FPRB Installation Manual for SPD Rev AB
Short Description
Download FPRB Installation Manual for SPD Rev AB...
Description
Installation Manual for SPD ISSUE
ECO # DATE
SECTION
REVISIONS DESCRIPTION
APPROVED
AA AB
06-30-2013 10-30-2013
All 3.1.3.7
New document for FPRB AA27540L Added special instruction when installing the N link cable into the Flexi Power terminal block
Wood Lou Wood Lou
NSN Flexi Power Rectifier FPRB PREPARED/DATE: Ferdinand Sisracon / 06/25/2013 CHECKED/DATE: Bear Chen /
MODEL NO.:AA27540L
Flexi Power Rectifier FPRB
Installation Manual for Surge Protective Device Flexi Power Rectifier FPRB
Manufactured by: Emerson Network Power / Embedded Power NSN Part Number: CS7000002.01 Manufacturing PN: AA25130L Visit us @ http://www.emersonnetworkpower.com
Installation Manual for SPD, Rev AB
Page 1 of 45
Flexi Power Rectifier FPRB
Manual Number: 970-009473-0000 Manual Issue: AB Manual Status: Standard Release Date: October 30, 2013 Copyright © 2013 Emerson Electric Co. All rights reserved. CONSIDER IT SOLVED Published in China This document, and the information it contains, are the property of Emerson Network Power Co., Ltd, and are protected by law. Both must be held in strictest confidence at all times. Emerson Network Power grants no license or right to copy, use or disclose either, expressly or by implication.
Disclaimer This document and the information contained herein are provided on an "AS IS" basis. Emerson Network Power may make improvements or changes in this documentation, at any time and without notice and as it sees fit. The information in this documentation was prepared by Emerson Network Power with reasonable care and is believed to be accurate. However, Emerson Network Power shall not assume responsibility for losses or damages resulting from any omissions, inaccuracies, or errors contained herein.
Installation Manual for SPD, Rev AB
Page 2 of 45
Flexi Power Rectifier FPRB
History Date DD-MM-YYY 30-06-2013
30-10-2013
Version
Author
Change Note No./Notes
AA
Ferdinand Sisracon
First release for FPRB
AB
Ferdinand Sisracon
Installation Manual for SPD, Rev AB
Release to be used as a common SPD Instruction Manual for both FPRA and FPRB Added special instruction to connect the N link cable for both FPRA and FPRB
Page 3 of 45
Flexi Power Rectifier FPRB Table of Contents History................................................................................................................................. 3 Table of contents ................................................................................................................ 4 List of figures....................................................................................................................... 5 List of tables ........................................................................................................................ 5 Preface ................................................................................................................................ 9 Application of this manual ............................................................................................ 10 Chapter 1 Product Introduction...................................................................................... 11 1.1 General Description ........................................................................................... 11 1.2 Main Specification of the SPD............................................................................ 11 1.3 Properties........................................................................................................... 16 Chapter 2 Preparation..................................................................................................... 18 2.1 Installation tools ................................................................................................ 18 2.2 Delivery contents ............................................................................................... 18 Chapter 3 SPD Installation .............................................................................................. 20 3.1 Make AC connection with the SPD .................................................................... 20 3.1.1 Preparation ........................................................................................... 21 3.1.2 Configure the Terminal Block ............................................................... 27 3.1.3 3-phase star (3Y) AC connection with the SPD ..................................... 29 3.1.4 Single-phase (1Φ) AC connection with the SPD ................................... 35 3.1.5 2-phase AC connection with the SPD.................................................. 38 3.1.6 3-phase delta (3Δ) AC connection with the SPD ................................... 40 3.2 Replace the SPD ................................................................................................. 44
Installation Manual for SPD, Rev AB
Page 4 of 45
Flexi Power Rectifier FPRB
List of Figures Figure 1 – Internal circuit diagram of the SPD............................................................................... 11 Figure 2 – Structure of the SPD ..................................................................................................... 12 Figure 3 – Dimension of the SPD – top view ................................................................................. 13 Figure 4 – Dimension of the SPD – side view ................................................................................ 14 Figure 5 – SPD configuration in a TN-S system.............................................................................. 16 Figure 6 – Checking failure of the SPD .......................................................................................... 17 Figure 7 – PDA rear internal chassis layout................................................................................... 21 Figure 8 – The AC cable connection chart..................................................................................... 27 Figure 9 – AC terminal block configuration – 1Φ and 2Φ Configuration ...................................... 28 Figure 10 – AC terminal block configuration – 3Δ ......................................................................... 28 Figure 11 – AC terminal block configuration – 3Y ......................................................................... 29 Figure 12 – Schematic diagram of AC connection with the SPD – 3Y ........................................... 29 Figure 13 - Assemble the Link Cables to SPD................................................................................. 30 Figure 14 - AC Ground wire ........................................................................................................... 31 Figure 15 - Secure the SPD into the DIN rail.................................................................................. 31 Figure 16 - Connect the Link cables to Terminal Block.................................................................. 32 Figure 17 - Special Instruction for N Link Cable Installation.......................................................... 33 Figure 18 – AC connection with the SPD - 3Y ................................................................................ 34 Figure 19 – Schematic diagram of AC connection with the SPD – 1Φ .......................................... 35 Figure 20 – SPD configuration for single-phase AC connection .................................................... 36 Figure 21 - Connection of AC link cables from SPD to Terminal Block.......................................... 37 Figure 22– Schematic diagram of AC connection with the SPD – 2- Phase .................................. 38 Figure 23 - AC connection with the SPD – 2- Phase ...................................................................... 39 Figure 24 – Schematic diagram of AC connection with the SPD – 3Δ ........................................... 40 Figure 25 - Connection of AC link cables and SPD ground cables ................................................. 41 Figure 26 – Connecting the AC terminal block – 3Δ ...................................................................... 42 Figure 27 3-phase delta (3Δ) AC connection with the SPD .......................................................... 43 Figure 28 – Removing the damaged OVP module from the SPD .................................................. 44 Figure 29 – The OVP module and the SPD base............................................................................ 45 Figure 30 – Fitting a new OVP module to the SPD ........................................................................ 45
List of Tables Table 1 – Contents of this manual .............................................................................................. 9 Table 2 – Symbols in this manual ............................................................................................... 9 Table 3 – Reference documents of the SPD ............................................................................ 10 Table 4 – Main specification of the SPD .................................................................................. 15 Table 5 – Delivery contents of the SPD.................................................................................... 19 Table 6 – Recommended preparation for AC mains cable ................................................... 22 Table 7 – AC connection with the SPD ..................................................................................... 23 Table 8 – Schematic diagram of AC connection with the SPD.............................................. 25
Installation Manual for SPD, Rev AB
Page 5 of 45
Flexi Power Rectifier FPRB
List of Terms
A
Ampere
AC
Alternative current
AWG
American Wire Gauge
BAT
Battery
BR
Battery Return
BTS
Base Transceiver Station
CB
Circuit Breaker
CSA
Cross Section Area
CU
Control unit
DC
Direct current
EMC
Electromagnetic Compatibility
ESD
Electrostatic Discharge
FPRB
Flexi Power Rectifier
GND
Ground
GUI
Graphical User Interface
IE
Internet Explorer
IP
Internet Protocol
L
Live cable from the AC mains
LAN
Local Area Network
LED
Light Emitting Diode
LVD
Low Voltage Disconnect
MAC
Media Access Control
MCB
Miniature Circuit Breaker
N
Neutral cable from the AC mains
PC
Personal Computer
PCB
Printed Circuit Board
PDA
Power Distribution Assembly
PE
Protective earth
PSU
Power Supply Unit
SPD
Surge Protective Device
V
Volt
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB VPN
Virtual Private Network
1Φ
Single-phase AC type
3Y
3-phase star AC type
3Δ
3-phase delta AC type
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB
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Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB
Preface About this manual This manual provides all the necessary information to operate, install and maintain the Surge Protective Device (SPD) used in the Flexi Power Rectifier (FPRB). Table 1 lists the contents of this manual: Table 1 – Contents of this manual Chapter
Title
Content
1
Product instruction
Describes the specifications and properties of the SPD
2
Preparation
Describes the SPD installation preparations
3
SPD installation
Describes how to install and replace the SPD into the FPRB
Terms and Symbols in this manual These term and symbols in Table 2 might appear in the manual: Table 2 – Symbols in this manual Symbol
Description Warning statement identifies conditions or practices that could result in bodily injury or loss of life. It warns the reader to be extremely careful. Caution statement identifies conditions or practices that could result in damage to this product or devices connect to it. It indicates that the reader must be careful. Provides hints to the user for easier installation The necessary supplementary of the article to let user be clearer.
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB
Reference documents Table 3 contains the reference documents of the SPD: Table 3 – Reference documents of the SPD Document
Emerson Network Power File No.
Product Specification – FPRB
970-009025-0000
FPRB Installation Manual for SPD (This manual)
970-009473-0000
FPRB User Manual
970-009474-0000
FPRB Installation Manual
970-009475-0000
FPRB Quick Start Guide for SPD
970-009476-0000
FPRB Quick Start Guide
970-009477-0000
Application of this manual This manual is regarded as a substitution of the part ‘Make AC connection without the SPD’ (refer to section 3.4 of the ‘Flexi Power Rectifier - Installation Manual’, Emerson File No. 970009475-0000). This manual is based on the present SPD in use. Emerson may change the SPD to a second source in future. However Emerson ensures the compatibility of the new SPD in the FPRB. This manual supports all applications of the SPD that can be used in the FPRB.
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB Chapter 1 Product Introduction 1.1
General Description The Flexi Power Rectifier (FPRX, Emerson part number AA25020L/ CS7000013.XX for 6kW and AA27540L/ CS7000030.XX for 9kW) is a 6kW or 9kW output power AC rectifier package respectively. The Surge Protective Device (SPD, Emerson part number AA25130L/ CS7000002.XX) is used to prevent damage to the FPRX caused by high input voltages or surge. The SPD consists of three equivalent OVP modules used between live cables and neutral cable from the AC mains; one OVP module used between the neutral cable from the AC mains and the earth; and one remote signaling contact. The SPDs mentioned in this manual are applicable for both 6kW and 9kW system. The SPD used is the same as the one we used in FPRA.
1.2
Main Specification of the SPD The SPD illustrated in this manual is made by ‘Phoenix Contact CO., Ltd’ (model number: VAL-MS 230IT/3+1-FM), or SICHUAN ZHONGGUANG LIGHTNING (model number: ZGG40-385(3+1)). 12 14
VAL-MS 230IT/3+1-FM
FM 11
VAL-MS 230 IT ST L1
L2
L3
N
F-MS 12 ST
Figure 1 – Internal circuit diagram of the SPD
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB The SPD (module name ‘VAL-MS 230IT/3+1-FM’) consists of three equivalent OVP modules used between live cables and neutral cable from the AC mains (module name ‘VAL-MS 230 IT ST’), one OVP module used between the neutral cable from the AC mains and the earth (module name ‘F-MS 12 ST’) and one remote signaling contact (module name ‘VAL-MS 230IT…-FM’) (see Figure 1). The four OVP modules and the remote signaling contact are all installed on the SPD base and can be removed from the base. This structure leads to easier configuration and replacement of the OVP modules (see Figure 2).
F-MS12 ST
VAL-MS 230 IT ST
Base VAL-MS 230IT…-FM
Terminal
Figure 2 – Structure of the SPD
Installation Manual for SPD, Rev AB
Page 12 of 45
Flexi Power Rectifier FPRB
Figure 3 and Figure 4 show the dimension of the SPD. The four OVP modules are of the same dimensions.
17.5m
70m
17.5m
VAL-MS 230IT/3+1-FM
ZGG40-385(3+1) Figure 3 – Dimension of the SPD – top view
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB
VAL-MS 230IT/3+1-FM
ZGG40-385(3+1)
Figure 4 – Dimension of the SPD – side view
Installation Manual for SPD, Rev AB
Page 14 of 45
Flexi Power Rectifier FPRB Table 4 lists the main specifications of the OVP modules. Table 4 – Main specification of the SPD Module name
Parameter
Specification
Description
VAL-MS 230 IT ST
UN (L-N / L-L)
230VAC / 400VAC
Rated voltage
UC (L-N)
385VAC
Clamping voltage
UP (L-N)
≤1.9kV
Protective voltage
In / Imax (8/20 μS)
20kA / 40kA
Rated discharge current / maximum discharge current
Screw thread / torque
M5 / 4.5Nm
F-MS 12 ST
UN (N-PE)
230 VAC
Rated voltage
(OVP module for N-PE)
UC (N-PE)
260VAC
Clamping voltage
UP (N-PE)
≤1.0kV
Protective voltage
In / Imax (8/20 μS)
20kA / 40kA
Rated discharge current / maximum discharge current
Screw thread / torque
M5 / 4.5Nm
Imax
AC: 3A (125V)
(OVP module for L-N)
VAL-MS 230IT…FM (Remote signaling contact)1
VAL-MS 230IT/3+1-FM (The whole SPD module)
0.75A (250V) DC: 2A (30V) Screw thread / torque
M2 / 0.25Nm
Temperature
-40°C ~ +80°C
IP-code
IP20
Class II
IEC 61643-1: 2005-01
Type 2
EN 61643-11: 2002-12
Installation Manual for SPD, Rev AB
Ingress Protection (IP) degree
Page 15 of 45
Flexi Power Rectifier FPRB Note: 1
Although the SPD remote signaling contact has three pins, only two are applied when configured in the FPRB. Refer to Figure 13
1.3
Properties
Typical use Figure 5 shows the configuration of the SPD in a TN-S system.
Figure 5 – SPD configuration in a TN-S system Note: It is recommended to use the SPD with a mains utility offering the appropriate line fuse protection.
Installation Manual for SPD, Rev AB
Page 16 of 45
Flexi Power Rectifier FPRB
Failure Detection
If any OVP module has been damaged, Emerson will provide the user with the individual OVP module but not the whole SPD for replacement. In the event that any one of the four OVP modules is damaged, the PDA will send alarm signal via the LCD. After opening the rear top cover of the PDA (refer to section 3.4 of the ‘Flexi Power Rectifier – Installation Manual’, Emerson File No. 970-009475-0000), the user can confirm which OVP module is in failure.
Failure Indication If the window is transparent, the OVP is OK; if the window is red, the OVP is damaged and should be replaced in time (see Figure 6).
Window
Figure 6 – Checking failure of the SPD
Installation Manual for SPD, Rev AB
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Flexi Power Rectifier FPRB Chapter 2 Preparation 2.1 Installation tools Tool kit: Allen key (hex key): 8 mm (0.31 in.) Allen key (hex key): 4 mm Awl: diameter of 2mm ESD wrist strap and cable TORX screwdriver set: T10, T20, T25 Flat screwdriver Cross screwdriver Wrench 13 mm (0.51 in.) Folding knife Adjustable (monkey) wrench Side cutters Lint-free swab or wipe and 99% alcohol for cleaning optical connectors Cable ties for routing cables Tape measure Flashlight, pocket lamp or torch Hammer drill Marker pen or comparable tool Pliers Wire-stripper Test equipment: Multi-meter
2.2 Delivery contents The SPD is optional for the user and shipped independent from the FPRB. Verify that all the material listed in Table 5 has been received and is in good condition. Report any missing or damaged items to our Emerson Network Power Service Department.
Installation Manual for SPD, Rev AB
Page 18 of 45
Flexi Power Rectifier FPRB
Table 5 – Delivery contents of the SPD Part
SPD
Figure
Description
Surge Protective Device
Usage
Emerson
Emerson
Part Number
Module Number
1 pc
440-0007000000
1 each
502-0004960000/
Manufacturer p/n:VAL-MS 230IT/3+1-FM Manufacturer: PHOENIX CONTACT (SEA), PTE. LTD.
Surge Protective Device Manufacturer p/n: ZGG40385(3+1) Manufacturer: SICHUAN ZHONGGUANG LIGHTNING PROTECTION TECHNOLOGIES CO.,LTD. SPD Jumper
Short link for SPD terminals in single-phase AC connection (Color of plastic may vary)
L line short link
L1/L2/L3 for three phase,
N line short link
N for three phase star,
SPD ground link SPD sense cable
500-0017690000 1
750-0066580000
1
438-0004230000
SPD ground link to Chassis
1
750-0009880000
SPD signal cable connecting to the MCU
1
750-0010040000
L for single phase (AWG10)
N for single phase (10mm2)
Installation Manual for SPD, Rev AB
Page 19 of 45
AA25130L
Flexi Power Rectifier FPRB Chapter 3 SPD Installation 3.1 Make AC connection with the SPD
The AC power supply must be switched off prior to accessing the AC cable.
This manual concentrates on the AC connection with the SPD, and omits the steps prior to the SPD installation, i.e. the AC terminal block configuration, etc. The user should refer to ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000) for the relevant previous steps. The colors of the AC mains wire used in this manual are for illustration purpose only. However, the user should verify the AC mains referring to the color-coding in the respective field or country of application.
Installation Manual for SPD, Rev AB
Page 20 of 45
Flexi Power Rectifier FPRB
3.1.1
Preparation
3.1.1.1
Detach the PDA rear top cover referring to ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000).
3.1.1.2
Loosen screws A, B and C as per attached photo with a TORX screwdriver (T20)
SPD DIN Rail
AC terminal block
SPD ground clamp
B
AC ground clamp
A
PDA earth cable
Strainrelief
C
SPD sensor connection
F Figure 7 – PDA rear internal chassis layout
Installation Manual for SPD, Rev AB
Page 21 of 45
Flexi Power Rectifier FPRB
3.1.1.3
Preparing the AC mains cable. The color of the wires may vary depending on the country where the SPD will be mounted. Table 6 – Recommended preparation for AC mains cable
(Tolerance: 3mm) AC type
L1
L2
L3
N
PE
Single-phase
A (mm)
55
70
100
(1Φ)
B (mm)
20
20
20
2-phase
A (mm)
55
100
N/A
B (mm)
20
20
N/A
3-phase delta
A (mm)
55
60
70
N/A
100
(3Δ)
B (mm)
20
20
20
N/A
20
3-phase star
A (mm)
55
60
70
85
100
(3Y)
B (mm)
20
20
20
20
20
Installation Manual for SPD, Rev AB
Page 22 of 45
Flexi Power Rectifier FPRB
Table 7 – AC connection with the SPD AC type AC mains
1Φ
AC terminal Chassis block
N/A
L1
6
N/A
L1 for three-phase
L
L2
5
N/A
L2 for three-phase
N/A
L3
4
N/A
L3 for three-phase
N
N
2
N/A
N for single phase
PE
N/A
N/A
AC ground clamp
N/A
N/A
SPD ground clamp
SPD ground link
N/A
L1
6
N/A
L1 for three-phase
L1
L2
5
N/A
L2 for three-phase
N/A
L3
4
N/A
L3 for three-phase
L2
N
2
N/A
N for single phase
N
N/A
N/A
AC ground clamp
N/A
N/A
SPD ground clamp
SPD ground link
N/A
3Y
L1
L1
6
N/A
L1 for three-phase
L2
L2
5
N/A
L2 for three-phase
Installation Manual for SPD, Rev AB
AC terminal block
SPD configuration
Configuration (2)
(3)
SPD
N/A 2-Phase
Short link available (1)
Terminals connection
Page 23 of 45
Short terminals 1,2,3 and 4,5,6 respectively
Short terminals L1, L2, L3
Short terminals 1,2,3 and 4,5,6 respectively
Short terminals L1, L2, L3
Short terminals 1,2,3
N/A
Flexi Power Rectifier FPRB
L3
L3
4
N/A
L3 for three-phase
N
N
2
N/A
N for three-phase star
PE
N/A
N/A
AC ground clamp
N/A
N/A
SPD ground clamp
SPD ground link
N/A
3Δ
L1
L1
5
N/A
L1 for three-phase
L2
L2
3
N/A
L2 for three-phase
L3
L3
1
N/A
L3 for three-phase
PE
N/A
N/A
AC ground clamp
N/A
N
N/A
SPD ground clamp
Short terminals 1,2 and 3,4 and 4,5 respectively
SPD ground link
Note: (1) The short link names listed herein are in accordance with the actual labels on the short links. (2) The AC terminal block should be configured before the AC connection. User shall refer to section 3.4 in Flexi Power Rectifier – Installation Manual (Emerson file No.970-009475-0000) for more details
Installation Manual for SPD, Rev AB
Page 24 of 45
N/A
Flexi Power Rectifier FPRB
(3) Refer to Table 3for the corresponding clamps. Table 8 – Schematic diagram of AC connection with the SPD AC Type
Schematic diagram
Configuration of AC terminal block Short terminals 1,2,3
AC Terminal Block SPD
1
L1
L2
L3
N
L1
L2
L3
N
2
3
4
5
6
3Y
PE
AC Mains
Short terminals 1,2,3; 4,5,6 respectively
AC Terminal Block
SPD L1 L2
L3
N
1
2
3
4
5
6
1Φ
PE
L
N
AC mains
Installation Manual for SPD, Rev AB
Page 25 of 45
Flexi Power Rectifier FPRB
AC Terminal Block SPD
1
L1
L2
L3
L1
L2
L3
2
3
4
5
6
Short terminals 1,2; 3,4; 5,6 respectively
N
3∆
PE
AC mains
Short terminals 1,2,3; 4,5,6 respectively
2-phase
Installation Manual for SPD, Rev AB
Page 26 of 45
Flexi Power Rectifier FPRB
3.1.2
Configure the Terminal Block
Verify the AC power system types in field, and make sure the corresponding bridge configuration is used.
The AC terminal block has been already configured for 3-phase star AC mains before the shipment. Therefore the user has to change the AC terminal block configuration if required referring to the actual AC type in field.
Insert the bridges and screws (provided as accessories) to the corresponding slots on top of the AC terminal block referring to the AC CABLE CONNECTION CHART located on the chassis (and reproduced in Figure 8). Secure the screws with a flat screwdriver, tightening to 0.8Nm.
Figure 8 – The AC cable connection chart There are three AC power system types (see above Figure), and thus three AC configurations of the AC terminal block.
Installation Manual for SPD, Rev AB
Page 27 of 45
Flexi Power Rectifier FPRB
Single-phase (1Φ) and Two-phase (2Φ ) configuration For Single- phase AC system, use two 3-pole bridges to short the terminals 1, 2, 3 and 4, 5, 6 respectively on the AC terminal block (see Figure 9)
Figure 9 – AC terminal block configuration – 1Φ and 2Φ Configuration
3- phase delta (3Δ) configuration For 3-phase delta AC system, use three 2-pole bridges to short the terminals 1, 2 and 3, 4 and 5, 6 respectively on the AC terminal block (see Figure 10 )
Figure 10 – AC terminal block configuration – 3Δ
Installation Manual for SPD, Rev AB
Page 28 of 45
Flexi Power Rectifier FPRB
3- phase star (3Y) configuration For 3-phase star AC system, use one 3-pole bridges to short the terminals 1, 2, 3 on the AC terminal block (see Figure 11)
Figure 11 – AC terminal block configuration – 3Y 3.1.3
3-phase star (3Y) AC connection with the SPD
AC Terminal Block SPD
PE
1
L1
L2
L3
N
L1
L2
L3
N
2
3
4
5
6
AC Mains Figure 12 – Schematic diagram of AC connection with the SPD – 3Y
Installation Manual for SPD, Rev AB
Page 29 of 45
Flexi Power Rectifier FPRB
The terminal marks in Figure 12 are in accordance with the actual SPD and AC terminal block. Use the indicated L or N short link for the AC mains as shown in Figure 12 and Table 7 referring to labels on the short links. The terminals 1, 2, 3 on the AC terminal block should be shorted before the connection. Refer to section 3.4 in Flexi Power Rectifier – Installation Manual (Emerson file No.970-009475-0000) for details. 3.1.3.1
Detach the cable strain-relief from the chassis by loosening the screw ‘C’ in Figure 7 with a TORX screwdriver (T20). Insert the AC mains cable on the strain relief.
3.1.3.2
Detach the AC ground clamp and SPD ground clamp from the chassis by loosening the screws ‘A’ and B ‘with a TORX screwdriver (T20).
3.1.3.3
Prepare the AC mains of 3-phase star as per Table 6.
3.1.3.4
Assemble the Link cables, the AC mains cable, the SPD sensor cable and the SPD grounding cable into the SPD. Refer to Figure 13
L1 for threephase L2 for threephase
SPD sense cable
L3 for threephase
N for threephase star
SPD ground cable Figure 13 - Assemble the Link Cables to SPD
Installation Manual for SPD, Rev AB
Page 30 of 45
Flexi Power Rectifier FPRB
Insert the connector of the SPD sense cable into the left two contacts; otherwise it will block the SPD from installing onto the chassis.
3.1.3.5
Fix the AC ground wire into the terminal lug.
. Figure 14 - AC Ground wire 3.1.3.6
Secure the SPD into the SPD DIN rail. Connect the SPD sense cable to the stand by mating connector. Connect the SPD grounding cable into the terminal lug. Refer to Figure 15.
SPD Grounding cable
SPD
SPD sense cable
Figure 15 - Secure the SPD into the DIN rail
Installation Manual for SPD, Rev AB
Page 31 of 45
Flexi Power Rectifier FPRB 3.1.3.7
Connect the AC link cables from SPD to the Terminal Block. Assemble the SPD grounding cable and the AC grounding cable into the PDA
SPD grounding cable lug
N link cable L3 link cable L2 link cable
AC grounding cable lug
L1 link cable
Figure 16 - Connect the Link cables to Terminal Block
1. Use the appropriate L and N short link referring to the label on the short links and the indications in Figure 12 and Table 7. 2. Rotate the N link cable 90 degrees either clockwise or counter clockwise when assembling the SPD on the FPRA due to the smaller slot of the terminal block. Refer to Figure 17 - Special Instruction for N Link Cable Installation
Installation Manual for SPD, Rev AB
Page 32 of 45
Flexi Power Rectifier FPRB
Figure 17 - Special Instruction for N Link Cable Installation
It is recommended to clamp the AC wire and the corresponding short link with one overlapping on another.
Installation Manual for SPD, Rev AB
Page 33 of 45
Flexi Power Rectifier FPRB Below figure shows the PDA rear layout after completing the 3-phase star AC connection with the SPD.
SPD ground cable N N short link
L3
L1 short link
L2 L2 short link L1
L3 short link
PE of AC mains
SPD sense cable Figure 18 – AC connection with the SPD - 3Y
3.1.3.8
After finishing and checking the AC cable installation, re-install the PDA rear cover referring to ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000).
After installation of the SPD kit has been completed, the installer should check the installation against the steps outlined within this document, supported by a multimeter to check for wiring continuity. It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
Installation Manual for SPD, Rev AB
Page 34 of 45
Flexi Power Rectifier FPRB 3.1.4
Single-phase (1Φ) AC connection with the SPD
SPD ground link SPD ground clamp
N for single phase
AC Terminal Block
SPD L1 L2
L3
N
1
2
3
4
5
6
L3 for three-phase AC ground clamp
PE
L
N
AC mains
L2 for three-phase L1 for three-phase
Figure 19 – Schematic diagram of AC connection with the SPD – 1Φ
The terminal marks in Figure 19 are in accordance with the actual SPD and AC terminal block. Use the indicated L or N short link for the AC mains as shown in Figure 19 and Table 7 referring to labels on the short links. The terminals 1,2,3 and 4,5,6 on the AC terminal block should be shorted respectively before the connection. Refer to section 3.4 in Flexi Power Rectifier – Installation Manual (Emerson file No.970-009475-0000) for details.
3.1.4.1
Perform the same procedure in preparing the AC cables SPD grounding cables and the SPD sense cables.
3.1.4.2
As indicated in Figure 19 and Table 7, the SPD terminals L1, L2 and L3 have to be paralleled by the SPD jumper (see Figure 20).
Installation Manual for SPD, Rev AB
Page 35 of 45
Flexi Power Rectifier FPRB
The user should loosen the three terminal clamps of L1, L2 and L3, and hold the SPD upside down. Thus the SPD jumper can be easily inserted into the parallel clamps. The jumper should be fixed in the SPD together with the live cables of the AC mains and L line short links.
SPD jumper
Figure 20 – SPD configuration for single-phase AC connection 3.1.4.3
Connect the live cable from the AC mains and L2 short link into terminal ‘L2’ on the SPD referring to Figure 19 and Table 7, tightening the top screw to 4.5Nm with a cross screwdriver (see Figure 21).
Installation Manual for SPD, Rev AB
Page 36 of 45
Flexi Power Rectifier FPRB
N for single phase
SPD ground link
L3 for threephase
SPD ground clamp
L2 for threephase
AC ground clamp
L1 for threephase
Figure 21 - Connection of AC link cables from SPD to Terminal Block 3.1.4.4
After finishing and checking the AC cable installation, re-install the PDA rear cover referring to section 3.4 in ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000).
Installation Manual for SPD, Rev AB
Page 37 of 45
Flexi Power Rectifier FPRB 3.1.5 2-phase AC connection with the SPD
SPD ground link SPD ground clamp
L3 for three-phase AC ground clamp
L2 for three-phase L1 for three-phase
Figure 22– Schematic diagram of AC connection with the SPD – 2- Phase
3.1.5.1
Perform the same procedure in preparing the AC cables SPD grounding cables and the SPD sense cables
3.1.5.2
As indicated in Figure 19 and Table 7, the SPD terminals L1, L2 and L3 have to be paralleled by the SPD jumper (see Figure 20).
Installation Manual for SPD, Rev AB
Page 38 of 45
Flexi Power Rectifier FPRB 3.1.5.3
Connect the AC link cables and the AC cables to the SPD and to terminal block. Refer to Figure 23) N for single phase
SPD ground link
L3 for threephase
SPD ground clamp
L2 for threephase
AC ground clamp
L1 for threephase Figure 23 - AC connection with the SPD – 2- Phase 3.1.5.4
After finishing and checking the AC cable installation, re-install the PDA rear cover referring to section 3.4 in ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000).
After installation of the SPD kit has been completed, the installer should check the installation against the steps outlined within this document, supported by a multimeter to check for wiring continuity. It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
Use DMM to measure L1-L2 voltage Ensure L1-L2 voltage between 180VAC-276VAC
Installation Manual for SPD, Rev AB
Page 39 of 45
Flexi Power Rectifier FPRB
The terminal marks in Figure 22 are in accordance with the actual SPD and AC terminal block. Refer to Single-phase (1Φ) AC connection for details.
3.1.6
3-phase delta (3Δ) AC connection with the SPD
SPD ground link
AC Terminal Block SPD L1
1 L2
L3
2
3
4
5
6
N L3 for three-phase L2 for three-phase
AC ground clamp
L1 for three-phase
PE
L1
L2
L3
AC mains
SPD ground clamp
Figure 24 – Schematic diagram of AC connection with the SPD – 3Δ
The terminal marks in Figure 24 are in accordance with the actual SPD and AC terminal block. Use the indicated L or N short link for the AC mains as shown in Figure 24 and Table 7 referring to labels on the short links. The terminals 1,2 and 3,4 and 5,6 on the AC terminal block should be shorted respectively before the connection. Refer to section 3.4 in Flexi Power Rectifier – Installation Manual (Emerson file No.970-009475-0000) for details.
Installation Manual for SPD, Rev AB
Page 40 of 45
Flexi Power Rectifier FPRB 3.1.6.1
Perform the same procedure in preparing the AC cables SPD grounding cables and the SPD sense cables
3.1.6.2
Configure the terminal block as per Figure 10
3.1.6.3
Assemble the AC cables, AC link cables into the SPD.
3.1.6.4
Assemble the AC link cables into the Terminal Block.
SPD grounding cable connected to N terminal of the SPD. N connected to Ground
Figure 25 - Connection of AC link cables and SPD ground cables
Installation Manual for SPD, Rev AB
Page 41 of 45
Flexi Power Rectifier FPRB 3.1.6.5
Connect the L1, L2 and L3 short links to terminals ‘5’, ‘3’, ‘1’ on the AC terminal block respectively referring to Figure 24 and Table 7,, tightening the top screws to 1.5Nm with a Cross screwdriver (see Figure 26).
SPD Sense Cable L3 short link SPD ground link
L2 short link
L1 short link Figure 26 – Connecting the AC terminal block – 3Δ
Installation Manual for SPD, Rev AB
Page 42 of 45
Flexi Power Rectifier FPRB 3.1.6.6
Figure 27 shows the PDA rear internal layout after completing the 3-phase delta AC connection with the SPD.
SPD ground link L3 for threephase
SPD ground clamp
L2 for threephase
AC ground clamp
L1 for threephase
Figure 27 3-phase delta (3Δ) AC connection with the SPD 3.1.6.7
After finishing and checking the AC cable installation, replace the PDA rear cover referring to section 3.4 in ‘Flexi Power Rectifier – Installation Manual’ (Emerson File No. 970-009475-0000).
After installation of the SPD kit has been completed, the installer should check the installation against the steps outlined within this document, supported by a multimeter to check for wiring continuity. It’s strongly suggested that the insulation test (2.5kV Hi-pot) is carried out.
Installation Manual for SPD, Rev AB
Page 43 of 45
Flexi Power Rectifier FPRB 3.2 Replace the SPD
The AC power supply must be switched off prior to accessing the SPD.
Ask Emerson Network Power service people for help if any OVP module has been damaged. Emerson will provide the user with the individual OVP module but not the whole SPD for replacement. The user shall only replace the damaged OVP module of the SPD without removing the whole SPD from the PDA chassis. The user can verify which OVP module has been damaged Referring to section Properties. 3.2.1 Hold the two sides of the damaged OVP module and pull it out from the SPD base (see Figure 28)
Figure 28 – Removing the damaged OVP module from the SPD
Installation Manual for SPD, Rev AB
Page 44 of 45
Flexi Power Rectifier FPRB
3.2.2
The SPD base is designed such that the two kinds of OVP modules cannot be mixed when installing onto it (see Figure 29).
Figure 29 – The OVP module and the SPD base
3.2.3
Fit the new module into its position on the SPD base (see Figure 30).
Figure 30 – Fitting a new OVP module to the SPD
Installation Manual for SPD, Rev AB
Page 45 of 45
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