R48-2000e3 Rectifier User Manual
Contents
1. Rectifier Module Indicators Indicator Normal State Alarm State Alarm Cause or input voltage Power oo Noi input fuse open Green Flashin The rectifier module is being g identified by the Controller AC input under over voltage PFC output under over voltage High temperature Moderate load sharing imbalance Rectifier modules are operating in an output power derating mode Welle rectifiers derate nea module temperature rises above or input voltage falls below acceptable values Loss of communication with the Flashing Controller the rectifier can provide power Severe load sharing imbalance Rectifier module output disabled for On any reason including overvoltage shutdown and internal output fuse Off open Rectifier addresses contradictory Flashing Pe fan rectifier module shuts Spec No 1R482000E3 9 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 gil Installing Rectifiers Figure 6 Installing Rectifier Module Rectifier modules can be inserted or removed with power applied hot swappable Note Each rectifier module locks into a module mounting shelf by means of a latch located on the bottom of the module The latch and rectifier module handle are interactive Pushing the handle up into the module s front panel causes the latch to extend to the locking position pulling the handle down out from t2. o os wwo anso oss s Note System output is initially adjusted to 54 48 volts DC as measured at the system sense point at 50 of full load and nominal input Percent of Full Load refers to percent of 34 5 amperes Table4 Maximum Input Current in 60Hz Input Nominal Input Voltage Input Current Input Voltage Amper s Note At 100 of full load with output adjusted to 58 volts DC as measured at the shelf output terminals Spec No 1R482000E3 4 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 eae e Efficiency Curve Refer to Figure 4 Figure 4 Efficiency Curve Efficiency Curve 98 96 94 92 90 88 86 84 Efficiency 0 10 20 30 40 50 60 70 80 90 100 Load of rated load Environmental Ratings does not exceed the Operating Ambient Temperature R tat e Operating Ambient Temperature Range algerie a anove e Single Rectifier Audible Noise At 25 C lt 50dB A with fan a 55 C 131 F to 80 C 176 F with derating in high speed Measurement made at 0 6m distance in ones front of rectifier and at same horizontal line of the middle b 40 C 40 F to 55 C 131 F with full power of rectifier performance e High Voltage Category e Temperature Coefficient 0 02 per degrees Celsius Power Distribution System TN TT IT Seiad API NE Tempe a
3. 300 386 FCC CFR 47 Part 15 class B equipment Telcordia GR 1089 CORE e Ventilation Requirements The rectifiers are fan cooled e EMI Load Range 10 100 and utilize front to back forced ventilation A rectifier must be mounted so ventilating openings are not blocked and temperature of the air entering the rectifier e GR 3108 Class 2 Compliant e Safety IEC 60950 EN 60950 UL 60950 Spec No 1R482000E3 5 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 Ss EMERSON Nlatiuninr Daiarc Net WOI k P owel Standard Features Type of Power Conversion Circuit High frequency Constant Voltage Mode For any initial output voltage setting from 42 to 58 volts output voltage remains constant regardless of load This is the normal operating condition in which loads are being supplied and batteries are float charged Rectifiers operate in the Constant Voltage Mode unless load increases to the point where the product of load current and output voltage is approximately 2000W Constant Power Mode As load increases above approximately 2000W non adjustable output current continues to increase but output voltage decreases as required to maintain constant output power Rectifiers operate in the Constant Power Mode unless load continues to increase to the point where the current limit setting is reached Constant Current Mode If load
4. Energy Systems North America Inc 2015 While every precaution has been taken to ensure accuracy and completeness herein Emerson Electric Co assumes no responsibility Business Critical Continui ty Emerson Network Power the Emerson Netw ork Power logo Emerson and Consider it Solved are service marks and and disclaims all liability for damages resulting from use of this trademarks of Emerson Electric Co EnergyMaster eSure NetPerform NetReach NetSpan NetSure and NetXtend are trademarks of Emerson information or for any errors or omissions Specifications subject to Network Power Energy Systems North America Inc Any other product brand or company names or logos are the property of the respective owner change without notice EMERSON CONSIDER IT SOLVED Spec No 1R482000E3 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015
5. increases to the current limit setting output voltage decreases linearly to maintain output current at the current limit setting Input Protection a Input Over Under Voltage Protection The rectifier will shut down at low or high voltage input based on the following voltage levels 1 Low Voltage Disable Point 80V 5 V hysteresis is 15 VAC for restart 2 High Voltage Disable Point 305V 5 V hysteresis is 10 VAC for restart b Between 85 V and 176 V the output power will be derated linearly based on the input voltage as follows 1 Atinput voltage of 85V with output gt 48V max output power is 800W 2 Atinput voltage of 120V with output gt 48V max output power is 1364W 3 Atinput voltage of 154V with output gt 48V max output power is 1750W 4 Atinput voltage of 176V and output gt 48V max output power is 2000W Output Protection a Overload Reverse Current The rectifier has a 63A fuse in the negative output DC bus This fuse is not customer replaceable The rectifier can be plugged into or pulled out of a shelf while operating without damage or opening the fuse Spec No 1R482000E3 Model No R48 2000e3 b Current Limiting The rectifier has a current limit function The current limit point can be set between the range of 4 to 41 7 A adjustable via the Controller The current limit accuracy is 1 5A when the output voltage ranges from 42 to 58 V Below 42 V the current will fold back to a
6. panel this will also retract the latch mechanism See Figure 6 6 Push the module completely into the shelf 7 Push the handle up into the module s front panel This will lock the module securely to the shelf Tighten the captive screw on the handle 8 Certain functions i e rectifier current limit rectifier addressing may require adjustment when adding or replacing a rectifier module Refer to Rectifier Current Spec No 1R482000E3 12 Model No R48 2000e3 1 Performing this procedure may activate external alarms Do one of the following If possible disable these alarms If these alarms cannot be easily disabled notify the appropriate personnel to disregard any alarms associated with this system while this procedure is performed Remove the rectifier from the shelf Refer to a previous procedure for step by step instructions Place the rectifier on a static safe work surface Connect an approved grounding strap to your wrist for the remainder of this procedure On this rectifier remove the front panel by removing the three 3 screws securing the front panel to the chassis For proper orientation of the new fan observe the location of the fan wires and the fan rotation and air flow arrows on the old fan Carefully remove the fan from the rectifier chassis and unplug the fan power cable from the printed circuit card Plug the power cable of the replacement fan into the connector on the printed circuit car
7. 08 240 volts AC single phase 3 a wire 50 60 Hz with an operating range of 100 to 250 a volts Acceptable input frequency range is 45 to 65 Hz oe 0 a ee o a i E3 BR m m man Permitted Variation 85 to 300 VAC Temperature C e Harmonic Content THD lt 5 from 50 to 100 of Note Green Line at 200Vac lt Vin lt 250Vac and 50Vdc lt Vout lt rated load Meets EN61000 3 2 56Vdc e Inrush Current Peak does not exceed 1 5 times of the Blue Line at 176Vac lt Vin lt 300Vac and 48Vdc lt Vout lt 58Vdc peak value of the maximum steady state input current at exclude Region full load nominal input voltage and for any duration of Yellow Line 264Vac lt Vin lt 300Vac and Vout lt 42Vdc AC input interrupts Under the above conditions Note 2000W 65 C 149 F and 200Vac lt Vin lt 250Vac and standard AC distribution circuit breakers will not trip 50Vdc lt Vout lt 56Vdc e Typical Input Data 50 Hz input e Regulation a Referto Table 1 a Static Steady state regulation is 0 6 as controlled b Maximum Input Current Refer to Table 2 within the rectifier for any and all combinations of load from no load to full load input voltage and Spec No 1R482000E3 2 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 eee Table 1 Typical Input Data in 50Hz Input Heat Dissipation BTU Hr Nomina
8. AFETY Informs the reader of fire safety information reminders precautions or policies or of the locations of fire fighting and fire safety equipment ISO Fire Safety SAFETY Informs the reader of general safety information reminders precautions or policies not related to a particular source of hazard or to fire safety ISO ANSI OSHA Spec No 1R482000E3 P Code UM1R482000E3 Model No R48 2000e3 I Revision F July 20 2015 NetSure Rectifier Module s User Manual UM1R482000E3 Revision F July 20 2015 eet Static Warning y Ata ATTENTION This equipment contains static sensitive components The warnings listed below must be observed to prevent damage to these components Disregarding any of these warnings may result in personal injury or damage to the equipment 1 Strictly adhere to the procedures provided in this document 2 Before touching any equipment containing static sensitive components discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm resistor Some wrist straps such as Emerson Network Power Part Number 631810600 have a built in one megohm resistor no external resistor is necessary Read and follow wrist strap manufacturer s instructions outlining use of a specific wrist strap 3 Donottouch traces or components on equipment containing static sensitive components Handle equipment containing static sensitive components only by the edges that do
9. Ce nana eau REO Note The rectifier module is recommended to be used in an orton environment with Pollution of Degree 2 or less Pollution e Relative Humidity This rectifier is capable of operating in Degree 2 applies where there is only non conductive an ambient relative humidity range of 0 to 95 non pollution that might temporarily become conductive due condensing to occasional condensation such as the office e Altitude 2000 m 6560 ft at full power power limited eerie for heights above 2000 m e EMI RFI Suppression e Surge Protection Compliance with EN61000 4 5 4kV a Rectifiers operating in an approved rectifier Line to Line 4kV Line to Earth Capable of withstanding mounting shelf conform to the requirements of FCC surges per ANSI IEEE C 62 41 1999 Category B3 across rules Part 15 Class B for Radiated and Conducted the input terminals emissions limits Note This level of protection is a widely used standard for b Rectifiers operating in an approved rectifier telecommunications power equipment As with all mounting shelf conform to the requirements of such equipment it is the end user s responsibility to European Norm EN55022 Class B for Radiated and provide an adequately sized Surge Suppression Conducted emissions limits Device at the commercial power service entrance of li Inf i the building that reduces all incoming surges to Compiance iniormauon levels below the classes categories stated for the e EMC ETSI EN
10. NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 Specification Number 1R482000E3 Model Number R48 2000e3 EMERSON Network Power NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 a This page is intentionally blank Spec No 1R482000E3 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 aa Table of Contents Admonishments Used in this Document eseseossesossesosssccoseecosseceossecosssecoseecossecossecossescossecosssecossecossecossescossesosseeoo ii SCC VV N s ti cacressiciecassicicvcestesaseactaceensasasascacisswscadiwsedaneesbacevcerbusdv ans tissseersecdsussunccessetiacaseachacnmaacdssass iii Modi e e E E 1 O N ea E E E E E E E A ET A E E E E A E O EE 1 DACON e E E E E 1 Operacion sesira 8 AC Input Protection Device Requirements RECOMMENCALtIONS sssssssssseeeeccccececeeeeseeeessssseeeeeeceeeeeeseessaeaaasssses 8 WAN MIN A ONS asc nc dca oa sa sss c vs ws vv EE ote vous sebee oad auctauaareevieeseteeonsuunecareruieess 8 Rectifier High Voltage Shutdown and Lockout Restart cceeeccssssesssssseseecccccccceeccesaeeeessseeeceecceceeeessssaeaaaasseeseeeeeees 8 FRG ION COTONE rene aosuu casa andy ose avsicnncous veya easedoueasac N a 8 aoee MACH ISSCC TS EE EAE AEE N E EE EN E EA E E AE EN E 10 Troubleshooting and ROD AUN asisem
11. Red On Spec No 1R482000E3 Model No R48 2000e3 Internal input fuse open Replace the rectifier module AC input voltage outside Correct the AC input voltage to within the acceptable the normal range range PFC over voltage Replace the rectifier module Moderate load sharing imbalance Check if the rectifier module is properly seated in the Shelf If this does not correct the fault replace the rectifier module Rectifier module not inserted into the slot Remove and properly insert the rectifier module completely Rectifier module over temperature protection which could be caused by 1 Fan rotor blocked 1 Remove any object that may be blocking the fan 2 Ventilation blocked 2 Remove any object that may be blocking the inlet or inlet or outlet outlet 3 Ambient temperature too high or rectifier 3 Lower the ambient temperature or relocate the heat module inlet too close toa source heat source Rectifier module Check the communication cables communication failure Remove and properly insert the rectifier module Output over voltage shutdown Severe load sharing imbalance Internal output fuse open Remove the rectifier module from its shelf and then reinstall after 30 seconds If rectifier module fails to start or shuts down again replace the rectifier module Rectifier module addresses Replace the rectifier module contradictory Alarm Indicator Fan not operating rectifier Replace t
12. d Carefully slide the replacement fan into the rectifier chassis ensure the fan wires and fan rotation and air flow arrows match the orientation of the old fan Code UM1R482000E3 Revision F July 20 2015 NetSure Rectifier Module s User Manual UM1R482000E3 Revision F July 20 2015 eet 8 Note that the fan has four holes in the front corners and Figure 7 Fan Replacement that the faceplate has three tabs Carefully slide the faceplate into position aligning the fan holes with the faceplate tabs Secure the faceplate to the rectifier chassis with the three 3 screws previously removed 9 Replace the rectifier into the shelf Refer to the previous procedure for step by step instructions 10 When the fan starts check to ensure that it is providing front to back airflow If air direction is wrong immediately remove the rectifier from the shelf Repeat previous steps to check fan orientation and correct as necessary Reinstall the rectifier and again check for proper airflow Align holes in fan with tabs on faceplate 11 Enable the external alarms or notify appropriate personnel that this procedure is finished Fan Faceplate Mounting 12 Ensure that there are no local or remote alarms active on Screws 3 the system Faceplate Spec No 1R482000E3 13 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 A TM ete NetSure Rectifier Module B EN N User Manual UM1R482000E3 Revision F J
13. e E E T 10 Tonbe hon a E E E EA EEE EE A E EEEE AAEE 10 Replacement Procedures ssssseccccccccccssseeusccccessssssseeeeeccccceeeseeueeeasssssesesececcceceessesaeeegaassseeeeeeeeeeceeeseseeeeegeassses 12 Spec No 1R482000E3 Code UM1R482000E3 Model No R48 2000e3 l Revision F July 20 2015 NetSure Rectifier Module EMERSON User Manual UM1R482000E3 Revision F July 20 201 5 Network Power _ Admonishments Used in this Document DANGER Warns of a hazard the reader will be exposed to that will likely result in death or serious injury if not avoided ANSI OSHA WARNING Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided This admonition is not used for situations that pose a risk only to equipment software data or service ANSI CAUTION Warns of a potential hazard the reader may be exposed to that could result in minor or 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 order to prevent equipment damage software corruption data loss or service interruption ISO FIRE S
14. f this 120 208 240VAC input and 48VDC output temperature for any reason such as a high ambient N temperature increases above approximately 55 C e Output Characteristics Refer to Figure 1 for a graph of 131 F the rectifier will not shut down Rather the output voltage vs output current rectifier limits its maximum output power to maintain the temperature of the power conversion circuit within design parameters Operation between 55 C 131 C and 80 C 176 F will result in output power being decreased Full power capability is restored when the Spec No 1R482000E3 1 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module a User Manual UM1R482000E3 Revision F July 20 201 5 Network Power temperature decreases to below approximately 55 C input frequency at a constant ambient temperature 131 F Refer to Figure 3 to view the relationship The associated system Controller may provide between the output power and the ambient increased regulation t ture ee b Dynamic For any step load change within the range WARNING The module is rated for continuous of 10 to 90 of full load within 50 microseconds operation at full output power up to 55 C 131 F per Telcordia GR 947 CORE the maximum voltage Operation between 55 C 131 F and 80 C 176 F transient will not exceed 5 of the initial steady state will result in output power decrease Operation above volta
15. failure The failure information will be reported to the Controller and the Controller will process the failure accordingly During a communication failure in order to protect the battery the rectifier output voltage will automatically be adjusted as follows When used with the SCU Controller rectifier output voltage goes to a default value 53 5 V which can be modified using the SCU Controller When used with the ACU Controller rectifier output voltage goes to the ACU float voltage setting this setting is stored in the rectifier The rectifier will revert to normal operation once normal Over Voltage Setting On Off Status Fault Alarms such as HVSD Fan Fail Protection Alarms such as Input Voltage Protection Inner DC Bus Voltage Protection High Temperature Protection Thermal Derating re AC Derating communication is restored AC Fail e Rectifier Output Current Imbalance When load sharing Imbalance Output Current severe imbalance output fuse open and the output Address current drops to zero in average current gt 10 system Code then the red fault indicator will illuminate Date e Monitoring Function The rectifier has a built in Software Version advanced DSP that monitors and controls the operation Hardware Version of the rectifier The DSP also communicates with the Controller in real time through the CAN bus Table 5 lists the different commands and information exchanged between the rectifier and the Contro
16. ge within 50 10 microseconds Recovery to 80 C 176 F is considered abnormal and should be within 1 of the initial steady state voltage does not used on a temporary basis only exceed 1 milliseconds Temporary Operation at Abnormal Temperature e Filtering Temporary operation is defined as a period of not a Voice Band Noise Complies with Telcordia GR 947 more than eight consecutive hours per day anda CORE total of not more than 15 days in a year This refers to atotal of 120 hours in any given year but no more than 15 occurrences in that one year period 1 Output noise according to Telcordia GR 947 CORE is lt 38 dBrnC typical at normal input and 20 to 70 of rated load for more Other power rating values are as follows refer to Figure than one rectifier 4 2 Psophometric noise is lt 2 mV typical at 20 to a Atan ambient temperature of 65 C 149 F 70 of rated load for more than one rectifier the power delivered by the rectifier is 1800W b Wide Band Noise Complies with Telcordia GR 947 b Atan ambient temperature of 70 C 158 F CORE the power delivered by the rectifier is 1500W 1 Wideband noise emission is lt 250 mV peak to Figure 3 Power Derating Based on Temperature peak between 0 Hz 100 MHz and lt 50 mV rms in any 3 kHz band 10 KHz 20 MHz Output power vs Temperature Vin 176Vac N O p AC Input Ratings 80 e Voltage Nominal 120 2
17. h rectifier module being installed in the system If the current sharing imbalance still persists following the verification suggested above replace the rectifier exhibiting the 7 After the rectifier modules are physically installed in the Current imbalance mounting shelf s they are ready for operation immediately after power is supplied to them 8 Certain functions i e rectifier current limit rectifier addressing may require adjustment when adding or replacing a rectifier module Refer to Rectifier Current Limit on page 8 and the Power System documentation for instructions Spec No 1R482000E3 10 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 Rectifier Fault Symptoms and Troubleshooting The fault indicators that can be displayed by the rectifier are as follows Refer to Table 7 fora list of possible causes and corrective actions e Power Indicator Green Off e Protection Indicator Yellow ON e Protection Indicator Yellow Flashing e Alarm Indicator Red ON e Alarm Indicator Red Flashing Table 7 Rectifier Module Troubleshooting Symptom Possible Cause s amp J EMERSON Network Power Suggested Action s Power Indicator No input voltage Make sure there is input voltage Green Off Protection Indicator Yellow On Protection Indicator Yellow Flashing Alarm Indicator
18. he fan Red Flashing module shuts down P 11 Code UM1R482000E3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 Ss EMERSON Nlatiuninr Daiarc Net WOI k P owel Replacement Procedures Rectifier Module Replacement Rectifier modules can be inserted or removed with power applied hot swappable Note Each rectifier module locks into a module mounting shelf by means of a latch located on the bottom of the module The latch and rectifier module handle are interactive Pushing the handle up into the module s front panel causes the latch to extend to the locking position pulling the handle down out from the module s front panel causes the latch to retract See Figure 6 DANGER Take care when removing a rectifier module that was in operation as rectifier module surfaces could be very hot A mechanism ensure the handle is in the open position when installing or removing a rectifier module NEVER hold the handle in the closed position when installing a rectifier module into a shelf 11 Limit on page 8 and the Power System documentation for instructions After the rectifier modules are physically installed in the mounting shelf s they are ready for operation immediately after power is supplied to them Verify that the rectifiers are operating normally Enable the external alarms or notify appropriate personnel that this procedure i
19. he module s front panel causes the latch to retract See Figure 6 CAUTION This rectifier module contains Double pole fusing parts of the equipment that remain energized might represent a hazard during servicing after operation of the fuse If the rectifiers are connected toa 3 phase system the neutral line should also have a fuse Aa WARNING To prevent damage to the latching mechanism ensure the handle is in the open position when installing or removing a rectifier module NEVER hold the handle in the closed position when installing a rectifier module into a shelf PROCEDURE Latch Note Refer to Figure 6 as this procedure is performed 1 Unpack the module 2 Place the module into an unoccupied mounting slot without sliding it in completely 3 Loosen the captive screw on the module s handle Pull the handle down out from the module s front panel this Trou bleshooti nga nd Re pair will also retract the latch mechanism See Figure 6 Troubleshooting 4 Push the module completely into the shelf Rectifier Current Sharing Imbalance 5 Push the handle up into the module s front panel This will lock the module securely to the shelf Tighten the When multiple rectifiers are operating in parallel and the load is captive screw on the handle greater than 10 if the current sharing imbalance among them is greater than 3 check if the rectifier is properly seated in the shelf 6 Repeat the above steps for eac
20. l Input Current Amperes 70 80 33 20 46 90 25 497 20 491 90 98 90 95 38 50 983 00 977 40 99 40 96 01 75 1476 10 1473 00 99 70 95 51 2 Percent of Full Load Input Input Power Efficiency Input VA Watts Factor Heat Voltage 113 27 77 54 133 05 255 65 372 35 418 56 454 89 90 41 74 01 124 04 203 11 319 75 oS 1980 00 1984 30 99 80 94 50 110 10 30 2144 00 2141 00 99 80 94 27 120 10 34 2151 00 2147 00 99 80 93 88 73 50 26 50 36 00 499 80 490 80 98 00 95 58 50 240 5 Note System output is initially adjusted to 54 48 volts DC as measured at the system sense point at 50 of full load and nominal input Percent of Full Load refers to percent of 34 5 amperes 983 90 974 70 99 00 96 27 Table 2 Maximum Input Current in 50Hz Input Nominal Input Voltage Input Current Input Voltage Amperes Note At 100 of full load with output adjusted to 58 volts DC as measured at the shelf output terminals Spec No 1R482000E3 3 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 a e Typical Input Data 60 Hz input a Referto Table 3 b Maximum Input Current Refer to Table 4 Table 3 Typical Input Data in 60Hz Input Heat Dissipation BTU Hr Nominal Input Percent Input of Full Load Current Voltage Amperes Power Efficiency Watts Factor Heat o Toa ona l a wa O O T SD
21. ller e Dimensions Mechanical Specifications a Millimeters 42 0 Height X 84 5 Width X 252 5 Depth b Inches 1 7 Height X 3 3 Width X 9 9 Depth e Weight 1 13 kg 2 49 Ibs e Indicators a Power Green LED b Protection Yellow LED c Alarm Red LED Spec No 1R482000E3 7 Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 NetSure Rectifier Module a User Manual UM1R482000E3 Revision F July 20 201 5 Network Power Ope ration Manual menu in the LCD menus or under the Rectifier Control Tab in the WEB Interface AC Input Protection Device Requirements Recommendations PN Rectifier Current Limit Refer to the system documentation supplied with the system the rectifier is installed in When setting total rectifier current limit the set point to each l rectifier is the total set point divided by the number of rectifiers Local Indicators For example if the system contains five rectifiers and the current Location and Identification Refer to Figure 5 limit is set to 150 amps then each rectifier has a current limit set point of 30 amps If one or more rectifiers are removed or fail it will take several seconds for the individual set points to the remaining rectifiers to be reset In the example given if one rectifier is removed the current limit set point will drop to 120 Description There are three 3 indicators located on the rectifier s front panel The functions of these indica
22. lower value c Advanced Current Limit Function The rectifier has an advanced Current Limit Function When a short circuit occurs at the rectifier output terminals the rectifier will keep its output current at a value below the maximum current limit set point This function effectively protects the rectifier and the equipment connected to the rectifier When the short circuit fault is cleared the rectifier will automatically restore back to normal operation d High Voltage Shutdown 1 Software settable HVSD level from controller 56 to 59 V The software restart hysteresis is 0 5 V 0 2 V 2 Back up hardware HVSD High Voltage Shut Down at 59 5 V 0 5 V 3 Inthe case of a second HVSD within 5 minutes time value configurable via the controller the unit shall require to be manually restarted Method of manual restart Reset the rectifier through the controller or remove the rectifier from the system and then re install the rectifier into the system Over Temperature Protection The rectifier provides over temperature protection by derating output power and recovers automatically Active Load Sharing The rectifier uses advanced digital active load sharing technology that maintains balancing to within 3 of rated current Hot Swappable The rectifier is designed to be plug and play The rectifier can be inserted or removed from a live DC power system with no damage When the rectifier is plugged into the system the
23. not have connector pads 4 After removing equipment containing static sensitive components place the equipment only on conductive or anti static material such as conductive foam conductive plastic or aluminum foil Do not use ordinary Styrofoam or ordinary plastic 5 Store and ship equipment containing static sensitive components only in static shielding containers 6 Ifnecessary to repair equipment containing static sensitive components wear an appropriately grounded wrist strap work ona conductive surface use a grounded soldering iron and use grounded test equipment Spec No 1R482000E3 sat Code UM1R482000E3 Model No R48 2000e3 HII Revision F July 20 2015 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 a This page is intentionally blank Spec No 1R482000E3 Code UM1R482000E3 Model No R48 2000e3 IV Revision F July 20 2015 S NetSure Rectifier Module a User Manual UM1R482000E3 Revision F July 20 2015 ike ntrod uction Figure 1 Output Voltage vs Output Current Output Voltage vs Output Current Overview Max Output Power 2000W The rectifier provides load power battery float current and battery recharge current during normal operating conditions The m l rectifier is a constant power design The rectifier is rated at its 50 dl maximum output power This means that within the normal 7 40 4 operating ambie
24. nt temperature range and input voltage range 30 1 the maximum available output power is a constant 2000W Within A 20 these ranges the rectifier operates in one of three modes a A i depending upon load demands Transition between modes is 0 5 10 15 20 25 30 35 40 45 50 completely automatic If ambient temperature rises above or Output Current A input voltage falls below acceptable values the rectifier continues to operate but at derated output power levels e Power Derating Based on Input Voltage The rectifier power varies with changes in input voltage and output voltage It uses an advanced power limitation method The lower input threshold is 85 VAC The rectifier can provide its maximum rated power 2000W as long as the input voltage is within the range of 176 to 300VAC Below 176 VAC and down to 85 VAC the rectifier will continue to operate normally but will be in a power derating mode The relationship between the output power and input voltage is illustrated in Figure 2 e Constant Voltage Mode For any initial output voltage setting from 42 to 58 volts output voltage remains constant regardless of load This is the normal operating condition in which loads are being supplied and batteries are float charged Rectifiers operate in the Constant Voltage Mode unless load increases to the point where the product of load current and output voltage is approximately 2000W e Constant Power Mode As load increases above appr
25. oximately 2000W non adjustable output current igure 2 Power Derating Based on Input Voltage continues to increase but output voltage decreases as Output power vs Input voltage and Vo gt 48V at Temp lt 55 C required to maintain constant output power Rectifiers 120 0 rs operate in the Constant Power Mode unless load ae og a 80 0 continues to increase to the point where the current limit 3 60 0 a setting is reached 2 40 0 S 20 0 e Constant Current Mode If load increases to the current z o0 limit setting output voltage decreases linea rly to 0 50 100 150 200 250 300 350 maintain output current at the current limit setting For R48 2000e3 Input voltage Vac Sp si fi cations Note Blue Line Linear derating from 85V AC to 176V AC DC Output Ratings Yellow Line Linear derating from 2000 watts at 176V AC to o 1000 watts at 132V AC Constant 1000 watts from 132V AC Note A current limitation can be set by the User and the output to 93V AC voltage level is set through the controller e Power Derating Based on Temperature The rectifier delivers full power when operating at an ambient temperature of 55 C 131 F or below Each rectifier continuously monitors the ambient temperature e Voltage Nominal 48 volts DC positive ground Output voltage is adjustable from 42 to 58 volts DC via the associated Controller e Output Power and Current 2000W 41 7A surrounding the power conversion circuit I
26. s finished Ensure that there are no local or remote alarms active on the system Rectifier Fan Replacement Each rectifier uses a fan P N 32010474 for cooling If fan replacement should become necessary perform the following procedure WARNING To prevent damage to the latching Refer to Figure 7 as this procedure is performed WARNING In a system with NO redundant rectifier battery must have sufficient reserve to power the load s while the rectifier is removed for fan replacement PROCEDURE Note When performing any step in this procedure that requires Note Refer to Figure 6 as this procedure is performed removal of existing hardware retain all hardware for use in subsequent steps 1 Performing this procedure may activate external alarms PROCEDURE Do one of the following If possible disable these alarms If these alarms cannot be easily disabled notify the appropriate personnel to disregard any alarms associated with this system while this procedure is performed 2 Loosen the captive screw on the module s handle Pull the handle down out from the module s front panel this will also retract the latch mechanism See Figure 6 3 Grasp the handle and pull firmly to remove the module from the shelf 4 Place the replacement rectifier module into the mounting position without sliding it in completely 5 Loosen the captive screw on the module s handle Pull the handle down out from the module s front
27. system output voltage will not be affected Cooling Each rectifier module contains a fan for front to back force air cooling a Fan Fault Protection The rectifier module shuts down and its alarm indicator red flashes if the fan fails Fan failure is detected and reported to Controller The fan is field replaceable b Fan Control Fan speed is continuously variable When input voltage is within normal range the built Code UM1R482000E3 Revision F July 20 2015 e 4 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 ee in processor adjusts fan speed according to the Table5 Exchange of Information between Rectifier and Controller rectifier module s internal temperature and output power For example a higher temperature or Commands signalsthatcan Information gathered by the output power increases the fan speed This feature be received by the Rectifier Controller from the Rectifier can be disabled via the controller allowing the fan to pT emn nE Se ieee laia run at full speed regardless of temperature Turn On Off Input Voltage e Paralleling Up to 32 rectifiers can be connected in Current Walk in On Off Output Voltage parallel in one system HVSD High Voltage Output Current Shutdown Reset Current Limit Setting e Communication Failure The rectifier s protection Current Limit Adjustment Temperature indicator yellow will flash should it experience a Voltage Regulation communication
28. tors are as shown in Table 6 Note DC voltage must be present at the rectifier output terminals amps 30 amps times four remaining rectifiers until the controller from battery or an operating rectifier or AC voltage at the can send updated set points to the remaining rectifiers This takes input terminals a couple communication cycles several seconds after which each T rectifier would have a new set point of 37 5 amps for a total of 150 Rectifier High Voltage Shutdown and Lockout amps The total current limit of the rectifiers should not be set Restart such that the loss of the redundant rectifiers will cause this PROCEDURE temporary set point to drop below the actual maximum expected load If batteries are used on the rectifier output the batteries Remove the rectifier wait 30 seconds or more until the LEDs on should support the load until the current limit set points can be re the rectifier extinguish then re insert the rectifier established due to loss of a rectifier The rectifier can also be restarted from the ACU LCD or WEB Interface menu via the rectifier Reset command found in the Spec No 1R482000E3 g Code UM1R482000E3 Model No R48 2000e3 Revision F July 20 2015 4 NetSure Rectifier Module User Manual UM1R482000E3 Revision F July 20 2015 nctwork Powe Figure 5 Local Indicator Locations Power Indicator Green Protection Indicator Yellow i Alarm Indicator Red Sey Table 6
29. uly 20 2015 Network Power The information contained in this document is subject to change without notice and may not be suitable for all applications While every precaution has been taken to ensure the accuracy and completeness of this document Emerson Network Power Energy Systems North America Inc assumes no responsibility and disclaims all liability for damages result ing from use of this information or for any errors or omissions Refer to other local practices or building codes as applicable for the correct methods tools and materials to be used in performing procedures not specifically described in this document The products covered by this instruction manual are manufactured and or sold by Emerson Network Power Energy Systems North America Inc This document is the property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited 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 manufacturer EmersonNetworkPower com Energy Systems North America EmersonNetworkPower eu EnergySyste ms EMEA Emerson Network Power
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