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Liebert 1500 User's Manual

1. q IY q Ey SS AG e 2 O 5 q C q gt caer q Di O O 20 Specifications Figure 20 Front view of the MPA100 power shelf shown empty 3 6 2 Electrical Specifications of the Power Shelves Each rectifier position provides interconnection points for AC input 208 to 240 V nominal DC output 48 V nominal and control and alarm signals 3 7 Rectifiers The Helios system 4000 48 can be equipped with Helios Rectifiers 100 48 for single phase 208 240 V AC operation with Helios Rectifiers 2001 48 for three phase 380 415 V AC operation or with Helios Rectifiers 200E 48 for three phase 480 V AC operation 3 7 1 Helios Rectifier 100 48 Mechanical specifications of the Helios Rectifier
2. gt lt 00 00 o O a Aux dist cabinets Main cabinet 1200 A rectifier cabinets Cables are used for inter cabinet connections 1500 3000 and 6000 A systems or connections to the overhead busbars 6000 system for ease of expansion on live systems In a 1500 3000 or 4000 A systems the power system battery return BR busbar is mounted externally from the cab inet to facilitate the connections of the battery return cables In a 6000 A system a separate BR busbar dedicated to the battery returns for the loads is mounted externally from the overhead busbar duct to facilitate the connections of the load battery return cables The Helios DC System 4000 48 provides a variety of monitoring and alarm features such as high low float and high low voltage alarm high voltage shutdown fuse and breaker alarm and rectifier failure alarms The Helios DC System 4000 48 uses Helios Rectifiers 2001 48 Helios Rectifiers 200E 48 or Helios
3. 8 Front view of the 16 QFF 0 5 A amp 12 ABS 5 30 A fuse 1 9 Front view of the 16 QFF 0 5 A amp 6 TPN 5 30 A fuse 1 9 Front view of the 8 TPN 5 30 A fuse 1 10 Front view of the 4 RS100P 70 100 A fuse 1 10 Front view of the 4 CRS200P 150 200 A 4 CRS200P 150 200 A w load shunts fuse 1 11 Front view of the 4 TPL 225 600 A fuse 1 11 Front view of the 18 TPS 1 70 A fuse 1 12 Front view of the 24 Plug In 1 100 A circuit breaker panel 14 Front view of the 4 70 250 A circuit breaker 1 15 Front view of the 2 400 A circuit breaker 1 16 Front view of the 1 600 700 A circuit breaker 1 16 Top and side views of the external battery return 18 Perspective view of the a terminating assemblies 19 Front view of the MPS300 power shelf shown empty 20 Front view of the MPA100 power shelf Shown 21 Front view of the Helios Recti
4. The DC output connections are 0 375 16 studs equipped with two hex nuts Table 11 Fuse sizes available for the 4 RS100P 70 100 A fuse panels Fuse type Current A CPC 70 A0722046 80 A0722045 HRC1 K 90 A0722044 100 A0722049 10 Specifications Figure 10 Front view of the 4 CRS200P 150 200 A 4 CRS200P 150 200 A w load shunts fuse panels O ALM o O d C M 7 f EAS 1 2 3 4 E A Nu M ia y 4 O 3 The DC output connections are 0 50 13 studs equipped with two hex nuts Table 12 shunts fuse panels Fuse type Current A CPC 110 A0329697 125 A0329696 HRC1 J 150 A0722041 175 A0722038 200 A0614832 Figure 11 Front view of the 4 TPL 225 600 A fuse panels Fuse sizes available for the 4 CRS200P 150 200 A 4 CRS200P 150 200 A w load O 48 V om a eoo olo m 4 1o i s p fs wq zu uw A FA e ALM ALM a SS AO jJ SO N E V E P A e p MB e 0 E e QJ LO 2J 2 The DC output connections are busbar angles that can accept 535MCM or 750MCM cables or the metric equivalent The lugs must be for t
5. 22 Specifications Figure 22 Front view of the Helios Rectifiers 2001 48 and 200E 48 EQL 9 0 n O TRIO m OO iso w A STUP DLY SLs 0 CC DC N RTEL Specifications 23 3 7 3 Electrical Specifications of the Helios Rectifiers 2001 48 and 200E 48 Table 27 The electrical specifications of the Helios Rectifiers 2001 48 and 200E 48 are listed in Table 27 Electrical specifications of the Helios Rectifiers 2001 48 and 200E 48 Parameter Input voltage Specification Helios Rectifier 2001 48 380 415 V AC three phase 47 63 Hz Input voltage range 330 to 475 V AC Helios Rectifier 200E 48 480 V AC three phase 47 63 Hz Input voltage range 430 to 520 V AC Input current Helios Rectifier 2001 48 18 3 A RMS nominal at 380 V AC input and 54 V DC 200A output 24 A RMS worst case Helios Rectifier 200E 48 15 A RMS nominal at 480 V AC input and 54 V DC 200A output 17 A RMS worst case Input protection A 3 pole 25 A circuit breaker opens all three lines Recommended AC service input 30 A 3 pole AC circuit breaker Output voltage Float 46 to 58 V DC Equalize O to 4 V DC above Float Maximum 60 V DC Output current 200 A nominal Adjustable between 100 and 210 A Output protection The rectifier is protected by a 250 A circuit
6. ooooooooooo eer 13 Externally Mounted Battery Return Busbar 18 3 4 4 Mechanical Specifications of the External Battery Return Busbar 18 3 4 2 Electrical Specifications of the External Battery Return Busbar 18 Terminating Assemblies 19 MPS300 MPA100 Power 20 3 6 1 Mechanical Specifications of the MPS300 and MPA100 Power Shelves 20 3 6 2 Electrical Specifications of the Power 1 21 ien RPM 21 3 7 1 Helios Rectifier 100 48 a rs 21 3 7 2 Helios Rectifiers 2001 48 and 200 48 22 3 7 8 Electrical Specifications of the Helios Rectifiers 2001 48 and 200E 48 24 BGA a crt CR ea eU dt eae antri Tord ES E NRO 24 Helios Monitor 3000 48 Optional 25 3 81 Mechanical 8 rs 25 3 8 2 Electrical Specifications 25 600 A and 1200 A Battery Disconnect Unit Optional 25 A ose b Pr eO US P ds tte n ORT EA a V ete PRIN 26 3 10 1 Mechanical Specifications 26 3 10 2 Electrical Specifications 26 3 11 4
7. 24 Specifications 3 8 3 8 1 Helios Monitor 3000 48 Optional Mechanical Specifications The mechanical specifications of the Helios Monitor 3000 48 are listed in Table 28 Table 28 Mechanical specifications of the Helios Monitor 3000 48 Figure Height Depth Width Weight Figure 23 45 mm 222 mm 280 mm 2 8 kg 1 75 in 8 75 in 11 0 in 6 2 Ib The above dimensions are without the mounting brackets The weight may vary slightly depend ing on the number and type of analog interface modules installed in the unit Figure 23 Front view of the Helios Monitor 3000 48 without the mounting brackets 3 8 2 3 9 UNIT ADRESS gt MODE SELECTION 4 PARAMETER SELECTION HELIOS Monitor 3000 48 LED INDICATOR ROTARY SWITCHES 12 DIGIT ALPHA NUMERIC DISPLAY 4 PUSH BUTTON KEYPAD Electrical Specifications The input voltage of the Helios Monitor 3000 48 is 48 V DC nominal with a range of 42 V DC to 60 V DC The input current drain is 400 mA This current drain may vary slightly depending upon the number and type of analog interface modules installed in the unit For more detailed electrical specifications of the Helios Monitor 3000 48 refer to the appropriate user manual listed in 6 0 Reference Documents 600 A and 1200 A Battery Disconnect Unit Optional The Battery Disconnect Units are 11 inches high and provides for 500 mm 19 in or 600 mm 23 in framework mounting or
8. If an Helios Monitor 3000 48 was supplied with your system refer to the Monitor 3000 user man ual SL 60015 for detailed operational characteristics 600 A and 1200 Battery Disconnect Units Optional The 600 A and 1200 A Battery Disconnect Units BDU are equipped with a circuit breaker that provides for automatic or manual disconnect but only manual reconnect The automatic discon nect is intended to serve the low voltage disconnect function to prevent batteries from deep dis charge that could damage them The circuit breaker has industrial grade contacts to connect and disconnect large currents and it is provided with a relay trip feature If battery disconnect unit s were supplied with your system refer to the user manual SL 60040 for the detailed operational characteristics of the battery disconnect unit 36 Operation 5 0 MAINTENANCE 5 1 General The following is a list of general preventive maintenance procedures which should be performed periodically as required according to the environmental conditions and customer maintenance policy to ensure trouble free operation of the Helios DC System 4000 48 clean all ventilation openings if these are used clean or replace the air filters on the rectifiers tighten all electrical connections check for hot fuses or breakers loose undersized or overloaded verify alarms and alarm thresholds verify calibration settings verify rectifier settings T
9. 77 0 lb Note 1 An alarm circuit pack with an alarm indication LED is standard on all panels Note 2 4 CRS200P 150 200 A w load shunts is equipped with four shunts Figure5 Front view of the 20 QFF 0 5 A fuse panels The DC output connections are wire wrap or solder Table 7 Fuse sizes available for the 20 QFF 0 5 A fuse panels Fuse type Current A CPC QFF1A 1 333 A0205202 QFF1B 2 A0205203 QFF1C 3 A0205204 QFF1D 5 A0205205 QFF1E 0 18 A0205206 QFF1F 0 25 A0205207 QFF1G 0 5 A0205208 QFF1H 0 75 A0205209 QFF3A DUMMY A0205210 8 Specifications Figure6 Front view of the 16 QFF 0 5 A amp 12 ABS 5 30 A fuse panels O ev ni ni TIT Ei 0 The DC output connections are No 8 32 studs equipped with two hex nuts Table 8 Fuse sizes available for the 16 QFF 0 5 A amp 12 ABS 5 30 A fuse panels Fuse type Current A CPC 5 A0327000 8 A0111415 10 A0315462 4AB ABS 12 A0267003 15 A0344157 20 A0314873 25 A0243206 30 A0328460
10. It is available in capacities of 1500 3000 4000 and 6000 A Auxiliary distribution cabinets can be added as required for addi tional distribution Remote monitoring temperature compensation and battery disconnect options are also available The 1500 3000 and 4000 A versions use internal 48 V bussing and external BR bussing while the 6000 version uses overhead bussing Figure 1 shows a typical bottom fed 4000 A system while Figure 2 shows a typical 6000 system Figure1 Front view of a typical bottom fed 4000 A Helios DC System 4000 48 power system In 0 Inn mo mo mo 17 t UIT LT El n LI B i 0000001 0000 wa i EOL AE E MAE 3 p Jp i GE D4 T E le E A 1 e al b b e oe o aAA D ale fit FEDERE a
11. Nominal current CPC 400 A no shunt P0748316 400 A with shunt P0748317 2 x 400 A no shunt P0748318 2 x 400 A with shunt P0748319 400 A with relay trip P0748320 The panel accepts up to two breakers 400 mid trip with or without the metering shunt option one breaker 400 A mid trip with the relay trip option takes a 3 pole space Figure 16 Front view of the 1 600 700 A circuit breaker panel o CIRCUIT BREAKER PANEL 900A MAX PANEL CAPACITY 4 s 1 600 700 A o ME e O FA REL SERNO 5 FUNIT 1 cu AMPS 600 s LOAD o _ 2 o o O O The DC output connections can accommodate four 750 MCM cables back to back The lugs must be for two 1 2 bolts at 1 3 4 c c Refer to Table 21 for the available circuit breakers and the maximum panel capacity Table 20 Circuit breaker kits available for the 1 600 700 A circuit breaker panel Nominal current CPC 600 A no shunt P0875700 600 A e w shunt P0875701 600 A e w relay trip P0875702 16 Specifications Electrical specifications of the circuit breaker panels The electrical specifications of the circuit breaker panels are described in Table 21 Table 21 Electrical specifications of the circuit breaker panels Circuit breakers Panel description Busbar Figure Max Quantity
12. Replace a cabinet alarm lamp as described below QU G9 BO ES Remove the LP fuse on the controller F31 Unscrew and remove the lens cap on the cabinet alarm lamp unit Pull the defective light bulb out Insert the new light bulb Screw back the lens cap on the cabinet alarm lamp unit Reinstall the LP fuse on the controller F31 removed in Step 1 48 Maintenance 6 0 REFERENCE DOCUMENTS Manual No Description SL 60040 600 A and 1200 A Battery Disconnect Unit SL 60014 TCM48 temperature compensation module SL 60026 Voltage level limits for rectifiers and controllers SL 60015 Helios Monitor 3000 48 remote surveillance unit SL 60033 Helios DC System 4000 48 Installation manual SL 60012 Helios Rectifier 100 48 SL 60036 Helios Rectifier 2001 48 SL 60037 Helios Rectifier 200E 48 Reference Documents 49 7 0 LIST OF TERMS A ampere ABS alarm battery supply ABSF alarm battery supply fuse AC or ac alternating current ACO alarm cut off AD Assembly drawing ADJ adjust or adjustment ALM alarm AMP ampere AUD audible AUX auxiliary AWG American wire gauging BAT battery BAT RTN battery return BDA battery disconnect alarm BDU battery disconnect unit BMU battery management unit BOD battery on discharge BODA battery on
13. The rectifiers contain aluminum electrolytic capacitors For this reason they shall be either kept in operation or energized once a year for at least two hours in order to maintain the electrolytic capacitors in good condition Maintenance 37 Air filter replacement In dusty environments the use of an air filter is strongly recommended When used it should be replaced at least once a year Do not install a wet filter on a rectifier To remove the filter simply unscrew it Install the new one by reversing the operation Contact your local Liebert representa tive for ordering information on air filters Fan unit replacement Visually inspect the airflow intake for any obstruction by foreign objects or excessive dust and dirt build up Open both AC and DC breakers If the rectifier is a Helios Rectifier 100 48 remove it from the power shelf Inspect the air outlet for obstruction by foreign objects Visually inspect the air outlet of the power shelf Helios Rectifier 100 48 or the cabinet Helios Rectifiers 2001 48 and 200E 48 The fan unit is field replaceable Contact your local Liebert representative for ordering information on replacement fans To install a new fan unit refer to the appropriate procedure and associated figures in the maintenance chapter of the applicable rectifier user manual listed in 6 0 Reference Documents If a problem is detected inside the rectifier contact Liebert Glo bal Services at 1 800 LIEBERT Do no
14. VR Power plant 48V busbars GRD ONOaABRWN Connectors Twenty six connectors to interface with external equipment as follows P1 to P24 signaling between the controller and the rectifiers P25 interface with the main power system shunt P26 interface with an AC monitoring device Refer to Figure 31 for the pin assignment of connectors P1 to P26 Eight connectors J1 to J8 for the interface between the two circuit boards of the controller for factory use only 4 3 MPS300 and MPA100 Power Shelves The MPS300 power shelf provides the interconnecting points for all the AC DC and control cabling and wiring for three Helios Rectifier 100 48 The MPA100 power shelf does the same for one Helios Rectifier 100 48 Refer to the appropriate rectifier user manual listed in 6 0 Reference Documents for detailed operation information on the MPS300 and MPA100 power shelves 34 Operation 4 4 4 5 4 6 4 7 Rectifiers The rectifiers provide isolated filtered and regulated DC power from either a single phase AC source Helios Rectifier 100 48 or a three phase AC source Helios Rectifier 2001 48 or 200E 48 for charging a positive grounded battery The nominal output is adjustable over the range of 46 to 59 5 V to float a 23 or 24 cell battery string The rectifiers are equipped with AC input and DC output circuit breakers a digital ammeter potentiometers for the adjustment of thresholds a
15. 0 Liebert DC POWER Helios DC System 4000 48 1500 3000 4000 amp 6000 A DC Power System User Manual 1 0 1 1 1 2 2 0 2 1 2 2 2 3 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 TABLE OF CONTENTS ABOUT THIS DOCUMENT lesser hh eee eee eee ees 1 Purpose of This Document uere he ee eee eH a ace CP 1 Applicability of This 1 INTRODUCTION nia ia annes eatin Pana Aare eu REESE C 2 D scriptlom A A A IUE ERU E LEN dg 2 APPIICAtIONS um e i OR UAR we 3 Control and Distribution Cabinets Typical 4 SPECIFICATIONS mra Sot iri T KS Ideo dte ge ex ERE E ear Rada Es 6 Bramework u cessi tele dee eU PSP VY bei MPO P MESS PB SR AES 6 3 1 1 Mechanical Specifications of a 6 3 1 2 Electrical Specifications of the 6 Conventional 7 3 2 1 Mechanical Specifications of the Conventional Controller 7 3 2 2 Electrical Specifications of the Conventional 7 Distribution Panels a reu V RR ERROR C er MW EA P eu 8 ggd Fuse Panels aerea rte A oa ee A reatu gree A uoo hm 8 3 3 2 Circuit Breaker Panels
16. 100 48 The mechanical specifications of the Helios Rectifier 100 48 are listed in Table 24 Table 24 Mechanical specifications of the Helios Rectifier 100 48 Figure Height Depth Width Weight Figure 21 178 mm 305 mm 584 mm 22 2 kg 7 0 in 12 0 in 23 0 in 49 Ib Figure 21 Front view of the Helios Rectifier 100 48 2 3 2 THSD Q RFAC EE AC on FAN 1 FAN 2 INRUSH 1 mE nocd ws NO ELO AO 20 000 0000 A 10 Q pona BEI Eo COE NM TR mg Quen RO CA 9 o m o ANP Q car AO 1 0 0000 0000 2000 00005 0 goon 0000 VOLT AMP Ses O f o Specifications 21 Electrical specifications of the Helios Rectifier 100 48 The electrical specifications of the Helios Rectifier 100 48 are listed in Table 25 Table25 Electrical specifications of the Helios Rectifier 100 48 Parameter Specification Input voltage 208 240 V AC 1 phase 47 63 Hz Input voltage range 176 to 264 V AC Input current 31 A nominal at 208 V AC input and 56 V DC 100 A output Recommended AC 50 A two pole AC circuit breaker service input Output voltage Float 48 to 58 V DC Equalize O to 4 V DC above Float Maximum 59 5 V DC Output current 100 A per rectifier 100 A for a one position shelf 300 A for a three position shelf Input protection A
17. AUX 2 ALM 2 Form C contacts HVSD 1 Form C contacts BOD 1 Form C contacts 2 Form C contacts 2 Form C contacts NOTE Form C contacts are rated at 0 5 A 60 V AC MINOR VIS 2 and MAJ VIS 2 are used for the cabinet alarm lamp Potentiometers Twelve potentiometers for the adjustment of alarm and control functions as described in Table 34 Table 34 Potentiometers Designation Description HVSD High Voltage Shutdown HV High Voltage Alarm LV Low Voltage Alarm HF High Float Alarm LF Low Float Alarm LVD Low Voltage Disconnect BOD Battery On Discharge VOLT ADJ Plant Voltage Adjustment REF CAL Reference Calibration METER ADJ Meter Adjustment AMP ADJ Ampere Adjustment LVR Low Voltage Reconnect Operation 29 Switches Four switches for the control of functions as described in Table 35 Table 35 Switches Designation Description EQUALIZE MAN AUTO Used to activate or deactivate the equalize function ACO Used to cancel the audible alarm signal CALIBRATE NORM CAL Used to activate or deactivate the calibration function CONT rotary switch Six position switch OFF AMP CHG VOLT BAT VOLT CAL TST DISPL DIP switches Three DIP switch modules for the setting of functions as described in Table 36 and as shown in Figure 27 and Figure 28 Table 36 DIP switch modules Designation Description SHUNT
18. Capacity capacity 24 Plug In 1 100 A Figure 13 24 1 100 A 900A 900 A max 4 70 250 A Figure 14 4 70 250 A 900 A 900 A max 2 400 A Figure 15 2 400 A 900 A 1 600 700 A Figure 16 1 600 A 900 A Specifications 17 3 4 3 4 1 Externally Mounted Battery Return Busbar The battery return busbar is designed to mount on the overhead racking for 6000 A systems and top cabled 1500 3000 or 4000 A power systems It can also be mounted on a wall or on the floor below the raised floor for bottom cabled 1500 3000 or 4000 A power systems which are assumed to be installed on a raised computer type floor Mechanical Specifications of the External Battery Return Busbar The external battery return busbar kit consists of a group of single busbar laminations and attachment hardware assembled as shown in Figure 17 6000 shown The kit can grow verti cally in such a way as to maintain the 3 ft maximum radius grounding requirement Laminations are added as required to increase the capacity The mechanical specifications of a single lamina tion are listed in Table 22 Table 22 Mechanical specifications of a single lamination Figure Length Width Thickness Figure 17 863 6 mm 152 4 mm 12 7 mm 34 inches 6 inches 0 5 inches Figure 17 Top and side views of the external battery return busbar 7 34 864 mm Ls O Ojo oo oo o
19. DC and whose current requirements do not exceed 6000 A capacity Introduction 3 2 3 Control and Distribution Cabinets Typical Configurations Figure 3 shows the front and side views of typical rectifier and distribution cabinets for a Helios DC System 4000 48 bottom cabled cabinets are illustrated top cabled versions are available Figure3 Typical configurations for Helios DC System 4000 48 control distribution and rectifier cabinets iL T sate IL ma Cus TT z EE 11 7189 Bs Ji ImmEmTEEREMY LAU ES E pis RARA Ene 0006000 TM Control and Distribution cabinet 1200A Rectifier cabinet 4 Introduction Cabinets are available in a variety of configurations as listed in the following tables N
20. Mo alle ASA 2 o e OO up 1200 A rectifier cabinets Main cabinet Aux dist cabinet 2 Introduction Figure2 Front view of a typical 6000 A Helios DC System 4000 48 power system 2 2 JA yA a T dh EH ES q gt ft ft ft E A
21. QFF 0 5 A amp Figure 7 8 0 30 A 250 A 6 TPN 5 30 A 250 A max 8 TPN 5 30 A Figure 8 8 31 60 A 300 A 250 A max 4 RS100P 70 100 A Figure 9 4 70 100 A 300 A 300 A max 4 CRS200P 150 200 A Figure 10 4 101 200 A 600 A 600 A max 4 CRS200P 150 200 A w load shunts 600 A max 4 TPL 225 600 A Figure 11 4 225 600 A 1600 A 1600 A max 18 TPS 1 70 A Figure 12 18 0 70A 600 A 600 A max 3 3 2 Circuit Breaker Panels Mechanical specifications of the circuit breaker panels The mechanical specifications of the circuit breaker panels are described in Table 16 Table 16 Mechanical specifications of the circuit breaker panels Panel description Figure Height Width Weight 24 Plug In 1 100 A Figure 13 165 mm 584 mm 9 1kg 900 A max 6 5 in 23 0 in 20 Ib 4 70 250 A Figure 14 178 mm 584 mm 10 5 kg 900 A max 7 0 in 23 0 in 25 Ib 2 400 A Figure 15 178 mm 584 mm 10 5 kg 7 0 in 23 0 in 25 Ib 1 600 700 A Figure 16 178 mm 584 mm 10 5 kg 7 0 in 23 0 in 25 Ib The 250 A circuit breaker has two poles thus the panel can accommodate a maximum of two 250 A breakers An alarm circuit pack with an alarm indication LED is standard on all panels Specifications 13 Figure 13 Front view of the 24 Plug In 1 100 A circuit breaker panel O The DC output connections vary according to the circuit breaker capacity maximu
22. QFF1A 1 333 A0205202 QFF1B 2 A0205203 QFF1C 3 A0205204 QFF1D 5 A0205205 QFF1E 0 18 A0205206 QFF1F 0 25 A0205207 QFF1G 0 5 A0205208 QFF1H 0 75 A0205209 QFF3A DUMMY A0205210 Figure7 Front view of the 16 QFF 0 5 A amp 6 TPN 5 30 A fuse panels O J FA 48 V ALM 1 2A The DC output connections are 0 250 20 studs equipped with two hex nuts Table 9 Fuse sizes available for the 16 QFF 0 5 A amp 6 TPN 5 30 A fuse panels Fuse type DC power TPN Current A CPC 1 A0380108 3 A0380109 6 A03801 11 10 A03801 12 15 A0380113 20 A0380147 25 A0380148 30 A0380149 Specifications 9 Figure8 Front view of the 8 TPN 5 30 A fuse panels 48 V ALM O 1 2 A O O O 9 O O The DC output connections are 0 250 20 studs equipped with two hex nuts Table 10 Fuse sizes available for the 8 TPN 5 30 A fuse panels Fuse type Current A CPC 35 A0380150 40 A0380151 DC power TPN 45 A0380152 50 A03801 14 60 A0380115 Figure9 Front view of the 4 RS100P 70 100 A fuse panels 7 ALM FA 1 2 3 4 1 2 3 4
23. SELECT To select the shunt size TIMER To select the duration of the equalize VOLT To select the equalize voltage Figure 27 Shunt range selection settings RANGE AMPS MIN MAX 55 to 100 100 to 170 170 to 340 340 to 500 500 to 1000 1000 to 1700 1700 to 3400 3400 to 7000 7000 to 14000 30 Operation Figure 28 Equalize voltage and duration settings TIMER VOLT Switch 1 Switch amp 1 2 3 10 sec 20 sec OEF EON 38 sec O 1 O 2 1 25h O 3 3 0 h o 6 5 0h LOP enabled switch in the ON position Fuses Thirty four fuses for circuit protection as described in Table 37 Except for the ABS fuse which is small tube type 9 32 dia x 1 1 4 long all fuses are of the QFF type Table 37 Fuse Designation Capacity Description ABS 15A 48 V supply for the office alarm circuit s ABS ALM 1 2A Alarm fuse for the above ABS fuse RC1 to RC24 1 1 3A 48 V sense supply for the rectifiers of the system CONV 1 2A Protection for the internal converter in the controller METER 1 2A Protection for the meter and selector panel if so equipped CHG 1 2A Protection for internal circuitry of the controller when the CONT rotary switch is in the CHG VOLT position Spare 1 and 2 0t05A For external loads as required ex Helios Monitor BAT 1 2A Protection for internal circuitry of the controller when the CONT rotary switch is in the BAT VOLT position CONT 1 1 3A Protection for the i
24. and charge and discharge fuse alarm inputs TB4 various alarm outputs to the office alarm circuits and LVD control and alarm TB5 various alarm outputs to the office alarm circuits remote TR signal input 48 V supply to cabinet alarm lamp and various small loads and AUX 1 and AUX 2 alarms inputs TB6 48 V supply to office alarm circuits if required and VR inputs and 48 V and ground inputs Refer to Figure 30 and Figure 31 for the pin assignment of terminal blocks TB1 to TB6 32 Operation Figure 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB4 NE 1451X cable or equivalent H L FLOAT ALM 1 H L FLOAT ALM 1 H L FLOAT ALM al H L FLOAT ALM 2 MIN RECT ALM To office MIN RECT ALM alarm x MAJ RECT ALM circuit ALM LVD ALM LVD ALM LOSS OF AC VOLT ALM LOSS OF AC VOLT ALM Input from DISCH fuse alarm circuits DFA Input from CHG fuse alarm circuits CFA NE 1451X cable or equivalent AUX ALM NO 1 1 AUX ALM NO 1 1 AUX ALM NO 1 2 AUX ALM NO 1 2 AUX ALM NO 2 1 To office AUX ALM NO 2 1 alarm circuit AUX ALM NO 2 2 AUX ALM NO 2 2 EQUALIZE ALM EQUALIZE ALM HVSD ALM HVSD ALM To LVD circuit RLVD Input alarm from LVD circuit LVDA C NC C NC NO C zlz 2 2 2 2 OJOJOJO O zz zz zz zz 1451 cable or equivalent MINOR VIS 1 MINO
25. c c hole spacing for cables up to 777 kcmil The terminating assembly is bolted to the top of the main or auxiliary distribution cabinets and therefore increase the cabinet height by 12 inches The weight of the terminating assembly is 12 5 kg 27 6 Ib An optional Lexan protective cover is available to protect the connections of the load cables Figure 18 Perspective view of the a terminating assemblies Optional protective cover Glastic ps Ry a AN ARE for main distribution cabinet for auxiliary distribution cabinet Specifications 19 3 6 MPS300 and MPA100 Power Shelves The MPS300 and MPA100 power shelves are required for the Helios Rectifier 100 48 which is plug in type rectifier The MPA100 power shelf supports one Helios Rectifier 100 48 while the MPS300 shelf can support up to three Helios Rectifiers 100 48 3 6 1 Mechanical Specifications of the MPS300 and MPA100 Power Shelves The mechanical specifications of the power shelves are listed in Table 23 Table 23 Mechanical specifications of the MPS300 and MPA100 power shelves Shelf model Figure Height Depth Width Weight MPS300 Figure 19 533 mm 381 mm 584 mm 16 6 kg 21 00 in 15 00 in 23 00 in 36 5 Ib MPA100 Figure 20 178 mm 381 mm 584 mm 5 4 kg 7 00 in 15 00 in 23 00 in 12 Ib UTPUT BUSBARS zi
26. discharge alarm BPG building principal ground BR battery return BRR battery return reference CAL calibrate CFA charge fuse alarm CHG charge COM common CONT control CSA Canadian Standard Association CTRL control DC or dc direct current DFA distribution fuse alarm DISCH discharge DSPL display EB earthquake brace EMI electromagnetic interference EQL equalize ESD electrostatic discharge EXT external F fuse FA fuse alarm FG frame ground FGB floor ground bar FS forced sharing ft foot ft lb foot pound GRD or GRND ground HF high float HV high voltage HVA high voltage alarm List of Terms high voltage shutdown HVSDA high voltage shutdown alarm HVSDR high voltage shutdown reset in inch in Ib inch pound IS interconnect schematic ISG isolated system ground L line Ib pound LED light emitting diode LF low float LOP loss of phase LV low voltage LVA low voltage alarm LVD low voltage disconnect LVDA low voltage disconnect alarm LVR low voltage reconnect m meter MAJ major MGB main ground bar MIN minor MNL manual MOP method of procedure MPS modular power shelf mV millivolt NC normally closed N m Newton meter NO normally open NORM normal psi pound per square inch PWR power RC Rectifier control RECT rect
27. loading Auxiliary distribution cabinet 32 3 kN sq m 71 Ib sq ft 26 9 N sq cm 39 Ib sq in Rectifier cabinet 50 1 kN sq m 110 2 Ib sq ft 41 8 N sq cm 60 6 Ib sq in Specifications 27 4 0 OPERATION 4 1 4 2 4 2 1 General This chapter describes the control adjustment and operational features of the Helios DC System 4000 48 Conventional Controller The Conventional Controller monitors the operation of the entire power plant It monitors all the alarms and it controls and monitors the rectifiers Provision is made on the back of the Conventional Controller to extend any occurring alarm to the alarm center through the facilities provided in the powered equipment of the control switches potentiometers operational and alarm visual indications are located at the front of the Conventional Controller Front Panel The front panel of the Conventional Controller is provided with the control alarm and operational features shown in Figure 26 and described in the following subsections Figure 26 Front view of the Conventional Controller Eu o f 000000 e BER ERES IR SO 83525558 A 22 ET Visual indicators A 4 5 digit red LED readout to display the system current and voltage and 18 LED
28. o o o o o o 0 0 o M EU o o 2 pu P der cO oce COP AO e 6 152 mm O Ojo o o o o o o o o o o o o o o o 000000005000 OO Top view of the external ground bar 9 Available configurations n asd i 1500 amp 3000 A 72 E IL pn ae Smaller busbar for 6 ES small wires and cables 1 LJ 1 6000 Side view of the external ground bar installed on auxiliary framing above the power system NOTE All bars and details are 0 5 in thich For 1500 A system only the bottom level is provided for the external battery return ground bar 3 4 2 Electrical Specifications of the External Battery Return Busbar A single busbar lamination has a current carrying capacity of 3000 A 18 Specifications 3 5 Terminating Assemblies Optional The optional terminating assembly allows top access connections for up to six loads Refer to Figure 18 Each load position is rated at 600 A and can accept up to three lugs having 1 or 1 3 4
29. one end of the control and signal cable supplied with the rectifier into the DB25 connector at the rear of the rectifier Plug the other end of the control and signal cable into the corresponding connector on the interface circuit board at the top top fed system or bottom bottom fed system of the rectifier cabinet Operate the AC circuit breaker of the new rectifier to the ON position With the DC breaker in the OFF position adjust the float equalize and high voltage shutdown voltage levels as required Refer to the appropriate rectifier user manual see 6 0 Reference Documents Install the corresponding sense fuse RC on the front of the controller Ensure that the FLS FS switch on the rectifier is set to the same position as that of the other rectifiers in the power system Operate the DC circuit breaker of the rectifier to the ON position Verify that the rectifier is sharing the load by observing its ammeter It should display approximately the same value as the ammeters on the other rectifiers If not adjust its float and equalize voltage levels as described in the appropriate rectifier user manual see 6 0 Reference Documents Figure 32 AC connections in a Helios Rectifier 200E 48 Teck cable or flexible conduit T GRD lt Partial view of the rectifier s rear panel right side as viewed from the rear TB1 42 Mainten
30. reinstall the AC protective cover For a Helios Rectifier 200E 48 or a Helios Rectifier 2001 48 equipped with an AC cord first connect the associated female receptacle supplied with the rectifier to the cable or wires incoming from the AC service panel refer to Figure 33 Then plug the male connector at the end of the rectifier AC cord into the female receptacle For a Helios Rectifier 200E 48 equipped with an AC cord feed the cables through the appro priate strain relief connector at the top top fed or bottom bottom fed of the rectifier AC junction box inside the cabinet refer to Figure 34 Use a flat blade screwdriver to tighten the strain relief connector then connect the wires to the appropriate terminals inside the junction box as shown in Figure 34 Use plastic cable ties to secure the wires at the tie down points one for each rectifier position inside the junction box Plug the male connector at the Maintenance 41 11 12 13 14 15 16 17 18 19 20 end of the rectifier AC cord into the corresponding female receptacle behind the junction box For the specific AC cable routing to be used with the Helios Rectifier 200E 48 refer to Figure 35 in the case of a top fed system or to Figure 36 in the case of a bottom fed system Make the ground and line connections as applicable at the AC service panel Install the four bolts for the DC connections to the busbar risers at the rear of the cabinet Plug
31. the ON position With the DC breaker in the OFF position adjust the float equalize and high voltage shutdown voltage levels as required Refer to the appropriate rectifier user manual see 6 0 Reference Documents Reinstall the sense fuse RC removed in Step 3 Ensure that the FLS FS switch on the rectifier is set to the same position as that of the other rectifiers in the power system Operate the DC circuit breaker of the rectifier to the ON position Verify that the rectifier is sharing the load by observing its ammeter It should display approximately the same value as the ammeters on the other rectifiers If not adjust its float and equalize voltage levels as described in the appropriate rectifier user manual see 6 0 Reference Documents Notify the alarm center of the end of the procedure 46 Maintenance 5 3 3 Adding or Replacing a Battery String For replacements proceed from Step 1 below For new installations go to Step 5 of this proce dure N WARNING 2 THIS PROCEDURE IMPLIES THAT ALL OR PART OF THE BATTERIES WILL BE MOMENTARILY TAKEN OUT OF SERVICE THIS WORK SHOULD THEN BE COMPLETED DURING REDUCED TRAFFIC HOURS AND OR WITH A DIESEL GENERATOR BACKUP AVAILABLE TO ENSURE NO LOSS OF SERVICE DURING A POSSIBLE AC OUTAGE IF MORE THAN ONE STRING IS TO BE REPLACED REPLACE ONLY ONE STRING AT A TIME AND DO NOT DISCONNECT THE NEXT STRING BEFORE THE PREVIOUS ONE IS RECONNECTED 1 Removal of the ol
32. the FLS FS switch on the rectifier is set to the same position as that of the other rectifiers in the power system Operate the DC circuit breaker of the new rectifier to the ON position Verify that the replacement rectifier is sharing the load by observing its ammeter It should display approximately the same value as the ammeters on the other rectifiers If not adjust its Float and Equalize voltage levels as described in the appropriate rectifier user manual see 6 0 Reference Documents Notify the alarm center of the end of the procedure Maintenance 45 Replacing a Helios Rectifier 2001 48 or 200E 48 1 2 3 4 10 11 12 18 14 15 16 17 18 19 20 21 22 23 Notify the alarm center of incoming alarms during this procedure Turn OFF the AC and DC circuit breakers on the rectifier to be replaced Remove the corresponding sense fuse on the front of the controller At the AC service panel place the AC circuit breaker associated with this rectifier in the OFF position For a Helios Rectifier 200E 48 without an AC cord remove the AC protective cover at the rear of the rectifier and disconnect the AC cable inside the rectifier refer to Figure 32 For a Helios Rectifier 2001 48 or 200E 48 equipped with an AC cord unplug the AC cord from the supply receptacle Remove the four bolts for the DC connections to the busbar risers at the rear of the cabinet Disc
33. two pole 45 A circuit breaker opens both lines Output protection The rectifier is protected by a 120 A circuit breaker at the output The output current is limited to a value adjustable from 50 to 105 of the rated capacity of the rectifier This circuit is factory set to 105 A Output regulation The rectifier output voltage is automatically regulated to remain within 0 5 of the selected value under all load conditions and within the specified input voltage frequency and ambient temperature ranges And within 196 for any combinations of specified input output and environmental conditions Efficiency Efficiency is better than 88 at a nominal input voltage of 208 240 V AC and an output load greater than 40 A Power factor Power factor is 0 99 at a nominal input voltage of 208 V AC and output loads greater than 40 A Electromagnetic The rectifier meets the FCC requirements for conducted and radiated EMI for Class interference EMI A equipment Heat dissipation 763 W 2606 Btu hr 3 7 2 Helios Rectifiers 2001 48 and 200E 48 Mechanical specifications of the Helios Rectifiers 2001 48 and 200E 48 The mechanical specifications of the Helios Rectifier 2001 48 and 200E 48 are listed in Table 26 Table 26 Mechanical specifications of the Helios Rectifiers 2001 48 and 200E 48 Figure Height Depth Width Weight Figure 22 254 mm 559 mm 521 mm 42 3 kg 10 in 22 in 20 5 in 93 Ib
34. wall mounting The units are equipped with a heavy duty circuit breaker that can be used to manually or automatically disconnect a battery string Reconnect is manual only The breaker is mid trip and equipped with a relay trip feature Figure 24 600 A Battery Disconnect Unit 600A BATTERY DISCONNECT UNIT TEST DISC FI autopisc DISABLE BDA SP FA CAL VOLT ADJ CALIBRATE GRD 9 9 OFF ON OFF ON OFF ON For more detailed electrical specifications of the Battery Disconnect Unit refer to the user man ual SL 60040 Specifications 25 3 10 AC Junction Box The AC junction box is required as an AC connection interface in rectifier cabinets where the Helios Rectifier 200E 48 is used Figure 25 Front view of the AC junction box with the front panel open Six receptacles to plug the cables from the rectifiers RECT6 RECT5 RECT 4 RECT3 RECT 2 RECT 1 o 123 45 6 7 8 9 101112 2 QD QD QD QD QD QD QD QD QD QD QD QD QD QD QD QD QD QD QD 3130596590 39953905970 3 10 1 Mechanical Specifications The junction box is made of zinc plated steel and can accommodate up to six one inch rigid or flex ible conduits The mechanical specifications are listed in Table 29 Table 29 Mechanical specifications
35. 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 5 0 5 1 5 2 5 3 6 0 7 0 Overall Power System Specifications 26 OPA ede Standards inter tala ate BU eis gala then nt 26 3 11 2 Mechanical Specifications of Fully Equipped Power Cabinets 26 3 11 3 Electrical SpecificatioOs cee es 27 3 11 4 Environmental Specifications 27 3 11 5 Floor and Point Loading 27 OPERATION RP 28 General io gen aut URL RA CEN RAE OT RE e 28 Conventional Controller RR es 28 ADA a Front Panels eiere ELS WEEDS ESSE EN bee es 28 42 2 Rear Panel NN de RO E Mr ERR ER 32 MPS300 and MPA100 Power 1 84 Recta A 35 AC Junction BOX oo o o hr hr rrr rr nns 35 Distribution Fanels ves 24 234 ss A Da ku A A oh aa IAN e 35 Terminating Assemblies Optional 35 Helios Monitor 3000 48 Optional e 36 600 A and 1200 Battery Disconnect Units 1 36 MAINTENANCE A ti 37 General mL 97 5 1 1 Helios Monitor 3000 48 37 5 1 2 Controller and 37 Trotibleshooting A
36. C 801 2 are applied to exposed parts of the power system Environmental Specifications Operating Temperature 0 to 50 C 32 to 122 F Humidity 0 to 95 non condensing Altitude Sea level to 2134 m 7000 ft Transportation NOTE Do NOT ship with the rectifiers installed in the rectifier cabinet s During transportation the equipment may be subjected to the following conditions without damage Temperature 50 to 75 C 58 to 167 F Humidity 0 to 95 non condensing 4kPa max WVP for 10 days Vibration TR NWT 000063 section 5 4 4 Transportation Vibration packaged equipment Shock TR NWT 000063 Section 5 4 1 Handling Drop Tests and Section 5 4 3 Installation Shop Tests Storage Temperature 50 to 75 C 58 to 167 F Humidity 0 to 95 non condensing 4kPa max WVP for 10 days Heat dissipation A Helios DC System 4000 48 rectifier cabinet equipped with six Helios Rectifier 2001 48 or 200E 48 will dissipate a maximum of 8 010 watts or 27 350 Btu hr Floor and Point Loading The floor loading is based on a footprint of 600 mm x 600 mm 23 6 in x 23 6 in plus a 30 inch aisle width 15 inches front and rear The point loading is based on distributing the cabinet weight over four shims each with an assumed area of 25 8 cm 4 in See Figure 1 for a typical system configuration for floor and point loading calculations Table 31 Floor and point loading Cabinet type Floor loading Point
37. C cord equipped with a male connector This male connector is plugged into a matching female receptacle at the rear of the AC junction box For the complete procedures for adding or replacing a rectifier refer to 5 0 Maintenance Note that caps are provided to protect the unused female receptacles Distribution Panels distribution panels provide local alarm indication on the panel itself and alarm extension to the controller for additional indication on the controller and the cabinet and further extension to remote alarm facilities Terminating Assemblies Optional Terminating assemblies are optional devices used to facilitate the connecting of loads to distribu tion fuses or circuit breakers larger than 199 A These assemblies can be used in top fed systems only they cannot be used on bottom fed systems Each terminating assembly provides connection facilities for up to six loads without having to route the cables inside the cabinet during installa tion Two terminating assemblies can be used on an auxiliary distribution cabinet while only one ter minating assembly can be used on a main control and distribution cabinet Operation 35 4 8 4 9 Helios Monitor 3000 48 Optional The Helios Monitor 3000 48 1s a microprocessor based unit used to monitor and record power sys tems operational data The recorded data is accessible locally by means of the front panel or the RS 232 port or remotely through the modem link
38. R VIS 1 To small internal battery return busbar ALARM VISUAL C MAJOR VIS 1 MAJOR VIS 1 ALARM VISUAL NC To cabinet MINOR AUD 1 alarm lamp MINOR AUD 1 To office alarm circuit MINOR AUD 2 MINOR AUD 2 MAJOR AUD 1 MAJOR AUD 1 4 NE 1451X cable or equivalent MAJOR AUD 2 MAJOR AUD 2 FUSE ALM FUSE ALM CHG FUSE ALM To office alarm circuit REMOTE EQUALIZE START Input from office remote circuit Operation 33 Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6 and connectors P1 to rectifier To AC am monitor H circuit P26 22GA 8 conductor shielded cable EQL To office alarm circuit ABSF If required Input from office IR remote circuit RECT FAN BECT FAN To office alarm circuit NE 1451X cable or equivalent LES CSV To cabinet alarm lamp 22GA 2 conductor 4V SPARE2 To load as required shielded cable 48V METER To meter amp selector NC GRD panel if so equipped NC SHUNT BOD To office alarm circuit BOD SHUNT the shunt NE 1451X cable wires should Aorequivatent be fused near AUX1 INPUT the shunt to AUX2 INPUT MIN revent fire required 3 48 V CHG busbar GRD alarm signals from auxiliary equipment as ae ass To Office alarm circuit or alarm reporting circuit if required NC NC NC NC NC Battery sense leads
39. Rectifiers 100 48 connected in parallel as building blocks to reach the maximum capacities The Helios Rectifiers 2001 48 operate from a 380 V to 415 V three phase 50 or 60 Hz AC source The Helios Rectifiers 2001 48 operate from a 480 V three phase 50 or 60 Hz AC source The Helios Rectifiers 100 operate from a 208 V to 240 V single phase 50 or 60 Hz AC source The 1200 A rectifier cabinet accepts up to six Helios Rectifiers 2001 48 or 200E 48 while the 1000 A rectifier cabinet accepts up to 10 Helios Rectifiers 100 48 The control and distribution cabinet and the auxiliary distribution cabinets are available with distribution busbar risers of 2000 A or 3000 A capacity The cabinets are seismic qualified to zone 4 Bellcore when anchored to a concrete floor whose compressive strength is at least 2 11 kg mm 3000 psi and when equipped with a seismic kit The cabinets are seismic qualified to zone 2 without the seismic kit The cabinets are equipped with a ventilated lockable door a ventilated top cover and two rear ventilated panels In many applications such as with DMS a consistent single point ground SPG topology must be maintained for all associated equipment The Helios DC System 4000 48 complies with this requirements for single point grounding the isolation kit is required Applications The Helios DC System 4000 48 is designed to operate with DMS systems or any other telecommu nication systems whose input is nominal 48 V
40. UTION A Precautions must be taken to avoid service interruptions Use properly insulated tools when working on the power distribution panels Replace a distribution fuse block as described below D A Notify the alarm center of incoming alarms during this procedure Remove the fuse from the fuse block to be replaced Remove the rear panels of the cabinet Carefully remove and insulate any load and alarm leads connected to the fuse block Carefully remove the fuse block Ensure that the fuse is removed from the new fuse block Carefully install the new fuse block Reconnect the load and alarm leads disconnected in Step 4 Install the fuse in the fuse block 10 Notify the alarm center of the end of this procedure Replacing a distribution circuit breaker Replace a distribution circuit breaker as described below WaAnoapwnr Notify the alarm center of incoming alarms during this procedure Place the circuit breaker to be replaced in the OFF position Remove the rear panels of the cabinet Carefully remove and insulate any load lead and alarm lead connected to the circuit breaker Carefully remove the circuit breaker Ensure that the new circuit breaker is in the OFF position before installing it Carefully install the new circuit breaker Reconnect the load and alarm leads disconnected in Step 4 Turn on the circuit breaker 10 Notify the alarm center of the end of this procedure Replacing a Cabinet Alarm Lamp
41. a bottom fed systeM 44 Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 Table 34 Table 35 Table 36 Table 37 Table 38 Table 39 TABLES Rectifier cabinets e ree eL Esel ube bae DERI IUS 5 Control and distribution cabinets srei er 5 Auxiliary distribution 2 2 dik rs 5 Mechanical specifications of the cabinet empty 6 Mechanical specifications of the Conventional 7 Mechanical specifications of the fuse 1 8 Fuse sizes available for the 20 0 5 A fuse 1 8 Fuse sizes available for the 16 0 5 A amp 12 ABS 5 30 A fuse panels 9 Fuse sizes available for the 16 0 5 A amp 6 TPN 5 30 A fuse 9 Fuse sizes available for the 8 TPN 5 30 A fuse 10 Fuse sizes available for the 4 RS100P 70 100 A fuse 10 Fuse sizes available for the 4 CRS200P 150 200 A 4 CRS200P 150 200 A w loa
42. ance Figure 33 AC connections in the female receptacle for a Helios Rectifier 2001 48 or a Helios Rectifier 200E 48 Cover gt Phase 2 orL2 Phase 1 or L1 Phase 3 or L3 Helios Rectifier 2001 48 Helios Rectifier 200E 48 380 V ac 480 V ac Teck cables or flexible conduits Junction box shown with front cover open lt y b A msc Screw type terminal block Knockout Six connectors 3 RECT RECT 2 RECT 1 to plug the RECT6 RECT5 RECT 4 3 cables from the rectifiers Maintenance 43 Figure 35 AC cable routing for the Helios Rectifiers 200E 48 in a top fed system Junctio box Partial view of Enlarged view of junction routing of the AC box cables from behind RECT 1 the junction box to the side of the rectifiers RECT 2 RECT 3 RECT 4 RECT 5 Rect Rect 5 RECTO wem Rect 4 ect 3 Partial view of Rect 1 E 2 Figure 36 AC cable routing for the Helios Rectifiers 200E 48 in a bottom fed system Partial view of Rect 6 Rect Rect 5 Rect 4 Rect RECT 1 37 2 Meet INE RECT2 RECT 3 4 5 Enlarged view of routing of the AC Partial cables from behind RECT6 view f the junction box to v jun
43. breaker at the output The output current is limited to a value adjustable from 50 to 105 of the rated capacity of the rectifier This circuit is factory set to 205 A Output regulation The rectifier output voltage is automatically regulated to remain within 0 5 of the selected value under all load conditions and within the specified input voltage frequency and ambient temperature ranges And within 196 for any combinations of specified input output and environmental conditions Efficiency Efficiency is better than 89 at nominal input voltage and an output load greater than 80 A Power factor Power factor is better than 0 99 at nominal input voltage and an output load greater than 80 A Electromagnetic interference EMI The rectifier meets the FCC requirements for conducted and radiated EMI for Class B equipment Heat dissipation 1 335 W 4 558 Btu hr at 54 V DC 200 A output Total harmonic distortion THD THD is less than 5 between half load and full load at nominal input voltage 3 7 4 Standards The following standards also apply to the rectifiers ANSI Std C62 41 TEEE Std 587 1980 Class A and B lightning surge 6000 V 3000 A 1 2 x 50 ms impulse 10 hits per second ANSI Std C82 41 oscillatory surge 2500 V 0 5 ms impulse 100kHz positive negative oscillat ing decay Bellcore TR TSY 000947 IEC 950 VDE EN 60950 EN 41003 CISPR 22 Class CE mark
44. cabinet alarm lamp Faulty or loose connection Failure to generate RFA alarm Faulty rectifier under appropriate conditions Faulty wiring Faulty RFA LED Failure to generate FA alarm Faulty wiring Faulty fuse Faulty FA LED Loose connection HV lamp lit High discharge voltage condition Incorrect HV level adjustment LV lamp lit Low discharge voltage condition Incorrect LV level adjustment HF lamp lit High discharge voltage condition Incorrect HF level adjustment LF lamp lit Low discharge voltage condition Incorrect LF level adjustment FA lamp lit Blown fuse or extended FA alarm CFA lamp lit Blown charge fuse DFA lamp lit Blown distribution fuse RECT MIN lamp lit One rectifier has failed RECT MAJ lamp lit Two or more rectifiers have failed RECT FAN lamp lit Defective rectifier fan s Maintenance 39 5 3 5 3 1 Table 39 Fault diagnosis Fault symptom Possible causes LOP lamp lit Loss of one or more phases in the AC supply HVSD lamp lit High voltage shutdown condition initiated by the controller LVD lamp lit Low voltage disconnect condition initiated by the controller AUX 1 lamp lit User defined alarm condition When a Battery Disconnect Unit is present this lamp will indicate that a battery disconnect alarm is ongoing AUX 2 lamp lit User defined alarm condition BOD lamp lit Low discharge voltage condition Incorrect BOD level adjust
45. ction the side of the h box rectifiers Junction box enlarged view Pauw e CR 44 Maintenance 5 3 2 Replacing a Rectifier Replace a rectifier as described below for a Helios Rectifier 100 48 or as in Replacing a Helios Rectifier 2001 48 or 200E 48 whichever is applicable Replacing a Helios Rectifier 100 48 Qu debo 10 11 12 13 14 15 Notify the alarm center of incoming alarms during this procedure Turn OFF the AC and DC circuit breakers on the rectifier Remove the corresponding sense fuse on the front of the controller Remove the left and right rectifier retaining bars by loosening the screws Slide the rectifier out of the shelf carefully Reuse the shipping carton of the new rectifier to store or ship the removed unit Ensure that the AC and DC circuit breakers on the new rectifier about to be plugged in are in the OFF position down Carefully slide the new rectifier into the shelf ensuring that it is fully inserted Reinstall the left and right side clamping brackets removed in Step 4 to secure the rectifier into position Operate the AC circuit breaker of the new rectifier to the ON position With the DC breaker in the OFF position adjust the float equalize and high voltage shutdown voltage levels as required Refer to the appropriate rectifier user manual see 6 0 Reference Documents Reinstall the sense fuse RC removed in Step 3 Ensure that
46. d shunts fuse panels 11 Fuse sizes available for the 4 TPL 225 600 A fuse 1 11 Fuse sizes available for the 18 TPS 1 70 A fuse 1 12 Electrical specifications of the fuse panels 13 Mechanical specifications of the circuit breaker 13 Plug in circuit breakers available for the 24 Plug In 1 100 A circuit breaker panel 14 Circuit breaker sizes available for the 4 70 250 A circuit breaker panel 15 Circuit breaker kits available for the 2 400 A circuit breaker panel 16 Circuit breaker kits available for the 1 600 700 A circuit breaker panel 16 Electrical specifications of the circuit breaker panels 17 Mechanical specifications of a single 18 Mechanical specifications of the MPS300 and MPA100 power shelves 20 Mechanical specifications of the Helios Rectifier 100 48 21 Electrical specifications of the Helios Rectifier 100 48 22 Mechanical specifications of the Helios Rectifiers 2001 48 and 200 48 22 Electrical specifications of the Helios Rectifiers 2001 48 and 200E 48 24 Mechanical specifications of the Helios Mo
47. d string Notify the alarm center of the possibility of incoming alarms during this procedure 2 Above the battery stand or at the top of the main cabinet for a 1500 3000 or 4000 A system or at the overhead busbars for a 6000 A system locate disconnect and isolate the charge leads and coming from the batteries being replaced 3 Disconnect the inter cell connectors from the individual battery cells and insulate each exposed terminal with electrician tape 4 The removed batteries shall be disposed of in accordance with local state and national environmental legislation 5 Installation of the new string If this is an addition locate and install the new battery stand according to the specifications and drawings If this is a replacement install the new battery string in the space vacated by the removed one 6 Install the new batteries and use the new connecting material supplied with the batteries to interconnect them 7 Perform the initial charging of this new battery string according to the battery manufacturer s specifications using an external power supply 8 Above the battery stand or at the top of the main cabinet for a 1500 3000 or 4000 A system or at the overhead busbars for a 6000 system connect the charge leads and coming from the new batteries 9 Notify the alarm center of the end of the procedure Maintenance 47 5 3 4 Replacement of a Distribution Fuse Block or Circuit Breaker 5 3 5 CA
48. d with a front door and door frame lockable equipped with ground straps and easily removable for installation or maintenance access a ventilated top cover made of non flammable plastic and two ventilated rear cover panels equipped with ground strap and easily removable for installation and maintenance access Bussing and equipment controller rectifiers distribution panels etc are added as required depending on the use of the cabinet Seismic bracing is also available as options When using the Cable Trough overhead cabling cannot enter from the front or rear of the system It must be confined to the system foot print and enter at the ends of the lineup The cabinets may be either top or bottom cabled as determined by the location of the bussing Mechanical Specifications of a Cabinet The mechanical specifications of an empty cabinet are listed in Table 4 Table 4 Mechanical specifications of the cabinet empty Framework type Height Depth Width Weight Cabinet 2134 mm 600 mm 600 mm 114 kg 84 0 in 23 6 in 23 6 in 251 Ib Refer to Figure 3 for typical views of cabinets Electrical Specifications of the Cabinets The electrical specifications of equipped cabinets are as follows The main control and distribution cabinet for a 1500 A system has a 2000 A busbar riser and a common equipment panel e w one 1500 A CHG and DISCH busbar and a 2500 A system shunt The main control and distribution cabin
49. ectrical Specifications of the Conventional Controller The operating voltage is 48 V DC Refer to the 4 0 Operation and the appropriate user manual listed in 6 0 Reference Documents for a detailed list of specifications operating parameters and features of the Conventional Controller Specifications 3 3 Distribution Panels 3 3 1 Fuse Panels Mechanical specifications of the fuse panels The mechanical specifications of the fuse panels are listed in Table 6 below Table 6 Mechanical specifications of the fuse panels Panel description Figure Height Width Weight 20 QFF 0 5 A Figure 5 76 2 mm 584 mm 3 kg 60 A max 3 0 in 23 0 in 6 6 Ib 16 QFF 0 5 A 8 Figure 6 76 2 mm 584 mm 5 kg 12 ABS 5 30 A 3 0 in 23 0 in 11 0 Ib 300 A max 16 QFF 0 5 A amp Figure 7 152 4 mm 584 mm 7 kg 6 TPN 5 30 A 6 0 in 23 0 in 15 4 Ib 250 A max 8 TPN 5 30 A Figure 8 152 4 mm 584 mm 7kg 250 A max 6 0 in 23 0 in 15 4 lb 4 RS100P 70 100 A Figure 9 152 4 mm 584 mm 8 kg 300 A max 6 0 in 23 0 in 17 8 lb 4 CRS200P 150 200 A Figure 10 228 6 mm 584 mm 22 kg 600 A max 9 0 in 23 0 in 48 4 lb 4 CRS200P 150 200 A Figure 10 228 6 mm 584 mm 24 kg w load shunts 9 0 in 23 0 in 52 9 lb 600 A max 4 TPL 225 600 A Figure 11 304 8 mm 584 mm 32 kg 1600 A max 12 0 in 23 0 in 70 4 lb 18 TPS 1 70 A Figure 12 178 mm 584 mm 35 kg 600 A max 7 0 in 23 0 in
50. et for a 3000A system has a 3000 A busbar riser and a common equipment panel e w two 1500 A CHG and DISCH busbars and a 4000 A system shunt The main control and distribution cabinet for a 4000A system has a 3000 busbar riser and a common equipment panel e w three 1500 A CHG and DISCH busbars and a 5000 A system shunt A 6000 A system has a 3000 A busbar riser in the main control and distribution cabinet the CHG and DISCH busbar and the shunt are external The auxiliary distribution cabinet is available with a 2000 or 3000 A busbar riser 1200 A rectifier cabinet has 1500 A busbar risers for the DC output of the rectifiers Specifications 3 2 3 2 1 Conventional Controller Mechanical Specifications of the Conventional Controller The mechanical specifications of the Conventional Controller are listed in Table 5 Table 5 Mechanical specifications of the Conventional Controller Figure Height Depth Width Weight Figure 4 152 mm 76 mm 584 mm 4 5 kg 6 0 in 3 0 in 23 in 10 Ib Figure4 Front view of the Conventional Controller e NORTEL ES c E CECHONUNCEEOTCUOETHNTW ER n pings eee ES a 7 06000 o HA o 0 000 0 0 00 0 000 0000 2188332558 5 pam 1 3 9z8 w 3 2 2 El
51. eu UR ER 39 Addition Replacement 40 5 3 1 Addition or Replacement of a 40 5 3 2 Replacing a Rectifl E ii a ld e bees SR Elmer ed 45 5 8 8 Adding or Replacing a Battery 47 5 3 4 Replacement of a Distribution Fuse Block or Circuit Breaker 48 5 3 5 Replacing a Cabinet Alarm Lamp 48 REFERENCE DOCUMENTS 0000 cece eee ewe hh nnn hann nn 49 EIST OF TERMS da 50 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 FIGURES Front view of a typical bottom fed 4000 A Helios DC System 4000 48 power system 2 Front view of a typical 6000 A Helios DC System 4000 48 power system 3 Typical configurations for Helios DC System 4000 48 control distribution and rectitier cabecita rer el eR e pacto ne tpe db DL Dm ta 4 Front view of the Conventional 7 Front view of the 20 QFF 0 5 A fuse
52. fier 100 48 21 Front view of the Helios Rectifiers 2001 48 and 200 48 23 Front view of the Helios Monitor 3000 48 without the mounting brackets 25 600 A Battery Disconnect Unit 25 Front view of the AC junction box with the front panel 26 Front view of the Conventional 28 Shunt range selection 30 Equalize voltage and duration 31 Terminal blocks and connectors layout at the rear of the Conventional Controller 32 Wiring diagram and pin assignment of terminal blocks TB1 to 4 33 Wiring diagram and pin assignment of terminal blocks TB5 and TB6 and connectors P Tto 26 22 reato a Dee Roa a serui Mta Od dain eater 34 AC connections in a Helios Rectifier 200 48 42 AC connections in the female receptacle for a Helios Rectifier 2001 48 or a Helios Rectifier 200E 48 EE hh ha 43 AC connections inside the junction box top fed shown for a Helios Rectifier 200E 48 43 AC cable routing for the Helios Rectifiers 200E 48 in a top fed system 44 AC cable routing for the Helios Rectifiers 200E 48 in
53. he voltage and alarm settings of the controller and rectifiers are based on the type of batteries used with the power system The recommended settings for various types of batteries can be found in SL 60026 Voltage Level Limits for Power Plants Rectifiers and Controllers If unlisted models of batteries are used it may be necessary to follow specific customer or manufacturer requirements The following is list of the tools and test equipment required to adjust the equipment in the Helios DC System 4000 48 a potentiometer screwdriver Bourns No 60 or equivalent a digital voltmeter Fluke 8050A or equivalent a dummy load 5 kVA Helios Monitor 3000 48 If the power system is equipped with a Helios Monitor 3000 48 refer to the user manual SL 60015 for maintenance and troubleshooting information Controller and Rectifiers The controller and the rectifiers need little maintenance The following should be checked period ically in order to ensure trouble free operation N WARNING PREVENTING DAMAGE TO THE EQUIPMENT DO NOT ATTEMPT ANY OTHER REPAIR THAN THOSE LISTED BELOW IF ANY PROBLEM PERSISTS CONTACT LIEBERT GLOBAL SERVICES AT 1 800 LIEBERT Cleaning Clean the front panels and the LED display screens with a soft cloth and isopropyl alcohol Calibration Verify the calibration of the alarm and control thresholds at least once a year Follow the calibra tion instructions detailed in the appropriate user manual Storage
54. ier 2001 48 or 200E 48 procedure whichever is applicable 40 Maintenance Adding a Helios Rectifier 100 48 1 8 9 10 11 Remove the rectifier blank panel and store it for future use Note Should a rectifier be removed at any time re install the blank panel to meet the regulatory requirements Verify that the AC DC and signalling cabling for the rectifier shelf has been previously installed and verified Ensure that the AC and DC circuit breakers on the front panel of the rectifier are in the OFF position Carefully slide the rectifier into position making sure that it 1s fully inserted Install the left and right side clamping brackets supplied with the rectifier to secure it into position Operate the AC circuit breaker of the new rectifier to the ON position With the DC breaker in the OFF position adjust the float equalize and high voltage shutdown voltage levels as required Refer to the appropriate rectifier user manual see 6 0 Reference Documents Install the corresponding sense fuse RC on the front of the controller Ensure that the FLS FS switch on the rectifier is set to the same position as that of the other rectifiers in the power system Operate the DC circuit breaker of the rectifier to the ON position Verify that the rectifier is sharing the load by observing its ammeter It should display approximately the same value as the ammeters on the other rectifiers If not adjust its f
55. ifier REF reference RFA rectifier failure alarm RPM remote power monitor RST reset SHT shunt SLS slope load share SPG single point ground connection SW switch TB terminal block TCM temperature compensation module TP test point TR temporary release TST test UL Underwriters Laboratories V volt VRLA valve regulated lead acid batteries WD wiring diagram WVP water vapor pressure List of Terms 51 52 List of Terms Liebert Helios DC System 4000 48 1500 3000 4000 amp 6000 A DC Power System Technical Support U S A 1 800 222 5877 Outside the U S A 614 841 6755 U K 44 0 1793 553355 France 33 1 4 87 51 52 Germany 49 89 99 19 220 Italy 39 2 98250 1 Netherlands 00 31 475 503333 E mail upstech Oliebert com Website http www liebert com Worldwide FAX 614 841 5471 tech support The Company Behind The Products With more than 500 000 installations around the globe Liebert is the world leader in computer protection systems Since its founding in 1965 Liebert has developed a complete range of support and protection systems for sensitive electronics Environmental systems close control air conditioning from 1 5 to 60 tons Power conditioning and UPS with power ranges from 250 VA to more than 1000 kVA ntegrated systems that provide both environmental and power protection in a single flexible package Monitoring and control on site or remote from sys
56. loat and equalize voltage levels as described in the appropriate rectifier user manual see 6 0 Reference Documents Adding a Helios Rectifier 2001 48 or 200E 48 1 2 10 Ensure that the and DC circuit breakers on the front panel of the rectifier are in the OFF position Use a manual lift or at least two people to lift the rectifier to its position rest it on the angle guides and slide it into the cabinet Align the mounting holes of the rectifier with those of the cabinet uprights and secure the rectifier in place using the eight mounting screws provided Note star washer must be used on one of the mounting screws Bring the connectorized AC cord up top fed or down bottom fed the cabinet and secure as required Install the required circuit breaker at the AC service panel Ensure that the circuit breaker installed per Step 5 is locked in the open OFF position Determine the length of cable or individual wires in conduit required to bring the AC supply from the AC service panel to the rectifier cabinet Cut the cable or wires to the required lengths then run and secure between the AC service panel and the rectifier cabinet Strip the sheeting and insulation material away from the ends of the wires to expose the AC leads For a Helios Rectifier 200E 48 without an AC cord remove the AC protective cover at the rear of the rectifier and connect the AC leads inside the rectifier as shown in Figure 32 then
57. m cable size is TA 2 0 2 0AWG The lugs must be for 3 8 dia bolts at 1 c c Refer to Table 21 for the maximum panel capacity Table 17 Plug in circuit breakers available for the 24 Plug In 1 100 A circuit breaker panel Nominal current CPC Std Trip CPC Mid Trip 1A A0723076 A0722751 5A A0723033 A0722752 10A A0723035 A0722754 15A A0723037 A0722755 20A A0723007 A0722695 25A A0723039 A0722707 30A A0723040 A0722715 35A A0723041 A0722717 40A A0723042 A0722721 45 A0723069 A0722722 50A A0723008 A0722726 60A A0723070 A0722727 65A A0723071 A0722497 70A A0723072 A0722732 80A A0723074 A0722733 90A A0723077 A0722750 100A A0723009 A0722496 14 Specifications Figure 14 Front view of the 4 70 250 A circuit breaker panel CIRCUIT BREAKER PANEL 4 70 250 A REL SERNO The DC output connections can accommodate two 4 0 cables back to back for each circuit breaker The required lugs can be either for two 3 8 holes at 1 c c or for two 1 2 holes at 1 3 4 c c Refer to Table 21 for the maximum panel capacity Table 18 Circuit breaker sizes available for the 4 70 250 A circuit breaker panel Nominal current CPC 70 A no shunt A0617079 70 A with shunt A0617080 70 A with
58. ment ACO lamp lit ACO switch has been operated during an alarm condition which is still ongoing EQL lamp lit The equalize function has been activated Rectifiers are not sharing the Incorrect float or equalize adjustment on one of the rectifiers load Sense leads opened on one rectifier Share mode incorrectly set Meter display is OFF Open meter fuse Meter and display failure Meter and display rotary switch in the OFF position Addition Replacement Procedures Addition or Replacement of a Rectifier IN WARNING PRECAUTIONS SHALL BE TAKEN TO AVOID SERVICE INTERRUPTIONS WHEN INSTALLING A RECTIFIER THE FLOAT AND EQUALIZE VOLTAGES MUST BE SET ACCORDING TO THE TYPE OF BATTERIES USED WITH THE SYSTEM FAILURE TO SET THESE VOLTAGES PROPERLY MAY RESULT IN BATTERY UNDERCHARGING OR OVERCHARGING AND OR BATTERY DAMAGE WARNING PROTECTING PERSONNEL AGAINST ELECTRICAL SHOCKS INPUT VOLTAGES TO THE RECTIFIERS ARE AT A DANGEROUS LEVEL ENSURE THAT THE CIRCUIT BREAKERS ARE LOCKED IN THE OFF POSITION AT THE AC SERVICE PANEL BEFORE ATTEMPTING TO WORK ON THE RECTIFIERS DANGEROUS VOLTAGES MAY STILL BE PRESENT AT THE TERMINALS EVEN IF THE RECTIFIERS ARE OFF USE A VOLTMETER TO VERIFY FOR THE PRESENCE OF SUCH VOLTAGES DO NOT SWITCH CIRCUIT BREAKERS TO ON UNTIL INSTRUCTED TO DO SO IN THE APPROPRIATE PROCEDURE Add a rectifier as described in the following procedure for a Helios Rectifier 100 48 or as in the Adding a Helios Rectif
59. nd LED indicators for alarm indications The rectifiers use high frequency switching technology and forced air cooling Refer to the appropriate rectifier user manual listed in 6 0 Reference Documents for detailed operation information on the Helios Rectifier 100 48 the Helios Rectifier 2001 48 or the Helios Rectifier 200E 48 AC Junction Box N WARNING PREVENTING ELECTRICAL SHOCKS WHEN OPENING THE DOOR OR WIRING THE AC INPUT OF THE RECTIFIERS INSIDE THE JUNCTION BOX ENSURE THAT THE ASSOCIATED AC BREAKERS LOCATED IN THE AC SERVICE PANEL ARE IN THE OFF POSITION AND THAT A WARNING TAG CLEARLY INDICATES THAT THESE BREAKERS ARE TO REMAIN OFF UNTIL THE AC WIRING HAS BEEN COMPLETED DO NOT INSERT FUSES OR OPERATE CIRCUIT BREAKER OR SWITCHES TO ON UNTIL THE WIRING IS COMPLETED AND YOU ARE INSTRUCTED TO DO SO The AC junction box is part of the rectifier cabinet used for the Helios Rectifier 200E 48 It is located at the top of the cabinet for top fed systems or at the bottom of the cabinet for bottom fed systems The AC junction box provides AC connection interface for up to six rectifiers and facilitates the addition and or replacement of rectifiers in a working system The AC supply from the AC service panel is hard wired inside the box at the time of the initial installation Detailed cabling and con necting guidelines for the AC junction box can be found in 5 0 Maintenance The rectifiers are provided with a factory installed A
60. nitor 8000 48 25 Mechanical specifications of the AC junction 26 Mechanical specifications of fully equipped power 26 Floor and point loading e Lk EP pem ee NOS P De GR ead ance Ne 27 Vasu alandicators ou Bes e ar epe e epe Ue te Oe 28 Transmitted alarms ii E A T EU OE DA PEE RSS 29 Potentiometers Teto n te tdeo ev mee e ade pe pe eie ie E 29 DO WALCH ES ose fore ace a ae 30 DIP switch modules sers uuu eei eden neto dates ON UE M uos 30 A RENO 31 DOINGS S hse a a be la at e SER Ob DO a es 31 Fa ultsdia gnosis svo baro eres ERE eT I ADOOS Mis Spend SS e OT e ec 39 1 0 ABOUT THIS DOCUMENT 1 1 1 2 Purpose of This Document This document provides all the necessary information to operate and maintain a Helios DC Sys tem 4000 48 power system The installation procedures for the Helios DC System 4000 48 power system are covered in instal lation manual SL 60034 Applicability of This Document This document applies to Helios DC System 4000 48 power systems having any configuration of equipment About This Document 1 2 0 INTRODUCTION 2 1 Description The Helios DC System 4000 48 is a positive ground 48 V DC nominal power system consisting of one control and distribution cabinet and one or more rectifier cabinets
61. nternal circuitry of the controller Plus one unused position Test points Three sets of test points for applications as described in Table 38 Table 38 Test points Designation Description CAL OUT and To connect an external meter when calibrating the LED readout for current readings VOLT and To connect an external meter when adjusting the BOD LF LV HF HV HVSD LVD and LVR thresholds PWR EXT and The connect an external power supply when adjusting the LVR threshold Operation 31 4 2 2 Rear Panel The rear panel of the Conventional Controller is provided with the connection interface features shown in Figure 30 and described in the following subsections Figure 29 Terminal blocks and connectors layout at the rear of the Conventional Controller Q o0000000000000000000 o0000000000000000000 99955995090950905099 0 O I jes TB4 TB5 o 1 9 J8 L 1 3 P26 P24 P22 P20 P18 P16 P14 P12 P10 P8 P6 P4 P2 o E J3 Terminal blocks Six terminal blocks to interface with external wiring as follows TB1 various alarm outputs to the office alarm circuits and the cabinet alarm lamp TB2 various alarm outputs to the office alarm circuits and remote equalize signal input TB3 various alarm outputs to the office alarm circuits
62. of the AC junction box Figure Height Depth Width Figure 25 264 mm 284 mm 521 mm 10 4 in 11 2 in 20 5 in 3 10 2 Electrical Specifications The junction box is designed to accommodate six 3 phase circuits 3 wires plus ground at a maxi mum voltage of 600 V AC and a capacity of 30 A per circuit 3 11 Overall Power System Specifications 3 11 1 Standards The Helios DC System 4000 48 meets the following North American and European standards UL 1801 CSA 22 2 80 7 225 TR TSY 000406 CE VDE 3 11 2 Mechanical Specifications of Fully Equipped Power Cabinets Table 30 Mechanical specifications of fully equipped power cabinets Total weight 4000 A control Total weight 1200 A rectifier Height Depth Width and distribution cabinet cabinet with six rectifiers 2134 mm 600 mm 600 mm 363 kg 440 kg 84 in 23 62 in 23 62 in 800 Ib approx 970 Ib approx 26 Specifications 3 11 3 3 11 4 3 11 5 Electrical Specifications Refer to the individual component s specifications Electromagnetic compliance EMC The equipment contained in the power system complies with the specifications of F CC Part 15 Subpart B for class A equipment CSA 108 8 for class and CISPR 22 for class A Electrostatic discharge ESD immunity No equipment damage or malfunctions shall occur when electrostatic discharge voltages of sever ity level 2 and 4 as specified by IE
63. onnect the control and signal cable from the DB25 connector at the rear of the rectifier Remove the mounting screws securing the rectifier to the cabinet Carefully slide the rectifier out of the cabinet CAUTION Due to the weight of the rectifier 55 kg 120 lb a manual lift or at least two persons are required to remove the rectifier Reuse the shipping carton of the new rectifier to store or ship the removed unit Ensure that the AC and DC circuit breakers on the front panel of the new rectifier are in the OFF position Lift the new rectifier to its position rest it on the angle guides and slide it into the cabinet CAUTION Due to the weight of the rectifier 55 kg 120 lb a manual lift or at least two persons are required to install the rectifier Align the mounting holes of the rectifier with those of the cabinet uprights and secure the rectifier in place using the eight mounting screws provided Note star washer must be used on one of the mounting screws Reinstall the four bolts for the DC connections to the busbar risers at the rear of the cabinet removed in Step 6 Reconnect the control and signal cable into the DB25 connector at the rear of the rectifier disconnected in Step 7 Reconnect the AC cable disconnected in Step 5 or the AC cord that was unplugged At the AC service panel place the AC circuit breaker associated with the rectifier in the ON position Operate the AC circuit breaker of the new rectifier to
64. ote that for a 6000 A system the cabling is always at the top Table 1 Rectifier cabinets Rectifier Cabinet Capacity Type Qty Cabled top or bottom 1200A Helios Rectifier 2001 6 Top 1200A Helios Rectifier 2001 6 Bottom 1000 A Helios Rectifier 100 48 10 Top or bottom 1200A Helios Rectifier 200E 6 Top 1200A Helios Rectifier 200E 6 Bottom 1200A Helios Rectifier 200E 6 Top 1200A Helios Rectifier 200E 6 Bottom Table 2 Control and distribution cabinets Nominal cabinet capacity Shunt capacity Riser busbar capacity Cabled top or bottom 1500A 2500 A 2000A Top 3000 A 4000 A 3000 A Top 4000 A 5000 A 3000 A Top 1500 A 2500 A 2000 A Bottom 3000 A 4000 A 3000 A Bottom 4000 A 5000 A 3000 A Bottom For a 6000 A system the charge busbars and the shunt are mounted externally from the control and distribution cabinet Table 3 Auxiliary distribution cabinets Nominal cabinet capacity Top busbar capacity Riser busbar capacity Cabled top or bottom 2000 A 3000 A 2000 A Top 2000 A 3000 A 2000 A Bottom 3000 A 4000 A 3000 A Top 3000 A 4000 A 3000 A Bottom Introduction 5 3 0 SPECIFICATIONS 3 1 3 1 1 Framework The Helios DC System 4000 48 uses cabinet type frameworks The same cabinet design is used for the main control and distribution cabinet the auxiliary distribution cabinets and the rectifier cab inets The cabinet is always equippe
65. relay trip A0617081 100 A no shunt A0616667 100 A with shunt A0616668 100 A with relay trip A0616669 150 A no shunt A0616670 150 A with shunt A0616671 150 A with relay trip A0616672 200 A no shunt A0616673 200 A with shunt A0616674 200 A with relay trip A0616675 225 A no shunt A0605489 225 A with shunt A0605490 225 A with relay trip A0605492 250 A no shunt A0616676 250 A with shunt A0616677 250 A with relay trip A0616678 The 4 70 250 A circuit breaker panel can accept up to four breakers 70 to 225 A mid trip with or without the metering shunt option 1 pole breakers two breakers 70 to 225 mid trip with the relay trip option takes a 2 pole space two breakers 250 A mid trip with or without the metering shunt option takes a two pole breaker one 250 breaker mid trip with the relay trip option takes a 3 pole space Specifications 15 Figure 15 Front view of the 2 400 A circuit breaker panel CIRCUIT BREAKER PANEL 2 400 A REL SERNO The DC output connections can accommodate two 750 MCM cables back to back for each circuit breaker The required lugs must be for two 1 2 holes at 1 3 4 c c Refer to Table 21 for the maximum panel capacity Table 19 Circuit breaker kits available for the 2 400 A circuit breaker panel
66. s to display the alarm conditions as described in Table 32 All alarm conditions are also displayed by a red incan descent cabinet alarm lamp Table 32 Visual indicators Designation Description Color RECT FAN Rectifier Fan Failure yellow EQL Equalize On yellow FA Fuse Failure Alarm Internal to the Controller red DFA Discharge Fuse Alarm red CFA not used Charge Fuse Alarm red RFA MIN Rectifier Failure Alarm Minor yellow RFA MAJ Rectifier Failure Alarm Major red ACO Alarm cut off red HVSD High Voltage Shutdown Alarm red HV High Voltage Alarm red LV Low Voltage Alarm red HF High Float Alarm yellow LF Low Float Alarm yellow LVD Low Voltage Disconnect red BOD Battery On Discharge red LOP Loss of Phase red AUX 1 BDA Auxiliary Major red AUX 2 Auxiliary Minor yellow 28 Operation Table 33 Transmitted alarms MIN VIS note 2 2 Form C contacts MAJ VIS note 2 MIN AUD 2 Form C contacts MAJ AUD Alarm Description RECT FAN 1 Form C contacts RFA MIN 1 Form C contacts RFA MAJ 1 Form C contacts H L FLOAT 2 Form C contacts EQL ALM 1 Form C contacts H L VOLT 2 Form C contacts FA 1 Form C contacts CHG FUSE 1 Form C contacts DISCH FUSE 1 Form C contacts LVD 1 Form C contacts LOSS OF AC VOLT 1 Form C contacts AUX 1 ALM 2 Form C contacts
67. t attempt to open the unit for on site servicing 38 Maintenance 5 2 Troubleshooting Table 39 provides a list of the problems that may occur on the Helios DC System 4000 48 along with their possible causes Blown fuses and tripped circuit breakers should always be investi gated before utilizing Table 39 Table 39 Fault diagnosis Fault symptom No DC output current Possible causes Open AC circuit breaker Open DC circuit breaker Faulty connection between the power shelf and the rectifier Helios Rectifier 100 48 Faulty connection between the rectifier and the power plant Sense leads opened Incorrect indication of the DC output current Incorrect meter calibration Loose shunt leads connection Low float voltage Faulty rectifier s Shorted battery cell s Prolonged power failure Incorrect float voltage adjustment Sense leads opened Low recharge voltage Incorrect float voltage adjustment Discharge load greater than the rectifiers capacity batteries are recharging or the system is in manual bypass Sense leads opened High float or recharge voltage Faulty rectifier s Incorrect Float Equalize adjustment Failure to generate alarms during alarm conditions Incorrect connections between the controller and the rectifiers and distribution panels Failure to generate cabinet alarm during minor or major alarm conditions Faulty LP fuse on the controller F31 Faulty
68. tems of any size or location Service and support through more than 100 service centers around the world and a 24 hour Customer Response Center While every precaution has been taken to ensure 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 O 1998 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert and the Liebert logo are registered trademarks of Liebert Corporation All names referred to are trademarks or registered trademarks of their respective owners Printed in U S A SL 60030 Revised June 1999
69. wo 1 2 dia bolts at 1 3 4 c c Table 13 Fuse sizes available for the 4 TPL 225 600 A fuse panels Fuse type Current A CPC 225 A0380138 300 A0380140 DC power TPL 400 A0380141 500 A0380142 600 A0380143 Specifications 11 Figure 12 Front view of the 18 TPS 1 70 A fuse panel MAX FUSE 70A 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 UNIT AMPS FA LOAD O FUSE PANEL NT6C21XX SER ND C 2 600 A MAX PANEL CAPACITY Can accept maximum 1 0 AWG cables and requires one hole lugs for 1 4 diameter studs Table 14 Fuse sizes available for the 18 TPS 1 70 A fuse panel Fuse type Current A CPC 1 A0601322 3 A0601323 5 A0601325 6 A0601326 10 A0601327 DC power TPS 15 A0601328 25 A0601330 30 A0601331 40 A0601332 50 A0601333 60 A0601334 70 A0601335 12 Specifications Electrical specifications of the fuse panels The electrical specifications of the fuse panels are described in Table 15 Table 15 Electrical specifications of the fuse panels Fuses Busbar Panel number Figure Quantity Capacity capacity 20 QFF 0 5 A Figure 5 20 0 5A 60A 60 A max 16 QFF 0 5 A 8 Figure 6 16 0 5A 300 A 12 ABS 5 30 A 12 0 30 A 300 A max 16

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