Page 3 - Astec; Advanced Power Systems; Installation and User Manual
Astec Advanced Power Systems Helios Rectifier 25/48 NT5C06D Installation and User Manual Helios Rectifier 25/48 Single Phase -48V, 25A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual Manual Number : UM5C06D ( 169-2071-504 ) Manual Status : Standard Manual Issue : ...
Page 5 - Publication history
5 Helios Rectifier 25/48 NT5C06D Installation and User Manual Publication history May 2001 Standard issue 7.00. Manual modified to reflect the Emerson identity. ( EC 102-26438 ) September 1999 Standard 6.0. Document modified to be in accordance with Astec standards. (ECN 102-17331) May 1999 Standa...
Page 6 - This page is left blank intentionally.
6 Publication history UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 This page is left blank intentionally.
Page 7 - Contents
7 Helios Rectifier 25/48 NT5C06D Installation and User Manual Contents Introduction.............................................................................................................. 11 Description ............................................................................................
Page 9 - List of Figures
Contents 9 Helios Rectifier 25/48 Installation and User Manual RFA fault ..............................................................................................................47 SEN FAIL fault ......................................................................................................
Page 11 - Description; negative slope method.
11 Helios Rectifier 25/48 NT5C06D Installation and User Manual 1. Introduction Description The NT5C06D Switch Mode Rectifier is rated for 25 A at -48 V DC. This rectifier incorporates AC input power factor correction circuitry, is highly efficient and lightweight (15 lbs.). It is fully connectoriz...
Page 12 - Applications; operate in temperatures ranging from 0°C to 65°C.; Equipment Identification; options for the NT5C06D Rectifier, and the MPS75 power shelves.
12 Introduction UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Applications The rectifier is designed to function as the prime source of power for equipment requiring -48 V DC. It will also operate as a battery charger or as a battery replacement (batteryless operation). Its low output noi...
Page 13 - V for floating a 23 or 24 cell battery string.
Introduction 13 Helios Rectifier 25/48 Installation and User Manual Helios Rectifier 25/48 NT5C06D(X) –48 V / 25 A Switch Mode Rectifier The NT5C06D provides -48 V / 25 A of isolated, filtered, and regulated DC power from a single phase AC source, for powering a load while charging a positiv...
Page 14 - Figure 3 - NT5C06D Switch Mode Rectifier
14 Introduction UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 2 - MPS75 Modular Power shelf- NT5C10C with 26-pin signal connectors Mountingholes (4) Signal cable connection DC connection Mountingholes (4) Figure 3 - NT5C06D Switch Mode Rectifier Height: 168 mm (6.60 inches) Depth: ...
Page 15 - Electrical specifications; Engineering department of Astec Advanced Power Systems).; Table 1 - Electrical specifications
15 Helios Rectifier 25/48 NT5C06D Installation and User Manual 2. Specifications Electrical specifications The NT5C06D rectifier operates within the electrical specifications listed in Table 1. (Refer to the Product Specification which can be obtained from the Engineering department of Astec Advan...
Page 16 - Output noise and ripple; shelf and with the rectifier in the local sensing mode.; Efficiency and Power Factor
16 Specifications UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Table 1 - Electrical specifications ( continued ) Output Protection: A single pole 35 A circuit breaker is connected in series with the negative output lead of the rectifier. The rectifier contains an adjustable output curren...
Page 17 - Environmental specifications
Specifications 17 Helios Rectifier 25/48 Installation and User Manual Environmental specifications Operating CAUTION An airflow clearance must be left at the rear of the shelf. A minimum of three inches is recommended. The rectifier will operate satisfactorily under the following environmental condi...
Page 19 - Installation and start up; Tools and test equipment
19 Helios Rectifier 25/48 NT5C06D Installation and User Manual 3. Installation and start up The power shelf must be installed on the framework and all AC, DC and control and alarm wiring must be connected before the rectifiers are physically plugged in. Tools and test equipment The following tools...
Page 20 - Procedure 1 - Installing the power shelf; Release the clamping bar from the front of the power shelf; Wiring the power shelf; The power shelf wiring should be installed by qualified; DANGER
20 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 1 - Installing the power shelf Step Action 1 Position the power shelf, without any rectifiers plugged in, against the framework. 2 Secure the shelf in the position indicated by the job drawing (normally d...
Page 21 - Installing the AC power; 2 AWG for each rectifier
Installation and start-up 21 Helios Rectifier 25/48 Installation and User Manual Installing the AC power Permanent AC connection to the MPS75 power shelf is done using two armored cable conductors, RW-90 or equivalent, as listed in Table 2. One must be routed to L1, and the other one to L2 and to th...
Page 22 - Figure 5 - Power shelf individual AC connection; the wire does not interfere with the rectifier connections.; CAUTION; been instructed to do so in the appropriate procedure.; DC Conductors Installation
22 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 5 - Power shelf individual AC connection FR GRD POS 3 POS 2 POS 1 L1 L2 L1 L2 L1 L2 6 5 4 3 2 1 When cabling the AC to the power shelf, make sure that each corresponding safety ground wire is properly connec...
Page 23 - Table 4 - DC cable wire size; Control and Alarm Connections
Installation and start-up 23 Helios Rectifier 25/48 Installation and User Manual Table 4 - DC cable wire size 1 RECT. POSITION 2 RECT. POSITIONS 3 RECT. POSITIONS 8 AWG 6 AWG 4 AWG Figure 6 - Connecting the DC power shelf Control and Alarm Connections The rectifier is interfaced to the power plant c...
Page 24 - Both RFA and Fan alarm relays are energized during; Designation
24 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Table 5 - Rectifier and Controller interface connections (8-pin connectors) Pin # Design. Description Signal 1 EQL Remote Equalize BAT RTN 2 RG+ Sensing Positive BAT RTN 3 RC- Sensing Negative -48V 4 FAN ALM Fan Fa...
Page 25 - The normally closeed (NC) annotation signifies that the
Installation and start-up 25 Helios Rectifier 25/48 Installation and User Manual Table 6 - Rectifier and Controller interface connections (26-pin connector) ( continued ) Pin # Designation Description Signal 23 DC BRK ALM DC Circuit Breaker NC 24 AC FAIL ALM AC Line Fail Alarm NC 25 SENSE FAIL ALM S...
Page 26 - Refer to MS5C06 for available 8-pin ribbon signal cables
26 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 7 - No controller, remote sensing connection for 8-pin signal cable shelves Note 1: Refer to MS5C06 for available 8-pin ribbon signal cables of different lengths to connect from the shelf back plane rectifie...
Page 27 - S IG N A L
Installation and start-up 27 Helios Rectifier 25/48 Installation and User Manual Figure 8 - No controller, remote sensing connection for a 26-pin signal connector shelf - + BA TTE RY o r d e s ire d re g u la tio n p o in t RC - RG + RC FU SE 1 .6 AM P S EE NO TE 4 2 0 AW G (SEE N O TE 3 ) 1 6 1 1 2...
Page 28 - Verification; Verify that the power shelf has been mechanically secured.; Installing the rectifier; Release the clamping bar by loosening the two captive screws; Factory setting; The rectifier is factory set as indicated in Table 7.
28 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Verification After completing the wiring of the power shelf perform the following: Procedure 2 - Verification Step Action 1 Verify that the power shelf has been mechanically secured. 2 Verify that all the wiring pe...
Page 29 - Rectifier meter accuracy; Repeat the following steps for each rectifier in turn.; Procedure 4 - Starting up the rectifier; Close the AC circuit breaker in the AC service (main) panel.; Float Voltage Adjustment :
Installation and start-up 29 Helios Rectifier 25/48 Installation and User Manual Rectifier meter accuracy The rectifier's current meter is precise within + 2%. Start-up and verification Repeat the following steps for each rectifier in turn. Procedure 4 - Starting up the rectifier Step Action 1 Close...
Page 30 - Step Action; Share
30 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 4 - Starting up the rectifier ( continued ) Step Action 10 In order to accurately adjust the rectifiers float and/or equalize (if different from factory setting) the current share mode setting must be tak...
Page 31 - Slope load sharing
Installation and start-up 31 Helios Rectifier 25/48 Installation and User Manual Procedure 4 - Starting up the rectifier ( continued ) Step Action 11 (ii) Forced Share In the forced share mode, the rectifier's output voltage setting is not modified with changes in output load as is the case in the S...
Page 32 - Slope Load Share; SLS / FS switch of each rectifier must be pushed towards the SLS.; Forced Load Share; Procedure 5 - Adjusting the load share; Verify that all the share mode settings are the same SLS or FS.
32 Installation and start-up UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Slope Load Share When the rectifier is connected in parallel with rectifiers in the same power shelf, or other power shelves, and this method of load sharing is desired, the SLS / FS switch of each rectifier must b...
Page 33 - circuitry and the cooling fan unit.
33 Helios Rectifier 25/48 NT5C06D Installation and User Manual 4. Operation In addition to rectifying the AC, the input circuit provides EMI filtering, inrush current limiting, low and high AC inhibit, power factor compensation, surge voltage protection, and is equipped with a 13 A AC breaker for ...
Page 34 - Front panel controls
34 Operation UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Front panel controls Figure 9 - NT5C06D - front view Features In addition to the features and performance characteristics described earlier, the rectifier provides the following features. Local float / equalize control The rectifi...
Page 35 - This unit does not have a start-up delay.; Indicators; Table 8 - Indicators; RFA; Fan failure alarm
Operation 35 Helios Rectifier 25/48 Installation and User Manual Start-up delay This unit does not have a start-up delay. Test points (V+, V-) Test points allow the user to measure the voltage at the point of regulation. A 100 ohm PTC resistor is placed in series with both leads to prevent damage ca...
Page 36 - Remote ON/OFF control; will be transmitted through the signal connector only.; Current limiting
36 Operation UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Local ON/OFF control (AC breaker) The AC input circuit breaker can be used to locally turn the rectifier ON/OFF. The local ON/OFF control overrides remote control signals. Remote ON/OFF control When a battery return (BAT RTN) sign...
Page 37 - Sequential start; Discharge of output capacitors; disconnected from the batteries or parallel units.
Operation 37 Helios Rectifier 25/48 Installation and User Manual Sequential start The rectifier TR lead is available for use with an external sequential start circuit. Parallel operation The rectifier is capable of operating in parallel with other rectifiers having similar output characteristics and...
Page 39 - Figure 10 - Power interface connections; Signal interface connector
Operation 39 Helios Rectifier 25/48 Installation and User Manual Figure 10 - Power interface connections Signal interface connector Figure 11 shows the pin assignment of the signal interface connector. This connector is used to interface all the control, alarm and monitoring signals with the power s...
Page 40 - Figure 11 - Control signal connections
40 Operation UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 11 - Control signal connections 1 1 - REMOTE EQL 2 - SENSING RG + 3 - SENSING RC - 4 - TEMPORARY RELEASE 5 - REMOTE HVSD RESET 6 - REMOTE HVSD 7 - RFA NC 8 - Not Connected 9 - FAN ALARM NC 10 - RFA COMMON 11 - FAN ALARM COM...
Page 41 - If the unit operates in a dusty environment the optional; Do not install a wet filter on the unit; Procedure 6 - Adjusting the float / equalize; Open the DC circuit breaker.
41 Helios Rectifier 25/48 NT5C06D Installation and User Manual 5. Maintenance The NT5C06D rectifier is virtually maintenance free. It requires periodic float / equalize verification (once every six months) and air filter replacement as required. Note: If the unit operates in a dusty environment th...
Page 42 - and Verification” section of this manual.; Cooling fan; Do not attempt to access the inside of the unit with a tool; Fan failure
42 Maintenance UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Procedure 6 - Adjusting the float / equalize ( continued ) Step Action 6 The float voltage should be adjusted with the rectifier in service, as follows: The rectifier is connected to the system and should carry some load. If the...
Page 43 - Fan replacement; Before replacing the fan, turn the rectifier OFF.; Keep any dirt, dust, moisture or metallic particles from; Procedure 7 - Replacing the fan; Replace with a new one.
Maintenance 43 Helios Rectifier 25/48 Installation and User Manual Fan replacement CAUTION Before replacing the fan, turn the rectifier OFF. Completely disconnect and remove it from the shelf. Wait thirty minutes to allow all internal capacitors to fully discharge and for all components to cool down...
Page 44 - Ensure that the fans spin freely, without interference.
44 Maintenance UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 Figure 12 - NT5C06D rear view CAUTION Ensure that the fans spin freely, without interference.
Page 45 - Do not run the rectifier without a fully operational fan or; Power shelf; The power shelf requires no maintenance.
Maintenance 45 Helios Rectifier 25/48 Installation and User Manual CAUTION Do not run the rectifier without a fully operational fan or with a fan other than the specified replacement for this cooling application. Power shelf The power shelf requires no maintenance.
Page 47 - Alarm indication; Table 9 - System fault diagnosis; An internal high voltage shutdown (HVSD) has
47 Helios Rectifier 25/48 NT5C06D Installation and User Manual 6. Troubleshooting Alarm indication RFA fault Table 9 - System fault diagnosis Fault symptom Possible causes No AC input or input out of bounds. No AC input or input out of bounds. AC Input/DC output circuit breaker is open. Rectifier ...
Page 48 - SEN FAIL fault
48 Troubleshooting UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 SEN FAIL fault Fault symptom Possible causes One or both remote sense leads is disconnected. DC breaker is open. Rectifier is still in walk-in. SEN FAIL Sense leads are reversed. Erratic load fault Fault symptom Possible cau...
Page 49 - ITEM CPC; Fan Assembly
49 Helios Rectifier 25/48 NT5C06D Installation and User Manual 7. Appendix A: Replacement parts ITEM CPC Fan Assembly P0710139 Air Filter Kit P0834732
Page 51 - Appendix B: Technical service assistance; Local toll-free prefixes; Country Prefix
51 Helios Rectifier 25/48 NT5C06D Installation and User Manual 8. Appendix B: Technical service assistance For technical assistance, 24-hours a day / 7 days a week, dial one of the following toll-free numbers. This service complements the services offered by field support organizations such as, th...
Page 52 - Toll-free technical assistance numbers; In Asia and the Pacific:
52 Appendix B: Technical service assistance UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 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 800-213-49156 Hon...
Page 53 - List of terms and acronyms
53 Helios Rectifier 25/48 NT5C06D Installation and User Manual 9. List of terms and acronyms ALM Alarm BAT Battery BAT RT N Battery Return C Common CL Current Limit CS Current Share EMI Electromagnetic Interference EQL Equalize FAN ALM Fan Alarm FLT Float FR GND Frame Ground FS Forced Load Share H...
Page 54 - TBD
54 List of terms and acronyms UM5C06D ( 169-2071-504 ) P0831010 Standard 7.00 May 2001 NO Normally Open NT Northern Telecom PCB Printed Circuit Board RFA Rectifier Fail Alarm RG+ Sensing Battery Positive RC - Sensing Battery Negative SEN FAIL Sense Fail SH + Shunt Positive SH - Shunt Negative SLS Sl...
Page 56 - Single Phase
Helios Rectifer 25/48 Single Phase − 48 V, 25 A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual Astec Advanced Power Systems Ltd 2280 Alfred-Nobel Blvd St-Laurent ( Quebec ) Canada H4S 2A4 Copyright 2001 Astec Advanced Power Systems Ltd All Rights Reserved The inf...
