Emerson Network Power NetSure 721NPBB 48V DC Power System Installation Instructions

NetSure

™

-48V DC Power System

Installation Instructions, IM582127000 (Issue N, June 19, 2015)

Specification Number: 582127000

Model Number: 721

NPBB

Main Bay Supplemental Bay

(E/W Spec. No. 588705000 Module Mounting Shelves)

Main Bay Supplemental Bay

(E/W Spec. No. 588705300 Module Mounting Shelves)

NetSure ™ -48V DC Power System


This page is intentionally blank.

Spec. No: 582127000

Model No: 721

NPBB

Code: IM582127000

Issue N, June 19, 2015



Table of Contents

Admonishments Used in this Document ............................................................................................................... iii

Important Safety Instructions .............................................................................................................................. iv

General Safety ........................................................................................................................................................iv

Voltages .................................................................................................................................................................iv

Battery ...................................................................................................................................................................iv

Personal Protective Equipment (PPE) ....................................................................................................................... v

Hazardous Voltage ................................................................................................................................................. v

Handling Equipment Containing Static Sensitive Components ................................................................................. v

Static Warning ..................................................................................................................................................... vi

General Information .............................................................................................................................................. 1

Customer Documentation Package ......................................................................................................................... 1

Installation Acceptance Checklist .......................................................................................................................... 1

Installing the System ............................................................................................................................................. 2

General Requirements ............................................................................................................................................ 2

Securing the Relay Rack to the Floor ........................................................................................................................ 2

Mounting System Components in an Equipment Rack ............................................................................................. 5

Installing Optional Battery Busbar Extension Kit, Part No. 554541 .......................................................................... 13

Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and 514714 ............................................................ 15

Installing Circuit Breakers and Fuses ...................................................................................................................... 17

Setting Jumpers and Switch Options.................................................................................................................... 28

Circuit Card Locations ........................................................................................................................................... 28

Jumpers on System Interface Circuit Card (Main Bay Only) ..................................................................................... 29

Switch Settings on IB2 Interface Board (Main Bay Only) .......................................................................................... 30

Switch Setting on Optional EIB Interface Board (Main Bay Only) ............................................................................. 30

Switch Setting on SM-DU (Supplemental Bays Only) .............................................................................................. 33

Switch Setting on SM-DU+ .................................................................................................................................... 37

Making Electrical Connections ............................................................................................................................ 39

Important Safety Instructions................................................................................................................................ 39

Wiring Considerations .......................................................................................................................................... 39

Relay Rack Grounding Connection (Frame Ground) ............................................................................................... 40

Central Office Ground Connection ........................................................................................................................ 40

Nominal 208/240 Volts AC Input and Equipment Grounding Connections (if equipped) ......................................... 41

400 Volts DC Input and Equipment Grounding Connections (if equipped) .............................................................. 52

External Alarm, Reference, Monitoring, and Control Connections .......................................................................... 60

Controller Ethernet Connection (if required).......................................................................................................... 77

Bay-to-Bay Communications Cable Connections ................................................................................................... 81

Installing Bay-to-Bay Busbars (582127000 List 1 with List 2 / List 3) ........................................................................ 83

Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705000 ....................... 86

Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705300 ....................... 88

Connecting Converter Output Cables 582127000 List 60....................................................................................... 90

Spec. No: 582127000

Model No: 721

NPBB

[i]

Code: IM582127000




Load Connections ................................................................................................................................................. 93

Battery Connections ............................................................................................................................................ 101

Installing and Connecting Batteries in List 93 Battery Tray (if furnished) ................................................................ 112

Installing the Modules ....................................................................................................................................... 121

Installing Rectifier or Converter Modules into Spec. No. 588705000 Module Mounting Shelves ............................ 121

Installing the Rectifier and Converter Modules into Spec. No. 588705300 Module Mounting Shelves .................... 122

Initially Starting, Configuring, and Checking System Operation ......................................................................... 124

Important Safety Instructions .............................................................................................................................. 124

Initial Startup Preparation.................................................................................................................................... 124

Initially Starting the System ................................................................................................................................. 124

ACU+ Controller Procedure ................................................................................................................................. 124

NCU Controller Procedure ................................................................................................................................... 128

Checking System Status ...................................................................................................................................... 132

Final Steps........................................................................................................................................................... 133

NetPerform™ Optimization Services ................................................................................................................. 135

Spec. No: 582127000

Model No: 721

NPBB

[ii]

Code: IM582127000




Admonishments Used in this Document

DANGER! Warns of a hazard the reader will be exposed to that will likely result in death or serious injury if not avoided. (ANSI, OSHA)

Danger

Warning

Caution

WARNING! Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided. This admonition is not used for situations that pose a risk only to equipment, software, data, or service. (ANSI)

CAUTION! Warns of a potential hazard the reader may be exposed to that could result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not used for situations that pose a risk only to equipment, data, or service, even if such use appears to be permitted in some of the applicable standards. (OSHA)

ALERT! Alerts the reader to an action that must be avoided in order to protect equipment, software, data, or service. (ISO)

Alert

ALERT! Alerts the reader to an action that must be performed in order to prevent equipment damage, software corruption, data loss, or service interruption. (ISO)

Alert

FIRE SAFETY! Informs the reader of fire safety information, reminders, precautions, or policies, or of the locations of fire-fighting and fire-safety equipment. (ISO)

Fire Safety

SAFETY! Informs the reader of general safety information, reminders, precautions, or policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA)

Safety

Spec. No: 582127000

Model No: 721

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[iii]

Code: IM582127000




Important Safety Instructions

General Safety

Danger

DANGER!

YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.

Performing the following procedures may expose you to hazards. These procedures should be performed by qualified technicians familiar with the hazards associated with this type of equipment. These hazards may include shock, energy, and/or burns. To avoid these hazards: a) The tasks should be performed in the order indicated. b) Remove watches, rings, and other metal objects. c) Prior to contacting any uninsulated surface or termination, use a voltmeter to verify that no voltage or the expected voltage is present. Check for voltage with both AC and DC voltmeters prior to making contact. d) Wear eye protection. e) Use double insulated tools appropriately rated for the work to be performed. f) For 400V DC input systems, do not work on an energized system without full arc flash and PPE protection.

Voltages

AC Input Voltages

Danger

DANGER! This system may operate from AC input voltage capable of producing fatal electrical shock. AC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any AC electrical connections are made.

Follow local lockout/tagout procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply AC input power to the system until all electrical connections have been completed and checked.

DC Input Voltages

Danger

DANGER! This system may operate from 400V DC input voltage capable of producing fatal electrical shock. DC input power must be completely disconnected from the branch circuits wiring used to provide power to the system before any DC electrical connections are made.

Follow local lockout/tagout procedures to ensure upstream branch circuit breakers remain de-energized during installation. DO NOT apply DC input power to the system until all electrical connections have been completed and checked.

DC Output and Battery Voltages

Danger

DANGER! This system produces DC Power and may have a battery source connected to it. Although the DC voltage is not hazardously high, the rectifiers/converters and/or battery can deliver large amounts of current.

Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact an output terminal or battery terminal or exposed wire connected to an output terminal or battery terminal. NEVER allow a metal object, such as a tool, to contact more than one termination or battery terminal at a time, or to simultaneously contact a termination or battery terminal and a grounded object. Even a momentary short circuit can cause sparking, explosion, and injury.

Danger

DANGER! Follow local lockout/tagout procedures to ensure DC branch circuit protection devices remain deenergized during installation at loads, as required.

Battery

Warning

WARNING! Correct polarity must be observed when connecting battery leads.

Warning

WARNING! Special safety precautions are required for procedures involving handling, installing, and servicing batteries. Observe all battery safety precautions in this manual and in the battery instruction manual. These precautions should be followed implicitly at all times.

Spec. No: 582127000

Model No: 721

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[iv]

Code: IM582127000




Warning

Danger

WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of batteries should be performed or supervised only by properly trained and qualified personnel knowledgeable about batteries and the required precautions.

The following precautions should be observed when working on batteries:

• Remove watches, rings, and other metal objects.

• Eye protection should be worn to prevent injury from accidental electrical arcs.

• Use certified and well maintained insulated tools.

Use double insulated tools appropriately rated for the work to be performed. Ensure that wrenches with more than one working end have only one end exposed.

• Do not lay tools or metal parts on top of batteries.

• Disconnect charging source prior to connecting or disconnecting battery terminals.

• Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed. When replacing batteries, replace with the same manufacturer and type, or equivalent.

• Dispose of used batteries according to the instructions provided with the batteries. Do not dispose of batteries in a fire. They may explode.

• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S

RECOMMENDATIONS AND SAFETY INSTRUCTIONS.

In addition to the hazard of electric shock, gas produced by batteries can be explosive and sulfuric acid can cause severe burns. Do not open or mutilate batteries.

Released electrolyte is harmful to the skin and eyes, and is toxic. If electrolyte comes into contact with skin, the affected area should be washed immediately with large amounts of water.

DANGER! This equipment may be used in conjunction with lead-acid batteries. Working near lead-acid batteries is dangerous!

• Batteries contain sulfuric acid.

• Batteries generate explosive gases during normal operation. Systems containing batteries should never be installed in an airtight room or space.

Only install in a ventilated environment.

• Batteries are an energy source that can produce high amounts of electrical current.

Alert

FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE

THAT YOU READ THESE INSTRUCTIONS AND FOLLOW

THEM EXACTLY.

WHEN WORKING WITH LEAD-ACID BATTERIES:

• Wear complete protection for eyes, face, hands, and clothing. Examples are safety goggles or face shield, a rubber apron and gloves.

• If battery acid enters your eye, immediately flush your eye with running cold water for at least 15 minutes. Get medical attention immediately.

• If battery acid contacts skin or clothing, wash immediately with soap and water.

ALERT! Performing maintenance and/or troubleshooting procedures may interrupt power to the loads, if battery reserve is not sufficient.

Personal Protective Equipment (PPE)

Danger

DANGER! ARC FLASH AND SHOCK HAZARD.

Appropriate PPE and tools required when working on this equipment. An appropriate flash protection boundary analysis should be done determine the

“hazard/risk” category, and to select proper PPE.

This product is intended only for installation in a

Restricted Access Location.

Only authorized and properly trained personnel should be allowed to install, inspect, operate, or maintain the equipment.

Do not work on LIVE parts. If required to work or operate live parts, obtain appropriate Energized Work

Permits as required by the local authority, per NFPA 70E

“Standard for Electrical Safety in the Workplace”.

Hazardous Voltage

Danger

DANGER! Hazard of electrical shock. More than one disconnect may be required to de-energize the system before servicing.

Handling Equipment Containing

Static Sensitive Components

Alert

ALERT! Installation or removal of equipment containing static sensitive components requires careful handling.

Before handling any equipment containing static sensitive components, read and follow the instructions contained on the Static Warning Page.

Spec. No: 582127000

Model No: 721

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[v]

Code: IM582127000




Static Warning

This equipment contains static sensitive components. The warnings listed below must be observed to prevent damage to these components. Disregarding any of these warnings may result in personal injury or damage to the equipment.

1.

Strictly adhere to the procedures provided in this document.

2.

Before touching any equipment containing static sensitive components, discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm resistor. Some wrist straps, such as Emerson Network Power Part Number

631810600, have a built-in one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s instructions outlining use of a specific wrist strap.

3.

Do not touch traces or components on equipment containing static sensitive components.

Handle equipment containing static sensitive components only by the edges that do not have connector pads.

4.

After removing equipment containing static sensitive components, place the equipment only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil. Do not use ordinary Styrofoam ™ or ordinary plastic.

5.

Store and ship equipment containing static sensitive components only in static shielding containers.

6.

If necessary to repair equipment containing static sensitive components, wear an appropriately grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded test equipment.

Spec. No: 582127000

Model No: 721

NPBB

[vi]

Code: IM582127000




General Information

Customer Documentation Package

This document (IM582127000) provides Installation Instructions for

NetSure™ -48V DC Power System Model 721

NPBB

, Spec. No.

582127000.

The complete Customer Documentation Package consists of…

NetSure ™ -48V DC Power System Installation Manual

• NetSure ™ -48V DC Power System Quick Start Guide:

QS582127000

• NetSure ™ -48V DC Power System Installation Instructions:

IM582127000

NetSure

™

ACU+ Controller User Manual

• NetSure

™ ACU+ Controller User Instructions:

UM1M820BNA (AC Input Voltage Systems) or

UM1M820DNA400 (DC Input Voltage Systems)

NetSure ™ NCU Controller User Manual

• NCU Controller 2nd Ethernet Port Retrofit Kit

Instructions: IM559251

• Engineering Drawings

• Also provided on the USB drive is a controller configuration drawing and the controller configuration files loaded into the controller as shipped.

Installation Acceptance Checklist

Provided in this section is an Installation Acceptance Checklist.

This checklist helps ensure proper installation and initial operation of the system. As the procedures presented in this document are completed, check the appropriate box on this list. If the procedure is not required to be performed for your installation site, also check the box in this list to indicate that the procedure was read.

When installation is done, ensure that each block in this list has been checked. Some of these procedures may have been factory performed for you.

Note:

The system is not powered up until the end of this checklist.

Note:

Some of these procedures may have been performed at the factory for you.

Installing the System

• NetSure

™ NCU Controller User Instructions:

UM1M830BNA (AC Input Voltage Systems)

USB Drive with All Customer Documentation

• Power System Quick Start Guide: QS582127000

• Power System Installation Instructions: IM582127000

• Power System User Instructions: UM582127000

• ACU+ Controller User Instructions: UM1M820BNA

• NCU Controller User Instructions: UM1M830BNA

• ACU+ Controller User Instructions: UM1M820DNA400

• Power System “System Application Guide”:

SAG582127000

• Module Mounting Shelf Power Data Sheet: PD588705000

• Rectifier Instructions: UM1R483500E

• Converter Instructions: UM1C400483500E

• Module Mounting Shelf Power Data Sheet: PD588705300

• Rectifier Instructions: UM1R482000E3

• Converter Instructions: UM1C48241500

• NCU Controller 2nd Ethernet Port Add-On Kit

Instructions: IM559252



Relay Rack Secured to Floor



System Components Mounted in Relay Rack (if required)



Optional Lug Adapter Busbar Kits Installed



Circuit Breakers Installed



Fuses Installed

Setting Jumper and Switch Options











Jumpers on System Interface Circuit Card Set

Factory Switch Setting on IB2 Interface Board Verified

Factory Switch Setting on Optional EIB Interface Board

Verified

Factory Switch Setting on SM-DU Verified

Factory Switch Setting on Optional SM-DU+ Verified

Making Electrical Connections





Relay Rack Grounding Connection (Frame Ground) Made

Central Office Ground Connection Made



AC Input and AC Input Equipment Grounding

Connections Made or

DC Input and Equipment Grounding Connections Made

Spec. No: 582127000

Model No: 721

NPBB

[1]

Code: IM582127000






External Alarm, Reference, Monitoring, and Control

Connections Made



Ethernet Connection Made (if required)



Bay-to-Bay Cable Connections Made (as required)



Bay-to-Bay Busbars Installed (as required)



Bay-to-Bay Busbar Covers Installed (as required)



Converter Output Cables (if furnished) Connections to

+24VDC Distribution Made (as required)



Load Connections Made



Battery Connections Made a.

Batteries Installed and Connected in an optional

Battery Tray (if furnished) b.

Optional Battery Tray Front Battery Covers Installed

(if furnished) c.

Optional Battery Tray Circuit Breaker Guards

Installed (if furnished)

Installing the Modules and Initially Starting the System



Rectifier and Converter Modules Installed



System Started, Configured, and Checked

Installing the System

General Requirements

• This product is intended only for installation in a restricted access location on or above a non-combustible surface.

• This product must be located in a controlled environment with access to Crafts persons only.

• This product is intended for installation in network telecommunication facilities (CO, vault, hut, or other environmentally controlled electronic equipment enclosure).

• This product is intended for connection to the common bonding network in a network telecommunication facility

(CO, vault, hut, or other environmentally controlled electronic equipment enclosure).

• The DC return connection to this system can remain isolated from system frame and chassis (DC-I).

• This system is suitable for installation as part of the

Common Bonding Network (CBN).

• The installer should be familiar with the installation requirements and techniques to be used in securing the relay rack to the floor.

• Rectifier, converter, and mounting shelf ventilating openings must not be blocked and temperature of air entering rectifiers and converters must not exceed rated operating ambient temperature range found in

SAG582127000.

• Clearance requirements are: a.

Recommended minimum aisle space clearance for the front of each bay is 2' 6". b.

Recommended minimum aisle space clearance for the rear of each bay is 2’ 0” for any of the following conditions:

1.

Multiple bay arrangements that incorporate rear inter-bay busbars (List 2 and List 3 bays).

2.

Addition of a module mounting shelf in the field.

3.

Making input connections to a field installed module mounting shelf.

4.

Adding battery tray(s) in the field.

For all other conditions, required minimum spacing from the rear of the bay to a wall or other solid surface is that which is specified for proper module mounting shelf ventilation. Refer to the specific module mounting shelf

Power Data Sheet or System Application Guide for ventilation spacing requirements.

Note:

Minimum spacing specified for ventilation may not permit replacement of certain components such as busbars or module mounting shelves.

Securing the Relay Rack to the Floor

All equipment cabinets are factory mounted to the relay rack(s) or shipping brackets specified when ordered.

The system consists of one to three relay racks. For busbarconnected systems (List 1 with List 2/List 3), locate relay racks in a line adjacent to each other, with no space between them. Place the List 1 Main Bay at the right or left side end, then the List 2

Supplemental Bay, then the List 3 Supplemental Bay (if furnished).

Secure the relay rack to the floor per site requirements. Refer to

“General Requirements” on page 2.

Ventilation Requirements

Refer to the “General Requirements” on page 2.

Spec. No: 582127000

Model No: 721

NPBB

[2]

Code: IM582127000




Relay Rack Floor Mounting Dimensions

Refer to Figure 1 for relay rack floor mounting dimensions.

Figure 1. Relay Rack Floor Mounting Dimensions (cont’d on next page)

Spec. No: 582127000

Model No: 721

NPBB

Notes:

1. All dimensions are in inches.

[3]

Code: IM582127000




Figure 1.

Relay Rack Floor Mounting Dimensions (cont’d from previous page, cont’d on next page)

Spec. No: 582127000

Model No: 721

NPBB

Notes:


[4]

Code: IM582127000




Figure 1.

Relay Rack Floor Mounting Dimensions (cont’d from previous page)

Notes:


Mounting System Components in an Equipment Rack

Note:

If the power system was ordered in a relay rack, these procedures have been performed at the factory.

This power system is designed to mount in a standard 23” relay rack having 1” or 1-3/4” multiple drillings. Refer to System

Application Guide SAG582127000 for overall dimensions and a list of available relay racks.

Mounting the Distribution Cabinet with

Module Mounting Shelf(s)

Note:

The distribution cabinet is factory connected to the module mounting shelf(s). The distribution cabinet with module mounting shelf(s) is mounted as a complete assembly.

The distribution cabinet with module mounting shelf(s) must be the top-most component in the rack. Perform the following steps to mount the distribution cabinet with module mounting shelf(s).

Danger

Danger

DANGER! The relay rack must be securely anchored to the floor before the distribution cabinet with module mounting shelf(s) is installed.

DANGER! The distribution cabinet with module mounting shelf(s) is heavy. Use a hoist, battery lift, or other appropriate lifting device to raise and support the assembly during the installation. Take appropriate precautions to avoid injury.

PROCEDURE

1.

Remove the distribution cabinet with module mounting shelf(s) from its shipping brackets. Position the assembly in the equipment rack. Note that part of the Input

Termination Assembly will have to be temporarily removed from the distribution cabinet to access the mounting hardware.

Note:

Install the ground washers so the teeth dig into the paint on the mounting angles. Torque all screws to 65 in-lbs.

2.

Mount the distribution cabinet to the relay rack using the

following hardware. Refer to Figure 2 .

a.

1-Row Cabinet: Install (8) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (8) No.

12 ground washers (P/N 215640600). b.

2-Row Cabinet: Install (10) 12-24 x 3/4" hex head thread-forming screws (P/N 218710600) and (10)

No. 12 ground washers (P/N 215640600). c.


No. 12 ground washers (P/N 215640600). d.


No. 12 ground washers (P/N 215640600).

3.

Mount the module mounting shelf to the relay rack using

hardware as shown Figure 3

or Figure 4 .

Spec. No: 582127000

Model No: 721

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[5]

Code: IM582127000




Figure 2. Distribution Cabinet Mounting Hardware

Mounting Hardware,

4 Places per Side

Mounting Hardware,

5 Places per Side

1-ROW CABINET

MOUNTING HARDWARE

12-24 X 3/4" THREAD FORMING HEX HEAD SCREW

NO. 12 GROUND WASHER

Module Mounting Shelf not shown for clarity only.

2-ROW CABINET

Spec. No: 582127000

Model No: 721

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Mounting Hardware,

6 Places per Side

3-ROW CABINET

[6]

Mounting Hardware,

8 Places per Side

4-ROW CABINET

Code: IM582127000




Figure 3. Module Mounting Shelf Spec. No. 588705000 Mounting Hardware

Spec. No: 582127000

Model No: 721

NPBB

Front

[7]

Secure the module mounting shelf(s) to the relay rack.

MOUNTING HARDWARE

12-24 x 3/4" Thread Forming

Hex Head Screw

No. 10/12 Ground Washer

Code: IM582127000




Figure 4. Module Mounting Shelf Spec. No. 588705300 Mounting Hardware

Spec. No: 582127000

Model No: 721

NPBB

Front

[8]

Secure the module mounting shelf(s) to the relay rack.

MOUNTING HARDWARE

12-24 x 3/4" Thread Formi

ng

Hex Head Screw

No. 10/12 Ground Washer

Code: IM582127000




Installing a 582127000 List 93 Battery Tray

Perform the following procedures to install a 582127000 List 93 Battery Tray.

DANGER! The relay rack must be securely anchored to the floor before a battery tray is installed.

Danger

Installing a Battery Tray

PROCEDURE

1.

To install a 582127000 List 93 Battery Tray, perform the procedure in

Figure 5 .

Figure 5. Installing a 582127000 List 93 Battery Tray

1. Slide battery tray into relay rack and secure to relay rack with 12-24 x 3/4" thread forming hex head screws and

#10/12 ground washers (1 place per side) or #12 flat washers (3 places per side). (Torque to 70 in-lbs).

2. Secure rear angle brackets (both sides) to battery tray with 1/4-20 x 3/4” bolts,

1/4” flat washers, 1/4” lock washers, and

1/4” nuts. (Torque to 84 in-lbs).

3. Secure rear angle brackets (both sides) to relay rack with 12-24 x 3/4" thread forming hex head screws and #10/12 ground washers (1 place per bracket) or #12 flat washers (1 place per bracket).

(Torque to 70 in-lbs).

4. Secure cabling brackets (both sides) to relay rack with 12-24 x 1/2" thread forming hex head screws. (Torque to 70 in-lbs).

Cabling

Bracket

Rear

Angle

Bracket

Battery Tray

Rear Angle Bracket

Spec. No: 582127000

Model No: 721

NPBB

Front

[9]

Rear

Code: IM582127000




Installing Optional Battery Disconnect Circuit Breakers

PROCEDURE

1.

To install an optional battery disconnect circuit breaker onto the List 93 Battery Tray, perform the procedure in

Figure 6 .

2.

Battery tray wiring is shown in “Installing and Connecting Batteries in List 93 Battery Tray (if furnished)” on page 112.

Figure 6. Installing Optional Battery Disconnect Circuit Breakers onto a List 93 Battery Tray

Spec. No: 582127000

Model No: 721

NPBB

Battery Disconnect

Circuit Breaker Assembly

(left side kit shown, right side kit available)

1. Remove the cover from the battery disconnect circuit breaker assembly.

2. Secure the battery disconnect circuit breaker assembly to the battery tray using 6-32 x 1/2” screws and 6-32

KEPS nuts (2-places).

3. Secure the ground lead under a battery tray relay rack mounting bolt.

4. After wiring to the battery disconnect circuit breaker, replace the cover.

[10]

Code: IM582127000




Installing Optional Front Battery Cover

PROCEDURE

1.

To install an optional front battery cover onto a List 93 Battery Tray, perform the procedure in

Figure 7 . Note that batteries

must be installed first, as described in “Installing and Connecting Batteries in List 93 Battery Tray (if furnished)” on page 112.

Figure 7. Installing Optional Front Battery Cover onto a List 93 Battery Tray

Use existing battery spacers.

Use kit supplied hardware.

Existing front battery bracket.

Kit supplied spacer bar.

Kit supplied cover.

Procedure

1. Install batteries.

2. Install kit battery cover to existing front battery bracket.

3. Install kit battery cover with existing front battery bracket to battery shelf.

Spec. No: 582127000

Model No: 721

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Assembled View

Kit Battery Cover

Assembled to Existing

Front Battery Bracket

Front View

Kit Battery Cover

Assembled to Existing

Front Battery Bracket

Rear View

[11]

Code: IM582127000




Installing Optional Circuit Breaker Guard

PROCEDURE

1.

To install an optional circuit breaker guard onto a battery disconnect circuit breaker, perform the procedure in

Figure 8 .

Figure 8. Installing Optional Circuit Breaker Guard

1. Remove this bracket.

2. Replace this hardware after removing existing bracket.

3. Install Circuit Breaker

Guard Bracket using existing hardware.

Installed View

Spec. No: 582127000

Model No: 721

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[12]

Code: IM582127000




Installing Optional Battery Busbar Extension Kit, Part No. 554541

This kit provides plates that extend the system busbars above the top of the distribution cabinet and increases the number of lug landings available for battery cables. This kit provides back-to-back landings for up to six lugs per polarity.

Installing Part No. 554541 Busbar Extension Kit

This kit consists of the following:

Qty. Part No. Description

2 554540 Busbar extension plates, flat

12 214204100 Flat washer, 3/8” x 1” O.D.

12 214825000 Belleville washer, 3/8”

12 227646800 Hex head bolt, 3/8-16 x 1-1/4”

Perform the following steps to install the battery busbar extension plates.

PROCEDURE

Refer to Figure 9 as the procedure is performed.

1.

Open the distribution cabinet front door.

2.

Install busbar extension plates as shown in

Figure 9 . Apply anti-oxidizing compound to busbar mating surfaces before assembling. Tighten bolts to the recommended torque value shown in Figure 9 .

Note:

Note that the busbars are notched. Some installations require the busbar to be rotate so the notch portion clears any protrusion present.

Note:

Install the Belleville lock washers so the concave side is towards the busbar.

3.

Close the distribution cabinet access door.

Spec. No: 582127000

Model No: 721

NPBB

[13]

Code: IM582127000




Figure 9. Installing Battery Busbar Extension Kit, Part No. 554541

1. Apply anti-oxidizing compound to busbar mating surfaces.

2. Install hardware,

6 places per busbar.

Assembly Order:

3/8-16 X 1-1/4” Bolt

3/8” Belleville Washer

3/8” Flat Washer

Extension Plate

System Busbar

3. Torque to 180 in-lbs.

Central

Office

Ground

GND RTN

Battery

(Return Side)

Busbar

-48V SUPPLY

(One Row Cabinet

Shown, Others Similar)

Battery

(Load Side)

Busbar

Spec. No: 582127000

Model No: 721

NPBB

Front View

[14]

Code: IM582127000




Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and 514714

These kits provide lug adapter busbars plus hardware for use with 2-pole and 3-pole circuit breakers.

Contents of Kit P/N 534449 (for 2-pole circuit breakers)


1 534447

1 534448

Busbar

Busbar

8 214110100 Flat Washer, 1/4”

4 214112100 Flat Washer, 3/8”

8 215111100 Lock Washer, 1/4”

4 215111300 Lock Washer, 3/8”

4 227640400 Hex Head Bolt, 1/4-20 x 3/4”

(not used)

2 227646600 Hex Head Bolt, 3/8-16 x 1”

8 228557100 Nut, 1/4-20

2 228567100 Nut, 3/8-16

Contents of Kit P/N 514714 (for 3-pole circuit breakers)


1 514676

1 514678

Busbar

Busbar

12 214110100 Flat Washer, 1/4”

4 214112100 Flat Washer, 3/8”

12 215111100 Lock Washer, 1/4”

4 215111300 Lock Washer, 3/8”

6 227640400 Hex Head Bolt, 1/4-20 x 3/4”

(not used)

2 227646600 Hex Head Bolt, 3/8-16 x 1”

12 228557100 Nut, 1/4-20

2 228567100 Nut, 3/8-16

Perform the following steps to install the lug adapter busbars.

PROCEDURE

Refer to Figure 10 as the procedure is performed. Note also the restrictions on location in Figure 10 .

1.

Open the distribution cabinet’s front door by turning the latch in the counterclockwise position.

2.

Install the lug adapter busbars as shown in

Figure 10 . Apply anti-oxidizing compound to busbar mating surfaces before

assembling. Recommended torque is 72 in-lbs using the supplied 1/4” bolts and hardware.

3.

Orient the load lug hardware as shown in

Figure 10 . Recommended torque is 300 in-lbs using the supplied 3/8” bolts and

hardware.

4.

Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door.

Spec. No: 582127000

Model No: 721

NPBB

[15]

Code: IM582127000




Figure 10. Installing Lug Adapter Busbar Kits

Busbar Adapter

Kit P/N 534449

Busbar Adapter

Kit P/N 514714

Busbar Adapter

Kit P/N 534449

Spec. No: 582127000

Model No: 721

NPBB

Notes:

Orient busbars as shown.

Shield not shown. Remove breakaway areas from shield as required.

Breakaways are only provided for positions

1-8, 9-12, and 23-24. This restricts 2 and 3-pole breaker adapter kits to be located in these positions only.

Circuit breaker locations for reference only.

[16]

Code: IM582127000




Installing Circuit Breakers and Fuses

Circuit breakers and/or fuses may have been factory installed for you. If so, verify their positions and sizes.

Installing Bullet Nose Type Fuseholders and TPS/TLS Fuses

CAUTION! A circuit breaker or fuse with a rating of 100A or greater SHALL HAVE an empty mounting position between it and any other overcurrent protective device.

Caution

Refer to the following procedure and install bullet nose type fuseholders and appropriately sized TPS/TLS fuses into the proper mounting positions in the distribution cabinet.

PROCEDURE

Note:

Refer to Figure 11 as this procedure is performed.

1.


2.

Orient the fuseholder as shown in Figure 11 . Insert the terminals on the rear of the fuseholder into their corresponding sockets

on the distribution panel. Ensure the alarm contact on the back of the fuseholder makes contact with the alarm terminal on the spring strip. Push fuseholder in firmly until fully seated in the distribution panel.

3.

When all fuseholders are installed, install an appropriately sized TPS/TLS fuse in each. To do this, remove the fuse carrier from the mounted fuseholder body. Hold the fuseholder body while you pull the fuse carrier from the body. Slide the fuse in place between the contacts of the fuse carrier. When done, push the fuse carrier back into the fuseholder body. Note that a polarizing key on the bottom of the carrier prevents the carrier from being inserted upside down.

4.

Verify that an 18/100 ampere alarm fuse is present in each fuseholder and that a plastic safety cover is installed on this fuse.

5.

Record all fuse sizes on the label provided on the shield.

6.

Close the distribution cabinet's front door. Turn the latch clockwise to secure the door.

Figure 11. Installing a Bullet Nose Type Fuseholder and TPS/TLS Fuse

Shorter Side to the Top

Insert these terminals into corresponding sockets on distribution panel.

GMT-X

Safety Fuse Cover

(Replacement

P/N 248898700)

Fuse Carrier

TPS/TLS Fuse

Fuseholder Body

Longer Side to the Bottom

Fuseholder Assembly

Fuseholder Assembly

Exploded View

Spec. No: 582127000

Model No: 721

NPBB

GMT-18/100A

Alarm Fuse

(Replacement

P/N 248610301)

Polarizing Keyway

Matches Key on

Bottom of Fuse Carrier

Fuseholder Assembly (P/N 117201) includes body & carrier, alarm fuse, and alarm fuse safety cover.

[17]

Code: IM582127000




Installing Bullet Nose Type Circuit Breakers

CAUTION! A circuit breaker or fuse with a rating of 100A or greater SHALL HAVE an empty mounting position between it and any other overcurrent protective device.

Caution

Refer to the following procedure and install appropriately sized bullet nose type circuit breakers into the proper mounting positions in the distribution cabinet.

PROCEDURE

Note:


1.


2.

Ensure that the circuit breaker is in the OFF position and is of the correct rating. Orient the circuit breaker as shown in Figure 12 .

Insert the terminals on the rear of the circuit breaker into their corresponding sockets on the distribution panel. Ensure the alarm contact on the back of the circuit breaker makes contact with the alarm terminal on the spring strip. Push distribution device in firmly until fully seated in the distribution panel.

3.

Record all circuit breaker sizes on the label provided on the shield.

4.


Figure 12. Installing a Bullet Nose Type Circuit Breaker

Shorter Side to the Top

Lettering on handle must be right side up.

Turn off before installing.

Insert these terminals into corresponding sockets on distribution panel.

Longer Side to the Bottom

Spec. No: 582127000

Model No: 721

NPBB

[18]

Code: IM582127000




Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block

Note:


Note:

Can only be installed in the 1-2, 3-4, 17-18, 19-20, 21-22, and 23-24 positions of the distribution panel.

PROCEDURE

1.


2.

Follow the steps in

Figure 13 .

3.

Install an appropriately sized GMT fuse in each fuse mounting position on the GMT Distribution Fuse Block as required. If dummy fuses are installed, first remove the dummy fuse. a.

Verify that dummy fuses are installed in all unused fuse positions on the GMT distribution fuse block. b.

Verify that a plastic safety cover is installed on all GMT fuses on the GMT distribution fuse block.

4.

Record all fuse sizes (installed on the GMT distribution fuse block) on the label provided on the shield.

5.


Spec. No: 582127000

Model No: 721

NPBB

[19]

Code: IM582127000




Figure 13. Installing an Optional Bullet Nose Type 6-Position GMT Distribution Fuse Block

1.

Press in tabs to release lug terminal busbars for positions to be occupied by GMT Fuse Block.

Spec. No: 582127000

Model No: 721

NPBB

2.

Remove two lug terminal busbars for positions to be occupied by GMT Fuse Block.

RTN Bar

3.

Plug in GMT Fuse Block and secure at two locations on the RTN bar.

Torque to 72 in-lbs.

[20]

GMT Fuse Block Installed View

Code: IM582127000




Installing TPH Fuses

Refer to the following procedure and install appropriately sized TPH fuses into the proper fuseholders in the distribution cabinet.

PROCEDURE

Note:


1.


2.

Remove the TPH fuse carrier from the mounted fuseholder body by grasping its handle and firmly pulling it straight out. Install the TPH fuse into the fuse carrier. When done, push the fuse carrier securely back into the mounted fuseholder body.

3.

Verify that a 1/4 ampere alarm fuse is installed in the GMT-type fuseholder located adjacent to the TPH fuseholder and that a plastic safety cover is install on this fuse.

4.

Record all fuse sizes on the cards provided within the fuseholders.

5.


Figure 14. Installing a TPH Fuse

Spec. No: 582127000

Model No: 721

NPBB

[21]

Code: IM582127000




Installing TPL-B Fuses

Refer to the following procedure and install appropriately sized TPL-B fuses into the proper fuseholders in the distribution cabinet.

PROCEDURE

Note:


1.


2.

Remove the fuse case from the mounted fuse block by grasping its handle and pulling it straight out.

3.

Verify that an 18/100 ampere alarm fuse is present in the GMT-type fuseholder located on the fuse block and that a plastic safety cover is installed on this fuse.

4.

Open the fuse case.

5.

Install the TPL fuse into the fuse case.

6.

Close the fuse case.

7.

Firmly plug the fuse and fuse case into the fuse block.

8.

Record all fuse sizes on the cards provided within the fuseholders.

9.


Figure 15. Installing TPL-B Fuses

GMT-18/100A Alarm Fuse

(P/N 248610301) and

GMT-X Safety Fuse Cover

(P/N 248898700)

(Both are provided w/ fuseblock)

Fuse Installed in

Open Fuse Case

(rear view)

Fuseblock

(P/N 516241)

Fuse Case

TPL Fuse

Fuse Installed in

Closed Fuse Case

(rear view)

Open Fuse Case View

Spec. No: 582127000

Model No: 721

NPBB

[22]

Code: IM582127000




Installing GJ/218 Circuit Breakers

Refer to the following procedure and install appropriately sized GJ/218 circuit breakers into the proper mounting positions in the distribution cabinet.

PROCEDURE

Note:


1.

Locate the appropriate circuit breaker mounting kit ordered with the circuit breaker. The circuit breaker mounting kit contains installation hardware, an alarm jumper, a shunt jumper (if applicable), a busbar (for 2-pole, 3-pole, and 4-pole circuit breakers), and a circuit breaker guard. Refer to SAG582127000 for part numbers of the circuit breaker mounting kits.

2.


3.

Ensure that the circuit breaker is in the OFF position, and is of the correct rating and type (electrical trip/mechanical trip or electrical trip only). Apply anti-oxidizing compound to busbar mating surfaces on the distribution panel and the circuit breaker.

Orient the circuit breaker over its mounting location. a.

Attach the alarm jumper connectors to the back of the circuit breaker, then plug the other end of the alarm jumper into its

corresponding connector. Wiring diagrams are provided in Figure 16 and at the end of this procedure.

b.

Shunted Breakers Only: Attach the shunt jumper connectors to the back of the circuit breaker, then route the jumper

through the hole in the distribution panel. Wiring diagrams are provided in Figure 16 ,

Figure 17

, and Figure 18 .

DANGER! The bolts being installed in the following step may be at system potential. Use insulated tools.

Danger

4.

Install the circuit breaker into its mounting position and secure with the provided hardware. Torque to 60 in-lbs.

5.

Install the circuit breaker guard and label (refer to

Figure 16 ).

6.

2-Pole, 3-Pole, and 4- Pole Circuit Breakers Only: Install the mounting kit supplied busbar as shown in

Figure 16 . Torque to 180

in-lbs.

7.

Shunted Breakers Only: Route and connect shunt leads to the SM-DU+ and Shunt Interface Assembly.

Note:

Refer to “Optional SM-DU+ and Shunt Interface Board” on page 74 for proper wiring procedure. Leads must be terminated

before switching breaker ON to avoid circuit fault.

8.

Record all circuit breaker sizes on the label provided on the shield.

9.


Spec. No: 582127000

Model No: 721

NPBB

[23]

Code: IM582127000




Figure 16. Installing a GJ/218 Circuit Breaker (1-Pole) (cont’d on next page)

Spec. No: 582127000

Model No: 721

NPBB

[24]

Code: IM582127000




Figure 16.

Installing a GJ/218 Circuit Breaker (2-Pole, 3-Pole, 4-Pole) (cont’d from previous page)

Spec. No: 582127000

Model No: 721

NPBB

[25]

Code: IM582127000




Figure 17. GJ/218 Circuit Breaker Wiring Diagram (List AC and AD)

Spec. No: 582127000

Model No: 721

NPBB

[26]

Code: IM582127000




Figure 18. GJ/218 Circuit Breaker Wiring Diagram (List BC and BD)

Spec. No: 582127000

Model No: 721

NPBB

[27]

Code: IM582127000




Setting Jumpers and Switch Options

Circuit Card Locations

Refer to Figure 19.

Figure 19. Circuit Card Locations

4-Row Cabinet Shown,

Others Similar

(Front Door Removed in

Illustration for Clarity)

IB2 (Main Bay Only)

(Interface Board)

(located on inside side panel)

Optional EIB (Main Bay Only)

(Extended Interface Board)


Optional SM-DU+ and

Shunt Interface Board

Controller

(Main Bay)

SM-DU

(Supplemental Bays)

Mounting Position

Optional LVD

Inhibit Switch

(factory installed if option specified)

Optional LVD

Driver Circuit Card

OR

Optional LVD Driver

Lite Circuit Card

Spec. No: 582127000

Model No: 721

NPBB

Optional Manual Battery

Disconnect Circuit Card

(Main Bay Only)

System Interface

Circuit Card

[28]

Code: IM582127000




Jumpers on System Interface Circuit Card (Main Bay Only)

Perform the following procedures to verify the factory settings and/or make the required settings per your site requirements. These procedures can also be used to make adjustments on a replacement circuit card.

Controller Power Option

The controller is always powered from the internal “system” bus. A jumper option allows the controller to be also powered by battery.

Battery power allows the controller to stay running in the event rectifiers are off or battery LVD opens (if installed). Note that if powering the controller from battery, the battery will drain if rectifiers are off or battery LVD opens (if installed). The controller’s power consumption is 5W.

PROCEDURE

1.

Refer to

Figure 20 and place the jumper on J8 in the “Battery Pwr” or “No Battery Pwr” position.

Internal/External Battery Monitoring

Selects to monitor (and display via the controller) battery voltage from either an “internal” or “external” source.

PROCEDURE

1.

Refer to

Figure 20 and place the jumper on J10 in the “Internal” or “External” position. If “External” is selected, connect sense leads to TB1-4 and TB1-5 (see Figure 20 ).

Figure 20. System Interface Circuit Card Jumper Locations

Spec. No: 582127000

Model No: 721

NPBB

1B 2B 3B

TB2

1A 2A 3A

J1

J2

J3

J4

J8

J10

1

TB1

5

TP1 TP2 TP3 TP4

J5

J8 (Main Bay Only)

Selects to power Controller from “Battery Power” or not.

No

Battery

Pwr

Battery

Pwr

1

2

3

7

8

9

Shorting Jumper

J8

J10 (Main Bay Only)

Battery Monitoring External / Internal

(see TB1-4 and TB1-5 for external monitoring points)

External Internal

Shorting Jumper

1

2

3

J10

7

8

9

TB1-2, TB1-3, TB1-4, TB1-5 Main Bay Only.

TB1-4: External Battery Monitoring (-)

TB1-5: External Battery Monitoring (+)

[29]

Code: IM582127000




Switch Settings on IB2 Interface Board (Main Bay Only)

Dip Switch SW1 on the IB2 board is used to set the communications address for this board. Refer to Table 1 for SW1 settings. Refer to

Figure 21 for SW1 location.

Perform the following procedure to verify the factory settings. This procedure can also be used to make adjustments on a replacement circuit card.

PROCEDURE

1.

Ensure SW1 is set per

Table 1

. Refer to Figure 21 for location.

Table 1. IB2 Interface Board Switch Settings

DIP Switch SW1

Setting

1 2

IB2 in Main Bay OFF OFF

Switch Setting on Optional EIB Interface Board (Main Bay Only)

Dip Switch SW1 on the EIB board is used to set the communications address for this board. Refer to Table 2 for SW1 settings. Refer to

Figure 22 for SW1 location.


PROCEDURE

1.

Ensure SW1 is set per

Table 2


Table 2. Optional EIB Interface Board Switch Settings

Setting

EIB in Main Bay

DIP Switch SW1

1

ON

2

OFF

Spec. No: 582127000

Model No: 721

NPBB

[30]

Code: IM582127000




Figure 21. IB2 Interface Board Switch Location and Settings (installed in Main Bay only)

IB2 Interface Board

(Top View)

Spec. No: 582127000

Model No: 721

NPBB

Switch SW1 is located in this corner of the IB2 Board.

1 2

SW1

In this system, switch settings must be in positions shown.

ON

Setting

IB2 in Main Bay

OFF

1 2

SW1

DIP Switch SW1

1

OFF

2

OFF

[31]

Code: IM582127000




Figure 22. Optional EIB Interface Board Switch Location and Settings (installed in Main Bay only)

Switch SW1 is located in this corner of the EIB Board.

Spec. No: 582127000

Model No: 721

NPBB

Setting

EIB in Main Bay

SW1

In this system, switch settings must be in positions shown.

OFF

ON

2 1

SW1

DIP Switch SW1

2

OFF

1

ON

Optional EIB Interface Board

(Top View)

2 1

SW1

[32]

Code: IM582127000




Switch Setting on SM-DU (Supplemental Bays Only)

SM-DU uses three (3) 8-bit switches for parameter setting (S1, S2, and S3). Refer to Table 3

for switch settings. Refer to Figure 23 for

switch locations.


PROCEDURE

1.

Ensure S1, S2, and S3 are set per

Table 3


Figure 23 . SM-DU Switch Location

Spec. No: 582127000

Model No: 721

NPBB

[33]

Code: IM582127000




Table 3. SM-DU Switch Settings (cont’d on next page)

DIP Switch S1

Communication

Address

1 2 3

OFF OFF OFF

OFF OFF ON

OFF ON OFF

OFF ON ON

ON OFF OFF

ON OFF ON

ON ON OFF

ON ON ON

Voltage

4

Shunt

5 6

NA

Shunt

Current

7

NA

OFF OFF

OFF ON

ON OFF

ON ON

NA

NA

8

OFF OFF OFF

OFF OFF ON

OFF ON OFF

OFF ON ON

ON OFF OFF

ON OFF ON

ON ON OFF

ON ON ON

Note 1: Setting for this system.

Description of Status

Address 8#

Address 1# (Setting for SM-DU in 1st Supp. Bay)

Address 2# (Setting for SM-DU in 2nd Supp. Bay)

Address 3#

Address 4#

Address 5#

Address 6#

Address 7#

Shunt Voltage: 75mV

Shunt Voltage: 25mV (Note 1)

Shunt Voltage: 50mV

Shunt Voltage: 60mV

Shunt Current: 500A (Note 1)

Shunt Current: 100A

Shunt Current: 200A

Shunt Current: 300A

Shunt Current: 400A

Shunt Current: 1000A



Spec. No: 582127000

Model No: 721

NPBB

[34]

Code: IM582127000




Table 3.

SM-DU Switch Settings (cont’d from previous page, cont’d on next page)

DIP Switch S2

Shunt 1

Setting

1 2

OFF OFF

OFF ON

ON OFF

ON ON

NA

NA

Shunt 2

Setting

3

OFF

OFF

ON

ON

NA

4

OFF

ON

OFF

ON

Shunt 3

Setting

5

OFF

ON

NA

6

OFF

OFF ON

ON OFF

ON

NA

Shunt 4

Setting

7

OFF

OFF

ON

ON

NA

8

OFF

ON

OFF

ON

Shunt 1 is Disabled


Shunt 1 is Used for Battery

Shunt 1 is Used for Load (Note 1)

Set via Software

Shunt 2 is Disabled

Shunt 2 is Used for Battery (Note 1)

Shunt 2 is Used for Load

Set via Software

Shunt 3 is Disabled (Note 1)



Set via Software




Set via Software


Spec. No: 582127000

Model No: 721

NPBB

[35]

Code: IM582127000




Table 3.

SM-DU Switch Settings (cont’d from previous page)

DIP Switch S3

Set via Software Contactor Type

1 2

Off

On

Safe Mode

3

NA

NA

Off

On

NA

Dry Contact

4

Off

NA NA

On

NA

On

Off

DIP Switch S3

Shunt 5 Setting

5

Off

Off

On

On

6

Off

On

Off

On

Reserved

7

NA

Calibration

Mode

8

NA

Off

On



Shunt parameter is set through DIP switch.

Shunt parameter is set via software. (Note 1)

Bi-Stable Contactor (Note 1)

Mono-Stable Contactor

LVD / reconnection is disabled upon communication failure.

LVD / reconnection is enabled upon communication failure. (Note 1)

LVD2 is a Dry Contact

LVD2 (Note 1)





Set via Software

Operation Mode (Note 1)

Calibration Mode

Spec. No: 582127000

Model No: 721

NPBB

[36]

Code: IM582127000




Switch Setting on SM-DU+

SM-DU+ uses two (2) 8-bit switches for parameter setting (SW1 and SW2). Refer to

Table 4

for SW1 and SW2 settings. Refer to

Figure 24

for SW1 and SW2 locations.


PROCEDURE

1.

Ensure SW1 and SW2 are set per

Table 4

. Refer to

Figure 24

for location.

Figure 24. Optional SM-DU+ Switch Location and Settings

Switches SW1 and SW2 are located in this corner of the SM-DU+.

Set each SM-DU+ in the system to a unique address.

SM-DU+ and


Spec. No: 582127000

Model No: 721

NPBB

SW1 and SW2

In this system, switch settings must be in the positions shown, except adressing switches, which must be set to a uniqe address.

SM-DU+

[37]

Code: IM582127000




Table 4. Optional SM-DU+ Switch Settings

DIP Switch SW1

Reserved

1 2

HW/

SW

3

NA

OFF

ON

4

Shunt

Voltage

5 6

NA

Shunt

Current

7

NA

OFF OFF

OFF ON

ON OFF

ON ON

NA

NA

OFF OFF

OFF OFF

OFF ON

OFF

ON

ON

ON

ON

ON

OFF

OFF

ON

ON

DIP Switch SW2

1

Reserved

2

NA

3 4

Communications

Address

5 6 7

OFF OFF OFF

OFF OFF ON

OFF ON

OFF ON

OFF

ON

ON OFF OFF

ON OFF

ON ON

ON ON

ON

OFF

ON

8

Baud

Rate

8

NA

OFF

ON

OFF

ON

OFF

ON

OFF

ON

NA

OFF

ON



Shunt parameter is set through DIP switch.

Shunt parameter is set through software (note 1).

Shunt Voltage: 25mV (note 1)

Shunt Voltage: 50mV

Shunt Voltage: 60mV

Shunt Voltage: 75mV

Shunt Current: 500A (note 1)

Shunt Current: 100A

Shunt Current: 200A

Shunt Current: 300A

Shunt Current: 400A





Address 1# (Setting for SM-DU+ in Main Bay)

Address 2# (Setting for SM-DU+ in 1st Supp. Bay)

Address 3# (Setting for SM-DU+ in 2nd Supp. Bay)

Address 4#

Address 5#

Address 6#

Address 7#

Address 8#

19200 (note 1)

9600

Spec. No: 582127000

Model No: 721

NPBB

[38]

Code: IM582127000




Making Electrical Connections

Important Safety Instructions

Danger

DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.

Wiring Considerations

All wiring and branch circuit protection should follow the current edition of the American National Standards Institute (ANSI) approved National Fire Protection Association's (NFPA) National

Electrical Code (NEC), and applicable local codes. For operation in countries where the NEC is not recognized, follow applicable codes.

For wire size, branch circuit protection, crimp lug, and general wiring recommendations; refer to System Application Guide

SAG582127000 and Power Data Sheet PD588705000 or

PD588705300.

Refer to drawing 031110100 for lug crimping information. Refer to drawings 031110200 and 031110300 for additional lug information.

Refer to Table 5 for supplemental lug crimping information when

using the special application crimp lug / strap combination.

Table 5. Supplemental Lug Crimping Information when using the

Special Application Crimp Lug / Strap Combination

Crimp Tool Required

Hydraulic Heads

1 ,

T&B Model TBM12 or TBM15

Crimp Lug Part No.

Color

Key

Die

Index/

Code

No.

Die Cat.

Number

245393500

245393600

245393700

245393800

Burndy:

YA25L-4TCG1

Burndy:

YA26L-4TCG1

Burndy:

YA27L-4TCG1

Burndy:

YA28L-4TCG1

Pink

Black

Orange

Purple

42H

45

50

54H

15508

15526

15530

15511

514872

514873

T & B:

256-30695-1879

Burndy:

YA29L-4TCG1

T & B:

256-30695-1880

Burndy:

YA31L-4TCG1

Yellow

Red

62

71

15510

15514

1 The lugs should be crimped to the specifications given in the manufacturer’s instructions furnished with the crimp tool or lug.

Spec. No: 582127000

Model No: 721

NPBB

[39]

Code: IM582127000




Relay Rack Grounding Connection (Frame Ground)

For relay rack grounding requirements, refer to the current edition of the American National Standards Institute (ANSI) approved

National Fire Protection Association's (NFPA) National Electrical

Code (NEC), applicable local codes, and your specific site requirements.

A customer's grounding network lead can be attached to the top of the relay rack. Provision is made for installing a lead with a twohole lug that has 1/4" bolt clearance holes on 5/8" centers. When using 1/4-inch hardware, recommended torque is 84 in-lbs when a

standard flat washer and lock washer are used. Refer to Figure 25

for locations.

Note:

REMOVE TAPE FROM HOLE LOCATIONS BEFORE INSTALLING

LUG.

Note:

The DC return connection to this system can remain isolated from system frame and chassis (DC-I).

Note:

This system is suitable for installation as part of the Common

Bonding Network (CBN).

Central Office Ground Connection

Landing points are provided on the battery return bus for a central

office ground lead (see Figure 52

and Figure 55 ). For central office

grounding requirements, refer to the current edition of the

American National Standards Institute (ANSI) approved National

Fire Protection Association's (NFPA) National Electrical Code (NEC), applicable local codes, and your specific site requirements.

Figure 25. Relay Rack Frame Grounding Connection Points

Frame Ground

Connection Point

(1/4” clearance holes on 5/8” centers)

Top View

(Typical Relay Rack)

Frame Ground

Connection Point

(1/4” clearance holes on 5/8” centers)

Top View

(Typical Relay Rack)

Spec. No: 582127000

Model No: 721

NPBB

[40]

Code: IM582127000




Nominal 208/240 Volts AC Input and Equipment

Grounding Connections (if equipped)

Danger


General

NOTE THAT THIS SYSTEM MAY BE EQUIPPED WITH AC OR DC

INPUTS. THESE PROCEDURES APPLY TO SYSTEMS WITH AC

INPUTS. SPECIFICALLY, THESE PROCEDURES APPLY TO THE

FOLLOWING EQUIPMENT:

• 582127000 List 40, 41, 42

• 588705000 List 22

• 588705000 List 31

• 588705000 List 32

• 588705300 List 3

Wiring Considerations



PD588705300.

AC Input Termination Assemblies

The available AC input options for this system are:

• The system can be equipped with an AC input termination assembly which provides a separate single phase AC input connection for each rectifier position

(582127000 List 40).

• The system can be equipped with an AC input termination assembly which provides a separate single phase AC input connection for every two (2) rectifier positions (582127000 List 41).

• The system can be equipped with an AC input termination assembly which provides a separate three phase AC input connection for every three (3) rectifier positions (582127000 List 42).

Direct AC Input Connections to the Module Mounting Shelves

• The system can be equipped with module mounting shelves that contain AC input terminal blocks which provide a separate single phase AC input connection for each rectifier position (588705000 List 31).

• The system can be equipped with module mounting shelves that contain AC input terminal blocks which provide a separate three phase AC input connection for every three (3) rectifier positions (588705000 List 32).

• The system can be equipped with module mounting shelves that contain AC input line cords (one for each rectifier module position) (588705000 List 22).

• The system can be equipped with module mounting shelves that contain AC input cable assemblies which provide a separate single phase AC input connection for every two (2) rectifier positions (588705300 List 3).

Connections to AC Input Termination Assemblies (582127000

List 40, 41, and 42)

The AC input termination assemblies provide circular openings at the top for AC input and grounding conductors. The openings accept 1 inch conduit fittings. It is recommended that AC input wiring be provided to all rectifier mounting positions, including currently unused positions. This wiring will ease future installation of rectifiers to meet increased load requirements.

Note:

A grounding conductor must be provided with each conduit.

PROCEDURE

Refer to Figure 26 ,

Figure 27

, or Figure 28 as these procedures are

performed.

Accessing Connections and Routing Wire

1.

Remove the two AC input connector covers and the AC input wireway covers by first loosening the fasteners that secure each of them.

2.

Install conduit fittings as required in the top of the AC

Input Termination Assembly. Plug buttons are provided, and must be installed in the openings not being used.

3.

Route wiring into the AC Input Termination Assembly through the previously installed conduit fittings.

Making AC Input Connections

1.

Make AC input connections as shown in

Figure 26 ,

Figure

27

, or Figure 28 . Connect each wire by inserting the

stripped end into the wire opening, and then tightening the screw. Torque connections to value shown in the appropriate illustration.

Note:

Terminal blocks for a system with maximum possible rectifier shelves shown. Your system may have less terminal blocks then shown.

Making Equipment Grounding Connections

Note:

Make equipment grounding connections to earth ground,

not

to the branch circuit neutral conductor.

Spec. No: 582127000

Model No: 721

NPBB

[41]

Code: IM582127000




1.

Connect equipment grounding leads to the frame ground studs using installer-provided ring lugs and factory-supplied mounting hardware. Torque connections to value shown in the appropriate illustration.

Reinstalling Covers

1.

After all AC input and equipment grounding connections have been made and checked, reinstall the two AC input connector covers and the AC input wireway covers.

Secure each by tightening the fasteners.

Spec. No: 582127000

Model No: 721

NPBB

[42]

Code: IM582127000




Figure 26. Nominal 208/240 Volts AC Input and Equipment Grounding Connections to AC Input Termination Assembly 582127000 List 40

(1 Feed per 1 Rectifier, Single Phase)

AC INPUT CONNECTIONS,

1 FEED PER 1 RECTIFIER, SINGLE PHASE

(582127000 LIST 40)

NOTE:

WIRING TO A FIELD INSTALLED

SHELF IS DONE AT THE REAR

OF THE SHELF.

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #1

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #2

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #3

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #4

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #5

(4-Row Cabinet Shown,

Others Similar)

Front Door Removed in

Illustration for Clarity

AC Wireway

Cover

AC Input

Connector Cover

AC Wireway

Cover

Rectifier Module (PCU) Mounting Slots

GND

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

Inside View

GND

RECTIFIER (PCU) AC INPUT FEEDS

1 FEED PER 1 RECTIFIER (PCU)

208-240VAC, 50/60Hz, SINGLE PHASE

Left Side

PCU 1

AC 1 AC 2

SHELF 1

PCU 2

AC 1 AC 2

PCU 3

AC 1 AC 2

Inside View

Right Side

Line to Line:

Connect Line 1 to Terminal 1.


GND

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

GND




PCU 4

AC 1 AC 2

SHELF 1

PCU 5

AC 1 AC 2

PCU 6

AC 1 AC 2

Line to Neutral

Connect Line to Terminal 1.

Connect Neutral to Terminal 2.

PCU 1

AC 1 AC 2

SHELF 3

PCU 2

AC 1 AC 2




PCU 3

AC 1 AC 2

PCU 1

AC 1 AC 2

Wire Size Capacity: 10-24 AWG.

Recommended Torque: 10 in-lbs.

SHELF 2

PCU 2

AC 1 AC 2

PCU 3

AC 1 AC 2

PCU 4

AC 1 AC 2

SHELF 2

PCU 5

AC 1 AC 2




PCU 6

AC 1 AC 2

PCU 4

AC 1 AC 2

SHELF 3

PCU 5

AC 1 AC 2

PCU 6

AC 1 AC 2

Spec. No: 582127000

Model No: 721

NPBB

PCU 1

AC 1 AC 2

SHELF 5

PCU 2

AC 1 AC 2




PCU 3

AC 1 AC 2

PCU 1

AC 1 AC 2

SHELF 4

PCU 2

AC 1 AC 2

PCU 3

AC 1 AC 2

PCU 4

AC 1 AC 2

SHELF 4

PCU 5

AC 1 AC 2




PCU 6

AC 1 AC 2

PCU 4

AC 1 AC 2

SHELF 5

PCU 5

AC 1 AC 2

PCU 6

AC 1 AC 2

[43]

Code: IM582127000





(1 Feed per 2 Rectifiers, Single Phase)

Spec. No: 582127000

Model No: 721

NPBB

[44]

Code: IM582127000





(1 Feed per 3 Rectifiers, Three Phase)

AC INPUT CONNECTIONS,

1 FEED PER 3 RECTIFIERS, THREE PHASE

(582127000 LIST 42)

NOTE:



OF THE SHELF.

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #1

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #2

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #3

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #4

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6

Shelf #5


FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

Inside View

GND


1 FEED PER 3 RECTIFIERS (PCU)

208-240VAC, 50/60Hz, THREE PHASE

GND

Left Side

SHELF 1 - PCUs #1 - #3

A B C


Others Similar)



AC Wireway

Cover

AC Input

Connector Cover

Inside View

Right Side

FRAME GROUND

CONNECTION

Four 10-32 X 3/4"

Studs and Hardware.

Recommended torque:

23 in-lbs.

GND





C B A

AC Wireway

Cover

GND







A B C


A B C





C B A


C B A





A B C


A B C





C B A


C B A

Spec. No: 582127000

Model No: 721

NPBB

[45]

Code: IM582127000




Direct AC Input Connections to 588705000 List 31

Module Mounting Shelves

Spec. No. 588705000 List 31 module mounting shelf contains AC input terminal blocks which provide a separate single phase AC input connection for each rectifier position.

2.

Install conduit fittings in the side or rear openings as required. Plug buttons are provided, and must be installed in the openings not being used.

3.

Route wiring into the shelf through the previously installed conduit fittings.

Circular openings are provided in the side panels (side feed) and rear covers (rear feed) of the module mounting shelf for AC input and equipment-grounding conductors. The openings accept 3/4 inch conduit fittings. AC input wiring should be provided to all rectifier mounting positions, including currently unused positions.

This wiring will ease future installation of rectifiers to meet increased load requirements.

Note:

A grounding conductor must be provided with each AC input feed.

PROCEDURE

Refer to Figure 29 as these procedures are performed.

Note:

Repeat the following procedures for each module mounting shelf in the power system.


Note:

In each shelf, module mounting positions are number 1-6 from left to right as viewed from the front.

1.


Figure 29 .

Connect each wire by inserting the stripped end into the wire opening, and then tightening the screw. Torque

connections to value shown in Figure 29 .


Note:


not


1.

Connect equipment grounding leads to the frame ground studs using installer-provided ring lugs and factory-supplied mounting hardware. Torque



1.

Remove the two AC input access covers from the rear of the module mounting shelf by first removing the screws that secure them.

Reinstalling Covers

1.

After all AC input and equipment grounding connections have been made and checked, reinstall the two AC input access covers on the back of the shelf. Secure with the previously removed screws.

Table 6. Nominal 208/240 Volts AC Input Connections (Single-Phase) to a 588705000 List 31 Module Mounting Shelf

Module Mounting Shelf

Left Side as

Viewed from Rear

PCU 4

PCU 5

PCU 6

1

2

1

2

1

2

208/240 VAC Service Type:

Line to Line:



Line to Neutral:

Connect Line to Terminal 1.

Connect Neutral to Terminal 2.

1

2

1

2

1

2

Right Side as

Viewed from Rear

PCU 1

PCU 2

PCU 3

Spec. No: 582127000

Model No: 721

NPBB

[46]

Code: IM582127000




Figure 29. Nominal 208/240 Volts AC Input Connections (Single-Phase) to a 588705000 List 31 Module Mounting Shelf

Holes for 3/4"

Conduit Fitting

(AC Input)

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6


(front view)

Rear View

Holes for 3/4"

Conduit Fitting

(AC Input)

Spec. No: 582127000

Model No: 721

NPBB

[47]

Rear View



AC

IN

Rectifier

Module 4

1

2

Rectifier

Module 5

1

2

Rectifier

Module 6

1

2

FRAME GROUND CONNECTION

ONE 10-32 X 3/4" STUD

AND HARDWARE.

Recommended torque: 23 in-lbs.


INDIVIDUAL RECTIFIER (PCU) FEED




1

2

Rectifier

Module 1

1

2

1

2

Rectifier

Module 2

AC

IN

Rectifier

Module 3


ONE 10-32 X 3/4" STUD

AND HARDWARE.


Code: IM582127000






Spec. No. 588705000 List 32 module mounting shelf contains AC input terminal blocks which provide a separate three phase AC input connection for every three (3) rectifier positions (two

3-phase AC input circuits, each phase of each input circuit supplies one rectifier module).

Circular openings are provided in the side panels (side feed) and rear covers (rear feed) of the module mounting shelf for AC input and equipment-grounding conductors. The openings accept 3/4 inch conduit fittings. AC input wiring should be provided to all rectifier mounting positions, including currently unused positions.

This wiring will ease future installation of rectifiers to meet increased load requirements.

Note:

A grounding conductor must be provided with each AC input feed.

PROCEDURE


Note:



1.

Remove the two AC Input Access Covers from the rear of the module mounting shelf by first removing the screws that secure them.

2.


3.



Note:


1.


Figure 30 .




Note:


not


1.



Reinstalling Covers

1.

After all AC input and equipment grounding connections have been made and checked, reinstall the two AC input access covers on the back of the shelf. Secure with the previously removed screws.

Spec. No: 582127000

Model No: 721

NPBB

[48]

Code: IM582127000




Figure 30. Nominal 208/240 Volts AC Input Connections (Three-Phase) to a 588705000 List 32 Module Mounting Shelf)

Holes for 3/4"

Conduit Fitting

(AC Input)

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6


(front view)

Rear View

Holes for 3/4"

Conduit Fitting

(AC Input)

Rear View



AC IN

Feed 2

(Rectifier

Modules

4-6)

(ØA)

(ØB)

(ØC)

Spec. No: 582127000

Model No: 721

NPBB

Mounting

Position

Rect 1

Rect 2

Rect 3

Rect 4

Rect 5

Rect 6


ONE 10-32 X 3/4" STUD

AND HARDWARE.


CONNECTIONS WITHIN THE SHELF

L1

TB1, Terminal

1 (ØA) 2 (ØB) 3 (ØC) 1 (ØA) 2 (ØB) 3 (ØC)

L1 L2

L1

L2

L2

TB2, Terminal

L1

L1

L2

L1

L2

L2

[49]



(ØA)

(ØB)

(ØC)

AC IN

Feed 1

(Rectifier

Modules

1-3)


ONE 10-32 X 3/4" STUD

AND HARDWARE.





Code: IM582127000




Direct AC Input Connections to 588705000 List 22 Module Mounting Shelves

Spec. No. 588705000 List 22 module mounting shelf is provided with six (6) factory installed AC input line cords (one for each rectifier

module position). Plug each AC line cord into a properly wired AC outlet or distribution box. Refer to Figure 31 .

Figure 31. Nominal 208/240 Volts AC Input and Equipment Grounding Connections to Module Mounting Shelf 588705000 List 22

(Single Phase, Line Cords)

Rect.

(PCU)

1

Rect.

(PCU)

2

Rect.

(PCU)

3

Rect.

(PCU)

4

Rect.

(PCU)

5

Rect.

(PCU)

6


(front view)

Rectifier

Module 4

Rear View

Rectifier

Module 6

Rectifier

Module 5


INDIVIDUAL RECTIFIER (PCU) FEED


Rectifier

Module 2

Rectifier

Module 3

Rectifier

Module 1

Spec. No: 582127000

Model No: 721

NPBB

[50]

Code: IM582127000




Direct AC Input Connections to 588705300 List 3 Module Mounting Shelves

Spec. No. 588705300 List 3 is equipped with plug-in AC input connectors located on the rear of the shelf. AC input cable assemblies with

mating connectors are available (see Power Data Sheet PD588705300). Make AC input connections per Figure 32 .

Figure 32. Nominal 120/208/240 Volts AC Input and Equipment Grounding Connections to Module Mounting Shelf 588705300 List 3

(Single Phase, Cable Assemblies)

Rear

Spec. No: 582127000

Model No: 721

NPBB

AC input connections are made using the supplied

AC input cable assemblies connected here.

Rear

Rectifiers are numbered left to right as viewed from the front.

AC Input for

Rectifier Positions

#3 and #4

AC Input for

Rectifier Positions

#5 and #6

AC Input for

Rectifier Positions

#1 and #2

AC Input Connector

(Cabinet Rear View)

* Color of AC Input

Cable Assembly Lead.

P/N 535232

P/N 547898

L1

Brown*

Ground

Green/Yellow*

L2-N

Blue*

Nominal

120/208/240V

AC Input

[51]

Code: IM582127000




400 Volts DC Input and Equipment Grounding

Connections (if equipped)

Danger

General


NOTE THAT THIS SYSTEM MAY BE EQUIPPED WITH AC OR DC

INPUTS. THESE PROCEDURES APPLY TO SYSTEMS WITH DC

INPUTS. SPECIFICALLY, THESE PROCEDURES APPLY TO THE

FOLLOWING EQUIPMENT:

• 582127000 List 45, 46, 47

• 588705000 List 41

• 588705000 List 42

Wiring Considerations



PD588705300.

DC Input Termination Assemblies

The available DC input options for this system are:

• The system can be equipped with a DC input termination assembly which provides a separate DC input connection for each converter position (582127000 List 45).

• The system can be equipped with a DC input termination assembly which provides a separate DC input connection for every two (2) converter positions (582127000 List

46).

• The system can be equipped with a DC input termination assembly which provides a separate DC input connection for every three (3) converter positions (582127000 List

47).

Direct DC Input Connections to the Module Mounting Shelves

• The system can be equipped with module mounting shelves that contain DC input terminal blocks which provide a separate DC input connection for each converter position (588705000 List 41).

• The system can be equipped with module mounting shelves that contain DC input terminal blocks which provide a separate DC input connection for every two (2) converter positions (588705000 List 42).

Connections to DC Input Termination Assemblies (582127000

List 45, 46, and 47)

The DC input termination assemblies provide circular openings at the top for DC input and grounding conductors. The openings accept 1 inch conduit fittings. It is recommended that DC input wiring be provided to all converter mounting positions, including currently unused positions. This wiring will ease future installation of converters to meet increased load requirements.

Note:

A grounding conductor must be provided with each conduit.

PROCEDURE

Refer to Figure 33 ,

Figure 34

, or Figure 35 as this procedure is

performed.


1.

Remove the two DC input connector covers and the DC input wireway covers by first loosening the fasteners that secure each of them.

2.

Install conduit fittings as required in the top of the DC

Input Termination Assembly. Plug buttons are provided, and must be installed in the openings not being used.

3.

Route wiring into the DC Input Termination Assembly through the previously installed conduit fittings.

Making DC Input Connections

1.

Make DC input connections as shown in

Figure 33 ,

Figure

34

, or Figure 35 . Connect each wire by inserting the

stripped end into the wire opening, and then tightening the screw. Torque connections to value shown in the appropriate illustration.

Note:

Terminal blocks for a system with maximum possible converter shelves shown. Your system may have less terminal blocks then shown.


1.

Connect equipment grounding leads to the frame ground studs using installer-provided ring lugs and factory-supplied mounting hardware. Torque connections to value shown in the appropriate illustration.

Reinstalling Covers

1.

After all DC input and equipment grounding connections have been made and checked, reinstall the two DC input connector covers and the DC input wireway covers.

Secure each by tightening the fasteners.

Spec. No: 582127000

Model No: 721

NPBB

[52]

Code: IM582127000




Figure 33. 400 Volts DC Input and Equipment Grounding Connections to DC Input Termination Assembly 582127000 List 45

(1 Feed per 1 Converter)

DC INPUT CONNECTIONS,

1 FEED PER 1 CONVERTER

(582127000 LIST 45)

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #1

Shelf #2

Shelf #3


Others Similar)



DC Wireway

Cover

DC Input

Connector Cover

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #4

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #5

Converter Module Mounting Slots

Inside View

Left Side

Inside View

Right Side

DC Wireway

Cover

NOTE:



OF THE SHELF.

GND GND

400VDC CONVERTER DC INPUT FEEDS


SHELF 1

Conv. 1 Conv. 2 Conv. 3

+ - + - + -

+

CONV1

+

CONV2

+

CONV3

-

GND GND



SHELF 1


+ - + - + -

+

CONV4

+

CONV5

+

CONV6

-

Conv. 1



SHELF 3


SHELF 2

Conv. 2

+ - + - + -

Conv. 3

+ - + - + -

+

CONV1

+

CONV2

+

CONV3

+

CONV1

+

CONV2

+

CONV3

-

Conv. 4



SHELF 2


SHELF 3

Conv. 5

+ - + - + -

Conv. 6

+ - + - + -

+

CONV4

+

CONV5

+

CONV6

+

CONV4

+

CONV5

+

CONV6

-

Spec. No: 582127000

Model No: 721

NPBB

Conv. 1



SHELF 5


SHELF 4

Conv. 2 Conv. 3

+ - + - + + - + - + -

+

CONV1

+

CONV2

+

CONV3

+

CONV1

+

CONV2

+

CONV3

-

Conv. 4



SHELF 4


SHELF 5

Conv. 5 Conv. 6

+ - + - + + - + - + -

+

CONV4

+

CONV5

+

CONV6

+

CONV4

+

CONV5

+

CONV6

-

[53]

Code: IM582127000





(1 Feed per 2 Converters)


1 FEED PER 2 CONVERTERS

(582127000 LIST 46)

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #1

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #2

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #3

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #4



Others Similar)



DC Wireway

Cover

DC Input

Connector Cover

DC Wireway

Cover

NOTE:



OF THE SHELF.

Inside View

Left Side

Inside View

Right Side

GND GND



SHELVES 1 AND 2

Conv. 1

+ -

Conv. 2

+ -

Conv. 3

+ -

CONV 1

+ -

CONV 2

+ -

CONV 3

+ -

GND GND



SHELVES 1 AND 2

Conv. 4

+ -

Conv. 5

+ -

Conv. 6

+ -

CONV 4

+ -

CONV 5

+ -

CONV 6

+ -

Spec. No: 582127000

Model No: 721

NPBB



SHELVES 3 AND 4

Conv. 1

+ -

Conv. 2

+ -

Conv. 3

+ -

CONV 1

+ -

CONV 2

+ -

CONV 3

+ -

[54]



SHELVES 3 AND 4

Conv. 4

+ -

Conv. 5

+ -

Conv. 6

+ -

CONV 4

+ -

CONV 5

+ -

CONV 6

+ -

Code: IM582127000








(582127000 LIST 47)

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #1

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #2

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #3

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #4

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6

Shelf #5


Inside View

Left Side


Others Similar)



DC Wireway

Cover

DC Input

Connector Cover

Inside View

Right Side

DC Wireway

Cover

NOTE:



OF THE SHELF.

GND GND



SHELF 1: Conv. #1 - #3

+ -

SHELF 1 CONV1-3

GND GND




+ -

SHELF 1 CONV4-6




+ -

SHELF 3 CONV1-3


+ -

SHELF 2 CONV1-3




+ -

SHELF 2 CONV4-6


+ -

SHELF 3 CONV4-6

Spec. No: 582127000

Model No: 721

NPBB




+ -

SHELF 5 CONV1-3


+ -

SHELF 4 CONV1-3

[55]




+ -

SHELF 4 CONV4-6


+ -

SHELF 5 CONV4-6

Code: IM582127000




Direct DC Input Connections to 588705000 List 41


Spec. No. 588705000 List 41 module mounting shelf contains DC input terminal blocks which provide a separate DC input connection for each converter position.

Circular openings are provided in the side panels (side feed) and rear covers (rear feed) of the module mounting shelf for AC input and equipment-grounding conductors. The openings accept 3/4 inch conduit fittings. DC input wiring should be provided to all converter mounting positions, including currently unused positions. This wiring will ease future installation of converters to meet increased load requirements.

Note:

A grounding conductor must be provided with each DC input feed.

PROCEDURE


Note:



1.

Remove the two DC input access covers from the rear of the module mounting shelf by first removing the screws that secure them.

2.


3.



Note:


1.


Figure 36 .




1.



Reinstalling Covers

1.

After all DC input and equipment grounding connections have been made and checked, reinstall the two DC input access covers on the back of the shelf. Secure with the previously removed screws.

Spec. No: 582127000

Model No: 721

NPBB

[56]

Code: IM582127000




Figure 36. 400 Volts DC Input and Equipment Grounding Connections to Module Mounting Shelf 588705000 List 41

(1 Feed per 1 Converter)

Holes for 3/4"

Conduit Fitting

(Input)

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6


(front view)

Rear View

Holes for 3/4"

Conduit Fitting

(Input)

Rear View



Converter

Module 4

400VDC

IN

Converter

Module 5

Converter

Module 6

+

-

+

-

+

-

+

-

+

-

+

-

Converter

Module 1

Converter

Module 2

Converter

Module 3


ONE 10-32 X 3/4" STUD

AND HARDWARE.


INDIVIDUAL 400VDC CONVERTER FEEDS

1 FEED PER CONVERTER


ONE 10-32 X 3/4" STUD

AND HARDWARE.


400VDC

IN

Spec. No: 582127000

Model No: 721

NPBB

[57]

Code: IM582127000






Spec. No. 588705000 List 42 module mounting shelf contains DC input terminal blocks which provide a separate DC input connection for every three (3) converter positions.

Circular openings are provided in the side panels (side feed) and rear covers (rear feed) of the module mounting shelf for DC input and equipment-grounding conductors. The openings accept 3/4 inch conduit fittings. DC input wiring should be provided to all converter mounting positions, including currently unused positions. This wiring will ease future installation of converters to meet increased load requirements.

Note:

A grounding conductor must be provided with each DC input feed.

PROCEDURE


Note:



1.

Remove the two DC Input Access Covers from the rear of the module mounting shelf by first removing the screws that secure them.

2.


3.



Note:


1.


Figure 37 .




1.



Reinstalling Covers

1.

After all DC input and equipment grounding connections have been made and checked, reinstall the two DC input access covers on the back of the shelf. Secure with the previously removed screws.

Spec. No: 582127000

Model No: 721

NPBB

[58]

Code: IM582127000




Figure 37. 400 Volts DC Input and Equipment Grounding Connections to Module Mounting Shelf 588705000 List 42


Holes for 3/4"

Conduit Fitting

(Input)

Conv.

1

Conv.

2

Conv.

3

Conv.

4

Conv.

5

Conv.

6


(front view)

Rear View

Holes for 3/4"

Conduit Fitting

(Input)

Rear View



400VDC IN

Feed 2

(Converter

Modules

4-6)

-

+

-

+

400VDC IN

Feed 1

(Converter

Modules

1-3)

Spec. No: 582127000

Model No: 721

NPBB


ONE 10-32 X 3/4" STUD

AND HARDWARE.


CONVERTER 400VDC INPUT FEEDS


[59]


ONE 10-32 X 3/4" STUD

AND HARDWARE.


Code: IM582127000




External Alarm, Reference, Monitoring, and Control Connections

Circuit Card Locations

Refer to Figure 38 .

Figure 38. Circuit Card Locations

4-Row Cabinet Shown,

Others Similar

(Front Door Removed in

Illustration for Clarity)

IB2 (Main Bay Only)

(Interface Board)


Optional EIB (Main Bay Only)

(Extended Interface Board)


Optional SM-DU+ and


Controller

(Main Bay)

SM-DU

(Supplemental Bays)

Mounting Position

Optional LVD

Inhibit Switch

(factory installed if option specified)

Optional LVD

Driver Circuit Card

OR

Optional LVD Driver

Lite Circuit Card

Spec. No: 582127000

Model No: 721

NPBB

Optional Manual Battery

Disconnect Circuit Card

(Main Bay Only)

System Interface

Circuit Card

[60]

Code: IM582127000




System Interface Circuit Card

The System Interface Circuit Card provides connections for the following.


• RS-485 (used for communication with SM modules)

• RS-232 (used for communication with a DPU)

• External Battery Monitoring (circuit card installed in Main Bay only)

• External System FA Signal (circuit card installed in Main Bay only)

• External Battery FA Signal (circuit card installed in Main Bay only)

• Battery Tray FA Signal

• Bay Voltage Monitoring Test Points

• Bay Load Shunt Monitoring Test Points

Spec. No: 582127000

Model No: 721

NPBB

[61]

Code: IM582127000




Figure 39. System Interface Circuit Card Connections

J1, J2, J3, J4

Distribution Panels FA Inputs

TB2

RS485 Connection

TB2 1A: RS485+

TB2 2A: RS485-

RS232 Connection

TB2 1B: CGND

TB2 2B: TXD232

TB2 3B:RXD232

TB2 3A: Internally used by system.

1

TB1

5

1B 2B 3B

J8

TB2

1A 2A 3A

J10

J1

J2

J3

J4

TP1 TP2 TP3 TP4

J5

TB1-1: Battery Tray FA

TB1-2: External Battery FA

TB1-3: External System FA

TB1-4: External Battery Monitoring (-)

TB1-5: External Battery Monitoring (+)

TP1 (+) and TP2 (-)

Bay Voltage

Monitoring

TB1

TB1-2, TB1-3, TB1-4, TB1-5 Main Bay Only.


Recommended Torque: 3.0 in-lbs.

FA Signals: System voltage applied to the terminal turns in an alarm.

TP3 (+) and TP4 (-)

Bay Load

Shunt Monitoring

J8 (Main Bay Only)

Selects to power Controller from “Battery Power” or not.

No

Battery

Pwr

Battery

Pwr

1

2

3

7

8

9

Shorting Jumper

J8

J10 (Main Bay Only)

Battery Monitoring External / Internal

(see TB1-4 and TB1-5 for external monitoring points)

External Internal

1

2

3

7

8

9

J10

Shorting Jumper

J5

CAN

System Interface

Card in Main Bay

System Interface Card in 1st Supplemental Bay

System Interface Card in 2nd Supplemental Bay

System Interface

Card in Last Bay

CAN termination plug must be installed.

Spec. No: 582127000

Model No: 721

NPBB

[62]

Code: IM582127000




IB2 (Controller Interface Board) Connections

(if required) (Main Bay Only)

The IB2 (Controller Interface Board) provides connection points for digital inputs, programmable relay outputs, and temperature probes. The IB2 interface board is mounted inside the distribution

cabinet. Refer to Figure 38 .

Digital Inputs and Programmable Relay Outputs

Digital input and relay output leads are connected to screw-type terminal blocks located on the IB2. Recommended torque for

these connections is 2.2 in-lbs. Refer to Figure 40 for terminal

locations. Refer to Table 7

and Table 8 for pin-out information.

Digital Inputs

Connect up to eight (8) digital inputs to the IB2. Note that you must supply both paths for the digital input (either a positive or negative signal and the opposite polarity return path). Observe

proper polarity. Refer to Figure 40

for terminal locations and Table

7 for pin-out information.

Note:

-48V is factory wired to the Digital Input #8 (-) terminal for your convenience and function predefined for ESTOP.

Customer-furnished system ground applied to terminal Digital

Input #8 (+) activates the ESTOP function. The ESTOP function shuts down and locks out the rectifiers or 400V DC input converters, opens the LVD’s, and shuts down the optional -48V to +24V DC converters. When the ESTOP signal is removed,

LVD’s close (if battery present) and -48V to +24V DC converters restart. To restart the rectifiers or 400V DC input converters; turn input power to the rectifiers/converters OFF, wait 30 seconds or more (until the LEDs on the module extinguish), then turn input power to the rectifiers/converters

ON.

The digital inputs can be programmed to provide an alarm when the signal is applied (HIGH) or removed (LOW). Refer to the ACU+

Instructions (UM1M820BNA or UM1M820DNA400) or NCU

Instructions (UM1M830BNA) for programming information.

Digital Input Ratings: Refer to the following. a.

Maximum Voltage Rating: 60V DC. b.

Active High: > 19V DC. c.

Active Low: < 1V DC.

The digital inputs may be preprogrammed for specific functions.

Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific configuration.

Programmable Relay Outputs

The IB2 provides eight (8) programmable alarm relays with dry

Form-C contacts. Connect up to eight (8) relay outputs to the IB2.

Refer to Figure 40

for terminal locations and Table 8 for pin-out

information.

Note:

The relay assigned to “Critical Summary” alarm (relay 1 by default) will operate in the “Fail Safe Mode”. “Fail Safe Mode” means Relay 1 is de-energized during an alarm condition, opening the contacts between the C and NO terminals, and closing the contacts between the C and NC terminals.

The remaining 7 relays energize during an alarm condition, closing the contacts between the C and NO terminals, and opening the contacts between the C and NC terminals.

Refer to the ACU+ Instructions (UM1M820BNA or

UM1M820DNA400) or NCU Instructions (UM1M830BNA) for programming information.

Relay Ratings: Refer to the following. a.

1A Steady State @ 30V DC. b.

3A Peak @ 30V DC.

The relays may be preprogrammed for specific functions. Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific configuration.

Temperature Probes

Note:

Each temperature probe consists of two pieces that plug together to make a complete probe. See SAG582127000 for part numbers and descriptions.

Temperature probes are connected to the IB2 (Controller Interface

Board) and/or optional EIB (Controller Extended Interface Board)

mounted inside the distribution cabinet. See Figure 40

and Figure

42 .

Up to two (2) temperature probes can be connected to the IB2. Up to two (2) additional temperature probes can be connected to the optional EIB. Any combination of the four (4) temperature probes can be programmed to monitor ambient temperature and/or battery temperature. A temperature probe set to monitor battery temperature can also be used for the rectifier battery charge temperature compensation feature, or the battery charge temperature compensation feature can be programmed to use the average or highest value of all battery temperature probes. The battery charge temperature compensation feature allows the controller to automatically increase or decrease the output voltage of the system to maintain battery float current as battery temperature decreases or increases, respectively. Battery life can be extended when an optimum charge voltage to the battery with respect to temperature is maintained. A temperature probe set to monitor battery temperature can also be used for the BTRM

(Battery Thermal Runaway Management) feature. The BTRM feature lowers output voltage when a high temperature condition exists to control against battery thermal runaway.

Spec. No: 582127000

Model No: 721

NPBB

[63]

Code: IM582127000




The temperature sensor end of the probe contains a tab with a

5/16” clearance hole for mounting.

A temperature probe programmed to monitor battery temperature should be mounted on the negative post of a battery cell to sense battery temperature. A temperature probe used for battery charge temperature compensation and/or BTRM (Battery

Thermal Runaway Management) should also be mounted on the negative post of a battery cell. A temperature probe programmed to monitor ambient temperature should be mounted in a convenient location, away from direct sources of heat or cold.

Spec. No: 582127000

Model No: 721

NPBB

[64]

Code: IM582127000




Figure 40. IB2 (Interface Board) Connections

Schematic Diagram of IB2 Board

IB2 TEMP

PROBE 2

IB2 TEMP

PROBE 1

DO1_NC

DO2_NC

DO1_COM

DO2_COM

DO1_NO

DO2_NO

DO3_NC

DO4_NC

DO3_COM

DO4_COM

DO3_NO

DO4_NO

DO5_NC

DO6_NC

DO5_COM

DO6_COM

DO5_NO

DO6_NO

DO7_NC

DO8_NC

DO7_COM

DO8_COM

DO7_NO

DO8_NO

DI1-

DI1+

DI2-

DI2+

DI3-

DI3+

DI4-

DI4+

DI5-

DI5+

DI6-

DI6+

DI7-

DI7+

DI8-

DI8+

J7

J8

J9

J3

J4

J5

J6

J2

3

1

2

4

J3-J9:



IB2 Board Assembly

* The relay assigned to “Critical Summary” alarm (relay 1 by default)

will operate in the “Fail Safe Mode”. “Fail Safe Mode” means Relay 1 is

de-energized during an alarm condition, opening the contacts between the

C and NO terminals, and closing the contacts between the C and NC terminals.

The remaining seven (7) relays energize during an alarm condition, closing the contacts between the C and NO terminals, and opening the contacts between the C and NC terminals.

Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific relay labeling.

Not all I/O points are available for customer connection (some are used for factory system connections).

Spec. No: 582127000

Model No: 721

NPBB

[65]

Code: IM582127000




Table 7. Programmable Digital Inputs – IB2

Programmable

Digital Input

IB2

Pin No.

Factory

Wiring

Default Digital

Input Function

Customer Defined

Digital Input Function

1

2

3

4

5

6

7

8

J3-2

J3-1

J3-4

J3-3

J3-6

J3-5

J4-2

J4-1

J4-4

J4-3

J4-6

J4-5

J5-2

J5-1

J5-4

J5-3

J5-5

J5-6

–

+

–

+

–

+

–

+

–

+

–

+

–

+

–

+

The digital inputs may be preprogrammed for specific functions and have factory wiring connected. Refer to the configuration drawing

(C-drawing) supplied with your system for your system’s specific configuration.

The digital inputs may be preprogrammed for specific functions. Refer to the configuration drawing (Cdrawing) supplied with your system for your system’s specific configuration.

(to customer

ESTOP switch)

-48VDC

ESTOP

--

-- not used not used not used

Note:

-48V is factory wired to the Digital Input #8 (-) terminal for your convenience and function predefined for ESTOP. Customerfurnished system ground applied to terminal Digital Input #8 (+) activates the ESTOP function. The ESTOP function shuts down and locks out the rectifiers or 400V DC input converters, opens the LVD’s, and shuts down the optional -48V to +24V DC converters.

When the ESTOP signal is removed, LVD’s close (if battery present) and -48V to +24V DC converters restart. To restart the rectifiers or 400V DC input converters; turn input power to the rectifiers/converters OFF, wait 30 seconds or more (until the LEDs on the module extinguish), then turn input power to the rectifiers/converters ON.

Spec. No: 582127000

Model No: 721

NPBB

[66]

Code: IM582127000




Table 8. Programmable Relay Outputs – IB2

Programmable

Relay Output

1

2

3

4

5

6

7

8

NC

NO

COM

NC

NO

COM

NC

NO

COM

NO

COM

NC

NO

COM

NC

NO

COM

NC

NO

COM

NC

NO

COM

NC

IB2

Pin No.

J7-1

J7-6

J7-4

J7-2

J8-5

J8-3

J8-1

J8-6

J8-4

J6-5

J6-3

J6-1

J6-6

J6-4

J6-2

J7-5

J7-3

J8-2

J9-5

J9-3

J9-1

J9-6

J9-4

J9-2

Alarms Assigned to this Relay

(Default)


Alarms Assigned to this Relay

(Custom)

Note:

The relay assigned to “Critical Summary” alarm (relay 1 by default) will operate in the “Fail Safe Mode”. “Fail

Safe Mode” means Relay 1 is de-energized during an alarm condition, opening the contacts between the C and

NO terminals, and closing the contacts between the C and NC terminals.

The remaining 7 relays energize during an alarm condition, closing the contacts between the C and NO terminals, and opening the contacts between the C and NC terminals.

Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific relay labeling.

Spec. No: 582127000

Model No: 721

NPBB

[67]

Code: IM582127000




Optional EIB (Controller Extended Interface Board) Connections (if required) (Main Bay Only)

The optional EIB (Controller Extended Interface Board) provides additional connection points for voltage and current inputs, programmable relay outputs, and temperature probes. The EIB extended interface board is mounted inside the distribution cabinet.


Current Inputs, Voltage Inputs, and Programmable Relay Outputs

Current input, voltage input, and relay output leads are connected to screw-type terminal blocks located on the optional EIB.

Recommended torque for these connections is 2.2 in-lbs. Refer to Figure 42

for terminal locations. Refer to Table 9 , Table 10

, and Table

11 for pin-out information.

Current Inputs

Connect up to three (3) shunt inputs to the EIB. Observe proper polarity. Refer to Figure 42

for terminal locations and Table 9 for pin-out

information.

Refer to the ACU+ Instructions (UM1M820BNA or UM1M820DNA400) or NCU Instructions (UM1M830BNA) and program the shunt input parameters found in the EIB menu.

Note:

The shunt needs to be installed in the hot (-48V) bus. Connect the plus side of the shunt to the positive shunt input on the EIB. Connect the negative side of the shunt to the negative shunt input on the EIB.

Voltage Inputs for Battery Block and Battery Midpoint Monitoring

The controller can monitor battery blocks (12V blocks) or midpoint battery voltage of battery strings connected to the EIB. The EIB provides a total of eight (8) DC voltage inputs for these connections. An alarm is issued when either battery block voltage or battery

midpoint voltage is abnormal. Refer to Figure 42

for terminal locations and Table 10 for pin-out information.

Refer to Figure 41 for connection details. Refer to the ACU+ Instructions (UM1M820BNA or UM1M820DNA400) or NCU Instructions

(UM1M830BNA) and program the following parameters found in the EIB menu.

• Battery Block Monitoring

Voltage Type: Set to “48 (Block 4)”. This selects the EIB to monitor up to two (2) 48V battery strings with four (4) 12V blocks per string.

BlockVDiff(12V): This menu item appears if “48 (Block 4)” is selected above. Set to the alarm threshold for battery block monitoring per site requirements. The controller issues an alarm when any block voltage of any battery string has an abnormal value. The alarm is issued when the difference between any block voltage and a reference voltage is greater than the value of the block voltage difference setting.

Block In-Use: Set to the number of 12V battery blocks being used.

• Midpoint Monitoring

Voltage Type: Set to “Midpoint”. This selects the EIB to monitor the midpoint voltage of up to eight (8) battery strings.

BlockVDiff(Mid): This menu item appears if “Midpoint” is selected above. Set to the alarm threshold for battery midpoint monitoring per site requirements. The controller issues an alarm when any battery midpoint voltage of any battery string has an abnormal value. The alarm is issued when the difference between any battery midpoint voltage and a reference voltage is greater than the value of the block voltage difference setting.

Block In-Use: Set to number of 12V battery blocks being used.

Spec. No: 582127000

Model No: 721

NPBB

[68]

Code: IM582127000




Figure 41. Sample Battery Block or Battery Midpoint Monitoring Connections

Battery Block Monitoring

Return

Rectifiers

-48V

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

Battery

String 1

+

12V

-

+

12V

-

Battery

String 2 to

DCV1

(J6-1) to

DCV2

(J6-2) to

DCV3

(J6-3) to

DCV4

(J6-4) to

DCV5

(J6-5) to

DCV6

(J6-6) to

DCV7

(J7-1) to

DCV8

(J7-3)

EIB Board Voltage Inputs

Load Shunt

Load

Battery Midpoint Monitoring

Return

Rectifiers

-48V

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

+

12V

-

Battery

String 1 to

DCV1

(J6-1)

+

12V

-

+

12V

-

Battery

String 2 to

DCV2

(J6-2)

+

12V

-

+

12V

-

Battery

String 3

+

12V

-

+

12V

-

Battery

String 4

+

12V

-

+

12V

-

Battery

String 5

+

12V

-

+

12V

-

Battery

String 6 to

DCV3

(J6-3) to

DCV4

(J6-4) to

DCV5

(J6-5)

EIB Board Voltage Inputs to

DCV6

(J6-6)

+

12V

-

+

12V

-

Battery

String 7 to

DCV7

(J7-1)

+

12V

-

+

12V

-

Battery

String 8 to

DCV8

(J7-3)

Load Shunt

Load

Spec. No: 582127000

Model No: 721

NPBB

[69]

Code: IM582127000




Programmable Relay Outputs

The EIB provides five (5) programmable alarm relays with dry Form-C contacts. Connect up to five (5) relay outputs to the IB2. Refer to

Figure 42

for terminal locations and Table 10 for pin-out information.

Refer to the ACU+ Instructions (UM1M820BNA or UM1M820DNA400) or NCU Instructions (UM1M830BNA) for programming information.

Relay Ratings: Refer to the following. a.

1A Steady State @ 30V DC. b.

3A Peak @ 30V DC.


Temperature Probes

Temperature probes can be connected to the optional EIB (Controller Extended Interface Board) mounted inside the distribution cabinet.

Refer to “Temperature Probes” on page 63.

Spec. No: 582127000

Model No: 721

NPBB

[70]

Code: IM582127000




Figure 42. EIB (Extended Interface Board) Connections

Schematic Diagram of EIB Board

EIB Board

D13_COM

DCV8

D13_NC

DCV7

DCV6

DCV5

DCV4

DCV3

DCV2

DCV1

SH3+

SH3-

SH2+

SH2-

SH1+

SH1-

D12_NO

D11_NO

D12_COM

D11_COM

D12_NC

D11_NC

D10_NO

DO9_NO

D10_COM

DO9_COM

D10_NC

DO9_NC

D13_NO

J5-J9



Spec. No: 582127000

Model No: 721

NPBB

[71]

Code: IM582127000




Table 9. Shunt Inputs – EIB

Shunt Input

Sh1

Sh2

Sh3

Table 10. Voltage Inputs – EIB

J5-2

J5-1

J5-4

J5-3

J5-6

J5-5

EIB

Pin No.

+

–

+

–

+

–

Voltage Input

Factory

Wiring

--

--

--

--

--

--

1

EIB

Pin No.

J6-1

6

7

8

2

3

4

5

J6-2

J6-3

J6-4

J6-5

J6-6

J7-1

J7-3

Battery

Block

Monitoring

Default

Function none none none

Default

Function

Customer

Defined Function

Spec. No: 582127000

Model No: 721

NPBB

[72]

Code: IM582127000




Table 11. Programmable Relay Outputs – EIB

Programmable Relay

9

10

11

12

13

Output

NC

NO

COM

NC

NO

COM

NC

NO

COM

NC

NO

COM

NC

NO

COM

EIB

Pin No.

J9-1

J9-6

J9-4

J9-2

J7-6

J7-4

J7-2

J8-5

J8-3

J8-1

J8-6

J8-4

J8-2

J9-5

J9-3

Alarms Assigned to this Relay

(Default)


Alarms Assigned to this Relay

(Custom)

Note:

The relays energize during an alarm condition, closing the contacts between the C and NO terminals, and opening the contacts between the C and NC terminals.

Spec. No: 582127000

Model No: 721

NPBB

[73]

Code: IM582127000




Optional SM-DU+ and Shunt Interface Board

The optional SM-DU+ and Shunt Interface Board provides connections for up to twenty-five (25) shunt inputs. Inputs are factory

connected to any distribution positions/devices containing shunts. Refer to Figure 43 .

PROCEDURE

Current Inputs: Connect up to twenty-five (25) shunt inputs to the Shunt Interface Board. Observe proper polarity. Note that some inputs may be factory connected, depending on distribution devices installed. Refer to the ACU+ Instructions (UM1M820BNA or

UM1M820DNA400) or NCU Instructions (UM1M830BNA) for programming information for the unused inputs.

Note:

The shunt needs to be installed in the hot (-48V) bus. Connect the plus side of the shunt to the positive shunt input on the SM-DU+.

Connect the negative side of the shunt to the negative shunt input on the SM-DU+.

Spec. No: 582127000

Model No: 721

NPBB

[74]

Code: IM582127000




Figure 43. SM-DU+ and Shunt Interface Board Connections

Schematic Diagram of SM-DU+ and Shunt Interface Board

SMDU+

541127

SHUNT

INTERFACE

J2

TB2

2

1

J3

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

17

18

19

20

25

26

21A

21B

20A

20B

19A

19B

18A

18B

25A

25B

24A

24B

23A

23B

22A

22B

17A

17B

16A

16B

15A

15B

14A

14B

SHUNT25+

SHUNT25-

SHUNT24+

SHUNT24-

SHUNT23+

SHUNT23-

SHUNT22+

SHUNT22-

SHUNT21+

SHUNT21-

SHUNT20+

SHUNT20-

SHUNT19+

SHUNT19-

SHUNT18+

SHUNT18-

SHUNT17+

SHUNT17-

SHUNT16+

SHUNT16-

SHUNT15+

SHUNT15-

SHUNT14+

SHUNT14-

1

2

3

J1

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

21

22

23

24

17

18

19

20

25

26

J1

3A

3B

2A

2B

1A

1B

5A

5B

4A

4B

7A

7B

6A

6B

11A

11B

10A

10B

9A

9B

8A

8B

TB1

13A

13B

12A

12B

SHUNT13+

SHUNT13-

SHUNT12+

SHUNT12-

SHUNT11+

SHUNT11-

SHUNT10+

SHUNT10-

SHUNT9+

SHUNT9-

SHUNT8+

SHUNT8-

SHUNT7+

SHUNT7-

SHUNT6+

SHUNT6-

SHUNT5+

SHUNT5-

SHUNT4+

SHUNT4-

SHUNT3+

SHUNT3-

SHUNT2+

SHUNT2-

SHUNT1+

SHUNT1-

SHUNT

INPUTS


TB1 - TB2



SM-DU+ and Shunt

Interface Board

Spec. No: 582127000

Model No: 721

NPBB

-

+

[75]

Code: IM582127000




Connecting a Device or System to the Controller’s CAN Bus

A supporting device or system may be connected to the Controller’s CAN Port. Refer to Figure 39

for location. Refer to Table 12 for pin-

outs. Refer also to the external device’s or system’s instruction manual.

General Procedure

1.

Remove the CAN termination plug from the bottom CAN connector on the System Interface circuit card of the last bay (see

Figure 39 for location). Connect the device or system to the bottom CAN connector on the System Interface circuit card of the

last bay. Refer to Table 12 for pin-outs. Refer also to the external device’s or system’s instruction manual.

Optional SM-Temp Module Procedure

The analog output of the SM-Temp Module may be connected to a controller’s temperature port input. In lieu of connecting the analog output of the SM-TEMP module to a temperature port input, the SM-TEMP module can simply be connected at the end of the Controller’s

CAN Bus (requires ACU+ version 3.02 or later). Refer to the SM-Temp Module Instructions (UM547490) for details.

CONNECTING THE SM-TEMP MODULE TO THE CONTROLLER’S CAN BUS

1.

Remove the CAN termination plug from the bottom CAN connector on the System Interface circuit card of the last bay.

Connect the SM-Temp Module CAN bus to the bottom CAN connector on the System Interface circuit card of the last bay. Refer

to Table 12 for pin-outs. Ensure the last SM-Temp Module (or if only one) has a CAN termination strap as shown in the SM-Temp

Module Instructions (UM547490).

Table 12. CAN Connections

Controller CAN

Port (RJ-45)

Pin Number

7

8

5

6

3

4

1

2

Function

CAN L

CAN H

--

--

--

--

--

--

SM-Temp Module

CAN Port

Pin Number

TB1-5 (CAN L)

TB1-3 (CAN H)

--

--

--

--

--

--

Spec. No: 582127000

Model No: 721

NPBB

[76]

Code: IM582127000




Controller Ethernet Connection (if required)

The controller provides a Web Interface via an Ethernet connection to a TCP/IP network. This interface can be accessed locally on a computer or remotely through a network. An RJ-45 10BaseT jack is provided on the front of the controller for connection into a

customer's network. This jack has a standard Ethernet pin configuration scheme, twisted pair. Refer to Figure 44 for location and Table

13 for pin outs. Use shielded Ethernet cable (grounded at both ends). Note that the controller’s RJ-45 jack is connected to chassis

ground. Refer to the ACU+ Instructions (UM1M820BNA or UM1M820DNA400) or NCU Instructions (UM1M830BNA) for operational details.

Note:

You can access the Web pages of the power system locally by using a "crossover" or “straight” cable connected directly between your PC and the controller.

Warning

WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP wiring.

The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building cabling/wiring that is grounded at both ends.

Table 13. Controller RJ-45 Ethernet Port Pin Configuration

Port Pin

Number

Name

4

5

6

7

8

1

2

3

Tx+

Tx-

Rx+

--

--

Rx-

--

--

Figure 44. Controller Ethernet Port

Definition

Write Signal +

Write Signal -

Read Signal + no connection no connection

Read Signal - no connection no connection

ACU+

NCU

10/100M Ethernet

Port (RJ-45)

ESC ENT

10/100M Ethernet

Port (RJ-45)

ESC ENT

Note:

NCU ONLY: If your system has an IB4 board, DO NOT connect your Local Area Network (LAN) to the NCU front Ethernet port. See “NCU

Controller Second Ethernet Port Connection (if IB4 board furnished)” on page 79.

Spec. No: 582127000

Model No: 721

NPBB

[77]

Code: IM582127000




Ethernet Connection through the Power System

The Ethernet cable can be routed from the notch on the left side of the bracket. It goes through the lances on the chassis, then goes up to be bundled with the harness and all other customer alarm and signal cables.

The existing cable ties can also be used to secure the Ethernet cable as it goes up to the top panel.

Figure 45. Network Connection through Power System

Ethernet wire coming out from one of the rectangular openings on top of cabinet panel

Cable ties

Lance

Bracket notch

* Removed some parts

for illustrative purposes.

Spec. No: 582127000

Model No: 721

NPBB

[78]

Code: IM582127000




NCU Controller Second Ethernet Port Connection (if IB4 board furnished)

Your system may be furnished with an IB4 board connected to the NCU backplane via a factory furnished and connected cable. The IB4 board provides a second Ethernet port. The Ethernet port located on the NCU Controller’s front panel can ONLY be used to connect a computer directly to the NCU. The Ethernet port located on the IB4 board can be used to connect the NCU to your Local Area Network

(LAN).

Note:

If your system has an IB4 board, DO NOT connect your Local Area Network (LAN) to the NCU front Ethernet port.

An RJ-45 10BaseT jack is provided on the IB4 board for connection into a customer's network. This jack has a standard Ethernet pin

configuration scheme, twisted pair. Refer to Figure 46

for location and Table 13 for pin outs. Use shielded Ethernet cable (grounded at

both ends). Note that the IB4 board’s RJ-45 jack is connected to chassis ground. Refer to the NCU Instructions (UM1M830BNA) for operational details.

Warning

WARNING! The intra-building port(s) of the equipment or subassembly is suitable for connection to intra-building or unexposed wiring or cabling only. The intra-building port(s) of the equipment or subassembly MUST NOT be metallically connected to the interfaces that connect to the OSP or its wiring. These interfaces are designed for use as intra-building interfaces only (Type 2 or Type 4 ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP wiring.

The intra-building port (RJ-45) of the equipment or subassembly must use shielded intra-building cabling/wiring that is grounded at both ends.

Spec. No: 582127000

Model No: 721

NPBB

[79]

Code: IM582127000




Figure 46. IB4 Board NCU Controller Second Ethernet Port

Spec. No: 582127000

Model No: 721

NPBB

[80]

Code: IM582127000




Bay-to-Bay Communications Cable Connections

The bays are interconnected using standard Cat5 communications cables. Supplemental bays are provided with a 25’ cable. Refer to

Figure 47 for a bay-to-bay cable diagram.

Note:

Maximum combined length of the Cat5 communications cables is 328’ (100m) per industry standards.

PROCEDURE

1.

For each bay in the power system, open the distribution cabinet’s front door by turning the latch in the counterclockwise position.

2.

Remove the terminating plug from the bottom connector on the System Interface Circuit Card installed in the Main Bay and place in the bottom connector on the System Interface Circuit Card in the last bay.

3.

Using a standard Cat5 communications cable, connect the bottom connector on the System Interface Circuit Card installed in the Main Bay to the top connector on the System Interface Circuit Card installed in the 1st Supplemental Bay.

4.

Using a standard Cat5 communications cable, connect the bottom connector on the System Interface Circuit Card installed in the 1st Supplemental Bay to the top connector on the System Interface Circuit Card installed in the 2nd Supplemental Bay (if furnished).

5.

For each bay in the power system, close the distribution cabinet’s front door. Turn the latch clockwise to secure the door.

Spec. No: 582127000

Model No: 721

NPBB

[81]

Code: IM582127000




Figure 47. Bay-to-Bay Communications Cable Connections

Front doors remove in illustration for clarity only.

System Interface Card in Last Bay

Main Bay 1st

Supplemental

Bay

2nd

Supplemental

Bay

Termination

Plug

System Interface

Card in Main Bay

System Interface Card in 1st Supplemental Bay

System Interface Card in 2nd Supplemental Bay

Use standard Cat5 communications cables.

1. Remove terminating plug from bottom connector on the System Interface Circuit Card installed in the Main Bay and place in bottom connector on the System Interface Circuit Card in the last bay.

2. Connect the bottom connector on the System Interface Circuit Card installed in the Main Bay to the top connector on the System Interface Circuit Card installed in the 1st Supplemental Bay.

3. Connect the bottom connector on the System Interface Circuit Card installed in the 1st Supplemental Bay to the top connector on the System Interface Circuit Card installed in the 2nd Supplemental Bay.

Spec. No: 582127000

Model No: 721

NPBB

[82]

Code: IM582127000




Installing Bay-to-Bay Busbars (582127000 List 1 with List 2 / List 3)

PROCEDURE

1.

When 582127000 List 3 and/or List 2 is ordered, bay-to-bay busbars and hardware are provided for system power connections

between distribution cabinets. Interconnect per Figure 48 .

Spec. No: 582127000

Model No: 721

NPBB

[83]

Code: IM582127000




Figure 48. Installing Bay-to Bay Busbars (List 2 and 3 Only) (cont’d on next page)

1. Remove center right (4-Row Cab.) or lower right (3-Row Cab.) Rear

Access Cover from distribution cabinets (note that the complete rear cover is removed in the illustration for clarity only).

2. Attach Return Angle Brackets.

3. Attach -48V Angle Brackets.

4. Attach flat Return Interbay Busbars.

5. Attach flat -48V Interbay Busbars.

6. Attach Insulator Standoffs onto

Return Interbay Busbars.

SEE NEXT PAGE FOR

ASSEMBLED VIEW

Return Angle Bracket

Secure 2 places with (in order listed)

3/8-16 x 1-1/4” Bolt,

3/8” Belleville Lockwasher, and

3/8” Flat Washer.


Spec. No: 582127000

Model No: 721

NPBB

1/4-20 Insulator Standoff

Secure from back of return interbay busbar with 1/4-20 x 5/8” Bolt and 1/4” Flat Washer.

Return Interbay Busbar

Secure in 4 places with (in order listed)

3/8-16 x 1-1/4” Bolt,

3/8” Belleville Lockwasher,

3/8” Flat Washer.


Hardware attached from other side.

-48V Angle Bracket


3/8-16 x 1-1/4” Bolt,


3/8” Flat Washer.


-48V Interbay Busbar


3/8-16 x 1-1/4” Bolt,


3/8” Flat Washer.


Hardware attached from other side.

[84]

Code: IM582127000




Figure 48.

Installing Bay-to Bay Busbars (List 2 and 3 Only) (cont’d from previous page)

Spec. No: 582127000

Model No: 721

NPBB

ASSEMBLED VIEW

7. Secure rear cover shields to previously installed insulator standoffs using

1/4-20 x 1/2” Bolt and 1/4” Flat Washer,

2 places each shield.

8. Secure rear cover shields to distribution cabinets using 6-32 x 3/8“ screws,

2 places each shield.

[85]

ATTACH REAR COVER SHIELDS

Code: IM582127000




Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705000

Each Spec. No. 588705000 module mounting shelf in the system is daisy-chained to the controller. A Controller CAN Bus connector is located at the top of each shelf and another at the bottom of each shelf. These connectors are used to interconnect the shelves to the

controller. Refer to Figure 49 for connector locations. These connections are factory made for shelves factory installed. The connection must be made if a rectifier field expansion shelf is installed as shown in Figure 49 . For field expansion, refer to the procedure in Power

System User Instructions UM582127000.

• The top connector of the top most module mounting shelf connects to the controller.

• The bottom connector of a shelf plugs into the top connector on the shelf below it.

• The bottom connector on the bottom most shelf must terminate back into the distribution cabinet.

Spec. No: 582127000

Model No: 721

NPBB

[86]

Code: IM582127000




Figure 49. Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705000

Distribution

Cabinet Wire

Harness

Slate and

Slate/White Wires

Brown and

Brown/White Wires

These cables are factory connected.

Existing

Rectifier Module

Mounting Shelf


Existing

Rectifier Module

Mounting Shelf


Existing

Rectifier Module

Mounting Shelf

Disconnect cable coming from distribution cabinet from this connector on bottom-most existing rectifier shelf, then connect to the top connector on the expansion rectifier shelf.

Expansion

Rectifier Module

Mounting Shelf

Connect the cable disconnected above

(coming from distribution cabinet) to bottom connector on expansion rectifier shelf.

Spec. No: 582127000

Model No: 721

NPBB

[87]

Exploded View Shown to Illustrate Wire Connections Only

Code: IM582127000




Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705300

Each Spec. No. 588705300 module mounting shelf in the system is daisy-chained to the controller. Controller CAN Bus connectors are located at the left and right rear of each shelf. The right side connector is factory jumpered so both connectors can be accessed from the

left side of the shelf. These connectors are used to interconnect the shelves to the controller and to other shelves. Refer to Figure 50 for

connector locations and an interconnect diagram. These connections are factory made for shelves factory installed. The connection

must be made if a rectifier field expansion shelf is installed as shown in Figure 50 . For field expansion, refer to the procedure in Power

System User Instructions UM582127000.

Spec. No: 582127000

Model No: 721

NPBB

[88]

Code: IM582127000




Figure 50. Control Bus Connections between Controller and Module Mounting Shelves Spec. No. 588705300

Distribution

Cabinet Wire

Harness

Exploded View Shown to

Illustrate Wire Connections Only

Slate and

Slate/White Wires

Brown and

Brown/White

Wires

Existing Module

Mounting Shelf

These connectors are factory connected.

Rear View

Factory provided jumper to bring connectors to same side of shelf.

Existing Module

Mounting Shelf



Rear View

Existing Module

Mounting Shelf



Rear View

X

Disconnect cable coming from distribution cabinet from this connector on bottom-most existing shelf, then connect to the same connector on the expansion shelf.

Now connect these two connectors together.

Expansion Module

Mounting Shelf


Rear View

Spec. No: 582127000

Model No: 721

NPBB

[89]

Code: IM582127000




Connecting Converter Output Cables 582127000 List 60

Connecting List 60 Converter Output Cables to List DA, DB, DC, or DD Distribution Panel

PROCEDURE

1.

A converter output cable is provided for each rectifier/converter shelf installed in the system, up to a maximum of four (4).

Locate the output cables (labeled /+/).

2.


3.

Loosen the (2) screws holding the plastic shield over the circuit breakers or fuseholders on the dual voltage distribution panel.

Slide the shield upwards and remove.

4.

Connect the output cables to the distribution bus panel subsystem (+24V) input terminals as shown in

Figure 51 . Apply

electrical anti-oxidizing compound to lug mating surfaces before connecting. Mount two lugs back-to-back per mounting

position if required. Torque as shown in Figure 51 .

5.

Continue with the next procedure.

Connecting List 60 Converter Output Cables to Module Mounting Shelf(s) Spec. No. 588705300

PROCEDURE

1.

Route the output cables installed in the previous procedure over the top of the distribution bus panel ground bar, toward the back of the cabinet, and down through the opening in the bottom of the distribution cabinet (between the cabinet main busbars).

2.

Install the distribution panel shield removed in the previous procedure. To do so, position the shield and slide downwards on screws. Tighten screws.

3.

Close the front door of the distribution cabinet.

4.

Remove the rear cover from the rectifier/converter shelf(s).

5.

Route the output cables previously connected to the distribution cabinet into the area at the rear of the module mounting shelf(s) Spec. No. 588705300.

6.

Connect the output cables to the module mounting shelf(s) Spec. No. 588705300 +24V bus as shown in

Figure 51 . Apply electrical anti-oxidizing compound to lug mating surfaces before connecting. Torque as shown in Figure 51 .

7.

Reinstall the rectifier/converter shelf(s) rear cover.

Spec. No: 582127000

Model No: 721

NPBB

[90]

Code: IM582127000




Figure 51. Installing Converter Output Cables (cont’d on next page)

Dual Voltage Distribution Panel

List DA (Lists DB, DC, and DD similar.)

Spec. No: 582127000

Model No: 721

NPBB

Connect /+/ jumpers to an available landing here.

Assembly order is: lug, 1/4" flat washer,

1/4" lock washer, 1/4-20 x 3/4” bolt.


To List DA, DB, DC, or DD


P/N 556228

Converter

Output Cable

[91]

This end is connected to rectifier/converter shelf

+24V bus (see next illustration).

Hardware provided with Converter Option Kit.

Code: IM582127000




Figure 51.

Installing Converter Output Cables (cont’d from previous page, cont’d on next page)

To List DA, DB, DC, or DD


(see previous illustration)

P/N 556228

Converter

Output

Cable

+24V Bus

Assembly order is: 1/4-20 x 1” bolt, 1/4” lock washer, 1/4” flat washer, lug, +24V Busbar, 1/4” flat washer, 1/4-20 nut.

TORQUE CONNECTIONS

TO 84 IN-LBS.

Spec. No: 582127000

Model No: 721

NPBB

[92]

Code: IM582127000




Load Connections

Loads are connected to the various distribution panels located inside the distribution cabinet(s), as detailed in this section.

Recommended Torques

• 72 in-lbs for 1/4-inch hardware (when using standard flat and lock washer).


Spec. No: 582127000

Model No: 721

NPBB

[93]

Code: IM582127000




Load Connections to Single Voltage Distribution Panels

List AA: -48V Distribution Panel (with Return Busbar) and

List AB: -48V Distribution Panel (without Return Busbar),

(24) Bullet/TPS/TLS Circuit Breaker/Fuse Positions

Load Return

Connections

-48VDC Load

Connections

Return Busbar

(not included with List AB)

LOAD AND LOAD RETURN CONNECTIONS

1/4-20 Studs on 5/8” Centers

(Customer must supply or order additional hardware)

Maximum Lug Width: 0.625 inches.

WARNING!

Observe proper polarity when making load connections.

List AC: -48V Distribution Panel (with Return Busbar) and

List AD: -48V Distribution Panel (without Return Busbar),

(4) GJ/218 Circuit Breaker Positions

Load Return

Connections

Return Busbar

(not included with List AD)

-48VDC Load

Connections

Caution: A circuit breaker or fuse with a rating of 100A or greater

SHALL HAVE an empty mounting position between it and any other overcurrent protective device.


3/8-16 Captive Nuts on 1” Centers



WARNING!


For an 800A circuit breaker, load must not exceed 600A.

Spec. No: 582127000

Model No: 721

NPBB

[94]

Code: IM582127000




List AE: -48V Distribution Panel,

(2) TPH Fuse Positions (without Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS




WARNING!


For an 800A fuse, load must not exceed 600A.

List AF: -48V Distribution Panel,

(2) TPH Fuse Positions (with Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS




WARNING!



Spec. No: 582127000

Model No: 721

NPBB

[95]

Code: IM582127000




List AG: -48V Distribution Panel,

(4) TPH Fuse Positions (without Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS


(Customer must supply

or order additional hardware)


Maximum fuse size is 400A.

WARNING!


List AH: -48V Distribution Panel,

(4) TPH Fuse Positions (with Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS





WARNING!


Spec. No: 582127000

Model No: 721

NPBB

[96]

Code: IM582127000




List AJ: -48V Distribution Panel,

(4) TPL-B Fuse Positions (without Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS

3/8-16 Studs on 1” Centers



WARNING!


List AK: -48V Distribution Panel,

(4) TPL-B Fuse Positions (with Shunts) (without Return Busbar)

-48VDC Load

Connections

LOAD CONNECTIONS

3/8-16 Studs on 1” Centers



WARNING!


Spec. No: 582127000

Model No: 721

NPBB

[97]

Code: IM582127000




Load Connections to Dual Voltage Distribution Panels

List DA: -48V/+24V Distribution Panel,

(17) –48V Bullet/TPS/TLS Circuit Breaker/Fuse Positions (with Return Busbar) and

(4) +24V Bullet/TPS/TLS Circuit Breaker/Fuse Positions (with Return Busbar)




Load Return

Connections

Maximum Lug Width:

0.625 inches.

Load

Connections

WARNING!


-48V Distrib ution

Caution: A circuit breaker or fuse with a rating of 100A or greater SHALL HAVE an empty mounting position between it and any other overcurrent protective device.

List DB: -48V/+24V Distribution Panel,



+24V Distr ibution LOAD AND LOAD RETURN CONNECTIONS



Load Return

Connections

Maximum Lug Width:

0.625 inches.

Load

Connections

WARNING!


-48V Distrib ution


Spec. No: 582127000

Model No: 721

NPBB

[98]

Code: IM582127000




List DC: -48V/+24V Distribution Panel,






Load Return

Connections

Maximum Lug Width:

0.625 inches.

Load

Connections

+24V Distr ibution

WARNING!



List DD: -48V/+24V Distribution Panel,






Load Return

Connections

Maximum Lug Width:

0.625 inches.

Load

Connections

+24V Distr ibution

WARNING!


-48V Distrib ution


Spec. No: 582127000

Model No: 721

NPBB

[99]

Code: IM582127000




Load Connections to Return Bar

List GA: Return Bar Panel

Load and/or Battery

Return Connections

LOAD AND/OR BATTERY RETURN CONNECTIONS




Load Connections to GMT Distribution Fuse Block

Optional Bullet Nose 6-Position GMT Distribution Fuse Block

Spec. No: 582127000

Model No: 721

NPBB

Load Return Leads

-48VDC Load Leads



35A maximum capacity per block.

Maximum GMT fuse size is 15A.

[100]

Code: IM582127000




Battery Connections

Important Safety Instructions

Danger

DANGER! Adhere to the “Important Safety Instructions” presented at the front of this document.

Warning

WARNING! Observe proper polarity when making battery connections.

Recommended Torques



• 180 in-lbs for 3/8-inch hardware (when using a Belleville lock washer).

Battery Connections to Optional Battery Disconnect Distribution Panels


Danger

Battery strings are connected to the various battery disconnect distribution panels (if furnished) located inside the distribution cabinet, as detailed in the illustrations in this section.

Spec. No: 582127000

Model No: 721

NPBB

[101]

Code: IM582127000




List BA: Battery Disconnect Distribution Panel (with Return Busbar) and

List BB: Battery Disconnect Distribution Panel (without Return Busbar),

(24) Bullet/TPS/TLS Circuit Breaker/Fuse Battery Disconnect Positions

BATTERY AND BATTERY RETURN CONNECTIONS

1/4-20 Studs on 5/8” Centers Maximum Lug Width: 0.625 inches.


Battery Return

Connections

Return Busbar

(not included with List BB)

-48VDC Battery

Connections

WARNING!

Observe proper polarity when making battery connections.

List BC: Battery Disconnect Distribution Panel (with Return Busbar) and

List BD: Battery Disconnect Distribution Panel (without Return Busbar),

(4) GJ/218 Circuit Breaker Battery Disconnect Positions




Battery Return

Connections

-48VDC Battery

Connections

Maximum Lug Width:

1.375 inches.

Return Busbar

(not included with List BD)


WARNING!


For an 800A circuit breaker, load must not exceed 600A.

Spec. No: 582127000

Model No: 721

NPBB

[102]

Code: IM582127000




List BE: Battery Disconnect Distribution Panel,

(2) TPH Fuse Battery Disconnect Position (without Shunts) (without Return Busbar)

BATTERY CONNECTIONS



-48VDC Battery

Connections


WARNING!



List BF: Battery Disconnect Distribution Panel,

(2) TPH Fuse Battery Disconnect Positions (with Shunts) (without Return Busbar)

BATTERY CONNECTIONS



-48VDC Battery

Connections


WARNING!


Spec. No: 582127000

Model No: 721

NPBB


[103]

Code: IM582127000




List BG: Battery Disconnect Distribution Panel,

(4) TPH Fuse Battery Disconnect Positions (without Shunts) (without Return Busbar)

BATTERY CONNECTIONS





-48VDC Battery

Connections

WARNING!


List BH: Battery Disconnect Distribution Panel,

(4) TPH Fuse Battery Disconnect Positions (with Shunts) (without Return Busbar)

BATTERY CONNECTIONS



-48VDC Battery

Connections



WARNING!


Spec. No: 582127000

Model No: 721

NPBB

[104]

Code: IM582127000




Battery Connections to Distribution Cabinet Battery Busbars


Danger

Battery may be connected to the battery busbars located in the distribution cabinet, as detailed in Figure 52

and Figure 53 , depending on

site requirements.

Figure 52. Battery Connections to Distribution Cabinet Battery Busbars

GND RTN

-48V SUPPLY

BATTERY AND

BATTERY RETURN CONNECTIONS

(4 landings per polarity)


(Customer must supply additional hardware)

Battery

(Return Side)

Busbar

1-Row Cabinet

Central Office

Ground

Battery

(Load Side)

Busbar

2-Row Cabinet

Central Office

Ground

Battery

(Return Side)

Busbar

Battery

(Load Side)

Busbar

BATTERY AND

BATTERY RETURN CONNECTIONS





Others Similar)

Central Office

Ground

Maximum Lug Width: 1.88 inches

(unless otherwise noted).

Battery

(Return Side)

Busbar

3-Row and 4-Row Cabinets

Battery

(Load Side)

Busbar





Spec. No: 582127000

Model No: 721

NPBB

Maximum Lug Width: 1.25 inches

(this location only).

Battery

(Return Side)

Busbar

Battery

(Load Side)

Busbar

[105]

Code: IM582127000




Figure 53. Battery Busbar Dimensions

1-Row Cabinet (GND RTN) 1-Row Cabinet (SUPPLY)

0.000

0.750

1.750

4.000

0.000

4.000

3/8-16

Captive Nut

2-Row Cabinet (GND RTN)

0.000

0.750

1.750

3/8-16

Captive Nut

3-Row and 4-Row Cabinet (GND RTN)

4.000

0.000

0.750

1.750

0.000

0.750

1.750

4.000

3/8-16

Captive Nut

Notes:


Spec. No: 582127000

Model No: 721

NPBB

3/8-16

Captive Nut

2-Row Cabinet (SUPPLY)

0.000

0.000

0.750

0.750

1.750

2.250

3.750

3/8-16

Captive Nut

3-Row and 4-Row Cabinet (SUPP LY)

0.000

0.750

1.750

4.000

0.000

0.750

1.750

[106]

3/8-16

Captive Nut

3/8-16

Captive Nut

0.750

1.750

3/8-16

Captive Nut

3/8-16

Captive Nut

Code: IM582127000




Battery Connections to Bay-to-Bay Rectifier Busbars (582127000 List 1 with List 2 / List 3)


Danger

IF THE SYSTEM DOES NOT CONTAIN A BATTERY SHUNT OR BATTERY DISCONNECT CONTACTOR, battery may be connected to the

582127000 List 2 and List 3 bay-to-bay rectifier busbars located on the rear of the distribution cabinets, as detailed in Figure 54 ,

depending on site requirements.

Spec. No: 582127000

Model No: 721

NPBB

[107]

Code: IM582127000




Figure 54. Battery Connections to Bay-to-Bay Rectifier Busbars

Detail A

RECTIFIER AND RECTIFIER RETURN CONNECTIONS

(CAN ONLY BE USED FOR BATTERY CONNECTIONS

IF THE SYSTEM DOES NOT CONTAIN A BATTERY

SHUNT OR BATTERY DISCONNECT CONTACTOR)


(Customer must supply additional hardware.)


(See Detail A)

Notes:


Rear busbar cover shields not shown in illustration.

GND RETURN

Rectifier (Return Side) Busbar

-48V Supply

Rectifier (Load Side) Busbar

Spec. No: 582127000

Model No: 721

NPBB

Rear

[108]

Code: IM582127000




Battery Connections to Optional Battery Busbar Extension Kit P/N 554541


Danger

Figure 55. Battery Connections to Optional Battery Busbar Extension Kit P/N 554541

BATTERY BUSBAR

EXTENSION KIT P/ N 554541

3/8” Clearance Holes on 1” Centers


Central

Office

Ground

GND RTN

Battery

(Return Side)

Busbar

-48V SUPPLY

(One Row Cabinet


Battery

(Load Side)

Busbar

Spec. No: 582127000

Model No: 721

NPBB

Front View

[109]

Code: IM582127000




Battery Connections to Optional Battery Landing Busbar Kit P/N 553584


Danger

Figure 56. Battery Connections to Optional Battery Landing Busbar Kit P/N 553584

1/4-20 x 0.875" Studs on 0.625" Centers,

24 Places (Customer must supply additional hardware.)

Plastic Shield

Rear View

-48V SUPPLY

Battery

(Load Side)

Busbar

GND RTN

Battery

(Return Side)

Busbar

Up to Six (6) Battery Leads (per polarity)

(One Row Cabinet


Spec. No: 582127000

Model No: 721

NPBB

[110]

Code: IM582127000




Battery Connections to Optional Battery Landing Busbar Kit P/N 555478


Danger

Figure 57. Battery Connections to Optional Battery Landing Busbar Kit P/N 555478

1/4-20 x 0.875" Studs on 0.625" Centers,

16 Places (Customer must supply additional hardware.)

Plastic Shield

Spec. No: 582127000

Model No: 721

NPBB

Rear View

-48V SUPPLY

Battery

(Load Side)

Busbar

GND RTN

Battery

(Return Side)

Busbar

Up to Eight (8) Battery Leads (per polarity).

[Four (4) battery landing positions, two (2) battery cable lugs back-to-back each position.]

[111]

(Two Row Cabinet


Code: IM582127000




Installing and Connecting Batteries in List 93 Battery Tray (if furnished)

Important Safety Instructions

WARNING! Correct polarity must be observed when connecting battery leads.

Warning

Warning

Warning

Danger

WARNING! Special safety precautions are required for procedures involving handling, installing, and servicing batteries.

Observe all battery safety precautions in this manual and in the battery instruction manual. These precautions should be followed implicitly at all times.

WARNING! A battery can present a risk of electrical shock and high short circuit current. Servicing of batteries should be performed or supervised only by properly trained and qualified personnel knowledgeable about batteries and the required precautions.

The following precautions should be observed when working on batteries:

• Remove watches, rings, and other metal objects.

• Eye protection should be worn to prevent injury from accidental electrical arcs.

• Use certified and well maintained insulated tools. Use double insulated tools appropriately rated for the work to be performed. Ensure that wrenches with more than one working end have only one end exposed.

• Do not lay tools or metal parts on top of batteries.

• Disconnect charging source prior to connecting or disconnecting battery terminals.

• Risk of explosion if battery is replaced with an incorrect type or if polarity is reversed. When replacing batteries, replace with the same manufacturer and type, or equivalent.

• Dispose of used batteries according to the instructions provided with the batteries. Do not dispose of batteries in a fire.

They may explode.

• ALWAYS FOLLOW THE BATTERY MANUFACTURER’S RECOMMENDATIONS AND SAFETY INSTRUCTIONS.

In addition to the hazard of electric shock, gas produced by batteries can be explosive and sulfuric acid can cause severe burns.

Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes, and is toxic. If electrolyte comes into contact with skin, the affected area should be washed immediately with large amounts of water.

DANGER! This equipment may be used in conjunction with lead-acid batteries.

Working near lead-acid batteries is dangerous!

• Batteries contain sulfuric acid.

• Batteries generate explosive gases during normal operation. Systems containing batteries should never be installed in an airtight room or space. Only install in a ventilated environment.

• Batteries are an energy source that can produce high amounts of electrical current.

FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE THAT YOU READ THESE INSTRUCTIONS AND FOLLOW THEM EXACTLY.

WHEN WORKING WITH LEAD-ACID BATTERIES:

• Wear complete protection for eyes, face, hands, and clothing. Examples are safety goggles or face shield, a rubber apron and gloves.

• If battery acid enters your eye, immediately flush your eye with running cold water for at least 15 minutes. Get medical attention immediately.

• If battery acid contacts skin or clothing, wash immediately with soap and water.

Spec. No: 582127000

Model No: 721

NPBB

[112]

Code: IM582127000




Battery Manufacturer Information

Refer to System Application Guide SAG582127000 for specifications and manufacturers of the batteries to be installed in this power system.

Installing Battery Landing Busbar Kit P/N 553584 (List 21) or 555478 (List 22, 23, or 24)


Danger

If the battery tray(s) was ordered with the system, these kits were installed at the factory. If a battery tray is installed in the field, customer must install the kit.

PROCEDURE

1.

Refer to Figure 58

or Figure 59 and install the Battery Landing Busbar Kit.

Figure 58. Battery Landing Busbar Kit P/N 553584

Hardware attached from other side.

Spec. No: 582127000

Model No: 721

NPBB

Rear View

Rear cover removed in illustration for clarity only.

Plastic Shield

(One Row Cabinet


-48V Angle Bracket


3/8-16 x 1-1/4” Bolt,

3/8” Belleville Lockwasher, and 3/8” Flat Washer.




3/8-16 x 1-1/4” Bolt,



Apply electrical anti-oxidizing compound to busbar mating surfaces.

[113]

Code: IM582127000




Figure 59. Battery Landing Busbar Kit P/N 555478

1. Remove top Rear Access Cover from distribution cabinet

(note that the complete rear cover is removed in the illustration for clarity only).

2. Attach Return Angle Bracket.

3. Attach -48V Angle Bracket.

4. Secure rear cover shield to distribution cabinet after wiring.

Hardware attached from other side.

Rear View

Plastic Shield

Spec. No: 582127000

Model No: 721

NPBB

-48V Angle Bracket

Secure in 2 places with existing hardware

(in order listed)

1/2-13 x 1-1/4” Bolt,


1/2” Flat Washer.


Apply electrical anti-oxidizing compound to busbar mating surfaces.



3/8-16 x 1-1/4” Bolt,



[114]

(Two Row Cabinet


Code: IM582127000




Wiring to the Battery Tray


Danger

If the battery tray(s) was ordered with the system, wiring to the battery tray was performed at the factory. If a battery tray is installed in the field, customer must wire to the battery tray.

PROCEDURE

1.

Refer to the wiring diagram provided in Figure 60

, and wire the battery tray for your application. Refer also to Figure 58 or

Figure 59 .

Spec. No: 582127000

Model No: 721

NPBB

[115]

Code: IM582127000




Figure 60. Wiring Diagram - List 93 Battery Tray (cont’d on next page)

Spec. No: 582127000

Model No: 721

NPBB

[116]

Code: IM582127000




Figure 60.

Wiring Diagram - List 93 Battery Tray (cont’d from previous page, cont’d on next page)

Spec. No: 582127000

Model No: 721

NPBB

[117]

Code: IM582127000




Figure 60.

Wiring Diagram - List 93 Battery Tray (cont’d from previous page)

Spec. No: 582127000

Model No: 721

NPBB

[118]

Code: IM582127000




Installing and Connecting Batteries


Danger

PROCEDURE

Note:


1.

If Battery Trays are Equipped With a Circuit Breaker: Turn OFF the Battery Disconnect circuit breaker located on all battery trays.

Refer to Figure 61 for locations. Follow local lockout/tagout procedures to ensure circuit breakers remain in the off position

during installation.

2.

Remove the battery retention bracket as shown in Figure 61 . To do so, remove the four 1/4-20 x 5/8” bolts and associated

washers.

3.

Slide batteries into the tray, with the battery terminals toward the front as shown in Figure 61 . Slide batteries into the tray as far

as they will go.

Note:

The battery retention bracket can be oriented two ways to accommodate batteries of different lengths. A correctly oriented bracket

will fit snuggly against the batteries. If your batteries require the alternate bracket orientation shown in Detail A o Figure 61 , remove

and reinstall the bullet-shaped spacers as shown in Detail A before performing the next step.

4.

Reinstall the battery retention bracket. The spacers on the bracket should separate the batteries from each other. Secure with

the hardware removed in a previous step. Refer to Figure 61 for washer location.

5.

Connect three links supplied by the battery manufacturer between pairs of battery terminals as shown in Figure 61 . Use

hardware furnished by the battery manufacturer. Torque hardware to battery manufacturer’s recommendations.

6.

Ensure the battery cable ends in all trays are insulated with sleeving before performing the next step.

Danger

DANGER! In multiple-tray installations, when batteries in one tray are connected, the battery cables in all trays will be energized. Remove sleeving from and connect one cable at a time. Do not allow a cable end to contact the battery tray or equipment rack.

WARNING! In the next step, observe correct polarity. Connect only cables labeled “+” to battery terminals labeled “+”.

Likewise, connect only cables labeled “–” to battery terminals labeled “–”.

Warning

7.

Connect the cables found in the battery tray to the battery terminals, “+” to “+” and “–” to “–”. Observe correct polarity. Refer

to Figure 61 . Secure with hardware furnished with the battery. Torque hardware to battery manufacturer’s recommendations.

8.

Repeat steps 1 through 7 for any remaining battery trays.

9.

If Battery Trays Are Equipped With a Circuit Breaker: To connect the batteries to the power system, turn ON the Battery

Disconnect circuit breaker located on all battery trays.

Spec. No: 582127000

Model No: 721

NPBB

[119]

Code: IM582127000




Figure 61. List 93 Battery Tray Battery Installation Details

Connect Link Furnished with Battery to these

Two Terminals

Connect NEG (-)

Battery Cable to this Terminal


Two Terminals


Two Terminals

Connect POS (+)

Battery Cable to this Terminal

Battery Retention

Bracket. See Detail A for alternate orientation.

Spacers Separate

Batteries (3 places per tray, front and back)

1/4-20 X 5/8” Bolt

1/4” Ground Washer

(1 place)

1/4-20 X 5/8” Bolt

1/4” Lock Washer

1/4” Flat Washer

(3 places)

If trays are equipped with circuit breakers,

TURN OFF ALL circuit breakers before installing and connecting any batteries!

Note:

1. Two trays shown as example.

2. Cabling detail omitted.

1/4" Ground

Washer

(1 Place)

Spec. No: 582127000

Model No: 721

NPBB

DETAIL A

Alternate Orientation of Retention Bracket

[120]

10-32 x 1/2" Pan Head Screw (3 Places)

No. 10 Flat Washer (3 Places)

No. 10 Lock Washer (3 Places)

Spacer (3 Places)

1/4-20 x 5/8" Hex

Head Screw

(4 Places)

1/4-20 Lock Washer

(3 Places)

1/4-20 Flat Washer

(3 Places)

Code: IM582127000




Installing the Modules

Installing Rectifier or Converter Modules into Spec.

No. 588705000 Module Mounting Shelves

Rectifier or converter modules are installed in a 588705000 module mounting shelf, depending on the shelf ordered.

• Rectifiers are installed in 588705000 List 21, List 22, 31, and 32 shelves.

• Converters are installed in 588705000 List 40, List 41, and 42 shelves.

Rectifier or converter modules can be inserted or removed with power applied (hot swappable).

Note:

The rectifier or converter module locks into the module mounting shelf through a latch located on the underside of the module. The latch and module handle are interactive. Push the handle into the module’s front panel, and the latch will pop out from the module bottom. Click the handle to pop it out from the module’s front panel, and the latch will retract

back into the module. The latch mechanism is shown in Figure

62 .

Warning

WARNING! To prevent damage to the latching mechanism, ensure the handle is in the open position when installing or removing a module. NEVER hold the handle in the closed position when installing a module into a shelf.

Note: 588705000 List 32 Rectifier Mounting Shelves Only (3-Phase

Input):

One three-phase input feeds the three rectifier modules on the left-hand side of the shelf. The second three-phase input feeds the modules on the right-hand side. To maintain phase balance, install rectifier modules in groups of three; that is, fill all three mounting positions on the left and/or all three on the right.

PROCEDURE

1.

Unpack the rectifier or converter modules.

2.

If present, remove blank cover panels from the module mounting positions into which modules are to be installed.

3.

Place the module into an unoccupied mounting slot without sliding it in completely.

4.

Click the module handle in order to pop it forwards out of the module’s front panel (this will also retract the latch mechanism located on the underside of the module).

5.

Push the module completely into the shelf.

6.

Push the handle into the front panel of the module. This will make the latch lock the module securely to the shelf.

7.

Repeat the above steps for each module being installed in the system.

8.

After the modules are physically installed in the mounting shelf(s), they are ready for operation immediately after power is supplied to them.

Figure 62. Installing Rectifier or Converter Modules into Spec. No.

588705000 Module Mounting Shelf

Spec. No: 582127000

Model No: 721

NPBB

[121]

Code: IM582127000




Installing the Rectifier and Converter Modules into

Spec. No. 588705300 Module Mounting Shelves

Rectifier and converter modules can be inserted or removed with power applied (hot swappable).

Rectifiers modules can be installed in any mounting position of each module mounting shelf. Converters modules can be installed in any of the three far right mounting positions of each module

mounting shelf. See Figure 63 .

Note:

Each rectifier and converter module locks into the module mounting shelf by means of a latch located on the bottom of the module. The latch and module handle are interactive.

Pushing the handle up into the module’s front panel causes the latch to extend to the locking position; pulling the handle down out from the module’s front panel causes the latch to

retract. See Figure 63 .

Warning

WARNING! To prevent damage to the latching mechanism, ensure the handle is in the open position when installing or removing a module. NEVER hold the handle in the closed position when installing a module into a shelf.

PROCEDURE

1.

Unpack the modules.

2.

Note the model number located on the front of each module. Model numbers starting with the letter “R” are rectifier modules. Model numbers starting with the letter

“C” are converter modules.

3.

Place the module into an unoccupied mounting position without sliding it in completely. Rectifiers modules can be installed in any mounting position of each module mounting shelf. Converters modules can be installed in any of the three far right mounting positions of each

module mounting shelf. See Figure 63 .

4.

Loosen the captive screw on the module’s handle. Pull the handle down out from the module’s front panel (this

will also retract the latch mechanism). See Figure 63 .

5.

Push the module completely into the shelf.

6.

Push the handle up into the module’s front panel. This will lock the module securely to the shelf. Tighten the captive screw on the handle.

7.

Repeat the above steps for each module being installed in the system.

8.

After the modules are physically installed in the mounting shelf(s), they are ready for operation immediately after power is supplied to them.

Spec. No: 582127000

Model No: 721

NPBB

[122]

Code: IM582127000




Figure 63. Installing Rectifier and Converter Modules into Spec. No. 588705300 Module Mounting Shelf

Front View

Rectifier

Mounting Positions

Rectifier or Converter

Mounting Positions

Module Mounting Shelf(s)

Rectifier or Converter Module

Captive Screw

Spec. No: 582127000

Model No: 721

NPBB

Model Number Label

(R48-2000e3 Rectifier)

(C48/24-1500 Converter)

[123]

Latch

Handle

Code: IM582127000




Initially Starting, Configuring, and

Checking System Operation

Important Safety Instructions

Caution

CAUTION! Performing various steps in the following procedures may cause a service interruption and/or result in the extension of alarms. Notify any appropriate personnel before starting these procedures. Also, notify personnel when these procedures are completed.

Initial Startup Preparation

• Ensure that all blocks, except the last one, in the

“Installation Acceptance Checklist” starting on page 1

have been checked.

• Ensure that module mounting positions are filled by a rectifier module, converter module, or a blank cover panel, as required. It is acceptable for positions to be left vacant.

• Refer to the configuration drawing (C-drawing) supplied with your power system documentation for factory settings of adjustable parameters.

Initially Starting the System

PROCEDURE

1.

Apply battery power to the system by closing the external battery disconnect(s) or protective device(s) that supplies battery power to the system, if furnished.

Close the system’s internal battery disconnect circuit breakers, if furnished.

2.

Apply AC or DC input power to the system (depending on configuration ordered) by closing ALL external AC or DC disconnects or protective devices that supply AC or DC input power to the module mounting shelves. Rectifiers and/or converters automatically start.

3.


4.

Place each distribution circuit breaker (if furnished) to the

ON position.

ACU+ Controller Procedure

Refer to this section if your system is furnished with an ACU+

Controller.

ACU+ Controller Initialization

Refer to Figure 64 for locations of the ACU+ local indicators and

navigation keys.

Figure 64. ACU+ Local Indicators and Navigation Keys

Minor Alarm

Indicator (Yellow)

Status

Indicator

(Green)

Critical or Major

Alarm Indicator

(Red)

Ethernet

Port

USB

Port

ESC ENT

Menu Navigation Keys

PROCEDURE

Note:

The initialization routine takes several minutes. During that time various alarm indicators may illuminate on the ACU+ front panel and an audible alarm may sound. Disregard all alarms. An audible alarm can be silenced at any time by momentarily depressing the

ENT

key on the ACU+ Controller.

1.

After the ACU+ is powered on, the display alternates between the “Emerson Network Power” screen and a screen displaying “Advanced Control Unit Plus Version

***** Starting….

2.

Next, the language screen appears. Press the up or down arrow key to select the desired language. Press the ENT key to confirm the selection. If no key is pressed within

10 seconds, the ACU+ selects the displayed language automatically.

3.

As initialization continues, the Main screen is displayed, but with zero volts. Initialization is not complete.

Refer to the ACU+ Instructions (UM1M820BNA or

UM1M820DNA400) for detailed instructions.

Spec. No: 582127000

Model No: 721

NPBB

[124]

Code: IM582127000




4.

When initialization is complete, the Main screen displays voltage and current normally, and no alarms are active.

temporary set point to drop below the actual maximum expected load. If batteries are used on the rectifier output, the batteries should support the load until the current limit set points can be re-established due to loss of a rectifier.

Verifying the Configuration File

5.

System information is displayed in multiple screens.

Repetitively press the up or down arrow key to view other system information screens one by one.

6.

From the Main screen, press ENT to go to the “Main

Menu” screen.

7.

From the Main Menu, select a submenu by repetitively pressing the up or down arrow key. The selected submenu will be indicated by the cursor. Press ENT to open the submenu.

Note:

Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until the Main screen appears.

8.

Verify and set the ACU+ controller as required for your application. Refer to the ACU+ Instructions

(UM1M820BNA or UM1M820DNA400) for procedures.

Note that you will have to program the ACU+ for any temperature probes and external inputs/outputs connected to the IB2 Interface Board, optional EIB

Interface Board, and optional SM-DU+ Shunt Interface

Board.

Note:

When setting total rectifier or total converter current limit, the set point to each unit is the total set point divided by the number of units. For example, if the system contains five rectifiers and the current limit is set to 150 amps then each rectifier has a current limit set point of 30 amps. If one or more rectifiers or converters are removed or fail it will take several seconds for the individual set points to the remaining rectifiers or converters to be reset. In the example given, if one rectifier is removed the current limit set point will drop to 120 amps (30 amps times four remaining rectifiers) until the controller can send updated set points to the remaining rectifiers. This takes a couple communication cycles (several seconds) after which each rectifier would have a new set point of 37.5 amps for a total of 150 amps. The total current limit of the rectifiers and converters should not be set such that the loss of the redundant rectifiers or converters will cause this

Your ACU+ was programmed with a configuration file that sets all adjustable parameters. The version number of the configuration file can be found on the configuration drawing (C-drawing) that is supplied with your power system documentation, and on a label located on the ACU+. You can verify that the correct configuration file has been loaded into your ACU+ by performing the following procedure.

Note:

The quantity of LVD’s and shunt values for your specific system may be different from the values shown on the C-drawing.

PROCEDURE

Note:

When viewing any of the following screens, if a key is not depressed within approximately 10 seconds, the ACU+ will automatically return to the Main screen.

1.

With the Main screen displayed, press ESC. A screen displays the serial number and software version.

2.

Press ENT. A screen displays the hardware version and

MAC address.

3.

Press ENT. A screen displays the configuration version number.

4.

Press ESC, or wait approximately 10 seconds, to return to the Main screen.

Checking Basic System Settings

Navigate through the controller menus and submenus to check system settings. You can adjust any parameter as required. Note that these settings can also be checked (and changed if required) via the WEB Interface.

Note:

Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until the Main screen appears.

PROCEDURE

1.

To Select a Sub-Menu:

Press the up or down arrow keys to move the cursor up and down the list of sub-menus in the menu screen

(selects the sub-menu), then press ENT to enter the selected sub-menu.

2.

To Enter a Password:

If a password screen opens, a password must be entered to allow the User to make adjustments. To enter a password, with the cursor at the User Name field (default

Spec. No: 582127000

Model No: 721

NPBB

[125]

Code: IM582127000



Installation Instructions, IM582127000 (Issue N, June 19, 2015) is “Admin”), press the down arrow key to move cursor down to the password line. Press ENT. “0” is highlighted.

Press the up arrow key once to change the “0” to”1”

(default password is “1”), then press ENT twice. (

Note:

If you have been assigned a unique User Name and password,

follow this procedure to enter these.)

3.

To Change a Parameter:

Press the up or down arrow keys to move the cursor up and down the list of parameters in the menu screen

(selects the parameter to change), then press ENT to change the selected parameter. The parameter field highlights. Press the up or down arrow keys to change the parameter value. Press ENT to confirm the change.

4.

Table 14 shows the menu navigation for some basic

settings. Refer to the separate ACU+ Manual

(UM1M820BNA or UM1M820DNA400) supplied with your power system for complete Local Display menus.

Table 14. ACU+ Basic Settings Menu Navigation

Parameter Menu Navigation

Date

Time

IP Communications Parameters

(IP address, subnet mask address, gateway address)

Float Voltage

Equalize Voltage

Battery Capacity

Main Menu / Settings / Controller / Date

Main Menu / Settings / Controller / Time

Main Menu / Settings / Communication

Main Menu / Settings / Battery / Charge / Float Voltage

Main Menu / Settings / Battery / Charge / EQ Voltage

Main Menu / Settings / Battery / Battery 1 / Rated Capacity

BTRM Feature

Main Menu / Settings / Battery / Basic / BTRM Action

Main Menu / Settings / Battery / Basic / BTRM Voltage

Temperature Compensation

Center Temperature

Main Menu / Settings / Battery / Temp Comp / Temp CompCenter

Temperature Compensation Slope Main Menu / Settings / Battery / Temp Comp / Temp Comp Coeff

Temperature Compensation Sensor Main Menu / Settings / Battery / Temp Comp / TempComp Sensor


Maximum Voltage

Main Menu / Settings / Battery / Temp Comp / Temp Comp Max V


Minimum Voltage

HVSD Limit

Main Menu / Settings / Battery / Temp Comp / Temp Comp Min V

Main Menu / Settings / Rectifier / All Rect Set / HVSD Limit

Rectifier Current Limit

Over Voltage Alarm 1


Under Voltage Alarm 1


Main Menu / Settings / Rectifier / All Rect Set / Curr Limit Pt

Main Menu / Settings / Power System / General / Over Voltage 1

Main Menu / Settings / Power System / General / Over Voltage 2

Main Menu / Settings / Power System / General / Under Voltage 1

Main Menu / Settings / Power System / General / Under Voltage 2

Changing Battery Capacity Rating in the ACU+

To change the battery capacity setting of the ACU+ to match the battery connected to the power system, perform the following procedure.

PROCEDURE

1.

With the Main screen displayed, press ENT to go to the

Main Menu. Navigate to and select “Settings” (ENT).

2.

If a password screen opens, a password must be entered to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this

Spec. No: 582127000

Model No: 721

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Installation Instructions, IM582127000 (Issue N, June 19, 2015) step and proceed to step 3). Otherwise, to enter a password, with the cursor at the User Name field (default is “Admin”), press the down arrow key to move cursor down to the password line. Press ENT. “0” is highlighted.



Note:



3.

With the Settings menu screen displayed, navigate to and select “Battery” (ENT) / “Battery 1” (ENT).

4.

Navigate to “Rated Capacity”. Press ENT. Use the up or down keys to adjust the value as required. Press ENT.

5.

Return to the Main screen by repeatedly pressing ESC

(escape).

Configuring the ACU+ Identification of Rectifiers and Assigning which Input Phase is Connected to the Rectifiers

When rectifiers are all installed prior to applying power and starting the system, the order in which the ACU+ identifies the rectifiers is by serial number (lowest serial number is Rect 1, next lowest is Rect 2, etc.). If you prefer the ACU+ to identify the rectifiers by position in the system, perform the following procedure.

Upon power up, the ACU+ arbitrarily assigns Phase A, B, or C to each rectifier. This assignment is used to display rectifier AC input phase voltage(s). The User may reassign the phase to each rectifier per your specific installation by following the procedure below.

PROCEDURE

1.



2.

If a password screen opens, a password must be entered to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this step and proceed to step 3). Otherwise, to enter a password, with the cursor at the User Name field (default is “Admin”), press the down arrow key to move cursor down to the password line. Press ENT. “0” is highlighted.



Note:



3.

With the Settings menu screen displayed, navigate to and select “Rectifier” (ENT).

4.

Navigate to “Rect #” (# is used here to represent the rectifier identification number). Press ENT. The rectifier

# menu screen is displayed, and the green LED on one rectifier starts flashing. This is the rectifier currently identified by the ACU+ as rectifier #. (If this is not the rectifier you want, press ESC to return to rectifier menu screen and select a different rectifier.)

5.

If you wish to change the Rectifier IDs, navigate to and select “Rectifier ID”. Press ENT. Use the up or down keys to change the ACU+ identification number for the flashing rectifier. Press ENT.

6.

If you wish to change the Rectifier Phase Assignment, navigate to and select “Rect Phase”. Press ENT. Use the up or down keys to change the phase connected to the flashing rectifier. Press ENT.

Note:

The new ID and/or phase assignment will not take effect until this entire procedure is completed and the new ID’s have been confirmed.

7.

Press ESC to return to rectifier menu screen.

8.

Navigate to and select the next rectifier.

9.

Repeat steps 4) through 8) for each of the remaining rectifiers in the system.

10.

When you have finished selecting identification numbers for all rectifiers, repeatedly press ESC to return to the

Main Menu.

11.

Navigate to and select “Manual” (ENT) / “Rectifier” (ENT)

/ “All Rect Ctrl” (ENT).

12.

Navigate to “Confirm ID/PH”. Press ENT. “Yes” highlights.

13.

Press ENT to select the operation. Press ENT again to confirm.

Note:

Check you numbering to be sure it is correct. If there where conflicts in your numbering, rectifiers with conflicts will be assigned the next available sequential number.

14.


(escape).

Configuring the ACU+ Identification of Converter Modules

When converters are all installed prior to applying power and starting the system, the order in which the ACU+ identifies the converters is by serial number (lowest serial number is Conv 1, next lowest is Conv 2, etc.).

If you prefer the ACU+ to identify the converters by position in the system, perform the following procedure.

Spec. No: 582127000

Model No: 721

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Code: IM582127000




PROCEDURE

1.



2.

If a password screen opens, a password must be entered to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this step and proceed to step 3). Otherwise, to enter a password, with the cursor at the User Name field (default is “Admin”), press the down arrow key to move cursor down to the password line. Press ENT. “0” is highlighted.



Note:



3.

With the Settings menu screen displayed, navigate to and select “Converter” (ENT).

4.

Navigate to “Conv #” (# is used here to represent the converter identification number). Press ENT. The converter # menu screen is displayed, and the green LED on one converter starts flashing. This is the converter currently identified by the ACU+ as converter #. (If this is not the converter you want, press ESC to return to converter menu screen and select a different converter.)

5.

Navigate to and select “Set Conv ID”. Press ENT. Use the up or down keys to change the ACU+ identification number for the flashing converter. Press ENT.

6.

Press ESC to return to converter menu screen.

7.

Navigate to and select the next converter.

8.

Repeat steps 4) through 7) for each of the remaining converters in the system.

9.

When you have finished selecting identification numbers for all converters, repeatedly press ESC to return to the

Main Menu.

10.

Navigate to and select “Manual” (ENT) / “Converter”

(ENT) / “All Conv Ctrl” (ENT).

11.

Navigate to “Confirm ID”. Press ENT. “Yes” highlights.

12.

Press ENT to select the operation. Press ENT again to confirm.

Note:

Check you numbering to be sure it is correct. If there where conflicts in your numbering, converters with conflicts will be assigned the next available sequential number.

13.


(escape).

ACU+ Alarm Relay Check

To verify operation of the external alarm relays, use the ACU+ alarm relay test feature. Refer to the ACU+ Instructions

(UM1M820BNA or UM1M820DNA400) for instructions in using this feature.

Note:

The relays may be preprogrammed for specific functions.

Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific configuration.

NCU Controller Procedure

Refer to this section if your system is furnished with an NCU

Controller.

NCU Controller Initialization

Refer to the NCU Instructions (UM1M830BNA) for detailed instructions.

Refer to Figure 65 for locations of the NCU local indicators and

navigation keys.

Figure 65. NCU Local Indicators and Navigation Keys

Status

Indicator

(Green)

M830D

Minor Alarm

Indicator (Yellow)

10/100M Ethernet

Port (RJ-45)

USB

Port

Critical or

Major Alarm

Indicator

(Red)

ESC ENT

Menu

Navigation

Keys

PROCEDURE

Note:

The initialization routine takes several minutes. During that time various alarm indicators may illuminate on the NCU front panel and an audible alarm may sound. Disregard all alarms.

An audible alarm can be silenced at any time by momentarily depressing the

ENT

key on the NCU Controller.

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Model No: 721

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1.

After the NCU is powered on, the display shows the

“Emerson Network Power” screen. The controller is initializing.

2.

When initialization is complete, the language screen appears. Press the up or down arrow key to select the desired language. Press the ENT key to confirm the selection.

3.

The Main Menu displays.

5.

From the Main Menu, press the UP and DOWN keys to highlight the desired Menu graphic in the Main Menu.

Press the ENT key to enter the selected menu.

Note:

Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until the Main

Menu appears.

6.

Verify and set the NCU controller as required for your application. Refer to the NCU Instructions

(UM1M830BNA) for procedures. Note that you will have to program the NCU for any temperature probes and external inputs/outputs connected to the IB2 Interface

Board, optional EIB Interface Board, and optional SM-DU+

Shunt Interface Board.

Note:

When setting total rectifier or total converter current limit, the set point to each unit is the total set point divided by the number of units. For example, if the system contains five rectifiers and the current limit is set to 150 amps then each rectifier has a current limit set point of 30 amps. If one or more rectifiers or converters are removed or fail it will take several seconds for the individual set points to the remaining rectifiers or converters to be reset. In the example given, if one rectifier is removed the current limit set point will drop to 120 amps (30 amps times four remaining rectifiers) until the controller can send updated set points to the remaining rectifiers. This takes a couple communication cycles (several seconds) after which each rectifier would have a new set point of 37.5 amps for a total of 150 amps. The total current limit of the rectifiers and converters should not be set such that the loss of the redundant rectifiers or converters will cause this temporary set point to drop below the actual maximum expected load. If batteries are used on the rectifier output, the batteries should support the load until the current limit set points can be re-established due to loss of a rectifier.

Verifying the Configuration File

4.

System information is displayed in multiple screens.

Press the ESC key to view other system information.

Press the down arrow key to view the next screen. Press the ESC key to return to the Main Menu.

Your NCU was programmed with a configuration file that sets all adjustable parameters. The version number of the configuration file can be found on the configuration drawing (C-drawing) that is supplied with your power system documentation, and on a label located on the NCU. You can verify that the correct configuration file has been loaded into your NCU by performing the following procedure.

Note:

The quantity of LVD’s and shunt values for your specific system may be different from the values shown on the C-drawing.

Spec. No: 582127000

Model No: 721

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Code: IM582127000




PROCEDURE

1.

With the Main Menu displayed, press ESC. A screen displays the NCU name, serial number, IP number, software version, hardware version, and configuration version number.

2.

Press the DOWN

key. A screen displays the NCU file system and MAC address.

3.

Press ESC to return to the Main Menu.

Checking Basic System Settings

Navigate through the controller menus and submenus to check system settings. You can adjust any parameter as required. Note that these settings can also be checked (and changed if required) via the WEB Interface.

Note:

Repeatedly press the “ESC” key to return in reverse order level by level from any submenu until the Main Menu appears.

PROCEDURE

1.

To Select a Sub-Menu:

Press the UP and DOWN keys to highlight the desired sub-menu. Press the ENT key to enter the selected submenu.

2.

To Select a User:

To select a User, use the UP and DOWN keys to move the cursor to the Select User field. Press ENT. Use the UP and

DOWN keys to select a User previously programmed into the NCU. Press ENT to select the User. Note that only

Users programmed into the NCU are shown. Users are programmed via the Web Interface.

3.

To Enter a Password:

To enter a password, use the UP and DOWN keys to move the cursor to the Enter Password field. Press ENT. Use the UP and DOWN keys to choose a character. Press ENT to accept and move to the next character. Continue this process until all characters are entered. Press ENT again to accept the password.

4.

To Change a Parameter:

Press the UP and DOWN keys to move up and down the list of parameters. Press ENT to select the parameter.

Press the UP and DOWN keys to change the parameter.

Press ENT to make the change. Press ESC to cancel the change.

5.

Table 15 shows the menu navigation for some basic

settings. Refer to the separate NCU Manual

(UM1M830BNA) supplied with your power system for complete Local Display menus.

Table 15. NCU Basic Settings Menu Navigation

Parameter

Date

Time

IP Communications Parameters

(IP address, subnet mask address, gateway address)

Float Voltage

Equalize Voltage

Battery Capacity

Battery Charge Temperature

Compensation

Rectifier Current Limit





Menu Navigation

Main Menu / Settings Icon / Sys Settings / Date.

Main Menu / Settings Icon / Sys Settings / Time.

Main Menu / Settings Icon / Comm Settings / enter parameters.

Main Menu / Settings Icon / Batt Settings / Charge / Float Voltage.

Main Menu / Settings Icon / Batt Settings / Charge / EQ Voltage.

Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2 Settings / Rated

Capacity.

Main Menu / Settings Icon / Batt Settings / Temp Comp (enter parameters).

Main Menu / Settings Icon / Rect Settings / Current Limit (set to enabled) then set

Curr Limit Pt.

Main Menu / Settings Icon / Other Settings / Over Voltage 1.

Main Menu / Settings Icon / Other Settings / Over Voltage 2.

Main Menu / Settings Icon / Other Settings / Under Voltage 1.

Main Menu / Settings Icon / Other Settings / Under Voltage 2.

Spec. No: 582127000

Model No: 721

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Code: IM582127000




Changing Battery Capacity Rating in the NCU

Change the battery capacity setting of the NCU to match the battery connected to the power system.

Local Menu Navigation:

Main Menu / Settings Icon / Batt Settings / Batt1 Settings or Batt2

Settings / Rated Capacity.

Web Menu Navigation:

Settings Menu / Battery Tab / Batt1 Rated Capacity and Batt2

Rated Capacity.


Configuring the NCU Identification of Rectifiers and

Assigning which Input Feed is Connected to the Rectifiers

When rectifiers are all installed prior to applying power and starting the system, the order in which the NCU identifies the rectifiers is by serial number (lowest serial number is Rect 1, next lowest is Rect 2, etc.). If you prefer the NCU to identify the rectifiers by position in the system, perform the following procedure.

Upon power up, the NCU arbitrarily assigns Feed AC1, AC2, or AC3 to each rectifier. This assignment is used to display rectifier AC input feed voltage(s). The User may reassign the feed to each rectifier per your specific installation by following the procedure below.


None.



Configuring the NCU Identification of Converters

When converters are all installed prior to applying power and starting the system, the order in which the NCU identifies the converters is by serial number (lowest serial number is Conv 1, next lowest is Conv 2, etc.). If you prefer the NCU to identify the converters by position in the system, perform the following procedure.


None.



NCU Alarm Relay Check

To verify operation of the external alarm relays, use the NCU alarm relay test feature. Refer to the NCU Instructions (UM1M830BNA) for instructions in using this feature.

Note:

The relays may be preprogrammed for specific functions.

Refer to the configuration drawing (C-drawing) supplied with your system for your system’s specific configuration.

Spec. No: 582127000

Model No: 721

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Code: IM582127000




Checking System Status

PROCEDURE

1.

Observe the status of the indicators located on the controller, rectifiers, and converters (if furnished). If the system is operating

normally, the status of these is as shown in Table 16 .

Table 16. Status and Alarm Indicators

Component Indicator Normal State

ACU+

NCU

Rectifier

Modules

Converter

Modules

or

or

or

or

or

or

Power

(Green)

Protection

(Yellow)

Alarm

(Red)

Power

(Green)

Protection

(Yellow)

Alarm

(Red)

Status

(Green)

Minor

(Yellow)

Critical or Major

Alarm (Red)

Status

(Green)

Minor

(Yellow)

Critical or Major

Alarm (Red)

On

Off

Off

On

Off

Off

On

Off

Off

On

Off

Off

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Final Steps

PROCEDURE

1.

If any controller configuration settings were changed, refer to the ACU+ Instructions (UM1M820BNA or UM1M820DNA400) or

NCU Instructions (UM1M830BNA) and save a copy of the configuration file. This file can be used to restore the controller settings, if required, at a later date.

• Note that provided on a USB drive furnished with the system is a controller configuration drawing (C-drawing) and the controller configuration files loaded into the controller as shipped.

2.

Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door.

3.

Verify all rectifier and converter modules and the controller are fully seated, latched, and the latch handle screws secured.

4.

Verify there are no external alarms and the local indicators are as shown in

Table 16 .

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Model No: 721

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Spec. No: 582127000

Model No: 721

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Code: IM582127000




NetPerform™ Optimization Services

At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both your business and your bottom line. That is why we offer a wide array of services to meet all of your network infrastructure needs.

Customer Service (Pre-Shipment)

Email [email protected]

Phone 1.800.800.1280 option 1

Customer Support Center (Post-Shipment)

Email

[email protected]

[email protected]

Pricing and availability

Associate.

[1,2] , purchase orders, expediting requests and order tracking. Ask for your company’s dedicated Customer Service

Email

Phone

[email protected] After an order has shipped, contact our Customer Support Center

1.956.661.6867 with related questions, concerns or claims.

Account Management

Email

Phone

[email protected]

1.800.800.1280 option 2

Spare Parts

Provides quotes and bid responses

(Reps, VARs & Distributors). for custom configured [2] DC power systems and outside plant enclosures for customers and channel partners

Pricing and purchase orders for spare parts, including but not limited to breakers, cables, fuses, rectifier fans, misc. breaker and fuse panels, enclosure fans, doors and switches, etc.

Phone 1.800.800.1280 option 5

DC Power Depot Repair

Email

Phone

[email protected]

1.800.800.1280 option 6

Creates and processes RMAs for depot repair and refurbishment.

Determines repair and refurbishment lead times and pricing based on warranties/contractual agreements. Provides repair shipping information and status.

Technical Support

Email

[email protected]

[email protected]

Answers technical product and system questions; determines status of warranties and contractual agreements for repair.

Phone

Email

1.800.800.5260

[email protected]

Phone 1.440.240.0639

[1] Contact Account Management for custom-configurations.

[2] Contact Spare Parts for parts and accessories.

Provide quotes and bid responses for application specific configured DC power systems for Liebert DC power sales reps.

Spec. No: 582127000

Model No: 721

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Code: IM582127000


NetSure

™

-48V DC Power System


Spec. No: 582127000

Model No: 721

NPBB

Code: IM582127000


Emerson Network Power NetSure 721NPBB 48V DC Power System Installation Instructions

Assistant Bot

NetSure

™

-48V DC Power System

Installation Instructions, IM582127000 (Issue N, June 19, 2015)

Specification Number: 582127000

Model Number: 721

This page is intentionally blank.

Table of Contents

Admonishments Used in this Document

Important Safety Instructions

General Safety

Voltages

Battery

Personal Protective Equipment (PPE)

Hazardous Voltage

Handling Equipment Containing

Static Sensitive Components

Static Warning

General Information

Customer Documentation Package

Installation Acceptance Checklist

Installing the System

General Requirements

Securing the Relay Rack to the Floor

Notes:

1. All dimensions are in inches.

Mounting System Components in an Equipment Rack

Secure the module mounting shelf(s) to the relay rack.

Secure the module mounting shelf(s) to the relay rack.

MOUNTING HARDWARE

12-24 x 3/4" Thread Formi

Installing Optional Battery Busbar Extension Kit, Part No. 554541

GND RTN

-48V SUPPLY

Installing Optional Lug Adapter Busbar Kits, Part Nos. 534449 and 514714

Notes:

Orient busbars as shown.

Shield not shown. Remove breakaway areas from shield as required.

Installing Circuit Breakers and Fuses

Shorter Side to the Top

Lettering on handle must be right side up.

Turn off before installing.

Insert these terminals into corresponding sockets on distribution panel.

Longer Side to the Bottom

Setting Jumpers and Switch Options

Circuit Card Locations

Jumpers on System Interface Circuit Card (Main Bay Only)

Switch Settings on IB2 Interface Board (Main Bay Only)

Switch Setting on Optional EIB Interface Board (Main Bay Only)

Switch Setting on SM-DU (Supplemental Bays Only)

Switch Setting on SM-DU+

Making Electrical Connections

Important Safety Instructions

Wiring Considerations

Relay Rack Grounding Connection (Frame Ground)

Central Office Ground Connection

Nominal 208/240 Volts AC Input and Equipment

Grounding Connections (if equipped)

400 Volts DC Input and Equipment Grounding

Connections (if equipped)

+ -

+ -

+ -

+ -

+ -

+ -

+ -

+ -

+ -

+ -

External Alarm, Reference, Monitoring, and Control Connections

OR

Battery Block Monitoring

Battery Midpoint Monitoring

Schematic Diagram of EIB Board

EIB Board

Controller Ethernet Connection (if required)

Ethernet wire coming out from one of the rectangular openings on top of cabinet panel