DIRECTIONS FOR USE

POWER SUPPLY SYSTEM NetSure 501, BZA 108 35, 48 V DC

Emerson Network Power Energy Systems AB 2007 All rights reserved

1553-BZA 108 35 Uen Rev B 2007-01-19 1(27)

DIRECTIONS FOR USE BZA 108 35

The contents of this document are subject to revision without notice due to continued progress in methodology, design, and manufacturing.

Emerson Network Power Energy Systems AB SE 141 82 Stockholm Sweden

Tel. +46 8 721 6000 Fax. +46 8 721 7177 www.emersonenergy.com

1553-BZA 108 35 Uen Rev 2007-01-19 2(27)

DIRECTIONS FOR USE BZA 108 35

Contents
1 2 3 4
4.1 4.2 4.3 4.4 4.5 4.6

Introduction Function Configurations Units in the system

Rectifier Rectifier subrack Control units Multifunction unit AC distribution AC connection terminals

4 4 5 8
8 10 11 11 12 12

5
5.1 5.2 5.3

Technical data
System Cabinet Rectifier

13
13 13 13

6 7 8
8.1 8.2 8.3 8.4

Installation Start-up and installation test Maintenance

Safety Scheduled maintenance Alarms Fault symptoms and trouble shooting

14 14 14
14 14 15 15

9
9.1 9.2 9.3 9.4 9.5 9.6 9.7

Exchange of units and parts

Exchange of rectifiers Rectifier fan replacement Exchange of distribution circuit-breaker Exchange of contactor Exchange of SCU/ACU Exchange of connector board Exchange of SCU/ACU supply fuses

21
21 22 23 24 25 25 26

10

Abbreviations used in this document

27

1553-BZA 108 35 Uen Rev 2007-01-19 3(27)

DIRECTIONS FOR USE BZA 108 35

Introduction
The NetSure 501 48 V DC power system consists of a stand-alone cabinet, DC-distribution unit, maximum 12 rectifiers of 1700 W, battery connections and a supervision unit.

Function
For the protection of the batteries during a power outage, the load is disconnected at a preset voltage or after a predetermined delay. To prolong the service of some loads at a long power outage, the DC distribution is divided into two branches. One is for normal load and one for priority load, so the disconnection can be made in two steps.

AC Mains
Subrack 2

6 rect.

DU, normal load

Priority Load

~ =
MFU LVD 1 & ICU
Subrack 1

6 rect. LVD 2

~ =
AC terminals
CAN-bus

Shunt Batt. CBs

Ext. Batts.

SCU/ ACU

Figure 1.

Example of system topology.

1553-BZA 108 35 Uen Rev 2007-01-19 4(27)

DIRECTIONS FOR USE BZA 108 35

Configurations
The cabinets can be configured with different numbers of rectifiers, batteryand distribution- circuit-breakers. They are built for overhead cabling.

Extension distribution unit

MFU and Control unit

Rectifier subrack Rectifier subrack

AC distribution unit (optional)

Figure 2.

Example of configuration with overhead cabling.

1553-BZA 108 35 Uen Rev 2007-01-19 5(27)

DIRECTIONS FOR USE BZA 108 35

The Figure 3 and Figure 4 give examples of standard configurations.

Cover panel 2 U AC terminals (if no ACD) MFU (battery CBs, LVDs, normal and prio load CBs R R R R R S/A C/C U/U R

ACD (optional) (BMG 653 39/21) Fire trap

Figure 3. Configuration with single rectifier subrack.

Cover panel 2 U AC teminals (if no ACD) Extension distribution CBs (normal load) Cover panel 2 U MFU (battery CBs, LVDs, normal and prio load CBs) R R R R R R R R R R S/A C/C U/U R R

ACD (option) (BMG 653 39/22) Fire trap

Figure 4. Configuration with double rectifier subracks.

1553-BZA 108 35 Uen Rev 2007-01-19 6(27)

DIRECTIONS FOR USE BZA 108 35

Basic configuration: Cabinet for overhead cabling Maximum 12 rectifiers 1700 W One or two rectifier subracks for maximum 6 rectifiers each MFU including maximum four battery CBs, distribution CBs, LVD contactors, a standard control unit (SCU) and a battery shunt AC terminal unit for maximum 12 rectifiers Battery temperature sensor KET 103 06/1

Options: Advanced control unit (ACU) Cables for battery, distribution, earthing and signalling Cabling materials (lugs, tie wraps, markings) Internal AC distribution unit for maximum 12 rectifiers External AC distribution units Mains cable Lifting eye bolts SAR 201 080/03 Cabinet anchoring material BMY 107 125/1 AC inlet pull-relief clamps Room temperature sensor KET 103 06/1 Spare parts

1553-BZA 108 35 Uen Rev 2007-01-19 7(27)

DIRECTIONS FOR USE BZA 108 35

4
4.1

Units in the system

Rectifier
The rectifier is voltage regulated of a constant power limitation type (1700 W) and designed to meet the most stringent electrical requirements as well as demands for high power density (fan cooling). It can work independently of the control unit, and can share the load actively and control the system voltage.

LEDs

Figure 5.

Rectifier.

4.1.1 LEDs
The front panel has three indicator LEDs. The functions of the LEDs are listed in the table below.
LED Power indicator (green) Normal ON Abnormal OFF Flashing ON Flashing Alarm indicator (red) OFF ON Flashing Cause of Abnormality No AC Mains Supply Rectifier is under control by SCU/ACU AC input over/undervoltage, PFC over/undervoltage and overtemperature Communication with SCU/ACU failure Output overvoltage Fan Failure

Protection indicator (yellow)

OFF

1553-BZA 108 35 Uen Rev 2007-01-19 8(27)

DIRECTIONS FOR USE BZA 108 35

4.1.2 Features
Hot swappable. The rectifier is plug-and-play to live inputs and outputs. Active load sharing. The rectifier uses advanced digital active load sharing technology for minimum load difference between units. Power derating by input voltage. The rectifier will go into power derated mode if the input AC voltage is too low or too high. Power derating by output load. The rectifier will limit its output power constant when the load exceeds the nominal output power. Power derating by temperature. For high temperatures the output load will be gradually reduced. See technical data. Current limiting function. The rectifier has a current limiting function. The current limit can be set from an SCU/ACU. Foldback current limiting function. If a short circuit occurs on the rectifier output terminals, the rectifier will keep its output current at a constant value. When the short circuit fault is cleared, the rectifier will automatically restore to normal operation. Adjustable output voltage. The voltage can be set from an SCU/ACU. Current walk-in. The rectifier can be set from an SCU/ACU to take load gradually in order to reduce the stress on generators, fuses etc. Fan control. The fans speed is controlled according to the rectifier internal temperature. The fan is stopped completely at low temperature and at very low or high input voltage.

4.1.3 Digital Signal Processor (DSP)

The rectifier has a built-in advanced DSP that monitors and controls the operation of the rectifier. The DSP also communicates with an SCU/ACU through a CAN bus. The rectifier can receive commands such as turning on/off, current walk-in on/off signal and high voltage alarm reset signal from an SCU/ACU. An SCU/ACU can adjust the output voltage, overvoltage alarm point, current walk-in time and the current limit of the rectifier. The rectifier reports its output voltage, output current, temperature, current limit setpoint, overvoltage setpoint, on/off status and alarm information to an SCU/ACU in real time. By querying the DSP, an SCU/ACU can get the following data from the rectifier: Input voltage, output voltage, output current, current limit setpoint, temperature of rectifier, and overvoltage setpoint.

1553-BZA 108 35 Uen Rev 2007-01-19 9(27)

DIRECTIONS FOR USE BZA 108 35

By querying the DSP, an SCU/ACU can get the following state information from the rectifier: On/off, protect (input protect, inner DC bus voltage protect; overtemperature), fault (HVSD, fan failure), thermal derating, AC derating, AC failure, and unbalance current. An SCU/ACU can get the following unit information from the rectifier: Address, code, date, SW version and HW version.

4.1.4 Protection functions

Input over/undervoltage protection. The rectifier will shut down and its yellow LED will emit light if the input voltage is outside the range 80 to 305 V AC. An alarm will be sent to the SCU/ACU. Output overvoltage protection. If the rectifier output voltage exceeds a limit that can be set from the SCU/ACU, the rectifier will shut down. If output over voltage occurs two times within 5 minutes, the rectifier can only be restarted manually and its red alarm LED will emit light. An alarm will be sent to the SCU/ACU. Over-temperature protection. The rectifier will limit its power to 50% of rated output power if its internal temperature is higher than 75 C. If the internal temperature reaches 80 C, the rectifier will shut down and its yellow LED will emit light. An alarm will be sent to the SCU/ACU. The alarm will cease and the rectifier will restart when the temperature becomes normal. Communication failure. At communication failure, the rectifier output voltage is reduced to a default value for protection of the battery. The yellow LED will flash and alarm will be sent to the SCU/ACU. Fan alarm. The red LED will flash at a fan fault and the rectifier will stop. Unbalance of Rectifier Output Current. When the output current of the rectifiers in a DC power system is unbalanced, the rectifier that outputs unbalanced current will be identified automatically and its yellow LED will emit light. An alarm will be sent to the SCU/ACU.

4.2

Rectifier subrack

Figure 6.

Subrack for six rectifiers.

The rectifier subrack has space for six rectifiers.

1553-BZA 108 35 Uen Rev 2007-01-19 10(27)

DIRECTIONS FOR USE BZA 108 35

4.3

Control units
The control unit is placed in the multifunction unit. It controls, supervises and communicates with the other units of the power supply system and manages alarm handling, etc. Two control units are available. The standard control unit (SCU) has an LCDdisplay, offers internal supervision and alarm handling, sends external alarm signals over relays and communicates externally via modem with external computer-based supervision systems (EEM, for example) that can be implemented for different maintenance activities. The advanced control unit (ACU) has, in addition to the SCU features, an interface to communicate with supervision modules (SM) for supervision of existing cabinets, AC mains and batteries, for example. It has a Web interface for communication with MS Explorer. For detailed information, refer to USERS GUIDE 5/1553-BMP 903 050 Uen, for the ACU and 5/1553-BMP 903 051 Uen, for the SCU.

4.4

Multifunction unit
+ terminals LVD contactors CB alarm board Connector board

DIN bar for CBs

Figure 7.

MFU.

The unit combines normal and priority distribution circuit-breakers battery CBs, a battery shunt (500 A) and one or two load disconnect contactors (125 and 500 A). The control unit (SCU/ACU) and the connector board are also mounted here.

1553-BZA 108 35 Uen Rev 2007-01-19 11(27)

DIRECTIONS FOR USE BZA 108 35

4.5

AC distribution

R1--------------------------------------------------------R12

L1 L2 L3 N PE Input terminal

Figure 8.

AC distribution unit seen from front.

For cabinets with double rectifier subracks, an AC distribution unit is available. It includes separate circuit breakers for each rectifier.

4.6

AC connection terminals

Figure 9.

Mains terminals.

A unit with maximum four terminal blocks can be delivered for the connection of totally 12 rectifiers.

1553-BZA 108 35 Uen Rev 2007-01-19 12(27)

DIRECTIONS FOR USE BZA 108 35

5
5.1

Technical data
System
Nominal DC voltage 48 V Maximum output current @ 48 V 212 A (with one rectifier subrack) or 425 A (with two rectifier subracks) Operational temperature 5 to +45 C (with hydraulic magnetic circuit-breakers) 5 to +30 C (with thermal/electro magnetic circuit-breakers) Storage temperature Relative humidity 40 to +75 C 5 to 90%

5.2

Cabinet
Building practice Height (incl. top cover and feet) Footprint (with x depth) Weight (fully equipped, without batteries) 23 1250, 1650, 1850, 2050 mm 400 or 600 x 600 mm maximum 150 kg

5.3

Rectifier
See data sheet EN/LZT 145 280 RA

1553-BZA 108 35 Uen Rev 2007-01-19 13(27)

DIRECTIONS FOR USE BZA 108 35

6 7 8

Installation
See INSTALLATION INSTRUCTIONS 1531-BZA 108 35 Uen.

Start-up and installation test

See TEST INSTRUCTIONS 1532-BZA 108 35 Uen.

Maintenance
Adequate knowledge of the power supply system is required. Refer to item 1 to 5 of this document.

8.1

Safety
The document SAFETY RULES 1550-1004 and local safety rules shall be followed when doing maintenance work in the power supply equipment. Measures that require work inside the cabinets or intervention in a unit shall always be carried out by adequately trained personnel with adequate knowledge of the power supply system. When in doubt about an action or how to carry it out, always call for adequately trained personnel. In case it is necessary to work on a live power supply system, the approval for this type of work must be given, based on local regulations governing for example the following areas: General rules for work on live equipment Certification of operatives conducted by certified supervisor Approved tools Customer approval

8.2

Scheduled maintenance
Use a vacuum cleaner to remove dust from the air inlets of the cabinets. Check and test the batteries according to the recommendations of the battery supplier. A scheduled performance test according to the following table shall be performed at least every two years according to item Test of signals and supervision in the document TEST INSTRUCTIONS 1532-BZA 108 35 Uen. Settings according to the document TABLE OF SET VALUES, shall be verified in this test.

A copy of the test result shall be kept in the logbook of the plant.

1553-BZA 108 35 Uen Rev 2007-01-19 14(27)

DIRECTIONS FOR USE BZA 108 35

8.3

Alarms
The different alarm categories used in the power supply system are Critical, Major, Observation and No Alarm. An alarm of category Critical requires immediate action, whatever the time of day or night. An alarm of category Major requires immediate action if it occurs during working-hours, otherwise as soon as the working-hours commence. An alarm of category Observation is an alarm that indicates a temporary state of operation and does not normally require any action. However, if the alarm persists for more than 20 hours, it must be investigated. If an alarm has category No Alarm it means that the alarm is deactivated and will not be shown in the display of the SCU/ACU.

8.3.1 Alarm categories

8.3.2 Procedure in case of alarm

Enter in the logbook of the power supply system all observations made at the moment of failure, such as date, time, system voltage and rectifier load. Enter also what alarm(s) are shown and any external disturbance such as thunderstorm or mains failure. Trace activated alarms by means of the alarm survey of the respective unit and the item, which describes what actions to take on the respective alarm.

8.4

Fault symptoms and trouble shooting

For system alarms, see USERS GUIDE 1553-BMP 903 051 Uen for the SCU and 1553-BMP 903 050 Uen for the ACU.

8.4.1 System alarms

Alarm on the SCU display Alarms Blocked Load Fuse Alarm Rect Not Respond

Alarm on the ACU display Alarm Blocked

Cause

Suggestion

The outgoing alarms are Check why before reconnecting the alarms. blocked from the SCU/ACU. Find out and eliminate the reason for the tripped circuit breaker before resetting it. Check the connectors and cables for the CAN loop. Exchange the rectifier that does not respond. Exchange the SCU/ACU.

Fuse Alarm One or more distribution circuit-breakers for the load have tripped. CAN Comm Fault There CAN communication is broken.

1553-BZA 108 35 Uen Rev 2007-01-19 15(27)

DIRECTIONS FOR USE BZA 108 35

Alarm on the SCU display LVD 1

Alarm on the ACU display LVD 1 Disconnected

Cause The contactor for the normal load is open because the battery is too deep discharged. The batteries are disconnected at a preset level, in order to protect them from over-discharging. The contactor for the prioritised load is open because the battery is too deep discharged. An LVD contactor is in a wrong state.

Suggestion If there is a mains failure, check that it is not caused by broken supply fuses. If the rectifiers are working, the problem may be that the system load is higher than the rectifier capacity, causing the batteries to discharge. If this is the reason, install more rectifiers. See LVD 1

LVD 2

LVD 2 Disconnected

LVD 1/ LVD Contactor 2 Open Fault Batt Curr High Batt Fuse Alarm

Check the contactor functions.

Abnorm Bat The boost charging curCurr rent exceeds the set max. value. Fuse Alarm Indicates that one or more battery fuses/circuit breakers have blown/tripped or been removed.

Check the settings.

If a battery fuse/circuit breaker has been removed/tripped manually, check with the person that removed/tripped it before reinserting/resetting it. Ensure that there is no fault before doing that. The battery fuse shall be reinserted by adequately trained personnel. Find out and eliminate the reason for the blown/tripped fuse/circuit breaker before swapping/resetting it.

If the battery fuse/circuit breaker is blown/tripped, the reason for the failure probably is overload or short circuit. Self-detect Err Manual Mode Non-Float Status ACU fault Manual Mode SCU/ACU failure.

Exchange the SCU/ACU.

The battery monitoring has Check why before resetting it to automatic. been set to Manual mode in the SCU/ACU. The system is not in Float Charge mode because of: The boost charge is active. The battery test is active. The boost charge will stop automatically. The discharge test will stop automatically. The discharge test will stop automatically. Check that it is not caused by broken supply fuses. Install more rectifiers.

Batt Discharge

The battery test is active. There is a mains failure. The system load is higher than the rectifier capacity, causing the batteries to discharge.

1553-BZA 108 35 Uen Rev 2007-01-19 16(27)

DIRECTIONS FOR USE BZA 108 35

Alarm on the SCU display Curr Discrepancy

Alarm on the ACU display Dis Curr Im

Cause

Suggestion

Check the batteries. The currents from two groups of batteries are not equal. Note: There must be two battery shunts in the system to activate this function. The short time battery test Check the batteries. has failed.

Short Test Fail Batt Test Fail Test Failure

The battery test has failed. Check the float charging level. Check that the load is lower than the capacity of the rectifiers. Check the battery according to the recommendations of the supplier.

Volt Discrepancy Mains Failure Multi-Rect Alarm Maintain Alarm Rectifier Lost

Rect Over Volt Mains Failure

Rectifier overvoltage

See item 8.4.2

All rectifiers have stopped. Check if there is a general mains failure. Check that it is not caused by broken supply fuses. See item 8.4.2 Check the settings of the Maintenance Time Delay See item 8.4.2 If the lost rectifier is to be removed permanently, the alarm must be reset from the SCU/ACU. Check the rectifiers.

Multi-rect fail Two or more rectifiers have stopped. Maintenance Alrm Rectifier Lost The maintenance timer gives alarm The SCU/ACU has detected a reduction in the number of running rectifiers. The output current of a rectifier is outside the average value for all rectifiers. A rectifier output voltage was higher than the rectifier HVSD setting and has shut down. AC input voltage outside the normal range. Rectifier overtemperature protection. Rectifier failure Rectifier protection

Load share Alarm

Rect HVSD

Check the rectifier HVSD setting. Replace the rectifier. See item 8.4.2 See item 8.4.2 See item 8.4.2 See item 8.4.2

Rect AC Fail Rect AC Failure Rect Over Temp Rect Failure Rectifier Failure Rect Protect Rect Protected

1553-BZA 108 35 Uen Rev 2007-01-19 17(27)

DIRECTIONS FOR USE BZA 108 35

Alarm on the SCU display Rect Fan Fails Rect Derated

Alarm on the ACU display Rect Fan Fail Rect Curr limit

Cause Rectifier fan failure. See item 8.4.2.

Suggestion

Rectifier overload. If the batteries are being recharged, the The load is higher than the alarm will cease by itself when the battery rectifier capacity. voltage has increased to the charging level. If the system load is higher than the rectifier capacity, the batteries will discharge. If this is the reason, install more rectifiers. If one or more of the rectifiers are out of order, exchange the faulty rectifiers.

DC Volt Low#1

Under Vol

The distribution voltage has dropped below the preset alarm level, usually initiated because of mains failure.

If there is a mains failure, check if some load could be switched off in order to prolong the operating time of the plant. If there is a rectifier failure, see item 8.4.2. If the system load is too high related to the rectifier capacity, install more rectifiers. If the batteries are being recharged, the alarm will cease by itself when the battery voltage has increased to the charging level.

DC Volt Low#2

Very Under Vol

See DC Volt Low#1/DC Under Voltage The distribution voltage has dropped below the preset alarm level, usually initiated because of mains failure. The system voltage exceeds the preset level. The system voltage exceeds the preset level. The mains voltage is too low. The mains voltage is too low. The mains voltage is too high. The temperature on a temperature sensor exceeds the set value. Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out why they have changed and correct them. Check the set float-, battery- and the overvoltage; if the limits are incorrect, find out why they have changed and correct them. Check the mains voltage. Check the settings of the SCU. See AC Voltage Low#2 Check the mains voltage. Check the settings of the SCU. Check the temperature. Check the settings of the SCU/ACU. If the temperature is OK, exchange the temperature sensor.

DC Volt High#1 DC Volt High#2 AC Voltage Low#2 AC Voltage Low#1 AC Voltage High

Over Voltage

Low Temp Temp Alarm /Low Amb Temp

1553-BZA 108 35 Uen Rev 2007-01-19 18(27)

DIRECTIONS FOR USE BZA 108 35

Alarm on the SCU display Temp High Alarm

Alarm on the ACU display

Cause

Suggestion

High Temp

Check the battery temperature. The temperature on a Check the settings of the SCU/ACU. battery temperature sensor exceeds the set value. If the temperature is OK, exchange the temperature sensor. The temperature on a See High Temp alarm. battery temperature sensor exceeds the set value. The temperature on a room temperature sensor exceeds the set value. Check the room temperature. Check the settings of the ACU. If the temperature is OK, exchange the temperature sensor. Check the cable and the connector of the temperature sensor. Exchange the temperature sensor. Wait for the test to stop automatically. See Mains Failure alarm.

Very hiTemp

High Amb Temp

No Temp Sensor 1 or 2

T Sensor Fault Plan BT AC failure BT Manual BT Short Test Cyclic BC Auto BC Manual BC

The temperature sensor has a fault. Planned battery test in progress. Mains failure.

Manual battery test in proWait for the test to stop automatically. gress. Short battery test in progress. Cyclic boost charge in progress. Wait for the test to stop automatically. Wait for the boost charge to stop automatically.

Automatic boost charge in Wait for the boost charge to stop automatiprogress. cally. Manual boost charge in progress. Wait for the boost charge to stop automatically, or stop it manually.

Charge Pro- The boost charge function The boost charge will be blocked by abnorhibit is blocked. mal conditions in the system. Power Major Power Minor High Load Ab load curr Over Power Digital 1 (to 6) DI 1 to DI 6 Indicate alarms on the digital inputs 1-6. Check the equipment connected to the corresponding input. Indicates Promt alarm (red LED) Indicates Main fail alarm (yellow LED) The system load is higher than the set level. Check the settings.

1553-BZA 108 35 Uen Rev 2007-01-19 19(27)

DIRECTIONS FOR USE BZA 108 35

8.4.2 Rectifier
The usual fault symptoms of the rectifier include: power indicator (green) off, protection indicator (yellow) on, protection indicator (yellow) flashing, alarm indicator (red) on, and alarm indicator (red) flashing.
Symptom Cause No input voltage Power indicator (green) off Input fuse/circuit-breaker fault AC input voltage outside the normal range PFC overvoltage Current sharing function is disabled Suggestion Make sure there is input AC voltage Replace the fuse with a new one of the same model or switch on the circuit-breaker. Check that the AC input voltage is within normal range Replace the rectifier Replace the rectifier

Rectifier overtemperature protection, which is caused by: Protection indicator (yelRemove the obstacle that block Fan blocked low) on the fan Ventilation blocked: the inlet or outlet Remove the objects that blocks blocked the inlet or outlet Ambient temperature too high or rectifier inlet too close to a heater Rectifier not completely inserted into the slot Protection indicator (yel- Rectifier communication failure low) flashing Alarm indicator (red) on Rectifier overvoltage Remove the heater, lower the ambient temperature Insert the rectifier properly Exchange the rectifier for a new one. Remove the rectifier from the DC power system and then reinsert it. Exchange the rectifier for a new one if the alarm continues. Replace the fan

Alarm indicator (red) flash- Fan not running ing

When multiple rectifiers are in parallel connection and the unbalance of current sharing among them is higher than 3 %, check if the communication cables are correctly connected. If the current sharing is still unsuccessful after the correction, replace the rectifier of which the current sharing is out of range.

1553-BZA 108 35 Uen Rev 2007-01-19 20(27)

DIRECTIONS FOR USE BZA 108 35

9
9.1

Exchange of units and parts

To order spare parts, contact Emerson Network Power Energy Systems AB.

Exchange of rectifiers
1. Loosen the fixing screw of the handle of the faulty rectifier. The handle will pop out and release the latch locking the rectifier to the subrack.

Fixing screw Handle

Figure 10. Rectifier handle. 2. Pull out the rectifier unit and remove it. 3. Make sure the handle of the new rectifier unit is locked in its socket with the fixing screw.

Latch

Figure 11. Locking latch. 4. Insert the new rectifier unit. Push it into its slot until the latch blocks the way. The latch is set to block the way with the purpose of charging the rectifier output filter slowly via a charging circuit, as the DC terminals may get damaged by a spark at a direct connection.

1553-BZA 108 35 Uen Rev 2007-01-19 21(27)

DIRECTIONS FOR USE BZA 108 35

5. Loosen the fixing screw of the handle, lift the handle, and the latch will withdraw into the rectifier. 6. Continue to push the rectifier into the slot completely. 7. Push the handle into its socket and fasten the fixing screw to lock the rectifier. Now the rectifier is fixed to the slot by the latch. The green LED emits light and the fan will start.

9.2

Rectifier fan replacement

If the fan does not work because it is faulty, exchange it for a new one. 1. Remove the rectifier according to item 9.1.

Fan cable plug

Fixing screw and fan holder Fan Front cover

Fixing screws

Figure 12. Fan replacement. 2. Loosen the three screws fixing the front cover to the chassis. 3. Lift out the front cover from the chassis and observe the orientation of the fan and its wires. 4. Unplug the power cable of the fan and remove the front cover with the fan. 5. Remove the fan from the front cover by removing its two fixing screws and holders. 6. Replace the fan and fix it to the front cover with the two screws and holders. 7. Plug the fan power cable back into the corresponding socket. 8. Mount the front cover and fix it with the three screws. 9. Reconnect the rectifier according to item 9.1.
1553-BZA 108 35 Uen Rev 2007-01-19 22(27)

DIRECTIONS FOR USE BZA 108 35

9.3

Exchange of distribution circuit-breaker

1. Open the distribution unit front. 2. Disconnect the distribution cable from the CB. 3. Loosen the CB fixing screw. See Figure 13. 4. Pull the locking device at the bottom of the faulty CB to release it from the DIN-rail. 5. Lift the CB to release it from the connecting fork. See Figure 13.

CB fixing screw
2

Figure 13. Releasing a distribution circuit-breaker. 6. Remove the CB according to Figure 14.

connecting fork

Figure 14. Removing a distribution circuit-breaker.

1553-BZA 108 35 Uen Rev 2007-01-19 23(27)

DIRECTIONS FOR USE BZA 108 35

7. Mount a new CB in the reverse order. 8. Lock the new CB to the DIN-rail and switch it off. 9. Connect the distribution cable to the CB. 10. Mount the front to the distribution unit and fix it with the captive screws.

9.4

Exchange of contactor
Note:

The system has no backup during this work.

Figure 15. Exchange of contactor. 1. Take off metallic bracelets, rings or similar that may cause short circuits in the equipment. Use insulated tools. Insulate the metal parts close to the contactor with plastic and tape. 2. Open the connector for the signalling cables connected to the contactor. 3. Remove the plastic cover and two rectifiers placed below the contactor. 4. Use an insulated 13 mm U-socket key to loosen the four fixing nuts of the contactor. 5. Hold the contactor and remove the four fixing nuts. 6. Pull the contactor straight down and remove it through the space in the rectifier subrack. 7. Insert the new contactor and fix it with four nuts. 8. Connect the signalling cables to the contactor. If the voltage is OK it should pull up. 9. Fit the plastic cover and two rectifiers below the contactor.
1553-BZA 108 35 Uen Rev 2007-01-19 24(27)

DIRECTIONS FOR USE BZA 108 35

9.5

Exchange of SCU/ACU
Note:

An LVD contactor is in its OFF- position will reconnect when the SCU/ACU is removed from a live system.

1. Unlock the control unit by pressing the handle so it pops out and pull out the control unit from the subrack. See Error! Reference source not found.. 2. Insert the new control unit into the subrack, push it in completely and lock it by pushing the handle into its socket.

9.6

Exchange of connector board

Connectors

Fixing screw

Figure 16. Connector board. 1. Remove the fixing screw, and then pull out the connector board from the subrack to access the cable connectors. See Error! Reference source not found..
Note:

Be careful not to damage the surface mounted components at the back of the board when pulling it out.

2. Disconnect, insulate and mark the signalling cables connected to the terminals of the connector board. 3. Exchange the connector board for a new one. 4. Connect the signalling cables to the terminals of the new board.
Note:

An LVD contactor is in its OFF- position will reconnect when the connector board is reconnected to a live system.

5. Insert the connector board into the subrack, push it in completely and fix it with a screw.

1553-BZA 108 35 Uen Rev 2007-01-19 25(27)

DIRECTIONS FOR USE BZA 108 35

9.7

Exchange of SCU/ACU supply fuses

There are two fuses at the back-plane board of the SCU/ACU. See Figure 17. If the display of the SCU/ACU is dead, the upper fuse (2 A) might have blown. The lower fuse (4 A) protects the supplies of the contactor coils.

2 A for SCU/ACU 4 A for contactors

Figure 17. Fuses for internal supplies.

1553-BZA 108 35 Uen Rev 2007-01-19 26(27)

DIRECTIONS FOR USE BZA 108 35

10

Abbreviations used in this document

AC ACD ACU BC BT CAN CB CENELEC DC DI DSP DU EEM EN ESD HVSD ICU LAN LCD LED LVD MFU PE PFC R SCU SELV SM Alternating Current AC Distribution Advanced Supervision Unit Battery Charge Battery Test Controller Area Network Circuit Breaker European Committee for Electrotechnical Standardization Direct Current Digital Input Digital Signal Processor Distribution Unit Emerson EnergyMaster ENERGYMASTER is a registered trademark of Emerson Network Power Energy Systems AB European Norm ElectroStatic Discharge High Voltage Switch Down InterConnection Unit Local Area Network Liquid Crystal Display Light Emitting Diode Low Voltage Disconnect Multi Function Unit Protective Earth Power Factor Controller Rectifier Standard Supervision Unit Safety Extra Low Voltage Supervision Module

1553-BZA 108 35 Uen Rev 2007-01-19 27(27)