CEMF CELL PANEL PRODUCT MANUAL

Transcription

1 CEMF CELL PANEL PRODUCT MANUAL This manual applies to the following panels: B B B B B PM , Issue 8 UNIPOWER, LLC 3900 Coral Ridge Drive Coral Springs, FL Phone: Toll Free: Web site

2 CEMF Cell Product Manual Front Matter RECEIVING INSTRUCTIONS & GENERAL EQUIPMENT INFORMATION Please Note: For your protection, the following information and the product manual should be read and thoroughly understood before unpacking, installing, or using the equipment. UNIPOWER, LLC presents all equipment to the delivering carrier securely packed and in perfect condition. Upon acceptance of the package from us, the delivering carrier assumed responsibility for its safe arrival to you. Once you receive the equipment, it is your responsibility to document any damage the carrier may have inflicted, and to file your claim promptly and accurately. 1. PACKAGE INSPECTION 1.1 Examine the shipping crate or carton for any visible damage: punctures, dents, and any other signs of possible internal damage. 1.2 Describe any damage or shortage on the receiving documents, and have the carrier sign their full name. 1.3 If your receiving freight bill notes that a Tip-N-Tell is attached to your freight, locate it. If the Tip-N-Tell arrow has turned even partially blue, this means the freight has been tipped in transport. Make sure the carrier notes this on your receipt before you sign for the freight. 2. EQUIPMENT INSPECTION 2.1 Within fifteen days, open the crate and inspect the contents for damages. While unpacking, be careful not to discard any equipment, parts, or manuals. If any damage is detected, call the delivering carrier to determine appropriate action. They may require an inspection. *SAVE ALL SHIPPING MATERIAL FOR THE INSPECTOR TO SEE! 2.2 After the inspection has been made, call UNIPOWER. We will determine if the equipment should be returned to our plant for repair, or if some other method would be more expeditious. If it is determined that the equipment should be returned to UNIPOWER, ask the delivering carrier to send the packages back to UNIPOWER at the delivering carrier's expense. 2.3 If repair is necessary, we will invoice you for the repair so that you may submit the bill to the delivering carrier with your claim form. 2.4 It is your responsibility to file a claim with the delivering carrier. Failure to properly file a claim for shipping damages may void warranty service for any physical damages later reported for repair. PM , Issue 8 i

3 CEMF Cell Product Manual Front Matter 3. HANDLING Equipment can be universally heavy or top-heavy. Use adequate humanpower or equipment for handling. Until the equipment is securely mounted, be careful to prevent the equipment from being accidentally tipped over. 4. NAMEPLATE Each piece of UNIPOWER equipment is identified by a part number on the nameplate. Please refer to this number in all correspondence with UNIPOWER. 5. INITIAL SETTINGS All equipment is shipped from our production area fully checked and adjusted. Do not make any adjustments until you have referred to the technical reference or product manual. 6. SPARE PARTS To minimize downtime during installation or operation, we suggest you purchase spare fuses, circuit boards and other recommended components as listed on the Recommended Spare Parts List in the back of the product manual. If nothing else, we strongly recommend stocking spare fuses for all systems. PM , Issue 8 ii

4 CEMF Cell Product Manual Front Matter ISSUE HISTORY ISSUE PAGE(S) DESCRIPTION ISSUED BY / DATE 8 ALL Updated UNIPOWER logo and contact information. See PCO# WD 6/28/17 PROPRIETARY AND CONFIDENTIAL The information contained in this product manual is the sole property of UNIPOWER, LLC. Reproduction of the manual or any portion of the manual without the written permission of UNIPOWER, LLC is prohibited. Copyright UNIPOWER, LLC 2015 DISCLAIMER Data, descriptions, and specifications presented herein are subject to revision by UNIPOWER, LLC without notice. While such information is believed to be accurate as indicated herein, UNIPOWER, LLC makes no warranty and hereby disclaims all warranties, express or implied, with regard to the accuracy or completeness of such information. Further, because the product(s) featured herein may be used under conditions beyond its control, UNIPOWER, LLC hereby disclaims and excludes all warranties, express, implied, or statutory, including any warranty of merchantability, any warranty of fitness for a particular purpose, and any implied warranties otherwise arising from course of dealing or usage of trade. The user is solely responsible for determining the suitability of the product(s) featured herein for user s intended purpose and in user s specific application. Throughout the remainder of this manual, UNIPOWER will mean UNIPOWER, LLC. PERSONNEL REQUIREMENTS Installation, setup, operation, and servicing of this equipment should be performed by qualified persons thoroughly familiar with this Product Manual and Applicable Local and National Codes. A copy of this manual is included with the equipment shipment. PM , Issue 8 iii

5 CEMF Cell Product Manual Front Matter TABLE OF CONTENTS 1 INTRODUCTION GENERAL DESCRIPTION SYSTEM OPERATION SPECIFICATIONS Electrical Specifications Mechanical Specifications Environmental Specifications INSTALLATION SELECTING A LOCATION MOUNTING THE CEMF CELL PANEL WIRING INITIAL CEMF CELL PANEL CHECKOUT LOCAL/REMOTE CONTROL CONVERSION OPERATION FUNCTIONAL OPERATION OPERATING PROCEDURES TROUBLESHOOTING LOGICAL TROUBLESHOOTING OVERALL FUNCTIONAL DESCRIPTION FUNCTIONAL SECTION DESCRIPTION VERIFYING CEMF CELL ADJUSTMENTS ADJUSTMENT PROCEDURES Adjusting the Low Cell Trip Points Adjusting the High Cell Trip Points CALIBRATION PROCEDURES MAINTENANCE CIRCUIT BOARD REPLACEMENT FUSE REPLACEMENT PM , Issue 8 iv

6 CEMF Cell Product Manual Introduction 1 INTRODUCTION 1.1 GENERAL DESCRIPTION The UNIPOWER Counter-electro Motive Force (CEMF) Cell is a rack-mounted device designed to protect sensitive equipment in DC power distribution systems from damage or incorrect operation caused by variations in battery voltage that occur normally during system operation. The CEMF Cell uses power diodes as voltage dropping devices, automatically switching the diodes in and out of the circuit to compensate for battery voltage variations. The CEMF Cell front panel is shown in Figure 1. The typical UNIPOWER CEMF Cell consists of two independent sections. Each section has two adjustable trip thresholds. The first trip threshold activates the compensating function, while the second threshold returns the CEMF Cell to normal operation. Figure 1: CEMF Cell Panel 1.2 SYSTEM OPERATION Normal system operation (no corrective action by either cell) is indicated by steady illumination of the two green light emitting diodes (LEDs) on the integral control module front panel. When either cell is activated, its associated yellow LED on the control module front panel, blinks. CELL ONE: (the low section) activates to increase the load voltage when the battery voltage drops below a preset threshold, a situation that often occurs during AC power outages. Cell One resets when the battery voltage increases above the second preset threshold and returns the circuit to normal operation. CELL TWO: (the high section) activates to reduce the load voltage when the battery voltage increases above a preset threshold, a situation that often occurs during battery equalization. Cell Two resets when the battery voltage drops below the second threshold and returns the circuit to normal operation. PM , Issue 8 1-1

7 CEMF Cell Product Manual Introduction 1.3 SPECIFICATIONS Electrical Specifications CEMF Rating Voltage and Current Requirements 24-volt 20 to 30 volts at 1.5 amperes 48-volt 40 to 60 volts at 1.5 amperes Battery fuse 5-ampere, GMT-type 5 (PN ) Mechanical Specifications The 50-ampere unit is 17 inches wide, 7 inches high, 12 inches deep, and 21 pounds in weight. The 100-ampere unit is 17 inches wide, 10.5 inches high, 12 inches deep, and 31 pounds in weight. The 200-ampere unit is 21 inches wide, 15.5 inches high, 12 inches deep, and 55 pounds in weight. The 400-ampere unit is 21 inches wide, 21 inches high, 16 inches deep, and 85 pounds in weight Environmental Specifications The UNIPOWER CEMF Cell Panel is capable of operating in temperatures ranging from 32 to 122 F (0 to 50 C), with humidity ranging from 0 to 100-percent, noncondensing. PM , Issue 8 1-2

8 CEMF Cell Product Manual Installation 2 INSTALLATION CAUTION: Make sure that the location has adequate ventilation and clearance (at least six inches above and below the CEMF Cell). Inadequate ventilation will cause the unit to over heat and perhaps malfunction. 2.1 SELECTING A LOCATION The CEMF Cell Panel must be installed in an area that is dry, well vented, with moderate temperature, free of obstruction, and pest-free. 2.2 MOUNTING THE CEMF CELL PANEL WARNING: The CEMF Cell can weight 85 pounds or more. Failure to follow proper mounting procedure could cause the cell to fall, causing personal injury and equipment damage. When the CEMF Cell is shipped from the factory, the mounting brackets are held in place by a few securing bolts. Be certain to install the additional securing bolts shipped with the unit before mounting the CEMF Cell in a relay rack. NOTE: The standard CEMF Cell is available in configurations for operation at a specific voltage (24 volts or 48 volts), and current (50, 100, 200 or 400 amperes). Specialized units are available. Check the unit s nomenclature plate to ensure it is the proper voltage and current for your application. The 50 and 100-ampere CEMF Cell Panel mounting brackets can be removed and repositioned so that the unit will fit into either a 19 or 23-inch relay rack. The 200 and 400-ampere units are designed only for use only in 23 inch relay racks. Units provided for special applications may have either the dual-sized mounting or only 23 inch mounting depending on physical requirements. To rack mount the CEMF Cell, follow the procedure below. PROCEDURE 1) Position the mounting brackets as shown in Figure 2. This step is not required for units designed for 23 inch racks only. Figure 2: Mounting Brackets 2) Secure the mounting brackets to the CEMF Cell, using any bolts removed in Step 1 and additional bolts shipped with the unit. PM , Issue 8 2-1

9 CEMF Cell Product Manual Installation 3) Secure the equipment rack to the floor and install wall or ceiling supports to the top of the rack (as required). 4) Support the CEMF Cell against the rack. Line-up the holes in the mounting brackets with the appropriate holes in the equipment rack. 5) Secure the CEMF Cell to the rack with appropriate hardware. 2.3 WIRING CAUTION: Read the section on Functional Operation in Chapter 3 before wiring the CEMF Cell to avoid possible damage to the cell during installation and testing. After mounting the CEMF Cell in the relay rack, wire-in the unit as follows. PROCEDURE 1) Disconnect the battery and rectifier(s) from the system. Remove all fuses and turn off all circuit breakers in the distribution panels. 2) Use Table 1 to determine the proper AWG size for cables to connect the CEMF Cell between the battery and load distribution panels. The BATT connection (terminal 11) must be connected nearest to the battery and the LOAD connection (terminal 10) nearest to the load. Since systems vary, UNIPOWER cannot specify exactly where these connections must be made. If you need assistance, contact UNIPOWER Field Service. Table 1: AWG Wire Size Selection Maximum Current Wire AWG Size 25 amperes amperes amperes amperes amperes amperes amperes paired amperes paired ) Using AWG 18 or larger wire, connect BATT+ (terminal 4) to the system ground bar. NOTE: On negative ground systems, connect BATT+ (terminal 4) to an appropriate positive setting point. 4) Inspect and verify all wiring connections before proceeding with Step 5. NOTE: When the next connection is made, one or both of the contactors may activate. 5) Using AWG 18 or larger wire, connect BATT- (terminal 5) to an appropriate negative sensing point. NOTE: Connect to the system ground bar in a negative ground system. 6) If desired, connect a remote (customer-supplied) alarm device to FA (terminal 5). This terminal provides a closure to HOT (terminal 5 in positive ground systems or terminal 4 in the negative ground systems) when the fuse blows. 7) Reconnect the battery and rectifier(s). Replace all fuses and turn on all circuit breakers in the distribution panels. PM , Issue 8 2-2

10 CEMF Cell Product Manual Installation 2.4 INITIAL CEMF CELL PANEL CHECKOUT Successful completion of the following inspections and tests indicate that the CEMF Cell has been installed correctly. NOTE: Test points mentioned in the text are located on the front panel of the CEMF Cell. All voltage measurements should be made using a digital voltmeter with at least 10 megohms input impedance and a precision of at least 3 ½ digits. The digital voltmeter should be equipped with 0.08 inch pin probes. PROCEDURE 1) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor energizes (activated condition), placing a bypass (shunt) around the Cell One power diodes and permitting battery voltage to increase. 2) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes (normal condition), placing the Cell One power diodes in series with the battery and load in order to decrease battery voltage and return the system to normal operation. The digital voltmeter reading should be higher than the reading in Step 1. 3) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth the battery voltage trip point at which the contactor energizes (normal condition), removing the Cell 2 power diodes from the circuit, permitting the battery voltage to increase. 4) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes (activated condition), placing the Cell 2 power diodes in series with the battery and load in order to reduce load voltage. The digital voltmeter reading should be higher than the reading obtained in Step 3. 5) The UNIPOWER CEMF Cell is now ready to be placed in service. NOTE: To adjust or change the threshold points, see Chapter 4, Section 5, Adjustment Procedures. 2.5 LOCAL/REMOTE CONTROL CONVERSION The CEMF Cell can be locally controlled by an internal control module or remotely by a meter and alarm panel. To convert to remote control, remove the control module from the CEMF Cell and wire directly to the meter and alarm panel. Instructions are included with the meter and alarm panel. To convert the CEMF Cell to local control, order the Local Control CEMF Kit from UNIPOWER. The kit contains complete instructions and all necessary parts. PM , Issue 8 2-3

11 CEMF Cell Product Manual Operation 3 OPERATION 3.1 FUNCTIONAL OPERATION The UNIPOWER CEMF Cell is designed to protect sensitive equipment in DC power distribution systems from damage or incorrect operation caused by variations in battery voltage that can occur during system operation. The CEMF Cell uses power diodes as voltage dropping devices, automatically switching the diodes in and out of the circuit to compensate for battery voltage variations. The typical UNIPOWER CEMF Cell consists of two independent sections, Cell One (the low section) and Cell Two (the high section). Each section has two adjustable trip thresholds. One trip threshold activates the control function, while the second threshold returns the CEMF Cell to normal operation. Normal system operation (no corrective action by either cell) is indicated by steady illumination of the two green light emitting diodes (LEDs) on the integral control module front panel. When either cell is activated, its associated yellow LED on the control module front panel blinks. 3.2 OPERATING PROCEDURES The ADJ/LAMP TEST switch performs tow functions. In the LAMP TEST posistion, it turns on all functioning LEDs on the front panel. In the ADJ position, the switch facilitates adjustment of the CEMF Cell and prevents it from altering the load voltage during adjustment. ADJ/LAMP TEST switch functions are listed in Table 2: Controls and Indicators. NOTE: When the ADJ switch is released, the contactors will go into the state consistent with the LED indicators. Four front panel LEDs are provided to indicate status of the CEMF Cell, two for each section (Cell One, the low section and Cell Two, the high section). All LED indications are active, in other words, operating states are indicated by lit LEDs, with unlit LEDs conveying no information. Front panel controls and indicators are shown in Figure 3: Front Panel Controls and Indicators. Figure 3: Front Panel Controls and Indicators PM , Issue 8 3-1

12 CEMF Cell Product Manual Operation Table 2: Controls and Indicators Control or Indicator ADJ/LAMP TEST switch Function In ADJ position, the switch performs three functions: (1) The yellow LEDs (normally blinking when ON) are steady when ON. (2) The time delays that prevent false activation of the CEMF Cell due to noise or transients are defeated. (3) The contactors used to switch the power diodes in and out of the circuit are latched in the state they were in when the ADJ switch was pushed. In LAMP TEST position, the switch turns on all functioning LEDs on the front panel. CELL 1/CELL OUT LED CELL 1/CELL IN LED CELL 2/CELL OUT LED CELL 2/CELL IN Blinks to indicate activated state of Cell One (the low section) Yellow of the CEMF Cell. Lights steadily to indicate normal operation of Cell One (the Green low section) of the CEMF Cell. Lights steadily to indicate normal operation of Cell Two (the Green high section) of the CEMF Cell. Blinks to indicate activated state of Cell Two (the high Yellow LED section) of the CEMF Cell. PM , Issue 8 3-2

13 CEMF Cell Product Manual Troubleshooting 4 TROUBLESHOOTING 4.1 LOGICAL TROUBLESHOOTING The logical sequesnce of trouble shooting includes recognizing the sysmptioms of faulty operation, then localizing the trouble to specifiec functions, and analyzing the failure. UNIPOWER recommends that CEMF Cell failures be isolated to the malfunctioning circuit board and that the faulty board be replaced or returned to the factory for repair. 4.2 OVERALL FUNCTIONAL DESCRIPTION Figure 4, CEMF Cell Power Diodes Functional Diagram, shows the major components of the system as described in the following paragraphs. Figure 4: CEMF Cell Power Diodes Functional Diagram Normal system operation (no corrective action by either cell) is indicated by steady illumination of the two green light emitting diodes (LEDs) on the integral control module front panel. When either cell is activated, its associated yellow LED on the control module front panel blinks. Normal operation for Cell One (the low section) places the Cell One power diodes in series with battery and load. When activated, Cell One bypasses the diodes, permitting the load voltage to rise. Normal operation for Cell Two (the high section) bypasses the power diodes between the battery and the load. When activated, Cell Two removes the bypass, placing the high section power diodes in series with the battery and the load in order to reduce the load voltage. Blinking yellow LEDs indicate that the cell is in its activated mode. Cell One (CELL 1, CELL OUT LED) usually activates when the battery is being discharged and the low section diodes are removed from the circuit. Cell Two (CELL 2, CELL IN LED) usually activates during equalization of the battery, when the high section power diodes are inserted into the circuit. The normal state for Cell One (CELL 1, CELL IN LED) and Cell Two (CELL 2, CELL OUT LED) is indicated by steady green LEDs. 4.3 FUNCTIONAL SECTION DESCRIPTION CELL ONE (low section): Cell One (the low section of the CEMF Cell) activates to increase the load voltage when the battery voltage drops below a preset threshold, a situation that often occurs during AC power outage. When Cell One activates, contactor K1 energizes, K1 s single contact closes, completing a bypass (short) circuit around the Cell One power diodes, removing the diodes from the system and permitting battery voltage to increase by approximately four volts. As long as Cell One is activated, the front panel CELL 1, CELL OUT LED (yellow) blinks. PM , Issue 8 4-1

14 CEMF Cell Product Manual Troubleshooting Cell One resets when battery voltage increases above the second preset threshold. Contactor K1 energizes. K1 s single contact opens, removeing the bypass (short) circuit around the Cell One power diodes so the power diodes are once again in series with the batery and load. This returns the circuit to normal operation. When Cell One resets, the front panel CELL 1, CELL IN LED (green) lights and remains lit (steady). CELL TWO (high section): Cell Two (the high section of the CEMF Cell) activates to reduce the load voltage when the battery voltage increases above a preset threshold, a situation that often occurs during battery equalization. When Cell Two is activated, contactor K2 de-energizes, K2 s single contact opens, removing the bypass around the high section power diodes, and placing the Cell Two diodes in series with the battery and load. The Cell Two power diodes reduce the battery voltage by approximately two volts. As long as Cell Two is activated, the front panel CELL 2, CELL IN LED (yellow) blinks. Cell Two resets when the battery voltage drops below the second threshold. K2 energizes and its contact closes, restoring the bypass around the high section power diodes and returning the circuit to normal operation. When Cell Two resets, the front panel CELL 2, CELL OUT LED (green) lights and remains lit (steady). 4.4 VERIFYING CEMF CELL ADJUSTMENTS NOTE: Test points mentioned in the test are located on the front panel of the CEMF Cell. All voltage measurements should be made using a digital voltmeter with at least 10 megohms input impedance and a precision of at least 3 ½ digits. The digital voltmeter should be equipped with 0.08 inch pin probes. NOTE: Voltage readings mentioned in the text are for a 48 volt system. For factory settings of 24 volt configurations, refer to Table 3: CEMF Cell Trip Voltage Settings. PROCEDURE 1) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor energizes (activated condition), removing the Cell One poer diodes from the circuit and permitting load voltage to increase. The digital voltmeter reading should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.10 volts). 2) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes (normal condition), returning the system to normal condition by placing the Cell One power diodes in series with the battery and load. The digital voltmeter reading should be higher than the reading obtained in Step 1, and should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.16 volts). 3) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor energizes (normal condition), placing a bypass (shunt) around the Cell Two power diodes, permitting the system to retrun to normal operation. The digital voltmeter reading should be within the range of 4.8 volts to 5.8 volts (factory setting is 5.46 volts). 4) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes, placing the Cell Two power diodes in series with the battery and load in order to reduce load voltage. The digital voltmeter reading slhould be higher thant the reading in Step 3, and should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.51 volts). NOTE: To adjust or change the threshold points, see the following adjustment procedure (Section 5). PM , Issue 8 4-2

15 CEMF Cell Product Manual Troubleshooting 4.5 ADJUSTMENT PROCEDURES Placing the ADJ/LAMP TEST rocker switch in the ADJ position locks the CEMF Cell in the condition present when the switch is pressed. This function prevents voltage fluctuations on the DC bus caused by the adjustment procedure. Adjustment procedures are quite simple and can be accomplicshed with the equipment energized. CAUTION: When the ADJ rocker switch is released, the CEMF Cell immediately transfers to the state indicated by the LEDs. Be sure the LEDs indicate the desired state before you release the ADJ switch. NOTE: Test points mentioned in the text are located on the front panel of the CEMF Cell. All voltage measurements should be made using a digital voltmeter with at least 10 megohms input impedance and a precision of at least 3 ½ digits. The digital voltmeter should be equipped with 0.08 inch pin probes. NOTE: Voltage readings mentioned in the text are for 48 volt systems. For factory settings for 24 volt configurations, see Table 3: CEMF Cell Trip Voltage Settings Adjusting the Low Cell Trip Points 1) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor energizes (activated condition). 2) To change the trip point, hold in the ADJ portion of the ADJ/LAMP TEST switch. Using a small screwdriver, adjust the front panel CELL 1, CELL OUT, ADJ potentiometer to one tenth of the desired trip voltage. The digital voltmeter reading should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.10 volts). 3) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 1, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes (normal condition), returnign the system to a normal condition. 4) To change the trip point, hold in the ADJ portion of the ADJ/LAMP TEST switch. Using a small screwdriver, adjust the front panel CELL 1, CELL IN, ADJ potentiometers to one tenth of the desired trip voltage. The digital voltmeter reading should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.16 volts). The reset trip voltage must be higher than the activating trip voltage established in Step Adjusting the High Cell Trip Points 1) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL OUT, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor energizes (normal condition). 2) To change the trip point, hold in the ADJ portion of the ADJ/LAMP TEST switch. Using a small screwdriver, adjust the front panel CELL 2, CELL OUT, ADJ potentiometer to one tenth of the desired trip voltage. The digital voltmeter reading should be within the range of 4.8 volts to 5.8 volts (factory setting is 5.46 volts). 3) Insert one probe of the digital voltmeter in the REF BATT+ test jack. Insert the other probe in the CELL 2, CELL IN, TP test jack. The voltage indicated on the digital voltmeter is one tenth of the battery voltage trip point at which the contactor de-energizes (activated condition). 4) To change the trip point, hold in the ADJ portion of the ADJ/LAMP TEST switch. Using a small screwdriver, adjust the front panel CELL 2, CELL IN, ADJ potentiometer to one tenth of the desired trip voltage. The digital voltmeter reading should be higher than the reset trip point established in Step 1, and should be in the range of 4.8 volts to 5.8 volts (factory setting is 5.51). PM , Issue 8 4-3

16 CEMF Cell Product Manual Troubleshooting Table 3: CEMF Cell Trip Voltage Settings (DVM readings are one tenth of the actual trip voltages) Unit Voltage Rating 24 volts Trip point adjustment range (volts) -2.4 to 2.9 CELL 1, CELL OUT Factory Settings CELL 1, CELL 2, CELL IN CELL IN CELL 2, CELL OUT volts -4.8 to CALIBRATION PROCEDURES The UNIPOWER CEMF Cell is calibrated at the factory and should not require calibration. Calibration and verification of calibration are simple procedures and may be accomplished while the system is energized. One adjusting potentiometer and three test point are provided inside the unit, on the rear of the printed circuit board. The voltage dividers inside the CEMF Cell are scaled to operate at one tenth of the actual voltage. The one tenth potentiometer is used to calibrate the input signal to exactly one tenth of the battery voltage. Turrettype test points REF, Vb, and Vb/10 provide convenient access for digital voltmeter clips to measure the battery voltage and its one tenth signal as set by the one tenth potentiometer. A reference (battery positive) test point is also provided. NOTE: Test points mentioned in the text are located in the rear of the CEMF Cell module. All voltage measurements should be made using a digital voltmeter with at least 10 megohms input impedance and a precision of at least 3 ½ digits. The digital voltmeter should be equipped with spring loaded test clips to connect to the turret test points. To verify and/or adjust the one tenth reference voltage, perform the following procedure. CAUTION: The heatsinks on the control board are HOT. Be sure to avoid contact between the heatsinks on the control board and the enclosure of the CEMF Cell or the unit could be damaged. PROCEDURE 1) Carefully remove the control assembly from the front of the CEMF Cell. 2) Locate the REF, Vb and Vb/10 turret test points on the rear of the control printed circuit board. 3) Connect the digital voltmeter between the REF and Vb test point. The voltmeter displays the battery voltage as seen at the input of the CEMF Cell (BATT+ to BATT-). Record this value. 4) Connect the digital voltmeter between the REF and Vb/10 test point. The voltmeter displays the voltage as seen by the voltage detection circuits. Record this voltage. CAUTION: The accuracy of the entire system depends on the precise setting of the 1/10 control. 5) Compare the voltages measured in Steps 3 and 4. The voltage measured in Step 4 should be exactly one tenth the voltage measured in Step 3. If there is any discrepancy, adjust the 1/10 control located near the test points and repeat Steps 3 through 5 until the setting is correct. PM , Issue 8 4-4

17 CEMF Cell Product Manual Maintenance 5 MAINTENANCE No periodic or scheduled maintenance is recommended for the UNIPOWER CEMF Cell. UNIPOWER suggests that the user isolate any problems to the circuit board level and either replace the faulty circuit board or return it to UNIPOWER for repair or replacement. 5.1 CIRCUIT BOARD REPLACEMENT There is one circuit board inside the CEMF Cell which can be stocked as a spare part. The circuit board is available in two configurations. 5.2 FUSE REPLACEMENT (1) 24 volt circuit board (PN ) (2) 48 volt circuit board (PN ) Always replace the front panel fuse with the type specified. The CEMF Cell front panel fuse is: 5-ampere GMT (PN ) PM , Issue 8 5-1

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20 ED B1 Issue ISSUES UNLESS OTHERWISE SPECIFIED. UNLESS OTHERWISE SPECIFIED. ISSUE # DESCRIPTION ISS. BY ISS. DATE A B 51. PANEL CAN BE MOUNTED IN A 19" OR 23" RACK BY PROPER PLACEMENT OF ADAPTER BRACKETS. 52. THE CEMF CELL CONTROL MODULE "A1" ASSY. SLIDES INTO AND MOUNTS ON THE FRONT PANEL. THE CONTROL MODULE PROVIDES FOR FRONT PANEL ADJUSTMENTS. SEE MANUAL FOR ADJUSTMENT INSTRUCTIONS. 53. FIELD WIRING TO TB1-4, 5, THE CONTROL MODULE CONTACTS TO TB1-1 THRU 6. THE CABLE IS LONG ENOUGH TO ALLOW MODULE TO BE PULLED OUT FOR SERVICING OR REPLACEMENT MOUNT LABELS ON REAR AS SHOWN HEATSINKS MUST BE INSULATED FROM THE CHASSIS. USE NYLON SHOULDER WASHER FRONT, NYLON FLAT WASHER BACK. 16 PLC'S, SEE DETAIL A USE THERMAL COMPOUND WHEN MOUNTING CR1 - CR8. DO NOT OVER TIGHTEN DIODE WIRING IS #4 GA BLACK, SLEEVED AND TIE WRAPPED WITH ACRYIGLASS, 5/8" WIDE AND OF SUFFICIENT LENGTH TO PROTECT CABLE IN CONTACT WITH METAL EDGES CONNECTION TO HEATSINK CHANNEL MUST BE ELECTRICALLY SOUND, SEE DETAIL B. 8 SEE PCO# WD 6/28/17 A B 106. DELETED C SH NO ISSUE SHEET INDEX PLACE "BAT" AND "LOAD" LABELS AS SHOWN CAREFULLY SOLDER D1 & D2 ( ) LEADS TO GA UNINSULATED, 0.250" FEM SLIP-ON LUG. DO NOT OVERHEAT DIODES. INSTALL WITH POLARITY AS SHOWN CAREFULLY ROUTE CABLES AS SHOWN, MAINTAINING STRAIN RELIEF AT ALL CONNECTIONS. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ± TOLERANCES ON: HOLES FRACTIONS DECIMALS (XX) DECIMALS (XXX) ANGLES ±1/32 ±0.020 ±0.010 ±1/2 SQUARE CORNERS AND ANGLES ARE 90 UNLESS OTHERWISE SPECIFIED. WORKMANSHIP: PER SPEC ENG032 MATERIAL: CHECKED BW 3/6/86 APPROVED APPROVED APPROVALS DATE DRAWN MWY 3/6/86 C FINISH: 110. USE GA UNINSULATED MINI SPRING SPADE #6 LUGS FOR TB1 CONNECTIONS, INSTALL TB1 LABEL AS SHOWN FOLLOW ALL MIS INSTRUCTIONS FOR MOUNTING COMPONENT PARTS, SIZING HARDWARE AND LUGS WHERE NOT EXPLICITLY CALLED OUT. PROPRIETARY INFORMATION NOT TO BE COPIED, USED, TRANSMITTED, OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER, LLC. D THE ISSUE OF SHEET REFLECTS THE LATEST ISSUE OF THE DRAWING SET. WHEN THE DRAWING SET IS REVISED, ONLY THE ISSUE NUMBERS OF MODIFIED SHEETS ARE CHANGED. THE ISSUE NUMBERS OF UNMODIFIED SHEETS ARE NOT CHANGED OBSERVE CABLE ROUTING DETAILS, ALWAYS LEAVE ADEQUATE STRAIN RELIEF. SIZE SCALE: N/A DOC TYPE / NUMBER PN SHEET: 1 OF 5 CEMF CELL -48 VOLTS 100 AMPS 111B FILE NAME: PN111B _SHT_1_ISS_8 ISSUE 8 D

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25 ADJ TEST ED B1 Issue ISSUES ISSUE DESCRIPTION ISS. BY A 1. THE ISSUE NUMBER OF SHEET 1 IS THE LATEST ISSUE OF THE DRAWING SET, AS REFERENCED BY THE SHEET INDEX. 2. ONLY MODIFIED DRAWINGS WILL BE GIVEN NEW ISSUE NUMBERS, OTHERWISE, THE CURRENT ISSUE REMAINS UNCHANGED FOR THAT SHEET. 51. UNASSIGNED 52. THE CEMF CELL MAY BE FURNISHED WITH A CONTROL CIRCUIT A SPACE IS PROVIDED IN THE FRONT PANEL FOR THIS "SLIDE-IN" CONTROL MODULE. THE CONTROL MODULE IS FRONT PANEL ADJUSTABLE. SEE MANUAL FOR ADJUSTMENT INSTRUCTIONS. # ISS. DATE 8 SEE PCO# WD 6/28/17 A 53. FIELD WIRING AT TERMINALS 4-6 IS REQUIRED WHEN THE CONTROL MODULE IS INCLUDED. 54. CONTROL MODULE CONNECTS TO TB1 TERMINALS 1-6. CABLE IS LONG ENOUGH TO ALLOW MODULE TO BE PULLED OUT FOR SERVICING OR REPLACEMENT. 55. TOP AND BOTTOM PERFORATED COVERS NOT SHOWN. 56. (S)= STANDARD DIODE; i.e. FLAG IS ANODE. (R)= REVERSE DIODE; i.e. FLAG IS CATHODE. B 57. PANEL IS EQUIPPED WITH: 1. K1 & K2 WITH 24VDC CONTROL COILS AND SERIES DROPPING RESISTORS (R1 & R2, 40 OHM 55 WATT.) 2. K1 & K2 WITH 48VDC CONTROL COILS. B UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ± TOLERANCES ON: HOLES FRACTIONS DECIMALS (XX) DECIMALS (XXX) ANGLES ±1/32 ±0.020 ±0.010 ±1/2 APPROVED APPROVED APPROVALS SQUARE CORNERS AND ANGLES ARE 90 UNLESS OTHERWISE SPECIFIED. DATE DRAWN SAN 10/25/87 CHECKED JB 10/25/87 C CONTROL E/W CONTROL MODULE W/O CONTROL MODULE MODEL NUMBER 111B B WORKMANSHIP: PER SPEC ENG032 MATERIAL: C FINISH: CEMF CELL SHEET INDEX SH NO ISSUE PROPRIETARY INFORMATION NOT TO BE COPIED, USED, TRANSMITTED, OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER, LLC. LAMP REF BATT+ CELL 1 CELL 2 5 AMP ADJ TP CELL OUT TP ADJ ADJ TP CELL IN CELL OUT TP ADJ CELL IN D SIZE CEMF CELL -48V, 200A 4 & 6V DROP DOC TYPE / NUMBER PN 111B-3218 ISSUE 8 D SCALE: N/A SHEET: 1 OF 2 FILE NAME: PN111B-3218_SHT_1_ISS_8

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28 ED B1 Issue ISSUES ISSUE DESCRIPTION ISS. BY # ISS. DATE 5 SEE PCO# WD 6/28/17 A 51. HOLES ARE PROVIDED FOR INPUT / OUTPUT CONNECTIONS BY SINGLE HOLE LUGS WITH 3/8" HARDWARE. APPLY EJC # 2 TO ALL CONNECTIONS. INPUT / OUTPUT WIRING MUST BE 2 EACH 2/0 MINIMUM. 52. SELECT THE PAINT COLOR FROM TABLE A: IE. 111B , COLOR A = ANSI 61 GRAY FINISH, IE. 111B , COLOR B = BEIGE FINISH APPLY EJC #2 TO ALL ALUMINUM MATING SURFACES. ANTI-OXIDATION COATING WILL BE APPLIED BETWEEN ALL LAYERS OF LAMINATED COPPER BUS STRUCTURE. A COMPOUND, SUCH AS EJC #2 WILL BE APPLIED TO JOINTED FLAT SURFACES PER MANUFACTURER'S INSTRUCTIONS MARK HEATSINK WITH DIODE POLARITY. DO NOT MARK WITH CR DESIGNATION. COLOR ANSI 61 GRAY TABLE A DESIGNATION A 103. USE ALCOHOL AND SCOTCH BRITE TO REMOVE CHROMA COAT FINISH FROM THE DIODE MATING SURFACES OF ALL HEATSINKS. APPLY EJC #2. B BEIGE B 104. TIGHTEN CLAMP EVENLY TO 2K LBS, HEATSINKS MUST REMAIN PARALLEL. 53. THIS UNIT DISSIPATES 2400W AT RATED MAXIMUM LOAD. PROVIDE VENTILATION SPACE ABOVE AND BELOW THE CEMF CELL. PROVIDE PROTECTION FOR HEAT SENSITIVE ITEMS ABOVE THE CEMF. 54. TOP SCREEN TEMPERATURES ARE HIGH AT RATED LOAD. APPLICATIONS SHOULD PREVENT CASUAL CONTACT WITH THE TOP SURFACE. 55. THE CEMF CAN BE FLUSH OR CENTER MOUNTED. SEE FIGURE 3 FOR MOUNTING EAR POSITIONS PLACE CAUTION LABEL, P/N , 5 PLC'S PER FRONT VIEW AND FIGURE 3. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ± TOLERANCES ON: HOLES FRACTIONS DECIMALS (XX) DECIMALS (XXX) ANGLES ±1/32 ±0.020 ±0.010 ±1/2 SQUARE CORNERS AND ANGLES ARE 90 UNLESS OTHERWISE SPECIFIED. WORKMANSHIP: PER SPEC ENG032 MATERIAL: FINISH: CHECKED TET 10/2/91 APPROVED VMB 11/12/91 APPROVED APPROVALS DATE DRAWN RCS 10/2/91 C PROPRIETARY INFORMATION NOT TO BE COPIED, USED, TRANSMITTED, OR DISCLOSED WITHOUT PRIOR WRITTEN PERMISSION FROM UNIPOWER, LLC. THE ISSUE OF SHEET 1REFLECTS THE LATEST ISSUE OF THE DRAWING SET. WHEN THE DRAWING SET IS REVISED, ONLY THE ISSUE NUMBERS OF MODIFIED SHEETS ARE CHANGED. THE ISSUE NUMBERS OF UNMODIFIED SHEETS ARE NOT CHANGED. SHEET INDEX SH NO ISSUE SIZE -48 VOLT CEMF CELL TWO STAGE, NOM. 4V & 6V, 400 AMP MAX. DOC TYPE / NUMBER PN 111B ISSUE 5 D SCALE: N/A SHEET: 1 OF 6 FILE NAME: PN111B _SHT_1_ISS_

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