User ManualTable of Contents1.0 About This Document71.1 Purpose of This Document71.2 Applicability of This Document72.0 Introduction82.1 Description8Figure 1 Front view of a typical bottom fed 4000 A Helios DC System 4000/48 power system8Figure 2 Front view of a typical 6000 A Helios DC System 4000/48 power system92.2 Applications92.3 Control and Distribution Cabinets - Typical Configurations10Figure 3 Typical configurations for Helios DC System 4000/48 control, distribution and rectifier ...10Table 1 Rectifier cabinets11Table 2 Control and distribution cabinets11Table 3 Auxiliary distribution cabinets113.0 Specifications123.1 Framework123.1.1 Mechanical Specifications of a Cabinet12Table 4 Mechanical specifications of the cabinet (empty)123.1.2 Electrical Specifications of the Cabinets123.2 Conventional Controller133.2.1 Mechanical Specifications of the Conventional Controller13Table 5 Mechanical specifications of the Conventional Controller13Figure 4 Front view of the Conventional Controller133.2.2 Electrical Specifications of the Conventional Controller133.3 Distribution Panels143.3.1 Fuse Panels14Mechanical specifications of the fuse panels14Table 6 Mechanical specifications of the fuse panels14Figure 5 Front view of the 20 QFF 0-5 A fuse panels14Table 7 Fuse sizes available for the (20) QFF 0-5 A fuse panels14Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels15Table 8 Fuse sizes available for the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels15Figure 7 Front view of the (16) QFF 0-5 A & (6) TPN 5-30 A fuse panels15Table 9 Fuse sizes available for the (16) QFF 0-5 A & (6) TPN 5-30 A fuse panels15Figure 8 Front view of the (8) TPN 5-30 A fuse panels16Table 10 Fuse sizes available for the (8) TPN 5-30 A fuse panels16Figure 9 Front view of the (4) RS100P 70-100 A fuse panels16Table 11 Fuse sizes available for the (4) RS100P 70-100 A fuse panels16Figure 10 Front view of the (4) CRS200P 150-200A/(4) CRS200P 150200A (w/load shunts) fuse pa...17Table 12 Fuse sizes available for the (4) CRS200P 150-200 A/(4) CRS200P 150200A (w/load shunt...17Figure 11 Front view of the (4) TPL 225-600 A fuse panels17Table 13 Fuse sizes available for the (4) TPL 225-600 A fuse panels17Figure 12 Front view of the (18) TPS 1-70 A fuse panel18Table 14 Fuse sizes available for the (18) TPS 1-70 A fuse panel18Electrical specifications of the fuse panels19Table 15 Electrical specifications of the fuse panels193.3.2 Circuit Breaker Panels19Mechanical specifications of the circuit breaker panels19Table 16 Mechanical specifications of the circuit breaker panels19Figure 13 Front view of the (24) Plug-In 1-100 A circuit breaker panel20Table 17 Plug-in circuit breakers available for the (24) Plug-In 1-100 A circuit breaker panel20Figure 14 Front view of the (4) 70-250 A circuit breaker panel21Table 18 Circuit breaker sizes available for the (4) 70-250 A circuit breaker panel21Figure 15 Front view of the (2) 400 A circuit breaker panel22Table 19 Circuit breaker kits available for the (2) 400 A circuit breaker panel22Figure 16 Front view of the (1) 600-700 A circuit breaker panel22Table 20 Circuit breaker kits available for the (1) 600-700 A circuit breaker panel22Electrical specifications of the circuit breaker panels23Table 21 Electrical specifications of the circuit breaker panels233.4 Externally Mounted Battery Return Busbar243.4.1 Mechanical Specifications of the External Battery Return Busbar24Table 22 Mechanical specifications of a single lamination24Figure 17 Top and side views of the external battery return busbar243.4.2 Electrical Specifications of the External Battery Return Busbar243.5 Terminating Assemblies (Optional)25Figure 18 Perspective view of the a terminating assemblies253.6 MPS300 and MPA100 Power Shelves263.6.1 Mechanical Specifications of the MPS300 and MPA100 Power Shelves26Table 23 Mechanical specifications of the MPS300 and MPA100 power shelves26Figure 19 Front view of the MPS300 power shelf (shown empty)26Figure 20 Front view of the MPA100 power shelf (shown empty)273.6.2 Electrical Specifications of the Power Shelves273.7 Rectifiers273.7.1 Helios Rectifier 100/4827Mechanical specifications of the Helios Rectifier 100/4827Table 24 Mechanical specifications of the Helios Rectifier 100/4827Figure 21 Front view of the Helios Rectifier 100/4827Electrical specifications of the Helios Rectifier 100/4828Table 25 Electrical specifications of the Helios Rectifier 100/48283.7.2 Helios Rectifiers 200I/48 and 200E/4828Mechanical specifications of the Helios Rectifiers 200I/48 and 200E/4828Table 26 Mechanical specifications of the Helios Rectifiers 200I/48 and 200E/4828Figure 22 Front view of the Helios Rectifiers 200I/48 and 200E/48293.7.3 Electrical Specifications of the Helios Rectifiers 200I/48 and 200E/4830Table 27 Electrical specifications of the Helios Rectifiers 200I/48 and 200E/48303.7.4 Standards303.8 Helios Monitor 3000/48 (Optional)313.8.1 Mechanical Specifications31Table 28 Mechanical specifications of the Helios Monitor 3000/4831Figure 23 Front view of the Helios Monitor 3000/48 (without the mounting brackets)313.8.2 Electrical Specifications313.9 600A and 1200A Battery Disconnect Unit (Optional)31Figure 24 600 A Battery Disconnect Unit313.10 AC Junction Box32Figure 25 Front view of the AC junction box (with the front panel open)323.10.1 Mechanical Specifications32Table 29 Mechanical specifications of the AC junction box323.10.2 Electrical Specifications323.11 Overall Power System Specifications323.11.1 Standards323.11.2 Mechanical Specifications of Fully Equipped Power Cabinets32Table 30 Mechanical specifications of fully equipped power cabinets323.11.3 Electrical Specifications33Electromagnetic compliance (EMC)33Electrostatic discharge (ESD) immunity333.11.4 Environmental Specifications33Operating33Transportation33Storage33Heat dissipation333.11.5 Floor and Point Loading33Table 31 Floor and point loading334.0 Operation344.1 General344.2 Conventional Controller344.2.1 Front Panel34Figure 26 Front view of the Conventional Controller34Visual indicators34Table 32 Visual indicators34Table 33 Transmitted alarms35Potentiometers35Table 34 Potentiometers35Switches36Table 35 Switches36DIP switches36Table 36 DIP switch modules36Figure 27 Shunt range selection settings36Figure 28 Equalize voltage and duration settings37Fuses37Table 37 Fuse37Test points37Table 38 Test points374.2.2 Rear Panel38Figure 29 Terminal blocks and connectors layout at the rear of the Conventional Controller38Terminal blocks38Figure 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB439Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P2640Connectors404.3 MPS300 and MPA100 Power Shelves404.4 Rectifiers414.5 AC Junction Box414.6 Distribution Panels414.7 Terminating Assemblies (Optional)414.8 Helios Monitor 3000/48 (Optional)424.9 600A and 1200 Battery Disconnect Units (Optional)425.0 Maintenance435.1 General435.1.1 Helios Monitor 3000/48435.1.2 Controller and Rectifiers43Cleaning43Calibration43Storage43Air filter replacement44Fan unit replacement445.2 Troubleshooting45Table 39 Fault diagnosis455.3 Addition / Replacement Procedures465.3.1 Addition or Replacement of a Rectifier46Adding a Helios Rectifier 100/4847Adding a Helios Rectifier 200I/48 or 200E/4847Figure 32 AC connections in a Helios Rectifier 200E/4848Figure 33 AC connections in the female receptacle for a Helios Rectifier 200I/48 or a Helios Rect...49Figure 34 AC connections inside the junction box (top fed shown) for a Helios Rectifier 200E/4849Figure 35 AC cable routing for the Helios Rectifiers 200E/48 in a top fed system50Figure 36 AC cable routing for the Helios Rectifiers 200E/48 in a bottom fed system505.3.2 Replacing a Rectifier51Replacing a Helios Rectifier 100/4851Replacing a Helios Rectifier 200I/48 or 200E/48525.3.3 Adding or Replacing a Battery String535.3.4 Replacement of a Distribution Fuse Block or Circuit Breaker54Replacing a distribution circuit breaker545.3.5 Replacing a Cabinet Alarm Lamp546.0 Reference Documents557.0 List of Terms56Size: 1.24 MBPages: 59Language: EnglishOpen manual