GE Industrial Solutions CPS2400U User Manual
Critical Power
Product Manual
CPS2400U Upstream System – 19”
Remote Power System
48 Vdc Input, ±190 Vdc Output
Converter/Limiter System
Service and Assistance - +1 877 546 3243 or +1 972 244 9288 PE.TechSupport@ge.com
© 2013 General Electric Company. All rights reserved. www.gecriticalpower.com
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CPS2400U Upstream System – 19” Product Manual CPS2400U
Table of Contents
Table of Contents ............................................................................................................................................................................................................................ 2
Table of Figures ................................................................................................................................................................................................................................ 3
Table of Tables .................................................................................................................................................................................................................................. 4
Introduction........................................................................................................................................................................................................................................ 5
Reference Documents ........................................................................................................................................................................................................ 5
Customer Service Contacts .............................................................................................................................................................................................. 5
On-Line Power Systems Product Manuals and Software ................................................................................................................................ 5
Product Description ....................................................................................................................................................................................................................... 6
Operation ................................................................................................................................................................................................................................... 7
Configurations ......................................................................................................................................................................................................................... 8
Installation .......................................................................................................................................................................................................................................... 9
Prepare for Installation ....................................................................................................................................................................................................... 9
Mount Shelves ....................................................................................................................................................................................................................... 10
Ground Converter Shelves .............................................................................................................................................................................................. 11
Connect Input Power ......................................................................................................................................................................................................... 12
Connect Load Wiring ......................................................................................................................................................................................................... 15
Inspect the Network ........................................................................................................................................................................................................... 16
Install Controller ................................................................................................................................................................................................................... 17
Set Shelf ID .............................................................................................................................................................................................................................. 18
Install Inter-Shelf Signal Cables ................................................................................................................................................................................... 20
Connect Office Alarms ...................................................................................................................................................................................................... 20
Connect Local Network .................................................................................................................................................................................................... 21
Install Converters ................................................................................................................................................................................................................. 22
Apply DC Power .................................................................................................................................................................................................................... 22
Verify Normal States .......................................................................................................................................................................................................... 23
Verify UL Installation Compliance ............................................................................................................................................................................... 23
Configure Controller ........................................................................................................................................................................................................... 23
Confirm Operation of Alarm Wiring ........................................................................................................................................................................... 24
Troubleshooting ............................................................................................................................................................................................................................. 25
System ....................................................................................................................................................................................................................................... 25
Alarm Card .............................................................................................................................................................................................................................. 27
Converter LEDs...................................................................................................................................................................................................................... 29
Locating Failed Fans .......................................................................................................................................................................................................... 30
Reference Information ............................................................................................................................................................................................................... 31
Connections ............................................................................................................................................................................................................................ 31
Vertical Spacing, Airflow, Baffles, and Fan Shelves ........................................................................................................................................... 33
Lugs ............................................................................................................................................................................................................................................. 34
Specifications .................................................................................................................................................................................................................................. 35
Dimensions ............................................................................................................................................................................................................................. 36
Standards Compliance ..................................................................................................................................................................................................... 37
Installation Area ................................................................................................................................................................................................................... 37
Installation Environment .................................................................................................................................................................................................. 37
Installation Category.......................................................................................................................................................................................................... 37
Safety ................................................................................................................................................................................................................................................... 38
Safety Statements ............................................................................................................................................................................................................... 38
Precautions ............................................................................................................................................................................................................................. 40
Appendix A: Operating Temperature Measurement and Vertical Spacing .................................................................................................... 41
Appendix B: Alarm Reference Table .................................................................................................................................................................................... 42
Appendix C: Operation without a Controller - Alarm Wiring .................................................................................................................................. 44
Appendix D: Installationsanleitung ...................................................................................................................................................................................... 47
Revision History .............................................................................................................................................................................................................................. 48
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Table of Figures
Figure 1 Block Diagram -48V Fed Converter Shelf ........................................................................................................................................................ 7
Figure 2 Configuration.................................................................................................................................................................................................................. 8
Figure 3 Fan Shelf Mounting ................................................................................................................................................................................................... 10
Figure 4 Baffle Mounting ........................................................................................................................................................................................................... 10
Figure 5 Converter Shelf Mounting ...................................................................................................................................................................................... 11
Figure 6 Converter Shelf Ground .......................................................................................................................................................................................... 11
Figure 7 ESD Jack .......................................................................................................................................................................................................................... 12
Figure 8 Converter Shelf DC Connections Access ....................................................................................................................................................... 12
Figure 9 Converter Shelf Input Power Connections .................................................................................................................................................... 13
Figure 10 Fan Shelf Input Power Connections .............................................................................................................................................................. 14
Figure 11 Converter Shelf Load Connector ..................................................................................................................................................................... 15
Figure 12 Fan Shelf Controller Cover .................................................................................................................................................................................. 17
Figure 13 Controller Installation ............................................................................................................................................................................................ 17
Figure 14 Alarm Card Access .................................................................................................................................................................................................. 18
Figure 15 Alarm Card Removal .............................................................................................................................................................................................. 18
Figure 16 Shelf ID Setting .......................................................................................................................................................................................................... 19
Figure 17 Inter-Shelf Cables .................................................................................................................................................................................................... 20
Figure 18 Controller Office Alarm Connector ................................................................................................................................................................. 20
Figure 19 Controller Network Wiring Connection ........................................................................................................................................................ 21
Figure 20 ESD Jack ....................................................................................................................................................................................................................... 22
Figure 21 Converter Installation ............................................................................................................................................................................................ 22
Figure 22 Normal LEDs............................................................................................................................................................................................................... 23
Figure 23 Alarm Card LEDs ...................................................................................................................................................................................................... 27
Figure 24 Converter LEDs and Test Points ....................................................................................................................................................................... 29
Figure 25 Fan Locations ............................................................................................................................................................................................................ 30
Figure 26 Office Alarm Connections with Controller .................................................................................................................................................. 31
Figure 27 Converter Shelf Output Connector ................................................................................................................................................................. 32
Figure 28 Fan Shelf Connections .......................................................................................................................................................................................... 33
Figure 29 Converter Slot Covers............................................................................................................................................................................................ 33
Figure 30 Converter Shelf Dimensions .............................................................................................................................................................................. 36
Figure 31 Fan Shelf Dimensions ............................................................................................................................................................................................ 36
Figure 32 Design Capacitance Safety Limit .................................................................................................................................................................... 39
Figure 33 Converter Slot Fillers .............................................................................................................................................................................................. 41
Figure 34 Office Alarm Pin Outs - Alarm Cards ............................................................................................................................................................. 44
Figure 35 Alarm Card Pin Out ................................................................................................................................................................................................. 46
Figure 36 Alarm Card Cables .................................................................................................................................................................................................. 46
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Table of Tables
Table 1 System Troubleshooting........................................................................................................................................................................................... 25
Table 2 -48V Input Feed Alarm State and LEDs ............................................................................................................................................................ 27
Table 3 Alarm Card State LEDs and Relays ..................................................................................................................................................................... 28
Table 4 Converter LEDs .............................................................................................................................................................................................................. 29
Table 5 Controller Office Alarm Cable ................................................................................................................................................................................ 31
Table 6 Converter Shelf Output Connector Pinout ...................................................................................................................................................... 32
Table 7 Lugs ..................................................................................................................................................................................................................................... 34
Table 8 Specifications ................................................................................................................................................................................................................. 35
Table 9 Minimum feed Loop Length for 10,000 A Short Circuit Current .......................................................................................................... 36
Table 10 Alarm Reference Table ........................................................................................................................................................................................... 42
Table 11 Converter Shelf Alarm Card States .................................................................................................................................................................. 44
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Calling from
Phone Number
• United States, Canada, Puerto Rico, and the US Virgin
+1 877 546 3243
• All other countries
+1 972 244 9288
Or contact your local field support center or your sales representative to discuss your specific needs.
Introduction
This manual is intended as a guide in assisting equipment understanding, installation, testing, and troubleshooting.
For additional assistance contact Customer Service or access additional information on-line.
Reference Documents
Document TITLE
CC848836981 Galaxy Pulsar Edge Product Manual
850035894 Galaxy Pulsar Edge Quick Start Guide
CC848853457 CPS3200U Technical Support Guide – Also applies to CPS2400U
Line Power Product Line Brochure – Specifications and Ordering Guide
Customer Service Contacts
Customer Service, Customer Training, Technical Support,
Product Repair and Return, and Warranty Service
Services provided include initiating the spare parts procurement process, ordering documents, product warranty
administration, and providing other product and service information.
GE phones are staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT -6), Monday through Friday, on normal
business days. At other times, this number is still available, but for emergencies only.
Islands
Or
1
USADCC
+ 877 546 3243
On-Line Power Systems Product Manuals and Software
Product manuals, technical support guides, product line brochures, and software are available on-line. Software
includes Easy View and SNMP MIB.
http://www.gecriticalpower.com
1
The USA direct country code for the country where the call is originating
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Product Description
The CPS2400U Upstream System delivers power over telephone lines. The primary application is enabling the delivery of
video bandwidth data rates to residences over twisted pairs by allowing placement of powered electronics at an
acceptable distance from the residence.
The Converter System distributes battery backed up power from existing -48V battery backed up sites such as Central
Offices and Remote Terminals to reliably power electronics near the home. It does this by converting the -48V to a
UL60950-21 safety approved + and – 190V current limited and ground fault protected sources.
Components and Features
See Line Power Product Line Brochure for details.
• Converter System
• Up to 24 converter shelves (576 output circuits)
• Converter Shelf - 19” shelf,
• Front access, mid-mount
• 12 Converter Card Slots, 24 output circuits
• Alarm Card
• Relays - Major and Minor, Form C
• Output Connector
• Redundant A and B -48V feeds
• Converter Cards
• Two independent dc/dc converters per card
• ±190 Vdc output, safety limited to 100VA and Ground Fault protected
• -48 Vdc input – Redundant A and B fed
• Connectorized and insulator shielded
• Hot swappable
• Fan Shelf
• Provides cooling air flow for a stack of up to 3 Converter Shelves
• Houses the system controller (optional)
• -48 Vdc input – Redundant A and B fed
• Redundant Cooling (optional with 2 Fan Shelves per stack of Converter Shelves
• Baffle
• Directs air flow - front intake, rear exhaust.
• Shields against material dropping into the Converter Shelves
• System Controller Galaxy Pulsar Edge – QS841E (optional)
• Web and SNMP over TCPIP
• Front Panel Display, Control, and Status LEDs
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Figure 1 Block Diagram -48V Fed Converter Shelf
Operation
-48V power input is distributed in an A and B redundant fashion to each of the converter cards and the alarm card.
There are two +/-190V circuits on each converter card. The circuits both boost the voltage and limit the current as
prescribed by UL60950-21 and GR-1089-CORE.
Warning: Ground faults or short circuits on the output do not permanently disconnect the output. The converter
circuit tests the line every 4 seconds and will re-energize if the wiring fault is cleared.
A serial communication bus links each converter to an alarm card at the end of each shelf.
The alarm card provides major and minor form C contacts, manages the converters and relays information to an
optional system controller using Galaxy Protocol over an RS485 bus. Up to 24 shelves can be controlled and monitored
by one system controller. The controller is WEB and SNMP capable.
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CPS2400U Upstream System – 19” Product Manual CPS2400U
Baffle
Baffle
Converter Shelves
Fan Shelves - 1 or 2
Converter Shelf Stack
Converter Shelf Stack
Controller
Converter Shelves
Fan Shelves - 1 or 2
Baffle
Configurations
Refer to Line Power System product line brochure for details.
Converter System 1 to 24 Converter Shelves (arranged in Converter Shelf Stacks)
+ 1 Controller (optional)
Optional Controller is installed in the Primary Fan Shelf.
Primary Fan Shelf not required in systems without Controller.
Converter Shelf Stack 1 to 3 Converter Shelves
+ 1 or 2 Fan Shelves
+ 1 Baffle
1 to 3
Secondary
no Controller
Primary
with Controller
in Primary Fan Shelf
1 to 3
Figure 2 Configuration
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CPS2400U Upstream System – 19” Product Manual CPS2400U
WARNING: Shock Hazard
•Complete Standard Insulated tool set
•Wire cutters and strippers
•Digital meter, +/- 0.02%
•Heat shrink gun
•Screw Drivers (flat-blade and Phillips)
•Torque wrench (0-240 in-lb / 28 Nm)
•ESD wrist strap
•Socket set
Installation
Prepare for Installation
Safety
Read and follow all safety statements, warnings, and precautions in the Safety section and Specifications section of
this manual and manuals of all other equipment before installing, maintaining or repairing the equipment.
WARNING: Shock Hazard
Load outputs are current limited +/-190V.
Outputs re-energize within 4 seconds when ground faults or short circuits are cleared.
Installation Tools
Equipment Identification
Identify the product you have received. Make sure to select procedural steps to match the equipment being installed.
Plan Installation
The system has been designed for mounting in relay racks or in equipment cabinets. It is designed for use with user
provided vertical airflow.
• Follow site specific engineering instructions to assure proper airflow for the specific installation.
• Refer to the Vertical Spacing, Airflow, Baffles, and Fan Shelves section for general spacing requirements.
Follow site engineering instructions.
Converter system shelves are installed arranged as one or more Converter Shelf Stacks.
Baffles
• Baffle Required at top of each Converter Shelf Stack in customer premise locations for UL compliance.
Baffles not Required in outside plant cabinets, CEVs, or huts.
• Baffles must be oriented to direct air in from the front (aisle) and out to the back of the rack.
Vertical Space Rules:
• Vertical space is permitted below Baffles for future Converter Shelf addition.
Baffle may be installed 12.5 inch rack space above a Fan Shelf.
• No vertical space between:
• Fan Shelves
• Fan Shelf and Converter Shelf
• Converter Shelves
Airflow and Fan Shelves
• Upward Airflow – provided by Fan Shelves.
• Fan Shelves provide adequate airflow for specified operating temperatures.
Airflow per specification may be provided by other devices.
• A Fan Shelf is required for each Converter Shelf Stack.
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Step
Action
1.
Before opening the packaging, carefully inspect the outside in the presence of shipping personnel for
signs of damage.
2.
Carefully open the packaging to verify that the contents are complete and undamaged.
3.
If damaged, follow the shipping carrier’s procedure for filing a damage claim.
4.
Save the shipping packaging until all parts are operating within specifications.
If the equipment must be returned, it should be repacked in the original shipping packing.
Step
Action
Notes:
5. Baffle –Orient to direct air in from the front (aisle) and out to the back of the rack.
1.
Mount Lowest Fan Shelf in a position allowing space above for all planned shelves.
2.
Mount the remaining shelves and baffles above the lowest shelf, working from bottom to
top.
• 1 Fan Shelf provides Converter Shelf Stack cooling.
• 2 Fan Shelves provide Converter Shelf Stack cooling with redundancy,
• Primary Fan Shelf
• Provides Controller support and Controller Display.
• Required only when the system is equipped with a Controller
• Maximum 1 per system
Planning Steps
1. Determine arrangement of each Converter Shelf Stack - Figure 2.
2. Determine vertical rack space required, including planned space for future expansion.
3. Determine the position of the lowest Fan Shelf.
Unpack Equipment
Make sure the framework has the space and the airflow to provide an acceptable operating environment for the
equipment. Then unpack the equipment.
Mount Shelves
1. Secure shelves with as many screws as possible.
2. Torque each shelf mounting screws to 35 in-lb
3. Leave no vertical space between shelves
4. Follow site engineering instructions for shelf positioning and order.
See Plan Installation Section.
Figure 3 Fan Shelf Mounting
Figure 4 Baffle Mounting
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Step
Action
1.
Run and connect the framework ground lead
2.
Repeat from for remaining Converter Shelves.
Ground Lead
Figure 5 Converter Shelf Mounting
Ground Converter Shelves
Fan shelves will be grounded when connecting input power.
to safety grounding point (frame ground, or main ground bar) per local practice.
6 AWG minimum
Apply NO-OX ID to all bare metal connections if required by local practice.
Torque to 35 in-lb (4 Nm).
Lugs landings - 1/4” studs on 5/8” centers.
Lugs for 6AWG conductor - T&B 6STR30W , Burndy YAV6C-L2TC14-FX or available equivalent:
Figure 6 Converter Shelf Ground
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Step
Action
Converter Shelves Connect Power
1.
Connect your personal ESD strap to the ESD jack on the left of a converter shelf before proceeding.
2.
Verify voltage and polarity of each wire before connecting.
Use a Volt meter.
3.
Remove power from all DC connections to be installed.
Verify with a Volt meter.
4.
5.
Open the distribution panel door on the right end of the shelf.
Press Latch to
Release Door
Connect Input Power
Figure 7 ESD Jack
Turn off circuit breakers and remove fuses.
Turn OFF circuit breakers assigned to this frame and verify with an volt meter
Figure 8 Converter Shelf DC Connections Access
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Step
Action
6.
Connect Four -48VDC branch circuits to the DC source
1. Pull connector straight off of its header.
7.
Close the distribution door.
Repeat from Step 2 for each Converter Shelves.
A -48V (1-6) Input
Screw
Notes:
1. Each feed supplies half of the shelf. A&B feeds for side 1 and A&B feeds for side 2.
2
2. Size each circuit to support 35 Amp List 2 Drains – 18-6AWG
.
3. Verify minimum loop cable length per Table 9.
4. -48V Returns (RTN) connections must be grounded.
2. Strip wire 1/2 inch
3. Insert wire fully into wire entry
4. Torque screw to 16 in-lb (1.7Nm)
5. Repeat from 2 for all wires
6. Push connector straight onto its header
B -48V (1-6) Input
RTN (1-6)
RTN (7-12)
A -48V (7-12) Input
B -48V (7-12) Input
Figure 9 Converter Shelf Input Power Connections
2
Reference NEC Table 310-16 for applications of not more than three conductors in a raceway and correction factors
for Ambient Temperatures over 30°C. Each installation will vary and the installer should review NEC cabling
requirements as well as local practice to ensure proper cable sizing is achieved for the local conditions.
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Step
Action
Fan Shelves Connect Power
8.
Connect Input Power and Frame Ground
Repeat from Step 8 for remaining Fan Shelves.
A Feed (-48V)
Screws
24 - 16 gauge
Notes:
1. Each feed supplies half of the shelf. A&B feeds for side 1 and A&B feeds for side 2.
2. Power feeds should be derived from a fuse or breaker panel using discrete cabling which is
independent from the converter shelf.
3. Fuse externally at 10 Amps.
4. Use ring lugs or alternate per local practice.
5. Returns for the A and B feeds are shared on the -48Vdc RTN.
6. The right position on the terminal block is the frame ground for the Fan Shelf.
7. Connect de-energized DC cabling (typically 16 AWG) as shown here.
8. Connect Frame Ground wire.
-48V RTN
B Feed (-48V)
Frame Ground
Figure 10 Fan Shelf Input Power Connections
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NOTE: Compliance Requirements
Step
Action
1.
Verify rating of all wire between the equipment and the primary protectors:
• 200V rated minimum
2.
Verify primary protection consistent with UL 497 is installed on all the telecommunication line cable.
3.
Mark or tag the load cable and load circuit panel.
Note: The panel may be a cross-connect panel or the 5-pin protector block near the building entrance.
4.
Run the load cable down the frame and attach as shown.
5.
Use Screw to secure.
Repeat for remaining Converter Shelves.
Clip
Connect Load Wiring
Provide a circuit from each converter into the designated network telephone pairs.
The wiring assignment information in Table 6 provides the appropriate connections for each circuit. Cables should be
provided with this pinout configuration to terminate the J1 output connector on each Converter Shelf.
• Connect only to UL60950-21 RFT-V Circuits.
• Do not connect to UL60950-21 RFT-C circuits.
• Output voltage (+/-190V) meets UL60950-21 RFT-V requirements.
• Use minimum 26AWG 200V rated wire between the converters and primary protectors.
Wireset Connector: RJ-21 type 50 pin plug:
• 22 AWG solid or stranded AMP 552173-1 or equivalent.
• 24 AWG solid or stranded or 26 AWG solid AMP 229974-1 or equivalent.
• The connector must be arranged with a right angle housing such that the cable exits to the pin 1 side.
• 26 AWG minimum
1. Mark the Converter Shelf load cable with the Shelf number.
2. Mark each load circuit at the panel converter number (including the shelf number).
1. Seat the cable connector to the shelf connector.
2. Secure the connector with the clip.
Figure 11 Converter Shelf Load Connector
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