DC POWER Helios DC System 4000/48 1500, 3000, 4000 & 6000 A DC Power System User Manual
TABLE OF CONTENTS 1.0 ABOUT THIS DOCUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Purpose of This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Applicability of This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 Overall Power System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.11.1 3.11.2 3.11.3 3.11.4 3.11.5 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Specifications of Fully Equipped Power Cabinets . . . . . . . . . . . . . . . . . . . . . Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURES 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 Front view of a typical bottom fed 4000 A Helios DC System 4000/48 power system . . . . . . .
TABLES 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 iv Rectifier cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.0 ABOUT THIS DOCUMENT 1.1 Purpose of This Document This document provides all the necessary information to operate and maintain a Helios DC System 4000/48 power system. The installation procedures for the Helios DC System 4000/48 power system are covered in installation manual SL-60034. 1.2 Applicability of This Document This document applies to Helios DC System 4000/48 power systems having any configuration of equipment.
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. It is available in capacities of 1500, 3000, 4000 and 6000 A. Auxiliary distribution cabinets can be added as required for additional distribution. Remote monitoring, temperature compensation and battery disconnect options are also available.
Figure 2 Front view of a typical 6000 A Helios DC System 4000/48 power system 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 A 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 cabinet to facilitate the connections of the battery return cables.
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).
Cabinets are available in a variety of configurations as listed in the following tables. Note that for a 6000 A system, the cabling is always at the top.
3.0 SPECIFICATIONS 3.1 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 cabinets.
3.2 Conventional Controller 3.2.1 Mechanical Specifications of the Conventional Controller The mechanical specifications of the Conventional Controller are listed in Table 5. Table 5 Figure 4 3.2.2 Mechanical specifications of the Conventional Controller Figure Height Depth Width Weight Figure 4 152 mm (6.0 in.) 76 mm (3.0 in.) 584 mm (23 in.) 4.5 kg (10 lb) Front view of the Conventional Controller Electrical Specifications of the Conventional Controller The operating voltage is -48 V DC.
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 60 A max Figure 5 76.2 mm (3.0 in.) 584 mm (23.0 in.) 3 kg (6.6 lb) (16) QFF 0-5 A & (12) ABS 5-30 A 300 A max Figure 6 76.2 mm (3.0 in.) 584 mm (23.0 in.) 5 kg (11.
Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels FA -48 V 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 & (12) ABS 5-30 A fuse panels Fuse type Current (A) CPC 5 A0327000 8 A0111415 10 A0315462 12 A0267003 15 A0344157 20 A0314873 25 A0243206 30 A0328460 QFF1A 1.333 A0205202 QFF1B 2 A0205203 QFF1C 3 A0205204 QFF1D 5 A0205205 QFF1E 0.18 A0205206 QFF1F 0.
Figure 8 Front view of the (8) TPN 5-30 A fuse panels FA ALM -48 V 1/2 A 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 DC power (TPN) Figure 9 Current (A) CPC 35 A0380150 40 A0380151 45 A0380152 50 A0380114 60 A0380115 Front view of the (4) RS100P 70-100 A fuse panels ALM FA (1) (2) (3) (4) (1) (2) (3) (4) -48 V The DC output connections are 0.
Figure 10 Front view of the (4) CRS200P 150-200 A/(4) CRS200P 150-200 A (w/load shunts) fuse panels (2) (1) (1) (3) (4) (3) FA ALM ALM (4) (2) The DC output connections are 0.50-13 studs equipped with two hex nuts.
Figure 12 Front view of the (18) TPS 1-70 A fuse panel MAX FUSE 70A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 FA UNIT AMPS LOAD FUSE PANEL 600 A MAX PANEL CAPACITY NT6C21XX Can accept maximum 1/0 AWG cables and requires one-hole lugs for 1/4” diameter studs.
Electrical specifications of the fuse panels The electrical specifications of the fuse panels are described in Table 15.
Figure 13 Front view of the (24) Plug-In 1-100 A circuit breaker panel The DC output connections vary according to the circuit breaker capacity: maximum cable size is 2/0AWG. The lugs must be for 3/8” dia. bolts at 1” c-c. Refer to Table 21 for the maximum panel capacity.
Figure 14 Front view of the (4) 70-250 A circuit breaker panel 900A MAX. PANEL CAPACITY CIRCUIT BREAKER PANEL NT6C12EEA (4) 70-250 1 FA REL ( ) SER NO ( ) 2 UNIT AMPS 1 225 2 225 3 225 4 225 LOAD 3 4 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.
Figure 15 Front view of the (2) 400 A circuit breaker panel 900A MAX. PANEL CAPACITY CIRCUIT BREAKER PANEL NT6C12EF (2) 400 A FA 1 REL ( ) SER NO ( ) UNIT AMPS 2 400 1 400 LOAD 2 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.
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 Figure Max.
3.4 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). 3.4.
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” 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 lb).
3.6 MPS300 and MPA100 Power Shelves The MPS300 and MPA100 power shelves are required for the Helios Rectifier 100/48, which is a 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.
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.
Electrical specifications of the Helios Rectifier 100/48 The electrical specifications of the Helios Rectifier 100/48 are listed in Table 25. Table 25 Electrical specifications of the Helios Rectifier 100/48 Parameter 3.7.
Figure 22 Front view of the Helios Rectifiers 200I/48 and 200E/48 VOLT VOLT CAL CUR CAL AMP CL ADJ VOLT/AMP 1 THSD RFA SEN FAIL EQL ADJ AC ON EQL HVSD FAN ALM CL EQL FFI 1.0A FF2 1.
3.7.3 Electrical Specifications of the Helios Rectifiers 200I/48 and 200E/48 The electrical specifications of the Helios Rectifiers 200I/48 and 200E/48 are listed in Table 27. Table 27 Electrical specifications of the Helios Rectifiers 200I/48 and 200E/48 Parameter 3.7.
3.8 Helios Monitor 3000/48 (Optional) 3.8.1 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 (1.75 in.) 222 mm (8.75 in.) 280 mm (11.0 in.) 2.8 kg (6.2 lb) The above dimensions are without the mounting brackets.
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 2 3 4 5 6 7 8 TB1 RECT 4 RECT 3 1 9 10 11 12 L1 L2 L3 GRD L1 L2 L3 GRD L1 L2 L3 GRD 1 RECT 5 2 3 RECT 2 4 5 6 7 8 TB2 RECT 1 9 10 11 12 L1 L2 L3 GRD L1 L2 L3 GRD L1 L2 L3 GRD RECT 6 3.10.
3.11.3 Electrical Specifications Refer to the individual component’s specifications. Electromagnetic compliance (EMC) The equipment contained in the power system complies with the specifications of FCC, Part 15, Subpart B for class A equipment, CSA 108.8 for class A and CISPR 22 for class A.
4.0 OPERATION 4.1 General This chapter describes the control, adjustment and operational features of the Helios DC System 4000/48. 4.2 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.
Table 33 Transmitted alarms 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) AUX 2 ALM (2 - Form C contacts) HVSD (1 - Form C contacts) BOD (
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.
Figure 28 Equalize voltage and duration settings TIMER Switch # 1 2 3 4 VOLT 5 6 Switch # 1 2 3 0.6V 10 sec. 1.3V 20 sec. OFF ON 1.9V 38 sec. 1 2 2.6V 1.25 h 3 4 3.2V 3.0 h 5 1 2 3 6 3.9V 5.0 h ON OFF 4.6V 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.
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 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB4 v NE-1451X cable NE-1451X cable (or equivalent) (or equivalent) TB3 H/L FLOAT ALM (1) H/L FLOAT ALM (1) H/L FLOAT ALM (2) H/L FLOAT ALM (2) MIN RECT ALM To office alarm circuit MIN RECT ALM MAJ RECT ALM MAJ RECT ALM LVD ALM LVD ALM LOSS OF AC VOLT ALM LOSS OF AC VOLT ALM C NC NO C NC NO C NC NO C NC NO C NC NO C NC NO Input from DISCH fuse alarm circuits DFA Input from CHG fuse alarm circuits CFA NE-1451X cable (or equivalent)
Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P26 22GA 8-conductor shielded cable To alarm To NT6C43PA interface or board or NT6C43PB rectifier rectifier interface interface card as card as required, required, ordirectly or directly to rectifier P1 TO P24 EQL ( ) 1 2 3 4 5 6 7 8 RG+ ( ) RC- ( ) TR ( ) FAN ( ) HVSD ( ) RFA ( ) to rectifier 22GA 2-conductor shielded cable Main SHUNT + plant SHUNT – shunt (the shunt wires should be fused near the shunt
4.4 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 200I/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.
4.8 Helios Monitor 3000/48 (Optional) The Helios Monitor 3000/48 is a microprocessor-based unit used to monitor and record power systems 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. If an Helios Monitor 3000/48 was supplied with your system, refer to the Monitor 3000 user manual, SL-60015, for detailed operational characteristics. 4.
5.0 MAINTENANCE 5.
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 representative 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.
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 investigated before utilizing Table 39.
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.
Adding a Helios Rectifier 100/48 1. 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. 2. Verify that the AC, DC and signalling cabling for the rectifier shelf has been previously installed and verified. 3. Ensure that the AC and DC circuit breakers on the front panel of the rectifier are in the OFF position. 4.
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.
Figure 33 AC connections in the female receptacle for a Helios Rectifier 200I/48 or a Helios Rectifier 200E/48 Cover Cover Phase 2 or L2 Phase 2 or L2 Phase 3 or L3 Phase 1 or L1 Phase 3 or L3 Phase 1 or L1 GRD GRD Helios Rectifier 200I/48 (380 V ac) Helios Rectifier 200E/48 (480 V ac) Figure 34 AC connections inside the junction box (top fed shown) for a Helios Rectifier 200E/48 Teck cables or flexible conduits Junction box shown with front cover open Screw type terminal block Tie down 1 2 3
Figure 35 AC cable routing for the Helios Rectifiers 200E/48 in a top fed system Junction box Partial view of junction box RECT 1 Enlarged view of routing of the AC cables from behind the junction box to the side of the rectifiers. RECT 2 RECT 3 RECT 4 RECT 5 RECT 6 Partial view of Rect. 1 Rect. Rect. 5 Rect. 4 Rect. 3 Rect. 2 1 Rect. 6 Figure 36 AC cable routing for the Helios Rectifiers 200E/48 in a bottom fed system Partial view of Rect. 6 RECT 1 Rect. Rect. 6 Rect. 5 4 Rect. Rect. 3 Rect.
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 200I/48 or 200E/48, whichever is applicable. Replacing a Helios Rectifier 100/48 1. 2. 3. 4. 5. 6. 7. 8. 9. 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.
Replacing a Helios Rectifier 200I/48 or 200E/48 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 46 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.
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 procedure. ! WARNING 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.
5.3.4 Replacement of a Distribution Fuse Block or Circuit Breaker ! CAUTION 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. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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.
6.0 REFERENCE DOCUMENTS Manual No.
7.
HVSD HVSDA HVSDR in. in.
52 List of Terms
Helios DC System 4000/48 1500, 3000, 4000 & 6000 A DC Power System Technical Support U.S.A. Outside the U.S.A. U.K. 1-800-222-5877 614-841-6755 +44 (0) 1793 553355 France +33 1 4 87 51 52 Germany +49 89 99 19 220 Italy Netherlands E-mail Web site Worldwide FAX tech support +39 2 98250 1 +00 31 475 503333 upstech@liebert.com http://www.liebert.
