Home

Emerson 120kW Installation Manual

1. A Distribution Panel d eR SL q Customer DC Input Connections i lil i to Load Distribution Panels A M8 studs on 25mm 1 centers P gt Recommended Torque 108 in Ibs 12 Nm Z gt Negative Bus ZA 200V D AA 3 Ig Positive Bus LOR f Distribution MA Torque these YZ Panel M8 studs on 2 Connections AMR i 1 25mm centers Lo P 108 in Ibs 12 Nm CR I lt v esd T P N 558103 List 21HA e LE ES Distribution Panels Interconnect Busbar two required Negative Bus c o o 200V D r 8 H Positive Bus Rear Spec No 584001200 Model No 9500 Distribution Module Bay 584001200 List 07 16 of 25 Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001200 Issue AA April 14 2014 Electrical Connections to Battery Cabinet 584001200 List 90 91 92 93 Danger Adhere to the Important Safety Instructions presented at the front of this document DO NOT attempt to work on an energized system Warning Check for correct polarity before making battery connections Note The maximum short circuit capacity of the circuit breakers in the system is 25kAIC Therefore the maximum number of Emerson provided Battery Cabinets is limited to a maximum of three 3 The use of a fourth Battery Cabinet will exceed the short circuit rating of the circ
2. ACU Controller ACU Controller Power and Control Section Front door removed in illustration for clarity only 120kW Power Module Bay 584001200 List 01 Spec No 584001200 Model No 9500 A EMERSON Network Power Power Module Bay External EPO Emergency Power Off Connections 11 of 25 The Power Module Bay has an Emergency Power Off EPO function operated by a remote contact provided by the User Note The external EPO switch wiring must be double insulated The wire must be 600V 18 16 AWG stranded for maximum runs between 82 and 197 feet 25 60m When the EPO switch is momentarily closed the main AC input circuit breaker located on the power and control section of the Power Module Bay and the battery disconnect circuit breakers if connected to the BATT1 CTRL BATT2 CTRL BATT3 CTRL and or BATT4 CTRL connectors located on the rear of the power and control section of the Power Module Bay are tripped open to isolate the system from all electrical sources Manual intervention is required to restart the system Restart the system by first turning ON the main AC input circuit breaker then the battery circuit breaker s PROCEDURE 1 Connect a customer provided external normally open switch between the EPO terminals provided on the rear of the power and control section of the Power Module Bay Refer to Figure 1
3. The Power Module Bay has an Emergency Power Off EPO function operated by a remote contact provided by the User When the EPO switch is momentarily closed the main AC input circuit breaker located on the power and control section of the Power Module Bay and the battery disconnect circuit breakers if connected to the BATT1 CTRL BATT2 CTRL BATT3 CTRL and or BATT4 CTRL connectors located on the rear of the power and control section of the Power Module Bay are tripped open to isolate the system from all electrical sources Manual intervention is required to restart the system Restart the system by first turning ON the main AC input circuit breaker then the battery circuit breaker s PROCEDURE 1 With the system operating momentarily depress the customer furnished Emergency Power Off switch 2 Verify that the main AC input circuit breaker located on the power and control section of the Power Module Bay and any connected battery circuit breakers open 3 Restart the system by first turning ON the main AC input circuit breaker then the battery circuit breaker s Checking System Status PROCEDURE 1 Observe the status of the indicators located on the ACU controller rectifier modules and power and control Spec No 584001200 Model No 9500 23 of 25 Table 4 Table4 Status and Alarm Indicators Component Indicator Normal State Status Green oe au Information ACU Yellow E
4. NetR each NetSpan NetSure and NetXtend are tradema rks of Emerson information or for any errors or omissions Specifications subject to Network Power Energy Syste ms 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 584001200 Code IM584001200 Model No 9500 Issue AA April 14 2014
5. Power Module Bay This lead MUST be connected to ground earth for proper operation of the HRMG circuit and the ground fault detection circuit Refer to Figure 4 for location THIS LEAD IS FACTORY CONNECTED TO THE RACK S GROUND BAR Caution Failure to terminate this conductor to ground earth will render the system ground fault detection circuit and the 200V DC voltage reference inoperable It is essential to properly bond this lead to ground earth Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System S Installation Manual IM584001200 Issue AA April 14 2014 e Figure 4 Power Module Bay HRMG Connection Figure 5 Power Module Bay AC Input Power Connections HRMG Ground Connection MUST BE PROPERLY CONNECTED TO GROUND AC Input Leads Opening for 51mm 2 Conduit AC Input Terminals M8 studs on 25mm 17 centers Recommended Torque 108 in lbs 12 Nm 120kW Power Module Bay 584001200 List 01 Power and Control Section 120kW Power Module Bay 584001200 List 01 Power and Control Section lt AC Input Ground Lead Studs Rear M8 studs on 25mm 1 centers Recommended Torque 108 in lbs 12 Nm Power Module Bay AC Input Power and AC Input Equipment Grounding Earthing Connections sepes e ttr e scent EA FE rape i ae ER HE THE Danger Adhere to the Important Safety Instructions
6. Bay Battery Shunt Connections eseseseeeeeseeeee eene nen nennen ennt nnne 12 Power Module Bay Battery Connections eese tenente nennen nennen nennt ennt enne tenente nennen 12 Electrical Connections to Distribution Module Bay 584001200 List 07 esee 15 Distribution Module Bay Rack Frame Grounding Earthing Connection essere 15 Distribution Module Bay Distribution Panel List 21 HA Connections esses 15 Electrical Connections to Battery Cabinet 584001200 List 90 91 92 93 sse 17 Installing the Rectifier Module esee eene eene eene eesis s seruos ns boosie esaesa soaa ae seins seen seen siete seen 17 18 Important Safety IMSEUCHONS Rp Cp 18 Initial Pr paration cedri perte rre iere i eno ee dee DIR DRAK ehe SE Y eS ine deve Een Pee SEES 18 Initially Starting the Systermi co iiia ceret rotten nen roten tete n repite reato eet el da Reve YG DWFN GA Ai pads 18 ACUt Controller InitializatiOn scene iret neret ero teet eene ro toe ira reete ra tueri a lita hiat red 20 Verifying the Configuration File 3 erecto rene rne reete nee duse coe Te eo ea DNA eo Una He ETUR a stats ca eV ce FT Edn nn 21 Changing Battery Capacity Rating in the ACU seseeieeeeseseeeeeeeeeeee tenente nennen nennen nenne nenne tee
7. DC and is potentially lethal Battery strings should be isolated from the power system before servicing WARNING Correct polarity must be observed when connecting battery leads WARNING Special safety precautions are required for procedures involving handling installing and servicing batteries Observe all battery safety precautions in this manual and in the battery instruction manual These precautions should be followed implicitly at all times Code 1M584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001200 Issue AA April 14 2014 WARNING A battery can present a risk of electrical shock and high short circuit current Servicing of batteries should be performed or supervised only by properly trained and qualified personnel knowledgeable about batteries and the required precautions The following precautions should be observed when working on batteries e Remove watches rings and other metal objects e Eye protection should be worn to prevent injury from accidental electrical arcs e Use certified and well maintained insulated tools Use double insulated tools appropriately rated for the work to be performed Ensure that wrenches with more than one working end have only one end exposed e Do not lay tools or metal parts on top of batteries e Disconnect charging source prior to connecting or disconnecting battery terminals e Risk of explosion if battery is
8. Main Menu Settings Controller Date Q EMERSON Network Power Time Main Menu Settings Controller Time IP Communications Parameters IP address subnet mask address gateway address Main Menu Settings Communication Float Voltage Main Menu Settings Battery Charge Output Voltage Equalize Voltage Main Menu Settings Battery Charge EQ Voltage Battery Capacity Main Menu Settings Battery Basic Ttl Rated Capac BTRM Feature Main Menu Settings Battery Basic BTRM Action Main Menu Settings Battery Basic BTRM Voltage Temperature Compensation Center Temperature Main Menu Settings Battery Temp Comp Temp Comp Ref Temperature Compensation Slope Main Menu Settings Battery Temp Comp Temp Comp Coeff Temperature Compensation Sensor HVSD Limit Main Menu Settings Rectifier All Rect Set HVSD Limit Rectifier Current Limit Main Menu Settings Rectifier All Rect Set Input Current Lmt Over Voltage Alarm 1 Main Menu Settings Power System Over Voltage 1 Over Voltage Alarm 2 Main Menu Settings Power System Over Voltage 2 Under Voltage Alarm 1 Main Menu Settings Power System Under Voltage 1 Under Voltage Alarm 2 Main Menu Settings Battery Temp Comp Temp Comp Probe Main Menu Settings Power System Unde
9. Nm 84 inlbs 9 5Nm 12 INPUT CONNECTIONS DC distribution panel DC input leads are connected to the distribution panel s as shown in Figure 15 Distribution Module Bay 584001200 List 07 Spec No 584001200 Code IM584001200 Model No 9500 1 5 of 25 Issue AA April 14 2014 EMERSON Network Power NetSure 9500 120kW 400V DC Power System Installation Manual IM584001 200 Issue AA April 14 2014 Figure 15 Distribution Module Bay DC Load Connections DC Input Connections and Interconnecting Two 2 DC Load Distribution Panels Front door removed in illustration for clarity only Distribution S Panel e 8 4200V DC Positive 4 i 5 Negative d Customer E Load Connections i to DC Distribution 2 Distribution Circuit Breakers s Panel M6 studs on ane 16mm 5 8 centers N left and right sides a Recommended Torque f 84 in lbs 9 5 Nm li Front 1 Distribution Module Bay X 584001200 List 07 Rear P Negative Positive Interconnecting Two 2 Bus Bus Load Distribution Panels
10. an Controller n Warning or Critical f Alarm off Red Power Green C p Rectifier Protection Modules Yellow AN off Alarm Ww Red ott Output Voltage On Power and Present Green Control Section Control Voltage On of Power Present Indicator Green Module Bay Ground Insulation Fault Off Alarm Red Final Steps PROCEDURE 1 Ifany ACU Controller configuration settings were changed refer to the ACU User Instructions UM1M820NNB 2 and save a copy of the configuration file This file can be used to restore the ACU Controller settings if required at a later date e Note that provided on a USB drive furnished with the system is an ACU configuration drawing C drawing and the ACU configuration files loaded into the ACU as shipped 2 Verify there are no external alarms and the local indicators are as shown in Table 4 Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System nd Installation Manual IM584001 200 Issue AA April 14 2014 eun NetPerform Optimization Services North America At Emerson Network Power we understand the importance of reliable equipment it s critical to both your business and your bottom line That is why we offer a wide array of services to meet all of your network infrastructure needs Customer Service Pre Shipment Email CustomerService ESNA Emerson com Pricing and availability purchase orders expediting requests and order tracking As
11. fire should a ground fault occur Refer also to the grounding earthing procedures in this document Output Ground Configuration This system is configured for High Resistance Midpoint Ground HRMG Ensure the HRMG lead is properly connected to ground earth per the instructions that follow Spec No 584001200 Model No 9500 Cable Routing The Power Module Bay and Distribution Module Bay are provided with top plates that have cable routing holes that either accept conduit fittings or corded connections Torque Torque all connections as specified in the illustrations presented in this section Electrical Connections to Power Module Bay 584001200 List 01 Power Module Bay Rack Frame Grounding Earthing Connection Refer also to General Grounding Earthing Guidelines on page 4 Supply a grounding earthing lead from site ground earth to the rack ground bar Refer to Figure 3 for connection point Figure 3 Power Module Bay Rack Frame Grounding Earthing Ground Bar Ground Bar M6 studs on M6 studs on 16mm peT 16mm 5 8 centers centers Recommended Recommended Torque Torque 84 in bs 9 5 Nm 84 in lbs 9 5 Nm 120kW Power Module Bay 584001200 List 01 Power Module Bay HRMG Connection 4 of 25 Refer also to General Grounding Earthing Guidelines on page 4 A ground lead exits the rear of the power and control section in the
12. monitor battery temperature battery charge temperature compensation and or BTRM Battery Thermal Runaway Management should be mounted to the center of the battery cell closest to the center of the cabinet to sense battery temperature A temperature probe programmed to monitor ambient temperature should be mounted in a convenient location away from direct sources of heat or cold To mount a temperature probe peel the backing from the self adhesive surface and affix the probe to a clean and dry surface Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for programming information Figure 8 Power Module Bay IB2 ACU Controller Interface Board Connections IB2 I O Wiring Opening P door removed in illustration for clarity only 120kW Power Module Bay 584001200 List 01 IB2 ACU Controller Interface Board Assembly located behing panel a eae a Control Section Rear IB2 ACU Controller Interface Board P N MA4C5U31 T Relay Output Term Blocks r Digital Input Term Blo
13. presented at the front of this document DO NOT attempt to work on an energized system PE AC input connections are made to AC input terminals located behind an access panel located on the rear of the power and control section Studs are also provided for the AC input ground earth lead Refer to Figure 5 for location and connection details Power Module Bay DC Load Distribution Connections Rear if DC distribution panel installed Ei bets AC Inpu Nominal 380V 400V 480V AC Danger Adhere to the Important Safety Instructions Three Phase 90 60 Hz presented at the front of this document DO NOT attempt to work on an energized system Warning Check for correct polarity before making connections Load distribution leads are connected to the load distribution panel s as shown in Figure 6 and Figure 7 Spec No 584001200 Code IM584001200 Medal nel 9500 5 of 25 Y 14 2014 NetSure 9500 120kW 400V DC Power System A EMERSON Installation Manual IM584001200 Issue AA April 14 2014 Network Power Figure 6 Power Module Bay DC Load Distribution Connections to Distribution Panel List 21HA Customer Load Connections to DC Distribution Circuit Breakers M6 studs on 16mm 5 8 centers left and right sides Distribution Panel s200v pc Positive Negative Recomended Torque 84 in l
14. s AC input circuit breaker on the front of the power and control section of the Power Module Bay Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System 9 Installation Manual IM584001200 Issue AA April 14 2014 a Figure 16 Installing a Rectifier Module into a Power Module Bay e Ensure that all blocks except the last one in the Installation Acceptance Checklist starting on page 1 have been checked e Ensurethe main AC input circuit breaker located on the power and control section of the Power Module Bay is in the OFF position e Ensure each rectifier module AC input circuit breaker located on the power and control section of the Power Module Bay is in the OFF position e Ensure that a rectifier module or a blank cover panel is installed in all rectifier mounting positions e Ensure each load distribution circuit breaker in the Power Latch Release Module Bay if distribution panel is installed and Protection Indicator Yellow Distribution Module Bay s is in the OFF position Power Indicator Green Alarm Indicator Red e Ensure each battery string circuit breaker is in the OFF position Initially Starting the System PROCEDURE Front View 1 Close the external AC disconnect or protective device that supplies AC power to the system 2 Placethe main AC input circuit breaker located on the System Startu p front of the power and control sect
15. that the procedure was read When installation is done ensure that each block in this list has been checked Some of these procedures may have been factory performed for you Note The system is not powered up until the end of the Installation Acceptance Checklist Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System nd Installation Manual IM584001 200 Issue AA April 14 2014 EMERSON Network Power Note Some of these procedures may have been performed at the factory for you Installing the System System Startup UO Equipment Inspection Completed U Rack s Cabinet s Secured to Floor Making Electrical Connections POWER MODULE BAY 584001200 LIST 01 Q Rack Frame Grounding Earthing Connection Made Q HRMG Connection Made U ACInput Power and AC Input Equipment Grounding Earthing Connections Made UO DCLoad Distribution Connections Made if DC distribution panel installed U 1B2 ACU Controller Interface Board Connections Made if required Q Temperature Probe Connections Made if required U ACU Controller Ethernet Connection Made O External EPO Emergency Power Off Connections Made if required U Battery Breaker Alarm Shunt Trip Connections Made if required Q Battery Connections Made if required DISTRIBUTION MODULEJ BAY 584001200 LIST 07 Q Rack Frame Grounding Earthing Connection Made U DCLoad Distribution Connections Made Q DC Distr
16. yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 Spec No 584001200 Model No 9500 21 of 25 EMERSON Network Power default password is 1 then press ENT twice Note If you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Settings menu screen displayed navigate to and select Battery ENT Basic ENT 4 Navigate to Rated Capacity Press ENT Usethe up or down keys to adjust the value as required Press ENT Note The default capacity value is 120 Ah per battery string for the Emerson provided Battery Cabinet For customer provided batteries enter the C10 battery capacity rating in Ah 5 Return to the Main screen by repeatedly pressing ESC escape Checking Basic System Settings Navigate through the controller menus and sub menus to check system settings You can adjust any parameter as required Note that these settings can also be checked and changed if required via the WEB Interface Note Repeatedly press the ESC key to return in reverse order level by level from any sub menu until the Main screen appears PROCEDURE To Select a Sub Menu Press the up or down arrow keys to mov
17. 0 25 Nm Refer to Figure 8 for terminal locations Referto Table 1 and Table 2 for pin out information e Digital Inputs Connect up to eight 8 digital inputs to the IB2 Note that you must supply both paths for the digital input either a positive or negative signal and the opposite polarity return path Observe proper polarity Refer to Figure 8 for terminal locations and Table 1 for pin out information Note 48V is available on terminal 5 5 and Return RTN is available on terminal J5 6 for customer connection to digital inputs The digital inputs can be programmed to provide an alarm when the signal is applied HIGH or removed LOW Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for programming information Digital Input Ratings Refer to the following a Maximum Voltage Rating 60V DC b Active High gt 19V DC C Active Low lt 1V DC e Programmable Relay Outputs The IB2 provides eight 8 programmable alarm relays with dry Form C contacts Connect up to eight 8 relay outputs to the IB2 Refer to Figure 8 for terminal locations and Table 2 for pin out information Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for programming information Relay Ratings Refer to the following a 1ASteady State 30V DC b 3APeak 30V DC Power Module Bay Temperature Probe Connections Note Each temperature probe consists of two pieces that plug together to make a com
18. 001 200 provides Installation Instructions for NetSure 9500 120kW 400V DC Power System Model 9500 Spec No 584001200 The complete Customer Documentation Package consists of NetSure 9500 120kW 400V DC Power System Installation Manual e Power System Installation Instructions IM584001200 NetSure 9500 120kW 400V DC Power System Operation Manual e PowerSystem Operation Instructions UM584001200 e Rectifier Instructions UM1R40015000e e Power System System Application Guide SAG584001200 NetSure 9500 400V DC Battery Cabinet Installation and Operation Manual e Battery Cabinet Installation and Operation Instructions IM58400120090 NetSure ACU Controller User Manual e ACU Controller User Instructions UM1M820NNB 2 USB Drive with All Customer Documentation e Power System Installation Instructions IM584001200 e Power System Operation Instructions UM584001200 e Battery Cabinet Installation and Operation Instructions IM58400120090 e Rectifier Instructions UM1R40015000e e Power System System Application Guide SAG584001200 e ACU Controller User Instructions UM1M820NNB 2 e Engineering Drawings e Also provided on the USB drive is an ACU configuration drawing and the ACU configuration files loaded into the ACU as shipped Spec No 584001200 Model No 9500 1 of 25 A EMERSON Network Power Recommended Tools and Test Equipment The following tools and test e
19. 090 to position and secure the Battery Cabinet to the floor A pallet jack or forklift is required to install the Battery Cabinet 3500 Ib capacity batteries shipped installed in the cabinet Making Electrical Connections Important Safety Instructions Wiring Considerations Danger Adhere to the Important Safety Instructions presented at the front of this document All AC input and 400V DC output wiring branch circuit protection and grounding earthing should follow the current edition of the American National Standards Institute ANSI approved National Fire Protection Association s NFPA National Electrical Code NEC and applicable local codes For operation in countries where the NEC is not recognized follow applicable codes For wire size branch circuit protection crimp lug and general wiring recommendations refer to System Application Guide SAG584001200 and the Battery Cabinet manual IM58400120090 General Grounding Earthing Guidelines For grounding earthing requirements refer to the current edition of the American National Standards Institute ANSI approved National Fire Protection Association s NFPA National Electrical Code NEC applicable local codes and your specific site requirements For operation in countries where the NEC is not recognized follow applicable codes Danger Failure to follow proper grounding earthing procedures can result in electric shock hazard to personnel and the risk of
20. 1 for location Figure 11 Power Module Bay EPO Emergency Power Off Terminals Qo mo 8o o EPO Connector Emergency Power Off 120KW Power Module Bay 584001200 List 01 Power and Control Section Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001 200 Issue AA April 14 2014 Power Module Bay Battery Breaker Alarm Shunt Trip Connections Power amp EMERSON Network Power Module Bay Battery Connections For Emerson provided Battery Cabinet a battery breaker alarm shunt trip cable P N 557867 is provided with the system This cable connects between the power and control section of the Power Module Bay see Figure 12 and the Battery Cabinet see Battery Cabinet instructions IM58400120090 Customer battery solutions must utilize a compatible battery breaker Also one 1 Battery Breaker Alarm Shunt Trip cable P N 557867 must be ordered for each battery string Battery breaker reguirements are as follows e Battery breaker must contain a 48V shunt trip with the following specifications a Rated Voltage 48 to 60 VDC b Maximum Release Duration 15ms c Minimum Resistance gt 15 ohm e Battery breaker must contain auxiliary contacts that are normally closed if the breaker is closed Minimum contact rating is 48V DC at 2A e It is recommended t
21. 584001200 Model No 9500 8 of 25 Issue AA April 14 2014 A NetSure 9500 120kW 400V DC Power System Installation Manual M584001 200 Issue AA April 14 2014 ET Table 2 Programmable Relay Outputs IB2 Programmable IB2 Alarms Assigned to this Relay Alarms Assigned to this Relay Relay Output Pin No Default Custom NO J6 5 1 COM J63 b ae Not Available NC J6 1 NO J6 6 2 COM J6 4 none NC J6 2 NO J7 5 3 COM J7 3 none NC J7 1 NO J7 6 4 COM 7 4 none NC 7 2 NO J8 5 5 COM J8 3 none NC J8 1 NO J8 6 6 COM J8 4 none NC J8 2 NO J9 5 7 COM J9 3 none NC J9 1 NO J9 6 8 COM J9 4 none NC J9 2 Model No 9500 5 9 of 25 Issue AA Apr 14 2014 NetSure 9500 120kW 400V DC Power System 5 Installation Manual IM584001 200 Issue AA April 14 2014 un Figure 9 Power Module Bay Temperature Probe Connections 2 a ou UU ws a Se i o di db db db A ES e o e o 9 I o e o 8 Leaf e e e Temperature Probe Connectors mE US 9 UN Y E Z IN 120kW Power Module Bay 584001200 List 01 Power and Control Section Spec No 584001200 Code IM584001200 Model No 9500 1 0 of 25 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System 9 Installation Manual IM584001200 Issue AA April 14 2014 ACU Co
22. 706 provides order shipping information and status Request DC Power Repair Service RMA Email EMEA HWServices Emerson com Creates and processes RMAs determines lead times and pricing Phone 421 32 7700 191 provides repair shipping information and status Spare Parts Email EMEA HWServices Emerson com Pricing and PO processing of spare parts including but not limited to breakers cables fuses rectifier fans misc breaker and fuse panels Phone 421 327700 881 enclosure fans doors amp switches etc DC Power Product Training Email EMEA Training emersonenergy com Requests for quotes order placement and scheduling For More Information To learn more about service offerings from Emerson Network Power please contact your sales representative or visit EmersonNetworkPower eu EnergySystems Spec No 584001200 Code IM584001200 Model No 9500 25 of 25 Issue AA April 14 2014 TM amp NetSure 9500 120kW 400V DC Power System EMERSON Installation Manual IM584001200 Issue AA April 14 2014 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 Refe
23. NetSure 9500 120kW 400V DC Power System Installation Manual IM584001200 Issue AA April 14 2014 Specification Number 584001200 Model Number 9500 EMERSON Network Power NetSure 9500 120kW 400V DC Power System amp Installation Manual M584001 200 Issue AA April 14 2014 a This page is intentionally blank Spec No 584001200 Code IM584001200 Model No 9500 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd Installation Manual IM584001200 Issue AA April 14 2014 eee Table of Contents Admonishments Used in this DoCUMENL sssscsscsssessssessssessssesssseessssessssessssessececsssesscsessssesasseesseneesssessnsesssees iii Important Safety Instructions iv ere vA iv Voltad amp Seis Wi ie ior Gn NWYD YN RYN dT NFYFC DF YN iv AC Input VOILA GOS P M iv DC Output and Battery Voltages eerte retener sassteecechetcsecnececbidenscadecdenecbiacactectigecsuesscbstsnecvceenesdvsaees iv Bathery UESIDMITOMEMI T iv Personal Protective Equipment PPE csscscssccsssscceccsceeceessscenceeesscescescescesseuecscesssasescesseassaceaseeeeeeseeceeeseeseneeeeeeees V Maintenance and Servicing Procedures cescsscsssesseseeeescesecsecseesecsecaeeaecsesseeaecaecseesseasesee
24. a built in one megohm resistor no external resistor is necessary Read and follow wrist strap manufacturer s instructions outlining use of a specific wrist strap 3 Do not touch traces or components on equipment containing static sensitive components Handle equipment containing static sensitive components only by the edges that do not have connector pads 4 After removing equipment containing static 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 If necessary to repair equipment containing static sensitive components wear an appropriately grounded wrist strap work on a conductive surface use a grounded soldering iron and use grounded test equipment Spec No 584001200 i Code 14584001200 Model No 9500 vii Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System amp Installation Manual M584001 200 Issue AA April 14 2014 a This page is intentionally blank Spec No 584001200 m Code 1M584001200 Model No 9500 viii Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System 9 Installation Manual M584001 200 Issue AA April 14 2014 General Information and Installation Checklist Customer Documentation Package This document 1M584
25. age is apparent If any damage is noted file a damage claim with the shipping agency within 24 hours and contact Emerson Network Power see NetPerform Optimization Services North America on page24 or NetPerform Optimization Services EMEA on page25 for contact information to inform them of the damage claim and the condition of the equipment Storing for Delayed Installation UO Rectifiers Installed Spec No 584001200 Model No 9500 2 of 25 If the equipment will not be installed immediately it must be stored indoors where the humidity is no higher than 95 non condensing The storage area must protect the system from excessive moisture Note For optimal battery life store Battery Cabinet at a temperature between 4 F to 77 F 20 C to 25 C Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System s Installation Manual IM584001200 Issue AA April 14 2014 Positioning and Securing the Power Module Bay 584001200 List 01 and Distribution Module Bay 584001200 List 07 to the Floor Position and secure the Power Module Bay and or Distribution Module Bay to the floor per site requirements Refer also to General Requirements on page 2 The Power Module Bay and Distribution Module Bay consists of rack P N 557861 standard or P N 557858 Seismic Refer to the following procedures STANDARD RACK P N 557861 INSTALLATION PROCEDURE 1 Use at least tw
26. arious alarm indicators may illuminate on the ACU front panel and an audible alarm may sound Disregard all alarms An audible alarm can be silenced at any time by momentarily depressing the ENTkey on the ACU Controller 1 Afterthe ACU is powered on the display alternates between the Emerson Network Power screen and a screen displaying Advanced Control Unit Plus Version Starting 2 Next the language screen appears Press the up or down arrow key to select the desired language Press the ENT key to confirm the selection If no key is pressed within 10 seconds the ACU selects the displayed language automatically English Spec No 584001200 Model No 9500 20 of 25 3 Asinitialization continues the Main screen is displayed but with zero volts Initialization is not complete 09 18 36 Float Auto NoAlm 4 When initialization is complete the Main screen displays voltage and current normally and no alarms are active 09 20 21 Float 380 0V 34A Auto NoAlm 5 System information is displayed in multiple screens Repetitively press the up or down arrow key to view other system information screens one by one 6 From the Main screen press ENT to go to the Main Menu screen Main Menu gt Status Settings ECO Mode Manual Quick Setting 7 From the Main Menu select a sub menu by repetitively pressing the up or down arrow key The selected sub menu will
27. attery Terminations M8 studs on 25mm 1 centers Batt Batt Batt Batt String String String String 1 2 3 4 Positive Battery Busbar Negative Positive Battery Busbars Bus this Side Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System S Installation Manual IM584001200 Issue AA April 14 2014 godere Electrical Connections to Distribution Module Bay Distribution Module Bay Distribution Panel List 21HA 584001200 List 07 Connections Distribution Module Bay Rack Frame Grounding Earthing Danger Adhere to the Important Safety Instructions Connection presented at the front of this document DO NOT attempt to work on an energized system Refer also to General Grounding Earthing Guidelines on page 4 A Warning Check for correct polarity before making Supply a grounding earthing lead from site ground earth to the rack ground bar Refer to Figure 14 for connection point Figure 14 Distribution Module Bay Rack Frame Grounding Earthing OUTPUT CONNECTIONS Load distribution leads are connected to the load distribution panel s as shownin Figure 15 connections Ground Bar Ground Bar M6 stud M6 stud ins en aia INTERCONNECTING DC DISTRIBUTION PANELS IF REQUIRED ters ters Recommended Recommend d DC distribution panels can be interconnected as shown in Figure Torque Torque 84 in lbs 9 5
28. be indicated by the cursor Press ENT to open the sub menu Note Repeatedly press the ESC key to return in reverse order level by level from any sub menu until the Main screen appears 8 Verify and set the ACU Controller as required for your application Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for procedures Note that you will have to program the ACU for any of the following a Battery capacity if different then the factory default of 120 Ah per battery string for the Emerson provided Battery Cabinet b Number of battery strings connected to the system This is set in the Module 1 Distribution menu Depending on the ACU configuration installed in your system 1 battery shunt or 4 battery shunts the menu item displayed is Battery Breaker 1 Installed or Battery String 1 Installed Fora 1 shunt system this sets the number of battery breakers being used in the system For a 4 shunt Code 1M584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd Installation Manual IM584001200 Issue AA April 14 2014 system this sets the number of shunts being used in the system and the number of battery breakers being used in the system c _ Temperature probes connected to the temperature probe inputs located on the power and control section of the Power Module Bay d External inputs outputs connected to the IB2 ACU Interface Board located on the power and cont
29. bs 9 5 Nm Front door removed in illustration for clarity only 120kW Power Module Bay 584001200 List 01 Negative Positive Bus Bus Figure 7 Power Module Bay DC Load Distribution Connections to Distribution Panel List 23HA Distribution Panel Customer Load Connection M8 studs on 25mm 17 centers Distribution Panel Distribution Panel Negative 200V DC Positive Recomended Torque 108 in lbs 12 Nm Front door removed in illustration for clarity only 120kW Power Module Bay 584001200 List 01 Power Module Bay IB2 ACU Controller Interface Board P N MA4C5U31 Connections The IB2 ACU Controller Interface Board provides connection points for digital inputs and programmable relay outputs The IB2 interface board is accessed from the rear of the power and control section of the Power Module Bay Loosen the two captive fasteners and slide the tray the IB2 assembly is mounted to out far enough to make the electrical connections Refer to Figure 8 When connecting input and output wires to the IB2 board route the leads through the opening provided in the tray the IB2 assembly is mounted to see Figure 8 DIGITAL INPUTS AND PROGRAMMABLE RELAY OUTPUTS Digital input and relay output leads are connected to screw type terminal blocks located on the IB2 Recommended torque for these connections is 2 2 in lbs
30. circuit breakers remain de energized during installation DO NOT apply AC input power to the system until all electrical connections have been completed and checked Spec No 584001200 Model No 9500 EMERSON Network Power DC Output and Battery Voltages DANGER This system produces DC Power and may have a battery source connected to it The DC voltage IS hazardously high and the rectifiers and or battery can deliver large amounts of current Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output terminal or battery terminal or exposed wire connected to an output terminal or battery terminal NEVER allow a metal object such as a tool to contact more than one termination or battery terminal at a time or to simultaneously contact a termination or battery terminal and a grounded object Even a momentary short circuit can cause sparking explosion and injury Follow local lockout tagout procedures to ensure DC branch circuit breakers remain de energized during installation at loads as required Extreme caution is required when performing maintenance Be constantly aware that this system contains high DC as well as AC voltages The maximum output voltage is 400V DC and is potentially lethal Check for voltage with both AC and DC voltmeters prior to making contact Battery if equipped iv DANGER When connected together the battery terminal voltage is 400V
31. cks Q o Relay J9 J8 J7 J6 J5 J4 J3 No 7 5 3 1 8 7 6 5 4 3 2 1 Input NO C NC NO C NC NO C NC NO C NC VEglegs egsegs osoeooeess No 31 6 31 5 31 5 3 1 5 3 115 3 1 5 3 1 NO C NC NO C NC NO C NC NO C NC O O OJO O OO O OO O O O O OJO O SJO Vag Relay 64 2 6 4 2 6 4 2 6 4 2 6 4 2 6 4 2 6 4 2 J12 No 8 6 4 2 87654321 Input LJ LILI LJ LJ L1 L1 L1 No eUiaa oar L1 _ Ed 0 0 O00 O un EE Ec ll lE m o EH ood mic A lo Luca moo O E Co UD D O Z SW1 Switch sections must be set to this position to interface with the ACU controller J3 J9 Wire Size Capacity 16 26 AWG 1 5 0 5mm Recommended Torque 2 2 in lbs 0 25 Nm Spec No 584001200 Model No 9500 7 of 25 Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System amp Installation Manual M584001 200 Issue AA April 14 2014 g rei Table 1 _ Programmable Digital Inputs IB2 Programmable Default Digital Customer Defined Digital Input Input Function Digital Input Function J3 2 1 none J3 1 J3 4 2 B3 none J3 6 3 B5 none J4 2 4 E none J4 4 5 43 none J4 6 6 14 5 none J5 2 7 5 1 none J5 4 8 153 none J5 5 48V J5 6 RTN 48V is available on terminal J5 5 and Return RTN is available on terminal J5 6 for customer connection to digital inputs Spec No 584001200 Code 1M
32. e nn enne tnter ennt ne enne nentes 4 Output Gro rid Configuration uineis itin ri cine era aora ater vanen P aeos eee o N DONEN AEE ENATOR ED a DAFAD AGO sa anas 4 Model No 9500 5 i Issue AA Apri 14 2014 NetSure 9500 120kW 400V DC Power System 9 Installation Manual IM584001200 Issue AA April 14 2014 a Cable ROUNO Em 4 MOU a Y FR E E A FFF YN HR R R R HF CR A RT FR AC NT E E 4 Electrical Connections to Power Module Bay 584001200 List 01 esee nennen 4 Power Module Bay Rack Frame Grounding Earthing Connection eese eene 4 Power Module Bay HRMG Connection esses nennen ener tenete nenne nennen tenete eene eene nenne 4 Power Module Bay AC Input Power and AC Input Equipment Grounding Earthing Connections 5 Power Module Bay DC Load Distribution Connections if DC distribution panel installed 5 Power Module Bay IB2 ACU Controller Interface Board P N MA4C5U31 Connections eese 6 Power Module Bay Temperature Probe Connections esses ELLYLL tette nnne nnne stein nein 6 ACU Controller Ethernet COTIlGCEOn iai tutos priae netto tot tinitenan stidne Pn Leo EDD gn Re eR puree 11 Power Module Bay External EPO Emergency Power Off Connections eese 11 Power Module Bay Battery Breaker Alarm Shunt Trip Connections eese 12 Power Module
33. e the cursor up and down the list of sub menus in the menu screen selects the sub menu then press ENT to enter the selected sub menu To Enter a Password If a password screen opens a password must be entered to allow the User to make adjustments To enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note If you have been assigned a unique User Name and password follow this procedure to enter these To Change a Parameter Press the up or down arrow keys to move the cursor up and down the list of parameters in the menu screen selects the parameter to change then press ENT to change the selected parameter The parameter field highlights Press the up or down arrow keys to change the parameter value Press ENT to confirm the change Table 3 shows the menu navigation for some basic settings Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for details and additional settings Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual M584001 200 Issue AA April 14 2014 Table 3 Configuring the ACU Identification of Rectifiers ACU Controller Basic Settings Local Menu Navigation Parameter Menu Navigation Date
34. eesasseasasceeeeeaeeeeeaeeaeeaeeaeeaees V ere C M E v D al Hazardous Iriput Power Sources utes Fee rnnnpt reete satuvdeuacusvunesetesvendeadeutunedvecsssdaesndaa EAEE NE vi Hazardous Voltage x t a Od Reque eR UR DR UAE EIER EISENACH dC PRISE PERI vi Handling Equipment Containing Static Sensitive Components 00 eeeesesseecseeeeeeesceecseeeeeceasseesceassesaeeeaseeeseeasseeaeees vi Static Ln M vii General Information and Installation Checklist eee ee reser eene eene eene eene nennen nna neta netus 1 Customer Documentation Package scsscsccsssscsessescecseseeseecsesesccescsesessessseesscsssenecssessesecscessesessascesesaseaeessenseeeeeeaes 1 NetSure 9500 120kW 400V DC Power System Installation Manual sess 1 NetSure 9500 120kW 400V DC Power System Operation Manual sess 1 NetSure 9500 400V DC Battery Cabinet Installation and Operation Manual sese 1 NetSure ACU Controller User Marital i 3 citet tette tt teer idees YT OD 1 USB Drive with All Customer Documentation esse seeseeseeesseeeeseeesseessseeseesseeacseeseseeaceassceaseaeaeeaeseeaseeseatees 1 Recommended Tools and Test Equipment esses enne nnt nnt nnne nne tn enne nn enne nn LL LY nL nn nn te nnne 1 Installation Acceptance Chec
35. g Examples are safety goggles or face shield a rubber apron and gloves e lf battery acid enters your eye immediately flush your eye with running cold water for at least 15 minutes Get medical attention immediately e If battery acid contacts skin or clothing wash immediately with soap and water ALERT Performing maintenance and or troubleshooting procedures may interrupt power to the loads if battery reserve is not sufficient Personal Protective Equipment PPE 4 A DANGER ARC FLASH AND SHOCK HAZARD Appropriate PPE and tools required when working on this equipment An appropriate flash protection boundary analysis should be done determine the hazard risk category and to select proper PPE Notice that PPE is applicable for both AC and DC voltages This product is intended only for installation in a restricted access location Only authorized and properly trained personnel should be allowed to install inspect operate or maintain the rack equipment Do not work on LIVE parts If required to work or operate live parts obtain appropriate Energized Work Permits as required by the local authority per NFPA 70E Standard for Electrical Safety in the Workplace or applicable local codes Maintenance and Servicing Procedures General WARNING All equipment maintenance and servicing procedures involve internal access and should be carried out only by trained personnel on a de energized system Extreme cauti
36. hat the battery breaker have a lock out tag out feature to allow for maintenance safety Power Module Bay Battery Shunt Connections The battery shunt connectors on the power and control section of the Power Module Bay are factory connected to the battery shunts also located in the Power Module Bay See Figure 12 Spec No 584001200 Model No 9500 Note Note Danger Adhere to the Important Safety Instructions presented at the front of this document DO NOT attempt to work on an energized system Warning Observe proper polarity when making battery connections The maximum short circuit capacity of the circuit breakers in the system is 25kAIC Therefore the maximum number of Emerson provided Battery Cabinets is limited to a maximum of three 3 The use of a fourth Battery Cabinet will exceed the short circuit rating of the circuit breakers in the system The short circuit current generated by a customer provided battery option cannot exceed 25kAIC Up to four battery strings can be connected to the battery terminals located in the Power Module Bay Connect the battery strings to the positive and negative battery connection points per Figure 13 Refer to SAG584001200 for wire size and crimp lug information See separate Battery Cabinet instructions IM58400120090 for connection points in the Battery Cabinet 12 0f 25 Code 1M584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Instal
37. heck with an Handling Equipment Containing AC and DC voltmeter to ensure safety before making Static Sensitive Components contact or using tools Even when the power is turned OFF dangerously high electric charges may exist within O ALERT Installation or removal of equipment containing the system Ned static sensitive components requires careful handling Before handling any equipment containing static sensitive components read and follow the instructions contained on the Static Warning Page Never work alone even if all power is removed from the equipment A second person should be standing by to assist and summon help in case an accident should occur Spec No 584001200 Code 14584001200 Model No 9500 vi Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd Installation Manual IM584001200 Issue AA April 14 2014 AS Static Warning A Aa ATTENTION This eguipment 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 eguipment 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
38. ibution Panels Interconnected if required U DC Input Connections Made BATTERY CABINET 584001200 LIST 90 91 92 93 Q Battery Cabinet Frame Grounding Earthing Connection Made Q 48V Battery Breaker Shunt Trip Connection Made O Battery Breaker Alarm Connections Made Q Battery Connections to the Power Module Bay Made positive and negative leads Installing the Rectifiers UO System Started Configured and Checked Installing the System General Requirements e This product is intended only for installation in a restricted access location on or above a non combustible surface e Theinstaller should be familiar with the installation requirements and techniques to be used in securing the rack s cabinet s to the floor e Temperature of air entering the system must not exceed rated operating ambient temperature range found in SAG584001200 e Front and rear access is required for installation Inspecting the Equipment and Storing for Delayed Installations Inspecting the Equipment Compare the contents of the shipment with the bill of lading Report any missing items to the carrier and your local Emerson representative immediately While the system is still on the truck inspect the equipment and shipping container s for any signs of damage or mishandling As the equipment is moved off the truck and unpacked visually examine the system for transit damage Do not attempt to install the system if dam
39. ion of the Power Important Safety Instructions Module Bay to the ON position Caution Performing various steps in the following 3 Place each rectifier module AC input circuit breaker procedures may cause a service interruption and or located on the front of the power and control section of result in the extension of alarms Notify any appropriate the Power Module Bay to the ON position Rectifiers personnel before starting these procedures Also notify automatically start personnel when these procedures are completed 4 Place each battery string circuit breaker to the ON osition Note Contact Emerson Services for startup assistance P 5 Place each load distribution circuit breaker in the Power Initial Preparation Module Bay if distribution panel is installed and Refer to Figure 17 for circuit breaker locations Distribution Module Bay s to the ON position Spec No 584001200 18 of 25 Code M584001200 Model No 9500 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd Installation Manual IM584001200 Issue AA April 14 2014 ae Figure 17 Circuit Breaker Locations 120KW Power Module Bay 120kW Power Module Bay Distribution Module Bay 584001200 List 01 584001200 List 07 yu F s Front door removed in Dp illustrations for clarity only E w y in Load Dis
40. k for your company s dedicated Customer Service Phone 1 800 800 1280 option 2 Associate Customer Support Center Post Shipment Email ESNACustomerSupportCenter Emerson com After an order has shipped contact our Customer Support Center Phone 1 956 661 6867 with related questions concerns or claims Account Management Email AccountManagement ESNA Emerson com Provides quotes and bid responses for custom configured DC power systems and outside plant enclosures for customers and channel partners Phone 1 800 800 1280 option 3 Reps VARs amp Distributors Spare Parts ESI DCpower Spares Emerson com Pricing and purchase orders for spare parts including but not limited to OSP Spares Emerson com breakers cables fuses rectifier fans misc breaker and fuse panels Phone 1 800 800 1280 option 5 enclosure fans doors and switches etc DC Power Depot Repair Email DCpower Repair Emerson com Creates and processes RMAs for depot repair and refurbishment Determines repair and refurbishment lead times and pricing based on warranties contractual agreements Provides repair shipping information Phone 1 800 800 1280 option 6 and status Technical Support DCpower TAC Emerson com OSP TAC Emerson com Answers technical product and system questions determines status of warranties and contractual agreements for repair Email Phone 1 800 800 5260 N Contact Account Management for custom configurations 1 Contact Spare Parts fo
41. klist ein iter rear ntn eon eterno eene eroe ote ener saeua Poena faena ain 1 Installing he Systemic iet ere esci te tee rte ee tere e DER e e ve e be RAF ee be ee abe ae erede ue Put 2 Making Electrical Connections i cissc issscacisccssscusdsonesesdessvscnssesanscedesxcostventesuasucsstesncsvieesloetacvudentussnsveassccouesdncovtcess 2 Installing the Rectiflers roseo enter rn ree aerae e SO Fette YNN DY SN CAN ag en DWF NER eH eu 2 System Startu ueu sil wn ee EE eene EF AG Y ON CYN SYW O AW YF RII vases conbignarcuvieedisepusadovass 2 Installing RETE cg eec M 2 General REQUIFEMEMES 5c c5s3 secscsececasiceceececs Fd 2 Inspecting the Equipment and Storing for Delayed Installations eese 2 INspecting the Equipments E 2 Storing for Delayed Installatio ERR 2 Positioning and Securing the Power Module Bay 584001200 List 01 and Distribution Module Bay 584001200 List 07 tothe FIOO s s ptr er e breton iere ended aedes 3 Positioning and Securing the Battery Cabinet 584001200 List 90 91 92 93 to the Floor esessss 4 Making Electrical Connections svir assos 4 linportant Safety lnstrtictionS cient ta ierat Pe CLUD FF RD RR nd Fd GY GG AEE 4 Wiring GonsideratiOnS ee Ieu eol uad dyn FD ma UEFA PUE ny nA Fn IT NF YNE F FERE ee ERAN BF a Tw Rae 4 General Grounding Earthing Guidelines esee eene entere nn
42. lation Manual IM584001200 Issue AA April 14 2014 eee Figure 12 Power Module Bay Battery Breaker Alarm Shunt Trip and Battery Shunt Connections Factory Connected 48V Battery Alarm Battery Battery Battery Breaker 1 4 Alarm Shunt Trip Shunt Shunt 2 1 Connector Pinouts Battery Alarm Battery m Shunt 1 4 t Shunt Trip RTN Battery Breaker 1 4 Gannepior 4 3 Alarm Shunt Trip Connector 48V Shunt Trip Use cable P N 557867 GIO GO 120kW Power Module Bay 584001200 List 01 Power and Control Section Spec No 584001200 Code 1M584001200 13 of 25 Issue AA April 14 2014 Model No 9500 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001 200 Issue AA April 14 2014 EMERSON Network Power Figure 13 Power Module Bay Battery Connections Recommended Torque 108 in Ibs 12 Nm Negative Bus this Side Main 120kW Power Module Bay DC Bus 584001200 List 01 Power and Control Section Ac cc ss Hs cc ss Aue Yg Spec No 584001200 Model No 9500 14 of 25 CUSTOMER CONNECTION TO BATTERY STRINGS Battery Terminals for 400V DC Battery Strings B
43. ld result in death or serious injury if not avoided This admonition is not used for situations that pose a risk only to eguipment 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 eguipment 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 eguipment 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 Safety FIRE SAFETY Informs the reader of fire safety information reminders precautions or policies or of the locations of fire fighting and fire safety equipment ISO 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 584001200 Model No 9500 Code 1M584001200 iii Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001 200 Issue AA April 14 2014 Important Safety Instructions General Safety DANGER YOU MUST FOLLOW APPROVED SAFETY PROCEDURES Performing
44. let Spec No 584001200 3 of 25 Model No 9500 EMERSON Network Power 6 Useapallet jack or forklift to raise the rack off the shipping pallet 7 Slide the shipping pallet out from under the rack 8 Position the rack for installation with the pallet jack or forklift 9 Bolt the rack to the floor per site requirements Figure 1 Removing Rack P N 557861 from Shipping Pallet Leave brackets bolted to the rack ifthey will be used to secure the rack to the floor Remove lag bolts from brackets on front and rear of the rack to free the shipping bracket from the pallet Rack will rest on casters when removing the shipping bolt down bracket Figure 2 Rack P N 557858 Floor Hole Drilling Pattern 84 84 4 A1 3314 3 314 17 37 X Y Ed i 898 35 37 y2 YX e NI pu Bottom View Notes 1 Dimensions are in mm inches Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System S Installation Manual IM584001200 Issue AA April 14 2014 EMERSON Network Power Positioning and Securing the Battery Cabinet 584001200 List 90 91 92 93 to the Floor Position and secure the Battery Cabinet to the floor per site requirements Refer also to General Requirements on page 2 The Battery Cabinet is furnished with separate installation and operation instructions Refer to these instructions IM58400120
45. n ennt enne 21 Checking Basic System Settinggs ecce iere treten eret ee einen e ete there eae seat tese Poena aenea eerie enean needs 21 Configuring the ACU Identification of RECtifiCrS 0 eee eeseeesseseeseseeeeseeeeseeacsceseeaeseeatseeaceesesassetacsessceaeseeassesaeeases 22 Checking the EPO Emergency Power Off Circuit if connected sss enne 23 EPO Emergency Power Off FUNCtION cssssscesessseseeseeseeseeseeseeseesecsecsecsesaeeseeaecseesaeeceeesaseneeseeaeeaeeaeeaeeaeeaeeaees 23 Checking System Status ves i iet er e ED RESINA SRI GDC dc ddd DID aY SEE ees Gao 23 Flite Ste M 23 NetPerform Optimization Services North America eeeeee eese en ee eee ene eene tn nennen assess aset essa sss tens seno 24 NetPerform Optimization Services EMEA sssccsssssccsssscsecssssescssssccecssscesssscccsssscccesssscccesssscsesssscesesesseeesees 25 Spec No 584001200 si Code IM584001200 Model No 9500 i Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd EMERSON Installation Manual IM584001200 Issue AA April 14 2014 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 cou
46. ntly identified by the ACU as rectifier If this is not the rectifier you want press ESC to return to rectifier menu screen and select a different rectifier Navigate to and select Rectifier ID Press ENT Use the up or down keys to change the ACU identification number for the flashing rectifier Press ENT Press ESC to return to rectifier menu screen Repeat steps 4 through 6 for each of the remaining rectifiers in the system Code 1M584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System amp Installation Manual IM584001200 Issue AA April 14 2014 EMERSON Network Power 8 When you have finished selecting identification numbers for all rectifiers repeatedly press ESC to return to the Main Menu 9 Navigate to and select Manual ENT Rectifier ENT All Rect Ctrl ENT 10 Navigate to Confirm ID PH Press ENT Yes highlights 11 Press ENT to select the operation Press ENT again to confirm Note Check your numbering to be sure it is correct If there where conflicts in your numbering rectifiers with conflicts will be assigned the next available sequential number 12 Return to the Main screen by repeatedly pressing ESC escape Checking the EPO Emergency Power Off Circuit if connected EPO Emergency Power Off Function section of the Power Module Bay If the system is operating normally the status of these is as shown in
47. ntroller Ethernet Connection The ACU controller provides a Web interface via an Ethernet connection This interface can be accessed locally on a computer or remotely through a network An RJ 45 10BaseT jack is provided on the front of the ACU controller for connection to a computer or into a customer s network This jack has a standard Ethernet pin configuration scheme twisted pair Referto Figure 10 for location Use shielded Ethernet cable grounded at both ends Note that the ACU RJ 45 jack is connected to chassis ground Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for operational details Warning The intra building port s of the equipment or subassembly is suitable for connection to intra building or unexposed wiring or cabling only The intra building port s of the equipment or subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its wiring These interfaces are designed for use as intra building interfaces only Type 2 or Type 4 ports as described in GR 1089 CORE Issue 4 and require isolation from the exposed OSP cabling The addition of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP wiring The intra building port RJ 45 of the equipment or subassembly must use shielded intra building cabling wiring that is grounded at both ends Figure 10 ACU Ethernet Port 10 100M Ethernet Port RJ 45
48. o people when moving the rack 2 Usinga pallet jack or forklift move the rack on its pallet tothe installation location 3 Cutthe shrink wrap and remove all packaging 4 Useal4mm socket or a 14mm wrench to remove the lag bolts securing each shipping bracket to the shipping pallet There are two brackets one in the front and one atthe rear of the rack Each bracket is secured by four bolts see Figure 1 Note Shipping brackets can also be used as an anchor bracket once unit is at final resting place Leave the shipping brackets attached if they will be used to secure the rack to the floor 5 Usea pallet jack or forklift to raise the rack off the shipping pallet 6 Slidethe shipping pallet out from under the rack 7 The rack may be positioned for installation either with the pallet jack or forklift or by rolling the rack on its casters If the casters are to be used to move the rack the leveling feet must be raised Position the rack and either lower the leveling feet or bolt the rack to the floor with the shipping anchoring brackets SEISMIC RACK P N 557858 INSTALLATION PROCEDURE 1 Use at least two people when moving the rack 2 Refer to Figure 2 and prepare the floor for the anchors being used to secure the rack 3 Using a pallet jack or forklift move the rack on its pallet tothe installation location 4 Cutthe shrink wrap and remove all packaging 5 Remove the bolts securing the rack to the shipping pal
49. on is required when performing maintenance and servicing procedures Be constantly aware that this system contains high DC as well as AC voltages Check for voltage with both AC and DC voltmeters prior to making contact Special safety precautions are required for procedures involving maintenance of this system and the batteries Code IM584001200 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Ad Installation Manual IM584001200 Issue AA April 14 2014 Ee Observe all safety precautions in this manual and in the Dual Hazardous Input Power Sources battery instruction manual before as well as during performance of all maintenance procedures Observe WARNING The system may be powered from dual all battery safety precautions before working on or near hazardous input power sources simultaneously the batteries Service personnel and test equipment Commercial AC and Battery DC Disconnect both should be standing on rubber mats Service personnel sources of power before servicing should wear insulating shoes for isolation from direct contact with the floor earth ground Hazardous Voltage DANGER Hazard of electrical shock More than one disconnect may be required to de energize the system before servicing This equipment contains several circuits that are energized with dangerous voltage Only test equipment designed for troubleshooting should be used This is particularly true for oscilloscopes Always c
50. plete probe See SAG584001200 for part numbers and descriptions Temperature probes are connected to connectors located on the rear of the power and control section of the Power Module Bay See Figure 9 Up to six 6 temperature probes can be connected to the power and control section of the Power Module Bay Any combination of the six 6 temperature probes can be programmed to monitor Spec No 584001200 6 of 25 Code IM584001200 Model No 9500 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Installation Manual IM584001200 Issue AA April 14 2014 ambient air temperature and or battery temperature A temperature probe set to monitor battery temperature can also be used for the rectifier battery charge temperature compensation feature The battery charge temperature compensation feature allows the controller to automatically increase or decrease the output voltage of the system to maintain battery float current as battery temperature decreases or increases respectively Battery life can be extended when an optimum charge voltage to the battery with respect to temperature is maintained A temperature probe set to monitor battery temperature can also be used for the BTRM Battery Thermal Runaway Management feature The BTRM feature lowers output voltage when a high temperature condition exist to control against battery thermal runaway amp EMERSON Network Power A temperature probe programmed to
51. quipment are recommended to install the DC Power System Contact Emerson for a full turn key installation quote e Non Contact Voltage Detector e Digital Multimeter DMM Capable of Measuring System AC Input and DC Output Voltages 600V AC DC Rated e NO OX ID A or Approved Equivalent e lineman Scissors e lineman Strippers e lineman s Cutters e Electrician s Insulated Screwdrivers Phillips No 1 and 2 e Electrician s Insulated Screwdrivers Flat Blade Small and Large e Insulated Nut Driver Set e Hexagonal Bit Set e Ratchet 1 2 13mm Drive e 10mm Socket 13mm Socket 14mm Socket or 14mm Wrench e Adjustable Torque Wrench 1 2 13mm Drive 0 in Ib 0 Nm to 125 in lb 14 Nm e Lug Compression Crimp Tool for Field Provided Battery Power Cable Terminations as required e Pallet Jack or Forklift Required to Move the Power Module Bay 367 Kg 810 Ibs Distribution Module Bay 204 Kg 450 lbs and Battery Cabinet 1500 Kg 3300 Ibs in Place e Tools Required for Rack Cabinet Floor Fastening Hardware Installation Acceptance Checklist Provided in this section is an Installation Acceptance Checklist This checklist helps ensure proper installation and initial operation of the system As the procedures presented in this document are completed check the appropriate box in this list If the procedure is not required to be performed for your installation site also check the box in this list to indicate
52. r Voltage 2 you have been assigned a unique User Name and password When rectifier modules are all installed prior to applying power and starting the system the order in which the ACU identifies the rectifiers is by serial number lowest serial number is Rect 1 next lowest is Rect 2 etc If you prefer the ACU to identify the rectifiers by position in the system perform the following procedure PROCEDURE 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Settings ENT 2 Ifa password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT O is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note If Spec No 584001200 Model No 9500 22 of 25 follow this procedure to enter these With the Settings menu screen displayed navigate to and select Rectifier ENT Navigate to Rect is used here to represent the rectifier identification number Press ENT The rectifier menu screen is displayed and the green LED on one rectifier starts flashing This is the rectifier curre
53. r parts and accessories For More Information To learn more about service offerings from Emerson Network Power please contact your sales representative call 1 800 800 1280 option 7 email ES Services Emerson com or visit EmersonNetworkPower com EnergySystems Spec No 584001200 Code IM584001200 Model No 9500 24 of 25 Issue AA April 14 2014 NetSure 9500 120kW 400V DC Power System Fd Installation Manual IM584001200 Issue AA April 14 2014 n NetPerform Optimization Services EMEA At Emerson Network Power we understand the importance of reliable equipment it s critical to both your business and your bottom line That is why we offer a wide array of services to meet all of your network infrastructure needs Technical Support Contact your sales representative Provides quotes and bid responses order placement and scheduling Freedom for design and deployment and optimization services Download Cre EmersonNetworkPower com service amp maintenance reports online EMEA Customer Support Center ESEMEACustomerSupportCenter Dealing with customer problems related to Emerson com Product field performance Product quality defects Product dead on arrival Incomplete or incorrect deliveries Quality and product support Email Phone 421 32 7700 888 Order DC Power amp OSP Order Status Email OPC EES EmersonNetworkPower com Creates and processes orders determines lead times and pricing Phone 421 32 7700
54. replaced with an incorrect type or if polarity is reversed When replacing batteries replace with the same manufacturer and type or equivalent e Dispose of used batteries according to the instructions provided with the batteries Do not dispose of batteries in a fire They may explode e ALWAYS FOLLOW THE BATTERY MANUFACTURER S RECOMMENDATIONS AND SAFETY INSTRUCTIONS In addition to the hazard of electric shock gas produced by batteries can be explosive and sulfuric acid can cause severe burns Do not open or mutilate batteries Released electrolyte is harmful to the skin and eyes and is toxic If electrolyte comes into contact with skin the affected area should be washed immediately with large amounts of water DANGER This equipment may be used in conjunction with lead acid batteries Working near lead acid batteries is dangerous e Batteries contain sulfuric acid e Batteries generate explosive gases during normal operation Systems containing batteries should never be installed in an airtight room or space Only install in a ventilated environment e Batteries are an energy source that can produce high amounts of electrical current Spec No 584001200 Model No 9500 v amp EMERSON Network Power FOR THESE REASONS IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS AND FOLLOW THEM EXACTLY WHEN WORKING WITH LEAD ACID BATTERIES e Wear complete protection for eyes face hands and clothin
55. rol section of the Power Module Bay Verifying the Configuration File Your ACU controller was programmed with a configuration file that provides initial settings for all adjustable parameters The version number of the configuration file can be found on the configuration drawing C drawing that is supplied with your power system documentation and ona label located on the ACU You can verify that the correct configuration file has been loaded into your ACU by performing the following procedure PROCEDURE Note When viewing any of the following screens if a key is not depressed within approximately 10 seconds the ACU will automatically return to the Main screen 1 With the Main screen displayed press ESC A screen displays the serial number and software version 2 Press ENT A screen displays the hardware version and MAC address 3 Press ENT Ascreen displays the configuration version number 4 Press ESC or wait approximately 10 seconds to return to the Main screen Changing Battery Capacity Rating in the ACU To change the battery capacity setting of the ACU to match the battery connected to the power system perform the following procedure PROCEDURE 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Settings ENT 2 Ifa password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not
56. rto 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 EnergyS ystems EMEA Emerson Network Power Energy Systems North America Inc 2014 While every precaution has been taken to ensure accuracy and completeness herein Emerson Electric Co assumes no responsibility Business Critical Continuity 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 trademar ks of Emerson Electric Co EnergyMaster eSure NetPerform
57. the following procedures may expose you to hazards These procedures should be performed by qualified technicians familiar with the hazards associated with this type of equipment These hazards may include shock energy and or burns To avoid these hazards a Thetasks should be performed in the order indicated b Remove watches rings and other metal objects C Priorto contacting any uninsulated surface or termination use a voltmeter to verify that no voltage or the expected voltage is present Check for voltage with both AC and DC voltmeters prior to making contact d Wear eye protection e Usecertified and well maintained insulated tools Use double insulated tools appropriately rated for the work to be performed f Do not work on an energized system without full arc flash and PPE protection DANGER All power and control wiring should be installed by a qualified electrician All power and control wiring must comply with the National Electrical Code NEC and applicable local codes For operation in countries where the NEC is not recognized follow applicable codes Voltages ACInput Voltages DANGER This system operates from AC input voltage capable of producing fatal electrical shock AC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any AC electrical connections are made Follow local lockout tagout procedures to ensure upstream branch
58. the respective rectifier module s AC input circuit breaker on the front of the power and control section of the Power Module Bay Refer to Figure 17 for circuit breaker location Place the Latch Release located on the front of the rectifier module to the LEFT position See Figure 16 Place the rectifier module into an unoccupied mounting slot without sliding it in completely Gently push the rectifier module into the mounting slot until it stops Note that the rectifier module will NOT be completely seated in the mounting slot until the next step is performed Live Systems Wait for the green power indicator to illuminate Ensuring the green power indicator stays on slide the Latch Release located on the front of the rectifier module to the RIGHT position Gently push the rectifier module into the mounting slot until it is completely seated De energized Systems Slide the Latch Release located on the front of the rectifier module to the RIGHT position Gently push the rectifier module into the mounting slot until it is completely seated Secure the rectifier module to the power and control section of the Power Module Bay by tightening the retaining screw Repeat the above steps for each rectifier module being installed in the system After the rectifier modules are physically installed in their mounting slots they are ready for operation immediately after power is supplied to them Close the respective rectifier module
59. tribution leh MO Circuit Breakers 1 i Load Distribution p W Circuit Breakers Load Distribution m ot Circuit Breakers p W W m w Main AC Input Load Distribution hu m Load Distribution Circuit Breaker Circuit Breakers wO Circuit Breakers 250A go 380V 400V 480V AC a w Rectifier Module Front AC Input Circuit Breakers 40A 380V 400V 480V AC Spec No 584001200 Code 1M584001200 Model No 9500 1 9 of 25 Y 14 2014 NetSure 9500 120kW 400V DC Power System 5 EMERSON Installation Manual IM584001 200 Issue AA April 14 2014 Network Power ACU Controller Initialization Note Your ACU controller was programmed with a configuration file that provides initial settings for all adjustable parameters Provided on a USB drive furnished with the system is an ACU configuration drawing C drawing and the ACU configuration files loaded into the ACU as shipped Refer to the ACU Controller Operation Instructions UM1M820NNB 2 for detailed instructions Refer to Figure 18 for locations of the ACU local indicators and navigation keys Figure 18 ACU Controller Local Indicators and Navigation Keys Information Alarm Indicator Yellow Status Warning or Critical Indicator Alarm Indicator Green Red 10 100M Ethernet Port RJ 45 USB Port Menu Navigation Keys PROCEDURE Note The initialization routine takes several minutes During that time v
60. uit breakers in the system Batteries are factory installed and connected in the Battery Cabinet Note Batteries are physically factory installed but require one series strap connection to complete the string wiring The batteries as shipped are connected with one wire disconnected in the middle of the string for shipping safety The Battery Cabinet is furnished with separate installation instructions IM58400120090 Refer to these instructions to make the follow connections to the Battery Cabinet e Battery Cabinet Frame Grounding Earthing Connection see also General Grounding Earthing Guidelines on page 4 e 48V Battery Breaker Shunt Trip Connection see also Power Module Bay Battery Breaker Alarm Shunt Trip Connections on page 12 e Battery Breaker Alarm Connections see also Power Module Bay Battery Breaker Alarm Shunt Trip Connections on page 12 e Battery Connections to the Power Module Bay see also Power Module Bay Battery Connections on page 12 amp EMERSON Network Power Installing the Rectifier Module The rectifier module is hot swappable It can be installed with the system operating if these instructions are carefully followed Note There is a two step insertion process PROCEDURE 1 2 10 Spec No 584001200 17 of 25 Model No 9500 Unpack the rectifier module If present remove the blank cover panel from the rectifier module mounting position Open

Emerson 120kW Installation Manual

Contents

Download Pdf Manuals

Related Search

Related Contents