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DIRECTIONS FOR USE

POWER SUPPLY SYSTEM NetSure 501,


BZA 108 35, 48 V DC

Emerson Network Power Energy Systems AB 2007 All rights reserved

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DIRECTIONS FOR USE BZA 108 35

The contents of this document are subject to revision without notice due
to continued progress in methodology, design, and manufacturing.

Emerson Network Power Energy Systems AB


SE 141 82 Stockholm
Sweden
Tel. +46 8 721 6000

Fax. +46 8 721 7177

www.emersonenergy.com

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DIRECTIONS FOR USE BZA 108 35

Contents
1

Introduction

Function

Configurations

Units in the system

4.1
4.2
4.3
4.4
4.5
4.6

Rectifier
Rectifier subrack
Control units
Multifunction unit
AC distribution
AC connection terminals

8
10
11
11
12
12

Technical data

13

5.1
5.2
5.3

System
Cabinet
Rectifier

13
13
13

Installation

14

Start-up and installation test

14

Maintenance

14

8.1
8.2
8.3
8.4

Safety
Scheduled maintenance
Alarms
Fault symptoms and trouble shooting

14
14
15
15

Exchange of units and parts

21

9.1
9.2
9.3
9.4
9.5
9.6
9.7

Exchange of rectifiers
Rectifier fan replacement
Exchange of distribution circuit-breaker
Exchange of contactor
Exchange of SCU/ACU
Exchange of connector board
Exchange of SCU/ACU supply fuses

21
22
23
24
25
25
26

10

Abbreviations used in this document

27

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DIRECTIONS FOR USE BZA 108 35

Introduction
The NetSure 501 48 V DC power system consists of a stand-alone cabinet,
DC-distribution unit, maximum 12 rectifiers of 1700 W, battery connections
and a supervision unit.

Function
For the protection of the batteries during a power outage, the load is disconnected at a preset voltage or after a predetermined delay.
To prolong the service of some loads at a long power outage, the DC distribution is divided into two branches. One is for normal load and one for priority
load, so the disconnection can be made in two steps.

AC Mains
Subrack 2

DU, normal load

6 rect.

Priority Load

~
=
MFU
LVD 1
& ICU
Subrack 1

6 rect.
LVD 2

~
=
Shunt

AC terminals
CAN-bus

Batt.
CBs

SCU/
ACU

Figure 1.

Example of system topology.

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Ext. Batts.

DIRECTIONS FOR USE BZA 108 35

Configurations
The cabinets can be configured with different numbers of rectifiers, batteryand distribution- circuit-breakers. They are built for overhead cabling.

Extension
distribution unit

MFU and Control unit

Rectifier subrack
Rectifier subrack

AC distribution
unit (optional)

Figure 2.

Example of configuration with overhead cabling.

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DIRECTIONS FOR USE BZA 108 35


The Figure 3 and Figure 4 give examples of standard configurations.

Cover panel 2 U
AC terminals (if no ACD)
MFU (battery CBs,

S/A

LVDs, normal and

C/C

prio load CBs

U/U

ACD (optional)
(BMG 653 39/21)
Fire trap
Figure 3.

Configuration with single rectifier subrack.

Cover panel 2 U
AC teminals (if no ACD)
Extension distribution CBs
(normal load)
Cover panel 2 U
MFU (battery CBs,

S/A

LVDs, normal and

C/C

prio load CBs)

U/U

ACD (option)
(BMG 653 39/22)
Fire trap
Figure 4.

Configuration with double rectifier subracks.

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DIRECTIONS FOR USE BZA 108 35


Basic configuration:

Cabinet for overhead cabling


Maximum 12 rectifiers 1700 W
One or two rectifier subracks for maximum 6 rectifiers each
MFU including maximum four battery CBs, distribution CBs, LVD contactors, a standard control unit (SCU) and a battery shunt
AC terminal unit for maximum 12 rectifiers

Battery temperature sensor KET 103 06/1

Options:

Advanced control unit (ACU)


Cables for battery, distribution, earthing and signalling
Cabling materials (lugs, tie wraps, markings)
Internal AC distribution unit for maximum 12 rectifiers
External AC distribution units
Mains cable
Lifting eye bolts SAR 201 080/03
Cabinet anchoring material BMY 107 125/1
AC inlet pull-relief clamps
Room temperature sensor KET 103 06/1
Spare parts

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DIRECTIONS FOR USE BZA 108 35

Units in the system

4.1

Rectifier
The rectifier is voltage regulated of a constant power limitation type (1700 W)
and designed to meet the most stringent electrical requirements as well as
demands for high power density (fan cooling). It can work independently of the
control unit, and can share the load actively and control the system voltage.

LEDs

Figure 5.

Rectifier.

4.1.1 LEDs
The front panel has three indicator LEDs. The functions of the LEDs are listed
in the table below.
LED
Power indicator
(green)

Protection indicator (yellow)

Alarm indicator
(red)

Normal
ON

OFF

OFF

Abnormal

Cause of Abnormality

OFF

No AC Mains Supply

Flashing

Rectifier is under control by SCU/ACU

ON

AC input over/undervoltage, PFC


over/undervoltage and overtemperature

Flashing

Communication with SCU/ACU failure

ON

Output overvoltage

Flashing

Fan Failure

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DIRECTIONS FOR USE BZA 108 35

4.1.2 Features

Hot swappable. The rectifier is plug-and-play to live inputs and outputs.

Active load sharing. The rectifier uses advanced digital active load sharing
technology for minimum load difference between units.

Power derating by input voltage. The rectifier will go into power derated
mode if the input AC voltage is too low or too high.

Power derating by output load. The rectifier will limit its output power constant when the load exceeds the nominal output power.

Power derating by temperature. For high temperatures the output load will
be gradually reduced. See technical data.

Current limiting function. The rectifier has a current limiting function. The
current limit can be set from an SCU/ACU.

Foldback current limiting function. If a short circuit occurs on the rectifier


output terminals, the rectifier will keep its output current at a constant
value. When the short circuit fault is cleared, the rectifier will automatically
restore to normal operation.

Adjustable output voltage. The voltage can be set from an SCU/ACU.

Current walk-in. The rectifier can be set from an SCU/ACU to take load
gradually in order to reduce the stress on generators, fuses etc.

Fan control. The fans speed is controlled according to the rectifier internal
temperature. The fan is stopped completely at low temperature and at
very low or high input voltage.

4.1.3 Digital Signal Processor (DSP)


The rectifier has a built-in advanced DSP that monitors and controls the
operation of the rectifier. The DSP also communicates with an SCU/ACU
through a CAN bus.

The rectifier can receive commands such as turning on/off, current walk-in
on/off signal and high voltage alarm reset signal from an SCU/ACU.

An SCU/ACU can adjust the output voltage, overvoltage alarm point, current walk-in time and the current limit of the rectifier.

The rectifier reports its output voltage, output current, temperature, current
limit setpoint, overvoltage setpoint, on/off status and alarm information to
an SCU/ACU in real time.

By querying the DSP, an SCU/ACU can get the following data from the
rectifier: Input voltage, output voltage, output current, current limit setpoint,
temperature of rectifier, and overvoltage setpoint.

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DIRECTIONS FOR USE BZA 108 35

By querying the DSP, an SCU/ACU can get the following state information
from the rectifier: On/off, protect (input protect, inner DC bus voltage protect; overtemperature), fault (HVSD, fan failure), thermal derating, AC
derating, AC failure, and unbalance current.

An SCU/ACU can get the following unit information from the rectifier: Address, code, date, SW version and HW version.

4.1.4 Protection functions

4.2

Input over/undervoltage protection. The rectifier will shut down and its yellow LED will emit light if the input voltage is outside the range 80 to
305 V AC. An alarm will be sent to the SCU/ACU.

Output overvoltage protection. If the rectifier output voltage exceeds a limit


that can be set from the SCU/ACU, the rectifier will shut down. If output
over voltage occurs two times within 5 minutes, the rectifier can only be
restarted manually and its red alarm LED will emit light. An alarm will be
sent to the SCU/ACU.

Over-temperature protection. The rectifier will limit its power to 50% of


rated output power if its internal temperature is higher than 75 C. If the internal temperature reaches 80 C, the rectifier will shut down and its yellow LED will emit light. An alarm will be sent to the SCU/ACU.
The alarm will cease and the rectifier will restart when the temperature becomes normal.

Communication failure. At communication failure, the rectifier output voltage is reduced to a default value for protection of the battery. The yellow
LED will flash and alarm will be sent to the SCU/ACU.

Fan alarm. The red LED will flash at a fan fault and the rectifier will stop.

Unbalance of Rectifier Output Current. When the output current of the rectifiers in a DC power system is unbalanced, the rectifier that outputs unbalanced current will be identified automatically and its yellow LED will
emit light. An alarm will be sent to the SCU/ACU.

Rectifier subrack

Figure 6.

Subrack for six rectifiers.

The rectifier subrack has space for six rectifiers.

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DIRECTIONS FOR USE BZA 108 35

4.3

Control units
The control unit is placed in the multifunction unit. It controls, supervises and
communicates with the other units of the power supply system and manages
alarm handling, etc.
Two control units are available. The standard control unit (SCU) has an LCDdisplay, offers internal supervision and alarm handling, sends external alarm
signals over relays and communicates externally via modem with external
computer-based supervision systems (EEM, for example) that can be implemented for different maintenance activities.
The advanced control unit (ACU) has, in addition to the SCU features, an interface to communicate with supervision modules (SM) for supervision of
existing cabinets, AC mains and batteries, for example. It has a Web interface
for communication with MS Explorer.
For detailed information, refer to USERS GUIDE 5/1553-BMP 903 050 Uen,
for the ACU and 5/1553-BMP 903 051 Uen, for the SCU.

4.4

Multifunction unit
+ terminals
LVD contactors

CB alarm
board

Connector
board

DIN bar for CBs

Figure 7.

MFU.

The unit combines normal and priority distribution circuit-breakers battery CBs,
a battery shunt (500 A) and one or two load disconnect contactors (125 and
500 A). The control unit (SCU/ACU) and the connector board are also
mounted here.

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DIRECTIONS FOR USE BZA 108 35

4.5

AC distribution

R1--------------------------------------------------------R12

Figure 8.

L1 L2 L3 N PE
Input terminal

AC distribution unit seen from front.

For cabinets with double rectifier subracks, an AC distribution unit is available.


It includes separate circuit breakers for each rectifier.

4.6

AC connection terminals

Figure 9.

Mains terminals.

A unit with maximum four terminal blocks can be delivered for the connection
of totally 12 rectifiers.

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DIRECTIONS FOR USE BZA 108 35

Technical data

5.1

System
Nominal DC voltage

48 V

Maximum output current @ 48 V 212 A (with one rectifier subrack) or


425 A (with two rectifier subracks)
Operational temperature

5 to +45 C (with hydraulic magnetic


circuit-breakers)
5 to +30 C (with thermal/electro magnetic
circuit-breakers)

5.2

5.3

Storage temperature

40 to +75 C

Relative humidity

5 to 90%

Cabinet
Building practice

23

Height (incl. top cover and feet)

1250, 1650, 1850, 2050 mm

Footprint (with x depth)

400 or 600 x 600 mm

Weight (fully equipped,


without batteries)

maximum 150 kg

Rectifier
See data sheet EN/LZT 145 280 RA

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DIRECTIONS FOR USE BZA 108 35

Installation
See INSTALLATION INSTRUCTIONS 1531-BZA 108 35 Uen.

Start-up and installation test


See TEST INSTRUCTIONS 1532-BZA 108 35 Uen.

Maintenance
Adequate knowledge of the power supply system is required. Refer to item 1
to 5 of this document.

8.1

Safety
The document SAFETY RULES 1550-1004 and local safety rules shall be followed when doing maintenance work in the power supply equipment. Measures that require work inside the cabinets or intervention in a unit shall always
be carried out by adequately trained personnel with adequate knowledge of
the power supply system. When in doubt about an action or how to carry it out,
always call for adequately trained personnel.
In case it is necessary to work on a live power supply system, the approval for
this type of work must be given, based on local regulations governing for example the following areas:

8.2

General rules for work on live equipment

Certification of operatives conducted by certified supervisor

Approved tools

Customer approval

Scheduled maintenance

Use a vacuum cleaner to remove dust from the air inlets of the cabinets.

Check and test the batteries according to the recommendations of the battery supplier.

A scheduled performance test according to the following table shall be


performed at least every two years according to item Test of signals and
supervision in the document TEST INSTRUCTIONS
1532-BZA 108 35 Uen. Settings according to the document TABLE OF
SET VALUES, shall be verified in this test.

A copy of the test result shall be kept in the logbook of the plant.

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8.3

Alarms

8.3.1 Alarm categories


The different alarm categories used in the power supply system are Critical,
Major, Observation and No Alarm.
An alarm of category Critical requires immediate action, whatever the time of
day or night.
An alarm of category Major requires immediate action if it occurs during working-hours, otherwise as soon as the working-hours commence.
An alarm of category Observation is an alarm that indicates a temporary state
of operation and does not normally require any action. However, if the alarm
persists for more than 20 hours, it must be investigated.
If an alarm has category No Alarm it means that the alarm is deactivated and
will not be shown in the display of the SCU/ACU.

8.3.2 Procedure in case of alarm


Enter in the logbook of the power supply system all observations made at the
moment of failure, such as date, time, system voltage and rectifier load. Enter
also what alarm(s) are shown and any external disturbance such as thunderstorm or mains failure.
Trace activated alarms by means of the alarm survey of the respective unit
and the item, which describes what actions to take on the respective alarm.

8.4

Fault symptoms and trouble shooting

8.4.1 System alarms


For system alarms, see USERS GUIDE 1553-BMP 903 051 Uen for the SCU
and 1553-BMP 903 050 Uen for the ACU.
Alarm on
the SCU
display

Alarm on
the ACU
display

Cause

Suggestion

The outgoing alarms are Check why before reconnecting the alarms.
blocked from the
SCU/ACU.

Alarms
Blocked

Alarm
Blocked

Load Fuse
Alarm

Fuse Alarm One or more distribution


circuit-breakers for the
load have tripped.

Rect Not
Respond

CAN
Comm
Fault

There CAN communication is broken.

Find out and eliminate the reason for the


tripped circuit breaker before resetting it.
Check the connectors and cables for the CAN
loop.
Exchange the rectifier that does not respond.
Exchange the SCU/ACU.

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DIRECTIONS FOR USE BZA 108 35

Alarm on
the SCU
display
LVD 1

LVD 2

Alarm on
the ACU
display
LVD 1 Disconnected

LVD 2 Disconnected

LVD 1/ LVD Contactor


2 Open
Fault

Cause

Suggestion

The contactor for the normal load is open because


the battery is too deep
discharged.
The batteries are disconnected at a preset level, in
order to protect them from
over-discharging.

If there is a mains failure, check that it is not


caused by broken supply fuses.

The contactor for the prioritised load is open because the battery is too
deep discharged.

See LVD 1

An LVD contactor is in a
wrong state.

Check the contactor functions.

If the rectifiers are working, the problem may


be that the system load is higher than the
rectifier capacity, causing the batteries to
discharge. If this is the reason, install more
rectifiers.

Batt Curr
High

Abnorm Bat The boost charging curCurr


rent exceeds the set max.
value.

Check the settings.

Batt Fuse
Alarm

Fuse Alarm

Indicates that one or more


battery fuses/circuit breakers have blown/tripped or
been removed.

If a battery fuse/circuit breaker has been


removed/tripped manually, check with the
person that removed/tripped it before reinserting/resetting it. Ensure that there is no
fault before doing that. The battery fuse
shall be reinserted by adequately trained
personnel.

If the battery fuse/circuit


breaker is blown/tripped,
the reason for the failure
probably is overload or
short circuit.

Find out and eliminate the reason for the


blown/tripped fuse/circuit breaker before
swapping/resetting it.

Exchange the SCU/ACU.

Self-detect
Err

ACU fault

SCU/ACU failure.

Manual
Mode

Manual
Mode

The battery monitoring has Check why before resetting it to automatic.


been set to Manual
mode in the SCU/ACU.

Non-Float
Status

Batt Discharge

The system is not in Float


Charge mode because of:
The boost charge is active.

The boost charge will stop automatically.

The battery test is active.

The discharge test will stop automatically.

The battery test is active.

The discharge test will stop automatically.

There is a mains failure.

Check that it is not caused by broken supply


fuses.

The system load is higher


than the rectifier capacity,
causing the batteries to
discharge.

Install more rectifiers.

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Alarm on
the SCU
display
Curr Discrepancy

Alarm on
the ACU
display
Dis Curr Im

Short Test
Fail
Batt Test
Fail

Cause

Suggestion

Check the batteries.


The currents from two
groups of batteries are not
equal.
Note: There must be two
battery shunts in
the system to activate this function.
The short time battery test Check the batteries.
has failed.

Test Failure

The battery test has failed. Check the float charging level.
Check that the load is lower than the capacity of the rectifiers.
Check the battery according to the recommendations of the supplier.

Volt Discrepancy

Rect Over
Volt

Rectifier overvoltage

Mains Failure

Mains Failure

All rectifiers have stopped. Check if there is a general mains failure.


Check that it is not caused by broken supply
fuses.

Multi-Rect
Alarm

Multi-rect fail Two or more rectifiers


have stopped.

See item 8.4.2

Maintain
Alarm

Maintenance Alrm

The maintenance timer


gives alarm

Check the settings of the Maintenance Time


Delay

Rectifier
Lost

Rectifier
Lost

The SCU/ACU has detected a reduction in the


number of running rectifiers.

See item 8.4.2


If the lost rectifier is to be removed permanently, the alarm must be reset from the
SCU/ACU.

Load share
Alarm

The output current of a


rectifier is outside the average value for all rectifiers.

Check the rectifiers.

Rect HVSD

A rectifier output voltage


was higher than the rectifier HVSD setting and has
shut down.

Check the rectifier HVSD setting.

Rect AC Fail Rect AC


Failure

See item 8.4.2

Replace the rectifier.

AC input voltage outside


the normal range.

See item 8.4.2

Rectifier overtemperature
protection.

See item 8.4.2

Rect Failure Rectifier


Failure

Rectifier failure

See item 8.4.2

Rect Protect Rect Protected

Rectifier protection

See item 8.4.2

Rect Over
Temp

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Alarm on
the SCU
display

Alarm on
the ACU
display

Cause

Suggestion

Rect Fan
Fails

Rect Fan
Fail

Rectifier fan failure.

See item 8.4.2.

Rect Derated

Rect Curr
limit

Rectifier overload.
If the batteries are being recharged, the
The load is higher than the alarm will cease by itself when the battery
rectifier capacity.
voltage has increased to the charging level.
If the system load is higher than the rectifier
capacity, the batteries will discharge. If this
is the reason, install more rectifiers.
If one or more of the rectifiers are out of
order, exchange the faulty rectifiers.

DC Volt
Low#1

Under Vol

The distribution voltage


has dropped below the
preset alarm level, usually
initiated because of mains
failure.

If there is a mains failure, check if some


load could be switched off in order to prolong the operating time of the plant.
If there is a rectifier failure, see item 8.4.2.
If the system load is too high related to the
rectifier capacity, install more rectifiers.
If the batteries are being recharged, the
alarm will cease by itself when the battery
voltage has increased to the charging level.

DC Volt
Low#2

Very Under
Vol

See DC Volt Low#1/DC Under Voltage


The distribution voltage
has dropped below the
preset alarm level, usually
initiated because of mains
failure.

DC Volt
High#1

Over Voltage

The system voltage exceeds the preset level.

Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out
why they have changed and correct them.

DC Volt
High#2

The system voltage exceeds the preset level.

Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out
why they have changed and correct them.

AC Voltage
Low#2

The mains voltage is too


low.

Check the mains voltage.

AC Voltage
Low#1

The mains voltage is too


low.

AC Voltage
High

The mains voltage is too


high.

Low Temp
Temp Alarm /Low Amb
Temp

The temperature on a
temperature sensor exceeds the set value.

Check the settings of the SCU.


See AC Voltage Low#2
Check the mains voltage.
Check the settings of the SCU.
Check the temperature.
Check the settings of the SCU/ACU.
If the temperature is OK, exchange the temperature sensor.

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Alarm on
the SCU
display
Temp High
Alarm

No Temp
Sensor 1 or
2

Alarm on
the ACU
display

Cause

Suggestion

High Temp

Check the battery temperature.


The temperature on a
Check the settings of the SCU/ACU.
battery temperature sensor exceeds the set value. If the temperature is OK, exchange the temperature sensor.

Very hiTemp

The temperature on a
See High Temp alarm.
battery temperature sensor exceeds the set value.

High Amb
Temp

The temperature on a
room temperature sensor
exceeds the set value.

T Sensor
Fault

The temperature sensor


has a fault.

Plan BT

Planned battery test in


progress.

Wait for the test to stop automatically.

AC failure
BT

Mains failure.

See Mains Failure alarm.

Manual BT

Manual battery test in proWait for the test to stop automatically.


gress.

Short Test

Short battery test in progress.

Wait for the test to stop automatically.

Cyclic BC

Cyclic boost charge in


progress.

Wait for the boost charge to stop automatically.

Auto BC

Automatic boost charge in Wait for the boost charge to stop automatiprogress.
cally.

Manual BC

Manual boost charge in


progress.

Check the room temperature.


Check the settings of the ACU.
If the temperature is OK, exchange the temperature sensor.
Check the cable and the connector of the
temperature sensor.
Exchange the temperature sensor.

Wait for the boost charge to stop automatically, or stop it manually.

Charge Pro- The boost charge function The boost charge will be blocked by abnorhibit
is blocked.
mal conditions in the system.
Power Major

Indicates Promt alarm


(red LED)

Power Minor

Indicates Main fail alarm


(yellow LED)

High Load

Ab load curr

The system load is higher


than the set level.

Check the settings.

Indicate alarms on the


digital inputs 1-6.

Check the equipment connected to the corresponding input.

Over Power
Digital 1 (to
6)

DI 1 to DI 6

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8.4.2 Rectifier
The usual fault symptoms of the rectifier include: power indicator (green) off,
protection indicator (yellow) on, protection indicator (yellow) flashing, alarm indicator (red) on, and alarm indicator (red) flashing.
Symptom

Power indicator (green) off

Cause

Suggestion

No input voltage

Make sure there is input AC voltage

Input fuse/circuit-breaker fault

Replace the fuse with a new one


of the same model or switch on
the circuit-breaker.

AC input voltage outside the normal


range

Check that the AC input voltage


is within normal range

PFC overvoltage

Replace the rectifier

Current sharing function is disabled

Replace the rectifier

Rectifier overtemperature protection, which is caused by:


Protection
indicator (yelRemove the obstacle that block
Fan blocked
low) on
the fan
Ventilation blocked: the inlet or outlet Remove the objects that blocks
blocked
the inlet or outlet
Ambient temperature too high or
rectifier inlet too close to a heater

Remove the heater, lower the


ambient temperature

Rectifier not completely inserted into


the slot

Insert the rectifier properly

Protection
indicator (yel- Rectifier communication failure
low) flashing

Exchange the rectifier for a new


one.

Alarm indicator (red) on

Remove the rectifier from the DC


power system and then reinsert
it. Exchange the rectifier for a
new one if the alarm continues.

Rectifier overvoltage

Alarm indicator (red) flash- Fan not running


ing

Replace the fan

When multiple rectifiers are in parallel connection and the unbalance of current sharing among them is higher than 3 %, check if the communication cables are correctly connected.
If the current sharing is still unsuccessful after the correction, replace the rectifier of which the current sharing is out of range.

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Exchange of units and parts


To order spare parts, contact Emerson Network Power Energy Systems AB.

9.1

Exchange of rectifiers
1. Loosen the fixing screw of the handle of the faulty rectifier. The handle will
pop out and release the latch locking the rectifier to the subrack.

Fixing screw
Handle

Figure 10. Rectifier handle.


2. Pull out the rectifier unit and remove it.
3. Make sure the handle of the new rectifier unit is locked in its socket with
the fixing screw.

Latch

Figure 11. Locking latch.


4. Insert the new rectifier unit. Push it into its slot until the latch blocks the
way. The latch is set to block the way with the purpose of charging the
rectifier output filter slowly via a charging circuit, as the DC terminals may
get damaged by a spark at a direct connection.

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5. Loosen the fixing screw of the handle, lift the handle, and the latch will withdraw into the rectifier.
6. Continue to push the rectifier into the slot completely.
7. Push the handle into its socket and fasten the fixing screw to lock the
rectifier. Now the rectifier is fixed to the slot by the latch.
The green LED emits light and the fan will start.

9.2

Rectifier fan replacement


If the fan does not work because it is faulty, exchange it for a new one.
1. Remove the rectifier according to item 9.1.

Fan cable plug

Fixing screw
and fan holder
Fan
Front cover

Fixing screws

Figure 12. Fan replacement.


2. Loosen the three screws fixing the front cover to the chassis.
3. Lift out the front cover from the chassis and observe the orientation of the
fan and its wires.
4. Unplug the power cable of the fan and remove the front cover with the fan.
5. Remove the fan from the front cover by removing its two fixing screws and
holders.
6. Replace the fan and fix it to the front cover with the two screws and holders.
7. Plug the fan power cable back into the corresponding socket.
8. Mount the front cover and fix it with the three screws.
9. Reconnect the rectifier according to item 9.1.
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DIRECTIONS FOR USE BZA 108 35

9.3

Exchange of distribution circuit-breaker


1. Open the distribution unit front.
2. Disconnect the distribution cable from the CB.
3. Loosen the CB fixing screw. See Figure 13.
4. Pull the locking device at the bottom of the faulty CB to release it from the
DIN-rail.
5. Lift the CB to release it from the connecting fork. See Figure 13.

CB fixing
screw
2

Figure 13. Releasing a distribution circuit-breaker.


6. Remove the CB according to Figure 14.

connecting fork

Figure 14. Removing a distribution circuit-breaker.


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DIRECTIONS FOR USE BZA 108 35


7. Mount a new CB in the reverse order.
8. Lock the new CB to the DIN-rail and switch it off.
9. Connect the distribution cable to the CB.
10. Mount the front to the distribution unit and fix it with the captive screws.

9.4

Exchange of contactor
Note:

The system has no backup during this work.

Figure 15. Exchange of contactor.


1. Take off metallic bracelets, rings or similar that may cause short circuits in
the equipment. Use insulated tools. Insulate the metal parts close to the
contactor with plastic and tape.
2. Open the connector for the signalling cables connected to the contactor.
3. Remove the plastic cover and two rectifiers placed below the contactor.
4. Use an insulated 13 mm U-socket key to loosen the four fixing nuts of the
contactor.
5. Hold the contactor and remove the four fixing nuts.
6. Pull the contactor straight down and remove it through the space in the
rectifier subrack.
7. Insert the new contactor and fix it with four nuts.
8. Connect the signalling cables to the contactor. If the voltage is OK it
should pull up.
9. Fit the plastic cover and two rectifiers below the contactor.
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DIRECTIONS FOR USE BZA 108 35

9.5

Exchange of SCU/ACU
Note:

An LVD contactor is in its OFF- position will reconnect when the


SCU/ACU is removed from a live system.

1. Unlock the control unit by pressing the handle so it pops out and pull out
the control unit from the subrack. See Error! Reference source not
found..
2. Insert the new control unit into the subrack, push it in completely and lock
it by pushing the handle into its socket.

9.6

Exchange of connector board

Connectors

Fixing screw

Figure 16. Connector board.


1. Remove the fixing screw, and then pull out the connector board from the
subrack to access the cable connectors. See Error! Reference source
not found..
Note:

Be careful not to damage the surface mounted components at the back of


the board when pulling it out.

2. Disconnect, insulate and mark the signalling cables connected to the terminals of the connector board.
3. Exchange the connector board for a new one.
4. Connect the signalling cables to the terminals of the new board.
Note:

An LVD contactor is in its OFF- position will reconnect when the connector board is reconnected to a live system.

5. Insert the connector board into the subrack, push it in completely and fix it
with a screw.

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DIRECTIONS FOR USE BZA 108 35

9.7

Exchange of SCU/ACU supply fuses


There are two fuses at the back-plane board of the SCU/ACU. See Figure 17.
If the display of the SCU/ACU is dead, the upper fuse (2 A) might have
blown.
The lower fuse (4 A) protects the supplies of the contactor coils.

2 A for SCU/ACU
4 A for contactors

Figure 17. Fuses for internal supplies.

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DIRECTIONS FOR USE BZA 108 35

10

Abbreviations used in this document


AC
ACD
ACU
BC
BT
CAN
CB
CENELEC
DC
DI
DSP
DU
EEM
EN
ESD
HVSD
ICU
LAN
LCD
LED
LVD
MFU
PE
PFC
R
SCU
SELV
SM

Alternating Current
AC Distribution
Advanced Supervision Unit
Battery Charge
Battery Test
Controller Area Network
Circuit Breaker
European Committee for Electrotechnical Standardization
Direct Current
Digital Input
Digital Signal Processor
Distribution Unit
Emerson EnergyMaster
ENERGYMASTER is a registered trademark of
Emerson Network Power Energy Systems AB
European Norm
ElectroStatic Discharge
High Voltage Switch Down
InterConnection Unit
Local Area Network
Liquid Crystal Display
Light Emitting Diode
Low Voltage Disconnect
Multi Function Unit
Protective Earth
Power Factor Controller
Rectifier
Standard Supervision Unit
Safety Extra Low Voltage
Supervision Module

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