Vertiv NetSure 801 CAA User Manual

NetSure 801 CAA Series Power Supply System

Instruction Manual

Version: V1.0

Revision date: August 16, 2018

BOM: 31013828

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 Group Corporation. NetPerform™,

NetReach™, NetSure™ and NetXtend™ are trademarks of Vertiv

Energy Systems, Inc. All other trademarks are the property of their respective owners.

© 2018 Vertiv Energy Systems, Inc. All rights reserved.

Vertiv | NetSure 801 CAA Series Power Supply System Instruction Manual 2

TABLE OF CONTENTS

Safety Precautions .................................................................................. 5

Electrical Safety .................................................................................. 5

Battery ................................................................................................ 6

Others ................................................................................................. 7

OVERVIEW ............................................................................................... 8

Model Information ............................................................................. 8

Overview ............................................................................................ 8

Components ....................................................................................... 9

Rectifier ................................................................................................... 9

Controller .............................................................................................. 11

AC Distribution Cabinet ......................................................................... 11

DC Distribution Cabinet ........................................................................ 16

Rectifier Cabinet .................................................................................... 24

installation preparation ........................................................................ 29

Installation Requirements ................................................................ 29

Environmental Requirements ............................................................... 29

Layout Requirements of The Equipment Room .................................... 29

Power Supply ........................................................................................ 32

Safety Protection................................................................................... 33

Equipment Running Environment Checklist ......................................... 34

Storage Conditions ........................................................................... 36

Installation Preparation ................................................................... 36

Unpacking Inspection ....................................................................... 40

Installation ............................................................................................ 42

Cabinet Installation .......................................................................... 42

Cabinet Placement ................................................................................ 42

Mounting Large Side Door And Small Side Door .................................. 43

Installation on The Floor ....................................................................... 43

Installation on Supporting Rack ............................................................ 45

Parallel Connection Between Cabinets ................................................. 46

Parallel Connection with Copper Bars .................................................. 46

Connecting Power Cables................................................................. 49

Connecting Earth Cable ......................................................................... 50

Connecting Cables Between Rectifier Cabinet and AC

Distribution Cabinet .............................................................................. 52

Connecting AC Input Cables .................................................................. 55

Connecting DC Emergency Lighting Cables (Optional) ......................... 57

Connecting DC Load Cables ................................................................... 58

Connecting Battery Cables .................................................................... 59

Installation Checklist ........................................................................ 60

Installing Rectifier and Controller .................................................... 61

Installing Rectifier ................................................................................. 61

Installing Controller ............................................................................... 62

The Installation and Wiring of The Controller IB2 Extension

Board ..................................................................................................... 63


Connecting Communication Cables and Auxiliary Power

Cable ................................................................................................. 66

Connecting Rectifier Cabinet Communication Cable ............................ 66

Connecting SPD Signal Parallel Connection Cable of Rectifier

Cabinet .................................................................................................. 68

Connecting Communication Cable of Distribution Cabinet .................. 69

Installing Options ............................................................................. 71

Installing Temperature Sensor .............................................................. 71

Testing ................................................................................................... 73

Note on Testing ................................................................................ 73

Power-on .......................................................................................... 73

Setting Basic Parameters ................................................................. 75

Setting DIP Switch ................................................................................. 75

Setting Basic Parameters for Controller................................................ 76

Checking Alarm and Operation Status ............................................. 82

Testing Controller .................................................................................. 82

Testing AC Distribution ......................................................................... 84

Testing DC Distribution ......................................................................... 85

Access Controller Through Web ........................................................... 86

Operation .............................................................................................. 94

Power Distribution LCD Operation................................................... 94

Controller Operation of Rectifier Cabinet ........................................ 96

System Alarm and Status ...................................................................... 96

Distribution Parameters Setting ........................................................... 96

Setting the Position Number of The Rectifier Manually .................. 96

Adding Load .................................................................................... 100

Adding Rectifier .............................................................................. 100

Maintenance ....................................................................................... 101

Maintenance Requirements .......................................................... 101

General ................................................................................................ 101

Maintenance Tools and Equipment .................................................... 101

Reference Technical Specification for Maintenance .......................... 102

Routine Maintenance Items ........................................................... 104

Routine Maintenance ..................................................................... 107

Basic Inspection .............................................................................. 108

Handling Controller Fault .................................................................... 108

Handling Rectifier Fault ....................................................................... 108

Replacing Rectifier ......................................................................... 110

Emergency Treatment .................................................................... 111

Appendix 1 Technical Parameters ..................................................... 113

Appendix 2 Alarm list ......................................................................... 116

Appendix 3 ENGINEERING DESIGN DIAGRAM ................................... 122

APPENDIX 4 WIRING DIAGRAM ......................................................... 138

Appendix 5 SPARE PARTS ................................................................... 156


SAFETY PRECAUTIONS

To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Caution, Notice, Warning, Danger" in this book do not represent all the safety points to be observed, and are only supplement to various safety points. Therefore, the installation and operation personnel must be strictly trained and master the correct operations and all the safety points before actual operation.

When operating Vertiv products, the safety rules in the industry, the general safety points and special safety instructions specified in this book must be strictly observed.

Electrical Safety

I. Hazardous voltage

DANGER! 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.

When water or moisture is found on the Subrack, turn off the power immediately. In moist environment, precautions must be taken to keep moisture out of the power system.

"Prohibit" warning label must be attached to the switches and buttons that are not permitted to operate during installation.

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

II. 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.

III. Dangerous energy

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.

IV. Multi-power input

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.

V. Power supply cable

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


VI. Tools

WARNING! In high voltage and AC operation, special tools must be used. No common or selfcarried tools should not be used.

VII 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.

VIII 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.

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

Non-standard operation on the battery will 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. Before any operation on battery, pay attention to the following points:

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

 Use special insulated tools.

 Use eye protection device, and take preventive measures.

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


 In battery transportation, the electrode of the battery should always be kept facing upward.

Never put the battery upside down or slanted.

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

I. Taking out rectifier

WARNING! When taking out the rectifier, you should replace with a new one or install a dummy plate immediately.

II. Hoisting heavy objects

WARNING! Never walk under the crane arm or the hoisted objects when hoisting heavy objects.

III. Sharp corners of the objects

WARNING! When moving equipment by hands, wear protective gloves to avoid injury by sharp objects.

IV. 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.

V. Binding signal lines

NOTICE! Signal lines should be bound separately from heavy current and high voltage lines, with binding interval no less than 150mm.


OVERVIEW

The NetSure 801 CAA 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.

Model Information

The model information of the power supply system is shown in Figure 1 .

Figure 1: Model information

NetSure 801 C A

Version number

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 represents the number 10, B represents the number 11, and so on.

Region. C: China.

Brand name of the power supply system.

Overview

The power supply system is composed of AC distribution cabinet, DC distribution cabinet, rectifier cabinet, controller, rectifier and options.

The number of AC distribution cabinet, DC 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 2 .


Figure 2: Three-cabinet system structure

Rectifier Controller

AC distribution cabinet Rectifier cabinet DC distribution cabinet

See Appendix 1 Technical Parameters for the technical parameters of AC distribution cabinet, DC distribution cabinet and rectifier cabinet.

Components

Rectifier

The system uses rectifier R48-5800A/R48-5800e, the frame structure of which mainly consists of panel, enclosure, handle, and so on, as shown in Figure 3 .


Figure 3: Rectifier appearance

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 4 , and functions of indicators are given in Table 1 .

Figure 4: Rectifier front panel

Power indicator Slide switch

Fixing screw

Protection indicator

Handle

Fault indicator

Current indicators

Table 1: Function of indicators

INDICATOR

NORMAL

STATE

FAULT

STATE

FAULT CAUSE

Power indicator

(Green)

On


(Yellow)

Fault indicator

(Red)

Current indicators

Off

Off on

Off No input and output

Flashing The rectifier is being operated through the host

On

AC input under/overvoltage, rectifier PFC output under/overvoltage, high-temperature, or current sharing imbalance

Flashing Rectifier communication failure

On

Output overvoltage, output fuse blown, or rectifier addresses contradictory

Flashing Faulty fan

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


Controller

For the specific content of the controller, please refer to M831D Controller User Manual .

AC Distribution Cabinet

The AC distribution cabinet is available in four models: PD380/400AFH-A-Y1, PD380/630AFH-A-Y1,

PD380/630AFA-A-Y1 and PD380/630AFH-A-YF. The appearances of the AC distribution cabinets are the same, as shown in Figure 5 .

Figure 5: Appearance of AC distribution cabinet

Indicator

Power distribution LCD


The internal structure of AC distribution cabinet PD380/400AFH-A-Y1 is shown in Figure 6 .

Figure 6: PD380/400AFH-A-Y1 AC distribution cabinet

Knife-blade switch

AC output MCB

(a) Front view (front door open)

Neutral busbar

Earth busbar

(b) Rear view (rear door open)



The internal structure of AC distribution cabinet PD380/630AFH-A-Y1 is shown in Figure 7 .

Figure 7: PD380/630AFH-A-Y1 AC distribution cabinet

SPD MCB

Knife-blade switch

Class C SPD

AC output MCB



Neutral busbar

Earth busbar


The internal structure of AC distribution cabinet PD380/630AFA-A-Y1 is shown in Figure 8 .

Figure 8: PD380/630AFA-A-Y1 AC distribution cabinet

ATS

ATS controller

AC output MCB



Neutral busbar

Earth busbar


The structure and configuration of PD380/630AFH-A-YF is determined by customer requirement.

See purchase order for description.

DC Distribution Cabinet

The DC distribution cabinet is available in seven models: PD48/1600DF-A-Y1, PD48/1600DF-A-Y2,

PD48/1600DF-A-YF, PD48/2500DF-A-Y1, PD48/2500DF-A-Y2, PD48/2500DF-A-Y3 and PD48/2500DF-

A-YF. The appearances of the DC distribution cabinets are the same, as shown in Figure 9 .


Figure 9: Appearance of DC distribution cabinet

Indicator

Power distribution LCD


The internal structure of PD48/1600DF-A-Y1 DC distribution cabinet is shown in Figure 10 .

Figure 10: PD48/1600DF-A-Y1 DC distribution cabinet

Battery fuse

Battery shunt

Output shunt

LCD

Power distribution monitoring

Output fuse

(a) Front view (open front door)


Total load current hall sensor

DC SPD

(b) Rear view (remove rear door)

The internal structure of DC distribution cabinet PD48/1600DF-A-Y2 is shown in Figure 11 .


Battery fuse

Battery shunt

Output shunt

LCD


Output fuse




DC SPD





Battery fuse

Battery shunt

Output shunt

LCD


Output fuse



DC SPD





Battery fuse

Battery shunt

Output shunt

LCD


Output fuse




DC SPD




Battery fuse

Battery shunt

Output shunt

LCD


Output fuse




DC SPD


The structure and configuration of PD48/1600DF-A-YF and PD48/2500DF-A-YF are determined by customer requirement. See purchase order for description.

Rectifier Cabinet

The structure of rectifier cabinet Rack1000-A is shown in Figure 15 , the structure of rectifier cabinet

Rack1500-A is shown in Figure 16 and the structure of rectifier cabinet Rack2000-A is shown in

Figure 17 .


Figure 15: Rack1000-A rectifier cabinet

Rectifier input MCB

Controller

Rectifier


Figure 16: Rack1500-A rectifier cabinet

Rectifier input MCB

Controller

Rectifier

Figure 17: Rack2000-A rectifier cabinet

Rectifier input MCB

Controller

Rectifier


The name, function and use of the cabinet components are given in Table 2 .

Table 2: Part name, function and use

NAME FUNCTION CABINET

Power LED

Fault LED

Display

AEM02U11 monitoring board

HDU1U11 monitoring board

When the mains input 1 is available, HL1 illuminates; when the mains input 2 is available, HL2 illuminates

When the AC input 1 is available, HL1 illuminates; when the AC input 2 is available, HL2 illuminates

When there is electricity in the busbar, the LED illuminates

When the distribution cabinet is in normal operation, it is off; it illuminates otherwise

Display the input voltage, current, frequency, running mains input number, SPD state, output MCB state and alarm information of the AC cabinet

Display the busbar voltage, total load current, battery voltage, battery current, load fuse status and alarm information of the DC cabinet

Measure the AC input voltage, phase-B current of the running mains input, main switch state, output MCB state, surge protection device (SPD) state; control the position of the main switch, generator start signal output; annunicate audible and visual alarms when the

AC cabinet malfunctions, and simultaneously transmit relevant information to the display of the AC cabinet and the controller

Measure the busbar voltage, total load current, battery voltage, battery current and load fuse status; annunicate audible and visual alarms when the DC cabinet malfunctions, and simultaneously transmit relevant information to the display of the DC cabinet and the controller

AC cabinet

Rectifier cabinet

DC cabinet

AC cabinet, DC cabinet

AC cabinet

DC cabinet

PD380/400AFH &

PD380/630AFH AC cabinet

DC cabinet

SMPDU1X3 shunt sampling board

Sample the load branch current, load fuse status of the

DC cabinet, and send information to the controller

DC cabinet

Class-C SPD

Discharge lightning strike current. The SPD indicator is green when the SPD operates normally, and turns red when it malfunctions. In this case, it must be replaced

SPD MCB

It is used to protect the SPD, and is closed when the SPD operates normally. When it trips, the SPD should be checked for damage. It is damaged, it must be replaced immediately, and the MCB should be closed; if the SPD is not damaged, close the MCB timely

Knife- blade switch or air breaker

It is used to control the switchover between the 2 mains inputs. This switch can be placed in 2 positions: ‘ I ’ and

‘ II ’ , respectively representing mains input 1 and mains input 2

ATS

It is used to control the switchover automatic between the 2 mains inputs. This switch can be placed in 2 positions: ‘ I ’ and ‘ II ’ , respectively representing mains input 1 and mains input 2

Vertiv | NetSure 801 CAA Series Power Supply System Instruction Manual

AC cabinet

AC cabinet

PD380/400AFH &

PD380/630AFH AC cabinet

PD380/630AFA AC cabinet

27

NAME FUNCTION

Output MCB Configured according to custermer requirement

Output fuse Configured according to custermer requirement

CABINET

AC cabinet

DC cabinet


INSTALLATION PREPARATION

Installation Requirements

Environmental Requirements

The environmental conditions of the equipment room must meet the requirements listed in Table 3 .

Table 3: Environmental conditions for the equipment room

ENVIRONMENTAL CONDITIONS RECONMMENDED RANGE

Ambient temperature

Humidity

Dust density

Sunlight

Corrosive materials

Vibration

Harmful organisms

Mould

Dampness

-5°C to 40°C

≤ 90%RH, no condensation

≤ 1mg/m3

No direct sunlight

No pollutants, such as salt, corrosive materials, and smoke.

≤ 1.5m/s²

None

None

Waterproof

The equipment may be prematurely damaged if dust or sand accumulates in it. The following measures are recommended for dirty environment:

1. The equipment should be installed in an airtight and air-conditioned room. The air conditioner filter should be adequately maintained without being obstructed. To reduce the dust in the equipment room, unattended equipment room is recommended.

2. Clean the air filter periodically to provide clean air.

Layout Requirements of The Equipment Room

Air exhaust and ventilation

When the power supply is working, the main exothermic part is the rectifier. To ensure free airflow around the power supply system, an 800mm clearance must be kept in front of the system and

800mm behind.

Cabling

The top cable entry system is introduced from the top of the cabinet, therefore wiring rack should be provided in the equipment room for top cable entry system, which is recommended to be at least 300mm above the equipment. For bottom cable entry system, cable trough should be provided in the equipment room, which should be no wider than the spacing between the equipment mounting holes.

NOTE!

To prevent electric coupling, AC cables should be run separate from DC cables and signal cables.

Installation surface

The installation surface is supposed to be cement floor or incombustible metal subrack.


Antistatic requirement

As for antistatic requirement, the absolute value of the static voltage of the equipment, wall and people to the ground should be less than 200V. Raised floor is highly recommended for the equipment room. The antistatic earth resistance should be not greater than 10 Ω . Care should be taken regarding antistatic during equipment unpacking, transportation and operation.

Lighting

Lighting in equipment room may be classified into general lighting and partial lighting. General lighting provides light for the whole room, while partial lighting is installed above the equipment cabinet or workstation to provide light for a restricted area. It is recommended to provide both lightings in the equipment room.

Clearance

1. At least 1.5m of clearance should be kept between the front of the power system cabinet and the wall.

2. At least 0.8m of clearance should be kept between the back of the power system cabinet and the wall.

3. At least 0.8m of clearance should be kept the sides of the power system cabinet and the wall.

4. At least 1.5m of clearance should be kept between the back of the power system cabinet and the front of another piece of equipment.

5. At least 1.2m of clearance should be kept between the back of the power system cabinet and the back of another piece of equipment.

6. Maintenance passage should be kept between equipment, which should not be less than 2m wide.

Refer to Figure 18 for the above requirements. No less than 0.2m of clearance should be kept between the battery and the wall, and no less than 0.8m of clearance should be kept between batteries.

Figure 18: Locating cabinet


Front of the cabinet

Clearance between cabinet side and the wall ≥

0.8m

Clearance

≥ 1.5m

Clearance between cabinet back and the wall ≥

0.8m

Weight capacity and shockproof requirements

When installing the power system in areas subject to frequent earthquakes, shockproof measures should be taken. Firstly, expansive bolts should be used to fix the system (refer to Installing

Cabinet ); secondly, the system should be reinforced as shown in Figure 19 to enhance its shockproof ability. Because the power supply system is relatively heavy, the weight capacity of the equipment room should meet relative requirements and is determined based on the equipment configuration.


Figure 19: Reinforcing the cabinet for shockproof purpose

Fire protection facility

The equipment room should comply with relevant fire protection regulations and requirements for power distribution, and provide adequate fire protection facility, such as dry-chemical extinguisher and automatically explosive fire protection ball.

Power Supply

General

Mains power should be used as the main AC source in communication field; backup batteries and generator should be provided according to the actual power source conditions. AC source composed of mains power and user-provided generator should use centralized power supply mode to supply power, and low voltage AC power supply system should use three-phase five-line mode.

The AC power cables should be copper core cable and sized to suit for the load. It is recommended that the power cables outside the equipment room should be buried directly under the ground or by means of cable pipe. Power cables should be run separate from signal cables.

Power supply adaptability

The power supply system is adaptable to various mains formats, including TN-C, TN-S, TN-C-S and

TT formats with three-phase four-wire or three-phase five- wire styles. If the power supply system uses IT mains format, users need to have the system made to order.

Capacity requirements

1. Power transformer

Because of the particularity of switch-mode power supply system, the power supply should provide relatively large redundancy. If the capacity of the power transformer is small, operation of other electric equipment may be affected. Calculated based on full configuration of the power supply system, the capacity of a dedicated transformer should exceed 1.25 times of the total capacity of the system. So, considering other electric equipment such as air conditioner, the capacity of the transformer should be even larger, and the upper capacity level should be selected according to the specifications.

PD380/400AFH-A-Y1 AC distribution cabinet is not supposed to be directly connected to the secondary side of a transformer with capacity greater than 800kVA. An extra distribution cabinet should be used between PD380/400AFH-A-Y1 AC distribution cabinet and the transformer for


short-circuit protection. PD380/630AFH-A-Y1 AC distribution cabinet is not supposed to be directly connected to the secondary side of a transformer with capacity greater than 1000kVA. An extra distribution cabinet should be used between PD380/630AFH-A-Y1 AC distribution cabinet and the transformer for short-circuit protection.

2. Generator

If the load of the power supply system is more than 50% of the generator capacity, when the higher harmonic current generated by the rectifiers passes the stator winding of the synchronous generator, the voltage waveform will be severely distorted, which will have two effects. One is, it will cause unstable running and mechanical vibration of the generator; and the other is, the harmonic current will make the generator overheat, thus accelerating the insulation ageing of the generator. This is not only harmful to the generator, but also affects the stable running of the power supply system. Therefore, the load of the power supply system should not exceed 50% of the generator capacity. It should be calculated based on the apparent power. A simple calculation of the generator capacity is: output voltage (taken as 60V) × output current (take the final configuration) × 2.

The power factor and excitation model of the generator should also be taken into consideration when selecting a generator. Brushless generator of fundamental wave excitation model should be used with caution.

Safety Protection

Lightning protection & surge protection

The lightning protection and earthing system of telecom stations should comply with relevant standards.

The power supply system is equipped with a Class- C SPD. To achieve better surge protection, it is recommended to mount Class-B SPD before the AC mains is connected to the system. The mounting of Class-B SPD is shown in Figure 20 .

Class-B SPD should be purchased and mounted by the user. If condition permits, it is recommended that the cable length between the Class-B SPD and the AC distribution unit of the power supply system range between 5 ～ 10m. And this section of cable should be routed indoors to avoid direct lightning strike. When mounting the Class-B SPD, attention should be paid to the sectional area and length of the cable connecting the Class-B SPD: the sectional area should be no less than 25mm 2 , the cable should be as short as possible, and so is the earth cable of the Class-B SPD. The SPDs should be inspected periodically to ensure their normal operation.

Figure 20: Diagram of SPD mounting & system earthing


Power supply system

5~10m

A

B

C

N

PE

SPD

SPD earth

System earth bar

-

48VDC

DC earth

Class-B SPD

+

SPD earth

Protective earth

Protective earth cable

DC earth cable

User earth bar

Earthing requirement

The earthing system in the communication equipment room is generally designed on the principle of common earth, that is, DC operation earth, SPD earth and protective earth sharing the same earth. The earth resistance should be in accordance with the specifications listed in Table 4 .

Table 4: Earth resistance requirements for communication station

EARTH

RESISTANCE

APPLICATION RANGE

<1Ω

<3Ω

<5Ω

10Ω

<20Ω

<10Ω

<15Ω

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

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

2000 routes

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

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

Microwave passive relay station

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

Suitable for those whose earth resistance rate is 100500Ω ·m, SPD earth in the interface between electric cable and aerial electric line

<20Ω

Suitable for those whose earth resistance rate is 5011000Ω ·m, SPD earth in the interface between electric cable and aerial electric line

Note: the content in the table is adapted from Installation Design Specifications for

Communication Power Supply Equipment

Equipment Running Environment Checklist

The equipment running environment checklist is given in Table 5 .


Table 5: Equipment running environment checklist

NO. ITEM INDEX PASS

1

Ambient temperature in equipment room

2 Humidity in equipment room

3 Lighting in equipment room

4 Height of equipment room

5

Static electricity in equipment room

6

Weight capacity and quakeproof ability

7 Radiation

8 Damp proof

9

10

Dust-proof

Fire protection

-5°C to +40°C

≤

70 to 200Lux

≥

95%

3m

Lay antistatic floor or antistatic rubber

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Accord with Level 8 quakeproof, and safety must be ensured

Yes/No

No blockage in equipment radiation passage Yes/No

No mildew breeding conditions Yes/No

No conductive dust and gas which deteriorate insulation

Fire fighting equipment such as fire extinguisher

Yes/No

Yes/No

11

12

Earth resistance

Sectional area of SPD earth cable

In accordance with relevant standards

Not less than 25mm2 ， the shorter the better

13 Colour of protective earth cable Greenyellow

14 Earth nut Copper, no less than M8

15

Tablet, symbol, tag of customer equipment

16 Violent vibration and shock

17

18

Sectional area of AC distribution cables

Fluctuation range of AC input voltage

Complete and clear

None

According to design specifications

According to equipment input specifications

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

19 Frequency fluctuation range 45Hz to 65Hz

20 Voltage of neutral line to ground Less than 10V

Twice larger than the actual capacity 21 Power of backup power source

22

Pollution or interference in power network

None

23 Colour code of AC bus

Yellow, green, red, light blue or marked with identifier

24

Capacity of the customer AC distribution cabinet

Meet equipment requirements

25 Wiring of AC distribution cables According to specifications

26 Colour code of DC load cables According to specifications

27

Sectional area of DC distribution cables

28 Earth wiring

According to requirements

According to specifications

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No


Storage Conditions

The product should be kept in the packing box prior to use. The warehouse ambient temperature should range between -40°C and 70°C and the relative humidity should not be higher than 95%.

Toxic gas, flammables, explosives, corrosives, severe vibration, shock and strong magnetic field are not permitted in the warehouse.

Installation Preparation

1. Tools required for power supply equipment installation include electric drill, wire cutter, wire presser, various wrenches, screwdriver, electrician knife, tinning furnace, staircase and steel saw.

See Maintenance Tools And Equipment for the specifications of the tools. The tools must be well insulated and antistatic handled before they are used.

2. Materials for electrical connection include AC cables, DC load connection cables, battery load connection cables, earth cables, and earth connection cables. The delivered cables and accessories are given in Table 6 (only include cables and accessories between rectifier cabinet and AC cabinet, and signal cables among AC cabinet, rectifier cabinet and DC cabinet).

Table 6: Delivered accessories

BOM

25030154

02300119

DESCRIPTION

AC input cable of rectifier cabinet,

25mm 2 , black

LENGTH NOTE

10.5 ~

27m

AC input cable of rectifier cabinet 3 ~ 6PCS

Applicable for the power connection between the AC distribution cabinet and rectifier cabinet

Applicable for crimping the AC input cable of the rectifier cabinet.

1PCS for each 1000A rectifier cabinet

04111498

04112962

W1PN5SL20-W1PN5Z cable suite

（ RS485 signal cable connected between AC ATS cabinet and rectifier cabinet, and connected between AC ATS cabinets-5.5m

）

WA4AASL05-WA4AAZ cable suite

(48V auxiliary power source cable)

5.5m

5.5m

04116169 W64AASL09 cable suite (CAN bus) 2.8m

Applicable for RS485 parallel cable among the AC distribution cabinet, rectifier cabinet and DC distribution cabinet)

21241727

02233399

02233400

21502330

Parallel cabinets board

Required for the AC cabinet and rectifier cabinet

Required for the DC cabinet

Large side door of the rectifier cabinet

21502332 Small side door of the rectifier

/

/

/

/

/

Applicable for the 48V auxiliary power source cable of the AC distribution cabinet

Used for locking the top parts of two adjacent cabinets

Include anchor screw used for installing the cabinet and engineering cable label

Include anchor screw used for installing the DC cabinet, engineering cable label, one fuse puller and one three-meter length of temperature cable

Used for sealing the lower part of rectifier cabinet side

Used for sealing the upper part of


BOM

21502443

21502444

21505285

21505286

21170326

21171348

21171316

21170328

21505287

02300119

21505235

21505274

DESCRIPTION cabinet

Large side door of the DC cabinet

Small side door of the DC cabinet

Parallel copper bar in Rectifier/DC cabinet

Parallel copper bar in Rectifier cabinet

Parallel copper bar in DC cabinet

4000A parallel copper bar component in Rectifier cabinet

4000A parallel copper bar component in DC cabinet

Internal parallel pad

Fixed piece assembly of parallel bar

Cabinets parallel copper bar accessories

External fixtures outside the rectifier cabinet

External parallel copper bar component of the rectifier cabinet

LENGTH NOTE

/

/

/

/

/

/

/

/

/

/

/

/ rectifier cabinet side

Used for sealing the lower part of

DC cabinet side

Used for sealing the upper part of

DC cabinet side

Internal parallel copper bar between Rectifier cabinet and DC cabinet. Applicable for rectifier cabinet – DC cabinet spaced placement

Internal parallel copper bar between Rectifier cabinets.

Applicable for rectifier cabinet –

DC cabinet non-spaced placement

Internal parallel copper bar between DC cabinets. Applicable for rectifier cabinet – DC cabinet non-spaced placement

Used in rectifier cabinet, overlapped on the internal copper bar of rectifier cabinet for flowing through 4000A current. Applicable for rectifier cabinet – DC cabinet non-spaced placement

Used in DC cabinet, overlapped on the internal copper bar of DC cabinet for flowing through 4000A current. Applicable for rectifier cabinet – DC cabinet non-spaced placement

For different cabinets, due to increased stacking, the height of the lap surface is inconsistent

As an option when the system adopts internal parallel connection

Used to fix the internal parallel copper bar to the bottom of the cabinet

Used to fix 21505274 and

21505277 copper bars, when the rectifier cabinets are paralleling externally

Used in rectifier cabinet, for leading out the copper bar from the top of the cabinet. Applicable for external paralleling, no internal paralleling and the rectifier cabinet – DC cabinet spaced placement


BOM DESCRIPTION LENGTH NOTE

21505277

21171289

21170327

Short copper bar component of external parallel in rectifier cabinet

External parallel copper bar component of the DC cabinet

Connection bar component for external parallel

/

/

/

Used in rectifier cabinet, for leading out the copper bar from the top of the cabinet. Applicable for external paralleling and internal paralleling (that is 6000A non-spaced placement)

Used in DC cabinet, for leading out the copper bar from the top of the cabinet

Connection bar used for external parallel, used to connect the

21505277 and 21171289

21505280

21171294

Expansion negative bar component of rectifier cabinet

Expansion negative bar component of DC cabinet

/

/

Used in rectifier cabinet, when used in expansion of old cabinets, convert the negative parallel port into the switch copper bar of CA7 parallel port

Used in DC cabinet, when used in expansion of old cabinets, convert the negative parallel port into the switch copper bar of CA7 parallel port

Note:

When the AC distribution cabinet is not selected, then accessories of the rectifier cabinet will not be delivered, because the distance from the superior cabinet to the rectifier cabinet cannot be calculated

3. Preparing cables

The cable design should meet relevant industry standards.

It is recommended to use the RVVZ cables as AC cables. The cable should reach at least +70°C temperature durability. With cable length shorter than 30 meters, the Cross-Sectional Area (CSA) calculation should be based on the current density of 2.5A/mm 2 .

The sectional area of the DC load cables and battery cables should be computed with the following formula:

A= Σ I × L / K △ U

In this formula: A is the sectional area of the lead (mm 2 ), Σ I is the total current (A) passing through the lead, L is the length (m) of the lead loop, △ U is the permitted voltage drop in the lead, while K is the conductivity factor. Kcopper=57. For the sake of distribution safety, the voltage drop on the cables should be compliant with corresponding rules.

The sectional area of the earth cables (including DC earth cable) shall exceed 95mm 2 .

The CSA of DC cable depends on the current flowing through the cable and the allowable voltage drop. To select the battery cable CSA, see Table 7 . Select the load cable CSA according to the Table

8 .


Table 7: Battery cable CSA selection

DC

CABINET

RATED

CURRENT

BATTERY

FUSE RATED

CURRENT

MAX.

BATTERY

CURRENT

MIN. CABLE CSA

SPECS OF THE

CABLE CONNECTOR

MAX. CABLE

LENGTH

(ALLOWABLE

VOLTAGE DROP:

0.5V)

1600A

2500A

800A

1000A

800A

1000A

2 × 240mm

2 × 240mm

2

2

OT cable connector of M12 or M16 size

OT cable connector of M12 or M16 size

10m

10m

Note:

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

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

Table 8: Load cable CSA selection

LOAD ROUTE

RATED

CURRENT

MAX.

OUTPUT

CURRENT

MIN.

CABLE CSA

MAX. CABLE LENGTH

(VOLT DROP: 0.5V,

WITH MIN. CSA)

MAX. CABLE

CSA

MAX. CABLE LENGTH

(VOLT DROP: 0.5V,

WITH MAX. CSA)

630A

500A

400A

300A

250A

160A

100A

630A 240mm

2

500A 240mm 2

400A 185mm 2

300A 120mm 2

250A

160A

100A

50A

32A

95mm 2

70mm 2

50mm 2

25mm

2

16mm 2

10m

13m

13m

11m

10m

12m

14m

300mm

2

300mm 2

300mm 2

240mm 2

185mm 2

95mm 2

95mm 2

50mm

2

25mm 2

13m

17m

21m

22m

21m

16m

27m

50A

32A

14m

7m

25m

11m

Note:

The specs are applicable at ambient temperature of 25°C

The MCB/fuse capacity should be strictly limited so that it can function properly upon load overcurrent. The capacity of 100A and above MCB/fuse is required to be 1.5 ~ 2 times larger than the load peak capacity, and the capacity of 63A and below MCB is twice of the peak load capacity. (If the output MCB of AC cabinet is connected to other loads of the rectifier cabinet, it should be used according to this principle.)

The CSA of grounding cable should be in accordance with that of the maximum power distribution cable, but not less than 95mm 2 .

The load fuses with capacity over 160A use M12 or M16 OT - shape cable connectors. The load fuses with capacity equal to or under 160A use M8 OT - shape cable connectors. The load MCBs uses the M8 OT - shape or pipe - shape cable connectors.


The recommended CSA of AC input cables are shown in Table 9 .

Table 9: AC input cable selection

CABINET

PD380/400AFH-

A-Y1

AC distribution cabinet

PD380/630AFH-

A-Y1


PD380/630AFA-

A-Y1


AC input MCB

Grounding busbar

Grounding busbar

Grounding busbar

SPECS

CONNECTOR

400A

One M16 bolt

AC input MCB 630A

One M16 bolt

AC input MCB 630A

One M16 bolt

REMARKS

CAPACITY CONNECTOR SPECS

Eight M12 bolts

(suggested cable

CSA 185mm 2 ) suggested cable CSA

120mm 2

Eight M16 bolts

(suggested cable

CSA 240mm 2 )

Suggested cable CSA

120mm 2

Eight M12 bolts

(suggested cable

CSA 240mm 2 )

Suggested cable CSA

120mm 2

The live line and neutral line of AC power supply

The grounding bar of the room





NOTE!

Generally, in design the total current passing through the lead is calculated based on full load configuration.

4. Purchase materials according to the construction materials list and inspect the materials. For example, check the heat durability, moisture resistance, flame resistance, and pressure resistance of the cables.

5. For the materials that need to be processed by other factories, the materials and the processing drawings should be provided in advance for processing.

6. The auxiliary materials for power supply installation include expansive bolts, cable lugs, cable ties, and insulating tape.

Unpacking Inspection

Explanation on packing

One suit of power system is packed up separately in many packing cases and delivered in suit. There is a printed packing label on the surface of each packing case. In the case which is pasted a 16mo red label on the surface, there is the packing list of the power system marked with “ packing list storage case ” . To inspect the equipment, you should:

1. Open the packing case and take out the packing list.

2. Check against the packing label when delivering the equipment.

3. Check the goods one by one according to the packing label after they arrive at the site.

4. Check the goods according to the packing list and equipment configuration and technical requirements.

Unpacking inspection

To ensure smooth installation, the equipment must be carefully inspected when it is unpacked. The checking should include:


1. The number and serial number of the packing cases according to the system packing case number.

2. The correctness of the equipment packing according to the packing list.

3. The number and type of the accessories according to the accessory list.

4. The completeness of the equipment configuration according to the system configuration.

5. The conditions of the goods through visual inspection. For example, check if the cabinet and case are damaged, if the cabinet and case have regained moisture; shake gently the rectifiers and controller to check if the parts and connections have been loosened during transportation.


INSTALLATION

This chapter introduces the installation and connection of NetSure 801 CAA series power supply system (power supply system for short).

Cabinet Installation

Cabinet Placement

Before installing and connecting the power system, make sure the layout of each cabinet in the power system, especially the placement of DC cabinet and rectifier cabinet. Different placement may directly impact the selection and installation of the parallel connection copper bars, there are mainly two placement modes:

Rectifier cabinet – DC cabinet spaced placement

The NetSure 801 CAA power supply system can be expanded up to 6000A. As the max current carrying capacity of single parallel connection bar is 2000A, when the system capacity exceeds

2000A, the system cabinets should be arranged in the way that the max current carrying capacity of one parallel connection bar does not exceed 2000A.

It is recommended to place the cabinets in the way of “Rectifier cabinet - DC cabinet- Rectifier cabinet- DC cabinet”. For a system composed of Rack1000-A rectifier cabinet, place one rectifier cabinet or two rectifier cabinets as a unit. For a system composed of Rack2000-A, Rack1500-A rectifier cabinet, place one rectifier cabinet as a unit.

Recommended arrangement of 6000A system using Rack1000-A rectifier cabinet.

Recommended arrangement of 6000A system using Rack2000-A, Rack1500-A rectifier cabinet:

Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement

If the installation site does not permit the cabinet arrangement shown above, it is suggested to use two parallel connection copper bars so that the current carrying capacity of single connection bar does not exceed 2000A.

If ‘ Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement ’ is adopted, the cabinet placement on the customer site must be stated or a schematic arrangement of the cabinets must be provided when pre-purchasing the power system.


NOTE!

Upon DC parallel connection of the power system, it is recommended to use the

‘ Rectifier cabinet – DC cabinet spaced placement ’ . If no statement about cabinet placement was made when purchasing the power system, the default shipping status of the power system is ‘ Rectifier cabinet – DC cabinet spaced placement ’ .

Mounting Large Side Door And Small Side Door

The rectifier cabinet and distribution cabinet have two side doors on both sides, as shown in Figure

21 According to distribution situation, cabinet placement and cabinet parallel connection, the side doors are configured in various ways.

Before installing and connecting the cabinet, check as follows:

1. Make sure the sides of the first cabinet and the last one in a row of cabinets must be closed. The rectifier cabinet need to install large side door and small side door. The AC distribution cabinet and

DC distribution cabinet need to install side doors.

2. Make sure the rectifier cabinets in the middle part of a row of cabinets are all installed with large side door, so that they can isolate from the adjacent cabinets. Do not install small side doors, so that interior parallel connection of cabinets and interior wiring can be easy performed.

3. Make sure the DC cabinets in the middle part of a row of cabinets are not installed with side doors.

The large side doors and small side doors of the rectifier cabinet are interchangeable, users can install the doors on the right side or the left side. The side doors of the DC distribution cabinet are same with rectifier cabinet, users can exchange them on the spot.

Figure 21: Side doors

Small side door of the rectifier cabinet

Large side door of the rectifier cabinet

Large side door of the DC cabinet

Installation on The Floor

Step 1: mark the installation position

Determine the installation position of the power supply cabinet in the equipment room according to the installation drawing. Based on the mechanical parameters (see Figure 22 ) of the installation holes of the power supply cabinet, determine the exact position of the center points of the installation holes on the floor, and mark them with a pencil or oil pen.


Figure 22: Installation size of the cabinet base (unit: mm)

600

600

4φ 18

(a) Installation size of the AC distribution cabinet

600

409 4φ 14

600 530

(b) Installation size of the rectifier cabinet

800 4φ 18

(c) Installation size of the DC distribution cabinet


Step 2: drill reserve holes

The expansive pipes delivered along with the system are generally M10 × 65mm. Therefore, use electric drill with drill bit Φ 14 to drill holes at the center points of the installation holes marked on the floor, and the depth of the holes should be 70mm. To avoid being off-center, be careful not to shake the drill, and try to keep it as vertical as possible to the floor.

Step 3: install expansive pipes

Clean the dust, and insert the expansive pipe into the reserve hole, knock it down gently using a hammer until the top of the expansive pipe is level with the ground.

Step 4: place cabinet in position

Move the cabinet to the installation position aligning the installation holes of the cabinet with the reserve holes on the ground.

Step 5: fix the cabinet

After the cabinet is in position, make some horizontal and vertical adjustments. Insert some iron pieces under the lower edge and corner of the cabinet to adjust the vertical obliquity of the cabinet within 5 degrees. Finally, screw down the tap bolt with plain washer and spring washer into the expansive pipe, and tighten it with wrench.

Installation on Supporting Rack

If antistatic floor is laid in the equipment room, a supporting rack should be made according to the height of the antistatic floor.

Step 1: place cabinet in position

Install the supporting rack on the floor as shown in Figure 23 . The installation steps are the same as

the first three steps in Installation on The Floor .

Figure 23: Installing supporting rack

Step 2: fix the cabinet

Install the power supply cabinet on the supporting rack, as shown in Figure 24.


Figure 24: Installing power cabinet on supporting rack

Plain

After the cabinet is installed, shake the cabinet from different directions. No obvious shake should be felt.

Parallel Connection Between Cabinets

Users need to use connection straps to fix adjacent cabinets at the top, as shown in Figure 25 . The connection straps are accessories.

Figure 25: Parallel connection between cabinets (top view, unit: mm)

600 800

600 600

68.5

Parallel Connection with Copper Bars

AC distribution cabinet and rectifier cabinet are connected by cables, while parallel connections between rectifier cabinets, between rectifier cabinet and DC distribution cabinet and between DC distribution cabinets are all achieved by means of parallel connection copper bars. Upon parallel connection of the power system, it is recommended to use the ‘ Rectifier cabinet – DC cabinet spaced placement ’ .

Take parallel connections between a rectifier cabinet and a DC distribution cabinet for example, the connection procedures are as follows:

1. Remove the upper side doors between the rectifier cabinet and the DC distribution cabinet.

2. Install the parallel copper bar nut kit.


3. Connect the DC positive bars and DC negative bars inside the rectifier cabinet and DC distribution cabinet respectively by parallel copper bars, as shown in Figure 26 .

4. If users use ‘ Rectifier cabinet - Rectifier cabinet and DC cabinet - DC cabinet parallel placement ’ , they need to contact Vertiv for technical support.

Take parallel connections between a rectifier cabinet and a DC distribution cabinet for example, the procedures for installing the parallel copper bar are as follows:

1). Install the nut kit on the parallel board V1 between the positive and negative cabinets adjacent to one side of the external parallel connection port, as shown in Figure 26 .

Figure 26: Parallel connection between cabinets (1)

Parallel board V1 between cabinets

External parallel connection port (reserved)

2). Install the nut kit on the main positive board V14 in DC cabinet (the nut kit has been installed on the copper bar of the negative cabinet at factory, therefore the on-site installation is unnecessary), as shown in Figure 27 . Note that if only one side of the DC cabinet needs to be paralleled, just install one side.


Nut kit

Main positive board V14 in DC cabinet

3). Install the parallel board between cabinets, connect one side with nut kit (adjacent to the external parallel connection port) to the parallel board in the rectifier cabinet, as shown in Figure

28 .



Nut kit (install on site)

Parallel positive board V12 in rectifier cabinet




Parallel positive board V14 in DC cabinet

Nut kit (installed at factory)

Parallel positive board V12 in rectifier cabinet




Parallel negative board V13 in DC cabinet

4). The installed parallel board is shown in Figure 29 . The nut kit of the rectifier cabinet should be installed on the parallel board between the cabinets, that of the DC distribution cabinet should be installed on the copper bar in the cabinet.


Positive parallel board in the rectifier cabinet

Nut kit

Parallel board between the cabinets

Positive parallel board in the DC cabinet

Nut kit

Negative parallel board in the rectifier cabinet


Negative parallel board in the DC cabinet

Front View


Nut kit

Negative parallel board in the DC cabinet

Positive parallel board

Parallel board in the DC cabinet between the cabinets

Nut kit Positive parallel board in the rectifier cabinet


Negative parallel board in the rectifier cabinet

Rear view

Parallel board

Positive parallel board in between the cabinets the rectifier cabinet Nut kit

Positive parallel board in the DC cabinet

Negative parallel board in the rectifier cabinet Negative parallel board in the DC cabinet

Nut kit


Top view

NOTE!

The power system uses distributed monitoring mode, the DC cabinet can be placed separately from the power system. Typical applications are placed in different load concentration points, such as different floors for nearest power distribution. The separately placed DC cabinet uses cable instead of copper bar for parallel connection with the power system. The connection point is the mounting holes of the copper bar, so that the system can correctly detect the load current.

Connecting Power Cables

NOTE!

Before electrical connection, turn off all the switches and fuses.

The accessory cables used in cable connection are given in Table 10 . Among which, 1 ~ 6 are power cables between cabinets, 7 ~ 11 are communication cables between cabinets. The AC input cable, battery cable and load cable should be prepared by user themselves.


Table 10: Accessory cables used in cable connection

NO. BOM

1

2

3

4

Usersupplied

Usersupplied

25030154

02300119

DESCRIPTION

Input cable of the AC distribution cabinet

User output cable of the AC distribution cabinet (not for the rectifier cabinet)

AC input cable of the rectifier cabinet, 25mm 2 , black

AC input cable of the rectifier cabinet

Battery input cable of the DC distribution cabinet

Load cable of the DC distribution cabinet

LENGTH

/

/

10.5 ~

27m

3 ~ 6PCS

NOTE

5

6

7

Usersupplied

Usersupplied

Usersupplied

Grounding cable

/

/

/

8

9

10

11

04111498

04112962

04116169

04113664

W1PN5SL20-W1PN5Z cable suite

(RS485 signal cable connected between AC ATS cabinet and rectifier cabinet, and connected between AC ATS cabinets-5.5m)


(48V auxiliary power source cable)

W64AASL09 cable suite (CAN bus)


(SPD signal parallel connection cable in rectifier cabinet)

5.5m

5.5m

2.8m

5.5m

Applicable for RS485 parallel cable among the

AC distribution cabinet, rectifier cabinet and DC distribution cabinet)

Applicable for 48V auxiliary power source cable of the AC distribution cabinet

Applicable for CAN loop connection of two or more rectifier cabinets

Applicable for SPD signal loop connection of two or more rectifier cabinets

Connecting Earth Cable

The power supply system uses common earth mode. The connection procedures are as follows.

1. Use the earth cable to connect the earth bolt at the rear lower part of the rectifier cabinet to the earth bar of the AC distribution cabinet, see Figure 30 and Figure 31 .


Figure 30: Earth terminal of the rectifier cabinet (rear view)

Earth terminal

Figure 31: Earth bar of the AC distribution cabinet (rear view)

AC neutral bar

AC earth bar

2. Use the earth cable to connect the earth bolt of the DC distribution cabinet to the earth bar of the AC distribution cabinet. The earth terminal of DC distribution cabinet is as shown in Figure 32 .


Figure 32: Earth terminal of the DC distribution cabinet (left view)

Earth terminal

3. Connect one end of the earth cable to the user earth bar, and the other end to the earth bar in the AC distribution cabinet (See Figure 31 and Figure 32 ).

4. Lead out the DC earth cable from the positive busbar of the DC distribution cabinet, and connect it to the copper earth bar in the equipment room. The sectional area of the DC earth cable increases with system capacity, and should be at least 95mm 2 .

Connecting Cables Between Rectifier Cabinet and AC Distribution Cabinet

For Rack1000-A rectifier cabinet, choose one 160A MCB as AC input switch of the rectifier cabinet.

For Rack1500-A and Rack2000-A rectifier cabinets, choose two 160A MCBs as AC input switches of the rectifier cabinet.

Follow the steps below to install the AC input cables of the rectifier cabinet.

1. If the AC input cables of the rectifier cabinet are routed inside the cabinets, users can use the accessory cables as the AC input cables. Otherwise users need to prepare armored cables by themselves. If the system capacity exceeds 2000A, users need to prepare extra cables. The cable specification cannot greater than 50mm 2 . The wiring is shown in Figure 33 .


Figure 33: Connection of AC input cables of rectifier cabinet in AC distribution cabinet (front view)

2. Connect one end of the cable to the output terminal of the selected MCB in the AC distribution cabinet (do not connect the neutral line). The AC input cable wiring is shown in Figure 34 and Figure

35 .

Figure 34: AC input cable wiring (manually switch AC distribution cabinet, rear view)

Front view Right view


Top view

Input cable wiring area

Output cable wiring area one

Output cable wiring area two

53

Figure 35: AC input cable wiring (automatically switch AC distribution cabinet, rear view)

Top view

Output cable wiring area

Input cable wiring area

Right view Front view

3. Connect the other end of the cable to the AC input terminal of the rectifier cabinet. The connection of AC input cables in rectifier cabinet is shown in Figure 36 .


Figure 36: Connection of AC input cables in rectifier cabinet

1B

1C

2B

2C

NOTE!

The Rack1500-A and Rack2000-A rectifier cabinet can work normally only when the two routes of AC input are accessed in.

Connecting AC Input Cables

The AC cables can enter the system from either the cabinet top from wiring rack or the cabinet bottom from cable trenching.

For AC distribution cabinet:

After the AC input cables are fed into the cabinet, connect them to the knife-blade switch or air breaker or ATS of the AC distribution cabinet, as shown in Figure 37 and Figure 38 .


Figure 37: Mains input cable connection to AC distribution cabinet (manually switch AC distribution cabinet, rear view)

1C

1N

1B

1A

2B

2A 2C

2N


Figure 38: Mains input cable connection to AC distribution cabinet (automatically switch AC distribution cabinet)

2N

1N 1C 1B 1A

2C

2B 2A

Terminal of route one input cable

Terminal of route two input cable

1N 1C 1B 1A

2N 2C 2B 2A

Top view

Rear view

Connecting DC Emergency Lighting Cables (Optional)

Connection of AC distribution cabinet and DC distribution cabinet

The DC emergency lighting contactor is an optional part that locates at the bottom part of the AC distribution cabinet, as shown in Figure 39 . (removing the panel). In the event of AC mains failure, the AC monitoring circuit closes the DC emergency lighting contactor, and then 48V voltage is available at its output terminal.

Choose a 100A load fuse in the DC distribution cabinet to supply DC power for emergency lighting, and then connect this fuse to the DC contactor by means of cable (which should be sized for the emergency lighting power).

Follow the steps below to connect the emergency lighting cables.

1. Determine the cable length according to the actual wiring route.

2. Add cable lugs to both ends of the cables.

3. Connect one end of the positive cable (cable 2) to the positive busbar of the DC distribution cabinet, and one end of the negative cable (cable 1) to the load fuse in the DC distribution cabinet.

4. Connect the other end of the positive cable (cable 2) to the positive emergency lighting busbar, and the other end of the negative cable (cable 1) to the DC contactor, as shown in Figure 39 .

5. Connect one end of the positive emergency lighting cable to the positive emergency lighting busbar, and the other end to the positive terminal of the emergency lighting. Connect one end of the negative emergency lighting cable to the bottom terminal of the emergency lighting MCB, and the other end to the negative terminal of the emergency lighting, as shown in Figure 39 .


Figure 39: Connection of emergency lighting cables in AC distribution cabinet

Positive input cable

Positive output cable

Negative input cable

Negative output cable

A amplified

A

Connecting DC Load Cables

The use of the DC distribution cabinet top cover is described below:

The cable entry holes of the DC distribution cabinet top cover are divided as load cable entry space and battery cable entry holes, as shown in Figure 40 . Lead the cables in or out the DC distribution cabinet from the top cover sponge or epoxy board.

Figure 40: Cable entry hole for top cover

Reserved copper bar entry holes of external parallel cabinets

Load cable entry space (epoxy board)

Sponge bar

Load cable / battery cable entry space (sponge)

NOTE!

1. The power supply line should not be spliced. It is highly recommended that the load cables, signal lines and customer cables be run separate to prevent them from affecting each other. 2. Before connecting, pull out the DC output fuse with fuse puller or turn off the MCB.

The DC load cables should be connected as follow:

Connect one end of the negative cable to the output terminal of the fuse, and the other end of the positive cable to the positive copper bar of the DC distribution cabinet, as shown in Figure 41 .


Figure 41: Connecting load cable of the DC distribution cabinet

Positive load cable

Negative load cable

Positive load cable

Negative load cable

Right view Rear view

Connecting Battery Cables

The connection of battery cables in DC distribution cabinet is described below.

The procedures of connecting battery cables are as follows:

1. Route and number the cables of the two batteries and mark their polarities.

2. Connect one end of the negative cable to the output terminal of the battery fuse and one end of the positive cable to the positive copper bar of the DC distribution cabinet. Add cable lugs to the other end of the positive and negative cables, bind the cable lugs with insulating tape, and put them beside the battery. Connect the cables to the battery when the DC distribution is to be initially tested, as shown in Figure 42 .

NOTE!

The battery negative cables should be connected to the two battery fuses, not the single one.


Figure 42: Battery cable connection in DC cabinet

Negative cable of battery two

Negative cable of battery one Positive cable of battery two

Positive cable of battery one

Front view Rear view

Installation Checklist

After installation, security check should be conducted using the following checklist.

Table 11: Installation checklist

NO STANDARDS AND REQUIREMENTS PASS NOTES

1 Constructed according to the design plan

2 The system cabinets are fixed with expansive screws

3 The cabinets are aligned

4 The installation equipment is clean

5 The installation equipment facilitates wiring

6 Cable wiring is covert

7 Cable is wired with consideration of the wiring of other systems

8 Cable pipe is laid in cable trenching

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

9 Cable labels are clear and accurate

10 Connector coat peeling is tidy and consistent

11 Type O or U terminal is used for the connection of signal lines

12 Cable lug is reasonably used in cable connection

Yes/No

Yes/No

Yes/No

Yes/No

13 SPD earth, DC power earth and protective earth are connected correctly Yes/No

14

Leeway is left for the length of connection cable and the cable wiring is covert

Yes/No


NO STANDARDS AND REQUIREMENTS PASS NOTES

15 The cable lugs and cable connectors are well connected

16 The screws in all cable connection points are firmly fixed

17

The original environment is restored which has been destroyed due to the construction

Yes/No

Yes/No

Yes/No

18 Scratch traces by marking pencils are left on the equipment

19

The busbar connection on the rack top for connection of parallel cabinets is up to requirements

20 The cables and cable trenching are level horizontally or vertically.

21 Distances between line cable ties are equal and consistent

22 Leeway is left in cable trenching

23 Separation measures are taken in cross wiring Yes/No

24 Wiring is far from high temperature equipment and corrosive liquid pipe Yes/No

25

26

Wiring on wiring rack is in accordance with the original wiring style

DC distribution branches and fuses are properly selected according to the corresponding loads

Yes/No

Yes/No

27 Surplus parts of the cable ties are left uncut

28

The placement of the equipment facilitates cabinet expansion and maintenance

29 The cabinet assembly is well-fixed and quakeproof-handled

30 Paint and galvanized layer on the cabinet are not peeled

31

32

No crumple or crack at the turning points of bus

For rectifier cabinet Rack2000-A, check that 2-route AC input is available.

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Yes/No

Installing Rectifier and Controller

System assembly involves the installation of rectifier and controller.

Installing Rectifier

The installation steps of rectifier are as following:

1. Place up the slide switch of the rectifier, and push the rectifier into the corresponding position in the rectifier cabinet (do not push it inward completely), as shown in Figure 43 (a).

2. Place down the slide switch, and then push the rectifier to the back until the rectifier panel is level with the rectifier cabinet panel, as shown in Figure 43 (b).

3. Tighten the bolts on the handle to fix the rectifier on the rack, as shown in Figure 43 (c) and

Figure 43 (d).

Figure 43: Installing rectifier

Fixing screw Handle

Slide switch

(a) (b)


(c) (d)

Installing Controller

The controller should be installed using the following procedures:

1. Unscrew the screws on the dummy plate, as shown in Figure 44 .

Figure 44: Position of the dummy plate

Dummy panel

2. Unscrew the captive screw at the top of the handle of the controller, as shown in Figure 45 .

Figure 45: Controller Panel diagram

3. Push the controller into the correct position, and then fix the screws on the panel, as shown in

Figure 46 .


Figure 46: Fixing the controller in the cabinet

Controller

NOTE!

There should be only one controller in the system even there are multiple rectifier cabinets. The controller should be installed on the right side of the rectifier cabinet. The dummy plate inside the rectifier cabinet without controller should be retained.

The Installation and Wiring of The Controller IB2 Extension Board

NOTICE!

The static electricity generated by the human body will damage the static sensitive elements on PCBs, such as large-scale ICs. Before touching any plug-in board, PCB or IC chip,

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

The Installation of the IB2 extension board

IB2 extension board of the rectifier is optional with the monitor. The installation steps are as follows ：

Unscrew the fixing bolts on the cover plate of the IB2 extension board, disassemble the cover plate of the IB2 expansion board. Use four screws IB2 extension board fix the installation components, as shown in Figure 47 .

Figure 47: IB2 extension board

Signal extension board

RS232 port


Cover plate

63

NOTE!

The IB2 extension board should be installing in the rectifier cabinet with the controller when there are multiple rectifier cabinets in the system.

IB2 user interface board

The external input and output signals are all connected to the IB2 user interface board. For the ports on the IB2 user interface board, see Figure 48 .

Figure 48: IB2 board pin definition

Alarm output dry contact, DC 15V~60V

DC 15V ～ 60V

-

+

5 3

4 2

5 3

4 2

5 3 1

1 5 3

4 2 4 2

J5

7 6 5 4 3 2

- - - - - - -

5 3 5 3 1

1 5 3

6 6 4 2 6

6 4 2

6 6 4 2

7 6 5 4 3 2 1

数字输入量接口

I I

2 2 I

2

C 接口

J1

Address DIP

地址拨码

NOTE!

1. J11 and J12 are temperature sensor ports. They are not used here. 2. J2 is I2C interface, and provides the power.

See Table 12 for the dry contact terminal definition.

Table 12: Dry contact terminal definition

NAME OF DOUBLE-

LAYER PORT

PIN NO. PIN NAME

J3

J4

5

6

1

2

1

2

3

4

3

4

DI1-

DI1+

DI2-

DI2+

DI3-

DI3+

DI4-

DI4+

DI5-

DI5+


DEFINITION

Digital input 1-

Digital input 1+

Digital input 2-

Digital input 2+

Digital input 3-

Digital input 3+

Digital input 4-

Digital input 4+

Digital input 5-

Digital input 5+

64

NAME OF DOUBLE-

LAYER PORT

PIN NO. PIN NAME DEFINITION

J4

J5

J6

J7

J8

J9

1

2

3

4

5

6

5

6

1

2

3

1

2

3

4

3

4

5

6

5

6

5

6

1

2

1

2

3

4

4

5

6

DI6-

DI6+

DI7-

DI7+

DI8-

DI8+

NA

NA

DO1_NC

DO2_NC

DO1_COM

DO2_COM

DO1_NO

DO2_NO

DO3_NC

DO4_NC

DO3_COM

DO4_COM

DO3_NO

DO4_NO

DO5_NC

DO6_NC

DO5_COM

DO6_COM

DO5_NO

DO6_NO

DO7_NC

DO8_NC

DO7_COM

DO8_COM

DO7_NO

DO8_NO

Connect alarm relay output

Connected the alarm output cables to the terminals DO1~8 (silkscreen) on IB2 board.

Digital input 6-

Digital input 6+

Digital input 7-

Digital input 7+

Digital input 8-

Digital input 8+

/

/

NC contact of relay 1


Common contact of relay 1


NO contact of relay 1




















NOTE!

Alarm relay contact capacity: Max. 1A@60Vdc and 60W; Min. 10uA@10Vdc.

Connect digital input

The digital input uses 15Vdc~60Vdc active signal, which can configure the digital input functions through the controller and WEB interface.

According to Figure 48 and the silkscreen, connect the signal cables to the corresponding terminals

DI1~8 on IB2 board. The connection in Figure 48 illustrates the connection of input terminal DI1.


Connect I 2 C cable

Connect the I 2 C cable plug reserved on the cabinet to the J2 port on IB2 board.

Connect RS232 communication cable

The RS232 port position of the rectifier cabinet is shown in Figure 47 . If you need to use it, lead the

RS232 cable from the secondary cable hole on the top of the rectifier cabinet and connect it to the

RS232 port on the left side of the controller. The interface specification is RS232 standard serial port DB9 male connector. The pin definition of RS232 port is shown in Figure 49 .

Figure 49: RS232 Pin definition

1

6 8 9

5

Connecting Communication Cables and Auxiliary Power Cable

Connecting Rectifier Cabinet Communication Cable

The steps of connecting CAN communication cables among multi rectifier cabinets are as follows:

1) Remove the matched resistance located on the back of rectifier cabinet, as shown in Figure 50 .

Figure 50: Matched resistance

Matched resistance

2) Connect the CAN communication cables between the rectifier cabinets.

2. Depending on your controller installation location in the Figure 51 , Figure 52 and Figure 53 , connect CAN communication cable between the rectifiers and matching resistance. And install the controller CAN communication and connection cables according to Figure 51 .

When the controller mounted to the rectifier on the right, connect the CAN communication cable between the rectifier cabinets as shown in Figure 51 .


Figure 51: Rectifier cabinet CAN communication cable connection diagram 1 (rear view)

When there rectifier cabinets, resistance here resistance here

When the controller mounted to the rectifier in the middle, connect the CAN communication cable between the rectifier cabinets as shown in Figure 52 .


Matching resistance

Matching resistance

When the controller mounted to the rectifier on the left, connect the CAN communication cable between the rectifier cabinets as shown in Figure 53 .


监控

模块

Controller


3. If there are more than three rectifier cabinets, please increase the number of the CAN parallel configuration communications cable, and connect as shown in Figure 51 , Figure 52 and Figure 53 , according to the controller of the location. CAN cable should use total style wiring, which makes the controller is always located at the beginning and the end of circuit. Retain the match resistance in the controller, and access a second match resistance on the other end of the circuit.

Connecting SPD Signal Parallel Connection Cable of Rectifier Cabinet

If there are two or more rectifier cabinets in the power system, it is necessary to connect the SPD signal cables between the rectifier cabinets. The specific steps are as follows.

1. Take off the shorting terminal of SPD signal cable from the rectifier cabinet (the shape is similar to the CAN loop communication cable terminal, in which the CAN loop communication cable terminal is a 2 PIN terminal, the SPD signal cable terminal is 4 PIN), and the position is similar to the

CAN matching resistor.

2. Connect the SPD parallel cables of the rectifier cabinet, the connections are shown in Figure 54 and Figure 55 . Note that the main cabinet (the rectifier cabinet that installs the controller) can only connect the parallel cable with one terminal, and the terminal cabinet should be connected to the cabinet with shorting terminals.


Figure 54: SPD signal cable connection diagram of two rectifier cabinets (rear view)

Short connection terminal

Monitor SPD SPD

Rectifier cabinet 2

Rectifier cabinet 1

Figure 55: SPD signal cable connection diagram of three rectifier cabinets (rear view)

Short connection terminal

Monitor SPD SPD SPD

Rectifier cabinet 3

Rectifier cabinet 2

Rectifier cabinet 1

Connecting Communication Cable of Distribution Cabinet

Connecting RS485 communication cable

In the three-cabinet power system, RS485 communication cables are used to connect AC distribution cabinet to DC distribution cabinet, and DC distribution cabinet to controller. The connection relation is shown in Figure 56 and Figure 57 .

For AC/DC distribution cabinet, reserved the 3 PIN plug-in connectors in the RS485 cables on the rear top of the cabinet, through the 3 PIN plug-in connectors connected RS485 cables of the distribution cabinets.


In the RS485 port of the M831D controller, connect the RS485 communication cables from distribution cabinet through 3 PIN SMR plug-in connectors.

Figure 56: Connection of communication cable in AC distribution cabinet (rear view)

RS485 port

RS485 port amplified

RS485A

RS485B

PE

RS485A

RS485B

PE

Figure 57: Connection of communication cable in DC distribution cabinet (front view)

RS485 port

RS485 port amplified

RS485A

RS485B

PE

RS485A

RS485B

PE

3. When the system has multiple AC cabinets or DC cabinets, connect the RS485 cables between cabinets according to Figure 58 . If the cabinet number is different from Figure 58 , increase or decrease the parallel cables between cabinets according to Figure 58 . The connection of RS485


cable should use bus type wiring, and the controller is always located at the first end or the end of the circuit.

4. When the DC distribution cabinet is placed separately from the power system, you also need to connect the DC cabinet to the RS485 communication cable of the power system. Otherwise, the system cannot monitor the cabinet and battery state.

Connecting 48V DC auxiliary power source cable of monitoring board in AC cabinet

Connect one end of the power cable in the accessories to the terminal with “AC cabinet 48V” label on the AC cabinet. And connect the other end to the terminal with “AC cabinet 48V” label on the

DC cabinet. Pay attention to the two poles of power and the cable color which must be corresponded (black to black, brown to brown). Each AC cabinet corresponds to a DC cabinet, as shown in Figure 58 .

Figure 58: Connection diagram of NetSure 801 CAA series power system communication cable and

48V DC auxiliary power source cable (front view)

RS485 communication cable RS485 communication cable RS485 communication cable RS485 communication cable

AEM02

Monitoring board

AEM02

Monitoring board

Parallel CAN communication cable

0V

-48V

HDU1U11

Monitoring board

SMPDUX3

Sampling board

Parallel CAN communication cable

0V

-48V

HDU1U11

Monitoring board

SMPDUX3

Sampling board

Monitor

0V

-48V

HDU1U11

Monitoring board

AC cabinet 1

AC cabinet 2

Rectifier cabinet 1

48V auxiliary power source cable of AC cabinet

DC cabinet 1

48V auxiliary power source cable of AC cabinet

Rectifier cabinet 2

DC cabinet 2

Rectifier cabinet 3

DC cabinet 3

Installing Options

Installing Temperature Sensor

AD592BN temperature sensor is an option. And the wiring steps are shown as follows:

1. Make cable connection to the temperature sensor. Pay attention to the cable definition and color.

2. Connect P101-3 socket which is connected to 3-core cable of the temperature sensor to J16 and

J17 sockets on the monitoring board of DC distribution cabinet (model: HDUL), as shown in Figure

59 . J16 has temperature compensation function. J17 perform temperature display function but not temperature compensation function. When there are multiple DC distribution cabinets, connect the temperature sensor cable with temperature compensation function to J16 socket on the monitoring board of DC distribution cabinet. For the setup method, refer to Setting DIP Switch .


Figure 59: Connection of temperature sensor

P101-3 socket

PGND

Signal port

+12

Temperature terminal J16

Temperature terminal J17

3. AD592BN is current type temperature sensor. Ensure that the sixth position (temperature sensor selection position) of the DIP switch on the DC distribution cabinet has been set ‘ OFF ’ . For the setup method, refer to Setting DIP Switch .

4. The temperature probe should be placed in the battery room, which can reflect most of the battery temperature. When fixing, do not connect the temperature probe with other heating devices or metal conductors.


TESTING

This chapter mainly introduces the notes on testing, system power-on, parameter setting, inquiry of alarm and operation information. For detailed using of M831D controller, please refer to M831D

Controller User Manual .

Note on Testing

Before putting the system into operation, testing must be conducted strictly following the testing steps. The following safety precautions must be observed in testing

 The system test requires extensive technical knowledge; therefore, the test engineers must have had relevant technical training. Be sure the test is conducted in accordance with the instructions in this manual.

 The system test involves working with live wires, therefore, during the test, stand on dry insulated objects, use insulated tools, and do not wear watch, necklace or any other metal objects.

 Avoid touching two live objects with different potentials.

 Before the switch-on operation, check whether the conditions of appropriate parts are normal.

 During operation, a warning sign “No switch on, in operation” should be posted on the equipment to prevent inadvertent operation.

 Close observation is required during test. The system should be turned off immediately when any malfunction occurs. The cause of the malfunction must be found out before resuming the operation.

Power-on

Inspection before power-on

The inspection steps as below:

1. Check that the earth cables of the cabinets are connected reliably and that the wiring and screws in the cabinet are fastened.

2. Open all the MCBs in the AC distribution cabinet, and then feed the mains supply to the system, measure the phase voltage of the three phases with a multimeter to confirm the mains condition. If everything is normal, proceed with the next step.

3. Turn on the knife-blade switch or input air breaker of the AC distribution cabinet, the running indicator of the AC distribution cabinet should illuminate.

4. Close the input MCB of the rectifier cabinet in the AC distribution cabinet, the power indicator of the rectifier cabinet should illuminate.

Preliminary test of rectifier

After introducing the AC mains, turn on one certain MCB of rectifier in the upper part of the rectifier cabinet. The power indicator of the corresponding rectifier should be on and the fan begins to run. After a while, the controller will display 53.5V rectifier output voltage and then turn off the

MCB of this rectifier. Check the other rectifiers one by one through turning on and off the rectifier

MCBs and see if they can work normally.


Preliminary test of controller

After the controller is powered on, it will do self-test without needing any operation. After about

50s, the M831D controller should start and display the following screen.

The first screen of M831D is the language selection screen. You can press ▲ or ▼ to select English or other local language. Then press “ENT” to enter default interface. It will enter fault interface directly after 30s without any operation, as the following figure.

Power Supply

09:22:58

53.5 V

3600.0 A

100%

Rect Cap Used: 22.3 %

In the default main screen:

Press ▲ + ▼ to select different menu;

Press the ENT key to enter the selected menu.

ICON NAME

Alarm

Setting

DESCRIPTION

View the active alarm and history alarm

Enter the setting menu

AC

Module

DC

View AC equipment information

View rectifier and inverter module information

View DC equipment information

Battery View battery information

Preliminary test of DC distribution and battery connection

Please connect the battery to the system according to the following steps.

1. Measure the battery voltage with multimeter and keep a record.


2. Turn on one rectifier, and set the rectifier voltage to a value with less than 0.5V difference from the battery voltage through the controller.

3. Use insulated tools, and connects the battery cables to the batteries according to the instructions of the battery manufacturer. The other end of the battery cables has already been connected to the battery fuse as required in Connecting Battery Cables .

NOTE!

Before access the battery, check with a multimeter that the battery polarities are correct. When connecting the battery, careful attention is required to prevent short circuit of the positive and negative poles of the battery. If two batteries are connected at one time, battery mutual charging due to unequal terminal voltages of the two batteries should be avoided.

4. Set the power supply voltage to the required battery float voltage through the controller (in this case, the rectifier should not be in current limiting state).

Setting Basic Parameters

Setting DIP Switch

1. Setting AC distribution cabinet

Distribution cabinet address, temperature sensor selection and communication speed are set through the DIP switches on the monitoring board. The DIP switch is shown in Figure 60 .

Figure 60: DIP switch

ON

1 2 3 4

Position ‘ON’ represent s ‘0’, and ‘OFF’ repr esents ‘1’. The setting explanation of bits 1 to 4 is given in Table 13 .

Table 13: Setting list of DIP switch

BIT DEFINITION

1 Manual/Auto switch

2 Auto switch mode

3 Reserved

4 Reserved

SETTING EXPLANATION

ON: manual switch; OFF: Auto switch

ON: ATS switch; OFF: contactor + controller switch

NOTE!

Address of the AC distribution cabinet is not set through the DIP switch, but set through the software.

2. Setting DC distribution cabinet

Distribution cabinet address, temperature sensor selection and communication speed are set through the DIP switches on the monitoring board. The DIP switch is shown in Figure 60 .

Bits 1 to 4 are used to set the addresses of the AC distribution cabinet and DC distribution cabinet.

Position ‘ON’ represent s ‘0’, and ‘OFF’ represent s ‘1’. The setting explanation of bits 1 to 4 is given in Table 14 .


Table 14: Setting DIP switches of DC distribution cabinet

BIT 1 BIT 2 BIT 3 BIT 4

1

0

1

0

1

1

0

1

0

1

0

1

0

0

1

0

0

0

1

1

0

0

1

1

0

0

1

1

0

0

1

1

0

0

0

0

1

1

1

1

0

0

0

0

1

1

1

1

0

0

0

0

0

0

0

0

1

1

1

1

1

1

1

1

NOTE!

Address of the AC distribution cabinet default setting from factory is 72, if there are multiple AC screens, set the cabinets address to 72, 73 ,… ,87.

CORRESPONDING

ADDRESS IN THE

CONTROLLER

83

84

85

86

87

79

80

81

82

72

73

74

75

76

77

78

The setting explanation of bits 5 to 8 is given in Table 15 .

Table 15: Setting list of DIP switch

BIT

5

6

7

8

DEFINITION

Reserved

Reserved

Reserved

Reserved

SETTING EXPLANATION

Default: OFF

Default: OFF

Default: OFF

Default: OFF

Setting Basic Parameters for Controller

To put the system into service, system setting must be done through the controller, battery group number, battery nominal capacity, charge current limit and other function requirements according to the actual system configuration. Otherwise, the system information display and output control cannot function normally.

1. At the default LCD screen (if stay in other screen, press ESC will exit to the default screen) of the controller in AC distribution cabinet, press ESC to enter the product information screen, as shown in

Figure 61 .

2. check whether the ‘ Address ’ is within the range of 64 ~ 71. If the address is out of the range or there are two or above AC screens set to the same address, then press and simultaneously at the first screen to enter the parameter setting screen and reset the address, and press Enter to confirm.

Figure 61: AC screen address


Model:

CommAddr:

SW Ver:

AEM02

64

V1.00

2. At the default LCD screen of DC distribution cabinet, press ESC to enter the product information screen. Check whether the ‘ Address ’ is within the range of Table 16 . If the address is out of the range in Table 16 or there are two or above DC screens set to the same address, then reset the address according to Setting DIP Switch .

Figure 62: DC screen address

Model: HDUL

Syetem Type: X3

CommAddr: 72

SW Ver: 1.001

3. At the controller MAINMENU screen in DC cabinet, press ENT to enter the ‘Settings’ screen

(password: 1), enter ‘ DC Settings ’ --> ’Total Load Brh:’ --> ’Total Load Curr’, set the b ranch number

(that is load branch number of the first layer in DC screen, the branches of the second layer and third layer are not calculated) and the sampling component type of the total load current.

Figure 63: Setting load sampling type



Tot alL oadBr h:

Tot alL oadCur r :

8

Hall



Table 16: DC screen setting

PARAMETER NAME

DESCRIPTION

Total Load Brh Total Load Curr

8

8

8

8

8

Hall

Hall

Hall

Hall

Hall

For PD48/2500DF-A-Y1





At the controller first screen in DC cabinet, press ENT to enter the ‘Settings’ screen (password: 1), enter ‘ Batt. Settings ’ --> ’ Shunt Qty :’, ‘Shunt Coef’ --> ’ Current ’, set the battery shunt quantity and battery shunt coefficient of the DC cabinet.

Figure 64: Setting battery shunt


Batt. String Qty: 2

Shunt Coef:

--Current: 1250A

Table 17: Battery shunt setting

Shunt Qty

4

4

4

2

2

PARAMETER NAME

Shunt Coef-Curr

1250A

1250A

1250A

1250A

1250A






DESCRIPTION

NOTE!

Except the above four parameters, other parameters of the DC distribution cabinet should be set in the M831D interface.

4. At the first screen of DC distribution cabinet, press ENT to enter ‘Settings’ --> ’System Parameters’ menu (password: 1), and confirm that the syst em type is ‘X3’.

Figure 65: Setting system type

ComDownLoad: N

LVD Enable: N

Syetem Type:

X3





5. At the controller MAINMENU screen in rectifier cabinet, press or to move the cursor to the setting icon

. Click the setting icon and input user name ( ‘ admin ’ ) and password ( ‘ 1 ’ ) to enter the setting screen.

6. Enter ‘ AC Settings ’ --> ’ AC Distrib 1 ’…… ’ AC Distrib n ’ , check the PD380/400AFH&PD380/630AFH

AC coefficients of transformer, the corresponding coefficient of PD380/630AFH would be 160, the corresponding coefficient of PD380/400AFH would be 100. If any inconsistencies exist, set the parameters as above.

Figure 66: AC settings

AC Distrib1

Curr Trans Coef:

160

Input Type:

3-Phase

Input Number:

2

AC Distrib1

Input Number:

2

Cur Measurement:

3-Phase

Output Number:

0


Table 18: AC transformer setting

PARAMETER NAME

DEFAULT

SETTING

DESCRIPTION

AC Transformer

Coefficient

160

100

Used for PD380/630AFH, the corresponding coefficient is 800/5

Used for PD380/400AFH, the corresponding coefficient is 500/5

Current Measure Ty Single phase

Set according to actual current transformer number, the default setting is single phase

7. Back to the setting screen, enter ‘ DC Settings ’ --> ’ DC Distrib 1 ’…… ’ DC Distrib n ’ , check whether the ‘ Hall Coefficient ’ is consistent with Table 19 . If any inconsistencies exist, reset the parameters according to Table 19 .


Figure 67: Load hall coefficient

DC Distrib1

Sensor Coeff:

4000

Num of Battery:

2

Temp Number:

1

Table 19: Setting DC hall sensor

Parameter name

Default setting Description

3000 Used for PD48/2500DF-A-Y1/Y2/Y3

Hall Coefficient

1500 Used for PD48/1600DF-A-Y1/Y2

8. Enter ‘ DC Settings ’ --> ’ DC Distrib 1 ’…… ’ DC Distrib n ’ , set the ‘Branch Curr Coeff’ and ‘Curr Output

Num’ according to actual situation .

Figure 68: Setting branch current coefficient and current output number

DC Distrib1

Temp Number:

1

Branch Curr Coeff:

500

Curr Output Num:

0

Table 20: Setting branch current coefficient and current output number in DC screen

Parameter name Default setting Description

Branch Curr Coeff 500

8

4

8

Used for PD48/1600DF and PD48/2500DF

Used for PD48/1600DF-A-Y1

Used for PD48/1600DF-A-Y2

Used for PD48/2500DF-A-Y1 Curr Output Num

6 Used for PD48/2500DF-A-Y2

12 Used for PD48/2500DF-A-Y3

9. Enter ‘ DC Settings ’ --> ’ DC Distrib 1 ’…… ’ DC Distrib n ’ , set the ‘Num of Output’, the default value is

64. If the number of output is less than 64, then there is no need to set the ‘Num of Output’.

Figure 69: Setting number of output

DC Distrib1

Branch Curr Coeff :

500

Curr Output Num:

0

Numof Output:

64


10. Back to ‘ DC Settings ’ --> ’ DC Distrib 1 ’…… ’ DC Distrib n ’ , set the ‘ Num of Battery ’ of each DC distribution screen according to actual connected battery strings.

Figure 70: Setting number of battery

DC Distrib1

Sensor Coeff:

4000

Num of Battery:

2

Temp Number:

1

11. Set battery parameters as follows:

Back to ‘ Settings ’ screen, enter ‘ Batt Settings ’ ->’ Charge ’ , set the actual connected battery string capacity, then click ‘ Reset Batt Cap ’ , select ‘ Yes ’ and press ENT to confirm. Back to the ‘ Batt

Settings ’ screen, enter the ‘ LargeDU ’ screen to set the battery current sampling coefficient. (The battery string index is related with the connected DC cabinet address and battery string number, if the DIP of DC Distrib 1 is set to 72, and the the DIP of DC Distrib 2 is set to 73, and the battery string number is set to 2, then the battery current coefficient of battery string1 and battery string 2 is the shunt coefficient of two battery ports in DC Distrib 1, and the current coefficient of battery string 3 and battery string 4 is the shunt coefficient of two battery ports in DC Distrib 2.)

Figure 71: Setting battery nominal capacity

Auto EQ:

Yes

Rated Capacity:

500Ah

Reset Batt Cap:

Yes

Charge

Figure 72: Setting battery string sampling coefficient

Batt Settings

Charge >

Battery Test >

Temp Comp >

LargeDU Batt1 >

LargeDU Batt2 >

Batt Settings

Charge >

Battery Test >

Temp Comp >

LargeDU Batt1 >

LargeDU Batt2 >

Back to ‘ Batt Settings ’ screen, enter ‘ Temp Comp ’ screen, set the ‘ Temp Comp Coeff ’ according to battery factory requirement. The default value is 72mV/°C (If no temperature sensor is configured, ignore this item), and set the ‘ TempComp Sensor ’ to ‘Ldu1 Temp1’ , as shown in Figure 73 . (If no temperature sensor is configured or the temperature compensation function needs to be canceled, then set the ‘ TempComp Sensor ’ to ‘ None ’ ). Meanwhile, set ‘ DC Settings ’  ’ DC Distrib 1  ’ Temp

Number ’ to 1 ~ 2 (if no temperature sensor is configured or the temperature compensation function needs to be canceled, then set the ‘ Temp Number ’ to ‘ 0 ’ ), as shown in Figure 74 .


Figure 73: Setting Temp Comp parameter

TempComp

TempComp Sensor:

LDU1-Temp1

TempComp Center:

25deg. C

Temp Comp Coeff:

72mV/deg. C

Figure 74: Setting Temp Number

DC Distrib1

Sensor Coeff:

4000

Num of Battery:

2

Temp Number:

1

NOTE!

‘ L du1 Temp1’ corresponds to the DC distribution screen that with the lowest address, therefore the temperature cable used to set the battery compensation temperature must be plugged into J16 terminal of the HDUL monitoring board with the lowest address. In DC screen.

Back to ‘ Batt Settings ’ screen, and enter the ‘ Charge ’ screen, set the ‘ Float Voltage ’ (default value:

53.5V) and ‘ EQ Voltage ’ (default value: 56.4V) according to the recommended value of the battery supplier, as shown in Figure 75 . For free EQ charge battery, the EQ voltage can be set 0.1V higher than the float voltage. Set the battery current limit according to Figure 75 .

Figure 75: Setting float/EQ voltage

Float Voltage:

53.5V

EQ Voltage:

55.0V

Batt Curr Limit:

0.09C10

Charge

Checking Alarm and Operation Status

Testing Controller

The controller can be tested after the parameter setting is completed based on the actual system configuration and battery management requirements.

Communication test

When the system is in normal operation, disconnecting the communication cable of any unit (AC distribution cabinet, DC distribution cabinet and controller) will interrupt the communication between the controller and this unit as well as other units in serial connection with this unit, and cause the controller to generate communication failure alarm. Real time data will be displayed in contrast with the background in LCD. By reconnecting the communication cable, the system will recover automatically.


Boost charge and float charge changeover

Click the setting icon, input user name ( ‘ admin ’ ) and password ( ‘ 1 ’ ) to enter the ‘ Settings ’ 

‘ Maintenance ’ screen, set the ‘ Auto/Man State ’ to ‘ Manual ’ , as shown in Figure 76 .

Figure 76: Setting Auto/Man State

Maintenance

Auto/Man State:

Auto

EQ/FLT Control:

EQCharge

LVD1:

LVD 1 Reconnect

Maintenance

LVD2:

LVD2 Reconnect

BattTestControl:

Stop

Rect Curr Limit:

121%

When the system is in float charge state, click the setting icon, input user name ( ‘ admin ’ ) and password ( ‘ 1 ’ ) to enter the ‘ Settings ’  ‘ Maintenance ’ screen, change the ‘ EQ/FLT Control ’ to ‘ EQ charge’, as shown in Figure 76 . The system will enter into EQ charge state, and the rectifiers will output EQ charge voltage . Change it back to ‘ F loat charge’ and the system will return to float charge state.

Rectifier adjustment

1. Refer to Setting the Position Number of The Rectifier Manually to enter the rectifier setting interface. Test the switching-on/off of the rectifier, the rectifier switching-on/off should be under control and normal.

2. Set the system float/EQ voltage in the LCD of the controller according to Setting Basic

Parameters for Controller , the rectifier voltage should be normally adjustable.

3. Under the condition that all the rectifier outputs are normal, observe and record the rectifier current-sharing characteristics at different total loads.

System status query

When the system has an alarm, at the main page of the controller, press and to move the cursor on , and press ENT to enter ‘Active Alarms’ screen, then you can view the active alarms; enter ‘Alarm History’ to view all the history alarms.

Figure 77: Main page of the controller

25/03/2014

09:22:58

R: 380V

S: 380V

T: 380V

53.5 V

0.0 A

100%

100% 100%

系统使用容量 : 0.0%

53.5 V

3600.0 A


Figure 78: Alarm page of the controller

Alarm

Active Alarms >

Alarm History >

At the main page of the controller, press and to move the cursor on , , , , and press

ENT to enter ‘AC’, ‘ Module ’, ‘DC’, ‘Battery’ submenus separately. Each s ubmenu will respectively display the status of equipment group and single equipment. Take ‘AC’ for example, you can query the ‘AC DistGroup’ and ‘AC Distrib1 ~ X’ separately. Press ESC to return to the previous menu.

Figure 79: Querying system status

25/03/2014

09:22:58

R: 380V

S: 380V

T: 380V

53.5 V

0.0 A

100%

100% 100%

系统使用容量 : 0.0%

AC DistGroup >

53.5 V AC Distrib 1>

3600.0 A

Testing AC Distribution

1. At the MAINMENU screen of the controller in AC cabinet , you can view the ‘AC Online’, ‘Status’,

‘Ctrl Mode’ and ‘SPD’, as shown in Figure 80 .

Figure 80: MAINMENU screen

AC Online: 1

Status: Alarm

Ctrl Mode: Manaul

SPD: Failure

2. Open the SPD MCB, the ‘SPD’ will display ‘Failure’, and meanwhile the ‘AC output MCB off alarm’ should be triggered on the controller in rectifier cabinet. After closing the SPD MCB, the ‘SPD’ should resume to ‘Normal’.

Figure 81: SPD failure alarm

AC Online: 1

Status: Alarm

Ctrl Mode: Manaul

SPD: Failure

3. Press and to enter the second screen, and check that the AC input current is consistent with actual input current.


Figure 82: AC input current

Current ：

Ia: 0.0A

Ib: 0.0A

Ic: 0.0A

4. In the case of accessing the battery, switch the two routes of AC input, the ‘AC Online’ should correspondingly display ‘1’ or ‘2’. Press and to enter the third or fourth screen, the corresponding AC1 should display ‘On’ or ‘Standby’.

Figure 83: AC online (1)

AC Online: 1

Status: Alarm

Ctrl Mode: Manaul

SPD: Failure

Figure 84: AC online (2)

AC 1 ： On 50Hz

-Uab ： 380V

-Ubc ： 380V

-Uca ： 380V

5. Press the ‘TEST’ button on any output circuit breaker panel, and press and to enter the fifth screen, the ‘DI Status: On’ should be changed to ‘Off’, and meanwhile the ‘AC output MCB off alarm’ should be triggered on the controller in rectifier cabinet. After switching on the circuit breaker, the ‘DI Status: Off’ should resume to ‘On’, and the alarm will disappear. Check each output circuit breaker in turn, and the results should meet the above description.

Figure 85: Output MCB off alarm

DI Status:

In: On Out: Off

Branch:

01: —— 02: ——

Testing DC Distribution

Connect some loads to the system and test the battery protection characteristics using the following steps.

1. At the MAINMENU screen of the controller in rectifier cabinet, press and to move the cursor on the setting icon , click this icon to enter the setting screen.

2. Input user name ( ‘ admin ’ ) and password ( ‘ 1 ’ ) to enter ‘ DC Settings ’  ’ DC DistGroup ’ , change the

‘ Under Voltage ’ to 52V, as shown in Figure 86 . Then reduce the load, and open the AC input MCB of the rectifier, the battery will discharge to the load, and the output voltage will decrease. When the battery output voltage drops below the undervoltage alarm point, the controller will generate battery undervoltage alarm.


Figure 86: Setting undervoltage alarm point

DC DistGroup

Over Voltage:

58.5V

Under Voltage:

45.0V

DC Settings

DC DistGroup>

DC Distrib1>

Branch CurrCoeff:

500

5. Entering ‘ DC Settings ’  ’ DC DistGroup

32

’ screen to lower the system overvoltage alarm point (for example, 52V), as shown in Figure 87.

When the output voltage of the module exceeds the alarm should automatically disappear.

Figure 87: Setting overvoltage alarm point

DC DistGroup

Over Voltage:

58.5V

Under Voltage:

45.0V

DC Settings

DC DistGroup>

DC Distrib1>

6. Connect a small load between the output terminal of a fuse link and the positive busbar (10k Ω resistance recommend), and pull out this fuse link, the controller should display ‘Out put ** disconnect’ alarm. Plug in the fuse link again, and the system will resume normal.

Temp Number:

7. Click the setting icon to enter the setting screen, input user name ( ‘ admin ’ ) and password ( ‘ 1 ’ ) to enter the ‘ Settings ’  ‘ Maintenance ’ screen, set the ‘ Auto/Man State ’ to ‘ Auto ’ , as shown in Figure

500

88 .

Curr Output Num:

Figure 88: Setting Auto/Man State

32

Load Measure Ty:

Hall

3000

Auto/Man State:

Auto

EQ/FLT Control:

EQCharge

LVD1:

LVD 1 Reconnect

By now, the system test is completed and the power supply system is in normal operation.

Access Controller Through Web

Login procedures are as follows:


1. To log in the controller, double-click the icon of IE to run the software, click the menus of Tools ->

Internet Options and then click the Connections button to pop up the interface shown in Figure 89 .


Figure 89: LAN setting (Step 1)

2. In the interface shown in Figure 89 , click the LAN Settings button to pop up the interface shown in Figure 90 .

Figure 90: LAN setting (Step 2)

In the above interface, uncheck the proxy option and click OK to finish the LAN setting.

NOTE!

The user only needs to do the above settings when the controller is connected to an intranet and the user has set that the access to the intranet needs to be made through proxy.

If the controller is connected to Internet and the user computer is connected to the intranet, the user cannot disable the proxy, otherwise you will have no access to the controller.


3. Select Internet Options from the Tools menu. The “Internet Options” window opens . In the

“Internet Options” w indow, select the General tab, as shown in Figure 91 .

Figure 91: Internet options

4. Click on the Settings button. The following window opens, as shown in Figure 92 . In the Settings window, choose “Every time I visit the webpage” and click OK.


Figure 92: Temporary internet files and history settings

5. In the “Internet Options” window, select the Security tab, as shown in Figure 93 .

Figure 93: Security tab


6. Click on Trusted sites . The following window opens, as shown in Figure 94.

Figure 94: Trusted sites

7. In the Trusted sites window, type or copy the address in the “ Add this website to the zone: ” box , as shown in Figure 95 .

Figure 95: Adding trusted sites (1)

NOTE!

Please check that you are using an address that starts with ‘https’, if not, but an address like http://10.39.3.200

, then uncheck the ‘Require server verification (https:) for all sites in the zone:’ box.


8. In you r browser, enter the controller’s IP address, User can view the IP address: Main menu 

Settings (password:1)  Communication Parameter, and then press the ENT key.

The following Web Interface Login window opens, as shown in Figure 96 . Enter a valid User Name and Password, and then click LOGIN.

By default, the “User Name” is "admin" and the “Password” is “ 1 ”.

Figure 96: Login the controller


9. Check whether all parameters in Figure 97 are correct.

Figure 97: M831D Homepage

10. Control the boost/float and rectifier switch, check whether the control function is correct.

11. Simulate fault alarms on the power system, and then check whether corresponding alarms are displayed in the homepage.


OPERATION

This chapter introduces the operation of the power distribution LCD, procedures of adding loads and rectifiers.

Power Distribution LCD Operation

1. LCD operation of AC distribution cabinet and DC distribution cabinet

The power distribution LCDs can display AC/DC power distribution data of communication power supply system. They are mounted on the front door of AC and DC distribution cabinet.

 Six keys are positioned below the LCD.

 ▲ , ▼ : Scroll the screen.

 ◄ , ► : Adjust the display brightness.

 ESC: Exit language switch interface without changing the language.

 ENT: confirm the language switch.

The displayed contents vary depending upon the different distribution forms.

If left idle for a certain time, the backlight will be off and the display will switch to the original screen. When you set parameters for the power distribution cabinet through the controller, the display will switch to the original screen if the currently displayed parameters are changed.

The LCDs of AC distribution cabinet are shown in Table 21 .

Table 21: Display contents in AC distribution LCD

NO. DISPLAY CONTENT

1

2

3

4

Main menu

AC distribution phase A/B/C current or AC distribution current

Stat/ Freq /Volt of AC Distri 1

Stat/ Freq /Volt of AC Distri 2

5 AC input/output MCB state

The LCDs of DC distribution cabinet are shown in Table 22 .

Table 22: Display contents in DC distribution LCD

NO. DISPLAY CONTENT

1

2

3

4

Bus Volt/Bus Stat/Load Curt of DC Distri

DC Distri Batt 1 ~ 4 Curr

DC Distri Temp 1 ~ 2

Load total current/power/electric quantity

5~30 1~26 shunts current/load ratio/power/electric quantity

Note:

1. At the MAINMENU screen, press ▲ or ▼ to view display content 1 ~ 3.

2. At the MAINMENU screen, press ENT in the ‘DC distribution’ to view display content 4.

3. Press ◄ or ► in the ‘DC distribution’ to view display content 5 ~ 30.

4. Press ▲ or ▼ at any screen to adjust the cursor position


System information screen

When the controller is powered on, the language selection interface will appear, and the default language is Chinese. If you need English interface, press ▲ or ▼ for language selection and then press the ENT key to confirm. Then the inside of the controller is initialized. After the initialization, the first system information page will appear in Figure 98 . Press ▲ or ▼, ◄ or ► to view the information listed in Table 21 and Table 22 .

Figure 98: First system information screen

AC Online: 1

Status: Alarm

Ctrl Mode: Manaul

SPD: Failure

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 8 minutes, the LCD screen will automatically return to the first system information screen. The time of that return will be recorded automatically, and can be queried through the host.

4. At the system information screen, press the ESC key to display monitoring information screen. As shown in Figure 99 .

Figure 99: Monitoring information screen

Model:

CommAddr:

SW Ver:

AEM02

64

V1.00

5. At the system information screen of AC screen, press and hold the ESC and ENT keys simultaneously for several seconds, the controller will be reset, and then the system will restart (DC screen dese not have this function).

Main menu screen

The main menu is the highest-level menu of the monitoring unit. At the sub-menus of this screen, you can query the alarms information, distribution, insulation, and parameter settings of the system. The main menu screen is shown in Figure 100 .

Figure 100: Main menu screen

AC Online: 1

Status: Alarm

Ctrl Mode: Manaul

SPD: Failure

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

2. At any sub-menu of the main menu screen, press the ESC key repeatedly to return to the higherlevel menu, and ultimately return to the main menu screen.


Distribution parameter setting

All the distribution parameters are set on the LCD screen of the system main controller, except the address of AC distribution screen, ‘Total load current branch’ , ‘Total load current’, ‘ BattShunt Qty’ and ‘Shunt Coef Curr’ of DC distribution screen. See Setting Basic Parameters for specific settings.

System Settings

The system settings screen is used to set the time, date and other parameters of the controller, the setting method is as follows:

1. At the Settings screen, press ▲ or ▼ to select the ‘ Sys set ’ menu. Then press the ENT key to confirm, as shown in Figure 101

Figure 101: System settings

Lang: English

CommAddr: 64

Baud: 19200bps

Parity: N

2. Press ▲ or ▼ ◄ ►

Then press the ENT key to confirm. The controller will automatically save the setting value.

Controller Operation of Rectifier Cabinet

System Alarm and Status

Please refer to Testing Controller for querying the system status.

Distribution Parameters Setting

All the distribution parameters are set on the LCD screen of the system main controller, except the address of AC distribution screen, ‘Total load current branch’, ‘Total load current’, ‘Batt Shunt Qty’ and ‘Shunt Coef Curr’ of DC distribution screen. See Setting Basic Parameters for specific settings.

NOTE!

The ‘System Type’ in the ‘System Settings ’ screen of the DC distribution cabinet shall not be changed arbitrarily. Otherwise, the system may not work normally.

Setting the Position Number of The Rectifier Manually

When the power supply system is in operation, each rectifier is given a position number by the controller. This position number is assigned automatically, and may change when the rectifier is repowered on. Then users need to set the position number of the rectifier manually though the

Web control interface in the controller.

1. Refer to Access Controller Through Web to enter the Web homepage window.

2. Select ‘ Power System ’ tab, as shown in Figure 102.


Figure 102: Power system status tab

The Power System Status tab displays power system status in a graphical block diagram format. This includes status of the input power, modules (i.e. rectifiers, converters), DC equipment, and battery.

3. Click on the ‘ Rectifier ’ icon to access the following window, as shown in Figure 103 .


Figure 103: Rectifier status web page

Displayed on the Rectifier Device Group status page are the individual rectifiers installed in the system.

4. Click an individual rectifier icon to display its status such as "Current Limit", "Valid Rated

Current", etc., as shown in Figure 104 .


Figure 104: Individual rectifier status page

5. Hover the mouse pointer on an individual rectifier icon , this icon changes to . Click to set the individual rectifier information and set the rectifier position number to actual position number, then click the ‘ Set ’ to confirm.

6. Click to go back to the individual rectifier status page, as shown in Figure 105 .

Figure 105: Individual rectifier settings page


NOTE!

During the setting, you can set the ‘ LED Control ’ to ‘ LED Control ’ to make sure the power indicator of the corresponding module flash, so as to make sure the actual position of that module.

Adding Load

Generally, the power system is not fully loaded at the initial operation stage. Power interrupt is not allowed once the priority load is put into operation. Therefore, new load adding must be a live operation.

Before adding DC load, a good construction design must be worked out. Select the load fuse or

MCB, process and lay the load cables, and attach serial number and polarity labels to the cables.

Cable connection should start from the load end. Connect the earth cable first, and then the -48V output fuse or the MCB. The tools used must be insulated and preventive measures against possible accidents must be worked out in advance. Refer to Connecting DC Load Cables for DC load cable connection.

Adding Rectifier

1. Remove dummy plates.

Some rectifier guide rails are idle and covered with dummy plates when the power supply system is not fully configured. Before adding rectifier, these dummy plates must be removed so that new rectifiers can be mounted.

2. Insert the new rectifier into position along the guide rail and fix it. See Installing Rectifier .

3. Set the address in the controller of the corresponding rectifier.

4. Close the corresponding AC input switch to feed AC power to this rectifier.

5. Repeat steps 1 to 4 to add all rectifiers.

6. Reset parameters for controller.

NOTE!

Connection and disconnection of rectifier’s external input cables shoul d be done by maintenance personnel, and the cables must be connected before switching on the rectifier, and disconnected after switching off the rectifier. The rated current of the rectifier input MCB is 20A, and its breaking capacity is 6kA.


MAINTENANCE

This chapter introduces basic maintenance requirements, routine maintenance items, maintenance operations, basic fixing methods and emergency treatment.

Maintenance Requirements

General

To ensure quality power supply and guarantee stable and reliable operation of the communication system, operation management and maintenance are necessary to the power supply system. Basic requirements for maintenance of power supply system include:

1. Guarantee uninterrupted quality power supply to the communication equipment.

2. Carry out periodic inspection and overhaul to ensure stable and reliable operation of the power supply system and prolong its operational life span.

3. Conduct effective troubleshooting to reduce the loss caused by faults.

4. Keep the equipment and environment clean to ensure that the environment in the equipment room conforms to the basic requirements of equipment operation.

5. Use new technologies and improve maintenance methods to achieve centralized monitoring, little or even no attendance.

To sum up, the power supply system maintenance includes routine maintenance, periodic inspection and technological reform. And the maintenance must be carried out in compliance with applicable industry standards and local regulations.

Maintenance Tools and Equipment

The common tools and instruments used in maintenance of power supply system are separately listed in Table 23 and Table 24 .

Table 23: Common tools for power equipment maintenance

NAME

Joint pliers

Diagonal cutting pliers

Tweezers

Blade screwdriver

Cross screwdriver

Wrench (double end wrench or fork wrench)

QUANTITY APPLICATIONS

1 piece

1 piece

1 piece

1 set

1 set

1 set

Shape and coil the naked pins and help to weld and assemble the surface of intensive device

Cut extra leads, pins of welding surface, and nylon binding clips

Help to weld and clean, pick up mini components, and coil tiny leads

Drive and remove plain screws and open boxes

Drive and remove cross screws

Wrench 6-angle or 4-angle bolts and nuts

Socket wrench

Adjustable wrench

Electric soldering iron

Wash brush

1 set

1 set

1 piece

1 piece

A kind of spinning tool used when there is no space for operation on the screw surface

Wrench 6-angle or 4-angle bolts and nuts. Note: when in use, the adjustable tongue shall turn to the inside of the spinning direction.

Weld components

Clean the equipment and dust inside boxes


NAME QUANTITY APPLICATIONS

Handsaw

Electrician knife

1 piece

1 piece

Saw the bus and cables. Note: The saw blade shall not turn to the handle.

Peel off the skin of cables, etc.

Electrician rubber mallet 1 piece

Auxiliary materials (nonspare parts)

Rectify cables or equipment location

Commonly-used auxiliary materials include insulating tape, selfadhesive label, soldering tin, nylon bandage, etc.

Table 24: Common instruments for power equipment maintenance

NAME QUANTITY APPLICATIONS

Multimeter

2 to 3 pieces

Earth resistance tester 1 piece

Megommeter (500V and 1000V withstand voltage)

1 piece/each

AC/DC clamp-on amper meter

1 piece

Measure AC/DC voltage, current and resistance

Measure the earth resistance

Dielectric strength test

Measure current

Contact Thermometer 1 piece

Measure the temperature of the surface and junction points of equipment

High/low-frequency noise tester

1 piece

*Ampere-hour meter 1 piece

Measure noise

AC/DC load meter 1 piece

Measure battery capacity

Measure and test the load capacity of power net, rectifier and batteries

Note*: testing devices that can be omitted

REMARK

Those instruments marked with * may be configured or not to those relatively less-equipped equipment room according to actual requirements

Reference Technical Specification for Maintenance

The power supply system consists of AC power supply, DC power supply and earthing system. To ensure communication quality and power supply security, the power supply quality must conform to some basic quality standards. Reference standards for AC, DC and earth resistance are shown in

Table 25 , Table 26 and Table 27 .


Table 25: Quality standards for DC power supply

STANDARD

VOLTAGE

(V)

VOLTAGE

VARIATION

RANGE AT THE

RECEIVING

END OF

TELECOM

EQUIPMENT

(V)

NOISE VOLTAGE (MV)

PSOPHOMETRICALLY

WEIGHTED NOISE

PEAK-

PEAK

VALUE

NOISE

WIDE

FREQUENCY

NOISE

(EFFECTIVE

VALUE)

MAXIMUM

PERMISSIBLE

VOLTAGE

DROP OF

POWER

SUPPLY

CIRCUIT (V)

- 48 - 40 to - 57 ≤ 2mV

≤ 200mV

0 to

20Mhz

≤ 50mV

@3.4kHz to

150kHz

≤ 20mV

@150kHz to

30Mhz

3

24 19.8 to 28.2 ≤ 2.4mV 1.8

Note: The voltage drop at the connectors of DC power supply circuit (including the fuse of the feed line output from the discharging busbar, and battery connectors) shall be in conformity with the following requirements or the temperature rise shall not exceed the permissible value: 1. If under 1000A, every hundred ampere ≤ 5mv; 2. If above 1000A, every hundred ampere ≤ 3mv.

Table 26: Quality standards for AC power supply

NOMINAL

VOLTAGE

(V)

220

380

VOLTAGE

VARIATION

RANGE AT THE

RECEIVING

END (V)

187 ~ 242

323 ~ 418

NOMINAL

FREQUENCY

(HZ)

VARIATION

RANGE OF

FREQUENCY

(HZ)

POWER FACTOR

BELOW

100KVA

ABOVE

100KVA

50

50

± 2.5

± 2.5

≥

≥

0.85

0.85

≥

≥

0.9

0.9

REMARK

The voltage imbalance of three-phase power supply shall not exceed 4%

Table 27: Earth resistance reference standards for communication station

NAME OF THE COMMUNICATION STATION

Comprehensive building, international telecom administration, tandem office, program control exchange with over 10 thousand lines, and toll exchange with over 2,000 lines.

Program control exchange with more than 2,000 lines but less than

10 thousand lines, and toll exchange with less than 2,000 lines.

Program control exchange with less than 2,000 lines, fiber terminal station, carrier repeater station, ground satellite station, and microwave junction station

Microwave relay station, fiber relay station

EARTH RESISTANCE ( Ω )

< 1

< 3

< 5

Microwave passive relay station

< 10

< 20 (may be up to 30

 in the case of high soil resistivity)


Routine Maintenance Items

This chapter introduces routine maintenance items for power supply system and maintenance operation methods. The power supply system maintenance items are list in Table 28.

Table 28: Maintenance items for power supply system

NO

.

ITEM TEST STANDARD

TEST

TOOLS

TEST METHOD

1

System current sharing

After each rectifier is over half load, the output current imbalance between rectifiers should be less than ±3%

Calculate the imbalance based on the output current of each rectifier displayed on the controller; or the rectifier output current displayed on each rectifier

2

Display of voltage / current

The difference between the rectifier voltage, busbar voltage and various output voltages displayed on the controller shall be less than 0.2V; the difference between the sum of the displayed currents of all rectifiers and the sum of charge current and total load current shall be within the specified error range

Read the voltage and current values displayed on the controller and rectifiers, and make judgement according to the above standards

3

Parameter setting

Conduct compliance check according to the record of the previously setting parameters

(parameter table)

Reset those parameters not in conformity with the specified requirements. The operation method of parameter setting can refer to Setting Basic Parameters for Controller

4

Communicatio n function

The communication between each system unit and the controller shall be normal and there shall be no record of frequent communication interrupt between one certain unit and the controller in the historical alarm record

5 Alarm function

Alarm should be given out in case of fault

Check the testable items on the spot. Testable items include AC mains failure, damage to SPDs (SPDs with alarm indicator or alarm contact), module failure and

DC fuse blowout (test shall be conducted on unload fuse)


NO

.

ITEM TEST STANDARD

TEST

TOOLS

TEST METHOD

6

7

Protection function

Management function

8 Noise index

Conduct compliance check according to factory parameters or parameters set through the controller

The calculation, storage and battery auto-management functions performed by the controller. The historical alarm record can be queried, and the battery auto-management function is testable

Psophometrically weighted noise ≤

2mV; peak – peak noise ≤ 200mV

Noise meter, oscillogra ph

This item is generally not easy to test when the system is in the operation. It is usually conducted when the protection function of the power supply is abnormal due to frequent occurrence of AC or DC protection. Test methods including testing the AC under/overvoltage protection function through external voltage regulator and testing the DC under/overvoltage protection function by forced discharge

1. Storage function: simulate an alarm, the controller will record the alarm information.

2. Battery automanagement: the battery charge mode and charge current can be adjusted and various protections can be implemented through the monitoring module according to the data set by the user

During noise measurement, the batteries should be separated from the power equipment. However, for the sake of safety of power supply, the batteries cannot be disconnected during field operation. Therefore, this test should only be done when the communication quality of the exchange is poor and the power supply quality of the power equipment is considered not in conformity with requirements. The psophometrically weighted noise, input through the positive and negative busbar, can be measured by a noise meter, which shall be geared to “telephone noise” measurement scale.

The peak – peak noise can


NO

.

9

ITEM

Internal connection

10

Vent duct and dust deposit

TEST STANDARD

TEST

TOOLS

TEST METHOD be measured by an oscillograph. For test method refer to the equipment operation instructions

The socket shall be well connected; the cables shall be well laid out and fixed; there shall be no cables that have been squeezed out of shaped by metal components; and there shall be no partial overheat or aging of connection cables

There shall be no blockage or dust deposit in the vent ducts of rectifier fans or vent ducts in the cabinets

Hairbrush es, leather bellows, etc

Remove, clean and wash the guard boards of the vent ducts and the fan; replace them after they have been dried

11 DC cables

11 DC cables

12

Configuration of DC circuit breakers

13

Voltage drop and temperature rise of nodes

The permissible voltage drop determined in circuit design is generally less than 0.5V (low impedance distribution)

The permissible voltage drop determined in circuit design is generally less than 0.5V (low impedance distribution)

The rated current of the DC circuit breaker should not be more than twice of the maximum load current. The rated current of the circuit breaker in each special equipment room should not more than 1.5 times of the maximum load current

Note down the maximum current flowing through the cables, look up the sectional area and wiring length of the cable in the design plan, calculate the voltage drop and check whether it meets the design requirements

Check the adaptability of the circuit breakers according to the recorded maximum current of each load

If below 1000A, the voltage drop s hould be ≤ 5mV for every hundred ampere; if above 1000A, the voltage drop should be ≤ 3mV; and the temperature rise of node should not exceed 70°C

Multimet er, semicond uctor thermom eter

Use multimeter to measure the voltage drop between the buses and cables at the two terminals of the node; and judge the rationality of the voltage drop of the node based on the current flowing through the node. Use the semiconductor thermometer to measure the temperature rise of the node. The measurement results should meet the temperature rise limitation and voltage drop limitation requirements


NO

.

ITEM

14

Basic requirements

(standards issued by the

Ministry of

Information

Industry)

TEST STANDARD

1. The power supply shall be installed in a dry and wellventilated room with no corrosive gas, and the temperature inside the room is less than 30°C.

2. The input AC voltage should range from -15% to +10% of the rated value. In case of big voltage fluctuation, automatic voltage stabilizing or regulating device should be installed.

3. The operating current should either go beyond the rated value or below 10% of the rated value for a long period. Various automatic, alarm and protection functions shall be normal.

4. It shall operate under the stabilized voltage and load share mode.

5. The wiring shall be kept neat, various parts such as switches, fuse breakers, connectors and connection terminals should be well connected, and there shall be no electric corrosion.

6. The cabinets of the power equipment shall be well earthed

TEST

TOOLS

TEST METHOD

Routine Maintenance

Routine maintenance of power equipment mainly involves management of the equipment room environment and inquiry of the equipment running status. The basic requirements for the management of the equipment room environment have been presented in detail in the previous section. Inquiry of the equipment running status is a part of the routine logs, generally including the following items:

1. The inquiry of the operating status of the power supply equipment can be completed through the controller. The status parameters that can be inquired include mains voltage, mains frequency,

DC output voltage, boost charge/float charge status, charge/discharge current, total load current, voltage and current of each rectifier, historical alarm record, etc.

2. Streamlined logs of the power supply status. The power equipment can measure mains voltage and record mains failure alarms, but cannot complete statistical work. To conduct statistical analysis of the operating status of the power grid, there shall be a detailed streamlined log of the status of the power net. In general, the status of the power grid shall be recorded once about every

2 hours, including the voltage and current of each phase of the power grid, the start and recovery time of mains failure, and the startup time and break time of the generator, etc.

3. Streamlined logs of the DC power supply status. The requirements for the streamlined logs of the

DC power supply status are similar to those for the streamlined logs of the AC power supply status.

Log items include DC output voltage, current of main loads, charge/discharge voltage and current, total load current, etc.


4. Faults maintenance. Overhaul and maintenance of other equipment shall be conducted in accordance with the requirements and methods provided by the manufacturer. But, during the routine maintenance, be sure to write down the fault causes and the maintenance results in the

“equipment calendar” . An equipment calendar shall be kept for each piece of equipment in the equipment room.

Basic Inspection

Handling Controller Fault

When the faults of the controller affect the DC power supply, turn off the controller.

Handling Rectifier Fault

NOTE!

If a rectifier is pulled out or there is faulty rectifier, users should reset the controller.

Or else the batteries cannot be boost charged

Fault phenomenon and handling method

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

The indicators positions are shown in Figure 106 .

Figure 106: Rectifier indicator position

Power indicator


Fault indicator

Change the position of the abnormal and normal rectifiers upon abnormity. If the abnormal rectifier still cannot work normally, refer to Table 29 to dispose the faults.

Table 29: Disposal methods for rectifier faults

FAULT

RELATED

ALARM

FAULT CAUSE

Power indicator off (green)

No alarm No input or output voltage

Fan is blocked

Protection indicator on

(yellow)

Rectifier over temperatur e

Main causes of overhe at protect ion for rectifie r

The vent duct is expedited: there are some blockages at air intake or air outlet

High temperature or pyrotoxin is near to the air intake of rectifier

The rectifier isn ’ t absolutely inserted into


PROPOSAL

Ensure having input and output voltage

Remove the object which blocks the fan operation

Remove the blockage at air intake and air outlet

Decrease ambient temperature or remove the pyrotoxin

Reinsert rectifier

108

FAULT

RELATED

ALARM

FAULT CAUSE PROPOSAL

Rectifier protection the frame

No current sharing

PFC output overvoltage protection

AC input voltage exceeding the normal range

Check the rectifier communication whether normal or not. If not, continue to check the connection of communication lines. Replace the fault rectifier when it works normally

Change the position of the abnormal and normal rectifiers. Replace the abnormal rectifier if it cannot work normally all the same

Ensure the AC input voltage whether in normal range or not

Protection indicator flashing

(yellow)

Rectifier communic ation failure

Rectifier communication failure

Check the communication lines connection whether well or not

Fault indicator on

(red)

Rectifier failure

Overvoltage

Remove the abnormal rectifier and restart. Replace the rectifier if it occurs overvoltage again

Fault indicator flashing (red)

Rectifier fan fault

Fan fault

Fault description

1. Internal short-circuit of rectifier

Replace new fan

The rectifier will automatically exit the system in case of internal short-circuit.

2. Damage to partial rectifier

In case of damage to partial rectifiers, if the remaining undamaged rectifiers are able to meet the power supply requirements of loads, just turn off the AC input switches of the damaged rectifiers.

3. Rectifier output overvoltage

The overvoltage of a single rectifier will not cause the overvoltage protection of all rectifiers.

However, if overvoltage protection occurs to all rectifiers, the system cannot recover automatically.

Treatment: turn off the AC input switches of all rectifiers and remover the rectifier to disconnect it.

At this time, the system voltage should be below 56.4V. Then insert rectifier one by one and turn on the AC input switches to observe the output current of it. When the AC input MCB of a certain rectifier is switched on, its output current is obviously bigger than that of the others. When the system voltage is higher than 56.4V, the rectifier with bigger output must be faulty Replace it. If all the rectifiers show the same symptom, you must turn off the monitoring and rectifiers and then restart the rectifiers.

NOTE!

During the treatment of rectifier fault, delete the address code of the closed rectifier in the rectifier parameters setting through the controller. Refer to M831D Controller User

Manual for deleting method.


Replacing Rectifier

NOTE!

Rectifier surface temperature may be high, be careful when you pull out the rectifier.

When rectifier is faulty, see the following procedures to replace:

1. Check the new rectifier to see whether there is any damage.

2. Disconnect the AC input MCB of the rectifier and loosen the fixing screw on the panel of the rectifier. See Figure 107 .

Figure 107: Rectifier position slide switch

Fixing screw Handle

Slide switch

3. Grasp the handles, pull the module out of the cabinet slowly until it stops, and put the slide switch on position. Then pull out the rectifier completely. Observe whether there is a appropriate controller alarm.

4. Disconnect the rectifier switch, put the slide switch on position, grasp the handles, and push the rectifier into cabinet slowly, until it stops, as shown in Figure 108 .

Figure 108: Replacing rectifier (1)


5. Put the slide switch on position. And then push the rectifier to the bottom until the rectifier panel is on the same level as the rectifier rack panel, as shown in Figure 109 .


6. Push the handle to the front panel, as shown in Figure 110 .


7. Tighten the fixing screw on the handle to fix the rectifier on the rack, as shown in Figure 111.


8. Close the AC input MCB of rectifier.

The power indicator of rectifier will light up after a short delay, and then the fan operates. The alarm stops.

9. Check the following items, including: the controller can identify the new rectifier; the new one has the same current sharing with the others; the controller will generate alarm when pulling out the new one. If all the checks are accordant, the new one operates normally.

Emergency Treatment

In order to keep uninterrupted DC power supply of the power supply system, some emergency measures shall be taken to cope with the faults that threaten DC power supply.

Faults that may occur in the power supply system and cause output interrupt mainly include unrecoverable damage to AC distribution circuit, short circuit of DC load or DC distribution, system shutdown due to breakdown of the controller, and blockage of rectifier due to DC output overvoltage, etc.

Emergency treatment of AC distribution

In case of failure of AC power supply to rectifier due to AC distribution fault, the AC mains can be directly introduced into the input switch of the rectifier.


Emergency treatment of DC distribution

1. Partial short-circuit of load

Disconnect the branch fuse that corresponds to the damaged loads. Replace the faulty fuse. If the fuse link is replaced for other reasons, it must make clear whether the load circuit where the fuse link is located permits power disconnection.

2. Distribution short circuit

When this fault occurs, it shall be treated as follows: disconnect the AC power supply; isolate the batteries from the system; and then use batteries and rectifiers to directly supply power to load.

Power failure

AC power failure is the general case in the operation of power supply system. If the continuous time is not long, the batteries are feed to DC. However, if the power failure is not clear or the continuous time is too long, restart the generator to power. And then transfer to feed the power supply system after 5min in order to reduce the effects to the power supply equipment during the process from starting to transition for generator.

Disastrous accidents

Disastrous accidents refer to communication equipment faults arising from disasters such as lightning strike, flood, earthquake and fire. For those disasters that may severely affect the safety of communications, emphasis shall be mainly laid on prevention. Meanwhile, communication exchanges shall have adequate human and material resources and work out effective countermeasures to deal with these disasters. They shall also prepare emergency management regulations and grave accidents rush-repair rules.


APPENDIX 1 TECHNICAL PARAMETERS

Table 30: Technical parameters of rectifier cabinet

PARAMETER

CATEGORY

PARAMETER DESCRIPTION

Operating temperature

-5°C ~ 40°C

Storage temperature

-40°C ~ 70°C

Environmental

Relative humidity 5%RH ~ 95%RH

Altitude

Other

≤ 2000m (derating is necessary above 2000m)

No conductive dust or erosive gases. No possibility of explosion

AC input system 3-phase 4-wire and 3-phase 5-wire

Rated input line voltage

380Vac

AC input

Input voltage range

Input AC voltage frequency

260Vac ~ 530Vac (error: 5Vac)

45Hz ~ 65Hz

Max input current

≤ 130A (304V input, Rack1000, Rack2000)

≤ 105A (304V input, Rack1500)

DC output

Mechanical

Power factor ≥ 0.98

Rated voltage 53.5Vdc

Nominal voltage 48Vdc

Output DC voltage 42Vdc ~ 57.6Vdc

Max output current

Rack1000-A: 1000A

Rack1500-A: 1500A

Rack2000-A: 2000A

Total regulation ≤ 1 %

Efficiency ≥ 90 %

Dimension (mm)

Weight (kg)

Rectifier cabinet

Controller M831D

2000 (H) × 600 (W) × 600 (D)

42 (H) × 86.6(W) × 211.5 (D)

Rectifier R48-5800A, R48-5800e 88 (H) × 244 (W) × 372 (D)

Rectifier cabinet (not including rectifier)

Rack1000-A ≤ 140

Rack2000-A ≤ 180

Controller M831D ≤ 2

Rectifier R48-5800A, R48-5800e ≤ 8

Table 31: Technical parameters of AC distribution cabinet

PARAMETER

CATEGORY

PARAMETER

Environmental

Operating temperature

Storage

DESCRIPTION

-5°C ~ 40°C

-40°C ~ 70°C


PARAMETER

CATEGORY

PARAMETER

AC input

AC output

Mechanical parameters

DESCRIPTION temperature

Relative humidity 5%RH ~ 95%RH

Altitude ≤ 2000m (derating is necessary above 2000m)

Other

AC input system

Input AC voltage frequency


TN-C, TN-S, TN-C-S and TT formats with three- phase four- wire or three- phase five- wire styles

Rated input phase voltage

380Vac

Input voltage range

260Vac ~ 530Vac (error is 5Vac)

45Hz ~ 65Hz

45Hz ~ 55Hz (PD380/630AFA-A-Y1)

PD380/400AFH-A-Y1:

10-route 3-phase output, 4-route single phase output, output total capacity not exceeding 400A:

160A/3P × 4, 100A/3P × 2, 63A/3P × 2, 32A/3P × 2, 63A/1P × 2,

32A/1P × 2

Distribution parameters

PD380/630AFH-A-Y1:


160A/3P × 6, 100A/3P × 2, 63A/3P × 2, 32A/3P × 2, 63A/1P × 4,

32A/1P × 4

PD380/630AFA-A-Y1:


160A/3P × 6, 100A/3P × 2, 63A/3P × 2, 32A/3P × 2, 63A/1P × 4,

32A/1P × 4

PD380/630AFH-A-YF: configuration in accordance with customer requirement （ If the input switch using MCB, shall not exceed the total capacity of the Cabinet input of MCB 80%)

Dimension (mm) 2000 (H) × 600 (W) × 600 (D)

Weight (kg) ≤ 280

Table 32: Technical parameters of DC distribution cabinet

PARAMETER

CATEGORY


Operating temperature -5°C ~ 40°C

Storage temperature -40°C ~ 70°C

Environmental

Relative humidity

Altitude

5RH ~ 95%RH

≤ 2000m (derating is necessary above 2000m)

DC input

Other

Rated input voltage

Input voltage range

Rated input current


48Vdc

42Vdc ~ 57.6Vdc (error: 0.3Vdc)

PD48/1600DF-A-Y1: 1600A ； PD48/1600DF-A-Y2: 1600A


PARAMETER

CATEGORY


DC output Distribution parameters

Mechanical parameters

Dimension (mm)

Weight (kg)

；

PD48/2500DF-A-Y1: 2500A ； PD48/2500DF-A-Y2: 2500A

PD48/2500DF-A-Y3: 2500A

PD48/1600DF-A-Y1

Battery charge current : ≤ 400A

Total load current : ≤ 1200A

18 routes load output:

400A (NT3) × 12, 200A (NT2) × 4, 100A (NT00) × 2,

8 shunts current sampling

PD48/1600DF-A-Y2




630A (NT3) × 4, 500A (NT3) × 6, 200A (NT2) × 4, 100A

(NT00) × 2,


PD48/2500DF-A-Y1




500A (NT3) × 16, 200A (NT2) × 4, 100A (NT00) × 2,


PD48/2500DF-A-Y2




630A (NT3) × 6, 500A (NT3) × 8, 400A (NT2) × 4, 100A

(NT00) × 2,


PD48/2500DF-A-Y3




500A (NT3) × 12, 200A (NT2) × 2, 100A (NT00) × 4,


PD48/1600DF-A-YF: Configured according to customer requirement

PD48/2500DF-A-YF: Configured according to customer requirement

2000 (H) × 800 (W) × 600 (D)

PD48/1600DF-A-Y1 ≤ 280, PD48/1600DF-A-Y2 ≤ 280

PD48/2500DF-A-Y1 ≤ 290, PD48/2500DF-A-Y2 ≤ 290,

PD48/2500DF-A-Y3 ≤ 290

PD48/2500DF-A-YF, PD48/1600DF-A-YF ≤ 290


APPENDIX 2 ALARM LIST

Table 33: Alarm list

SN

Alarm device

1

2

3

4

5

M831D system

Alarm name

SelfDetect Fail

CAN Com fail

Config Error 1

Config Error 2

Imbalance Curr

Alarm category

Related relay

Alarm description

Observation None Controller hardware failure

Observation None

No rectifier is able to communicate

Observation None

Observation None

Critical Relay 1

This alarm occurs when configuration file has error.

This alarm occurs when backup configuration file has error

The rectifier output current is not equal to sum of the load current detected by the DC distribution unit and the battery current. The alarm reasons are as follows:

1. Battery shunt coefficient is wrongly set; 2. Part of the rectifiers are not monitored by the controller; 3. Wiring of

DC distribution unit is wrong.

Judging method:

1. When there are more than

2 rectifiers, if the absolute value of the sum of rectifier output current, load current of DC distribution unit and battery current is bigger than the 2.5 X number of rectifiers

(current of each rectifier is

2.5A), then the current is unbalanced.

2. When there are less than 2 rectifiers, if the absolute value of the sum of rectifier output current, load current of DC distribution unit and battery current is bigger than the 5 X number of rectifiers

(current of each rectifier is

5A), then the current is unbalanced.

If the alarm condition is met, there is a 50s delay.

An exception:

If the system has a LVD alarm, ‘ System current unbalance ’ alarm does not occur


11

12

13

14

16

17

6

7

8

9

10

18

19

20

25

26

27

28

21

22

23

24

29

30

31

32

33

34

SN

35

36

37

38

39

Alarm device

M831D system

Rect Group

Rectifier

Alarm name

Alarm category

Over Load Observation

EStop/EShutdown Critical

DHCP Failure

PLC Config Err

485 Comm Fail

Observation

Observation

Critical

Over Voltage 1

Over Voltage 2

Under Voltage 1

Critical

Critical

Critical

Under Voltage 2 Critical

DG Run OverTemp Observation

DG1 is Running Observation

DG1 is Running

DG1 Failure

DG1 Failure

Observation

Observation

Observation

Grid is on

Hi Ambient Temp

Observation

Observation

Lo Ambient Temp Observation

Sensor Fault Observation

DI1 Alarm

DI2 Alarm

DI3 Alarm

DI4 Alarm

Critical

Critical

Critical

Critical

DI5 Alarm

DI6 Alarm

DI7 Alarm

DI8 Alarm

IB Comm Fail

Critical

Critical

Critical

Critical

Critical

Related relay

Multi-Rect Fail Critical Relay 4

Rectifier Lost

ECO Active

AllRectCommFail

ECO Cycle Alarm

AC Failure

Major

Observation

Major

Observation

Major

Relay 4

Relay 4

Alarm description

This alarm happens when rectifier AC power fails.

The controller can memorize the number of rectifiers. If the number of detected rectifiers is less than the number memorized by the controller, then this alarm occurs. This alarm can only be ceased manually

This alarm happens when rectifier AC power fails


41

42

43

44

SN

Alarm device

40

45

46

Rectifier

47

48

49

50

51

52

53

54 Battery

Group

55

56

57

58

Alarm name

Rect Temp High

Rect Fault

Over Voltage

Rect Protected

Fan Failure

Current limit

Rect Comm Fail

Derated

Curr Shara Alm

Low AC Protect

ShortBatTestRun

EQ for Test

Manual Test

Planned Test

AC Fail Test

Manual EQ

Auto EQ

Cyclic EQ

Dsch Curr Imb

Alarm category

Observation None

Major

Major

Observation None

Major

Observation None

Major

Observation

Observation

Major

Observation

Observation

Observation

Observation

Observation

Observation

Observation

Observation

Observation

Related relay

Alarm description

Relay 4

Relay 4

Relay 4

Relay 4

This alarm happens when rectifier has over temperature fault

This alarm happens when rectifier fails

This alarm happens when DC output over voltage occurs

This alarm happens when rectifier is under protection

This alarm happens when rectifier fan fails.

This alarm happens when rectifier limits its output current

This alarm happens when rectifier communication fails

The alarm happens when rectifier power limit occurs

The alarm happens when rectifier current unbalance occurs

The alarm happens during short test

The alarm happens during pre-boost charging

The alarm happens during manual battery test

The alarm happens during planed battery test

The alarm happens during AC power failure test

The alarm happens during manual battery test

The alarm happens during auto boost charging

The alarm happens during timed boost charging

The alarm happens when discharging current is unbalanced


68

69

70

71

76

77

78

79

72

73

74

75

80

81

82

83

SN

59

60

61

62

63

64

65

66

67

Alarm device

Battery

Group

Large DU

Batt

Alarm name

Alarm category

Related relay

Alarm description

Abnl Batt Curr Observation

TempComp Active Observation

Battery Disch

Battery TestFail

VHi Batt Temp

High Batt Temp

Low Batt Temp

TempSensorFail

Batt Fuse Fail

Batt Over Volt

Batt Under Volt

Batt Over Curr

Observation

Major

Observation

Observation

Observation

Observation

Critical

Critical

Critical

Critical

Relay 3

Relay 3

Relay 3

Relay 3

When the boost charging time is longer than “boost charging protection time”, then system changes to float charging, at this time, the controller checks if the battery current meets the conditions for transferring to boost charging condition, and this alarm happens if this condition is satisfied 3 times

The alarm happens when temperature compensation is enabled

The alarm happens during current limitation process

The alarm happens if the battery test is ended because the voltage is reduced to

“Voltage of end of batte ry test”

The alarm happens if battery charging current is bigger than “battery current limiting point”

Large DU

AC Dist

Mains Failure


Mains 1 Fail

Mains 2 Fail

Mains 3 Fail

M1 Uab/Ua Fail

M1 Ubc/Ub Fail

M1 Uca/Uc Fail

M2 Uab/Ua Fail

M2 Ubc/Ub Fail

M2 Uca/Uc Fail

M3 Uab/Ua Fail

M3 Ubc/Ub Fail

M3 Uca/Uc Fail

Major

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Critical

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2

Relay 2


SN

Alarm device

Alarm name

Alarm category

Related relay

Alarm description

89

90

91

92

93

94

84

85

86

87

88

95

97

98

108

109

110

111

112

113

99

100

101

102

103

105

106

107

114

115

116

117

118

119

120

121

122

123


DC distribution cabinet

Over Frequency

Under Frequency

Observation None

Observation None

M1 Uab/Ua OverV Observation Relay 2

M1 Ubc/Ub OverV Observation Relay 2

M1 Uca/Uc OverV Observation Relay 2







M1 Uab/Ua UnderV Observation Relay 2

M1 Ubc/Ub UnderV Observation Relay 2

M1 Uca/Uc UnderV Observation Relay 2







Input MCCB Trip Critical

Output MCCB Trip Critical

Relay 2

Relay 2

SPD Trip

Comm Fail

DC Over Volt

DC Under Volt

Critical

Critical

Critical

Critical

Output1~64 Discon Critical

Comm Fail Critical

LVD1

LVD2

Critical

Critical

Relay 2

Relay 2

Relay 3

Relay 3

Relay 3

Relay 3

Relay 3

Relay 3

The LVD1 alarm is generated in LVD equipment, not in DC distribution screen

The LVD2 alarm is generated in LVD equipment, not in DC distribution screen

T1 Over Temp

T2 Over Temp

T3 Over Temp

T1 Under Temp

T2 Under Temp

T3 Under Temp

T1 Sensor Fail

T2 Sensor Fail

Critical

Critical

Critical

Major

Relay 3

Relay 3

Relay 3

Relay 3

Major

Major

Relay 3

Relay 3

Observation None

Observation None


SN

Alarm device

124

Alarm name

T3 Sensor Fail

Alarm category

Related relay

Observation None

Alarm description


APPENDIX 3 ENGINEERING DESIGN DIAGRAM

Engineering design diagram for AC distribution cabinet

Figure 112: PD380/400AFH-A-Y1 engineering design diagram (front view, unit mm)

910.5

1060.5

1209.5

1359.5

2000.0

341.0

600.0


Figure 113: PD380/630AFH-A-Y1 engineering design diagram (rear view, unit mm)

364.5

724.5

2000.0

600.0


Figure 114: PD380/630AFA-A-Y1 engineering design diagram (front view, unit mm)

910.5

1060.5

1210.5

1359.5

1509.5

2000.0

341.0

600.0


Engineering design diagram for rectifier cabinet

Figure 115: RACK2000-A engineering design diagram (unit mm)

389.7

156.7

27

600

2000

1684

RACK2000-A front view RACK2000-A rear view



389.7

156.7

27

600

2000

1684




156.7

27

600

2000

1684



Engineering design diagram for DC distribution cabinet

Figure 118: PD48/1600DF-A-Y1 engineering design diagram (front view, unit mm)

213 358

100

475.5

752

50

931

1205

1642

77

40


Figure 119: PD48/1600DF-A-Y1 engineering design diagram (rear view, unit mm)

93

340



213 358

100

475.5

752

50

941

1195

1741

77

40



93

340



213 358

100

475.5

752

50

941

1185

1741

77

40



93

340



100

475.5

752

50

941

1185

1741

77

40



93

340



213 358

100

475.5

752

50

941

1065

1642

77

40



93

340


APPENDIX 4 WIRING DIAGRAM

Figure 128: PD380/400AFH-A-Y1 AC distribution cabinet wiring diagram (a)

Front view

38

XT3

W17

W18 W6

W6

1 3

2 4

39

QF0

29-J13-9

W18

40-COM

11

12

14

40

SPD

L1 L2 L3

PE

W6

N

W6

W17

41

XT3

W6

W6

46

FU1

47

FU2

W7

48

FU3

51

FU4

52

FU5

W7

53

FU6

54

FU7

55

FU8

W7

56

FU9

1 1

2 2

W24

2 2 2

W24

2 2 2

W24

2

Rear view

2

1

28

PA1

51-2

W24

53-2

1

2

27

HL2

LCD

JP2

W17

LCD

J20 J4

InIn+ IcIc+ IbIb+ IaIa+

LOAD_CURR

31

PA2

W40

RS485 cable

W29

I2C J6

CAN_LCAN_H

CAN J5

B A

RS485_2

B A

RS485_1

J7

0V 0V -48V -48V

POWER

J12

40-NC

12-B14

W18

39-11

12-B11

H4

35-1

35-2

36-2

W19

46-2

W24

48-2

2

1 26

HL1

29

XT1 PE bar

41-PE

33-PE

W6

W24

W24 W24 W24

Front door

H1

J1

A1 B1 C1 N1

J2

A2 B2 C2 N2 A B C N

J3

H2

32

PA3

PE

J4

33-PE

W24

H4

H3

W1

33

XT4

W24

W24

Cabinet

PE A1

EB_VOLT

B1 C1

J1

N1 A2

DG_VOLT

B2 C2

J2

N2 A

LOAD_VOLT

B C N

J3

W24 W24 W24


JS3

AGND2 K2b

DO_KM

AGND1 K1b

138

Figure 129: PD380/400AFH-A-Y1 AC distribution cabinet wiring diagram (b)

W19 W19

MCB alarm contact （ AC output unit 2~4 ）

35

1XK

2

1

3

36

2XK

2

1

3

12

QF12

B12

B11

B14

13

QF13

B12 B14

B11

W19 W19

14

QF14

B12

B11

B14

W18

15

QF15

B12

B11

B14

1

QS

W7

U1

W7

V1

W7

W1

W24

N1

W7

U2

U

V2

W7

38-1 1

V

W17

38-3 2

37

LH1

W7

W2

W

W6

39-2

W24

54-1

W6

W24

39-4

55-1

W6

39-6

W24

56-1

W24

N2

MCB main contact （ AC output unit 2~4 ）

12

QF12

14

QF14

13

QF13

15

QF15 W8

W5

Triode bus strip

1 3 5

2

QF2

2 4 6

1 3 5

3

QF3

2 4 6

1 3 5

4

QF4

2 4 6

1

5

QF5

2

1

6

QF6

2

W8

W5

Triode bus strip

1 3 5

7

QF7

2 4 6

1 3 5

8

QF8

2 4 6

1 3 5

9

QF9

2 4 6

1

10

QF10

2

1

11

QF11

2


W24

32-J3-1

N

N bar

30

XT2

W6

39-8

139

Figure 130: PD380/630AFH-A-Y1 AC distribution cabinet wiring diagram (a)

Front view

38

XT3

W17

39

QF0

29-J13-9

W18

40-COM

11

12

14

1 3

2 4

W6

W6

40

SPD

W18 W6

L1 L2 L3 PE

N

W6

41

XT3

W6

W6

W17

Rear view

2

1

28

PA1

51-2

W24

53-2

2

1

27

HL2

LCD

JP2

W17

LCD

J20 J4


LOAD_CURR

31

PA2

W40

RS485 cable

W29

I2C J6

CAN_LCAN_H

CAN J5

B

RS485_2

A B A

RS485_1

J7

0V 0V -48V

POWER

-48V

J12

40-NC

12-B14

W18

39-11

12-B11

H4

35-1

35-2

36-2

W19

46-2

W24

48-2

1

26

HL1

2

46

FU1

47

FU2

W7

48

FU3

51

FU4

52

FU5

W7

53

FU6

54

FU7

55

FU8

W7

56

FU9

1 1 1

2 2

W24

2

1 1 1

2 2

W24

2

1 1

2 2

W24

2

1

29

XT1 PE bar

41-PE

33-PE

W6

W24

W24 W24 W24

H1

J1

A1 B1 C1 N1

J2

A2 B2 C2 N2 A B C N

J3

H2

32

PA3

PE

J4

33-PE

W24

Front door W1

33

XT4

W24

Cabinet

W24

PE A1

EB_VOLT

B1 C1

J1

N1 A2

DG_VOLT

B2 C2

J2

N2

A

LOAD_VOLT

B C N

J3

W24 W24 W24


JS3

AGND2 K2b

DO_KM

AGND1 K1b

140

Figure 131: PD380/630AFH-A-Y1 AC distribution cabinet wiring diagram (b)

W19 W19


35

1XK

2

1

3

36

2XK

2

1

3

12

QF12

B12

B11

B14

13

QF13

B12 B14

B11

W19 W19

14

QF14

B12 B14

B11

W18

15

QF15

B12

B11

B14

1

QS

W7

U1

W7

V1

W7

W1

W24

N1

W7

U2

U

W6

39-2

W24

54-1

V2

W7

38-1 1

V

W17

38-3 2

W6

39-4

55-1

W24

W7

37

LH1

W2

W6

39-6

56-1

W24

W

W24

N2

16

QF16

B12 B14

B11

17

QF17

B12

B11

B14

MCB main cotact （ AC output unit 2~4 ）

12

QF12

14

QF14

16

QF16

13

QF13

15

QF15

17

QF17

2

QF2

W5

W8

Triode bus strip

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1

2

1

2

1

2

1

2

7

QF7

W5

W8

Triode bus strip

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1

2

1

2

1

2

1

2


W24

32-J3-1

N

N bar

30

XT2

W6

39-8

141

Figure 132: PD380/630AFA-A-Y1 AC distribution cabinet wiring diagram (a)

Rear view

W6

48

FU3

51

FU4

1

52

FU5

W6

1

53

FU6

1

W6

39

1QF1

31-J13-9

W18

40-COM

11

12

14

1

W6

1 1

54

FU7

1

55

FU8

W6

1

56

FU9

1 59

2QF1

60-NC

W18

31-J13-1

11

12

14

2 2 2 2 2 2 2

40

1SPD

W18 W6

W6

L1 L2 L3 PE

41

XT3

W6

W24

W17

38

XT3

1 3

2 4

W24

2 2

W24

60

2SPD

W18 W6

W6

L1 L2 L3 PE

61

XT3 W6

N

Front door rear view

W24 W6

28

PA1

2

1

LCD

JP2

W17

LCD

J20 J4


LOAD_CURR

31

PA2

51-2

W24

53-2

1

27

HL2

2

W40

RS485 cable

W29

I2C J6

CAN_LCAN_H

CAN J5

B A

RS485_2

B A

RS485_1

J7

0V 0V -48V

POWER

-48V

J12

40-NC

43-X4-1

12-B14

W18

43-X4-2

39-11

12-B11

43-X4-5

43-X4-6

43-X4-8

W18

W17

46-2

W24

48-2

2

1

26

HL1

W24 W6

Left side

1-X1-U1A

1-X1-U1B

1-X1-U1C

C2000 front view

1-X1-U2A

1-X1-U2B

1-X1-U2C

43

ATS-C

C2000 controller

Top

DI7 DI7 DI6 DI6 DI5 DI5 FIREFIRE+ PGND DGND RS485- RS485+

LCD

DO3 DO3 D02 DO2 DO1 DO1 ALM-COMALM-NO

X2

X3

X3

Right side

Note ： 1. If (ATS cable 230S400SLW 01-1) is unneccersary, discard it.

W40

W18 Standard cable ： LTSC2000SLW03

W18

PE A1

EB_VOLT

B1 C1

J1

N1 A2

DG_VOLT

B2 C2

J2

N2

A

LOAD_VOLT

B C N

J3

W24 W24 W24


JS3

AGND2 K2b

DO_KM

AGND1 K1b

142

Figure 133: PD380/630AFA-A-Y1 AC distribution cabinet wiring diagram (b)


12

QF12

B12

B11

B14

13

QF13

B12 B14

B11

1

ATSE

External user power-1

U1 V1 W1

W6 W6 W6 W6

W27

N1

Top

U1A(L) U1B(L)U1C(N) U2A(L) U2B(L)U2C(N)X1

W39(ATS cable)

W5

Right side

X2

External user power-2

W6

U2 V2 W2 N2

W6 W6 W6

14

QF14

B12 B14

B11

16

QF16

B12 B14

B11

W8

W18

15

QF15

B12 B14

B11

17

QF17

B12 B14

B11

Triode bus strip

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

W8

1

2

1

2

1

2

1

2

Triode bus strip

ATSE

W5

W5

2-1

3-1

W24

54-1

U

38-1 1

V

W17

38-3 2

W5

W5

2-2

3-2

W24

55-1

37

LH1

W5

W5

2-3

3-3

W24

56-1

W

W5 W5

1 3 5

2

QF1

2 4 6

1 3 5

3

QF2

2 4 6


12

QF12

14

QF14

16

QF16

13

QF13

15

QF15

17

QF17

N

N


W24

31-J3-1

N bar

30

XT2

39-8

W6

59-8

1 3 5

2 4 6

1 3 5

2 4 6

1 3 5

2 4 6

1

2

1

2

1

2


1

2

143

Figure 134: PD380/630AFA-A-Y1 AC distribution cabinet wiring diagram (c)

PE bar

29

XT1

Front door

W1

Cabinet


Figure 135: Rack2000-A wiring diagram (a)

W28

PE

+0V

49

PD3

SPD13DZ

PE 0V -48V

PE W25

+0V

-48V

-48V

W26 52-49

52-46

1

2

1

2

1

2

1

2

52-4

52-2 W26 W28

PE

W01(04116174) matched resistance

+0V

W06

W09

-

CAN+ CANPE +

31

H2-1

RECT.II-1

1

3

2

4

11-2

11-4

11-6

W04

-48V

W12


W09

21

H1-1

1

3

2

4

W04

-

CAN+ CANPE +

W06

PE

1-2

1-4

1-6

RECT.I-1

W09

W09

CAN+ CAN- PE +

32

H2-2

RECT.II-2

3

1 2

4

W06

PE

12-2

12-4

12-6

W04

CAN+ CAN- PE +

33

H2-3

RECT.II-3

1

3

2

4

W06

PE

13-2

13-4

13-6

W04

W09

W09

CAN+ CANPE +

22

H1-2

RECT.I-2

1

3

2

4

PE

2-2

2-4

2-6

W04

CAN+ CANPE +

23

H1-3

RECT.I-3

3

1 2

4

W06

PE

3-2

3-4

3-6

W04

W09

W09

CAN+ CAN- PE +

34

H2-4

RECT.II-4

1

3

2

4

W06

PE

14-2

14-4

14-6

W04

CAN+ CAN- PE +

35

H2-5

RECT.II-5

3

1 2

4

W06

15-2

15-4

15-6

W04

W09

W09

CAN+ CANPE +

24

H1-4

RECT.I-4

3

1 2

4

W06

PE

4-2

4-4

4-6

W04

CAN+ CANPE +

25

H1-5

RECT.I-5

1

3

2

4

W06

PE

5-2

5-4

5-6

W04

W09

W09

CAN+ CAN- PE +

36

H2-6

RECT.II-6

1

3

2

4

W06

PE

16-2

16-4

16-6

W04

CAN+ CAN- PE +

37

H2-7

RECT.II-7

1

3

2

4

W06

PE

17-2

17-4

17-6

W04

W09

W09

CAN+ CANPE +

CAN+ CANPE +

26

H1-6

RECT.I-6

1

3

2

4

W06

PE

6-2

6-4

6-6

W04

27

H1-7

RECT.I-7

1

3

2

4

W06

PE

7-2

7-4

7-6

W04

+0V -48V

W09

W09

W09

W12

CAN+ CAN- PE +

-

CAN+ CAN- PE +

-

CAN+ CAN- PE +

38

H2-8

RECT.II-8

3

1 2

4

W06

PE

18-2

18-4

18-6

W04

W09

CAN+ CANPE +

28

H1-8

RECT.I-8

3

1 2

4

W06

PE

8-2

8-4

8-6

W04

39

H2-9

RECT.II-9

1

3

2

4

W06

PE

19-2

19-4

19-6

W04

40

H2-10

RECT.II-10

1

3

2

4

W06

PE

20-2

20-4

20-6

W04

W09

W09

-

CAN+ CANPE +

-

CAN+ CANPE +

29

H1-9

RECT.I-9

1

3

30

H1-10

RECT.I-10

1

3

2

4

W06

9-2

9-4

9-6

W04

2

4

W06

10-2

10-4

10-6

W04

+0V -48V

W12

CAN+ CAN-

Socket rear view

1

3

-

CAN+ CANPE +

-48V +0V


PE

54

JX5

PE bar

2

4

PE

A

B

C

Rear view of controller

52

ACU+

W26

50

49

48

47

46

45

44

43

42

41 39

40 38

37 35

36 34

33

32

31

30

29

28

27 25

26 24

23 21

22 20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

W26 W26

W26 W26

To CAN bus

Bind at the rear right side of the cabinet

145

Figure 136: Rack2000-A wiring diagram (b)

47

PD1

W26

D-level SPD1

Cabinet shell

NC C PE N

L1 L2 L3

41

JX1

A

1

2

3

B

4

W02

47-L1

W01

1-1

4-1

8-1

47-L2

1-3

4-3

8-3

W01

43

FU1

47-L3

1-5

4-5

8-5

W03 W03

W01

55

HD1

44

FU2

5

C

6

Front view

A

1

2

3

B

42

JX2

4

48-L1

12-1

15-1

19-1

48-L2

12-3

15-3

19-3

W01

45

FU3

48-L3

12-5

15-5

19-5

W03 W03

56

HD2

W01

46

FU4

5

C

6

W02

Triode confluence

W01

1

QF1-1

1 3 5

2 4 6

2

QF1-2

1 3

2 4 6

5

W04

Triode confluence

11

QF2-1

1 3 5

2 4 6

1 3

12

QF2-2

2 4 6

5

W04

W01

48

PD2

W26

D-level SPD2

Cabinet shell

NC C PE N

L1 L2 L3

W02

W01

Triode confluence

W01

3

QF1-3

1 3 5

2 4 6

W04

4

QF1-4

1 3 5

2 4 6

5

QF1-5

1 3 5

2 4 6

W04

1 3

6

QF1-6

2 4 6

5

W04 W04

13

QF2-3

1 3 5

2 4 6

14

QF2-4

1 3 5

2 4 6

W04 W04

15

QF2-5

1 3 5

2 4 6

W04

16

QF2-6

1 3 5

2 4 6

W04

Triode confluence

W01

7

QF1-7

1 3

2 4 6

5

W04

1 3

8

QF1-8

2 4 6

5

W04

9

QF1-9

1 3 5

2 4 6

10

QF1-10

1 3

2 4 6

5

W04 W04

Triode confluence W01

17

QF2-7

1 3

2 4 6

5

18

QF2-8

1 3

2 4 6

5

W04

W04

1 3

19

QF2-9

2 4 6

5

20

QF2-10

1 3

2 4 6

5

W04 W04

Front view of IB2 board

51

JX3

W26

MA4C5U31 board (optional)

50

JKB

J2

52-13

W26

52-15

3

1

4

2

52-11

52-12

W26

6

1

8

9

5



W28

PE

+0V

PE

49

PD3

SPD13DZ

PE 0V -48V

W25

+0V

-48V

-48V

W26

52-49

52-46

52-4

52-2 W26

W28

PE


+0V

W09

-

CAN+ CANPE +

33

H2-3

RECT.II-3

3

1

2

4

W06

PE

13-2

13-4

13-6

W04

-48V

W12


W09

-

CAN+ CANPE +

23

H1-3

RECT.I-3

3

1

2

4

W06

PE

3-2

3-4

3-6

W04

W09

W09

CAN+ CANPE +

34

H2-4

RECT.II-4

3

1 2

4

W06

PE

14-2

14-4

14-6

W04

-

CAN+ CANPE +

35

H2-5

RECT.II-5

3

1

2

4

W06

PE

15-2

15-4

15-6

W04

W09

W09

CAN+ CANPE +

24

H1-4

RECT.I-4

3

1 2

4

W06

PE

4-2

4-4

4-6

W04

-

CAN+ CANPE +

25

H1-5

RECT.I-5

1

3

2

4

W06

PE

5-2

5-4

5-6

W04

W09

CAN+ CANPE +

36

H2-6

RECT.II-6

3

1

2

4

W06

PE

16-2

16-4

16-6

W04

W09

W09

CAN+ CANPE +

-

CAN+ CANPE +

37

H2-7

RECT.II-7

3

1 2

4

W06

PE

17-2

17-4

17-6

W04

38

H2-8

RECT.II-8

1

3

2

4

W06

PE

18-2

18-4

18-6

W04

W09

CAN+ CANPE +

26

H1-6

RECT.I-6

3

1

2

4

W06

PE

6-2

6-4

6-6

W04

CAN+ CANPE +

27

H1-7

RECT.I-7

3

1 2

4

W06

PE

7-2

7-4

7-6

W04

W09

-

CAN+ CANPE +

28

H1-8

RECT.I-8

1

3

2

4

W06

PE

8-2

8-4

8-6

W04

+0V -48V

W09

CAN+ CANPE +

39

H2-9

RECT.II-9

3

1 2

4

W06

PE

19-2

19-4

19-6

W04

W12

W09

CAN+ CANPE +

29

H1-9

RECT.I-9

3

1 2

4

W06

PE

9-2

9-4

9-6

W04

W09

CAN+ CANPE +

30

H1-10

RECT.I-10

3

1 2

4

W06

PE

10-2

10-4

10-6

W04

+0V -48V

W12

CAN+ CAN-

Socket rear view

3

1

-

8 7 6

CAN+ CANPE +

-48V +0V

2

4

PE

54

JX5

PE bar

PE

A

B

C


Rear view of controller kit

52

ACU+

W26

50

49

48

47

46

45

44

43

42

41

40

39

38

37 35

36 34

33

32

31

30

29

28

27 25

26 24

23

22

21 19

20 18

17

16

15 13

14 12

11

10

9

8

7

6

5

4

3

2

1

W26 W26

W26 W26 to CAN bus


147


47

PD1

W26

D-level SPD1

Cabinet shell

NC C PE N

L1 L2 L3

W02

47-L1

1-1

W01

4-1

8-1

W02

43

FU1

47-L2

1-3

4-3

8-3

A

1

2

41

JX1

3

B

4

47-L3

1-5

4-5

8-5

55

HD1

W02

44

FU2

5

C

6

Front view

48-L1

12-1

15-1

19-1

W02

45

FU3

48-L2

12-3

15-3

19-3

A

1

2

48-L3

12-5

15-5

19-5

3

B

42

JX2

4

56

HD2

W02

46

FU4

5

C

6

W02

W01

Triode confluence

W01

3

QF1-3

1 3 5

2 4 6

W04

4

QF1-4

1 3 5

2 4 6

W04

5

QF1-5

1 3 5

2 4 6

W04

6

QF1-6

1 3

2 4 6

5

W04

13

QF2-3

1 3 5

2 4 6

W04

14

QF2-4

1 3 5

2 4 6

W04

15

QF2-5

1 3 5

2 4 6

W04

16

QF2-6

1 3 5

2 4 6

W04


7

QF1-7

1 3

2 4 6

5

W04

8

QF1-8

1 3

2 4 6

5

W04

9

QF1-9

1 3

2 4 6

5

W04

1 3

10

QF1-10

2 4 6

5

W04


17

QF2-7

1 3

2 4 6

5

W04

18

QF2-8

1 3

2 4 6

5

W04

19

QF2-9

1 3

2 4 6

5

W04

48

PD2

W26

D-level SPD2

Cabinet shell

NC C PE N

L1 L2 L3

W02

IB2 board front view

51

JX3

W26

MA4C5U31 board (optional)

52-13

W26

52-15

50

JKB

J2

3

1

4

2

52-11

52-12

W26

6

1

8

9

5



W28

PE

+0V

-48

PE

49

PD3

PE

SPD13DZ

0V -48V

W25

+0V

-48V

W26

52-49

52-46

52-4

52-2 W26

1

2

1

2


W28

PE

+0V

W09

CAN+ CANPE +

26

H2-1

RECT.II-1

3

1 2

4

W06

PE

6-2

6-4

6-6

W04

-48

W12

1

2

1

2


1

2

1

2

1 2

W09

CAN+ CANPE +

21

H1-1

RECT.I-1

3 4

W06

PE

1-2

1-4

1-6

W04

W12

W09

-

CAN+ CANPE

+

27

H2-2

RECT.II-2

1

3

2

4

W06

PE

7-2

7-4

7-6

W04

W09

-

CAN+ CANPE

+

22

H1-2

RECT.I-2

3

1 2

4

PE

2-2

2-4

2-6

W04

1

2

1

2

W09

CAN+ CANPE +

28

H2-3

RECT.II-3

3

1 2

4

W06

PE

9-2

9-4

9-6

W04

1

2

1

2

W09

CAN+ CANPE +

23

H1-3

RECT.I-3

1

3

2

4

W06

PE

3-2

3-4

3-6

W04

W09

-

CAN+ CANPE +

29

H2-4

RECT.II-4

3

1

2

4

W06

PE

9-2

9-4

9-6

W04

1

2

1

2

W09

CAN+ CANPE +

30

H2-5

RECT.II-5

1

3

2

4

W06

PE

10-2

10-4

10-6

W04

W12

W09

-

CAN+ CANPE +

24

H1-4

RECT.I-4

1

3

2

4

W06

PE

4-2

4-4

4-6

W04

PE

54

JX5

PE bar

1

2

1

2

W09

CAN+ CANPE +

25

H1-5

RECT.I-5

3

1 2

4

W06

PE

5-2

5-4

5-6

W04

W12

CAN+ CAN-

-

9

8

CAN+

7

CAN-

6

PE

1

+

-48V +0V

Socket rear view

1

3

2

4

PE

A

B

C


Rear view of controller kit

52

ACU+

W26

50

49

48

47

46

45

44

43

42

41 39

40 38

37

36

35

34

33

32

31 29

30 28

27

26

25

24

23

22

21 19

20 18

17

16

15 13

14 12

11

10

9

8

7

6

5

4

3

2

1

W26 W26

W26 W26 to CAN bus


149


47

PD1

W26

D-level SPD

Cabinet shell

NC C PE N

L1 L2 L3

W02 47-L1

W01

2-1

4-1

7-1

9-1

W02

43

FU1

47-L2

2-3

4-3

7-3

9-3

1

A

2

W02

55

HD1

47-L3

2-5

4-5

7-5

9-5

41

JX1

3

B

4

W02

44

FU1

6

5

C

W01

Triode confluence

1 3 5

1

QF1-1

2 4 6

1 3 5

2

QF1-2

2 4 6

1 3 5

3

QF1-3

2 4 6

W04 W04

W04

Triode confluence

1 3 5

6

QF2-1

2 4 6

1 3 5

7

QF2-2

2 4 6

1 3 5

8

QF2-3

2 4 6

W04 W04

W01

W01

Triode confluence Triode confluence

W01

4

QF1-4

1 3 5

2 4 6

1 3 5

5

QF1-5

2 4 6

W04 W04

1 3 5

9

QF2-4

2 4 6

1 3 5

10

QF2-5

2 4 6

W04

W04

W04

-48V +0V


IB2 board front view

MA4C5U31 board(optional)

52-13

W26

52-15

3

1

50

JKB

J2

4

2

52-11

52-12

W26

6

1

51

JX3

W26

8

9

5

150

Figure 141: PD48/1600DF-A-Y1 DC distribution cabinet wiring diagram

Rear view Front view

W08 M+

W08 to plug terminal

2

1

32

31

NC NC RTS NC

RS485ARS485B CAN-HCAN-L RS485ARS485B

CAN-HCAN-L

J22 J21

RS485-2CAN-2

OGND TXD RXD

DCD

J19

MODEM/RS232

J23 J20

RS485-1 CAN-1

J41

J33

1

HDUL

J34

F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 to fuse output copper bar

W13

J39 J38

POWER-POWER+ POWER- POWER+

J35

BF4 BF3 BF2 BF1 F26 F25 F24 F23 F22 F21 F20 F19 F18 F17 F16

POWER+ LVD2-A POWER+

J27

DI1+ DI1DI2+ DI2- DI3+ DI3DI4+ DI4-

J26

12V+ LIGHT

J28

J1

J3

Hall sensor port J5

J7

J9

2

1

12V12V+

12V12V+

J40

LCD

12V12V+

J2

32

31

J43

HGND5V

J37

12V12V+

J4

12V12V+

12V12V+

12V12V+

J6

12V12V+

J8

J18

12V12V+ GND AI10 12V12V+

J44

J10

J15

GND VC2 VB2 VA2 VC2 VB2 VA2

J11

GND AI11 12V12V+ GND AI12 12V12V+

J12

J16

J30

LVD2-LVD2+ LVD1LVD1+

J13


J14 J17

J29

J24 to X1 to X2

GND VCC TEST VFL VFH CLK SDA SCL GND

J25

12V12V+ VFL VFH CLK SDA SCL

7-1

7-2

8-2

8-1

W14

9

PD5

48V auxilary power terminal V-

SPD13DZ

V+ PE

W11

W08 1-J35-BF1

5

1BFU

1

2

1

2

W08

1-J18-BI1-

7

RB1

1

W08

1-J18-BI1+ 2

W08

1-J35-BF2

6

2BFU

1

2

1

2

W08

1-J18-BI1-

8

RB2

W08

1-J18-BI2+

1

2

M-

W08

1-J1-12V+

1-J1-12V-

1-J1-AI1

1-J1-GND

1

2

3

4

11

TA

3-J1

W14

2

1

01

2

1

12

Shunt1

02

2

1

2

1

13

Shunt2

03

2

1

2

1

14

Shunt3

04

2

1

2

1

15

Shunt4

05

2

1

2

1

16

Shunt5

06

2

2

1

17

Shunt6

3-J2

W14

1

07

2

1

2 18

1

Shunt7

08

2

1

2 19

1

Shunt8

10

PD6 to ground

1-J34

W13

W11

20

FU1

28

FU9

21

FU2

29

FU10

22

FU3

30

FU11

23

FU4

31

FU12

32

FU13

24

FU5

33

FU14

25

FU6

26

FU7

34

FU15

35

FU16

27

FU8

Plug terminal T1

Plug terminal T2(reserved)

W13

W11

1-J25

W08

J7

W13

W08

J5

W08

Lead one earth cable to rack

To ground

W11 1-J39-POWER+

5-V+

1-J39-POWER-

5-V-

4

PD4

09

1

2

1

17

2

1

18

2

10

1

2

11

1

2

12

1

2

13

1

2

14

1

2

15

1

2

16

1

2

Plug terminal T4

W13

1-J35

36

FU17

37

FU18

2

SMPDUX3

W14 W14

J6

J4

J3

W14

J2

W14

J1

Earth cable

Front door

W10

Left rear door

W10

Rack

Rack

Right rear door

W10

Rack




W08

W08 to plug terminal

2

1

32

31

NC NC RTS NC

RS485ARS485B CAN-HCAN-L

RS485A RS485B CAN-HCAN-L

J22 J21

RS485-2CAN-2

OGND TXD RXD

DCD J23

J19

MODEM/RS232 terminal

J20

RS485-1 CAN-1

J41

J33

1

HDUL

J34

F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1 to fuse output copper bar

W13

J39 J38

J35


POWER+ POWER+

J27


J26

Reserved DI

2

1

12V+ LIGHT

J28

J1

GND AI1 12V12V+

W08

J40

LCD

GND AI2 12V12V+

J2

32

31

J43

HGND5V

J37 to R1 board

J3


J4

Hall sensor port J5

GND AI5 12V12V+

J7

GND AI7 12V12V+

GND AI6 12V12V+

J6

GND AI8 12V12V+

J8

J18

J9

GND

AI9 12V12V+

GND

AI10 12V12V+

J44

J10

J15


J11


J12

J16

（ 48V output terminal ）

J30


J29

J13

GND

AI13 12V12V+

GND

AI14 12V12V+

J14 J17

1-J39-2

W11

J24 to X1 to X2

GND VCC TEST VFL VFH CLK SDA SCL

J25

GND VCC TEST 12V12V+ VFL VFH CLK SDA SCL

W14

9

PD5

48V auxilary power terminal

V-

SPD13DZ

V+ PE

W11

W08 1-J35-BF1

5

1BFU

1

2

1

2

W08

1-J18-BI1-

7

RB1

1

W08

1-J18-BI1+ 2

W08

1-J35-BF2

6

2BFU

1

2

1

2

W08

1-J18-BI1-

8

RB2

W08

1-J18-BI2+

1

2

W08

1-J1-12V+

1-J1-12V-

1-J1-AI1

1-J1-GND

3

4

1

2

11

TA

3-J1

W14

2

1

01

2

1

12

Shunt1

2

02

1

2 13

1

Shunt2

2

03

1

2 14

1

Shunt3

2

04

1

2 15

1

Shunt4

10

PD6

To ground

1-J34

W13

16

FU1

17

FU2

18

FU3

19

FU4

W11

20

FU5

21

FU6

22

FU7

23

FU8

24

FU9

25

FU10

26

FU11

27

FU12

W11

Plug terminal T1

Plug terminal T2(reserved) W13 to fuse output copper bar

W13

1-J25

W08

J7

W08

Plug terminal T4

2

SMPDUX3

Lead one earth cable to rack

J5

To ground

W11 1-J39-POWER+

5-V+

1-J39-POWER-

5-V-

4

PD4

J6

W08

09

1

2

10

1

2

11

1

2

1

17

2

1

18

2

1

19

2

1

20

2

12

1

2

13

1

2

W13

1-J35

28

FU13

29 30 31

FU14 FU15 FU16

14

1

2

15

1

2

16

1

2

W14

J4

J3 J2

W14

J1

Earth cable

Front door

W10

Rack

Left rear door

W10

Rack

Right rear door

W10

Rack

M+

M-




M+

W08

W08

To plug terminal

2

1

32

31

NC NC RTS

NC

RS485A RS485B CAN-HCAN-L RS485A RS485B CAN-HCAN-L

TXD RXD DCD

J22 J21

RS485-2CAN-2

J23

J19


J20

RS485-1 CAN-1


J26

2

1

12V+ LIGHT

J28

J1

GND AI1 12V12V+

J40

LCD

GND AI2 12V12V+

J2

32

31

J43

HGND5V

J37

J3


J4

J33

J41

Hall sensor port J5

GND AI5 12V12V+

J7

GND AI7 12V12V+

GND AI6 12V12V+

J6

GND AI8 12V12V+

J8

J18

1

HDUL

J9


J44

J10

J34

F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

To fuse output copper bar

W13

J39 J38

POWER- POWER+ POWER- POWER+

J35


J27

POWER+ LVD2-A POWER+ POWER+ SW2 POWER+

J15


J30


J11


J12

J16

J13


J14 J17

J29

J24 to X1 to X2


J25


7-1

7-2

8-2

8-1

W14

9

PD5


V-

SPD13DZ

V+ PE

W08

1-J1-12V+

1-J1-12V-

1-J1-AI1

1-J1-GND

W11

1

2

3

4

1-J34

W13

W08 1-J35-BF1

5

1BFU

1

2

1

2

W08

1-J18-BI1-

7

RB1

1

W08

1-J18-BI1+ 2

W08

1-J35-BF2

6

2BFU

1

2

1

2

W08

1-J18-BI1-

8

RB2

W08

1-J18-BI2+

1

2

20

FU1

28

FU9

21

FU2

29

FU10

22

FU3

30

FU11

23

FU4

31

FU12

32

FU13

24

FU5

33

FU14

25

FU6

26

FU7

34

FU15

35

FU16

27

FU8

M-

11

TA

3-J1

W14

01

2

1

2

1

12

Shunt1

02

2

1

2

1

13

Shunt2

03

2

1

2

1

14

Shunt3

04

2

1

2

1

15

Shunt4

05

2

1

2

1

16

Shunt5

06

2

2

1

17

Shunt6

3-J2

W14

1

07

2

1

2

1

18

Shunt7

08

2

1

2

1

19

Shunt8

Plug terminalT1

Plug terminalT2(reserve)

W13

W11

W13 To fuse output copper bar

1-J25

W08

J7

W08

Plug terminal T4

2

SMPDUX3

W14 W14

J6

W08

Lead an earth cable to rack

J5

To ground

W11 1-J39-POWER+

5-V+

1-J39-POWER-

5-V-

4

PD4

09

1

2

10

1

2

11

1

2

12

1

2

W13

17

1

2

18

1

2

19

1

2

20

1

2

21

1

2

22

1

2

13

1

2

1-J35

36

FU17

37 38 39

FU18 FU19 FU20

40

FU21

41

FU22

14

1

2

15

1

2

16

1

2

J4

J3

W14

J2

W14

J1

Earth cable

Front door

W10

Rack

Left rear door

W10

Rack

Right rear door

W10

Rack



Rear view

W08

W08

To plug terminal

2

1

32

31

Front view

M+


J22 J21

RS485-2 CAN-2

NC NC RTS NC

TXD RXD DCD

J19


J23 J20

RS485-1 CAN-1


J41

J33

1

HDUL

J34

F15 F14 F13 F12 F11 F10 F9 F8 F7 F6 F5 F4 F3 F2 F1

To fuse output copper bar

J39

W13

J38

POWERPOWER+

J35


POWER+ POWER+

J27


J26

2

1

12V+ LIGHT

J28

J1

GND AI1 12V12V+

J3

GND AI3 12V12V+

J40

LCD

GND AI2 12V12V+

J2

32

31

J43

HGND 5V

J37

GND AI4 12V12V+

J4

Hall sensor port

J5

GND AI5 12V12V+

J7

GND AI7 12V12V+

J9

GND AI9 12V12V+

GND AI6 12V12V+

J6

GND AI8 12V12V+

J8

J18

GND AI10 12V12V+

J10

J44

J15


J11


J12

J16

（ 48V 电 power output terminal

J13

J30


J29


J14 J17

J24 to X1 to X2


J25


7-1

7-2

8-2

8-1

W14

W11

Plug terminal T1

Plug terminal T2(reserve)


W13

1-J25

W08

J7

W08

Plug terminal T4

2

SMPDUX3

Reserved

W14

J5

W08


To ground

W11 1-J39-POWER+

5-V+

1-J39-POWER-

5-V-

4

PD4

J6

J4

J3 J2

W14

J1

Earth cable

Front door

W10

Rack

Left rear door

W10

Rack

Right rear door

W10

Rack

9

PD5


V-

SPD13DZ

V+ PE

W11

W08 1-J35-BF1

5

1BFU

1

2

1

2

W08

1-J18-BI1-

7

RB1

1

W08

1-J18-BI1+ 2

1-J35-BF2

W08

6

2BFU

1

2

W08

1-J18-BI1-

8

RB2

W08

1-J18-BI2+

1

2

1

2

1-J1-12V+

1-J1-12V-

W08 1-J1-AI1

1-J1-GND

3

4

1

2

11

TA

3-J1

W14

01

2

1

2

1

12

Shunt1

02

2

1

2 13

1

Shunt2

03

2

1

14

Shunt3

04

2

1

2 15

1

Shunt4

05

2

1

2

1

16

Shunt5

06

2

1

2

1

17

Shunt6

10 To ground

PD6

1-J34

W13

W11

18

FU1

24

FU7

19

FU2

25

FU8

20

FU3

26

FU9

21

FU4

27

FU10

28

FU11

22

FU5

29

FU12

23

FU6

30

FU13

31

FU14

M-

07

1

2

08

1

2

09

1

2

10

1

2

15

1

2

16

1

2

17

1

2

18

1

2

19

1

2

20

1

2

11

1

2

12

1

2

13

1

2

14

1

2

W13

1-J35

32

FU15

33

FU16

34

FU17

35 36 37

FU18 FU19 FU20



Rear view

J41

W08

To plug terminal

NC NC RTS NC

RS485A RS485B CAN-H CAN-L

J22

J21

RS485-2 CAN-2


OGND DTR TXD RXD

DCD

J19

J23 J20

RS485-1 CAN-1


DI1+ DI1DI2+ DI2DI3+ DI3DI4+ DI4-

J26

Reserved DI

J33

1

HDUL

Front view

M+

W08

2

1

32

31

2

1

12V+

LIGHT

J28

J1

GND AI1 12V12V+

1 W08

32

31

HGND 5V

J40

LCD

GND AI2 12V12V+

J2

J37

To R1 board

J43

J3


J4

7-1

7-2

8-2

8-1

W14

9

PD5


V-

SPD13DZ

V+ PE

+

-

W11

W08

1-J35-BF1

5

1BFU

1

2

1

2

W08

1-J18-BI1-

1

7

RB1

W08

1-J18-BI1+ 2

W08

1-J35-BF2

6

2BFU

1 1

2 2

1-J18-BI1-

W08

8

RB2

1

W08

1-J18-BI2+ 2

M-

1-J1-12V+

W08

1-J1-12V-

1-J1-AI1

1-J1-GND

3

4

1

2

To ground

10

PD6

11

TA

3-J1

W14

01

2

1

2 12

1

Shunt1

02

2

1

2

1

13

Shunt2

03

2

1

2

1

14

Shunt3

04

2

1

2 15

1

Shunt4

05

2

1

2

1

16

Shunt5

06

2

2

1

17

Shunt6

3-J2

W14

2

2

1

18

Shunt7

1 1

07

2

08

1

2

1

19

Shunt8

W11

1-J34

W13

20

FU1

28

FU9

21

FU2

28

FU10

22

FU3

29

FU11

23

FU4

30

FU12

31

FU13

24

FU5

32

FU14

25

FU6

26

FU7

27

FU8

Plug terminal T1

Plug terminal T2(reserve)


W13

W11

1-J25

J7

W08

W08

Plug terminal T4

2

SMPDUX3

W14 W14

J5

W08


To ground

W11 1-J39-POWER+

5-V+

1-J39-POWER-

5-V-

4

PD4

J6

3-J1

W14

09

1

2

1

2

33

Shunt9

10

1

2

1

2

34

Shunt10

11

1

2

1

2

35

Shunt11

12

1

2

1

2

36

Shunt12

13

1

2

1

2

17

1

18

2

1

19

2

1

20

2

14

1

2

W13

1-J35

41

FU15

42 43 44

FU16 FU17 FU18

J4

J3

W14

J2

W14

J1

Earth cable

Front door

W10

Left rear door

W10

Rack

Rack

Right rear door

W10

Rack


APPENDIX 5 SPARE PARTS

Table 34: Spare parts

CABINET TYPE BOM DESCRIPTION

Rectifier cabinet

PD380/400AFH,

PD380/630AFH and

PD380/630AFA AC distribution cabinet

PD48/1600DF and

PD48/2500DF DC distribution cabinet

02230350

03035630

SPD-D level-385Vac-5kA -10kA, 3-phase, no indicator, FM-screw installation

03025735 Manufacture board-W4485Z-SPD13D-DC SPD

23040022 LCD display-JYG-12864J9G （ R ） -YS6L2-VB

Finished board-AEM02U11-AEM021Z intelligent detection & switch board- AEM02U11

02470229

SPD-VH40TA385M-385Vac-20kA-40kA, 3-phase-guide rail installation-ROHS

19040350 Fuse-Time-lag fuse-500V-10A￠ 5.2*20mm-/-IEC-UL

23040022 LCD display-JYG-12864J9G （ R ） -YS6L2-VB

03035634

Finished board-HDUL1U11-48V distribution monitoring board-

HDUL1U11

03025735 Manufacture board- W442FZ-SPD13D-DC SPD


VertivCo.com |

Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, USA

11AD1209MU (RH 01/17)

Vertiv NetSure 801 CAA User Manual

NetSure 801 CAA Series Power Supply System

Instruction Manual

TABLE OF CONTENTS

SAFETY PRECAUTIONS

Electrical Safety

Battery

Others

OVERVIEW

Model Information

Overview

Components

INSTALLATION PREPARATION

Installation Requirements

Storage Conditions

Installation Preparation

Unpacking Inspection

INSTALLATION

Cabinet Installation

Plain

Connecting Power Cables

Installation Checklist

Installing Rectifier and Controller

Connecting Communication Cables and Auxiliary Power Cable

Installing Options

TESTING

Note on Testing

Power-on

Setting Basic Parameters

Checking Alarm and Operation Status

OPERATION

Power Distribution LCD Operation

Controller Operation of Rectifier Cabinet

Setting the Position Number of The Rectifier Manually

Adding Load

Adding Rectifier

MAINTENANCE

Maintenance Requirements

Routine Maintenance Items

Routine Maintenance

Basic Inspection

Replacing Rectifier

Emergency Treatment

APPENDIX 1 TECHNICAL PARAMETERS

APPENDIX 2 ALARM LIST

APPENDIX 3 ENGINEERING DESIGN DIAGRAM

APPENDIX 4 WIRING DIAGRAM

PE bar

29

XT1

Front door

Cabinet

APPENDIX 5 SPARE PARTS

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Table of contents