Vertiv NetSure 801 CA7 User manual

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.

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

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

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

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

Make sure the cable and cable labels are in accordance with actual installation before cable connection.

Tools

Warning

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

Thunderstorm

Danger

Never perform high voltage, AC, iron tower, or mast operations on a day with thunderstorms about.

In thunderstorms, strong electromagnetic field will be generated in the air. Therefore the equipment should be solidly

earthed in time to avoid damage by lightning strikes.

Static

Notice

The static electricity generated by the human body will damage the static sensitive elements on circuit board, such as

large-scale ICs, etc. Before touching any plug-in board, circuit board and IC chip, ESD wrist strap must be worn to prevent

body static from damaging the sensitive elements. The other end of the antistatic wrist strap must be solidly earthed.

Short circuit

Danger

During operation, never short-circuit the positive and negative poles of the DC distribution unit of the system or the

non-earthing pole and the earth. The power supply equipment is a constant voltage DC power supply. Short circuit will

result in equipment burning and endanger human safety.

Check carefully the polarity of the cable and connection terminals when performing live DC operations.

As the operation space in the DC distribution unit is very tight, please carefully select the operation space.

Never wear a watch, bracelet, bangle, ring, or other conductive objects in operation.

Insulated tools must be used.

In live operations, keep the arm muscle in tense state so that when tool connection is loosened, the free

journey between the human body and tool is reduced to the minimum.

Battery

Danger

Before 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

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

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 Model Information .......................................................................................................................................... 1 
2 Overview ....................................................................................................................................................... 2 
3 Components .................................................................................................................................................. 4 
3.1 Rectifier .............................................................................................................................................. 4 
3.2 Controller ............................................................................................................................................ 5 
3.3 AC Distribution Cabinet ....................................................................................................................... 6 
3.4 DC Distribution Cabinet ......................................................................................................................10 
3.5 Rectifier Cabinet ................................................................................................................................15 
Chapter 2 Installation Preparation ...............................................................................................................................18 
1 Installation Requirements ..............................................................................................................................18 
1.1 Environmental Requirements ..............................................................................................................18 
1.2 Layout Requirements Of The Equipment Room ...................................................................................18 
1.3 Power Supply .....................................................................................................................................20 
1.4 Safety Protection ................................................................................................................................20 
1.5 Equipment Running Environment Checklist .........................................................................................21 
2 Storage Conditions .......................................................................................................................................22 
3 Installation Preparation..................................................................................................................................22 
3.1 Field Check ........................................................................................................................................22 
3.2 Tools And Materials Preparation .........................................................................................................22 
4 Unpacking Inspection ....................................................................................................................................24 
Chapter 3 Installation ..................................................................................................................................................26 
1 Installing Cabinet ..........................................................................................................................................26 
1.1 Installation On The Floor ....................................................................................................................26 
1.2 Installation On Supporting Rack ..........................................................................................................27 
1.3 Parallel Connection Between Cabinets ...............................................................................................28 
1.4 Parallel Connection With Copper Bars ................................................................................................29 
1.5 Installation Of System Above 2000A ...................................................................................................30 
1.6 Mounting Large Side Door And Small Side Door .................................................................................30 
1.7 Placing DC Cabinet Separate From System ........................................................................................31 
2 Connecting Power Cables .............................................................................................................................31 
2.1 Connecting Earth Cable .....................................................................................................................32 
2.2 Connecting Cables Between Rectifier Cabinet And AC Distribution Cabinet .........................................33 
2.3 Connecting AC Input Cables ...............................................................................................................35 
2.4 Connecting Emergency Lighting Cables (Optional) ..............................................................................36 
2.5 Connecting DC Load Cables ..............................................................................................................37 
2.6 Connecting Battery Cables .................................................................................................................39 

3 Installation Checklist .....................................................................................................................................40 
4 Installing Rectifier And Controller ...................................................................................................................40 
4.1 Installing Rectifier ...............................................................................................................................40 
4.2 Installing Controller ............................................................................................................................41 
4.3 The Installation And Wiring Of The Controller IB2 Extension Board ......................................................42 
5 Connecting Communication Cables And Auxiliary Power Cable ......................................................................44 
5.1 Connecting Rectifier Cabinet Communication Cable ............................................................................44 
5.2 Connecting Communication Cable Of Distribution Cabinet ...................................................................46 
6 Installing Options ..........................................................................................................................................48 
Chapter 4 Testing .......................................................................................................................................................50 
1 Notes On Testing ..........................................................................................................................................50 
2 Power-on ......................................................................................................................................................50 
3 Setting Basic Parameters ..............................................................................................................................51 
3.1 Setting DIP Switch .............................................................................................................................51 
3.2 Setting Basic Parameters For Controller .............................................................................................53 
4 Checking Alarm And Operation Status ...........................................................................................................56 
4.1 Testing Controller ...............................................................................................................................56 
4.2 Testing DC Distribution .......................................................................................................................57 
4.3 Access Controller Through Web .........................................................................................................58 
Chapter 5 Operation ...................................................................................................................................................63 
1 Power Distribution LCD Operation .................................................................................................................63 
2 Setting The Position Number Of The Rectifier Manually .................................................................................69 
3 Adding Load .................................................................................................................................................71 
4 Adding Rectifier ............................................................................................................................................71 
Chapter 6 Maintenance ...............................................................................................................................................73 
1 Maintenance Requirements ...........................................................................................................................73 
1.1 General..............................................................................................................................................73 
1.2 Maintenance Tools And Equipments ...................................................................................................73 
1.3 Reference Technical Specification For Maintenance ............................................................................74 
2 Routine Maintenance Items ...........................................................................................................................75 
3 Routine Maintenance ....................................................................................................................................77 
4 Basic Inspection............................................................................................................................................77 
4.1 Handling Controller Fault ....................................................................................................................77 
4.2 Handling Rectifier Fault ......................................................................................................................78 
5 Replacing Rectifier ........................................................................................................................................79 
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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Vertiv NetSure 801 CA7 User manual

Vertiv NetSure 801 CA7 User manual

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