ETA Systems Power Supply SM5505 User Manual

CPC Series  
Conditioned Power Center  
RoHS Compliant  
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Table of Contents  
Caution Notice...............................................................................................................5  
Section 1-General .........................................................................................................6  
Section 2 – Safety  
2.1 ANSI Warning Notices ..............................................................................7  
2.2 Inherent Hazards.......................................................................................7  
2.3 Alerts and Labels.......................................................................................7  
2.4 Safety Interlocks........................................................................................9  
2.5 Lockout/Tagout..........................................................................................9  
2.6 Conformance with Regulations...............................................................10  
2.7 Product Liability.......................................................................................10  
2.8 Emergency Contact Information .............................................................10  
Section 3 – Product Overview  
3.1 Product Purpose......................................................................................11  
3.2 Standard Features...................................................................................12  
3.3 Optional Features....................................................................................12  
3.4 Feature/Model Matrix ..............................................................................13  
Section 4 – Preparation  
4.1 Unpackaging ...........................................................................................14  
Section 5 – Installation  
5.1 Location...................................................................................................17  
5.2 Conduit Landings ....................................................................................17  
5.2.1Top Feed................................................................................17  
5.2.2 Bottom Feed .........................................................................17  
5.3 Outer Panel Removal..............................................................................18  
5.4 Alternate Conduit Landing Locations......................................................18  
5.5 Main Input Circuit Breaker.......................................................................18  
5.5.1 Fixed Input Circuit Breaker...................................................18  
5.5.2 Programmable Circuit Breaker .............................................19  
5.6 Isolation Transformer ..............................................................................19  
5.6.1Transformer Primary Voltage Adjustment .............................20  
5.6.2 Output Voltage Fine Adjustment...........................................21  
5.7 Grounding................................................................................................21  
5.8 Lockout/Tagout........................................................................................22  
5.9 Input Power Connections........................................................................23  
5.10 Output Power Connections...................................................................23  
5.11 Optional Line Cord/Receptacles ...........................................................23  
Section 6 - Operation  
6.1 Restoring for Service...............................................................................24  
6.2 Energizing the Power Conditioner ..........................................................24  
6.3 Energizing the Load ................................................................................25  
6.4 Orderly Shutdown....................................................................................25  
Section 7 - Options  
7.1 Passive Harmonic Filter ..........................................................................26  
7.2 Basic Power Metering .............................................................................26  
7.3 Power Management................................................................................26  
7.4 Phase Loss - Low Voltage Detect...........................................................27  
7.5 External EMO Connector ........................................................................27  
7.6 Seismic Anchorage .................................................................................27  
7.7 SEMI S2-0200.........................................................................................28  
7.7.1 Input Power Conductor Restraints.......................................28  
7.7.2 SEMI S2-0200 Compliant EMO...........................................28  
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Table of Contents  
Section 8 - Troubleshooting/Maintenance  
8.1 Troubleshooting Conditions....................................................................30  
8.1.1 Source Circuit Breaker Trips Out .........................................30  
8.1.2 Input Circuit Breaker Trips Out.............................................30  
8.1.3 TVSS Fault LEDs Illuminate.................................................31  
8.1.4 Harmonic Filter Circuit Breaker Trips Out ............................32  
8.2 Rountine Maintenance............................................................................32  
Section 9 - Service and Support  
9.1 Technical Service Assistance.................................................................33  
9.2 Customer Service ...................................................................................33  
9.3 Product Warranty....................................................................................33  
Section 10 - Specifications  
10.1 System Schematic ................................................................................34  
10.2 Standard EMO Circuit...........................................................................35  
10.3 Semi S2-0200 Compliant EMO Circuit .................................................36  
10.4 Output Voltage Fine Adjustment...........................................................37  
Document Revision History..........................................................................................38  
Detailed Specifications.................................................................................................39  
4
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P L E A S E !  
For maximum safety, reliability, and user satisfaction,  
please read all of the following important information  
carefully. When finished, If you are in doubt about any  
phase of the installation, operation, maintenance or use  
of this product contact the manufacturer immediately  
for additional assistance.  
5
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Section 1 - General  
This manual describes the installation, connection, adjustment and operation of electrically powered equipment.  
For your convenience, this document has been divided into the following nine sections.  
Section 1 - General: The section which your are currently reading describes the manual’s structure and the  
location of pertinent information required to install, operate, troubleshoot, repair, and maintain the product.  
Section 2 - Safety: This section provides information on the safe installation and use of the product.  
Section 3 - Product Overview: This section describes the product’s function and purpose, gives examples of  
some applications where it may be used, and describes the both standard and optional product features. It also  
gives details on unpacking and inspecting the product on arrival and preparing it for installation.  
Section 4 - Preparation: This section provides information on unpacking and moving the conditioner.  
Section 5 - Installation: This section provides details on locating and leveling the product, landing conduits,  
grounding, connecting input and output wiring, configuring operating voltages, and preparing the unit prior to  
energizing and putting into service.  
Section 6 - Operation: This section of the manual provides the information required to operate the product and  
its controls.  
Section 7 - Optional Equipment: This section gives detailed information on features which are available as  
options. Your particular product may be equipped with one or more options. If so, this section will provide the  
information necessary to use the options.  
Section 8 - Troubleshooting and Maintenance: This section provides all the information necessary to maintain  
the product, troubleshoot a failure or malfunction, and to repair the product when possible.  
Section 9 - Service and Support: This section provides the information necessary to obtain service and support  
on the product.  
Section 10 - Technical Specifications: This section provides complete technical specifications. Consult the  
information in this section for detailed information on conduit landings and electrical parameters for the specific  
model you are installing.  
As you use this manual for the installation, operation, and maintenance of the product, you may be  
required to consult different sections of this manual in the process of completing specific tasks.  
6
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Section 2 - Safety  
- IMPORTANT SAFETY INSTRUCTIONS -  
- SAVE THESE INSTRUCTIONS -  
2.1 ANSI Warning Notices  
Failure to observe reasonable precautions in the use of this product may result in fire, injury, electrocution and/or  
death. Please observe all notices and warnings. This equipment must be installed in accordance with all  
applicable national, state, county, and/or municipal codes. If you are in doubt about any phase of installation or  
operation, contact the manufacturer immediately for assistance. While this entire document is important, certain  
portions may require your special attention. These passages are clearly marked with the notices shown below.  
Please observe all safety notices carefully. Each has a specific meaning.  
C A U TIO N indicates a  
potentially hazardous  
situation w hich, if not  
avoided, could result in  
m inor or m oderate injury.  
It m ay also be used to  
alert against unsafe  
practices.  
D A N G E R indicates an  
im m inently hazardous  
situation w hich, if not  
avoided, w ill result in  
death or serious injury.  
W A R N IN G indicates a  
potentially hazardous  
situation w hich, if not  
avoided, could result in  
death or serious injury.  
2.2 Inherent Hazards  
This product uses electricity and high voltages are present inside the cabinet. This product is equipped with a  
lockout/tagout feature on the input circuit breaker to prevent accidentally energizing the product during installa-  
tion, maintenance, and/or repair. This product is also equipped with safety interlock circuits, which will de-  
energize the product when a cover is removed. In all such cases, hazardous touch voltages will still be present  
at the rear of the product’s input circuit breaker where input power feeds are attached. Working on the product  
under such circumstances is classified under SEMI S2-0200 as a Type 4 Task. This may be changed to a Type  
1 task and complete safety may be assured by disconnecting power to the product (and locking and tagging out)  
at the source.  
Failure to follow proper safety precautions as well as intentionally defeating the safety interlocks built into the  
product’s design will negate the safety features designed into this product and may subject the user to death or  
serious injury.  
2.3 Alerts and Labels  
This product’s enclosure is provided with warning labels in appropriate locations to call your attention to important  
user information. The labels and their locations include the following:  
7
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Section 2 - Safety  
On both removable side panels, near the top of the panel and approximately in the middle are the following warn-  
ings. Each calls attention to a specific hazard requiring special attention.  
WARNING  
LINE VOLTAGE PRESENT  
WITH MACHINE POWER OFF.  
Risk of electric shock or burn.  
Turn off and lock out facility power before  
servicing.  
With the front panel circuit breaker of the power conditioner turned off and locked out, potentially hazardous  
touch voltages are confined to the input power conductors at the rear of the circuit breaker. Entering the cabinet  
under these circumstances is classified as a Type 4 task under SEMI S2-0200 guidelines. This hazard label  
alerts personnel to the need to turn off and lock out power to the power conditioner at the facility source. Doing  
so will eliminate all potentially hazardous voltages inside the enclosure. Entering the enclosure under these cir-  
cumstances if a Type 1 task under SEMI S2-0200.  
WARNING  
Hot surface inside.  
Contact may cause burn.  
Do not touch.  
Wear protective gear before  
servicing internal parts.  
PLEASE NOTE: After extended operation, internal parts of the power conditioner may become very hot.  
This hazard label calls attention to the need for protective gear when entering the equipment enclosure.  
Inside the power conditioner enclosure another warning similar to the one  
shown at the left warns once again of the presence of very hot surfaces  
and the potential for injury and burns. This warning is accompanied by  
the legend “CAUTION - HOT SURFACE” and is attached to the upper steel  
frame of the isolation transformer on the primary side.  
8
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Section 2 - Safety  
2.4 Safety Interlocks  
This product incorporates a safety interlock circuit that functions as a  
secondary means of protection for personnel. Protective side panels and  
hazard warning labels provide primary protection. However, in the event one  
or more side panels are removed from the product prior to being de-  
energized, the safety interlock system will de-energize the power conditioner.  
The circuit consists of two safety interlock switches (one per each side access  
panel) located in the center of the top side frame of the power conditioner.  
The switches operate as a normally open circuit connected to the shunt trip  
coil of the input circuit breaker. See Figure A. Activating either of these safety  
Figure A  
interlock switches causes a 24 VDC signal to energize the shunt trip coil of the breaker. The 24 VDC signal is  
derived from a low voltage, fused tap on the transformer secondary. The shunt trip circuit also uses stored  
energy from a capacitive circuit to ensure that the shunt trip mechanism will function even in the event of a power  
outage. The safety interlock switches are shown on the general circuit diagram found in subsection 10.1 of  
Section 10 of this manual.  
If the power conditioner shunt trips as a result of removing the side panels, hazard-  
ous voltages will remain at the input voltage connection to the rear of the main cir-  
cuit breaker. Entering the enclosure under these conditions is classified as a Type  
4 task under SEMI S2-0200 guidelines. This can be changed to a Type 1 task by disconnecting power at  
the source before entering the enclosure.  
2.5 Lockout/Tagout  
The rotary handle of the main breaker is equipped with a  
hinged center insert clearly identified with an arrow. The  
rotary handle of the main breaker must be in the horizontal  
position to proceed. See Figure B. Depress the insert on  
the arrow on the left hand side causing the insert to extend  
on the right revealing a slot to accommodate a locking  
device as shown in Figure C. The lockout/tagout feature is  
Figure B  
Figure C  
designed to prevent personnel from accidentally energizing  
the power conditioner while maintenance, service or repair  
is being performed. With the lockout/tagout engaged, hazardous voltages are still present at the rear of the input  
circuit breaker where input power feeds connect to the power conditioner. Entering the enclosure under these  
circumstances is classified as a Type 4 Task under SEMI S2-0200. Entering the enclosure may be classified as  
a Type 1 Task if power is disconnected from the power conditioner at the source.  
9
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Section 2 - Safety  
2.6 Conformance with Applicable Laws and Regulations  
This equipment must be installed and used in accordance with all applicable local, county, state, provincial, and  
federal regulations. In the United States, these regulations include, but may not be limited to, those of the NFPA,  
NEC, and other regulating bodies. Outside of the United States, other specific laws and regulations may apply.  
Compliance with applicable regulations is the responsibility of the installer, user, or owner of the power  
conditioner.  
2.7 Product Liability  
Product liability refers to the liability of any or all parties along the chain of manufacture of any product for  
damage caused by the product. Product defects may include inherent design defects, manufacturing defects,  
and defects in marketing. The manufacturer of this product has taken every possible precaution to ensure that  
design defects do not exist and that manufacturing defects will not occur. Marketing defects generally result from  
a lack of proper instructions or failures to warn of latent dangers associated with the product. The manufacturer  
has taken great care in preparing this manual to ensure that the documentation is proper, correct, and complete.  
However, the manufacturer cannot control how the product documentation is used or how well it is read and  
understood. It remains the sole responsibility of the installer, user, and owner of this product to thoroughly review  
and understand the documentation that accompanies the product. Those installing, using, servicing, and  
maintaining the product should observe all warning notices in both the documentation and on the product and  
contact the manufacturer if any part of the installation, use, or service procedures of this product are unclear.  
Statutory product liability provisions can be, geographically speaking, very diverse. In the United States, the  
Department of Commerce has created a Model Uniform Products Liability Act (MUPLA) for voluntary use by the  
states. However, there remains no federal product liability law. For further information consult the products  
liability statutes that may apply for the state or country where you reside. Also consult the manufacturer’s  
warranty statement in Section 9.3 of this manual concerning implied and expressed warranties of merchantability  
and fitness for purpose.  
2.8 Emergency Contact Information  
In an occurrence requiring emergency assistance from the manufacturer, please call (800) 321-6699. Normal  
business hours are 8 am to 5 pm, Central Time. In EMEA, emergency calls should be directed to +44 (0) 1793  
553980. Normal business hours for our European operations are 8:00 to 17:00 GMT. Outside of normal  
business hours, the manufacturer’s phone systems provide an emergency after hours phone number.  
10  
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Section 3 - Product Overview  
Welcome to the world of conditioned power. Electrical power users from around the world benefit from the use of  
clean, quality power. That's why we developed the Conditioned Power Center (CPC). The CPC Series is a low-  
impedance power conditioner that provides high peak-load capability. You'll find that we've engineered these  
products to provide features not readily available as standard equipment on other three-phase power line  
conditioning products. The CPC series of products provide the functionality and flexibility that your business  
needs in a power quality solution-both now and in the future.  
3.1 Product Purpose  
The CPC is designed to eliminate high-frequency noise and high-voltage impulses (also known as spikes or  
surges) from the AC power that runs your electronic equipment. The power conditioner installs between the  
power source and the critical load. And because it is a three-phase device, the CPC provides protection for all  
transformer phases that power a large system. Sophisticated electronic systems contribute to the profitability of  
your business, and clean power is an essential element in their reliable operation. Each electronic system  
responds to power-quality problems differently, but properly protected systems benefit in a variety of ways. These  
benefits include fewer hardware failures, fewer "no problem found" service calls, less system downtime, higher  
manufacturing yield, better image quality and longer equipment life.  
The CPC power conditioning series incorporates these three important power quality elements:  
1. A low-impedance isolation transformer - The transformer is the "heart" of the power conditioning system. It  
provides unequaled protection against common mode (neutral to ground) disturbances and voltages. In addition,  
it provides all the criteria necessary to meet National Electrical Code 250-5d requirements for a "separately  
derived power source." The isolation transformer can be specified to accommodate the variety of electrical supply  
voltages and frequencies that are encountered throughout the world.  
2. A low pass filter - The filter is responsible for removing normal mode (phase to neutral and phase to phase)  
noise components from the electrical power. These power disturbances are the ones that are caused by your  
system's "electrical neighbors" (i.e. elevators, copy machines, motors, HVAC equipment and even other  
computer systems).  
3. A surge diverter - The surge diverter is part of the input (primary) circuit of the isolation transformer. This  
ensures that any voltage impulses generated within the facility (our outside of it due to occurrences like lightning  
and utility activities) do not interfere with the connected system. Although the surge diverter is designed to  
handle substantial energies, catastrophic events may occur, which damage one or more of the circuit’s protective  
elements. If such damage occurs, one or more of the TVSS Fault LEDs on the power conditioner’s front panel  
will illuminate. Consult Section 8.1.3 for instructions on how to proceed if a TVSS Fault LED illuminates.  
11  
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Section 3 - Product Overview  
3.2 Standard Features  
These include a “power on “ LED, TVSS Fault LEDs (one per phase), a lockout/tagout provision for the front  
panel input circuit breaker, safety interlocks, casters, and leveling feet. In addition, the CPC offers a range of  
options as described below.  
3.3 Optional Features  
Input line cord - This option is available on models 45 kVA and smaller.  
Output receptacles - This option is available on all models. A range of different receptacle styles (each with  
over-current protection) may be added to the CPC power conditioner.  
Distribution panels - This option is available only on models 85 kVA and larger. It provides a standard 42 circuit  
Square D panelboard from which the conditioner’s power may be distributed to individual branch circuits each  
with their own dedicated circuit breaker.  
External EMO connector - This optional connector (if so equipped) is part of the power conditioner’s EMO  
(emergency machine off) circuit. It provides a point for connecting the power conditioner’s EMO circuit to an  
external control or the master EMO circuit of a computer room or similar facility. See Section 7.3  
Seismic anchorage brackets - This options permits stabilization of the power conditioner in seismically active  
(earthquake prone) areas. Seismic design data is included in the specification sheet found in Section 10.  
A 5th harmonic filter - The GPI Series 2000 may be ordered with an optional passive 5th harmonic filter. When  
so equipped, the CPC will significantly reduce the fifth odd order harmonic current regardless of origin (line or  
load). Passive harmonic filters tuned to other order harmonics are available special order. Consult the  
manufacturer for more information. If the CPC you are installing is equipped with an optional harmonic filter,  
consult Section 7.1 of this manual for complete information regarding it’s location and operation.  
Zig-Zag transformer - This option is only available on models 85 kVA and larger. Special transformers with  
zigzag secondary windings for the elimination of harmonic currents are available as a special order from the  
manufacturer.  
Basic metering/Power management package - All CPC models may be equipped with basic metering  
functions using Power Measurements Limited 6200 ION monitor. A full power management package is available  
on models 85 kVA and larger. This package uses a Power Measurements ION 7500 monitor and provides  
multiple functions including low voltage/phase loss/phase reversal detection and protection.  
12  
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Section 3 - Product Overview  
complete monitoring of three phase voltages, currents, phase angles, power factor, demand, energy usage,  
event logs and more. If the CPC is equipped with the power management option, documentation prepared by  
Power Measurements Limited will accompany this manual. The table below illustrates a matrix of standard  
equipment and options for each model of GPI Series 2000.  
3.4  
Feature  
Matrix  
S= Standard  
O= Option  
NA = Not Available  
ABC10.0-XDXY  
ABC15.0-XDXY  
ABC20.0-XDXY  
ABC25.0-XDXY  
ABC30.0-XDXY  
ABC35.0-XDXY  
ABC45.0-XDXY  
ABC55.0-XDXY  
ABC65.0-XDXY  
ABC75.0-XDXY  
ABC85.0-XDXY  
ABC100.0-XDXY  
ABC125.0-XDXY  
ABC150.0-XDXY  
ABC175.0-XDXY  
ABC200.0-XDXY  
ABC230.0-XDXY  
ABC250.0-XDXY  
ABC300.0-XDXY  
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
O
O
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
NA NA  
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
NA  
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
13  
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Section 4 - Preparation  
IMPORTANT ! Each unit is fully inspected and tested prior to leaving the factory. CPC series products  
are packed carefully in approved shipping crates. However, since we cannot control handling during  
shipping, damage in transit is possible. Please retain all packing materials until the power conditioner is  
installed and operating satisfactorily. If damage to the shipping container is evident, you may file a claim  
with the shipper. Concealed damage can also be claimed with the shipper within fifteen (15) days.  
Immediately contact the shipping company to arrange for any visual inspection or report. Contact the  
manufacturer if you require assistance. Do not install or apply power to units if there is external damage  
or if internal components or connections are loose or "rattle." Always check all electrical connections  
during installation to verify a tight connection.  
4.1 Unpackaging  
The CPC series is packaged in a sturdy shipping container. For models 20 kVA and smaller, the container  
consists of a shipping pallet/skid with an outer cardboard housing. For models 25 kVA and larger, the shipping  
container consists of a bottom pallet/skid, a packing block, four wooden sides, and a top.  
For 20 kVA and smaller conditioners, perform the following five steps to remove the power conditioner from the  
packaging crate.  
Step 1 - Remove the outer cardboard carton from the shipping pallet.  
Step 2 - The power conditioner is attached to the shipping pallet with metal bands. Using a metal snips or band  
cutter, cut the metal bands and remove them from the packing crate.  
The metal bands are under tension. When cut, they may spring out of control if not  
held securely. The bands may be very sharp. Gloves and eye protection are rec-  
ommended before cutting and removing the metal bands. Failure to follow this pre-  
caution may result in injury to eyes or other body parts. Wear protective gear.  
Step 3 - Remove the protective plastic bag and foam cushion wrap and dispose of appropriately.  
Step 4 - Consult Figure D on Page 16. Remove the 2 x 4 cleat at the front of the pallet by removing the lag  
screws.  
Step 5 - Remove the front 4 x 4 shipping skid by removing the lag screws. The shipping pallet may now be  
“rocked” forward on the center skid allowing the power conditioner to roll off the pallet onto the floor.  
Refer to the diagram in Figure E on page 16 for unpacking power conditioners 25 kVA and larger. You will need  
a Phillips screwdriver (preferably power) and a band cutter or metal snips. Follow these seven steps.  
Step 1 - Remove the top of the packing crate by removing the screws that secure the top to the four sides of the  
crate. Once the screws are removed the top may be lifted off the crate and set to one side.  
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Section 4 - Preparation  
Step 2 - A packing block assembly rests on top of the power conditioner to secure it tightly inside the packing  
crate. Remove the packing block assembly by removing the screws that are driven through the crate front and  
back panels into the ends of the wooden struts. The packing block may now be removed and set to one side.  
Step 3 - The front and back panels of the packing crate should be removed next. The front and back panels are  
secured to the side panels and to the shipping pallet with screws along the edges and bottom of the panels.  
Remove the screws from one panel at a time. Remove the panels and set them to one side.  
Step 4 - The side panels are removed next by removing the screws that secure them to the pallet. Remove the  
screws from the bottom of the side panels and set the panels to one side.  
Step 5 - The power conditioner is attached to the shipping skid with metal bands. Using a metal snips or band  
cutter, cut the metal bands and remove them from the packing crate.  
Step 6 - The power conditioner is wrapped in foam cushion wrap and then enclosed in a protective plastic bag to  
prevent moisture from entering the enclosure. Remove the outer plastic bag and foam cushion wrap from the  
power conditioner and dispose of them appropriately.  
Depending on the rating, the CPC power conditioner may weigh as much as 3000  
pounds (1500 kg.). The next steps involve removing the power conditioner from the  
shipping skid. Carelessness may result in injury.  
Step 7 - The power conditioner is now free of the shipping container and bottom pallet/skid. A fork truck with  
sufficient fork length and height and a minimum rating of two tons may be used to raise the power conditioner a  
few inches off the bottom pallet.  
IMPORTANT ! Never lift the power conditioner with the forklift from the front. Doing so may damage the  
front bezel. Always lift the power conditioner with the forklift on the side or back.  
Once raised clear of the bottom pallet, pull the pallet away from the power conditioner and set it off to the side  
with the rest of the shipping container panels. The power conditioner is shipped with the threaded leveling feet  
extended for stability. Retract the leveling feet by turning them in a sufficient number of turns. This will allow the  
power conditioner to rest on its casters when lowered to the floor. The power conditioner may now be lowered to  
the floor and the fork lift removed.  
Take a few minutes to inspect the unit for any visible damage. If damage is present, contact the carrier for an  
inspection before proceeding. If no damage is present, move the power conditioner to its installation location on  
its casters. Once placed into its final position, make sure the unit is leveled and stabilized using the leveling feet.  
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Section 4 - Preparation  
Figure D - Shipping Crate Disassembly - 10 to 20 kVA  
1. Cardboard outer carton  
2. Shipping pallet  
3. 2 x 4 front cleat  
4. Front skid  
1
After removing the front  
cleat and front skid, the  
pallet may be rocked for-  
ward on the middle skid  
and the power conditioner  
may be easily rolled off the  
pallet and onto the floor.  
3
2
4
Figure E—Shipping Crate Disassembly - 25 kVA to 300 kVA  
1
1. Crate Top  
2. Packing Block  
2
3. Front Side  
4. Back Side  
5. Right Side  
6. Left Side  
4
7. Shipping Pallet/Skid  
6
5
Shipping crate should be dis-  
assembled in the numerical  
order shown. Removing pan-  
els 1 through 7 will provide  
total access to the power con-  
ditioner, which is enclosed in  
foam wrap and plastic and  
banded to shipping skid #7.  
3
7
IMPORTANT ! Retain all parts of the shipping container and packaging material until after the CPC series  
has been installed and proper operation verified. Once installed and operational integrity is verified, the  
packaging material may be discarded.  
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Section 5 - Installation  
5.1 Location  
For best performance, the CPC series should be installed within fifty (50) wire feet maximum of the protected  
load. Refer to the dimensional information shown in the specifications sheet accompanying this document. Allow  
six inches of free space on all sides of the CPC series to provide for proper air circulation. The unit is designed to  
operate at high efficiency and is convection cooled. If the unit is installed in a facility that has a raised flooring  
system, ensure that the flooring system can support the weight of the ETA power conditioner. Consult the  
specification sheet found in Section 10 of this manual for dimensions and weights.  
The power conditioner is not weatherproof and must be installed in a dry location.  
During winter months, the transition from cold temperatures to a warm indoor  
climate may result in significant condensation. Make sure that the power  
conditioner has been given enough time to acclimate to its environment and that condensation has  
evaporated before installing and energizing the conditioner.  
5.2 Conduit Landings  
The power conditioner is designed to accept conduit landings on the top panel, rear panel and on the unit bottom  
(for raised floor applications). It is not possible to land conduits on the side panels due to interference with the  
ventilation slots and/or the internal frame components.  
5.2.1 Top Feed  
Conduit holes may be punched or cut anywhere in the top panel except within 3” of any edge. It is important to  
avoid landing conduits within 3” of the panel edges to prevent interference with the frame of the power  
conditioner. Consult the specification sheet in Section 10 of this manual for additional guidance.  
5.2.2 Rear Feed  
Consult the specification sheet in Section 10 of this manual for allowable rear conduit landing locations.  
Prior to drilling or cutting any top or rear panel, the panel must be removed.  
Drilling or cutting conduit access holes with panels mounted on the conditioner  
may result in metal shavings or other debris falling into or on the transformer or  
other system components resulting in damage when power is applied to the system. The manufacturer  
is not responsible for damage caused by improper or careless installation. Please take proper  
precautions by removing panels before drilling, cutting, or punching conduit access holes. Failure to  
follow this precaution will void the product warranty.  
5.2.3 Bottom Feed  
Consult the specification sheet in Section 10 of this manual for allowable bottom conduit landing locations.  
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Section 5 - Installation  
5.3 Outer Panel Removal  
The side panels, the back panel, the top panel and the front panel have all been designed for easy removal prior  
to installation. The side panels must be removed first. Turn the quarter turn fasteners counterclockwise and  
remove the side panels.  
A bonding strap is attached to the bottom of each side panel with a hand fastener  
and lock-washer. The bonding strap electrically grounds the side panel to the  
frame during normal operation. This bonding strap must be disconnected for  
complete removal of the side panel taking care not to misplace the fastener and lock-washer. It is  
extremely important that the bond strap be reconnected to the side panel when the side panel is  
replaced. Failure to reconnect the ground strap may result in an electrical shock hazard in the event of  
an electrical fault.  
The back panel, top panel and front panel are held in place by threaded fasteners, which are accessible once the  
side panels have been removed. Removing these fasteners will allow the top, back, and front to be removed.  
5.4 Alternate Conduit Landing Locations  
In the event, it is not possible to land conduits on the power conditioner top, rear, or bottom panels, consult with  
the manufacturer. Although less desirable, alternate conduit landings can be accommodated. The manufacturer  
can provide information, detailed drawings, and instructions for landing conduits at alternate locations.  
5.5 Main Input Circuit Breaker  
Depending on the primary voltage configuration of the power conditioner’s isolation transformer, the conditioner  
will be equipped with one of two types of circuit breakers. If the power conditioner uses a single voltage primary  
(i.e. 480 volts) the power conditioner will come equipped with a circuit breaker rated at the proper amperage to  
accommodate the power conditioner’s power rating at the specified input voltage. If the isolation transformer has  
a primary voltage configuration capable of accepting multiple input voltages through the use of changeable taps,  
the power conditioner will be equipped with a programmable circuit breaker. Prior to being shipped, a tag is  
attached to the main circuit breaker of each power conditioner on the front panel. The tag indicates the  
transformer primary configuration, breaker type, and input voltage setting. Based on the type of circuit breaker  
shown on the tag, consult either Sec. 5.5.1 or 5.5.2 for more information  
5.5.1 Fixed Input Circuit Breakers  
Before beginning installation, check the tag on the circuit breaker. The power conditioner has been  
manufactured and shipped according to the input voltage specified at the time the order was placed. If the input  
voltage information shown on the tag does not match the voltage available at your site and if the tag indicates the  
transformer in the power conditioner has a single voltage primary, then the input circuit breaker will have a fixed  
value. Under the circumstances, you will not be able to proceed with the installation. Contact the company who  
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Section 5 - Installation  
5.5.2 Programmable Circuit Breakers  
Before beginning installation, check the tag on the circuit breaker. The power conditioner has been  
manufactured and shipped according to the input voltage specified at the time the order was placed. If the input  
voltage information shown on the tag does not match the voltage available at your site, check the tag to  
determine the transformer primary configuration and circuit breaker type. If equipped with a programmable circuit  
breaker and a transformer with a multiple voltage primary, it will be necessary to adjust the transformer’s primary  
taps. Transformer primary tap connections are included in the specification sheet found in Section 10 of this  
manual.  
Breaker operating parameters such as input current, inrush characteristics, and time delay may all be  
programmed to make it easier to adapt the power conditioner in the field to a full range of site installation  
voltages. In order to reprogram the circuit breaker, it is necessary to gain access to the front of the breaker itself.  
This is accomplished by removing the side panels as described previously in Sec. 5.3. Once the side panels  
have been removed, proceed as follows:  
1. The front bezel is attached to the frame of the power conditioner with screws on each side of the conditioner  
frame. Remove the screws on each side of the front bezel, and remove the bezel from the power conditioner. (If  
equipped with optional power management package or basic metering package, it will also be necessary to  
unplug the wiring harness connecting the power management computer to the power conditioner before  
removing the bezel. This is done by disconnecting at the Molex connector).  
2. The front control panel is now accessible. It is hinged on the left side. Undo the screw on the right side of the  
control panel and swing the control panel out to the left exposing the front of the breaker.  
3. A hinged cover protects the breaker DIP switches. Raise the cover to gain access to the DIP switches.  
Change DIP switch settings using the instructions included in the specifications sheet found in Section 10 of this  
manual. Consult the manufacturer if you have any questions or difficulties.  
5.6 Isolation Transformer  
NOTE: CPC series power conditioners utilize a low-impedance isolation transformer. When first  
energized, transformers of this kind typically exhibit a high "inrush" current that may approach 10-15  
times the nominal rating. While inrush currents quickly decay to nominal, it is possible to experience  
"nuisance" tripping of the source circuit breaker. If this occurs consult the manufacturer for options.  
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Section 5 - Installation  
Transformers are designed to meet a variety of requirements. Some locations (Europe, for example) have  
standardized on a single input voltage. In other cases customers may specify multiple input voltages to  
accommodate the variety of voltages commonly found in the United States. The CPC series conditioner can  
accommodate either style of transformer - single voltage or multiple voltage primary.  
The conditioner is a "delta-wye" system. The input or primary side of the transformer accepts power from either a  
delta or wye power system at the voltages for which the transformer has been designed. Delta feeds are  
desirable because they reduce wiring and installation costs by eliminating the neutral conductor from the input  
wiring arrangement. In addition, feeding the CPC series with a higher input voltage reduces input amperage and  
further reduces installation costs by allowing the use of less expensive, smaller gauge electrical conductors and  
conduits. Consult the tag on the input circuit breaker. If the power conditioner you are installing has a single  
voltage primary, the site voltage must match the transformer primary voltage. Power conditioners with multiple  
voltage primaries may be changed to accommodate a variety of site voltages.  
The secondary configuration of the transformer is a five wire wye requiring three phase conductors, a neutral,  
and a safety ground.  
5.6.1 Transformer Primary Voltage Adjustment  
Depending on the design of the isolation transformer, the  
power conditioner may accommodate different input voltages.  
The voltages are selected by changing primary taps. If  
necessary, changes may be made to the input voltage setting  
by changing connections on the transformer primary windings  
at the locations shown in Figure F to the left. Most voltage  
changes can be accomplished in 15 minutes or less. Consult  
the specification sheet found in Section 10 of this manual for  
detailed information on the specific connections required to  
Figure F  
accommodate any of the allowable input voltages. In the event  
that the voltage adjustment information in this manual is  
missing, input voltage configuration information is also shown  
on a data plate attached to the top of the transformer as shown  
in Figure G to the left.  
Figure G  
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Section 5 - Installation  
5.6.2 Output Voltage Fine Adjustment  
The transformer secondary of the power conditioners is a 5 wire  
Wye configuration (three phase conductors, one neutral and one  
safety ground). Output voltage can be adjusted plus-or-minus five  
percent ( + 5%) (as shown in Figure H to the right) to accommodate  
site-specific voltage differences . This is accomplished by moving  
the output lugs and connections on the transformer secondary.  
Consult the information found in Section 10.4 on page 37 of this  
manual for detailed information on the location of the transformer  
secondary taps and the settings necessary to make fine  
adjustments up or down.  
Figure H  
IMPORTANT! Output power feeds connect directly to the lugs provided at the transformer secondary. If  
the CPC series power conditioner is equipped with the Power Management Option, it will be necessary (if  
changing output voltage taps) to also move current transformers to the appropriate transformer  
secondary tap at the same time the output lug and associated wiring is moved.  
5.7 Grounding  
The presence of a code legal safety ground on both the input and the output  
circuits of the power conditioner is required to prevent fire hazards and to ensure  
personnel safety. If a safety ground connections cannot be made or are made  
incorrectly, do not proceed with the installation until this problem is corrected. Failure to observe this  
warning may result in fire or electrical shock hazard in the event of an electrical fault.  
The CPC series product family is considered to be information technology equipment for the purposes of the  
National Electrical Code as defined in NEC Article 645. Before proceeding, please review any requirements for  
proper grounding of the conditioner. This is critical for proper operation as well as personnel safety and fire  
prevention. Grounding requirements and guidelines can be confusing. Contact the manufacturer if you are unsure  
about proper grounding methods or techniques.  
The National Electrical Code (NEC), in Article 250-20d, describes a "separately derived system" as one in which  
the output neutral is bonded to safety ground. The key advantage of such an arrangement is the complete  
elimination of neutral to ground (common mode) voltages and noise at the point of power delivery to a critical  
load. The power conditioner meets all the requirements for a separately derived system as defined by U.S. and  
Canadian electrical codes.  
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Section 5 - Installation  
Specific locations for connecting the input and output safety ground conductors are discussed in Sections 5.9 and  
5.10 that follow. These sections cover the information necessary to connect electrical wiring to both the main and  
to the load. Please review both sections carefully before beginning the actual electrical installation. A  
sophisticated electronic system will benefit greatly when all parts of the system and all system peripherals are  
powered from a single power source. It is recommended that all parts of the system share this common power  
source and its common, "clean" ground. Non-isolated code minimum input safety grounds are permitted.  
Dedicated input safety grounding conductors are also permitted. They may be either isolated or non-isolated. If  
an isolated input safety ground connection is desired, it should be a continuous, insulated, isolated conductor that  
is routed directly back to the service entrance panel-board. The ground lug connection of the power conditioner  
may also be connected to a separate grounding electrode or to building steel, provided that a separate low-  
impedance grounding path (either copper conductor or conduit) is present and connects to the electrical system  
ground. Excellent guidelines for grounding practices are also available by consulting the Federal Information  
Processing Standards Publication (FIPS Pub. 94) published in 1983.  
Connecting input wiring to the main source of power may require working inside  
switchgear or distribution panelboards containing live voltages. Contact with live  
voltages will result in injury or death. Working inside live switchgear is classified  
as a Type 4 Task under SEMI S2-0200 guidelines. Prior to beginning input power connections, be sure to  
follow any lockout/tagout procedures pertinent to your service equipment. Failure to observe this  
warning may result in live voltages being present on conductors being connected to the input power  
connections of the power conditioner.  
Strict compliance with the following lockout/tagout procedure for the CPC series is  
required to assure personnel safety when making input and output power  
connections. Working inside the power conditioner with the lockout/tagout  
engaged may be classified by SEMI S2-0200 guidelines as a Type 4 task if electrical power is not de-  
energized and locked out at the source. If also locked out at the source, the task is reduced to Type 1.  
5.8 Lockout/Tagout Procedure  
The rotary handle of the main breaker must be in the  
horizontal (OFF) position to proceed. The rotary handle is  
equipped with a hinged center insert clearly identified with  
an arrow. See Figure I at left. Depressing the insert on  
the arrow on the left hand side will cause the insert to  
extend on the right. This will reveal a slot to accommodate  
a locking device as shown in Figure J to the right. Place a  
Figure I  
Figure J  
locking device in the slot and lock it. A warning label  
(tagout) should be affixed to notify personnel that input power to the power conditioner has been locked out.  
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Section 5 - Installation  
5.9 Input Power Connections  
The three-phase input connection is made at  
the lugs marked L1, L2, and L3 directly on the  
main circuit breaker shown in Figure K to the  
right. The safety ground connection is made  
at the dual lug marked “PE” on the rear of the  
panel immediately behind the main circuit  
breaker shown in Figure L to the right. Locate  
all connection points prior to committing to the  
conductor lengths. Input conductor sizes are  
Figure K  
Figure L  
determined by electrical code. For the convenience of the installer, the manufacturer has provided these, along  
with other installation information, on the specification sheets included in Section 10 of this manual. Consult the  
specification sheet for the conductor sizes required for the power conditioner.  
5.10 Output Power Connections  
The load is connected to the lugs provided on the transformer's secondary  
winding shown in Figure M to the right. Safety ground is connected to the  
Neutral/Ground bus lug. This device provides a neutral ground bond. The  
transformer secondary is also equipped with additional taps that allow the  
installer to make fine adjustments to the output voltage of plus-or-minus  
five percent ( + 5%) of nominal output to accommodate site-specific input  
voltage differences. The power conditioner is shipped with the output  
Figure M  
conductor connection lugs attached to the nominal output voltage  
connection. If it is necessary to utilize the fine adjustment taps, the output conductors and the connection lugs  
must be moved to the appropriate tap. For detailed connection diagrams, consult Section 10.4.  
IMPORTANT NOTE! If this power conditioner is equipped with the basic metering or the power  
management option, be sure to also move the associated current transformers to the appropriate  
transformer secondary tap at the same time the output lug and output conductors are moved.  
5.11 Models With Optional Line Cord/Output Receptacles  
CPC series models 45 kVA and smaller may be equipped with optional input line cords. CPC series models of all  
sizes may be equipped with optional output receptacles. If equipped with an input power cord, the installation  
instructions discussed in paragraphs 5.9 will not apply. If equipped with output receptacles, the installation  
instructions discussed in paragraph 5.10 may not apply. In all cases, it remains critical to observe all grounding  
practices discussed in paragraph 5.7. If equipped with both line cord and receptacles, installation is a plug and  
play operation. In any case be sure the site voltage matches the power conditioner configuration.  
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Section 6 - Operation  
6.1 Restoring For Service  
When wiring connections have been completed (or after maintenance or repair operations are finished) it will be  
necessary to perform several tasks before the power conditioner can be put into service. Take these steps in the  
following order:  
1. Verify that all electrical connections are tight.  
2. Verify that the enclosure, transformer and all other internal components are free of metal shavings, debris,  
and installation/maintenance tools.  
3. Replace any front, top, rear, or side panels that have been removed.  
4. Disengage the lockout/tagout provision at the source (if engaged).  
5. Disengage the lockout/tagout provision on the front panel circuit breaker of the power conditioner.  
A bonding strap is attached to the bottom of each side panel with a hand fastener  
and lock-washer. The bonding strap electrically grounds the side panel to the  
frame during normal operation. This bonding strap must be reconnected to the  
side panel when the side panel is replaced. Failure to reconnect the ground strap may result in an  
electrical shock hazard in the event of an electrical fault.  
6.2 Energizing the Power Conditioner  
Once the power conditioner has been installed, it’s time to apply power and verify its proper operation. Perform  
the following steps:  
1. If equipped with the harmonic mitigation option, turn on the harmonic filter circuit breaker.  
2. Rotate the front panel circuit breaker’s rotary handle one quarter turn clockwise to the “On” or red position.  
3. Verify that the green “power on” LED is illuminated and the red TVSS Fault LEDs are extinguished (this is the  
normal state for the front panel LEDs).  
4. If equipped with either the basic metering or the power management option, verify that the Power  
Measurements device is powered on and operating. If so equipped also verify steps 6 and 7 below. If not  
equipped with either option, proceed to Section 6.3.  
5. Using the keypad on the Power Measurements device, verify the that phases A, B, and C are present.  
6. Verify that phases A, B, and C each show the correct nominal voltage for the load being powered. Voltages  
must match the voltage requirements of the load.  
NOTE: The installer may verify the output voltage of the power conditioner using an appropriate  
voltmeter at either the output receptacles of the power conditioner (if so equipped) or at the input power  
terminals inside the connected load. This final step is recommended prior to energizing the load.  
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Section 6 - Operation  
(NOTE: Under "no load" conditions, the transformer in the power conditioner will "step up" the output  
voltage a few percent. This design characteristic compensates for losses within the transformer once  
actual load is applied. As a result, an output voltage that is slightly higher than the nominal input voltage  
is normal under unloaded conditions.)  
(NOTE: For further information on Power Measurements Limited meters or monitors, consult the  
separate owner’s manual. A separate manual will accompany this document if the power conditioner is  
equipped with either option.)  
6.3 Energizing the Load  
Power is now available to the load. Perform the following steps in the order shown.  
1. Energize the load in accordance with any recommended load power-up procedures.  
2. Verify the proper operation of the load and the entire system.  
3. If equipped with the basic metering or the power management option, you may use the keypad on the Power  
Measurements monitor, to observe and/or verify the following:  
a) Load currents for Phase A, B, and C are properly indicated  
b) All other monitor functions are operating normally. (A manual is included as Section 10 with this  
document if the power conditioner is equipped with the power management option.)  
If all connections have been properly made and correct operation of the system has been verified, normal  
operations may begin. The power conditioner is now quietly providing full-time protection to your critical system.  
In the event that the power conditioner is ever dangerously overloaded for any reason, the main circuit breaker  
will shut off, removing power from the connected load.  
6.4 Orderly Shutdown  
To shutdown the power conditioner in an orderly manner, first turn off all connected loads. Then turn off the  
power conditioner by rotating the handle of the front panel circuit breaker one quarter turn counter-clockwise to  
the “off” position. Verify that the front panel green power LED is extinguished. No residual energy is stored after  
then power conditioner is de-energized.  
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Section 7 - Options  
7.1 Passive Harmonic Filter  
The passive harmonic filter package is located below the transformer  
secondary on the left side of the power conditioner. See Figure N to the  
left. This circuit is bi-directional. It will mitigate odd order harmonic  
currents originating from the load or the facility. Because passive  
harmonic filters have a tendency to "sink" harmonics regardless of the  
source, it is necessary to protect this circuit in the event of excessive  
odd order harmonic content in the facility electrical system. To  
accomplish this, the power conditioner provides a circuit breaker on the  
front panel. Should the facility have excessive odd order harmonics, the  
Figure N  
circuit breaker will trip. The circuit breaker may be reset while the power conditioner is operating. Unless the  
source of excessive harmonic current is located and corrected, the circuit breaker will likely trip again  
immediately.  
NOTE: The CPC series will operate properly and provide power conditioning even if the harmonic  
mitigation breaker is tripped. The breaker may be reset with power applied to the unit. However, it will be  
necessary to address the harmonic condition of the facility electrical system if breaker tripping persists.  
7.2 Basic Metering  
If equipped with this option, a Power Measurements Limited Series 6200 ION compact modular power meter will  
be installed in the front panel adjacent to the input circuit breaker. The 6200 ION provides energy and demand  
measurements, per phase voltage, current, frequency and power factor, peak current demand, THD, and other  
real-time, true RMS electrical parameters. Communications capability is also available. Contact the  
manufacturer of the power conditioner for more information about optional communications capabilities.  
7.3 Power Management  
If equipped with this option, the power conditioner will have a Power Measurements Limited Series 7500 ION  
power monitor installed in the front bezel. The 7500 ION is shown in Figure X. The 7500 ION monitor provides  
measurement of critical operating parameters such as voltage, current, power factor and demand. It also  
provides the ability to monitor apparent power, true power, reactive power and to display vector diagrams,  
harmonic currents and a wealth of other information in either alphanumeric or bar graph formats. The 7500 ION  
monitor stores waveforms and event logs and makes them available to facilities or systems managers when  
equipped with one of several optional communications interface cards. Optional communications interfaces  
include, 10Base-T or 10Base-FL Ethernet, RS-232, RS485, or modem connections. An optical port on the front  
panel is standard. Contact the manufacturer of the power conditioner for more information about optional  
communications capabilities.  
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Section 7 - Options  
7.4 Phase Loss/Low Voltage Detection and Protection  
When equipped with the power management option, the 7500 ION monitor also provides:  
1. Protection from the loss of one or more input phases  
2. Protection for a low-voltage condition occurring on one or more phases (Protection from a high-voltage  
conditions is also optionally available)  
Should a phase loss or low voltage occur, the 7500 ION will “shunt” trip the power conditioner breaker within 50  
msec. of the occurrence. In this event, turn off the load. Then re-energize the GPI Series 2000 input breaker to  
return power to the power conditioner. The 7500 ION monitor may then be used to diagnose the event that  
caused the shunt trip. If the power conditioner immediately trips again once it is energized, this indicates that the  
low voltage or phase loss condition that originally caused the shunt trip still exists and must be corrected prior to  
restoring operation. (Shunt trip delays other than 50 msec. can be programmed via the 7500 ION monitor.  
Consult the manufacturer for instructions or assistance.  
NOTE: Any phase that drops below 80% of nominal voltage is considered a “phase loss” condition. The  
7500 Ion monitor is powered from phase A of the transformer secondary. If the 7500 Ion monitor appears  
to have no power, this is an indication that phase A may be lost. Caution should be exercised, however,  
as phases B and C may be still be energized.  
7.5 External EMO  
If equipped with the external EMO option, the power conditioner will be provided  
with a set of terminals as a point for connecting the power conditioner’s EMO  
circuit to a remote pushbutton or as a means to integrate it into the master EMO  
circuit frequently found in computer rooms or semiconductor production facili-  
ties. The external EMO contact terminal block is marked ‘TB1” and is located  
inside the power conditioner on the rear of the panel immediately behind the  
main circuit breaker as shown in Figure O to the right. The external EMO con-  
tacts are clearly marked. When connected to an external EMO circuit, the acti-  
Figure O  
vation of any EMO pushbutton or control anywhere in the master circuit will acti-  
vate the shunt trip circuit of the power conditioner.  
7.6 Seismic Anchorage  
When equipped with seismic anchorage brackets, the power conditioner will meet the requirements of SEMI S2-  
0200 Paragraph 19 . The seismic anchors are designed to allow the power conditioner to withstand a horizontal  
loading of 63% of the power conditioner’s weight acting on its own center of mass. Seismic anchorage brackets  
are designed to prevent the power conditioner from overturning during seismic activity and possibly injuring per-  
sonnel. Consult the specification sheet found in Section 10 of this manual for detailed information and drawings  
showing physical dimensions, anchorage locations, weight distributions, and center of mass locations. Seismic  
anchorage kits may be ordered for any installation and are not restricted solely to SEMI applications .  
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Section 7 - Options  
7.7 SEMI S2-0200 Certification  
For use in semiconductor fabrication applications, the manufacturer offers a version of the power conditioner that  
incorporates special modifications of the basic product family that are required for the power conditioner to meet  
the safety requirements of the Semiconductor Equipment and Materials International (SEMI) safety standard S2-  
0200. Included in the additional requirements for SEMI S2-0200 certification are provisions for special labeling,  
an approved EMO (emergency machine off) circuit, input power conductor restraints (for additional safety in seis-  
mically active locations), and product documentation that meets or exceeds the criteria specified in SEMI S2-  
0200. Compliant documentation and labeling are provided with every product. Choosing the SEMI S2-0200  
option adds the following additional features:  
7.7.1 Input Power Conductor Restraints  
SEMI S2-0200 guidelines recognize that the power conditioner, when used in semiconductor operations, may  
be installed in geographic areas that experience frequent (sometimes violent) seismic activity. The seismic an-  
chorage option described in paragraph 7.6 is designed to limit horizontal and vertical movement of the power  
conditioner, and since the product may be installed in seismically active locations for non-semiconductor applica-  
tions, the anchorage kit is provided as a separate option. For full compliance with SEMI S2-0200, however,  
SEMI requires that the input power conductors also be provided with a restraint system to prevent their detach-  
ment from the input circuit breaker up to the limits of movement provided by the anchorage kits. When ordered  
with the SEMI S2-0200 certification option, the power conditioner will be fitted with a steel bracket installed inside  
the power conditioner enclosure running horizontally from side to side and near the top of the enclosure. At-  
tached to this steel bracket is a plastic bag containing additional hardware for clamping the input power conduc-  
tors to the steel restraint bracket. Once the input power conductors have been attached to the input circuit  
breaker, the clamping hardware should be installed.  
Take care not to severely over-tighten the clamping hardware to the extent that  
the input power conductors are greatly distorted or the conductor insulation is  
damaged in any way. Doing so may lead to conductor failure or short circuit,  
which is not covered by the product warranty.  
7.7.2 SEMI S2-0200 Compliant EMO  
The EMO (emergency machine off) circuit provided with the SEMI S2-0200 option is considerably different from  
the standard EMO design due to the incorporation of additional components designed to increase personnel  
safety. For a complete details on the design of the SEMI-S2-0200 EMO circuit, please consult the schematics  
on pages 34 (general system schematic), 35 (standard EMO circuit, and 36 (SEMI S2-0200 EMO) found in this  
product manual. The standard EMO circuit operates as a normally open (N.O.) circuit that, when  
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Section 7 - Options  
activated by the closure of an interlock switch or EMO button, provides a DC voltage to the over-voltage shunt  
trip coil of the input circuit breaker. In the standard EMO design, the DC voltage is derived via a full wave bridge  
rectifier powered from a 24 volt AC tap on the main transformer secondary winding.  
For SEMI S2-0200 approval, the EMO functions differently from the standard EMO. The SEMI S2-0200 EMO  
operates as a normally closed (N.C.) circuit which provides a continuous DC voltage to an under-voltage shunt  
trip coil in the input circuit breaker. Activating the EMO pushbutton or a panel interlock opens the safety circuit  
and removes DC voltage activating the shunt trip. The DC voltage is derived from a separate 24 volt AC step-  
down transformer powered from the output side of the input circuit breaker. When first starting the GPI Series  
2000, no power is available at the circuit breaker output since it’s under-voltage shunt trip will ensure that it re-  
mains in the tripped position. When first starting the power conditioner, it is necessary to provide power to the  
EMO circuit. This is accomplished via a “push to start” pushbutton located on the front panel. The button is iden-  
tified by a label with the legend “DEPRESS BUTTON WHILE ENERGIZING MAIN BREAKER” The “push to  
start” button energizes the EMO circuit power transformer from the input side of the input circuit breaker, which  
provides the initial DC voltage to energize the under-voltage shunt trip of the input circuit breaker. For starting  
GPI Series 2000 power conditioners equipped with SEMI S2-0200 option, follow these simple steps:  
1. Make sure that the input circuit breaker is rotated fully to it’s farthest left position.  
2. Make sure that the EMO pushbutton is in its operating position (turn in direction of arrow to disengage)  
3. Press and hold the “push to start” button while rotating the input circuit breaker to the right  
4. Verify that the “power on” LED on the front panel is illuminated  
5. Release the “push to start” button  
The power conditioner will now be operating normally and any connected loads may be energized. Please con-  
sult the schematics on pages 34, 35, and 36 of this manual for more information.  
If a power conditioner equipped with the SEMI S2-0200 option is de-energized for  
any reason (including a shunt trip due to EMO or interlock activation), mains power  
will still be present at the input side of the input circuit breaker, and at the terminals  
of the “push to start” switch. Working inside the power conditioner under these conditions may be  
classified by SEMI S2-0200 guidelines as a Type 4 task. The task may be reduced to Type 1 if mains  
power is de-energized and locked out at the facility source. The manufacturer recommends locking and  
tagging out the facility source whenever it is necessary to enter the power conditioner enclosure.  
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Section 8 - Troubleshooting/Maintenance  
8.1 Conditions Requiring Troubleshooting  
Four conditions may occur, which require operators or service personnel to troubleshoot the function of the power  
conditioner. Each may be individually evaluated. These four occurrences include:  
1. Source circuit breaker (at switchgear or distribution panelboard) trips out  
2. Front panel circuit breaker trips out  
3. TVSS Fault LED (one or more) illuminate  
4. Harmonic filter circuit breaker trips out (if equipped with harmonic filter option)  
8.1.1 Source Circuit Breaker Trip  
The power conditioner utilizes a low-impedance isolation transformer. When first energized, transformers of this  
kind typically exhibit a high "inrush" current that may approach 10-15 times the nominal rating. While inrush  
currents quickly decay to nominal, it is possible to occasionally experience "nuisance" tripping of the source  
circuit breaker. If this occurs, consult the manufacturer for direct assistance in troubleshooting this condition.  
8.1.2 Input Circuit Breaker Trips  
In the event the front panel breaker on the power conditioner trips out, one of five conditions is likely at fault. You  
may effectively troubleshoot this condition by checking each of the following five areas. They are listed in order  
or probability.  
8.1.2.1 Electrical Load Has Exceeded Capacity - If the amount of electrical load has exceeded the  
capacity of the power conditioner, the front panel circuit breaker is designed to trip. Load may exceed capacity  
as a result of a short circuit in the load or too much load having been added to the power conditioner. In either  
event, turn off all load power switches and recycle power to the conditioner by turning the circuit breaker handle  
to the extreme counter-clockwise position and then rotating back to the clockwise “On” position. If this restores  
the power conditioner to normal operation (with no loads powered up) it will be necessary to either remove load  
from the conditioner or troubleshoot the load to determine if a short circuit condition exists.  
8.1.2.2 Phase Loss or Low Voltage Occurrence - This condition will cause the front panel circuit  
breaker to trip only if the power conditioner is equipped with the power management option. To troubleshoot this  
condition, rotate the circuit breaker handle to the extreme counter-clockwise position and then rotate clockwise to  
the “On” position. If the phase loss/low voltage condition was temporary the power conditioner will once again be  
operating and the 7500 ION monitor can be used to retrieve the phase loss or low voltage data from the log files.  
If after resetting the circuit breaker it immediately trips out once again, this is an indication that the phase loss or  
low voltage condition is still present. If a phase loss or low voltage is found not to exist consult the following  
sections for information on further troubleshooting on additional failure conditions.  
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Section 8 - Troubleshooting/Maintenance  
Prior to performing maintenance of any kind, lockout and tagout the electrical  
power at both the facility source and the input circuit breaker. Under these condi-  
tions, entering the equipment enclosure will be classified as a Type 1 task under  
SEMI S2-0200 guidelines. Power must be locked out and tagged out at both locations prior to entering  
the enclosure for maintenance purposes.  
8.1.2.3 EMO Has Been Activated - The front panel EMO pushbutton latches in a closed position once it  
has been depressed. Ensure that the EMO button has not been depressed by turning the button in the direction  
of the arrows and allowing it to spring back to its normal operating position. If the power conditioner is equipped  
with the external EMO option, further ensure that remote EMO buttons or connected external EMO circuits have  
not been activated. Once all EMO buttons and circuits have been verified, rotate the circuit breaker handle to the  
extreme counter-clockwise position and then rotate clockwise to the “On” position. If the circuit breaker once  
again trips immediately, contact the manufacturer for further instructions.  
8.1.2.4 Safety Interlocks Activated - Check both side panels of the power conditioner for proper instal-  
lation and secure fit. Both panels must be firmly in place and securely fastened with the quarter turn fasteners  
provided. A loose or improperly attached panel will allow the safety interlocks to activate and shunt trip the front  
panel circuit breaker. Once the panels have been checked, rotate the circuit breaker handle to the extreme  
counter-clockwise position and then rotate clockwise to the “On” position.  
If the circuit breaker once again trips immediately, contact the manufac-  
turer for further instructions.  
8.1.3 TVSS Fault LEDs Illuminate  
If one or more TVSS Fault LEDs illuminate, it is an indication that the  
TVSS components may be damaged. These components are protected  
Figure P  
by fuses. The TVSS module and it’s associated fuses are located inside  
the power conditioner enclosure, on the right side below the isolation transformer as illustrated in Figure P to the  
right. The TVSS module itself is attached to the rear of the mounting panel. Three resistors are associated with  
the fuses. The resistors function as “pull up” resistors to light the front panel LEDs should one or more of the  
fuses open. The TVSS module, fuses, and resistors are accessed by removing one or both side panels as de-  
scribed in Section 5.3.  
The fuses may be checked for continuity using an ordinary multi-meter. Open fuses may be replaced on site us-  
ing an Amptrap ATQ20, Time Delay, 10 kA IR, 500 VAC, 20A fuse or equivalent. Once the fuses have been  
replaced, replace the side panels as described in Section 6.1 taking care to reattach the grounding straps. Once  
completed, rotate the circuit breaker to the clockwise “On” position. If one or more of the TVSS Fault LEDs re-  
illuminate, the fuses have opened once again. This indicates that the TVSS element is damaged and requires  
replacement. Contact the manufacturer to order a replacement part.  
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Section 8 - Troubleshooting/Maintenance  
8.1.4 Harmonic Filter Circuit Breaker Trips Out  
If equipped with a harmonic filter option, the power conditioner will incorporate a  
passive harmonic filter. One characteristic of such filters is that they tend to  
“sink” harmonics regardless of whether the source is the load or the facility. In  
some circumstances, it is possible that the load and the facility together may  
require more reactive current than the filter is rated to provide. For that reason,  
models equipped with the harmonic filter option include a circuit breaker to  
pretect the filter from delivering reactive current current in excess of its capabili-  
ties. The circuit breaker is located on the front panel as illustrated in Figure Q to  
Figure Q  
the left. The circuit breaker will trip if its reactive current capabilities are exceeded. The circuit breaker may be  
reset at any time without interrupting the operation of the power conditioner. However, unless the source of ex-  
cessive harmonics is located and eliminated, the circuit breaker is likely to once again trip as soon as it has been  
reset. If tripping of the harmonic circuit breaker is frequent and persistent, this is an indication of high harmonic  
content within the facility electrical system which could be investigated and corrected.  
8.2 Routine Maintenance  
Little routine maintenance is required for the CPC series to function reliably for many years. Depending on the  
application for which the power conditioner is being used, however, occasional routine cleaning may be recom-  
mended. Some applications and installation environments generate significant dust residue. This may be espe-  
cially true in printing facilities. Because the CPC series is convection cooled, it is important to prevent dust  
buildup from blocking the ventilation slots. Dust buildup should also be removed from inside the power condi-  
tioner enclosure. Dust may be easily removed with any ordinary shop vacuum. Remove dust as often as re-  
quired to keep ventilation slots clear and excessive dust from accumulating inside the enclosure.  
To perform maintenance inside the enclosure, it will be necessary to de-energize the power conditioner as de-  
scribed in Section 6.5 and remove the side panels as described in Section 5.3. Make sure to observe Section 6.1  
carefully when completed before returning the power conditioner to service.  
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Section 9 - Service and Support  
9.1 Technical and Service Assistance  
In North and South America, the manufacturer offers toll-free technical and customer service assistance by  
calling 800-321-6699. Business hours are Monday through Friday, 8:00 a.m. to 5:00 p.m. Central Time. In  
EMEA, contact the manufacturer’s international headquarters in the United Kingdom at +44 (0) 1793 553980. UK  
business hours are 8:00 to 17:00 GMT. In the event of an emergency outside of normal business hours, the  
manufacturer’s phone systems provide an emergency after hours phone number. Technical and service inquiries  
Support. You may also register your ownership of the product on the .  
9.2 Customer Service  
Should it ever be necessary to obtain service on your power conditioner, please obtain the following information  
from the data plate attached to the rear of the unit. To process service requests, we will require:  
Model number  
Part number  
Serial number  
With this information in hand, contact the manufacturer at the numbers given above to arrange for service. In  
most cases, the power conditioner will require service on site. Units may only be returned to the manufacturer  
after obtaining a Return Material Authorization (RMA) number. This number must be clearly marked on the  
shipping container and packing slip accompanying any returned product. Unauthorized return shipments will be  
refused. Units to be returned must be shipped prepaid to the manufacturer in an appropriate shipping container.  
Additional charges will be billed for repair costs due to shipping damage resulting from inadequate packing.  
9.3 Product Warranty  
The manufacturer warrants its power conditioner (known hereafter as the “product”) to be free from defects in  
material and workmanship for a period of five years from the date of shipment. The product will be repaired or (at  
manufacturer’s option) replaced at no charge during this warranty period. The manufacturer makes no  
warranties, expressed or implied, of merchantability, fitness for a particular purpose, performance, condition,  
capacity or otherwise. The manufacturer is not liable for incidental or consequential damages, monetary loss,  
loss of sales, or loss of business resulting from failure or malfunction of the product. Warranty is void on any  
product that is misused, misapplied, abused, altered or repaired by any unauthorized personnel or where  
evidence of tampering exists. The foregoing constitutes the sole and exclusive remedy of the purchaser and is in  
lieu of all other warranties. No greater degree of liability is imposed on the manufacturer.  
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Section 10 - Specifications  
10.1 CPC Series Schematic  
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Section 10 - Specifications  
10.2 GPI Series 2000 Standard EMO  
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Section 10 - Specifications  
10.3 GPI Series 2000 Semi S2 EMO  
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Section 10 - Specifications  
10.4 Output Voltage Fine Adjustment  
IMPORTANT: ALL WORK TO BE DONE  
BY A LICENSED ELECTRICIAN  
-5%  
-5%  
-5%  
Nominal  
+5%  
Nominal  
+5%  
Nominal  
+5%  
TRANSFORMER SECONDARY  
The output voltage of the transformer may be adjusted +5% from nominal using the taps shown above. First  
disconnect the power and all load equipment. After removing the side panels, move the wire from the  
“nominal” transformer tap to the desired adjustment tap to adjust output voltage up or down. Replace side  
panels. Then energize the transformer and check for proper desired voltage at output before reconnecting  
and energizing the load.  
IMPORTANT NOTE: BE SURE TO ADJUST THE TAPS ON ALL THREE PHASES.  
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Document Revision History  
Part #  
Title  
Rev. Letter  
Rel. Date  
03/01/2006  
Next Rev. Level  
SM5505  
Conditioned  
Rev. A  
Rev. B  
Power Center  
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ETA Systems  
1450 Lakeside Drive  
Waukegan, IL 60085  
(800) 321-6699  
Phone: (330) 677-4424 - Fax: (330) 677-4471  
SM5505- Rev. A - 03/01/2006, © 2006 ETA Systems.  
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