OmniMetrix Hero 40 Amp Tap Commander User manual

Document No.: IM-1508
Revision Level: 03
Approval Date: 10-JUNE-2020
Author: T. Robinson/C Fisher
Approved By: C. Fisher
1
Hero™40 Amp Tap Commander
Installation Guide
The 40 Amp Tap Commander ™ connects to the Rectifier and Hero 1 or Hero 2 Rectifier Monitor and
allows the user to adjust the output voltage of the rectifier locally, remotely via OmniView or
automatically to keep the rectifier output current relatively constant.
1. Verify the following components are included in the package and are free from damage:
•Tap Commander Module
•Tap Commander Interface Cable (6’)
•Tap Power Cable
•14 Yellow Tap Wires
•Snap-Track (for mounting the Tap Commander)
•Installation Instructions
2. Before installing the Tap Commander:
•Using a multimeter, measure and record the Shunt Voltage
•Using a multimeter, measure and record the Output Voltage
•Using a multimeter, find and mark two Taps that measure 11-15 VAC between them. These
will be Power Taps for the 40 Amp Tap Commander.
•Install the Hero RMU (see installation guide included with the Hero)
•During the installation of the Hero, route the Tap Commander Accessory cable through the
conduit. See the note on the next page if you must cut the 4 pin connector off.
•Make sure the current protection wires are firmly screwed down on the external Interrupter
Relay connections.
•Turn on the AC power to the rectifier and confirm the Blue Heartbeat LED on the Hero board
is blinking once per second (this can take up to ten minutes)
•The external Interrupter Relay must be wired correctly and operational before installation
of the Tap Commander.
oHero 1 –Test the Interrupter Relay by issuing a Rectifier Off command from
Omniview. Confirm the relay is open by using a multimeter to measure mV across
the shunt, the mV reading should be zero. After confirmation, issue a Rectifier On
command from Omniview.
oHero 2 - Test the relay by pressing and holding the red “Interrupter Relay” button
for three seconds, on the Hero 2 Interface Board. The Red LED should illuminate
below the red “Interrupter Relay” button signifying the relay is open. Confirm the
relay is open by using a multimeter to measure mV across the shunt, the mV reading
should be zero. After confirmation, press and hold the red “Interrupter Relay”
button until the Red LED goes out on the Interface Board. NOTE: The button on the
Interface Board are only active when the blue Heartbeat light is flashing.
•The external Interrupter Relay is an integral part of the Tap Commander design. If the
external Interrupter Relay is not working correctly, do not proceed with installation of the
Tap Commander until that problem is resolved
3. Installation:
•Power down the AC to the Rectifier
•Remove the shorting bars from the rectifier

Document No.: IM-1508
Revision Level: 03
Approval Date: 10-JUNE-2020
Author: T. Robinson/C Fisher
Approved By: C. Fisher
2
Hero™40 Amp Tap Commander
Installation Guide
•Mount the Tap Commander inside the Rectifier (It can rest free on the bottom screen, be
mounted on the door or back of the rectifier, mounting materials not included)
•If necessary, route the interface cable through the conduit from the Hero to the rectifier. If
the 4 pin connector must be removed in order to route through the conduit, insert stripped
wires according to the diagram below, otherwise plug in the 4 pin connector as shown.
•Connect the Tap Power Cable to the two Power Taps previously identified and to the
provided Power Connection on the Tap Commander.
40 Amp Tap Commander
POWER CONNECTION
CONTROL CONNECTION
ALTERNATE CONTROL
CONNECTION
BUTTONS

Document No.: IM-1508
Revision Level: 03
Approval Date: 10-JUNE-2020
Author: T. Robinson/C Fisher
Approved By: C. Fisher
3
Hero™40 Amp Tap Commander
Installation Guide
If the 4 pin connector
has to be removed in
order to insert the
cable in the conduit,
strip and insert the
wires here according to
the diagram below.
Plug 4 pin connector
here as shown.
Connect wires from Power
Taps here.
6
5
4
3
2
1
SDA
SCL
5V
GND
6 PIN
CONNECTOR
4 PIN
CONNECTOR
ON
TAP COMMANDER
BLUE CONNECTOR
CONN1
ON
HERO 1
TRM6
1
2
3
4
3 2 1
6 5 4
WIRE ENTRYSIDE
1 GREEN
2 WHITE
3 RED
4 BLACK
5
6
6 PIN
CONNECTOR
ON
HERO 2
ACCESSORY
•Plug the 6 pin connector into the designated connector on the Hero:
oHero 1 - TRM6 on the main board.
oHero 2 - ACCESSORY on the Communication Module

Document No.: IM-1508
Revision Level: 03
Approval Date: 10-JUNE-2020
Author: T. Robinson/C Fisher
Approved By: C. Fisher
4
Hero™40 Amp Tap Commander
Installation Guide
•Route the yellow Tap Wires except for the Common wires to the appropriate taps on the
rectifier. Each Tap Wire is labelled on both ends as follows:
COARSE COMMON, COARSE 1, COARSE 2, …COARSE 6
FINE COMMON, FINE 1, FINE 2, …FINE 6
•Connect the Ring Terminals to the Rectifier Taps as labelled. If the Rectifier has less taps
than 6 coarse/fine, combine the higher wire numbers (e.g. 5/6) on the last coarse (or fine)
tap
•Power up the AC to the rectifier and wait for the Hero to come online (Blue Heartbeat LED is
blinking once per second. This can take up to ten minutes)
•After the Hero comes online, issue a Reset Tap Commander command. The Interrupter
Relay will open and then close. Once this is finished, power down the rectifier and connect
the Common Wires. Then power up the rectifier and wait for the Hero to come online.
4. The Tap Commander will default to Coarse 1/Fine 1 on initial start up
5. The Tap Commander has Up/Down buttons for operating the taps
6. Using the data from Step 2 adjust the Taps, by pressing and holding the “Up” button, until the
desired Output Voltage and Current is reached. After the button is released, you must wait for
the Hero to go into normal communication mode (the Blue Heartbeat LED will blink once per
second) before further adjustments to the Tap settings can be made
7. Measure the shunt mV with a multimeter and confirm that it corresponds with the data from
Step 2
8. Installation is now complete

Document No.: IM-1508
Revision Level: 03
Approval Date: 10-JUNE-2020
Author: T. Robinson/C Fisher
Approved By: C. Fisher
5
Hero™40 Amp Tap Commander
Installation Guide
SIZE FSCM NO DWG NO REV
HC-402120 -
SCALE none SHEET 1 OF 1
DRAWN BY
Carey Fisher
40A Tap Commander Kit for Hero
ENGINEERING
C FISHER
P/N:
29MAY2019
1
2
3
4
5
40A Tap Commander Kit for Hero
reference_designator QTY UOM item_name vendor_1 vendor_item_number_1
1 40A Tap Commander 1 each 40A Tap Commander Power Cable OMX 402105
2 SnapTrack (4" Wide) 1 8" long SnapTrack (4" Wide) OMX 402118
3 TAP COMMANDER ACCESSORY CABLE 1 each Control Cable OMX 840-00006A(H1) 401063A-72 (H2)
4 40A Tap Commander Power Cable 1 72" 40A Tap Commander Power Cable OMX 400732
5 Tap Wiring 1 set SET, TAP COMMANDER TAP WIRES OMX 402092
H2
H1
For Hero 1 or Hero 2 units:
Jumper will be installed in either the H1 or H2.