ABB CPS6000-Systems-48V DC Power Installation Manual Download Page 3

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CP:S6000_External Distribution_IG

Rev. 1.3

Table of Contents

Customer Service Contacts

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Safety Statements

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Product Specification

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Installation

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Unpacking and Safety Precautions

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Installation Tools

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Torque Settings

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Frame Mounting

DC Reference (CO) Ground and Chassis Ground

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Battery String and DC Load Connections

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Battery Monitoring Connections

Local Port (RS

232 / USB) Connection

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Rectifier Installation

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Initial Start

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Minimum Controller Configuration

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Troubleshooting

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Rectifier Alarms

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Troubleshooting Chart

Product Warranty

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Appendix A: Pulsar Controller

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User Interface Overview

Menu Navigation Buttons

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System Status Display

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Appendix B: Pulsar Wiring Connector Definitions

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7. Revision

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PRODUCT MANUAL

CPS6000

Systems (

48V DC Power)

Installation Manual

Summary of Contents for CPS6000-Systems-48V DC Power

Page 1: ... 2021 ABB All rights reserved CP S6000_External Distribution_IG Rev 1 3 INSTALLATION GUIDE CPS6000 Systems 48V DC Power Installation Manual 19 and 23 Inch Systems Product Manual CC848879683 Issue 2 March 2010 ...

Page 3: ...d 14 Battery String and DC Load Connections 17 Battery Monitoring Connections 23 Local Port RS 232 USB Connection 26 Rectifier Installation 28 4 Initial Start up 29 Minimum Controller Configuration 29 5 Troubleshooting 33 Rectifier Alarms 33 Troubleshooting Chart 34 6 Product Warranty 37 Appendix A Pulsar Controller 39 User Interface Overview 39 Menu Navigation Buttons 40 System Status Display 40 ...

Page 4: ...ay on normal business days At other times this number contacts an answering service with on call personnel for out of service emergencies Customer Training ABB Power offers customer training on many Power Systems products For information call 1 972 244 9288 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 lat...

Page 5: ... 60950 1 1ST Edition or evaluated to EN60950 1 by an EC Notified Body as appropriate The CE Mark demonstrates compliance with the European Union Council Directives for Low Voltage and EMC INSTALLATION SITE Install only in restricted access areas dedicated equipment rooms equipment closets or the like in accordance with paragraphs 110 18 110 26 and 110 27 of the U S National Electric Code NEC NFPA ...

Page 6: ...to be applied only to the correct size conductor as specified by the connector manufacturer using only the connector manufacturer s recommended tooling or tooling approved for that connector If the proper connector for the country of installation is not provided obtain appropriate connectors and follow manufacturer s and all local requirements for proper connections All national and local rules an...

Page 7: ...ned in the appropriate battery product manuals Batteries are connected in parallel with the output of the rectifiers Turning off the rectifiers will not necessarily remove power from the bus Make sure the battery power is also disconnected and or follow safety procedures while working on any equipment that contains hazardous energy voltage ...

Page 9: ...al block options are located either on the back of the rectifier shelf or in a front accessible ac box as shown in the figure below The initial distribution panel includes the Pulsar controller mounted on the door and either 20 or 26 selectable distribution positions that can be configured as either battery inputs or load outputs Systems may be equipped with Low Voltage Battery Disconnect LVBD Low...

Page 10: ...or the rectifier Figure 2 Typical Rectifier Numbering Model Number ofRec tifier Max DC Current Idc NominalDC Voltage Vdc DC Voltage Vdc Range AC Voltage Vac Range NominalAC Current A Max BTU hr Max Watts QS861A 15A 48 42 58 85 150 7 8 450 132 48 42 58 150 275 4 4 445 130 QS852A 20A 48 42 58 150 275 6 454 133 QS853A 25A 48 42 58 150 275 7 4 724 212 QS862A 25 30A 48 42 58 85 150 12 0 604 177 48 42 5...

Page 11: ...tputs Figure 3 shows the option where all load positions are connected to the system through a low voltage load disconnect LVLD Figure 4 shows the option where the battery positions are all connected to the system through a low voltage battery disconnect LVBD Breaker sizes up to 250A TPS fuses to 70A and GMT fuses to 12A are available bullet modules for this system DC Connections are made with dou...

Page 13: ...ion Tools Wire cutters and strippers Digital meter 0 02 Heat shrink gun Screw Drivers 1 and 2 Phillips Torque wrench 0 240 in lb 28 Nm Cable crimpers 5 16 7 16 and 3 8 nut drivers and sockets Torque Settings The following table lists the recommended torque settings for all mechanical and electrical connections according to screw and nut size Frame Mounting The CPS6000 system is designed for a stan...

Page 14: ...bs 74 lbs 2 Distribution 2 Rectifier Shelf 74 lbs 97 lbs DC Reference CO Ground and Chassis Ground Use a 1 4 diameter double hole lug on 5 8 center Not provided to ground the chassis as shown in the figure below Torque connection to 65 in lbs The DC reference ground is connected to the return bus as shown below Use a 3 8 diameter double hole lug on 1 centers Not provided Figure 5 DC Reference Grou...

Page 15: ... AC Box has knockouts for or 1 conduit Two sets of conduit ground studsare located in the box These studs accept two hole groundlugs on 5 8 centers One two or three rectifiers may be fed from a single ac feed using jumpers between the blocks Attachjumpers as shown below Torque screw to 10 in lbs Snap loose plastic divider Install strap to connect adjacent blocks If feeding 3 positions At tachwire ...

Page 16: ...the box These studs accept two hole ground lugs on centers One two or three rectifiers may be fed from a single ac feed using jumpers be tween the blocks Attach jumpers as shown below Torque screw to 10 in lbs AC feed per rectifier no jumpers AC per two rectifiers 1 jumper per 2 blocks AC per three rectifiers 2 jumpers between 3 blocks If feeding 3 positions At tachwire to center block Terminal Bl...

Page 17: ...0 68 Adapter buses are available for larger cables Notice the color coding in the distribution Bus bars with brown labeling are returns Bus Bar with blue labeling are 48V Labels are provided to identify battery verses load positions on the ID label on the front door The initial distribution panel with the controller is rated for 600A The supplemental upper panel is rated for 300A Load distribution...

Page 19: ...rs 901352617 1 4 20 nutsare provided Torque to 65 in lbs using 7 16 socket Secure the Return Load Cable then the Load Cable Cable size is 2 AWG or less Verify wiring polarity at the input of the load equipment Insert single pole TPS fuseholder into the distribution as shown on the left side of thepicture above Verify that the alarm pin is straight before insertion Ensure no TPS fuse or GMT Alarm F...

Page 20: ...ch centers Verify wiring polarity at the input of the load equipment Insert three pole breaker into the distribution as shown in the distribution picture above Verify that the alarm pin is straight before insertion Ensure Circuit Breakers are in theOFF position prior to installation Leave breaker switch in the OFF position until the load equipment is ready to be energized GMT Bullet Fuse Modules T...

Page 21: ...l from battery breakers The Yellow Wire is 48FAJ from load breakers 3 J2 Voltage Temperature VT Probe Connection RJ 45 connection from Voltage Thermal VT probes from mid string battery post of battery If using ES771 Voltage Module Verify the 1 Wire serial bus reference The ES771 modules must be referenced to the most negative potential of the DC bus This reference is achieved by the proper setting...

Page 22: ... to Open or Close on alarm as required These jumpers set the ten Form C alarm outputs on the connector J4 Carefully move each of respective configuration jumpers to the desired contact type Open On Alarm or Closed OnAlarm position as required per site instructions Pin 1 6 J5 Local Area Network LAN Connection Insert a 10 100Base T CAT 5 LAN wireset into the LAN connector on the top edge of the cont...

Page 23: ...dule 108958422 card is used There is a maximum 16 probes The highest temperature measured from all installed VT probes is used by the controller for slope thermal compensation The number of probes per string is to be defined by the user Typical installation requires 1 thermal probe in the middle of each string of batteries as shown in the following figures Figure 9 VT Probe Connections for Monitor...

Page 24: ...e B style cable at the 3 pin connector 3 Insert the 3 pin connector end into the receptacle on the 1st VT Probe 4 Place the first probe to the battery post as shown in the picture Note Probes are typically installed one per string located in the center ofthe string Note Do not mount the VT Probe under a lug or battery strap The probe mounts on top of the lug or battery strap Note Probes can be mou...

Page 25: ... the string Do not cut the brown wire 3 Dress and attach the snap fit connector on the brown wire to the appropriate snap fit pin on the ES771A J1 J3 4 Verify the number of modules 1 registered with the controller with command MENU STATUS BATTERIES NUM MID STRING V Note Modules will only be recognized when there is actual potential applied through the VTprobe to the ES771 module 5 If required conn...

Page 26: ... avoids LAN conflicts should the controller ever be connected to a Local Area Network As good policy always restore the controller to Client mode Step Action 1 Press Menu or Accept key 2 Press down arrow to Configuration 3 Press the right arrow key or square accept key to advance 4 Press down arrow to Communications Ports 5 Press the right arrow key or square accept key to advance 6 Press down arr...

Page 27: ...Settings 7 Press the right arrow key or square accept key to advance 8 Press down arrow to highlight DHCP 9 Press the right arrow key or square accept key to advance 10 Press down arrow to toggle to CLIENT 11 Press save 12 Press the Back Arrow to return to the default screen 13 Wait 2 minutes 14 Activate changes by removing the latching PWR connection located on the lower right of thecontroller un...

Page 28: ...efore engaging the rectifier connector into the back of the rectifier slot press the Latch release button the latch will spring open See Figure 11 2 Firmly push the rectifier into the rectifier slot until the connector on the rear ofthe rectifier engages with the connector at the back of the rectifier slot on the CPS shelf The latch will pop most of the way up when the rectifier is properlyseated ...

Page 29: ...entral Standard Time and the following float voltage related settings If these standard defaults are OK no configuration is required Refer to the table below to change these defaults For more advanced operations please see the Advanced Features User Guide for the Pulsar Plus Controller Alarm Description Float Voltage The factory default setting is 54 5V Very High Voltage Major Alarm occurs and the...

Page 30: ...date the entries before the system date is modified 2 Time Format This field allows you to select one of the following time display formats 12 or 24 hour Use the or key to select desired format and press ENTER to save the change Time Allows you to change set the time Daylight Enables or Disables Daylight Savings per the new standards created by the Energy Policy Act of 2001 Started in 2007 3 Batte...

Page 31: ...r Redundancy Batteries Contactors Boost System Settings and Communication Ports The Float Settings option will be highlighted press the Display Menu key to access the Float Settings Menu The Set Point option will be highlighted Press the Display Menu key to view or change the Float voltage Set Point Use the left and right arrow keys to adjust the Set Point voltage Once the Voltage has been set to ...

Page 33: ...s Three LEDs are provided two green LEDs named AC OK and DC OK and a red LED named Alarm Their indications are listed below followed by complete status descriptions LEDs On x either state AC OK DC OK ALARM Condition Normal Operation Start Up Hiccup Remote Standby High Voltage Shutdown Thermal Alarm Internal Failure AC Fail PFC Fail Input Fuse Missing AC LowInput AC 15 ms Flashing Current Limit Ope...

Page 34: ...oltage is out of range Internal rectifier fault 1 Verify ac power to rectifiers is available 2 Verify rectifier input circuit breakers are closed 3 If problem is not corrected replace rectifiers RED MAJ Battery on Discharge Rectifier output voltage hasfallen below the battery on discharge threshold set by the user If commercial ac power is present but the system voltage remains low call your local...

Page 35: ...er s failure 1 Reset the rectifier s by removing the rectifier s waiting approximately 30s and replacing the rectifier s 2 If problem persists replace the rectifier 3 If problem still persists call your local field representative RED MAJ Major Communication Fail R or missing LVD Board LVD Board lost communication with the controller 1 Replace Distribution Module Board Note 2 2 If problem persists ...

Page 36: ...thermal alarm Excessive ambient temperature Multiple rectifier failure 1 Verify that there is no obstruction of the vertical airflow path 2 Reset the rectifier by removing the rectifier waiting approximately 30 seconds and replacing the rectifier 3 If problem persists replace the rectifier 4 If problem still persists call your local field representative AMBER MIN Minor Communication Fail Single Re...

Page 37: ...rchase price and installation charges if installed by Seller Where Seller has elected to repair a Seller s Manufactured Product other than Cable and Wire Products which has been installed by Seller and Seller ascertains that the Product is not readily returnable for repair Seller will repair the Product at Customer s site With respect to Cable and Wire Products manufactured by Seller which Seller ...

Page 38: ...nty 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 without limitation fuses light bulbs motor brushes and the like Seller s warranty does not extend to any system into which the Product is incorporated This warranty applies to Customer only and may not...

Page 39: ...e available through the local craft port using Easy View software or the LAN port using a PC web browser Easy View is a Lineage Power Systems GUI provided for local serial port or remote MODEM access The display shows the rectifiers 48 voltage V2 and current If converters were present their voltage would display as V1 The display V1 versus V2 correlates with test jacks The large font indicates the...

Page 40: ...decrease the value of the parameter Direction Buttons In the Menus the direction buttons navigate tomake a selection A black box highlighting a menu item indicates that the item has sub menus Enter Button Enters a sub menu or confirms a parameter change From the Home Page only goes to the top level Main menu ESC Button Goes up one menu level or exits a parameter change without There are three basi...

Page 41: ... following alarms are present Fuse Minor One or more of the following alarms are present Open String LVBD Open Fuse Major BD System above configured Battery on Discharge BD threshold Blinks at an On Off Rate of 1 2 second ON 1 4 second Off to indicate a manual or automatic battery test in progress State not presently assigned System equal to or below configured Battery on Discharge BD threshold Th...

Page 42: ...test jacks allow measurement of the system voltage with a hand held meter The jacks are referenced with C Common V1 Not Used in this system and V2 48 Voltage Measurement between C and V2 jacks corresponds to the voltage referenced on the default front panel screen Local Craft Port The local DB 9 RS232 asynchronous serial port is behind a cover on the front panel A laptop PC can be connected to the...

Page 43: ...nfiguration as wellas some operations A person with administratorlevel access can enable this feature through the remote interfaces Standard controllers are shipped from the factory with this featuredisabled Front Panel Menu Structure Feature content at the front panel is functionally divided at the NE843 s Main Menu into the following categories Alarms Warnings Status Control Operations History C...

Page 49: ...ry Input Return Aux Input 2 Auxiliary input to monitor a contact closure or open to its respective return on pin 8 BR Aux2 Auxiliary Input Return Aux Power Major Input Auxiliary input to monitor a contact closure to the non grounded side of a dc bus R AMJ 48V to create the standard Auxiliary Power Major alarm 4 O Plant Battery Test GroupStandby TR GSTR Dedicated input to be monitored for a contact...

Page 50: ...contact type can be changed see Advanced Features User Guide Network LAN Connection Optional The NE843 provides an Ethernet connection for a LAN and or Craft port connection Connector LAN provides a standard RJ45 shielded receptacle connection for a standard Cat 5 connection to the controller s 10 100Base T port This port has two main modes of operation Server mode LAN mode Static and DCHP Client ...

Page 52: ...lient modes of operation the controller is supplied an IP address and other network parameters and can be remotely monitored and accessed through the LAN This is generally a permanent connection between the controller and LAN so a Shielded Cat 5 cable is suggested This page intentionally left blank ...

Page 53: ...3 2021 ABB All rights reserved CP S6000_External Distribution_IG Rev 1 3 7 Revision Rev Description Date 1 2 Updated as per template 02 22 2022 1 3 Updated page footer corrected to Installatiion Guide 4 17 23 ...

Page 54: ...greed 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 ...

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