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Astec

 Advanced Power Systems

 

Astec

Advanced Power Systems

A part of Emerson Network Power

 

UM5C06D ( 169-2071-504 ) 

Helios Rectifier 25/48 

Single Phase -48V, 25 A 

Power Factor Corrected Switch Mode Rectifier 
NT5C06D 

Installation and User Manual 

 

 

 

 

P0831010   Standard 7.00   May 2001 

Summary of Contents for NT5C06D

Page 1: ... Advanced Power Systems A part of Emerson Network Power UM5C06D 169 2071 504 Helios Rectifier 25 48 Single Phase 48V 25 A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual P0831010 Standard 7 00 May 2001 ...

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Page 3: ...keep all information contained herein confidential and shall protect same in whole or in part from disclosure and dissemination to all third parties and use the same for start up operation troubleshooting and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design quality at Astec Advanced Power Systems Ltd to ensure that...

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Page 5: ...102 17331 May 1999 Standard 5 0 Document modified to reflect Astec identity Figure 11 modified ECN 102 14852 March 1997 Std release 4 0 New Float Voltage and Current Limit Factory Setting August 1996 Std release 3 0 Removal of extended temperature rectifier models Table 1 and Table 6 note revised February 1996 Std release 2 0 This issue is to cover the revision of Installation and Start Up procedu...

Page 6: ...6 Publication history UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 This page is left blank intentionally ...

Page 7: ...e 16 Efficiency and Power Factor 16 Reliability 16 Heat Dissipation 16 Electromagnetic interference EMI 16 Environmental specifications 17 Operating 17 Transportation 17 Storage 17 Installation and start up 19 Tools and test equipment 19 Installing the power shelf 19 Wiring the power shelf 20 Installing the AC power 21 DC Conductors Installation 22 Control and Alarm Connections 23 Verification 28 ...

Page 8: ...al ON OFF control AC breaker 36 Remote ON OFF control 36 Remote voltage sensing 36 Sense fail alarm SEN FAIL 36 Current limiting 36 Soft start walk in 36 AC inrush current 36 Sequential start 37 Parallel operation 37 Discharge of output capacitors 37 Input AC voltage monitor 38 Thermal shutdown 38 Remote high voltage shutdown 38 Local remote high voltage shutdown reset 38 Remote equalize control 3...

Page 9: ... pin signal cable shelves 26 Figure 8 No controller remote sensing connection for a 26 pin signal connector shelf 27 Figure 9 NT5C06D front view 34 Figure 10 Power interface connections 39 Figure 11 Control signal connections 40 Figure 12 NT5C06D rear view 44 List of Tables Table 1 Electrical specifications 15 Table 2 AC cable wire size 21 Table 3 AC Fuses 21 Table 4 DC cable wire size 23 Table 5 ...

Page 10: ...10 Contents UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 This page is left blank intentionally ...

Page 11: ...E system connected phase to neutral that is 220 V phase neutral The negative and positive outputs of each rectifier are connected to two common busses BAT 48 and BAT RTN The power shelf is designed for a typical capacity of 75 A The design of the rectifiers allows rectifiers located in the same power shelf or other shelves which are connected in parallel to share the load either by forced load sha...

Page 12: ... This section contains a description of the major components and available options for the NT5C06D Rectifier and the MPS75 power shelves NT5C06DA 48 V 25 A Switch Mode Rectifier brown NT5C06DB 48 V 25 A Switch Mode Rectifier dolphin grey NT5C10C X Rack mount power shelf family 23 mounting Note Many shelf models with different colors and features are available MPS75 NT5C10C X power shelf 23 inch Th...

Page 13: ...with other rectifiers running the DC circuit breaker must be in the OPEN position OFF position Each rectifier plugs into the MPS75 power shelf and does not require any other connections The rectifier is equipped with a 13 A two pole AC input circuit breaker a 35 A single pole DC output circuit breaker a digital ammeter and a set of LEDs switches and potentiometers for threshold adjustments and ala...

Page 14: ...pin signal connectors Mounting holes 4 Signal cable connection DC connection Mounting holes 4 Figure 3 NT5C06D Switch Mode Rectifier Height 168 mm 6 60 inches Depth 260 mm 10 25 inches Width 149 mm 5 85 inches Weight 6 8 kg 15 lbs EQL FLT FAN HVSD ON RFA DC CC OUTPUT V V SO RTIE LOAD CHARGE 3MA 250V F1 AC CA MPR25 MPR15 ...

Page 15: ...C When three phase 208 240 V AC source is available to power the MPS75 it is preferable to distribute the rectifiers among the phases Input Current Rating 7 5 A nominal at 208 V AC input and 56 V DC 25 A output Use RW 90 wire or equivalent as listed in Table 2 Recommended AC Service Input Fusing Two slow flow fuse PRN type or equivalent one for each AC line input or one slow trip circuit breaker f...

Page 16: ... current to full load including the current limit mode Less than 32 dBrnC for loads less than 1 A Less than 10 mVrms in any 3 kHz band between 10 kHz and 20 MHz Measurements are made with batteries at the output terminals of the power shelf and with the rectifier in the local sensing mode Less than 250 mV peak to peak switching voltage spikes measured differentially by an oscilloscope with a 100 M...

Page 17: ...filter Humidity 0 to 95 RH non condensing Altitude Sea level to 2100 m 7000 ft Transportation During transportation the rectifier can be subjected to the following conditions without sustaining damage Temperature Range 55 C 67 F for 16 hours 70 C 158 F dry heat Humidity 0 to 95 non condensing 4 kPa max Vibration 38mm sec max 10 to 30 Hz 610 mm 24 inch drop when packaged Pressure 12 kPa min equiv t...

Page 18: ...cations UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 The rectifier contains aluminum electrolytic capacitors having a shelf life of 5 years or greater when stored at the maximum rated storage temperature ...

Page 19: ... Screwdriver flat blade 3 32 inch Screwdriver Burns No 60 or equivalent Cable strippers electrician s knife Wire stripper Cable cutters 2 0 Linesman s pliers Open and box ended wrenches set Socket set 1 2 inch drive Ratchet Wrench 1 2 inch drive Torque limiting torque wrench 1 2 inch drive Crimper T B 12 or 15 Ton head with 94H die Digital Multimeter Fluke 8000A or equivalent Installing the power ...

Page 20: ...allation after the wire connections have been completed end Wiring the power shelf Once the power shelf has been installed and firmly secured proceed with the wiring CAUTION The power shelf wiring should be installed by qualified personnel and in accordance with the local electrical codes DANGER Input voltage to the rectifier and the power shelf is at a hazardous potential Ensure that the power sw...

Page 21: ...st comply to the local electrical code The power shelf is equipped with a strain relief to terminate the conduit The cable length should be minimized and be properly secured Table 2 AC cable wire size 2 RECTIFIER POSITIONS 3 RECTIFIER POSITIONS Individual AC 12 AWG for each rectifier 12 AWG for each rectifier Common AC 8 AWG 6 AWG Table 3 AC Fuses 2 RECTIFIER POSITIONS 3 RECTIFIER POSITIONS Indivi...

Page 22: ...power shelf with a 0 25 inch terminating ring lug The wire must be routed along the top back of the shelf and come out the back opening on the right DC cabling side Make sure that the wire does not interfere with the rectifier connections CAUTION Do not insert fuses or operate circuit breakers switches until the entire system has been assembled and you have been instructed to do so in the appropri...

Page 23: ...e backplane of the power shelf see Figures 1 and 2 for location These signal connectors provide control alarm and monitoring signals The power shelf provides two types of signal connectors One ribbon cable 26 pin female connector or multiple eight pin male cable connectors are used to interface the rectifiers to the power plant controller and monitoring unit The control inputs are activated by a B...

Page 24: ...ctor Pin Designation Description Signal 1 RC1 Sensing Negative rect 1 BAT 2 RFA1 NC Rectifier 1 fail alarm NC 3 TR1 Temporary Release Rect 1 Bat RTN 4 SH1 Shunt Positive Rect 1 50 mV 5 SH1 Shunt Negative Rect 1 50 mV 6 RC2 Sensing Negative Rect 2 BAT 7 RFA2 NC Rectifier 2 fail alarm NC 8 TR2 Temporary Release Rect 2 Bat RTN 9 SH2 Shunt Positive Rect 2 50 mV 10 SH3 Shunt Negative Rect 3 50 mV 11 RC...

Page 25: ...n pins 17 and 18 are floating These two alarm commons must be connected to the bat RTN at the system level for applications requiring non floating alarm signals The rect 1 indicates the rectifier in position 1 located on the right side of the MPS75 shelf In applications where no controller is available or desired the current sharing functions among rectifiers in SLOPE or FORCE mode are still avail...

Page 26: ... the shelf back plane rectifier position to the remote sensing point Note 2 Identify the wire color corresponding to RG pin 2 and RC pin 3 to be used for the remote sensing Completely cut out completely the 8 pin connector leaving the signal wires loose Insulate each unused wire with electrical tape Use the pin references to identify the signals as described above Note 3 Use 20 AWG 105 C wire Note...

Page 27: ...See note 2 16 Note 1 Refer to MS5C06 for available signal cables of different lengths to connect from the shelf backplane rectifier position to the remote sensing point Note 2 Use a printed circuit or wire wrap board to interface all the 26 pin connector ribbons from all the shelves All RC signal connections pin 11 6 1 must be joined together All the RC connections pin 20 must also be joined toget...

Page 28: ...screws 2 Remove the blank panel for the rectifier to be installed place a finger in the hole lift up pull forward then lower to disengage upper tabs from the shelf top Store the panel at the bottom of the shelf under the rectifier 3 Ensure that both AC and DC circuit breakers are in the OFF position 4 Use a voltmeter to verify that the AC supply at the input of the shelf is 208 240 V AC nominal 5 ...

Page 29: ...irements for Float Equalize and HVSD limits found in User Manual 167 7011 010 If the rectifier s factory set limits have to be changed proceed as follows otherwise proceed to step 13 High Voltage Shutdown HVSD Adjustment 5 With the DC circuit breaker OFF keep the AC breaker on and turn the HVSD potentiometer fully clockwise 6 Turn the FLT potentiometer slowly clockwise until the output voltage rea...

Page 30: ...y 0 25 A Therefore to accurately PRESET the rectifier s float voltage it s running current within the plant environment must be predicted and the output voltage modified according to expression below V preset Vo desired Io running x 3v 25 or Io running x 3v For example if the rectifier is expected to provide 12 5 A at 52 2 V then Vo preset 52 2 12 5 x 3 V 25 52 2 15 V 52 35 V In Slope Share mode t...

Page 31: ... EQL position Turn the EQL potentiometer clockwise to increase the voltage or counterclockwise to decrease it Use the same consideration as in Float Adjustment for determining the desired EQL setting 13 Current Limit Verification CL The current limit is factory set to 30 A The CL ADJ potentiometer can be set within the range of 12 5 to 30 A Verification or adjustment of the CL setting point requir...

Page 32: ...does not share the load with the other rectifiers in the power plant take the following steps Procedure 5 Adjusting the load share Step Action 1 Verify that all the share mode settings are the same SLS or FS 2 Verify that all the rectifier sense points are the same 3 Verify that all the rectifiers are in float or all are in the equalize mode that is the modes are not mixed 4 If the above three cas...

Page 33: ...al shunt for output DC current measurement and a 35 A circuit breaker for output protection The monitoring circuitry includes soft start rectifier fail alarm RFA monitoring and control for local and remote equalize temporary release thermal shutdown low and high AC voltage inhibit loss of AC voltage alarm local and remote high voltage shutdown HVSD local and remote HVSD reset and fan failure detec...

Page 34: ... The rectifier normally delivers a float voltage set by the FLT potentiometer When the switch is placed in the EQL position the rectifier changes to equalize mode and boosts the output voltage to the value set by the EQL potentiometer High voltage shutdown HVSD local This potentiometer sets the internal threshold level for the local high voltage shutdown monitor circuit High voltage shutdown remot...

Page 35: ...A alarm and light up the RFA LED color red located on the front panel If the disappearance of switching however is caused by an incorrect adjustment of the output FLT voltage resulting in no output load the RFA will not be triggered since no real failure will have occurred Fan failure alarm Loss of all or part of the cooling system activates the FAN ALM and lights up the appropriate LED on the fro...

Page 36: ...ctifier will limit the output current to 30 A 0 5 A factory setting The current limit level can be adjusted between 12 5 A to 30 A at 54 5 V DC or to any combination limited to 1635 W of output power within the adjustable voltage range Extended periods of operation in the current limiting mode and repeated transitions between constant voltage operation and constant current operation will have no d...

Page 37: ...e rectifier This mode should be used when rectifiers from different vendors are used which are not all equipped with the forced load sharing feature In this mode the units will share the load within 10 of their maximum output rating b Forced Load Sharing FS When the SLS FS switch is set to the FS position forced load sharing is achieved by an internal control circuit which by slightly modifying th...

Page 38: ...rectifier will shut down within 50 ms if it is supplying more than 3 A 0 75 A Local remote high voltage shutdown reset The rectifier may be reset from an HVSD condition either by toggling the rectifier s AC circuit breaker or by applying a ground signal at the HVSDR input of the rectifier provided that the TR lead is not activated If the HVSD condition subsides the rectifier will restart automatic...

Page 39: ...ignal interface connector This connector is used to interface all the control alarm and monitoring signals with the power shelf that in turn interfaces these with the Controller The control inputs are activated by a ground BAT RTN signal The alarms are extended by relay contacts and are isolated from each other and from the chassis All contacts are rated 60 V DC and 0 5 A ...

Page 40: ...ENSING RC 4 TEMPORARY RELEASE 5 REMOTE HVSD RESET 6 REMOTE HVSD 7 RFA NC 8 Not Connected 9 FAN ALARM NC 10 RFA COMMON 11 FAN ALARM COMMON 12 SHUNT 13 SHUNT 14 FAN ALARM NO 15 RFA NO 16 GROUND 17 SENSE COMMON 18 SENSE NC 19 SENSE NO 20 Not Connected 21 Not Connected 22 Not Connected 23 Not Connected 24 Not Connected 25 Not Connected 25 ...

Page 41: ... Do not install a wet filter on the unit To remove the filter simply unscrew it Re install it by reversing the operation Float equalize The float equalize voltage level of the rectifier can be verified and adjusted with the rectifier in or out of service To verify the equalize setting point with the rectifier out of service proceed as follows Procedure 6 Adjusting the float equalize Step Action 1 ...

Page 42: ...clockwise end High voltage shutdown HVSD To verify or readjust the HVSD follow steps 5 to 8 of the Rectifier Startup and Verification section of this manual Cooling fan Visually inspect the airflow intake for any obstruction by foreign objects or excessive dust and dirt build up Open both the AC and DC breakers and remove the rectifier from the power shelf Inspect the air outlet for obstruction by...

Page 43: ... solidly on a clean workbench carefully remove the four mounting screws that hold the fan assembly in place 3 Slowly and carefully remove the fan assembly by pulling it from the chassis 4 Replace with a new one 5 Mount the fan assembly in the same orientation as the old one Ensure the orientation of the fans is such that the air is blown outwards when the fans are operated 6 Mount the fan and fan ...

Page 44: ...44 Maintenance UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 Figure 12 NT5C06D rear view CAUTION Ensure that the fans spin freely without interference ...

Page 45: ... 25 48 Installation and User Manual CAUTION Do not run the rectifier without a fully operational fan or with a fan other than the specified replacement for this cooling application Power shelf The power shelf requires no maintenance ...

Page 46: ...46 Maintenance UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 This page is left blank intentionally ...

Page 47: ...output circuit breaker is open Rectifier has received a HVSD signal from the controller An internal high voltage shutdown HVSD has occurred The internal High voltage shutdown point set too low below float or equalize setting Excessive impedance in one or both sense leads The cooling fan is failed DC circuit breaker is open A thermal shutdown has occurred Defective unit Excessive ambient air temper...

Page 48: ...eeds total rectifier capacity Current or voltage float fault Fault symptom Possible causes With paralleled units the float and or equalize is misadjusted causing one or more units to carry the load Unit is in equalize mode and paralleled units are not Remote sense lead has excessive impedance or are not connected on one or more rectifiers System batteries are in a recharge mode after AC outage Cur...

Page 49: ...49 Helios Rectifier 25 48 NT5C06D Installation and User Manual 7 Appendix A Replacement parts ITEM CPC Fan Assembly P0710139 Air Filter Kit P0834732 ...

Page 50: ...50 Appendix A Replacement parts UM5C06D 169 2071 504 P0831010 Standard 7 00 May 2001 This page is left blank intentionally ...

Page 51: ...ervice ETAS and the Installation Technical Assistance Service ITAS 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 0021 Denmark 00 Finland 00 or 990 France 00 Germany 00 Hong Kong 001 Ireland 00 Japan 001 KDD 041 ITJ 0061 IDC Korea ...

Page 52: ...6 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 08 1571 012288 Colombia 980 192288 Dominican Rep...

Page 53: ...qualize FAN ALM Fan Alarm FLT Float FR GND Frame Ground FS Forced Load Share HVSD High Voltage Shutdown HVSDR High Voltage Shutdown Reset LED Light Emitting Diode LVA Low Voltage Alarm LVD Low Voltage Disconnect LVDR Low Voltage Disconnect Reconnect MPA Modular Power Adapter MPL Modular Power Low Voltage Disconnect MPR Modular Power Rectifier MPS Modular Power Shelf MTBF Mean Time Between Failures...

Page 54: ...O Normally Open NT Northern Telecom PCB Printed Circuit Board RFA Rectifier Fail Alarm RG Sensing Battery Positive RC Sensing Battery Negative SEN FAIL Sense Fail SH Shunt Positive SH Shunt Negative SLS Slope Load Sharing TBD To be Determined THSD Thermal Shutdown TR Temporary Release ...

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Page 56: ... to all third parties and use the same for start up operation troubleshooting and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design quality at Astec Advanced Power Systems Ltd to ensure that the equipment complies with the operation standards This equipment generates uses and can radiate radio frequency energy and i...

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