Emerson Yarway 7100 Series Installation Instructions Manual Download Page 1

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-48 VDC Power System

Installation Instructions, IM582127000100 (Revision A, January 9, 2017)

Specification Number: 582127000100, 582127000103

Model Number: 7100

582127000100

582127000103

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Summary of Contents for Yarway 7100 Series

Page 1: ...re 48 VDC Power System Installation Instructions IM582127000100 Revision A January 9 2017 Specification Number 582127000100 582127000103 Model Number 7100 582127000100 582127000103 S t o c k C h e c k c o m ...

Page 2: ... Installation Instructions IM582127000100 Revision A January 9 2017 Spec No 582127000100 582127000103 Document Code IM582127000100 Model No 7100 Revision A January 9 2017 This page is intentionally blank S t o c k C h e c k c o m ...

Page 3: ...cations 15 Jumper on System Interface Board 16 Switch Setting on IB2 Controller Interface Board 17 Switch Setting on Optional EIB Controller Extended Interface Board 17 Making Electrical Connections 19 Important Safety Instructions 19 Wiring Considerations 19 Relay Rack Grounding Connection Frame Ground 20 Central Office Ground Connection 20 Nominal 208 VAC 240 VAC Input and Equipment Grounding Co...

Page 4: ...ns IM582127000100 Revision A January 9 2017 Spec No 582127000100 582127000103 Document Code IM582127000100 Model No 7100 Revision A January 9 2017 ii Checking System Status 50 Final Steps 50 NetPerform Optimization Services 51 S t o c k C h e c k c o m ...

Page 5: ...r moderate 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 o...

Page 6: ...branch circuit breakers remain de energized during installation DO NOT apply AC input power to the system until all electrical connections have been completed and checked DC Output and Battery Voltages DANGER This system produces DC power and may have a battery source connected to it Although the DC voltage is not hazardously high the rectifiers and or battery can deliver large amounts of current ...

Page 7: ...sive 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 ACID BATTERIES Follow the reco...

Page 8: ... 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 containing static...

Page 9: ...is an Installation Acceptance Checklist This checklist helps ensure proper installation and initial operation of the system As the procedures presented in this document are completed check the appropriate box on this list If the procedure is not required to be performed for your installation site also check the box in this list to indicate that the procedure was read When installation is done ensu...

Page 10: ...e used in securing the relay rack to the floor Rectifier converter and mounting assembly ventilating openings must not be blocked and temperature of air entering rectifiers and converters must not exceed rated operating ambient temperature range found in SAG582127000 Clearance requirements are a Recommended minimum aisle space clearance for the front of the bay is 2 6 b Recommended minimum aisle s...

Page 11: ...gure 2 Installing Battery Trays Front Rear Rear Rear 3 Secure rear angle brackets both sides to relay rack with 12 24 x 1 2 thread forming hex head screws 2 places per side and 10 12 ground washers 1 place per bracket or 12 flat washers 1 place per bracket Torque to 70 in lbs 4 Secure cabling brackets both sides to relay rack with 12 24 x 1 2 thread forming hex head screws Torque to 70 in lbs 2 Se...

Page 12: ...trays perform the procedure detailed in Figure 3 Figure 3 Installing Battery Disconnect Circuit Breakers onto Battery Trays Battery Disconnect Circuit Breaker Assembly left side kit shown right side kit available 1 Remove the cover from the battery disconnect circuit breaker assembly 2 Secure the battery disconnect circuit breaker assembly to the battery tray using 8 32 nuts 2 places and 8 flat wa...

Page 13: ...to the wiring diagram provided in Figure 5 2 Rout the cables into the battery trays Route the cables labeled 1 and 1 into the bottom tray Route the cables labeled 2 and 2 into the middle tray Route the cables labeled 3 and 3 into the top tray 3 Connect the 1 2 and 3 cables to the battery disconnect circuit breaker located on the respective battery tray Refer to Figure 6 Cables labeled 1 2 and 3 ar...

Page 14: ...ons IM582127000100 Revision A January 9 2017 Spec No 582127000100 582127000103 Document Code IM582127000100 Model No 7100 Revision A January 9 2017 6 Figure 5 Battery Tray Wiring Diagram to Return Busbar to 48V Battery Busbar S t o c k C h e c k c o m ...

Page 15: ...Connect the stripped end of alarm jumper P N 524384 to TB1 located on the System Interface Board 48VDC is applied to the alarm lead when the circuit breaker is in the OFF position Refer to Figure 6 Refer also to Figure 17 Connecting Battery Temperature Probes Procedure Three battery temperature probes are provided Refer also to Temperature Probes on page 23 1 Connect a temperature probe to the Sys...

Page 16: ...dware To Battery To Power System To Power System To Power System Yellow Alarm Wire Harness P N 524384 3rd Battery Tray Battery Disconnect Circuit Breaker 2nd Battery Tray Battery Disconnect Circuit Breaker 1st Battery Tray Battery Disconnect Circuit Breaker Procedure 1 Connect kit supplied YELLOW jumper alarm lead P N 524384 to circuit breaker C Common alarm terminals on ALL Battery Disconnect Cir...

Page 17: ...ption 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 Nut 1 4 20 2 228567100 Nut 3 8 16 Perform the following steps to install the lug adapter busbars Procedure Refer to Figure 7 as the procedure is perfo...

Page 18: ... 582127000100 582127000103 Document Code IM582127000100 Model No 7100 Revision A January 9 2017 10 Figure 7 Installing Lug Adapter Busbar Kits Notes Orient busbars as shown Circuit breaker locations for reference only Busbar Adapter Kit P N 534449 Busbar Adapter Kit P N 514714 S t o c k C h e c k c o m ...

Page 19: ...ack of the fuseholder makes contact with the alarm terminal on the spring strip Push fuseholder in firmly until fully seated in the distribution panel 3 When all fuseholders are installed install an appropriately sized TPS TLS fuse in each To do this remove the fuse carrier from the mounted fuseholder body Hold the fuseholder body while you pull the fuse carrier from the body Slide the fuse in pla...

Page 20: ...cedure NOTE Refer to Figure 9 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 9 Insert the terminals on the rear of the circuit breaker into their corresponding sockets on the distributi...

Page 21: ...e position 2 Follow the steps in Figure 10 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 installed in all unused fuse positions on the GMT distribution fuse block b Verify that a plastic safety cover is installed on all GMT fuses on the GM...

Page 22: ...e 10 Installing an Optional Bullet Nose Type 6 Position GMT Distribution Fuse Block P N 549017 RTN Bar 1 Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block Remove plastic busbar plugs first Plastic Busbar Plugs 2 Plug in GMT Fuse Block 3 Connect supplied jumper from GMT Fuse Block to Return Bar Torque to 75 in lbs Part of P N 549017 Part of P N 549017 S t o c k C h e c ...

Page 23: ...ary 9 2017 15 Setting Jumpers and Switch Options Circuit Card Locations Refer to Figure 11 Figure 11 Circuit Card Locations Front Door Removed in Illustration for Clarity Distribution Cabinet IB2 1 Interface Board 1 MA4C5U31 IB4 2nd Ethernet Port Board 558076 Optional EIB 1 Extended Interface Board MA455U41 System Interface Board 562662 NCU Controller 1M830DNA S t o c k C h e c k c o m ...

Page 24: ...by the rectifiers if functional This is the default setting If you lose AC power and your battery contactor opens the controller will shut down Jumper in Battery Power Position The controller is powered from the battery side of the battery contactor If the battery LVD contactor opens the controller is powered by the battery and the battery will drain The controller s power consumption is 5W If you...

Page 25: ...re 11 for circuit card location Refer to Figure 13 for switch location Table 1 IB2 Controller Interface Board Switch Setting Setting DIP Switch SW1 1 2 IB2 1 OFF OFF Switch Setting on Optional EIB Controller Extended Interface Board Dip Switch SW1 on the optional EIB board is used to set the communications address for this board Refer to Table 2 for SW1 settings Refer to Figure 14 for SW1 location...

Page 26: ... Extended Interface Board Switch Location and Setting 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 IB2 Interface Board Setting DIP Switch SW1 1 2 IB2 1 OFF OFF SW1 ON OFF 1 2 SW1 Setting DIP Switch SW1 1 2 EIB 1 OFF OFF EIB Extended Interface Board EIB Extended Interface Board Top View SW1 J3 J4 J2 ...

Page 27: ...to System Application Guide SAG582127000 Refer to drawing 031110100 for lug crimping information Refer to drawings 031110200 and 031110300 for additional lug information Refer to Table 3 for supplemental lug crimping information when using the special application crimp lug strap combination Table 3 Supplemental Lug Crimping Information when using the Special Application Crimp Lug Strap Combination...

Page 28: ...nnections DANGER Adhere to the Important Safety Instructions presented at the front of this document Wiring Considerations Refer to Table 4 for recommended wire sizes and branch circuit protection Connections to AC Input Termination Assemblies The AC input termination assemblies provide circular openings at the top for AC input and grounding conductors The openings accept 1 inch conduit fittings I...

Page 29: ...tions of the American National Standards Institute ANSI approved National Fire Protection Association s NFPA National Electrical Code NEC Table 310 15 B 16 for copper wire at 90 C conductor temperature For operation in countries where the NEC is not recognized follow applicable codes 4 Equipment grounding conductors must be provided with the AC input conductors supplied to the assembly Frame groun...

Page 30: ...rminal AC 2 Wire Size Capacity 6 14 AWG Recommended Torque 18 in lbs RECTIFIER AC INPUT FEEDS 1 FEED PER 2 RECTIFIERS 208 VAC 240 VAC 50 Hz 60 Hz SINGLE PHASE FRAME GROUND CONNECTION Three 10 32 X 3 4 Studs and Hardware Recommended torque 23 in lbs AC 2 AC 1 Shelf 2 and 4 Rectifier 6 Shelf 2 and 4 Rectifier 5 Shelf 2 and 4 Rectifier 4 Shelf 1 and 3 Rectifier 6 Shelf 1 and 3 Rectifier 5 Shelf 1 and...

Page 31: ... or increases respectively Battery life can be extended when an optimum charge voltage to the battery with respect to temperature is maintained A temperature probe set to monitor battery temperature can also be used for the BTRM Battery Thermal Runaway Management feature The BTRM feature lowers output voltage when a high temperature condition exists to control against battery thermal runaway The t...

Page 32: ...e Probes starting on page 23 NCU CAN Port see Connecting a Device or System to the NCU CAN Bus if required starting on page 34 Figure 17 System Interface Board Connections System Interface Board System Interface Board CAN termination plug P N 548398 must be installed if an external device is not connected to the system TP1 and TP2 System Voltage J5 System Temp 1 NCU CAN Port J6 System Temp 2 C1 CR...

Page 33: ...eak 30 VDC The relays are preprogrammed for specific functions Refer to the configuration drawing C drawing supplied with your system for your system s specific configuration Digital Inputs Connect up to eight 8 digital inputs to the IB2 Note that you must supply both paths for the digital input either a positive or negative signal and the opposite polarity return path Observe proper polarity Refe...

Page 34: ... 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 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 Controller IB2 TEMP PROBRE 1 IB2 TEMP PROBE 2 IB2 Interface Board Top View The relay assigned to Critical Summary alarm relay 1 ...

Page 35: ... COM J8 3 NC J8 1 6 NO J8 6 Rectifier Alarms COM J8 4 NC J8 2 7 NO J9 5 Over Very Low Voltage COM J9 3 NC J9 1 8 NO J9 6 Battery Temperature COM J9 4 NC J9 2 NOTE The relay assigned to Critical Summary alarm relay 1 on the IB2 by default will operate in the Fail Safe Mode Fail Safe Mode means Relay 1 is de energized during an alarm condition opening the contacts between the C and NO terminals and ...

Page 36: ...h your system for your system s specific configuration J3 1 2 J3 4 J3 3 3 J3 6 J3 5 4 J4 2 J4 1 5 J4 4 J4 3 6 J4 6 J4 5 7 J5 2 J5 1 8 J5 4 to customer ESTOP switch ESTOP J5 3 48 VDC J5 5 not used not used not used J5 6 NOTE 48V is factory wired to the Digital Input 8 terminal for your convenience and function predefined for ESTOP Customer furnished system ground applied to terminal Digital Input 8...

Page 37: ...ions UM1M830BNA and program the following parameters Battery Block Monitoring Voltage Type Set to 48 Block 4 This selects the EIB to monitor up to two 2 48V battery strings with four 4 12V blocks per string BlockVDiff 12V This menu item appears if 48 Block 4 is selected above Set to the alarm threshold for battery block monitoring per site requirements The controller issues an alarm when any block...

Page 38: ...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 Return 48V Load Shunt Load 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 EIB Board Voltage Inputs Rectifiers 12V...

Page 39: ...Schematic Diagram of EIB Board MA455U41 EIB SH1 SH1 SH2 SH2 SH3 SH3 J5 J6 J7 J8 J9 V1 V2 V3 V4 V5 V6 V7 RLY5_NC V8 RLY5_COM RLY1_NC RLY2_NC RLY1_COM RLY2_COM RLY1_NO RLY2_NO RLY3_NC RLY4_NC RLY3_COM RLY4_COM RLY3_NO RLY4_NO J3 1 J3 2 J3 3 J4 1 J4 2 J4 3 2 4 3 1 J2 RLY5_NO 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 12 3 4 5 6 1 23 4 5 6 SHUNT INPUTS VOLTAGE INPUTS RELAY OUTPUTS EIB TEMP PROBE 2 EIB TEMP P...

Page 40: ...00 Revision A January 9 2017 32 Table 7 Shunt Inputs EIB Shunt Input EIB Pin No Factory Wiring Default Function Customer Defined Function Sh1 J5 2 none J5 1 Sh2 J5 4 none J5 3 Sh3 J5 6 none J5 5 Table 8 Voltage Inputs EIB Voltage Input EIB Pin No Default Function 1 J6 1 Battery Block Monitoring 2 J6 2 3 J6 3 4 J6 4 5 J6 5 6 J6 6 7 J7 1 8 J7 3 S t o c k C h e c k c o m ...

Page 41: ...y be preprogrammed for specific functions Refer to the configuration drawing C drawing supplied with your system for your system s specific configuration COM J8 3 NC J8 1 2 NO J8 6 COM J8 4 NC J8 2 3 NO J9 5 COM J9 3 NC J9 1 4 NO J9 6 COM J9 4 NC J9 2 5 NO J7 6 COM J7 4 NC J7 2 NOTE The relays energize during an alarm condition closing the contacts between the C and NO terminals and opening the co...

Page 42: ...st device on the controller s CAN bus has a CAN termination plug Refer also to the external device s or system s instruction manual Optional SM Temp Module The analog output of the SM Temp Module may be connected to an NCU temperature port input In lieu of connecting the analog output of the SM TEMP module to an NCU temperature port input the SM TEMP module can simply be connected at the end of th...

Page 43: ...rnet pin configuration scheme twisted pair Refer to Figure 11 for IB4 board location Refer to Figure 21 for Ethernet port location Use shielded Ethernet cable grounded at both ends Note that the IB4 board s RJ 45 jack is connected to chassis ground Refer to the NCU Instructions UM1M830BNA for operational details WARNING The intra building port s of the equipment or subassembly is suitable for conn...

Page 44: ...tions 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 Caution A 100 A circuit breaker or fuse SHALL HAVE an empty mounting position between it and any other overcurrent protective device 100 A circuit breakers can be used without a space provided the continuous current in each 100 A device d...

Page 45: ...9 2017 37 LOAD CONNECTIONS TO GMT DISTRIBUTION FUSE BLOCK Figure 24 Optional Bullet Nose 6 Position GMT Distribution Fuse Block P N 549017 Wire Size Capacity 26 14 AWG Recommended Torque 4 5 in lbs 35A maximum capacity per block Maximum GMT fuse size is 15A Load Return Leads 48VDC Load Leads 1 4 20 Hardware Torque to 75 in lbs Part of P N 549017 Part of P N 549017 S t o c k C h e c k c o m ...

Page 46: ...ent WARNING Observe proper polarity when making battery connections RECOMMENDED TORQUES 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 CONNECTIONS TO DISTRIBUTION CABINET BATTERY BUSBARS DANGER Adhere to the Important Safety Instructions presented at the front of this document Battery is connect...

Page 47: ...Busbars Battery Return Side Busbar Battery Load Side Busbar GND RTN 48V SUPPLY Distribution Cabinet Battery Return Side Busbar Battery Load Side Busbar BATTERY RETURN CONNECTIONS 6 landings 3 8 16 Captive Nuts on 1 Centers Customer must supply hardware BATTERY CONNECTIONS 5 landings 3 8 16 Captive Nuts on 1 Centers Customer must supply hardware Maximum Lug Width 1 88 inches Central Office Ground u...

Page 48: ...ions IM582127000100 Revision A January 9 2017 Spec No 582127000100 582127000103 Document Code IM582127000100 Model No 7100 Revision A January 9 2017 40 Figure 26 Battery Busbar Dimensions Notes 1 All dimensions are in inches S t o c k C h e c k c o m ...

Page 49: ...e to battery manufacturer s recommendations 6 Ensure the battery cable ends in all trays are insulated with sleeving before performing the next step DANGER In multiple tray installations when batteries in one tray are connected the battery cables in all trays will be energized Remove sleeving from and connect one cable at a time Do not allow a cable end to contact the battery tray or equipment rac...

Page 50: ...ee Detail A for hardware build up Connect Link Furnished with Battery to these Two Terminals TURN OFF ALL circuit breakers before installing and connecting any batteries Connect NEG Battery Cable to this Terminal Also connect a provided temperature probe to this terminal in each battery tray Connect Link Furnished with Battery to these Two Terminals Connect Link Furnished with Battery to these Two...

Page 51: ...talled the kits provide rectifier bus landing points for 350 kcmil cables Refer to Figure 28 Figure 28 Special Application Rectifier Bus Landing Point Kit P N 563574 GND RTN Positive Cable 48V SUPPLY Negative Cable Components removed in illustration for clarity only Rear P N 563574 Hardware Buildup 3 8 16 x 1 1 4 Bolt 3 8 Flat Washer Lug Busbar 3 8 Flat Washer 3 8 Lock Washer 3 8 16 Nut Torque to ...

Page 52: ... when installing or removing a module NEVER hold the handle in the closed position when installing a module into a shelf Procedure 1 Unpack the modules 2 Note the model number located on the front of each module Model numbers starting with the letter R are rectifier modules Model numbers starting with the letter C are converter modules 3 Place the module into an unoccupied mounting position withou...

Page 53: ...January 9 2017 45 Figure 29 Installing Rectifier and Converter Modules into Spec No 588705300 Module Mounting Assembly Rectifier or Converter Module Model Number Label R48 2000e3 Rectifier C48 24 1500 Converter Captive Screw Latch Handle Rectifiers Only in Top Shelf Rectifiers in Any Position Rectifiers or Converters in Far Right Three Positions Front View S t o c k C h e c k c o m ...

Page 54: ...kers if furnished 2 Apply AC input power to the system by closing ALL external AC disconnects or protective devices that supply AC input power to the module mounting assemblies Rectifiers and converters automatically start 3 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 4 Place each distribution circuit breaker if furnished to the ON position NCU ...

Page 55: ...ining rectifiers to be reset In the example given if one rectifier is removed the current limit set point will drop to 120 amps 30 amps times four remaining rectifiers until the controller can send updated set points to the remaining rectifiers This takes a couple communication cycles several seconds after which each rectifier would have a new set point of 37 5 amps for a total of 150 amps The tot...

Page 56: ...nd DOWN keys to move up and down the list of parameters Press ENT to select the parameter Press the UP and DOWN keys to change the parameter Press ENT to make the change Press ESC to cancel the change Table 11 shows the menu navigation for some basic settings Refer to the separate NCU Manual UM1M830BNA supplied with your power system for complete Local Display menus Table 11 NCU Basic Settings Men...

Page 57: ... NCU identifies the rectifiers is by serial number lowest serial number is Rect 1 next lowest is Rect 2 etc If you prefer the NCU to identify the rectifiers by position in the system perform the following procedure Upon power up the NCU arbitrarily assigns Feed AC1 AC2 or AC3 to each rectifier This assignment is used to display rectifier AC input feed voltage s The User may reassign the feed to ea...

Page 58: ...Converter Modules Power Green On Protection Yellow Off Alarm Red Off Final Steps Procedure 1 If any controller configuration settings were changed refer to the NCU Instructions UM1M830BNA and save a copy of the configuration file This file can be used to restore the controller settings if required at a later date Note that provided on a USB drive furnished with the system is a controller configura...

Page 59: ...igured 2 DC power systems and outside plant enclosures for customers and channel partners Reps VARs Distributors Phone 1 800 800 1280 option 2 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 ...

Page 60: ...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 Names of companies and products are trademarks or registered trademarks of the respective companies Any questions regarding usage of trademark names should be directed to the original manu...

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