Liebert 4000 manual

DC P OWER Helios DC System 4000/48 1500, 300 0, 4000 & 6000 A DC Power System User Manual[...]

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i T ABLE OF CONTENTS 1.0 A BOUT T HIS D OCUMEN T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Purp ose of This Docum ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Applicabilit y of This Document . . . . . . . . . . . . . . . . . [...]

ii 3.11 Over all P ower System Spec ificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.11.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6 3.11.2 Mechanical Specificat ions of Ful ly Equipped Power Cabinets . . [...]

ii i FIGURES Figure 1 Front view o f a typical bo ttom fed 4000 A H elios DC Sy stem 4000/48 power syst em . . . . . . . 2 Figure 2 Front view o f a typical 600 0 A Helios D C System 4 000/48 powe r system . . . . . . . . . . . . . . . . 3 Figure 3 Typical configurat ions for He lios DC System 400 0/48 cont rol, distribu tion and rectifier cabinets[...]

iv T ABLES Table 1 Rectifier cab inets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 2 Control and distrib ution cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 3 Auxiliary dis tribution cab inets . .[...]

About Thi s Document 1 1.0 A BOUT T HIS D OCUMENT 1.1 Purpose of This Document This do cument prov ides all the n ecessary information to operate an d maintain a Helios DC Sys- tem 4000/4 8 power s ystem. The ins tallation procedu res for th e Helios D C System 4000/48 pow er system a re covere d in instal- lation man ual SL-6003 4. 1.2 Applicabili[...]

2 I ntroductio n 2.0 I NTRODUCTION 2.1 D escrip tion The Heli os DC S ystem 4000 /48 is a po sitive gro und, -48 V DC nominal power sys tem consis ting of one control and distribution cabinet and one or more rectifier cabinets. It is available in capacities of 1500 , 3000, 40 00 and 60 00 A. Auxili ary distribut ion cabinets can be ad ded as requi [...]

Introduc tion 3 Figure 2 Front vie w of a typical 6000 A H elios DC System 4 000/48 pow er system Cables are used for in ter-cabinet connections (1500, 300 0 and 6000 A s ystems) or co nnections t o the over head busb ars (6000 A s ystem) for ease of ex pansion on live syste ms. In a 1 500, 3000 o r 4000 A syste ms, the powe r system batte ry retur[...]

4 I ntroductio n 2.3 Control and Distribution Cabinets - T ypical Configurations Figure 3 shows the front and side views of typical rectifier and distribution cabinets for a Helios DC Syste m 4000/48 ( bottom cabled cabinets are i llustrated - top cabled versions are av ailable). Figure 3 T yp ical config urations for Helios DC Syst em 4000/48 cont[...]

Introduc tion 5 Cabinets a re availab le in a varie ty of conf iguration s as liste d in the fol lowing t ables. Note t hat for a 6000 A sy stem, t he cabling is always at the top. T able 1 Rect ifier cabinets Cabi net C apac ity Rectif ier Cabled top or bottom Type Qty 1200 A Helios Rectifier 200I 6 Top 1200 A Helios R ectifier 200I 6 Bottom 1000 [...]

6 Sp ecification s 3.0 S PECIFICATIONS 3.1 Framew ork The Helio s DC Sy stem 400 0/48 uses ca binet type frameworks . The same cabinet des ign is use d for the main con trol and distribu tion cabin et, the auxilia ry distributio n cabinets and th e rectifier cab- inets. T he cabine t is always eq uipped with a front door and door frame (lockabl e, [...]

Specific ations 7 3.2 Conventional Controller 3.2.1 Mechanical Speci fications of the Conve ntional Controll er The mech anical spec ifications o f the Conve ntional Controller a re liste d in Table 5. Figure 4 Front view of the Conventional Controller 3.2.2 Electrica l Specificati ons of the Conventional Controller The op erating vol tage is -48 V[...]

8 Sp ecification s 3.3 Distribution Panels 3.3.1 Fuse Panels Mechanical spec ification s of the fuse panels The mechani cal specif icatio ns of the fuse pa nels are listed in Table 6 below. Figure 5 Front view of the 20 QFF 0-5 A fuse panels The DC output connections are wire wrap or sol der. T able 6 Mechanica l specificat ions of the f use panels[...]

Specific ations 9 Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels The DC output conne ctions are No. 8 -32 studs equipped w ith two hex nuts . Figure 7 Front view of the (16) QFF 0-5 A & (6) TPN 5-3 0 A fuse panels The DC output conne ctions are 0.2 50-20 studs equipp ed with two hex nut s. T able 8 Fuse size s avail[...]

10 Specific ations Figure 8 Front view of the (8) TPN 5-3 0 A fuse panels The DC output conne ctions are 0.2 50-20 studs equipp ed with two hex nut s. Figure 9 Front vie w of the (4) RS100P 70- 100 A fuse panels The DC output conne ctions are 0.3 75-16 studs equipp ed with two hex nut s. T able 1 0 Fuse sizes a vailable fo r the (8) TPN 5-30 A fu s[...]

Specifica tions 11 Figure 1 0 Front view of the (4) CRS200P 150-200 A / (4) CRS20 0P 150-200 A (w/load shunts) fuse panels The DC output conne ctions are 0.5 0-13 studs equi pped with two hex nuts. Figure 1 1 Front view of the (4 ) TPL 225-600 A fuse panels The DC o utput con nections are busba r angles th at can accep t 535MC M or 750MCM cables, o[...]

12 Specific ations Figure 12 Front view of the (18) TPS 1-70 A fuse panel Can accept maximum 1/0 AW G cables and requires on e-hole lugs for 1/4” dia meter st uds. T abl e 14 Fuse size s available f or the (1 8) TPS 1-70 A fuse pa nel Fuse type Current (A) CPC DC power (TPS ) 1 A0601 322 3 A0601 323 5 A0601 325 6 A0601 326 10 A060132 7 15 A060132[...]

Specifica tions 13 Electrica l specificati ons of the fuse panels The electr ical specifi cations of the fu se panels are described in Tabl e 15. 3.3.2 Circuit Breaker Panels Mechanical spec ifications of the c ircuit breaker panels The mechan ical specif ications of the circuit bre aker panels are described in Table 16. T able 15 Electr ica l spec[...]

14 Specific ations Figure 13 Front view of the (2 4) Plug-In 1-100 A circuit breaker panel The DC output connect ions vary according to the circuit breaker capacity: maximum cable size is 2/0A WG. Th e lugs m ust be for 3/ 8” dia. bolts at 1” c -c. Refer to Table 21 for the maximum panel capacity. T abl e 17 Plug-in c ircuit break ers availab l[...]

Specifica tions 15 Figure 14 Front view of the (4) 70-250 A circuit breaker panel The DC output connections can accommodate two 4/0 cables back t o back for each circuit breaker. The require d lugs can be either for two 3/8” holes at 1” c- c or for tw o 1/2” holes at 1-3/4” c-c. Refer to Table 21 for the maximum panel capacity. The (4) 70-2[...]

16 Specific ations Figure 15 Front view of the (2) 400 A circuit breaker panel The DC o utput connect ions can accom modate two 750 MCM cables back to back for e ach circuit breaker. Th e requir ed lugs must be for two 1/2” holes at 1-3/4” c-c. Refer to Table 21 for the maximum panel capacity. The panel a ccepts up to: • two breake rs (400 A)[...]

Specifica tions 17 Electrica l specifications of the ci rcuit breaker panels The electri cal specifica tions of the circui t breaker panels are de scribed in Table 21. T abl e 21 Electrical s pecificat ions of the circuit bre aker panel s Panel de scripti on Figure Circui t breakers Busbar capa city Max. Quan tity Capaci ty (24) Plug -In 1-100 A 90[...]

18 Specific ations 3.4 Externally Mounted Battery Ret urn Busbar The batt ery return busba r is desig ned to mount on the ov erhead rack ing for 6000 A systems an d top cabl ed 1500, 300 0 or 4000 A power sys tems. It can also be mo unted on a wall or on the floo r below the raised floor for b ottom cabl ed 1500, 3000 or 40 00 A power sy stems ( wh[...]

Specifica tions 19 3.5 T erminating Assemblies (Optional) The optional terminating assembly allows top access conn ections for up to six loads. Refer to Figure 18. Each l oad position is rated at 600 A and can accept up to three lugs having 1” or 1-3/4” c-c hole spacin g, for cables up to 777 kcmi l. The termin ating as sembly is b olted to th [...]

20 Specific ations 3.6 MPS 300 and MP A100 Power Shel ves The MPS 300 and MPA1 00 power shel ves are requ ired for the H elios Rectifie r 100/48, w hich is a plug-in type rectifier. The MPA100 power shelf supports one Helios Rect ifier 100/48, whil e the MPS300 shelf can s upport up to three He lios Rectif iers 100/48. 3.6.1 Mechanical Speci ficati[...]

Specifica tions 21 Figure 20 Front view of the MP A1 00 power shel f (shown empty) 3.6.2 Electrica l Specificati ons of the Power Shelves Each rectifier position provides interconnection points for AC input (208 to 240 V nominal ), DC output ( -48 V nomina l) and cont rol and ala rm signals. 3.7 Rectifiers The Helio s system 40 00/48 can be equipp [...]

22 Specific ations Electrica l specifications of the Heli os Rectifier 100/ 48 The ele ctrical spec ifications of the Helios Rectifier 100 /48 are liste d in Table 25. 3.7.2 Helios Rect ifiers 20 0I/48 and 200E/ 48 Mechanical spec ification s of the Heli os Rectifie rs 200I/48 and 200E/48 The mech anical specif ications o f the Helios Rectifier 200[...]

Specifica tions 23 Figure 22 Front vie w of the Helio s Rectifier s 200I/48 a nd 200E/48 VOLT AMP VOL T CAL FS ST UP DLY SLS CC/ DC 0 1 EQL THSD CL AD J EQL AD J RFA SEN FAIL HVSD FAN ALM EQL AC ON CL VOU TÐ FFI 1.0A FF2 1.0A FLT AD J V O LT / AM P VOU T+ HVSD AD J FLT CA/AC 1 0 CUR CAL[...]

24 Specific ations 3.7.3 Electrica l Specificati ons of the Helios Rectifiers 200I /48 and 200E/48 The ele ctrical spec ifications o f the Helio s Rectifiers 2 00I/48 and 2 00E/48 a re liste d in Table 27. 3.7.4 St andards The fo llow ing st andard s als o appl y to the rectif ier s: • ANSI Std. C62.41/IEEE S td. 587-1980, C lass A and B lightnin[...]

Specifica tions 25 3.8 Helios Monitor 3000/48 (Optional) 3.8.1 Mechanical Speci fications The mech anical spe cifications of the He lios Mon itor 3000/ 48 are list ed in Table 28. The ab ove dimensio ns are wi thout the mounting bra ckets. Th e weight may vary slig htly depen d- ing on t he number a nd type o f analog in terface mod ules insta lled[...]

26 Specific ations 3.10 AC Junction Box The AC jun ction box is required as an AC conne ction interface in rectifier cab inets wher e the Helios Rectifier 200 E/48 is used. Figure 25 Front view of the AC junction box (with the front panel open) 3.10.1 Mechanical Speci fications The juncti on box is mad e of zinc pla ted steel and can accommodate up[...]

Specifica tions 27 3.1 1.3 Electrical Specifica tions Refer t o the indiv idual comp onent’s specificat ions. Electromagneti c compliance ( EMC) The e quipme nt con tained in the p ower s ystem complie s with t he sp ecifi cations of FCC , Part 15, Subpart B for class A equipment, CSA 108.8 for class A and CISPR 22 for class A. Electrosta tic dis[...]

28 Operation 4.0 O PERATION 4.1 Gene ral This chap ter describe s the con trol, adjus tment and o perational features of the Helios DC System 4000/48. 4.2 Conventional Controller The Convent ional Contro ller monit ors the operat ion of the entire power pl ant. It mon itors all t he alarms, and it controls and monitors the rectifiers. Provis ion is[...]

Operati on 29 Potentiometer s Twelve potentiometers for th e adjustment of alarm and control functions as described in Table 34. T able 3 3 T r ansmitted alarms Alar m Descripti on RECT FAN (1 - Form C con tacts) RFA MI N (1 - Form C c ontacts) RFA MAJ (1 - Form C c ontacts) H/L FLOAT (2 - Form C conta cts) EQL ALM (1 - Form C contacts) H/L VOLT (2[...]

30 Operation Switches Four switches for the co ntrol of functions as described in Table 35. DIP switches Three DIP switch modules fo r the setting of functions as described in Table 36 and as shown in Figure 27 and Figure 28. Figure 27 Shunt range selection set tings T ab le 35 Switches Desi gnatio n Descrip tion EQUALIZ E MAN/AUTO Used to activate[...]

Operati on 31 Figure 28 Equalize voltage and dura tion settings Fuses Thirty-four fuses for circuit protecti on as described in Table 37. Except for the ABS fuse, which is small tu be type (9 /32” dia x 1-1/4” lon g), al l fuses are of the Q FF type . T est points Three se ts of te st points fo r applicatio ns as des cribed in Table 38. T able [...]

32 Operation 4.2.2 Rear Panel The rear pa nel of the Con ventional Co ntroller is provided with t he connect ion interfa ce features shown in Figure 30 and described in th e following sub sections. Figure 29 T erminal blocks and connectors layout at the rear of the Conventional Controller T erminal blocks Six termi nal bloc ks to in terface w ith e[...]

Operati on 33 Figure 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB4 v 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 TB3 TB1 TB4 TB2 To o ffice circuit To o ffice circuit To[...]

34 Operation Figure 31 Wiring diagra m and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P26 Connectors Twen ty-six co nnect ors to in terfac e with extern al equ ipment as foll ows: • P1 to P24: signaling between the controller and the rectifiers • P25: inte rface with the mai n power system shunt • P26 : inte rface wi [...]

Operati on 35 4.4 Rectifiers The recti fiers provide isolated , filtered and re gulated DC power, from either a single-phas e AC source (Helios Rectifier 100/48) or a three-phase AC source (Helios Rectifier 200I/48 or 2 00E/48), for charging a positive grounded battery. The nomina l output is adjustabl e over the ra nge of -46 to -5 9.5 V to f loat[...]

36 Operation 4.8 Helios Monitor 3000/48 (Optional) The Helios Monitor 3000/48 is a microprocessor-based unit used to monitor and record powe r sys- tems opera tional da ta. The reco rded data is acces sible lo cally by mea ns of the front panel or the RS-232 port, or remotely through the mode m link. If an Helio s Monit or 3000/48 wa s suppl ied wi[...]

Mainte nance 3 7 5.0 M AINTENANCE 5.1 Gene ral The foll owing is a list of ge neral preven tive maint enance procedur es which shoul d be performed periodically as required according to the environmental conditions and customer maintenance polic y to ens ure tro uble fr ee operat ion of the H elios DC System 4000/ 48: • clean al l ventilat ion op[...]

38 Maint enance Air filt er replacement In dusty envi ronments, th e use of an ai r filter is strongly recommend ed. When used , it should b e replaced at least once a year. Do n ot install a wet filter on a rectifier. T o remove the filte r, simply unscrew it . Install the new one by reversing the ope ration. Contact yo ur local Lie bert repres en[...]

Mainte nance 3 9 5.2 T roublesho oting Table 39 provides a li st of the probl ems that may occur on the Hel ios DC System 4 000/48, al ong with their possible causes. Blown fuses and tripped circuit breakers should always be investi- gated be fore utilizing Table 39. T able 39 Fault diagnosis Fault sympto m Possib le ca uses No DC o utput c urrent [...]

40 Maint enance 5.3 Addition / Replacement Procedures 5.3.1 Addition or Replacement of a Rectifier Add a rectifie r as describ ed in the following p rocedure for a Helio s Rectifier 100/48 or as in the Adding a Helios Rectifier 200I/48 or 200E/48 procedure, whi chever is applica ble. LOP l amp lit Loss of o ne or more phases i n the A C supply HVSD[...]

Mainte nance 4 1 Adding a Hel ios Rectifier 100/48 1. Remove th e rectifier bla nk panel a nd store it for f uture use. Note: Should a rectifier be removed at any time, re-install the blank panel t o meet the regulatory requirements. 2. Verify that the AC, DC and signalling cabling for the rectifier shelf has been previously installe d and verified[...]

42 Maint enance end of the rectifier AC cord int o the corresponding female receptacle behind the ju nction box. For the s pecific AC cab le routing to be used w ith the H elios Rect ifier 200E/48, refer to Figure 35 in the case of a top fed s ystem, or to Figure 36 in the c ase of a bottom fed sy stem. 11. Make the gro und and line connecti ons as[...]

Mainte nance 4 3 Figure 33 AC conne ctions in the female r eceptacle fo r a Helios Rect ifier 200I/48 or a Helios Rect ifier 200E/48 Figure 34 AC connect ions inside t he junction b ox (top fed shown) for a Helios Rect ifier 200E/4 8 Phase 2 or L2 Phase 3 or L3 Cover GRD Phase 1 or L1 Phase 2 or L2 Phase 3 or L3 Cover GRD Phase 1 or L1 Helios Recti[...]

44 Maint enance Figure 35 AC cable r outing for the Helios Rectif iers 200E /48 in a top f ed system Figure 36 AC cable ro uting for the Helios Rectif iers 200E/48 in a bott om fed system Juncti on box RECT 6 RECT 5 RECT 4 RECT 3 RECT 2 RECT 1 Partial view of juncti on box Partial view of Rect . 1 Rect. 6 Rect. 5 Rect. 4 Rect. 3 Rect. 2 Rect. 1 Enl[...]

Mainte nance 4 5 5.3.2 Replacing a Rectifier Replace a re ctifier as describ ed below fo r a Helios Re ctifier 100/4 8 or as in Replacing a Helios Rectifier 200I/48 or 200E/48, whichever is ap plicable. Replacing a Helios Rectifi er 100/48 1. Notify the alarm center of incomi ng alarms during this proce dure. 2. Turn OFF the AC and DC circuit break[...]

46 Maint enance Replacing a Helios Rectifi er 200I/48 or 200E/48 1. Notify the alarm center of i ncoming alarms during this procedure. 2. Turn OFF the AC and DC circuit breakers on the rectifier to be replaced. 3. Remove t he corresp onding sense fuse on the front of the cont roller. 4. At the AC service panel, place the AC circuit break er associa[...]

Mainte nance 4 7 5.3.3 Adding or Repl acing a Batter y String For replaceme nts, procee d from Step 1 below. F or new instal lations , go to St ep 5 of this proce- dure. 1. Rem oval of the old st rin g: Notify the alarm cente r of the possi bility of i ncoming al arms during thi s procedure. 2. Above t he batte ry stand, or a t the top o f the mai [...]

48 Maint enance 5.3.4 Replacement of a Distri bution Fuse Block or Circuit Breaker Replace a d istribution fuse block as describe d below. 1. Notify the alarm center of i ncoming alarms during this procedure. 2. Rem ove the fuse f rom th e fus e block t o be r eplac ed. 3. Remove the rear panels of the cab inet. 4. Carefully remove and insulate any[...]

Reference Do cuments 49 6.0 R EFERENCE D OCUMENTS Manual No. Desc ript ion SL-60040 600 A and 1 200 A Battery Disconne ct Unit SL-60014 TCM48 temp erature compe nsation mod ule SL-60026 Voltage lev el limi ts for recti fiers and controlle rs SL-60015 Helios Monitor 30 00/48 rem ote surve illance u nit SL-60033 Helios DC Sys tem 4000/48 Inst allatio[...]

50 List of T erms 7.0 L IST OF T ERMS A ampere ABS alar m battery suppl y ABSF ala rm batt ery suppl y fuse AC or ac al tern atin g curre nt ACO alar m cut-off AD Assembly drawin g ADJ adjus t or adjust ment ALM alarm AMP ampere AUD audibl e AUX auxil iary AWG Americ an wire g auging BAT battery BAT R TN battery retu rn BDA battery disconn ect alar[...]

List of Terms 5 1 HVSD high v oltage shutdown HVSDA high vo ltag e shut down alarm HVSDR high v oltage shutdown r eset in. inch in.-l b inch-poun d IS interconne ct schema tic ISG isolated sy stem ground L line lb pound LED li ght em itti ng dio de LF low floa t LOP loss of phase LV low vol tage LVA low voltag e alarm LVD low voltag e discon nect L[...]

52 List of T erms[...]

Revised : June 199 9 Helios DC System 4000/48 1500, 300 0, 4000 & 60 00 A DC Pow er System T echnical Support The Company Behind The Products With mo re than 5 00,000 inst allation s around t he globe , Lieber t is the wo rld leader in comput er prot ectio n syste ms. S ince its fou nding in 19 65, Lieb ert h as deve loped a com plete range of [...]