Emerson 200I-48-NT5C05C User Manual

Emerson Energy Systems

UM5C05C ( 169-2081-501 )

Helios Modular Switch Mode Rectifier
200I/48NT5C05C

Installation and User Manual

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P0745680 Standard 6.00 October 2001

Helios Modular Switch Mode Rectifier

3

200I/48

NT5C05C



Installation and User Manual

Manual Number : UM5C05C ( 169-2081-501 )
Manual Status : Standard
Manual Issue : 6.00
Release Date : October 2001
P0745680

Copyright  2001 Astec Internat ional Lt d
All Rights Reserved

Published in Canada
The information contained in this manual is the property of Astec Int ernational Ltd and is subject to change without

notice. Astec International Ltd reserves the right to mak e c hanges in design or components as progress in engineering
and manufacturing may warrant. Except as specifically authorized in writing by the V.P. of E ngineering and Product
Manufacturing of Astec Internat ional Lt d, t he holder of this manual shall keep all information contained herein confidential
and shall protect same, in whole or in part, f rom disclosure and dissemi nat ion to all third parties, and use the sam e f or
start-up, operation, and maint enance purposes only. Any modific at i on t o the equipment must be approved by the person
responsible for product safety and design quality at Astec International Ltd to insure that the equipment com plies with t he
operation standards.

This equipment has been tested and f ound to comply with the limits for a Clas s A digital device, pursuant to part 15 of the
FCC Rules. These limits are designed to provide reasonable protection against harm ful interference when the equipment
is operated in a commerc ial environment. The equipment generates, uses, and can radiate radio frequency energy, and if
not installed and used in accordance with the ins t ructions contained in the Installation and User Manuals, can cause
harmful interference to radio communications. Operation of t his equipment in a residential area is likely to caus e harmful
interference, in which case the user will be required to correct the interference at his own expense.

Helios and Helios Candeo are trademarks of Astec I nternational Ltd. The Emerson logo is a trademark and service mark of
Emerson Electric Co.

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

Publication history

October 2001

Standard Issue 6.00. Manual restructured and updated to reflect Emerson
Energy Systems and Emerson Network Power identities. ( ECN 102-26804 )

March 1998

Issue 5.0. Standard. Reference change from NT5C05CB to NT5C05C.

July 1997

Issue 4.0. Standard EMI compliance information and table of content
numbering corrections.

June 1995

Issue 3.0. Standard. Revised rectifier installation procedure in a cabinet.

September 1994

Issue 2.0. Standard. Few revisions and additions from the previous issue.

July 1994

Issue 1.0. Standard. Few changes from the previous issue and the document
is now rated “Standard”

5

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

6 Publication history

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UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Contents

1. General information .................................................................................... 11

1.1. Purpose of this manual .............................................................................. 11

1.2. Models and mounting configurations ......................................................... 12

2. Specifications..............................................................................................13

2.1. Mechanical and electrical specifications.................................................... 13

2.2. Operation specifications and ambient conditions....................................... 14

2.3. Mechanical and electrical specifications of a 1200 A cabinet.................... 16

2.4. Ambient conditions of a 1200 A cabinet..................................................... 16

3. Installation.................................................................................................... 17

3.1. Mounting configurations............................................................................. 17

3.2. Tools and test equipment........................................................................... 17

3.3. Cautions and Warnings.............................................................................. 17

3.3.1. Installing in a frame.............................................................................. 20

3.3.2. Installing in a cabinet ........................................................................... 20

3.4. Cabling and connecting.............................................................................. 22

3.5. Connecting the dc output terminals to the busbars.................................... 23

3.5.1. Securing the dc output terminals to the busbars in a 1200 A cabinet . 24

3.5.2. Running and connecting the dc between busbars and a rectifier........ 24

3.6. Connecting ac to the rectifiers.................................................................... 24

3.7. Connecting the control signals................................................................... 28

3.7.1. Monitoring of the shunt current............................................................ 29

4. Functional description................................................................................ 31

4.1. Overview .................................................................................................... 31

4.1.1. Input circuit .......................................................................................... 31

4.1.2. Output circuit........................................................................................ 31

4.1.3. Monitoring and control circuits............................................................. 32

4.1.4. Output capacitors................................................................................. 32

4.2. Description of the front panel ..................................................................... 32

4.2.1. Breakers .............................................................................................. 32

4.2.2. Switches, controls and LEDs............................................................... 33

4.2.3. Front panel LEDs................................................................................. 34

4.2.4. Local and remote adjustments and controls........................................ 35

4.2.5. Voltage / current displaytest and measurement............................... 36

4.2.6. Float and equalize voltage control....................................................... 37

4.2.7. Current limit adjustment and rectifier regulating test........................... 37

4.2.8. Rectifier parallel operation................................................................... 38

4.2.9. HVSD ( high voltage shutdown ).......................................................... 40

4.2.10. TR ( temporary inhibition ) and sequential start................................... 40

4.2.11. Control signals on connector P1.......................................................... 42

5. Operation...................................................................................................... 45

5.1. Standard settings ....................................................................................... 45

5.2. Starting up and adjusting ........................................................................... 46

7

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

8 Contents

6. Maintenance................................................................................................. 49

6.1. Replacing the air filter ................................................................................ 49

6.2. Replacing the fan unit ................................................................................ 49

6.3. Calibrating the Volt / Amp Multimeter......................................................... 50

6.4. Resetting the rectifier after an HVSD ( high voltage shutdown )................ 51

7. Troubleshooting.......................................................................................... 53

8. Appendix A : Replacement parts ............................................................... 55

9. Appendix B : Technical service assistance.............................................. 57

9.1. Local toll-free prefixes................................................................................ 57

9.2. Toll-free technical assistance numbers...................................................... 58

10. Abbreviations and acronyms..................................................................... 59

List of Figures

Figure 1 - Front view of the modular 200I / 48 switch mode rectifier................... 11

Figure 2 - Typical mounting in a cabinet or frame................................................ 12

Figure 3 - Anchoring the cabinet.......................................................................... 21

Figure 4 - Installing the rectifier............................................................................ 22

Figure 5 - Connecting the dc to the busbars with a shunt on the battery

side or a shunt on the ground side ...................................................... 23

Figure 6 - Cabling ac the NT5C05CA / CB rectifiers............................................ 26

Figure 7 - Connect the power leads to the L1, L2 and L3 terminals of the

rectifier................................................................................................. 26

Figure 8 - Connecting ac to the rectifier NT5C05CC........................................... 27

Figure 9 - Typical connections between rectifiers and the conventional

controller.............................................................................................. 28

Figure 10 - Front panel controls and LEDs.......................................................... 33

Figure 11 - Replacing the fan unit........................................................................ 49

List of Tables

Table 1 - Mechanical specifications of the rectifier .............................................. 13

Table 2 - Electrical specifications of the rectifier.................................................. 13

Table 3 - Operation specifications of the rectifier ................................................ 14

Table 4 - Ambient conditions for the rectifier ....................................................... 15

Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet .............. 16

Table 6 - Electrical specifications of the NT6C43CB........................................... 16

Table 7 - Ambient conditions for the NT6C43CB 1200 A cabinet........................ 16

Table 8 - Pin assignment for connectors J7 to J12.............................................. 29

Table 9 - Pin assignment for connector J13 ........................................................ 30

Table 10 - Designation of the LEDs on the front panel........................................ 34

Table 11 - Adjusting the potentiometers and switches ........................................ 36

Table 12 - Rectifier input / output signals to the controller................................... 36

Table 13 - Setting the start-up delay....................................................................41

Table 14 - Control signal connections on P1 ....................................................... 42

Table 15 - Standard settings for the rectifier........................................................ 45

Table 16 - Diagnosing system faults....................................................................53

List of Procedures

Procedure 1 - Installing the rectifier in a frame.................................................... 20

Procedure 2 - Installing a rectifier in a cabinet..................................................... 21

Procedure 3 - Securing the dc output terminals to the busbars of the cabinet.... 24

Procedure 4 - Typical dc cabling in a frame application ...................................... 24

Procedure 5 - Cabling the ac input to the NT5C05CA / CB rectifiers .................. 25

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Contents 9

Procedure 6 - Connecting the ac male plug between the NT5C05CC rectifier

and the ac female plug in a 1200 A cabinet.................................. 27

Procedure 7 - Connecting the NT5C05CC to the controller................................. 28

Procedure 8 - Connecting an NT5C05CC rectifier directly to a controller ........... 29

Procedure 9 - Starting up the rectifier.................................................................. 46

Procedure 10 - Replacing the fan unit ................................................................. 50

Procedure 11 - Calibrating the meter...................................................................51

Procedure 12 - Resetting the rectifier after a high voltage shutdown.................. 51

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

10 Contents

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UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

1. General information

1.1. Purpose of this manual

This manual provides installation, operation and maintenance information
for the NT5C05CA / CB / CC 200I modular switch mode rectifiers with an
input voltage of 380 / 415 V ac and an output capacity of 200 A at a
nominal voltage of –48 volts. This manual covers all applications of the
rectifier referred to as the 200I ( “I” standing for “International” ) market.

Figure 1 - Front view of the modular 200I / 48 switch mode rectifier

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The NT5C05CA / CB / CC rectifiers are designed to operate continuously
in a -48 V power system, equipped with or without batteries. It can be
integrated into a small-embedded system or a larger power plant
configuration. It is forced air-cooled by four fans contained in the unit, one
of which is are redundant, if one fan fails this will not cause a shutdown of
the rectifier. The rectifiers can be operated in conjunction with other
Emerson rectifiers as well as with the models and conventional controllers
of other manufacturers available on the market.

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

12 General information

1.2. Models and mounting configurations

Two models of 200I rectifiers are available :

• Models NT5C05CA / CB, without an ac cable

• Model NT5C05CC, equipped with an ac cable terminated with a

male plug

Up to six switch mode 200I rectifiers can be installed in a 23-inch
NT6C43CB 1200 A cabinet or in an NT6C40 type frame. The cabinet is
specifically designed to provide modularity within a very compact unit.
For wooden floor applications in a zone 4 seismic region, up to three
rectifiers can be installed in a mounting frame mounting, but they must
installed in the three lowest mounting positions in the frame.

Figure 2 - Typical mounting in a cabinet or frame

be

RECTIFIER No. 1

RECTIFIERNo. 2

RECTIFIER No. 3

RECTIFIER No. 4

RECTIFIER No. 5

RECTIFIER No. 6

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

2. Specifications

2.1. Mechanical and electrical specifications

13

Table 1 - Mechanical specifications of the rectifier

Height :
Depth :
Width :
Weight :

Table 2 - Electrical specifications of the rectifier

Input voltage :

Input current :

Input protection :
Output floating

voltage :
Equalizing voltage :
High voltage

shutdown :
Output current :
Output protection :
Current limit :

10.0 inches ( 25.4 cm )

22.0 inches ( 55.9 cm )

20.5 inches ( 52.1 cm )

92.6 lbs ( 42 kg )

Nominal : 380 / 415 V ac
Range : 330 ±5 V ac to 475 ±5 V ac
Frequency : 47 to 63 Hz
Note: After an out of range line condition shutdown,

the rectifiers will restart automatically at a line

voltage within 350 ±5 V ac to 460 ±5 V ac.
Nominal: 18 A RMS ( at 415 V ac )
Worst case: 24 A RMS
25 A ac breaker, 3 Ø

−46 V dc to —58 V dc

0 to −4 V dc above the floating voltage

−52 V to −60 V dc

200 A ( 330 to 475 V ac input )
200 – 250 A dc circuit breaker
50% to 105% of the rated output current

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

14 Specifications

2.2. Operation specifications and ambient conditions

Table 3 - Operation specifications of the rectifier

Output regulation :

Temperature drift :

Output noise and
ripple :

Total harmonic
distortion ( THD ) :

Efficiency :

Power factor :

Heat dissipation :

Electromagnetic
interference ( EMI ) :

Reliability:

At the output terminals, the voltage is within ±0.5% of
the set voltage value for all specified input and output
variations, and within ±1% for any combination of
specified input, output and ambient conditions.

Unless otherwise stated, all input and output
parameters such as input voltage range, output current
and voltage, current limit, etc. shall not vary more than
2% over the operating temperature range.

• less than 22 dB of random noise on C band at voice
frequency over the entire operating range of the
rectifier, including operation in the current limit mode,
and at low, nominal and high input voltage conditions
( with or without batteries and measured at the point
of regulation )

• less than 20 mV RMS in any 3 kHz band between 10
kHz and 20 MHz ( measurements made with or
without batteries at the output terminals of the
rectifier and with the rectifier in the local sensing
mode )

• less than 250 mV peak to peak switching voltage
spikes ( measured differentially with an a 100 MHz
oscilloscope )

Less than 5%.

Better than 89% at a nominal input voltage of 350 V ac
and for an output current ( load ) greater than 80 A.

Better than 99% with an output current ( load ) greater
than 80 A.

The maximum heat dissipation is 1420 watts
( 4846 BTU / hr ) for an output current ( load ) of 200 A
at –58 V dc ( when the ac input is 330-475 V )

The NT5C05CA / CB rectifiers when used in the
rectifier cabinet NT6C43CA / CB ( equipped with the
ac EMI filter kit NT6C18KB, or the NT5C05CC without
external EMI filter ) meet the CISPR requirements for
conducted and radiated EMI as specified in Publication
22 for Class "A" equipment.

The rectifier has an MTBF greater than 120 000 hours
under normal operating conditions, at 77°F ( 25°C ) as
per Telcordia Technologies TR332 method.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Table 4 - Ambient conditions for the rectifier

Specifications 15

Operating
conditions

Transportation
conditions

Storage conditions

A minimum airflow clearance of 2 inches ( 5 cm ) is
required at the rear of the rectifier.

The rectifier will operate properly under the following
conditions.

Temperature: 32°F to 122°F ( 0°C to +50°C )

32°F to 104°F ( 0°C to +40°C ) with air
filters

Humidity: 0 to 95% RH ( non-condensing ) at 4

kPa max. equiv. to 7,000 ft. ( 2,100 m )
above sea level

During transportation, the rectifier can be subjected to
the following conditions without sustaining damage.

Temperature: –67°F ( –55°C ) for 16 hours

140°F ( +60°C ) dry heat

Humidity: 0 to 95% RH ( non-condensing ) at

4 kPa max.

Vibration: 38 mm / s max. ( 10 Hz to 30 Hz )

sinusoidal, 18-inch ( 457 mm ) drop
when packaged

Pressure: 12 kPa min. equiv. to 49,212 ft.

( 15,000 m above sea level)

Temperature shock : −58°F to 140°F ( −50°C to 60°C )

During storage, the rectifier may be subjected to the
following conditions without damage :

Temperature: –67°F ( –55°C ) for 16 hours to 140°F

( +60°C ) dry heat

Humidity: 0 to 95% RH ( non-condensing ) at

4 kPa maximum

The rectifier contains aluminum electrolytic capacitors
that have a shelf life of five years or greater at the
maximum rated storage temperature.

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

16 Specifications

2.3. Mechanical and electrical specifications of a 1200 A cabinet

Table 5 - Mechanical specifications of the NT6C43CB 1200 A cabinet

Height :
Depth :

Width :

Table 6 - Electrical specifications of the NT6C43CB 1200 A cabinet

Input voltage :
Output voltage :
Output current :

84.00 inches ( 213.36 cm )

23.63 inches ( 60.0 cm )

23.63 inches ( 60.0 cm )

380 / 415 V ac three phase
–46 V dc to –58 V dc
1200 A

2.4. Ambient conditions of a 1200 A cabinet

Table 7 — Ambient conditions for the NT6C43CB 1200 A cabinet

Operating
conditions

Storage conditions

The cabinet is designed for use under the following
ambient conditions.

Temperature: 0°C to 50°C ( 32°F to 122°F )

Humidity: 0 to 95% RH ( non-condensing )
Altitude: sea level to 7,000 ft ( 2,100 m )
During transportation and storage, the acceptable

ambient conditions are :
Temperature: –55°C ( –67°F )

Humidity: 0 to 95% RH ( non-condensing )

0° to 40°C ( 32° to 104°F ) with air
filters

+60°C ( 140°F ) dry heat

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

3. Installation

3.1. Mounting configurations

The NT5C05CA / CB / CC rectifiers are designed for installation in a
1200 A cabinet ( NT6C43CB ) or in a standard frame ( NT6C40 or
equivalent ). In this chapter, a different procedure is provided for each
mounting method. The rectifiers are shipped loose, not mounted in the
frame or cabinet. Upon reception, remove the rectifier from its shipping
carton and inspect it for physical damage. Report any damage to your
immediate supervisor.

3.2. Tools and test equipment

The following tools and test equipment are required :

• screwdriver, flat blade, 3/16 inch ( 5 mm )

• potentiometer screwdriver, Bourns No. 60, or equivalent

• heavy cable strippers or electrician’s knife

• heavy cable cutters ( AWG 4/0 or metric No. 110 )

• nut drivers ( set )

• socket set ( 1/2 inch or 15 mm drive )

• torque limiting wrench ( 1/2 inch. or 15 mm drive )

• crimper, T&B, 15CA54R Violet die

• digital multimeter, Fluke 8000A or equivalent

17

3.3. Cautions and Warnings

The following precautions must be adhered to at all times
and installing power equipment.

when handling

CAUTION

Protecting the premises

Protect the floors and walls against damage with sheets of
plywood, cardboard, or other suitable material when
handling the equipment.

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual

18 Installation

CAUTION

Preventing damage caused by over-tightening

Do not over-tighten nuts and bolts. Over-tightening can
strip the threads or break the bolts. Apply the appropriate
torque values.

CAUTION

Personal safety and protecting the equipment

Use a dolly truck, forklift, or hoist whenever possible
when handling and moving the equipment, as power
equipment is heavy. If a forklift is used, do not remove the
packing material before having moved the equipment to
its final location. If a dolly truck is used, the packing
material can be removed in the reception area. When
handling cabinets with equipment installed in them,
exercise care to ensure they do not tip over, as they can be
top heavy.

CAUTION

Preventing personal injury

When cutting material, wear gloves and goggles. Break all
corners and sharp edges with a flat file.

CAUTION

Optimizing the life of the equipment

Make sure there are no obstructions in front of the
ventilation openings that can restrict the flow of air.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Installation 19

WARNING

Generator requirements for Emerson Energy Systems
Power Systems

For information on selecting ac generators that will
effectively maintain peak performance and operating
characteristics, for all Astec APS power systems, go to the
partners’ section of the Emerson Energy Systems web site
at www.EmersonEnergy-NA.com

. To obtain access to the

partners’ section follow the instructions found on the
partner’ page, or dial our nearest local 1−800 technical

support line ( refer to “Appendix C : Technical service
assistance” of this manual for the telephone number ).

DANGER

Grounding

The frame ground leads must be connected before any
other leads. This is to prevent the cabinets and any other
metal structures from carrying dangerous ac or dc voltage
levels.

DANGER

Protecting against electrical shocks

The cabling of the power plant, and all other required
cabling, must be carried out by qualified personnel and in
conformance with local and national electrical codes. AC
input voltages to the rectifiers are at a dangerous level.
Ensure that the circuit breakers are locked in the OFF
position in the ac service panel before working on the
power plant. Dangerous voltages may be present at the
output dc terminals even if the rectifiers are OFF. Use a
voltmeter to verify for the presence of such voltages. Do
not put the circuit breakers to ON until the entire system
has been assembled and you have been instructed to do so.
Verify, and identify with a tag, the proper polarity of the
battery leads before connecting them to the power plant.

Emerson Energy Systems Rectifier 200I/48NT5C05C Installation and User Manual