LiteOn PF-2223-1 User Manual

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3-Phase 22.5kW Power Supply System

USER GUIDE

PF-2223-1-UG-01 Page 1 of 12 June 2015

USER GUIDE

PF-2223-1

3-Phase 22.5kW Power System

© 2015 Copyright Lite-On Technology Corporation ALL RIGHTS RESERVED. Lite-On is a trademark of Lite-On Technology Corporation, registered in the United States and other countries. This document may contain inaccuracies and typographical errors. Lite-On cannot be held responsible for any errors or omissions contained in this document. All content is provided “As Is” and “As Available”. Lite-On reserves the right to correct errors or omissions in this document. Other brand names mentioned herein are for identification purposes only and may be the trademarks of their respective holder (s). Specifications and data are subject to change without notice.

Contents

Introduction ...................................................................................................................................................... 3

General Safety .................................................................................................................................................. 3

Required Tools for Installation and Maintenance ............................................................................................ 3

Unpacking and Checklist ................................................................................................................................... 3

Equipment Inspection ....................................................................................................................................... 4

Power Shelf and Rack Preparations .................................................................................................................. 4

Shelf Support Brackets Installation ............................................................................................................ 5

Linking Bus Bar Installation ........................................................................................................................ 5

Power Shelf Installation .................................................................................................................................... 5

Cable and Wire Installation .............................................................................................................................. 6

Output Power Connections ........................................................................................................................ 6

Input Power Connections ........................................................................................................................... 6

C13 Receptacle Connections ...................................................................................................................... 7

Power Supply Unit Installation and Removal ................................................................................................... 7

Power Supply Unit LED Status .......................................................................................................................... 8

Shelf Controller Installation (Optional) ............................................................................................................. 9

Battery Backup System Installation (Optional) ............................................................................................... 10

Warranty ......................................................................................................................................................... 11

Related Documentation .................................................................................................................................. 11

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USER GUIDE

PF-2223-1

3-Phase 22.5kW Power System

Indicates highly-dangerous consequences such as fire, serious injury, or death when failing to comply with the instructions.

Indicates dangerous consequences such as moderate injury or equipment damage when failing to comply with the instructions.

Introduction

The 22.5kW Power System is a 3-phase, 10-slot chassis with 2.5KW Power Supply Units (PSUs) that provides stable DC output power (12.5VDC / 1800A). This 21-inch power system uses up to 10 high-power, hot-swappable PSUs for flexibility in full power or redundant operation. For more information about the

22.5kW Power Shelf, refer to the Lite-On 22.5kW Power Shelf Datasheet.

The 2.5kW PSUs efficiently supply both main output DC power and standby DC power from either AC or DC sources. These compact PSUs provide 2.5kW, 12.5V / 200A for main power output and 30W, 12V / 2.5A for standby power applications. In addition, they support PMBUS 1.2 with boot loader, LED status indicators, and circuit protection features. For more information about the 2.5kW PSU, refer to the Lite-On 2.5kW Power Supply Unit Datasheet.

This user guide provides instructions to install and use the 22.5kW Power System. For instructions on initial startup, refer to the Lite-On 3-Phase 22.5kW Power Supply System Startup Guide.

General Safety

This user guide uses the safety conventions described below. Ensure that you follow the safety instructions in this guide and observe its directives to protect you from injury and to protect your equipment from damage.

WARNING

Caution

Required Tools for Installation and Maintenance

The following tools are required for installing and maintaining the Power System.

• #2 and #3 Phillips screwdrivers

• Flat blade screwdriver

• T-20 star driver for input power connector

• 10mm and 13mm wrenches for connecting linking bus bars

• Digital Multimeter (DMM) for testing and verifying power

• Torque driver to tighten connectors and cables

Unpacking and Checklist

Carefully unpack the rack, Power Shelf, and Power Modules and move them to the staging area for assembly. It is recommended that you keep the packaging in case equipment needs to be returned to the supplier.

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A least two people are required to remove the rack from its shipping container to ensure that the rack stays upright and does not fall on personnel.

The following tools are required for unpacking.

• Screwdriver for removing screws from rack packaging

• Wrench for removing bolts from rack packaging

• Crowbar for opening wooden boxes (if nailed)

• Box cutter or utility knife for opening cardboard packaging

WARNING

To unpack the rack from its shipping crate:

1. Remove the front panel from the shipping crate.

2. Remove any shipping bolts from the rack that hold the rack to the crate.

3. If necessary, remove any shipping blocks or straps from around the rack.

4. If necessary, raise the leveling feet to their highest position.

5. Secure a ramp to the front of the crate.

6. Using two or more people, carefully roll the rack out of the crate and down the ramp.

7. Inspect the rack to ensure that it was not damaged during shipping.

To unpack items from cardboard shipping boxes:

1. If necessary, remove any shipping straps from around the box.

2. Place the box upright and cut through the tape on the top of the box.

3. Remove the item(s) from the box along with any shipping foam if necessary.

4. Remove the item(s) from any shipping foam or wrapping material.

After all items have been unpacked, verify that you have received all the items as specified by the shipping paperwork.

Equipment Inspection

After unpacking the equipment, inspect it for damage that might have resulted from shipment. Check for the items below and contact the shipper in the unlikely event that damage is found.

• Bent connectors, alignment pins, or chassis

• Any cracks or chips on plastic components

• Unusual scratches or marks

• Dents in sheet metal or panels

• Corrosion or evidence of water or chemical damage

• Indications that the device was dropped

• Loose parts inside the equipment

Power Shelf and Rack Preparations

These instructions assume that the rack has been moved into place and is installed properly. If necessary, refer to the Lite-On 21-inch Open Compute Project compliant Rack User Guide for more information about installing the 21-inch OCP rack.

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3-Phase 22.5kW Power System

If the Linking Bus Bars are color coded, ensure that they are installed on the correct bus that corresponds with its color.

To prevent risk of electrical shock to personnel, ensure that power is not activated inside

verify that electrical power is turned off to the rack.

The Power Shelf slides into a 21-inch OCP rack and is supported in the rack by shelf support brackets. If the Shelf Support Brackets are not already installed in the rack, follow instructions “Shelf Support Brackets Installation” on page 5 to install the brackets.

Before the Power Shelf is installed into the rack, Linking Bus Bars are loosely installed on the rear of the Power Shelf; they are tightened after the Power Shelf is mounted into the rack. Follow instructions “Linking Bus Bar Installation” on page 5 to install linking bus bars.

Shelf Support Brackets Installation

The weight of the power shelf is supported in the rack by two Shelf Support Brackets. Each bracket is held in place by four M6 x 12mm self-threading screws.

To Install the Shelf Support Brackets:

1. Place a Shelf Support Bracket in the correct position in the rack and loosely attach it to the shelf

with four M6 screws.

2. Place the other Shelf Support Bracket in the correct position in the rack and loosely attach it to the

shelf with four M6 screws.

3. Torque all Shelf Support Bracket screws to 6.1 N-m (4.5 ft-lbs).

Linking Bus Bar Installation

Linking Bus Bars are installed, but not tightened, to the output power connectors on the rear of the Power Shelf before it is mounted into the rack. After the Power Shelf is installed in the rack, the other ends of the Linking Bus Bars are connected to the rack bus bars and their bolts are tightened then. Linking Bus Bars may be color coded: red for +12V and black for ground.

Caution

To Install Linking Bus Bars to the Power Shelf:

1. With four M8 x 15mm SEMS bolts, install a Linking Bus Bar to an output power bus bar on the

Power Shelf, but do not tighten the bolts. These bolts will be tightened later after the Power Shelf is mounted into the rack.

2. Install the remainder of Linking Bus Bars to the bus bars on the Power Shelf, but do not tighten the

bolts. The Power Shelf is now ready to be installed into the rack.

Power Shelf Installation

After the Shelf Support Brackets are installed into the rack and the Linking Bus Bars are installed on the rear of the Power Shelf, it can be installed into the rack.

WARNING

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the rack while installing equipment. Use a DMM to test any potentially live wires and

USER GUIDE

PF-2223-1

3-Phase 22.5kW Power System

The Power Shelf with Linking Bus Bars weighs more than 50 pounds. Use two or more people to move the Power Shelf and to install the Power Shelf into the rack.

Two people are required to install the Power Shelf with its installed Linking Bus Bars into

the other person guides the Linking Bus Bars in place from the rear of the rack.

To prevent risk of electrical shock to personnel, ensure that power is not activated when

electrical power is turned off.

Caution

To Install the Power Shelf into the Rack:

1. Carefully lift the Power Shelf with its Linking Bus Bars and move it into the rack on top of the Shelf

Support Brackets.

Caution

2. Push the Power Shelf into the rack until the latch brackets connect into the matching slots in the

front of the rack. Ensure that the Linking Bus Bars are properly aligned to the rack bus bars.

the rack. One person pushes the Power Shelf into the rack from the front of the rack and

Cable and Wire Installation

After the Power Shelf is installed into the rack, it can be connected to rack bus bars.

Output Power Connections

Output power from the Power Shelf is connected to the rack bus bars via Linking Bus Bars. At this point in the installation, the Linking Bus Bars should already be connected to the Power Shelf bus bars, but not yet tightened. The steps below describe how to install the remaining bolts for the Linking Bus Bars.

To install the output power connections (linking bus bars):

1. Using four M8 x 15mm SEMS bolts for each Linking Bus Bar, connect each Linking Bus Bars to its

corresponding bus bars in the rack. Do not tighten them yet.

2. After all Linking Bus Bars have been installed with four M8 x 15mm SEMS bolts on each end,

torque the bolts on both ends of the Linking Bus Bar to 17 N-m (12.5 ft-lbs).

Input Power Connections

The Power Shelf accepts 3-phase power from a Phoenix Contact PC 35 HC connector. The connector is secured to the Power Shelf by two screws that mate with the connector.

WARNING

The power input connector in the Power Shelf is shown below. Use this as a guide when installing wires to the matching Phoenix Contact PC 35 HC input connector.

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wiring the power connector. Use a DMM to test any potentially live wires and verify that

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3-Phase 22.5kW Power System

C13 Receptacles

(as viewed from rear of Power Shelf)

Phase A Input Power

Left three C13 receptacles (same voltage as Phase A)

Phase B Input Power

None

Phase C Input Power

Right three C13 receptacles (same voltage as Phase C)

C13 receptacle voltage is the same as the input voltage to the Power Shelf (phase A or

manufacturer.

To install input power connectors:

1. Install the wires into the Phoenix Contact PC 35 HC connector according to local wiring standards

and in accordance to the 3-phase electrical configuration (delta or wye connection) of your system.

2. Torque the wiring set screws to 4 N-m (3.0 ft-lbs).

3. If this is the first time that the Power Shelf is powered up, do not attach the power connector to

the Power Shelf yet. Refer to the Lite On 3-Phase 22.5kW Power System Startup Guide for initial startup instructions.

C13 Receptacle Connections

There are six C13 receptacles on the rear of the Power Shelf that provide single-phase AC power output. As viewed from the rear of the Power Shelf, the left three C13 receptacles receive power from Phase A (L1) and the right three C13 receptacles receive power from Phase C (L3).

Caution

If necessary, connect devices to one or more of the C13 receptacles. Each set of three C13 receptacles are protected by a 20A circuit breaker.

phase C). Ensure that any device you plug into a C13 receptacle can support this voltage. If you are unsure if your equipment can support this voltage, check with the

Power Supply Unit Installation and Removal

The Power Shelf supports up to ten hot-swappable Power Supply Units (PSUs). A PSU can be plugged into any slot in the Power Shelf and they are keyed so they cannot be inserted incorrectly. The 3-phase AC input power is distributed as shown in the table below.

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3-Phase 22.5kW Power System

Power Shelf Slots

(as viewed from front of Power Shelf left to right)

PSU1-A

PSU3-A

PSU1-B

PSU4-B

PSU1-C

PSU3-C

Spring Latch

Phase A Input Power

Phase B Input Power

Phase C Input Power

If all 10 slots in the Power Shelf are not used, populate the appropriate slots so that each phase has an equal number of PSUs or is within 1 PSU of the max on a single phase. For example, if a total of 7 PSUs are used, then the phase breakout should be 3, 2, and 2. Cover any unused slot with a provided slot cover. Also, consider the load on the C13 receptacles when balancing phases.

As shown below, PSUs are held in place with a spring latch.

PSU2-A

PSU2-B PSU3-B

PSU2-C

To install a Power Supply Unit:

1. Slide a PSU into an empty slot of the Power Shelf until it clicks into place. Both lights on the PSU

illuminate green to indicate that it is operational. Refer to “Power Supply Unit LED Status” on page 8 for more information on the PSU LED status.

2. Slide the remaining PSUs into the empty slots in the Power Shelf until they click into place.

To remove a Power Supply Unit:

• Lift the spring latch on the front of a PSU, pull the handle, and slide the PSU out from the Power

Shelf.

Power Supply Unit LED Status

Under normal operating conditions, both indicator lights LED 1 and LED 2 illuminate solid green; the table below shows other LED combinations and status.

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3-Phase 22.5kW Power System

Status

LED 1 (Input) Green Color

LED 2 (Output) Bicolor

AC_LOSS

Off

Vin_OV_Fault

Off

Vin_UV_Fault

Off

AC_Normal

Solid Green

ALL_Normal

Solid Green

Vout_OV_Warning

Solid Green

Blink Green

Vout_UV_Warning

Solid Green

Blink Green

Iout_OC_Warning

Solid Green

Blink Green

OT1_Warning

Solid Green

Blink Green

OT2_Warning

Solid Green

Blink Green

OT3_Warning

Solid Green

Blink Green

PSON

Solid Green

Blink Yellow

FAN_LOCK

Solid Green

Solid Yellow

Vout_OV_Fault

Solid Green

Solid Yellow

Iout_OC_Fault

Solid Green

Solid Yellow

OTP_Fault

Solid Green

Solid Yellow

Vout_UV_Fault

Solid Green

Solid Yellow

LATCH_SD

Solid Green

Solid Yellow

SCP_Fault

Solid Green

Solid Yellow

STB_UV_Fault

Solid Green

Solid Yellow

STB_OV_Fault

Solid Green

Solid Yellow

STB_OCP_Fault

Solid Green

Solid Yellow

STB_OTP_Fault

Solid Green

Solid Yellow

LED 1 Input Power

LED 2 Output Power

Shelf Controller Installation (Optional)

While optional, the shelf controller is necessary for system communication to the power system created by the power shelf along with a battery shelf. The shelf controller is an integral part of a complete DC UPS system with communication capabilities. It provides communication to the Lite-On Site Monitoring Controller (SMC) or other monitoring software for information and/or event-based responses.

On the front of the power shelf is a slot for the Shelf Controller. As shown below, a Shelf Controller is held in place with a spring latch.

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3-Phase 22.5kW Power System

To prevent risk of electrical shock to personnel, ensure that power is not activated when

power is turned off to the rack.

Spring Latch

Shelf Controller Slot

To install a Shelf Controller:

• Slide the Shelf Controller into the Shelf Controller slot of the Power Shelf until it clicks into place.

The green LED on the Shelf Controller illuminates to indicate normal operation.

To remove a Shelf Controller:

• Lift the spring latch on the front of the Shelf Controller and slide it out from the Power Shelf.

Battery Backup System Installation (Optional)

The optional Battery Backup System (BBS) is a separate shelf with multiple slots for Li-ion Backup Battery Units (BBUs) that provides DC backup power for the Power System.

WARNING

To install the Battery Backup System:

1. Ensure that power is turned off to the rack.

2. Place a BBS Support Bracket in the correct position in the rack and loosely attach it to the shelf

with two M6 x 12mm self-threading screws.

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installing the BBS. Use a DMM to test any potentially live wires and verify that electrical

USER GUIDE

PF-2223-1

3-Phase 22.5kW Power System

3. Place the other BBS Support Bracket in the correct position in the rack and loosely attach it to the

shelf with two M6 x 12mm self-threading screws.

4. Torque the screws to 6.1 N-m (4.5 ft-lbs).

5. Slide the BBS into the rack.

6. Using two M8 x 18mm SEMS bolts, connect each BBS bus bar to corresponding bus bars in the

rack.

7. Torque the bus bar bolts to 17 N-m (12.5 ft-lbs).

8. Connect a supplied BBS communication cable from the Power Shelf BBS port to one of the

communication ports on the BBS.

9. Turn on power to the shelf.

Warranty

If you experience any problems with your Lite-On equipment, contact Lite-On Power Systems Solutions at 1-469-331-9838.

LiteOn PF-2223-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual