Preparation 31

Table 12 Symbols on the FPRA

Protective earth terminal:

Connect the protective earth cable in the indicated position.

System earth terminal:

Connect the system earth cable in the indicated position.

Recycle:
User cannot dispose of this electronic product in the trash. To
protect the environment, please recycle.

2.2 Installation site

To ensure normal operation and long service life of the product, install it in an
environment that meets the following requirements:
x Temperature
The FPRA should be used and maintained in the temperature that
defined in Table 4.
x Cleanness
Dust is a hazard to the operation to the device. The dust accumulated
on the chassis can be absorbed by static electricity and result in poor
contact of metal connectors. This not only shortens the service life of
your device but may also cause communication failures.
Besides dust, the harmful gases, containing salts, acids and sulfides,
can accelerate the corrosion and aging of metals.
x Ventilation
Each rectifier has an integrated fan for cooling. The airflow is from the
rear to the front of the rectifier unit. Consideration should be given to
the amount of clearance necessary to ensure FPRA cooling when
configured within cabinets.

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 Preparation 32

2.3 Installation tools and test equipments

The installation tools and test equipments are prepared in field.

Tool kit:
x Allen key (hex key): 8 mm (0.31 in.)
Awl: diameter of 2mm
ESD wrist strap and cable
TORX screwdriver set: T10, T20, T25
Flat screwdriver
Cross screwdriver
Wrench 8 mm (5/16 inch)
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
x Test equipments
PC (optional)
Multi-meter: FLUKE 170 or equivalent
DC Current clamp: FLUKE I410 or equivalent

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 Preparation 33

2.4 Check list of the FPRA

Figure 8 shows the product tree of the iPSU in which the FPRA is
included.

Customer configuration

AA25020L AA25000L AA25130L

Flexi 3U
Flexi Power
mounting covers Rectifier Unit Transient
Rectifier 6000
front/back 1/2/3 Protection Unit
FPRA
FMCA

Figure 8 Product tree

Table 13 lists the delivery contents by FPRA.

One FPRA (AA25020L) may adopt one or two or three rectifiers

(AA25000L) to meet the users requirement.
The Transient Protection Unit (AA25130L) is optional for the user, and is
supplied independently with the FPRA (AA25000L).
The part number listed in Table 13 is based on the present materials used,
and Emerson may change some materials and corresponding part
numbers in future. Therefore the user should contact Emerson for updated
information in time.

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 Preparation 34

Table 13 Delivery contents by FPRA

Name Figure Description Usage Emerson Emerson

Part Number Module Number

Case The case of the FPRA, in N/A

which the PDA and rectifiers 1
are installed.

PDA The distribution of AC input 85570602630

and DC output 1

Cable gland Cable entry of the FPRA 2 18370104780

Temperature cable The temperature sensor of the 1

FPRA 8087000695x

AA25020L
Parallel cable The communication cable for 8087000694x
RS422 interface 1

Ethernet cable Ethernet cable compliant with 1

T568A/B 8087000897x

System earth cable Connects the FPRA to system 1

earth 8087000987x

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 Preparation 35

Phoenix Used to configure the AC 1 40570002800

3-pole Bridge terminal block

Phoenix Used to configure the AC 3 40570002790

terminal block
2-pole Bridge

Cable tie Used to tie the cables 50 18870001600

AA25020L
Cable restraint Used to tie thick cable, such 2 18370104720
as AC cable

M3 screw Used to fix the cable restraint 4 41300000208

M5 screw Used to fix the cases when 2 41300000181

stacked for parallel
configuration

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 Preparation 36

SPD Surge Protection Discharge 1 10070000400

SPD jumper Short link for SPD terminals in 1 18370102980/

single-phase AC connection
40370110040

L line short link L1/L2/L3 for three phase, 1 8087000880x

AA25130L
L for single phase (AWG12)

N line short link N for three phase star, 1 8087000879x

N for single phase (AWG 8)

SPD ground link SPD ground link 1 8087000902x

SPD Sense Cable SPD signal cable connecting 1 8087000925x

to the MCU

Rectifier The AC/DC module 1/2/3 AA25000L

AA25000L

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 Hardware Installation 37

Chapter 3 Hardware Installation

Before hardware installation, please note:

All the precautions listed in the Safety summary.
The installation should be carried out only by qualified personnel and in
accordance with local electrical codes.

The installation sequence summary of the various system modules

described below is mandatory for first time installation of the FPRA
components. The detailed installation procedure for each module can be
found in the appropriate sections further on in this document.

3.1 Detach the PDA from the case

Figure 9 presents the FPRA before the installation.

A B C

Figure 9 The FPRA before the installation

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 Hardware Installation 38

(1) Remove the two cable glands from the case.

Loosen the four screws with a TORX screwdriver (T25), and remove the
cable glands from the case (see Figure 10).

Figure 10 Detaching the cable glands

(2) Release the PDA earth cable.
Release the PDA earth cable by loosening the nut with a wrench (8mm)
(see Figure 11).

Figure 11 Releasing the PDA earth cable

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 Hardware Installation 39

(3) Release the RS485 cables.

Release the three RS485 cables by manually loosening the three cable
ties originally (see Figure 12).

Figure 12 Releasing the RS485 cables

(4) Detach the PDA from the case.
Loosen the two screws on the front panel of the PDA with a Cross
screwdriver, and pull the PDA out of the case horizontally along its guide
rail on the bottom of the case (see Figure 13).

Figure 13 Detaching the PDA from the case

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 Hardware Installation 40

(5) Insert the cables through the cable gland if required.

Before inserting the cables through the cable gland, the AC mains and battery
blocks must be switched off.

If the cable gland was used, the AC mains cable, DC cables, temperature
cable and parallel cable are mandatory, however the Alarm In and Alarm Out
cables are optional to pass through the cable gland before installing them into
the PDA.

The two cable glands are usually used as cable entries or bases on which
the front cover of the FPRA are installed. The user decides either to use
the left, right or both cable glands referring to the placement of the FPRA
in field.
If two cable glands are used, the holes in the same position on the two
cable glands are used for the same cable. The use of the right cable gland
is for illustration herein.
The cable gland configuration shown herein is recommended for the user,
however the user can distribute the holes in field freely.

Do not strip the end insulator of the cables prior to inserting them through the
cable gland to prevent crisscross.

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 Hardware Installation 41

There are three types of DC cables configuration (refer to Figure 21 and

Table 14), thus corresponding three types of recommended configuration
of the cable glands (see Figure 14, Figure 15 and Figure 16).

Alarm
System earth cable

BAT2
Parallel cable

Temperature
cable

LOAD2

AC cable

RTN2

RTN5 Parallel cable

DC GND
Alarm

Figure 14 Cable gland configuration option1

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 Hardware Installation 42

LOAD2 LOAD1
Alarm

BAT2
Parallel cable
System earth cable

BAT1
Temperature
cable

BAT3 DC GND
AC cable

RTN5

RTN3

Parallel cable
RTN4

Alarm
RTN2 RTN1

Figure 15 Cable gland configuration option2

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 Hardware Installation 43

Alarm LOAD2

BAT2
Parallel cable
System earth cable

BAT1
Temperature
cable

BAT3 DC GND
AC cable

RTN5

RTN3

Parallel cable
RTN4

Alarm RTN1

Figure 16 Cable gland configuration option3

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 Hardware Installation 44

Puncture the waterproof of the cable gland with an awl (2mm), and insert
the corresponding cable through the hole (see Figure 17).

Take care not to break the waterproof of the cable gland while inserting the
cable.

Figure 17 Inserting the cable through the cable gland

3.2 Route the DC cables

(1) Detach the drawer from the PDA.
Loosen the two screws with a Cross screwdriver, and pull the drawer out
of the PDA (see Figure 18).

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 Hardware Installation 45

2
1

Figure 18 Removing the drawer from the PDA

(2) Remove the front panel from the PDA.
Loosen the six screws on the front panel and two screws on the window of
the breakers with a TORX screwdriver (T10), and detach the front panel
from the PDA (see Figure 19).

Figure 19 Removing the front panel from the PDA

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 Hardware Installation 46

(3) Remove the sub cover from the PDA.

Loosen the four screws on the sub cover with a screwdriver (Torx10), and
remove the sub cover from the PDA (see Figure 20).

Figure 20 Removing the sub cover from the PDA

(4) Identify the DC terminals.

The lower DC terminals and RTN1~5 are shorted together for the
positive earth connection and connected to the system earth
mechanically. The upper DC terminals are for the 48V connection.
Identify the DC terminals and the marks on the DC inlet grommet. The DC
terminals internal the PDA and the pre-exit holes on the DC inlet grommet
are in the one-to-one relationship (see Figure 21 and Figure 22).

The names in Figure 21 and Figure 22 are for illustration purpose only.
They are not printed on the DC inlet grommet.
The +/- in Figure 21, Figure 22 indicates the proper polarity of the load or
battery string to be connected.
In the event that the load in field has a protective earth cable, the user can
connect this grounding cable into any of the terminals in the lower row.

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 Hardware Installation 47

LOAD2(-) BAT1(-) BAT2(-)

MCB switch
Lever bar
CB1 CB2 CB3 CB4 CB5 BAT3(-)

LOAD1(-)

Insulator
Terminals
short link
RTN4(+)

RTN5(+)
LOAD
GND

RTN1(+) RTN2(+) RTN3(+)

Figure 21 DC terminals distribution

LOAD2(-) BAT1(-) BAT2(-) BAT3(-)

LOAD1(-)

Fixing
pole
LOAD
GND

RTN5(+)

RTN1(+) RTN2(+) RTN3(+) RTN4(+)

Figure 22 DC inlet grommet

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 Hardware Installation 48

(5) Configuration of the DC cables.

Make sure to switch off the battery blocks before configuring the DC cables.

The current passing through each MCB cannot exceed 63A in any DC
cables configuration.
When the Load / battery terminals are configured for different loads /
batteries, the short link for load / battery terminals and switch lever bar for
load / battery MCB must be removed.

If not needed, the short links for load / battery terminals and switch lever bar
for load / battery MCB must be removed:
Loosen the screws of the load / battery terminals with a flat screwdriver, and
then take off the short link for the terminals with a set of pliers (see Figure 23
and Figure 24).
Take off the switch lever bar for load / battery MCB with a set of pliers (see
Figure 23 and Figure 24).
There are three options for the battery and load cable configuration in field
(see Table 14).

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 Hardware Installation 49

Figure 23 Removing the load terminals short link and MCB switch lever bar

Figure 24 Removing the battery terminals short link and MCB switch lever bar

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 Hardware Installation 50

Table 14 Three typical battery / load cables configurations

CSA size Cable Recommended Installing

Option Cable name Breakers configuration
(mm2) number sequence (2)

Load & return 35 2

Load MCB parallel
1 Battery & return 50 (3) 2 571/2$' &
571%$7 Battery MCB parallel
Load
35 1
Grounding (1)
Load & Return 35 4
571/2$'
Battery & return 35 6 571/2$'
2 571%$7571 No MCB parallel
Load %$7571
35 1 BAT3(-)
Grounding (1)

Load & Return 35 2

571/2$'
3
Battery & return 16 6 571%$7 Load MCB parallel
571%$7571
Load
35 1 %$7
Grounding (1)

Note: (1) The user determines whether to use the DC load grounding cable referring to the battery and load conditions in field.
(2) It is easier to install the individual DC cable into the indicated DC terminal plug following the recommended sequence.
2
(3) The total CSA of the cables applied in one DC terminal plug cannot exceed 50 mm . The user is to choose the proper DC
cables in field.

Flexi Power Rectifier Installation Manual