Document Outline

• 1.0 About This Document
  • 1.1 Purpose of This Document
  • 1.2 Applicability of This Document
• 2.0 Introduction
  • 2.1 Description
    • Figure 1 Front view of a typical bottom fed 4000 A Helios DC System 4000/48 power system
    • Figure 2 Front view of a typical 6000 A Helios DC System 4000/48 power system
  • 2.2 Applications
  • 2.3 Control and Distribution Cabinets - Typical Configurations
    • Figure 3 Typical configurations for Helios DC System 4000/48 control, distribution and rectifier ...
    • Table 1 Rectifier cabinets
    • Table 2 Control and distribution cabinets
    • Table 3 Auxiliary distribution cabinets
• 3.0 Specifications
  • 3.1 Framework
    • 3.1.1 Mechanical Specifications of a Cabinet
      • Table 4 Mechanical specifications of the cabinet (empty)
    • 3.1.2 Electrical Specifications of the Cabinets
  • 3.2 Conventional Controller
    • 3.2.1 Mechanical Specifications of the Conventional Controller
      • Table 5 Mechanical specifications of the Conventional Controller
      • Figure 4 Front view of the Conventional Controller
    • 3.2.2 Electrical Specifications of the Conventional Controller
  • 3.3 Distribution Panels
    • 3.3.1 Fuse Panels
      • Mechanical specifications of the fuse panels
      • Table 6 Mechanical specifications of the fuse panels
      • Figure 5 Front view of the 20 QFF 0-5 A fuse panels
      • Table 7 Fuse sizes available for the (20) QFF 0-5 A fuse panels
      • Figure 6 Front view of the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels
      • Table 8 Fuse sizes available for the (16) QFF 0-5 A & (12) ABS 5-30 A fuse panels
      • Figure 7 Front view of the (16) QFF 0-5 A & (6) TPN 5-30 A fuse panels
      • Table 9 Fuse sizes available for the (16) QFF 0-5 A & (6) TPN 5-30 A fuse panels
      • Figure 8 Front view of the (8) TPN 5-30 A fuse panels
      • Table 10 Fuse sizes available for the (8) TPN 5-30 A fuse panels
      • Figure 9 Front view of the (4) RS100P 70-100 A fuse panels
      • Table 11 Fuse sizes available for the (4) RS100P 70-100 A fuse panels
      • Figure 10 Front view of the (4) CRS200P 150-200A/(4) CRS200P 150200A (w/load shunts) fuse pa...
      • Table 12 Fuse sizes available for the (4) CRS200P 150-200 A/(4) CRS200P 150200A (w/load shunt...
      • Figure 11 Front view of the (4) TPL 225-600 A fuse panels
      • Table 13 Fuse sizes available for the (4) TPL 225-600 A fuse panels
      • Figure 12 Front view of the (18) TPS 1-70 A fuse panel
      • Table 14 Fuse sizes available for the (18) TPS 1-70 A fuse panel
      • Electrical specifications of the fuse panels
      • Table 15 Electrical specifications of the fuse panels
    • 3.3.2 Circuit Breaker Panels
      • Mechanical specifications of the circuit breaker panels
      • Table 16 Mechanical specifications of the circuit breaker panels
      • Figure 13 Front view of the (24) Plug-In 1-100 A circuit breaker panel
      • Table 17 Plug-in circuit breakers available for the (24) Plug-In 1-100 A circuit breaker panel
      • Figure 14 Front view of the (4) 70-250 A circuit breaker panel
      • Table 18 Circuit breaker sizes available for the (4) 70-250 A circuit breaker panel
      • Figure 15 Front view of the (2) 400 A circuit breaker panel
      • Table 19 Circuit breaker kits available for the (2) 400 A circuit breaker panel
      • Figure 16 Front view of the (1) 600-700 A circuit breaker panel
      • Table 20 Circuit breaker kits available for the (1) 600-700 A circuit breaker panel
      • Electrical specifications of the circuit breaker panels
      • Table 21 Electrical specifications of the circuit breaker panels
  • 3.4 Externally Mounted Battery Return Busbar
    • 3.4.1 Mechanical Specifications of the External Battery Return Busbar
      • Table 22 Mechanical specifications of a single lamination
      • Figure 17 Top and side views of the external battery return busbar
    • 3.4.2 Electrical Specifications of the External Battery Return Busbar
  • 3.5 Terminating Assemblies (Optional)
    • Figure 18 Perspective view of the a terminating assemblies
  • 3.6 MPS300 and MPA100 Power Shelves
    • 3.6.1 Mechanical Specifications of the MPS300 and MPA100 Power Shelves
      • Table 23 Mechanical specifications of the MPS300 and MPA100 power shelves
      • Figure 19 Front view of the MPS300 power shelf (shown empty)
      • Figure 20 Front view of the MPA100 power shelf (shown empty)
    • 3.6.2 Electrical Specifications of the Power Shelves
  • 3.7 Rectifiers
    • 3.7.1 Helios Rectifier 100/48
      • Mechanical specifications of the Helios Rectifier 100/48
      • Table 24 Mechanical specifications of the Helios Rectifier 100/48
      • Figure 21 Front view of the Helios Rectifier 100/48
      • Electrical specifications of the Helios Rectifier 100/48
      • Table 25 Electrical specifications of the Helios Rectifier 100/48
    • 3.7.2 Helios Rectifiers 200I/48 and 200E/48
      • Mechanical specifications of the Helios Rectifiers 200I/48 and 200E/48
      • Table 26 Mechanical specifications of the Helios Rectifiers 200I/48 and 200E/48
      • Figure 22 Front view of the Helios Rectifiers 200I/48 and 200E/48
    • 3.7.3 Electrical Specifications of the Helios Rectifiers 200I/48 and 200E/48
      • Table 27 Electrical specifications of the Helios Rectifiers 200I/48 and 200E/48
    • 3.7.4 Standards
  • 3.8 Helios Monitor 3000/48 (Optional)
    • 3.8.1 Mechanical Specifications
      • Table 28 Mechanical specifications of the Helios Monitor 3000/48
      • Figure 23 Front view of the Helios Monitor 3000/48 (without the mounting brackets)
    • 3.8.2 Electrical Specifications
  • 3.9 600A and 1200A Battery Disconnect Unit (Optional)
    • Figure 24 600 A Battery Disconnect Unit
  • 3.10 AC Junction Box
    • Figure 25 Front view of the AC junction box (with the front panel open)
    • 3.10.1 Mechanical Specifications
      • Table 29 Mechanical specifications of the AC junction box
    • 3.10.2 Electrical Specifications
  • 3.11 Overall Power System Specifications
    • 3.11.1 Standards
    • 3.11.2 Mechanical Specifications of Fully Equipped Power Cabinets
      • Table 30 Mechanical specifications of fully equipped power cabinets
    • 3.11.3 Electrical Specifications
      • Electromagnetic compliance (EMC)
      • Electrostatic discharge (ESD) immunity
    • 3.11.4 Environmental Specifications
      • Operating
      • Transportation
      • Storage
      • Heat dissipation
    • 3.11.5 Floor and Point Loading
      • Table 31 Floor and point loading
• 4.0 Operation
  • 4.1 General
  • 4.2 Conventional Controller
    • 4.2.1 Front Panel
      • Figure 26 Front view of the Conventional Controller
      • Visual indicators
      • Table 32 Visual indicators
      • Table 33 Transmitted alarms
      • Potentiometers
      • Table 34 Potentiometers
      • Switches
      • Table 35 Switches
      • DIP switches
      • Table 36 DIP switch modules
      • Figure 27 Shunt range selection settings
      • Figure 28 Equalize voltage and duration settings
      • Fuses
      • Table 37 Fuse
      • Test points
      • Table 38 Test points
    • 4.2.2 Rear Panel
      • Figure 29 Terminal blocks and connectors layout at the rear of the Conventional Controller
      • Terminal blocks
      • Figure 30 Wiring diagram and pin assignment of terminal blocks TB1 to TB4
      • Figure 31 Wiring diagram and pin assignment of terminal blocks TB5 and TB6, and connectors P1 to P26
      • Connectors
  • 4.3 MPS300 and MPA100 Power Shelves
  • 4.4 Rectifiers
  • 4.5 AC Junction Box
  • 4.6 Distribution Panels
  • 4.7 Terminating Assemblies (Optional)
  • 4.8 Helios Monitor 3000/48 (Optional)
  • 4.9 600A and 1200 Battery Disconnect Units (Optional)
• 5.0 Maintenance
  • 5.1 General
    • 5.1.1 Helios Monitor 3000/48
    • 5.1.2 Controller and Rectifiers
      • Cleaning
      • Calibration
      • Storage
      • Air filter replacement
      • Fan unit replacement
  • 5.2 Troubleshooting
    • Table 39 Fault diagnosis
  • 5.3 Addition / Replacement Procedures
    • 5.3.1 Addition or Replacement of a Rectifier
      • Adding a Helios Rectifier 100/48
      • Adding a Helios Rectifier 200I/48 or 200E/48
      • Figure 32 AC connections in a Helios Rectifier 200E/48
      • Figure 33 AC connections in the female receptacle for a Helios Rectifier 200I/48 or a Helios Rect...
      • Figure 34 AC connections inside the junction box (top fed shown) for a Helios Rectifier 200E/48
      • Figure 35 AC cable routing for the Helios Rectifiers 200E/48 in a top fed system
      • Figure 36 AC cable routing for the Helios Rectifiers 200E/48 in a bottom fed system
    • 5.3.2 Replacing a Rectifier
      • Replacing a Helios Rectifier 100/48
      • Replacing a Helios Rectifier 200I/48 or 200E/48
    • 5.3.3 Adding or Replacing a Battery String
    • 5.3.4 Replacement of a Distribution Fuse Block or Circuit Breaker
      • Replacing a distribution circuit breaker
    • 5.3.5 Replacing a Cabinet Alarm Lamp
• 6.0 Reference Documents
• 7.0 List of Terms