IMS48 Product Manual

IMS48 Product Manual

Product Manual
Issue 1.12
Nov 2010
 IMS48 Product Manual

Table of Contents
1. Introduction ............................................................................................................... 3
1.1. Additional Product Documentation ............................................................... 3
2. Product Description .................................................................................................. 4
2.1. Overview ........................................................................................................ 4
2.2. Cabinets.......................................................................................................... 4
2.3. Rectifiers ........................................................................................................ 4
2.4. AC input connection ...................................................................................... 5
2.5. DC distribution............................................................................................... 6
2.6. Power Distribution Units (PDU) .................................................................... 6
2.7. Load Distribution Units (LDU) ..................................................................... 8
2.8. Battery connection panels ............................................................................ 10
2.9. AC distribution panel ................................................................................... 11
2.10. Pulsar Controller: ......................................................................................... 12
3. Specifications ........................................................................................................... 13
4. Safety ........................................................................................................................ 14
4.1. Safety Statements ......................................................................................... 14
4.2. Warning Statements and Safety Symbols .................................................... 16
4.3. Precautions ................................................................................................... 17
5. Product Warranty ................................................................................................... 18

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1. Introduction

The following document outlines the features for the INFINITY IMS48 range of indoor DC
power systems.

The systems are designed to provide a -48VDC nominal via distribution to customer loads
with battery backup.

Standard system capacities will be as follows:

• IMS48100: 100 Amps

• IMS48200: 200 Amps

• IMS48300: 300 Amps

• IMS48400: 400 Amps

• IMS48600: 600 Amps

1.1. Additional Product Documentation

• Advanced Features User Guide for the Pulsar Controller

• Rectifier product data sheet

• System installation guide

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2. Product Description

2.1. Overview

The IMS48 systems comprise of the following key elements:

• Cabinet
• AC Distribution
• AC Isolation options
• DC Distribution
• Battery Connection/Isolation
• System Controller
• Power Module (s)

For detailed information regarding specific system layout and connection details please
refer to the system integration guide.

2.2. Cabinets
The system cabinets are 600mm x 600mm standard footprint. Cable access is configurable
for top or bottom. Access for maintenance is via front or top only.

Cabinets are available in the following standard heights:

• 500mm: 9U
• 1000mm: 22U
• 2000mm: 42U

Standard cabinet is IP20 rated.

Battery shelves are available which are suitable for the installation of a 48 Volt string of 12
Volt 150 Ah front terminal battery cells with a total weight of approximately 220kgs and
available space for a battery string 530mm wide X 560mm deep.

Fixings are provided for lifting bolts as well as floor anchoring. Smaller cabinets are suitable
for mounting on top each other or a battery rack.

2.3. Rectifiers
Standard system platforms will include the following rectifier options:

• IMS48100: 2 X EP0800 rectifier shelves (6 X EP0800, 800W rectifiers)

• IMS48200: 1 X CP rectifier shelf (4 X CP rectifiers. CP1800 / CP2725)
• IMS48300: 2 X NP rectifier shelf (3 X NP rectifiers. NP1500 / NP2500)
• IMS48400: 2 X CP rectifier shelves (8 X CP rectifiers. CP1800 / CP2725)
• IMS48600: 3 X CP rectifier shelves (12 X CP rectifiers. CP1800 / CP2725)

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2.4. AC input connection

The cabinets are equipped with an AC input terminal mounted in the top rear with options for
three phases Star or Delta connection.

AC input wiring should be rated for the following input requirements:

• IMS48100: 16 Amps per phase

• IMS48200: 32 Amps per phase
• IMS48300: 32 Amps per phase
• IMS48400: 50 Amps per phase
• IMS48600: 63 Amps per phase

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2.5. DC distribution
The DC distribution panels incorporate DIN rail and panel mounting options for a variety of
distribution components; breakers, fuse holders, contactors, shunts etc.

Access for installation and maintenance is from the front only.

2.6. Power Distribution Units (PDU)

The Power Distribution Units should comprise of the following components:

• DC distribution frame
• Battery isolation: Breakers or Fuses
• Battery current shunt
• Low Voltage Battery Disconnect (LVBD) contactor.
• Maintenance switch to force contactor closure
• DC load distribution: Breakers or fuses
• Common +ve bus bar
• Low Voltage Load Disconnect (LVLD) contactor. Optional: Not fitted as standard.

The Power Distribution Units are configured as per the following schematic:

LOAD +VE BATT +VE

POSITIVE COMMON BUS

+VE
RECTIFIER
INPUT
-VE

LVLD NEGATIVE BUS SHUNT LVBD BATT -VE

OPTION

NON PRIORITY PRIORITY BATTERY

LOAD BREAKERS LOAD BREAKERS BREAKERS

There are two standard ratings of Power Distribution Unit:

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PDM100: The PDM100 will be rated for a maximum DC output of 100 Amps and will
comprise of the following power components and ratings:

• Battery isolation: 2 X DIN breakers or HRC fuses each rated at 125Amps.

Alternatively 4 X 63 Amp DIN breakers or HRC fuses.
• Battery current shunt: 125A
• LVBD contactor: 125A
• DC load distribution: Up to 63A DIN breakers or HRC fuses.
• Bus bars: 125 Amps.

PDM200: The PDM200 will be rated for a maximum DC output of 200 Amps and will
comprise of the following power components and ratings:

• Battery isolation: 2 X breakers or HRC fuses each rated at 250Amps. Alternatively 4

X 125 Amp DIN breakers or HRC fuses.
• Battery current shunt: 250A
• LVBD contactor: 200A
• DC load distribution: Up to 125A DIN breakers or HRC fuses.
• Bus bars: 250 Amps.

PDM400 / PDU600: Due to the physical size of the battery components required for a 400 /
600 Amp system it will not be practical to fit these within a PDU. This will be achieved
utilising a separate Load Distribution Unit (LDU) along with a battery connection panel
(BATT).

PDU600 with LVD and 4x125A Battery Breaker

PDU600 with LVD and 4x125A Battery Breaker

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2.7. Load Distribution Units (LDU)

The Load Distribution Units follow the same design guidelines as the Power Distribution Units
but without battery connection. These units are to supply supplemental DC distribution where
the customer’s needs are greater than those supplied by the PDU alone or where the battery
connection hardware is mounted on a separate panel due to the size or quantity of
components.

The load Distribution Units comprise of the following components:

• DC distribution frame
• DC load distribution: Breakers or fuses
• Common +ve bus bar
• Low Voltage Load Disconnect (LVLD) contactor. Optional: Not fitted as standard.

There will be three standard Load Distribution Units:

• LDU200: 200 Amps total load output

• LDU400: 400 Amps total load output
• LDU600: 600 Amps total load output

Style, rating and quantity of DC distribution components will be dependent on customer’s

requirements.

LDU600

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The Power Distribution Units are configured as per the following schematic diagram:
LOAD +VE

POSITIVE COMMON BUS

+VE
RECTIFIER
INPUT
-VE

LVLD NEGATIVE BUS

OPTION

NON PRIORITY PRIORITY

LOAD BREAKERS LOAD BREAKERS

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2.8. Battery connection panels

Two options are available for battery connection for higher capacity systems:

BATT400: This panel includes the following components:

• Low Voltage Disconnect contactor (LVBD) 400 Amps

• Maintenance switch to force closure of the contactor.
• Battery shunt: 400 Amps
• 2 X 400 Amp fuse holders
• Provision for additional fuse holders
• Battery return connection
• Front access only for installation and maintenance.

BATT600: This panel is to include the following components:

• Low Voltage Disconnect contactor (LVBD) 600 Amps

• Maintenance switch to force closure of the contactor.
• Battery shunt: 600 Amps
• 2 X 600 Amp fuse holders
• Provision for additional fuse holders
• Battery return connection
• Front access only for installation and maintenance.

Batt600 with 3x600A TPS Breaker and LVD

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2.9. AC distribution panel

In general the Infinity IMS48 systems will not be fitted with AC distribution Units as the rectifier
units are hot pluggable and the cable sizes required for the system are sufficient to carry the
potential fault currents back to the main system isolator.

However where customer requirements demand the installation of individual rectifier AC

circuit breakers the relevant AC components may be mounted within a 3U panel with front for
operation and maintenance.

AC Distribution panel access

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2.10. Pulsar Controller:

The monitor and control system for the IMS48 systems is the Pulsar Controller. Features
include:

• Local or remote viewing and configuration
of system parameters, alarm thresholds,
and user-definable alarm inputs and relays
• Extensive rectifier/converter Monitoring and
Control
• Advanced Battery Management to
maximize and manage battery health
• Emergency Power Off (EPO) to meet local
emergency services code requirements
• System voltage & current monitoring
• LVBD Low Voltage Disconnect contactor
control and monitoring
• dc Distribution monitoring
• Standard and Programmable Alarms
• Extensive Voltage, Current, Temperature,
and Binary Input monitoring
• Standard and programmable Office Alarm
relays
• Digital communications to all system
devices

Plant Status LEDs

RS232 and Ethernet

Ports to plug in a PC
to use Web Pages

Voltage LCD Menu

Test Jacks Display Navigation

See the Advanced Features User Guide for the Pulsar Controller for further detail.

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3. Specifications

Electrical
AC Input Configurable for Three Phase Star or Delta AC connections
Output Distribution Load and Battery connections via front access
Maximum Discharge Current 100A/200A/400A/600A depending on system configuration
Maximum Recharge Current Installed rectifier capacity minus plant load
Altitude -60 to 2,500m
Humidity 5% to 95% non-condensing
Harmonics EN61000-3-2 (IEC61000-3-2)
Voltage Fluctuations EN61000-3-3 (IEC61000-3-3)
Electrostatic Discharge EN61000-4-2 Level 3 , No error; Level 4, No Damage
RF Immunity IEC61000-4-3 Level 3
EFT IEC61000-4-4 Level 3
Surge IEC 61000-4-5 Level 3, No Error; Level 4, No Damage
Conducted Immunity IEC 61000-4-6 Level 3
Voltage Dips, Interruptions, and IEC 61000-4-11
Variations
Safety Agency Approval Unit shall be CE marked for use within Europe and meet
requirements of EN60950 and EN55022 level B

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4. Safety

4.1. Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or
repairing the IMS48 system:

• Install only in restricted access areas (dedicated equipment rooms, equipment closets, or
the like) in accordance with articles 110-16, 110-17, and 110-18 of the U.S. National
Electric Code (NEC), ANSI/NFPA No. 70, and pursuant to applicable local codes.

• This equipment is to be used in controlled environments (an area where the humidity is
maintained at levels that cannot cause condensation on the equipment, the
contaminating dust is controlled, and the steady-state ambient temperature is within
the range specified).

• This equipment must not be installed over combustible surfaces.

• If the proper connector for the country of installation is not provided, obtain appropriate
connectors and follow manufacturers and all local requirements for proper
connections. All national and local rules and regulations should be followed when
making field connections.

• The main output voltage (48V) meets SELV requirements.

• Insulation on field-wired conductors should be rated no less than 90° Celsius. Wire
conductor size should be sized per electrical codes for 75° Celsius wire, and based on
the current capacity of the associated protection device. Wiring internal to enclosed
equipment cabinets should be rated at 105° Celsius (minimum).

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

documentation.

• Battery input cables must be dressed to avoid damage to the conductors (caused by
routing around sharp edges or routing in areas where wires could get pinched) and
undue stress on the connectors.

• Fuse and/or circuit breaker loads must not exceed 80% of the fuse and/or circuit breaker
current rating. Distribute loads across the panel.

• The short circuit current capability of the battery input to the distribution panel must not
exceed 10,000A.

• AC branch circuits to this equipment must be protected with either fuses or circuit
breakers sized as required by the National Electric Code (NEC) and/or local codes.
The maximum size of the over-current protector is based on the type of shelf. Refer to
the equipment ratings to assure rating of equipment will not exceed 80% of the value
of the protector chosen.

• An accessible ac disconnect/protection device to remove ac power from the equipment

in the event of an emergency must be provided.

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• High leakage currents are possible due to contribution from simultaneous multiple AC
input connections. Earth ground connection is essential before connecting the ac
source to the shelf. This connection must be achieved by ensuring that the C.O.
grounding stud is connected as shown in the Installation Section, or quality service
personnel shall ensure that the rack system is bonded per the provision below.

• Installing fuses or circuit breakers not specified for use in these distribution modules
may result in injury to service personnel or equipment damage. Use only replacement
parts listed in this manual and on the equipment drawings.

• While installing batteries, follow all safety precautions outlined in the appropriate
battery product manuals.

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4.2. Warning Statements and Safety Symbols

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

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

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

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

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

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

This symbol is used to identify the presence of hazardous ac or dc voltages. It

may also be used to warn of hazardous energy levels.

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

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

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

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

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

• The equipment could be powered by multiple ac inputs. Ensure that the appropriate
circuit protection device for each ac input being serviced is disconnected before
servicing the equipment. Do not disconnect permanent bonding provisions unless all ac
inputs are disconnected.

• Batteries may be connected in parallel with the output of the rectifiers. Turning off the
rectifiers will not necessarily remove power from the bus. Make sure the battery power
is also disconnected and/or follow safety procedures while working on any equipment
that contains hazardous energy/voltage.

• Hazardous energy and voltages are present in the unit and on the interface cables that
can shock or cause serious injury. Follow all safety warnings and practices when
servicing this equipment. When equipped with ringer modules, hazardous voltages will
be present on the ringer output connectors.

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

• Use only properly insulated tools.

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

• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and
distribution components can produce severe arcing.

• Test circuits before touching.

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

• Be aware of potential hazards before servicing equipment.

• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the
condition of these circuits, especially wiring).

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

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5. Product Warranty

A. Seller warrants to Customer only, that:

1. As of the date title to Products passes, Seller will have the right
to sell, transfer, and assign such Products and the title conveyed
by Seller shall be good;
2. During the warranty period stated in Sub-Article B below,
Seller’s Manufactured Products (products manufactured by
Seller), which have been paid for by Customer, will conform to
industry standards and Seller’s specifications and shall be free
from material defects;
3. With respect to Vendor items (items not manufactured by
Seller), Seller warrants that such Vendor items, which have
been paid for by Customer, will be free from material defects
for a period of sixty (60) days commencing from the date of
shipment from Seller’s facility.
B. The Warranty Period listed below is applicable to Seller’s
Manufactured Products furnished pursuant to this Agreement,
commencing from date of shipment from Seller’s facility, unless
otherwise agreed to in writing:

Warranty Period
Product Type New Product Repaired Product*
Central Office Power
24 Months 6 Months
Equipment**
* The Warranty Period for a repaired Product or part thereof is six (6)
months or, the remainder of the unexpired term of the new Product
Warranty Period, whichever is longer.
** The Warranty Period for Products ordered for Use in Systems or
equipment Manufactured by and furnished by Seller is that of the initial
System or equipment.

C. If, under normal and proper use during the applicable Warranty Period,
a defect or nonconformity is identified in a Product and Customer
notifies Seller in writing of such defect or nonconformity promptly
after Customer discovers such defect or nonconformity, and follows
Seller's instructions regarding return of defective or nonconforming
Products, Seller shall, at its option attempt first to repair or replace
such Product without charge at its facility or, if not feasible, provide a
refund or credit based on the original purchase price and installation
charges if installed by Seller. Where Seller has elected to repair a
Seller’s Manufactured Product (other than Cable and Wire Products)
which has been installed by Seller and Seller ascertains that the
Product is not readily returnable for repair, Seller will repair the
Product at Customer’s site.

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With respect to Cable and Wire Products manufactured by Seller

which Seller elects to repair but which are not readily returnable for
repair, whether or not installed by Seller, Seller at its option, may
repair the cable and Wire Products at Customer’s site.
D. If Seller has elected to repair or replace a defective Product, Customer
shall have the option of removing and reinstalling or having Seller
remove and reinstall the defective or nonconforming Product. The cost
of the removal and the reinstallation shall be borne by Customer. With
respect to Cable and Wire Products, Customer has the further
responsibility, at its expense, to make the Cable and Wire Products
accessible for repair or replacement and to restore the site. Products
returned for repair or replacement will be accepted by Seller only in
accordance with its instructions and procedures for such returns. The
transportation expense associated with returning such Product to Seller
shall be borne by Customer. Seller shall pay the cost of transportation
of the repaired or replacing Product to the destination designated by
Customer.
E. Except for batteries, the defective or nonconforming Products or parts
which are replaced shall become Seller's property. Customer shall be
solely responsible for the disposition of any batteries.
F. If Seller determines that a Product for which warranty service is
claimed is not defective or nonconforming, Customer shall pay Seller
all costs of handling, inspecting, testing, and transportation and, if
applicable, traveling and related expenses.
G. Seller makes no warranty with respect to defective conditions or
nonconformities resulting from actions of anyone other than Seller or
its subcontractors, caused by any of the following: modifications,
misuse, neglect, accident, or abuse; improper wiring, repairing,
splicing, alteration, installation, storage, or maintenance; use in a
manner not in accordance with Seller’s or Vendor’s specifications or
operating instructions, or failure of Customer to apply previously
applicable Seller modifications and corrections. In addition, Seller
makes no warranty with respect to Products which have had their serial
numbers or month and year of manufacture removed, altered, or
experimental products or prototypes or with respect to expendable
items, including, without limitation, fuses, light bulbs, motor brushes,
and the like. Seller’s warranty does not extend to any system into
which the Product is incorporated. This warranty applies to Customer
only and may not be assigned or extended by Customer to any of its
customers or other users of the Product.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL
OTHER EXPRESS AND IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED
TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. CUSTOMER’S SOLE AND EXCLUSIVE REMEDY SHALL BE SELLER’S
OBLIGATION TO REPAIR, REPLACE, CREDIT, OR REFUND AS SET FORTH ABOVE
IN THIS WARRANTY.

Product Manual
Issue 1.12
Nov 2010