Page 3 - Emerson Energy Systems; NT5C05C Installation and User Manual; Installation and User Manual
3 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Helios Modular Switch Mode Rectifier 200I/48 NT5C05C Installation and User Manual Manual Number : UM5C05C ( 169-2081-501 ) Manual Status : Standard Manual Issue : 6.00 Release Date : October 2001 P0745680 Copyr...
Page 5 - Publication history; numbering corrections.
5 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Publication history October 2001 Standard Issue 6.00. Manual restructured and updated to reflect Emerson Energy Systems and Emerson Network Power identities. ( ECN 102-26804 ) March 1998 Issue 5.0. Standard. Reference ...
Page 6 - Publication history; This page is left blank intentionally.
6 Publication history UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems This page is left blank intentionally.
Page 7 - Contents
7 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Contents 1. General information .................................................................................... 11 1.1. Purpose of this manual .........................................................................
Page 8 - Contents
8 Contents UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 6. Maintenance ................................................................................................. 49 6.1. Replacing the air filter ...............................................................................
Page 9 - Contents 9
Contents 9 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Procedure 6 - Connecting the ac male plug between the NT5C05CC rectifier and the ac female plug in a 1200 A cabinet .................................. 27 Procedure 7 - Connecting the NT5C05CC to the controller...
Page 10 - 0 Contents
10 Contents UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems This page is left blank intentionally.
Page 11 - General information; Purpose of this manual; Figure 1 - Front view of the modular 200I / 48 switch mode rectifier
11 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 1. General information 1.1. Purpose of this manual This manual provides installation, operation and maintenance information for the NT5C05CA / CB / CC 200I modular switch mode rectifiers with an input voltage of 380 /...
Page 12 - 2 General information; Models and mounting configurations; Two models of 200I rectifiers are available :; Figure 2 - Typical mounting in a cabinet or frame
12 General information UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 1.2. Models and mounting configurations Two models of 200I rectifiers are available : • Models NT5C05CA / CB, without an ac cable • Model NT5C05CC, equipped with an ac cable terminated with a male plug Up to si...
Page 13 - Mechanical and electrical specifications; Table 1 - Mechanical specifications of the rectifier
13 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 2. Specifications 2.1. Mechanical and electrical specifications Table 1 - Mechanical specifications of the rectifier Height : 10.0 inches ( 25.4 cm ) Depth : 22.0 inches ( 55.9 cm ) Width : 20.5 inches ( 52.1 cm ) Wei...
Page 14 - 4 Specifications; Operation specifications and ambient conditions; Table 3 - Operation specifications of the rectifier; • less than 22 dB of random noise on C band at voice
14 Specifications UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 2.2. Operation specifications and ambient conditions Table 3 - Operation specifications of the rectifier Output regulation : At the output terminals, the voltage is within ±0.5% of the set voltage value for all spec...
Page 15 - Specifications 15; Table 4 - Ambient conditions for the rectifier
Specifications 15 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Table 4 - Ambient conditions for the rectifier Operating conditions A minimum airflow clearance of 2 inches ( 5 cm ) is required at the rear of the rectifier. The rectifier will operate properly under t...
Page 16 - 6 Specifications; Mechanical and electrical specifications of a 1200 A cabinet; Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet; Ambient conditions of a 1200 A cabinet; Table 7 — Ambient conditions for the NT6C43CB 1200 A cabinet
16 Specifications UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 2.3. Mechanical and electrical specifications of a 1200 A cabinet Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet Height : 84.00 inches ( 213.36 cm ) Depth : 23.63 inches ( 60.0 cm ) Width : 23.63...
Page 17 - configurations; The following tools and test equipment are required :; Cautions and Warnings; CAUTION; Protecting the premises
17 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 3. Installation 3.1. Mounting configurations The NT5C05CA / CB / CC rectifiers are designed for installation in a 1200 A cabinet ( NT6C43CB ) or in a standard frame ( NT6C40 or equivalent ). In this chapter, a differe...
Page 18 - 8 Installation; Preventing damage caused by over-tightening; Personal safety and protecting the equipment; Preventing personal injury; Optimizing the life of the equipment
18 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems CAUTION Preventing damage caused by over-tightening Do not over-tighten nuts and bolts. Over-tightening can strip the threads or break the bolts. Apply the appropriate torque values. CAUTION Personal safety and protec...
Page 19 - Installation 19; WARNING; Grounding; DANGER; Protecting against electrical shocks
Installation 19 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual WARNING Generator requirements for Emerson Energy Systems Power Systems For information on selecting ac generators that will effectively maintain peak performance and operating characteristics, for all As...
Page 20 - 0 Installation; Short circuit hazard; Install each rectifier beginning with the lowest mounting
20 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems DANGER Short circuit hazard The rectifiers, and the batteries in particular, can deliver high current if a short to ground occurs. When working on live equipment, remove all personal jewellery, use properly insulated ...
Page 21 - Installation 21; Figure 3 - Anchoring the cabinet; Procedure 2 - Installing a rectifier in a cabinet
Installation 21 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual in the concrete floor, the secondary anchor locations may be used. An optional cabinet isolation kit is available consisting of four anchor bushings and a base pad. If this kit is installed, place the pad...
Page 22 - 2 Installation; Install an external tooth lock washer on one of the screws to; Figure 4 - Installing the rectifier; Cabling and connecting
22 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems Procedure 2 - Installing a rectifier in a cabinet ( continued ) Step Action 4 Place the rectifier on the L-shaped guides located in the lowest position of the cabinet and slide it towards the rear until the mounting b...
Page 23 - Installation 23; Connecting the dc output terminals to the busbars; the ground side
Installation 23 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 3.5. Connecting the dc output terminals to the busbars The dc outputs of the rectifier are connected to the busbars as illustrated in Figure 5. There are two methods : • BAT GRD ( + ) of the rectifier con...
Page 24 - 4 Installation; Securing the dc output terminals to the busbars in a 1200 A; Tighten the bolts by applying a torque of 6.5; rectifier; Apply a torque of 6.5; Connecting ac to the rectifiers
24 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 3.5.1. Securing the dc output terminals to the busbars in a 1200 A cabinet For cabinet applications, no dc cabling is required; the output terminals of the rectifier are connected directly to the busbars. Procedure 3 ...
Page 25 - Hazardous potentials
Installation 25 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual DANGER Hazardous potentials Input voltage to the cabinet is at a hazardous potential. Make sure the power is OFF and that the lever in the ac service panel is locked in the OFF position before attempting ...
Page 26 - 6 Installation
26 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems Figure 6 - Cabling ac the NT5C05CA / CB rectifiers PART OF OPTIONAL KIT P0872151 HEX HEAD CAP SCREW AND WASHERS ( 4 PLACES ) SIGNAL CAB LES TO THE PLANT CONTROLLER REMOVE PLATE TOACCESS CONNECTORS A C FEED TORECTIFIER...
Page 27 - Installation 27; and the ac female plug in a 1200 A cabinet; Connecting the control signals; Figure 8 - Connecting ac to the rectifier NT5C05CC
Installation 27 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Procedure 6 - Connecting the ac male plug between the NT5C05CC rectifier and the ac female plug in a 1200 A cabinet Step Action 1 Install the ac breaker ( 30 A / 3 phases per rectifier ) in the 380 / 415 ...
Page 28 - 8 Installation; Procedure 7 - Connecting the NT5C05CC to the controller; Connect the NT6C43PB board ( positions J7 to J12 ) to the; controller; CONTROLLER NT
28 Installation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 3.7. Connecting the control signals For all applications with conventional controllers ( such as NT6C25BA or NT6C25BB ) or front access controllers ( NT6C25FA ), execute the steps contained in Procedure 7 to connect t...
Page 31 - Functional description
31 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 4. Functional description 4.1. Overview 4.1.1. Input circuit The input circuit offers the following characteristics : • ac rectifying • EMI filtering • inrush current limiting, a walk-in circuit limits the output curr...
Page 32 - 2 Functional description; Description of the front panel
32 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 4.1.3. Monitoring and control circuits The monitoring and control circuits offer the following characteristics : • soft start • rectifier fail alarm ( RFA ) • control for local and remote equalize ( EQL ) • ...
Page 33 - Functional description 33; Figure 10 - Front panel controls and LEDs
Functional description 33 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 4.2.2. Switches, controls and LEDs There are switches and potentiometers on the front panel to adjust the operating parameters of the rectifier. The LED indicators indicate the operating and ala...
Page 34 - Indicates the rectifier is in equalizing mode.
34 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 4.2.3. Front panel LEDs Table 10 - Designation of the LEDs on the front panel LED Color Description AC ON Green Input ac voltage operational CL Yellow Current Limit EQL Yellow Rectifier is in equalize mode F...
Page 35 - Functional description 35; abnormal or out of range ac input voltage
Functional description 35 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual HVSD ( high voltage shutdown ) The rectifier monitors itself for high voltage and will shut down when its output voltage exceeds a preset adjustable value ( between -52 V and -60 V ). RFA ( rect...
Page 37 - Functional description 37; Instruction Manual
Functional description 37 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual VOLT / AMP digital meter switch This switch is used to select the measurement display mode of the digital meter. The output voltage or the output current modes can be selected. VOUT+, VOUT −−−− ...
Page 38 - 8 Functional description; Two methods for sharing load current are available :
38 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems The rectifier can be started when it is connected across a completely discharged battery without requiring human intervention or operating protective devices. A transition from constant voltage operation to ...
Page 39 - Functional description 39; If the rectifier is expected to provide 100 A at 48 V
Functional description 39 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Example 1 : If the rectifier is expected to provide 100 A at 48 V V ( preset ) = 48 V + 0.8 V + ( 100 x 300 mV ) 200 V ( preset ) = 48 V + 0.8 V + 0.15 V = 48.95 V Example 2 : If the rectifier i...
Page 40 - 0 Functional description; HVSD ADJ ( high voltage shutdown adjust ) potentiometer; The rectifier may be reset from an HVSD condition locally by :; TR ( temporary inhibition ) and sequential start
40 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 4.2.9. HVSD ( high voltage shutdown ) HVSD ADJ ( high voltage shutdown adjust ) potentiometer Use this potentiometer to set the internal threshold level at which the local high voltage shutdown condition sho...
Page 41 - Functional description 41
Functional description 41 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Table 13 - Setting the start-up delay POSITION DELAY POSITION DELAY 0 X X X X X X X X X X X X X X X X X X X X 4 SEC 12 SEC 20 SEC 28 SEC 36 SEC 44 SEC 52 SEC 60 SEC 1 X X X X X X X X X X X X 68 ...
Page 42 - Remote ON / OFF control TR; Table 14 - Control signal connections on P1
42 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems Remote ON / OFF control TR When a ground signal is applied to the 'Temporary Release' ( TR ) input, the rectifier inhibits its operation and triggers the RFA. When the remote ground signal is discontinued th...
Page 44 - 4 Functional description
44 Functional description UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems This page is left blank intentionally.
Page 45 - settings; Table 15 - Standard settings for the rectifier
45 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 5. Operation 5.1. Standard settings The parameters of the NT5C05CA / CB / CC rectifiers are set as indicated in Table 15. For different settings refer to User Manual Voltage_level entitled Voltage Level Limits for Pow...
Page 46 - 6 Operation; Starting up and adjusting; Procedure 9 - Starting up the rectifier; Put the ac circuit breaker in the main ac service panel to ON.; Adjusting the high voltage shutdown ( HVSD ); Turn the HVSD potentiometer fully clockwise.
46 Operation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 5.2. Starting up and adjusting Procedure 9 - Starting up the rectifier Step Action 1 Put the dc circuit breaker to OFF ( 0 position ). Open the sensing leads by removing the corresponding RC fuse ( when the rectifier is ...
Page 48 - 8 Operation; Turn ON the other rectifiers in the system.; Setting the start-up delay; Deactivate the EQL mode to return to the normal float mode.
48 Operation UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems Procedure 9 - Starting up the rectifier ( continued ) Step Action 23 Turn ON the other rectifiers in the system. Setting the start-up delay 24 Use this feature to reduce the inrush currents when two or more rectifiers ar...
Page 49 - Replacing the air filter; Figure 11 - Replacing the fan unit
49 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 6. Maintenance 6.1. Replacing the air filter In dusty environments, the use of air filters is strongly recommended. If used they should be replaced at least once a year. 6.2. Replacing the fan unit The fan unit, consi...
Page 50 - Preventing short circuits; Calibrating the Volt / Amp Multimeter
50 Maintenance UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems CAUTION Preventing short circuits The replacement operation is safe, as only SELV circuitry is present behind the fan assembly. However, due to the possible presence of residual charges in the output circuit, do not us...
Page 51 - Resetting the rectifier after an HVSD ( high voltage shutdown )
Maintenance 51 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual Procedure 11 - Calibrating the meter Step Action 1 Make sure the remote sense leads are disconnected by removing the corresponding RC − fuse from the controller. 2 Set the VOLT/AMP switch to AMP. Set the o...
Page 52 - 2 Maintenance
52 Maintenance UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems This page is left blank intentionally.
Page 54 - 4 Troubleshooting; No ac input voltage.
54 Troubleshooting UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems Table 16 – Diagnosing system faults Fault symptom Possible causes The AC ON LED is not lit. • No ac input voltage. • The input circuit breaker is open. • AC voltage is present but is out of operational limits. The ...
Page 55 - ITEM; Fan Assembly
55 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 8. Appendix A : Replacement parts ITEM PART NUMBER ( CPC ) Fan Assembly P0723582 Fuse 1 A ( FF1, FF2 on Display PCB ) A0287301 Air filter P0744757 Air filter frame P0744559
Page 56 - 6 Appendix A: Recommended Replacement Parts
56 Appendix A: Recommended Replacement Parts UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems This page is left blank intentionally.
Page 57 - Appendix B : Technical service assistance; Local toll-free prefixes; Country Prefix; Korea
57 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 9. Appendix B : Technical service assistance For technical assistance, 24 hours a day / 7 days a week, dial one of the following toll-free numbers. This service complements the services offered by field support organi...
Page 58 - Toll-free technical assistance numbers; In Asia and the Pacific:
58 Appendix B : Technical service assistance UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems 9.2. Toll-free technical assistance numbers United States: 1-800-992-8417 Canada: 1-800-363-2288 In Europe: In Asia and the Pacific: Austria 800-213-49156 Australia 800-213-49156 Belgium 8...
Page 59 - Abbreviations and acronyms
59 Emerson Energy Systems Rectifier 200I/48 NT5C05C Installation and User Manual 10. Abbreviations and acronyms ALCO Alarm cut-off ALM Alarm AUTOST Auto restart Indicator C Common CL Current limit indicator EMI Electromagnetic interference EQL Equalize FAN ALM Fan alarm HVSD High voltage shutdown ...
Page 60 - 0 Abbreviations and acronyms
60 Abbreviations and acronyms UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems RFA Rectifier fail alarm RG+ Remote ground bus ( positive ) RMT ACK Remote acknowledge SEN FAIL Sense fail THSD Thermal shutdown TR Temporary release VCAL Voltage reading calibration
