Emerson 200I/48-NT5C05C manual

Emerson Energy Sy stems Helios Modular Sw itch Mode Rectifier 200I/48  NT5C05C Installation and User Manual V OL T A M P V O L T C A L C U R C A L T H S D H V S D R F A FA N A L M V O L T + V O U T - S E N F A IL E Q L A C ON C L FF 1 1 . 0 A F F 2 1 .0A C L A D J E Q L A D J E Q L F LT A DJ H VS D A D J I I S T U P D L Y S L S F S D C / C C A C[...]

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3 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Helios Modular Sw itch Mode Rectifier 200I/48     NT5C05C Installation and User Manual Manual Number : UM5C05C ( 169-2081-501 ) Manual Status : Standard Manual Issue : 6.00 Release Date : October 2001 P0745680 Copyright  2001 As tec Int ernat ional[...]

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5 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Publication history October 2001 Standard Is sue 6.00. Manual restruct ured and updated to reflect Emers on Energy Systems and Emerson Network Power identities . ( ECN 102-26804 ) March 1998 Issue 5.0. Standard. Reference change from NT 5C05CB to NT5C05C. July 19[...]

6 Publication histor y UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems This page is le ft blank intentionally .[...]

7 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Contents 1. General info rmation .................................................................................... 11 1.1. Purpose of this manual .............................................................................. 11 1.2. Models and m ounting config[...]

8 Contents UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 6. Main tenance ................................................................................................. 49 6.1. Replacing the air f ilter ................................................................................ 49 6.2. Replacing the fan unit ...........[...]

Contents 9 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Procedure 6 - Connecting the ac m ale plug between the NT5C05CC rectif ier and the ac fem ale plug in a 1200 A cabinet .................................. 27 Procedure 7 - Connec ting the NT5C05CC to the contr oller................................. 28 Pro[...]

10 Contents UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems This page is le ft blank intentionally .[...]

11 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 1. General information 1.1. Purpose of this manual This manual provides installation, operation and maintenance information for the NT5C05CA / CB / CC 200I modular switch mode rectifiers with an input voltage of 380 / 415 V ac and an output capacity of 200 A at [...]

12 General inf orm ation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 1.2. Models and mounting configurations Two models of 200I rectifiers are available : • Models NT5C05CA / CB, without an ac cable • Model NT5C05CC, equipped with an ac cable terminated with a male plug Up to six switch mode 200I rectifiers can be instal[...]

13 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 2. Specifications 2.1. Mechanical and electrical specificat ions Table 1 - Mech anical specification s of the rectif ier Height : 10.0 inches ( 25.4 c m ) Depth : 22.0 inches ( 55.9 c m ) Width : 20.5 inches ( 52.1 c m ) Weight : 92.6 lbs ( 42 k g ) Table 2 - El[...]

14 Specific ations UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 2.2. Operation specifications and ambient condit ions Table 3 - Operation specification s of the rectif ier Output regulati on : At the output term inals, the voltage is within ±0.5% of the set voltage value for all specif ied input and output variations, and wi[...]

Specific ations 15 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Table 4 - A mbient c onditions for the r ectifier Operatin g conditions A m inimum airf low clearance of 2 inc hes ( 5 cm ) is required at the rear of the rectif ier. The r ectifier will operate pr operly under the following conditions. Tem perat[...]

16 Specific ations UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 2.3. Mechanical and electrical specificat ions of a 1200 A cabinet Table 5 - Mechan ical specifications o f the NT 6C43CB 1200 A cabinet Height : 84.00 inches ( 213.36 c m ) Depth : 23.63 inches ( 60.0 c m ) Width : 23.63 inches ( 60.0 c m ) Table 6 - Electrical [...]

17 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 3. Installation 3.1. Mounting configurations The NT5C05CA / CB / CC re ctifiers are designed f or installation in a 1200 A cabinet ( NT6C43CB ) or in a standard frame ( NT6C40 or equivalent ). In this chapter, a different procedure is provided for each mounting [...]

18 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems CA UTION Preventi ng damage cause d by over-tighte ning Do not over-tighten nuts and bolts. Over-tightening can strip the threads or break the bolts. Apply the appropriate torque values. CA UTION Pers onal safety and protec ting the equipment Use a dolly truck, fork[...]

Installation 19 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual WA RNING Generato r requiremen ts for Emerso n Energy Systems Pow er Systems For informa tion on selecting a c gener ators that will effectively maintain peak performance and operati n g characteristics, for all Astec APS power systems, go to the pa[...]

20 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems DA NGER Short ci rcuit hazar d The rectif iers, and the batter ies in particular, c an deliver high current if a short to ground occurs. When working on live equipment, remove all personal jewellery , use properly insulated tools, and cover any live busbars with a i[...]

Installation 21 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual in the concrete floor, the secondary anchor locations may be used. An optional cabinet isolation kit is available consisting of four anchor bushings and a base pad. I f this kit is i nstalled, place the pad on the floor and the bushings on the ancho[...]

22 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Procedure 2 - In stalling a rectifier in a cabinet ( con tinued ) Step A ction 4 Place the rect ifier on the L-s haped guides located in the lowest position of the c abinet and slide it towards the rear until the mounting brack ets com e into contact with the fr ame[...]

Installation 23 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 3.5. Connecting the dc output terminals to the busbars The dc outputs of the r ectifier are connected to the busba rs as illustrated in Figure 5. There are two methods : • BAT GRD ( + ) of the rectifi er connected to the CHG/ DI SCH GRD busbar and[...]

24 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 3.5.1. Securing the dc output terminals to t he busbars in a 1200 A cabinet For cabinet applications, no dc cabling is required; the output terminals of the rectifier are connected di rectly to the busbars. Proce dure 3 - Sec uring the dc output ter minals to the bu[...]

Installation 25 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual DA NGER Hazardous pote ntials I nput voltage to the cabinet is at a hazardous potential. Make sure the powe r is OFF and that the lever in the ac service pa nel is locked in the OFF position before attempting to connect the input line voltage to the[...]

26 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Figure 6 - Cablin g ac the NT 5C05CA / CB rect ifiers PAR T OF O PT I ONAL KIT P0872151 HEX H EAD C AP SC R EW AND WASH ER S ( 4 PL ACES ) SIGN A L C A BL E S T O TH E PLAN T C O NTR OLLER R EMO VE PL A T E TO AC CE SS CO NNE CT O RS A C F EED T O RECTIF IE RS AA RE[...]

Installation 27 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Procedure 6 - Con necting th e ac male plug bet ween t he NT5C05CC rectif ier and the ac f emale plug in a 1200 A cabinet Step A ction 1 Install the ac break er ( 30 A / 3 phas es per rec tifier ) in the 380 / 415 volts ac s ervice panel. 2 Put the [...]

28 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 3.7. Connecting the control signals For all applications with conventional controllers ( such as NT6C25BA or NT6C25BB ) or front access controllers ( NT6C 25FA ), execute the steps contained in Procedure 7 to connect the NT5C05CC rectifier ( see Figure 9 ). Procedur[...]

Installation 29 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Procedure 8 - Co nnecting an NT5C05CC rectifier d irectly to a controller Step A ction 1 If an NT 6C43PB interconnect boar d is not available, each rec tifier m ust be connected dir ectly to the contro ller with the following cables : • P0723784, [...]

30 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Table 9 - Pin assignment for connector J13 Pin Function J13-1 SH+ ( re ctifier 1 ) J13-2 SH − ( rectifie r 1 ) J13-3 SH+ ( re ctifier 2 ) J13-4 SH − ( rectifie r 2 ) J13-5 SH+ ( re ctifier 3 ) J13-6 SH − ( rectifie r 3 ) J13-7 SH+ ( re ctifier 4 ) J13-8 SH −[...]

31 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 4. Functional description 4.1. Overv iew 4.1.1. Input circuit The input circuit offers the following characteristics : • ac rectifying • EMI filtering • inrush curre nt limiting, a walk-in c ircuit limits the output curre nt rise to 25 A per second • low[...]

32 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 4.1.3. Monitoring and control circuits The monitoring a nd control circuits off er the following character istics : • soft start • rectifier fail alarm ( RFA ) • control for local and rem ote equalize ( EQL ) • temporary release ( TR ) • thermal[...]

Functional desc ription 33 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 4.2.2. Sw itches, controls and LEDs There are switches and potentiometers on the front panel to adjust the operating parameter s of the rectifie r. The L ED indicators indicate the operating and alarm conditions. Figure 10 - Front panel c[...]

34 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 4.2.3. Front panel LEDs Table 10 - Des ignation of the LEDs on the front panel LED Color Description AC ON Green Input ac voltage operational CL Yellow Current Lim it EQL Y ellow Rectif ier is in equalize mode FAN ALM Red Fan fail alarm HVSD Red High volt[...]

Functional desc ription 35 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual HVSD ( high voltage shutdown ) The rectif ier monitors itself for hig h voltage and will shut down when its output voltage exceeds a preset adjust able value ( between -52 V and -60 V ). RFA ( rectifier f ailure alarm ) The rectif ier mon[...]

36 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Table 11 - A djusting the poten tiometers and switch es Potentio meters Descriptio n CL ADJ Current lim it adjust ( 100 A to 210 A ) CUR CAL Current reading calibrati on EQL ADJ Equalize voltage adjust ( 0 V to − 4 V ) FLT ADJ Float voltage adjust ( −[...]

Functional desc ription 37 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual VOLT / A MP digital meter switch This switch is used to selec t the measurement displa y mode of the digita l meter. The output voltage or the output current modes can be selected. VOUT+, VOUT − − − − test points These test points[...]

38 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems The rectifier can be started when it i s connected across a completely discharged battery without requiring human intervention or operating protective devices. A transition from constant voltage operation to constant current operation and from constant cu[...]

Functional desc ription 39 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Example 1 : I f the rectifier is ex pected to provide 100 A at 48 V V ( preset ) = 48 V + 0.8 V + ( 100 x 300 mV ) 200 V ( preset ) = 48 V + 0.8 V + 0.15 V = 48.95 V Example 2 : I f the rectifier is ex pected to provide 40 A at 48 V V ( p[...]

40 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 4.2.9. HVSD ( high volt age shutdow n ) HVSD A DJ ( high vo ltage shutdow n adjust ) potentiometer Use this potentiometer to set the internal thr eshold level at which the loc al high voltage shutdown condition should occur. Remote HVSD I n addition to th[...]

Functional desc ription 41 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Table 13 - Setting t he start-u p delay POSITION DEL AY POSITION DEL AY 0 X X X X X X X X X X X X X X X X X X X X 4 SEC 12 SEC 20 SEC 28 SEC 36 SEC 44 SEC 52 SEC 60 SEC 1 X X X X X X X X X X X X 68 SEC 76 SEC 84 SEC 92 SEC 100 SEC 108 SEC[...]

42 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Remote ON / OFF control TR When a ground signal is applied to the 'Temporary Release' ( TR ) input, the rectif ier inhibits its operation a nd trigge rs the RFA. When the re mote ground sig nal is discontinued the rectifier returns to normal ope[...]

Functional desc ription 43 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Table 14 - Control signal connec tions on P1 ( conti nued ) Connectio n Signal Description P1-11 NC No connection P1-12 NC No connection P1-13 CB OFF ( NC ) Output br eaker OF F ( NC ) P1-14 RG+ Remote sens e ( + ) P1-15 TR Rectifier tem [...]

44 Functional desc ription UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems This page is le ft blank intentionally .[...]

45 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 5. Operation 5.1. Standard settings The parameters of the NT5C05CA / CB / CC rectifiers are set as indicated in Table 15. For dif ferent setting s refer to User Manual Voltage _level entitled Voltage Level Limits for Power Plants, Rectifiers and Controllers. Tab[...]

46 Operation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 5.2. Starting up and adjust ing Procedure 9 - St arting up the rectifier Step A ction 1 Put the dc circ uit breaker to OFF ( 0 pos ition ). Open the sensing leads by removing the cor responding RC f use ( when the rectif ier is used with a controller ) or by disconnec [...]

Operation 47 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Proce dure 9 - Star ting up the rec tifier ( continue d ) Step A ction A djusting the fl oat voltage 14 Ensure that the EQL / FLT switch is on the FLT position. 15 To adjust the f loat voltage to the proper level, turn the FLT potentiom eter clock wise[...]

48 Operation UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Proce dure 9 - Star ting up the rec tifier ( continue d ) Step A ction 23 Turn ON the other rectifier s in the system. Setting the s tart-up delay 24 Use this feature to reduc e the inrush cur rents when two or mor e rectif iers are connec ted to a com m on ac input. S[...]

49 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 6. Maintenance 6.1. Replacing the air filter I n dusty environments, the use of air filters is strong ly recommende d. If used they should be replaced at least once a y ear. 6.2. Replacing the fan unit The fan unit, consistin g of four fans and a fan plate, can [...]

50 Maintenance UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems CA UTION Preventi ng short circ uits The replacement operation i s safe, as only SELV circuitry is present behind the fan assembly . However, due to the possible presence of residual charges in the output circuit, do not use me tal tools within the rectifie r enclosu[...]

Maintenance 51 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual Procedure 11 - Calib rating th e meter Step A ction 1 Make s ure the rem ote sense leads ar e disconnected by rem oving the corres ponding RC − fuse f rom the controller. 2 Set the VOLT /AMP switch to AMP. Set the output load of the plant so the re[...]

52 Maintenance UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems This page is le ft blank intentionally .[...]

53 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 7. Troubleshooting Table 16 - Diagnos ing sys tem faults Fault sy mptom Possible causes The RFA LED is lit. • No ac input or input is out of bounds ( ac ON LED is extinguis hed ). • AC Input / dc output circ uit breaker is open. • The r ectifier has receiv[...]

54 Troubles hooting UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems Table 16 – Dia gnosing sy stem faults Fault sy mptom Possible causes The AC O N LED is not lit. • No ac input voltage. • The input c ircuit break er is open. • AC voltage is present but is out of operational lim its. The unit will res tart when the ac re[...]

55 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 8. Appendix A : Replacement parts ITEM PA RT NUM BER ( CPC ) Fan Assem bly P0723582 Fuse 1 A ( F F1, FF2 on Display PCB ) A0287301 Air filter P0744757 Air filter fram e P0744559[...]

56 Appendix A: Recom m ended Replacem ent Parts UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems This page is le ft blank intentionally .[...]

57 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 9. Appendix B : Technical service assistance For technical assistance, 24 hours a day / 7 day s a week, dial one of the following toll-f ree numbers. This se rvice compleme nts the services offered by field support organizations such as, the Emergency Technical [...]

58 Appendix B : T echnical ser vice assis tance UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems 9.2. Toll-free technical assist ance numbers United Stat es: 1-800-992-8417 Canada : 1- 800-363-2288 In Europe: In A sia and t he Pacific: Austria 800-213-49156 Australia 800-213-49156 Belgium 800-213-49156 Hong Kong 800-213-49156 Den[...]

59 Emerson En ergy Systems Rectif ier 200I/48  NT 5C05C Installation and User Manual 10. Abbrev iations and acrony ms A LCO Alarm cut-off AL M Alarm A UTOST Auto restart Indicator C Common CL Current limit indica tor EMI Electromag netic inter ference EQL Equalize FA N A LM Fan alarm HVSD High voltage shutdown HVSDR High voltage shutdown reset L[...]

60 Abbreviations and acr ony m s UM5C05C P0745680 Standard 6.00 October 2001 Emerson En ergy Systems RFA Rectifie r fail ala rm RG+ Remote ground bus ( positive ) RMT ACK Remote acknowledge SEN FA IL Sense fa il THSD Thermal shutdown TR Temporary release VCA L Voltage r eading ca libration[...]

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Emer son En erg y Sys tem s a part of Emerson Network Pow er Helios Modular Switch Mode Rectifier 200I/48     NT5C05C Installation and User Manual Em erson Energy Sy s tem s 2280 Alfred- Nobel Blvd St-Laurent ( Quebec ) Canada H4S 2A4 Manual Number : UM5C05C ( 169-2081-501 ) Manual Status : Standard Manual Issue : 6.00 Release Date : Oc[...]