Emerson NetSure 721NPBB User Instructions

Emerson NetSure 721NPBB User Instructions

-48v dc power system
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NetSure
-48V DC Power System
User Instructions, UM582127000 (Issue AD, January 20, 2014)
Specification Number: 582127000
Model Number: 721
NPBB
Main Bay
Supplemental Bay
Main Bay
Supplemental Bay
(E/W Spec. No. 588705000 Module Mounting Shelves)
(E/W Spec. No. 588705300 Module Mounting Shelves)
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Summary of Contents for Emerson NetSure 721NPBB

  • Page 1 ™ NetSure -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Specification Number: 582127000 Model Number: 721 NPBB Main Bay Supplemental Bay Main Bay Supplemental Bay (E/W Spec. No. 588705000 Module Mounting Shelves) (E/W Spec. No. 588705300 Module Mounting Shelves)
  • Page 2 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) This page is intentionally blank. Spec. No: 582127000 Code: UM582127000 Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 3: Table Of Contents

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Table of Contents Admonishments Used in this Document ........................ ii Important Safety Instructions ..........................iii General Safety ................................iii Voltages .................................iii Battery ...................................iii Personal Protective Equipment (PPE) ........................iv Hazardous Voltage ..............................iv Handling Equipment Containing Static Sensitive Components .................iv Static Warning ..............................
  • Page 4: Admonishments Used In This Document

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) 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! Warns of a potential hazard the reader may be exposed to that could result in death or serious injury if not avoided.
  • Page 5: Important Safety Instructions

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Important Safety Instructions General Safety DC Input Voltages DANGER! DANGER! This system may operate from 400V DC input YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. voltage capable of producing fatal electrical shock. DC Danger Danger input power must be completely disconnected from the...
  • Page 6: Personal Protective Equipment (Ppe)

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) WARNING! A battery can present a risk of electrical FOR THESE REASONS, IT IS OF CRITICAL IMPORTANCE shock and high short circuit current. Servicing of THAT YOU READ THESE INSTRUCTIONS AND FOLLOW Warning batteries should be performed or supervised only by THEM EXACTLY.
  • Page 7: Static Warning

    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.
  • Page 8 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) This page is intentionally blank. Spec. No: 582127000 Code: UM582127000 [vi] Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 9: System Overview

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) System Overview Customer Documentation Package This power system is designed to power a load while charging a This document (UM582127000) provides User Instructions for positive grounded battery. This power system is capable of NetSure™...
  • Page 10: Operating Procedures

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) ESTOP Function Module Mounting Shelf (Spec. No. 588705000) If an ESTOP switch is wired to the ACU+ IB2 Interface Board, The system may contain one or more Spec. No. 588705000 customer-furnished system ground applied to terminal DI8+ module mounting shelves, each of which houses up to six (6) activates the ESTOP function.
  • Page 11 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 1. Circuit Card Locations 4-Row Cabinet Shown, Optional EIB (Main Bay Only) Others Similar (ACU+ Extended Interface Board) (Front Door Removed in (located on inside side panel) Illustration for Clarity) IB2 (Main Bay Only) (ACU+ Interface Board)
  • Page 12 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) System Interface Circuit Card The system interface circuit card contains test points to externally monitor bay voltage and bay load. Refer to Figure Figure 2. System Interface Circuit Card Bay Load Shunt Scale List 21, 1-Row Cabinet 800A / 25mV...
  • Page 13 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Optional LVD Driver Circuit Card The optional LVD driver circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 3.
  • Page 14 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Optional LVD Driver Lite Circuit Card The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 4.
  • Page 15 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Optional Manual Battery Disconnect Circuit Card (Main Bay Only) The optional manual battery disconnect circuit card contains a manual battery disconnect switch and indicator. Refer to Figure Figure 5.
  • Page 16 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) SM-DU Circuit Card The SM-DU is used in supplemental bays in place of ACU+ controller. The SM-DU monitors the bay and reports to the controller. The controller sends commands to the SM-DU to fulfill battery management and load control functions according to the received data.
  • Page 17: Maintenance

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Adding a Rectifier or Converter Module to an Existing Maintenance Module Mounting Shelf Spec. No. 588705300 System Maintenance Procedures To increase system current capacity, a rectifier module can easily It is recommended to perform the maintenance procedures listed be added to an existing module mounting shelf Spec.
  • Page 18 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) 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. Repeat the above steps for each module being installed in the system. After the modules are physically installed in the mounting shelf(s), they are ready for operation immediately after power is supplied to them.
  • Page 19: Installing A Field Expansion Module Mounting Shelf Spec. No. 588705000

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Installing a Field Expansion Module Mounting Shelf Hardware build-up for these connections are: 1/4-20 x 1" bolt, Spec. No. 588705000 1/4" Belleville lock washer, DANGER! Adhere to the “Important Safety Instructions” 1/4"...
  • Page 20 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 8. Installing a Field Expansion Module Mounting Shelf Spec. No. 588705000 (cont’d on next page) Front View Rear View (Install Expansion (Remove Rear Shield from Module Mounting Shelf) Module Mounting Shelf and Shelf Above It)
  • Page 21 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 8. Installing a Field Expansion Module Mounting Shelf Spec. No. 588705000 (cont’d from previous page) Rear View Completed View (Install Output Busbars from Kit) Expansion Shelf Expansion Shelf...
  • Page 22 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 9. ACU+ CAN Bus, Module Mounting Shelf Spec. No. 588705000 Distribution Cabinet Wire Harness Slate and Slate/White Wires Brown and Brown/White Wires These cables are factory connected.
  • Page 23: Installing A Field Expansion Module Mounting Shelf Spec. No. 588705300

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Installing a Field Expansion Module Mounting Shelf module mounting shelf and the studs on the shelf above it. Secure these busbars to the expansion module Spec. No. 588705300 mounting shelf with the hardware provided with the DANGER! Adhere to the “Important Safety Instructions”...
  • Page 24 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 10. Installing a Field Expansion Module Mounting Shelf Spec. No. 588705300 1. Remove busbar rear shield from existing rectifier/converter shelves. Remove the cut-out panel from the busbar rear shield. Busbar Rear Shield Cut-Out Panel 2.
  • Page 25 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 11. ACU+ CAN Bus, Module Mounting Shelf Spec. No. 588705300 Distribution Cabinet Wire Harness Exploded View Shown to Illustrate Wire Connections Only Slate and Slate/White Wires Existing Module Brown and Mounting Shelf...
  • Page 26: Changing The Acu+ Lvd Control Level For A Contactor

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Changing the ACU+ LVD Control Level for a and save a copy of the configuration file. This file can be used to restore the ACU+ Controller settings, if required, at a later date. Contactor •...
  • Page 27 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) are removed or fail it will take several seconds for the individual set PROCEDURE points to the remaining rectifiers or converters to be reset. In the With the Main screen displayed, press ENT to go to the example given, if one rectifier is removed the current limit set Main Menu.
  • Page 28: Replacement Information

    NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Navigate to “Clear Comm Fail”. Press ENT. “Yes” If a password screen opens, a password must be entered highlights. to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this Press ENT to select the operation.
  • Page 29 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 12. Installation of Safety Fuse Covers can change the identification number, see “Configuring the ACU+ Identification of Rectifiers” or “Configuring the ACU+ Identification Safety Cover Safety Cover of Converters”...
  • Page 30 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) fuseholder in firmly until fully seated in the distribution Remove the fuse carrier from the mounted fuseholder body by pulling it straight out. Hold the fuseholder body panel.
  • Page 31 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Replacing a Bullet Nose Circuit Breaker Remove the fuse carrier from the mounted fuseholder body by grasping its handle and pulling straight out. PROCEDURE Remove the open fuse from the fuse carrier and replace it Note: Refer to Figure 14...
  • Page 32 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) rating. Ensure that a plastic safety cover is installed on Close the fuse case. the alarm fuse. Push the fuse case securely back into the mounted fuse block.
  • Page 33 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Install the replacement circuit breaker into its mounting trip/mechanical trip or electrical trip only). Orient the circuit breaker over its mounting location. Re-attach the position and secure with the hardware previously alarm wiring and shunt wiring (if applicable) to the back removed.
  • Page 34 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 17. Replacing a GJ/218 Circuit Breaker (1-Pole) (cont’d on next page) INSTALLING CIRCUIT BREAKER Alarm jumper connector. Holes to route shunt jumper through (if applicable). 1/4"...
  • Page 35 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 17. Replacing a GJ/218 Circuit Breaker (2-Pole, 3-Pole, 4-Pole) (cont’d from previous page) Alarm jumper connectors. INSTALLING CIRCUIT BREAKER Holes to route shunt jumper through (if applicable). 2-pole breaker shown.
  • Page 36 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 18. GJ/218 Circuit Breaker Wiring Diagram (List AC and AD) Spec. No: 582127000 Code: UM582127000 [28] Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 37 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 19. GJ/218 Circuit Breaker Wiring Diagram (List BC and BD) Spec. No: 582127000 Code: UM582127000 [29] Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 38 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Carefully label the connectors plugged into the circuit Circuit Card Replacement Procedures card. These connectors must be plugged into the same Warning! Circuit cards used in this power system connectors on the replacement circuit card.
  • Page 39 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) 17. Enable the external alarms, or notify appropriate personnel that this procedure is finished. 18. Ensure that there are no local or remote alarms active on the system. Figure 20.
  • Page 40 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Remove the screws securing the circuit card and remove SM-DU Circuit Card Replacement (Supplemental Bays Only) the circuit card from the distribution cabinet. PROCEDURE In this step, ensure you do not intermix the old and Performing this procedure may activate external alarms.
  • Page 41 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 21. SM-DU Circuit Card Replacement (Supplemental Bays Only) SM-DU SM-DU Spec. No: 582127000 Code: UM582127000 [33] Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 42 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) the wire end with electrical tape. Repeat for each wire to IB2 (ACU+ Interface Board) and Optional EIB (ACU+ Extended Interface Board) Replacement (Main Bay Only) be removed.
  • Page 43 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 22. IB2 (ACU+ Interface Board) Connector Locations IB2 Board Assembly J3-J9: Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs. Spec. No: 582127000 Code: UM582127000 [35] Model No: 721 Issue AD, January 20, 2014...
  • Page 44 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 23. EIB (ACU+ Extended Interface Board) Connector Locations Optional EIB Interface Board Assembly Optional EIB Interface Board (Top View) J5-J9 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs.
  • Page 45 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Unplug all connectors plugged into the circuit card. SM-DU+ and Shunt Interface Assembly Replacement Remove the screw securing the SM-DU+ and Shunt PROCEDURE Interface Assembly to the bottom of the distribution Performing this procedure may activate external alarms.
  • Page 46 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 24. SM-DU+ and Shunt Interface Assembly Connector Locations SM-DU+ and Shunt Interface Board TB1 - TB2 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs. SM-DU+ Shunt Interface Board Spec.
  • Page 47 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Carefully label the connectors plugged into the circuit Optional LVD Driver and LVD Driver Lite Circuit Card Replacement card. These connectors must be plugged into the same connectors on the replacement circuit card.
  • Page 48 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 25. Optional LVD Driver Circuit Card Connector Locations J1, J2, J3 To LVLD contactor, uses ACU+ DO NOT change a Low Voltage LVD1 control setting (Level 1). Load Disconnect contactor to LVD Control Level 2 (LVD2) if J4, J5, J6...
  • Page 49 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 26. Optional LVD Driver Lite Circuit Card Connector Locations DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 (LVD2) if the system is furnished with a Low Voltage Battery Disconnect contactor.
  • Page 50 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 27. Optional Manual Battery Disconnect Circuit Card Connector Optional Manual Battery Disconnect Circuit Card Replacement Locations PROCEDURE 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 future alarms associated with this system while the procedure is being...
  • Page 51 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) washer, 3/8” hardened flat washer, 2-places. Torque to Locate the in-line FA/CBA connector located near the back of the panel, and separate the connector halves. 180 in-lbs.) Refer to Figure 28 and remove the hardware securing the...
  • Page 52 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 28. Replacing a Distribution Panel Battery Busbar Ground Busbar Hardware Hardware Battery Distribution Distribution Panel Panel Distribution Panel Hardware Hardware Load Distribution Ground Busbar Panel Hardware System Load Distribution Busbar...
  • Page 53 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Disconnect the wiring to the contactor by unplugging the Replacing a Battery or Load Disconnect Contactor quick disconnects. Danger! All sources of AC and DC power must be Note the orientation of the contactor to ensure the completely disconnected from this power system Danger...
  • Page 54 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 29. Replacing a Battery Disconnect Contactor in a 1-Row Distribution Cabinet 5/16-18 x 1” Bolt Battery Disconnect 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer Contactor (concave side of Belleville Lock Washers face each other)
  • Page 55 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 30. Replacing a Battery Disconnect Contactor in a 2, 3, or 4-Row Distribution Cabinet 1/2-13 x 1-1/4” Bolt 1/2" Belleville Lock Washer 1/2" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 1/2"...
  • Page 56 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 31. Replacing a Load Disconnect Contactor in a 1-Row Distribution Cabinet 5/16-18 x 1” Bolt 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer Load (concave side of Belleville Disconnect Lock Washers face each other) Contactor...
  • Page 57 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) Figure 32. Replacing a Load Disconnect Contactor in a 2, 3, or 4-Row Distribution Cabinet Components removed in Load Disconnect illustration for clarity only. Contactor 5/16-18 Nut 5/16"...
  • Page 58 NetSure ™ -48V DC Power System User Instructions, UM582127000 (Issue AD, January 20, 2014) This page is intentionally blank. Spec. No: 582127000 Code: UM582127000 [50] Model No: 721 Issue AD, January 20, 2014 NPBB...
  • Page 59: Netperform™ Optimization Services

    NetPerform™ Optimization Services At Emerson Network Power, we understand the importance of reliable equipment – it’s critical to both your business and your bottom line. That is why we offer a wide array of services to meet all of your network infrastructure needs.
  • Page 60 Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Powe r, 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.

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