Emerson ASTEC Helios Candeo AP6C75AA Installation Manual Download

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Cabling and connecting

IM6C75AA P0914426 Standard 3.00 March 2001

J8-7

OUTPUT PORT 3 (NC)

CH3 OUT (NO)

J8-19

OUTPUT PORT 7 (NC)

CH7 OUT (NO)

J8-8 OUTPUT PORT 3 (COM)

CH3 OUT (NC)

J8-20 OUTPUT PORT 7 (COM)

CH7 OUT (NC)

J8-9

OUTPUT PORT 3 (NO)

CH3 (COM)

J8-21

OUTPUT PORT 7 (NO)

CH7 (COM)

J8-10

OUTPUT PORT 4 (NC)

CH4 OUT (NO)

J8-22

OUTPUT PORT 8 (NC)

CH8 OUT (NO)

J8-11 OUTPUT PORT 4 (COM)

CH4 OUT (NC)

J8-23 OUTPUT PORT 8 (COM)

CH8 OUT (NC)

J8-12

OUTPUT PORT 4 (NO)

CH4 (COM)

J8-24

OUTPUT PORT 8 (NO)

CH8 (COM)

Figure 4.17 – Wiring layout on the Battery Connection Module

TB1

TB2

J11

TB4

TB3

Slide card out

Open door

Table 4.12 – Terminal assignment of the TB1 to TB4 terminal blocks and J11 connector on the Battery
Connection Module

Pin No.

Designation

Pin No.

Designation

TB1-1 BR+ Remote Sense

TB2-1 Temperature Sensor 1 +5V (red)

TB1-2 –48V Remote Sense

TB2-2 Temperature Sensor 1 – (black)

TB1-3 Contactor Kill Switch A

TB2-3 Temperature Sensor 2 +5V (red)

TB1-4 Fuse alarm input

TB2-4 Temperature Sensor 2 – (black)

TB1-5 Contactor Kill Switch B

TB2-5 Shield

TB3-1 –48V uninterruptible DC supply (fused at 2 A)

J11-1 BR+ for cabinet lamp

TB3-2 –48V uninterruptible DC supply (fused at 2 A)

J11-2 –48V for cabinet lamp

TB4-1 BR+ uninterruptible DC supply

J11-3 Not connected

Summary of Contents for ASTEC Helios Candeo AP6C75AA

Page 1: ...Astec Advanced Power Systems Astec Advanced Power Systems A part of Emerson Network Power Helios Candeo Power System AP6C75AA Installation Manual P0914426 Standard 3 00 March 2001 IM6C75AA ...

Page 2: ......

Page 3: ...ress 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 a...

Page 4: ......

Page 5: ... 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...

Page 6: ...6 Publication history IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 7: ...nt 17 2 3 Precautions 18 2 4 Receiving the material 20 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 ...

Page 8: ...g 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...

Page 9: ...ern 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...

Page 10: ...over 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 ...

Page 11: ... 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 ...

Page 12: ...12 Contents IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 13: ...ave 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 meth...

Page 14: ...14 About this document IM6C75AA P0914426 Standard 3 00 March 2001 Figure 1 1 Perspective view of a typical top fed AP6C75AA Helios Candeo power system ...

Page 15: ...About this document 15 Helios Candeo Power System AP6C75AA Installation Manual Figure 1 2 Perspective view of a typical bottom fed AP6C75AA Helios Candeo power system ...

Page 16: ... the rectifiers and to bring the power system to a fully operational state 6 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 7 Appendices provide information on drawings Customer services technical support and feedback form for the manual as well as a list of terms desc...

Page 17: ...fier 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 2 2 Tools a...

Page 18: ...llowed 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 o...

Page 19: ...ge 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 ...

Page 20: ...re 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...

Page 21: ...ware 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 ...

Page 22: ...ntenance 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 se...

Page 23: ...ere 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 installa...

Page 24: ...ced 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...

Page 25: ... 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 m...

Page 26: ...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 capac...

Page 27: ...cribed 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 a...

Page 28: ...rocedure 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...

Page 29: ...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 anch...

Page 30: ...me base 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 ...

Page 31: ...he 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...

Page 32: ...ocedure 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 backb...

Page 33: ...nd 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 ...

Page 34: ... Figure 3 11 Perspective view of a bottom installed interframe DC link bar between adjacent frames DC backbones top fed applications Figure 3 12 Perspective view of a top installed interframe DC link bar between adjacent frames DC backbones bottom fed applications Anchor cover cap ...

Page 35: ...d 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 instal...

Page 36: ...rdware see section 3 1 1 2 and Figure 3 15 Figure 3 15 Special support group for isolated applications VIEW A A A A Side view of top of frame A0802264 5 wraparound isolating sheet one per channel 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 syst...

Page 37: ...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 ...

Page 38: ...March 2001 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 ...

Page 39: ...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...

Page 40: ... 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...

Page 41: ...605216 6 AWG 6 Flex 3 8 in 1 in 0 58 D A0378678 4 AWG 4 Flex 1 4 in 5 8 in 0 5 0 56 S A0772786 4 AWG 4 Flex 1 4 in 1 in 0 5 A0902814 4 AWG 4 Flex 3 8 in 1 in 0 58 D A0720337 2 AWG 1 4 in 5 8 in 0 59 0 61 S A0668456 2 AWG 3 8 in 1 in 0 67 D A0666799 2 Flex 1 4 in 5 8 in 0 67 0 68 S A0668309 2 Flex 3 8 in 1 in 0 67 0 68 D A0618236 1 0 AWG 1 4 in 5 8 in 0 75 S A0600125 1 0 AWG 1 4 in 1 in 0 75 A02979...

Page 42: ... 3 8 in 1 in 1 63 A0297954 750 kcmil 1 2 in 1 75 in 1 89 1 94 A0322414 777 kcmil 3 8 in 1 in 2 17 2 19 A0617599 777 kcmil NT 3 8 in 1 in 1 63 A0320866 777 kcmil 1 2 in 1 75 in 2 17 end Note NT means narrow tongue Table 4 5 Cable size equivalents AWG to Metric Cable size see notes 1 and 2 Circular mils Square millimeters Equivalent metric cable 20 AWG 1020 0 519 1 18 AWG 1624 0 8232 1 16 AWG 2583 1...

Page 43: ...t of torque values applying to various sizes of bolts Table 4 6 Torque values for bolted connections Bolt size Threads inch Torque in lb Tension lb 8 10 1 4 5 16 3 8 7 16 1 2 5 8 3 4 7 8 1 32 36 24 32 20 28 18 20 16 24 14 20 13 20 11 10 9 8 18 20 23 32 80 100 140 150 250 275 400 425 550 575 920 1400 1950 2580 625 685 705 940 1840 2200 2540 2620 3740 3950 5110 5120 6110 6140 7350 9300 11100 12900 4...

Page 44: ... 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 sys...

Page 45: ...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 ...

Page 46: ... 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 plat...

Page 47: ...deo power system framework Battery stand rack or stack FG 6 AWG Collector cable sized per note 1 and Table 4 6 FG sized per note 2 and Table 4 6 BPG or FGB NT6C75AA Helios Candeo power system framework FG sized per Table 4 6 or Figure 4 3 Connection of the frame ground lead inside the frame Holes for 1 4 bolts at 5 8 c c Holes for 3 8 bolts at 1 c c Holes for 1 2 bolts at 1 3 4 c c ...

Page 48: ... 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 complet...

Page 49: ...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 ...

Page 50: ...te 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 r...

Page 51: ...lding AC supply AC service panel Pull box if required Conduit AC box at top of frame AC rail AC channel Figure 4 6 Typical layout of individual armored cables inside the frame upright Inside frame upright Strain relief connector model supplied may be different from model illustrated Tightening screw L1 L2 GRD Armored cables Enlarged view Strain relief connectors Part of rectifier AC interface modu...

Page 52: ...onnector model supplied may be different from model illustrated When using larger size cables the bottom five cables must be overlaid on the previous ten cables 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 Details of connections inside the rectifier AC interface module Removing the blank fillers...

Page 53: ...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 ...

Page 54: ...e 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 connecti...

Page 55: ...ure 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 ...

Page 56: ...ve space for future connections Connect the 48 V cables on the 48 V busbar in the rear section of the panel in the same maner 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 Chapt...

Page 57: ...ze 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 ...

Page 58: ... of connecting loads to load clips inside distribution modules 5 8 c c spacing 1 for double clip 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 ...

Page 59: ... DOUBLE LOAD CLIP WITH THE COVER OPEN VIEW A TO INSTALL A PLACE IT ON MAKING SUR ARE INSERT SLOTS AND THE REAR U INTO PLACE 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 lar...

Page 60: ...igure 4 14 Typical cabling layout inside top fed and bottom fed Helios Candeo power systems Top fed system Bottom fed system Typical layout for the load cables inside a top fed Distribution Module Typical layout for the load cables inside a bottom fed Distribution Module ...

Page 61: ... 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 c...

Page 62: ...s 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 CA...

Page 63: ... 3 CH2 IN J7 6 INPUT PORT 3 Auxiliary alarm 3 programmable Minor default CH2 IN J7 7 INPUT PORT 4 CH3 IN J7 8 INPUT PORT 4 Generator on fixed Minor fixed CH3 IN J7 9 INPUT PORT 5 CH4 IN J7 10 INPUT PORT 5 Generator overload fixed Major fixed CH4 IN J7 11 INPUT PORT 6 CH5 IN J7 12 INPUT PORT 6 System shutdown fixed Major fixed CH5 IN Table 4 11 Terminal assignment of the J8 connector on the System ...

Page 64: ...ttery Connection Module TB1 TB2 J11 TB4 TB3 Slide card out Open door Table 4 12 Terminal assignment of the TB1 to TB4 terminal blocks and J11 connector on the Battery Connection Module Pin No Designation Pin No Designation TB1 1 BR Remote Sense TB2 1 Temperature Sensor 1 5V red TB1 2 48V Remote Sense TB2 2 Temperature Sensor 1 black TB1 3 Contactor Kill Switch A TB2 3 Temperature Sensor 2 5V red T...

Page 65: ...equired 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 t...

Page 66: ...n 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 Connector TB1 1 2 3 4 5 Contactor bypass swi...

Page 67: ... 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 ...

Page 68: ...k 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...

Page 69: ...rframe data link cable s Interframe data link cable Interframe data link module Front view of interframe data link module Storage locations for impedance plugs Plug in locations for interframe data link cables and impedance plugs First frame In between frame s Last frame locations of impedance plugs J1 J2 HOLDER 4 5 5 Connecting the uninterrupted DC supply leads To connect the uninterrupted DC sup...

Page 70: ...ries 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 Wa...

Page 71: ...ssary 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 t...

Page 72: ...72 Cabling and connecting IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 73: ...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 Heli...

Page 74: ...ectifier 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 Lockinglatches shown in the open position Enlargeviewof alockinglatch shown in the open position Loc...

Page 75: ...rizontal 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...

Page 76: ...Standard 3 00 March 2001 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 ...

Page 77: ...ptable 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 dra...

Page 78: ...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 breake...

Page 79: ...ide a Distribution Module P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 AMPS LOAD P13 P14 P15 P16 P17 P18 P19 P20 P12 50 A LC01 BAY 106 9 Example of designation ATTENTION CAUTION SURFACES CHAUDES HOT SURFACES Label behind door inside distribution panel 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 iden...

Page 80: ...ed 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 a...

Page 81: ... P0567206 11 8 LOCKWASHER P0286117 10 8 MACHEINE SCREW 10 32 P0140692 9 2 PLASTIC BUSHING P0567297 8 1 PLASTIC BUSHING P0592311 7 1 AUXILIARY BRACKET P0916605 6 1 TOP COVER P0915464 00 0 P0916276 5 1 TOP PLASTIC FASCIA P0913618 4 1 BOTTOM PLASTIC FASCIA P0913619 3 2 SIDE SKIN P0909064 2 1 DOOR ASSEMBLY P0909065 1 2 TOP BOTTM ANGLE P0909062 ITEM QTY DESCRIPTION PAT NO 6 5 Touch up of damaged and or...

Page 82: ...82 End of job routines and turnover IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 83: ...83 Helios Candeo Power System AP6C75AA Installation Manual Appendix A Drawings Drawing No Description IS6C75A AP6C75AA Helios Candeo interconnect schematic ...

Page 84: ...84 Appendix A Drawings IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 85: ...ors 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 teleph...

Page 86: ...86 Appendix B Recommended AC generator requirements for APS Power Systems IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 87: ...eo Power System AP6C75AA Installation Manual 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 ...

Page 88: ...88 Appendix C Recommended replacement parts IM6C75AA P0914426 Standard 3 00 March 2001 This page is left blank intentionally ...

Page 89: ...ice 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 ...

Page 90: ...56 In Asia Pacific Australia Hong Kong Japan South Korea Malaysia New Zealand Philippines Singapore Taiwan 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 Caribbean And Latin America Cala Bahamas Barbados Brazil Columbia Dominican Republic Jamaica Mexico Puerto Rico Trinidad Tobago 1 800 389 0081 1 800 534 0225...

Page 91: ...91 Helios Candeo Power System AP6C75AA Installation Manual Fold and tape Astec Advanced Power Systems Dept W5542 2280 Alfred Nobel Blvd Saint Laurent Quebec Canada H4S 2A4 Fold here BUSINESS REPLY MAIL FIRST CLASS Astec Advanced Power Systems ...

Page 92: ...C75AA 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 Excellent Satisfactory Inadequate Accuracy 1 2 3 Clarity...

Page 93: ...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 ...

Page 94: ... List of terms IM6C75AA P0914426 Standard 3 00 March 2001 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 ...

Page 95: ......

Page 96: ...ced 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 Ast...

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Emerson ASTEC Helios Candeo AP6C75AA, Installation Manual

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Summary of Contents for ASTEC Helios Candeo AP6C75AA

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