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Liebert 1500 User Manual

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DC P
OWER
Helios DC System 4000/48
1500, 3000, 4000 & 6000 A
DC Power System
User
Manual

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  Summary of Contents for Liebert 1500

  • Page 1 DC P OWER Helios DC System 4000/48 1500, 3000, 4000 & 6000 A DC Power System User Manual...
  • Page 3: Table Of Contents

    BOUT OCUMENT Purpose of This Document ..........1 Applicability of This Document .
  • Page 4 3.11 Overall Power System Specifications ........26 3.11.1 Standards .
  • Page 5 Figure 1 Front view of a typical bottom fed 4000 A Helios DC System 4000/48 power system ..2 Figure 2 Front view of a typical 6000 A Helios DC System 4000/48 power system ....3 Figure 3 Typical configurations for Helios DC System 4000/48 control, distribution and rectifier cabinets .
  • Page 6 Table 1 Rectifier cabinets............. . 5 Table 2 Control and distribution cabinets .
  • Page 7: About This Document

    BOUT OCUMENT 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.
  • Page 8: Introduction

    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.
  • Page 9: Applications

    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 cab- inet to facilitate the connections of the battery return cables.
  • Page 10: Control And Distribution Cabinets - Typical Configurations

    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 configurations for Helios DC System 4000/48 control, distribution and rectifier cabinets Control and Distribution cabinet...
  • Page 11: Table 1 Rectifier Cabinets

    1200 A 1200 A Table 2 Control and distribution cabinets Nominal cabinet capacity Shunt capacity 1500 A 3000 A 4000 A 1500 A 3000 A 4000 A For a 6000 A system, the charge busbars and the shunt are mounted externally from the control and distribution cabinet.
  • Page 12: Specifications

    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.
  • Page 13: Conventional Controller

    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 Mechanical specifications of the Conventional Controller Figure Height Figure 4 152 mm (6.0 in.) Figure 4 Front view of the Conventional Controller 3.2.2 Electrical Specifications of the Conventional Controller The operating voltage is -48 V DC.
  • Page 14: Distribution Panels

    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 (20) QFF 0-5 A 60 A max (16) QFF 0-5 A &...
  • Page 15: Figure 6 Front View Of The (16) Qff 0-5 A & (12) Abs 5-30 A Fuse Panels

    Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels -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) 4AB (ABS)
  • Page 16: Figure 8 Front View Of The (8) Tpn 5-30 A Fuse Panels

    Figure 8 Front view of the (8) TPN 5-30 A fuse panels 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 Current (A) DC power (TPN) Figure 9...
  • Page 17: Figure 10 Front View Of The (4) Crs200P 150-200 A

    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. Table 12 Fuse sizes available for the (4) CRS200P 150-200 A/(4) CRS200P 150-200 A (w/load shunts) fuse panels Fuse type Current (A)
  • Page 18: Figure 12 Front View Of The (18) Tps 1-70 A Fuse Panel

    Figure 12 Front view of the (18) TPS 1-70 A fuse panel FUSE PANEL NT6C21XX 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) DC power (TPS)
  • Page 19: Circuit Breaker Panels

    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 Panel number (20) QFF 0-5 A 60 A max (16) QFF 0-5 A & (12) ABS 5-30 A 300 A max (16) QFF 0-5 A &...
  • Page 20: Figure 13 Front View Of The (24) Plug-In 1-100 A Circuit Breaker Panel

    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.
  • Page 21: Figure 14 Front View Of The (4) 70-250 A Circuit Breaker Panel

    Figure 14 Front view of the (4) 70-250 A circuit breaker panel CIRCUIT BREAKER PANEL (4) 70-250 A NT6C12EE 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.
  • Page 22: Figure 15 Front View Of The (2) 400 A Circuit Breaker Panel

    Figure 15 Front view of the (2) 400 A circuit breaker panel CIRCUIT BREAKER PANEL NT6C12EF (2) 400 A 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.
  • Page 23: Table 21 Electrical Specifications Of The Circuit Breaker Panels

    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 (24) Plug-In 1-100 A Figure 13 900 A max (4) 70-250 A Figure 14 900 A max...
  • Page 24: 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).
  • Page 25: Terminating Assemblies (Optional)

    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.
  • Page 26: Mps300 And Mpa100 Power Shelves

    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.
  • Page 27: Electrical Specifications Of The Power Shelves

    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. 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 200I/48 for three phase 380/415 V AC operation, or with...
  • Page 28: Helios Rectifiers 200I/48 And 200E/48

    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 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...
  • Page 29: Figure 22 Front View Of The Helios Rectifiers 200I/48 And 200E/48

    Figure 22 Front view of the Helios Rectifiers 200I/48 and 200E/48 CA/AC VOLT VOLT VOLT/AMP THSD FAIL AC ON 1.0A 1.0A HVSD VOUT+ VOUTÐ HVSD ST UP CC/DC Specifications...
  • Page 30: Electrical Specifications Of The Helios Rectifiers 200I/48 And 200E/48

    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 Input voltage Helios Rectifier 200I/48: Helios Rectifier 200E/48: Input current Helios Rectifier 200I/48: 18.3 A RMS nominal at 380 V AC input and -54 V DC, 200 A...
  • Page 31: Helios Monitor 3000/48 (Optional)

    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 Figure 23 45 mm (1.75 in.) 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.
  • Page 32: Ac Junction Box

    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) RECT 6 1 2 3 4 5 6 7 8 9 10 11 12 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-...
  • Page 33: 3.11.3 Electrical Specifications

    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. 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 IEC-801-2, are applied to exposed parts of the power system.
  • Page 34: Operation

    PERATION 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.
  • Page 35: Table 33 Transmitted Alarms

    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) (1 - Form C contacts)
  • Page 36: Figure 27 Shunt Range Selection Settings

    Switches Four switches for the control of functions as described in Table 35. Table 35 Switches Designation EQUALIZE MAN/AUTO CALIBRATE NORM/CAL CONT rotary switch 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.
  • Page 37: Figure 28 Equalize Voltage And Duration Settings

    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 Switch # 10 sec. 20 sec.
  • Page 38: Rear Panel

    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 terminal blocks to interface with external wiring as follows: •...
  • Page 39: Figure 30 Wiring Diagram And Pin Assignment Of Terminal Blocks Tb1 To Tb4

    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 (2) H/L FLOAT ALM (2) MIN RECT ALM To office MIN RECT ALM alarm MAJ RECT ALM circuit...
  • Page 40: Mps300 And Mpa100 Power Shelves

    Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to 22GA 8-conductor shielded cable To alarm EQL ( ) interface NT6C43PA RG+ ( ) board or NT6C43PB rectifier RC- ( ) rectifier interface TR ( ) interface card as...
  • Page 41: Rectifiers

    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.
  • Page 42: Helios Monitor 3000/48 (Optional)

    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 Helios Monitor 3000/48 was supplied with your system, refer to the Monitor 3000 user man- ual, SL-60015, for detailed operational characteristics.
  • Page 43: Maintenance

    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.
  • Page 44 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.
  • Page 45: Troubleshooting

    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...
  • Page 46: Addition / Replacement Procedures

    Table 39 Fault diagnosis Fault symptom LOP lamp lit HVSD lamp lit LVD lamp lit AUX 1 lamp lit AUX 2 lamp lit BOD lamp lit ACO lamp lit EQL lamp lit Rectifiers are not sharing the load Meter display is OFF Addition / Replacement Procedures 5.3.1 Addition or Replacement of a Rectifier...
  • Page 47 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.
  • Page 48: Figure 32 Ac Connections In A Helios Rectifier 200E/48

    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.
  • Page 49: Figure 33 Ac Connections In The Female Receptacle For A Helios Rectifier 200I/48 Or

    Figure 33 AC connections in the female receptacle for a Helios Rectifier 200I/48 or a Helios Rectifier 200E/48 Helios Rectifier 200I/48 (380 V ac) Figure 34 AC connections inside the junction box (top fed shown) for a Helios Rectifier 200E/48 1 2 3 4 5 6 7 8 9 10 11 12 Six connectors RECT 6...
  • Page 50: Figure 35 Ac Cable Routing For The Helios Rectifiers 200E/48 In A Top Fed System

    Figure 35 AC cable routing for the Helios Rectifiers 200E/48 in a top fed system Junction RECT 1 RECT 2 RECT 3 RECT 4 RECT 5 RECT 6 Figure 36 AC cable routing for the Helios Rectifiers 200E/48 in a bottom fed system RECT 1 RECT 2 RECT 3...
  • Page 51: Replacing A Rectifier

    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.
  • Page 52 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.
  • Page 53: Adding Or Replacing A Battery 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.
  • Page 54: Replacement Of A Distribution Fuse Block Or Circuit Breaker

    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. Notify the alarm center of incoming alarms during this procedure. 2.
  • Page 55: Reference Documents

    EFERENCE OCUMENTS Manual No. 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...
  • Page 56: List Of Terms

    IST OF ERMS ampere alarm battery supply ABSF alarm battery supply fuse AC or ac alternating current alarm cut-off Assembly drawing adjust or adjustment alarm ampere audible auxiliary American wire gauging battery BAT RTN battery return battery disconnect alarm battery disconnect unit battery management unit battery on discharge BODA...
  • Page 57 HVSD high voltage shutdown HVSDA high voltage shutdown alarm HVSDR high voltage shutdown reset inch in.-lb inch-pound interconnect schematic isolated system ground line pound light emitting diode low float loss of phase low voltage low voltage alarm low voltage disconnect LVDA low voltage disconnect alarm low voltage reconnect...
  • Page 58 List of Terms...
  • Page 59: 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 developed a complete range of support and protection systems for sensitive electronics: •...