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DC P OWER Helios DC System 4000/48 1500, 300 0, 4000 & 6000 A DC Power System User Manual.
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i T ABLE OF CONTENTS 1.0 A BOUT T HIS D OCUMEN T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Purp ose of This Docum ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 3.11 Over all P ower System Spec ificat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.11.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii i FIGURES Figure 1 Front view o f a typical bo ttom fed 4000 A H elios DC Sy stem 4000/48 power syst em . . . . . . . 2 Figure 2 Front view o f a typical 600 0 A Helios D C System 4 000/48 powe r system .
iv T ABLES Table 1 Rectifier cab inets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 2 Control and distrib ution cabinets . . . . . . . . . . . . . . . . . . . . . . .
About Thi s Document 1 1.0 A BOUT T HIS D OCUMENT 1.1 Purpose of This Document This do cument prov ides all the n ecessary information to operate an d maintain a Helios DC Sys- tem 4000/4 8 power s ystem. The ins tallation procedu res for th e Helios D C System 4000/48 pow er system a re covere d in instal- lation man ual SL-6003 4.
2 I ntroductio n 2.0 I NTRODUCTION 2.1 D escrip tion The Heli os DC S ystem 4000 /48 is a po sitive gro und, -48 V DC nominal power sys tem consis ting of one control and distribution cabinet and one or more rectifier cabinets. It is available in capacities of 1500 , 3000, 40 00 and 60 00 A.
Introduc tion 3 Figure 2 Front vie w of a typical 6000 A H elios DC System 4 000/48 pow er system Cables are used for in ter-cabinet connections (1500, 300 0 and 6000 A s ystems) or co nnections t o the over head busb ars (6000 A s ystem) for ease of ex pansion on live syste ms.
4 I ntroductio n 2.3 Control and Distribution Cabinets - T ypical Configurations Figure 3 shows the front and side views of typical rectifier and distribution cabinets for a Helios DC Syste m 4000/48 ( bottom cabled cabinets are i llustrated - top cabled versions are av ailable).
Introduc tion 5 Cabinets a re availab le in a varie ty of conf iguration s as liste d in the fol lowing t ables. Note t hat for a 6000 A sy stem, t he cabling is always at the top.
6 Sp ecification s 3.0 S PECIFICATIONS 3.1 Framew ork The Helio s DC Sy stem 400 0/48 uses ca binet type frameworks . The same cabinet des ign is use d for the main con trol and distribu tion cabin et, the auxilia ry distributio n cabinets and th e rectifier cab- inets.
Specific ations 7 3.2 Conventional Controller 3.2.1 Mechanical Speci fications of the Conve ntional Controll er The mech anical spec ifications o f the Conve ntional Controller a re liste d in Table 5. Figure 4 Front view of the Conventional Controller 3.
8 Sp ecification s 3.3 Distribution Panels 3.3.1 Fuse Panels Mechanical spec ification s of the fuse panels The mechani cal specif icatio ns of the fuse pa nels 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 sol der.
Specific ations 9 Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels The DC output conne ctions are No. 8 -32 studs equipped w ith two hex nuts . Figure 7 Front view of the (16) QFF 0-5 A & (6) TPN 5-3 0 A fuse panels The DC output conne ctions are 0.
10 Specific ations Figure 8 Front view of the (8) TPN 5-3 0 A fuse panels The DC output conne ctions are 0.2 50-20 studs equipp ed with two hex nut s. Figure 9 Front vie w of the (4) RS100P 70- 100 A fuse panels The DC output conne ctions are 0.3 75-16 studs equipp ed with two hex nut s.
Specifica tions 11 Figure 1 0 Front view of the (4) CRS200P 150-200 A / (4) CRS20 0P 150-200 A (w/load shunts) fuse panels The DC output conne ctions are 0.
12 Specific ations Figure 12 Front view of the (18) TPS 1-70 A fuse panel Can accept maximum 1/0 AW G cables and requires on e-hole lugs for 1/4” dia meter st uds.
Specifica tions 13 Electrica l specificati ons of the fuse panels The electr ical specifi cations of the fu se panels are described in Tabl e 15. 3.3.2 Circuit Breaker Panels Mechanical spec ifications of the c ircuit breaker panels The mechan ical specif ications of the circuit bre aker panels are described in Table 16.
14 Specific ations Figure 13 Front view of the (2 4) Plug-In 1-100 A circuit breaker panel The DC output connect ions vary according to the circuit breaker capacity: maximum cable size is 2/0A WG. Th e lugs m ust be for 3/ 8” dia. bolts at 1” c -c.
Specifica tions 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 t o back for each circuit breaker. The require d lugs can be either for two 3/8” holes at 1” c- c or for tw o 1/2” holes at 1-3/4” c-c.
16 Specific ations Figure 15 Front view of the (2) 400 A circuit breaker panel The DC o utput connect ions can accom modate two 750 MCM cables back to back for e ach circuit breaker. Th e requir ed lugs must be for two 1/2” holes at 1-3/4” c-c. Refer to Table 21 for the maximum panel capacity.
Specifica tions 17 Electrica l specifications of the ci rcuit breaker panels The electri cal specifica tions of the circui t breaker panels are de scribed in Table 21. T abl e 21 Electrical s pecificat ions of the circuit bre aker panel s Panel de scripti on Figure Circui t breakers Busbar capa city Max.
18 Specific ations 3.4 Externally Mounted Battery Ret urn Busbar The batt ery return busba r is desig ned to mount on the ov erhead rack ing for 6000 A systems an d top cabl ed 1500, 300 0 or 4000 A power sys tems.
Specifica tions 19 3.5 T erminating Assemblies (Optional) The optional terminating assembly allows top access conn ections for up to six loads. Refer to Figure 18. Each l oad position is rated at 600 A and can accept up to three lugs having 1” or 1-3/4” c-c hole spacin g, for cables up to 777 kcmi l.
20 Specific ations 3.6 MPS 300 and MP A100 Power Shel ves The MPS 300 and MPA1 00 power shel ves are requ ired for the H elios Rectifie r 100/48, w hich is a plug-in type rectifier. The MPA100 power shelf supports one Helios Rect ifier 100/48, whil e the MPS300 shelf can s upport up to three He lios Rectif iers 100/48.
Specifica tions 21 Figure 20 Front view of the MP A1 00 power shel f (shown empty) 3.6.2 Electrica l Specificati ons of the Power Shelves Each rectifier position provides interconnection points for AC input (208 to 240 V nominal ), DC output ( -48 V nomina l) and cont rol and ala rm signals.
22 Specific ations Electrica l specifications of the Heli os Rectifier 100/ 48 The ele ctrical spec ifications of the Helios Rectifier 100 /48 are liste d in Table 25.
Specifica tions 23 Figure 22 Front vie w of the Helio s Rectifier s 200I/48 a nd 200E/48 VOLT AMP VOL T CAL FS ST UP DLY SLS CC/ DC 0 1 EQL THSD CL AD J EQL AD J RFA SEN FAIL HVSD FAN ALM EQL AC ON CL VOU TÐ FFI 1.
24 Specific ations 3.7.3 Electrica l Specificati ons of the Helios Rectifiers 200I /48 and 200E/48 The ele ctrical spec ifications o f the Helio s Rectifiers 2 00I/48 and 2 00E/48 a re liste d in Table 27. 3.7.4 St andards The fo llow ing st andard s als o appl y to the rectif ier s: • ANSI Std.
Specifica tions 25 3.8 Helios Monitor 3000/48 (Optional) 3.8.1 Mechanical Speci fications The mech anical spe cifications of the He lios Mon itor 3000/ 48 are list ed in Table 28.
26 Specific ations 3.10 AC Junction Box The AC jun ction box is required as an AC conne ction interface in rectifier cab inets wher e the Helios Rectifier 200 E/48 is used.
Specifica tions 27 3.1 1.3 Electrical Specifica tions Refer t o the indiv idual comp onent’s specificat ions. Electromagneti c compliance ( EMC) The e quipme nt con tained in the p ower s ystem complie s with t he sp ecifi cations of FCC , Part 15, Subpart B for class A equipment, CSA 108.
28 Operation 4.0 O PERATION 4.1 Gene ral This chap ter describe s the con trol, adjus tment and o perational features of the Helios DC System 4000/48. 4.2 Conventional Controller The Convent ional Contro ller monit ors the operat ion of the entire power pl ant.
Operati on 29 Potentiometer s Twelve potentiometers for th e adjustment of alarm and control functions as described in Table 34. T able 3 3 T r ansmitted alarms Alar m Descripti on RECT FAN (1 - Form .
30 Operation Switches Four switches for the co ntrol of functions as described in Table 35. DIP switches Three DIP switch modules fo r the setting of functions as described in Table 36 and as shown in Figure 27 and Figure 28.
Operati on 31 Figure 28 Equalize voltage and dura tion settings Fuses Thirty-four fuses for circuit protecti on as described in Table 37. Except for the ABS fuse, which is small tu be type (9 /32” dia x 1-1/4” lon g), al l fuses are of the Q FF type .
32 Operation 4.2.2 Rear Panel The rear pa nel of the Con ventional Co ntroller is provided with t he connect ion interfa ce features shown in Figure 30 and described in th e following sub sections.
Operati on 33 Figure 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB4 v 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 .
34 Operation Figure 31 Wiring diagra m and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P26 Connectors Twen ty-six co nnect ors to in terfac e with extern al equ ipment as foll .
Operati on 35 4.4 Rectifiers The recti fiers provide isolated , filtered and re gulated DC power, from either a single-phas e AC source (Helios Rectifier 100/48) or a three-phase AC source (Helios Rectifier 200I/48 or 2 00E/48), for charging a positive grounded battery.
36 Operation 4.8 Helios Monitor 3000/48 (Optional) The Helios Monitor 3000/48 is a microprocessor-based unit used to monitor and record powe r sys- tems opera tional da ta. The reco rded data is acces sible lo cally by mea ns of the front panel or the RS-232 port, or remotely through the mode m link.
Mainte nance 3 7 5.0 M AINTENANCE 5.1 Gene ral The foll owing is a list of ge neral preven tive maint enance procedur es which shoul d be performed periodically as required according to the environmen.
38 Maint enance Air filt er replacement In dusty envi ronments, th e use of an ai r filter is strongly recommend ed. When used , it should b e replaced at least once a year. Do n ot install a wet filter on a rectifier. T o remove the filte r, simply unscrew it .
Mainte nance 3 9 5.2 T roublesho oting Table 39 provides a li st of the probl ems that may occur on the Hel ios DC System 4 000/48, al ong with their possible causes. Blown fuses and tripped circuit breakers should always be investi- gated be fore utilizing Table 39.
40 Maint enance 5.3 Addition / Replacement Procedures 5.3.1 Addition or Replacement of a Rectifier Add a rectifie r as describ ed in the following p rocedure for a Helio s Rectifier 100/48 or as in the Adding a Helios Rectifier 200I/48 or 200E/48 procedure, whi chever is applica ble.
Mainte nance 4 1 Adding a Hel ios Rectifier 100/48 1. Remove th e rectifier bla nk panel a nd store it for f uture use. Note: Should a rectifier be removed at any time, re-install the blank panel t o meet the regulatory requirements.
42 Maint enance end of the rectifier AC cord int o the corresponding female receptacle behind the ju nction box. For the s pecific AC cab le routing to be used w ith the H elios Rect ifier 200E/48, refer to Figure 35 in the case of a top fed s ystem, or to Figure 36 in the c ase of a bottom fed sy stem.
Mainte nance 4 3 Figure 33 AC conne ctions in the female r eceptacle fo r a Helios Rect ifier 200I/48 or a Helios Rect ifier 200E/48 Figure 34 AC connect ions inside t he junction b ox (top fed shown).
44 Maint enance Figure 35 AC cable r outing for the Helios Rectif iers 200E /48 in a top f ed system Figure 36 AC cable ro uting for the Helios Rectif iers 200E/48 in a bott om fed system Juncti on box RECT 6 RECT 5 RECT 4 RECT 3 RECT 2 RECT 1 Partial view of juncti on box Partial view of Rect .
Mainte nance 4 5 5.3.2 Replacing a Rectifier Replace a re ctifier as describ ed below fo r a Helios Re ctifier 100/4 8 or as in Replacing a Helios Rectifier 200I/48 or 200E/48, whichever is ap plicable. Replacing a Helios Rectifi er 100/48 1. Notify the alarm center of incomi ng alarms during this proce dure.
46 Maint enance Replacing a Helios Rectifi er 200I/48 or 200E/48 1. Notify the alarm center of i ncoming alarms during this procedure. 2. Turn OFF the AC and DC circuit breakers on the rectifier to be replaced. 3. Remove t he corresp onding sense fuse on the front of the cont roller.
Mainte nance 4 7 5.3.3 Adding or Repl acing a Batter y String For replaceme nts, procee d from Step 1 below. F or new instal lations , go to St ep 5 of this proce- dure. 1. Rem oval of the old st rin g: Notify the alarm cente r of the possi bility of i ncoming al arms during thi s procedure.
48 Maint enance 5.3.4 Replacement of a Distri bution Fuse Block or Circuit Breaker Replace a d istribution fuse block as describe d below. 1. Notify the alarm center of i ncoming alarms during this procedure. 2. Rem ove the fuse f rom th e fus e block t o be r eplac ed.
Reference Do cuments 49 6.0 R EFERENCE D OCUMENTS Manual No. Desc ript ion SL-60040 600 A and 1 200 A Battery Disconne ct Unit SL-60014 TCM48 temp erature compe nsation mod ule SL-60026 Voltage lev el.
50 List of T erms 7.0 L IST OF T ERMS A ampere ABS alar m battery suppl y ABSF ala rm batt ery suppl y fuse AC or ac al tern atin g curre nt ACO alar m cut-off AD Assembly drawin g ADJ adjus t or adju.
List of Terms 5 1 HVSD high v oltage shutdown HVSDA high vo ltag e shut down alarm HVSDR high v oltage shutdown r eset in. inch in.-l b inch-poun d IS interconne ct schema tic ISG isolated sy stem gro.
52 List of T erms.
Revised : June 199 9 Helios DC System 4000/48 1500, 300 0, 4000 & 60 00 A DC Pow er System T echnical Support The Company Behind The Products With mo re than 5 00,000 inst allation s around t he globe , Lieber t is the wo rld leader in comput er prot ectio n syste ms.
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