NetSure™ Rectifier Module User Manual, UM1R123000 Document Code: 11UJ9716ER (Revision D, September 28, 2015) Specification Number: 1R123000, 1R123300 Model Number: R12-3000, R12-3300 NetSure™ Rectifier Module User Instructions, UM1R123000 This page is intentionally blank. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table of Contents Admonishments Used in this Document ................................................................................................................ ii Important Safety Instructions .............................................................................................................................. iii General Safety ........................................................................................................................................................iii Voltages .................................................................................................................................................................iii Hazardous Voltage .................................................................................................................................................iii Handling Equipment Containing Static Sensitive Components .................................................................................iii Static Warning ..................................................................................................................................................... iv Introduction ......................................................................................................................................................... 1 Overview ................................................................................................................................................................ 1 Specifications ......................................................................................................................................................... 1 Operation ........................................................................................................................................................... 10 AC Input Protection Device Requirements/Recommendations............................................................................... 10 Local Indicators..................................................................................................................................................... 10 Rectifier High Voltage Shutdown and Lockout Restart ........................................................................................... 10 Rectifier Current Limit ........................................................................................................................................... 10 Installing Rectifiers ............................................................................................................................................... 11 Troubleshooting and Repair ................................................................................................................................ 13 Troubleshooting ................................................................................................................................................... 13 Replacement Procedures ...................................................................................................................................... 15 Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [i] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Admonishments Used in this Document DANGER! Warns of a hazard the reader will be exposed to that will likely result in death or serious injury if not avoided. (ANSI, OSHA) Danger Warning Caution WARNING! Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided. This admonition is not used for situations that pose a risk only to equipment, software, data, or service. (ANSI) CAUTION! Warns of a potential hazard the reader may be exposed to that could result in minor or moderate injury if not avoided. (ANSI, OSHA) This admonition is not used for situations that pose a risk only to equipment, data, or service, even if such use appears to be permitted in some of the applicable standards. (OSHA) ALERT! Alerts the reader to an action that must be avoided in order to protect equipment, software, data, or service. (ISO) Alert ALERT! Alerts the reader to an action that must be performed in order to prevent equipment damage, software corruption, data loss, or service interruption. (ISO) Alert FIRE SAFETY! Informs the reader of fire safety information, reminders, precautions, or policies, or of the locations of fire-fighting and fire-safety equipment. (ISO) Fire Safety SAFETY! Informs the reader of general safety information, reminders, precautions, or policies not related to a particular source of hazard or to fire safety. (ISO, ANSI, OSHA) Safety Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [ii] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Important Safety Instructions General Safety Danger DC Input/Output Voltages DANGER! YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. Danger 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. Check for voltage with both AC and DC voltmeters prior to making contact. Hazardous Voltage Danger d) Wear eye protection. e) Use double insulated tools appropriately rated for the work to be performed. AC Input Voltages Warning DANGER! This system operates from AC input voltage capable of producing fatal electrical shock. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 DANGER! Hazard of electrical shock. More than one disconnect may be required to de-energize the system before servicing. Handling Equipment Containing Static Sensitive Components Voltages Danger DANGER! This system produces DC Power and may have a battery source connected 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 an output terminal or battery terminal or exposed wire connected to an output terminal or 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. [iii] WARNING! Installation or removal of equipment containing static sensitive components requires careful handling. Before handling any equipment containing static sensitive components, read and follow the instructions contained on the Static Warning Page. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Static Warning This equipment contains 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 equipment containing static sensitive components, 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 traces or components on equipment containing static sensitive components. Handle equipment containing static sensitive components only by the edges that do not have connector pads. 4. After removing equipment containing static sensitive components, place the equipment 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 equipment containing static sensitive components only in static shielding containers. 6. If necessary to repair equipment containing static sensitive components, wear an appropriately grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded test equipment. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [iv] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Introduction Figure 1. Output Voltage vs. Output Current (R12-3000) The rectifier provides load power during normal operating conditions. The rectifier is rated at its 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 3000 W or 3300 W (depending on model). Within these ranges, the rectifier operates 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, the rectifier continues to operate but at derated output power levels. • • Constant Voltage Mode: For any initial output voltage setting from 12.0 VDC to 13.2 VDC, output voltage remains constant regardless of load. This is the normal operating condition, in which loads are supplied. The rectifier operates in the constant voltage mode unless load increases to the point where the product of load current and output voltage is approximately 3000 W or 3300 W (depending on model). Constant Power Mode: As load increases above approximately 3000 W or 3300 W (depending on model) (non-adjustable), output current continues to increase, but output voltage decreases as required to maintain constant output power. The rectifier operates in the constant power mode unless load continues to increase to the point where the current limit setting is reached. Output Voltage vs. Output Current, Max. Output Power 3000 W 16 14 12 10 8 6 4 2 0 0 50 100 150 200 Output Current (A) 250 300 Figure 2. Output Voltage vs. Output Current (R12-3300) Output Voltage (V) • Output Voltage (V) Overview Output voltage vs. Output current, Max. Output Power 3300W 18 15 12 9 6 3 0 0 • 50 100 150 200 Output Current (A) 250 300 Power Derating Based on Input Voltage: The rectifier power varies with changes in input voltage and output voltage. It uses an advanced power limitation method. The lower input threshold is 85 VAC. The rectifier can provide its maximum rated power (3000 W or 3300 W, depending on model) as long as the input voltage is within the range of 176 VAC to 305 VAC. Below 176 VAC, and down to 85 VAC, the rectifier will continue to operate normally but will be in a power derating mode. The relationship between the output power and input voltage is illustrated in Figure 3. Constant Current Mode: If load increases to the current limit setting, output voltage decreases linearly to maintain output current at the current limit setting. Specifications DC Output Ratings Note: The current limit and output voltage level can be set by the User through the controller. • • Figure 3. Power Derating Based on Input Voltage Voltage: Nominal +12 VDC, negative ground. Output voltage is adjustable from +12.0 VDC to +13.2 VDC via the associated controller. % of Output Power • Output Power and Current: a. R12-3000: 3000 W (250 A) @ 208 VAC / 220 VAC / 230 VAC / 277 VAC input and +12 VDC output. b. R12-3300: 3300 W (275 A) @ 208 VAC / 220 VAC / 230 VAC / 277 VAC input and +12 VDC output. 120.0% 100.0% 80.0% 60.0% 40.0% 20.0% 0.0% 0 Output Characteristics: Refer to Figure 1 or Figure 2 for a graph of output voltage vs. output current. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 Output Power vs. Input Voltage and Vo > 12 V at Temp ≤ 45 ℃ [1] 50 100 150 200 250 300 350 Input Voltage (VAC) Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 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) 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 °C) and +75 °C (+167 °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 4 to view the relationship between the output power and the ambient temperature. Figure 4. Power Derating Based on Temperature Output Power vs. Temperature at 305 VAC ≥ Vin ≥ 176 VAC % of Output Power • Warning At an ambient temperature of +55 °C (+131 °F), the power delivered by the rectifier is 2500 W. b. At an ambient temperature of +65 °C (+149 °F), the power delivered by the rectifier is 2000 W. 80 60 40 20 10 30 50 Temperature (℃) 70 90 and 176 VAC < Vin < 305 VAC. • Regulation: a. Static: Steady state regulation is ±1% as controlled within the rectifier for any and all combinations of load from no load to full load, input voltage, and input frequency at a constant ambient temperature. The associated system controller may provide improved regulation. b. Dynamic Load: Response time ≤1000 us and overshot ≤ 5 % for load changes at 50 % - 25 % - 50 % and 50 % - 75 % - 50 % at rated output voltage and current For any step load change within the range of 10 % to 90 % of full load within 1000 microseconds, per Telcordia GR-947-CORE, the maximum voltage transient will not exceed 5 % of the initial steady state voltage within 250±10 microseconds. Recovery to within ±1 % of the initial steady state voltage does not exceed 4 milliseconds. 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.) • Filtering: a. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 -10 Note: 3000 W or 3300 W (depending on model) @ +45 °C (+113 °F) WARNING! The rectifier is rated for continuous operation at full output power up to +45 °C (+113 °F). Operation between +45 °C (+113 °F) and +75 °C (+167 °F) will result in output power decrease. Operation above +75 °C (+167 °F) is considered abnormal and should be used on a temporary1 basis only. 1 100 0 Other power rating values are as follows (refer to Figure 4): a. 120 [2] Voice Band Noise: Peak-peak voltage is ≤120 mV at 0 MHZ to 20 MHZ and normal output voltage. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 AC Input Ratings • Voltage: Nominal 208 VAC / 220 VAC / 230 VAC / 277 VAC, single phase, 3-wire, 50 Hz / 60 Hz, with an operating range of 200 VAC to 277 VAC. Acceptable input frequency range is 45 Hz to 65 Hz. • Inrush Current: Peak does not exceed 1.5 times of the peak value of the maximum steady-state input current at full load. • Typical Input Data: 50 Hz Input Permitted Variation: 85 VAC to 305 VAC. • • Harmonic Content (ITHD): Meets EN61000-3-2. ≤5 % from 50 % to 100 % of rated output current at (208 VAC, 220 VAC, 230 VAC, and 277 VAC), 50 Hz, 12 VDC, and 25 °C. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [3] a. Refer to Table 1 or Table 3. b. Maximum Input Current: Refer to Table 2 or Table 4. Typical Input Data: 60 Hz Input a. Refer to Table 5 or Table 7. b. Maximum Input Current: Refer to Table 6 or Table 8. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 1. Typical Input Data, 50Hz Input (R12-3000) Nominal Input Voltage Percent of Full Load Input Current (Amperes) Input VA Input Watts Power Factor Efficiency % Heat Dissipation BTU/Hr 0 0.43 88.7 31.3 +0.3552 -- 106.79 25 3.23 669.3 649.2 +0.9699 92.30 170.58 50 7.73 1597.0 1581.7 +0.9904 94.49 297.58 75 10.83 2231.5 2218.5 +0.9942 94.24 436.26 100 13.99 2876.6 2863.6 +0.9950 93.72 613.28 110 15.55 3207.5 3190.3 +0.9955 93.43 715.50 0 0.48 114.5 32.5 +0.2841 -- 110.88 25 2.83 680.9 647.5 +0.9511 92.42 167.39 50 6.68 1601.5 1578.5 +0.9857 94.67 287.10 75 9.33 2233.5 2213.2 +0.9909 94.52 413.68 100 12.02 2872.9 2854.8 +0.9936 94.10 575.13 110 13.39 3197.3 3179.2 +0.9944 93.79 673.13 0 0.50 138.5 34.07 +0.246 -- 118.26 25 2.76 764.50 730.10 +0.955 93.30 166.77 50 5.3 1468.2 1435.90 +0.978 95.00 244.60 75 7.84 2170.88 2147.00 +0.989 95.18 352.63 100 10.43 2890.12 2867.00 +0.992 94.89 500.05 110 11.48 3180.08 3161.00 +0.994 94.62 579.45 208 240 277 Note: System output is initially adjusted to 12 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 227.3 amperes. Table 2. Maximum Input Current, 50Hz Input (R12-3000) Nominal Input Voltage Input Voltage Input Current (Amperes) 208/240/277 176 18.54 Note: At 100% of full load with output adjusted to 13.2 volts DC as measured at the module mounting assembly output terminals. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [4] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 3. Typical Input Data, 50Hz Input (R12-3300) Nominal Input Voltage Percent of Full Load Input Current (Amperes) Input VA Input Watts Power Factor Efficiency % Heat Dissipation BTU/Hr 0 0.40 83.2 36.7 +0.4405 -- 125.15 25 4.31 895.6 886.2 +0.9895 93.32 202.16 50 8.44 1754.6 1747.5 +0.9960 94.40 334.10 75 12.62 2635.0 2630.3 +0.9982 94.09 530.32 100 17.02 3535.9 3532.9 +0.9991 93.20 819.75 110 17.34 3597.3 3594.3 +0.9992 93.10 846.74 0 0.45 107.8 35.5 +0.3289 -- 121.03 25 3.75 899.7 884.2 +0.9828 93.59 193.41 50 7.32 1755.5 1743.7 +0.9933 94.79 309.99 75 11.02 2632.3 2623.0 +0.9965 94.39 502.19 100 14.69 3525.9 3518.9 +0.9980 93.59 769.88 110 14.81 3553.5 3545.9 +0.9979 93.44 794.04 0 0.50 138.3 29.9 +0.2162 -- 102.02 25 3.27 906.1 882.2 +0.9736 93.80 186.81 50 6.37 1763.3 1740.2 +0.9869 94.83 307.12 75 9.52 2636.0 2616.3 +0.9925 94.44 496.54 100 12.73 3521.6 3506.4 +0.9957 93.69 755.51 110 13.03 3603.2 3588.5 +0.9959 93.56 789.01 208 240 277 Note: System output is initially adjusted to 12 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 275 amperes. Table 4. Maximum Input Current, 50Hz Input (R12-3300) Nominal Input Voltage Input Voltage Input Current (Amperes) 208/240/277 176 20.22 Note: At 100% of full load with output adjusted to 13.2 volts DC as measured at the module mounting assembly output terminals. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [5] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 5. Typical Input Data, 60Hz Input (R12-3000) Nominal Input Voltage Percent of Full Load Input Current (Amperes) Input VA Input Watts Power Factor Efficiency % Heat Dissipation BTU/Hr 0 0.50 103.5 31.4 +0.3046 -- 107.13 25 3.26 678.8 648.1 +0.9549 92.18 172.99 50 7.73 1602.9 1581.3 +0.9865 94.46 298.70 75 10.80 2235.8 2218.1 +0.9921 94.27 433.45 100 13.93 2879.9 2862.5 +0.9940 93.79 606.56 110 15.53 3207.2 3189.4 +0.9944 93.47 710.39 0 0.56 134.3 31.8 +0.2371 -- 108.50 25 2.86 687.5 647.3 +0.9416 92.35 168.93 50 6.70 1606.2 1578.2 +0.9826 94.66 287.70 75 9.35 2237.1 2212.3 +0.9892 94.51 414.66 100 12.04 2875.4 2854.4 +0.9927 94.08 576.98 110 13.40 3199.2 3178.9 +0.9936 93.80 672.86 0 .50 138.5 38.01 +0.204 -- 129.61 25 2.81 779.53 731.20 +0.938 93.10 172.05 50 5.34 1478.37 1435.50 +0.971 94.95 247.07 75 7.88 2181.91 2147.00 +0.984 95.10 358.94 100 10.46 2898.99 2870.00 +0.990 94.73 515.81 110 11.52 3190.72 3162.99 +0.991 94.55 587.99 208 240 277 Note: System output is initially adjusted to 12 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 227.3 amperes. Table 6. Maximum Input Current, 60Hz Input (R12-3000) Nominal Input Voltage Input Voltage Input Current (Amperes) 208/240/277 176 18.53 Note: At 100% of full load with output adjusted to 13.2 volts DC as measured at the module mounting assembly output terminals. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [6] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 7. Typical Input Data, 60Hz Input (R12-3300) Nominal Input Voltage Percent of Full Load Input Current (Amperes) Input VA Input Watts Power Factor Efficiency % Heat Dissipation BTU/Hr 0 0.48 99.7 36.3 +0.3642 -- 123.99 25 4.33 899.7 886.4 +0.9852 93.35 201.04 50 8.45 1756.9 1747.2 +0.9945 94.58 322.95 75 12.70 2636.5 2630.7 +0.9978 94.09 530.26 100 16.96 3535.8 3531.8 +0.9988 93.23 815.84 110 17.40 3626.0 3621.8 +0.9989 93.11 851.80 0 0.55 132.0 36.1 +0.2738 -- 123.30 25 3.79 908.5 884.3 +0.9734 93.52 195.54 50 7.32 1759.9 1743.2 +0.9905 94.82 308.27 75 11.00 2635.1 2622.2 +0.9951 94.39 501.63 100 14.69 3527.4 3517.8 +0.9973 93.60 768.09 110 15.06 3613.0 3603.4 +0.9973 93.51 798.10 0 0.61 168.4 33.1 +0.1963 -- 112.86 25 3.32 914.0 882.4 +0.9654 93.75 188.32 50 6.40 1773.9 1740.9 +0.9814 94.87 305.08 75 9.53 2643.9 2616.5 +0.9896 94.46 494.34 100 12.75 3528.4 3506.9 +0.9939 93.68 756.24 110 13.04 3607.2 3586.1 +0.9942 93.61 781.57 208 240 277 Note: System output is initially adjusted to 12 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 275 amperes. Table 8. Maximum Input Current, 60Hz Input (R12-3300) Nominal Input Voltage Input Voltage Input Current (Amperes) 208/240/277 176 20.24 Note: At 100% of full load with output adjusted to 13.2 volts DC as measured at the module mounting assembly output terminals. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [7] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 • 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. Typical Efficiency Curve: See Figure 5. Figure 5. Typical Efficiency Curve (at 240 VAC input, 50 Hz, 25 °C) Efficiency Curve • Single Rectifier Audible Noise: At 25 °C ≤ 60 dB(A) with fan. Measurement made at 0.6 m distance in front of rectifier and at same horizontal line of the middle of rectifier. • High Voltage Category: II. 88 • Power Distribution System: TN/TT/IT. 86 Note: The rectifier is recommended to be used in an Efficiency (%) 98 96 94 92 90 84 0 10 20 30 40 50 60 70 Load (% of rated load) 80 environment with Pollution of Degree 2 or less. Pollution Degree 2 applies where there is only non-conductive pollution that might temporarily become conductive due to occasional condensation (such as the office environment). 90 100 Environmental Ratings • Operating Ambient Temperature Range: a. +45 °C (+113 °F) to +75 °C (+167 °F) with derating output. b. -10 °C (14 °F) to +45 °C (+113 °F) with full power performance. • Temperature Coefficient: 0.02% per degrees Celsius. • Storage Ambient Temperature Range: -40 °C (-40 °F) to +85 °C (+185 °F). • • • • Relative Humidity: This rectifier is capable of operating in an ambient relative humidity range of 0% to 95%, noncondensing. Altitude: 2000 m (6560 ft) at full power (power limited for heights above 2000 m). Compliance Information • EMC: ETSI EN 300 386, FCC CFR 47 Part 15 class A, Telcordia GR-3160, EN 55022/EN 55024. • EMI Load Range: 5 % to 100 %. • Safety: IEC 60950, EN 60950,UL 60950-1. Warning Surge Protection: Compliance with EN61000-4-5 (4 kV Line to Line, 4 kV Line to Earth). Capable of withstanding surges per ANSI/IEEE C 62.41 1999 Category B3 across the input terminals. telecommunications and data center 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 rectifier is fan cooled and utilizes front to back forced ventilation. A rectifier must Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 WARNING! This is a class A product. In a domestic environment, this product may cause radio interference in which case the User may be required to take adequate measures. Standard Features • Type of Power Conversion Circuit: High frequency. • Constant Voltage Mode: For any initial output voltage setting from 12.0 VDC to 13.2 VDC, output voltage remains constant regardless of load. This is the normal operating condition, in which loads are supplied. The rectifier operates in the constant voltage mode unless load increases to the point where the product of load current and output voltage is approximately 3000 W or 3300 W (depending on model). • Constant Power Mode: As load increases above approximately 3000 W or 3300 W (depending on model) (non-adjustable), output current continues to increase, but output voltage decreases as required to maintain Note: This level of protection is a widely used standard for • EMI/RFI Suppression: Rectifiers operating in an approved module mounting assembly conform to the requirements of FCC rules Part 15, Subpart A, Class A for radiated and conducted emissions limits. [8] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 unit shall require to be manually restarted. Method of manual restart: Remove the rectifier, wait 30 seconds or more (until the LEDs on the rectifier extinguish), then re-insert the rectifier. constant output power. The rectifier operates 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. Over-Temperature Protection: The rectifier provides over temperature protection by derating output power and recovers automatically. • Active Load Sharing: The rectifier uses advanced digital active load sharing technology that maintains balancing to within 3 % of rated current. • Hot Swappable: The rectifier is designed to be plug-andplay. 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 remain within the specified regulation range. • Cooling: Each rectifier contains two fans for front-toback forced convection cooling. Input Protection: a. b. c. • • Input Over/Under Voltage Protection: The rectifier shuts down at low or high voltage input; based on the following voltage levels: 1. Low Voltage Disable Point: 80 V, ±5 V; hysteresis is at least15 VAC for restart. 2. High Voltage Disable Point: 310 V, ±4 V; hysteresis is at least10 VAC for restart. Between 132 V and 176 V the output power will be derated linearly based on the input voltage as follows: 1. At input voltage of 85 V with output >12 V, max output power is 1500 W. 2. At input voltage of 132 V with output >12 V, max output power is 1500 W (R12-3000) or 1650 W (R12-3300). 3. At input voltage of 150 V with output >12 V, max output power is 2114 W (R12-3000). 4. At input voltage of 176 V and output >12 V, max output power is 3000 W (R12-3000) or 3300 W (R12-3300). AC Input Fuse: 280 V / 25 A. Output Protection: a. b. Current Limiting: The rectifier has a current limit function. The current limit point can be set between the range of 0 A to 250 A (R12-3000) or 0 A to 275 A (R12-3300), adjustable via the controller. Refer to “Rectifier Current Limit” on page 10. The current limit accuracy is ±10 A when the output voltage ranges from 12 V to 13.2 V. High Voltage Shutdown (HVSD): 1. Software settable HVSD level (from controller) 13 V to 13.6 V. The software restart hysteresis is 0.5 V, ±0.2 V. 2. Back-up hardware HVSD at 14 V, ±0.5 V. 3. In the case of a second HVSD within 5 minutes (time value configurable via the controller) the Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [9] a. Fan Fault Protection: The rectifier shuts down and its alarm indicator (red) flashes if either fan fails. Fan failure is detected and reported to controller. The fans are not field replaceable. b. Fan Control: Fan speed is continuously variable. When input voltage is within normal range, the builtin processor adjusts fan speed according to the rectifier’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: Up to twenty-seven (27) rectifiers can be connected in parallel in one system. • Communication Failure: The rectifier’s protection indicator (yellow) flashes should it lose communication with the controller. • Rectifier Output Current Imbalance: When there is a severe imbalance in the load-sharing, the red fault indicator will illuminate. • Monitoring Function: The rectifier has a built-in advanced DSP (Digital Signal Processor) that monitors and controls the operation of the rectifier. The DSP also communicates with the associated controller in real time through the CAN bus. Table 9 lists the different commands and information exchanged between the rectifier and the controller. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 9. Exchange of Information between Rectifier and 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) Voltage • Current Limit Adjustment • Output Voltage Setpoint Information Gathered by the Controller from the Rectifier • • • • • • • • • • • • • • • • • • Input Voltage Output Voltage Output Current Current Limit Setting Rectifier Temperature HVSD 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 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 6. Description: There are three (3) alarm and status indicators located on the rectifier’s front panel. The functions of these indicators are as shown in Table 10. Note: AC voltage must be present at the rectifier input terminals. Figure 6. Rectifier Local Indicators Locations Mechanical Specifications • Dimensions (H x W x D): 41.4 x 124 x 453.2 mm (1.6 x 4.9 x 17.8 inches) • Weight: 3.0 kg (6.6 lbs) (R12-3000), 3.5 kg (7.7 lbs) (R12-3300). • Local Controls: None. • Local Status and Alarm Indicators (see also Table 10): a. Power (Green LED) b. Protection (Yellow LED) c. Alarm (Red LED) Alarm Indicator (Red) Protection Indicator (Yellow) Power Indicator (Green) Rectifier High Voltage Shutdown and Lockout Restart Procedure 1. Remove the rectifier, wait 30 seconds or more (until the LEDs on the rectifier extinguish), then re-insert the rectifier. Rectifier Current Limit When setting total rectifier current limit, the set point to each rectifier is the total set point divided by the number of rectifiers. For example, if the system contains five rectifiers and the current limit is set to 150 amps then each rectifier has a current limit set Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [10] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 a couple communication cycles (several seconds) after which each rectifier would have a new set point of 37.5 amps for a total of 150 amps. The total current limit of the rectifiers should not be set such that the loss of the redundant rectifiers will cause this temporary set point to drop below the actual maximum expected load. point of 30 amps. If one or more rectifiers are removed or fail it will take several seconds for the individual set points to the remaining rectifiers to be reset. In the example given, if one rectifier is removed the current limit set point will drop to 120 amps (30 amps times four remaining rectifiers) until the controller can send updated set points to the remaining rectifiers. This takes Table 10. Rectifier Local Indicators Indicator Power (Green) Protection (Yellow) Alarm (Red) Normal State Alarm State No input voltage. Internal input fuse open. Off On Flashing On Flashing Loss of communication with controller (the rectifier can provide power). On Severe load sharing imbalance. Rectifier output disabled for any reason, including overvoltage shutdown. Rectifier addresses contradictory. DC failure. Off Off Installing Rectifiers Caution Rectifiers can be inserted or removed with power applied (hot swappable). WARNING! To prevent damage to the latching mechanism, ensure the handle is in the open position when installing or removing a rectifier. NEVER hold the handle in the closed position when installing a rectifier into a module mounting assembly. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 The rectifier is being identified by the controller. AC input under/over voltage. PFC over-voltage, under-voltage, or fault. Moderate load sharing imbalance. Rectifier not inserted into the slot completely. Rectifier is not in the position. Rectifier over-temperature protection. Flashing Warning Alarm Cause [11] One or both fans not operating (rectifier shuts down). CAUTION! This rectifier contains double pole fusing; parts of the equipment that remain energized might represent a hazard during servicing after operation of the fuse. If the rectifiers are connected to a 3-phase system, the neutral line should also have a fuse. All-pole circuit breaker should be provided if used in IT power system. Note: Electrical, fire, mechanical enclosures should be provided in the end-product. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Note: The rectifier locks into the module mounting assembly Figure 7. Installing or Removing a Rectifier through a latch located on the underside 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. Clicking the handle to pop it out from the module’s front panel causes the latch to retract. Note: For safety, the unit rear connector output DC pins are disabled until "awakened" inside the module mounting assembly. To install or remove a module, push the handle built into the front cover in and release at the top center of the cover as shown here. Procedure Refer Figure 7 as this procedure is performed. 1. Unpack the rectifier. 2. Note the model number located on the front of the module. Ensure the correct module is being installed. 3. If present, remove the blank cover panel from the module mounting position into which a rectifier is to be installed. 4. Place the rectifier into an unoccupied mounting position without sliding it in completely. 5. Push the handle built into the rectifier’s front cover in and release at the top center of the cover as shown in in Figure 7. This pops the handle 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 module mounting assembly. 7. Push the handle into the front panel of the rectifier. This will lock the rectifier securely to the module mounting assembly. 8. Repeat the above steps for each rectifier being installed in the system. 9. After the rectifiers are physically installed in the module mounting assembly(s), they are ready for operation immediately after power is supplied to them. The handle pop forwards out of the module’s front panel. Note this will also retract the latch mechanism located on the underside of the module. THE HANDLE MUST BE IN THE OPEN POSITION WHEN INSTALLING A MODULE. To remove a module from a module mounting assembly, pull the handle down to pivot it out from the module’s front panel. This will slide the module slightly out of the module mounting assembly, releasing the module from the mounting assembly connector. 10. Certain functions (i.e. rectifier current limit, rectifier addressing) may require adjustment when adding or replacing a rectifier. Refer to “Rectifier Current Limit” on page 10 and the power system documentation for instructions. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [12] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Troubleshooting and Repair Rectifier Fault Symptoms and Troubleshooting Troubleshooting The fault indicators that can be displayed by the rectifier are as follows. Refer to Table 11 for a list of possible causes and corrective actions. Rectifier Current Sharing Imbalance When multiple rectifiers are operating in parallel and the load is greater than 20 %, if the current sharing imbalance among them is greater than 3 %, check if the rectifier is properly seated in the module mounting assembly. If the current sharing imbalance still persists following the verification suggested above, replace the rectifier exhibiting the current imbalance. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [13] • Power Indicator (Green) OFF • Protection Indicator (Yellow) ON • Protection Indicator (Yellow) Flashing • Alarm Indicator (Red) ON • Alarm Indicator (Red) Flashing Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Table 11. Rectifier Troubleshooting Symptom Power Indicator (Green) On Power Indicator (Green) Off Protection Indicator (Yellow) On Protection Indicator (Yellow) Flashing Alarm Indicator (Red) On Alarm Indicator (Red) Flashing Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 Possible Cause(s) Suggested Action(s) AC is on. 12 VDC is on. No action required. No input voltage. Make sure there is input voltage. Internal input fuse open. Replace the rectifier. AC input under/over voltage. Correct the AC input voltage to within the acceptable range. PFC over-voltage, under-voltage, or fault. Change the failure rectifier position, if it still doesn't work, replace the rectifier. Moderate load sharing imbalance. Check if the rectifier is properly seated in the module mounting assembly. If this does not correct the fault, replace the rectifier. Rectifier not inserted into the slot completely. Remove and properly insert the rectifier. Rectifier is not in the position. Check if the contacts of the module mounting assembly’s mating socket is ok. Change the failure rectifier position, if it still doesn't work, change the rectifier. Rectifier over-temperature protection. Fan rotor blocked: remove any object that may be blocking the fan. Ventilation blocked (inlet or outlet): remove any object that may be blocking the inlet or outlet. Ambient temperature too high or rectifier inlet too close to a heat source: lower the ambient temperature or relocate the heat source. Loss of communication with controller (the rectifier can provide power). Check the communication cables. Remove and properly insert the rectifier and controller. Severe load sharing imbalance. Rectifier output disabled for any reason, including overvoltage shutdown. 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. Rectifier addresses contradictory. Replace the rectifier. DC failure. Change the failure rectifier position ,if it still doesn't work, replace the rectifier. One or both fans not operating (rectifier shuts down). Replace the rectifier. [14] Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 Replacement Procedures 3. Pull the handle down to pivot it out from the module’s front panel. As you pull the handle down, the module will slide out of the module mounting assembly, releasing the module from the mounting assembly connector. 4. Remove the rectifier from the module mounting assembly. 5. Place the replacement rectifier into the mounting position without sliding it in completely. 6. Push the handle built into the rectifier’s front cover in and release at the top center of the cover as shown in in Figure 7. This pops the handle forward out of the rectifier’s front panel (this will also retract the latch mechanism located on the underside of the rectifier). 7. Push the rectifier completely into the module mounting assembly. 8. Push the handle into the front panel of the rectifier. This will lock the rectifier securely to the module mounting assembly. 9. Certain functions (i.e. rectifier current limit, rectifier addressing) may require adjustment when adding or replacing a rectifier. Refer to “Rectifier Current Limit” on page 10 and the power system documentation for instructions. Rectifier Replacement Rectifiers can be inserted or removed with power applied (hot swappable). Danger Warning 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 rectifier. NEVER hold the handle in the closed position when installing a rectifier into a module mounting assembly. Note: The rectifier locks into the module mounting assembly through a latch located on the underside 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. Clicking the handle to pop it out from the module’s front panel causes the latch to retract. Procedure Refer Figure 7 as this procedure is performed. 1. 2. 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. Push the handle built into the rectifier’s front cover in and release at the top center of the cover as shown in in Figure 7. This pops the handle forward out of the rectifier’s front panel (this will also retract the latch mechanism located on the underside of the rectifier). Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 [15] 10. After the rectifiers are physically installed in the module mounting assembly(s), they are ready for operation immediately after power is supplied to them. Verify that the rectifiers are operating normally. 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. Document Code: 11UJ9716ER Revision D, September 28, 2015 NetSure™ Rectifier Module User Instructions, UM1R123000 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. The products covered by this instruction manual are manufactured and/or sold by Emerson Network Power, Energy Systems, North America, Inc. 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. Names of companies and products are trademarks or registered trademarks of the respective companies. Any questions regarding usage of trademark names should be directed to the original manufacturer. EmersonNetworkPower.com/Energy Systems (North America ) EmersonNetworkPower.eu/EnergySystems (EMEA) © Emerson Network Power, Energy Systems, North America, Inc. 2015. Business-C ritical Continui ty ™, Emerson Network Powe r™, the Emerson Netw ork Power logo , Emer son™ and Conside r it Solved are serv ice marks and trademar ks of Emer son Electric Co. EnergyMaster ™, eSure™, NetPer form™, NetR each ™, NetSpan™, NetSure™ and NetXtend ™ are tradema rks of Eme rson Network Power, Energy Syste ms, Nor th America, Inc . Any other product, brand, or company names or logos are the property of the respective owner. Spec. No: 1R123000, 1R123300 Model No: R12-3000, R12-3300 While every precaution has been taken to ensure accuracy and completeness herein, Emerson Electric Co. assumes no responsibility, and disclaims all liability, for damages resulting from use of this information or for any errors or omissions. Specifications subject to change without notice. Document Code: 11UJ9716ER Revision D, September 28, 2015