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NETSURE™ 701z

DC Power Systems

USER AND
INSTALLATION MANUAL

Document Name: UIM48701Zb - Rev A


REVISION DATE: 01/08/2010
SCN: 11771
ECN: N/A
NETSURE
TM
701z
DC Power systems

List of Contents
List of Contents ............................................................................................................... 2
1 Power System ........................................................................................................ 3
1.1 Description .................................................................................................................... 3
2 Sub-Assemblies ...................................................................................................... 4
Mechanical Layout.................................................................................................................... 4
3 System Supervision Unit ......................................................................................... 5
3.1 Description .................................................................................................................... 5
4 Installation............................................................................................................. 6
4.1 Unpacking ..................................................................................................................... 6
4.2 Cabinet Mounting ........................................................................................................... 6
4.3 Installation of Rectifier Modules....................................................................................... 7
4.4 Installation of DC/DC Converter Modules.......................................................................... 7
4.5 Earthing ........................................................................................................................ 7
4.6 AC Input Connections ..................................................................................................... 8
4.7 48V DC Load Output Connections .................................................................................... 9
4.8 24V DC/DC Output Connections..................................................................................... 11
4.9 Outgoing Alarm Connections ......................................................................................... 12
4.10 Digital Inputs Connections ............................................................................................ 13
4.11 Battery Installation ....................................................................................................... 13
5 Communication Setup for WEB Interface.................................................................15
6 Spare Parts List .....................................................................................................19
6.1 Recommended Spares .................................................................................................. 19
7 Annexure ..............................................................................................................20
7.1 Technical Specifications – Netsure™ 701z DC Power System ........................................... 20
7.2 Technical Specifications – Rectifier Module R48-3200 ...................................................... 21
7.3 Technical Specifications PS231 ...................................................................................... 22
7.4 Failure Report .............................................................................................................. 23
7.5 System Interconnection Diagram ................................................................................... 25

UIM48701Zb-Rev A 2
NETSURE
TM
701z
DC Power systems

1 Power System
1.1 Description
The NetSure™ 701z is a flexible DC Power System suitable for communication
networks and IT applications requiring small to medium range power. This is primarily
a -48V DC (positive common) modular rectifier system with built in provision for 24V
DC system. The system is supplied in a cabinet which includes provision for load and
battery distribution. Space for various types of batteries forms an integral part of the
system. The flexible system configurations, which are designed to meet various
demands, include the choice of different types of rectifiers, controllers, range of
supervision units and a two stage low voltage load disconnect. For details, refer to the
respective manuals.
The NetSure™ 701z is suitable for supplying loads of up to 12.8KW with N+1 rectifier
module redundancy. This standard system includes a 23-inch 5-rectifier sub-
assembly, 23-inch distribution sub-assembly, 23-inch DC/DC sub-assembly and a 4-
battery System Cabinet.

DISTRIBUTION
RECTIFIER SUB-ASSEMBLY
SUB SYSTEM
ASSEMBLY CONTROLLER
RECTIFIER
MODULE
DC/DC DUAL 24V DISTRIBUTION
SUB-ASSEMBLY
DC/DC MODULE

BATTERY STRING 4

SYSTEM
CABINET
BATTERY STRING 3

BATTERY
CIRCUIT BATTERY STRING 2
BREAKER

BATTERY STRING 1

Fig 1.1: Example of NetSure™ 701z with DC/Dc


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2 Sub-Assemblies
2.1 Mechanical Layout

DC LOAD DC DISTRIBUTION AC DISTRIBUTION


DISTRIBUTION RECTIFIER AC
CIRCUIT INPUT
BREAKERS

AC INPUT
ISOLATOR

USER
INTERFACE
RECTIFIER BOARD
MODULE CONTROLLER
STATUS LEDs

SYSTEM
CONTROLLER
DC/DC DUAL
SUB-ASSEMBLY

DC/DC 24V
MODULE DISTRIBUTION

Fig 2.1: Example of sub-assemblies

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3 System Supervision Unit


3.1 Description

ETHERNET
PORT

STATUS LEDs

LCD DISPLAY

USER
CONTROLS
(KEYPAD)

CONTROLLER
EJECTION
LEVER

Fig 3.1: Front view of the installed Advanced Controller Unit (ACU)

The System Controller is controller is available in two versions: Standard Controller


Unit (SCU) and Advanced Controller Unit (ACU).
This controller is responsible for supervising and controlling the power system. An
Ethernet port enables connection to a laptop / PC to facilitate advanced system
monitoring and control (ACU only).
The Controller is equipped with a LCD display for local indication of system
parameters such as: output system voltage, load current, battery temperature,
battery block voltages, battery currents and alarms.
All system parameters can be adjusted utilising the LCD display and keypad
i.e. the 6 buttons located on the Controller’s front panel.
The Controller facilitates advanced functionality such as:
• comprehensive system supervision
• comprehensive alarms for easy diagnostics
• comprehensive battery management, battery charge current limit and temperature
compensated float charge
• dual low voltage battery disconnect
• battery discharge data logging and alarm history storage
• Programmable Logic Control (PLC)
WEB browser is used as a PC user interface, intended for configuration, test,
installation and maintenance of Power Systems.
For more information on System Controller/s, refer to the respective SCU or ACU
Manuals.

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4 Installation
All NetSure™ 701z DC Power Systems must be installed as per instructions of this
chapter.

4.1 Unpacking
1. The Power System is factory tested and inspected. Upon receiving the Power
System, make sure that all the boxes listed in the shipping specification are
delivered, and that they have the correct type numbers.
2. The final unpacking of each unit should not be done until just before the
installation. There might be loose parts packed with the units (e.g. screws) and
to prevent losing them, the unpacking should be done when installing the
equipment.
3. The Power System is delivered completely wired and configured to accept up to 5
rectifier modules (configuration dependant).
4. The Rectifier modules are separately packed, and the actual quantity to be
installed depends on the load requirement and the battery recharge requirement.
5. When unpacking the Rectifier modules from the carton, first visually inspect them
for damage that might have occurred during transportation. If a Rectifier module
appears to have been physically damaged, do not install it into the Power System
or attempt to switch it on. Damaged equipment should be returned to Emerson
(refer to Failure Report chapter).

4.2 Cabinet Mounting


The System Cabinet can be fixed to the floor and to the wall by means of
L-shaped brackets (refer to Figure 4.1), The distance between the system cabinet and
the wall can only be at a minimum of 70mm and maximum of 85mm to allow for
system cooling. During transportation, both brackets are mounted at the top-rear of
the cabinet.

WALL MOUNTING BRACKET

FLOOR MOUNTING BRACKET

Fig 4.1: Floor and wall mounting

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4.3 Installation of Rectifier Modules


1. Ensure that AC input isolator, all AC circuit breakers and the AC supply from the
Distribution Board are switched off.
2. Align the Rectifier module with the guide rails inside the Rectifier sub-assembly,
ensuring the correct orientation of the module.
3. Release the rectifier ejection lever.
4. Gently slide the module into the guide rails until its rear connector plugs into the
respective receptacles at the back.
5. Close the rectifier ejection lever to lock the rectifier in place.
6. Should the rectifier NOT fit, check that it is correct for the voltage used. A 24V
Rectifier module cannot be connected to the 48V system or vice versa.
7. For more information on rectifiers, refer to the respective rectifier manuals.

4.4 Installation of DC/DC Converter Modules


1. Align the module with the guide slots inside the sub rack and gently slide the unit in.
2. Push the module in until its front facia touches the front of the sub rack.
3. Turn the captive thumbscrew to secure the DC/DC converter to the sub rack.
4. Should the module not fit, ensure that it is correct for the voltage used (e.g. a 48V
DC to DC converter cannot be inserted into a 24V sub rack and vice versa).

4.5 Earthing
An earth stud is provided for DC earthing connections (cabinet and positive common
DC output) located inside, on the top left-hand side of the system cabinet.
The Power System’s DC output is floating, i.e. not connected to earth potential. This
is the -48V system and if required, the positive DC output (battery positive busbar)
can be connected to earth.

SYSTEM
EARTH
STUD

BATTERY
POSITIVE
BUSBAR

Fig 4.2: Earth stud

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4.6 AC Input Connections


1. Ensure that the AC supply from the Distribution Board is switched off, before any
AC connections are made.
2. Remove the cabinet top cover by removing the screws holding it in place. This will
provide top access to the Distribution sub-assembly.
3. Open the Distribution fascia by turning the thumb screw marked as “Cover
Release Screw” and lightly pulling it. The Distribution fascia is hinged at the
bottom.
4. Remove the AC protection cover, by loosening the screws securing it.

Access can now be gained to the AC input connection terminals (L1, L2, L3, N and PE)
as shown in Figure 4.3.

CABLE STRAP
POINT

PROTECTIVE
EARTH
CONNECTION

NEUTRAL
CONNECTION
OPTIONAL
SURGE
ARRESTOR
L1, L2 and L3
CONNECTIONS

Fig 4.3: Example of AC distribution

The Power System can be connected to either a single-phase (1+N+PE) or three-


phase (3+N+PE) AC input supply.
Single Phase (1+N+PE) Connection
The AC input cable should enter the cabinet at the top right-hand side.
Recommended minimum circuit breaker rating in the distribution board for single-
phase connection is > 100A for NetSure™ 701z.
For the single-phase (1+N+PE) connection, a 3-core cable rated in accordance with
the circuit breaker in the Main Distribution Board and Local Standards/Directives must
be used to provide AC supply to the Power System.
For Single phase operation, all three phase terminals (L1, L2 & L3), must be linked
together (link not provided).
After the AC input supply cable has been terminated, it must be strapped to the cable
strap point provided on the AC Distribution where the cable exits the enclosure (refer
to Figure 4.3).

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Three Phase (3+N+PE) Connection


The AC input cable should enter the cabinet at the top right-hand side.
Recommended minimum circuit breaker rating in the distribution board for 3-phase
connection is > 40A per phase for NetSure™ 701z.
For the three-phase (3+N+PE) connection, a 5-core cable rated in accordance with
the circuit breaker in the Main Distribution Board and Local Standards/Directives must
be used to provide AC supply to the Power System.
After the AC input supply cable has been terminated, it must be strapped to the cable
strap point provided on the AC Distribution where the cable exits the enclosure (refer
to Figure 4.3).

4.7 48V DC Load Output Connections

PRIORITY LOAD NORMAL LOAD


CIRCUIT BREAKERS CIRCUIT BREAKERS

LOAD
DISTRIBUTION
LABEL

Fig 4.4: Example of DC load distribution

The standard DC distribution caters for termination of Priority loads and Normal loads.
The Normal Load “NL” circuit breakers (also known as Low Priority “LP”) and Priority
Load “PL” circuit breakers (also known as High Priority “HP”) are grouped as per
Figure 4.4. The number and grouping of circuit breakers is configuration dependant.
The purpose of the circuit breakers may be indicated on the “Load Distribution Label”
(if applicable).
The positive load connections are to be terminated on the common positive busbar at
the back of the load circuit breakers. The positive load cables must be connected to
the tunnel terminals or M8 bolts (refer to Figure 4.5) and tightened. Maximum
recommended cable size is 50mm², minimum recommended cable size is 2.5mm²,
torque of 4 to 5Nm.
The negative load connections are made to the relevant distribution circuit breakers.
Maximum recommended cable size is 50mm² (circuit breaker dependant), minimum
recommended cable size is 2.5mm². The recommended torque for circuit breaker
terminals is 2 to 3 Nm.

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Mount cable in tunnel terminal


UNDERNEATH Common busbar
before tightning.
Fig 4.5: Termination of negative load cables

The System Controller monitors the status of the distribution circuit breakers. For
monitoring purposes, each circuit breaker is assigned with a sense wire (circuit
breaker sense wire), which must be connected to it.
The circuit breaker sense wires must be connected to the load circuit
breakers together with the negative load cables.

The circuit breaker sense wires are colour coded and grouped into 5 banks.
Black: Group 1 – circuit breaker position 1, 2, 3, 4 and 5
Brown: Group 2 – circuit breaker position 6, 7, 8, 9 and 10
Red: Group 3 – circuit breaker position 11, 12, 13, 14 and 15
Orange: Group 4 – circuit breaker position 16, 17, 18, 19 and 20
Yellow: Group 5 – circuit breaker position 21, 22, 23, 24 and 25.

Note that each group of circuit breaker sense wires are equipped with a spare, 6th
wire, which is to be used as a replacement in an unlikely event of sense wire failure.
All un-used sense wires must be placed into the trunking, located behind the circuit
breakers.

The DC output cables should be strapped to the cable strain relief strap points,
provided at the back of the Distribution sub-assembly. These cables should be then
routed through the top of the battery cabinet (holes are provided).

Cable size shall be selected in accordance with circuit breaker rating and allowable
voltage drop. The maximum recommended voltage drop is 400mV.
To meet the voltage drop, the following formula could be used as a guideline for
selecting the minimum cross-sectional area required for the load cables:
Amin [mm2] = 0.05 x L [m] x I [Adc]
Amin Minimum cross-sectional area of load cable in mm2
L total length of positive and negative cable in meters
I circuit breaker rating in amperes DC.

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4.8 24V DC/DC Output Connections


The DC output distribution is situated on the right-hand side of the DC/DC sub rack and
is protected by a removable cover. The cover can be removed by loosening the M3
screw (undo a few turns only) situated behind the circuit breaker cover plate.

The DC output termination points are indicated on the Fig. 4.6.

The maximum cross-sectional area of DC output cables per single-pole circuit breaker is
25mm2.

Cable size should be selected based on current carrying capacity and/or allowable
voltage drop. Also in accordance with DC output circuit breaker/fuse rating. The
recommended maximum voltage drop is 400mV. The formula to select the minimum
cross-sectional area required for the DC cables based on voltage drop in Paragraph 4.7
applies.

Correct colour coding should be used (red for positive and blue for negative cable).

The “Output Common” connections are on the common output busbar, located behind
the circuit breakers. Ensure that the cables are correctly inserted into the terminal
(refer to Fig. 4.5).

The recommended torque for the tunnel terminals is 4 Nm, while for the circuit breaker
terminals is 2 Nm to 3 Nm.

OUTPUT
COMMON
(NEGATIVE)

CIRCUIT BREAKER
PROTECTED
OUTPUT
(POSITIVE)

Fig 4.6: Output connection points in negative common output configuration

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4.9 Outgoing Alarm Connections


Eight potential free relays for the purpose of outgoing alarms are provided on the
User Interface Board, located above the System Controller (refer to Figures 2.1 and
3.1). Every relay output has N/C (normally closed) and N/O (normally-open) contacts.

The relay mapping to specific alarm are Emerson configurable functions (also refer to
the respective ACU Manual).

For the the ACU, the outgoing alarm relays are grouped in the following manner
(default configuration):
• Relay RL1 – AC Failure, AC Voltage High, AC Voltage Low 1, AC Voltage Low 2
• Relay RL2 – DC Voltage low 1
• Relay RL3 – DC Voltage Low 2
• Relay RL4 – DC Voltage High 1, DC Voltage High 2
• Relay RL5 – Multiple Rectifier Failure, Rectifier Failure, Rectifier Fan Failure,
Rectifier HVSD, Rectifier AC Failure, Rectifier Protect, Rectifier Not Responding,
DC/DC Fail.
• Relay RL6 – Load Fuse, DC/DC Load Fuse
• Relay RL7 – Battery Fuse
• Relay RL8 – Spare

ALARM RELAY
OUTPUTS

DIGITAL POWER FOR


INPUTS DIGITAL INPUTS

Fig 4.7: Outgoing Alarm Relays and Digital Inputs

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4.10 Digital Inputs Connections


The System Controller offers a comprehensive Programmable Logic Control (PLC). For
details on this function, refer to the respective SCU or ACU Manuals.

Eight isolated Digital Inputs and their DC supply points are provided for the purpose
of PLC. These inputs are located on the User Interface Board, above the System
Controller (refer to Figures 2.1 and 3.1). By default, these inputs are not configured,
but can be configured to meet the customers’ needs.

For input connection points, refer to Figure 4.7.

4.11 Battery Installation


The battery distribution cabling is pre-wired as standard.
The system cabinet comprises four battery shelves. The battery space available for
each string in standard configuration is: 540mm (W) x 570mm (D) x 320mm (H).
Each battery shelf is designed to accommodate four (VRLA) 12V-battery blocks with
front terminals. Four 12V-battery blocks are always connected in series. Suitable links
(not provided) should be used for connecting battery blocks in a string.
The front terminal battery blocks must be placed next to each other (refer to Figure
4.9).

Repeat the following procedure for each battery string installed. Battery string 1 is
always at the bottom of the cabinet (refer to Figure 1.1).
1. Switch all four battery circuit breakers off (located next to each battery shelf).
2. Remove the Battery compartment cover by removing the four M6 screws (if
applicable).
3. Place all four 12V battery blocks on a shelf.
4. The negative battery cable, located on the left-hand side of the battery cabinet,
must be connected to the negative battery pole.
5. The positive battery cable, located on the right hand side, must be connected to
the positive battery pole.
6. Please consult the Battery manufacturer for the correct torque on the battery
terminals.
7. Replace the Battery compartment cover (if applicable).

Battery temperature sensors are factory fitted and do not require installation.

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The String Voltage Equalisers are optional items (configuration dependant).

BLOCK 4-

BLOCK 4+

BLOCK 3+

BLOCK 2+

BLOCK 1+

Fig 4.8: String Voltage Equaliser Battery Sense Terminal Ring

Some system configurations offer more advanced battery management (addition of


SM BAT unit for block voltage and individual string current monitoring). In such
instances, for the Power System to be able to perform such advanced battery
management, the battery sense wiring and the terminal rings must be mounted on
the battery poles.
A set of battery sense wires and terminal rings must be attached to each installed
battery. Each wire in a set is marked, indicating the required connection to the
specified 12V battery block.

The 12V battery blocks in a string are numbered from 1 to 4. The block connected to
the positive (red) battery wire is Block 1, while the one connected to the negative
(blue) battery wire is Block 4.

BATTERY BATTERY
NEGATIVE POSITIVE
POLE POLE

4 3 2 1

Block Block Block Block Block Block Block Block


4- 4+ 3- 3+ 2- 2+ 1- 1+

Fig 4.9: Example of Battery Block installation and numbering

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5 Communication Setup for WEB Interface


Only the Advanced Controller Unit (ACU) is supporting the WEB interface.
There are two means of communication to the ACU: direct (cable and Ethernet
Switch) and remote (via LAN). Please note that WEB Interface has a limit of 5 users
which could simultaneously log onto the ACU.

Minimum Hardware and Software Requirements


- 1 x Pentium III, 1GHz processor based PC or Laptop,
- 1 x Standard Ethernet Network Cable,
- Operating system: Windows 2000 or Windows XP (ensure that you have
administrator rights on your user profile),
- Internet Explorer 6,
- Log-on access to ACU via WEB Interface (user name and password for browsing
only or for changing ACU parameters).

Connections
Connect the standard Ethernet Network cable between the ACU “Ethernet Port” and
the PC “Ethernet Port”.

ACU Setup
For successful communication with ACU, determine the following ACU parameters:
- IP Address (default: 192.168.0.1)
- Subnet Mask (default: 255.255.254.0)
- Default Gateway (default: none)

Using the front panel keypad, follow the link below:


Press “Enter” button, Main Menu / Parameter Set / <enter user name: admin and
password: 1> /System Parameter / <set IP Address, Subnet Mask and Default
Gateway>.

The last screen will show the IP Address of ACU, Subnet Mask and Default Gateway
(write it down).

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PC setup
Ensure that you are not connected to any network i.e. you will be running your
PC/laptop offline. Boot up you PC/laptop and enter your Windows log-on user name
and password. Please note that you must have administrator rights.
Within the Windows desktop, right click on the “My Network Places” icon and click on
“Properties”.

In the next window, right click on “Local Area Connection” and click on Properties.

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In the next window, select “Internet Protocol (TCP/IP)” and click on button
“Properties”.

For communication via LAN, note that the below parameters are specific to your
network (LAN) and therefore must be changed appropriately.

If the communication with ACU is directly via Ethernet cable, then the parameters
may be left to their default values.

In the next window, select “Use the following IP address” radio button and enter the
following.
- IP address: The first 3 segments of IP address must be identical to the ACU IP
address, while the fourth segment must differ. Example: 192.168.0.2
- Subnet Mask: the same as the ones entered into the ACU. Example:
255.255.254.0
- Default Gateway: the same as the ones entered into the ACU (if using the default
ACU setting, then do not set this parameter).

Click on “OK” button and close all other open windows.

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Now, you need to setup your Internet Explorer for correct operation.
Launch the Internet Explorer. Click on “Tools” and then “Internet Options…”.

In the following window, select “Connections” tab and then click on “LAN Settings…”
button.

In the following window, uncheck the “Use the proxy server for your LAN”. Click “OK”
buttons in all windows.

Communicating with ACU


In the “Address” field of the Internet Explorer, enter the ACU’s IP address (example:
http:// 192.168.0.1) and click on “Go” button.
Once the communication is established, in the first screen of ACU WEB Interface, you
will be prompted your “User Name” (default: admin) and “Password” (default: 1).
For more details on WEB interface, please refer to the ACU User Manual.

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6 Spare Parts List


6.1 Recommended Spares
DESCRIPTION OF ITEM ORDERING CODE

5A DC Circuit Breaker CBI 9445


10A DC Circuit Breaker CBI 9060
15A DC Circuit Breaker CBI 9079
20A DC Circuit Breaker CBI 9061
32A DC Circuit Breaker CBI 9062
40A DC Circuit Breaker CBI 9893
50A DC Circuit Breaker CBI 9297
63A DC Circuit Breaker CBI 9821
100A DC Circuit Breaker CBI 9633
150A DC Circuit Breaker CBI 9703

200A Battery Circuit Breaker CBI 10075


25A AC Circuit Breaker CBI (rectifier input) 10070
3-pole AC Disconnect Switch 63A CBI 9063
Class II Surge Arrestor 20kA, 3ph+N, pitch 4x13mm (optional) 10069
Combo Surge Arrestor, 3ph+N, with alarm, pitch 4x18mm (optional) 10324

Rectifier Module 48V 3.2kW (R48-3200) 10049


Rectifier Module Blanking Cover 3x2U (DMBM4.120.071/N) 10050

ACU - Advanced Controller Unit M800D (configuration dependant) 10067


SCU – Standard Controller Unit M501D (configuration dependant) 10068
SM BAT (configuration dependant) 10054
SM IO (configuration dependant) 10076
SM AC (configuration dependant) 10077
Connector Board 1x2U Mini/Medium (S6415X2) 10080
System Interface Card 10102

Battery Sense Cable Set for SM BAT, 5m (SMB11SL1) 10079


Controller Temperature Sensor 3m (W75C5FSL2) 10055
Controller Temperature Sensor 10m (W74C5FSL1) 10071
SM Unit Temperature Sensor 10m (SMIO11SL1) 10056
String Voltage Equaliser 48V (configuration dependant) 9675
Battery String Sense Wiring Harness (for Equaliser only) 9738
Battery Circuit Breaker Sense Wire Harness 10035

Normal Load Contactor (NetSure™ 701z) 9901


Battery Contactor (NetSure™ 701z) 9901
Load Circuit Breaker Sense Wire Harness (for 25 CBs) 10063
Load Circuit Breaker Sense Wire Connector (10-way) 9414

DC/DC Converter 48V to 24V, 600W 9582


DC/DC Blanking Cover 9765
DC/DC CB Sense Card 11456

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7 Annexure
7.1 Technical Specifications – Netsure™ 701z DC Power System
Rectifier Type R48-3200
Input Data
Nominal Input Voltage 200 to 240Vac, 1φ (1+N+PE)
Operational Input Voltage 85 to 290Vac
Nominal Frequency Range 45 to 65Hz
Maximum Input Current, 1φ <100Aac
Power Derating below 176Vac
Output data 48V
Nominal Output Voltage -48Vdc
Adjustable Output Voltage Range -42Vdc to -58Vdc
Maximum Output Current 335A
Maximum Output Power 16kW
Power Derating above 45°C
System Common Positive
Output data 24V
Nominal Output Voltage +24Vdc
Maximum Output Current 250A
Maximum Output Power 6kW
Power Derating above 45°C
System Common Negative

Distribution / Protection
AC Input Terminals up to 35mm2
AC Input Switch 63A, 3-phase AC Input Isolator
Surge Protection Optional
Rectifier Input Circuit Breakers 5 x 25A
48V Load Distribution up to 25 circuit breakers
up to 50mm2 (circuit breaker rating dependant)
Battery Distribution 4 x 200A circuit breakers
Battery Capacity up to 4 x 165Ah (12V front terminal battery blocks)
Alarm Interface 8 x Alarm Relay Outputs (potential free contacts)
Minimum rating - 10mA @ 5Vdc
Maximum rating 2A @ 30Vdc / 0.5A @ 125Vac
8 x Digital Inputs

User Interface LCD Display, user control keypad – full functionality


Ethernet Port (configuration dependant, ACU only)
Environmental Data
Operational Temperature Range -5° to +70°C
Temperature Range (full power) -5° to +45°C
Relative Humidity < 90% (non-condensing)
Altitude 0 to 2000m ASL
Cooling Front to back thermally controlled forced air-cooling
Marking CE
EMC EN 300 386-2 class B
Electrical Safety IEC 60950
Mechanical Data
Dimensions (H x W x D) 1800 x 600 x 600mm
Max configuration 5 x rectifier modules, 4 x 165Ah battery strings
Net Weight (approximately) 150kg, excluding rectifiers and batteries

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7.2 Technical Specifications – Rectifier Module R48-3200


R48-3200
Input Data
Nominal Input Voltage Range 200 to 240Vac
Operational Input Voltage 85 to 290Vac
Input Frequency Range 45 to 65Hz
Maximum Input Current <20Aac
Power Factor 0.99
Total Harmonic Distortion < 5% from 50 to 100% of rated load

Output Data
Nominal Output Voltage 48Vdc
Factory Set Output Voltage 53.5V
Adjustable Output Voltage Range 42Vdc to 58Vdc
Maximum Output Power 3200W
Output Power, derated for input voltage 85 to 176Vac
Output Power, derated for temperature above 50°C
Maximum Output Current 67A
Efficiency 92%
Psophometrically Weighted Noise ≤ 1mV at 5 to 100% of rated load

Control & Monitoring


Rectifier alarm & signalling Alarm & status reported via CAN bus to System
Controller
Visual Indication Green LED – Normal Operation
Flashing Green LED – Rectifier indicator
Yellow LED – Alarm
Flashing Yellow LED – Rectifier Comms Failure
Red LED – Failure
Flashing Red LED – Fan failure

Protection
AC Input over- and under-voltage protection
AC Input over-current protection
DC Output over-voltage protection
DC Output over-current and short circuit protection
Overheat protection

Environmental Data
Operational Temperature Range -40° to +75°C
Full Power Temperature Range -40° to +45°C
Storage Temperature Range -40° to +75°C
Relative Humidity 0% to 95% (non-condensing)
Altitude 0 to 2000m ASL
Cooling Front to back thermally controlled forced air-cooling
Marking CE
EMC EN 300 386:2001 class B
Electrical Safety IEC 60950

Mechanical Data
Dimensions (W x H x D) 132 x 86 x 287 mm
Enclosure IP20
Net Weight 3.5kg

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7.3 Technical Specifications PS231


Input Data PS231
Nominal Input Voltage Range 41Vdc to 60Vdc
Non-destructive Input Range 0Vdc to 65Vdc
Start-up Voltage 47.0 ± 0.3Vdc
Low Voltage Shutdown 40.6 ± 0.5Vdc
High Voltage Shutdown 64.0 ± 1.0Vdc
Input Current < 18Adc
Inrush Current (0.1 to 0.5ms) ≤ 100Adc
Off State Input Current ≤ 5mAdc

Output Data
Nominal Output Voltage 27Vdc
Over-voltage Control 29.10 ± 0.75Vdc
Rated Output Current 23.0 ± 0.3Adc
Overload Capacity (≤ 1s) 30Adc @ 20Vdc
Short Circuit Current < 27Adc
Rated Output Power 600W
Output Voltage Droop (at 25°C) 13mV/A
Line Regulation 30mV
Load Regulation (at 25°C) 300mV
Current Sharing Within 20% of rated output current
Psophometrically Weighted Noise < 0.5mV
Efficiency at rated output power >88%

Alarm and Indication


Alarm DC/DC Module Fail alarm, relay output
Status Indication Bi-colour LED (red, green and extinguished)

Protection
Input over- and under-voltage protection
Output over-voltage protection
Output short circuit protection
Overheat protection

Mechanical Data
Dimensions W62 x H130 x D260 mm
Enclosure IP20
Net Weight 1.3kg

Environmental Data
Operational Temperature Range -15° to +65°C
Normal Operation Temp. Range 0° to +45°C
Storage Temperature Range -20° to +80°C for 3 months
Relative Humidity 10% to 95% non-condensing
Altitude 0 to 2500m ASL
Cooling Front to back thermally controlled fan
Marking CE
EMC including surge immunity EN 300 386

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7.4 Failure Report

COMPLETED BY: Date: THIS FORM MUST BE SENT TO:


Customer Service Centre
CUSTOMER’S CONTACT DETAILS: Emerson Network Power (South Africa) (Pty) Ltd
P.O Box 1931
Sunninghill
2157
Johannesburg
South Africa
Fax: +27 11 807 8103
e-mail: energyhelp.za@emerson.com

FAULTY PRODUCT DETAILS: ENVIRONMENTAL CONDITIONS AT TIME OF FAILURE:


TYPE NO:
Temperature:
SERIAL NO.
Humidity:
EMPLOYED IN WHAT SYSTEM:
Air handling i.e. open
or closed environment:

FAULT DISCOVERED UPON: SOURCE OF FAILURE IN YOUR WHAT WAS THE CONSEQUENCE
OPINION: OF THE FAILURE:

1. Delivery 1. Design 1. Inconvenienced

2. Unpacking 2. Manufacturing 2. Resulted in a Site Visit

3. Installation 3. Documentation 3. Emergency Site Visit

4. Initial test 4. Transportation 4. Temporary


interruption of service

5. After operation of 5. Installation 5. Extended interruption


……….Years. of service

6. Other________________ 6. Handling 6. Other______________


____________________ __________________
____________________ __________________
____________________ 7. Other_______________ __________________
____________________ ___________________ __________________
____________________ __________________ _________________

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Check list for the System:

YES / NO
Do all SM units communicate with the System Controller?
Do all Rectifiers communicate with the System Controller? YES / NO

Are both contactors powered? YES / NO

Can you establish communications with the System Controller?


What is the total load current? A

What are the amounts of current for Normal Load & Priority Load? NL= PL=

Specify:
How many battery strings are installed?
What is the capacity of each battery string? Specify: Ah

Are the batteries configured correctly? YES / NO


YES / NO
Are the date and time set correctly on the System Controller?
List the Active Alarms:
Can you access all the history logs? YES / NO

If so, please attach to this form.

Check list for the rectifiers:


YES / NO
Is there any visible mechanical damage?
Is the AC power within the operating range of the rectifiers? YES / NO

How many rectifiers are installed in the system? Specify:

What is the status of the rectifiers’ input circuit breakers? ON / OFF

Are the rectifiers powered? YES / NO

Are the rectifiers delivering power? YES / NO

What is the status of the rectifier LEDs? Specify:

Additional information:

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7.5 System Interconnection Diagram

CAN BUS NOT


INDICATED

S6415X1

A1731

J2

J3
J4
J5

- COMMON

+ 24V

S6415X2

J21
J2
J1
J20

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UIM48701Zb-Rev A 26