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Emerson 721NPBB Power Supply User Manual

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1. cO oy amp A Apply electrical anti oxidizing compound to busbar mating surfaces 2 By A SA e LY 4 ae 2 AS 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 2 row Distribution Cabinet shown 3 or 4 row cabinet similar Red White White Black Wire Wire Figure 4 19 Replacing a Battery Disconnect Contactor in a 2 3 or 4 Row Distribution Cabinet Page 58 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 5 16 18 x 1 Bolt 8 5 16 Belleville Lock Washer ims 5 16 Belleville Lock Washer A ios concave side of Belleville Aree Picone Lock Washers face each other FAL oC e ontactor 5 16 Hardened Flat Washer 1 4 places NA P Torque to 100 in lbs Apply electrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only Cont
2. Repeat for each wire to be reconnected 13 Remove the grounding wrist strap 14 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 15 Enable the external alarms or notify appropriate personnel that this procedure is finished 16 Ensure that there are no local or remote alarms active on the system IB2 Board Assembly IB2 TEMP IB2 TEMP PROBRE 1 to ACU PROBE 2 T g Connector IB2 Board Top View 3 5 3 KDE 9 2g oq SQ 29 oS 28 SQ 1 NC NO C eoo 1 5 3 J9 T G 3 NNNNNNNNNNNN J3 J9 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs Figure 4 11 IB2 ACU Interface Board Connector Locations Chapter 4 Troubleshooting and Repair Page 43 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 Spec No 582127000 Model 721NPBB Optional EIB Interface Board Assembly Optional EIB Interface Board Top View AL ve SS RELAYS COCO OOCOOCD OO COCOC Oe INPUTS AL YS L2 ASRS SF RFCSF SHIUNT VOLTAGE
3. TROUBLESHOOTING AND REPAIR eere eene nen nnn nnn 22 Contact MTOR ALON EE Eoo D nm 22 Controller Rectifiers and Optional Converters resessie a a nennen nennen nennen nnns nnns nnne ei 22 ACUS Gohlroller GONTGQUIAL ON 222 tetro to tee oie tato Eo densa Fee ean toot ocu et eso Ead eeu Ee vagox eben ex et assa sd exo extus ena ads 22 System Trog bleshieotnd IMTONMAON eti oni tee ich aries ehm pets din pagato e uisu gaara as cba dap tua Didot q Us 22 Heblacemernb intoriiallOssveruad e comes isan RUD vee a ERG E NN euler Wien ura S OUO LUN cru CON DT OD DAVE I NEN ERAN ER VOD GE a 25 Replacement ASSemDIES tse atus be Pub vasi ei Mala at sate bestia beeline a detente Auc ad 25 Replacement CASS xis ciate hie m m uU mem 25 aisejzie i u mfee e tem c Em 25 Replacing a Rectifier Module in a Spec No 588705000 Shelf 25 Replacing a Rectifier or Converter Module in a Spec No 588705300 Shelf eseeeusessse 25 Table of Contents Page i This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Rep ac
4. X INPUTS Fs ADO g OQOOQOOOOOCOOOUDOU O O O O O O O O O O O OQ O O AAUAUUUUUUUUUUUUA J5 J9 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs Figure 4 12 EIB ACU Extended Interface Board Connector Locations Page 44 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 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 Open the distribution cabinet s front door by turning the latch in the counterclockwise position Warning Damage to the ci
5. 582127000 Model 721NPBB INSTALLING A FIELD EXPANSION RECTIFIER CONVERTER MODULE MOUNTING SHELF SPEC NO 588705300 Danger Adhere to the Important Safety Instructions presented at the front of this document Note Refer to Figure 3 4 and Figure 3 5 as this procedure is performed Procedure 1 4 Remove the busbar rear shield from the existing rectifier converter shelves Remove the cut out panel from the busbar rear shield by gently bending the panel until it snaps from the busbar rear shield Remove the hardware from the lowest module mounting shelf s 48V return and 24V if present busbars Install the expansion module mounting shelf directly below the bottom most module mounting shelf in the rack Use the mounting hardware provided with the expansion module mounting shelf Hardware build up is 12 24 x 3 4 screw and flat washer 1 set per side 12 24 x 3 4 screw and ground washer 1 set per side Note Install the ground washers so the teeth make contact with the metal on the mounting angles Torque all screws to 65 in Ibs Remove the busbar rear shield from the expansion module mounting shelf Note Apply electrical anti oxidizing compound to busbar mating surfaces before 5 9 performing the next step Install the busbars provided with the expansion module mounting shelf between the studs on the expansion module mounting shelf and the studs on the shelf above it Secure these busbars to th
6. 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 User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 J1 J2 J3 J4 Distribution Panels FA Inputs J8 Main Bay Onl Selects to power Controller from Battery Power or not No Battery Battery Pwr Pwr RS485 Connection TB2 1A RS485 TB2 2A RS485 Shorting Jumper RS232 Connection TB2 1B CGND TB2 2B TXD232 TB2 3B RXD232 J10 Main Bay Only Battery Monitoring External Internal see TB1 4 and TB1 5 for external monitoring points E322 2 223 LILLE II miat IEEE External Internal C 1 1 TB1 5 3 9 TP1 TP2 TP3 TP4 Shorting Jumper J10 J5 EE CAN MER TB1 1 Battery Tray FA TP1 and TP2 TP3 and TPA TB1 2 External Battery FA Bay Voltage Bay Load TB1 3 External System FA Monitoring shunt Monitoring TB1 4 External Battery Monitoring TB1 5 External Battery Monitoring nO QOO QUO Co TB1 TB1 2 TB1 3 TB1 4 TB1 5 Main Bay Only Wire Size Capacity 22 12 AWG Recommended Torque 3 0 in lbs FA Signals Battery applied to the terminal turns in an alarm Figure 4 9 system Interface Circuit Card Connector Locations Chapter 4 Troubleshooting and Repair Page 39 This document is property of Emerson Network Power Energy Syste
7. Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 SM DU 520 0 J4 J4A S1 S2 12 34567 8 1234567 8 1234567 8 fel la a nl ind Cal Ca Ln Ca Lede Ln Cal Land Cal nd end Cin Ta ad ed Cal fe Figure 4 10 SM DU Circuit Card Replacement Supplemental Bays Only Chapter 4 Troubleshooting and Repair Page 41 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB IB2 ACU Interface Board and Optional EIB ACU Extended Interface Board Replacement Main Bay Only 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 inadvert
8. LD CLD Rectifier Module CP m CLD Gc LDD CLD Mounting Shelf CD da rb 11D GD a oO GEL IP CA IP GHD e i These cables are conca factory connected NET O ifi owe q I CY TD dC TID amp yy Rectifier Module gt P III Mounting Shelf TED E EID D o These cables are eee 1 factory connected TNT O Existing ifi Rectifier Module aS Mounting Shelf O GLD dA r3 GAD ec EGP Gn edA rarum GAD i Disconnect cable coming from distribution U cabinet from this connector on bottom most ___ existing rectifier shelf then connect to the top connector on the expansion rectifier shelf o _Expansion ps Rectifier Module eb 5 Mounting Shelf ir a Connect the cable disconnected above we coming from distribution cabinet to bottom Exploded View Shown to Illustrate Wire Connections Only connector on expansion rectifier shelf Figure 3 3 ACU CAN Bus Rectifier Module Mounting Shelf Spec No 588705000 Chapter 3 Maintenance Page 17 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 Issue AC January 2 2013 User Instructions spec No
9. 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 UM582127000 Issue AC January 2 2013 User Instructions spec No 582127000 Model 721NPBB Optional EIB Main Bay Only ACU Extended Interface Board located on inside side panel Sg Uo SB oO 6 955 o o seo CO 6 O o z Q O _ c C 6 lt LL Illustration for Clarity IB2 Main Bay Only ACU Interface Board located on inside side panel DAW aw aa Optional SM DU and Shunt Interface Board ACU Controller Main Bay SM DU E us Me oH 0 a6 c A c Oo o EC OD 5 ag 22 o Optional LVD Driver Circuit Card SS gt co 2 c a9 c 9 T on O Disconnect Circuit Card Main Bay Only System Interface Circuit Card otc 26 Xil O 2 S 8g mm z9 cz 2 3 on O 1 Figure 2 Circuit Card Locations Page 5 Chapter 2 Operating Procedures This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 Us
10. can be used to restore the ACU Controller settings if required at a later date e Note that provided on a USB drive furnished with the system is an ACU configuration drawing C drawing and the ACU configuration files loaded into the ACU as shipped SYSTEM TROUBLESHOOTING INFORMATION This system is designed for ease in troubleshooting and repair The various indicators as described in CHAPTER 2 OPERATING PROCEDURES and in the Controller Rectifier and Converter Instructions are designed to isolate failure to a specific element Once the faulty element has been identified refer to Replacement Information and Replacement Procedures in this chapter Troubleshooting Alarm Conditions on the ACU Controller The ACU Controller displays alarm conditions as listed in the Available Alarms section of the ACU Instructions UM1M820BNA Programmable external alarm relays are also available Refer to the System Installation Instructions 1M582127000 and the configuration drawing C drawing supplied with your power system documentation for your alarm relay configurations The ACU s Active Alarm and Alarm History submenus allow the User to view alarm details Refer to the ACU Instructions UM1M820BNA to access these menus Checking the ACU Current Limit Point after Adding or Removing a Rectifier If a rectifier is added to the power system the system current limit point will automatically increase by the percentage each existing re
11. circuit card Refer to Figure 4 14 or Figure 4 15 7 Unplug all connectors plugged into the circuit card 8 Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet 9 Slide the replacement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card 10 Ensure that the LVD Inhibit Switch is in the middle OFF position 11 Plug all connectors removed from the old circuit card into the same position on the replacement circuit card 12 Push the LVD Inhibit Switch to the down ON position 13 Remove the grounding wrist strap 14 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 15 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 16 Enable the external alarms or notify appropriate personnel that this procedure is finished 17 Ensure that there are no local or remote alarms active on the system Page 48 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User
12. in lieu of the 1 4 20 x 1 bolts see Figure 3 2 4 Disconnect the cable coming from the distribution cabinet from the bottom connector on the bottom most existing rectifier shelf 5 Connect the bottom connector on the bottom most existing rectifier shelf to the top connector on the expansion rectifier shelf 6 Connect the cable disconnected in step 4 coming from distribution cabinet to the bottom connector on expansion rectifier shelf Replace the rear covers removed in step 2 above 8 Refer to the Power System Installation Instructions 1M582127000 and connect AC input power to the expansion shelf 9 Refer to the Rectifier Instructions and install rectifier modules into the expansion shelf as required Page 14 Chapter 3 Maintenance This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Front View Rear View Install Expansion Remove Rear Shield from Rectifier Module Mounting Shelf Rectifier Module Mounting Shelf and Shelf Above It Figure 3 2 cont d on next page Installing a Field Expansion Rectifier Module Mount
13. in the Manual menu in the LCD menus or under the Rectifier Control Tab in the WEB Interface ACU BATTERY CHARGE CURRENT LIMIT FEATURE Functionality After a commercial AC failure 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 ACU can be programmed to limit the battery current to a preset level by limiting the charging voltage of the rectifiers Should the battery current still exceed a higher preset value an alarm is issued In this system the ACU Battery Charge Current Limit feature is set to be disabled Refer to the ACU Controller Instructions UM1M820BNA to enable and program this feature if desired If enabled battery charge current is limited to the value set in the ACU Controller as long as battery voltage is above 47VDC LOCAL CONTROLS AND INDICATORS Refer to the Controller Rectifier and Converter Instructions for descriptions of the local controls and indicators located on these units Refer to this section for descriptions of the local controls and indicators located on the circuit cards installed inside the distribution cabinet Circuit Card Locations Refer to Figure 2 1 Page 4 Chapter 2 Operating Procedures This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems
14. manual are manufactured and or sold by Emerson Network Power Energy Systems North America Inc This document is the property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Names of companies and products are trademarks or registered trademarks of the respective companies Any questions regarding usage of trademark names should be directed to the original manufacturer EmersonNetworkPower com EnergySystems North America EmersonNetworkPower eu EnergySystems EMEA Emerson Network Power Energy Systems North America 2013 Business Critical Continuity Emerson Network Power the Emerson Network Power logo Emerson and Consider it Solved are service marks and trademarks of Emerson Electric Co EnergyMaster eSure NetPerform NetReach NetSpan NetSure and NetXtend are trademarks of Emerson Network Power Energy Systems North America EMERSON CONSIDER IT SOLVED
15. of the circuit breaker color and location on circuit breaker Wiring diagrams are provided in Figure 4 6 Figure 4 7 and Figure 4 8 Carefully disconnect the shunt wiring from the back of the circuit breaker ensuring the exposed end does not contact any energized circuit 6 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 circuit breaker as recorded above Wiring diagrams are provided in Figure 4 6 Figure 4 7 and Figure 4 8 Danger The bolts being installed in the following step may be at system potential Use insulated tools 7 Install the replacement circuit breaker into its mounting position and secure with the hardware previously removed Torque to 60 in lbs 8 Transfer the circuit breaker guard from the old circuit breaker to the new circuit breaker 9 Operate the replacement circuit breaker to the ON position 10 Verify no Circuit Breaker Alarms are active 11 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Page 32 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy
16. off battery for maintenance purposes The power system is designed for operation with the positive output grounded Chapter 1 System Overview Page 1 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB This system consists of the following componenis e Distribution Cabinet 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 GJ 218 circuit breakers The distribution cabinet may be equipped with low voltage load disconnect LVLD low volta
17. the door 15 Enable the external alarms or notify appropriate personnel that this procedure is finished 16 Ensure that there are no local or remote alarms active on the system Page 46 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 SM DU and Shunt Interface Board TB1 TB2 Wire Size Capacity 16 26 AWG Recommended Torque 2 2 in lbs SM DU Shunt Interface Board 2 SW2 SWI Lr LL Lr Lr Lr co Lr LL Lr LI Lr Lr LL Lr Lr LL 1234567812345678 AaAKXKrrrrry LIMELE UTETE Se ee Figure 4 13 SM DU and Shunt Interface Assembly Connector Locations Chapter 4 Troubleshooting and Repair Page 47 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM58
18. the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note f you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Manual menu screen displayed navigate to and select Rectifier ENT All Rect Ctrl ENT 4 Navigate to Clear Rect Lost Press ENT Clear highlights 5 Press ENT to select the operation Press ENT again to confirm 6 Return to the Main screen by repeatedly pressing ESC escape Clearing a Converter Lost Alarm If the ACU Controller resets while a converter communications fail alarm is active the converter communications fail alarm is replace with a converter lost alarm To clear the alarm perform the following procedure Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Manual ENT 2 If a password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the curso
19. the circuit card and remove the circuit card from the distribution cabinet 7 Inthis step ensure you do not intermix the old and replacement circuit cards Set the switches on the replacement circuit card to the same setting as the old circuit card Switch settings are documented in CHAPTER 3 SETTING JUMPERS AND SWITCH OPTIONS of the Power System Installation Instructions IM582127000 8 Slide the replacement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card 9 Plug connectors J1 J2 and J3 into the circuit card 10 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 11 Remove the grounding wrist strap 12 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 13 Temporarily remove then re insert the ACU Wait for the ACU to initialize 14 Enable the external alarms or notify appropriate personnel that this procedure is finished 15 Ensure that there are no local or remote alarms active on the system Page 40 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power
20. the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited 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 your network infrastructure needs Customer Service Pre Shipment Email CustomerService ESNA Emerson com Pricing and availability l purchase orders expediting requests and order tracking Ask for your company s dedicated Customer Service Phone 1 800 800 1280 option 2 Associate Customer Support Center Post Shipment Email ESNACustomerSupportCenter Emerson com After an order has shipped contact our Customer Support Center Phone 1 956 661 6367 with related questions concerns or claims Account Management Email AccountManagement ESNA Emerson com Provides quotes and bid responses for custom configured I DC power systems and outside plant enclosures for customers and channel partners Phone 1 800 800 1280 option 3 Reps VARs amp Distributors Spare Parts DCpower Spares Emerson com Email 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 C
21. 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 Rectifier Converter Module Mounting Shelf Spec No 588705300 The system may contain one or more Spec No 588705300 rectifier converter 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 Page 2 Chapter 1 System Overview This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 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 f
22. 00 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 5 16 18 x 1 Bolt Battery 5 16 Belleville Lock Washer 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 i Apply electrical anti oxidizing compound to busbar mating surfaces Components removed in illustration for clarity only 90 90 eo ea ae ao 2 ee eo oo 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 Figure 4 18 Replacing a Battery Disconnect Contactor in a 1 Row Distribution Cabinet Chapter 4 Troubleshooting and Repair Page 57 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 Spec No 582127000 Model 721NPBB 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 in lbs
23. 00 Model 721NPBB Issue AC January 2 2013 Replacing a Distribution Panel 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 Procedure Note Hefer to Figure 4 17 as this procedure is performed Removing the Distribution Panel 1 9 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 Locate the in line FA CBA connector located near the back of the panel and separate the connector halves Refer to Figure 4 17 and remove the hardware securing the panel s Ground Busbar if equipped to the distribution cabinet s busbar For load distribution panels refer to Figure 4 17 and remove the hardware securing the panel s System Load Distribution busbar to the distribution cabinet s busbar For battery distribution panels refer to Figure 4 17 and remove the hardware securi
24. 1028120 QNV 8u34V3U8 LINDYID I0 310N ONTYNLIVINNVW SALON 5NIU11NI9N1 310N ONT MVC 10 20 30 uvasng 1V8 O d uvasng o gt A NL uvgsng 1v8 Ol JO Aluo og 189 co co yvasng 2 xs 2 15 s 3 z QNO Old if S pd E VY f ane 01 q3u1n034 Sv AUu311V8 WO3J Figure 4 8 GJ 218 Circuit Breaker Wiring Diagram List BC and BD Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited Page 36 User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Circuit 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 2 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 equipm
25. 2127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Optional LVD Driver and LVD Driver Lite 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 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 3 Connect an approved grounding strap to your wrist Attach the other end to a Suitable ground 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 middle OFF position 5 Remove the top and front panels to access the circuit cards at the bottom of the distribution cabinet 6 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the replacement
26. A Technical Manual from the experts in Business Critical Continuity NetSure 48V DC Power System User Instructions UM582127000 Issue AC January 2 2013 Specification Number 582127000 Model Number 721NPBB EMERSON Network Power This page is intentionally blank User Instructions UM582127000 spec No 582127000 Model 721NPBB Issue AC January 2 2013 TABLE OF CONTENTS CONTENTS PAGE IMPORTANT SAFETY INSTRUCTIONS eeeeeeee ener rune nennen nnn n anna n nhan nna n nna iii i a crus cr iii VOIAQ CS rr or RN iii ES Ty P iii S resier ielarigeleP EE s me IV STATIC NW APININO ioneiti ei ioni sec acavcneceaavens consi od eno Ree Cen IAE e coe Dod V CHAPTER T SYSTEM OVERVIEW 5 iisksiskasskuakeiSEskaRONaERENUERNRERKEER eRFRESYRUaERSSERAKEERERKESREERNRENEEEREEE 1 Customer Documentation Package cite treiber eae ea ei to bea avian Mani tem tme tient eoe Maciel ae 1 SEI esc NOELi mias auc ud eMe udicot t inicne miae n tomate inde betta cafu tti ritardi dudas etu Wubi cR Ursi nutu opt 1 CHAPTER 2 OPERATING PROCEDURES 1 21 eere ener nen n nnn nnn nnn runners 4 Controller Rectifiers and Optional Converters sseeesssssesssssesssseseee eene nnnn nnns nna nnns nna n anas 4 Fe OR UN CO IMac T P eeed 4 ACU Battery Charge Current Limit Feature ccccccccccccsesssceeeceeeseceeeceeeeceeeeeeaeeeeseaasseees
27. AHS 90 LON 3uv SYAdWAF u34v3u8 1102812 ANY SYAMVINE LINDIIID 10 SILON ONTYNLIVINNYW SALON 9N13433NI19N3 310N ONT MVC vasng 1v8 O d uvasng o cn gt A NL gvasng 1v8 Ol Aluo OV IST E z QN9 O d 5 S Z PS d S NL uvasng QN9 OL 03410034 SV LNINdINOJ OL Page 35 Figure 4 7 GJ 218 Circuit Breaker Wiring Diagram List AC and AD Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions spec No 582127000 Model 721NPBB Issue AC January 2 2013 UM582127000 KINO SINQHS M 3 Su343v3ug diUl 1VOINVHO3A 1V218412313 403 NOILdO ONIYIM S0 KINO SINM HS M 3 Su34V31u8 dil 1v31812313 404 NOILdO ONTYIM FO SUdMVIN diYL 1v31812313 904 NOILdO ONTYIM 0 OJNI SOF HLIM JONVOYOODV NI Q3HSINUAJ 38 TIVHS ALIOVdVD ONY ALILNVAQ lvoldAL 3uv NMOHS u34v3u8 LINDIID 10 033v348 dll 1VOINVHO3A 1v218u12313 403 NOILdO ONIUIM 20 WO 6 38 Ol NOLLVYAdO Abt 903 SAVI1 INAHS 35U3A3U AljivuyvdiS GASVHIUNd 38 LSAW ONV ASSY JO LUVd Q3 4I23dS 1S1MUu3HIO LON SQv3l YO10D 80 NOI1V3u3d0 ASV YOF Q3UIM NMOHS JUV Su3uv3ug GILNAHS 90 LON Juv SYAdWAF u3 vjug8 1
28. E J1 J4 J4A m LED MN J2 een jea eee LS S1 S2 S3 ln onl Lond and Land Lak nl fon nl Cin onl Lod Lod Land Land nl Land Land Lk nl nl ol Canl nl Figure 2 6 SM DU Circuit Card Page 10 Chapter 2 Operating Procedures This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 CHAPTER 3 MAINTENANCE SYSTEM MAINTENANCE PROCEDURES It is recommended to perform the maintenance procedures listed in Table 3 1 every 6 months to ensure continual system operation PROCEDURE REFERENCED IN COMPLETED V Check ventilation openings for obstructions such as dust papers manuals etc IM582127000 Inspect and tighten all installer s Chapter 4 connections Making Electrical Connections Note This table may be reproduced as necessary to record and document system performance Table 3 1 Maintenance Procedures to be Performed at 6 Month Intervals ADDING A RECTIFIER MODULE TO AN EXISTING RECTIFIER MODULE MOUNTING SHELF SPEC NO 588705000 To increase system current capacity a rectifier module can easily be added
29. Instructions UM1M820BNA for a download procedure There are also labels located near the SM DU and SM DU in the supplemental bay that detail the ACU settings for this bay Once the ACU has been programmed for the newly installed supplemental bay refer to the ACU Instructions UM1M820BNA and save a copy of the SettingParam run file Chapter 3 Maintenance Page 21 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB CHAPTER 4 TROUBLESHOOTING AND REPAIR CONTACT INFORMATION Support contact information is provided on the inside of the back cover of this document CONTROLLER RECTIFIERS AND OPTIONAL CONVERTERS For troubleshooting and repair instructions on these units refer to the following documents e ACU Controller Instructions UM1M820BNA e Rectifier Instructions UM1R483500E or UM1R482000E3 e Converter Instructions UM1C48241500 ACU CONTROLLER CONFIGURATION If any ACU Controller configuration settings were changed refer to the ACU Instructions UM1M820BNA and save a copy of the configuration file This file
30. Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 e E 540972 1547 702 m H E H mu dau vx CELEC LIEHEHIHIHALTL LIT U c N O O U um L3 e u z J g sc D Lr o 4 To LVLD contactor uses ACU DO NOT change 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 r J4 J5 J6 To LVLD contactor uses ACU LVD2 control setting Level 2 HEDRE S Boo J7 To LVBD contactor uses ACU LVD2 control setting Level 2 I Notes 1 Connects up to 4 LVLD and 1 LVBD contactors 2 Switch and indicator located on circuit card installed in Main Bay only Figure 4 14 Optional LVD Driver Circuit Card Connector Locations Chapter 4 Troubleshooting and Repair Page 49 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 LVD2
31. LING A FIELD EXPANSION RECTIFIER MODULE MOUNTING SHELF SPEC NO 588705000 Danger Adhere to the Important Safety Instructions presented at the front of this document Note Refer to Figure 3 2 and Figure 3 3 as this procedure is performed Procedure 1 Install the expansion rectifier module mounting shelf directly below the bottom most rectifier module mounting shelf in the rack Use the mounting hardware provided in the expansion busbar kit Hardware build up is 12 24 x 3 4 screw and flat washer 1 set per side 12 24 x 3 4 screw and ground washer 1 set per side Note Install the ground washers so the teeth make contact with the metal on the mounting angles Torque all screws to 65 in Ibs 2 Onthe rear of the expansion rectifier module mounting shelf and the existing shelf installed directly above it remove the rear shield that covers the output busbars Note Apply electrical anti oxidizing compound to busbar mating surfaces before performing the next step 3 Secure the existing shelf s busbars to the expansion shelf s mating busbars with the supplied interconnect busbars and hardware Hardware build up for these connections are 1 4 20 x 1 bolt 1 4 Belleville lock washer 1 4 flat washer Install the Belleville lock washer so the concave side is towards the busbar Torque all connections to 60 in lbs If installing a second expansion rectifier module mounting shelf 1 4 20 nuts included are required
32. 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 User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 INSTALLING CIRCUIT BREAKER Alarm jumper connector Holes to route shunt jumper through if applicable 1 4 Hardened gt Flat Washer Apply anti oxidizing compound to busbar mating Vi 1 4 Belleville surfaces before mounting circuit breakers Lock Washer 1 4 20 x 3 4 Bolt 2 places Torque to 60 in lbs INSTALLING CIRCUIT BREAKER GUARD 10 32 X 7 16 PH 10 LW CIRCUIT BREAKER GUARD LABEL T orcun BREAKER GUARD m ocn SIDE OF GUARD Y OFF ON en EK X f rf F NPR DIST ASSY SHOWN FOR EXAMPLE ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING BREAKERS WITH SHUNTS STANDARD TRIP BREAKER ELECTRICAL TRIP BREAKER STANDARD TRIP IBEACICHANDEE WHITE HANDLE BREAKER i BLACK HANDLE SHUNTED BRKR JUMPER BLACK 3 SHUNTED BRKR JUMPER BLACK ALARM JUMPER BROWN NC ALARM JUMPER RED C s ALARM JUMPER BROWN ELECTRICAL TRIP e ALARM JUMPER RED BREAKER SHUNTED BRKR JUMPER RED S2 SHUNTED BRKR JUMPER RED WHITE HANDLE COM Figure 4 6 cont d on next page Replacing a GJ 218 Circuit Breaker 1 Pole Chapter 4 Tr
33. TED BRKR JUMPER BLACK ALARM JUMPER BROWN NC ALARM JUMPER RED C ALARM JUMPER BROWN t e ELECTRICAL TRIP e ALARM JUMPER RED BREAKER SHUNTED BRKR JUMPER RED 1 9 S2 SHUNTED BRKR JUMPER RED WHITE HANDLE Figure 4 6 cont d from previous page Installing a GJ 218 Circuit Breaker 2 Pole 3 Pole 4 Pole Page 34 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 Issue AC January 2 2013 spec No 582127000 Model 721NPBB User Instructions AINO SLNAHS M 3 Syu3uviug diui IWIINVHIAW 1v2I812313 YOU NOIIdO ONIYIM SO AINO SINQHS M 3 Su34V3u8 dis 1V21812313 YO NOILdO 9NISIM v0 Su34V3u8 didl 1V21812313 YO NOIIdO 9NISIM 0 OJNI 80f HLIM 39NVOU4ODO V NI QiHSINUQJ 38 T IVHS ALI2VdVO ONV ALILNYNO TWIIdAL 3uv NMOHS Su34V1U8 LIf2UID LO Su34viug diul 1VOINVHO3N 1vV21u12313 u03J NOILdO 9NISIM 20 V9 e 18 Ol NOILYYJdO Ave X04 SQV3 LNAHS 3591A1H AliivuvdiS qdSvHOund 38 ISAW ANV ASSV 4O LUVd Q3134123dS 3S1MU3HIO LON SQV31 30102 80 Noi1vuidO Agr 903 Q3UIM NMOHS JUV SYIMVING GILN
34. U and Shunt Interface Assembly into the mounting position inside the distribution cabinet and secure with the screw removed from the old assembly 11 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 12 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 Chapter 4 Troubleshooting and Repair Page 45 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB cannot be pulled out of the terminal block Repeat for each wire to be reconnected 13 Remove the grounding wrist strap 14 Close the distribution cabinet s front door Turn the latch clockwise to secure
35. a Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Replacing a TPL B Fuse Procedure Note Refer to Figure 4 5 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 case from the mounted fuse block by grasping its handle and pulling it straight out 3 Open the fuse case 4 Remove the open fuse from the fuse case and replace it with the same type and rating 5 Close the fuse case 6 Push the 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 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 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 OA Fuseblock P N 516241 TPL Fuse Fuse Case Fuse Installed in Closed Fuse Case re
36. actor styles vary between manufacturer s Violet White Wire Violet Wire Violet White Wire Violet Wire Black Wire Black Wire Red Wire Figure 4 20 Replacing a Load Disconnect Contactor in a 1 Row Distribution Cabinet Chapter 4 Troubleshooting and Repair Page 59 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 Spec No 582127000 Model 721NPBB 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 in lbs 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 Violet White Wire Black Wire Violet Wire Black Wire Red Wire Figure 4 21 Replacing a Load Disconnect Contactor in a 2 3 or 4 Row Distribution Cabinet Page 60 Chapter 4 Troubleshooting and Repair This document is prop
37. ar view Open Fuse Case View Figure 4 5 Replacing a TPL B Fuse Chapter 4 Troubleshooting and Repair Page 31 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Replacing a GJ 218 Circuit Breaker Procedure Note Refer to Figure 4 6 as this procedure is performed 1 Open 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 4 6 Figure 4 7 and Figure 4 8 Carefully disconnect the alarm wiring from the back of the circuit breaker ensuring the exposed end does not contact any energized circuit 5 Shunted Breakers Only Record each shunt wire located on the back
38. ard into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card 12 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 13 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 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 14 Remove the grounding wrist strap 15 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 16 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 17 Enable the external alarms or notify appropriate personnel that this procedure is finished 18 Ensure that there are no local or remote alarms active on the system Page 38 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power
39. ause sparking explosion and injury Correct polarity must be observed when connecting battery leads 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 ttmes Remove watches rings and other metal objects before connecting battery leads Important Safety Instructions Page ili This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB CIRCUIT CARD HANDLING Warning Installation or removal of the circuit cards requires careful handling Before handling any circuit card read and follow the instructions contained on the Static Warning Page Page iv Important Safety Instructions This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written perm
40. 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 4 1 for installation details oafety Cover Safety Cover P N 248898700 P N 102774 GMT Y Figure 4 1 Installation of Safety Fuse Covers Page 26 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Replacing a TPS TLS Fuse Procedure Note Refer to Figure 4 2 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 pulling it straight out 3 Remove the open fuse from the fuse carrier and replace it with the same type and rating 4 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 5 Push the fuse carrier securely back into the mounted fuseholder body Note t
41. ctifier was set to provide prior to the addition If a rectifier is removed from the system and the Rect Comm Fail alarm is reset the current limit point will remain unchanged unless the capacity of the remaining rectifiers is not sufficient to maintain the present current limit point If that happens the current limit point will automatically increase to the maximum 12196 of the remaining rectifiers It is recommended that the current limit point be checked whenever a rectifier is added to or removed from the power system Page 22 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Settings ENT 2 If a password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the
42. d Repair Page 29 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Replacing a TPH Fuse Procedure Note Refer to Figure 4 4 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 On the 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 the distribution cabinet s front door Turn the latch clockwise to secure the door Fuseholder Body Fuse Carrier Figure 4 4 Replacing a TPH Fuse Page 30 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North Americ
43. down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note f you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Settings menu screen displayed navigate to and select Rectifier ENT All Rect Set ENT 4 Navigate to Current Limit Pt The current limit in amperes is displayed If no change is required go to step 6 To make a change proceed with step 5 5 With the cursor at Current Limit Pt press ENT to change the current limit point Use the up or down arrow keys to set as desired then press ENT 6 Return to the Main screen by repeatedly pressing ESC escape Clearing a Rectifier Communications Fail Alarm after Removing a Rectifier 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 as described in the following procedure Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Manual ENT 2 Ifa password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at th
44. e ACU Identification of Converters in Chapter 5 of the separate Power System Installation Manual 1M582127000 Replacing the ACU Controller Refer to the ACU Instructions UM1M820BNA for a controller replacement procedure Chapter 4 Troubleshooting and Repair Page 25 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Replacing a Distribution Device General Replace distribution devices with the same type and rating Refer to System Application Guide SAG582127000 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 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
45. e User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note f you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Manual menu screen displayed navigate to and select Rectifier ENT All Rect Ctrl ENT 4 Navigate to Clear Comm Fail Press ENT Yes highlights 5 Press ENT to select the operation Press ENT again to confirm 6 Return to the Main screen by repeatedly pressing ESC escape Clearing a Converter Communications Fail Alarm after Removing a 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 as described in the following procedure Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Manual ENT Chapter 4 Troubleshooting and Repair Page 23 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is str
46. e expansion module mounting shelf with the hardware provided with the expansion module mounting shelf Secure these busbars to the shelf above the expansion module mounting shelf with the hardware previously removed Torque to 60 in lbs Hardware build up for these connections are M6 Nut M6 Belleville lock washer M6 flat washer Disconnect the cable coming from the distribution cabinet from the connector on the bottom most existing module mounting shelf and connect this cable to the same connector on the expansion module mounting shelf Connect the open connector on the bottom most existing module mounting shelf to the open connector on the expansion module mounting shelf Re install the rear busbar shield previously removed from the existing module mounting shelf Re install the rear busbar shield previously removed from the expansion module mounting shelf Refer to the Power System Installation Instructions IM582127000 and connect AC input power to the expansion module mounting shelf 10 Refer to the Power System Installation Instructions 1M582127000 and install Page 18 rectifier and converter modules into the expansion module mounting shelf as required Chapter 3 Maintenance This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it wi
47. e setting as the old circuit card Switch settings are documented in CHAPTER 3 SETTING JUMPERS AND SWITCH OPTIONS of the Power System Installation Instructions 1M582127000 10 Secure the replacement circuit card to the bracket and re install the circuit card and bracket into the distribution cabinet 11 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 12 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 energized object After securing the wire gently tug on the wire Page 42 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 to ensure that it cannot be pulled out of the terminal block
48. ent 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 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 3 Connect an approved grounding strap to your wrist Attach the other end to a Suitable ground 4 Remove the 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 4 9 6 Carefully label the connectors plugged into the circuit card These connectors must be plugged into the same connectors on the rep
49. ently contact any energized electrical termination 2 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 3 Connect an approved grounding strap to your wrist Attach the other end to a suitable ground 4 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 4 11 or Figure 4 12 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 4 11 or Figure 4 12 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 6 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 the wire end with electrical tape Repeat for each wire to be removed 7 Unplug all connectors plugged into the circuit card 8 Remove the circuit card by removing the bracket the circuit card is mounted to Remove the circuit card from the bracket 9 Inthis step ensure you do not intermix the old and replacement circuit cards oet the switch on the replacement circuit card to the sam
50. er Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB System Interface Circuit Card The system interface circuit card contains test points to externally monitor bay voltage and bay load Refer to Figure 2 2 O Bay Load Shunt Scale List 21 1 Row Cabinet 800A 25mV 32A per mV List 22 2 Row Cabinet 2000A 25mV 80A per mV List 23 3 Row Cabinet 2500A 25mV 100A per mV List 24 4 Row Cabinet 2500A 25mV 100A per mV QEEM LL NEN p e i oie QUITTER LUI LLL ccc e TB1 Iii TP1 TP2 TP3 TP4 TP1 and TP2 TP3 and TP4 Bay Voltage Bay Load Monitoring Shunt Monitoring Figure 2 2 System Interface Circuit Card Page 6 Chapter 2 Operating Procedures This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Optional LVD Driver Circuit Card The optional LVD driver circuit card installed in the main bay contains an LVD inhibit switch and indicator Refer to Figure 2 3 LVD driver circuit cards are required for 2 3 or 4 row distribution cabinets that contain th
51. erty of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 This Page Left Intentionally Blank Chapter 4 Troubleshooting and Repair Page 61 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB REVISION RECORD Description of Change LP216539 AC LLP217311 a ila Current Limit Functionality added to Operating Procedures LLP218149 Adding 588705300 R48 2000e3 and C48 24 1500 Removing 588249700 Page 62 Revision Record This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without
52. essaeeeeessaageeesssaaeeeees 4 Local Oonirolssand IndiodlOESisei contenu i solani fea as astctun ccm tania is bea LIE S II ELI E dep LU LE 4 e resaer iio Bereit MEM cM PEN MDC PO RERUM 4 System Inter ace Circuit Cane ace i ood ve COM e eo oen i c oae tte dodi ved des o Oe e ve eee a foo pot 6 Optional EVD Driver Circuit 2 oT 7 Optional EVD Driver Lte Circuit Card arseen lata de sie ede e S E 8 Optional Manual Battery Disconnect Circuit Card Main Bay Only ccccecccccceeeceeceeeeeeseeeeeesseeeeeesaeeeeeeas 9 SM DU Circuit Card mE O 10 CHAPTER 3 MAINTENANCE oec Deo ep Dens ucc Epp Cu eo a hoe let cee 11 system Maintenance PrOCCOUICS a ce oo eed ter oo theo Re eod Sed evant we ew aad ed ee 11 Adding a Rectifier Module to an Existing Rectifier Module Mounting Shelf Spec No 588705000 11 Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec No 588705300 11 Installing a Field Expansion Rectifier Module Mounting Shelf Spec No 588705000 ssusss 14 Installing a Field Expansion Rectifier Converter Module Mounting Shelf Spec No 588705300 18 Changing the ACU LVD Control Level for a Contactor ssseeeesesseseeseeeneeeennn nennen 21 Adding a supplemental Bayn the Fielda isisi bag ob es E M a ade tan Pantin en on tut E nep Daran mend On ee xus 21 CHAPTER 4
53. etwork Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Distribution Cabinet Wire Harness Exploded View Shown to Illustrate Wire Connections Only Slate and Slate White Wires Existing Module Mounting Shelf Brown and Brown White Wires These connectors are factory connected K Factory provided jumper V to bring connectors to same side of shelf Existing Module Mounting Shelf These connectors are factory connected Rear View Factory provided jumper V to bring connectors to same side of shelf Existing Module Mounting Shelf These connectors are factory connected Rear View Factory provided jumper V to bring connectors to l same side of shelf J Disconnect cable coming from distribution cabinet from this connector on TES Expansion Module bottom most existing r Mounting Shelf shelf then connect to the same connector on the expansion shelf Rear View S a 3 e 7p Now connect these es f Factory provided jumper two connectors together V to bring connectors to g E same side of shelf oa _ 7 ed A hes A Figure 3 5 ACU CAN Bus Rectifier Module Mounting Shelf Spec No 588705300 Page 20 Chapter 3 Maintenance This document is property of Emerson Network Power Energy Sys
54. f 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 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 3 Connect an approved grounding strap to your wrist Attach the other end to a suitable ground 4 Remove the top and front panels to access the circuit cards at the bottom of the distribution cabinet 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 4 16 6 Unplug all connectors plugged into the circuit card 7 Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet 8 Place the replacement circuit card into the mounting position inside the distribution cabinet and secure with the screws removed from the old circuit card 9 Plug all connectors removed from the old circuit card into the same position on the replacement circuit card 10 Remove the grounding wrist st
55. ge battery disconnect LVBD and manual battery disconnect e ACU Advanced Control Unit Plus Controller The system contains one controller The 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 an LCD display and keypad for local access The controller provides Ethernet connection and supports software upgrade via its USB port It also comes with a comprehensive web page and SNMP capability for remote system management Refer to the ACU Controller Instructions UM1M820BNA for more information e Rectifier Module Mounting Shelf Spec No 588705000 The system may contain one or more Spec No 588705000 rectifier module mounting shelves each of which houses up to six 6 rectifier modules Refer to Power Data Sheet PD588705000 for more information e Rectifier Modules for use in Spec No 588705000 The system contains rectifier modules
56. gs 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 d Wear eye protection and use recommended tools e Use double insulated tools appropriately rated for the work to be performed Performing maintenance and or troubleshooting procedures may interrupt power to the loads if battery reserve is not sufficient AC Input Voltages Danger This system operates from AC 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 DO NOT apply AC power to the system until all electrical connections have been completed and checked DC Input Output Voltages Danger BATTERY Danger Danger This system produces DC Power and may require battery to be connected to it Although the DC voltage is not hazardously high the rectifiers and or battery can deliver large amounts of current Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact a battery terminal or exposed wire connected to a battery terminal NEVER allow a metal object such as a tool to contact more than one termination or battery terminal at a time or to simultaneously contact a termination or battery terminal and a grounded object Even a momentary short circuit can c
57. hat a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down 6 Verify no Fuse Alarms are active 7 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Shorter Side to the Top Insert these terminals into corresponding sockets on distribution panel Fuseholder Assembly Fuseholder Body TPS TLS Fuse GMT X cce Fuse Carrier Safety Fuse Cover Replacement P N 248898700 Longer Side to the Bottom Fuseholder Assembly 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 Figure 4 2 Replacing a TPS TLS Fuseholder and or Fuse Chapter 4 Troubleshooting and Repair Page 27 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Replacing a Bullet Nose Fuseholder Procedure Note Refer to Figure 4 2 as this procedure is performed 1 Open the distributio
58. ictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB 2 If a password screen opens a password must be entered to allow the User to make adjustments If a password was previously entered and has not yet timed out skip this step and proceed to step 3 Otherwise to enter a password with the cursor at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then press ENT twice Note f you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Manual menu screen displayed navigate to and select Converter ENT All Conv Ctrl ENT 4 Navigate to Clear Comm Fail Press ENT Yes highlights 5 Press ENT to select the operation Press ENT again to confirm 6 Return to the Main screen by repeatedly pressing ESC escape Clearing a Rectifier Lost Alarm If the ACU Controller resets while a rectifier communications fail alarm is active the rectifier communications fail alarm is replace with a rectifier lost alarm To clear the alarm perform the following procedure Procedure 1 With the Main screen displayed press ENT to go to the Main Menu Navigate to and select Manual ENT 2 If a password screen opens a password must be entered to allow
59. if E the system is furnished with a Low Voltage Battery Disconnect contactor J1 To LVLD contactor uses ACU LVD1 control setting Level 1 RE J3 Ca x To LVLD contactor uses ACU dns LVD2 control setting Level 2 is rz V LD Bi J2 To LVBD contactor uses ACU 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 600A or less 2 Only one 1 contactor per level can be accommodated J2 and J3 are on Level 2 only one 1 of these connectors can be used at a time 3 Switch and indicator located on circuit card installed in Main Bay only w w w w w w w E ux cm a av av av T T T Figure 4 15 Optional LVD Driver Lite Circuit Card Connector Locations Page 50 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Optional Manual Battery Disconnect Circuit Card Replacement Procedure 1 Performing this procedure may activate external alarms Do one of the following I
60. ing NEAGU Genio T 25 Meplacing a Distibuton D CVIC Cis T 26 Circuit Card Replacement Procedures io deni uuiere als ete ie trea EO aer et rece ks eeu ere ie eeu eee 37 Replacing a DISITIDU OD PANG sedeo dra VV ase EE de d e Dv paa av nu e T a etd D Dv a va dra E n Ee Ex Cc NUR 53 Replacing a Battery or Load Disconnect Contactor cccccccseeeeceeeceeeeeeeeeeseeeeeeeesseeeeeessueaseeeesseaseeeessaaees 56 Page il Table of Contents This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 IMPORTANT SAFETY INSTRUCTIONS GENERAL SAFETY Danger Caution VOLTAGES 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 The tasks should be performed in the order indicated b Remove watches rin
61. ing Shelf Spec No 588705000 Chapter 3 Maintenance Page 15 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Rear View Install Output Busbars from Kit Completed View 1st Expansion Shelf 2nd Expansion Shelf Figure 3 2 cont d from previous page Installing a Field Expansion Rectifier Module Mounting Shelf Spec No 588705000 Page 16 Chapter 3 Maintenance This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Distribution Cabinet Wire Harness Slate and Slate White Wires Brown and Brown White Wires These cables are factory connected o SSD ES eS Lp GEN Existing I0 40M M E LDO Z
62. ions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Replacing a Bullet Nose Circuit Breaker Procedure Note Refer to Figure 4 3 as this procedure is performed 1 Open the distribution cabinet s front door by turning the latch in the counterclockwise position 2 Operate the defective circuit breaker to the OFF position 3 Gently rock the defective circuit breaker up and down while pulling firmly outward until the breaker is free from the distribution panel 4 Ensure that the circuit breaker is in the OFF position and is of the correct rating 5 Orient the circuit breaker as shown in Figure 4 3 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 makes contact with the alarm terminal on the spring strip 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 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 Figure 4 3 Replacing a Bullet Nose Circuit Breaker Chapter 4 Troubleshooting an
63. ir individual components on any rectifier module converter module controller or circuit card Refer to SAG582127000 System Application Guide for replacement part numbers Replacement Cables 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 Module in a Spec No 588705000 Shelf Refer to the Rectifier Instructions UM1R483500E for a rectifier module replacement procedure Refer also to System Troubleshooting Information in this chapter The rectifier module being replaced is assigned by the ACU the lowest available identification number If desired you can change the identification number see Configuring the ACU Identification of Rectifiers in Chapter 5 of the separate Power System Installation Instructions 1M582127000 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 in this chapter The rectifier or converter module being replaced is assigned by the ACU the lowest available identification number If desired you can change the identification number see Configuring the ACU Identification of Rectifiers or Configuring th
64. ission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 STATIC WARNING ATTENTION The printed circuit cards used in this equipment contain 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 static sensitive Component or printed circuit card containing such a component 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 Do not touch the traces or components on a printed circuit card containing static sensitive components Handle the printed circuit card only by the edges that do not have connector pads 4 After removing a printed circuit card containing a static sensitive component place the printed circuit card 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 Sto
65. lacement circuit card Refer to Figure 4 9 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 7 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 8 Unplug all connectors plugged into the circuit card Chapter 4 Troubleshooting and Repair Page 37 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB 9 Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet 10 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 the old circuit card Jumper settings are documented in CHAPTER 3 SETTING JUMPERS AND SWITCH OPTIONS of the Power System Installation Instructions IM582127000 11 Slide the replacement circuit c
66. m the old panel to the replacement panel 11 Replace the plastic shield covering the circuit breakers or fuseholders on the replacement panel 12 Verify no Circuit Breaker Fuse Alarms are active 13 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Page 54 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 Battery Busbar Hardware Ground Busbar Hardware Battery Distribution Distribution Panel Ss Panel Distribution Panel Hardware Fi E oad Hardware rif are n s Distribution Ground Busbar iW 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 O HIRIE RRIS zn ZH s MEL HEH efell c a hO OOOHO 24 jumpers Assembly order is lug 1 4 flat washer 1 4 lock washer 1 4 20 bolt Torque to 84 in lbs Figure 4 17 Replacing a Distribution Panel Chapter 4 Troubleshoo
67. ms North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB SM DU Circuit Card Replacement Supplemental Bays Only 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 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 3 Connect an approved grounding strap to your wrist Attach the other end to a Suitable ground 4 Remove the top and front panels to access the circuit cards at the bottom of the distribution cabinet See Figure 4 10 5 Remove connectors J1 J2 and J3 from the circuit card 6 Remove the screws securing
68. n low voltage disconnect Momentary UP Position Closes all LVD Contactors inhibit mode circuit has been disabled Middle Position OFF ACU DOES NOT control LVD s inhibit mode through the use of the DOWN Position ON ACU controls LVD s LVD Inhibit switch Figure 2 4 Optional LVD Driver Lite Circuit Card Page 8 Chapter 2 Operating Procedures This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 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 2 5 p Ree 540973 dee 6 Manual Battery i 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 Bat
69. n cabinet s front door by turning the latch in the counterclockwise position 2 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 3 Gently rock the defective fuseholder up and down while pulling firmly outward until the fuseholder is free from the distribution panel 4 Orient the fuseholder as shown in Figure 4 2 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 5 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 6 Verify no Fuse Alarms are active 7 Close the distribution cabinet s front door Turn the latch clockwise to secure the door Page 28 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instruct
70. ng the panel s Battery Busbar to the distribution cabinet s busbar 10 For dual voltage load distribution panels refer to Figure 4 17 and remove the hardware securing the 24V jumper leads 11 Refer to Figure 4 17 and remove the hardware securing the distribution panel to the distribution cabinet Remove the panel from the distribution cabinet Chapter 4 Troubleshooting and Repair Page 53 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Installing the Distribution Panel Note In 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 1 Orient the 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 10 flat washer 4 places 2 For dual voltage load distribution panels replace the hardware securing the 24V jumper leads 1 4 20 bolt 1 4 lock washer 1 4 flat washer T
71. odules Place the module into an unoccupied mounting position without sliding it in completely Rectifiers modules can be installed in any mounting position of each module mounting shelf Converters modules can be installed in any of the three far right mounting positions of each module mounting shelf as viewed from the front See Figure 3 1 Loosen the captive screw on the module s handle Pull the handle down out from the module s front panel this will also retract the latch mechanism See Figure 3 1 Push the module completely into the shelf Push the handle up into the module s front panel This will lock the module securely to the shelf Tighten the captive screw on the handle Repeat the above steps for each module being installed in the system After the modules are physically installed in the mounting shelf s they are ready for operation immediately after power is supplied to them Note It is recommended that the current limit point be checked whenever a rectifier is added to or removed from the power system Refer to Checking the ACU Current Limit Point after Adding or Removing a Rectifier in CHAPTER 4 TROUBLESHOOTING AND REPAIR Note The rectifier or converter being added is assigned by the ACU the lowest Page 12 available identification number If desired you can change the identification number see Configuring the ACU Identification of Rectifiers or Configuring the ACU Identification of C
72. on 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 UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Optional LVD Driver Lite Circuit Card The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit switch and indicator Refer to Figure 2 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 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 5427573 O 5AfRf4 aes in ie Switch and indicator located on circuit card installed in Main Bay only Note The UP position will not close the LVBD contactor LVD Inhibit if the battery is manually disconnected using the Active Indi Manual Battery Disconnect Switch eae LVD Inhibit Switch Illuminates when the Momentary UP Middle Dow
73. onverters in Chapter 5 of the separate Power System Installation Manual IM582127000 Chapter 3 Maintenance This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 CSD G5 CL C1 AS a C SD a a SS S38 SS SD CL GD Ge G w wm Sseosesep spe thae Deer Module Mounting Shelf s Front View Rectifier Rectifier or Converter Mounting Positions Mounting Positions Rectifier Converter Handle Se di INNS NN A SN SS S Aie VO Figure 3 1 Installing Rectifier and Converter Modules in a Spec No 588705300 Shelf Chapter 3 Maintenance Page 13 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB INSTAL
74. or more information Chapter 1 System Overview Page 3 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB CHAPTER 2 OPERATING PROCEDURES CONTROLLER RECTIFIERS AND OPTIONAL CONVERTERS For operation instructions on these units refer to the following documents e ACU Controller Instructions UM1M820BNA e Rectifier Instructions UM1R483500E or UM1R482000E3 e Converter Instructions UM1C48241500 ESTOP FUNCTION If an ESTOP switch is wired to the ACU IB2 Interface Board customer furnished system ground applied to terminal DI8 activates the ESTOP function The ESTOP function shuts down and locks out the rectifiers opens the LVD s and shuts down the converters When the ESTOP signal is removed LVD s close if battery present and converters restart To restart the rectifiers turn AC power to the rectifiers OFF wait 30 seconds or more until the LEDs on the rectifier extinguish then turn AC power to the rectifiers ON Rectifiers can also be restarted from the ACU LCD or WEB Interface menu via the Rectifier Reset command found
75. orque to 84 in Ibs 3 For battery distribution panels replace the hardware securing the panel s Battery Busbar to the distribution cabinet s busbar 3 8 16 x 1 1 4 bolt 3 8 Belleville lock washer 3 8 hardened flat washer 2 places Torque to 180 in Ibs 4 Forload 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 5 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 lbs 6 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 7 On panels equipped with shunts reconnect the shunt leads Warning In the next step observe correct polarity otherwise equipment damage will result 8 On panels equipped with a ground busbar reconnect the load return or battery return wiring to the ground busbar 9 Reconnect the load or battery wiring to the circuit breaker or fuse positions 10 Transfer the plug in circuit breakers or fuses fro
76. oubleshooting and Repair Page 33 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 Spec No 582127000 Model 721NPBB INSTALLING CIRCUIT BREAKER Alarm jumper connectors 2 pole breaker shown Holes to route shunt jumper through if applicable 3 pole and 4 pole breakers similar 1 4 Hardened Flat Washer Apply anti oxidizing compound to busbar mating 1 4 Belleville surfaces before mounting circuit breakers Lock Washer 1 4 20 x 3 4 Bolt 4 places 2 pole brk 6 places 3 pole brk 8 places 4 pole brk INSTALLING CIRCUIT BREAKER GUARD 10 32 X 7 16 PH Torque to 60 in lbs 10 LW CIRCUIT BREAKER GUARD LABEL 5 Jf orcun BREAKER GUARD aN raum LONGER SIDE OF GUARD OFF ON I CE i DI _______ 7 B EF EF a a a E E E E S E E E E E E E E E E E E T TYPICAL DIST ASSY SHOWN FOR EXAMPLE ALARM WIRING BREAKERS W OUT SHUNTS ALARM WIRING BREAKERS WITH SHUNTS TANDARD TRIP BREAKER BLACK HANDLE ELECTRICAL TRIP BREAKER STANDARD TRIP WHITE HANDLE BREAKER BLACK HANDLE SHUNTED BRKR JUMPER BLACK eo S1 SHUN
77. r at the User Name field default is Admin press the down arrow key to move cursor down to the password line Press ENT 0 is highlighted Press the up arrow key once to change the 0 to 1 default password is 1 then Page 24 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 press ENT twice Note f you have been assigned a unique User Name and password follow this procedure to enter these 3 With the Manual menu screen displayed navigate to and select Converter ENT All Conv Ctrl ENT 4 Navigate to Clear Conv Lost Press ENT Clear highlights 5 Press ENT to select the operation Press ENT again to confirm 6 Return to the Main screen by repeatedly pressing ESC escape 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 repa
78. rap 11 Reinstall the top and front panels that cover the circuit cards at the bottom of the distribution cabinet 12 Close the distribution cabinet s front door Turn the latch clockwise to secure the door 13 Enable the external alarms or notify appropriate personnel that this procedure is finished 14 Ensure that there are no local or remote alarms active on the system Chapter 4 Troubleshooting and Repair Page 51 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB PL RI P COG A ARIP Figure 4 16 Optional Manual Battery Disconnect Circuit Card Connector Locations Page 52 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 5821270
79. rcuit card may result if the next step is not followed 3 Connect an 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 circuit card Refer to Figure 4 13 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 4 13 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 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 7 Unplug all connectors plugged into the circuit card 8 Remove the screw securing the SM DU and Shunt Interface Assembly to the bottom of the distribution cabinet and remove the assembly 9 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 CHAPTER 3 SETTING JUMPERS AND SWITCH OPTIONS of the Power System Installation Instructions 1M582127000 10 Slide the replacement SM D
80. re and ship static sensitive devices or printed circuit cards containing such components only in static shielding containers 6 If necessary to repair a printed circuit card containing a static sensitive component wear an appropriately grounded wrist strap work on a conductive surface use a grounded soldering iron and use grounded test equipment Static Warning Page v This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB This Page Left Intentionally Blank Page vi Static Warning This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 Issue AC January 2 2013 User Instructions spec No 582127000 Model 721NPBB CHAPTER 1 SYSTEM OVERVIEW CUSTOMER DOCUMENTATION PACKAGE This document UM582127000 provides User Instruc
81. rear access panel s 4 Disconnect the wiring to the contactor by unplugging the quick disconnects 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 Installing the Replacement Contactor 1 Position the replacement contactor oriented the same way as the old 2 Secure the contactor with the hardware removed above Refer to Figure 4 18 Figure 4 19 Figure 4 20 or Figure 4 21 for hardware build up and recommended torque 3 Replace the wiring to the contactor by plugging in the quick disconnects Refer to Figure 4 18 Figure 4 19 Figure 4 20 or Figure 4 21 4 For the 2 3 or 4 row distribution cabinet replace the distribution cabinet s rear access panel s Restarting the Power System 1 Reconnect the AC and DC power sources to the power system 2 Start the power system Refer to the separate nstallation Instructions IM582127000 for a startup procedure 3 Verify no alarms are active Page 56 Chapter 4 Troubleshooting and Repair This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM5821270
82. reates 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 1 280 option 6 and status Technical Support DCpower TAC Emerson com OSP TAC Emerson com Answers technical product and system questions determines status of warranties and contractual agreements for repair Email Phone 1 800 800 5260 l Contact Account Management for custom configurations 71 Contact DC Power Spare Parts for parts and accessories For More Information To learn more about service offerings from Emerson Network Power please contact your sales representative call 1 800 800 1280 option 7 email ES Services Emerson com or visit EmersonNetworkPower com EnergySystems 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
83. ree 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 o547702 O PaO Mag x EI m g30gg s oo Switch and indicator located on circuit card installed in LVD Inhibit Main Bay 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 ACU DOES NOT control LVD s inhibit mode through the use of the DOWN Position ON ACU controls LVD s LVD Inhibit switch Figure 2 3 Optional LVD Driver Circuit Card Chapter 2 Operating Procedures Page 7 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emers
84. rica Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 Issue AC January 2 2013 User Instructions spec No 582127000 Model 721NPBB Rectifiers modules can be installed in any mounting position of each module mounting shelf Converters modules can be installed in any of the three far right mounting positions of each module mounting shelf as viewed from the front See Figure 3 1 Note Each rectifier and converter module locks into the module mounting shelf by means of a latch located on the bottom of the module The latch and module handle are interactive Pushing the handle up into the module s front panel causes the latch to extend to the locking position pulling the handle down out from the module s front panel causes the latch to retract See Figure 3 1 Warning To prevent damage to the latching mechanism ensure the handle is in the open position when installing or removing a module NEVER hold the handle in the closed position when installing a module into a shelf Procedure Unpack the modules Note the model number located on the front of each module Model numbers starting with the letter R are rectifier modules Model numbers starting with the letter C are converter m
85. tems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 CHANGING THE ACU LVD CONTROL LEVEL FOR A CONTACTOR The ACU Controller has two available 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 4 14 and Figure 4 15 for connector location and function Note 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 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 ACU Controller to program the ACU Controller for use with the newly installed supplemental bay Refer to the ACU
86. tery Disconnect Contactor Momentarily place switch in the UP position to close the contactor Figure 2 5 Optional Manual Battery Disconnect Circuit Card Main Bay Only Chapter 2 Operating Procedures Page 9 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB SM DU Circuit Card The SM DU is used in supplemental bays in place of ACU 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 2 1 Refer to Figure 2 6 for location me n Red critical or major alarm Alarm Yellow Off On A minor alarm SM DU is non operational Operation A 1 3Hz flashing indicates the SM DU Green On EE is being identified by the Controller 9 A 1Hz flashing indicates a communication failure Table 2 1 SM DU Indicators Doe
87. thout the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited User Instructions UM582127000 Spec No 582127000 Model 721NPBB Issue AC January 2 2013 1 Remove busbar rear shield from existing rectifier converter shelves Remove the cut out panel from the busbar rear shield va DO a a ajaja s OOODOODD DDDDODODO coc a m pecreon POCO eI aj 3 Busbar Rear Shield Cut Out Panel ud ui 2 Remove hardware from the lowest module mounting shelf s 48V return and 24V if present busbars m 3 Install th ion modul L2 Install the expansion module esu Mus MALAE mounting shelf into the rack EZ ZZ cuz c BPP cx 4 Remove busbar rear shield from E P expansion module mounting shelf o AW HEE JU SS SR RLI JEY FNN QS SS SS TUR liil MLL 5 Install the busbars provided with the expansion module mounting shelf between the shelves Torque to 60 in lbs 6 Re install the rear busbar shields previously removed Figure 3 4 Installing a Field Expansion Module Mounting Shelf Spec No 588705300 Chapter 3 Maintenance Page 19 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson N
88. ting and Repair Page 55 This document is property of Emerson Network Power Energy Systems North America Inc and contains confidential and proprietary information owned by Emerson Network Power Energy Systems North America Inc Any copying use or disclosure of it without the written permission of Emerson Network Power Energy Systems North America Inc is strictly prohibited UM582127000 User Instructions Issue AC January 2 2013 spec No 582127000 Model 721NPBB Replacing a Battery or Load Disconnect Contactor 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 before proceeding Note In 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 Note Refer to Figure 4 18 Figure 4 19 Figure 4 20 or Figure 4 21 as this procedure is performed Removing the Contactor 1 Verify all AC and DC power sources are disconnected from the power system 2 For the 1 row distribution cabinet the contactor can be accessed from the top of the distribution cabinet For the 2 3 or 4 row distribution cabinet the contactor can be accessed from the rear and top of the distribution cabinet 3 For the 2 3 or 4 row distribution cabinet remove the distribution cabinet s
89. tions for NetSure Power System Model 721NPBB Spec No 582127000 The complete Customer Documentation Package consists of Bound System Installation Manual e Power System Installation Instructions IM582127000 e Power System Quick Start Guide QS582127000 Bound ACU Controller User Manual e ACU Controller User Instructions UM1M820BNA includes instructions for 1M820DNA Controller USB Drive with All Customer Documentation Power System Installation Instructions IM582127000 Power System Quick Start Guide QS582127000 Power System User Instructions UM582127000 Power System System Application Guide SAG582127000 Rectifier Module Mounting Shelf Power Data Sheet PD588705000 e Rectifier Instructions UM1R483500E Rectifier Converter Module Mounting Shelf Power Data Sheet PD588705300 e Rectifier Instructions UM1R482000E3 e Converter Instructions UM1C48241500 e Engineering Drawings e Also provided on the USB drive is an ACU configuration drawing and the ACU configuration files loaded into the ACU as shipped SYSTEM DESCRIPTION 48V DC up to 4000 Amperes Power System The NetSure 721NPBB DC Power System is a complete integrated power system containing rectifiers optional 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
90. to an existing rectifier module mounting shelf Spec No 588705000 that contains an empty rectifier module mounting position lt is recommended that the current limit point be checked whenever a rectifier module is added to or removed from the power system Refer to Checking the ACU Current Limit Point after Adding or Removing a Rectifier in CHAPTER 4 TROUBLESHOOTING AND REPAIR The rectifier module being added is assigned by the ACU the lowest available identification number If desired you can change the identification number see Configuring the ACU Identification of Rectifiers in Chapter 5 of the separate Power System Installation Instructions 1M582127000 e For rectifier module installation instructions refer to Rectifier Instructions UM1R483500E ADDING A RECTIFIER OR CONVERTER MODULE TO AN EXISTING MODULE MOUNTING SHELF SPEC NO 588705300 To increase system current capacity a rectifier module can easily be added to an existing module mounting shelf Spec No 588705300 that contains an empty rectifier module mounting position Likewise to increase subsystem capacity a DC DC converter module can be added to a module mounting shelf Spec No 588705300 that contains an empty converter module mounting position Rectifier and converter modules can be inserted or removed with power applied hot swappable Chapter 3 Maintenance Page 11 This document is property of Emerson Network Power Energy Systems North Ame

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