NetSure™ Rectifier Module
User Instructions
UM1R483500E (Issue AG, November 20, 2012)
SPEC. NOS.
MODELS
1R483200
1R483200E
1R483500E
R48-3200
R48-3200E
R48-3500E
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Power logo are trademarks and service marks of Emerson Electric Co.
NetSure™, NetSpan™, NetReach™, NetXtend™, and NetPerform™
are trademarks of Emerson Network Power, Energy Systems, North America, Inc.
All other trademarks are the property of their respective owners.
The products covered by this instruction manual are manufactured and/or
sold by Emerson Network Power, Energy Systems, North America, Inc.
The information contained in this document is subject to change without notice and may not be
suitable for all applications. While every precaution has been taken to ensure the accuracy and
completeness of this document, Emerson Network Power, Energy Systems, North America, Inc.
assumes no responsibility and disclaims all liability for damages resulting from use of this information
or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct
methods, tools, and materials to be used in performing procedures not specifically described in this document.
This document is the 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.
Copyright
©
2012, Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved throughout the world.
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
TABLE OF CONTENTS
Introduction .......................................................................................................................... 1
Overview ....................................................................................................................... 1
Specifications ................................................................................................................ 2
Operation ........................................................................................................................... 17
AC Input Protection Device Requirements/Recommendations .................................. 17
Local Indicators ........................................................................................................... 17
Rectifier High Voltage Shutdown and Lockout Restart ............................................... 18
Installing Rectifiers ...................................................................................................... 18
Troubleshooting and Repair .............................................................................................. 19
Troubleshooting .......................................................................................................... 19
Replacement Procedures ........................................................................................... 21
Revision Record ................................................................................................................ 24
INTRODUCTION
Overview
The Rectifiers provide load power, battery float current, and battery recharge current
during normal operating conditions. The Rectifiers are a constant power design. The
Rectifiers are rated at their maximum output power. This means that, within the normal
operating ambient temperature range and input voltage range, the maximum available
output power is a constant 3200W or 3500W (depending on Rectifier model). Within
these ranges, the Rectifiers operate in one of three modes, depending upon load
demands. Transition between modes is completely automatic. If ambient temperature
rises above or input voltage falls below acceptable values, Rectifiers continue to operate
but at derated output power levels.
Constant Voltage Mode: For any initial output voltage setting from 42 to 58 volts,
output voltage remains constant regardless of load. This is the normal operating
condition, in which loads are being supplied and batteries are float charged.
Rectifiers operate in the Constant Voltage Mode unless load increases to the point
where the product of load current and output voltage is approximately 3200W or
3500W (depending on Rectifier model).
Constant Power Mode: As load increases above approximately 3200W or 3500W
(depending on Rectifier model) (non-adjustable), output current continues to
increase, but output voltage decreases as required to maintain constant output
power. Rectifiers operate in the Constant Power Mode unless load continues to
increase to the point where the current limit setting is reached.
Constant Current Mode: If load increases to the current limit setting, output voltage
decreases linearly to maintain output current at the current limit setting.
Page 1
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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Specifications
DC Output Ratings
Voltage: Nominal -48.0 VDC, Positive Ground.
a) Adjustment Range: The output voltage can be set within the range of -42V to
-58V, adjustable via the Controller.
Output Power and Current:
a) Spec. No. 1R483200, Model R48-3200 and Spec. No. 1R483200E, Model
R48-3200E: 3200W, maximum (55.2A @ -58 VDC to 66.6A @ -48 VDC).
b) Spec. No. 1R483500E, Model R48-3500E: 3500W, maximum (60.3A @ -58
VDC to 72.9A @ -48 VDC).
Output Characteristics:
a) Refer to Figure 1, Figure 2, and Figure 3 for graphs of rectifier output voltage vs.
output current.
R48-3200 Output Voltage vs. Output Current at Max. Power 3200W
60
Output Voltage (V)
50
40
30
20
10
0
0
5
10
15
20
25
For R48-3200
30
35
40
45
50
55
60
65
70
Output Current (A)
Figure 1
Output Voltage vs. Output Current [R48-3200 (1R483200)]
Page 2
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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
R48-3200e Output Voltage vs. Output Current at Max. Power 3200W
60
Output Voltage (V)
50
40
30
20
10
0
0
5
10
15
20
25
For R48-3200e
30
35
40
45
50
55
60
65
70
Output Current (A)
Figure 2
Output Voltage vs. Output Current [R48-3200E (1R483200E)]
R48-3500e Output Voltage vs. Output Current at Max. Power 3500W
60
Output Voltage (V)
50
40
30
20
10
0
0
5
10
15
20
25
For R48-3500e
30
35
40
45
50
55
60
65
70
75
Output Current (A)
Figure 3
Output Voltage vs. Output Current [R48-3500E (1R483500E)]
Power Derating Based on Input Voltage:
a) R48-3200 (1R483200): See Figure 4.
b) R48-3200E (1R483200E): See Figure 5.
c) R48-3500E (1R483500E): See Figure 6.
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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
R48-3200 Output Power vs. Input Voltage and Vo
48V at Temp
45°C
% of output power
120
100
80
60
40
20
0
0
50
100
For R48-3200
150
200
250
300
350
Input Voltage (Vac)
Figure 4
Power Derating Based on Input Voltage (R48-3200 [1R483200])
R48-3200e Output Power vs. Input Voltage and Vo
48V at Temp
45°C
% of output power
120
100
80
60
40
20
0
0
50
100
For R48-3200e
150
200
250
300
350
Input Voltage (Vac)
Figure 5
Power Derating Based on Input Voltage (R48-3200E [1R483200E])
R48-3500e Output Power vs. Input Voltage and Vo
48V at Temp
45°C
% of output power
120
100
80
60
40
20
0
0
50
100
For R48-3500e
150
200
250
300
350
Input Voltage (Vac)
Figure 6
Power Derating Based on Input Voltage (R48-3500E [1R483500E])
Page 4
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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Power Derating Based on Temperature: The Rectifier delivers full power when
operating at an ambient temperature of +45 C (+113 F) or below. Each Rectifier
continuously monitors the ambient temperature surrounding the power conversion
circuit. If this temperature for any reason (such as a high ambient temperature or
failed fan) increases above approximately +45 C (+113 F), the Rectifier will not shut
down. Rather, the Rectifier limits its maximum output power to maintain the
temperature of the power conversion circuit within design parameters. Operation
between +45 C (+113 F) and +75 C (+158°F) will result in output power being
decreased. Full power capability is restored when the temperature decreases to
below approximately +45 C (+113 F). Refer to Figure 7, Figure 8, and Figure 9 to
view the relationship between the output power and the ambient temperature.
1) Rectifiers 1R483200 and 1R483200E provide a minimum of 2320 watts at 65°C
and from 48.0 to 58.0VDC.
2) Rectifier 1R483500E provides a minimum of 2700 watts at 65°C and from 48.0 to
58.0VDC.
Warning: The module is rated for continuous operation at full output power up
to +45°C (+113°F). Operation between +45°C (+113°F) and +75°C
(158°F) will result in output power decrease. Operation above +75°C
1
(+158°F) is considered abnormal and should be used on a temporary
basis only.
1
Temporary Operation at Abnormal Temperature: Temporary operation is
defined as a period of not more than eight consecutive hours per day, and a total of
not more than 15 days in a year. (This refers to a total of 120 hours in any given
year, but no more than 15 occurrences in that one-year period.)
R48-3200 Output Power vs. Temperature at Vin > 176 Vac
% of output power
120
100
80
60
40
20
0
-40
-20
For R48-3200
0
20
40
60
80
100
Temperature (°C)
Figure 7
Typical Thermal Power Limit Curve (R48-3200 [1R483200])
Page 5
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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
R48-3200e Output Power vs. Temperature at 264V
Vin
176 Vac
% of output power
120
100
80
60
40
20
0
-40
-20
0
For R48-3200e
20
40
60
80
100
Temperature (°C)
Figure 8
Typical Thermal Power Limit Curve (R48-3200E [1R483200E])
R48-3500e Output Power vs. Temperature at 264V
Vin
176 Vac
% of output power
120
100
80
60
40
20
0
-40
-20
For R48-3500e
0
20
40
60
80
100
Temperature (°C)
Figure 9
Typical Thermal Power Limit Curve (R48-3500E [1R483500E])
Page 6
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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Regulation:
a) Output Voltage Tolerance:
Output voltage tolerance:
< ± 0.2% 25A load
< ± 0.5% 25A load
+15°C - +35°C
-5°C - +55°C
Static regulation, including input voltage variation and temperature variation:
< ± 0.5% 5-100% load
+15°C - +35°C
< ± 1%
5-100% load
-5°C - +55°C
Uin = 176-290 Vac, f = 45 Hz - 65 Hz
Output voltage decreases with increased output current.
Overshoot of output voltage at startup ≤ ±1%.
b) Dynamic Response Characteristic (at rated input and output voltage):
Response time ≤ 200us and overshoot ≤ 5% for load changes at
50% - 25% - 50% and 50% - 75% - 50%.
Overshoot or undershoot ≤ 5% and output recovers within ±1% of regulation
band in ≤ 4ms for load changes at 10% - 90% and 90% - 10%.
(Telcordia GR-947.)
Filtering (with or without battery):
a) Voice Band Noise: Complies with Telcordia GR-947-CORE.
1) Output noise according to Telcordia GR-947-CORE: < 32dBrnC between
180V~290Vac input and 10 - 100% load (output voltage > 42V, for any
application with > 1 Rectifier).
2) Psophometric noise is ≤ 1mV between 180V~290Vac input and 10 -100%
load (output voltage > 42V) and 16.66-6000Hz. (for any application with > 1
Rectifier).
b) Wide Band Noise: Complies with Telcordia GR-947-CORE.
1) Typically 130 millivolt peak-to-peak. Does not exceed 250 millivolt peak-topeak.
2) Typically 13 millivolts rms. Does not exceed 30 millivolt rms.
Output Discharge: The output capacitors automatically discharge when the
Rectifier is disconnected from the batteries and AC is turned OFF. Time constant is
less than 1 minute.
Power Interruption: The Rectifier starts when connected to a fully discharged
battery or capacitor bank (bus voltage > 15V) without operating protective devices or
requiring the shedding of load or needing any manual intervention. The Rectifier
starts under all line and environmental conditions, when the output terminals are
connected to an impedance of less than 15 milliohms.
Stability Criteria: Complies with GR947 Core R3-20. Stability criteria: > 30 deg. of
phase margin when gain is unity (0 dB) and gain down to < - 6 dB when phase is 180
deg.
Page 7
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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
AC Input Ratings
Voltage: Nominal 208/240 volts AC, single phase, 50/60 Hz, with an operating range
of 176 to 264 volts. Acceptable input frequency range is 45 to 65 Hz.
Safe Voltage: The system can tolerate 415 volts AC without damage.
Harmonic Content (THD): < 5% THD at 50% - 100% load. The voltage source
must have a voltage THD of < 1.1%.
The Rectifier complies with EN61000-3-2.
Inrush Current: Peak does not exceed 1.5 times the steady state peak value of the
input current at full load, nominal input voltage, and for any duration of AC input
interrupts. Under the above conditions, standard AC distribution circuit breakers will
not trip.
Typical Input Data (1R483200): 60 Hz input.
a) System output is initially adjusted to 54.48 volts DC as measured at the system
sense points at 50% of full load and nominal input. “Percent of Full Load” refers
to percent of 55 Amperes.
Nominal
Input
Voltage
208
240
Percent
of Full
Load
Input
Current
(Amperes)
Input
VA
Input
Watts
Power
Factor
%
Heat
Efficiency
Dissipation
%
BTU/Hr
0
0.62
127
69
54.2
--
235.25
25
4.13
856
842
98.8
88.9
319.31
50
7.92
1644
1639
99.7
91.0
479.51
75
11.87
2457
2453
99.8
91.6
701.88
100
16.02
3298
3297
99.8
90.9
1020.09
110
17.28
3561
3558
99.8
90.5
1156.27
120
16.88
3478
3477
99.8
89.9
1208.42
0
0.68
163
66
61.2
--
225.31
25
3.65
865
846
97.7
88.7
325.42
50
6.89
1648
1633
99.4
91.9
453.62
75
10.23
2445
2441
99.8
92.1
654.78
100
13.68
3269
3265
99.8
91.8
917.81
110
14.84
3538
3534
99.8
91.3
1050.24
120
14.46
3455
3454
99.8
90.5
1118.21
b) Maximum Input Current: at 100% of full load with output adjusted to 58 volts
DC as measured at the shelf output terminals.
Nominal Input
Voltage
Input
Voltage
Input Current
(Amperes)
208/240
176
20.42
Page 8
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Typical Input Data (1R483200E): 60 Hz input.
a) System output is initially adjusted to 54.48 volts DC as measured at the system
sense points at 50% of full load and nominal input. “Percent of Full Load” refers
to percent of 55 Amperes.
Nominal
Input
Voltage
208
240
Percent
of Full
Load
Input
Current
(Amperes)
Input
VA
Input
Watts
Power
Factor
%
Heat
Efficiency
Dissipation
%
BTU/Hr
0
0.42
89
11
12.2
--
36.53
25
3.80
798
782
98.0
95.71
114.64
50
7.42
1553
1547
99.6
96.62
178.38
75
11.18
2334
2331
99.8
96.31
293.16
100
15.20
3166
3164
99.9
95.64
471.10
110
16.36
3406
3406
99.9
95.54
518.52
120
16.28
3424
3422
99.9
95.00
583.64
0
0.50
121
10
8.80
--
35.67
25
3.33
806
780
96.8
95.90
109.19
50
6.44
1556
1543
99.1
96.84
166.43
75
9.77
2356
2349
99.7
96.63
270.25
100
12.86
3094
3089
99.8
96.19
401.59
110
14.08
3395
3386
99.8
96.05
456.47
120
14.06
3398
3394
99.8
95.35
539.14
b) Maximum Input Current: at 100% of full load with output adjusted to 58 volts
DC as measured at the shelf output terminals.
Nominal Input
Voltage
Input
Voltage
Input Current
(Amperes)
208/240
176
19.30
Figure 10
Efficiency Curve [R48-3200E (1R483200E)]
Page 9
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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Typical Input Data (1R483500E): 60 Hz input.
a) System output is initially adjusted to 54.48 volts DC as measured at the system
sense points at 50% of full load and nominal input. “Percent of Full Load” refers
to percent of 60 Amperes.
Nominal
Input
Voltage
208
240
Percent
of Full
Load
Input
Current
(Amperes)
Input
VA
Input
Watts
Power
Factor
%
Heat
Efficiency
Dissipation
%
BTU/Hr
0
0.42
87
11
12.5
--
34.5
25
4.20
872
853
97.7
95.28
132.7
50
8.20
1700
1690
99.4
96.00
221.2
75
12.34
2553
2546
99.7
95.48
378.6
100
16.66
3441
3435
99.8
94.31
651.1
110
18.32
3781
3775
99.8
93.68
800.1
120
18.36
3790
3782
99.8
93.29
854.6
0
0.49
118
11
9.2
--
34.2
25
3.66
877
850
96.9
95.59
123.2
50
7.11
1704
1684
98.8
96.34
201.0
75
10.65
2547
2535
99.5
95.86
343.9
100
14.34
3423
3414
99.7
94.90
576.4
110
15.75
3758
3748
99.7
94.36
703.8
120
15.79
3768
3757
99.7
93.91
765.4
b) Maximum Input Current: at 100% of full load with output adjusted to 58 volts
DC as measured at the shelf output terminals.
Nominal Input
Voltage
Input
Voltage
Input Current
(Amperes)
208/240
176
21.60
Efficiency Curve
98.00%
Efficiency (%)
97.00%
96.00%
95.00%
200Vac
230Vac
220Vac
250Vac
94.00%
93.00%
92.00%
91.00%
90.00%
0
10
20
30
40
50
60
70
Load (% of rated load)
Figure 11
Efficiency Curve [R48-3500E (1R483500E)]
Page 10
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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Environmental Ratings
Operating Ambient Temperature Range:
a) -40°C (-40°F) to +75°C (+167°F) with derating output.
b) -40°C (-40°F) to +45 C (+113 F) with full power performance.
c) Temperature Coefficient:
0.01% per degrees Celsius.
Storage Ambient Temperature Range: -40°C (-40°F) to 75°C (+167°F).
Relative Humidity: This Rectifier is capable of operating in an ambient relative
humidity range of 0% to 95%, non-condensing.
Altitude: 2000 m (6560 ft) at full power (power limited for heights above 2000 m).
Surge Protection: Compliance with EN61000-4-5 Installation Class 4, and capable
of withstanding surges per ANSI/IEEE C 62.41 1999 Category B3 across the input
terminals.
Note: This level of protection is a widely used standard for telecommunications
power equipment. As with all such equipment, it is the end user's
responsibility to provide an adequately sized Surge Suppression Device at the
commercial power service entrance of the building that reduces all incoming
surges to levels below the classes/categories stated for the equipment.
Ventilation Requirements: The Rectifiers are fan cooled and utilize front to back
forced ventilation. A Rectifier must be mounted so ventilating openings are not
blocked and temperature of the air entering the Rectifier does not exceed the
Operating Ambient Temperature Range stated above.
Single Rectifier Audible Noise:
a) At 25°C ≤ 53dB(A) with fan in high speed; Measurement made at 0.6m
distance in front of Rectifier and at same horizontal line of the middle of Rectifier.
b) At 25°C ≤ 45dB(A) with fan in low speed; Measurement made at 1m distance
in front of Rectifier and at same horizontal line of the middle of Rectifier.
EMI/RFI Suppression:
a) Rectifiers operating in an approved Rectifier Mounting Shelf conform to the
requirements of FCC rules Part 15, Subpart B, Class B for Radiated and
Conducted emissions limits.
b) Rectifiers operating in an approved Rectifier Mounting Shelf conform to the
requirements of European Norm, EN55022, Class B for Radiated and Conducted
emissions limits.
Compliance Information:
a) Safety Compliance: This unit meets the requirements of UL 60950-1, Standard
for Information Technology Equipment, and is UL Recognized as a power supply
for use in Telephone, Electronic Data Processing or Information Processing
Equipment. This unit meets the requirements of CAN/CSA 22.2, No. 60950-00
and is tested and Certified by UL ("c UR")as a Component Type Power Supply.
b) The Rectifiers are RoHS compliant, 5/6.
Page 11
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UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Standard Features
Type of Power Conversion Circuit: High frequency.
Constant Voltage Mode: For any initial output voltage setting from 47 to 58 volts,
output voltage remains constant regardless of load. This is the normal operating
condition, in which loads are being supplied and batteries are float charged.
Rectifiers operate in the Constant Voltage Mode unless load increases to the point
where the product of load current and output voltage is approximately 3200W or
3500W (depending on Rectifier model).
Constant Power Mode: As load increases above approximately 3200W or 3500W
(depending on Rectifier model) (non-adjustable), output current continues to
increase, but output voltage decreases as required to maintain constant output
power. Rectifiers operate in the Constant Power Mode unless load continues to
increase to the point where the current limit setting is reached.
Constant Current Mode: If load increases to the current limit setting, output voltage
decreases linearly to maintain output current at the current limit setting.
Input Protection:
a) Fuse: On the input, two UL recognized fuses are used, not user-replaceable.
b) Input Voltage Protection: Operating range is 85-290Vac. Derating from 85Vac
to 176Vac. Withstand 415Vac input w/o damage.
1) The Rectifier will shut down at low or high voltage input; Low voltage disable
point: 80V±3V; Hysteresis at least 15 VAC for restart. High voltage disable
point: 295V±5V; Hysteresis at least 10 VAC for restart.
2) Between 85V and 176V the output power will be derated linearly according to
input voltage per Figure 4, Figure 5, and Figure 6.
3) Over Voltage Isolation: The Rectifier will be disconnected from the AC input
when a preset non-adjustable value is reached.
AC Fail Alarm: The Rectifier issues an "AC Fail Alarm" when AC input voltage
drops below 164Vac. This alarm clears when AC input voltage recovers above
169Vac.
Output Protection:
a) Overload / Reverse Current: An output fuse is provided on each Rectifier. This
fuse is not customer replaceable. The Rectifier can be plugged into or pulled out
of a shelf while operating, without damage or opening the fuse.
b) Current Limiting: The maximum current delivered by the rectifier can be set via
the Controller from 10% to 121% of its rating at maximum rated output voltage.
Output Current Limit Error: ≤ ±1.5A.
c) High Voltage Shutdown:
1) Internal: If Rectifier output voltage exceeds an adjustable preset value and
it is delivering more than 10% of its rated current, the Rectifier shuts down.
After approximately 6 seconds, the Rectifier automatically restarts. If
Rectifier output voltage again exceeds the high voltage shutdown value
within 5 minutes, the Rectifier shuts down and locks out. Manual restart is
then required. If the Rectifier does not experience a high voltage condition
within the 5-minute time-period, the restart circuit is reset.
Page 12
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
If two or more Rectifier are installed in a shelf, or if the shelf is paralleled with
other Rectifier Mounting Shelves, only the Rectifier causing the high voltage
condition shuts down.
2) Backup: If Rectifier output voltage exceeds a second (non-adjustable)
value, the Rectifier shuts down and locks out regardless of load. Manual
restart is then required.
Over-Temperature Protection: The Rectifier provides overtemperature protection
by derating output power and recovers automatically.
Hot Swappable: The Rectifier is designed to be plug-and-play. The Rectifier can be
inserted or removed from a live DC power system with no damage. When the
Rectifier is plugged into the system, the system output voltage will not be affected.
High Temperature Alarm: Each Rectifier continuously monitors the ambient
temperature surrounding the power conversion circuit. If this temperature exceeds a
preset non-adjustable value, local and extended Rectifier Fail alarms are activated.
The alarms will automatically be removed when the ambient temperature surrounding
the power conversion circuit decreases to below a preset non-adjustable value.
Cooling: Each Rectifier Module contains a fan for front-to-back force air-cooling.
a) Fan Fault Protection: The Rectifier Module shuts down and its alarm indicator
(red) flashes if the fan fails. Fan failure is detected and reported to Controller.
The fans are field replaceable.
b) Fan Control: Fan speed is continuously variable. When input voltage is within
normal range, the built-in processor adjusts fan speed according to the Rectifier
Module’s internal temperature and output power. For example, a higher
temperature or output power increases the fan speed. This feature can be
disabled via the controller, allowing the fan to run at full speed regardless of
temperature.
Paralleling: This Rectifier may be connected in parallel with any Rectifier of the
same polarity and adjusted to the same output voltage.
Output Current Walk-In:
a) Normal Start:
Start up time, defined as beginning at AC switch on and ending when full
output power has been reached, consists of two time intervals, the delay
period and the output voltage rampup period.
During the delay period the output voltage will be zero.
Start up time (AC on, till full power): ≤ 5 seconds.
Output voltage ramp up period, t: 50 ≤ t ≤ 150 ms.
(10% to 90% of full power)
The Rectifier will not suffer any damage, when subjected to repetitive AC
switch on / switch off operations.
b) Current Walk-In (if enabled via Controller):
90% load in > 8S, 100% load in < 124s.
According to Telcordia GR-947-CORE, R3-19.
Page 13
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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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Communication Failure: The Rectifier’s protection indicator (yellow) will flash
should it experience a communication failure. The failure information will be reported
to the Controller and the Controller will process the failure accordingly. During a
communication failure, in order to protect the battery, the Rectifier output voltage will
automatically be adjusted as follows. When used with the SCU+ Controller, Rectifier
output voltage goes to a default value (53.5 V, which can be modified using the
SCU+ Controller). When used with the ACU+ Controller, Rectifier output voltage
goes to the ACU+ float voltage setting (this setting is stored in the Rectifier). The
Rectifier will revert to normal operation once normal communication is restored.
Rectifier Output Current Imbalance:
a) When the average current of all Rectifier Modules is greater than 20% of full
rated current, and the difference between local Rectifier Module current and
average current is greater than 16% of full rated current, the yellow protection
indicator will illuminate.
b) When the average current of all Rectifier Modules is greater than 10% of full
rated current, and local Rectifier Module current is less than 1.5% of full rated
current, then the red fault indicator will illuminate.
Page 14
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Monitoring Function: The Rectifier has a built-in advanced DSP that monitors and
controls the operation of the Rectifier. The DSP also communicates with the
Controller in real time through the CAN bus. Table 1 lists the different commands
and information exchanged between the Rectifier and the Controller.
Commands / signals that can be
received by the Rectifier from the
Controller.
Turn On/Off
Current Walk-in On/Off
HVSD (High Voltage Shutdown)
Reset
Current Limit Adjustment
Voltage Regulation
Information gathered by the
Controller from the Rectifier.
Input Voltage
Output Voltage
Output Current
Current Limit Setting
Temperature
Over Voltage Setting
On/Off Status
Fault Alarms, such as:
HVSD
Fan Fail
Protection Alarms, such as:
Input Voltage Protection
Inner DC Bus Voltage Protection
High Temperature Protection
Thermal Derating
AC Derating
AC Fail
Imbalanced Output Current
Address
Code
Date
Software Version
Hardware Version
Table 1
Exchange of Information between Rectifier and Controller
External Control Circuits: Provided via the associated Controller. Refer to the
separate Power System documentation for a complete description of available
external control circuits.
External Alarm Circuits: Provided via the associated Controller. Refer to the
separate Power System documentation for a description of available external alarms.
Page 15
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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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Mechanical Specifications
Dimensions:
a) Millimeters: 132.0 (Height) X 85.3 (Width) X 287.0 (Depth)
b) Inches: 5.20 (Height) X 3.36 (Width) X 11.3 (Depth)
Weight: 3.5 kg (7.7 lbs).
Indicators:
a) Power (Green)
b) Protection (Yellow)
c) Alarm (Red)
Page 16
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
OPERATION
AC Input Protection Device Requirements/Recommendations
Refer to the system documentation supplied with the system the rectifier is installed in.
Local Indicators
Location and Identification: Refer to Figure 12.
Description: There are three (3) indicators located on the Rectifier’s front panel. The
functions of these indicators are as shown in Table 2.
Note: DC voltage must be present at the Rectifier output terminals, (from battery or an
operating Rectifier) for local indicators to illuminate.
Power Indicator
(Green)
Protection Indicator
(Yellow)
Alarm Indicator
(Red)
Figure 12
Local Indicator Locations
Indicator
Power
(Green)
Protection
(Yellow)
Normal State
Alarm State
Off
On
Flashing
Off
On
Flashing
Alarm
(Red)
On
Off
Flashing
Alarm Cause
No input voltage.
Internal input fuse open.
The Rectifier Module is being identified
by the Controller.
AC input under/over voltage.
PFC output under/over voltage.
High temperature.
Moderate load sharing imbalance.
Loss of communication with controller.
Severe load sharing imbalance.
Rectifier Module output disabled for any
reason, including overvoltage shutdown
and internal output fuse open.
Rectifier addresses contradictory.
Faulty fan (Rectifier Module shuts
down).
Table 2
Local Indicators
Page 17
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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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Rectifier High Voltage Shutdown and Lockout Restart
Remove the rectifier, wait 30 seconds or more (until the LEDs on the rectifier extinguish),
then re-insert the rectifier.
The rectifier(s) 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).
Installing Rectifiers
The Rectifier is hot swappable. It can be installed with the system operating.
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) Place the Rectifier into an unoccupied mounting slot without sliding it in
completely.
2) Click the Rectifier handle in order to pop it forward out of the Rectifier's front
panel (this will also retract the latch mechanism located on the underside of the
Rectifier). Refer to Figure 13 for latch mechanism illustration.
3) Push the Rectifier completely into the shelf.
4) Push the handle into the front panel of the Rectifier. This locks the Rectifier
securely to the shelf.
5) Repeat the above steps for each Rectifier being installed in the system.
6) After the Rectifiers are physically installed in the mounting shelf(s), they are
ready for operation immediately after power is supplied to them.
7) Certain functions (i.e. rectifier current limit, rectifier addressing) may require
adjustment when adding or replacing a Rectifier Module. Refer to the Power
System documentation for instructions.
Figure 13
Installing a Rectifier
Page 18
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
TROUBLESHOOTING AND REPAIR
Troubleshooting
Rectifier Current Sharing Imbalance
When multiple Rectifiers are operating in parallel and the load is greater than 10%, if the
current sharing imbalance among them is greater than 3%, check if the Rectifier is
properly seated in the shelf.
If the current sharing imbalance still persists following the verification suggested above,
replace the Rectifier exhibiting the current imbalance.
Rectifier Fault Symptoms and Troubleshooting
The fault indicators that can be displayed by the Rectifier are as follows. Refer to Table 3
for a list of possible causes and corrective actions.
Power Indicator (Green) OFF
Protection Indicator (Yellow) ON
Protection Indicator (Yellow) Flashing
Alarm Indicator (Red) ON
Alarm Indicator (Red) Flashing
Page 19
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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.
UM1R483500E
Issue AG, November 20, 2012
Symptom
Power
Indicator
(Green) Off
Protection
Indicator
(Yellow) On
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Possible Cause(s)
Suggested Action(s)
No input voltage.
Make sure there is input voltage.
Internal input fuse open.
Replace the Rectifier.
AC input voltage outside the
normal range.
Correct the AC input voltage to
within the acceptable range.
PFC over-voltage.
Replace the Rectifier.
Moderate load sharing imbalance.
Replace the Rectifier.
Rectifier not inserted into the slot
completely.
Remove and properly insert the
Rectifier.
Rectifier over-temperature protection, which could be caused by:
1. Fan rotor blocked.
1. Remove any object that may
be blocking the fan.
2. Ventilation blocked (inlet or
outlet).
2. Remove any object that may
be blocking the inlet or outlet.
3. Ambient temperature too high
or Rectifier inlet too close to a
heat source.
3. Lower the ambient temperature
or relocate the heat source.
Rectifier communication failure.
Check the communication cables.
Remove and properly insert the
Rectifier.
Alarm
Indicator
(Red) On
Output over-voltage shutdown.
Severe load sharing imbalance.
Internal output fuse open.
Remove the Rectifier, wait 30
seconds or more (until the LEDs
on the rectifier extinguish), then
re-insert the Rectifier. If Rectifier
fails to start or shuts down again;
replace the Rectifier.
Alarm
Indicator
(Red)
Flashing
Fan not operating
(Rectifier shuts down).
Replace the fan.
Protection
Indicator
(Yellow)
Flashing
Table 3
Rectifier Troubleshooting
Page 20
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Replacement Procedures
Rectifier Replacement
Danger: Take care when removing a Rectifier that was in operation, as Rectifier
surfaces could be very hot.
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.
The Rectifier is hot swappable. It can be removed and installed with the system
operating.
Procedure
1) Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any alarms associated with this
system while this procedure is performed.
2) On the Rectifier to be removed, click the Rectifier’s handle in order to pop it
forward out of the Rectifier's front panel. This will retract the latch mechanism
located on the underside of the Rectifier and thus unlock the Rectifier from the
shelf. Refer to Figure 13 for latch mechanism illustration.
3) Slide the Rectifier out by pulling forward.
4) Place the replacement Rectifier into the mounting slot without sliding it in
completely.
5) On the replacement Rectifier, click the Rectifier’s handle in order to pop it forward
out of the Rectifier's front panel (this will also retract the latch mechanism located
on the underside of the Rectifier).
6) Push the Rectifier completely into the shelf.
7) Push the handle into the front panel of the Rectifier. This locks the Rectifier
securely to the shelf.
8) Certain functions (i.e. rectifier current limit, rectifier addressing) may require
adjustment when adding or replacing a Rectifier Module. Refer to the Power
System documentation for instructions.
9) After the Rectifiers are physically installed in the mounting shelf(s), they are
ready for operation immediately after power is supplied to them. Verify that the
Rectifiers are operating normally.
10) Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
11) Ensure that there are no local or remote alarms active on the system.
Page 21
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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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
Rectifier Fan Replacement
Each Rectifier uses a fan (P/N 32010086 for 1R483200 rectifier module. P/N 32010109
for 1R483200E and 1R483500E rectifier module) for cooling. If fan replacement should
become necessary, perform the following procedure.
Refer to Figure 14 as this procedure is performed.
Caution: In a system with NO redundant Rectifier, battery must have sufficient
reserve to power the load(s) while the Rectifier is removed for fan
replacement.
Note: When performing any step in this procedure that requires removal of existing
hardware, retain all hardware for use in subsequent steps.
Procedure
1) Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any alarms associated with this
system while this procedure is performed.
2) Remove the Rectifier from the shelf. Refer to a previous procedure for step-bystep instructions.
3) Place the Rectifier Module on a static-safe work surface. Connect an approved
grounding strap to your wrist for the remainder of this procedure.
4) On this Rectifier, loosen the three (3) screws on the Rectifier front cover and
remove the cover.
5) For proper orientation of the new fan, observe the location of the fan wires and
the air flow arrows on the old fan.
6) Unplug the power cable of the old fan and remove the fan.
7) Plug the power cable of the new fan and place the new fan in the space vacated
by the old fan. Ensure the fan wires and air flow arrows match the orientation of
the old fan.
8) Position the Rectifier front cover back into place and secure with the screws
previously removed.
9) Replace the Rectifier into the shelf. Refer to the previous procedure for step-bystep instructions.
10) When the fans start, check to ensure that each is providing front-to-back airflow.
If air direction is wrong, immediately remove the Rectifier Module from the shelf.
Repeat previous steps to check fan orientation, and correct as necessary.
Reinstall the Rectifier Module and again check for proper airflow.
11) Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
12) Ensure that there are no local or remote alarms active on the system.
Page 22
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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
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
UM1R483500E
Issue AG, November 20, 2012
Figure 14
Rectifier Fan Replacement
Page 23
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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.
UM1R483500E
Issue AG, November 20, 2012
User Instructions
Spec. No. 1R483200 (Model R48-3200)
Spec. No. 1R483200E (Model R48-3200E)
Spec. No. 1R483500E (Model R48-3500E)
REVISION RECORD
Issue
Change
Number
(ECO)
AA
LLP214213
New
AB
LLP214923
Communication Failure description updated for when used with an ACU+
Controller.
AC
LLP216644
Correct wrong content of GBB rectifier fan replacement PNs.
AD
LLP216539
Typical input data updated.
AE
LLP217095
AF
LLP217311
Items 1) and 2) added to the “Thermal Power Limiting” description under
“Standard Features”.
HVSD Restart instructions updated.
AG
LLP217962
Corrected Typical Input Data for 1R483500E.
Description of Change
Page 24
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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.
NetPerform™ Optimization Services
At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both
your business and your bottom line. That is why we offer a wide array of services to meet all of your
network infrastructure needs.
Technical Support
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Phone
1.800.800.5260
Answers technical product and system
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contractual agreements for repair.
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Phone
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Pricing and PO processing of spare parts,
including but not limited to breakers, cables,
fuses, rectifier fans, misc. breaker and fuse
panels, enclosure fans, doors & switches, etc.
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Creates and processes RMAs, determines
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