Emerson 200I/48-NT5C05C User manual

Emerson Energy Systems
UM5C05C ( 169-2081-501 )
Helios Modular Switch Mode Rectifier
200I/48NT5C05C
Installation and User Manual
HELIOS
V OL T
V O LT
CA L
AM P
CUR
CA L
CL
AD J
I
EQ L
AD J
TH S D
0
HV SD
RF A
SEN
F A IL
FA N
A LM
EQ L
V O L T+
V O U T-
E QL
A C ON
FF 1
1 .0 A
F F2
1 .0A
F LT
CL
F LT
A DJ
A C/C A
H VS D
A DJ
I
S T UP
DL Y
S LS
I
D C /C C
P0745680 Standard 6.00 October 2001
FS
3
Helios Modular Switch 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 Astec International Ltd
All Rights Reserved
Published in Canada
The information contained in this manual is the property of Astec International Ltd and is subject to change without
notice. Astec International Ltd reserves the right to make changes in design or components as progress in engineering
and manufacturing may warrant. Except as specifically authorized in writing by the V.P. of Engineering and Product
Manufacturing of Astec International Ltd, the holder of this manual shall keep all information contained herein confidential
and shall protect same, in whole or in part, from disclosure and dissemination to all third parties, and use the same for
start-up, operation, and maintenance purposes only. Any modification to the equipment must be approved by the person
responsible for product safety and design quality at Astec International Ltd to insure that the equipment complies with the
operation standards.
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment
is operated in a commercial environment. The equipment generates, uses, and can radiate radio frequency energy, and if
not installed and used in accordance with the instructions contained in the Installation and User Manuals, can cause
harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his own expense.
Helios and Helios Candeo are trademarks of Astec International Ltd. The Emerson logo is a trademark and service mark of
Emerson Electric Co.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
5
Publication history
October 2001
Standard Issue 6.00. Manual restructured and updated to reflect Emerson
Energy Systems and Emerson Network Power identities. ( ECN 102-26804 )
March 1998
Issue 5.0. Standard. Reference change from NT5C05CB to NT5C05C.
July 1997
Issue 4.0. Standard EMI compliance information and table of content
numbering corrections.
June 1995
Issue 3.0. Standard. Revised rectifier installation procedure in a cabinet.
September 1994
Issue 2.0. Standard. Few revisions and additions from the previous issue.
July 1994
Issue 1.0. Standard. Few changes from the previous issue and the document
is now rated “Standard”
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
6 Publication history
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UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
7
Contents
1. General information .................................................................................... 11
1.1. Purpose of this manual .............................................................................. 11
1.2. Models and mounting configurations ......................................................... 12
2. Specifications .............................................................................................. 13
2.1. Mechanical and electrical specifications .................................................... 13
2.2. Operation specifications and ambient conditions....................................... 14
2.3. Mechanical and electrical specifications of a 1200 A cabinet .................... 16
2.4. Ambient conditions of a 1200 A cabinet..................................................... 16
3. Installation.................................................................................................... 17
3.1. Mounting configurations ............................................................................. 17
3.2. Tools and test equipment........................................................................... 17
3.3. Cautions and Warnings.............................................................................. 17
3.3.1. Installing in a frame.............................................................................. 20
3.3.2. Installing in a cabinet ........................................................................... 20
3.4. Cabling and connecting.............................................................................. 22
3.5. Connecting the dc output terminals to the busbars.................................... 23
3.5.1. Securing the dc output terminals to the busbars in a 1200 A cabinet . 24
3.5.2. Running and connecting the dc between busbars and a rectifier ........ 24
3.6. Connecting ac to the rectifiers.................................................................... 24
3.7. Connecting the control signals ................................................................... 28
3.7.1. Monitoring of the shunt current ............................................................ 29
4. Functional description ................................................................................ 31
4.1. Overview .................................................................................................... 31
4.1.1. Input circuit .......................................................................................... 31
4.1.2. Output circuit........................................................................................ 31
4.1.3. Monitoring and control circuits ............................................................. 32
4.1.4. Output capacitors................................................................................. 32
4.2. Description of the front panel ..................................................................... 32
4.2.1. Breakers .............................................................................................. 32
4.2.2. Switches, controls and LEDs ............................................................... 33
4.2.3. Front panel LEDs................................................................................. 34
4.2.4. Local and remote adjustments and controls........................................ 35
4.2.5. Voltage / current displaytest and measurement............................... 36
4.2.6. Float and equalize voltage control ....................................................... 37
4.2.7. Current limit adjustment and rectifier regulating test ........................... 37
4.2.8. Rectifier parallel operation ................................................................... 38
4.2.9. HVSD ( high voltage shutdown ).......................................................... 40
4.2.10. TR ( temporary inhibition ) and sequential start................................... 40
4.2.11. Control signals on connector P1.......................................................... 42
5. Operation...................................................................................................... 45
5.1. Standard settings ....................................................................................... 45
5.2. Starting up and adjusting ........................................................................... 46
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
8 Contents
6. Maintenance................................................................................................. 49
6.1. Replacing the air filter ................................................................................ 49
6.2. Replacing the fan unit ................................................................................ 49
6.3. Calibrating the Volt / Amp Multimeter......................................................... 50
6.4. Resetting the rectifier after an HVSD ( high voltage shutdown )................ 51
7. Troubleshooting .......................................................................................... 53
8. Appendix A : Replacement parts ............................................................... 55
9. Appendix B : Technical service assistance .............................................. 57
9.1. Local toll-free prefixes ................................................................................ 57
9.2. Toll-free technical assistance numbers...................................................... 58
10. Abbreviations and acronyms ..................................................................... 59
List of Figures
Figure 1 - Front view of the modular 200I / 48 switch mode rectifier ................... 11
Figure 2 - Typical mounting in a cabinet or frame................................................ 12
Figure 3 - Anchoring the cabinet .......................................................................... 21
Figure 4 - Installing the rectifier............................................................................ 22
Figure 5 - Connecting the dc to the busbars with a shunt on the battery
side or a shunt on the ground side ...................................................... 23
Figure 6 - Cabling ac the NT5C05CA / CB rectifiers............................................ 26
Figure 7 - Connect the power leads to the L1, L2 and L3 terminals of the
rectifier ................................................................................................. 26
Figure 8 - Connecting ac to the rectifier NT5C05CC ........................................... 27
Figure 9 - Typical connections between rectifiers and the conventional
controller .............................................................................................. 28
Figure 10 - Front panel controls and LEDs .......................................................... 33
Figure 11 - Replacing the fan unit ........................................................................ 49
List of Tables
Table 1 - Mechanical specifications of the rectifier .............................................. 13
Table 2 - Electrical specifications of the rectifier.................................................. 13
Table 3 - Operation specifications of the rectifier ................................................ 14
Table 4 - Ambient conditions for the rectifier ....................................................... 15
Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet .............. 16
Table 6 - Electrical specifications of the NT6C43CB ........................................... 16
Table 7 - Ambient conditions for the NT6C43CB 1200 A cabinet........................ 16
Table 8 - Pin assignment for connectors J7 to J12.............................................. 29
Table 9 - Pin assignment for connector J13 ........................................................ 30
Table 10 - Designation of the LEDs on the front panel ........................................ 34
Table 11 - Adjusting the potentiometers and switches ........................................ 36
Table 12 - Rectifier input / output signals to the controller................................... 36
Table 13 - Setting the start-up delay .................................................................... 41
Table 14 - Control signal connections on P1 ....................................................... 42
Table 15 - Standard settings for the rectifier........................................................ 45
Table 16 - Diagnosing system faults.................................................................... 53
List of Procedures
Procedure 1 - Installing the rectifier in a frame .................................................... 20
Procedure 2 - Installing a rectifier in a cabinet..................................................... 21
Procedure 3 - Securing the dc output terminals to the busbars of the cabinet .... 24
Procedure 4 - Typical dc cabling in a frame application ...................................... 24
Procedure 5 - Cabling the ac input to the NT5C05CA / CB rectifiers .................. 25
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Contents 9
Procedure 6 - Connecting the ac male plug between the NT5C05CC rectifier
and the ac female plug in a 1200 A cabinet .................................. 27
Procedure 7 - Connecting the NT5C05CC to the controller................................. 28
Procedure 8 - Connecting an NT5C05CC rectifier directly to a controller ........... 29
Procedure 9 - Starting up the rectifier .................................................................. 46
Procedure 10 - Replacing the fan unit ................................................................. 50
Procedure 11 - Calibrating the meter................................................................... 51
Procedure 12 - Resetting the rectifier after a high voltage shutdown .................. 51
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
10 Contents
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UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
11
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 a
nominal voltage of –48 volts. This manual covers all applications of the
rectifier referred to as the 200I ( “I” standing for “International” ) market.
Figure 1 - Front view of the modular 200I / 48 switch mode rectifier
HELIO S
V OL T
V O LT
CA L
AM P
CU R
CA L
I
CL
AD J
EQ L
AD J
TH S D
0
HV SD
RF A
SEN
F A IL
FA N
A LM
EQ L
V O L T+
V O U T-
A C ON
E QL
FF 1
1 .0 A
F F2
1 .0 A
F LT
CL
F LT
A DJ
AC/C A
H VS D
A DJ
I
S T UP
DL Y
S LS
FS
I
D C /C C
The NT5C05CA / CB / CC rectifiers are designed to operate continuously
in a -48 V power system, equipped with or without batteries. It can be
integrated into a small-embedded system or a larger power plant
configuration. It is forced air-cooled by four fans contained in the unit, one
of which is are redundant, if one fan fails this will not cause a shutdown of
the rectifier. The rectifiers can be operated in conjunction with other
Emerson rectifiers as well as with the models and conventional controllers
of other manufacturers available on the market.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
12 General information
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 installed in a 23-inch
NT6C43CB 1200 A cabinet or in an NT6C40 type frame. The cabinet is
specifically designed to provide modularity within a very compact unit.
For wooden floor applications in a zone 4 seismic region, up to three
rectifiers can be installed in a mounting frame mounting, but they must be
installed in the three lowest mounting positions in the frame.
Figure 2 - Typical mounting in a cabinet or frame
RECTIFIER No. 1
RECTIFIER No. 2
RECTIFIER No. 3
RECTIFIER No. 4
RECTIFIER No. 5
RECTIFIER No. 6
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
13
2. Specifications
2.1.
Mechanical and electrical specifications
Table 1 - Mechanical specifications of the rectifier
10.0 inches ( 25.4 cm )
Height :
Depth :
22.0 inches ( 55.9 cm )
Width :
20.5 inches ( 52.1 cm )
Weight :
92.6 lbs ( 42 kg )
Table 2 - Electrical specifications of the rectifier
Nominal : 380 / 415 V ac
Input voltage :
Range : 330 ±5 V ac to 475 ±5 V ac
Frequency : 47 to 63 Hz
Note: After an out of range line condition shutdown,
the rectifiers will restart automatically at a line
voltage within 350 ±5 V ac to 460 ±5 V ac.
Nominal: 18 A RMS ( at 415 V ac )
Input current :
Worst case: 24 A RMS
Input protection :
25 A ac breaker, 3 Ø
Output floating
voltage :
−46 V dc to —58 V dc
Equalizing voltage :
0 to −4 V dc above the floating voltage
High voltage
shutdown :
−52 V to −60 V dc
Output current :
200 A ( 330 to 475 V ac input )
Output protection :
200 – 250 A dc circuit breaker
Current limit :
50% to 105% of the rated output current
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
14 Specifications
2.2.
Operation specifications and ambient conditions
Table 3 - Operation specifications of the rectifier
Output regulation :
At the output terminals, the voltage is within ±0.5% of
the set voltage value for all specified input and output
variations, and within ±1% for any combination of
specified input, output and ambient conditions.
Temperature drift :
Unless otherwise stated, all input and output
parameters such as input voltage range, output current
and voltage, current limit, etc. shall not vary more than
2% over the operating temperature range.
Output noise and
ripple :
• less than 22 dB of random noise on C band at voice
frequency over the entire operating range of the
rectifier, including operation in the current limit mode,
and at low, nominal and high input voltage conditions
( with or without batteries and measured at the point
of regulation )
• less than 20 mV RMS in any 3 kHz band between 10
kHz and 20 MHz ( measurements made with or
without batteries at the output terminals of the
rectifier and with the rectifier in the local sensing
mode )
• less than 250 mV peak to peak switching voltage
spikes ( measured differentially with an a 100 MHz
oscilloscope )
Total harmonic
distortion ( THD ) :
Less than 5%.
Efficiency :
Better than 89% at a nominal input voltage of 350 V ac
and for an output current ( load ) greater than 80 A.
Power factor :
Better than 99% with an output current ( load ) greater
than 80 A.
Heat dissipation :
The maximum heat dissipation is 1420 watts
( 4846 BTU / hr ) for an output current ( load ) of 200 A
at –58 V dc ( when the ac input is 330-475 V )
Electromagnetic
interference ( EMI ) :
The NT5C05CA / CB rectifiers when used in the
rectifier cabinet NT6C43CA / CB ( equipped with the
ac EMI filter kit NT6C18KB, or the NT5C05CC without
external EMI filter ) meet the CISPR requirements for
conducted and radiated EMI as specified in Publication
22 for Class "A" equipment.
Reliability:
The rectifier has an MTBF greater than 120 000 hours
under normal operating conditions, at 77°F ( 25°C ) as
per Telcordia Technologies TR332 method.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Specifications 15
Table 4 - Ambient conditions for the rectifier
Operating
conditions
A minimum airflow clearance of 2 inches ( 5 cm ) is
required at the rear of the rectifier.
The rectifier will operate properly under the following
conditions.
Temperature:
32°F to 122°F ( 0°C to +50°C )
32°F to 104°F ( 0°C to +40°C ) with air
filters
Humidity:
Transportation
conditions
0 to 95% RH ( non-condensing ) at 4
kPa max. equiv. to 7,000 ft. ( 2,100 m )
above sea level
During transportation, the rectifier can be subjected to
the following conditions without sustaining damage.
Temperature:
–67°F ( –55°C ) for 16 hours
140°F ( +60°C ) dry heat
Humidity:
0 to 95% RH ( non-condensing ) at
4 kPa max.
Vibration:
38 mm / s max. ( 10 Hz to 30 Hz )
sinusoidal, 18-inch ( 457 mm ) drop
when packaged
Pressure:
12 kPa min. equiv. to 49,212 ft.
( 15,000 m above sea level)
Temperature shock : −58°F to 140°F ( −50°C to 60°C )
Storage conditions
During storage, the rectifier may be subjected to the
following conditions without damage :
Temperature:
–67°F ( –55°C ) for 16 hours to 140°F
( +60°C ) dry heat
Humidity:
0 to 95% RH ( non-condensing ) at
4 kPa maximum
The rectifier contains aluminum electrolytic capacitors
that have a shelf life of five years or greater at the
maximum rated storage temperature.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
16 Specifications
2.3.
Mechanical and electrical specifications of a 1200 A cabinet
Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet
84.00 inches ( 213.36 cm )
Height :
Depth :
23.63 inches ( 60.0 cm )
Width :
23.63 inches ( 60.0 cm )
Table 6 - Electrical specifications of the NT6C43CB 1200 A cabinet
2.4.
Input voltage :
380 / 415 V ac three phase
Output voltage :
–46 V dc to –58 V dc
Output current :
1200 A
Ambient conditions of a 1200 A cabinet
Table 7 — Ambient conditions for the NT6C43CB 1200 A cabinet
Operating
conditions
The cabinet is designed for use under the following
ambient conditions.
Temperature:
0°C to 50°C ( 32°F to 122°F )
0° to 40°C ( 32° to 104°F ) with air
filters
Storage conditions
Humidity:
0 to 95% RH ( non-condensing )
Altitude:
sea level to 7,000 ft ( 2,100 m )
During transportation and storage, the acceptable
ambient conditions are :
Temperature:
–55°C ( –67°F )
+60°C ( 140°F ) dry heat
Humidity:
UM5C05C P0745680 Standard 6.00 October 2001
0 to 95% RH ( non-condensing )
Emerson Energy Systems
17
3. Installation
3.1.
Mounting configurations
The NT5C05CA / CB / CC rectifiers are designed for 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 method. The rectifiers are shipped loose, not mounted in the
frame or cabinet. Upon reception, remove the rectifier from its shipping
carton and inspect it for physical damage. Report any damage to your
immediate supervisor.
3.2.
Tools and test equipment
The following tools and test equipment are required :
• screwdriver, flat blade, 3/16 inch ( 5 mm )
• potentiometer screwdriver, Bourns No. 60, or equivalent
• heavy cable strippers or electrician’s knife
• heavy cable cutters ( AWG 4/0 or metric No. 110 )
• nut drivers ( set )
• socket set ( 1/2 inch or 15 mm drive )
• torque limiting wrench ( 1/2 inch. or 15 mm drive )
• crimper, T&B, 15CA54R Violet die
• digital multimeter, Fluke 8000A or equivalent
3.3.
Cautions and Warnings
The following precautions must be adhered to at all times when handling
and installing power equipment.
CAUTION
Protecting the premises
Protect the floors and walls against damage with sheets of
plywood, cardboard, or other suitable material when
handling the equipment.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
18 Installation
CAUTION
Preventing damage caused by over-tightening
Do not over-tighten nuts and bolts. Over-tightening can
strip the threads or break the bolts. Apply the appropriate
torque values.
CAUTION
Personal safety and protecting the equipment
Use a dolly truck, forklift, or hoist whenever possible
when handling and moving the equipment, as power
equipment is heavy. If a forklift is used, do not remove the
packing material before having moved the equipment to
its final location. If a dolly truck is used, the packing
material can be removed in the reception area. When
handling cabinets with equipment installed in them,
exercise care to ensure they do not tip over, as they can be
top heavy.
CAUTION
Preventing personal injury
When cutting material, wear gloves and goggles. Break all
corners and sharp edges with a flat file.
CAUTION
Optimizing the life of the equipment
Make sure there are no obstructions in front of the
ventilation openings that can restrict the flow of air.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 19
WARNING
Generator requirements for Emerson Energy Systems
Power Systems
For information on selecting ac generators that will
effectively maintain peak performance and operating
characteristics, for all Astec APS power systems, go to the
partners’ section of the Emerson Energy Systems web site
at www.EmersonEnergy-NA.com. To obtain access to the
partners’ section follow the instructions found on the
partner’ page, or dial our nearest local 1−800 technical
support line ( refer to “Appendix C : Technical service
assistance” of this manual for the telephone number ).
DANGER
Grounding
The frame ground leads must be connected before any
other leads. This is to prevent the cabinets and any other
metal structures from carrying dangerous ac or dc voltage
levels.
DANGER
Protecting against electrical shocks
The cabling of the power plant, and all other required
cabling, must be carried out by qualified personnel and in
conformance with local and national electrical codes. AC
input voltages to the rectifiers are at a dangerous level.
Ensure that the circuit breakers are locked in the OFF
position in the ac service panel before working on the
power plant. Dangerous voltages may be present at the
output dc terminals even if the rectifiers are OFF. Use a
voltmeter to verify for the presence of such voltages. Do
not put the circuit breakers to ON until the entire system
has been assembled and you have been instructed to do so.
Verify, and identify with a tag, the proper polarity of the
battery leads before connecting them to the power plant.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
20 Installation
DANGER
Short circuit hazard
The rectifiers, and the batteries in particular, can 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 insulating sheet of canvas to prevent short circuits that
could be caused by falling tools or parts.
3.3.1. Installing in a frame
When shipped, the NT5C05CA / CB / CC switch mode rectifiers are
configured for installation in a standard frame. As the rectifier is heavy,
use a manual forklift to mount the rectifier in a frame. If a forklift is not
available, two persons, exercising care, can lift the rectifier into place and
secure it.
Procedure 1 - Installing the rectifier in a frame
Step
1
Action
Note : Install each rectifier beginning with the lowest mounting
position in the frame.
Align the mounting brackets of the rectifier with the mounting holes in
the frame and insert the locating pins into these holes.
2
Lift the rectifier and align the middle holes in the mounting brackets
of the rectifier with the locating pins inserted in the frame. Slide the
rectifier into position onto the locating pins.
3
Secure the rectifier to the frame by inserting and tightening a
mounting screw ( provided ) in the uppermost holes of each
mounting bracket ( one on the left side and one on the right side ).
4
Remove the locating pins and install the other six mounting screws.
Tighten the screws applying a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ±
0.5 N-m ).
end

3.3.2. Installing in a cabinet
The cabinet is 23.56 inches ( 600 mm ) wide and deep, and 84 inches
( 2134 mm ) high. The anchors provided to secure the cabinet in place are
intended for installation on 3000 psi ( 2 kg per sq. mm ) compressive
strength concrete. Anchors for seismic applications are available upon
request. Slotted holes are provided in the base of the cabinet for anchoring.
The primary locations should be used as a first choice ( see Figure 3 ). If a
steel-reinforcing rod is encountered when drilling the holes for the anchors
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 21
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. If this kit is installed, place the pad on the floor
and the bushings on the anchors, and position the cabinet on top.
Figure 3 - Anchoring the cabinet
590 mm
(23.13 po.)
520 mm
(20.42 po.)
600 mm
(23.56 po.)
SECONDARY LOCATION
FOR FLOOR ANCHORS
+
PRIMARY LOCATION
FOR FLOOR ANCHORS
+
526 mm
(20.68 po.)
Procedure 2 - Installing a rectifier in a cabinet
Step
Action
1
Loosen and remove the screws securing the mounting brackets to
each side of the rectifier.
2
Reposition and secure the mounting brackets to the holes located
nearest the front of the rectifier, on each side of the rectifier.
3
Remove the blank panel from the cabinet and put the self tapping
screws in a secure location, for future use.
continued

Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
22 Installation
Procedure 2 - Installing a rectifier in a cabinet ( continued )
Step
Action
4
Place the rectifier on the L-shaped guides located in the lowest
position of the cabinet and slide it towards the rear until the mounting
brackets come into contact with the frame of the cabinet. The front of
the rectifier should be flush with the front of the cabinet and the
output bussing should be in contact with the riser busbars located at
the rear of the cabinet.
5
Align the mounting holes in the brackets of the rectifier with the
mounting holes in the frame. Secure the rectifier in place by inserting
and tightening the self-tapping screws removed in Step 3.
Note : Install an external tooth lock washer on one of the screws to
assure good ground continuity between the rectifier and the
frame.
end

Figure 4 - Installing the rectifier
HELIOS
VOLT
CAL
CUR
CAL
VOLT
AMP
EQL
ADJ
EQL
VOLT/AMP
THSD
AC/CA
HVSD
SEN
FAIL
AC ON
FAN
ALM
EQL
CL
VOUT+
VOUT-
RFA
SELF-TAPPING SCREW
( P097F813 )
CL
ADJ
FLT
FF1
1.0A
FF2
1.0A
FLT
ADJ
HVSD
ADJ
ST UP
DLY
SLS
DC/CC
HELIOS
3.4.
FS
ET LOCK WASHER
VOLT
CAL
Cabling and connecting
The ac cables of the rectifier must always exit each rectifier from the right
side, when viewed from the rear.
The dc cables of the rectifier must always exit each rectifier from the left
side, when viewed from the rear.
The system alarm interface cable must always exit each rectifier from the
right side, when viewed from the front.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 23
3.5.
Connecting the dc output terminals to the busbars
The dc outputs of the rectifier are connected to the busbars as illustrated in
Figure 5. There are two methods :
• BAT GRD ( + ) of the rectifier connected to the CHG/ DISCH
GRD busbar and the –48 V of the rectifier connected to the
CHG BAT busbar
• BAT GRD ( + ) of the rectifier connected to the CHG GRD
busbar and the -48V of the rectifier connected to the CHG/
DISCH BAT busbar
Figure 5 - Connecting the dc to the busbars with a shunt on the battery side or a shunt on
the ground side
+
CHG / DISCH
GRD BUSBAR
LOAD
+ BAT GRD
RECTIFIER - -48V
-
CHG BAT
BUSBAR
SHUNT
DISCHARGE
BAT BUSBAR
FUSE
PANEL
SHUNT ON THE BATTERY SIDE
+
CHG GRD
BUSBAR
SHUNT
DISCHARGE
GRD BUSBAR
+ BAT GRD
RECTIFIER - -48V
LOAD
CHG / DISCH
BAT BUSBAR
FUSE
PANEL
SHUNT ON THE GRD SIDE ( PREFERRED CONFIGURATION )
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
24 Installation
3.5.1. Securing the dc output terminals to the busbars in a 1200 A
cabinet
For cabinet applications, no dc cabling is required; the output terminals of
the rectifier are connected directly to the busbars.
Procedure 3 - Securing the dc output terminals to the busbars of the
cabinet
Step
Action
1
Connect the BAT GRD output terminal of the rectifier to the BR
busbar, and the –48 V output terminal of the rectifier to the –48 V
busbar located at the rear of the cabinet.
2
Tighten the bolts by applying a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ±
0.5 N-m ).
end

3.5.2. Running and connecting the dc between busbars and a
rectifier
For frame applications, use terminal lug A0361762, supplied with the unit,
and no. 110 ( 4/0 ) metric cable.
Procedure 4 - Typical dc cabling in a frame application
Step
Action
1
Connect the BAT GRD output terminal of the rectifier to the CHG
GRD busbar of the power plant. Connect the –48 V output terminal
of the rectifier to the CHG / DISCH BAT busbar of the power plant
( see Figure 5 ).
2
Apply a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ± 0.5 N-m ) on the bolts
securing the lugs to the rectifier terminals.
end

3.6.
Connecting ac to the rectifiers
WARNING
Electrical connections should meet standards
The electrical installation must be carried out by qualified
personnel and in accordance with local electrical codes.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 25
DANGER
Hazardous potentials
Input voltage to the cabinet is at a hazardous potential.
Make sure the power is OFF and that the lever in the ac
service panel is locked in the OFF position before
attempting to connect the input line voltage to the ac box
of the cabinet.
Procedure 5 - Cabling the ac input to the NT5C05CA / CB rectifiers
Step
Action
1
Install the ac breaker ( 30 A / 3 phase per rectifier ) in the 380 /
415 volts ac service panel and lock it in the open ( OFF ) position.
2
Put the ac breaker to OFF.
3
Run the ac armored cable ( metric no. 25 [ 10 AWG ] 3 conductors
and ground ) from the service panel, through the top of the cabinet,
to the rear of the rectifier.
4
Secure the ac cable to the side of the cabinet using cable ties and
adhesive anchors. Make sure the cable are located in a manner that
will not interfere with the insertion of the rectifier ( see Figure 6 ).
5
Ground the conduit sheath to the ac service panel. Insulate the
conduit connector at the rectifier end with electrical tape to isolate it
from the ac ground.
6
Remove the two ac protection plates located at the rear of the
rectifier.
7
Strip 10 inches ( 250 mm ) of armored insulation from the end of the
ac cable. Insert the wires in the 90° conduit connector ( see Figure
7 ).
8
Run the signal cable from the rectifier to the interconnect board or
controller as described in the "Control signal connections" section.
9
Connect the green ground wire to the FR GND terminal.
10
Connect the power leads to the L1, L2 and L3 terminals ( any phase
sequence ) ( see Figure 7 ).
11
Tighten the elbow connector and reassemble the ac protection plate.
12
Run the signal cable from the rectifiers to the interconnect board or
controller as specified in the " Connecting the control signals"
section.
13
Secure the signal cables to the insulating busbar support, located in
the cabinet, with cable ties.
14
Start-up the rectifier as described in the “ Start-up “ procedure.
end

Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
26 Installation
Figure 6 - Cabling ac the NT5C05CA / CB rectifiers
SIGNAL CABLES TO THE
PLANT CONTROLLER
AC FEED TO
RECTIFIERS
PART OF OPTIONAL
KIT P0872151
A
CABLE
TIE
A
SIGNAL CABLE
Note: Dress the cables carefully to
clear the insertion path of the
rectifier.
HEX HEAD CAP SCREW
AND WASHERS
( 4 PLACES )
SECTION A-A
REMOVE PLATE TO
ACCESS CONNECTORS
SHOWING TOP VIEW
OF AC CABLING
REAR VIEW OF A
TOP FED ARRANGEMENT SHOWING
OPTIONAL BUSBAR COVER KIT P0872151
( WITH REAR PANELS REMOVED )
Figure 7 - Connect the power leads to the L1, L2 and L3 terminals of the rectifier
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 27
Procedure 6 - Connecting the ac male plug between the NT5C05CC rectifier
and the ac female plug in a 1200 A cabinet
Step
Action
1
Install the ac breaker ( 30 A / 3 phases per rectifier ) in the 380 /
415 volts ac service panel.
2
Put the ac breaker for the NT5C05CC rectifier, located in the ac
service panel, to OFF.
3
Run the metric no. 25 ( 10 AWG ) ac supply cable ( 3 conductors
and ground ) to the female receptacle ( see Figure 8 ). Connect the
female connector to the male connector.
4
Run the signal cable from the rectifier to the interconnect board or
controller as specified in the " Connecting the control signals "
section.
5
Secure the signal cables to the insulating busbar support, located in
the cabinet, with cable ties.
6
Start-up the rectifier as described in the “ Start-up “ section.
end

Figure 8 - Connecting ac to the rectifier NT5C05CC
A
A
BROWN
BLACK
BLUE
TB1
L1 L2 L3
GRD
CONNECTION
R1 (TB1-L1)
S2 (TB1-L2)
T3 (TB1-L3)
WIRE COLOR
BLUE
BROWN
BLACK
GREEN / YELLOW
GREEN/YELLOW
SECT A-A
FEMALE CONNECTOR
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Rectifier 200I/48NT5C05C Installation and User Manual
28 Installation
3.7.
Connecting the control signals
For all applications with conventional controllers ( such as NT6C25BA or
NT6C25BB ) or front access controllers ( NT6C25FA ), execute the steps
contained in Procedure 7 to connect the NT5C05CC rectifier ( see Figure
9 ).
Procedure 7 - Connecting the NT5C05CC to the controller
Step
Action
1
Connect each rectifier to the NT6C43PB board ( positions J1 to J6 ),
located at the top front of the cabinet or frame, with P0747000
cables.
2
•
Connect the NT6C43PB board ( positions J7 to J12 ) to the
controller with P0736355 cables for conventional controllers ;
and with P0736268 cables for front access controllers.
end

Figure 9 - Typical connections between rectifiers and the conventional
controller
Cables P0747000
Rectifier
#6
Rectifier
#5
Rectifier
#4
Rectifier
#3
Rectifier
#2
Rectifier
#1
NT6C43PB
J13
MONITOR
J1
J2
J3
J4
J5
J6
J7
J8
J9
J10
J11
J12
Cables P0736355
CONTROLLER NT
(NT6C25BA or NT6C25BB)
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Installation 29
Procedure 8 - Connecting an NT5C05CC rectifier directly to a controller
Step
1
Action
If an NT6C43PB interconnect board is not available, each rectifier
must be connected directly to the controller with the following
cables :
•
P0723784, P0723785 or P0723786 ( for conventional
controllers )
•
P0723708, P0723709 or P0723210 ( for front access
controllers )
end

For controllers not manufactured by Emerson Energy Systems see Table
12 in the " Functional Description " chapter describing the pin assignments
of the rectifier. Refer to Table 8 for the pin assignments of connectors J7
to J12 on board NT6C43PB.
Note:
The alarm and control signals in Table 8 are all ground
signals except for the RC– signal that is a –48 V
battery signal.
Table 8 - Pin assignment for connectors J7 to J12
Pin
Label
Function
Input/ Output
1
EQL
Equalize
Input
2
RG+
Remote sense
Input
3
RC–
Remote sense
Input
4
FAN ALM
Fan fail alarm
Output
5
HVSDR
6
HVSD
7
RFA
8
TR
High voltage shutdown reset
Input
High voltage shutdown
Input
Rectifier failure alarm
Temporary release
Output
Input
3.7.1. Monitoring of the shunt current
A 12-pin connector ( J13 ) is also available on the NT6C43PB
interconnect board for monitoring the individual output current shunt
readings ( 250 A / 50 mV for example ) of each rectifier in a cabinet or a
frame ( see Table 9 ).
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
30 Installation
Table 9 - Pin assignment for connector J13
Pin
Function
J13-1
SH+ ( rectifier 1 )
J13-2
SH− ( rectifier 1 )
J13-3
SH+ ( rectifier 2 )
J13-4
SH− ( rectifier 2 )
J13-5
SH+ ( rectifier 3 )
J13-6
SH− ( rectifier 3 )
J13-7
SH+ ( rectifier 4 )
J13-8
SH− ( rectifier 4 )
J13-9
SH+ ( rectifier 5 )
J13-10
SH− ( rectifier 5 )
J13-11
SH+ ( rectifier 6 )
J13-12
SH− ( rectifier 6 )
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
31
4. Functional description
4.1.
Overview
4.1.1. Input circuit
The input circuit offers the following characteristics :
• ac rectifying
• EMI filtering
• inrush current limiting, a walk-in circuit limits the output current
rise to 25 A per second
• low and high ac inhibit
• power factor compensation
• surge voltage protection
• ac breaker for input protection
For all input and output conditions specified in this manual, when the
rectifier is turned on, the ac current will not exceed the maximum steadystate value.
4.1.2. Output circuit
The output circuit offers the following characteristics :
• shunt for output dc current sensing
• 225 A dc circuit breaker for output protection
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Rectifier 200I/48NT5C05C Installation and User Manual
32 Functional description
4.1.3. Monitoring and control circuits
The monitoring and control circuits offer the following characteristics :
• soft start
• rectifier fail alarm ( RFA )
• control for local and remote equalize ( EQL )
• temporary release ( TR )
• thermal shutdown ( THSD )
• input ac monitoring
• local and remote high voltage dc shutdown ( HVSD )
• local and remote HVSD reset
• fan failure detection
4.1.4. Output capacitors
The output capacitors will be completely discharged ( < 2 V ) two minutes
after the ac power has been removed and the rectifier has been
disconnected from the batteries or the parallel rectifiers.
4.2.
Description of the front panel
4.2.1. Breakers
DC circuit breaker
A dc circuit breaker is provided to protect against current overload and to
manually disconnect from the power plant.
When the breaker is in the 0 ( OFF ) position, an RFA is triggered and the
remote sense leads RG+ and RC– are internally disconnected. The rectifier
will continue to operate, allowing the adjustment of the FLT, EQL and
HVSD set points.
AC breaker
The input ac circuit breaker can be used to locally turn the rectifier ON or
OFF. The local ON / OFF control overrides any remote control signals
( for example, TR ). Putting the breaker to OFF causes an RFA to be
issued and the RFA LED to light up, as long as the rectifier output is
connected to batteries.
UM5C05C P0745680 Standard 6.00 October 2001
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Functional description 33
4.2.2. Switches, controls and LEDs
There are switches and potentiometers on the front panel to adjust the
operating parameters of the rectifier. The LED indicators indicate the
operating and alarm conditions.
Figure 10 - Front panel controls and LEDs
VOLT
VOLT
CAL
AMP
CUR
CAL
CL
ADJ
EQL
ADJ
VOLT/AMP
THSD
RFA
HVSD
FAN
ALM
VOUT+
SEN
FAIL
EQL
EQL
AC ON
CL
FF1
1.0A
FF2
1.0A
FLT
FLT
ADJ
VOUT-
HVSD
ADJ
ST UP
DLY
SLS
FS
DC/CC
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Rectifier 200I/48NT5C05C Installation and User Manual
34 Functional description
4.2.3. Front panel LEDs
Table 10 - Designation of the LEDs on the front panel
LED
Color
Description
AC ON
Green
Input ac voltage operational
CL
Yellow
Current Limit
EQL
Yellow
Rectifier is in equalize mode
FAN ALM
Red
Fan fail alarm
HVSD
Red
High voltage shutdown
RFA
Red
Rectifier fail alarm
SEN FAIL
Red
Remote sense fail
THSD
Red
Thermal shutdown
AC ON ( ac voltage monitoring )
The rectifier monitors the input voltage and if the voltage exceeds the set
limit, it will inhibit its operation and trigger a rectifier failure alarm
( RFA ). The rectifier will resume its normal operation automatically when
the specified input voltage has been re-established.
CL ( current limit indicator )
This LED lights up if the rectifier is in current limit. The rectifier limits
the output current to 205 A + 5 A ( adjusted in the factory ), 50% to 105%
of the rated output current.
EQL ( equalize )
Indicates the rectifier is in equalizing mode.
FAN ALM ( fan failure alarm )
This LED lights up when the FAN ALM is activated due to a defect in the
fan system. The fan configuration includes redundancy to ensure the
rectifier will continue working properly if one of the fans fails. If only one
fan fails, a rectifier failure alarm RFA will not be triggered. It is, however,
imperative to repair or change the fan unit as soon as possible to preserve
this redundant feature.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Functional description 35
HVSD ( high voltage shutdown )
The rectifier monitors itself for high voltage and will shut down when its
output voltage exceeds a preset adjustable value ( between -52 V and
-60 V ).
RFA ( rectifier failure alarm )
The rectifier monitors its operation and triggers a global RFA if it detects
an internal failure, causing the RFA LED to light up. One of the following
will trigger an alarm :
• abnormal or out of range ac input voltage
• output fuse failure
• system or internal shutdown ( thermal, HVSD, TR )
• internal failure causing a power switching malfunction
If the switching malfunction is caused by an improper adjustment of the
output float voltage, the RFA alarm will not be triggered. The RFA feature
will be activated if the ac power is removed in a system where batteries are
present.
SEN FAIL ( sense fail alarm )
This LED lights up if the remote sense leads are not connected, or if the
RC fuse has blown.
THSD ( thermal shutdown )
This LED lights up when the rectifier is protecting itself against
overheating by suspending its operation for the duration of the high
temperature condition. An RFA alarm will also be triggered.
4.2.4. Local and remote adjustments and controls
The current and voltage calibration, adjustment and control can be set
through potentiometers and switches ( see Table 11 ) located on the front
panel, or by remote signals sent from the controller ( see Tables 8 and 12 ).
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
36 Functional description
Table 11 - Adjusting the potentiometers and switches
Potentiometers
CL ADJ
Description
Current limit adjust ( 100 A to 210 A )
CUR CAL
Current reading calibration
EQL ADJ
Equalize voltage adjust ( 0 V to −4 V )
FLT ADJ
Float voltage adjust ( −46 V to −58 V )
HVSD ADJ
High voltage shutdown adjust ( −52 V to −60 V )
VOLT CAL
Voltage reading calibration
Switches
EQL / FLT
SLS / FS
ST UP DELAY
VOLT / AMP
Description
Equalize / Float selection switch
Slope load sharing / Forced load sharing selection
Start-up delay selection DIP ( 4 sec to 2 min )
Voltage and current display selection switch
Table 12 - Rectifier input / output signals to the controller
Designation
Description
RG+ / RC−
External reference voltage across the batteries
measured through the controller to regulate the voltage.
HVSD
HVSDR
TR
Remote High Voltage Shutdown input activated by a
BAT RTN signal.
Remote High Voltage Shutdown Reset input activated by
a BAT RTN signal.
Remote Inhibit input activated by a BAT RTN signal.
EQL
Remote Equalize input activated by a BAT RTN signal.
RFA
Rectifier Failure Alarm output activating a form C contact
F ALM
Fan Failure Alarm output activating a form C contact
SHUNT ( + ) and
SHUNT ( − )
Rectifier Current input / output ( 50 mV / 250 A )
CURRENT
SHARE
Common Forced Current Share Mode ( 0-12 V )
4.2.5. Voltage / current display
test and measurement
CUR CAL / VOLT CAL potentiometers
These potentiometers are used to calibrate the digital display meter for
current and voltage measurements. As the two potentiometers affect each
other, current calibration must be performed before voltage calibration.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Functional description 37
VOLT / AMP digital meter switch
This switch is used to select the measurement display mode of the digital
meter. The output voltage or the output current modes can be selected.
VOUT+, VOUT−
− test points
These test points are used to measure the voltage at the point of regulation.
A 5 kohm resistor is placed in series with both sensing leads to prevent
short-circuits at the jack terminals. The resistor may affect reading
accuracy, depending on the impedance of the meter. Refer to the
Instruction Manual for your meter to determine its internal impedance and
correction factor.
4.2.6. Float and equalize voltage control
Local FLOAT / EQL switch and potentiometers
The rectifier is equipped with a FLOAT / EQL switch.
When the FLOAT / EQL switch is held in the EQL position, the rectifier
goes into equalize mode and boosts the output voltage to the value set by
the EQL potentiometer.
When the switch FLOAT / EQL is held in the FLT position, the rectifier
delivers a float voltage set by the FLT potentiometer.
Remote equalize control EQL
The rectifier is equipped with remote equalize control. This control is
activated by a remote ground signal ( BAT RTN ). The rectifier returns to
normal ( float voltage ) operation when this signal is removed.
4.2.7. Current limit adjustment and rectifier regulating test
CL ADJ potentiometer
The rectifier limits the output current to a select value ranging from 100 A
to 210 A, set by the CL ADJ potentiometer. The factory adjustment is
205 A ±5 A. Extended periods of operation in the current limiting mode
and repeated transitions between constant-voltage operation and constantcurrent operation have no detrimental effect on the performance or service
life of the rectifier.
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
38 Functional description
The rectifier can be started when it is 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 current operation to constant
voltage operation occurs automatically, as determined by the output
current. The current limiting circuit is functional in float and equalize
modes.
4.2.8. Rectifier parallel operation
The rectifier can operate in parallel with other rectifiers having similar
output characteristics. It shares the total load in proportion to its output
rating. Two methods for sharing load current are available :
•
Slope sharing
•
Forced sharing
Selecting either mode is done by setting the two bottom DIP switches,
SLS / FS, located on the front panel. The rectifier is factory set to the slope
sharing mode.
Slope sharing ( SLS )
When both bottom DIP switches are set to the SLS position, conventional
load sharing is achieved through a -300 mV slope on the output voltage of
the rectifier, from no load to full load. This mode should be used when
rectifiers from different manufacturers are not all equipped with the forced
load-sharing feature. In this mode, the units will share the load within
±10% of their maximum output rating.
To accurately preset the float voltage of the rectifier, its current in the plant
environment must be predicted and the preset output floating voltage must
be calculated using the formula found below. In the formula, 0.8 volts is
added to the float voltage to compensate for an internal voltage drop when
the rectifier dc breaker is put in the ON position.
V ( preset ) = Vo ( desired ) + 0.8 V + ( Io ( running ) x 300 mV )
200
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Functional description 39
Example 1 : If the rectifier is expected 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 : If the rectifier is expected to provide 40 A at 48 V
V ( preset ) = 48 V + 0.8 V + ( 40 x 300 mV )
200
V ( preset ) = 48 V + 0.8 V + 0.06 V = 48.86 V
Forced sharing ( FS )
When both bottom DIP switches ( SLS / FS ) are set to the FS position,
forced load sharing is achieved by an internal control circuit that modifies
the loop reference to equally share the output currents between rectifiers.
The setting of the output voltage is not modified with changes in output
load, as is the case in the slope share mode. In this mode, the rectifiers will
share the load within ±2 % of their maximum output rating.
For this to occur the rectifiers must communicate their operating current to
the other rectifiers in the same power plant. The current share terminal of
all the rectifiers ( P1-17 ) in the same power plant must be connected
through the control cables and controller. In applications using the
NT6C43PB interconnect board, such a connection is implemented
automatically.
Adjust the rectifier float voltage to the desired system float voltage, plus
0.8 volts, to compensate for an internal drop when the rectifier dc breaker
is put in the ON position.
Example 3 : for 48 V float voltage
V ( preset ) = 48 V + 0.8 V = 48.8 V
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
40 Functional description
4.2.9. HVSD ( high voltage shutdown )
HVSD ADJ ( high voltage shutdown adjust ) potentiometer
Use this potentiometer to set the internal threshold level at which the local
high voltage shutdown condition should occur.
Remote HVSD
In addition to the local high voltage shutdown feature, the controller of the
power plant controller can shut down any rectifier by sending a high
voltage shutdown signal, ground ( BAT RTN ) pulse. The rectifier will
shut down within 50 ms if it is supplying more than 10% of its full load
rating.
As is the case for the internal high voltage shutdown condition, two HVSD
events must occur within an interval of two minutes to lock out the
rectifier permanently. An ac breaker reset or an HVSDR signal can be
used to restart the rectifier.
Local and remote HVSD reset
The rectifier may be reset from an HVSD condition locally by :
4.2.10.
•
toggling the ac circuit breaker to OFF then to ON ( or the ac
breaker in the distribution panel )
•
sending a remote ground signal to the HVSDR input through the
controller restart ( provided the 'TR' lead has not been activated )
TR ( temporary inhibition ) and sequential start
Sequential start
The TR input can be interfaced to an external sequential start circuit.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Functional description 41
Table 13 - Setting the start-up delay
SWITCH
#
1
0
6
5
4
3
POSITION
1
1
NOTE: Switches 3
to 6 ( top four
switches ) are
used to set the
start-up delay.
POSITION
1
4 SEC
DELAY
0
68 SEC
X
6
X
5
X
X
4
X
X
3
X
X
6
X
5
X
4
3
X
X
X
X
20 SEC
X
X
3
X
6
X
X
28 SEC
X
X
X
X
3
X
X
5
X
92 SEC
X
4
6
84 SEC
X
X
X
5
76 SEC
X
X
5
4
12 SEC
X
6
2
DELAY
0
36 SEC
X
100 SEC
X
X
4
X
X
3
X
X
6
5
X
4
3
44 SEC
X
X
X
X
X
6
X
X
52 SEC
5
X
4
X
X
X
6
X
X
60 SEC
X
5
X
X
4
X
X
3
X
X
Emerson Energy Systems
116 SEC
X
X
3
108 SEC
X
124 SEC
Rectifier 200I/48NT5C05C Installation and User Manual
42 Functional description
Remote ON / OFF control TR
When a ground signal is applied to the 'Temporary Release' ( TR ) input,
the rectifier inhibits its operation and triggers the RFA. When the remote
ground signal is discontinued the rectifier returns to normal operation ( see
Table 14 ).
Start up delay DIP switch
The rectifier can provide a start-up delay of from 4 seconds up to
120 seconds, with a resolution of 8 seconds and an accuracy of +1 second.
Use of this feature is recommended when two or more rectifiers are
connected to a common ac input to stagger the inrush currents. A front
panel DIP switch can be set to provide the start-up delays listed in Table
13.
4.2.11.
Control signals on connector P1
The P1 connector, located at the rear of the rectifier, can be used to verify
all the control and alarm signals when troubleshooting the rectifier ( see
Table 14 ).
The control inputs are activated by a ground ( BAT RTN ) signal. The
alarms, extended by relay contacts, are isolated from each other and the
rectifier frame. All contacts are rated 60 V and 0.5 A dc. The normal status
of each contact is defined when the rectifier operates normally in the
remote sense mode with no alarm. Contacts NC ( normally closed ) and
NO ( normally opened ) refer to the de-energized state of their relay coils.
Table 14 - Control signal connections on P1
Connection
Signal
P1-1
EQL
Description
Equalize
P1-2
RC −
P1-3
HVSDR
Remote sense ( − )
P1-4
RFA ( NC )
P1-5
FAN ALM ( NC )
P1-6
FAN ALM ( C )
P1-7
SH−
P1-8
RFA ( NO )
P1-9
SENSE ( C )
P1-10
SENSE ( NO )
High voltage shutdown reset
Rectifier fail alarm ( NC )
Fan fail alarm ( NC contact )
Fan fail alarm ( C )
Output current shunt voltage ( - )
Rectifier fail alarm ( NO )
Sense fail alarm ( C )
Sense fail alarm ( NO )
continued

UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Functional description 43
Table 14 - Control signal connections on P1 ( continued )
Connection
Signal
P1-11
NC
No connection
P1-12
NC
No connection
P1-13
CB OFF ( NC )
P1-14
RG+
P1-15
TR
P1-16
HVSD
P1-17
CURRENT SHARE
P1-18
RFA ( C )
P1-19
SH+
P1-20
FAN ( NO )
P1-21
GRD
P1-22
SENSE FAIL ( NC )
P1-23
NC
No connection
P1-24
NC
No connection
P1-25
CB OPEN ( C )
Emerson Energy Systems
Description
Output breaker OFF ( NC )
Remote sense ( + )
Rectifier temporary released by
controller
High voltage shutdown
Forced share link
Rectifier fail alarm ( C )
Shunt ( + )
Fan fail ( NO )
Reference ground
Sense fail alarm ( NC )
Output breaker OFF ( C )
Rectifier 200I/48NT5C05C Installation and User Manual
44 Functional description
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UM5C05C P0745680 Standard 6.00 October 2001
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45
5. Operation
5.1.
Standard settings
The parameters of the NT5C05CA / CB / CC rectifiers are set as indicated
in Table 15. For different settings refer to User Manual Voltage_level
entitled Voltage Level Limits for Power Plants, Rectifiers and Controllers.
Table 15 - Standard settings for the rectifier
Parameter
Setting
Rectifier float output voltage ( FLOAT )
52.1 ±0.1 V dc
Rectifier equalize output voltage
( EQUALIZE )
52.8 ±0.1 V dc
Rectifier high voltage shutdown threshold
56.5 ±0.1 V dc
Rectifier output current limit
Rectifier start delay
205 A ±5 A
4 sec
Low ac input disconnect
330 ±5 V ac
Low ac input reconnect
350 ±5 V ac
High ac input disconnect
475 ±5 V ac
High ac input reconnect
460 ±5 V ac
Load sharing method
Emerson Energy Systems
Slope
Rectifier 200I/48NT5C05C Installation and User Manual
46 Operation
5.2.
Starting up and adjusting
Procedure 9 - Starting up the rectifier
Step
Action
1
Put the dc circuit breaker to OFF ( 0 position ). Open the sensing
leads by removing the corresponding RC fuse ( when the rectifier is
used with a controller ) or by disconnecting the alarm and control
cable ( when the rectifier is used without a controller ).
2
Put the ac circuit breaker in the main ac service panel to ON.
3
Put the 25 A, 3Ø, ac circuit breaker of the rectifier being tested to
ON. The green ac ON LED should light up.
Note : The output capacitors are precharged automatically when the
dc cables are connected at the rear of the rectifier.
4
Put the meter selector to the VOLT position. The meter will display
the voltage value to which the rectifier has been adjusted.
5
Connect a digital multimeter to test points VOUT+ and VOUT– on
the front panel. The voltage reading should be within 1% of the
rectifier meter reading. If not, calibrate it as described in the
“ Maintenance ” section.
6
Determine the system requirements for float, equalize and HVSD
limits by referring the User Manual Voltage_Level entitled Voltage
Level Limits for Power Plants, Rectifiers and Controllers.
7
If the factory threshold limits of the rectifier must be verified or
changed, go to Step 8; otherwise go to Step 14.
Adjusting the high voltage shutdown ( HVSD )
8
Put the dc circuit breaker to OFF ( O ).
9
Turn the HVSD potentiometer fully clockwise.
10
Turn the FLT potentiometer slowly clockwise to set the output
voltage on the display of the rectifier to the required HVSD threshold.
The EQL / FLT switch and the EQL potentiometer are used if the
voltage cannot be set with the FLT potentiometer.
11
Turn the HVSD potentiometer counterclockwise until the rectifier
shuts down.
12
Turn the FLT potentiometer counterclockwise two turns and put the
ac breaker to OFF.
13
Wait a few seconds for the rectifier to shut down and put the ac
breaker to ON to reset it.
continued

UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Operation 47
Procedure 9 - Starting up the rectifier ( continued )
Step
Action
Adjusting the float voltage
14
Ensure that the EQL / FLT switch is on the FLT position.
15
To adjust the float voltage to the proper level, turn the FLT
potentiometer clockwise to increase the voltage or counterclockwise
to decrease it.
Adjusting the equalize voltage ( EQL )
16
Set the EQL / FLT switch to EQL. Turn the EQL potentiometer
clockwise to increase the voltage or counterclockwise to decrease it.
17
Put the FLOAT / EQL switch in the FLOAT position.
Adjusting the slope share
18
Select the slope share mode by setting the two bottom DIP switches
to SLS ( see Figure 10 ). Verify that the rectifier displays the required
float value. If required, adjust it with the FLT potentiometer.
19
Connect the sense leads by inserting the RC fuse in the controller or
by reconnecting the control cable.
20
Put the dc breaker located on the front of the rectifier to ON.
21
The rectifier is now connected to the system and should carry some
current. If it is connected in parallel with other rectifiers, verify that
the total system current is shared equally amongst the rectifiers. Put
the switch on each rectifier to AMP. Find the mean current of the
rectifiers by adding all the currents measured on each rectifier and
dividing the total current by the number of rectifiers
IT = I1 + 12 +I3 … + In
n
n
Set the current from each rectifier to this mean value. If the current
reading of one of the rectifiers is too low, or is 0, slowly increase the
current by turning the FLT potentiometer clockwise until proper
sharing is achieved. If the current reading is too high or if rectifier is
in the current limit mode, turn the FLT potentiometer
counterclockwise.
Note : Adjust all the rectifiers in sequence to the mean value of the
currents, and readjust more precisely if necessary.
Verifying the current limit
22
Turn OFF some of the other rectifiers to force the rectifier under test
to pick up a load current of at least 210 A. When the rectifier reaches
about 205 A, the yellow CL LED should light up.
continued

Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
48 Operation
Procedure 9 - Starting up the rectifier ( continued )
Step
23
Action
Turn ON the other rectifiers in the system.
Setting the start-up delay
24
Use this feature to reduce the inrush currents when two or more
rectifiers are connected to a common ac input. Set the DIP switches
on the front panel for the required start-up delay, from 4 to 124
seconds ( see Table 13 ).
Adjusting the forced load sharing
25
If the forced share mode is chosen, adjust the float voltage of each
rectifier to the appropriate value plus 0.8 volts in slope share mode,
as described above. For example, to have a 52.1 V float voltage :
52.1 V +0.8 V = 52.9 V.
This compensates for the internal voltage drop when the dc breaker
of the rectifier is put in the ON position. Connect all the FS wires of
the rectifiers together and set the two bottom DIP switches, located
on the front panel, to FS for forced load sharing ( see Figure 10 ).
26
If the rectifiers are connected to the NT6C43PB board, in the cabinet
or frame option, the P1-17 signals from all the rectifiers are
automatically connected. After step 25 has been completed, the
rectifiers will automatically share the output current.
When forced load sharing is desired, but the NT6C43PB board is not
used or is bypassed, pins P1-17 of all the rectifiers must be made
common at a single point. This connection could be a splice
connection of all the P1-17 wires in the control cables, using a 2B16
splice from T&B ( or equivalent ) in the control panel.
The E1 terminal on the NT6C43PB board can be used when forced
load sharing is desired amongst rectifiers on two, or more, cabinets
or frames. In this case, the E1 terminal from all the cabinets or racks
must be daisy chained with metric No. 7 ( AWG 22 ) wire.
27
Repeat step 21, but in equalize mode, to verify that the current is
shared equally amongst the rectifiers when a remote equalize signal
is applied, or when all local FLOAT / EQL toggle switches are
toggled in the EQL position. If the current reading is too low, or is 0,
turn the EQL potentiometer clockwise until proper sharing is
achieved. If the current is too high, or if the rectifier is in the current
limit mode, turn the EQL potentiometer counterclockwise.
28
Deactivate the EQL mode to return to the normal float mode.
end

UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
49
6. Maintenance
6.1.
Replacing the air filter
In dusty environments, the use of air filters is strongly recommended. If
used they should be replaced at least once a year.
6.2.
Replacing the fan unit
The fan unit, consisting of four fans and a fan plate, can be replaced. To
install a new fan unit, execute the steps outlined in Procedure 10 and
illustrated in Figure 11.
Figure 11 - Replacing the fan unit
HELIO S
V OL T
V O LT
CA L
AM P
CUR
CA L
CL
AD J
I
EQ L
AD J
TH S D
0
HV S D
RF A
SEN
F A IL
FA N
A LM
EQ L
V O L T+
V O U T-
A C ON
E QL
FF 1
1 .0 A
F F2
1 .0 A
F LT
CL
F LT
A DJ
A C/C A
H VS D
ADJ
I
ST UP
DL Y
S LS
FS
I
D C /C C
REMO VE THESE FIVE SCREWS
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
50 Maintenance
CAUTION
Preventing short circuits
The replacement operation is 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 metal tools within the rectifier
enclosure. To remove the fan assembly mounting screws
you need a screwdriver, but all the other operations
described below can and should be performed without
any tools.
Procedure 10 - Replacing the fan unit
Step
Action
Disassembling
1
Put the ac and dc breakers to OFF.
2
Remove the five screws securing the fan plate ( see Figure 11 ).
3
Swing open the assembly and disconnect all four fan cables.
4
Lift the assembly out the holes and pull it out towards you.
Re-assembling
5
Insert the hinged bracket of the new assembly into the slotted holes
on the left and reconnect the cables to the four fans.
6
Place the four fan cables close to the display panel, removing as
much slack length as possible, so the cables will not interfere with
the fan blades after the fan unit is secured in place.
7
Swing the fan unit closed and secure it in plate with the five screws.
8
Check fan fuses FF1 and FF2 and replace as required.
9
Put the ac and dc breakers to ON.
end

6.3.
Calibrating the Volt / Amp Multimeter
In a cabinet or frame application, where the signal cables are connected to
the NT6C43PB board, use a digital multimeter, at J13 on the NT6C43PB
board, to monitor the shunt reading of the rectifier, as indicated in Table 9.
In any applications where the NT6C43PB board is absent or has been
bypassed, pins P1-19 and P1-7 of the signal connector provide the shunt
reading. To access pins P1-19 and P1-7 use a cut P0747000 cable. If the
meter must be calibrated execute the steps in Procedure 11.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Maintenance 51
Procedure 11 - Calibrating the meter
Step
Action
1
Make sure the remote sense leads are disconnected by removing
the corresponding RC− fuse from the controller.
2
Set the VOLT/AMP switch to AMP. Set the output load of the plant
so the rectifier delivers a current of approximately 100 A. Measure
the voltage between VOUT+ and VOUT −, located on the front panel,
with a digital meter.
3
Convert this measured voltage to a current value ( 50 mV
corresponding to 250 A ).
current
voltage
=
250 A
50 mV
If the voltage measured is 20.2 mV :
measured current
=
250 A X ( 20.2 mV ) = 101 A
50 mV
Rotate the CUR CAL potentiometer on the display panel until this
value is displayed.
4
Put the VOLT / AMP switch to VOLT. Adjust the V CAL
potentiometer so that the reading displayed on the meter of the
rectifier is identical to the reading on the digital meter.
5
Put the rectifier to OFF and reconnect the sense leads.
end

6.4.
Resetting the rectifier after an HVSD ( high voltage shutdown )
To reset the rectifier after an HVSD condition has occurred execute one of
the steps contained in Procedure 12.
Procedure 12 - Resetting the rectifier after a high voltage shutdown
Step
Action
Locally
1
Toggle the ac circuit breaker on the unit itself, or the associated ac
breaker in the distribution panel OFF and ON ( wait until the green ac
ON LED extinguishes before toggling the breaker back to ON ).
Remotely
2
Apply a ground signal at the HVSDR input of the rectifier.
end

Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
52 Maintenance
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UM5C05C P0745680 Standard 6.00 October 2001
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53
7. Troubleshooting
Table 16 - Diagnosing system faults
Fault symptom
The RFA LED is lit.
The HVSD LED is lit.
Possible causes
•
No ac input or input is out of bounds ( ac ON
LED is extinguished ).
•
AC Input / dc output circuit breaker is open.
•
The rectifier has received an HVSD signal from
the controller, or a TR signal is present.
•
An internal high voltage shutdown ( HVSD ) has
occurred.
•
Two cooling fans or fuses have failed.
•
The inrush fuse has blown.
•
The dc circuit breaker is open.
•
A thermal shutdown has occurred.
•
Ambient air temperature is high.
•
Air inlet / outlet air is blocked, or the air filter is
clogged.
•
A rectifier is in 'Start Time Delay' mode and the
RFA will cease when the required time delay has
elapsed.
•
Defective rectifier.
•
The internal high voltage shutdown point is set
to low ( below the float or equalize setting ).
•
The controller triggered a remote HVSD.
−continued−
−
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
54 Troubleshooting
Table 16 – Diagnosing system faults
Fault symptom
The AC ON LED is not
lit.
The FAN ALM LED is
lit.
Possible causes
•
No ac input voltage.
•
The input circuit breaker is open.
•
AC voltage is present but is out of operational
limits. The unit will restart when the ac returns to
the operating level.
•
AC has just been applied and the rectifier will
momentarily start ( after an inrush control
delay ).
•
The fuse of one or both fans has blown.
•
One or both fans have failed.
Note 1 : If a single fan failed or a fuse blew, the
rectifier will continue to operate while
triggering a local and remote FAN ALM.
Note 2 : If two cascaded fans failed or both fuses
blew, the rectifier will shut down and
trigger local and remote RFA alarms.
The SEN FAIL LED is
lit.
The CL LED is lit.
•
One, or both, remote sense leads is
disconnected.
•
Excessive impedance in one or both sense
leads.
•
The dc circuit breaker is open but the unit is in
remote sense.
•
The output load requirement exceeds the total
rectifier capacity.
•
With paralleled units, the float or equalize is
maladjusted causing one or more units to carry
the load.
•
The unit is in "equalize" mode and paralleled
units are not.
•
The remote sense lead has excessive
impedance on one or more rectifiers.
•
The system batteries are in recharge mode after
an ac outage.
•
The current share mode selection is not the
same for all units.
•
The forced share line is disconnected ( in FLS
only ).
—end—
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
55
8. Appendix A : Replacement parts
ITEM
PART NUMBER ( CPC )
Fan Assembly
P0723582
Fuse 1 A ( FF1, FF2 on Display PCB )
A0287301
Air filter
P0744757
Air filter frame
P0744559
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
56 Appendix A: Recommended Replacement Parts
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UM5C05C P0745680 Standard 6.00 October 2001
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57
9. Appendix B : Technical service assistance
For technical assistance, 24 hours a day / 7 days a week, dial one of the
following toll-free numbers. This service complements the services
offered by field support organizations such as, the Emergency Technical
Assistance Service ( ETAS ), and the Installation Technical Assistance
Service ( ITAS ).
9.1.
Local toll-free prefixes
The following prefixes give access to toll-free numbers in various
countries. For further information, please contact the local service
provider.
Country
Australia
Belgium
Brazil
Denmark
Finland
France
Germany
Hong Kong
Ireland
Japan
Korea
Malaysia
Netherlands
New Zealand
Singapor
Switzerland
United Kingdom
Emerson Energy Systems
Prefix
0011
00
000815
00
00 or 990
00
00
001
00
001 ( KDD )
041 ( ITJ )
0061 ( Idc )
001( Korea
Telecom )
002 ( Dacom )
003 ( Once )
00
00
00
001
00
00
Rectifier 200I/48NT5C05C Installation and User Manual
58 Appendix B : Technical service assistance
9.2.
Toll-free technical assistance numbers
United States:
In Europe:
Austria
Belgium
Denmark
Finland
France
Germany
Ireland
Italy
Netherlands
Norway
Sweden
Switzerland
United Kingdom
*1
1-800-992-8417
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
In the Caribbean and Latin America
( CALA ):
Bahamas
1-800-389-0081
Barbados
1-800-534-0225
Brazil
7101-2288
Colombia
980-192288
Dominican
1-888-7514232
Republic
Jamaica
1-800-850-1755
Mexico
001-800-514-2288
Puerto Rico
Trinidad &
Tobago
*1
1-800-363-2288
Canada:
In Asia and the Pacific:
Australia
800-213-49156
Hong Kong
800-213-49156
Japan
800-213-49156
Malaysia
800-213-49156
New Zealand
800-213-49156
Philippines
1-800-1-110-0131
Singapore
800-213-49156
South Korea
800-213-49156
Taiwan
800-213-49156
In the Middle-East:
Israel
800-213-49156
1-888-680-2288
1-800-363-2288
The United Kingdom includes England, Guernsey, the Isle of Man, Jersey,
Northern Ireland, and Scotland.
Note :
For countries not covered by a toll-free service dial
Canada ( country code 001 ) at 514-832-0201.
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
59
10. Abbreviations and acronyms
ALCO
Alarm cut-off
ALM
Alarm
AUTOST
Auto restart Indicator
C
Common
CL
Current limit indicator
EMI
Electromagnetic interference
EQL
Equalize
FAN ALM
Fan alarm
HVSD
High voltage shutdown
HVSDR
High voltage shutdown reset
LED
Light Emitting Diode
LOP
Loss of phase
MPR
Modular power rectifier
NC
Normally closed
NO
Normally open
PCB
Printed circuit board
RC−
−
Remote charge bus ( negative )
Emerson Energy Systems
Rectifier 200I/48NT5C05C Installation and User Manual
60 Abbreviations and acronyms
RFA
Rectifier fail alarm
RG+
Remote ground bus ( positive )
RMT ACK
Remote acknowledge
SEN FAIL
Sense fail
THSD
Thermal shutdown
TR
Temporary release
VCAL
Voltage reading calibration
UM5C05C P0745680 Standard 6.00 October 2001
Emerson Energy Systems
Helios Modular Switch Mode Rectifier
200I/48
NT5C05C
Installation and User Manual
Emerson Energy Systems
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 : October 2001
P0745680
Copyright  2001 Astec International Ltd
All Rights Reserved
Published in Canada
The information contained in this manual is the property of Astec International
Ltd and is subject to change without notice. Astec International Ltd reserves the
right to make changes in design or components as progress in engineering and
manufacturing may warrant. Except as specifically authorized in writing by the
V.P. of Engineering and Product Manufacturing of Astec International Ltd, the
holder of this manual shall keep all information contained herein confidential and
shall protect same, in whole or in part, from disclosure and dissemination to all
third parties, and use the same for start-up, operation, and maintenance
purposes only. Any modification to the equipment must be approved by the
person responsible for product safety and design quality at Astec International
Ltd to insure that the equipment complies with the operation standards.
This equipment has been tested and found to comply with the limits for a Class
A digital device, pursuant to part 15 of the FCC Rules. These limits are designed
to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in
accordance with Installation and User Manuals, may cause harmful interference
to radio communications. Operation of this equipment in a residential area is
likely to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
Helios Candeo is a trademark of Astec International Ltd. The Emerson logo is a
trademark and service mark of Emerson Electric Co.
Emerson Energy Systems
a part of Emerson Network Power