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© 2021 ABB. All rights reserved.

5. Pre

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Installation

CPS3200U Installation

Purpose

CPS3200U Shelf Installation guide for generic installations. Additional requirements are needed for

application specific installations. Refer to Appendix A for spacing requirements.

Audience

Field application personnel

Precautions

Read Safety section prior to installation.

Observe ESD protection while installing circuit packs

Safety

•

Always consider personal safety.

•

Make sure the system is properly grounded per the National Electrical Code, local building codes, and any
specific company requirements per standard practice.

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Remove all metal jewelry before beginning the installation.

Installation Tools

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A Complete Standard Insulated tool set

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Wire cutters and strippers

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Heat shrink gun

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Torque wrench (0

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240 in

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lb / 28 Nm)

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Sockets

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Digital meter, +/

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0.02%

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Screw Drivers (flat

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blade and Phillips)

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ESD wrist strap

System Identification

Identify the product you have received. Make sure to select procedural steps to match the product

you have.

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Summary of Contents for CPS3200U

Page 1: ...Page 1 2021 ABB All rights reserved PRODUCT MANUAL ...

Page 2: ...fications 10 3 Ordering 13 Ordering Codes 13 Lugs 14 4 Safety 15 Safety Statements 15 Warning Statements and Safety Symbols 18 Precautions 19 5 Pre Installation 21 Purpose 21 Audience 21 Precautions 21 Safety 21 Installation Tools 21 System Identification 21 6 Installing the Shelf Level Upstream Product 23 Unpacking Shelf Level Upstream Product 23 Installing and Powering the CP3200U Converter Shel...

Page 3: ...nstalling the Office Alarm Connector 44 9 Reference Information 45 QS982A Converter LED Information Map 45 QS982A LED Information Map visual 46 Alarm Card Information 47 QS912A Converter Shelf 48 QS930A Fan Shelf 50 10 Maintenance 51 Filter Cleaning 51 11 Product Warranty 53 Appendix A Operating Temperature Measurement and Vertical Spacing 55 Operating Temperature 55 Baffles and Fan Trays 55 Appen...

Page 4: ... Converter Shelves 29 Figure 13 Installing a Baffle 29 Figure 14 Mounting the Fan Shelf 30 Figure 15 Inserting Fan Trays 30 Figure 16 Open the Wiring Region of the Fan Shelf 30 Figure 17 Alarm Wiring for Fan Shelf 31 Figure 18 DC Cabling Fan Trays in CPS3200U Systems 31 Figure 19 Cover the Wiring Region of the Fan Shelf 32 Figure 20 Fan Tray LEDs 32 Figure 21 Mounting the Filter Bracket 33 Figure ...

Page 5: ...4 Figure 36 QS982 LEDs and Test Points 45 Figure 37 Alarm Card Faceplate 47 Figure 38 Shelf ID Rotary Switches 47 Figure 39 QS912A Dimensions 48 Figure 40 Output Connectors 49 Figure 41 QS930 Fan Shelf Dimensions 50 Figure 42 QS930 Fan Shelf Connections and Fuses 50 Figure 43 Converter Shelf with Slot Fillers 56 Figure 44 Alarm Card Office Alarm Pinout and Shelf ID 59 Figure 45 Alarm Card Office A...

Page 6: ...rdering Codes 13 Table 3 Output Connector Pinout 26 Table 4 QS982A LED Information Map 39 Table 5 QS982A Converter LED Information Map 45 Table 6 QS982A Converter LED Information Map visual 46 Table 7 Output Connector Pinout 49 Table 8 Alarm Reference 57 Table 9 Shelf Alarm Card State 60 ...

Page 7: ... converter shelf meets the applicable requirements of these North American product standards UL60950 21 UL60950 1 Telcordia GR 3108 CORE GR 1089 CORE GR 487 CORE converter shelf and GR 063 CORE Summary The CPS3200U Upstream System delivers power over telephone lines The primary application is enabling the delivery of video bandwidth data rates to residences over twisted pairs by allowing placement...

Page 8: ...rough Friday on normal business days At other times this number is still available but for emer gencies only Calling from United States Canada Puerto Rico and the US Virgin Islands All other countries Or Contact your local field support center or your sales representative to discuss your specific needs On Line Power Systems Product Manuals and Software Product manuals technical support guides prod...

Page 9: ...t the output The converter circuit tests the line every 4 seconds and will re energize if the wiring fault is cleared A serial communication bus links each converter to an alarm card at the end of each shelf The alarm card provides major and minor form C contacts manages the converters and relays information to a ABB Power CPS6000 family controller using Galaxy Protocol over an RS485 bus Up to 24 ...

Page 10: ... C 85 C Power per C L Card 21 Input Power at 42 6 Vdc input Pin 2403 W Power Dissipation Pdiss 40 W Output Power Pout 200 W Output 378 95 0 251 Voltage line to line VO 380 382 Vdc Power per C L circuit PO 97 7 100 W Current per C L circuit IOUT 257 262 mA Isolation 1500 Vdc Input to Output Voltage Physical Height Width Depth Weight lb kg 23 Inch Shelf 3 5 88 9 21 4 543 6 12 304 30 13 6 Fan Shelf 3...

Page 11: ...tube protector For example 3C3EW provides the part in a red color This protector has a voltage breakdown range of 265 465 Volts and an impulse spark over range of 265 700 Volts The 5 Pin protector must be marked as a special circuit consistent with the marking protocol in the users network Protectors are provided by the telco customer Network equipment and components along the powering circuit sha...

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Page 13: ...llation CC109121984 QS930B 108997623 QS920A CC109102118 Alarm Module Spare Expansion Items Provide a 4 ft long wire set to transmit alarm signals past a baffle Use when adding a second fan shelf to an existing system H5694820G050 CC109122074 H5694820G051 CC109132271 H5694820G012 CC109122082 Converter Shelf RJ45 wire set hardware alarm board same as QS912A above Note A baffle must be placed above t...

Page 14: ...347576 YAV4C L2TC14 FX LCDX4 14A L FLEX LCD4 14A L STR 54206 STR 54206 FLEX 4 45 STR FLEX YAV4C L2TC14 FX 45 LCDX4 14AH L FLEX LCD4 14AH L STR 54206UF STR 54206UF FLEX 6 Straight STR FLEX 3 405347519 YAV6C L2TC14 FX LCDX6 14A L FLEX LCD6 14A L STR 54205 STR 54205 FLEX 6 45 STR FLEX YAV6C L2TC14 FX 45 LCDX6 14AH L FLEX LCD6 14AH L STR 54205UF STR 54205UF FLEX 8 S h S 75 406021626 YA8CL2TC14 LCDX8 1...

Page 15: ...ined at levels that cannot cause condensation on the equipment the contaminating dust is controlled and the steady state ambient temperature is within the range specified For multi shelf systems up to 3 this equipment has been evaluated for continuous use in central office environments with ambient temperatures from 40 C to 50 C when used with the QS982A converters For multi shelf systems up to 2 ...

Page 16: ...urrent rating Distribute loads across the panel The short circuit current capability of the battery input to the panel must not exceed 10 000A DC branch circuits to this equipment must be protected with either fuses or circuit breakers Refer to the equipment ratings to assure rating of equipment will not exceed 80 of the value of the protector chosen For applications in cabinets huts vaults and ce...

Page 17: ...Page 17 2021 ABB All rights reserved Figure 2 Capacitance Safety Limits ...

Page 18: ... This symbol is used to identify the presence of hazardous ac or dc voltages It mayalso 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 sometype of statement for example Battery voltage present Risk of injury due to high current Avoid contacting conduc...

Page 19: ...es when servicing this equipment When equipped with QS982A modules hazardous voltages 190Vdc will be present on the output connectors and associated interconnection cables In addition to proper job training and safety procedures the following are some basic precautions that should always be used Use only properly insulated tools Remove all metallic objects key chains glasses rings watches or other...

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Page 21: ...t packs Safety Always consider personal safety Make sure the system is properly grounded per the National Electrical Code local building codes and any specific company requirements per standard practice Remove all metal jewelry before beginning the installation Installation Tools A Complete Standard Insulated tool set Wire cutters and strippers Heat shrink gun Torque wrench 0 240 in lb 28 Nm Socke...

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Page 23: ...l all parts are operating within specifications If the equipment must be re turned it should be repacked in the original shipping crate Installing and Powering the CP3200U Converter Shelf Position the Shelf and mechanically attach it to the frame Step Action Locate the 2 mounting brackets one on each side of the CPS3200U shelf align the holes in the shelf mounting bracket with the holes in the mou...

Page 24: ...pplications of not more than three conductors in a raceway and correction factors for Ambient Temperatures Over 30 C Each instal lation will vary and the installer should review NEC cabling requirements as well as local practice to ensure proper cable sizing is achieved for the local conditions Lugs for 6AWG conductor are as follows or available equivalent Burndy YAV6C L2TC14 FX 6 Using the hardwa...

Page 25: ...quivalent T B 6STR30W Burndy YAV6C L2TC14 FX 3 Torque connections to 4 Nm or 35 in lbs Attach the Load Wiring Provide a circuit from each converter into the designated network telephone pairs Follow the steps in the table below to attach load wiring to the CPS3200U shelf Step Action 1 The wiring assignment information in the following table provides the appropriate connections for each circuit A c...

Page 26: ... 37 BK O 7a 13 G BK 7a 38 BK G 15a 13 G BK 15a 38 BK G 7b 14 BR BK 7b 39 BK BR 15b 14 BR BK 15b 39 BK BR 8a 15 SL BK 8a 40 BK SL 16a 15 SL BK 16a 40 BK SL 8b 16 BL Y 8b 41 Y BL 16b 16 BL Y 16b 41 Y BL spare 17 O Y spare 42 Y O spare 17 O Y spare 42 Y O spare 18 G Y spare 43 Y G spare 18 G Y spare 43 Y G spare 19 BR Y spare 44 Y BR spare 19 BR Y spare 44 Y BR spare 20 SL Y spare 45 Y SL spare 20 SL...

Page 27: ...larm Wiring For systems where alarming is processed through a central controller using serial communications each shelf must have a unique address Otherwise all alarm cards should be left in their factory de fault state of address 0 0 Skip this step if no QS941 will be present in the system Warning You must properly protect yourself against ESD discharge prior to accessing the alarm card and setti...

Page 28: ...Page 28 2021 ABB All rights reserved Step Action 2 Remove the alarm card Figure 10 Removing Alarm Card 3 4 ac ac m Note Door must be level to remove alarm card ...

Page 29: ... the Fan Shelf to allow for three CPS3200U Shelves or be removed and reattached every time a CPS3200U shelf is added Note There are two to airflow options provided for different applications Airflow direction optimized for CO deployments provided by the FTTN fan shelf is downward Airflow direction for OSP applications is bottom to top Baffles should be oriented to direct cold air from the aisle th...

Page 30: ...l a fan shelf below each set of 3 CPS3200U shelves Step Action 1 Install the Fan Shelf using as many fasteners as the frame will accept 2 Insert two fan trays operating the latches as shown 3 Remove the clear plastic cover from the wiring area Figure 16 Open the Wiring Region of the Fan Shelf Figure 15 Inserting Fan Trays Lexan Cover ...

Page 31: ... Returns for the A and B feeds are shared on the 48Vdc RTN The lowest posi tion on the terminal block is to provide frame ground for the fan shelf Power feeds should be derived from a fuse or breaker panel using discrete cabling which is independent from the converter shelf Figure 18 DCCabling Fan Traysin CPS3200U Systems Included Communication Wire set Fan Shelf Converter Shelf Door removed for v...

Page 32: ...Page 32 2021 ABB All rights reserved Step Action 6 7 Resolve Alarm states by first assuring that DC power is being provided to both the A and the B Lexan Cover ...

Page 33: ...Page 33 2021 ABB All rights reserved Step Action 2 ...

Page 34: ...Page 34 2021 ABB All rights reserved Step Action Slide the filter in to the filter bracket 4 ...

Page 35: ...e spark over range of 265 700 Volts Protectors with a lower voltage breakdown rating will be problematic 7 Inspect the Network Check and Mark WiringCompliance The CPS3200U 190V system is classified as an A3 circuit tested according to GR 1089 CORE Issue 6 As such each location in the network where the output is available to be touched must be protected and marked as an A3 voltage Voltage Class Gen...

Page 36: ...flash there is no leakage path to ground at operating voltage er To meet UL60950 21 specific procedural steps must be taken at the time of installation This sec tion goes through those steps These steps should be performed before power is distributed in the network Normally the final step is performed by closing the circuit using a 5 pin protector after DC power is applied to the system ...

Page 37: ...e 37 2021 ABB All rights reserved Step Action 1 2 3 4 5 6 CPS3200U shelf 7 housing catches 8 9 Insert empty slot fillers into all unused slots to control airflow in multi shelf systems 8 Final Installation ...

Page 38: ... Volts section Step Action Observe the LEDs 2 Use the state table below to determine the state of the system and required corrective actions if needed Figure 27 QS982A Faceplate and LEDs Note Test points work best if each voltage is measured with respect to ground ...

Page 39: ...of circuit b Standby statecan be set using the QS941 controller or web browser Loss of comm Check seating on Alarm card and converter card Ground fault Check 5 pin protectors and faults to ground Overcurrent or under voltage Check output lines for shorts toeach other OV or internal failure Replace unit Thermal Alarm Solve Thermal problem card not powered or input se failure Check source voltage La...

Page 40: ... 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 demonstrate an alarm state by turning the display red Using the buttons on the keypad the specific alarm can be retrieved by pressing the Back Arrow When the system returns to normal function the display will be green To connect CPS2300U shelves to an IP Drop follow thes...

Page 41: ...Page 41 2021 ABB All rights reserved Step Action 5 Install the controller into the fan shelf Figure 31 Installing the Controller ...

Page 42: ...ress has been assigned to the QS941 controller Press the square key on the upper right hand corner ofthekeypad to display the menu 8 Press the down arrow key 2 times to scroll down to the Status item on the menu 9 Press the right arrow to advance to the Status menu 10 Press the down arrow key 8 times to scroll down to the Network Settings item and selectbypressingthe right arrow key 11 Press the r...

Page 43: ...Page 43 2021 ABB All rights reserved Step Action 14 ...

Page 44: ...eoptions listed below 2 Available alarm cables are as follows CC848773671 10ft alarm cable for QS941 controllers 848748558 25ft alarm cable for QS941 controllers CC848764448 50ft alarm cable for QS941 controllers 848748566 150ft alarm cable for QS941 controllers ...

Page 45: ...rved Overview QS982A Converter LED Information Map Action Required OK LED Fault LED Conditions Notes None Green Off Off Yellow Standby Green Green voltage Off problem Off Off Off Observe Lamp Test Lamps test requested from controller ...

Page 46: ...depending on desired state of circuit b Standbystate can be set using the QS941 controller or web browser Loss of comm Check seating on Alarm card and converter card Ground fault Check 5 pin protectors and faults to ground Overcurrent or under voltage Check output lines for shorts to each other OV or internal failure Replace unit Thermal Alarm Solve Thermal problem card not powered or input Check ...

Page 47: ...Page 47 2021 ABB All rights reserved The alarm card faceplate looks one of these depending on whether you have a front access system on the left or a rear access system on the right ...

Page 48: ...Page 48 2021 ABB All rights reserved ...

Page 49: ...Page 49 2021 ABB All rights reserved Figure 40 Output Connectors EMI performance is enhanced when the output cable shield is grounded only at the CPS3200 end of the shield ...

Page 50: ...Page 50 2021 ABB All rights reserved Note Returns for A and B feeds are shared on the 48Vdc RTN terminal The lowest position on the terminal block is frame ground ...

Page 51: ...Page 51 2021 ABB All rights reserved 10 Maintenance ...

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Page 53: ... promptly after Customer discovers such defect or nonconformity and follows Seller s instructions regarding return of defective or nonconforming Products Seller shall at its option attempt first to repair or replace such Product without charge at its facility or if not feasible provide a refund or credit based on the original purchase price and installation charges if installed by Seller Where Sel...

Page 54: ...ordance with Seller s or Vendor s specifications or operating instructions or failure of Customer to apply previously applicable Seller modifications and corrections In addition Seller makes no warranty with respect to Products which have had their serial numbers or month and year of manufacture removed altered or experimental products or prototypes or with respect to expendable items including wi...

Page 55: ...y reasons a three shelf system is rated to operate in 55C environments Baffles and Fan Trays For Central Office applications baffles are used between every set of three Converter 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...

Page 56: ...d on a fan shelf Any gaps between converter shelves or absence of slot covers can cause service effecting problems Note All unpopulated converter slots must be filled with slot fillers For example the figure below shows a shelf with operational converters in the first two slots and slot fillers in the remaining 14 slots Figure 43 Converter Shelf with Slot Fillers ...

Page 57: ...ation Fail 1 Card Removed Yellow Min Yellow Min Green Off Check to see that all cards are seated Replace non functioning cards Communication Fail 2 Cards Red Maj Communication Fail Communication Cable Removed Red Maj Flashing Red Green Off communication Communication Removed Red Maj Green Flashing Red None Standby Green Green Yellow Circuit Fail Open Fuse Yellow Min Yellow Min Green Flashing Yello...

Page 58: ...8 2021 ABB All rights reserved QS941 Alarm Card Converter Card Alarm Display What it means LED State Relay State Alarm LED State Relay State OK LED State Alarm LED State Yellow Min Min Green terminal Aborted ...

Page 59: ...act closures for Power Major and Power Minor for operation without a controller Wire these relays into the alarm network in deployments where a controller is not utilized If a controller is installed then an alarm cable can be attached to the QS941A controller during final installation in section 8 under Installing the QS941A Ethernet Module ...

Page 60: ... is to not exceed the 48 AMPS L2 input current per feed The A bus feeds are designated A1 8 and A9 16 and power shelf slots 1 8 left side and 9 16 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 as follows Alarm Relay E Energized relay in non alarm state D De energized ...

Page 61: ... 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 While an active PMJ is present the Alarm Card ignores the state of the PMN bus and does not assert a PNM relay LED action This IS necessary since the same LED is used for both Minor Yellow and Major Red visual indication The Alarm Card also mon...

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Page 63: ...en used with the QS982A converters Page 28 added Otherwise all alarm cards should be left in their factory default state of address 0 0 Skip this step if no QS941 will be present in the system Page 28 added text and changed picture to show angle required to remove alarm card Page 38 Measurement from the exterior of the CPS3200U shelf to the cabinet or building ground bus should indicate a resistan...

Page 64: ...reed particulars shall prevail ABB does not accept 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 disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB C...

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