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DC Power Systems
USER AND
INSTALLATION MANUAL
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
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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
2 Sub-Assemblies
2.1 Mechanical Layout
AC INPUT
ISOLATOR
USER
INTERFACE
RECTIFIER BOARD
MODULE CONTROLLER
STATUS LEDs
SYSTEM
CONTROLLER
DC/DC DUAL
SUB-ASSEMBLY
DC/DC 24V
MODULE DISTRIBUTION
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ETHERNET
PORT
STATUS LEDs
LCD DISPLAY
USER
CONTROLS
(KEYPAD)
CONTROLLER
EJECTION
LEVER
Fig 3.1: Front view of the installed Advanced Controller Unit (ACU)
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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).
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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
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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
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LOAD
DISTRIBUTION
LABEL
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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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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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)
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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
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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.
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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BLOCK 4-
BLOCK 4+
BLOCK 3+
BLOCK 2+
BLOCK 1+
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
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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)
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).
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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.
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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
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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
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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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%
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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FAULT DISCOVERED UPON: SOURCE OF FAILURE IN YOUR WHAT WAS THE CONSEQUENCE
OPINION: OF THE FAILURE:
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YES / NO
Do all SM units communicate with the System Controller?
Do all Rectifiers communicate with the System Controller? YES / NO
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
Additional information:
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S6415X1
A1731
J2
J3
J4
J5
- COMMON
+ 24V
S6415X2
J21
J2
J1
J20
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