Netsure v200 Retrofit Um486531003

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NetSure V200E50 DC Power Retrofit

Installation and User Instructions


UM486531003 (Issue AG, November 30, 2012)

SPEC. NO. MODEL


Business-Critical Continuity, Emerson Network Power, and the Emerson Network
Power logo are trademarks and service marks of Emerson Electric Co.

NetSure, NetSpan, NetReach, NetXtend, and NetPerform


are trademarks of Emerson Network Power, Energy Systems, North America, Inc.

All other trademarks are the property of their respective owners.

The products covered by this instruction manual are manufactured and/or


sold by Emerson Network Power, Energy Systems, North America, Inc.

The information contained in this document is subject to change without notice and may not be
suitable for all applications. While every precaution has been taken to ensure the accuracy and
completeness of this document, Emerson Network Power, Energy Systems, North America, Inc.
assumes no responsibility and disclaims all liability for damages resulting from use of this information
or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct
methods, tools, and materials to be used in performing procedures not specifically described in this document.

This document is the property of Emerson Network Power, Energy Systems, North America, Inc.
and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use or disclosure of it without the written permission
of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.


Copyright 2012, Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved throughout the world.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

TABLE OF CONTENTS
Introduction .......................................................................................................................... 3
General ......................................................................................................................... 3
Existing System Compatibility Matrix ............................................................................ 3
Specifications ...................................................................................................................... 4
DC Output Ratings ........................................................................................................ 4
AC Input Ratings ........................................................................................................... 6
Environmental Ratings .................................................................................................. 7
Standard Features ........................................................................................................ 8
Installation.......................................................................................................................... 11
Safety Statement......................................................................................................... 11
Checking System Compatibility .................................................................................. 12
Remove Style Strips from Power Bay ......................................................................... 12
Remove the Power Conversion Unit (PCU) or Blank Cover Panel ............................ 12
Install the Mounting Frame ......................................................................................... 14
Install the Rectifiers ..................................................................................................... 17
Install Remaining Retrofits in Power Bay .................................................................... 19
Reinstall Style Strips on Power Bay............................................................................ 19
Repeat Procedure for Remaining Power Bays ........................................................... 19
Load Share Alarm ....................................................................................................... 19
Local Sense ................................................................................................................ 20
Final Step .................................................................................................................... 20
Operation ........................................................................................................................... 22
Local Indicators ........................................................................................................... 22
Rectifier High Voltage Shutdown and Lockout Restart ............................................... 23
Troubleshooting and Repair .............................................................................................. 23
Troubleshooting .......................................................................................................... 23
Replacement Procedures ........................................................................................... 25
Revision Record ................................................................................................................ 32

Page 1
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

STATIC WARNING

The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below
must be observed to prevent damage to these components. Disregarding any of these warnings may result in
personal injury or damage to the equipment.
1. Strictly adhere to the procedures provided in this manual.
2. Before touching any static sensitive component or printed circuit card containing such a component,
discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm
resistor. Some wrist straps, such as Emerson Network Power Part Number 631810600, have a built-in
one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturers
instructions outlining use of a specific wrist strap.
3. Do not touch the traces or components on a printed circuit card containing static sensitive components.
Handle the printed circuit card only by the edges that do not have connector pads.
4. After removing a printed circuit card containing a static sensitive component, place the printed circuit card
only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil.
Do not use ordinary Styrofoam or ordinary plastic.
5. Store and ship static sensitive devices or printed circuit cards containing such components only in static
shielding containers.
6. If necessary to repair a printed circuit card containing a static sensitive component, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded
test equipment.

Page 2
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

INTRODUCTION
General
The NetSure Model V200E50 DC Power Retrofit is a power solution comprising a
Mounting Frame that allows two (2) new-generation NetSure Rectifiers (Model
R48-5800e, Spec. No. 1R485800e), to be installed in the NetSure Model 1231V1, Spec.
No. 582121300 Power Bay. The Retrofit replaces one V200E50 Power Conversion Unit
(PCU), and can operate with or without the original PCUs in the same system.
The V200 Retrofit provides load power, battery float current, and battery recharge current
during normal operating conditions. Each rectifier in the Retrofit incorporates a constant
power design. This means that, within the normal operating ambient temperature range,
the maximum output power available is a constant 11,600W per Retrofit. Within the
normal temperature range, the rectifiers operate in one of three modes, depending upon
load demands. Transition between modes is completely automatic.
Constant Voltage Mode: For any initial output voltage setting from 47 to 58 volts,
output voltage remains constant regardless of load. This is the normal operating
condition, in which loads are being supplied and batteries are float charged.
Rectifiers operate in the Constant Voltage Mode unless load increases to the point
where the product of load current and output voltage is approximately 11,600W per
V200 Retrofit.
Constant Power Mode: As load increases above approximately 11,600W per V200
Retrofit (non-adjustable), output current continues to increase, but output voltage
decreases as required to maintain constant output power. Rectifiers operate in the
Constant Power Mode unless load continues to increase to the point where the
current limit setting is reached.
Constant Current Mode: If load increases to the current limit setting, output voltage
decreases linearly to maintain output current at the current limit setting.
Existing System Compatibility Matrix
Refer to Table 1 for a compatibility matrix.

MCA Controller Remote Sense


1 Release Date Upgradeable? 2
Version Lead Drop
5.2.0 After 9/13/2006
5.1.0 After 10/8/2004 NOT REQUIRED 50 mV
5.0.0 After 9/2/03
YES
4.9.0 or less (requires return of
Prior 9/2003
to existing MCA and --
After 11/2000
4.4.3 or better exchange for new
version MCA)
Cannot Upgrade,
4.4.2 or less Prior 11/2000 Need to Purchase --
New Version MCA
1
System OK (enter) / Configure Menu (enter) / Verify Inventory (enter) / Navigate to MCA SWV ########.
2
Maximum voltage drop between local bus and sense point.

Table 1
Compatibility Matrix

Page 3
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

SPECIFICATIONS
DC Output Ratings
Voltage: Nominal -48 volts DC, Positive Ground.
a) Without Battery Charge Temperature Compensation: Float voltage is
adjustable from 47.00 to 58.00 volts DC. Test/equalize voltage is adjustable from
45.00 to 58.00 volts DC. Adjustment is made via the system MCA. Refer to
System Application Guide SAG582121300 for factory settings of Float and
Test/Equalize voltages. The output voltage temperature coefficient (1/C) does
not exceed 0.01% per degree centigrade from 0C to +40C.
b) With Battery Charge Digital Temperature Compensation Probe: This
operating parameter is identical in systems equipped with the V200E50 Retrofits
and systems equipped with the original V200E50 Power Conversion Units
(PCUs). Refer to System Application Guide SAG582121300 for a complete
description.
c) With Battery Charge Analog Temperature Compensation Module: This
operating parameter is identical in systems equipped with the V200E50 Retrofits
and systems equipped with the original V200E50 Power Conversion Units
(PCUs). Refer to System Application Guide SAG582121300 for a complete
description.
Power and Current, One (1) V200 Retrofit: 11,600W, maximum (200.0A @ 58VDC to
241.6A @ 48VDC). Figure 1 shows the relationship between output voltage and output
current at maximum power.

Output Voltage vs. Output Current, Max. Output


Power 11,600 W
70
60
Output voltage (V)

50
40
30
20
10
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
Output current (A)

Figure 1
Output Voltage vs. Output Current

Page 4
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Power Derating Based on Input Voltage: See Figure 2.

Output Power vs. Input Voltage at Tamb < 45 C


120

% of max. output power


100

80

60

40

20

0
250 275 300 325 350 375 400 425 450 475 500 525 550
Input voltage (VAC)

Figure 2
Output Power vs. Input Voltage

Regulation (Rectifier Default):


a) Voltage Regulation: 1%
b) Load Regulation: 0.5%
c) Line Regulation: 0.1%
d) Overshoot at Startup: 1%
e) Dynamic Response (at rated input and output voltage values):
Response time is 200 s, and the overshoot is 5% for load changes at
50%-25%-50% and 50%-75%-50%.
Overshoot or undershoot is 5% and within 1% of the regulation band, 4 ms at
50 s for load changes at 10%-90% and 90%-10%.
Regulation (via system MCA)
a) Static: The Power System MCA controls the steady state output voltage to
within 0.5% of any voltage setting within the range of 44.0 to 58.0 volts DC for
any and all combinations of load from no load to full load, input voltage, and input
frequency at a constant ambient temperature. If the MCA's regulation feature is
disabled for any reason, steady state regulation is 1.0% as controlled within the
Rectifiers.
b) Dynamic Response: For any step load change from 10% to 90% or from 90%
to 10% of full rated load within 250 microseconds, shall not cause the voltage
measured at the output to overshoot or undershoot more than 5% of the
regulated output level within 1 millisecond. The output voltage must return and
stay within the 1% regulation band within 4 milliseconds and within the 0.5%
regulation band within 3 seconds.
Any step change of the line voltage within the range of 260 to 530 volts shall not
cause the output voltage to deviate outside the 0.5% regulation band.

Page 5
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Filtering (with or without battery): Typical readings were taken at nominal input
voltage, nominal output voltage, 50% load, and 25C ambient.
a) Voice Band Noise: Complies with Telcordia GR-947-CORE.
1) Typically 17.68 dBrn C-message weighting. Does not exceed 32 dBrn C.
2) Typically 0.200 millivolts psophometric. Does not exceed 1 millivolt
psophometric.
b) Wide Band Noise: Complies with Telcordia GR-947-CORE.
1) Typically 45 millivolts peak-to-peak. Does not exceed 200 millivolts peak-to-
peak
2) Typically 4.3 millivolts rms. Does not exceed 100 millivolts rms.

AC Input Ratings
Voltage: Nominal 480 volts AC, single phase, 60 Hz, with an operating range of 260 to
530 volts. Acceptable input frequency range is 45 to 65 Hz.
Safe Voltage: The system can tolerate 600 volts AC without damage.
Total Harmonic Distortion (THD): < 5% from 50% - 100% load.
Inrush Current: Peak does not exceed 1.5 times the steady state peak value of the
input current at full load, nominal input voltage, and for any duration of AC input
interrupts. Under the above conditions, standard AC distribution circuit breakers will not
trip.
Typical Input Data: One (1) V200E50 Retrofit, 60 Hz input.
a) System output is initially adjusted to 54.48 volts DC as measured at the system
sense point at 50% of full load and nominal input. Percent of Full Load refers to
percent of 200 Amperes.

Nominal Percent Input Heat


Input Input Power Efficiency
Input of Full Current Dissipation
VA Watts Factor %
Voltage Load (Amperes) (BTU/Hr
0 1.14 944 105 0.111 - 358
25 4.18 3471 3198 0.921 94.59 587
50 6.90 5730 5579 0.974 96.21 724
480 75 10.46 8686 8585 0.988 96.39 1058
100 13.94 11561 11485 0.993 96.15 1508
110 14.42 11949 11864 0.993 95.99 1625
120 14.49 12011 11922 0.992 95.70 1747
Table 2
Input Characteristics
b) Typical Power Factor: 0.973
c) Typical Operating Efficiency: 96.39% at best point at 75% of full load
d) Maximum Input Current: 17.19A

Page 6
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

e) Maximum Input Current: at 100% of full load with output adjusted to 58 volts
DC as measured at the Retrofit output terminals, and input voltage as shown.

Nominal Input Input Current


Input Voltage Voltage (Amperes)
480 408 17.19
Table 3
Maximum Input Current
f) Typical Efficiency versus Output Current: See Figure 3.
97.0

96.0

95.0

94.0

93.0

92.0

91.0

90.0

89.0

88.0

87.0
0 10 20 30 40 50 60 70 80 90 100

Figure 3
Typical Efficiency

Environmental Ratings
Operating Ambient Temperature Range:
a) Operational: -40C to +65C (-40F to +149F)
b) Full Rated Load: -40C to +45C (-40F to +113F)
c) Reduced Load: +45C to +65C (+113F to +149F). Refer to Figure 4.
Storage Ambient Temperature Range: -40C to +80C (-40F to +176F).
Humidity: This system is capable of operating in an ambient relative humidity range of
0% to 90%, non-condensing.
Altitude: 2000 m (6560 ft) at full power (power limited for heights above 2000 m).
Ventilation Requirements: When equipped with V200 Retrofits, a VPS Power Bay must
be mounted so ventilating openings are not blocked and temperature of the air entering
the cabinet does not exceed the Operating Ambient Temperature Range stated
previously.
In addition, the distance from the rear of a VPS Power Bay to a wall or other solid
structure must not be less than 15 inches. This will assure proper air flow through the
V200 Retrofits.

Page 7
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Audible Noise: The audible noise at any point one meter from any vertical surface of a
Power Bay, with one V200 Retrofit installed and fans operating, does not exceed the
following typical levels. A Sound Level Meter conforming to ANSI S1.4 was used.
a) Fan at Low Speed: < 59 dBA
b) Fan at High Speed: < 67 dBA
EMI/RFI Suppression: A V200 Retrofit operating in a NetSure Power Bay conforms to
the requirements of FCC rules Part 15, Subpart B, Class A for Radiated and Conducted
emissions limits.
Surge Protection: Complies with IEEE C62 41-1991 Class B3, 6kV/3kA (1.2/50 s
surge voltage and 8/20 s surge current).
Note: This level of protection is a widely used standard for telecommunications power
equipment. As with all such equipment, it is the end user's responsibility to
provide an adequately sized Surge Suppression Device at the commercial power
service entrance of the building that reduces all incoming surges to levels below
the classes/categories stated for the equipment.
Compliance Information
a) Safety: The rectifiers have been recognized to meet the UL/EN/IEC 60950-2000
safety standard and are CE marked.
b) RoHS: The rectifiers are RoHS compliant, 5/6.
Standard Features
Type of Power Conversion Circuit: High frequency.
Float Charging Output Mode: This operating parameter is identical in systems
equipped with the V200E50 Retrofits and systems equipped with the original V200E50
Power Conversion Units (PCUs). Refer to System Application Guide SAG582121300 for
a complete description.
Test/Equalize Charging Output Mode: This operating parameter is identical in systems
equipped with the V200E50 Retrofits and systems equipped with the original V200E50
Power Conversion Units (PCUs). Refer to System Application Guide SAG582121300 for
a complete description.
Output Mode (Float or Test/Equalize) Selection: This operating parameter is identical
in systems equipped with the V200E50 Retrofits and systems equipped with the original
V200E50 Power Conversion Units (PCUs). Refer to System Application Guide
SAG582121300 for a complete description.
Input Protection:
a) Input Fusing: Input fusing is provided in each rectifier. This fusing is not
customer replaceable.
b) Input Over-Voltage Protection: A rectifier shuts down and its protection
indicator (yellow) illuminates when the input voltage increases to above 530VAC.
This condition is reported to the system MCA, which issues an AC Fail alarm.
When the AC input voltage decreases to within design parameters, the rectifier
automatically restarts.
c) Input Under-Voltage Protection: A rectifiers protection indicator (yellow)
illuminates when the input voltage decreases to below 256VAC. The rectifier
shuts down and the system MCA issues an AC Fail alarm if the input voltage
decreases to below approximately 248VAC. When the AC input voltage
increases to within design parameters, the rectifier automatically restarts.

Page 8
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Output Protection:
a) Current Limiting: The maximum current delivered by the system can be
programmed from 10% to 110% of total system capacity. The system MCA
automatically adjusts the current limit circuit on each V200 Retrofit so that this
value is not exceeded. If a V200 Retrofit fails, the MCA automatically resets
current limit point of each remaining V200 Retrofit to maintain this value. The
MCA also insures that the current limit circuit of each remaining V200 Retrofit is
not set above 110% of its capacity. The default current limit setting is the sum of
the output ratings of each installed V200 Retrofit. If a V200 Retrofit is added to
the system, the system current limit is automatically increased by the rating of the
new V200 Retrofit and the new current limit value is displayed.
The current limiting point can be adjusted without removing a V200 Retrofit. One
adjustment changes the setting of all V200 Retrofits.
The current limit is factory set at 100% of rated full load, unless otherwise
specified.
b) Thermal Power Limiting: Each rectifier continuously monitors the ambient
temperature surrounding the power conversion circuit. If this temperature for any
reason (such as a high ambient temperature) increases above approximately
+45C (+113F), the Rectifier will not shut down. Rather, the rectifier will limit its
maximum output power to maintain the temperature of the power conversion
circuit within design parameters. Operation between +45C (+113F) and +65C
(149F) will result in the output power being decreased. Full power capability is
restored when the temperature decreases to below approximately +45C
(+113F). Figure 4 illustrates typical operating parameters.
Warning: The module is rated for continuous operation at full output power up to
+45C (+113F). Operation between +45C (+113F) and +65C (149F)
will result in output power decreasing. Operation above +65C (+149F)
1
is considered abnormal and should be used on a temporary basis only.
1
Temporary Operation at Abnormal Temperature: Temporary operation refers
to a period of not more than eight consecutive hours per day, and a total of
not more than 15 days in a year. (This refers to a total of 120 hours in any
given year, but no more than 15 occurrences in that one year period.)

Output Power vs. Temperature at Uin > 304 VAC


120

100
% of output power

80

60

40

20

0
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80
Temperature (C)

Figure 4
Typical Thermal Power Limit Curve

Page 9
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

c) Output Fusing: Output fusing is provided in each Rectifier. If a fuse opens,


local and remote Rectifier Fail Alarms activate. This fusing is not customer
replaceable.
d) High Voltage Shutdown (Each Rectifier):
1) Selective: If rectifier output voltage exceeds an adjustable preset value and
is delivering more than 10% of its rated current, the rectifier shuts down.
After approximately 6 seconds, the rectifier automatically restarts. If rectifier
output voltage again exceeds the high voltage shutdown value within 5
minutes, the rectifier shuts down and locks out. Manual restart is then
required (by turning AC power off or removing the rectifier, then reapplying
AC power or reinserting the rectifier). If the rectifier does not experience a
high voltage condition within the 5 minute time period, the restart circuit is
reset.
Only the rectifier causing the high voltage condition shuts down.
Setpoint is adjustable from 56.00 to 59.50 volts DC. Factory set at 57.50
volts, unless otherwise specified. One adjustment at the system MCA
changes the setting of all Rectifiers.
2) Backup: If rectifier output voltage exceeds a second (non-adjustable) value,
the rectifier shuts down and locks out regardless of load. Manual restart is
then required. The backup HVSD setpoint is 59.5V (within the range of 58.5
to 60V).
Load Sharing (via system MCA): The MCA load sharing feature automatically
balances the load to within 2% of the rectifiers rated output current. If the MCA's load
sharing feature is disabled for any reason, advanced digital active load sharing
technology in each Rectifier balances the load. The MCA's load sharing feature is
disabled whenever the system is in current limit, the system is delivering more than 97%
capacity, or the system is delivering less than 3% capacity.
Note: For optimal load sharing between the V200 Retrofits and legacy V200 PCUs,
MCA version 4.2.0 or newer is required. With earlier MCA versions, system
functionality is maintained; however, load sharing will not be proportional.
Startup Time: Each rectifier has two startup modes:
a) Normal Soft Start Time: The duration from the time when the Rectifier is
powered on to the time when the Rectifier provides output voltage is <8s.
b) Current Walk-In: The rise time of the Rectifier output voltage is >8s at 90% of
the rated load, and the maximum time is 90s at 100% of the rated load.
Hot Swappable: Each rectifier is designed to be plug-and-play. The rectifier can be
inserted or removed from a live DC power system with no damage. When the rectifier is
plugged into the system, the system output voltage will not be affected.

Note: The Retrofit Mounting Frame CANNOT be installed in or removed from the
Power Bay unless all Rectifiers are first removed from the Mounting Frame.
Doing so will defeat the precharge circuit in the rectifiers and cause arching
and pitting on the DC power connector!

Cooling: Each rectifier contains two fans for front-to-back forced convection cooling.
Fan Control: When the PFC bus voltage is within a normal range, the built-in processor
adjusts the fans speed according to the Rectifiers internal temperature and output
current. For example, a higher temperature or output current will increase the fan speed.

Page 10
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Above 45C at full load, the fan operates at full speed. When the PFC bus voltage is
abnormal, such as very low bus voltage, the fan turns off.
Fan Fault Protection: An alarm will be generated upon a fan fault. In such cases, the
fault indicator (red) on the Rectifier front panel will flash and the Rectifier will also inhibit
its output. Auto-recovery is enabled upon the clearing of the corresponding fault.
Communication Failure: A rectifiers protection indicator (yellow) will begin flashing
should it experience a communication failure. The failure information will be reported to
the Controller and the Controller will process the failure accordingly. During a
communication failure, in order to protect the battery, rectifier output voltage will
automatically adjusted to a default value of 53.5 V. The rectifier will revert to normal
operation once normal communication is restored.
Imbalance of Rectifier Output Current: When the output current of a rectifier in a DC
power system is unbalanced, the rectifier having the unbalanced output current will be
identified automatically and its protection indicator (yellow) will illuminate.
The failure information will be reported to the Controller and the Controller will process
the failure accordingly.
Paralleling: A Power System equipped with V200 Retrofits may be connected in parallel
with any rectifier of the same polarity and adjusted to the same output voltage.
Emergency Shutdown and Fire Alarm Disconnect: The rectifiers can be inhibited by
application of an external ground signal to the system. Manual restart is required. This
option is selectable on the bays only and not the retrofit shelf.
Note: The cooling fans will continue to operate if AC input voltage is present.
Net Weight: 67 Lbs. (Mounting Frame with Two Rectifiers)

INSTALLATION
Safety Statement
Danger: INSTALLERS MUST FOLLOW APPROVED SAFETY PROCEDURES.
Hazardous AC and DC power sources are connected to, and are present
within, the Power System. Following this installation procedure will
minimize the possibility of personal injury or equipment damage. Refer to
the documentation provided with your Power System for any installation
or maintenance procedures beyond the scope of this upgrade procedure.
The NetSure Model V200E50 DC Power Retrofit is designed to mount in a Model
1231V1, Spec. No. 582121300 Power Bay. Installation in any other Power System
should not be attempted.
Installation consists of removing one existing V200E50 Power Conversion Unit (PCU) or
blank cover panel from the Power Bay, installing the V200 Retrofit Mounting Frame in the
Power Bay, and installing the two furnished NetSure R48-5800e Rectifiers in the
Mounting Frame.
The V200E50 Retrofit can be installed while the Power System is in service. Before
starting, ensure that all AC input and DC output connections to the Power Bay are intact.
No changes or adjustments are required for these connections when installing the
V200E50 Retrofit. All wiring and grounding should follow the current edition of the
National Electrical Code and applicable local codes.
Performing this upgrade procedure may activate external alarms. Do one of the
following. If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any future alarms associated with this
system while this procedure is being performed.

Page 11
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Follow the procedures below to replace one or more existing V200E50 Power Conversion
Units (Rectifiers) with the NetSure V200E50 Retrofit.
Checking System Compatibility
Check your system compatibility before starting this procedure as follows.
Procedure
1) With SYSTEM OK being displayed on the MCA Interface Pad, check your MCA
software version by pressing and releasing the FUNCTION SET ENTER
pushbutton.
2) Repeatedly press and release the FUNCTION SELECT DOWN arrow
pushbutton until "CONFIGURE MENU" is displayed.
3) Press and release the FUNCTION SET ENTER pushbutton.
4) "VERIFY INVENTORY" is displayed. Press and release the FUNCTION SET
ENTER pushbutton.
5) Repeatedly press and release the FUNCTION SELECT DOWN arrow
pushbutton until "MCA SWV ########" is displayed.
6) Record the MCA software version number displayed.
7) Refer to Table 1. If the MCA software version is 5.2, 5.1, or 5.0; proceed with
this procedure.
If the MCA software version is 4.9 or less and 4.4.3 or better; return your existing
MCA and exchange it for a new version MCA.
If the MCA software version is 4.4.2 or less; purchase a new version MCA.
8) To return to the beginning of the MCA Logic Tree, press and release the
FUNCTION SET YES (+) and NO (-) pushbuttons simultaneously.
Remove Style Strips from Power Bay
Procedure
1) Remove the two style strips from the front left and right edges of the VPS Power
Bay being upgraded. These conceal the mounting hardware. The style strips
are secured at the bottom with a captive fastener, and at the top with a pin that
passes through a hole in the style strip. To remove the style strip, loosen the
captive fastener at the bottom, and slide the bottom of the style strip out and up.
Remove the Power Conversion Unit (PCU) or Blank Cover Panel
Procedure
1) If the mounting position in the Power Bay has a cover panel rather than a V200
PCU, remove the cover panel by first removing the four screws that secure it.
Then skip steps 2 and 3.
Note: In the next step, the OUTPUT SWITCH has a mechanical interlock that
prevents a PCU from being plugged into or pulled out of a bay with the device
in the "on" position.
Caution: In a system with NO redundant Rectifier, battery must have sufficient
reserve to power the load(s) while the Rectifier is removed.
2) On the PCU to be removed, place the Standby/Operate switch to the "standby"
position, then the OUTPUT SWITCH to the 0 "off" position. See Figure 5 for
locations.

Page 12
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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

FAN
FAIL FAIL

Figure 5
Switch Locations

Danger: In the next step, use two people to remove a PCU. A PCU weighs
approximately 80 lbs.
Note: In the next step, a safety latch is present on each PCU that prevents the PCU
from inadvertently being removed completely from the Power Bay.
3) Loosen the captive fasteners on the front of the PCU to be removed. Use the
handles provided on the front of the PCU, and pull the PCU out until it is stopped
by a safety latch located on the right-hand side panel of the PCU. Refer to
Figure 6 for latch and release location. Depress and hold the latch release, and
remove the PCU from the Power Bay. Support the bottom of the PCU as you
pull it out.

LATCH SAFETY
RELEASE LATCH

Figure 6
Right Side View of V200 PCU Showing Location of Safety Latch and Latch Release

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Install the Mounting Frame


The Retrofit Mounting Frame CANNOT be installed in the Power Bay unless all
Rectifiers are first removed from the Mounting Frame. Doing so will defeat the
precharge circuit in the rectifiers and cause arching and pitting on the DC power
connector!

Checking the Power Bays Rectifier


AC/Data Connector in Older Style Bays
Identifying Older Style Bays
1) Older style bays have Rectifier AC/Data connectors that do not have springs as
shown in Figure 7. In bays that have Rectifier AC/Data connectors without
springs, perform the following procedure.

Spring
Newer Style Bays
Have the Springs,
Older Style Bays
Do Not Have Springs

Rectifier
AC/Data
Connector

Spring

Figure 7
Identifying Older Style Bays

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Check Procedure (Older Style Bays Only)


1) With the PCU removed, use a quality wooden carpenters ruler or other non-
conductive rule. Place the measuring device directly against the unpainted
bracket holding the AC/Data connector. Take two measurements, one on the
bottom of connector directly next to the bolt through the black ac housing, and
note the distance to the front outside of the left side panel. Take second
measurement on the top of the AC/Data connector. Both must measure 15-5/16
+ 1/16 or -1/16 tolerance. See Figure 8.

Figure 8
Taking Measurements
2) Pay close attention to the measurements, they must be within 15-1/4 to 15-3/8.
If a measurement is greater than 15-3/8 or less than 15-1/4, adjustment is
required (see next procedure).
Adjustment Procedure (Older Style Bays Only, if required)
1) When adjustment of the PCU slot is required, it is recommended to remove the
PCU below the slot which requires adjustment. This allows the AC/Data
connector to be moved as required to properly set the 15-5/16 measurements.
Note: The MCA will alarm with the removal of any PCU, so be aware Minor and
Major alarms could be generated during this process.
2) In the PCU slot to be adjusted, remove the rear sheet metal panel on the rear of
bay and locate the two Philips 1/4 self tapping screws at the bottom of panel,
which holds the AC connector. Loosen these screws. See Figure 9.
3) Directly to the right of the two Philips screws is a single 1/4 inch hex bolt which
also must be loosened for lower adjustment. See Figure 9.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Loosen These

Figure 9
Locating the Bottom Two 1/4 Self Tapping Screws and 1/4 Hex Bolt
4) Next loosen the two Philips 1/4 self tapping screws at the top of the PCU
position to be adjusted. See Figure 10.

Loosen These

Figure 10
Locating the Top Two 1/4 Self Tapping Screws
5) With hardware loosened, measure the bottom first for a 15-5/16 and secure the
single 1/4 hex bolt first.
6) With bottom secured at 15-5/16, move to the top of the AC connector and
measure for 15-5/16, then secure the two Philips screws at the top of the back
plane sheetmetal.
Note: The process of measurement and securing the hardware may take two
people to keep the panel from moving when retorqueing the hardware.
7) Torque the top and bottom 1/4 screws (2 each) and bottom 1/4 bolt to 84 in-lbs.
8) Recheck the measurements by performing the previous procedure to verify the
proper measurements.

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Mounting Procedure
1) Remove the front cover panel from the Mounting Frame by first loosening two
captive fasteners. Refer to Figure 11.

Mounting Frame

Front Cover Panel

Captive Fasteners

Figure 11
Removing the Cover Panel from the Mounting Frame

Note: In the next step, the Mounting Frame CANNOT be installed in the Power
Bay unless all Rectifiers are first removed from the Mounting Frame.
Doing so will defeat the precharge circuit in the rectifiers and cause
arching and pitting on the DC power connector!

2) Ensure no Rectifiers are present in the Mounting Frame.


3) Slide the empty Mounting Frame into an open mounting position in the Power
Bay.
4) Using the hardware supplied, secure the Mounting Frame to the Power Bay.
Electrical Connections
All electrical connections to the Mounting Frame are made automatically when the
Mounting Frame is installed in the Power Bay. No additional connections are required.

Install the Rectifiers


Procedure
1) Place one Rectifier into an unoccupied mounting position in the Mounting Frame
without sliding it in completely.
2) Push the Safety Latch Release located on the front of the Rectifier UP. Refer
to Figure 12 for an illustration.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Handle
Captive
Fastener Safety
Safety
Latch
Latch
Release Handle Pin

Figure 12
Rectifier Handle and Safety Latch

3) Gently push the Rectifier into the Mounting Frame until it stops. Note that the
Rectifier will NOT be completely seated in the Mounting Frame until the next step
is performed.
4) Push the Safety Latch Release located on the front of the Rectifier DOWN.
Gently push the Rectifier into the Mounting Frame until it is completely seated.
5) Push the Rectifier handle in and secure the Rectifier to the bay by tightening the
captive fastener located on the handle.
6) Repeat Step 1 though 5 for each of the remaining Rectifiers.
7) After the Rectifiers are physically installed in the Mounting Frame, they are ready
for operation immediately after power is supplied to them.
8) On the Power System controller (MCA), update the system inventory as
necessary. Refer to the Power System documentation for a procedure.
Note: The MCA identifies the entire Retrofit Assembly as one PCU.
9) Ensure that there are no local or remote alarms active on the system.
10) Install the front cover on the Mounting Frame. Secure by tightening the two
captive fasteners. Refer to Figure 13.

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

(2) R48-5800
Rectifiers Installed

Mounting Frame

Front Cover Panel


Captive Fasteners
Figure 13
Securing Front Cover Panel

Install Remaining Retrofits in Power Bay


Repeat the installation procedure for each V200 Retrofit remaining to be installed in the
Power Bay.
Reinstall Style Strips on Power Bay
After all Retrofits have been installed in the Power Bay, replace the left and right style
strips on the front of the bay by sliding the top of the style strip up and over the pin
located on top of the bay, then sliding the bottom in and securing with the captive
fastener.
Repeat Procedure for Remaining Power Bays
Repeat the entire installation procedure for any remaining Power Bays in the Power
System that are to receive the V200 Retrofit.
Load Share Alarm
When mixing the retrofit rectifiers with existing rectifiers in the same system, turn off the
load share alarm as follows.
Procedure
1) With "SYSTEM OK" being displayed on the MCA Interface Pad, press and
release the FUNCTION SET ENTER pushbutton.
2) Repeatedly press and release the FUNCTION SELECT DOWN arrow
pushbutton until "CONFIGURE MENU" is displayed.
3) Press and release the FUNCTION SET ENTER pushbutton.
4) Repeatedly press and release the FUNCTION SELECT DOWN arrow
pushbutton until "SHARE ALARM OFF" or "SHARE ALARM ON" is displayed.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

5) If "SHARE ALARM ON" is displayed, perform steps 6) through 8) to toggle this


setting to off. If "SHARE ALARM OFF" is displayed, proceed with step 8).
6) To toggle this setting, press and release the ALARM CUTOFF and FUNCTION
SET ENTER pushbuttons simultaneously.
7) "ARE YOU SURE? +-" is displayed. Press and release the FUNCTION SET
YES (+) pushbutton.
8) Press and release the FUNCTION SET YES (+) and NO (-) pushbuttons
simultaneously, to return to the beginning of the MCA menu tree.
Local Sense
If the system is wired for remote sense, it is recommended to switch to local sense as
follows.
Procedure
1) Open the top access door located on the rear of the 1st VPS Power Bay (the bay
with rectifiers #1-7) by loosening the two captive fasteners.
Danger: Hazardous AC and DC voltages are present on terminations behind
the access door.
2) Refer to Figure 14 and locate "VPS Power Bay to MCA Interface" circuit card
509962. Locate connector J1 on the circuit card.
3) If the wires connected to J1 run to the busbars on the upper left of the bay, the
unit is locally sensed. If the wires connected to J1 run to a remote point
elsewhere within the plant, it is remote sensed. The load sharing performance of
the Retrofit rectifiers will be better when locally sensed.
4) If the system is determined to be wired for remote sense, carefully change it over
for local sense as follows. Disconnect, insulate, and tie back the remote sense
leads connected to J1. Connect a 20 AWG local sense lead from the Bays
Positive output busbar to terminal 2 of J1. Connect a 20 AWG local sense lead
from the Bays Negative output busbar to terminal 1 of J1.
Final Step
Enable the external alarms, or notify appropriate personnel that this procedure is finished.

Page 20
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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

-SNS +SNS

J1

J42
J40 J41 J43 J44 J45 J46 J47
J30 F1

"VPS POWER BAY TO MCA INTERFACE"


CIRCUIT CARD 509962

REAR VIEW OF
1st VPS POWER BAY

Figure 14
VPS Power Bay to MCA Interface Circuit Card 509962

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

OPERATION
Local Indicators
Four indicators are located on the front panel of each rectifier in the V200 Retrofit. The
functions of these indicators are as shown in Table 4. Refer to Figure 15 for the location
and identification of the local indicators.
Note: DC voltage must be present at the V200 Retrofit output terminals, (from battery or
an operating rectifier) for local indicators to illuminate.

Power
Indicator
(Green)

Protection
Indicator
(Yellow)

Fault
Indicator
(Red)

Output Current
Indicator
Figure 15
Status Indicators

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Normal Fault
Indicator Fault Cause
State State

Power No input voltage.


On Off
(Green) Internal input fuse open.

AC input under/over voltage.


PFC output under/over voltage.
Protection On
Off High temperature.
(Yellow)
Load sharing imbalance.
Flashing Rectifier communication failure.
Rectifier output disabled for any reason (including overvoltage
Alarm On shutdown and internal output fuse open).
Off Rectifier addresses contradictory.
(Red)
Flashing Faulty fan (Rectifier shuts down).

Shows the output current. Each LED segment represents 10A. If the
Current On -- Rectifier is in current limit (output current > 100A), the tenth LED will
blink.

Table 4
Local Indicators

Rectifier High Voltage Shutdown and Lockout Restart


Procedure
Turn AC power to the V200 Retrofit OFF or remove the rectifier from the V200 Mounting
Frame, wait 30 seconds or more; then turn AC power to the V200 Retrofit ON or re-insert
the rectifier. Refer to Replacing a Rectifier on page 25 for a rectifier removal procedure.

TROUBLESHOOTING AND REPAIR


Troubleshooting
Rectifier Current Sharing Imbalance
When multiple Rectifiers are operating in parallel and the current sharing imbalance
among them is greater than 3%, check to verify the Rectifier is properly seated in the
Mounting Frame. (Refer to Replacing a Rectifier on page 25 for procedure to remove
and reinstall a Rectifier.)
If the current sharing imbalance still persists following the verification suggested above,
replace the rectifier exhibiting the current imbalance.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Rectifier Fault Symptoms and Troubleshooting


The Power System controller (MCA) provides the same fault indications for the Retrofit as
for the original V200E50 PCUs. Refer to your Power System documentation for details.
Note: The system MCA identifies each V200 Retrofit as one PCU. If a PCU fault
condition is indicated, observe the local indicators on the Rectifiers in that Retrofit
to localize the fault to one Rectifier.
The fault indicators that each Rectifier can display are as follows: Power indicator
(green) OFF, Protection indicator (yellow) ON or FLASHING, and Alarm indicator (red)
ON or FLASHING. Refer to Table 5 for a list of possible causes and corrective actions.

Symptom Possible Cause(s) Suggested Action(s)


Power No input voltage. Verify input voltage is available.
Indicator
(Green) Off Internal Input fuse open. Replace the Rectifier.
AC input voltage outside the normal Correct the AC input voltage to
range. within the acceptable range.
PFC over-voltage. Replace the Rectifier.
See Rectifier Current Sharing
Current sharing imbalance.
Imbalance on page 23.
Rectifier over-temperature protection, which could be caused by:
Protection Remove any object that may be
Indicator 1. Fan rotor blocked.
blocking the fan rotor.
(Yellow) On
Remove any object that may be
2. Ventilation blocked (inlet or outlet).
blocking the inlet or outlet.
3. Ambient temperature too high or
Lower the ambient temperature or
Rectifier inlet too close to a heat
relocate the heat source.
source.
Rectifier not inserted into the slot Remove and properly inset the
completely. Rectifier.
Protection Check the communication cables.
Indicator Remove and properly insert the
Rectifier communication failure.
(Yellow) Rectifier.
Flashing Replace Interface Circuit Card.
Remove the Rectifier from the
Overvoltage shutdown. Mounting Frame and then reinstall
Alarm Indicator
after 30 seconds. If Rectifier fails to
(Red) On Internal output fuse open. start or shuts down again, replace
Rectifier.
Alarm Indicator Fans not operating (Rectifier shuts
Replace the fan.
(Red) Flashing down)
Table 5
Rectifier Fault Symptoms and Troubleshooting

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Replacement Procedures
Replacing a Rectifier
Danger: Use caution when removing a Rectifier that has been operating, as
Rectifier surfaces could be very hot.
Warning: In order to prevent damage to the latching mechanism, do not use
excessive force on the Rectifier handle when pushing the Rectifier into
the Mounting Frame.
Caution: In a system with NO redundant Rectifier, battery must have sufficient
reserve to power the load(s) while the Rectifier is removed.
Rectifiers can be inserted or removed with power applied (hot swappable).
Procedure
1) Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any future alarms associated with
this system while this procedure is being performed.
2) Remove the front cover panel from the Mounting Frame by first loosening two
captive fasteners. Refer to Figure 11.
3) THIS STEP MUST BE PERFORMED WITH THE SAFETY LATCH RELEASE
IN THE DOWN (LOCKED) POSITION. On the Rectifier to be removed, loosen
the captive fastener (located on the Rectifiers handle) securing the Rectifier to
the Mounting Frame. Pull the handle out, and gently pull the Rectifier out until it
stops. The Rectifier CANNOT be completely removed until the next step is
performed. Refer to Figure 12 for an illustration.
4) Push the Safety Latch Release located on the front of the Rectifier UP. Slide
the Rectifier completely out of the Mounting Frame.
5) Place the new Rectifier into its mounting position in the Mounting Frame without
sliding it in completely.
6) Push the Safety Latch Release located on the front of the Rectifier UP. Refer
to Figure 12 for an illustration.
7) Gently push the Rectifier into the Mounting Frame until it stops. Note that the
Rectifier will NOT be completely seated in the Mounting Frame until the next step
is performed.
8) Push the Safety Latch Release located on the front of the Rectifier DOWN.
Gently push the Rectifier into the Mounting Frame until it is completely seated.
9) Push the Rectifier handle in and secure the Rectifier to the bay by tightening the
captive fastener located on the handle.
10) After the Rectifier is physically installed in the Mounting Frame, it is ready for
operation immediately after power is supplied to it. Verify that the Rectifier is
operating normally.
11) On the Power System controller (MCA), update the system inventory as
necessary. Refer to the Power System documentation for a procedure.
12) Ensure that there are no local or remote alarms active on the system.
13) Install the front cover on the Mounting Frame. Secure by tightening the two
captive fasteners. Refer to Figure 13.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Replacing the Rectifier Interface Circuit Card


One Rectifier Interface Circuit Card, Part No. 547568, is located within the V200 Retrofit
Mounting Frame. To replace this circuit card perform the following procedure.
Caution: When performing any step in this procedure that requires removal or
installation of hardware, use caution to ensure no hardware is dropped
and left inside the cabinet; otherwise service interruption or equipment
damage may occur.
Warning: Circuit cards used in this equipment contain static-sensitive devices.
Read the Static Warning page at the front of this document before
performing the following procedure.
Note: When performing any step in this procedure that requires removal of existing
hardware, retain all hardware for use in subsequent steps.
Procedure
1) Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any future alarms associated with
this system.
2) Remove the front cover panel from the Mounting Frame by first loosening two
captive fasteners. Refer to Figure 11.

Note: The Retrofit Mounting Frame CANNOT be installed in or removed from


the Power Bay unless all Rectifiers are first removed from the Mounting
Frame. Doing so will defeat the precharge circuit in the rectifiers and
cause arching and pitting on the DC power connector!

3) Remove both Rectifiers from Mounting Frame. Refer to the previous procedure,
Replacing a Rectifier, for step-by-step instructions.
4) Remove the two style strips from the front left and right edges of the VPS Power
Bay being upgraded. These conceal the mounting hardware. The style strips
are secured at the bottom with a captive fastener, and at the top with a pin that
passes through a hole in the style strip. To remove the style strip, loosen the
captive fastener at the bottom, and slide the bottom of the style strip out and up.
5) Remove the four screws that secure the Mounting Frame to the Power Bay.
Remove the Mounting Frame to a static-safe work station.
Warning: Damage to the circuit card may result if the next step is not followed.
6) Connect an approved grounding strap to your wrist. Attach the other end to a
suitable ground.
7) Remove the top cover from the Mounting Frame by first removing three screws
from each side along the top. Refer to Figure 16.
8) Locate the interface circuit card, Part No. 547568. Refer to Figure 16.

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Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

Top Cover

Interface Circuit Card


P/N 547568

Figure 16
Replacing the Rectifier Interface Circuit Card

9) Disconnect two (2) cables from the interface circuit card.


10) Remove the one screw that secures the circuit card. Carefully lift the circuit card
from its mounting posts, and remove.
11) Place the circuit card over its mounting posts and carefully press down at each
post until fully seated. Install and tighten the one mounting screw.
12) Connect the two cables previously disconnected.
13) Install the top cover on the Mounting Frame and secure with the six previously
removed screws.
14) Remove the grounding wrist strap.

Note: In the next step, the Retrofit Mounting Frame CANNOT be installed in the
Power Bay unless all Rectifiers are first removed from the Mounting
Frame. Doing so will defeat the precharge circuit in the rectifiers and
cause arching and pitting on the DC power connector!

15) Slide the Mounting Frame into its mounting position in the Power Bay. Secure
with the four previously removed screws.
16) Install the two Rectifiers into the Mounting Frame. Refer to the previous
procedure, Replacing a Rectifier, for step-by-step instructions.

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UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

17) After the Rectifiers are physically installed in the Mounting Frame, they are ready
for operation immediately after power is supplied to them. Verify that the
Rectifiers are operating normally.
18) On the Power System controller (MCA), update the system inventory as
necessary. Refer to the Power System documentation for a procedure.
19) Ensure that there are no local or remote alarms active on the system.
20) Install the front cover on the Mounting Frame. Secure by tightening the two
captive fasteners. Refer to Figure 13.
Replacing a Fan in a Rectifier
Each Rectifier in a Mounting Frame uses two fans for cooling. If fan replacement should
become necessary, perform the following procedure. It is recommended that both fans in
the Rectifier be replaced at the same time.
Refer to Figure 17 as this procedure is performed.
Caution: In a system with NO redundant Rectifier, battery must have sufficient
reserve to power the load(s) while the Rectifier is removed for fan
replacement.
Warning: Circuit cards used in this equipment contain static-sensitive devices.
Read the Static Warning page at the front of this document before
performing the following procedure.
Note: When performing any step in this procedure that requires removal of existing
hardware, retain all hardware for use in subsequent steps.
Procedure
1) Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any future alarms associated with
this system while this procedure is being performed.
2) Remove the Rectifier from the Mounting Frame. Refer to a previous procedure,
Replacing a Rectifier, for step-by-step instructions.
3) Place the Rectifier on a static-safe work surface. Connect an approved
grounding strap to your wrist for the remainder of this procedure.
4) Remove the five (5) faceplate mounting screws shown in Figure 17 from the
Rectifier. Remove the faceplate.
5) Carefully pull the fan(s) out from the Rectifier chassis, until the fan power
cable(s) can be accessed.
6) Unplug the fan power cable(s) from connector(s) on the PC board, and remove
the fan(s).
7) Plug the power cable(s) of the replacement fan(s) into the connector(s) on the
PC board.
8) Place each fan in its cavity in the Rectifier chassis, orienting the fan so that:
a) The arrow on the fan body points toward the rear of the Rectifier, and
b) The power cable exits the fan body toward the other fan, as shown in Figure
17.
9) Reinstall the faceplate on the Rectifier chassis. Ensure that no fan wiring is
pinched. Secure faceplate with the five (5) previously removed screws.

Page 28
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

10) Reinstall the Rectifier into the Mounting Frame. Refer to a previous procedure,
Replacing a Rectifier.
11) When the fans start, check to ensure that each is providing front-to-back airflow.
If air direction is wrong, immediately remove the Rectifier from the Mounting
Frame. Repeat previous steps to check fan orientation, and correct as
necessary. Reinstall the Rectifier and again check for proper airflow.
12) Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
13) Ensure that there are no local or remote alarms active on the system.

Page 29
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Faceplate
to Chassis
Screws

Fan Rotation Arrows


(Location varies)

Fan

Faceplate
to Chassis
Screws

Fan

Fan mating power


connectors located
at top of Rectifier
chassis

Rectifier
Faceplate

P o sition fans with


po wer cables exitin g
fans here.

Fro nt V ie w

Figure 17
Rectifier Fan Replacement

Page 30
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Installation and User Instructions UM486531003
Spec. No. 486531003 (V200E50) Issue AG, November 30, 2012

This Page Left Intentionally Blank

Page 31
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
UM486531003 Installation and User Instructions
Issue AG, November 30, 2012 Spec. No. 486531003 (V200E50)

Revision Record
Change
Issue Number Description of Change
(ECO)
AA LLP214942 New
AB LLP215618 Specification revisions.
AC LLP216267 Load sharing note added to specifications.
Change 1R485800 to 1R485800E in LVPS, and add the 1R485800E as an
AD LLP216414
available option in the NS801.
AE LLP217652 Updated per product evaluation report.
AF LLP217652 Added compatibility matrix table and procedure.
AG LLP218026 Added procedure to check AC/Data connectors in older style bays.

Page 32
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
NetPerform Optimization Services
At Emerson Network Power, we understand the importance of reliable equipment its critical to both
your business and your bottom line. That is why we offer a wide array of services to meet all of your
network infrastructure needs.

Technical Support
Email [email protected] Answers technical product and system
[email protected] questions; determines status of warranties and
Phone 1.800.800.5260 contractual agreements for repair.

Services - Design, Deployment & Optimization


Email [email protected] Provides quotes and bid responses, order
Phone 1.800.800.1280, option 7 placement and scheduling for design, and
deployment and optimization services.
FreedomCare Secure.EmersonNetworkPower.com Download service & maintenance reports
online.

Spare Parts
Email [email protected] Pricing and PO processing of spare parts,
[email protected] including but not limited to breakers, cables,
fuses, rectifier fans, misc. breaker and fuse
Phone 1.800.800.1280, option 5
panels, enclosure fans, doors & switches, etc.

DC Power Depot Repair


Email [email protected] Creates and processes RMAs, determines
Phone 1.800.800.1280, option 6 lead times and pricing, provides repair
shipping information and status.

DC Power Product Training


Email [email protected] Requests for quotes, order placement and
scheduling.
Phone 1.800.800.1280, option 8

For More Information


To learn more about service offerings from Emerson Network Power, please contact your sales
representative, call 1-800-800-1280 option 7, email [email protected] or visit
www.EmersonNetworkPower.com/EnergySystems.

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