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DC POWER
Helios DC System 4000/48
1500, 3000, 4000 & 6000 A
DC Power System
User
Manual
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TABLE OF CONTENTS BOUT HIS OCUMENT 1.0 A T D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 Purpose of This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Applicability of This Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.11 Overall Power System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.11.1 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 3.11.2 Mechanical Specifications of Fully Equipped Power Cabinets . . . . . . . . . . . . . . . . . . . . . 26 3.11.3 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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FIGURES 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 4 Front view of the Conventional Co
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TABLES Table 1 Rectifier cabinets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 2 Control and distribution cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 3 Auxiliary distribution cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Table 4 Mechanical specifications of the cabinet (empty) .
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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 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. 1.2 Applicability of This Document This document applies to Helios DC System 4000/48 power systems having any configuration of equipment. About This Document 1
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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 addi- tional distribution. Remote monitoring, temperature compensation and battery disconnect options are also available. The 1500, 3000 and 4000 A versions use internal -48
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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
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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 configurations for Helios DC System 4000/48 control, distribution and rectifier cabinets Control and Distribution cabinet 1200A Rectifier cabinet 4 Introduction
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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 Rectifier Cabinet Capacity Type Qty Cabled top or bottom 1200 A Helios Rectifier 200I 6 Top 1200 A Helios Rectifier 200I 6 Bottom 1000 A Helios Rectifier 100/48 10 Top or bottom 1200 A Helios Rectifier 200E 6 Top 1200 A Helios Rectifier 200E 6 Bottom 1200 A Helios Rectifier 200E 6 Top 1200 A Helios Rectifier 200E 6 B
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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 cab- inets. The cabinet is always equipped with a front door and door frame (lockable, equipped with ground straps, and easily removable for installation or maintenance access), a ventilated top cover made of non-flammable plastic, and two ventilated rear cover panels (eq
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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 Mechanical specifications of the Conventional Controller Figure Height Depth Width Weight Figure 4 152 mm 76 mm 584 mm 4.5 kg (6.0 in.) (3.0 in.) (23 in.) (10 lb) Figure 4 Front view of the Conventional Controller 3.2.2 Electrical Specifications of the Conventional Controller The operating voltage is -48 V DC. Refer
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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 Figure 5 76.2 mm 584 mm 3 kg 60 A max (3.0 in.) (23.0 in.) (6.6 lb) (16) QFF 0-5 A & Figure 6 76.2 mm 584 mm 5 kg (12) ABS 5-30 A (3.0 in.) (23.0 in.) (11.0 lb) 300 A max (16) QFF 0-5 A & Figure 7 152.4 mm 584 mm 7 kg (6)
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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 4AB (ABS) 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 0.25 A0205207 QFF1G 0.5 A0205208 QFF
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Figure 8 Front view of the (8) TPN 5-30 A fuse panels FA -48 V ALM 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) CPC 35 A0380150 40 A0380151 DC power (TPN) 45 A0380152 50 A0380114 60 A0380115 Figure 9 Front view of the (4) RS100P 70-100 A fuse panels ALM (2) (3) (4) (1) (2) (3) (4) (1) FA -48 V The DC output connections are 0.375-16 studs equipped with two hex nuts. Table
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Figure 10 Front view of the (4) CRS200P 150-200 A/(4) CRS200P 150-200 A (w/load shunts) fuse panels (2) (1) (1) (4) (3) (3) FA ALM ALM (4) (2) 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) CPC 110 A0329697 125 A0329696 HRC1-J 150 A0722041 175 A0722038 200 A0614832 Figure 11 Front view of the (4) TPL 225-600 A fuse panels -48 V (2) (4) (1)
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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 UNIT AMPS FA LOAD 600 A MAX PANEL CAPACITY 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
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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 Fuses Busbar Panel number Figure Quantity Capacity capacity (20) QFF 0-5 A Figure 5 20 0-5 A 60 A 60 A max (16) QFF 0-5 A & Figure 6 16 0-5 A 300 A (12) ABS 5-30 A 12 0-30 A 300 A max (16) QFF 0-5 A & Figure 7 8 0-30 A 250 A (6) TPN 5-30 A 250 A max Figure 8 (8) TPN 5-30 A 8 31-60 A 300 A 250 A max (4) RS100P 70-100 A Figur
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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 Plug-in circuit breakers available for the (24) Plug-In 1-100 A circuit breaker panel Nominal current CPC Std Trip CPC Mid Trip 1 A A0723076 A0722751 5 A A0723033 A0722752 10 A A0723035 A0722754 15 A A0723037 A072275
