06 User Manual, 48 V, 40 Amp, NetSure 503 IA4

NetSureTM 503IA4 DC POWER SYSTEM
NetsureTM 503 IA4
DC Power System
User Manual
Emerson part No.
Revision
Revision Date
744800400508
06
26.02.15
Copyright 2009 by Emerson Network Power India Pvt. Ltd.

All rights reserved. The contents in this document are subject to change without notice.
Homepage: www.emersonnetworkpower.com
Head Office:
EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED
Plot No. C-20, Road No. 19,
Wagle Industrial Estate
Thane 400 604, Maharashtra, INDIA
Phone: (00 91 22) 33154400
Fax: (00 91 22) 25800829 / 25828358
Dear Customer,
Please accept our thanks for giving us the privilege to serve you by choosing Emerson make 503
IA4 DCPS.
If this is your first Emerson 503 IA4 DCPS, we hope it is the beginning of a long relationship which
delivers value to your organization. If you already own and use Emerson Product, we are doubly
honored by your decision of continuing this relationship.
It is our constant endeavor to partner you for the growth and success of your Business. This
philosophy is reflected in our Mission statement To deliver value through Air & Power Quality
solutions to achieve customer delight. Please do give us feedback to help us realize our Mission.
Emerson Network Power (India) Private Limited
IMPORTANT
This manual contains information concerning the installation, operation and maintenance of the
DC Power System.
All relevant parts of the manual should be read prior to commencing installation.
The DCPS must be commissioned by an engineer approved by the manufacturer (or his
agent) before being put into service. Failure to observe this condition will invalidate any
implied warranty.
The DCPS has been designed for Telecom use only.
The DCPS has not been designed for direct use in any life support application. If you encounter
any problem with the procedures contained in this manual, you should seek immediate
assistance from Emerson Network Power (India) Pvt. Ltd. Sales Office from whom the
equipment was purchased. Alternatively contact the Emerson Network Power (India) Pvt. Ltd
Customer Service & Support department at the address shown below:
EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED

Plot No. C-20, Road No. 19,
Wagle Industrial Estate
Thane (West) 400 604,
Maharashtra, INDIA
Phone: (00 91 22) 33154400
Customer Care / Service Helpline Number:

Toll Free: 1800 209 6070
Chargeable: +91-22-66231200
Revision history of 744800400508 User Manual For- Net sure 503 IA4
Following is the reference version history summary of all the revisions made in User Manual
for Net sure 503 IA4 Power System.
Version
Revision Description
No.
Prepared
Reviewed
Approved
by
By
by
Date
00
00
SKM
TJ
RY
14.11.14
01
As per ECO3-508
SKM
TJ
RY
08.12.14
02
As per ECO3-538
SKM
TJ
RY
19.12.14
03
As per ECO3-562
SKM
TJ
RY
20.01.15
SKM
TJ
RY
11.02.15
SKM
TJ
RY
16.02.15
SKM
TJ
RY
26.02.15
Inverter Installation
Procedure Added
04
As per ECO3-588,GA
Changed
05
As per ECO-588 PCB

Schematic Changed
06
As per ECO3-596
SCEMATIC Changed
Contents
Chapter-1
General Description
1.1 Introduction
1.2 Features
1.3 Construction
1.4 Cooling
Chapter 2 DCPS Introduction
2.1 Features
2.2 Operation Theory
2.3 Lightning Protection
2.4 BLVD
10
2.5 Alarm and Protection
10
Chapter 3 System Configuration

3.1 System Configuration
Chapter 4 System Components
4.1 R48-2000e3 Rectifier
11
11
13
13
4.1.1 Form and Interface
13
4.1.2 Main Functions and Features
14
4.1.3 Specifications
16
Chapter 5 Controller Details
17
5.1 650VA Inverter
28
5.1.1 General
28
5.1.2 Main Specifications
28
5.1.3 Electrical Characteristics
28
5.1.4 Communication Mode
30
5.1.5 Mechanical Characteristics and Connector Definition
31
5.2 Distribution Board Details

Chapter 6 System Specifications & General Requirements
37
39
6.1 Technical Specifications
39
6.2 Cable Input & Output Details
38
Chapter 7 ELECTRICAL DRAWINGS
40
General Guideline for system Installation / Maintenance / Service
44
Chapter-1 General Description

1.1 Introduction
Outdoor Enclosure is a power pack unit to deliver 48V DC Power supply from internal /
external DC Power system, with inbuilt / external battery bank to Telecom Equipment. The
whole power pack unit is housed inside a dust proof duly cooled protected cabinet suitable for
outdoor application.
1.2 Features
Some of the key features of Battery Cooler Outdoor Enclosure are
Provision to house Telecom
Provision to house DC Power system
Provision to house battery bank
Controlled environment against dust and rain.
Controlled internal temperature due to heat dissipation from internal equipments.
Ease of installation and accessibility to internal parts.
1.3 Construction
The Outdoor Enclosure Cabinet is made of Powder coated Galvanized sheet metal, which
gives excellent resistance to corrosion. The thickness of sheet metal parts depends on the
load bearing capacity.
The roof is tapered so that there is no accumulation of water on it. In order to have full dust
proof protection, all the joints and edges are properly sealed with welding / sealant. For doors,
EPDM gaskets are used. This makes the enclosure totally protected from dust and rain.
Since the enclosure is designed for Outdoor application, there is direct impact of solar heat
on the enclosure. Especially during summer / peak hours the ambient temperature rises
considerably high. This can affect the performance of internal equipments. Hence the cooling
system should be designed in consideration to this.
Mounting Provision of ODU
1.
Pole / Wall/Base Mounted Outdoor Enclosure:
These are very compact size Outdoor Enclosures, suitable for mounting at streets,
highways etc on Pole. The size for such enclosures are 375mm x 580mm x 675mm
(W x D x H). The Pole mounting kit has provision of mounting the Enclosure. The
cooling is through fan filter arrangement.
Pole /Wall/Base Mounted Outdoor Enclosure
1.4 Cooling
The Outdoor Enclosure is designed to house Telecom equipments / Batteries / DC power
system. All these items produce heat during operation. If this heat is not extracted out, it will
re-circulate internally and severally affect the performance of these items, affecting its
working life.
1. Fan Filter Cooling: In this arrangement, the air enters the enclosure from front
bottom of door, through dust proof filter (G3 / G4 grade) and is taken out through DC
Fans from top rear / sides. The filter used is easily removable for cleaning, by blower,
water or vacuum cleaner. Both - filter and fans are covered with protective hood for
preventing water entering inside.
The numbers of fans are decided on various factors like CFM, Heat load, external
ambient temperature. In this, the internal temperature is higher than external ambient.
The typical value is 7 - 10 deg C, which means if ambient is 40 deg C, internal max.
temp will be 50 deg C.
A typical layout of Fan filter Cooling Outdoor Enclosure is shown below
Chapter 2 DCPS Introduction

NETSURE 503 IA4 Power system consists of R48-2000eW rectifiers, Standard Controller
Unit (M225S), AC distribution and DC distribution, which consist of distribution unit for load
and battery. The Load distribution and Battery Distribution units can be designed as per
users requirement. This system is used as a power supply for telecom equipment with
system nominal voltage of -48V and positive terminal earthed.
2.1 Features
The power system is easy-to-operate/install/maintain. Its main features are:
Rectifier uses APFC technology and therefore its power factor is up to 0.99
Wide AC input voltage range of 85~290V
Rectifier efficiency is >95% at the peak
Rectifiers compliant with UL, CE and NEBS standards
2.2 Operation Theory

The basic operating theory of power system is shown in the following figure:
Power cable
Signal cable
Figure 1-1 Basic operation theory diagram
AC Input Terminals
Rectifier AC
Breakers
Rectifiers
Back Board
Control Unit
C Class SPD
Battery 1
BLVD
LLVD
(Optional)
Non Prior Load
Prior Load
Battery n
AC mains inputs rectifiers through AC input terminals and rectifiers breakers. The output of
rectifier connects to Load distribution board. Batteries connect to the loads through BLVD
(Relay on Distribution board) . The monitoring unit collects the working states of each part of
the system and generates alarm to alert users.
2.3 Lightning Protection

Net sure 503 IA4 Power System has Class C SPD for perfect lightning protection on input
side.
A built-in II/C Surge Protection Devices (SPDs) is installed in the system, while each rectifier
is designed with perfect lightning protection circuits. The whole system can withstand 8/20s
surge current 20kA for 5 times, or 8/20s surge current 40kA once. To further protect the
10
system, Class I/B SPD which comes as optional item (with through current capacity of at least
50kA) can be installed close to the main AC distribution board.
2.4 BLVD
Batteries will start discharging to power loads once the AC mains fails. When the battery
Voltage drops to 44V (BLVD point, adjustable), the BLVD contactor will act to cut off the
connection between the batteries and the system, stopping the power output and protecting
the batteries. When AC mains recover, rectifiers will resume outputs, BLVD contactors will
close automatically, and the system will restore to normal operation.
2.5 Alarm and Protection

Based on the real-time data collected by the monitoring module, the system can detect the
states of output breakers, battery breakers and class II/C SPD. User can set the severity level
of faults such as AC input over/under-voltage, DC output over/under-voltage, etc. so as to
raise audible/visual alarms upon designated faults. User can also set alarm types of alarm dry
contacts.
Chapter 3 System Configuration

3.1 System Configuration
The typical outline of Cabinet of NETSURE 503 IA4 is illustrated in Figure.
Outline DC System in ODU
11
12
13
Chapter 4 System Components

4.1 R48-2000e3 Rectifier
R 48 2000 e3
HIGH EFFICIENCY
2000 W OUTPUT POWER
Figure 1-4: Model Number

4.1.1 Form and Interface
There are 3 indicators on the front panel. The location of the indicators is shown in Figure1-5.
Figure 1-5: Front Panel

The functions of the indicators are listed in Table 1-1.
Table 1-1:Function of Indicators
Indicator
Normal state Fault state

Off
Power indicator
(Green)
On
Protection indicator
(Yellow)
Off
Flashing
On
Flashing
Fault indicator (Red) Off
On
Flashing
Fault cause
No input voltage.Internal input fuse open.
The rectifier module is being identified by the
Controller.
AC input under/over voltage.PFC output
under/over voltage.High temperature.
Moderate load sharing imbalance.
Loss of communication with the Controller (the
rectifier can provide power).
Severe load sharing imbalance.rectifier module
output disabled for any reason, including
overvoltage shutdown and internal output fuse
open.Rectifier addresses contradictory.
Faulty fan (rectifier module shuts down).
14
4.1.2 Main Functions and Features
1. Constant Voltage Mode

For any initial output voltage setting from 42 to 58 volts, output voltage remains constant
regardless of load. This is the normal operating condition, in which loads are being supplied
and batteries are float charged. Rectifiers operate in the Constant Voltage Mode unless load
increases to the point where the product of load current and output voltage is approximately
2000W.
2. Constant Power Mode
As load increases above approximately 2000W (non-adjustable), output current continues to
increase, but output voltage decreases as required to maintain constant output power.
Rectifiers operate in the Constant Power Mode unless load continues to increase to the point
where the current limit setting is reached.
3. Constant Current Mode
If load increases to the current limit setting, output voltage decreases linearly to maintain
output current at the current limit setting.
4. Output Characteristics
The relationship between output voltage and current is summarized in below table and
depicted graphically in Figure 1-6.
Output Power
Output Current
Output Voltage
2000 W
34.48 A
58Vdc
2000 W
41.66 A
48Vdc
Figure 1-6: Output Characteristics

5. Current Limit Function
The rectifier has a current limit function. The current limit point can be set between
The range of 4 to 41.7 A, adjustable via the Controller. The current limit accuracy is 1.5A
when the output voltage ranges from 42 to 58 V. Below42 V the current will fold back to a
lower value.
6. Advanced Current Limit Function
The rectifier has an advanced Current Limit Function. When a short circuit occurs at the
rectifier output terminals, the rectifier will keep its output current at a value below the
maximum current limit set point. This function effectively protects the rectifier and the
equipment connected to the rectifier. When the short circuit fault is cleared, the rectifier will
automatically restore back to normal operation..
15
7. Fan Control
When the input voltage is within a normal range, the built-in processor adjusts the fans speed
according to the rectifiers internal temperature and Load. For example, a higher temperature
and load will increase the fan speed. Above 45C with full load, the fan will be operating at full
speed. When the input voltage is abnormal, such as very low or high input voltage, the fan will
turn off.
8. Input Over/Under Voltage Protection
a. Input Over/Under Voltage Protection: The rectifier will shut down at low or high voltage
input; based on the following voltage levels:
1. Low Voltage Disable Point: 80V, 5 V; hysteresis is 15 VAC for restart.
2. High Voltage Disable Point: 305V, 5 V; hysteresis is 10 VAC for restart.
b. Between 85 V and 176 V the output power will be derated linearly based on the input
voltage as follows:
1. At input voltage of 85V with output >48V, max output power is 800W.
4. At input voltage of 176V and output >48V, max output power is 2000W
9. Output over Voltage Protection (HVSD)
There are two kinds of HVSD:
a. The fixed hardware HVSD is 59.5V (within the range of 59 to 60V), In case of hardware
HVSD; the rectifier has to be restarted manually.
b. The software HVSD is settable; its level (from controller) is from 56V to 59V.
The rectifier will shut down when its output voltage is higher than HVSD set point. Note that
the HVSD set point can be modified through the SCU and the permissible range is from 56 V
to 59 V. The occurrence of a HVSD condition will cause the rectifiers alarm indicator (red) to
light up. The failure information will be reported to the SCU and the SCU will process the
failure accordingly. Note also that the rectifier can only be restarted manually should a HVSD
condition occur twice within a 5-minute interval.
The rectifier also has two additional software settings that can be configured using the SCU:
Manual restart and Automatic restart attempt should be within 5 seconds of a HVSD
condition.
10. Over Temperature Protection
The rectifier provides over temperature protection by derating output power and recovers
automatically.
11. Hot Swappable
The rectifier is designed to be plug-and play. The rectifier can be inserted or removed from a
live DC power system with no damage. When the rectifier is plugged into the system, the
system output voltage will not be affected.
12. Communication Failure
The rectifiers protection indicator (yellow) will flash should it experience a communication
failure. The failure information will be reported to the SCU and the SCU will process the
failure accordingly. During a communication failure, in order to protect the battery, the rectifier
output voltage will automatically adjust to 53.5 V (this is a default value which can be modified
using the SCU). The rectifier will revert to normal operation once normal communication is
restored.
16
13. Fan Fault Protection

An alarm will be generated upon a fan fault. In such cases, the fault indicator (red) on the
rectifier front panel will flash and the rectifier will also inhibit its output. Auto-recovery is
enabled upon the clearing of the corresponding fault.
4.1.3 Specifications
1. Environmental
Storage Ambient Temperature Range:: -40 to 70C

Full rated output power of 2000 W for temperatures -40 to 55C.
Power limitation for temperatures higher than 50C.
Derating Temperature Output range: +40 to 70C
Relative humidity: up to 95%
Altitude: 2000 m (6560 ft) at full power (power limited for heights above 2000 m).
2. Input
Input voltage: 85 to 300 Vac, single-phase three-wire

Rated input voltage: 200 to 250 Vac
Input current: <12A @ 2000 W, and at an input voltage of 176 Vac
Inrush current: less than1.5 times of the rated input steady-state peak value
Allowable input power frequency: 45-65 Hz
Rated input power frequency: 50/60 Hz

3. Output
Output voltage: 42 to 58 V
Output DC current: 0 to 41 A
Voltage regulation: 1%
Load regulation: 0.5%
Line regulation: 0.1%
Overshoot at startup: 1%
Power factor >0.98 (50% to 100% load)
Efficiency > 95%(At Peak)
Ripple 200mV at 0-20MHZ
Acostic Noise 50db
4. Dimensions
42 mm (Height) X 84.5 mm (Width) X 252.5 mm (Depth)

5. Weight
Under 1.13 kg
Chapter 5 Controller Details
17
18
19
20
21
22
23
24
25
26
27
28
5.1 650VA Inverter

5.1.1
General
Q456 is a back-up pure sine wave inverter hat can convert the 48V DC power supply or battery to
220V/50HZ. The load can be powered by bypass directly when the AC mains is normal, and the
unit will switch to DC inverting mode via internal conversion when the AC mains is ubnormal. The
output of the inverter is 220Vac/50HZ, the output power of the inverter is 650VA. The inverter is
featured with input and output over-voltage protection, under-voltage alarm, short circuit
protection, over-temperature protection, etc. The unit can report the information via RS485
communication. The inverter can be used for communication, home office, electricity, industrial
control, security, transportation, etc.
5.1.2
Rated
Main Specifications
Output
AC Input
Power
Voltage Range
DC Input
Voltage Range
650VA
176-264Vac
40-57.6VDC
5.1.3
Rated
Output Voltage
220Vac
Output
Output
voltage range current range
220V3%
0-2.54A
Electrical Characteristics
DC Input Characteristics
No.
Item
Technical Requirement
Unit
1.1
DC rated input voltage
48
Vdc
1.2
DC input voltage range
40-57.6
Vdc
1.3
Max. input current
15
1.4
Input reverse
protection
yes
Remarks
Battery voltage 42V
50% load test.
power off
AC Input Characteristics
No.
Item
Unit
2.1
AC input voltage
176-264
Vac
Remarks
2.2
AC input current
2.3
Input frequency
50
Hz
2.4
PFC
0.9
2.5
Cooling model
Fan cooling
29
Output Characteristics
NO.
3.1
Item
Rated Output Power
650
Unit
VA
Remarks
DC input inverting mode
3.2
Effective Output Power
520
3.3
Rated Output Voltage
220
VAC
3.4
Output Voltage Range
2203%
VAC
176-264
0-2.5
VAC
A
Bypass mode
3.5
Output Current Range
3.6
Efficiency
88
DC input voltage 48V
3.7
Output Frequency
500.5
Hz
Inverting mode
3.8
Output Waveform
Pure sine wave

%
Resistive load
mS
Resistive load
3.9
3.10
3.11
3.12
3.13
3.14
Output Waveform
AC/inverter switch time

Dynamic voltage
4.1
4.2
4.3
4.4
4.5
10
5
60
mS
transient range
Transient Recovery
Time
Output current crest
factor
Noise
4
No.
Distortion
55
dbA
Protection Characteristics
Item
Over Temperature
protection
Battery Under
Voltage Protection
Battery Low Voltage
Alarm
Battery over Voltage
Protection
Battery over Voltage
recovery
Unit
yes
Remarks
Auto Recovering
40-42
VDC
Power off
43
VDC
Hysteresis 0.5VDC
62-65
VDC
55-60
VDC
30
4.6
Output over Current
4.7
Protection
Output Short Circuit
4.8
Battery Reversing
Output Over Voltage
245
VAC
200
VAC
200000
Protection
Output under Voltage
Alarm
4.12
Alarm, Hiccup Mode
yes
Protection
4.10
Alarm, Hiccup Mode
yes
Protection
4.9
4.11
600VA*1.25=750VA1
minute protection
600VA*1.50=900VA10
seconds protection
MTBF
5.1.4 Communication Mode

No.
Item
RS485 Communicate
Technical
Requirements
Communication
protocol:
total ZXDU45/75/150
Battery under voltage
Dry contact 1
disconnection
Inverter fault
Dry contact 2
disconnection
Dry contact 3
AC power off
disconnection
Remarks
5.1.5 Mechanical Characteristics and Connector Definition
1. Outline dimension L*W*H =301mm*126mm*43.5mm
2. DC input connector definition:
Pin
Definition
BAT-
BAT+
3.AC input connector definition:

Pin
Definition
CHGND
31
32
4.Output connector definition:
Pin
Definition
CHGND
5. Signal connector definition:
Pin
Definition
1
2
3
4
5
6
7
8
9
RS485
RS485
5V+
5VDry contact 1
Dry contact 12COM
Dry contact 2
Dry contact 3
Dry contact 3
6. Other Requirements:
NO.
Item
Requirements
Placement mode
horizontally
Grounding mode
Good conductive contact via shell, the front panel,

fastening screws with integrated cabinet.
Conformal
coating
Moistureproof, dustproof and corrosion resistant
Remarks
33
1. Replacing the Inverter: Follow the below steps while replacing the Inverter Module.
a) Switch off the AC mains input MCB (common MCB for Inverter & Rectifier Module).
b) Press the inverter ON/Off switch (RED button on front face
of inverter to OFF Position.
c) Remove Inverter DC input wires from 9 way Connector strip
d) Remove Inverter AC input wires from 9 way connector strip.
e) Remove Inverter AC output wires from 9 way connector strip
f) Pull out the Inverter modules gently without disturbing the
Connector strip & other internal wires of the system.
g) Take a new Invert Module & arrange its input & outputs wire back to front with the help of
cable ties & tie base.
h) Put labels/ color tape to easily identify the AC input / output, DC Input cables gently insert
the Module in its slot without interfering with other components / wires.
i) Connect Inverter AC output wires to 9 way connector, maintaining the polarity.
j) Connect Inverter AC Input wires to 9 way connector, maintaining the polarity.
k) Connect Inverter DC Input wires to 9 way connector, maintaining the polarity.
l) Switch ON the mains input MCB & Press the RED button on invert front face to ON position.
AC OUTPUT
PH
1
PH
E
2
AC INPUT
E
5
BLANK
9 WAY CONNECTOR
DC INPUT
-VE +VE
8
DB9 CONNECTOR
34
Replacement of Power Distribution Board

Removal of old PCB and PCB Mounting Plate
1. Remove all load wires from PCB terminal (CN1, CN2, CN3-1, CN3-2) and incoming wires
(L, N, E) from 3 pin Connector.
Disconnect the wires
2. Disconnect the FAN wires (Two- way Molex connector) & remove 4 Nos of
from 19 rack to remove the DCPS from ODU Cabinet.
M6 screw
3. Remove the top plate of DCPS.And remove the wires from PCB terminal (CN5, CN6, CN7
& TB-1.) & Earthing wire from PCB mounting stud
Disconnect the wires
4. Remove the PCB and PCB mounting plate from DCPS cabinet.
35
Installation of New PCB and PCB Mounting Plate

1. After Removal of old PCB & PCB plate from DCPS cabinet take the new PCB Mounting
Plate.
2. Mount the New PCB on PCB mounting Plate .As per Bellow Fig.
3. After mounting the PCB in PCB plate fix the whole assy in DCPS cabinet as per Bellow
Fig.
36
4. Do the internal wiring on PCB terminal (CN5, CN6, CN7 & TB-1.) as per electrical
Schematic and close the top plate. Wire the earthing cable E6 on PCB mounting Plate.
5. Install the DCPS in ODU cabinet.with 4 Nos of M6 screw And connect the fan wires
(2 way Molex Connector )
6. Connect the Battery and DC & ac load wires to New PCB as per bellow Fig.
Connect AC load-1(L,N&E)
Connec the battery

Wires (+ve & -ve)
connect the DC load
(+ve & -ve ) wires
37
Service person Need to carry bellow Material while Servicing.

Sr. No
Description
Screw Driver Star Type & Flat Type
Wire Cutter
Spanner M6, M8 & M3
Insulation Tap
5.
Multi Meter
283206391000-Fuse, No Lead, Glass Cartridge, Time Delay, 6.3 Amp, 250 Vac,
5.2 X 20 mm
283200011000-Fuse, Radial, Glass Cartridge, 1 Amp, 250 Vac, 5 X 20 mm
Clamp Meter
Distribution Board Details

Schematic for Distribution Board
GND
DISTRIBUTION BOARD
Rev-01
1
2
CN3-1
9
PH
N
8
7
CN7
N
N
N
N
CN3-2
FUSE-1A
FUSE-1A
FUSE-1A
FUSE-1A
FUSE-2A
FUSE-15A
1
2
3
4
Qty
-VE
+VE
BATT. MCB -VE O/P
3
2
PH
PH
PH
PH
4
3
BLVD
FUSE-2A
2
1
BATT. MCB -VE I/P
2
1
RM -VE
RM +VE
BSH
CN6
1
16
-VE
+VE
-VE
CN2
CN5
+VE
15
33
19
28
29
34
TO CONTROLLER
CN1
+VE
-VE
38
Connector Details
2. CN1- Pin-1 Battery (-Ve) Supply

Pin-2 Battery (+Ve) Supply
3. CN2-Pin-(1,2,3,4) For DC Distribution

4. CN3-Pin-(1,2,3,4,5,6,7,8) For AC Distribution
5. CN5-Pin-(1,2)-For Battery MCB
Pin-(3,4)- For Inverter DC I/P.
6. CN6-Pin-(1,2)- For Rectifier DC Input

7. CN7-Pin-(1,2)-For Inverter AC O/P
8. CN10-Pin-(1,2,)-For Battery Shunt
Pin-(3,4)-For Battery & Load fuse
Pin-(5,6)-For BLVD
Pin-(7,8)-DC Supply (+Ve) & (-Ve)
5.2 Cable Input & Output Details
CABLE DETAILS INPUT & OUTPUT

AC INPUT (L,N,E)
BATTERY INPUT
AC / DC LOAD
CABLE SIZE - 2.5SQMM Max.

LUG TYPE - FORK / RING TYPE
LUG SIZE - CRIMP SIZE 2.5SQMM
INTERNAL DIA - 4 MM
8MM
EXTERNAL DIA
CABLE SIZE - 2.5SQMM
LUG TYPE - PIN TYPE
LUG SIZE - CRIMP SIZE -2.5 SQ MM
CABLE SIZE - 1SQMM Max.
LUG TYPE -PIN TYPE
LUG SIZE -CRIMP SIZE -1SQ MM
Chapter 6 System Specifications & General Requirements

6.1 Technical Specifications
Input
Operating Voltage
Output Power
THD
Power Factor
Output
Output Voltage
Efficiency
Ripple
Environmental
Conditions
Ambient temperature
Recommended Range
90V to 300V for Single phase
40A @ 48V DC, 500W AC
< 5%
> 0.99
Recommended Range
42V to 58V by rectifier,
>94%
<100mV p-p
Humidity
90%RH, non-condensing
Dust
1mg/m
Sunlight
Corrosives
No direct sunlight
No pollutants, such as salt, acid, and smoke, etc.
Shake
1.5m/s
Insects, pests, and

termites
Mildew
Moisture
Fire protection
Recommended Range
-5~45C
3
None
None
Water proof
No flammable on the top/bottom of the cabient.
39

40
Chapter 7 ELECTRICAL DRAWINGS
L
N
E1
L
N
E
AC IN
GND
DC Out
GND
FAN TRAY
36
41
SWITCH
-VE +VE
DC I/P
L CONNECTOR
38 1
2
(+VE)
(- VE)
1
2
PH
N
CN7
FUSE-15A
34
E6
GND
CN3-1
8 N
7 N
N
PH
PH
PH
PH
+VE
-VE
+VE
-VE
-VE
+VE
3
2
CN3-2
FUSE-1A
FUSE-1A
FUSE-1A
FUSE-1A
FUSE-2A
CN2
2
1
CN1
DC (+VE) EARTH BUS
BSH
FUSE-2A
DISTRIBUTION BOARD
Rev-01
29
BLVD
28
-VE
+VE
BATT. MCB -VE O/P
19
BATT. MCB -VE I/P
CN5
RM -VE
RM +VE
33
TO CONTROLLER
15
W110
1
W111 2
W116 3
18,37
1
2
CN6
E7
16
W117 4
W114
W115
15A/1P MCB
- 48V DC BUS
1 2 2 WAY CONNECTOR
35
40
9 WAY
CONNECTOR
1 2 3 4 5 6 7 8 9
E5
E4
Rectifier Modules
2000W
W202
E3
W201
SPD-C
W204
L1
W207
W203
COM
NO
EB/MAINS INPUT
MCB 15A /1P,1Nos
W200
E2
GND
AC EARTH BUS BAR ODU
NC
PH N E PH N E
W112
E
GND
GND
W206
AC I/P
AC O/P
INVERTER
650VA
W113
W208
W205
GND
To AC LOAD
To DC LOAD
BATTERY
CAN_L
CAN_H
16
15
18
19
1 CAN_L
2 CAN_H
3 OC1+
4 OC15 OC2+
6 OC27 BAT 1_SH+
8 BAT 1_SH9 BAT _FUSE1
10 BAT _FUSE2
11 LOAD_FUSE
12 GND
13 DO-1
14 DO-2
15 VCC_5V
POWERBATBLANK
POWE+
BLVD COMM
BLVD OFF
SPD+
SPD-
2
3
4
5
6
7
8
DI_DOOR+ 9
DI_DOOR10
DO2M
28
29
1
2
42
1
2
TXD
RXD
GND
PFC OUTPUT DETAILS

Mains / SPD Fail Batt
on Discharge/BLVD Fail/
DC O/P Low /High
Rectifier Fail
TEMP.+
TEMP.-
2
3
PFC
DO1
DO2
34
12
J7
1
RS-232
DO1
33
37
11
DO2
M225S
J6
PE
J3
DO2
41
42
General Guideline for system Installation / Maintenance / Service

1. There should be proper arrangement of Ladder / base to install / uninstall / service the Pole / Wall
mounted units. Ladder / base should be stable and capable to withstand the weight of service person.
2.
3.
4.
5.
6.
7.
Minimum two persons are required to install / uninstall / service the unit.
Ensure that any lifting equipment that used in moving the cabinet has sufficient lifting capacity.
Ensure to connect external earthing to the Enclosure on the base.
Do not uses spray cleanser to clean the equipment, this may damage the system.
Ensure Gasket is intact and door is closing properly.
Use Proper Hardware to Install the unit on Pole / wall/ base. All required hardware is supplied with
unit.
8. Air filter if not cleaned regularly will affect the cooling and will increase the internal temperature of
Outdoor Enclosure.
9. SPD needs to be checked while preventive maintenance, replace immediately if found faulty.
10. RED Button on Front face of Inverter should always be in ON position during normal operation of the
unit
11. Make sure that there is no loose contact between AC and DC, System ground, Breakers etc.
12. Do not close the battery circuit breaker / fuse before the equipment has been commissioned.
13. Before switching ON the system the AC input system the AC input frequency and voltage must be
verified.
14. Dont force rectifier into the slot if it does not slide or connect easily. Remove and reinsert the rectifier.
15. Ensure that the alarm limit are set correctly ,Incorrect setting may trigger false alarms
16. Replacing the Inverter: Follow the below steps while replacing the Inverter Module.
m) Switch off the AC mains input MCB (common MCB for Inverter & Rectifier Module).
n) Press the inverter ON/Off switch (RED button on front face
of inverter to OFF Position.
o) Remove Inverter DC input wires from 9 way Connector strip
p) Remove Inverter AC input wires from 9 way connector strip.
q) Remove Inverter AC output wires from 9 way connector strip
r) Pull out the Inverter modules gently without disturbing the
connector strip & other internal wires of the system.
s) Take a new Invert Module & arrange its input & outputs wire back to front with the help of
cable ties & tie base.
t) Put labels/ color tape to easily identify the AC input / output, DC Input cables gently insert
the Module in its slot without interfering with other components / wires.
u) Connect Inverter AC output wires to 9 way connector, maintaining the polarity.
v) Connect Inverter AC Input wires to 9 way connector, maintaining the polarity.
w) Connect Inverter DC Input wires to 9 way connector, maintaining the polarity.
x) Switch ON the mains input MCB & Press the RED button on invert front face to ON position.
17. In case of any service query please contact customer care Toll free number for assistance.
Appendix 2
CHECK LIST FOR INSTALLATION INSPECTION AT SITE
Site Name:
Site ID:
1. Check that the system is properly packed & not in damage condition. In Case it is
damage inform customer so as to claim insurance.
2. In case of no damage observed, remove the system from the packing material.
3. Check for any transparent damage, in case of any damage the same should be
corrected before taking up future steps.
4. Check for the mounting platform, if the system has to be installed on the top of battery.
Otherwise grouting provision for free standing installation.
5. Check wires at AC distribution board & DC common points for loose connections.
6. Check all control cable connector are connected at proper connector on the PCB.
7. Check all bus bar joining points for loose connection.
8. Ensure that the earthling potential is less than 2V at the distribution panel.
9. Ensure that the earth resistance is less than 1Ohm.
Recommended Tools
Multi meter
Box type screw driver M6, M8 & M10

Set of spanners, cutter, stripper & pliers
Crimping tool up to 120 sq mm
Check
Date:
Place:
Signature:
(Installation Engineer)
Note: To be retained by customer for his record.
OK
43
44
Emerson Network Power (India) Private Limited

Warranty Terms & Conditions:
1. The warranty is applicable to all parts of the power system against manufacturing/ design
defects, except consumable parts susceptible to external operating conditions like surge
protection devices and fuse.
2. The warranty is valid for a period of 18 months from date of supply and 12 months from date of
commissioning, whichever is earlier.
3. The warranty is valid only if:
a) the equipment was selected for use within the manufacturers specifications.
b) is installed / commissioned / serviced by EMERSON NETWORK POWER (I) PVT. LTD. Trained
/ Authorized / Technical / Engineer.
c) Operated in accordance with the instructions given in operating / user manual supplied along
with the system.
d) Is operated in an environment and within the temperature limits specified by the manufacture.
4. Any warranty replaced part will carry the benefit of the unexpired portion of the original warranty
period only.
5. Any fault / damage occurred out of abuse /misuse; lightning, heavy input surges beyond the
limit specified by the manufacturer, over loading, riots, floods etc. and act of god are not covered
under warranty.
6. The warranty is not valid for if the equipment is resold by the customer or if it is bought from any
other source which is not authorized by EMERSON NETWORK POWER (I) PVT. LTD.
7. Any dispute shall be subjected to jurisdiction of Thane Mumbai only.

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NetSureTM 503IA4 DC POWER SYSTEM

NetsureTM 503 IA4

Emerson part No.

Copyright 2009 by Emerson Network Power India Pvt. Ltd.

NetSureTM 503IA4 DC POWER SYSTEM

Emerson Network Power (India) Private Limited

NetSureTM 503IA4 DC POWER SYSTEM

EMERSON NETWORK POWER (INDIA) PRIVATE LIMITED

Customer Care / Service Helpline Number:

NetSureTM 503IA4 DC POWER SYSTEM

As per ECO-588 PCB

NetSureTM 503IA4 DC POWER SYSTEM

Chapter 2 DCPS Introduction

2.2 Operation Theory

2.3 Lightning Protection

2.5 Alarm and Protection

Chapter 3 System Configuration

4.1.1 Form and Interface

4.1.2 Main Functions and Features

Chapter 5 Controller Details

5.1 650VA Inverter

5.1.2 Main Specifications

5.1.3 Electrical Characteristics

5.1.4 Communication Mode

5.1.5 Mechanical Characteristics and Connector Definition

5.2 Distribution Board Details

6.1 Technical Specifications

6.2 Cable Input & Output Details

Chapter 7 ELECTRICAL DRAWINGS

General Guideline for system Installation / Maintenance / Service

NetSureTM 503IA4 DC POWER SYSTEM

Chapter-1 General Description

Provision to house battery bank

Controlled environment against dust and rain.

Controlled internal temperature due to heat dissipation from internal equipments.

Ease of installation and accessibility to internal parts.

Pole / Wall/Base Mounted Outdoor Enclosure:

NetSureTM 503IA4 DC POWER SYSTEM

NetSureTM 503IA4 DC POWER SYSTEM

NetSureTM 503IA4 DC POWER SYSTEM

Chapter 2 DCPS Introduction

2.2 Operation Theory

Non Prior Load

2.3 Lightning Protection

NetSureTM 503IA4 DC POWER SYSTEM

2.5 Alarm and Protection

NetSureTM 503IA4 DC POWER SYSTEM

Chapter 3 System Configuration

Outline DC System in ODU

NetSureTM 503IA4 DC POWER SYSTEM

NetSureTM 503IA4 DC POWER SYSTEM

Chapter 4 System Components

Figure 1-4: Model Number

Figure 1-5: Front Panel

Normal state Fault state

Fault indicator (Red) Off

NetSureTM 503IA4 DC POWER SYSTEM

4.1.2 Main Functions and Features

1. Constant Voltage Mode

Figure 1-6: Output Characteristics

NetSureTM 503IA4 DC POWER SYSTEM

NetSureTM 503IA4 DC POWER SYSTEM

13. Fan Fault Protection

1. Outline dimension LWH =301mm126mm43.5mm