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Emerson NT5C06D manual

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Table of contents for the manual

  • Page 1

    Astec Advanced Power Systems Aste c Advanced Power Syst ems A part of E merson Net work Power UM5C06D ( 169-2071-504 ) Helios Rectifier 25/48 Singl e Phase -48V, 25 A Power Factor Correct ed Switch Mo de Rectifier NT5C06D Installation and User Manual P0831010 Standard 7.00 May 2001[...]

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    [...]

  • Page 3

    Astec Advanced Power Systems Helios Rec tifier 25/48  NT5C06D Installati on and User Manual Helios Rectifier 25/48 Singl e Phase -48V, 25A Power Factor Correct ed Switch Mo de Rectifier NT5C06D Installation and User Manual Manual Number : UM5C06D ( 169-2071-504 ) Manual St atus : Standard Manual Issu e : 7.00 Release Date : May 2001 P0831010 Cop[...]

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  • Page 5

    5 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual Publication hi story May 2001 Standard issue 7.00. Manual modified to reflect the Emerson identity. ( EC 102-26438 ) September 1999 Standard 6.0. Document modified to be in accordance with As tec standards. (ECN 102-17331) May 1999 Standard 5.0. Document modified to reflect Astec i[...]

  • Page 6

    6 Publicati on history UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 This page is left blank intentionally.[...]

  • Page 7

    7 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual Contents Introduction .............................................................................................................. 11 Descripti on .................................................................................................... 11 Applicat ions ...............[...]

  • Page 8

    8 Content s UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Forced Load Share ................................................................................................32 Load Share Ad justment Procedure ........................................................................32 Operation .............................................[...]

  • Page 9

    Conte nts 9 Helios R ectifie r 25/48 Installati on and User Manual RFA fau lt ..............................................................................................................47 SEN FAIL fau lt ......................................................................................................48 Erratic load faul t ..................[...]

  • Page 10

    10 Contents UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 This page is left blank intentionally.[...]

  • Page 11

    11 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 1. Introduction Descripti on The NT5C06D Switch Mode Rectifi er is rated for 25 A at -48 V DC. This rectifier incorpor ates AC input power factor corr ection circuitry, is highly efficient and lightweight (15 lbs .). It is fully connectorized and plugs into a power shelf into whic[...]

  • Page 12

    12 Introducti on UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Applications The rectifier is designed to function as the prime s ource of power for equipment requiring -48 V DC. It will also operate as a battery charger or as a battery replacement (batteryless operation). Its low output noise a nd good voltage regulation, combined with [...]

  • Page 13

    Introduc tion 13 Helios R ectifie r 25/48 Installati on and User Manual Helios Rectifier 25/ 48     NT5C06D(X) –48 V / 25 A Switch Mod e Rectifier The NT5C06D provides -48 V / 25 A of isolated, fi ltered, and regulated DC power from a s ingle phase AC source, for powering a load while char ging a positive grounded battery. The output [...]

  • Page 14

    14 Introducti on UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 2 - MPS75 Modular Power shelf- NT5C10C wit h 26-pin signal connectors Moun tin g hole s ( 4) Sign al ca ble c onne cti on DC conn ecti on Mo unti ng ho l es ( 4) Figure 3 - NT5C06D Switch Mode Rectifi er Height: 168 mm (6.60 inches) Depth: 260 mm (10.25 inches) Width:[...]

  • Page 15

    15 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 2. Specifications Electrical specifications The NT5C06D rectif ier operates within the electric al specifications listed in Table 1. (Refer to the Product Specif ication which can be obtained from the Engineering depart ment of Astec Advanced Power Systems). Table 1 - Electrical s[...]

  • Page 16

    16 Specificati ons UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Table 1 - Electrical specifications ( continued ) Output P rotection: A single pol e 35 A circuit breaker is conne cted in series with the negati ve output lead of the re ctifier. The recti fier contai ns an adju stable output current l imit circui t for protecti on agains[...]

  • Page 17

    Specificat ions 17 Helios R ectifie r 25/48 Installati on and User Manual Environmental sp ecifications Operati ng CAUTION An airflow clearance mus t be left at the rear of the shelf. A minimum of three inches is r ecommended. The rectifier will operate s atisfactorily under the following environmental conditions: Temperature Range: 0° to +65° C [...]

  • Page 18

    18 Specificati ons UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 The rectifier contains aluminum electrolytic capacitor s having a shelf life of 5 years or greater when stored at the maximum rated s torage temperature.[...]

  • Page 19

    19 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 3. Installation and start up The power shelf must be installed on the framework and all A C, DC and control and alarm wiring must be connected before the r ectifiers are physically plugged in. Tools and t est equipm ent The following tools and tes t equipment are required: • Scr[...]

  • Page 20

    20 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 1 - Ins talling th e power shel f Step Action 1 Positi on the power shel f, without any recti fiers plugg ed in, agai nst the framework. 2 Secure the shel f in the posi tion indi cated by the j ob drawing (normall y directly below the c ontroller o r a[...]

  • Page 21

    Instal lation and start- up 21 Helios R ectifie r 25/48 Installati on and User Manual Installing the AC power Permanent AC connectio n to the MPS75 power shelf is done using two armored cable conductor s, RW-90 or equivalent, as listed in Table 2. One must be routed to L1, and the other one to L2 and to the safety shelf frame ground (FR GND). The c[...]

  • Page 22

    22 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 5 - Power s helf indivi dual AC connection FR GRD POS 3 POS 2 POS 1 L1 L2 L1 L2 L1 L2 6 5 4 3 2 1 When cabling the AC to the power shelf, make sure that each cor responding safety ground wire is pr operly connected to the terminal designated F R GND. This[...]

  • Page 23

    Instal lation and start- up 23 Helios R ectifie r 25/48 Installati on and User Manual Table 4 - DC cabl e wire size 1 RECT. POSITIO N 2 RECT. POSITIO NS 3 RECT. POSITIO NS 8 AWG 6 AWG 4 AWG Figure 6 - Connec ting the D C power shelf Control an d Alar m Connections The rectifier is interfaced to the power plant controller thr ough the signal connect[...]

  • Page 24

    24 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Table 5 - Rectifier a nd Controller int erface conn ections (8-p in connect ors) Pin # Design. Description Signal 1 EQL Remote E qualize BAT RTN 2 RG+ Sensing Posit ive BAT RTN 3 RC- Sensing Negative -48V 4 FAN ALM Fan Fail ure BAT RTN 5 HVSDR Remote High V olta[...]

  • Page 25

    Instal lation and start- up 25 Helios R ectifie r 25/48 Installati on and User Manual Table 6 - Rectifier an d Controller interf ace connec tions (26-pin connec tor) ( conti nued ) Pin # Designation Description Signal 23 DC BRK ALM DC Circuit Brea ker NC 24 AC FAIL ALM AC Line Fail Al arm NC 25 SENSE FAIL ALM Sen se Fa il NC 26 FAN ALM Fan Alarm NC[...]

  • Page 26

    26 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 7 - No cont roller, remote sensing connec tion for 8-pin s ignal cable s helves Note 1: Refer to MS5C06 for available 8-pin ribbon signal cables of different lengths to connect from the s helf back plane rectifier position to the remote sensing point. Not[...]

  • Page 27

    Instal lation and start- up 27 Helios R ectifie r 25/48 Installati on and User Manual Figur e 8 - No contro ller, remot e sensing conne ction for a 26-pin signal connect or shelf - + BA TTE R Y or desi r ed r eg ul ati on point RC- RG + RC FUSE 1.6 AM P SEE NO TE 4 2 0 AW G (SEE NO TE 3) 1 6 11 20 16 2 6 pin s r i bbon c onne ctor m a te Forc e s h[...]

  • Page 28

    28 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Verification After completing the wiri ng of the power shelf perfor m the following: Procedure 2 - Ve rification Step Action 1 Verify t hat the power shelf has been mech anically secur ed. 2 Verif y that all the wiring perf ormed is correct by using a voltmet er[...]

  • Page 29

    Instal lation and start- up 29 Helios R ectifie r 25/48 Installati on and User Manual Rectifier met er accurac y The rectifier's current meter is precise within + 2%. Start- up and ver ificatio n Repeat the following st eps for each r ectifier in turn. Procedure 4 - Sta rting up t he rectifier Step Action 1 Close the AC circ uit breaker i n th[...]

  • Page 30

    30 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 4 - Sta rting up t he rectifier ( con tinued ) Step Action 10 In order t o accuratel y adjust the rect ifiers f loat and/or equaliz e (if different from fact ory setti ng) the current share mode sett ing must be take n into account. Two modes of sh are[...]

  • Page 31

    Instal lation and start- up 31 Helios R ectifie r 25/48 Installati on and User Manual Procedure 4 - Sta rting up t he rectifier ( con tinued ) Step Action 11 (ii) Forced Share In the force d share mode, t he rectif ier's output voltage sett ing is not modifi ed with changes i n output load as is the cas e in the Slope Sh are mod e. The p reset[...]

  • Page 32

    32 Install ation and start-up UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Slope Loa d Share When the rectifier is conn ected in parallel with re ctifiers in the same power shelf, or other power shelves, and this method of load sharing is desired, the SLS / FS switch of each rectif ier must be pushed towards the SL S. Forced L oad Shar[...]

  • Page 33

    33 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 4. Operation In addition to rectifying the AC, the input circuit provides EMI filter ing, inrush current limiting, low and high A C inhibit, power factor compensation, surge voltage protection, a nd is equipped with a 13 A AC breaker for input protection. The output section provid[...]

  • Page 34

    34 Opera tion UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Front panel controls Figure 9 - NT5C06D - fr ont view Features In addition to the features and performance characteristics described earlier, the rectifier provides the following features. Local float / equaliz e control The rectifier is equipped with a float / equalize swi tch[...]

  • Page 35

    Operati on 35 Helios R ectifie r 25/48 Installati on and User Manual St art-u p de lay This unit does not have a start-up delay. Test points (V+ , V-) Test points allow the us er to measure the voltage at the point of regulation. A 100 ohm PTC resistor is placed in series with both leads to prevent damage caused by s hort circuits at the jack termi[...]

  • Page 36

    36 Opera tion UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Loca l ON/OFF cont rol (AC b reake r) The AC input circuit brea ker can be used to locally turn the r ectifier ON/OFF. The local ON/OFF control overrides remote control signals. Remot e O N/OFF co ntro l When a battery return (BAT RTN) signal is applied to the 'Tempora ry [...]

  • Page 37

    Operati on 37 Helios R ectifie r 25/48 Installati on and User Manual Sequential start The rectifier TR lead is av ailable for use with an external sequential s tart circuit. Parallel op eration The rectifier is capable of operating in parallel with other rectifiers having similar output characteristics and shares the total loa d proportionally to i[...]

  • Page 38

    38 Opera tion UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Input AC voltage mo nitor The rectifier monitors the input voltage, inhibits its operation and sends an RFA when the AC voltag e decreases below 176 or ris es above 264 V AC. An AC FAIL alarm contact is transmitted through the signal connector. The rectifier r ecovers its norma[...]

  • Page 39

    Operati on 39 Helios R ectifie r 25/48 Installati on and User Manual Figure 10 - Power in terface connections Signal in terface conn ector Figure 11 shows the pin assi gnment of the sig nal int erfac e connector. This connector is used to interface a ll the control, alarm and monitor ing signals with the power shelf that, in turn, interfaces these [...]

  • Page 40

    40 Opera tion UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 11 - Control si gnal connections 1 1 - REMO TE EQL 2 - SE NSING RG + 3 - SE NSING RC - 4 - TEM PORAR Y RELE ASE 5 - REMO TE HVSD RESET 6 - REMO TE HVSD 7 - RF A NC 8 - Not Connect ed 9 - FAN ALARM NC 10 - RFA COMMON 11 - FAN ALARM C OMMON 12 - SHUNT + 13 - SHUNT - 14 - F[...]

  • Page 41

    41 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 5. Maintenance The NT5C06D rectifier is virtually mainten ance free. It requires periodic float / equalize verif ication (once every six months) and air filter replacement as required. Note: If the unit operates in a dust y environment the optional air filter is r ecommended. It m[...]

  • Page 42

    42 Ma inten ance UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 6 - Adjusting the float / equalize ( c ontinued ) Step Action 6 The float voltage shoul d be adjust ed with the rect ifier in servi ce, as foll ows: The recti fier is connected t o the system and sho uld carry some loa d. If the rec tifier is c onn ecte d in pa ral[...]

  • Page 43

    Mainte nance 43 Helios R ectifie r 25/48 Installati on and User Manual Fan repl acement CAUTION Before replac ing the fan, turn the rec tifier OFF. Completely disconnect an d remove it from the shelf. Wait thirty minutes to allow all internal capacitors to fully discharge and for all com ponents to cool down. CAUTION Keep any dirt, dust, moisture o[...]

  • Page 44

    44 Ma inten ance UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 12 - NT5C06D rear v iew CAUTION Ensure that the fans spin freel y, without interference.[...]

  • Page 45

    Mainte nance 45 Helios R ectifie r 25/48 Installati on and User Manual CAUTION Do not run the rectifier without a fully operational fan or with a fan other than the specified repla cement for this cooling application. Power shelf The power shelf requires no maintenance.[...]

  • Page 46

    46 Ma inten ance UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 This page is left blank intentionally.[...]

  • Page 47

    47 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 6. Troubleshoot ing Alarm indic ation RFA fault Table 9 - Syste m fault diagnos is Fault sympto m Possible causes No AC input or input out of bounds. No AC input or input out of bounds. AC Input /DC output ci rcuit br eaker is ope n. Rectif ier has received a HVS D signal f rom th[...]

  • Page 48

    48 Troubleshooti ng UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 SEN FAIL fault Fault sympto m Possible cau ses One or both remote sense l eads is discon nected. DC breaker i s open. Rectifie r is s till in walk -in. SEN FAIL Sense leads ar e reversed. Erratic loa d fault Fault sympto m Possible cau ses Erratic load Requirement ex ceed[...]

  • Page 49

    49 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 7. Appendi x A: Replacement parts ITEM CPC Fan Assembly P0710139 Air Filter Kit P0834732[...]

  • Page 50

    50 Appendix A: Replacem ent parts UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 This page is left blank intentionally.[...]

  • Page 51

    51 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 8. Appendix B: Technical service assistance For technical ass istance, 24-hour s a day / 7 days a week, dial on e of the following toll-free numbe rs. This service complements the services offered by field support organizations such as, the Emergency Technical Assistance Service ([...]

  • Page 52

    52 Appendix B: Techni cal service assi stance UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Toll-free technical assist ance num bers United States: 1-800-992-8417 Canada: 1-800-363-2288 In Europe: In Asia and the P acific: Austria 800-213-49156 Australia 800-213-49156 Belgium 800-213-49156 Hong Kong 800-213-49156 Denmark 800-213-49156 J[...]

  • Page 53

    53 Helios Rec tifier 25/48  NT5C06D Installati on and User Manual 9. List of terms and acronyms ALM Alarm BAT B atter y BAT RT N B atte ry Retu rn C Common CL Current Limit CS Current Share EMI Elect romagnetic Interferenc e EQL Equaliz e FAN ALM Fan Alarm FLT Float FR GND Frame Ground FS Forc ed Load Sha re HVSD High Volt age Shutdo wn HVSDR Hi[...]

  • Page 54

    54 List of terms and ac ronyms UM5C06 D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 NO Nor mally Open NT Northern Telecom PCB Printe d Circuit Boar d RFA Rec tifier F ail Ala rm RG+ Sensing Bat tery Positi ve RC - Sensing B attery Negat ive SEN FAIL Sen se Fail SH + Shunt Positi ve SH - Shunt Negati ve SLS Slope Load Sh aring TBD To be Determi[...]

  • Page 55

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  • Page 56

    Helios Rectifer 25/48 Single Phase − 48 V, 25 A Power Factor Corrected Switch Mode Rectifier NT5C06D Install ation and User Manual Astec Advanc ed Power Systems L td 2280 Al fred-No bel B lvd St-Laure nt ( Quebec ) Canada H4S 2A 4 Copyright  20 01 As tec Adva nced Power Sys tems L td All Rights Res erved The informati on contained in this manu[...]