Tyco CPS6000 Product Manual
CPS6000
-48V Indoor/Outdoor Power Shelf
Product Manual
Select Code 167-102-105
Comcode 108992120
Issue 16
May 2006
This document is relevant to the following equipment series:
Controllers: QS840A App version 1.8 and defaults version Std-1.0
Rectifiers:
QS841A App version 1.2 and defaults version Std-1.0
15A QS861A 1:1E
20A QS852A 1:0D
25/30A QS862A 1:1G
40A QS864A 1:0C
50A QS865A 1:1D
Series
Notice:
The information, specifications, and procedures in this manual are subject to change
without notice. Tyco Electronics assumes no responsibility for any errors that may appear
in this document.
© 2006 Tyco Electronics Power Systems, Inc. (Mesquite, Texas)
All International Rights Reserved
Printed in U.S.A.
CPS6000 –48V Indoor/Outdoor Power Shelf
Table of Contents
1 Introduction..............................................................................................................6
Overview...................................................................................................................6
Customer Service Contacts.......................................................................................8
2 Product Description.................................................................................................9
CPS6000 System Overview......................................................................................9
Block Diagrams ......................................................................................................10
Shelf Design............................................................................................................13
Configurations.........................................................................................................14
Distribution and Power Module Configurations.....................................................15
Battery Reserve System ..........................................................................................16
Specifications..........................................................................................................17
3 Engineering and Ordering ....................................................................................25
Engineering Information.........................................................................................25
Ordering Information..............................................................................................27
4 Safety.......................................................................................................................35
Safety Statements....................................................................................................35
Warning Statements and Safety Symbols...............................................................38
Precautions..............................................................................................................39
Special Installation Notes .......................................................................................40
5 Installation..............................................................................................................42
CPS6000 Installation ..............................................................................................42
Installing the CPS6000 Shelf..................................................................................43
Install the CPS6000 Shelf .......................................................................................45
Controller ................................................................................................................46
QS845A Supplementary Shelf Board .....................................................................48
Thermal Compensation Connections......................................................................50
Office Alarms..........................................................................................................54
Controller Connections ...........................................................................................55
AC Connections......................................................................................................55
C.O. Ground Conductor Installation.......................................................................60
Rectifier Installation................................................................................................61
Ringer Installation...................................................................................................62
Battery Strings Installation .....................................................................................66
Load Connections ...................................................................................................69
Circuit Breaker and Fuse Installation .....................................................................75
Terminate Load Connections - Direct to Bus Connections ....................................76
Load Connections - Bulk Output ............................................................................77
Battery and Load Connections - External DC Distribution Panel ..........................78
Initial Start-up .........................................................................................................84
6 AC, Alarm, and Control Cable Reference Information.....................................87
Overview.................................................................................................................87
AC Utility Connection ............................................................................................87
Controller Connections ...........................................................................................88
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Auxiliary Alarms ....................................................................................................90
Additional Bulk Output Module Connections ........................................................91
7A QS840A System Controller ................................................................................92
Overview.................................................................................................................92
CPS6000 Controller Minimum Configuration........................................................98
User Interface and Display......................................................................................98
Minimum Configuration.........................................................................................98
7B QS841A System Controller ..............................................................................108
Overview...............................................................................................................108
Status.....................................................................................................................117
Control/Operations................................................................................................120
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 –48V Indoor/Outdoor Power Shelf
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 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
Tyco Electronics 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://power.tycoelectronics.com/
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CPS6000 –48V Indoor/Outdoor Power Shelf
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.
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. Ringers power ringing signaling outputs and
are powered by -48Vdc.
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
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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.
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.
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CPS6000 –48V Indoor/Outdoor Power Shelf
Figure 2-1a: CPS6000 System with Distribution Module
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CPS6000 –48V Indoor/Outdoor Power Shelf
Figure 2-1b: CPS6000 System with Distribution Module
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CPS6000 –48V Indoor/Outdoor Power Shelf
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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CPS6000 –48V Indoor/Outdoor Power Shelf
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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CPS6000 –48V Indoor/Outdoor Power Shelf
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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CPS6000 –48V Indoor/Outdoor Power Shelf
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
5
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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CPS6000 –48V Indoor/Outdoor Power Shelf
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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CPS6000 –48V Indoor/Outdoor Power Shelf
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: QS860A 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 9.2A 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 4.9A at 120 Vac
2.9A 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) 108W (369 BTU) at 120 Vac operation
100W (341 BTU) at 240 Vac operation
Power Factor >0.98 (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: 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
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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-F: 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
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-G: QS853A 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 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
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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-H: 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%
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-I: 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
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
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range dc to 100 MHz
CPS6000 –48V Indoor/Outdoor Power Shelf
Selective High-Voltage Shutdown Above 58 Vdc
Backup High-Voltage Shutdown Above 60 Vdc for 1 millisecond
Table 2-J: 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
Table 2-K: 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
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
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CPS6000 –48V Indoor/Outdoor Power Shelf
Thermal Limiting Output VA may be reduced by reducing Vac when
operating simultaneously above 50°C and less than
-50Vdc input.
Vac is reduced only sufficiently to prevent damage to
the ringer.
Load Power Factor Operating: 0.5 Leading to 0.9 Lagging
No Damage: 0 Leading to 0.7 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
While shutdown due to external fault, restart will be
performed at approximately 2 minute intervals.
Table 2-L: 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
Table 2-M: 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,
Issue 16 May 2006 26
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 Tyco Electronics Power Systems web site.
This guide will augment the information found here. To download, go to
http://power.tycoelectronics.com/es_cps6000.html and click on the CPS6000 System
Ordering Guide link.
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
Distribution Module Lugs
The 3.4-inch wide Distribution Modules require M5 double hole lugs on 5/8-inch centers for
battery breaker and CO ground connections. Straight lugs may be used for most applications.
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.
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 25 CC408606883
5 CC408606842 30 CC408606891
10 CC408606850 40 CC408606900
15 CC408606867 45 CC408606917
20 CC408606875 50 CC408606925
Pluggable Strap
Size(Amps) Comcode
100A Pluggable Strap CC109106548
Distribution Module GMT Fuses
The following GMT fuses have been accepted for use in dc load applications, are available
for the current Distribution Module.
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CPS6000 –48V Indoor/Outdoor Power Shelf
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, 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 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
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. Check with Sales Team
regarding availability
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CPS6000 –48V Indoor/Outdoor Power Shelf
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.
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.
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.
Issue 16 May 2006 30
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