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Helios Modular Switch Mode Rectifier 200/48

1. NS 3 al 27 sul C c Ola 2 O aw 2 O E SRT U sows v gt FN an hi I h O LAOS VOLTIAMP 250V a O wo EN omo C wo O o a es ES ay huso w de VOUT VOUT Q I TERN DE CONTROLE gt gt 5 SOUS LE COWERCLE o 2 agam pad H o E j Derec 5 O A Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 12 General information Helios 200 A rectifier models and mounting configurations 1 1 1 Rectifiers not equipped with connectors NT5C05DC DD These rectifiers require conventional ac and de wiring and are equipped with a de breaker and adjustable current limit They can be installed in a frame NT6C40 a 1000 A cabinet NT6C43DA and a 1200 A cabinet NT6C43AA AB see Figures 4 and 5 Figure 2 Rear view of the rectifiers not equipped with connectors NT5C05DC DD 1 1 2 Rectifier equipped with ac dc and signals connectors NT5CO5DB This rectifier is equipped with input ac output de and alarm connectors It has also a de breaker and adjustable current limit Up to five 200 A NTSCOSDB rectifiers see Figure 4 can be installed in a 1000 A cabinet NT6C43DA Cables terminated with connectors ac de and alarms are provided with t
2. 8 9 and 14 Table 12 Designation of the adjustment potentiometers on the front panel Potentiometer Description CL ADJ Current limit adjust CUR CAL Current calibration EQL ADJ Equalize voltage adjust FLT ADJ Float voltage adjust HVSD ADJ High voltage shutdown adjust VOLT CAL Voltage calibration Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 48 Functional description Table 13 Designation of the switches on the front panel Switch Description ALCO Alarm cut off EQL FLT Equalized Floated voltage selection RECT TST Rectifier test ST UP DELAY Start up delay selection 4 seconds to 2 minutes SW5 Slope Forced load sharing selection SLS FS Note SW5 is located on the control card VOLT AMP Rectifier voltage and current display selection Table 14 Rectifier and controller interface connections Designation Description RG RC External reference voltage across the batteries measured through the controller to regulate the voltage HVSD Remote High Voltage Shutdown input activated by a BAT RTN signal HVSDR Remote High Voltage Shutdown Reset input activated by a BAT RTN signal TR Remote Inhibit input activated by a BAT RTN signal EQL Remote Equalize input activated by a BAT RTN signal RFA Rectifier Failure Alarm output activating a form C contact F ALM Fan Failure Alarm output activating a form C contact SHUNT
3. 4 2 10 3 Start up delay dip switch The rectifier can provide a start up delay of 4 seconds up to 124 seconds with a resolution of 8 seconds and an accuracy of 1 second Use of this feature is recommended when two or more rectifiers are connected to a common ac input to stagger the inrush currents A start up delay of 8 seconds would be suitable in such a case A dipswitch located on the front panel can be set to provide the start up delays listed in Table 15 Table 15 Setting the start up delay of the rectifiers Delay Switch Position Delay Switch Position Number 1 0 Number 1 0 4 seconds 6 X 68 seconds 6 X 5 X 5 X 4 X 4 Xx 3 X 3 X 12 6 X 76 seconds 6 X seconds 5 X 5 xX 4 Xx 4 Xx 3 3 X 20 6 X 84 seconds 6 X seconds 5 X 5 x 4 4 Xx 3 X 3 X 28 6 X 92 seconds 6 X seconds 5 X 5 xX 4 4 Xx 3 3 X 36 6 x 100 6 X seconds 5 seconds 5 x 4 Xx 4 Xx 3 X 3 X 44 6 X 108 6 X seconds 5 seconds 5 X 4 Xx 4 Xx 3 3 X continued UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Functional description 53 Table 15 Setting the start up delay of the rectifiers continued Delay Switch Position Delay Switch Position Number 1 0 Number 1 0 52 6 X 116 6 x seconds 5 x seconds 5 x 4 X 4 X 3 X 3 Xx 60 6 Xx 124 6 Xx seconds 5 x seconds 5 X 4 Xx 4 Xx 3 Xx 3 X Emerson Energy Systems Rectifier
4. FR GRD and the three phase ac power leads in positions L1 L2 and L3 Reinstall the ac cover removed in step 5 Repeat steps 1 to 9 for each rectifier Make the ground and line connections L1 L2 L3 at the ac service panel end Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 30 Installation Figure 9 AC connections to the NT5C05DC DD rectifiers without connectors Teck cable or flexible conduit No 3 6 cable recommended AC cover GRD Partial view of the rectifier s rear panel right side as viewed from the rear TB1 For systems requiring an extra ground connection an 8 AWG wire green insulated and withstanding up to 105 C can be installed in addition to the existing cable and can be connected to an external system ground To install this wire follow the instructions in Procedure 4 Procedure 4 Running an additional ac ground to the rectifier Step Action 1 Crimp a 0 25 inch ring lug terminal on the wire 2 Secure the lug to the clinch nut located on the back panel of the rectifier located below the ac connection plate and surrounded by silver grounding tape with a 0 25 20 screw Remove the protective peeling from the grounding tape if there is any before sliding the lug onto the clinch nut end UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation
5. Rectifier Current input output 50 mV 250 A and SHUNT ay CURRENT Common Forced Current Share Mode 0 12 V SHARE 4 2 4 Voltage current display test and measurement 4 2 4 1 CUR CAL VOLT CAL potentiometers These potentiometers are used to calibrate the digital display meter for current and voltage measurements As the two potentiometers affect each other current calibration must be performed before voltage calibration 4 2 4 2 VOLT AMP digital meter switch This switch is used to select the measurement display mode of the digital meter The output voltage or the output current modes can be selected 4 2 4 3 VOUT VOUT test points These test points are used to measure the voltage at the point of regulation A 5 kohm resistor is placed in series with both sensing leads to prevent UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Functional description 49 short circuits at the jack terminals The resistor may affect reading accuracy depending on the meter impedance Refer to the Instruction Manual for your meter to determine its internal impedance and correction factor 4 2 5 Float and equalize voltage control 4 2 5 1 Local FLOAT EQL switch and potentiometers The rectifier is equipped with a Float Equalize switch e When the FLOAT EQL switch is held in the EQL position the rectifier changes to equalize mode and boosts the output voltage to the value set b
6. ISA AAA A A A 21 3 1 Installation Overview 0 ceceeeccee cece ee eeeeeaeeeceeeeeeeeeanaeeeeeeeeeeeaaeaeeeeeeeeeeeenaees 21 3 1 1 Installing in a Cabinet cis cee ra E A O 21 3 1 2 lnstaling m a aNG essa ys ceees ude ceeds iia 24 gta TINE 24 3 1 4 Tools and test equipment occcoonoccccnnnoccccnononcnnnanoncnnnnnoncnnnnancnn nana nnnnnnnns 24 3 2 Cautions and WarinQS ooccccocccnnnninnnocnnncccnnnccnnnnn canon nnnnc crac nana cnn 24 3 3 Installing the Teter Sei a a aR 27 3341 Installing ma Taense rsa taa 27 3 3 2 Installing in a Cabinet rren a Ga AS a a a E 27 3 4 Cabling and connecting the rectifiers ssseesse essensen eei resrresrrssrnesrresrrssnns 28 3 4 1 Cabling ac to rectifiers NT5CO5DC DD without connectors 28 3 4 2 Supplying ac to the NT5CO5DB rectifier equipped with connectors 31 3 5 Connecting the dc output terminals of the rectifier to the busbars 33 3 5 1 Inserting the dc connector cabled to the busbars of the 1000 A cabinet to the NT5CO5DB rectifier cecccceseeeeeeeeeeeeeseeeeseeeeeeeeeeaes 34 3 5 2 Securing dc lugs from the busbars to the NT5C05DC DD rectifier O 34 3 5 3 Securing dc lugs from the busbars to the NT5C05DC DD rectifier ina 1000 A CabiNBtoooocccocccnconinccnoccnccnnccnnnnnnonccnncnnnnnnnn nn nn cnn nn nnnnnnncnncnnns 34 3 5 4 Securing the dc terminals of a NT5C05DC DD rectifier in the FOMA CAN done al decos do Me 35 3 6 Connecting controls a
7. signal The alarm contacts are extended by relays and are isolated from each other and from the rectifier chassis All contacts are rated 60 V dc and 0 5 A Connecting alarms and controls on J3 A multi conductor cable assembly terminated with a right angle DB25 locking connector is provided for connection to J3 on the rectifier Procedure 11 Connecting alarms to the rectifier with a DB25 connector Step Action 1 Prepare the DB25 connector by moving the slide latch into the up position 2 Place the connector into position cable going up over J3 and press on it firmly 3 Push the slide latch into the down position end Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual Table 8 Control and alarm signals on J3 Connection Signal Description 1 EQL Equalize 2 RC Remote sense 3 HVSDR High voltage shutdown reset 4 RFA NC Rectifier failure alarm NC 5 FAN NC Fan failure alarm NC 6 FAN C Fan failure alarm center 7 SH Shunt 8 RFA NO Rectifier failure alarm NO 9 SENSE C Sense fail alarm center 10 SENSE NO Sense fail alarm NO 11 NC No connection 12 PRESENT 2 13 NC No connection 14 RG Remote sense 15 TR Rectifier temporary release by the controller 16 HVSD High voltage shutdown 17 CURRENT Forced share link SHARE 18 RFA C Rectifier fail
8. February 2002 Emerson Energy Systems 63 8 Appendix A Replacement parts ITEM PART NUMBER CPC Fan Assembly grey P0747481 Fan Assembly brown P0712535 Fuse 1 A 250 V F2 A0288248 Fuse 1 A FF1 FF2 on Display PCB A0287301 Fuse 1 6 A RC fuse A0384386 Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 64 Appendix A Replacement parts This page is left blank intentionally UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 65 9 Appendix B Technical service assistance For technical assistance 24 hours a day 7 days a week dial one of the following toll free numbers This service complements the services offered by field support organizations such as the Emergency Technical Assistance Service ETAS and the Installation Technical Assistance Service ITAS 9 1 Local toll free prefixes The following prefixes give access to toll free numbers in various countries For further information please contact the local service provider Pp Country Prefix Belgium o o pp w France SY gt ema Y O CA 0 Japan 001 KDD 0061 IDC Korea 001 Korea Telecom 002 Dacom 003 Once w Netherlands O O o oS S S New Zealand 4 Switzerland United Kingdom 2 Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 66 App
9. Installation 3 1 Installation overview 3 1 1 Installing in a cabinet The 1000 A cabinet can house up to five 200 A NTSCOSDB DC DD rectifiers The 1200 A cabinet can house up to six 200 A NTSCOSDC DD switch mode rectifiers The ac and dc are hard wired to the NTSCOSDC DD rectifiers without connectors see Figures 6 and 8 e the ac cable is run from the ac service panel to each rectifier e the output dc terminals of the rectifiers are connected to the busbars located at the top of the cabinet or to the vertical busbars The ac and dc from the 1000 A Cabinet are connected to the NTSCOSDB rectifiers equipped with connectors see Figure 7 e the ac is hard wired from the service panel to a junction box located on the top of the cabinet and ac cables with connectors are hard wired to the junction box for each rectifier e the dc cable assembly with a connector inserted in the rectifier is secured to the busbars located at the top of the cabinet see Figure 7 Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 22 Installation Figure 6 The ac and dc hard wired to the NT5C05DC DD rectifiers in a 1000 A cabinet e LEILA aca UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 23 Figure 7 The ac and dc connectors inserted in a NT5CO5DB rectifier in a 1000 A cabinet Figure 8 The
10. The frame ground leads must be connected before any other leads This is to prevent the cabinets and any other metal structures from carrying dangerous ac or dc voltage levels DANGER Protecting against electrical shocks The cabling of the power plant and all other cabling must be carried out by qualified personnel and in conformance with the local and national electrical codes AC input voltages to the rectifiers are at a dangerous level Ensure that the circuit breakers are locked in the OFF position in the ac service panel before working on the power plant Dangerous voltages may be present at the output de terminals even if the rectifiers are OFF Use a voltmeter to verify for the presence of such voltages Do not put the circuit breakers to ON until the entire system has been assembled and you have been instructed to do so Verify and identify with a tag the proper polarity of the battery leads before connecting them to the power plant DANGER Short circuit hazard The rectifiers and especially the batteries can deliver high current if a short to ground occurs When working on live equipment remove all personal jewelry use properly insulated tools and cover any live busbars with an insulating sheet of canvas to prevent short circuits that could be caused by falling tools or parts UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 27 3 3 I
11. ac and dc hard wired to NT5C05DC DD rectifiers in a 1200 A cabinet u a i a f Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 24 Installation 3 1 2 3 1 3 Installing in a frame Up to five 200 A NTSCOSDC DD switch mode rectifiers can be installed in a frame NT6C40 The ac and dc are connected as follows e the ac cable is run from the ac service panel to the rectifier e the output dc terminals of the rectifier are connected to the busbars Cables The types of cables used for each rectifier are e a3 conductor 6 AWG ac armored cable e a4 0 dc cable for BAT 48 V and BAT GND connections Tools and test equipment The following tools and test equipment are required to perform the installation e potentiometer screwdriver Bourns No 32 e potentiometer screwdriver Bourns No 60 e flat head screwdriver e digital voltmeter Fluke 8000 A or equivalent 3 2 Cautions and Warnings The following Cautions and Warnings must be observed at all times when handling and installing power equipment CAUTION Protecting the premises Protect the floors and walls against damage with sheets of plywood cardboard or other suitable material when handling the equipment CAUTION Preventing damage caused by over tightening Do not over tighten nuts and bolts Over tightening can strip the threads or break the bolts Apply the appropriate torque UM5C05D P071
12. and use the same for start up operation and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design quality at Astec International Ltd to insure that the equipment complies with the operation standards This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment The equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions contained in the Installation and User Manuals can cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Candeo is a trademark of Astec International Ltd The Emerson logo is a trademark and service mark of Emerson Electric Co Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual Publication history February 2002 Standard Issue 10 00 In Table 4 value for Total harmonic distortion THD was Less than 5 EC 102 29883 October 2001 Standard Issue 9 00 Manual restructured and updated to reflect Emerson identity ECN 102 26804 Februar
13. slowly increase the current by turning the FLT potentiometer clockwise until proper sharing is achieved If the current reading is too high or if rectifier is in the current limit mode turn the FLT potentiometer counterclockwise Note Adjust all the rectifiers in sequence to the mean value of the currents and readjust more precisely if necessary 24 If the forced share mode is chosen adjust the float voltage of each rectifier to the appropriate value plus 0 8 volts in slope share mode as described above For example to have a 52 1 V float voltage adjust to 52 1 V 0 8 V 52 9 V This compensates for the internal voltage drop when the dc breaker of the rectifier is put in the ON position Connect all the FS wires of the rectifiers together and put switch SW5 in the upper position for forced sharing mode on all the rectifiers The slope mode LED D35 will extinguish The system will stabilize when the last switch is closed 25 Repeat step 23 but in equalize mode to verify that the current is shared equally amongst the rectifiers when a remote equalize signal is applied or all local FLOAT EQL toggle switches are put in the EQL position If the current reading is too low or is 0 turn the EQL potentiometer clockwise until proper sharing is achieved If the current is too high or if the rectifier is in the current limit mode turn the EQL potentiometer counterclockwise 26 Deactivate the EQL mode to ret
14. terminated with lugs are factory installed on the busbars of the cabinet see Figure 6 Procedure 9 Connecting the dc output terminals of a rectifier without connectors in the 1000 A cabinet Step Action 1 Connect the lugs of the cables from the cabinet busbars to the 48 V and BAT GRD terminals located at the rear of the NT5C05DC DD rectifier end UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 35 3 5 4 Securing the dc terminals of a NT5CO5DC DD rectifier in the 1200 A cabinet Procedure 10 Connecting the dc output terminals of a rectifier without connectors in a 1200 A cabinet application Step Action 1 Locate the four holes corresponding to the holes of the dc terminals in the vertical busbar risers located at the rear of the rectifier Insert four connecting bolts through these holes and screw them into the terminals of the rectifier See Figure 11 2 Tighten the bolts by applying a torque of 6 5 0 5 ft lbs 8 5 0 5 N m end 3 6 Connecting controls and alarms 3 6 1 The connector J3 located on the right side of the rectifier when viewed from the front of the rectifier or TB2 located behind the lower display panel can be used to extend control alarm and monitoring signals see Tables 8 and 9 to the controller or to the monitoring system The control inputs are activated by a ground BAT RTN
15. 1 DC circuit breaker rectifiers NT5C05DB DD only A dc circuit breaker is provided to protect against current overload and to manually disconnect from the power plant When the breaker is in the 0 OFF position an RFA is triggered and the remote sense leads RG and RC are internally disconnected The rectifier will however continue to operate allowing for the adjustment of the FLT EQL and HVSD set points 4 2 1 2 AC breaker The input ac circuit breaker can be used to locally turn the rectifier ON or OFF The local ON OFF control overrides any remote control signals such as TR 4 2 1 3 Slow start fuse F2 This fuse 1 A 250 V is connected in line with the inrush circuitry to protect the input inrush resistor against a prolonged high power dissipation condition if an internal failure occurs UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Functional description 45 4 2 2 Description of the LEDs on the front panel Table 11 Designation of the LEDs on the front panel DEL designation Color Description AC ON Green Input ac voltage is operational ALCO Red Alarm cut off AUTO ST Yellow Auto restart CL Yellow Current limit EQL Yellow Rectifier is in equalize mode FAN ALM Red Fan failure alarm HVSD Red High voltage shutdown HVSD TST Yellow High voltage shutdown test LOP Yellow Loss of phase PRECH Yellow Output capacitor pre charge RFA Red Re
16. 200 48 NT5C05D User Manual 54 Functional description This page is left blank intentionally UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 55 5 Operation 5 1 Standard settings The standard settings of the rectifier are described in Table 16 Table 16 Standard settings for the rectifier Starting delay all switches set to 4 sec 1 sec OFF Current sharing Negative slope sharing 5 2 Starting up and adjusting the rectifier The FLT voltage can be adjusted while the rectifier is running main fuse and sense leads installed To achieve negative slope load sharing follow the instructions contained in Procedure 14 Procedure 14 Starting up and adjusting the rectifier Step Action 1 Put the dc circuit breaker OFF 0 position Open the sensing leads by removing the corresponding RC fuse when the rectifier is used with a controller or by removing the in line fuse on the RC wire when the rectifier is used without a controller 2 Close the ac circuit breaker ON located in the main ac service panel continued Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 56 Operation Procedure 14 Starting up and adjusting the rectifier continued Step Action Pre char ging 3 In asystem with batteries or with other rectifiers the output capacitors of the rectifier must be pre
17. 2975 Standard 10 00 February 2002 Emerson Energy Systems Installation 25 WARNING Personal safety and protecting the equipment Use a dolly truck forklift or hoist whenever possible to handle and move the equipment as power equipment is heavy If a forklift is used do not remove the packing material before moving the equipment to its final location If a dolly truck is used the packing material can be removed before moving the equipment to its final location When handling cabinets with equipment installed in them exercise care to ensure they do not tip over as they can be top heavy WARNING Preventing personal injuries When cutting material wear gloves and safety goggles Break the corners and sharp edges with a file CAUTION Optimizing the life of the equipment Make sure there are no obstructions in front of the ventilation openings that could restrict the flow of air WARNING Generator requirements for Emerson Energy Systems power systems For information on selecting ac generators that will effectively maintain peak performance and operating characteristics for all Emerson Energy Systems power systems contact your local Emerson Energy Systems representative if required refer to the Technical service assistance chapter of this manual for the telephone number Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 26 Installation DANGER Grounding
18. 31 3 4 2 Supplying ac to the NT5CO5DB rectifier equipped with connectors The ac is hard wired from the service panel to a junction box top right of the rectifier cabinet when viewed from the rear Connect the ac from the service panel to the 1000 A cabinet NT6C43DA with a 6 AWG 4 conductor armored cable or equivalent An ac cable with connectors is run between each rectifier to the ac junction box see Figure 10 DANGER Avoiding personal injury Make sure the power is OFF at the ac service panel before attempting to connect the input line voltage to the ac junction box of the cabinet A Procedure 5 Running the ac to a cabinet Loosen and remove the screws securing the side panel of the ac junction box at the top right inside the cabinet Install a 6 AWG 10 compression lug on the end of each conductor in the ac junction box using the proper crimping tool Make sure that the safety ground wire is properly connected to terminals E6 to E10 inside the ac box of the cabinet labels indicate which terminal block position corresponds to which rectifier position Put the ac and dc circuit breakers on the front of the rectifier to O OFF Install a circuit breaker in the ac service panel and lock it in OFF position Cut the ac cable or the individual wires in the conduit to the required length and run it from the ac service panel to the rectifier cabinet 7 Strip the sheathing and i
19. 5 V as an example 60 V is not allowed Output protection 225 Adc circuit breaker Output current 200 A at 176 to 264 V ac input Current limit 50 to 105 adjustable at the front of the rectifier For input protection external to the rectifier use a 60 A or greater capacity circuit breaker for each phase Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 18 Specifications 2 2 Operation specifications and ambient conditions Table 4 Operation specifications of the rectifier Efficiency gt 90 at a nominal input voltage of 208 V ac and an output load greater than 80 A Power factor gt 94 at a nominal input voltage of 208 V ac and an output load greater than 80 A Heat dissipation 1120 watts at 58 V 200 A Electromagnetic The rectifier meets the FCC requirements for conducted interference EMI and radiated EMI for Class A equipment Total harmonic Less than 35 distortion THD Certification This rectifier is Underwriters Laboratories UL1950 and CSA 22 2 no 950 recognized and is VDE approved to IEC950 All components used are rated to UL94V 0 for flammability Table 5 Ambient conditions required for the rectifier Operating An airflow clearance must be left at the rear of the conditions rectifier a minimum space of 2 inches 5 cm is recommended The rectifier operates satisfactorily with
20. Emerson Energy Systems Helios Modular Switch Mode Rectifier 200 48 NT5C05D Installation and User Manual SLOW O START min ma EN HIHIH QU 1A 250V D Ps 5 2 b eee E ie 2 Ol emerger po o p oil Deiec N pa P0712975 Standard 10 00 February 2002 EMERSON Helios Modular Switch Mode Rectifier 200 48 NT5C05D Installation and User Manual Manual Number UM5CO05D 169 2081 500 Manual Status Standard Manual Issue 10 00 Release Date February 2001 P0712975 Copyright 2001 2002 Astec International Ltd All Rights Reserved Published in Canada The information contained in this manual is the property of Astec International Ltd and is subject to change without notice Astec International Ltd reserves the right to make changes in design or components as progress in engineering and manufacturing may warrant Except as specifically authorized in writing by the V P of Engineering and Product Manufacturing of Astec International Ltd the holder of this manual shall keep all information contained herein confidential and shall protect same in whole or in part from disclosure and dissemination to all third parties
21. T BUSBAR FUSE PANEL SHUNT ON THE GRD SIDE PREFERRED CONFIGURATION Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 34 Installation 3 5 1 3 5 2 3 5 3 Inserting the dc connector cabled to the busbars of the 1000 A cabinet to the NT5CO5DB rectifier Procedure 7 Connecting the dc between the 1000 A cabinet and the rectifier equipped with connectors Step Action 1 Insert the dc plug of the cables factory installed coming from the busbars located at the top of the cabinet into the dc receptacle located at the rear of each rectifier see Figures 3 4 and 7 end Securing dc lugs from the busbars to the NT5C05DC DD rectifier in a frame For frame applications use the Emerson Energy Systems number A0361762 terminal lugs supplied with the unit and a no 110 4 0 metric cable Procedure 8 Typical dc cabling of a rectifier without connectors in a frame Step Action 1 Connect he BAT GRD output terminal of the rectifier to the CHG GRD busbar of the power plant Connect the 48 V output terminal of the rectifier to the CHG DISCH BAT busbar of the power plant See Figure 9 2 Apply a torque of 6 5 0 5 ft lbs 8 5 0 5 N m on the bolts securing the lugs to the rectifier terminals end Securing dc lugs from the busbars to the NT5C05DC DD rectifier in a 1000 A cabinet In cabinet applications the de cables
22. TB2 remove the section of the front panel of the rectifier located below the LED display Insert the signal cable through a hole in the side of the rectifier near TB2 2 Make connections from the TB2 terminal block of each rectifier to the remote sense point as shown in Figure 14 for the cable information refer to document MS5C05 Modular Structure 3 For an NT5C05DD type rectifier remove the connections on TB2 2 and TB2 3 before running the connections to an NT5CO5DD type rectifier remove the connections on TB2 for remote sensing without a controller 4 Use different color 20 AWG 105 C wires for RG TB2 2 and RC on TB2 3 5 Use a 1 6 A fuse A0384386 and ferrule type fuse holder A0384387 continued Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 42 Installation Procedure 13 Connecting the rectifier alarm without a controller continued Step Action 6 Do not install the fuse until the float adjustment has been completed as described in Procedure 14 Starting up and adjusting the rectifier end UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 43 4 Functional description 4 1 Overview 4 1 1 Input circuit The input circuit has the following characteristics e ac rectifying e EMI filtering e inrush current limiting to 25 A second e low and high ac inhibit e power fa
23. a oo A mo g0 UPPER e o 4o oo y aeto ooo 600 D oo a e is D 0 o asa HR oso een o a El Eo FRONT VIEW REAR VIEW UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems General information 15 An NT6C40 frame can house up to five 200 A NTSCOSDC DD switch mode rectifiers see Figure 5 Figure 5 View showing five rectifiers NT5C05DC DD in a frame lt a 200 A Rectifiers NT5CO5DC DD I Cf Framework NT6C40 Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 16 General information This page is left blank intentionally UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 17 2 Specifications 2 1 Mechanical and electrical specifications Table 2 Mechanical specifications Height 12 inches 30 48 cm Depth 22 inches 55 88 cm Width 20 5 inches 52 07 cm Weight 120 lbs 54 43 kg Table 3 Electrical specifications Input voltage Nominal 3 phase 208 240 V ac Input current 46 i RMS worst case 33 A RMS nominal at 220 V ac Input protection 50 A ac breaker 1 A fuse Output floating 46 V dc to 56 V dc adjustable to 59 5 V voltage Output equalizing 0 to 4 V dc above the floating voltage voltage The float plus equalize cannot be more than 59
24. acronyms RC Remote charge bus negative RFA Rectifier failure alarm RG Remote ground bus positive RMT ACK Remote acknowledge SEN FAIL Sense fail THSD Thermal shutdown TR Temporary release VCAL Voltage reading calibration UM5C05D P0712975 Standard 9 00 October 2001 Emerson Energy Systems Helios Modular Switch Mode Rectifier 200 48 NT5C05D Installation and User Manual Emerson Energy Systems 2280 Alfred Nobel Blvd St Laurent Quebec Canada H4S 2A4 Manual Number UM5CO05D 169 2081 500 Manual Status Standard Manual Issue 10 00 Release Date February 2002 P0712975 Copyright 2001 2002 Astec International Ltd All Rights Reserved Published in Canada The information contained in this manual is the property of Astec International Ltd and is subject to change without notice Astec International Ltd reserves the right to make changes in design or components as progress in engineering and manufacturing may warrant Except as specifically authorized in writing by the V P of Engineering and Product Manufacturing of Astec International Ltd the holder of this manual shall keep all information contained herein confidential and shall protect same in whole or in part from disclosure and dissemination to all third parties and use the same for start up operation and maintenance purposes only Any modification to the equipment must be approved by the person responsible for product safety and design qualit
25. an unit Step Action Disassembling 1 Remove the front plate located below the display panel and check fuses FF1 and FF2 on the display PCB Replace if necessary If the fuses are not blown and the fans are still not running execute the following steps Put the ac breaker to OFF Unscrew and remove only the two screws securing the fan unit lift it and pull it away from the rectifier unit Note Do not remove all the screws holding the fans together as re assembly would be difficult Disconnect the four power connectors from the fans Note The polarity of the fan cable must be respected Note the orientation of the connectors before removing the fans Place the fan unit flat on a table screen side on the table and fans on top being careful not to damage the connectors Note lf by mistake you have removed the screws holding the fans together reposition the washers between the two fans before re inserting the screws Re assembling 6 Re connect the four power connectors on all the fans of the new module Note The power connection cables to the fans are of different lengths The longer cables must be connected to the two fans located on the left hand side in any order and the shorter cables must be connected to the fans on the right hand side in any order Secure the fan unit in place with the two mounting screws Put the ac breaker to ON
26. are charging as when the rectifier is starting up 4 2 2 11 RFA rectifier failure alarm The rectifier monitors its state of operation and triggers a global alarm RFA upon detecting an internal failure The RFA LED will light up to indicate the following conditions e abnormal or out of range ac input voltage e output fuse failure e system or internal shutdown thermal HVSD TR UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Functional description 47 e internal failure causing a power switching malfunction If the switching malfunction is caused by an improper adjustment of the output float voltage the RFA alarm will not be triggered 4 2 2 12 RMT ACK remote acknowledge It lights up when the rectifier acknowledges commands received from the remote controller 4 2 2 13 SEN FAIL sense fail alarm It lights up if the remote sense leads are not connected or if the RC fuse has blown 4 2 2 14 THSD thermal shutdown It lights up when the rectifier protects itself against overheating by inhibiting its operation for the duration of a high temperature condition The RFA alarm is also triggered 4 2 3 Local and remote adjustments and controls The current and voltage calibration adjustment and control are set by the potentiometers see Table 12 and switches see Table 13 located on the front panel but also by remote signals from the controller see Tables
27. charged before putting the dc breaker to ON in the following situations e For model NT5CO5DB the pre charge of the output capacitors is done automatically when the connector of the dc cable is plugged at the back of the rectifier e For models NT5CO5DC DD the pre charge of the output capacitors is done by executing Step 4 Put the ac circuit breaker of the rectifier being tested to ON The green ac ON LED should light up Put the meter selector switch in the VOLT position The meter will display the voltage value to which the rectifier has been adjusted Connect a digital meter to test points VOUT and VOUT The voltage reading should be within 0 5 of the reading displayed on the rectifier If not calibrate it as described in the Maintenance section Determine the system requirements for float equalize and HVSD limits by referring the User Manual Voltage_level entitled Voltage Level Limits for Power Plants Rectifiers and Controllers 8 If the factory set limits of the rectifier must be verified or changed go to Step 9 otherwise go to Step 19 Adjustin g the high voltage shutdown HVSD 9 Put the dc circuit breaker to OFF 0 10 Turn the HVSD potentiometer fully clockwise CW 11 Turn the FLT potentiometer slowly clockwise to set the output voltage displayed on the display of the rectifier to the required HVSD threshold 12 Turn the HVSD potentiomete
28. ctifier failure alarm RMT ACK Yellow Remote acknowledge SEN FAIL Red Remote sense fail THSD Red Thermal shutdown 4 2 2 1 AC ON ac voltage monitoring The rectifier monitors the input voltage and if the voltage exceeds the specified limit it will inhibit its operation and trigger a rectifier failure alarm RFA The rectifier will resume its normal operation automatically when the specified input voltage has been re established 4 2 2 2 ALCO alarm cut off It lights up when the ALCO switch is set to inhibit the alarm transmission to the controller but the alarms on the rectifier are still activated 4 2 2 3 AUTOST auto restart indicator It lights up if an RFA is caused by a TR signal or by an ac input voltage surge but is not the caused by an internal failure 4 2 2 4 CL current limit indicator It lights up if the rectifier is in current limit The rectifier limits the output current to 210 A 5 A Older rectifiers may have a potentiometer to adjust the current limit from 50 to 105 of the full load rating Extended periods of operation in the current limiting mode and repeated transitions between constant voltage operation and constant current operation have no detrimental effect on the performance and service life Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 46 Functional description of the rectifier The rectifier can start when it is connected to a completely discharg
29. ctor compensation e surge voltage protection e ac breaker for input protection e ac current during the turn on sequence of the rectifier under all input and output conditions specified in this manual will not exceed its full load steady state value 4 1 2 Output circuit The output circuit has the following characteristics e additional EMI filtering e shunt for output de current sensing e 225 A de circuit breaker for output protection 4 1 3 Monitoring and control circuits The monitoring and control circuits have the following characteristics e soft start e rectifier fail alarm RFA e monitoring and control for local and remote equalize EQL Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 44 Functional description 4 2 4 1 4 e temporary release of the rectifier TR e thermal shutdown THSD e input ac monitoring e local and remote high voltage shutdown HVSD e local and remote HVSD reset HVSD e fan failure detection Internal logic power supply The internal logic power supply provides the various voltages required for the logic circuitry and the cooling fan unit Output capacitors The output capacitors will be completely discharged lt 2 V two minutes after the ac power has been removed and the rectifier has been disconnected from the batteries or the parallel rectifiers Description of the front panel 4 2 1 Breakers and fuses 4 2 1
30. ed battery without requiring human intervention or protective operating devices Transitions from constant voltage operation to constant current operation and conversely will occur automatically as determined by the output current The current limit circuit is operational in both the float and equalize modes 4 2 2 5 EQL equalize Indicates the rectifier is in equalizing mode 4 2 2 6 FAN ALM fan failure alarm It lights up when the FAN ALM is activated because all or part of the fan system is defective The fan configuration has built in redundancy to ensure the rectifier will be working properly If only one fan fails a rectifier failure alarm RFA will not be triggered It is however imperative to repair or change the fan unit as soon as possible to preserve the redundant feature 4 2 2 7 Internal HVSD high voltage shut down The rectifier monitors itself for high voltage and will shut down when its output voltage exceeds a preset adjustable value between 52 V to 60 V 4 2 2 8 HVSD TST high voltage shutdown test Switching HVSD TST to ON will allow the remote HVSD signals to be activated without a load connected The HVSD TST LED will light up when this option is selected 4 2 2 9 LOP loss of phase It lights up if any combination of input ac phase failure occurs causing improper operation of the rectifier 4 2 2 10 _ PRECH precharge of the output capacitors It lights up if the output capacitors
31. eeeeeeeneeeeeeenaeeeeeenaeeeeeeaas 49 4 2 6 Current limit adjustment and rectifier regulating test 49 AZT Alam cut uri a ene ee aaA 50 4 2 8 Rectifiers operating in parallel oooconnnnccnnnnnicinnnnnncnnnocncnnnccnnnnnnannnnnnnn 50 4 2 9 HVSD high voltage shut down cocooocconccconoccccccnconcccnonanononananncnnncnnnns 51 4 2 10 TR temporary inhibition and sequential start sseeesseeeeeeeeeeeseees 51 A A ceed rennet 55 5 1 Standards Wicca a 55 5 2 Starting up and adjusting the rectifier oooonoconnininnnnnnnnccnnccnnoranncccnnncnnnnnns 55 6 MalntOn ane ici ads 59 6 1 Replacing the air filters eee eecescceeeeseeceeeeneeeeeeeeeeeeeeeneeeeeeeneeeeeesneaeenenees 59 6 2 Calibrating the digital Meter 0 ccccececeeeeeeeeeeeeeeeeeeeeceeeeeseaeeesaeeeeneeesaees 59 6 3 Replacing the fan UNE e sbean a a a a 60 T Troubleshooting eeseeeeceenseeeeeensneeeeenssneeeeenseeeeeenseeeeeseeseeeeeseseeeeeseseeeseeens 61 8 Appendix A Replacement pattS ssssssssuunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnn 63 Appendix B Technical service assistance ooocncnnnnnnconoconenennnananaancnnnnnos 65 9 1 Local toll free prefixes ropan iia een ianiai ean KENEEN AEAEE 65 9 2 Toll free technical assistance NUMbEIS ooooccnnncccnnnoccccnononnnnnanancnn cnn nnnnnnnnn 66 10 Abbreviations and aCronyMS ssssssssuunnennnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn na 67 List of Figur
32. end UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 61 7 Troubleshooting Before servicing the rectifier make sure the wires for the control and monitoring signals from the controller or the alarm reporting circuit are properly connected The signals described in Tables 8 9 and 14 are extended from the rectifier to the controller or to the alarm reporting circuit Table 17 Diagnosing system faults Fault symptom Possible causes The RFA LED is lit e no ac input or the input is out of bounds ac ON LED is not lit e the ac input dc output circuit breakers are open or the output fuse is blown older models e the rectifier has received an HVSD signal from the controller or a TR signal is present e an internal high voltage shutdown HVSD condition has occurred e the slow start fuse has blown e the dc circuit breaker is open e athermal shutdown has occurred excessive ambient air temperature air inlet or outlet is blocked or the air filter is clogged e arectifier is in Start Time Delay mode and the RFA will cease when the preset time delay has elapsed e adefective rectifier continued Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 62 Troubleshooting Table 17 Diagnosing system faults Fault symptom Possible causes The HVSD LED is lit the internal high voltage shutdown point i
33. endix B Technical service assistance 9 2 Toll free technical assistance numbers United States 1 800 992 8417 Canada 1 800 363 2288 In Asia and the Pacific Australia 800 213 49156 Hong Kong 800 213 49156 Japan 800 213 49156 Malaysia 800 213 49156 New Zealand 800 213 49156 Philippines 1 800 1 110 0131 Singapore 800 213 49156 South Korea 800 213 49156 Taiwan 800 213 49156 EA SA In the Caribbean and Latin America In the Middle East CALA Dominican 1 888 7514232 Republic Jamaica 1 800 850 1755 S Mexico 001 800 514 2288 Puerto Rico 1 888 680 2288 Trinidad amp 1 800 363 2288 Tobago The United Kingdom includes England Guernsey the Isle of Man Jersey Northern Ireland and Scotland Note For countries not covered by a toll free service dial Canada country code 001 at 514 832 0201 UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 67 10 Abbreviations and acronyms ALCO ALM AUTOST C CL EMI EQL FAN ALM HVSD HVSDR LED LOP MPR NC NO PCB Alarm cut off Alarm Auto restart Indicator Common Current limit indicator Electromagnetic interference Equalize Fan alarm High voltage shutdown High voltage shutdown reset Light Emitting Diode Loss of phase Modular power rectifier Normally closed Normally open Printed circuit board Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 68 Abbreviations and
34. er with a DB25 connector 35 Procedure 12 Connecting alarms on TB2 cceccceeeeeeeeeceeeeeseeeeeaeeeeeeseeeeees 37 Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 10 Contents Procedure 13 Connecting the rectifier alarm without a controller 41 Procedure 14 Starting up and adjusting the rectifier ooocococccccnnccinnnnnnncccnacccnns 55 Procedure 15 Calibrating the digital meter of the rectifier eeeeeeeeeeeeeeeeeeee 59 Procedure 16 Replacing the fan unit o ncccnnnnnccnnnnncccnnnnoccconnorcccnnnrrc cnn ronca 60 UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 11 1 General information 1 1 Purpose and applications of this manual This manual describes how to install operate and maintain the 200 A Helios Modular Switch Mode Rectifiers NTSCO5BD DC DD It contains information on all applications of these rectifiers designed to operate continuously in a 48 V power system equipped with or without batteries These rectifiers can be part of a small embedded system or a larger general power plant configuration The rectifiers will operate with Emerson Energy Systems rectifiers and can be used with the products of other manufacturers They are designed to interface with conventional controllers Figure 1 Front view of the NT5C05DB DC DD modular switch mode rectifiers
35. es Figure 1 Front view of the NT5C05DB DC DD modular switch mode rectifier Sara eea a aa Ea aa saws Sk sien Sas ANMA OE 11 Figure 2 Rear view of the rectifiers not equipped with connectors GNT5CO5DG ADD J e asana aa a EE TE 12 Figure 3 Rear view of the rectifier equipped with connectors CNTSCOSDB tre ci drid 13 Figure 4 View showing five NT5CO5DB rectifiers in a 1000 A cabinet 14 Figure 5 View showing five rectifiers NT5CO5DC DD ina frame 15 Figure 6 The ac and dc hard wired to the NT5C05DC DD rectifiers in a TODO A cablMeta oc Aa ae 22 Figure 7 The ac and dc connectors inserted in a NT5CO5DB rectifier in a O O cceecterer ctr rerecer rrr errr cer er 23 UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Contents 9 Figure 8 The ac and dc hard wired to NT5CO5DC DD rectifiers in a 1200A cabiletai ninia ies 23 Figure 9 AC connections to the NT5C05DC DD rectifiers without CONOCIO iii dd Ad dadas 30 Figure 10 AC connections to a cabinet for rectifiers with connectors 32 Figure 11 Connecting the dc to the busbars with a shunt on the battery side or a shunt on the ground SidE oooonccccnnnncccccnnoccccnnnonannnnonnancnnnnos 33 Figure 12 Connecting the NT5CO5DC DD rectifiers to a conventional controller ico ini way ta viandeden lt acaveestasteaneheers 38 Figure 13 Connecting the NT5C05DC DD rectifiers to a front access Con
36. fier permanently An ac breaker reset or an HVSDR signal can be used to restart the rectifier 4 2 9 3 HVSD test switch The rectifier can be shut down by an external remote HVSD signal from the controller only if it is delivering more than 20 A This makes it difficult to test the high voltage shutdown sequence on a single rectifier when it is isolated from a load the output fuse has been removed Selecting the HVSD TST will allow the remote HVSD signal to be activated even under a no load condition The HVSD TST LED will light up when this option is selected 4 2 9 4 Local and remote HVSD reset The rectifier may be reset from an HVSD condition locally by toggling the ac circuit breaker to OFF then to ON or by toggling the associated ac breaker in the distribution panel A remote ground signal sent to the HVSDR input by the controller will restart the rectifier provided the TR lead has not been activated 4 2 10 TR temporary inhibition and sequential start 4 2 10 1 Sequential start The TR input of the rectifier can be interfaced to an external sequential start circuit 4 2 10 2 Remote ON OFF control TR When a ground signal is applied to the Temporary Release TR input the rectifier inhibits its operation and activates the RFA When the remote ground signal is discontinued the rectifier returns to normal operation Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 52 Functional description
37. he controller TB2 7 RFA NO Rectifier failure NO TB2 8 CURRENT SHARE Forced current share TB2 9 FAN ALM NC Fan alarm NC TB2 10 RFA C Rectifier failure alarm TB2 11 FAN ALM NO Fan alarm NO TB2 12 SH Output current shunt voltage TB2 13 SH Output current shunt voltage TB2 14 FAN ALM C Fan alarm common contact TB2 15 RFA NC Rectifier failure alarm NC TB2 16 REF GRD Battery and control reference ground Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 38 Installation Figure 12 Connecting the NT5C05DC DD rectifiers to a conventional controller RECTIFIER L1 O L2 O L3 TB2 EOL O RG RC TR FR GRD i 2 3 4 HVSDR 5 O 6 7 8 9 Ron HVSD RFA NO CURRENT SHARE FAN ALM NC 9 C RFA C 10 FAN ALM NO 11 O SH 12 O SH 13 0 FAN ALM C 14 O RFA NC 15 y 7 REF GRD 16 T l CABLE ASSEMBLY SEE NOTES 3 AND 4 6 20 AWG WIRE SEE NOTE 5 5 Note 1 For RFA and FAN ALM signals NC and NO indicate the state Note 2 Note 3 Note 4 Note 5 of the C Form contacts when an alarm is present Connect the REF GND pin TB2 16 the FAN ALM C pin TB2 14 and the REA C pin TB2 10 together using 22 AWG wire to extend battery ground as a failure alarm Other signals besides the ones used for conventional and f
38. he ac and dc breakers are OFF Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 28 Installation Procedure 2 Installing the rectifiers in a cabinet Step Action 1 Loosen and remove the screws securing the brackets to the sides of the rectifier Reposition and secure the mounting brackets over the holes located nearest the front of the rectifier with the screws removed in Step 1 Remove the blank panel from the position the rectifier will be installed in the cabinet Put the bottom of the rectifier in the L shaped guides in the cabinet and slide it into the cabinet until the mounting brackets make contact with the frame of the cabinet Align the mounting holes in the brackets of the rectifier with the mounting holes in the frame Secure the rectifier by installing and tightening the eight mounting screws provided for this purpose Note Install an external tooth lock washer on the bottom screw of the right mounting bracket to ensure proper grounding continuity between the rectifier and the frame of the cabinet end 3 4 Cabling and connecting the rectifiers The ac cables of the rectifier must always exit each rectifier from the right side when viewed from the rear see Figure 2 The dc cables of the rectifier must always exit each rectifier from the left side when viewed from the rear The system alarm interface cable must always exit each rectifier fr
39. he cabinet for the five rectifier positions The ac and dc connections are located at the rear of the cabinet and the alarm connections are located at the front of the cabinet UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems General information 13 Figure 3 Rear view of the rectifier equipped with connectors NT5C05DB Ji Ol ge ng gr di o Q a T a A O zA As a daa nid o a B ou D Bao 088 2 g Bo ATTENTION CAUTION x o o o O Table 1 contains a list of the connector types and indicates the connections between each rectifier and the cabinet The lowest position in the cabinet is position 1 and the uppermost is position 5 You must connect the female connectors J1 J2 and J3 to the correspondent male connectors P1 P2 and B3 0 eee AAA ooo one o Sn 08 ono 0 o O J1 1 to P1 1 J2 1 to P2 1 J3 1 to P3 1 Table 1 Connections between the rectifier and the 1000 A cabinet Connector Type Rectifier Connector Cabinet Connector AC connector J1 P1 DC connector J2 P2 Alarm connector J3 P3 Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 14 General information Figure 4 View showing five NT5CO5DB rectifiers in a 1000 A cabinet O oT s 020 dorloriobiobior o o9 Ss RIERS 8 gt 3 gt lol lol lol lo o ro o o r 7 7 al o 305 o o
40. in the following temperature range 32 F to 122 F 0 C to 50 C Transportation During transportation the rectifier can be subjected to conditions the following conditions without sustaining damage 67 F 55 for 16 hours 140 F 60 C dry heat Storage conditions For storage the rectifier must not be kept in an environment not exceeding the following temperatures 58 F 50 C for 16 hours 140 F 60 C dry heat The rectifier contains aluminum electrolytic capacitors that have a shelf life of five years or greater at the maximum rated storage temperature Note For detailed specifications contact your local Emerson Energy Systems representative UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Specifications 19 2 3 Mechanical and electrical specifications of the 1000 A cabinet Table 6 Mechanical specifications of the 1000 A cabinet Height 84 inches 213 36 cm Depth 30 inches 76 2 cm Width 27 inches 68 58 cm Table 7 Electrical specifications of the 1000 A cabinet Input voltage 208 240 V ac 3 phases Output voltage 46 V dc to 58 V de Output current 1000A Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 20 Specifications This page is left blank intentionally UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 21 3
41. merson Energy Systems Rectifier 200 48 NT5C05D User Manual 40 Installation 3 6 3 Cabling alarms and control signals in the cabinet The interface board NT6C43PA located at the top front of the cabinet acts as an interface between any of the five rectifier positions and the control or monitoring systems of the power plant The interconnections are described in Table 10 The interface cables from the rectifier and interface board are part of the cabinet wiring factory assembled Table 10 Interconnection designations on the NT6C43PA interface board From Rectifier J6 J10 To Power Plant To monitor J11 see see Note 1 Controller J1 J5 Note 2 1 EQL 1 EQL 1 SH Rect 1 2 RG 2 RG 2 SH Rect 1 2 RC 2 RC 2 SH Rect 2 4 FAN ALM NC 4 FAN ALM NC 4 SH Rect 2 5 HVSDR 5 HVSDR 5 SH Rect 3 6 HVSD 6 HVSD 6 SH Rect 3 7 RFA NC 7 RFA NC 7 SH Rect 4 8 TR 8 TR 8 SH Rect 4 9 SH 9 SH Rect 5 10 SH 10 SH Rect 5 11 CURRENT SHARE 11 NC see Note 3 12 NC 12 NC Note 1 Refer to document MS5C05 Modular Structure for the part number of the cable Choose the proper wire according to the controller conventional or front access and the proper cable length required between the shelf and the power plant controller Note 2 The shunt signal is 1 mV and corresponds to 5 A Note 3 On the interface board co
42. nd alarMS ooooonnncnncccninncnnnncnnnocnnancccnnnncnanrnnnnnnnnnncccns 35 3 6 1 Connecting alarms and controls on J3 oooocccnnnccccnnnoccncnononcnnncnnnnnnnnnnnn 35 3 6 2 Connecting alarms and controls on TB2 eeeeeeeeeeeereerrerrresnresesasaa 36 3 6 3 Cabling alarms and control signals in the cabinet oonnnnninnninnn on 40 3 6 4 Connecting the float share without a Controller 0 ccscceeesseeeeeees 41 Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 8 Contents 4 Functional description cccceseseeeceseeeee eee seeeeeenseeneeensneeeeeeeseeeenenseeeeenens 43 4 1 OVervie w EE E A 43 451 4 INnpulclrcUlla cai 43 41 25 OUTPUT CIRCUIT in A ainda 43 4 1 3 Monitoring and control circuits ooononccnnnnniccnnnnccncnnnocnncnanannnnnnncnnn nn 43 4 1 4 Internal logic power supply cccoooccccconoccccnonoccnnnnnoncncnanononn nano ncnnnnannnnnnnns 44 4 1 5 Output CapacitOrS ci da 44 4 2 Description of the front panel ococconoccccnonoccccnonoccccnonancncnnnncccnnna cnc cnnnancccnnns 44 4 2 1 Breakers and JUSS ssiri irridet kiai dr dedide adinik rdar 44 4 2 2 Description of the LEDs on the front panel 45 4 2 3 Local and remote adjustments and Controls 0 ccceeeeeeeeeeeeeeeenees 47 4 2 4 Voltage current display test and measurement sseeeeeeeeeeeseeees 48 4 2 5 Float and equalize voltage control eeeeceee
43. nnection 11 is used for forced current sharing between compatible rectifiers Terminal El is provided for extending the current share line 20 AWG supporting up to 105 C to the other rectifiers The current share lines must be connected together to achieve forced load sharing UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 41 3 6 4 Connecting the float share without a controller Provision is made to extend sensing leads RG and RC to the battery or to the CHG DISCH busbar operation without batteries of the power plant Opening either sensing lead will not adversely affect the rectifier output voltage and the rectifier will default into internal sensing mode When a controller is not available the current share between rectifiers in SLOPE or FORCE mode is still available The regulation signal cables RC and RG that were connected to the desired remote sensing location must now be connected to the batteries see Figure 14 Figure 14 Connecting signal wires RC RG without a controller RC FUSE 1 6 AMP 20 AWG WIRE RC A 20 AWG WIRE RG 87654321 87654321 87654321 TB2 TB2 TB2 87654321 TB2 RECT 1 RECT 2 RECT 3 RECT 4 BATTERY OR DESIRED POINT Procedure 13 Connecting the rectifier alarm without a controller Step Action 1 To gain access to rectifier signal terminal block
44. nstalling the rectifiers 3 3 1 Installing in a frame Whenever possible use a manual forklift to install the rectifiers in a frame If a forklift is not available two people can lift the unit in place but they must exercise care in order to not injure themselves as the rectifier is heavy Procedure 1 Installing the rectifiers in a frame Step Action 1 Note Install each rectifier beginning with the lowest mounting position in the frame Align the mounting brackets of the rectifier with the mounting holes in the frame and insert the locating pins Align the middle holes in the mounting brackets with the locating pins and slide it into position onto the locating pins Secure the rectifier to the frame by inserting and tightening at least two mounting screws provided in the uppermost holes of each mounting bracket one in the left mounting bracket and one in the right mounting bracket Remove the locating pins and install the other six screws Note Tighten the screws applying a torque of 6 5 0 5 ft lbs 8 5 0 5 N m end 3 3 2 Installing in a cabinet Make sure the cabinet has been secured to the floor with the installation kit provided To mount a rectifier in a 1000 A cabinet the mounting brackets must be removed and be repositioned WARNING Protecting the equipment against electrical damage Before installing the rectifiers in the 1000 A cabinet make that t
45. nsulating material from the ends of the wires With a flat blade screwdriver remove one round knockout located at the top of the junction box and in the hole install the strain relief connector for the ac cable Insert the ac three phase cable in the elbow strain relief Use a flat blade screwdriver to tighten the strain relief connector Connect the ground bare or green wire and three phases L1 L2 L3 inside the junction box Repeat steps 2 to 10 for each rectifier Reinstall the cover of the junction box en Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 32 Installation Procedure 6 describes how to connect the ac to rectifiers equipped with connectors in a cabinet The ac cable is terminated with a Hubbell 50A twist lock female connector see Figure 10 The plug of the flex ac cord from the junction box is connected to the ac receptacle located at the rear of each NTS5COSDB rectifier equipped with connectors see Figures 3 and 7 Procedure 6 Connecting the ac to a rectifier with a connector in a 1000 A cabinet Step Action 1 Verify that the rectifier is securely installed in the cabinet 2 Position the female connector with the exposed chassis ground band on top and insert it into the rectifier 3 Push the male connector firmly into the female receptacle on the rectifier and lock it into position by turning it clockwise end Figure 10 AC connecti
46. occcccanonnncnnno 52 Table 16 Standard settings for the rectifier oooonnoccccnnnccccconoccccononnncnanannnnnnn 55 Table 17 Diagnosing system faultS oooocoonnccccnonocccccononcccnanancncnnnanoncnna cnc cnnnancncnnns 61 List of Procedures Procedure 1 Installing the rectifiers in a frame eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeees 27 Procedure 2 Installing the rectifiers in a Cabinet oooooonnnninnccnnnnnnnnncocccccncnnnnnnos 28 Procedure 3 Cabling ac to the rectifiers cccccccecsesecesseeeeeesseeeeesseseeeeseneaees 29 Procedure 4 Running an additional ac ground to the rectifier 30 Procedure 5 Running the ac to a Cabinet cccccceeeeeceeeceeeeeeeeeeeeneeeeeeeeeteees 31 Procedure 6 Connecting the ac to a rectifier with a connector in a 1000 A Cabinet sis 2idat eet aets ahve A svae agh og aiad 32 Procedure 7 Connecting the dc between the 1000 A cabinet and the rectifier equipped with CONNECHOSMS 0 cccececeseeeeceeceeeeeeeeeeneeaeeeeeeeeeeseaees 34 Procedure 8 Typical dc cabling of a rectifier without connectors in a frame 34 Procedure 9 Connecting the dc output terminals of a rectifier without connectors in the 1000 A Cabinet c ccceceeeeeeeeeeeeeeeeeeeeetees 34 Procedure 10 Connecting the dc output terminals of a rectifier without connectors in a 1200 A cabinet application eee 35 Procedure 11 Connecting alarms to the rectifi
47. om the right side when viewed from the front 3 4 1 Cabling ac to rectifiers NT5CO5DC DD without connectors The ac supply of each NTSCOSDC DD rectifier is hard wired as shown in Figures 6 7 and 9 and as described in Procedure 3 WARNING Protecting the equipment against electrical damage Before connecting the rectifier to the ac service make sure that the line voltage is OFF and that the ac and de circuit breakers of the rectifier are in the OFF position UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 29 Procedure 3 Cabling ac to the rectifiers On the front panel of the rectifier put the ac and dc circuit breakers to O OFF Install the required circuit breaker in the ac service panel and lock it in the open OFF position Cut the ac cable to the required length or the individual wires in the ac conduit and run it from the ac service panel to the rectifier Strip the insulation material from the ends of the cable to expose the wires Using a flat blade screwdriver remove the ac cover from the rear of the rectifier see Figure 9 If not already done install a strain relief elbow connector at the rear of the rectifier Insert the ac three phase cable in the elbow strain relief guide located on the back of the rectifier Tighten the strain relief elbow connector with a flat blade screwdriver Connect the green earth ground terminal in the GRD position
48. ons to a cabinet for rectifiers with connectors Teck cables or flexible conduits installed in the strain relief Junction box shown with cover removed L1 L2 L3 NA fy PE O RECT 1 RECT 2 RECT 3 RECT 4 RECT 5 Factory installed connector equipped ac cords for each rectifier UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 33 3 5 Connecting the dc output terminals of the rectifier to the busbars The dc outputs of the rectifier are connected to the busbars as illustrated in Figure 11 There are two possible options e BAT GRD of the rectifier connected to the CHG DISCH GRD busbar and 48 V of the rectifier connected to the CHG BAT busbar e BAT GRD of the rectifier connected to the CHG GRD busbar and 48V of the rectifier connected to the CHG DISCH BAT busbar Figure 11 Connecting the dc to the busbars with a shunt on the battery side or a shunt on the ground side CHG DISCH GRD BUSBAR LOAD uile BAT GRD RECTIFIER 48y i CHG BAT DISCHARGE SHUNT BUSBAR BAT BUSBAR ends PANEL SHUNT ON THE BATTERY SIDE CHG GRD DISCHARGE BUSBAR SHUNT GRD BUSBAR TL BAT GRD RECTIFIER 48V LOAD CHG DISCH BA
49. r counterclockwise CCW until the rectifier shuts down 13 Turn the FLT potentiometer counterclockwise two turns and open the ac breaker 14 Wait a few seconds for the rectifier to be OFF and put the ac breaker to ON close to reset the rectifier continued UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Operation 57 Procedure 14 Starting up the rectifier continued Step Action Adjusting the float voltage FLOAT 15 Ensure that the EQL FLT switch is in the FLT position 16 To adjust the float voltage to the recommended level turn the FLT potentiometer clockwise to increase the voltage or counterclockwise to decrease it Adjusting the equalize voltage EQL 17 Set the EQL FLT switch to EQL Turn the EQL potentiometer clockwise to increase the voltage or counterclockwise to decrease it 18 Put the FLOAT EQL switch in the FLOAT position Adjusting the current share Note Forced sharing FS and slope SLS sharing can be achieved with or without a controller If no controller is used refer to the Connecting the float share without a controller section 19 Select the load sharing mode by using the SW5 switch located near the slope mode green LED D35 on control card NT5CO5PR Refer to the Rectifiers operating in Parallel section for details To access this switch remove the f
50. ront access type controllers are available at TB2 Refer to document MS5C05 Modular Structure for the part number of the cable assembly required between the controller and rectifier The part numbers differ depending on the length of the cable and the type of controller The cable assembly consists of an 8 pin connector pin 8 no connection with a different wire color for each pin Insert the free end of the appropriate wire color into terminal TB2 as shown in Figure 12 conventional type controller or in Figure 13 front access type controller The CURRENT SHARE line is available at TB2 8 for each NTSCOSDC DD rectifier These must be connected together for forced load sharing The recommended wire used to connect the CURRENT SHARE lines between all the system rectifiers is 20 AWG 105 C UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 39 Figure 13 Connecting the NT5C05DC DD rectifiers to a front access controller z L1 L2 TOAC L3 SERVICE PANEL GRD RECTIFIER TB1 L1 L2 L3 EQL FR GRD RG RC TR HVSDR HVSD RFA NO CURRENT SHARE FAN ALM NC RFA C FAN ALM NO 11 SH 12 SH 13 FAN ALM C 14 RFA NC 15 REF GRD 16 oO DOAN DOA amp WO PD TB2 k o ao ow NY 20 AWG WIRE SEE NOTE 5 y 4 7 CABLE ASSEMBLY SEE NOTE 3 E
51. ront display panel The share mode is normally set when the unit is first installed The rectifier is factory set to the slope sharing mode Put switch SW5 in the lower position for the slope sharing mode The slope mode LED D35 will light up 20 If the slope share mode is chosen verify that the rectifier is displaying the required system float value Adjust it with the FLT potentiometer A 300 mV float voltage drop is from 0 to full current 21 Insert the RC fuse of the controller For systems without a controller install the RC fuse in the in line fuse holder see Figure 14 22 Put the dc circuit breaker located on the front of the rectifier to ON continued Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 58 Operation Procedure 14 Starting up the rectifier continued Step Action 23 The rectifier is now connected to the system and should carry some current If it is connected in parallel with other rectifiers verify that the total system current is shared equally amongst the rectifiers Put the switch of each rectifier to the AMP position Find the mean current of the rectifiers by adding all the currents measured on each rectifier and dividing the total current by the number of rectifiers I h 12 13 In n n Set the current from each rectifier to this mean value If the current reading of one of the rectifiers is too low or is 0
52. s set too low below the float or equalize setting excessive impedance in one or both sense leads a remote HVSD was issued from the controller the dc circuit breaker is open but the rectifier is in remote sense The AC ON LED is not lit no ac input voltage the input circuit breaker is open the ac voltage is present but is out of operational limits the unit will restart when the ac returns within operational limits the ac has just been applied and the rectifier will momentarily start after an inrush control delay The FAN ALM LED is lit one or both fan fuses have blown one or both fans have failed Note lf a single fan fails or a fuse blows the rectifier will continue to operate while triggering a local and remote FAN ALM The SEN FAIL LED is lit One or both remote sense lead s is are disconnected The CL LED is lit the output load requirement exceeds the total capacity of the rectifier with paralleled rectifiers the float or equalize is maladjusted causing one or more rectifiers to carry the load the unit is in equalize mode and paralleled units are not the remote sense leads have excessive impedance on one or more rectifiers the system batteries are in recharge mode after an ac outage the current sharing mode selection is not the same for all units the forced share line is disconnected in FLS only end UM5C05D P0712975 Standard 10 00
53. the units will share the load within 10 of their maximum output rating 4 2 8 2 Forced sharing When switch SWS is set in the upper position the D35 LED is OFF forced load sharing is achieved by an internal control circuit modifying the loop reference to equally share the output currents between rectifiers For this to occur the rectifiers must communicate their operating current to other rectifiers in the same power plant This is done by interconnecting the CURRENT SHARE extended on El of the NT6C43PA circuit board or TB2 8 of all the rectifiers set in the forced share mode In this mode the rectifiers will share the load within 2 of their maximum output rating UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Functional description 51 4 2 9 HVSD high voltage shut down 4 2 9 1 HVSD ADJ high voltage shutdown adjust potentiometer This potentiometer sets the internal threshold level at which the local high voltage shutdown condition should occur 4 2 9 2 Remote HVSD In addition to the local high voltage shutdown feature the power plant controller can shut down any rectifier by sending a high voltage shutdown signal ground BAT RTN pulse The rectifier will shut down within 50 ms if it is supplying more than 10 of its full load rating As is the case for the internal high voltage shutdown condition two HVSD events must occur within an interval of two minutes to lock out the recti
54. troller a Ra 39 Figure 14 Connecting signal wires RC RG without a controller 41 List of Tables Table 1 Connections between the rectifier and the 1000 A cabinet 13 Table 2 Mechanical Specifications ooooonnncccnonnccccnnnoccccnnonnccnnnancnc nan ncccnnnancccnns 17 Table 3 Electrical specifications snoren aea nc 17 Table 4 Operation specifications of the rectifier oooooocconncccconoccccnanoncccnanannncnno 18 Table 5 Ambient conditions required for the rectifier o ooconnnncnnnnnicnnnnnnaccco 18 Table 6 Mechanical specifications of the 1000 A CabiNet oooooonnnccccnnnnnnnccoccccco 19 Table 7 Electrical specifications of the 1000 A cabine t eeeeeeeeeeeeeeeeeeeeee 19 Table 8 Control and alarm signals on J3 c cccecceceeeceeseceeeeeceeeeesaeeesaeeteeeeetaas 36 Table 9 Signals on terminal block TB2 oooooccoonoccccnonoccncnanoncncnanoncnccnonnncnanonnncnns 37 Table 10 Interconnection designations on the NT6C43PA interface board 40 Table 11 Designation of the LEDs on the front panel ooooocccconnoccccnonoccccnananccccnn 45 Table 12 Designation of the adjustment potentiometers on the front panel 47 Table 13 Designation of the switches on the front panel 48 Table 14 Rectifier and controller interface CONNEectiONS oooocnnnnccccnnnnnnnnccanncon 48 Table 15 Setting the start up delay of the rectifiers ooonnoocconnnccccon
55. uman intervention or operating protective devices The current limiting circuit is functional in float and equalize modes Emerson Energy Systems Rectifier 200 48 NT5C05D User Manual 50 Functional description 4 2 7 Alarm cut off 4 2 7 1 ALCO ON alarm cut off switch The ALCO switch is set to inhibit the transmission of alarms from terminal block TB2 to the controller when there is a rectifier failure alarm RFA or a fan alarm FAN ALM The LED ALCO lights up when this switch is ON 4 2 8 Rectifiers operating in parallel The rectifier is capable of operating in parallel with other rectifiers having similar output characteristics It shares the total load in proportion to its output rating Two methods for sharing load current are available e Slope sharing e Forced sharing Selecting either mode is done by setting switch SW5 located near LED D35 on control card NTSCOSPR To access this switch remove the front display panel The sharing mode is normally set during initial installation The rectifier is factory set to slope sharing mode 4 2 8 1 Slope sharing When switch SWS is set in the lower position conventional load sharing is achieved through a 300 mV slope on the output voltage of the rectifier from no load to full load The slope mode LED indicator D35 will light up This mode should be used when rectifiers from different vendors are not all equipped with the forced load sharing feature In this mode
56. ure alarm center 19 SH Shunt 20 FAN NO Fan failure normally open 21 BAT RTN Battery ground or return 22 SENSE NC Sense fail alarm NC 23 NC No connection 24 PRESENT 1 25 NC No connection Note The signals listed above are accessible through J3 a DB25 connector mounted at the lower right side of the rectifier when the rectifier is viewed from the front 3 6 2 Connecting alarms and controls on TB2 Follow Procedure 12 to access terminal block TB2 Then connect the alarm wires as described in Figure 12 for the conventional controller and as in Figure 13 for the front access controller UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Installation 37 Procedure 12 Connecting alarms on TB2 Step Action 1 To access terminal block TB2 remove the section of the front panel located below the LED display 2 Insert the signal cable into the rectifier through the hole located on the right side of the rectifier and run the connector to TB2 on the left side end Table 9 Signals on terminal block TB2 Connection Signal Description TB2 1 EQL Equalize signal from the controller TB2 2 RG Remote sense TB2 3 RC Remote sense TB2 4 TR Temporary release from the controller TB2 5 HVSDR High voltage shutdown reset signal from the controller TB2 6 HVSD High voltage shutdown signal from t
57. urn to the normal float mode end UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems 59 6 Maintenance 6 1 Replacing the air filter In a dusty environment the use of air filters is strongly recommended They should be replaced at least once a year 6 2 Calibrating the digital meter Procedure 15 Calibrating the digital meter of the rectifier Step Action 1 Put the VOLT AMP switch located on the front panel to AMP While the rectifier is delivering current of approximately 100 A measure the voltage between TB2 13 and TB2 12 with a multimeter Convert this voltage to a current value 50 mV corresponds to 250A current 250A voltage 50 mV If the voltage measured is 20 2 mV measured current 250 A X 20 2 mV 101 A 50 mV Turn the CUR CAL potentiometer located on the display panel until this value 101 A is displayed on the rectifier Put the VOLT AMP switch to VOLT and measure the output voltage on the test jacks VOUT VOUT located on the front panel Turn the VOLT CAL pot until the measured value is displayed on the rectifier end Note The accuracy of the meter is 1 full scale for current and 0 5 for voltage measurement Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 60 Maintenance 6 3 Replacing the fan unit Procedure 16 Replacing the f
58. y 1997 Standard Issue 8 00 to revise information on signal Cable Connector J3 October 1995 Standard Issue 7 00 to revise the Specification section BAT ALM and precharge switch August 1995 Standard Issue 6 00 to revise information on Specification and Installation procedures January 1995 Standard Issue 5 00 to include the breaker feature and connectorization of ac and output dc July 1994 Standard Release 4 00 April 30 1993 Standard Release 3 00 May 29 1992 Standard Release 2 00 Emerson Energy Systems Rectifier 200 48 NT5C05D Installation and User Manual 6 Publication history May 29 1991 Standard Release 1 00 UM5C05D P0712975 Standard 10 00 February 2002 Emerson Energy Systems Contents 1 General information 0i 22 22502028 sched fecSaced ici acacia dica 11 1 1 Purpose and applications of this Manual eect eeeeeeeeeeeeeeeeeeeeeees 11 1 2 Helios 200 A rectifier models and mounting configurations o c 12 1 2 1 Rectifiers not equipped with connectors NT5C05DC DD 12 1 2 2 Rectifier equipped with ac dc and signals connectors AM O 12 2 SPOCHICAtiONS iii naaa 17 2 1 Mechanical and electrical specifications ooonnnncccnnnnnicionncccnnnonnccnanacncnnnn 17 2 2 Operation specifications and ambient conditionS eeeeeeeeeeeeeseeeseennee 18 2 3 Mechanical and electrical specifications of the 1000 A cabinet 19
59. y at Astec International Ltd to ensure that the equipment complies with the operation standards This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with Installation and User Manuals may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his expense Candeo is a trademark of Astec International Ltd The Emerson logo is a trademark and service mark of Emerson Electric Co Emerson Energy Systems EM ERSON a part of Emerson Network Power
60. y the EQL potentiometer e When the FLOAT EQL switch is held in the FLT position the rectifier delivers a float voltage set by the FLT potentiometer 4 2 5 2 Remote equalize control EQL The rectifier is equipped with remote equalize control This control is activated by a remote ground signal BAT RTN The rectifier returns to normal Float voltage operation upon removal of the signal 4 2 6 Current limit adjustment and rectifier regulating test 4 2 6 1 RECT TST rectifier test This switch is toggled briefly to verify that the unit is actually regulating When it is not in its center position the output voltage should either drop or rise by less than 2 if the output is isolated from other units or batteries If the rectifier is connected to other rectifiers or to a battery toggling this switch will either bring the output current to zero or into current limit indicating that the rectifier is regulated properly 4 2 6 2 CL ADJ potentiometer The rectifier limits the output current to a value ranging from 100 A to 210 A set by the CL ADJ potentiometer The factory adjustment is 205 A 5 A Extended periods of operation in the current limiting mode and repeated transitions between constant voltage operation and constant current operation have no detrimental effect on the performance or life of the rectifier The rectifier is capable of starting when it is connected across a completely discharged battery without requiring h

Helios Modular Switch Mode Rectifier 200/48

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