Liebert® PPC™ Precision Power Center
Contents
1. AC Power For Business Critical Continuity Liebert PPC Precision Power Center User Manual Three Phase 300 450 amp 800kVA 60 Hz EMERSON Network Power TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS 0000 e eee ee ees 1 SAVE THESE INSTRUCTIONS 0 0 0 cee ee ees 1 1 0 INSTALLATION INSTRUCTIONS iria da ADO A 2 1 1 Unpacking and Installation aora aida isa Dita 2 1 1 1 Unpacking and Preliminary Inspection ccc ee ee eens 2 tliz Handlne Comsiderations sas dara lab ada ar a dn db ee 2 kks Wnt Preparavionvs iweiitactds was Id eee ee ee es 3 Li Location Consideras aia dw ete eS eae er wed we eee oe OS we eae 3 1 2 Power and Control WiN eesse ee ee EVE A AS AAA T 1 2 1 Distribution Section Mounting and Wiring T 1 2 2 Side Section Electrical Connections 10 L23 Input Lower ConnectiOne sow x serie a e era ta be Mesa A Seah ed 11 L24 System ronda ad da pa bone o do 12 1 2 9 Groti aine Electrode Conductor 204 6426 003 6400 idad ELEeKE DEES OS 12 12 60 Ou tp t Power Connections i 244 Sesh a a we PELE Se A ea a 13 127 Control Wiring Connections i 2c gieot pete tasa rs DA 14 2 0 INSPECTION AND STARTUP CHECKLIST 000 eee eee eee eee ees 16 21 Internal Inspection Overview 16 2 2 Internal Inspection Procedure 16 20 Startup and Monitoring System Check Overview 0 0 0 0 0 ccc eee ee eee 17 2 4 Startup e roce d Ue2. a O O r ees Main N O REPO Source Input K6 OR esse Overtemp Breaker Switch i i Shunt A EE sesh Trip y e 0 Building at RI Interface HA A A E i B SO 6 OL Relay 14 Installation Instructions Figure 10 Typical control wiring for power monitoring LOW VOLTAGE TERMINAL STRIP Comm Cable RED To Liebert Comm Cable BLK EJ SiteScan RS 232 RXD WAT PT System RS 232 TXD RED Remove Jumper When 5th Customer Alarm RS 232 COM BLK Is Used 5th Customer Alarm W214 E ere 2 4th Customer Alarm W213 ed io 3rd Customer Alarm W212 oe eres ee jo 2nd Customer Alarm W211 aia 1 F Alarm o 1st Customer Alarm W210 EE H a Inputs a Cust Alarm Common W209 bet A O O O l gt Summary Alarm N O W208 y de ano ar 2 Summary Alarm N C W207 T ummary 2 OS J Alarm i Summary Alarm Com W206 bs L220 Output N O REPO W205 BLK E O O 24 VDC W204 MAL 2 24 NO REPO REPO Com W203 fe _GRN N C REPO _W202 F7 A ae E 24 WDC w201 Doo ee S Remove Jumper When Normally Closed N C REPO ls Used Building Interface NOTES 1 Building interface relay can be used for remote shutdown or alarm Relay is energized during normal operation DPDT contacts rated 1 4 hp at 120VAC 10A at 28VDC or 240VAC 2 Other N O REPO devices may be wired in parallel to the N O REPO contacts Other N C REPO devices may be wired in series to the N C REP
3. 049 5841 257 Asia 29 F The Orient Square Building F Ortigas Jr Road Ortigas Center Pasig City 1605 Philippines 63 2 687 6615 Fax 63 2 730 9572 Emerson Network Power The global leader in enabling Business Critical Continuity E ACPower I Embedded Computing Connectivity EU Embedded Power E DC Power Infrastructure Management amp Monitoring Precision Cooling EmersonNetworkPower com E Outside Plant E Racks amp Integrated Cabinets E Power Switching amp Controls E Services Surge Protection Emerson Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks of Emerson Electric Co or one of its affiliated companies 2010 Emerson Electric Co
4. Startup Checklist 2 3 Startup and Monitoring System Check Overview Checklists Follow the detailed step by step instructions in the following two sections when install ing and starting up the Liebert PPC 2 4 Startup Procedure 2 5 Monitoring System Check Initial system startup A qualified electrician should be employed to perform the equipment inspection and startup Liebert system startup may be arranged by contacting your local Emerson sales representative or Emerson Network Power Liebert Services at 1 800 543 2378 Warranty A copy of the checklist furnished with the unit must be completed signed dated and returned to Emerson Network Power see Section 2 6 Warranty coverage of the equipment 1s not effective unless the checklist 1s received by the factory A WARNING Equipment inspection and startup should be performed only by trained personnel Hazardous voltages are present during startup procedures Electrical safety precautions must be followed throughout inspection and startup Table 4 Torque specifications unless otherwise labeled Nut and Bolt Combinations Electrical Connections With Electrical Connections With 1 Belleville Washer 2 Belleville Washers Bolt Shaft 1 4 M6 5 16 M8 1 2 M12 Figure 11 Acceptable hardware configurations for torque specifications Table 4 Bolt Belleville Washer PLZ Flat Washer E Ss P Belleville Washer Nut 17 Inspection and Startup C
5. ansiada wise cs ada as ace ie ee weed 18 2 5 DMionitorino System Check ante da la a ld la arica 19 2 6 Send Completed Checklist to Emerson Network Power 0 0 0 0 00 cee 19 3 0 OPERATING INSTRUCTIONS 0 00 cece ee eee eee eee renee eens 20 3 1 Startup Procedures dr ts dd ra ah ore dira Ava Dek orate amp 20 ll oNimersency ShUtdOW tii s 54 6 A bees ee hee abet ae tae ame de 20 2 2 Normal System SAULdOW i creer eta A A ES oe he se a 20 Silo Normal System OlArtup o lt 44 04 2 oes BGS S44 penis SN SOEs aaa dra eee Oe 21 alte Nana estaria aioe aad hi ais aA Bie eae area wae al eee Rea ars ates aS i 21 3 2 Power Monitor Panel oi ees rin vaciadas avia ata ita Dia Oo eed 22 4 0 MAINTENANCE acceso radie Ea E EE Aa 25 4 1 Corrective Maintenance Repaso 25 4 2 Preventive Maintenance Inspection amp Cleaning 0 0 0 0 ccc eee eee 26 A 2AL E o e hans wm ha boa we ana See Ew hae ah oe a a ee Ge eRe dank 26 Figure 1 Figure 2 Figure 8 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 FIGURES Recommended minimum service and ventilation clearances for 300 and 450kVA units 4 Recommended minimum service and ventilation clearances for SOOKVA units 4 Footprint and floor cutout dimensions for Transformer Section 300 and 450kVA units 5 Footprint and floor cutout dimensions for Transformer Section 80
6. circuit breaker If the circuit breaker has been tripped Off instead of being turned Off the circuit breaker handle must be moved to the Off position before being turned On If the unit has a voltage monitoring panel verify proper output voltages before turning On output circuit breakers Turn On the panelboard main breakers if supplied Individually turn On each output circuit breaker following the load equipment manufacturer s startup sequence Figure 12 300 450kVA unit with doors open 3 1 4 Manual Restart If the unit s manual restart feature has been selected the unit s main input circuit breaker will be tripped by a power outage preventing repetitive application of unstable voltage and allowing for an orderly system restart If the main input circuit breaker is tripped by a power outage follow the instructions in 3 1 3 Normal System Startup after power is restored 21 3 2 Operating Instructions Power Monitor Panel DISPLAY EMERGENCY POWER OUTPUT VOLTAGE OFF Hold Sequence ALARM PRESENT SILENCE lO Liebert Monitored Parameters A 4 20 character LCD display is provided to indicate the input voltages line to line output voltages line to line and line to neutral output currents each phase neutral and ground output voltage THD output current THD crest factor K factor output kVA kW kW Hours power factor percent load and output frequency Press the Scan button to activat
7. the unit permits such sizing without imposing an energy use penalty during initial operation Keep the load balanced Balancing of loads is good design practice on any three phase system Accordingly each distribution panel is load balanced at the factory based on output branch circuit breaker sizes All additions to the system should be arranged to preserve this balance Figure 8 Typical Liebert PPC grounding arrangement pe Si Soe ee pom re eee eee eee ee Service Entrance ms N E 2 Output E Signal Reference Grid L Service Entrance If Used Grounding Electrode JE System Local Grounding Electrode Conductor SA Per NEC 250 30 a A n WARNING Verify that incoming line voltage circuits are de energized and locked out before installing output breakers and cables Code compliance All output cables and connections must comply with the NEC and all other appli cable codes Padlock off provisions All output breakers that are hard wired to the load equipment must be equipped with a padlock off accessory for the output circuit breaker The padlock off accessory 1s used to lock out and tag the circuit breaker when service is performed on the hard wired load equipment in accordance with OSHA safety rules 13 Installation Instructions 1 2 7 Control Wiring Connections The NEC Article 645 requires that Emergency Power Off EPO switches be located at the principal room exits All standard Liebert power conditi
8. 0kVA units 5 Footprint and floor cutout dimensions for Distribution Sections 300 800kVA units 6 300 450kVA Liebert PPC single line diagram 0 00 ccc eee 8 800kVA Liebert PPC single line diagram 0 0 ce eee eens 9 Typical Liebert PPC grounding arrangement 0 0 00 ccc ee eens 13 Simpliiticd sautdo wn cercas a dia AA dai 14 Typical control wiring for power MONI OTINAZB ee ee eee eens 15 Acceptable hardware configurations for torque specifications Table 4 17 300 450k VA unit with doors op n id A A aa a Aia 21 TABLES 300 800kVA Liebert PPC dimensions 2 Heat Otto 3 AIC and suggested minimum input wire size data for OCPD ooooo momo 11 Torque specifications unless otherwise labeled o oooooooooomomo momo de R5S 232 ASCIL port customer commands 10d A AAA de a A i 24 Monitored parameters data definlti0ns ce ee ee ee eee ee eas 24 fi IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 5 A A NOTE Read the entire manual before installing or operating the system WARNING The shipping bands may be under tension Use appropriate eye face and hand protection to safeguard against injury from band backlash WARNING Verify that all incoming line voltage power and low voltage control circuits are de energized and locked out before installing cables or making connections whether in the junction box or
9. A local grounding electrode conductor is recommended in addition to the equipment safety ground that is normally run with the input power conductors Electrode connection As shown in Figure 8 the grounding electrode conductor 1s run from the unit to the nearest effectively grounded item below shown in order of preference e Building steel e Metal water pipe e Other made grounding electrode Sizing of the grounding electrode conductor is based on the secondary circuit conductors According to the NEC Table 250 66 Recommended methods for running the grounding electrode conductor shown in order by preference for system performance and as acceptable by local and other applicable codes Outside of conduit where not subject to damage Inside non metallic conduit Inside non ferrous conduit Inside ferrous conduit bonded to the ferrous conduit at both ends as acceptable by local and other applicable codes 12 Installation Instructions 1 2 6 Output Power Connections Output circuit breakers with ground and neutral provisions are available as an option for installation inside the unit for connecting loads as required For best performance the Liebert PPC should be located as close to the load as practical Initial system output loading should be between 50 and 75 of rated capacity This allows the addi tion of future loads without immediately investing in another power conditioner The high partial load efficiency of
10. B to phase C Volts phase C to phase A Volts phase A to neutral Volts phase B to neutral Volts phase C to neutral If output voltage is incorrect check for wiring errors incorrect input voltage or improper transformer tap Contact Liebert Services at 1 800 543 2378 or your local Emerson representative for assistance NOTE The Liebert PPC transformer has input voltage taps for each input phase e For 3800kVA units the taps are arranged in 2 1 2 increments Taps include two above nominal voltage upper range limit of 5 and four below nominal voltage lower range limit of 10 e For 450kVA units the taps are arranged in 3 increments Taps include two above nominal voltage upper range limit of 6 and three below nominal voltage lower range limit of 9 e For SOORVA units the taps are arranged in 4 increments Taps include two above nominal voltage upper range limit of 8 and two below nominal voltage lower range limit of 8 This permits the transformer to provide the proper output voltage for a range of input voltages Should it be necessary the tap arrangement may be changed to match the input voltage a Open the main input circuit breaker b Select tap arrangement to match input voltage Refer to transformer nameplate for tap information c Secure each line to its proper tap d Repeat Steps 6 to 8 __ 9 Depress the local Emergency Power Off EPO switch and verify system shutdown Turn the
11. Internal Inspection Procedure when performing detailed inspection 2 2 Internal Inspection Procedure A WARNING All equipment inspection procedures are to be performed with power to the unit turned off and locked out EXTERIOR INSPECTION Confirm that the exterior of the unit 1s undamaged Confirm that service and ventilation clearances are adequate see Figures 1 and 2 INTERIOR INSPECTION 3 Remove accessible exterior panels NOTE When removing exterior panels disconnect panel ground wires by separating the easy disconnect terminals located on the frame When replacing exterior panels reconnect all panel ground wires Inspect all wire and conductor insulation for damage Check all transformer terminal connections for tightness Retorque if necessary Check all breaker connections for tightness Retorque if necessary 4 5 6 7 Check all terminal block connections for tightness Retorque if necessary 8 Check transformer mounting bolts for tightness Retorque if necessary 9 Remove any foreign objects from the components and the interior area of the unit Make sure air passages on transformers are clear and free of debris 10 Check that the intake and exhaust air screens are clean and free of obstructions ___ 11 Replace side panels leaving access to circuit breakers for the following startup procedure NOTE When replacing the side panels be sure to reconnect the panel ground wires 16 Inspection and
12. O contacts Multiple REPO lamps and other 24VDC loads may be wired in parallel to the REPO lamps Maximum 24VDC supply available 1s 1A total Both N O and N C REPO switches are powered from the same supply 3 All auxiliary control devices and cabling to be field supplied except as noted 4 Overtemperature alarm contacts change state when unit overtemperature 1s sensed 5 RS 232 port must be connected to low voltage terminal strip inside unit Connect using suitable 300V communication cable 15 Inspection and Startup Checklist 2 0 INSPECTION AND STARTUP CHECKLIST Unit Serial Number Unit Model Number Date 2 1 Internal Inspection Overview A detailed internal inspection should be performed after the unit is in place and before it is energized to ensure trouble free startup The same internal inspection should be carried out when performing preventive maintenance A WARNING Verify that all incoming power and control circuits are de energized and locked out before performing the internal inspection Open the unit Remove the exterior panels to gain access to the internal components of the Liebert PPC e Visually inspect Check to make sure wiring and components are not damaged e Check power connections Check all power connections for tightness Refer to Table 4 for torque requirements of all electrical connections Perform formal detailed inspection Follow the procedures described in the next section 2 2
13. aS To K 191mm 16 406mm so TT 780mm 18 457mm 7 x 26 178 x 660mm typ Installation Instructions Figure 5 Footprint and floor cutout dimensions for Distribution Sections 300 800kVA units on lt mm 5 o ja 152mm aoe ra 13 49 Mu oem 1067mm Cutout area ig for cable S Ohy entry exit re 26 5 da 2 672mm 785mm lt NG 62mm 1 2 1 2 1 Installation Instructions Power and Control Wiring Power and control wiring should be installed by licensed electricians All power and control wiring must comply with the NEC and applicable local codes Refer to Figures 6 and 7 for single line diagrams Distribution Section Mounting and Wiring Each 300 and 450kVA Liebert PPC requires a distribution section for routing input output cables and to provide output distribution Each 800kVA Liebert PPC requires two 2 distribution sections Distribution sections are shipped separate from the main unit Each distribution section has base dimensions of 42 x 30 in 1067 x 762mm and should be mounted on the right side of the transformer section Each 800kVA Liebert PPC requires one distribution section on each side on the transformer section Provide a floor cutout for exit of output cables as shown in Figures 3 4 and 5 Align the distribution side section with the main unit and bolt the two frames together using the four bolts and hardware provided See Figure 1 for 300 450kVA uni
14. chnicians Liebert AC power precision cooling and monitoring products and services from Emerson Network Power deliver Efficiency Without Compromise by helping customers optimize their data center infrastructure to reduce costs and deliver high availability While every precaution has been taken to ensure the accuracy and completeness of this literature Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions 2010 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert is a registered trademark of Liebert Corporation All names referred to are trademarks or registered trademarks of their respective owners SL 20048 _REVO_09 10 Technical Support Service Web Site www liebert com Monitoring liebert monitoring emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS amp Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS amp Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy 39 049 9719111 Fax 39
15. d clearance at the front of the unit is required for service access by the National Electrical Code NEC Article 110 26 Clearance above the unit is required for cooling air flow exhaust Heat Output Like any electrical device the Liebert PPC produces heat under normal operation Include this heat output see Table 2 when calculating the environmental conditions of the room Table 2 Heat output Full Load Heat Output Installation Instructions Figure 1 Recommended minimum service and ventilation clearances for 300 and 450kVA units 18 in 460mm Minimum clearance above unit for cooling air flow 12 in 305mm f Minimum Recommended Areas shaded gray indicate access eearance additional access Taa i below unit for at right clearance of 42 in 1067mm REQUIRED AT FRONT bottom cable exit NOTE Service access clearance dimensions 42 in 1067mm Figure2 Recommended minimum service and ventilation clearances for 800kVA units 18 in 460mm Minimum clearance above unit for cooling air flow f 12 in 305mm Recommended Minimum additional access Areas shaded gray indicate access clearance at right clearance of 42 in 1067mm below unit for REQUIRED AT FRONT bottom cable exit NOTE Service access clearance dimensions 42 in 1067mm Installation Instructions Figure 3 Footprint and floor cutout dimensions for Transformer Section 300 and 450kVA units Cutout area for cooling air flow
16. e the Autoscan mode where all monitored parameters are sequentially displayed automatically Momen tarily press the Hold Sequence button to interrupt the Autoscan mode Press the Hold Sequence button to allow manual selection of the sequentially displayed stage of overtemperature sensing After correction of the alarm condition the alarm will automatically reset Alarms When any of the following alarms occurs an alarm message appears on the LCD the audi ble alarm is activated and the Alarm Present Silence button is illuminated Press the Alarm Pres ent Silence button to silence the audible alarm After the alarm condition is corrected press the Alarm Present Silence button to reset the alarm when prompted by a message on the LCD or by any central monitoring system e Output Overvoltage Indicates one or more of the output phase voltages has exceeded the pre set limit normally 6 of nominal The high output voltage should be verified and corrective action taken In the absence of other procedures a normal orderly system shutdown should be performed to prevent load equipment damage e Output Undervoltage Indicates one or more of the output phase voltages has exceeded the preset limit normally 13 of nominal The low output voltage should be verified and corrective action taken In the absence of other procedures a normal orderly system shutdown should be performed to prevent load equipment damage e Output Voltage THD Indicate
17. gt Unit date 05 15 97 lt LF gt lt CR gt UID lt CR gt Unit ID Unit No PDU 21B__ _ lt LF gt lt CR gt KVA lt CR gt Nominal kVA 0150 lt LF gt lt CR gt V lt CR gt Nominal L L voltage 0208 lt LF gt lt CR gt System information UNIT MODEL_NUMBER___ SERIAL_NUMBER SS1 lt CR gt 20 character fields SITE_ID_ NUMBER TAG NUMBER with comma separators lt LF gt lt CR gt Number of current alarms SA lt CR gt 20 character alarms with time stamp Monitored parameters 0484 0485 0483 0210 0212 0211 0121 0122 0121 0068 32 comma separated data 0085 0120 0131 0018 0030 0092 0033 0600 0038 0041 fields see Table 6 for 0043 0549 0632 0599 00001528 0018 0019 0020 0045 descriptions of field positions 0047 0049 0044 lt LF gt lt CR gt 02 OUTPUT_OVERVOLTAGE _ _ 05 15 97 01 25 30A OUTPUT_OVERCURRENT_ _ 05 15 97 01 27 46A lt LF gt lt CR gt UPMD lt CR gt Table 6 Monitored parameters data definitions Fela Number Dataten Uns Fetaumber Datatem Une O rape vos DAI ve O e owo ome ao oww om O a foupurvetHo om 8 pat otege za vos 2 opa HO om as owym om 5 Out Votage YN vos 2 OutputizTHO om o Out Voltage 2 vos 28 Outes wrs as POuput crest Fasor o1 27 fouputiy crest Factor 01 m foutputcurent2 ams 28 Output iz Gest Factor 01 O a oupa on er er er Le 01 Power of Full 24 4 0 4 1 Maintenance MAINTENANCE Corrective Maintenance Repair Even the mo
18. he easy disconnect terminals at the unit frame Remove the bolts holding the unit to the shipping pallet in each of the four bottom corners Remove shipping blocks from under the unit then remove chocks from all casters Roll the unit off the pallet onto the floor Roll the unit to the installation location For units located on a raised floor use care when positioning the unit over the floor cutout to avoid casters falling through the cutout CAUTION A Before maneuvering the unit into its final position read and follow all advisories in the following section 1 1 4 Location Considerations co DY Location Considerations The Liebert PPC should be located within the computer room and or close to the load s which it is supplying The unit should not be located over combustible surfaces Equipment location should employ the shortest output distribution cable runs consistent with logi cal equipment arrangement and allowances for future additions Operating Environment Ambient temperatures of 32 F to 104 F 0 C to 40 C with a relative humidity of 0 to 95 non condensing Top or Bottom Clearance is required for exit of cables and conduit For bottom exit this clearance is automatically provided by a raised floor minimum height 12 in 305mm For top exit this clearance is 18 in 460mm Recommended minimum service clearances are shown in Figure 1 800 and 450kVA units and Figure 2 800kVA units The indicate
19. hecklist 2 4 Startup Procedure A WARNING Startup procedures should be performed only by qualified personnel Hazardous voltages are present in the equipment throughout the majority of the startup procedure Use proper safety equipment Proceed with caution 1 Make certain that all circuit breakers are in the Off position and that power to the unit 1s locked out 2 Verify proper input power connections to unit including equipment grounding conductor and local erounding electrode conductor 3 Turn On the building input power to the unit 4 Check the phase rotation at the main input breaker Phase rotation should be A B C left to right 5 Check and record the input voltage at the main input breaker Measured voltages should correspond to the unit s nameplate input voltage Volts phase A to phase B Volts phase B to phase C Volts phase C to phase A 6 Turn On the main input breaker wait one minute If breaker trips Off check for wiring errors including control connections Contact Liebert Services or the location factory representative for assistance 7 Check the phase rotation at the line side terminals of the panelboard or panelboard main breaker s The rotation should be A B C left to right 8 Check and record the voltages at the line side terminals of the output circuit breaker Measured voltages should correspond to the unit s nameplate output voltage within 4 0 Volts phase A to phase B Volts phase
20. in the unit Equipment inspection and startup should be performed only by trained personnel Lethal voltages are present during startup procedures Electrical safety precautions must be followed throughout inspection and startup Only qualified service personnel should perform maintenance on the Liebert PPC All voltage sources to the unit must be disconnected before inspecting or cleaning within the cabinet Lethal voltages exist within the equipment during operation Observe all warnings and cautions in this manual Failure to comply may result in serious injury or death Obtain qualified service for this equipment as instructed The monitoring system contains a lithium battery for memory backup Danger of explosion if battery is incorrectly replaced Replace only with same or equivalent type Dispose of used batteries according to manufacturer s instructions NOTE The unit should not be loosened from the shipping pallet until after all handling by forklift or pallet jack is completed All power and control wiring should be installed by licensed electricians and must comply with the NEC and applicable codes 1 0 1 1 Installation Instructions INSTALLATION INSTRUCTIONS Unpacking and Installation NOTE Read the entire manual before installing and operating the system Upon receipt of a Liebert PPC the installer should perform the following steps to ensure a quality installation Unpacking and Preliminary Inspection A qual
21. ity installation begins on the receiving dock 1 Inspect the shipping crate s for damage or signs of mishandling before unpacking the unit s Check Shock Watch indicator 2 Open the shipping crates carefully Use care to avoid puncturing the container with sharp objects that would damage the contents 3 Remove the packing and vapor barriers and inspect the equipment for any obvious shipping damages NOTE The units should not be loosened from the shipping pallet until after all handling by forklift or pallet jack is completed Complete internal inspection should be accomplished only after equipment positioning and prior to electrical hookup If any damage as a result of shipping is observed immediately file a damage claim with the shipping agency and forward a copy to Emerson Network Power 1050 Dearborn Drive P O Box 29186 Columbus Ohio 43229 USA Handling Considerations The Liebert PPC is bolted to a wooden pallet to allow handling by forklift equipment Easily moved The Liebert PPC is furnished with casters to allow the unit to be rolled into place after it has been unbolted from the pallet e Check size and weight Refer to Table 1 and the cabinet drawings furnished with the unit for size and weight information e Plan the route Decide the best route for the unit to follow to the installation area to ensure that all passages are large enough to accommodate the unit and the floors are adequate to support the weigh
22. lection from the unit front panel simultaneously press the Scan and Hold membrane buttons while the time and date screen is displayed on the LCD A cursor appears on the selected time and date field Use the Scan button to increment the highlighted field and the Hold button to decrement the highlighted field Use the Silence push button to select the next time and date field The time can be displayed in AM PM or 24 hour format Simultaneously press the Scan and Hold buttons to exit the clock language set screens RS 232 ASCII Communications Port Units with power monitoring are equipped with an isolated RS 232 ASCII communications port which allows access to unit monitored parameters and alarm information The RS 232 port connections are located on the low voltage control terminal strip inside the unit See typical control wiring in Figure 10 The ASCII interface default parameters are as follows nrc 15 252 Using EA Votage Lora esse sire Haga efor The ASCII port uses a Query Response Format 23 Operating Instructions The list of available customer commands is shown in Table 5 Only one command is serviced at a time Valid commands are terminated with a carriage return ODh Commands are accepted in upper or lowercase Responses are in uppercase terminated with a line feed OAh and carriage return ODh Table 5 RS 232 ASCII port customer commands Time lt CR gt Unit time 03 40 37A lt LF gt lt CR gt Date lt CR
23. n section neutral wire 47 and ground wire 50 conductors are connected to the trans former section main ground bus bar see unit wiring diagram shipped with unit For 800kVA units each distribution section 1s fed from an output breaker mounted in the transformer section For 300 450kVA units with current monitoring route each side section conductor through the appro priate current transformer CT in the main unit NOTE Distribution section conductors must pass through the current transformers in the same direction as the main untt panelboard conductors Use the existing main untt panelboard wiring for reference 10 1 2 3 Installation Instructions Input Power Connections The input power feeder enters through the distribution section and routes to the transformer section where it 1s connected to the busbars located inside the unit A WARNING Verify that all incoming line voltage power and low voltage control circuits are de energized and locked out before installing cables or making connections in the unit To minimize disturbances caused by other loads in the building the three phase power input to the unit should be supplied directly from the service entrance or other power source a dedicated power feeder The input feeder circuit should be sized in accordance with the NEC and any local building codes to assure the feeder s ability to safely carry the system s full load current including losses Inp
24. oning systems have provision for external shutdown control from Remote Emergency Power Off REPO stations Figure 9 is a simplified diagram of the shutdown circuitry of the Liebert PPC Low voltage control circuit As shown in Figure 9 the control circuit operates on 24VDC The shutdown device represented by the REPO switch activates a low current 24VDC relay that oper ates the shunt trip mechanism The shunt trip solenoid opens the main input breaker which de ener gizes the Liebert PPC Multiple unit shutdown When more than one Liebert PPC is installed by the user a typical requirement is that actuation of a single device REPO for example must shut down all Liebert PPC units The low voltage control circuits of all standard Liebert PPC systems are designed to meet this requirement External control wiring connections for remote shutdown alarm and or monitoring are made to the low voltage control terminal strip located inside the unit Control wiring connections are shown in Figure 10 Code compliance Control wiring connections must comply with the NEC and all other applicable codes A WARNING Verify that all incoming high voltage power and low voltage control circuits are de energized and locked out before installing cables or making connections whether in the junction box or in the unit Figure 9 Simplified shutdown circuit Liebert PPC lec 24 VDC Devices Gates QLO 1 4 S O O 1 Unit EPO
25. rected Where high neutral currents are the result of harmonic load currents all affected components including output wiring should be verified to be suitable for the current 22 Operating Instructions e Frequency Deviation Indicates that the output frequency has exceeded preset limits normally 0 5Hz The frequency deviation should be verified and the cause investigated and corrected e Phase Sequence Error Indicates that the output phase sequence is not A B C The phase sequence should be verified and corrective action taken Three phase loads sensitive to phase sequence should not be operated without proper phase sequence e Phase Loss Indicates that one or more of the phase voltages is low or missing The low voltage condition should be verified and corrective action taken In the absence of other procedures a nor mal orderly shutdown should be performed to prevent equipment damage Ground Overcurrent Indicates the system ground current has exceeded the preset limit nor mally 5A The overcurrent condition should be verified and corrective action taken Possible causes are wiring errors ground faults and excessive leakage current e Customer Alarms 5 Indicates customer designated alarms The cause and corrective action depend on the nature of the alarm See 1 2 7 Control Wiring Connections for contact closure connection information To Set Clock Language Selection To set the clock or change the language se
26. rst 24 hours 30 days and 6 months of operation should help determine a pattern for the inspection schedule Electrical connections and component mountings should be inspected after the first 24 hours 30 days and 6 months of operation Inspections should be conducted annually thereafter Ventilation openings and grilles should be inspected and cleaned every six months to one year A complete inspection and operational checkout should be performed annually This is best done by performing the inspection and startup procedures outlined in 2 0 Inspection and Startup Checklist Liebert Services offers a complete range of preventive maintenance services These include thorough equipment performance checks and calibration of electronics Contact Liebert Services at 1 800 543 2378 for details 26 Ensuring The High Availability Of Mission Critical Data And Applications AAA Emerson Network Power a business of Emerson NYSE EMR is the global leader in enabling Business Critical Continuity from grid to chip for telecommunication networks data centers health care and industrial facilities Emerson Network Power provides innovative solutions and expertise in areas including AC and DC power and precision cooling systems embedded computing and power integrated racks and enclosures power switching and controls infrastructure management and connectivity All solutions are supported globally by local Emerson Network Power service te
27. s that the voltage distortion on one or more of the output phases has exceeded the preset limit normally 10 THD The cause of the high output voltage distor tion should be investigated and corrective action if any taken Transformer Overtemp Indicates a unit transformer overtemperature condition The cause of the overtemperature condition should be investigated and corrected Possible causes are unit overload excessive non linear loading inadequate ventilation high or low input voltage and a monitoring malfunction Failure to correct the overtemperature condition may result in an auto matic system shutdown due to the second stage of overtemperature sensing e Output Overcurrent Indicates one or more of the output phase currents has exceeded the pre set limit normally 95 of the unit s full load amp rating The overcurrent condition should be verified and corrective action taken In the absence of other procedures some of the output loads should be turned off to reduce unit loading If unbalanced phase currents exist some of the loads should be shifted from higher loaded phases to lower loaded phases e Neutral Overcurrent Indicates that the neutral current has exceeded the preset limit nor mally 95 of the unit s full load amp rating The overcurrent condition should be verified and investigated to see if corrective action is required In some cases high neutral current indicates phase current unbalance which should be cor
28. st reliable equipment may fail Contact Liebert Services for fast repair of your unit and minimum downtime of your installation A WARNING Only qualified service personnel should perform maintenance on the Liebert PPC Standard electrical troubleshooting procedures should be used to isolate problems in the unit If there are questions contact Liebert Services Repair or replacement of standard items such as circuit breakers fuses transformers capacitors and indicator lights can be either handled by qualified electricians or referred to Liebert Services Repairs related to the monitoring system should be referred to Liebert Services To contact Liebert Services for information or repair service call 1 800 543 2378 25 4 2 4 2 1 Maintenance Preventive Maintenance Inspection amp Cleaning Air circulation through the cabinet may cause dust to accumulate on internal components Cleaning should be done as necessary during electrical inspections Annual general system inspections cleaning and operation checks are recommended to ensure sys tem performance and long service life A WARNING Only qualified service personnel should perform maintenance on the Liebert PPC All voltage sources to the unit must be disconnected before inspecting or cleaning within the cabinet Inspection Schedule It is difficult to establish a schedule for periodic cleanings since conditions vary from site to site Inspections after the fi
29. supply overcurrent protection device 11 1 2 4 1 2 5 Installation Instructions System Grounding The performance and safety of any power conditioning system depends on proper grounding Figure 8 shows the typical grounding arrangements for the Liebert PPC Equipment grounding Proper grounding is required for safe operation but also enhances equip ment performance All power feeders must include equipment grounding means as required by the NEC and local codes An insulated ground conductor is recommended to be run in each feeder conduit Ground conductors must be at least the minimum size per NEC Table 250 122 Larger wire sizes may be used for increased system performance If the input power feeder conduit is used as a grounding conductor adequate electrical continuity must be maintained at all conduit connections Using isolating bushings in a metal conduit run can be a safety hazard and is not recommended Signal reference grid If the unit is used to supply power to a computer room an area equipped with a signal reference grid or a grounded raised floor stringer system a grounding conductor should be connected from the system ground bus to the grid or floor system This conductor should be stranded or braided 8 AWG or larger and as short as practical Less than 3 ft 1m is recommended Grounding Electrode Conductor Required by code The Liebert PPC should be grounded according to the safety practices of NEC 25030 a
30. t Is there adequate room in doorways elevators ramps etc Are there any non nego tiable corners or offsets in the hallways e Move with care To prevent panel damage Emerson recommends removing the exterior panels before the unit is moved When replacing panels remember to reconnect all panel ground wires Table 1 300 800kVA Liebert PPC dimensions oe Transformer Section Section Distribution Side Section s L eo ei w o 4 e EEE 23 010922 321618 77 0980 080 2987 NOTES 1 800kVA requires two 2 distribution side sections 2 Includes a 1 side panel 1 1 3 Installation Instructions Unit Preparation The Liebert PPC may be easily removed from the shipping pallet and installed by the user A typical procedure follows 1 Set the palletized assembly in a level area where there is enough room to roll the unit and entire cable assembly off the pallet 2 Cut the shipping bands A WARNING The shipping bands may be under tension Use appropriate eye face and hand protection to safeguard against injury from band backlash 3 Remove the factory provided ramp from its shipping position One ramp is provided per order packed in front of the unit Place the ramp adjacent to the pallet to provide a smooth path from pallet to floor 4 Remove side and rear panels from the module An Allen wrench for the side panels is furnished in the installation packet Carefully disconnect panel ground wires by pulling t
31. t modifications special site considerations or company policies that may require changes to the standard equipment operation Emergency Shutdown To perform an immediate system shutdown during emergency conditions lift the protective clear cover and push the EPO switch on the front door of the unit NOTE Depending on the control circuit wiring operation of the unit EPO switch may cause other equipment to shut down If the site is equipped with a REPO switch for example as required by NEC Article 645 at the prin cipal exit doors activate one of the REPO switches to perform an immediate room shutdown Normal System Shutdown To perform a normal system shutdown Shut down the load equipment for example a computer system according to the manufac turer s recommendations The load equipment can be turned Off at each piece of load equipment or at the Liebert PPC s output distribution circuit breaker panels located behind the unit s front door Turn Off all unit output breakers then turn Off the unit s main input circuit breaker To remove all power from the unit turn Off the building power to the unit s input breaker or junc tion box 20 Operating Instructions 3 1 3 Normal System Startup Make certain all unit circuit breakers are in the Off position All unit circuit breakers are located behind the front doors as shown in Figure 12 Turn On building power to the unit Turn On the unit s main input
32. ther 480 552 700 2 500 kcmil the top or the bottom of the 450 A distribution section 4004 700A MIB Interrupting Rating 380 480V 600V Standard 100KA Installation Instructions Figure 7 800kVA Liebert PPC single line diagram ISOLATION SQ D I LINE PANELBOARD TRANSFORMER N MAMAR INPUT D 3 PHASE SQ D I LINE PANELBOARD 3 WIRE G Ee a LIGHTING SURGE SPIKE SUPPRESSION OPT OPT E poo AA JJ ll Suggested Minimum Input Wire Size NOTES Full MIB Suggested L Load Trip Feeder Input kVA Voltage Amps Amps Wire Size eoo ves 1000 4 350 kemi 1000A 1200A MIB 2 Interrupting Rating Standard High The maximum number of output breakers that can be installed in an I Line panelboard is e Ten 10 250A frame or Eight 8 400A LA frame or e Six 6 600A LI frame Input cables can enter through elther the top or the bottom of the transformer section Installation Instructions 1 2 2 Side Section Electrical Connections Five conductors three phase conductors neutral and ground are furnished with the distribution sec tion for connection to the transformer section in the field along with an intercabinet frame ground conductor For 300 450kVA units the distribution section phase conductors are connected directly to the trans former terminals e Phase A wire 14 to X1 Phase B wire 15 to X2 e Phase C wire 16 to X3 The distributio
33. tion inside the unit b With the unit On measure and record the DC control voltage on terminals 1 and 3 com c Control voltage Voltage should be between 20 and 28VDC Customer Alarms a With the unit On simulate alarm operation by jumpering the appropriate low voltage control terminals Refer to the control wiring installation drawing furnished with the unit b Verify correct alarm operation by the Power Monitor Panel and or by the centralized monitoring system Send Completed Checklist to Emerson Network Power After performing all procedures described in this section 2 0 Inspection and Startup Checklist sign date and return the completed Inspection and Startup Checklist form furnished with the unit to Emerson Network Power 1050 Dearborn Drive P O Box 29186 Columbus Ohio 43229 USA NOTE Warranty is not in effect unless the Inspection and Startup Checklist form is received by the factory 19 3 0 3 1 3 1 1 Operating Instructions OPERATING INSTRUCTIONS Startup Procedures Before the unit 1s placed into service after initial installation after equipment relocation or after equipment has been de energized for an extended period of time perform equipment inspection and startup procedures as detailed in 2 0 Inspection and Startup Checklist After initial system startup use the following guidelines for standard equipment operation These guidelines should be reviewed for any special equipmen
34. ts and Figure 2 for 800kVA units 300 450kVA units are shipped with a left side panel on the transformer section and a right side panel on the distribution section 800kVA units ship with a left side panel on the left distribution section and a right side panel on the right side distribution section The transformer section of an 800kVA unit ships without side panels After electrical connections are completed install the side panels on the transformer and distribution section enclosures Installation Instructions Figure 6 300 450kVA Liebert PPC single line diagram amine ISOLATION i TRANSFORMER I LINE PANELBOARD SEE NOTE 1 OUTPUT INPUT LIGHTING SURGE SPIKE ARRESTOR 3 PL or Morr OPT SUBFEED OUTPUT BREAKERS TRANSFORMER SECTION DISTRIBUTION SECTION A BY OTHERS WN INPUT 3 PHASE OPT PANELBOARD AND 3 WIRE G SUBFEED BREAKER SEE NOTE 2 Suggested Minimum Input Wire Size NOTES Full MIB Suggested 1 The maximum number of output Input Load Trip Feeder breakers that can be installed in kVA Voltage Amps Amps Wire Size an I Line panelboard is a 069 000 oem Ten 10 2508 frame or Cao f ae e Bight 4008 LA frame or e Six 6 600A LI frame 300 415 430 2 350 kcmil AN A cen 2 Input is through the distribution 480 372 500 2 250kcmil section to the transformer section 600 297 400 2 3 0 AWG Input cables can be through ei
35. unit back on __ 10 If the system is equipped with any Remote Emergency Power Off REPO switches test each to ensure proper operation Note that the REPO switch may shut down more equipment or systems than just the Liebert PPC 18 2 5 2 6 Inspection and Startup Checklist Monitoring System Check Basic Indicators a Turn On the building power to the unit then turn the main input breaker On b Check that the local Emergency Power Off button is illuminated and the Alarm Present button is off not illuminated Manual Restart Check if the unit is equipped with manual restart a Turn on building power to the unit Turn the main input breaker On b Turn off all building power to the unit c Observe that the main input breaker automatically trips open upon power loss d Restore building power to the unit and return the main input breaker to On Power Monitor Panel a Turn the unit On b Ensure that the voltage values indicated by the Monitor Panel correspond to the voltage values measured at the main input circuit breaker Step 5 in 2 4 Startup Procedure and output circuit breaker Step 8 in 2 4 Startup Procedure Centralized Monitoring System if the unit is connected to a centralized monitoring system a Turn the unit and centralized monitoring system On b Verify proper communication to the monitor system operation Control Voltage a Obtain access to the low voltage terminals in the low voltage control sec
36. ut feeder conductors should be sized for no more than 2 voltage drop If operation at undervolt age conditions for extended periods of time is desired the input feeders must be oversized Typical conductor size data is shown in Table 3 All connections must comply with the NEC and all other applicable codes The main input feeder should consist of three phase conductors and one safety ground conductor 3W G Table 3 AIC and suggested minimum input wire size data for OCPD CATE NE EE 8k 4 Volts FLA OCPD wire size AWG kAIC rr E Oo p o OI II w x w ow s O w e o O ETT O FLA Full Load Amps of Liebert PPC OCPD Overcurrent Protection Device inside Liebert PPC Wire sizes based on NEC 2008 Table 310 16 using 75 C copper conductor Parallel feeders per NEC 2008 Sections 300 3 and 310 4 NOTES 1 Main input power feeder should be a dedicated feeder direct from service entrance or other power source if possible 2 Ground conductors recommended to be insulated conductors run with power conductors for increased system performance Ground conductor minimum size per NEC Table 250 122 Input power feeder conduit may be used as the safety ground conductor When conduit is used adequate electrical continuity must be maintained at conduit connections to enclosures and throughout conduit run 3 Input feeder wire size listed is the minimum feeder size recommended Larger wire size may be required because of voltage drop or
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