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NetSure™ -48V DC Power System

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1. OO0O0000000000000 NN 45 09 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs Spec No 582127000 45 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 EMERSON Network Power SM DU and Shunt Interface Assembly Replacement PROCEDURE 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 future alarms associated with this system while the procedure is being performed DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination 2 Openthe distribution cabinet s front door by turning the latch in the counterclockwise position WARNING Damage to the circuit card may result if the next step is not followed 3 Connectan approved grounding strap to your wrist Attach the other end to a suitable ground 4 Carefully label the wires connected to the shunt input terminal blocks on circuit card These wires must be connected to the same terminals on the replacement circ
2. iii Personal Protective Equipment PPP ivt Eater caen eR Vra aen ears Uva Viv x ausos iv iv Handling Equipment Containing Static Sensitive COMPONENLS sssccccccccceecccseeeesssssesececcceceeeeeeseauaeasssseeeeeeeeees iv VV T V Syste mM OV 25 cc D P 1 Customer 1 SECU eapite 1 Operating PE OG COG 2 Controller Rectifiers and 5 2 1 2101 X 2 Controller Battery Charge Current Limit Feature 2 ontos and Indic ONS ER 3 eA Css ci M 10 System Maintenance S 10 Adding a Rectifier or Converter Module to an Exist
3. 39 109 1917 6 QJ e i 1 These cables SG factory connected Existing Module Mounting Shelf gt A iD Disconnect cable coming from distribution cabinet from this connector on bottom most m existing shelf then connect to the top connector on the expansion shelf il Expansion Module Mounting Shelf 1 a lia DP it 149 cla ep dV Connect the cable disconnected above coming from distribution cabinet to bottom Exploded View Shown to Illustrate Wire Connections Only connector on expansion shelf Spec No 582127000 15 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Installing a Field Expansion Module Mounting Shelf module mounting shelf and the studs on the shelf above Spec No 588705300 it Secure these busbars to the expansion module mounting shelf with the hardware provided with the DANGER Adhere to the Important Safety Instructions expansion module mounting shelf Secure these busbars presented at the front of this document to the shelf above the expansion module mounting shelf Note Refer to Figure 10 and Figure 11 as this procedure is performed is PROCEDURE Hardware build up
4. F3 CRS J2 CRI RM gt ors 5 40973 Fa Q Replacing a Distribution Panel DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination PROCEDURE Note Refer to Figure 35 as this procedure is performed Removing the Distribution Panel 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position Remove the plastic shield covering the circuit breakers or fuseholders on the panel to be removed by loosening the screws holding the shield and sliding the shield upwards Disconnect all load or battery wiring from the circuit breaker or fuse positions On panels equipped with a ground busbar remove all load return or battery return wiring from the ground busbar On panels equipped with shunts label the shunt leads then remove them from the panel Code UM582127000 Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 EMERSON Network Power 6 Locate the in line FA CBA connector located near the back of the panel and separate the connector halves 7 Re
5. NR NECEM RAM Ivi eiewesevad S TEES SEE 59 Model No J21NPBB 0 sue AH February 17 2019 NetSure 48V DC Power System amp EMERSON User Instructions UM582127000 Issue AH February 17 2015 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 Safety FIRE SAFETY Informs the reader of fire safety information reminders precautions or policies or of the locations of fire fighting and fi
6. 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 Specification Number 582127000 Model Number 721NPBB SS te a Se Sa SS Sana SS 9 09 90 9 9 o o 6 B B 98 Main Bay Supplemental Bay Main Bay Supplemental Bay E W Spec No 588705000 Module Mounting Shelves E W Spec No 588705300 Module Mounting Shelves EMERSON NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 PEE This page is intentionally blank Spec No 582127000 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE Table of Contents Admonishments Used in this Document esesesssesossesosssscossecosseccossecosseccossecossecossecossesosssecosssecossecossecossescossecosseeoo ii Important Safety Instructions ee eR P iii S RELIANCE m m iii idol T c iii inia
7. GUT dem Refer to Figure 12 and remove the hardware securing the 24V jumper leads Insulate and tie back these leads 10 Referto Figure 12 andlocate the in line FA CBA connector located near the back of the distribution panel Separate the connector halves 11 Referto Figure 12 and remove the hardware securing the distribution panel s ground busbar to the distribution cabinet s busbar 12 Referto Figure 12 and remove the hardware securing the distribution panel s system load distribution busbar to the distribution cabinet s busbar 13 Referto Figure 12 and remove the hardware securing the distribution panel to the distribution cabinet Remove the distribution panel from the distribution cabinet Spec No 582127000 19 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 eee Figure 12 Removing Installing the Distribution Panel 10 32 x 5 8 Screw Ground Busbar 10 Flat Washer Hardware 1 4 20 x 1 Bolt Torque to 31 in Ibs Distribution Panel 1 4 Flat Washer Hardware Components removed in illustration for clarity only 0 9 9 99900000 OO OG 35141551 555 222220 List DB Dual Voltage Distribution Panel List DA DC DD similiar Spec No 582127000 Model No
8. 1 From the front of the distribution panel remove the three bolts and hardware from the 24V input power busbar 2 From rear of the distribution panel remove the two bolts and hardware from the 24V input power busbar 3 Remove the 24V input power busbar from the distribution panel Set aside for later re installation 4 Remove the three 24V input lead busbars from the distribution panel Refer to Figure 14 and press in the tab to release a 24V input lead busbar Slide the 24V input lead busbar up and out of the distribution panel Repeat for all three busbars Set aside for later re installation Figure 14 Removing the 24V Input Power Busbar and Input Lead Busbars List DB Dual Voltage Distribution Panel 24V Input Lead Busbars List DA DC DD similar lt gt Press in Tabs to Release Input Lead Busbars 24V Input Power Busbar A Y A URP Met IIS NA M CREER RES Q YL AG 21256 7 4 19 2 e 21 A f 2 ORES p DAZ x 2 Q 24V Input Power Busbar Spec No 582127000 22 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE Moving the Distribution Device Busbar and Distribution Lead Busbars Left or Right
9. PROCEDURE 1 Determine how you are reconfiguring the distribution panel adding 48V or 24V distribution positions Locate the distribution device busbars and distribution device lead busbars to be moved 2 From the front of the distribution panel remove the two screws and hardware securing the appropriate distribution device busbar s The busbar s are located to the left or to the right of the open space created when the 24V input power busbar was removed in the previous procedure 3 From the rear of the distribution panel remove the two bolts and hardware securing the distribution device link busbar s between the distribution device busbar s to be moved and the one adjacent to it 4 Slidethe distribution device busbar s three 3 positions to the left or to the right 5 From the front of the distribution panel re install the two screws and hardware to secure the distribution device busbar s just moved Torque as indicated in Figure 15 6 Fromtherear of the distribution panel re install the distribution device link busbar s between the distribution device busbar s just moved and the one adjacent to it with the two bolts and hardware previously removed Apply anti oxidizing compound to busbar mating surfaces Torque as indicated in Figure 15 7 Removethe four distribution device lead busbars located above the position s of each of the distribution device busbar s were moved from Refer to Figure 15 and press in the tab to
10. amp User Instructions UM582127000 Issue AH February 17 2015 EE Reconfiguring a Dual Voltage Distribution Panel Perform the following procedure to reconfigure a dual voltage distribution panel List DA DB DC DD to move distribution positions from one voltage to the other DANGER Performing this procedure exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination Note Save all removed hardware Hardware will be re used Removing the Distribution Panel PROCEDURE 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 future alarms associated with this system while the procedure is being performed 2 Open distribution cabinet s front door by turning the latch in the counterclockwise position P Remove the plastic shield covering the circuit breakers and or fuseholders on the distribution panel to be removed by loosening the screws holding the shield and sliding the shield upwards Record circuit breaker and or fuse positions and sizes Remove circuit breakers and or fuseholders Label the load leads Disconnect all load leads from the circuit breaker and or fuse positions Disconnect all load return leads from the ground busbar
11. into corresponding sockets on distribution panel Fuseholder Assembly Fuseholder Body Longer Side TPS TLS Fuse ode GMT X Ls Car Safety Fuse Cover Replacement Fuseholder Assembly P N 248898700 Exploded View Polarizing Keyway Fuseholder Assembly P N 117201 includes Matches Key on body amp carrier alarm fuse and alarm fuse safety cover GMT 18 100A Bottom of Fuse Carrier Alarm Fuse Replacement P N 248610301 Replacing a Bullet Nose Circuit Breaker 3 Gently rock the defective circuit breaker up and down while pulling firmly outward until the breaker is free from PROCEDURE the distribution panel Note Referto Figure 21 as this procedure is performed 4 Ensure that the circuit breaker is in the OFF position and 1 Open the distribution cabinet s front door by turning the is of the correct rating latch in the counterclockwise position 5 Orient the circuit breaker as shown in Figure 21 Insert the terminals on the rear of the circuit breaker into their corresponding sockets on the distribution panel Ensure the alarm contact on the back of the circuit breaker 2 Operate the defective circuit breaker to the OFF position Spec No 582127000 31 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 makes contact with the alarm terminal on the spring stri
12. the old circuit card Jumper settings are documented in the Setting Jumpers and Switch Options section of the Power System Installation Instructions IM582127000 Slide the replacement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card Plug all connectors removed from the old circuit card into the same position on the replacement circuit card DANGER In the next step external alarm wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object Reconnect the external wiring to the correct terminals on the customer connection terminal block First remove the electrical tape that was applied to the bare wire end a previous step DO NOT allow the bare wire end to contact any grounded or energized object After securing the wire gently tug on the wire to ensure that it cannot be pulled out of the terminal block Repeat for each wire to be reconnected Remove the grounding wrist strap Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet Close the distribution cabinet s front door Turn the latch clockwise to secure the door Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System S User Instructions UM582127000 Issue February 17 2015 EMERSON Network Power 17 Enable the external alarms o
13. through the use of the DOWN Position ON Controller controls LVD s LVD Inhibit switch Spec No 582127000 6 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48V DC Power System 3 User Instructions UM582127000 Issue February 17 2015 Optional LVD Driver Lite Circuit The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit switch and indicator Refer to Figure 4 LVD driver lite circuit cards are required for distribution cabinets that contain two LVLD contactors or one LVLD contactor and one LVBD contactor LVBD contactor must be rated at 600A or lower Figure 4 Optional LVD Driver Lite Circuit Card CAUTION If the switch is returned to the ON normal position when low voltage disconnect alarms are active a low voltage disconnection will occur WARNING While the LVD inhibit switch is in the OFF inhibit position a low voltage disconnection will not occur if battery or load voltage decreases below the low voltage disconnect setpoint For maximum battery protection this switch should NOT be left in the OFF inhibit position B 542 873 O 547874 154415 rir Switch and indicator located on circuit card installed in Main Bay onl y Note The UP position will not close the LVBD contactor VD Inhibit if the battery is manually disconnected using the Manual Battery Disconnect Switch Active Indi
14. 1V8 01 Code UM582127000 Issue AH February 17 2015 37 Spec No 582127000 Model No 721NPBB amp EMERSON Network Power 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 NINO 5 5 M 4 S434V348 4181 1VOINVHO3A 1V21312313 804 NOILdO 911314 90 AINO siNnHs 3 Suayv3ug 41 1 1 1312113 404 1140 91131 Su3uviug 4131 1 1313113 804 NOILdO 911318 160 0411 GOP HLIM FONVGYODOY NI 03851104 38 TIVHS ALIOVdVO ANY ALILNYNO TWOIdAL 3uV NMOHS Su3uv3N8 1102812 110 Su3yv3ug 4141 TVOINVHO3N 1721912313 404 NOILdO ONINIA 720 Ol Noi1vu3d0 404 54 31 LNAHS 543434 AMivusvdis 38 LSNW ANY ASSY 40 1 031312345 ISIMYIHLO LON SQV31 40109 80 4 404 43811 NMOHS SYIMVAYG GALNNHS 90 LON Su3dwnr 113813 ANY SYAMVING LINDYID 10 SALON 9NI3n12V30NYA 3100 5N1933NI9N3 310N 911 84 676 uvasng 10 SALON gt 28 1811 yyasna 2 AND 0 4 ND 01 43411033 Sv Au3llv8 Figure 26 GJ 218 Circuit Breaker Wiring Diagram List BC and BD Code UM582127000 Issue AH February 17 2015 38 uyasnd 0 4 2 Lyd uvasna 1V8 Ol Spec No 582127000 Model No 721NPBB NetSure 48V DC Power System ss EMERSON User Instructions UM582127000 Issue AH February 17 2015 Network Power Circui
15. 721NPBB IR 1 4 Belleville Lock Washer Torque to 60 in lbs List DB Dual Voltage O N SR 69 20 Distribution Panel morc t 2 List DA DC DD similiar GARR Re r lt AA il i 4 662 TRZ X fl Ce GIA 2 AGA AA Se 10 32 x 5 8 Screw 810 Flat Washer Torque to 31 in lbs ef alo Distribution Panel SS Hardware System Load RL C 44 Distribution Busbar ARR A 20 Hardware 1 4 20 1 Bolt dd 2 ARG gt 1 4 Belleville Lock Washer Si AA 1 4 Flat Washer Torque to 60 in Ibs In Line FA CBA Connector 1 4 20 x 5 8 Bolt 1 4 Lock Washer 1 4 Flat Washer Torque to 75 in Ibs O 9 O O O O O O O O O 0 0 0 yO O O O O 5 NA Gena RESO 21 5 55 20 582127000 Issue AH February 17 2015 NetSure 48V DC Power System S User Instructions UM582127000 Issue February 17 2015 Reworking the Distribution Panel Introduction You can reconfigure the distribution panel to swap 24V distribution positions for 48V distribution positions and vice versa in groups of four The resulting assembly can have 5 24V
16. Board Controller Main Bay SM DU Supplemental Bays Mounting Position Optional LVD Driver Circuit Card Inhibit Switch Optional LVD factory installed if option specified Optional Manual Battery Disconnect Circuit Card Main Bay Only System Interface Circuit Card o O gt um gt 9 OJ T2 Q O Code UM582127000 Issue AH February 17 2015 4 Spec No 582127000 Model No 721NPBB NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 System Interface Circuit The system interface circuit card contains test points to externally monitor bay voltage and bay load Refer to Figure 2 Figure 2 System Interface Circuit Card Bay Load Shunt Scale List 21 1 Row Cabinet 800A 25mV 32A per mV List 22 2 Row Cabinet 2000A 25 80A per mV List 23 3 Row Cabinet 2500A 25 100A per mV List 24 4 Row Cabinet 2500A 25 100A per mV TB1 1 2 TP4 1 2 Bay Voltage Load Monitoring Shunt Monitoring Spec No 582127000 5 Code UM582127000 Model No 721NPBB Issue February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 gen Optional LVD Driver Circ
17. and 16 48V 9 24V and 12 48V 13 24V and 8 48V or 17 24V and 4 48V positions You do this by removing the subsystem input power busbar and associated input lead busbars then moving the appropriate distribution device busbar and associated distribution device lead busbars left or right in increments of four 4 positions then re installing the subsystem input power busbar and associated input lead busbars The distribution devices alarm spring most also be appropriately moved Refer to the following procedures to reconfigure the distribution panel Figure 13 Reworking the Distribution Panel Introduction List DB Dual Voltage Distribution Panel List DA DC DD similar Move 24V Input Power Busbar 4 Positions Left or Right in Increments of Four Positions Move 24V Input Lead Busbars Oo 4 Positions Left Right in Distribution Device Increments of Four Positions Lead Busbars Distribution Device lead Busbars Move 24V Input Power Busbar 4 Positions Left or Right in Increment of Four Positions Move 24V Move 48V Distribution Device 4 OR J Distribution Device Busbar Right Busbar Left Spec No 582127000 Code UM582127000 Model No 721NPBB 21 Issue AH February 17 2015 NetSure 48V DC Power System S User Instructions UM582127000 Issue February 17 2015 EMERSON Network Power Removing the 24V Input Power Busbar and Input Lead Busbars PROCEDURE
18. for these connections are M6 Nut 1 Remove the busbar rear shield from the existing module M6 Belleville lock washer mounting shelves Remove the cut out panel from the M6 flat washer busbar rear shield by gently bending the panel until it 6 Disconnect the cable coming from the distribution snaps from the busbar rear shield 9 cabinet from the connector on the bottom most existing 2 Remove the hardware from the lowest module mounting module mounting shelf and connect this cable to the shelf s 48V return and 24V if present busbars Same connector on the expansion module mounting shelf 3 Install the expansion module mounting shelf directly below the bottom most module mounting shelf in the 7 Connect the open connector on the bottom most rack Use the mounting hardware provided with the existing module mounting shelf to the open connector expansion module mounting shelf on the expansion module mounting shelf Hardware build up is 8 Re install the rear busbar shield previously removed from 12 24 x 3 4 screw and flat washer 1 set per side the existing module mounting shelf Re install the rear 12 24 x 3 4 screw and ground washer 1 set per side busbar shield previously removed from the expansion module mounting shelf Note Install the ground washers so the teeth make 9 contact with the metal on the mounting angles 9 Refer to the Power System Installation Instructions Torque all screws to 65 in Ibs IM582127
19. on the replacement circuit card DANGER In the next step external alarm wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object Reconnect the external wiring to the correct terminals on the shunt input terminal blocks First remove the electrical tape that was applied to the bare wire end in a previous step DO NOT allow the bare wire end to contact any grounded or energized object After securing the wire gently tug on the wire to ensure that it cannot be pulled out of the terminal block Repeat for each wire to be reconnected Remove the grounding wrist strap Close the distribution cabinet s front door Turn the latch clockwise to secure the door Enable the external alarms or notify appropriate personnel that this procedure is finished Ensure that there are no local or remote alarms active on the system Code UM582127000 Issue AH February 17 2015 48V DC Power System 5 User Instructions UM582127000 Issue AH February 17 2015 EE Figure 31 SM DU and Shunt Interface Assembly Connector Locations SM DU and Shunt Interface Board 1 TB2 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs Shunt Interface Board SW2 SWI HHBBHBBB 12345678 12345678 E E E E m a a arrears Spec No 582127000 47 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetS
20. release a distribution device lead busbar Slide the distribution device lead busbar up and out of the distribution panel Repeat for all distribution device lead busbars 8 Remove the polarity labels from these positions Turn over the polarity labels so the other polarity shows Re install the polarity labels to the left or right of the original position into the positions the distribution device lead busbars will be moved to in the next step 9 Re install the distribution device lead busbars three 3 positions to the left or to the right of the original positions Slide a distribution device lead busbar down and into the distribution panel Repeat for all distribution device lead busbars Spec No 582127000 23 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System S User Instructions UM582127000 Issue February 17 2015 Figure 15 Moving the Distribution Device Busbar and Distribution Lead Busbars Left or Right List DB Dual Voltage Distribution Panel List DA DC DD similar Apply a thin coating of electrical anti oxidizing compound to the mating surfaces of the busbars 1 4 20 x 5 8 Bolt 1 4 Lock Washer 1 4 Flat Washer Torque to 75 in lbs Remove polarity label Move 48V Distribution Move 24V Distribution Turn over polarity label Device Busbar s lt OR J Device Busbar s so other polarity shows 3 Positions Left 2 3 Positions Right Repla
21. 000 and connect AC input power to the expansion module mounting shelf 4 Remove the busbar rear shield from the expansion P 9 module mounting shelf 10 Refer to the Power System Installation Instructions IM582127000 and install rectifier and converter Note Apply electrical anti oxidizing compound to busbar 9 modules into the expansion module mounting shelf as mating surfaces before performing the next step required 5 Install the busbars provided with the expansion module mounting shelf between the studs on the expansion Spec No 582127000 16 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 es NetSure 48V DC Power System EMERSON User Instructions UM582127000 Issue AH February 17 2015 Network Power Figure 10 Installing a Field Expansion Module Mounting Shelf Spec No 588705300 1 Remove busbar rear shield from existing rectifier converter shelves Remove the cut out panel from the busbar rear shield Busbar Rear Shield 4 Cut Out Panel 2 Remove hardware from the lowest module mounting shelf s 48V return and 24V if present busbars 3 Install the expansion module mounting shelf into the rack 4 Remove busbar rear shield from expansion module mounting shelf 5 Install the busbars provided with the expansion module mounting shelf between the shelves Torque to 60 in Ibs 6 Re install the rear busbar shields previously r
22. 30BNA for a procedure Replacing a Rectifier or Converter Module in a Spec No 588705300 Shelf Refer to the Rectifier User Instructions UM1R482000E3 or Converter User Instructions UM1C48241500 for a rectifier and converter module replacement procedure Refer also to System Troubleshooting Information on page 28 The rectifier or converter module being replaced is assigned by the controller the lowest available identification number If desired Code UM582127000 Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 EMERSON Network Power you can change the identification number Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure Replacing the Controller Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a controller replacement procedure Replacing a Distribution Device General Replace distribution devices with the same type and rating Refer to System Application Guide 5 582127000 for part numbers Distribution Fuse Alarm Fuse Replacement If a distribution fuse opens the associated alarm fuse opens Replace the distribution fuse before replacing the alarm fuse PROCEDURE 1 An alarm fuse is removed by pulling it straight out of the fuseholder If the alarm fuse is located in a modular fuse carrier
23. 400 for more information NCU NetSure Control Unit The NCU Controller provides power system control including optional low voltage battery disconnect LVBD and low voltage load disconnect LVLD control rectifier control including a charge control function converter control metering functions monitoring functions and local remote alarm functions The controller also supports rectifier temperature compensation if the system is equipped with a temperature probe s Temperature probe s may also be designated to monitor ambient temperature and or battery temperature The controller also provides data acquisition system alarm management and advanced battery and energy management The controller contains a color LCD display and keypad for local access The controller provides an Ethernet port and comes with comprehensive webpages for remote access The controller has SNMP capability for remote system management The controller supports software upgrade via its USB port Refer to the NCU Controller Instructions UM1M830BNA for more information Module Mounting Shelf Spec No 588705000 Module Mounting Shelf Spec No 588705300 The system may contain one or more Spec No 588705000 module mounting shelves each of which houses up to six 6 rectifier modules or six 6 converter modules Refer to Power Data Sheet PD588705000 for more information Rectifier Modules for use in Spec No 588705000 The system may co
24. 5 5 48V DC Power System Installing a Field Expansion Module Mounting Shelf Spec No 588705000 cont d from previous page Figure 8 US 1 ta ene Vel A UD 7 5 22 3 v EP zs 9 FEED ET www ul 3 y PS vy ere jn E SV A m eee D 0 n po 1 an Code UM582127000 Issue AH February 17 2015 Completed View c 0 st E m Q LLI 5 g 9 9 ca il CO 5 Yo 5 O 0 eS 2 NZ N 9 gt NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 5 Network Powel Figure 9 Controller CAN Bus Module Mounting Shelf Spec No 588705000 Distribution Cabinet Wire Harness Slate and Slate White Wires Brown and Brown White Wires These cables are factory connected Existing zz i Module Mounting Shelf CEP GD Gap WS EE These cables are e Det aD _ E Wm SED Ee TED GED Existing qT 9 EE e eS Module Mounting Shelf gt EE GD
25. A400 e NCU Controller Instructions UM1M830BNA Rectifier Instructions UM1R483500E or UM1R482000E3 e Converter Instructions UM1C400483500E UM1C48241500 ESTOP Function If an ESTOP switch is wired to the IB2 Controller Interface Board customer furnished system ground applied to terminal DI8 activates the ESTOP function The ESTOP function shuts down and locks out the rectifiers or 400V DC input converters opens the LVD s and shuts down the optional 48V to 24V DC converters When the ESTOP signal is removed LVD s close if battery present and 48V to 24V DC converters restart To restart the rectifiers or 400V DC input converters turn input power to the rectifiers converters OFF wait 30 seconds or more until the LEDs on the module extinguish then turn input power to the rectifiers converters ON Controller Battery Charge Current Limit Feature Functionality After a failure of the input source commercial AC or DC or when some battery cells are permanently damaged the current to the batteries can be quite extensive To avoid overheating or further damages to the battery the controller can 2 Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 aw be programmed to limit the battery current to a preset level by Local Controls and Indicators limiting the charging voltage of the rectifiers converters Should th
26. BREAKERS W OUT SHUNTS ALARM WIRING BREAKERS WITH SHUNTS STANDARD AND ELECTRICAL TRIP BREAKER STANDARD AND ELECTRICAL BLACK HANDLE SHUNTED BRKR JUMPER RED ALARM JUMPER BROWN ALARM JUMPER RED SHUNTED BRKR JUMPER BLACK Spec No 582127000 Code UM582127000 Model No 721NPBB 36 Issue AH February 17 2015 EMERSON Network Power 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 Figure 25 GJ 218 Circuit Breaker Wiring Diagram List AC and AD 22 18 01 031312345 3 1 4 10 LON SQV31 0102 90 SALON ONT YNLOVANNYN uyasnd 419 O d O4JNI gor HLIM FONYGYODOY NI 1 38 ALIOWdYD ANY ALILNYNO TWOIdAL 38V NMOHS SYINVING LINDYID LO 440 804 54 31 LNAHS 3S93A3U NOILYYIdO 03811 NMOHS SYAMVING GALNNHS 90 SALON 5N1933N15N3 419 01 43811038 Sv 13141003 OL SLNM HS SHAMVING 4181 1VOINVHO3N 19215123713 404 NOILdO 60 KINO SINMHS SYINVING 17219193713 404 NOILdO 911318 fO Su3yv3u8 4131 1V21812313 404 01140 91131860 SYIYYIYA 4181 TVOINVHOAW 1V21812313 404 1140 9NIYIM 720 1 44 GASVHOUNd 38 150 ANY ASSY 40 LON 34v 110212 ANY SYAMVING 1112812 710 3100 9NIAYUO uvasna uvasng LY 0 4 RA vasna
27. Converter If a converter module is removed from the system a converter communications failure alarm is generated If the converter module will not be replaced the alarm should be cleared Refer to the ACU Instructions UM1M820BNA UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure Clearing a Rectifier Lost Alarm If the controller resets while a rectifier communications fail alarm is active the rectifier communications fail alarm is replace with a rectifier lost alarm Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure to clear the alarm Spec No 582127000 Model No 721NPBB 29 Refer to SAG582127000 System Application Guide for replacement part numbers Replacement Procedures DANGER Adhere to the Important Safety Instructions presented at the front of this document Replacing a Rectifier or Converter Module in a Spec No 588705000 Shelf Refer to the Rectifier Instructions UM1R483500E or Converter User Instructions UM1C400483500E for a rectifier and converter module replacement procedure Refer also to System Troubleshooting Information on page 28 The rectifier or converter module being replaced is assigned by the controller the lowest available identification number If desired you can change the identification number Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M8
28. Damage to the circuit card may result if the next step is not followed 3 Connectan approved grounding strap to your wrist Attach the other end to a suitable ground 4 Removethe top and front panels to access the circuit cards at the bottom of the distribution cabinet 5 Carefully label any wires connected to the customer connection terminal block on the circuit card These wires must be connected to the same terminals on the replacement circuit card Refer to Figure 27 Spec No 582127000 Model No 721NPBB 39 10 11 12 13 14 15 16 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 27 DANGER In the next step external wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object Remove the external wiring from the customer connection terminal block DO NOT allow the bare wire end to contact any grounded or energized object Isolate the wire end with electrical tape Repeat for each wire to be removed Unplug all connectors plugged into the circuit card Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet In this step ensure you do not intermix the old and replacement circuit cards Set the shorting jumpers on the replacement circuit card to match the locations on
29. February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE SM DU Circuit Card The SM DU is used in supplemental bays in place of a controller The SM DU monitors the bay and reports to the controller The controller sends commands to the SM DU to fulfill battery management and load control functions according to the received data There are three 3 status and alarm indicators located on the SM DU The functions of these indicators from top to bottom as shown in the illustration are as shown in Table 1 Refer to Figure 6 for location Table 1 5 00 Indicators Indicator Normal State Fault State Fault Cause Alarm i Red A critical or major alarm Alarm alarm Yellow SM DU is non operational Operation A 1 3Hz flashing indicates the Green SM DU is being identified by the Flashing Controller A 1Hz flashing indicates a communication failure Figure 6 SM DU Circuit Card d 43 24 42 51 52 53 123 45 6 7 123 45 6 7 123 45 6 7 24444480 24444480 114444 Spec No 582127000 9 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System 5 User Instructions UM582127000 Issue AH February 17 2015 Maintenance Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec No 588705300 To increase system current capacity a rectifier
30. KER GUARD LABEL CIRCUIT BREAKER A LONGER SIDE OF GUARD ami ON OFF DIST ASSY SHOWN FOR EXAMPLE ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING BREAKERS WITH SHUNTS STANDARD AND ELECTRICAL TRIP BREAKER STANDARD AND ELECTRICAL BLACK HANDLE TRIP BREAKER BLACK HANDLE SHUNTED BRKR JUMPER RED ALARM JUMPER BROWN ALARM JUMPER RED SHUNTED BRKR JUMPER BLACK Spec No 582127000 35 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System S User Instructions UM582127000 Issue February 17 2015 EMERSON Network Power Figure 24 Replacing 218 Circuit Breaker 2 Pole 3 Pole 4 Pole cont d from previous page INSTALLING CIRCUIT BREAKER Alarm jumper connectors Holes to route shunt jumper through if applicable 2 pole breaker shown 3 pole and 4 pole breakers similar 1 4 Hardened Flat Washer Apply anti oxidizing compound to busbar mating S 1 4 Belleville surfaces before mounting circuit breakers Lock Washer 1 4 20 x 3 4 Bolt 4 places Torque to 60 in Ibs INSTALLING CIRCUIT BREAKER GUARD 10 32 X 7 16 PH 10 32 LW CIRCUIT BREAKER GUARD LABEL CIRCUIT BREAKER ANN LONGER SIDE OF GUARD gt DIST ASSY SHOWN FOR EXAMPLE ALARM WIRING
31. Power e NCU Controller 2nd Ethernet Port Retrofit Kit Instructions IM559251 e Engineering Drawings Also provided on the USB drive is a controller configuration drawing and the controller configuration files loaded into the controller as shipped System Description e NetSure 48V DC Power System Quick Start Guide 25582127000 e NetSure 48V DC Power System Installation Instructions IM582127000 NetSure ACU Controller User Manual e NetSure ACU Controller User Instructions UM1M820BNA AC Input Voltage Systems UM1M820DNA400 DC Input Voltage Systems NetSure NCU Controller User Manual e NetSure NCU Controller User Instructions UM1M830BNA AC Input Voltage Systems USB Drive with All Customer Documentation 48V DC up to 4000 Amperes Power System The NetSure 721NPBB DC Power System is a complete integrated power system containing 48V DC rectifiers or converters optional 24V DC converters intelligent control metering monitoring and distribution This power system is designed to power a load while charging a positive grounded battery This power system is capable of operating in a batteryless installation or off battery for maintenance purposes The power system is designed for operation with the positive output grounded This system consists of the following components Distribution Cabinet e Power System Quick Start Guide 5582127000 e Power System Installat
32. Side 6 19 x 1 2 Screw Torque to 9 6 165 Move Alarm Spring s OR Move Alarm Spring s 3 Positions Right 3 Positions Left Typical After View _ 2 Spec No 582127000 25 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 PESO Re Installing the 24V Input Power Busbar and Input Lead Busbars PROCEDURE 1 Re install the 24V input lead busbars Slide the 24V input lead busbars down and into the distribution panel in the mounting locations created when the distribution device lead busbars were moved in the previous procedure 2 Re install the 24V input power busbar into the distribution panel in the position created when the distribution device busbar in the previous procedure was moved 3 Fromthe front of the distribution panel re install the three bolts and hardware to secure the 24V input power busbar to the 24V input lead busbars Torque as indicated in Figure 17 4 Fromthe rear of the distribution panel re install the two bolts and hardware to secure the 24V input power busbar Torque as indicated in Figure 17 Figure 17 Re Installing the 24V Input Power Busbar and Input Lead Busbars List DB Dual Voltage Distribution Panel List DA DC DD similar 24V Input Lead Busbars Apply a thin coating of electrical anti oxidizing compound to the mating surfaces of the busb
33. U Circuit Card Replacement Supplemental Bays Only 6 Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet 7 Inthis step ensure you do not intermix the old and 1 Performing this procedure may activate external alarms replacement circuit cards Set the switches on the Do one of the following If possible disable these alarms replacement circuit card to the same setting as the old If these alarms cannot be easily disabled notify the circuit card Switch settings are documented in the appropriate personnel to disregard any future alarms Setting Jumpers and Switch Options section of the associated with this system while the procedure is being Power System Installation Instructions IM582127000 8 Slide the replacement circuit card into the mounting DANGER Performing the next steps exposes service position inside the distribution cabinet and secure with personnel to battery potential Exercise extreme the screws removed from the old circuit card caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination 10 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 9 Plug connectors 1 2 and J3 into the circuit card 2 distribution cabinet s front door by turning the latch in the counterclockwise position 11 Remove the grounding wrist
34. ars Press in Tabs to Release E 24V Input 1 4 20 x 5 8 Bolt Input Lead Busbars Power Busbar 1 4 Lock Washer 1 4 Flat Washer Torque to 75 Front 24V Input 1 4 20 x 3 4 Bolt Power Busbar 1 4 Lock Washer 1 4 Flat Washer Torque to 75 in lbs Spec No 582127000 26 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 aw Moving the 24V 48V Label on the Distribution Device Cover to the New Position PROCEDURE 1 Move the polarity label on the distribution device cover right or left to align with the distribution positions moved in the previous procedures Figure 18 Moving the 24V 48V Label on the Distribution Device Cover to the New Position List DB Dual Voltage Distribution Panel List DA DC DD similar ove this Label Left Replacing the Distribution Panel Note the following procedure before making busbar to busbar connections apply a thin coating of electrical anti oxidizing compound to the mating surfaces of the busbars PROCEDURE 2 Orient the distribution panel into the distribution cabinet checking to ensure no wires are pinched Replace the hardware securing the distribution panel to the distribution cabinet Refer to Figure 12 for hardware build up Torque as indicated in Figure 12 3 Reconnect the 24V jumper leads Refer to Figure 12 fo
35. attery disconnect LVBD and manual battery disconnect Controller The controller controls the operation of the rectifier and converter modules The controller also provides power system control metering monitoring and alarm functions ACU Advanced Control Unit Plus The ACU Controller provides power system control including optional low voltage battery disconnect LVBD and low voltage load disconnect LVLD control rectifier control including a charge control function converter control metering functions monitoring functions and local remote alarm functions The controller also supports Code UM582127000 Issue AH February 17 2015 5 48V DC Power System EMERSON User Instructions UM582127000 Issue AH February 17 2015 Network Power rectifier temperature compensation if the system is equipped with a temperature probe s Temperature probe s may also be designated to monitor ambient temperature and or battery temperature The controller also provides data acquisition system alarm management and advanced battery and energy management The controller contains an LCD display and keypad for local access The controller provides an Ethernet port and comes with comprehensive webpages for remote access The controller has SNMP capability for remote system management The controller supports software upgrade via its USB port Refer to the ACU Controller Instructions UM1M820BNA or UM1M820DNA
36. battery terminal NEVER allowa 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 DANGER Follow local lockout tagout procedures to ensure DC branch circuit protection devices remain de energized during installation at loads as required 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 UM582127000 Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 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 protection should be worn to prevent injury from accidental electrical arcs Use certified and well maintained in
37. between manufacturer s Violet White Wire Violet Wire Violet White Wire Black Wire Violet Wire Black Wire Red Wire Spec No 582127000 57 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System 3 5 User Instructions UM582127000 Issue AH February 17 2015 Power Figure 39 Replacing a Load Disconnect Contactor in a 2 3 or 4 Row Distribution Cabinet Load Disconnect Components removed in Contactor illustration for clarity only 5 16 18 Nut 5 16 Belleville Lock Washer 5 16 Belleville Lock Washer concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 Apply electrical anti oxidizing compound to busbar mating surfaces 2 row Distribution Cabinet shown 3 or 4 row cabinet similar Contactor styles vary between manufacturer s Violet White Wire Violet Wire 517 Violet White Wire ack wire Violet Wire Black Wire Red Wire Code UM582127000 Spec No 582127000 58 Issue AH February 17 2015 Model No 721NPBB NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 NetPerform Optimization Services 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 you
38. bruary 17 2015
39. cator LVD Inhibit Switch Illuminates when the Momentary UP Middle Down low voltage disconnect Momentary UP Position Closes all LVD Contactors inhibit mode circuit has been disabled Middle Position OFF Controller DOES NOT control LVD s inhibit mode through the use of the DOWN Position ON Controller controls LVD s LVD Inhibit switch Spec No 582127000 7 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System 3 User Instructions UM582127000 Issue AH February 17 2015 EMERSON Network Power Optional Manual Battery Disconnect Circuit Card Main Bay Only The optional manual battery disconnect circuit card contains a manual battery disconnect switch and indicator Refer to Figure 5 Figure 5 Optional Manual Battery Disconnect Circuit Card Main Bay Only EL BANGS Manual Battery Manual Battery Disconnect llluminates if the Battery Disconnect Contactor has Disconnect Switch Active Indicator been manually disconnected placed in open position Momentary UP Middle Momentary Down Momentary UP Position Closes latches in close position the Battery Disconnect Contactor Middle Position Normal Operation Momentary DOWN Position Opens latches in open position the Battery Disconnect Contactor Momentarily place switch in the UP position to close the contactor Spec No 582127000 3 Code UM582127000 Model No 721NPBB Issue AH
40. ce polarity label in Press in Tabs to Release relocated distribution o 9 Distribution Device Lead Busbars positions 6 32 x 3 4 Screw 6 Lock Washer 6 Flat Washer Torque to 11 in lbs Move 24V Distribution Move 48V Distribution Device Busbar s lt OR Device Busbar s 3 Positions Right 3 Positions Left Spec No 582127000 24 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE Moving the Alarm Spring s Left or Right PROCEDURE 1 Located the alarm spring s and alarm spring link s to be moved 2 From rear of the distribution panel remove the appropriate alarm spring link s 3 From rear of the distribution panel remove the screw s from the alarm spring s to be moved Slide the alarm spring s three 3 positions to the left or to the right Secure with the screw s just removed Torque as indicated in Figure 16 4 Re install the alarm spring link s to the opposite side of the alarm spring s just moved and to the alarm spring adjacent to it Torque as indicated in Figure 16 Figure 16 Moving the Alarm Spring s Left or Right List DB Dual Voltage Distribution Panel List DA DC DD similar Typical Before View 6 19 x 5 16 Screw Torque to 9 6 in Ibs Place Alarm Spring Link on Opposite Side Place Alarm Spring Link on Opposite
41. cure the door Replacing a Bullet Nose Fuseholder PROCEDURE Note Refer to Figure 20 as this procedure is performed 1 30 Open the distribution cabinet s front door by turning the latch in the counterclockwise position Remove the fuse carrier from the mounted fuseholder body by pulling it straight out Hold the fuseholder body while you pull the fuse carrier from the body Gently rock the defective fuseholder up and down while pulling firmly outward until the fuseholder is free from the distribution panel Orient the fuseholder as shown in Figure 20 Insert the terminals on the rear of the fuseholder into their corresponding sockets on the distribution panel Ensure the alarm contact on the back of the fuseholder makes contact with the alarm terminal on the spring strip Push fuseholder in firmly until fully seated in the distribution panel Push the fuse carrier securely back into the mounted fuseholder body Note that a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down Code UM582127000 Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE 6 Verify no Fuse Alarms are active 7 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Figure 20 Replacing a TPS TLS Fuseholder and or Fuse Shorter Side to the Top Insert these terminals
42. e LVD control levels LVD1 and LVD2 The level used to control a contactor is determined by which connector on the LVD circuit card its control leads are plugged into To change the LVD control level for a contactor simply switch which LVD connector it is plugged into if an open connector is available on the LVD circuit card Refer to Figure 32and Figure 33 for connector location and function Note DO change a Low Voltage Load Disconnect contactor to LVD Control Level 2 LVD2 if the system is furnished with a Low Voltage Battery Disconnect contactor Adding a Supplemental Bay in the Field Refer to the Power System Installation Instructions IM582127000 for procedures detailing mounting and wiring of the supplemental bay Supplied with the supplemental bay is a USB drive which contains a SettingParam run file Download this file into the controller to program the controller for use with the newly installed supplemental bay Refer to the ACU Instructions UM1M820BNA or UM1M820DNAA400 NCU Instructions UM1M830BNA for a download procedure There are also labels located near the SM DU and SM DU in the supplemental bay that detail the controller s settings for this bay Once the controller has been programmed for the newly installed supplemental bay refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions 1 830 save a copy of the SettingParam run file Troubleshooting and R
43. e a Low Voltage LVD1 control setting Level 1 Load Disconnect contactor to LVD Control Level 2 LVD2 if the system is furnished with a Low Voltage Battery Disconnect contactor J5 46 To LVLD contactor uses Controller LVD2 control setting Level 2 8088 800 97 LVBD contactor uses Controller LVD2 control setting Level 2 Notes 1 Connects up to 4 LVLD and 1 LVBD contactors 2 Switch and indicator located on circuit card installed in Main Bay onl y Spec No 582127000 49 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 33 Optional LVD Driver Lite Circuit Card Connector Locations DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 LVD2 if the system is furnished with a Low Voltage Battery Disconnect contactor ni J1 To LVLD contactor uses Controller LVD1 control setting Level 1 J3 To LVLD contactor uses Controller LVD2 control setting Level 2 547873 O 547874 42 LVBD contactor uses Controller LVD2 control setting Level 2 Can only be used if it is contained in a List 21 1 row cabinet Notes 1 Connects up to 2 LVD contactors rated at 600 A or less 2 Only one 1 contactor per level can be accommodated J2 and J3 are on Level 2 only one 1
44. e battery current still exceed a higher preset value an alarm is issued Refer to the Controller Rectifier and Converter Instructions for descriptions of the local controls and indicators located on these units The controller limits the current going to the batteries based on the Battery Current Limit set point which is a percentage of the battery capacity in C10 For example 0 1C10 would mean 10 of the battery capacity Refer to this section for descriptions of the local controls and indicators located on the circuit cards installed in the distribution cabinet Refer to the ACU Instructions UM1M820BNA or Crenit cara Location UM1M820DNA400 NCU Instructions UM1M830BNA to program this feature Battery charge current is limited to the value setin the controller as long as battery voltage is above 47V DC Refer to Figure 1 Spec No 582127000 3 Code UM582127000 Model 721NPBB Issue AH February 17 2015 5 48V DC Power System ey EMERSON er etwork Pow User Instructions UM582127000 Issue AH February 17 2015 Circuit Card Locations Figure 1 Optional EIB Main Bay Only Extended Interface Board located on inside side panel Others Similar Row Cabinet Shown Front Door Removed in Illustration for Clarity Interface Board located on inside side panel IB2 Main Bay Only 4 2 22 Loess Optional SM DU and Shunt Interface
45. e latch clockwise to secure the door Spec No 582127000 Model No 721NPBB 32 PROCEDURE Note Refer to Figure 23 as this procedure is performed 1 Openthe distribution cabinet s front door by turning the latch in the counterclockwise position 2 Removethe fuse case from the mounted fuse block by grasping its handle and pulling it straight out 3 Openthe fuse case 4 Removethe open fuse from the fuse case and replace it with the same type and rating 5 Closethe fuse case 6 Pushthe fuse case securely back into the mounted fuse block 7 Replace the alarm fuse located in the front of the TPL B fuse block Replace only with a fuse of the same type and rating Ensure that a plastic safety cover is installed on the alarm fuse 8 Closethe distribution cabinet s front door Turn the latch clockwise to secure the door Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System amp EMERSON User Instructions UM582127000 Issue AH February 17 2015 Satanic Figure 23 Replacing a TPL B Fuse GMT 18 100A Alarm Fuse P N 248610301 and GMT X Safety Fuse Cover P N 248898700 Both are provided w fuseblock Fuse Installed in Open Fuse Case rear view Fuseblock Fuse Installed in Closed Fuse Case rear view Replacing a 218 Circuit Breaker PROCEDURE Note Refer Figure 24 Figure 25 and Figure 26 as this procedure is performed 1 Ope
46. ectrical Safety in the Workplace Hazardous Voltage DANGER Hazard of electrical shock More than one disconnect may be required to de energize the system before servicing Handling Equipment Containing Static Sensitive Components iv ALERT Installation or removal of equipment containing 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 Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System 54 User Instructions UM582127000 Issue AH February 17 2015 EE Static Warning 41 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 contain
47. ed or energized object Remove the external wiring from the customer connection terminal blocks DO NOT allow the bare wire end to contact any grounded or energized object Isolate 43 10 11 12 13 14 15 16 the wire end with electrical tape Repeat for each wire to be removed Unplug all connectors plugged into the circuit card Remove the circuit card by removing the bracket the circuit card is mounted to Remove the circuit card from the bracket In this step ensure you do not intermix the old and replacement circuit cards Set the switch on the replacement circuit card to the same setting as the old circuit card Switch settings are documented in the Setting Jumpers and Switch Options section of the Power System Installation Instructions IM582127000 Secure the replacement circuit card to the bracket and re install the circuit card and bracket into the distribution cabinet Plug all connectors removed from the old circuit card into the same position on the replacement circuit card DANGER In the next step external alarm wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object Reconnect the external wiring to the correct terminals on the customer connection terminal block First remove the electrical tape that was applied to the bare wire end in a previous step DO NOT allow the bare wire end to contact any grounded or en
48. em may operate from 400V DC input voltage capable of producing fatal electrical shock DC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any DC electrical connections are made Follow local lockout tagout procedures to ensure upstream branch circuit breakers remain de energized during installation DO NOT apply DC input power to the system until all electrical connections have been completed and checked DC Output and Battery Voltages Spec No 582127000 Model No 721NPBB DANGER This system may operate 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 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 iii DANGER This system produces DC Power and may have a battery source connected to it Although the DC voltage is not hazardously high the rectifiers converters 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
49. emoved Code UM582127000 Spec No 582127000 17 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 11 Controller CAN Bus Module Mounting Shelf Spec No 588705300 Distribution Cabinet Wire Exploded View Shown to Illustrate Wire Connections Only Slate and Slate White Wires Brown and Existing Module Brown White Mounting Shelf Wires These connectors Rear View are factory connected Factory provided jumper 2 to bring connectors to same side of shelf Existing Module Mounting Shelf These connectors are factory connected Rear View Factory provided jumper Q to bring connectors to same side of shelf Existing Module Mounting Shelf These connectors are factory connected Q to bring connectors to same side of shelf uu Ze Disconnect cable coming 7 from distribution cabinet from this connector on m Expansion Module bottom most existing Mounting Shelf shelf then connect to the same connector on the expansion shelf Now connect these Factory provided jumper two connectors together Q to bring connectors to same side of shelf A ps 7 pd PL Spec No 582127000 1 8 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System
50. epair Contact Information Support contact information is provided on the inside of the back cover of this document Controller Rectifiers and Converters For troubleshooting and repair instructions on these units refer to the following documents e ACU Controller Instructions UM1M820BNA or UM1M820DNA400 e NCU Controller Instructions UM1M830BNA e Rectifier Instructions UM1R483500E or UM1R482000E3 e Converter Instructions UM1C400483500E or UM1C48241500 Spec No 582127000 Model No 721NPBB EMERSON Network Powel Controller Configuration If any controller configuration settings were changed refer to the ACU Instructions 1 820 or UM1M820DNA400 NCU Instructions UM 1M830BNA and save copy of the configuration file Thisfile can be used to restore the controller settings if required at a later date e Note that provided on a USB drive furnished with the system is a controller configuration drawing C drawing and the controller configuration files loaded into the controller as shipped System Troubleshooting Information This system is designed for ease in troubleshooting and repair The various indicators as described in Local Controls and Indicators on page 3 and in the Controller and Rectifier Instructions are designed to isolate failure to a specific element Once the faulty element has been identified refer to Replacement Information on page 29 and Replacement Proced
51. ergized object After securing the wire gently tug on the wire to ensure that it cannot be pulled out of the terminal block Repeat for each wire to be reconnected Remove the grounding wrist strap Close the distribution cabinet s front door Turn the latch clockwise to secure the door Enable the external alarms or notify appropriate personnel that this procedure is finished Ensure that there are no local or remote alarms active on the system Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 Figure 29 IB2 Controller Interface Board Connector Locations _ Ow Ow gt IB2 Board Assembly 5 co N O af 99 da CN IB2 Board Top View J3 J9 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs Spec No 582127000 44 Code UM582127000 Model 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE Figure 30 EIB Controller Extended Interface Board Connector Locations Optional EIB Interface Board Assembly Optional EIB Interface Board Top View RLYI3 RLYIO 2 2 2 2 O oo e VA NESSO d S OOODOOOOOOOOQOD INPUTS INPUTS 22 0 IL LL N CO O 2
52. f desired be installed in any mounting position of each module you can change the identification number Refer to the ACU mounting shelf Converters modules can be installed in Instructions UM1M820BNA or UM1M820DNA400 or NCU any of the three far right mounting positions of each Instructions UM1M830BNA for a procedure module mounting shelf as viewed from the front See Figure 7 e Forrectifier module installation instructions refer to Rectifier Instructions UM1R483500E 4 Loosenthe captive screw on the module s handle Pull the handle down out from the module s front panel this e Forconverter module installation instructions refer to will also retract the latch mechanism See Figure 7 Converter Instructions UM1C400483500E 5 Push the module completely into the shelf Spec No 582127000 1 0 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 6 Push the handle up into the module s front panel This will lock the module securely to the shelf Tighten the captive screw the handle 7 Repeat the above steps for each module being installed in the system 8 After the modules are physically installed in the mounting shelf s they are ready for operation immediately after power is supplied to them Note Itis recommended that the current limit point be checked whenever a rectifier is added t
53. fer to Figure 35 and remove the hardware securing the panel s Ground Busbar if equipped to the distribution cabinet s busbar 8 Forload distribution panels refer to Figure 35 and remove the hardware securing the panel s System Load Distribution busbar to the distribution cabinet s busbar 9 Forbattery distribution panels refer to Figure 35 and remove the hardware securing the panel s Battery Busbar to the distribution cabinet s busbar 10 For dual voltage load distribution panels refer to Figure 35 and remove the hardware securing the 24V jumper leads 11 Referto Figure 35 and remove the hardware securing the distribution panel to the distribution cabinet Remove the panel from the distribution cabinet Installing the Distribution Panel Note Inthefollowing procedure before making busbar to busbar connections apply a thin coating of electrical anti oxidizing compound to the mating surfaces of the busbars 1 Orientthe replacement distribution panel into distribution cabinet checking to ensure no wires are pinched Replace the hardware securing the distribution panel to the distribution cabinet 10 32 x 5 8 bolt 410 flat washer 4 places 2 Fordualvoltage load distribution panels replace the hardware securing the 24V jumper leads 1 4 20 bolt 1 4 lock washer 1 4 flat washer Torque to 84 in Ibs 3 Forbattery distribution panels replace the hardware securing the panel s Battery Busbar to the dist
54. hold the fuse carrier in place with your thumb while pulling on the alarm fuse to prevent the entire carrier from inadvertently being pulled out 2 Safety fuse covers are provided for all Bussmann GMT type fuses installed in the system These covers snap onto the fuses and provide protection from exposed electrical terminations when a fuse opens Insure that the safety fuse cover is installed after replacing a fuse Refer to Figure 19for installation details Figure 19 Installation of Safety Fuse Covers Safety Cover Safety Cover P N 248898700 P N 102774 GMT Y Spec No 582127000 Model No 721NPBB Replacing a TPS TLS Fuse PROCEDURE Note Refer to Figure 20 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position Remove the fuse carrier from the mounted fuseholder body by pulling it straight out Remove the open fuse from the fuse carrier and replace it with the same type and rating Replace the alarm fuse located in the front of the fuse carrier with the same type and rating Ensure that a plastic safety cover is installed on the alarm fuse Push the fuse carrier securely back into the mounted fuseholder body Note that a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down Verify no Fuse Alarms are active Close the distribution cabinet s front door Turn the latch clockwise to se
55. ing Module Mounting Shelf Spec No 588705000 10 Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec No 588705300 10 Installing a Field Expansion Module Mounting Shelf Spec No 588705000 12 Installing a Field Expansion Module Mounting Shelf Spec No 588705300 16 Reconfiguring a Dual Voltage Distribution 19 Changing the Controller s Control Level for a COMtACTOF cccccccccccecececceeeesssseeeeeeeccceceeeeeesaeaaeasssseeeeeeceess 28 Adding a Supplemental Bay in the Field 28 Troubleshooting and 28 Comac ION NAC MEE RR 28 Controller Rectifiers TUS QU v Eau organa n EXER EVO TEUER Ur 28 COND OWNER Oli GUI AE OM 28 System Troubleshooting Information cccccccccccccccsccccessssseseeeeccccccceeeeuaecessssseseeeeeeeccceessuseecgaasseeeeeeeeeceeeeeseaas 28 01 12714 0 TS 29 Replacement Procedures aa T 29 NeiPertorid Optimization
56. ing 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 Ifnecessary 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 582127000 Code UM582127000 Model No 721NPBB v Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 PEE This page is intentionally blank Spec No 582127000 Code UM582127000 Model No 721NPBB vi Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 System Overview Customer Documentation Package This document UM582127000 provides User Instructions for NetSure 48V DC Power System Model 721NPBB Spec No 582127000 The complete Customer Documentation Package consists of NetSure 48V DC Power System Installation Manual ss EMERSON 4 sl Dau Network
57. ion Instructions IM582127000 e Power System User Instructions UM582127000 e ACU Controller User Instructions UM1M820BNA e NCU Controller User Instructions UM1M830BNA e ACU Controller User Instructions UM1M820DNA400 e Power System System Application Guide SAG582127000 e Module Mounting Shelf Power Data Sheet PD588705000 Rectifier Instructions UM1R483500E e Converter Instructions UM1C400483500E e Module Mounting Shelf Power Data Sheet PD588705300 e Rectifier Instructions UM1R482000E3 e Converter Instructions UM1C48241500 e NCU Controller 2nd Ethernet Port Add On Kit Instructions IM559252 Spec No 582127000 1 Model No 721NPBB The system always includes a minimum of one distribution cabinet which provides DC distribution through fuses and or circuit breakers The distribution cabinet is factory mounted in the relay rack or shipping brackets specified when ordered Four different sizes of distribution cabinets are available to accept from one 1 to four 4 distribution panels A variety of distribution panels are available that provide load distribution battery distribution and dual voltage load distribution for use with 24V converters These distribution panels are configured to accept either bullet nose type circuit breakers and TPS TLS fuseholders TPH fuses TPL B fuses or 218 circuit breakers The distribution cabinet may be equipped with low voltage load disconnect LVLD low voltage b
58. ircuit breaker as recorded above Wiring diagrams are provided in Figure 24 Figure 25 and Figure 26 DANGER The bolts being installed in the following step may be at system potential Use insulated tools Install the replacement circuit breaker into its mounting position and secure with the hardware previously removed Torque to 60 in Ibs Transfer the circuit breaker guard from the old circuit breaker to the new circuit breaker Code UM582127000 Issue AH February 17 2015 5 48V DC Power System 5 User Instructions UM582127000 Issue AH February 17 2015 PEN 9 Operate the replacement circuit breaker to the ON 11 Close the distribution cabinet s front door Turn the latch position clockwise to secure the door 10 Verify no Circuit Breaker Alarms are active Spec No 582127000 34 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 24 Replacing a GJ 218 Circuit Breaker 1 Pole cont d on next page INSTALLING CIRCUIT BREAKER Alarm jumper connector Holes to route shunt jumper through if applicable 1 4 Hardened Flat Washer Apply anti oxidizing compound to busbar mating b surfaces before mounting circuit breakers ions aia 2 places Torque to 60 in Ibs INSTALLING CIRCUIT BREAKER GUARD 10 32 X 7 16 PH 10 32 LW CIRCUIT BREA
59. ll screws to 65 in Ibs expansion module mounting shelf 2 Ontherearofthe expansion module mounting shelf and 7 Replace the rear covers removed in step 2 above the existing shelf installed directly above it remove the 8 Refertothe Power System Installation Instructions rear shield that covers the output busbars y IM582127000 and connect AC or DC input power to the Note Apply electrical anti oxidizing compound to busbar expansion module mounting shelf mating surfaces before performing the next step 9 9 P 9 Refer to the Rectifier or Converter Instructions and install 3 Secure the existing shelf s busbars to the expansion rectifier or converter modules into the expansion module shelf s mating busbars with the supplied interconnect mounting shelf as required busbars and hardware Spec No 582127000 12 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 8 Installing a Field Expansion Module Mounting Shelf Spec No 588705000 cont d on next page Front View Rear View Install Expansion Remove Rear Shield from Module Mounting Shelf Module Mounting Shelf and Shelf Above It Spec No 582127000 13 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 le r Alantan ml Network amp EMERSON rk Pov User Instructions UM582127000 Issue AH February 17 201
60. module can easily It is recommended to perform the maintenance procedures listed be added to an existing module mounting shelf Spec No System Maintenance Procedures in Table 2 every 6 months to ensure continual system operation 588705300 that contains an empty rectifier module mounting Table 2 Maintenance Procedures to be Performed at 6 Month position Likewise to increase subsystem capacity a DC DC Intervals converter module can be added to a module mounting shelf Spec No 588705300 that contains an empty converter module mounting position PROCEDURE REFERENCED IN COMPLETED Rectifier and converter modules can be inserted or removed with Check ventilation power applied hot swappable openings for Rectifiers modules can be installed in any mounting position of obstructions such each module mounting shelf Converters modules be installed as dust papers mand am in any of the three far right mounting positions of each module a mounting shelf as viewed from the front See Figure 7 Inspect and tighten Note Each rectifier and converter module locks into the module all installers aking ectrica mounting shelf by means of a latch located on the bottom of connections Sonn cle the module The latch and module handle are interactive section Pushing the handle up into the module s front panel causes Note This table may be reproduced as necessary to record and the latch to extend to the locking p
61. n the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Operate the defective circuit breaker to the OFF position DANGER The bolts being removed in the following step may be at system potential Use insulated tools 3 Remove the hardware securing the circuit breaker to the distribution panel and partially remove the circuit breaker 4 Record each alarm wire located on the back of the circuit breaker color and location on circuit breaker Wiring diagrams are provided in Figure 24 Figure 25 and Figure 26 Carefully disconnect the alarm wiring from the back of the circuit breaker ensuring the exposed end does not contact any energized circuit Spec No 582127000 Model No 721NPBB 33 P N 516241 TPL Fuse Fuse Case Open Fuse Case View Shunted Breakers Only Record each shunt wire located on the back of the circuit breaker color and location on circuit breaker Wiring diagrams are provided in Figure 24 Figure 25 and Figure 26 Carefully disconnect the shunt wiring from the back of the circuit breaker ensuring the exposed end does not contact any energized circuit Ensure that the replacement circuit breaker is in the OFF position and is of the correct rating and type electrical trip mechanical trip or electrical trip only Orient the circuit breaker over its mounting location Re attach the alarm wiring and shunt wiring if applicable to the back of the c
62. nded that the current limit point be checked whenever a rectifier module or converter module is added to or removed from the power system Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 When setting total rectifier or total converter current limit the set point to each unit is the total set point divided by the number of units For example if the system contains five rectifiers and the current limit is set to 150 amps then each rectifier has a current limit set point of 30 amps If one or more rectifiers or converters are removed or fail it will take several seconds for the individual set points to the remaining rectifiers or converters to be reset In the example given if one rectifier is removed the current limit set point will drop to 120 amps 30 amps times four remaining rectifiers until the controller can send updated set points to the remaining rectifiers This takes a couple communication cycles several seconds after which each rectifier would have a new set point of 37 5 amps for a total of 150 amps The total current limit of the rectifiers and converters should not be set such that the loss of the redundant rectifiers or converters will cause this temporary set point to drop below the actual maximum expected load If batteries are used on the rectifier output the batteries should support the load until the current limit set points can be
63. ns 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 EnergySystems EMEA Emerson Network Power 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 C ritical 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 NetPer form each NetSpan NetSure and NetXtend are trademarks of Emerson information or for any errors 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 582127000 Code UM582127000 Model No 721NPBB Issue AH Fe
64. ntain rectifier modules which provide load power battery float current and battery recharge current during normal operating conditions Refer to the Rectifier Instructions UM1R483500E for more information e Converter Modules for use in Spec No 588705000 The system may contain converter modules which provide load power battery float current and battery recharge current during normal operating conditions Refer to the Converter Instructions UM1C400483500E for more information Spec No 582127000 Model No 721NPBB The system may contain one or more Spec No 588705300 module mounting shelves each of which houses rectifier modules and optional DC DC converter modules Refer to Power Data Sheet PD588705300 for more information e Rectifier Modules for use in Spec No 588705300 The system contains rectifier modules which provide load power battery float current and battery recharge current during normal operating conditions Refer to the Rectifier Instructions UM1R482000E3 for more information e Optional DC DC Converter Modules for use in Spec No 588705300 Where 24V DC load power is also required DC DC converter modules are available Refer to the Converter Instructions UM1C48241500 for more information Operating Procedures Controller Rectifiers and Converters For operation instructions on these units refer to the following documents e ACU Controller Instructions UM1M820BNA or UM1M820DN
65. o or removed from the power system Refer Checking the Controller s Current Limit Point after Adding or Removing a Rectifier Module or Converter Module on page 28 Note The rectifier or converter being added is assigned by the controller the lowest available identification number If desired you can change the identification number Refer to the ACU Instructions UM 1M820BNA or UM 1M820DNA400 NCU Instructions UM1M830BNA for a procedure Figure 7 Installing Rectifier and Converter Modules in a Spec No 588705300 Shelf S838 3835 S338 Se Loe cee eee eee eee ae SSS OS SB OSES QS 5 G25 Baa GS GSI Ga SS oue oc SSD C eer o ee e eDoe Ses ernsenoc c crecen SSS gama 4 o X a Woo Wee 0 0 0 D 4 93 5037 O7 41 24 po 5 Module Mounting Shelf s NES xxx EREE ERER Front View Rectifier Rectifier or Converter Mounting Positions Mounting Positions Rectifier or Converter Module Model Number Label R48 2000e3 Rectifier C48 24 1500 Converter Latch Spec No 582127000 11 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Iss
66. of these connectors can be used at a time 3 Switch and indicator located on circuit card installed in Main Bay onl y Y T Y T T a a Spec No 582127000 50 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 sy EMERSON Power Networ k Powel Optional Manual Battery Disconnect Circuit Card Replacement PROCEDURE iF 10 11 12 13 14 Spec No 582127000 Model No 721NPBB 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 future alarms associated with this system while the procedure is being performed DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination Open the distribution cabinet s front door by turning the latch in the counterclockwise position WARNING Damage to the circuit card may result if the next step is not followed Connect an approved grounding strap to your wrist Attach the other end to a suitable ground Remove the top and front panels to access the circuit cards at the bottom of the di
67. oller Extended Interface Board Replacement Main Bay Only PROCEDURE 1 Spec No 582127000 Model No 721NPBB 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 future alarms associated with this system while the procedure is being performed DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination Open the distribution cabinet s front door by turning the latch in the counterclockwise position WARNING Damage to the circuit card may result if the next step is not followed Connect an approved grounding strap to your wrist Attach the other end to a suitable ground Carefully label the wires connected to the customer connection terminal blocks on the circuit card These wires must be connected to the same terminals on the replacement circuit card Refer to Figure 29 or Figure 30 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 29 or Figure 30 DANGER In the next step external alarm wiring may be energized from an external source DO NOT allow bare wire ends to contact any ground
68. ontactor 4 Disconnect the wiring to the contactor by unplugging the quick disconnects DANGER All sources of AC and DC power must be completely disconnected from this power system before performing this procedure Use a voltmeter to verify no DC voltage is present on the system busbars 5 Note the orientation of the contactor to ensure the replacement is installed the same way Unbolt the contactor 4 places and remove Save all hardware before proceeding Installing the Replacement Contactor Note the following procedure before making busbar to busbar 1 Position the replacement contactor oriented the same connections apply a thin coating of electrical anti oxidizing way as the old compound to the mating surfaces of the busbars 2 Secure the contactor with the hardware removed above PROCEDURE Refer to Figure 36 Figure 37 Figure 38 or Figure 39 for hardware build up and recommended torque Note Referto Figure 36 Figure 37 Figure 38 or Figure 39 as this procedure is performed 3 Replace the wiring to the contactor by plugging in the quick disconnects Refer to Fiqure 36 Figure 37 Figure Removing the Contactor 38 or Figure 39 1 Verify all AC and DC power sources are disconnected 4 Forthe 2 3 or 4 row distribution cabinet replace the from the power system distribution cabinet s rear access panel s 2 Forthe 1 row distribution cabinet the contactor can be Restarting the Power System accessed from
69. osition pulling the handle document system performance down out from the module s front panel causes the latch to retract See Figure 7 WARNING prevent damage to the latching Adding Rectifi er or Converter Module to an Existi ng mechanism ensure the handle is in the open position when Module Mounting Shelf Spec No 588705000 installing or removing a module NEVER hold the handle in the closed position when installing a module into a shelf To increase system current capacity a rectifier or converter module can easily be added to an existing module mounting shelf Spec No 588705000 that contains an empty rectifier or converter module mounting position 1 Unpack the modules It is recommended that the current limit point be checked 2 Note the model number located on the front of each whenever a rectifier or converter module is added to or removed module Model numbers starting with the letter R are from a 588705000 shelf in the power system Refer to Checking rectifier modules Model numbers starting with the letter the Controller s Current Limit Point after Adding or Removing a are converter modules ver ON 3 Place the module into an unoccupied mounting position The rectifier or converter module being added is assigned by the without sliding it in completely Rectifiers modules can controller the lowest available identification number I
70. ource that can produce high amounts of electrical current Spec No 582127000 Model No 721NPBB amp EMERSON Network Powel FOR THESE REASONS IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS AND FOLLOW THEM EXACTLY WHEN WORKING WITH LEAD ACID BATTERIES Wear complete protection for eyes face hands and clothing Examples are safety goggles or face shield a rubber apron and gloves e If 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 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 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 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 El
71. p Push distribution device in firmly until fully seated in the distribution panel 6 Operate the replacement circuit breaker to the ON position 7 Verify no Circuit Breaker Alarms are active 8 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Figure 21 Replacing a Bullet Nose Circuit Breaker Shorter Side to the Top Lettering on handle must be right side up Insert these terminals into corresponding sockets Turn off on distribution panel before installing Longer Side to the Bottom Replacing a TPH Fuse EMERSON Network Power Figure 22 Replacing a TPH Fuse Fuseholder Body Fuse Carrier Replacing a TPL B Fuse PROCEDURE Note Refer to Figure 22 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Remove the fuse carrier from the mounted fuseholder body by grasping its handle and pulling straight out 3 Remove the open fuse from the fuse carrier and replace it with the same type and rating 4 Push the fuse carrier securely back into the mounted fuseholder body 5 distribution panel locate the open alarm fuse associated with the TPH fuse being replaced Replace the alarm fuse with the same type and rating Ensure that a plastic safety cover is installed on the alarm fuse 6 Close distribution cabinet s front door Turn th
72. place the plastic shield covering the circuit breakers or fuseholders on the replacement panel Verify no Circuit Breaker Fuse Alarms are active Close the distribution cabinet s front door Turn the latch clockwise to secure the door Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 35 Replacing a Distribution Panel Battery Busbar Hardware Ground Busbar Hardware Battery D Distribution Distribution Panel lt lt Eon Panel Distribution Panel Hardware Hardware Load a Distribution Ground Busbar Panel Hardware System Load Distribution Busbar Hardware Front Components removed in illustration for clarity only List DA Dual Voltage Distribution Panel Lists DB DC and DD similar E 11 aL 1 11 BR TB HHG 24 US 253 Ou lo Sr OLORO 24 jumpers Assembly order is lug 1 4 flat washer 1 4 lock washer 1 4 20 bolt Torque to 84 in Ibs Spec No 582127000 53 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Replacing a Battery or Load Disconnect C
73. r hardware build up Torque as indicated in Figure 12 4 Replace the hardware securing the distribution panel s system load distribution busbar to the distribution cabinet s busbar Refer to Figure 12 for hardware build up Torque as indicated in Figure 12 5 Replace the hardware securing the distribution panel s ground busbar to the distribution cabinet s busbar Torque as indicated in Figure 12 6 Plug the in line FA CBA connector located near the back of the distribution panel into the mating connector half in the distribution cabinet Refer to Figure 12 WARNING In the next step observe correct polarity otherwise equipment damage will result 7 Reconnectthe load return leads to the ground busbar 8 Reconnectthe load leads to the circuit breaker and or fuse positions 9 Replace the circuit breakers and or fuseholders 10 Replace the plastic shield covering the circuit breakers and or fuseholders on the distribution panel 11 Verify no circuit breaker fuse alarms are active 12 Closethe distribution cabinet s front door Turn the latch clockwise to secure the door 13 Ensure that there are no local or remote alarms active on the system Spec No 582127000 27 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 Changing the Controller s LVD Control Level for a Contactor The controller has two availabl
74. r network infrastructure needs Customer Service Pre Shipment Email CustomerService ESNA Emerson com Pricing and availability l l purchase orders expediting requests and order tracking Ask for your company s dedicated Customer Service Phone 1 800 800 1280 option 1 Associate Customer Support Center Post Shipment Email ESNACustomerSupportCenter Emerson com an order has shipped contact our Customer Support Center Phone 1 956 661 6867 with related questions concerns claims Account Management Email AccountManagement ESNA Emerson com Provides quotes and bid responses for custom configured l DC power systems and outside plant enclosures for customers and channel partners Phone 1 800 800 1280 option 2 Reps VARs amp Distributors Spare Parts Email 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 T AC Emerson com OSP TAC Emerson com Answers technical product and sy
75. r notify appropriate personnel that this procedure is finished 18 Ensure that there are no local or remote alarms active on the system Figure 27 System Interface Circuit Card Connector Locations 41 92 J3 J4 Distribution Panels FA Inputs J8 Main Bay Only Selects to power Controller from Battery Power or not No Battery Battery Pwr Pwr 1 7 21 8 RS485 Connection 3 9 2 1A RS485 TB2 2A RS485 Shorting Jumper 48 RS232 Connection TB2 1B CGND TB2 2B TXD232 TB2 3B RXD232 410 Main Bay Only Battery Monitoring External Internal see TB1 4 and TB1 5 for external monitoring points External Internal 1 O 7 2 O 018 3 O x 19 1 TB1 5 TP1 TP2 TP4 Shorting Jumper J10 J5 Ee CAN L TB1 1 Battery Tray FA 1 TP2 4 1 2 External Battery FA Bay Voltage Bay Load 1 3 External System FA Monitoring Shunt Monitoring 1 4 External Battery Monitoring 1 5 External Battery Monitoring TB1 TB1 2 TB1 3 TB1 4 TB1 5 Main Bay Only Wire Size Capacity 22 12 AWG Recommended Torque 3 0 in Ibs FA Signals Battery applied to the terminal turns in an alarm Spec No 582127000 40 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 48 DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE SM D
76. re established due to loss of a rectifier Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier amp EMERSON Network Power Clearing a Converter Lost Alarm If the controller resets while a converter communications fail alarm is active the converter communications fail alarm is replace with a converter lost alarm Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure to clear the alarm Replacement Information Replacement Assemblies When a trouble symptom is localized to a faulty rectifier module converter module controller or system circuit card that particular device or circuit card should be replaced in its entirety No attempt should be made to troubleshoot or repair individual components on any rectifier module converter module controller or circuit card Refer to SAG582127000 System Application Guide for replacement part numbers Replacement Cables If a rectifier module is removed from the system a rectifier communications failure alarm is generated If the rectifier module will not be replaced the alarm should be cleared Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA for a procedure Clearing a Converter Communications Fail Alarm after Removing a
77. re 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 582127000 Model No 721NPBB Code UM582127000 ii Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 sy EMERSON Power Networ k Powel Important Safety Instructions General Safety DANGER YOU MUST FOLLOW APPROVED SAFETY PROCEDURES Performing 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 Prior to 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 Use double insulated tools appropriately rated for the work to be performed f For400V DC input systems do not work on energized system without full arc flash and PPE protection Voltages AC Input Voltages DC Input Voltages DANGER This syst
78. ribution cabinet s busbar 3 8 16 x 1 1 4 bolt 3 8 Belleville lock Spec No 582127000 Model No 721NPBB 12 13 washer 3 8 hardened flat washer 2 places Torque to 180 in lbs For load distribution panels replace the hardware securing the panel s System Load Distribution busbar to the distribution cabinet s busbar 1 4 20 x 1 bolt 1 4 Belleville lock washer 1 4 Belleville lock washer concave side of Belleville lock washers face each other 1 4 hardened flat washer 2 places Torque to 60 in Ibs Replace the hardware securing the panel s Ground Busbar if equipped to the distribution cabinet s busbar 1 4 20 x 1 bolt 1 4 Belleville lock washer 1 4 Belleville lock washer concave side of Belleville lock washers face each other 1 4 hardened flat washer 2 places Torque to 60 in Ibs Locate the in line FA CBA connector located near the back of the panel and plug it into the mating connector half in the distribution cabinet On panels equipped with shunts reconnect the shunt leads WARNING In the next step observe correct polarity otherwise equipment damage will result On panels equipped with a ground busbar reconnect the load return or battery return wiring to the ground busbar Reconnect the load or battery wiring to the circuit breaker or fuse positions Transfer the plug in circuit breakers or fuses from the old panel to the replacement panel Re
79. ssue AH February 17 2015 Figure 37 Replacing a Battery Disconnect Contactor in a 2 3 or 4 Row Distribution Cabinet 2 row Distribution Cabinet shown 3 or 4 row cabinet similar Spec No 582127000 Model No 721NPBB 56 amp EMERSON Network Power 1 2 13 x 1 1 4 Bolt 1 2 Belleville Lock Washer 1 2 Belleville Lock Washer concave side of Belleville Lock Washers face each other 1 2 Hardened Flat Washer 4 places Torque to 500 Apply electrical anti oxidizing compound to busbar mating surfaces Battery Disconnect Contactor Shown being removed from front for clarity only Removal is from rear Components removed in illustration for clarity only Brown White Wire Brown Wire Red White White Black Wire Wire Code UM582127000 Issue AH February 17 2015 NetSure 48V DC Power System 54 User Instructions UM582127000 Issue AH February 17 2015 EMERSON Network Power Figure 38 Replacing a Load Disconnect Contactor in a 1 Row Distribution Cabinet 5 16 18 x 1 Bolt 5 16 Belleville Lock Washer 5 16 Belleville Lock Washer concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 in lbs Load gt Disconnect Contactor Apply electrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only Contactor styles vary
80. stem questions determines status of warranties and contractual agreements for repair Email Phone 1 800 800 5260 Email DCpowerReps ESNA Emerson com Provide quotes and bid responses for application specific configured DC Phone 1 440 240 0639 power systems for Liebert DC power sales reps 1 Contact Account Management for custom configurations 21 Contact Spare Parts for parts and accessories Spec No 582127000 59 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 _ 5 NetSure 48V DC Power System EMERSON User Instructions UM582127000 Issue AH February 17 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 contai
81. strap WARNING Damage to the circuit card may result if the 12 Close the distribution cabinet s front door Turn the latch next step is not followed clockwise to secure the door 13 Temporarily remove then re insert the controller Wait an approved qrounding strap to your wrist ee 3 for the controller to initialize Attach the other end to a suitable ground 14 Enable the external alarms or notify appropriate 4 Remove the top and front panels to access the circuit personnel that this procedure is finished cards at the bottom of the distribution cabinet See Figure 28 15 Ensure that there are no local or remote alarms active on 5 Remove connectors J1 J2 and J3 from the circuit the system Spec No 582127000 41 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 28 SM DU Circuit Card Replacement Supplemental Bays Only 24 51 52 123456 7 8 123456 7 8 123456 7 8 n and 1 Spec No 582127000 42 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System User Instructions UM582127000 Issue AH February 17 2015 sy EMERSON Power Networ k Powel IB2 Controller Interface Board and Optional EIB Contr
82. stribution cabinet Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 34 Unplug all connectors plugged into the circuit card Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet Place the replacement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card Plug all connectors removed from the old circuit card into the same position on the replacement circuit card Remove the grounding wrist strap Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet Close the distribution cabinet s front door Turn the latch clockwise to secure the door Enable the external alarms or notify appropriate personnel that this procedure is finished Ensure that there are no local or remote alarms active on the system 51 Figure 34 Optional Manual Battery Disconnect Circuit Card Connector Locations CRY Am CRA F1 RS CRS R2 R1 CR1 CRF CR A mi HUI 1 F4
83. sulated 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 Donotlaytools 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 replaced with an incorrect type or if polarity is reversed When replacing batteries replace with the same manufacturer and type or equivalent 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 an energy s
84. t Card Replacement Procedures WARNING Circuit cards used in this power system contain static sensitive devices Read the Static Warning at the front of this document before performing any of the following procedures General The following circuit card replacement procedures can be performed with the system operating Refer to Figure 1 for circuit card locations CAUTION When performing any step in these procedures that requires removal or installation of hardware use caution to ensure no hardware is dropped and left inside the cabinet otherwise service interruption or equipment damage may occur Note When performing any step in these procedures that requires removal of existing hardware retain all hardware for use in subsequent steps System Interface Circuit Card Replacement PROCEDURE 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 future alarms associated with this system while the procedure is being performed DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination 2 distribution cabinet s front door by turning the latch in the counterclockwise position WARNING
85. tch to the down ON position latch in the counterclockwise position termination 13 Remove the grounding wrist strap WARNING Damage to the circuit card may result if the next step is not followed 14 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 3 Connect an approved grounding strap to your wrist Attach the other end to a suitable ground 15 Closethe distribution cabinet s front door Turn the latc clockwise to secure the door 4 If any of the low voltage disconnect contactors is open and it is desired to be closed push the LVD Inhibit Switch located on the circuit card installed in the main bay to the UP position momentarily and then leave the switch in the 17 Ensure that there are no local or remote alarms active on middle OFF position the system 16 Enable the external alarms or notify appropriate personnel that this procedure is finished 5 Remove the top and front panels to access the circuit cards at the bottom of the distribution cabinet Spec No 582127000 48 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Figure 32 Optional LVD Driver Circuit Card Connector Locations 540972 1547 702 E S Ey vete cu YE LVLD contactor uses Controller DO NOT chang
86. the top of the distribution cabinet For the 2 3 or 4 row distribution cabinet the contactor can be 1 Reconnect the AC and DC power sources to the power accessed from the rear and top of the distribution system cabinet 2 Startthe power system Referto the separate Installation 3 Forthe2 3 or 4 row distribution cabinet remove the Instructions IM582127000 for a startup procedure distribution cabinet s rear access panel s 3 Verify no alarms are active Spec No 582127000 54 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 NetSure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 EE Figure 36 Replacing a Battery Disconnect Contactor in a 1 Row Distribution Cabinet 5 16 18 x 1 Bolt Battery 5 16 Belleville Lock Washer 1 Disconnect 5 16 Belleville Lock Washer Contactor concave side of Belleville Lock Washers face each other 5 16 Hardened Flat Washer 4 places Torque to 100 1 Apply electrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only Contactor styles vary between manufacturer s Brown Wire Brown White Wire Red White Wire Brown Wire Brown White Wire White Black Wire White Black Wire Red White Wire Spec No 582127000 55 Code UM582127000 Model No 721NPBB Issue AH February 17 2015 5 48V DC Power System User Instructions UM582127000 I
87. ue AH February 17 2015 Installing a Field Expansion Module Mounting Shelf Hardware build up for these connections are Spec No 588705000 1 4 20 x 1 bolt 1 4 Belleville lock washer DANGER Adhere to the Important Safety Instructions 1 4 flat washer presented at the front of this document Install the Belleville lock washer so the concave side is Note Refer to Figure 8 and Figure 9 as this procedure is towards the busbar Torque all connections to 60 in lbs erformed If installing a second expansion module mounting shelf PROCEDURE 1 4 20 nuts included are required in lieu of the 1 4 20 x 1 Install the expansion module mounting shelf directly 1 bolts see Figure 8 below the bottom most module mounting shelf in the 4 Disconnect the cable coming from the distribution rack Use the mounting hardware provided in the cabinet from the bottom connector on the bottom most expansion busbar kit existing module mounting shelf Hardware build up is 5 Connect the bottom connector on the bottom most 12 24 3 4 screw and flat washer 1 set per side existing module mounting shelf to the top connector on 12 24 3 4 screw and ground washer 1 set per side the expansion module mounting shelf Note Install the ground washers so the teeth make 6 Connectthe cable disconnected in step 4 coming from contact with the metal on the mounting angles distribution cabinet to the bottom connector on Torque a
88. uit Card The optional LVD driver circuit card installed in the main bay contains an LVD inhibit switch and indicator Refer to Figure 3 LVD driver circuit cards are required for 2 3 or 4 row distribution cabinets that contain three or more LVD contactors LVBD and or LVLD or if the distribution cabinet is equipped with an LVBD contactor rated 1200A or higher CAUTION If the switch is returned to the ON normal position when low voltage disconnect alarms are active a low voltage disconnection will occur WARNING While the LVD inhibit switch is in the OFF inhibit position a low voltage disconnection will not occur if battery or load voltage decreases below the low voltage disconnect setpoint For maximum battery protection this switch should NOT be left in the OFF inhibit position Figure 3 Optional LVD Driver Circuit Card 0247799 O 3 1 Switch and indicator located on circuit card installed in LVD Inhibit Mali S only Note The UP position will not close the LVBD contactor Active Indicator LVD Inhibit Switch if the battery is manually disconnected using the Manual Battery Disconnect Switch Illuminates when the Momentary UP Middle Down low voltage disconnect Momentary UP Position Closes all LVD Contactors inhibit mode circuit has been disabled Middle Position OFF Controller DOES NOT control LVD s inhibit mode
89. uit card Refer to Figure 31 5 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement circuit card Refer to Figure 31 DANGER In the next step external alarm wiring may be energized from an external source DO NOT allow bare wire ends to contact any grounded or energized object 6 Remove the external wiring from the shunt input terminal blocks DO NOT allow the bare wire end to contact any grounded or energized object Isolate the wire end with electrical tape Repeat for each wire to be removed Spec No 582127000 Model No 721NPBB 10 11 12 13 14 15 16 Unplug all connectors plugged into the circuit card Remove the screw securing the SM DU and Shunt Interface Assembly to the bottom of the distribution cabinet and remove the assembly SM DU In this step ensure you do not intermix the old and replacement circuit cards Set the switches on the replacement circuit card to the same settings as the old circuit card Switch settings are documented in the Setting Jumpers and Switch Options section of the Power System Installation Instructions IM582127000 Slide the replacement SM DU and Shunt Interface Assembly into the mounting position inside the distribution cabinet and secure with the screw removed from the old assembly Plug all connectors removed from the old circuit card into the same position
90. ure 48V DC Power System amp User Instructions UM582127000 Issue AH February 17 2015 Optional LVD Driver and LVD Driver Lite Circuit Card 6 Carefully label the connectors plugged into the circuit Replacement card These connectors must be plugged into the same connectors on the replacement circuit card Refer to PROCEDURE Figure 32 or Figure 33 1 Performing this procedure may activate external alarms 7 Unplugall connectors plugged into the circuit card Do one of the following If possible disable these alarms If these alarms cannot be easily disabled notify the appropriate personnel to disregard any future alarms associated with this system while the procedure is being 9 Slide the replacement circuit card into the mounting performed position inside the distribution cabinet and secure with the screws removed from the old circuit card 8 Removethe screws securing the circuit card and remove the circuit card from the distribution cabinet DANGER Performing the next steps exposes service personnel to battery potential Exercise extreme 10 Ensure that the LVD Inhibit Switch is in the middle OFF caution not to inadvertently contact or have any tool position inadvertently contact any energized electrical 11 Plugall connectors removed from the old circuit card into the same position on the replacement circuit card 2 Open distribution cabinet s front door by turning the 12 Push the LVD Inhibit Swi
91. ures on page 29 Troubleshooting Alarm Conditions on the Controller The controller displays alarm conditions as listed in the Available Alarms or Resolving Alarms section of the controller s User Manual Programmable external alarm relays are also available Refer to the System Installation Instructions IM582127000 and the configuration drawing C drawing supplied with your power system documentation for your alarm relay configurations The controller s Active Alarm and Alarm Historysubmenus allow the User to view alarm details Refer to the ACU Instructions UM1M820BNA or UM1M820DNA400 or NCU Instructions UM1M830BNA to access these menus Checking the Controller s Current Limit Point after Adding or Removing a Rectifier Module or Converter Module 28 If a rectifier module or converter module is added to the power system the system current limit point will automatically increase by the percentage each existing rectifier or converter was set to provide prior to the addition If a rectifier module or converter module is removed from the system and the Rect Comm Fail or Conv Comm Fail alarm is reset the current limit point will remain unchanged unless the capacity of the remaining rectifiers or converters is not sufficient to maintain the present current limit point If that happens the current limit point will automatically increase to the maximum 12126 of the remaining rectifiers or converters It is recomme

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