Instruction/ maintenance manual of the product 540VDC Emerson
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AC P ow er For Bu siness -Critical C ontin uit y™ Li eber t ® FS ™ DC Ene rgy S tora ge Syste m Us er Manu al - 200kW / 12 Secon ds, 540VDC DISCONTINUED PR ODUCT.
DISCONTINUED P R O D U C T.
i T ABLE OF CONTENTS I MPORTANT S AFETY I NSTRU CTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.0 G ENERAL S YSTEM I NFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 5.0 S YSTEM O VERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.1 Detailed System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii 6.4 Menu Tree and Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6.4.1 Screen Tree Menu Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv A PPENDIX A.0 UPS I NTERCONNECTION K ITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Appendix A.1 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Appendix A .
v Appendix B.3 DCM Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Appendix B.3.1 Logging into the D CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi FIGURES Figure 1 Liebert FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 2 Single Liebert FS unit or multiple Lie bert FS units integrated into a UPS system.
vii Figure 54 Control panel view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Figure 55 Main screen functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
viii Figure 109 Networks view, turn off DH CP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Figure 110 Networks view, edit settings (service level) . . . . . . . . . . . . . . . . . . . . . .
ix Figure 157 Multiple Liebert FS+DC units operating with a UPS in conjunction with batteries . . . . . . . . . 151 Figure 158 Two Liebert FS units operating in a para lleled for capaci ty (not redundancy) configuration, with a UPS and without batteries attach ed to the DC bus .
x DISCONTINUED P R O D U C T.
1 I MPORT ANT S AFET Y I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual co ntains important instructio ns that should be fo llowed during installation and mainte- nance of your Liebert FS. ! WARNING The installation of the Liebert FS must comply with applica ble national, federal, state and local codes.
2 Safety Precautions Read this manual thoroughly, paying spec ial attention to the sections that apply to you, before work- ing with the Liebert FS. Under typical operation and with all ca binet doors closed, only normal safety precautions are neces- sary.
General System Information 3 1.0 G ENERAL S YSTEM I NFORMATION 1.1 General Information 1.1.1 Safety Considerations Read and follow the instructions i n this manual be fore interacting with the system. This document contains important information and instructions fo r your Lieb ert FS.
General System Information 4 1.2 General System Descrip tion The Liebert FS is a flywheel energy storage system , a mechanical battery that stores energy in the form of a rotating mass. This energy is imme diately convertible to useful electric power.
General System Information 5 Figure 2 Single Liebert FS unit or mu ltiple Liebert FS unit s integrated into a UPS system Figure 3 Liebert FS unit(s) integrated into UPS system for ride-t hrough to bac.
General System Information 6 Figure 4 One or more Liebert FS units in p arallel with one or more battery strings, battery cabine ts or batteries in racks 1.2.1 General Spe cifications Table 2 summarizes the technical spec ifications of the Liebert FS.
General System Information 7 1.2.2 Features and Benefit s The Liebert FS provides clean constant DC output to the DC bus, at the user-selected, regulated volt- age, until t he stored energy is de pleted. See Figure 5 for a graphic representation of the performance power and duration curves of single and paralleled unit combi nations.
General System Information 8 For distribution in Europe, the Liebert FS is CE-marked and meets the applicable requirements of the following European directives: “Low Voltage Directive” 73/23/EEC a.
General System Information 9 Figure 6 Integrating a single Liebert FS unit into a UPS system Several Liebert FS units can be pu t in parallel to achieve hi gher power output and higher ride- through duration (see Figure 7 ).
Site Preparation 10 2.0 S ITE P REP ARATION Site preparation for the Liebert FS is minimal. If a UPS system is al ready installed, the only require- ments are to properly: • Place the unit in relation to walls, ceiling a nd other equipment an d • Fasten the unit to the floor.
Site Preparation 11 2.3 Flooring Requirement s 2.3.1 Floor Loading The Liebert FS should be mounted on a finished surface, such as concrete, block, brick or wood.
Site Preparation 12 2.4.2 St atus/Control Connections Site preparation for Sta tus/Control connections vary according to the type of UPS interconnection kit provided with your Liebert FS. Liebert recommends maki ng Status/Control connections on the UPS system side.
Unloading and Unpacking 13 3.0 U NLOADING AND U NP ACKING 3.1 Inspection Before Removal From the T ruck While the Liebert FS shipping pa ckage is still on the truck: • Inspect the equipment and shipping containe r(s) for any signs of da mage or mishandling.
Unloading and Unpacking 14 3.2.1 Handling The Liebert FS shipping package i s designed to be handled using a forkli ft. Forklift operators must avoid rough handling when picking up , moving and lowering it.
Unloading and Unpacking 15 5. Use a forklift to remove the cabinet from the shipping pallet. To lift the Liebert FS, the forks should b e inse rted between the caster wheel assemblies (se e Figure 10 ). Forks must be extended to the full dept h of the cabinet—at least 6 ft.
Unloading and Unpacking 16 Figure 12 Lo cation of serial and model number plate (c abinet side p anel removed and open door) 3.3 Positioning the Liebert FS 3.3.1 Moving the Liebert FS When moving the unit a shor t distance, the Liebert FS may be ro lled on its built-in casters (see Figure 13 ) to its location.
Installation 17 4.0 I NST ALLATION The Liebert FS system design and sa fety characteristics allow for a relatively simpl e and quick instal- lation. The system is d esigned to be rolled o r lift ed into place and bolted to the floor using Liebert's mounting kit, included wit h the system.
Installation 18 Figure 15 Interna l layout NOTE The Liebert FS is designed for front-access-only for in stallation and maintenance. While the likelihood of repair is minimal, some repair procedures require side and/or rear access.
Installation 19 4.1 Cabinet Floor Mounting • For placement on concrete, masonry or stone floors, see 4.1.1 - Concrete, Masonry or Stone Floor Mounting . • For placement on wood floors, see 4.1.2 - Wood Floor Mounting . • For placement on raised flo ors, see 4.
Installation 20 4.1.1 Concrete, Masonry or S tone Floor Mounting Mounting Kit for Concrete, Masonry or S tone Floors Liebert has i ncluded a complete an choring kit with each Liebert FS for surface mo unting. The kit is intended to secure ly fasten the Li ebert FS to its intended location for operational safety and seismic requirements.
Installation 21 5. Drill 2" (51mm) deep holes in prepared surface using the drill bit included in the ki t per bolt pattern described in Figure 149 - Floor mounting template . The setter rod should be used as a depth gauge to ensure proper depth.
Installation 22 8. Match mounting brackets with the hole s on the bottom of the cabinet (see Figure 21 ). Make sure that the bracket holes al ign with the mounting spots on the underside of the cabinet and secure the brac ket s wi th th e fou r (4 ) 1/2" diameter x 3/4" long (12.
Installation 23 11. Insert and begin tightening two (2) hex head bolts with one washer each through bracket mounted at front of cabinet into anchor inserts in mounting surface (see Figure 23 ). Figure 23 Mounting front bolt s—front side of cabinet 12.
Installation 24 4.1.2 Wood Floo r Mounting Determine which of these cases applies to your installation: • For wood flooring over concre te, follow the instructions in 4.1.1 - C oncrete, Mason ry or Stone Floor Mounting . • For wood flooring on joists, follow the instructions in this section.
Installation 25 4.1.3 Raised Floor Mounting Raised Floor Mounting Kit Liebert has included a complete anchoring kit with each Liebert FS for surface mounting. The kit is intended to securely fasten the Liebert FS to its location for operational safety and seismic requirements.
Installation 26 6. Attach a large diameter wash er, a lock washer an d a nut to each he x flange bolts as des cribed in Figure 25 and Figure 155 . 7. Check the bubble level o n the fl oor of the cabinet on the right hand side of the Power Conv ersion Module (see Figure 24 ).
Installation 27 Figure 27 Liebert FS with circuit breake r mounting plate and access p anels for DC and control wiring connections Figure 28 T ypical circuit breaker wiring for DC connections (view from rear of circuit breake r) ! CAUTION Do not cut entry holes for conduit while the access plates are still set on the top of the Liebert FS cabinet.
Installation 28 4.2.2 DC Power Connections The instructions for installation of DC power connection s vary according to the ty pe of UPS intercon- nection kit integr ated into your Lie bert FS unit. Follow th e installation instructio ns in Appendix A.
Installation 29 4.2.5 AC Auxiliary Control Power Suppl y Connections The AC auxiliary power supply connections to the Liebert FS are made through the auxiliary power fused disconnect on the mounting plate above the inductor-cap acitor module and to the right of the optional VIB and DCM module s (see Figure 30 ).
Installation 30 The AC wire is field-supplied. Wi re size and installation must comp ly with all applicable local, regional and national regu lations (e.g., National Electric Code for USA). An 18 AWG cable (approxi- mate metric equivalent: 0.82mm 2 wire section) is recommended for this connection.
Installation 31 4.2.6 Remote Monitoring Connections—Op tional The Liebert FS standard unit does not include remote monitoring connections. Remote monitoring capabilities are p rovided as an option see Figure 34 ).
System Overview 32 5.0 S YSTEM O VERVIEW 5.1 Det ailed System Description Figure 35 Liebert FS front view UPS Interconnectio n Kit Power Conversio n Module Built-In Casters, 4 Magnetic Levitation Modu.
System Overview 33 5.1.1 System Module Description The Liebert FS is a modular system composed as follows: • Control Panel • UPS In terconne ction Kit • Power Conversion Module • Main Control Modu le • Flywheel Module • E-Stop (optional-specia l order) Components are illustrated in Figure 35 .
System Overview 34 5.1.2 Power System The electrical system of th e Liebert FS is shown in Figure 36 . The schematic show s the Magnetic Levitation Module [see 5.1. 7 - Magnetic Levitation Module (MLM) ]. The pre-charge resistor and contactor which limit the inrush current into the DC bus capacitors.
System Overview 35 5.1.4 User interfaces Control Panel The Liebert FS uses a Control Panel as the primary means for an operator to interface with the sys- tem. Operating parameter values are di splayed and updated in re al time. Alarm states a nd system notices are also displayed when they occur.
System Overview 36 5.1.6 Power Conversion Module Power Conversion Module Controller (PCMC) The Power Conversion Module Controller is locate d within the Power Conversion Module. The PCM C uses microprocessor-controll ed logic to control the six pulse IGBT solid state switches and monitor t he active magnetic levitation system.
System Overview 37 5.1.7 Magnetic Levit ation Module (MLM) The Magnetic Levi tation Module pro vides control of the active magnetic levita tion hardware. The Liebert FS has a unique active magnetic levitati on system that ful ly levi tates the flywheel-rotat- ing group, allow ing the flywheel to rotate without any physical co ntact.
System Overview 38 5.1.8 Flywheel Module The Flywheel Module houses several major components: • The Rotating Group (high-speed carbon composite flywheel, high-speed shaft and roto r of the Motor-Gen.
System Overview 39 5.1.9 Rotor/Flywheel—Rot ating Group The flywheel is made of carbon/glass composite. This is mounted on a metal shaft with integral motor-rotor and together these comp onents form the ro tating group.
System Overview 40 5.1.1 1 V acuum System During manufacture, the vacuum chambers are evacuated and baked to remove water vapor. The vac- uum system is then permanently sealed off to prev ent any air entering the system and to remove the possibility of accidental loss of va cuum.
System Overview 41 5.1.12 Flywheel Sensors Spee d The speed detection system use s an infrared emitter an d a sensor to detect the rotation of the shaft. A hole drilled through the shaft allows ligh t to pass an d is detected on the opposite side by an infrared detector.
System Overview 42 5.1.13 System Safety Every composite flyw heel is inspected, spi n balanc ed and tested to 110% over-speed in accordance with NEMA guidelines. A patented dual-wall safety system ensures that in the unlikely event a fly- wheel were to separate during oper ation, the inner housing would reta in the carbon fiber.
System Overview 43 5.1.15 V entilation and Cooling The Liebert FS stator and power el ectronics are liquid cooled with a liqui d-to-air radiato r. The radia- tor within the Liebert FS package is designed for natural and forced air-cooling. Air inlets are pro- vided from the bottom front of the Liebert FS enclosure.
System Overview 44 Figure 44 V olt age and Induct ance curve The V-I (Voltage and Inductance) curve (see Figure 44 ) shows the performance characteristics an d modes of operation of the Liebert FS system based on the seven u ser-configurable system parameters.
System Overview 45 Regulation V oltage Del ta During Disch arge (V reg Delta 2) Vreg Delta 2 is the programmed amou nt of voltage dr op from the Transition State of Charge to the end of discharge (T S.
System Overview 46 5.3.1 OFF Mode When the Liebert FS is initially powered on, it en ters the OFF mode and ma gneti cally levitates its rotating group. A manual user command will make the system transition from OFF mode to STAR- TUP mode if all startup conditions are met.
System Overview 47 5.3.4 CHARGE Mode To charge the Liebert FS, the Lieb ert FS will draw power from the UPS DC bus to accelerate the fly- wheel (as long as the UPS DC bus voltage is higher than Vcharge). In this mode, the Liebert FS St ate of Charge (SOC) will progressive ly increase from 0% to 100%.
System Overview 48 5.3.6 DISCHARGE Mode Starting from either CHARGE or READY mo de, the Liebert FS will enter the DISCHAR GE mode if the UPS DC Bus Voltage goes below Vcharge.
System Overview 49 Following a User Command In any mode, except OFF mode, the user may comma nd the Liebert FS to tr ansition in SHUTDOWN. While in SHUTDOWN mode, the user will still be ab le to comma.
System Overview 50 Figure 53 T ypical opera tion modes K E Y # MO DE DE S CRI P TIO N 1 R E AD Y Idl e c ondi t i on w ai t i ng for ev ent 2 DI S CHA RG E 3 CHA RGE F S s uppor ti ng the c r i t i cal l oad C har gi ng to t op s peed A B C D E Gr i d Suppl y l os t , F S s uppor ti ng the l oad Gener ator St ar ts , A .
System Overview 51 5.4 Maintenance and Reliability The Liebert FS is designed to re quire minimal preventive servicin g and maintenance. There are no user serviceable parts in the Liebert FS. Please co ntact a Liebert-Certified Te chnician before attempt- ing to remove or service any components of the sy stem.
Operation 52 6.0 O PERATION 6.1 Operator Controls The Liebert FS uses a Control Panel as the primary mea ns for an operator to interface with the sys- tem.
Operation 53 6.2 Control Panel The Control Panel (see Figure 54 ) below represents the Control Pa nel on the Liebert FS. The dia- gram is labeled as a reference for the various ke ys, functions and data foun d on the Control Panel.
Operation 54 6.2.1 Main screen function descripti ons Figures 55 and 56 . provide descriptions and locat ions of the information and functions availa ble from the Main screen and the Fault Screen. Figure 55 Main screen functi ons Figure 56 Fault screen functions Liebert FS 48020 RPM: SOC: SOC: BUS: PWR: 73.
Operation 55 6.2.2 System MODE Indicators The Liebert FS has nine modes of operation: OFF, STARTUP, CHARGE , READY, DISCHARGE, SHUTDOWN, COAST, FAULT and STANDBY. These are displayed on the main screen of the control panel as identified in Figure 55 .
Operation 56 6.2.4 Other St atus Indicators The Liebert FS system disp lays additional indicat ors during operation. • Option Statu s; DCM or VIB (examp le: V abbreviation for VIB enabled • Security Levels • PWM: Pulse Width Modulation Status (ON or OFF) • SOC: State of Charge (0-100 %) SOC shows a relative energy stored in the s yst em.
Operation 57 6.3 Security Access 6.3.1 Security Levels The Liebert FS software has two security leve ls: READ-ONLY and USER. Secu rity levels restrict access to system resources, such as EEPROM par ameters, terminal commands and display panel functions.
Operation 58 Figure 57 Menu tree U s er/ Adv Ti me / Da te T em perat ures Volt ages H is t ory Opt ions C harge Elec t ric al N et w ork Vit als Pas s w ord I nput S/ N R eboot Sec urit y About T ool.
Operation 59 6.4.2 Navigation and Operation of Control Pan el Navigation of the menu screens is simple and intuitive. From the Ma in Screen, also referred to as “Home”, menu functions a nd screens can be accessed by using the funct ion keys and the numeric key- pad.
Operation 60 Figure 59 READ ONL Y leve l p arameter view screen In the USER mode, below the 7 basic parameters can be modified, see 6.3.2 - Pa ssword for access level and passwords. Pressing the corresponding number to the param eter to the left of the number will take you to th e parameter setup screen for that particular parameter.
Operation 61 Each EEPROM parameter has its own screen which contains paramete r description, data range, cur- rent value and default value button. Default button shows the default value for the parameter. From this screen the UP/DOWN arrow keys can used to move be tween parameters.
Operation 62 6.4.6 T emperatures MENU>VIEW>TEMPERATURES shows the temp eratures of various system parts . Figure 66 T emperatu re view 6.4.7 V oltages MENU>VIEW>VOLTAGES shows the m ajor power supply voltages on the controller board. These values are updated continuously.
Operation 63 • Discharge: The most recent discharge (LAST DISCHARGE) is displayed in time (sec.) and energy (kW) on this screen as are the accumulated discharge time/energy (TOT AL DISC HARGE) and the number of times system ha s discharged (D ISCHARGE COUNT).
Operation 64 • Vitals (USER or above): Key system efficiency and performance measurements are displayed i n Max/Min measurements along with the date recorded.
Operation 65 6.4.10 Network—Requires DCM Option The Network view screen displays the addresses of the DCM. Static address settings can be entered using the keypad into this screen.
Operation 66 6.4.1 1 Electrical The screen MENU>VIEW>ELECTRICAL shows the majo r electrical system variables. These quanti- ties are updated continuously. Figure 81 Electrical view 6.4.12 V itals MENU>VIEW>VITALS shows the current vital system values.
Operation 67 Figure 83 Password screens USER level password can be modified by pressing th e CHG PW butto n. Current password is required to change the password. The USER level password should be between 3 - 1 2 digits length, hence di gits after 13th are ignored if more than 12 digits are entered.
Operation 68 Figure 85 Change p assword 6.4.14 About About screen shows the version of the firmware and com pany informatio n. The controller board has two DSPs and each DSP has bootloader and ap plication firmware. Figure 86 ABOUT screen Figure 87 Serial numbers 6.
Operation 69 6.5 System S tartup 6.5.1 Initial System S tartup Procedu re Initial System Startup is defi ned as the first or initial startup followin g installation of the system. Several additional steps are required prior to th e normal startup procedur e includi ng the following Inspection before Initial System Startup, (Section 5.
Operation 70 6.5.3 Control Parameters Setup at Initial System S tartup Please have the relevant UPS Inte rconnection Kit Handbook (Liebert UPS Interconnection Kit [IKIT] Handbook for sp ecific Brand and Mod el UPS) av ailable for the Liebert technician.
Operation 71 6.5.5 Regular S tartup Procedure 6.5.6 Inspection Before Regular S tartup The following verificat ions must be done before pe rforming a regular startup of the Liebert FS (see 6.
Operation 72 V alidation of Control Para meters Setup 1. Once the Control Panel has su ccessfully booted up, the C ontro l Panel will display the Main Screen (see Figure 55 ). 2. Verify the Control Parameters values are correct. (Consult Table 9 an d the relevant UPS Interconnection Kit Handbook for choosing the proper Control Parameters values).
Maintenance 73 7.0 M AINTENANCE 7.1 Safety Precautions Observe all safety precautions in this manual, paying particular attention to Important Safety Instructions on page 1 . ONLY qualified service pe rsonnel should pe rfo rm maintenance on the Liebert FS.
Maintenance 74 7.2 Liebert Services Startup, maintenance and training progra ms for the Liebert FS are available through your Liebert sales representative.
Maintenance 75 7.4 Maintenance Schedule The Liebert FS maintenance schedule consists of actions listed in Table 11 . 7.5 Record Log Set up a maintenance log to record schedu led checks and any abnormal conditi ons.
Maintenance 76 7.6 Optional Air Fi lters The optional air filters must be inspected and se rviced on a regular sche dule. The period between inspections will depen d upon environmen tal conditio ns. Under normal conditions, the air filters wi ll require cleaning or replacement approximately every 12 months.
Maintenance 77 7.9 Reporting a Problem If a problem occurs within the Li ebert FS, re view all alarm messa ges along with other pertinent data. This information should be given by telephone to the Liebert service representative’s office nearest you.
Trou bleshooting 78 8.0 T ROUBLESHOOTING 8.1 General The Liebert FS is capable of detecting conditions outside of normal operatin g pa rameters and provid- ing notice at the Control Panel. This data is recorded as either Warn i ngs or Faults and can be viewed in the software menu tree at the screen location MENU>VIEW>.
Trou bleshooting 79 Figure 91 W arning history Figure 92 Fault history The warnings, faul t meanings and possible cau ses in the following text and in Table 15 may be used in troubleshooting the messa ges and may also aid in identifying condi tions outside the flywheel sys- tem that may adversely affect it.
Trou bleshooting 80 Table 15 lists the warnings and some tr oublesho oting steps that may be taken if any of the Warnings in appear. If Warnings persist, contact your local Liebert representative or contact Lieb ert Services at 800-543- 2378. You may also visi t the Liebert Web site for information at www.
Trou bleshooting 81 8.3 Fault s A Fault is defined as an und esirable system operating condition tha t could cause further damage to the system or potentially drop the load. Once dete cted, Faults may trigger an appropriate emergency action such as shutting the unit down.
Trou bleshooting 82 Faults. Table 17 - Troubleshooting describes actions that may al leviate the condition or provide valuable inform ation for technical su pport. Faults that initiate an AU TOSHUTDOWN include: MISER, RU NOUT, PWR SPLY VOLT (at high speed), and will require Servic e level and higher to reset.
Trou bleshooting 83 Fault messages displayed can, in some cases, be investigated for a solution. Listed below in Table 17 are troubleshooti ng steps for the Fault messages that ca n occur. Refer to the general drawings in Appendix D.0 - Installation Drawings for the location of system components.
UPS Interconnection Kits 84 A PPENDIX A.0 UPS I NTERCONNECTION K I TS Your Liebert FS is equipped with a UPS interco nnect ion kit to connect it to one of these Liebert UPS systems: • Liebert Series.
UPS Interconnection Kits 85 Power and status/control wiring must be run in separate conduits or cable trays. Refer to Appendix D.0 - Installation Drawings for locations of the various electr ical connections between Liebert FS system(s) and UPS system.
UPS Interconnection Kits 86 Appendix A.1.2 DC Power Connections The DC power connections to the Liebert FS are made through the circuit breaker (see Fi gure 96 ) in the UPS interconnection kit installed in your Li ebert FS.
UPS Interconnection Kits 87 Appendix A.2 Inst alling the Liebert FS With a Liebert Series 610, Liebert Series 600T or Liebert Series 600 The Liebert Series 610/600T/600 UP S inter connection kit for the Liebert F S is compa tible with the Liebert Series 610, Liebert Series 6 00T and Liebert Series 600 models in Table 19 .
UPS Interconnection Kits 88 Appendix A.2.2 St atus/Control Connections - Liebert Series 610/600T/600 UPS Interconnection Kit The status/control interfac e is the Status/C ontrol Terminal Bloc k.
UPS Interconnection Kits 89 Appendix A.2.4 Liebert FS Configuration - Single Liebert FS on Liebert Series 610/600T/ 600 DC Bus The following Software Control Parameters must be set when the Liebert FS is conne cted to the DC bus of the Liebert Series 610/600T/600 UPS system.
UPS Interconnection Kits 90 Appendix A.3 Inst alling the Lieber t FS With a Liebert Npower UPS The Liebert Npower UPS interconnection kit for the Liebe rt FS is compatible with the Liebert Npower models in Table 22 . Figure 99 Liebert FS integrated into a Liebert Npower UPS system Appendix A.
UPS Interconnection Kits 91 Appendix A.3.2 St atus/Control Connections - Liebert Npower UPS Interconnection Kit The status/control interface is the Liebert Npower Battery Informa tion Board (BIB).
UPS Interconnection Kits 92 Appendix A.3.5 Liebert FS Configuration - Multip le Liebert FS Unit s on Liebert Npower DC Bus Liebert FS Software Control Parameters must be reset when multip le Liebert F.
UPS Interconnection Kits 93 Appendix A.4 Inst alling the Lieber t FS With a Liebert Series 300 UPS The Liebert Series 300 UPS interconnection kit for the Liebert FS is compat ible with the Liebert Series 300 model s in Table 25 . Figure 100 L iebert Series 300 UPS Appendix A.
UPS Interconnection Kits 94 Appendix A.4.2 St atus/Control Connections - Liebert Series 300 UPS Interconnection Kit The status/control interfac e is the Status/C ontrol Terminal Bloc k.
UPS Interconnection Kits 95 Appendix A.4.4 Liebert FS Configuration - Single Liebert FS on Series 300 DC Bus The following Sof tware Control Parameters must be reset when the Liebert FS is connected to the DC Bus of the Liebert Series 300 UPS system. Instructions to set these parameters on the Li ebert FS are in 6.
UPS Interconnection Kits 96 Appendix A.5 Inst alling the Liebert FS With a Liebert HiPulse UPS The Liebert HiPulse UPS interconnection kit for th e Liebert FS is compatible with the Liebert HiPulse™ models in Table 28 .
UPS Interconnection Kits 97 Appendix A.5.3 IKIT -A05 DC Power Connections The DC power connections to the Liebe rt FS are made through the circuit-breaker (see Figure 103 ) in the IKIT-A05. The minimum wire size to be used is 1/0 AWG - 600VDC wire (54 mm 2 wire section).
UPS Interconnection Kits 98 Appendix A.5.5 Single Liebert FS on UPS DC Bus The following Liebert FS Software Control Parameters must be set wh en a single Liebert FS is con- nected alone on the DC bus of the L iebert HiPulse UPS system. Instructions on setting these parame ters on the Liebert FS are fo und in 6.
UPS Interconnection Kits 99 Appendix A.5.7 Liebert FS Configuration – Multiple Lie bert FS Units Liebert FS Software Control Parameters must be reset when multip le Liebert FS units are connected in parallel on the DC bus of a Liebert HiPulse™ UPS system.
Data Collection Module 100 A PPENDIX B.0 D A TA C OLLECTION M OD ULE Appendix B.1 General Information Appendix B.1.1 Overview The Data Collection Module (DCM) is desi gned to provide real-time data moni toring and data storage for the Liebert FS. The DCM co llects data on virtually ever y event that occurs in the Liebert FS.
Data Collection Module 101 Appendix B.2.2 DCM Requirement s The Data Collection Module requires a connection to an existin g ne twork via an Ethernet cable. An RJ-45 jack is built directly into the bottom of th e faceplate of the DCM and located adjacent to the power supply co nnection.
Data Collection Module 102 To view t he Network setti ngs return to the View menu and pr ess number 6 “Network”. The Network view screen displays the networ k addresses coming from the DCM. Static address settings can be entered using the keypad into this screen.
Data Collection Module 103 Appendix B.2.3 Accessing the DCM From a personal computer connected to the same network as the DC M, enter the IP Address of the DCM, assigned by the LAN network se rver or manual ly configured, into the address line of the Inter- net browser to gain access to the DCM as seen in Figure 111 .
Data Collection Module 104 • Software Ve rsion: The current version of th e s oftware running on the DCM. • Configuration Type: Select from the drop-down menu as to w hether it is a Static IP Address or a DHCP server assigned.
Data Collection Module 105 Appendix B.3.3 Dat afiles Screen This screen lists the different file s types for viewing an d download. Ther e are five files types: F, S, L, A and D. • F indicates a fa st data packet, containin g electrical informa tion such as volt ages, amps and wa tts.
Data Collection Module 106 Appendix B.4 DCM T roubleshooting Appendix B.4.1 DCM T roubleshooting Principles There are few circumstances in wh ich the Liebert FS might operate in an unexpected manner. This section explains a few of the se circumstances and offers some solutions to such issues.
V ersatile Interface Board 107 A PPENDIX C.0 V ERSATILE I NTERFACE B OARD Appendix C.1 General Informati on—V ersatile Inter face Board Appendix C.1.1 V ersatile Interface Board Overview The Versatile Interface Boa rd (VIB) is designed to provide real-ti me status feedback and control of the Liebert FS.
V ersatile Interface Board 108 Appendix C.1.2 VIB Features The VIB provides full y isolated inputs and outputs th at operate on a wide range of voltages for maxi- mum flexibility. Each I/O is prog rammed to perform a dedicated func tion. The specific function of each I/O is listed below in Table 34 .
V ersatile Interface Board 109 Figure 1 17 I/O Designa tions I / O L abel ( X20) ~ I /O 2 I/ O 3 I/ O 4 I/ O 5 I /O 6 I /O 7 I /O 8 I /O 9 I/O 1 0 COM N.C . W/ N.O. COM N.C . W /N.O. COM N.C . W /N.O. COM N.C . W /N.O. COM N.C . W /N.O. COM N.C . W /N.
V ersatile Interface Board 110 Appendix C.2 VIB Inst alla tion and Configuration Appendix C.2.1 VIB Inst allation The VIB has been installed behi nd the service pa nel of the Liebert FS. The power/communications cable has been connected to the Main Control Module at the factory .
V ersatile Interface Board 111 Appendix C.2.5 VIB Connections The VIB is sup plied with remo vable screw-terminal connectors to allow for easy integration Figure 119 . The user must supply the wire as specified below to make the connections to the VIB connectors.
V ersatile Interface Board 112 Appendix C.4 T roubleshooting the VIB Appendix C.4.1 UIB St ate Not Displayed on the Front Panel • Check that no other faults ar e present on the display panel. • Call Liebert fo r instructions on how to e nable the VIB func tionality.
Installation Drawings 113 A PPENDIX D.0 I NST ALLATION D RAWINGS Appendix D.1 Liebert FS Flywheel Submitt al Document Matrix Following is a list of submitta l documents that must accompany each Liebert FS that ships from the factory. The documents are groupe d by L iebert FS model number.
Installation Drawings 114 Appendix D.2 Other Li ebert FS Drawings Following is a list of addi tional Liebert FS drawings that are availa ble for distribution.
Installation Drawings 115 Figure 121 Electrical connections DISCONTINUED P R O D U C T.
Installation Drawings 116 Figure 122 Electrical system block diagram DISCONTINUED P R O D U C T.
Installation Drawings 117 Figure 123 24 UVR, circuit breaker to terminal block wiring Figure 124 48 UVR, circuit breaker to terminal block wiring Note: PCM is UPS module.
Installation Drawings 118 Figure 125 Outline drawing, Liebert FS cabinet 12-100120-00 Rev . 01 DISCONTINUED P R O D U C T.
Installation Drawings 119 Figure 126 Control wiring, external interconnect di agram—Liebert FS ca binet to Liebert Npower UPS module Figure 127 Control wiring external in terconnect—Liebert FS to Liebe rt Series 300 C . G. #17 C . G. #19 Li ebert FS Lieber t Npower UPS M odul e 12- 100120 - 01 R ev.
Installation Drawings 120 Figure 128 Control wiring—external interconne ct diagram, Liebert FS ca binet to Liebert Series 610 UPS module Li ebert FS Li ebert Seri es 610 UPS M odul e 12 - 100120 - 03 Rev . 01 FUSE D DI SCO NNECT Provided by ot her s ; 120V, 60H z AC , 400 V A UP S -Pr ot ect ed Aux.
Installation Drawings 121 Figure 129 Contro l wiring—external int erconnect diagram, Liebert FS cabinet to Lie bert Series 610 UPS module 10 10 1 2 3 9 9 F used D isc on nect Li ebe rt F S St at us/.
Installation Drawings 122 Figure 130 Elevation drawing, Liebert FS cabinet with shipping p ackage 12-100120-08 Rev . 01 48" (1219mm) 4.4" (1 12mm) 45" (1 143mm) 24" (610mm) Shipping Support Bands (on either side) 54" (1372mm) 76.
Installation Drawings 123 Figure 131 Elevation drawing—Liebert FS cabinet 7 0. 9" (18 0 1 m m) 2 5" (6 35 mm) Front Top B ott om 32. 5" (826 m m) R i ght Sid e St andard Upgraded I nter act ive Display 12- 100120 - 09 R ev.
Installation Drawings 124 Figure 132 Control wiring diagram, Liebert FS power rack system in p a rallel for cap acity 12-100120-10 Rev . 01 FS 200 FS 200 Cabinet Unit 1 FS 200 Cabinet Unit 1 FS 200 Ca.
Installation Drawings 125 Figure 133 Liebert FS cabinet wi th optional power terminal block 12-100120- 1 1 Rev . 01 Opt ional Power T erminal Block (shown without cover) Motor an d Bearing Contr oller Module Power Conversion Module Gr ound Str ap Liebert Module Fan s NEG GND POS NEG GND POS To p V i e w 24.
Installation Drawings 126 Figure 134 Liebert FS cabinet mechanica l installa tion D o N ot Ti ghte n H al f- S iz e V i ew of Flo or A nc hor R e ar Moun t 12- 10 012 0- 12 R ev . 01 3 2- 5” ( 82 5. 5m m ) R i ght -Si de V i ew 36 ” ( 914 m m ) Mi nimum Fr ont C le ara nce 12” (3 05m m ) O ve r hea d C l ea r anc e W ei g ht : 130 0 l b .
Installation Drawings 127 Figure 135 Elevation dr awing—Liebert FS cabinet with integrated circuit breaker 12-100120 -13 Rev . 01 Factory-I n tegrated Circuit Breaker (shown wit hout cover) Motor and Bearing Contr oller Module Power Conversion Module Ground Strap Liebert FS M odule Fan s NEG GND POS NEG GND POS T op V iew 24.
Installation Drawings 128 Figure 136 One-line drawing, three Liebert FS systems in p arallel configuration Bi- D ir e c t io n a l Power C onv er ter F L YW HE EL N or mal ly O pen F ac tor y - I nteg.
Installation Drawings 129 Figure 137 Control wiring diagram—Liebert FS cabinet - manually operated circuit breaker 1 3 3 4 5 6 7 8 9 10 (+ ) (- ) (+ ) ( -) ( GN D) To Lie ber t FS P CM D C O ut put NO TE 1. P C M – P ow er C onver si on M odul e TB 1 UV R Con t r o l NC NO CO M T o Li eber t U P S Modul e 12 - 100 120- 1 6 R ev.
Installation Drawings 130 Figure 138 One-line diagram—Liebert FS syste ms with factory-integrat ed circuit breakers with Lieb ert UPS module B i- Dir e ct io n a l P ow er C o nv e r t e r N OT ES 1. Npow e r : 2- 8 uni t s i n par al l el wi thout r equi r i ng a D C di s c onnect s witc h.
Installation Drawings 131 Figure 139 One-line diagram—single Liebert FS system with factor y-integrated circuit breake r supplying Liebert UPS module B attery /DC In Li ebert FS Syste m 12- 100120 - 18 R ev.
Installation Drawings 132 Figure 140 Control wiring diagram—Liebert FS - optional electrically operated circ uit breaker Liebert Npower unit s T B3 T B1 T B2 TB5 TB 9 P2 T B8 40 0 4 01 113 T her m (.
Installation Drawings 133 Figure 141 T wo-eight p aralleled Liebert FS unit s with factory-integr ated circuit breaker in p arallel with a Liebert UPS B i- Dir e ct io n a l P ow er C o nv e rt e r N OT ES 1. Series 610/600 r e qui r es the us e of MBD for mor e tha n thr ee u ni ts in par al lel .
Installation Drawings 134 Figure 142 One-line diagram, single Liebert FS and batter y with factory-integrated circuit breaker su pplying Liebert UPS—UPS DC terminal point of common co nnection Liebert U P S Modul e R e ct if ier Inverter 3 Ou t 3 In Liebert F S S y s t em B i - Directi onal Power C onvert er 12 -100120 - 21 R ev .
Installation Drawings 135 Figure 143 One-line diagram, single Liebert FS and batter y with factory-integrated circuit breaker su pplying Liebert UPS—UPS battery point of co mmon connection Liebert U P S Modul e R e ct if ier Inver ter 3 Ou t 3 In Liebert FS Syste m 12 -100120 -22 Re v.
Installation Drawings 136 Figure 144 St atus/control wiring, multiple unit s 3 U VR 9 9 8 8 7 7 6 6 5 5 3 3 2 2 10 10 4 4 1 1 End ( N) Li eb er t F S C abi net F S Status / Co ntr ol Ter mi nal B l oc.
Installation Drawings 137 Figure 145 Wiring specifications, Liebert FS and Liebert Series 300 Wire No. Terminal Designati on Signal Name Maximum Voltage Maximum Current Color Wire Size & Type Maxi.
Installation Drawings 138 Figure 146 Wiring specifications, Liebert FS and Liebert Npower Wire No. Terminal Des ignation Signal Name Maximum Voltage Maximum Current Color Wire Size & Type Maximum .
Installation Drawings 139 Figure 147 Wiring specifications, Liebert FS and Liebert Series 610 Wire No. Terminal Designati on Signal Name Maximum Volta ge Maximum Current Color Wire Size & Type Max.
Installation Drawings 140 Figure 148 Wiring specifications, Liebert FS and Liebert HiPulse, Liebert NXL or Liebe rt NX WIRING SPECIFICA TIONS FOR THE LIEBERT FS AND LIEBERT HIPUL SE, LIEBERT NXL OR LIEBERT NX ARE A V AILABLE BY CONT ACTING: Y our local Liebert Sales Representative Y our local Liebert Serv ice Representative Liebert Corp.
Installation Drawings 141 Figure 149 Floor mounting template 16" ( 406mm ) N OT E: I f ho le is dr i lle d to o dee p, b ack f ill t o cor re ct t o prop er dep t h . 2 . 2 5 (5 7 mm) ma x. 4X O5 /8 " (16 mm) M a son Dr i ll x 2. 00 (51 m m) min .
Installation Drawings 142 Figure 150 Syste m mounting kit Dr il l Te m p la te Dw g 1 6 B ol ts an d Washers c om e w i t h cabi net 3 7 4 5 2 8 DISCONTINUED P R O D U C T.
Installation Drawings 143 Figure 151 L iebert FS block diagr am OPT I ON AL CA PACI TORS FIL TE R P REC H A R GE B O ARD C APA C I T O R BANK F U SE BOA R D P O W E R I NT E RF A CE BO A R D P OWE R B.
Installation Drawings 144 Figure 152 Power line diagram DISCONTINUED P R O D U C T.
Installation Drawings 145 Figure 153 UPS cable entry—bott om ( + ) B us (- ) B us Gr o un d Bu s Li ebe rt FS C abi net Un it N Liebe rt FS C abi ne t U n it N L ie b e r t F S Ca b in e t U ni t N 3- Phas e Out p ut U PS C ABINET 3- Pha se I np u t NOTES 1.
Installation Drawings 146 Figure 154 UPS cable entry—top ( + ) B us ( - ) B us Gro un d B us Li ebe rt FS C abi net U n it 1 Liebe rt FS C abi ne t U ni t 2 L ie b e r t F S Ca b in e t U ni t N 3- P has e Out p ut U PS C ABINET 3- Pha se I np u t NOTES 1.
Installation Drawings 147 Figure 155 Raised floor mounting 2" ( 5 0m m) dia . 1/ 2" (12 . 7 mm) dia . s te e l bolt L arg e d i ameter w ash er L o ckw ash er Rai sed f loor F N OT E : C om .
Specifications 148 A PPENDIX E.0 S PECIFICATIONS T able 36 T echnical specifications INPUT, DC Float Voltage 350 through 600 VDC; > 520 VDC requi red for 200kW Charging Current 5 through 50 Amps pe.
Specifications 149 Appendix E.1 Ground T est Procedure The purpose of the GTS is to confirm integrity of gr ounding path. This test is performed when the sys- tem is completely shutdown and isolated from all external powers.
Auxiliary Backup AC Power Supp ly 150 A PPENDIX F. 0 A UXILIARY B ACKUP AC P OWER S UPPLY Appendix F .1 Overview The Liebert FS must be operated with a backup A C power supply to protect the unit’s .
Auxiliary Backup AC Power Supp ly 151 Appendix F .3.1 Operating the Liebert FS+DC in Parallel With Batteries If the Liebert FS is operating in parallel with batteries, Liebert recommends attaching the backup AC power supply to the output of the UPS, as shown in Figures 156 and 157 .
Auxiliary Backup AC Power Supp ly 152 Appendix F .3.2 Operating the Liebert FS Without Batteries If the Liebert FS is operating without batteries, Lieber t recommends feeding the backup AC power supply from a separate, protected supp ly. This may be the output of another UPS or a su pply from a separate feeder circuit (see Figures 158 and 159 ).
Auxiliary Backup AC Power Supp ly 153 Appendix F .4 Scenarios This section describes five scenarios that might occur. • Loss of backup AC supply at 0 RPM - This causes a fault message to appe ar on the control panel to indicate there is a problem with the ba ckup supply .
Auxiliary Backup AC Power Supp ly 154 DISCONTINUED P R O D U C T.
DISCONTINUED P R O D U C T.
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An important point after buying a device Emerson 540VDC (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
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If you already are a holder of Emerson 540VDC, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Emerson 540VDC.
However, one of the most important roles played by the user manual is to help in solving problems with Emerson 540VDC. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Emerson 540VDC along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
