Power System Manual CXPS 48-2T 48V Pos Gnd 053-393-B0
This page intentionally left blank. Argus Technologies Ltd. Burnaby, British Columbia. Telephone: 604 436 5900 Fax: 604 436 1233 Argus Technologies reserves the right to make changes to the products and information contained in this document without notice. Copyright 2008 Argus Technologies Ltd. Argus® is a registered trademark of Argus Technologies Ltd. All Rights Reserved. Printed in Canada. Visit www.argus.
Power System Manual CXPS 48-2T 48V Pos Gnd Power System 053-393-B0 Drawing List: The following drawings are included in this manual to provide the necessary information required for routine operation and fault diagnosis of the system.
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Specifications for Argus’ CXPS 48-2T 48Vdc Power System Output Voltage: 42 to 60Vdc within rated limits Current: System: up to 825A standard configuration, (expandable to 1200A via additional rectifier shelf) Rectifier: 67A @ 48Vdc nominal (75A max.) Power: System: up to 39,600W standard configuration, (expandable to 57,600W via additional rectifier shelf) Rectifier: 3600W maximum Heat Dissipation (per rectifier): <1415 BTU per hour Static Load Regulation: Better than ±0.
Specifications for Argus Technologies’ CXPS 48-2T 48Vdc Power System Continued Connections Load Connections: AM breakers (1-pole): 1/4” holes on 5/8” centers AM breakers (multiple pole): 3/8” holes on 1” centers GMT fuses: screw terminals 0.34mm2 to 4mm2 (#22 to #12 AWG) Battery Terminations: 3/8” holes on 1” centers, 4 sets per polarity Rectifier Terminations: 3/8” holes on 1” centers Alarm Connections: 0.
Specifications for Argus Technologies’ CXPS 48-2T 48Vdc Power System Continued Safety NOTE: Safety certifications performed at rectifier level only. EN 60950 Rectifier output shall be rated SELV suitable for connection to TNV-1 circuits UL 60950 CSA C22.2 No.
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This section contains important instructions that should be followed during the installation and maintenance of equipment and batteries. Please read all of the instructions before operating the equipment, and save this manual for future reference. A licensed electrician MUST perform connections to the branch circuit of service feed.
Electrical Safety WARNING Hazardous voltages are present at the input of a power system. The DC output from rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing. Before working with any live battery or power system, follow these precautions: • • • Remove all metallic jewelry; e.g., watches, rings, metal rimmed glasses, necklaces.
TABLE OF CONTENTS 1 INTRODUCTION ............................................................................................................................................................. 1 1.1 1.2 1.3 1.4 2 FEATURES ................................................................................................................................................................... 3 2.1 2.2 2.3 2.4 3 Main Rectifier States .................................................................................
1 Introduction 1.1 Scope of the Manual This instruction manual covers the features and installation of Argus Technologies’ CXPS 48-2T 48V 825A Power System. For advanced detail on the system components used in the CXPS 48-2T, please refer to the following manuals: • • Cordex 48-3.6kW Rectifier Module: 010-600-B2 (010-567-20 pre-RoHS) [This manual also provides CXCM4 (controller) installation details.] Cordex Controller (CXC) Software: 034-109-B2 or latest revision of software.
1.3 System Configurations The system is available to order in the following configurations: Description Part Number CXPS 48-2T, Cordex base 48V 825A power system, 23” rail mount ................................................ 053-393-20-000 CXPS 48-2T system with 22RU relay rack, battery mount ................................................................ 053-393-20-010 CXPS 48-2T system with 7 foot Z4 relay rack ...................................................................................
2 Features 2.1 System Overview The basic system configuration is called out by Argus part number 053-393-20-000 (Figure 1); which includes: • • • • • • 1200A Two-Tier Distribution Center (Vista II Two-Tier UDC) Cordex System Modular Controller 4RU (CXCM4) Two (2) Cordex 48-3.6kW 6-module rectifier shelves Kydex rear cover 23” rack mount rails System integration cabling and bus work.
2.2.2 DC Distribution Installed 2.2.2.1 Tier 1 (Lower) The lower distribution tier in the CXPS 48-2T has support for eighteen (18) AM-type plug-in breaker positions with an 800A shunt and 600A LVD. This option is a split-tier design – factory configured – with a jumper to support eighteen (18) 48Vdc breaker positions. The jumper is removable for future system installation / upgrade of 48V-24V converters.
Touch screen RS-232 (craft port) Reset (RST) button Ethernet port System status LEDs Figure 3–Cordex CXCM4 model system controller front panel 2.3.2.2 LEDs The CXCM4 has three LEDs located on the front panel. These are used to display the alarm status of the power system, CXCM4 progress and status during startup, and file transfers. Alarm Conditions The CXCM4 illuminates the LED that corresponds to the system alarm status.
2.3.3 Analog Input Channels The CXCM4 has analog input channels for voltage, current, and temperature. 2.3.3.1 Voltage Inputs Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCM4 software is pre-configured to monitor V2 for both load and battery voltage. V2 is used as the system reference for rectifier float voltage, low voltage disconnect (LVD), system high voltage alarm, and system low voltage alarm. V1 is available for additional voltage measurements. 2.
2.4 Cordex 48-3.6kW Rectifiers 2.4.1 Rectifier Overview The CXPS 48-2T system is provisioned for use with the high-density Cordex 48-3.6kW rectifier system. The system ships complete with two (2) 23” 6-module rectifier shelves installed. Individual 3.6kW (75A) rectifiers are ordered separately. NOTE: The two (2) installed 6-module shelves with one CXCM4 (controller) allow for up to eleven (11) 3.6kW modules in a single 825A system.
DC ON The middle LED (green) is on when the rectifier is delivering power to the load. The LED turns off when the rectifier is off; e.g., when commanded via the CXC.
NOTE: For Cordex rectifier systems without batteries (or with a very light load; below 2.5% of rated output) it is recommended that the ramp test be disabled to avoid nuisance alarms. The Ramp Test feature is enabled/disabled via the CXC menu item: Rectifiers, Configure Settings. 2.4.6 Heat Dissipation Each rectifier module is equipped with at least one front-mounted fan. The fan operates at temperatures above 0°C (32°F). Cooling of the module is front-to-rear with the exhaust air exiting at the back.
2.4.13 Power Limiting Each rectifier module is designed to limit power output to the module specification. This enables more current to be supplied at lower output voltages, and allows matching of output to the demand of constant power loads, normally seen with telecom equipment. This feature may also be used for a faster recharge of flooded batteries paralleled with the load. NOTE: Current limiting overrides the power-limiting feature. 2.4.
3 Inspection 3.1 Packing Materials All Argus products are shipped in rugged, double walled boxes and suspended via solid inserts to minimize shock that may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit Association standards. Power systems are custom packaged in heavy-duty plywood crates. Products are also packaged with Cortex. This plastic wrap contains a corrosive-inhibitor that protects the product from corrosion for up to two years.
4 Installation This chapter is provided for qualified personnel to install and interconnect the power components within the Argus power system. Regarding battery installation, refer primarily to the manufacturer’s guidelines for more specific information. NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual. 4.1 Safety Precautions Refer to the Important Safety Instructions near the front of this manual. 4.
4.3 Power System Assembly and Mounting The power system must be mounted in a clean and dry environment. Sufficient free space must be provided at the front and rear of the power system. This is to meet the cooling requirements of the rectifiers utilized in the power system and to allow easy access to the power system components. 4.3.
4.5 Battery Installation This information is provided as a guideline and is not meant to imply that batteries are part of this power system. WARNING Follow battery manufacturer’s safety recommendations when working around battery systems and review the safety instructions provided in this manual. 4.5.1 Preparation/Mounting Batteries should be located in a temperature-controlled environment. The temperature should be regulated at approx. 25°C (77°F).
After assembly, batteries should be numbered and “as received” readings taken, including specific gravity, cell voltage and temperature. One cell will be designated as the pilot cell; this is usually the cell with either the lowest specific gravity or voltage. Refer to manufacturer's literature for guidelines.
5 Wiring This chapter provides cabling details and notes on cable sizing for DC applications with respect to the product. WARNING Ensure that power is removed by turning off rectifiers and removing battery line fuse or connection before attempting work on the wiring connections. Use a voltmeter to verify the absence of voltage. Clearly mark the correct polarity of the battery leads before commencing work on DC connections.
5.4 DC Output Connections WARNING Leave cables or bus bars disconnected at battery and verify output polarity using a voltmeter. Make battery connections only after all other wiring is completed. DC output wire shall be UL approved XHHW or RHH/RHW (for Canadian users, RW90 Type). Control and sense wires shall be UL approved Style 1015 (for Canadian users, TEW type). The common output leg of the rectifier system should be connected to ground. This is typically done at the load common termination point. 5.
To remove PEM nuts: 1. Place a 9/16" socket over the PEM nut to be removed. 2. Insert a 3/8" bolt through the socket and thread into the PEM nut. 3. Using a socket wrench with a 9/16" drive, tighten the head of the bolt until the action pulls the PEM nut from the bus bar. Bolt through socket PEM removed Figure 7–PEM nut removal for back-to-back connections on the battery bus bars 5.4.2 Load Distribution Refer to guidelines supplied with the load equipment.
proper cable management and to not overload the capacity of a single tier (600A LVD limitation). TPS fuses may be used instead of breakers via a plug-in breaker cartridge, which installs into any AM-type plug-in breaker panel configuration. See Figure 9 below: Figure 9–Plug-in breaker/fuse cartridge 5.4.2.2 GMT Fuses The CXPS 48-2T is factory configured with (10) GMT type fuse positions for additional 48V load distribution. The fuse assembly is rated for maximum capacity of 30A.
5.5.1 Re-Configure Split Tier Distribution 1. Remove the copper jumper bridging the 8-position and 10-position breaker rows. 2. Locate the alarm card on the left hand side of the internal wall of the distribution center. Reference the Customer Connections drawing at the rear of the manual. 3. Locate the terminal blocks. The 10-position breaker alarming – factory configured for 48V distribution – is wired to TB12-42 “Pri Alm In.
Converter output (-GND) wire connection location Converter output (+24V) wire routing location Figure 11–Rear of CXPS 48-2T system showing converter -GND output connection and converter +24V wire routing location Converter Output Cabling (+24V HOT Connection) Terminate the #2 AWG cable with pre-terminated 1/4”-5/8”C lug (With wire marker #16) to the +24V (hot) output terminal labeled “E3” using hardware supplied with shelf.
Upper distribution tier (2-tier model) for converter input feeds Converter output (+24V) wireway Converter output (+24V) wire connection (jumper bar removed) Figure 12–Connection points and wire routing for +24V input into split tier distribution Converter Input Cabling (+GND Connection) Terminate the #6 AWG cable with pre-terminated 1/4”-5/8”C lug (with wire marker #13) to the +GND input terminal labeled “E2” using hardware supplied with shelf.
5.5.2.2 Converter Fail Alarm Locate #18 AWG wire with tag #17 Attach end with ring lug to -GND output terminal on converter shelf (E4). Attach unterminated wire end to TB2-8 “Conv Fail” on alarm connection at rear of CSM02 shelf. Locate #18 AWG wire with tag #18 Attach unterminated wire end to TB2-7 “Conv Fail” on alarm connection at rear of CSM02 shelf.
5.6 Controller I/O Connections WARNING Ensure that input power and output power is removed before attempting work on the CXC’s wiring connections.
5.6.2 Digital Inputs The digital input channels are used to monitor various alarm and control signals. All input channels are voltage activated and accept a bipolar (i.e. negative or positive) DC signal directly. 5.6.2.1 Connection Method Typical Argus systems use the “reset with Hot and trigger with Ground” connection. The digital input is wired in such a way that the Hot is wired directly into one of the input terminals; e.g., negative input for -48V systems.
5.6.3 Relay Outputs Terminals provide contacts for extending various alarm or control signals. Each relay output can be wired for NO or NC operation during an alarm or control condition. See Figure 15. Figure 15–Showing relay connections in the de-energized state Relays can be programmed to energize or de-energize during an alarm condition (see CXC Software manual). When the CXC reset button is pressed or power is lost, all relays de-energize. 5.6.3.
6 System Startup Visually inspect the installation thoroughly. After completing the system installation and power system wiring, perform the following startup and test procedure to ensure proper operation: 6.1 Check System Connections • • 6.2 Verify AC and Power the Rectifier Shelf • • • • 6.3 Install one power module. Verify ac input voltage is correct and turn on the corresponding feeder breaker. The power module OK LED should illuminate after a preset start delay.
7 Operation 7.1 Main Rectifier States Rectifier operation can be broken up into five main states: 1. 2. 3. 4. 5. Off, Start delay, Soft start, Normal operation, Turning off. Each state is characterized as being distinct and necessary for the operation of the rectifier. These states are briefly described below. 7.1.1 Off State The rectifier will be in the Off state immediately after power is applied to the rectifier or after a rectifier shutdown.
7.2.1 Output Voltage Modes Voltage modes can be thought of as modes that, under software control, can directly adjust the output voltage. The qualification of ‘under software control’ is made because there are processes that occur in the rectifier that can change the output voltage that do not adjust the output voltage directly (such as the rectifier being in current limit).
8 Maintenance Although very little maintenance is required with Argus systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualified service personnel should do repairs. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year. WARNING: HIGH VOLTAGE AND SHOCK HAZARD. Use extreme care when working inside the unit while the system is energized. Do not make contact with live components or parts.
1. 2. 3. 4. 5. 6. 7. 8. 8.2 Shut off the unit and unscrew the front fastener that secures the power module to the shelf. Slide the module 10 cm (4”) out of the shelf and wait two minutes for module capacitors to discharge. Remove the four screws (two each side) that secure the front panel to the module chassis. Slide the front panel out. Disconnect the fan power lead wires (one set per fan) and front panel ribbon cable from the module. Remove the screws that secure the fans to the front panel.
9 Argus Conventions 9.1 Numbering System Argus Technologies uses an eight-digit drawing number system, which is broken into three blocks. The first three digits describe the category of the product; e.g., rectifier or fuse panel. The next three digits indicate the sequence in which the product number was allocated in a particular category.
REVISIONS DESCRIPTION REV BY DATE APPD B ADDED -030 CONFIGURATION RP 07/10 GS 18.8 477.13 018-574-20 020-419-20 LTR 7.3 186.30 29.710 754.63 27.735 704.47 24.235 615.57 21.235 539.37 17.235 437.77 13.735 348.87 10.235 259.97 7.235 183.77 3.235 82.17 0.235 5.97 22.312 566.73 0 23.000 584.21 6.0 153.10 030-716-20 THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT.
REVISIONS LTR DESCRIPTION REV BY DATE APPD 20.3 516.70 018-574-20 018-574-20 20.3 516.70 40.5 1028.70 84.0 2133.60 020-419-20 020-419-20 030-716-20 030-716-20 030-694-20 31.6 802.64 010-567-20 23.6 599.44 010-567-20 28.6 726.44 8.0 203.20 11.0 279.40 25.6 649.27 19.8 502.19 16.5 419.10 7.0 177.
REVISIONS 20.3 516.70 LTR DESCRIPTION REV BY DATE APPD 018-574-20 84.0 2133.60 020-419-20 030-716-20 12.25 311.15 23.1 585.80 010-567-20 8.0 203.20 030-709-20 25.6 649.27 19.8 502.19 16.5 419.10 THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. 11.3 286.
REVISIONS LTR REV BY DESCRIPTION DATE APPD BATTERY RETURN 4 X 3/8"-16 HARDWARE ON 1" CENTERS SITE GROUND 1 X 3/8"-16 HARDWARE ON 1" CENTER BATTERY HOT 4 X 3/8"-16 HARDWARE ON 1" CENTERS CIRCUIT BREAKER RETURNS 1/4"-20 HARDWARE ON 5/8" CENTERS CIRCUIT BREAKER OUTPUTS 1/4"-20 HARDWARE ON 5/8" CENTERS SEE DETAIL D (SHT2) SEE DETAIL A SEE DETAIL C (SHT2) SEE DETAIL B (SHT3) 037-163-20 JUMPER KIT REMOVE WHEN USING FOR 24V DISTRIBUTION WITH OPTIONAL CONVERTERS DETAIL A (DOOR NOT SHOWN) TOP TIER E/W 20
REVISIONS LTR REV BY DATE APPD COMMON F1 F2 F1 F2 F3 F4 F5 F3 CXCM4 INTERFACE CONNECTIONS DESCRIPTION F4 F5 COMMON F6 F7 F6 F7 F8 F9 F10 F8 F9 F10 DETAIL C CXCM4 I/O PCB DETAIL D GMT FUSE PCB THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. NTS SCALE TITLE CONNECTION, CXPS 48-2T CORDEX POWER SYSTEM c 2006 ARGUS TECHNOLOGIES ISSUE DATE SIZE TYPE DWG NO.
REVISIONS LTR DESCRIPTION REV BY DATE APPD THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. NTS SCALE DETAIL B 030-716-20 SHELF WIRING TITLE CONNECTION, CXPS 48-2T CORDEX POWER SYSTEM c 2006 ARGUS TECHNOLOGIES ISSUE DATE SIZE TYPE DWG NO.
WARRANTY AND SERVICE INFORMATION Technical Support Technical support staff are available for answering general questions related to installation, operation and maintenance of Argus products. In Canada and the USA, call Argus toll free at +1-888-GO-ARGUS (+1-888-462-7487) 7:30 am to 5:00 pm Pacific Standard Time. For emergencies, call +1-888-GO-ARGUS (+1-888-462-7487) 24 hours a day, seven days a week. Customers outside Canada and the USA, call +1-604-436-5547 for technical support.
Service Centers Factory Service Centers Canada and International Argus Technologies Ltd. ATTN: RMA Returns 7033 Antrim Avenue Burnaby, BC, V5J 4M5 Canada Tel: +1 604 436 5900 Fax: +1 604 436 1233 Email: returns@argusdcpower.com USA Argus Technologies Inc. ATTN: RMA Returns 3116 Mercer Avenue Bellingham, WA, 98225 USA Tel: +1-360 756 4904 Fax: +1-360 647 0498 Email: returns-usa@argusdcpower.com Asia-Pacific PCM Electronics (Dong Guan) Co., Ltd.
