NetSure™ 4015 30kW 400V DC Power System Installation Instructions IM584000300 (Issue AB, April 3, 2013) COMPONENT SPEC. NO.
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Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 TABLE OF CONTENTS CONTENTS PAGE IMPORTANT SAFETY INSTRUCTIONS .................................................................................. iii General Safety .................................................................................................................................................... iii Voltages ..................................................................................
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Tasks to Be performed for Customer Integrated Systems ................................................................................. 17 Grounding .................................................................................................................................................... 17 Sub-Racks Electrical Interconnections .......................................................................
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 IMPORTANT SAFETY INSTRUCTIONS GENERAL SAFETY DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. Performing the following procedures may expose you to hazards. These procedures should be performed by qualified technicians familiar with the hazards associated with this type of equipment. These hazards may include shock, energy, and/or burns.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) BATTERY (IF EQUIPPED) DANGER! When connected together, the battery terminal voltage is 400V DC and is potentially lethal. Battery strings should be isolated from the power system before servicing. WARNING! Correct polarity must be observed when connecting battery leads. WARNING! Special safety precautions are required for procedures involving handling, installing, and servicing batteries.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 DANGER! THIS EQUIPMENT MAY BE USED IN CONJUNCTION WITH LEAD-ACID BATTERIES. WORKING NEAR LEAD-ACID BATTERIES IS DANGEROUS! Batteries contain sulfuric acid. Batteries generate explosive gases during normal operation. Systems containing batteries should never be installed in an airtight room or space. Only install in a ventilated environment.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) MAINTENANCE AND SERVICING PROCEDURES General WARNING! All equipment maintenance and servicing procedures involve internal access and should be carried out only by trained personnel on a de-energized system. Extreme caution is required when performing maintenance and servicing procedures. Be constantly aware that this system contains high DC as well as AC voltages.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 STATIC WARNING The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below must be observed to prevent damage to these components. Disregarding any of these warnings may result in personal injury or damage to the equipment. 1. Strictly adhere to the procedures provided in this document. 2.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) This Page Left Intentionally Blank Page viii Static Warning This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 CHAPTER 1. GENERAL INFORMATION AND INSTALLATION ACCEPTANCE CHECKLIST CUSTOMER DOCUMENTATION PACKAGE This document (IM584000300) provides Installation Instructions for NetSure™ Power System Model 4015-X003, Spec. No. 584000300, and the individual components (Spec. Nos. listed on the front cover of this document) comprising the system.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Power and Control Sub-Rack (List 11, 12) General Item Part Number Qty.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 DC Load Distribution Sub-Rack (List 21, 22, 23, 24) General Item Part Number Qty.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Battery Tray (List 91, 92) General Item Part Number Qty.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 RECOMMENDED TOOLS AND TEST EQUIPMENT The following tools and test equipment are recommended to install the DC Power System. Contact Emerson for a full turn key installation quote.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) INSTALLATION ACCEPTANCE CHECKLIST General The individual components of the DC Power System may be shipped as a complete solution factory installed and wired in an IT rack, or may be shipped separately to be installed in a customer provided IT rack.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 Checklist – Customer Integrated System (ship loose) Chapter 2. Installing the System Equipment Inspection Completed IT Rack Secured to Floor Power and Control Sub-Rack, Load Distribution Sub-Rack(s), and Battery Tray(s) Installed in IT Rack Chapter 3.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) CHAPTER 2. INSTALLING THE SYSTEM The individual components of the DC Power System may be shipped as a complete solution factory installed and wired in an IT rack, or may be shipped separately to be installed in a customer provided IT rack. GENERAL REQUIREMENTS This product is intended only for installation in a restricted access location on or above a non-combustible surface.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 INSPECTING THE EQUIPMENT AND STORING FOR DELAYED INSTALLATIONS Inspecting the Equipment Compare the contents of the shipment with the bill of lading. Report any missing items to the carrier and your local Emerson representative immediately. While the DC Power System is still on the truck, inspect the equipment and shipping container(s) for any signs of damage or mishandling.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) d) Using a hex wrench, raise each leveling feet until the IT rack is resting on the casters. 8) Position the IT rack. 9) Lower the leveling feet or bolt the IT rack to the floor by using the shipping brackets (the shipping brackets will have to be re-attached to the IT rack if removed for rolling the IT rack into position).
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 e) Secure the rear mounting brackets to the power and control sub-rack with the furnished hardware (hardware is installed from inside the sub-rack, the rear mounting brackets have captive fasteners). 3) If furnished, the battery tray(s) is typically installed at the bottom of the IT rack due to the weight of the batteries. Note: Only install the battery tray(s) at this time.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) The rear mounting bracket can be adjusted from 28.75” (730mm) to 32.25” (819mm) for the Power and Control Sub-Rack and 26.39” (670mm) to 32.60” (828mm) for the Batter Tray. Use supplied IT cage nut/screw for mounting. (3) per side for the distribution sub-rack(s). (4) per side (front and rear brackets) for the power and control sub-rack. (3) per side (front and rear brackets) for the battery tray(s).
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 CHAPTER 3. MAKING ELECTRICAL CONNECTIONS IMPORTANT SAFETY INSTRUCTIONS Danger: Adhere to the “Important Safety Instructions” presented at the front of this document.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Top Plate Two options available: 1) P/N 554472. Holes sized for imperial conduit fittings (25mm [1”] conduit fittings except AC Input and External Battery which are 32mm [1.25”] conduit fittings). 2) P/N 554473. Holes sized for corded connections using metric cord grips (38mm [1.5”] holes).
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 When System Components are Furnished Loose to be Installed in a Customer Furnished IT Rack If the system components are furnished loose to be installed in a customer furnished IT rack, the following connections are required. Refer to Figure 3-2 for a cable routing diagram.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Alarm Leads Opening for 25mm (1”) Conduit DC Distribution Leads Openings for 25mm (1”) Conduit (snap bushings are furnished for use without conduit) AC Input Leads Opening for 25mm (1”) Conduit Battery Leads Openings for 19mm (0.75”) Conduit (top and bottom) Distribution Sub-Rack Power and Control Sub-Rack DC Output Leads Openings for 32mm (1.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 TASKS TO BE PERFORMED FOR CUSTOMER INTEGRATED SYSTEMS ALSO MAKE THE CONNECTIONS DESCRIBED UNDER “Tasks to Be Perform for All Installations” STARTING ON PAGE 25. Grounding Danger: Failure to follow proper grounding procedures can result in electric shock hazard to personnel or the risk of fire, should a ground fault occur.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 Load Distribution Sub-Rack Return Busbar (-Bus) Grounding Point (cover removed) (NPG Configurations Only) Note: This connection can be made here or on the power and control sub-rack as shown below.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Power and Control Sub-Rack HRMG Ground Connection (HRMG Configurations Only) (MUST BE PROPERLY CONNECTED TO GROUND) Rear View (covers removed) A lead exits the rear of the power and control sub-rack in a High Resistance Midpoint Ground (HRMG) configuration. This lead MUST be connected directly to ground for proper operation of the mid-point grounding circuit and the ground fault detection circuit.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 Sub-Racks Electrical Interconnections If the system components are furnished loose to be installed in a customer furnished IT rack, the following electrical interconnections are required. Connecting the Load Distribution Sub-Rack(s) to the Power and Control Sub-Rack Note: If you are connecting “bulk” loads, refer to “Power and Control Sub-Rack Bulk Output Connections (if required)” on page 40.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Load Distribution Sub-Rack DC Input Cables (Factory connected in load distribution sub-rack, customer to route into power and control sub-rack and connect to power and control sub-rack DC output terminals.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 Battery Tray Alarm / Control Connections - 1 Tray Only Internal/External Battery Tray Control/Alarm Connectors (If an internal or external battery tray is not connected, MUST have termination plugs installed.) (Use either connector.) Power and Control Sub-Rack Rear 1. Remove a termination plug from one of the connectors (either one) located on the rear of the power and control sub-rack. 2.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Battery Tray Alarm / Control Connections - 2 or More Trays Internal/External Battery Tray Control/Alarm Connectors (If an internal or external battery tray is not connected, MUST have termination plugs installed.) (Use either connector.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 TASKS TO BE PERFORM FOR ALL INSTALLATIONS Grounding Danger: Failure to follow proper grounding procedures can result in electric shock hazard to personnel or the risk of fire, should a ground fault occur.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) System Grounding Connections Overview HRMG System Grounding To Building Facility Ground AC Input Conduit Gnd (if req’d) +- DC Load Distribution Sub-Rack IT Rack Main Ground Bar Rack Frame Ground ±200V DC Load Wiring Power & Control Sub-Rack HRMG Ground Connection Battery Tray NOTES: 1. Refer to SAG584000300 for recommended ground lead wire sizes.
Installation Instructions Spec. No.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) AC Input Power Connections Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. DO NOT attempt to work on an energized system. AC input connections are made to an AC input terminal block located behind an access panel located on the rear of the power and control sub-rack. Studs are also provided for the AC Input ground leads.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 DC Load Distribution Electrical Connections to List 21-24 DC Load Distribution Sub-Rack(s) (if furnished) Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. DO NOT attempt to work on an energized system. Warning: Check for correct polarity before making connections.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Load Distribution Sub-Rack (HRMG Configurations) DETAIL A Load Connections to Load Distribution Circuit Breakers Field Connection to External Customer Loads. OBSERVE CORRECT POLARITY.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 Installing Battery Sub-Trays in List 91 and 92 Battery Tray(s) (if furnished) Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. Warning: Ensure battery breaker on front of battery tray is turned off and lockedout before beginning work. Warning: The battery tray is pre-wired with output battery cables with exposed ends.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Note: Battery tray must be installed in rack before installing batteries. Battery Tray Battery tray output cables not shown for clarity. Battery Retaining Bracket X On the sub-trays that hold five (5) batteries, one battery string cable is disconnected and sleeved at the factory. Locate this lead and connect it to the open battery terminal in that tray.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 External Battery Connections (if required) Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. DO NOT attempt to work on an energized system. Warning: Observe proper polarity when making battery connections. Up to five internal or external battery strings can be connected to busbars located in the power and control sub-rack.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Note: These connection points are used both for connecting external battery strings and the internal battery trays. A maximum of five (5) external and internal battery strings (total) can be connected to the power and control sub-rack.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 IB2 (ACU+ Controller Interface Board) Connections (if required) The IB2 (ACU+ Controller Interface Board) provides connection points for digital inputs, programmable relay outputs, and temperature probes. The IB2 interface board is accessed from the front of the power and control sub-rack.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Temperature Probes Note: Each temperature probe consists of two pieces that plug together to make a complete probe. See SAG584000300 for part numbers and descriptions. Up to two (2) temperature probes can be connected to the IB2. Any combination of the two (2) temperature probes can be programmed to monitor ambient air temperature and/or battery temperature.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) Top cover removed in illustration for clarity only. I/O Wiring Cable Tray IM584000300 Issue AB, April 3, 2013 I/O Wiring Opening for 25mm (1”) Conduit Power and Control Sub-Rack Front ACU+ IB2 Interface Board 10/100M Ethernet Port (RJ-45) ESC ENT ACU+ Top View ACU+ IB2 Interface Board Relay No. J9 Relay Output Term. Blocks J8 J7 J6 7 NO C NO Relay No.
IM584000300 Issue AB, April 3, 2013 Programmable Digital Input 1 2 3 4 5 6 7 8 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Pin No. J3-2 + J3-1 – J3-4 + J3-3 – J3-6 + J3-5 – J4-2 + J4-1 – J4-4 + J4-3 – J4-6 + J4-5 – J5-2 + J5-1 – J5-4 + J5-3 – -- J5-5 -- J5-6 Default Digital Input Function Customer Defined Digital Input Function none none none none none none none none not used not used Table 3-1 Programmable Digital Inputs Page 38 Chapter 3.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) Programmable Relay Output 1 2 3 4 5 6 7 8 IB2 Pin No.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) Power and Control Sub-Rack Bulk Output Connections (if required) Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. DO NOT attempt to work on an energized system. Warning: Check for correct polarity before making connections. Note: These connection points may not be available if DC load distribution sub-racks are installed.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 CHAPTER 4. INSTALLING THE RECTIFIER MODULE The rectifier module is hot swappable. It can be installed with the system operating if these instructions are carefully followed. Note: There is a two step insertion process. Procedure 1) Unpack the rectifier module. 2) Open the respective rectifier module’s AC input circuit breaker on the front of the power and control sub-rack.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) CHAPTER 5. INITIALLY STARTING THE SYSTEM Caution: Performing various steps in the following procedures may cause a service interruption and/or result in the extension of alarms. Notify any appropriate personnel before starting these procedures. Also, notify personnel when these procedures are completed. Note: Contact Emerson sales for startup assistance.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 INITIALLY STARTING THE SYSTEM Procedure 1) Close the external AC disconnect or protective device that supplies AC power to the system. 2) Place each rectifier module AC input circuit breaker located on the front of the power and control sub-rack to the ON position. Rectifiers automatically start. 3) Place each internal battery tray circuit breaker to the ON position.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) ACU+ CONTROLLER INITIALIZATION Note: For factory configured systems, your controller was programmed with a configuration file that sets all adjustable parameters. Provided on a USB drive furnished with the system is an ACU+ configuration drawing (C-drawing) and the ACU+ configuration files loaded into the ACU+ as shipped.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 2) Next, the language screen appears. Press the up or down arrow key to select the desired language. Press the ENT key to confirm the selection. If no key is pressed within 10 seconds, the ACU+ selects the displayed language automatically. 3) As initialization continues, the Main screen is displayed, but with zero volts. Initialization is not complete.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) VERIFYING THE CONFIGURATION FILE For factory configured systems, your ACU+ was programmed with a configuration file that sets all adjustable parameters. The version number of the configuration file can be found on the configuration drawing (C-drawing) that is supplied with your power system documentation, and on a label located on the ACU+.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 CHECKING BASIC SYSTEM SETTINGS Navigate through the controller menus and sub-menus to check system settings. You can adjust any parameter as required. Note that these settings can also be checked (and changed if required) via the WEB Interface. Note: Repeatedly press the “ESC” key to return in reverse order level by level from any sub-menu until the Main screen appears.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 CONFIGURING THE ACU+ IDENTIFICATION OF RECTIFIERS When rectifier modules are all installed prior to applying power and starting the system, the order in which the ACU+ identifies the rectifiers is by serial number (lowest serial number is Rect 1, next lowest is Rect 2, etc.). If you prefer the ACU+ to identify the rectifiers by position in the system, perform the following procedure.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) CHECKING THE SYSTEM SHUTDOWN CIRCUIT Procedure 1) With the system operating, momentarily depress the System Shutdown pushbutton located on the power and control sub-rack. 2) Verify that the rectifier module AC input circuit breakers located on the power and control sub-rack and the battery circuit breaker located on the internal battery trays open.
Installation Instructions Spec. No. 584000300 (Model 4015-X003) IM584000300 Issue AB, April 3, 2013 FINAL STEPS Procedure 1) If any ACU+ Controller configuration settings were changed, refer to the ACU+ User Instructions (UM1M820NNB-1) and save a copy of the configuration file. This file can be used to restore the ACU+ Controller settings, if required, at a later date.
IM584000300 Issue AB, April 3, 2013 Installation Instructions Spec. No. 584000300 (Model 4015-X003) REVISION RECORD Issue Change Number (ECO) AA LLP216775 New AB LLP218630 Misc. updates. System packaging tables revised. Page 52 Description of Change Revision Record This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy Systems, North America, Inc.
NetPerform™ Optimization Services At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both your business and your bottom line. That is why we offer a wide array of services to meet all of your network infrastructure needs. Customer Management (Pre Shipment) Email NetSure4000Series@Emerson.com Phone 1.800.800.1280 option 1 [1] Pricing and availability , quotes, purchase orders, expediting requests and order tracking.
