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NetSure

 9500 120kW 400V DC Power System 

Operation Manual, UM584001200 (Issue AA, April 14, 2014) 

Spec. No: 584001200 

 

Code:  UM584001200 

Model No: 9500 

 

Issue AA, April 14, 2014 

[iii]

 

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.  To avoid 
these hazards: 

a)  The tasks should be performed in the order 

indicated. 

b)  Remove watches, rings, and other metal objects. 

c)  Prior to contacting any uninsulated surface or 

termination, use a voltmeter to verify that no 
voltage or the expected voltage is present.  Check 
for voltage with both AC and DC voltmeters prior to 
making contact. 

d)  Wear eye protection. 

e)  Use certified and well maintained insulated tools.  

Use double insulated tools appropriately rated for 
the work to be performed. 

f)  Do not work on an energized system without full arc 

flash and PPE protection. 

 

DANGER! 

All power and control wiring should be 

installed by a qualified electrician.  All power and control 
wiring must comply with the National Electrical Code 
(NEC) and applicable local codes.  For operation in 
countries where the NEC is not recognized, follow 
applicable codes. 

Voltages 

AC Input Voltages 

 

DANGER! 

This system operates from AC input voltage 

capable of producing fatal electrical shock.  AC input 
power must be completely disconnected from the 
branch circuits wiring used to provide power to the 
system before any AC electrical connections are made.  
Follow local lockout/tagout procedures to ensure 
upstream branch circuit breakers remain de-energized 
during installation.  DO NOT apply AC input power to 
the system until all electrical connections have been 
completed and checked. 

DC Output and Battery Voltages 

 

DANGER! 

This system produces DC Power and may have 

a battery source connected to it.  The DC voltage IS 
hazardously high and the rectifiers and/or battery can 
deliver large amounts of current.  Exercise extreme 
caution not to inadvertently contact or have any tool 
inadvertently contact an output terminal or battery 
terminal or exposed wire connected to an output 
terminal or battery terminal.  NEVER allow a metal 
object, such as a tool, to contact more than one 
termination or battery terminal at a time, or to 
simultaneously contact a termination or battery 
terminal and a grounded object.  Even a momentary 
short circuit can cause sparking, explosion, and injury. 

Follow local lockout/tagout procedures to ensure DC 
branch circuit breakers remain de-energized during 
installation at loads, as required. 

Extreme caution is required when performing 
maintenance.  Be constantly aware that this system 
contains high DC as well as AC voltages. 

The maximum output voltage is 400V DC and is 
potentially lethal. 

Check for voltage with both AC and DC voltmeters prior 
to making contact. 

 

 

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.  Observe all battery safety precautions in this 
manual and in the battery instruction manual.  These 
precautions should be followed implicitly at all times. 

Danger

Danger

Warning

Warning

Danger

Danger

Danger

Summary of Contents for netsure 9500

Page 1: ...NetSure 9500 120kW 400V DC Power System Operation Manual UM584001200 Issue AA April 14 2014 Specification Number 584001200 Model Number 9500 ...

Page 2: ...NetSure 9500 120kW 400V DC Power System Operation Manual UM584001200 Issue AA April 14 2014 Spec No 584001200 Code UM584001200 Model No 9500 Issue AA April 14 2014 This page is intentionally blank ...

Page 3: ...ry Options 2 HRMG High Resistance Midpoint Ground Configuration 200V DC 2 Operating Procedures 2 Controller and Rectifiers 2 Battery Cabinet if furnished 2 Local Controls and Indicators 2 Distribution Panel Lockout Tagout LOTO 3 HRMG Configuration Ground Fault Detection Circuit Operation 3 EPO Emergency Power Off 3 Adding a Circuit Breaker to a List 21HA Distribution Panel 5 Maintenance 5 Importan...

Page 4: ...derate injury if not avoided ANSI OSHA This admonition is not used for situations that pose a risk only to equipment data or service even if such use appears to be permitted in some of the applicable standards OSHA ALERT Alerts the reader to an action that must be avoided in order to protect equipment software data or service ISO ALERT Alerts the reader to an action that must be performed in order...

Page 5: ...o ensure upstream branch circuit breakers remain de energized during installation DO NOT apply AC input power to the system until all electrical connections have been completed and checked DC Output and Battery Voltages DANGER This system produces DC Power and may have a battery source connected to it The DC voltage IS hazardously high and the rectifiers and or battery can deliver large amounts of...

Page 6: ...s should never be installed in an airtight room or space Only install in a ventilated environment Batteries are an energy source that can produce high amounts of electrical current FOR THESE REASONS IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS AND FOLLOW THEM EXACTLY WHEN WORKING WITH LEAD ACID BATTERIES Wear complete protection for eyes face hands and clothing Examples are safety...

Page 7: ...and DC voltmeter to ensure safety before making contact or using tools Even when the power is turned OFF dangerously high electric charges may exist within the system Never work alone even if all power is removed from the equipment A second person should be standing by to assist and summon help in case an accident should occur Dual Hazardous Input Power Sources WARNING The system may be powered fr...

Page 8: ...810600 have a built in one megohm resistor no external resistor is necessary Read and follow wrist strap manufacturer s instructions outlining use of a specific wrist strap 3 Do not touch traces or components on equipment containing static sensitive components Handle equipment containing static sensitive components only by the edges that do not have connector pads 4 After removing equipment contai...

Page 9: ...system containing rectifiers intelligent control metering monitoring and distribution A system can consist of a Power Module Bay optional Distribution Module Bay and Battery Cabinets This power system is capable of operating either with or without batteries online Power Module Bay List 01 The Power Module Bay consists of the following components All Power Module Bay components are factory installe...

Page 10: ...els factory installed and connected in a cabinet List 90 91 92 93 Each Battery Cabinet houses one 1 400V battery string consisting of twenty eight 28 12V battery blocks 336V nominal Refer to the Battery Cabinet instructions IM58400120090 for more information Note The maximum short circuit capacity of the circuit breakers in the system is 25kAIC Therefore the maximum number of Emerson provided Batt...

Page 11: ...iting the available current during accidental line to ground contact Continuous bus operation with a single pole ground fault Limitation of potential arc flash due to limited energy during an insulation ground fault condition However it is important to locate and isolate any ground faults that occur in order to preserve these benefits The voltages between the Bus and Bus will shift when a ground f...

Page 12: ... Rectifier 1 Rectifier 4 Rectifier 3 Rectifier 6 Rectifier 5 Rectifier 8 Rectifier 7 Main AC Input Circuit Breaker Rectifier AC Input Circuit Breakers Rectifier 1 Rectifier 2 Rectifier 3 Rectifier 4 AC Main Rectifier 5 Rectifier 6 Rectifier 7 Rectifier 8 Front Output Voltage Present Indicator Ground Insulation Fault Alarm Indicator Control Voltage Present Indicator Output Voltage Present Control V...

Page 13: ...tion leads to 66 in lbs 7 Nm 7 Replace the distribution panel s top or bottom front cover Secure the cover to the distribution panel 8 Place each circuit breaker to the OFF position 9 Connect all power sources to the distribution panel 10 Place each circuit breaker to the ON position 11 Ensure that there are no local or remote alarms active on the system Maintenance Contact Emerson Network Power f...

Page 14: ...s if required at a later date Note that 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 System Troubleshooting Information This system is designed for ease in troubleshooting and repair The various indicators as described in Operating Procedures on page 2 and in the controller and rectifier i...

Page 15: ...ment no attempt should be made to troubleshoot or repair an individual rectifier controller or circuit card Replacement Procedures Danger Adhere to the Important Safety Instructions presented at the front of this document Replacing a Rectifier or Rectifier Fan Refer to the Rectifier Instructions UM1R40015000e for a rectifier replacement procedure and a rectifier fan replacement procedure Refer als...

Page 16: ...lack Torque these connections to 62 in lbs 7 Nm 6 Place the replacement circuit breaker into its mounting position feeding the attached leads to the rear of the distribution panel Orient the ON OFF positions as shown in Figure 2 7 Replace the distribution panel s top or bottom front cover Secure the cover to the distribution panel 8 Place each circuit breaker to the OFF position 9 Connect all powe...

Page 17: ...DC Input Bus 200V DC Input Bus to 200V DC Load Distribution Terminal to 200V DC Load Distribution Terminal to 200V DC Load Distribution Terminal to 200V DC Load Distribution Terminal to 200V DC Input Bus to 200V DC Input Bus to 200V DC Input Bus to 200V DC Input Bus Rear View Rear View Off Off On On Red Jumper Black Jumper Red Jumper Black Jumper Rear 200V DC Load Distribution Terminal 200V DC Loa...

Page 18: ...rnal AC input circuit breaker remains in the OFF position during this procedure 3 Remove the left and right rear access covers from the power and control section 4 Locate the surge protector 5 Disconnect the surge protector wiring from the surge protector wiring terminal block 6 Unplug the surge protector plug in connector from the connector inside the power and control section 7 Disconnect the su...

Page 19: ... 11 of 13 Figure 3 AC Input Surge Protector Replacement Rear Power and Control Section Cover L1 L2 L3 Factory Wiring This Side AC Surge Protector AC Surge Protector Terminal Block AC Surge Protector Ground Lead AC surge protector ground lead is routed into main AC section and connected to a ground stud AC Surge Protector Plug In Connector Rear AC Surge Protector ...

Page 20: ...s and outside plant enclosures for customers and channel partners Reps VARs Distributors Phone 1 800 800 1280 option 3 Spare Parts Email DCpower Spares Emerson com OSP Spares Emerson com Pricing and purchase orders for spare parts including but not limited to breakers cables fuses rectifier fans misc breaker and fuse panels enclosure fans doors and switches etc Phone 1 800 800 1280 option 5 DC Pow...

Page 21: ...y defects Product dead on arrival Incomplete or incorrect deliveries Quality and product support Phone 421 32 7700 888 Order DC Power OSP Order Status Email OPC EES EmersonNetworkPower com Creates and processes orders determines lead times and pricing provides order shipping information and status Phone 421 32 7700 706 Request DC Power Repair Service RMA Email EMEA HWServices Emerson com Creates a...

Page 22: ...cument 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 Emerson Network Power Energy Systems North America Inc assumes no responsibility and disclaims all liability for damages result ing from use of this information or for any errors or omissions Refer to other local prac...

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