ABB NES48-19-4U-AC7-PS3-DIN15B250P-LVBD-ACSPD User manual

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Quick Start Guide
NES-Flex DIN with Integrated AC
NES-Flex DIN with Integrated AC is available as either a one-shelf or two-shelf power system. The system is
factory-configured with LVBD, Pulsar Plus controller, AC circuit breakers, and surge protection. Two shelf system
includes LVLD for 6 priority and 9 non-priority
NES48-19-4U-AC7-PS3-DIN15B250P-LVBD-ACSPD
Tools Required:
• Torque wrench (0-40Nm)
• Screw Drivers - Phillips and flat
• Sockets - metric and inch
• Wire cutters and strippers
• Cable crimpers
Step 1 - Mount System
Prepare the system for mounting to the frame.
1. Reposition mounting ears if required - may be moved back (up to
5”).
Torque to 2.8 Nm (25 in-lb) - Phillips screwdriver.
Mount the system to the frame.
1. Attach system to frame using minimum of eight screws (four per
side) #12-24 screws (provided).
Mounting Ears
Inter-Shelf Bracket
Rectifier Shelf
Step 2 - Ground Chassis
Attach ground cable to rear of system.
Torque to 4 Nm (35 in-lb) - 5/16” (8 mm) socket.
Notes:
1. Lug landing is M5 on 5/8” (16 mm) centers (lug not provided)
2. 10 mm2 (10 AWG) recommended
3. Some applications may rely on frame mounting screws
for chassis ground omitting the chassis ground cable
Chassis Ground
Quick Start Guide

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Quick Start Guide
Step 3 - Connect System DC Reference (CO) Ground — Make one connection to
power system
Connect DC Reference Ground to left-most
position on the Return Bus - M8 lug (not provided).
10 mm2 (10AWG) recommended
Torque to 14 Nm (120 in-lb) - 1/2” (13 mm) socket.
DC Reference (CO) Ground
Step 4 - Connect AC Input
Connect the 5-wire 3-phase “wye” input to the AC terminal blocks.
Note: AC Input to rectifiers is line to neutral.
Danger: Turn OFF and lock-out tag-out the AC source
before making AC connections. When connecting
to AC mains, follow all local and national wiring rules.
Caution: When routing AC , ensure cables do not
come in contact with sharp or rough surfaces that
may damage
insulation and cause a short circuit.
1. Remove AC Cover (four screws) - back left of unit.
2. Connect AC conduit. Remove knockout for 1” conduit either
on side or bottom of box.
3. Connect Conduit Ground Wire - 6 mm2 (8 AWG). Lug landing is
M6 on 5/8” (16 mm) centers (lug not provided). Torque to
7.3 Mn (65 in-lb).
4. Insert wire in terminal blocks in this order: Neutral, Line 1, Line 2,
System Recommended Wire Gauge Recommended External 3-Phase AC Breaker
1 shelf system 10 AWG 30A
2 shelf system 8 AWG 50A
Ground Wire
Screws
AC conduit connection knockouts for 1” conduit
Wire Entry Underneath

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Quick Start Guide
Information: Breaker Location Diagram
Battery Loads AC
One Shelf System
Battery Priority Non-Priority AC
Loads
Two Shelf System
Step 5 - Connect Batteries - skip if no batteries installed
Install Battery Breaker Kits - skip if battery breakers are installed or batteries are not present
1. Connect alarm wire to battery breaker (wires provided).
Connect Fastons to breaker terminals.
Terminal 11 - Red
Terminal 12 - Black
2. Mount breaker to DIN rail.
a. Verify that breaker is OFF (handle down).
b. Fully open the screw connections at breaker
bottom - #2 Phillips
c. Slide breaker over bus tabs and engage top DIN rail fully
IMPORTANT - Verify top DIN rail engagement.
d. Tighten the breaker bottom connection - #2 Phillips
3. Connect alarm wires to Alarm Card HDR3.
BAT1 Aux + Red
BAT1 Aux - Black
a. Run wires to HDR3.
b. Cut wires.
c. Strip 12 mm (1/2”).
d. Push release lever, insert wire, release lever, Pull
wire to verify.
4. Repeat for additional Battery Breakers, BAT2, etc

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Quick Start Guide
Connect Batteries (continued)
1. Connect Battery Return Cable to Return Bus. Battery Return Lug Landings - M8 bolts (lug not provided). Torque to 14 Nm
(120 in-lb) - 1/2” (13 mm) socket.
2. Verify that breaker is OFF (handle down).
CAUTION: Verify battery voltage and polarity with a voltmeter before proceeding.
3. Connect Battery Cable to lug adapter (factory assembled to breaker). Battery Lug Landings - M8 bolts (lug not provided).
Torque to 14 Nm (120 in-lb) - 1/2” (13 mm) socket.
Note: Larger battery breaker may include adaptor bus for two connections.
4. Verify torque of adaptor and bus connection to circuit breaker. Torque to 2-2.3 Nm (20 in-lb) - #2 Phillips.
5. Repeat for additional Battery connections.
Step 6 - Connect Loads (Outputs)
For system with LVLD (two shelf system only), note positions of priority (critical) versus non-priority (non-critical)
loads. There can be up to 6 priority and 9 non-priority loads.
1. Verify that breaker is OFF (handle down).
2. Mount breaker to DIN rail.
a. Fully open the connection at breaker bottom - #2 Phillips.
b. Slide breaker over bus tab and fully engage top DIN rail.
IMPORTANT—Verify top DIN rail engagement.
a. Tighten the breaker bottom connection - #2 Phillips. Hold firmly downward and torque to 2-2.3 Nm (20 inlb).
3. Connect alarm wire to load breaker.
Note: This wire will be secured to the breaker along side the load wire.
a. Fully open the screw connection at breaker top - #2 Phillips.
b. Choose any wire from the bundle of black wires behind the breakers. Cut wire. Strip 10 mm (3/8”). Insert wire into
breaker load connection. Do not tighten the breaker connection.
Release Levers
Push to release
Lug Adapter
Alarm Card HDR3
Battery Connection
Battery Return Connection
DIN Rail Engagement
Return Bus
Bus Tabs
Breaker Bus
Connection
11 12
Alarm
Wires

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Quick Start Guide
Step 6 - Connect Loads (Outputs) (continued)
4. Repeat for additional Load Breakers.
Connect Loads (Outputs)
1. Connect load return wire to the Load Return Bus - M6 lug
(not provided).
2.Connect load wire to breaker.
a. Strip load wire to 10 mm (3/8”).
b. Insert load wire into breaker load wire connection along
side the alarm wire.
Load
Return Bus
Load Return Connection
Alarm wire:
secure with the
load wire
Breaker
Load
Connection
Screw
Breaker Bus
Connection
Screw
Bus Tabs
DIN Rail
Step 7 - Label Connections
ID label is in front of the breakers or on the door.
Mark each connected circuit identification on the ID label ID Label Example
Step 8 - Connect Controller Cables
For additional details, see Steps 11 and 12 for controller information, and Information Sections on battery
monitoring and alarm connections.
1. Connect LAN (10Base-T Ethernet) Communication.
2. Connect 1-Wire Battery Monitoring Cables.
3. Connect alarm input and output cables.
Alarm Relay Jumpers
LAN
Alarm Outputs
Alarm Inputs
Thermal
Slide the unit into the power slot approximately
3/4 of the way.
Step 9 - Install Rectifiers
Open the faceplate by sliding the
faceplate latch to the left until the
faceplate releases and swings
outward.
Slide the unit into the slot until it engages
with the back of the shelf. Swing the
faceplate closed to fully seat the rectifier.
Verify the faceplate is latched.

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Quick Start Guide
Step 10 - Initial Start Up
Bring Rectifiers Online:
1. Verify the AC and DC connections are complete and secure.
2. Turn on AC input breakers.
Bring Batteries Online:
3. Measure voltage of all battery strings.
4. Set float voltage in controller to lowest measured valid string voltage.
5. Turn on battery breaker of any battery string within 1/2 volt of this lowest measured voltage.
6. Continue by adjusting system voltage up to next measured string not on-line.
Repeat process 5 and 6 until all battery strings are on-line.
Step 11 - Configure Controller
Notes: 1. The Pulsar Plus Controller Family Product Manual includes additional information.
2. This system automatically configures Rectifier Parameters.
View and Change Parameters and Alarm Severity
View and change system parameters from the factory defaults via
a. Controller Display
b. Craft Port on front of controller using a laptop with EasyView2 software
or HyperTerminal.
EasyView2 (GUI) software can be downloaded from www.abbpowerconversion.com
c. J5 LAN port web pages using a laptop with browser. LAN port Server mode is for local laptop connection. Set the
LAN port to Server: With the controller set to Server enter the default IP address 192.168.2.1 (default) in the web
browser address field.
Warning: Do not connect J5 LAN port to a network when set to Server. Set the controller to Client or Static before
connecting to the network. Static is the factory default setting and the typical setting for most networks.
LAN Port - Local / Network
The LAN port is be configured as Local or Network
controller display menu path: Configuration > Communication Ports > Network Settings > DHCP > mode
CLIENT or SERVER
Local (Server): LAN connects to a laptop.
Local (Server) is a temporary setting. When configuration is complete, return LAN port to Network (Client)
mode.
Craft Port behind door

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Quick Start Guide
Step 11 - Configure Controller (continued)
Alarm Relay Jumpers and 1-Wire Data reference
Jumpers are located on the top of the controller.
Alarm Relay Jumper Factory Defaults are Open On Alarm
1-Wire Reference Factory Default is -48V.
Step 12 - Controller Basic Operation
Controller Alarm Status: The display changes colors; Green = Normal, Amber = Minor Alarm, Red = Critical/Major
Alarm
Some alarms may occur during initial installation; example: thermal probe fail or Major/Minor communication
fail.
Clear these alarms: Via Controller Display: follow the menu path; Menu > Control/Operation > Clear Events or
Uninstall Equipment.
Via web pages or EasyView2; Select the Maintenance tab > clear latched events and clear
missing devices.
Verify Basic Installation Settings: Date, Time, Battery Type, number of strings and float voltage
Controller Display - Menu > Configuration > System Settings and Menu > Configuration > Batteries.
Web pages or EasyView2 - Installation Tab for Date, Time. Site ID and Site Description
Settings Tab > Battery Management for Battery
Type and number of battery strings installed
Plant Status LEDs
LCS Display
Voltage Test Jacks Menu Navigation
Cart port
behind door
Front Display
Front Display Menu Map
Web Home Page

Page 8
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Quick Start Guide
Information: Battery Monitoring Connections
Battery Monitoring is accomplished with a “Daisy Chained” series of probes. The Probes monitor battery
temperature and voltage (ES771 required to monitor voltage). Bolt the Probe under the “–“ terminal connector
hardware; NOT under the connecting lug. Max per system: Probes - 16, ES771 Modules - 6.
Ordering Codes Descriptions
CC109142980 QS873A Battery Thermal Probe
150026698 QS873B Ambient Probe
CC848817024 B 10’ controller to thermal probe wireset
CC109157434 B 20’ controller to thermal probe wireset
CC848822560 C 1’ thermal probe to thermal probe wireset
848719803 C 5’ thermal probe to thermal probe wireset
850037334 C 20’ thermal probe to thermal probe wireset
Ordering Codes Descriptions
108958422 ES771A Voltage Monitor Card
CC848791517 D 2 ½’ ES771A to probe wireset
CC848797290 D 6’ ES771A to probe wireset
848719829 D 10’ ES771A to probe wireset
CC848791500 G 4’ ES771A to ES771A or controller wireset
848652947 G 10’ ES771A to ES771A or controller wireset
Battery Temperature Measurement Battery Temperature and Voltage Measurement

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Quick Start Guide
Information: Alarm Connection
Alarm Outputs
Alarm relays are factory set to Open On Alarm. If Close On Alarm is desired ad- just controller alarm jumpers. See
diagram in step 8 for the location of the con- troller alarm jumpers. Alarm output is a 20-pin latching connector.
Alarm relays
Alarm Inputs
Pin Color
Option 2
Standard Controller Alarm
Output Defaults
Color
Option 1
PCR Power Critical 1BLBL
PCR_C Power Critical_C 11 Bl/BKW
PMJ Power Major 2OO
PMJ_C Power Major_C 12 O/BKW
PMN Power Minor 3GG
PMN_C Power Minor_C 13 G/BKW
R1 Battery On Discharge 4WBR
R1_C Battery On Discharge_C
(BD_C) 15 WW/BK
R2 Very Low Voltage (VLV) 5SBK
R2_C Very Low Voltage_C
(VLV_C) 15 WBK/W
R3 Fuse Alarm Major (FAJ) 6BL BL/W
R3_C Fuse Alarm Major_C
(FAJ_C) 16 RBL/R
R4 AC Fail (ACF) 7OQ/R
R4_C AC Fail_C (ACF_C) 17 RR
R5 Rectifier Fail (RFA) 8GG/W
R5_C Rectifier Fail_C (RFA_C) 18 RR/G
R6 Mult. Rectifier Fail
(MRFA) 9BR W/R
R6_C Mult. Rectifier Fail_C
(MRFA_C) 19 RR/W
R7 High Voltage (HV) 10 SBK/R
R7_C High Voltage_C (HV_C) 20 RR/BK
Standard Controller
Alarm Output Defaults
Pin Color
Option 1
Color
Option 2
PCR Power Critical 1BL BL
PCR_C Power Critical_C 11 WBl/BK
PMJ Power Major 2OO
PMJ_C Power Major_C 12 WO/BK
PMN Power Minor 3GG
PMN_C Power Minor_C 13 WG/BK
R1 Battery On
Discharge 4BR W
R1_C Battery On
Discharge_C
(BD_C) 15 WW/BK
R2 Very Low Voltage
(VLV) 5SBK
R2_C Very Low Voltage_C
(VLV_C) 15 WBK/W
R3 Fuse Alarm Major
(FAJ) 6BL BL/W
R3_C Fuse Alarm Major_C
(FAJ_C) 16 RBL/R
R4 AC Fail (ACF) 7OQ/R
Alarm Output Cables Alarm Input Cables
CC848890137 5 ft. CC848890153 5 ft.
CC109157442 15ft CC848865980 15ft
CC848817635 50 ft CC848817651 50 ft
CC848817643 150 ft CC848817668 150 ft

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Quick Start Guide
Alarm Reset
Information: Clear Breaker Alarm
The Alarm Card monitors all breakers that were once ON.
Breaker Alarms occur while breakers are OFF or TRIPPED.
Clear Breaker Alarm
Turn the breaker ON
or
Press the Alarm Reset button to ignore all breakers that are OFF or TRIPPED, until they
Information: Rectifier Options
Rectifier Input Output 48Vdc
Recommended 3-phase AC Breaker (PH-N) “WYE”
1-shelf
(3 rectifiers)
AC Breaker/Wire Gauge
1-shelf
(3 rectifiers)
AC Breaker/Wire Gauge
Eco Recer
blue
NE050ECO48ATEZ ac 200-277 Vac 50A 20A /12 AWG 40A / 8 AWG
Recer
blue
NE075AC48ATEZ ac 200-277 Vac 75A 30A / 10 AWG 50A / 8 AWG
NE050AC48ATEZ ac 208-277 Vac 50A 20A / 12 AWG 40A / 8 AWG
Surge Protectors
Force During insert to
module to the base
Information: Surge Protectors
Surge Protection Device consists of three RU-320-25 field-replaceable modules protecting Line to Neutral and
one RU-180-25 field -replaceable module protecting Neutral to Ground. See page11 for ordering replacement
module information.
Replace pluggable modules if RED indicator tab is visible on any of the multiple pole units. To remove:
1. Verify that you have the correct replacement module.
2. Disconnect power.
3. Pull the pluggable module from the base.
4. Push a new pluggable module into the base. You will hear a “click”, indicating that the module is set in place. An
insertion “key” built into the unit will help ensure that the module has been correctly selected.
CAUTION : Use of
excessive ion, can
result in damage
L1 L2 L3
Red Indicator
Window
N