Astec Advanced Power Systems UM5C06D ( 169-2071-504 ) Helios Rectifier 25/48 Single Phase -48V, 25 A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual P0831010 Standard 7.
Astec Advanced Power Systems Helios Rectifier 25/48 Single Phase -48V, 25A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual Manual Number : UM5C06D ( 169-2071-504 ) Manual Status : Standard Manual Issue : 7.00 Release Date : May 2001 P0831010 Copyright 2001 Astec Advanced Power Systems Ltd All Rights Reserved Published in Canada The information contained in this manual is the property of Astec Advanced Power Systems and is subject to change without notice.
Publication history May 2001 Standard issue 7.00. Manual modified to reflect the Emerson identity. ( EC 102-26438 ) September 1999 Standard 6.0. Document modified to be in accordance with Astec standards. (ECN 102-17331) May 1999 Standard 5.0. Document modified to reflect Astec identity. Figure 11 modified. (ECN 102-14852) March 1997 Std. release 4.0. New Float Voltage and Current Limit Factory Setting. August 1996 Std. release 3.0.
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Contents Introduction.............................................................................................................. 11 Description.................................................................................................... 11 Applications .................................................................................................. 12 Equipment Identification ..................................................................................
Contents Forced Load Share ................................................................................................32 Load Share Adjustment Procedure ........................................................................32 Operation.................................................................................................................. 33 Front panel controls........................................................................................ 34 Features ............................
Contents 9 RFA fault ..............................................................................................................47 SEN FAIL fault ......................................................................................................48 Erratic load fault...................................................................................................48 Current or voltage float fault ................................................................................
Contents This page is left blank intentionally. UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
1. Introduction Description The NT5C06D Switch Mode Rectifier is rated for 25 A at -48 V DC. This rectifier incorporates AC input power factor correction circuitry, is highly efficient and lightweight (15 lbs.). It is fully connectorized and plugs into a power shelf into which up to three rectifiers can be installed. The rectifier is forced air cooled with air entering from the front and exhausting out the rear of the power shelf.
Introduction Applications The rectifier is designed to function as the prime source of power for equipment requiring -48 V DC. It will also operate as a battery charger or as a battery replacement (batteryless operation). Its low output noise and good voltage regulation, combined with a 0.01% V coefficient for each degree C of temperature, provides an excellent charging facility to maintain a battery fully charged.
Introduction 13 Helios Rectifier 25/48 NT5C06D(X) –48 V / 25 A Switch Mode Rectifier The NT5C06D provides -48 V / 25 A of isolated, filtered, and regulated DC power from a single phase AC source, for powering a load while charging a positive grounded battery. The output voltage can be adjusted from 46.0 to 56.0 V for floating a 23 or 24 cell battery string. The rectifier is designed for automatic precharge upon insertion into the MPS75 power shelf.
Introduction Figure 2 - MPS75 Modular Power shelf- NT5C10C with 26-pin signal connectors Mounting holes (4) Mounting holes (4) Signal cable connection DC connection Figure 3 - NT5C06D Switch Mode Rectifier Height: 168 mm (6.60 inches) Depth: 260 mm (10.25 inches) Width: 149 mm (5.85 inches) Weight:6.8 kg (15 lbs) EQL FLT FAN HVSD ON RFA DC CC AC CA OUTPUT F1 3MA 250V V+ VSO RTIE UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
2. Specifications Electrical specifications The NT5C06D rectifier operates within the electrical specifications listed in Table 1. (Refer to the Product Specification which can be obtained from the Engineering department of Astec Advanced Power Systems). Table 1 - Electrical specifications Input Voltage Rating: Nominal 208 / 240 V AC single-phase, 47-63 Hz. Input Voltage Range 176 to 264 V AC. Starting range 184 to 260 V AC.
Specifications Table 1 - Electrical specifications ( continued ) Output Protection: A single pole 35 A circuit breaker is connected in series with the negative output lead of the rectifier. The rectifier contains an adjustable output current limit circuit for protection against damage from overloads. This circuit is factory set to limit the output current to 30 A. It can, however, be adjusted from 12.5 A to 30 A. Output Regulation: At point of regulation: within ± 0.
Specifications 17 Environmental specifications Operating CAUTION An airflow clearance must be left at the rear of the shelf. A minimum of three inches is recommended. The rectifier will operate satisfactorily under the following environmental conditions: Temperature Range: 0° to +65° C (32° to 149° F) NT5C06DA/DB equipped without an air filter 0° to +50° C (32° to 122° F) equipped with an air filter Humidity: 0 to 95% RH (non-condensing) Altitude: Sea level to 2100 m (7000 ft.
Specifications The rectifier contains aluminum electrolytic capacitors having a shelf life of 5 years or greater when stored at the maximum rated storage temperature. UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
3. Installation and start up The power shelf must be installed on the framework and all AC, DC and control and alarm wiring must be connected before the rectifiers are physically plugged in. Tools and test equipment The following tools and test equipment are required: • Screwdriver, flat blade (3/8-inch) • Screwdriver, flat blade (3/32-inch) • Screwdriver, Burns No.
Installation and start-up Procedure 1 - Installing the power shelf Step Action 1 Position the power shelf, without any rectifiers plugged in, against the framework. 2 Secure the shelf in the position indicated by the job drawing (normally directly below the controller or another shelf). At least one star washer must be installed on one holding screw to ensure maximum framework ground continuity.
Installation and start-up 21 Installing the AC power Permanent AC connection to the MPS75 power shelf is done using two armored cable conductors, RW-90 or equivalent, as listed in Table 2. One must be routed to L1, and the other one to L2 and to the safety shelf frame ground (FR GND). The cabling must comply to the local electrical code. The power shelf is equipped with a strain relief to terminate the conduit. The cable length should be minimized and be properly secured.
Installation and start-up Figure 5 - Power shelf individual AC connection POS 3 POS 2 POS 1 L1 L2 L1 L2 L1 L2 FR GRD 65 4 3 2 1 When cabling the AC to the power shelf, make sure that each corresponding safety ground wire is properly connected to the terminal designated FR GND.
Installation and start-up 23 Table 4 - DC cable wire size 1 RECT. POSITION 2 RECT. POSITIONS 3 RECT. POSITIONS 8 AWG 6 AWG 4 AWG Figure 6 - Connecting the DC power shelf Control and Alarm Connections The rectifier is interfaced to the power plant controller through the signal connectors provided on the backplane of the power shelf (see Figures 1 and 2 for location). These signal connectors provide control, alarm, and monitoring signals. The power shelf provides two types of signal connectors.
Installation and start-up Table 5 - Rectifier and Controller interface connections (8-pin connectors) Pin # 1 2 3 4 5 6 7 8 Design.
Installation and start-up 25 Table 6 - Rectifier and Controller interface connections (26-pin connector) ( continued ) Pin # 23 24 25 26 Designation DC BRK ALM AC FAIL ALM SENSE FAIL ALM FAN ALM Note: Description DC Circuit Breaker AC Line Fail Alarm Sense Fail Fan Alarm Signal NC NC NC NC The normally closeed (NC) annotation signifies that the alarm is sent when the contact between the alarm (NC) and alarm common is closed (short-circuited).
Installation and start-up Figure 7 - No controller, remote sensing connection for 8-pin signal cable shelves Note 1: Refer to MS5C06 for available 8-pin ribbon signal cables of different lengths to connect from the shelf back plane rectifier position to the remote sensing point. Note 2: Identify the wire color corresponding to RG+ pin 2 and RC- pin 3 to be used for the remote sensing. Completely cut out completely the 8-pin connector, leaving the signal wires loose.
Installation and start-up 27 Figure 8 - No controller, remote sensing connection for a 26-pin signal connector shelf 20 AWG (SEE NO TE 3) SEE NO TE 4 RC- RC FUSE 1.
Installation and start-up Verification After completing the wiring of the power shelf perform the following: Procedure 2 - Verification Step 1 2 3 4 Action Verify that the power shelf has been mechanically secured. Verify that all the wiring performed is correct by using a voltmeter. Verify that all connections are mechanically correct (that is, tight, correct connector, correct marking etc.) Reinstall the AC and DC junction box cover on the left and right sides.
Installation and start-up 29 Rectifier meter accuracy The rectifier's current meter is precise within + 2%. Start-up and verification Repeat the following steps for each rectifier in turn. Procedure 4 - Starting up the rectifier Step 1 2 Action Close the AC circuit breaker in the AC service (main) panel. Connect an external meter to test points V- and V+ on the rectifier to be tested. 3 Switch the AC circuit breaker of the rectifier. The voltmeter will indicate a float voltage.
Installation and start-up Procedure 4 - Starting up the rectifier ( continued ) Step 10 Action In order to accurately adjust the rectifiers float and/or equalize (if different from factory setting) the current share mode setting must be taken into account. Two modes of share are offered in the NT5C06DA/DB. (i) Slope Share The output voltage linearly decreases by -300mV from 0-100% of output current capacity (0-25 A).
Installation and start-up 31 Procedure 4 - Starting up the rectifier ( continued ) Step 11 Action (ii) Forced Share In the forced share mode, the rectifier's output voltage setting is not modified with changes in output load as is the case in the Slope Share mode. The preset output voltage is the value the rectifier will operate at throughout its load range*. Adjust the rectifier float voltage to the desired system float voltage.
Installation and start-up Slope Load Share When the rectifier is connected in parallel with rectifiers in the same power shelf, or other power shelves, and this method of load sharing is desired, the SLS / FS switch of each rectifier must be pushed towards the SLS. Forced Load Share When the preferred method for load sharing is Forced Load Share, the SLS / FS switch of each rectifier must be pushed toward the FS designation.
4. Operation In addition to rectifying the AC, the input circuit provides EMI filtering, inrush current limiting, low and high AC inhibit, power factor compensation, surge voltage protection, and is equipped with a 13 A AC breaker for input protection. The output section provides additional EMI filtering and contains an internal shunt for output DC current measurement and a 35 A circuit breaker for output protection.
Operation Front panel controls Figure 9 - NT5C06D - front view Features In addition to the features and performance characteristics described earlier, the rectifier provides the following features. Local float / equalize control The rectifier is equipped with a float / equalize switch. The rectifier normally delivers a float voltage set by the FLT potentiometer.
Operation 35 Start-up delay This unit does not have a start-up delay. Test points (V+, V-) Test points allow the user to measure the voltage at the point of regulation. A 100 ohm PTC resistor is placed in series with both leads to prevent damage caused by short circuits at the jack terminals.
Operation Local ON/OFF control (AC breaker) The AC input circuit breaker can be used to locally turn the rectifier ON/OFF. The local ON/OFF control overrides remote control signals. Remote ON/OFF control When a battery return (BAT RTN) signal is applied to the 'Temporary Release' (TR) input, the rectifier inhibits its operation ( no RFA will be transmitted). Upon removal of the remote ground signal the rectifier returns to normal operation.
Operation 37 Sequential start The rectifier TR lead is available for use with an external sequential start circuit. Parallel operation The rectifier is capable of operating in parallel with other rectifiers having similar output characteristics and shares the total load proportionally to its output rating.
Operation Input AC voltage monitor The rectifier monitors the input voltage, inhibits its operation and sends an RFA when the AC voltage decreases below 176 or rises above 264 V AC. An AC FAIL alarm contact is transmitted through the signal connector. The rectifier recovers its normal operation automatically when the input voltage returns within the acceptable limits, without any operator intervention.
Operation 39 Figure 10 - Power interface connections Signal interface connector Figure 11 shows the pin assignment of the signal interface connector. This connector is used to interface all the control, alarm and monitoring signals with the power shelf that, in turn, interfaces these with the Controller. The control inputs are activated by a ground (BAT RTN) signal. The alarms are extended by relay contacts and are isolated from each other and from the chassis. All contacts are rated 60 V DC and 0.5 A.
Operation Figure 11 - Control signal connections 1 25 UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
5. Maintenance The NT5C06D rectifier is virtually maintenance free. It requires periodic float / equalize verification (once every six months) and air filter replacement as required. Note: If the unit operates in a dusty environment the optional air filter is recommended. It must be inspected and changed, or thoroughly cleaned, at least every 12 months, or sooner if the dust level is high. CAUTION Do not install a wet filter on the unit. To remove the filter, simply unscrew it.
Maintenance Procedure 6 - Adjusting the float / equalize ( continued ) Step 6 Action The float voltage should be adjusted with the rectifier in service, as follows: The rectifier is connected to the system and should carry some load. If the rectifier is connected in parallel with other rectifiers, verify that the total system load current is shared equally among the rectifiers.
Maintenance 43 Fan replacement CAUTION Before replacing the fan, turn the rectifier OFF. Completely disconnect and remove it from the shelf. Wait thirty minutes to allow all internal capacitors to fully discharge and for all components to cool down. CAUTION Keep any dirt, dust, moisture or metallic particles from entering into the unit. Procedure 7 - Replacing the fan Step Action 1 Disconnect the 3-pin fan connector located below the fan assembly (refer to Figure 12).
Maintenance Figure 12 - NT5C06D rear view CAUTION Ensure that the fans spin freely, without interference. UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
Maintenance 45 CAUTION Do not run the rectifier without a fully operational fan or with a fan other than the specified replacement for this cooling application. Power shelf The power shelf requires no maintenance.
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6. Troubleshooting Alarm indication RFA fault Table 9 - System fault diagnosis Fault symptom RFA Possible causes No AC input or input out of bounds. No AC input or input out of bounds. AC Input/DC output circuit breaker is open. Rectifier has received a HVSD signal from the controller. An internal high voltage shutdown (HVSD) has occurred. The internal High voltage shutdown point set too low (below float or equalize setting). Excessive impedance in one or both sense leads. The cooling fan is failed.
Troubleshooting SEN FAIL fault Fault symptom SEN FAIL Possible causes One or both remote sense leads is disconnected. DC breaker is open. Rectifier is still in walk-in. Sense leads are reversed. Erratic load fault Fault symptom Erratic load Possible causes Requirement exceeds total rectifier capacity. Current or voltage float fault Fault symptom Current or voltage float Possible causes With paralleled units, the float and/or equalize is misadjusted causing one or more units to carry the load.
7.
Appendix A: Replacement parts This page is left blank intentionally. UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
8. Appendix B: Technical service assistance For technical assistance, 24-hours a day / 7 days a week, dial one of the following toll-free numbers. This service complements the services offered by field support organizations such as, the Emergency Technical Assistance Service (ETAS), and the Installation Technical Assistance Service (ITAS). Local toll-free prefixes The following prefixes give access to toll-free numbers in various countries.
Appendix B: Technical service assistance Toll-free technical assistance numbers United States: In Europe: Austria Belgium Denmark Finland France Germany Ireland Italy Netherlands Norway Sweden Switzerland United Kingdom *1 1-800-992-8417 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 800-213-49156 In the Caribbean and Latin America (CALA): Bahamas 1-800-389-0081 Barbados 1-800-534-0
9.
List of terms and acronyms NO Normally Open NT Northern Telecom PCB Printed Circuit Board RFA Rectifier Fail Alarm RG+ Sensing Battery Positive RC - Sensing Battery Negative SEN FAIL Sense Fail SH + Shunt Positive SH - Shunt Negative SLS Slope Load Sharing TBD To be Determined THSD Thermal Shutdown TR Temporary Release UM5C06D ( 169-2071-504 ) P0831010 Standard 7.
Helios Rectifer 25/48 Single Phase −48 V, 25 A Power Factor Corrected Switch Mode Rectifier NT5C06D Installation and User Manual Astec Advanced Power Systems Ltd 2280 Alfred-Nobel Blvd St-Laurent ( Quebec ) Canada H4S 2A4 Copyright 2001 Astec Advanced Power Systems Ltd All Rights Reserved The information contained in this manual is the property of Astec Advanced Power Systems and is subject to change without notice.
