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Emerson Energy Systems
UM5C05C ( 169-2081-501 )
Helios Modular Switch Mode Rectifier
200I/48 NT5C05C
Installation and User Manual
H E L I O S
I
0
A C / C A
P0745680 Standard 6.00 October 2001
V O L T
V O L T
C A L
C U R
A M P
C A L
C L
A D J
E Q L
A D J
S E N
T H S D
R F A
A C O N
E Q L
F A IL
FF 1
F F 2
F L T
1 . 0 A
1 .0A
FA N
H V S D
E Q L
C L
A L M
F LT
A D J
V O L T +
V O U T -
H VS D
A D J
I
S T U P
D L Y
S L S
I
D C / C C
F S
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Table of Contents
Related Manuals for Emerson 200I/48-NT5C05C
Summary of Contents for Emerson 200I/48-NT5C05C
- Page 1 Emerson Energy Systems UM5C05C ( 169-2081-501 ) Helios Modular Switch Mode Rectifier 200I/48 NT5C05C Installation and User Manual H E L I O S A C / C A P0745680 Standard 6.00 October 2001 V O L T V O L T...
- Page 3 Helios and Helios Candeo are trademarks of Astec International Ltd. The Emerson logo is a trademark and service mark of Emerson Electric Co.
- Page 5 Publication history October 2001 Standard Issue 6.00. Manual restructured and updated to reflect Emerson Energy Systems and Emerson Network Power identities. ( ECN 102-26804 ) 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.
- Page 6 6 Publication history This page is left blank intentionally. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems...
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Page 7: Table Of Contents
4.2.10. TR ( temporary inhibition ) and sequential start... 40 4.2.11. Control signals on connector P1... 42 5. Operation... 45 5.1. Standard settings ... 45 5.2. Starting up and adjusting ... 46 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual... - Page 8 10. Abbreviations and acronyms ... 59 List of Figures Figure 1 - Front view of the modular 200I / 48 switch mode rectifier ... 11 Figure 2 - Typical mounting in a cabinet or frame... 12 Figure 3 - Anchoring the cabinet ... 21 Figure 4 - Installing the rectifier...
- Page 9 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 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual...
- Page 10 10 Contents This page is left blank intentionally. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems...
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Page 11: General Information
The rectifiers can be operated in conjunction with other Emerson rectifiers as well as with the models and conventional controllers of other manufacturers available on the market. -
Page 12: Models And Mounting Configurations
Model NT5C05CC, equipped with an ac cable terminated with a male plug Up to six switch mode 200I rectifiers 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. -
Page 13: Specifications
High voltage shutdown : Output current : Output protection : Current limit : Emerson Energy Systems 10.0 inches ( 25.4 cm ) 22.0 inches ( 55.9 cm ) 20.5 inches ( 52.1 cm ) 92.6 lbs ( 42 kg ) Nominal : 380 / 415 V ac Range : 330 ±5 V ac to 475 ±5 V ac... -
Page 14: Operation Specifications And Ambient Conditions
EMI as specified in Publication 22 for Class "A" equipment. The rectifier has an MTBF greater than 120 000 hours under normal operating conditions, at 77°F ( 25°C ) as per Telcordia Technologies TR332 method. Emerson Energy Systems... -
Page 15: Table 4 - Ambient Conditions For The Rectifier
Table 4 - Ambient conditions for the rectifier Operating conditions Transportation conditions Storage conditions Emerson Energy Systems A minimum airflow clearance of 2 inches ( 5 cm ) is required at the rear of the rectifier. The rectifier will operate properly under the following conditions. Temperature: 32°F to 122°F ( 0°C to +50°C ) -
Page 16: Mechanical And Electrical Specifications Of A 1200 A Cabinet
7,000 ft ( 2,100 m ) During transportation and storage, the acceptable ambient conditions are : Temperature: –55°C ( –67°F ) +60°C ( 140°F ) dry heat Humidity: 0 to 95% RH ( non-condensing ) Emerson Energy Systems... -
Page 17: Installation
3.3. Cautions and Warnings The following precautions must be adhered to at all times when handling and installing power equipment. Emerson Energy Systems CAUTION Protecting the premises Protect the floors and walls against damage with sheets of plywood, cardboard, or other suitable material when handling the equipment. - Page 18 When cutting material, wear gloves and goggles. Break all corners and sharp edges with a flat file. CAUTION Optimizing the life of the equipment Make sure there are no obstructions in front of the ventilation openings that can restrict the flow of air. Emerson Energy Systems...
- Page 19 Astec APS power systems, go to the partners’ section of the Emerson Energy Systems web site at www.EmersonEnergy-NA.com. To obtain access to the partners’ section follow the instructions found on the partner’...
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Page 20: Installing In A Frame
20 Installation 3.3.1. Installing in a frame When shipped, the NT5C05CA / CB / CC switch mode rectifiers are configured for installation in a standard frame. As the rectifier is heavy, use a manual forklift to mount the rectifier in a frame. If a forklift is not available, two persons, exercising care, can lift the rectifier into place and secure it. -
Page 21: Figure 3 - Anchoring The Cabinet
Remove the blank panel from the cabinet and put the self tapping screws in a secure location, for future use. Emerson Energy Systems 600 mm (23.56 po.) 526 mm (20.68 po.) -
Page 22: Cabling And Connecting
UM5C05C P0745680 Standard 6.00 October 2001 Action assure good ground continuity between the rectifier and the frame. VOLT VOLT VOLT/AMP THSD AC ON FAIL 1.0A 1.0A HVSD VOUT+ VOUT- HVSD ST UP DC/CC VOLT SELF-TAPPING SCREW ( P097F813 ) ET LOCK WASHER Emerson Energy Systems... -
Page 23: Connecting The Dc Output Terminals To The Busbars
BAT GRD RECTIFIER -48V BAT GRD RECTIFIER -48V SHUNT ON THE GRD SIDE ( PREFERRED CONFIGURATION ) Emerson Energy Systems CHG / DISCH GRD BUSBAR CHG BAT SHUNT BUSBAR SHUNT ON THE BATTERY SIDE CHG GRD SHUNT... -
Page 24: Securing The Dc Output Terminals To The Busbars In A 1200 A Cabinet
0.5 ft-lbs ( 8.5 WARNING Electrical connections should meet standards The electrical installation must be carried out by qualified personnel and in accordance with local electrical codes. 0.5 ft-lbs ( 8.5 0.5 N-m ) on the bolts Emerson Energy Systems... -
Page 25: Procedure 5 - Cabling The Ac Input To The Nt5C05Ca / Cb Rectifiers
Secure the signal cables to the insulating busbar support, located in the cabinet, with cable ties. Start-up the rectifier as described in the “ Start-up “ procedure. Emerson Energy Systems DANGER Hazardous potentials Input voltage to the cabinet is at a hazardous potential. -
Page 26: Figure 6 - Cabling Ac The Nt5C05Ca / Cb Rectifiers
AC FEED TO RECTIFIERS SIGNAL CABLE REMOVE PLATE TO ACCESS CONNECTORS REAR VIEW OF A CABLE Note: Dress the cables carefully to clear the insertion path of the rectifier. SECTION A-A SHOWING TOP VIEW OF AC CABLING Emerson Energy Systems... -
Page 27: Figure 8 - Connecting Ac To The Rectifier Nt5C05Cc
Start-up the rectifier as described in the “ Start-up “ section. Figure 8 - Connecting ac to the rectifier NT5C05CC L1 L2 L3 Emerson Energy Systems and the ac female plug in a 1200 A cabinet Action CONNECTION... -
Page 28: Connecting The Control Signals
UM5C05C P0745680 Standard 6.00 October 2001 Action 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. Cables P0747000 CONTROLLER NT (NT6C25BA or NT6C25BB) Emerson Energy Systems... -
Page 29: Monitoring Of The Shunt Current
: For controllers not manufactured by Emerson Energy Systems see Table 12 in the " Functional Description " chapter describing the pin assignments of the rectifier. Refer to Table 8 for the pin assignments of connectors J7 to J12 on board NT6C43PB. -
Page 30: Table 9 - Pin Assignment For Connector J13
SH+ ( rectifier 3 ) SH ( rectifier 3 ) SH+ ( rectifier 4 ) SH ( rectifier 4 ) SH+ ( rectifier 5 ) SH ( rectifier 5 ) SH+ ( rectifier 6 ) SH ( rectifier 6 ) Emerson Energy Systems... -
Page 31: Functional Description
4.1.2. Output circuit The output circuit offers the following characteristics : shunt for output dc current sensing 225 A dc circuit breaker for output protection Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual... -
Page 32: Monitoring And Control Circuits
( for example, TR ). Putting the breaker to OFF causes an RFA to be issued and the RFA LED to light up, as long as the rectifier output is connected to batteries. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems... -
Page 33: Switches, Controls And Leds
The LED indicators indicate the operating and alarm conditions. Figure 10 - Front panel controls and LEDs VOLT THSD HVSD Emerson Energy Systems VOLT/AMP AC ON FAIL VOUT+ VOUT- Rectifier 200I/48 NT5C05C Installation and User Manual... -
Page 34: Front Panel Leds
UM5C05C P0745680 Standard 6.00 October 2001 Color Description Green Input ac voltage operational Yellow Current Limit Yellow Rectifier is in equalize mode Fan fail alarm High voltage shutdown Rectifier fail alarm Remote sense fail Thermal shutdown Emerson Energy Systems... -
Page 35: Local And Remote Adjustments And Controls
( see Table 11 ) located on the front panel, or by remote signals sent from the controller ( see Tables 8 and 12 ). Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Functional description 35... -
Page 36: Voltage / Current Display Test And Measurement
Rectifier Failure Alarm output activating a form C contact Fan Failure Alarm output activating a form C contact Rectifier Current input / output ( 50 mV / 250 A ) Common Forced Current Share Mode ( 0-12 V ) Emerson Energy Systems... -
Page 37: Float And Equalize Voltage Control
Local FLOAT / EQL switch and potentiometers The rectifier is equipped with a FLOAT / 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. -
Page 38: Rectifier Parallel Operation
ON position. V ( preset ) = Vo ( desired ) + 0.8 V + ( Io ( running ) x 300 mV ) UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems... - Page 39 0.8 volts, to compensate for an internal drop when the rectifier dc breaker is put in the ON position. Example 3 : for 48 V float voltage Emerson Energy Systems V ( preset ) = 48 V + 0.8 V = 48.8 V Rectifier 200I/48 NT5C05C Installation and User Manual...
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Page 40: Hvsd ( High Voltage Shutdown )
( provided the 'TR' lead has not been activated ) 4.2.10. TR ( temporary inhibition ) and sequential start Sequential start The TR input can be interfaced to an external sequential start circuit. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems... -
Page 41: Table 13 - Setting The Start-Up Delay
Table 13 - Setting the start-up delay SWITCH POSITION NOTE: Switches 3 to 6 ( top four switches ) are used to set the start-up delay. Emerson Energy Systems DELAY 4 SEC 12 SEC 20 SEC 28 SEC 36 SEC 44 SEC... -
Page 42: Control Signals On Connector P1
Use of this feature is recommended when two or more rectifiers are connected to a common ac input to stagger the inrush currents. A front panel DIP switch can be set to provide the start-up delays listed in Table 4.2.11. - Page 43 P1-16 P1-17 P1-18 P1-19 P1-20 P1-21 P1-22 P1-23 P1-24 P1-25 Emerson Energy Systems Signal No connection No connection CB OFF ( NC ) Output breaker OFF ( NC ) Remote sense ( + ) Rectifier temporary released by controller HVSD...
- Page 44 44 Functional description This page is left blank intentionally. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems...
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Page 45: Operation
Rectifier start delay Low ac input disconnect Low ac input reconnect High ac input disconnect High ac input reconnect Load sharing method Emerson Energy Systems Parameter Rectifier 200I/48 NT5C05C Installation and User Manual Setting 52.1 ±0.1 V dc 52.8 ±0.1 V dc 56.5 ±0.1 V dc... -
Page 46: Starting Up And Adjusting
Turn the FLT potentiometer slowly clockwise to set the output voltage on the display of the rectifier to the required HVSD threshold. The EQL / FLT switch and the EQL potentiometer are used if the voltage cannot be set with the FLT potentiometer. - Page 47 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 total current by the number of rectifiers Set the current from each rectifier to this mean value.
- Page 48 If the current is too high, or if the rectifier is in the current limit mode, turn the EQL potentiometer counterclockwise. Deactivate the EQL mode to return to the normal float mode. UM5C05C P0745680 Standard 6.00 October 2001 52.1 V +0.8 V = 52.9 V. Emerson Energy Systems...
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Page 49: Maintenance
Figure 11 - Replacing the fan unit H E L I O S A C / C A Emerson Energy Systems RE M O VE T H E SE F I V E S C RE W S Rectifier 200I/48 NT5C05C Installation and User Manual... -
Page 50: Calibrating The Volt / Amp Multimeter
To remove the fan assembly mounting screws you need a screwdriver, but all the other operations described below can and should be performed without any tools. Action Emerson Energy Systems... -
Page 51: Resetting The Rectifier After An Hvsd ( High Voltage Shutdown )
Make sure the remote sense leads are disconnected by removing the corresponding RC fuse from the controller. Set the VOLT/AMP switch to AMP. Set the output load of the plant so the rectifier delivers a current of approximately 100 A. Measure the voltage between VOUT+ and VOUT , located on the front panel, with a digital meter. - Page 52 52 Maintenance This page is left blank intentionally. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems...
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Page 53: Troubleshooting
Table 16 - Diagnosing system faults Fault symptom The RFA LED is lit. The HVSD LED is lit. Emerson Energy Systems Possible causes No ac input or input is out of bounds ( ac ON LED is extinguished ). AC Input / dc output circuit breaker is open. - Page 54 The system batteries are in recharge mode after an ac outage. The current share mode selection is not the same for all units. The forced share line is disconnected ( in FLS only ). —end— Emerson Energy Systems...
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Page 55: Appendix A : Replacement Parts
8. Appendix A : Replacement parts ITEM Fan Assembly Fuse 1 A ( FF1, FF2 on Display PCB ) Air filter Air filter frame Emerson Energy Systems PART NUMBER ( CPC ) P0723582 A0287301 P0744757 P0744559 Rectifier 200I/48 NT5C05C Installation and User Manual... - Page 56 56 Appendix A: Recommended Replacement Parts This page is left blank intentionally. UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems...
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Page 57: Appendix B : Technical Service Assistance
Ireland Japan Korea Malaysia Netherlands New Zealand Singapor Switzerland United Kingdom Emerson Energy Systems Country Rectifier 200I/48 NT5C05C Installation and User Manual Prefix 0011 000815 00 or 990 001 ( KDD ) 041 ( ITJ ) 0061 ( Idc ) -
Page 58: Toll-Free Technical Assistance Numbers
Israel 1-800-534-0225 7101-2288 980-192288 1-888-7514232 1-800-850-1755 001-800-514-2288 1-888-680-2288 1-800-363-2288 For countries not covered by a toll-free service dial Canada ( country code 001 ) at 514-832-0201. 1-800-363-2288 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 1-800-1-110-0131 800-213-49156 800-213-49156 800-213-49156 800-213-49156 Emerson Energy Systems... -
Page 59: Abbreviations And Acronyms
10. Abbreviations and acronyms ALCO AUTOST FAN ALM HVSD HVSDR Emerson Energy Systems Alarm cut-off Alarm Auto restart Indicator Common Current limit indicator Electromagnetic interference Equalize Fan alarm High voltage shutdown High voltage shutdown reset Light Emitting Diode Loss of phase... - Page 60 60 Abbreviations and acronyms RMT ACK SEN FAIL THSD VCAL UM5C05C P0745680 Standard 6.00 October 2001 Rectifier fail alarm Remote ground bus ( positive ) Remote acknowledge Sense fail Thermal shutdown Temporary release Voltage reading calibration Emerson Energy Systems...
- Page 62 Helios Candeo is a trademark of Astec International Ltd. The Emerson logo is a trademark and service mark of Emerson Electric Co.