GE Industrial Solutions CPS6000 User Manual

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CPS6000

-48V Indoor/Outdoor Power Shelf

Product Manual Select Code 167-102-105 Comcode 108992120 Issue 21 January 2008

This document is relevant to the following equipment series:

Controllers: QS840A 1:1 E App version 1.9 and defaults version Std-1.0

Rectifiers:

QS841A 1:0D App version 1.4.1 and defaults version Std-1.0

15A QS861A 1:1F 20A QS852A 1:0E 25A QS853A 1:0A 25/30A QS862A 1:1H 40A QS864A 1:0E 50A QS865A 1:1E

Series

Notice:

The information, specifications, and procedures in this manual are subject to change without notice. Lineage Power assumes no responsibility for any errors that may appear in this document.

CPS6000 –48V Indoor/Outdoor Power Shelf

1 Introduction..............................................................................................................6

Overview...................................................................................................................6

Customer Service Contacts.......................................................................................8

2 Product Description.................................................................................................9

CPS6000 System Overview......................................................................................9

Block Diagrams ......................................................................................................10

Shelf Design............................................................................................................12

Configurations.........................................................................................................13

Distribution and Power Module Configurations.....................................................14

Battery Reserve System ..........................................................................................15

Specifications..........................................................................................................16

3 Engineering and Ordering ....................................................................................24

Engineering Information.........................................................................................24

Ordering Information..............................................................................................26

4 Safety.......................................................................................................................32

Safety Statements....................................................................................................32

Warning Statements and Safety Symbols...............................................................35

Precautions..............................................................................................................36

Special Installation Notes .......................................................................................37

5 Installation..............................................................................................................39

CPS6000 Installation ..............................................................................................39

Installing the CPS6000 Shelf..................................................................................40

Install the CPS6000 Shelf .......................................................................................42

Controller ................................................................................................................43

QS845A Supplementary Shelf Board .....................................................................45

Thermal Compensation Connections......................................................................47

Office Alarms..........................................................................................................51

Controller Connections ...........................................................................................52

AC Connections......................................................................................................52

C.O. Ground Conductor Installation.......................................................................57

Rectifier Installation................................................................................................58

Ringer Installation...................................................................................................59

Battery Strings Installation .....................................................................................63

Load Connections ...................................................................................................67

Circuit Breaker and Fuse Installation .....................................................................73

Terminate Load Connections - Direct to Bus Connections ....................................74

Load Connections - Bulk Output ............................................................................75

Battery and Load Connections - External DC Distribution Panel ..........................76

Initial Start-up .........................................................................................................82

6 AC, Alarm, and Control Cable Reference Information.....................................85

Overview.................................................................................................................85

AC Utility Connection ............................................................................................85

Controller Connections ...........................................................................................86

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Auxiliary Alarms ....................................................................................................88

Additional Bulk Output Module Connections ........................................................89

7A QS840A System Controller ................................................................................90

Overview.................................................................................................................90

CPS6000 Controller Minimum Configuration........................................................96

User Interface and Display......................................................................................96

Minimum Configuration.........................................................................................96

7B QS841A System Controller ..............................................................................107

Overview...............................................................................................................107

Status.....................................................................................................................116

Control/Operations................................................................................................119

Configuration ........................................................................................................121

10/100 Base-T Ethernet Port.................................................................................128

8 Rectifier.................................................................................................................135

Overview...............................................................................................................135

Alarms and Displays.............................................................................................136

Features and Functions .........................................................................................138

9 QS872A Distribution Monitoring Module.........................................................139

Overview...............................................................................................................139

10 Ringer Chassis and Ringers ..............................................................................141

Ringer Chassis ......................................................................................................141

Ringer....................................................................................................................142

Types of Ringing...................................................................................................143

11 Peripheral Devices .............................................................................................146

Voltage/Thermal Probes .......................................................................................146

Remote Voltage Monitor Module.........................................................................147

12 ES772A Remote Distribution Module..............................................................149

Overview...............................................................................................................149

Module Features....................................................................................................151

Module Connector Definitions .............................................................................152

22-position external distribution panel .................................................................159

13 Troubleshooting .................................................................................................160

Checking for Defective VT-Probes ......................................................................162

14 Product Warranty..............................................................................................163

Appendix A: T1.317 Command Language ...........................................................165

Initializing the QS840A Controller.......................................................................165

T1.317 Command Language.................................................................................166

Appendix B: Battery Functions .............................................................................190

Float Mode............................................................................................................190

Slope Thermal Compensation...............................................................................190

Plant Battery Test..................................................................................................193

Boost Mode...........................................................................................................194

Appendix C: Alarms and Relays ...........................................................................197

Alarm Relays ........................................................................................................197

Alarms...................................................................................................................197

Appendix D: EasyView for Windows® for the CPS6000 Controller.................202

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Overview...............................................................................................................202

Loading the EasyView Application......................................................................202

Making the Connection.........................................................................................202

Configuring a Site.................................................................................................203

Serial Port Setup ...................................................................................................203

Connect to Site......................................................................................................203

Navigating Once Connected .................................................................................204

Appendix E: Pigtail Alarm Cable..........................................................................206

Appendix F: Operating Temperature Measurement and Vertical Spacing......209

Overview...............................................................................................................209

Revision History......................................................................................................210

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1 Introduction

Overview

CPS6000 -48V Outdoor Power System is a modular power system designed for 19-inch (483mm) and 23-inch (584mm) applications where reliability, space conservation and environmental considerations are critical. This highly dense power system occupies minimum space and its modular architecture enables an exact fit to custom needs.

The shelf architecture is based on the widely accepted and acclaimed CPS4000 systems. AC power is brought in on the left side of the shelf. The first slot on the left side is occupied by the controller. DC Output is aggregated on the right side of the shelf. Rectifiers/Ringers occupy the slots available between the controller and the DC output

Figure 1-1: CPS6000 System with Distribution Module

The CPS6000 currently supports -48V primary loads up to 8.2kW of N+1 redundant power in a single 19-inch shelf, and up to 10.9kW of N+1 redundant power in a 23-inch shelf with a Bulk Output Module and 50A rectifiers.

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CPS6000 systems may include up to 4 bulk-output shelves: an Initial shelf with controller, and up to three supplemental shelves. External distribution is used with multi-shelf systems.

Ringer Chassis may be installed in Power Slots. Each Ringer Chassis supports one ringing output in either non-redundant (simplex) or 1 + 1 redundant (duplex) operation. Ringer distribution is direct from the Ringer Chassis.

The system controller card is powered by the system bus voltage and is located on the left side of the shelf. The controller allows setting of system parameters, and various alarm thresholds locally on the four-line LCD graphics display with intuitive navigation. The controller can perform periodic battery tests and has a provision for user-definable alarm inputs as well as alarm relays.

Applications

CPS6000 fits Outside Plant(OSP) applications, digital loop carrier, remote switch, fiber in the loop, cable television cabinets, Intelligent Vehicle Highway System (IVHS), Personal Communications Service (PCS), cellular, and customer premises applications.

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Customer Service Contacts

Customer Service, Technical Support, Product Repair and Return, and Warranty Service

For customers in the United States, Canada, Puerto Rico, and the US Virgin Islands, call 1800-THE-1PWR (1-800-843-1797). This number is staffed from 7:00 am to 5:00 pm Central Time (zone 6), Monday through Friday, on normal business days. At other times this number is still available, but for emergencies only. Services provided through this contact include initiating the spare parts procurement process, ordering documents, product warranty administration, and providing other product and service information.

For other customers worldwide the 800 number may be accessed after first dialing the AT&T Direct country code for the country where the call is originating, or you may contact your local field support center or your sales representative to discuss your specific needs.

Customer Training

Lineage Power offers customer training on many Power Systems products. For information call 1-972-284-2163. This number is answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6), Monday through Friday.

Downloads and Software

To download the latest product information, product software and software upgrades, visit our web site at http://www.lineagepower.com/

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2 Product Description

CPS6000 System Overview

CPS6000 power systems are comprised of shelves, rectifiers, ringer chassis, ringers, and distribution modules. Several types of distribution modules are available. The Bulk Output Module provides connection to an external distribution without consuming a shelf power slot.

The CPS6000 is available as single-shelf systems and multiple-shelf systems with both 19inch and 23-inch shelves.

Single Shelf Systems

• With Distribution Module: all components contained in single shelf.

• With Bulk Output Module: uses external distribution, accommodates all other

components within the shelf.

Multi-Shelf Systems

• With Bulk Output Module: uses external distribution, accommodates all other

components within the shelves.

AC power is supplied to the rectifiers which produce regulated -48V dc output voltage. This voltage is used to power all other system components including ringers, the system controller and the LVD boards. Batteries are connected to distribution, internal or external. Some Distribution Modules provide battery circuit breakers. Single-Slot and Double-Slot Distribution Module options include GMT-style fuses and bullet-style circuit breakers.

The batteries are monitored by the system controller to ensure their peak performance and longevity against thermal issues. They are monitored via the Voltage/Thermal Probes (VTProbes), which are connected from the Distribution Module to the battery.

The Remote Voltage Monitor (RVM) module may be used with the VT-Probes in making voltage measurements for battery string-voltage imbalance detection. Additional VT-Probes may used by connecting them in a daisy-chain fashion.

The system controller monitors all system parameters and performs battery management functions. It communicates with all devices using the RS-485 bus. The RVM and VT-Probe communicate with the controller using the 1-Wire® from Maxim Integrated Products, Inc.

The LVBD contactor is used to connect the battery strings to the main power bus. Under ac fail conditions, the battery current will be flowing through the contactor to the output distribution in supporting the load. To prevent deep discharge of batteries, the CPS6000 can disconnect the batteries from the load by opening the LVBD contactor.

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CPS6000 also offers an optional low voltage load disconnect (LVLD) contactor. Non-critical loads and loads sensitive to low voltages can be connected to the system via the LVLD in the Distribution Module. CPS6000 disconnects these loads at a set threshold during a battery discharge. This reduces drain on the batteries and extends reserve time available for critical loads.

With the Bulk Output Module, a supplementary shelf may be paralleled to the primary shelf to create a larger plant. Only the primary shelf would contain the system controller. The supplementary shelf only requires signal connections to the primary shelf, and power connections to an external distribution panel. The controller can monitor for open protectors, current from a battery shunt, and monitor and control a low voltage disconnect contactor via the Remote Distribution Module (RDM).

Block Diagrams

2-1a and 2-1b are basic block diagrams of the CPS6000 System in a single shelf with a Distribution Module. Figure 2-2 shows the Bulk Output Module in place of the Distribution Module.

Figure 2-1a: CPS6000 System with Distribution Module

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Figure 2-1b: CPS6000 System with Distribution Module

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Figure 2-2: CPS6000 System with Bulk Output Module

Shelf Design

Features

• The shelf is available in 19-inch (phase 2) and 23-inch standard widths and has the

following features:

• Accepts plug-in rectifier, ringer and Distribution Modules.

• 19-inch shelves provide 4 Power Slots.

• 23-inch shelves provide 5 Power Slots

• Rectifiers, Ringer Chassis, and Distribution Modules may be installed in Power Slots.

Permits growth of plant capacity and easy maintenance without service interruption.

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Configurations

The 19-Inch Shelf provides four Power Slots.

The 23-Inch Shelf provides five Power Slots.

Power Slots support Rectifiers, Ringer Chassis, and Distribution Modules. Figure 2-3 shows the show the locations of the CPS6000 components in the19-inch and 23-inch shelves with the Single-Slot Distribution Module.

Figure 2-3: CPS6000 Systems with Single-Slot Distribution Module

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Distribution and Power Module Configurations

The 19-inch shelf has four Power Slots, and the 23-inch shelf has five Power Slots for power modules (Rectifiers and up to two Ringer Chassis) and distribution options (See 2- 4). With Bulk Output Distribution only, all slots are available for power modules. The Single-Slot Distribution Module occupies the right-most Power Slot, and the Double-Slot Distribution Module occupies the right-most two Power Slots, leaving the remaining Power Slots available for power modules. Up to two Ringer Chassis can be installed in the right-most remaining Power Slots.

Figure 2-4: Distribution and Power Module Configurations

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Battery Reserve System

Introduction

A battery reserve system is a key component for a reliable power system. The CPS6000 provides a primary voltage of -48Vdc that drives load equipment. At the same time, it provides float and recharge capability for the battery reserve system. If an ac power failure occurs, the batteries provide power to the load equipment until the ac can be restored.

Types of Batteries

CPS6000 may be used with valve-regulated lead-acid (VRLA) batteries. Up to four strings of VR-type batteries or equivalent general trade batteries may be connected directly to a CPS6000 shelf.

Certain Nickel-Cadmium (Ni-Cd) and Lithium-Ion batteries may also be used with the CPS6000. Please contact your sales representative for details. CPS6000 is also compatible to Flooded lead-acid batteries.

See Appendix D for detailed descriptions of battery related functions; float and boost charging, thermal compensation, and system battery test functions.

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Specifications

Table 2-A: CPS6000 System Specifications

Shelf Single 19-inch or 23-inch shelf Power Slots per Shelf 4 (19-inch shelf), 5 (23-inch shelf) Power Units Installed Position

Installed from the Right

Bulk Output Module

Distribution Module

Ringer Chassis

Installed from the Left

Rectifier Input Distribution Dual ac input (19 and 23-inch shelves)

System Architecture Primary output: 1 primary output power bus per shelf Primary Power Bus Current with Bulk Output Module Output Distribution Primary Bus

Bulk Output Module

Single-Slot and Double-Slot

Distribution Modules

Maximum Discharge Current Based on rectifier capacity. See Note 2 Maximum Recharge Current Installed shelf –48V rectifier capacity minus plant –48V load Operating Ambient Temperature -40 to 75 °C (-40 to 167 °F), see Note 3 Altitude -200 to 13,000 feet (-61 to 3962 meters). See Note 4 Humidity 10% to 95% non-condensing Audible Noise < 60 dBA Radiated and Conducted Emissions FCC Part 15, Class B

Harmonics EN61000-3-2 (IEC61000-3-2) Voltage Fluctuations EN61000-3-3 (IEC61000-3-3) Electromagnetic Immunity Meets Telcordia GR-1089-CORE Electrostatic Discharge EN61000-4-2 Level 3 RF Immunity IEC61000-4-3 Level 3, 10 V/m EFT IEC61000-4-4 Level 3, No Error; Level 4, No Damage Surge IEC 61000-4-5 Level 3, No Error; Level 4, No Damage Conducted Immunity IEC 61000-4-6 Level 3, 10V Voltage Dips, Interruptions, and Variations IEC 61000-4-11 Earthquake Rating Zone 4, upper floors Safety Agency Approval

Rectifiers

Bulk Output Module Single-Slot Distribution Module Double-Slot Distribution Module Ringer Chassis Rectifiers (19-inch shelf) (23-inch shelf)

Individual ac input (19 and 23-inch shelves) Single ac input (19 and 23-inch shelves)

19-inch shelf: 227A 23-inch shelf: 283A Battery connections: double-hole lugs to terminate battery strings.

-48 Vdc bulk power outputs to loads or distribution

• Bullet-style circuit breakers

• GMT-style fuses

See Note 2.

EN55022 (CISPR22), Class B

Underwriters Laboratories (UL) Listed per Subject Letter 1801: Power Distribution Center for Communications Equipment, and cUL Certified (CSA 22.2 950): Safety of Information Technology Equipment VDE licensed to VDE0805/EN60950

Unit

Max. per

Shelf

1 1 1 2 4 5

Power Slots

Each

0 1 2 1 1 1

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Rectifiers are individually UL Recognized (UL1950), cUL Certified (CSA 22.2 234) or evaluated to EN60950 by an EC

Notified Body, as appropriate. European Economic Community (EEC) Directives

Note 1: CPS6000 can be used with four strings of batteries depending on Distribution Module Note 2: When used with Single-Slot and Double-Slot Distribution Modules, maximum output is limited to

200A or the size of the LVD contactor installed (if smaller). See Section 3 for limitations on maximum currents through Distribution Modules.

Note 3: Operating temperatures and required airflow are different when used with specific rectifiers. See

Tables 2-D through 2-F for rectifier information.

Note 4: For altitudes above 5000 feet, derate the temperature by 3.6 °F per 1000 feet. For altitudes above

1524 meters, derate the temperature by 0.656 degrees Celsius per 100 meters.

Note 5: Power Unit Install Positions:

• Install these units in order beginning with the right most Power Slot First: Distribution Module Second: Ringer Chassis

• Install these units in order beginning with the left most Power Slot First: Rectifiers

EMC Directive 89/336/EEC

Low Voltage Directive 73/23/EEC as amended by Marking

Directive 93/68/EEC

Installation Category

CPS6000 is suitable for connection to ac utility systems where the expected level of lightning surges complies with ANSI C62.41 Category B or IEC 60664-1 Overvoltage Category II.

A service entrance surge protector is required in applications where the installation categories can not be classified as being compliant to either ANSI C62.41 Category B or IEC 60664-1 Overvoltage Category II.

CPS6000 rectifiers have been tested for repeated lightning surges typically found in an Overvoltage Category III installation; however, a service entrance surge protector is recommended in cabinet applications to bring the power feeds in compliance to the installation categories above. The service entrance protection should be coordinated with the protection provided in the power modules.

The power module provides common-mode protection via a 320V MOV in series with a 2500V gas-discharge device and differential-mode protection via a 320V MOV in series with a 3.5A fuse.

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Table 2-B: CPS6000 Physical Specifications

Rectifier 3.41 (86.6) 3.4 (86.3) 11.2 (284.5) 5.75 (2.6) Ringer Chassis 3.41 (86.6) 3.4 (86.3) 11.2 (284.5) 3.45 (1.6) Ringer 2.4 (61.0) 1.51 (38.4) 9.9 (252) 1.25 (0.6) 19-Inch Shelf 3.41 (86.6) 17.37 (441.2) 12 (304) –

23-Inch Shelf 3.41 (86.6) 20.95 (532.1) 12 (304) –

Single-Slot Distribution Module 3.41 (86.6) 5.1 (129.5) 12 (304) 9 (4.1) Double-Slot Distribution Module 3.41 (86.6) 8.5 (216) 12 (304) TBM Bulk Output Module 3.41 (86.6) 1.59 (40.4) 12 (304) 4 (1.8)

23-Inch Frame Mounting Requirements

19-Inch Frame Mounting Requirements

Height

in. (mm)

Standard 23 and 26-inch relay racks:

•Vertical mounting centers: 1.0 in. (25 mm) and 1.75 in. (44 mm)

•Horizontal mounting centers: 22.32 in. (567 mm)

Standard 19-inch relay racks:

•Vertical mounting centers: 1.0 in. (25 mm) and 1.75 in. (44 mm)

•Horizontal mounting centers: 18.31 in. (465 mm)

Width

in. (mm)

Depth

in. (mm)

front access

13.25 (337)rear access

12.7 (5.77)

front access

13.25 (337)rear access

Weight

lb (kg)

7.5 (3.41)

Table 2-C: CPS6000 Shelf Specifications

Control Unit QS840A / QS841A Nominal Output Voltages 48/52/54.5 Vdc Operating Voltage Range 42 to 58 Vdc Maximum Output Current 200A per 19-inch shelf; 250A per 23-inch shelf (see Note 1) Nominal Input Voltage 100/120/200/208/240 Vac Input Voltage Ranges 85 to 275 Vac Max Nominal Input Current per Rectifier (based on 25A rectifier for low line ac, and 50A rectifier for high line ac) Boost Voltage 48 to 58 Vdc Output Voltage Regulation ±0.5% Output Noise: Ripple Wideband Noise Load Share Accuracy 1.5A (maximum) for QS862A Maximum Discharge Current (see Note) Maximum Recharge Current Installed rectifier capacity minus plant load Low-Voltage Disconnect 39 to 50 Vdc Low-Voltage Reconnect 39 to 55 Vdc Heat Dissipation 177W (604 BTU) per QS862A at full load and

13A at 120 Vac

14.5A at 208 Vac

100 mVrms maximum, 10 Hz to 20 MHz < 250 mV pk-pk over the range dc to 100 MHz

227A per 19-inch shelf; 284A per 23-inch shelf

120 Vac operation;

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132W (450 BTU) per QS861A rectifier at full load and 120 Vac operation; 212W (724 BTU) per QS862A at full load and 240 Vac operation; 130W (445 BTU) per QS861A rectifier at full load and 240 Vac operation; 267W (911 BTU) per QS865A rectifier at full load and 240 Vac operation;

Power Factor > 0.98 for loads > 50% of full load

Note: Maximum current is based on Bulk Output Module and 50A QS865A rectifier. System capacity will decrease with lower rated rectifiers.

Power Slots Available for Rectifiers or Ringer Chassis

Shelf

19-Inch Shelf 4 3 2 23-Inch Shelf 5 4 3

None (Bulk Output Module)

Distribution Module

Single-Wide Double-Wide

Rectifiers

Table 2-D: QS861A Rectifier Specifications

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc Output Current 0 to 15A at 54.5V Nominal Input Voltage 100/120/200/208/240 Vac (Shutdown from 135 to

150V) Input Voltage Ranges 85 to 275 Vac Input Current 8A at 120 Vac

4.4A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +75 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 132W (450 BTU) at 120 Vac operation

130W (445 BTU) at 240 Vac operation Power Factor >0.99 (low-line), >0.98 (high line) Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

Table 2-E: QS852A Rectifier Specifications

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc

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Output Current 0 to 20A at 54.5V Nominal Input Voltage 1200/208/240 Vac Input Voltage Ranges 150 to 275 Vac Input Current 6A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +75 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 133 W (454 BTU) at 240 Vac operation Power Factor >0.98 (high line) Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

Table 2-F: QS853A Rectifier Specifications

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc Output Current 0 to 25A at 54.5V (100/120 Vac) Nominal Input Voltage 200/208/240 Vac Input Voltage Ranges 150 to 275 Vac (Shutdown from 135 to 150V) Input Current 7.4A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +75 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 212W (724 BTU) at 200 to 240 Vac operation Power Factor >0.98 for loads > 50% full load Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

Table 2-G: QS862A Rectifier Specifications

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc Output Current 0 to 25A at 54.5V (100/120 Vac)

0 to 30A at 54.5V (200/240 Vac) Nominal Input Voltage 100/120/200/208/240 Vac Input Voltage Ranges 85 to 275 Vac (Shutdown from 135 to 150V) Input Current 13A at 120 Vac

8.8A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +75 °C Output Voltage Regulation ±0.5%

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Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 177W (604 BTU) at 100 to 120 Vac operation

212W (724 BTU) at 200 to 240 Vac operation Power Factor >0.98 for loads > 50% full load Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

Table 2-H: QS864A Rectifier Specifications (Preliminary)

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc Output Current 0 to 40A at 54.5V Nominal Input Voltage 200/208/240 Vac Input Voltage Ranges 150 to 275 Vac Input Current 11.8A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +75 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 240W (819 BTU) at 240 Vac operation Power Factor >0.98 for loads > 50% full load Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

Table 2-I: QS865A Rectifier Specifications

Nominal Output Voltage 48/52/54.5 Vdc Operating Output Voltage Ranges 42 to 58 Vdc Boost Voltage 48 to 58 Vdc Output Current 0 to 50A at 54.5V Nominal Input Voltage 200/208/240 Vac Input Voltage Ranges 150 to 275 Vac Input Current 14.5A at 208 Vac Operating Frequency Range 45 to 66 Hz Operating Temperature -40 to +65 °C Output Voltage Regulation ±0.5% Output Noise, Ripple 250 millivolts peak to peak maximum, over the

range dc to 100 MHz Load Share Accuracy 1.5A maximum deviation between rectifiers Heat Dissipation (per rectifier, full load) 267W (911 BTU) at 240 Vac operation Power Factor >0.98 for loads > 50% full load Selective High-Voltage Shutdown Above 58 Vdc Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond

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Table 2-J: QS820A Ringer Specifications

Input Voltage -40 to -57 Vdc See Output VA Thermal Limiting. Nominal Input Voltage -48 Vdc Input Current 5 A max. Output Voltage ac tolerance ± 5 Vac Regulation ±5% ac component only dc Offset

dc Offset Tracking

Harmonic Distortion 5% THD Crest Factor 1.21 to 1.51 Output Frequency 15 to 50 Hz

Frequency tolerance ± 1 Hz

Output VA 100 VA Thermal Limiting Output VA may be reduced by reducing Vac when

Load Power Factor Operating: 0.5 Leading to 0.9 Lagging

Operating Temperature -40 to +75 °C See Output VA Thermal Limiting. Heat Dissipation 50 W (170 BTU / hr) Under Voltage Shutdown 50% of Output Vac Set Point

ac Component

Type of ringing Battery Backed Ground Backed Ground Backed no-dc

Error

65 to 100 Vac Factory Default: 100Vac

• -40 to +57 Vdc Battery Backed

• +40 to +57 Vdc Ground Backed

• 0 Vdc Offset Disabled

• dc Offset tracks dc Input Voltage

• Factory Default: Enabled

• Battery or Ground Backed is selected by Ringer

Chassis jumper J12 or by external connection of Ring Rtn to Battery or to Ground. Factory Default:

Battery Backed by Jumper See figures in the Ringer section. ± 3 Vdc

Factory Default: 20 Hz

operating simultaneously above 50°C and less than

-50Vdc input. Vac is reduced only sufficiently to prevent damage to the ringer.

No Damage: 0 Leading to 0.7 Lagging

While shutdown due to external fault, restart will be performed at approximately 2 minute intervals.

Table 2-K: QS840A and QS841A Control Unit Specifications

Operating Input Voltage Range 38 to 60 Vdc Input Power 6.0 watts maximum Plant Parameter Setting Through front panel LCD display and menu keys or with

IBM compatible PC with RS-232 port. 841 also has 10/100

Baset-T network ability Alarm Contact Ratings 60 Vdc, 0.5A, Form-C Operating Temperature -40 to +75 °C

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Table 2-L: QS845A Supplementary Board Specifications

Operating Input Voltage Range Input power through QS840A or QS841A Plant Parameter Setting None, communicates with shelf components QS840A/QS841A Alarm Contact Ratings None Operating Temperature -40 to +75 °C

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CPS6000 –48V Indoor/Outdoor Power Shelf

3 Engineering and Ordering

Engineering Information

Introduction

This section discusses the factors to be considered in determining the number of rectifiers and ringers required in both non-redundant and redundant battery plants.

Rectifier Sizing (Non-Redundant Systems)

In non-redundant systems, the installed rectifier capacity of the battery plant must be sufficient to provide the current required for the load during normal operations as well as the current required to recharge the battery following ac power outages.

For the telecommunications industry, the system load current is known as the average busyhour current. (The average busy-hour current drain is defined as the average busy-hour current drain during busy season with the plant operating at the normal voltage.) Therefore, the minimum installed rectifier capacity (mirc) is the sum of the average busy-hour (abh) current and the required battery recharge current, or

mirc = abh + recharge current

The battery recharge current is determined by two system considerations: the maximum time the system is required to operate in the absence of ac power (reserve time), and the time allocated to recharge the battery after ac power returns. These two times and Figure 3-1 may be used to determine the recharge factor. This factor, when multiplied by the average busyhour current, determines the minimum installed rectifier capacity, or:

mirc = abh x recharge factor

The mirc divided by the individual rectifier capacity determines the number of rectifiers (of equal capacity) required for a non-redundant system.

Rectifier Sizing (Redundant Systems)

In redundant systems, a spare on-line rectifier is included so that the loss of any one rectifier will not cause the available plant capacity to fall below the required minimum installed rectifier capacity. Thus, the loss of a rectifier will not affect the normal system operation nor will it cause the batteries to discharge, and will allow the batteries to recharge in the required time.

In cases where the additional spare rectifier will provide the required battery recharge current, the mirc satisfies the requirements for both non-redundant and redundant systems. In other cases, rectifiers in addition to the redundant rectifier may be required to provide the battery recharge current. Typically, the number of spare rectifiers required for a redundant system is the larger of one spare rectifier or 200% of the rated load.

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CPS6000 –48V Indoor/Outdoor Power Shelf

Figure 3-1: Recharge Factor vs. Recharge Time

Plant Configuration Examples

1. To illustrate the relationships between mirc, abh current drains, the recharge factor, and battery recharge current for non-redundant and redundant systems, consider the following examples. Note that the QS862A rectifier provides 25A at 54.5 Vdc (100-120 Vac) and 30A at 54.5 Vdc (200-240Vac).

A battery plant is required to provide a load current of 50 amperes, have an 8-hour discharge time (reserve time) and recharge to 95% of battery capacity in 24 hours. Determine the number of rectifiers required for non-redundant systems.

From Figure 3-1, the recharge factor is 1.38. mirc = abh x recharge factor mirc = 50 x 1.38 = 69 amperes

For low line ac using QS862A 25A (100-120 Vac) rectifiers, three rectifiers (69/25 =

2.76) are required to provide the minimum installed capacity of 69 amperes for a nonredundant system. If one rectifier fails, the remaining rectifiers will provide the abh capacity.

2. An alternate method to calculate the number of rectifiers necessary is to utilize power. In the above example, the requisite current is 50A. As most battery plant loads are looking into constant-power loads, the 50A would increase as the battery voltage decreases during battery discharge. Assuming the 50A is the current being drawn from the load at the plant float voltage of 54.5V, the total power being drawn by the load is 2725W (54.5V x 50A).

We can utilize the recharge factors from Figure 3-1 and use a modified mirc formula,

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CPS6000 –48V Indoor/Outdoor Power Shelf

therefore: mirc = power x recharge factor mirc = 2725W x 1.38 = 3761W

In this high line ac example using QS862A 1635W (200-240 Vac) constant power rectifiers, three rectifiers (3761/1635 = 2.3) are needed to support the load and recharge the batteries within the requisite time.

Ringer and Ringer Chassis

Ringer Chassis each support one 100 VA ringing output. Redundant ringing outputs require two Ringers in each Ringer Chassis.

Ordering Information

Ordering Guide

An ordering guide may be downloaded from the Lineage Power web site. This guide will augment the information found here.

Note: Ordering information here is presented only from the viewpoint of miscellaneous

item ordering and may not be complete. Complete System ordering should done using the ordering guide only.

Comcodes

The CPS6000 can be ordered by 9-digit numeric character sets called comcodes. The following guides you through the comcode selection process in creating a power system. Please refer to the product description section on the individual components for more details.

Power Shelves

Shelves are available in 23-inch (584 mm) and 19-inch (483 mm) rail widths. Mounting hardware is provided. Refer to Ordering Guide for other shelf types.

Baffle

A 1U tall baffle is available to mount between shelves, below the shelf or above the shelf. See Appendix F for application information.

Distribution Modules

The Platform has standard single slot, dual slot, front bulk and rear bulk output module options. An external 23” distribution panel is also available for systems with the bulk output. Battery breakers are available in lieu of the battery straps. However, maximum current allowed through each battery breaker is 50A instead of the 100A through the battery strap. For load breakers in a single slot distribution module, a max of two 60A load breakers can be used. If only a single breaker is used in the topmost position, a 70A breaker may be used

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CPS6000 –48V Indoor/Outdoor Power Shelf

Office Alarm Cable

WARNING

Disconnect alarm cable before cutting it to length. Cutting the alarm cable while it is

plugged into the controller will damage the controller.

A cable assembly is available that mates to the host-interface connector on the controller allowing access to alarms. This cable is terminated on one end with a connector that mates to the Distribution Module host-interface connector, and un-terminated on the other end. Refer to the ordering guide for cable lengths available

Distribution Module Circuit Breakers

The following bullet-style circuit breakers, which have been accepted for use in dc load and battery applications, are available for the current Distribution Module. These breakers only alarm for a trip condition. For a single slot distribution module, a max of two 60A load breakers can be used. If only a single breaker is used in the topmost position, a 70A breaker may be used

Size (Amps) Comcode Size (Amps) Comcode

3 407998137 25 407998194

5 407998145 30 407998202 10 407998152 45 407998210 15 407998160 50 407998228 16 407998178 60 407998236 20 407998186 70 407998244

Some versions of the distribution module accept breakers that alarm for trip or open condition. The comcodes for such breakers are provided below. These breakers can ONLY be used with specific distribution modules

Size (Amps) Comcode Size (Amps) Comcode

3 CC408606834 30 CC408606891

5 CC408606842 40 CC408606900 10 CC408606850 45 CC408606917 15 CC408606867 50 CC408606925 20 CC408606875 60 CC408606933 25 CC408606883

Caution - Please check the type of breaker the distribution module accepts before using the above comcodes

Pluggable Strap

Size(Amps) Comcode

100A Pluggable Strap CC109106548

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Distribution Module GMT Fuses

The following GMT fuses have been accepted for use in dc load applications, are available for the current Distribution Module.

Size (Amps) Comcode Size (Amps) Comcode

0.25 405006222 7.5 405725433

0.5 406976894 10 406159236

1.33 405673146 12 407845197 2 405181983 15 406473959 3 406976985 20 408555453 5 406159061

The following shows the possible fuse loading scenario for the Single-Slot and Double-Slot Distribution Modules. 20A fuse positions can be used only with factory wiring. When using 20A fuses, adjacent fuse positions must be left open.

For the Single-Slot Distribution Module with 10 GMT fuses, Field installation is only rated for 10A fuses. No more than 80A may be carried through the 10 fuse positions, or 40A through each half section. 15A and lower rated fuses may be used in any combination and position, as long as they do not violate the previous 80A/40A rule.

For the Single-Slot Distribution Module with 5 GMT fuses, a maximum load of 32 A is permitted with restrictions on the fuse positions. Specifically:

Position F1 defined as the bottom fuse position and F5 as the top fuse position.

1. Configuration #1 - F1+F2 <= 15A, F3<=15A, and F5+F4<= 10A

2. Configuration #2 - F1<=15A; F2=No Fuse; F3<=15A; F4=No Fuse; F5<=10A 3.

For the Double-Slot Distribution Module, each 8-fuse board can support a maximum of 80A.

Single-Slot Distribution Module

Position Max Fuse Position Max Fuse Position Max Fuse

10 10 15A 8 15A/20A

9 20A 9 7 8 8 15A 6 15A/20A 7 20A 7 5 6 6 15A 4 15A/20A 5 5 3 4 20A 4 15A 2 15A/20A 3 3 1 2 20A 2 15A 1 1 15A

(Arrows indicate

alternate positions)

Double-Slot

Distribution Module

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Controller

There are two controller options for the CPS6000. The QS840A system controller allows for control and monitoring of system functions and setting of all system parameters. The QS841 provides integrated Ethernet access and other enhanced features. Refer to Section 5 for more controller details and Appendix A for programming information. The QS845A supplemental kit allows up to 3 supplemental shelves to be controlled by the QS840A/QS841A controller on the primary shelf.

Rectifiers

The constant-power rectifiers each occupy a single slot in the CPS6000 shelf. If a full complement of rectifiers is not required, a rectifier slot filler may be to cover empty rectifier slots. The slot filler is not necessary from an earthquake standpoint.

Model Amperage Comcode

QS861A Rectifier 15A low and high line ac 108993531

QS852A Rectifier 20A high line ac CC109106440

QS853A Rectifier 25A high line ac CC109121290

QS862A Rectifier 25A low line/30A high line ac 108986704

QS864A Rectifier 40A high line ac 108994513

QS865A Rectifier 50A high line ac 108990074

QS850 Slot Filler N/A 108994273

Ringer Chassis

Ringer Chassis each occupy a single Power Slot in the CPS6000 Shelf.

Ringer Chassis Comcode

QS820M Ringer Chassis 108991262

Ringer Output Cable

Ringer Cables one per Ringer Output (Ringer Chassis).

Item Comcode

Ringer Output Cable H569-470 G kit – 15’ cable with connector for CPS6000/CPS2000 shelf on one end and unterminated leads on the other end. Ringer Output Cable – 150 ft CC848804765 Commercial - Molex:

Plug 39-01-4031 Socket (3 per plug):

Terminal Type 5556

16 AWG 39-00-0079 18 AWG 39-00-0059

Tool 11-01-0197

847922101

Commercial

Ringers

Up to two Ringers plug into a Ringer Chassis.

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One Ringer per Ringer Chassis is non-redundant (simplex). Two Ringers per Ringer Chassis is 1 + 1 redundant (duplex).

Ringer Comcode

QS820A Ringer 108990082

AC Power Cables

An ac power cable must be ordered. A standard ac cable set will not fit in the CPS6000 shelf. Verify that the sum of the input currents for all the rectifiers served by an ac circuit breaker does not exceed 80% of the breaker’s rating.

Table 3-A: Rectifier AC Input Current Table

Lineage

Power

Rectifier (A)

Model

Number of

Rectifier

Nominal

Input

Voltage

Number of

Rectifiers

per AC feed

Nominal AC

Current (A)

Minimum Circuit

Breaker value recommended

(A)*

75°C Minimum

Recommended

Wire Gauge

(AWG)*

120 1 7.8 15 14 120 2 15.6 20 12 120 3 23.4 30 10 120 4 31.2 40 8

15A QS861A

120 5 39.1 50 8 208 1 4.4 15 14 208 2 8.8 15 14 208 3 13.2 20 12 208 4 17.6 25 10 208 5 22.0 30 10 208 1 6 15 14 208 2 12 15 14

20A QS852A

208 3 18 25 10 208 4 24 30 10 208 5 30 40 8 208 1 7.4 15 14 208 2 14.8 20 12

25A QS853A

208 3 22.2 30 10 208 4 29.6 40 8 208 5 37.0 50 8 120 1 13.0 20 12 120 2 26.0 35 8 120 3 39.1 50 8

25/30A QS862A

208 1 8.8 15 14 208 2 17.6 25 10 208 3 26.4 35 8 208 4 35.3 45 8 208 1 11.8 15 14

40A QS864A

208 2 23.5 30 10 208 3 35.3 45 8

50A QS865A

208 1 14.5 20 12 208 2 29.1 40 8

*Conduit and further temperature deratings may be required in some installations .Cross-check table with local code and regulation requirements

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Thermal Compensation

Thermal Compensation: For thermal compensation, the QS873A Voltage/Thermal probe (VT-Probe) and its associated cables must be ordered. Refer to Section 5 for details on their interconnection, and Section 9 for more information on VT-Probes. The probe is provided with a weatherproof case.

Thermal Compensation/Voltage Monitoring: When voltage monitoring for battery string voltage imbalance detection is to be implemented in addition to thermal compensation, the VT-probe and its associated cables must be ordered. Refer to Section 5 for details on their interconnection, and Section 9 for more information on VT-Probes and voltage monitoring.

Remote Distribution Monitor Module

The Remote Distribution Monitor Module allows the CPS6000 system controller to monitor for open circuit breakers and fuses, monitor current through a battery shunt, and monitor/control low-voltage disconnect contactors at an external distribution panel that is bulk-fed from the CPS6000 system. See Section 11 for more details.

Inter-Shelf Kit for Multiple Shelves

Supplementary bulk-output shelves may be added to a bulk-output primary shelf to create a larger plant. Only the primary shelf requires a controller. The inter-shelf kit contains a QS845 shelf controller (with blank faceplate) and a connecting cable with connectors on both ends.

Refer to Appendix F for thermal considerations while paralleling shelves.

Lugs

Please refer to ordering guide H569-470 for lugs specific to distribution modules. The following table is generic and needs to be used in conjunction with the ordering guide.

Note: TEPS lugs in the WP91412 specification are Burndy parts. The Panduit and T&B (and any others) may have different dimensions.

WP-91412

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)

List

Comcode Burndy Equivalent Panduit Similar T&B Similar

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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4 Safety

Safety Statements

Please read and follow all safety instructions and warnings before installing, maintaining, or repairing the CPS6000 System:

• The CE Mark demonstrates compliance with the European Union Council Directives

for Low Voltage and EMC.

• The CPS6000 platform is Underwriters Laboratories (UL) Listed per Subject Letter

1801, DC Power Distribution Centers for Telecommunications Equipment.

• CPS6000 shelves equipped with QS820A ringers (in development) have hazardous

secondary voltages on the secondary bus output connectors.

• 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.

• 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).

• This equipment has been evaluated for continuous use in ambient temperature from -

40°C to 75°C when used with the QS862A rectifier.

• 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 and all local requirements for proper connections. All national and local rules and regulations should be followed when making field connections.

• Load connections to Bulk Output Modules should be made in close proximity to the

power shelf.

• The main output voltage (48V) meets SELV requirements.

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• 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.

• Battery 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 (J1) are not fused within the distribution

panel; therefore, current limiting protection for these contacts must be provided by external circuits. Maximum ratings for alarm 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 distribution panel must

not exceed 10,000A.

• AC branch circuits to this equipment must be protected with either fuses or circuit

breakers sized as required by the National Electric Code (NEC) and/or local codes. The maximum size of the over-current protector is based on the type of shelf. Refer to the equipment ratings to assure rating of equipment will not exceed 80% of the value of the protector chosen.

• An accessible ac disconnect/protection device to remove ac power from the equipment

in the event of an emergency must be provided.

• High leakage currents are possible due to contribution from simultaneous multiple AC

input connections. Earth ground connection is essential before connecting the ac source to the shelf. This connection must be achieved by ensuring that the C.O. grounding stud is connected as shown in the Installation Section, or quality service personnel shall ensure that the rack system is bonded per the provision below.

• In enclosed equipment cabinets, the CPS6000 mounting framework must be connected

directly to the cabinet ac service ground bus. For applications in huts, vaults, and central offices, the CPS6000 mounting framework must be connected to the system integrated ground grid.

• Installing fuses or circuit breakers not specified for use in these distribution 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.

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• While installing batteries, follow all safety precautions outlined in the appropriate

battery product manuals.

• The terminal block for the GMT fuse panel is rated for 20A with factory wiring, but

only 10A for field installation.

• All ac inputs for the J85470S1 L12 and L13 must be connected to maximum 60A panel

board breakers from maximum two ac conduit connections.

• CPS6000 outputs are not connected to earth. Earthing of rectifier outputs may be

performed externally to the shelf at a “ground window” or “mesh ground”. Connection of Ringer tip outputs to CPS6000 Battery or Ground is optional via Ringer Chassis jumper or external connection.

• The QS841 has an IEEE 802.3 compliant 10Base-T network interface with a

grounded connector shield.. Where intra building lightning surge protection is of concern, Lineage Power recommends the use of a shielded cable, where both ends are tied to ground. This cable must be supplied by the user. (example: CAT 5 E STP)

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CPS6000 –48V Indoor/Outdoor Power Shelf

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.

Indicates the presence of a hazard that will cause death or severe personal

DANGER

WARNING

CAUTION

injury if the hazard is not avoided.

Indicates the presence of a hazard that can cause death or severe personal injury if the hazard is not avoided.

Indicates the presence of a hazard that will or can cause minor personal injury or property damage if the hazard is not avoided.

This symbol identifies the need to refer to the equipment instructions for important information.

These symbols (or equivalent) are used to identify the presence of hazardous ac mains voltage.

This symbol is used to identify the presence of hazardous ac or dc voltages. It may also be used to warn of hazardous energy levels.

One of these two symbols (or equivalent) may be used to identify the presence of 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 precautions.” One of these two symbols may be used to identify the presence of a hot surface. It 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 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 accompanied by some type of statement, for example: “Fuses can cause arcing and sparks. Risk of eye injury. Always wear safety glasses.”

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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 ac inputs. Ensure that the appropriate

circuit protection device for each ac input being serviced is disconnected before servicing the equipment. Do not disconnect permanent bonding provisions unless all ac inputs are disconnected.

• Batteries may be connected in parallel with the output of the rectifiers. Turning off the

rectifiers will not necessarily remove power from the bus. Make sure the battery power is 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 ringer modules, hazardous voltages will be present on the ringer output connectors.

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.

• Test circuits before touching.

• 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.

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Special Installation Notes

Deutsch

Installationsanleitung

Eingangsspannung ( Voltage ) : 2x AC 120/200-240V V Eingangsstrom ( Current ) : QS801A, max 45A, QS800A, max 30A Eingangsleistung ( Watts ) : Nennfrequenz ( Frequency ) : 50 / 60 Hz

Seriennummer ( Assembly No. ):--

Modellnummer (Modell No. ) : QS801A, QS 800A

Abmessungen sind nur zur Referenz : 150mm x 22.5mm x 77.5mm ( Dimensions are for reference only )

Max. Umgebungstemperatur : max. 75 deg. C ( Max. Operation temperatur )

Achtung: Für kontinuierlichen Feuerschutz sollte die Sicherung nur mit einer des gleichen Types ersetzt werden. Sicherungswert : ( Warning : For continued protection against fire replace with same type and rating of fuse )

Das System ist ein Gerät der Schutzklasse I / Überspannungs Kategorie II ( Power Supply is a Class I equipment / overvlotage category II )

Ausgangsspannungen und -stöme: DC 58 V / SELV ( Output Voltage and Current )

--Das Gerät darf nur in Räumen mit beschränktem Zutritt aufgestellt werden. ( Nur ausgebildetes Personal )

--Nur für Aufstellung auf Boden oder einer anderen brennbaren Oberfläche geeignet.

--Das Gerät hat keinen eigenen Ausschalter, es muß daher mit einem Ein- und Ausschalter im Versorgungskreis versehen sein.

--Das Gerät ist für den Einbau in IT- Geräte in einem Rahmen bestimmt (siehe weitere Anleitung)

--Beim Einbau des Gerätes ist daraf zu achten das alle Anforderungen gemäß EN60950 eingehalten werden.

ACHTUNG: HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKREIS UNBEDINGT ERDUNGSVERBINDUNG HERSTELLEN

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Espanol

Notas especiales para instalaciones en países de habla hispana

• Instrucciones de instalación

(Installation Instructions)

• Voltaje (Voltage):

Vea tabla 2-A

• Corriente (Current):

Vea tabla 2-A

• Frecuencia (Frequency):

50/60Hz

• Voltaje y corriente de salida (Output Voltage and Current):

Vea tabla 2-A

• Temperatura máxima de operación (Maximum Operation Temperature):

75°C (167°F)

• Sin cabina contra incendios, suelo no combustible

(No fire enclosure, non-combustible floor)

• Evaluado en EN60950

(Evaluated to EN60950)

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5 Installation

CPS6000 Installation

Purpose

CPS6000 Shelf Installation guide for generic installations. Additional requirements are needed for application specific installations. Refer to Appendix F for spacing requirements.

Audience

Field application personnel.

Precautions

Observe ESD protection while installing circuit packs

Safety

• Always consider personal safety.

• Make sure the system is properly grounded per the National Electrical Code and local

building codes.

• Remove all metal jewelry before beginning the installation.

Installation Tools

•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

•48 Volt test load

Parts List

Single-Wide Distribution Module

Double-Wide Distribution Module

Ringer Chassis Shelf

Comcode Qty Description

801085119 802286773 802841635 407646330 408515823

7-22050-2 801085119 802286773 802841635 407646330

7-22050-2 848702007

7-22050-2 1 #4 Screw 901078717 8 12-24 mounting screw

3/8-inch bolt

3/8-inch lock washer

3/8-inch flat washer

Shelf plastic bushing

Fuse puller

#4 screw

3/8-inch bolt

3/8-inch lock washer

3/8-inch flat washer

Shelf plastic bushing

#4 screw

Spacer

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Installing the CPS6000 Shelf

CPS6000 Unpacking and Installation

There are two distribution options for the CPS6000, a Single-Slot Distribution Module and a Bulk Output Module. Only one distribution box can be used in a CPS6000 shelf. This hardware assembly is field installable, however in most cases the factory will have already installed the distribution module when it is required.

Step Action

1. Unpacking. Inspect the shipping container for any signs of damage. If damage exists, have the carrier’s representative sign a note acknowledging the damage.

2. Carefully cut the sealing tape and remove the shelf from the carton. Use the parts list to verify all materials are included. Save the shipping package until all parts are operating within specifications.

3. Is there a Distribution Module already installed in the right-most shelf position?

Yes - Go to the Install the

CPS6000 shelf section.

4. Remove the Distribution Module Assembly from the carton. The Assembly and the shelf will be shipped in separate cartons.

5. Is the Single-Slot or the Bulk Output Distribution Module being installed?

Bulk Output Distribution Module - Go to Step 8.

6. Slide the Assembly into the rightmost slot.

7. Verify the hook on the front engages under the shelf. See Figure 5-1.

No – Continue

Single-Slot or Double-Slot Distribution Module - Continue.

Figure 5-1: Distribution Module

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Step Action

8. Insert one #4 Screw inside the left side of the Bulk Output Module, hand tight to approximately 5 in-lb. See Figure 5-2.

9. Insert one #4 Screw on the right side of the shelf, hand tight to approximately 5 in-lb. See Figure 5-3.

10. Put a 3/8-inch lock washer and a flat washer on the 3/8-inch bolt. Locate the two access holes on the rear of the shelf. Attach the Distribution Module to the shelf with the washers and two bolts. Torque to 240 in-lb.

11. Cover the two access holes with the Black Plastic Covers shown.

Figure 5-2: Bulk Output Module

Figure 5-3: Distribution Module

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Install the CPS6000 Shelf

Important Note

The following procedures are in order for a typical application. If the left side of the shelf will be blocked after the shelf is installed in the framework, the following procedures should be done before installing the shelf:

• Inter-Shelf Connections (multi-shelf installations only)

• AC Connections

• Office Alarm Cable

• Thermal Probe Connection

Leave a sufficient service loop on these cables.

Install the CPS6000 Shelf

Follow the steps in the table below to mount the CPS6000 shelf into a 19-inch or 23-inch frame.

Step Action

1. Locate the 2 mounting brackets, one on each side of the CPS shelf; align the holes in the shelf-mounting bracket with the holes in the mounting frame. See Figure 5-4.

2. Attach the CPS shelf to the frame using a minimum of four (two on each side) of the 12-24 screws included in the supplied parts bag. Refer to the table below for Torque Specifications.

Hardware

Torque

Nm In-lbs.

Metric M5 4 35

12-24 4 35

Metric M6 7.3 65

Figure 5-4: CPS6000 Frame Mounting

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Controller

Controller Installation

The Controller mounts in the controller housing located on the left side of the CPS shelf, Figure 5-5. The Controller is field installable, however in most cases it will be factory installed.

Warning: You must properly protect the Controller against ESD discharge.

Note: There is an ESD cord connection located on the left side of the shelf.

Step Action

1. Does the CPS shelf have the Controller already installed? Yes - Proceed to the Rectifier

installation section

2. Slide the controller into the shelf until it is fully seated in the connector on the

rear of the CPS shelf. See Figure 5-5.

3. Connect one end of the display cable to the connector on the controller.

Connect the display faceplate to the other end of the display cable. Carefully dress the display cable when attaching to the shelf to ensure the cable does not get pinched.

4. Insert the tab on the bottom of the faceplate into the slot on the bottom of the

controller housing.

5. Push the display faceplate into the shelf until the latch on the top of the

controller housing catches.

No - Continue

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Figure 5-5: Controller Installation

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QS845A Supplementary Shelf Board

Multi-Shelf Installations

The QS845A allows up to four CPS6000 shelves to be paralleled. It can be used either with the QS840A or the QS841A controller. This board is installed in the controller position on supplemental CPS6000 shelves and enables the subsequent shelf equipment to communicate with the controller on the initial shelf. The following procedure is for installing the QS845A Supplementary Boards and making inter-shelf connections.

Install the QS845A Supplementary Shelf Board

Step Action

1. Does the system have a supplementary shelf? Yes - Continue No - Proceed to Thermal

Compensation Connections

2. Does the supplementary shelf have the QS845A controller already installed? Yes - Proceed to Thermal

Compensation Connections

3. Slide the QS845A into the shelf until it is fully seated in the connector on the

rear of the CPS shelf. See Figure 5-6.

4. Insert the tab on the bottom of the faceplate into the slot on the bottom of the

controller housing.

5. Push the display faceplate into the shelf until the latch on the top of the

controller housing catches.

No - Continue

Figure 5-6: QS845A Supplementary Board Installation

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Inter-Shelf Connection

Refer to Figure 5-7 for the following procedure.

Step Action

1. Connect a shelf-interconnect cable from P5 (SYS AUX PORT) on the primary

shelf controller to the shelf SHF 2 connector on shelf 2.

2. Using shelf-interconnect cables, daisy-chain the remaining shelves as required,

connecting from the TO NEXT SHELF connector, to the next applicable shelf connector as shown.

Figure 5-7: Inter-Shelf Connections

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Thermal Compensation Connections

Thermal Compensation

The optional QS837A VT-Probes are used to measure battery temperature for slope thermal compensation, and to measure battery voltage for battery voltage imbalance detection when the Voltage Monitoring Module 108958422 card is used. There is a maximum 18 probes.

Note: The number of probes per string is to be defined by the user. Typical installation requires 1 thermal probe per string of batteries.

Refer to Section 11 Peripheral Devices for more details about Voltage/Thermal Probes and the Remote Voltage Monitoring Module if required.

Note: Do Not mount the VT-Probe under a lug or battery strap. The probe mounts on top of the - lug or battery strap.

Note: Probes can be mounted prior to making the connections at the controller.

Step Action

1. Is the Voltage Monitoring option being used?

2. No - Locate the 848719795 Thermal

Probe Cable. Near the 3 Pin connector (Probe end), the volt sense wire has a 1 Pin connector on the end, cut and discard this wire and insulate the trimmed end.

3. Connect the 3 Pin Connector into the 3 position plug on the VT-Probe.

4. Connect the other end of the Thermal Probe Cable to the controller P5- SYS AUX

PORT connector. See Figure 5-8.

5. Are additional VT-Probes being used?

6. Yes - Using a interconnect cable

connect the 2 pin connector to the first thermal probe and then connect the next probe with the 3 pin connector, daisy chain until all probes are connected. See Figure 5-8.Two interconnect cables are available;

• 5 foot cable 848719803

• 10 foot cable 848719811

7. Attach probe case to each VT-Probe making sure the case pin inserts into the hole

on the probe. Close the case and verify the case is securely latched. See Figure 5-9.

Yes - Connect the 848652947 Battery Voltage Monitor Cable between the ES771A Battery Voltage Monitor Card and the controller P5- SYS AUX PORT connector. See Figure 5-10.

No - Complete.

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Figure 5-8: VT-Probe Connections to Controller

Figure 5-9a: Connecting Battery Monitor Voltage Wire to Thermal Probe Cable

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Figure 5-9b: Tie Wraps for strain relief and additional support

Figure 5-9c: Connecting Thermal Probe Cable to the battery

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Figure 5-10: VT-Probe/Battery Voltage Monitor Connections to Controller

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Office Alarms

An office alarm connector (J1) is provided on the QS840A/QS841A controller board. This connector provides access to the output of the alarm relays. Discrete wire and ribbon cable assemblies are available for making office alarm connections to the controller.

Step Action

1. Determine which office alarm connections are required per user specifications.

2. Make user-defined terminations of the Office Alarm Cable leads as shown in

Figure 5-11.

3. Connect the Office Alarm Cable to J1 on the QS840A Controller.

Figure 5-11: J1 Office Alarm Connector

Refer to Appendix E for an adapter cable that uses the CPS4000 alarm color scheme if required.

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Controller Connections

The QS840A and QS841A provide the same interfaces with the exception of the LAN connection which is available on the QS841A. The QS841A provides a standard RJ45 receptacle, P6, for the 10/100 Base-T Ethernet connection. Following is the view of the controller and its interfaces.

The QS841A has an IEEE 802.3 compliant 10Base-T network interface with a grounded connector shield. Where intra building lightning surge protection is of concern,

Lineage

Power recommends the use of a shielded cable, where both ends are tied to ground. This

cable must be supplied by the user. (example: CAT 5 E STP)

Connection to the LAN is made by attaching standard Cat-5 cable from P5 to the appropriate 10/100Base-T LAN connection. The cable should be appropriately dressed out of the CPS6000 system to the LAN connection. The shroud of P5 has been terminated to chassis to accommodate the use of a shielded Cat-5 cable connection.

AC Connections

AC Connections to Shelf

Review the ac connection on the installed shelf. Refer to Tables 3-B and 3-C for detailed CPS6000 rectifier ac input requirements.

Caution: Ensure ac power is OFF and use appropriate lock-out tag-out procedures before continuing with ac connections.

Caution: When connecting to utility source, ensure all local and national wiring rules are being complied with.

Caution: When routing AC cables ensure cable does not come in contact with sharp or rough surfaces that may damage insulation and cause a short circuit. Make sure cable does not come in contact with any pinch points such as doors.

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Step Action

1. Insert the H569-470A ac cord into the ac receptacles on the CPS shelf. Refer

Figure 5-12a, b, c or d for the appropriate shelf

2. Terminate the supply end of the cable with an appropriate plug (plug not

provided).

Figure 5-12a: Dual AC Input Connections

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Figure 5-12b: Single cord AC Input Connections

Figure 5-12c: Dual AC Input Cord (10 Awg, 10 ft) Connections

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Figure 5-12d: Rear AC Input Connections

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AC Connections to External AC Distribution Panel

CAUTION: Disconnect all AC branch circuits prior to making AC connections to the CPS6000 System.

Ensure ac power is OFF to the CPS6000 system before continuing with ac When connecting to utility source, ensure all local and national wiring rules are being complied with.

Figure 5-13: AC Input Connections

Refer to Rectifier AC Input Current table for input current values of rectifiers

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C.O. Ground Conductor Installation

Use an M6 double-hole lug on 5/8-inch center (Not provided) to terminate one end of the Central Office (C.O.) ground conductor to the CPS shelf. Terminate the other end of the conductor with a lug appropriate for the installation site. The C.O. Ground conductor can be top or bottom fed. 6 AWG is the maximum gauge that can be used with regular 5/8-inch center lugs. To use 2 AWG, a suitable narrow tongue lug like the Burndy/FCI may be evaluated.

Install C.O. Ground Conductor

This procedure is used to connect the Central Office Ground Conductor.

Step Action

1. Is the cable routed from the top?

2. Yes - Connect the conductor lug to

the bottom 2 positions for C.O. ground. See Figure 5-14a and b.

3. Connect the C.O. ground conductor to the top two mounting positions.

4. Attach the M6 screws and torque to 65 in-lb (7.3 Nm).

No - Continue.

Figure 5-14a: C.O. Ground Conductor Connection

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Figure 5-14b: C.O. Ground Conductor Connection

Rectifier Installation

Install the Rectifier

This procedure is used to install the rectifier in the CPS6000 shelf. Figure 5-15 is a 23-inch shelf with 4 rectifier positions and a Single-Slot Distribution Module.

Note: All rectifier ac and dc connections are made when rectifiers are seated in the shelf. Rectifiers will power up when ac is applied to the shelf.

Step Action

1. Before engaging the rectifier connector into the back of the rectifier slot, press

the Latch release button, the latch will spring open. See Figure 5-15.

2. Firmly push the rectifier into the rectifier slot until the connector on the rear of

the rectifier engages with the connector at the back of the rectifier slot on the CPS shelf. The latch will pop most of the way up when the rectifier is properly seated. Push the latch up into the latched position.

3. Repeat until all rectifiers are installed.

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Figure 5-15: Rectifier Installation

Ringer Installation

Install the Ringer Chassis and Ringer Modules

This procedure is used to install ringer chassis’s and ringer modules in the CPS6000 shelf. Figure 5-16 shows a shelf, Ringer chassis and a Distribution Module. Up to two Ringer Chassis’s may be installed per shelf, one in each of the two right-most power slots to the left of the Distribution Section. Each Ringer chassis accepts two ringer modules, a primary and a spare. For redundant ringing, install both Primary and Spare Ringers in each Ringer Chassis. The Ringer chassis and ringer modules are shipped separate.

Warning: Consider the Ring signal as hazardous voltage.

Warning: Ringer chassis’s and Ringer modules will be powered when installed in the shelf

when rectifiers and/or battery power is present.

Note: Ringer output connections are made after ringers are seated in the Ringer chassis.

Note: The primary and spare Ringer modules install facing opposite directions.

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Note: No rectifiers may be installed to the right of a Ringer Chassis.

Step Action

Slide the ringer chassis into the power slot until the connector on the rear of the ringer chassis engages with the connector at the back of the power slot on the shelf. Verify the hook under the front left of the ringer chassis hooks under the shelf.

2. Press down on the faceplate latch and open the faceplate. See Figure 5-16.

Secure the ringer chassis to the shelf using one #4 screw, hand tight to approximately 5 inlbs. See Figure 5-16.

4. Repeat until all ringer chassis’s are installed.

Figure 5-16: Ringer Chassis Installation

Step Action

5. Locate connector on rear of ringer module and the mating connector on the inside

rear of the ringer chassis. Align the ringer module connector with the ringer chassis connector. Place the ringer module in the guides and slide the ringer in until it fully engages with the connector at the back of the ringer chassis.

Note: The Ringer modules install facing opposite directions. See figure 5-17.

6. Repeat until all primary and spare ringer modules are installed.

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Figure 5-17: Ringer Installation

Step Action

7. Use Tip Jumper J12 to set the Ringer output type. See Figure 5-16 for J12 Tip

Jumper location. Note: Ringer output type is determined by connecting Ring Return (Tip) to Battery

or Ground. External connection of Ring Return (TIP) to Battery or Ground may be used with J12 in EXTERNAL position. Ringer output is disabled if Ring Return is not connected to Battery or to ground. See Section 10 for more information on Ringing Types.

Ringing Type

Ground Backed 1. TIP BAT Battery Backed 2. TIP GND Ground Backed – no-dc 2. TIP GND Also requires Controller configuration of

Externally Selected 3. EXTERNAL Requires external connection of Tip to

Tip Jumper J12 Position

Comments

dc Offset: Disabled

Battery or Ground.

8. Warning: Consider the Ring signal as hazardous voltage.

Connect Ringer loads using Molex 39-01-4031 connector, Socket Terminal to the HDR13 plug located inside the Ringer Chassis at the bottom-front. See Figure 5-

18.

9. Route ringer load cables through upper or lower notches in Ringer chassis and

distribution module chassis. See Figure 5-18.

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Figure 5-18: Ringer Load Cable and Routing

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Battery Strings Installation

Up to four battery strings can be connected to the CPS6000 Distribution Module.

Warning: Batteries contain hazardous electrical energy, sulfuric acid, and explosive hydrogen gas. Follow all precautions noted in the manufacturer’s literature accompanying the batteries.

Warning: If a battery disconnect switch is being used, mount the switch before proceeding and make sure it is in the OFF/OPEN position prior to making any connections.

Connect Battery Strings

This procedure is used to connect up to four battery strings to the CPS6000.

Step Action

1. If battery circuit breakers are required, remove the straps installed by the

factory and install the bullet-style circuit breakers into the bottom two positions in the Distribution Module. See Figure 5-19. Caution: Turn the circuit breakers to the OFF position until the unit is ready to be energized.

2. Place batteries on the battery trays in a 48 V string arrangement per

manufacturer’s instructions.

3. Make battery string V- and RTN connections to the Distribution Module.

Refer to the appropriate Figures 5-19b through 5-19e for battery string connections to Distribution Modules.

5. Secure the cables to the battery terminals with M6 nuts. Torque to 65 in-lb

(7.3 Nm).

Figure 5-19a: Accessing Battery String Connections

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Figure 5-19b: Battery String Connections – Single-Slot, No GMT Fuses

Figure 5-19c: Battery String Connections – Single-Slot, 5 GMT Fuses

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Figure 5-19d: Battery String Connections – Single-Slot, 10 GMT Fuses

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Figure 5-19e: Battery String Connections – Double-Slot

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Load Connections

Loads can be connected using 2 bullet-style circuit breakers, GMT fuses or Direct Bus Connections.

Double-Slot Distribution Module Note

Check if Double-Slot Distribution Module positions can be used for load positions, make connections as described here. Positions are converted from battery to a load positions using an adapter on the circuit breaker. This is described in the section, “Installing Circuit Breakers and Fuses.”

Terminate Load Connections - Bullet-Style Circuit Breakers

Two Circuit Breakers can be installed in the top two positions in the Distribution Module. The load terminals on the circuit breakers can secure cabling from 18 AWG (1mm2) to No. 2 AWG (33mm2).

Step Action

1. Insert Load breakers in the top two positions in the Distribution Module.

2. Terminate the load cables on the load buss with M6 nuts and torque to 65 in-lb

(7.3Nm). See Appropriate Figures 5-20a, through 5-20c for Distribution Module connections.

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Figure 5-20a: Rear Load Connections

Figure 5-20b: Front Load Connections – Single-Slot, 5 GMT Fuses

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Figure 5-20c: Front Load Connections – Single-Slot, 10 GMT Fuses; Double-Slot

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Terminate Load Connections - GMT Fuses

Single-Slot Distribution

When using 20 A fuses adjacent fuse positions must be left open. No more than 80A may be carried through the 10 fuse positions, or 40A per half-section. Up to 14 AWG wire can be used to connect loads to each of the fuse positions. See Figure 5-21 for fuse position and terminal block designations.

Double-Slot Distribution

The 16 GMT fuse position terminal blocks will accommodate 10 AWG wire. Each fuse board (A and B) has 8 GMT positions and is sized to handle up to 80A of total current and can support up to four 20 amp fuses if spaced properly. If 20A fuses are used, then adjacent fuse positions must be left empty. See Figure 5-22 for fuse position and terminal block designations.

Step Action

1. Strip 0.24 inches (0.6cm) of insulation from the wire.

2. Insert the stripped wire through the side of the shelf and into the screw

terminal. Torque to 4.5 in. lbs (0.5 Nm). See Figure 5-21 for Single-Slot, and Figure 5-22 for Double-Slot Distribution Modules.

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Figure 5-21: GMT Fuse Connections, Single-Slot Distribution Module

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Figure 5-22: GMT Fuse Connections, Double-Slot Distribution Module

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Circuit Breaker and Fuse Installation

Figure 5-23 and 5-24shows the proper circuit breaker and fuse orientation for installation. Retention bracket may or may not be provided with all configurations.

Figure 5-23: Circuit Breaker Retention Bracket

Figure 5-24: Circuit Breaker and Fuse Installation

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Terminate Load Connections - Direct to Bus Connections

The Distribution Module can be connected directly to the unprotected (no fuses or circuit breakers) dc output bus. Connections are made from the top of the unit. Lug covers are not

provided they must be ordered separately.

Warning: Cables terminated directly to the DC output bus in Figure 5-25 are unfused. Ensure

cables ends are protected before terminating cables.

Step Action

1. Terminate 45° lugs (with 1/4-inch holes on 5/8-inch centers) to bus landings

(hot spots) and torque M6 screws to 65 in-lbs. (7.3Nm).

2. Break tabs off back of lug cover (see Figure 5-25).

3. Insert the front post of the lug cover into the mounting hold and snap the tab

on the back of the lug cover into place.

Figure 5-25: Direct Connection to V+ (shown) / V- Output Bus

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Load Connections - Bulk Output

Bulk Output Distribution Option

Load connections are made to the Bulk Output Distribution Module as shown in Figures 526a or 5-26b or 5-26C

Figure 5-26a: Front Bulk Output Load Connections – up to 2Awg

Figure 5-26b: Large Cable (1Awg) Bulk Output Load Connections

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Figure 5-26c: Rear Bulk Output Load Connections

Battery and Load Connections - External DC Distribution Panel

Battery Cable Connection

Dress battery cables internal to the equipment frame up the right side of the frame to enter the top of a Group 163 distribution panel of H5694720 arranged for battery input.

Group 163 distribution panels are typically factory configured with four positions for battery input and eighteen positions configured for load outputs.

Figure 5-27: Distribution Factory Configuration

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Configure Additional Battery Inputs (optional)

Configure the distribution panel for the additional battery inputs as required, in groups of four.

Step Action

1. Remove breaker terminal posts in groups of four.

2. Install busbars.

3. Remove jumpers and reinstall as shown to separate the alarm contacts between

the battery input and load output sections.

If optional internal battery switches are required:

Install 1, 2, or 3 pole battery switches as required to match battery discharge current. Make sure switch is down, in the OFF position.

If optional internal battery switches are not required:

Install no-switch jumper busses as required.

5. Using a voltmeter, verify polarity of the battery cables.

6. Attach the POSITIVE cable to the RTN bus position in line with the switch.

7. Attach the NEGATIVE cable to the busbar directly above the switch.

8. Using a voltmeter, verify polarity of the battery connection between the RTN

and battery input bus.

9. Leave the switch in the OFF position until the unit is ready to be energized.

Figure 5-28: Remove Circuit Breaker Terminal Posts

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Figure 5-29: Install 4-String Battery Busbar

Figure 5-30: Relocate Alarm Jumper

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Figure 5-31: Jumper Locations in Completed 8-Position Configuration

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Figure 5-32: Battery and Load Connections to Distribution Panel

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Bullet Style Circuit Breakers

Comcode Amperage CB Positions Min Wire Gauge

407998137 3 1 10 407998145 5 1 10 407998152 10 1 10 407998160 15 1 10 407998178 16 1 10 407998186 20 1 10 407998194 25 1 10 407998202 30 1 10 408213486 40 1 10 407998210 45 1 8 407998228 50 1 8 407998236 60 1 6 407998244 70 1 6 407998251 80 1 4 407998269 90 1 4 407998277 100 1 2 408185353 125 2 2 408185346 150 2 1/0 408564941 200 3 2/0 408535752 250 3 4/0

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Initial Start-up

The system is ready to be powered up. Please verify all connections are as described prior to applying ac power.

Step Action

1. If using battery disconnect switches place them in their ON/CLOSED

positions prior to applying ac power.

2. Turn on the ac service circuit breakers to apply power to the CPS6000 power

system.

3. Verify that All LEDs on all components including rectifiers, controllers, LVD

boards, and remote voltage monitor modules are green.

4. Verify that the reading on the controller display is 54.5 Vdc. Note that if the

connected batteries are not fully charged, the voltage may be lower. If possible, open the external disconnect switches or activate the disconnect switches in the Distribution Module prior to making measurements.

5. If the conditions in Steps 3 and 4 are not met refer to Section 13,

Troubleshooting.

6. Refer to Section 6 for changing system parameters from the default settings if

required (float voltages, alarm thresholds, controller settings, etc.)

7. For QS841A only :

If network parameters have been obtained from the corporate network administrator and the controller is ready to be configured for network operations follow the steps below: Otherwise the installation is complete.

The following Network Configuration Parameters must be obtained from your Network Administrator before starting:

• IP address

• Subnet mask

• Host name

• Gateway IP address

Note: Host and Gateway may be optional.

Configuration of the network parameters may be done in one of two different ways:

(1) Easy View (2) Serial Port

8 Configuring the network parameters for QS841A only :

Using EasyView

Using a PC with EasyView running connected to J3 of the QS841A go to

Configure

parameters and click “OK” to save.

Port Communications Æ Network Port 1. Enter all network

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Serial Port

The appropriate IP address, subnet mask, hostname, and default gateway IP address must be configured on the QS841A through serial port J3.

To login to the QS841A, follow these steps:

a. Start-up the PC terminal program (Windows Terminal,

ProComm, etc.) using the following communication

parameters: Baud : 9600 Data : 8 Parity : none Stop : 1 Handshaking: none Flow Control: none

b. Connect the PC to the QS841A local port (RS-232) connector

c. Wait for any diagnostic messages to pass. d. Wait for the “ENTER PASSWORD:” command line prompt. e. Type the Network Administrator password (default:

administrator).

Wait for the “$” prompt.

8A Configuring Static Network Parameters

After a valid password entry, a login header with the following format similar to that below will be displayed:

Board Code QS841A Serial Number 05DJ09112345

Boot Block version 1.0 Application Code version 1.0 Default Web Pages version 1.0 Custom Web Pages not found

Ethernet Address 00-60-1D-00-5C-07 IP Address not configured Subnet Mask not configured Default Gateway not configured Host Name not configured

For assistance type help

Typing HELP at the “$” will show all available network administration commands and command line formats.

*note: 1) commands are not case sensitive

2) for the commands that follow, ddd is a number from 0 – 255

• To set the IP Address, type:

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CHA NET1,IP=ddd.ddd.ddd.ddd

Verify by typing:

STA NET1,IP

• To set the Subnet mask, type: CHA NET1,SUB=ddd.ddd.ddd.ddd Verify by typing: STA NET1,SUB

• Optional: To set the Default Gateway Address, type: CHA NET1,GTWY=ddd.ddd.ddd.ddd Verify by typing: STA NET1,GTWY

•

Optional: To set the Host Name, type: CHA NET1,HOST=“hostname” Verify by typing: STA NET1,HOST

8B Logging out of the QS841A MCU.

To terminate the configuration session, enter the “bye” command. The QS841A will notify the user if configuration is not complete. This message will have the following format:

NOTICE: Default Gateway may be required for network access. Host Name may be required for network access.

Logging off...

Messages referencing the Gateway and Host Name are acceptable, since these parameters are optional.

Note: If the IP address or Subnet mask messages appear, for example:

IP Address is required for network access. Subnet mask is required for network access.

Then the configuration procedure must be repeated.

8C Post Installation Procedure.

Once configuration has been completed

g. Disconnect the PC from the QS841A local port (RS-232)

connector J3.

h. After approximately one minute, observe the LEDs on the J3

network connector:

• Green - STATUS LED: ON

• Yellow - Link / Active LED: ON

The QS841A should be communicating over the network.

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6 AC, Alarm, and Control Cable

Reference Information

Overview

This section contains additional information (connector pin designations, etc.) that may be required for making, customizing, or troubleshooting system connections.

AC Utility Connection

Note: Each ac connection to the CPS6000 shelf is to be provided with circuit breaker protection at maximum 40A for a 23-inch shelf with dual ac feed and low-line (120V) input. For high-line (200-240V) input, a 40A circuit breaker is adequate.

CAUTION: Ensure ac power is OFF to the CPS6000 system before continuing with ac utility connection.

The 23-inch dual-feed shelf requires the H569-470 G50A ac cord, which consists of two sets and is unterminated at the utility end. Insert these into the ac receptacles on the CPS6000 shelf. Terminate the other end with an appropriate plug. Follow all safety rules provided with the plug when connecting the plug to the cable assembly. Refer to the following table for ac feed polarity.

AC Voltage

120V 200 to 240V Cable Color Code Cable Color Code

Line 1 Line 1 Black Brown Neutral Line 2 / Neutral White Blue Ground Ground Green Green / Yellow

Guide the utility end of the ac cords to the utility source. When routing cable, please ensure cable does not traverse any sharp or rough surfaces that may over time cause its insulation to abrade. Also, please be careful to route cables away from doors and the like to prevent any possible damage from pinching.

When connecting to utility source, ensure all local and national wiring rules are being complied with.

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Controller Connections

Figure 6-1 shows the Controller connector locations.

Figure 6-1: Controller Connectors for QS840 and QS841A

Shelf Paralleling Connector

J2 is a 4-pin connector provided on the controller for paralleling up to three additional shelves. This connector is accessible when the controller is inserted in the shelf. Two of the lines on the connector are used for inter-shelf RS-485 communication (RS485+, RS485-), two for shelf addressing, and one for the current share for rectifiers and one for V-. Pin assignments for this connector are shown in the following table:

Pin Signal Description

1 RS485+ RS-485 GP communication bus 2 RS485- RS-485 GP communication bus 3 RECT_PG_EN Programming enable signal to rectifier (future use) 4 ISHARE Rectifier analog current share

Auxiliary Port Connector

An RJ-45 receptacle (P5) is provided on the QS840A/QS841A board for connecting to the QS773X VT-Probes or to the QS771A Remote Voltage Monitor. This connector is accessible when the controller is inserted in the shelf. The signals and pin assignments for this interface are shown in the following table:

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Pin Signal Description

1 RS-485 + RS485 GP communication bus 2 RS-485 - RS485 GP communication bus 3 SIG_RTN Protected signal return for RS485 and 1-wire 4 5 1-Wire 1-wire communication signal 6 +5V Protected +5V Power 7 8

Local RS232 Serial Port Connector

A DB-9 connector (J3) with a male housing and female pins supporting a local RS-232 port with a subset of handshake signals is provided for local terminal access. This connector provides an isolated RS-232 communication port for notebook computers and PCs.

The local port pin assignments should take the assignment as a Data Circuit-terminating Equipment (DCE). This assignment is shown in the following table.

Pin Signal Description

1 RS-232 DCD *RS-232 Data Carrier Detect (output) 2 RS-232 TXD RS-232 Transmit (output) 3 RS-232 RXD RS-232 Receive (input) 4 RS-232 DSR RS-232 Data Set Ready (input) 5 RS-232 ISO GND RS-232 Isolated Ground 6 RS-232 DTR *RS-232 Data Terminal Ready (output) 7 RS-232 CTS RS-232 Clear To Send (input) 8 RS-232 RTS RS-232 Request To Send (output) 9 NC No Connect

* These signals are not necessary for supporting a local port connection.

LAN Connection (Ethernet)

A standard integrated RJ-45 receptacle (P6) is provided on the QS841A for connecting to an appropriate 10/100 Base-T LAN. P6 is shielded with the shield being tied to chassis. This connector is accessible when the controller is inserted in the shelf. The signals and pin assignments for this interface follow industry standard and are shown in the following table:

Pin Signal Description

1 TX+ Tranceive Data+ 2 TX- Tranceive Data3 RX+ Receive Data+ 4 n/c Not connected 5 n/c Not connected 6 RX- Receive Data7 n/c Not connected 8 n/c Not connected

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Auxiliary Alarms

Distribution Module

Four auxiliary alarm inputs are provided, auxiliary inputs 1 through 4, and are configurable through RS-232 interface of the controller. Auxiliary alarm inputs can be made on the AMM board. Remove the Distribution Module side cover and AMM board for access to the connector as shown. The auxiliary alarm input connector pin assignments are shown below.

Figure 6-2: P5 Auxiliary Alarms Connector

*Alarms are generated by connecting alarm contact inputs to Vminus, typically through a clean relay contact from the monitored device.

Alarm* 1 Auxiliary 1 2 Auxiliary 2 3 Auxiliary 3 4 Auxiliary 4 5 Return (Vminus/Battery)

Mating connector information for this 4-pin connector is as follows:

Housing: Amp part number 1445022-4 Contact (on a strip): Amp part number 794606-2 Contact (loose piece): Amp part number 794610-2

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Bulk Output Module

A fuse alarm input for monitoring an external distribution is available on the Bulk Output Module on connector J3, pin 1 (Figure 6-3).

Figure 6-3: Bulk Output Module Connectors

The input can be connected to a relay which provides system voltage on alarm. Pin 2 (V-) can be used to provide system voltage with a clean relay contact.

Additional Bulk Output Module Connections

Vsense-, Vsense+

Pins 1 and 2 (Vsense- and Vsense+) on J2 are wired to monitor system voltage internal to the Bulk Output Module. To monitor system voltage externally, unplug the mating connector from J2 and connect Vsense- and Vsense+ to the external source to be monitored.

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7A QS840A System Controller

Overview

The QS840A Controller provides system monitoring and control features, as well as office alarm outputs from rectifiers, LVD boards, and remote modules. This section describes the controller features, functions and alarms.

Controls and Display

Figure 7-1 shows the front panel controls and display of the controller.

Figure 7-1: QS840A Controller Faceplate

The backlight of the four-line LCD display changes color to reflect the system alarm status as follows:

Green Normal

Amber Minor Alarms Present

Red Major Alarms Active

The up and down arrow keys can be used to adjust screen contrast when the controller is displaying the default screen. Contrast adjustment is also available through the menus at Menu>Configuration>System Settings. At the default menu, the left and right arrows are also used to toggle the display from displaying the system voltage or the system load current. Otherwise, the left and right arrow keys are used to navigate the menus and the up and down arrow keys are used to change values when configuring the system. A black box highlighting a menu item indicates that the item has sub-menus.

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Connectors

Figure 7-2 shows a side view of the controller unit.

Figure 7-2: QS840A Controller Unit Side View

An isolated RS-232 connector (J3) is provided for local access or for connection to an external modem. The software interface is compatible with Lineage Power EasyView for Windows GUI software for PCs. Software support is also provided for use with Lineage Power Galaxy Manager for web-based remote access and monitoring.

The controller also includes six alarm relays. Two are pre-assigned as power Major and power Minor alarm relays. The four remaining relays are available as user-definable alarms and have been predefined for the various QS840A configurations.

Software

The software is functionally divided on the Main Menu into the following categories:

Alarms

Warnings

Status

Control/Operations

History

Configuration

The following figures show a map view of each category and the settings and operations found in each, and are followed by brief descriptions of the menu items. Alarms and Warnings are not hierarchal mapped and are presented in chronological order of occurrence when they are present. “No Active Alarms” or “No Active Warnings” will be displayed when they are no alarms or warnings detected by the controller.

Figures 7-3a through 7-3d provide a menu flow map of the QS840A controller software followed by brief descriptions of the menu items. Older or customer controller may have only some of the described menu items

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Figure 7-3a: Software Menu Map

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Figure 7-3b: Control / Operations and History Menus

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Figure 7-3c: Configuration Menu (part 1)

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Figure 7-3d: Configuration Menu (part 2)

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CPS6000 Controller Minimum Configuration

General Information

QS840A is the nerve center of the CPS6000 Battery Plant. The controller has six alarm relays; Two are pre-assigned as power major and power minor alarms. The four remaining relays are available as user-definable alarms to external devices.

QS840A

• Provides system monitoring and control features

• Controls alarm reporting from rectifiers, Low Voltage Disconnects (LVD), and other

system components.

User Interface and Display

Overview

QS840Aís primary user interface is a front panel display which includes the following:

• An array of simple push-button controls

• A backlit four-line LCD display that changes color to reflect the system alarm status as

follows:

Green Normal

Amber Minor Alarms Present

Red Major Alarms Active

Minimum Configuration

The Controller has many configurable parameters. All parameters are discussed in this section. The following steps cover the minimum configuration.

Key Description Function

Display Menu

Up and Down Arrows

Left and Right Arrows

Previous Menu

Press to access the menu. Display Menus, Refresh, Save Changes

Press to adjust values when configuring the system parameters. Also used to adjust screen contrast when the controller default screen is displayed.

Press to select the digit to adjust and navigate the menus.

Press to back up to a previous menu.

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Step Action

1. From the default screen, press the Display Menu key to see the Main Menu.

2. Press the down arrow key until Configuration is highlighted, press the Display Menu key and the following selections are available; Float settings, Shunt rating, Rectifier Redundancy, Batteries, Contactors, Boost, System Settings, and Communication Ports.

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3. The Float Settings option will be highlighted, press the Display Menu key to access the Float Settings Menu.

4. The Set Point option will be highlighted. Press the Display Menu key to view or change the Float voltage Set Point. Use the left and right arrow keys to adjust the Set Point voltage. Once the Voltage has been set to the desired value Press the Display Menu key to save the change. The voltage range is

42.0 to 56.5 Volts. Factory default is -54.5V.

5. Select Voltage Alarms to set the four Voltage Alarm thresholds.

Alarm Description

Very High Voltage Major

High Voltage Minor

BD (Battery on Discharge) Major

Very Low Voltage Major

Alarm occurs and the unit is shut down when the system detects voltage above its set threshold. The threshold can be set from 50V to 60V in 1V increments. The factory default setting is 57V

Alarm indicates an abnormally high output voltage but does not shut the unit down. The alarm threshold can be set from 50V to 60V in 1V increments. The factory default setting is 56V.

Alarm occurs when the system is operating either completely or partially on battery power. The alarm threshold can be set from 46V to 55V in 0.1V increments. The factory default setting is 51.0V.

Alarm indicates an imminent system shutdown due to discharging batteries or low output voltage. Factory default -

46.0V.

Note: Factory defaults listed are for the standard QS840A controller.

Status

This area of the menu provides an overview of system threshold settings, equipment operation, and present component values. Only state type information is available in this menu. No configuration or operations are possible from the Status portion of the menu system. Following are the elements available in the Status menu.

Rectifiers: Total installed capacity of the system, total output current of all rectifiers, and the individual rectifier currents by rectifier number (Gnn).

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Batteries: The following battery management information is available under Status:

Installed Capacity User entered system battery capacity in AH. Automatically entered

when using smart Lithium batteries.

On-Line Capacity Available battery reserve from installed capacity value directly

connected to the bus. It is always the same value configured for installed capacity except for when the smart lithium batteries are

utilized. Current Current flowing into or out of the batteries. Number Of Strings The total number of battery strings installed in the system. Highest Temp Highest battery temperature being measured by the thermal probes. Temp Probes Number of installed thermal probes. Mid-Cell Volts Number of installed Mid-cell voltage measurement modules. Battery Test Result Shows whether the most recent battery test was completed, and the

reserve time. Next Test The date of the next automatic battery discharge test. The automatic

discharge test feature must be enabled for this to work. Live Reserve Time Present value of battery reserve time calculated by the controller

Shunt Currents:

A maximum of six measured currents from each Distribution Control

and Monitoring module present in the system is displayed.

Disconnect States: The status of the LVBD (Low Voltage Battery Disconnect) and

LVLD1-3 (Low Voltage Load) disconnects are displayed. “None” is displayed if there are no contactors in the system.

Alarm Thresholds: Present alarm threshold settings in xx.xV format of the following system alarms:

Float Voltage Alarms

Boost Voltage Alarms

High Batt Temp Highest temperature being measured by the thermal probes Reserve Low Low battery reserve time High Ambient Temp High ambient temperature Low Ambient Temp Low ambient temperature

Ringer Thresholds: Present status of up to two ringer chassis:

State Ringer chassis present or not VA Output VA of ringer Primary Ringer module present in primary position Secondary Ringer module present in secondary/redundant position

Very High Major, Very High Minor, BD Major and Very Low Major

Very High Major and High Minor

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Enable-Disable Info: Displays the enable/disable status of the following features:

Temp Comp Temperature compensation Low Temp Comp Low temperature compensation Recharge Ilim Recharge current limit Auto Boost Automatic boost charge Auto Batt Test Automatic battery test Rect Redund Rectifier redundancy Mid-Cell V Mon Mid-cell voltage monitoring Imminent Shutdn Imminent system shutdown alarm (LVBD) Local Write Whether or not the system can be configured through the local port. Modem Write Whether or not the system can be configured through the modem port.

System Info: Various high level system statuses.

Controller Info Provides the versions of software for the overall controller

(QS840A_MC1), boot block of the controller, display, and the defaults. Date System controller present date using configured format. Time System controller present time using configured format. Ambient Temperature System controller present temperature using configured format.

Control/Operations

The following are the system control and operation functions that can be performed from the front panel. These operations are generally used in post installation and maintenance modes.

Start Lamp Test Temporarily illuminates all status indicators of attached rectifiers,

distribution monitoring and control modules and the system controller.

Restart Rectifiers Restarts all system serial controlled rectifiers. Does not affect

rectifiers, and other system devices that are already functioning.

Clear Events Used to clear momentary events or alarms. It clears the following

system alarms: Check Battery, Reserve Time Low, Battery Voltage Imbalance

Uninstall Equipment Clears alarms related to the removal of a system component such

as a rectifier, thermal probe, or voltage monitoring module. Alarm Test Initiates the asserting the Form-C alarms. Start Battery Test Initiates the manual battery test feature. A stop battery test

operation is displayed to interrupt the testing and return the unit to

normal operation. The manual battery test utilizes the configured

test duration and a system bus voltage threshold to represent the

end of reserve. Start Boost

Initiates the manual battery Boost feature. A stop battery Boost

operation is displayed to interrupt the Boost operation mode and

return the unit to normal operation.

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Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Introduction

Overview

Customer Service Contacts

2 Product Description

CPS6000 System Overview

Block Diagrams

Shelf Design

Configurations

Distribution and Power Module Configurations

Battery Reserve System

Specifications

3 Engineering and Ordering

Engineering Information

Ordering Information

4 Safety

Safety Statements

Warning Statements and Safety Symbols

Precautions

Special Installation Notes

5 Installation

CPS6000 Installation

Installing the CPS6000 Shelf

Install the CPS6000 Shelf

Controller

QS845A Supplementary Shelf Board

Thermal Compensation Connections

Office Alarms

Controller Connections

AC Connections

C.O. Ground Conductor Installation

Rectifier Installation

Ringer Installation

Battery Strings Installation

Load Connections

Circuit Breaker and Fuse Installation

Terminate Load Connections - Direct to Bus Connections

Load Connections - Bulk Output

Battery and Load Connections - External DC Distribution Panel

Initial Start-up

Overview

AC Utility Connection

Controller Connections

Auxiliary Alarms

Additional Bulk Output Module Connections

7A QS840A System Controller

Overview

CPS6000 Controller Minimum Configuration

User Interface and Display

Minimum Configuration