Astec Advanced Power Systems
IM6C75AA
Helios Candeo Power System
AP6C75AA
Installation Manual
P0914426 Standard 3.00 March 2001
Astec Advanced Power Systems
A part of Emerson Network Power
Astec Advanced Power Systems
Helios Candeo Power System
AP6C75AA
Installation Manual
Document Number: IM6C75AA
Document Issue: 3.00
Document Status: Standard
Release Date: March 2001
P0914426
2001 Astec Advanced Power Systems Ltd.
All rights reserved
Printed in Canada
The information contained in this manual is the property of Astec Advanced Power Systems Ltd and is subject to change without
notice. Astec Advanced Power Systems Ltd reserves the right to make changes in design or components as progress in engineering
and manufacturing may warrant. Except as specifically authorized in writing by Astec Advanced Power Systems Ltd, the holder of
this manual shall keep all information contained herein confidential and shall protect same, in whole or in part, from disclosure and
dissemination to all third parties, and use the same for installation purposes only. Changes or modifications not expressly approved
by the party responsible for compliance could void the user’s authority to operate this equipment.
Astec Advanced Power Systems
A part of Emerson Network Power
Helios, Helios Candeo, Advanced Power Systems and the Helios Candeo logo are trademarks of Astec International Ltd. The
Emerson logo is a trademark and a service mark of Emerson Electric Co.
Helios Candeo Power System – AP6C75AA Installation Manual
5
Publication history
March 2001
Standard Issue 3.00. Revisions and improvements throughout the manual and
convert to latest Emerson template. (ECN102-25123)
January 2001
Standard Issue 2.0. Minor revisions throughout the manual and change from
Astec to Emerson identity.
December 2000
Standard Issue 1.0. General revision throughout to add latest information and
comments from field trial. The document is now rated Standard.
October 2000
Preliminary Issue 3.0. Third draft of this manual. General revision throughout to
add latest information.
August 2000
Preliminary Issue 2.0. Second draft of this manual. General revision throughout
for field trial purposes.
February 2000
Preliminary Issue 1.0. First draft of this manual for tech trial purposes.
Helios Candeo Power System – AP6C75AA Installation Manual
6 Publication history
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
7
Contents
1.
1.1.
1.2.
1.3.
1.4.
About this document
13
Purpose of this document............................................................................................ 13
Applicability of this document ..................................................................................... 13
How this document is organized .................................................................................. 16
Reference documents.................................................................................................. 16
2.1.
2.2.
2.3.
2.4.
Preparation
17
Installation overview ................................................................................................... 17
Tools and test equipment ............................................................................................ 17
Precautions ................................................................................................................. 18
Receiving the material................................................................................................. 20
2.
3.
Locating and erecting the frame(s)
21
3.1. General ....................................................................................................................... 21
3.1.1.
Isolation considerations.................................................................................. 21
3.1.1.1. Floor isolation pad..................................................................................... 21
3.1.1.2. Top isolation ............................................................................................. 21
3.1.2.
Waterproof floor considerations ..................................................................... 21
3.2. Locating the frame(s) .................................................................................................. 22
3.2.1.
Marking the floor............................................................................................ 22
3.3. Floor anchoring ........................................................................................................... 23
3.3.1.
Drilling the floor.............................................................................................. 23
3.3.1.1. Concrete floor........................................................................................... 23
3.3.1.2. Wood floor ................................................................................................ 24
3.3.2.
Standard concrete floor anchoring.................................................................. 25
3.4. Erecting the frame(s)................................................................................................... 25
3.5. Securing the frame(s) in place ..................................................................................... 27
Helios Candeo Power System – AP6C75AA Installation Manual
8 Contents
3.5.1.
Standard anchoring in a concrete floor ........................................................... 27
3.5.2.
Wood floor...................................................................................................... 28
3.5.3.
Earthquake anchoring..................................................................................... 29
3.5.4.
Raised floor.................................................................................................... 30
3.6. Securing adjacent frames............................................................................................ 31
3.7. Installing the interframe DC link bar between adjacent frames DC backbones ............. 32
3.8. Top support................................................................................................................. 35
3.9. Installation of frame earthquake bracing kit(s)............................................................. 36
3.10. Module installation ...................................................................................................... 37
4.
Cabling and connecting
39
4.1. General ....................................................................................................................... 39
4.1.1.
Basic ruling .................................................................................................... 39
4.1.2.
Connecting lugs.............................................................................................. 40
4.1.3.
Torque values for bolted connections ............................................................. 43
4.1.4.
Cabling layout ................................................................................................ 43
4.2. Cabling and connecting the grounding leads ................................................................ 45
4.2.1.
Connecting the power plant frame ground (or safety ground) lead(s)............... 45
4.2.2.
Connecting the power plant battery return reference (BRR) lead .................... 48
4.3. Cabling and connecting the AC supplies for the rectifiers ............................................ 49
4.3.1.
Segregation between AC conductors and other conductors ............................ 49
4.3.2.
Cabling and connecting the rectifier AC interface modules ............................. 50
4.4. DC cabling and connecting .......................................................................................... 54
4.4.1.
Segregation from AC cables ........................................................................... 55
4.4.1.1. Connecting the battery cables in the Battery Connection Module(s) .......... 55
4.4.1.2. Connecting the DC load cables.................................................................. 56
4.5. Miscellaneous cabling and connecting ......................................................................... 62
4.5.1.
Connecting the Remote Sense leads to the batteries ...................................... 65
4.5.2.
Connecting the alarms to the office alarm circuit............................................ 66
4.5.3.
Installing and connecting the temperature probes........................................... 67
4.5.4.
Connecting of the interframe data link cable(s)............................................... 69
4.5.5.
Connecting the uninterrupted DC supply leads................................................ 69
4.5.6.
Connections at the communication ports ........................................................ 70
4.6. Final connections at the batteries................................................................................ 70
5.
Start-up and adjustment procedures
73
General ....................................................................................................................... 73
Voltage levels.............................................................................................................. 73
Installation of the rectifiers on the frame(s)................................................................. 73
Initial start-up, testing and adjustment of the system.................................................. 75
5.1.
5.2.
5.3.
5.4.
IM6C75AA P0914426 Standard 3.00 March 2001
Contents 9
6.
End of job routines and turnover
77
6.1. General ....................................................................................................................... 77
6.2. Designation ................................................................................................................. 77
6.2.1.
Frame numbering............................................................................................ 77
6.2.2.
Rectifiers........................................................................................................ 78
6.2.3.
Distribution .................................................................................................... 78
6.3. Installing the top cover................................................................................................ 80
6.4. Installation of the optional cabinet look-alike covers and door ..................................... 80
6.5. Touch-up of damaged and/or scratched painted surfaces ............................................ 81
6.6. Equipment turnover ..................................................................................................... 81
Appendix A: Drawings
83
Appendix B: Recommended AC generator requirements for APS power systems
85
Appendix C: Recommended replacement parts
87
Appendix D: Technical service assistance
89
List of terms
93
List of Figures
Figure 1.1 – Perspective view of a typical top fed AP6C75AA Helios Candeo power system .... 14
Figure 1.2 – Perspective view of a typical bottom fed AP6C75AA Helios Candeo power
system ........................................................................................................................ 15
Figure 3.1 – Floor anchor marking pattern ................................................................................ 23
Figure 3.2 – Appropriate method of lifting a Helios Candeo frame by its top ............................. 27
Figure 3.3 – Assembly stack-up for standard concrete anchors ................................................ 28
Figure 3.4 – Assembly stack-up for wood floor anchors............................................................ 28
Figure 3.5 – Assembly stack-up for earthquake concrete anchors............................................. 30
Figure 3.6 – Typical methods of anchoring a frame on a raised floor......................................... 30
Figure 3.7 – Alternate method of anchoring the rods to the sub-floor........................................ 31
Figure 3.8 – Top view of the interframe linking plate ................................................................ 31
Figure 3.9 – Securing adjacent frames...................................................................................... 32
Figure 3.10 – Top view of an installed interframe DC link bar between adjacent frames DC
backbones (top or bottom fed)..................................................................................... 33
Figure 3.11 – Perspective view of a bottom installed interframe DC link bar between
adjacent frames DC backbones (top fed applications).................................................. 34
Figure 3.12 – Perspective view of a top installed interframe DC link bar between adjacent
frames DC backbones (bottom fed applications) .......................................................... 34
Figure 3.13 – Exploded view of the bolting material for the interframe DC link bar ................... 35
Figure 3.14 – Typical top support group for standard frames.................................................... 36
Helios Candeo Power System – AP6C75AA Installation Manual
10 Contents
Figure 3.15 – Special support group for isolated applications.................................................... 36
Figure 3.16 – Installation of the frame earthquake bracing kit .................................................. 37
Figure 4.1 – Typical cabling layouts for top-fed Helios Candeo power system installations ....... 44
Figure 4.2 – Typical installation of the power system frame ground lead .................................. 47
Figure 4.3 – Connection of the frame ground lead inside the frame ........................................... 47
Figure 4.4 – Typical installation of the power system battery return reference ground lead...... 48
Figure 4.5 – Typical conduit, AC box and channel installation for bulk wiring (top fed
applications only) ........................................................................................................ 51
Figure 4.6 – Typical layout of individual armored cables inside the frame upright...................... 51
Figure 4.7 – Typical layout of individual armored cables on the outside of the frame ................ 52
Figure 4.8 – Cabling and connecting the rectifier AC interface modules .................................... 52
Figure 4.9 – Connecting the battery cables inside a Battery Connection Module....................... 56
Figure 4.10 – Cabling and connecting inside a Distribution 500 module .................................... 58
Figure 4.11 – How to remove load clips .................................................................................... 59
Figure 4.12 – Setting the J2 jumper for standard or mid-trip circuit breaker alarm.................... 59
Figure 4.13 – Enlarged view of installed angle bracket for cables larger than 2/0 ..................... 59
Figure 4.14 – Typical cabling layout inside top-fed and bottom-fed Helios Candeo power
systems ...................................................................................................................... 60
Figure 4.15 – Typical method of tapping a riser cable to a larger cable for a large load............. 62
Figure 4.16 – Connector layout inside the System Manager (front cover open) ......................... 63
Figure 4.17 – Wiring layout on the Battery Connection Module................................................. 64
Figure 4.18 – Method of connecting the Remote Sense lead to the batteries ............................ 66
Figure 4.19 – Side view of a temperature probe ....................................................................... 67
Figure 4.20 – Locating a temperature probe for external battery temperature measurements ... 68
Figure 4.21 – Locating a temperature probe for ambient temperature measurements ............... 68
Figure 4.22 – Connections of the interframe data link cable(s).................................................. 69
Figure 5.1 – Perspective view of a rectifier with the locking latches in the open position.......... 74
Figure 6.1 – Typical stamping of AP6C75AA Helios Candeo frame(s) ....................................... 78
Figure 6.2 – Typical stamping on the label inside a Distribution Module .................................... 79
Figure 6.3 – Typical stamping tags for conductors.................................................................... 79
Figure 6.4 – Installation of the optional cabinet look-alike covers.............................................. 81
List of Tables
Table 4.1 – Flammability rating of wires and cables for the United States ................................ 40
Table 4.2 – Flammability rating of wires and cables for Canada ............................................... 40
Table 4.3 – Connecting facilities of the AP6C75AA Helios Candeo power system .................... 40
Table 4.4 – Two-hole connecting lugs....................................................................................... 41
Table 4.5 – Cable size equivalents (AWG to Metric) .................................................................. 42
Table 4.6 – Torque values for bolted connections ..................................................................... 43
Table 4.7 – Recommended cable size for the frame ground collector......................................... 46
Table 4.8 – Preferred cable sizes and quantities for the AC input supply of the rectifiers.......... 50
Table 4.9 – Terminal assignment of the J4 connector on the System Manager......................... 62
Table 4.10 – Terminal assignment of the J7 connector on the System Manager....................... 63
Table 4.11 – Terminal assignment of the J8 connector on the System Manager....................... 63
Table 4.12 – Terminal assignment of the TB1 to TB4 terminal blocks and J11 connector on
the Battery Connection Module ................................................................................... 64
IM6C75AA P0914426 Standard 3.00 March 2001
Contents 11
List of Procedures
Procedure 3.1 – Marking the floor for the anchor positions....................................................... 22
Procedure 3.2 – Drilling for the anchor positions in a concrete floor.......................................... 24
Procedure 3.3 – Drilling for the anchor positions in a wood floor .............................................. 24
Procedure 3.4 – Installing and setting standard anchors in a concrete floor .............................. 25
Procedure 3.5 – Lifting and locating a Helios Candeo frame at its final location........................ 26
Procedure 3.6 – Securing the frame(s) to a concrete floor using standard anchors (nonearthquake applications) ............................................................................................. 27
Procedure 3.7 – Securing the frame(s) to a wood floor ............................................................. 28
Procedure 3.8 – Securing the frames to a concrete floor with earthquake anchors................... 29
Procedure 3.9 – Installing the interframe DC link bar between adjacent frames DC
backbones................................................................................................................... 32
Procedure 4.1 – Installing and connecting the power plant frame ground leads......................... 46
Procedure 4.2 – Installing and connecting the battery return reference lead ............................. 49
Procedure 4.3 – Cabling and connecting the rectifier AC interface modules .............................. 53
Procedure 4.4 – Connecting the battery cables at the Helios Candeo power system................. 55
Procedure 4.5 – Connecting the distribution loads .................................................................... 61
Procedure 4.6 – Installing and connecting the Remote Sense leads........................................... 65
Procedure 4.7 – Installing and connecting the temperature probes............................................ 67
Procedure 4.8 – Connecting the battery string cables at the batteries ...................................... 70
Procedure 5.1 – Inserting the rectifiers in the frame ................................................................. 75
Procedure 6.1 – Installing the doorframe .................................................................................. 80
Helios Candeo Power System – AP6C75AA Installation Manual
12 Contents
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
13
1.
1.1.
About this document
Purpose of this document
This document provides detailed guidelines and procedures for the installation
of an AP6C75AA Helios Candeo power system.
This document is intended to be used by Astec Advanced Power Systems
installers, and non-Astec installers such as value added resellers and subcontractors, installing power equipment on behalf of Astec Advanced Power
Systems, as well as end users performing their own installation.
Note: Hazardous voltages are present in the AP6C75AA Helios Candeo
power system and the installation must be done by qualified personnel only. It
is strongly recommended that the installation personnel have basic power
installation training as is available from Astec Advanced Power Systems
(course No. M601).
1.2.
Applicability of this document
This document applies specifically to the initial installation of an AP6C75AA
Helios Candeo power system. For upgrades or modifications to an existing
AP6C75AA Helios Candeo power system, refer to the “Maintenance” Chapter
of user manual UM6C75A, or the specific method of procedure (MOP)
developed specifically for the project.
For installation guidelines applying to other equipment, refer to the applicable
Astec Advanced Power Systems manuals or, in the case of non-Astec equipment
(ex.: batteries), refer to manufacturer’s guidelines.
Specific Customer requirements may sometimes override the guidelines in the
present manual. In such cases, a written Customer agreement must be obtained.
The following illustrations show typical top fed and bottom fed AP6C75AA
Helios Candeo power systems.
Helios Candeo Power System – AP6C75AA Installation Manual
14 About this document
Figure 1.1 – Perspective view of a typical top fed AP6C75AA Helios Candeo power system
IM6C75AA P0914426 Standard 3.00 March 2001
About this document 15
Figure 1.2 – Perspective view of a typical bottom fed AP6C75AA Helios Candeo power system
Helios Candeo Power System – AP6C75AA Installation Manual
16 About this document
1.3.
How this document is organized
This document is divided into seven parts:
1)
2)
3)
4)
5)
6)
7)
1.4.
Front matters: contain the document information, the Table of Contents
and the present Chapter.
Preparation: describes the procedures when receiving, handling and
storing the equipment, the tools and test equipment requirements, and the
warning and cautions.
Physical installation: describes the procedures to install, level, align and
anchor the AP6C75AA Helios Candeo power system frame(s) and the
associated hardware.
Cabling and connecting: describes the procedures to cable and connect the
safety and reference grounds for the system, the AC supply for the
rectifiers, the batteries and the loads, as well as the wiring for the alarms
and the optional equipment such as battery disconnect unit(s).
Equipment start-up and adjustment procedures: describes the procedures
to insert the rectifiers and to bring the power system to a fully operational
state.
End of job routines and turnover: describes the items to be completed to
ensure that the equipment meets all applicable quality standards before it
is turned over to the Customer.
Appendices: provide information on drawings, Customer services,
technical support, and feedback form for the manual, as well as a list of
terms describing the acronyms and abbreviations used throughout the
document.
Reference documents
In addition to the present manual, it is recommended that the following
documentation be also available to perform the installation of the AP6C75AA
Helios Candeo power system:
• user manual UM6C75A, Description, Operation and Maintenance Manual
for the AP6C75AA Helios Candeo power system,
• user manual 167-7011-010, Voltage levels for controllers and rectifiers,
• other Astec Advanced Power Systems manuals as required, such as:
AP6C18MC/MD battery disconnect:
user manual UM6C18MC/MD
• all job specifications and drawings,
• other applicable manufacturer’s user guides (for example: batteries)
• specific Customer requirements and guidelines, if any.
IM6C75AA P0914426 Standard 3.00 March 2001
17
2.
Preparation
2.1.
Installation overview
The following is the recommended sequence for the installation and start-up
procedures. The sequence may change according to job and site conditions.
•
•
•
•
•
•
•
•
•
•
•
•
2.2.
Obtain the recommended tools and test equipment.
Read the "Precautions" section carefully.
Check that all the equipment and materials have been delivered.
Proceed with the physical installation of the power system frame(s).
Install and connect the safety and reference ground cables.
Install and connect the AC input cabling for the rectifier.
Install and connect the DC cabling between the AP6C75AA Helios Candeo
and the batteries.
Connect the loads to the Distribution Module(s) as required.
Install and connect the wiring for the optional equipment as required.
Install and connect the external alarm and monitoring wiring as required.
Insert the rectifiers in the rectifier frame(s).
Start-up, verify and adjust the complete system.
Tools and test equipment
The following tools and test equipment are required:
•
•
•
•
•
•
•
•
•
•
•
•
dolly truck
safety goggles
screwdriver, flat blade, 10 mm (3/8 in.)
screwdriver, flat blade, 2 mm (3/32 in.)
cable strippers/electrician’s knife
wire stripper
linesman pliers
hacksaw
cable cutters (up to 750 kcmil)
crimper and die set (up to T&B 15 ton head)
open end and box end wrench sets
socket set (12.5 mm [1/2 in.] drive)
Helios Candeo Power System – AP6C75AA Installation Manual
18 Preparation
•
•
•
•
•
•
•
•
•
•
•
•
2.3.
ratchet set (12.5 mm [1/2 in.] drive)
torque limiting wrench (10 mm [3/8 in.] drive)
canvas sheets, 1 m x 2 m (4 ft x 6 ft)
hammer drill
13 mm (1/2 in. [standard]) or 18 mm (11/16 in. [earthquake]) concrete bit
vacuum cleaner
Hilti HST 3/8” anchor setting tool
digital multimeter, Fluke 8050A or equivalent
clamp-on ammeter, Fluke 36 or equivalent
dry load bank, 48 V, 5 kW minimum
a portable computer equipped with modem and RS-232 ports
if two or more Helios Candeo frames are installed on your project, add a
large rubber mallet to the above list
Precautions
The following precautions shall be followed at all time when handling and
installing power equipment:
WARNING
Preventing electrical shocks
For safety reasons, the frame ground leads must always be
connected before any other leads. This is to prevent the
frame(s) and any other metallic structures from carrying
dangerous AC or DC voltage levels.
WARNING
Protecting the equipment against electrical damage.
Do not perform the final connecting of the battery leads to the
batteries before being instructed to do so in the appropriate
section of this manual.
WARNING
High Current Hazard
The rectifiers, and especially the batteries, can deliver high
current should a short to ground occur. When working on live
equipment, remove all personal jewelry, use properly insulated
tools, and cover any live busbars with a canvas sheet to prevent
short circuits caused by falling tools or parts.
IM6C75AA P0914426 Standard 3.00 March 2001
Preparation 19
WARNING
Protecting personnel against electrical shocks.
The power plant cabling shall be performed by qualified
personnel in conformance with local and national electrical
codes.
Input voltages to the rectifiers are at a dangerous level. Ensure
that the circuit breakers are locked in the OFF position at the
AC service panel before attempting to work on the power
plant. Dangerous voltages may still be present at the terminals
even if the rectifiers are OFF. Use a voltmeter to verify for the
presence of such voltages. Do not switch circuit breakers to
ON until the entire system has been assembled and that you
have been instructed to do so in the appropriate procedure.
Improper wiring can cause personal injury and equipment
damage. Verify for proper polarity of the battery leads before
connecting them to the power plant by clearly identifying the
positive and the negative leads.
CAUTION
Safety and equipment protection
Power equipment is heavy (pre-assembled frames, batteries,
etc.). Use a dolly truck, forklift, or hoist whenever possible for
handling and moving the equipment. If a forklift is used, do not
remove the shipping crates before the equipment has been
moved near its final installation location. If a dolly truck is used,
the shipping packages may be removed at the point of
reception. When handling frames with equipment mounted on
them, care must be exercised to ensure that they do not tip
over, as some of these are top heavy.
CAUTION
Protecting the equipment against damages when lifting
If a Helios Candeo frame needs to be lifted by its top for
moving or locating purposes, the appropriate hardware and
method described in the next Chapter must be used in order to
insure that no damages are caused to the top of the frame.
Helios Candeo Power System – AP6C75AA Installation Manual
20 Preparation
CAUTION
Protection of Customer premises
Protect the floors and walls against damage when handling the
equipment.
CAUTION
Preventing over torque damage
Do not over torque nuts and bolts. Over torquing causes the
threads to strip or the bolt to break. Use the appropriate torque
values indicated in each section.
CAUTION
Preventing personal injuries
When cutting material, always use the appropriate safety
equipment, such as gloves and goggles. Use a flat file to deburr
cuts.
CAUTION
Optimizing equipment life
To optimize the service life of this equipment, make sure there
are no obstructions in front of the ventilation openings.
2.4.
Receiving the material
The individual AP6C75AA Helios Candeo power system frames are shipped as
pre-assembled and pre-tested power frames, including the System Manager, the
rectifiers, the Battery Connection Module and the Distribution Module(s). Other
material such as the AC box, cables, wires, connecting material, fuses, and
mounting hardware are shipped separately.
Upon receiving the AP6C75AA Helios Candeo power system frame(s), System
Manager and rectifiers, remove the packaging and inspect for damage. Verify
that all material ordered is received and is in good condition. Report any missing
or damaged items to your Astec Advanced Power Systems Customer Services
department. Refer to Appendix D for the telephone number of the nearest
Customer Services department.
IM6C75AA P0914426 Standard 3.00 March 2001
21
3.
Locating and erecting the frame(s)
3.1.
General
This Chapter provides an overview of the requirements and procedures to be
followed when locating, erecting, aligning, leveling and anchoring the
AP6C75AA Helios Candeo power system frame(s).
3.1.1. Isolation considerations
In systems where ISG (isolated system ground) topology is used, hardware for
isolating the frame(s) from the floor is supplied per the specifications. It is
important that this isolation equipment be installed properly to preserve the
integrity of the isolated system ground system.
3.1.1.1. Floor isolation pad
The floor isolation pad is a sheet of isolating material that is inserted between
the floor and the bottom of the frame. Anchoring holes that match those of the
frame are provided in this isolation pad. The anchoring hardware also includes
special isolating washers and bushings. Refer to the anchor assembly stack-up
drawings in Figure 3.3 and Figure 3.5 further in this Chapter.
3.1.1.2. Top isolation
If the floor isolation kit is provided, it means that ISG topology is desired and
that the top of the equipment must also be kept isolated. If the top of the frame
is to be attached to the overhead structure (see section 3.8 further in this
Chapter), and if the overhead structure (auxiliary framing and cable racks) meets
ISG requirements, the top of the frame(s) may be attached directly to it with
metallic hardware. However, if the overhead structure does not meet ISG
requirements, special hardware shall be used to prevent electrical continuity
between the top of the frame(s) and the overhead structure.
3.1.2. Waterproof floor considerations
In locations where the natural water table is high, the building floor lying on or
in the ground may be of a special waterproof design to prevent water from
seeping through it.
Such floors must not be drilled for anchoring of the frame(s).
Helios Candeo Power System – AP6C75AA Installation Manual
22 Locating and erecting the cabinets
In non-earthquake areas, it may be permitted to locate the frame(s) on the floor
without floor anchoring. In earthquake areas, it may be necessary to pour a new
slab of concrete over the existing floor and to anchor the frame(s) into that new
slab.
At all times, it should be the Customer’s responsibility to provide the methods
and/or building modifications required for such applications.
3.2.
Locating the frame(s)
Use the floor plans and the specifications to determine where the AP6C75AA
Helios Candeo power system frame(s) will be located.
Note 1: There shall be a spacing of at least 6” (15 cm) between the back of
the Helios Candeo frame(s) and a wall or any other obstruction, this for
proper ventilation purposes.
Note 2: There shall be a spacing of at least 30” (75 cm) between the front of
the Helios Candeo frame(s) and a wall or any other equipment or obstruction,
this for safe and proper circulation of maintenance personnel.
Note 3: As mentioned in the previous Chapter, the AP6C75AA Helios
Candeo power system frames are shipped as pre-assembled and pre-tested
power frames, including the System Manager, the rectifiers, the Battery
Connection Module and the Distribution Module(s). Since it is required to
remove the rectifiers from the frame(s) in order to perform the AC input
cabling for the rectifiers per section 4.3.2 of Chapter 4, it is suggested to
remove all the rectifiers from the frame(s) now as this will lighten the frame
and thus ease the installation effort. Store the rectifiers in a safe location, and
do not reinstall these until told to do so in the appropriate section of this
manual.
3.2.1. Marking the floor
Use the template supplied with each Helios Candeo frame to mark the floor for
the anchor positions of the frame(s). Proceed as described in Procedure 3.1 and
as illustrated in Figure 3.1.
Procedure 3.1 – Marking the floor for the anchor positions
Step
1
2
3
Action
Use the floor plan to locate the template in the exact final position of the frame.
Use a marker pen to mark the floor for the anchor hole positions.
Repeat steps 1 and 2 for any other frame, if applicable.
–end–
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 23
Figure 3.1 – Floor anchor marking pattern
23.63”
2.00”
19.58”
16.15”
Preferred location for
the anchors
1.43”
12.15”
15.0”
Non-preferred location for
the anchors
Front
3.3.
Floor anchoring
Note: Floor anchoring requirements may be different where the equipment is
earthquake braced. Specific requirements for such applications shall be either
covered in the job specifications or provided by the Customer.
3.3.1. Drilling the floor
3.3.1.1. Concrete floor
For applications where concrete floor anchoring is used, drill the floor as
described in the following procedure.
CAUTION
Preserving the integrity of earthquake installations
If the application is earthquake but regular anchors were
provided in the specifications, do not use the latter since the
installation will not meet earthquake requirements. Approved
earthquake type anchors shall be ordered to complete the
installation as required to meet earthquake requirements.
However, if the application is non-earthquake but earthquake
anchors were provided in the specifications, the latter can be
used if standard anchors are not readily available, in order to
avoid time loss while waiting for standard anchors. The
earthquake anchors will only provide a stronger and better
support.
Helios Candeo Power System – AP6C75AA Installation Manual
24 Locating and erecting the cabinets
Procedure 3.2 – Drilling for the anchor positions in a concrete floor
Step
Action
1
Check with the customer and architect floor plans that there are no pipes,
conduits, beams or any other obstructions in the concrete slab that could
interfere with the drilling.
2
Place the inlet of a vacuum cleaner near the floor marking in such a way that it
will pick-up the dust while drilling the hole.
3
Start the vacuum cleaner.
4
Use a hammer drill equipped with the appropriate size masonry drill bit to drill
the hole; maintain the drill at a 90° angle with the floor.
Note 1: For standard anchors (HILTI HDI 3/8” or 10 mm) supplied with
Advanced Power Systems equipment, use a 1/2” (13 mm) drill bit.
Note 2: For earthquake anchors (HILTI HSL 11/16” or 18 mm) supplied with
Advanced Power Systems equipment, use an 11/16” (18 mm) drill bit.
Note 3: For standard anchors, the depth of the hole should be the length of the
anchor plus 1/8” (3 mm). For earthquake anchors, the depth of the hole should
be 4” (102 mm).
5
After drilling the hole, use the vacuum cleaner to clean all the dust in and
around the hole.
6
Repeat steps 2 to 5 for every anchoring hole for the frame.
7
Repeat steps 2 to 6 for any other frame, if applicable.
–end–
3.3.1.2. Wood floor
For applications where wood floor anchoring is used, drill the floor as described
in the following procedure.
Procedure 3.3 – Drilling for the anchor positions in a wood floor
Step
Action
1
Check with the customer and the architect floor plans that there are no pipes,
conduits, beams or other obstructions in the wood floor that could interfere
with the drilling.
2
Use a drill equipped with the appropriate size wood drill bit to drill the hole;
maintain the drill at a 90° angle with the floor.
Note: The size of the hole should be approximately 60% of the size of the lag
screw.
–continued–
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 25
3
After drilling the hole, use the vacuum cleaner to clean all the wood chips and
dust in and around the hole.
4
Repeat steps 2 and 3 for every anchoring hole for the frame.
5
Repeat steps 2 to 4 for any other frame, if applicable.
–end–
3.3.2. Standard concrete floor anchoring
Standard concrete floor anchoring is that type used in non-earthquake areas. If
standard concrete floor anchoring is used, the anchors must be installed and set
now as described in the following procedure (refer to Figure 3.3) before erecting
the frame(s).
Procedure 3.4 – Installing and setting standard anchors in a concrete floor
Step
Action
1
Drop the anchor into the hole drilled per Procedure 3.2.
2
Insert the appropriate setting tool into the anchor and hit it with a hammer to
expand the anchor until the collar of the setting tool rests against the shoulder
of the anchor.
3
Remove the setting tool.
4
Repeat steps 1 to 3 for every anchor for the frame.
5
Repeat steps 1 to 4 for any other frame, if applicable.
–end–
3.4.
Erecting the frame(s)
CAUTION
Protect the equipment against damages when lifting.
If a Helios Candeo frame needs to be lifted by its top for
moving or locating purposes, the appropriate hardware and
method described below must be used in order to insure that
no damages are caused to the top of the frame. The same
method applies to lift the frame out of its shipping crate.
Each Helios Candeo frame is shipped with a stiffening bar and two lifting
eyebolts installed at the factory (see Figure 3.2). Do not remove, loosen or
replace these eyebolts and this stiffening bar until the frame is properly installed
and anchored to the floor at its final location. These eyebolts and stiffening bar
shall be reinstalled should the frame needs to be lifted by its top at anytime.
Helios Candeo Power System – AP6C75AA Installation Manual
26 Locating and erecting the cabinets
There is only one appropriate method to lift a Helios Candeo frame by its top
and it is described in the following procedure and illustrated in Figure 3.2. This
method also applies when lifting the frame out of its shipping crate.
CAUTION
Protect the AC box against damages when lifting the frame.
If provided, the optional AC box used for the AC feeds of the
rectifiers is shipped separately. If, for any reason, this AC box
has been installed prior to lifting the frame by its top, remove it
to prevent damages to it during lifting.
Procedure 3.5 – Lifting and locating a Helios Candeo frame at its final location
Step
Action
1
Install a shackle in each factory-installed eyebolt at the top of the frame,
ensuring that the factory-installed stiffening bar is also present.
2
Install a lifting sling of appropriate weight capacity and length as shown in
Figure 3.2.
Note: It is important that the length be appropriate to maintain an angle of
more than 45°.
3
Use a hoist of appropriate weight capacity to lift the frame up and of the floor.
4
If the hoist is of the mobile type, use it to carry the frame to its final location.
If the hoist is of the fixed type, lower the frame on a dolly or forklift to carry
the frame to its final location. Then, the same hoisting method described in
steps 1 to 3 shall be used to lift the frame off the dolly or forklift and lower it
to its final location on the floor.
5
Use the same procedure for any other frame, if applicable.
–end–
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 27
Figure 3.2 – Appropriate method of lifting a Helios Candeo frame by its top
Typical sling
arrangement
Shackle
Never use the sling
without shackles as this
may break the eyebolts
Direction
of pull
Shackle
Do not use at 45° or less
Top of frame
Stiffening bar:
DO NOT
REMOVE
PRIOR TO
LIFTING
3.5. Securing the frame(s) in place
3.5.1. Standard anchoring in a concrete floor
Secure the frame(s) to a concrete floor using standard anchors as described in
the following procedure (refer to Figure 3.3).
Procedure 3.6 – Securing the frame(s) to a concrete floor using standard anchors
(non-earthquake applications)
Step
Action
1
If applicable, install the floor isolation pad where the frame is to be installed.
2
Lower the frame to its exact final position over the anchoring holes (and the
isolation pad if applicable).
3
Install the anchoring stud in each anchoring hole.
4
Install the anchoring hardware for each anchor; follow the stack-up order
shown in Figure 3.3.
5
Level the frame for proper horizontal and vertical leveling as required using
incompressible shims.
6
Tighten each anchor applying a torque of 25 ft-lb (34 N-m).
7
Repeat steps 1 to 6 for any other frame, if applicable.
–end–
Helios Candeo Power System – AP6C75AA Installation Manual
28 Locating and erecting the cabinets
Figure 3.3 – Assembly stack-up for standard concrete anchors
Threaded rod
Flat washer
Split ring washer
Flat washer
Hex nut
Isolating bushing
Frame base
Isolation pad
(optional)
Concrete
floor
3/8" (10 mm)
drop in anchor
3.5.2. Wood floor
Secure the frame(s) to a wood floor as described in the following procedure
(refer to Figure 3.4).
Procedure 3.7 – Securing the frame(s) to a wood floor
Step
Action
1
Lower the frame in its exact final position, over the anchoring holes drilled per
Procedure 3.3.
2
Install the anchoring hardware for each anchor position; follow the stack-up
order shown in Figure 3.4.
3
Level the frame for proper horizontal and vertical levelling as required as
required using incompressible shims.
4
Tighten each lag screw as required.
5
Repeat steps 1 to 4 for any other frame, if applicable.
–end–
Figure 3.4 – Assembly stack-up for wood floor anchors
Washer
Washer
Lag screw
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 29
3.5.3. Earthquake anchoring
Earthquake anchoring is that type used in earthquake areas up to Zone 4 per
requirements from Telcordia Technologies (formerly Bellcore).
CAUTION
Preserving the integrity of earthquake installations
The AP6C75AA Helios Candeo power system frame is
earthquake qualified when properly anchored to a 3000 psi
(2.11 kg per sq. mm) concrete floor. The earthquake
qualification is not valid otherwise.
CAUTION
Preserving the integrity of earthquake installations
Zone 4 (Bellcore) earthquake rating of the power system
cannot be guaranteed on floors other than concrete. When
installed on a wooden floor, the installation is not earthquake
qualified.
Secure the frame(s) to a concrete floor using earthquake anchors as described in
the following procedure (refer to Figure 3.5).
Procedure 3.8 – Securing the frames to a concrete floor with earthquake anchors
Step
Action
1
If applicable, install the floor isolation pad where the frame is to be installed.
2
Lower the frame to its exact final position over the anchoring holes (and the
isolation pad if applicable).
3
Drop the anchors into the holes drilled per Procedure 3.2.
4
If necessary, use a hammer to insert the anchors until the upper edge of their
upper anchor sleeves is flush with the frame base. See Figure 3.5.
Note: The penetration hatch marks on the upper anchor sleeve are at least
flush with the concrete floor or below it.
5
Install the anchoring stud in each anchoring hole.
6
Install the anchoring hardware for each anchor; follow the stack-up order
shown in Figure 3.5.
7
Level the frame for proper horizontal and vertical leveling as required as
required using incompressible shims.
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
30 Locating and erecting the cabinets
8
Set each anchor applying a torque of 60 ft-lb (81 N-m).
9
Repeat steps 1 to 8 for any other frame, if applicable.
–end–
Figure 3.5 – Assembly stack-up for earthquake concrete anchors
Threaded rod
Flat washer
Plate washer
Frame base
Hex nut
Belleville washer
Insulating bushing (optional)
Isolation pad
(optional)
Leveling shims
Sleeve
Collapsible sleeve
Top of sleeve flush
with frame base
Expanding sleeve
Cone
Concrete
floor
Penetration hatch marks
(can be lower than floor
level)
3.5.4. Raised floor
The methods of securing a Helios Candeo frame on a raised floor may vary
according to the type of raised floor being used and specific Customer
requirements. Figure 3.6 and Figure 3.7 show typical suggested methods of
securing a Helios Candeo frame on a raised floor. Note that these illustrations
are for reference only and that the shown method for earthquake applications is
not certified.
Figure 3.6 – Typical methods of anchoring a frame on a raised floor
Raised
floor
Raised
floor
5/8”
anchor
5/8” threaded
rods, four per
framework
5/8” anchor
In non-earthquake applications
IM6C75AA P0914426 Standard 3.00 March 2001
5/8” threaded rods,
eight per framework (four
vertical, four at an angle)
Adjustable sets of
90° brackets, eight
per framework
In earthquake applications
Locating and erecting the cabinets 31
Figure 3.7 – Alternate method of anchoring the rods to the sub-floor
Cantruss or Unistrut channels anchored to floor, then rods bolted to channels.
Specific requirements and procedures for the anchoring of power frames may be
supplied either by the job specifications, by the Customer or by the raised floor
manufacturer.
3.6.
Securing adjacent frames
Adjacent frames are secured to each other using the interframe linking plate
(P0916605) shown in the following illustration. This plate is shipped with every
frame. Note that the lifting eyebolts and stiffening bar must be removed prior to
installing the plate. Note also that if top supports are used per section 3.8, the
installation of the plate will be part of it.
Figure 3.8 – Top view of the interframe linking plate
Figure 3.9 shows the typical method of securing adjacent frames to each other
with the interframe linking plate.
Helios Candeo Power System – AP6C75AA Installation Manual
32 Locating and erecting the cabinets
Figure 3.9 – Securing adjacent frames
Use the interframe linking plate
(shown in the previous illustration) to
secure adjacent frames to each
other. Screw finger tight only until the
interframe DC link bar and top
supporting hardware are installed.
3.7.
Installing the interframe DC link bar between adjacent frames DC backbones
Install and secure the interframe DC link bar between adjacent frame DC
backbones as described in the following procedure and as illustrated in Figure
3.10, Figure 3.11, Figure 3.12, and Figure 3.13. The procedure is the same for
top or bottom fed applications, as well as from the 2nd to the 3rd frame, from the
3rd frame to the 4th frame, and so on.
CAUTION
Prevent damages to equipment
Handle the interframe DC link bar very carefully to prevent any
damages that could prevent the bar from being properly fitted
into place.
Procedure 3.9 – Installing the interframe DC link bar between adjacent frames DC
backbones
Step
1
Action
For a top fed application, install the anchor protective covers supplied as part of
the DC link bar kit over the anchoring studs that will be close to it once the DC
link bar is installed. To do so, peel of the protective paper over the stick-on tape
on the small tabs of the protective covers and secure in place by pressing firmly
in place as shown in Figure 3.10 and Figure 3.11.
–continued–
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 33
2
Carefully slide the interframe DC link bar into position. Enter through the front
or through the openings made for that purpose in the frame uprights, whichever
is most convenient, as shown by the arrows in Figure 3.10.
3
Align the mounting holes on the interframe DC link bar with the mounting holes
on the back bone inside the first frame and secure in place using the hardware
supplied for that purpose. Refer to Figure 3.13.
Note: If it is difficult to do the final aligning of the holes, use a rubber mallet
and give horizontal blows on the bar as required. DO NOT use a metal tool, as
this will damage the bar.
4
Align the mounting holes on the interframe DC link bar with the mounting holes
on the back bone inside the second frame and secure in place using the
hardware supplied for that purpose. Refer to Figure 3.13.
Note 1: It may be necessary to loosen the frame from the floor anchors and to
loosen the interframe linking plate installed per section 3.6 in order to be able to
do so.
Note 2: Again, If it is difficult to do the final aligning of the holes, use a rubber
mallet and give horizontal blows on the bar and/or the frame as required. DO
NOT use a metal tool, as this will damage the bar and/or the frame.
5
Install safety liners to protect the connections at each end of the DC link bar(s)
as required. Refer to Figure 3.12.
6
Once the interframe linking bar is properly secured, tighten the interframe
linking plate at the top of the frames and retighten the framework(s) to the
floor if loosen per note 1 in step 4.
–end–
Figure 3.10 – Top view of an installed interframe DC link bar between adjacent frames DC backbones
(top or bottom fed)
Tab with stick-on tape
Tab with stick-on tape
Anchor cover cap
Anchor cover cap
(top fed applications only)
DC link bar
Front
Helios Candeo Power System – AP6C75AA Installation Manual
34 Locating and erecting the cabinets
Figure 3.11 – Perspective view of a bottom installed interframe DC link bar between adjacent frames
DC backbones (top fed applications)
Anchor
cover cap
Figure 3.12 – Perspective view of a top installed interframe DC link bar between adjacent frames DC
backbones (bottom fed applications)
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 35
Figure 3.13 – Exploded view of the bolting material for the interframe DC link bar
3.8.
Top support
The type of frame used for the Candeo power system is designed for
freestanding seismic applications and must not be attached to any other
structure than the supporting floor in order to maintain the anti-seismic
qualification in seismic applications.
In non-seismic applications, if the top of the frame is to be attached to any
overhead structure, the standard method consists of using standard hardware to
attach the top of the frame to a ceiling or wall supported overhead structure
(auxiliary framing).
Follow standard installation drawings supplied through the specifications. Figure
3.14 shows a typical top support group for standard frames.
Helios Candeo Power System – AP6C75AA Installation Manual
36 Locating and erecting the cabinets
Figure 3.14 – Typical top support group for standard frames
A
Shown without the cable rack for clarity
Interframe link
plate if two or
more frames
are provided
Auxiliary framing
A
Cable rack
Front view
Front
VIEW A - A
Frame channel
upright
Note: If the installation is attached to an overhead structure attached to the
ceiling or walls and that the site requires ISG grounding topology, then top
isolation hardware must always be used along with the top supporting
hardware (see section 3.1.1.2 and Figure 3.15),
Figure 3.15 – Special support group for isolated applications
A
A
A0802264
5” wraparound
isolating sheet
(one per channel)
Side view of
top of frame
VIEW A - A
3.9.
Installation of frame earthquake bracing kit(s)
If the installation is seismic qualified, install the optional earthquake bracing
kit(s) provided for the frame(s) of your AP6C75AA Helios Candeo power
system as shown in the following illustration.
Note 1: It may be necessary to remove some modules to install the
earthquake bracing kit(s).
Note 2: All positions that are not occupied by equipment on the frame
(System Manager, rectifiers, Distribution Modules, etc.) must be filled with
blank panels in order to maintain the seismic qualification of the system.
IM6C75AA P0914426 Standard 3.00 March 2001
Locating and erecting the cabinets 37
Figure 3.16 – Installation of the frame earthquake bracing kit
P0909060
relay rack
7 foot high
(not part of kit)
P0909058
strap
(2 places)
P0916463
hex jam nut
(4 places)
P0432022
hex nut
(4 places)
P0912564
tapered bushing
(4 places)
P0916467
button head screw
(4 places)
P0382879
Lock washer
(4 places)
Note: On one of the bracing bar, it may be necessary to relocate the
P0432022 hex nut behind the bar in order to clear some of the amber plastic
caps protecting the head of the screws holding the backbone in place. Do not
remove these plastic caps and be careful not to break these since the screws
are carrying the potential (+ or –) of the backbone portion they are holding.
3.10. Module installation
Once the physical installation of the frame(s) and associated hardware is
completed, install/reinstall the equipment modules that require cabling
operations (System Manager, Battery Connection Modules and Distribution
Modules).
Note: Ensure that the mounting rails on each set of two adjacent modules are
properly engaged into each other before sliding the module into the frame in
order that each module is mounted in a perfect horizontal position and at the
appropriate level to match the mounting holes on the frame uprights. The top
of the framework is also equipped with a mounting rail to guide and secure
the first module at the top of the frame.
Helios Candeo Power System – AP6C75AA Installation Manual
38 Locating and erecting the cabinets
The rectifiers do not require any cabling and shall not be installed until told to
do so in the appropriate Chapter.
Follow the equipment specifications provided for your job, observing the
position numbers punched onto the frame uprights near the mounting holes.
IM6C75AA P0914426 Standard 3.00 March 2001
39
4.
Cabling and connecting
4.1.
General
This Chapter covers the cabling and connecting procedures for the AP6C75AA
Helios Candeo power system. These procedures are divided into five sections:
•
•
•
•
cabling and connecting the frame and reference grounds,
cabling and connecting the AC supply for the rectifiers,
cabling and connecting the DC cables from the batteries,
cabling and connecting the DC cables between the Helios Candeo power
system and the loads, and
• miscellaneous cabling.
4.1.1. Basic ruling
The followings are basic rules applying to cabling and connecting:
• It is very important that properly sized conductors be installed between the
AC service panel and the rectifiers, as well as between the power plant, the
batteries and the loads. The protective circuits in the equipment, the
performance, and the overall safety of the equipment depend on the proper
amperage and acceptable voltage drops.
• Although DC power wiring and cabling in telecommunication applications
tend to exceed electrical code requirements, mostly due to the voltage drop
requirements, all applicable electrical code(s) take precedence over the
guidelines and procedures in the present Chapter, wherever applicable.
• When terminal lugs are used, these should be of the crimped type, shall have
two holes for ground cables, and should preferably have two holes also for
other cables.
• DC leads are usually all black. However, there may be exceptions where the
Customer requires that the equipment ground be green, and some battery
feeders be color coded if several feeds are used.
• All wires and cables used shall be made of copper covered with insulation
having the flammability rating required by the governing code. Refer to
Table 4.1 and Table 4.2 for guidelines based on the National Electrical Code
(USA) and the Canadian Electrical Code (Canada) respectively.
Helios Candeo Power System – AP6C75AA Installation Manual
40 Cabling and connecting
Table 4.1 – Flammability rating of wires and cables for the United States
If the cables are used in:
Plenum (note 1)
Commercial buildings, including risers
Commercial buildings, general purpose (no risers)
they must meet the following rating (note 2):
UL910 (“CMP” marking) (or FT1 in conduit)
UL1666 (“CMR” marking)
UL1581 or IEEE383 (“CMG” or “CM” marking)
Table 4.2 – Flammability rating of wires and cables for Canada
If the cables are used in:
Plenum (note 1)
Commercial buildings
they must meet the following rating (note 3):
FT6 (“CMP” marking) (or FT1 in conduit)
FT4 (“CMR” marking)
Note 1: * Plenums are defined as suspended ceilings or raised floors whose
space is used in the handling of air.
Note 2: If the building is a utility as defined by the NEC Article 90-2(b)(4),
then UL VW1 rated cable is permitted but not preferred.
Note 3: If the building is a utility as defined by the CEC Section 0, then FT1
rated cable is permitted but not preferred.
4.1.2. Connecting lugs
Table 4.3 shows the connecting facilities available on the Helios Candeo
bussing, while Table 4.4 shows the two-hole connecting lugs available from
Astec Advanced Power Systems. Table 4.5 provides a list of equivalent metric
size cables for commonly used American Wire Gauging (AWG) cables.
Note: Since the Helios Candeo is a very compact power system, the turning
radius for cabling within the frame is limited. It is therefore recommended to
use only flex type cables.
Table 4.3 – Connecting facilities of the AP6C75AA Helios Candeo power system
Connecting point
–48 V and BR busbars in the Battery
Connection Module
•
•
Single load clip in a Distribution Module
Double load clip in a Distribution Module
BR+ busbar in a Distribution Module
Copper angle for large cable on BR busbar
•
•
•
•
Available terminations
6 sets of holes for either 3/8” bolts at 1” c-c or 1/2” bolts at
1-3/4” c-c per busbar
5 sets of holes for 1/4” bolts at either 1” c-c or 5/8” center
per busbar
1 set of 1/4” studs at 5/8” c-c per circuit breaker position
1 set of 3/8” studs at 1” c-c per circuit breaker position
20 sets of holes tapped for 1/4” bolts at 5/8” c-c
1 set of holes tapped for 3/8” bolts at 1” c-c
–continued–
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 41
Top and bottom frame ground connecting
plate
•
•
•
1 set of holes tapped for 1/4” bolts at 5/8” c-c
1 set of holes tapped for 3/8” bolts at 1” c-c
1 set of holes tapped for 1/2” bolts at 1-3/4” c-c
Table 4.4 – Two-hole connecting lugs
Terminal lug
CPC
Gauge
Bolt size
Holes spacing
C-C (in.)
Tongue width
(approx. in.)
A0355546
A0724948
A0344529
A0379437
A0377621
A0367944
A0376705
A0605216
A0378678
A0772786
A0902814
A0720337
A0668456
A0666799
A0668309
A0618236
A0600125
A0297944
A0368972
A0380048
A0320864
A0902928
A0368787
A0297945
A0297946
A0361762
A0297947
A0320863
A0616116
A0297949
10 AWG
10 AWG
8 AWG / 8 Flex
8 AWG / 8 Flex
8 AWG / 8 Flex
6 AWG / 6 Flex
6 AWG / 6 Flex
6 AWG / 6 Flex
4 AWG / 4 Flex
4 AWG / 4 Flex
4 AWG / 4 Flex
2 AWG
2 AWG
2 Flex
2 Flex
1/0 AWG
1/0 AWG
1/0 AWG
1/0 AWG
2/0 AWG or 1/0 Flex
2/0 AWG or 1/0 Flex
2/0 Flex
2/0 Flex
2/0 AWG or 1/0 Flex
2/0 Flex
4/0 AWG
4/0 AWG
4/0 Flex
4/0 Flex (NT*)
4/0 Flex
1/4 in.
1/4 in.
1/4 in.
1/4 in.
3/8 in.
1/4 in.
1/4 in.
3/8 in.
1/4 in.
1/4 in.
3/8 in.
1/4 in.
3/8 in.
1/4 in.
3/8 in.
1/4 in.
1/4 in.
3/8 in.
1/2 in.
1/4 in.
3/8 in.
1/4 in.
3/8 in.
1/2 in.
1/2 in.
3/8 in.
1/2 in.
3/8 in.
3/8 in.
1/2 in.
5/8 in.
1 in.
5/8 in.
1 in.
1 in.
5/8 in.
1 in.
1 in.
5/8 in.
1 in.
1 in.
5/8 in.
1 in.
5/8 in.
1 in.
5/8 in.
1 in.
1 in.
1.75 in.
5/8 in.
1 in.
5/8 in.
1 in.
1.75 in.
1.75 in.
1 in.
1.75 in.
1 in.
1 in.
1.75 in.
0.43 - 0.47
0.41 - 0.47
0.43 - 0.47
0.41 - 0.47
0.57
0.42 - 0.45
0.58
0.58
0.5 - 0.56
0.5
0.58
0.59 - 0.61
0.67
0.67 - 0.68
0.67 - 0.68
0.75
0.75
0.75
0.75
0.83
0.83
0.94
0.94
0.75
0.94
1.03
1.03
1.25
0.76
1.25
Fits single (S)
and/or double
(D) load clips
S
S
D
S
D
S
D
S
D
S
D
S
D
S
D
S
D
D
D
D
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
42 Cabling and connecting
A0902943
A0352982
A0297951
A0320862
A0902946
A0320865
A0361885
A0297952
A0902953
A0322413
A0320867
A0379473
A0654576
A0297954
A0322414
A0617599
A0320866
313 kcmil
350 kcmil
350 kcmil
373 kcmil
373 kcmil (NT*)
373 kcmil
500 kcmil
500 kcmil
535 kcmil
535 kcmil (NT*)
535 kcmil
750 kcmil
750 kcmil (NT*)
750 kcmil
777 kcmil
777 kcmil (NT*)
777 kcmil
3/8 in.
3/8 in.
1/2 in.
3/8 in.
3/8 in.
1/2 in.
3/8 in.
1/2 in.
3/8 in.
3/8 in.
1/2 in.
3/8 in.
3/8 in.
1/2 in.
3/8 in.
3/8 in.
1/2 in.
1 in.
1 in.
1.75 in.
1 in.
1 in.
1.75 in.
1 in.
1.75 in.
1 in.
1 in.
1.75 in.
1 in.
1 in.
1.75 in.
1 in.
1 in.
1.75 in.
1.38
1.29 - 1.34
1.29 - 1.34
1.52 - 1.63
0.96
1.52 - 1.61
1.52 - 1.61
1.52 - 1.61
1.81
1.63
1.81
1.89 - 1.94
1.63
1.89 - 1.94
2.17 - 2.19
1.63
2.17
–end–
Note: * NT means narrow tongue.
Table 4.5 – Cable size equivalents (AWG to Metric)
Cable size (see notes 1 and 2)
20 AWG
18 AWG
16 AWG
14 AWG
12 AWG
10 AWG
8 AWG
6 AWG
4 AWG
2 AWG
0 AWG (or 1/0)
00 AWG (or 2/0)
0000 AWG (or 4/0)
313 MCM (or kcmil)
350 MCM (or kcmil)
373 MCM (or kcmil)
Circular mils
1020
1624
2583
4107
6530
10380
16510
26250
41740
66370
105600
133100
211600
313600
350000
373700
Square millimeters
0.519
0.8232
1.309
2.081
3.309
5.261
8.368
13.30
21.15
33.63
53.48
67.42
107.2
159
177.36
189
–continued–
IM6C75AA P0914426 Standard 3.00 March 2001
Equivalent metric cable
1
1
1.5
2.5
4
6
10
16
25
35
50 or 70
70
120
150 or 185
185
185 or 240
Cabling and connecting 43
500 MCM (or kcmil)
535 MCM (or kcmil)
750 MCM (or kcmil)
777 MCM (or kcmil)
500000
535300
750000
777700
253.36
271
380.00
394
300
300
400
400
Note 1: For large cables, sizes are expressed using the shortcut notation
MCM or kcmil which both represent “thousands of circular mils”.
Note 2: Wire sizes 0, 00 and 0000 are also represented as 1/0, 2/0 and 4/0
respectively.
4.1.3. Torque values for bolted connections
Bolted connections should be properly tightened to ensure appropriate contact
without stressing or breaking the bolts. This is done by using a torque wrench to
apply the appropriate torque value. The following Table provides a list of torque
values applying to various sizes of bolts.
Table 4.6 – Torque values for bolted connections
Bolt size
#8
#10
1/4”
5/16”
3/8”
7/16”
1/2”
5/8”
3/4”
7/8”
1”
Threads/inch
32
36
24
32
20
28
18
20
16
24
14
20
13
20
11
10
9
8
Torque (in-lb)
18
20
23
32
80
100
140
150
250
275
400
425
550
575
920
1400
1950
2580
Tension (lb)
625
685
705
940
1840
2200
2540
2620
3740
3950
5110
5120
6110
6140
7350
9300
11100
12900
4.1.4. Cabling layout
The AP6C75AA Helios Candeo power system makes use of plug-in interfaces
that reduce cabling operations to a minimum. The cabling required to be done at
the time of installation is very straightforward.
• The rectifier’s AC cables enter the frame on the left side, as viewed from the
front, and are brought to the rectifier AC interface modules, some inside the
fame upright and some on the outside of the frame for individual armored
cables, or through the AC channel for the bulk wiring option.
Helios Candeo Power System – AP6C75AA Installation Manual
44 Cabling and connecting
• The battery cables are entering the frame through the center, at the top for a
top-fed system, or at the bottom for a bottom-fed system.
• The load cables to the protection devices and the battery return busbars
inside the Distribution Modules are entering the frame through the center, at
the top for a top-fed system, or at the bottom for a bottom-fed system.
• The system alarm interface cable with the outside world shall always exit the
main cabinet on the left side, as viewed from the rear.
Figure 4.1 shows typical cabling layouts for top-fed Helios Candeo power
system installations (note that your equipment may be different than that shown
in this illustration).
Figure 4.1 – Typical cabling layouts for top-fed Helios Candeo power system installations
System equipped with:
1 - Battery Connection Module
1 - large Distribution Module
1 - small Distribution Module
IM6C75AA P0914426 Standard 3.00 March 2001
System equipped with:
1 - Battery Connection Module
2 - small Distribution Modules
Cabling and connecting 45
4.2.
Cabling and connecting the grounding leads
This section covers the cabling and connecting of the grounding leads for the
AP6C75AA Helios Candeo power system: the frame or safety ground lead(s) for
the frame(s) and the battery return reference (BRR) ground lead for the system.
CAUTION
Follow local requirements and electrical code.
The grounding methods described in this section are generic.
Specific local, provincial, state or federal electrical codes and
grounding requirements, as well as specific Customer or
communication equipment requirements shall prevail.
CAUTION
Maintain the integrity of the frame or safety ground.
The frame or safety ground shall not be confused with the
reference ground lead, nor with the battery return leads. The
frame or safety ground shall be wired in such a way as not to be
carrying any AC or DC current at any time.
Note 1: In some equipment sites, depending on the grounding topology and
the size of the building, the floor ground bar (FGB) and the building principal
ground (BPG) may be the same busbar.
Note 2: In some equipment sites, depending on the grounding topology, the
power plant battery return reference ground bar (BRR) may be determined as
being the single point ground (SPG). Then, the battery return reference (BRR)
lead is usually run to the floor ground bar (FGB).
4.2.1. Connecting the power plant frame ground (or safety ground) lead(s)
Unless specifically instructed otherwise in the specifications or by the Customer,
the frame ground leads, also referred to as the safety ground leads, are usually
connected as described in Procedure 4.1 and as shown in Figure 4.2 and Figure
4.3.
Note 1: The frame ground collector cable is normally sized according to its
length (distance between the main DC distribution cabinet and the FGB or
BPG) as well as the maximum fuse or circuit breaker size that can be provided
in the power plant. Refer to the following Table for the AP6C75AA Helios
Candeo power system.
Note 2: The frame ground drop into the Helios Candeo frame shall be the
same size as the frame ground collector. The frame ground drop into battery
stands, racks or stacks is usually No. 6 AWG.
Helios Candeo Power System – AP6C75AA Installation Manual
46 Cabling and connecting
Table 4.7 – Recommended cable size for the frame ground collector
Cable length
0 to 20’
20 to 40’
40 to 80’
80 to 160’
Recommended size (see notes 1 and 2)
No. 2 AWG
No. 0 AWG
No. 0000 AWG
No. 500 kcmil
Procedure 4.1 – Installing and connecting the power plant frame ground leads
Step
Action
1
If the power system is sharing a frame ground (FG) collector cable with other
equipment, go to step 2. If the power system is not sharing a frame ground
collector cable with other equipment, go to step 3.
2
Use the appropriate two-hole lug to connect one end of a cable sized per note
2 and Table 4.7 to the frame ground plate at the top of the frame for a top-fed
system or at the bottom for a bottom-fed system, as shown in Figure 4.3.
Apply the appropriate torque per Table 4.6 depending on the size of the bolting
material used. Connect the other end of this cable to the frame ground
collector with a parallel tap connector as shown in the left side illustration of
Figure 4.2.
Note: The collector wire should be sized per note 2 and Table 4.7.
3
Use the appropriate two-hole lug to connect one end of a cable sized per note
1 and Table 4.7 to the frame ground plate at the top of the frame for a top-fed
system or at the bottom for a bottom-fed system, as shown in Figure 4.3.
Apply the appropriate torque per Table 4.6 depending on the size of the bolting
material used. Connect the other end of this cable to the nearest Floor Ground
Bar (FGB), which in some sites may be the Building Principal Ground (BPG) as
shown in the right side illustration of Figure 4.2.
4
Repeat step 2 or 3 for any other frame(s) as applicable.
5
Secure the cables as required and use an identification tag bearing the mention
“PWR PLT FG” to identify the cable(s) at the BPG or FGB ground bar
connection.
–end–
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 47
Figure 4.2 – Typical installation of the power system frame ground lead
BPG or FGB
BPG or FGB
FG – sized per note
2 and Table 4.6
FG - sized per
Table 4.6
Collector cable –
sized per note 1
and Table 4.6
FG - 6 AWG
or
NT6C75AA
Helios Candeo
power system
framework
NT6C75AA
Helios Candeo
power system
framework
Battery stand,
rack or stack
Figure 4.3 – Connection of the frame ground lead inside the frame
Holes for
1/2” bolts at
1-3/4” c-c
Holes for
3/8” bolts
at 1” c-c
Holes for
1/4” bolts
at 5/8” c-c
Helios Candeo Power System – AP6C75AA Installation Manual
48 Cabling and connecting
4.2.2. Connecting the power plant battery return reference (BRR) lead
Unless specifically instructed otherwise in the specifications or by the Customer,
the battery return reference (BRR) lead is usually connected as shown in Figure
4.4 and as described in Procedure 4.2.
CAUTION
Maintain the integrity of the grounding system.
To avoid the possibility of ground loops, which should always
be avoided, only one battery return reference (BRR) lead is
required per system regardless of the number of frames in the
system.
Note 1: The battery return reference cable should be sized equal to or larger
than the size of the largest distribution cable used in the power plant.
Note 2: In some cases, the power plant battery return busbar may be
determined to be the SPG. In such cases, the BRR lead should be run to the
nearest FGB or BPG.
Note 3: The front cover of the Battery Connection Module can be removed
completely to facilitate the cabling and connecting operations.
Figure 4.4 – Typical installation of the power system battery return reference ground lead
SPG (see note 2)
Alternate method for
a bottom fed system
BRR cable
(sized per
note 1)
BR busbar
BRR
cable
BR busbar
NT6C75AA
Helios
Candeo
framework
NT6C75AA
Helios
Candeo
framework
Raised
floor
BRR cable sized per note 1
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 49
Procedure 4.2 – Installing and connecting the battery return reference lead
Step
Action
1
Connect one end of the battery return reference (BRR) ground cable to the
BR+ battery return busbar inside the Battery Connection Module (see Figure
4.4). Use the leftmost or rightmost position on the busbar, depending whether
the cable is coming from the left side or the right side of the frame.
2
Connect the other end of this cable to the SPG ground bar as identified in the
job specifications or the Customer requirements (see Figure 4.4).
3
At each end of this cable, install a permanent brass or fiber tag bearing the
mention “DO NOT DISCONNECT”, as well as a second tag bearing the mention
“BRR”.
4
Secure the cable as required.
–end–
4.3.
Cabling and connecting the AC supplies for the rectifiers
This section covers the AC portion of the cabling and connecting. On the
AP6C75AA Helios Candeo power system, AC power is used mainly to feed the
rectifiers of the power plant.
The present section provides only the specific “in-box” procedures for running
the AC feeders down or up the AP6C75AA Helios Candeo frames and into the
rectifier AC interface modules.
For information on subjects such as basic rulings about AC wiring and
connecting, electrical code requirements, certified or licensed electricians
requirements, permit requirements, methods of bringing the AC supply to the
equipment, etc., refer to project or customer specifications, specific customer
guidelines and local codes and bylaws.
4.3.1. Segregation between AC conductors and other conductors
Electrical codes require that conductors carrying AC current be installed
separately from conductors carrying DC current and signals. Furthermore, some
Customer may require that the minimum distance between the AC and DC
conductors exceed that of the electrical code requirements (for example: for
noise induction purposes).
On the AP6C75AA Helios Candeo power system, this is not a problem since
the AC cabling for the rectifiers is installed either in an AC channel or on the
left side of the frame where there are no other cables. However, the installer
shall attempt to maintain segregation when running AC cables on cable racks
used for other types of cables.
Helios Candeo Power System – AP6C75AA Installation Manual
50 Cabling and connecting
4.3.2. Cabling and connecting the rectifier AC interface modules
The AP6C75AA Helios Candeo power system uses single-phase AC input, 50 A
DC output, plug-in type rectifiers. Each rectifier position requires its own AC
feed. The rectifier can be connected phase-to phase to a 120/240 V single phase
AC source or a 120/208 V 3-phase AC source, in which case the recommended
AC supply circuit breaker is a 30 A 2-pole unit, or phase-to-neutral to a 230/415
V 3-phase AC source, in which case the recommended AC supply circuit
breaker is a 30 A single-pole unit. When a 3-phase AC source is being used, it is
preferable to distribute the rectifiers evenly among the three phases.
Note: The operating range is 80 V ac to 295 V ac at 45-65 Hz. Do not operate
from a higher voltage source.
There are two methods of bringing the AC feeds to the rectifier positions:
• Bulk wiring (individual wires) for up to 20 rectifiers within rigid or flex
conduits attached to the optional AC box at the top of the frame as shown
in Figure 4.5, and down the AC channel to each individual rectifier position
as shown Figure 4.8. Note that until an optional bottom AC box is available,
this method is not available for bottom fed applications
• Individual armored cables, some of which are brought down or up within
the frame upright to each individual rectifier position as shown in Figure 4.6,
the others being brought down or up on the outside of the frame as shown
in Figure 4.7 (left side as viewed from the font) to each individual rectifier
position as shown in Figure 4.8. The maximum number of cables inside and
outside the frame is dependent upon the type of cable used as per Table 4.8.
Note: For applications using two frames or more, bulk wiring is required
since there is no space for individual cables in-between the frame.
The following Table lists the type and size of cables used according to local
preferences and the resulting number of cables inside and outside the frame.
Table 4.8 – Preferred cable sizes and quantities for the AC input supply of the rectifiers
Cable type
Preferred
type in:
TECK-90 7TF-1002AJ Canada
MC 7XF-1003AJ
USA
MC 7A-1002A
USA
TBD
Europe
Number of cables
inside the frame
0-10
0-10
0-16
TBD
Number of cables on the
outside of the frame
11-25
11-25
17-25
TBD
Maximum number
of rectifiers
25
25
25
TBD
The AC connections for the rectifiers are done on rectifier AC interface
modules installed on the AC rail, on the left side of the frame as viewed from
the front.
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 51
Figure 4.5 – Typical conduit, AC box and channel installation for bulk wiring (top fed applications only)
P PLUG
Snap plug
ADAPTER
ACAC
adapter
AC service
panel
AC LID
AC
end
cap
Building AC supply
Conduit
LINKING PLATE
RBAY
ULE
Pull box
(if required)
AC box at top
of frame
AC
rail
AC
channel
DC/DATA
BUS
RELAY RACK
Figure 4.6 – Typical layout of individual armored cables inside the frame upright
Armored cables
Strain relief
connectors
Enlarged view
Part
of rectifier
AC interface
module
Tightening
screw
Strain relief
connector
(model
supplied
may be
different
from model
illustrated)
AC channel in
top section of
left side of
framework
L1
L2
GRD
Inside
frame
upright
Side view
(inside
uprightl)
Front view
Helios Candeo Power System – AP6C75AA Installation Manual
52 Cabling and connecting
Figure 4.7 – Typical layout of individual armored cables on the outside of the frame
Armored
cables
Strain relief
connectors
Enlarged view
Part of
rectifier AC
interface module
Tightening
screw
Strain relief
connector
(model
supplied
may be
different
from model
illustrated)
L1
L2
GRD
Inside
frame
upright
Bottom section
of left side of
framework
When using
larger size
cables, the
bottom five
cables must
be overlaid
on the
previous ten
cables
Side view
Front view
Figure 4.8 – Cabling and connecting the rectifier AC interface modules
Partial view of
AC rail inside
the framework
50 A rectifier AC
interface module
Cut the vertical
stringers at
these four
locations and
remove the
two blank
fillers
Removing the blank fillers for each
rectifier AC interface module when
using the bulk wiring option
Details of connections inside the
rectifier AC interface module
IM6C75AA P0914426 Standard 3.00 March 2001
L1
L2
GRD
TB1
Cabling and connecting 53
Connect the AC supply to the rectifier AC interface modules as described in
Procedure 4.3 and as shown in Figure 4.8. If bulk wiring is used, the optional
AC box, channel and conduits as shown in Figure 4.5 should have been installed
prior to starting the procedure. Note that in individual cables are used, the
installation procedure is similar for top and bottom fed systems.
WARNING
Preventing electrical shocks
When wiring the AC input of the rectifiers, ensure that the
associated AC breakers, located in the AC service panel, are in
the OFF position and that a warning tag clearly indicates that
these breakers are to remain OFF until the AC wiring has been
completed. Do not insert fuses, or operate circuit breaker or
switches to ON until the whole plant is assembled and you are
instructed to do so.
Procedure 4.3 – Cabling and connecting the rectifier AC interface modules
Step
Action
1
Install the required number and type of circuit breakers at the AC service panel.
2
Ensure that the circuit breakers installed per step 1 are locked in the open (OFF)
position.
3
Determine the length of the cables (or individual wires in conduit) required to
bring the AC supply from the AC service panel to the rectifier positions.
4
Cut the cables (or wires) to the required length, then run and secure these
between the AC service panel and the Helios Candeo frame.
5
For bulk wiring in conduits, bypass steps 6 to 10 and go to step 11. For
individual armored cables, proceed with step 6.
6
Strip the sheeting and insulation material away from the ends of the cables to
expose the wires approximately 12” at the rectifier level.
7
Feed the cables incoming through the AC channel down or up the channel to the
appropriate rectifier position.
8
For those rectifier positions fed by individual cables incoming inside the frame
upright, install a strain relief connector on the rectifier AC interface module,
feed the cables through the strain relief connectors, use a flat blade
screwdriver to tighten the strain relief connectors, and then place and secure
the rectifier AC interface module in place (refer to Figure 4.6).
9
If applicable, install the required strain relief connectors for the cables that will
be incoming from the outside of the frame (refer to Figure 4.7).
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
54 Cabling and connecting
10
If applicable, feed the cables incoming from the outside of the frame through
the strain relief connectors installed in step 9 and bring the wires within the
rectifier AC interface module at the appropriate rectifier position (refer to Figure
4.7). Use a flat blade screwdriver to tighten the strain relief connectors.
11
For the rectifier positions fed by bulk wiring in conduits or individual cables
incoming from the outside of the frame, remove the black fillers (two per
position) at the appropriate rectifier AC interface module positions (refer to
Figure 4.8),feed the individual wires through the hole in the rectifier AC
interface module, and then place and secure the rectifier AC interface module in
place refer to Figure 4.7).
12
Make the ground (bare or green wire) and line (L1 and L2) connections on the
rectifier AC interface module as shown in Figure 4.8.
13
Repeat steps 1 to 12, as applicable, for all the rectifiers in the frame.
14
Then, make the ground and line connections as applicable at the AC service
panel.
15
If individual cables are used, secure those on the outside of the frame with
lacing cord or plastic cable ties using the slot in the side of the frame for that
purpose. Secure also all cables on the cable racks as required. Note that for
large size cables, the last five cables must be overlaid on the previous ten
cables as show in Figure 4.7.
–end–
4.4.
DC cabling and connecting
This section covers the DC portion of the cabling and connecting. On the
AP6C75AA Helios Candeo power system, DC cabling is used mainly between:
• the batteries and the Battery Connection Module on the Helios Candeo
frame,
• the Distribution Modules and the loads.
The present section provides only the specific “in-box” procedures for bringing
the DC feeders down or up the AP6C75AA Helios Candeo frame and to the
appropriate modules, as well as connecting these feeders inside the modules.
The Battery Connection Module and Distribution Modules are usually mounted
at the top of the frame for a top fed system, or at the bottom of the frame for a
bottom fed system. The cabling layout is similar in both cases.
Before making any connection, ensure that all contact surfaces on the busbars
are clean and coated with a thin coat of NO-OX- ID “A”, or approved
equivalent, compound.
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 55
4.4.1. Segregation from AC cables
DC current carrying wires and cables are normally segregated from AC current
carrying cables as mentioned in section 4.3.1 of the present Chapter.
4.4.1.1. Connecting the battery cables in the Battery Connection Module(s)
WARNING
Protect the equipment against electrical damage.
Do not make the final connecting of the battery leads at the
batteries before being instructed to do so in the appropriate
section of this Chapter. Note that the connections can be done
now if external battery disconnect units are used and these are
left in the OFF (open) position, or if some intercell connectors
are left open on each battery string to ensure that no power is
applied to the power system.
When connecting the battery cables inside the Battery Connection Module(s)
(BCM), start placing the lugs from right to left, leaving access clear for future
cabling. Note that in a multiple frame system, the batteries associated with each
frame must be connected on the Battery Connection Module in that particular
frame.
Before making any connection, ensure that all contact surfaces on the busbars
are clean and coated with a thin coat of NO-OX-ID “A” compound, or an
approved equivalent.
Connect the battery cables at the AP6C75AA Helios Candeo power system as
described in Procedure 4.4 and as shown in Figure 4.9.
Note: The front cover of the Battery Connection Module can be removed
completely to facilitate the cabling and connecting operations.
Procedure 4.4 – Connecting the battery cables at the Helios Candeo power system
Step
1
2
3
4
Action
Verify that all circuit breakers are open (OFF) and that all fuses, if any, are
removed on the Helios Candeo power system.
Determine the length and size of battery cables required, cut to the appropriate
length, install, and secure in place as required.
Using electrical tape, isolate the cable ends at the battery end.
At the Helios Candeo power system, form the cables into their final position in
the Battery Connection Module and cut to the exact length.
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
56 Cabling and connecting
5
6
8
7
Use the appropriate lug to mark the cables, then strip the cables to the correct
length.
Crimp the appropriate two-hole lugs onto the cable ends.
Connect the –48V lead(s) inside the Battery Connection Module as shown in
Figure 4.9, applying a torque per Table 4.6 depending on the size of the bolting
material used.
Connect the battery return lead(s) (+) inside the Battery Connection Module as
shown in Figure 4.9, applying a torque per Table 4.6 depending on the size of
the bolting material used.
–end–
Figure 4.9 – Connecting the battery cables inside a Battery Connection Module
BRR
cable
Connect the –48 V cables on the
–48 V busbar in the rear section
of the panel in the same maner.
Connect cables from the
same battery string
back to back to
save space for
future
connections
BR busbar
4.4.1.2. Connecting the DC load cables
The following procedure assumes that all the Distribution Modules required for
the initial job have been factory-installed. Should it become necessary to install
additional Distribution Modules in the field, refer to the “Maintenance” Chapter
of user manual UM6C75AA for the applicable procedures.
Before making any connection, ensure that all contact surfaces on the busbars
are clean and coated with a thin coat of NO-OX-ID “A”, or approved
equivalent, compound.
In bottom fed applications, when cabling loads to the distribution, it is best to
start from the bottom or lowest installed Distribution Module and work towards
the top of the frame. In top fed applications, when cabling loads to the
distribution, it is best to start from the top or highest installed Distribution
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 57
Module and work towards the bottom of the frame. This will allow for easy
access into the frame during future expansion or repair. All load cables should
be formed towards the rear, then upward (top fed) or downward (bottom fed) to
exit the top or bottom of the frame.
The distribution of the AP6C75AA Helios Candeo power system being
modular, many configurations of Distribution Modules are possible. Procedure
4.5 and Figure 4.10 to Figure 4.14 are therefore generic and should be adapted
to suit the Distribution Module configuration of your specific power system.
The single load clip can accommodate single-pole circuit breakers in sizes from
1 to 60 A, while the double load clip can accommodate single-pole circuit
breakers in sizes from 65 to 100 A or 150 A double-pole circuit breakers. Note
that when 150 A circuit breakers are used, there shall be one empty space
between adjacent load clip/circuit breaker assemblies.
Note: Do NOT mix standard trip and mid-trip circuit breakers within the
same Distribution Module.
The single load clip can accommodate lugs for cable sizes up to 2/0, while the
double load clip can accommodate lugs for cable sizes up to 4/0. For loads
using only one cable up to size 2/0 on a single load clip or 4/0 on a double load
clip, this single cable is connected directly to the load clip. For loads requiring
cables larger than 2/0 on a single load clip or 4/0 on a double load clip, a 2/0 or
4/0 riser must be connected directly to the load clip, brought out of the frame,
and tapped to the appropriate size cable(s) above or below the power system as
shown in Figure 4.15.
The holes battery return (BR) busbar can accommodate lugs using 1/4” bolts at
5/8” c-c, which is sufficient for cable sizes up to 2/0. For battery return cables
larger than 2/0, a special angle bracket must be installed on the battery return
(BR) busbar in order to accommodate the lugs for cable sizes up to 4/0. For
loads requiring cables larger than 4/0, a 4/0 riser must also be connected to the
copper angle bracket, brought out of the frame, and tapped to the appropriate
size cable(s) above or below the power system as shown in Figure 4.15.
Connect the distribution loads as described in Procedure 4.5 and as shown in
Figure 4.10 to Figure 4.15. The method is the same whether the system is top
fed or bottom fed. Refer to the rightmost column of Table 4.4 for the lugs that
fit the single and double load clips respectively.
Note 1: The front cover of the Distribution Modules can be removed
completely to facilitate cabling and connecting operations.
Note 2: The hinged cover of the individual double load clips can also be
removed completely to facilitate cabling and connecting operations.
Helios Candeo Power System – AP6C75AA Installation Manual
58 Cabling and connecting
Figure 4.10 – Cabling and connecting inside a Distribution 500 module
Insert load clip into
distribution module
as shown
Single position
load clip for
loads
under
65 A
Dual position
load clip
for loads
65 A or
more
5/8” c-c spacing
(1” for double clip)
Method of
connecting
loads to load
clips inside
distribution
modules
5/8” wide tongue
(1-1/4” for double clip)
Method of inserting circuit breaker into Distribution Module
Use angle bracket
on BR busbar for
lugs over 2/0
(see Figure 4.13)
Installation and wiring of a GMT 0-10 A
distribution fuse module
Set J2 jumper for standard (bottom position) or mid trip (top position)
alarm as required (see Figure 4.12).
Typical layout of the load cables inside a Distribution Module
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 59
Figure 4.11 – How to remove load clips
TO REMOVE THE
LOAD CLIP
LIFT THIS
TAB USING A
SCREWDRIVER
INSERTED INTO
THE SLOT
TO INSTALL A
PLACE IT ON
MAKING SUR
ARE INSERT
SLOTS, AND
THE REAR U
INTO PLACE
VIEW OF THE DOUBLE LOAD CLIP
WITH THE COVER OPEN
VIEW A
TO REMOVE THE LOAD C
LIFT THIS TAB WITH A
SCREWDRIVER OR OTHE
SIMILAR OBJECT.
VIEW OF THE SINGLE LOAD CLIP
WITH THE COVER CLOSED
Figure 4.12 – Setting the J2 jumper for standard or mid-trip circuit breaker alarm
Figure 4.13 – Enlarged view of installed angle bracket for cables larger than 2/0
Helios Candeo Power System – AP6C75AA Installation Manual
60 Cabling and connecting
Figure 4.14 – Typical cabling layout inside top-fed and bottom-fed Helios Candeo power systems
Bottom fed system
Top fed system
Typical layout for the load cables inside a top fed
Distribution Module
IM6C75AA P0914426 Standard 3.00 March 2001
Typical layout for the load cables inside a bottom fed
Distribution Module
Cabling and connecting 61
Procedure 4.5 – Connecting the distribution loads
Step Action
1
Verify that all circuit breakers are open (OFF) and that all fuses, if any, are removed
on every Distribution Modules.
2
Determine the length, size and quantity of load cables required, cut to the
appropriate length, install, and secure in place as required.
3
It is suggested to connect the load cables at the equipment end first.
4
At the Helios Candeo power system, form the load cables into their final position
inside the Distribution Modules, then cut to the exact length.
5
Use the appropriate lug to mark the cables and strip the cables to the correct length.
6
Crimp the appropriate two-hole lugs onto the cable ends.
7
If not previously done, install the appropriate load clips required for the load cables.
Refer to Figure 4.10.
8
Connect the first –48 V load cable to the appropriate load clip inside the Distribution
Module as shown in Figure 4.10 to Figure 4.14. Torque according to Table 4.6
depending on the size of the bolts or studs.
For large loads using a 2/0 (single load clip) or 4/0 (double load clip) cable as a riser,
use “C” or “H” taps to tap this riser to the larger cables above or below the power
system, as shown in Figure 4.15.
9
Repeat step 8 for each –48 V load cable in turn.
10 If cables larger than 2/0 are used as battery returns, install the required copper angle
brackets in the appropriate positions on the battery return (BR) busbar.
11 Connect the BR+ load cables to the BR+ busbar (or copper angle brackets) inside
the applicable Distribution Module as shown in Figure 4.10 to Figure 4.14. Torque
according to Table 4.6 depending on the size of the bolts or studs.
For large loads using a riser cable, use “C” or “H” taps to tap this riser to the larger
cables above or below the power system, as shown in Figure 4.15.
12 Once all loads have been connected, use a multimeter to verify the polarity and
continuity of the cables, and that there are no short circuits.
13 If provided but not previously done, install the GMT 0-10 A Distribution Module and
cable the loads to it as shown in Figure 4.10.
14 If not previously done, install the required circuit breakers for the loads. Refer to
Figure 4.10. Insure that the J2 jumper on the right side of each Distribution Module
is set for standard or mid trip alarms as required as shown in Figure 4.12 (do not mix
standard and mid-trip circuit breakers within the same Distribution Module).
–end–
Helios Candeo Power System – AP6C75AA Installation Manual
62 Cabling and connecting
Figure 4.15 – Typical method of tapping a riser cable to a larger cable for a large
load
Large cable
to load
Note: Cable drop must
be sized to withstand
current capacity of the
circuit’s protection fuse
or circuit breaker.
“C” or “H” tap
2/0 or 4/0 riser
(see note)
To the Distribution Module inside the frame
4.5.
Miscellaneous cabling and connecting
This section covers the wiring and connecting of miscellaneous circuits and
equipment associated with the AP6C75AA Helios Candeo power system, such
as:
• the Remote Sense (VR) leads between the batteries and the Battery
Connection Module
• the alarm and control leads between the System Manager and the office
alarm circuit,
• the external sensors for the temperature compensation option of the power
system, if provided,
• the interframe data link cable(s) between adjacent frames,
• the –48 V uninterruptible DC supply on the Battery Connection Module, as
required, and
• the various communication ports as required.
CAUTION
Maintain the requirement s for Class B equipment.
It is important that all small wires and cables installed per this
section be formed and routed as required in order that the
system meets the requirements for Class B equipment.
Table 4.9 – Terminal assignment of the J4 connector on the System Manager
Pin No.
J4-1
Designation
Auxiliary power input BR
IM6C75AA P0914426 Standard 3.00 March 2001
Pin No.
J4-2
Designation
Auxiliary power input –48 V dc
Cabling and connecting 63
Figure 4.16 – Connector layout inside the System Manager (front cover open)
1J4
1
J7
Output ports
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
Aux power
Input ports
IN
+ - + - + - + - + - + -
J8
1
CANFAR
DE9 male
RS-485
DE9 male
Ethernet port RJ45 jack
RS-232
DE9 male
Table 4.10 – Terminal assignment of the J7 connector on the System Manager
Pin No.
Input port number
Alarm description
Alarm level
J7-1
J7-2
J7-3
J7-4
J7-5
J7-6
J7-7
J7-8
J7-9
J7-10
J7-11
J7-12
INPUT PORT 1 +
INPUT PORT 1 –
INPUT PORT 2 +
INPUT PORT 2 –
INPUT PORT 3 +
INPUT PORT 3 –
INPUT PORT 4 +
INPUT PORT 4 –
INPUT PORT 5 +
INPUT PORT 5 –
INPUT PORT 6 +
INPUT PORT 6 –
Auxiliary alarm 1
(programmable)
Auxiliary alarm 2
(programmable)
Auxiliary alarm 3
(programmable)
Generator on
(fixed)
Generator overload
(fixed)
System shutdown
(fixed)
Minor (default)
Minor (default)
Minor (default)
Minor (fixed)
Major (fixed)
Major (fixed)
Internal connector
information
CH0 IN +
CH0 IN –
CH1 IN +
CH1 IN –
CH2 IN +
CH2 IN –
CH3 IN +
CH3 IN –
CH4 IN +
CH4 IN –
CH5 IN +
CH5 IN –
Table 4.11 – Terminal assignment of the J8 connector on the System Manager
Pin
No.
Output port number
J8-1
J8-2
J8-3
J8-4
J8-5
J8-6
OUTPUT PORT 1 (NC)
OUTPUT PORT 1 (COM)
OUTPUT PORT 1 (NO)
OUTPUT PORT 2 (NC)
OUTPUT PORT 2 (COM)
OUTPUT PORT 2 (NO)
Internal
connector
information
CH1 OUT (NO)
CH1 OUT (NC)
CH1 (COM)
CH2 OUT (NO)
CH2 OUT (NC)
CH2 (COM)
Pin
No.
Output port number
J8-13
J8-14
J8-15
J8-16
J8-17
J8-18
OUTPUT PORT 5 (NC)
OUTPUT PORT 5 (COM)
OUTPUT PORT 5 (NO)
OUTPUT PORT 6 (NC)
OUTPUT PORT 6 (COM)
OUTPUT PORT 6 (NO)
Internal
connector
information
CH5 OUT (NO)
CH5 OUT (NC)
CH5 (COM)
CH6 OUT (NO)
CH6 OUT (NC)
CH6 (COM)
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
64 Cabling and connecting
J8-7
J8-8
J8-9
J8-10
J8-11
J8-12
OUTPUT PORT 3 (NC)
OUTPUT PORT 3 (COM)
OUTPUT PORT 3 (NO)
OUTPUT PORT 4 (NC)
OUTPUT PORT 4 (COM)
OUTPUT PORT 4 (NO)
CH3 OUT (NO)
CH3 OUT (NC)
CH3 (COM)
CH4 OUT (NO)
CH4 OUT (NC)
CH4 (COM)
J8-19
J8-20
J8-21
J8-22
J8-23
J8-24
OUTPUT PORT 7 (NC)
OUTPUT PORT 7 (COM)
OUTPUT PORT 7 (NO)
OUTPUT PORT 8 (NC)
OUTPUT PORT 8 (COM)
OUTPUT PORT 8 (NO)
CH7 OUT (NO)
CH7 OUT (NC)
CH7 (COM)
CH8 OUT (NO)
CH8 OUT (NC)
CH8 (COM)
Figure 4.17 – Wiring layout on the Battery Connection Module
J11
TB2
Open door
Slide card out
TB4
TB3
TB1
Table 4.12 – Terminal assignment of the TB1 to TB4 terminal blocks and J11 connector on the Battery
Connection Module
Pin No.
TB1-1
TB1-2
TB1-3
TB1-4
TB1-5
TB3-1
TB3-2
TB4-1
Designation
BR+ Remote Sense
–48V Remote Sense
Contactor Kill Switch A
Fuse alarm input
Contactor Kill Switch B
–48V uninterruptible DC supply (fused at 2 A)
–48V uninterruptible DC supply (fused at 2 A)
BR+ uninterruptible DC supply
IM6C75AA P0914426 Standard 3.00 March 2001
Pin No.
TB2-1
TB2-2
TB2-3
TB2-4
TB2-5
J11-1
J11-2
J11-3
Designation
Temperature Sensor 1 +5V (red)
Temperature Sensor 1 – (black)
Temperature Sensor 2 +5V (red)
Temperature Sensor 2 – (black)
Shield
BR+ for cabinet lamp
–48V for cabinet lamp
Not connected
Cabling and connecting 65
4.5.1. Connecting the Remote Sense leads to the batteries
The Remote Sense + and Remote Sense – voltage regulation leads are used to
feed the sensing signal inputs of the System Manager so they in turn regulate the
rectifiers in order to provides the appropriate battery voltage at the battery
terminals. It is important that these leads be connected as close as possible to
the common connecting points for all the batteries to ensure that the reference
voltage is not affected by load variations. The best connecting point for the
sense leads are usually the overhead battery busbars, that is the busbars located
directly above the battery strings and serving as the common connecting point
for all of them.
If the power system does not incorporate the use of overhead battery busbars
and that each battery string is connected directly to a Candeo system’s Battery
Connection Module, the best connecting points are then next to the battery
cable connections on the busbars in this Battery Connection Module. In such
case, the Remote Sense leads are not required since the system is regulating by
default the voltage at the Battery Connection Module, which is already
connected directly to the busbars in the Battery Connection Module.
In either situation, it is essential to adjust the plant voltage through the System
Manager user interface in order to ensure that the appropriate voltage is applied
to the battery strings. Refer to the important notes in the “Voltage levels for
controllers and rectifiers” user manual (refer to Section 1.4 for manual number)
If these are required, install and connect the Remote Sense leads as described in
the following procedure and as illustrated in Figure 4.17 and Figure 4.18.
CAUTION
Prevent erratic output voltage from the rectifiers
If external battery disconnect units are used, or if the battery
low voltage disconnect option within the Battery Connection
Module(s) is used, it is recommended not to provide the
Remote Sense leads. The system will then use the default
sensing points within the Battery Connection Module(s).
Procedure 4.6 – Installing and connecting the Remote Sense leads
Step
Action
1
Run a red No. 16 AWG cable between the Battery Connection Module and the
common battery connecting points.
2
Connect one end of this cable to terminal 2 (Remote Sense–) of the TB1
connector on the Battery Connection Module. Refer to Figure 4.17.
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
66 Cabling and connecting
3
If requested by the Customer, connect the other end of this cable to an in-line
fuse holder as shown in Figure 4.18.
4
Connect the wire (or the other side of the in-line fuse holder, if applicable) to the
–48V common connecting point for the batteries as shown in Figure 4.18.
5
Run a black No. 16 AWG cable between the Battery Connection Module and the
common battery connecting points.
6
Connect one end of this cable to terminal 1 (Remote Sense+) of the TB1
connector on the Battery Connection Module. Refer Figure 4.17.
7
Connect the other end of this cable to the BR+ common connecting point for
the batteries.
8
Secure the wires as required, and use identification tags to properly identify the
“Remote Sense–” and “Remote Sense+” leads at the connections at the
battery end.
–end–
Figure 4.18 – Method of connecting the Remote Sense lead to the batteries
In-line fuse holder with one 1.6 A fuse
(optional as per Customer preferences).
Battery
+
Connectors
TB1 and TB2
of the control
assembly in
5 4 3 2 1
5 4 3 2 1
the battery Connector
Connector
connection
TB2
TB1
module
Contactor
bypass switch
4.5.2. Connecting the alarms to the office alarm circuit
In the AP6C75AA Helios Candeo power system, the interface with the outside
world (incoming alarms from supplementary or optional equipment, outgoing
alarms to office alarm circuits, etc.) is done through the screw type terminal
strips located at the front of the System Manager.
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 67
Use the appropriate switchboard type cable (the terminal strips can
accommodate gauge 16 to 26 wires) to connect all applicable signals according
to job specifications, configuration sheets, drawings, equipment, and customer
requirements. Refer also to Figure 4.16 as well as to Table 4.10 and Table 4.11.
Note 1: Input ports 4, 5 and 6 are programmed at the factory and cannot be
modified. The other input ports and all output ports are user programmable,
but may have been factory programmed (check appropriate documentation).
Note 2: If not done at the factory, the C (common) terminals for all alarm
relay contacts shall be looped together.
Note 3: The looped alarm contacts shall then be connected to a –48 V
battery or battery return (BR+) source according to the customer alarm
system requirements.
4.5.3. Installing and connecting the temperature probes
If the temperature compensation feature of your Helios Candeo power system is
to be used, it is necessary to install the two temperature probes required for that
purpose. One probe is used to monitor the ambient temperature near the power
system, while the other probe is used to monitor external battery temperature.
Each probe consists of a semiconductor temperature sensor encapsulated in a
standard cable terminal lug and is available in various configurations of lug-hole
sizes and cable lengths. Refer to the Figure 4.19.
Figure 4.19 – Side view of a temperature probe
Cable to Battery Connection Module
Standard one-hole cable lug
Sensor device encapsulated in lug barrel
Cut excess cable
including connector as required
Locate and install the temperature probes as described in the following
procedure and as shown in Figure 4.20 and Figure 4.21.
Procedure 4.7 – Installing and connecting the temperature probes
Step
Action
1
Open the front cover and pull out the printed circuit card in the top right section
of the Battery Connection Module to gain access to the terminal blocks.
2
Locate and install the temperature probe used for external battery temperature
measurements as shown in Figure 4.20.
3
Run the cable attached to the probe to the Battery Connection Module and cut
the excess cable length, including the connector at the end of the cable.
–continued–
Helios Candeo Power System – AP6C75AA Installation Manual
68 Cabling and connecting
4
Route the cable inside the Battery Connection Module as shown in Figure 4.17
and connect the red and black wires and the shield to the TB2 terminal block
according to the terminal assignment given in Table 4.12 and according to the
position programmed for Battery Temperature in the System Manager (1 or 2).
5
Locate and install the temperature probe used for ambient temperature
measurements as shown in Figure 4.21.
6
Run the cable attached to the probe to the Battery Connection Module and cut
the excess cable length, including the connector at the end of the cable.
7
Route the cable inside the Battery Connection Module as shown in Figure 4.17
and connect the red and black wires and the shield to the TB2 terminal block
according to the terminal assignment given in Table 4.12 and according to the
position programmed for Ambient Temperature in the System Manager (1 or 2).
8
Push back the printed circuit card and close the front cover in the top right
section of the Battery Connection Module.
9
Secure the two cables as required.
–end–
Figure 4.20 – Locating a temperature probe for external battery temperature
measurements
Cable to Battery
Connection Module
Insert the probe between the cell post and
the connector nut or bolt when making the
battery connection.
Probe
Top of cell
Figure 4.21 – Locating a temperature probe for ambient temperature measurements
Cable to Battery
Connection Module
Probe
Mounting
surface
Use a screw or bolt of the appropriate size to locate the
probe on a surface that is most representative of the
ambient temperature.
CAUTION: The selected surface must not be affected by
hot or cold temperature from rectifiers, direct sunlight
through windows, heating or air conditioning equipment,
etc.
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 69
4.5.4. Connecting of the interframe data link cable(s)
If your job includes two or more Helios Candeo frames, install and connect the
interframe data link cable(s) as illustrated in Figure 4.22.
CAUTION
Prevent erratic communications
The impedance plugs are required to insure that the
communication link is properly balanced. Do not remove a
plug if no cable is being connected in the associated jack. When
a cable between two frames is being installed, remove the plug
and store it in the associated storage location. Do not discard
these plugs. If a cable is removed for any reason, the plug
must be reinstalled to maintain the communication link
properly balanced.
Figure 4.22 – Connections of the interframe data link cable(s)
Interframe data
link cable
Interframe data
link module
J1
Plug-in
Storage
locations for
locations for
HOLDER
interframe
impedance
data link
plugs
cables and
J2
impedance
plugs
Front view of interframe data link module
= locations of
impedance plugs
First frame
In-between frame(s)
Last frame
4.5.5. Connecting the uninterrupted DC supply leads
To connect the uninterrupted DC supplies, route the wires inside the Battery
Connection Module as shown in Figure 4.17 and connect the wires to the TB3
and TB4 terminal blocks according to the terminal assignment given in Table
4.12. It is recommended to protect these circuits with 2 A fuses.
It is recommended to use one of these supplies to feed the System Manager
AUX POWER IN terminal block as shown in Figure 4.16. This will allow the
System manager to remain operative during a low voltage disconnect condition
when the internal low voltage disconnect option and/or external battery
disconnect units are used.
Helios Candeo Power System – AP6C75AA Installation Manual
70 Cabling and connecting
4.5.6. Connections at the communication ports
The System Manager of the Helios Candeo power system provides several
access ports to communicate with the system. These are:
•
•
•
•
•
the RS-232 port,
the RS-485 / RS-422 port,
the CANFAR port,
the Ethernet port, and
an optional external modem (which connects into the RS-232 port).
The RS type ports are accessible through DE9 type connectors, while the
Ethernet port is accessible through a RJ45 jack inside the System Manager. It is
recommended to use shielded cables for these ports in order to meet the
requirements for Class B equipment.
Note: The CANFAR port is for Astec APS engineers use only for internal
programming and no attempt to access the system through that port shall be
made in the field.
4.6.
Final connections at the batteries
Once all cabling and connecting per the previous sections have been completed,
make the final connection of the battery string leads at the batteries as described
in the following procedure.
Note: If the connections were previously done because of the presence of
external battery disconnect units or if some intercell connectors were left
open on each battery string instead (as described in the Warning box in
section 4.4.1.1), close the circuit breakers on the battery disconnect units or
the intercell connectors at this point, applying the Warning and note in step 6
of the following procedure.
Procedure 4.8 – Connecting the battery string cables at the batteries
Step
Action
1
Verify that all circuit breakers are open (OFF) and that all fuses, if any, are
removed on the AP6C75AA Helios Candeo power system.
2
Form the cables into their final position and cut to the exact length.
3
Use the appropriate lug to mark the cables, then strip the cables to the correct
length.
4
Crimp the appropriate two-hole lugs onto the cable ends.
–continued–
IM6C75AA P0914426 Standard 3.00 March 2001
Cabling and connecting 71
5
Connect the –48 V lead(s) at the negative (–) terminal(s) of the battery string(s).
Torque as recommended by the battery manufacturer.
6
Connect the battery return lead(s) (+) at the positive (+) terminal(s) of the
battery string(s). Torque as recommended by the battery manufacturer.
WARNING! Before completing the connection of the battery return leads (+)
from the AP6C75AA Helios Candeo power system battery return busbar (BR+)
to the positive (+) terminal of the battery strings, measure with a voltmeter
across the connection to be made. The voltage difference measured must not be
greater than 0.05 volt. This is necessary to prevent significant current flow and
thus any sparking. If the voltage difference is greater than 0.05 volt, then use a
resistance lamp in series across the connection to equalize the potential.
Note: Any potential difference that may exist should be small and would be
caused by internal circuits of the AP6C75AA Helios Candeo power
system. If the resistance lamp continues to glow brightly as the
connection is being made, the installer should discontinue from making
the connection and rather proceed to re-verify all cabling for possible
short circuits. Verify again that all circuit breakers are in the OFF
position and that all fuses are removed on the power system.
–end–
Once the battery string cables have been connected, use a multimeter to check
for proper polarity at the charge and discharge busbars before installing any
fuses or operating any circuit breakers.
Helios Candeo Power System – AP6C75AA Installation Manual
72 Cabling and connecting
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
73
5.
5.1.
Start-up and adjustment procedures
General
The AP6C75AA Helios Candeo is an intelligent power system controlled by a
microprocessor-based unit called the “System Manager”. There are absolutely
no hardware type adjustments such as potentiometers, switches, etc. on this type
of controller. Even the rectifiers are fully dependent on the System Manager for
their settings.
5.2.
Voltage levels
Operating and alarm voltage levels for the AP6C75AA Helios Candeo power
system are dependent upon the type of batteries being used with the system and
whether the temperature compensation function is used or not. Refer to user
manual 167-7011-010 for some recommended voltage levels for specific type of
batteries with or without temperature compensation.
For non-listed battery types, refer to the battery manufacturer’s specifications
and recommendations. Refer also to the customer specifications and
requirements.
5.3.
Installation of the rectifiers on the frame(s)
Once the installation of the AP6C75AA Helios Candeo power system has been
fully completed per the preceding Chapters, reinstall the rectifiers (removed per
section 3.2 of Chapter 3) as described in the following procedure prior to
starting-up and testing the system.
WARNING
Protecting personnel against electrical shocks.
Input voltages to the rectifiers are at a dangerous level. Ensure
that the circuit breakers are locked in the OFF position at the
AC service panel before installing the rectifiers.
Helios Candeo Power System – AP6C75AA Installation Manual
74 Start-up and adjustment procedures
WARNING
Protecting personnel against electrical shocks.
Except for the fan module, these rectifiers contain no field
serviceable parts. Dangerous voltages are present inside the
rectifier while it is in operation. Do not attempt field repair.
Send to your nearest Astec APS Customer Services department.
Refer to Appendix D for the telephone number of the nearest
Customer Services department.
Figure 5.1 – Perspective view of a rectifier with the locking latches in the open
position
Mounting rails
Locking
mechanism
Locking latches
(shown in the open position)
Locating pins
Mounting rails
Enlarge view of a locking latch
(shown in the open position)
IM6C75AA P0914426 Standard 3.00 March 2001
Start-up and adjustment procedures 75
CAUTION
Preventing damage to the locking mechanism
When sliding the System Manager and the Rectifier Module into
the Helios Candeo Power System, the locking latches must be
fully open to prevent damage to the locking mechanism system
(see Figure 5.1).
Procedure 5.1 – Inserting the rectifiers in the frame
Step
Action
1
Verify that the AC cabling and AC interface module for the rectifier position
have been installed and verified.
2
Ensure that the left and right side latches are in the full open position as shown
in Figure 5.1.
3
Carefully slide the rectifier into position, making sure that the mounting rails of
adjacent modules are properly engaged into each other before sliding the
module into the frame in order that each module is mounted in a perfect
horizontal position and that the locking pins pass through the appropriate
mounting holes on the frame upright.
4
Close the left and right side latches to their full closed position to secure the
rectifier into position.
5
Repeat steps 1 to 4 for each rectifier in the frame.
–end–
5.4.
Initial start-up, testing and adjustment of the system
At initial start-up, the system goes through the following self-test and
initialization routine:
• The System Manager gathers information to build the inventory of all the
modules in the system and validates their compatibility with the System
Manager.
• While the System Manager is initializing, the red pathfinder indicator is lit.
• Once ON, it also lights up all the pathfinder indicators for five seconds.
• It then leaves only the pathfinder indicator reflecting the actual state of
operation lit.
The conditions indicated by the pathfinders are as follows :
Green pathfinder lit; the System Manager is operational.
Yellow pathfinder lit; the Maintenance Mode is active.
Red pathfinder lit; the System Manager is initializing or faulty.
Helios Candeo Power System – AP6C75AA Installation Manual
76 Start-up and adjustment procedures
Once the Green pathfinder is lit, proceed as described in the “Start-up and
Configuration Settings”, “Monitoring Modules” and “Maintenance Functions”
Chapters of user manual UM6C75AA to bring the complete system to a fully
operational state.
IM6C75AA P0914426 Standard 3.00 March 2001
77
6.
End of job routines and turnover
6.1.
General
This Chapter covers the job routines to be performed towards the end of the
installation project to ensure that the finished product meets all Astec Advanced
Power Systems and Customer standard requirements.
6.2.
Designation
Designation is a process by which all power circuits and equipment are stamped
for proper identification, fast locating and future maintenance.
It can be done with a manual designating kit using individual rubber stamps with
paint or ink, with an electronic designating kit using stick-on ribbon, or with
individual stick-on letters and numbers.
Verify with the customer for the acceptable method(s). Some customer may
even have color preferences for the designation. If the Customer has no
preference, other factors may govern the final choice, such as consistency with
existing equipment, availability of a particular designating kit, etc.
The smallest acceptable character size is 3/16”.
Stamp the equipment as described in the following sections and according to the
information in the drawings and specifications.
6.2.1. Frame numbering
When adding the AP6C75AA Helios Candeo frame(s) to an existing lineup or
starting a new lineup in a power equipment room with existing equipment, the
designation should match the existing stamping (method, color and size) for
consistency, unless the Customer or the specification says otherwise.
The type of frame used for the AP6C75AA Helios Candeo power system is
usually stamped at the front and rear of the frame, at the bottom, as shown in
the following illustration.
Helios Candeo Power System – AP6C75AA Installation Manual
78 End of job routines and turnover
Note that each frame is provided with a label on which the installer can use the
appropriate marking method to identify the frame.
Figure 6.1 – Typical stamping of AP6C75AA Helios Candeo frame(s)
3/4” characters
minimum
102.3
6.2.2. Rectifiers
Unlike on other power plants, the rectifiers used in the AP6C75AA Helios
Candeo power system do not need to be identified by physical designation, this
for two reasons:
• These rectifiers are of the plug-in type and they do plug in a universal back-
bone rather than in dedicated shelves. Should a rectifier become defective, it
would be then replaced by a spare unit and the designation sequence would
thus be broken.
• Each rectifier has an electronic signature associated with its serial number.
This signature is programmed in the System Manager module where it is also
associated with its physical position in the frame.
The rectifiers have thus a virtual designation.
6.2.3. Distribution
All distribution circuits shall be properly identified at the front and, if possible,
at the rear of the protection devices (circuit breakers) without any exception.
On the AP6C75AA Helios Candeo power system, the front designation of
distribution circuits is done on the label behind the door of the Distribution
Module (visible when the door is in the open position).
Refer to the job drawings for the name of the circuit associated with each circuit
breaker, and to the equipment drawings for the location of the stamping on the
Distribution Modules. The stamped information should at least include the
equipment name, the equipment location (bay No.) and the circuit breaker
rating.
IM6C75AA P0914426 Standard 3.00 March 2001
End of job routines and turnover 79
The following illustration shows a typical example of stamping on the label
inside a Distribution Module. Note that the front cover of the Distribution
Modules are fully removable to ease the stamping procedures. If there are more
than one Distribution Modules, ensure that the front covers are not
interchanged.
Figure 6.2 – Typical stamping on the label inside a Distribution Module
Example of
designation
P12
50 A
LC01
BAY
106.9
Label
behind door
inside distribution panel
ATTENTION / CAUTION
SURFACES CHAUDES / HOT SURFACES
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19
P20
AMPS
LOAD
Since the Helios Candeo is a front access power system there is no provision for
stamping at the rear of the Distribution Modules. If a second mean of
identifying distribution loads is required, plastic cable ties with a designation
card (such as in the following illustration) can be used on the distribution
conductors.
Figure 6.3 – Typical stamping tags for conductors
INVERTER 1
BAY 001.1
P1
PDC-01
FEEDER “A”
Helios Candeo Power System – AP6C75AA Installation Manual
80 End of job routines and turnover
6.3.
Installing the top cover
The top cover (item 6 in Figure 6.4) is used to prevent any foreign objects from
falling into the frame and possibly causing short-circuits. The cover is a semirigid plastic (UL94V0 flammability) with pre-punched holes for ventilation. Cut
cable access holes as required by removing the “webs” around the intended
cabling access points using side cutters, then install the cover using the hardware
supplied for that purpose (item 15 in Figure 6.4).
6.4.
Installation of the optional cabinet look-alike covers and door
If the frame(s) of your AP6C75AA Helios Candeo power system is (are)
equipped with cabinet look-alike covers and door, install these as described in
Procedure 6.1 and as shown in Figure 6.4.
Note: The door is reversible and can be mounted to open from right to left
or left to right. However, the handle itself is not reversible.
Procedure 6.1 – Installing the doorframe
Step
Action
1
Using the appropriate hardware to secure these in place, install the top and
bottom door mounting angles (item 1).
2
Using the appropriate hardware to secure these in place, install the left and
right side skin panels (item 3).
3
Insert the top and bottom hinge-pins of the door (item 2) into the hinge-holes in
the top and bottom door mounting angles (left or right side as required).
4
Using the appropriate hardware to secure these in place, install the top and
bottom plastic plates (items 4 and 5).
5
Using the appropriate hardware to secure it in place, install the top auxiliary
bracket (item 7).
–end–
IM6C75AA P0914426 Standard 3.00 March 2001
End of job routines and turnover 81
Figure 6.4 – Installation of the optional cabinet look-alike covers
CABINET KIT - 7 FEET
APP.P0912452
14
15
12
7
1
6
5
3
13
11
8
10
RE
(N
9
SCALE 0.063
15
4 SCREW, THREAD ROLLING, 12/24 P097F813
1415 24 NUT,
KEPS,
1/4-20 ROLLING 12-24
P0622768
SCREW
THREAD
P097F813
P0622768
1314 22 SCREW,
HEX
HEAD, 1/4-20
P0574197
NUTKEPS
1/4-20
P0574197
SCREW
HEX HEAD 1/4-20
1213 52 SPEED
NUT
P0567206
P0567206
SPEED NUT
1112 85 LOCKWASHER
P0286117
P0286117
LOCKWASHER
10 11 88 MACHEINE
SCREW, 10-32
P0140692
P0140692
10 8 MACHINE SCREW 10-32
9 9 22 PLASTIC
BUSHING
P0567297
PLASTIC
BUSHING
P0567297
8 8 11 PLASTIC
BUSHING
P0592311
P0592311
PLASTIC
BUSHING
7 7 11 AUXILIARY
BRACKET
P0916605
P0916606
AUXILIARY
BRACKET
6 6 11 TOP
P0915464-00-0
P0916276
TOPCOVER
P0915464-00-00
COVER
P0916276
TOPPLASTIC
PLASTIC
FACIA
P0913618
5 5 11 TOP
FASCIA
P0913618
BOTTOM
PLASTIC
FACIA
P0913619
4 4 11 BOTTOM
PLASTIC
FASCIA
P0913619
P0909064
SIDESKIN
SKIN
3 3 22 SIDE
P0909064
2
1
P0909065
DOOR
ASSEMBLY
2
1 DOOR ASSEMBLY
P0909065
2 TOP/BOTTOM ANGLE
1
P0909062
1ITEM QTY
2 TOP/BOTTM
ANGLE
P0909062
DESCRIPTION
PART
NO.
ITEM QTY DESCRIPTION
PAT NO.
6.5.
12
2
1
4
10
11
CABINET KIT
P0912452
SCALE 0.063
Touch-up of damaged and/or scratched painted surfaces
Touch-up any scratched, marred or damaged painted surfaces to ensure that no
bare metal is exposed. Use the appropriate matching color: matching paint is
available from Astec Advanced Power Systems for this equipment.
Cut ends of floor anchoring studs and overhead structure hardware shall be
touched-up as well to prevent corrosion by rust.
6.6.
Equipment turnover
Once the installation of the AP6C75AA Helios Candeo power system has been
fully completed, including all the operational tests and adjustments, turnover the
system to the customer, including all spares and documentation supplied per the
specifications for the system.
Obtain the applicable customer acknowledgments.
Helios Candeo Power System – AP6C75AA Installation Manual
82 End of job routines and turnover
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
83
Appendix A: Drawings
Drawing No.
Description
IS6C75A
AP6C75AA Helios Candeo interconnect schematic
Helios Candeo Power System – AP6C75AA Installation Manual
84 Appendix A: Drawings
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
85
Appendix B: Recommended AC generator
requirements for APS power systems
For proper operation and reliability of your Astec APS power systems, AC
generators should meet the requirements of the “Engine Alternator Standard”
document (spec. 4PI-00038) available in the partners’ section of the Astec APS
web site www.astecaps.com. In order to obtain access to the partners section,
please follow the instructions on the partners page or contact your applicable
technical support line or your local sales representative (refer to Appendix D for
the applicable telephone number).
Helios Candeo Power System – AP6C75AA Installation Manual
86 Appendix B: Recommended AC generator requirements for APS Power Systems
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
87
Appendix C: Recommended replacement parts
Refer to Appendix A of user manual the UM6C75AA for the recommended
replacement parts for the AP6C75AA Helios Candeo power system.
Helios Candeo Power System – AP6C75AA Installation Manual
88 Appendix C: Recommended replacement parts
This page is left blank intentionally.
IM6C75AA P0914426 Standard 3.00 March 2001
89
Appendix D: Technical service assistance
Astec Advanced Power Systems
Emergency Technical Assistance Service
• 24 hours/7 days a week Toll-Free Emergency Technical Assistance Line
• On-line support service that complements field technical support
organizations and field service groups including ETAS (Emergency
Technical Assistance Service) and ITAS (Installation Technical Assistance
Service)
• APS has the expertise and resources to provide full service technical support
at various levels
• Please refer to the telephone listing to locate your local toll-free technical
support number
Local Pre-Fixes to Toll-Free Services
• The following pre-fixes should be used to access the toll-free numbers
• Please be familiar with this information and verify as required with your
local service provider
Country
Australia
Belgium
Brazil
Denmark
Finland
France
Germany
Hong-Kong
Ireland
Pre-fix
0011
00
0021
00
00
00
00
001
00
Country
Japan
Pre-fix
001 (KDD)
0041 (ITJ)
0061 (IDC)
Korea
Malaysia
Netherlands
New-Zealand
Switzerland
UK
001
00
00
00
00
00
Helios Candeo Power System – AP6C75AA Installation Manual
90 Appendix D: Technical service assistance
APS Emergency Technical Assistance Service Toll-Free Telephone Numbers
In the U.S.A.:
In Europe:
Austria
Belgium
Denmark
Finland
France
Germany
Ireland
Italy
Netherlands
Norway
Sweden
Switzerland
UK (see note below)
In the Caribbean
And Latin America
(Cala)
Bahamas
Barbados
Brazil
Columbia
Dominican Republic
Jamaica
Mexico
Puerto Rico
Trinidad & Tobago
1-800-992-8417
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
To be allocated
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
In Canada:
In Asia & Pacific:
Australia
Hong Kong
Japan
South-Korea
Malaysia
New-Zealand
Philippines
Singapore
Taiwan
1-800-363-2288
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
800-213-49156
1-800-1-110-0131
800-213-49156
800-213-49156
In the Middle East:
Israel
800-213-49156
1-800-389-0081
1-800-534-0225
08-15836-32288
980-192288
1-888-751-4232
1-800-850-1755
001-800-514-2288
1-888-680-2288
1-800-363-2288
• For countries not covered by a toll free service, dial Canada (country code
001) at 514-832-6707.
Note: UK includes England, Northern Ireland, Scotland, Guernsey, Jersey
and Isle of Man.
IM6C75AA P0914426 Standard 3.00 March 2001
Appendix D: Technical service assistance 91
Fold and tape
Astec Advanced Power Systems
BUSINESS REPLY MAIL
FIRST CLASS
Astec Advanced Power Systems
Dept. W5542
2280 Alfred-Nobel Blvd
Saint-Laurent (Quebec) Canada
H4S 2A4
Fold here
Helios Candeo Power System – AP6C75AA Installation Manual
92 Appendix D: Technical service assistance
Your Opinion Is Important To Us
Please help us better meet your needs by completing and returning the following questionnaire. Your replies give
us valuable insight into the effectiveness of our documentation
Document title: Helios Candeo Power System Installation Manual, IM6C75AA
Job function:
Are you an Astec Advanced Power Systems employee?
Yes
No
How did you use this document?
Introduction to subject
Reference
Training
Planning
Installation
Sales
Maintenance
Advanced knowledge
Other _________________________________________________________________
To rate this document, please circle one of the following numbers:
Accuracy
Clarity
Completeness
Organization
Interest Level
Usefulness
Timeliness
Overall
Excellent
Satisfactory
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
Additional comments:
Thank you for your response.
IM6C75AA P0914426 Standard 3.00 March 2001
Inadequate
3
3
3
3
3
3
3
3
93
List of terms
A
ampere
AC or ac
alternating current
AWG
American wire gauging
BAT
battery
BAT RTN
battery return
BCM
Battery Connection Module
BPG
building principal ground
BR
battery return
BRR
battery return reference
c-c
center to center
DC or dc
direct current
F
fuse
FG
frame ground
FGB
floor ground bar
ft-lb
foot-pound
GRD or GRND
ground
Hz
hertz
in-lb
inch-pound
ISG
isolated system ground
kcmil
Thousand circular mils
L
line
lb
pound
MGB
main ground bar
MOP
method of procedure
Helios Candeo Power System – AP6C75AA Installation Manual
94 List of terms
N-m
Newton-meter
psi
pound per square inch
SPG
single point ground (connection)
TB
terminal block
UL
Underwriters Laboratories
UM
user manual
V
volt
IM6C75AA P0914426 Standard 3.00 March 2001
Helios Candeo Power System
AP6C75AA
Installation Manual
Astec Advanced Power Systems Ltd.
2280 Alfred-Nobel Blvd
Saint-Laurent (Quebec) Canada
H4S 2A4
Copyright  2001 Astec Advanced Power Systems Ltd.
All rights reserved
The information contained in this manual is the property of Astec Advanced
Power Systems Ltd and is subject to change without notice. Astec Advanced
Power Systems Ltd reserves the right to make changes in design or components
as progress in engineering and manufacturing may warrant. Except as
specifically authorized in writing by Astec Advanced Power Systems Ltd, the
holder of this manual shall keep all information contained herein confidential
and shall protect same, in whole or in part, from disclosure and dissemination to
all third parties, and use the same for installation purposes only. Changes or
modifications not expressly approved by the party responsible for compliance
could void the user’s authority to operate this equipment.
Astec Advanced Power Systems
A part of Emerson Network Power
Helios, Helios Candeo, Advanced Power Systems and the Helios Candeo logo
are trademarks of Astec International Ltd. The Emerson logo is a trademark and
a service mark of Emerson Electric Co.
Document Number: IM6C75AA
Document Issue: 3.00
Document Status: Standard
Date: March 2001
P0914426
Published in Canada