LECTRO 36VDC, Technical Manual

Page 1: ...CPR TM Series Broadband Power Supply 36VDC and 48VDC Technical Manual Effective March 2004 ...

Page 2: ...Power Alpha Technologies Protecting The Power in Communications ...

Page 3: ...RTM Series Broadband Power Supply Technical Manual Effective March 2004 745 573 B0 001 REV A 2004 Alpha Technologies Contacting Alpha Technologies For general product information and customer service 1 800 863 3930 7 00 AM to 5 00 PM Pacific Time For complete technical support 1 800 863 3364 7 00 AM to 5 00 PM Pacific Time or 24 7 emergency support EC DECLARATION OF CONFORMITY Units that are label...

Page 4: ...n 22 3 2 Battery Installation and Connection 25 3 2 1 48V Battery Installation Procedure 26 3 2 2 36V Battery Installation Procedure 27 3 2 3 Connecting an Additional 48V Battery String 28 3 2 4 Connecting an Additional 36V Battery String 28 3 2 5 Removing Batteries 30 3 3 Operation 33 3 4 Maintenance 35 3 4 1 Routine Maintenance Checks 35 3 4 2 CPR Power Supply Maintenance Log Sheet 36 3 4 3 Batt...

Page 5: ...ion points for 60Hz 15A units 24 Fig 3 3 Connection points for 50Hz units 24 Fig 3 4 Connection points for 60Hz 24A units 24 Fig 3 5 48V Battery Connections Single String 26 Fig 3 6 36V Battery Connections Single String 27 Fig 3 7 48V Battery Connections Parallel Strings 28 Fig 3 8 36V Battery Connections Parallel Strings 29 Fig 3 9 48V Parallel Battery Sense Wiring 30 Fig 3 10 36V Parallel Batter...

Page 6: ... of the product Use caution whenever working in the area to prevent electrical shock INHALATION HAZARD DON T BREATHE VAPORS This symbol indicates an inhalation hazard may exist in this area of the product Use caution whenever working in the area to prevent possible inhalation of harmful fuel or exhaust vapors NO MATCHES OR OPEN FLAMES This symbol indicates a fire or explosive hazard may exist in t...

Page 7: ...allation maintenance service and replacement must be performed by authorized personnel only Never use uninsulated tools or other conductive materials when installing maintaining servicing or replacing batteries Use special caution when connecting or adjusting battery cabling An improperly connected battery cable or an unconnected battery cable can result in arcing a fire or possible explosion A ba...

Page 8: ...rify load requirements prior and during connection process Prior to handling the batteries touch a grounded metal object to dissipate any static charge that may have developed on your body Alpha Technologies is not responsible for unit damage due to enclosure or installation temperatures which exceed the operating temperature of the product The Lectro CPR UPS is a 36 or 48Vdc system designed for u...

Page 9: ...es contain lead and lead compounds Wash hands after handling California Proposition 65 Wear protective clothing insulated gloves eye protection etc whenever installing maintaining servicing or replacing batteries If any battery emission contacts the skin wash immediately and thoroughly with water Follow your company s approved chemical exposure procedures If any battery emission contacts the eye w...

Page 10: ...of the enclosure is recommended Follow the Battery Manufacturer s approved transportation and storage instructions y Always replace batteries with those of an identical type and rating Never install old or untested batteries y Do not charge batteries in a sealed container Each individual battery should have at least 0 5 inches of space between it and all surrounding surfaces to allow for convectio...

Page 11: ...The service disconnect and service disconnect installation is subject to local electrical codes and should be approved for application in a NEMA 3R enclosure rated 120 240V with a non interrupted neutral termination y For 120 VAC 60 Hz units the service disconnect shall be a high magnetic type circuit breaker rated for 20 amperes in the line lead only y For 240 VAC units the service disconnect sha...

Page 12: ...ep hands and tools clear of fans Fans are thermostatically controlled and will turn on automatically y Power supplies can reach extreme temperatures under load y Use caution around sheet metal components and sharp edges Mechanical Safety ...

Page 13: ...S These instructions should be followed during installation and maintenance of the power supply batteries cabinet status monitor and any options and or ancillary equipment The purpose of this manual is to provide the reader with the necessary information to install the enclosure the power supply connect the battery strings perform an initial turn up and test of the CPR TM Power Supply and to perfo...

Page 14: ...B0 001 REV A EXTERNAL INDICATOR LAMPS GROUND SKIRT PADLOCK HASP EXTERNAL INDICATOR LAMPS Fig 1 1 Ground Mount Front View of 4 battery cabinet with ground skirt Fig 1 2 Pole Mount Front View of 8 battery cabinet 1 2 Cabinet Nomenclature ...

Page 15: ...U ADAPTOR DISCONNECT BREAKER BOX COAX SEIZURE CLAMP SNAP IN CONNECTOR TO POWER SUPPLY INPUT FEED THRU ADAPTOR AT REAR OF BOTTOM SHELF 1 2 Cabinet Nomenclature continued Fig 1 3 Pole Mount Rear View of cabinet Fig 1 4 Typical Placement of Disconnect Breaker on rear of Cabinet Fig 1 5 Coax Feed Thru Adapter Normal Location Bottom Shelf ...

Page 16: ...cabinet mounting point Wire to power line in accordance with local codes NOTE The disconnect box should have a high magnetic type circuit breaker capable of passing short duration inrush currents and have a minimum rating as shown below For 120 VAC 60 Hz units the service disconnect shall be a high magnetic type circuit breaker rated for 20 amperes in the line lead only For 240 VAC 60 Hz units the...

Page 17: ... Drill 11 16 17 5mm holes in the pole at the marked locations 5 Attach the bracket to the pole using 5 8 M16 2 0 hardware not provided Make sure that the head of the bolt is next to the pole bracket and the nut is at the rear of the pole Tighten securely 6 Raise the cabinet and set into place on the bracket already attached to the pole The slots on the pole bracket should be pointing downward so t...

Page 18: ...res in the line lead only 3 From the disconnect box install conduit to the power supply site and turn a stub up to extend above grade level Drive a suitable ground rod according to local codes 4 Install appropriate size conduit for the output connections and turn a stub up to extend 1 above the pad surface cast into the concrete Make sure to match conduit locations with the appropriate cabinet loc...

Page 19: ...C output are positioned at the desired locations just outside the ground skirt Optional The conduit stub ups may pass through the cement pad as shown below 10 Pour level and finish concrete to the bottom of the template Allow a curing time of 24 hours 11 Attach ground skirt to power supply cabinet Align skirt inside bottom lip of the cabinet and secure using 10 32 X 3 8 screws from the parts kit 1...

Page 20: ...national codes Where allowed exothermic welding may be used as an alternative to Burndy clamps and connectors 1 Service Grounding required 6 bare copper wire from Service Neutral Ground Bar with 2 ground rods located 6 apart Lightning Protection optional 1 2 x 8 Copper ground rod four places driven about 2 feet typical from the corners of the pad 6 bare Copper wire loop terminated to each ground r...

Page 21: ...adapter may be mounted on the back of the cabinet Figure 1 3 or in one of the holes in the bottom battery shelf typical for ground mounting see Figure 1 5 Use the lock nut to secure the adapter and the large O ring to the cabinet Tighten securely Repeat this procedure for units with dual outputs 24 amp model 6 Install your choice of coax cable in the adapter A 90 adapter may be required for some i...

Page 22: ... the connector colors match Green is electrically tied to chassis ground electrically the same as white in Alpha enclosures 3 Connect the green ground wire from the CPR TM UPS to the back of the mounting bolt that holds the exterior ground clamp to the wall of the enclosure Use the 10 hardware provided 4 For those power supplies with IEC power cords plug the cord into the receptacle on the left si...

Page 23: ...tor into the RJ 11 port on the left side of the CPR TM module 9 Confirm that the battery breaker on the front of the CPR TM module is open off Connect the ring lugs at the other end of this harness to the positive and negative terminals of the battery as described in Section 3 2 Use appropriate flat washers when connecting this harness to smaller battery terminals Plug the large gray battery power...

Page 24: ...e D AC input E Temp probe connector A AC output fitting Note Green w yellow trace and solid yellow cables may also be used for output connection B Output voltage select C Battery power cable connection D AC input E Temp probe connector 3 1 CPR TM Module Installation and Connection continued F Generator Interface Mini Node Fig 3 4 Connection points for 60Hz 24A units Fig 3 2 Connection points for 6...

Page 25: ...th the same amp hour rating Do not mix old and new batteries replace batteries as a set using UL recognized batteries CAUTION Servicing of batteries shall be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries CAUTION The following precautions shall be observed when working with batteries Follow approved OSHA ...

Page 26: ...ewton meters 5 Confirm that the CPR TM DC circuit breaker is off down Connect the black battery cable which comes from the gray connector on the CPR TM module to the negative terminal of the right battery Torque connection to 60 inch pounds 6 8 Newton meters 6 Measure the DC voltage to ensure proper installation of all battery wiring Open circuit DC voltage should measure between 45 volts and 51 v...

Page 27: ... Confirm that the CPR TM DC circuit breaker is off down Connect the black battery cable which comes from the red and black connector on the CPR TM module to the negative terminal of the right battery Torque connection to 60 inch pounds 6 8 Newton meters 6 Measure the DC voltage to ensure proper installation of all battery wiring Open circuit DC voltage should measure between 34 volts and 38 5 volt...

Page 28: ...the left battery Reconnect this lead with the red lead of the inter shelf connection cable 5 Connect the three 3 battery interconnection jumpers as shown below Torque all connections to 60 inch pounds 6 8 Newton meters 6 Disconnect the black battery lead cable from the upper shelf at the negative terminal of the right battery Reconnect this lead with the black lead of the inter shelf connection ca...

Page 29: ...ttery Reconnect this lead with the red lead of the inter shelf connection cable 5 Connect the two 2 battery interconnection jumpers as shown below Torque all connections to 60 inch pounds 6 8 Newton meters 6 Disconnect the black battery lead cable from the upper shelf at the negative terminal of the right battery Reconnect this lead with the black lead of the inter shelf connection cable Torque co...

Page 30: ...d Middle Longer lead Orange BATTERY SENSE INPUT TEMP PROBE INPUT Gray Anderson Connector For Level 3 wiring refer to manual P N 040 0080 1501 3 2 5 Battery Removal 1 Turn the DC circuit breaker off down and observe all precautions for the safe handling of batteries as previously outlined 2 Remove all batteries in the reverse order of installation Fig 3 9 48V Battery Sensing and Temperature Probe C...

Page 31: ...ABINET FRONT RED BLACK OPTIONAL XM STYLE TEMPERATURE PROBE Negative Black Middle Orange Positive Red Middle Longer lead Orange BATTERY SENSE INPUT TEMP PROBE INPUT Red and Black Anderson Connector For Level 3 wiring refer to manual P N 040 0080 1501 Fig 3 10 36V Battery Sensing and Temperature Probe Connection Parallel Strings ...

Page 32: ...RED BLACK OPTIONAL XM STYLE TEMPERATURE PROBE Negative Black Middle Orange Positive Red If unused tuck connector out of the way BATTERY INPUT TEMP PROBE INPUT Gray Anderson Connector Middle Longer Orange For Level 3 wiring refer to manual P N 040 0080 1501 Fig 3 11 Battery Sensing and Temperature Probe Connection Single String ...

Page 33: ...Troubleshooting 4 Verify that the Output Voltage green LED is lit on the front display The CPR TM System should now be providing power to your network Verify with a voltmeter at the point where the coax exits the cabinet 5 The front panel display includes bar graph indicators to describe input voltage levels battery voltage levels and output load levels 6 Check the front panel test points with a t...

Page 34: ... AC operation from a generator the CPR provides a relaxed AC input criteria mode To set generator mode press the OUTPUT ON and INVERTER TEST buttons simultaneously To return to normal mode press the OUTPUT ON and INVERTER TEST buttons again After 48 hours in generator mode the CPR will put itself back into normal mode 10 Once the unit has returned to normal operation after the inverter test the sy...

Page 35: ...attention See Section 4 1 for troubleshooting information 5 The CPR TM system will automatically and periodically load test the batteries If a failing battery is detected the battery LED red on the front panel will illuminate If the battery LED is illuminated replace the affected battery or string of batteries and press the battery LED reset button on the front panel See Section 3 2 1 for the batt...

Page 36: ...ltmeter Readings Cable Output Voltage ________ Battery Voltage ________ AC Amps ________ Test Points Test Points Clamp on Probe Press Inverter Test button Standby AC voltage _______ Fan Running Y N Remove Dust and Moisture from Cabinet ______OK Comments _______________________________________________________ ________________________________________________________________ _________________________...

Page 37: ... is fully charged prior to placing it into service Never mix batteries that are at different states of charge Refer to battery date codes Make sure that the open circuit voltage for each battery in a string is greater than 12 8 volts Never mix battery types or batteries that are at different states of charge A different state of charge condition likely exists if the open circuit voltage for any ba...

Page 38: ...nsfer to standby either during a power failure or an inverter test Inverter failure If the Battery LED is off on the front panel then the inverter may have failed and the CPRTM module should be replaced Battery breaker open Close battery breaker on front panel Battery too weak to support inverter Front panel battery LED should be illuminated Test batteries with a load tester Replace any that fail ...

Page 39: ...k Inverter red LED is lit Inverter is operating This is normal if Utility power has failed Measure AC input voltage with a true RMS voltmeter If power is present verify Utility voltage and frequency is within the limits shown above in this table AC input Low red LED is lit AC input voltage is below 96 or 161 for 230V nominal units or 192 for 240V nominal units VAC unit will be in standby mode runn...

Page 40: ...licable 3 Locate and pull out the ribbon cable with the connector inside of the CPR Communicator TM module slot 4 Plug in the ribbon cable connector into the PC board connector on the CPR CommunicatorTM module 5 Insert the CPR CommunicatorTM module into the open slot on the CPR and secure with the two mounting screws Use caution when inserting so as not to pinch the ribbon cable between the slot a...

Page 41: ...Module features 1 Weak Battery Indicator LEDs one per string 2 Battery Sensing Harness connects to battery terminals 3 Wiring to external cabinet LEDs LEVEL TWO Allows for remote status monitoring with access to additional more detailed information Level Two is essentially the same as Level One with the addition of a DE 9 connector located on the front of the communication module The DE 9 connecto...

Page 42: ... I and II battery sense cables are NOT compatable with the level III module Refer to the embedded transponder manual P N 040 0080 1501 for detailed instructions and wiring harnesses NOTE All three levels have the ability to provide local indications Each level uses a different communication module mounted on the left side of the CPR module 1 Test the CPR Communicator for the correct signals by mon...

Page 43: ...0 V o lts m s 1 0 0 V o lts m s 1 3 1 1 3 1 1 3 1 1 3 1 1 3 1 E F F IC IE N C Y 8 7 V r m s O N L IN E R E S T M O D E 1 0 0 lo a d 8 0 lo a d 6 0 lo a d 4 0 lo a d 9 1 9 1 9 1 9 1 9 1 9 0 9 1 9 1 9 0 9 1 8 9 8 9 8 9 8 8 8 9 8 5 8 5 8 4 8 5 8 5 8 7 V T a p R a te d C u rre n t 7 5 V T a p R a te d C u rre n t 6 0 V T a p R a te d C u rre n t 1 5 0 1 5 0 1 5 0 N A 1 6 5 1 5 5 1 8 0 1 6 0 N A 1 9 2 ...

Page 44: ...8 8 8 5 8 5 8 7 V T a p R a te d C u rre n t 7 5 V T a p R a te d C u rre n t 6 0 V T a p R a te d C u rre n t 1 5 0 N A 1 5 5 N A 1 8 0 1 5 0 E F F IC IE N C Y 8 7 V r m s IN V E R T E R M O D E V d c 1 0 0 lo a d 8 0 lo a d 6 0 lo a d 4 0 lo a d 8 8 8 7 8 7 8 7 8 6 8 7 8 1 8 3 F O L D B A C K N E A R S H O R T C IR C U IT C U R R E N T 8 7 V T a p 7 5 V T a p 6 0 V T a p 2 2 A N A 2 0 A N A 1 9 ...

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