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Summary of Contents for 581127000

Page 1: ...NetSure 24V DC Power System Installation Instructions IM581127000 Issue AB March 22 2012 SPEC NO MODEL 581127000 710NPBA ...

Page 2: ...ess of this document Emerson Network Power Energy Systems North America Inc assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions Refer to other local practices or building codes as applicable for the correct methods tools and materials to be used in performing procedures not specifically described in this document T...

Page 3: ...ting System Components in an Equipment Rack 7 Mounting the Distribution Cabinet with Module Mounting Assembly 7 Installing a List 93 Battery Tray 10 Installing Optional Lug Adapter Busbar Kits Part Nos 534449 and 514714 14 Installing Circuit Breakers and Fuses 16 Installing Bullet Nose Type Fuseholders and TPS TLS Fuses 16 Installing Bullet Nose Type Circuit Breakers 18 Installing an Optional Bull...

Page 4: ... Load Connections to GMT Distribution Fuse Block 73 Battery Connections 74 Important Safety Instructions 74 Recommended Torques 74 Battery Connections to Optional Battery Disconnect Distribution Panels 74 Battery Connections to Distribution Cabinet Battery Busbars 78 Battery Connections to Optional Battery Landing Busbar Kit P N 541371 79 Battery Connections to Optional Battery Landing Busbar Kit ...

Page 5: ...Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited ACU Alarm Relay Check 100 Final Steps 108 REVISION RECORD 110 ...

Page 6: ...the loads if battery reserve is not sufficient VOLTAGES AC Input Voltages Danger This system operates from AC 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 DO NOT apply AC power to the system until all electrical connections have bee...

Page 7: ...nd proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited CIRCUIT CARD HANDLING Warning Installation or removal of the circuit cards requires careful handling Before handling any circuit card read and follow the instruc...

Page 8: ...ectricity from yourself by wearing a wrist strap grounded through a one megohm resistor Some wrist straps such as Emerson Network Power Part Number 631810600 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 the traces or components on a printed circuit card containing...

Page 9: ...ll Customer Documentation Power System Installation Instructions IM581127000 Power System Quick Start Guide QS581127000 Power System User Instructions UM581127000 Power System System Application Guide SAG581127000 Power Data Sheet PD588705200 PD588705201 PD588705202 PD588705203 PD588705204 Rectifier Instructions UM1R243000 Converter Instructions UM1C24481500 Engineering Drawings Also provided on t...

Page 10: ... Fuses Installed Chapter 3 Setting Jumper and Switch Options Jumpers on System Interface Circuit Card Set Switch Setting on IB2 Interface Board Set Switch Setting on Optional EIB Interface Board Set Switch Setting on Optional SM DU Set Chapter 4 Making Electrical Connections Relay Rack Grounding Connection Frame Ground Made AC Input and AC Input Equipment Grounding Connections Made External Alarm ...

Page 11: ...ller should be familiar with the installation requirements and techniques to be used in securing the relay rack to the floor Clearance requirements are a Recommended minimum aisle space clearance for the front of the relay rack is 2 6 b Recommended minimum aisle space clearance for the rear of the relay rack is 2 0 for any of the following conditions 1 Addition of a Module Mounting Assembly in the...

Page 12: ...tains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Relay Rack Floor Mounting Dimensions Refer to Figure 2 1 for relay rack floor mounting dimensions Figure 2 1 cont d on next page Relay Rack F...

Page 13: ...gy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 1 cont d from previous page cont d on next page Relay Rack Floor Mounting Dimensions ...

Page 14: ...Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 1 cont d from previous page Relay Rack Floor Mounting Dimensions ...

Page 15: ...ng assembly Danger The relay rack must be securely anchored to the floor before the distribution cabinet with module mounting assembly is installed The distribution cabinet with module mounting assembly is heavy Use a hoist battery lift or other appropriate lifting device to raise and support the assembly during the installation Take appropriate precautions to avoid injury Procedure 1 Remove the d...

Page 16: ...ntial and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 2 Distribution Cabinet Mounting Hardware View MOUNTING HARDWARE 12 24 X 1 2 THREAD FORMING HEX HEAD SCREW NO 12 GROUND WASHER Module Mounting She...

Page 17: ...ms North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 3 Module Mounting Assembly Mounting Hardware View Secure the Module Mounting Shelf to the relay rack ...

Page 18: ...ttery Tray Procedure 1 To install a List 93 Battery Tray perform the procedure in Figure 2 4 Figure 2 4 Installing a List 93 Battery Tray Battery Tray Rear Angle Bracket Rear Angle Bracket Cabling Bracket Front Rear 1 Slide battery tray into relay rack and secure to relay rack with 12 24 x 3 4 thread forming hex head screws and 10 12 ground washers 1 place per side or 12 flat washers 3 places per ...

Page 19: ...ure 1 To install optional battery disconnect circuit breakers onto the List 93 Battery Tray perform the procedure in Figure 2 5 2 Battery tray wiring is shown in Installing and Connecting Batteries in List 93 Battery Tray in Chapter 4 Making Electrical Connections Figure 2 5 Installing Optional Battery Disconnect Circuit Breakers onto a List 93 Battery Tray Battery Disconnect Circuit Breaker Assem...

Page 20: ...cover onto a List 93 Battery Tray perform the procedure in Figure 2 6 Note that batteries must be installed first as described in Installing and Connecting Batteries in List 93 Battery Tray in Chapter 4 Making Electrical Connections Figure 2 6 Installing Optional Front Battery Cover onto a List 93 Battery Tray Assembled View Kit Battery Cover Assembled to Existing Front Battery Bracket Rear View K...

Page 21: ... Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Installing Optional Circuit Breaker Guard Procedure 1 To install an optional circuit breaker guard onto a battery disconnect circuit breaker perform the procedure in Figure 2 7 Figure 2 7 Installing Optional Circuit Breaker Guard 1 Remove this bracket...

Page 22: ...646600 Hex Head Bolt 3 8 16 x 1 8 228557100 Nut 1 4 20 2 228567100 Nut 3 8 16 Contents of Kit P N 514714 for 3 pole circuit breakers Qty Part No Description 1 514676 Busbar 1 514678 Busbar 12 214110100 Flat Washer 1 4 4 214112100 Flat Washer 3 8 12 215111100 Lock Washer 1 4 4 215111300 Lock Washer 3 8 6 227640400 Hex Head Bolt 1 4 20 x 3 4 not used 2 227646600 Hex Head Bolt 3 8 16 x 1 12 228557100...

Page 23: ...merson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 8 Installing Lug Adapter Busbar Kits Notes Orient busbars as shown as required Breakaways are only provided for positions 1 8 9 12 and 23 24 This restricts 2 and 3 pole breaker adapter kits...

Page 24: ...inet Procedure Note Refer to Figure 2 9 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Orient the fuseholder as shown in Figure 2 9 Insert the terminals on the rear of the fuseholder into their corresponding sockets on the distribution panel Ensure the alarm contact on the back of the fuseholder makes contact with...

Page 25: ...erson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 9 Installing a Bullet Nose Type Fuseholder and TPS TLS Fuse Fuseholder Assembly Longer Side to the Bottom Shorter Side to the Top Fuse Carrier Fuseholder Body TPS TLS Fuse Polarizing Keyway Matches Key on Bottom of Fuse Carrier Fuseholder Assembly Exploded View Fuseholder Assembly P N 117201 includes body carrier ...

Page 26: ... cabinet Procedure Note Refer to Figure 2 10 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Ensure that the circuit breaker is in the OFF position and is of the correct rating Orient the circuit breaker as shown in Figure 2 10 Insert the terminals on the rear of the circuit breaker into their corresponding sockets...

Page 27: ...fer to Figure 2 11 as this procedure is performed Procedure 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Follow the steps in Figure 2 11 3 Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse Block as required If dummy fuses are installed first remove the dummy fuse a Verify that dummy fuses are ...

Page 28: ...y copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 11 Installing an Optional Bullet Nose Type 6 Position GMT Distribution Fuse Block Press in tabs to release lug terminal busbars for positions to be occupied by GMT Fuse Block Remove two lug terminal busbars for positions to be occupied by GMT Fu...

Page 29: ...rs in the distribution cabinet Procedure Note Refer to Figure 2 12 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Remove the TPH fuse carrier from the mounted fuseholder body by grasping its handle and firmly pulling it straight out Install the TPH fuse into the fuse carrier When done push the fuse carrier securel...

Page 30: ...abinet s front door by turning the latch in the counterclockwise position 2 Remove the fuse case from the mounted fuse block by grasping its handle and pulling it straight out 3 Verify that an 18 100 ampere alarm fuse is present in the GMT type fuseholder located on the fuse block and that a plastic safety cover is installed on this fuse 4 Open the fuse case 5 Install the TPL fuse into the fuse ca...

Page 31: ...eaker is in the OFF position and is of the correct rating and type electrical trip mechanical trip or electrical trip only Apply anti oxidizing compound to busbar mating surfaces on the distribution panel and the circuit breaker Orient the circuit breaker over its mounting location a Attach the alarm jumper connectors to the back of the circuit breaker then plug the other end of the alarm jumper i...

Page 32: ...ut the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 14 cont d on next page Installing a GJ 218 Circuit Breaker 1 Pole 1 4 Hardened Flat Washer 1 4 Belleville Lock Washer 1 4 20 x 3 4 Bolt 2 places Torque to 60 in lbs OFF ON Apply anti oxidizing compound to busbar mating surfaces before mounting circuit breakers INSTALLING CIRCUIT BREA...

Page 33: ...rk Power Energy Systems North America Inc is strictly prohibited Figure 2 14 cont d from previous page Installing a GJ 218 Circuit Breaker 2 Pole 3 Pole 4 Pole 1 4 Hardened Flat Washer 1 4 Belleville Lock Washer 1 4 20 x 3 4 Bolt 4 places Torque to 60 in lbs Apply anti oxidizing compound to busbar mating surfaces before mounting circuit breakers OFF ON INSTALLING CIRCUIT BREAKER GUARD INSTALLING C...

Page 34: ...ower Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 15 GJ 218 Circuit Breaker Wiring Diagram List AC and AD List AC Only ...

Page 35: ...ower Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 2 16 GJ 218 Circuit Breaker Wiring Diagram List BC and BD List BC Only ...

Page 36: ...ystems North America Inc is strictly prohibited CHAPTER 3 SETTING JUMPERS AND SWITCH OPTIONS CIRCUIT CARD LOCATIONS Refer to Figure 3 1 Figure 3 1 Circuit Card Locations IB2 ACU Interface Board located on inside side panel Optional EIB ACU Extended Interface Board located on inside side panel Optional SM DU and Shunt Interface Board 4 Row Cabinet Shown Others Similar Front Door Removed in Illustra...

Page 37: ...justments on a replacement circuit card Controller Power Option The controller is always powered from the internal system bus A jumper option allows the controller to be also powered by battery Battery power allows the controller to stay running in the event rectifiers are off or battery LVD opens if installed Note that if powering the controller from battery the battery will drain if rectifiers a...

Page 38: ...sclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 3 2 System Interface Circuit Card Jumper Locations J8 Selects to power Controller from Battery Power or not Shorting Jumper No Battery Pwr Battery Pwr External Internal J8 J10 1 2 3 7 8 9 3 2 1 J10 Battery Monitoring External Internal see TB1 4 and TB1 5 for externa...

Page 39: ...er to Figure 3 3 for SW1 location Perform the following procedure to verify the factory settings This procedure can also be used to make adjustments on a replacement circuit card Procedure 1 Ensure SW1 is set per Table 3 1 Refer to Figure 3 3 for location Setting DIP Switch SW1 1 2 IB2 OFF OFF Table 3 1 IB2 Interface Board Switch Settings SWITCH SETTING ON OPTIONAL EIB INTERFACE BOARD Dip Switch S...

Page 40: ... Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 3 3 IB2 Interface Board Switch Location and Settings J12 SW1 J2 J11 J9 J8 J7 J6 J5 J4 J3 IB2 Interface Board Top View Switch SW1 is located in this corner of the IB2 Board on ON off OFF 1 2 1 2 SW1...

Page 41: ... Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 3 4 Optional EIB Interface Board Switch Location and Settings SW1 In this system switch settings must be in positions shown Optional EIB Interface Board Top View Switch SW1 is located in th...

Page 42: ...1 and SW2 Refer to Table 3 3 for SW1 and SW2 settings Refer to Figure 3 5 for SW1 and SW2 locations Perform the following procedure to verify the factory settings This procedure can also be used to make adjustments on a replacement circuit card Procedure 1 Ensure SW1 and SW2 are set per Table 3 3 Refer to Figure 3 5 for location Figure 3 5 Optional SM DU Switch Location and Settings SM DU and Shun...

Page 43: ...DIP switch ON Shunt parameter is set through software note 1 NA OFF OFF NA Shunt Voltage 25mV note 1 OFF ON Shunt Voltage 50mV ON OFF Shunt Voltage 60mV ON ON Shunt Voltage 75mV NA OFF OFF OFF Shunt Current 500A note 1 OFF OFF ON Shunt Current 100A OFF ON OFF Shunt Current 200A OFF ON ON Shunt Current 300A ON OFF OFF Shunt Current 400A ON OFF ON Shunt Current 1000A ON ON OFF Shunt Current 1500A ON...

Page 44: ...nized follow applicable codes For wire size branch circuit protection crimp lug and general wiring recommendations refer to System Application Guide SAG581127000 and Power Data Sheet PD588705200 PD588705201 PD58870520102 PD58870520103 PD58870520104 Refer to drawing 031110100 for lug crimping information Refer to drawings 031110200 and 031110300 for additional lug information Refer to Table 4 1 for...

Page 45: ...ional Electrical Code NEC applicable local codes and your specific site requirements A customer s grounding network lead can be attached to the top of the relay rack Provision is made for installing a lead with a two hole lug that has 1 4 bolt clearance holes on 5 8 centers When using 1 4 inch hardware recommended torque is 84 in lbs when a standard flat washer and lock washer are used Refer to Fi...

Page 46: ...ductor must be provided with each conduit PROCEDURE Refer to Figure 4 2 as these procedures are performed Accessing Connections and Routing Wire 1 Remove the two AC input connector covers and the AC input wireway covers by first loosening the fasteners that secure each of them 2 Install conduit fittings as required in the top of the AC input wireways Plug buttons are provided and must be installed...

Page 47: ...einstall the two AC input connector covers and the AC input wireway covers Secure each by tightening the fasteners Figure 4 2 cont d on next page AC Input and Equipment Grounding Connections to Factory Installed Module Mounting Shelves 4 Row Cabinet Shown Others Similar Front Door Removed in Illustration for Clarity AC INPUT CONNECTIONS INDIVIDUAL PCU FEED 581127000 LIST 40 WHEN EQUIPPED WITH 5887...

Page 48: ...000 LIST 40 WHEN EQUIPPED WITH 588705202 Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Shelf 1 Shelf 2 NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF THE EXPANSION SHELF Rectifier Module PCU Mounting Slots Inside View Left Side Inside View Right Side GND GND GND GND AC 1 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 1 AC 1 AC...

Page 49: ...B Slot F Slot C Slot G Slot D Slot H Rectifier Module PCU Mounting Slots NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF THE EXPANSION SHELF Shelf 1 Shelf 2 Shelf 3 Inside View Left Side Inside View Right Side AC 1 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 SLOT A SLOT B SLOT E SLOT F SLOT C SLOT D SLOT G SLOT H INDIVIDUAL RECTIFIER PCU AC INPUT FEEDS 208 2...

Page 50: ...er Module PCU Mounting Slots NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF THE EXPANSION SHELF Shelf 1 Shelf 2 Shelf 3 Shelf 4 Inside View Left Side Inside View Right Side AC 1 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 SLOT A SLOT B SLOT E SLOT F SLOT C SLOT D SLOT G SLOT H AC 1 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 2 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 AC 1 S...

Page 51: ...nput and Equipment Grounding Connections to Factory Installed Module Mounting Shelves 4 Row Cabinet Shown Others Similar Front Door Removed in Illustration for Clarity AC INPUT CONNECTIONS DUAL PCU FEED 581127000 LIST 41 WHEN EQUIPPED WITH 588705201 Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Rectifier Module PCU Mounting Slots NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF T...

Page 52: ...ing Shelves 4 Row Cabinet Shown Others Similar Front Door Removed in Illustration for Clarity AC INPUT CONNECTIONS DUAL PCU FEED 581127000 LIST 41 WHEN EQUIPPED WITH 588705202 Inside View Left Side Inside View Right Side Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Shelf 1 Shelf 2 NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE RE...

Page 53: ...00 LIST 41 WHEN EQUIPPED WITH 588705203 Inside View Left Side Inside View Right Side Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Rectifier Module PCU Mounting Slots NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF THE EXPANSION SHELF Shelf 1 Shelf 2 Shelf 3 GND GND GN...

Page 54: ...ght Side Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H Rectifier Module PCU Mounting Slots NOTE WIRING TO AN EXPANSION SHELF IS DONE AT THE REAR OF THE EXPANSION SHELF Shelf 1 Shelf 2 Shelf 3 Shelf 4 GND GND GND GND AC 2 A...

Page 55: ... assembly by first removing the screws that secure them 2 Install conduit fittings in the side or rear openings as required Plug buttons are provided and must be installed in the openings not being used 3 Route wiring into the shelf through the previously installed conduit fittings Making AC Input Connections Note Module mounting positions are lettered left to right as viewed from the front of the...

Page 56: ...d Equipment Grounding Connections to Field Expansion Module Mounting Assembly Slot A Slot E Slot B Slot F Slot C Slot G Slot D Slot H AC IN AC IN Rectifier Module PCU Mounting Slots Front View Holes for 3 4 Conduit Fitting AC Input Holes for 3 4 Conduit Fitting AC Input Rear View Rear View FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HARDWARE FRAME GROUND CONNECTION ONE 10 32 X 3 4 STUD AND HA...

Page 57: ...th America Inc is strictly prohibited EXTERNAL ALARM REFERENCE MONITORING AND CONTROL CONNECTIONS Circuit Card Locations Refer to Figure 4 4 Figure 4 4 Circuit Card Locations IB2 ACU Interface Board located on inside side panel Optional EIB ACU Extended Interface Board located on inside side panel Optional SM DU and Shunt Interface Board 4 Row Cabinet Shown Others Similar Front Door Removed in Ill...

Page 58: ...c Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited System Interface Circuit Card The System Interface Circuit Card provides connections for the following Refer to Figure 4 5 RS 485 used for communication with SM modules RS 232 used for communication with a DPU External Battery Monitoring External Sys...

Page 59: ...ystem Voltage Monitoring TB1 1 Battery Tray FA TB1 2 External Battery FA TB1 3 External System FA TB1 4 External Battery Monitoring TB1 5 External Battery Monitoring 1 1A 2A 3A 1B 2B 3B 5 RS485 Connection TB2 1A RS485 TB2 2A RS485 RS232 Connection TB2 1B CGND TB2 2B TXD232 TB2 3B RXD232 J1 J2 J3 J4 J8 TB2 TB1 TP1 TP2 TP3 TP4 J10 J5 TB1 Wire Size Capacity 22 12 AWG Recommended Torque 3 0 in lbs FA ...

Page 60: ...verters When the ESTOP signal is removed LVD s close if battery present and converters restart To restart the rectifiers turn AC power to the rectifiers OFF wait 30 seconds or more then turn AC power to the rectifiers ON Rectifiers can also be restarted via the Local and Web interface ACU menus using the rectifier reset command The digital inputs can be programmed to provide an alarm when the sign...

Page 61: ...t as a battery probe can also be designated to be used for the battery charge temperature compensation feature or the battery charge temperature compensation feature can be programmed to use the average or highest value of all battery temperature probes The battery charge temperature compensation feature allows the controller to automatically increase or decrease the output voltage of the system t...

Page 62: ...NO terminals and opening the contacts between the C and NC terminals Not all I O points are available for customer connection some are used for factory system connections J3 J9 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs MA4C5U31 IB2 DI1 DI1 DI2 DI2 DI3 DI3 J3 J4 J5 J6 J7 J8 J9 DI4 DI4 DI5 DI5 DI6 DI6 DI7 DI7 DI8 DI8 DO1_NC DO2_NC DO1_COM DO2_COM DO1_NO DO2_NO DO3_NC DO4_NC DO3_COM ...

Page 63: ...ide the distribution cabinet Recommended torque for these connections is 5 in lbs a Current Inputs Connect up to three 3 shunt inputs to the EIB Extended Interface Board Observe proper polarity Refer to Table 4 2 to determine what shunt input to connect to on the EIB board Refer to the ACU User Instructions UM1M820BNA and program the shunt input parameters found in the EIB menu Number of Battery S...

Page 64: ...t to the number of 12V battery blocks being used Midpoint Monitoring Voltage Type Set to Midpoint This selects the EIB to monitor the midpoint voltage of up to eight 8 battery strings BlockVDiff Mid This menu item appears if Midpoint is selected above Set to the alarm threshold for battery midpoint monitoring per site requirements The ACU issues an alarm when any battery midpoint voltage of any ba...

Page 65: ...ca Inc is strictly prohibited Figure 4 7 EIB Extended Interface Board Connections MA455U41 EIB SH1 SH1 SH2 SH2 SH3 SH3 J5 J6 J7 J8 J9 DCV1 DCV2 DCV3 DCV4 DCV5 DCV6 DCV7 DO5_NC DCV8 DO5_COM DO1_NC DO2_NC DO1_COM DO2_COM DO1_NO DO2_NO DO3_NC DO4_NC DO3_COM DO4_COM DO3_NO DO4_NO J3 1 J3 2 J3 3 J4 1 J4 2 J4 3 2 4 3 1 J2 DO5_NO 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 SHUNT INPUTS VO...

Page 66: ... Battery Midpoint Monitoring Connections Battery Midpoint Monitoring Battery Block Monitoring Battery String 1 to DCV1 J6 1 to DCV2 J6 2 to DCV3 J6 3 to DCV4 J6 4 to DCV5 J6 5 to DCV6 J6 6 to DCV7 J7 1 to DCV8 J7 3 Battery String 2 Battery String 3 EIB Board Voltage Inputs Battery String 4 Battery String 5 Battery String 6 Battery String 7 Battery String 8 Rectifiers 24V Return Load Shunt Load Bat...

Page 67: ...ing information for the unused inputs Note The shunt needs to be installed in the hot 24V bus Connect the plus side of the shunt to the positive shunt input on the SM DU Connect the negative side of the shunt to the negative shunt input on the SM DU Optional SM Temp Module The analog output of the SM Temp Module may be connected to an ACU temperature port input In lieu of connecting the analog out...

Page 68: ...HUNT INPUTS 541127 SHUNT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J2 SHUNT25 SHUNT25 SHUNT24 SHUNT24 SHUNT23 SHUNT23 SHUNT22 SHUNT22 SHUNT21 SHUNT21 SHUNT20 SHUNT20 SHUNT19 SHUNT19 SHUNT18 SHUNT18 SHUNT17 SHUNT17 SHUNT16 SHUNT16 SHUNT15 SHUNT15 SHUNT14 SHUNT14 TB2 25A 25B 24A 24B 23A 23B 22A 22B 21A...

Page 69: ... to the ACU User Instructions UM1M820BNA for operational details Note You can access the Web pages of the power system locally by using a crossover or straight cable connected directly between your PC and the ACU Warning The intra building port s of the equipment or subassembly is suitable for connection to intra building or unexposed wiring or cabling only The intra building port s of the equipme...

Page 70: ...ONTROLLER AND MODULE MOUNTING SHELVES Each module mounting shelf in the system is daisy chained to the controller A connector is located at the top of each shelf and another at the bottom of each shelf These connectors are used to interconnect the shelves to the controller Refer to Figure 4 11 for connector locations These connections are factory made for shelves factory installed The connection m...

Page 71: ...rictly prohibited Figure 4 11 Control Bus Connections between Controller and Module Mounting Shelves Connector Location to Controller Connector Location to shelf mounted below or if bottom shelf to termination connector Rear Connector Location to shelf mounted above Front 588705200 Expansion Shelf 588705201 Shelf or Top Shelf in 588705202 588705203 or 588705204 Shelf Assembly Communications Cable ...

Page 72: ...olding the plastic shield over the circuit breakers or fuseholders on the dual voltage distribution panel Slide the shield upwards and remove 4 Connect the output jumpers to the distribution bus panel subsystem 48V input terminals as shown in Figure 4 12 Apply electrical anti oxidizing compound to lug mating surfaces before connecting Mount two lugs back to back per mounting position if required T...

Page 73: ... Shelf in 588705202 588705203 or 588705204 Shelf Assembly Rear 588705200 Expansion Module Mounting Shelf Shorting Block if 4th shelf has Converter Option Dual Voltage Distribution Panel If more than three shelves with the Converter Option installed connect 48 jumpers for the 4th shelf here Assembly order is lug 1 4 flat washer 1 4 lock washer 1 4 20 nut Torque to 84 in lbs Note that a shorting blo...

Page 74: ...twork Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited LOAD CONNECTIONS Loads are connected to the various distribution panels located inside the distribution cabinet as detailed in this section Recommended Torques 72 in lbs for 1 4 inch hardware when using stan...

Page 75: ...bution Panel with Return Busbar and List AD 24V Distribution Panel without Return Busbar 4 GJ 218 Circuit Breaker Positions 24VDC Load Connections Load Return Connections LOAD AND LOAD RETURN CONNECTIONS 1 4 20 Studs on 5 8 Centers Customer must supply or order additional hardware Maximum Lug Width 0 625 inches Return Busbar not included with List AB Observe proper polarity when making load connec...

Page 76: ...4V Distribution Panel 2 TPH Fuse Positions without Shunts without Return Busbar List AF 24V Distribution Panel 2 TPH Fuse Positions with Shunts without Return Busbar 24VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 88 inches Observe proper polarity when making load connections WARNING For an 800A circuit ...

Page 77: ...trictly prohibited List AG 24V Distribution Panel 4 TPH Fuse Positions without Shunts without Return Busbar List AH 24V Distribution Panel 4 TPH Fuse Positions with Shunts without Return Busbar 24VDC Load Connections LOAD CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 75 inches Maximum fuse size is 400A Observe proper polarity whe...

Page 78: ...y Systems North America Inc is strictly prohibited List AJ 24V Distribution Panel 4 TPL B Fuse Positions without Shunts without Return Busbar List AK 24V Distribution Panel 4 TPL B Fuse Positions with Shunts without Return Busbar 24VDC Load Connections LOAD CONNECTIONS 3 8 16 Studs on 1 Centers Customer must supply or order additional hardware Maximum Lug Width 1 5 inches Observe proper polarity w...

Page 79: ...Breaker Fuse Positions with Return Busbar and 8 48V Bullet TPS TLS Circuit Breaker Fuse Positions with Return Busbar Load Connections Load Return Connections LOAD AND LOAD RETURN CONNECTIONS 1 4 20 Studs on 5 8 Centers Customer must supply or order additional hardware Maximum Lug Width 0 625 inches 48V Distribution 24V Distribution Observe proper polarity when making load connections WARNING Cauti...

Page 80: ... Return Busbar and 16 48V Bullet TPS TLS Circuit Breaker Fuse Positions with Return Busbar Load Connections Load Return Connections LOAD AND LOAD RETURN CONNECTIONS 1 4 20 Studs on 5 8 Centers Customer must supply or order additional hardware Maximum Lug Width 0 625 inches 48V Distribution 24V Distribution Observe proper polarity when making load connections WARNING Caution A circuit breaker or fu...

Page 81: ...permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Load Connections to Return Bar List GA Return Bar Panel Load Connections to GMT Distribution Fuse Block Optional Bullet Nose 6 Position GMT Distribution Fuse Block Load and or Battery Return Connections LOAD AND OR BATTERY RETURN CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order add...

Page 82: ...s Danger Adhere to the Important Safety Instructions presented at the front of this document Warning Observe proper polarity when making battery connections Recommended Torques 72 in lbs for 1 4 inch hardware when using standard flat and lock washer 300 in lbs for 3 8 inch hardware when using standard flat and lock washer 180 in lbs for 3 8 inch hardware when using a Belleville lock washer Battery...

Page 83: ...bar and List BD Battery Disconnect Distribution Panel without Return Busbar 4 GJ 218 Circuit Breaker Battery Disconnect Positions 24VDC Battery Connections Battery Return Connections BATTERY AND BATTERY RETURN CONNECTIONS 1 4 20 Studs on 5 8 Centers Maximum Lug Width 0 625 inches Customer must supply or order additional hardware Return Busbar not included with List BB Observe proper polarity when ...

Page 84: ... Fuse Battery Disconnect Position without Shunts without Return Busbar List BF Battery Disconnect Distribution Panel 2 TPH Fuse Battery Disconnect Positions with Shunts without Return Busbar 24VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Maximum Lug Width 1 88 inches Customer must supply or order additional hardware Observe proper polarity when making battery connec...

Page 85: ...ct Distribution Panel 4 TPH Fuse Battery Disconnect Positions without Shunts without Return Busbar List BH Battery Disconnect Distribution Panel 4 TPH Fuse Battery Disconnect Positions with Shunts without Return Busbar 24VDC Battery Connections BATTERY CONNECTIONS 3 8 16 Captive Nuts on 1 Centers Customer must supply or order additional hardware Observe proper polarity when making battery connecti...

Page 86: ...y prohibited Battery Connections to Distribution Cabinet Battery Busbars Danger Adhere to the Important Safety Instructions presented at the front of this document Battery may be connected to the battery busbars located in the distribution cabinet as detailed in this section depending on site requirements 4 Row Cabinet Shown Others Similar Battery Return Side Busbar Battery Return Side Busbar Batt...

Page 87: ...en permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Battery Connections to Optional Battery Landing Busbar Kit P N 541371 Danger Adhere to the Important Safety Instructions presented at the front of this document Figure 4 13 Battery Connections to Optional Battery Landing Busbar Kit P N 541371 Rear View GND RTN 24V SUPPLY Plastic Shield Up to Six 6 Batter...

Page 88: ...n permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Battery Connections to Optional Battery Landing Busbar Kit P N 550265 Danger Adhere to the Important Safety Instructions presented at the front of this document Figure 4 14 Battery Connections to Optional Battery Landing Busbar Kit P N 550265 1 4 20 x 0 875 Studs on 0 625 Centers 16 Places Customer must s...

Page 89: ... complete protection for eyes face hands and clothing Examples are safety goggles or face shield a rubber apron and gloves If battery acid enters your eye immediately flush your eye with running cold water for at least 15 minutes Get medical attention immediately If battery acid contacts skin or clothing wash immediately with soap and water NEVER smoke or allow a flame or spark near batteries NEVE...

Page 90: ...gy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Installing Battery Landing Busbar Kit P N 541371 List 21 or 550265 List 22 23 or 24 If the battery tray s was ordered with the system these kits were installed at the factory If a battery tray is installed in the field cust...

Page 91: ... Network Power Energy Systems North America Inc is strictly prohibited Figure 4 15 Battery Landing Busbar Kit P N 541371 Rear View Plastic Shield One Row Cabinet Shown Others Similar Return Angle Bracket Secure 2 places with in order listed 3 8 16 x 1 1 4 Bolt 3 8 Belleville Lockwasher and 3 8 Flat Washer Torque to 180 in lbs 24V Angle Bracket Secure 2 places with in order listed 3 8 16 x 1 1 4 Bo...

Page 92: ... 550265 Two Row Cabinet Shown Others Similar Rear View Plastic Shield 1 Remove top Rear Access Cover from distribution cabinet note that the complete rear cover is removed in the illustration for clarity only 2 Attach Return Angle Bracket 3 Attach 24V Angle Bracket 4 Secure rear cover shield to distribution cabinet after wiring Return Angle Bracket Secure 2 places with in order listed 3 8 16 x 1 1...

Page 93: ...th America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Wiring to the Battery Tray If the battery tray s was ordered with the system wiring to the battery tray was performed at the factory If a battery tray is installed in the field customer must wire to the battery tray Procedure 1 Refer to ...

Page 94: ...Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 4 17 cont d on next page Wiring Diagram List 93 Battery Tray ...

Page 95: ...work Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Figure 4 17 cont d from previous page Wiring Diagram List 93 Battery Tray ...

Page 96: ... reinstall the bullet shaped spacers as shown in Detail A before performing the next step 4 Reinstall the battery retention bracket The spacers on the bracket should separate the batteries from each other Secure with the hardware removed in a previous step Refer to Figure 4 18 for washer location 5 Connect two links supplied by the battery manufacturer between pairs of battery terminals as shown i...

Page 97: ...es No 10 Flat Washer 3 Places 1 4 Ground Washer 1 Place 1 4 20 x 5 8 Hex Head Screw 4 Places 1 4 20 Lock Washer 3 Places 1 4 20 Flat Washer 3 Places Note 1 Two trays shown as example 2 Cabling detail omitted Connect POS Battery Cable to this Terminal string 2 Spacers Separate Batteries 3 places per tray front and back Battery Retention Bracket See Detail A for alternate orientation 1 4 20 X 5 8 Bo...

Page 98: ...ules can be operated in that shelf See Figure 5 1 Rectifiers will operate in any mounting position in any shelf If a shelf accepts DC DC converter modules they must be installed in any or all of the four middle mounting positions Figure 5 1 Module Location Diagrams on the front of each shelf Note Each rectifier and DC DC converter module locks into the module mounting assembly by means of a latch ...

Page 99: ...DC converter modules 3 Check the module location diagram on the front of the shelf to determine which type of module rectifier or DC DC converter can be installed in each mounting position See Figure 5 1 4 If present remove blank cover panels from the mounting positions into which rectifier or DC DC converter modules are to be installed 5 Place the module into an unoccupied mounting slot without s...

Page 100: ... Ensure that all blocks for Chapters 2 through 4 in the Installation Acceptance Checklist located in Chapter 1 have been checked Ensure that module mounting positions are filled by a rectifier module DC DC converter module or a blank cover panel as desired It is acceptable for positions to be left vacant Refer to the configuration drawing C drawing supplied with your power system documentation for...

Page 101: ... Procedure Note The initialization routine takes several minutes During that time various alarm indicators may illuminate on the ACU front panel and an audible alarm may sound Disregard all alarms An audible alarm can be silenced at any time by momentarily depressing the ENT key on the ACU Controller 1 After the ACU is powered on the display alternates between the Emerson Network Power screen and ...

Page 102: ...stem information is displayed in multiple screens Repetitively press the up or down arrow key to view other system information screens one by one 6 From the Main screen press ENT to go to the Main Menu screen 7 From the Main Menu select a submenu by repetitively pressing the up or down arrow key The selected submenu will be indicated by the cursor Press ENT to open the submenu Note Repeatedly pres...

Page 103: ...s 3 Press ENT A screen displays the configuration version number 4 Press ESC or wait approximately 10 seconds to return to the Main screen Checking Basic System Settings Navigate through the controller menus and submenus to check system settings You can adjust any parameter as required Procedure To Select a Sub Menu Press the up or down arrow keys to move the cursor up and down the list of sub men...

Page 104: ...ery Charge EQ Voltage Temperature Compensation Center Temperature Main Menu Settings Battery Temp Comp Temp CompCenter Temperature Compensation Slope Main Menu Settings Battery Temp Comp Temp Comp Coeff Temperature Compensation Sensor Main Menu Settings Battery Temp Comp TempComp Sensor Temperature Compensation Maximum Voltage Main Menu Settings Battery Temp Comp Temp Comp Max V Temperature Compen...

Page 105: ... it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Checking System Status Procedure 1 Observe the status of the indicators located on the ACU rectifiers and converters if furnished If the system is operating normally the status of these is as shown in Table 5 1 Component Indicator Normal State ACU Status Green On Minor Yellow Off Cri...

Page 106: ...ESC escape Configuring the ACU Identification of Rectifiers and Assigning which Input Phase is Connected to the Rectifiers When rectifiers are all installed prior to applying power and starting the system the order in which the ACU identifies the rectifiers is by serial number lowest serial number is Rect 1 next lowest is Rect 2 etc If you prefer the ACU to identify the rectifiers by position in t...

Page 107: ...heck you numbering to be sure it is correct If there where conflicts in your numbering rectifiers with conflicts will be assigned the next available sequential number 14 Return to the Main screen by repeatedly pressing ESC escape Configuring the ACU Identification of Converter Modules When converters are all installed prior to applying power and starting the system the order in which the ACU ident...

Page 108: ... can be used to verify operation of the external alarm relays in a power system equipped with an ACU with the factory default configuration Note that alarm relays on an ACU with a custom configuration may operate differently Note There are two methods to check alarm relays The first is by actually causing an alarm The second is by using the ACU alarm relay check function The first method is used i...

Page 109: ...2 Verify the ACU displays the Main screen If not press ESC repeatedly to return to the Main screen 3 Pull one rectifier half way out of the shelf To do this first loosen the captive screw on the module handle Pull the handle to pivot it out of the module front panel this will also retract the latch mechanism located at the right side of the module Refer to Figure 5 2 for latch mechanism illustrati...

Page 110: ...e converter half way out of the shelf To do this first loosen the captive screw on the module handle Pull the handle to pivot it out of the module front panel this will also retract the latch mechanism located at the right side of the module Refer to Figure 5 2 for latch mechanism illustration a Requirement An audible alarm sounds Alarm will be silenced in Requirement c b Requirement ACU Critical ...

Page 111: ...e ACU displays the Main screen If not press ESC repeatedly to return to the Main screen 3 Record the system voltage displayed on the ACU Main screen 4 Press ENT to go to the Main Menu Navigate to and select Settings ENT 5 If a password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proc...

Page 112: ...ritical Summary Alarm and Relay 4 Under Voltage 1 Alarm remain active External Relay 5 Under Voltage 2 Alarm activates 10 Press ESC repeatedly to return to the Main Menu Navigate to Settings ENT Power System ENT General ENT 24V Under Volt2 11 Press ENT Use the up or down arrow keys to adjust the 24V Under Volt2 setting to the value recorded in step 8 Press ENT 12 Use the up or down arrow keys to s...

Page 113: ...nt press the ESC key repeatedly to return to the Main Menu Then navigate as follows Settings ENT Power System ENT General ENT 24V Over Volt2 Record the displayed voltage setpoint 9 Press ENT Use the up or down arrow keys to adjust the 24V Over Volt2 value to one half volt below the system voltage recorded in step 3 Press ENT a Requirement An audible alarm sounds Alarm will be silenced in Requireme...

Page 114: ...it breaker in the OFF open position a Requirement An audible alarm sounds Alarm will be silenced in Requirement c b Requirement ACU Critical Major alarm indicator goes from off to red c Requirement ACU displays Alarm To see the specific alarm press ENT to display the Main Menu Navigate as follows Status ENT Active Alarm ENT The Active Alarm screen lists one critical alarm Press ENT DC Fuse Unit Ro...

Page 115: ... Network Power Energy Systems North America Inc is strictly prohibited 6 Adjust the IB2 Temp1 High 2 setpoint to 10 degrees below the temperature recorded in step 2 a Requirement An IB2 Temp1 High 2 alarm is displayed b Requirement External Relay 12 High 2 Battery Temperature Alarm requires EIB Interface Board to be installed in the system activates 7 Using the Web Interface adjust the IB2 Temp1 H...

Page 116: ...ited Final Steps 1 If any ACU Controller configuration settings were changed refer to the ACU User Instructions UM1M820BNA and save a copy of the configuration file This file can be used to restore the ACU Controller settings 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 ...

Page 117: ...cument is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited This Page Left Intentionally Blank ...

Page 118: ...rica Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited REVISION RECORD Issue Change Number ECO Description of Change AA LLP215523 New AB LLP216783 Updated for ACU version 3 02 ...

Page 119: ... 800 800 1280 option 7 FreedomCare Secure EmersonNetworkPower com Spare Parts Email DCpower Spares Emerson com OSP Spares Emerson com Pricing and PO processing of spare parts including but not limited to breakers cables fuses rectifier fans misc breaker and fuse panels enclosure fans doors switches etc Phone 1 800 800 1280 option 5 DC Power Depot Repair Email DCpower Repair Emerson com Creates and...

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