Vertiv NetSure 801 CAA Series User manual

NetSure 801 CAA Series Power Supply System
Instruction Manual
Version: V1.0
Revision date: August 16, 2018
BOM: 31013828

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

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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

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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

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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.

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VI. Tools
WARNING! In high voltage and AC operation, special tools must be used. No common or self-
carried 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.

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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.

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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
The number of the rectifier in the typical power supply system. If the number
ranges between 0 ~ 9, the character is represented by a number. If the number
is larger than 9, the character is represented by a letter, for example, A represents
the number 10, B represents the number 11, and so on. A: 10.
Region. C: China.
Output power of the rectifier. The output power of R48-5800: 5800W.
Brand name of the power supply system.
7
Version number
A
Rectifier number in typical power supply system: 4. If the number is
larger than 9, the character is represented by a letter, for example, A
represents the number 10, B represents the number 11, and so on.
the rectifier: 5800W
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.

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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.

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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
Slide switch
Handle
Fixing screw
Power indicator
Protection indicator
Fault indicator
Current indicators
Table 1: Function of indicators
INDICATOR
NORMAL
STATE
FAULT
STATE
FAULT CAUSE
Power indicator
(Green)
On
Off
No input and output
Flashing
The rectifier is being operated through the host
Protection
indicator
(Yellow)
Off
On
AC input under/overvoltage,
rectifier PFC output under/overvoltage, high-temperature,
or current sharing imbalance
Flashing
Rectifier communication failure
Fault indicator
(Red)
Off
On
Output overvoltage, output fuse blown, or rectifier
addresses contradictory
Flashing
Faulty fan
Current
indicators
on
Shows the output current, each LED represents 10A. If the
rectifier is in current limiting state (output current > 100A),
the tenth LED will blink. If the output current of the
rectifier is smaller than 2A, no current indicator will be on

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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
Power distribution LCD
Indicator

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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)

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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
Knife-blade switch
SPD MCB
AC output MCB
Class C SPD
(a) Front view (front door open)

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Neutral busbar Earth busbar
(b) Rear view (rear door open)
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
(a) Front view (front door open)

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Neutral busbar Earth busbar
(b) Rear view (rear door open)
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.

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Figure 9: Appearance of DC distribution cabinet
Indicator
Power distribution LCD

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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
Output fuse
LCD
Power distribution
monitoring
(a) Front view (open front door)

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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.
Figure 11: PD48/1600DF-A-Y2 DC distribution cabinet
Battery fuse
Power distribution
monitoring
LCD
Battery shunt
Output shunt
Output fuse
(a) Front view (open front door)

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Total load current hall sensor
DC SPD
(b) Rear view (remove rear door)