Crucial Power Products Life Line Regulator, Medical Power PC User's Manual
Below you will find brief information for Life Line Regulator, Medical Power PC. These three-phase, 60 Hertz, self-contained, modular units provide isolation and regulation of AC power. They are designed to protect sensitive medical devices and electronics from power surges, sags, and transients. Each phase is regulated independently, ensuring reliable and high-quality power for your critical equipment.
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User’s Manual
Life Line Regulator
Medical Power PC
Operating Documentation
Doc #. 6002--xxx
Revision A
Installation and Operating Documentation
When the Lights Go out -- We Turn On
Price $50.00
Crucial Power Products
Congratulations on selecting one of the fine products from Crucial Power Products, the Leader in Power
Protection Technology. Our wide product offering includes Uninterruptible Power Systems (UPS), Power
Conditioners, Automatic Voltage Regulators and Specialty Transformers (e.g. computer---grade, medical---grade). Since our beginnings in 1975, Crucial Power Products has shipped thousands of these fine products around the world, to discerning customers, for use on sensitive equipment and critical applications. Our customers, both new and long---time, continue to enjoy security and peace of mind as they realize what it means to ”When the lights go out, we turn on”.
One of our goals is to make these manuals both comprehensive and easy to use. This
new--format
Technical Manual is the result of ideas and inputs from customers who have taken an active interest in our continued success. We invite constructive feedback on our products and documentation via fax, mail or telephone.
HEADQUARTERS
Crucial Power Products
5900 Triumph Street
Commerce, CA 90040
SALES
Phone (800) 244---4069
FAX No.
(800) 246---2346
email: [email protected]
SALES
Phone (800) 244---4069
FAX No.
(800) 246---2346 email: [email protected]
Office Hours
8:00 AM to 5:00 PM PST a
Crucial Power Products
Crucial Power Products
Proprietary Reproduction or Distribution Forbidden
NOTICE: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION
This document contains proprietary and confidential information of Crucial
Power Products. In consideration of the receipt of this document, the recipient agrees not to copy any of its contents, nor disclose them to or allow them to be used by any person not currently a Crucial Power Products employee or an employee of the recipient having a need to know, without the express written consent of Crucial Power Products, and further agrees to surrender this document to Crucial Power Products when the reason for its receipt has terminated.
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Crucial Power Products
SAFETY
Safety precautions are important when operating or servicing electrical equipment. The following symbols are used extensively throughout this manual. Always heed these precautions since they are essential to the safe operation and servicing of this product.
DANGER!!
THIS DANGER SYMBOL IDENTIFIES A CONDITION OR ACTION WHICH WILL
RESULT IN SEVERE INJURY OR DEATH TO AN INDIVIDUAL OR SEVERE DAM-
AGE TO EQUIPMENT OR OTHER PROPERTY.
CAUTION
This Caution symbol identifies a condition or action which may result in minor injury to an individual or minor damage to the equipment or other property.
This unit was designed for specific applications. It should not be modified and/or used for any application other than for that which it was designed. Optional equipment not described in the sales literature of this manual should not be installed without first checking with the Service department. If you have any questions about this unit’s application call the Service department at the number shown on the previous page.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and maintenance of the unit and batteries.
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Crucial Power Products
IMPORTANT SAFEGUARDS
When using electrical equipment, basic safety precautions should always be followed including the following:
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
1.
Do not use outdoors.
2.
Do not mount near gas or electric heaters.
3.
Use caution when servicing batteries. Battery acid can cause burns to skin and eyes. If acid is spilled on skin or in eyes, flush acid with fresh water and contact a physician immediately.
4.
Equipment should be mounted in locations or at heights where it will not readily be subjected tampering by unauthorized personnel.
5.
The use of accessory equipment not recommended by the manufacture may cause an unsafe condition.
6.
Do not use this equipment for other than intended use.
SAVE THESE INSTRUCTIONS
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Crucial Power Products
REV A
REVISION HISTORY
REV DATE PRIMARY REASON FOR CHANGE
A . . . . .
July 25, 2003 . . .
Preliminary Release.
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LIST OF EFFECTIVE PAGES
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A
Crucial Power Products
REV A
TABLE OF CONTENTS
SECTION
SECTION 1 -- OPERATION
1---1 INTRODUCTION
1---1---1 Life Line Regulator
1---1---2 Medical Power PC
1---2 BENEFITS
1---3 TRANSFORMER
1---4 PRODUCT FEATURES
1---4---1 Bypass Switch
1---4---2 Input Main Circuit Breaker (IMCB)
1---4---3 Power On Indicators
1---4---4 Input and Output Power Terminals
1---4---5 Input Filter
1---4---6 Output Filter
1---5 REGULATION COMPONENTS
1---6 STARTING THE UNIT
1---7 OPERATION
1---7---1 Normal Condition
1---7---2 Nonregulating Condition
SECTION 2 -- PREINSTALLATION
2---1 LOCATION CONSIDERATIONS
2---2 FLOOR LOADING
2---3 CABLE ACCESS AND FLOOR LAYOUT
2---3---1 Cable Access
2---4 MOUNTING
SECTION 3 -- INSTALLATION
3---1 INSTALLATION
3---1---1 Unpacking
3---1---2 Inspection
3---1---3 Input Cable Installation --- Life Line Regulator & Medical Power PC
100 --- 300 kVA
3---1---4 Output Cable Installation --- Life Line Regulator and Medical Power PC
125 --- 300 kVA
3---1---5 Input Cable Installation --- Medical Power PC 15 --- 100 kVA
3---1---6 Output Cable Installation --- Medical Power PC 15 --- 100 kVA
3---1---7 Startup --- Life Line Regulator and Medical Power PC (100 --- 300 kVA)
3---1---8 Startup --- Medical Power PC 15 --- 100 kVA
3---1---9 Calibrate Control Logic Board
3---2
3---4
3---5
3---6
3---7
3---8
3---10
PAGE
1--1
1---9
1---9
1---10
1---10
1---11
1---14
1---15
1---15
1---15
1---1
1---2
1---3
1---4
1---4
1---4
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1---9
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2---1
2---4
2---5
2---5
2---7
3--1
3---1
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3---2 i
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REV A
SECTION
3---2 CONFIGURATION
3---3 RENEWAL PARTS, Life Line Regulator
3---3---1 Vendor Parts List, Life Line Regulator
3---4 RENEWAL PARTS, Medical Power PC (15 --- 75 kVA)
3---4---1 Vendor Parts List, Medical Power PC (15 --- 75 kVA)
3---5 RENEWAL PARTS, Medical Power PC (100 --- 300 kVA)
3---5---1 Vendor Parts List, Medical Power PC (100 --- 300 kVA)
SECTION 4 -- OPTIONS
4---1 INTRODUCTION
4---2 REMOTE EMERGENCY POWER OFF STATION, Medical Power PC
4---2---1 Installation for REPO
4---3 THERMAL REMOTE EMERGENCY POWER OFF STATION
4---3---1 Installation for Thermal REPO
4---4 SECONDARY SURGE PROTECTION
4---5 MAIN INPUT CIRCUIT BREAKER, Medical Power PC (15 --- 75 kVA)
4---6 INPUT/OUTPUT FILTERING
4---7 POWER ISLAND
4---7---1 Features
4---7---2 Power Island Specifications
4---7---3 Preinstallation
4---7---4 Output Interconnect Cable Installation
4---7---5 Output Cable Installation
4--1
4---1
4---2
4---2
4---4
4---4
4---6
4---6
4---7
4---8
4---8
4---9
4---10
4---12
4---13
PAGE
3---13
3---14
3---15
3---17
3---18
3---19
3---20
APPENDIX A -- SPECIFICATIONS
APPENDIX B -- SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A--1
B--1
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G--1
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REV A
LIST OF ILLUSTRATIONS
ILLUSTRATION PAGE
Section 1 OPERATIONS
1---1
1---2
1---3
1---4
. .
. .
REGULATED SYSTEM RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFE LINE REGULATOR AND MEDICAL POWER PC (100 --- 300 KVA)
MEDICAL POWER PC (15 --- 100 KVA) FOR 480 VAC INPUT
(15 --- 75 KVA) FOR 208 VAC INPUT
LIFE LINE REGULATOR; 15 TO 150 KVA, 480 VAC INPUT
MEDICAL POWER PC; 125 --- 150 KVA, 480 VAC INPUT
MEDICAL POWER PC (15 --- 75 KVA) FEATURES
. . . . . . . . . . . . . . . . . . .
1---5
1---6
1---7
1---8
. .
. .
. .
. .
LIFE LINE REGULATOR; 175 KVA TO 300 KVA, 480 VAC INPUT
PHASE---STABILIZER; 125 KVA TO 300 KVA WITH 480 VAC INPUT
LIFE LINE REGULATOR, PHASE---STABILIZER; 175 KVA TO 300 KVA, 208 VAC INPUT
INPUT FILTER WIRING
1---9 . .
.
OUTPUT FILTER WIRING
1---10 REGULATION PANEL ASSEMBLY LAYOUT
1---11 .
REGULATION PANEL ASSEMBLY LAYOUT
1---12 .
REGULATION BLOCK DIAGRAM
1---1
1---2
1---3
1---5
1---6
1---7
1---8
1---10
1---10
1---11
1---12
1---13
Section 2 PREINSTALLATION
2---1
2---2
2---3
2---4
. .
. .
. .
. .
LIFE LINE REGULATOR AND MEDICAL POWER PC (100 --- 300 KVA) CABLE ACCESS
MEDICAL POWER PC (15 --- 75 KVA) CABLE ACCESS
MEDICAL POWER PC (15 --- 75 KVA) CLEARANCES
LIFE LINE REGULATOR AND MEDICAL POWER PC (100 --- 300 KVA) CLEARANCES
Section 3 INSTALLATION
3---1 . .
CONTROL LOGIC BOARD
3---2 . .
SCR DRIVER BOARD
Section OPERATIONS
4---1 . .
REPO BOX
4---2
4---3
4---4
4---5
4---6
4---7
4---8
. .
. .
. .
. .
. .
. .
. .
REPO WIRING
THERMAL REPO WIRING
INPUT FILTER WIRING
OUTPUT FILTER WIRING
POWER ISLAND
POWER ISLAND FEATURES
POWER ISLAND CABLE ACCESS
4---9 . .
.
POWER ISLAND FLOOR TILE CUTOUT
4---10 POWER ISLAND DIMENSIONS AND CLEARANCES
2---6
2---6
2---7
2---8
3---12
3---13
4---2
4---3
4---4
4---7
4---7
4---8
4---9
4---10
4---11
4---11 iii
Crucial Power Products
REV A
LIST OF TABLES
TABLE
1---1
2---1
2---2
2---3
2---4
3---1
3---2
3---3
4---2
PRODUCT FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFE LINE REGULATOR SITE PLANNING SPECIFICATIONS
MEDICAL POWER PC SITE PLANNING SPECIFICATIONS
LIFE LINE REGULATOR FLOOR LOADING
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEDICAL POWER PC FLOOR LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFE LINE REGULATOR CURRENT TRANSFORMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MEDICAL POWER PC (15 --- 75 KVA) CURRENT TRANSFORMERS . . . . . . . . . . . . . . . . . . . . .
MEDICAL POWER PC (100 --- 300 KVA) CURRENT TRANSFORMERS
OPTIONS MATRIX
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PAGE
1---5
2---2
2---4
2---5
2---6
3---16
3---18
3---20
4---1 iv
Crucial Power Products
REV A
SECTION 1 -- OPERATION
1--1 INTRODUCTION
This manual provides installation, operation and maintenance information for the Life Line regulators and Medical
Grade PC units. A detailed description of each product is provided in the following subsections.
All components used are of the highest quality and specifically selected to achieve the highest level of performance.
These units are UL listed and conform to National Electric Code (NEC) and Occupational Safety and Health Act
(OSHA) standards.
The Life Line regulators and Medical Grade PC have tapped electronic voltage regulators. Six taps are on each primary winding of the transformer. Each tap is controlled by a silicon---controlled rectifier (SCR) switch and can become active at any time. Input line---to---line voltage and line current are monitored for each phase. Peak voltage is compared with a desired reference. Depending on this comparison, the regulation logic activates the proper SCR switch when the phase current becomes zero. This changes the primary---to---secondary turns ratio which corrects output voltage to the desired nominal. The correction process starts in less than one cycle. See Illustration 1---1.
500
480
420
0
--480
SAG
SURGE
INPUT
CORRECTED
CORRECTED
IN 1 CYCLE
IN 1 CYCLE
480
0
--480
OUTPUT
Life Line Regulators
REGULATED TO +/-- 3% OF NOMINAL TYPICAL
Medical Power PC
REGULATED TO +/-- 2% OF NOMINAL TYPICAL
ILLUSTRATION 1---1
1---1
Crucial Power Products
REV A
1--1--1 Life Line Regulators
The Life Line Regulators are designed to provide the reliable, high---quality power necessary to meet the needs of today’s sensitive electronics.
These three---phase, 60 Hertz, self---contained, modular units provide isolation and regulation of AC power. The zero---current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between
+10% surge and ---26% sag about the nominal rated voltage with an output voltage range of ± 3% typical to ± 4% maximum. Each phase is regulated independently.
The Life Line Regulators are available in input voltages of 208 or 480 VAC and output voltages of 208Y/120 and
480Y/277 VAC. These units are available in sizes ranging from 15 kVA to 300 kVA. The specific rating information for your unit is provided on the label plate located on the front panel. Refer to Appendix A.
The Life Line Regulators unit is shown in Illustration 1---2.
LIFE LINE REGULATORS AND MEDICAL POWER PC (100 --- 300 KVA)
WITH 208 VAC INPUT OR (125---300 KVA WITH 480 VAC INPUT
ILLUSTRATION 1---2
1---2
Crucial Power Products
REV A
1--1--2 Medical Power PC
The Medical Power PC power conditioner is designed to provide the reliable, high---quality power necessary to suit the needs of today’s sensitive medical devices.
This three---phase, 60 Hertz, self---contained, modular unit provides isolation and regulation of AC power. The zero---current tap switching voltage regulation circuitry automatically adjusts for an input voltage range between
+8% surge and ---10% sag about the nominal rated voltage with an output voltage range of ± 1.5% typical to ± 2% maximum. Each phase is regulated independently.
The Medical Power PC is available in input voltages of 208 or 480 VAC and output voltages of 208Y/120 and
480Y/277 VAC. This unit is available in sizes ranging from 15 kVA to 300 kVA. The specific rating information for your unit is provided on the label plate located on the front panel. Refer to Appendix A.
The 15 to 100 kVA Medical Power PC with 480 VAC or the 15---75 kVA with 208 VAC is shown in Illustration 1---3. The
125 to 300 kVA Medical Power PC with 480 VAC input or the 100---300 kVA with 208 VAC input is shown in Illustration
1---2.
MEDICAL POWER PC (15 --- 100 KVA) FOR 480 VAC INPUT
(15 --- 75 KVA) FOR 208 VAC INPUT
ILLUSTRATION 1---3
1---3
Crucial Power Products
REV A
1--2 BENEFITS
The Life Line Regulators and Medical Power PC protect electronic equipment from an overvoltage condition during line power surges and an undervoltage condition during sags. In addition, the unit protects equipment load by attenuating transients present on utility power lines. overvoltage, overcurrent, and transient conditions stress electronic components and decrease system reliability.
In medical applications, voltage fluctuations affect the image quality of imaging systems. Artifacts are introduced under sag conditions. Regulating power maintains image quality, resulting in more consistent images.
1--3 TRANSFORMER
The transformer contained in the unit is designed for convection cooling by means of free circulation of air through the bottom, front and back of the unit. Maximum ambient temperatures should not exceed 104˚F (40˚C). The transformer contains built---in thermal sensors which monitor internal temperatures. In models with a Input Main Circuit breaker (IMCB), the thermal sensors send a shunt trip signal to the IMCB in the event of an over temperature condition.
1--4 PRODUCT FEATURES
Sections 1---4 and 1---5 describe the features of the Life Line Regulators and Medical Power PC. Some features described in Section 1---4 are standard on all models while other features are offered as options. Refer to Table 1---1 to determine if the features described in this section are applicable to your unit. Refer to Section 4, Options, for information on optional features.
TABLE 1---1
PRODUCT FEATURES
Bypass Switch
Main Input
Circuit Breaker
Power On
Indicators
Input Filter
Output Filter
OPTION
Input/Output Power Terminals
Life Line
Regulators
S
N
N
S
O
S
Medical Power
(15 --- 75 kVA)
TABLE KEY: S = Standard equipment, O = Available as an option, N = Not available for this model.
MODEL
S
O
S
S
S
S
Medical Power
(100 --- 300 kVA)
S
N
N
S
S
S
1---4
Crucial Power Products
REV A
1--4 PRODUCT FEATURES (continued)
OUTPUT
FILTER
(Optional)
INPUT POWER
FILTER
REGULATION
ELECTRONIC PANEL:
-- Heat Sinks
-- SCR Snubber Boards
-- SCR Power Blocks
-- Reference Transformers
-- SCR Driver Boards
-- SCR Control Boards
-- Fuses
MAIN POWER
TRANSFORMER
BYPASS
SWITCH
INPUT AND OUTPUT
POWER
TERMINAL
INPUT & OUTPUT
CABLE ACCESS
(BOTH SIDES)
9/16” Dia.
Mounting Holes
LIFE LINE REGULATORS; 15 TO 150 KVA, 480 VAC INPUT
MEDICAL POWER PC; 125 --- 150 KVA, 480 VAC INPUT
ILLUSTRATION 1---4
1---5
Crucial Power Products
REV A
1--4 PRODUCT FEATURES (continued)
INPUT POWER
TERMINALS
POWER ON
INDICATORS
INPUT/OUTPUT
FILTER
MAIN
TRANSFORMER
REAR
VENTILATION
OUTPUT POWER
TERMINALS
REGULATION
ELECTRONIC PANEL:
-- Heat Sinks
-- SCR Snubber Boards
-- SCR Power Blocks
-- Reference Transformers
-- SCR Driver Boards
-- SCR Control Boards
-- Fuses
BYPASS
SWITCH
FRONT
VENTILATION
MAIN INPUT
CIRCUIT BREAKER
MEDICAL POWER PC (15 --- 75 KVA) FEATURES
ILLUSTRATION 1---5
1---6
Crucial Power Products
REV A
1--4 PRODUCT FEATURES (continued)
OUTPUT
FILTER
INPUT
FILTER
REGULATION
ELECTRONICS
PANEL
BYPASS
SWITCH
FANS for
Electronic
Cooling
FAN FUSE
MAIN POWER
TRANSFORMER
OUTPUT POWER
TERMINALS
INPUT POWER
TERMINALS
INPUT & OUTPUT
CABLE ACCESS
(BOTH SIDES)
9/16” Dia.
Mounting Holes
LIFE LINE REGULATOR; 175 KVA TO 300 KVA, 480 VAC INPUT
MEDICAL POWER PC; 125 KVA TO 300 KVA WITH 480 VAC INPUT
ILLUSTRATION 1---6
1---7
Crucial Power Products
REV A
1--4 PRODUCT FEATURES (continued)
OUTPUT
FILTER
INPUT
FILTER
REGULATION
ELECTRONIC
PANEL
INPUT AUTO
TRANSFORMER
BYPASS SWITCH
INPUT POWER
TERMINALS
MAIN POWER
TRANSFORMER
OUTPUT POWER
TERMINALS
FANS for
Electronic Cooling
FAN FUSE
INPUT & OUTPUT
CABLE ACCESS
(BOTH SIDES)
9/16” Dia.
Mounting Holes
LIFE LINE REGULATOR AND MEDICAL POWER PC; 175 KVA TO 300 KVA, 208 VAC INPUT
ILLUSTRATION 1---7
1---8
Crucial Power Products
REV A
1--4--1 Bypass Switch
The bypass switch is located on the front panel. See Illustrations 1---4 thru 1---7. This switch bypasses voltage regulation but maintains the functioning of the voltage change/isolation transformer between input and output. In
AUTO position line to---neutral voltages are regulated. In MAN (manual) position, regulation logic is bypassed and input power is applied to load via transformer without regulation. Select the MAN position if there is a problem with regulation logic circuitry. Refer to Section 1---7---2, Nonregulating Condition for the procedure to operate the unit in bypass mode.
CAUTION
The Bypass Switch must never be changed with the unit powered up.
1--4--2 Main Input Circuit Breaker (IMCB)
The MAIN INPUT CIRCUIT BREAKER (IMCB) located on the front panel of the unit, is used to switch power to the unit
ON and OFF. See Illustration 1---5.
The IMCB is shunt tripped by activation of a solenoid within the breaker when remote switches or thermal switches in the main transformer sense an over temperature condition. If the IMCB is shunt tripped, refer to Section NO TAG,
Miscellaneous Problems for the reset procedure.
An optional undervoltage shunt---trip is available.
Be sure to observe ALL warnings and cautions when setting the IMCB to ON or OFF.
1--4--3 Power On Indicators
Power On Indicators are located on the front of the unit. See Illustration 1---5. There is one neon indicating light for each of the three phases. If a phase is lost, the corresponding indicator will extinguish indicating which phase is not powered.
1--4--4 Input and Output Power Terminals
Input and Output power connections are made at the terminals located beneath the transformer except the illustration 1---5 where the terminals are located above and to the rear of the main transformer. See Illustration 1---4. Terminals are labeled H1, H2, H3, or L1, L2, L3 for the input cable connections and X0, X1, X2, X3 for the output cable connections.
1---9
Crucial Power Products
REV A
1--4--5 Input Filter
The Input filter is installed on the primary side of the transformer. The input filter consists of a resistor/capacitor network which acts as a large snubber circuit to eliminate high frequency impulses from entering the power system.
See Illustration 1---8.
R3
(L1) H1
(L2) H2
R1
(L3) H3
R2
R4
R5
R6
C2
C1
INPUT FILTER WIRING
ILLUSTRATION 1---8
C3
1--4--6 Output Filter
The Output filter is installed on the transformer secondary. It consists of a capacitor network which prevents noise from being fed back to the unit from noise generating loads. See Illustration 1---9.
Output filters are standard on the Medical Power PC and optional on other models.
X3
X0
X2
X1
C6
C5
C4
OUTPUT FILTER WIRING
ILLUSTRATION 1---9
1---10
Crucial Power Products
REV A
1--5 REGULATION COMPONENTS
Regulation is accomplished by solid---state electronics which control the tap switching function at the zero---current---crossing. Refer to Section NO TAG, THEORY OF OPERATION for more detail.
The regulation components are mounted on the regulation panel and can be seen by removing the front panel. See
Illustration 1---10 and 1---11. The regulation components include 3 SCR Control logic boards, 3 SCR Driver boards,
18 SCR/SCR Snubber board assemblies, 3 current transformers, 3 reference transformers, and 3 heatsinks. See
Illustration 1---12 for a block diagram of the regulation panel components.
Each SCR Control logic board has seven LEDs. The first six LEDs indicate the active tap selection during operation.
LED 7 indicates power is applied to the board and is always lit during operation.
To Bypass To Bypass To Bypass
HEATSINK (3)
SCR (18)
FUSELINK (15)
SCR SNUBBER
BOARD (18)
SCR DRIVER
BOARD (3)
REFERENCE
TRANSFORMER (3)
FUSES FOR
REF. TRANSFORMER (3)
(NOT ON ALL MODELS)
SCR CONTROL
LOGIC BOARD (3)
To
Current
Transformer
To
Current
Transformer
To
Current
Transformer
REGULATION PANEL ASSEMBLY LAYOUT
ILLUSTRATION 1---10
1---11
Crucial Power Products
REV A
1--5 REGULATION COMPONENTS (continued)
To
Current
Transformer
HEATSINK (3)
SCR (18)
SCR SNUBBER
BOARD (18)
FUSELINK (15)
REFERENCE
TRANSFORMER (3)
SCR DRIVER
BOARD (3)
SCR CONTROL
LOGIC BOARD (3)
FUSES FOR
REF. TRANSFORMER (3)
To
Current
Transformer
To
Current
Transformer
REGULATION PANEL ASSEMBLY LAYOUT
ILLUSTRATION 1---11
FUSES FOR
FAN (3)
1---12
Crucial Power Products
REV A
1--5 REGULATION COMPONENTS (continued)
OUTPUT
INPUT
INPUT
BYPASS
SWITCH
3
4
1
MANUAL
CURRENT
XFMR
AUTO
4 WIRES
FUSE
8 WIRES
P1
SCR
DRIVER
BOARD
FUSEWIRE
(5 TIMES)
SCR/
SNUBBER
BOARD
(6 TIMES)
REFERENCE
TRANSFORMER
P2
P1
CONTROL
LOGIC
BOARD
P3
REGULATION BLOCK DIAGRAM
ILLUSTRATION 1---12
Note 1.
On Life Line Regulators Tap 5 of the transformer is selected. On the Medical Power PC, Tap 4 is selected.
1---13
Crucial Power Products
REV A
1--6 STARTING THE UNIT
This procedure is to be used only for starting the unit during the normal course of operation. Follow this operating procedure any time the unit has been turned off in a non---emergency situation.
CAUTION
If this is the initial startup or if the unit has been moved, perform the
Startup procedure in Section 3--1--7 before applying power to the unit.
CAUTION
If the unit is connected to a Power Island modular distribution center, verify that all panelboard output circuit breakers are OFF before turning on branch feeder circuit breaker.
1.
Verify that Bypass Switch is set to AUTO.
2.
Verify that connected load is OFF.
3.
Energize facility branch circuit breaker.
4.
Open front door (Medical Power PC only).
5.
Set IMCB to ON (Medical Power PC only).
6.
Close front door.
7.
Turn ON connected load.
1---14
Crucial Power Products
REV A
1--7 OPERATION
This unit is designed for unattended continuous operation. Units that have an IMCB can be switched ON and OFF on a regular basis using the IMCB as a switch.
1--7--1 Normal Condition
When the unit is powered up and regulating, the power on indicating lights will be illuminated on the Medical Power
PC only.
The normal operating condition of the unit is as follows:
1.
Facility branch circuit breaker set to ON.
2.
Bypass switch in AUTO position.
3.
Input Main Circuit Breaker ON (if applicable).
4.
Connected load set to ON.
D
If Power Island connected, output panelboard circuit breakers ON (as required).
1--7--2 Nonregulating Condition
In case the regulating circuits fail to regulate, the unit can continue to operate in bypass mode (without regulation) until regulation can be restored. Follow the procedure listed below to operate the unit in bypass mode.
Note
The following procedure is only for temporary operation. Voltage surge and sag protection is not available for any load while the bypass switch is in manual mode (bypass switch is set to MAN).
1.
Turn connected load OFF.
2.
Set facility branch circuit breaker to OFF.
3.
Set IMCB to OFF (if applicable).
4.
Turn bypass switch from AUTO to MAN.
5.
Set facility branch circuit breaker to ON.
6.
Set IMCB to ON (if applicable).
7.
Turn connected load ON.
8.
Refer to manufacturer’s service personnel.
1---15
Crucial Power Products
REV A
SECTION 2 -- PREINSTALLATION
2--1 LOCATION CONSIDERATIONS
OPERATING ENVIRONMENT. Provide an operating environment which meets the following conditions:
D
AMBIENT TEMPERATURE 32˚ to 104˚ F
0˚ to 40˚ C
D
RELATIVE HUMIDITY
Line Line Regulators and Medical Power PC: 10% to 90% (noncondensing)
POSITIONING. Position the unit so that the regulating electronics are not obstructed by objects that could make servicing the unit difficult. Allow minimum service access clearances as defined in Illustrations 2---3 and 2---4.
This unit is air cooled by convection. Do not block air flow from the front, rear, or bottom of the unit.
2---1
Crucial Power Products
REV A
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
TABLE 2---1
Line Line Regulators SITE PLANNING SPECIFICATIONS
NOMINAL INPUT VOLTAGE
INPUT VOLTAGE RANGE
MAXIMUM INPUT VOLTAGE
FREQUENCY (Hz)
AMBIENT TEMPERATURE ˚F (˚C)
NOMINAL
RATED
CURRENT
139
60
208
90
42
18
83
36
277.6
120
625
270.6
694
300.8
833
361
347
150
416
180.4
485.8
210.5
555
240.6
COOLING
BTU/hr
208
154 --- 229
229
WEIGHT lbs (kg)
480
355 --- 528
528
60
80 (26.7)
SIZE H x W x D in. (cm)
WITHOUT PACKAGING
1250 (567)
1000 (454)
1400 (635)
1100 (499)
1500 (680)
1200 (544)
1700 (771)
1400 (635)
2000 (907)
1500 (680)
2250 (1021)
1600 (726)
2450 (1111)
1800 (817)
2900 (1315)
1950 (885)
32 X 26.5 X 17
(107 X 67 X 43)
40.5 X 31.5 X 22
(103 X 80 X 56)
66 X 50.5 X 32 (168 X 128 X 81)
40.5 X 31.5 X 22 (103 X 80 X 56)
66 X 50.5 X 32 (168 X 128 X 81)
51.5 X 40.5 X 26.5 (131 X 103 X 67)
66 X 50.5 X 32 (168 X 128 X 81)
51.5 X 40.5 X 26.5 (131 X 103 X 67)
66 X 50.5 X 32
(168 X 128 X 107)
2---2
Crucial Power Products
REV A
TABLE 2---2
MEDICAL POWER PC SITE PLANNING SPECIFICATIONS
NOMINAL INPUT VOLTAGE
INPUT VOLTAGE RANGE
MAXIMUM INPUT VOLTAGE
FREQUENCY (Hz)
AMBIENT TEMPERATURE ˚F (˚C)
INPUT
VOLTAGE
NOMINAL
RATED
CURRENT
694
301
833
361
555
240.6
625
270.6
277.6
120
347
150
416
180.4
485.8
210.5
139
60
208
90
42
18
83
36
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
208
480
COOLING
BTU/hr
WEIGHT lbs (kg)
1300 (590)
1150 (522)
1400 (635)
1200 (544)
1550 (703)
1250 (567)
1800 (817)
1450 (658)
2100 (953)
1550 (703)
2350 (1066)
1650 (748)
2550 (1157)
1900 (862)
3000 (1361)
2000 (907)
208
187.2 --- 225
225
60
80 (26.7)
480
432 --- 518
518
SIZE H x W x D in. (cm)
WITHOUT PACKAGING
42 X 32 X 22
(107 X 81 X 56)
42 X 32 X 27
(107 X 81 X 69)
66 X 50.5 X 32 (168 X 127 X 81)
42 X 32 X 22 (107 X 81 X 56)
66 X 50.5 X 32 (168 X 128 X 81)
51.5 X 40.5 X 26.5 (131 X 103 X 67)
66 X 50.5 X 32 (168 X 128 X 81)
51.5 X 40.5 X 26.5 (131 X 103 X 67)
66 X 50.5 X 32
(168 X 128 X 81)
2---3
Crucial Power Products
REV A
2--2 FLOOR LOADING
Sizes and weights of units are listed in the following tables. Provide a floor with strength sufficient for loads specified.
kVA SIZE
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
208
480
208
480
TABLE 2---3
Line Line Regulators FLOOR LOADING
FLOOR LOADING lbs/sq ft (kg/sq m) kVA SIZE
108 (414)
208 (1013)
121 (464)
148 (723)
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
208
480
208
480
FLOOR LOADING lbs/sq ft (kg/sq m)
129 (489
161 (788)
152 (563)
126 (464)
179 (662)
134 (497)
202 (746)
143 (530)
220 (811)
161 (597)
260 (960)
175 (646)
2---4
Crucial Power Products
REV A
kVA SIZE
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
208
480
208
480
TABLE 2---4
Medical Power PC FLOOR LOADING
FLOOR LOADING lbs/sq ft (kg/sq m) kVA SIZE
112 (431)
192 (934)
121 (464)
161 (788)
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
208
480
208
480
FLOOR LOADING lbs/sq ft (kg/sq m)
134 (513)
168 (822)
155 (597)
125 (480)
181 (696)
134 (513)
206 (778)
142 (546)
220 (845)
164 (629)
259 (994)
172 (662)
2--3 CABLE ACCESS AND FLOOR LAYOUT
2--3--1 Cable Access
Cable access to the Line Line Regulators and Medical Power PC, sizes 100 to 300 kVA, is through a 4” diameter hole in the right and left sides of the unit throught which the input and output cables can be passed. Cable access to the
Medical Power PC, sizes 15 to 75 kVA is through an opening in the left and right side of the unit. See Illustrations 2---1 and 2---2.
2---5
Crucial Power Products
REV A
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
INPUT/OUTPUT
CABLE ENTRANCE
LINE LINE REGULATORS AND MEDICAL POWER PC (100 --- 300 KVA) CABLE ACCESS
ILLUSTRATION 2---1
LEFT SIDE VIEW
FRONT VIEW
RIGHT SIDE VIEW
CABLE
ACCESS
OPENING
20
(50.8)
6
(15.2)
5
(12.7)
2
(5.1)
14
(35.6)
6
(15.2) for 75 kVA and 100 kVA
5” deep back screen 15 used
MEDICAL POWER PC (15 --- 75 KVA) WITH 208 VAC INPUT, (15---100 KVA) WITH 480 VAC INPUT ACCESS
ILLUSTRATION 2---2
2---6
Crucial Power Products
REV A
2--4 MOUNTING
The Medical Power PC, sizes 15 to 75 kVA are equipped with leveling jacks to provide firm footing when the unit is set in its permanent location. With the leveling jacks in place, the unit cannot roll on the wheels. If local code requires the unit to be more firmly secured, mount the unit to the floor using angle brackets. A seismic option is available to mechanically attach the unit to the floor.
The Line Line Regulators and Medical Power PC, sizes 100 to 300 kVA, are equipped with angle---iron feet that have four 9/16---inch diameter holes pre drilled for mounting. Units can be bolted to the floor using these mounting holes.
22”(54)
TOP VIEW
NOTE:
INDICATES AIR FLOW
ALL DIMENSIONS ARE
IN INCHES (CENTIMETERS)
54”(200)
FRONT PANEL
(HALF OPEN)
FRONT
DOOR
15”
(38)
FRONT VIEW
42”(107)
SIDE VIEW
59”(150)
MEDICAL POWER PC (15 --- 75 KVA) CLEARANCES
ILLUSTRATION 2---3
2---7
Crucial Power Products
REV A
2--4 MOUNTING (continued)
14”
(35.6)
TOP VIEW
SERVICE ACCESS
SPACE REQUIRED
26.5”
(67)
14”
(35.6)
38”
(96.5)
NOTE:
INDICATES AIR FLOW
ALL DIMENSIONS ARE
IN INCHES (CENTIMETERS)
WEIGHT -- 520 LBS (236 KGS)
FLOOR LOADING -- 106 LBS/SQ.FT.
17”
(43)
14”(35.6)
32”
(81.3)
FRONT VIEW SIDE VIEW
LINE LINE REGULATORS AND MEDICAL POWER PC (100 --- 300 KVA) CLEARANCES
ILLUSTRATION 2---4
2---8
Crucial Power Products
REV A
SECTION 3 -- INSTALLATION
3--1 INSTALLATION
Install unit using the procedures in this section. Final installation must be in accordance with NEMA standards and conform to local electrical codes as appropriate.
3--1--1 Unpacking
Unit is shipped on a pallet, secured with metal bands and can be handeled using a fork lift or pallet jack.
DANGER!!
CUT METAL BANDS CAREFULLY. THEY ARE UNDER TENSION AND MAY
CAUSE INJURY.
1.
Position the container away from walls or other obstructions.
2.
Cut metal shipping bands.
3.
Remove cardboard cover. Avoid puncturing the cardboard cover with sharp objects which may damage the surface of the unit.
4.
Remove the unit from the pallet.
D
Life Line Regulators and Medical Power PC (100--- 300 kVA) can be removed using fork lift.
D
Medical Power PC (15 --- 75 kVA) come with integral casters and are packed with a wooden ramp. Secure ramp from slipping and roll unit off pallet. Secure ramp to pallet before rolling unit down ramp.
5.
Remove protective plastic film.
6.
Inspect unit for damage per Section 3---1---2, Inspection.
7.
Move unit to installation site.
8.
Before final positioning of unit, verify that all cable routing conduit and raceway is positioned properly.
CAUTION
unit weighs from 400 lbs (181 kg) to 3,500 lbs (1,588 kg) including the packaging. Use care when rolling unit with integral casters. Plywood or steel plates may be used to distribute weight and protect floor surface from overload damage.
3---1
Crucial Power Products
REV A
3--1--2 Inspection
Perform the following Inspection procedure of the unit to check for obvious damage or safety hazards that may have occurred during shipping or handling of the unit. All units must be inspected when received and again prior to use.
Any damage must be reported immediately to ON---LINE POWER, INC. or an authorized representative. Freight damage claims should be initiated with the carrier.
CAUTION
Do not connect unit to building power until the following procedure has been completed.
1.
Inspect all external surfaces (panels, covers, etc.) for abrasions, indentations, or other obvious damage.
2.
File a claim with shipping agency for any damage caused by shipping.
3.
Forward a copy of damage claim to ON---LINE POWER, INC. at the following address:
ON---LINE POWER, INC.
5701 Smithway Street
City of Commerce, CA 90040
3--1--3 Input Cable Installation -- Life Line Regulators & Medical Power PC 100 -- 300 kVA
The customer---furnished input power cable provides power from the building power source to the unit. Both the circuit which feeds this cable and this cable should be dedicated to providing power only to this unit. This cable must include three, power conductors and an insulated ground conductor. Size the cable to suit the unit kVA rating, the input voltage and the overall length of the cable. The input power cable size and installation must be in accordance with the National Electrical Code (NEC) and applicable local requirements.
A parity sized ground, with respect to the primary input conductors is recommended. The grounding conductor is to be grounded to earth at the service equipment or other acceptable true building ground.
The unit has one 4---inch diameter hole in each side of the frame to accomodate the input and output power cables.
There are no holes in the side panels. The holes in the panels can be sized, located and punched or drilled when the cable is installed. The input power cable can be connected through the left or right side of the unit.
If cables are crossed or wires are likely to touch, insulating sleeves or their equivalent must be used to prevent wires from touching.
Tools Required
D
Phase Rotation Meter
CAUTION
Input power connection and required branch circuit breaker should be installed by a licensed electrical contractor in accordance with local codes.
3---2
Crucial Power Products
REV A
3--1--3 Input Cable Installation -- Life Line Regulators & Medical Power PC 100 -- 300 kVA (continued)
CAUTION
Primary and secondary power circuit conductors must not touch each other. If conductors touch, use insulating sleeves.
DANGER!!
VERIFY THAT INCOMING HIGH---VOLTAGE CIRCUITS ARE DE---ENERGIZED
BEFORE CONTINUING WITH THIS PROCEDURE.
PROCEDURE:
1.
Turn facility circuit breaker to OFF, lock and tagout in accordance with OSHA Lockout/Tagout requirements.
2.
Remove top cover by unbolting two bolts on each side of cover.
3.
Remove front panel by unbolting six bolts at corners and at left and right sides of panel.
4.
Punch or drill a hole in side panel.
D
Locate hole so that it aligns with existing hole in frame. See Illustration 2---4. Size hole to suit cable/conduit.
5.
Insert cable/conduit through hole in panel and into hole in frame. Secure with appropriate fitting.
6.
Prepare cable ends by removing 3/4---inch of insulation from each input power cable conductor.
7.
Identify each phase conductor according to phase A, B, C. Identify ground conductor.
8.
Route and connect phase conductors to input terminals on input labelled H1, H2, and H3 or L1, L2, and L3.
See Illustration 1---4, 1---5, 1---6, and 1---7.
9.
Locate ground lug on side of cabinet.
10. Route and connect ground conductor to ground lug.
11. Proceed to Section 3---1---4, for instructions to install output power cable.
3---3
Crucial Power Products
REV A
3--1--4 Output Cable Installation -- Life Line Regulators and Medical Power PC 125 -- 300 kVA
The customer---furnished output power cable provides power from the unit to a connected load or to a Power Island when distribution to more than one connected load is required.
The unit has one 4---inch diameter hole in each side of the frame --- as described in the preceeding section. The output power cable can be connected through the left or right side of the unit.
PROCEDURE:
1.
Turn facility circuit breaker to OFF, lock and tagout in accordance with OSHA Lockout/Tagout requirements.
2.
Remove top cover by unbolting two bolts on each side of cover.
3.
Remove front panel by unbolting six bolts at corners and at left and right sides of panel.
4.
Punch or drill a hole in side panel.
D
Locate hole so that it aligns with existing hole in frame. See Illustration 2---4. Size hole to suit cable/conduit.
5.
Insert cable/conduit through hole in panel and into hole in frame. Secure with appropriate fitting.
6.
Prepare cable ends by removing 3/4---inch of insulation from each output power cable conductor.
7.
Identify each phase conductor according to phase A, B, C, Neutral, and Ground conductor.
8.
Route and connect phase conductors to output terminals of the transformer X0, X1, X2, and X3.
See Illustration 1---4, 1---5, 1---6, and 1---7.
9.
Locate ground lug.
10. Route and connect ground conductor to ground lug.
11. Proceed to Section 3---1---7, Startup.
3---4
Crucial Power Products
REV A
3--1--5 Input Cable Installation -- Medical Power PC 15 -- 100 kVA
The customer---furnished input power cable provides power from the building power source to the unit. Both the circuit which feeds this cable and this cable should be dedicated to providing power only to this unit. This cable must include three power conductors and an insulated ground conductor. Size the cable to suit the unit kVA rating, the input voltage and the overall length of the cable. The input power cable size and installation must be in accordance with the National Electrical Code (NEC) and applicable local requirements.
A parity sized ground, with respect to the primary input conductors is recommended. The grounding conductor is to be grounded to earth at the service equipment or other acceptable true building ground.
The input power cable should be installed through the left side panel. No holes are provided in the panel. A hole can be sized, located and drilled or punched when the cable is installed.
If cables are crossed or wires are likely to touch, insulating sleeves or their equivalent must be used to prevent wires from touching.
PROCEDURE:
1.
Turn OFF facility circuit breaker, lock and tagout according to OSHA requirements.
2.
Open front door.
3.
Verify that the Main Input Circuit Breaker is set to OFF (as applicable).
4.
Open the hinged front panel by unbolting the three screws on the left side of panel and removing the screw to the top and swinging panel to the right.
5.
Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel.
DANGER!!
VERIFY THAT INCOMING HIGH---VOLTAGE CIRCUITS ARE DE---ENERGIZED
BEFORE CONTINUING WITH THIS PROCEDURE.
6.
Punch or drill holes in left side panel to accomodate input cable.
7.
Route and connect the 3 power wires to input power terminals labelled L1, L2, and L3.
See Illustration 1---5.
8.
Route and connect the ground wire to the ground lug on the cabinet.
9.
Proceed to Section 3---1---6 to install output cable.
3---5
Crucial Power Products
REV A
3--1--6 Output Cable Installation -- Medical Power PC 15 -- 100 kVA
The customer---furnished output power cable provides power from the unit to a connected load or to a Power Island when distribution to more than one connected load is required.
This cable should be installed through the right side panel. No holes are provided in the panel. A hole can be sized, located and drilled or punched when the cable is installed.
Procedure
1.
Turn OFF facility circuit breaker, lock and tagout according to OSHA requirements.
2.
Open front door.
3.
Verify that the Main Input Circuit Breaker is set to OFF (as applicable).
4.
Open the top panel by removing the screw from the front panel and lift the top panel to it’s up position.
5.
Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel.
DANGER!!
VERIFY THAT INCOMING HIGH---VOLTAGE CIRCUITS ARE DE---ENERGIZED
BEFORE CONTINUING WITH THIS PROCEDURE.
6.
Punch or drill holes in right side panel to accomodate output cable.
7.
Route and connect the 4 power wires to output terminals. (X0, X1, X2, and X3)
See Illustration 1---5.
8.
Route and connect the ground wire to the ground lug on the cabinet.
9.
Proceed to Section 3---1---7, Startup to complete the installation.
3---6
Crucial Power Products
REV A
3--1--7 Startup -- Life Line Regulators and Medical Power PC (100 -- 300 kVA)
After connecting the input and output cables and before placing the unit in service, verify the output voltage using the following procedure.
Tools Required
D
Phase Rotation Meter
D
Voltage meter
DANGER!!
FATAL ELECTRIC SHOCK HAZARD!! TO PREVENT FATAL ELECTRIC SHOCK
DISCONNECT POWER FROM UNIT AND LOCK OFF BEFORE YOU PERFORM
THE FOLLOWING PROCEDURE.
PROCEDURE:
1.
Verify that facility circuit breaker is OFF, locked and tagged according to OSHA requirements.
2.
Check power connections.
3.
Verify that there are no obstructions that restrict air flow.
4.
Unlock facility circuit breaker and set to ON.
5.
Check that input power is phased in clockwise rotation (A, B, C). Use phase rotation meter.
6.
Measure the input voltages phase to phase and be sure the readings agree with the values listed on the label plate.
7.
Measure the line---to---neutral output voltages as follows: a. Verify that output line to neutral voltages agree with the values listed on the label plate located on the front panel and in Appendix A.
D
If output voltage readings are out of specification, refer to Section 3---1---9, Calibrate Control Logic
Board, otherwise, continue to next step.
8.
Turn OFF power to connected load.
9.
Turn OFF facility circuit breaker, lock and tagout according to OSHA requirements.
3---7
Crucial Power Products
REV A
3--1--7 Startup -- Life Line Regulators and Medical Power PC (100 -- 300 kVA) (continued)
10. Replace front panel.
11. Unlock and turn ON power to facility circuit breaker.
The unit is ready for service.
3--1--8 Startup -- Medical Power PC 15 -- 100 kVA
After connecting the input and output cables and before placing the unit in service, verify the output voltage using the following procedure.
Tools Required
D
Phase Rotation Meter
D
Voltage meter
PROCEDURE:
1.
Verify that connected load is OFF.
2.
Turn OFF facility circuit breaker, lock and tagout according to OSHA requirements.
DANGER!!
FATAL ELECTRIC SHOCK HAZARD!! TO PREVENT FATAL ELECTRIC SHOCK
DISCONNECT POWER FROM UNIT AND LOCK OFF BEFORE YOU PERFORM
THE FOLLOWING PROCEDURE.
3.
Open front door.
DANGER!!
FATAL SHOCK HAZARD!! LETHAL VOLTAGES EXIST WITHIN THE UNIT DUR-
ING THE FOLLOWING CHECK. FOLLOW THE STEPS BELOW EXACTLY. FAIL-
URE TO DO SO COULD RESULT IN SEVERE INJURY OR DEATH.
3---8
Crucial Power Products
REV A
3--1--8 Startup -- Medical Power PC 15 -- 100 kVA (continued)
4.
Verify that IMCB is OFF.
5.
Check power connections.
6.
Verify that there are no obstructions that restrict air flow.
7.
Unlock facility circuit breaker and set to ON.
8.
Turn on IMCB on Medical Power PC.
9.
Check that input power is phased in clockwise rotation (A, B, C). Use phase rotation meter.
10. Measure the input voltages phase to phase and be sure the readings agree with the values listed on the label plate.
11. Measure the line---to---neutral output voltages as follows: b. Verify that output line to neutral voltages agree with the values listed on the label plate located on the inside of the front door and in Appendix A.
D
If output voltage readings are out of specification, refer to Section 3---1---9, Calibrate Control Logic
Board, otherwise, continue to next step.
12. Turn OFF IMCB.
13. Turn OFF facility circuit breaker, lock and tagout according to OSHA requirements.
14. Close front panel.
15. Unlock and turn ON facility circuit breaker.
16. Turn IMCB ON (as applicable).
17. Close front door.
The unit is ready for service.
3---9
Crucial Power Products
REV A
3--1--9 Calibrate Control Logic Board
The SCR driver board has seven green LEDs. LED 7 indicates power is applied to the board and is illuminated any time power to the unit is on. LEDs 1 through 6 represent tap settings and only one of these six LEDs should be on at any time. See Illustration 3---2. It is normal for the LED’s 1 through 6 to delay 6 seconds after the power LED has turned on.
If no LED is lit or if two or more LEDs are lit, immediately turn facility circuit breaker OFF or turn IMCB to OFF (if installed). The regulator can be placed on manual operation for emergency service. See Section 1---7---2.
If only one LED (1 through 6) is lit, perform the following calibration:
PROCEDURE:
1.
Turn connected load OFF.
2.
Turn facility circuit breaker OFF, lock and tagout in accordance with OSHA Lockout/Tagout requirements.
3.
Open Life Line Regulators, Medical Power PC (100 --- 300 kVA) as follows: a. Remove front panel by unbolting six screws at corners and left and right sides of each panel.
4.
Open Medical Power PC (15 --- 75 kVA) as follows: a. Open front door.
b. Set IMCB to OFF (as applicable).
c. Open hinged front panel by unbolting three screws at left side of panel. Swing panel to right.
5.
Unlock facility circuit breaker and turn ON.
6.
Set IMCB to ON (as applicable).
7.
Turn connected load ON.
3---10
Crucial Power Products
REV A
3--1--9 Calibrate Control Logic Board (continued)
DANGER!!
FATAL SHOCK HAZARD!! LETHAL VOLTAGES EXIST WITHIN THE UNIT DUR-
ING THE FOLLOWING CHECK. FOLLOW THE STEPS BELOW EXACTLY. FAIL-
URE TO DO SO COULD RESULT IN SEVERE INJURY OR DEATH.
8.
Make the following adjustments on the Control logic board for phase A: See Illustration 3---1.
a. Measure AC voltage across R1 or R2. Voltage should be between 10 and 100mv.
b. Measure DC voltage across C42.
c. Adjust R62 until voltage reads 8.5 VDC with a load of 1 kw for 50 kVA or less and 2 kw load for 75 kVA or larger.
Note
Potentiometer R62 is a 30---turn pot. It may require several turns before output level changes.
d. Adjust R39 counter clockwise until LED 6 is lit. See Illustration 3---1 and Illustration 3---2.
e. Measure DC voltage across C42.
f. Adjust R62 until voltage reads 8.5 V.
g. Measure neutral---to---phase A output voltage between transformer terminals X1 and X0.
Refer to Appendix B for transformer terminal configuration.
h. Adjust R39 until output voltage reads 120V or 277V, phase to neutral, depending on rated output voltage.
D
Output voltage should be ± 3% of nominal for Life Line Regulators
Output voltage should be ± 2% of nominal for Medical Power PC
Note
Output voltage does not change linearly as potentiometer R39 is rotated. Output voltage does a step change. Pot R39 is a 30---turn pot. It may require several turns before output level changes.
i. Repeat the procedure on the phase---B and phase---C Control logic boards. Take voltage measurements between transformer terminals X2 and X0 and between X3 and X0 respectively for phase B and C.
3---11
Crucial Power Products
REV A
R33 U9 CR29
R2
R1
R62
R39
CONTROL LOGIC BOARD
ILLUSTRATION 3---1
3---12
C42
Crucial Power Products
REV A
SCR DRIVER BOARD
ILLUSTRATION 3---2
3--2 CONFIGURATION
The unit is shipped factory configured. No configuration is necessary. Do not change tap connections.
3---13
Crucial Power Products
REV A
3--3 RENEWAL PARTS, Life Line Regulator
INPUT/OUTPUT
FILTER ASSY
9100--001--01
INPUT FILTER ASSY
1690--002
1690--012
SCRs
1625--012--01
1625--004--01
Snubber PCB
1625--002--01
Driver PCB
1400--003
1400--001A
Ref. Transformer
2025--002
Fuse,
Ref. Transformer input
1625--003--01
Control Logic PCB
1680--021
BYPASS SWITCH
3---14
Crucial Power Products
REV A
3--3--1 Vendor Parts List, Life Line Regulator
Vendor No.
1680---021
1680---042
1425---001
1425---004
1425---003
1425---007
1425---002
1690---002
1690---012
1690---011
1625---004---01
1625---012---01
121543003---02
1625---002---01
1400---001A
1400---003
9100---001---01
1625---003---01
Vendor
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Description (Remarks)
SWITCH, BYPASS, 1 USED
SWITCH, BYPASS, 1 USED
TRANSFORMER, CURRENT 50:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 1000:1, 3 USED (Note 1)
TRANSFORMER, CURRENT 100:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 200:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 400:5, 3 USED (Note 1)
SCR, 15---50 KVA MODEL, 18 USED
SCR, 75---175 KVA MODEL, 18 USED
SCR, 200---300 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 15---50 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 75---175 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 200---300 KVA MODEL, 18 USED
PCB, SCR DRIVER, 3 USED
TRANSFORMER, REFERENCE, 208 V PRI, 3 USED
TRANSFORMER, REFERENCE, 480 V PRI, 3 USED
INPUT FILTER ASSY, 1 USED (not shown)
PCB, CONTROL LOGIC, 3 USED
NOTES:
1.
For current transformer part numbers, refer to Tables 3---1.
2.
Reference transformer part numbers:
For 208 V input use 1400---001A
For 480 V input use 1400---003
3---15
Crucial Power Products
REV A
225
250
300
100
125
150
175
200
3--3--1 Vendor Parts List, Life Line Regulator (continueed)
SIZE
(KVA)
TABLE 3---1
LIFE LINE REGULATOR CURRENT TRANSFORMERS
MODEL
NUMBER
PR015B0500T3
PR015B0900T3
PR015H0500T3
PR015H0900T3
PR030B0500T3
PR030B0900T3
PR030H0500T3
PR030H0900T3
PR050B0500T3
PR050B0900T3
PR050H0500T3
PR050H0900T3
PR075B0500T3
PR075B0900T3
PR075H0500T3
PR075H0900T3
PR100H0500T3
PR100H0900T3
PR125H0500T3
PR125H0900T3
PR150H0500T3
PR150H0900T3
PR175H0500T3
PR175H0900T3
PR200H0500T3
PR200H0900T3
PR225H0500T3
PR225H0900T3
PR250H0500T3
PR250H0900T3
PR300H0500T3
PR300H0900T3
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
480
208 & 480
208 & 480
208 & 480
208 & 480
208 & 480
208 & 480
208 & 480
CURRENT
TRANSFORMER
1425---001
1425---017
1425---007
1425---003
1425---007
1425---003
1425---005
1425---007
1425---007
1425---007
1425---005
1425---005
1425---002
1425---002
1425---004
1425---004
3---16
Crucial Power Products
REV A
3--4 RENEWAL PARTS, Medical Power PC (15 -- 75 kVA)
9100--006--01
INPUT/OUTPUT
FILTER ASSY
1680--021
Bypass Switch
1690--002
1690--012
SCRs
1625--004--01
1625--012--01
Snubber PCB
2075--002
Fuse,
Ref. Transformer
1625--002--01
Driver PCB
1625--003--02
Control Logic PCB
SEE NOTE 2
Ref. Transformer
3---17
Crucial Power Products
REV A
3--4--1 Vendor Parts List, Medical Power PC (15 -- 75 kVA)
Vendor No.
1680---021
1425---001
1425---017
1425---003
1425---005
1425---007
1690---002
1690---012
1625---004---01
1625---012---01
1625---002---01
1400---001A
1400---003
9100---001---01
9100---006---01
Vendor
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Description (Remarks)
SWITCH, BYPASS, 1 USED
TRANSFORMER, CURRENT 50:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 25:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 100:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 300:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 200:5, 3 USED (Note 1)
SCR, 15---50 KVA MODEL, 18 USED
SCR, 75 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 15---50 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 75 KVA MODEL, 18 USED
PCB, SCR DRIVER, 3 USED
TRANSFORMER, REFERENCE, 208 V PRI, 4 USED (Note 2)
TRANSFORMER, REFERENCE, 480 V PRI, 6 USED (Note 2)
INPUT FILTER ASSY, 1 USED (not shown)
INPUT/OUTPUT FILTER ASSY, 1 USED (not shown)
NOTES:
1.
For current transformer PART numbers, refer to Table 3---2.
2.
Reference transformer vendor numbers:
For 208 V input use 1400---001A
For 480 V input use 1400---003
SIZE
(KVA)
TABLE 3---2
MEDICAL POWER PC (15 --- 75 kVA) CURRENT TRANSFORMERS
MODEL
NUMBER
PS015B0500T3
PS015B0900T3
PS015H0500T3
PS015H0900T3
PS030B0500T3
PS030B0900T3
PS030H0500T3
PS030H0900T3
PS050B0500T3
PS050B0900T3
PS050H0500T3
PS050H0900T3
PS075B0500T3
PS075B0900T3
PS075H0500T3
PS075H0900T3
INPUT
VOLTAGE
208
480
208
480
208
480
208
480
H1, H2, H3
1425---001
1425---017
1425---007
1425---003
1425---007
1425---003
1425---005
1425---007
3---18
Crucial Power Products
REV A
3--5 RENEWAL PARTS, Medical Power PC (100 -- 300 kVA)
9100--006--01
INPUT/OUTPUT
FILTER ASSY
1690--012
SCRs
1625--012--01
Snubber PCB
1625--002--01
Driver PCB
1400--001A
1400--003
Ref. Transformer
2025--002
Fuse,
Ref. Transformer input
1625--003--02
Control Logic PCB
1680--021
Bypass Switch
3---19
Crucial Power Products
REV A
3--5--1 Vendor Parts List, Medical Power PC (100 -- 300 kVA)
Vendor No.
1680---017
1425---007
1425---005
1425---002
1690---012
1690---011
1625---012---01
1625---002---01
121543003---02
1400---001
1400---003
9100---006---01
Vendor
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Crucial Power
Description (Remarks)
SWITCH, BYPASS, 1 USED
TRANSFORMER, CURRENT 200:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 300:5, 3 USED (Note 1)
TRANSFORMER, CURRENT 400:5, 3 USED (Note 1)
SCR, 100---175 KVA MODEL, 18 USED
SCR, 200---300 KVA MODEL, 18 USED
PCB, SNUBBER, SCR, 100---300 KVA MODEL, 18 USED
PCB, SCR DRIVER, 3 USED
PCB, SNUBBER SCR 200---300 KVA MODEL, 18 USED
TRANSFORMER, REFERENCE, 208 V PRI, 4 USED (Note 2)
TRANSFORMER, REFERENCE, 480 V PRI, 6 USED (Note 2)
INPUT/OUTPUT FILTER ASSY, 1 USED (not shown)
NOTES:
1.
For current transformer vendor numbers, refer to Table 3---3.
2.
Reference transformer vendor numbers:
For 208 V input use 1400---001A
For 480 V input use 1400---003
SIZE
(KVA)
100
125
150
175
200
225
250
300
TABLE 3---3
MEDICAL POWER PC (100 --- 300 KVA) CURRENT TRANSFORMERS
MODEL
NUMBER
PS100H0500T3
PS100H0900T3
PS125H0500T3
PS125H0900T3
PS150H0500T3
PS150H0900T3
PS175H0500T3
PS175H0900T3
PS200H0500T3
PS200H0900T3
PS225H0500T3
PS225H0900T3
PS250H0500T3
PS250H0900T3
PS300H0500T3
PS300H0900T3
INPUT
VOLTAGE
480
480
480
480
480
480
480
480
CURRENT
TRANSFORMER
1425---007
1425---007
1425---005
1425---005
1425---002
1425---002
1425---004
1425---004
3---20
Crucial Power Products
REV A
SECTION 4 -- OPTIONS
4--1 INTRODUCTION
Crucial Power offers a number of options which can enhance the performance of the Life Line Regulator and Medical
Power PC and expand the units’ power distribution capacity to suit facility requirements.
This section discusses the functions and capabilities of the following options:
D
Remote Emergency Power Off (REPO) Station
D
Thermal (REPO) Station
D
Surge Protection
D
Main Input Circuit Breaker
D
Output Filtering
Some of the options listed above are provided as standard equipment on some models of Crucial Medical Power
PCs and Life Line Regulators while other options are only available on some models. Refer to Table 4---1 to clarify options availability.
TABLE 4---1
OPTIONS MATRIX
MODEL
OPTION
REPO
Thermal REPO
Surge
Protection
Main Input
Circuit Breaker
Output
Filtering
N
N
O
N
O
N
N
S
O
S
Medical Power PC
(100 --- 300 kVA)
N
N
S
N
S
TABLE KEY: S = Standard equipment, O = Available as an option, N = Not available for this model.
4---1
Crucial Power Products
REV A
4--2 REMOTE EMERGENCY POWER OFF STATION, Medical Power PC up to 75 kVA
The Remote Emergency Power Off Station (REPO) is a wall---mounted unit that enables operating personnel to remotely shut down the Medical Power PC or Life Line Regulator in an emergency. The REPO station consists of a painted sheet metal enclosure with a guarded, momentary, normally open, red tactile switch. See Illustration 4---1 for REPO---box size and mounting hole location.
The REPO station is designed to be vertically mounted and can be located anywhere an emergency shut---off is required. The REPO station is provided with a 50---foot, two---conductor cable (15 m). Other length cables are available in five---foot increments.
4(10.2)
3(7.6)
2(5.1)
REPO BOX
ILLUSTRATION 4---1
4--2--1 Installation for REPO
The REPO cable will be 50 to 100 feet (15 --- 30 m) long depending on length ordered. The cable is supplied with a two---pin connector on one end and bare wires on the other end. The bare wires connect to a terminal block in the
Medical Power PC.
Procedure
1.
Select the location for the REPO box.
2.
Mount REPO box on wall or other structure using fasteners that are appropriate for the surface on which the
REPO box is to be mounted.
3.
Remove REPO box cover.
4---2
Crucial Power Products
REV A
4--2--1 Installation for REPO (continued)
4.
Connect 2 wires in REPO cable to terminals on REPO switch as shown in Illustration 4---2.
5.
Turn OFF main facility circuit breaker, lock and tagout in accordance with OSHA requirements.
6.
Open front door of Medical Power PC.
7.
Set IMCB to OFF.
8.
Remove floor tiles as required to route REPO cable from REPO box to Medical Power PC.
9.
Route REPO cable up through opening in floor (as applicable) and into conduit entry opening.
10. Locate the two---terminal REPO terminal block in the Medical Power PC.
11. Connect the 2 wires in REPO cable to REPO terminal block. See Illustration 4---2.
12. Replace floor tiles as required.
13. Set IMCB to ON.
14. Close front door of Medical Power PC.
15. Set main facility circuit breaker to ON.
TO T.B.
TB5
+28 VDC
SHUNT TRIP
REPO WIRING
ILLUSTRATION 4---2
REPO SWITCH
3
N.O.
4
4---3
Crucial Power Products
REV A
4--3 THERMAL REMOTE EMERGENCY POWER OFF STATION
The Thermal REPO is a wall mounted unit that functions as a dual temperature warning and shutdown monitor. The first and second stage over temperature settings are field selectable. The Thermal REPO provides a contact closure for the first stage alarm, and a unit shutdown interface for the second stage over---temperature response. In addition, the Thermal REPO displays the ambient temperature on a 3---digit display.
The Thermal REPO station is designed to be vertically mounted at eye level or slightly lower. It can be located anywhere an emergency shut---off is required. The Thermal REPO is provided with a 50---foot (15 m), three---conductor cable. Longer cables are available in five---foot increments up to 100 feet (30 m).
Thermal REPO Specifications:
D
Temperature range
D
Dimensions
D
Weight
4--3--1 Installation for Thermal REPO
The Thermal REPO cable will be 50 to 100 feet (15 --- 30 m) long depending on length ordered. The cable is supplied with bare wires on the both ends. The bare wire ends connect to the terminals inside the Thermal REPO enclosure.
WHITE
BLACK
RED
GND
+24VDC
SHUNT TRIP
JUMPER 1 & 12
TWO--STAGE
THERMO
REPO SWITCH
14
12
1
2
THERMAL REPO WIRING
ILLUSTRATION 4---3
4---4
Crucial Power Products
REV A
4--3--1 Installation for Thermal REPO (continued)
Note
The Thermal REPO is shipped with separate operating instructions.
Procedure
1.
Select the location for the Thermal REPO box.
2.
Remove Thermal REPO box cover.
3.
Mount Thermal REPO box on wall or other structure using mounting holes located in the back of Thermal REPO enclosure. Use fasteners that are appropriate for the surface on which the Thermal REPO box is to be mounted.
4.
Connect three wires in Thermal REPO cable to terminals on Thermal REPO switch as shown in Illustration 4---3.
5.
Turn OFF main facility circuit breaker, lock and tagout in accordance with OSHA requirements.
6.
Open front door of Medical Power PC.
7.
Set IMCB to OFF.
8.
Route Thermal REPO cable from Thermal REPO box to Medical Power PC. Remove floor tiles as required.
9.
Open front panel of Medical Power PC.
10. Route Thermal REPO cable up through opening in floor (as applicable) and into conduit entry opening.
11. Locate terminal block on the Medical Power PC.
12. Connect the three wires to the terminal block.
13. Replace floor tiles as required.
14. Close front panel of Medical Power PC.
15. Set IMCB to ON.
16. Close front door of Medical Power PC.
17. Set main facility circuit breaker to ON.
4---5
Crucial Power Products
REV A
4--4 SURGE PROTECTION
The Secondary Surge Suppression circuit consists of a special output filter comprising fuse---protected metal oxide varistors and indicator lights. This option is designed to reduce the effect of load induced electrical noise on other electronics such as connected loads. In addition, the secondary surge suppression circuit prevents electronic and electromechanical devices from interfering with each other.
The characteristics of the filter assembly are as follows:
D
Parallel (shunt) operation
D
Response time of less than five nanoseconds
D
Repetitive transient to 5,000 volts per second
D
Clamping voltage (208Y/120):
Ratio 1.2, 144 Vac line to neutral, 364 Vac line to line
Ratio 1.75, 210 Vac line to neutral, 364 Vac line to line
D
Peak pulse power rating:
27 kW line to neutral
13.4 kW line to line
D
Fused for circuit protection with visual blown fuse indicators (one per phase)
The secondary surge suppression circuit is factory installed at the time of production. No assembly or adjustments are required.
4--5 MAIN INPUT CIRCUIT BREAKER, Phase Stabilizer (15 -- 75 kVA)
The optional MAIN INPUT CIRCUIT BREAKER (IMCB) is used to switch power to the Phase Stabilizer unit ON and
OFF. The IMCB is located on the front panel of the unit, behind the hinged front door.
Be sure to observe ALL warnings and cautions when setting the IMCB to ON or OFF.
This option is factory installed at the time of production. No assembly or adjustments are required.
4---6
Crucial Power Products
REV A
4--6 INPUT/OUTPUT FILTERING
The Input/Output filter comprises an input filter installed on the primary and an output filter installed on the secondary of the transformer. The input filter consists of a resistor/capacitor network which acts as a large snubber circuit to eliminate high frequency impulses from entering the power system. The output filter consists of a capacitor network which, when coupled with the primary filter, virtually eliminates most electronic noise from reaching the applied load or being fed back to the unit from noise generating loads. See Illustration 4---4 and 4---5.
R3
(L1) H1
(L2) H2
R1
(L3) H3
R2
R5
R6
R4
X0
X1
C2
C1
INPUT FILTER WIRING
ILLUSTRATION 4---4
X3
X2
C3
C6
C5
C4
OUTPUT FILTER WIRING
ILLUSTRATION 4---5
4---7
Crucial Power Products
REV A
4--7 POWER ISLAND
4--7--1 Features
The Power Island is a modular power distribution center which can be used with either the Medical Power PC or Life
Line Regulator. The Power Island can extend the distribution capability of the Medical Power PC or Life Line Regulator by up to 42 and 84 pole positions.
The 225---amp or 450---amp Power Island is available in two models. The Power Island---42 can accommodate one
42---pole panelboard and the Power Island 84 can accommodate two 42---pole panelboards. The standard panelboard is a 225---amp Square---D Snap---On. For other panelboard configurations, refer to your Crucial Power Sales
Representative. The style and function of both Power Island models coordinates with and complements the design of the Phase Stabilizer in the 15 to 75 kVA sizes. See Illustration 4---6.
The Power Island provides three neon phase indicators, located on the front of the unit. Each phase is independently monitored. If a phase is lost the corresponding indicator will extinguish, showing which phase is having the problem.
Power--Island 84
POWER ISLAND
ILLUSTRATION 4---6
Power--Island 42
4---8
Crucial Power Products
REV A
4--7--2 Power Island Specifications
MODEL
Power Island/42
Power Island/84
W
DIMENSIONS in. (cm)
H D
14 (36)
28 (71)
42 (107)
42 (107)
24 (61)
24 (61)
WEIGHT lbs. (kg)
175 (74)
225 (102)
FLOOR LOADING lbs/ft (kg/m )
75 (360)
48 (236)
Power--Island 84
REAR VIEW
Panelboards
Full Capacity
Ground Bus
Isolated
Full Capacity
Neutral Bus
Tiered & Slotted
Output Conduit
Landing Brackets
Main Input
Conduit Landing Bracket
Power--Island 42
REAR VIEW
POWER ISLAND FEATURES
ILLUSTRATION 4---7
4---9
Crucial Power Products
REV A
4--7--3 Preinstallation
Determine the location of the Power Island and routing of input and output cables prior to installation. Because the
Power Island is a stand---alone unit it can be placed as close to the load as possible. The following Illustrations are provided to aid in determining cable access, floor layout and service clearances.
See Illustrations 4---8, 4---9 and 4---10.
34”
(86cm)
34”
(86cm)
16”
(41cm)
16”
(41cm)
24”
(61cm)
REAR VIEW
26”
(66cm)
BOTTOM VIEW
Power--Island 84
10”
(25cm)
12”
(30cm)
REAR VIEW
BOTTOM VIEW
Power--Island 42
POWER ISLAND CABLE ACCESS
ILLUSTRATION 4---8
4---10
Crucial Power Products
REV A
4--7--3 Preinstallation (continued)
10
(25)
14”
(36cm)
FRONT
FLOOR TILE
CUTOUT
UNIT
FOOTPRINT
POWER ISLAND FLOOR TILE CUTOUT
ILLUSTRATION 4---9
18”
(46cm)
70”
(178cm)
18
(46)
FRONT
FRONT DOOR
FULLY OPEN
29.5”
(75cm)
Power--Island 84
FRONT DOOR
FULLY OPEN
15.5”
(39cm)
Power--Island 42
POWER ISLAND DIMENSIONS AND CLEARANCES
ILLUSTRATION 4---10
4---11
18”
(46)
56”
(142cm)
14”
(36cm)
Crucial Power Products
REV A
4--7--4 Input Interconnect Cable Installation
An optional 225---amp or 450---amp Output Interconnect Cable is available to connect the Power Island to the Medical Power PC or Life Line Regulator. This cable is specified in 5---foot increments to a maximum of 50 feet (15 m).
The following instructions cover installation of the Input Interconnect Cable to the Medical Power PC or Life Line
Regulator. If a Power Island 84 is being installed, two input interconnect cables are required.
Procedure
1.
Turn OFF main facility circuit breaker to Medical Power PC or Life Line Regulators lock and tagout in accordance with OSHA requirements.
2.
Open front door of Power Island.
DANGER!!
POTENTIAL ELECTRICAL HAZARDS TO HUMAN LIFE EXIST WITHIN THIS
EQUIPMENT WHEN ENERGIZED. DISCONNECT INPUT POWER TO UNIT BE-
FORE OPENING ENCLOSURE OR TOUCHING INTERNAL PARTS.
3.
Verify that IMCB is set to OFF.
4.
Verify that all output circuit breakers are set to OFF.
5.
Remove front panel of Power Island.
6.
Remove floor tiles as required and route Input Interconnect Cable between Power Island and Medical Power
PC or Life Line Regulator.
7.
Route Input Interconnect Cable up through floor opening (as applicable) and into Main Input Conduit Landing
Bracket.
8.
Connect the grounding conductor to the ground bus in the Power Island.
9.
Connect the power conductors to the Input Main Circuit Breaker located at the top of the panelboard in the
Power Island.
4---12
Crucial Power Products
REV A
4--7--4 Output Interconnect Cable Installation (continued)
10. Access the interior of Medical Power PC or Life Line Regulator as follows:
D
Phase Stabilizer (15 --- 75 kVA) a. Raise hinged lid.
b. The Power Island Interconnect cable can be routed through the bottom or through the right side of the
Phase Stabilizer.
D
Life Line Regulators, Phase Stabilizer (100 --- 300 kVA) a. Remove top cover by unbolting two bolts on each side of cover.
b. Remove front panel by unbolting six bolts.
11. Route Output Interconnect Cable up through floor opening (as applicable) and into conduit entry opening.
12. Connect the grounding conductor to the ground bus in the Medical Power PC or Life Line Regulator.
13. Connect the power conductors to the Output Power Terminal Block in the Medical Power PC or Voltage
Regulator.
4--7--5 Output Cable Installation
The following instructions cover installation of the Output Cables between the connected loads and the Power
Island:
Note
The equipment to be connected to the Power Island may require special grounding procedures.
Refer to technical documentation which accompanies that equipment.
Procedure
1.
Turn OFF facility circuit breaker to Medical Power PC or Life Line Regulator, lock and tagout according to OSHA requirements.
2.
Open front door of Power Island.
3.
Verify that IMCB is set to OFF.
4.
Verify that all output circuit breakers are set to OFF.
4---13
Crucial Power Products
REV A
4--7--5 Output Cable Installation (continued)
DANGER!!
POTENTIAL ELECTRICAL HAZARDS TO HUMAN LIFE EXIST WITHIN THIS
EQUIPMENT WHEN ENERGIZED. DISCONNECT INPUT POWER TO UNIT BE-
FORE OPENING ENCLOSURE OR TOUCHING INTERNAL PARTS.
5.
Open front door of Power Island.
6.
Open hinged front panel by unbolting the three screws on the left side of panel and swinging panel to the right.
7.
Remove rear panel by unbolting 6 screws located on the corners and right and left sides of the panel.
8.
Remove floor tiles as required.
9.
Route output cable between equipment to be powered and Power Island.
10. Pass output cable through floor opening and up into cable landing bracket.
11. Secure conduit fitting to landing bracket. Install noninsulated bushings on all conduits and flexes.
12. Route and connect the 1 to 3 power wires to output circuit breaker.
13. Route and connect the ground wire to the ground bus. See Illustration 4---7 for location of ground bus.
14. Route and connect the neutral wire to the neutral bus. See Illustration 4---7 for location of neutral bus.
15. Replace rear panel.
16. Replace hinged front panel.
4---14
Crucial Power Products
REV A
APPENDIX A -- SPECIFICATIONS
TABLE A---1
SPECIFICATIONS
LIFE LINE REGULATOR
NOMINAL INPUT VOLTAGE
INPUT VOLTAGE RANGE
MAXIMUM INPUT VOLTAGE
NOMINAL RATED CURRENT (A)
FREQUENCY (Hz)
OUTPUT VOLTAGE REGULATION
LINE---TO---LINE VARIATION
RESPONSE TIME
FILTERS:
INPUT
OUTPUT
COOLING REQUIREMENT (BTU/hr)
WEIGHT lbs (kg) (estimated)
OUTPUT VOLTAGE
CAPACITY (KVA)
NUMBER OF PHASES
SURGE RATING
HARMONICS ADDED
POWER FACTOR
AMBIENT TEMPERATURE ˚F (˚C)
SIZE H X W X D in. (cm)
208 VAC 480 VAC
154 --- 229
229
See Table 2---1
355 --- 528
528
60
± 3% Typical, ± 4% Maximum
LESS THAN 2%
1 Cycle Typical
YES
Optional
See Table 2---1
See Table 2---1
208Y120 VAC or 480Y277 VAC
15, 30, 50, 75, 100, 125, 150,
175, 200, 225, 250, 300 kVA
3
200% of Full Load for 10 Seconds
1000% of Full Load for 1 Cycle
1% Maximum
Greater Than 96%
80 (26.7)
See Table 2---1
A---1
Crucial Power Products
REV A
NOMINAL INPUT VOLTAGE
INPUT VOLTAGE RANGE
MAXIMUM INPUT VOLTAGE
NOMINAL RATED CURRENT (A)
FREQUENCY (Hz)
OUTPUT VOLTAGE REGULATION
LINE---TO---LINE VARIATION
RESPONSE TIME
FILTERS:
INPUT
OUTPUT
SECONDARY SURGE SUPPRESSION
COOLING REQUIREMENT (BTU/hr)
WEIGHT lbs (kg) (estimated)
OUTPUT VOLTAGE
CAPACITY (KVA)
NUMBER OF PHASES
SURGE RATING
HARMONICS ADDED
POWER EFFICIENCY
AMBIENT TEMPERATURE ˚F (˚C)
SIZE H X W X D in. (cm)
TABLE A---2
SPECIFICATIONS
MEDICAL POWER PC
208 VAC
187 --- 225
225
See Table 2---2
60
± 1.5%Typical, ± 2% Maximum
LESS THAN 2%
1 Cycle Typical
480 VAC
432---518
518
YES
YES
YES
See Table 2---2
See Table 2---2
208Y120 VAC or 480Y277 VAC
15, 30, 50, 75, 100, 125, 150, 175, 200, 225, 250, 300 kVA
3
200% For 10 Seconds
1% Maximum
Greater Than 96%
80 (26.7)
See Table 2---2
A---2
Crucial Power Products
REV A
AC
Current transformer
Front door
Front panel
IMCB
NEC
NEMA
OSHA
PCB
REPO
Thermal REPO
Reset (a circuit breaker)
SCR
Shunt Trip
Trip
TB
GLOSSARY
Air Conditioning
The transformer used to feed a current signal to the logic board.
The hinged front door on the Medical Power PC (15 --- 75 Kva). It covers the bypass switch and the IMCB if installed.
The hinged panel behind the front door on theMedical Power PC (15 --- 75 kVA) into which the bypass switch and the IMCB (if installed) are mounted.
InputMain Circuit Breaker — The circuit breaker on the front panel used to switch power to the CP 18 ON and OFF. Optional on Medical Power PC
(15 --- 75 kVA).
National Electric Code
National Electrical Manufacturers Association
Occupational Safety and Health Administration
Printed Circuit Board — A surface for the mounting and interconnection of electronic components.
Remote Emergency Power Off — A switch, separate from but wired to the regulation unit, when pressed, shunt trips the Main Input Circuit Breaker.
Thermal Remote Emergency Power Off — A thermal activated switch, separate from but wired to the regulation unit, which reacts to a predetermined temperature range by shunt tripping the Main Input Circuit Breaker.
Snap the breaker first to OFF position, then to ON.
Silicon---Controlled Rectifier
A device for tripping a circuit breaker indirectly, using a signal to activate a solenoid, instead of directly, because of an overcurrent condition.
A circuit breaker in an open position as a result of an overcurrent condition to the load, or as the result of a remote trip command (shunt trip). In a tripped condition, power to the load is off. The tripped circuit breaker position differs from the off position in that the breaker must first be turned to the off position before restoring power to the load.
Terminal Block
G---1
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Key features
- Three-phase, 60 Hz operation
- Automatic voltage regulation
- Isolation and surge protection
- Independent phase regulation
- UL listed
- Convection cooled
- Bypass switch for manual operation
