Liebert FS™ DC Energy Storage System
User Manual - 190kW/10 Seconds, 540VDC
AC Power
For Business-Critical Continuity™
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.0 GENERAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Requesting Assistance from Liebert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 General System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2.1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 Applicable Standards and Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.0 SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1 System Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Flooring Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.1 Floor Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.2 Floor-Space Occupation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3.3 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1 DC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.2 Status/Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.3 Grounding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.4 AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4.5 Remote Monitoring Connections—Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.0 UNLOADING AND UNPACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1 Inspection Before Removal From the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Positioning the Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.1 Moving the Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3.2 Storing the Liebert FS for Delayed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.1 Cabinet Floor Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Concrete, Masonry or Stone Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1.2 Wood Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1.3 Raised Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.1 General Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.2 DC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.3 Status/Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.4 Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.5 AC Auxiliary Control Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.6 Remote Monitoring Connections—Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Startup Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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5.0 SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Detailed System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.1 System Module Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1.2 Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.3 System Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1.4 User interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1.5 UPS Interconnection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.1.6 Power Conversion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1.7 Magnetic Levitation Module (MLM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.8 Flywheel Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.9 Rotor/Flywheel—Rotating Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.10 Motor Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.11 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.12 Flywheel Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1.13 System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.14 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.1.15 Ventilation and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.2 List of System User-Configurable Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.1 OFF Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.2 STANDBY Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.3 STARTUP Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.3.4 CHARGE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3.5 READY Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3.6 DISCHARGE Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3.7 SHUTDOWN Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3.8 COAST Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.9 FAULT Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Maintenance and Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.1 Operator Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2.1 Main screen function descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.2.2 System MODE Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2.3 System STATUS Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2.4 Other Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.3 Security Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3.1 Security Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3.2 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3.3 EPROM (System) Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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6.4 Menu Tree and Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4.1 Screen Tree Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.4.2 Navigation and Operation of Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.3 System Setup and Parameter Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.4 View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.4.5 Time/Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.4.6 Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4.7 Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4.8 History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.4.9 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4.10 Network—Requires DCM Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.4.11 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4.12 Vitals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4.13 Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4.14 About . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.4.15 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.5 System Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5.1 Initial System Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5.2 Inspection before Initial System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.5.3 Control Parameters Setup at Initial System Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.5.4 Initial System Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.5.5 Regular Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5.6 Inspection Before Regular Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5.7 Starting up the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.6 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.2 Liebert Global Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.5 Record Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.6 Optional Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.7 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.8 Detecting Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.9 Reporting a Problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.10 Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.11 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.12 Limited Life Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.2 Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.3 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
iii
APPENDIX A.0 UPS INTERCONNECTION KITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Appendix A.1 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Appendix A.1.1 General Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Appendix A.1.2 DC Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Appendix A.2 Installing the Liebert FS With a Liebert Series 610, Liebert Series 600T
or Liebert Series 600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Appendix A.2.1 Description - Liebert Series 610/600T/600 UPS Interconnection Kit . . . . . . . . . . . . . . 87
Appendix A.2.2 Status/Control Connections - Liebert Series 610/600T/600 UPS
Interconnection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Appendix A.2.3 UPS Configuration - Liebert FS and Liebert Series 610, 600T or 600 . . . . . . . . . . . . . 88
Appendix A.2.4 Liebert FS Configuration - Single Liebert FS on Liebert
Series 610/600T/600 DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix A.2.5 Liebert FS Configuration - Multiple Liebert FS Units on Liebert
Series 610/600T/600 DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix A.3 Installing the Liebert FS With a Liebert Npower UPS . . . . . . . . . . . . . . . . . . . . 90
Appendix A.3.1 Description - Liebert Npower UPS Interconnection Kit . . . . . . . . . . . . . . . . . . . . . . . . 90
Appendix A.3.2 Status/Control Connections - Liebert Npower UPS Interconnection Kit . . . . . . . . . . . 91
Appendix A.3.3 UPS Configuration - Liebert FS and Liebert Npower . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendix A.3.4 Liebert FS Configuration - Single Liebert FS Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendix A.3.5 Liebert FS Configuration - Multiple Liebert FS Units on Liebert
Npower DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Appendix A.4 Installing the Liebert FS With a Liebert Series 300 UPS . . . . . . . . . . . . . . . . . . 93
Appendix A.4.1 Description - Liebert Series 300 UPS Interconnection Kit . . . . . . . . . . . . . . . . . . . . . . 93
Appendix A.4.2 Status/Control Connections - Liebert Series 300 UPS Interconnection Kit . . . . . . . . . 94
Appendix A.4.3 UPS Configuration - Liebert FS and Liebert Series 300 . . . . . . . . . . . . . . . . . . . . . . . . 94
Appendix A.4.4 Liebert FS Configuration - Single Liebert FS on Series 300 DC Bus . . . . . . . . . . . . . . 95
Appendix A.4.5 Liebert FS Configuration - Multiple Liebert FS Units on Liebert
Series 300 DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Appendix A.5 Installing the Liebert FS With a Liebert HiPulse UPS . . . . . . . . . . . . . . . . . . . . 96
Appendix A.5.1 Description—HiPulse UPS Interconnection Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Appendix A.5.2 Status/Control Connections—Liebert HiPulse UPS Interconnection Kit . . . . . . . . . . . 96
Appendix A.5.3 IKIT-A05 DC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Appendix A.5.4 UPS Configuration—Liebert FS and Liebert HiPulse . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Appendix A.5.5 Single Liebert FS on UPS DC Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Appendix A.5.6 Single Liebert FS in Parallel with Battery Pack on UPS DC Bus . . . . . . . . . . . . . . . . 98
Appendix A.5.7 Liebert FS Configuration – Multiple Liebert FS Units . . . . . . . . . . . . . . . . . . . . . . . . . 99
APPENDIX B.0 DATA COLLECTION MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Appendix B.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B.1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B.2 DCM Installation and Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B.2.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Appendix B.2.2 DCM Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Appendix B.2.3 Accessing the DCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Appendix B.2.4 Configuring DCM System Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Appendix B.3 DCM Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Appendix B.3.1 Logging into the DCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Appendix B.3.2 Status and Detailed Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Appendix B.3.3 Datafiles Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Appendix B.4 DCM Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Appendix B.4.1 DCM Troubleshooting Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Appendix B.4.2 Resetting the DCM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
APPENDIX C.0 VERSATILE INTERFACE BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix C.1 General Information—Versatile Interface Board . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix C.1.1 Versatile Interface Board Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix C.1.2 VIB Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Appendix C.2 VIB Installation and Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix C.2.1 VIB Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix C.2.2 VIB Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix C.2.3 VIB Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix C.2.4 VIB Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Appendix C.2.5 VIB Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix C.3 VIB Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix C.3.1 VIB Operational States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix C.4 Troubleshooting the VIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix C.4.1 UIB State Not Displayed on the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix C.4.2 VIB in “Disabled” or “Not Available” State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix C.4.3 Inputs Not Recognized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Appendix C.4.4 Outputs Not Asserted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
APPENDIX D.0 INSTALLATION DRAWINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Appendix D.1 Liebert FS Flywheel Submittal Document Matrix . . . . . . . . . . . . . . . . . . . . . . . 113
Appendix D.2 Other Liebert FS Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
APPENDIX E.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Appendix E.1 Ground Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
APPENDIX F.0 AUXILIARY BACKUP AC POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Appendix F.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Appendix F.2 Backup AC Power Supply Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Appendix F.3 Recommended Backup Power Supply Configuration . . . . . . . . . . . . . . . . . . . . . 150
Appendix F.3.1 Operating the Liebert FS+DC in Parallel With Batteries. . . . . . . . . . . . . . . . . . . . . . 151
Appendix F.3.2 Operating the Liebert FS Without Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Appendix F.4 Scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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FIGURES
Figure 1 Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 2 Single Liebert FS unit or multiple Liebert FS units integrated into a UPS system. . . . . . . . . . . . 5
Figure 3 Liebert FS unit(s) integrated into UPS system for ride-through to backup generator. . . . . . . . . . 5
Figure 4 One or more Liebert FS units in parallel with one or more battery strings, battery
cabinets or batteries in racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Liebert FS DC power duration for one or multiple units in parallel . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 6 Integrating a single Liebert FS unit into a UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 7 Integrating multiple Liebert FS units into a UPS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8 Liebert FS shipping package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 9 Removing lag bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 10 Lifting the Liebert FS cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 11 Removing the metal support plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 12 Location of serial and model number plate (cabinet side panel removed and open door) . . . . . . 16
Figure 13 Liebert FS cabinet caster location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 14 Dimensions, general layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 15 Internal layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 16 Floor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 17 Floor mounting template layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 18 Checking hole depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 19 Inserting anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 20 Expanding anchors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 21 Securing mounting brackets to the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 22 Mounting rear bolts—rear side of cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 23 Mounting front bolts—front side of cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 24 Bubble level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 25 Raised floor mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 26 Liebert FS cabinet with UPS interconnection kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 27 Liebert FS with circuit breaker mounting plate and access panels for DC and control
wiring connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 28 Typical circuit breaker wiring for DC connections (view from rear of circuit breaker) . . . . . . . . 27
Figure 29 Ground connection on the Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 30 Service panel location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 31 Auxiliary backup power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 32 Auxiliary power fused disconnect with connection points for AC wire . . . . . . . . . . . . . . . . . . . . . 30
Figure 33 Top access panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 34 Remote monitoring (DCM) connections (inside cabinet front door) . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 35 Liebert FS front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 36 Electrical system schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 37 Schematic of the levitation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 38 Liebert FS flywheel module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 39 Rotating group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 40 Cross-section of the synchronous reluctance motor rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 41 Vacuum system operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 42 Schematic for the speed and temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 43 Cutaway flywheel module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 44 Voltage and Inductance curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 45 Vreg delta help screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 46 STANDBY mode diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 47 Startup mode diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 48 CHARGE mode diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 49 READY mode diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 50 DISCHARGE mode diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 51 SHUTDOWN mode diagram - shutdown after full discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 52 SHUTDOWN mode diagram - user-initiated shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 53 Typical operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
vi
Figure 54 Control panel view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 55 Main screen functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 56 Fault screen functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 57 Menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 58 User level main menu screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 59 READ ONLY level parameter view screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 60 USER level or above parameter edit screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 61 HELP screen for User Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 62 Graphical HELP screen for VREG DELTA1, VREG TSOC, and VREG DELTA2
Transition setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 63 USER or higher level parameter selection for view/edit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 64 VIEW menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 65 TIME/DATE set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 66 Temperature view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 67 Figure 5-14. Voltages view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 68 History view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 69 Charge history. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 70 Discharge history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 71 Discharge History, Event list screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 72 Warning history, Event list screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 73 Fault history, Event list screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 74 Vitals history view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 75 Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 76 Counters - screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 77 Options view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 78 Networks view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 79 Networks view, Edit DHCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 80 Networks view, Edit Settings (Service level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 81 Electrical view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 82 Vitals view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 83 Password screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 84 Change password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Figure 85 Change password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 86 ABOUT screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 87 Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 88 Tools for USER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 89 USER level menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 90 VIEW menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 91 Warning history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 92 Fault history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 93 Warning screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 94 Fault screen descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 95 Top view of Liebert FS Cabinet with UPS interconnection kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 96 Circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 97 Liebert Series 610 225kVA UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 98 Liebert Series 610/600T/600 status/control terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 99 Liebert FS integrated into a Liebert Npower UPS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 100 Liebert Series 300 UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 101 Liebert Series 300 status/control terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 102 Liebert HiPulse status/control terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 103 Circuit-breaker (open door and cabinet faceplate removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 104 Data Collection Module location, features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 105 DCM LAN connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 106 Options view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 107 Enable or disable DCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 108 Networks view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
vii
Figure 109 Networks view, turn off DHCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 110 Networks view, edit settings (service level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Figure 111 DCM screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 112 DCM setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 113 DCM status screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 114 Datafiles screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 115 Data Collection Module reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Figure 116 VIB components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 117 I/O Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 118 Versatile Interface Board mounted in the Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 119 VIB screw terminal connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 120 No UVR, circuit breaker to terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 121 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 122 Electrical system block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 123 24 UVR, circuit breaker to terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 124 48 UVR, circuit breaker to terminal block wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 125 Outline drawing, Liebert FS cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 126 Control wiring, external interconnect diagram—Liebert FS cabinet to Liebert Npower
UPS module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 127 Control wiring external interconnect—Liebert FS to Liebert Series 300 . . . . . . . . . . . . . . . . . . 119
Figure 128 Control wiring—external interconnect diagram, Liebert FS cabinet to Liebert
Series 610 UPS module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 129 Control wiring—external interconnect diagram, Liebert FS cabinet to Liebert
Series 610 UPS module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Figure 130 Elevation drawing, Liebert FS cabinet with shipping package . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Figure 131 Elevation drawing—Liebert FS cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Figure 132 Control wiring diagram, Liebert FS power rack system in parallel for capacity . . . . . . . . . . . . 124
Figure 133 Liebert FS cabinet with optional power terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 134 Liebert FS cabinet mechanical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 135 Elevation drawing—Liebert FS cabinet with integrated circuit breaker . . . . . . . . . . . . . . . . . . 127
Figure 136 One-line drawing, three Liebert FS systems in parallel configuration . . . . . . . . . . . . . . . . . . . . 128
Figure 137 Control wiring diagram—Liebert FS cabinet - manually operated circuit breaker . . . . . . . . . . 129
Figure 138 One-line diagram—Liebert FS systems with factory-integrated circuit breakers
with Liebert UPS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Figure 139 One-line diagram—single Liebert FS system with factory-integrated circuit breaker
supplying Liebert UPS module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Figure 140 Control wiring diagram—Liebert FS - optional electrically operated circuit breaker
Liebert Npower units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Figure 141 Two-eight paralleled Liebert FS units with factory-integrated circuit breaker in parallel
with a Liebert UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Figure 142 One-line diagram, single Liebert FS and battery with factory-integrated circuit breaker
supplying Liebert UPS—UPS DC terminal point of common connection . . . . . . . . . . . . . . . . . . 134
Figure 143 One-line diagram, single Liebert FS and battery with factory-integrated circuit
breaker supplying Liebert UPS—UPS battery point of common connection . . . . . . . . . . . . . . . 135
Figure 144 Status/control wiring, multiple units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Figure 145 Wiring specifications, Liebert FS and Liebert Series 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Figure 146 Wiring specifications, Liebert FS and Liebert Npower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Figure 147 Wiring specifications, Liebert FS and Liebert Series 610 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Figure 148 Wiring specifications, Liebert FS and Liebert HiPulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Figure 149 Floor mounting template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Figure 150 System mounting kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Figure 151 Liebert FS block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Figure 152 Power line diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Figure 153 UPS cable entry—bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Figure 154 UPS cable entry—top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Figure 155 Raised floor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Figure 156 A single Liebert FS+DC unit operating with a UPS in conjunction with batteries . . . . . . . . . . 151
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Figure 157 Multiple Liebert FS+DC units operating with a UPS in conjunction with batteries . . . . . . . . . 151
Figure 158 A single Liebert FS unit operating with a UPS and without batteries attached
to the DC bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 159 Multiple Liebert FS units operating with a UPS and without batteries attached
to the DC bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Figure 160 Liebert FS connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
TABLES
Table 1 System information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 2 General system specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 3 Tightening torque for ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 4 Control panel keyboard layout (refer to Figure 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 5 Operation modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 6 System status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 7 EEPROM parameter number ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 8 PCMC parameters, read-only and user (Liebert FS software) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 9 Control parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table 10 Software versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table 11 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table 12 Torque specifications (unless otherwise labeled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Table 13 Recommended test equipment and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 14 Projected component life, replacement schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 15 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table 16 Faults—causes and responses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Table 17 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Table 18 Key to UPS model interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Table 19 Liebert Series 610/600T/600 model ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 20 Liebert FS Software Control Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 21 Liebert FS Software Control Parameters varying with UPS size . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 22 Liebert Npower model ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Table 23 Liebert FS Software Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Table 24 Liebert FS Software Control Parameters varying with UPS size . . . . . . . . . . . . . . . . . . . . . . . . . 91
Table 25 List of Liebert Series 300 models ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Table 26 Liebert FS Software Control Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table 27 Liebert FS Software Control Parameters varying with UPS size . . . . . . . . . . . . . . . . . . . . . . . . . 95
Table 28 Liebert HiPulse model ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Table 29 Liebert FS Software Control Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 30 Liebert FS Software Control Parameters varying with UPS size . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 31 Liebert FS Software Control Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 32 Liebert FS Software Control Parameters varying with UPS size . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 33 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Table 34 VIB I/O functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Table 35 Submittal documents accompanying Liebert FS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table 36 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ix
x
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and maintenance of your Liebert FS.
WARNING
!
The installation of the Liebert FS must comply with applicable national, federal, state and
local codes.
ONLY qualified service personnel should perform maintenance on the Liebert FS
system. When performing maintenance with any part of the equipment, service personnel
and test equipment should be standing on rubber mats. The service personnel should wear
insulating shoes for isolation from direct contact with the floor (earth ground).
Never work alone, even if all power is removed from the equipment. A second person should
be standing by to assist and summon help in case an accident should occur.
Under typical operation and with all UPS doors closed, only normal safety precautions are
necessary. The area around the Liebert FS system should be kept free of puddles of water,
excess moisture and debris.
Special safety precautions are required for procedures involving handling, installation and
maintenance of the UPS system. Observe all safety precautions in this manual before
handling, installing or operating the UPS system.
This equipment contains circuits that are energized with high voltage. Only test
equipment designed for troubleshooting and for use with those voltages should be used.
Always check with an AC and DC voltmeter to ensure safety before making contact or using
tools. Even when the power is turned Off, dangerously high electric charges may exist within
the UPS.
WARNING
!
Exercise extreme care when handling Liebert FS cabinets to avoid equipment damage or
injury to personnel. Refer to Section 3.0 and Section 4.0 for equipment handling
information and installation procedures.
In case of fire involving electrical equipment, use only carbon dioxide fire extinguishers or
others approved for use in fighting electrical fires.
WARNING
!
Extreme caution is required when performing maintenance.
Be constantly aware that the Liebert FS contains high DC as well as AC voltages. With input
power off and the battery disconnected, high voltage at filter capacitors and power circuits
should be discharged within 30 seconds. However, if a power circuit failure has occurred, you
should assume that high voltage may still exist after shutdown. Check with a voltmeter
before making contact.
Check for voltage with both AC and DC voltmeters prior to making contact.
WARNING
!
When the Liebert FS is under power, both the operator and any test equipment must be
isolated from direct contact with earth ground and the Liebert FS chassis frame by using
rubber mats.
Some components within the cabinets are not connected to chassis ground. Any contact
between floating circuits and the chassis is a lethal shock hazard. Exercise caution that the
test instrument exterior does not make contact either physically or electrically with earth
ground.
1
CAUTION
!
Do not loosen or tamper with vacuum components and fittings.
CAUTION
!
This unit contains components sensitive to electrostatic discharge.
CAUTION
!
Do not remove plug-in printed circuit cards during operation. Improper removal of a card can
cause severe damage to the unit.
CAUTION
!
The 110/230VAC must remain connected at all times to ensure reliable backup power to
Liebert FS auxiliaries.
CAUTION
!
Do not use this unit for other than its intended use.
CAUTION
!
A qualified electrician must perform all electrical connections.
All wiring size and installation must comply with all applicable local, regional and national
regulations (e.g., National Electric Code for USA).
Safety Precautions
Read this manual thoroughly, paying special attention to the sections that apply to you, before working with the Liebert FS.
Under typical operation and with all cabinet doors closed, only normal safety precautions are necessary. The area around the Liebert FS should be kept free from puddles of water, excess moisture or
debris.
Special safety precautions are required for procedures involving handling, installation and maintenance of the Liebert FS. Observe precautions in 7.0 - Maintenance before as well as during performance of any maintenance procedure on the Liebert FS.
This equipment contains circuitry that is energized with high voltage. Only test equipment designated for troubleshooting should be used. This is particularly true for oscilloscopes. Always check
with an AC and DC voltmeter to ensure safety before making contact or using tools. Even when the
power is turned Off, dangerously high voltage may exist at the capacitor banks.
ONLY qualified service personnel should perform maintenance on the Liebert FS. When performing
maintenance with any part of the equipment under power, service personnel and test equipment
should be standing on rubber mats. The service personnel should wear insulating shoes for isolation
from direct contact with the floor (earth ground).
One person should never work alone. A second person should be standing by to assist and summon
help in case an accident should occur.
2
1.0 GENERAL SYSTEM INFORMATION
1.1 General Information
1.1.1 Safety Considerations
Read and follow the instructions in this manual before interacting with the system. This document
contains important information and instructions for your Liebert FS. All procedures defined in the
manual related to unpacking, installing and operating the unit must be followed.
Refer to this manual before contacting Liebert Global Services for technical assistance.
WARNING
!
Failure to recognize electrical hazards could prove fatal. Failure to abide by instructions
provided herein may void your warranty.
1.1.2 Requesting Assistance from Liebert
If you require assistance for any reason, contact Liebert Global Services at 1-800-LIEBERT
(1-800-543-2378). Have the following information available:
Table 1 System information
Date Purchased
Date Installed
Location
System Model Number
System Serial Number
Interconnected UPS Manufacturer
Interconnected UPS Model
Software Version; Primary *
Software Version; Secondary *
Software Version; Bootloader *
General System Information
3
1.2 General System Description
The Liebert FS is a flywheel energy storage system, a mechanical battery that stores energy in the
form of a rotating mass. This energy is immediately convertible to useful electric power.
The Liebert FS is available with a wide performance range up to 190 kW as a single unit configuration.
Figure 1 Liebert FS
General System Information
The Liebert FS is configured as a two-terminal plus ground DC flywheel power system and is used as
a functional replacement for or an availability supplement to a bank of chemical batteries for an
Uninterruptible Power System. Like a chemical battery bank, Liebert FS receives charge and float
power from the two terminal UPS DC bus and returns power to the same DC bus whenever the bus
voltage droops below a programmable threshold level.
Integrated into a UPS, the Liebert FS is used as the alternate source of power to supply DC power to
the UPS inverter if the AC supply voltage (UPS input) is outside the acceptable range. The Liebert FS
supplies power to the UPS inverter until the utility power is restored, until an alternate power source
is available, or until the Liebert FS’ energy is exhausted.
One or more Liebert FS units may be integrated into UPS and can be put in parallel as shown in
Figures 2 and 3, to achieve higher power output or higher ride-through duration.
4
General System Information
Figure 2 Single Liebert FS unit or multiple Liebert FS units integrated into a UPS system
UPS Block Diagram
UPS
Utility
Power
EMER SO
Network Power
N
Liebert FS Unit 1
AC
DC Bus
DC
Liebert
EMER SO
Network Power
N
Liebert FS Unit 2 Liebert FS Unit N
DC
Loads
AC
Liebert
EMER SO
Network Power
N
Liebert
Figure 3 Liebert FS unit(s) integrated into UPS system for ride-through to backup generator
UPS Block Diagram
Utility
Power
ATS
Backup
Generator
AC
DC Bus
DC
Loads
UPS
EMERSO
Network Power
N
DC
Liebert
EMER SO
Network Power
N
Liebert
AC
EMER SO
Network Power
N
Liebert
Liebert FS Unit 1 Liebert FS Unit 2 Liebert FS Unit N
5
General System Information
Figure 4 One or more Liebert FS units in parallel with one or more battery strings, battery cabinets or
batteries in racks
UPS Block Diagram
UPS
Utility
Power
AC
DC Bus
DC
DC
Loads
AC
EMERSON
Network Power
Liebert
FS Unit 1
Lieber t
EMERSON
Network Power
Lieber t
Liebert
FS Unit 2
1.2.1 General Specifications
Table 2 summarizes the technical specifications of the Liebert FS.
Table 2 General system specifications
Rated Power Delivery
Input Voltage (DC) 360 through 600 VDC; > 520 VDC required for 190kW
Output Voltage (DC) 350 through 590 VDC; > 510 VDC required for 190kW
Input Voltage Aux. (AC) 85 VAC – 265 VAC (47-63Hz)
Operating Temperature -20°C to 50°C (-4°F to 122°F)
Non-Operating Temperature -20°C to 80°C (-4°F to 176°F)
Dimensions (W x D x H) 63 x 83 x 180 cm (25 x 33 x 71 in)
Total Weight 590 kg (1,300 lb)
EMERSON
Network Power
Liebert
Lieber t
Battery 1
FS Unit N
Dependent upon the duration required;
refer to Figure 5
Battery 2 Battery N
For more-detailed technical specifications, refer to Technical specifications on page 148.
6
1.2.2 Features and Benefits
The Liebert FS provides clean constant DC output to the DC bus, at the user-selected, regulated voltage, until the stored energy is depleted. See Figure 5 for a graphic representation of the performance
power and duration curves of single and paralleled unit combinations.
Key Technological Features
• Active magnetic bearings
• Internal, integrated vacuum system
• Synchronous reluctance motor-generator
• Fiber composite flywheel
• Unique patented safety system
Key Customer Benefits
• High reliability
• Significantly increased power supply reliability
• Low total cost of ownership
• Operational flexibility
• Environmentally friendly
• Easy to install and easy to operate.
• Low standby losses
• Small footprint
• Lightweight
• Reliable, cost effective power systems for UPS ride-through needs
General System Information
1.2.3 Applicable Standards and Certification
For distribution in North America, the Liebert FS is listed to the following Underwriter’s Laboratory
(UL) applicable requirements:
• UL 508, Standard for Safety for Electrical Industrial Control Equipment;
• UL 1004, Standard for Safety for Electric Motors;
• UL 1248, Standard for Safety for Engine-Generator Assemblies;
The Liebert FS is designed in accordance with the applicable sections of the requirements published by:
• National Fire Protection Association (NFPA)/National Electric Code (NEC)
• National Electrical Manufacturer's Association (NEMA)
• Occupational Safety & Health Administration (OSHA)
The Liebert FS is also listed to the following Canadian Standards as determined by UL (cUL):
• CSA-C22.2 No. 100-04, “Motors and Generators,”
• CSA-C22.2 No. 14-95, “Industrial Control Equipment,”
The "Uniform Building Code (UBC) Zone 4" certification requirements.
7
For distribution in Europe, the Liebert FS is CE-marked and meets the applicable requirements of
the following European directives:
“Low Voltage Directive” 73/23/EEC and its amendments by the directive 93/68/EEC;
“Machinery Directive” 98/037/EEC and its amendments by the directive 98/79/EEC;
• IEC/EN 60439-1:1999—”Low-voltage switchgear and control gear assemblies Part 1: Typetested and partially type-tested assemblies”
• IEC/EN 60204-1:1997—”Safety of machinery - Electrical equipment of machines Part 1: General requirements”
• EN 1127-1:1997—”Explosive atmospheres: Explosion prevention and protection Part 1: Basic
concepts and methodology”
• Machinery Directive Annex 1—”Essential Health and Safety Requirements Relating to the
Design and Construction of Machinery and Safety Components”
“Electromagnetic Compatibility (EMC) Directive” 89/336/EEC and its amendments by the directives 92/31/EEC and 93/68/EEC.
Figure 5 Liebert FS DC power duration for one or multiple units in parallel
1900 kW-sec delivered
GT model, 510 VDC, with filter
General System Information
10 seconds at 190kW (max. power)
@ 510 VDC min
kWb = Refers to Kilowatts on the DC bus of the UPS system
Discharge Voltage = 510VDC
The Liebert FS is integrated into UPS systems as shown in Figures 2 through 4 and Figures 6
and 7.
8
Figure 6 Integrating a single Liebert FS unit into a UPS system
UPS Block Diagram
Bypass
Breaker
Bypass
Static
Switch
General System Information
GRID
Utility
Feeder
Breaker
UPS
Input
Breaker
UPS
Rectifier
EMERSON
Network Power
UPS
DC
Bus
Lieber t
UPS
Output
Breaker
CRITICAL
AC LOADS
Liebert FS
Several Liebert FS units can be put in parallel to achieve higher power output and higher ridethrough duration (see Figure 7). One or more Liebert FS units may also be connected in parallel with
a UPS battery plant (valve- regulated or wet cells) to provide an overall incremental reliability and
life improvement for the DC battery plant. In this situation, the Liebert FS unit would be connected
in parallel with the battery plant (through its own disconnect device) to the UPS DC Bus.
Figure 7 Integrating multiple Liebert FS units into a UPS system
Bypass
GRID
Utility
Feeder
Breaker
Bypass Breaker
UPS
Input
Breaker
EMERSON
Network Power
Liebert FS
Unit #1
Static
Switch
UPS
Rectifier
Liebert
UPS Block Diagram
UPS
DC Bus
EMERSON
Network Power
Liebert FS
Unit #2
Lieber t
UPS
Inverter
EMERSON
Liebert FS
Network Power
Unit #N
UPS
Output
Breaker
Lieber t
CRITICAL
AC LOADS
9
2.0 SITE PREPARATION
Site preparation for the Liebert FS is minimal. If a UPS system is already installed, the only requirements are to properly:
• Place the unit in relation to walls, ceiling and other equipment and
• Fasten the unit to the floor.
CAUTION
!
The following sections should be read thoroughly before proceeding with site preparation for
installing the Liebert FS.
NOTE
All drawings referred to in this section are in Appendix D.0 - Installation Drawings.
2.1 System Location
Choose a location for the Liebert FS that offers:
• Easy connection to inputs, outputs and auxiliary equipment
• Enough space to service the Liebert FS
• Air circulation sufficient to expel heat produced by Liebert FS
• Protection against moisture and excessive humidity (not to exceed 95% non-condensing)
• Protection against excessive dust and other particulate matter
• Compliance with fire prevention regulations and practices
• Operating environment temperature of -4°F to 122°F (-20°C to 50°C)
Site Preparation
2.2 Environmental Considerations
Place the system in a clean, dust-free environment. Air must be free to circulate around the cabinet(s). The system pulls air through the front of the Liebert FS and exhausts it out the top for cooling.
If the unit must be located in a dusty environment, Liebert recommends installing an optional air filter, which mounts on the lower inside of the Liebert FS door.
Adequate ventilation, including air conditioning if necessary, must be provided to limit heat accumulation. The ambient temperature for the unit must be from -4°F to 122°F (-20°C to 50°C). Avoid placing the unit in direct sunlight or near other heat sources.
There is a 32°F (0°C) minimum ambient temperature requirement for starting up the unit. Once the
unit has been running for some time, it will keep itself warm enough in ambient temperatures as low as
-4°F (-20°C).
Humidity is not to exceed 95% (non-condensing).
10
2.3 Flooring Requirements
2.3.1 Floor Loading
The Liebert FS should be mounted on a finished surface, such as concrete, block, brick or wood. The
floor must be strong enough to support the equipment load and suitable for installation of an anchoring kit with vertical floor loading properly calculated (assume 2,000 PSI or 140 kg/cm
caster wheels; this includes safety factors).
• When installing on a concrete, masonry or stone floor, use the factory-supplied masonry fasteners
(anchors). The fastener manufacturer’s allowable shear load (parallel to floor) for these fasteners
is 2,030 lb. (9 kN) when mounted in normal-weight concrete (2,000 to 3,000 PSI; 140-210 kg/cm
of at least 3 in. (7.6cm) thickness.
• If installing on a floor consisting of a material other than normal-weight concrete as described
above, the mounting should be capable of sustaining a shear load (parallel to floor) of at least
1,500 lb. (6.7 kN) for each of the four mounting points.
• If installing on a raised floor that is less than 2 in. (5cm) thick or constructed of a material not
appropriate for the masonry fasteners provided or lag screw engagement, mount using through
bolts with nuts and large diameter washers as shown in Figure 155.
Full details for mounting the cabinet are found in 4.1 - Cabinet Floor Mounting.
NOTE
The above loads (both the fastener manufacturer load and the minimum mounting load)
include the required safety factors.
Site Preparation
2
contact load at
2
)
2.3.2 Floor-Space Occupation
The Liebert FS cabinet requires a floor space of 23" wide by 33" deep (63 x 83cm), resulting in a footprint of 5.7 square feet (0.5m
2
2.3.3 Clearances
The Liebert FS installation requires a ceiling height of at least 7 ft. (214cm).
The unit occasionally vents air out of the top. Loose ceiling tiles above the unit may be moved by the
airflow. Ample clearance to access the cable connection at the top of the unit must also be provided.
All system electrical connections are to be routed through the top or side of the cabinet.
A 36" (91cm) clearance is required in the front of the unit for National Electrical Code (NEC) compliance.
Maintenance access to all components is from the front; no side or back access is required for maintenance. Either side of the system cabinet can be placed against walls (assuming minimum distance
from edge of floor). Repair may require access to the rear of the unit. In this unlikely instance, the
unit may need to be rolled out from its installed location (cabinet is on casters).
2.4 Electrical Considerations
CAUTION
!
A qualified electrician must perform all electrical connections. The wires (DC power,
grounding, optional status/control and auxiliary power supply) that connect the Liebert FS
system(s) to the UPS system must be provided by the electrical contractor (standard) or by
Liebert as an option. Wire size and installation must comply with all applicable local, regional
and national regulations (e.g., National Electric Code for USA).
).
2.4.1 DC Power Connections
Place the Liebert FS as close as practical to the interconnected UPS. The maximum distance allowed
between the UPS and the Liebert FS depends on power levels and the type of DC cables used. Liebert
requires sizing DC cables and placing the Liebert FS for a maximum of no more than 2V loop drop (at
rated power) between the UPS and the Liebert FS.
The Liebert FS is delivered with the standard UPS interconnection kit for connection of the positive
and negative terminals coming from the UPS DC bus or from an external disconnect switch.
For details, see 4.2.2 - DC Power Connections.
11
2.4.2 Status/Control Connections
Site preparation for Status/Control connections vary according to the type of UPS interconnection kit
provided with your Liebert FS.
Liebert recommends making Status/Control connections on the UPS system side.
For details, refer to 4.2.3 - Status/Control Connections.
2.4.3 Grounding Connections
A grounding wire must be connected from the Liebert FS to the UPS ground terminal. Identify in
advance the location of the grounding terminal on the UPS system. For further details, see 4.2.2 - DC
Power Connections.
2.4.4 AC Power Connections
Plan for the availability of a dedicated 110 or 230VAC, 50 or 60Hz circuit with branch circuit protection as a source for AC auxiliary power supply to the Liebert FS. This AC power must be rated for
400VA and must be located either on the output circuit of the UPS system or on another UPS-protected circuit. A qualified electrical contractor should make arrangements for this connection to be
permanent.
Site Preparation
The field-supplied AC wire must comply with all applicable local, regional and national regulations
(e.g., National Electric Code for USA). An 18 AWG (0.82mm
tion.
For details, see 4.2.5 - AC Auxiliary Control Power Supply Connections and Appendix F.0 -
Auxiliary Backup AC Power Supply.
2.4.5 Remote Monitoring Connections—Optional
If the optional Data Collection Module (DCM) is provided with your Liebert FS system, plan to have
communication cables (local network connection, phone line) installed to support the remote notification and/or monitoring options chosen.
For details, see 4.2.6 - Remote Monitoring Connections—Optional.
2
) cable is recommended for this connec-
12
3.0 UNLOADING AND UNPACKING
NOTE
All drawings referred to in this section are in Appendix D.0 - Installation Drawings.
3.1 Inspection Before Removal From the Truck
While the Liebert FS shipping package is still on the truck:
• Inspect the equipment and shipping container(s) for any signs of damage or mishandling. Check
also if the shock and tilt gauges (installed for shipping purposes) indicate excessive shock and/or
tilting. If any damage is noted, file a damage claim with the shipping agency within 24 hours and
contact your local sales representative or Liebert at 1-800-LIEBERT to notify them of the damage
claim and the condition of the equipment.
• Compare the contents of the shipment with the bill of lading. Report any missing items to the carrier, your local Liebert representative and Liebert at 1-800-LIEBERT immediately. Please have
the bill of lading available.
CAUTION
!
Do not attempt to install the system if damage is apparent.
3.2 Unloading
Figure 8 Liebert FS shipping package
Unloading and Unpacking
76"
(1933mm)
Front View
Do not tilt the Liebert FS
more than 15 degrees
from vertical.
The FS as shipped (see Figure 8) can weigh up to 1,462 lb. (663kg). It must be handled with care. It
must be kept upright—pay special attention to the arrows, which indicate the upright position.
45"
(1143mm)
Top View
Side View
24"
(610mm)
(1219mm)
4.4"
(112mm)
Shipping Support
Bands
(on either side)
Metal
Support
Plates
(one on
either side)
Shipping Weight:1462 lb. (663kg)
Weight, unit only: 1300 lb (590kg)
48"
14623
13
3.2.1 Handling
The Liebert FS shipping package is designed to be handled using a forklift. Forklift operators must
avoid rough handling when picking up, moving and lowering it.
CAUTION
!
Exhibit care when handling Liebert FS cabinet to avoid equipment damage or injury to
personnel. Failure to do so could throw off the calibration of the mechanical components
contained in the unit and possibly cause permanent damage.
CAUTION
!
The Liebert FS has sensitive electronics and mechanical components that have been
calibrated prior to shipment.
CAUTION
!
Test lift and balance the cabinet before transporting it. Maintain minimum tilt from vertical
at all times—do not exceed 15 degrees of tilt.
CAUTION
!
Sheet metal components and framework may have sharp edges.
3.2.2 Unpacking
Unloading and Unpacking
To reduce the possibility of shipping damage, flywheel cabinets are secured to the pallet by two
mounting brackets and two banding straps. These same two mounting brackets are used to mount the
cabinet to the floor.
Packing elements should be removed in this order to ease unpacking:
1. Cut and remove the banding straps (see Figure 8).
CAUTION
!
Use care when removing banding straps and metal mounting brackets. The banding straps
are under tension and may snap violently, causing injury. Always wear proper eye and foot
protection when unpacking or installing the system.
2. Remove hex head bolts holding mounting brackets to pallet as shown in Figure 9.
3. Remove lag bolts holding metal mounting brackets to pallet.
4. Remove mounting brackets from Liebert FS.
Figure 9 Removing lag bolts
Lag bolts
securing
Liebert FS to
shipping pallet
Metal mounting
bracket bolted to
shipping pallet
14
5. Use a forklift to remove the cabinet from the shipping pallet.
To lift the Liebert FS, the forks should be inserted between the caster wheel assemblies (see
Figure 10). Forks must be extended to the full depth of the cabinet—at least 6 ft. (2m) fork
length—to properly support the equipment (see Figure 10). This likely requires fork extenders.
The Liebert FS unit can weigh up to 1,300 lb. (590kg) and must be handled with care.
Figure 10 Lifting the Liebert FS cabinet
Forks must be
extended the
full depth of the
cabinet
6. Unbolt and remove the two metal support plates (one on either side of the pallet).
Figure 11 Removing the metal support plates
Unloading and Unpacking
Metal
support
plate
Caster
(for moving
short
distances)
Leveling
foot (one
on each
corner)
NOTE
Retain the four bolts (1/2" diameter x 1-3/4" long; 12.7mm diameter x 44.5mm long) attaching
the metal support plates to the cabinet. These will be used to attach brackets to the cabinet for
surface mounting.
7. Examine the Liebert FS internally and externally for transit damage. Report any damage to the
shipper, your local Liebert representative and Liebert immediately.
CAUTION
!
Do not attempt to install the system if there is any damage.
8. Check visually for loose connections and unsecured components in the cabinet.
9. You will find the installation manual, operation manual and options manual (if any) enclosed in
the pocket inside the cabinet door (see Figure 12).
10. You will find the serial number and model number plate mounted on the cabinet door pocket or on
the upper right corner of the face of the cabinet frame inside the door (see Figure 12). Record the
model number and serial number in Table 1 - System information.
15
Unloading and Unpacking
Figure 12 Location of serial and model number plate (cabinet side panel removed and open door)
Serial Number
and Model
Number Plates
3.3 Positioning the Liebert FS
3.3.1 Moving the Liebert FS
When moving the unit a short distance, the Liebert FS may be rolled on its built-in casters (see
Figure 13) to its location.
Manuals
CAUTION
!
Before moving the Liebert FS across a floor, determine whether the surface will support the
unit’s weight—1,462 lb. (663kg) as shipped; 1,300 lb. (590kg) uncrated.
Figure 13 Liebert FS cabinet caster location
Casters on each corner
(for moving unit short
distances only)
When moving the unit a longer distance or over rough flooring, move the Liebert FS with a forklift or
similar equipment to facilitate the relocation and to reduce vibration of the unit.
CAUTION
!
Ensure that the handling equipment is rated for the weight of the Liebert FS—1,462 lb.
(663kg) as shipped; 1,300 lb. (590kg) uncrated.
3.3.2 Storing the Liebert FS for Delayed Installation
If the equipment will not be installed immediately, it must be stored indoors where the temperature
stays within -4°F to 176°F (-20°C to 80°C) and the humidity is no higher than 95% (non-condensing).
16
4.0 INSTALLATION
The Liebert FS system design and safety characteristics allow for a relatively simple and quick installation. The system is designed to be rolled or lifted into place and bolted to the floor using Liebert's
mounting kit, included with the system. The mounting kit in most cases does not require any special
floor preparations (see3.0 - Unloading and Unpacking).
CAUTION
!
The Liebert FS system must be installed in accordance with the instructions and drawings in
this manual.
CAUTION
!
Never attempt to install or power up any unit suspected of damage during shipment.
CAUTION
!
The Initial System Startup must be performed ONLY under the supervision of a
Liebert-certified service technician to ensure proper system operation. Failure to abide by
instructions provided herein may void your warranty.
Contact your local Liebert sales representative or Liebert at 1-800-LIEBERT to arrange for
system startup.
Figure 14 Dimensions, general layout
Installation
Top
Bottom
Control
Panel
71-1/8"
(1801mm)
25"
(636mm)
Front
17
32-1/2"
(828mm)
Right Side
12-100120-09
Figure 15 Internal layout
Installation
Data
Control
Module
Versatile
Interface
Board
Inductor
Capacitor
Module
Power
Convers ion
Module
Factory-Integrated
Circuit Breaker
Fan
Magnetic
Levitation
Module
71-1/8"
(1807mm)
Flywheel
Module
25"
(636mm)
Front
(door open)
32-1/2"
(828mm)
Right Side
(panel removed )
NOTE
The Liebert FS is designed for front-access-only for installation and maintenance. While the
likelihood of repair is minimal, some repair procedures require side and/or rear access.
Normally, the easiest way to handle this is to disconnect the power and control wiring and roll
the unit out into an open area on its casters. While it is acceptable, under certain
circumstances, to connect the Liebert FS to its companion UPS unit through the sides of the
Liebert FS and UPS cabinets rather than through external conduit, repair access to the Liebert
FS unit will be easier to facilitate if through-cabinet wiring is not installed.
18
4.1 Cabinet Floor Mounting
NOTE
Before beginning, ensure that the floor where the Liebert FS will be mounted meets the floor
loading specifications in 2.3 - Flooring Requirements.
• For placement on concrete, masonry or stone floors, see 4.1.1 - Concrete, Masonry or Stone
Floor Mounting.
• For placement on wood floors, see 4.1.2 - Wood Floor Mounting.
• For placement on raised floors, see 4.1.3 - Raised Floor Mounting.
Figure 16 Floor mounting
Installation
Floor Mounting
Bracket
EMERSON
Network Power
Liebert
NOTE
All drawings referred to in this section are in Appendix D.0 - Installation Drawings.
19
4.1.1 Concrete, Masonry or Stone Floor Mounting
Mounting Kit for Concrete, Masonry or Stone Floors
Liebert has included a complete anchoring kit with each Liebert FS for surface mounting. The kit is
intended to securely fasten the Liebert FS to its intended location for operational safety and seismic
requirements.
This kit includes (items depicted in Figure 150):
• Two (2) cabinet mounting brackets (from shipping pallet)
• Four (4) concrete expansion anchors
• Two (2) drop-in hex head anchor bolts
• Two (2) washers for anchor bolts
• One (1) masonry drill bit
• One (1) floor mounting template (Figure 149)
• Two (2) drop-in hex flange anchor bolts
• One (1) setter rod or drive pin (specifically designed for measuring hole depth and for expanding
the anchors)
• Four (4) hex bolts from shipping package, each 1/2" diameter and 3/4" long (12.7mm diameter x
20mm long)
Mounting Tools
These tools are needed for the mounting the Liebert FS on the floor:
• Concrete drill with 1/2" (12.7mm) minimum chuck size
• Masonry drill bit (included in mounting kit)
• Masonry drill bit—used for pilot hole—for example, 1/8" (3.2mm) diameter
• Setter rod (included in mounting kit)
• Hammer or mallet, 16 oz. (0.5kg) or larger
• Shop vacuum cleaner (to remove dust from hole when drilling)
• 3/4" (19mm) combination wrench
• 18mm combination wrench
Installation
Concrete, Masonry or Stone Floor Mounting Instructions
To mount the Liebert FS cabinet on the floor:
1. Prepare a clean, level, finished surface, free of obstructions, for installation of the mounting kit.
2. Tape the floor mounting template mounting template (Figure 149) to the installation location.
3. Using a bit smaller than the one provided in the mounting kit, drill a pilot hole at each of the four
places marked with an “X” on the template.
4. Remove template and continue with larger drill bit provided.
Figure 17 Floor mounting template layout
X X
Drill 4 holes, each
2" (51mm) deep,
with 5/8" masonry bit
X X
16"
(406mm)
29-1/2"
(749mm)
Front of Liebert FS
20
5. Drill 2" (51mm) deep holes in prepared surface using the drill bit included in the kit per bolt
pattern described in Figure 149 - Floor mounting template. The setter rod should be used as a
depth gauge to ensure proper depth. The setter rod is marked with two circles indicating the
maximum and minimum hole depth allowed (see Figure 18).
If a hole is drilled too deep, refill the hole with debris to the achieve proper depth.
Figure 18 Checking hole depth
Installation
Setter Rod (provided)
6. Insert four (4) drop-in concrete expansion anchors into drilled holes.
Figure 19 Inserting anchors
Concrete Floor
Depth Marks
2.05"
(52mm)
Insert a nchor flush with floor .
Use hammer if required.
7. Tap anchors into drilled holes using hammer or mallet. When top of anchor is flush with
mounting surface, use setter rod to expand and secure.
Figure 20 Expanding anchors
Strike with
hammer
to set plug
21
8. Match mounting brackets with the holes on the bottom of the cabinet (see Figure 21). Make sure
that the bracket holes align with the mounting spots on the underside of the cabinet and secure
the brackets with the four (4) 1/2" diameter x 3/4" long (12.7mm diameter x 20mm long) hex bolts
retained from the shipping package. Tighten the bolts with a torque of 40 foot-pounds (54 N-m).
Figure 21 Securing mounting brackets to the cabinet
9. Insert the two (2) hex flange bolts in the rear anchors, where the back of the cabinet will be.
Complete tightening of the rear bolts should result in 1/2" (12.7mm) gap between bolt flange and
floor (see Figure 22 and Figure 134). The rear bolts must be tightened to 20 foot-pounds
(27 N-m) of torque. Bolt height or length may need to be adjusted if mounting surface is uneven or
if mounting bracket does not slide beneath bolt flange.
10. Position and align cabinet and bracket slots with the newly inserted bolts at rear and position
cabinet such that bolts fit in bracket slots (see Figure 22).
Installation
Bolt securing bracket
to cabinet
Figure 22 Mounting rear bolts—rear side of cabinet
1/2"
(12.7mm)
floor to
flange
22
11. Insert and begin tightening two (2) hex head bolts with one washer each through bracket
mounted at front of cabinet into anchor inserts in mounting surface (see Figure 23).
Figure 23 Mounting front bolts—front side of cabinet
12. Check the bubble level on the floor of the cabinet on the right hand side of the Power Conversion
Module (see Figure 24). The Liebert FS is sufficiently level when the bubble is within the outer of
the two circles. If the bubble is outside the outer circle, use the leveling feet to adjust until bubble
is within the outer circle.
Installation
Figure 24 Bubble level
13. Once the cabinet is level, firmly tighten the front bolts to drop-in anchors as shown in
Figure 134. The front bolts must be tightened to 40 foot-pounds (54 N-m) of torque.
Bubble
level
23
4.1.2 Wood Floor Mounting
Determine which of these cases applies to your installation:
• For wood flooring over concrete, follow the instructions in 4.1.1 - Concrete, Masonry or Stone
Floor Mounting.
• For wood flooring on joists, follow the instructions in this section.
Wood Floor Mounting Parts
• Two (2) cabinet mounting brackets (previously secured Liebert FS cabinet to shipping pallet)
• Four (4) (1/2" diameter x 2-1/2" long) [or 12.7mm diameter x 63.5mm] lag screws (not included in
mounting kit) are recommended
• One floor mounting template, see Figure 149
• Four (4) 1/2" diameter x 3/4" long (12.7mm diameter x 20mm long) hex bolts (from shipping package—see 3.2.2 - Unpacking)
Wood Floor Mounting Tools
The following tools are needed for the cabinet wood floor mounting:
• Electric drill
• 1/4" (7mm) drill bit
• Drill bit—used for pilot hole—for example, 1/8" (3.2mm) diameter
• Shop vacuum cleaner (to remove dust from hole when drilling)
• 3/4" (19mm) combination wrench
• 18mm combination wrench
Installation
Wood Floor Mounting Instructions
Installation in wood floor on joists does not require drop-in anchors.
1. Prepare a clean, level surface, free of obstructions, for installation of the mounting kit.
2. Tape the floor mounting template (Figure 149) to the installation location.
3. Drill pilot holes, remove the template and use a 1/4" (7mm) drill bit to drill holes 2.5" (64mm)
deep.
CAUTION
!
Ensure that holes are centered in the joist.
4. Match mounting brackets with holes under base of cabinet (see Figure 21). Make sure that the
bracket holes align with the mounting spots on the underside of the cabinet and secure brackets
with the four hex bolts retained from the shipping package. Each bolt is 1/2" diameter x 3/4" long
(12.7mm diameter x 20mm long). Tighten the bolts with a torque wrench at 40 foot-pounds
(54 N-m).
5. Insert two lag screws through bracket mounted at rear of cabinet leaving head with 1/2" (12.7mm)
gap above floor (see Figure 22).
6. Position and align cabinet and bracket slots with the newly drilled holes at rear and position
cabinet such that bolts fit in bracket slots (see Figure 22).
7. Insert two (2) lag screws through bracket mounted at front of cabinet (see Figure 23).
8. Check the bubble level on the floor of the cabinet on the right hand side of the Power Conversion
Module (see Figure 24). The Liebert FS is sufficiently level when the bubble is within the outer of
the two circles. If the bubble is outside the outer circle, use the leveling feet to adjust until bubble
is within the outer circle.
9. Once the cabinet is level, firmly tighten the front lag screws to a torque 40 foot-pounds (54 N-m).
24
4.1.3 Raised Floor Mounting
Raised Floor Mounting Kit
Liebert has included a complete anchoring kit with each Liebert FS for surface mounting. The kit is
intended to securely fasten the Liebert FS to its location for operational safety and seismic requirements.
The anchoring kit includes:
• One floor mounting template, Figure 149
• 2 cabinet mounting brackets
• 4 drop-in hex flange bolts, each 1/2" diameter, 3" long (12.7mm, 76.mm)
• 4 washers (1/2" hole and 2" outer diameter) for hex flange bolts
• 4 lock washers for hex flange bolts
• 4 nuts for hex flange bolts, each 1/2" (12.7mm)
• 4 hex bolts, each 1/2" diameter, 3/4" long (12.7mm diameter, 20mm long) retained from shipping
package (see 3.2.2 - Unpacking)
Raised Floor Mounting Tools
The following tools are needed for the cabinet raised floor mounting:
• Electric drill with 1/2" (12.7mm) minimum chuck size
• 5/8" (16mm) drill bit
• Drill bit—used for pilot hole—for example, 1/8" (3.2mm) diameter
• 3/4" (19mm) combination wrench
• 18mm combination wrench
Installation
Raised Floor Mounting Instructions
To mount the Liebert FS cabinet on the floor:
1. Prepare a clean, level finished surface, free of obstructions, for installation of mounting kit.
2. Tape the floor mounting template (see Figure 149) to installation location, pre-drill a pilot hole,
then remove paper and continue with 5/8" (16mm) drill bit.
3. Match mounting brackets with holes under base of cabinet (see Figure 21). Make sure that the
bracket holes align with the mounting spots on the underside of the cabinet and secure brackets
with the four 1/2" diameter x 3/4" long (12.7mm diameter x 20mm long) hex bolts retained from
the shipping package. The bolts must be tightened to 40 foot-pounds (54 N-m) of torque.
4. Position and align cabinet and bracket slots with the newly drilled holes (see Figure 22).
5. Insert four drop-in hex flange bolts through bracket mounted at front and rear of cabinet (see
Figure 23).
Figure 25 Raised floor mounting
2"
(50mm) dia.
Large diameter washer
Lockwasher
1/2" (12.7mm)
dia. steel bolt
25
Raised
floor
6. Attach a large diameter washer, a lock washer and a nut to each hex flange bolts as described in
Figure 25 and Figure 155.
7. Check the bubble level on the floor of the cabinet on the right hand side of the Power Conversion
Module (see Figure 24). The Liebert FS is sufficiently level when the bubble is within the outer of
the two circles. If the bubble is outside the outer circle, use the leveling feet to adjust until bubble
is within the outer circle.
8. Once cabinet is level, firmly tighten down all hex flange bolts with nuts. The bolts must be
tightened to 40 foot-pounds (54 N-m) of torque.
4.2 Wiring Connections
4.2.1 General Wiring Considerations
CAUTION
!
A qualified electrical contractor must perform all electrical connections. The wires (DC power,
ground, upgraded status/control and auxiliary power supply) that connect the Liebert FS
system(s) to the UPS system are field-supplied or by Liebert as an option. Wire size and
installation must comply with all applicable local, regional and national regulations (e.g.,
National Electric Code for USA).
The electrical connections to the Liebert FS are:
•DC power
• Status/control (upgraded)
•Ground
• Auxiliary backup power
• Remote monitoring—optional
Installation
Figure 26 Liebert FS cabinet with UPS interconnection kit
Ground Terminal
DC Power
Terminals
Front
Circuit
Breaker
Manufacturer’s
Connection
Status/Control
Terminal Block
(upgraded)
Power and Status/Control wiring must be run in separate conduits or cable trays. Refer to Appendix
D.0 - Installation Drawings for locations of the various electrical connections between Liebert FS
system(s) and UPS system.
Rear
Fan Coil Module
CAUTION
!
Power and Status/Control wiring must be separated.
26
Installation
CAUTION
!
Do not cut entry holes for conduit while the access plates are still set on the top of the
Liebert FS cabinet. Remove the access plates from the cable-access areas in the top of the
Liebert FS cabinet prior to cutting entry holes in them.
CAUTION
!
After reinstalling access plates, be certain that no foreign matter (metal shavings, insulation
or wire fragments, etc.) remains inside the Liebert FS. Likewise, be certain to block any
“extra holes” in the plates through which foreign matter (or rodents) could later enter the
Liebert FS.
CAUTION
!
The instructions for installation of DC Power AND Status/Control connections vary according
to the type of UPS interconnection kit that is integrated into your Liebert FS unit.
Figure 27 Liebert FS with circuit breaker mounting plate and access panels for DC and control wiring
connections
Control and
Communication
Access Panel
Circuit Breaker
Mounting Plate
Figure 28 Typical circuit breaker wiring for DC connections (view from rear of circuit breaker)
POS
POS
DC and Ground
Connections
Access Panel
TOP VIEW
NEG
NEG
27
4.2.2 DC Power Connections
The instructions for installation of DC power connections vary according to the type of UPS interconnection kit integrated into your Liebert FS unit. Follow the installation instructions in Appendix
A.0 - UPS Interconnection Kits for the relevant UPS interconnection kit installed in your unit.
4.2.3 Status/Control Connections
The instructions for installing Status/Control connections vary according to the type of UPS interconnection kit that is integrated into your Liebert FS. Follow the installation instructions in Appendix
A.0 - UPS Interconnection Kits for the relevant UPS interconnection kit installed in your unit.
4.2.4 Ground Connections
A ground connection is available on the Liebert FS (see Figure 29). The electrical contractor must
ensure that the Liebert FS is effectively grounded to UPS chassis or UPS ground terminal. The
ground connection must be as short as possible. The maximum ground wire size is 1/0 AWG - 600VDC
wire (54mm
and national regulations (e.g., National Electric Code for USA). Check all connections with Multimeter to verify ground continuity. (Refer also to Appendix E.1 - Ground Test Procedure.
!
Figure 29 Ground connection on the Liebert FS
2
wire section). Wire size and installation must comply with all applicable local, regional
CAUTION
Ensure that all grounds are secure and free of corrosion. Proper grounding is necessary for
optimum performance, safety and reliability.
Installation
Ground Terminal
Locations (DC
ground and filter
caps if required)
Side panel
removed for
clarity.
The tightening torque for the ground connections must be in accordance with Table 3. Use these values unless the equipment is labeled with a different torque value.
Table 3 Tightening torque for ground connection
Ground Wire Gauge Tightening Torque
Approximate metric
AWG
4 21 110 12
2 34 150 17
1 42 150 17
1/0 54 180 20
equivalent wire section (mm
2
)
Inch-
pounds N-m
28
4.2.5 AC Auxiliary Control Power Supply Connections
The AC auxiliary power supply connections to the Liebert FS are made through the auxiliary power
fused disconnect on the mounting plate above the inductor-capacitor module and to the right of the
optional VIB and DCM modules (see Figure 30). See Appendix F.0 - Auxiliary Backup AC
Power Supply for details on the purpose of the auxiliary AC power supply.
Figure 30 Service panel location
Service Panel (cover removed);
Provides access to fused disconnect
and the optional VIB and DCM.
Installation
The Auxiliary Power Fused Disconnect (see Figure 31) accommodates the connection of an AC wire
(Line, Neutral, Ground) and is rated for 110/230 VAC - 50/60 Hz. Open the circuit while wiring, check
the fuses and then close it. The AC wire must be connected to the auxiliary power fused disconnect
from the top to a dedicated AC circuit rated for 400VA with branch circuit protection. This AC outlet
must be connected to a protected low-voltage (110VAC-230VAC, 400VA) source. A qualified electrical
contractor should make this connection permanent.
The AC wire is field-supplied. It must conform to all applicable local, regional, national regulations,
such as the National Electric Code for USA. An 18 AWG (0.82 mm
connection.
Tighten the connections for the 18 AWG cable (0.82 mm
Figure 31 Auxiliary backup power connections
Location of MCM
(cover plate
removed)
2
) cable is recommended for this
2
) to 15 inch-pounds (1.6N-m).
AC Auxiliary
Power Fused
Disconnect
CAUTION
!
The AC power supply must remain connected at all times. Precautions must be taken to
ensure that the connection is not broken. Disconnection may cause damage to the equipment.
29
The AC wire is field-supplied. Wire size and installation must comply with all applicable local,
regional and national regulations (e.g., National Electric Code for USA). An 18 AWG cable (approximate metric equivalent: 0.82mm
2
wire section) is recommended for this connection.
Figure 32 shows the auxiliary power fused disconnect and terminals 1, 2 and 3, the landing points
for the AC wire on the Liebert FS side. Open the circuit while wiring, check the fuses and close afterwards when ready to test or start up Liebert FS.
Figure 32 Auxiliary power fused disconnect with connection points for AC wire
Terminal 1
Neutral
Terminal 2
Terminal 3
Ground
Line
Fused disconnect
Installation
The AC wire should be pulled from the left (top access recommended) and through the rear top access
panel (see Figure 33). Run the AC wire along the underside of the top cabinet frame rail from the
rear to the front of the cabinet. Terminate the AC wire at the fused disconnect (pictured in Figure 32;
see also Figure 26).
Figure 33 Top access panel
Top access
panel for
AC auxiliary
power supply
connections
Front of Liebert FS
30
4.2.6 Remote Monitoring Connections—Optional
The Liebert FS standard unit does not include remote monitoring connections. Remote monitoring
capabilities are provided as an option see Figure 34). If your unit is equipped with the optional Data
Collection Module (DCM), refer to the installation and configuration instructions in Appendix B.0 -
Data Collection Module.
Figure 34 Remote monitoring (DCM) connections (inside cabinet front door)
Location of MCM
(cover plate
removed)
4.3 Startup Considerations
Installation
AC Auxiliary
Power Fused
Disconnect
CAUTION
!
The Initial System Startup must be performed ONLY under the supervision of a
Liebert-certified service technician to ensure proper system operation. Failure to abide by
instructions provided herein may void your warranty.
Contact your local Liebert representative or call 1-800-LIEBERT to arrange for system
startup.
31
5.0 SYSTEM OVERVIEW
5.1 Detailed System Description
Figure 35 Liebert FS front view
Front View (door open,
right side panel removed)
UPS Interconnection Kit
System Overview
LCD
Control
Panel
Motor Generator
Filter Assembly
Power
Conversion
Module
Air Filter
(optional)
Versatile Interface
Board (option)
Data Collection
Module (option)
Magnetic Levitation
Module (above
flywheel module)
Flywheel Module)
Built-In Casters, 4
32
5.1.1 System Module Description
The Liebert FS is a modular system composed as follows:
• Control Panel
• UPS Interconnection Kit
• Power Conversion Module
• Main Control Module
• Flywheel Module
• E-Stop (optional-special order)
Components are illustrated in Figure 35.
Control Panel
The Liebert FS uses a control panel as the primary means for an operator to interface with the system.
UPS Interconnection Kit
The UPS Interconnection Kit is a module that enables the physical interconnection of the Liebert FS
and a UPS system. There are several versions that vary, depending on the UPS model.
The Liebert FS is delivered with a UPS interconnection kit consisting of a circuit breaker for connection of the positive and negative terminals coming from the UPS DC bus or from an external disconnect switch.
System Overview
Power Conversion Module
The power conversion module is a bi-directional power electronics-based power converter capable of
sourcing or sinking power to and from the UPS DC bus.
While performing the Liebert FS’s backup power mission, the power conversion module converts
“variable frequency - variable voltage” AC power from the Liebert FS’ motor-generator and delivers
regulated DC voltage output to the UPS DC bus.
Conversely, for the Liebert FS’s needs in charging power, the power conversion module converts DC
power from the UPS DC bus into “variable frequency - variable voltage” AC power for the Liebert FS’
motor-generator.
Main Control Module
The Main Control Module provides the overall control of the Liebert FS as well as the specific control
for:
• Motor-generator
• Active magnetic levitation hardware
Flywheel Module
The Flywheel Module houses several major components:
• Motor-generator—synchronous reluctance technology
• Rotating group—high-speed carbon composite flywheel, high-speed shaft and rotor of the motorgenerator
• 5-axis active magnetic levitation hardware
• Molecular vacuum pump
E-Stop
The E-Stop is an Emergency Stop that allows the Liebert FS to disconnect from the UPS. The E-Stop
is a CE requirement for systems shipping to Europe (and other areas requiring the CE Mark). The
feature is available elsewhere as an option. Two choices are available for how the E-Stop is powered,
internally or externally. If E-Stop is activated, Liebert FS will enter a self-discharge and shutdown
mode.
33
5.1.2 Power System
The electrical system of the Liebert FS is shown in Figure 36. The schematic shows the Magnetic
Levitation Module [see 5.1.7 - Magnetic Levitation Module (MLM)]. The pre-charge resistor and
contactor which limit the inrush current into the DC bus capacitors. The six-pulse IGBT power converter (IGBT Power Conversion Module (PCM) on page 36) which is controlled by the Power
Conversion Module Controller (Power Conversion Module on page 33) and which also monitors
and controls the operation of the entire system. These components are housed within the Power Conversion Module. The Flywheel Module is shown as a cross-section to illustrate the rotating group and
the synchronous reluctance motor-generator.
Figure 36 Electrical system schematic
System Overview
Flywheel Module
IGBT Power Converter
+
Soft Start
To UPS
Battery
Input
-
DC Monitoring
Power Conversion Module Controller
Control
Panel
5.1.3 System Performance
The maximum output power of the Liebert FS varies according to the duration required. This is illustrated in Figure 5 (output power versus time). Increased power, duration or redundancy may be
achieved by adding units in parallel as shown in Figures 2 through 4.
Motor Generator Controls
Remote Monitoring
COM
& Controls (Optional)
Back up
AU Auxiliary
Speed
Sensors
Sensors
Position
Temperature
Sensors
Magnetic Levitation
Module
34
5.1.4 User interfaces
Control Panel
The Liebert FS uses a Control Panel as the primary means for an operator to interface with the system. Operating parameter values are displayed and updated in real time. Alarm states and system
notices are also displayed when they occur. User configurable system parameters are adjusted via the
Control Panel.
Data Collection Module (DCM)
An optional software and hardware package that reads data from the Liebert FS is available. The
data is stored and then can be transmitted through an RS-232 port, over a LAN (Local Area Network)
or over the Internet, enabling a diagnostic reporting capability.
Versatile Interface Board (VIB)
An optional software and hardware package is available that allows for remote monitoring and control; via isolated auxiliary contacts:
Monitored Information
•OFF Mode
• STARTUP Mode
• CHARGE Mode
• State of Charge (SOC) = 0%
• State of Charge (SOC) = 12.5%
• State of Charge (SOC) = 25%
• State of Charge (SOC) = 37.5%
• State of Charge (SOC) = 50%
• State of Charge (SOC) = 62.5%
• State of Charge (SOC) = 75%
• State of Charge (SOC) = 87.5%
• Full Charge (SOC) = 100%
• DISCHARGE Mode
• SHUTDOWN Mode
• WARNING Mode
• FAULT mode
• Rotor Hot Standby
System Overview
Control Commands
•Startup
• Shutdown
•Clear Fault
5.1.5 UPS Interconnection Kit
The UPS Interconnection Kit (IKIT) is a module of the Liebert FS that simplifies the interconnection
to a UPS system. There are different versions of the IKIT available that have been specifically developed for the UPS systems the Liebert FS can integrate with. The Liebert FS in the standard configuration is delivered with an IKIT consisting of a fused Power Terminal Block for connection of the
Positive and Negative terminals coming from the UPS DC bus or from an external disconnect switch.
35
5.1.6 Power Conversion Module
Power Conversion Module Controller (PCMC)
The Power Conversion Module Controller is located within the Power Conversion Module. The PCMC
uses microprocessor-controlled logic to control the six pulse IGBT solid state switches and monitor the
active magnetic levitation system.
These operations are firmware controlled eliminating the need for manual adjustments. The logic
includes a self-test and diagnostic circuitry to identify any faults. Diagnostics are performed via a PC
through the RS232 communication port or through the control panel located on the front of the Liebert FS.
IGBT Power Conversion Module (PCM)
The PCMC provides the overall control of the Liebert FS as well as the specific control for the synchronous reluctance motor generator via the IGBT solid-state switches within the Power Conversion
Module.
The Power Conversion Module is a bi-directional system capable of sourcing or sinking power to and
from the stator. It converts variable frequency, variable voltage from the stator and delivers a constant voltage DC output. Conversely, it converts DC power from the UPS System DC Bus to variable
frequency, variable voltage output to the stator as directed by the PCMC to increase the speed of the
synchronous reluctance motor-generator.
When delivering DC power, the output of the synchronous reluctance generator is rectified to DC by
passing the high frequency AC current through a solid-state power conversion device. The DC output
voltage of the Liebert FS has less than 2% Vrms ripple.
System Overview
The voltage and frequency are adjusted using Pulse Width Modulation. The IGBT switches operate at
a frequency of 18 kHz to produce the smooth sinusoidal current waveform to and from the motor generator. This is smoothed out further using an inductive and capacitive filter.
36
5.1.7 Magnetic Levitation Module (MLM)
T
The Magnetic Levitation Module provides control of the active magnetic levitation hardware.
The Liebert FS has a unique active magnetic levitation system that fully levitates the flywheel-rotating group, allowing the flywheel to rotate without any physical contact. This has a number of advantages over mechanical bearing systems:
• Reduced drag- Mechanical bearings have a drag that is proportional to the square of the speed.
The levitation system developed by Liebert uses the same power regardless of speed.
• Reliability and zero maintenance- The levitation system ensures there is no contact between the
rotating parts and the housing and therefore there are no components to wear out. This ensures
the unit will operate maintenance free for the life of the system.
The levitation system, works by measuring the displacement using a capacitive sensor, if the distance
needs to be adjusted; the current to the electromagnet is altered to change the displacement, each
axis is measured and controlled separately with its own capacitive sensor, electromagnet and feedback loop which, is controlled by the MLM. This is all done using analog control so it is very fast acting and reliable. There are 5 different circuits working independently, these are: Radial: Upper X, Y;
Lower X, Y and Axial: Z Only
The principle of operation is the same in each case. The upper radial Y-axis is shown in Figure 37.
Figure 37 Schematic of the levitation system
Z
System Overview
Y
X
DISPLACEMENT
MEASUREMENT
AMPLIFIER
ELECTRO
MAGNET
CAPACITIVE
ROTOR
CONDITIONER
DISPLACEMENT SIGNAL
INFRARED EMITTER
Active Magnetic Levitation Hardware
AMPLIFIER
ELECTROMAGNET
CONTROLLER
DISPLACEMEN
SETPOINT
The electromagnets and capacitive displacement sensors that provide the active magnetic levitation
are located within the flywheel module. See 5.1.7 - Magnetic Levitation Module (MLM) for a full
description of their operation.
37
5.1.8 Flywheel Module
The Flywheel Module houses several major components:
• The Rotating Group (high-speed carbon composite flywheel, high-speed shaft and rotor of the
Motor-Generator)
• The Motor-Generator (synchronous reluctance technology)
• The Molecular Vacuum Pump
• Flywheel Sensors
• Active Magnetic Levitation Hardware
• Safety System
Figure 38 Liebert FS flywheel module
System Overview
Axial Electromagnet
Inner Housing
Carbon Fiber
Flywheel
M-G Stator
Liquid Cooling
Passages
Upper Radial
Electromagnet
Molecular Vacuum
System
Synchronous Reluctance
4-pole M-G Rotor
Lower Radial
Electromagnet
38
5.1.9 Rotor/Flywheel—Rotating Group
The flywheel is made of carbon/glass composite. This is mounted on a metal shaft with integral
motor-rotor and together these components form the rotating group. The rotating group is magnetically levitated and centered so that it does not touch any other part while in normal operation.
Figure 39 Rotating group
System Overview
5.1.10 Motor Generator
The rotor is positioned within the stator in such a way that the rotor and stator provide the
motor-generator function of the Liebert FS. The stator is liquid cooled and operates within a housing
in which air has been evacuated. Together the stator and rotor operate as a synchronous reluctance
motor-generator produces enough power for the system to supply its own internal demand and to supply to the output DC bus up to the rated power. The illustration in Figure 40 shows the four poles of
the synchronous reluctance machine.
Figure 40 Cross-section of the synchronous reluctance motor rotor
39
5.1.11 Vacuum System
During manufacture, the vacuum chambers are evacuated and baked to remove water vapor. The vacuum system is then permanently sealed off to prevent any air entering the system and to remove the
possibility of accidental loss of vacuum. The Liebert FS does not require an external vacuum pump to
maintain a suitable vacuum level; the vacuum system instead relies on absorbers to maintain a rough
vacuum within the upper chamber. A zero-maintenance molecular drag pump acts with the flywheel
shaft to maintain a high-vacuum in the lower chamber, as shown in Figure 41. Vacuum levels of
much less than 100 microTorr (10-7 atmosphere) are maintained in the lower chamber. The absorber
material only needs to be recharged or changed, once every 15 years.
Figure 41 Vacuum system operation
Air and Water Vapor
Upper Chamber
System Overview
Rotating Shaft
Molecular Drag Pump
Lower Chamber
40
5.1.12 Flywheel Sensors
Speed
The speed detection system uses an infrared emitter and a sensor to detect the rotation of the shaft. A
hole drilled through the shaft allows light to pass and is detected on the opposite side by an infrared
detector. This signal is used to detect the rotor angle, the speed and any over speed condition. The
pulsed signal passes into the 6711 DSP to be converted into a speed signal. This is then passed to the
2812 DSP. The 2812 checks for over-speed and shuts down the power electronics if this occurs. If
either of the processors lock-up, the rotor will slow down, this guarantees that on over-speed cannot
occur.
Temperature
The stator and rotor temperature detectors are thermocouples and are both conditioned in a similar
way. The stator sensor is a Type J thermocouple potted into the stator windings. The rotor sensor is a
non-contact type sensor that detects the temperature of the rotor surface and gives an output in a
Type J thermocouple format.
Figure 42 Schematic for the speed and temperature sensors
NON- CONTACT
ROTOR
TEMPERATURE
SENSOR
J TYPE
THERMOCOUPLE
OUTPUT
STA TOR
WINDINGS
ROTOR
STA TOR
TEMPERATURE
SENSOR
J TYPE
THERMOCOUPLE
System Overview
AMPLIFIERS, CONDITIONERS,
LINEARIZERS AND COLD
JUNCTION COMPENSATION IN
ONE CHIP
SUPPLY
FROM
CIRCUIT
BOARD
INFR AR ED
DETECTOR
CONDITIONER
AND DIVIDE BY 2
DSP 6711
TIMER INPUT
DETERMINES
SPEED
DSP 2812
DETECTS
OVERSPEED
41
5.1.13 System Safety
Every composite flywheel is inspected, spin balanced and tested to 110% over-speed in accordance
with NEMA guidelines. A patented dual-wall safety system ensures that in the unlikely event a flywheel were to separate during operation, the inner housing would retain the carbon fiber. As the carbon fiber separates, it will expand and transfer its torque to the inner housing. The inner housing is
then allowed to rotate inside the outer housing. The cooling fluid in the outer housing, which surrounds the inner housing acts as a dynamic brake. The stored energy is released in a controlled manner as the flywheel / inner housing comes to a rest. The outer housing holds the entire safety system
and acts as a reservoir for the cooling fluid
The Liebert FS has been previously tested under the following fault conditions with no adverse safety
effects:
• Motor-generator AC short circuit
• DC short circuit
• Power Conversion Module failure
• Magnetic Levitation System failure
• Composite rotor failure
• Motor Rotor Failure
• Loss of Vacuum
Figure 43 Cutaway flywheel module
System Overview
5.1.14 Cabinet
The Liebert FS is a compact design housed in a free-standing cabinet with a NEMA 1 construction
rating or IEC equivalent. No space is required between the back or sides of the cabinet and any walls.
The front clearance of 36" per the National Electrical Code is required. The Liebert FS accommodates
top (standard) and side entry cables. The Liebert FS can be rolled into place and go through standard
doors.
Outer Housing
Rotating Group
Inner Housing
Coolant
42
5.1.15 Ventilation and Cooling
The Liebert FS stator and power electronics are liquid cooled with a liquid-to-air radiator. The radiator within the Liebert FS package is designed for natural and forced air-cooling. Air inlets are provided from the bottom front of the Liebert FS enclosure. Air exhaust is from the top of the unit. Air
filters are provided as an option. A minimum 12" clearance overhead is required for the exhaust airflow.
The Liebert FS was designed with reliability in mind, the radiator is positioned to take advantage of
natural cooling and forced-air is only used when there is an elevated temperature. This also applies to
the circulating pump for the coolant, which is a highly reliable magnetically coupled centrifugal pump
that is powered with a brushless DC motor. This pump operates only when there is an elevated temperature within the stator or the PCM, this extends the life of the pump to the point that it will continue to operate over the life of the unit.
5.2 List of System User-Configurable Parameters
In order to support a wide set of UPS integrations, the Liebert FS can be configured using the following operating parameters: See 6.0 - Operation for more information on these parameters and
instructions on system setup and entering parameters to system.
Charge Voltage (Vcharge)
Vcharge is the voltage threshold above which the Liebert FS begins to charge/recharge.
Vcharge must be set at least 10VDC greater than Vreg.
System Overview
• Range: 360-600VDC
• Default setting: 520VDC
Regulation Voltage (Vreg)
• Vreg is the voltage setpoint at which the Liebert FS will regulate the DC bus voltage in Discharge
Mode
• Vreg must be set at least 10 VDC less than Vcharge.
• Range: 350-590VDC
• Default setting: 510VDC
Maximum Charge Current (Max Charge Current)
• Max Charge Current is the Maximum Current the Liebert FS is allowed to draw from the UPS
DC bus.
• Range—1-50A (typical operation requires a minimum of 3A or 5A)
• Default setting—20 A
Charge Conductance (Charge Amps/Volts)
Charge amps/volts is used to set the Liebert FS charging current drawn from the UPS DC bus based
upon how much the UPS DC bus voltage is above Vcharge and so without exceeding the Max Charge
Current.
• Range—0.1-10 A/V
•Default setting: 2 A/V
43
Figure 44 Voltage and Inductance curve
DC Bus
Current
Overload : Constant Current
Mode
Disch arge
Mode
Charge
Vreg
User Adjustable Parameters :
1. Vcharge: 260V – 600V
2. Vreg: 250 V – 590 V
3. C harge Amps /Volt: 0.1A/V – 10A/V
4. Max Charge Current : 1A – 50A
Behavior: Voltage Source
Vcharge
Max Charge Current
Charge
Behavior : Current Sink
Amps/
Volt
System Overview
DC Bus
Voltage
The V-I (Voltage and Inductance) curve (see Figure 44) shows the performance characteristics and
modes of operation of the Liebert FS system based on the seven user-configurable system parameters.
Regulation Voltage Delta During Discharge (Vreg Delta 1)
Vreg Delta is the programmed amount of voltage drop from the beginning of discharge (SOC = 100%)
to the Vreg Delta TSOC.
• Range—from 0 to (Vreg - 250) VDC
(Ex: if Vreg = 500, then the Vreg Delta1 can be set between 0 and 250 VDC)
• Default setting—0 VDC
Regulation Voltage Delta Transition at State of Charge (Vreg Delta T SOC)
•Range—0-100%
•Default setting—0
44
System Overview
Regulation Voltage Delta During Discharge (Vreg Delta 2)
Vreg Delta 2 is the programmed amount of voltage drop from the Transition State of Charge to the
end of discharge (T SOC to the end of discharge (SOC = 0%)
• Range—From 0 to (Vreg - Vreg Delta1) VDC
(Ex: if Vreg = 500, and Vreg Delta1 = 50, Vreg Delta2 can be set between 0 and 200 VDC)
• Default setting—0VDC
NOTE
Programming of Regulation Voltage (Vreg) Delta User Configurable Parameters
• During a discharge the regulation voltage (Vreg) can be adjusted by setting the three
parameter set points described above; Vreg Delta 1, the Transition State of Charge (T SOC)
and Vreg Delta 2. (For more information on programming these parameters from the
Control Panel see 6.4.1 - Screen Tree Menu Functions)
• The Liebert FS allows for programming two different discharge slopes (Vreg Delta1 and
Vreg Delta2) and enabling a soft “handcuff” or transition before end of discharge.
(Ex: if T SOC = 20 then transition from Vreg Delta 1 to Vreg Delta 2 will take place when
80%, (Vreg TSOC), of the stored energy has been discharged, see Figure 45).
• Vreg Delta1 is used to program an initial slope from beginning of discharge to Vreg TSOC
over which the regulated voltage value will decrease and at which point a transition will
automatically occur to the secondary slope to 0% SOC at the Vreg Delta2 setpoint.
Figure 45 Vreg delta help screen
[2]V_REG******-------------------------
| ****** [5]DELTA1
V| ******------------ O| **
L| **-------- T|
|----------------+---+
100% [7]TSOC 0%
5.3 Modes of Operation
The Liebert FS consists of a variety of operational modes. Each mode is based on a set of programmed
conditions. The Control Panel indicates the current mode and the status of that mode. Function keys
are enabled or disabled depending on the mode and status.
The Liebert FS modes are:
•OFF
•STANDBY
• STARTUP
• CHARGE
• READY
• DISCHARGE
• SHUTDOWN
•COAST
•FAULT
The Liebert FS is programmed to operate in a variety of conditional modes. The modes and status for
each mode will be indicated on the control panel. The Liebert FS is set up to transition through the
various modes with no or minimal user intervention.
|
|
|
[6]DELTA2
|
45
5.3.1 OFF Mode
When the Liebert FS is initially powered on, it enters the OFF mode and magnetically levitates its
rotating group. A manual user command will make the system transition from OFF mode to STARTUP mode if all startup conditions are met.
NOTE
Startup conditions are:
System Overview
• UPS DC bus voltage
• Status is “OK”.
The Liebert FS also will enter OFF mode at the end of a shutdown and will transition automatically
from SHUTDOWN mode to OFF mode.
5.3.2 STANDBY Mode
In STANDBY Mode, the Liebert FS will be ready for Startup but be in a STANDBY Mode waiting for
user initiation of STARTUP Mode (State of Charge = 0%). By pressing the STARTUP button “F1” at
that point the Liebert FS will automatically transition into STARTUP Mode.
Figure 46 STANDBY mode diagram
State of Charge < 0 State of Charge > 0
The Liebert FS will be in STANDBY Mode as long as:
• Liebert FS’s SOC is less than 0%; and
• UPS DC Bus Voltage = Vcharge
• STARTUP has not been initiated
≥
Vcharge and
0%
UPS DC Bus Voltage = Vcharge
10
9
0
9.
%
5
%
5.3.3 STARTUP Mode
In STARTUP mode, the Liebert FS will charge (increase flywheel speed) up to the minimum operating speed (State of Charge = 0%). At that point the Liebert FS will automatically transition into
CHARGE mode.
Figure 47 Startup mode diagram
State of Charge < 0 State of Charge > 0
Note: UPS DC Bus Voltage ≥ Vcharge
The Liebert FS will be in STARTUP mode as long as:
• Liebert FS’s SOC is less than 0% and
• UPS DC Bus Voltage ≥ Vcharge.
NOTE
In STARTUP mode, the Liebert FS will not be capable of supporting the UPS DC bus.
In case the UPS DC bus voltage drops below Vcharge while in STARTUP mode, the Liebert FS will
transition automatically into COAST mode. As soon as the UPS DC bus voltage rises above Vcharge,
the Liebert FS automatically exits COAST mode and resumes STARTUP mode.
0%
99.5%
1
00%
46
5.3.4 CHARGE Mode
To charge the Liebert FS, the Liebert FS will draw power from the UPS DC bus to accelerate the flywheel (as long as the UPS DC bus voltage is higher than Vcharge). In this mode, the Liebert FS State
of Charge (SOC) will progressively increase from 0% to 100%.
Figure 48 CHARGE mode diagram
State of Charge < 0 State of Charge > 0
The Liebert FS will be in CHARGE mode as long as:
• Liebert FS’s SOC is between 0% and 100% and
• UPS DC Bus Voltage
NOTE
While in CHARGE mode, the Liebert FS will be capable of supporting the UPS DC bus.
≥ Vcharge.
0%
Note: UPS DC Bus Voltage ≥ Vcharge
System Overview
99.5%
1
00%
5.3.5 READY Mode
When the SOC reaches 100%, the unit will automatically transition into the READY mode. This is the
mode in which the Liebert FS will spend most of its operating time. In this mode, the Liebert FS
maintains its State Of Charge greater than 99.5%. The Liebert FS’s SOC will be allowed to drift down
to SOC = 99.5%, at which point it will transition back into CHARGE mode and charge back up to
READY mode and SOC = 100%. During normal operation, the Liebert FS will continue to automatically transition between the READY and CHARGE modes to maintain a SOC between 99.5 and 100%
until either a DISCHARGE or SHUTDOWN is initiated.
Figure 49 READY mode diagram
State of Charge < 0 State of Charge > 0
The Liebert FS will be in READY mode as long as:
• Liebert FS’s SOC is between 99.5% and 100% and
• UPS DC Bus Voltage
≥ Vcharge.
0%
Note: UPS DC Bus
Voltage ≥ Vcharge
99.5%
1
00%
NOTE
While in READY mode—just as in CHARGE mode—the Liebert FS will be capable of
supporting the UPS DC bus.
47
5.3.6 DISCHARGE Mode
Starting from either CHARGE or READY mode, the Liebert FS will enter the DISCHARGE mode if
the UPS DC Bus Voltage goes below Vcharge. In DISCHARGE mode, the Liebert FS will regulate the
DC bus at Vreg.
Figure 50 DISCHARGE mode diagram
State of Charge < 0 State of Charge > 0
The Liebert FS will be in DISCHARGE mode as long as:
• UPS DC Bus Voltage < Vcharge and
• Liebert FS’s SOC is more than 0%.
The Liebert FS will leave the DISCHARGE mode and transition into CHARGE mode if the UPS DC
bus recovers (UPS DC Bus Voltage = Vcharge) before the Liebert FS’s SOC reaches 0%. In case the
UPS DC bus doesn’t recover before the Liebert FS’s SOC reaches 0%, the Liebert FS will transition
into SHUTDOWN mode.
0%
Note: UPS DC Bus Voltage = Vreg
System Overview
99.5%
1
00%
5.3.7 SHUTDOWN Mode
In SHUTDOWN mode, the flywheel will actively spin down.
There are two ways the Liebert FS can transition into SHUTDOWN mode, by a complete discharge
and by a user command.
Following a Liebert FS Discharge Down to SOC = 0%
This is the most common SHUTDOWN process. This occurs when the Liebert FS’s SOC drops below
0% and the UPS System DC Bus voltage is less than Vcharge. If the Liebert FS entered the SHUTDOWN mode after leaving DISCHARGE mode, the Liebert FS will automatically transition into
STARTUP mode provided the UPS System DC Bus voltage returns to a value greater than Vcharge
(i.e., when the electric grid returns or the standby generator supplies power to the UPS).
Figure 51 SHUTDOWN mode diagram - shutdown after full discharge
State of Charge < 0 State of Charge > 0
Note: UPS DC Bus Voltage < Vcharge
0%
99.5%
1
00%
48
Following a User Command
In any mode, except OFF mode, the user may command the Liebert FS to transition in SHUTDOWN.
While in SHUTDOWN mode, the user will still be able to command the Liebert FS to transition into
CHARGE mode (if SOC > 0%) or STARTUP mode (if SOC < 0%), provided that the UPS System DC
bus voltage is greater than Vcharge.
Figure 52 SHUTDOWN mode diagram - user-initiated shutdown
State of Charge < 0 State of Charge > 0
0%
5.3.8 COAST Mode
A transition into COAST mode can occur when the UPS System DC Bus voltage drops below Vcharge
while the Liebert FS is in STARTUP mode. While in COAST mode, the Liebert FS is in an idling condition where it neither draws nor generates any power.
System Overview
99.5%
1
00%
As soon as the UPS DC Bus Voltage rises above Vcharge, the Liebert FS will automatically exit
COAST mode and resume STARTUP mode.
After five minutes in COAST Mode, if the UPS DC Bus voltage has not risen above Vcharge, the
Liebert FS will automatically transition into SHUTDOWN Mode.
5.3.9 FAULT Mode
The Liebert FS includes self-test and diagnostic circuitry such that most systems malfunctions can be
identified. In case of a system malfunction, the Liebert FS will transition into FAULT mode.
While in FAULT mode, the Liebert FS is disabled—all power electronics are turned off. Most faults
are cleared automatically by the system without the need for user intervention. Some faults do
require user action to clear the fault or to notify Liebert Global Services. Refer to the 8.0 - Trouble-
shooting for more information).
NOTE
Depending on the nature of the fault, the Liebert FS may still be capable of supporting the UPS
DC bus. Refer to 8.0 - Troubleshooting for more information.
The Liebert FS is programmed to operate in a variety of conditional modes. The modes and status for
each mode will be indicated on the control panel. The Liebert FS is set up to transition through the
various modes with no or minimal user intervention. Figure 53 illustrates the various modes of operation.
49
Figure 53 Typical operation modes
System Overview
KEY # MOD E DESC RIPTION
1 READY Idle condi ti on waiting for event
2 DISCHARGE
3 CHARGE
A
B
C
D
E
V Generator
V Gri d
V Load
480
VAC
0 VAC
Gr id Supply lost , FS s upporti ng the l oad
Generator Star ts , A .T.S. tr ansfer s the load
FS full y char ged ready to s upport the l oad
FS s upports t he load as the A .T.S . tr ansiti ons back to grid s upply
FS full y char ged ready to s upport the l oad
A B C D E
AC
VOLTAGE
FS s upporting the cr itical load
Char ging to top s peed
GEN
Gri d
ATS
AC Pow er F lo w
UPS Module
DC Power Flow
AC Po wer Flo w
Flywheel
Module
V Fl oat
Vcharge
Vreg
TOP
SPEED
MIN
SPEED
ZERO
SPEED
DC Bus Voltage
FS
MODES
FS Speed
DC
VOLTAGE
1 2 3 1 2 13
R. P. M .
50
5.4 Maintenance and Reliability
The Liebert FS is designed to require minimal preventive servicing and maintenance. There are no
user serviceable parts in the Liebert FS. Please contact a Liebert-Certified Technician before attempting to remove or service any components of the system. No bearings maintenance or replacement is
required over the life of the Liebert FS under normal operation conditions. No vacuum pump maintenance or replacement is required over the life of the Liebert FS under normal operation conditions.
The optional inlet air filter in the cabinet will need to be replaced when it is sufficiently dirty as to
reduce the flow of air into the cabinet. Ambient conditions at the installation site will determine the
frequency of replacement. The Liebert FS Flywheel Module is designed for fifteen-year service life
before first scheduled maintenance. At fifteen years, the vacuum absorbers should be replaced or
regenerated.
The reliability of the Liebert FS power electronics is consistent with UPS power electronics of comparable energy levels. The mechanical assemblies are of higher life and reliability than other commercially available flywheel systems due to the elimination of rolling element bearings and external
vacuum-pumping systems.
System Overview
51
6.0 OPERATION
6.1 Operator Controls
The Liebert FS uses a Control Panel as the primary means for an operator to interface with the system. The Control Panel enables the operator to perform the following tasks:
Initial setup and adjustments to programmable parameters (access limited by Security
Access function):
• Set the Liebert FS Control Parameters
• Configure Liebert FS for operation with external equipment
Initial setup and adjustments to Security Access functions
• Set pass codes and access levels
Execute operational procedures:
• Startup and shutdown of the Liebert FS.
Quick view of operational status:
• View current Mode of Operation
•View current Status
Access System Status reports:
Operation
• Check temperatures and voltages
• Check vital system health indicators
Access System History
• Check number of discharges
• Check for total hours of operation
• Check for warnings and faults history
Monitor the power flow between the Liebert FS and a UPS and other Liebert FS meter
readings:
• Monitor power flow from Liebert FS to the UPS DC Bus or from UPS to the Liebert FS
• Monitor Liebert FS State of Charge
• Monitor DC Bus Voltage
• Determine if the critical load is being supplied power from the Liebert FS
• Monitor charging after discharge
52
6.2 Control Panel
10
The Control Panel (see Figure 54) below represents the Control Panel on the Liebert FS. The diagram is labeled as a reference for the various keys, functions and data found on the Control Panel.
NOTE
(The actual locations of status indicators on the Control Panel display, corresponding to the
numbers below, may vary from Figure 54 depending on software version.)
Figure 54 Control panel view
See Table 4
for keyboard layout
6
5
3
Operation
9
8
11
LIEBE RT FS
MODE:
7
DISCHARGE
STATUS:
OK
MENU SHUTDN LOCK
D V U C P
RPM:
SOC:
SOC:
BUS:
PWR:
50652
93.3%
500 V
190 .2kW
12
13
14
4
2
1
F1 F2 F3 F4 F5 F6
I
!
0 1 2 3
. 4 5 6
- 7 8 9
X
15
16
17
18
19
NOTE
The control panel view is for reference only. Not all items will be enabled and visible on the
screen at the same time during operation
Navigating the control panel is a simple process that involves responses to user prompts displayed in
the control panel. Using the panel to operate the unit will be described further in this section.
Table 4 Control panel keyboard layout (refer to Figure 54)
Keyboard
Location Operation / Navigation Keys
1 Numerical Keypad 11 SOC: State of Charge Bar
2 LEDs used for Servicing 12 SOC: State of Charge Value
3 F2 Shutdown key - Main Screen 13 PWR: Bus Power
4 F1 Start Up key - Main Screen 14 F5 More Information key - Fault Screen
5 Soft Menus 15 F6 Menu key - Main Screen
6
7
STATUS: System status (see 6.2.3 -
System STATUS Indicators)
MODE: System mode (see 6.2.2 -
System MODE Indicators)
8 BUS: Internal DC Bus Voltage 18 Scroll Up and Down keys
9 RPM: Flywheel Rotation Speed 19 Backspace
10 Power and Options: On/Off
Keyboard
Location Screen Indication Keys
16 F3 Clear Fault key - Fault Screen
17 Enter key
53
6.2.1 Main screen function descriptions
Figures 55 and 56. provide descriptions and locations of the information and functions available
from the Main screen and the Fault Screen.
Figure 55 Main screen functions
Current Operating Mode
Liebert FS
Current Security Level
Option Status
Operation
Contactor Status
PWM
Status
D V U C P
Status
Message
MODE:
STATUS:
START LOCK
DISCHARGE
OK
SHUT DN MENU
F1 F2 F3 F4 F5 F6
Startup Button
Figure 56 Fault screen functions
Liebert FS
MODE:
STATUS:
FAULT
2 FAULTS
RPM:
SOC:
SOC:
BUS:
PWR:
Shutdown Button
Fault Status Message
Panel Lock/Unlock Button
D V U C P
RPM:
SOC:
SOC:
BUS:
PWR:
CLEAR MENU
MORE
12.3kW
48020
73.4%
545V
12.3kW
48020
73.4%
545V
Charge
Status
Internal
Bus
Voltage
Menu
Button
Bus
Power
F1 F2 F3 F4 F5 F6
Fault Clear Button
More Information
Button
54
6.2.2 System MODE Indicators
The Liebert FS has nine modes of operation: OFF, STARTUP, CHARGE, READY, DISCHARGE,
SHUTDOWN, COAST, FAULT and STANDBY. These are displayed on the main screen of the control
panel as identified in Figure 55. Table 5 lists the system Modes along with the corresponding Contactor Status, and the Conditions required to operate in these Modes: external voltage range, speed
and command.
NOTE:
See 5.3 - Modes of Operation for further details on modes of operation.
Table 5 Operation modes
Mode Contactor
OFF Open Vext < Vchg 0 ~ 3500 —
STANDBY Open Vext > Vchg 0 ~ 200 —
STARTUP Close Vext > Vchg 200 ~ Min Speed STARTUP
CHARGE Close Vext > Vchg Min Speed ~ Max Speed STARTUP
READY Close Vext > Vchg Max Speed ~ Max Speed + 200 STARTUP
DISCHARGE Close Vext < Vchg Min Speed ~ Max Speed STARTUP
COAST Close 330 < Vext < Vchg 200 ~ Min Speed STARTUP
SHUTDOWN Open Vext < 330 200 ~ Min Speed STARTUP
Open Any Min Speed ~ Max Speed SHUTDOWN
Close Vext > 330 200 ~ Min Speed SHUTDOWN
FAULT Open Any 0 ~ Max Speed —
STANDBY — After CLRFLT
Min Speed: Minimum operating speed; State of Charge (SOC) will be 0% at this speed.
Max Speed: Maximum operating speed; State of Charge (SOC) will be 100% at this speed.
Operation
Condition
External Voltage Speed Command
6.2.3 System STATUS Indicators
The Liebert FS system displays multiple status conditions during operation. Table 6 shows the complete list of status indicators for the Liebert FS and the corresponding condition.
Table 6 System status indicators
Message Condition
1 OK All systems operating normally.
2 READY All systems operational and ready for startup.
3 APPLY 520*V External voltage is less than the Charge Voltage*
4 n WARNINGS Multiple warnings
5 n FAULTS Multiple faults
6 OVERSPEED Speed is higher than the Max Speed plus 200 RPM
7 TESTING VACUUM Vacuum testing at 10000 RPM
8 OPENING CONTACTOR Waiting until the current is stabilized
9 CLOSING CONTACTOR Waiting until the voltages are stabilized
10 WAIT Waiting until the voltages are stabilized
* Charge voltage is an adjustable user parameter; 520V is used only as an example.
55
6.2.4 Other Status Indicators
The Liebert FS system displays additional indicators during operation.
• Option Status; DCM or VIB (example: V abbreviation for VIB enabled
Operation
RPM:
SOC:
SOC:
51050
95.2%
RPM:
SOC:
SOC:
VV
51050
95.2%
RPM:
SOC:
SOC:
V
51050
95.2%
RPM:
SOC:
SOC:
Operative Inoperative Disabled Uninstalled
Default setting
• Security Levels
P
RPM:
SOC:
SOC:
PWM on PWM off
RPM:
SOC:
SOC:
READ ONLY USER SERVICE
Default setting
• PWM: Pulse Width Modulation Status (ON or OFF)
• SOC: State of Charge (0-100%)
SOC shows a relative energy stored in the system. SOC is determined with the following equa-
tion. It is 100% at Max Speed. A negative SOC means the required energy in % to get to the
CHARGE state.
SOC
51050
95.2%
51050
95.2%
RPM:
SOC:
SOC:
RPM:
SOC:
SOC:
51050
95.2%
U
51050
95.2%
2
MinRpm
rpm
------------------------------------------------------------------
–
2
MaxRpm
MinRpm
–
RPM:
SOC:
SOC:
2
22()
S
51050
95.2%
100×=
51050
95.2%
•Contactor Status
RPM:
SOC:
SOC:
• LOCK/UNLOCK of the Control Panel
Control Panel can be locked or unlocked for security purposes. Locking or unlocking the display panel
requires a user password to confirm. See 6.3.2 - Password.
• PWR: Bus Power
PWR shows the DC power transfer in kW. Positive power indicates DISCHARGE and negative
power indicates CHARGE, respectively.
C
51050
95.2%
RPM:
SOC:
SOC:
Closed Open
56
51050
95.2%
6.3 Security Access
6.3.1 Security Levels
The Liebert FS software has two security levels: READ-ONLY and USER. Security levels restrict
access to system resources, such as EEPROM parameters, terminal commands and display panel
functions. From the Main Screen, Figure 55, the display can be locked at any time to prevent use of
Control Panel. Pressing F4 button under “LOCK” will prompt the user to enter a password to “LOCK”
the system. Once locked F4 will now read “UNLOCK” and pressing this will prompt you to enter the
Password to the system so that the user will be able to operate the Control Panel and adjust system
parameters and settings.
6.3.2 Password
READ-ONLY level has no password and it is default level at reset.
The USER level password is user-configurable and saved in EEPROM. The default USER level password is “1234”, and the password should be between 3 - 12 digits.
6.3.3 EPROM (System) Parameters
EEPROM (system) parameters can be accessed through display panel or terminal commands. They
can be read and written through terminal or display panel, but accessible parameters are limited by
security levels. The parameters for each level have different number range. Unused numbers are
reserved for future usage.
Table 7 EEPROM parameter number ranges
Security Level Parameter Number Range
Read-Only 0 ~ 99
User (Editable) 0 ~ 99
Operation
6.4 Menu Tree and Navigation
6.4.1 Screen Tree Menu Functions
The following diagram shows all of the screens accessible from the control panel and the path to bring
up these screens. The screens are used for configuring the Liebert FS for operation and accessing data
current and historical data on its performance. The screens are organized by five primary function
areas; Parameters, View, Security, About, and Tools. These are displayed on the Main Menu screen.
Some of the screens require User level or Service level passwords to access as shown in the legend
below. Refer to 6.3 - Security Access for more information on this subject.
Table 8 PCMC parameters, read-only and user (Liebert FS software)
No Parameter Name Unit Default Minimum Maximum
1 Vcharge Setpoint V 520 360 800
2 Vreg Setpoint V 510 350 790
3 Icharge Max Setpoint A 30 1 50
4 Amps per Volt Setpoint A/V 20 1 50
5 Vreg Delta Setpoint 1 V 0 0 150
6 Vreg Delta Transition (SOC) % 0 0 100
7 Vreg Delta Setpoint 2 V 0 0 150
57
Figure 57 Menu tree
Operation
Parameters
ViewMenu
Securit y
About
User/ Adv
Time/ Date
Temperatures
Voltages
History
Options
Electrical
Network
Vitals
Password Input
S/N
View/ Set
Charge
Discharge
Warning
Fault
Vitals
Counters
Rotor
Stator
IGBT
PCM/ PPM
MLM/ MCM
Cabinet
24V PS #1
24V PS #2 *
* FS models only
Max Drag Power
Min Drag Power
Last 10k Drag
Max Miser
Max Runout
Contact Closure
Shutdown to Off
Bootup Count
Hours since bootup
Pump On-time
Fan 1 On-time
Fan 2 On-time*
* FS, Ser ial P or N
units only
Tools
LEGEND
Reboot
All Level Menu
User Level Menu
58
6.4.2 Navigation and Operation of Control Panel
Navigation of the menu screens is simple and intuitive. From the Main Screen, also referred to as
“Home”, menu functions and screens can be accessed by using the function keys and the numeric keypad. The function keys, F1- F6, initiate certain system functions and Modes; STARTUP, SHUTDOWN and also perform certain menu screen functions; DONE, PREVIOUS, NEXT, and HOME. The
up and down arrows on the control panel enable the user to scroll up or down certain menus. The
numeric keypad can be used to enter values for system setup and the Enter and Backspace keys to
enter numbers or backspace to change entry. Pressing F6 or DONE completes the entry process.
Always double check by going back to the previous screen to verify the entry is complete and accurate.
To access the Main Menu press the F6 button below the “Menu” option in the lower right. When
pressed, the “Menu” key, will display the Main Menu screen as shown in Figure 58. From this screen
each of the submenus may be accessed, provided the user has security access where needed, refer to
Figure 57.
Each screen in the menu tree will show numbers in front of the subject if more information is available at the next menu level. Pressing the number for the subject using the numeric keypad will bring
up that screen. If the subject is preceded by a double arrow symbol (>>) instead of a number no further information is available or the parameter may not be modified without security access.
At each screen and level in the menu tree, when finished accessing data or changing system parameters, the user may select DONE using the function keys to move back to the prior screen in the menu
or when available press HOME, F5, to return to the Main Screen. On some screens such as in the History screens you will be able to access additional screens of data recorded by pressing NEXT, see
Figures 70 and 71.
Operation
Figure 58 User level main menu screen
MENU>
1. PARAMETERS
2. VIEW
3. SECURITY
4. ABOUT
5. TOOLS
F1 F2 F3 F4 F5 F6
I
!
0 1 2 3
. 4 5 6
- 7 8 9
6.4.3 System Setup and Parameter Access
DONE
X
Setting up the Liebert FS:
In order to operate the system the system parameters must be configured for the application. The system parameters or “EEPROM” parameters can be accessed by first pressing MENU, F6, and the number one (1) button on the Control Panel keypad for the PARAMETERS screen. Liebert FS software
has two kinds of access screen according to the security level.
In READ-ONLY mode, seven basic parameters can be monitored. Modifying the parameters in this
mode is not allowed. In this mode the parameters will have double arrow symbols to the left of the
parameters.
59
Figure 59 READ ONLY level parameter view screen
Operation
>>
V_CHARGE SETPOINT
>>
V_REG SETPOINT
>>
MAX CHARGE CURRENT
>>
CHARGE AMPS/VOLT
>>
V_REG_DELTA 1
>>
V_REG_DELTA TRANSITION SOC
>>
V_REG_DELTA 2
HELP DONE
In the USER mode, below the 7 basic parameters can be modified, see 6.3.2 - Password for access
level and passwords. Pressing the corresponding number to the parameter to the left of the number
will take you to the parameter setup screen for that particular parameter.
Figure 60 USER level or above parameter edit screen
1.
V_CHARGE SETPOINT
2.
V_REG SETPOINT
3.
MAX CHARGE CURRENT
4.
CHARGE AMPS/VOLT
5.
V_REG_DELTA 1
6.
V_REG_DELTA TRANSITION SOC
7.
V_REG_DELTA 2
HELP DONE
In setting the parameters there is a help screen to guide the user through the setup and help visualize
the operation the system when utilizing this parameter. The help screens are displayed in
Figures 61 and 62. The help screen also describes the other system parameters used in operation.
520 V
500 V
2.0 A
520 V
500 V
30.0
2.0 A
0 V
0 %
0 V
30.0
A
0 V
0%
0 V
/V
/V
Figure 61 HELP screen for User Setup Parameters
When voltage is above [1] V_CHARGE
Flywheel charges up and draws :
(( Vbus – [1] V_CHARGE) * [4] AMPS/VOLT) amps,
Not exceeding [3] MAX CHARGE CURRENT.
When voltage sags, it is regulated at
[2] V_REG whose slope can be adjusted by
[5] DELTA 1, [6] SOC TRANS, & [7] DELTA 2
MORE DONE
DONE
Figure 62 Graphical HELP screen for VREG DELTA1, VREG TSOC, and VREG DELTA2 Transition setup
(Pressing the “MORE” button, F1, from Figure 5-8. accesses this screen)
[2]V_REG******-------------------------
PREV
|
|
V
|
O
|
L
|
T
|
---------------------+----+
100% [7]TSOC 0%
******
[5]DELTA1
******-------------
|
**
|
**---------
|
[6]DELTA2
|
DONE
60
Each EEPROM parameter has its own screen which contains parameter description, data range, current value and default value button. Default button shows the default value for the parameter. From
this screen the UP/DOWN arrow keys can used to move between parameters. The UP/Down arrow
will increase/decrease the parameter number, respectively.
Figure 63 USER or higher level parameter selection for view/edit
Operation
6.4.4 View
Functions in MENU > VIEW display various system status including real-time and statistical data.
The menu path is represented in the upper left hand corner of the screen and lets you know your current screen location in the menu tree. You can select the function by entering the number.
Figure 64 VIEW menu
MENU>VIEW>
6.4.5 Time/Date
2:
VREG SETPOINT:
RANGE
CURRENT
NEW VALUE
:
:
:
DEFAULT CANCEL DONE
1. TIME/DATE
2. TEMPERATURES
3. VOLTAGES
4. HISTORY
5. OPTIONS
220 .. 510V
500V
6. NETWORK
7. ELECTRICAL
8. VITALS
HOME DONE
In MENU>VIEW>TIME/DATE, system time is displayed and can be adjusted. However, USER security level or higher is required to adjust the time or date, see 6.3.2 - Password. Pressing SET button
changes to the edit mode. Cursor will blink on NEW TIME. You can type in new time data or move to
NEW DATE by UP/DOWN arrow button. Moving to NEW DATE should be made before typing in any
digits. All digits for time (4 digits) or date (6 digits) should be typed in before ENTER or you will get
the INVALID INPUT error message.
Figure 65 TIME/DATE set
SET HOME DONE
CURRENT TIME
NEW TIME
CURRENT DATE
NEW DATE
:
10:49
:
hh:mm (24HR)
03/08/07
:
mm/dd/yy
:
61
6.4.6 Temperatures
MENU>VIEW>TEMPERATURES shows the temperatures of various system parts.
Figure 66 Temperature view
>>
ROTOR
>>
STATOR
>>
IGBT
>>
PPM
>>
MCM
6.4.7 Voltages
MENU>VIEW>VOLTAGES shows the major power supply voltages on the controller board. These
values are updated continuously.
NOTE
If an earlier model Liebert FS, serial number P or N, flywheel system has been upgraded with
this software, it will display only the 24V power supply voltage.
Figure 67 Figure 5-14. Voltages view
67.12 °C
40.20 °C
52.22 °C
46.17 °C
38.46 °C
>>>>CABINET
24V PS
Operation
35.12°C
50.34°C
DONEHELP
>>
>>
>>
6.4.8 History
The Liebert FS records and stores a limited history of the following items; CHARGE, DISCHARGE,
WARNING, FAULT, VITALS, and COUNTERS which are listed in the main History menu screen.
(See Figure 69). In the event list screens, Figures 71 through 73, users may move between pages
using the PREV and NEXT buttons. History data can be cleared by RESET button. SERVICE or
higher level is required to reset the list.
Figure 68 History view
MENU>VIEW>HISTORY>
1. CHARGE
2. DISCHARGE
3. WARNING
4. FAULT
5. VITALS
• Charge: The most recent charge (LAST CHARGE) is displayed in time (sec.) and energy (kW) on
this screen as are the accumulated charge time/energy (TOTAL CHARGE). (See Figure 69.)
Figure 69 Charge history
3.3V:
5V:
12V:
3.29 V
5.01 V
11.99 V
>>
24V #1:
>>
24V #2:
>>
24V BKP:
6. COUNTERS
24.01 V
24.00 V
23.99 V
HOME DONE
HOME DONE
>> LAST CHARGE:
>> TOTAL CHARGE:
62
12.34
56.78
12345
12345678
HOME DONE
sec
kW
sec
kW
• Discharge: The most recent discharge (LAST DISCHARGE) is displayed in time (sec.) and energy
(kW) on this screen as are the accumulated discharge time/energy (TOTAL DISCHARGE) and the
number of times system has discharged (DISCHARGE COUNT). (SeeFigure 70.)
Figure 70 Discharge history
Operation
>> LAST DISCHARGE:
>> TOTAL DISCHARGE:
>> DISCHARGE COUNT:
LIST
• A Discharge History event list screen, Figure 72, is available and shows the event number, date
(month./day/year), time of event (00:00-24:00) average power (kW), and duration of discharge (seconds). The recorded events are sequentially numbered and listed from most recent to last. The letter “D” after the time indicates that this is the DISCHARGE History screen.
The first screen has the function options of NEXT or DONE viewing. The next page will have the
function button options of PREV (Previous), NEXT or DONE.
Figure 71 Discharge History, Event list screen
08 04/31/06 10:15 D
09 03/21/06 03:11 D
10 03/10/06 20:25 D
11 02/01/06 14:12 D
12 01/15/06 09:18 D
13 11/11/05 18:35 D
14 04/25/05 22:12 D
• Warning/Fault: Liebert FS software holds 35 warning and fault event information, respectively. Seven warnings/faults are displayed in a single screen.
12345678
31.26kW
41.46kW
75.61kW
37.36kW
51.21kW
95.20kW
33.76kW
PREV
12.34
56.78
12345
sec
kW
sec
kW
123
HOME DONE
38.14s
08.10s
21.04s
18.19s
28.44s
16.10s
27.12s
NEXT DONE
Figure 72 Warning history, Event list screen
01 03/10/05 11:43 W
02 03/10/05 10:37 W
03 02/24/05 04:03 W
04 01/30/05 23:22 W
05 12/20/04 13:45 W
06 11/13/04 07:28 W
07 09/30/04 16:23 W
Figure 73 Fault history, Event list screen
01 03/10/05 11:43 F
02 03/10/05 10:37 F
03 02/24/05 04:03 F
04 01/30/05 23:22 F
05 12/20/04 13:45 F
06 11/13/04 07:28 F
07 09/30/04 16:23 F
RESET
AUX POWER LOW
VIB INOPERATIVE
OVERSPEED
STATOR HOT
ROTOR HOT
RUNOUT
VACUUM
NEXT DONE
CURRENT OFFSET
CHECKSUM
SOFTWARE OV
DC BUS OV
SPARE OPEN
INTER PROCR COMM
MISER
NEXT DONE
63
• Vitals (USER or above): Key system efficiency and performance measurements are displayed in
Max/Min measurements along with the date recorded.
Figure 74 Vitals history view
Operation
MAX DRAG POWER:
>>
>>
MIN DRAG POWER:
>>
LAST 10K DRAG:
>>
MAX MISER:
MAX RUNOUT:
>>
• Counters (USER or above) provide totals of run time hours; system and components, and numbers
of startup and shutdown events; contactor closures and bootup. OPERATING HOURS is the total
operating hours in the CHARGE/ DISCHARGE/ READY mode.
Figure 75 Counters
>>
CONTACTOR CLOSURE:
SHUTDOWN TO OFF:
>>
BOOTUP COUNT:
>>
HOURS SINCE BOOTUP:
>>
>>
OPERATING HOURS:
NEXT
Figure 76 Counters - screen 2
>>
PUMP ON-TIME:
>>
FAN#1 ON-TIME:
>>
FAN#2 ON-TIME:
1.23 @
1.23 @
10.0 W, 11/30/05
2.0 W, 11/29/05
1.0 W, 11/30/05
12345, 11/28/05
34567, 11/27/05
HOME DONE
3
4
5
12.34
1234567hrhr
HOME DONE
12.34 hr
56.78 hr
19.24 hr
BACK
6.4.9 Options
Each option, if installed, can be enabled by pressing its number and its status will then be displayed.
Additional information on setup and operation of these options is available in the related section of
this manual.
Figure 77 Options view
HOME
1. DCM : INOPERATIVE
2. VIB : OPERATIVE
HOME DONE
64
6.4.10 Network—Requires DCM Option
The Network view screen displays the addresses of the DCM. Static address settings can be entered
using the keypad into this screen. If this option is installed, reference the Liebert Data Collection
Module (DCM) Option Manual for more information on setting up the DCM on a network and or
assigning IP addresses. Figure 78 shows the Network screen in a read-only mode.
Figure 78 Networks view
>>
DHCP:
>>
IP ADDRESS:
>>
NET MASK:
>>
DEFAULT GATEWAY:
>>
DNS SERVER:
By entering a Password to access the User level mode (see 6.3.2 - Password), you can edit this function. Pressing the EDIT button, F1, will place the system in the edit mode. The DHCP must be disabled or turned OFF to proceed with setting IP addresses and other settings. After pressing EDIT you
will see up/down arrows next to the DHCP ON value. Pressing the up or down arrows on the keypad
will allow you to turn OFF or ON this function.
Figure 79 Networks view, Edit DHCP
Operation
ON
192.168.1.155
255.255.255.0
192.168.1.1
192.168.1.13
HOME DONE
>>
DHCP:
>>
IP ADDRESS:
>>
NET MASK:
>>
DEFAULT GATEWAY:
>>
DNS SERVER:
EDIT
Once you have turned DHCP OFF, press EDIT again and now you will see numbers next to each of
the settings. Pressing the corresponding number will allow you to enter or change that value. At any
time you may press CANCEL to cancel the changes. Once the changes or entries are complete, press
APPLY to complete entry process. Pressing APPLY will reboot system and in a few minutes the system will display the new screen.
Figure 80 Networks view, Edit Settings (Service level)
>>
DHCP:
>>
IP ADDRESS:
>>
NET MASK:
>>
DEFAULT GATEWAY:
>>
DNS SERVER:
CANCEL
ON
192.168.1.155
255.255.255.0
192.168.1.1
192.168.1.13
HOME DONE
ON
192.168.1.155
255.255.255.0
192.168.1.1
192.168.1.13
HOME DONE
65
6.4.11 Electrical
The screen MENU>VIEW>ELECTRICAL shows the major electrical system variables. These quantities are updated continuously.
NOTE
Positive values for DC BUS CURRENT and OUTPUT POWER indicate Discharge mode and
negative values for same indicate Charge mode.
Figure 81 Electrical view
6.4.12 Vitals
MENU>VIEW>VITALS shows the current vital system values. These quantities are updated continuously.
>>
INT. BUS VOLTAGE:
>>
EXT. BUS VOLTAGE:
>>
DC BUS CURRENT:
>>
OUTPUT POWER:
>>
STATUS OF CHARGE:
500
V
500
V
100
A
50
Kw
65.78
%
HOME DONE
Operation
Figure 82 Vitals view
6.4.13 Security
Security levels can be changed in the MENU>SECURITY screen.
>>
DRAG POWER:
>>
MISER:
>>
RUNOUT:
>>
RPM:
12.34
1.234
0.012
12345
W
C
Mil
RPM
HOME DONE
66
Figure 83 Password screens
Operation
PASSWORD:
DONE
PASSWORD: ****
PASSWORD CONFIRMED
DONE
PASSWORD: ****
INVALID PASSWORD
USER level password can be modified by pressing the CHG PW button. Current password is required
to change the password. The USER level password should be between 3 - 12 digits length, hence digits
after 13th are ignored if more than 12 digits are entered.
Figure 84 Change password
PASSWORD:
CHG PW
CURRENT PASSWORD:
LOGOUT
DONE
U
DONE
DONE
CURRENT PASSWORD:
****
NEW PASSWORD:
DONE
67
Figure 85 Change password
Operation
6.4.14 About
About screen shows the version of the firmware and company information. The controller board has
two DSPs and each DSP has bootloader and application firmware.
Figure 86 ABOUT screen
S/N HOME
Figure 87 Serial numbers
CURRENT PASSWORD:
NEW PASSWORD:
RE-ENTER PASSWORD:
PASSWORD CHANGED HOME
LIEBERT CORPORATION
COPYRIGHT 2003-2006
APPL: PRI-3.00 SEC-3.01
BL : PRI-3.02 SEC-3.01
>>
SYSTEM S/N:
>>
FM S/N:
>>
MLM S/N:
>>
PCM S/N:
>>
SO#:
>>
USER
****
******
******
001
001
0001
0002
123-456-7
USER-DEFINE
HOME
DONE
DONE
DONE
6.4.15 Tools
Tools menu has REBOOT function for USER to reboot system.
Figure 88 Tools for USER
MENU>TOOLS>
1. REBOOT
68
HOME
DONE
6.5 System Startup
6.5.1 Initial System Startup Procedure
Initial System Startup is defined as the first or initial startup following installation of the system.
Several additional steps are required prior to the normal startup procedure including the following
Inspection before Initial System Startup, (Section 5.5.2), and Control Parameters Setup (Section
5.5.3.). These steps are required to ensure safe and proper startup of flywheel system and for warranty purposes.
CAUTION
!
The Initial System Startup shall ONLY be performed under the supervision of a
Liebert-certified service technician in order to ensure proper system operation. Failure to
abide by instructions provided herein may void your warranty.
6.5.2 Inspection before Initial System Startup
A Liebert technician will perform the following tasks:
• Visual Inspection
Inspect equipment for signs of damage
Verify installation per drawings
Inspect cabinet for foreign objects
Verify ground conductors are properly sized and connected
Verify all printed circuit boards are configured properly
• Mechanical Inspection
Check all control wiring connections for tightness
Check all power wiring connections for tightness
Check that cabinet is attached to the floor
Check all terminal screws, nuts and/or spade lugs for tightness
Check all cooling pump connections
• Electrical Inspection
Check fuses for continuity
Check and verify UPS DC bus voltage
•Pre-Startup
Perform MLM Pre-Start procedure using Boot Up process with UPS DC bus
Perform MLM Inspection and test
Verify UPS settings and adjustments
Run pumps and fans for several minutes
Operation
69
6.5.3 Control Parameters Setup at Initial System Startup
Please have the relevant UPS Interconnection Kit Handbook (Liebert UPS Interconnection Kit [IKIT]
Handbook for specific Brand and Model UPS) available for the Liebert technician. The Control
Parameters Setup values that need to be programmed are included in this manual.
You may record in Table 9 the values found in the specific IKIT (Interconnection Kit) Handbook for
your UPS. For future reference you may also want to record Software Versions; Primary and Secondary and Bootloader Version from the About parameter screen, Section 5.4.12. above.
Table 9 Control parameters
Control Parameter Value Default
Charge Voltage VDC 520
Regulation Voltage VDC 510
Maximum Charge Current A 30
Charging Amps/Volts A/V 2
Vreg Delta 1 VDC 0
Vreg TSOC % 0
Vreg Delta 2 VDC 0
Table 10 Software versions
Software Application Version
Operation
Primary application 2812
Secondary application 6711
Primary Bootloader
Secondary Bootloader
The Liebert technician will perform or direct the Control Parameters Setup (described in 6.4.1 Screen Tree Menu Functions) and proceed to the Initial Startup Procedure.
NOTE
DC bus ripple voltage should be measured and taken into consideration when programming
the Charge Voltage; the Charge voltage should be below the DC float voltage and include
compensation for any ripple voltage present to avoid frequent charging and discharging.
6.5.4 Initial System Startup Procedure
A Liebert technician will perform or direct the following tasks at Initial System Startup:
• Inspection before Initial System Startup (Section 5.5.2. of this manual)
• System Control Parameters Setup
• Assist with Initial System Startup
• Complete Warranty documentation
• Complete commissioning documentation
• Provide basic user training on Liebert FS operation *
70
6.5.5 Regular Startup Procedure
CAUTION
!
The Initial System Startup shall be performed ONLY under the supervision of a Liebert
technician to ensure proper system operation. Failure to abide by instructions provided herein
may void your warranty.
NOTE
A regular startup is any startup after the Initial System Startup.
6.5.6 Inspection Before Regular Startup
The following verifications must be done before performing a regular startup of the Liebert FS (see
6.5.7 - Starting up the System):
1. Make sure the Liebert FS is properly secured to the floor with the Liebert-provided mounting kit
and in compliance with the floor mounting instructions in 4.1 - Cabinet Floor Mounting.
2. Check for coolant leaks in and around the Liebert FS unit.
3. Ensure that Liebert FS cabinet panels are in place on the cabinet and that no tools have been left
in the cabinet
4. Ensure that the Liebert FS Main circuit-breaker (optional) or the customer-provided external DC
disconnect switch is open
5. Verify that the AC Auxiliary Backup Power is connected and powered by closing fused disconnect
or wall disconnect and check if the Control Panel is ON and with no warning or fault messages
displayed.
Operation
The Liebert FS may now be started up.
6.5.7 Starting up the System
CAUTION
!
The following procedure assumes that the Initial System Startup has been performed under
the supervision of a Liebert technician.
Powering Up the Liebert FS
Once AC voltage is applied to the Liebert FS, the Liebert FS Control Panel will boot up. Its screen will
begin to illuminate after 5 to 10 seconds and then display a series of boot up protocols.
Booting Up
1. It takes about 25 seconds to load and initialize the primary application software at STARTUP or
after reset.
2. Title block and firmware versions will be displayed (see Figure 82). If the secondary DSP does
not boot up properly, versions for the secondary DSP may be corrupted or zero.
3. EEPROM checksum will be calculated and compared with the stored value. EEPROM checksum
fault will be generated if they do not match. For this case, default values are loaded for
parameters in RAM. However, EEPROM contents are not changed.
CAUTION
!
Do not attempt to run the system unless the system loads valid parameters.
4. Response from secondary DSP will be checked. “INTERPROCESSOR COMM FAULT” will be
generated if the communication is not set up properly. The controller will reset itself for this case.
5. Previous operation command (STARTUP or SHUTDOWN) will be retrieved to determine the
current operation mode.
6. Option status is checked. Current available options are VIB and DCM.
71
Operation
Validation of Control Parameters Setup
1. Once the Control Panel has successfully booted up, the Control Panel will display the Main
Screen (see Figure 55).
2. Verify the Control Parameters values are correct. (Consult Table 9 and the relevant UPS
Interconnection Kit Handbook for choosing the proper Control Parameters values).
3. Adjust the Control Parameters values if necessary (see 6.4.1 - Screen Tree Menu Functions).
for instruction on how to change the values of the Control Parameters) then press “F6 DONE”.
Initiating Liebert FS Startup Sequence
NOTE
Startup procedures will vary for each UPS model.
1. Once sufficient DC voltage is applied to the UPS DC Bus, the Liebert FS will be able to transition
from the OFF Mode to Startup Mode, unless system was previously Shutdown by command.
The following action is conditional on the UPS interconnection kit that has been installed on your
Liebert FS:
• Standard UPS Interconnection Kit (IKIT-STD)
The Standard UPS interconnection kit (IKIT-STD) includes a fused Power Terminal Block. It is
recommended for maintenance use to have an external disconnect switch installed between the
UPS and the Liebert FS.
Close the customer-provided external disconnect switch at the time indicated by the UPS startup
procedure.
• Optional UPS Interconnection Kit
NOTE
Optional UPS interconnection kits include circuit-breakers then referred to as “Liebert FS
Main circuit-breaker”.
Open the Liebert FS cabinet front door and close the Liebert FS main circuit-breaker at the time
indicated by the UPS startup procedure. Close the cabinet door.
2. The Control Panel will then show the Main screen (see Figure 55). The System Mode should read
“OFF”. The Liebert FS will actively check for presence of sufficient voltage to allow system
startup.
3. As soon as the UPS DC bus voltage is greater than Vcharge, the System Status will change from
“OFF” to “STAND BY”. The “F1 STARTUP” key will then be enabled.
4. Press the “F1 STARTUP” key.
Liebert FS Startup Sequence
As soon as the “F1 STARTUP” key is pressed, the Liebert FS will launch its startup sequence. This
will progressively lead the Liebert FS through the different Modes of Operation (STAND BY, STARTUP, CHARGE) to eventually reach a ready state of idling (READY Mode) once it is completely
charged up. The automatic transition between modes is described in 5.2 - List of System User-Con-
figurable Parameters.
6.6 Shutdown Procedure
There are two ways the Liebert FS may enter a Shutdown sequence: either a) following a Liebert FS
discharge down to SOC = 0%; or b) following a user-initiated command.
In any Mode, except OFF Mode, the user may command the Liebert FS to transition in SHUTDOWN
Mode by pressing the “F2 SHUTDOWN” key. This action is recommended for normal shutdown of the
system. In this condition, the Liebert FS will not discharge to support an outage. You will be asked to
confirm “Yes” or “No” to SHUTDOWN. Press “Yes” to confirm shutdown and put system in SHUTDOWN mode.
For more information concerning the SHUTDOWN Mode, please refer to 5.2 - List of System User-
Configurable Parameters.
72
7.0 MAINTENANCE
7.1 Safety Precautions
Observe all safety precautions in this manual, paying particular attention to Important Safety
Instructions on page 1.
ONLY qualified service personnel should perform maintenance on the Liebert FS.
Observe all of the warnings below before performing any maintenance on the Liebert FS and associated equipment.
WARNING
!
Before performing preventive maintenance tasks, the Liebert FS must be de-energized and
electrically isolated (both AC and DC connections to the Liebert FS must be electrically
disconnected).
!
CAUTION
Always identify connecting wiring prior to disconnecting any wiring.
Do not substitute parts except as authorized by Liebert Corporation.
Keep Liebert FS cabinets free of foreign materials such as solder, wire cuttings, etc.
Maintenance
Contact Liebert Global Services if you are not sure of the procedures to follow or if you are not
familiar with the circuitry.
WARNING
!
Extreme caution is required when performing maintenance.
Be constantly aware that the Liebert FS contains high DC as well as AC voltages. With input
power off and the battery disconnected, high voltage at filter capacitors and power circuits
should be discharged within 30 seconds. However, if a power circuit failure has occurred, you
should assume that high voltage may still exist after shutdown. Check with a voltmeter
before making contact.
Check for voltage with both AC and DC voltmeters prior to making contact.
When the Liebert FS is under power, both the operator and any test equipment must be
isolated from direct contact with earth ground and the chassis frame by using rubber mats.
Some components within the cabinet are not connected to chassis ground.
Any contact between floating circuits and the chassis is a lethal shock hazard. Use differential
oscilloscopes when measuring a floating circuit. The differential input should have at least
800 VRMS common mode input rating and a common mode rejection ratio of at least 80dB.
Exercise caution that the test instrument exterior does not make contact, either physically or
electrically, with earth ground.
In case of fire involving electrical equipment, use only carbon dioxide fire extinguishers or
others approved for use in fighting electrical fires.
73
7.2 Liebert Global Services
Startup, maintenance and training programs for the Liebert FS are available through your Liebert
sales representative.
Professional Startup
Liebert FS Startup—Liebert’s customer engineers perform a thorough, non-powered inspection of
the units and will then conduct a complete electrical checkout that includes calibrating all components to published specifications. Customer operation training will be conducted during startup.
Load bank testing and full site acceptance testing are additional services that can be performed during a Liebert FS startup. One preventive maintenance service call can be added to the initial
Liebert FS startup agreement.
Maintenance Agreements: The Signature Program
Liebert FS Service Agreements—Liebert Global Services (LGS) has a variety of available maintenance agreements, depending on specific site needs. Choose the level of support appropriate for each
installation. Mission-critical sites can have the standard parts-and-labor, around-the-clock coverage
for their Liebert FS, with or without scheduled preventive maintenance visits. Other sites can benefit
from a variety of money-saving options.
While the Liebert FS is designed to be maintenance-free, Liebert suggests at least one preventive
maintenance visit per year. This preventive maintenance work would normally be done in conjunction
with a service visit for another Liebert UPS product. The annual visit will require taking the
Liebert FS off-line for a thorough, nonpowered inspection. These visits are in addition to the general
housekeeping tasks (changing air filters, etc.) that can be performed by customer personnel.
Maintenance
Training
Customer training courses include the proper operation of the system, emergency procedures, preventive maintenance and some corrective maintenance.
Warranties
Contact Liebert Global Services if you have any questions regarding the warranty on your Liebert FS.
7.3 Routine Maintenance
You are encouraged to become thoroughly familiar with the equipment, but at no time should you go
beyond the specific procedures in this manual while performing maintenance or correcting a malfunction. If you have any doubt as to what must be done, call Liebert Global Services at 1-800-LIEBERT
for further instructions.
The Liebert FS is designed for unattended operation, but does require some common-sense maintenance:
• Keep good records—Troubleshooting is easier if you have historical background
• Keep it clean—Keep the Liebert FS free of dust and moisture
• Keep it cool—The Liebert FS will reliably meet all performance specifications and design life at
temperatures up to 122°F (50°C)
• Keep connections tight—Tighten all connections at installation and at least annually thereafter
(see torque requirements,Table 12)
74
7.4 Maintenance Schedule
WARNING
!
Any maintenance on the system should be delayed by at least 10 minutes after system is shut
down to be certain all electronics have discharged. Use appropriate safety precautions to
ensure unit is disconnected and de-energized.
CAUTION
!
Unless specified otherwise, ONLY a Liebert-certified service technician should perform all
maintenance work. Failure to use a Liebert technician for maintenance actions, unless
specifically noted, may void your warranty.
The Liebert FS maintenance schedule consists of actions listed in Table 11.
Table 11 Maintenance schedule
Item/Action
System Visual Inspection *
System Cleaning (if necessary)
System Testing
(and adjustments, if necessary)
PCM Capacitor Bank — —
Flywheel Module —
UPS Interconnection Kit (if option installed) —
Air Filter (if option installed)
Every
1 yr
Check
or Test
Check
or Test
—
Check
or Test
Frequency
Every
3 yrs
— — — Liebert/Owner
— — — Liebert/Owner
Check
or Test
Check
or Test
Check
or Test
— — — Liebert/Owner
Every
6 yrs
— — Liebert
Service or
Replace
—
— — Liebert
Every
15 yrs
— Liebert
Service or
Replace
Service
Performer
Liebert
Maintenance
NOTE
The recommended System Visual Inspection every year should include a check and torque of
cabinet DC circuit breaker box lug connections and the DC ground; see the relevant section of
Appendix A.0 - UPS Interconnection Kits for torque requirements.
NOTE
Liebert may determine additional maintenance actions as necessary and issue service or
technical bulletins to address any additions.
NOTE
The optional inlet Air Filter in the cabinet will need to be replaced when it is sufficiently dirty
to significantly reduce the flow of air into the cabinet. Ambient conditions at the installation
site will determine the frequency of replacement if option is installed
7.5 Record Log
Set up a maintenance log to record scheduled checks and any abnormal conditions.
The log should have space for all metered parameter indications including phase readings, alarm
messages, mode of operation, air filter replacement date and observation notes.
A periodic walk-through inspection of the Liebert FS room is advised to check for visible and audible
indications of problems. Log the inspection, metered parameter indications and any discrepancies.
75
7.6 Optional Air Filters
The optional air filters must be inspected and serviced on a regular schedule. The period between
inspections will depend upon environmental conditions. Under normal conditions, the air filters will
require cleaning or replacement approximately every 12 months.
CAUTION
!
Be certain recyclable filter elements are dry before reinstalling them in the Liebert FS.
Abnormal or dusty conditions will require more-frequent cleaning and replacement of air filters
(sometimes as often as every two months). Inspect installations in new buildings more often, then
extend the inspection period as experience dictates.
7.7 Torque Requirements
All electrical connections must be tight. Table 12 provides the torque values for the connections in
the Liebert FS. Use these values unless the equipment is labeled otherwise.
Table 12 Torque specifications (unless otherwise labeled)
Nut And Bolt Combinations
Bolt Shaft Size
1/4 53 6.0 46 5.2
5/16 107 12 60 6.8
3/8 192 22 95 11
1/2 428 48 256 29
Grade 2
Standard
Lb-in N-m Lb-in N-m
Electrical Connections
With Belleville Washers
Maintenance
Circuit Breakers with Compression Lugs (For Power Wiring)
Current Rating Lb-in N-m
250A 250 28
Circuit Breakers with Compression Lugs (For Control Wiring)
AWG Wire Size or Range Lb-in N-m
#22 - #14 3.5 to 5.3 0.4 to 0.6
7.8 Detecting Trouble
It is important that the operator check the instrument readings if abnormal equipment performance
is suspected. Any metered value that differs appreciably from normal could mean an impending malfunction and should be investigated.
Items to check include:
• Alarm messages indicate malfunction or impending malfunction. A daily check of the operator
control panel will help to provide an early detection of problems. Refer to Table 16 to interpret
alarm messages.
• Tracing a problem to a particular section is facilitated by alarm messages and the metered
parameter indications. These are stored in the Status Reports and can be displayed at the operator control panel or at an optional terminal. A Liebert Global Services engineer will be familiar
with test points inside the unit.
76
7.9 Reporting a Problem
If a problem occurs within the Liebert FS, review all alarm messages along with other pertinent data.
This information should be given by telephone to the Liebert service representative’s office nearest
you. This information can be downloaded to Liebert Global Services by using the optional modem.
Contact Liebert Global Services at 1-800-LIEBERT to report a problem or to request assistance.
7.10 Corrective Actions
For each alarm message on the operator control panel, you can find the recommended corrective
action in Ta b l e 1 6 .
7.11 Recommended Test Equipment
Table 13 lists recommended test equipment and tools required to maintain, troubleshoot and repair
the Liebert FS. You may substitute instruments of equivalent range and accuracy.
All instruments should be calibrated and be within the current calibration cycle. Calibration data for
the instruments should be maintained in equipment-history files and the instruments labeled for
audit and verification.
Table 13 Recommended test equipment and tools
Qty Test Equipment Manufacturer Model or Type
1 Oscilloscope Tektronix, H-P or Fluke DC to 50 MHz
2 Voltage Probes Tektronix, H-P or Fluke 10X, with 10 ft cable
2 Voltage Probes Tektronix, H-P or Fluke 100X, with 10 ft cable
1 Digital Multi-meter Fluke 87, with test leads
1 Tool Kit N/A Standard electrical contractor tools
Maintenance
7.12 Limited Life Components
Your Liebert FS has a design life well in excess of 15 years. Well-maintained units can continue to
provide economic benefits for 20 years or more. Long-life components are used in your Liebert FS
wherever practical and cost-effective.
However, due to current component material and manufacturing technology limitations, a few components in your Liebert FS will wear out and require replacement in less than 10 years. The following
limited-life components are utilized in your Liebert FS. In order to prevent a wear-out failure of one of
these components affecting your critical load operations, it is recommended these components be periodically inspected and replaced before their expected wear-out life. Individual users may have sitespecific requirements that differ from these typical life expectations.
Table 14 Projected component life, replacement schedule
Component Expected Life Replace in:
Power DC filter capacitors About 7 years 5-6 years
Air filters, disposable
(see also 7.6 - Optional Air Filters)
Power capacitors are considered “failed” when their measured capacitance is –5% below their nameplate rating.
In most cases, replacement components must exactly match the original component specifications and
are not readily available from third-party component distributors. For assistance with your specific
component specifications, replacement component selection and sourcing, call 1-800-Liebert.
For customers using Liebert Global Services’ Preventive Maintenance Services, periodic inspection of
these components are part of this service as is recommending to customers replacement intervals to
avoid interruptions in critical load operations.
1-3 years Check 4 times/year
77
8.0 TROUBLESHOOTING
NOTE
Refer to this section before calling Liebert Global Services for support.
8.1 General
The Liebert FS is capable of detecting conditions outside of normal operating parameters and providing notice at the Control Panel. This data is recorded as either Warnings or Faults and can be viewed
in the software menu tree at the screen location MENU>VIEW>. These Warnings and Faults can also
be communicated by the Versatile Interface Board (VIB), if this option has been installed, to an external device or system; (see Appendix C.0 - Versatile Interface Board). This data will also be
recorded in the Data Collection Module option if this has been selected. Please see Appendix B.0 -
Data Collection Module for instructions on how to access this data via the DCM.
Any Warnings and Faults that may occur will be displayed on the Main screen of the Control Panel.
The Liebert FS’ Warnings and Faults tables (see Tables 15 and 16), describe these Warnings, meanings and possible causes. The operator action required or automatic system function that will result is
explained.
In addition to the information displayed on the Main screen, other system information that can be
used for troubleshooting is available and can be accessed from the Control Panel. From the Main
screen the Menu screen can be selected by pressing (F6) on the Control Panel located below MENU.
Troubleshooting
Figure 89 USER level menu
MENU>
1. PARAMETERS
2. VIEW
3. SECURITY
4. ABOUT
5. TOOLS
Selecting View displays various system statuses including real-time and historical data. You can
select the function by number.
Figure 90 VIEW menu
MENU>VIEW>
1. TIME/DATE
2. TEMPERATURES
3. VOLTAGES
4. HISTORY
5. OPTIONS
Selecting History will provide a history of Warnings and Faults as introduced in Section 5, Operations, of this manual. Other information that can be useful in troubleshooting are the Temperatures,
Voltages, Options, Electrical and Vitals screens.
HOME
6. NETWORK
7. ELECTRICAL
8. VITALS
HOME DONE
DONE
Warning/Fault: The Liebert FS holds 35 warning and fault information, respectively. A single screen
shows seven warnings or faults. Users can move between pages using PREV, NEXT button. (See
Figures 91 and 92 below).
78
Figure 91 Warning history
Troubleshooting
01 03/10/05 11:43 W
02 03/10/05 10:37 W
03 02/24/05 04:03 W
04 01/30/05 23:22 W
05 12/20/04 13:45 W
06 11/13/04 07:28 W
07 09/30/04 16:23 W
Figure 92 Fault history
01 03/10/05 11:43 F
02 03/10/05 10:37 F
03 02/24/05 04:03 F
04 01/30/05 23:22 F
05 12/20/04 13:45 F
06 11/13/04 07:28 F
07 09/30/04 16:23 F
RESET
The warnings, fault meanings and possible causes in the following text and in Table 15 may be used
in troubleshooting the messages and may also aid in identifying conditions outside the flywheel system that may adversely affect it.
8.2 Warnings
AUX POWER LOW
VIB INOPERATIVE
OVERSPEED
STATOR HOT
ROTOR HOT
RUNOUT
VACUUM
NEXT DONE
CURRENT OFFSET
CHECKSUM
SOFTWARE OV
DC BUS OV
SPARE OPEN
INTER PROCR COMM
MISER
NEXT DONE
A Warning is an indication of an abnormal system condition significant enough to warrant being
annunciated and logged. Warning conditions may indicate that a system parameter is out of its normal operating range, or may signal an external problem. A Warning indication is for information only
and does not require any operator intervention for continued operation of the unit. While in Warning
condition, normal operation of the unit will continue unimpeded. A warning can indicate an operating
condition that warrants observation and may require preventative maintenance.
Figure 93 Warning screen
Liebert FS
MODE:
STATUS:
The Warning condition is indicated by the System Status field displaying “WARNING” in the Control
Panel window (see Figure 93). If one Warning is present, the Warning Label (see Table 15.) will be
displayed.
While the Warning condition exists, and if more than one Warning is present, F5 the “More Info” key
will be enabled in the Control Panel window. If pressed, the separate Warning Labels will be displayed in the Control Panel window.
D V U C
RPM:
CHARGE
2 WARNINGS
SHUTDN MORE MENU
Warning Status Message
LOCK
SOC:
SOC:
BUS:
PWR:
More information
Button (F5)
39562
45.4%
538V
32.3kW
Any of eight warnings could occur while the Liebert FS is operating. Warnings give advance alert of
potential problems and schedule service and preventive maintenance. These can be monitored and
investigated through the use of data from the Control Panel and system tests.
79
Troubleshooting
Table 15 lists the warnings and some troubleshooting steps that may be taken if any of the Warnings
in appear.
Table 15 Warnings
Warning
Label
AUXPOWER
LOW
VACUUM
LOW
MISER HIGH Miser voltage is higher than 2V Calibrate board
RUNOUT
HIGH
PWR SPLY
VOLT LOW
VIB
INOPERATIVE
OVERSPEED Speed is higher than the Max Speed
SET TIME/
DATE
* Warnings of this nature should be monitored and may be used to schedule preventive maintenance.
Meaning / Possible Causes Troubleshooting
Auxiliary power supply is low when the system is
not in OFF mode.
Factory-configurable warning
Drag power exceeds 85W
Runout is higher than 2.0 mil.
Power supply for PPMC/PCMC is lower than 21V.
VIB inoperative while enabled Check VIB cable connections and wiring
Time and date have not been set Set Time/Date in Menu>View>Time/Date
*
*
Check / Test Auxiliary power supply
Check Vitals and Vacuum History
Check Vitals and Runout History
Power supply for PPMC/PCMC is lower
than 21V
Have Certified Service personnel check
software settings
If Warnings persist, contact your local Liebert representative or contact Liebert Global Services at
800-543-2378. You may also visit the Liebert Web site for information at www.liebert.com.
NOTE
A “Standby, Motor Hot” message may be displayed as a result of consecutive and repetitive
discharges. This is not a Warning but a normal operating occurrence that may occur due to
frequent charging and discharging of system. Once motor cools it will automatically resume
operation.
80
8.3 Faults
A Fault is defined as an undesirable system operating condition that could cause further damage to
the system or potentially drop the load. Once detected, Faults may trigger an appropriate emergency
action such as shutting the unit down. Most Fault conditions are automatically taken care of by the
Liebert FS control system and require no Operator intervention. A few Fault conditions may be
resolved only through operator intervention or service by a Liebert technician.
A Fault condition must be valid for a certain amount of time before it is recognized as an active Fault.
This prevents spurious signals from causing false Fault detection and unnecessary state changes.
Figure 93 shows the appearance of an active Fault on the main screen.
Figure 94 Fault screen descriptions
Troubleshooting
Fault Status Message
Liebert FS
MODE:
STATUS:
Fault Clear Button (F3)
FAULT
2 FAULTS
CLEAR MORE MENU
D V U C
RPM:
SOC:
SOC:
BUS:
PWR:
More information
Button (F5)
48351
75.4%
538V
0.0kW
Bus Power
While in Fault condition, normal operation of the unit is suspended, the operation of the Power Conversion Module is paused, and the unit transitions into FAULT Mode, where it waits for one of the following to occur:
1. The condition to clear the fault [AUTO CLEAR]
2. The unit to automatically transition in SHUTDOWN Mode [AUTO SHUTDOWN]
3. Operator action [OPERATOR CLEAR].
The Fault condition is indicated by the System Mode displaying “FAULT” in the Control Panel window.
If there are multiple Fault conditions present, the F5 “More Info” key will be enabled in the Control
Panel window. If pressed, information related to the specific Faults will be displayed in the Control
Panel window (see Figures 54 through 56). If there are multiple faults they will both be displayed by
pressing the F5 “MORE” button.
In many cases, when FAULT Mode is entered, the Fault may be cleared by pressing the F3 “CLEAR
FAULT” button on the Control Panel or utilizing the VIB option - if enabled - to send a “CLEAR
FAULT” signal to the system. In order to “CLEAR FAULT” the operator must be in proper security
access level; User or above. Table 16 describes the fault labels, meanings and possible causes for the
81
Troubleshooting
Faults. Table 17 - Troubleshooting describes actions that may alleviate the condition or provide
valuable information for technical support.
Table 16 Faults—causes and responses
Operator
Fault Label Meaning / Possible Causes
GROUND FAULT Ground fault current out of range. X
HW BUS OV HW overvoltage. (hardware protection) X
X PHASE OC AC phase overcurrent. x = A, B, C. X
IGBT OVRTEMP IGBT overtemperature. X
VACUUM FAULT Drag power exceeds 125W. X
RUNOUT FAULT Runout higher than 2.9mil. X
MISER FAULT Miser voltage is higher than 5V. X
BEARING Magnetic bearing fault. X
AUX POWER LOW
INTER PRCR COMM
PWR SPLY VOLT
UNDEF PDP INT Undefined PDP interrupt. X
CURRENT OFFSET AC motor current sensor error. X
SW OV
CHECKSUM
CONTACTOR TIME OUT
CONTACTOR CLOSE FAIL Contactor failed to close on startup. X
FAN OPEN Fan open circuit or disconnected. X
FAN SHORT Fan short circuit. X
PUMP OPEN Pump open circuit or disconnected. X
PUMP SHORT Pump short circuit. X
HW OVERSPEED Hardware detected overspeed. X
PRECHARGE PROTECTION
BUS CURRENT OFFSET DC current sensor error. X
S - Indicates a Certified Service Provider will be required to reset system.
Auxiliary power supply voltage is low when the
system is in Off mode. Configurable fault.
Communication error with secondary DSP. System
reboots.
Power supply voltage is lower than 19V. (Speed
dependent; auto shutdown at high speed)
DC bus voltage is higher than the threshold, which is
service-configurable.
Calculated checksum does not match the stored
checksum.
Bus voltage/current is not stable while trying to close
or open contactor.
Stop PWM when large voltage differential exists
between internal and external bus.
Clear*
Auto
Clear
X
X
XX
X
S
X
X
Auto
Shutdown
NOTE
If a fault recurs after being cleared by the operator, and the condition persists, contact your
Liebert technician.
Faults that initiate an AUTOSHUTDOWN include: MISER, RUNOUT, PWR SPLY VOLT (at high
speed), and will require Service level and higher to reset.
82
Troubleshooting
Fault messages displayed can, in some cases, be investigated for a solution. Listed below in Table 17
are troubleshooting steps for the Fault messages that can occur.
Table 17 Troubleshooting
Fault Label Troubleshooting Action
GROUND FAULT Contact Service provider. Schedule service.
HW BUS OV Check DC bus voltage at UPS and adjust as necessary to within threshold.
X PHASE OC Check IGBT, resistor diodes.
IGBT OVRTEMP Check cooling pump, test pump and fans.
VACUUM FAULT Check in History, Vitals, collect data, contact Certified Service Provider.
RUNOUT FAULT Check in History, Vitals, collect data, contact Certified Service Provider.
MISER FAULT Check calibration in Tools.
BEARING Contact Service provider. Schedule service.
AUX POWER LOW Check and test Auxiliary Power module.
INTER PRCR COMM Contact Service provider. Schedule service.
PWR SPLY VOLT Check data in Menu>View>Electrical.
UNDEF PDP INT Contact Service provider. Schedule service.
CURRENT OFFSET Contact Service provider. Schedule service.
SW OV Contact Service provider. Schedule service.
CHECKSUM Contact Service provider. Schedule service.
CONTACTOR TIME OUT Check DC bus voltage at UPS and adjust as necessary to within threshold.
CONTACTOR CLOSE FAIL Check DC bus voltage at UPS and adjust as necessary to within threshold.
FAN OPEN Check fan connections.
FAN SHORT Check fan.
PUMP OPEN Check pump connections.
PUMP SHORT Check pump.
HW OVERSPEED Contact Service provider. Schedule service.
PRECHARGE PROTECTION Contact Service provider. Schedule service.
BUS CURRENT OFFSET Check bus voltages, contact service provider to calibrate settings.
Refer to the general drawings in Appendix D.0 - Installation Drawings for the location of system
components.
If a Fault condition persists contact your Liebert technician. You may also visit the Liebert Web site
at www.liebert.com for information.
83
APPENDIX A.0UPS INTERCONNECTION KITS
Your Liebert FS is equipped with a UPS interconnection kit to connect it to one of these Liebert UPS
systems:
• Liebert Series 610™, 600T™ or 600™
• Liebert Npower™
• Liebert Series 300™
• Liebert HiPulse™
The Liebert FS system must be installed according to the instructions in 4.0 - Installation. Integrate
your Liebert FS system into an Uninterruptible Power Supply (UPS) system in accordance with the
instructions and drawings in this manual.
CAUTION
!
The initial system startup must be performed ONLY under the supervision of a
Liebert-certified service technician to ensure proper system operation. Failure to abide by
instructions provided herein may void your warranty.
Contact your local Liebert sales representative or Liebert Global Services at 1-800-LIEBERT
to arrange for system startup.
NOTE
Before beginning installation, ensure that your Liebert FS unit is equipped with the correct
UPS interconnection kit.
UPS Interconnection Kits
The first two digits of the Liebert FS model number represent the UPS system the product is
designed for, as shown in Table 18.
Table 18 Key to UPS model interconnection
Liebert FS Model # Use With Liebert UPS
25FS Liebert Series 300
37FS Liebert Npower
39FS Liebert Series 610/600T/600
Contact Liebert Liebert HiPulse (50Hz European Model)
Appendix A.1 Wiring Connections
Appendix A.1.1 General Wiring Considerations
CAUTION
!
A qualified electrical contractor must perform all electrical connections. The wires (DC power,
ground, optional status/control and auxiliary backup power) that connect the Liebert FS
system(s) to the UPS system are field-supplied or, as an option, by Liebert. Wire size and
installation must comply with all applicable local, regional and national regulations (e.g.,
National Electric Code for USA).
The electrical connections to the Liebert FS are:
•DC power
• Status/control
•Ground
• Auxiliary backup power
• Remote monitoring (optional)
NOTE
The connection instructions included in this section address ONLY the cabling of the DC power
and Status/Control connections specific to the individual UPS interconnection kits.
Instructions for installing ground, auxiliary backup power and remote monitoring connections
are in 4.0 - Installation.
84
Power and status/control wiring must be run in separate conduits or cable trays. Refer to Appendix
D.0 - Installation Drawings for locations of the various electrical connections between Liebert FS
system(s) and UPS system.
CAUTION
!
Power and status/control wiring must be separated
Figure 95 Top view of Liebert FS Cabinet with UPS interconnection kit
Ground Terminal
DC Power
Terminals
UPS Interconnection Kits
Front
Fan Coil Module
Circuit
Breaker
Manufacturer’s
Connection
Status/Control
Terminal Block
(upgraded)
CAUTION
!
Do not cut entry holes for conduit while the access plates are still set on the top of the
Liebert FS cabinet. Remove the access plates from the cable-access areas in the top of the
Liebert FS cabinet prior to cutting entry holes.
CAUTION
!
After reinstalling access plates, be certain that no foreign matter (metal shavings, insulation
or wire fragments, etc.) remains inside the Liebert FS. Likewise, be certain to block any
“extra holes” in the plates through which foreign matter (or rodents) could later enter the
Liebert FS.
Rear
85
Appendix A.1.2 DC Power Connections
The DC power connections to the Liebert FS are made through the circuit breaker (see Figure 96) in
the UPS interconnection kit installed in your Liebert FS. The maximum wire size for the circuit
breaker terminals is 350MCM - 600VDC (approximate metric equivalent: 150mm
size and installation must comply with all applicable local, regional and national regulations (e.g.,
National Electric Code for USA).
Figure 96 Circuit breaker
The Liebert FS cabinet is configured for top entry cables in standard configuration. The cables can
also be run through the side panels. The Liebert FS cabinet does not accommodate bottom entry
cables.
UPS Interconnection Kits
2
wire section). Wire
Liebert FS
Positive
Terminal
Liebert FS
Negative
Terminal
The connection of the circuit breaker is described in Figure 135 - Elevation drawing—Liebert FS
cabinet with integrated circuit breaker. Refer to this drawing to ensure that the adequate con-
nections are performed.
Circuit Breaker Torque
Tighten the positive and negative terminals of the DC power connections on the circuit breaker to
250 in-lb. (29 N-m) unless the equipment is labeled with a different torque value.
86
UPS Interconnection Kits
Appendix A.2 Installing the Liebert FS With a Liebert Series 610, Liebert Series 600T or
Liebert Series 600
The Liebert Series 610/600T/600 UPS interconnection kit for the Liebert FS is compatible with the
Liebert Series 610, Liebert Series 600T and Liebert Series 600 models in Table 19.
Table 19 Liebert Series 610/600T/600 model ratings
UPS Output Rating
kVA
kW
Figure 97 Liebert Series 610 225kVA UPS
65 80 100 125 150 225 300 400 400 450 500 500 625 750 750 1,000
52 64 80 100 120 180 240 320 360 360 400 450 500 600 675 900
Appendix A.2.1 Description - Liebert Series 610/600T/600 UPS Interconnection Kit
The Liebert Series 610/600T/600 UPS interconnection kit for the Liebert FS is composed of:
DC Power Interface
One Thermal-Magnetic Molded Case circuit breaker rated for 250 ADC - 600VDC equipped with:
• An undervoltage relay (UVR) rated for 48VDC, 50 mA
• Auxiliary contacts: Normally Open (NO) and Normally Closed (NC).
Status/Control Interface
One Status/Control Terminal Block used to ensure the status/control connections between the
Liebert FS and the Liebert Series 610/600T/600.
87
UPS Interconnection Kits
Appendix A.2.2 Status/Control Connections - Liebert Series 610/600T/600 UPS Interconnection Kit
The status/control interface is the Status/Control Terminal Block. The connection of the Status/Control Terminal Block is described in Figure 137 - Control wiring diagram—Liebert FS cabinet -
manually operated circuit breaker. Refer to this drawing to ensure that proper connections are
performed. In case multiple Liebert FS units are connected to the same UPS DC bus, refer to Figure
129 - Control wiring—external interconnect diagram, Liebert FS cabinet to Liebert Series
610 UPS module to perform the Status/Control connections between each Liebert FS.
This interconnection kit includes Status/Control Connections that enable transfer of signals between
the Liebert FS system(s) and the UPS system such as:
• Circuit breaker status (closed/open); and
• Undervoltage relay coil excitation voltage.
Figure 98 Liebert Series 610/600T/600 status/control terminal block wiring
Y
e
l
l
o
w
Row for
installation of
contractor wire
connections
Two r o w s
B
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42 3 5 7 8 961 10
The recommended gauge for Status/Control connection wires is 16 AWG - 600VDC (1.3mm
tion). Wire size and installation must comply with all applicable local, regional and national regulations (e.g., National Electric Code for USA).
Appendix A.2.3 UPS Configuration - Liebert FS and Liebert Series 610, 600T or 600
To optimize the integration between the Liebert Series 610/600T/600 UPS system and the Liebert FS,
some parameters must be checked on the UPS system:
• The UPS rectifier walk-in time must be set as short as possible. Contact your Liebert representative if your unit has received the upgraded board that enables the setting of “rectifier walk-in
time” lower than standard.
• Ensure that the “auto battery self test” has either been disabled or upgraded to accommodate
Liebert FS integration.
2
wire sec-
88
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