Emerson 200I/48-NT5C05C, Installation And User Manual

Page 1: ...anual V OL T A M P V O LT C A L C U R C A L TH S D H V S D RF A FA N A LM V OL T V O U T S E N F A IL E Q L A C ON C L FF 1 1 0 A F F2 1 0A C L AD J EQ L AD J E QL F LT A DJ H VS D A D J I I S T U P D L Y S LS F S D C C C AC CA I 0 HELIOS F LT P0745680 Standard 6 00 October 2001 UM5C05C 169 2081 501 ...

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Page 3: ...rties and use the same for start up operation and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design quality at Astec International Ltd to insure that the equipment complies with the operation standards This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15...

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Page 5: ...804 March 1998 Issue 5 0 Standard Reference change from NT5C05CB to NT5C05C July 1997 Issue 4 0 Standard EMI compliance information and table of content numbering corrections June 1995 Issue 3 0 Standard Revised rectifier installation procedure in a cabinet September 1994 Issue 2 0 Standard Few revisions and additions from the previous issue July 1994 Issue 1 0 Standard Few changes from the previo...

Page 6: ...6 Publication history UM5C05C P0745680 Standard 6 00 October 2001 Emerson Energy Systems This page is left blank intentionally ...

Page 7: ...a 1200 A cabinet 24 3 5 2 Running and connecting the dc between busbars and a rectifier 24 3 6 Connecting ac to the rectifiers 24 3 7 Connecting the control signals 28 3 7 1 Monitoring of the shunt current 29 4 Functional description 31 4 1 Overview 31 4 1 1 Input circuit 31 4 1 2 Output circuit 31 4 1 3 Monitoring and control circuits 32 4 1 4 Output capacitors 32 4 2 Description of the front pan...

Page 8: ...roller 28 Figure 10 Front panel controls and LEDs 33 Figure 11 Replacing the fan unit 49 List of Tables Table 1 Mechanical specifications of the rectifier 13 Table 2 Electrical specifications of the rectifier 13 Table 3 Operation specifications of the rectifier 14 Table 4 Ambient conditions for the rectifier 15 Table 5 Mechanical specifications of the NT6C43CB 1200 A cabinet 16 Table 6 Electrical ...

Page 9: ...nd the ac female plug in a 1200 A cabinet 27 Procedure 7 Connecting the NT5C05CC to the controller 28 Procedure 8 Connecting an NT5C05CC rectifier directly to a controller 29 Procedure 9 Starting up the rectifier 46 Procedure 10 Replacing the fan unit 50 Procedure 11 Calibrating the meter 51 Procedure 12 Resetting the rectifier after a high voltage shutdown 51 ...

Page 10: ...10 Contents UM5C05C P0745680 Standard 6 00 October 2001 Emerson Energy Systems This page is left blank intentionally ...

Page 11: ... CA L CU R CA L TH S D H V S D R F A FA N A LM V OL T V O U T S E N F A IL E Q L A C ON C L FF 1 1 0 A F F2 1 0A C L AD J EQ L AD J E QL F LT A D J H VS D A D J I I S T U P D L Y S LS F S DC C C AC CA I 0 HELIOS F LT The NT5C05CA CB CC rectifiers are designed to operate continuously in a 48 V power system equipped with or without batteries It can be integrated into a small embedded system or a lar...

Page 12: ...fiers can be installed in a 23 inch NT6C43CB 1200 A cabinet or in an NT6C40 type frame The cabinet is specifically designed to provide modularity within a very compact unit For wooden floor applications in a zone 4 seismic region up to three rectifiers can be installed in a mounting frame mounting but they must be installed in the three lowest mounting positions in the frame Figure 2 Typical mount...

Page 13: ...ac Range 330 5 V ac to 475 5 V ac Frequency 47 to 63 Hz Note After an out of range line condition shutdown the rectifiers will restart automatically at a line voltage within 350 5 V ac to 460 5 V ac Input current Nominal 18 A RMS at 415 V ac Worst case 24 A RMS Input protection 25 A ac breaker 3 Ø Output floating voltage 46 V dc to 58 V dc Equalizing voltage 0 to 4 V dc above the floating voltage ...

Page 14: ... RMS in any 3 kHz band between 10 kHz and 20 MHz measurements made with or without batteries at the output terminals of the rectifier and with the rectifier in the local sensing mode less than 250 mV peak to peak switching voltage spikes measured differentially with an a 100 MHz oscilloscope Total harmonic distortion THD Less than 5 Efficiency Better than 89 at a nominal input voltage of 350 V ac ...

Page 15: ... rectifier can be subjected to the following conditions without sustaining damage Temperature 67 F 55 C for 16 hours 140 F 60 C dry heat Humidity 0 to 95 RH non condensing at 4 kPa max Vibration 38 mm s max 10 Hz to 30 Hz sinusoidal 18 inch 457 mm drop when packaged Pressure 12 kPa min equiv to 49 212 ft 15 000 m above sea level Temperature shock 58 F to 140 F 50 C to 60 C Storage conditions Durin...

Page 16: ... V ac three phase Output voltage 46 V dc to 58 V dc Output current 1200 A 2 4 Ambient conditions of a 1200 A cabinet Table 7 Ambient conditions for the NT6C43CB 1200 A cabinet Operating conditions The cabinet is designed for use under the following ambient conditions Temperature 0 C to 50 C 32 F to 122 F 0 to 40 C 32 to 104 F with air filters Humidity 0 to 95 RH non condensing Altitude sea level t...

Page 17: ...pervisor 3 2 Tools and test equipment The following tools and test equipment are required screwdriver flat blade 3 16 inch 5 mm potentiometer screwdriver Bourns No 60 or equivalent heavy cable strippers or electrician s knife heavy cable cutters AWG 4 0 or metric No 110 nut drivers set socket set 1 2 inch or 15 mm drive torque limiting wrench 1 2 inch or 15 mm drive crimper T B 15CA54R Violet die ...

Page 18: ...uipment is heavy If a forklift is used do not remove the packing material before having moved the equipment to its final location If a dolly truck is used the packing material can be removed in the reception area When handling cabinets with equipment installed in them exercise care to ensure they do not tip over as they can be top heavy CAUTION Preventing personal injury When cutting material wear...

Page 19: ...efore any other leads This is to prevent the cabinets and any other metal structures from carrying dangerous ac or dc voltage levels DANGER Protecting against electrical shocks The cabling of the power plant and all other required cabling must be carried out by qualified personnel and in conformance with local and national electrical codes AC input voltages to the rectifiers are at a dangerous lev...

Page 20: ... the rectifier with the mounting holes in the frame and insert the locating pins into these holes 2 Lift the rectifier and align the middle holes in the mounting brackets of the rectifier with the locating pins inserted in the frame Slide the rectifier into position onto the locating pins 3 Secure the rectifier to the frame by inserting and tightening a mounting screw provided in the uppermost hol...

Page 21: ...p Figure 3 Anchoring the cabinet 600 mm 23 56 po 520 mm 20 42 po 590 mm 23 13 po 526 mm 20 68 po SECONDARY LOCATION FOR FLOOR ANCHORS PRIMARY LOCATION FOR FLOOR ANCHORS Procedure 2 Installing a rectifier in a cabinet Step Action 1 Loosen and remove the screws securing the mounting brackets to each side of the rectifier 2 Reposition and secure the mounting brackets to the holes located nearest the ...

Page 22: ...n place by inserting and tightening the self tapping screws removed in Step 3 Note Install an external tooth lock washer on one of the screws to assure good ground continuity between the rectifier and the frame end Figure 4 Installing the rectifier HELIOS AC CA VOLT AMP VOLT AMP VOLT CAL CUR CAL CL ADJ EQL ADJ EQL FLT THSD HVSD RFA FAN ALM VOUT SEN FAIL EQL VOUT AC ON CL FF1 1 0A FF2 1 0A FLT ADJ ...

Page 23: ...ectifier connected to the CHG BAT busbar BAT GRD of the rectifier connected to the CHG GRD busbar and the 48V of the rectifier connected to the CHG DISCH BAT busbar Figure 5 Connecting the dc to the busbars with a shunt on the battery side or a shunt on the ground side RECTIFIER BAT GRD 48V CHG DISCH GRD BUSBAR CHG BAT BUSBAR SHUNT DISCHARGE BAT BUSBAR FUSE PANEL LOAD SHUNT ON THE BATTERY SIDE REC...

Page 24: ...f 6 5 0 5 ft lbs 8 5 0 5 N m end 3 5 2 Running and connecting the dc between busbars and a rectifier For frame applications use terminal lug A0361762 supplied with the unit and no 110 4 0 metric cable Procedure 4 Typical dc cabling in a frame application Step Action 1 Connect the BAT GRD output terminal of the rectifier to the CHG GRD busbar of the power plant Connect the 48 V output terminal of t...

Page 25: ... interfere with the insertion of the rectifier see Figure 6 5 Ground the conduit sheath to the ac service panel Insulate the conduit connector at the rectifier end with electrical tape to isolate it from the ac ground 6 Remove the two ac protection plates located at the rear of the rectifier 7 Strip 10 inches 250 mm of armored insulation from the end of the ac cable Insert the wires in the 90 cond...

Page 26: ...LES TO THE PLANT CONTROLLER REMOVE PLATE TO ACCESS CONNECTORS AC FEED TO RECTIFIERS A A REAR VIEW OFA TOP FED ARRANGEMENT SHOWING OPTIONAL BUSBAR COVER KIT P0872151 WITH REAR PANELS REMOVED SECTION A A SHOWING TOP VIEW OF AC CABLING Note Dress the cables carefully to clear the insertion path of the rectifier CABLE TIE SIGNAL CABLE Figure 7 Connect the power leads to the L1 L2 and L3 terminals of t...

Page 27: ...ply cable 3 conductors and ground to the female receptacle see Figure 8 Connect the female connector to the male connector 4 Run the signal cable from the rectifier to the interconnect board or controller as specified in the Connecting the control signals section 5 Secure the signal cables to the insulating busbar support located in the cabinet with cable ties 6 Start up the rectifier as described...

Page 28: ...n 1 Connect each rectifier to the NT6C43PB board positions J1 to J6 located at the top front of the cabinet or frame with P0747000 cables 2 Connect the NT6C43PB board positions J7 to J12 to the controller with P0736355 cables for conventional controllers and with P0736268 cables for front access controllers end Figure 9 Typical connections between rectifiers and the conventional controller Rectifi...

Page 29: ...tifier Refer to Table 8 for the pin assignments of connectors J7 to J12 on board NT6C43PB Note The alarm and control signals in Table 8 are all ground signals except for the RC signal that is a 48 V battery signal Table 8 Pin assignment for connectors J7 to J12 Pin Label Function Input Output 1 EQL Equalize Input 2 RG Remote sense Input 3 RC Remote sense Input 4 FAN ALM Fan fail alarm Output 5 HVS...

Page 30: ...assignment for connector J13 Pin Function J13 1 SH rectifier 1 J13 2 SH rectifier 1 J13 3 SH rectifier 2 J13 4 SH rectifier 2 J13 5 SH rectifier 3 J13 6 SH rectifier 3 J13 7 SH rectifier 4 J13 8 SH rectifier 4 J13 9 SH rectifier 5 J13 10 SH rectifier 5 J13 11 SH rectifier 6 J13 12 SH rectifier 6 ...

Page 31: ...its the output current rise to 25 A per second low and high ac inhibit power factor compensation surge voltage protection ac breaker for input protection For all input and output conditions specified in this manual when the rectifier is turned on the ac current will not exceed the maximum steady state value 4 1 2 Output circuit The output circuit offers the following characteristics shunt for outp...

Page 32: ... has been disconnected from the batteries or the parallel rectifiers 4 2 Description of the front panel 4 2 1 Breakers DC circuit breaker A dc circuit breaker is provided to protect against current overload and to manually disconnect from the power plant When the breaker is in the 0 OFF position an RFA is triggered and the remote sense leads RG and RC are internally disconnected The rectifier will...

Page 33: ...d potentiometers on the front panel to adjust the operating parameters of the rectifier The LED indicators indicate the operating and alarm conditions Figure 10 Front panel controls and LEDs FF2 1 0A FLT FF1 1 0A CL AC ON VOUT EQL SEN FAIL VOUT FAN ALM RFA THSD EQL EQL ADJ CL ADJ CUR CAL VOLT CAL HVSD VOLT AMP AMP VOLT HVSD ADJ FLT ADJ ST UP DLY SLS FS DC CC ...

Page 34: ...ilure alarm RFA The rectifier will resume its normal operation automatically when the specified input voltage has been re established CL current limit indicator This LED lights up if the rectifier is in current limit The rectifier limits the output current to 205 A 5 A adjusted in the factory 50 to 105 of the rated output current EQL equalize Indicates the rectifier is in equalizing mode FAN ALM f...

Page 35: ...function If the switching malfunction is caused by an improper adjustment of the output float voltage the RFA alarm will not be triggered The RFA feature will be activated if the ac power is removed in a system where batteries are present SEN FAIL sense fail alarm This LED lights up if the remote sense leads are not connected or if the RC fuse has blown THSD thermal shutdown This LED lights up whe...

Page 36: ...tion Description RG RC External reference voltage across the batteries measured through the controller to regulate the voltage HVSD Remote High Voltage Shutdown input activated by a BAT RTN signal HVSDR Remote High Voltage Shutdown Reset input activated by a BAT RTN signal TR Remote Inhibit input activated by a BAT RTN signal EQL Remote Equalize input activated by a BAT RTN signal RFA Rectifier Fa...

Page 37: ...OAT EQL switch When the FLOAT EQL switch is held in the EQL position the rectifier goes into equalize mode and boosts the output voltage to the value set by the EQL potentiometer When the switch FLOAT EQL is held in the FLT position the rectifier delivers a float voltage set by the FLT potentiometer Remote equalize control EQL The rectifier is equipped with remote equalize control This control is ...

Page 38: ...d sharing Selecting either mode is done by setting the two bottom DIP switches SLS FS located on the front panel The rectifier is factory set to the slope sharing mode Slope sharing SLS When both bottom DIP switches are set to the SLS position conventional load sharing is achieved through a 300 mV slope on the output voltage of the rectifier from no load to full load This mode should be used when ...

Page 39: ...rs The setting of the output voltage is not modified with changes in output load as is the case in the slope share mode In this mode the rectifiers will share the load within 2 of their maximum output rating For this to occur the rectifiers must communicate their operating current to the other rectifiers in the same power plant The current share terminal of all the rectifiers P1 17 in the same pow...

Page 40: ...ms if it is supplying more than 10 of its full load rating As is the case for the internal high voltage shutdown condition two HVSD events must occur within an interval of two minutes to lock out the rectifier permanently An ac breaker reset or an HVSDR signal can be used to restart the rectifier Local and remote HVSD reset The rectifier may be reset from an HVSD condition locally by toggling the ...

Page 41: ...X X X X X X X X X X X 4 SEC 12 SEC 20 SEC 28 SEC 36 SEC 44 SEC 52 SEC 60 SEC 1 X X X X X X X X X X X X 68 SEC 76 SEC 84 SEC 92 SEC 100 SEC 108 SEC 116 SEC 124 SEC 0 X X X X X X X X X X X X 1 X X X X X X X X X X X X X X X X X X X X 0 1 4 3 2 1 SWITCH 6 5 4 3 6 5 4 3 6 5 4 3 6 5 4 3 6 5 4 3 6 5 4 3 6 5 4 3 6 5 4 3 6 5 NOTE Switches 3 to 6 top four switches are used to set the start up delay ...

Page 42: ...ector located at the rear of the rectifier can be used to verify all the control and alarm signals when troubleshooting the rectifier see Table 14 The control inputs are activated by a ground BAT RTN signal The alarms extended by relay contacts are isolated from each other and the rectifier frame All contacts are rated 60 V and 0 5 A dc The normal status of each contact is defined when the rectifi...

Page 43: ...o connection P1 13 CB OFF NC Output breaker OFF NC P1 14 RG Remote sense P1 15 TR Rectifier temporary released by controller P1 16 HVSD High voltage shutdown P1 17 CURRENT SHARE Forced share link P1 18 RFA C Rectifier fail alarm C P1 19 SH Shunt P1 20 FAN NO Fan fail NO P1 21 GRD Reference ground P1 22 SENSE FAIL NC Sense fail alarm NC P1 23 NC No connection P1 24 NC No connection P1 25 CB OPEN C ...

Page 44: ...44 Functional description UM5C05C P0745680 Standard 6 00 October 2001 Emerson Energy Systems This page is left blank intentionally ...

Page 45: ...Plants Rectifiers and Controllers Table 15 Standard settings for the rectifier Parameter Setting Rectifier float output voltage FLOAT 52 1 0 1 V dc Rectifier equalize output voltage EQUALIZE 52 8 0 1 V dc Rectifier high voltage shutdown threshold 56 5 0 1 V dc Rectifier output current limit 205 A 5 A Rectifier start delay 4 sec Low ac input disconnect 330 5 V ac Low ac input reconnect 350 5 V ac H...

Page 46: ... the front panel The voltage reading should be within 1 of the rectifier meter reading If not calibrate it as described in the Maintenance section 6 Determine the system requirements for float equalize and HVSD limits by referring the User Manual Voltage_Level entitled Voltage Level Limits for Power Plants Rectifiers and Controllers 7 If the factory threshold limits of the rectifier must be verifi...

Page 47: ...ted on the front of the rectifier to ON 21 The rectifier is now connected to the system and should carry some current If it is connected in parallel with other rectifiers verify that the total system current is shared equally amongst the rectifiers Put the switch on each rectifier to AMP Find the mean current of the rectifiers by adding all the currents measured on each rectifier and dividing the ...

Page 48: ...n the P1 17 signals from all the rectifiers are automatically connected After step 25 has been completed the rectifiers will automatically share the output current When forced load sharing is desired but the NT6C43PB board is not used or is bypassed pins P1 17 of all the rectifiers must be made common at a single point This connection could be a splice connection of all the P1 17 wires in the cont...

Page 49: ...nit The fan unit consisting of four fans and a fan plate can be replaced To install a new fan unit execute the steps outlined in Procedure 10 and illustrated in Figure 11 Figure 11 Replacing the fan unit V OL T A M P V O LT C A L C U R C A L TH S D H V S D R F A FA N A LM V O L T V O U T S E N F A IL E Q L A C ON C L FF 1 1 0 A F F2 1 0A C L AD J EQ L AD J E Q L F LT A D J H VS D A D J I I S T U P...

Page 50: ...nsert the hinged bracket of the new assembly into the slotted holes on the left and reconnect the cables to the four fans 6 Place the four fan cables close to the display panel removing as much slack length as possible so the cables will not interfere with the fan blades after the fan unit is secured in place 7 Swing the fan unit closed and secure it in plate with the five screws 8 Check fan fuses...

Page 51: ... Rotate the CUR CAL potentiometer on the display panel until this value is displayed 4 Put the VOLT AMP switch to VOLT Adjust the V CAL potentiometer so that the reading displayed on the meter of the rectifier is identical to the reading on the digital meter 5 Put the rectifier to OFF and reconnect the sense leads end 6 4 Resetting the rectifier after an HVSD high voltage shutdown To reset the rec...

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Page 53: ... is present An internal high voltage shutdown HVSD has occurred Two cooling fans or fuses have failed The inrush fuse has blown The dc circuit breaker is open A thermal shutdown has occurred Ambient air temperature is high Air inlet outlet air is blocked or the air filter is clogged A rectifier is in Start Time Delay mode and the RFA will cease when the required time delay has elapsed Defective re...

Page 54: ...gering a local and remote FAN ALM Note 2 If two cascaded fans failed or both fuses blew the rectifier will shut down and trigger local and remote RFA alarms The SEN FAIL LED is lit One or both remote sense leads is disconnected Excessive impedance in one or both sense leads The dc circuit breaker is open but the unit is in remote sense The CL LED is lit The output load requirement exceeds the tota...

Page 55: ...stems Rectifier 200I 48 NT5C05C Installation and User Manual 8 Appendix A Replacement parts ITEM PART NUMBER CPC Fan Assembly P0723582 Fuse 1 A FF1 FF2 on Display PCB A0287301 Air filter P0744757 Air filter frame P0744559 ...

Page 56: ...56 Appendix A Recommended Replacement Parts UM5C05C P0745680 Standard 6 00 October 2001 Emerson Energy Systems This page is left blank intentionally ...

Page 57: ...tance Service ETAS and the Installation Technical Assistance Service ITAS 9 1 Local toll free prefixes The following prefixes give access to toll free numbers in various countries For further information please contact the local service provider Country Prefix Australia 0011 Belgium 00 Brazil 000815 Denmark 00 Finland 00 or 990 France 00 Germany 00 Hong Kong 001 Ireland 00 Japan 001 KDD 041 ITJ 00...

Page 58: ... 213 49156 Singapore 800 213 49156 Italy 800 213 49156 South Korea 800 213 49156 Netherlands 800 213 49156 Taiwan 800 213 49156 Norway 800 213 49156 Sweden 800 213 49156 Switzerland 800 213 49156 United Kingdom 1 800 213 49156 In the Caribbean and Latin America CALA In the Middle East Bahamas 1 800 389 0081 Israel 800 213 49156 Barbados 1 800 534 0225 Brazil 7101 2288 Colombia 980 192288 Dominican...

Page 59: ... Auto restart Indicator C Common CL Current limit indicator EMI Electromagnetic interference EQL Equalize FAN ALM Fan alarm HVSD High voltage shutdown HVSDR High voltage shutdown reset LED Light Emitting Diode LOP Loss of phase MPR Modular power rectifier NC Normally closed NO Normally open PCB Printed circuit board RC Remote charge bus negative ...

Page 60: ...C P0745680 Standard 6 00 October 2001 Emerson Energy Systems RFA Rectifier fail alarm RG Remote ground bus positive RMT ACK Remote acknowledge SEN FAIL Sense fail THSD Thermal shutdown TR Temporary release VCAL Voltage reading calibration ...

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Page 62: ...from disclosure and dissemination to all third parties and use the same for start up operation and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design quality at Astec International Ltd to insure that the equipment complies with the operation standards This equipment has been tested and found to comply with the limits...