Installation, Operation, and Maintenance Manual
TLR5 Table of Contents 1
Safety and Recommended Recommended Practices Practices .................................. .................................................... .................. 2 1.1 1.2 1.3 1.4
General practices............................. ....................................................... .................................................................... ............. 2 AC input circuit breaker sizing ............................................ ............................... 3 DC output wire sizing .................................................... ......................................................................................... ..................................... 4 Torque settings...................... ........................................................ .............................................................................. ...................... 8
2
Required Tools ................................... ..................................................... .................................... .................................. ................ 8
3
Site and Equipment Preparation................................... Preparation.................................................... ....................... ...... 8
4
Power Plant Mounting Mounting and Wiring Wiring .................................... ...................................................... .................. 8 4.1 4.2 4.3 4.4
Mechanical mounting...................................................... .................................... 8 AC input.......................................................... input... ........................................................................................................... .................................................... 9 DC output........................................................ output. ........................................................................................................... .................................................... 9 Alarms and control...................................... ........................................................ 9
5
Power-Up ................................... .................................................... .................................. .................................. ......................... ........ 10
6
Troubleshooting Troubleshooting ................................... .................................................... .................................. ............................... .............. 10
Appendix A ................................... ..................................................... .................................... .................................... ........................... ......... 12
Installation, Operation, and Maintenance Manual
1 Safety and Recommended Practices 1.1 General practices For use in restricted access locations only. Suitable for mounting on concrete or other non-combustible surfaces This product accepts an AC Voltage between 90 and 264 VAC, 47 to 63 Hz, and produces a regulated output of 21-28 VDC or 42-56 VDC(depending upon deployed power supplies) capable of delivering a max of 300 Amperes DC for a 24 V power supplies or max 250 Amperes DC for a 48V power supplies in an ambient operating temperature range of -40 oC to +75oC (depending upon deployed Power supplies). HAZARDOUS VOLTAGE AND ENERGY LEVELS ARE PRESENT WHICH CAN PRODUCE SERIOUS SHOCKS AND BURNS. Only authorized, qualified, and trained personnel should attempt to work on this equipment. Removal of HI-POT seal on the power supply may create a safety problem and will void product warranty. Refer to datasheets for full product specifications. The CE mark on the product is applied to show conformance to the requirements outlined in the European Union’s low voltage directive (72/23/EEC) as amended by the CE
WARNING: HIGH LEAKAGE CURRENT: EARTH CONNECTION ESSENTIAL BEFORE CONNECTING SUPPLY ACHTUNG: HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKREIS UNBEDINGT ERDUNGSVERBINGDUNG HERSTELLEN Use double hole, UL listed lugs for all DC connections to prevent lug rotation and inadvertent contact with other circuits. Terminal strip connections require only single hole lugs. Class 1, 90°C wire is recommended for all DC connections. Minimum wire sizes are shown in Table 3. In practice, loop voltage drop considerations will usually dictate larger than minimum safe wire size. Connections to multiple loads are recommended to be made through an external distribution with overcurrent protection.
Installation, Operation, and Maintenance Manual
1.2 AC input circuit breaker sizing Table 1 shows the required input voltages for the available power supplies. The power supplies under wide line (WL) can be connected to a nominal input voltage between 100 V & 240V. The power supplies under high line (HL) can be connected to a nominal input voltage between 200 V & 240V. Wide Line (100V – 240V)
High Line (200V – 240V)
TL50048 TL50024 TL100048 TL100024
TL150048 TL150024 TL200048 TL250048
Table 1 – Power supply input Voltage
This system utilizes a single or dual feed AC architecture (as shown in Figure 1) via a rear AC terminal block. The terminal block is strapped to support the single feed architecture (Figure A 5). With the straps removed the system requires a dual AC input. N+1 DC Bus
1 y r l e p w p o u
2 y r l e p w p o u
3 y r l e p w p o u
4 y r l e p w p o u
5 y r l e p w p o u
Installation, Operation, and Maintenance Manual
N+1 DC Bus
1 y r l e p w p o u P S
2 y r l e p w p o u P S
3 y r l e p w p o u P S
4 y r l e p w p o u P S
5 y r l e p w p o u P S
AC Line 1 AC Line 2 Figure 2 - Dual feed AC wiring architecture
For a dual AC feed 24 V architecture up to five power supplies of up to 60A capacity each may be installed for a total system capacity of up to 300A. Connect Line 1 to an AC source (40A max.) that is protected for three power supplies with a circuit breaker sized according to Table 2. Connect Line 2 to an AC source (27A max.) that is protected for two power supplies with a circuit breaker sized according to Table 2. Size each AC feed wire according to the corresponding rows of Table 2. For a dual AC feed 48 V architecture up to five power supplies of up to 50A capacity each may be installed for a total system capacity of up to 250A. Connect Line 1 to an AC source (51.9A max.) that is protected for three power supplies with a circuit breaker sized according to Table 2. Connect Line 2 to an AC source (34.6A max.) that is protected for two power supplies with a circuit breaker sized according to Table 2. Size each AC feed wire according to the corresponding rows of Table 2.
Installation, Operation, and Maintenance Manual
Number of Power Supplies on AC Feed
1
2
3
Minimum Input Voltage
Model Number of Power Supplies
Maximum rated AC Current
Circuit breaker exact value to use (A)
90 °C Wire Gauge to use at 30 °C ambient (AWG)
90
TL50048
7.4
15
14
90
TL100048
14.6
15
14
180
TL150048
11
15
14
180
TL200048
14.7
15
14
180
TL250048
18.4
20
12
90
TL50024
7.6
15
14
90
TL100024
15
15
14
180
TL150024
9.4
15
14
90
TL50048
14.8
15
14
90
TL100048
29.2
30
10
180
TL150048
22.1
30
10
180
TL200048
29.5
30
10
180
TL250048
36.8
50
8
90
TL50024
15.1
15
14
90
TL100024
29.9
30
10
180
TL150024
18.8
20
12
90
TL50048
22.1
30
10
90
TL100048
43.8
50
8
180
TL150048
33.1
50
8
180
TL200048
44.2
50
8
180
TL250048
55.2
75
6
90
TL50024
22.7
30
10
90
TL100024
44.9
50
8
Installation, Operation, and Maintenance Manual
1.3 DC output wire sizing There are two main considerations for sizing DC wire; ampacity and voltage drop. Ampacity refers to a safe current carrying level as specified by non-profit organizations such as Underwriters Laboratories and the National Fire Prevention Association, which publishes the National Electric Code. Voltage drop is simply the amount of voltage loss in a length of wire due to ohmic resistance of the conductor. DC wire may be sized for either ampacity or voltage drop depending on branch load loop length and conductor heating. In general, ampacity considerations will drive wire selection for short loop lengths (less than 50 feet) and voltage drop will drive wire selection for long loop lengths (greater than 50 feet). The National Electric Code table 310.16 provides ampacity values for various sizes, bundles, and insulation temperature rated wire. ALWAYS FOLLOW NEC RULES AND YOUR LOCAL COMPANY PRACTICES WHEN SELECTING DC WIRING AND PROTECTION. Table 3 shows MAXIMUM recommended wire sizes.
r e w o P t n a l P
DC Output Pads
Installation, Operation, and Maintenance Manual
Number of Power supplies on DC bus
1
2
3
Model Number of power supply
AWG at room ambient
Number of Conductors per leg
TL50048
10
1
TL100048
10
1
TL150048
8
1
TL200048
4
1
TL250048
3
1
TL50024
10
1
TL100024
4
1
TL150024
3
1
TL50048
6
1
TL100048
4
1
TL150048
4
1
TL200048
4
2
TL250048
2
1
TL50024
4
1
TL100024
4
2
TL150024
2
1
TL50048
3
1
TL100048
3
1
TL150048
2
1
TL200048
4
2
TL250048
3
2
TL50024
3
1
Installation, Operation, and Maintenance Manual
1.4 Torque settings Table 4 shows recommended torque settings for all mechanical and electrical connections according to screw or nut size. Screw or Nut Size 8-32 10-32 12-24 ¼-20
Torque (in-lbs) 22 37 50 65
Table 4 - Recommended Torque Settings for Field Wiring Terminations
2 Required Tools Lambda Power Plants are designed to be installed with a minimum number of commonly available tools. • #1 & #2 Phillips Screwdrivers #1 & #2 Flat Head Screwdrivers • Set of Box Wrenches, Ratchet Set, or Nut Drivers • • Wire and Cable Strippers • Wire and Cable Crimpers
Installation, Operation, and Maintenance Manual
4.2 AC input When ready to power up, activate the external AC circuit breakers feeding the rack.
4.3 DC output Remove rear cover and install DC output load wiring from connection pads (Figure A 2) to respective distribution points using appropriately sized wire as called out in Section 1.3.
4.4 Alarms and control Access to alarms and control signals is accomplished via a rear mounted connector as shown in Figure A 3. This connector may be accessed by Communications Cable Part No. CA312181051. Follow the strain relief instructions provided with the cable. Table 5 provides a functional description and color code. The second color is the stripe. J1 PIN
1 2
WIRE COLOR
Description
WHT/BLK Shelf Bias: A regulated 12V/100ma bias supply. Referenced to Pin 11. BLK
SCL: I2C clock line. Referenced to Pin 11.
3
2 BLK/WHT SDA: I C data line. Referenced to Pin 11.
4
WHT/RED Logic Ground: Isolated ground for opto-coupled alarms.
5
RED
Module Disable: Opto-coupled input. Applying 5V between this pin and Pin 4 will disable all modules in the shelf.
6
Module 0 (leftmost slot) AC Fail. Opto-coupled alarm output that is “active RED/WHT low on fault.” 10ma sink capability. Referenced to Pin 4
7
WHT/GRN Module 1 AC Fail
Installation, Operation, and Maintenance Manual
5
Power-Up
Once all AC and DC connections have been secured and checked, install each power supply sequentially by sliding and latching each power supply into a rack position as shown in Figure A 4. The power supplies will start in high fan speed mode and reduce their speed according to the ambient and plant conditions within 10 seconds. The AC OK and DC OK LED’s will illuminate and the ALM LED will extinguish.
6 Troubleshooting The modular, plug-n-play nature of this plant makes diagnostics and repair very easy. Make sure that all power supplies are properly seated and latched into their respective slots. Make sure that all power and signal connectors are properly mated. Table 6 lists problems and potential solutions. PROBLEM DC OK LED Extinguished
AC OK LED Extinguished
Table 6 - Problems and Solutions
SOLUTIONS Replace bad power supply unit - unlatch, remove and replace with spare. System short circuit – inspect and replace load and wiring. Reset commercial circuit breaker to the dedicated AC circuit that feeds system. Seek alternative power source until power is restored.
Installation, Operation, and Maintenance Manual • •
Updated AWG and breaker sizes in Table 2 & Table 3 Added Table 1 – Power supply input Voltage
Installation, Operation, and Maintenance Manual
Appendix A Installation Photos Mounting Brackets (2 Places)
AC Receptacles
Figure A 1 - Rack Top/Front View
DC Pads
Alarms/Signal
Figure A 3 - Alarm/Signal Connector
Figure A 2 - Rack Rear View
AC Input Section Figure A 4 - Power Supply Insertion
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Page 12 of 13
Version 3.1 4/15/03
Installation, Operation, and Maintenance Manual
Appendix A Installation Photos Screws are #8-32
Line 1 Line/Neutral1 Line 2 Line/Neutral2
Single AC Input Straps Figure A 5 - AC Terminal Block Connections
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Page 13 of 13
Version 3.1 4/15/03
