Critical Power Product Manual PEC 827E 120 VAC AC Distribution Shelf 6180498P (23 For Conduit), 6180529P (23 W/Outlets) 6180542P (19 For Conduit), 6180533P (19 W/Outlets) This document issue 4ge is updated with GE brand and contact information only, no other content change from issue 4. Issue 4 release date: August 2007. Service and Assistance - +1 877 546 3243 or +1 972 244 9288 PE.TechSupport@ge.com 2013 General Electric Company. All rights reserved. http://www.ge.com/powerelectronics 4380164PD Issue 04ge March 2013 1
Table of Contents... 2 Foreword... 3 Product Information... 3 WARNINGS... 4 CAUTIONS... 4 1: Installer Information... 5 1.1 General... 5 1.2 Equipment Included in Shipment... 5 1.3 Tools and Test Equipment Required for Installation and Acceptance Test... 5 2: Mechanical Installation... 6 2.1 General... 6 2.2 Installation... 6 3: Electrical Connections... 8 3.1 General... 8 3.2 120 VAC to AC Distribution Shelf FROM EACH INVERTER SHELF... 8 3.3 Load Connections... 12 3.4 Load Connections (With Outlets)... 13 3.5 Frame Ground Connection... 14 4: Initial Turn On and Acceptance Procedures... 15 4.1 General... 15 5: AC Distribution Panel Ratings... 15 Description T-Drawing for AC Distribution Shelf Part Number 4390670T 4380164PD Issue 04ge March 2013 2
This manual is intended to help the user of the 827E AC distribution shelf to install, test, troubleshoot, and understand the shelf. If you should have any questions or problems, please contact one of the following sources: SERVICE - If for any reason further assistance is needed on any power equipment, complete engineering and field service groups are available in Galion, Ohio, to assist you in any way possible. CALL: 419.468.7700 Field Service OR 419.468.7600 and ask for Field Service PARTS ORDERING - Replacement parts for power equipment may be obtained by forwarding a Purchase Order to: GE OR Fax to: 419.468.9780 1376 State Route 598 Galion, Ohio 44833 Include the following information: A. GE part number and engineering level of equipment B. If part is electrical, give circuit reference numbers and GE part numbers. C. If part is mechanical in nature, give description as to where it is used. RETURN & REPAIR - Equipment may be returned to the Factory for repair. In order to do this, the procedure must be as follows: A. Call: +1 972 244 9288 or toll-free at 888-546-3243 B. Request a Returned Material Authorization (RMA) number for the defective equipment. C. Return material prepaid to: GE 1376 State Route 598 Galion, Ohio 44833 Attn: RS & R Dept Please take a moment when the product is new to fill in this information. This data will allow faster service when calling GE to order accessories, spare parts, or request field service. First, locate the product information label. This is typically located on the upper front of the equipment frame, or on the rear of the frame. Fill in the part number, as it appears on the label, in the space below. PART NUMBER DATE CODE: SERIAL NUMBER ECN Level: 860 P 4380164PD Issue 04ge March 2013 3
1. Electrical shock hazard. Do not attempt to remove, maintain, or install this equipment with power applied. Personnel that attempt to work on this equipment with the power applied may subject themselves or others to electrical shock that may cause serious injury or death. 2. The use of this equipment by unauthorized or untrained personnel should not be attempted. Personnel that work on this equipment without the proper training may subject themselves or others to electrical shock that may cause serious injury or death. 3. Do not attempt to work on this equipment if it is, or has been, exposed to a high moisture condition. It is recommended the equipment be returned to GE to be properly tested. Working on this equipment during a high moisture condition subjects the user to electrical shock that may cause serious injury or death. 1. Follow proper grounding instructions. 2. If connecting batteries, remove the battery-box-fuse or trip the circuit breaker. Check batteries and connections for proper polarity and power before connecting the batteries to the system. 3. To remove the circuit breakers or fuses, the DC and/or AC input to the system will need to be disconnected, thereby disabling the system output to the load(s). Take the necessary precautions and inform the plant engineer that the system output power to the loads will be disabled. 4. Before performing any maintenance, ensure AC or DC power is not applied to the system. 5. Fuse holders, fuses, and circuit breakers are not to be loaded to more than 80 percent of their ampere rating. 4. Use of an attachment other than one approved by GE will void any and all warranties, implied or other, and will increase risk of fire, or may possibly cause electrical shock, injury, or death to personnel. 5. Do not operate this equipment if it has been dropped or otherwise damaged. Trying to operate this equipment if it has been damaged subjects yourself or others to electrical shock that may cause serious injury or death. 6. Before you proceed, ensure the input source is not live and the input circuit breaker(s)/fuse(s) has been tripped or removed. If these procedures have not been followed and the input/output power is live, serious personnel injury or death may occur. 7. A rack/shelf may contain several operating systems. If there is another system in the general area you want to install this system, be cautious of any exposed connectors or wires and, with permission, remove power to the other systems. Failure to take the necessary safety precautions subjects the installer or maintenance personnel to severe electrical shock that may cause serious injury or death. 8. This equipment may connect to lead-acid batteries. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash hands after touching batteries. 4380164PD Issue 04ge March 2013 4
1.1 GENERAL This equipment provides output distribution of nominal 120 VAC, 60 Amps maximum from each 827E inverter shelves. A maximum of four inverter shelves per AC Distribution Shelf is allowed. AC Distribution is accomplished through twelve (23 ) or eight (19 ) distribution breakers per shelf. The system can be equipped with or without AC distribution outlets. The AC Distribution Shelf is designed to be bottom or side fed from the inverter shelves, allowing easy connection points to the bus bars in the AC Distribution Shelf. 1.2 Equipment Included in Shipment The AC distribution shelf is completely self-contained and comes equipped with the hardware needed to connect the distribution of the inverter plant to the internal bus bars located in the AC Distribution Shelf, and for connection of the distribution points to the loads. The following equipment is available as standard or optional equipment: Note: The 23 shelf is rated to 200 Amps with each distribution side (left or right, six CB s each) rated to a maximum of 100 Amps. The 19 shelf is rated to 100 Amps maximum output. Each circuit breaker position is rated to a maximum of 70 Amps. Size breakers and loads accordingly. OEM Equipment Purpose Quantity Standard or Optional Shelf Output distribution of 120 VAC nominal from the 827E Inverter Plant As equipped Standard Distribution Breakers, 10-70 Amp Load protection Maximum 12 (23 ) or 8 (19 ) breakers per shelf Optional 1.3 Tools and Test Equipment Required for Installation and Acceptance Test Equipment Purpose Quantity Torque Wrench rated to Torque connection points. 1 50 ft. pounds Digital Meter Distribution verification 1 Figure 1-1. AC Distribution Shelf (Front View) 4380164PD Issue 04ge March 2013 5
2.1 General The following instructions are provided to properly install the system. Provided are general mechanical connections. For information relevant to electrical connections, power requirements, etc., refer to Chapter 3. NOTE: The AC distribution panel shown is the 23 conduit version (6180498P). 2.2 Installation Install the AC Distribution Shelf as follows: A. Remove the rear panel of the AC Distribution Shelf. Open the front door of the AC Distribution Shelf. Figure 2-1. AC Distribution Shelf (Rear View) Figure 2-2. AC Distribution Shelf Open Front Access Cover 4380164PD Issue 04ge March 2013 6
B. Remove the rear panel of the inverter shelf. Refer to Inverter manual 4380419PD. Warning: Prior to performing the following step, ensure the DC input power to the Inverter system is turned off, opened, or disconnected. This will eliminate the AC output of the Inverter shelf to help avoid potential injury. C. It is recommended that the AC Distribution Shelf be positioned above the inverter shelf(s). Secure the AC Distribution Shelf to the frame with four mounting screws, locating a mounting screw at each corner of the AC Distribution Shelf. Route the cable that exits the access port on the Inverter Shelf to the AC Distribution Shelf through the wire-way attached to the top of the frame. Refer to Figure 2-3. Figure 2-3. AC Wire Way from 827E Inverter Shelf to AC Distribution Panel D. Refer to Electrical Installation, Chapter 3. E. After the electrical connections have been made, re-install the rear covers on the Inverter Shelf and the AC Distribution Shelf. Close the front cover on the AC Distribution Shelf. Install the side cover, top cover, and the bottom cover to the wire-way. Installation is complete. 4380164PD Issue 04ge March 2013 7
3.1 General This chapter provides the electrical connections for the AC Distribution Shelf. Recommendations, when made, are provided for wire size and input breaker requirements. Tighten all connections to the SAE torque specifications listed below: BOLT SIZE Inches 1/4 5/16 3/8 7/16 1/2 BOLT STEEL Grade 5 FT LBS/IN LBS 7.6 / 91.2 15.3 / 183.6 27.0 / 324.0 43.0 / 516.0 64.0 / 768.0 Note: 827E Inverter connections are provided in manual 4380419PD. 3.2 120 VAC to AC Distribution Shelf from Each Inverter Shelf Connect the cables that exit the AC terminal block (TB2) on the rear of the Inverter shelf to the AC Distribution Shelf. The three cables are identified as Line, Neutral, and Ground. Secure the cables to the compression lugs on the AC terminal block (cable provided with system). Connect the cables to the Inverter Shelf distribution terminal block as follows: Note: All AC wiring must be in conduit per the National Electric Standards. Conduit knockouts are on the rear (1/2" or 3/4" for loads) of the unit. There is a wire-way on the right (looking from the rear) for wiring from the inverter shelf to the AC distribution panel. 1 The cable identified as Ground (green) from each shelf must be connected to the GND (Ground) bus on the distribution shelf. 2. The cable identified as Neutral (white) from each shelf must be connected to the NEUT. (Neutral) bus on the distribution shelf. Refer to Figure 3-3. 3. The cable identified as Line (black) from each shelf must be connected to the Line bus on the distribution shelf. Up to four 827E Inverter Shelf can be connected to the AC distribution shelf to provide power output. See figure 3-2. Terminal Capacity Terminal Type Recommended Wire Size 6 AWG 250 MCM Compression 6 AWG 6 AWG 250 MCM 1/4" on 5/8 (Two Hole Lug) 6 AWG 4380164PD Issue 04ge March 2013 8
Figure 3-1. 120 VAC From Inverter Shelf to AC Distribution Panel (Right Side) 4380164PD Issue 04ge March 2013 9
NEUTRAL LINE GROUND Figure 3-2: AC Distribution Shelf Input Connections Rear View (Unwired) AC Input From Inverter Shelves Figure 3-3: AC Distribution Shelf Input Connections Front View (Fully wired) 4380164PD Issue 04ge March 2013 10
BUILDING. GROUND OPTIONAL Figure 3-4: Block AC Wiring diagram from the 827E Inverter shelves to the distribution shelf. 4380164PD Issue 04ge March 2013 11
3.3 Load Connections Refer to paragraph 3.4 for systems with outlets. Connect the Load line (black) connection to the output of the selected circuit breaker. Connect the Neutral (white) and Ground (green) connections from the load to the terminal blocks identified as Neutral and Ground inside the AC Distribution Shelf. Tighten these connections until completely secure. See Figure 3-4. Circuit Breaker Rating Terminal Capacity Terminal Type Recommended Wire Size 2 70 Amps per position 4-14 AWG Compression Dependant on load Note: All load wiring exiting this shelf must be in conduit per the National Electrical Standards. Conduit knockouts are provided on the rear of the unit. Ground Connections Neutral Connections Line Connections Figure 3-5: Ground, Load, Neutral Connections Loads are routed under the Neutral connection and out the rear of the AC Panel. Figure 3-6: Load Connections cable routing 4380164PD Issue 04ge March 2013 12
Loads routed through wireway as shown. Figure 3-6: Load Wireway Top View All load cables are to be routed through the wireway as shown in figure 3-6. Loads exit the AC Distribution Panel via the rear access holes. Knockouts are provided for 1/2" or 3/4" conduit as required. Panels with knockouts are removable to facilitate removal of knockouts. 3.4 LOAD CONNECTIONS (WITH OUTLETS) Refer to paragraph 3-3 for systems without outlets. All internal connections to outlets from CB distribution has been accomplished at the factory, except load wire. Load wire (black) from the outlet will need to be connected to the load side of the circuit breaker when installed. Installer is required to fabricate the plugs for the load connections using the recommended wire size as identified in the chart below. See Figure 3-5. Circuit Breaker Rating Terminal Capacity Terminal Type Recommended Wire Size 2 15 Amps per position 4-14 AWG Compression Dependant on load Ground Load Neutral Figure 3-7: Ground, Load, Neutral Connections (With Outlets) 4380164PD Issue 04ge March 2013 13
3.5 Frame Ground Connection Install a ground cable to the 1/4 on 5/8 center Frame ground location on the rear of the system and to the plant Frame ground. See Figure 3-8. Terminal Type 1/4 on 5/8 Centers for Inserts Recommended Wire Size As Required NEUTRAL CONNECTION Frame Ground Connection Figure 3-8: GEC Ground Connection 4380164PD Issue 04ge March 2013 14
4.1 General This chapter provides the initial turn on and acceptance procedures for the AC Distribution Shelf. Note: Pull all distribution fuses/set all CB s to OFF prior to performing the operational checkout procedure. Step Description Pass/Fail Initials Date 1. Ohm wires from AC Distribution Shelf to the Inverter Shelf to ensure proper connection. 2. Ohm wires from AC Distribution Shelf to Loads to ensure proper connection. 3. Apply input DC to the Inverter Shelf. 4. Perform the operational test of the Inverter Shelf per manual 4380419PD 5. Remove all tools and test equipment. -This page intentionally left blank- Part Number Maximum Current Rating Voltage Rating Maximum Circuit Breaker Rating 6180498P (23 For Conduit) 200 Amps 120VAC 70 Amps per circuit position 6180529P (23 W/Outlets) 180 Amps 120VAC 15 Amps per circuit position 6180542P (19 For Conduit) 100 Amps 120VAC 70 Amps per circuit position 6180533P (19 W/Outlets) 100 Amps 120VAC 15 Amps per circuit position 4380164PD Issue 04ge March 2013 15