R48-2000e3 Rectifier User Manual

NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Specification Number: 1R482000E3
Model Number: R48-2000e3
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
This page is intentionally blank.
Spec. No: 1R482000E3
Model No: R48-2000e3
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Table of Contents
Admonishments Used in this Document ................................................................................................................ ii
Static Warning ..................................................................................................................................................... iii
Introduction ......................................................................................................................................................... 1
Overview ................................................................................................................................................................ 1
Specifications ......................................................................................................................................................... 1
Operation ............................................................................................................................................................. 8
AC Input Protection Device Requirements/Recommendations................................................................................. 8
Local Indicators....................................................................................................................................................... 8
Rectifier High Voltage Shutdown and Lockout Restart ............................................................................................. 8
Rectifier Current Limit ............................................................................................................................................. 8
Installing Rectifiers ............................................................................................................................................... 10
Troubleshooting and Repair ................................................................................................................................ 10
Troubleshooting ................................................................................................................................................... 10
Replacement Procedures ...................................................................................................................................... 12
Spec. No: 1R482000E3
Model No: R48-2000e3
i
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
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: 1R482000E3
Model No: R48-2000e3
ii
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
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: 1R482000E3
Model No: R48-2000e3
iii
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
This page is intentionally blank.
Spec. No: 1R482000E3
Model No: R48-2000e3
iv
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Introduction
Figure 1. Output Voltage vs. Output Current
Output Voltage vs. Output Current,
Max. Output Power 2000W
Overview
The rectifier provides load power, battery float current, and
battery recharge current during normal operating conditions. The
rectifier is a constant power design. 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 2000W. 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 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 2000W.
•
Constant Power Mode: As load increases above
approximately 2000W (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.
Output Voltage (V)
•
•
Output Characteristics: Refer to Figure 1 for a graph of
output voltage vs. output current.
Spec. No: 1R482000E3
Model No: R48-2000e3
0
0
5
10
15
20
25
30
35
40
45
50
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 (2000W) as long as the
input voltage is within the range of 176 to 300VAC.
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 2.
Output power vs. Input voltage and Vo>48V at Temp≤55°C
120.0%
100.0%
80.0%
60.0%
40.0%
20.0%
0.0%
50
100
150
200
250
300
350
Input voltage (Vac)
Note: Blue Line: Linear derating from 85V AC to 176V AC.
Yellow Line: Linear derating from 2000 watts at 176V AC to
1000 watts at 132V AC. Constant 1000 watts from 132V AC
to 93V AC.
voltage level is set through the controller.
Output Power and Current: 2000W (41.7A) @
120/208/240VAC input and -48VDC output.
10
Figure 2. Power Derating Based on Input Voltage
Note: A current limitation can be set by the User and the output
•
20
For R48-2000e3
DC Output Ratings
Voltage: Nominal -48 volts DC, positive ground. Output
voltage is adjustable from -42 to -58 volts DC via the
associated Controller.
30
0
Specifications
•
40
Output Current (A)
% of output power
•
41.7
34.5
60
50
•
1
Power Derating Based on Temperature: The rectifier
delivers full power when operating at an ambient
temperature of +55°C (+131°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 +55°C
(+131°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 +55°C (+131°C)
and +80°C (+176°F) will result in output power being
decreased. Full power capability is restored when the
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
input frequency at a constant ambient temperature.
The associated system Controller may provide
increased regulation.
temperature decreases to below approximately +55°C
(+131°F). Refer to Figure 3 to view the relationship
between the output power and the ambient
temperature.
b.
WARNING! The module is rated for continuous
operation at full output power up to +55°C (+131°F).
Operation between +55°C (+131°F) and +80°C (+176°F)
will result in output power decrease. Operation above
+80°C (+176°F) is considered abnormal and should be
used on a temporary1 basis only.
Warning
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.)
Filtering:
a.
Other power rating values are as follows (refer to Figure
3):
a.
At an ambient temperature of +65°C (+149°F),
the power delivered by the rectifier is 1800W.
b.
At an ambient temperature of +70°C (+158°F),
the power delivered by the rectifier is 1500W.
Dynamic : For any step load change within the range
of 10% to 90% of full load within 50 microseconds,
per Telcordia GR-947-CORE, the maximum voltage
transient will not exceed 5% of the initial steady state
voltage within 50±10 microseconds. Recovery to
within 1% of the initial steady state voltage does not
exceed 1 milliseconds.
b.
Voice Band Noise: Complies with Telcordia GR-947CORE.
1.
Output noise according to Telcordia
GR-947-CORE is < 38 dBrnC typical at normal
input and 20% to 70% of rated load for more
than one rectifier.
2.
Psophometric noise is ≤ 2 mV typical at 20% to
70% of rated load for more than one rectifier.
Wide Band Noise: Complies with Telcordia GR-947CORE.
1.
Figure 3. Power Derating Based on Temperature
Output power vs. Temperature @ Vin≥ 176Vac
120
AC Input Ratings
% of output power
100
•
80
60
40
20
0
-40
-20
0
20
40
60
80
Voltage: Nominal 120/208/240 volts AC, single phase, 3wire, 50/60 Hz, with an operating range of 100 to 250
volts. Acceptable input frequency range is 45 to 65 Hz.
Permitted Variation: 85 to 300 VAC.
100
Temperature (°C)
•
Harmonic Content (THD): ≤5% from 50% to 100% of
rated load. Meets EN61000-3-2.
•
Inrush Current: Peak does not exceed 1.5 times of the
peak value of the maximum steady-state 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: 50 Hz input.
Note: Green Line: at 200Vac < Vin < 250Vac and 50Vdc < Vout <
56Vdc.
Blue Line: at 176Vac < Vin < 300Vac and 48Vdc < Vout < 58Vdc,
exclude Region1.
Yellow Line: 264Vac < Vin < 300Vac and Vout < 42Vdc.
Note: 2000W @ +65°C (+149°F) and 200Vac < Vin < 250Vac and
50Vdc < Vout <56Vdc.
•
Wideband noise emission is < 250 mV peak to
peak between 0 Hz – 100 MHz, and < 50 mV
rms in any 3 kHz band 10 KHz – 20 MHz.
Regulation:
a.
Refer to Table 1.
a.
b.
Maximum Input Current: Refer to Table 2.
Static : Steady state regulation is ±0.6% as controlled
within the rectifier for any and all combinations of
load from no load to full load, input voltage, and
Spec. No: 1R482000E3
Model No: R48-2000e3
2
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Table 1.
Typical Input Data in 50Hz Input
Nominal
Input
Voltage
Percent
of Full Load
Input
Current
(Amperes)
Input
VA
Input
Watts
Power
Factor %
Efficiency
% Heat
Heat
Dissipation
BTU/Hr
0
0.32
70.80
33.20
46.90
--
113.27
25
2.24
497.20
491.90
98.90
95.38
77.54
50
4.71
983.00
977.40
99.40
96.01
133.05
75
7.08
1476.10
1473.00
99.70
95.51
255.65
100
9.53
1980.00
1984.30
99.80
94.50
372.35
110
10.30
2144.00
2141.00
99.80
94.27
418.56
120
10.34
2151.00
2147.00
99.80
93.88
454.89
0
0.32
73.50
26.50
36.00
--
90.41
25
2.08
499.80
490.80
98.00
95.58
74.01
50
4.09
983.90
974.70
99.00
96.27
124.04
75
6.13
1472.80
1466.30
99.50
95.94
203.11
100
8.23
1974.20
1968.90
99.70
95.24
319.75
110
8.90
2133.00
2129.00
99.70
94.87
372.63
120
8.93
2142.00
2138.00
99.70
94.38
409.95
208
240
Note: System output is initially adjusted to 54.48 volts DC as measured at the system sense point at 50% of full load and
nominal input. “Percent of Full Load” refers to percent of 34.5 amperes.
Table 2.
Maximum Input Current in 50Hz Input
Nominal Input
Voltage
Input Voltage
Input Current
(Amperes)
208/240
176
11.73
Note: At 100% of full load with output adjusted to 58
volts DC as measured at the shelf output
terminals.
Spec. No: 1R482000E3
Model No: R48-2000e3
3
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
•
Table 3.
Typical Input Data: 60 Hz input.
a.
Refer to Table 3.
b.
Maximum Input Current: Refer to Table 4.
Typical Input Data in 60Hz Input
Nominal
Input
Voltage
Percent
of Full Load
Input
Current
(Amperes)
Input
VA
Input
Watts
Power
Factor %
Efficiency
% Heat
Heat
Dissipation
BTU/Hr
0
0.34
73.20
29.60
40.43
--
100.99
25
2.39
499.90
492.40
98.50
95.27
79.46
50
4.73
985.80
978.10
99.20
95.94
135.49
75
7.09
1479.60
1474.00
99.60
95.43
229.83
100
9.54
1985.80
1982.20
99.70
94.59
365.87
110
10.31
2147.00
2142.00
99.80
94.24
420.95
120
10.35
2154.00
2149.00
99.80
93.82
452.12
0
0.36
105.40
31.80
30.55
--
108.5
25
2.10
504.70
491.00
97.20
95.59
73.88
50
4.11
989.30
975.90
98.60
96.18
127.19
75
6.15
1478.00
1469.60
99.30
95.73
214.10
100
8.25
1978.70
1972.20
99.60
95.08
331.10
110
8.92
2140.00
2132.00
99.60
94.78
379.70
120
8.95
2147.00
2140.00
99.60
94.32
414.71
208
240
Note: System output is initially adjusted to 54.48 volts DC as measured at the system sense point at 50% of full load and
nominal input. “Percent of Full Load” refers to percent of 34.5 amperes.
Table 4.
Maximum Input Current in 60Hz Input
Nominal Input
Voltage
Input Voltage
Input Current
(Amperes)
208/240
176
11.73
Note: At 100% of full load with output adjusted to 58
volts DC as measured at the shelf output
terminals.
Spec. No: 1R482000E3
Model No: R48-2000e3
4
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
•
Efficiency Curve (Refer to Figure 4.)
Figure 4. Efficiency Curve
Efficiency (%)
Efficiency Curve
98
96
94
92
90
88
86
84
0
10
20
30
40
50
60
70
80
90 100
Load (% of rated load)
does not exceed the Operating Ambient Temperature
Range stated above.
Environmental Ratings:
•
Operating Ambient Temperature Range:
a.
+55°C (+131°F) to +80°C (+176°F) with derating
output.
b.
-40°C (-40°F) to +55°C (+131°F) with full power
performance.
•
Temperature Coefficient: 0.02% per degrees Celsius.
•
Storage Ambient Temperature Range: -40°C (-40°F) to
+70°C (+158°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).
•
Single Rectifier Audible Noise: At 25°C ≤50dB(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.
•
High Voltage Category: II
•
Power Distribution System: TN/TT/IT
Note: The rectifier module is recommended to be used in an
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).
•
EMI/RFI Suppression:
Surge Protection: Compliance with EN61000-4-5 (4kV
Line to Line, 4kV Line to Earth). Capable of withstanding
surges per ANSI/IEEE C 62.41 1999 Category B3 across
the input terminals.
a.
Rectifiers operating in an approved rectifier
mounting shelf conform to the requirements of FCC
rules Part 15, Class B for Radiated and Conducted
emissions limits.
Note: This level of protection is a widely used standard for
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.
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.
•
•
Compliance Information
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
Spec. No: 1R482000E3
Model No: R48-2000e3
5
•
EMC: ETSI EN 300 386, FCC CFR 47 Part 15 class B,
Telcordia GR-1089-CORE.
•
EMI Load Range: 10-100%.
•
Safety: IEC 60950, EN 60950, UL 60950.
•
GR-3108 Class 2 Compliant
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Standard Features
•
Type of Power Conversion Circuit: High frequency.
•
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 2000W.
•
•
•
Constant Power Mode: As load increases above
approximately 2000W (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.
Current Limiting: The rectifier has a current limit
function. The current limit point can be set between
the range of 4 to 41.7 A, adjustable via the
Controller. The current limit accuracy is ±1.5A when
the output voltage ranges from 42 to 58 V. Below
42 V the current will fold back to a lower value.
c.
Advanced Current Limit Function: The rectifier has
an advanced Current Limit Function. When a short
circuit occurs at the rectifier output terminals, the
rectifier will keep its output current at a value below
the maximum current limit set point. This function
effectively protects the rectifier and the equipment
connected to the rectifier. When the short circuit
fault is cleared, the rectifier will automatically
restore back to normal operation.
d.
High Voltage Shutdown:
Constant Current Mode: If load increases to the current
limit setting, output voltage decreases linearly to
maintain output current at the current limit setting.
1.
Software settable HVSD level (from controller)
56 to 59 V. The software restart hysteresis is
0.5 V, ±0.2 V.
2.
Back-up hardware HVSD (High Voltage Shut
Down) at 59.5 V, ±0.5 V.
3.
In the case of a second HVSD within 5 minutes
(time value configurable via the controller) the
unit shall require to be manually restarted.
Method of manual restart: Reset the rectifier
through the controller or remove the rectifier
from the system and then re- install the rectifier
into the system.
Input Protection:
a.
b.
•
b.
Input Over/Under Voltage Protection: The rectifier
will shut down at low or high voltage input; based on
the following voltage levels:
1.
Low Voltage Disable Point: 80V, ±5 V;
hysteresis is 15 VAC for restart.
2.
High Voltage Disable Point: 305V, ±5 V;
hysteresis is 10 VAC for restart.
•
Between 85 V and 176 V the output power will be
derated linearly based on the input voltage as
follows:
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
not be affected.
•
Cooling: Each rectifier module contains a fan for front-toback force air-cooling.
1.
At input voltage of 85V with output >48V, max
output power is 800W.
2.
At input voltage of 120V with output >48V, max
output power is 1364W.
3.
At input voltage of 154V with output >48V, max
output power is 1750W.
4.
At input voltage of 176V and output >48V, max
output power is 2000W.
Output Protection:
a.
Overload / Reverse Current: The rectifier has a 63A
fuse in the negative output DC bus. 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.
Spec. No: 1R482000E3
Model No: R48-2000e3
6
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 fan is field replaceable.
b.
Fan Control: Fan speed is continuously variable.
When input voltage is within normal range, the builtCode: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
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: Up to 32 rectifiers can be connected in
parallel in one system.
•
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: When load sharing
severe imbalance (output fuse open) and the output
current drops to zero in average current >10% system,
then the red fault indicator will illuminate.
•
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 5 lists
the different commands and information exchanged
between the rectifier and the Controller.
Spec. No: 1R482000E3
Model No: R48-2000e3
Table 5.
Exchange of Information between Rectifier and Controller
Commands / signals that can
be received by the Rectifier
Module from the Controller.
Information gathered by the
Controller from the Rectifier
Module.
• Turn On/Off
• Current Walk-in On/Off
• HVSD (High Voltage
Shutdown) Reset
• Current Limit Adjustment
• Voltage Regulation
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
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
Imbalance Output Current
Address
Code
Date
Software Version
Hardware Version
Mechanical Specifications
•
7
Dimensions:
a.
Millimeters: 42.0 (Height) X 84.5 (Width) X 252.5
(Depth)
b.
Inches: 1.7 (Height) X 3.3 (Width) X 9.9 (Depth)
•
Weight: 1.13 kg (2.49 lbs)
•
Indicators:
a.
Power (Green LED)
b.
Protection (Yellow LED)
c.
Alarm (Red LED)
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
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 5.
Description: There are three (3) indicators located on the
rectifier’s front panel. The functions of these indicators are as
shown in Table 6.
Note: DC voltage must be present at the rectifier output terminals
(from battery or an operating rectifier) or AC voltage at the
input terminals.
Rectifier High Voltage Shutdown and Lockout
Restart
PROCEDURE
Remove the rectifier, wait 30 seconds or more (until the LEDs on
the rectifier extinguish), then re-insert the rectifier.
Manual menu in the LCD menus or under the Rectifier Control Tab
in the WEB Interface).
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
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
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. If batteries are used on the rectifier output, the batteries
should support the load until the current limit set points can be reestablished due to loss of a rectifier.
The rectifier can also be restarted from the ACU+ LCD or WEB
Interface menu (via the rectifier Reset command, found in the
Spec. No: 1R482000E3
Model No: R48-2000e3
8
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Figure 5. Local Indicator Locations
Power Indicator (Green)
Protection Indicator (Yellow)
Alarm Indicator (Red)
Table 6.
Rectifier Module Indicators
Indicator
Power
(Green)
Normal State
Alarm State
Off
On
Flashing
On
Protection
(Yellow)
Alarm
(Red)
Off
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.
Rectifier modules are operating in an
output power derating mode
(rectifiers derate when module
temperature rises above or input
voltage falls below acceptable
values).
Loss of communication with the
Controller (the rectifier can provide
power).
On
Severe load sharing imbalance.
Rectifier module output disabled for
any reason, including overvoltage
shutdown and internal output fuse
open.
Rectifier addresses contradictory.
Off
9
No input voltage.
Internal input fuse open.
Flashing
Flashing
Spec. No: 1R482000E3
Model No: R48-2000e3
Alarm Cause
Faulty fan (rectifier module shuts
down).
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Installing Rectifiers
Figure 6. Installing Rectifier Module
Rectifier modules can be inserted or removed with power applied
(hot swappable).
Note: Each rectifier module locks into a module mounting shelf by
means of a latch located on the bottom of the module. The
latch and rectifier module handle are interactive. Pushing the
handle up into the module’s front panel causes the latch to
extend to the locking position; pulling the handle down out
from the module’s front panel causes the latch to retract. See
Figure 6.
Caution
Warning
Captive Screw
Handle
CAUTION! This rectifier module 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.
WARNING! To prevent damage to the latching
mechanism, ensure the handle is in the open position
when installing or removing a rectifier module. NEVER
hold the handle in the closed position when installing a
rectifier module into a shelf.
PROCEDURE
Latch
Note: Refer to Figure 6 as this procedure is performed.
1.
Unpack the module.
2.
Place the module into an unoccupied mounting slot
without sliding it in completely.
3.
Loosen the captive screw on the module’s handle. Pull
the handle down out from the module’s front panel (this
will also retract the latch mechanism). See Figure 6.
4.
Push the module completely into the shelf.
5.
Push the handle up into the module’s front panel. This
will lock the module securely to the shelf. Tighten the
captive screw on the handle.
6.
Repeat the above steps for each rectifier module being
installed in the system.
7.
After the rectifier modules are physically installed in the
mounting shelf(s), they are ready for operation
immediately after power is supplied to them.
8.
Certain functions (i.e. rectifier current limit, rectifier
addressing) may require adjustment when adding or
replacing a rectifier module. Refer to “Rectifier Current
Limit” on page 8 and the Power System documentation
for instructions.
Spec. No: 1R482000E3
Model No: R48-2000e3
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.
10
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Rectifier Fault Symptoms and Troubleshooting
The fault indicators that can be displayed by the rectifier are as follows.
Refer to Table 7 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
Table 7.
Rectifier Module Troubleshooting
Symptom
Power Indicator
(Green) Off
Protection
Indicator
(Yellow) On
Possible Cause(s)
Suggested Action(s)
No input voltage.
Make sure there is input voltage.
Internal input fuse open.
Replace the rectifier module.
AC input voltage outside
the normal range.
Correct the AC input voltage to within the acceptable
range.
PFC over voltage.
Replace the rectifier module.
Moderate load sharing
imbalance.
Check if the rectifier module is properly seated in the
shelf. If this does not correct the fault, replace the
rectifier module.
Rectifier module not
inserted into the slot
completely.
Remove and properly insert the rectifier module.
Rectifier module 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
3. Lower the ambient temperature or relocate the heat
too high or rectifier
module inlet too close to a source.
heat source.
Protection
Indicator
(Yellow)
Flashing
Alarm
Indicator
(Red) On
Alarm Indicator
(Red) Flashing
Spec. No: 1R482000E3
Model No: R48-2000e3
Rectifier module
communication failure.
Check the communication cables.
Remove and properly insert the rectifier module.
Output over-voltage
shutdown. Severe load
sharing imbalance.
Internal output fuse open.
Remove the rectifier module from its shelf and then
reinstall after 30 seconds. If rectifier module fails to
start or shuts down again; replace the rectifier module.
Rectifier module addresses
Replace the rectifier module.
contradictory.
Fan not operating (rectifier
Replace the fan.
module shuts down).
11
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Replacement Procedures
Limit” on page 8 and the Power System documentation
for instructions.
Rectifier Module Replacement
9.
Rectifier modules can be inserted or removed with power applied
(hot swappable).
Note: Each rectifier module locks into a module mounting shelf by
means of a latch located on the bottom of the module. The
latch and rectifier module handle are interactive. Pushing the
handle up into the module’s front panel causes the latch to
extend to the locking position; pulling the handle down out
from the module’s front panel causes the latch to retract. See
Figure 6.
Danger
Warning
DANGER! Take care when removing a rectifier module
that was in operation, as rectifier module 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 module. NEVER
hold the handle in the closed position when installing a
rectifier module into a shelf.
PROCEDURE
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.
Rectifier Fan Replacement
Each rectifier uses a fan (P/N: 32010474) for cooling. If fan
replacement should become necessary, perform the following
procedure.
Refer to Figure 7 as this procedure is performed.
Warning
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.
WARNING! 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.
Note: Refer to Figure 6 as this procedure is performed.
1.
After the rectifier modules 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.
PROCEDURE
1.
Loosen the captive screw on the module’s handle. Pull
the handle down out from the module’s front panel (this
will also retract the latch mechanism). See Figure 6.
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.
3.
Grasp the handle and pull firmly to remove the module
from the shelf.
Remove the rectifier from the shelf. Refer to a previous
procedure for step-by-step instructions.
3.
4.
Place the replacement rectifier module into the
mounting position without sliding it in completely.
Place the rectifier on a static-safe work surface. Connect
an approved grounding strap to your wrist for the
remainder of this procedure.
5.
Loosen the captive screw on the module’s handle. Pull
the handle down out from the module’s front panel (this
will also retract the latch mechanism). See Figure 6.
4.
On this rectifier; remove the front panel by removing the
three (3) screws securing the front panel to the chassis.
5.
For proper orientation of the new fan, observe the
location of the fan wires and the fan rotation and air flow
arrows on the old fan.
6.
Carefully remove the fan from the rectifier chassis and
unplug the fan power cable from the printed circuit card.
7.
Plug the power cable of the replacement fan into the
connector on the printed circuit card. Carefully slide the
replacement fan into the rectifier chassis (ensure the fan
wires and fan rotation and air flow arrows match the
orientation of the old fan).
2.
6.
Push the module completely into the shelf.
7.
Push the handle up into the module’s front panel. This
will lock the module securely to the shelf. Tighten the
captive screw on the handle.
8.
Certain functions (i.e. rectifier current limit, rectifier
addressing) may require adjustment when adding or
replacing a rectifier module. Refer to “Rectifier Current
Spec. No: 1R482000E3
Model No: R48-2000e3
12
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
Figure 7. Fan Replacement
8.
Note that the fan has four holes in the front corners and
that the faceplate has three tabs. Carefully slide the
faceplate into position, aligning the fan holes with the
faceplate tabs. Secure the faceplate to the rectifier
chassis with the three (3) screws previously removed.
9.
Replace the rectifier into the shelf. Refer to the previous
procedure for step-by-step instructions.
10. When the fan starts, check to ensure that it is providing
front-to-back airflow. If air direction is wrong,
immediately remove the rectifier from the shelf. Repeat
previous steps to check fan orientation, and correct as
necessary. Reinstall the rectifier and again check for
proper airflow.
Align holes in fan with
tabs on faceplate.
11. Enable the external alarms, or notify appropriate
personnel that this procedure is finished.
Fan
12. Ensure that there are no local or remote alarms active on
the system.
Spec. No: 1R482000E3
Model No: R48-2000e3
13
Faceplate Mounting
Screws (3)
Faceplate
Code: UM1R482000E3
Revision F, July 20, 2015
NetSure™ Rectifier Module
User Manual, UM1R482000E3 (Revision F, July 20, 2015)
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
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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
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Spec. No: 1R482000E3
Model No: R48-2000e3
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.
Code: UM1R482000E3
Revision F, July 20, 2015