Alpha CXPS-M 48-24-1200-600A User Manual
Medium Capacity Distributed Power System
Models: Cordex CXPS-M 48-1200A
Cordex CXPS-M 48/24-1200/600A
Installation & Operation Manual
Part # 9400004-J0
Effective: 05/2012
member of The Group
™
Your Power Solutions Partner
Modular High Capacity Distributed Power System
Models: Cordex CXPS-M 48-1200A
Cordex CXPS-M 48/24-1200/600A
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photo-
graphs may not match your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe operation of this powering
system, contact Alpha Technologies or your nearest Alpha representative.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power
supplies, generators, batteries, or other hardware if used or operated in any manner or
subject to any condition inconsistent with its intended purpose, or if installed or operated in an unapproved manner, or improperly maintained.
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: +1-604-436-5547
Email: support@alpha.ca
Copyright
Copyright © 2012 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the proprietary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies assumes no liability resulting from errors or omissions in this document, or from the use of the information
contained herein. Alpha Technologies reserves the right to make changes in the product design without reservation and without notification to its users.
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9400004-J0 Rev B
Table of Contents
1. Safety ....................................................................................................................................7
1.1 Safety Symbols .......................................................................................................................... 7
1.2 General Safety ........................................................................................................................... 7
1.3 Mechanical Safety ...................................................................................................................... 7
1.4 Electrical Safety ......................................................................................................................... 8
1.5 Battery Safety ............................................................................................................................ 8
2. Introduction ...........................................................................................................................9
2.1 Scope of the Manual .................................................................................................................. 9
2.2 Options and Additional Alpha Products ...................................................................................... 9
3. Product Description.............................................................................................................10
3.1 Specications ............................................................................................................................11
3.2 Cordex 4kW Rectier Shelves ................................................................................................. 12
3.3 Cordex 2kW Rectier Shelves ................................................................................................. 12
3.4 Cordex 1.2kW Rectier Shelves .............................................................................................. 12
3.5 Cordex Converter Shelves (dual voltage systems) .................................................................. 13
3.6 Distribution and Termination .................................................................................................... 16
3.7 Battery Terminations ................................................................................................................ 19
3.8 Distribution Shunts ................................................................................................................... 21
3.9 Low Voltage Load Disconnect .................................................................................................. 22
3.10 Distribution Panel Alarms ....................................................................................................... 23
3.11 External Low Voltage Battery Disconnect (purchased separately) ........................................24
3.12 Cordex System Controller ...................................................................................................... 24
4. Pre-Installation Preparation ................................................................................................27
4.1 Site Selection ........................................................................................................................... 27
4.2 Tools and Test Equipment ........................................................................................................ 29
4.3 Floor Loading ........................................................................................................................... 29
4.4 Unpacking the Equipment ........................................................................................................ 30
5. Installation ...........................................................................................................................31
5.1 Floor drilling for standard anchoring ........................................................................................ 31
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5.2 Placing and Securing the Bay .................................................................................................. 32
5.3 Mounting the External Battery Return Bus Bar (Optional) ....................................................... 33
5.4 Battery Installation ................................................................................................................... 34
6. Installation - AC, DC and Grounding Cables.......................................................................37
6.1 Installation Notes ..................................................................................................................... 37
6.2 AC Supply for the Rectiers ..................................................................................................... 39
6.3 Connecting the Frame and Reference Grounds ...................................................................... 40
6.4 External Battery Return Bar Wiring (Optional) ......................................................................... 42
6.5 Battery Connections ................................................................................................................. 43
6.6 Connecting DC Load Cables to Breaker/Fuse Circuitry ........................................................... 44
6.7 Connecting Load Cables to TPL Circuitry ................................................................................ 46
6.8 Final installation steps .............................................................................................................. 47
6.9 External Alarm Wiring .............................................................................................................. 50
7. System Startup ...................................................................................................................51
7.1 Check System Connections ..................................................................................................... 51
7.2 Verify AC and Power the Rectier Shelf ...................................................................................51
7.3 Check Battery Polarity and Connect ....................................................................................... 51
7.4 Final Conguration and Test .................................................................................................... 51
8. Test and Commissioning Overview .....................................................................................52
8.1 System ..................................................................................................................................... 52
8.2 Battery ...................................................................................................................................... 52
8.3 Documentation ......................................................................................................................... 52
9. Maintenance .......................................................................................................................53
9.1 Rectiers .................................................................................................................................. 53
9.2 Controller Lithium Battery Replacement .................................................................................. 53
9.3 Batteries ................................................................................................................................... 53
9.4 Adding Rectier Shelves .......................................................................................................... 54
9.5 Spares ...................................................................................................................................... 55
10. Acronyms and Denitions .................................................................................................56
11. Warranty ............................................................................................................................57
11.1 Battery Warranty ....................................................................................................................57
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List of Figures
Figure 1 — Example of a CXPS-M 1200 A power system with dual voltage .................................. 10
Figure 2 — CXDF 24-48/2kW converter module ............................................................................ 13
Figure 3 — Rear view showing DC charge buses (covers removed) ............................................. 14
Figure 4 — 1200A dual voltage system .......................................................................................... 15
Figure 5 — DC distribution modules ............................................................................................... 16
Figure 6 — Dual Voltage distribution modules ................................................................................ 17
Figure 7 — Distribution module installation shield .......................................................................... 18
Figure 8 — Battery termination (front view) .................................................................................... 19
Figure 9 — Remote battery return bar: customer connections (single bar shown) ......................... 20
Figure 10 — TPL shunts ................................................................................................................. 21
Figure 11 — Breaker bank shunt (one per bank) ............................................................................ 21
Figure 12 — Shunt mux panel mounted on the inside door of the top distribution module ............ 21
Figure 13 — LVD circuits ................................................................................................................ 22
Figure 14 — CB/fuse alarm LEDs and LVD control ........................................................................ 23
Figure 15 — CXCP controller mounted in a distribution module .................................................... 24
Figure 16 — Control cards .............................................................................................................. 25
Figure 17 — Battery terminations shown with protective covers .................................................... 27
Figure 18 — Template for anchoring bolts ......................................................................................31
Figure 19 — External battery return bus bar kit (2 bars shown) ..................................................... 33
Figure 20 — Battery shelf in the bay ............................................................................................... 34
Figure 21 — Temperature probe .....................................................................................................35
Figure 22 — Shelf AC connection (208Vac, 3 phase, 3-wire shown with rear cover removed) ......39
Figure 23 — Frame and reference returns (front view) ................................................................... 40
Figure 24 — Frame reference ground (top of bay) ......................................................................... 41
Figure 25 — Remote battery return bar wiring ................................................................................ 42
Figure 26 — External battery return bus bar (dual level shown) ..................................................... 43
Figure 27 — Battery terminations (front view) ................................................................................ 43
Figure 28 — Preparation for 2-pole and 3-pole breakers ............................................................... 44
Figure 29 — Breaker distribution module before load cables are installed ..................................... 45
Figure 30 — Breaker load cable and return connections ................................................................ 45
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Figure 31 — High capacity TPL fuse wiring (shown with 2x 750 MCM wire) .........................................46
Figure 32 — Final load cable arrangement (shown with protective covers removed) .................... 47
Figure 34 — Insulation cover (rear view) ....................................................................................... 48
Figure 33 — Top Kydex cover with cuts for cable entry ..................................................................48
Figure 35 — Insulation covers in place ........................................................................................... 49
Figure 36 — Securing Insulation covers to bay .............................................................................. 49
Figure 37 — Route of external signal wiring ................................................................................... 50
Figure 38 — CAN bus termination .................................................................................................. 54
Figure 39 — CAN OUT connection .................................................................................................54
List of Tables
Table A — Specications for Mid Capacity Power Systems...................................................................11
Table B — Mid Capacity Power Systems Output Congurations..........................................................16
Table C — Modular distribution components and termination .............................................................. 16
Table D — Typical VRLA battery maintenance report ........................................................................... 36
Table E — Cable size equivalents (AWG to Metric) .............................................................................. 38
Table F — Recommended torque values..............................................................................................38
Table G — Typical Ground Reference Conductor Selection ................................................................. 41
Table H — Sample maintenance log.....................................................................................................53
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1. Safety
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that
must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.
1.1 Safety Symbols
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
The use of ATTENTION indicates specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure.
Notes are designated with a check mark, the word NOTE, and a rule beneath which the
information appears
CAUTION!
CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment. Cautions are designated with a yellow warning triangle, the word CAUTION,
and a rule beneath which the information appears.
WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to personnel.
Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath
which the information appears.
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or
user.
1.2 General Safety
WARNING!
This system is designed to be installed in a restricted access location that is inaccessible to the general public.
1.3 Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.
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1.4 Electrical Safety
WARNING!
Hazardous voltages are present at the input of power systems. The DC output from rec-
tiers and batteries, though not dangerous in voltage, has a high short-circuit current
capacity that may cause severe burns and electrical arcing.
• Before working with any live battery or power system, follow these precautions:
a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
b. Wear safety glasses with side shields at all times during the installation.
c. Use OSHA approved insulated hand tools.
WARNING!
Lethal voltages are present within the power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to
the grounded portion of the bay (both AC and DC) before performing any installation or
removal procedure.
• Do not work alone under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment. Input voltages can range up to
480 Vac. Ensure that the utility power is disconnected and locked out before performing any installation or
removal procedure.
• Ensure that no liquids or wet clothes come into contact with internal components.
• Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input
power is disconnected.
1.5 Battery Safety
• Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all
metallic objects from your hands and neck.
• Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.
• Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm.
Battery post terminals and related accessories contain lead and lead compounds. Wash your hands after
handling batteries.
WARNING!
Follow battery manufacturer’s safety recommendations when working around battery
systems. Do not smoke or introduce an open ame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can explode.
• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery manufacturer for recommended local authorized recyclers.
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2. Introduction
2.1 Scope of the Manual
This instruction manual explains the features, installation, interconnection and startup of the Alpha CXPS-M Cordex system, both single and dual voltage. Images contained in this document are for illustrative purposes only
and may not exactly match your installation.
In addition to this manual, the following documentation may be included in the documentation package that ships
with the Alpha CXPS-M:
• Cordex Controller (CXC) Software manual
• Alpha Modular Switched Mode Rectifier System 48-4.0kW/ 48-12kW: part number 9400000-J0
• Alpha Modular Switched Mode Rectifier System 48-2.0kW/ 48-1.8kW: part number 030-807-J0
• Cordex 48-1.2kW 19" Front Access Shelf System: part number 030-834-J0
• Cordex DC/ DC Converter CXDF 24-48/2kW: part number 012-526-B2
• Cordex DC/ DC Converter CXDF 48-24/2kW: part number 012-527-B2
Product Overview
CXPS-M power systems provide a power solution for mid-sized communications applications— central offices,
data center, cell sites and cable headend facilities. The main source of power for the power system is commercial AC power, which is converted to DC by the modular switched mode rectifiers. It is a fully automatic system,
which provides float and equalize capability.
These systems have many benefits:
• Flexible distribution options including plug-in breakers and TPL and TPS fuse holders
• Mid range -48V and + 24V power plants can be constructed up to 1200A using a single 4" bus arrangement
• High efficiency modular rectifiers reduce operating costs
• High efficiency modular converters for dual voltage applications
• Compact front access design reduces floor space footprint (26" x 20")
• Low voltage load or battery disconnect options
• Cordex system controller for configuration, monitoring and control of the entire DC power system from its
central panel and graphics display. Other controller features include: event data storage, alarm generation,
group rectifier configuration and remote access.
Rectifier Shelves
Rectifier shelves are wired out to the AC source provided by the customer.
Converter
For dual voltage systems, Cordex converters support small to medium 24Vdc loads from a 48Vdc power system
or small to medium 48Vdc loads from a 24Vdc power system.
Distribution Modules
A Cordex system controller is mounted in the door of a distribution module (Figure 1). An optional shunt multiplexer (MUX) panel (with CAN interface) can be used to monitor up to 16 channels (e.g. shunts). TPL fuse, TPS fuse
and AM breaker options are available.
2.2 Options and Additional Alpha Products
The system offers several advanced features with add-on options. These options can be included by the customer at time of ordering or can be added in the future; e.g. additional Cordex rectifiers. Additional products can be
ordered separately; such as a Fusible Battery Disconnect Panel – provides a fusible battery disconnect contactor
with a control circuit to enable remote low voltage disconnect (LVD) and reset-able emergency power off (EPO).
There are status indicators for the auto disconnect, manual disconnect and remote disconnect features.
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3. Product Description
Figure 1 shows a 1200 A dual voltage
system with three distribution modules.
The following sections describe these
components:
• Rectifier shelf (3.1, 3.2, 3.3, 3.4)
• Optional dual voltage converter
shelf (3.1, 3.5)
• Distribution and termination (3.6)
• Alarms and indicators
• Cordex controller (3.12)
Door-mounted Cor-
dex controller
Distribution Module #3
Distribution Module #2
Distribution Module #2
Rectier shelf
Rectier shelf
Converter shelf
(dual voltage)
Battery shelf
Battery shelf
10
Figure 1 — Example of a CXPS-M 1200 A power system with dual voltage
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3.1 Specifications
T able A — Specications for Mid Capacity Power Systems
Model number
Model
CXPS-M
1200
23" Rack 19" Rack
Maximum Output Power 57.6 kW 57.6 kW 57.6 kW
Maximum Current 1200 A
Dimensions (with Kydex cover)
Metric (cm) 213.3 H x 66.0 W x 48.2 D 213.3 H x 48.2 W x 48.2 D
Imperial (in) 84 H x 23 W x 19 D 84 H x 19 W x 19 D
Weight (rack with 2 distribution modules and two rectier shelves)
Metric (kg) 227 approx 191 approx
Imperial (lb) 500 approx 425 approx
Input AC to 4.0/3.6 kW Rectier Shelves (per feed)
208-277 Vac, 1 PH/ 22-15A
48-4.0 kW Shelf
360-480 Vac, 3 PH – 3 wire + N + Protective
Earth (PE)/ 22-15A
208-240 Vac, 3 PH - 3 wire + PE/ 39-30A
CXPS-M
1200/600
1200 A primary
600 A secondary
CXPS-M
1200-19
1200 A
208-277 Vac, 1 PH/ 22-15A
24-3.6 kW Shelf
Frequency Range
Recommended Feeder Breaker
Single Phase:
Three Phase: 30 A, #10 AWG Wye connection 4W
208-277 Vac, 1 PH/ 17-13A
360-480 Vac, 3 PH – 3 wire + N + PE/ 17-13A
208-240 Vac, 3 PH - 3 wire + PE/ 30-26A
45 ~ 65 Hz, (±0.5 Hz)
6x 30 A, #10 AWG per rectier shelf 5x 30 A, #10 AWG per rectier shelf
50 A, #6 AWG Delta connection 3W
208-277 Vac, 1 PH/ 17-13A
N/A
Input AC to 1.2 /2.0 kW Rectier Shelves (per feed)
48-2.0 kW Shelf 120-240 Vac, 1 PH/ 36-27A 120-240 Vac, 1 PH/ 12-9A
48-1.2 kW 19" Shelf* 120-240 Vac, 1 PH/ 12-15A 120-240 Vac, 1 PH/ 12-15A
Frequency range
Recommended Feeder Breaker
(2.0 kW Shelf)
Recommended Feeder Breaker
(1.2 kW Shelf)
1x 120 or 240 Vac, 50 A, #6 AWG (three
module feed)
1x 120 or 240 Vac, 30 A, #10 AWG (two
module feed)
120 Vac, 15A, #14 AWG (per individual feed of two rectiers)
240 Vac, 20A, #12 AWG (per individual feed of two rectiers)
45 ~ 65 Hz, (±0.5 Hz)
4x 120 or 240 Vac, 15A, #14AWG (per
rectier shelf)
Distribution Modules
No. of Modules/Bay Max 4 Max 2
2 banks of 12 plug-in bullet positions OR
Options per Module
1 bank of 12 plug-in bullet positions/1 bank of 3 positions TPL fuses combination
*The 19" shelf can be mounted in a 23" shelf with additional hardware.
2 banks of 3 positions of TPL fuses OR
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3.2 Cordex 4kW Rectifier Shelves
Each bay can contain up to five Cordex shelves that hold up to six individual rectifier modules.
3.2.1 AC Termination Wiring
The individual Cordex rectifier shelves are wired to the customer-provided AC termination panel. The AC input is
routed through a 1" knockout for direct connection to the rectifier shelf with appropriately sized wire according to
the local electrical codes.
Each shelf requires two AC input circuits. The required input voltage varies depends on the rectifier shelf option
chosen at the time of ordering—see Table A for details.
3.2.2 Cordex Rectifier Modules (Purchased Separately)
The rectifier modules are "hot swappable" allowing for quick replacement and easy maintenance of the system.
(They can be inserted or removed from the shelf without removing AC power or shutting down the entire system.)
See the Cordex rectifier shelf manual included with the system documentation package for detailed information.
The CXC controller provides central control of the rectifiers’ output level, load sharing, temperature compensation
and alarm reports. A CAN bus cable is wired or daisy-chained to each rectifier shelf for communication with the
Alpha CXC System Controller.
3.2.3 Rectifier Alarms and LEDs
Rectifier status, such as Mains OK, Minor and Major alarms, display on the rectifier front panel.
• When a Rectifier Major alarm is present, the module has shut down due to a critical fault.
• A Rectifier Minor alarm indicates the module has a noncritical alarm, however, it has not shut down.
See the Cordex rectifier manual included with the system documentation package for detailed information.
3.3 Cordex 2kW Rectifier Shelves
Each 2kw Cordex shelf holds up to five individual
rectifier modules.
See the shelf manual that ships with your system (P/N
030-807-J0) for rectifier and shelf details.
3.4 Cordex 1.2kW Rectifier Shelves
Cordex CXRF-HP 48-1.2kW 1RU shelf holds up to five
individual rectifier modules.
See the shelf manual that ships with your system (P/N
030-834-J0) for rectifier and shelf details.
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9400004-J0 Rev B
3.5 Cordex Converter Shelves (dual voltage systems)
Converter shelves are part of a dual voltage system. Depending on the required load voltage, the converters are
one of:
• 24V to 48VDC, 2 kW output per module (24-48V
5-Mod 23" shelf part number: 030-900-20)
• 48VDC to 24V, 2 kW output per module (48-24V
5-Mod 23" shelf part number: 030-900-20)
Figure 2 — CXDF 24-48/2kW converter module
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3.5.1 DC Charge Buses - Single Voltage
Each rectifier bay has two vertical charge bars—one that connects all the return terminals and one that connects
all the "hot" terminals of the rectifier shelves to the distribution modules (Figure 3). These bus bars are rated to
120 0A.
Battery returns can be connected to the top of the return bus bars. Optional external battery termination bus bars
are available to increase the number of terminations available (see "3.7 Battery Terminations" on page 19).
Batt (return)
Batt ("hot")
14
Relay Rack: 030-683-20
7' x 23" Zone 4
Figure 3 — Rear view showing DC charge buses (covers removed)
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3.5.2 DC Charge Buses - Dual Voltage
Dual voltage systems have three vertical charge bars:
• One connecting all of the return terminals
• One busbar connecting all the "hot" terminals of the rectifier shelves and the input to the converter shelf–rat-
ed for the maximum 1200A current.
• The third bus bar delivers secondary voltage from the converters to the load–rated to 600A.
Primary
voltage bus
Common
return bus
Secondary
voltage bus
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Figure 4 — 1200A dual voltage system
15
3.6 Distribution and T ermination
A 23" rack mounted system, is available with single 1200A output or 1200 A primary/ 600 A secondary (dual voltage with a common return). A 19" rack mounted system, is only available with a single 1200A output.
Table B — Mid Capacity Power Systems Output Congurations
Model number
Model
CXPS-M
1200
23" Rack 19" Rack
Maximum Output Power 57.6 kW 57.6 kW 57.6 kW
Maximum Current 1200 A
The fuse/circuit breaker distribution modules feature high capacity, modularity, and simplified installation. These
features provide effective secondary load distribution and protection for multiple DC feeds up to 600 amps.
3.6.1 Single Voltage Distribution
Each bay can have up to four distribution modules with a total current
capacity of 1200A. Table C lists component options across all four distribution modules.
Each module can contain one of the following configurations:
• 2 banks of 12 plug-in AM breakers/ TPS fuse holders
• 2 banks of 3 TPL fuses
• 1 bank of 12 plug-in AM breakers/ TPS fuse holders and 1 bank of
TPL fuses
Figure 5 shows a combination of two modules with two banks of circuit
breakers and two modules with one bank of TPL fuses and one bank of
plug-in breakers.
CXPS-M
1200/600
1200 A primary
600 A secondary
CXPS-M
1200
1200 A
16
Figure 5 — DC distribution modules
Table C — Modular distribution components and termination
Component Type Description/Connection
Fuses GMT: Up to 10 positions, up to 15A (max)
TPL, high capacity: Up to 6 positions, 800A max fuses
TPL, low capacity: Up to 24 positions, 300A max fuses
TLS/TPS plug-in bullet: Up to 96 positions, 125A max fuses
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Table C — Modular distribution components and termination
Component Type Description/Connection
Breakers AM plug-in bullet: up to 96 positions
Output
termination
GMT Fuse: 0.34 to 2.5 mm
TPL fuse, high capacity: 2 hole 3/8" diameter on 1" centers, dual cable landing, 2x 750 MCM
TPL fuse, low capacity: 2 hole 3/8" diameter on 1" centers, 1x 350 MCM
TLS/TPS/AM breaker 1 pole and 2 pole: 1/4" diameter on 5/8" centers
1 pole, max 100A
2 pole, 125A to 150A
3 pole, 175A to 250A
2
(14 to 22AWG)
3 pole: 3/8" diameter on 1" centers
Module/Bank
Capacity
TLS/TPS/AM breaker 1200A/ 2x 600A per bank
TPL fuse 1200A/ 2x 600A
TPL fuse/ AM breaker 1200A/ 1x 600A plus 1x 600A
3.6.2 Dual Voltage Distribution
Each bay can have up to four distribution modules with a total current capacity of 1200A primary/ 600A secondary The top distribution module has primary distribution only and can contain any of the following configurations:
• 2 banks of 12 plug-in AM breakers/ TPS fuse holders
• 2 banks of 3 TPL fuses
• 1 bank of 12 plug-in AM breakers/ TPS fuse holders and 1 bank of TPL fuses
The remaining distribution modules with dual voltage distribution can have.
• 2 banks of 12 plug-in AM breakers/ TPS fuse holders
• Primary bank of 3 TPL fuses and secondary bank of 12 plug-in AM breakers/ TPS fuse holders
Primary distribution
Primary distribution
Primary distribution
Primary distribution
9400004-J0 Rev B
Secondary distribution
Secondary distribution
Figure 6 — Dual Voltage distribution modules
17
3.6.3 Safety Features
Insulating shield
Each distribution bay has an insulating shield to the front of the bus bars. This shield prevents casual touching of
the bus bars with cable lugs and tools while working inside the distribution module. It also maintains separation
between the cables and the bus bars.
Insulation shield
Figure 7 — Distribution module installation shield
Circuit Breaker Guard
The pivoting circuit breaker guard, with a circuit designation strip, prevents accidental tripping of a breaker
and provides a secondary retention method.
Circuit breaker
guard
18
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3.7 Battery Terminations
The vertical DC busbars terminate in the top distribution module. Each busbar has 3 battery connection points (6
connections if made both front and back)—3/8" on 1" centers.
Optional extensions, available in kit #0380060-001, can be attached to the "hot" primary and battery return
busbars to provide more connection points (either 3/8" on 1" centers or 1/2" on 1 3/4" centers). Refer to kit
#0380060-001 for installation instructions.
Optional extensions
"hot"
primary
Return
Extensions are not available
for secondary voltage bus-
bars (dual voltage option)
Figure 8 — Battery termination (front view)
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