NetSure™ -48V DC Power System User Instructions, UM582127000 (Issue AC, January 2, 2013) Specification Number: 582127000 Model Number: 721NPBB
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User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 TABLE OF CONTENTS CONTENTS PAGE IMPORTANT SAFETY INSTRUCTIONS .................................................................................. iii General Safety .................................................................................................................................................... iii Voltages ..........................................................................................
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing the ACU+ Controller ................................................................................................................... 25 Replacing a Distribution Device ................................................................................................................... 26 Circuit Card Replacement Procedures ..................................................................................
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 IMPORTANT SAFETY INSTRUCTIONS GENERAL SAFETY Danger: YOU MUST FOLLOW APPROVED SAFETY PROCEDURES. Performing the following procedures may expose you to hazards. These procedures should be performed by qualified technicians familiar with the hazards associated with this type of equipment. These hazards may include shock, energy, and/or burns.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) CIRCUIT CARD HANDLING Warning: Installation or removal of the circuit cards requires careful handling. Before handling any circuit card, read and follow the instructions contained on the Static Warning Page. Page iv Important Safety Instructions This document is property of Emerson Network Power, Energy Systems, North America, Inc.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 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 document. 2.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) This Page Left Intentionally Blank Page vi Static Warning 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.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 CHAPTER 1. SYSTEM OVERVIEW CUSTOMER DOCUMENTATION PACKAGE This document (UM582127000) provides User Instructions for NetSure™ Power System Model 721NPBB, Spec. No. 582127000.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) This system consists of the following components. Distribution Cabinet The system always includes a minimum of one distribution cabinet, which provides DC distribution through fuses and/or circuit breakers. The distribution cabinet is factory mounted in the relay rack or shipping brackets specified when ordered.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Optional DC-DC Converter Modules (for use in Spec. No. 588705300) Where +24V DC load power is also required, DC-DC converter modules are available. Refer to the Converter Instructions (UM1C48241500) for more information. Chapter 1. System Overview Page 3 This document is property of Emerson Network Power, Energy Systems, North America, Inc.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) CHAPTER 2. OPERATING PROCEDURES CONTROLLER, RECTIFIERS, AND OPTIONAL CONVERTERS For operation instructions on these units, refer to the following documents.
User Instructions Spec. No.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) System Interface Circuit Card The system interface circuit card contains test points to externally monitor bay voltage and bay load. Refer to Figure 2-2.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Optional LVD Driver Circuit Card The optional LVD driver circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 2-3. LVD driver circuit cards are required for 2-, 3-, or 4-row distribution cabinets that contain three or more LVD contactors (LVBD and/or LVLD); or if the distribution cabinet is equipped with an LVBD contactor rated 1200A or higher.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Optional LVD Driver Lite Circuit Card The optional LVD driver lite circuit card installed in the main bay contains an LVD inhibit switch and indicator. Refer to Figure 2-4. LVD driver lite circuit cards are required for distribution cabinets that contain two LVLD contactors or one LVLD contactor and one LVBD contactor. LVBD contactor must be rated at 600A or lower.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Optional Manual Battery Disconnect Circuit Card (Main Bay Only) The optional manual battery disconnect circuit card contains a manual battery disconnect switch and indicator. Refer to Figure 2-5. J2 J1 S1 Manual Battery Disconnect Switch Manual Battery Disconnect Active Indicator Illuminates if the Battery Disconnect Contactor has been manually disconnected (placed in open position).
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) SM-DU Circuit Card The SM-DU is used in supplemental bays in place of ACU+ controller. The SM-DU monitors the bay and reports to the controller. The controller sends commands to the SM-DU to fulfill battery management and load control functions according to the received data. There are three (3) status and alarm indicators located on the SM-DU.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 CHAPTER 3. MAINTENANCE SYSTEM MAINTENANCE PROCEDURES It is recommended to perform the maintenance procedures listed in Table 3-1 every 6-months to ensure continual system operation. PROCEDURE REFERENCED IN Check ventilation openings for obstructions such as dust, papers, manuals, etc. Inspect and tighten all installer's connections. COMPLETED (√) -IM582127000, Chapter 4. Making Electrical Connections.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Rectifiers modules can be installed in any mounting position of each module mounting shelf. Converters modules can be installed in any of the three far right mounting positions of each module mounting shelf (as viewed from the front). See Figure 3-1. Note: Each rectifier and converter module locks into the module mounting shelf by means of a latch located on the bottom of the module.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Module Mounting Shelf(s) Front View Rectifier Mounting Positions Rectifier or Converter Mounting Positions Rectifier Converter Captive Screw Captive Screw Handle Handle Latch Latch Figure 3-1 Installing Rectifier and Converter Modules in a Spec. No. 588705300 Shelf Chapter 3. Maintenance Page 13 This document is property of Emerson Network Power, Energy Systems, North America, Inc.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) INSTALLING A FIELD EXPANSION RECTIFIER MODULE MOUNTING SHELF SPEC. NO. 588705000 Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. Note: Refer to Figure 3-2 and Figure 3-3 as this procedure is performed. Procedure 1) Install the expansion rectifier module mounting shelf directly below the bottommost rectifier module mounting shelf in the rack.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Front View (Install Expansion Rectifier Module Mounting Shelf) Rear View (Remove Rear Shield from Rectifier Module Mounting Shelf and Shelf Above It) Figure 3-2 (cont’d on next page) Installing a Field Expansion Rectifier Module Mounting Shelf Spec. No. 588705000 Chapter 3. Maintenance Page 15 This document is property of Emerson Network Power, Energy Systems, North America, Inc.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Rear View (Install Output Busbars from Kit) Completed View 1st Expansion Shelf 2nd Expansion Shelf Figure 3-2 (cont’d from previous page) Installing a Field Expansion Rectifier Module Mounting Shelf Spec. No. 588705000 Page 16 Chapter 3. Maintenance This document is property of Emerson Network Power, Energy Systems, North America, Inc.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Distribution Cabinet Wire Harness Slate and Slate/White Wires Brown and Brown/White Wires These cables are factory connected. Existing Rectifier Module Mounting Shelf These cables are factory connected. Existing Rectifier Module Mounting Shelf These cables are factory connected.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) INSTALLING A FIELD EXPANSION RECTIFIER/CONVERTER MODULE MOUNTING SHELF SPEC. NO. 588705300 Danger: Adhere to the “Important Safety Instructions” presented at the front of this document. Note: Refer to Figure 3-4 and Figure 3-5 as this procedure is performed. Procedure 1) Remove the busbar rear shield from the existing rectifier/converter shelves.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 1. Remove busbar rear shield from existing rectifier/converter shelves. Remove the cut-out panel from the busbar rear shield. Busbar Rear Shield Cut-Out Panel 2. Remove hardware from the lowest module mounting shelf’s -48V, return, and +24V (if present) busbars. Rear 3. Install the expansion module mounting shelf into the rack. 4. Remove busbar rear shield from expansion module mounting shelf. Front Rear 5.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Distribution Cabinet Wire Harness Exploded View Shown to Illustrate Wire Connections Only Slate and Slate/White Wires Existing Module Mounting Shelf Brown and Brown/White Wires These connectors are factory connected. Rear View Factory provided jumper to bring connectors to same side of shelf. Existing Module Mounting Shelf These connectors are factory connected.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 CHANGING THE ACU+ LVD CONTROL LEVEL FOR A CONTACTOR The ACU+ Controller has two available LVD control levels (LVD1 and LVD2). The level used to control a contactor is determined by which connector on the LVD circuit card its control leads are plugged into.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) CHAPTER 4. TROUBLESHOOTING AND REPAIR CONTACT INFORMATION Support contact information is provided on the inside of the back cover of this document. CONTROLLER, RECTIFIERS, AND OPTIONAL CONVERTERS For troubleshooting and repair instructions on these units, refer to the following documents.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Procedure 1) With the Main screen displayed, press ENT to go to the Main Menu. Navigate to and select “Settings” (ENT). 2) If a password screen opens, a password must be entered to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this step and proceed to step 3).
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) 2) If a password screen opens, a password must be entered to allow the User to make adjustments. If a password was previously entered and has not yet timed out, skip this step and proceed to step 3). Otherwise, to enter a password, with the cursor at the User Name field (default is “Admin”), press the down arrow key to move cursor down to the password line. Press ENT. “0” is highlighted.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 press ENT twice. (Note: If you have been assigned a unique User Name and password, follow this procedure to enter these.) 3) With the Manual menu screen displayed, navigate to and select “Converter” (ENT) / “All Conv Ctrl” (ENT). 4) Navigate to “Clear Conv Lost”. Press ENT. “Clear” highlights. 5) Press ENT to select the operation. Press ENT again to confirm.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing a Distribution Device General Replace distribution devices with the same type and rating. Refer to System Application Guide SAG582127000 for part numbers. Distribution Fuse “Alarm Fuse” Replacement If a distribution fuse opens, the associated alarm fuse opens. Replace the distribution fuse before replacing the alarm fuse. Procedure 1) An alarm fuse is removed by pulling it straight out of the fuseholder.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Replacing a TPS/TLS Fuse Procedure Note: Refer to Figure 4-2 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Remove the fuse carrier from the mounted fuseholder body by pulling it straight out. 3) Remove the open fuse from the fuse carrier and replace it with the same type and rating.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing a Bullet Nose Fuseholder Procedure Note: Refer to Figure 4-2 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Remove the fuse carrier from the mounted fuseholder body by pulling it straight out. Hold the fuseholder body while you pull the fuse carrier from the body.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Replacing a Bullet Nose Circuit Breaker Procedure Note: Refer to Figure 4-3 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Operate the defective circuit breaker to the OFF position. 3) Gently rock the defective circuit breaker up and down while pulling firmly outward until the breaker is free from the distribution panel.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing a TPH Fuse Procedure Note: Refer to Figure 4-4 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Remove the fuse carrier from the mounted fuseholder body by grasping its handle and pulling straight out. 3) Remove the open fuse from the fuse carrier and replace it with the same type and rating.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Replacing a TPL-B Fuse Procedure Note: Refer to Figure 4-5 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Remove the fuse case from the mounted fuse block by grasping its handle and pulling it straight out. 3) Open the fuse case. 4) Remove the open fuse from the fuse case and replace it with the same type and rating.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing a GJ/218 Circuit Breaker Procedure Note: Refer to Figure 4-6 as this procedure is performed. 1) Open the distribution cabinet’s front door by turning the latch in the counterclockwise position. 2) Operate the defective circuit breaker to the OFF position. Danger: The bolts being removed in the following step may be at system potential. Use insulated tools.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 INSTALLING CIRCUIT BREAKER Alarm jumper connector. Holes to route shunt jumper through (if applicable). ON OFF Apply anti-oxidizing compound to busbar mating surfaces before mounting circuit breakers. 1/4" Hardened Flat Washer 1/4" Belleville Lock Washer 1/4-20 x 3/4” Bolt (2 places) Torque to 60 in-lbs.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Alarm jumper connectors. INSTALLING CIRCUIT BREAKER Holes to route shunt jumper through (if applicable). 2-pole breaker shown. 3-pole and 4-pole breakers similar. ON OFF Busbar Apply anti-oxidizing compound to busbar mating surfaces before mounting circuit breakers.
UM582127000 Issue AC, January 2, 2013 List AC Only User Instructions Spec. No. 582127000 (Model 721NPBB) Figure 4-7 GJ/218 Circuit Breaker Wiring Diagram (List AC and AD) Chapter 4. Troubleshooting and Repair Page 35 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.
User Instructions Spec. No. 582127000 (Model 721NPBB) List BC Only UM582127000 Issue AC, January 2, 2013 Figure 4-8 GJ/218 Circuit Breaker Wiring Diagram (List BC and BD) Page 36 Chapter 4. Troubleshooting and Repair 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.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Circuit Card Replacement Procedures Warning: Circuit cards used in this power system contain static-sensitive devices. Read the Static Warning at the front of this document before performing any of the following procedures. General The following circuit card replacement procedures can be performed with the system operating. Refer to Figure 2-1 for circuit card locations.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) 9) Remove the screws securing the circuit card and remove the circuit card from the distribution cabinet. 10) In this step, ensure you do not intermix the old and replacement circuit cards. Set the shorting jumpers on the replacement circuit card to match the locations on the old circuit card. Jumper settings are documented in CHAPTER 3.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 J1, J2, J3, J4 Distribution Panels FA Inputs J8 (Main Bay Only) Selects to power Controller from “Battery Power” or not.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) SM-DU Circuit Card Replacement (Supplemental Bays Only) 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 the procedure is being performed.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 SM-DU SM-DU Figure 4-10 SM-DU Circuit Card Replacement (Supplemental Bays Only) Chapter 4. Troubleshooting and Repair Page 41 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.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) IB2 (ACU+ Interface Board) and Optional EIB (ACU+ Extended Interface Board) Replacement (Main Bay Only) 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 the procedure is being performed.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 to ensure that it cannot be pulled out of the terminal block. Repeat for each wire to be reconnected. 13) Remove the grounding wrist strap. 14) Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door. 15) Enable the external alarms, or notify appropriate personnel that this procedure is finished.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Optional EIB Interface Board Assembly J8 J9 Optional EIB Interface Board (Top View) J5 J6 J7 SW1 J2 J3 J4 J5-J9 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs. Figure 4-12 EIB (ACU+ Extended Interface Board) Connector Locations Page 44 Chapter 4. Troubleshooting and Repair This document is property of Emerson Network Power, Energy Systems, North America, Inc.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 SM-DU+ and Shunt Interface Assembly Replacement 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 the procedure is being performed.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) cannot be pulled out of the terminal block. Repeat for each wire to be reconnected. 13) Remove the grounding wrist strap. 14) Close the distribution cabinet’s front door. Turn the latch clockwise to secure the door. 15) Enable the external alarms, or notify appropriate personnel that this procedure is finished. 16) Ensure that there are no local or remote alarms active on the system. Page 46 Chapter 4.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 SM-DU+ and Shunt Interface Board TB1 - TB2 Wire Size Capacity: 16-26 AWG. Recommended Torque: 2.2 in-lbs. RS 232 RS485 RS485 J5 J3 can TB2 J4 J4A Red Indicator Yellow Indicator Green Indicator SW2 SW1 1B 1A pow er J1 J7 SHUNT J1 J8 SHUNT TB1 J6 FUSE J2 ON Shunt Interface Board OFF 12345678 12345678 SM-DU+ Figure 4-13 SM-DU+ and Shunt Interface Assembly Connector Locations Chapter 4.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Optional LVD Driver and LVD Driver Lite Circuit Card Replacement 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 the procedure is being performed.
User Instructions Spec. No. 582127000 (Model 721NPBB) J5 J6 J3 UM582127000 Issue AC, January 2, 2013 J4 J2 J1 J1, J2, J3 To LVLD contactor, uses ACU+ LVD1 control setting (Level 1). J7 J4, J5, J6 To LVLD contactor, uses ACU+ LVD2 control setting (Level 2). S1 DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 (LVD2) if the system is furnished with a Low Voltage Battery Disconnect contactor. J7 To LVBD contactor, uses ACU+ LVD2 control setting (Level 2). Notes: 1.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) DO NOT change a Low Voltage Load Disconnect contactor to LVD Control Level 2 (LVD2) if the system is furnished with a Low Voltage Battery Disconnect contactor. J1 To LVLD contactor, uses ACU+ LVD1 control setting (Level 1). J3 To LVLD contactor, uses ACU+ LVD2 control setting (Level 2). J3 J1 J2 To LVBD contactor, uses ACU+ LVD2 control setting (Level 2).
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Optional Manual Battery Disconnect Circuit Card Replacement 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 the procedure is being performed.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) J2 J1 Figure 4-16 Optional Manual Battery Disconnect Circuit Card Connector Locations Page 52 Chapter 4. Troubleshooting and Repair 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.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Replacing a Distribution Panel Danger: Performing this procedure exposes service personnel to battery potential. Exercise extreme caution not to inadvertently contact or have any tool inadvertently contact any energized electrical termination. Procedure Note: Refer to Figure 4-17 as this procedure is performed.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Installing the Distribution Panel Note: In the following procedure, before making busbar-to-busbar connections, apply a thin coating of electrical anti-oxidizing compound to the mating surfaces of the busbars. 1) Orient the replacement distribution panel into distribution cabinet, checking to ensure no wires are pinched.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Battery Busbar Hardware Ground Busbar Hardware Battery Distribution Panel Distribution Panel Hardware Distribution Panel Hardware Load Distribution Panel Ground Busbar Hardware System Load Distribution Busbar Hardware Front Front Components removed in illustration for clarity only. List DA Dual Voltage Distribution Panel (Lists DB, DC, and DD similar.) /+24/ jumpers.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Replacing a Battery or Load Disconnect Contactor Danger: All sources of AC and DC power must be completely disconnected from this power system before performing this procedure. Use a voltmeter to verify no DC voltage is present on the system busbars before proceeding.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 Battery Disconnect Contactor 5/16-18 x 1” Bolt 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 5/16" Hardened Flat Washer (4 places) Torque to 100 in-lbs. Apply electrical anti-oxidizing compound to busbar mating surfaces. Components removed in illustration for clarity only. Front Contactor styles vary between manufacturer’s.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) 1/2-13 x 1-1/4” Bolt 1/2" Belleville Lock Washer 1/2" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 1/2" Hardened Flat Washer (4 places) Torque to 500 in-lbs. Apply electrical anti-oxidizing compound to busbar mating surfaces. Battery Disconnect Contactor Front Shown being removed from front for clarity only. Removal is from rear.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 5/16-18 x 1” Bolt 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 5/16" Hardened Flat Washer (4 places) Torque to 100 in-lbs. Load Disconnect Contactor Apply electrical anti-oxidizing compound to busbar mating surfaces. Components removed in illustration for clarity only. Front Contactor styles vary between manufacturer’s.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) Components removed in illustration for clarity only. Load Disconnect Contactor 5/16-18 Nut 5/16" Belleville Lock Washer 5/16" Belleville Lock Washer (concave side of Belleville Lock Washers face each other) 5/16" Hardened Flat Washer (4 places) Torque to 100 in-lbs. Apply electrical anti-oxidizing compound to busbar mating surfaces. Front 2-row Distribution Cabinet shown, 3 or 4-row cabinet similar.
User Instructions Spec. No. 582127000 (Model 721NPBB) UM582127000 Issue AC, January 2, 2013 This Page Left Intentionally Blank Chapter 4. Troubleshooting and Repair Page 61 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.
UM582127000 Issue AC, January 2, 2013 User Instructions Spec. No. 582127000 (Model 721NPBB) REVISION RECORD Issue Change Number (ECO) AA LLP216539 AB LLP217311 AC LLP218149 Page 62 Description of Change New Battery Charge Current Limit Functionality added to Operating Procedures chapter. Adding 588705300, R48-2000e3, and C48/24-1500. Removing 588249700. Revision Record This document is property of Emerson Network Power, Energy Systems, North America, Inc.
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