Emerson 721NPBB User Manual
NetSure™ -48V DC Power System
User Instructions, UM582127000 (Issue AC, January 2, 2013)
Specification Number: 582127000
Model Number: 721NPBB
This page is intentionally blank.
User Instructions UM582127000
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
TABLE OF CONTENTS
CONTENTS PAGE
IMPORTANT SAFETY INSTRUCTIONS .................................................................................. iii
General Safety .................................................................................................................................................... iii
Voltages .............................................................................................................................................................. iii
Battery ................................................................................................................................................................. iii
Circuit Card Handling .......................................................................................................................................... iv
STATIC WARNING .................................................................................................................... v
CHAPTER 1. SYSTEM OVERVIEW .......................................................................................... 1
Customer Documentation Package ..................................................................................................................... 1
System Description .............................................................................................................................................. 1
CHAPTER 2. OPERATING PROCEDURES .............................................................................. 4
Controller, Rectifiers, and Optional Converters ................................................................................................... 4
ESTOP Function .................................................................................................................................................. 4
ACU+ Battery Charge Current Limit Feature ....................................................................................................... 4
Local Controls and Indicators............................................................................................................................... 4
Circuit Card Locations ................................................................................................................................... 4
System Interface Circuit Card ........................................................................................................................ 6
Optional LVD Driver Circuit Card ................................................................................................................... 7
Optional LVD Driver Lite Circuit Card ............................................................................................................ 8
Optional Manual Battery Disconnect Circuit Card (Main Bay Only) .............................................................. 9
SM-DU Circuit Card ..................................................................................................................................... 10
CHAPTER 3. MAINTENANCE ................................................................................................. 11
System Maintenance Procedures ...................................................................................................................... 11
Adding a Rectifier Module to an Existing Rectifier Module Mounting Shelf Spec. No. 588705000 ................... 11
Adding a Rectifier or Converter Module to an Existing Module Mounting Shelf Spec. No. 588705300 ............ 11
Installing a Field Expansion Rectifier Module Mounting Shelf Spec. No. 588705000 ....................................... 14
Installing a Field Expansion Rectifier/Converter Module Mounting Shelf Spec. No. 588705300 ...................... 18
Changing the ACU+ LVD Control Level for a Contactor .................................................................................... 21
Adding a Supplemental Bay in the Field ............................................................................................................ 21
CHAPTER 4. TROUBLESHOOTING AND REPAIR ................................................................ 22
Contact Information ............................................................................................................................................ 22
Controller, Rectifiers, and Optional Converters ................................................................................................. 22
ACU+ Controller Configuration .......................................................................................................................... 22
System Troubleshooting Information ................................................................................................................. 22
Replacement Information ................................................................................................................................... 25
Replacement Assemblies ............................................................................................................................ 25
Replacement Cables ................................................................................................................................... 25
Replacement Procedures ................................................................................................................................... 25
Replacing a Rectifier Module (in a Spec. No. 588705000 Shelf) ................................................................ 25
Replacing a Rectifier or Converter Module (in a Spec. No. 588705300 Shelf) ........................................... 25
Table of Contents Page i
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
Replacing the ACU+ Controller ................................................................................................................... 25
Replacing a Distribution Device ................................................................................................................... 26
Circuit Card Replacement Procedures ........................................................................................................ 37
Replacing a Distribution Panel .................................................................................................................... 53
Replacing a Battery or Load Disconnect Contactor .................................................................................... 56
REVISION RECORD ................................................................................................................ 62
Page ii Table of Contents
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
IMPORTANT SAFETY INSTRUCTIONS
GENERAL SAFETY
Danger: YOU MUST FOLLOW APPROVED SAFETY PROCEDURES.
Performing the following procedures may expose you to hazards. These
procedures should be performed by qualified technicians familiar with the
hazards associated with this type of equipment. These hazards may
include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other metal objects.
c) Prior to contacting any uninsulated surface or termination, use a
voltmeter to verify that no voltage or the expected voltage is present.
d) Wear eye protection, and use recommended tools.
e) Use double insulated tools appropriately rated for the work to be
performed.
Caution: Performing maintenance and/or troubleshooting procedures may
interrupt power to the loads, if battery reserve is not sufficient.
VOLTAGES
AC Input Voltages
Danger: This system operates from AC voltage capable of producing fatal
DC Input/Output Voltages
Danger: This system produces DC Power and may require battery to be connected
BATTERY
Danger: Correct polarity must be observed when connecting battery leads.
Danger: Special safety precautions are required for procedures involving
electrical shock. AC input power must be completely disconnected from
the branch circuits wiring used to provide power to the system before any
AC electrical connections are made. DO NOT apply AC power to the
system until all electrical connections have been completed and checked.
to it. Although the DC voltage is not hazardously high, the rectifiers
and/or battery can deliver large amounts of current. Exercise extreme
caution not to inadvertently contact or have any tool inadvertently contact
a battery terminal or exposed wire connected to a battery terminal.
NEVER allow a metal object, such as a tool, to contact more than one
termination or battery terminal at a time, or to simultaneously contact a
termination or battery terminal and a grounded object. Even a momentary
short circuit can cause sparking, explosion, and injury.
handling, installing, and servicing batteries. Observe all battery safety
precautions in this manual and in the battery instruction manual. These
precautions should be followed implicitly at all times. Remove watches,
rings, and other metal objects before connecting battery leads.
Important Safety Instructions Page iii
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
CIRCUIT CARD HANDLING
Warning: Installation or removal of the circuit cards requires careful handling.
Before handling any circuit card, read and follow the instructions
contained on the Static Warning Page.
Page iv Important Safety Instructions
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
STATIC WARNING
The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below
must be observed to prevent damage to these components. Disregarding any of these warnings may result in
personal injury or damage to the equipment.
1. Strictly adhere to the procedures provided in this document.
2. Before touching any static sensitive component or printed circuit card containing such a component,
discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm
resistor. Some wrist straps, such as Emerson Network Power Part Number 631810600, have a built-in
one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s
instructions outlining use of a specific wrist strap.
3. Do not touch the traces or components on a printed circuit card containing static sensitive components.
Handle the printed circuit card only by the edges that do not have connector pads.
4. After removing a printed circuit card containing a static sensitive component, place the printed circuit card
only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil.
Do not use ordinary Styrofoam or ordinary plastic.
5. Store and ship static sensitive devices or printed circuit cards containing such components only in static
shielding containers.
6. If necessary to repair a printed circuit card containing a static sensitive component, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded
test equipment.
Static Warning Page v
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
This Page Left Intentionally Blank
Page vi Static Warning
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
CHAPTER 1. SYSTEM OVERVIEW
CUSTOMER DOCUMENTATION PACKAGE
This document (UM582127000) provides User Instructions for NetSure™ Power System
Model 721NPBB, Spec. No. 582127000.
The complete Customer Documentation Package consists of…
Bound System Installation Manual
Power System Installation Instructions: IM582127000
Power System Quick Start Guide: QS582127000
Bound ACU+ Controller User Manual
ACU+ Controller User Instructions: UM1M820BNA
(includes instructions
for 1M820DNA Controller)
USB Drive with All Customer Documentation
Power System Installation Instructions: IM582127000
Power System Quick Start Guide: QS582127000
Power System User Instructions: UM582127000
Power System “System Application Guide”: SAG582127000
Rectifier Module Mounting Shelf Power Data Sheet: PD588705000
Rectifier Instructions: UM1R483500E
Rectifier/Converter Module Mounting Shelf
Power Data Sheet: PD588705300
Rectifier Instructions: UM1R482000E3
Converter Instructions: UM1C48241500
Engineering Drawings
Also provided on the USB drive is an ACU+ configuration drawing and the ACU+
configuration files loaded into the ACU+ as shipped.
SYSTEM DESCRIPTION
-48V DC @ up to 4000 Amperes Power System
The NetSure™ 721NPBB DC Power System is a complete integrated power system
containing rectifiers, optional converters, intelligent control, metering, monitoring, and
distribution.
This power system is designed to power a load while charging a positive grounded
battery. This power system is capable of operating in a batteryless installation or off
battery for maintenance purposes. The power system is designed for operation with the
positive output grounded.
Chapter 1. System Overview Page 1
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
This system consists of the following components.
Distribution Cabinet
The system always includes a minimum of one distribution cabinet, which provides
DC distribution through fuses and/or circuit breakers. The distribution cabinet is
factory mounted in the relay rack or shipping brackets specified when ordered.
Four different sizes of distribution cabinets are available to accept from one (1) to
four (4) distribution panels. A variety of distribution panels are available that provide
load distribution, battery distribution, and dual voltage load distribution for use with
+24V converters. These distribution panels are configured to accept either bullet
nose type circuit breakers and TPS/TLS fuseholders, TPH fuses, TPL-B fuses, or
GJ/218 circuit breakers.
The distribution cabinet may be equipped with low voltage load disconnect (LVLD),
low voltage battery disconnect (LVBD), and manual battery disconnect.
ACU+ (Advanced Control Unit Plus) Controller
The system contains one controller. The controller provides power system control
(including optional low voltage battery disconnect (LVBD) and low voltage load
disconnect (LVLD) control), rectifier control (including a charge control function),
converter control, metering functions, monitoring functions, and local/remote alarm
functions. The controller also supports rectifier temperature compensation if the
system is equipped with a temperature probe(s). Temperature probe(s) may also be
designated to monitor ambient temperature and/or battery temperature. The
controller also provides data acquisition, system alarm management, and advanced
battery and energy management. The controller contains an LCD display and
keypad for local access. The controller provides Ethernet connection and supports
software upgrade via its USB port. It also comes with a comprehensive web page
and SNMP capability for remote system management. Refer to the ACU+ Controller
Instructions (UM1M820BNA) for more information.
Rectifier Module Mounting Shelf (Spec. No. 588705000)
The system may contain one or more Spec. No. 588705000 rectifier module
mounting shelves, each of which houses up to six (6) rectifier modules. Refer to
Power Data Sheet PD588705000 for more information.
Rectifier Modules (for use in Spec. No. 588705000)
The system contains rectifier modules, which provide load power, battery float
current, and battery recharge current during normal operating conditions. Refer
to the Rectifier Instructions (UM1R483500E) for more information.
Rectifier/Converter Module Mounting Shelf (Spec. No. 588705300)
The system may contain one or more Spec. No. 588705300 rectifier/converter
module mounting shelves, each of which houses rectifier modules and optional
DC-DC converter modules. Refer to Power Data Sheet PD588705300 for more
information.
Rectifier Modules (for use in Spec. No. 588705300)
The system contains rectifier modules, which provide load power, battery float
current, and battery recharge current during normal operating conditions. Refer
to the Rectifier Instructions (UM1R482000E3) for more information.
Page 2 Chapter 1. System Overview
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
Optional DC-DC Converter Modules (for use in Spec. No. 588705300)
Where +24V DC load power is also required, DC-DC converter modules are
available. Refer to the Converter Instructions (UM1C48241500) for more
information.
Chapter 1. System Overview Page 3
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
CHAPTER 2. OPERATING PROCEDURES
CONTROLLER, RECTIFIERS, AND OPTIONAL CONVERTERS
For operation instructions on these units, refer to the following documents.
ACU+ Controller Instructions (UM1M820BNA)
Rectifier Instructions (UM1R483500E or UM1R482000E3)
Converter Instructions (UM1C48241500)
ESTOP FUNCTION
If an ESTOP switch is wired to the ACU+ IB2 Interface Board, customer-furnished system
ground applied to terminal DI8+ activates the ESTOP function. The ESTOP function
shuts down and locks out the rectifiers, opens the LVD’s, and shuts down the converters.
When the ESTOP signal is removed, LVD’s close (if battery present) and converters
restart. To restart the rectifiers; turn AC power to the rectifiers OFF, wait 30 seconds or
more (until the LEDs on the rectifier extinguish), then turn AC power to the rectifiers ON.
Rectifiers can also be restarted from the ACU+ LCD or WEB Interface menu (via the
Rectifier Reset command, found in the Manual menu in the LCD menus or under the
Rectifier Control Tab in the WEB Interface).
ACU+ BATTERY CHARGE CURRENT LIMIT FEATURE
Functionality: After a commercial AC failure or when some battery cells are permanently
damaged, the current to the batteries can be quite extensive. To avoid overheating or
further damages to the battery, the ACU+ can be programmed to limit the battery current
to a preset level by limiting the charging voltage of the rectifiers. Should the battery
current still exceed a higher preset value, an alarm is issued.
In this system, the ACU+ Battery Charge Current Limit feature is set to be disabled.
Refer to the ACU+ Controller Instructions (UM1M820BNA) to enable and program this
feature, if desired. If enabled, battery charge current is limited to the value set in the
ACU+ Controller, as long as battery voltage is above 47VDC.
LOCAL CONTROLS AND INDICATORS
Refer to the Controller, Rectifier, and Converter Instructions for descriptions of the local
controls and indicators located on these units.
Refer to this section for descriptions of the local controls and indicators located on the
circuit cards installed inside the distribution cabinet.
Circuit Card Locations
Refer to Figure 2-1.
Page 4 Chapter 2. Operating Procedures
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
IB2 (Main Bay Only)
(ACU+ Interface Board)
(located on inside side panel)
Optional EIB (Main Bay Only)
(ACU+ Extended Interface Board)
(located on inside side panel)
Optional SM-DU+ and
Shunt Interface Board
4-Row Cabinet Shown,
Others Similar
(Front Door Removed in
Illustration for Clarity)
System Interface
Circuit Card
OR
Optional LVD
Driver Circuit Card
Optional LVDDriver
Lite Circuit Card
ACU+ Controller
(Main Bay)
SM-DU
(Supplemental Bays)
Mounting Position
Optional Manual Battery
Disconnect Circuit Card
(Main Bay Only)
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
Chapter 2. Operating Procedures Page 5
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Figure 2-1
Circuit Card Locations
UM582127000 User Instructions
TP3 (+) and TP4 (-)
Bay Load
Shunt Monitoring
TP1 (+) and TP2 (-)
Bay Voltage
Monitoring
J7
TB2
J1
1
1
1
1
J2
J3
J4
J8
TB1
TP1 TP2 TP3 TP4
J5
J10
Bay Load Shunt Scale
List 21, 1-Row Cabinet
800A/ 25mV
32A per mV
List 22, 2-Row Cabinet
2000A/ 25mV
80A per mV
List 23, 3-Row Cabinet
2500A/ 25mV
100Aper mV
List 24, 4-Row Cabinet
2500A/ 25mV
100Aper mV
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
System Interface Circuit Card
The system interface circuit card contains test points to externally monitor bay voltage
and bay load. Refer to Figure 2-2.
Figure 2-2
System Interface Circuit Card
Page 6 Chapter 2. Operating Procedures
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
LVD Inhibit Switch
Momentary UP / Middle / Down
Momentary UP Position: Closes all LVD Contactors (inhibit mode).
Middle Position: OFF (ACU+ DOES NOT control LVD’s)(inhibit mode).
DOWN Position: ON (ACU+ controls LVD’s).
LVD Inhibit
Active Indicator
Illuminates when the
low voltage disconnect
circuit has been disabled
through the use of the
LVD Inhibit switch.
J6 J5 J4
J3 J2 J1
J9
J7
S1
Note: The UP position will not close the LVBD contactor
if the battery is manually disconnected using the
Manual Battery Disconnect Switch.
Switch and indicator located
on circuit card installed in
Main Bay only.
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
Optional LVD Driver Circuit Card
The optional LVD driver circuit card installed in the main bay contains an LVD inhibit
switch and indicator. Refer to Figure 2-3. LVD driver circuit cards are required for 2-, 3-,
or 4-row distribution cabinets that contain three or more LVD contactors (LVBD and/or
LVLD); or if the distribution cabinet is equipped with an LVBD contactor rated 1200A or
higher.
Caution: If the switch is returned to the ON (normal) position when low voltage
disconnect alarms are active, a low voltage disconnection will occur.
Warning: While the LVD inhibit switch is in the OFF (inhibit) position, a low
voltage disconnection will not occur if battery or load voltage decreases
below the low voltage disconnect setpoint. For maximum battery
protection, this switch should NOT be left in the OFF (inhibit) position.
Chapter 2. Operating Procedures Page 7
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Optional LVD Driver Circuit Card
Figure 2-3
UM582127000 User Instructions
LVD Inhibit Switch
LVD Inhibit
Active Indicator
Momentary UP / Middle / Down
Momentary UP Position: Closes all LVD Contactors (inhibit mode).
Middle Position: OFF (ACU+ DOES NOT control LVD’s) (inhibit mode).
DOWN Position: ON (ACU+ controls LVD’s).
Illuminates when the
low voltage disconnect
circuit has been disabled
through the use of the
LVD Inhibit switch.
J1J3
J2
S1
Note: The UP position will not close the LVBD contactor
if the battery is manually disconnected using the
Manual Battery Disconnect Switch.
Switch and indicator located
on circuit card installed in
Main Bay only.
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
Optional LVD Driver Lite Circuit Card
The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit
switch and indicator. Refer to Figure 2-4. LVD driver lite circuit cards are required for
distribution cabinets that contain two LVLD contactors or one LVLD contactor and one
LVBD contactor. LVBD contactor must be rated at 600A or lower.
Caution: If the switch is returned to the ON (normal) position when low voltage
disconnect alarms are active, a low voltage disconnection will occur.
Warning: While the LVD inhibit switch is in the OFF (inhibit) position, a low
voltage disconnection will not occur if battery or load voltage decreases
below the low voltage disconnect setpoint. For maximum battery
protection, this switch should NOT be left in the OFF (inhibit) position.
Page 8 Chapter 2. Operating Procedures
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Optional LVD Driver Lite Circuit Card
Figure 2-4
User Instructions UM582127000
Momentary UP / Middle / Momentary Down
Momentary UP Position: Closes (latches in close position) the Battery Disconnect Contactor.
Middle Position: Normal Operation.
Momentary DOWN Position: Opens (latches in open position) the Battery Disconnect Contactor.
Momentarily place switch in the UP position to close the contactor.
Manual Battery Disconnect
Active Indicator
Manual Battery
Disconnect Switch
Illuminates if the Battery Disconnect Contactor has
been manually disconnected (placed in open position).
J1
J2
S1
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
Optional Manual Battery Disconnect Circuit Card (Main Bay Only)
The optional manual battery disconnect circuit card contains a manual battery disconnect
switch and indicator. Refer to Figure 2-5.
Figure 2-5
Optional Manual Battery Disconnect Circuit Card (Main Bay Only)
Chapter 2. Operating Procedures Page 9
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Indicator
Normal State
Fault State
Fault Cause
Alarm
(Red)
Off
On
A critical or major alarm.
Alarm
(Yellow)
Off
On
A minor alarm.
Operation
(Green)
On
Off
SM-DU is non-operational.
Flashing
A 1/3Hz flashing indicates the SM-DU
is being identified by the Controller.
A 1Hz flashing indicates a
communication failure.
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
SM-DU Circuit Card
The SM-DU is used in supplemental bays in place of ACU+ controller. The SM-DU
monitors the bay and reports to the controller. The controller sends commands to the
SM-DU to fulfill battery management and load control functions according to the received
data.
There are three (3) status and alarm indicators located on the SM-DU. The functions of
these indicators (from top to bottom as shown in the illustration) are as shown in Table
2-1. Refer to Figure 2-6 for location.
Table 2-1
SM-DU Indicators
Figure 2-6
SM-DU Circuit Card
Page 10 Chapter 2. Operating Procedures
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
PROCEDURE
REFERENCED IN
COMPLETED (√)
Check ventilation openings for
obstructions such as dust, papers,
manuals, etc.
--
Inspect and tighten all installer's
connections.
IM582127000,
Chapter 4.
Making Electrical
Connections.
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
CHAPTER 3. MAINTENANCE
SYSTEM MAINTENANCE PROCEDURES
It is recommended to perform the maintenance procedures listed in Table 3-1 every
6-months to ensure continual system operation.
Note: This table may be reproduced as necessary to record and document
system performance.
Table 3-1
Maintenance Procedures to be Performed at 6-Month Intervals
ADDING A RECTIFIER MODULE TO AN EXISTING RECTIFIER MODULE MOUNTING SHELF SPEC. NO. 588705000
To increase system current capacity, a rectifier module can easily be added to an existing
rectifier module mounting shelf Spec. No. 588705000 that contains an empty rectifier
module mounting position.
It is recommended that the current limit point be checked whenever a rectifier module is
added to or removed from the power system. Refer to “Checking the ACU+ Current Limit
Point after Adding or Removing a Rectifier” in “CHAPTER 4. TROUBLESHOOTING AND
REPAIR”.
The rectifier module being added is assigned by the ACU+ the lowest available
identification number. If desired, you can change the identification number, see
“Configuring the ACU+ Identification of Rectifiers” in Chapter 5 of the separate Power
System Installation Instructions (IM582127000).
For rectifier module installation instructions, refer to Rectifier Instructions
(UM1R483500E).
ADDING A RECTIFIER OR CONVERTER MODULE TO AN EXISTING MODULE MOUNTING SHELF SPEC. NO. 588705300
To increase system current capacity, a rectifier module can easily be added to an existing
module mounting shelf Spec. No. 588705300 that contains an empty rectifier module
mounting position. Likewise, to increase subsystem capacity a DC-DC converter module
can be added to a module mounting shelf Spec. No. 588705300 that contains an empty
converter module mounting position.
Chapter 3. Maintenance Page 11
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Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Rectifier and converter modules can be inserted or removed with power applied (hot
swappable).
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
Rectifiers modules can be installed in any mounting position of each module mounting
shelf. Converters modules can be installed in any of the three far right mounting
positions of each module mounting shelf (as viewed from the front). See Figure 3-1.
Note: Each rectifier and converter module locks into the module mounting shelf by
means of a latch located on the bottom of the module. The latch and module
handle are interactive. Pushing the handle up into the module’s front panel
causes the latch to extend to the locking position; pulling the handle down out
from the module’s front panel causes the latch to retract. See Figure 3-1.
Warning: To prevent damage to the latching mechanism, ensure the handle is in
the open position when installing or removing a module. NEVER hold
the handle in the closed position when installing a module into a shelf.
Procedure
1) Unpack the modules.
2) Note the model number located on the front of each module. Model numbers
starting with the letter “R” are rectifier modules. Model numbers starting with the
letter “C” are converter modules.
3) Place the module into an unoccupied mounting position without sliding it in
completely. Rectifiers modules can be installed in any mounting position of each
module mounting shelf. Converters modules can be installed in any of the three
far right mounting positions of each module mounting shelf (as viewed from the
front). See Figure 3-1.
4) Loosen the captive screw on the module’s handle. Pull the handle down out from
the module’s front panel (this will also retract the latch mechanism). See Figure
3-1.
5) Push the module completely into the shelf.
6) Push the handle up into the module’s front panel. This will lock the module
securely to the shelf. Tighten the captive screw on the handle.
7) Repeat the above steps for each module being installed in the system.
8) After the modules are physically installed in the mounting shelf(s), they are ready
for operation immediately after power is supplied to them.
Note: It is recommended that the current limit point be checked whenever a rectifier
is added to or removed from the power system. Refer to “Checking the ACU+
Current Limit Point after Adding or Removing a Rectifier” in “CHAPTER 4.
TROUBLESHOOTING AND REPAIR”.
Note: The rectifier or converter being added is assigned by the ACU+ the lowest
available identification number. If desired, you can change the identification
number, see “Configuring the ACU+ Identification of Rectifiers” or
“Configuring the ACU+ Identification of Converters” in Chapter 5 of the
separate Power System Installation Manual (IM582127000).
Page 12 Chapter 3. Maintenance
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
User Instructions UM582127000
Rectifier Converter
Latch
Captive Screw
Handle
Captive Screw
Latch
Handle
Module Mounting Shelf(s)
Rectifier
Mounting Positions
Rectifier or Converter
Mounting Positions
Front View
Spec. No. 582127000 (Model 721NPBB) Issue AC, January 2, 2013
Figure 3-1
Installing Rectifier and Converter Modules in a Spec. No. 588705300 Shelf
Chapter 3. Maintenance Page 13
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM582127000 User Instructions
Issue AC, January 2, 2013 Spec. No. 582127000 (Model 721NPBB)
INSTALLING A FIELD EXPANSION RECTIFIER MODULE MOUNTING SHELF SPEC. NO. 588705000
Danger: Adhere to the “Important Safety Instructions” presented at the front of
this document.
Note: Refer to Figure 3-2 and Figure 3-3 as this procedure is performed.
Procedure
1) Install the expansion rectifier module mounting shelf directly below the bottommost rectifier module mounting shelf in the rack. Use the mounting hardware
provided in the expansion busbar kit.
Hardware build-up is: 12-24 x 3/4" screw and flat washer, (1) set per side.
12-24 x 3/4" screw and ground washer, (1) set per side.
Note: Install the ground washers so the teeth make contact with the metal on
the mounting angles. Torque all screws to 65 in-lbs.
2) On the rear of the expansion rectifier module mounting shelf and the existing
shelf installed directly above it, remove the rear shield that covers the output
busbars.
Note: Apply electrical anti-oxidizing compound to busbar mating surfaces before
performing the next step.
3) Secure the existing shelf’s busbars to the expansion shelf’s mating busbars with
the supplied interconnect busbars and hardware.
Hardware build-up for these connections are:
1/4-20 x 1" bolt,
1/4" Belleville lock washer,
1/4" flat washer.
Install the Belleville lock washer so the concave side is towards the busbar.
Torque all connections to 60 in-lbs.
If installing a second expansion rectifier module mounting shelf, 1/4-20 nuts
(included) are required in lieu of the 1/4-20 x 1” bolts (see Figure 3-2).
4) Disconnect the cable coming from the distribution cabinet from the bottom
connector on the bottom-most existing rectifier shelf.
5) Connect the bottom connector on the bottom-most existing rectifier shelf to the
top connector on the expansion rectifier shelf.
6) Connect the cable disconnected in step 4) (coming from distribution cabinet) to
the bottom connector on expansion rectifier shelf.
7) Replace the rear covers removed in step 2) above.
8) Refer to the Power System Installation Instructions (IM582127000) and connect
AC input power to the expansion shelf.
9) Refer to the Rectifier Instructions and install rectifier modules into the expansion
shelf as required.
Page 14 Chapter 3. Maintenance
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
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