NetSure 801 CA7 Power Supply System (New Skelecton)
User Manual
Version
V1.1
Revision date
BOM
December 21, 2018
31013510
Vertiv Tech provides customers with technical support. Users may contact the nearest Vertiv local sales
office or service center.
Copyright © 2018 by Vertiv Tech Co., Ltd.
All rights reserved. The contents in this document are subject to change without notice.
Vertiv Tech Co., Ltd.
Address: Block B2, Nanshan I Park ,No.1001 Xueyuan Road, Nanshan District, Shenzhen, 518055, PR
China
Homepage: www.vertivco.com
E-mail: overseas.support@vertivco.com
Safety Precautions
To prevent unexpected problems, please read the operation instructions and safety precautions very carefully
before installation operation. The “Caution, Notice, Warning, Danger” in this manual do not represent all of the
safety points that should be observed, and are only used as supplementary to the operation safety. Therefore,
the personnel responsible for the installation and operation of Vertiv products must be strictly trained to master
the correct operations and all the safety points before actual operation.
When working on Vertiv products, relevant industry safety rules and special safety instructions provided by Vertiv
must be observed.
Electrical Safety
High voltage
Danger
Danger
High voltage power supply provides power for equipment operation, any direct contact or indirect contact through moist
objects with high voltage or AC mains will result in fatal injury.
Relevant industry safety regulations must be observed during the installation of AC power supply
equipment. The people who do the AC standard installation must be licensed to operate high voltage and
AC power.
During operation, metal objects such as watches, bracelets, bangles, rings, etc. must be removed.
In case water or moisture is found on the cabinet, turn off the power immediately. In moist environments,
take strict precautions to prevent water from entering the equipment.
“Prohibit” warning label must be attached to the switches and buttons which are not permitted to be
operated on during installation.
Danger
Danger
Nonstandard or incorrect high voltage operation can present risk of electric shock or burn. The connection and wiring of AC
cables must be in compliance with local rules and regulations. Only those who are licensed to operate high voltage and AC
power can perform high voltage operations.
Expected short-circuit current
Notice
Notice
The short-circuit breaking capacity of the rectifier AC input MCB is 6kA. If the expected short-circuit current of AC input
loop exceeds 6kA, please contact Vertiv technical support.
Dangerous energy
Danger
Warning
The power system contains output exceeds 240VA, when installing into end system care must be taken that the output and
appropriate wire may not be touched.
Multi-power input
Danger
Warning
Prevent electric shock and dangerous energy. Even if the AC input power is cut off, there is still dangerous conductive parts
fed by battery existing.
Power supply cable
Notice
Notice
Make sure the cable and cable labels are in accordance with actual installation before cable connection.
Tools
Warning
Warning
In high voltage and AC operation, special tools must be used. No common or self-carried tools should be used.
Thunderstorm
Danger
Danger
Never perform high voltage, AC, iron tower, or mast operations on a day with thunderstorms about.
In thunderstorms, strong electromagnetic field will be generated in the air. Therefore the equipment should be solidly
earthed in time to avoid damage by lightning strikes.
Static
Notice
Notice
The static electricity generated by the human body will damage the static sensitive elements on circuit board, such as
large-scale ICs, etc. Before touching any plug-in board, circuit board and IC chip, ESD wrist strap must be worn to prevent
body static from damaging the sensitive elements. The other end of the antistatic wrist strap must be solidly earthed.
Short circuit
Danger
Danger
During operation, never short-circuit the positive and negative poles of the DC distribution unit of the system or the
non-earthing pole and the earth. The power supply equipment is a constant voltage DC power supply. Short circuit will
result in equipment burning and endanger human safety.
Check carefully the polarity of the cable and connection terminals when performing live DC operations.
As the operation space in the DC distribution unit is very tight, please carefully select the operation space.
Never wear a watch, bracelet, bangle, ring, or other conductive objects in operation.
Insulated tools must be used.
In live operations, keep the arm muscle in tense state so that when tool connection is loosened, the free
journey between the human body and tool is reduced to the minimum.
Battery
Danger
Danger
Before working on the battery, read very carefully the safety precautions for battery transportation and the correct battery
connection method.
Non-standard operation on the battery will result in danger. In operation, pay close attention to prevent battery
short circuit and spill of the electrolyte. The spill of the electrolyte will pose potential threat to the equipment and
erode the metal objects and circuit board, thus causing damage to the equipment and short circuit of the circuit
board.
For safety reasons, before working on the battery, pay attention to the following points:
Remove the watch, bracelet, bangle, ring, and other metal objects.
Use insulated tools.
Wear eye protection and take preventive measures.
Wear rubber gloves and apron to guard against spilt electrolyte.
In battery transportation, the electrode of the battery should always be kept facing upward. Never put the
battery upside down or slanted.
After battery installation, check carefully that the battery cable polarity is correct and the connections are solid.
After battery connections are made and before the system is switched on, the battery fuse must be in open state
in case the battery is damaged due to overdischarge in this period.
Others
Taking out rectifier
Notice
Warning
When taking out the rectifier, you should replace with a new one or install a dummy plate immediately.
Hoisting heavy objects
Notice
Warning
Never walk under the crane arm or the hoisted objects when hoisting heavy objects.
Sharp corners of the objects
Notice
Warning
When moving equipment by hands, wear protective gloves to avoid injury by sharp objects.
Inserting and extracting boards
Notice
Notice
Do not use too much force in inserting single boards to prevent the contact pins on the motherboard to be twisted. Insert the
boards along the slots to avoid short circuit resulting from the contact of circuit boards. Never touch the connectors of the
boards when holding the boards.
Binding signal lines
Notice
Notice
Signal lines should be bound separately from heavy current and high voltage lines, with binding interval no less than
150mm.
Contents
Chapter 1 Introduction ................................................................................................................................................. 1
1.1 Model Information .......................................................................................................................................... 1
1.2 Overview ....................................................................................................................................................... 2
1.3 Components .................................................................................................................................................. 4
1.3.1 Rectifier .............................................................................................................................................. 4
1.3.2 Controller ............................................................................................................................................ 5
1.3.3 AC Distribution Cabinet ....................................................................................................................... 6
1.3.4 DC Distribution Cabinet ......................................................................................................................10
1.3.5 Rectifier Cabinet ................................................................................................................................15
Chapter 2 Installation Preparation ...............................................................................................................................18
2.1 Installation Requirements ..............................................................................................................................18
2.1.1 Environmental Requirements ..............................................................................................................18
2.1.2 Layout Requirements Of The Equipment Room ...................................................................................18
2.1.3 Power Supply .....................................................................................................................................20
2.1.4 Safety Protection ................................................................................................................................20
2.1.5 Equipment Running Environment Checklist .........................................................................................21
2.2 Storage Conditions .......................................................................................................................................22
2.3 Installation Preparation..................................................................................................................................22
2.3.1 Field Check ........................................................................................................................................22
2.3.2 Tools And Materials Preparation .........................................................................................................22
2.4 Unpacking Inspection ....................................................................................................................................24
Chapter 3 Installation ..................................................................................................................................................26
3.1 Installing Cabinet ..........................................................................................................................................26
3.1.1 Installation On The Floor ....................................................................................................................26
3.1.2 Installation On Supporting Rack ..........................................................................................................27
3.1.3 Parallel Connection Between Cabinets ...............................................................................................28
3.1.4 Parallel Connection With Copper Bars ................................................................................................29
3.1.5 Installation Of System Above 2000A ...................................................................................................30
3.1.6 Mounting Large Side Door And Small Side Door .................................................................................30
3.1.7 Placing DC Cabinet Separate From System ........................................................................................31
3.2 Connecting Power Cables .............................................................................................................................31
3.2.1 Connecting Earth Cable .....................................................................................................................32
3.2.2 Connecting Cables Between Rectifier Cabinet And AC Distribution Cabinet .........................................33
3.2.3 Connecting AC Input Cables ...............................................................................................................35
3.2.4 Connecting Emergency Lighting Cables (Optional) ..............................................................................36
3.2.5 Connecting DC Load Cables ..............................................................................................................37
3.2.6 Connecting Battery Cables .................................................................................................................39
3.3 Installation Checklist .....................................................................................................................................40
3.4 Installing Rectifier And Controller ...................................................................................................................40
3.4.1 Installing Rectifier ...............................................................................................................................40
3.4.2 Installing Controller ............................................................................................................................41
3.4.3 The Installation And Wiring Of The Controller IB2 Extension Board ......................................................42
3.5 Connecting Communication Cables And Auxiliary Power Cable ......................................................................44
3.5.1 Connecting Rectifier Cabinet Communication Cable ............................................................................44
3.5.2 Connecting Communication Cable Of Distribution Cabinet ...................................................................46
3.6 Installing Options ..........................................................................................................................................48
Chapter 4 Testing .......................................................................................................................................................50
4.1 Notes On Testing ..........................................................................................................................................50
4.2 Power-on ......................................................................................................................................................50
4.3 Setting Basic Parameters ..............................................................................................................................51
4.3.1 Setting DIP Switch .............................................................................................................................51
4.3.2 Setting Basic Parameters For Controller .............................................................................................53
4.4 Checking Alarm And Operation Status ...........................................................................................................56
4.4.1 Testing Controller ...............................................................................................................................56
4.4.2 Testing DC Distribution .......................................................................................................................57
4.4.3 Access Controller Through Web .........................................................................................................58
Chapter 5 Operation ...................................................................................................................................................63
5.1 Power Distribution LCD Operation .................................................................................................................63
5.2 Setting The Position Number Of The Rectifier Manually .................................................................................69
5.3 Adding Load .................................................................................................................................................71
5.4 Adding Rectifier ............................................................................................................................................71
Chapter 6 Maintenance ...............................................................................................................................................73
6.1 Maintenance Requirements ...........................................................................................................................73
6.1.1 General..............................................................................................................................................73
6.1.2 Maintenance Tools And Equipments ...................................................................................................73
6.1.3 Reference Technical Specification For Maintenance ............................................................................74
6.2 Routine Maintenance Items ...........................................................................................................................75
6.3 Routine Maintenance ....................................................................................................................................77
6.4 Basic Inspection............................................................................................................................................77
6.4.1 Handling Controller Fault ....................................................................................................................77
6.4.2 Handling Rectifier Fault ......................................................................................................................78
6.5 Replacing Rectifier ........................................................................................................................................79
6.6 Emergency Treatment ...................................................................................................................................80
Appendix 1 Technical Parameter .................................................................................................................................82
Appendix 2 Alarm List .................................................................................................................................................87
Appendix 3 Terminologies ...........................................................................................................................................91
Appendix 4 Engineering Design Diagram.....................................................................................................................93
Appendix 5 Spare Part List........................................................................................................................................ 108
Appendix 6 Wiring Diagram ....................................................................................................................................... 109
Chapter 1 Introduction 1
NetSure 801 Series Power Supply System User Manual
Chapter 1 Introduction
The NetSure 801 CA7 series power supply system (power supply system for short) is a new generation of telecom
power supply with exceptional reliability and performance. It is designed by Vertiv incorporating years of experience in
development and equipment operation on power network.
This chapter introduces the model information, overview and components.
1.1 Model Information
Take NetSure 801 CA7 power supply system for example, the model information of the NetSure 801 series power
supply system is shown in Figure 1-1.
NetSure 801 C A
The number of the rectifier in the typical power supply system. If the number
ranges between 0 ~ 9, the character is represented by a number. If the number
is larger than 9, the character is represented by a letter, for example, A represents
the number 10, B represents the number 11, and so on. A: 10.
Region. C: China.
Output power of the rectifier. The output power of R48-5800: 5800W.
Brand name of the power supply system.
7
Version number
Figure 1-1 Model information
2 Chapter 1 Introduction
NetSure 801 Series Power Supply System User Manual
1.2 Overview
The power supply system is composed of AC distribution cabinet, DC distribution cabinet, AC/DC integrated
distribution cabinet, rectifier cabinet, controller, rectifier and options.
The number of AC distribution cabinet, DC distribution cabinet, AC/DC integrated distribution cabinet and rectifier
cabinet can be configured according to customer requirement. The capacity of the system can be expanded to 6000A
at most. The system composed of one AC distribution cabinet, one DC distribution cabinet and one rectifier cabinet is
shown in Figure 1-2.
DC distribution cabinet
AC distribution cabinet
Rectifier cabinet
ControllerRectifier
Figure 1-2 Three-cabinet system structure
The technical parameter of the rectifier cabinet is given in Table 1-1.
Table 1-1 Technical parameter of rectifier cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
AC input
Input system
3- phase 4-wire and 3- phase 5-wire
Iined voltage
380Vac
Voltage range
260Vac ~ 530Vac (errors: 5Vac)
Frequency
45Hz ~ 65Hz
Max. current
≤ 130A (304V input)
Power factor
≥ 0.98
DC output
Voltage range
53.5Vdc
Nominal voltage
48Vdc
Output DC voltage
42Vac ~ 57.6Vac
Max. current
Rack1000-7: 1000A
Rack2000-7: 2000A
Voltage stabilizing precision
≤ 1%
Efficiency
≥ 90%
Chapter 1 Introduction 3
NetSure 801 Series Power Supply System User Manual
Parameter
Description
Mechanical
Dimensions
mm (H × W
× D)
Recitifier cabinet
2000mm × 600mm × 600mm
Controller(M831D)
42mm × 86.60mm × 211.5mm
Recitifier (R48-5800A、
R48-5800e)
88mm × 244mm × 372mm
Weight (kg)
Recitifier cabinet (not include
the rectifier)
Rack1000-7 ≤ 140；Rack2000-7 ≤ 180
Controller(M831D)
≤ 2
Recitifier (R48-5800A、
R48-5800e)
≤ 8
The technical parameter of the AC distribution cabinet is given in Table 1-2.
Table 1-2 Technical parameter of AC distribution cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C ;
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
AC input
Input system
TN-C, TN-S, TN-C-S, TT, 3- phase 4-wire and 3- phase 5-wire network
forms
Rated line voltage
380Vac
Voltage range
260Vac ~ 530Vac (errors: 5Vac)
Frequency
45Hz ~ 65Hz
45Hz ~ 55Hz (Configuring PD380/630AFA-7-Y1)
AC output
Distribution parameter
PD380/400AFH-7-Y2:
6 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 400A:
160A/3P × 4, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7-Y3:
8 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 630A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
PD380/630AFH-7/YF: Configured according to customer requirement (IF
the input switch using MCB, shall not exceed the total capacity of the
Cabinet input of MCB 80%)
AC output
Distribution parameter
PD380/630AFA-7/Y4:
8 route 3- phase input, 6 route single phase output，Output total capacity
does not exceed 600A:
160A/3P × 6, 63A/3P × 1, 32A/3P × 1, 32A/1P × 3, 20A/1P × 3
Mechanical
Dimensions mm (W × D × H)
2000mm × 800mm × 600mm
Weight (kg)
PD380/400AFH-7-Y2, PD380/630AFH-7-Y3 ≤ 240,
PD380/630AFA-7-Y4 ≤ 250, PD380/630AFH-7/YF ≤ 270
The technical parameter of the DC distribution cabinet is given in Table 1-3.
Table 1-3 Technical parameter of DC distribution cabinet
Parameter
Description
Environmental
Operating temperature
-5°C ~ 40°C ;
Storage temperature
-45°C ~ 70°C
Relative humidity
5%RH ~ 95%RH
Altitude
≤ 2,000m (derating is necessary above 2,000m)
Others
No conductive dust or erosive gases. No possibility of explosion
DC input
Rated voltage
48Vac
Voltage range
42Vac ~ 57.6Vac (errors: 0.3Vac)
Rated input current
PD48/1600DF-7-Y3: 1600A; PD48/1600DF-7-Y4: 1600A;
PD48/2500DF-7-Y3: 2500A; PD48/2500DF-7-Y4: 2500A
DC output
Load current
PD48/1600DF-7-Y3: ≤ 1200A; PD48/1600DF-7-Y4: ≤ 1200A;
PD48/2500DF-7-Y3: ≤ 2000A; PD48/2500DF-7-Y4: ≤ 2000A
4 Chapter 1 Introduction
NetSure 801 Series Power Supply System User Manual
Parameter
Description
DC output
Battery charging current
PD48/1600DF-7-Y3: ≤ 400A; PD48/1600DF-7-Y4: ≤ 400A;
PD48/2500DF-7-Y3: ≤ 500A; PD48/2500DF-7-Y4: ≤ 500A
Distribution parameter
PD48/1600DF-7-Y3, 22 routes load output:
500A (NT3) × 6, 200A (NT2) × 2, 100A (NT00) × 8, 63A (NT00) × 6
PD48/1600DF-7-Y4, 24 routes load output:
400A (NT3) × 12, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 6
PD48/2500DF-7-Y3，30 routes load output:
630A (NT3) × 8, 400A (NT2) × 4, 200A (NT2) × 4, 100A (NT00) × 8, 63A
(NT00）× 6
PD48/2500DF-7-Y4，26 routes load output:
500A (NT3) × 16, 200A (NT2) × 4, 100A (NT00) × 2, 63A (NT00) × 4
DC output
Distribution parameter
PD48/1600DF-7/YF: Configured according to customer requirement
PD48/2500DF-7/YF: Configured according to customer requirement
Mechanical
Dimensions mm (W × D × H)
2000mm × 800mm × 600mm
Weight (kg)
PD48/1600DF-7-Y3 ≤ 280; PD48/1600DF-7-Y4 ≤ 280;
PD48/2500DF-7-Y3 ≤ 290; PD48/2500DF-7-Y4 ≤ 290;
PD48/2500DF-7/YF, PD48/1600DF-7/YF ≤ 290
1.3 Components
1.3.1 Rectifier
The system uses rectifier R48-5800A, the frame structure of which mainly consists of panel, enclosure, handle, and
so on, as shown in Figure 1-3.
Figure 1-3 Rectifier appearance
Chapter 1 Introduction 5
NetSure 801 Series Power Supply System User Manual
There are LEDs, slide switch and handle on the front panel, and AC input socket, DC output socket and
communication port on the rear panel. The front panel is shown in Figure 1-4, and functions of indicators are given in
Table 1-4.
Slide switch
Handle
Fixing screw
Power indicator
Protection indicator
Fault indicator
Current indicators
Figure 1-4 Rectifier front panel
Table 1-4 Function of indicators
Indicator
Normal state
Fault state
Fault cause
Power indicator
(Green)
On
Off
No input and output
Flashing
The rectifier is being operated through the host
Protection indicator
(Yellow)
Off
On
AC input under/overvoltage,
rectifier PFC output under/overvoltage, high-temperature, or current sharing
imbalance
Flashing
Rectifier communication failure
Fault indicator
(Red)
Off
On
Output overvoltage, output fuse blown, or rectifier addresses contradictory
Flashing
Faulty fan
Current indicators
on
Shows the output current, each LED represents 10A. If the rectifier is in
current limiting state (output current > 100A), the tenth LED will blink. If the
output current of the rectifier is smaller than 2A, no current indicator will be
on
1.3.2 Controller
The controller specific content see the M831D Controller User Manual.
6 Chapter 1 Introduction
NetSure 801 Series Power Supply System User Manual
1.3.3 AC Distribution Cabinet
The AC distribution cabinet is available in four models: PD380/400AFH-7-Y2, PD380/630AFH-7-Y3,
PD380/630AFA-7-Y4 and PD380/630AFH-7/YF. The appearances of the AC distribution cabinets are the same, as
shown in Figure 1-5.
AC mains indicator
Failure indicator
Power distribution
LCD
Figure 1-5 Appearance of AC distribution cabinet
The internal structure of AC distribution cabinet PD380/400AFH-7-Y2 is shown in Figure 1-6.
Knife-blade switch
Class C SPD
SPD MCB
AC output MCB
Buzzer
Buzzer control switch
Monitoring board
Signal transfer board
AC sampling board
(a) Front view (door open)
Chapter 1 Introduction 7
NetSure 801 Series Power Supply System User Manual
Earth busbar
Neutral busbar
Cover plate
(b) Rear view (door open)
Figure 1-6 PD380/400AFH-7-Y2 AC distribution cabinet
The internal structure of AC distribution cabinet PD380/630AFH-7-Y3 is shown in Figure 1-7.
Class C SPD
SPD MCB
Buzzer
Buzzer control switch
Monitoring board
Signal transfer board
AC sampling board
AC output MCB
Knife-blade switch
(a) Front view (door open)
8 Chapter 1 Introduction
NetSure 801 Series Power Supply System User Manual
Earth busbar
Neutral busbar
Cover plate
(b) Rear view (door open)
Figure 1-7 PD380/630AFH-7-Y3 AC distribution cabinet
ATS controller
ATS
Monitoring board
AC sampling board
AC output MCB
(a) Front view (door open)
Chapter 1 Introduction 9
NetSure 801 Series Power Supply System User Manual
Neutral busbar
Earth busbar
SPD MCB
SPD
(b) Rear view (door open)
Figure 1-8 PD380/630AFA-7-Y4 AC distribution cabinet
The structure and configuration of PD380/630AFH-7/YF is determined by customer requirement. See purchase order
for description.
10 Chapter 1 Introduction
NetSure 801 Series Power Supply System User Manual
1.3.4 DC Distribution Cabinet
The DC distribution cabinet is available in six models: PD48/1600DF-7-Y3, PD48/1600DF-7-Y4, PD48/1600DF-7/YF,
PD48/2500DF-7-Y3, PD48/2500DF-7-Y4 and PD48/2500DF-7/YF. The appearances of the DC distribution cabinets
are the same, as shown in Figure 1-9.
Power indicator
Failure indicator
Power distribution
LCD
Figure 1-9 Appearance of DC distribution cabinet
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