AC Power For Business-Critical Continuity™ Liebert FPC™ User Manual - 15 kVA - 300kVA, 3 Phase, 50 & 60 Hz
TABLE OF CONTENTS 1.0 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.1 Unpacking and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.2 2 2 5 5 7 Additional Distribution Mounting & Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.2.1 1.2.2 1.3 Unpacking and Preliminary Inspection . . . .
FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Typical cabinet and floor planning dimension data, 23" (584mm) cabinet, 15-125 kVA . . . . . . . . 3 Typical cabinet and floor planning dimension data, 47" (1194mm) cabinet 50-300kVA . . . . . . . . 4 Recommended minimum service and ventilation clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INSTRUCTIONS NOTE Read the entire manual before installing or operating the system. ! WARNING ! WARNING The shipping bands may be under tension. Use appropriate eye, face, and hand protection to safeguard against injury from band backlash. Verify that all incoming line voltage (power) and low-voltage (control) circuits are de-energized and locked out before installing cables or making connections, whether in the junction box or in the unit.
Installation Instructions 1.0 INSTALLATION INSTRUCTIONS 1.1 Unpacking and Installation NOTE Read the entire manual before installing and operating the system. Upon receipt of a Liebert FPC™, the installer should perform the following steps to ensure a quality installation. 1.1.1 Unpacking and Preliminary Inspection A quality installation begins on the receiving dock. 1. Inspect the shipping crate(s) for damage or signs of mishandling before unpacking the unit(s). Check the Shock-Watch™ indicator. 2.
Installation Instructions Figure 1 Typical cabinet and floor planning dimension data, 23" (584mm) cabinet, 15-125 kVA Overall Dim. 39-1/2" (1003mm) Including hinge and bezel projection Overall Dimension 25.2" (640mm) including side panels Overhead clearance of 18" (457mm) recommended for cooling airflow 1.2" (30mm) 34" (864mm) 1.
Installation Instructions Figure 2 Typical cabinet and floor planning dimension data, 47" (1194mm) cabinet 50-300kVA Overall Dimension 48.6" (1235mm) including side panels Overall Dim. 39-1/2" (1003mm) Including hinge and bezel projection 1.3" (33mm) 6" (152mm) 33.8" (859mm) 35" (889mm) 6" (152mm) 1.
Installation Instructions 1.1.3 Unit Preparation The Liebert FPC may be easily removed from the shipping pallet and installed by customer personnel. A typical procedure is as follows: 1. Set the palletized assembly in a level area where there is enough room to roll the Liebert FPC and entire cable assembly off the pallet onto the floor. 2. Cut the shipping bands. ! WARNING The shipping bands may be under tension and may snap violently when cut.
Installation Instructions Figure 3 Recommended minimum service and ventilation clearances Minimum clearance of 18" (457mm) above unit is recommended for cooling airflow See Notes 2 and 3. Minimum clearance of 6" (152mm) below unit is recommended for cable entry and exit Front and rear access is required. See Notes 1 and 2. NOTE 1. Service access is required at the front and rear. 2. Service access clearance dimensions: 36" (914mm) for units up to 150V to ground.
Installation Instructions 1.1.5 Floor Pedestal Installation Floor pedestals are optional equipment that provide clearance for bottom cable entry or exit for FPC units not installed on raised flooring. The pedestals are adjustable over a limited range (approximately 3-1/2" [89mm]) to allow leveling the FPC and minor adjustments in the unit’s installed height. ! CAUTION Floor pedestals may be reverse-assembled for shipping. Before installation, the pedestals should be reassembled as shown in Figure 4.
Installation Instructions 1.2 Additional Distribution Mounting & Wiring For Liebert FPCs with more than four panelboards, the additional panelboards are furnished in Liebert FDC enclosures, which are shipped separately from the Liebert FPC. 1.2.1 Liebert FDC Distribution Mounting The Liebert FDC distribution cabinet has the same base dimensions as a 23" (584mm) cabinet FPC (23-1/2" wide x 38" deep [597 x 965mm]) and may be mounted on either the left or right side of the FPC. 1.
Installation Instructions To minimize disturbances from other loads in the building, the 3-phase power input to the FPC should be supplied directly from the service entrance or other power source (a dedicated power feeder). The input feeder circuit should be sized in accordance with the NEC and any local building codes to ensure the feeder’s ability to safely carry the system’s full load current, including losses. Input feeder conductors should be sized for no more than 2% voltage drop.
Installation Instructions Figure 6 Electrical connection location for 47" (1194mm) cabinet—Front view FPC15000 Rev. 0 Figure 7 Electrical connection location for 47" (1194mm) cabinet—Rear view FPC15000 Rev.
Installation Instructions Figure 8 Electrical connection location for 47" cabinet with SqD I-Line panelboard—Front view FPC15002 Rev. 0 Figure 9 Electrical connection location for 47" cabinet with SqD I-Line panelboard—Rear view Square “D” I-Line Panelboard 1.75" (44.4mm) .88" (22mm) 3.28" (83mm) 1.75" (44.4mm) .88" (22mm) 11 3.28" (83mm) Detail B Output Ground Busbar Approx. 1/4" Thick FPC15002 Rev.
Installation Instructions Table 4 Suggested minimum input wire size data Units with Transformers kVA 15 30 50 75 100 125 Transformerless Units Input Voltage Input FLA Input OPD Suggested Feeder Wire Size (AWG) Full Load Amps MIB Trip Amps Suggested Feeder Wire Size (AWG) 208 43 60 #6 AWG 42 60 #6 AWG 240 38 50 #8 AWG - - - 380 24 30 #10 AWG 23 30 #10 AWG 400 23 30 #10 AWG 22 30 #10 AWG 415 22 30 #10 AWG 21 30 #10 AWG 480 19 25 #10 AWG - - - 600 15
Installation Instructions Table 4 Suggested minimum input wire size data (continued) Units with Transformers kVA 150 200 225 300 Transformerless Units Input Voltage Input FLA Input OPD Suggested Feeder Wire Size (AWG) Full Load Amps MIB Trip Amps Suggested Feeder Wire Size (AWG) 208 427 600 (2) 350 kcmil * 416 600 (2) 350 kcmil * 240 370 500 (2) 250 kcmil * - - - 380 234 300 350 kcmil 228 300 350 kcmil 400 223 300 350 kcmil 217 300 350 kcmil 415 215 300 350 kcm
Installation Instructions 1.3.2 Junction Box Installation Main input (power) and low-voltage (control) junction boxes are available for the Liebert FPC to simplify customer connections. The junction boxes, if used, can either be shipped with the system or can be advance-shipped for installation during the roughing-in stage of new construction. Liebert supplies flexible, 10-foot-long (3m) conduit with cables for connecting the junction boxes to the unit.
Installation Instructions Figure 10 Low voltage control junction box connections, typical 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Building Interface Relay Factory-supplied low-voltage control cable Figure 11 Main input junction box connections, typical A B C Customer input power connection 3-phase, 3-wire + GND for units with transformer 3-phase, 4-wire + GND for units without transformer 1.3.
Installation Instructions Signal Reference Grid If the unit is used to supply power to a computer room or area that is equipped with a signal reference grid or a grounded raised-floor stringer system, a grounding conductor should be connected from the system ground bus to the grid or floor system. This conductor should be stranded or braided #8 AWG or larger, and as short as practical. Less than 3 ft. (1m) is recommended. 1.3.
Installation Instructions Figure 12 Typical grounding arrangements Input J-box (if used) Liebert FPC (with transformer) N N G G Service entrance grounding electrode system Output Service Entrance G Local grounding electrode conductor per NEC 250-28 Signal reference grid (if used) Typical Liebert FPC with transformer grounding arrangement Input J-box (if used) Liebert FPC (without transformer ) N N N G G G Service entrance grounding electrode system Typical Liebert FPC without transform
Installation Instructions 1.3.5 Output Power Connections Output circuit breaker(s) and/or panelboards with ground and neutral provisions are provided inside the unit for connecting load(s) as required. (See Figures 5 through 8.) Flexible output distribution cables for use in data processing areas under a raised floor are optional and may be factory-supplied. Cable lengths and layout should be well-planned: • Cable access—Cable routes should follow aisles between equipment.
Installation Instructions Figure 13 Typical Liebert FPC equipment arrangement Liebert FPC Remote Emergency Power Off Switch (REPO) Ground electrode conductor (not by Liebert ) required per NEC for units with transformer Main input power to unit (not by Liebert ) 3-phase , 3-wire plus ground for units with transformer 3-phase , 4-wire plus ground for units without transformer Low voltage junction box and cable * Flexible distribution cables per customer specifications *Transient suppression plate
Installation Instructions 1.3.6 Control Wiring Connections NEC Article 645 requires that emergency power off (EPO) switches be located at the principal room exits. All standard Liebert power conditioning systems have provisions for external shutdown control from Remote Emergency Power Off (REPO) stations. Figure 14 is a simplified diagram of the shutdown circuitry of the Liebert FPC. Low-Voltage Control Circuit Control wiring connections must comply with the NEC and all other applicable codes.
Installation Instructions Figure 15 Typical control wiring for units without monitoring Factory-Supplied Wiring Low Voltage Terminal Strip Overtemp Alarm N.O. W208 Overtemp Alarm N.C. W207 Alarm Com. W206 N.O. REPO W205 24VDC W204 REPO Com. W203 N.C. REPO W202 24VDC W201 Building Interface Relay A 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 S BLK WHT GRN N.O. REPO N.C. REPO 4 7 1 R B Overtemp Alarm Output Remove jumper when Normally Closed (N.C.) REPO is used 3 9 6 NOTES 1.
Installation Instructions Figure 16 Typical control wiring for units with monitoring Low Voltage Terminal Strip Comm Cable+(RED) Comm Cable-(BLK) RS-232 RXD (WHT) RS-232 TXD (RED) Factory-Supplied Wiring RS-232 COM (BLK) 5th Customer Alarm W214 4th Customer Alarm W213 3nd Customer Alarm W212 2nd Customer Alarm W211 1st Customer Alarm W210 Summary Alarm N.O. W208 Summary Alarm N.O. W208 Summary Alarm N.C. W207 Summary Alarm Com. W206 N.O. REPO W205 24VDC W204 REPO Com. W203 N.C.
Equipment Inspection and Startup 2.0 EQUIPMENT INSPECTION AND STARTUP 2.1 Internal Inspection A detailed internal inspection should be performed after the unit is in place and before it is energized, to ensure trouble free startup. The same internal inspection should be carried out when performing preventive maintenance. ! WARNING Verify that all incoming line voltage (power) and low-voltage (control) circuits are de-energized and locked out before performing the internal inspection.
Equipment Inspection and Startup Table 11 Torque specifications, general Electrical connections with 1 Belleville washer Electrical connections with 2 Belleville washers Torque Torque lb-in N-m lb-in N-m Bolt shaft size, in./mm 1/4 / M6 40 4.5 80 9.0 5/16 / M8 80 9.0 180 18.0 3/8 / M10 120 13.6 240 27.1 1/2 / M12 480 54.3 — — Input and output breakers Up to 150 amp 80 9.0 160 18.0 175 - 500A 120 13.6 240 27.
Inspection and Startup Checklist 3.0 INSPECTION AND STARTUP CHECKLIST Unit Serial Number Unit Model Number Date 3.1 Inspection ! WARNING All equipment inspection procedures are to be performed with power to the unit turned off and locked out. ___ 1. Confirm that the exterior of unit is undamaged (including cables and receptacles, if furnished). ___ 2. Confirm that service and ventilation clearances are adequate. (See Figures 1 through 3.) ___ 3. Remove accessible exterior and internal panels. ___ 4.
Inspection and Startup Checklist 3.2 Startup ! WARNING Startup procedures should be performed only by qualified personnel. Hazardous voltages are present in the equipment throughout the majority of the start-up procedure. Use proper safety equipment. proceed with caution. When opening the main input circuit breaker wait a minimum of one minute before reclosing. 1. Make certain that all circuit breakers are in the OFF position and that power to the unit is locked out.
Inspection and Startup Checklist NOTE The Liebert FPC transformer has input voltage taps for each input phase. The taps are arranged in 2-1/2% or 5% intervals ranging from -10% to nominal to +5%. This permits the transformer to provide the proper output voltage for a range of input voltages. Should it be necessary, the tap arrangement may be changed to match the input voltage: • Open main input circuit breaker. • Select tap arrangement to match input voltage.
Inspection and Startup Checklist Customer Alarms If customer alarms are provided: ___ 1. With the FPC ON, simulate alarm operation by jumpering the appropriate low-voltage control terminals. (Refer to the control wiring installation drawing furnished with the unit.) ___ 2. Verify correct alarm annunciation by the Power Monitor Panel and/or by the Centralized Monitoring System. 3.
Operating Instructions 4.0 OPERATING INSTRUCTIONS 4.1 Startup Procedures Before the unit is placed into service after initial installation, after equipment relocation, or after equipment has been de-energized for an extended period of time, perform equipment inspection and start-up procedures as detailed in 2.0 - Equipment Inspection and Startup and 3.0 - Inspection and Startup Checklist. After initial system startup, the following guidelines can be used for standard equipment operation.
Operating Instructions 4.2 Basic Monitor Panel (Units Without Monitoring) Alarm Present/Silence Upon occurrence of a transformer overtemperature condition, the “Alarm Present/Silence” switch will become illuminated and the audible alarm will be activated. Pushing the “Alarm Present/Silence” switch will silence the audible alarm. The cause of the overtemperature condition should be investigated and corrected.
Operating Instructions Alarms - Upon occurrence of any of the following alarms, the alarm message appears on the LCD display, the Alarm Present/Silence switch is illuminated, and the audible alarm is activated. Pressing the “Alarm Present/Silence” switch silences the audible alarm. After the alarm condition is corrected, the alarm can be reset by pressing the “Alarm Present/Silence” switch when prompted by the LCD display or by way of any Central Monitoring System.
Operating Instructions To Set Unit Clock - To set the clock from the unit front panel, simultaneously press the Scan and Hold membrane switches while the time and date screen is displayed on the LCD. A cursor should appear on the selected time and date field. Use the Scan switch to increment the highlighted field and the Hold switch to decrement the highlighted field. Use the Silence push button to select the next time and date field. The time can be displayed in AM/PM or 24-hour format.
Operating Instructions Table 17 Field # Monitored parameters data definitions Data item Units 1 Input Voltage A-B Volts 2 Input Voltage B-C Volts 3 Input Voltage C-A Volts 4 Output Voltage X-Y Volts 5 Output Voltage Y-Z Volts 6 Output Voltage Z-A Volts 7 Output Voltage X-N Volts 8 Output Voltage Y-N Volts 9 Output Voltage Z-N Volts 10 Output Current X Amps 11 Output Current Y Amps 12 Output Current Z Amps 13 Neutral Current Amps 14 Ground Current 0.
Maintenance 5.0 MAINTENANCE 5.1 Repair Even the most reliable equipment may fail. Liebert Global Services is at your service to assure fast repair of your unit and minimum downtime of your installation. ! WARNING Only qualified service personnel should perform maintenance on the Liebert FPC system. Standard electrical troubleshooting procedures should be used to isolate problems in the unit. If there are questions, don’t hesitate to contact Liebert Global Services.
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