Alpha DCP03 300A User Manual

DCP03 300A Distribution Center

Installation & Operation Manual

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DCP03 300A Distribution Center

020-702-B2

The following documents and drawings are included in this manual:

• Specifications: 020-702-B1

• Installation and Operation Instructions 020-702-C0

• Customer connection drawing: 020-702-08

• Outline drawing: 020-702-06

• Schematic 020-702-05

Alpha Technologies Ltd. 020-702-B2 Rev C WC

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

1. Please read this manual prior to use to become familiar with the product’s numerous features and operating procedures. To obtain a maximum degree of safety, follow the sequences as outlined.

2. This manual provides warnings and special notes for the user:

a. Points that are vital to the proper operation of the product or the safety of the operator are

indicated by the heading: WARNING.

b. A notation that is in Bold or Italic typeface covers points that are important to the

performance or ease of use of the product.

3. Before using the product, read all instructions and cautionary markings on the product and any equipment connected to the product.

4. Do not expose the product to rain or snow; install only in a clean, dry environment.

5. CAUTION – Unless otherwise noted, use of an attachment not recommended or sold by the product manufacturer can result in a risk of fire, electric shock, or injury to persons.

6. CAUTION – Do not operate the product if it has received a sharp blow, it has been dropped, or otherwise damaged in any way – return it to a qualified service center for repair.

7. CAUTION – Do not disassemble the product – call our qualified service centers for servicing. Incorrect reassembling can result in a risk of electrical shock or fire.

8. WARNING – Use care working around battery systems. Before unpacking and handling batteries, thoroughly read and follow the documentation from the battery manufacturer with special regard to safety precautions.

9. WARNING – Under abnormal operating conditions, or as a result of damage and/or misuse of a battery, potentially hazardous conditions could occur including burns from sulphuric acid or injury from explosive gases.

10. WARNING – Whenever working with batteries there is a short-circuit current hazard. Extreme caution must be taken to prevent electrical arcing, electrical burns or shock.

TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................................................................................. 1

1.1 Scope of the Manual ..................................................................................................................................... 1

1.2 Product Overview .......................................................................................................................................... 1

1.3 Part Numbers and List Options ..................................................................................................................... 2

2 DISTRIBUTION CENTER FEATURES ................................................................................................................................ 3

2.1 Distribution Configurations ............................................................................................................................ 3

2.2 Low Voltage Disconnect (LVD) ..................................................................................................................... 3

2.3 Shunt ............................................................................................................................................................. 3

2.4 Internal Alarm Card ....................................................................................................................................... 4

2.5 CXCI I/O Terminal Block (Option) ................................................................................................................. 4

2.6 CXCM2 I/O Terminal Block (Option) ............................................................................................................. 5

2.7 4R/8D ADIO or 8R/8D 8DIO (Option) ........................................................................................................... 5

3 INSPECTION.................................................................................................................................................................. 7

3.1 Packing Materials .......................................................................................................................................... 7

3.2 Check for Damage ........................................................................................................................................ 7

4 INSTALLATION .............................................................................................................................................................. 8

4.1 Safety Precautions ........................................................................................................................................ 8

4.2 Tools Required .............................................................................................................................................. 8

4.3 Preparation/Mounting .................................................................................................................................... 8

4.4 Breaker Installation ....................................................................................................................................... 9

4.5 Breaker Removal .......................................................................................................................................... 9

5 WIRING ...................................................................................................................................................................... 10

5.1 Calculating Output Wire Size Requirements............................................................................................... 10

5.2 System and Battery Connections ................................................................................................................ 10

5.3 Alarm Connections ...................................................................................................................................... 12

5.4 Grounding ................................................................................................................................................... 12

5.5 CAN Serial Ports (4R/8D ADIO or 8R/8D 8ADIO Option) .......................................................................... 13

6 SYSTEM STARTUP ...................................................................................................................................................... 14

6.1 Check System Connections ........................................................................................................................ 14

6.2 Verify AC and Power the Rectifier Shelf ..................................................................................................... 14

6.3 Check Battery Polarity and Connect ........................................................................................................... 14

6.4 CXC Reset .................................................................................................................................................. 14

7 MAINTENANCE ........................................................................................................................................................... 15

8 ACRONYMS AND DEFINITIONS ..................................................................................................................................... 16

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Breaker Trip LED

Door securing knob

Universal mounting bracket

1 Introduction

1.1 Scope of the Manual

This instruction manual covers the features and installation of Alpha Technologies DCP03 300A Distribution Center.

NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.

1.2 Product Overview

The DCP03 300A Distribution Center is an integrated DC system distribution package designed for small to midsized power applications.

The compact unit installs in three rack units of space. The design allows for front access to DC and signal connections after installation.

All distribution wires are connected via two-hole termination lugs.

Up to 18 plug-in breakers can be installed at up to 100A per position. As an option, the system can be configured with 4 battery breaker and 14 load breaker positions. Optional multiple pole breaker adapter kits are also available.

Current shunts and low voltage disconnects (LVDs) can be installed as options.

The DCP03 also includes options for mounting CXCI and CXCM2 controller I/O terminal blocks behind the front door of the distribution center. This allows for front access connections to controller I/O when using the distribution center with Cordex 1.8kW rectifiers and integrated controllers.

In addition, the 4R/8D ADIO or 8R/8D 8DIO Cordex peripherals can be installed in the front door expanding the I/O capabilities of the CXC system controller.

The DCP03 has rear bus bars for rectifier input for either cabling or bus bar connections for fast system integration with Cordex 1.8kW rectifiers.

NOTE: Refer also to the manuals supplied for the individual modules within the system for further definition of features;

for example, details of controller operation are provided in the current version software manual.

020-702-C0 Rev C WC Page 1 of 16

Figure 1–Front angle view of the DCP03 300A Distribution Center

1.3 Part Numbers and List Options

This product is available to order under the following part numbers and list options:

Description Part Number/List Option

DCP03 300A Distribution Center (18-position) ............................................................................................................. 020-702-20

Basic unit ............................................................................................................................................................................. *List 0

24 Volt, negative ground ..................................................................................................................................................... List 1,4

48 Volt .................................................................................................................................................................................... List 2

19” center mount .................................................................................................................................................................. List 19

19” flush mount .................................................................................................................................................................... List 21

23” center mount .................................................................................................................................................................. List 23

23” flush mount .................................................................................................................................................................... List 25

Charcoal finish with white (contrasting) silkscreen ............................................................................................................. *List 56

24Vdc LVD (for List 1,4 only) ............................................................................................................................................ **List 71

48Vdc LVD (for List 2 only) ............................................................................................................................................... **List 72

CXCI I/O Interface ............................................................................................................................................................. **List 74

CXCM2 I/O Interface ......................................................................................................................................................... **List 75

4R/8D ADIO (requires List 74) ............................................................................................................................................. List 79

8R/8D 8DIO (requires List 74) .............................................................................................................................................. List 80

Jumper, no shunt (when L84 not equipped) ......................................................................................................................... List 81

Jumper, no LVD (when L71/72 not equipped) ...................................................................................................................... List 82

400A shunt (not available for 24Vdc CXCI) .......................................................................................................................... List 84

18 load breaker positions ..................................................................................................................................................... List 87

4 battery and 14 load breaker positions ............................................................................................................................. *List 88

Top cover ........................................................................................................................................................................... *List 93

* Default option ** Mutually exclusive, consult factory

This product is compatible with following options:

Description Part Number

Bus bar, 300A UDC to single 19" or 23" 1.8kW shelf (2x required per system) ........................................................... 614-840-13

Bus bar, 300A UDC to dual 19" 1.8kW shelves (2x required per system) .................................................................... 614-841-13

Kydex cover kit, for 300A UDC and single 19" or 23" 1.8kW shelf .............................................................................. 037-202-20

Kydex cover kit, for 300A UDC and dual 19" 1.8kW shelves ....................................................................................... 037-207-20

Breaker, AM-type mid-trip plug-in, 1A .......................................................................................................................... 470-300-10

Breaker, AM-type mid-trip plug-in, 3A .......................................................................................................................... 470-301-10

Breaker, AM-type mid-trip plug-in, 5A .......................................................................................................................... 470-302-10

Breaker, AM-type mid-trip plug-in, 10A ........................................................................................................................ 470-303-10

Breaker, AM-type mid-trip plug-in, 15A ........................................................................................................................ 470-304-10

Breaker, AM-type mid-trip plug-in, 20A ........................................................................................................................ 470-305-10

Breaker, AM-type mid-trip plug-in, 25A ........................................................................................................................ 470-306-10

Breaker, AM-type mid-trip plug-in, 30A ........................................................................................................................ 470-307-10

Breaker, AM-type mid-trip plug-in, 35A ........................................................................................................................ 470-308-10

Breaker, AM-type mid-trip plug-in, 40A ........................................................................................................................ 470-309-10

Breaker, AM-type mid-trip plug-in, 45A ........................................................................................................................ 470-310-10

Breaker, AM-type mid-trip plug-in, 50A ........................................................................................................................ 470-311-10

Breaker, AM-type mid-trip plug-in, 60A ........................................................................................................................ 470-312-10

Breaker, AM-type mid-trip plug-in, 70A ........................................................................................................................ 470-313-10

Breaker, AM-type mid-trip plug-in, 80A ........................................................................................................................ 470-314-10

Breaker, AM-type mid-trip plug-in, 90A ........................................................................................................................ 470-315-10

Breaker, AM-type mid-trip plug-in, 100A ...................................................................................................................... 470-316-10

Load breaker kit, AM-type mid-trip plug-in, 125A (2-pole) ............................................................................................ 747-523-20

Load breaker kit, AM-type mid-trip plug-in, 150A (2-pole) ............................................................................................ 747-524-20

Load breaker kit, AM-type mid-trip plug-in, 175A (3-pole) ............................................................................................ 747-525-20

Load breaker kit, AM-type mid-trip plug-in, 200A (3-pole) ............................................................................................ 747-526-20

Load breaker kit, AM-type mid-trip plug-in, 250A (3-pole) ............................................................................................ 747-527-20

Battery breaker, AM-type series-trip plug-in, 100A ....................................................................................................... 470-347-10

Battery breaker kit, AM-type series-trip plug-in, 150A (2-pole) ..................................................................................... 747-503-20

Battery breaker kit, AM-type series-trip plug-in, 250A (3-pole) ..................................................................................... 747-504-20

The above information is valid at the time of publication. Consult factory for up-to-date ordering information.

020-702-C0 Rev C WC Page 2 of 16

Load breaker

2 Distribution Center Features

2.1 Distribution Configurations

The DCP03 contains 18 total AM-type plug-in breaker positions with two-hole connection points for both breaker output and the ground return bus. The breaker distribution can be configured one of two ways:

1. List 87 configuration provides for all 18 positions to be dedicated to load distribution. In this configuration, both

rectifier and battery connections must be made on the rear bus bar input or external to the distribution center.

2. List 88 configuration allows for 4 battery breaker and 14 load breaker positions as shown below:

Battery breaker connections

connections

Figure 2–DCP03 configured for 4 battery and 14 load breakers

NOTE: Load breakers require mid-trip AM plug-In breakers, and battery breakers require series-trip AM plug-In breakers.

NOTE: When there is no power on the rectifiers and there is only one battery circuit breaker, there will be no alarm if the

circuit breaker trips.

2.2 Low Voltage Disconnect (LVD)

An optional 400A LVD can be installed for both 48Vdc and 24Vdc system configurations. If the system is configured with 18 load breakers, the LVD will be installed in series with the load (LVLD). If the system is configured with 4 battery and 14 load breakers, the LVD will be installed in series with the batteries (LVBD).

If an LVD is not equipped, the system must be provisioned with a jumper to bypass the LVD position (List 82).

2.3 Shunt

An optional 400A shunt can be installed for system current measurement. If the system is configured with 18 load breakers, the shunt will be installed in series with the load. If the system is configured with 4 battery and 14 load breakers, the shunt will be installed in series with the batteries.

NOTE: Shunt option requires 48V option (List 2) when used with CXCI.

NOTE: Shunt option is not available for 24V option when used with CXCI.

020-702-C0 Rev C WC Page 3 of 16

If a shunt is not equipped, the system must be provisioned with a jumper to bypass the shunt position (List 81).

LVD override switch

I/O customer connection points

2.4 Internal Alarm Card

The DCP03 includes a standard alarm card providing a common interface point to internal system I/O connections, an LVD override switch, and LED indication of breaker trip.

The alarm card provides terminal block access to internal signals such as binary alarms for breaker trip & LVD open, alarm relay for driving LVD, and analog inputs for current (shunt) and voltage measurements. The terminal blocks provide a single point of access to these signals for connecting to an external system controller. Refer to the customer connections (020–702–08) drawing at the rear of this manual for details on terminal block assignments.

The LVD override switch provides the user with the ability to inhibit or override LVD contactor operation as a safeguard during controller maintenance. A green LED signals when the LVD is in normal operation mode and a yellow LED signals when the switch has been placed into the override position.

2.5 CXCI I/O Terminal Block (Option)

When using the DCP03 as a distribution solution for use with a 1.8kW rectifier shelf with integrated CXCI controller, an I/O terminal block can be installed in the UDC front door for front access to controller signals.

The CXCI terminal block kit comes with a 25-pin D-sub wire harness for connection to the back of the 1.8kW rectifier shelf using the CXCI controller. Refer to the manual for the 1.8kW rectifier shelf (or system).

The internal signals from the distribution center are wired to the CXCI I/O board direct from the internal alarm board. The remaining relay outputs, digital inputs, and analog inputs are available on the board via terminal blocks for customer connection of external signals. Refer to the customer connections (020–702–08) drawing at the rear of this manual for details on terminal block assignments.

Figure 3–Internal alarm card

D-sub wire harnesses to 1.8kW shelf

020-702-C0 Rev C WC Page 4 of 16

CXCI I/O terminal block assembly

DB-style cable connections to

Figure 4–Internal alarm card and CXCI I/O terminal block option

2.6 CXCM2 I/O Terminal Block (Option)

When using the DCP03 as a distribution solution for use with a 1.8kW rectifier shelf with a modular CXCM2 controller, an I/O terminal block can be installed in the UDC front door for front access to controller signals.

The CXCM2 terminal block kit comes with 25-pin, 15-pin, and 9-pin D-sub wire harnesses for connection to the back of the 1.8kW rectifier shelf using the CXCM2 controller. Refer to the manual for the 1.8kW rectifier shelf (or system).

The internal signals from the distribution center are wired to the CXCM2 I/O board direct from the internal alarm board. The remaining relay outputs, digital inputs, and analog inputs are available on the board via terminal blocks for customer connection of external signals. Refer to the customer connections (020–702–08) drawing at the rear of this manual for details on terminal block assignments.

1.8kW shelf

CXCM2 I/O terminal block assembly

Figure 5–Internal alarm card and CXCM2 I/O terminal block option

2.7 4R/8D ADIO or 8R/8D 8DIO (Option)

The 4R/8D ADIO or 8R/8D 8DIO Cordex peripheral can also be installed on the front door of the DCP03. The 4R/8D ADIO option expands the I/O capability of an existing Cordex controller by adding an additional 4 relays outputs and 8 digital inputs. The 8R/8D 8DIO option expands the I/O capability of an existing Cordex controller by adding an additional 8 relays outputs and 8 digital inputs.

The 4R/8D ADIO or 8R/8D 8DIO peripheral installs on the right side of the front door. They connect to the Cordex system via CAN communications using RJ-12 offset communications cables.

All I/O connections are made via screw terminal blocks. Refer to the customer connections (020–702–08) drawing at the rear of this manual for details on terminal block assignments.

NOTE: The 4R/8D ADIO option and the 8R/8D 8DIO option cannot be used in the same configuration with the CXCM2

I/O terminal block assembly. For applications requiring CXCM2 and ADIO/ 8DIO, one of the two devices must be mounted externally to the distribution center. Consult factory for options.

020-702-C0 Rev C WC Page 5 of 16

ADIO power supply

Customer I/O

terminal blocks

Customer I/O

connection

CAN in/out

connections via terminal blocks

Figure 6–4R/8D ADIO option

8DIO power supply connection

CAN in/out

connections via

Figure 7–8R/8D 8DIO option

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