A technical manual from the experts
in Business-Critical Continuity™
LORAIN® Precharge Assembly
Part Nos.: 510142 and 528478
Installation and Operation Instructions
Section 5823 (Issue AF, April 26, 2011)
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The products covered by this instruction manual are manufactured and/or
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The information contained in this document is subject to change without notice and may not be
suitable for all applications. While every precaution has been taken to ensure the accuracy and
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assumes no responsibility and disclaims all liability for damages resulting from use of this information
or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct
methods, tools, and materials to be used in performing procedures not specifically described in this document.
This document is the property of Emerson Network Power, Energy Systems, North America, Inc.
and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission
of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Copyright © 2011, Emerson Network Power, Energy Systems, North America, Inc.
All rights reserved throughout the world.
Instructions
Part Nos. 510142 and 528478
Section 5823
Issue AF, April 26, 2011
TABLE OF CONTENTS
Description...........................................................................................................................1
General .........................................................................................................................1
Installation ...........................................................................................................................1
Mounting .......................................................................................................................1
Electrical Connections ..................................................................................................1
Operation .............................................................................................................................2
Controls and Indicators .................................................................................................2
Precharge Procedures ..................................................................................................2
Troubleshooting...................................................................................................................5
Repair and Replacement Information ...........................................................................5
Routine Maintenance...........................................................................................................5
Revision Record ................................................................. Error! Bookmark not defined.
DESCRIPTION
General
LORAIN® Precharge Assembly Part Nos. 510142 and 528478 are designed to precharge
a load through a circuit breaker housing or fuseholder case. The Precharge Assembly is
designed to plug directly into a TPS type fuseholder case. An Adapter Assembly (P/N
509854) is provided with the TPL distribution panels used in a 582120600 Power System.
This Adapter Assembly is designed to plug directly into a TPL type fuseholder case used
in this power system. Note that TPL type fusholders in other systems may be different.
All other applications for precharging will use the supplied Adapter Cable.
The Precharge Assembly weighs 1 lb 12 ounces. The dimensions for the Precharge
Assembly in inches are 1.281 height, 4.625 width, and 5.781 depth. The Precharge
Assembly is finished in Off-White (Lorain Spec. M500-117) for P/N 510142, and Textured
Gray (Lorain Spec. M500-147) for P/N 528478.
INSTALLATION
Mounting
The Precharge Assembly comes standard with a convenient mounting bracket. This
mounting bracket is designed for storing the Precharge Assembly when not in use.
Electrical Connections
The Precharge Assembly will derive input power from the system bus. This will happen
when the Precharge Assembly is connected across a circuit breaker housing or
fuseholder case in a live circuit.
Page 1
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Section 5823
Issue AF, April 26, 2011
Instructions
Part Nos. 510142 and 528478
OPERATION
Controls and Indicators
The following switch and LED indicators are located on the front panel of the Precharge
Assembly.
a) CHARGE SWITCH: This momentary toggle switch (S1) will close the circuit and
precharge the load.
b) FUSE ALARM: This red LED will illuminate if fuse F1 on the outside of the
Precharge Assembly case opens.
c) CHARGE: This red LED indicator will illuminate when charging a load.
The switch and indicators on the Precharge Assembly are labeled twice. The redundant
labeling is for ease of operation in two positions.
Precharge Procedures
These instructions contain two separate precharge procedures. The first procedure is
used for precharging a circuit through a fuseholder. The second procedure is used for
precharging a circuit through a circuit breaker. Refer to the appropriate procedure when
precharging a circuit.
Precharging a Circuit Protected by a Fuse
Perform the following procedure to precharge a load through a fuseholder case in a
distribution circuit. This procedure is intended for use with several types of fuses. Most
applications require using the furnished precharge Adapter Cable. TPS type and TPL
type (582120600 Power System only) fuses do not require the Adapter Cable. For TPS
fuses, the unit plugs directly into the fuseholder case. For TPL fuses used in 582120600,
an Adapter Assembly plugs directly into the fuseholder case. While performing this
procedure, only perform the steps that are applicable to the type of fuseholder in the
circuit.
Danger: Servicing personnel must observe all safety precautions normally
associated with maintenance and connection of electronic equipment,
and must avoid direct contact with any energized electrical termination.
This Precharge Assembly is used with equipment that is conducting high
DC output current; therefore, servicing personnel must remove watches,
rings, or other jewelry before making equipment connections.
a) Remove fuseblock from fuse case or open fuseholder of circuit to be precharged.
b) Verify a fuse is installed in fuseholder or fuseblock. If not, install the correct size
fuse into the fuseholder or fuseblock that was opened or removed in the previous
step. Refer to system manual for proper fuse installation.
c) Remove associated GMT alarm fuse if not already removed.
d) Have a GMT alarm fuse ready to insert immediately after precharging.
Page 2
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Instructions
Part Nos. 510142 and 528478
Section 5823
Issue AF, April 26, 2011
e) Insert the Precharge Assembly (TPS fuse only) or Adapter Assembly (TPL fuse
used in 582120600 only) into fuse case. If using the TPL Adapter Assembly,
plug the cable into J1 located on the Precharge Assembly. Refer to Figure 1 for
J1 location. For all other applications, connect the Adapter Cable as follows.
1) Locate connector J1 on the front of the Precharge Assembly. Refer to Figure
1 for connector J1 location.
2) Locate the Adapter Cable provided with the Precharge Assembly.
3) Mate the connector on Adapter Cable to Connector J1 on Precharge
Assembly.
4) Connect the Adapter Cable to the precharge connector associated with the
circuit to be precharged.
f)
Move CHARGE SWITCH toward the CHARGE LED and hold in place.
g) CHARGE LED will first illuminate then extinguish when voltage level reaches
approximately 40 VDC.
Caution: After removing or disconnecting the Precharge Assembly, the
original fuse must be replaced or fuseholder closed within
approximately 10 seconds. This will ensure the circuit is still holding
a precharge.
h) When the CHARGE LED extinguishes, release the CHARGE SWITCH on the
Precharge Assembly.
i)
Remove Precharge Assembly (TPS fuse only) or Adapter Assembly (TPL fuse
used in 582120600 only) from fuse case.
j)
Quickly insert original fuseblock into circuit that was just precharged or close
fuseholder.
k) If using the Adapter Cable, disconnect the cable from the connector on the circuit
that was precharged.
l)
If applicable, insert a GMT alarm fuse into fuseholder of circuit that was
precharged.
m) If CHARGE LED does not extinguish release CHARGE switch and check for a
short circuit.
n) This completes the fuse precharge procedure.
Precharging a Circuit Protected by a Circuit Breaker
Perform the following procedure to precharge a load through a circuit breaker case in a
distribution circuit. This procedure requires using the furnished precharge Adapter Cable.
Page 3
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Section 5823
Issue AF, April 26, 2011
Instructions
Part Nos. 510142 and 528478
Danger: Servicing personnel must observe all safety precautions normally
associated with maintenance and connection of electronic equipment,
and must avoid direct contact with any energized electrical termination.
This Precharge Assembly is used with equipment that is conducting high
DC output current; therefore, servicing personnel must remove watches,
rings, or other jewelry before making equipment connections.
o) Move the circuit breaker handle of the circuit to be precharged to the OFF (open)
position.
p) Locate connector J1 on the front of the Precharge Assembly. Refer to Figure 1
for connector J1 location.
q) Locate the Adapter Cable provided with the Precharge Assembly.
r)
Mate the Adapter Cable to the Precharge Assembly connector J1.
s) Connect the Adapter Cable to the precharge connector associated with the circuit
to be precharged.
t)
Move CHARGE SWITCH toward the CHARGE LED and hold in place.
u) CHARGE LED will first illuminate then extinguish when voltage level reaches
approximately 40 VDC.
Caution: After disconnecting the Precharge Assembly, the circuit breaker
handle must be moved to the ON (closed) position. Also the GMT
alarm fuse must be inserted (if applicable). Both tasks must be
performed within approximately 10 seconds of disconnecting the
Precharge Assembly. This will ensure the circuit is still holding a
precharge.
v) When CHARGE LED extinguishes, release CHARGE SWITCH on Precharge
Assembly.
w) Quickly close the circuit breaker handle of circuit that was just precharged.
x) If CHARGE LED does not extinguish, release CHARGE switch and check for a
short circuit.
y) Disconnect the precharge Adapter Cable from the connector on the circuit that
was precharged.
z) This completes circuit breaker precharge procedure.
Page 4
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Instructions
Part Nos. 510142 and 528478
Section 5823
Issue AF, April 26, 2011
J1
J1
Adapter supplied with
panels E/W TPL fuses
Figure 1
Front and ISO Views of Precharge Assembly
TROUBLESHOOTING
The only component inside the Precharge Assembly that is customer replaceable is Fuse
F1.
Repair and Replacement Information
Replaceable Fuses: If fuse F1 (2 Amp slow blow) in the Precharge Assembly opens,
replace it with the same type and rating, or equivalent. Replacement fuse F1 Part No. is
248423300 or Bussmann MDL-2, or Littelfuse 313002.
ROUTINE MAINTENANCE
The Precharge Assembly does not require any routine maintenance.
Page 5
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Section 5823
Issue AF, April 26, 2011
Instructions
Part Nos. 510142 and 528478
REVISION RECORD
Issue
Change
Number
(ECO)
AA
AB
AC
AD
AE
AF
LLP015987
LLP025115
LLP031111
LLP202579
LLP205275
LLP215442
Description of Change
New
Document format changed to match new standard.
Instructions for TPL Adapter Assembly added.
Now Emerson Network Power.
P/N 528478 added.
Implementation of new spiral bound covers.
Page 6
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
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