ABB CPS6000 Product Manual Download

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PRODUCT MANUAL

CPS6000

48V Indoor/Outdoor Power Shelf

Product Manual

Select Code 167

102

105

Ordering code 108992120

Issue 21

January 2008

Summary of Contents for CPS6000

Page 1: ...Page 1 Copyright 2021 ABB All rights reserved PRODUCT MANUAL CPS6000 48V Indoor Outdoor Power Shelf Product Manual Select Code 167 102 105 Ordering code 108992120 Issue 21 January 2008 Jl ll ll ...

Page 2: ...0 QS841A 1 0D App version 1 4 1 and defaults version Std 1 0 Rectifiers Series 15A QS861A 1 1F 20A QS852A 1 0E 25A QS853A 1 0A 25 30A QS862A 1 1H 40A QS864A 1 0E 50A QS865A 1 1E Notice The information specifications and procedures in this manual are subject to change without notice ABB Power assumes no responsibility for any errors that may appear in this document Jl ll ll ...

Page 3: ...nformation 25 4 Safety 31 Safety Statements 31 Warning Statements and Safety Symbols 33 Precautions 34 Special Installation Notes 34 5 Installation 37 CPS6000 Installation 37 Installing the CPS6000 Shelf 38 Install the CPS6000 Shelf 40 Controller 41 QS845A Supplementary Shelf Board 43 Thermal Compensation Connections 45 Office Alarms 49 Controller Connections 50 AC Connections 50 C O Ground Conduc...

Page 4: ...r 83 Overview 83 CPS6000 Controller Minimum Configuration 89 User Interface and Display 89 Minimum Configuration 89 7B QS841A System Controller 99 Overview 99 Status 107 Control Operations 109 Configuration 111 10 100 Base T Ethernet Port 117 8 Rectifier 125 Overview 125 Alarms and Displays 126 Features and Functions 127 9 QS872A Distribution Monitoring Module 129 Overview 129 10 Ringer Chassis an...

Page 5: ...Mode 175 Slope Thermal Compensation 175 Plant Battery Test 177 Boost Mode 179 Appendix C Alarms and Relays 181 Alarm Relays 181 Alarms 181 Appendix D EasyView for Windows for the CPS6000 Controller 189 Overview 189 Loading the EasyView Application 189 Making the Connection 189 Configuring a Site 189 Serial Port Setup 189 Connect to Site 190 Navigating Once Connected 190 Appendix E Pigtail Alarm Ca...

Page 7: ... on the right side of the shelf Rectifiers Ringers occupy the slots available between the controller and the DC output 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 CPS6000 systems may include up to 4 bulk output shelves an Initial ...

Page 8: ...ill 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 ABB Direct country code for the country where the call is originating or you ma...

Page 9: ... thermal issues They are monitored via the Voltage Thermal Probes VT Probes 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 syst...

Page 10: ...tion Panel 1 Rmil3 Jl ll ll 1YT Probe1 T Probe1 VT Probe1 RS 485 t 1 Vire Bus User Programming via RS 232 Bus or via 1 Vi re Bus L __ J AC Input Battery Strings Circuit Breaker or Strap Option Main 48V Output Ringer Chassis Op1 ional Redunlant Ringers j _ 1 j _ 1 1 I 1 I I I I I I I I I _ I _ _ I _____ I _ _ __ _ LVD Board LVBD Fuse or CB Output Option Distribution Module C O Ground Battery Return...

Page 11: ...Bus AC Input ROM 3 I I I RvM 2 I g System Controller Rectifier Rectifier Jl ll ll VT Probe1 I VT Probe11 VT Probe11 Battery Strings Circuit Breaker or Strap Option J I l LVBD I I I I I I I I LVD s I I I I Board I I I I I I I I I I I I I I I LVLD output Main 48V output Distribution Module C O Ground Battery Return Load Return 1 VT Probe VoltagefThermal Probe 2 RVM Remote Voltage Monitor Module 3 RD...

Page 12: ... may be installed in Power Slots Permits growth of plant capacity and easy maintenance without service interruption External Distribution Panel 1 RDM3 1 RS 485 ___ ___1 _ 1 VVire l Bus 1 Supplementary Shelf 1 Boards OS84S I User Programming via RS 232 Bus _ _ __ System Controller or lia 1 ire Bus L J Ringer Chassis VT Probe1 VT Probe1 Main 48V Output Jl ll ll To External i Distribution Panel RS 48...

Page 13: ...9 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 leav...

Page 14: ...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 batt...

Page 15: ...fuses See Note 2 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 Noi...

Page 16: ...ifiers 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 EMC Directive 89 336 EEC Low Voltage Directive 73 23 EEC as amended by Marking Directive 93 68 EEC Note 1 CPS6000 can be used with four strings of batteries depending on Distribution Module Note 2 When used with Single Slot...

Page 17: ...in 25 mm and 1 75 in 44 mm Horizontal mounting centers 18 31 in 465 mm 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 ...

Page 18: ...er 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 E 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 ...

Page 19: ...gulation 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 E QS852A Rectifier Spec...

Page 20: ...bove 58 Vdc Backup High Voltage Shutdown Above 60 Vdc for 1 millisecond Table 2 H 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 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 ...

Page 21: ...1 to 1 51 Output Frequency 15 to 50 Hz Factory Default 20 Hz Frequency tolerance 1 Hz Output VA 100 VA 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 Tempera...

Page 22: ...g 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 Table 2 L QS845A Supplementary Board Specifications Jl ll ll ...

Page 23: ...bsence 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 busy hour 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 ...

Page 24: ...vide the minimum installed capacity of 69 amperes for a non redundant 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 v...

Page 25: ...lso 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 us...

Page 26: ...vailable for the current Distribution Module Caution Please check the type of breaker the distribution module accepts before using the above Ordering codes Pluggable Strap Size Amps Ordering code 100A Pluggable Strap CC109106548 Size Amps Ordering code 0 25 405006222 0 5 406976894 1 33 405673146 2 405181983 3 406976985 5 406159061 Size Amps Ordering code 7 5 405725433 10 406159236 12 407845197 15 ...

Page 27: ...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 sh...

Page 28: ... Chassis is non redundant simplex Two Ringers per Ringer Chassis is 1 1 redundant duplex Ringer Ordering code 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 ABB Power Rectifie...

Page 29: ...40 8 Table 3 A Rectifier AC Input Current Table continued Conduit and further temperature deratings may be required in some installations Cross check table with local code and regulation requirements Thermal Compensation Thermal Compensation For thermal compensation the QS873A Voltage Thermal probe VT Probe and its associated cables must be ordered Refer to Section 5 for details on their interconn...

Page 30: ...e is generic and needs to be used in conjunction with the ordering guide Note TEPS lugs in the WP91412 specification are Burndy parts The Panduit and T B and any others may have different dimensions GA Description WP 91412 List Ordering code Burndy Equivalent Panduit Similar T B Similar 2 Straight STR 54 405348202 YA2CL 2TC14 LCD2 14A Q 54207 STR 2 Straight FLEX 8 405347683 YAV2C L2TC14 FX LCDX2 1...

Page 31: ...follow manufacturer s and all local requirements for proper connections All national and local rules and regulations should be followed when making field connections Load connections to Bulk Output Modules should be made in close proximity to the power shelf The main output voltage 48V meets SELV requirements Insulation on field wired conductors should be rated no less than 90 Celsius Wire conduct...

Page 32: ...ce sparks during interruption or clearing of a fault on a high energy circuit Use only fuses provided with safety caps for this type of circuit Installing telecom type fuses not equipped with safety caps may result in injury to service personnel While installing batteries follow all safety precautions outlined in the appropriate battery product manuals The terminal block for the GMT fuse panel is ...

Page 33: ...tatement for example Battery voltage present Risk of injury due to high current Avoid contacting conductors with uninsulated metal objects Follow safety precautions One of these two symbols may be used to identify the presence of a hot surface It may also be accompanied by a statement explaining the hazard A symbol like this with a lightning bolt through the hand also means that thepart is or coul...

Page 34: ...r job training and safety procedures the following are some basic precautions that should always be used Use only properly insulated tools Remove all metallic objects key chains glasses rings watches or other jewelry Wear safety glasses Fuses can produce sparks High energy levels on buses and distribution components can produce severe arcing Test circuits before touching Lock out and tag circuit b...

Page 35: ...eim Einbau des Gerätes ist daraf zu achten das alle Anforderungen gemäß EN60950 eingehalten werden ACHTUNG HOHER ABLEITSTROM VOR ANSCHLUSS AN DEN VERSORGUNGSSTROMKREIS UNBEDINGT ERDUNGSVERBINDUNG HERS TELLEN Espanol Notas especiales para instalaciones en países de habla hispana Instrucciones de instalación Installation Instructions Voltaje Voltage Vea tabla 2 A Corriente Current Vea tabla 2 A Frec...

Page 37: ...efore beginning the installation Installation Tools Wire cutters and strippers Heat shrink gun Torque wrench 0 240 in lb 28 Nm 48 Volt test load Digital meter 0 02 Screw Drivers flat blade and Phillips ESD wrist strap Part List Ordering code Qty Description Single Wide 801085119 2 3 8 inch bolt Distribution Module 802286773 2 3 8 inch lock washer 802841635 2 3 8 inch flat washer 407646330 2 Shelf ...

Page 38: ... remove the shelf from the carton Use the parts list to verify all materials are included Save the shipping package until all parts are operating within specifications 3 Is there a Distribution Module already installed in the right most shelf position Yes Go to the Install the CPS6000 shelf section No Continue 4 Remove the Distribution Module Assembly from the carton The Assembly and the shelf wil...

Page 39: ... a 3 8 inch lock washer and a flat washer on the 3 8 inch bolt Locate the two access holes on the rear of the shelf Attach the Distribution Module to theshelf with the washers and two bolts Torque to 240 in lb 11 Cover the two access holes with the Black Plastic Covers shown 4 Screw Hand Tight approximately 5 in lb 3 8 Bolt 801085119 3 8 Lock Washer 802286773 3 8 Flat Washer 814251898 Torque 240 i...

Page 40: ...ient service loop on these cables Install the CPS6000 Shelf Follow the steps in the table below to mount the CPS6000 shelf into a 19 inch or 23 inch frame Step Action 1 Locate the 2 mounting brackets one on each side of the CPS shelf align the holes in the shelf mounting bracket with the holes in the mounting frame See Figure 5 4 2 Attach the CPS shelf to the frame using a minimum of four two on e...

Page 41: ...he Rectifier Installation section No Continue 2 Slide the controller into the shelf until it is fully seated in the connector on therear of the CPS shelf See Figure 5 5 3 Connect one end of the display cable to the connector on the controller Connect the display faceplate to the other end of the display cable Carefully dress the display cable when attaching to the shelf to ensure the cable does no...

Page 42: ... rights reserved Push the faceplate into the shelf until the latch catches on the top Tab on the bottom of the faceplate inserted into slot in the shelf Connect the display cable between the controller and the display Display Cable ...

Page 43: ...upplementary Shelf Board Step Action 1 Does the system have a supplementary shelf Yes Continue No Proceed to Thermal Compensation Connections 2 Does the supplementary shelf have the QS845A controller already installed Yes Proceed to Thermal Compensation Connections No Continue 3 Slide the QS845A into the shelf until it is fully seated in the connector on therear of the CPS shelf See Figure 5 6 4 I...

Page 44: ...controller to the shelf SHF 2 connector on shelf 2 2 Using shelf interconnect cables daisy chain the remaining shelves as required connecting from the TO NEXT SHELF connector to the next applicable shelf connector as shown Figure 5 7 Inter Shelf Connections Bend back insulation cover J2 SHELF SHELF Connector Controller in Primary Shelf QS845A on Shelf 4 QS845A on Shelf 2 QS845A on Shelf 3 J3 RS232...

Page 45: ...ng option being used 2 No Locate the 848719795 ThermalProbe Cable Near the 3 Pin connector Probe end the volt sense wire has a 1 Pin connector on the end cut and discard this wire and insulate the trimmed Yes Connect the 848652947 Battery Voltage Monitor Cable between the ES771A Battery Voltage Monitor Card and the controller P5 SYS AUX PORT connector See Figure 5 10 3 Connect the 3 Pin Connector ...

Page 46: ...95 10 Thermal Probe Cable Auxiliary Port Connector P5 SYS AUX PORT 848719803 5 or 848719811 10 Thermal Probe Interconnect Cables 2 Pin Connector 3 Pin Connector Note 848719795 848719803 and 848719811 all come with a discrete wire for Battery Voltage Sense If not used then trim and insulate trimmed end Plug wires into QS873A prior to placing QS873A into case Wires to straddle case as shown Place QS...

Page 47: ...res to case loop for strain relief Cable tie around case for additional support Top of case Case loop Plug wires into the probe prior to placing the probe into the case Place probe in the case and make sure the case pin inserts into hole in the board V Power Cable V Power Cable QS873A VT Probe Mounting Hardware Do Not mount beneath power lug 2 1 3 Mount or top of power lg as shown 0 0 J 1111 1 1 ...

Page 48: ...848719892 10 Thermal probe to ES771A 848652947 Battery Voltage Monitor Cable 848719795 8487719803 848719811 and 848719829 Battery Voltage Sense Cables all come with a discrete voltage sense wire figure 5 8 If battery voltage monitoring is used trim and insulted the trimmed end of this wire 108958422 ES771A Battery Voltage Monitor Card 108987611 QS873A Thermal probe 3 Pin Connector Sattel Voltage S...

Page 49: ...1 Default BD User Configurable Alarm Relay 2 ALM2 Default ACF User Configurable Alarm Relay 3 ALM3 Default RFA User Configurable arm Relay 4 ALM4 Default Battery Test in Progress Plant Battery Test Input Protected Analog Ground Emergency Power Off Protected Analog Ground Auxiliary Power Major Input Protected nalog Ground Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 Signal d...

Page 50: ...ction The cable should be appropriately dressed out of the CPS6000 system to the LAN connection The shroud of P5 has been terminated to chassis to accommodate the use of a shielded Cat 5 cable connection AC Connections AC Connections to Shelf Review the ac connection on the installed shelf Refer to Tables 3 B and 3 C for detailed CPS6000 rectifier ac input requirements Caution Ensure ac power is O...

Page 51: ...Insert the H569 470A ac cord into the ac receptacles on the CPS shelf Refer Figure 5 12a b c or d for the appropriate shelf 2 Terminate the supply end of the cable with an appropriate plug plug not provided Figure 5 12a Dual AC Input Connections AC Input Connectors AC Input Cable AC Input Connectors Jl ll ll ...

Page 52: ...t Connections Figure 5 12c Dual AC Input Cord 10 Awg 10 ft Connections Power Slots 1 3 and 5 Power Slots 2 And 4 AC Input Cables Rectifiers 2 and 4 AC Input Knockout for 3 4 Inch Conduit or type SO cord One AC Input foe each Group of Rectifiers Rectifiers 1 3 and 5 Ai ltll ...

Page 53: ...ystem before continuing with ac When connecting to utility source ensure all local and national wiring rules are being complied with Refer to Rectifier AC Input Current table for input current values of rectifiers Refer to Rectifier AC Input Current table for input current values of rectifiers AC Duct 1 Inch Conduit per Shelf AC termination Panel AC for Bottom Shelf 10 Gauge Wire 20A Circuit Break...

Page 54: ...enter lugs To use 2 AWG a suitable narrow tongue lug like the Burndy FCI may be evaluated Install C O Ground Conductor This procedure is used to connect the Central Office Ground Conductor Step Action 1 Is the cable routed from the top 2 Yes Connect the conductor lug to the bottom 2 positions for C O ground See Figure 5 14a and b No Continue 3 Connect the C O ground conductor to the top two mounti...

Page 55: ...shelf Rectifiers will power up when ac is applied to the shelf Step Action 1 Before engaging the rectifier connector into the back of the rectifier slot press the Latch release button the latch will spring open See Figure 5 15 2 Firmly push the rectifier into the rectifier slot until the connector on the rear of the rectifier engages with the connector at the back of the rectifier slot on the CPS ...

Page 56: ...nd Ringer modules will be powered when installed in the shelf when rectifiers and or battery power is present Note Ringer output connections are made after ringers are seated in the Ringer chassis Note The primary and spare Ringer modules install facing opposite directions Note No rectifiers may be installed to the right of a Ringer Chassis Figure 5 15 Rectifier Installation Single Slot Distribu T...

Page 57: ...rew hand tight to approximately 5 in lbs See Figure 5 16 4 Repeat until all ringer chassis s are installed Step Action 5 Locate connector on rear of ringer module and the mating connector on the insiderear of the ringer chassis Align the ringer module connector with the ringer chassis connector Place the ringer module in the guides and slide the ringer in until it fully engages with the connector ...

Page 58: ...s 8 Warning Consider the Ring signal as hazardous voltage Connect Ringer loads using Molex 39 01 4031 connector Socket Terminal to the HDR13 plug located inside the Ringer Chassis at the bottom front See Figure 5 18 9 Route ringer load cables through upper or lower notches in Ringer chassis and distribution module chassis See Figure 5 18 Ringing Type Tip JumperJ12 Position Comments Ground Backed 1...

Page 59: ...ircuit breakers are required remove the straps installed by the factory and install the bullet style circuit breakers into the bottom two positions in the Distribution Module See Figure 5 19 Caution Turn the circuit breakers to the OFF position until the unit is ready to be energized 2 Place batteries on the battery trays in a 48 V string arrangement per manufacturer s instructions 3 Make battery ...

Page 60: ...ns Single Slot No GMT Fuses Figure 5 19a Accessing Battery String Connections Front Insulation Lug Insulation Lexan Lug Cover Battery And Return Cables String 4 String 2 String 3 String 1 String 3 String 2 String 4 Battery Circuit Breaker Position String 1 Battery Power V RTN Jl ll ll ...

Page 61: ...Position Battery Circuit Breaker Position Battery And Return Cables String 2 String 1 String 2 String 1 Battery Power V RTN String 1 String 2 Distribution Module Right Side View Battery Power V Battery Returns RTN 4 Position Bus Bar for Battery and load Returns RTN Single Slot Distribution Module Front View with Door Open Battery Circuit Braker Positions Battery Power V String 2 String 2 String 1 ...

Page 62: ...led in the top two positions in the Distribution Module The load terminals on the circuit breakers can secure cabling from 18 AWG 1mm2 to No 2 AWG 33mm2 Step Action 1 Insert Load breakers in the top two positions in the Distribution Module 2 Terminate the load cables on the load buss with M6 nuts and torque to 65 in lb 7 3Nm See Appropriate Figures 5 20a through 5 20c for Distribution Module conne...

Page 63: ... Rear Load Connections Load Cables Vout 2 Single Contactor System RTN Return V Bus RTN 48V 48V 48V Bus Return V Bus RTN RTN LVLD LVLD V Bus 48V Bus 48V Dual Contactor System V RTN Battery Power Vout 1 Vout 2 Vout 1 Cables route behind GMT fuse Board C O Ground Position I ___ c Load Circuit erea1 er positiOOS I J Ai ltll ...

Page 64: ...Braker 1 Circuit Braker 1 Circuit Braker 2 Double Slot Distribution Module with LVLD Front View with Door Open Load and Return Cables Load Circuit Braker Positions Vout 1 Vout 2 Vout 2 See Note See Note Note These position are only available for load connection in Distribution Modules equipped with Low Voltage Load Disconnect LVLD contactors Circuit Braker 1 Circuit Braker 2 Circuit Braker Load Re...

Page 65: ...urrent and can support up to four 20 amp fuses if spaced properly If 20A fuses are used then adjacent fuse positions must be left empty See Figure 5 22 for fuse position and terminal block designations Step Action 1 Strip 0 24 inches 0 6cm of insulation from the wire 2 Insert the stripped wire through the side of the shelf and into the screw terminal Torque to 4 5 in lbs 0 5 Nm See Figure 5 21 for...

Page 66: ...Positions GMT Fuse Terminal Blocks 16 GMT Fuse Positions Load Power Terminal Blocks Load Return Terminal Blocks I F1 1 F2 F3 F4 F5 F6 F7 F9 F8 F10 F11 F13 F12 F14 F15 F16 __ F1 CS F2 S F3 0 F4 0 FS CS F6 S F7 0 F8 0 F9 CS F10 S F11 0 F12 0 F13 S F14 S F15 0 F16 0 __ CS S 0 0 0 S 0 l 0 0 0 l S 0 0 l F1 F2 F3 F4 FS F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 Jl ll ll ...

Page 67: ... Breaker and Fuse Installation Figure 5 23 and 5 24shows the proper circuit breaker and fuse orientation for installation Retention bracket may or may not be provided with all configurations Circuit Braker Retention Bracket Alarm Contact Receptacle Alarm Contacts Indicator Battery Circuit Breaker GMT Fuse Double Slot Distribution Module Only Jl ll ll ...

Page 68: ...s in Figure 5 25 are unfused Ensure cables ends are protected before terminating cables Step Action 1 Terminate 45 lugs with 1 4 inch holes on 5 8 inch centers to bus landings hot spots and torque M6 screws to 65 in lbs 7 3Nm 2 Break tabs off back of lug cover see Figure 5 25 3 Insert the front post of the lug cover into the mounting hold and snap the tabon the back of the lug cover into place Lug...

Page 69: ...tion Load connections are made to the Bulk Output Distribution Module as shown in Figures 5 26a or 5 26b or 5 26C To Bus Bar Terminal Bulk output Distribution Right Side view 4 Position Bus Bar for Battery and Load returns V 4 Position Bus Bar for Battery and Load returns V Back to back lug connection if additional cables are required 48V Connections 1 ga RNT Connections 1 ga Bulk Output Distribut...

Page 70: ...ter the top of a Group 163 distribution panel of H5694720 arranged for battery input Group 163 distribution panels are typically factory configured with four positions for battery input and eighteen positions configured for load outputs Bulk Output Distribution Module RTN Connections 1 ga 48V Connections 1 ga Back of Shelf Alarm Jumpers 4 battery Positions 18 Output Load positions Return Connectio...

Page 71: ... switches as required to match battery discharge current Make sure switch is down in the OFF position If optional internal battery switches are not required Install no switch jumper busses as required 5 Using a voltmeter verify polarity of the battery cables 6 Attach the POSITIVE cable to the RTN bus position in line with the switch 7 Attach the NEGATIVE cable to the busbar directly above the swit...

Page 72: ... ABB All rights reserved Figure 5 29 Install 4 String Battery Busbar Figure 5 30 Relocate Alarm Jumper Install alarm jumper into this position Remover alarm jumper from this position Alarm Jumper 6 6 6 6 0 f9 6 6 6 9 6 616 o ...

Page 73: ...n lugs Ordering Code STD Wire Ga FLEX Wire Ga 405356171 14 10 14 10 405348178 8 8 406338400 6 6 405347576 4 4 405348202 2 405347683 2 407817568 1 0 407817550 2 0 1 0 407817576 2 0 Ordering Code STD Wire Ga class B FLEX Wire Ga class I 406338665 2 405348228 1 0 405348236 2 0 1 0 406021725 2 0 405348251 4 0 4 0 405347923 407890763 350 350 407890748 three Position and Two position Load and return lug...

Page 74: ...battery disconnect switches place them in their ON CLOSED positions prior to applying ac power 2 Turn on the ac service circuit breakers to apply power to the CPS6000 power system 3 Verify that All LEDs on all components including rectifiers controllers LVD boards and remote voltage monitor modules are green 4 Verify that the reading on the controller display is 54 5 Vdc Note that if the connected...

Page 75: ...iate IP address subnet mask hostname and default gateway IPaddress must be configured on the QS841A through serial port J3 To login to the QS841A follow these steps Start up the PC terminal program Windows Terminal ProComm etc using the following communication parameters Baud 9600 Data 8 Parity noneStop 1 Handshaking noneFlow Control none Connect the PC to the QS841A local port RS 232 connectorJ3 ...

Page 76: ...nfiguration session enter the bye command The QS841A will notify the user if configuration is not complete This message will have the following format NOTICE Default Gateway may be required for network access Host Name may be required for network access Logging off Messages referencing the Gateway and Host Name are acceptable since the separameters are optional Note If the IP address or Subnet mas...

Page 77: ...eptacles on the CPS6000 shelf Terminate the other end with an appropriate plug Follow all safety rules provided with the plug when connecting the plug to the cable assembly Refer to the following table for ac feed polarity AC Voltage 120V 200 to 240V Cable Color Code Cable Color Code Line 1 Line 1 Black Brown Neutral Line 2 Neutral White Blue Ground Ground Green Green Yellow Guide the utility end ...

Page 78: ...5 RS 485 GP communication bus 3 RECT_PG_EN Programming enable signal to rectifier future use 4 ISHARE Rectifier analog current share Auxiliary Port Connector An RJ 45 receptacle P5 is provided on the QS840A QS841A board for connecting to the QS773X VT Probes or to the QS771A Remote Voltage Monitor This connector is accessible when the controller is inserted in the shelf The signals and pin assignm...

Page 79: ...ata Set Ready input 5 RS 232 ISO GND RS 232 Isolated Ground 6 RS 232 DTR RS 232 Data Terminal Ready output 7 RS 232 CTS RS 232 Clear To Send input 8 RS 232 RTS RS 232 Request To Send output 9 NC No Connect LAN Connection Ethernet A standard integrated RJ 45 receptacle P6 is provided on the QS841A for connecting to an appropriate 10 100 Base T LAN P6 is shielded with the shield being tied to chassi...

Page 80: ...input connector pin assignments are shown below Pin Alarm 1 Auxiliary 1 2 Auxiliary 2 3 Auxiliary 3 4 Auxiliary 4 5 Return Vminus Battery Alarms are generated by connecting alarm contactinputs to Vminus typically through a clean relay contact from the monitored device Figure 6 2 P5 Auxiliary Alarms Connector Mating connector information for this 4 pin connector is as follows Housing Amp part numbe...

Page 81: ...ional Bulk Output Module Connections Vsense Vsense Pins 1 and 2 Vsense and Vsense on J2 are wired to monitor system voltage internal to the Bulk Out put Module To monitor system voltage externally unplug the mating connector from J2 and connect Vsense and Vsense to the external source to be monitored J3 Bulk Output Module J2 J3 J2 rnrn rn I I Pin Positions facing into connectors Pin Descriptions J...

Page 83: ... can be used to adjust screen contrast when the controller is displaying the default screen Contrast adjustment is also available through the menus at Menu Configuration System Settings At the default menu the left and right arrows are also used to toggle the display from displaying the system voltage or the system load current Otherwise the left and right arrow keys are used to navigate the menus...

Page 84: ...ons Software The software is functionally divided on the Main Menu into the following categories Alarms Warnings Status Control Operations History Configuration The following figures show a map view of each category and the settings and operations found in each and are followed by brief descriptions of the menu items Alarms and Warnings are not hierarchal mapped and are presented in chronological ...

Page 85: ...1 LVBD LVLD1 3 Very High Major High Minor BD Major 1 Float Voltage Alrms 1 Very Low Major ____________________ Boost Voltage Alrms 1 _ Very High Major High Minor BO Major High Batt Temp Reserve Low High Ambient T Low Ambient T Ringers Chassis 1 2 1 1 State VA Enable Disable 1 Temp Comp Info Low Temp Comp System Info Recharge llim Auto Boost Auto Batt Test Reel Redundancy Mid Cell V Mon Imminent Sh...

Page 86: ...tory Clear Statistics Start Battery Test Start Boost Disconnects Reset Admin Passwd History I A larm History r BD History Boost History I I I All Devices Rectifiers Ringers Alarm History BD History Boost History Clear Basic Clear Trer d I I I I I I Jl ll ll Plant Load I High BattT I Clear BD I Ambient Temp I All Basic I Disconnect Reconnect LVBD Disconnect Reconnect LVLD 1 Disconnect Reconnect LVL...

Page 87: ... n RalirQ Redundancy Batt Type Installed Capacity Battery Strings End of Discharge I I Batt Temp Mana lement r Battery Test f RechargeAmp Lirnitr IVoltage Imbalance ID1 4 Type VPiy High Major High Minor BD Major Very Low Major High Temp Alarm Tamp Comp I ligh Temp Comp Nominal Temp Lowfamp Comp Manual Test I utomatio Test IReclifier Voltage Reserve Low Limit Limit To r Jl ll ll Duration l larm Vol...

Page 88: ...tomatic System Settings Display Contrast Date Time Daylight Savings Display T Units High Ambient T Low Ambient T Communication I Port Type Ports I Local Port Settires Modem Port Setting LVBD Disoonnect Control Reconnect Control I LVLD n Disconnect Control Reconnect Control Very High Major High Minor Write Access Baud Rate Flow Control Write Access Baud Rate Flow Control Rings to Answer Mode Voltag...

Page 89: ... includes the following An array of simple push button controls A backlit four line LCD display that changes color to reflect the system alarm status as follows Green Normal Amber Minor Alarms Present Red Major Alarms Active Minimum Configuration The Controller has many configurable parameters All parameters are discussed in this section The following steps cover the minimum configuration Key Desc...

Page 90: ...s highlighted press the Display Menu key and the follow ing selections are available Float settings Shunt rating Rectifier Redundancy Batteries Contactors Boost System Settings and Communication Ports r IMain Menu I Co1trol O Jera tions History Config1 ralion Ccnfig ration Foal Settings Sht nl Rectifiers Bal nrims Corilaclms I Boost Communication Purl I I I I I I I I I I Jl ll ll ...

Page 91: ... in 1V increments The factory default setting is 56V BD Battery on Discharge Major Alarm occurs when the system is operating either completely or partially on battery pow er The alarm threshold can be set from 46V to 55V in 0 1V increments The factory default setting is 51 0V Very Low Voltage Major Alarm indicates an imminent system shutdown due to discharging batteries or low output voltage Facto...

Page 92: ... battery test was completed and thereserve time Next Test The date of the next automatic battery discharge test The automatic discharge test feature must be enabled for this to work Live Reserve Time Present value of battery reserve time calculated by the controller Float VoltageAlarms Very High Major Very High Minor BD Major and Very Low major Boost VoltageAlarms Very High Major and High Minor Hi...

Page 93: ...tery test feature A stop battery test operation is displayed to interrupt the testing and return the unit to normal operation The manual battery test utilizes the configured test duration and a system bus voltage threshold to represent the end of reserve Start Boost Initiates the manual battery Boost feature A stop battery Boost operation is displayed to interrupt the Boost operation mode and retu...

Page 94: ...ntrolled These boards must be identified by assigning them an address and an appropriate operation The following is shown for completeness ID1 4 The operation Type of each shunt monitoring circuit on system distribution boards 1 4 must be assigned based upon actual system implementation The operational Type may be None Forno shunt Battery Monitoring battery currents and Load for load currents ID1 ...

Page 95: ... to a specific contactor function The controller can assign up to four IDs to boards used for controlling LVDs Each unique ID number can be assigned to one of the following LVBD 1 Low Voltage Battery Disconnect 1 LVLD1 Low Voltage Load Disconnect 1 LVLD2 Low Voltage Load Disconnect 2 LVLD3 Low Voltage Load Disconnect 3 or NONE Each of these assignments has its own unique programmable parameters Se...

Page 96: ...wn below Voltage Nominal ringer output AC voltage Range 65 100 VACrms Factorydefault is 100 Frequency Nominal ringer output frequency Range 15 50 Hz Factory default is 20 DC Offset Enable or Disable the capability of configuring a DC offset voltage to the Ring Output The factory default setting is Enabled Redundancy Enable or disable the loss of redundancy alarm Alarms when one of the two ringer m...

Page 97: ... the following communication parameters Port Type Set the communication port to either Local or Modem Factorydefault is Local Local Port Settings Enable or disable Write Access the ability to change system settings through the local port The factory default setting is enabled Set the port Baud Rate to auto 2400 4800 9600 or 19200 The factory default setting is auto Set port Flow Control to none HW...

Page 99: ... perspective which is applicable to respective feature implementation in the web pages Controls and Display Figure 7 1 shows the front panel controls and display of the controller The backlight of the four line LCD display changes color to reflect the system alarm status as follows Green Normal Amber Minor Alarms Present Red Major Alarms Active The up and down arrow keys can be used to adjust scre...

Page 100: ...iguring the controller to place this port into Server mode In this mode the port serves as the Ethernet Craft port and allows standard Web browsers to be used for accessing the controller This port should never be plugged into the office LAN if it is in the DHCP Server mode Factory default for this port operation is Static requiring an IP address to be programmed for the unit Connector P5 is used ...

Page 101: ...eatures will not be changed through a maintenance routine Thus they require entrance of the correct PIN in order for the parameter or feature to be modified in the field There are some Control Operations that also require the PIN shown below 1 Clear History 2 Clear Statistics 3 Disconnects Manual disconnect reconnect of any LVLD LVBD 4 Enter Boost Other Control Operations features listed below do ...

Page 102: ...l for more than user configurable time out value The QS841A has a factory configured default of 30 minutes This time is adjustable between 1 120 minutes in 1 minute increments An internal counter shall be kept and reset if the user leaves the default menu and returns to others menus before the time out period is reached The following figures show a menu flow map for each primary category along wit...

Page 103: ...mp Recharge lllm Emergency Pwr Off Alarm Test Auto Boost Auto Batt Test Reel Redundancy Mid Cell V Mon Imminent Shutdown Disconnects Ringer DC Offset Ringer Redundency Remote Rect Off LocalWrle Modem Wrrte Network Write User Names Port 1 2 I I System Controller Info I I Da te Time Ambient Temp Jl ll ll Installed Capacity Number of Strings Current Highest Temp Temperature Probes Mid Cell Volts Batt...

Page 107: ...ttery test was completed and the reserve time Next Test The date of the next automatic battery discharge test The automatic discharge test feature must be enabled for this to work Shunt Currents Up to six shunt measurements can be displayed through appropriate Distribution Control and Monitoring modules The NX400 is equipped with four QS871 distribution control and monitoring modules These modules...

Page 108: ...the system can be configured through the modem port Network Write Whether or not the system can be configured through the network Usernames Whether or not usernames and password identification has been enabled Network Settings This section of the menu displays the settings of the Network parameters for up to two Ports The standard QS841A port is considered Port 1 A second network port is achieved ...

Page 109: ...Only access Read Write access is available when the feature has been enabled System Info This section of the menu displays various high level system status Controller Info Provides software versions for overall controller boot block display and web pages It also provides the file used for factory defaults along with its version number For the NX400 the display is of the format vNX d d Date System ...

Page 110: ...interval Start Battery Test Initiates the manual battery test feature A stop battery test operation is displayed to interrupt the testing and return the unit to normal operation The manual battery test utilizes the configured test duration and a system bus voltage threshold to represent the end of reserve Disconnects Provides individual manual control of the four Low Voltage Disconnects LVBD LVLD1...

Page 111: ...he history log was cleared The number of these events counts towards the total number of Modem Network PIN and Local port eventswhich can be up to 48 events Configuration This area of the menu system is where system operational parameters system device information and alarm thresholds are set up These items have been pre configured for the standard QS841A controller Note The controller requires ti...

Page 112: ...D1 and NONE for the rest ID1 6 Rating The current rating of each shunt being monitored by the system distribution boards 1 6 must be configured based upon actual system implementation All shunts are assumed to be 50mV The current rating may be from 0 9999 Amps The factory default is 300A for ID1 4 and 600 for ID5 6 Rectifiers The following features pertaining to rectifiers can be configured Redund...

Page 113: ...able range is 0 16 The NX400 system factory default is 0 strings End of Dchrg The user defined system bus voltage at which the batteries are considered tobe at the end of their reserve capability for manual battery testing End of Discharge This end of discharge voltage is used for automatic and opportunistic reserve time calculations It has a range of 36 00 to 48 00V The system factory default is ...

Page 114: ...a system bus voltage threshold Voltage or based on both reaching the system bus voltage threshold and an elapsed time from once the system has been placed on discharge BD and at least two or more rectifiers are reporting AC failures Voltage Time The Voltage and Time mode of operation can also be selected for reconnecting LVDs In this case the elapsed time configured is the time from once the recon...

Page 115: ...operation parameters that include the ringer output voltage 65 100VAC ringer output frequency 15 50Hz whether it has remote DC Offset Enabled Disabled and if the ringer chassis is operating in the redundant mode Enabled Disabled are defined in this configuration menu Boost The Boost function allows battery charging to be expedited by raising the system voltage to Boost level for a set time The fol...

Page 116: ...tting is required by the EBW in the NX400 system in order to provide the SNMP management port Local Port Settings Provides the ability to Enable or Disable Write access to the controller theability to change system settings through the SNMP management or local port The factory default setting is enabled The baud rate number of data bits parity number of stop bits and flow control parameters for th...

Page 117: ...ted by removing power from the unit by removing and re inserting the unit into the shelf In addition there is the ability to Enable or disable Write access for someone who is attached to the Craft port The factory default setting is Enabled 10 100 Base T Ethernet Port The 10 100Base T Ethernet is designed for remote access and system management but can be set up to provide a Craft interface port W...

Page 118: ...sing the PIN The Home Page shown previously has tabs that are partitioned as the following Home Main login page that shows representative graphic of the plant The graphic will depict the number of shelves rectifiers in place with their appropriate outputs empty slots and indicate which rectifiers are in alarm High level summary for the Batteries Distribution Alarms present and controller summary a...

Page 119: ...able through the web interface Web pages will continually be enhanced Consult appropriate ABB Power personnel for addi tional details Selecting the Reports tab produces the following screen Settings Items in this menu are used to configure all the individual system parameters features and thresholds These fields are arranged by System Reserve Communication and Programming Installation This tab all...

Page 120: ...eserved As an example selecting Inventory from the Reports screen produces the following page Obtaining a chronological view of the alarm events is also available by selecting Event History from the reports screen produces the following page ...

Page 122: ...t 2021 ABB All rights reserved Selecting the Settings tab produces the web page from which configuration for all individual items can be performed Selecting Battery in the Settings screen produces the following web page ...

Page 123: ... reserved Selecting the Installation tab produces the web page from which a quick high level configuration can be performed Configuring the battery type site ID date and time are generally the only configuration items required for the plant ...

Page 125: ... fans and operates from 40 to 75 C ambient temperature The QS862A rectifier produces 1363W from 90V to 132 Vac and 1635W from 180V to 275 Vac From 85 to 90 Vac low line and 150 to 180 Vac high line it goes into limited power mode where it continues to perform at a reduced output power level It has two built in fans and operates from 40 to 75 C ambient temperature If it is initially powered up from...

Page 126: ...shed by disengaging the power supply from its mating connector on the shelf waiting until the front panel LEDs have stopped illuminating and then reinserting it back in the shelf Thermal Alarm Power Limiting The rectifier power limits itself to protect itself from thermal damage yet at the same time trying to support the load An internal critical temperature is monitored If the temperature exceeds...

Page 127: ...r it will blink its Alarm LED Once communication is lost with the system controller the rectifier output voltage will remain at the last voltage set by the system controller Features and Functions QS86xA Output Power Curve The following graph shows the QS86xA rectifier output power curve This curve is valid for both low line and high line operation Use the table following the curve for the current...

Page 128: ... system controller Note that the rectifier will remain at the last voltage it was set to should the system controller fail or be removed Rectifier Power A B C D 25A 1362 5W 23 49A 25A 28 39A 20A 30A 1635W 28 19A 30A 34 06A 24A 15A 818W 14 09A 15A 17 03A 12A 50A 2725W 46 98A 50A 56 77A 40A 40A 2180W 37 59A 40A 45 42A 32A 500W 500W 8 6A 9 2A 10 4A 7 3A ...

Page 129: ...ote that during a battery on discharge event the system controller signals the LVD board to disconnect the batteries from the system once the battery strings have discharged to the threshold voltage set by the user This command is not possible during a communication failure If communication is lost during this event the LVD boards will disconnect at the backup disconnect voltage of 35V 1V Similarl...

Page 130: ... is powered up the QS872A will close the contactors and present the output bus voltage at the battery terminals If an external disconnect switch is being used to take battery strings off line for replacement care must be taken to ensure battery connections are correct at the switch This is because the contactors remain closed when an external disconnect switch is used to disconnect the batteries f...

Page 131: ...t from that Ringer Chassis is powered by that ringer Should that ringer be removed or fail ringing output will not provide ringing and an alarm will be sent and displayed by the Controller Ringer Overview Warning The Ring signal shall be considered hazardous and shall be spaced from other circuits by 0 055 in 1 4 mm Ringers convert dc to ringing power QS820A Ringers convert 48Vdc to a 100VA ringin...

Page 132: ...ree types of ringing Battery Backed Ground Backed and Ground Backed no dc Ringing type is selected by selecting dc Offset polarity and by enabling or disabling dc Offset dc Offset polarity is set by the J12 Ringer Chassis jumper or external connection dc Offset may be disabled via controller setting if desired Ring Return tied to VBUS Tip wire Ring 48Vdc VBUS Ground VBUS Voltage Ring Ring wire Rin...

Page 133: ...ault pattern 2 Normal is only active when no other condition is active 3 Fan Fail chassis fan is not a Ringer failure and does not affect LEDs 4 Output Power or Voltage is reduced limited to less than the Operational Setting due to excessive external load or excessive ringer temperature Status Descriptions Normal Operation Ringer is operating within specification without output limiting Standby Ri...

Page 134: ...matic when the external fault is removed In this mode the Ringer shuts down and restarts briefly at intervals of approximately 2 minutes to test for the presence of the external fault Restart will cause restart immediately Internal Fault Ringer output is disabled shutdown due to excessive temperature or Ringer failure Recovery from Internal Fault Excessive Temperature recovery is automatic when th...

Page 135: ...mal Probe VT Probe J2 This 3 position connector serves to connect the VT Probe to the Distribution Module using the H569 470GB 848719715 cable It may also be connected to the ES771A Remote Voltage Monitor Module or be connected to other VT Probes in daisy chaining using either the H569 470GC 848719803 5 ft or the H569 470GD 848719811 10 ft cable This connector also serves to connect the VT Probes ...

Page 136: ...dress the ES771A A setting of 0 produces and invalid ID alarm Valid ID settings are from 1 through six Status LED The module illuminates its green LED when plugged into the 1 wire network and with the VT probe attached to negative battery terminal of the mid string voltage The LED will illuminate red when the controller determines that one or more of the strings from the unit has exceeded the Mid ...

Page 137: ...al features Figure 12 1 ES772A Remote Distribution Module Controls LED and Connectors Receptacle J1 User connections to external distribution module Receptacle J3 User connections to external distribution module J100 J101 User connections to the QS840A System Controller Auxiliary Port Connector P5 and to other devices such as the QS873A VT Probe and the ES771A Remote Voltage Monitor Module Recepta...

Page 138: ...ternal source J5 pins 11 and 12 2 inputs to alarm upon closure to VBus for distribution protector open alarms J1 pins 6 and 13 2 inputs to alarm upon closure to VBus for battery circuit breaker open alarms J1 pins 7 and 14 2 LVBD or LVLD Contactor Manual Disconnect Switches are provided These switches allows users to manually open up to two external contactors to disconnect a battery string from t...

Page 139: ...e connections should be positive during battery discharge Control and monitor two contactors These connections are to control and monitor two contactors either of which could be a load or battery disconnect device Monitor plant voltage for backup LVD function in case of failure of controller during battery discharge Module Connector Definitions The ES772A module has five connectors that the user i...

Page 140: ...o VBus Connect to NC terminal of breaker microswitch or to indicator lead of GMT fuse other end C referenced to VBus 14 EXT BAT SW2 Alarm input for external battery disconnect switch alarms on closure to VBus Connect to NC micro switch of US StyleCB other end C referenced to VBus micro switch must close upon manual opening of CB Table 12 A Connector J1 Pin out Definitions continued Pin Name Defini...

Page 141: ...devices with a micro switch that closes on an alarmed state Examples of this might be a Door Open alarm or a Fan Fail alarm Since these devices all alarm on a contact closure the protectors of the same type may have the indicating NC terminal connected together and the C terminals connected together and connected as shown above This is not the case for DIN style circuit breakers which must be indi...

Page 142: ...y of the two strings is correct to each other Improper connection will result in one string being shorted to the other string and the system can not protect against this With the above connections the following alarms will be issued for the conditions noted ContactorFail Alarm Contactor Open Alarm Open String Alarm QS840ALED ES772 LED Open Integral ES772A Disconnect Switch X RED BlinkingAMBER Batt...

Page 143: ...onnection will result in one string being shorted to the other string and the system can not protect against this With the above connections the following alarms will be issued for the conditions noted This assumes the external disconnect switch is used to open and close the battery charging path to the batteries Figure 12 5 Alarm Connections for DIN Style Load Protectors ContactorFail Alarm Conta...

Page 144: ...ES772A to the controller via the Auxiliary Port connector on the QS840A controller and then connect the QS873A to the unused RJ 45 jack on the ES772A If the ES772A is being used with both the QS873A and the ES771A Remote Voltage Monitoring Module connect either the ES771A or the QS873A to the QS840A controller as both have two RJ 45 jacks for serial communication purposes Then connect the two jack...

Page 145: ...ble battery positions that can be configured either with the battery bus or the load bus using an adapter plate All lug connections shall accept double holed lugs Staggered vertical arrangement of up to three distributions directly stacked with wiring access Contactor control measurements and alarms with the QS84x compatible ES772 module CO ground connection Contactor options ñ None LVBD LVLD 500A...

Page 147: ... 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 onDischarge Rectifier output voltage has fallen 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 field represent...

Page 148: ... and replacing the rectifier s 2 If problem persists replace therectifier 3 If problem still persists call your local field representative RED MAJ Major Communicatio n Fail R or missing LVD Board LVD Board lost communication with the controller 1 Replace Distribution ModuleBoard Note 2 2 If problem persists call your local field representative RED MAJ Major Communicatio n FailMinor Ringer Redundan...

Page 149: ...epresentative AMBER MIN Rectifier Fail Single rectifier 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 rep...

Page 150: ... Ringers not fully seated in Ringer Chassis Ringer not powered Failed Ringer 1 Fully seat Ringers in Ringer Chassis 2 Provide 48Vdc from Rectifiers or batteries 3 Replace failed Ringer 4 If problem persists call your local field representative any any Failed Ringer Replace Ringer Note 1 While in hiccup mode Rectifiers will attempt to restart every 10 seconds for a maximum of 3 times Ringers will a...

Page 151: ...ent command see Appendix A If the registered number of probes is equal to the total number of probes connected remember you ve removed a probe so the total number should be one less than that during installation then the first probe is defective Replace the probe with a different probe and follow the above procedure to ensure it is operational 3 If the system controller LED remains green or the nu...

Page 153: ...able for repair Seller will repair the Product at Customer s site With respect to Cable and Wire Products manufactured by Seller which Seller elects to repair but which are not readily returnable for repair whether or not installed by Seller Seller at its option may repair the cable and Wire Products at Customer s site D If Seller has elected to repair or replace a defective Product Customer shall...

Page 154: ...which the Product is incorporated This warranty applies to Customer only and may not be assigned or extended by Customer to any of its customers or other users of the Product THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE CUSTOMER S SOLE AND EXCLUSIVE ...

Page 155: ...s user and super user A user has read ability and can only get status information from the CPS6000 A super user can change configurations and perform control operations All access to CPS6000 is via the T1 317 command set to be discussed later This section describes how to log into the system via an RS 232 local port The first step to logging in is to get to an ENTER PASSWORD prompt From a terminal...

Page 156: ...tatus of the plant the command cha is used to change a plant parameter and the command ope is used to initiate a plant function A person at the user level can only perform the sta operations A person at the super user level can also perform the cha and ope operations Instructions in the T1 317 command set take the following form command object attribute parameter Certain commands do not require a ...

Page 157: ... Plant voltage x number dd dd V dc1 adc External Battery Shunt Size x number ddd d A dc1 sha1 Plant shunt size x x number 0 9999 200 0 none dc1 trd Plant total rectifier drain x number ddd d A dc1 isd Imminent shutdown enable x x number 0 disable 1 enable dc1 cap Total rectifier capacity x number ddd dA dc1 rss Rectifier restart x x number 0 no action 1 restart dc1 bod Battery on discharge x numbe...

Page 158: ...ost voltage threshold x x number 50 60 57V hva1 fth Very high float voltage threshold x x number 50 60 57V hva1 sev Very high voltage severity x x text MAJ MIN or RO rtl1 acc Reserve time low relay x x text R1 R2 R3 R4 or rtl1 ast Reserve time low alarm state x number 0 not active 1 active rtl1 sev Reserve time low severity x x text MAJ MIN or RO rtll thr Reserve time low threshold x x number 0 99...

Page 159: ...nor communication alarm state x number 0 not active 1 active cma1 sev Minor communication severity x x text MAJ MIN or RO cno1 acc Contactor 1 open relay x x text R1 R2 R3 R4 or cno1 ast Contactor 1 open alarm state x number 0 not active 1 active cno1 sev Contactor 1 open severity x x text MAJ MIN or RO cno2 acc Contactor 2 open relay x x text R1 R2 R3 R4 or cno2 ast Contactor 2 open alarm state x...

Page 160: ...or tpa1 ast Thermal probe fail alarm state x number 0 not active 1 active tpa1 sev Thermal probe fail severity x x text MAJ MIN or RO vmf1 acc Voltage module fail relay x x text R1 R2 R3 R4 or vmf1 ast Voltage module fail alarm state x number 0 not active 1 active vmf1 sev Voltage module fail severity x x text MAJ MIN or RO vsf1 acc Sense voltage fail relay x x text R1 R2 R3 R4 or vsf1 ast Sense v...

Page 161: ...d properly configured the voltage imbalance detection alarm is asserted when the controller detects an imbalance between the two halves of each battery string being monitored AC Fail The ac fail alarm is asserted when the controller detects a single ac fail alarm from any rectifier Rectifier Fail The rectifier fail alarm is asserted when the controller detects a single rectifier fail alarm from an...

Page 162: ...ividual rectifiers Note that the rectifier numbering starts from the left most position of the master shelf shelf number 1 When obtaining individual rectifier status information the following information may be transmitted ON Rectifier operating normally User may use ope to turn ON a rectifier in standby OFF Rectifier has been shutdown due to hardware failure STANDBY User has inhibited the rectifi...

Page 163: ...100A in 1A increments At least one battery string must be present to have this function operate Battery Reserve Management Related Commands obj attr description sta cha ope type range of values br1 hbt Highest battery temperature x number dd C br1 adc Total battery current x number d A for discharge for charge br1 bts Plant battery test lower rect V x x number 0 stop 1 start br1 scd Battery voltag...

Page 164: ...y Contactor Related Commands obj attr description sta cha ope type range of values Low voltage battery disconnect threshold x x number 39 48 42 V cn1 rth Low voltage battery reconnect threshold x x number 39 48 44 V cn2 dth Low voltage load disconnect threshold x x number 39 48 42 V cn2 rth Low voltage load reconnect threshold x x number 39 48 44 V Low Voltage Battery Disconnect Threshold Sets the...

Page 165: ...the minimum temperature for which low temperature thermal compensation is continued Nominal Temperature This sets the reference temperature at which increases in temperature above this reference temperature will result in the output voltage being decreased at the slope selected by the user Temperatures below the reference temperature will result in the output voltage being increased at the slope s...

Page 166: ... command reports all the active alarm conditions in the plant One alarm message is listed per line in the report The table below lists the default alarm messages Note that if user changes the severity of the alarm the corresponding change will show up in the alarm message However alarm conditions with the RO severity will not be displayed the rec command discussed later should be used Alarm Messag...

Page 167: ...d below to illustrate how this command works cha ps1 sid My Plant Change the site id to My Plant cha p1 phn 123456789 Change the primary phone number to 123456789 You must be logged in as a super user to use this command His Report Alarm History Syntax his Description Syntaxhis where obj attr is an object attribute pair as defined in the following sum dc1 adc report plant load current statistics s...

Page 168: ...ore completing DISCHARGEBoost suspended because of a battery discharge CANCELEDBoost canceled by user ALARMBoost cancelled by an alarm condition DISABLEDAuto boost cancelled by being disabled his Report BD history Syntax dc1 bod Description This command reports the battery discharge history in the following format his dc1 bod 30 MAY 03 15 11 12 MANUAL COMPLETED 118 3 23 01 APR 03 03 11 12 BD COMPL...

Page 169: ...e following lis rec G11 G12 G13 _ login Log in Syntax login password where password is either the user super user or administrator password Description This command is used to log in as a user super user or administrator For example if you are currently logged into the controller as a user but would like to change the site id you must first use this command to log in as a super user You must be lo...

Page 170: ... The line starting with VDC identifies the DC voltage The line is the end of command identifier sum Report Statistics Syntax sum obj attr where obj attr is an object attribute pair defined by the following sum dc1 adcReport plant load current statistics sum br1 hbtReport highest battery temperature statistics sum br1 amtReport ambient temperature statistics Description This command reports the hig...

Page 171: ...m hourly averages and up to 13 monthly averages of the daily maximum hourly averages The following is an example of a command response sum dct1 DCT1 SRC DC1 ADC CLR 01 JAN 2001 12 00 00 DHI 29 JAN 2002 02 00 00 123 2 30 JAN 2003 05 00 00 120 1 31 JAN 2003 14 00 00 122 8 DLI 29 JAN 2002 12 00 00 120 9 30 JAN 2003 08 00 00 118 7 31 JAN 2003 01 00 00 119 2 DHH 29 JAN 2002 02 00 00 122 1 30 JAN 2003 0...

Page 172: ... maximum voltages and lowest voltage at end of discharge The following is an example of a command response sum dc1 bod DC1 BOD CLR 29 JUN 04 10 27 11 BEG 30 JUN 04 10 38 36 END 30 JUN 04 10 42 53 DUR 256 VAL 0 51 08 8 50 18 18 49 24 20 48 87 248 48 36 252 49 76 254 50 84 256 51 13 The line is the end of command identifier The in the example above is the user command line prompt GUI Report GUI Comp...

Page 173: ...ognized password 223 INVALID PASSWORD New password contains an illegal character 224 NEW PASSWORD MISMATCH First and second copy of new passwords don t match 304 INVALID PARAMETER An attempt was made to change a parameter to an illegal value 319 INVALID ATTRIBUTE An invalid object id was specified in the command or a command referred to an attribute that doesn t support it 320 INVALID OBJECT An in...

Page 175: ...emperature Compensation The system controller automatically enables high temperature compensation if a VT thermal probe is detected The feature can be disabled by disconnecting all thermal probes and updating the serial links using the Lamp Test function Settings for this feature are as follows V Step Down Battery step temperature can be set from 45 C to 85 C The factory default setting is 75 C Hi...

Page 176: ...the graph shown below Lowering the plant voltage helps to keep the batteries at their optimum state of charge while protecting them from thermal runaway Thermal runaway is a complex sealed battery phenomenon where for one or more of a number of reasons one or more cells in a string are unable to dissipate the internal heat generated by their charging current and experience an increase in internal ...

Page 177: ...utt If Low Temperature Compensation is enabled temperatures monitored between this point and the Lower Thermal Limit ltt will result in a proportional increase of plant voltage to a level corresponding to lsp ntt ltt 24 V above the fsp at the ltt Upper Temperature Slope usp The slope rate for the voltage decrease per cell when the battery temperature is above the ntt Battery Thermal Slope Nominal ...

Page 178: ... the highest possible LVD contactor disconnect threshold so as not to accidentally open the LVD contactor Lowering the rectifier output voltage to 44V creates a battery on discharge condition If the batteries are present and healthy the plant voltage will remain above 48V and the batteries will support the load If the batteries are not present or are not able to support the load the plant voltage ...

Page 179: ...ng a battery discharge once the BD alarm has been retired provided the duration of the discharge was greater than 4 minutes The controller will not enter the auto boost charging mode if the discharge duration was less than 4 minutes When in auto boost mode the controller raises the plant voltage to the value selected by the user The controller keeps the plant in this mode of operation for a minimu...

Page 180: ... the alarm is issued the Float Set Point fsp and the Battery on Discharge BoD threshold values are reduced by 1 24th Once the alarm has been cleared by the CLE command the plant reverts to its normal fsp however the BoD threshold is maintained at the new threshold for up to four minutes before reverting back to the old threshold This is done to ensure the batteries have had enough time to charge u...

Page 181: ...hows which alarms may be assigned along with their factory default settings Alarms Table C 1 shows a list of all alarms along with their descriptions default settings ranges and or severity and affected alarm relays and LEDs LED LED Alarm Relays Alarm Event Description Default Setting Range Severity PMJ PMN Relay1 Relay2 Relay3 Relay4 PMJ PMN NORM AUX MD Red Yellow Green Red Auxiliary 1 Alarm asse...

Page 182: ... on Discharge Voltage threshold generally used to indicate the system is completely or partially operating on battery power hasbeen reached System batteries are discharging 51 1V Major 46 55V Major Minor RO Check Battery Alarm asserted when battery does not pass the manual automatic or periodicdischarge tests Manual discharge tests must be user invoked Minor Major Minor RO Circuit Pack Failure Ext...

Page 183: ...e measurement has reached the configured low ambient temperature threshold 40 C Minor 40 10 C Major Minor RO Controller Fail Controller has power and has failed Implemented in hardware N A N A Defective TempProbe Controller determines a 1 wire probet to be defective Minor Major Minor RO Fan Fail One or more rectifiers has reported afailed fan Major Major Minor RO Fuse Major An input that has been ...

Page 184: ...eration 56V 50 60V High Float Voltage Major A possible damaging Very High DC bus voltage threshold set for the normal Float mode of operation has been reached The controller will issue a command to shut any offending rectifier s off 57 0V Major 50 60V Major Minor RO High Float Voltage Minor Voltage threshold during the normal Float mode of operation used to indicatean abnormally high output DC vol...

Page 185: ... contactor did not open or close when expected or is asserting an alarm in the closed state Major Major Minor RO LV Disconnect Contactor 2 Low Voltage Disconnect Contactor 2 isin the Open state either through manual Major Major Minor RO Open intervention or LVD disconnect Manual Or Periodic Battery Test In Progress Condition asserted to provide a remote indication that a battery test has been init...

Page 186: ...st be enabled and assumes N 1 rectifiers arepresent in the system Disabled by default Disabled Minor Enabled Disabled Major Minor RO Reserve TimeLow Reserve time low alarm threshold configured for systems calculated back up reserve has been reached 0 hours Minor 0 99 9 hours Major Minor RO Sense Fuse Alarm that is automatically asserted when the controller senses the DC bus voltage to be lower tha...

Page 187: ...wo halves of each battery string for more than 24 hours Feature isenabled through the use of 771 voltage modules Major Minor RO Note 1 Communication loss with a single rectifier or any number of thermal probes is considered a PMN alarm Communication loss with the LVD card is considered a PMJ alarm Note 2 Communication loss with multiple rectifiers or devices other than thermal probes shall be cons...

Page 189: ... screen This is where the system alarms warnings and site descriptions are displayed To configure a site press the F11 key from this screen or select Setup Sites from the Options menu The Site List popup screen is displayed On this screen hit the Add button and then the Modify button On the Description field type in an identifier e g CPS6000 Controller Connection Then select Set Default Passwords ...

Page 190: ...visible There are three pull down menus you may choose to gain access to plant features and functions They are Configure Control and Status Configure This pull down menu allows one to access all CPS6000 controller parameters that may be uniquely configured It allows access to set alarm thresholds and alarm relays set battery connect and disconnect thresholds enable auto boost mode and set boost ch...

Page 191: ...t system i e battery current battery temperature number of VT Probes and ES771A Voltage Imbalance Detection modules are present It also allows rectifier management i e provides information as to the number of rectifiers present and their output current Exiting To exit the program either hit the Disconnect icon or hit File and Exit ...

Page 193: ...M1 BD 8 BR W BD_C R 8 ALM1 BD 9 W S BD_NC C 9 ALM1 BD 10 S W MJF_NO Ringer Converter_NO O 13 ALM3 RFA 11 R BL MJF_C Ringer Converter_C R 14 ALM3 RFA 12 BL R MJF_NC Ringer Converter_NC C 15 ALM3 RFA 13 14 R O 2ACF_NO LV_NO O 16 ALM4 Batt Test 15 O R 2ACF_C LV_C R 17 ALM4 Batt Test 16 R G 2ACF_NC LV_NC C 18 ALM4 Batt Test 17 18 19 20 21 22 S R ACF_NO O 10 ALM2 ACF 23 BK BL ACF_C R 11 ALM2 ACF 24 BL ...

Page 194: ...a1 MAJ MIN MIN Change from MAJ to MIN for both versions Multiple AC Fail macf1 R2 MAJ R4 MAJ MIN Changes to both versions High Battery Temp bta1 MIN MAJ MAJ Change from MIN to MAJ for both versions Major Fuse Alarm faj1 MAJ R3 MAJ R3 MAJ Relay R3 is Major Fuse alarmfor both versions ES648A Comments cha faj1 acc R3 Enable relay R3 as Major Fuse Alarm cha mrfa1 acc Disable relay R3 as Multiple Recti...

Page 195: ... Plant Battery Test Active cha vla1 acc R4 Enable relay R4 as Low Voltage Alarm cha macfl acc Disable relay R2 as Multiple AC Fail cha macfl sev MIN Change Multiple Rectifier Failure to MIN cha bda1 sev RO Change Battery On Discharge from PMJ to RO cha rls1 acc Disable relay R3 as Redundancy Loss cha rfa1 sev MIN Change Single Rectifier Failure to MIN cha rfa1 acc Disable all relays for Single Rec...

Page 197: ... within their operating limits Rectifiers that operate at 75 C must see air intake with temperatures less than or equal to 75 C at the rectifier inlet When using a dual or multi shelf arrangement the ambient intake to the lower most shelf and the heat gain through the shelf shall be considered while determining the air intake temperatures of the subsequent shelves If the air temperature is exceedi...

Page 199: ...fication tables 2 D1 D2 and D3 Page 3 4 Updated power shelves and distribution modules Corrected comcode for H569 470 G60A Page 3 9 Updated Shelf AC Input Current Table Page 5 12 Moved Discrete Office Alarm Connector from Appendix E Added Section 6 AC Alarm and Control Cable Reference Information Pages 7 4 through 7 6 Added CPS6000 Controller Minimum Configuration section Added Section 10 QS820A R...

Page 200: ...rdering codes Added new thermal probe sketch for strain relief Issue 17 Added sketch of new distribution module with 2 load breakers 2 battery breakers and 5 GMT fuse positions Issue 18 Updated AC table for 50A rectifiers to remove non applicable configurations Issue 19 Removed Shelf AC input current table Added 150 ft ringer cable comcode Issue 20 Corrected information related to Fig 5 13 Issue 2...

Page 201: ...the agreed 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...

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