1

Surge Protect Discharge

For
Flexi Power Rectifier
Quick Start Guide

Emerson Network Power Co., Ltd.

http://www. emersonnetworkpower.com.cn

Manual Version: 01

Surge Protect Discharge for FPRA Quick Start Guide

 2

Manual Number: 03370500100

Manual Issue: 1.0
Manual Status: Standard
Release Date: Sep 2008

Copyright 2008 Emerson Network Power Co., Ltd.

All rights reserved

Published in China
This document, and the information it contains, are the property of Emerson
Network Power Co., Ltd, and are protected by law. Both must be held in strictest
confidence at all times. Emerson Network Power grants no license or right to
copy, use or disclose either, expressly or by implication.

Disclaimer

This document and the information contained herein are provided on an "AS
IS" basis. Emerson Network Power may make improvements or changes in
this documentation, at any time and without notice and as it sees fit. The
information in this documentation was prepared by Emerson Network Power
with reasonable care and is believed to be accurate. However, Emerson
Network Power shall not assume responsibility for losses or damages
resulting from any omissions, inaccuracies, or errors contained herein.

Surge Protect Discharge for FPRA Quick Start Guide

 History 3

History

Date Version Author Change Note No./Notes

02/09/2008 01 David Cao First release

Surge Protect Discharge for FPRA Installation Manual

 Table of contents 4

Table of contents
History...................................................................................................................3
Table of contents ..................................................................................................4
List of figures ........................................................................................................4
List of tables..........................................................................................................4
List of terms ..........................................................................................................5
Preface .................................................................................................................7
SPD installation.....................................................................................................9
SPD replacement................................................................................................17
Appendix Tools and Torques ...........................................................................19

List of figures
Figure 1 PDA rear internal chassis layout ................................................................ 9
Figure 2 Connecting the SPD 3Y.......................................................................... 13
Figure 3 Connecting the AC terminal block 3Y................................................... 14
Figure 4 AC connection with the SPD - 3Y............................................................. 15
Figure 5 Removing the damaged OVP module from the SPD ............................ 17
Figure 6 Fitting a new OVP module to the SPD .................................................... 18

List of tables
Table 1 Reference documents.................................................................................... 7
Table 2 Configurations of AC connection with the SPD ....................................... 10
Table 3 Schematic diagram of AC connection with the SPD............................... 12
Table 4 Tools and torques required for installation ............................................... 19

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 List of terms 5

List of terms

A Ampere
AC Alternative current
AWG American Wire Gauge
BAT Battery
BR Battery Return
BTS Base Transceiver Station
CB Circuit Breaker
CSA Cross Section Area
CU Control unit
DC Direct current
EMC Electromagnetic Compatibility
ESD Electrostatic Discharge
FPRA Flexi Power Rectifier
GND Ground
GUI Graphical User Interface
IE Internet Explorer
IP Ingress Protection
IP Internet Protocol

L Live cable from the AC mains

LAN Local Area Network

LED Light Emitting Diode
LVD Low Voltage Detection
MAC Media Access Control
MCB Micro Circuit Breaker
N Neutral cable from the AC mains

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 List of terms 6

PC Personal Computer
PCB Printed Circuit Board
PDA Power Distribution Assembly
PE Protective earth
PSU Power Supply Unit
SPD Surge Protect Discharge
V Volt
VPN Virtual Private Network
1 Single-phase AC type
3Y 3-phase star AC type
3 3-phase delta AC type

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 Preface 7

Preface

About this guide

This quick start guide is for quick installation or an overview of the SPD. Thus
only the three-phase star AC connection with SPD is described in this guide.
User shall refer to the main SPD user manual (Emerson file No. 03370500080)
for more details about the other AC connections.

SPD Introduction
The Flexi Power Rectifier (FPRA, Emerson part number AA25020L) is an up
to 6kW output power AC rectifier package. The Surge Protect Discharge
(SPD, Emerson part number AA25130L) is used to prevent the damages to
the FPRA that caused by input over voltage or surge.
The SPD consists of three same OVP modules that used between live cables
and neutral cable from the AC mains; one OVP module that used between
the neutral cable from the AC mains and the earth; and one remote signaling
contact.

Reference documents
The reference documents of the SPD contains:

Table 1 Reference documents

Document Emerson Network Power File No.

Internal product specification System / PDA 41970005110

Internal product specification Rectifier 41970004980

Surge Protect Discharge for Flexi Power

Rectifier User Manual (main SPD user 03370500080
manual)

- To be continued -

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 Preface 8

Table 1 Reference documents

Flexi Power Rectifier - User Manual 03370500090

Flexi Power Rectifier- Installation Manual 03370500070

Surge Protect Discharge for Flexi Power

03370500100
Rectifier Quick Start Guide (this manual)

Flexi Power Rectifier Quick Start Guide 03370500110

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 SPD installation 9

SPD installation
Warning: The AC power supply must be switched off prior to any access of the AC cable.
Note: The 3-phase star AC connection with SPD is for illustration herein.
Refer to Appendix Tools and Torques for each installation step.

Figure 1 shows the PDA rear internal chassis layout.

PDA rear cover

SPD DIN Rail

AC terminal block

D
E

SPD ground clamp

SPD sensor
connection
AC ground clamp
PDA earth cable C

B
Strain-relief
Rear cover
retention cable

A
Figure 1 PDA rear internal chassis layout

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 SPD installation 10

Table 2 Configurations of AC connection with the SPD

AC Terminals connection Short link available (1) AC terminal block SPD

type configuration
Configuration (2)
(3)
AC SPD AC terminal Chassis
mains block

N/A L1 6 N/A L1 for three-phase Short terminals 1,2,3 Short terminals

and 4,5,6 respectively L1, L2, L3
L L2 5 N/A L2 for three-phase

N/A L3 4 N/A L3 for three-phase

1
N N 2 N/A N for three-phase star

PE N/A N/A AC ground clamp N/A

N/A N/A SPD ground clamp SPD ground link

L1 L1 5 N/A L1 for three-phase Short terminals 1,2 N/A

and 3,4 and 4,5
L2 L2 3 N/A L2 for three-phase respectively

3 L3 L3 1 N/A L3 for three-phase

N/A N N/A SPD ground clamp SPD ground link

PE N/A N/A AC ground clamp N/A

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 SPD installation 11

Table 2 Configurations of AC connection with the SPD

AC Terminals connection Short link available (1) AC terminal block SPD

type configuration
Configuration (2)
(3)
AC SPD AC terminal Chassis
mains block

L1 L1 6 N/A L1 for three-phase Short terminals 1,2,3 N/A

L2 L2 5 N/A L2 for three-phase

L3 L3 4 N/A L3 for three-phase

3Y
N N 2 N/A N for three-phase star

PE N/A N/A AC ground clamp N/A

N/A N/A SPD ground clamp SPD ground link

Note: (1) The short link names listed herein are in accordance with the actual labels on the short links.
(2) The AC terminal block should be configured before the AC connection. User shall refer to section 3.4 in Flexi Power Rectifier
Installation Manual (Emerson file No.03370500070) for more details.
(3) Refer to Figure 1 for the corresponding clamps.

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 SPD installation 12

Table 3 Schematic diagram of AC connection with the SPD

AC Schematic diagram Configuration of AC

Type terminal block

Short terminals 1,2,3

AC Terminal Block
SPD 1 2 3 4 5 6

L1 L2 L3 N

3Y

PE L1 L2 L3 N
AC Mains

Short terminals 1,2,3;

AC Terminal Block
SPD 4,5,6 respectively
L1 L2 L3 N 1 2 3 4 5 6

PE L N
AC mains

AC Terminal Block
Short terminals 1,2; 3,4;
5,6 respectively
SPD 1 2 3 4 5 6

L1 L2 L3 N

PE L1 L2 L3
AC mains

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 SPD installation 13

1.1 Detach the cable strain-relief from the chassis by loosening the screw
A in Figure 1.
1.2 Detach the AC ground clamp and SPD ground clamp from the chassis
by loosening the screws B and C in Figure 1.
1.3 Fit the PE cable from the AC mains into the AC ground clamp.
1.4 Fit the live cables from the AC mains and the bare end of L line short
links into the terminals L1, L2 and L3 on the SPD respectively
referring to the diagram of 3Y AC connection in Table 2 and Table 3
(see Figure 2).
1.5 Fit the neutral cable from the AC mains and the flat end of N short link
into terminal N on the SPD referring to the diagram of 3Y AC
connection in Table 2 and Table 3 (see Figure 2).

N short link

L3

L2

L3 short link

L2 short link
L1

L1 short link

Figure 2 Connecting the SPD 3Y

1.6 Fit the ground cable link into the SPD ground clamp, and the other end

into the SPD ground terminal on the SPD referring to the diagram
of 3Y AC connection in Table 2 and Table 3.

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 SPD installation 14

1.7 Secure the AC ground clamp back into its position on the chassis,
tightening the screw B (refer to Figure 1).
1.8 Secure the SPD ground clamp back into its position on the chassis,
tightening the screw C in Figure 1.
1.9 If required, detach the AC terminal block from the chassis by loosening
screws D and E in Figure 1. This will provide a better view of the AC
terminal block connections.
1.10 Connect the L1, L2 and L3 line short links to terminals 6, 5, 4 on the
AC terminal block respectively referring to the diagram of 3Y AC
connection in Table 2 and Table 3 (see Figure 3).
1.11 Connect the N line short link to terminal 2 on the AC terminal block
referring to the diagram of 3Y AC connection in Table 2 and Table 3
(see Figure 3).

N short link

L3 short link

L2 short link

L1 short link

Figure 3 Connecting the AC terminal block 3Y

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 SPD installation 15

1.12 Connect the SPD sense cable to the SPD remote signaling contact.
1.13 Secure the SPD to the DIN Rail by locating the grounding side bottom
slot of the SPD onto the DIN Rail and pressing down on the SPD until
it locks in position.
1.14 Refit AC terminal block if removed from chassis, tightening the screws
D and E in Figure 1.
1.15 Connect the SPD sense cable to the PDA sense connection, and
restrain the cable to position F on the chassis in Figure 1.
1.16 Restrain the AC cable on the socket by fitting the Strain-relief,
tightening the screw A in Figure 1.
Figure 4 shows the PDA rear layout after completing the 3-phase star AC
connection with the SPD.

SPD ground cable

N SPD sense cable

L3 L3 short link

L2 L2 short link

L1
L1 short link

PE of AC mains N short link

Figure 4 AC connection with the SPD - 3Y

1.17 Replace the PDA rear cover referring to section 3.4 in Flexi Power
Rectifier Installation Manual (Emerson File No. 03370500070).

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 SPD installation 16

CAUTION: After installation of the SPD kit has been completed, the installer should
check the installation against the steps outlined within this document, supported
by a multi-meter to check for wiring continuity. Its strongly suggested that the
insulation test (2.5kV Hi-pot) is carried out.

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 SPD replacement 17

SPD replacement
Warning: The AC power supply must be switched off prior to any access of the SPD.

2.1 Hold the two sides of the damaged OVP module and pull it out from
the SPD base (see Figure 5).

Figure 5 Removing the damaged OVP module from the SPD

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 SPD replacement 18

2.2 Fit the new module into its position on the SPD base (see Figure 6).

Figure 6 Fitting a new OVP module to the SPD

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 Appendix 19

Appendix Tools and Torques

********************************************************************
Refer to the table below for the tools and torques required for each installation step:
********************************************************************

Table 4 Tools and torques required for installation

Step Tool Usage Torque (N.m)

1.1 TORX screwdriver (T25) Loosen screw --

1.2 TORX screwdriver (T25) Loosen screw --
1.3 Flat screwdriver Tighten screw 1.5
1.4 Cross screwdriver Tighten screw 4.5
1.5 Cross screwdriver Tighten screw 4.5
1.6 TORX screwdriver (T25) Tighten screw 4.5
1.7 TORX screwdriver (T25) Tighten screw 2.0
1.8 TORX screwdriver (T25) Tighten screw 2.0
1.9 TORX screwdriver (T25) Loosen screw --
1.10 Flat screwdriver Tighten screw 1.5
1.11 Flat screwdriver Tighten screw 1.5
1.12 Manual Connection Fit
1.13 Manual Install the SPD Fit
1.14 TORX screwdriver (T25) Tighten screw 2.0
1.15 Manual Connection Fit
1.16 TORX screwdriver (T25) Tighten screw 2.0
1.17 TORX screwdriver (T10) Tighten screw 0.8
2.1 Manual Remove the OVP --
2.2 Manual Install the OVP Fit

Surge Protect Discharge for FPRA Installation Manual