GE Industrial Solutions CPS3200U User Manual
Critical Power
Product Manual
CPS3200U Upstream System
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. http://www.ge.com/powerelectronics
CC848779826 Issue 09 December 2013 1
CPS3200U Upstream System – 23” Product Manual CPS3200U
Table of Contents
Table of Contents ...............................................................................................................................................................................................................................2
Table of Figures ..................................................................................................................................................................................................................................3
Table of Tables ....................................................................................................................................................................................................................................4
1 Introduction ......................................................................................................................................................................................................................................5
Reference Documents ............................................................................................................................................................................................................5
Customer Service Contacts ..................................................................................................................................................................................................6
On-Line Power Systems Product Manuals and Software .......................................................................................................................................6
2 Product Description .......................................................................................................................................................................................................................7
Operation .....................................................................................................................................................................................................................................7
Configurations ...........................................................................................................................................................................................................................7
Specifications .............................................................................................................................................................................................................................8
3 Ordering .............................................................................................................................................................................................................................................9
Ordering Codes ..........................................................................................................................................................................................................................9
Lugs ................................................................................................................................................................................................................................................9
4 Safety................................................................................................................................................................................................................................................ 10
Safety Statements ................................................................................................................................................................................................................. 10
Warning Statements and Safety Symbols .................................................................................................................................................................. 13
Precautions .............................................................................................................................................................................................................................. 14
5 Pre-Installation ............................................................................................................................................................................................................................. 15
Purpose ...................................................................................................................................................................................................................................... 15
Audience .................................................................................................................................................................................................................................... 15
Precautions .............................................................................................................................................................................................................................. 15
Safety .......................................................................................................................................................................................................................................... 15
Installation Tools .................................................................................................................................................................................................................... 15
System Identification ........................................................................................................................................................................................................... 15
6 Installing the Shelf Level Upstream Product ................................................................................................................................................................... 16
Unpacking Shelf Level Upstream Product .................................................................................................................................................................. 16
Installing and Powering the CP3200U Converter Shelf ......................................................................................................................................... 16
Ground the Shelf .................................................................................................................................................................................................................... 18
Attach the Load Wiring ....................................................................................................................................................................................................... 18
Set Shelf ID and Attach Alarm Wiring ........................................................................................................................................................................... 20
Installing the Baffle ............................................................................................................................................................................................................... 22
Installing the Fan Shelf ........................................................................................................................................................................................................ 22
Installing the Filter Bracket and Filter ........................................................................................................................................................................... 26
7 Inspect the Network - Check and Mark Wiring Compliance .................................................................................................................................... 28
8 Final Installation........................................................................................................................................................................................................................... 29
Installing the Converters .................................................................................................................................................................................................... 29
Apply DC Power ...................................................................................................................................................................................................................... 30
Recognizing Normal States ............................................................................................................................................................................................... 30
QS982A LED Information Map ......................................................................................................................................................................................... 31
Confirm Operation of Alarm Wiring ............................................................................................................................................................................... 32
Installing the QS941A Ethernet Module ....................................................................................................................................................................... 32
Installing the Office Alarm Connector ........................................................................................................................................................................... 36
9 Reference Information .............................................................................................................................................................................................................. 37
QS982A Converter LED Information Map .................................................................................................................................................................... 37
QS982A LED Information Map (visual) .......................................................................................................................................................................... 38
Alarm Card Information ...................................................................................................................................................................................................... 39
QS912A Converter Shelf ..................................................................................................................................................................................................... 40
QS930A Fan Shelf .................................................................................................................................................................................................................. 42
10 Maintenance ............................................................................................................................................................................................................................... 43
Filter Cleaning ......................................................................................................................................................................................................................... 43
11 Product Warranty ..................................................................................................................................................................................................................... 44
Appendix A: Operating Temperature Measurement and Vertical Spacing........................................................................................................... 46
Operating Temperature ...................................................................................................................................................................................................... 46
Baffles and Fan Trays .......................................................................................................................................................................................................... 46
Appendix B: Alarm Reference Table ....................................................................................................................................................................................... 47
Appendix C: Operation without a Controller - Alarm Wiring ....................................................................................................................................... 49
CPS3200U Shelf Alarm Card State Table ..................................................................................................................................................................... 50
Alarm Card Logical Operation of LEDs and Alarm Relays .................................................................................................................................... 50
Revision History ............................................................................................................................................................................................................................... 51
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Table of Figures
Figure 1 Block Diagram -48V Fed CPS3200U Shelf ............................................................................................................................................................ 7
Figure 2 Capacitance Safety Limits......................................................................................................................................................................................... 12
Figure 3 QS912A Converter Shelf ............................................................................................................................................................................................. 16
Figure 4 Mounting the Converter Shelf .................................................................................................................................................................................. 16
Figure 5 Preparing to Make DC Connections to Converter Shelf ................................................................................................................................ 17
Figure 6 Making DC Connections to Converter Shelf ...................................................................................................................................................... 17
Figure 7 Grounding Converter Shelf ....................................................................................................................................................................................... 18
Figure 8 Output Wiring for Converter Shelves .................................................................................................................................................................... 19
Figure 9 Accessing Alarm Cards ............................................................................................................................................................................................... 20
Figure 10 Removing Alarm Card .............................................................................................................................................................................................. 20
Figure 11 Setting Shelf ID ............................................................................................................................................................................................................ 21
Figure 12 Signal Wiring between Converter Shelves....................................................................................................................................................... 21
Figure 13 Installing a Baffle ........................................................................................................................................................................................................ 22
Figure 14 Mounting the Fan Shelf ............................................................................................................................................................................................ 22
Figure 15 Inserting Fan Trays .................................................................................................................................................................................................... 23
Figure 16 Open the Wiring Region of the Fan Shelf ......................................................................................................................................................... 23
Figure 17 Alarm Wiring for Fan Shelf ..................................................................................................................................................................................... 24
Figure 18 DC Cabling Fan Trays in CPS3200U Systems ................................................................................................................................................. 24
Figure 19 Cover the Wiring Region of the Fan Shelf ........................................................................................................................................................ 25
Figure 20 Fan Tray LEDs .............................................................................................................................................................................................................. 25
Figure 21 Mounting the Filter Bracket.................................................................................................................................................................................... 26
Figure 22 Filter Retention Bracket ........................................................................................................................................................................................... 26
Figure 23 Install Filter .................................................................................................................................................................................................................... 27
Figure 24 Secure Filter Retention Bracket ............................................................................................................................................................................ 27
Figure 25 Shelf Level ESD Jack .................................................................................................................................................................................................. 29
Figure 26 Installing Converters ................................................................................................................................................................................................. 29
Figure 27 QS982A Faceplate and LEDs ................................................................................................................................................................................. 30
Figure 28 Fan Shelf Right Hand Cover ................................................................................................................................................................................... 32
Figure 29 Fan Shelf Controller Jumper .................................................................................................................................................................................. 32
Figure 30 Preparing a Fan Shelf for a CPS Controller ...................................................................................................................................................... 33
Figure 31 Installing the Controller ........................................................................................................................................................................................... 33
Figure 32 Controller Wiring ......................................................................................................................................................................................................... 34
Figure 33 Fan Shelf RS-485 Jacks ............................................................................................................................................................................................ 35
Figure 34 Signal Cables - System ............................................................................................................................................................................................. 35
Figure 35 Office Alarm Cable Pinout ....................................................................................................................................................................................... 36
Figure 36 QS982 LEDs and Test Points .................................................................................................................................................................................. 37
Figure 37 Alarm Card Faceplate ............................................................................................................................................................................................... 39
Figure 38 Shelf ID Rotary Switches.......................................................................................................................................................................................... 39
Figure 39 QS912A Dimensions .................................................................................................................................................................................................. 40
Figure 40 Output Connectors .................................................................................................................................................................................................... 41
Figure 41 QS930 Fan Shelf Dimensions ................................................................................................................................................................................ 42
Figure 42 QS930 Fan Shelf Connections and Fuses ........................................................................................................................................................ 42
Figure 43 Converter Shelf with Slot Fillers ............................................................................................................................................................................ 46
Figure 44 Alarm Card Office Alarm Pinout and Shelf ID ................................................................................................................................................. 49
Figure 45 Alarm Card Office Alarm Cables .......................................................................................................................................................................... 49
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Table of Tables
Table 1 Specifications ..................................................................................................................................................................................................................... 8
Table 2 Ordering Codes .................................................................................................................................................................................................................. 9
Table 3 Output Connector Pinout ............................................................................................................................................................................................ 19
Table 4 QS982A LED Information Map ................................................................................................................................................................................... 31
Table 5 QS982A Converter LED Information Map ............................................................................................................................................................. 37
Table 6 QS982A Converter LED Information Map (visual) .............................................................................................................................................. 38
Table 7 Output Connector Pinout ............................................................................................................................................................................................ 41
Table 8 Alarm Reference .............................................................................................................................................................................................................. 47
Table 9 Shelf Alarm Card State ................................................................................................................................................................................................. 50
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CPS3200U Upstream System – 23” Product Manual CPS3200U
1 Introduction
Overview
The CPS3200U is the premier upstream dc/dc converter for line powering FTTN networks. The 3200U contains 16 dc/dc
converter/limiter cards in a dense 2 RU shelf. Each card contains a pair of independent -48 Vdc input to ±190 Vdc
output converters with each output safety limited to 100VA. In addition, each output terminal is safety Ground Fault
protected. The cards are fully connectorized and insulator shielded, inrush current protected and completely hot
swappable, making card addition to in-service shelves in the field an easy, one step process. The converter card shelf is
completely front access, with all -48V input and RJ21 output connections made on connectors in front of the midmount shelf brackets. The alarm and communications connections are also on the front of the shelf.
The CPS3200U converter shelf meets the applicable requirements of these North American product standards:
UL60950-21, UL60950-1, Telcordia GR-3108-CORE, GR-1089-CORE, GR-487-CORE (converter shelf), and GR-063-CORE.
Summary
The CPS3200U 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.
48 Vdc Input, ±190 Vdc Output Converter/Limiter System distributes battery backed up power from existing -48V
battery backed up sites like 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
source. Each front access shelf provides 32 channels.
Reference Documents
Document Title
CC848836981 Galaxy Pulsar Edge Product Manual
CC848853457 CPS3200U Technical Support Guide
Line Power Product Line Brochure – Specifications and Ordering Guide
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Calling from
Phone Number
+1 877 546 3243
+1 972 244 9288
Or contact your local field support center or your sales representative to discuss your specific needs.
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 Energy 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.
• United States, Canada, Puerto Rico, and the US Virgin
Islands
• All other countries
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
CC848779826 r09 December 2013 6
CPS3200U Upstream System – 23” Product Manual CPS3200U
2 Product Description
Figure 1 Block Diagram -48V Fed CPS3200U Shelf
Basic block diagram of single converter shelf System
Operation
Power comes in as -48V and 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 a Lineage
Power CPS6000 family controller using Galaxy Protocol over an RS485 bus. Up to 24 shelves can be controlled and
monitored by one CPS6000 family controller. The CPS6000 controller is WEB and SNMP capable.
Configurations
32 circuit, front access +/-190V shelves come in two configurations - airflow from bottom to top and airflow from top to
bottom. A single IP drop can be used to manage up to 24 shelves or 768 circuits.
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Table 1 Specifications
Electrical
Parameter
Symbol
Min
Typical
Max2
Unit
Input Voltage
Operating Continuous
Non-operating, No Damage
V
-40 0 -52.8
-60
-40
Vdc
Transient (@ duration =)
1 µs
V
-200
Input Current - (per half shelf
at 97.7W on all circuits)
VIN = 54.4V
I
IN
34.7
Adc
VIN = 52.1V
I
IN
36.2
Adc
VIN = 42.6V
I
IN
44.3
Adc
VIN = 40.0V
I
47.2
Adc
Temperature
Normal Operating Ambient
Temperature at 150 lfm airflow
TA -40 50
°C
Operating Ambient Temperature
at higher (TBD) airflow
TA -40 75
°C
Cold Start Temperature
TA
-40
°C
Storage Temperature
T
stg
-55 85
°C
Power – per C/L Card
Input Power at -42.6 Vdc input
Pin
2403
W
Power Dissipation
Pdiss
21
40*
W
Output Power
Pout
200
W
Output
Voltage – line to line
VO 378
380
382
Vdc
Power – per C/L circuit
PO 95.0
97.7
100
W
Current – per C/L circuit
I
OUT
251
257
262
mA
Isolation
Input to Output Voltage
1500
Vdc
Physical
Height
in (mm)
Width
in (mm)
Depth
in (mm)
Weight
lb (kg)
23-Inch Shelf
3.5 (88.9)
21.4 (543.6)
12 (304)
30 (13.6)
Fan Shelf
3.5 (88.9)
21.4 (543.6)
12 (304)
20 (9.0)
1U Baffle
1.75 (44.4)
21.4 (543.6)
12 (304)
4 (1.8)
Specifications
I
5 Seconds
rise and fall rate of 10V/ms)
10 ms (
10 µs
V
tr
V
tr
V
tr
tr
IN
-65
-75
-100
Vdc
Installation Category
CPS3200U output circuits are suitable for connection to telephone lines that are equipped with primary lightning
protectors consistent with UL 497. The user must provide protection on each copper pair to a level corresponding to a
CommScope 3C*EW Gas tube primary protector or equivalent gas tube protector [For example: 3C3EW provides the
part in a red color]. This protector has a voltage breakdown range of 265-465 Volts and an impulse spark over range of
<265-700 Volts. The 5-Pin protector must be marked as a “special circuit” consistent with the marking protocol in the
users network. Protectors are provided by the telco customer.
Network equipment and components along the powering circuit shall have suitable insulation resistance at 200 Vdc
from each conductor to ground and a total insulation resistance suitable for 400 Vdc from line to line.
2
Max = Absolute Maximum Rating
3
These are maximum situations with each circuit loaded to 100W. No actual or engineered application would load
every circuit to this level. In the absence of detailed information about the network we would recommend using the
typical dissipation value of 21 Watts for most applications with 30W per card for highly loaded networks.
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Table 2 Ordering Codes
CODE
COMCODE
DESCRIPTION
Items for new installation or growth of existing installations
QS912A
108996732
Converter Shelf with Alarm Module (provides landings for double-hole lugs)
QS982A
108996641
Converter Card (For first install on single shelf systems the sum of converters cards
Converter slot fillers)
CC109121992
Converter slot filler
QS930A
108996930
Fan Shelf with 2 redundant fan trays
QS941A
108996947
Controller with Display and Ethernet capabilities
CC848756577
Airflow baffle without bracket for air filter
CC109102638
Airflow baffle with bracket for air filter. Includes air filter.
Replacement air filter CC109121984 listed below.
Spares: Items for repair or maintenance of existing installation
CC109121984
Air filter to be used with Airflow baffle CC109102638 (Spare)
QS930B
108997623
Fan tray assembly (Spare)
QS920A
CC109102118
Alarm Module (Spare)
Expansion Items: Provide a 4 ft long wireset to transmit alarm signals past a baffle.
Use when adding a second fan shelf to an existing system.
H5694820G050
CC109122074
Fan Shelf w/2 fan trays, wireset, baffle, filter, controller cover
H5694820G051
CC109132271
Fan Shelf w/2 fan trays, wireset, baffle, controller cover
H5694820G012
CC109122082
Converter Shelf, RJ45 wireset, hardware, alarm board (same as QS912A above)
Similar Lugs
Panduit
T&B
3 Ordering
Ordering Codes
This is a short list of CPS3200 items that can be purchased. See Line Power Product Line Brochure for detail.
and converter slot fillers should be 16. For example: 14 Converter cards and 2
Note: A baffle must be placed above the topmost converter shelf for use in customer premise locations for UL safety
compliance. Baffles are not required in restricted access locations such as outside plant cabinet, CEV or hut locations.
The baffle can be ordered separately from the above list or in combination with a fan shelf by choosing an item from
this list.
Lugs
GA Description
2 Straight, STR 54 405348202 YA2CL-2TC14 LCD2-14A-Q 54207 (STR)
2 Straight, FLEX 8 405347683 YAV2C-L2TC14-FX LCDX2-14A-E 54208 (Flex)
2 45°, STR - - YA2CL-2TC14-45 LCD2-14AH-Q 54207UF (STR)
2 45°, FLEX 193 408210524 YAV2C-L2TC14-FX-45 LCDX2-14AH-E 54208UF (Flex)
4 Straight, STR / FLEX 5 405347576 YAV4C-L2TC14-FX LCDX4-14A-L (FLEX)
4 45°, STR / FLEX - - YAV4C-L2TC14-FX-45 LCDX4-14AH-L (FLEX)
6 Straight, STR / FLEX 3 405347519 YAV6C-L2TC14-FX LCDX6-14A-L (FLEX)
6 45°, STR / FLEX - - YAV6C-L2TC14-FX-45 LCDX6-14AH-L (FLEX)
8 Straight, STR / FLEX 75 406021626 YA8CL2TC14 LCDX8-14A-L (FLEX)
8 45°, STR / FLEX - - YA8CL2TC14-45 LCDX8-14AH-L (FLEX)
WP-91412
List Comcode Burndy Equivalent
NOTE: May have different dimensions.
54206 (STR)
LCD4-14A-L (STR)
LCD4-14AH-L (STR)
LCD6-14A-L (STR)
LCD6-14AH-L (STR)
LCD8-14A-L (STR)
LCD8-14AH-L (STR)
54206 (FLEX)
54206UF (STR)
54206UF (FLEX)
54205 (STR)
54205 (FLEX)
54205UF (STR)
54205UF (FLEX)
542040410 (STR)
542040410 (FLEX)
N/A
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CPS3200U Upstream System – 23” Product Manual CPS3200U
4 Safety
Safety Statements
Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the CPS3200U
System:
• The CPS3200U platform is Underwriters Laboratories (UL) Listed per UL60950-21.
• CPS3200U shelves have high, current limited, voltages on the output connectors with ground fault protection.
• For the product to be safe the chassis must be grounded by a permanent means.
• The return conductor of the -48V shall be terminated in the ground window, (held at frame ground potential).
• Install only in restricted access areas (dedicated equipment rooms, equipment closets, or the like) in accordance
with articles 110-16, 110-17, and 110-18 of the U.S. National Electric Code (NEC), ANSI/NFPA No. 70, and
pursuant to applicable local codes.
• The telecommunication line cable, carrying the +/-190V inside the cabinet between the equipment and the
primary protectors, shall be minimum 26 AWG, and rated minimum 200V. Consideration shall be taken at the
time of installation to verify cable rating.
• Primary protection must be provided on all the telecommunication line cable consistent with UL 497.
• Airflow must be provided at a rate of 175 lfm across the entire cross section of the shelf for operation in
environments up to 65 C, when measured at the inlet of the warmest converter shelf.
• This equipment is to be used in controlled environments (an area where the humidity is maintained at levels that
cannot cause condensation on the equipment, the contaminating dust is controlled, and the steady-state
ambient temperature is within the range specified).
• For multi-shelf systems (up to 3), this equipment has been evaluated for continuous use in central office
environments with ambient temperatures from -40°C to 50°C when used with the QS982A converters. For multishelf systems (up to 2), this equipment has been evaluated for continuous use in outside plant cabinet, CEV, and
hut applications with ambient temperatures from -40°C to +75°C. Proper airflow is required in all cases to ensure
maximum performance.
• This equipment must not be installed over combustible surfaces.
• For installations in the United States, Listed compression connectors are to be used to terminate Listed field-
wired conductors where required. For all installations, the appropriate connector is to be applied only to the
correct size conductor as specified by the connector manufacturer, using only the connector manufacturer's
recommended tooling or tooling approved for that connector.
• If the proper connector for the country of installation is not provided, obtain appropriate connectors and follow
manufacturer’s requirements and all local requirements for proper connections. All national and local rules and
regulations should be followed when making field connections.
• The subject product is not provided with a dc mains disconnect. Provision for mains disconnect such as branch
circuit breakers shall be provided by the end product installation.
• The main output voltage (+/-190V) meets UL60950-21RFT-V requirements. DO NOT CONNECT TO RFT-C
CIRCUITS.
• Insulation on field-wired conductors should be rated no less than 90° Celsius. Wire conductor size should be
sized per electrical codes for 75° Celsius wire, and based on the ampacity of the associated protection device.
Wiring internal to enclosed equipment cabinets should be rated at 105° Celsius (minimum).
• Torque electrical connections to the values specified on labels or in the product documentation.
• Input cables must be dressed to avoid damage to the conductors (caused by routing around sharp edges or
routing in areas where wires could get pinched) and undue stress on the connectors.
• Alarm contacts on the office alarm connector (TB1) are not fused within the distribution panel; therefore, current
limiting protection for these contacts must be provided by external circuits. Maximum ratings for alarm
CC848779826 r09 December 2013 10
CPS3200U Upstream System – 23” Product Manual CPS3200U
connections are 60Vdc and 0.5 amperes. Exceeding these maximum ratings could result in fire or damage to the
unit.
• Fuse and/or circuit breaker loads must not exceed 80% of the fuse and/or circuit breaker current rating.
Distribute loads across the panel.
• The short circuit current capability of the battery input to the panel must not exceed 10,000A.
• DC branch circuits to this equipment must be protected with either fuses or circuit breakers. Refer to the
equipment ratings to assure rating of equipment will not exceed 80% of the value of the protector chosen.
• For applications in cabinets, huts, vaults, and central offices, the CPS3200U mounting framework must be
connected to the system integrated ground grid.
• Installing fuses or circuit breakers not specified for use in these modules may result in injury to service personnel
or equipment damage. Use only replacement parts listed in this manual and on the equipment drawings.
• The telecom-type (e.g., GMT type) fuses can produce sparks during interruption or clearing of a fault on a high
energy circuit. Use only fuses provided with safety caps for this type of circuit. Installing telecom-type fuses not
equipped with safety caps may result in injury to service personnel.
• The designed capacitance between +/-190V RFT-V conductors is 2.2uF and the measured capacitance between
+/-190V and earth is 4.4uF. DO NOT add capacitance to the system to reach values that exceed safety limits per
the following figure:
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Figure 2 Capacitance Safety Limits
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CPS3200U Upstream System – 23” Product Manual CPS3200U
Indicates the presence of a hazard that will cause death or severe personal injury if
Indicates the presence of a hazard that can cause death or severe personal injury if
Indicates the presence of a hazard that will or can cause minor personal injury or
This symbol identifies the need to refer to the equipment instructions for important
These symbols (or equivalent) are used to identify the presence of hazardous ac mains
This symbol is used to identify the presence of hazardous ac or dc voltages. It may
One of these two symbols (or equivalent) may be used to identify the presence of
precautions.”
One of these two symbols may be used to identify the presence of a hot surface. It
hazardous voltage levels.
This symbol is used to identify the protective safety earth ground for the equipment.
This symbol is used to identify other bonding points within the equipment.
This symbol is used to identify the need for safety glasses and may sometimes be
Warning Statements and Safety Symbols
The symbols may sometimes be accompanied by some type of statement; e.g., “Hazardous voltage/energy inside. Risk
of injury. This unit must be accessed only by qualified personnel.” Signal words as described below may also be used to
indicate the level of hazard.
DANGER
WARNING
CAUTION
the hazard is not avoided.
the hazard is not avoided.
property damage if the hazard is not avoided.
information.
voltage.
also be used to warn of hazardous energy levels.
rectifier and battery voltages. The symbol may sometimes be accompanied by some
type of statement, for example: “Battery voltage present. Risk of injury due to high
current. Avoid contacting conductors with uninsulated metal objects. Follow safety
may also be accompanied by a statement explaining the hazard. A symbol like this
with a lightning bolt through the hand also means that the part is or could be at
accompanied by some type of statement, for example: “Fuses can cause arcing and
sparks. Risk of eye injury. Always wear safety glasses.”
CC848779826 r09 December 2013 13
CPS3200U Upstream System – 23” Product Manual CPS3200U
Precautions
When working on or using this type of equipment, the following precautions should be noted:
• This unit must be installed, serviced, and operated only by skilled and qualified personnel who have the necessary
knowledge and practical experience with electrical equipment and who understand the hazards that can arise
when working on this type of equipment.
• The equipment could be powered by multiple dc inputs. Ensure that the appropriate circuit protection device for
each dc input is disconnected before servicing the equipment. Do not disconnect permanent bonding provisions
unless all dc inputs are disconnected.
• DC inputs may be connected in parallel to power the dc-dc converters. Disconnecting one dc input will not
necessarily remove power from the bus. Make sure all battery power sources are also disconnected and/or follow
safety procedures while working on any equipment that contains hazardous energy/voltage.
• Hazardous energy and voltages are present in the unit and on the interface cables that can shock or cause
serious injury. Follow all safety warnings and practices when servicing this equipment. When equipped with
QS982A modules, hazardous voltages (+/-190Vdc) will be present on the output connectors and associated
interconnection cables.
In addition to proper job training and safety procedures, the following are some basic precautions that should always
be used:
• Use only properly insulated tools.
• Remove all metallic objects (key chains, glasses, rings, watches, or other jewelry).
• Wear safety glasses. Fuses can produce sparks. High energy levels on buses and distribution components can
produce severe arcing.
• Do not rely on simple volt meter tests to determine if the +/-190V output circuit is off line. Physically break the
circuit by removing the associated QS982A converter before touching the +/-190V RFT-V circuit. Confirmationtest each circuit for 5 seconds before touching. In some line fault modes, power is cycled on every 4 seconds. The
presence of a fault may make it difficult to determine if the circuit is online. Always physically break the circuit.
• Lock out and tag circuit breakers/fuses when possible to prevent accidental turn on.
• Be aware of potential hazards before servicing equipment.
• Identify exposed hazardous electrical potentials on connectors, wiring, etc. (note the condition of these circuits,
especially wiring).
• Use care when removing or replacing covers; avoid contacting circuits.
CC848779826 r09 December 2013 14
CPS3200U Upstream System – 23” Product Manual CPS3200U
•A 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
•Sockets
5 Pre-Installation
CPS3200U Installation
Purpose
CPS3200U Shelf Installation guide for generic installations. Additional requirements are needed for application specific
installations. Refer to Appendix A for spacing requirements.
Audience
Field application personnel
Precautions
Read Safety section prior to installation.
Observe ESD protection while installing circuit packs
Safety
• Always consider personal safety.
• Make sure the system is properly grounded per the National Electrical Code, local building codes, and any specific
company requirements per standard practice.
• Remove all metal jewelry before beginning the installation.
Installation Tools
System Identification
Identify the product you have received. Make sure to select procedural steps to match the product you have.
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CPS3200U Upstream System – 23” Product Manual CPS3200U
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 package until all parts are operating within specifications. If the equipment
must be returned, it should be repacked in the original shipping crate.
Step
Action
1.
Locate the 2 mounting brackets, one on each side of the CPS3200U shelf; align the holes in the shelf-
6 Installing the Shelf Level Upstream Product
Unpacking Shelf Level Upstream Product
Make sure the framework has the space and the airflow to provide an acceptable operating environment for the
CPS3200U shelf. Then unpack the equipment.
Figure 3 QS912A Converter Shelf
(Shown configured with 2 operational circuits and 14 slot fillers for airflow control)
Installing and Powering the CP3200U Converter Shelf
Position the Shelf and mechanically attach it to the frame
mounting bracket with the holes in the mounting frame. Attach the brackets to the frame using two
screws per frame as shown.
Figure 4 Mounting the Converter Shelf
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