GE Industrial Solutions CPS6000-M2 User Manual
CPS6000-M2 Frame-Mounted Battery Plant
Model H5694720
Product Manual
Select Code 167-793-112
Comcode CC848802595
Issue 8
January 2008
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.
© 2008 Lineage Power
All International Rights Reserved
Printed in U.S.A.
CPS6000-M2 Installation Guide H5694720
Table of Contents
1 Introduction.................................................................................................................... 5
Document Objectives...................................................................................................... 5
Additional Product Documentation ................................................................................ 5
Customer Service Contacts............................................................................................. 6
2 Product Description....................................................................................................... 7
Architecture..................................................................................................................... 8
Millennium II Controller................................................................................................. 9
Rectifier Shelves ........................................................................................................... 10
QS-Series Rectifiers...................................................................................................... 12
QS-Series Ringers......................................................................................................... 12
AC Input........................................................................................................................ 14
Battery Options and Monitoring Features..................................................................... 14
DC Distribution and Battery Termination .................................................................... 15
Specifications................................................................................................................ 16
3 Safety............................................................................................................................. 21
Safety Statements.......................................................................................................... 21
Warning Statements and Safety Symbols..................................................................... 23
Precautions.................................................................................................................... 24
Handling Batteries ........................................................................................................ 25
Special Installation Notes ............................................................................................. 26
4 Installation.................................................................................................................... 28
Preparation .................................................................................................................... 28
Anchoring Frame .......................................................................................................... 31
Connecting Frame Ground............................................................................................ 32
Connecting Central Office Ground (COG)................................................................... 33
Connecting AC Utility .................................................................................................. 34
Installing Batteries ........................................................................................................ 35
Installing and Wiring DC Loads................................................................................... 40
Installing QS-Series Rectifiers...................................................................................... 44
Installing QS-Series Ringers......................................................................................... 46
Controller Connections ................................................................................................. 48
Installing Optional Circuit Packs.................................................................................. 55
5 Controller User Interface............................................................................................ 63
Controller Display Menu Maps .................................................................................... 70
Minimum Controller Configuration.............................................................................. 74
Controller Defaults........................................................................................................ 79
Web Interface................................................................................................................ 84
6 Acceptance Testing ...................................................................................................... 89
7 Troubleshooting ........................................................................................................... 92
Troubleshooting Controller Circuit Pack...................................................................... 99
Modem and Data Switch Cards .................................................................................... 99
Controller Alarm Descriptions.................................................................................... 100
Clear Events................................................................................................................ 104
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Uninstall Devices........................................................................................................ 105
Troubleshooting QS-Series Rectifiers ........................................................................ 105
Troubleshooting QS-Series Ringers ........................................................................... 107
Troubleshooting VT-Probes........................................................................................ 109
8 Ordering Information and Spare Parts .................................................................. 110
9 Product Warranty...................................................................................................... 118
Appendix A: Battery Functions................................................................................... 120
Appendix B: EasyView for Windows®........................................................................ 127
Appendix C: Upgrading Software Through Network Connection Or Craft Port.. 130
Revision History............................................................................................................ 134
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CPS6000-M2 Installation Guide H5694720
1 Introduction
Document Objectives
This manual provides installation and maintenance information for the Lineage Power
CPS6000-M2 power system:
• Product Description
• Safety Information
• Installation Procedures
• Test and Acceptance
• Troubleshooting
• Controller and Rectifier Operations
• Product Warranty
Audience
Equipment Installers – Instructions for installation, test, and acceptance.
Equipment Users – Plant basics and troubleshooting.
CAUTION: 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.
Applications
The 48V CPS6000-M2 is ideally suited for small central office (CO) applications and high end
huts and vaults.
Additional Product Documentation
For additional specification, engineering and installation information, refer to the following
drawings as needed. These drawings may be accessed on our web site at
http://lineagepower.com/. Click on Energy Systems Products/CPS6000 Plants.
Drawing Description
H5694720 Ordering Guide
167-790-063 Remote Peripheral Monitoring (RPM)
157-010-202 210E Thermal Probe Multiplexer Module
167-792-182 Advanced Features User Guide For The
Millennium II
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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 1-800THE-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, 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://lineagepower.com/
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2 Product Description
The 48V CPS6000-M2 Power Plant is a 23 inch wide, front access, frame mounted battery plant.
The system integrates QS series vertical airflow rectifiers and ringers, dc distribution options,
battery connections and the Galaxy Millennium II controller in 500A and 1000A capacity
systems. System dimensions are 25.5 inches wide, 15 inches deep and 29.8 inches tall (500A
system) or 38.5 inches tall (1000A system). This allows the system to be mounted in either a 42
inch (1/2 height) frame for mounting on a battery stand or Unigy battery stack or in a 7 foot (full
height) framework with battery trays.
The system operates directly from commercial power in 208/220/240Vac single phase @
50/60Hz. 110Vac operation is also available with some rectifiers. AC connects to a terminal
block panel at the top of the system.
48V CPS6000-M2 DC Power System Configuration
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Architecture
The plant architecture is shown in the diagram below. The CPS6000-M2 System rectifiers accept
alternating current (ac) power and produce a regulated dc -48V nominal voltage distributed to
float the batteries, power the controller and power the loads through distribution circuit breakers
or fuses. Batteries are used to provide backup dc power when the ac is lost. They are connected in
parallel with the rectifiers through either optional battery breakers or a low voltage disconnect
(LVD). AC power is distributed to each rectifier through ac terminal blocks located in the ac
termination panel at the top of the frame. The Millennium II system controller monitors and
controls system operation.
CPS6000-M2 Block Diagram
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Millennium II Controller
The Millennium II controller is located on the door of the dc distribution. It uses an RS485 bus to
serially monitor and control rectifiers, ringers and peripheral modules called RPM’s. It can also
monitor and control external power equipment, including standby generators, converter plants,
and inverters.
Local viewing and setting of system parameters and various alarm thresholds, user-definable
alarm inputs and relays can be accessed either by a LCD graphics display with intuitive
navigation mounted on the front door of the system or by the local RS-232 port connected to a
notebook computer.
Remote access is available through a 10/100 Base-T network connection to the world wide web
(internet) or your enterprise network (intranet) using standard browsers such as Microsoft Internet
Explorer® or Netscape® Navigator. There is also an optional BSM5 56k bps modem available.
The controller performs various battery management functions to ensure peak performance and
protection from thermal issues. In addition to monitoring for open battery breakers, measuring
current from the battery shunt and monitoring and control of a optional low voltage battery
disconnect contactor, the controller also measures battery string temperature and voltage with
either traditional analog thermistor based temperature probes or digital QS873 Voltage/Thermal
Probes (VT Probes) for slope thermal compensation. The VT probes connect in a daisy-chain
fashion with one probe mounted to the negative post of each mid-string battery using the serial 1Wire® bus.
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Rectifier Shelves
Rectifier shelves are equipped in either two shelf (500A system) or four shelf (1000A
system) arrangements. DC output from each rectifier is bused up the back to the
distribution and protected by clear lexan covers. Individual AC feeds from terminal
blocks in the ac box route down the ac duct to a connector on each shelf. Serial
communication cables daisy-chain from QS845A interface boards on the left side of each
shelf and up to the controller.
The system is designed to allow field upgrades from two shelf to four shelf systems. This
can be safely accomplished on working systems because the new shelves are first
installed and then bus and cable links added.
DC Bussing to Rectifier Shelves (Rear View)
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QS845A Rectifier Interface Board Access
Rectifier Communication Connections
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QS-Series Rectifiers
These constant power rectifiers are hot pluggable for quick installation. All interconnections (AC
input, DC output, and control) are made automatically during insertion. The rectifiers
communicate with the controller via a digital RS-485 serial cable allowing all rectifier settings to
be made automatically by the controller. Load-share circuits allow all rectifiers to apportion the
plant load equally, reducing the stress on individual units. The rectifier uses temperature
dependent variable speed fans to provide vertical flow cooling. QS-series of rectifiers are
available in 15A and 25A operating from 85VAC to 275VA and 20A, 30A, 40A, and 50A
operating from 150VAC to 275VAC.
QS-Series Rectifier
QS-Series Ringers
QS820A Ringers convert -48Vdc to a 100VA ringing power output with configurable ac voltage,
ac frequency, and dc offset. A ringer chassis may be installed in the two rightmost positions of
any rectifier shelf. Each ringer chassis includes two vertical airflow fans, accepts up to two
QS820A ringers, a primary and a spare, and provides a single ringing output. Install one ringer
for non-redundant (simplex) operation and two ringers for redundant (duplex) operation. Should
the primary ringer fail or be removed, the ringer output is provided by the spare ringer. The
controller provides ringer output voltage and frequency settings, status and alarm communication.
If communication is lost, the ringers continue to operate with the last received configuration.
QS820A Ringers and QS820M Chassis
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Types of Ringing
QS820 Ringers can be configured to provide one of three types of ringing: Battery Backed,
Ground Backed, and Ground Backed-no dc. Ringing type is selected with jumper J12 on the
chassis and by enabling or disabling dc Offset in the controller
Ground
(VBUS+)
Ring Return
tied to VBUS+
Voltage
(Tip wire)
Ring
(Ring wire)
-48Vdc
(VBUS-)
Ground
(VBUS+)
-48Vdc
(VBUS-)
Voltage
Ring
(Ring wire)
Battery Backed
(Common in USA)
Ring
(Ring wire)
Ground
(VBUS+)
-48Vdc
(VBUS-)
Ring Return
tied to VBUS+
(Tip wire)
Voltage
Ground Backed
No dc
Ring Return
tied to -48Vdc
(Tip wire)
Ground Backed
Ring Signaling Types
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AC Input
• Connects to AC termination
panel at the top of the
system.
• One 1-inch conduit per
shelf.
• Each rectifier fed
individually by 10 gage wire
protected with a 20A circuit
breaker or fuse.
Battery Options and Monitoring Features
Battery Options
• Designed for operation with Flooded, VRLA,
NiCad, and Lithium batteries (Nickel metal
Hydride in the future).
• Half-height systems mount on Unigy II
batteries, Full Height systems may be
equipped with battery trays.
• Battery trays available for up to 170Ahr
batteries with Anderson PowerPole®
connectors or circuit breaker disconnects.
Battery Monitoring Features
• Open String (OS) Alarms
• Emergency Power Off (EPO) for
disconnecting batteries from the system
• Temperature/voltage probes (up to 16) used in
Battery Management options
Slope Thermal Compensation
Battery High Temp Disconnect
• Battery Discharge Test
• Battery Shunt
Low Voltage Battery Disconnect/Reconnect Contactor (LVBD)
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DC Distribution and Battery Termination
Group 660 Option
• Two 19 position bullet
distribution panels each
rated at 400A.
• 12 pair of battery landings
for battery cables up to
350Kcmil. (6 pair with
750Kcmil cable) 3/8” studs
on 1” centers
• 8 position center section for
optional 800A Low Voltage
Battery Disconnect
(LVBD), GJ type circuit
breakers with 25mV shunts
or TPL-C fuse blocks with
1500A, 50mV shunts.
Group 661 Option
• One 19 position bullet
distribution panel rated at
400A.
• One fuse panel rated at
600A equipped with 4 TPS
fuses with 100A, 50mV
shunt monitoring and 4
TPL-B fuses with 600A,
50mV shunt monitoring
• RPM shunt monitoring for
fuse panel and up to 4
center TPL-C fuse blocks
with 1500A, 50mV shunt
monitoring
• 12 pair of battery landings
for battery cables up to
350Kcmil. (6 pair with
750Kcmil cable) 3/8” studs
on 1” centers
• 8 position center section for
optional 800A Low Voltage
Battery Disconnect
(LVBD), GJ type circuit
breakers with 25mV shunt
or TPL-C fuse blocks with
1500A, 50mV shunt.
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Specifications
AC Input
Input Distribution
Wire Size 10 AWG minimum for individual feeds.
System Voltage -48V
Maximum Output Current:
Two Rectifier Shelves (G255) 450A charge, 500A discharge
Four Rectifier Shelves (G256) 800A charge, 1000A discharge
Maximum Recharge Current Installed rectifier capacity minus plant -48V load
Low-Voltage Disconnect 39 to 50 Vdc
Low-Voltage Reconnect 39 to 55 Vdc
Safety Agency Approvals
VDE licensed to VDE0805/EN60950
European Economic Community
(EEC) Directives
Radiated and Conducted
Emissions
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
Operating Ambient Temperature -20 to 45 °C
Altitude -200 to 13,000 feet (-61 to 3962 meters)
Humidity 10% to 95% non-condensing
Audible Noise < 60 dBA
Earthquake Rating Zone 2 or Zone 4, upper floors, depending on battery configuration
Note 1: 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.
Terminal Blocks per rectifier fed from 20A breaker or fuse at the AC
service panel.
System Output
Safety / Standards Compliance
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
Rectifiers are individually UL Recognized (UL1950), cUL Certified
(CSA 22.2 234) or evaluated to EN60950 by an EC Notified Body, as
appropriate.
EMC Directive 89/336/EEC, Low Voltage Directive 73/23/EEC as
amended by Marking Directive 93/68/EEC
FCC Part 15, Class A
EN55022 (CISPR22), Class A
IEC 61000-4-11
Environmental
See Note 1
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Installation Category
CPS6000-M2 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-M2 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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Millennium II Controller
General Specifications
Input Voltage Range -48 Vdc (Range: 18-60V)
Maximum Input Power 36W depending upon options
Display Graphic displayed arranged to
8-line by 40-character backlit LCD
Configuration Method Through front panel LCD display and menu keys
Through IBM compatible PC with RS-232 port
Through LAN internet connection
Mounting Requirements Door mounted
Input/Outputs Specifications
Form C Alarm Output Contact Ratings 60VDC at 0.5A
Plant Voltage Measurement
Accuracy
0 to 50 °C (±.05% of full scale + 1
count)
-40 to 85 °C (±0.1% of full scale + 1
count)
Resolution
Plant Current Measurement
Accuracy
Resolution
Temperature Measurement
Accuracy
Thermistor temperature
One-Wire Serial probes
Resolution
4-20mA Input Monitor
Accuracy
Resolution
General (0-5V) Input
Accuracy
Resolution
48V Systems: ±40 mV
48V Systems: ±70 mV
0.01V
0 to +50 °C : ±0.5% of full scale
-40 to +85 °C: ±1.25% of full scale
1A
-5 to +55 °C: ±2°C
-40 to +85 °C: ±3°C
-5 to +55 °C: ±1°C
-40 to +85 °C: ±3°C
0.1°C
±100µA
±10.0µA
0 to +50 °C: ±0.5% of full scale
-40 to +85 °C: ±1.0% of full scale
0.01VDC
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Rectifiers
Item Specification
Nominal Output Voltage 48/52/54.5 Vdc
Operating Output Voltage
42 to 58 Vdc
Ranges
Boost Voltage 48 to 58 Vdc
Output Current QS861A: 0 to 15A at 54.5V
QS862A: 0 to 30A at 54.5V
QS852A: 0 to 20A at 54.5V
QS853A: 0 to 25A at 54.5V
QS864A: 0 to 40A at 54.5V
QS865A: 0 to 50A at 54.5V
Nominal Input Voltage QS861A: 100/120/208/240
Vac
QS862A: 100/120/208/240
Vac
Input Voltage Ranges QS861A: 85 to 275 Vac
(Shutdown from 135 to
150V)
QS862A: 85 to 275 Vac
QS852A: 208/240 Vac
QS853A: 208/240 Vac
QS864A: 208/240 Vac
QS865A: 208/240 Vac
QS852A: 150 to 275 Vac
QS853A: 150 to 275 Vac
QS864A: 150 to 275 Vac
QS865A: 150 to 275 Vac
(Shutdown from 135 to
150V)
Input Current QS861A: 8A at 120 Vac
4.4A at 208 Vac
QS862A: 13A at 120 Vac
8.8A at 208 Vac
QS852A: 7.4A at 208 Vac
QS853A: 7.4A at 208 Vac
QS864A: 11.8A at 208 Vac
QS865A: 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 at Full Load QS861A: 141W (480 BTU) per rectifier at 120 Vac operation
160W (546 BTU) per rectifier at 240 Vac operation
QS862A: 177W (604 BTU) at 100 to 120 Vac operation
212W (724 BTU) at 200 to 240 Vac operation
QS852A: 133W (454 BTU) per rectifier at 240 Vac operation
QS853A: 151W (515 BTU) per rectifier at 240 Vac operation
QS864A: 240W (819 BTU) per rectifier at 240 Vac operation
QS865A: 267W (911 BTU) per rectifier at 240 Vac operation
Selective High-Voltage
Above 58 Vdc
Shutdown
Backup High-Voltage
Above 60 Vdc for 1 millisecond
Shutdown
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Ringers
Item Specification
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
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
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
± 3 Vdc
Error
Factory Default: 20 Hz
100 VA
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.
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3 Safety
Safety Statements
Please read and follow all safety instructions and warnings before installing, maintaining, or
repairing the CPS6000-M2 System:
• The CE Mark demonstrates compliance with the European Union Council Directives for
Low Voltage and EMC.
• The CPS6000-M2 platform is Underwriters Laboratories (UL) Listed per Subject Letter
1801, DC Power Distribution Centers for Telecommunications Equipment.
• CPS6000-M2 shelves equipped with QS820A ringers 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 65°C.
• 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.
• The main output voltage (48V) meets SELV requirements.
• 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).
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• 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 board are not fused; 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.
• 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.
• An accessible ac disconnect/protection device to remove power from the equipment in the
event of an emergency must be provided. Disconnect all AC branch circuits prior to making
AC connections.
• 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.
• While installing batteries, follow all safety precautions outlined in the appropriate battery
product manuals.
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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 non-insulated 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:
Issue 8 January 2008 23
“Fuses can cause arcing and sparks. Risk of eye injury. Always wear
safety glasses.”
CPS6000-M2 Installation Guide H5694720
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.
• High leakage currents may be possible on this type of equipment. Make sure the equipment
is properly safety earth grounded before connecting power.
• 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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CPS6000-M2 Installation Guide H5694720
Handling Batteries
• To direct attention to the possible source of danger from battery gases, post one or more
warning signs, lettered in large characters, in a conspicuous location near the battery. For
example:
• Fully brief anyone who is permitted access to battery areas on the hazards of handling lead-
acid batteries. Make it clear to anyone handling, unpacking, or installing lead-acid batteries
that they contain electrolyte (sulfuric acid and water). Everyone must wear protective
equipment such as rubber gloves, rubber aprons, full face mask, and splash-proof goggles
when performing any activity involving handling of batteries or cells containing electrolyte.
• A storage battery gives no indication by its appearance of the potential energy stored in it.
All lead-acid storage cells/batteries have enormous short circuit capability which can result
in serious burns. Use extreme care to avoid shorting out cell and/or battery terminals.
Shorting a cell or battery with a non insulated tool can vaporize or throw the tool.
• All lead-acid batteries generate hydrogen gas, even under open circuit conditions. If not
permitted to escape, this gas can build up to explosive concentrations. NEVER tamper with
or block the vent caps of the 12IR125 battery modules. A damaged gas vent cap could
become clogged, resulting in an explosion due to internal pressure. Such an explosion could
short circuit other battery modules and result in a fire. ALWAYS place batteries in a wellventilated area. NEVER place battery modules in a sealed environment.
• In case of electrolyte contact with the skin, remove the electrolyte immediately by flushing
the affected area with large amounts of plain tap water. In case of electrolyte in the eye,
pour water into the inner corner of the eye and allow at least one quart of water to run over
the eye and under the eyelid. Eye injuries should be treated by a physician immediately.
Issue 8 January 2008 25
CPS6000-M2 Installation Guide H5694720
Special Installation Notes
Deutsch
• Installationsanleitung
• Eingangsspannung ( Voltage ) : 120/200-240VAC , DC 54VDC
Eingangsstrom ( Current ) : <15A per rectifier, DC 15A-1000A
Eingangsleistung ( Watts ) :
Nennfrequenz ( Frequency ) : 50 / 60 Hz
• Seriennummer ( Assembly No. ): J5694720
• Modellnummer (Modell No. ) : H5694720
• Abmessungen sind nur zur Referenz : 978mm x 648mm x 381mm
( Dimensions are for reference only )
• Max. Umgebungstemperatur : max. 45 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
Issue 8 January 2008 26
CPS6000-M2 Installation Guide H5694720
Espanol
Notas especiales para instalaciones en países de habla hispana
• Instrucciones de instalación (Installation Instructions)
• Voltaje (Voltage): 120/200-240VAC
• Corriente (Current): <15A per rectifier
Frecuencia (Frequency): 50/60Hz
• Voltaje y corriente de salida (Output Voltage and Current): 54VDC, 15A-1000A
Temperatura máxima de operación (Maximum Operation Temperature):
45°C (113°F)
• Sin cabina contra incendios, suelo no combustible
(No fire enclosure, non-combustible floor)
• Evaluado en EN60950
(Evaluated to EN60950)
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CPS6000-M2 Installation Guide H5694720
4 Installation
This section describes the following installation sequence for the CPS6000-M2 power system.
1. Preparations
2. Anchoring frame
3. Connecting frame ground
4. Connecting CO ground
5. Connecting ac utility
6. Installing batteries
7. Wiring dc loads and installing fuses/circuit breakers
8. Installing rectifiers and converters
9. Controller Connections
10. Starting Up System
Preparation
Safety
Please review all safety warnings in Section 3 before beginning the installation process. Observe
all warnings and labels on the equipment.
WARNING: Due to the possibility of working on energized circuits during these
procedures, all tools and test equipment must be insulated in an approved manner.
Proper ESD protection is required in order to prevent ESD damage to the
equipment.
WARNING: Only qualified personnel should install and service the power
system and plug-in modules. Hazardous energy and voltages are present in the
unit and on the interface cables and will shock or cause serious injury or death if
safety precautions are ignored. Follow all safety warnings and practices when
servicing this equipment.
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CPS6000-M2 Installation Guide H5694720
Wiring Guidelines
• All electrical connections should be made using the proper crimping tools and dies and
should be torqued to values specified.
• All building wiring should comply with the NEC and other applicable local codes.
• The temperature rating of the wire must be 90°C minimum.. Wire gauge must be sized based
on 75°C wire and the ampacity of the associated branch-circuit protection.
• Wiring internal to enclosed equipment cabinets must be rated no less than 105° Celsius.
Packaging
• All packages should be opened with a box cutter with the blade minimally exposed so that
only the sealing tape is cut.
• Save all packaging material until the system has been powered up and all parts are operating
within specifications.
Installation Tools
You will need the following tools to install and test the CPS6000-M2 System.
• Wire cutters and strippers
• Heat shrink gun
• 5/16-inch (8 mm) hex driver
• Digital meter with an accuracy of
±0.02%
• Screw drivers (flat-blade and Phillips)
• ESD wrist strap
• 48V test load
• Calibrated clamp-on dc current meter
(0.1 ADC sensitivity)
• Torque wrench
• Socket wrenches:
− 7/16” and 9/16” for load and
battery connections;
− 19 mm for anchor bolts;
− 12" extension for socket
• Masonry drill kit as required
• Compression for installation of various
compression lugs
• Protective canvas
• Insulating rubber mat
• Standard insulated installation tools,
screwdrivers, etc.
• Windows-based personal computer
laptop (PC) and cable to connect the PC
communications port to the local port of
the controller OR a CAT5 LAN cable.
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CPS6000-M2 Installation Guide H5694720
Accounting for Ship Loose Materials
QTY H5694720 Group COMCODE DESCRIPTION
60 660, 661 802841635 Flat Washer, 3/8
60 660, 661 801829607 Lock Washer, 3/8
60 660, 661 841064777 Nut Hex, 3/8
40 660, 661 230707-1 Amp Barrel Terminal
144 660, 661 901352617 Nut ¼ - 20
3 441, 451, 471 406954222 Cable ties for securing battery cables
1 441, 451, 471 CC848809104 2 gauge battery cable
2 440-471 901281444 Phillips flat head screws 10-32 x 3/8
3 440-471 848466884 Battery separators
1 440, 441, 451, 471 CC848768201 Front battery bracket
1 441, 451, 471 CC848770248 Clear cover for battery breaker
2 441, 451, 471 845143858 Screw 6-32 x ¼
2 101-104 CC408575947 ¼-20 x ¾-inch HH bolt
2 101-104 801829557 ¼-inch lockwasher
2 101-104 CC408576012 ¼-inch flat washer
1 104 CC848795385 Drill template
Torque Requirements
Torque (in-lb) Connection
10 AC terminal block screws
35 10-32 screw for dc rear covers and ac duct
35 12-24 frame-mounting screws
65 1/4-20 nuts for bullet panel loads
135 M8 bolts for large breaker and fuse kits and LVBD connections
240 3/8-16 nuts for large breaker and fuse load leads and all battery leads
Issue 8 January 2008 30
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