EMERSON. Network Power DIRECTIONS FOR USE POWER SUPPLY SYSTEM NetSure™ 501, BZA 108 35, -48 V DC © Emerson Network Power Energy Systems AB 2007 ~ All rights reserved 1859-BZA 108 35 Uen Rev 8 2007-01-19 1@7)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, +4687217177 _www.emersonenergy.com 1853-BZA 108 36 Uen Rev 2007-01-19 2027)DIRECTIONS FOR USE - BZA 108 35 Contents Introduction Function Configurations Units in the system Rectifier Rectifier subrack Control units Multifunction unit AC distribution AC connection terminals Technical data System Cabinet Rectifier Installation Start-up and installation test Maintenance Safety Scheduled maintenance Alarms Fault symptoms and trouble shooting Exchange of units and parts Exchange of rectifiers Reetifier fan replacement Exchange of distribution circuit-breaker Exchange of contactor Exchange of SCU/ACU Exchange of connector board Exchange of SCU/ACU supply fuses Abbreviations used in this document 1853-BZA 108 36 Uen Rev 2007-01-19 3027)DIRECTIONS FOR USE - BZA 108 35 1 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. 2 Function For the protection of the batteries during a power outage, the load is discon- nected at a preset voltage or after a predetermined delay. To prolong the service of some loads at a long power outage, the DC distribu- tion 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 DU, normal load Priority Load i AC terminals Figure 1. Example of system topology. 1853-BZA 108 36 Uen Rev 2007-01-19 4027)DIRECTIONS FOR USE - BZA 108 35 Configurations The cabinets can be configured with different numbers of rectifiers, battery- and 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. 1583-BZA 108 36 Uen Rev 2007-01-19 527)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, —|S/A LVDs, normal and —_|C/C| prio load CBs WU. R |R IR |R |R IR 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, —_|S/A LVDs, normaland —_|C/C| prio load CBs lulu R JR JR JR |R JR R IR IR IR |R_ IR ACD (option) (BMG 653 39/22) ire tray Figure 4. Configuration with double rectifier subracks. 1853-BZA 108 36 Uen Rev 2007-01-19 627)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 contac- tors, 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 pul-relief clamps Room temperature sensor KET 103 06/1 ‘Spare parts 1853-BZA 108 36 Uen Rev 2007-01-19 7027)DIRECTIONS FOR USE - BZA 108 35 41 411 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. Figure 5. Rectifier. LEDs The front panel has three indicator LEDs. The functions of the LEDs are listed in the table below. LED Normal | Abnormal Cause of Abnorm: Power indicator OFF No AC Mains Supply (ereen) oN @ Flashing _ [Rectifier is under control by SCU/ACU ‘AC input overlundervoltage, PFO Protection indica- ON overlundervoltage and over- tor (elon) OFF temperature Flashing | Communication with SCU/ACU failure [Alarm indicator ON Output overvoltage “4 OFF (red) Flashing [Fan Failure 1583-BZA 108 36 Uen Rev 2007-01-19 827)DIRECTIONS FOR USE - BZA 108 35 4.1.2 4.1.3 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 con- stant 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 fan's 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. 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, cur- rent 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. 1853-BZA 108 36 Uen Rev 2007-01-19 9027)DIRECTIONS FOR USE - BZA 108 35 41.4 4.2 © 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 pro- tect; 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: Ad- dress, code, date, SW version and HW version. Protection functions © Input over/undervoltage protection. The rectifier will shut down and its yel- low 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. © Qver-temperature protection, The rectifier will limit its power to 50% of ated output power if its internal temperature is higher than 75 °C. If the i ternal temperature reaches 80 °C, the rectifier will shut down and its yel- low 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 be- comes normal, * Communication failure. At communication failure, the rectifier output volt- age 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. © Eanalarm, 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 rec tifiers in a DC power system is unbalanced, the rectifier that outputs un- balanced current will be identified automatically and its yellow LED will emit light. An alarm will be sent to the SCU/ACU Rectifier subrack Figure 6. Subrack for six rectifiers. The rectifier subrack has space for six rectifiers, 1853-BZA 108 36 Uen Rev 2007-01-19 10(27)DIRECTIONS FOR USE - BZA 108 35 43 44 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 handiing, etc. Two control units are available. The standard control unit (SCU) has an LCD- display, 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 imple- mented for different maintenance activities. The advanced control unit (ACU) has, in addition to the SCU features, an in- terface 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 USER'S GUIDE 5/1553-BMP 903 050 Uen, for the ACU and §/1553-8MP 903 051 Uen, for the SCU Multifunction unit + terminals LVD contactors 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. 1583-BZA 108 36 Uen Rev 2007-01-19 117)DIRECTIONS FOR USE - BZA 108 35 4.5 AC distribution laololololelalalolololalelelolololelolololole! g IS IG 8 Input terminal Figure 8. AC distribution unit seen from front. For cabinets with double rectifier subracks, an AC distribution unit is available. Itincludes 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. 1583-BZA 108 36 Uen Rev 2007-01-19 1227)DIRECTIONS FOR USE - BZA 108 35 5.1 5.2 5.3 Technical data System Nominal DC voltage ~48V Maximum output current @ 48 V_ 212A (with one rectifier subrack) or Operational temperature Storage temperature Relative humidity Cabinet Building practice Height (incl. top cover and feet) Footprint (with x depth) Weight (fully equipped, without batteries) Rectifier 425 A (with two rectifier subracks) -5 to +45 °C (with hydraulic magnetic circuit-breakers) -5 to +30 °C (with thermal/electro magnetic circuit-breakers) -40 to +75 °C 5 to 90% 23" 1250, 1650, 1850, 2050 mm 400 or 600 x 600 mm. maximum 150 kg See data sheet EN/LZT 145 280 RA 1853-BZA 108 36 Uen Rev 2007-01-19 1327)DIRECTIONS FOR USE - BZA 108 35 8.1 8.2 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 Safety The document SAFETY RULES 1550-1004 and local safety rules shall be fol- lowed when doing maintenance work in the power supply equipment. Meas- ures 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 ex- ample the following areas © General rules for work on live equipment ‘+ Certification of operatives conducted by certified supervisor Approved tools © Customer approval 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 bat- tery supplier. + Ascheduled 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. 1853-BZA 108 36 Uen Rev 2007-01-19 14(27)DIRECTIONS FOR USE - BZA 108 35 8.3 Alarms 8.3.1 Alarm categories 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 ifit occurs during work- ing-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 fan alarm has category No Alarm it means that the alarm is deactivated and will not be shown in the display of the SCU/ACU 8.3.2 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 thunder- storm or mains failure. Trace activated alarms by means of the alarm survey of the respective unit and the item, whieh describes what actions to take on the respective alarm. 8.4 Fault symptoms and trouble shooting 8.4.1. System alarms For system alarms, see USER'S GUIDE 1553-BMP $03 051 Uen for the SCU and 1553-8MP $03 050 Uen for the ACU. ‘Alarm on | Alarm on the SCU | the ACU Cause Suggestion display | display JAlarms [Alarm | The outgoing alarms are |Check why before reconnecting the alarms. Blocked | Blocked —_| blocked from the SCUIACU. Load Fuse |Fuse Alarm [One or more distribution |Find out and eliminate the reason for the Alarm cireuit-breakers for the | tripped circuit breaker before resetting it. load have tripped Rect Not [CAN There CAN communica- [Check the connectors and cables for the CAN Respond |Comm | tion is broken. loop. Fault Exchange the rectifier that does not respond. Exchange the SCUIACU 1853-BZA 108 36 Uen Rev 2007-01-19 1827)DIRECTIONS FOR USE - BZA 108 35 ‘Alarm on | Alarm on theSCU | the ACU Cause Suggestion display | display LvD 1 LV 1 Dis- |The contactor for the nor- if there is a mains failure, check that itis not connected |mal load is open because | caused by broken supply fuses the battery is too deep Jischarged. ifthe rectifiers are working, the problem may The batteries are discon- | be that the system load is higher than the nected at a preset level, in | rectifier capacity. causing the batteries to order to protect them from | discharge. If this is the reason, install more over-discharging rectifiers LvD2 LVD_2Dis- |The contactor for the pri. |See LVD 1 connected _Joritised load is open be- cause the battery is 100 [deep discharged. LVD W/LVD |Contactor [An LVD contactors ina |Check the contactor functions. 20pen ‘| Fault wrong state. Batt Curr | Abnorm Bat |The boost charging cur- | Gheck the settings High Curr rent exceeds the set max. value Batt Fuse [Fuse Alarm indicates that one or more [if a battery fuse/circuit breaker has been Alarm battery fuses/circuit break- | removeditripped manually, check with the ers have blown\tripped or |person that removeditripped it before rein- been removed. serting/resetting it. Ensure that there is no ‘fault before doing that, The battery fuse shall be reinserted by adequately trained personnel Ifthe battery fuse/circuit | Find out and eliminate the reason for the breaker is blownitripped, | blown\tripped fuseleircuit breaker before the reason for the fallure | swapping/resetting it probably is overioad or short circuit Self-detect [ACU fault |SCU/ACU failure Exchange the SCU/ACU Emr Manual |Manual —_| The battery monitoring has | Check why before resetting itto automatic Mode Mode been set to "Manual mode" in the SCU/ACU. Non-Float The system is not in Float Status Charge mode because of: [The boost charge is ac- | The boost charge will stop automatically tive [The battery testis active. |The discharge test will stop automatically, Batt Dis- [The battery testis active. |The discharge test will stop automatically, charge There is a mains failure. Check that itis not caused by broken supply fuses. The system load is higher than the rectifier capacity, causing the batteries to ischarge Install more rectifiers. 1853-BZA 108 36 Uen Rev 2007-01-19 16(27)DIRECTIONS FOR USE - BZA 108 35 ‘Alarm on | Alarm on theSCU | the ACU Cause Suggestion display | display Curr Dis- Dis Currim |The currents from two | Check the batteries. crepancy groups of batteries are not, equal Note: There must be two battery shunts in the system to act vate this function. Short Test ‘The short time battery test [Check the batteries, Fail has failed Batt Test | Test Failure |The battery test has failed, | Check the float charging level. Fall Check that the load is lower than the capac- ity of the rectifiers Check the battery according to the recom- mendations of the supplier. Volt Dis- [Rect Over | Restifer overvoltage See item 8.4.2 crepancy | Volt Mains Fail- [Mains Fail- |All rectifiers have stopped. | Check ifthere is a general mains failure. ure ure Check that itis not caused by broken supply fuses. MuttiRect | Muiti-rectfail| Two or more rectifiers | See item 8.4.2 Alarm have stopped Maintain |Mainte- [The maintenance timer | Check the settings of the Maintenance Time Alarm nance Alrm | gives alarm Delay Rectifier Rectifier |The SCUACUhasde- [See item 8.4.2 Lost Lost tected a reduction in the _ | Ifthe lost rectifier is to be removed perma- number of running rectii-. |nently, the alarm must be reset from the ers, SCUIACU. Load share The output current ofa | Check the rectifiers. Alarm rectifier is outside the a) erage value for all rectfi- ers. Rect HVSD [A rectifier output voltage | Check the rectifier HVSD setting \was higher than the recti- Rider ne 29° P95 | Replace the rectifier Rect AC Fail]Rect AC [AC input voltage outside | See item 8.4.2 Failure _| the normal range. Rect Over Rectifier overtemperature [See item 8.4.2 Temp protection, Rect Failure [Rectifier [Rectifier failure See item 842 Failure Rect Protect Rect Pro- | Rectifier protection See item 8.4.2 tected 1853-BZA 108 36 Uen Rev 2007-01-19 1727)DIRECTIONS FOR USE - BZA 108 35 Alarm on | Alarm on the SCU | the ACU Cause Suggestion display | display RectFan Rect Fan _ |Rectifer fan failure See item 84.2. Fails Fail Rect Der [Rect Curr | Rectifier overioad ifthe batteries are being recharged, the ated limit “The load is higher than the | alarm will cease by itself when the battery rectfier capacity voltage has increased to the charging level. Ifthe 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 fauity rectifiers DC Vor [Under Vol |The distribution voltage |i there is a mains failure, check if some Lows has dropped below the load could be switched off in order to pro- preset alarm level, usually |iong the operating time of the plant Byrated Because of maINS Ti there is a rectifier fallure, see item 8.42 ifthe system load is too high related to the rectifier capacity, install more rectifiers Ifthe batteries are being recharged, the alarm will ease by itself when the battery voltage has inereased to the charging level. DE Ver [Very Under |The distribution voltage [See DC Volt Low#/DC Under Voltage Low#2 [vol has dropped below the preset alarm level, usually tiated because of mains failure De Vor [Over Voit- |The system voltage ex _ | Check the set float, batiery- and the over- Hightt — age ceeds the preset level, _| voltage: ifthe limits are incorrect, find out why they have changed and correct them. OC Volt The system voltage ex- | Check the set float-, batlery- and the over- High#2 ceeds the preset level. | voltage: ifthe limits are incorrect, find out hvhy they have changed and correct them, JAC Voltage ‘The mains voltage is too | Check the mains voltage Lowa low. Check the settings of the SCU JAC Voltage The mains voltage is too Ac vo ihe See AC Voltage Lovt2 JAC Voltage ‘The mains voltage is too | Check the mains voltage. High high. Check the settings of the SCU Check the temperature LowTemp |The temperature on a Temp Alarm |iLow Amb |temperature sensor ex. | Check the settings of the SCU/ACU. Temp _| ceeds the set value. ifthe temperature is OK, exchange the tem- perature sensor. 1853-BZA 108 36 Uen Rev 2007-01-19 1227)DIRECTIONS FOR USE - BZA 108 35 ‘Alarm on | Alarm on theSCU | the ACU Cause Suggestion display | display Check the battery temperature The temperature on a Teme Mich Inigh Temp [battery temperature sen- [Check the setings ofthe SCUIACU. sor exceeds the set value. lit the temperature Is OK, exchange the tem- perature sensor Very hie |The temperature on a tn, battery temperature sen- | See High Temp alarm. e sor exceeds the set value th Check the room temperature 1e temperature on a figh amo |ccimtemerature sensor [OTEK he stings ofthe ACU exceeds the set value. if the temperature is OK, exchange the tem- perature sensor. No Temp Check the cable and the connector of the TSensor | The temperature sensor Sensor tor [Fat eee {temperature sensor. Exchange the temperature sensor. Planned battery test in Plan BT es Wait for the test to stop automatically ag falure I nains faiure ‘See Mains Failure alarm, Manual BT semeel battery test in Pro- | wait for the test to stop automatically Short Test cee battery test in pro | wait for the test to stop automatically Cyclic boost charge in| Wait for the boost charge to stop automati- Cyelle BC | progress. cally. Jauto aq [Automatic boost charge in | Wait for the boost charge to stop automat progress. cally Manual boost charge in| Wait for the boost charge to stop automat Manual BC | progress cally, or stop it manually. Charge Pro- |The boost charge function | The boost charge will be blocked by abnor- hibit is blocked mal conditions in the system) Indicates “Promt’ alarm Power Major (osteo) Indicates “Main fai” alarm Power Minor (yelow LED) High Load | Ab load curr | The system load is higher | check the settings. than the set level. (Over Power Digital 1(t0 [514% pie [indicate alarms on the [Check the equipment connected to the cor- 6) digital inputs 1-6. responding input 1853-BZA 108 36 Uen Rev 2007-01-19 19027)DIRECTIONS FOR USE - BZA 1 08 35 8.4.2 Re ier The usual fault symptoms of the rectifier include: power indicator (green) off protection indicator (yellow) on, protection indicator (yellow) flashing, alarm in- dicator (red) on, and alarm indicator (red) flashing. ‘Symptom Cause ‘Suggestion Power indica- tor (green) off No input voltage Make sure there is input AC volt- age Input fuse/circuit-breaker fault Replace the fuse with a new one of the same model or switch on the circut-breaker [AC input voltage outside the normal range Check that the AC input voltage is within normal range PFC overvoltage Replace the rectifier (Current sharing function is disabled Replace the rectifier Rectifier overtemperature protection, wt hich is caused by: Protection indicator (yel- Remove the obstacle that block low)on Fan blocked pene Ventilation blocked: the inlet or outlet [Remove the objects that blocks blocked the inlet or outlet [Ambient temperature too highor | Remove the heater, lower the rectifier inlet too close toa heater [ambient temperature Rectifier not completely inserted into Ihe slot Insert the rectifier properly Protection Exchange the rectifier for a new indicator (yel- | Rectifier communication failure ig low) flashing one. Remove the rectifier from the DC Alarm indica- power system and then reinsert tor (red) on Rectifier overvoltage it, Exchange the rectifier for a new one if the alarm continues. Alarm indica- tor (red) fiash- ing Fan not running Replace the fan When multiple rectifiers are in parallel connection and the unbalance of cur- rent sharing among them is higher than 3 %, check if the communication ca- bles are correctly connected. If the current sharing is still unsuccessful after the correction, replace the recti- fier of which the current sharing is out of range. 1853-BZA 108 36 Uen Rev 2007-01-19 2027)DIRECTIONS FOR USE - BZA 108 35 9 Exchange of units and parts To order spare parts, contact Emerson Network Power Energy Systems AB. 9.1 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 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. 1583-BZA 108 36 Uen Rev 2007-01-19 217)DIRECTIONS FOR USE - BZA 108 35 5. Loosen the fixing screw of the handle, lift the handle, and the latch will with- draw into the rectifier. 6. Continue to push the reetifer 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 Fixing screw and fan holder ws 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 hold- ers. 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 1583-BZA 108 36 Uen Rev 2007-01-19 2227)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 Figure 13. Releasing a distribution circuit-breaker. 6. Remove the CB according to Figure 14. J Figure 14. Removing a distribution circuit-breeker. connecting fork 1853-BZA 108 36 Uen Rev 2007-01-19 2327)DIRECTIONS FOR USE - BZA 108 35 9. 10. Mount a new CB in the reverse order. Lock the new CB to the DIN-rail and switch it off. Connect the distribution cable to the CB. 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 simitar that may cause short circuits in the equipment. Use insulated tools. Insulate the metal parts close to the contactor with plastic and tape. Open the connector for the signalling cables connected to the contactor. Remove the plastic cover and two rectifiers placed below the contactor. Use an insulated 13 mm U-socket key to loosen the four fixing nuts of the contactor. Hold the contactor and remove the four fixing nuts. Pull the contactor straight down and remove it through the space in the rectifier subrack. Insert the new contactor and fix it with four nuts. Connect the signalling cables to the contactor. If the voltage is OK it should pull up. Fit the plastic cover and two rectifiers below the contactor. 1583-BZA 108 36 Uen Rev 2007-01-19 2427)DIRECTIONS FOR USE - BZA 108 35 9.5 Exchange of SCU/ACU Note: ‘An LVD contactor is in it’s OFF- position will reconnect when the SCU/ACU is removed from a live system. 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... 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 | 5A Fixing screw Figure 16. Connector board. 1 Note: Note: 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. Be careful not to damage the surface mounted components at the back of the board when pulling it out. Disconnect, insulate and mark the signalling cables connected to the ter- minals of the connector board. Exchange the connector board for a new one. Connect the signalling cables to the terminals of the new board, ‘An LVD contactor is in it’s OFF- position will reconnect when the connec- tor board is reconnected to a live system. Insert the connector board into the subrack, push it in completely and fix it with a screw. 1583-BZA 108 36 Uen Rev 2007-01-19 2527)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, 2A for SCUIACU 4A for contactors Figure 17. Fuses for internal supplies. 1583-BZA 108 36 Uen Rev 2007-01-19 26(27)DIRECTIONS FOR USE - BZA 108 35 10 Abbreviations used in this document AC Alternating Current ACD AC Distribution ACU Advanced Supervision Unit BC Battery Charge BT Battery Test CAN Controller Area Network cB Circuit Breaker CENELEC European Committee for Electrotechnical Standardization Dc Direct Current DI Digital input DsP Digital Signal Processor Du Distribution Unit EEM Emerson EnergyMaster™ ENERGYMASTER is a registered trademark of Emerson Network Power Energy Systems AB EN European Norm ESD ElectroStatic Discharge HVSD High Voltage Switch Down Icu InterConnection Unit LAN Local Area Network Leb Liquid Crystal Display LED Light Emitting Diode LD Low Voltage Disconnect MFU Multi Function Unit PE Protective Earth PFC Power Factor Controller R Rectifier scuU Standard Supervision Unit SELV Safety Extra Low Voltage sM Supervision Module 1853-BZA 108 36 Uen Rev 2007-01-19 2727)