GE Industrial Solutions H2007001 G21 User Manual

H2007001 G21 Series

Infinity D Power System

with -48 Volt Rectifiers, +24 Volt Converters, and Pulsar Controller

Installation Guide

Installation Guide LineagePower.com Comcode CC848853515 Issue 2.0 June 2009

Infinity D Power System Installation Guide: -48V Plants H2007001

Notice: The information, specifications, and procedures in this manual are subject to change without notice. Lineage Power assumes no responsibility for any errors that may appear in this document.

Infinity D Power System Installation Guide: -48V Plants H2007001

1. Introduction.............................................................................................................. 5

Document Objectives.................................................................................................

Audience .................................................................................................................... 5

Applications ...............................................................................................................

Customer Service Contacts........................................................................................ 6

2. Product Description................................................................................................. 7

Overview.................................................................................................................... 7

3. Safety.......................................................................................................................11

Safety Statements..................................................................................................... 11

Warning Statements and Safety Symbols................................................................ 14

Precautions............................................................................................................... 15

Handling Batteries ................................................................................................... 16

Special Installation Notes ........................................................................................ 17

Deutsch .............................................................................................................. 17

Español............................................................................................................... 18

4. Installation.............................................................................................................. 21

Preparation ............................................................................................................... 21

Anchor the Frame .................................................................................................... 23

Ground the Framework............................................................................................ 23

Connect Frame Ground...................................................................................... 23

Install Batteries ........................................................................................................ 24

Mount the Subframe System to the Frame or Cabinet............................................. 25

Wire the Subframe ................................................................................................... 26

Identify Areas for Each Type of Wiring............................................................ 26

Connect ac Utility .................................................................................................... 27

Wire the Battery Connection Module...................................................................... 33

Connect Central Office Ground (COG)............................................................. 34

Connect External Battery Cables....................................................................... 35

Wire -48V DC Loads...............................................................................................

Install dc Bullet Style Circuit Breaker Modules for -48V Loads ...................... 40

Wire +24V DC Loads..............................................................................................

Install dc Bullet Style Circuit Breaker Modules for +24V Loads ..................... 46

Wire Loads served by GMT Type Fuses ................................................................. 51

Install Rectifiers and Converters..............................................................................

Rectifier/Converter Installation Procedure ........................................................ 54

Install Battery Instrumentation ................................................................................ 57

Install Battery VT Probes...................................................................................

Setup Pulsar Controller............................................................................................ 63

Install Controller Field Wiring........................................................................... 64

Change LAN to Server Mode ............................................................................

Restore the LAN Connection to Client Mode....................................................

Acceptance Testing.................................................................................................. 67

5. Troubleshooting..................................................................................................... 71

Troubleshooting NE-Series Rectifiers/Converters .................................................. 72

65 66

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Troubleshooting VT-Probes..................................................................................... 74

6. Product Warranty.................................................................................................. 75

Appendix A: Pulsar Controller......................................................................................77

User Interface Overview..........................................................................................

Menu Navigation Buttons........................................................................................

System Status Display.............................................................................................. 78

LCD Backlight................................................................................................... 78

NE843 Status LEDs ........................................................................................... 79

Audible Alarm ...................................................................................................

Voltage Test Jacks .............................................................................................

Local and Remote Access Ports......................................................................... 80

Front Panel Menu Structure..................................................................................... 81

Front Panel PIN.................................................................................................. 82

Front Panel Menu Flow .....................................................................................

Appendix B: Reference Information.............................................................................

Pulsar Controller Field Wiring Connector Definitions............................................ 89

Reference Information for 26 inch Frame ............................................................... 91

Revision History..............................................................................................................

77 78

79 80

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1. Introduction

Document Objectives

This manual provides installation and maintenance information for the Lineage Power Infinity D power system:

• Safety Information

• Product Description

• Installation Procedures

• Test and Acceptance

• Troubleshooting, including Controller and Rectifier Operations

• Product Warranty

Audience

• Equipment Installers – Instructions for installation, test, and acceptance.

• Equipment Users – Plant basics and troubleshooting.

CAUTION: This unit must be installed, serviced, and operated only by skilled and qualified personnel who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment.

Additional Product Documentation

• 2007001 Ordering Guide:

• Configuration and Ordering Information

• Specifications of System, Rectifiers, Converters, and Controller

• Spare and Maintenance Parts Lists

• Engineering Information, such as ac Service Breakers, Conduit and Wiring

Sizing, and dc Wiring Information

Applications

Infinity D represents the state-of-the-art high density power system with a 18x26x84 inch footprint that are suited for sites ranging from 50A to 1200A power requirements. The 48Vdc power system provides 960 amperes at the 80% load capacity with a -48 to +24Vdc converter shelf that provides four 75 ampere units for a total of 300 amps at +24V.

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Customer Service Contacts

Customer Service, Technical Support, Product Repair and Return, and Warranty Service

For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797). This number is staffed from 7:00 am to 5:00 pm Central Time (zone 6), Monday through Friday, on normal business days. At other times this number is still available, for emergencies only. Services provided through this contact include initiating the spare parts procurement process, ordering documents, product warranty administration, and providing other product and service information.

For other customers worldwide the 800 number may be accessed after first dialing the AT&T Direct country code for the country where the call is originating, or you may contact your local field support center or your sales representative to discuss your specific needs.

Customer Training

Lineage Power offers customer training on many Power Systems products. For information call 1-972-284-2163. This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday.

Downloads and Software

To download the latest product information, product software and software upgrades, visit our web site at http://www.lineagepower.com/

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[

2. Product Description

Overview

Shown here is an Infinity D equipment only frame made up of six Infinity D Power Modules. Three different modules are shown: one Battery Connection Module, four Rectifier System Modules and one Converter System Module. Principal elements are

labeled:

[Battery Hot Terminations] [Shunt & Optional LVBD Contactor] [Battery Return Terminations]

Rectifier System Module

AC Input Terminals

4 Rectifier Plug in Slots

(one required per plant)

Converter System Module

4 Converter Plug in Slots

Plant Controller

DC Distribution

includes:

Battery Connection Module

{

[

Colors indicate: Rectifier Module output

voltage (Blue label is -48V)

Distribution Circuit Breaker output voltage (Blue label is -48V)

Converter Distribution Circuit Breaker output voltage (Orange label is +24V)

Converter module output voltage(-48V to +24V converters shown with orange marking)

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Battery Connection Module

Batteries power the load equipment when ac input to the rectifiers is lost. The batteries are connected to the Battery Connection Module at the top of the frame. An optional Low Voltage Battery Disconnect (LVBD) contactor provides deep discharge protection if desired. The System Shunt also resides in the Battery Connection Module.

Rectifier System Module

On the left side of each Rectifier System Module ac is supplied to front accessible terminal blocks that feed each of the 4 rectifier positions.

The rectifier positions are labeled 1 through 4 from the bottom to the top. At product introduction, all NE rectifiers operate from 208 to 240VAC nominal.

The DC Distribution provides 10 bullet circuit breaker positions per Rectifier System module, with room to optionally add 10 more.

Pulsar Controller

The Pulsar system controller monitors and controls system operation. It is required for all remote telemetry, dry contact alarm closures and precise control of battery voltage.

Converter System Module

The converter positions are labeled 1 through 4 from the bottom to the top. Converters for this plant are available to convert from -48V to +24V.

The DC Distribution provides 10 bullet circuit breaker positions per Converter System module. An alternative distribution will add 10 more for a total of 20.

Frame

By simply changing the door, this system can be configured to work with frame sizes of 19”, 23”, and 26” frameworks. Preconfigured part numbers for modules that fit into each framework are available in the sizes common for most applications. Growth is achieved by adding one of these supplementary modules. Installation instructions ship with each module.

Frame Size 19” 23” 26”

-48V Rectifier System Module

-48 to +24V Converter System Module

H2007001 G020E, or 20F

H2007001 G040E

H2007001 G020C, or 20D

H2007001 G040C

H2007001 G020A, or 20B

H2007001 G040A

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Infinity D Block Diagram

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Note on AC surge protection requirements: Our rectifier product Safety Approval is performed to assure safe and reliable performance in IEC 60664-1 Installation Category II environments. Building AC surge protection devices installed prior to the rectifiers must provide this degree of protection.

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3. Safety

Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the Lineage power system:

• The CE Mark demonstrates compliance with the European Union Council Directives

for Low Voltage and EMC.

• This system is Underwriters Laboratories (UL) Listed per Subject 1801, Power

Distribution Centers for Telecommunications Equipment (UL 60950-1).

• Install only in restricted access areas (dedicated equipment rooms, equipment closets,

or the like) in accordance with articles 110.27 of the U.S. National Electric Code (NEC), ANSI/NFPA No. 70, and pursuant to applicable local codes.

• Not for use in a computer room as defined in the Standard for the Protection of

Electronic Computer/Data Processing Equipment, ANSI/NFPA 75.

o Ne peut être utilisé dans une salle d’ordinateurs telle que définie dans la

norme ANSI/NFPA 75 Standard for Protection of Electronic Computer/Data Processing Equipment

• This equipment is to be used in controlled environments (an area where the humidity

is maintained at levels that cannot cause condensation on the equipment, the contaminating dust is controlled, and the steady-state ambient temperature is within the range specified).

• This equipment has been evaluated for continuous use in ambient temperature from

-40°C to 45°C. Maximum 45°C ambient for plant outputs not exceeding 960A charge and 1200A discharge, otherwise maximum 40°C ambient.

• This equipment must not be installed over combustible surfaces.

• For installations in the United States, Listed compression connectors are to be used to

terminate Listed field-wired conductors where required. For all installations, the appropriate connector is to be applied only to the correct size conductor as specified by the connector manufacturer, using only the connector manufacturer's recommended tooling or tooling approved for that connector.

• If the proper connector for the country of installation is not provided, obtain

appropriate connectors and follow manufacturers and all local requirements for proper connections. All national and local rules and regulations should be followed when making field connections.

• The main output voltage (less than 60Vdc for all configurations) meets SELV

requirements. Loads connected between -48 volts and +24 volts are not SELV and therefore shall not be connected.

• Insulation on field-wired conductors should be rated no less than 90° Celsius. Wire

conductor size should be sized per electrical codes for 75° Celsius wire, and based on the ampacity of the associated protection device. Wiring internal to enclosed equipment cabinets should be rated at 105° Celsius (minimum).

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• Torque electrical connections to the values specified on labels or in the product

documentation.

• Battery input cables must be dressed to avoid damage to the conductors (caused by

routing around sharp edges or routing in areas where wires could get pinched) and undue stress on the connectors.

• Alarm contacts on the office alarm board are not fused; therefore, current limiting

protection for these contacts must be provided by external circuits. Maximum ratings for alarm connections are 60Vdc and 0.5 amperes. Exceeding these maximum ratings could result in fire or damage to the unit.

• Fuse and/or circuit breaker loads must not exceed 80% of the fuse and/or circuit

breaker current rating. Distribute loads across the panel.

• The short circuit current capability of the battery input to the distribution panel must

not exceed 10,000A.

• Wiring methods used for the connection of the equipment to the AC Mains Supply

shall be in accordance with the National Electric Code, ANSI/NFPA 70, and the Canadian Electrical Code, Part 1, CSA C22.1. Maximum 20 A protective device is required for each branch circuit powering one power supply. Maximum 40 A protective device is required for each branch circuit powering two power supplies. Refer to the equipment ratings to assure rating of equipment will not exceed 80% of the value of the protector chosen.

• High leakage currents are possible due to contribution from simultaneous multiple ac

input connections. Earth ground connection is essential before connecting the ac source to the shelf. This connection is achieved by bonding the AC grounding conductor(s) to the AC grounding terminal(s).

• DC Ground System: Due to potentially high DC fault currents, the rack should first

be connected to the office DC ground system per the appropriate telecom industry practices. This Ground connection should be made before any DC power or the AC connections are made to avoid the possibility of damaging the AC ground if a DC fault should occur.

• Readily accessible disconnect/protection device(s) must be incorporated in the

building installation wiring in order to remove power from the equipment in the event of an emergency or required servicing.

• Disconnect all ac branch circuits prior to servicing. Multiple sources of ac may be

present.

• CAUTION – DOUBLE POLE/NEUTRAL FUSING o ATTENTION. Double pôle/fusible sur le neutre.

• Installing fuses or circuit breakers not specified for use in these distribution modules

may result in injury to service personnel or equipment damage. Use only replacement parts listed in this manual and on the equipment drawings.

• The telecom-type (for example, GMT type) fuses can produce sparks during

interruption or clearing of a fault on a high energy circuit. Use only fuses provided with safety caps for this type of circuit. Installing telecom-type fuses not equipped with safety caps may result in injury to service personnel.

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• While installing batteries, follow all safety precautions outlined in the appropriate

battery product manuals.

• The intra-building port(s) of the equipment or subassembly is suitable for connection

to intrabuilding or unexposed wiring or cabling only. The intra-building port(s) of the equipment or subassembly MUST NOT be metallically connected to interfaces that connect to the OSP or its wiring. These interfaces are designed for use as intrabuilding interfaces only (Type 2 or Type 4 ports as described in GR-1089-CORE, Issue 4) and require isolation from the exposed OSP cabling. The addition of Primary Protectors is not sufficient protection in order to connect these interfaces metallically to OSP wiring. The Ethernet port is suitable for connection only to shielded intrabuilding cabling grounded at both ends.

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Warning Statements and Safety Symbols

The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside. Risk of injury. This unit must be accessed only by qualified personnel.” Signal words as described below may also be used to indicate the level of hazard.

Indicates the presence of a hazard that will cause death or severe

DANGER

WARNING

CAUTION

personal injury if the hazard is not avoided.

Indicates the presence of a hazard that can cause death or severe personal injury if the hazard is not avoided.

Indicates the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided.

This symbol identifies the need to refer to the equipment instructions for important information.

These symbols (or equivalent) are used to identify the presence of hazardous ac mains voltage.

This symbol is used to identify the presence of hazardous ac or dc voltages. It may also be used to warn of hazardous energy levels.

One of these two symbols (or equivalent) may be used to identify the presence of rectifier and battery voltages. The symbol may sometimes be accompanied by some type of statement, for example: “Battery voltage present. Risk of injury due to high current. Avoid contacting conductors with uninsulated metal objects. Follow safety precautions.” One of these two symbols may be used to identify the presence of a hot surface. It may also be accompanied by a statement explaining the hazard. A symbol like this with a lightning bolt through the hand also means that the part is or could be at hazardous voltage levels. This symbol is used to identify the protective safety earth ground for the equipment.

This symbol is used to identify other bonding points within the equipment.

This symbol is used to identify the need for safety glasses and may sometimes be accompanied by some type of statement, for example: “Fuses can cause arcing and sparks. Risk of eye injury. Always wear safety glasses.”

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Precautions

When working on or using this type of equipment, the following precautions should be noted:

• This unit must be installed, operated, and serviced, only by qualified technical

personnel, who have the necessary knowledge and practical experience with electrical equipment and who understand the hazards that can arise when working on this type of equipment. Equipment in these locations will contain parts at HAZARDOUS energy levels that can be directly accessed and are only protected by guarding and/or warning.

• The equipment may be powered by multiple ac inputs. Disconnect all AC branch

circuits before servicing. Do not disconnect grounding, bonding conductors, or permanent bonding provisions unless all ac inputs are disconnected.

• High leakage current exists. Grounding/Earth connection must be provided before

connecting supply.

• Batteries may be connected in parallel with the output of the rectifiers. Turning off

the rectifiers will not necessarily remove power from the bus. Make sure the battery power is also disconnected and/or follow safety procedures while working on any equipment that contains hazardous energy/voltage.

• Hazardous energy and voltages are present in the unit and on the interface cables that

can shock or cause serious injury. Follow all safety warnings and practices when servicing this equipment. When equipped with ringer modules, hazardous voltages will be present on the ringer output connectors.

In addition to proper job training and safety procedures, the following are some basic precautions that should always be used:

• Use only properly insulated tools.

• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).

• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and

distribution components can produce severe arcing.

• Test circuits before touching.

• Lock out and tag circuit breakers/fuses when possible to prevent accidental turn on.

• Be aware of potential hazards before servicing equipment.

• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the

condition of these circuits, especially wiring).

• Use care when removing or replacing covers; avoid contacting circuits.

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Handling Batteries

• To direct attention to the possible source of danger from battery gases, post one or

more warning signs, lettered in large characters, in a conspicuous location near the battery. For example:

• Fully brief anyone who is permitted access to battery areas on the hazards of handling

lead-acid batteries. Make it clear to anyone handling, unpacking, or installing leadacid batteries that they contain electrolyte (sulfuric acid and water). Everyone must wear protective equipment such as rubber gloves, rubber aprons, full face mask, and splash-proof goggles when performing any activity involving handling of batteries or cells containing electrolyte.

• A storage battery gives no indication by its appearance of the potential energy stored

in it. All lead-acid storage cells/batteries have enormous short circuit capability which can result in serious burns. Use extreme care to avoid shorting out cell and/or battery terminals. Shorting a cell or battery with a non insulated tool can vaporize or throw the tool.

• All lead-acid batteries generate hydrogen gas, even under open circuit conditions. If

not permitted to escape, this gas can build up to explosive concentrations. NEVER tamper with or block the vent caps of the batteries. A damaged gas vent cap could become clogged, resulting in an explosion due to internal pressure. Such an explosion could short circuit other battery modules and result in a fire. ALWAYS place batteries in a well-ventilated area. NEVER place battery modules in a sealed environment.

• In case of electrolyte contact with the skin, remove the electrolyte immediately by

flushing the affected area with large amounts of plain tap water. In case of electrolyte in the eye, pour water into the inner corner of the eye and allow at least one quart of water to run over the eye and under the eyelid. Eye injuries should be treated by a physician immediately.

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Special Installation Notes

Deutsch

Installationsanleitung

Eingangsspannung ( Voltage ) :+24, -48 Eingangsstrom ( Current ) : Max 1200A Eingangsleistung ( Watts ) : Nennfrequenz ( Frequency ) : 50 / 60 Hz

Seriennummer ( Assembly No. ):-Modellnummer (Model No. ) : Infinity NE

Abmessungen sind nur zur Referenz : 660mm x 533.4mm x 2133.6mm ( Dimensions are for reference only )

Max. Umgebungstemperatur : max. 45 deg. C ( Max. Operation temperature )

Achtung: Für kontinuierlichen Feuerschutz sollte die Sicherung nur mit einer des gleichen Types ersetzt werden. Sicherungswert : ( Warning : For continued protection against fire replace with same type and rating of fuse )

Das System ist ein Gerät der Schutzklasse I / Überspannungs Kategorie II ( Power Supply is a Class I equipment / overvlotage category II )

Ausgangsspannungen und -stöme: DC 58 V / SELV ( Output Voltage and Current )

--Das Gerät darf nur in Räumen mit beschränktem Zutritt aufgestellt werden. ( Nur ausgebildetes Personal )

--Nur für Aufstellung auf Boden oder einer anderen brennbaren Oberfläche geeignet.

--Das Gerät hat keinen eigenen Ausschalter, es muß daher mit einem Ein- und Ausschalter im Versorgungskreis versehen sein.

--Das Gerät ist für den Einbau in IT- Geräte in einem Rahmen bestimmt (siehe weitere Anleitung)

--Beim Einbau des Gerätes ist daraf zu achten das alle Anforderungen gemäß EN60950 eingehalten werden.

ACHTUNG: HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKR EIS UNBEDINGT ERDUNGSVERBINDUNG HERSTELLEN

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Español

Notas especiales para instalaciones en países que hablan español.

• Instrucciones de instalación

(Installation Instructions)

• Voltaje (Voltage):

+24, -48

• Corriente (Current):

Max 1200 A

• Frecuencia (Frequency):

50/60Hz

• Voltaje y corriente de salida (Output Voltage and Current):

• Temperatura máxima de operación (Maximum Operation Temperature):

45°C (113°F)

• Sin cabina contra incendios, suelo no combustible

(No fire enclosure, non-combustible floor)

• Evaluado en EN60950

(Evaluated to EN60950)

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UL Ratings as reflected in the UL Report in May 2009. Please note the available rectifier output is reduced from the nameplate rating when converters are introduced to the system.

ELECTRICAL RATING:

J2008001

Model

H2007001 Type A(+)

H2007001 Type B(+)

H2007001 Type C(+)

H2007001 Type D(+)

(+) May be followed by –SD. When followed by –SD, the AC input will be up to 16 or 8 feeds rated:

(16)x 15 amps each feed or (8)x 30 amps each feed.

(++) The marked output voltage may be any voltage range or specified voltage as long as it is within

the range specified in the electrical rating table.

(+++) Maximum 45°C ambient for output rating not exceeding 960A charge and 1200A discharge.

Otherwise, 40°C ambient. The secondary (converter) input is a load for the primary (rectifier) output. This must be considered when loading the plant to its maximum rated primary output.

Battery

Panel L001, L002, L005, or L006 L003, L004, L007, or L008

L001, L002, L005, or L006

L003, L004, L007, or L008

L001, L002, L005, or L006 L003, L004, L007, or L008

L001, L002, L005, or L006

L003, L004, L007, or L008

V (50/60Hz) Current Vdc (++) Max Current(+++) Max Power

200-240 (up to 28 feeds)

Input (ac) Output (dc)

640A charge 800A discharge

15 A draw 22 – 29

1280A charge 1600A discharge

Primary:

15 A draw

15 A draw 44 – 57

15 A draw

22 – 29

Secondary: 48 – 54.5

Primary: 22 – 29

Secondary: 48 – 54.5

Primary: 44 – 57

Secondary: 24–27.25

Primary: 44 – 57

Secondary: 24–27.25

Primary: 640A charge 800A discharge Secondary: 120A Primary: 1280A charge 1600A discharge Secondary: 120A

640A charge 800A discharge

1280A charge 1600A discharge

Primary: 640A charge 800A discharge Secondary: 300A Primary: 1280A charge 1600A discharge Secondary: 300A

17,500 W

34,985 W

17,500 W maximum combined output

34,985 W maximum combined output

34,880 W

69,760 W

34,880 W maximum combined output

69,760 W maximum combined output

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DC DISTRIBUTION PANEL OVERCURRENT-PROTECTION DEVICE

CONFIGURATIONS

Shelf(+)

Maximum

Amps(++),(+++)

Manufacturer Series Rating(+++++)

Airpax

Circuit Breakers

LMLK,

LMLHPK

3-70A 1-pole

100A 2-pole 150A 2-pole 250A 3-pole

Comments

Cumulative adjacent circuit breaker ratings cannot exceed 250A.

6 fuse holders –

J2007002

(+) - Includes all List options. (++) - Maximum amps that the distribution section of the shelf is rated. Power supply output may be

(+++) - Plant ratings that exceed 640A charge and 800A discharge: top shelf adjacent to battery panel

(++++) - The J2007002 L051 shelf option is ten additional bullet-breaker positions located on right side

(+++++) - Plant ratings that exceed 640A charge and 800A discharge: top shelf adjacent to battery panel

400 charge 500 discharge

Lineage Power

rated less.

shall not exceed 336A charge and 400A discharge.

of shelf.

shall not use either a 150A 2-pole or 250A 3-pole circuit breaker.

QSGMT6

J2007002

L005

(++++)

57.6A total; 15A

rated fuse/position

3-70A 1-pole

100A 2-pole

R/C (QPQY2/8); uses R/C fuse (JDYX2) by

SOC, Type AX1 or

Cumulative circuit

breaker ratings cannot

exceed 200A.

POWER SUPPLIES ALLOWED

Power Supply Model(#) Type Manufacturer Certification NE075AC24 rectifier NE030DC48 converter NE100AC24 rectifier NE050AC48 rectifier NE075DC24 converter (#) - May be provided with a non-safety affecting suffix.

IN H2007001 POWER DISTRIBUTION CENTER

Lineage Power

R/C (QQGQ2/QQGQ8)

AX1-B

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4. Installation

Preparation

Safety

Please review all safety warnings in Section 3 before beginning the installation process. Observe all warnings and labels on the equipment.

WARNING: Due to the possibility of working on energized circuits during these procedures, all tools and test equipment must be insulated in an approved manner. Proper ESD protection is required in order to prevent ESD damage to the equipment.

WARNING: Only qualified personnel should install and service the power system and plug-in modules. Hazardous energy and voltages are present in the unit and on the interface cables and will shock or cause serious injury or death if safety precautions are ignored. Follow all safety warnings and practices when servicing this equipment.

Installation Sequence

1. Anchor the Frame

2. Ground the Framework

3. Install Batteries

4. Connect ac Utility

5. Connect Central Office Ground

6. Connect External Battery Cables

7. Wire -48 V dc loads and circuit breakers

8. Wire +24 V dc loads and circuit breakers

9. Install Rectifiers and Converters

10. Install Battery Instrumentation

Wiring Guidelines

• All electrical connections should be made using the proper crimping tools and dies

and should be torqued to values specified.

• All building wiring should comply with the NEC and other applicable local codes.

• The temperature rating of the wire must be 90°C minimum. Wire gauge must be

sized based on 75°C wire and the ampacity of the associated branch-circuit protection.

• Wiring internal to enclosed equipment cabinets must be rated no less than 105°

Celsius.

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Packaging

• All packages should be opened with a box cutter with the blade minimally exposed so

that only the sealing tape is cut.

• Save all packaging material until the system has been powered up and all parts are

operating within specifications

Installation Tools

You will need the following tools to install and test the Infinity D.

• Wire cutters and strippers

• Heat shrink gun

• 5/16-inch (8 mm) hex driver

• Digital meter with an accuracy of

±0.02%

• Screw drivers (flat-blade and

Phillips)

• ESD wrist strap

• 48 or/and 24V test load

• Calibrated clamp-on dc current

meter (0.1 ADC sensitivity)

• Torque wrench

• Socket wrenches:

• 7/16” and 9/16” for load and

battery connections;

• 19 mm for anchor bolts;

• 12" extension for socket

• Masonry drill kit as required

• Compression for installation of

various compression lugs

• Protective canvas

• Insulating rubber mat

• Standard insulated installation tools,

screwdrivers, etc.

• Required Insulated Tool Kit 1000v

DC Telecom set to include ESD protection

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Anchor the Frame

Floor Mounted Frames

Mount the selected frame securely to the floor using floor anchors rated for the Seismic Zone of the site. We sell a floor anchor kit (847135688) with 4 Hilti 12mm Cap bolts that may be appropriate for the frame you have selected.

Step Action

Mark floor using template, frame itself, or measurements in Appendix B if 26” frame selected.

Drill anchor holes.

2. Caution: Follow safe floor drilling procedures to prevent possible asbestos exposure.

Place frame and install floor anchors according to manufacturer requirements.

Battery or Battery Stand Mounted Half- and Third-Height Frames:

Step Action

Place and secure frame to battery or battery stand per instructions provided with the battery

stand or adapter.

Ground the Framework

Connect Frame Ground

Step Action

Select a Frame Ground landing on the top cross rail of the frame, or on the bottom or the rack

rails depending on frame and site parameters.

Remove covering tape and clean. If required by local code or practice, treat with an oxidation

inhibitor such as NO-OX.

Secure Frame Ground connection

Use 7/16” socket. Torque to 65 in·lbs. (7 Nm)

Battery or Battery Stand Mounted Frames:

If required by local code or practice, battery or battery stand mounted frames may be grounded to the frame or chassis of the other equipment. Select a Frame Ground landing at the side of the frame and clean.

Step Action

Select a Frame Ground landing at the side of the frame and clean.

Remove covering tape and clean. If required by local code or practice, treat with an oxidation inhibitor such as NO-OX.

Secure Frame Ground connection.

Use 7/16” socket. Torque to 65 in·lbs. (7 Nm)

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Infinity D Power System Installation Guide: -48V Plants H2007001

Install Batteries

WARNING: All batteries contain hazardous electrical energy. Lead-acid batteries contain sulfuric acid and explosive hydrogen gas. Follow all precautions noted in the literature accompanying the batteries. Use only insulated tools.

CAUTION: Equipment frame anchoring, load rating, and seismic zone rating should be verified before field installing trays and batteries.

Installing External Batteries

Step Action

Place batteries on battery trays, battery stands, or other satisfactory supporting surface and

interconnect per manufacturer’s instructions to create 48V strings as required.

Yes - physically mount switch to an

appropriate place and ensure it is in the OFF position prior to making any connections.

Connect the battery hot conductor(s) to the line side of the disconnect switch and torque

connection per manufacturer's specification. Connect the load side conductor to the disconnect switch and torque connection per

manufacturer's specification.

Is an external disconnect switch being used?

No – Finished.

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Infinity D Power System Installation Guide: -48V Plants H2007001

Mount the Subframe System to the Frame or Cabinet

The Infinity D is provided in integrated Subframes. Each Subframe contains one Battery Connection Module, one Pulsar Controller and one or more Rectifier System Modules. Converter System Modules are not required to have a valid system and are

typically on the bottom of the power equipment stack in any given Subframe. Step 1 below shows the elements included in the smallest valid Subframe.

Step Action

Mount the Subframe to the rack.

Use the fasteners and torque values provided by the frame supplier to secure flanges on the right

and left hand frame rails. Use at least 2 rack screws per side for each element in the Subframe. This Subframe requires at least 8 rack screws.

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Infinity D Power System Installation Guide: -48V Plants H2007001

Wire the Subframe

Identify Areas for Each Type of Wiring

The Infinity D is designed for overhead wiring.

Step Action

Look at the framework from the top.

Location

for

1” AC

Conduit

Drop

Battery Hot

Terminations

TOP VIEW

Alarm & Control

[secured near door hinge]

Infinity D Framework – Top View

Address: CO Grounding, AC wiring, Battery wiring, DC wiring and Alarm & Control wiring.

CO Ground (RTN)

DC Distribution

Battery Return Terminations

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Infinity D Power System Installation Guide: -48V Plants H2007001

Connect ac Utility

Circled below is the part of the Block Diagram to be wired first.

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Infinity D Power System Installation Guide: -48V Plants H2007001

WARNING: Disconnect all ac branch circuits prior to making ac connections to the system. When connecting to utility source, ensure compliance to all local and national wiring rules.

There are only 2 options for AC wiring: Four 20A AC circuit breakers per shelf or two 40A AC circuit breakers per shelf .If you have 4 AC circuit breaker per shelf, one for each of the rectifier positions, start at step 1 here. If you have 2 AC circuit breakers per shelf, one AC circuit

breaker for each pair of rectifiers, skip this procedure and go to the next procedure in this section.

Step Action

Loosen the screws that secure the AC

wiring cover.

Loosen Screws

Remove the AC wiring cover.

Remove the conduit knockout.

At the AC service panel install a 20A double pole circuit breaker for each rectifier position. Choose

the breaker size according to code for the wire type and environmental conditions for your site. Use 10 AWG wire for each rectifier.

Route two wires for each active rectifier position through 1 inch conduit and fitting, up to a total of

8 active wires and one ground (PE), into the AC wiring compartment. Terminate the PE (ground) wire to the

chassis using a double hole lug (on 5/8 inch centers) with a UL accepted crimp and tool.

Terminate Ground Wire

Illustration of

wiring flow

through conduit

hole

Torque ground lug nuts to 65 inch·lbs or 7N·m using a 7/16 inch socket wrench.

Strip 0.32 inches (8 mm) of insulation off the end of each AC wire.

Examine the AC input terminal block provided in your shelf. Is the terminal block of single level

configuration similar to that shown in the figure above?

Issue 2.0, June 3, 2009 28

+ 64 hidden pages

GE Industrial Solutions H2007001 G21 User Manual

Infinity D Power System

Table of Contents

1. Introduction

Customer Service Contacts

2. Product Description

3. Safety

Safety Statements

Warning Statements and Safety Symbols

Precautions

Handling Batteries

Special Installation Notes

4. Installation

Installation Sequence

Anchor the Frame

Ground the Framework

Install Batteries

Mount the Subframe System to the Frame or Cabinet

Wire the Subframe

Connect ac Utility