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NetSure™ 2100 Series
-48 VDC Power System
User Manual (UM582138000), Revision A
Specification Number: 582138000
Model Number: 2100
The information contained in this document is subject to change without notice and may not be suitable for all applications. While every precaution has been taken to ensure the accuracy and completeness of this document, Vertiv Group Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct methods, tools, and materials to be used in performing procedures not specifically described in this document.
This document may contain confidential and/or proprietary information of
Vertiv Group Corporation, and its receipt or possession does not convey any right to reproduce, disclose its contents, or to manufacture or sell anything that it may describe. Reproduction, disclosure, or use without specific authorization from Vertiv Group Corporation is strictly prohibited.
Vertiv and the Vertiv logo are trademarks or registered trademarks of
Vertiv Co. All other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners.
© 2019 Vertiv Co. All rights reserved.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 2
TABLE OF CONTENTS
Admonishments Used in this Document ............................................................ 5
Handling Equipment Containing Static Sensitive Components............................. 8
Checking the Controller’s Current Limit Point after Adding or
Clearing a Rectifier Communications Fail Alarm after Removing a
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 3
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 4
ADMONISHMENTS USED IN THIS DOCUMENT
DANGER! Warns of a hazard the reader will be exposed to that will likely result in death or serious injury if not avoided. (ANSI, OSHA)
WARNING! Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided. This admonition is not used for situations that pose a risk only to equipment, software, data, or service. (ANSI)
CAUTION! Warns of a potential hazard the reader may be exposed to that could result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not used for situations that pose a risk only to equipment, data, or service, even if such use appears to be permitted in some of the applicable standards. (OSHA)
ALERT! Alerts the reader to an action that must be avoided in order to protect equipment, software, data, or service. (ISO)
ALERT! Alerts the reader to an action that must be performed in order to prevent equipment damage, software corruption, data loss, or service interruption. (ISO)
FIRE SAFETY! Informs the reader of fire safety information, reminders, precautions, or policies, or of the locations of fire-fighting and fire-safety equipment. (ISO)
SAFETY! Informs the reader of general safety information, reminders, precautions, or policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 5
IMPORTANT SAFETY INSTRUCTIONS
Safety Admonishments Definitions
General Safety
DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These procedures should be performed by qualified technicians familiar with the hazards associated with this type of equipment.
These hazards may include shock, energy, and/or burns. To avoid these hazards: a) The tasks should be performed in the order indicated. b) Remove watches, rings, and other metal objects. c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to making contact. d) Wear eye protection. e) Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for the work to be performed.
Voltages
AC Input Voltages
DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. AC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any AC electrical connections are made. Follow local lockout/tagout procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply AC input power to the system until all electrical connections have been completed and checked.
DC Output and Battery Voltages
DANGER! This system produces DC power and may have a battery source connected to it. Although the DC voltage is not hazardously high, the rectifiers and/or battery can deliver large amounts of current.
Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output terminal or battery terminal or exposed wire connected to an output terminal or battery terminal.
NEVER allow a metal object, such as a tool, to contact more than one termination or battery terminal at a time, or to simultaneously contact a termination or battery terminal and a grounded object. Even a momentary short circuit can cause sparking, explosion, and injury.
DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices remain de-energized during installation at loads, as required.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 6
Battery
Refer to the battery manufacturer documentation for specific battery safety instructions. The following are general guidelines.
WARNING! Correct polarity must be observed when connecting battery leads.
WARNING! Special safety precautions are required for procedures involving handling, installing, and servicing batteries. Observe all battery safety precautions in this manual and in the battery instruction manual. These precautions should be followed implicitly at all times.
WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of batteries should be performed or supervised only by properly trained and qualified personnel knowledgeable about batteries and the required precautions.
The following precautions should be observed when working on batteries:
• Follow the recommended PPE requirements per the SDS for the battery to be used.
• Batteries are an energy source that can produce high amounts of electrical current.
• Remove watches, rings, and other metal objects.
• Eye protection should be worn to prevent injury from accidental electrical arcs.
• Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for the work to be performed. Ensure that wrenches with more than one working end have only one end exposed.
• Do not lay tools or metal parts on top of batteries.
• Verify that no current will flow when the battery is connected or disconnected by opening battery disconnects (if available) or adjusting the system to match battery voltage.
• Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed.
Recommended to replace batteries with the same manufacturer and type, or equivalent.
• Dispose of used batteries according to the instructions provided with the batteries. Do not dispose of batteries in a fire. They may explode.
• Batteries may generate explosive gases during normal operation. Systems containing batteries should never be installed in an airtight room or space. Only install in a ventilated environment.
• Batteries may contain sulfuric acid. If battery acid enters your eye, immediately flush your eye with running cold water for at least 15 minutes. Get medical attention immediately. If battery acid contacts skin or clothing, wash immediately with soap and water.
• Do not open or mutilate batteries.
• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S RECOMMENDATIONS AND SAFETY
INSTRUCTIONS.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 7
ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads, if battery reserve is not sufficient.
Personal Protective Equipment (PPE)
DANGER! ARC FLASH AND SHOCK HAZARD.
Appropriate PPE and tools required when working on this equipment. An appropriate flash protection boundary analysis should be done determine the “hazard/risk” category, and to select proper PPE.
This product is intended only for installation in a Restricted Access Location.
Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain the equipment.
Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work
Permits as required by the local authority, per NFPA 70E “Standard for Electrical Safety in the
Workplace”.
Hazardous Voltage
DANGER! HAZARD OF ELECTRICAL SHOCK.
More than one disconnect may be required to de-energize the system before servicing.
Handling Equipment Containing Static Sensitive Components
ALERT! Installation or removal of equipment containing static sensitive components requires careful handling. Before handling any equipment containing static sensitive components, read and follow the instructions contained on the Static Warning Page.
Maintenance and Replacement Procedures
CAUTION! When performing any step in procedures that requires removal or installation of hardware, use caution to ensure no hardware is dropped and left inside the unit; otherwise service interruption or equipment damage may occur.
NOTE! When performing any step in procedures that requires removal of existing hardware, retain all hardware for use in subsequent steps, unless otherwise directed.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 8
STATIC WARNING
This equipment contains static sensitive components. The warnings listed below must be observed to prevent damage to these components. Disregarding any of these warnings may result in personal injury or damage to the equipment.
1.
Strictly adhere to the procedures provided in this document.
2.
Before touching any equipment containing static sensitive components, discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some wrist straps have a built-in one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s instructions outlining use of a specific wrist strap.
3.
Do not touch traces or components on equipment containing static sensitive components. Handle equipment containing static sensitive components only by the edges that do not have connector pads.
4.
After removing equipment containing static sensitive components, place the equipment only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do not use ordinary Styrofoam ™ or ordinary plastic.
5.
Store and ship equipment containing static sensitive components only in static shielding containers.
6.
If necessary to repair equipment containing static sensitive components, wear an appropriately grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded test equipment.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 9
This Page Intentionally Blank.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 10
CUSTOMER DOCUMENTATION PACKAGE
This document (UM582138000) provides User Instructions for NetSure™ 2100 Series -48 VDC Power System,
Spec. No. 582138000.
The complete Customer Documentation Package consists of…
NetSure™ -48 VDC Power System Installation Manual
• Power System Installation Instructions: IM582138000
NetSure™ Mini Control Unit User Manual
• Mini Control Unit User Instructions: UM1M831ANA
USB Drive with All Customer Documentation
• Power System Installation Instructions: IM582138000
• Power System User Instructions: UM582138000
• Power System “System Application Guide”: SAG582138000
• Mini Control Unit User Instructions: UM1M831ANA
• Rectifier Instructions: UM1R481000e3
• Engineering Drawings
SD582138000
T582138000
• Also provided on the USB drive is a controller configuration drawing and the controller configuration files loaded into the controller as shipped.
For factory settings of all configurable controller parameters, refer to the Configuration Drawing (C-drawing) supplied with your power system.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 11
SYSTEM DESCRIPTION
-48 VDC @ up to 62.5 Amperes Power System
The NetSure™ 2100 Series -48 VDC Power System is an integrated power system containing rectifiers, intelligent control, metering, monitoring, and distribution.
This power system is designed to power a load while charging a positive grounded battery. This power system is capable of operating in a batteryless installation or off battery for maintenance purposes. The power system is designed for operation with the positive output grounded.
The NetSure™ 2100 Series -48 VDC Power System consists of the following components mounted in a 19” or
23” wide relay rack or cabinet rack. Wall mounting options are also available.
NetSure™ Mini Control Unit (Controller)
The controller provides power system control (including optional low voltage battery disconnect [LVBD]), rectifier control (including a charge control function), metering functions, monitoring functions, local/remote alarm functions, and connections for binary inputs and programmable relay outputs via a system interface board. The controller also supports rectifier temperature compensation if the system is equipped with a temperature probe(s). Temperature probe(s) may also be designated to monitor ambient temperature and/or battery temperature. The controller also provides data acquisition, system alarm management, and advanced battery and energy management. The controller contains a front panel display and keypad for local access.
The controller provides an Ethernet port and comes with comprehensive webpages for remote access. The controller has optional SNMP v3 capability for remote system management. Refer to the mini control unit instructions (UM1M831ANA) for more information.
Rectifier Modules
The system contains rectifier modules which provide load power, battery float current, and battery recharge current during normal operating conditions. Refer to the rectifier instructions (UM1R481000e3) for more information.
Distribution Unit
Various distribution unit options are available. See SAG582138000 for descriptions. The distribution unit can be equipped with an optional Low Voltage Battery Disconnect (LVBD) contactor. The various distribution units provide DC distribution through circuit breakers and/or fuses.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 12
OPERATING PROCEDURES
Controller and Rectifier
For operation instructions on these units, refer to the following documents.
• Mini Control Unit Instructions (UM1M831ANA)
NOTE! The controller’s default “User Name” is "admin" and the default “Password” is “640275”.
• Rectifier Instructions (UM1R481000e3)
Controller Battery Charge Current Limit Feature
Functionality: After a failure of the input source (commercial AC) or when some battery cells are permanently damaged, the current to the batteries can be quite extensive. To avoid overheating or further damages to the battery, the controller can be programmed to limit the battery current to a preset level by limiting the charging voltage of the rectifiers. Should the battery current still exceed a higher preset value, an alarm is issued.
The controller limits the current going to the batteries based on the “Battery Current Limit” set point which is a percentage of the battery capacity in C10. For example, 0.1C10 would mean 10% of the battery capacity.
Refer to the mini control unit Instructions (UM1M831ANA) to program this feature. Battery charge current is limited to the value set in the controller, as long as battery voltage is above 47 VDC.
Local Controls and Indicators
Controller and Rectifier
Refer to the controller and rectifier instructions for descriptions of the local controls and indicators located on these units.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 13
MAINTENANCE
System Maintenance Procedures
system operation.
Table 1: Maintenance Procedures to be Performed at 6-Month Intervals
Procedure Referenced In
Check ventilation openings for obstructions such as dust, papers, manuals, etc.
--
Inspect and tighten all installer's connections.
IM582138000
Adding a Rectifier
To increase system current capacity, a rectifier module can easily be added if an empty rectifier module mounting position is available.
Refer to rectifier instructions UM1R481000e3 for a rectifier installation procedure.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 14
TROUBLESHOOTING AND REPAIR
Contact Information
Refer to Section 4154 (provided with your customer documentation) for support contact information.
Controller and Rectifier
For troubleshooting and repair instructions on these units, refer to the following documents.
• Mini Control Unit Instructions (UM1M831ANA)
• Rectifier Instructions (UM1R481000e3)
Controller Configuration
If any controller configuration settings were changed, refer to the mini control unit instructions (UM1M831ANA) and save a copy of the configuration file. This file can be used to restore the controller settings, if required, at a later date.
NOTE! Provided on a USB drive furnished with the system is a controller configuration drawing
(C-drawing) and the controller configuration files loaded into the controller as shipped.
System Troubleshooting Information
General
This system is designed for ease in troubleshooting and repair. The various indicators as described in the controller and rectifier instructions are designed to isolate failure to a specific element. Once the faulty element
Troubleshooting Alarm Conditions on the Controller
The controller displays alarm conditions as listed in the “Resolving Alarms” section of the controller’s user manual. Programmable external alarm relays are also available. Refer to the system installation instructions
(IM582138000) and the controller configuration drawing (C-drawing) supplied with your power system documentation for your alarm relay configurations.
The controller’s Active Alarm and Alarm History submenus allow the user to view alarm details. Refer to the mini control unit instructions (UM1M831ANA) to access these menus.
Checking the Controller’s Current Limit Point after Adding or Removing a Rectifier
If a rectifier module is added; the respective current limit point in amps will automatically increase to maintain the same percentage. For example, if the current limit was set to 100% of combined capacity and a rectifier module is added, the new current limit setpoint will be 100% of the combined capacity including the new rectifier module.
If a rectifier module is removed from the system (and the Rect Comm Fail is cleared), the current limit point will remain unchanged unless the capacity of the remaining rectifiers is not sufficient to maintain this current limit point. If that happens, the current limit point will automatically decrease to the maximum (121% of the remaining rectifiers).
It is recommended that the current limit point be checked whenever a rectifier is added to or removed from the power system.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 15
When setting total rectifier current limit, the set point to each rectifier is the total set point divided by the number of rectifiers. For example, if the system contains three rectifiers and the current limit is set to 30 amps then each rectifier has a current limit set point of 10 amps. If one or more rectifiers are removed or fails it will take several seconds for the individual set points to the remaining rectifiers to be reset. In the example given, if one rectifier is removed the current limit set point will drop to 20 amps (10 amps times two remaining rectifiers) until the controller can send updated set points to the remaining rectifiers. This takes a couple communication cycles (several seconds) after which each rectifier would have a new set point of 15 amps for a total of 30 amps.
The total current limit of the rectifiers should not be set such that the loss of the redundant rectifiers will cause this temporary set point to drop below the actual maximum expected load. If batteries are used on the rectifier output, the batteries should support the load until the current limit set points can be re-established due to loss of a rectifier.
Refer to the mini control unit instructions (UM1M831ANA) for a procedure.
Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier
If a rectifier module is removed from the system, a rectifier communications failure alarm is generated. If the rectifier module will not be replaced, the alarm should be cleared.
Refer to the mini control unit instructions (UM1M831ANA) for a procedure.
Clearing a Rectifier Lost Alarm
If the controller resets while a rectifier communications fail alarm is active, the rectifier communications fail alarm is replaced with a rectifier lost alarm.
Refer to the mini control unit instructions (UM1M831ANA) for a procedure to clear the alarm.
Replacement Information
Replacement Assemblies
When a trouble symptom is localized to a faulty rectifier, controller, or system circuit card; that particular device or circuit card should be replaced in its entirety. No attempt should be made to troubleshoot or repair individual components on any rectifier, controller, or circuit card.
Refer to system application guide SAG582138000 for replacement part numbers.
Replacement Procedures
DANGER!
Adhere to the “Important Safety Instructions” starting on page 6.
Replacing a Rectifier
Troubleshooting Information” on page 15.
The rectifier being replaced is assigned by the mini control unit the lowest available identification number. If desired, you can change the identification number, see “Configuring the Mini Control Unit Identification of
Rectifiers” in the separate power system installation manual (IM582138000).
Replacing the Mini Control Unit
Refer to the mini control unit instructions (UM1M831ANA) for a controller replacement procedure.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 16
Replacing a GMT Distribution Fuse
Replace distribution devices with the same type and rating. Refer to system application guide SAG582138000 for part numbers.
Procedure
1.
Refer to Figure 1 or Figure 2 and replace the fuse. Ensure a safety fuse cover is installed on the
replacement fuse, as shown in Figure 3 .
2.
Verify no alarms are active.
Figure 1: GMT Distribution Fuse Replacement (List AA)
Front
GMT Fuse
Safety Cover
Figure 2: GMT Distribution Fuse Replacement (List CA)
Front
GMT Fuse
Safety Cover
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 17
Figure 3: Installation of Safety Fuse Covers
Safety Cover
P/N 248898700
(GMT-X)
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 18
Replacing a Bullet Nose Circuit Breaker
Replace distribution devices with the same type and rating. Refer to system application guide SAG582138000 for part numbers.
Procedure
1.
Operate the defective circuit breaker to the OFF position.
2.
Remove the cover from the circuit breaker mounting positions.
3.
Gently rock the defective circuit breaker back and forth while pulling firmly outward until the breaker is free from the distribution unit.
4.
Ensure that the replacement circuit breaker is in the OFF position, and is of the correct rating.
5.
circuit breaker into their corresponding sockets on the distribution unit. Ensure the alarm contact on the back of the circuit breaker makes contact with the alarm terminal on the distribution unit. Push distribution device in firmly until fully seated in the distribution unit.
6.
Replace the cover over the circuit breaker mounting positions and tighten the captive fastener.
7.
Operate the replacement circuit breaker to the ON position.
8.
Verify no alarms are active.
Figure 4: Replacing a Bullet Nose Circuit Breaker (List CA)
Front
Insert these terminals into corresponding sockets on distribution unit.
Shorter Side of Breaker
Longer Side of Breaker
Shorter Side of Breaker
Insert these terminals into corresponding sockets on distribution unit.
Load Disconnect Circuit Breakers
OFF Position Towards Center
Vertiv |
Components removed in illustration for clarity only.
Turn circuit breaker off before installing.
NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 19
Replacing the External IB4 Assembly (if furnished)
DANGER!
Adhere to the “Important Safety Instructions” starting on page 6.
WARNING!
Circuit cards used in this power system contain static-sensitive devices. Read the “Static
Warning” on page 9 before performing any of the following procedures.
The external IB4 assembly can be replaced with the system operating.
Procedure
1.
Performing this procedure may activate external alarms. Do one of the following. If possible, disable these alarms. If these alarms cannot be easily disabled, notify the appropriate personnel to disregard any future alarms associated with this system while the procedure is being performed.
WARNING! Damage to the circuit card may result if the next step is not followed.
2.
Connect an approved grounding strap to your wrist. Attach the other end to a suitable ground.
3.
Loosen the captive fastener securing the latch mechanism to the front of the mini control unit. Pull the latch mechanism away from the mini control unit (this will retract the latch mechanism located on the bottom of the mini control unit). This unlocks the mini control unit from the shelf. Slide the mini control unit partially out from the shelf.
4.
Carefully label the connectors plugged into the assembly. These connectors must be plugged into the same connectors on the replacement assembly.
5.
Unplug all connectors plugged into the assembly.
6.
Replace the defective assembly with the new assembly.
7.
Plug all connectors removed from the old assembly into the same position on the replacement assembly.
8.
Slide the mini control unit completely into its mounting position. Push the latch mechanism into the front panel of the mini control unit, and secure by tightening the captive fastener. This locks the mini control unit securely to the shelf.
9.
Remove the grounding wrist strap.
10.
To verify that the IB4 board is functioning, verify the mini control unit IP address is 192.168.100.100 as follows. From the Main Screen on the mini control unit local display, press the ESC button, then the ENT key repeatedly until the IP address is displayed. Verify the displayed IP address is 192.168.100.100.
11.
Enable the external alarms, or notify appropriate personnel that this procedure is finished.
12.
Ensure that there are no local or remote alarms active on the system.
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 20
Figure 5: External IB4 Assembly
External IB4
Assembly
USB-A Port
(not used)
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Customer connected to power shelf via supplied cable.)
Top Cover
Removed
USB-A Port
(not used)
10M Ethernet
Port (RJ-45)
LAN Connection
USB-B Port
(Customer connected to power shelf.)
Vertiv | NetSure™ 2100 Series -48 VDC Power System User Manual (UM582138000) | Rev. A 21
VertivCo.com |
Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA
UM582138000 (RA 04/19)
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