Emerson 582127000 User Instructions Download

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NetSure

™

-48V DC Power System

User Instructions, UM582127000 (Issue AD, January 20, 2014)

Spec. No: 582127000

Code: UM582127000

Model No: 721

NPBB

Issue AD, January 20, 2014

[48]

Figure 31.

Replacing a Load Disconnect Contactor in a 1-Row Distribution Cabinet

Load

Disconnect

Contactor

Components removed in

illustration for clarity only.

Front

5/16-18 x 1” Bolt

5/16" Belleville Lock Washer

(concave side of Belleville

Lock Washers face each other)

5/16" Hardened Flat Washer

(4 places)

Torque to 100 in-lbs.

Apply electrical anti-oxidizing

compound to busbar

mating surfaces.

Contactor styles vary

between manufacturer’s.

Black Wire

Violet/White Wire

Violet Wire

Red Wire

Violet/White Wire

Violet Wire

Black Wire

Red Wire

Summary of Contents for 582127000

Page 1: ...Shelves E W Spec No 588705300 Module Mounting Shelves Main Bay Supplemental Bay Main Bay Supplemental Bay NetSure 48V DC Power System User Instructions UM582127000 Issue AD January 20 2014 Specification Number 582127000 Model Number 721NPBB ...

Page 2: ...NetSure 48V DC Power System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 This page is intentionally blank ...

Page 3: ...ry Charge Current Limit Feature 2 Local Controls and Indicators 2 Maintenance 9 System Maintenance Procedures 9 Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec No 588705000 9 Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec No 588705300 9 Installing a Field Expansion Module Mounting Shelf Spec No 588705000 11 Installing a Field Expan...

Page 4: ...rate 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 t...

Page 5: ...ut Voltages DANGER This system may operate from 400V DC input voltage capable of producing fatal electrical shock DC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any DC electrical connections are made Follow local lockout tagout procedures to ensure upstream branch circuit breakers remain de energized during installation DO ...

Page 6: ... acid Batteries generate explosive gases during normal operation Systems containing batteries 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 ...

Page 7: ...0600 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 containi...

Page 8: ...NetSure 48V DC Power System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 vi This page is intentionally blank ...

Page 9: ... purposes The power system is designed for operation with the positive output grounded This system consists of the following components Distribution Cabinet The system always includes a minimum of one distribution cabinet which provides DC distribution through fuses and or circuit breakers The distribution cabinet is factory mounted in the relay rack or shipping brackets specified when ordered Fou...

Page 10: ...00E or UM1C48241500 ESTOP Function If an ESTOP switch is wired to the ACU IB2 Interface Board customer furnished system ground applied to terminal DI8 activates the ESTOP function The ESTOP function shuts down and locks out the rectifiers or 400V DC input converters opens the LVD s and shuts down the optional 48V to 24V DC converters When the ESTOP signal is removed LVD s close if battery present ...

Page 11: ... Only 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 Illustration for Clarity System Interface Circuit Card OR Optional LVD Driver Circuit Card Optional LVD Driver Lite Circuit Card ACU Controller Main Bay SM DU Supplemental Bays Mounting Position Optional Manual Battery Disconnect Circuit ...

Page 12: ...t points to externally monitor bay voltage and bay load Refer to Figure 2 Figure 2 System Interface Circuit Card TP3 and TP4 Bay Load Shunt Monitoring TP1 and TP2 Bay Voltage Monitoring J7 TB2 J1 1 1 1 1 J2 J3 J4 J8 TB1 TP1 TP2 TP3 TP4 J5 J10 Bay Load Shunt Scale List 21 1 Row Cabinet 800A 25mV 32A per mV List 22 2 Row Cabinet 2000A 25mV 80A per mV List 23 3 Row Cabinet 2500A 25mV 100A per mV List...

Page 13: ...e the LVD inhibit switch is in the OFF inhibit position a low voltage disconnection will not occur if battery or load voltage decreases below the low voltage disconnect setpoint For maximum battery protection this switch should NOT be left in the OFF inhibit position Figure 3 Optional LVD Driver Circuit Card LVD Inhibit Switch Momentary UP Middle Down Momentary UP Position Closes all LVD Contactor...

Page 14: ...LVD inhibit switch is in the OFF inhibit position a low voltage disconnection will not occur if battery or load voltage decreases below the low voltage disconnect setpoint For maximum battery protection this switch should NOT be left in the OFF inhibit position Figure 4 Optional LVD Driver Lite Circuit Card LVD Inhibit Switch LVD Inhibit Active Indicator Momentary UP Middle Down Momentary UP Posit...

Page 15: ... Optional Manual Battery Disconnect Circuit Card Main Bay Only Momentary UP Middle Momentary Down Momentary UP Position Closes latches in close position the Battery Disconnect Contactor Middle Position Normal Operation Momentary DOWN Position Opens latches in open position the Battery Disconnect Contactor Momentarily place switch in the UP position to close the contactor Manual Battery Disconnect ...

Page 16: ...ctions according to the received data There are three 3 status and alarm indicators located on the SM DU The functions of these indicators from top to bottom as shown in the illustration are as shown in Table 1 Refer to Figure 6 for location Table 1 SM DU Indicators Indicator Normal State Fault State Fault Cause Alarm Red Off On A critical or major alarm Alarm Yellow Off On A minor alarm Operation...

Page 17: ...elf Spec No 588705300 To increase system current capacity a rectifier module can easily be added to an existing module mounting shelf Spec No 588705300 that contains an empty rectifier module mounting position Likewise to increase subsystem capacity a DC DC converter module can be added to a module mounting shelf Spec No 588705300 that contains an empty converter module mounting position Rectifier...

Page 18: ...r is added to or removed from the power system Refer Checking the ACU Current Limit Point after Adding or Removing a Rectifier Module or Converter Module on page 18 Note The rectifier or converter being added is assigned by the ACU the lowest available identification number If desired you can change the identification number see Configuring the ACU Identification of Rectifiers or Configuring the A...

Page 19: ... performing the next step 3 Secure the existing shelf s busbars to the expansion shelf s mating busbars with the supplied interconnect busbars and hardware Hardware build up for these connections are 1 4 20 x 1 bolt 1 4 Belleville lock washer 1 4 flat washer Install the Belleville lock washer so the concave side is towards the busbar Torque all connections to 60 in lbs If installing a second expan...

Page 20: ...82127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 12 Figure 8 Installing a Field Expansion Module Mounting Shelf Spec No 588705000 cont d on next page Front View Install Expansion Module Mounting Shelf Rear View Remove Rear Shield from Module Mounting Shelf and Shelf Above It ...

Page 21: ...4 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 13 Figure 8 Installing a Field Expansion Module Mounting Shelf Spec No 588705000 cont d from previous page Rear View Install Output Busbars from Kit Completed View 1st Expansion Shelf 2nd Expansion Shelf ...

Page 22: ...unting Shelf Existing Module Mounting Shelf These cables are factory connected These cables are factory connected These cables are factory connected Existing Module Mounting Shelf Expansion Module Mounting Shelf Exploded View Shown to Illustrate Wire Connections Only Disconnect cable coming from distribution cabinet from this connector on bottom most existing shelf then connect to the top connecto...

Page 23: ...xidizing compound to busbar mating surfaces before performing the next step 5 Install the busbars provided with the expansion module mounting shelf between the studs on the expansion module mounting shelf and the studs on the shelf above it Secure these busbars to the expansion module mounting shelf with the hardware provided with the expansion module mounting shelf Secure these busbars to the she...

Page 24: ...ter shelves Remove the cut out panel from the busbar rear shield 2 Remove hardware from the lowest module mounting shelf s 48V return and 24V if present busbars 3 Install the expansion module mounting shelf into the rack 4 Remove busbar rear shield from expansion module mounting shelf 5 Install the busbars provided with the expansion module mounting shelf between the shelves Torque to 60 in lbs 6 ...

Page 25: ...ory connected These connectors are factory connected These connectors are factory connected Existing Module Mounting Shelf Expansion Module Mounting Shelf Disconnect cable coming from distribution cabinet from this connector on bottom most existing shelf then connect to the same connector on the expansion shelf Now connect these two connectors together Rear View Factory provided jumper to bring co...

Page 26: ...ttings 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 Local Controls and Indicators on page 2 and in the Controller a...

Page 27: ...rn to the Main screen by repeatedly pressing ESC escape Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier If a rectifier module is removed from the system a rectifier communications failure alarm is generated If the rectifier module will not be replaced the alarm should be cleared as described in the following procedure PROCEDURE 1 With the Main screen displayed press ENT t...

Page 28: ... screen displayed press ENT to go to the Main Menu Navigate to and select Manual ENT 2 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 proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cu...

Page 29: ...g it straight out of the fuseholder If the alarm fuse is located in a modular fuse carrier hold the fuse carrier in place with your thumb while pulling on the alarm fuse to prevent the entire carrier from inadvertently being pulled out 2 Safety fuse covers are provided for all Bussmann GMT type fuses installed in the system These covers snap onto the fuses and provide protection from exposed elect...

Page 30: ...the spring strip Push fuseholder in firmly until fully seated in the distribution panel 5 Push the fuse carrier securely back into the mounted fuseholder body Note that a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down 6 Verify no Fuse Alarms are active 7 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Figure ...

Page 31: ...llet Nose Circuit Breaker Replacing a TPH Fuse PROCEDURE Note Refer to Figure 15 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Remove the fuse carrier from the mounted fuseholder body by grasping its handle and pulling straight out 3 Remove the open fuse from the fuse carrier and replace it with the same type and...

Page 32: ... 3 Remove the hardware securing the circuit breaker to the distribution panel and partially remove the circuit breaker 4 Record each alarm wire located on the back of the circuit breaker color and location on circuit breaker Wiring diagrams are provided in Figure 17 Figure 18 and Figure 19 Carefully disconnect the alarm wiring from the back of the circuit breaker ensuring the exposed end does not ...

Page 33: ...s are provided in Figure 17 Figure 18 and Figure 19 Danger The bolts being installed in the following step may be at system potential Use insulated tools 7 Install the replacement circuit breaker into its mounting position and secure with the hardware previously removed Torque to 60 in lbs 8 Transfer the circuit breaker guard from the old circuit breaker to the new circuit breaker 9 Operate the re...

Page 34: ...cont d on next page 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 BREAKER GUARD INSTALLING CIRCUIT BREAKER Alarm jumper connector Holes to route shunt jumper through if applicable ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING BREA...

Page 35: ...4 Belleville Lock Washer 1 4 20 x 3 4 Bolt 4 places 2 pole brk 6 places 3 pole brk 8 places 4 pole brk Torque to 60 in lbs Apply anti oxidizing compound to busbar mating surfaces before mounting circuit breakers OFF ON INSTALLING CIRCUIT BREAKER GUARD INSTALLING CIRCUIT BREAKER Alarm jumper connectors Holes to route shunt jumper through if applicable ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING...

Page 36: ...er System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 28 Figure 18 GJ 218 Circuit Breaker Wiring Diagram List AC and AD List AC Only ...

Page 37: ...er System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 29 Figure 19 GJ 218 Circuit Breaker Wiring Diagram List BC and BD List BC Only ...

Page 38: ...placement circuit card Refer to Figure 20 6 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 20 Danger In the next step external wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object 7 Remove the external wiring from...

Page 39: ...ernal Internal J8 J10 1 2 3 7 8 9 J10 Main Bay Only Battery Monitoring External Internal see TB1 4 and TB1 5 for external monitoring points J5 CAN TP3 and TP4 Bay Load Shunt Monitoring TP1 and TP2 Bay 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 ...

Page 40: ... circuit cards at the bottom of the distribution cabinet See Figure 21 5 Remove connectors J1 J2 and J3 from the circuit card 6 Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet 7 In this step ensure you do not intermix the old and replacement circuit cards Set the switches on the replacement circuit card to the same setting as the old circuit ca...

Page 41: ...er System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 33 Figure 21 SM DU Circuit Card Replacement Supplemental Bays Only SM DU SM DU ...

Page 42: ...wiring from the customer connection terminal blocks DO NOT allow the bare wire end to contact any grounded or energized object Isolate the wire end with electrical tape Repeat for each wire to be removed 7 Unplug all connectors plugged into the circuit card 8 Remove the circuit card by removing the bracket the circuit card is mounted to Remove the circuit card from the bracket 9 In this step ensur...

Page 43: ...re Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs J12 RELAY SW1 7 J2 J11 5 3 1 Relay Output Terminal Blocks Digital Input Terminal Blocks J9 J8 J7 J6 J5 J4 J3 8 6 4 2 8 7 6 5 4 3 2 1 IB2 Board Top View NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO C NC 5 3 1 4 6 2 5 3 1 4 6 2 5 3 1 4 6 2 5 3 1 4 6 2 5 3 1 4 6 2 5 3 1 4 6 2 5 3 1 4 6 2 Connector to ACU IB2 TEMP PROBRE 1 IB2 TEMP...

Page 44: ...7000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 36 Figure 23 EIB ACU Extended Interface Board Connector Locations Optional EIB Interface Board Top View Optional EIB Interface Board Assembly SW1 J3 J4 J2 J9 J8 J7 J6 J5 J5 J9 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs ...

Page 45: ...e end to contact any grounded or energized object Isolate the wire end with electrical tape Repeat for each wire to be removed 7 Unplug all connectors plugged into the circuit card 8 Remove the screw securing the SM DU and Shunt Interface Assembly to the bottom of the distribution cabinet and remove the assembly 9 SM DU In this step ensure you do not intermix the old and replacement circuit cards ...

Page 46: ... 24 SM DU and Shunt Interface Assembly Connector Locations TB1 TB2 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs SM DU and Shunt Interface Board pow er can RS485 RS485 SHUNT SHUNT FUSE RS 232 SW1 SW2 J1 J7 J8 J6 J3 J4 J4A J5 ON OFF 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Red Indicator Yellow Indicator Green Indicator Shunt Interface Board SM DU 1A 1B TB1 TB2 J2 J1 ...

Page 47: ...led in the main bay to the UP position momentarily and then leave the switch in the middle OFF position 5 Remove the top and front panels to access the circuit cards at the bottom of the distribution cabinet 6 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 25 or Figure 26 7 Unplu...

Page 48: ...U LVD1 control setting Level 1 J4 J5 J6 To LVLD contactor uses ACU LVD2 control setting Level 2 J7 To LVBD contactor uses ACU LVD2 control setting Level 2 Notes 1 Connects up to 4 LVLD and 1 LVBD contactors 2 Switch and indicator located on circuit card installed in Main Bay only J6 J5 J4 J3 J2 J1 J7 S1 DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 LVD2 if the system...

Page 49: ... J3 are on Level 2 only one 1 of these connectors can be used at a time 3 Switch and indicator located on circuit card installed in Main Bay only J1 To LVLD contactor uses ACU LVD1 control setting Level 1 J3 To LVLD contactor uses ACU LVD2 control setting Level 2 J2 To LVBD contactor uses ACU LVD2 control setting Level 2 Can only be used if it is contained in a List 21 1 row cabinet J1 J3 J2 S1 DO...

Page 50: ...acement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card 9 Plug all connectors removed from the old circuit card into the same position on the replacement circuit card 10 Remove the grounding wrist strap 11 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 12 ...

Page 51: ...bolt 1 4 lock washer 1 4 flat washer Torque to 84 in lbs 3 For battery distribution panels replace the hardware securing the panel s Battery Busbar to the distribution cabinet s busbar 3 8 16 x 1 1 4 bolt 3 8 Belleville lock washer 3 8 hardened flat washer 2 places Torque to 180 in lbs 4 For load distribution panels replace the hardware securing the panel s System Load Distribution busbar to the d...

Page 52: ...n illustration for clarity only Front Front Battery Distribution Panel Load Distribution Panel Ground Busbar Hardware Ground Busbar Hardware Battery Busbar Hardware Distribution Panel Hardware System Load Distribution Busbar Hardware Distribution Panel Hardware 24 jumpers Assembly order is lug 1 4 flat washer 1 4 lock washer 1 4 20 bolt Torque to 84 in lbs List DA Dual Voltage Distribution Panel L...

Page 53: ...tion cabinet the contactor can be accessed from the rear and top of the distribution cabinet 3 For the 2 3 or 4 row distribution cabinet remove the distribution cabinet s rear access panel s 4 Disconnect the wiring to the contactor by unplugging the quick disconnects 5 Note the orientation of the contactor to ensure the replacement is installed the same way Unbolt the contactor 4 places and remove...

Page 54: ... Apply electrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only Contactor styles vary between manufacturer s Front 5 16 18 x 1 Bolt 5 16 Belleville Lock Washer 5 16 Belleville Lock Washer concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 in lbs White Black Wire Brown Wire Brown White Wire...

Page 55: ...lectrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only Front 2 row Distribution Cabinet shown 3 or 4 row cabinet similar Shown being removed from front for clarity only Removal is from rear 1 2 13 x 1 1 4 Bolt 1 2 Belleville Lock Washer 1 2 Belleville Lock Washer concave side of Belleville Lock Washers face each other 1 2 Hardened Flat Washe...

Page 56: ...ntactor Components removed in illustration for clarity only Front 5 16 18 x 1 Bolt 5 16 Belleville Lock Washer 5 16 Belleville Lock Washer concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 in lbs Apply electrical anti oxidizing compound to busbar mating surfaces Contactor styles vary between manufacturer s Black Wire Violet White Wire Violet W...

Page 57: ...on Cabinet shown 3 or 4 row cabinet similar Apply electrical anti oxidizing compound to busbar mating surfaces 5 16 18 Nut 5 16 Belleville Lock Washer 5 16 Belleville Lock Washer concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 in lbs Components removed in illustration for clarity only Front Contactor styles vary between manufacturer s Black ...

Page 58: ...NetSure 48V DC Power System User Instructions UM582127000 Issue AD January 20 2014 Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AD January 20 2014 50 This page is intentionally blank ...

Page 59: ...ant 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 Power Depot Repair ...

Page 60: ...ment 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 practi...

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