC state

56.4V

The rectifier output voltage in BC state. The Boost must be higher than the Float

Boost

Limit (current limit point)

0.1C10 ~

0.25C10

0.1C10

The maximum battery charging current. C10 is the battery nominal capacity, which is generally set to 10% ~ 20% of the capacity of one battery string

Over (over current point)

0.3C10 ~ 1.0C10

0.3C10

When the battery charging current is higher than the ‘Over’ value, the controller w ill generate the battery charge over-current alarm

Automatic Boost

-Enable

Y, N

Select ‘Y’ to enable this function; Select ‘N’ to disable this function

Automatic Boost

-Current

0.050C10 ~

0.080C10

0.06C10

The controller will control the system to enter the BC state when the

battery capacity decreases to the value of ‘To Boost Cap’, or w hen the

charging current reaches the ‘To Boost Curr ent’. The battery charging voltage is the ‘Boost’ value

Automatic Boost

-Cap

10% ~ 99%

80%

Const Boost

-Current

0.002C10 ~

0.02C10

0.01C10

The system in BC state will enter the FC state automatically w hen the charging current decreases to the ‘Const Boost Current’ value and after the ‘Const Boost Time’. The battery charge voltage then will be the Float state

Const Boost -Time

30min ~ 1440min

180min

Cyclic Boost

-Enable

Y, N

Select ‘Y’ to enable this function Select ‘N’ to disable this function

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Parameter

Range

Factory setting

Value description

Cyclic Boost

-Period

48h ~ 8760h

2400h

The ‘Cyc Boost Period’ is the interval between two cyclic BCs. The battery charging voltage is the ‘Boost’ value, and the charging time is the ‘Cyc Boost Time’

Cyclic Boost -Time

30min ~ 2880min

720min

Boost Limit Time

60min ~ 2880min

1080min

During the BC state, to ensure the system safety, the controller w ill forcibly control the system to enter the FC state, when the BC time reaches the ‘BoostLimitTime’

The BC/FC switchover diagram is shown in Figure 4-27.

Battery charge current bigger

than 'To Boost Current'

Battery capacity smaller

than 'To Boost Cap'

Constant BC

time-up

Charge current

smaller than

'Const Boost

Current'

Constant

BC time longer than

'BoostLimitTime'

FC time longer than 'Cyc Boost Period'

BC time longer than 'Cyc Boost Time'

Abnormal situation (such as AC power-

off, battery route faulty, and rectifier

communication failure)

Figure 4-27 BC/FC switchover diagram

Battery test parameters

1. At the BAT Settings screen, press ▲ or ▼ to select the ‘Battery Test’ menu, then press the ENT key to confirm. There are five screens, as shown in Figure 4-28.

End Test:



-Volt: 45.2V



-Time: 300min

-Cap: 0.70C10

Cyc Test En: N



Cyc Test Time:



01-01-00:00

04-01-00:00





07-01-00:00

10-01-00:00

Short Test:



-Enable: No



-Alarm: 10A

-Period: 720h

-Time: 5min



Stable Test



-Enable: No

-Current: 9999A

Figure 4-28 Battery test settings screen

2. Press ▲ or ▼ to select one screen or one of the parameters, and press ◄ or ► to select the parameter value. Then press the ENT key to confirm and save the change.

The controller can do battery test, and record 10 groups of battery test data (accessible only through the host). After the battery test is started, the controller will adjust the rectifier output voltage to the setting value of the ‘End Test Volt’, then the battery discharge will begin. The controller will stop the battery test if the battery voltage reaches the ‘End Test Volt’, or the discharge time reaches the ‘End Test Time’, or the battery capacity reaches the ‘End Tes t Cap’. Afterwards, it will restore the rectifier output voltage to the normal FC voltage, begin the battery charge and switch the system to battery auto-management.

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Meanwhile, the test start time-voltage, end time-voltage and battery remaining capacity will be recorded. The records can be queried through the host. During the battery test, if abnormalities occur, the controller will stop the battery test automatically. The value description of the battery test parameters is listed in Table 4-10.

Table 4-10 Description of the battery test parameter setting

Parameter

Range

Factory setting

Value description

End Test Volt

43.1V ~ 57.9V

45.2V

The controller will stop the battery test and sw itch to FC state if the battery voltage reaches the ‘End Test Volt’, or the discharge time reaches the ‘End Test Time’, or the battery capacity reaches the ‘End Test Cap’

End Test Time

5min ~ 1440min

300min

End Test Cap

0.01C10 ~

0.95C10

0.7C10

Cyc Test En

Y, N

Select ‘Y’ to enable this function; Select ‘N’ to disable this function

Cyc Test Time

Month, day, time

01-01-00:00

When the parameter ‘Cyc Test En’ is set to ‘Y’, the controller will test the battery according to the ‘Cyc Test Time’

04-01-00:00

07-01-00:00

10-01-00:00

Short Test Enable

Y, N y Whether using the short test function

Short Test Alarm

1A ~ 100A

10A

The short test is used for discharge test comparison of the tw o battery strings. The inspection for the battery feature is valuable when one battery is not discharged for a long time. If the battery is not discharged w ithin the ‘ShortTest Period’, the controller w ill start a short test, w hose operation time is set by the parameter ‘ShortTest Time’. By the end of the test, if the diff erence in the discharge currents of the two battery strings is bigger than the ‘Short Test Alarm’, the battery discharge abnormal alarm w ill be generated

Short Test Period

24h ~ 8760h

720h

Short Test Time

1min ~ 60min

5min

Stable Test Enable

Y, N

The stable test is conducted with constant battery discharge current. To execute the stable test, the present load current should be bigger than the current value set by stable test. The stable test is suitable for bigger load and relative stable load current, otherwise, do not exercise it. The current v alue is set through the parameter ‘Stable Test Current’. If the

parameter ‘StableTest Enable’ is set to ‘Y’, the test w ill be started once

the battery satisfies the test condition

Stable Test Current

0 ~ 9999A

9999A

The schematic diagram of the test function is shown Figure 4-29.

Battery Auto-management

battery test

Rectifier output voltage lower than battery voltage

Battery

discharges

Rectifier hot

standby

'End Test Volt'

is reached

'End Test Cap' is

reached

'End Test Time' is

reached

Manual/

Timed start

Figure 4-29 Schematic diagram of the test function

Temperature compensation parameters

1. At the BAT Settings screen, press ▲ or ▼ to select the ‘Temp. Comp’ menu, then press the ENT key to confirm. There are two screens, as shown in Figure 4-30.

Center Temp: 25°



Coeff: 72mV/°



Temp: No

Batt T H2: 50°





Batt T H1: 50° Batt T L1: 0°

Figure 4-30 Temperature compensation settings screen

2. Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value. Then press the ENT key to confirm and save the change.

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The value description of the temperature compensation parameters is listed in Table 4-11.

Table 4-11 Description of the temperature compensation parameter setting

Parameter

Range

Factory setting

Value description

Center Temp

10°C ~ 40°C

25°C

FC voltage derated value = (Batt Temp – ‘Center Temp’) * Temp Coeff. In the case of rectifier communication interruption, DC over/undervoltage or battery fuse alarm, the controller will not do temperature compensation to the battery FC voltage

Coeff

0 ~ 500mV/°C

72mV/°C

Temp

Ambient Temp, None, Battery Temp

None

Amb Temp: The temperature measured by sensor is the ambient temperature; Batt Temp: The temperature measured by sensor is the battery temperature; None: No temperature is measured by sensor

Batt T H2

-40°C ~ +100°C

50°C

When the detected battery temperature is higher than Batt T H2/Batt T H1, the controller w ill generate an alarm

Batt T H1

-40°C ~ +100°C

50°C

Batt T L1

-40°C ~ +100°C

0°C

The controller w ill generate an alarm w hen the detected battery temperature is lower than Batt T L1

4.7.3 AC Settings

At the Settings screen, press ▲ or ▼ to select the ‘AC Settings’ menu, then press the ENT key to enter the AC Settings screen, as shown in Figure 4-31.

Over Volt: 280V



Low Volt: 180V



Under Volt: 80V AC In: Auto



AC PH: 3-PH



Figure 4-31 AC settings screen

Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value, then press the ENT key to confirm.

The value description of the AC parameters is listed in Table 4-12.

Table 4-12 Description of the AC parameter setting

Parameter

Range

Factory setting

Value description

Over Volt

50V ~ 300V

280V

The controller w ill generate an AC over-voltage alarm when the AC input voltage is higher than the setting value

Low Volt

50V ~ 300V

180V

The controller w ill generate an AC low-voltage alarm when the AC input voltage is lower than the setting value The value of the Low Volt must be lower than that of the Over Volt

Under Volt

50V ~ 300V

80V

Set it according to the actual requirement

AC In

Auto, No, Manual

Auto

Set it according to the AC input mode of AC sampling board. Choose ‘N’ if the AC sampling board is not configured

AC PH

1-PH, 3-PH

3-PH

Set it according to the actual configuration. Choose ‘1-PH’ or ‘3-PH’ if the AC sampling board is configured

4.7.4 DC Settings

At the Settings screen, press ▲ or ▼ to select the ‘DC Settings’ menu, then press the ENT key to enter the DC Settings screen, as shown in Figure 4-32.

Over Volt 2: 58.5V





Low Volt 1: 45.0V Low Volt 2: 45.0V

L-Shunt En: N



Shunt Coeff:



-Current: 300A

-Volt: 25mV

500A 75mV

Figure 4-32 DC settings screen

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Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value, then press the ENT key to confirm. The value description of the DC parameters is listed in Table 4-13.

Table 4-13 Description of the DC parameter setting

Parameter

Range

Factory setting

Value description

Over Volt

40V ~ 60V

58.5V

The DC OverVolt alarm will be generated when the system DC voltage is higher than the setting value

The values of these three parameters should be: Over Volt > Low Volt 1 > Low Volt 2

Low Volt 1

45.0V

The DC Low Volt1 alarm will be generated when the system DC voltage is lower than the setting value

Low Volt 2

45.0V

The DC Low Volt2 alarm will be generated when the system DC voltage is lower than the setting value

L-Shunt

Y, N

Set it according to the actual instance

Shunt Coeff

-Current

1A ~ 5000A

They can be set w hen the shunt options are ‘SET’ in the system with load shunt

Shunt Coeff

-Volt

1mV ~ 500mV

4.7.5 Rectifier Settings

At the Settings screen, press ▲ or ▼ to select the ‘Rect Settings’ menu, then press the ENT key to confirm. There are three screens, as shown in Figure 4-33.

Position En: N



HVSD: 59.0V



Default V: 53.5V

R-Posi: 1-1

Walk-in On: N



Walk-in: 8s



Interval T: 0s

AC OverV On: N



ACCurrLim: 30A



Figure 4-33 Rectifier settings screen

Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value, then press the ENT key to confirm. The value description of the rectifier parameters is listed in Table 4-14.

Table 4-14 Description of the rectifier parameter setting

Parameter

Range

Factory setting

Value description

Position En

Y, N

Y: The controller will prompt you to set the rectifier position after the rectifier and controller are powered on. N: You do not need to set the rectifier position

R-Posi

1 ~ 30

R-Posi: represented in two figures, the first figure represents the rectifier number, the next figure represents the position number. Press the ENT key to select the rectifier, press ◄ or ► to change the position number. When the controller is communicating with a rectifier, the green indicator on the corresponding rectifier will blink

HVSD

56V ~ 59V

59V

The rectifier over-voltage alarm will be generated when the rectifier output voltage is higher than the setting value

Default V

48V ~ 58V

53.5V

‘Default V’ output occurs when rectifier communication is interrupted. This setting value must be lower than the ‘HVSD’ voltage value

Walk-in On

Y, N

It means the rectifier voltage will rise from 0V to the ‘Default V’ value after the ‘Walk-in T’ value

Walk-in

8s ~ 128s

Interval T

0s ~ 10s

The controller can set the DC-DC interval start of the system rectifiers. Start time = rectifier address * interval

AC OverV On

Y, N

The controller can set the rectifier to ‘Over Volt En’, meanwhile, the rectifier can start forcibly. The controller w ill automatically set the rectifier with least address to have this function. If the rectifier alw ays exceeds the normal voltage for 60s, the function will be cancelled automatically

ACCurrLim

1A ~ 50A

30A

The controller limits the input current of the rectifier within the AC current limit range

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4.7.6 System Settings

At the Settings screen, press ▲ or ▼ to select the ‘Sys Settings’ menu, then press the ENT key to enter the password confirmation screen. After inputting the correct password (user level password, default: 1), the three screens shown in Figure 4-34 are displayed.

Lang: Chinese



Tzone GMT+08: 00



Date: 2000-01-15

System Type:



48V/SET



ComDownLoad: N Reset PWD: N

Reset Para: N



Op1 PWD: ******



Op2 PWD: ******

Adm PWD: ******

Figure 4-34 Settings screen upon user level

If the ‘Rest Para’ is set to ‘Y’, press the ENT key and prompt a screen shown in Figure 4-35.

Notice: ENT Continue ESC Quit

Figure 4-35 Prompt screen for resetting system

Press the ESC key to cancel the resetting. Press the ENT key to execute the resetting. At this time, all the parameters will return to the default value. It is recommended to execute system resetting when the controller cannot work normally through the method of powering off or restoration.

Press ▲ or ▼ to select the parameter you need, and press ◄ or ► to select the parameter value, then press the ENT key to confirm.

The value description of the system parameters is listed in Table 4-15.

Table 4-15 Description of the system parameter setting

Parameter

Range

Factory setting

Value description

Lang

Chinese, English

English

Set it according to your need

Tzone

- - Set it according to actual instance

Date

2000 ~ 2099

Set the time according to the current actual time, regardless of whether it is a leap year or not

System Type

24V/100 24V/300 24V/500 24V/1000 24V/SET 48V/100 48V/300 48V/500 48V/1000 48V/SET

PS48300-3B/1800: 48V/300

The system type of the controller has been set according to the actual instance before the controller is delivered with power system. You do not need to change the value except that the controller needs to be replaced with a new one. After changing the type, the controller w ill restart and other parameters will resume the default. You need to change some parameters according to the battery and other equipment configured with the system

ComDownLoad

Y, N N

Reset PWD

Y, N N Whether resetting the password to the default

Reset Para

Y, N N Whether resetting the parameters to the defaults

Op1 PWD

The passw ord can be six digits long at most. If it is shorter than six digits, end it with a #. Use ▲ or ▼ to change the number, and ◄ or ► to move the cursor left or right. Press the ENT key to confirm. You should input the same number twice to validate the setting

Op2 PWD

Adm PWD

4.7.7 Communication Settings

At the Settings screen, press ▲ or ▼ to select the ‘Comm Settings’ menu, then press the ENT key to enter the screen shown in Figure 4-36.

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Address: 1



Comm Mode: RS232



BaudRate: 9600 IP/Subnet/Gate:

192.168.1.2



255.255.255.0



192.168.1.1 CallbackTime: 3

Phone Number:





......

Figure 4-36 Communication settings screen

When the communication mode is set to ‘Modem’, the callback phone number and callback time should be set. Use ◄ or ► to modify the number and move the cursor to left or right to change the callback phone number, then press

the ENT key to confirm. The value description of the communication parameters is listed in Table 4-16.

Table 4-16 Description of the communication parameter setting

Parameter

Range

Factory setting

Value description

Address

1 ~ 254

The addresses of the power systems in the same monitored office should be different

Comm Mode

Modem

RS232

The power system only supports RS232 communication mode

BaudRate

1200bps ~ 9600bps

9600bps

Make sure that the baud rates of both sending and receiving parties are the same

IP/Subnet/Gate

Set it according to the actual instance

CallbackTime

- - Phone Number

4.8 Energy Saving Settings

The Energy Saving is a sub-menu of the main menu. At the MAINMENU screen, press ▲ or ▼ to select the ‘Energy Saving’ menu, then press the ENT key to enter the password confirmation screen. After inputting the correct password, the screen shown in Figure 4-37 is displayed.

Save Enable: Y Cyc Period: 168h Rect Work: 80% Rect Limit: 1

Figure 4-37 Energy saving screen

If you want the system to operate in energy saving mode, set ‘Save Enable’ to ‘Y’, otherwise, set it to ‘N’. Set ‘Cyc Period’ according to the actual instance. The energy saving operating principle of the system is described below.

1. Operating principle In energy saving mode, the controller will switch off some rectifiers, the operative rectifiers will power all loads. Each

operative rectifier works on the best efficiency to improve utilization ratio of the rectifier and reduce energy consumption. After certain time (that is, ‘Cyc Period’ shown in Figure 4-37), the previously inoperative rectifiers will work, while the previously operative rectifiers will stop work. The two states alternate to make sure that the working hours of the rectifiers in the system approach. If the battery current and load current change, the controller will switch off some operative rectifiers or switch on some inoperative rectifiers, according to the actual condition. In any case, the system guarantees at least one rectifier to work.

2. Prerequisite If the battery is configured and the load current has no instant shock, the system will operate in energy saving mode,

that is, ‘Save Enable’ is set to ‘Y’.

3. Advantage

Working on the best efficiency to save energy. Balancing working hours of the rectifiers to prolong the life of the rectifier. In shutdown state, preventing rectifiers from being damaged by AC inrush to reduce lightning fault.

4. Abnormal situation handling Switch on all the rectifiers when the busbar voltage is faulty (DC over-voltage or under-voltage).

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Switch on all the rectifiers when a rectifier alarm (communication interruption) is generated. Switch on all the rectifiers when an AC alarm (AC power-off) is generated. Switch on all the rectifiers automatically when the system has no controller or the communication between the

rectifier and the controller is interrupted.

Delay implementation when the rectifier receives shutdown command, immediately execute when the rectifier

receives startup order.

The value description of the energy saving parameters is listed in Table 4-17.

Table 4-17 Description of the energy saving parameter setting

Parameter

Range

Factory setting

Value description

Save Enable

Y, N

It can be set to ‘Y’ only when the battery is configured with no instant load current shock

Cyc Period*

1h ~ 8760h

48h

Time of rectifier is in power-on state and power-off state, it can be set according to the actual requirement

Rect Work

30% ~ 90%

80%

Output capacity percentage. More rectifiers will start to work when larger than this setting percentage

Rect Limit

1 ~ 30

Minimum number of the rectifier in energy saving state

Note*: Cyc Period, Rect Work and Rect Limit are available only w hen ‘Save Enable’ is set to ‘Y’

4.9 Fast Settings

The Fast Settings is a sub-menu of the main menu. At the MAINMENU screen, press ▲ or ▼ to select the ‘Fast Settings’ menu, then press the ENT key to enter the password confirmation screen. After inputting the correct password, the screen shown in Figure 4-38 is displayed.

System Type:

48V/SET

Capacity: 300Ah

600Ah

Figure 4-38 Fast settings screen

At the Fast Settings screen, you can set the system type and battery capacity, as listed in Table 4-18.

Table 4-18 List of fast settings

Parameter

Range

Factory setting

Value description

System Type

24V/100 24V/300 24V/500 24V/1000 24V/SET 48V/100 48V/300 48V/500 48V/1000 48V/SET

NetSure 731 C62：48V/300 NetSure 731 CC2：48V/500

The system type of the controller has been set according to the actual instance before the controller is delivered with power system. You do not need to change the value except that the controller needs to be replaced with a new one. After changing the type, the controller w ill restart and other parameters will resume the defaults. You need to change some parameters according to the battery and equipment configured with the system

Capacity

50Ah ~ 5000Ah

300Ah

The total capacity of the batteries connected w ith each shunt. You should set this parameter according to the actual battery configuration

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Chapter 5 Technical Parameters of Rectifier

This chapter introduces the appearance and structure, functions and features, and technical parameters of the rectifier.

5.1 Appearance and Structure

Front panel

The front panel of the rectifier has three indictors, as shown in Figure 5-1.

Power indicator

Protection indicator

Fault indicator

Alarm indicator

Protection indicator

Power indicator

Figure 5-1 Front panel of the rectifier

The description of the indicator function is shown in Table 5-1.

Table 5-1 Description of the indicator function

Abnormal

Alarm

Abnormal state

Suggested Action(s)

Pow er indicator

No alarm No input, output voltage

Restore the input, output voltage

Auxiliary power source failure

Change the position of the abnormal rectifier and normal rectifier, if the abnormal rectifier does not work, replace the rectifier

Protection indicator on

Rectifier over-temperature

Fan rotor blocked

Remove any object that may be blocking a fan rotor.

Ventilation blocked

Remove any object that may be blocking the inlet or outlet.

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

Lower the ambient temperature; relocate the heat source.

Rectifier protection

Rectifier load sharing imbalance

Check whether the communication of the rectifier is normal, if no, check whether the communication cable connection is normal, if the connection is abnormal, replace the faulty rectifier.

PFC output over/under voltage protection

Change the position of the abnormal rectifier and normal rectifier, if the abnormal rectifier doesnot work, replace the rectifier

AC input out the normal range

Correct the AC input voltage to within the acceptable range.

Protection indicator flashing

Rectifier communication failure

Communication failure between controller and rectifier

Check whether the communication cable connection is normal

Alarm indicator on

Rectifier failure Rectifier overvoltage

Pull out the rectifier and restart, if overvoltage persists, replace the rectifier

Two or more rectifiers have the same ID in one system

Contact Vertiv for repair

Alarm indicator on

System current sharing imbalance

Rectifier severe load sharing imbalance

Check whether the communication of the rectifier is normal, if no, check whether the communication cable connection is normal, if the connection is abnormal, replace the faulty rectifier.

Alarm indicator flashing

Faulty rectifier fan

Replace the fan.

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Rear panel

There are AC input socket and DC output socket on the rear panel of the rectifier, as shown in Figure 5-2.

J6J5J4J3J2J1 J7 J8 J16 J26J14 J24J13 J23J12 J22J11 J21J15 J25

PEPEPEPEPEPEPE

Figure 5-2 Rear panel of the rectifier

Functions of the socket pins are listed in Table 5-2.

Table 5-2 Pin functions

Socket

Function

AC input socket

Rectifier 1 AC input

Rectifier 2 AC input

Rectifier 3 AC input

Rectifier 4 AC input

Rectifier 5 AC input

Rectifier 6 AC input

Rectifier AC earthing

DC output socket

J11 ~ J16

Negative pole of the DC output

J21 ~ J26

Positive pole of the DC output

CAN/matching resistance

Matching resistance/CAN

5.2 Functions And Features

Hot swappable

The rectifier is hot pluggable. When the rectifier is plugged into or removed from the system which is powered on, the system or module will not be damaged.

Active load-sharing

When the loads (60 rectifiers at most) range from 10% ~ 100%, rectifiers in the same cabinet can perform load sharing, and maintain the average current difference of the rectifiers within ± 2A. Current sharing condition: 220V input, 53.5V output, loads range from 10% ~ 100%.

Power limiting based on input voltage

The rectifier can output its maximum power (3000W) when the input voltage ranges from 176Vac to 305Vac. The rectifier can work normally (but in linear power limiting mode) when the input voltage ranges from 85Vac to 176Vac. The relationship between the output power and input voltage is shown in Figure 5-3.

Figure 5-3 Relationship between output power and input power

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Output characteristics

The relationship between output voltage and current is listed in Table 5-4.

Table 5-3 Output characteristics

Output power

Output current

Output voltage

3000W

51.7A

58Vdc

3000W

62.5A

48Vdc

Power limiting based on temperature

Rectifier can work in the range of -40°C to 70°C ; The input voltage range: 176V ~ 264V; Temperature in the range of -40°C ~ 45°C, outputs full power: 3000W; Temperature in the range of 45°C ~ 55°C , derating from 3000W to 2900W; Temperature in the range of 55°C ~ 65°C , derating from 2900W to 2250W; Temperature in the range of 65°C ~ 70°C , derating from 2250W to 0W.

Figure 5-4 Output power and temperature

Output current limiting adjustment

The maximum current of the rectifier can range from 10% to 120% of the full load through the controller programming. If the controller communication fails, the default rectifier current is 100% of the full load rated power. The full load rectifier is defined as the maximum available current (62.5A) in the output load range. The rectifier can start as long as connected to a fully discharged battery or capacitor bank. There is no need to run the rectifier protection device, manual intervention is also unnecessary.

Output voltage regulation

Nominal output voltage: -48V DC, positive earthing. Adjustable within the range: -42V from -58V. User can regulate the range through the controller, regulation precision is ± 0.1V.

Fan control

When the input voltage is in the normal range, the in-built processor will regulate the fan speed (stepless regulation) according to the internal temperature and output power of the rectifier. For example, the fan speed increases with the rectifier temperature or the output power. The rectifier can be set to full speed through the corresponding controller.

Input over/under voltage protection

When the input voltage is less than 80Vac, the yellow indicator will be on, and the rectifier will stop working. When the input voltage returns to the normal range, the rectifier will automatically work in normal state. Low input voltage will not trigger the corresponding input protection device.

When the input voltage exceeds 305Vac, the yellow indicator will be on, and the rectifier will stop working. When the input voltage returns to the normal range, the rectifier will automatically work in normal state.

The rectifier will report the event to the controller when overvoltage protection occurs.

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Output overvoltage protection

1. The SW overvoltage protection point can be set through the controller, the setting range is 56V ~ 59V. It should be

0.5V higher than output voltage, and the default value is 59V. The SW overvoltage protection mode can be selected through the controller:

1) Lock out at the first overvoltage Once the output voltage reaches software protection point, the rectifier will shut down and hold that state. it requires

manual resetting to restore the operation

2) Lock out at the second overvoltage (by default) When the output voltage reaches the software protection point, the rectifier will shutdown, and restart automatically

after 5 seconds. If the overvoltage happens again within a set time (default: 5min. Configurable through controller), the rectifier will shut down and hold that state. It requires manual resetting to restore the operation. If the output current is less than 10 percent of the rated output current, the rectifier will not shut down.

Manual resetting: Resetting can be done manually through the controller, or by removing the rectifier from system  Note

If the output current is less than 10 percent of the rated output current, the rectifier will not shut down.

2. Overvoltage hardware protection: When the output voltage (unadjustable) reaches the hardware protection point (58.5V ~ 60V), the rectifier will shutdown, and restart automatically after 5 seconds. If the overvoltage happens again within a set time (default: 5min. configurable through controller), the rectifier will shut down and hold that state. It requires manual resetting to restore the operation.

Overtemperature protection Power limiting based on temperature

Each rectifier monitors the working temperature of the power-switching circuit. No matter in what reason (for instance, high ambient temperature or fan fault) the temperature increase + 35C, the rectifier will not power off. But it will limit the maximum power output, and then turn into the power limiting status to guarantee the power-switching circuit temperature is in the setting range. The operation at temperature from +35C to +70C will minimize the output power. When the temperature dropped to about +35C, the full power will restore.

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 Warning

The continuous running rated full power output temperature of the rectifier reaches up to +35C full power. The operation at the temperature from +35C to +70C will minimize the output power. The operation at temperature above +70C is abnormal, the running is temporary1.

1Temporary running at abnormal temperature: The continuous running time for temporary running in one day cannot exceed 8 hours, in one year cannot exceed 15 days (that is, it cannot exceed 120 hours in one year, the frequency cannot exceed 15 days).

PFC over/under voltage

If the inner bus voltage value exceeds the over/under voltage threshold, the rectifier would be shut down, and the yellow indicator would be on.

Communication failure

The yellow indicator on the rectifier panel will flash when the rectifier experiences a communication failure. To protect the battery, when the rectifier communication failure occurs, the rectifier output voltage will automatically adjust to

53.5V (according to actual need, different voltages can be preset). The yellow indicator on the rectifier panel will be

normal when the rectifier communication is restored. Auto-recovery is enabled upon the clearing of the corresponding fault.

Fan fault protection

An alarm will be generated upon a fan fault. In such cases, the red indicator on the rectifier panel will flash, the rectifier will be off, no voltage output. Auto-recovery is enabled upon the clearing of the corresponding fault.

Imbalance output current

When there are multiple rectifiers in the power system, the rectifier with high load sharing error will be recognized automatically, and the yellow indicator on the panel will be on.

The failure information will be reported to the associated system controller and the controller will process the failure accordingly.

Monitoring function

There’s a built-in digital signal processor in the rectifier. The processor monitors and controls the rectifier operation, and communicates with the controller in real time through the CAN bus. Table 5-5 lists the exchanged commands and information between the rectifier and controller.

Table 5-4 Exchanged information between the rectifier and controller

Receiving command and

signal of the rectifier

Pow er on / Off, current marching technique on / off, overvoltage shutdown reset, current limiting regulation, voltage regulation

Controller information

reported by the rectifier

Input voltage, output voltage, output current, current limiting setting, temperature, overvoltage setting, pow er on / off status, fault alarm (overvoltage shutdown, fan fault), protection information (input voltage protection, internal busbar voltage protection, high temperature protection), high temperature derating, input derating, input power failure, output current not sharing, address, code, date, software version, hardware version

5.3 Technical Parameters

Table 5-5 Technical parameters of the rectifier

Parameters

Name

Description

Environmental Operating temperature

-5C ~ 40C (derating is necessary above 35C, startup in -40C)

Relative humidity

≤ 95% , non-condensing

Altitude

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

Cooling mode

Forced cooling

AC input

Input system

1-phase 3-wire

Voltage range

85Vac ~ 305Vac

Rated voltage

200Vac ~ 240Vac

Max. static voltage upon no operation

415Vac Input current

< 22A

Impact current upon startup

< 31A

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Parameters

Name

Description

AC input Input impact current

< 150% steady state input peak current

Allowable grid frequency

45Hz ~ 65Hz

Rated grid frequency

50Hz/ 60Hz

DC output

Voltage range

42V ~ 58V

DC current

0 ~ 62.5A

Total regulation

≤ ±0.6%

Load regulation

≤ ±0.5%

Voltage regulation

≤ ±0.1%

Startup impact range

≤ ±1%

Mechanical parameters

Dimension

43.6mm (H) × 85.1mm (W) × 330mm (D)

Weight

≤ 3kg

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NetSure 731 CC2, NetSure 731 C62 Series Power Supply System User Manual

Chapter 6 Troubleshooting

This chapter describes the alarm handling and maintenance of the power system. The maintenance personnel must have adequate knowledge about the 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 power system shall maintain the inner part of the cabinet.

6.1 Handling Alarms

The controller alarms are classified into four types: critical alarm, major alarm, observation and no alarm. The phenomenon and description of the alarm are shown in Table 6-1.

Table 6-1 Alarm description and phenomenon

Alarm level

Description

Phenomenon

Critical alarm, major alarm

These tw o types of alarms have strong impacts on the system performance. Whenever these alarms are generated, users are supposed to handle them immediately

The alarm indicator of the controller w ill be on and audible alarm will be given

Observation

When this type of alarm is raised, the power system maintains normal output for a while. If the alarm occurs during w atch time, it should be handled immediately. If the alarm occurs during non-watch time, it should be handled during watch time

Only the alarm indicator of the controller will be on

No alarm

If alarms are set as ‘no alarm’ by users, when these alarms occur, no visual or audible indication will be generated and the power system works normally

None

The handling methods of common alarms are given in Table 6-2.

Table 6-2 Handling methods of common alarms

No.

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 power system, it is suggested to run the generator five minutes to minimize the impact on the 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 rectifier will stop operation when the mains voltage is more than 530V. 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 304V, the output power of the rectifiers will be derated. And if lower than 260V, the rectifiers will stop working. If the mains voltage is under the AC under-voltage value, the mains grid should be improved

SPD failure

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 set 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. Pow er 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

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

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No.

Alarm

Handling method

Load Fuse Alarm, Batt Fuse Alarm

Check if the corresponding MCB is sw itched 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. Pow er off the rectifier, and then pow er it on after a while. If the alarm persists, replace the rectifier

Rect Protect

Check if the mains voltage is above 530V or under 260V. 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 fan

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

Batt Over Temp

1. Check if the battery compartment temperature is too high. If yes, cool down the battery compartment.

2. Check if there is battery internal fault. If yes, replace the faulty battery

6.2 Handling Rectifier Fault

Fault judgement and handling method

Rectifier faults include power indicator (green) off, protection indicator (yellow) on, protection indicator (yellow) flashing, fault indicator (red) on and fault indicator (red) flashing.

The indicators are shown in Figure 6-1.

Power indicator

Protection indicator

Fault indicator

Figure 6-1 Rectifier indicator

The methods to handle the fault of the rectifier are listed in Table 6-3.

Table 6-3 Methods to handle the fault of the rectifier

Symptom

Controller alarms

Causes

Handling method

Green indicator off

No alarm No input/output voltage

Restore input voltage

Input fuse broken

Replace the rectifier

Yellow indicator on

Rect Protect

Overtemperat ure protection due to:

Fan blocked

Remove the object that blocks the fan

Ventilation path blocked at the inlet or vent

Remove the object at the inlet or vent

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

Decrease the ambient temperature or remove the heat source

Load sharing imbalance

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

Yellow indicator on

Rect Protect PFC output overvoltage protection

Change the position of the normal rectifier and faulty rectifier. If the faulty rectifier cannot working, replace the rectifier

AC input voltage abnormal

Make sure that the AC input voltage is normal

Red indictor on

Rect Failure Rectifier overvoltage

Pull out the rectifier. If the protection is triggered again, replace the rectifier

Inner fuse broken

Contact Vertiv for maintenance

System bad

Serious load sharing imbalance

Check whether the rectifier communication is normal.

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Symptom

Controller alarms

Causes

Handling method

Red indictor on

current imbalance

Serious load sharing imbalance

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

Red indicator blinks

Rect Fan Fails

Fan fault

Replace the fan

Replacing rectifier fan

If the rectifier fan is faulty, use the following procedures to replace the fan:

1. Performing this procedure may activate external system 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 future alarms associated with this system.

2. Remove the rectifier from the shelf. Refer to the related procedure for step-by-step instructions.

3. Place the rectifier on a static-safe work surface. Connect an approved grounding strap to your wrist for the

remainder of this procedure.

4. Remove the two faceplate mounting screws shown in Figure 5-2 from the Rectifier Module. Remove the faceplate.

5. Carefully pull the fan(s) out from the rectifier, until the fan power cable(s) can be accessed.

6. Unplug the fan power cable(s) from connector(s) on the PC board, and remove the fan(s).

7. Plug the power cable(s) of the replacement fan(s) into the connector(s) on the PC board.

8. Place each fan in its cavity in the module, orienting the fan so that:

The arrow on the fan body points toward the rear of the Rectifier Module, and The power cable exits the fan body toward the other fan, as shown in Figure 6-2.

9. Reinstall the faceplate on the rectifier. Ensure that no fan wiring is pinched. Secure faceplate with the two

previously removed screws.

10. Reinstall the rectifier into the shelf as described in the previous procedure.

11. When the fans start, check to ensure that each is providing front-to-back airflow. If air direction is wrong,

immediately remove the rectifier from the shelf. Repeat previous steps to check fan orientation, and correct as necessary. Reinstall the rectifier and again check for proper airflow.

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

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

Panel

Fan

Power cable

Figure 6-2 Rectifier fan replacement

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Rectifier replacement

Other than a rectifier fan replacement, no attempt should be made to troubleshoot or repair individual components on any rectifier. You should take the following procedures when a rectifier is faulty.

1. Refer to Figure 5-2Figure 6-2 during this procedure.

2. Performing this procedure may activate external system 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 future alarms associated with this system.

3. On the module being replaced, loosen the screw that is located on the module handle. (Turn the screw several turns counterclockwise to loosen.) Pivot the handle 90 degrees to the open position.

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

5. On the replacement module, loosen the screw that is located on the module handle. (Turn the screw several turns counterclockwise to loosen.) Pivot the handle 90 degrees to the open position.

6. Place the module into the mounting position in the shelf, and with the handle still in the open position, push the module completely into the shelf.

7. Push the handle into the front panel of the module. This will lock the module securely in the shelf. Tighten the screw on the handle.

8. Reset the system controller as required.

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

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

6.3 Handling Controller Fault

Fault judgement

The fault phenomena of the controller are LCD failure or displayed contents incorrect. You should take the following procedures to judge fault causes:

1. Loosen the three fixing screws on the PCB cover and remove the cover, as shown in Figure 6-3.

Cover of the PCB board

Fixing screw of the cover

PCB board

Front panel of the controller

LCD

PCB

PCB cover

Figure 6-3 Removing cover

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2. Judge fault causes according to the indicator status of the PCB, as listed in Table 6-4.

Table 6-4 Fault causes and handling methods of the controller

Phenomenon

Fault cause

Handling method

Watchdog indicator off, power indicator off

PCB has no auxiliary power supply

Check if J8 terminal on PCB is connected reliably. If the connection is reliable and the terminal voltage is normal (approximately the busbar voltage of the power system), the PCB is faulty and needs replacement

Pow er indicator on, watchdog indicator on or off

Softw are not running

Replace the PCB

Watchdog indicator flashing, LCD display incorrect

Signal cable connection incorrect or PCB faulty

Check if the signal cable connection is correct and reliable. If not, reconnect it. If yes, the PCB is faulty and needs replacement

Watchdog indicator flashing, LCD no display

PCB faulty or LCD faulty

Replace the LCD according to Replacing the LCD in this section. Check if the LCD displays normally. If yes, the fault handling is over. If not, the PCB is faulty and needs replacement

Pow er indicator on, watchdog indicator on or off, LCD displaying ‘Bootloader is Running’

Softw are is updating about firmw are

The controller w ill switch back to main program automatically after five minutes. If not, the application has not been w ritten successfully or has been destroyed. You need to write the application again. If still not, the CPU is damaged

The indicators and terminals of the PCB are shown in Figure 6-4.

31 32

J1 J2

J4 J5

J10

J12J11

RS232

Temp

LCD

Power indicator Watchdog indicator

Figure 6-4 Indicators and terminals of the PCB

Replacing the PCB  Note

Take care when replacing components of the controller. During replacement, unplug the terminals strictly in the order shown in the following procedures, failure to observe this may result in system shutdown.

The procedures for replacing PCB are described as follows:

1. Unplug the J8 power supply terminal to power off the PCB.

2. Unplug other terminals and DI/DO cables.

3. Wrap the DI/DO cable terminals with insulating tape. To prevent short circuit, keep the disconnected terminals and

cables insulated from components of the power system and the PCB.

4. Remove the fixing screws of the PCB and replace the PCB. Note that the screwdriver should be prevented from

touching the bare parts of the signal cables to prevent short circuit.

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5. Connect the signal cables in reverse sequence, that is, reconnect signal cables other than J8, J10 terminal cables and DI/DO cables.

6. Check the cable connections. If the connections are correct, reconnect J8 terminal. If the watchdog indicator flashes and power indicator is on, the PCB works normally.

7. Check the voltages of J10 terminal with a multimeter. Make sure that it outputs low voltage. Connect J10 terminal.

8. Set the parameters of the controller according to Chapter 4.7 Setting Parameters.

Replacing the LCD

The procedures for replacing the LCD are described as follows:

1. Unplug J8 and J10 terminals of the PCB.

2. Unplug the terminal tape cable connected the LCD and screen.

3. Replace the LCD. Restore the J3 terminal tape cable connected the LCD and screen. Pay attention not to short the LCD with the power system or the PCB.

4. Check the voltages of J10 terminal with a multimeter. Make sure that it outputs low voltage.

5. Insert the J10 terminal, and the LCD is replaced.

6. Insert the J8 terminal to power on the PCB of the controller.

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Appendix 1 Technical Data

Table 1 Technical data

Parameter