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

H E L I O S

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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

H E L I O S

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AM P

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1 . 0 A

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A DJ

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S L S FS

I

D

C / C C

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

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

12 General information

1.2. Models and mounting configurations

Two models of 200I rectifiers are available :

• Models NT5C05CA / CB, without an ac cable

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

male plug

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

20 Installation

3.3.1. Installing in a frame

DANGER

Short circuit hazard

The rectifiers, and the batteries in particular, can deliver
high current if a short to ground occurs. When working
on live equipment, remove all personal jewellery, use
properly insulated tools, and cover any live busbars with
a insulating sheet of canvas to prevent short circuits that
could be caused by falling tools or parts.

When shipped, the NT5C05CA / CB / CC switch mode rectifiers are
configured for installation in a standard frame. As the rectifier is heavy,
use a manual forklift to mount the rectifier in a frame. If a forklift is not
available, two persons, exercising care, can lift the rectifier into place and
secure it.

Procedure 1 - Installing the rectifier in a frame

Step Action

Note : Install each rectifier beginning with the lowest mounting

1

position in the frame.

Align the mounting brackets of the rectifier with the mounting holes in
the frame and insert the locating pins into these holes.

2

3

4

Lift the rectifier and align the middle holes in the mounting brackets
of the rectifier with the locating pins inserted in the frame. Slide the
rectifier into position onto the locating pins.

Secure the rectifier to the frame by inserting and tightening a
mounting screw ( provided ) in the uppermost holes of each
mounting bracket ( one on the left side and one on the right side ).

Remove the locating pins and install the other six mounting screws.
Tighten the screws applying a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ±

0.5 N-m ).

3.3.2. Installing in a cabinet

The cabinet is 23.56 inches ( 600 mm ) wide and deep, and 84 inches
( 2134 mm ) high. The anchors provided to secure the cabinet in place are
intended for installation on 3000 psi ( 2 kg per sq. mm ) compressive
strength concrete. Anchors for seismic applications are available upon
request. Slotted holes are provided in the base of the cabinet for anchoring.
The primary locations should be used as a first choice ( see Figure 3 ). If a
steel-reinforcing rod is encountered when drilling the holes for the anchors

end

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

in the concrete floor, the secondary anchor locations may be used. An

(

optional cabinet isolation kit is available consisting of four anchor
bushings and a base pad. If this kit is installed, place the pad on the floor
and the bushings on the anchors, and position the cabinet on top.

Figure 3 - Anchoring the cabinet

SECONDARY LOCATION

FOR FLOOR ANCHORS

600 mm

(23.56 po.)

Installation 21

m

po.)

m
0

(20.42

9
5

520 mm

)

.
o

p
3

1

.
3
2

PRIMARYLOCATION

FOR FLOORANCHORS

Procedure 2 - Installing a rectifier in a cabinet

Step Action

1

2

3

+

+

526 m m

(20.68 po.)

Loosen and remove the screws securing the mounting brackets to
each side of the rectifier.

Reposition and secure the mounting brackets to the holes located
nearest the front of the rectifier, on each side of the rectifier.

Remove the blank panel from the cabinet and put the self tapping
screws in a secure location, for future use.

continued

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

22 Installation

Procedure 2 - Installing a rectifier in a cabinet ( continued )

Step Action

4

Place the rectifier on the L-shaped guides located in the lowest
position of the cabinet and slide it towards the rear until the mounting
brackets come into contact with the frame of the cabinet. The front of
the rectifier should be flush with the front of the cabinet and the
output bussing should be in contact with the riser busbars located at
the rear of the cabinet.

5

Align the mounting holes in the brackets of the rectifier with the
mounting holes in the frame. Secure the rectifier in place by inserting
and tightening the self-tapping screws removed in Step 3.

Note : Install an external tooth lock washer on one of the screws to

Figure 4 - Installing the rectifier

assure good ground continuity between the rectifier and the
frame.

end

HELIOS

AC/CA

HELIOS

3.4. Cabling and connecting

The ac cables of the rectifier must always exit each rectifier from the right
side, when viewed from the rear.

The dc cables of the rectifier must always exit each rectifier from the left
side, when viewed from the rear.

The system alarm interface cable must always exit each rectifier from the
right side, when viewed from the front.

SELF-TAPPING SCREW
( P097F813 )

ET LOCK WASHER

VOLT/AMP

VOUT-

VOLT
CAL
CUR

CL

CAL

ADJ
EQL

ADJ

SEN
FAIL

EQL

EQL

FLT

ACON

FF1

FF2

1.0A

1.0A

CL

FLT

ADJ

HVSD

ADJ

ST UP

DLY
SLS FS

DC/CC

VOLT
CAL

VOLT

AMP

THSD

RFA
FAN

HVSD

ALM

VOUT+

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Installation 23

3.5. Connecting the dc output terminals to the busbars

The dc outputs of the rectifier are connected to the busbars as illustrated in
Figure 5. There are two methods :

• BAT GRD ( + ) of the rectifier connected to the CHG/ DISCH

GRD busbar and the –48 V of the rectifier connected to the
CHG BAT busbar

• BAT GRD ( + ) of the rectifier connected to the CHG GRD

busbar and the -48V of the rectifier connected to the CHG/
DISCH BAT busbar

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

the ground side

CHG / DISCH

+

RECTIFIER

-

+

RECTIFIER

-

BAT GRD

+

-48V

-

BAT GRD

+

-48V

-

SHUNT ON THE GRD SIDE ( PREFERRED CONFIGURATION )

GRD BUSBAR

CHG BAT

BUSBAR

SHUNTON THE BATTERY SIDE

CHG GRD

BUSBAR

CHG / DISCH
BATBU SBAR

SHUNT

SHUNT

LOAD

DISCHARGE

BATBUSBAR

DISCHARGE

GRD BUSBAR

FUSE

PANEL

FUSE

PANEL

LOAD

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

24 Installation

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

3.5.2. Running and connecting the dc between busbars and a

cabinet

For cabinet applications, no dc cabling is required; the output terminals of
the rectifier are connected directly to the busbars.

Procedure 3 - Securing the dc output terminals to the busbars of the

cabinet

Step Action

1

2

Connect the BAT GRD output terminal of the rectifier to the BR
busbar, and the –48 V output terminal of the rectifier to the –48 V
busbar located at the rear of the cabinet.

Tighten the bolts by applying a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ±

0.5 N-m ).

end

rectifier

For frame applications, use terminal lug A0361762, supplied with the unit,
and no. 110 ( 4/0 ) metric cable.

Procedure 4 - Typical dc cabling in a frame application

Step Action

1

2

Connect the BAT GRD output terminal of the rectifier to the CHG
GRD busbar of the power plant. Connect the –48 V output terminal
of the rectifier to the CHG / DISCH BAT busbar of the power plant
( see Figure 5 ).

Apply a torque of 6.5 ± 0.5 ft-lbs ( 8.5 ± 0.5 N-m ) on the bolts
securing the lugs to the rectifier terminals.

3.6. Connecting ac to the rectifiers

WARNING

Electrical connections should meet standards

The electrical installation must be carried out by qualified
personnel and in accordance with local electrical codes.

end

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Installation 25

DANGER

Hazardous potentials

Input voltage to the cabinet is at a hazardous potential.
Make sure the power is OFF and that the lever in the ac
service panel is locked in the OFF position before
attempting to connect the input line voltage to the ac box
of the cabinet.

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

Step Action

1

2
3

4

5

6

7

8

9

10

11
12

13

14

Install the ac breaker ( 30 A / 3 phase per rectifier ) in the 380 /
415 volts ac service panel and lock it in the open ( OFF ) position.

Put the ac breaker to OFF.
Run the ac armored cable ( metric no. 25 [ 10 AWG ] 3 conductors

and ground ) from the service panel, through the top of the cabinet,
to the rear of the rectifier.

Secure the ac cable to the side of the cabinet using cable ties and
adhesive anchors. Make sure the cable are located in a manner that
will not interfere with the insertion of the rectifier ( see Figure 6 ).

Ground the conduit sheath to the ac service panel. Insulate the
conduit connector at the rectifier end with electrical tape to isolate it
from the ac ground.

Remove the two ac protection plates located at the rear of the
rectifier.

Strip 10 inches ( 250 mm ) of armored insulation from the end of the
ac cable. Insert the wires in the 90° conduit connector ( see Figure

7 ).
Run the signal cable from the rectifier to the interconnect board or

controller as described in the "Control signal connections" section.
Connect the green ground wire to the FR GND terminal.

Connect the power leads to the L1, L2 and L3 terminals ( any phase
sequence ) ( see Figure 7 ).

Tighten the elbow connector and reassemble the ac protection plate.
Run the signal cable from the rectifiers to the interconnect board or

controller as specified in the " Connecting the control signals"
section.

Secure the signal cables to the insulating busbar support, located in
the cabinet, with cable ties.

Start-up the rectifier as described in the “ Start-up “ procedure.

end

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

26 Installation

C

A

e

Figure 6 - Cabling ac the NT5C05CA / CB rectifiers

SIGNAL

HEX HEAD CAP SCREW

BLES TOTHE

PLANT CONTROLLER

PART OF OPTIONAL

KIT P0872151

AND WASHERS

( 4 PLACES )

AA

REAR VIEW OF A

TOP FED ARRANGEMENT SHOWING

OPTIONAL BUSBAR COVER KIT P0872151

( WITH REAR PANELS REMOVED )

AC FEED TO
RECTIFIERS

SIGNAL CABLE

REMOVE PLATE TO
ACCESSCONNECTORS

CABLE

TIE

Note: Dress the cables carefully to

clear the insertion path of th
rectifier.

SECTIONA-A

SHOWING TOP VIEW

OF AC CABLING

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

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

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

and the ac female plug in a 1200 A cabinet

Step Action

1

Install the ac breaker ( 30 A / 3 phases per rectifier ) in the 380 /
415 volts ac service panel.

2

Put the ac breaker for the NT5C05CC rectifier, located in the ac
service panel, to OFF.

3

Run the metric no. 25 ( 10 AWG ) ac supply cable ( 3 conductors
and ground ) to the female receptacle ( see Figure 8 ). Connect the
female connector to the male connector.

4

Run the signal cable from the rectifier to the interconnect board or
controller as specified in the " Connecting the control signals "
section.

5

Secure the signal cables to the insulating busbar support, located in
the cabinet, with cable ties.

6

Start-up the rectifier as described in the “ Start-up “ section.

Figure 8 - Connecting ac to the rectifier NT5C05CC

Installation 27

end

A

GRD

TB1

L1 L2 L3

R1 (TB1-L1) BLUE
S2 (TB1-L2)
T3 (TB1-L3)

WIRE COLORCONNECTION

BROWN

BLACK

GREEN / YELLOW

A

BROWN
BLUE

GREEN/YELLOW

SECTA-A

FEMALE CONNECTOR

BLACK

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

28 Installation

3.7. Connecting the control signals

For all applications with conventional controllers ( such as NT6C25BA or
NT6C25BB ) or front access controllers ( NT6C25FA ), execute the steps
contained in Procedure 7 to connect the NT5C05CC rectifier ( see Figure
9 ).

Procedure 7 - Connecting the NT5C05CC to the controller

Step Action

1

2

Figure 9 - Typical connections between rectifiers and the conventional

Connect each rectifier to the NT6C43PB board ( positions J1 to J6 ),
located at the top front of the cabinet or frame, with P0747000
cables.

• Connect the NT6C43PB board ( positions J7 to J12 ) to the
controller with P0736355 cables for conventional controllers ;
and with P0736268 cables for front access controllers.

controller

end

Rectifier

#6

Rectifier

#5

Rectifier

#4

Rectifier

#3

Rectifier

#2

Rectifier

#1

NT6C43PB

MONITOR

Cables P0736355

Cables P0747000

J13

J1 J2 J3 J4 J5 J6
J7 J8 J9 J10 J11 J12

CONTROLLER NT

(NT6C25BA or NT6C25BB)

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Installation 29

Procedure 8 - Connecting an NT5C05CC rectifier directly to a controller

Step Action

1

If an NT6C43PB interconnect board is not available, each rectifier
must be connected directly to the controller with the following
cables :

• P0723784, P0723785 or P0723786 ( for conventional

controllers )

• P0723708, P0723709 or P0723210 ( for front access

controllers )

end

For controllers not manufactured by Emerson Energy Systems see Table
12 in the " Functional Description " chapter describing the pin assignments
of the rectifier. Refer to Table 8 for the pin assignments of connectors J7
to J12 on board NT6C43PB.

Note: The alarm and control signals in Table 8 are all ground

signals except for the RC– signal that is a –48 V
battery signal.

Table 8 - Pin assignment for connectors J7 to J12

Pin Label Function Input/ Output

1
2
3
4
5
6
7
8

EQL Equalize Input

RG+ Remote sense Input

RC– Remote sense Input

FAN ALM Fan fail alarm Output

HVSDR High voltage shutdown reset Input

HVSD High voltage shutdown Input

RFA Rectifier failure alarm Output

TR Temporary release Input

3.7.1. Monitoring of the shunt current

A 12-pin connector ( J13 ) is also available on the NT6C43PB
interconnect board for monitoring the individual output current shunt
readings ( 250 A / 50 mV for example ) of each rectifier in a cabinet or a
frame ( see Table 9 ).

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

30 Installation

Table 9 - Pin assignment for connector J13

Pin Function

J13-1 SH+ ( rectifier 1 )
J13-2

J13-3 SH+ ( rectifier 2 )
J13-4

J13-5 SH+ ( rectifier 3 )
J13-6

J13-7 SH+ ( rectifier 4 )
J13-8

J13-9 SH+ ( rectifier 5 )

J13-10
J13-11 SH+ ( rectifier 6 )

J13-12

SH− ( rectifier 1 )

SH− ( rectifier 2 )

SH− ( rectifier 3 )

SH− ( rectifier 4 )

SH− ( rectifier 5 )

SH− ( rectifier 6 )

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

4. Functional description

4.1. Overview

4.1.1. Input circuit

The input circuit offers the following characteristics :

• ac rectifying

• EMI filtering

• inrush current limiting, a walk-in circuit limits the output current

rise to 25 A per second

• low and high ac inhibit

• power factor compensation

• surge voltage protection

• ac breaker for input protection

For all input and output conditions specified in this manual, when the
rectifier is turned on, the ac current will not exceed the maximum steady­state value.

31

4.1.2. Output circuit

The output circuit offers the following characteristics :

• shunt for output dc current sensing

• 225 A dc circuit breaker for output protection

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

32 Functional description

4.1.3. Monitoring and control circuits

The monitoring and control circuits offer the following characteristics :

• soft start

• rectifier fail alarm ( RFA )

• control for local and remote equalize ( EQL )

• temporary release ( TR )

• thermal shutdown ( THSD )

• input ac monitoring

• local and remote high voltage dc shutdown ( HVSD )

• local and remote HVSD reset

• fan failure detection

4.1.4. Output capacitors

The output capacitors will be completely discharged ( < 2 V ) two minutes
after the ac power has been removed and the rectifier has been
disconnected from the batteries or the parallel rectifiers.

4.2. Description of the front panel

4.2.1. Breakers
DC circuit breaker

A dc circuit breaker is provided to protect against current overload and to
manually disconnect from the power plant.

When the breaker is in the 0 ( OFF ) position, an RFA is triggered and the
remote sense leads RG+ and RC– are internally disconnected. The rectifier
will continue to operate, allowing the adjustment of the FLT, EQL and
HVSD set points.

AC breaker

The input ac circuit breaker can be used to locally turn the rectifier ON or
OFF. The local ON / OFF control overrides any remote control signals
( for example, TR ). Putting the breaker to OFF causes an RFA to be
issued and the RFA LED to light up, as long as the rectifier output is
connected to batteries.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

4.2.2. Switches, controls and LEDs

A

A

There are switches and potentiometers on the front panel to adjust the
operating parameters of the rectifier. The LED indicators indicate the
operating and alarm conditions.

Figure 10 - Front panel controls and LEDs

Functional description 33

VOLT

MP

THSD

HVSD

RFA

FAN
ALM

VOUT+

VOLT/AMP

SEN

FAIL
EQL

VOUT-

C ON

CL

VOLT
CAL

CUR
CAL

FF1

1.0A

DC/CC

FF2

1.0A

HVSD

ST UP

DLY

SLS

CL

ADJ

EQL

ADJ
EQL

FLT

FLT

ADJ

ADJ

FS

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

34 Functional description

4.2.3. Front panel LEDs

Table 10 - Designation of the LEDs on the front panel

LED Color Description

AC ON Green Input ac voltage operational

CL Yellow Current Limit

EQL Yellow Rectifier is in equalize mode

FAN ALM Red Fan fail alarm

HVSD Red High voltage shutdown

RFA Red Rectifier fail alarm

SEN FAIL Red Remote sense fail

THSD Red Thermal shutdown

AC ON ( ac voltage monitoring )

The rectifier monitors the input voltage and if the voltage exceeds the set
limit, it will inhibit its operation and trigger a rectifier failure alarm
( RFA ). The rectifier will resume its normal operation automatically when
the specified input voltage has been re-established.

CL ( current limit indicator )

This LED lights up if the rectifier is in current limit. The rectifier limits
the output current to 205 A +

5 A ( adjusted in the factory ), 50% to 105%

of the rated output current.

EQL ( equalize )

Indicates the rectifier is in equalizing mode.

FAN ALM ( fan failure alarm )

This LED lights up when the FAN ALM is activated due to a defect in the
fan system. The fan configuration includes redundancy to ensure the
rectifier will continue working properly if one of the fans fails. If only one
fan fails, a rectifier failure alarm RFA will not be triggered. It is, however,
imperative to repair or change the fan unit as soon as possible to preserve
this redundant feature.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Functional description 35

HVSD ( high voltage shutdown )

The rectifier monitors itself for high voltage and will shut down when its
output voltage exceeds a preset adjustable value ( between -52 V and

-60 V ).

RFA ( rectifier failure alarm )

The rectifier monitors its operation and triggers a global RFA if it detects
an internal failure, causing the RFA LED to light up. One of the following
will trigger an alarm :

• abnormal or out of range ac input voltage

• output fuse failure

• system or internal shutdown ( thermal, HVSD, TR )

• internal failure causing a power switching malfunction

If the switching malfunction is caused by an improper adjustment of the
output float voltage, the RFA alarm will not be triggered. The RFA feature
will be activated if the ac power is removed in a system where batteries are
present.

SEN FAIL ( sense fail alarm )

This LED lights up if the remote sense leads are not connected, or if the
RC fuse has blown.

THSD ( thermal shutdown )

This LED lights up when the rectifier is protecting itself against
overheating by suspending its operation for the duration of the high
temperature condition. An RFA alarm will also be triggered.

4.2.4. Local and remote adjustments and controls

The current and voltage calibration, adjustment and control can be set
through potentiometers and switches ( see Table 11 ) located on the front
panel, or by remote signals sent from the controller ( see Tables 8 and 12 ).

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

36 Functional description

Table 11 - Adjusting the potentiometers and switches

Potentiometers Description

CL ADJ Current limit adjust ( 100 A to 210 A )

CUR CAL Current reading calibration

EQL ADJ

FLT ADJ
HVSD ADJ
VOLT CAL Voltage reading calibration

Switches Description

EQL / FLT Equalize / Float selection switch

SLS / FS Slope load sharing / Forced load sharing selection

ST UP DELAY Start-up delay selection DIP ( 4 sec to 2 min )

VOLT / AMP Voltage and current display selection switch

Table 12 - Rectifier input / output signals to the controller

Designation Description

RG+ / RC−

HVSD Remote High Voltage Shutdown input activated by a

HVSDR Remote High Voltage Shutdown Reset input activated by

TR Remote Inhibit input activated by a BAT RTN signal.
EQL Remote Equalize input activated by a BAT RTN signal.
RFA Rectifier Failure Alarm output activating a form C contact

F ALM Fan Failure Alarm output activating a form C contact

SHUNT ( + ) and

SHUNT ( − )

CURRENT

SHARE

Equalize voltage adjust ( 0 V to −4 V )
Float voltage adjust ( −46 V to −58 V )
High voltage shutdown adjust ( −52 V to −60 V )

External reference voltage across the batteries
measured through the controller to regulate the voltage.

BAT RTN signal.

a BAT RTN signal.

Rectifier Current input / output ( 50 mV / 250 A )

Common Forced Current Share Mode ( 0-12 V )

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

CUR CAL / VOLT CAL potentiometers

These potentiometers are used to calibrate the digital display meter for
current and voltage measurements. As the two potentiometers affect each
other, current calibration must be performed before voltage calibration.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

VOLT / AMP digital meter switch

This switch is used to select the measurement display mode of the digital
meter. The output voltage or the output current modes can be selected.

VOUT+, VOUT−−−− test points

These test points are used to measure the voltage at the point of regulation.
A 5 kohm resistor is placed in series with both sensing leads to prevent
short-circuits at the jack terminals. The resist or may affect reading
accuracy, depending on the impedance of the meter. Refer to the
Instruction Manual for your meter to determine its internal impedance and
correction factor.

4.2.6. Float and equalize voltage control
Local FLOAT / EQL switch and potentiometers

The rectifier is equipped with a FLOAT / EQL switch.

Functional description 37

When the FLOAT / EQL switch is held in the EQL position, the rectifier
goes into equalize mode and boosts the output voltage to the value set by
the EQL potentiometer.

When the switch FLOAT / EQL is held in the FLT position, the rectifier
delivers a float voltage set by the FLT potentiometer.

Remote equalize control EQL

The rectifier is equipped with remote equalize control. This control is
activated by a remote ground signal ( BAT RTN ). The rectifier returns to
normal ( float voltage ) operation when this signal is removed.

4.2.7. Current limit adjustment and rectifier regulating test
CL ADJ potentiometer

The rectifier limits the output current to a select value ranging from 100 A
to 210 A, set by the CL ADJ potentiometer. The factory adjustment is
205 A ±5 A. Extended periods of operation in the current limiting mode
and repeated transitions between constant-voltage operation and constant­current operation have no detrimental effect on the performance or service
life of the rectifier.

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

38 Functional description

The rectifier can be started when it is connected across a completely
discharged battery without requiring human intervention or operating
protective devices. A transition from constant voltage operation to
constant current operation and from constant current operation to constant
voltage operation occurs automatically, as determined by the output
current. The current limiting circuit is functional in float and equalize
modes.

4.2.8. Rectifier parallel operation

The rectifier can operate in parallel with other rectifiers having similar
output characteristics. It shares the total load in proportion to its output
rating. Two methods for sharing load current are available :

• Slope sharing

• Forced sharing

Selecting either mode is done by setting the two bottom DIP switches,
SLS / FS, located on the front panel. The rectifier is factory set to the slope
sharing mode.

Slope sharing ( SLS )

When both bottom DIP switches are set to the SLS position, conventional
load sharing is achieved through a -300 mV slope on the output voltage of
the rectifier, from no load to full load. This mode should be used when
rectifiers from different manufacturers are not all equipped with the forced
load-sharing feature. In this mode, the units will share the load within

±10% of their maximum output rating.
To accurately preset the float voltage of the rectifier, its current in the plant

environment must be predicted and the preset output floating voltage must
be calculated using the formula found below. In the formula, 0.8 volts is
added to the float voltage to compensate for an internal voltage drop when
the rectifier dc breaker is put in the ON position.

V ( preset ) = Vo ( desired ) + 0.8 V + ( Io ( running

) x 300 mV )

200

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Functional description 39

Example 1 : If the rectifier is expected to provide 100 A at 48 V

V ( preset ) = 48 V + 0.8 V + ( 100

x 300 mV )

200

V ( preset ) = 48 V + 0.8 V + 0.15 V = 48.95 V

Example 2 : If the rectifier is expected to provide 40 A at 48 V

V ( preset ) = 48 V + 0.8 V + ( 40

x 300 mV )

200

V ( preset ) = 48 V + 0.8 V + 0.06 V = 48.86 V

Forced sharing ( FS )

When both bottom DIP switches ( SLS / FS ) are set to the FS position,
forced load sharing is achieved by an internal control circuit that modifies
the loop reference to equally share the output currents between rectifiers.
The setting of the output voltage is not modified with changes in output
load, as is the case in the slope share mode. In this mode, the rectifiers will

share the load within ±2 % of their maximum output rating.
For this to occur the rectifiers must communicate their operating current to

the other rectifiers in the same power plant. The current share terminal of
all the rectifiers ( P1-17 ) in the same power plant must be connected
through the control cables and controller. In applications using the
NT6C43PB interconnect board, such a connection is implemented
automatically.

Adjust the rectifier float voltage to the desired system float voltage, plus

0.8 volts, to compensate for an internal drop when the rectifier dc breaker
is put in the ON position.

Example 3 : for 48 V float voltage

V ( preset ) = 48 V + 0.8 V = 48.8 V

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

40 Functional description

4.2.9. HVSD ( high voltage shutdown )
HVSD ADJ ( high voltage shutdown adjust ) potentiometer

Use this potentiometer to set the internal threshold level at which the local
high voltage shutdown condition should occur.

Remote HVSD

In addition to the local high voltage shutdown feature, the controller of the
power plant controller can shut down any rectifier by sending a high
voltage shutdown signal, ground ( BAT RTN ) pulse. The rectifier will
shut down within 50 ms if it is supplying more than 10% of its full load
rating.

As is the case for the internal high voltage shutdown condition, two HVSD
events must occur within an interval of two minutes to lock out the
rectifier permanently. An ac breaker reset or an HVSDR signal can be
used to restart the rectifier.

Local and remote HVSD reset

The rectifier may be reset from an HVSD condition locally by :

• toggling the ac circuit breaker to OFF then to ON ( or the ac

breaker in the distribution panel )

• sending a remote ground signal to the HVSDR input through the

controller restart ( provided the 'TR' lead has not been activated )

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

The TR input can be interfaced to an external sequential start circuit.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Table 13 - Setting the start-up delay

Functional description 41

01

NOTE: Switches 3
to 6 ( top four
switches ) are
used to s et the
sta r t- up de l a y .

SWITCH
#

6

5

4

3

2

1

POSITION DELAY POSITION DELAY

1
6
5
4
3
6
5
4

X

3
6
5

X

4
3
6
5

X

4

X

3
6

X

5
4
3
6

X

5
4

X

3
6

X

5

X

4
3
6

X

5

X

4

X

3

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

X
X
X
X

X
X
X
X

0

X
X
X

X
X

X

X

X

X
X

X

X

68 SEC

76 SEC

84 SEC

92 SEC

100 SEC

108 SEC

116 SEC

124 SEC

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

42 Functional description

Remote ON / OFF control TR

When a ground signal is applied to the 'Temporary Release' ( TR ) input,
the rectifier inhibits its operation and triggers the RFA. When the remote
ground signal is discontinued the rectifier returns to normal operation ( see
Table 14 ).

Start up delay DIP switch

The rectifier can provide a start-up delay of from 4 seconds up to
120 seconds, with a resolution of 8 seconds and an accuracy of +
Use of this feature is recommended when two or more rectifiers are
connected to a common ac input to stagger the inrush currents. A front
panel DIP switch can be set to provide the start-up delays listed in Table

13.

4.2.11. Control signals on connector P1

The P1 connector, located at the rear of the rectifier, can be used to verify
all the control and alarm signals when troubleshooting the rectifier ( see
Table 14 ).

1 second.

The control inputs are activated by a ground ( BAT RTN ) signal. The
alarms, extended by relay contacts, are isolated from each other and the
rectifier frame. All contacts are rated 60 V and 0.5 A dc. The normal status
of each contact is defined when the rectifier operates normally in the
remote sense mode with no alarm. Contacts NC ( normally closed ) and
NO ( normally opened ) refer to the de-energized state of their relay coils.

Table 14 - Control signal connections on P1

Connection Signal Description

P1-1 EQL Equalize
P1-2

P1-3 HVSDR High voltage shutdown reset
P1-4 RFA ( NC ) Rectifier fail alarm ( NC )
P1-5 FAN ALM ( NC ) Fan fail alarm ( NC contact )
P1-6 FAN ALM ( C ) Fan fail alarm ( C )
P1-7

P1-8 RFA ( NO ) Rectifier fail alarm ( NO )
P1-9 SENSE ( C ) Sense fail alarm ( C )

P1-10 SENSE ( NO ) Sense fail alarm ( NO )

RC − Remote sense ( − )

SH−

continued

Output current shunt voltage ( - )

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Functional description 43

Table 14 - Control signal connections on P1 ( continued )

Connection Signal Description

P1-11 NC No connection
P1-12 NC No connection
P1-13 CB OFF ( NC ) Output breaker OFF ( NC )
P1-14 RG+ Remote sense ( + )
P1-15 TR Rectifier temporary released by

controller
P1-16 HVSD High voltage shutdown
P1-17 CURRENT SHARE Forced share link
P1-18 RFA ( C ) Rectifier fail alarm ( C )
P1-19 SH+ Shunt ( + )
P1-20 FAN ( NO ) Fan fail ( NO )
P1-21 GRD Reference ground
P1-22 SENSE FAIL ( NC ) Sense fail alarm ( NC )
P1-23 NC No connection
P1-24 NC No connection
P1-25 CB OPEN ( C ) Output breaker OFF ( C )

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

44 Functional description

This page is left blank intentionally.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

5. Operation

5.1. Standard settings

The parameters of the NT5C05CA / CB / CC rectifiers are set as indicated
in Table 15. For different settings refer to User Manual Voltage_level
entitled Voltage Level Limits for Power Plants, Rectifiers and Controllers.

Table 15 - Standard settings for the rectifier

Rectifier float output voltage ( FLOAT ) 52.1 ±0.1 V dc
Rectifier equalize output voltage

( EQUALIZE )
Rectifier high voltage shutdown threshold 56.5 ±0.1 V dc
Rectifier output current limit 205 A ±5 A
Rectifier start delay 4 sec
Low ac input disconnect 330 ±5 V ac
Low ac input reconnect 350 ±5 V ac
High ac input disconnect 475 ±5 V ac
High ac input reconnect 460 ±5 V ac
Load sharing method Slope

45

Parameter Setting

52.8 ±0.1 V dc

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

46 Operation

5.2. Starting up and adjusting

Procedure 9 - Starting up the rectifier

Step Action

1

2
3

4

5

6

7

Put the dc circuit breaker to OFF ( 0 position ). Open the sensing
leads by removing the corresponding RC fuse ( when the rectifier is
used with a controller ) or by disconnecting the alarm and control
cable ( when the rectifier is used without a controller ).

Put the ac circuit breaker in the main ac service panel to ON.
Put the 25 A, 3Ø, ac circuit breaker of the rectifier being tested to

ON. The green ac ON LED should light up.
Note : The output capacitors are precharged automatically when the

dc cables are connected at the rear of the rectifier.

Put the meter selector to the VOLT position. The meter will display
the voltage value to which the rectifier has been adjusted.

Connect a digital multimeter to test points VOUT+ and VOUT– on
the front panel. The voltage reading should be within 1% of the
rectifier meter reading. If not, calibrate it as described in the
“ Maintenance ” section.

Determine the system requirements for float, equalize and HVSD
limits by referring the User Manual Voltage_Level entitled Voltage
Level Limits for Power Plants, Rectifiers and Controllers.

If the factory threshold limits of the rectifier must be verified or
changed, go to Step 8; otherwise go to Step 14.

Adjusting the high voltage shutdown ( HVSD )

8
9

10

11

12

13

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Put the dc circuit breaker to OFF ( O ).
Turn the HVSD potentiometer fully clockwise.
Turn the FLT potentiometer slowly clockwise to set the output

voltage on the display of the rectifier to the required HVSD threshold.
The EQL / FLT switch and the EQL potentiometer are used if the
voltage cannot be set with the FLT potentiometer.

Turn the HVSD potentiometer counterclockwise until the rectifier
shuts down.

Turn the FLT potentiometer counterclockwise two turns and put the
ac breaker to OFF.

Wait a few seconds for the rectifier to shut down and put the ac
breaker to ON to reset it.

continued

Procedure 9 - Starting up the rectifier ( continued )

Step Action

Adjusting the float voltage

14
15

Ensure that the EQL / FLT switch is on the FLT position.
To adjust the float voltage to the proper level, turn the FLT

potentiometer clockwise to increase the voltage or counterclockwise
to decrease it.

Adjusting the equalize voltage ( EQL )

16

Set the EQL / FLT switch to EQL. Turn the EQL potentiometer
clockwise to increase the voltage or counterclockwise to decrease it.

17

Put the FLOAT / EQL switch in the FLOAT position.

Adjusting the slope share

18

Select the slope share mode

by setting the two bottom DIP switches
to SLS ( see Figure 10 ). Verify that the rectifier displays the required
float value. If required, adjust it with the FLT potentiometer.

19

Connect the sense leads by inserting the RC fuse in the controller or
by reconnecting the control cable.

20
21

Put the dc breaker located on the front of the rectifier to ON.
The rectifier is now connected to the system and should carry some

current. If it is connected in parallel with other rectifiers, verify that
the total system current is shared equally amongst the rectifiers. Put
the switch on each rectifier to AMP. Find the mean current of the
rectifiers by adding all the currents measured on each rectifier and
dividing the total current by the number of rectifiers

I

= I

+ 1

+I

T

1

2

… + I

3

n n

Operation 47

n

Set the current from each rectifier to this mean value. If the current
reading of one of the rectifiers is too low, or is 0, slowly increase the
current by turning the FLT potentiometer clockwise until proper
sharing is achieved. If the current reading is too high or if rectifier is
in the current limit mode, turn the FLT potentiometer
counterclockwise.

Note : Adjust all the rectifiers in sequence to the mean value of the

currents, and readjust more precisely if necessary.

Verifying the current limit

22

Turn OFF some of the other rectifiers to force the rectifier under test
to pick up a load current of at least 210 A. When the rectifier reaches
about 205 A, the yellow CL LED should light up.

continued

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

48 Operation

Procedure 9 - Starting up the rectifier ( continued )

Step Action

23

Setting the start-up delay

24

Adjusting the forced load sharing

25

26

27

28

Turn ON the other rectifiers in the system.

Use this feature to reduce the inrush currents when two or more
rectifiers are connected to a common ac input. Set the DIP switches
on the front panel for the required start-up delay, from 4 to 124
seconds ( see Table 13 ).

If the forced share mode
rectifier to the appropriate value plus 0.8 volts in slope share mode,
as described above. For example, to have a 52.1 V float voltage :

This compensates for the internal voltage drop when the dc breaker
of the rectifier is put in the ON position. Connect all the FS wires of
the rectifiers together and set the two bottom DIP switches, located
on the front panel, to FS for forced load sharing ( see Figure 10 ).

If the rectifiers are connected to the NT6C43PB board, in the cabinet
or frame option, the P1-17 signals from all the rectifiers are
automatically connected. After step 25 has been completed, the
rectifiers will automatically share the output current.

When forced load sharing is desired, but the NT6C43PB board is not
used or is bypassed, pins P1-17 of all the rectifiers must be made
common at a single point. This connection could be a splice
connection of all the P1-17 wires in the control cables, using a 2B16
splice from T&B ( or equivalent ) in the control panel.

The E1 terminal on the NT6C43PB board can be used when forced
load sharing is desired amongst rectifiers on two, or more, cabinets
or frames. In this case, the E1 terminal from all the cabinets or racks
must be daisy chained with metric No. 7 ( AWG 22 ) wire.

Repeat step 21, but in equalize mode, to verify that the current is
shared equally amongst the rectifiers when a remote equalize signal
is applied, or when all local FLOAT / EQL toggle switches are
toggled in the EQL position. If the current reading is too low, or is 0,
turn the EQL potentiometer clockwise until proper sharing is
achieved. If the current is too high, or if the rectifier is in the current
limit mode, turn the EQL potentiometer counterclockwise.

Deactivate the EQL mode to return to the normal float mode.

is chosen, adjust the float voltage of each

52.1 V +0.8 V = 52.9 V.

end

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

6. Maintenance

6.1. Replacing the air filter

In dusty environments, the use of air filters is strongly recommended. If
used they should be replaced at least once a year.

6.2. Replacing the fan unit

The fan unit, consisting of four fans and a fan plate, can be replaced. To
install a new fan unit, execute the steps outlined in Procedure 10 and
illustrated in Figure 11.

Figure 11 - Replacing the fan unit

H E L I O S

I

0

A C / C A

V OL T

AM P

T H S D

H

V S

D

FA

R

FA N
A

L M

V OL T + V O U T-

49

O L T

V
C A L

C

U R

C A L

C L
A D J

E Q L
A D J

S E N

A C ON

FA I L

E Q L

C L

E Q L

F F 1

FF2

F L T

1 . 0 A

1 . 0 A

F LT
A DJ

H V

S

D

D J

A

I

UP

ST

D L Y

S L S FS

I

D

C / C C

RE M O VE T H E SE F I V E S C RE W S

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

50 Maintenance

CAUTION

Preventing short circuits

The replacement operation is safe, as only SELV
circuitry is present behind the fan assembly. However,
due to the possible presence of residual charges in the
output circuit, do not use metal tools within the rectifier
enclosure. To remove the fan assembly mounting screws
you need a screwdriver, but all the other operations
described below can and should be performed without
any tools.

Procedure 10 - Replacing the fan unit

Step Action
Disassembling

1
2
3
4

Re-assembling

5

6

7
8
9

Put the ac and dc breakers to OFF.
Remove the five screws securing the fan plate ( see Figure 11 ).
Swing open the assembly and disconnect all four fan cables.
Lift the assembly out the holes and pull it out towards you.

Insert the hinged bracket of the new assembly into the slotted holes
on the left and reconnect the cables to the four fans.

Place the four fan cables close to the display panel, removing as
much slack length as possible, so the cables will not interfere with
the fan blades after the fan unit is secured in place.

Swing the fan unit closed and secure it in plate with the five screws.
Check fan fuses FF1 and FF2 and replace as required.
Put the ac and dc breakers to ON.

end

6.3. Calibrating the Volt / Amp Multimeter

In a cabinet or frame application, where the signal cables are connected to
the NT6C43PB board, use a digital multimeter, at J13 on the NT6C43PB
board, to monitor the shunt reading of the rectifier, as indicated in Table 9.
In any applications where the NT6C43PB board is absent or has been
bypassed, pins P1-19 and P1-7 of the signal connector provide the shunt
reading. To access pins P1-19 and P1-7 use a cut P0747000 cable. If the
meter must be calibrated execute the steps in Procedure 11.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Maintenance 51

Procedure 11 - Calibrating the meter

Step Action

1

2

3

4

5

Make sure the remote sense leads are disconnected by removing
the corresponding RC− fuse from the controller.

Set the VOLT/AMP switch to AMP. Set the output load of the plant
so the rectifier delivers a current of approximately 100 A. Measure

the voltage between VOUT+ and VOUT −, located on the front panel,
with a digital meter.

Convert this measured voltage to a current value ( 50 mV
corresponding to 250 A ).

current

voltage 50 mV

If the voltage measured is 20.2 mV :

measured current

Rotate the CUR CAL potentiometer on the display panel until this
value is displayed.

Put the VOLT / AMP switch to VOLT. Adjust the V CAL
potentiometer so that the reading displayed on the meter of the
rectifier is identical to the reading on the digital meter.

Put the rectifier to OFF and reconnect the sense leads.

end

= 250 A

= 250 A X ( 20.2 mV ) = 101 A

50 mV

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

To reset the rectifier after an HVSD condition has occurred execute one of
the steps contained in Procedure 12.

Procedure 12 - Resetting the rectifier after a high voltage shutdown

Step Action

Locally

1

Remotely

2

Toggle the ac circuit breaker on the unit itself, or the associated ac
breaker in the distribution panel OFF and ON ( wait until the green ac
ON LED extinguishes before toggling the breaker back to ON ).

Apply a ground signal at the HVSDR input of the rectifier.

end

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

52 Maintenance

This page is left blank intentionally.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

7. Troubleshooting

Table 16 - Diagnosing system faults

Fault symptom Possible causes

53

The RFA LED is lit.

The HVSD LED is lit. • The internal high voltage shutdown point is set

• No ac input or input is out of bounds ( ac ON
LED is extinguished ).

• AC Input / dc output circuit breaker is open.

• The rectifier has received an HVSD signal from

the controller, or a TR signal is present.

• An internal high voltage shutdown ( HVSD ) has
occurred.

• Two cooling fans or fuses have failed.

• The inrush fuse has blown.

• The dc circuit breaker is open.

• A thermal shutdown has occurred.

• Ambient air temperature is high.

• Air inlet / outlet air is blocked, or the air filter is

clogged.

• A rectifier is in 'Start Time Delay' mode and the
RFA will cease when the required time delay has
elapsed.

• Defective rectifier.

to low ( below the float or equalize setting ).

• The controller triggered a remote HVSD.

−−−−continued−−−−

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

54 Troubleshooting

Table 16 – Diagnosing system faults

Fault symptom Possible causes

The AC ON LED is not
lit.

The FAN ALM LED is
lit.

The SEN FAIL LED is
lit.

• No ac input voltage.

• The input circuit breaker is open.

• AC voltage is present but is out of operational

limits. The unit will restart when the ac returns to
the operating level.

• AC has just been applied and the rectifier will
momentarily start ( after an inrush control
delay ).

• The fuse of one or both fans has blown.

• One or both fans have failed.

Note 1 : If a single fan failed or a fuse blew, the

rectifier will continue to operate while
triggering a local and remote FAN ALM.

Note 2 : If two cascaded fans failed or both fuses

blew, the rectifier will shut down and
trigger local and remote RFA alarms.

• One, or both, remote sense leads is
disconnected.

• Excessive impedance in one or both sense
leads.

• The dc circuit breaker is open but the unit is in
remote sense.

The CL LED is lit. • The output load requirement exceeds the total

rectifier capacity.

• With paralleled units, the float or equalize is
maladjusted causing one or more units to carry
the load.

• The unit is in "equalize" mode and paralleled
units are not.

• The remote sense lead has excessive
impedance on one or more rectifiers.

• The system batteries are in recharge mode after
an ac outage.

• The current share mode selection is not the
same for all units.

• The forced share line is disconnected ( in FLS
only ).

—end—

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

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

55

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

56 Appendix A: Recommended Replacement Parts

This page is left blank intentionally.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

57

9. Appendix B : Technical service assistance

For technical assistance, 24 hours a day / 7 days a week, dial one of the
following toll-free numbers. This service complements the services
offered by field support organizations such as, the Emergency Technical
Assistance Service ( ETAS ), and the Installation Technical Assistance
Service ( ITAS ).

9.1. Local toll-free prefixes

The following prefixes give access to toll-free numbers in various
countries. For further information, please contact the local service
provider.

Country Prefix

Australia 0011
Belgium 00
Brazil 000815
Denmark 00
Finland 00 or 990
France 00
Germany 00
Hong Kong 001
Ireland 00
Japan 001 ( KDD )

041 ( ITJ )

0061 ( Idc )

Korea 001( Korea

Telecom )

002 ( Dacom )

003 ( Once )
Malaysia 00
Netherlands 00
New Zealand 00
Singapor 001
Switzerland 00
United Kingdom 00

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

58 Appendix B : Technical service assistance

9.2. Toll-free technical assistance numbers

United States:

In Europe: In Asia and the Pacific:

Austria 800-213-49156 Australia 800-213-49156
Belgium 800-213-49156 Hong Kong 800-213-49156
Denmark 800-213-49156 Japan 800-213-49156
Finland 800-213-49156 Malaysia 800-213-49156
France 800-213-49156 New Zealand 800-213-49156
Germany 800-213-49156 Philippines 1-800-1-110-0131
Ireland 800-213-49156 Singapore 800-213-49156
Italy 800-213-49156 South Korea 800-213-49156
Netherlands 800-213-49156 Taiwan 800-213-49156
Norway 800-213-49156
Sweden 800-213-49156
Switzerland 800-213-49156
United Kingdom

*1

In the Caribbean and Latin America
( CALA ):

Bahamas 1-800-389-0081 Israel 800-213-49156
Barbados 1-800-534-0225
Brazil 7101-2288
Colombia 980-192288
Dominican

Republic
Jamaica 1-800-850-1755
Mexico 001-800-514-2288

Puerto Rico 1-888-680-2288
Trinidad &

Tobago

*1

The United Kingdom includes England, Guernsey, the Isle of Man, Jersey,

Northern Ireland, and Scotland.

1-800-992-8417

800-213-49156

1-888-7514232

1-800-363-2288

Canada:

In the Middle-East:

1-800-363-2288

Note : For countries not covered by a toll-free service dial

Canada ( country code 001 ) at 514-832-0201.

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

10. Abbreviations and acronyms

59

ALCO
ALM
AUTOST
C
CL
EMI
EQL
FAN ALM
HVSD
HVSDR
LED

Alarm cut-off

Alarm

Auto restart Indicator

Common

Current limit indicator

Electromagnetic interference

Equalize

Fan alarm

High voltage shutdown

High voltage shutdown reset

Light Emitting Diode

LOP
MPR
NC
NO
PCB

RC−−−−

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

Loss of phase

Modular power rectifier

Normally closed

Normally open

Printed circuit board

Remote charge bus ( negative )

60 Abbreviations and acronyms

RFA
RG+
RMT ACK
SEN FAIL
THSD
TR
VCAL

Rectifier fail alarm

Remote ground bus ( positive )

Remote acknowledge

Sense fail

Thermal shutdown

Temporary release

Voltage reading calibration

UM5C05C P0745680 Standard 6.00 October 2001 Emerson Energy Systems

Helios Modular Switch Mode Rectifier
200I/48NT5C05C

Installation and User Manual

Emerson Energy Systems
2280 Alfred-Nobel Blvd
St-Laurent ( Quebec ) Canada
H4S 2A4

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

Copyright  2001 Astec Internat ional Lt d
All Rights Reserved

Published in Canada

The information contained in this manual is the property of Astec Int ernat ional
Ltd and is subject to change without notice. Astec International Ltd res erves the
right to make changes in design or components as progress in engineering and
manufacturing may warrant. Except as specifically authorized in writing by the
V.P. of Engineering and Product Manufacturing of Astec International Lt d, t he
holder of this manual shall keep all information contained herein confidential and
shall protect same, in whole or in part, from disclosure and dissemi nat ion t o all
third parties, and use the same for start-up, operation, and m aintenance
purposes only. Any modification to the equipment m us t be approved by the
person responsible for product safet y and des ign quality at Astec International
Ltd to insure that the equipment c omplies with the 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 t he F CC Rules . These limits are designed
to provide reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This equipment generates,
uses, and can radiate radio frequency energy and, if not installed and used in
accordance with Installation and Us er Manuals, may cause harmful interference
to radio communications. Operation of this equipment in a resident ial area is
likely to cause harmful interf erenc e in which c as e t he user will be required to
correct the interference at his own expense.

Helios Candeo is a trademark of As t ec International Ltd. The Emers on logo is a
trademark and service m ark of Emerson Electric Co.

Emerson EnergySystems

a part of Emerson Network Po wer