User`s Manual Life Line Regulator Medical Power PC When the
Contents
1. HL Crucial Power Products REV LIST OF ILLUSTRATIONS ILLUSTRATION Section 1 OPERATIONS 1 1 1 2 1 3 d 1 1 9 1 10 REGULATION PANEL ASSEMBLY LAYOUT 1 12 1 11 REGULATED SYSTEM LIFE LINE REGULATOR AND MEDICAL POWER 100 300 KVA MEDICAL POWER PC 15 100 KVA FOR 480 VAC INPUT 15 75 KVA FOR 208 INPUT LIFE LINE REGULATOR 15 TO 150 KVA 480 VAC INPUT MEDICAL POWER PC 125 150 KVA 480 VAC INPUT MEDICAL POWER PC 15 75 KVA FEATURES LIFE LINE REGULATOR 175 KVA TO 300 KVA 480 VAC INPUT PHASE STABILIZER 125 KVA TO 300 KVA WITH 480 INPUT LIFE LINE REGULATOR PHASE STABILIZER 175 KVA 300 KVA 208 VAC INPUT INPUT FILTER WIRING OUTPUT FILTER WIRING REGULATION PANEL ASSEMBLY LAYOUT REGULATION BLOCK DIAGRAM Section 2 PREINSTALLATION 2 1 m m m LIFE LINE REGULATOR AND MEDICAL POWER 100 300 CABLE ACCESS MEDICAL POWER 15 75 KVA CABLE ACCESS MEDICAL POWER PC 15 75 KVA CLEARANCES LIFE LINE REGULATOR AND MEDICAL POWER PC 100 300 KVA CLEARANCES Section 3 INSTALLATION 3 1 3 2 CONTROL LOGIC BOARD SCR DRIVER BOARD Section OPERATIONS A od g 12. WIRING THERMAL WIRING INPUT FILTER WIRING OUTPUT FILTER WIRING POWER ISLAND POWER ISLAND FEATURES POWER ISLAND CABLE ACCESS POWER ISLAND FLOOR TILE CUTOUT POWER ISLAND DIMENSIONS AND CLEARANCES B 1 FWD AAA Crucial Power Products REV LIST OF TABLES TABLE PAGE 1 1 PRODUCT FEATURES cares epi Edu PR QU IE ad eaae rne a 1 5 2 1 LIFE LINE REGULATOR SITE PLANNING SPECIFICATIONS 2 2 2 2 MEDICAL POWER PC SITE PLANNING SPECIFICATIONS 2 4 2 3 LIFE LINE REGULATOR FLOOR LOADING 2 5 2 4 MEDICAL POWER PC FLOOR LOADING 2 6 3 1 LIFE LINE REGULATOR CURRENT TRANSFORMERS 3 16 3 2 MEDICAL POWER 15 75 CURRENT TRANSFORMERS 3 18 3 3 MEDICAL POWER 100 300 KVA CURRENT TRANSFORMERS 3 20 4 2 OPTIONS MATRIX IER PUR Adr d 4 1 Crucial Power Products REVA SECTION 1 OPERATION 1 1 INTRODUCTION This manual provides installation operation and maintenance information for the Life Line regulators and Medical Grade PC units A detailed description of each product is provided in the following subsections All components used are ofthe highest qualit
3. fh fh tit M MEDICAL POWER 15 75 KVA CLEARANCES ILLUSTRATION 2 3 Crucial Power Products REVA 2 4 MOUNTING continued TOP VIEW NOTE gt INDICATES AIR FLOW ALL DIMENSIONS ARE IN INCHES CENTIMETERS WEIGHT 520 LBS 236 KGS SERVICE ACCESS 38 FLOOR LOADING 106 LBS SQ FT SPACE REQUIRED 96 5 14 14 17 35 6 35 6 43 26 5 EN 147 35 6 FRONT VIEW SIDE VIEW LINE LINE REGULATORS AND MEDICAL POWER 100 300 KVA CLEARANCES ILLUSTRATION 2 4 Crucial Power Products REVA SECTION 3 INSTALLATION 3 1 INSTALLATION Install unit using the procedures in this section Final installation must be in accordance with NEMA standards and conform to local electrical codes as appropriate 3 1 1 Unpacking Unit is shipped on a pallet secured with metal bands and can be handeled using a fork lift or pallet jack o CUT METAL BANDS CAREFULLY THEY ARE UNDER TENSION AND MAY CAUSE INJURY Position the container away from walls or other obstructions Cut metal shipping bands Remove cardboard cover Avoid puncturing the cardboard cover with sharp objects which may damage the surface of the unit Remove the unit from the pallet e Life Line Regulators and Medical Power PC 100 300 kVA can be removed using fork lift e Medical Power PC 15 75 kVA come with integral casters and are packed with a
4. 550 00 Power Pnonucrs User s Manual Life Line Regulator Medical Power PC Operating Documentation Doc 6002 xxx Revision A Installation and Operating Documentation When the Lights Go out We Turn On Crucial Power Products Congratulations on selecting one of the fine products from Crucial Power Products the Leader in Power Protection Technology Our wide product offering includes Uninterruptible Power Systems UPS Power Conditioners Automatic Voltage Regulators and Specialty Transformers e g computer grade medical grade Since our beginnings in 1975 Crucial Power Products has shipped thousands of these fine products around the world to discerning customers for use on sensitive equipment and critical applications Our customers both new and long time continue to enjoy security and peace of mind as they realize what it means to When the lights go out we turn on One of our goals is to make these manuals both comprehensive and easy to use This new format Technical Manual is the result of ideas and inputs from customers who have taken an active interest in our continued success We invite constructive feedback on our products and documentation via fax mail or telephone HEADQUARTERS Crucial Power Products 5900 Triumph Street Commerce CA 90040 SALES Phone 800 244 4069 FAX No 800 246 2346 email info crucialpower com SALES Phone 800 244 4069 FAX No 800
5. Line Regulators 5 of the transformer is selected On the Medical Power 4 is selected 1 13 Crucial Power Products REVA 1 6 STARTING THE UNIT This procedure is to be used only for starting the unit during the normal course of operation Follow this operating procedure any time the unit has been turned off in a non emergency situation If this is the initial startup or if the unit has been moved perform the Startup procedure in Section 3 1 7 before applying power to the unit If the unit is connected to a Power Island modular distribution center verify that all panel board output circuit breakers are OFF before turning on branch feeder circuit breaker 1 Verify that Bypass Switch is set to AUTO 2 Verify that connected load is OFF 3 Energize facility branch circuit breaker 4 front door Medical Power PC only 5 IMCB to ON Medical Power PC only 6 Close front door 7 Turn ON connected load 1 14 Crucial Power Products REVA 1 7 OPERATION This unit is designed for unattended continuous operation Units that have an IMCB can be switched ON and OFF on a regular basis using the IMCB as a switch 1 7 1 Normal Condition When the unit is powered up and regulating the power on indicating lights will be illuminated on the Medical Power PC only The normal operating condition of the unit is as follows 1 Facility branch circuit breaker set to ON 2 Bypass switch in
6. 20 oz m 45 aU 50 15 52 Me 1 3 d C zey Hi vtl 4 ozy 9 8 L te y EE p 924 e 204 4 L en 220 19 Mad ory hs gy Li cy j Vid P SCR DRIVER BOARD ILLUSTRATION 3 2 3 2 CONFIGURATION The unit is shipped factory configured No configuration is necessary Do change tap connections 3 13 Crucial Power Products REV A 3 3 RENEWAL PARTS Life Line Regulator INPUT OUTPUT FILTER ASSY 9100 001 01 INPUT FILTER ASSY 1690 002 1690 012 SCRs 1625 012 01 1625 004 01 Snubber PCB 1625 002 01 Driver PCB 1400 003 1400 001A Ref Transformer 2025 002 Fuse Ref Transformer input 1625 003 01 Control Logic PCB 1680 021 BYPASS SWITCH Crucial Power Products REV A 3 3 1 Vendor Parts List Life Line Regulator Vendor No Vendor Description Remarks 1680 021 Crucial Power SWITCH BYPASS 1 USED 1680 042 Crucial Power SWITCH BYPASS 1 USED 1425 001 Crucial Power TRANSFORMER CURRENT 50 5 3 USED Note 1 1425 004 Crucial Power TRANSFORMER CURRENT 1000 1 3 USED Note 1 1425 003 Crucial Power TRANSFORMER CURRENT 100 5 3 USED Note 1 1425 007 Crucial Power TRANSFORMER CURRENT 200 5 3 USED Note 1 1425 002 Crucial Power TRANSFORMER CURRENT 400 5 3 USED Note 1 1690 002 Crucial Power SCR 15 50 KVA MODEL 18 USED 1690 012 Crucial Power SCR 75 175 KVA MODE
7. INPUT OUTPUT CABLE ENTRANCE LINE LINE REGULATORS AND MEDICAL POWER PC 100 300 KVA CABLE ACCESS ILLUSTRATION 2 1 LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW CABLE ACCESS OPENING _ 4 6 _ 35 6 15 2 for 75 kVA and 100 kVA 12 7 5 deep back screen 15 used MEDICAL POWER 15 75 KVA WITH 208 VAC INPUT 15 100 KVA WITH 480 VAC INPUT ACCESS ILLUSTRATION 2 2 Crucial Power Products REVA 2 4 MOUNTING The Medical Power PC sizes 15to 75 kVA are equipped with leveling jacks to provide firm footing when the unit is set in its permanent location With the leveling jacks place the unit cannot roll on the wheels If local code requires the unit to be more firmly secured mount the unit to the floor using angle brackets A seismic option is available to mechanically attach the unit to the floor The Line Line Regulators and Medical Power PC sizes 100 to 300 kVA are equipped with angle iron feet that have four 9 16 inch diameter holes pre drilled for mounting Units can be bolted to the floor using these mounting holes M M NOTE gt INDICATES AIR FLOW ALL DIMENSIONS TOP VIEW IN INCHES CENTIMETERS 54 200 FRONT PANEL 1 N N N Se 2 DOOR m i NON Lag S 38 NES N WON d 59 150 42 107 SIDE VIEW
8. VERIFY THAT INCOMING HIGH VOLTAGE CIRCUITS ARE DE ENERGIZED BEFORE CONTINUING WITH THIS PROCEDURE 6 Punch or drill holes in right side panel to accomodate output cable 7 Route and connect the 4 power wires to output terminals X1 X2 and See Illustration 1 5 8 Route and connect the ground wire to the ground lug on the cabinet 9 Proceed to Section 3 1 7 Startup to complete the installation Crucial Power Products REV A 3 1 7 Startup Life Line Regulators and Medical Power PC 100 300 kVA After connecting the input and output cables and before placing the unit in service verify the output voltage using the following procedure Tools Required e Phase Rotation Meter e Voltage meter FATAL ELECTRIC SHOCK HAZARD TO PREVENT FATAL ELECTRIC SHOCK DISCONNECT POWER FROM UNIT AND LOCK OFF BEFORE YOU PERFORM THE FOLLOWING PROCEDURE PROCEDURE 1 2 Verify that facility circuit breaker is OFF locked and tagged according to OSHA requirements Check power connections Verify that there are no obstructions that restrict air flow Unlock facility circuit breaker and set to ON Check that input power is phased in clockwise rotation A B C Use phase rotation meter Measure the input voltages phase to phase and be sure the readings agree with the values listed on the label plate Measure the line to neutral output voltages as follows a Verify that output line to neutral voltage
9. 11 12 13 14 15 16 17 Verify that IMCB is OFF Check power connections Verify that there are no obstructions that restrict air flow Unlock facility circuit breaker and set to ON Turn on IMCB on Medical Power PC Check that input power is phased in clockwise rotation A B C Use phase rotation meter Measure the input voltages phase to phase and be sure the readings agree with the values listed on the label plate Measure the line to neutral output voltages as follows b Verify that output line to neutral voltages agree with the values listed on the label plate located on the inside of the front door and in Appendix A f output voltage readings are out of specification refer to Section 3 1 9 Calibrate Control Logic Board otherwise continue to next step Turn OFF IMCB Turn OFF facility circuit breaker lock and tagout according to OSHA requirements Close front panel Unlock and turn ON facility circuit breaker Turn IMCB ON as applicable Close front door The unit is ready for service Crucial Power Products REV 3 1 9 Calibrate Control Logic Board The SCR driver board has seven green LEDs LED 7 indicates power is applied to the board andis illuminated any time power to the unit is LEDs 1 through 6 represent tap settings and only one of these six LEDs should be at any time See Illustration 3 2 It is normal for the LED s 1 through 6 to delay 6 seconds aft
10. The IMCB is located on the front panel of the unit behind the hinged front door Be sure to observe ALL warnings and cautions when setting the IMCB to ON or OFF This option is factory installed at the time of production No assembly or adjustments are required Crucial Power Products REVA 4 6 INPUT OUTPUT FILTERING The Input Output filter comprises an input filter installed on the primary and an output filter installed on the secon dary ofthe transformer The inputfilter consists of a resistor capacitor network which acts as a large snubber circuit to eliminate high frequency impulses from entering the power system The output filter consists of a capacitor net work which when coupled with the primary filter virtually eliminates most electronic noise from reaching the applied load or being fed back to the unit from noise generating loads See Illustration 4 4 and 4 5 INPUT FILTER WIRING ILLUSTRATION 4 4 C4 OUTPUT FILTER WIRING ILLUSTRATION 4 5 Crucial Power Products REVA 4 7 POWER ISLAND 4 7 1 Features The Power Island is a modular power distribution center which can be used with either the Medical Power PC or Life Line Regulator The Power Island can extend the distribution capability of tne Medical Power PC or Life Line Regula tor by up to 42 and 84 pole positions The 225 amp or 450 amp Power Island is available in two models The Power Island 42 can accommodate one 42 pole panelboard and the
11. 246 2346 email info crucialpower com Office Hours 8 00 AM to 5 00 PM PST Crucial Power Products Crucial Power Products Proprietary Reproduction or Distribution Forbidden NOTICE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION This document contains proprietary and confidential information of Crucial Power Products In consideration of the receipt this document the recipi ent agrees notto copy any ofits contents nor disclose them to or allow them to be used by any person not currently a Crucial Power Products employee or an employee of the recipient having a need to know without the express written consent of Crucial Power Products and further agrees to surrender this Crucial Power Products when the reason for its receipt has terminated Crucial Power Products SAFETY Safety precautions are important when operating or servicing electrical equipment The following symbols are used extensively throughout this manual Always heed these precautions since they are essential to the safe operation and servicing of this product THIS DANGER SYMBOL IDENTIFIES A CONDITION OR ACTION WHICH WILL RESULT IN SEVERE INJURY OR DEATH TO AN INDIVIDUAL OR SEVERE DAM AGE TO EQUIPMENT OR OTHER PROPERTY This Caution symbol identifies a condition or action which may result in minor injury to an individual or minor damage to the equipment or other property This unit was designed for specific applications It should not be mo
12. 3 1 7 Startup Crucial Power Products REV 3 1 5 Input Cable Installation Medical Power PC 15 100 kVA The customer furnished input power cable provides power from the building power source to the unit Both the circuit which feeds this cable and this cable should be dedicated to providing power onlyto this unit This cable must include three power conductors and an insulated ground conductor Size the cable to suit the unit kVA rating the input voltage and the overall length of the cable The input power cable size and installation must be in accordance with the National Electrical Code NEC and applicable local requirements A parity sized ground with respectto the primary input conductors is recommended The grounding conductor isto be grounded to earth at the service equipment or other acceptable true building ground The input power cable should be installed through the left side panel No holes are provided in the panel A hole can be sized located and drilled or punched when the cable is installed If cables are crossed or wires are likely to touch insulating sleeves or their equivalent must be used to prevent wires from touching PROCEDURE 1 Turn OFF facility circuit breaker lock and tagout according to OSHA requirements 2 Open front door 3 Verify that the Main Input Circuit Breaker is set to OFF as applicable 4 Open the hinged front panel by unbolting the three screws on the left side of panel a
13. KVA NUMBER VOLTAGE TRANSFORMER BEER EXE NE NN Crucial Power Products REVA SECTION 4 OPTIONS 4 1 INTRODUCTION Crucial Power offers a number of options which can enhance the performance ofthe Life Line Regulator and Medical Power PC and expand the units power distribution capacity to suit facility requirements This section discusses the functions and capabilities of the following options e Remote Emergency Power Off REPO Station Thermal REPO Station e Surge Protection e Main Input Circuit Breaker Output Filtering Some of the options listed above are provided as standard equipment on some models of Crucial Medical Power PCs and Life Line Regulators while other options are only available on some models Refer to Table 4 1 to clarify options availability TABLE 4 1 OPTIONS MATRIX MODEL OPTION Medical Power PC Medical Power PC Life Line Regulator 75 kVA DEM 300 kVA Thermal Ege eee Protection Main Input Circuit Breaker Output TABLE KEY S Standard equipment O Available as an option N Not available for this model Crucial Power Products REVA 4 2 REMOTE EMERGENCY POWER OFF STATION Medical Power PC up to 75 kVA The Remote Emergency Power Off Station is a wall mounted unit that enables operating personnel to re motely shut down the Medical Power PC or Life Line
14. Products REV 3 1 4 Output Cable Installation Life Line Regulators and Medical Power 125 300 kVA The customer furnished output power cable provides power from the unit to a connected load or to a Power Island when distribution to more than one connected load is required The unit has one 4 inch diameter hole in each side of the frame as described in the preceeding section The output power cable can be connected through the left or right side of the unit PROCEDURE 1 Turn facility circuit breaker to OFF lock and tagout in accordance with OSHA Lockout Tagout requirements 2 Remove top cover by unbolting two bolts on each side of cover 3 Remove front panel by unbolting six bolts at corners and at left and right sides of panel 4 Punch or drill a hole in side panel Locate hole so that it aligns with existing hole in frame See Illustration 2 4 Size hole to suit cable conduit 5 Insert cable conduit through hole in panel and into hole in frame Secure with appropriate fitting 6 Prepare cable ends by removing 3 4 inch of insulation from each output power cable conductor Identify each phase conductor according to phase C Neutral and Ground conductor 8 Route and connect phase conductors to output terminals of the transformer X1 X2 and See Illustration 1 4 1 5 1 6 and 1 7 9 Locate ground lug 10 Route and connect ground conductor to ground lug 11 Proceed to Section
15. ambient temperatures should not exceed 104 40 C The trans former contains built in thermal sensors which monitor internal temperatures In models with a Input Main Circuit breaker IMCB the thermal sensors send a shunt trip signal to the IMCB in the event of an over temperature condition 1 4 PRODUCT FEATURES Sections 1 4 and 1 5 describe the features of the Life Line Regulators and Medical Power PC Some features described in Section 1 4 are standard on all models while other features are offered as options Refer to Table 1 1 to determine if the features described in this section are applicable to your unit Refer to Section 4 Options for information on optional features TABLE 1 1 PRODUCT FEATURES MODEL OPTION Life Line Medical Power Medical Power Regulators 15 75 kVA 100 300 Main Input Circuit Breaker imas 8 Indicators pte 1 5 s 5 5 TABLE KEY S Standard equipment Available as an option Not available for this model Crucial Power Products REVA 1 4 PRODUCT FEATURES continued OUTPUT FILTER Optional INPUT POWER FILTER REGULATION ELECTRONIC PANEL Heat Sinks SCR Snubber Boards SCR Power Blocks Reference Transformers SCR Driver Boards SCR Control Boards Fuses MAIN POWER TRANSFORMER INPUT AND OUTPUT POWER TERMINAL BYP
16. wooden ramp Se cure ramp from slipping and roll unit off pallet Secure ramp to pallet before rolling unit down ramp Remove protective plastic film Inspect unit for damage per Section 3 1 2 Inspection Move unit to installation site Before final positioning of unit verify that all cable routing conduit and raceway is positioned properly unit weighs from 400 16 181 kg to 3 500 155 1 588 kg including the packaging Use when rolling unit with integral casters Plywood or steel plates may be used to distribute weight and protect floor surface from overload damage 3 1 Crucial Power Products REV 3 1 2 Inspection Perform the following Inspection procedure ofthe unit to check for obvious damage or safety hazards that have occurred during shipping or handling of the unit All units must be inspected when received and again prior to use Any damage must be reported immediately to ON LINE POWER INC or an authorized representative Freight damage claims should be initiated with the carrier Do not connect unit to building power until the following procedure has been completed 1 Inspect all external surfaces panels covers etc for abrasions indentations or other obvious damage 2 claim with shipping agency for any damage caused by shipping 3 Forward a copy of damage claim to ON LINE POWER INC at the following address ON LINE POWER INC 5701 Smithway Street City of Commerce
17. 0 125 150 175 200 225 250 300 NUMBER OF PHASES 20096 of Full Load for 10 Seconds SURGE RATING 100096 of Full Load for 1 Cycle HARMONICS ADDED 196 Maximum POWER FACTOR AMBIENT TEMPERATURE 80 26 7 Greater Than 9696 SIZE H X W XD in cm See Table 2 1 Crucial Power Products REVA TABLE A 2 SPECIFICATIONS MEDICAL POWER PC NOMINAL INPUT VOLTAGE INPUT VOLTAGE RANGE 208 VAC 187 225 MAXIMUM INPUT VOLTAGE 225 NOMINAL RATED CURRENT A See Table 2 2 FREQUENCY Hz OUTPUT VOLTAGE REGULATION 1 596Typical 2 Maximum LINE TO LINE VARIATION RESPONSE TIME LESS THAN 2 1 Cycle Typical FILTERS INPUT YES OUTPUT YES SECONDARY SURGE SUPPRESSION YES COOLING REQUIREMENT BTU hr See Table 2 2 WEIGHT 16 kg estimated See Table 2 2 OUTPUT VOLTAGE 208Y120 VAC or 480Y277 VAC CAPACITY KVA 15 30 50 75 100 125 150 175 200 225 250 300 kVA NUMBER OF PHASES SURGE RATING 200 For 10 Seconds HARMONICS ADDED POWER EFFICIENCY 1 Maximum Greater Than 96 AMBIENT TEMPERATURE F C 80 26 7 SIZE H XW X D in cm See Table 2 2 Crucial Power Products REV AC Current transformer Front door Front panel IMCB NEC NEMA OSHA PCB REPO Thermal REPO Reset a circuit breaker SCR Shunt Trip Trip TB GLOSSARY Air Conditioning The transformer used to feed a current signal to the logic board The hinge
18. 1 7 Startup Life Line Regulator and Medical Power PC 100 300 3 1 8 Startup Medical Power PC 15 100 kVA 3 1 9 Calibrate Control Logic Board PAGE 1 a 1 1 A Crucial Power Products REVA SECTION 3 2 CONFIGURATION 3 8 RENEWAL PARTS Life Line Regulator 3 3 1 Vendor Parts List Life Line Regulator 3 4 RENEWAL PARTS Medical Power 15 75 kVA 3 4 1 Vendor Parts List Medical Power PC 15 75 kVA 3 5 RENEWAL PARTS Medical Power 100 300 3 5 1 Vendor Parts List Medical Power PC 100 300 SECTION 4 OPTIONS 4 1 INTRODUCTION 4 2 REMOTE EMERGENCY POWER OFF STATION Medical Power 4 2 1 Installation for REPO 4 3 THERMAL REMOTE EMERGENCY POWER OFF STATION 4 3 1 Installation for Thermal REPO 4 SECONDARY SURGE PROTECTION 5 MAIN INPUT CIRCUIT BREAKER Medical Power 15 75 kVA 6 INPUT OUTPUT FILTERING 7 POWER ISLAND 4 7 1 Features 4 7 2 Power Island Specifications 4 7 3 Preinstallation 4 7 4 Output Interconnect Cable Installation 4 7 5 Output Cable Installation APPENDIX SPECIFICATIONS APPENDIX SPECIFICATIONS GLOSSARY iue ee aei aede di oia gt 11 gt
19. 40 5 26 5 131 103 67 1900077 23800 480 210 5 1450 658 700 655 27200 9 25 BINE 2350 1066 2 EH 66 X 50 5 X 32 16500748 168 X 128 X 81 BIG 1157 1 1900 862 862 1361 2000 907 907 Crucial Power Products REVA 2 2 FLOOR LOADING Sizes and weights of units are listed in the following tables Provide a floor with strength sufficient loads specified TABLE 2 3 Line Line Regulators FLOOR LOADING INPUT FLOOR LOADING INPUT FLOOR LOADING KVA SIZE VOLTAGE Ibs sq ft kg sq m KVA SIZE VOLTAGE Ibs sq ft kg sq m mem 128 628 175 160 788 146 710 200 176 862 225 250 Crucial Power Products REVA TABLE 2 4 Medical Power PC FLOOR LOADING INPUT FLOOR LOADING INPUT FLOOR LOADING SIZE VOLTAGE Ibs sq ft kg sq m KVA SIZE VOLTAGE Ibs sq ft kg sq m m ES 82 399 m p we E jus px E mem 2 3 CABLE ACCESS AND FLOOR LAYOUT 2 3 1 Cable Access Cable access to the Line Line Regulators and Medical Power PC sizes 100 to 300 kVA is through a 4 diameter hole in the right and left sides of the unit throught which the input and output cables can be passed Cable access to the Medical Power PC sizes 15to 75 kVA is through an opening in the left and right side ofthe unit See Illustrations 2 1 and 2 2 Crucial Power Products REVA LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW
20. ASS SWITCH INPUT amp OUTPUT CABLE ACCESS BOTH SIDES 9 16 Dia Mounting Holes LIFE LINE REGULATORS 15 TO 150 KVA 480 VAC INPUT MEDICAL POWER 125 150 KVA 480 VAC INPUT ILLUSTRATION 1 4 Crucial Power Products REVA 1 4 PRODUCT FEATURES continued POWER ON INDICATORS OUTPUT POWER TERMINALS REGULATION SRM ELECTRONIC PANEL Heat Sinks SCR Snubber Boards SCR Power Blocks Reference Transformers SCR Driver Boards SCR Control Boards Fuses INPUT OUTPUT FILTER MAIN TRANSFORMER REAR VENTILATION FRONT VENTILATION MAIN INPUT CIRCUIT BREAKER BYPASS SWITCH MEDICAL POWER PC 15 75 KVA FEATURES ILLUSTRATION 1 5 Crucial Power Products REVA 1 4 PRODUCT FEATURES continued OUTPUT FILTER INPUT FILTER REGULATION ELECTRONICS PANEL BYPASS SWITCH MAIN POWER TRANSFORMER OUTPUT POWER TERMINALS INPUT POWER TERMINALS Electronic Cooling INPUT amp OUTPUT FAN FUSE CABLE ACCESS BOTH SIDES 9 16 Dia Mounting Holes LIFE LINE REGULATOR 175 KVA TO 300 KVA 480 VAC INPUT MEDICAL POWER PC 125 KVA TO 300 KVA WITH 480 VAC INPUT ILLUSTRATION 1 6 Crucial Power Products REVA 1 4 PRODUCT FEATURES continued OUTPUT FILTER INPUT FILTER INPUT AUTO REGULATION TRANSFORMER ELECTRONIC PANEL BYPASS SWITCH INPUT POWER TERMINALS MAIN POWER TRANSFORMER OU
21. ASSEMBLY LAYOUT ILLUSTRATION 1 10 1 11 HEATSINK 3 SCR 18 FUSELINK 15 SCR SNUBBER BOARD 18 SCR DRIVER BOARD 3 REFERENCE TRANSFORMER 3 FUSES FOR REF TRANSFORMER 3 NOT ON ALL MODELS SCR CONTROL LOGIC BOARD 3 Crucial Power Products REVA 1 5 REGULATION COMPONENTS continued HEATSINK 3 SCR 18 c SCR SNUBBER BOARD 18 FUSELINK 15 niu i ii REFERENCE TRANSFORMER 3 SCR DRIVER BOARD 3 SCR CONTROL LOGIC BOARD 3 Transformer FUSES FOR REF TRANSFORMER 3 B Current FUSES FOR Transformer Transformer FAN 31 REGULATION PANEL ASSEMBLY LAYOUT ILLUSTRATION 1 11 1 12 Crucial Power Products REVA 1 5 REGULATION COMPONENTS continued OUTPUT BYPASS FUSEWIRE 5 TIMES SCR SNUBBER BOARD 6 TIMES 8 WIRES DRIVER BOARD CONTROL P2 LOGIC BOARD P1 REFERENCE RANSFORMER REGULATION BLOCK DIAGRAM ILLUSTRATION 1 12 Note 1
22. AUTO position 3 Input Main Circuit Breaker ON if applicable 4 Connected load set to ON e f Power Island connected output panelboard circuit breakers ON as required 1 7 2 Nonregulating Condition In case the regulating circuits fail to regulate the unit can continue to operate in bypass mode without regulation until regulation can be restored Follow the procedure listed below to operate the unit in bypass mode Note The following procedure is only for temporary operation Voltage surge and sag protection is not available for any load while the bypass switch is in manual mode bypass switch is set to MAN 1 Turn connected load OFF 2 Setfacility branch circuit breaker to OFF 3 SetIMCB to OFF if applicable 4 Turn bypass switch from AUTO to MAN 5 Set facility branch circuit breaker to ON 6 IMCB to ON if applicable 7 Turn connected load ON 8 Refer to manufacturer s service personnel 1 15 Crucial Power Products REVA SECTION 2 PREINSTALLATION 2 1 LOCATION CONSIDERATIONS OPERATING ENVIRONMENT Provide an operating environment which meets the following conditions AMBIENT TEMPERATURE 32 to 104 F 0 1040 C RELATIVE HUMIDITY Line Line Regulators and Medical Power PC 1096 to 9096 noncondensing POSITIONING Position the unit so that the regulating electronics are not obstructed by objects that could make servicing the unit difficult Allow minimum service access clearance
23. CA 90040 3 1 3 Input Cable Installation Life Line Regulators amp Medical Power 100 300 kVA The customer furnished input power cable provides power from the building power source to the unit Both the circuit which feeds this cable and this cable should be dedicated to providing power onlyto this unit This cable must include three power conductors and an insulated ground conductor Size the cable to suit the unit kVA rating the input voltage and the overall length of the cable The input power cable size and installation must be in accordance with the National Electrical Code NEC and applicable local requirements A parity sized ground with respect to the primary input conductors is recommended The grounding conductor isto be grounded to earth at the service equipment or other acceptable true building ground The unit has one 4 inch diameter hole in each side of the frame to accomodate the input and output power cables There are no holes in the side panels The holes in the panels can be sized located and punched or drilled when the cable is installed The input power cable can be connected through the left or right side of the unit If cables are crossed or wires are likely to touch insulating sleeves or their equivalent must be used to prevent wires from touching Tools Required e Phase Rotation Meter Input power connection and required branch circuit breaker should be installed by a licensed electrical contractor in
24. E v Crucial Power Products REV A 3 4 1 Vendor Parts List Medical Power 15 75 kVA Vendor No Vendor Description Remarks 1680 021 Crucial Power SWITCH BYPASS 1 USED 1425 001 Crucial Power TRANSFORMER CURRENT 50 5 3 USED Note 1 1425 017 Crucial Power TRANSFORMER CURRENT 25 5 3 USED Note 1 1425 003 Crucial Power TRANSFORMER CURRENT 100 5 3 USED Note 1 1425 005 Crucial Power TRANSFORMER CURRENT 300 5 3 USED Note 1 1425 007 Crucial Power TRANSFORMER CURRENT 200 5 3 USED Note 1 1690 002 Crucial Power SCR 15 50 KVA MODEL 18 USED 1690 012 Crucial Power SCR 75 KVA MODEL 18 USED 1625 004 01 Crucial Power PCB SNUBBER SCR 15 50 KVA MODEL 18 USED 1625 012 01 Crucial Power PCB SNUBBER SCR 75 KVA MODEL 18 USED 1625 002 01 Crucial Power PCB SCR DRIVER 3 USED 1400 001A Crucial Power TRANSFORMER REFERENCE 208 V PRI 4 USED Note 2 1400 003 Crucial Power TRANSFORMER REFERENCE 480 V PRI 6 USED Note 2 9100 001 01 Crucial Power INPUT FILTER ASSY 1 USED not shown 9100 006 01 Crucial Power INPUT OUTPUT FILTER ASSY 1 USED not shown NOTES 1 For current transformer PART numbers refer to Table 3 2 2 Reference transformer vendor numbers For 208 V input use 1400 001A For 480 V input use 1400 003 TABLE 3 2 MEDICAL POWER PC 15 75 kVA CURRENT TRANSFORMERS Em Nm Doe KVA NUMBER VOLTAGE mimus Crucial Power Products REV A 3 5 RENEWAL PARTS Med
25. FFECTIVE PAGES PAGE REV PAGE REV PAGE REV PAGE REV PAGE REV Title 1 10 1 15 21102 8 3 1 103 20 4 110 4 14 A1 to 2 A Qiu ti petenis A Title 2 1to2 9 B Title C Crucial Power Products REV SECTION SECTION 1 1 1 uk NO SECTION 2 2 1 2 2 2 3 2 4 SECTION 3 3 1 TABLE OF CONTENTS OPERATION INTRODUCTION 1 1 1 Life Line Regulator 1 1 2 Medical Power PC BENEFITS TRANSFORMER PRODUCT FEATURES 1 4 1 Bypass Switch 2 Input Main Circuit Breaker IMCB 3 Power On Indicators 4 Input and Output Power Terminals 5 Input Filter 6 Output Filter ULATION COMPONENTS STARTING THE UNIT OPERATION 1 7 1 Normal Condition 1 7 2 Nonregulating Condition 1 4 1 4 1 4 1 4 1 4 PREINSTALLATION LOCATION CONSIDERATIONS FLOOR LOADING CABLE ACCESS AND FLOOR LAYOUT 2 3 1 Cable Access MOUNTING INSTALLATION INSTALLATION 3 1 1 Unpacking 3 1 2 Inspection 3 1 3 Input Cable Installation Life Line Regulator amp Medical Power PC 100 300 kVA 3 1 4 Output Cable Installation Life Line Regulator and Medical Power PC 125 300 3 1 5 Input Cable Installation Medical Power PC 15 100 kVA 3 1 6 Output Cable Installation Medical Power 15 100 kVA 3
26. ILLUSTRATION 1 9 1 10 Crucial Power Products REVA 1 5 REGULATION COMPONENTS Regulation is accomplished by solid state electronics which control the tap switching function at the zero cur rent crossing Refer to Section TAG THEORY OF OPERATION for more detail The regulation components are mounted on the regulation panel and can be seen by removing the front panel See Illustration 1 10 and 1 11 The regulation components include 3 SCR Control logic boards 3 SCR Driver boards 18 SCR SCR Snubber board assemblies 3 current transformers 3 reference transformers and 3 heatsinks See Illustration 1 12 for a block diagram of the regulation panel components Each SCR Control logic board has seven LEDs The first six LEDs indicate the active tap selection during operation LED 7 indicates power is applied to the board and is always lit during operation To Bypass To Bypass To Bypass i i 000000000000 000000000000 00000000000 CJ CJ C E Current Current Current Transformer Transformer Transformer REGULATION PANEL
27. L 18 USED 1690 011 Crucial Power SCR 200 300 KVA MODEL 18 USED 1625 004 01 Crucial Power PCB SNUBBER SCR 15 50 KVA MODEL 18 USED 1625 012 01 Crucial Power SNUBBER SCR 75 175 KVA MODEL 18 USED 121543003 02 Crucial Power PCB SNUBBER SCR 200 300 KVA MODEL 18 USED 1625 002 01 Crucial Power PCB SCR DRIVER 3 USED 1400 001 Crucial Power TRANSFORMER REFERENCE 208 V PRI 3 USED 1400 003 Crucial Power TRANSFORMER REFERENCE 480 V PRI 3 USED 9100 001 01 Crucial Power INPUT FILTER ASSY 1 USED not shown 1625 003 01 Crucial Power PCB CONTROL LOGIC 3 USED NOTES 1 For current transformer part numbers refer to Tables 3 1 2 Reference transformer part numbers For 208 V input use 1400 001A For 480 V input use 1400 003 Crucial Power Products REV A 3 3 1 Vendor Parts List Life Line Regulator continueed TABLE 3 1 LIFE LINE REGULATOR CURRENT TRANSFORMERS SIZE MODEL INPUT CURRENT 75 mm m mm NES m mm mm RENE em m9 mem om Crucial Power Products REV A 3 4 RENEWAL PARTS Medical Power PC 15 75 kVA 1680 021 Bypass Switch 1690 002 1690 012 SCRs 9100 006 01 INPUT OUTPUT FILTER ASSY Kee 1625 002 01 Driver PCB 1625 003 02 Control Logic PCB 2075 002 Fuse SEE NOTE 2 Ref Transformer Ref Transformer 1625 004 01 1625 012 01 Snubber PCB N
28. Power Island 84 can accommodate two 42 pole panelboards The standard panel board is a 225 amp Square D Snap On For other panelboard configurations refer to your Crucial Power Sales Representative The style and function of both Power Island models coordinates with and complements the design of the Phase Stabilizer in the 15 to 75 kVA sizes See Illustration 4 6 The Power Island provides three neon phase indicators located on the front ofthe unit Each phase is independent ly monitored If a phase is lost the corresponding indicator will extinguish showing which phase is having the prob lem Power Island 84 Power Island 42 POWER ISLAND ILLUSTRATION 4 6 Crucial Power Products REVA 4 7 2 Power Island Specifications MODEL DIMENSIONS in cm WEIGHT FLOOR LOADING k ft k 1 75 050 Power Island 84 225 102 48 236 Panelboards Full Capacity Ground Bus Isolated Full Capacity Neutral Bus Tiered amp Slotted Output Conduit Landing Brackets 7 Main Input Conduit Landing Bracket Power Island 84 Power Island 42 REAR VIEW REAR VIEW POWER ISLAND FEATURES ILLUSTRATION 4 7 Crucial Power Products REVA 4 7 3 Preinstallation Determine the location of the Power Island and routing of input and output cab
29. Regulator in an emergency The REPO station consists of a painted sheet metal enclosure with a guarded momentary normally open red tactile switch See Illustration 4 1 for REPO box size and mounting hole location The REPO station is designed to be vertically mounted and can be located anywhere an emergency shut off is required The REPO station is provided with a 50 foot two conductor cable 15 m Other length cables avail able in five foot increments mE pes e 3 7 6 7 17 8 _ ILLUSTRATION 4 1 4 2 1 Installation for REPO The cable will be 50 to 100 feet 15 30 m long depending on length ordered The cable is supplied with two pin connector on one end and bare wires on the other end The bare wires connect to a terminal block in the Medical Power PC Procedure 1 Select the location for the REPO box 2 Mount REPO box on wall or other structure using fasteners that are appropriate for the surface on which the REPO box is to be mounted 3 Remove REPO box cover Crucial Power Products REVA 4 2 1 Installation for REPO continued 4 Connect 2 wires in REPO cable to terminals on REPO switch as shown in Illustration 4 2 5 Turn OFF main facility circuit breaker lock and tagout in accordance with OSHA requirements 6 Open front door of Medical Power PC 7 IMCB to OFF 8 Remove floor tiles as required to route REPO cable from REPO box to Me
30. TPUT POWER TERMINALS FANS for Electronic Cooling INPUT amp OUTPUT CABLE ACCESS FAN FUSE BOTH SIDES 9 16 Dia Mounting Holes LIFE LINE REGULATOR AND MEDICAL POWER PC 175 KVA TO 300 KVA 208 VAC INPUT ILLUSTRATION 1 7 Crucial Power Products REVA 1 4 1 Bypass Switch The bypass switch is located on the front panel See Illustrations 1 4 thru 1 7 This switch bypasses voltage regulation but maintains the functioning of the voltage change isolation transformer between input and output In AUTO position line to neutral voltages are regulated In MAN manual position regulation logic is bypassed and input power is applied to load via transformer without regulation Select the MAN position if there is a problem with regulation logic circuitry Refer to Section 1 7 2 Nonregulating Condition for the procedure to operate the unit in bypass mode The Bypass Switch must never be changed with the unit powered up 1 4 2 Main Input Circuit Breaker IMCB The MAIN INPUT CIRCUIT BREAKER IMCB located on the front panel of the unit is used to switch power to the unit ON and OFF See Illustration 1 5 The is shunttripped by activation of a solenoid within the breaker when remote switches or thermal switches in the main transformer sense an over temperature condition If the IMCB is shunt tripped refer to Section NO TAG Miscellaneous Problems for the reset procedure An optional undervoltage
31. accordance with local codes Crucial Power Products REV 3 1 3 Input Cable Installation Life Line Regulators amp Medical Power 100 300 kVA continued Primary and secondary power circuit conductors must not touch each other If conductors touch use insulating sleeves VERIFY THAT INCOMING HIGH VOLTAGE CIRCUITS DE ENERGIZED BEFORE CONTINUING WITH THIS PROCEDURE PROCEDURE 1 2 10 11 Turn facility circuit breaker to OFF lock and tagout in accordance with OSHA Lockout Tagout requirements Remove top cover by unbolting two bolts on each side of cover Remove front panel by unbolting six bolts at corners and at left and right sides of panel Punch or drill a hole in side panel Locate hole so that it aligns with existing hole in frame See Illustration 2 4 Size hole to suit cable conduit Insert cable conduit through hole in panel and into hole in frame Secure with appropriate fitting Prepare cable ends by removing 3 4 inch of insulation from each input power cable conductor Identify each phase conductor according to phase A B C Identify ground conductor Route and connect phase conductors to input terminals on input labelled H1 H2 and H3 or L1 L2 and L3 See Illustration 1 4 1 5 1 6 and 1 7 Locate ground lug on side of cabinet Route and connect ground conductor to ground lug Proceed to Section 3 1 4 for instructions to install output power cable Crucial Power
32. d front door on the Medical Power PC 15 75 Kva It covers the bypass Switch and the IMCB if installed The hinged panel behind the front door on theMedical Power 15 75 kVA into which the bypass switch and the IMCB if installed are mounted InputMain Circuit Breaker The circuit breaker on the front panel used to switch power to the CP 18 ON and OFF Optional on Medical Power PC 15 75 kVA National Electric Code National Electrical Manufacturers Association Occupational Safety and Health Administration Printed Circuit Board A surface for the mounting and interconnection of elec tronic components Remote Emergency Power Off A switch separate from but wired to the regula tion unit when pressed shunt trips the Main Input Circuit Breaker Thermal Remote Emergency Power Off A thermal activated switch separate from but wired to the regulation unit which reacts to a predetermined temperature range by shunt tripping the Main Input Circuit Breaker Snap the breaker first to OFF position then to ON Silicon Controlled Rectifier A device for tripping a circuit breaker indirectly using a signal to activate a sole noid instead of directly because of an overcurrent condition A circuit breaker in an open position as a result of an overcurrent condition to the load or as the result of a remote trip command shunttrip In a tripped condition power tothe load is off The tripped circuit breaker
33. dical Power PC 9 Route REPO cable up through opening in floor as applicable and into conduit entry opening 10 Locate the two terminal REPO terminal block the Medical Power 11 Connect the 2 wires in REPO cable to REPO terminal block See Illustration 4 2 12 Replace floor tiles as required 13 Set IMCB to ON 14 Close front door of Medical Power PC 15 Set main facility circuit breaker to ON REPO SWITCH 5 28 SHUNT TRIP REPO WIRING ILLUSTRATION 4 2 Crucial Power Products REVA 4 3 THERMAL REMOTE EMERGENCY POWER OFF STATION The Thermal REPO is a wall mounted unit that functions as a dual temperature warning and shutdown monitor The first and second stage over temperature settings are field selectable The Thermal REPO provides a contact closure and a unit shutdown interface for the second stage over temperature response In addi for the first stage alarm tion the Thermal REPO displays the ambient temperature on a 3 digit display The Thermal REPO stat ion is designed to be vertically mounted at eye level or slightly lower It can be located any where an emergency shut off is required The Thermal is provided with a 50 foot 15 m three conductor cable Longer cables are available in five foot increments up to 100 feet 30 m Thermal REPO Specifications e Temperature range e Dimensions e Weight 4 3 1 Installation for The
34. dified and or used for any application other than for that which it was designed Optional equipment not described in the sales literature of this manual should not be installed without first checking with the Service department you have any questions about this unit s application call the Service department at the number shown on the previous page IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the unit and batteries Crucial Power Products IMPORTANT SAFEGUARDS When using electrical equipment basic safety precautions should always be followed including the following READ AND FOLLOW ALL SAFETY INSTRUCTIONS 1 Do not use outdoors 2 Do not mount near gas or electric heaters 3 Use caution when servicing batteries Battery acid can cause burns to skin and eyes If acid is spilled on skin or in eyes flush acid with fresh water and contact a physician immediately 4 Equipment should be mounted in locations or at heights where it will not readily be subjected tampering by unauthorized personnel 5 The use of accessory equipment not recommended by the manufacture may cause an unsafe condition 6 Donotuse this equipment for other than intended use SAVE THESE INSTRUCTIONS Crucial Power Products REVA REVISION HISTORY REV DATE PRIMARY REASON FOR CHANGE Ass July 25 2003 Preliminary Release LIST OF E
35. e wires to the terminal block Replace floor tiles as required Close front panel of Medical Power PC Set IMCB to ON Close front door of Medical Power PC Set main facility circuit breaker to ON Crucial Power Products REVA 4 4 SURGE PROTECTION The Secondary Surge Suppression circuit consists of a special output filter comprising fuse protected metal oxide varistors and indicator lights This option is designed to reduce the effect of load induced electrical noise on other electronics such as connected loads In addition the secondary surge suppression circuit prevents electronic and electromechanical devices from interfering with each other The characteristics of the filter assembly are as follows e Parallel shunt operation e Response time of less than five nanoseconds e Repetitive transient to 5 000 volts per second e Clamping voltage 208Y 120 Ratio 1 2 144 Vac line to neutral 364 Vac line to line Ratio 1 75 210 Vac line to neutral 364 Vac line to line Peak pulse power rating 27 kW line to neutral 13 4 kW line to line e Fused for circuit protection with visual blown fuse indicators per phase The secondary surge suppression circuit is factory installed at the time of production No assembly or adjustments are required 4 5 MAIN INPUT CIRCUIT BREAKER Phase Stabilizer 15 75 kVA The optional MAIN INPUT CIRCUIT BREAKER IMCB is used to switch power to the Phase Stabilizer unit ON and OFF
36. er the power LED has turned on If no LED is lit or if two or more LEDs are lit immediately turn facility circuit breaker OFF or turn IMCB to OFF if installed The regulator can be placed on manual operation for emergency service See Section 1 7 2 If only one LED 1 through 6 is lit perform the following calibration PROCEDURE 1 Turn connected load OFF 2 facility circuit breaker OFF lock and tagout in accordance with Lockout Tagout requirements 3 OpenLife Line Regulators Medical Power PC 100 300 kVA as follows a Remove front panel by unbolting six screws at corners and left and right sides of each panel 4 Open Medical Power 15 75 kVA as follows a Open front door b Set IMCB to OFF as applicable c Open hinged front panel by unbolting three screws at left side of panel Swing panel to right 5 Unlock facility circuit breaker and turn ON 6 Set IMCB to ON as applicable 7 Turn connected load ON Crucial Power Products REVA 3 1 9 Calibrate Control Logic Board continued FATAL SHOCK HAZARD LETHAL VOLTAGES EXIST WITHIN THE UNIT DUR ING THE FOLLOWING CHECK FOLLOW THE STEPS BELOW EXACTLY FAIL URE TO DO SO COULD RESULT IN SEVERE INJURY OR DEATH 8 Make the following adjustments on the Control logic board for phase A See Illustration 3 1 a b Measure AC voltage across R1 or R2 Voltage should be between 10 and 100mv Measure DC voltage across C42 Ad
37. f Power Island Open hinged front panel by unbolting the three screws on the left side of panel and swinging panelto the right Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel Remove floor tiles as required Route output cable between equipment to be powered and Power Island Pass output cable through floor opening and up into cable landing bracket Secure conduit fitting to landing bracket Install noninsulated bushings on all conduits and flexes Route and connect the 1 to 3 power wires to output circuit breaker Route and connect the ground wire to the ground bus See Illustration 4 7 for location of ground bus Route and connect the neutral wire to the neutral bus See Illustration 4 7 for location of neutral bus Replace rear panel Replace hinged front panel Crucial Power Products REV APPENDIX A SPECIFICATIONS TABLE A 1 SPECIFICATIONS LIFE LINE REGULATOR NOMINAL INPUT VOLTAGE INPUT VOLTAGE RANGE MAXIMUM INPUT VOLTAGE 208 VAC 480 VAC 154 229 355 528 NOMINAL RATED CURRENT See Table 2 1 FREQUENCY Hz OUTPUT VOLTAGE REGULATION 396 Typical 496 Maximum LINE TO LINE VARIATION RESPONSE TIME LESS THAN 296 1 Cycle Typical FILTERS INPUT YES OUTPUT Optional COOLING REQUIREMENT BTU hr See Table 2 1 WEIGHT Ibs kg estimated OUTPUT VOLTAGE See Table 2 1 208Y120 VAC or 480Y277 VAC 15 30 50 75 10
38. gulation of AC power zero current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between 1096 surge and 2696 sag about the nominal rated voltage with an output voltage range of 396 typical to 496 maximum Each phase is regulated independently The Life Line Regulators are available in input voltages of 208 or 480 VAC and output voltages of 208Y 120 and 480Y 277 VAC These units are available in sizes ranging from 15 kVA to 300 kVA The specific rating information for your unit is provided on the label plate located on the front panel Refer to Appendix A The Life Line Regulators unit is shown in Illustration 1 2 a THe LIFE LINE REGULATORS AND MEDICAL POWER 100 300 WITH 208 VAC INPUT OR 125 300 KVA WITH 480 VAC INPUT ILLUSTRATION 1 2 Crucial Power Products REVA 1 1 2 Medical Power PC The Medical Power PC power conditioner is designed to provide the reliable high quality power necessary to suit the needs of today s sensitive medical devices This three phase 60 Hertz self contained modular unit provides isolation and regulation of AC power The zero current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between 896 surge and 10 sag about the nominal rated voltage with an output voltage range of 1 5 typical to 2 maximum Each phase is regulated independently The Medical Power PC is avai
39. ical Power 100 300 kVA 9100 006 01 INPUT OUTPUT FILTER ASSY 1690 012 SCRs 1625 012 01 Snubber PCB 1625 002 01 Driver PCB 1400 001A 1400 003 Ref Transformer 2025 002 Fuse Ref Transformer input 1625 003 02 Control Logic PCB 1680 021 Bypass Switch Crucial Power Products REV A 3 5 1 Vendor Parts List Medical Power PC 100 300 kVA Vendor No Vendor Description Remarks 1680 017 Crucial Power SWITCH BYPASS 1 USED 1425 007 Crucial Power TRANSFORMER CURRENT 200 5 3 USED Note 1 1425 005 Crucial Power TRANSFORMER CURRENT 300 5 3 USED Note 1 1425 002 Crucial Power TRANSFORMER CURRENT 400 5 3 USED Note 1 1690 012 Crucial Power SCR 100 175 KVA MODEL 18 USED 1690 011 Crucial Power SCR 200 300 KVA MODEL 18 USED 1625 012 01 Crucial Power SNUBBER SCR 100 300 KVA MODEL 18 USED 1625 002 01 Crucial Power PCB SCR DRIVER 3 USED 121543003 02 Crucial Power SNUBBER SCR 200 300 KVA MODEL 18 USED 1400 001 Crucial Power TRANSFORMER REFERENCE 208 V PRI 4 USED Note 2 1400 003 Crucial Power TRANSFORMER REFERENCE 480 V PRI 6 USED Note 2 9100 006 01 Crucial Power INPUT OUTPUT FILTER ASSY 1 USED not shown NOTES 1 For current transformer vendor numbers refer to Table 3 3 2 Reference transformer vendor numbers For 208 V input use 1400 001A For 480 V input use 1400 003 TABLE 3 3 MEDICAL POWER PC 100 300 KVA CURRENT TRANSFORMERS
40. just R62 until voltage reads 8 5 VDC with a load of 1 kw for 50 kVA or less and 2 kw load for 75 kVA or larger Note Potentiometer R62 is a 30 turn pot It may require several turns before output level changes Adjust R39 counter clockwise until LED 6 is lit See Illustration 3 1 and Illustration 3 2 Measure DC voltage across C42 Adjust R62 until voltage reads 8 5 V Measure neutral to phase A output voltage between transformer terminals X1 and XO Refer to Appendix B for transformer terminal configuration Adjust R39 until output voltage reads 120V or 277V phase to neutral depending on rated output voltage Output voltage should be 396 of nominal for Life Line Regulators Output voltage should be 296 of nominal for Medical Power PC Note Output voltage does not change linearly as potentiometer R39 is rotated Output voltage does a step change Pot R39 is a 30 turn pot It may require several turns before output level changes Repeat the procedure on the phase B and phase C Control logic boards Take voltage measurements between transformer terminals X2 and and between X3 and respectively for phase B and C Crucial Power Products REV CR29 OR E Ar e C18 CED 615 R2 C42 CONTROL LOGIC BOARD ILLUSTRATION 3 1 Crucial Power Products REV
41. lable in input voltages of 208 or 480 VAC and output voltages of 208Y 120 and 480Y 277 VAC This unitis available in sizes ranging from 15 kVA to 300 kVA The specific rating information for your unit is provided on the label plate located on the front panel Refer to Appendix A The 15to 100 kVA Medical Power PC with 480 VAC or the 15 75 kVA with 208 VAC is shown in Illustration 1 3 The 125 to 300 kVA Medical Power PC with 480 VAC input or the 100 300 kVA with 208 input is shown Illustration 1 2 V MEDICAL POWER PC 15 100 KVA FOR 480 VAC INPUT 15 75 FOR 208 INPUT ILLUSTRATION 1 3 Crucial Power Products REVA 1 2 BENEFITS The Life Line Regulators and Medical Power PC protect electronic equipment from an overvoltage condition during line power surges and an undervoltage condition during sags In addition the unit protects equipment load by attenuating transients present on utility power lines overvoltage overcurrent and transient conditions stress elec tronic components and decrease system reliability In medical applications voltage fluctuations affect the image quality of imaging systems Artifacts are introduced under sag conditions Regulating power maintains image quality resulting in more consistent images 1 3 TRANSFORMER The transformer contained in the unit is designed for convection cooling by means of free circulation of air through the bottom front and back ofthe unit Maximum
42. les prior to installation Because the Power Island is a stand alone unit it can be placed as close to the load as possible The following Illustrations are provided to aid in determining cable access floor layout and service clearances See Illustrations 4 8 4 9 and 4 10 1 1 34 34 86 86 16 16 41 41 24 26 DENN s 10 zA 12 61cm 66cm 25cm 30cm REAR VIEW BOTTOM VIEW REAR VIEW BOTTOM VIEW Power Island 84 Power Island 42 POWER ISLAND CABLE ACCESS ILLUSTRATION 4 8 Crucial Power Products REVA 4 7 3 Preinstallation continued 10 25 14 36cm FLOOR TILE CUTOUT UNIT FOOTPRINT POWER ISLAND FLOOR TILE CUTOUT ILLUSTRATION 4 9 18 46cm 70 178 1 zem FRONT DOOR FULLY OPEN Power Island 84 29 5 75cm FRONT DOOR FULLY OPEN POWER ISLAND DIMENSIONS AND CLEARANCES ILLUSTRATION 4 10 14 36cm Zi md 56 142cm 15 5 L 39cm Power Island 42 Crucial Power Products REVA 4 7 4 Input Interconnect Cable Installation An optional 225 amp or 450 amp Output Interconnect Cable is available to connect the Power Island to the Medi cal Power PC or Life Line Regulator This cable is specified in 5 foot increments to a maximum of 50 feet 15 m The following inst
43. nd removing the screw to the top and swinging panel to the right 5 Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel VERIFY THAT INCOMING HIGH VOLTAGE CIRCUITS ARE DE ENERGIZED BEFORE CONTINUING WITH THIS PROCEDURE 6 Punch or drill holes in left side panel to accomodate input cable 7 Route and connect the 3 power wires to input power terminals labelled L1 L2 and L3 See Illustration 1 5 8 Route and connect the ground wire to the ground lug on the cabinet 9 Proceed to Section 3 1 6 to install output cable Crucial Power Products REV 3 1 6 Output Cable Installation Medical Power 15 100 The customer furnished output power cable provides power from the unit to a connected load or to a Power Island when distribution to more than one connected load is required This cable should be installed through the right side panel No holes are provided in the panel A hole can be sized located and drilled or punched when the cable is installed Procedure 1 Turn OFF facility circuit breaker lock and tagout according to OSHA requirements 2 Open front door 3 Verify that the Main Input Circuit Breaker is set to OFF as applicable 4 the top panel by removing the screw from the front panel and lift the top panel to it s up position 5 Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel
44. position differs from the off posi tion in that the breaker must first be turned to the off position before restoring power to the load Terminal Block
45. r through the right side of the Phase Stabilizer e Life Line Regulators Phase Stabilizer 100 300 kVA Remove top cover by unbolting two bolts on each side of cover Remove front panel by unbolting six bolts 11 Route Output Interconnect Cable up through floor opening as applicable and into conduit entry opening 12 Connect the grounding conductor to the ground bus in the Medical Power PC or Life Line Regulator 18 Connect the power conductors to the Output Power Terminal Block in the Medical Power PC or Voltage Regulator 4 7 5 Output Cable Installation The following instructions cover installation of the Output Cables between the connected loads and the Power Island Note The equipment to be connected to the Power Island may require special grounding procedures Refer to technical documentation which accompanies that equipment Procedure 1 Turn OFF facility circuit breaker to Medical Power PC or Life Line Regulator lock and tagout according to requirements 2 Open front door of Power Island 3 Verify that IMCB is set to OFF 4 that all output circuit breakers are set to OFF Crucial Power Products REVA 4 7 5 Output Cable Installation continued 10 11 12 13 14 15 16 POTENTIAL ELECTRICAL HAZARDS TO HUMAN LIFE EXIST WITHIN THIS EQUIPMENT WHEN ENERGIZED DISCONNECT INPUT POWER TO UNIT BE FORE OPENING ENCLOSURE OR TOUCHING INTERNAL PARTS Open front door o
46. rmal The Thermal REPO cable will be 50 to 100 feet 15 30 m long depending on length ordered The cable is supplied with bare wires on the both ends The bare wire ends connect to the terminals inside the Thermal REPO enclosure TWO STAGE THERMO REPO SWITCH WHITE GND A X Back A RED V SHUNT TRIP 5 JUMPER 1 8 12 THERMAL WIRING ILLUSTRATION 4 3 Crucial Power Products REVA 4 3 1 Installation for Thermal REPO continued Note The Thermal REPO is shipped with separate operating instructions Procedure 1 2 Select the location for the Thermal REPO box Remove Thermal REPO box cover Mount Thermal REPO box on wall or other structure using mounting holes located in the back of Thermal REPO enclosure Use fasteners that are appropriate for the surface on which the Thermal REPO box is to be mounted Connect three wires in Thermal REPO cable to terminals on Thermal REPO switch as shown in Illustration 4 3 Turn OFF main facility circuit breaker lock and tagout in accordance with OSHA requirements Open front door of Medical Power PC Set IMCB to OFF Route Thermal REPO cable from Thermal REPO box to Medical Power PC Remove floor tiles as required Open front panel of Medical Power PC Route Thermal REPO cable up through opening in floor as applicable and into conduit entry opening Locate terminal block on the Medical Power PC Connect the thre
47. ructions cover installation of the Input Interconnect Cable to the Medical Power PC or Life Line Regulator If a Power Island 84 is being installed two input interconnect cables are required Procedure 1 Turn OFF main facility circuit breaker to Medical Power PC or Life Line Regulators lock and tagout in accor dance with OSHA requirements 2 Open front door of Power Island POTENTIAL ELECTRICAL HAZARDS TO HUMAN LIFE EXIST WITHIN THIS EQUIPMENT WHEN ENERGIZED DISCONNECT INPUT POWER TO UNIT BE FORE OPENING ENCLOSURE OR TOUCHING INTERNAL PARTS 3 Verify that IMCB is set to OFF 4 Verify that all output circuit breakers are set to OFF 5 Remove front panel of Power Island 6 Remove floor tiles as required and route Input Interconnect Cable between Power Island and Medical Power PC or Life Line Regulator 7 Route Input Interconnect Cable up through floor opening as applicable and into Main Input Conduit Landing Bracket 8 Connect the grounding conductor to the ground bus in the Power Island 9 Connect the power conductors to the Input Main Circuit Breaker located at the top of the panelboard in the Power Island Crucial Power Products REVA 4 7 4 Output Interconnect Cable Installation continued 10 Access the interior of Medical Power PC or Life Line Regulator as follows a b e Phase Stabilizer 15 75 kVA Raise hinged lid The Power Island Interconnect cable can be routed through the bottom o
48. s agree with the values listed on the label plate located on the front panel and in Appendix A e f output voltage readings are out of specification refer to Section 3 1 9 Calibrate Control Logic Board otherwise continue to next step Turn OFF power to connected load Turn OFF facility circuit breaker lock and tagout according to OSHA requirements 3 7 Crucial Power Products REV 3 1 7 Startup Life Line Regulators and Medical Power 100 300 kVA continued 10 Replace front panel 11 Unlock and turn ON power to facility circuit breaker The unit is ready for service 3 1 8 Startup Medical Power PC 15 100 kVA After connecting the input and output cables and before placing the unit in service verify the output voltage using the following procedure Tools Required e Phase Rotation Meter e Voltage meter PROCEDURE 1 Verify that connected load is OFF 2 Turn OFF facility circuit breaker lock and tagout according to OSHA requirements FATAL ELECTRIC SHOCK HAZARD TO PREVENT FATAL ELECTRIC SHOCK DISCONNECT POWER FROM UNIT AND LOCK OFF BEFORE YOU PERFORM THE FOLLOWING PROCEDURE 3 Open front door FATAL SHOCK HAZARD LETHAL VOLTAGES EXIST WITHIN THE UNIT DUR ING THE FOLLOWING CHECK FOLLOW THE STEPS BELOW EXACTLY FAIL URE TO DO SO COULD RESULT IN SEVERE INJURY OR DEATH Crucial Power Products REV A 3 1 8 Startup Medical Power PC 15 100 kVA continued 4 5 10
49. s as defined in Illustrations 2 3 and 2 4 This unit is air cooled by convection Do not block air flow from the front rear or bottom of the unit Crucial Power Products REVA TABLE 2 1 Line Line Regulators SITE PLANNING SPECIFICATIONS NOMINAL INPUT VOLTAGE Hat INPUT VOLTAGE RANGE 154 229 MAXIMUM INPUT VOLTAGE 088 FREQUENCY Hz AMBIENT TEMPERATURE F 80 26 7 INPUT NOMINAL COOLING WEIGHT Ibs kg SIZE H x W x Din cm SIZE VOLTAGE RATED BTU hr CURRENT WITHOUT PACKAGING 15 2040 400 181 107 X67 x49 IE paese 6800 700 318 em e Exec 1400 635 2000 907 1500 680 30600 m n 1021 66 50 5 32 34000 40800 1500 680 Crucial Power Products REVA TABLE 2 2 MEDICAL POWER PC SITE PLANNING SPECIFICATIONS NOMINAL INPUT VOLTAGE Lo INPUT VOLTAGE RANGE MAXIMUM INPUT VOLTAGE ee AMBIENT TEMPERATURE F C NOMINAL SIZE H x Wx D in INPUT COOLING SIZE VOLTAGE RATED BTU hr CURRENT WITHOUT PACKAGING 2040 400 181 7 42 X 32 X 22 4080 500 227 MOT BI X B6 189 6800 700 318 10200 900 408 dor KO 55 1300 590 66 50 5 32 168 127 81 1150 522 42 X 32 X 22 107 X 81 X 56 1400 635 66 X 50 5 X 32 168 X 128 X 81 17000 fp 1200 544 51 5 X 40 5 X 26 5 131 X 103 X 67 28 46 1550 703 66 X 50 5 X 32 168 X 128 X 81 20400 48 1804 1250 567 51 5
50. shunt trip is available Be sure to observe ALL warnings and cautions when setting the IMCB to ON or OFF 1 4 3 Power On Indicators Power On Indicators are located on the front of the unit See Illustration 1 5 There is one neon indicating light for each ofthethree phases Ifa phase is lost the corresponding indicator will extinguish indicating which phase is not powered 1 4 4 Input and Output Power Terminals Input and Output power connections are made at the terminals located beneath the transformer except the illustra tion 1 5 where the terminals are located above and to the rear ofthe main transformer See Illustration 1 4 Termi nals are labeled H1 H2 H3 or L1 L2 L3 for the input cable connections and XO X1 X2 X3 for the output cable connections Crucial Power Products REVA 1 4 5 Input Filter The Input filter is installed on the primary side of the transformer The input filter consists of a resistor capacitor network which acts as a large snubber circuit to eliminate high frequency impulses from entering the power system See Illustration 1 8 INPUT FILTER WIRING ILLUSTRATION 1 8 1 4 6 Output Filter The Output filter is installed on the transformer secondary It consists of a capacitor network which prevents noise from being fed back to the unit from noise generating loads See Illustration 1 9 Output filters are standard on the Medical Power PC and optional on other models OUTPUT FILTER WIRING
51. y and specifically selected to achieve the highest level of performance These units are UL listed and conform to National Electric Code NEC and Occupational Safety and Health Act OSHA standards The Life Line regulators and Medical Grade PC have tapped electronic voltage regulators Six taps are on each primary winding of the transformer Each tap is controlled by a silicon controlled rectifier SCR switch and can become active at any time Input line to line voltage and line current are monitored for each phase Peak voltage is compared with a desired reference Depending on this comparison the regulation logic activates the proper SCR switch when the phase current becomes zero This changes the primary to secondary turns ratio which corrects output voltage to the desired nominal The correction process starts in less than one cycle See Illustration 1 1 500 480 420 7290 INPUT CORRECTED CORRECTEDN 1 CYCLE IN 1 CYCLE 480 480 OUTPUT Life Line Regulators REGULATED TO 3 OF NOMINAL TYPICAL Medical Power PC REGULATED TO 2 OF NOMINAL TYPICAL REGULATED SYSTEM RESPONSE ILLUSTRATION 1 1 Crucial Power Products REVA 1 1 1 Life Line Regulators The Life Line Regulators are designed to provide the reliable high quality power necessary to meet the needs of today s sensitive electronics These three phase 60 Hertz self contained modular units provide isolation and re
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