TDK-Lambda THR4 Manual de usuario

THR4

Installation,Operation,andMaintenanceManual

THR4

THR400

August 2009

Version A4

This datasheet has been downloaded fromhttp://www.digchip.com at this page

Revision A4 : August, 2009

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

THR4-SSERIES POWER SYSTEM

Page. 2

Table

Contents

Safety

and

Recommended

Practices 3

1.1 General practices 3

1.2 FCC Compliance Statement 4

Warning 4

Product

Section 5

2.1 Power Module Specification 5

2.1.1 DC Output Voltage 5

2.1.2 Heat Dissipation 5

2.2 AC input Voltage Requirements 6

2.2.1 AC Input Voltage 6

2.2.2 AC Input Wire Diagrams 6

2.2.3 AC current and cable sizing 7

2.3 DC Input Diagrams 9

2.3.1 Circuit Drawings 9

2.3.2 DC Reference Ground 9

2.3.3 DC Wire Sizing 9

2.3.4 DC lug requirements 10

2.4 Torque Settings 11

Required

Tools 11

Site

and

Equipment

Preparation 11

Power

Plant

Mounting

and

Wiring 11

5.1 Mechanical mounting 11

5.2 AC input 12

5.2.1 Dual feed with terminal blocks 12

5.2.2 Individual feed with terminal blocks 13

5.2.3 Individual feed with IEC320 receptacle 13

5.2.4 AC cord brackets 13

5.3 DC Output 14

5.3.1 Circuit 1 15

5.3.2 Circuit 23 15

5.4 Alarm connections 15

5.5 NIC interface 16

5.6 I2C communictaion connection 16

Test

and

Turn-uup 17

6.1 Power Up 17

Alarm

Cable

Pinout 17

Replacement

Items 19

Troubleshooting 20

9.1 Problems and solutions 20

9.2 Short circuit & current limit 20

10)

NIC Information 21

10.1 NIC card settings 21

10.2 NIC card replacement 24

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

THR4-SSERIES POWER SYSTEM

This product accepts a nominal AC Voltage

between 100 and 240 VAC, 47 to 63 Hz,

and produces a regulated output of 10.5-14

VDC capable of delivering a max of 400

Amperes (300 amps continuous) DC for 12V

rectifiers, 21-28 VDC capable of delivering a

max of 200 Amperes DC for 24V rectifiers,

28-42V

capable of delivering a max of 160 amperes

DC for 36V rectifiers, 42-56 VDC capable of

delivering a max of 200 Amperes DC for

48V rectifiers, in an ambient operating tem-

perature range of -40°C to +70°C (depend-

ing upon deployed rectifiers and shelf).

HAZARDOUS

VOLTAGE

AND

ENERGY

LEVELS

ARE

PRESENT

WHICH

CAN

PRODUCE

SERIOUS

SHOCKS

AND

BURNS.

Only authorized, qualified, and trained per-

sonnel should attempt to work on this equip-

ment. Refer to datasheets for full product

specifications.

Observe all local and national electrical,

environmental, and workplace codes.

Each power shelf should be fed from a dedi-

cated AC branch circuit of a Terra Neutral

(TN) power system.

If a line cord(s) is (are) used as the AC

connection means, the plug end of the cord

is considered to be the primary disconnect

means, and reasonable access must be

given to the plug and receptacle area. The

receptacle must be fed with a breaker or

fuse according to Table 4.

For hard-wired AC connections, a readily

accessible disconnect device shall be incor-

porated in the building installation wiring.

Select a wall breaker and wire sizes accord-

ing to Table 4.

CAUTION:

ALL

RECTIFIERS

EMPLOY

INTERNAL

DOUBLE

POLE/NEUTRAL

FUSING

Use double hole, UL listed lugs for all DC

connections to prevent lug rotation and inad-

vertent contact with other circuits.

Class 1 wire is recommended for all DC con-

nections. Minimum wire sizes are shown in

Table 5. In practice, loop voltage drop con-

siderations will usually dictate larger than

minimum safe wire size.

Connection and mounting torque require-

ments are listed in Table 7.

Lambda does not recommend shipping the

rack with the power modules installed. Power

modules should be shipped in separate boxes.

Revision A4 : August, 2009

Page. 3

Safety

and

Recommended

Practices

1.1

General

practices

For use in restricted access locations only.

Suitable for mounting on concrete or other non-combustible surfaces

1.2

FCC

Compliance

Statement

Note: This device complies with Part 15 of FCC Rules. Operation is subject to the following two

conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause

undesired operation.

This equipment has been tested and found to comply with the limits for a Class A digital device,

pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection

against harmful interference when the equipment is operated in a commercial environment. This

equipment generates, uses, and can radiate radio frequency energy and, if not installed and used

in accordance with the instruction manual, may cause harmful interference to radio communica-

tions. Operation of this equipment in a residential area is likely to cause harmful interference in

which case the user will be required to correct the interference at his own expense.

1.2.1

Warning

Changes or modifications to this unit not expressly approved by the party responsible for the

compliance could void the user's authority to operate this equipment.

Revision A4 : August, 2009

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THR4-SSERIES

POWER SYSTEM

Product

Section

2.1

Power

Module

Specification

2.1.1

Output

Voltage

Table 1 shows the DC voltage range and max current for each model of power module for this system.

2.1.2

Heat

Dissipation

Table 2 displays the max and typical BTU/hr of heat dissipated for each power module.

Max is calculated at 180VAC, Max VDC and current values for the power module, and typical is

calculated at 240 VAC, typical VDC and current values.

Revision A4 : August, 2009

Page. 5

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

THR4-SSERIES POWER SYSTEM

DC Output Voltage

TH120048 42-56 25

TH200048 42-56 40

TH250048 42-56 50

TH200036* 28-42 40

TH120024 21-28 50

TH120012 10.5-14 100

Model Voltage min/max Max Current

Table

Heat Dissipation

TH120048 451 833

TH200048 635 897

TH250048 794 1106

TH200036 423 648

TH120024 564 856

TH120012 735 992

Model Typical BTU/hr Max BTU/hr

Table

*max power 1440 watts

AC Line 1

AC Line 2

Power Module 1

N+1 DC Out

Power Module 2

Power Module 3

Power Module 4

Revision A4 : August, 2009

Page. 6

THR4-SSERIES

POWER SYSTEM

2.2

Input

Requirement

2.2.1

Input

Voltage

Table 3 shows the required AC input voltages for the available power modules. The power mod-

ules under wide line (WL) can be connected to a nominal input voltage between 100 V & 240V.

The power modules under high line (HL) can be connected to a nominal input voltage between

200 V & 240V.

Table

Power

Module

Input

Voltages

2.2.2

Input

Wire

Diagrams

This system utilizes a dual or individual feed AC architecture (Figure 1 & Figure 2).

2.2.2.1

Dual

feed

A system with a dual feed AC architecture feeds power module slots 0 & 1 with feed 1, and

power module slots 2 & 3 with feed 2. The AC connections on the shelf are made via rear

accessed compression style terminal blocks see Figure 6. These terminal blocks will accept up to

a maximum of a 10 AWG wire, and should be torqued to 6 in-lbs. Keep this wire size limitation

in mind when sizing the quantity and size of the power modules. Size your AC breaker and

wiring according to Table 4.

Figure

Dual

Feed

wiring

architecture

Table

Power Module Input Voltages

TH120048 TH200048

TH120024 TH200036

TH75012 TH250048

TH120012

Wide Line (100V - 240V) High Line (200V - 240V)

AC Line 1 AC Line 2 AC Line 3 AC Line 4

Power Module 1

N+1 DC Out

Power Module 2

Power Module 3

Power Module 4

Revision A4 : August, 2009

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3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

THR4-SSERIES POWER SYSTEM

2.2.2.2

Individual

feed

A system with an individual feed AC architecture feeds each power module slot with an AC feed.

There are two different styles of individual feeds for this system.

The first style of connection is made via rear accessed compression style terminal blocks see

Figure 6. These terminal blocks will accept up to a maximum of a 10 AWG wire, and should be

torqued to 6 in-lbs.

The second style is made via rear accessed IEC320 receptacles, see Figure 8. The connections

should be sized with an AC service no larger than 15 amps. Keep this limitation in mind when

sizing the power modules. Securing brackets are available to hold the IEC320 AC cords to the

shelf, see Figure 9 for more information. Size your AC breaker and wiring according to Table 4.

Figure

Individual

feed

wiring

architecture

2.2.3

current

and

cable

sizing

To size your AC feeds properly, use the example below. Failure to size the AC breaker and wiring

properly can result in nuisance breaker trips or even fire. If you anticipate future growth, size the

AC breaker and wiring for the expected future capacity.

Use section 2.2.2 to determine your AC input architecture, for example a dual feed.

Determine the quantity and model number of the power modules that will be used, for example

two TH120048 (48V, 25A).

Determine the sites AC input nominal AC voltage and compare it to Table 3 for power module

compatibility, for example, the TH120048 power module will accept either low line or high line

AC voltage.

Revision A4 : August, 2009

Page. 8

THR4-SSERIES

POWER SYSTEM

For this example we will assume that future growth is necessary so we will size the AC feed for

four power modules. Using Table 4, each AC feed, to the pair of TH120048, power modules will

require will require a 20 amp breaker with 12 AWG wire, at high line, per feed.

NOTE: Under-sizing your AC breaker and wiring could cause nuisance breaker trips and system

outages. ALWAYS

NEC

RULES

AND

YOUR

LOCAL

COMPANY

PRACTICES

WHEN

SELECTING

WIRING

AND

PROTECTION.

The Table 4 below uses a minimum nominal input voltage to determine AC current requirements.

90 V corresponds to a nominal low line voltage of 100VAC and 180 V corresponds to a nominal

highline voltage of 200VAC.

Individual

Feed

Dual

Feed

Recommended AC Circuit Breaker & Wire Sizes

Number of Model # Minimum Maximum Circuit Breaker 90°C Minimum Wire

Type of Power Modules of Power Input

rated

AC Minimum Value Gauge to use at 30°C

Feed on AC Feed Module Voltage Current (Amps) to use (Amps) ambient (AWG)

TH120048 90 17.6 20 12

TH120048 180 8.8 15 14

TH200048 180 13.8 15 14

TH250048 180 16.9 20 12

TH200036 180 9 15 14

TH120024 90 17.4 20 12

TH120024 180 8.7 15 14

TH120012* 90 15 15 12

TH120012 180 8.9 15 14

TH120048 90 35.2 N/A N/A

TH120048 180 17.6 20 12

TH200048 180 27.6 30 10

TH250048 180 33.8 N/A N/A

TH200036 180 9 20 12

TH120024 180 17.4 20 12

TH120012* 90 30 30 10

TH120012 180 17.8 20 12

*1200W Table

Revision A4 : August, 2009

Page. 9

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

THR4-SSERIES POWER SYSTEM

2.3 DC Output Wire Requirements

2.3.1

Circuit

Drawings

Figure

Wire

Diagram

Each system is equipped with 2 unprotected bulk output connections; one set located on each

side of the rear of the shelf. The THR4 rack will only accept lugs and THR400 will accept lugs or

bus bars. Unprotected bulk connections are double, ¼"-20 (M6) studs with 5/8" centers. The

maximum tongue width for bulk connections is 0.67". Select a wire or bus bar size for the bulk

outputs according to the current rating as shown in Table 5. Choose lugs according to section

Table 6. The polarity of the system is universal; therefore the polarity of the output is determined

by the system grounding. See section 2.3.2 for more detail. The THR4 is capable of delivering a

max of 200 amps total, 100 amps per side. The THR400 is capable of delivering a max of 400

amps total (300 amps continuous), 200 amps per side.

2.3.2 DC

Reference Ground

The Lambda Power system is a fully floating system. This means that neither the positive nor the

negative are tied to the chassis or an earth ground. An external reference or earth ground may

be connected to either the positive output or the negative output depending the desired output

polarity. As always follow your company's guidelines for sizing and attaching a reference ground.

2.3.3

Wire

Sizing

There are two main considerations for sizing DC wire, ampacity and voltage drop. Ampacity

refers to a safe current carrying level as specified by non-profit organizations such as

Underwriters Laboratories and the National Fire Prevention Association, which publishes the

National Electric Code. Voltage drop is simply the amount of voltage loss in a length of wire

due to ohmic resistance of the conductor. DC wire may be sized for either ampacity or voltage

drop depending on branch load loop length and conductor heating. In general, ampacity

considerations will drive wire selection for short loop lengths (less than 50 feet) and voltage

drop will drive wire selection for long loop lengths (greater than 50 feet).

The National Electric Code table 310.16 provides ampacity values for various sizes, bundles, and

insulation temperature rated wire. ALWAYS

NEC

RULES

AND

YOUR

LOCAL

COMPANY

PRACTICES

WHEN

SELECTING

WIRING

AND

PROTECTION.

Table 5 shows recommended

wire sizes.

Unprotected

output

wires

shall

based

the

total

power

module

capacity

the

rack.

For

example,

using

Table

below,

system

with

two

V1000A

(48V,

20A)

rectifiers

for

total

capacity

requires

one

AWG

set

cables.

2.3.4

lug

requirements

Table 5 below is a list of lug part numbers from Burndy that can be used for DC connections.

Wire type should be considered when determining the type of lug to use. These part numbers are

based on flex style cable. Follow your company practices when determining the exact lug

required. Systems requiring more than a 2 AWG (max 125 A) connection will need custom bus

bars. Note: ¼" holes will work on M6 studs.

Revision A4 : August, 2009

Page. 10

THR4-SSERIES

POWER SYSTEM

Min. Recommended DC AWG for 90°C

Cabling

10 16 AWG*

20 14 AWG

30 12 AWG

40 10 AWG

50 8 AWG

75 6 AWG

100 2 AWG

125 2 AWG

150 (1)1 AWG or (2) 6 AWG

175 (1)2/0 AWG or (2) 4 AWG

200 (1)3/0 AWG or (2) 2 AWG

Total Power Module Wire & Lug Gauge (AWG) using 90°C

Current Rating (A) wire (NEC Table 310.16)

Table

* For wire sizes less than 15 A not covered in NEC Table

310.16 use Table 3B - Sizes of Conductors, UL60950, "Safety

of Information Technology Equipment", Dec., 2000 for non-

building wiring.

Lug Part Number for DC Output

Total Power Burndy Amp Ring

Supply Wire Lug Part Terminal Part

Capacity AWG # # Desciption

10 AMPS 16 AWG 321045 SH Ring Terminal 1/4 Stud

15 AMPS 14 AWG 321045 SH Ring Terminal 1/4 Stud

20 AMPS 12 AWG 323763 SH Ring Terminal 1/4 Stud

30 AMPS 10 AWG 323763 SH Ring Terminal 1/4 Stud

30 AMPS 10 AWG YAV102TC14 DH Lug Standard Barrel 1/4 Stud, 5/8 Center

50 AMPS 8 AWG YA8CL2TC14 DH Lug Standard Barrel 1/4 Stud, 5/8 Center

75 AMPS 6 AWG YAV6C-L2TC14-FX DH Lug Standard Barrel 1/4 Stud, 5/8 Center

100 AMPS 2 AWG YAV2C-L2TC14-FX DH Lug Standard Barrel 1/4 Stud, 5/8 Center

125 AMPS 2 AWG YAV2C-L2TC14-FX DH Lug Standard Barrel 1/4 Stud, 5/8 Center

Table

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