SAG582126000 System Application Guide Spec. No. 582126000 (Model 701NVBB) Issue AV, February 21, 2014 Home SYSTEM OVERVIEW Description: -48VDC @ up to 4000 amperes Power System. This power system is designed to power a load while charging a positive grounded battery. This system is capable of operating in a batteryless installation or off battery for maintenance purposes. The system is designed for operation with the positive output grounded. The NetSure™ 701NVBB DC Power System is a complete integrated power system containing rectifiers (PCUs), intelligent control, metering, monitoring, and distribution. This power system consists of the following components. • Distribution Cabinet The system always includes a minimum of one Distribution Cabinet, which provides DC distribution through fuses and/or circuit breakers. Four different sizes of Distribution Cabinets may be ordered to accept from one (1) to four (4) Distribution Bus Modules. A variety of Distribution Bus Modules are available that provide combinations of load distribution, battery distribution, low voltage load or battery disconnect, and manual battery disconnect. The Distribution Cabinet is factory mounted in the relay rack specified when ordered. Most of the Distribution Bus Modules accept either TPS/TLS-type fuseholders or Bullet Nose-type circuit breakers. TPH-type fuses and GJ/218-type circuit breakers are also available in ratings up to 600 amps. • Meter-Control-Alarm (MCA) Assembly The system contains one MCA. The MCA controls the operation of the Rectifier Modules (PCUs). The MCA also provides power system control, metering, monitoring, and alarm functions. • Rectifier Module (PCU) Mounting Shelves The system contains one or more Rectifier Module (PCU) Mounting Shelves, each of which houses up to six (6) Rectifier Modules (PCUs). Refer to PD588705000 for more information. • Rectifier Modules (PCUs) The system contains Rectifier Modules (PCUs), which provide load power, battery float current, and battery recharge current during normal operating conditions. Refer to UM1R483500e (Rectifier User Instructions) for more information. • DC-DC Converter System Where +24VDC load power is required, DC-DC Converters are available in this power system. • Monitoring System An LMS1000 Monitoring System may also be furnished. Refer to SAG586505500 for more information. Page 1 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) Home Family: Spec. No.: Model: Output Voltage: Rectifier System Input Voltage Output Capacity: System: Bay: Distribution Bus Module: Rectifier Module (PCU) 1R483200 and 1R483200e: Agency Approval: Framework Type: Mounting Width: Mounting Depth: Distribution Cabinet: Rectifier Module Mounting Shelf: Battery Tray: Access: Supplemental Bay(s) Available: Control: Color: Environment: NetSure™ 582126000 701NVBB -48 Volts DC 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. 4000 Amperes, maximum 2000 Amperes, maximum (1500A maximum when equipped with List AH; 1200A maximum when equipped with List RA or RB) 500 Amperes, maximum (List ND rated for 960A) 55.2A @ -58VDC to 66.6A @ -48VDC UL 1801 Listed (“c UL”), NEBS Relay Rack 23 Inches, nominal 18 Inches (single-bay), 21 Inches (multi-bay) (List RC, RD, and RE adds 5.25 inches to back of system, see Overall Dimensions Illustrations) 18 Inches 24.4 Inches Front, Sides, and Rear for Installation and Maintenance, Front for Operation One Microprocessor Bay and Rectifier Module Faceplates: Textured Gray (Spec. M500-147) Rectifier Shelf and Rectifier Modules Bodies: Bright Zinc Plating (Spec. M500-53) -40°C to +40°C (-40°F to +104°F) Page 2 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) Home 582126000 Main Bay:……………………………………………...…List 1 Supplemental Bay (located next to Main Bay):………List 2 Supplemental Bay 'Distribution Only' Option:………...List 4 Supplemental Bay (located away from Main Bay):.….List 5 List 45, 46: Top Mount AC Input Termination Panel Distribution Bus Row D (Row 4) Distribution Bus Row C (Row 3) Distribution Cabinet List 24 (4-Row) List 23 (3-Row) List 22 (2-Row) List 21 (1-Row) MCA List 10, 11, 12, 13 LMS1000 Monitoring System List 80 Distribution Bus Row B (Row 2) Distribution Bus Row A (Row 1) Rectifier Module Mounting Shelf Components List 31 Rectifier Module P/N 1R483200e or P/N 1R483200 See Also System Overview Table of Contents List Descriptions Specifications Physical Size Information Related Documentation Distribution Assembly List AA, AB, AC, AD, AE, AG, AH, AJ, AK, AL, AM, AN, AP, BA, CA, CB, CD, CE, CF, CG, CJ, EA, GB, JA, JB, JC, JD, KA, LB, LC, NA, NB, NC, ND, TA, TB List RA: LV Battery Disconnect List RB, RC: Manual Battery Disconnect List RD: LV/Manual Battery Disconnect List RE: LV Battery Disconnect Other Options List 29: Distribution Cabinet Top Shield List 62: 20A Converter Module List 63, 64: 160A DC-DC Converter Shelves List 71: Optional Audible Alarm and Alarm Termination Circuit Card List 72: MCA Interface Modem Option List 73:MCA Interface WinLink Software List 74: MCA Interface Combination Modem/RS-232 Option List 75: MCA Interface Ethernet Option: WinLink Compatible + Web Interface List 76: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + SNMP List 77: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + Battery Monitoring List 78: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + SNMP + Battery Monitoring List 79: Capacitor Precharge Assembly List 92: Battery System List 93: Battery Tray Page 3 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) TABLE OF CONTENTS System Overview Picture List Descriptions Accessory Descriptions Specifications Physical Size Information Related Documentation SYSTEM OVERVIEW................................................................................................................................................. 1 TABLE OF CONTENTS ............................................................................................................................................. 4 LIST DESCRIPTIONS ................................................................................................................................................ 8 List 1: Main Bay Common Equipment (Power and Distribution) ..................................................................... 8 List 2: Supplemental Bay Common Equipment (Power and Distribution) (located next to Main Bay) ........... 9 List 4: “Distribution Only” Option for Lists 2 or 5 ........................................................................................... 10 List 5: Supplemental Bay Common Equipment (Power and Distribution) (located away from Main Bay) ................................................................................................................................................................ 10 List 10: MCA (Standard Application) ............................................................................................................. 11 List 11: MCA (Special Application) ................................................................................................................ 11 List 12: MCA (Special Application) ................................................................................................................ 11 List 13: MCA (Special Application) ................................................................................................................ 12 List 21: One-Row Distribution Cabinet .......................................................................................................... 12 List 22: Two-Row Distribution Cabinet .......................................................................................................... 13 List 23: Three-Row Distribution Cabinet ....................................................................................................... 14 List 24: Four-Row Distribution Cabinet ......................................................................................................... 14 List 29: Top Shield for Distribution Cabinet ................................................................................................... 15 List 31: Rectifier Module Mounting Shelf Interface Components .................................................................. 15 List 45: Top Mount AC Input Termination Panel for Single Phase Input ...................................................... 15 List 46: Top Mount AC Input Termination Panel for Three Phase Input ....................................................... 16 List 62: Optional 20A Converter Module ....................................................................................................... 17 List 63: Optional 160A Converter Shelf (Initial Shelf).................................................................................... 17 List 64: Optional 160A Converter Shelf (Expansion Shelf) ........................................................................... 18 List 71: Optional Audible Alarm and Alarm Termination Circuit Card ........................................................... 18 List 72: MCA Interface Modem Option .......................................................................................................... 19 List 73: MCA Interface WinLink Software ..................................................................................................... 19 List 74: MCA Interface Combination Modem/RS-232 Option ....................................................................... 20 List 75: MCA Interface Ethernet Option: WinLink Compatible + Web Interface ........................................... 20 List 76: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + SNMP ............................. 21 List 77: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + Battery Monitoring .......... 21 List 78: MCA Interface Ethernet Option: WinLink Compatible + Web Interface + SNMP + Battery Monitoring ....................................................................................................................................................... 22 List 79: Capacitor Precharge Assembly ........................................................................................................ 22 List 80: LMS1000 Monitoring System ........................................................................................................... 23 List 92: Battery Stand Interface Components ............................................................................................... 23 List 93: Battery Tray, Pre-Cabled .................................................................................................................. 24 List AA: Distribution Bus Module (P/N 509840) (24) Fuse/Circuit Breaker System Positions ...................... 28 List AB: Distribution Bus Module (P/N 428316100) (3) GJ/218 Circuit Breaker System Positions .............. 29 List AC: Distribution Bus Module (P/N 507198) (3) GJ/218 Circuit Breaker System Positions .................... 30 List AD: Distribution Bus Module (P/N 509565) (8) GJ/218 Circuit Breaker System Positions (Upper Two Rows) ......................................................................................................................................... 31 List AE: Distribution Bus Module (P/N 509648) (8) GJ/218 Circuit Breaker System Positions (Lower Two Rows) ......................................................................................................................................... 32 List AG: Distribution Bus Module (P/N 514010) (2) TPH Fuse System Positions ........................................ 33 List AH: Distribution Bus Module Ground Bar Assembly (P/N 500676) for Use with Up to (2) List AG, AJ, CG, or CJ; or (1) List AP ................................................................................................................... 34 List AJ: Distribution Bus Module (P/N 520819) (2) TPH Fuse System Positions with Load Metering Shunts ............................................................................................................................................................ 35 Page 4 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) List AK: Distribution Bus Module (P/N 520805) (24) Fuse/Circuit Breaker System Positions ...................... 36 List AL: Distribution Bus Module Ground Bar Assembly for Use with Up to (2) List AK ............................... 37 List AM: Distribution Bus Module (P/N 524632) (20) Fuse/Circuit Breaker System Positions (1) 3Pole Input Disconnect Fuse/Circuit Breaker Position .................................................................................... 38 List AN: Distribution Bus Module (P/N 541386) (24) Fuse/Circuit Breaker System Positions ...................... 39 List AP: Distribution Bus Module (P/N 541537) (4) TPH Fuse System Positions ......................................... 40 List BA: Distribution Bus Module (P/N 520600) (12) Fuse/Circuit Breaker System Positions with LVD (8) Fuse/Circuit Breaker System Positions without LVD ........................................................................ 41 List CA: Distribution Bus Module (P/N 509846) (20) Fuse/Circuit Breaker System Positions w/LVLD ........................................................................................................................................................... 42 List CB: Distribution Bus Module (P/N 509904) (3) GJ/218 Circuit Breaker System Positions w/LVLD ........................................................................................................................................................... 43 List CD: Distribution Bus Module (P/N 507197) (3) GJ/218 Circuit Breaker System Positions w/LVLD ........................................................................................................................................................... 44 List CE: Distribution Bus Module (P/N 509563) (8) GJ/218 Circuit Breaker System Positions w/LVLD (Upper Two Rows) ............................................................................................................................ 45 List CF: Distribution Bus Module (P/N 509646) (8) GJ/218 Circuit Breaker System Positions w/LVLD (Lower Two Rows) ............................................................................................................................ 46 List CG: Distribution Bus Module (P/N 514037) (2) TPH Distribution Fuse Positions w/LVLD .................... 47 List CJ: Distribution Bus Module (P/N 520937) (2) TPH Distribution Fuse Positions with Load Metering Shunts and LVLD ............................................................................................................................ 48 List EA: Distribution Bus Module (P/N 509852) (16) Fuse/Circuit Breaker System Positions and (4) Fuse/Circuit Breaker Battery Disconnect Positions ....................................................................................... 49 List GB: Distribution Bus Module (P/N 513963) (8) Fuse/Circuit Breaker System Positions w/LVD and (1) TPH Fuse Battery Disconnect Position ............................................................................................. 50 List JA: Distribution Bus Module (Part No. 524482) (4) –48V Fuse/Circuit Breaker System Positions and (16) +24V Fuse/Circuit Breaker Subsystem Positions ........................................................... 51 List JB: Distribution Bus Module (Part No. 524496) (12) –48V Fuse/Circuit Breaker System Positions and (8) +24V Fuse/Circuit Breaker Subsystem Positions ............................................................. 52 List JC: Distribution Bus Module (Part No. 524620) (14) –48V Fuse/Circuit Breaker System Positions and (6) +24V Fuse/Circuit Breaker Subsystem Positions ............................................................. 53 List JD: Distribution Bus Module (Part No. 524788) (14) –48V Fuse/Circuit Breaker System Positions and (8) +24V Fuse/Circuit Breaker Subsystem Positions ............................................................. 54 List KA: Distribution Bus Module (Part No. 524571) (4) –48V Fuse/Circuit Breaker System Positions and (16) +24V Fuse/Circuit Breaker Subsystem Positions ........................................................... 55 List LB: Distribution Bus Module (Part No. 524578) (8) –48V Fuse/Circuit Breaker System Positions w/LVD and (8) +24V Fuse/Circuit Breaker Subsystem Positions .................................................. 56 List LC: Distribution Bus Module (Part No. 524583) (12) –48V Fuse/Circuit Breaker System Positions w/LVD and (4) +24V Fuse/Circuit Breaker Subsystem Positions .................................................. 57 List NA: Distribution Bus Module (P/N 514336) (20) Fuse/Circuit Breaker Battery Disconnect Positions ......................................................................................................................................................... 58 List NB: Distribution Bus Module (P/N 513809) (3) GJ/218 Circuit Breaker Battery Disconnect Positions ......................................................................................................................................................... 59 List NC: Distribution Bus Module (P/N 514025) (1) TPH Fuse Battery Disconnect Position ........................ 60 List ND: Distribution Bus Module (P/N 514030) (2) TPH Fuse Battery Disconnect Positions ...................... 61 List RA: 1200A Low Voltage Battery Disconnect (LVBD) Contactor and Control Circuit (P/N 528442) .......................................................................................................................................................... 62 List RB: 1200A Manual Battery Disconnect Contactor with Local and Remote Alarm (P/N 528443) .......... 63 List RC: 2000A Manual Battery Disconnect Contactor with Local and Remote Alarm (P/N 528446) .......... 64 List RD: 2000A Low Voltage/Manual Battery Disconnect Contactor with Battery Current Monitoring (P/N 528447) .................................................................................................................................................. 65 List RE: 2000A Low Voltage Battery Disconnect Contactor with Battery Current Monitoring (P/N 535064) .......................................................................................................................................................... 66 List TA: 800A Bulk Feed Distribution Bus Module (P/N 541530) (Internal Shunt) ........................................ 67 List TB: 1200A Bulk Feed Distribution Bus Module (P/N 541530), Bypass Shunt Busbar (P/N 541535), and External Shunt Monitoring Kit (P/N 541134) (External Shunt) ................................................ 68 Page 5 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) ACCESSORY DESCRIPTIONS ............................................................................................................................... 69 Rectifier Modules............................................................................................................................................... 69 Rectifier Module (PCU), High-Efficiency (P/N 1R483200e) ........................................................................... 69 Rectifier Module (PCU) (P/N 1R483200) ....................................................................................................... 69 Relay Racks ....................................................................................................................................................... 70 Transition Plates to Mount Relay Rack on Top of GNB Absolyte IIP Batteries .......................................... 71 Distribution Devices .......................................................................................................................................... 72 GMT Load Distribution Fuse Block Assembly Kit (P/N 514432) (10) GMT Fuse Positions........................... 72 GMT-Type Load Distribution Fuses ............................................................................................................... 74 Replacement Alarm, Reference, and Control Fuses ..................................................................................... 75 TPH-Type Fuses ............................................................................................................................................ 76 GJ/218-Type Circuit Breakers ........................................................................................................................ 77 Bullet Nose-Type Circuit Breakers and Bullet Nose-Type Fuseholders e/w TPS/TLS Fuses ....................... 79 Wiring Components .......................................................................................................................................... 83 Load Distribution Wire Sizes and Lugs Selection .......................................................................................... 83 Input Battery Wire Sizes and Lugs Selection ................................................................................................. 84 Standard Crimp Lug Tables ........................................................................................................................... 86 Special Application Crimp Lug / Strap Combination Table ............................................................................ 87 Wire Size and Lug Selection Tables for Load and Battery Connections to TPS/TLS Fuses and Bullet Nose-Type Circuit Breakers or Battery Branch Circuits ....................................................................... 88 Wire Size and Lug Selection Tables for Load and Battery Connections to TPH Fuses and GJ/218Type Circuit Breakers or Battery Branch Circuits .......................................................................................... 90 AC Input Branch Circuit Protection and Wire Size Selection (when Optional List 45 Top Mount AC Input Termination Panel is Furnished) ........................................................................................................... 92 AC Input Branch Circuit Protection and Wire Size Selection (when Optional List 46 Top Mount AC Input Termination Panel is Furnished) ........................................................................................................... 93 AC Input Branch Circuit Protection and Wire Size Selection (when wiring to Rectifier Module Mounting Shelf[s]) .......................................................................................................................................... 93 Relay Rack Frame Grounding Requirements ................................................................................................ 94 External Alarm, Reference, and Control Wire Sizes ...................................................................................... 94 Rectifier Module Mounting Position Blank Cover Panel (P/N 21140440)..................................................... 95 Battery Charge Temperature Compensation Probe for Single Probe Digital Compensation (P/Ns 107021 and 106824) ........................................................................................................................................... 95 Battery Charge Temperature Compensation Probe Concentrator for Multiple Probe Use (TXM) ............ 96 Battery Temperature Probe Concentrator Kit (P/N 524570) .......................................................................... 96 Analog Battery Temperature Probe (P/N 521262) ......................................................................................... 96 TXM Extension Cable (P/N 514153) .............................................................................................................. 96 Adding Additional Shelf in Field Output Busbar Kit (P/N 529139) ............................................................... 97 Battery Busbar Extension Kit (P/N 514713) .................................................................................................... 98 Battery Busbar Extension Kit (P/N 529143) .................................................................................................... 98 Battery Landing Busbar Kit (P/N 541371) ....................................................................................................... 98 Lug Adapter Busbar for 225-250 Amp Bullet Nose Type Circuit Breaker (P/N 514717) ............................. 99 Lug Adapter Busbar Kit for 125-200 Amp Bullet Nose Type Circuit Breaker (P/N 534449) ....................... 99 Lug Adapter Busbar Kit for 225-250 Amp Bullet Nose Type Circuit Breaker (P/N 514714) ....................... 99 Bullet Distribution Assembly Lug Hardware Kit (P/N 520332) .................................................................... 100 Bullet Distribution Assembly Lug Hardware Kit (P/N 101212) .................................................................... 100 LVD Contactor Bypass Kits (P/Ns 514910 and 514912)............................................................................... 100 External Shunt Monitoring Kit (P/N 541134) ................................................................................................. 100 System Load Shunt Test Point Kit (P/N 545569) .......................................................................................... 101 Optional Front Battery Cover Kits ................................................................................................................. 101 Replacement Cables ....................................................................................................................................... 102 Replacement Components ............................................................................................................................. 105 SPECIFICATIONS.................................................................................................................................................. 106 1.1 Environmental Ratings ............................................................................................................................. 106 1.2 Compliance Information ........................................................................................................................... 106 Page 6 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide Spec. No. 582126000 (Model 701NVBB) 1.3 MCA Features ............................................................................................................................................ 106 PHYSICAL SIZE INFORMATION .......................................................................................................................... 117 Overall Dimensions ......................................................................................................................................... 117 List 24 (Four Bus Row Cabinet) ................................................................................................................... 117 List 23 (Three Bus Row Cabinet) ................................................................................................................. 118 List 22 (Two Bus Row Cabinet) .................................................................................................................... 119 List 21 (One Bus Row Cabinet) .................................................................................................................... 120 List 31 (Rectifier Module Mounting Shelf), List 45 or 46 (Top Mount AC Termination Panel), List 80 (LMS1000 Monitoring System), List 92 (Battery Stands), and List RC, RD, and RE (Battery Disconnects)................................................................................................................................................. 121 List 93 (Battery Tray) .................................................................................................................................... 122 Optional Digital Battery Charge Temperature Compensation Probe (P/N 107021 and 106824) ................ 123 Optional Analog Battery Temperature Probe (P/N 521262) ........................................................................ 123 Electrical Connection Locations and Dimensions ....................................................................................... 124 Input Battery ................................................................................................................................................. 124 Load Distribution .......................................................................................................................................... 129 AC Input ....................................................................................................................................................... 129 External Alarm, Reference, and Control ...................................................................................................... 132 RELATED DOCUMENTATION .............................................................................................................................. 133 BATTERY MANUFACTURER INFORMATION .................................................................................................... 134 REVISION RECORD .............................................................................................................................................. 135 Page 7 of 135 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. SAG582126000 Issue AV, February 21, 2014 System Application Guide