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ABB CPS2400U, Product Manual

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Page 3

 

© Copyright 2021 ABB. All rights reserved. 

 

 

PRODUCT MANUAL

 

CPS2400U Upstream System –

 19”

 

Remote Power System

 

48 V

dc

 Input, ±190 V

dc

 Output Converter/Limiter System

 

TABLE OF CONTENTS

 

Table of Contents

 ...................................................................................................................................... 

3

 

Table of Figures 

 ········································································································································ 

5

 

Table of Tables  

 ········································································································································· 

6

 

Introduction

 ··············································································································································· 

7

 

Reference Documents

 ····································································································································· 

7

 

Customer Service Contacts

 ···························································································································· 

7

 

On

-

Line Power Systems Product Manuals and Software

 ·········································································· 

7

 

Product Description

 ·································································································································· 

9

 

Operation

 ······················································································································································· 

10

 

Configurations

 ··············································································································································· 

11

 

Installation

 ··············································································································································· 

13

 

Prepare for Installation

 ································································································································· 

13

 

Mount Shelves

 ··············································································································································· 

14

 

Ground Converter Shelves

 ···························································································································· 

16

 

Connect Input Power

 ····································································································································· 

16

 

Connect Load Wiring

 ···································································································································· 

20

 

Inspect the Network

 ····································································································································· 

.21

 

Install Controller

 ············································································································································ 

22

 

Set Shelf ID

 ····················································································································································· 

23

 

Install Inter

-

Shelf Signal Cables

 ·················································································································· 

25

 

Connect Office Alarms

 ································································································································· 

25

 

Connect Local Network

 ································································································································ 

26

 

Install Converters

 ···········································································································································

27

 

Apply DC Power

 ··············································································································································

27

 

Verify Normal States

····································································································································· 

28

 

Verify UL Installation Compliance

 ·············································································································· 

28

 

Configure Controller

 ····································································································································· 

28

 

Confirm Operation of Alarm Wiring

 ··········································································································· 

29

 

Troubleshooting

 ······································································································································ 

31

 

System

 ····························································································································································· 

31

 

Alarm Card

 ······················································································································································ 

33

 

Summary of Contents for CPS2400U

Page 1: ...Page 1 Copyright 2021 ABB All rights reserved PRODUCT MANUAL CPS2400U Upstream System 19 Remote Power System 48 Vdc Input 190 Vdc Output Converter Limiter System Jl ll ll ...

Page 2: ...Page 2 Copyright 2021 ABB All rights reserved This page intentionally left blank Jl ll ll ...

Page 3: ...e 7 Product Description 9 Operation 10 Configurations 11 Installation 13 Prepare for Installation 13 Mount Shelves 14 Ground Converter Shelves 16 Connect Input Power 16 Connect Load Wiring 20 Inspect the Network 21 Install Controller 22 Set Shelf ID 23 Install Inter Shelf Signal Cables 25 Connect Office Alarms 25 Connect Local Network 26 Install Converters 27 Apply DC Power 27 Verify Normal States...

Page 4: ...cifications 42 Dimensions 43 Standards Compliance 44 Installation Area 44 Installation Environment 44 Installation Category 44 Safety 45 Safety Statements 45 Precautions 47 Appendix A Operating Temperature Measurement and Vertical Spacing 48 Appendix B Alarm Reference Table 50 Appendix C Operation without a Controller Alarm Wiring 52 Appendix D Installationsanleitung 55 Revision 56 Jl ll ll ...

Page 5: ...arm Card Removal 23 Figure 16 Shelf ID Setting 24 Figure 17 Inter Shelf Cables 25 Figure 18 Controller Office Alarm Connector 25 Figure 19 Controller Network Wiring Connection 26 Figure 20 ESD Jack 27 Figure 21 Converter Installation 27 Figure 22 Normal LEDs 28 Figure 23 Alarm Card LEDs 33 Figure 24 Converter LEDs and Test Points 35 Figure 25 Fan Locations 37 Figure 26 Office Alarm Connections wit...

Page 6: ...larm Card State LEDs and Relays 34 Table 4 Converter LEDs 36 Table 5 Controller Office Alarm Cable 38 Table 6 Converter Shelf Output Connector Pinout 39 Table 7 Lugs 41 Table 8 Specifications 42 Table 9 Minimum feed Loop Length for 10 000 A Short Circuit Current 43 Table 10 Alarm Reference Table 50 Table 11 Converter Shelf Alarm Card States 52 Jl ll ll ...

Page 7: ...lude initiating the spare parts procurement process ordering documents product warranty administration and providing other product and service information ABB phones are staffed from 7 00 am to 5 00 pm USA Central Time Zone GMT 6 Monday through Friday on normal business days At other times this number is still available but for emergencies only Calling from Phone Number United States Canada Puerto...

Page 8: ...Page 8 Copyright 2021 ABB All rights reserved This page intentionally left blank Jl ll ll ...

Page 9: ...s Converter System Up to 24 converter shelves 576 output circuits Converter Shelf 19 shelf Front access mid mount 12 Converter Card Slots 24 output circuits Alarm Card Relays Major and Minor Form C Output Connector Redundant A and B 48V feeds Converter Cards Two independent dc dc converters per card 190 Vdc output safety limited to 100VA and Ground Fault protected 48 Vdc input Redundant A and B fe...

Page 10: ...he line every 4 seconds and will re energize if the wiring fault is cleared A serial communication bus links each converter to an alarm card at the end of each shelf The alarm card provides major and minor form C contacts manages the converters and relays information to an optional system controller using Galaxy Protocol over an RS485 bus Up to 24 shelves can be controlled and monitored by one sys...

Page 11: ...elf not required in systems without Controller Converter Shelf Stack 1 to 3 Converter Shelves 1 or 2 Fan Shelves 1 Baffle Baffle Controller in Primary Fan Shelf Baffle Converter Shelves 1 to 3 Fan Shelves 1 or 2 Converter Shelves 1 to 3 Fan Shelves 1 or 2 Converter Shelf Stack Primary with Controller Converter Shelf Stack Secondary no Controller Figure 2 Configuration I r I I a g I Cl 111 1 0 io I...

Page 12: ...Page 12 Copyright 2021 ABB All rights reserved This page intentionally left blank Jl ll ll ...

Page 13: ...n Installation The system has been designed for mounting in relay racks or in equipment cabinets It is designed for use with user provided vertical airflow Follow site specific engineering instructions to assure proper airflow for the specific installation Refer to the Vertical Spacing Airflow Baffles and Fan Shelves section for general spacing requirements Follow site engineering instructions Con...

Page 14: ...table operating environment for the equipment Then unpack the equipment Step Action 1 Before opening the packaging carefully inspect the outside in the presence of shipping personnel for signs of damage 2 Carefully open the packaging to verify that the contents are complete and undamaged 3 dam m 4 Save the shipping packaging until all parts are operating within specifications If the equipment must...

Page 15: ...Page 15 Copyright 2021 ABB All rights reserved Figure 3 Fan Shelf Mounting Figure 4 Baffle Mounting Figure 5 Converter Shelf Mounting Jl ll ll ...

Page 16: ...leadto safety grounding point frame ground or main ground bar per loc al practice Apply NO OXID to all bare metal connections Ifrequired by local practlce Torqueto351n lb 4Nm ure 6 can enerShelf llllUld Lugs landings 1 4 studs on5 rcenters Lugs fot 6AWG conductor TIB 6STR30W Burndy YAV6C l 2TCA FX or available equivalent ConverterShelves Comect Power ConnectyourpersonalESD straptotheESDJ konthelef...

Page 17: ...nections to be installed Turn off circuit breakers and remove fuses Verify with a Volt meter 4 Turn OFF circuit breakers assigned to this frame and verify with an volt meter 5 Open the distribution panel door on the right end of the shelf Ftpwe 8 OolNffltr SIMlf DC CGnnea1ons Aams Jl ll ll ...

Page 18: ... 1 7Nm 5 Repeat from 2 for all wires 6 Push connector straight onto its header Figure 9 Converter Shelf Input Power Connections 7 Close the distribution door Repeat from Step 2 for each Converter Shelves 48V A 1 6 48V B 1 6 RTN 1 6 RTN 7 12 48V A 7 12 48V B 7 12 A 48V 1 6 Input B 48V 1 6 Input RTN 1 6 RTN 7 12 A 48V 7 12 Input B 48V 7 12 Input Screw 2 Reference NEC Table 310 16 for applications of...

Page 19: ...ch is independent from the converter shelf 3 Fuse externally at 10 Amps 4 Use ring lugs or alternate per local practice 5 Returns for the A and B feeds are shared on the 48Vdc RTN 6 The right position on the terminal block is the frame ground for the Fan Shelf 7 Connect de energized DC cabling typically 16 AWG as shown here 8 Connect Frame Ground wire Figure 10 Fan Shelf Input Power Connections Re...

Page 20: ...solid orstranded AMP552173 1 orequtvalent 24AWG solid or stranded or 26AWGsolidAMP 229974 1 orequivalent Jl ll ll Theconnectormustbearrangedwith arightanglehousing suchthatthecableexttstotheptn1side Vertfy rating af all wire between die equipment and the primaryprotectors 26A WGmlnlmum 21 0Vrated minimum Verifyprimaryprotection consistent with UL497 isinstilled on all the telecommunication line Ci...

Page 21: ...nce to ground on each line of the circuit less than 10μF The QS982 introduces 4 4μF The remote electronics and line must introduce less than 5 6 μF of capacitance Is the total capacitance line to line of the circuit less than 40μF The QS982 introduces 2 2μF The remote electronics and line must introduce less than 37 2 μF of m Is the remote equipment also a RFT V voltage limited circuit Both ends o...

Page 22: ...rt between tip and ring Note 1 This step is shown here only for completeness It is to be performed after the Apply DC Power section is completed 2 Circuit powering is usually accomplished by closing the circuit using a 5 pin protector after DC power applied to the system Install Controller Step Action 1 2 Screw Remcwethe cowrfromthe left hand end oftha PrimaryFanShelf withthedisplay Flglft12 Fan S...

Page 23: ... Set ID address of each shelf to a unique value Systems Without Controller ID address not used Step Action 1 2 Open the distribution door Remove the alann card Jl ll ll Brlngdocirto aposltlonbef_ _ _ alumcud Flglft 14AlumeaidAaless Doorn111tbefullyap111to _alann cud Figu l5Alllfflc rdllttn 91 ...

Page 24: ...B All rights reserved Step Action 3 Use a small Phillips screw driver set to 2 for12 cards per shelf 4 Shelf 6 Shelf 5 Shelf 4 Shelf 3 Shelf 2 Shelf 1 Shelf 6 Setting Shelf 1 Setting Cards per shelf 1 12 12 12 12 0 0 6 UNIT TEN ...

Page 25: ...e Alarms See Appendix C Operation without a Controller Alarm Wiring for systems without a controller Step Action 1 1 Controller 2 See footnote on page 26 Install only as shown Inter Shelf Cable to Bottom Fan Shelf of Converter Shelf Stack above if present Inter Shelf Cable to Top Converter Shelf of Converter Shelf Stack below if present Inter Shelf Cables Top P1 and bottom P2 shelf connectors have...

Page 26: ... connection IPaddress assigned to the controller Prass the square key a on the upper right hand comerofthe keypad to display the menu Pressthedown arrow key 2timesto scrolldown tothe Status item on tile menu Pressthe rightarrow II toadvancetothe Status menu Press die down arrow key repeatedly to scroll down to die Networtc Settings Item and select by Pnissthe right arrow toadvanmtodie NetworkSitti...

Page 27: ...top and bottom of the slot 2 Slide the converter into the slot 3 Push firmly seat the converter until the converter latch engages 4 Repeat from Step 2 for remaining Converters 5 Install empty slot fillers into all unused slots of multi shelf Converter Shelf Stacks Apply DC Power Fault LEDs will flash red until communications is established between the system components see Verify Normal States for...

Page 28: ...put If red lights do not flash there is no leakage path to ground at operating voltage If the FLT light does not blink yellow there is no hard short between tip and ring Note Circuit powering is usually accomplished by closing the circuit using a 5 pin protector with DC power applied to the system Configure Controller Refer to Galaxy Pulsar Edge Quick Start Guide Verify and edit controller paramet...

Page 29: ...sures If alarm wiring is correct 1 The loss of A or B input power should result in the assertion of a Power Minor 2 The loss of both A and B input power which will result in a loss of service should result in a Power Major and a Power Minor 3 If a controller is installed in the system then it will indicate an alarm state by red display backlight Using the buttons on the keypad specific alarms can ...

Page 30: ...Page 30 Copyright 2021 ABB All rights reserved This page intentionally left blank Jl ll ll ...

Page 31: ...mmunication Communication Clrc ultFall Back llowar Red RIii State Al11111Cud Alarm Flashing Ralay Stata LED Alann Flashing Flashing Flashing 81111 Plwlem Jl ll ll 81111 Salutlan Execute Controller commands Latdled Controller Alarm Clear EYents and UnlMtall orAlarm for RemOYed Eqq ment Short to ShorttoGround 1card RemOYed controller control o at1o111 web Pages Maintenancetab Malcesureeach converter...

Page 32: ...ing wlll Interruptserviceto theotlllr NneSIMld bythe onwrta I Fan Tray Failed Replacefan shelfortray 1of6 fansFailed onone Replacafan shelfortray FanShelforTray 2 FanShelvesorTrays Replacefan shelves or trays Al 6Power Fall B1 6 PowerFall Restore DC Input powerto theAl Input terminal Restore DC input POWW flowing to the Bl 6ln ut A l2PowerFail DC power to the A7 12 input 87 12 PowerFall Restore DC...

Page 33: ...dicate the combined alarm state of the shelf including Converter Cards and 48V input voltage feeds State A1 6 B1 6 A7 12 B7 12 B Green Green OK Low Red Green Minor Low Green Red Minor Low Red Green Minor Low Green Red Minor Low Low Red Red Major Low Low Red Green Major Low Low Red Red Major Low Low Red Red Major Low Low Green Red Major Low Low Red Red Major Low Low Low Red Red Major Low Low Low Re...

Page 34: ...Converter Shelves and Fan Shelves Shelf Alarm State the highest alarm state within the shelf including Converter Cards and 48V Input Feeds Fan Shelf state if wired and Alarm Card I2 C to RS 485 communication processor OK No alarms are active all OK PMN Minor alarms only are active PMJ Major at least one major alarm is active Fan Shelf Alarm State the alarm state of the connected Fan Shelves Each F...

Page 35: ...ote Test points work best if each voltage is measured with respect to ground Conditions Notes None Green Off Off Yellow Standby browser Green to ground other Green voltage Off problem Off voltage Off Off Conditions None Test Point for 190V Output QS982 Converted LEDs See footnote on page 36 ...

Page 36: ...d ActiGtl Alqund OKLED Green a b OCK i Red Blinking 6 FLT _ r I I a _ b 9 O K9 OflT o f 1 a b go K 8 FLT Red Blinking Red Blinking _ Green i Yellow Blinking Red Blinking Off orr Red Blinking c Off Off _ Lf 1 a b Red Green t uK i Alternating O fiJ Red Yellow I Alternating I FaultLED Lossofcommunicationwith Ground fault OWrcurrant Undervoltage Overvoltage Internalf lllure Thermal Alann Latdl alarm a...

Page 37: ...Information This section contains additional information connector pin designations etc that may be required for making customizing or troubleshooting system connections Connections Controller Office Alarm Connections See Appendix C Operation without a Controller Alarm Wiring for systems without a controller Controller Office Alarm Connector is located on the front of the Primary Fan Shelf Figure ...

Page 38: ...hall be arranged with a right angle housing such that the cable exits to the pin 1 side Ground Lead InputAlarm 5 Closure to pin3 w InputAlarm 3 Closureto pin3 System 48Vfor InputAlumsABS Alarm Relays Return Alarm Relay 6 Return Alarm Relay1Return WHT BLK Alarm Relay 2 Retum Alarm Relay3 4 Return R InputAlann8 Closure to pin 3 InputAlann4 Closureto pin 3 Alarm Relay4 Alarm Relay5 AlarmRelay6 GR WHT...

Page 39: ... 2b 29 3a 5 3a 30 3b 6 3b 31 4a 7 4a 32 4b 8 4b 33 5a 9 5a 34 5b 10 5b 35 6a 11 6a 36 6b 12 6b 37 7a 13 7a 38 7b 14 7b 39 8a 15 8a 40 8b 16 8b 41 9a 17 9a 42 9b 18 9b 43 10a 19 10a 44 10b 20 10b 45 11a 21 11a 46 11b 22 11b 47 12a 23 12a 48 12b 24 12b 49 25 50 EMI performance is enhanced when the output cable shield is grounded only at the CPS2400 end of the shield Jl ll ll COfflllrtarout BL W W BL...

Page 40: ...door cabinets without baffles Note where the air entering the second shelf may be heated above 65C inlet temperature additional airflow beyond the minimum 175 linear feet per minute is required These cases require an engineered solution Central Office Application Converter Shelf Stacks Figure 2 are rated to operate in 55 C environments Up to 2 Converter Shelf Stacks may be mounted in a single fram...

Page 41: ...P 91412 List 2 54 405348202 YA2CL 2TC14 LCD2 14A Q 2 8 405347683 YAV2C L2TC14 FX LCDX2 14A E 2 YA2CL 2TC14 45 LCD2 14AH Q 2 193 408210524 YAV2C L2TC14 FX 45 LCDX2 14AH E 4 5 405347576 YAV4C L2TC14 FX 4 YAV4C L2TC14 FX 45 6 3 405347519 YAV6C L2TC14 FX 6 YAV6C L2TC14 FX 45 8 75 406021626 YA8CL2TC14 8 YA8CL2TC14 45 N A 10 These similar lugs may have different dimensions from WP 91412 lugs ...

Page 42: ...100 1 µs 200 IIN 26 0 Adc IIN 27 2 Adc IIN 33 2 Adc IIN 35 4 Adc 10 000 21 Pin 24013 Pdiss 4013 Pout 200 Output VO 378 380 382 Vdc PO 95 0 97 7 100 IOUT 251 257 262 mA 1500 Vdc TA 40 50 TA 40 65 TA 40 75 TA 40 Tstg 55 85 m 1 ab ab 2 Physical Parameter Symbol Min Typical Max Unit 3 Inch Component Height Width Depth Weight See footnote on page 44 ...

Page 43: ...G 10 8 6 4 2 Dimensions 5 0 in 127 mm 3 3 in 84 mm 17 2 in 437 mm 11 9 in 303 mm Top Front Figure 30 Converter Shelf Dimensions 17 2 in 437 mm 1 73 in 44 mm 5 0 in 127 mm 11 9 in 303 mm Front Top Figure 31 Fan Shelf Dimensions See footnote on page 44 ...

Page 44: ... consistent with UL 497 Each copper pair must be provided with protection external to this equipment to a level equivalent to a CommScope 3C EW Gas tube primary protector For example 3C3EW provides the part in a red color This protector has a voltage breakdown range of 265 465 Volts and an impulse spark over range of 265 700 Volts Protectors are provided by the telco customer The 5 Pin protector m...

Page 45: ...ctor to the correct size conductor as specified by the connector manufacturer using only the connector manufacturer s recommended or approved tooling for that connector Torque electrical connections to the values specified on labels or in the product documentation Dress cables to avoid damage to the conductors and undue stress on the connectors Size protectors fuses or circuit breakers as required...

Page 46: ... 2uF and the measured capacitance between 190V and earth is 4 4uF DO NOT add capacitance to the system to reach values that exceed safety limits per the following figure 1 1500 120 10000 1000 100 10 0 1 0 01 10 100 1000 10000 C uF Key U Voltage of the RFT circuit Figure 32 Design Capacitance Safety Limit Line to earth Line to line S4651A ...

Page 47: ...he ringer output connectors Use the following precautions in addition to proper job training and safety procedures Use only properly insulated tools Remove all metallic objects key chains glasses rings watches or other jewelry Follow Lock Out Tag Out LOTO procedures customer specified site specific or general as appropriate Disconnect all power input before servicing the equipment Check for multip...

Page 48: ...nverter shelves Fan Shelves are required for every set of three Converter shelves No more than 6 shelves may be located in a particular frame Slot covers must be used on all empty slots when more than one shelf is being cooled by a particular airflow device Always mount converter shelves above the fan tray that cools them Leave no space between the top of a fan tray and the converter shelf above i...

Page 49: ...Page 49 Copyright 2021 ABB All rights reserved Figure 33 Converter Slot Fillers ...

Page 50: ... shelf alarm card and converter card level Controller LED State LED State OK State LED State Yellow Min Yellow Min Green Yellow Yellow Min Yellow Min Red Red Fail Yellow Min Yellow Min Green Fail 2 Cards Red Maj Fail Red Maj Red Green communication Fail Removed Red Maj Green Red None Standby Green Green Yellow Yellow Min Yellow Min Green Yellow card Yellow Min Yellow Min Yellow card Failed Yellow ...

Page 51: ...State LED State Yellow Min Min Green Yellow Min Min Green Fail Yellow Min Min Green Fail Yellow Min Min Green Red Maj Maj Green Red Maj Maj Green Yellow Min OK Green Green feature remote expected Yellow Min OK Green Green Aborted OK Green Green measurement Yellow Min OK Green Green ...

Page 52: ...signated A1 6 and A9 12 and power shelf slots 1 6 left side and 7 12 right side respectively The B bus feeds are also designated in an identical fashion The alarm card monitors the 48v on each of these four feeds and asserts alarms and indicators Table 11 A1 6 B1 6 A7 12 B7 12 PMN PMJ 1 OK OK OK OK GRN GRN GRN OFF 2 LOW OK OK OK RED GRN OFF YEL 3 OK LOW OK OK GRN RED OFF YEL 4 OK OK LOW OK RED GRN...

Page 53: ... PMJ bus When the PMN bus is active pulled low the Alarm card asserts a PMN relay and lights the ALM LED Yellow When the PMJ bus is active pulled low the Alarm card asserts a PMJ relay and lights the ALM LED Red The Alarm Card ignores the state of the PMN bus and does not assert a PNM relay LED action while an active PMJ is present This is necessary since a single LED is used for both Minor Yellow...

Page 54: ...ipped with a controller provide all alarms via the controller alarm connector and require no office alarm wiring to alarm cards Inter Shelf Signal Cables are only required between Fan Shelves and the adjacent Converter Shelf in systems without a Controller Step Action instructions To Office Alarm network 6 5 4 3 2 1 TB1 Alarm Board Open on Alarm Open on Alarm Open on Alarm Open on Alarm Return Ret...

Page 55: ... temperature Achtung Das Netzteil darf nur in Räumen mit beschränkten Zutritt verwendet werden Das System ist ein Gerät der Schutzklasse I Überspannungs Kategorie II Ausgangsspannungen und stöme DC 190V max 100W bei IEC 60950 21 Das Gerät hat keinen eigenen Ausschalter es muß daher mit einem Ein und Ausschalter im Versorgungskreis versehen sein Das Gerät hat kein Brandschutzgehäuse es darf daher n...

Page 56: ...ed fan shelf DC wire gage and maximum temperature of 3 shelf system Standards Compliance section Added Appendix D r03 Update Install Inter Shelf Signal Cables page 20 add reference to Galaxy Pulsar Edge Quick Start Guide r02 Minor Revisions r01 Initial release 4 2 Updated as per template 02 08 2022 ...

Page 57: ...t any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction is closure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright 2021 ABB All rights reserved ABB 601 Shi...

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