DONGAH ELECOMM CPRS-1400, Installation Manual

Page 1: ...208VAC 3Phase Input 48VDC Output 1400Amps per Rack 200Amps per Module 60Port per Rack CPRS 1400 1400DD INSTALLATION MANUAL ...

Page 2: ...n 10 2 3 Unpacking 10 2 3 1 Tools 10 3 Installation Cabling 12 3 1 Exterior View of Rectifier System 12 3 1 1 Front View 14 3 2 Preparation for Rack Installation 16 3 2 1 Rack Connection 16 3 2 2 Fixing Anchor 17 3 3 Cabling 18 3 3 1 Chassis Ground 18 3 3 2 GND Connection 19 3 3 3 Surge Observer Ground 20 3 3 4 AC Input Connection 20 3 3 5 BATTERY LVD Switch 22 3 3 6 Installation of BATT Monitorin...

Page 3: ...NSTALLATION CHECK LIST 40 4 2 Rectifier Module Insertion Deletion 41 4 2 1 Rectifier Module Installation 41 4 2 2 Rectifier Module Deletion 41 4 3 Normal Operation 42 4 3 1 Initial Operation Status Check 42 Note that this manual has been written for both rectifier CPRS 1400 and distribution panel CPRS 1400DD The descriptions on the distribution panel are specified separately All of the other ones ...

Page 4: ...please contact Dongahelecomm This document deals with safety directions with the following symbols Check of Contained Materials Make sure that the delivered product is the same one that you ordered Check first the quantity of the delivered articles as specified in the enclosed sheet Thene make sure that there are any missing parts deformation damage peeled out paints unscrews or damage of cables D...

Page 5: ...re load or grounding wire ports It may cause an electric shock or short circuit Pay attention not to reverse polarity of signaling cables and detection cables when connected It may cause a fire Do not leave alien materials such as sheathes of electric wires screws and so on inside the product It may cause an electric shock or fire DC output is connected to the battery before the system starts to b...

Page 6: ...n signal should be used at 60V or lower of input voltage and 0 5A or lower of circuit current Before you take apart or insert the RS232C and RS485 ports of the control module turn off the control module switch When you take apart or insert the rectifier unit from to the rectifier system turn off the rectifier unit switch Rectifier unit should be inserted and taken apart in line with the guide rail...

Page 7: ... and experience should repair this product Violating this direction may cause an electrtic shock or fire As AC input and DC voltage are applied take particular attention not to have electric shock or short circuit when the system is tested or repaired Even when the system is turned on while commercial power is failed AC input may be fed to the system Take particular attention to test and repair wo...

Page 8: ... 5V 0 2V at 50 load 2 Operating voltage 44 0V 59 0V 3 Output current max 1400A 200A 7 Modules 4 Output distribution circuit 60 ports in an independent rack CPRS 1400DD Table 1 Output Distribution NO OUTPUT PORT DC AC CAPACITY VOLTAGE DETAIL 300Amax L1 Power supply to inverter 200Amax L2 L5 Power supply to load 1 L1 L60 DC 100Amax 48V L6 L60 Power supply to load 2 BATT 1 DC 800A 2EA 48V Power suppl...

Page 9: ... 2V 9 Output Ripple Noise 250mV or less at peat point 1 2 Safety Specifications 1 2 1 Electro Magnetic Interference EMI Î FCC PART 15 SUBPART B CLASS A 450kHz f 1 6MHz 1mV 60dB or lower 1 6MHz f 30MHz 3mV 69 5dB or lower 1 2 2 Surge Voltage of Power Cable Î Voltage 6kV 1 2 50 Current 3kA 8 20 1 2 3 Leaked Current Î 100mA or lower 1 3 Environmental Characteristics 1 3 1 Operating Temperature Humidi...

Page 10: ...ions may cause damages to the system Transportation of the system should be made using a container vehicle If truck or other vehicles are used measures to protect from rains should be provided 2 3 Unpacking Unpacking should be carried out at a place near installation place Then check exterior of the package if there are any damages caused in the process of transportation 2 3 1 Tools 1 Portable com...

Page 11: ...ial attention not to be injured when handling sharp articles steel bank conner bracket etc Unpack the system in due order so that the system will not be broken out 1 Get rid of the steel bands 3 Take apart the carton box 2 Get rid of the conner brackets 5 Separate the pallet from the enclosure 4 Take out the cushion pad 6 Get rid of the inner package Figure 1 Unpacking ...

Page 12: ...CPRS 1400 1400D INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 12 47 3 Installation Cabling 3 1 Exterior View of Rectifier System Figure 2 Exterior View of CPRS 1400 ...

Page 13: ...CPRS 1400 1400D INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 13 47 Figure 3 Exterior View of CPRS 1400DD ...

Page 14: ...CPRS 1400 1400D INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 14 47 3 1 1 Front View Figure 4 Front View of CPRS 1400 ...

Page 15: ...CPRS 1400 1400D INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 15 47 Figure 5 Front View of CPRS 1400D ...

Page 16: ...lean and dry and provide minimum of 50cm of space at the front and rear side of the rack Front side of the rack should be easy to ventilate air All other parts than rectifier modules have been fully installed Options are not the case Options NFB to be added for output Spare battery fuse and fuse holder 3 2 1 Rack Connection M16 X 14 A A CPRS 1400 CPRS 1400DD CPIS 3K 6K M12 NUT M12 X 40mm BUS BAR M...

Page 17: ... INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 17 47 3 2 2 Fixing Anchor Figure 7 Anchor Fixing Point Bottom View Figure 8 Anchor Fixing Method SIDE VIEW 8 M16 TAP Nut Welding ANCHOR Hole ...

Page 18: ...f the chassis is maximum 500kg In output of the CPRS 1400 1400DD rectifier is connected through the terminal block and bus bar AC input and output connection should be made paying attention to input voltage and polarity orientation of it 3 3 1 Chassis Ground The rectifier chassis should be connected using the green wire 14SQ to the main ground busbar for safety The chassis ground should be connect...

Page 19: ...47 3 3 2 GND Connection Output GND of the rectifier RETURN should be connected to the main ground busbar over 100SQ cable for safety reason BATTERY GND Return BUSBAR BOLT M12 40mm LUG 45mm PITCH 2 HOLE CPRS 1400 CPRS 1400DD CPIS 3K 6K GND Bus bar 48V Bus bar BATT Bus bar Figure 10 GND Connection ...

Page 20: ... 320 AC INPUT RATIG 3Q3W 310A 47 63Hz AC INPUT WIRE 150S Q or greater Figure 11 Surge Absorbor Ground Connection 3 3 4 AC Input Connection AC input cable should be separated from DC output as much as possible to minimize EMI As AC 3ϕ3W 208V input is used cable should be connected after voltage of it is checked Thickness of the input cable should be minimum of 150SQ 300 MCM Screw should be M12 1 ho...

Page 21: ...rbor ÍÎ MGB 6 MCM 14SQ MGB BATT 1 cable DC DIST ÍÎ BATT BANK 1 500MCM 250SQ X 2P BATT 2 cable DC DIST ÍÎ BATT BANK 2 500MCM 250SQ X 2P BATT 3 cable DC DIST ÍÎ BATT BANK 3 500MCM 250SQ X 2P BATT 4 cable DC DIST ÍÎ BATT BANK 4 500MCM 250SQ X 2P BATT 5 cable DC DIST ÍÎ BATT BANK 5 500MCM 250SQ X 2P RESER VED BATT 6 cable DC DIST ÍÎ BATT BANK 6 500MCM 250SQ X 2P RESER VED Output Cable L1 L60 DC DIST Í...

Page 22: ... For installation or extension of the battery pull out the switch to the OPEN side For normal operation the switch should be placed at the NORMAL position to receive battery backup Figure 12 LVD Switch 3 3 6 Installation of BATT Monitoring Module The BATT monitoring module measures output current temperature of each battery bank and the voltage of battery cell and informs the result to control pan...

Page 23: ...battery connect a sensor to each of the battery cells and measure voltage of each cell Sensor connection starts with the first port cell 1 and then continues to cell 24 in parallel In the same way connect the sensor to all cells See Fig 14 Connect the sensor to the battery Then connect the sensor connector to 2 Batt Cell connector of the BATT monitoring module See Fig 13 ...

Page 24: ...400D INSTALLATION MANUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 24 47 1 Power Input 2 Battery cell check 3 RS 485 4 Temp Probe 5 Current Sensor Figure 13 BATT Monitoring Module 1 2 4 3 5 1 2 3 4 5 ...

Page 25: ... batt cell check sensor Then connect the temperature probe to the 4 connector in the batt cell check module to measure temperature of the battery bank Then fix it to the middle of the battery bank See Fig 13 14 3 3 9 Current Sensor per Battery Bank To measure current per battery bank connect the final output busbar of the battery to current measurement sensor See Fig 14 3 3 10Comm Cable Connection...

Page 26: ...Comm Cable and Alarm Cable Connection in Control Panel 1 IPSet DIP SW 2 IPSet DIP SW 3 Lan cable Figure 15 Rear View of Control Panel With Cover 1 Remote Controlling LAN Cable Connection IP Address Setting When PMS is Used a LAN Cable Connection As shown below connect the LAN cable to the connector 1 2 3 ...

Page 27: ... 47 Figure 16 CPRC B at the Control Panel Rear Without Cover b IP Address Setting How to Set IP Set DIP Switch in Fig 15 SW1 SW2 SNMP ON ON OFF OFF OFF OFF RS232 OFF OFF OFF OFF ON ON IP SET OFF OFF ON ON OFF OFF How to Set IP Set DIP Switch in Fig 15 1 2 SNMP OFF OFF IP SET OFF ON 3 Lan cable ...

Page 28: ...le Connection Figure 17 CPRC M at the Rear of Control Panel Without Cover How to Operate the IP Setup Program Execute Dongah exe in the furnished program Then the following screen will be displayed Figure 18 IP Setup As shown in above Figure select a serial port and click Connect Then the RS232 1 1cable Select Click ...

Page 29: ...e IP Setup program has been normally launched Figure 18 1 IP Setup In above Figure select 1 Local IP Setup Then the following screen will be displayed Figure 18 2 IP Setup Key in local IP gateway and netmask numbers and click OK Then you escape to X button Then select 2 Server IP Setup to display the following screen 1 Local IP setup 2 Server IP setup ...

Page 30: ... corresponding server IP Then click OK to return to X button 2 Comm Cable Connection in Battery Monitoring Module In the right view connect the comm cable of the Batt monitor module to one of J20 J25 connectors Figure 19 Comm Cable Connection 3 Inverter Comm Cable Connection Read out the input voltage output voltage battery voltage output current frequency and alarm status of the inverter in opera...

Page 31: ...will be sent out over contacts Pin assignment is as shown in Table 3 J3 and 4 are A contact and B contact J5 is common port User may select an alarm port or use J3 J5 or J4 J5 MOLEX 51067 0500 will be used for connector PIN alarm indications are as follows RECF Î Rectifier alarm DCF Î Output voltage alarm OV UV BF Î Battery alarm INVF Î Inverter alarm CTRLF Î Control panel alarm Figure 20 ALARM Ca...

Page 32: ...ORMAL SHORT BF 5 COMMON NORMAL OPEN NORMAL SHORT INVF 6 COMMON NORMAL OPEN NORMAL SHORT CTRLF 3 3 12DC Output Connection DC output connection should be made referring to Table 4 Figures 21 and 22 To connect the LOAD output cable open the front door of CPRS 1400DD unscrew the distribution panel and then connect the output cable to corresponding port To connect LOAD RETURN GND open the rear door as ...

Page 33: ...004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 33 47 Load 300Amax Load 200Amax Load 100Amax Figure 21 Output Cable Connection LOAD CONNECTIONS Load 300Amax Load 200Amax Load 100Amax Figure 22 Output Cable Connection LOAD RETURN GND CONNECTIONS ...

Page 34: ...25mm 22mm 2HOLE LUG Î BOLT M8 20mm 3 3 13Battery Cable Connection Fuse Location Caution Battery should be connected when all other cables have been connected Before connecting the battery fuse and the alarm fuse should be taken apart And set open the LVD OPEN NORMAL switch of the control panel Once the cabling is completed put the fuse to the original place and then insert the alarm fuse Battery f...

Page 35: ...NUAL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 35 47 M12 NUT M12 X 40mm BATT BUS BAR TERMINAL BATTERY SIDE BUSBAR BOLT SIZE M12 30mm Figure 23 Battery Connection Figure 24 Battery Fuse Layout and Installation CPRS 1400DD ...

Page 36: ...E HOLDER BASE PULLOUT TPH TYPE FUSE 800A Figure 25 Battery Fuse Type 3 3 14BAT FUSE ALARM Fuse for internal battery fuse open alarm 0 5A When the battery fuse is opened visible fuse open alarm will be turned on HOLE turns to white to indicate the fault NOMAL FUSE OPEN ALARM FUSE Figure 26 Battery Fuse Alarm ...

Page 37: ... of Output NFB DC distribution frame of the rectifier accommodates 60 circuits The rectifier contains 1 300A port 4 200A ports and 55 100A ports Load 300Amax Load 200Amax Load 100Amax Switch S W가 OFF된 상태에서 화살푶 방향으로 밀어 넣는다 Insert to the arrow direction when the switch has been off Figure 27 Output NFB Installation ...

Page 38: ...AL Issue 2004 07 ED 0 CPRS 1400 1400D INSTALLATION MANUAL 38 47 BULLET Nose TYPE 2POLE 150A DC CIRCUIT PROTECTOR CARLINGSWITCH BULLET Nose TYPE 1POLE 5A 70A DC CIRCUIT PROTECTOR CARLINGSWITCH Figure 28 Installation Direction NFB Type 1 ...

Page 39: ...odule and setting ID are as listed below When shipped the ID setting DIP switch at the rectifier rear has been set Rectifier module ID should be set from top to bottom from 1 to 7 Depending on the rectifier moduel installed check module setup in the LCD of the control panel Î For how to set refer to 3 2 1 Operation Manual ON 1 2 3 DIP SWITCH Figure 29 Rectifier Module ID Setup DIP Switch ...

Page 40: ...k if the rectifier module LED is all green and check output voltage 4 1 INSTALLATION CHECK LIST To check installation of the system take the following procedure 1 Check if the rack has been fixed to the floor 2 Check if the battery charge temperature compensation probe has been fixed 3 Check if the RS485 interface of the control panel has been installed and connected 4 Check if the SNMP interface ...

Page 41: ...r module should be inserted to the rack from the top Then insert each module until it reaches the contact Then tighten the screen at the panel front Turn on the NFB at the top and turn on the power switch MODULE NFB POWER S W Figure 30 Front View 4 2 2 Rectifier Module Deletion Turn off the NFB and the power switch of the rectifier module Then unscrew the module and pull it off seizing the handle ...

Page 42: ...cation with the control panel is failed or not connected Check the initialization checkpoints again Î Check if fan operates normally 2 Control Panel CPRC Î Check if the status indication LED turns the NORMAL Green on Î Check if output voltage is correctly displayed on the VOLT METER window Î Check if output current is correctly displayed on the AMPERE METER window Depending on load displayed value...

Page 43: ...ARM FAIL Make choice of audio alarm switch Green LED NORMAL Red LED FAIL Comm Status Display RX REC TX MONITOR RX TX In communication with Rectifier unit In communication with SNMP LCD Display Operating display menu OPERATING F1 F2 F3 F4 F5 F6 DISPLAY EDIT ENTER UP DOWN ALARM V 1 0 Temp OFF 880Amax MANUAL FL MODE 54 5Vadj 3 How to Charge Battery EQ Charge Start Î Initial EQ charge is necessary to ...

Page 44: ...fault password is 000000 Press F3 OPERATING F1 F2 F3 F4 F5 F6 DISPLAY EDIT ENTER UP DOWN ALARM E n t e r P a s s N u m b e r F 1 0 0 0 0 0 0 F 6 Keep pressing F2 until the following view is displayed OPERATING F1 F2 F3 F4 F5 F6 DISPLAY EDIT ENTER UP DOWN ALARM B a t t e r y E Q C h a r g i n g S t a r t N O Press F4 to set to YES OPERATING F1 F2 F3 F4 F5 F6 DISPLAY EDIT ENTER UP DOWN ALARM B a t t...

Page 45: ...0 CPRS 1400 1400D INSTALLATION MANUAL 45 47 Press F5 to confirm Then the EQ charge default 56 0V will be started OPERATING F1 F2 F3 F4 F5 F6 DISPLAY EDIT ENTER UP DOWN ALARM V 1 0 Temp OFF 880Amax AUTO EQ MODE 56 0Vadj Figure 31 Control Panel LCD Display ...

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Page 47: ...0 RECTIFIER INSTALLATION MANUAL 2004 Dongahelecomm Corp All rights reserved Information in this document is proprietary to dongahelecomm No information contained here may be copied translated transcribed or duplicated by any form without the prior written consent of Dongahelecomm http www Dongahelecomm co kr ...