Liebert 6000 A - Manuals

iv TABLES Table 1 Rectifier cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 2 Control and distribution cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

About This Document 1 1.0 A BOUT T HIS D OCUMENT 1.1 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...

2 Introduction 2.0 I NTRODUCTION 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 distributio...

Introduction 3 Figure 2 Front view of a typical 6000 A Helios DC System 4000/48 power system 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, ...

4 Introduction 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). Figure 3 Typical configura...

Introduction 5 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. Table 1 Rectifier cabinets Cabinet Capacity Rectifier Cabled top or bottom Type Qty 1200 A Helios Rectifier 200I 6 Top 1200 A Helio...

6 Specifications 3.0 S PECIFICATIONS 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 cab- inets. The cabinet is always equipped with a front d...

Specifications 7 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. Figure 4 Front view of the Conventional Controller 3.2.2 Electrical Specifications of the Conventional Contr...

8 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. Figure 5 Front view of the 20 QFF 0-5 A fuse panels The DC output connections are wire wrap or solder. Table 6 Mechani...

Specifications 9 Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels The DC output connections are No. 8-32 studs equipped with two hex nuts. Figure 7 Front view of the (16) QFF 0-5 A & (6) TPN 5-30 A fuse panels The DC output connections are 0.250-20 studs equipped with ...

10 Specifications Figure 8 Front view of the (8) TPN 5-30 A fuse panels The DC output connections are 0.250-20 studs equipped with two hex nuts. Figure 9 Front view of the (4) RS100P 70-100 A fuse panels The DC output connections are 0.375-16 studs equipped with two hex nuts. Table 10 Fuse sizes ava...

Specifications 11 Figure 10 Front view of the (4) CRS200P 150-200 A / (4) CRS200P 150-200 A (w/load shunts) fuse panels The DC output connections are 0.50-13 studs equipped with two hex nuts. Figure 11 Front view of the (4) TPL 225-600 A fuse panels The DC output connections are busbar angles that c...

12 Specifications Figure 12 Front view of the (18) TPS 1-70 A fuse panel 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 DC power (TPS) 1 A0601322 3 A0601323 5 A0601325 6 ...

Specifications 13 Electrical specifications of the fuse panels The electrical specifications of the fuse panels are described in Table 15. 3.3.2 Circuit Breaker Panels Mechanical specifications of the circuit breaker panels The mechanical specifications of the circuit breaker panels are described in...

14 Specifications 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. Table 17 P...

Specifications 15 Figure 14 Front view of the (4) 70-250 A circuit breaker panel The DC output connections can accommodate two 4/0 cables back 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 ...

16 Specifications Figure 15 Front view of the (2) 400 A circuit breaker panel 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. The panel acc...

Specifications 17 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 Panel description Figure Circuit breakers Busbar capacity Max. Quantity Ca...

18 Specifications 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, ...

Specifications 19 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 t...

20 Specifications 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...

Specifications 21 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...

22 Specifications Electrical specifications of the Helios Rectifier 100/48 The electrical specifications of the Helios Rectifier 100/48 are listed in Table 25. 3.7.2 Helios Rectifiers 200I/48 and 200E/48 Mechanical specifications of the Helios Rectifiers 200I/48 and 200E/48 The mechanical specificat...

Specifications 23 Figure 22 Front view of the Helios Rectifiers 200I/48 and 200E/48 VOLT AMP VOLT CAL FS ST UPDLY SLS CC/DC 0 1 EQL THSD CLADJ EQLADJ RFA SEN FAIL HVSD FAN ALM EQL AC ON CL VOU TÐ FFI1.0A FF21.0A FLTADJ VOLT/AMP VOU T+ HVSDADJ FLT CA/AC 1 0 CURCAL

24 Specifications 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. 3.7.4 Standards The following standards also apply to the rectifiers: • ANSI Std. C62.41/IEEE Std. 587-198...

Specifications 25 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. The above dimensions are without the mounting brackets. The weight may vary slightly depend- ing on the number and type of analo...

26 Specifications 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) 3.10.1 Mechanical Specifications The junction box is made of ...

Specifications 27 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 fo...

28 Operation 4.0 O PERATION 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 m...

Operation 29 Potentiometers Twelve potentiometers for the adjustment of alarm and control functions as described in Table 34. 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 A...

30 Operation Switches Four switches for the control of functions as described in Table 35. 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. Figure 27 Shunt range selection settings Table 35 Switches Designation Descr...

Operation 31 Figure 28 Equalize voltage and duration settings 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. Test points Three sets of test points for applications as...

32 Operation 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 Terminal blocks Six...

34 Operation Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P26 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 sys...

Operation 35 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 ov...

36 Operation 4.8 Helios Monitor 3000/48 (Optional) The Helios Monitor 3000/48 is 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.If an H...

Maintenance 37 5.0 M AINTENANCE 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/...

38 Maintenance 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. C...

Maintenance 39 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 Pos...

40 Maintenance 5.3 Addition / Replacement Procedures 5.3.1 Addition or Replacement of a Rectifier Add a rectifier as described in the following procedure for a Helios Rectifier 100/48 or as in the Adding a Helios Rectifier 200I/48 or 200E/48 procedure, whichever is applicable. LOP lamp lit Loss of o...

Maintenance 41 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 h...

42 Maintenance 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. 11. Ma...

Maintenance 43 Figure 33 AC connections in the female receptacle for a Helios Rectifier 200I/48 or a Helios Rectifier 200E/48 Figure 34 AC connections inside the junction box (top fed shown) for a Helios Rectifier 200E/48 Phase 2or L2 Phase 3or L3 Cover GRD Phase 1or L1 Phase 2or L2 Phase 3or L3 Cov...

Maintenance 45 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. Notify the alarm center of incoming alarms during this procedure.2...

46 Maintenance Replacing a Helios Rectifier 200I/48 or 200E/48 1. Notify the alarm center of incoming alarms during this procedure.2. Turn OFF the AC and DC circuit breakers on the rectifier to be replaced.3. Remove the corresponding sense fuse on the front of the controller.4. At the AC service pan...

Maintenance 47 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. 1. Removal of the old string: Notify the alarm center of the possibility of incoming alarms during this procedure. 2. Above the battery stan...

48 Maintenance 5.3.4 Replacement of a Distribution Fuse Block or Circuit Breaker Replace a distribution fuse block as described below.1. Notify the alarm center of incoming alarms during this procedure.2. Remove the fuse from the fuse block to be replaced.3. Remove the rear panels of the cabinet.4. ...

Reference Documents 49 6.0 R EFERENCE D OCUMENTS 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 Heli...

Revised: June 1999 Helios DC System 4000/48 1500, 3000, 4000 & 6000 A DC Power System Technical 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 devel...