Summary of Contents for DONGAH ELECOMM CPRS-1400
- Page 1 CPRS-1400,1400DD INSTALLATION MANUAL 208VAC 3Phase Input -48VDC Output 1400Amps per Rack 200Amps per Module, 60Port per Rack...
-
Page 2: Table Of Contents
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 - CONTENTS - System Specifications Electric Characteristics........8 1.1.1 Input Characteristics........8 1.1.2 Output Characteristics ........8 Safety Specifications ........9 1.2.1 Electro Magnetic Interference (EMI) ......9 1.2.2 Surge Voltage of Power Cable ....... 9 1.2.3... - Page 3 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 are descriptions on rectifier.
- Page 4 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Safety Tips For Your Safe Operation… - Before starting the installation, operation, test and repair work, please read carefully al of the directions specified in this manual for your safe operation of the system.
- Page 5 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 《Directions in Operation》 Injury, Electric Shock, Fire ●Do not run this system in a place with flammable or corrosive gases, dewdrops or humidity. (It may cause an electric shock or fire.) ●Do not try to modify this product.
- Page 6 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ●When cables are connected, battery should be separated from the rectifier system except one point of the conductor at each cell. ●Start operation after the connections of battery wire, load, and grounding wire are taken apart from NFB and fuses.
- Page 7 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 《Test & Repair》 Electric Shock, Fire ●Qualified labor should perform test and repair work periodically with designated methods. (Violating this direction may cause an electric shock or fire.) ●Only qualified labor with due knowledge and experience should repair this product.
-
Page 8: System Specifications
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 System Specifications 1.1 Electric Characteristics 1.1.1 Input Characteristics 1) Rated input voltage : 3Φ3W(delta connection) 208V 2) Input voltage : 177V ~ 239V 3) Input frequency : 47Hz ~ 63Hz 4) Input rush current : 100Apeak or less (per rectifier module) 5) Throughput : 88% or greater (at 25% ∼... -
Page 9: Safety Specifications
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 • Battery Fuse : 800A×2EA 5)Stability of input and load : ±1.0%(0.54V) 6)Output current limitation : at 40％ ∼ 110％ 7)Output over voltage protection : Suspend rectifier module at 59.0V ∼... -
Page 10: Weight
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 1.4.2 Weight CPRS-1400 ⇒ 500 Kg or less (rectifier module : 35 Kg) CPRS-1400DD ⇒ 280 Kg or less 2 Package 2.1 Packing State This power supply system is shipped with packages of individual rectifier modules. - Page 11 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ●Before unpacking the system, read carefully the listed directions. ●Pay special 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.
-
Page 12: Installation & Cabling
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3 Installation & Cabling 3.1 Exterior View of Rectifier System Figure 2. Exterior View of CPRS-1400 CPRS-1400,1400D INSTALLATION MANUAL 12 /47... - Page 13 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Figure 3. Exterior View of CPRS-1400DD CPRS-1400,1400D INSTALLATION MANUAL 13 /47...
-
Page 14: Front View
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.1.1 Front View Figure 4. Front View of CPRS-1400 CPRS-1400,1400D INSTALLATION MANUAL 14 /47... - Page 15 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Figure 5. Front View of CPRS-1400D CPRS-1400,1400D INSTALLATION MANUAL 15 /47...
-
Page 16: Preparation For Rack Installation
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.2 Preparation for Rack Installation This rectifier has been designed with 23 inch rack, and fixed with anchor bolts. The installation place should be clean and dry, and provide minimum of 50cm of space at the front and rear side of the rack. -
Page 17: Fixing Anchor
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.2.2 Fixing Anchor 8-M16 TAP Nut Welding ANCHOR Hole Figure 7. Anchor Fixing Point (Bottom View) SIDE VIEW Figure 8 . Anchor Fixing Method CPRS-1400,1400D INSTALLATION MANUAL 17 /47... -
Page 18: Cabling
●Before starting the operation read carefully the following directions. ●Weight of 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. -
Page 19: Gnd Connection
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 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... -
Page 20: Surge Observer Ground
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.3.3 Surge Observer Ground Surge observer ground should be connected to the main ground busbar using a green wire (14SQ) for safety. SURGE Absorbor Ground AC INPUT WIRE : 150S.Q or greater... - Page 21 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Table 2) In/Output Cable Connection & Lugs Classification Connection Point Wire Size Remark AC Input AC DIST. INPUT T/B 300 MCM (150SQ) 3ϕ,3W Chassis Ground RECTIFIER 6 MCM (14SQ) Ground GND BUSBAR...
-
Page 22: Battery Lvd Switch
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.3.5 BATTERY LVD Switch This switch enables to open the LVD(Low Voltage Disconnect). It is used to open the connection between battery and rectifier by force. 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. -
Page 23: Batt Cell Check Sensor Connection
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.3.7 BATT Cell Check Sensor Connection In order to check any fault on the 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. - Page 24 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 (3) (4) : Power Input : Battery cell check : RS 485 : Temp Probe : : Current Sensor Figure 13. BATT Monitoring Module CPRS-1400,1400D INSTALLATION MANUAL 24 /47...
-
Page 25: Temperature Sensor Connection
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Hall CT Box -48V (2)Cell Check SENSOR (1)Power In (5)Current Sensor (4) Temp. PROBE Battey Cell Check Module (3)RS 485 Figure14. BATTERY CELL CHECK SENSOR CONNECTION 3.3.8 Temperature Sensor Connection Connect the 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. -
Page 26: Comm Cable And Alarm Cable Connection In Control Panel
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.3.11 Comm Cable and Alarm Cable Connection in Control Panel IPSet DIP SW : IPSet DIP SW : Lan cable Figure 15 Rear View of Control Panel(With Cover) 1) Remote Controlling LAN Cable Connection & IP Address Setting (When PMS is Used.) - Page 27 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Lan cable Figure 16. CPRC-B at the Control Panel Rear(Without Cover) b. IP Address Setting ① How to Set IP Set DIP Switch in Fig. 15 SNMP RS232 IP SET ② How to Set IP Set DIP Switch in Fig. 15...
- Page 28 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ③ IP Setup RS232 Cable Connection RS232 1:1cable Figure 17. CPRC-M at the Rear of Control Panel (Without Cover) ④ How to Operate the IP Setup Program Execute Dongah.exe in the furnished program. Then, the following screen will be displayed.
- Page 29 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 following screen will be displayed, which means that the IP Setup program has been normally launched. 1. Local IP setup 2.Server IP setup Figure 18-1 IP Setup In above Figure, select 1.
- Page 30 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Figure 18-3 IP Setup In this screen, up to 4 IPs can be input. That is, max. 4 servers can operate. For a server to be used, give a mark to...
- Page 31 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 4) ALARM Cable Connection Connect the ALARM cable to the J3~J5 connectors in Figure 20. Alarm status of the rectifier will be sent out over contacts. Pin assignment is as shown in Table 3.
-
Page 32: Dc Output Connection
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 <Table 2>. Alarm Pin TABLE (J3,J4,J5) ALARM COMMON NORMAL OPEN NORMAL RECF SHORT COMMON NORMAL OPEN NORMAL SHORT COMMON NORMAL OPEN NORMAL SHORT COMMON NORMAL OPEN NORMAL SHORT COMMON NORMAL OPEN... - Page 33 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Load 100Amax Load 300Amax Load 200Amax LOAD (-) CONNECTIONS) Figure 21. Output Cable Connection ( Load 300Amax Load 200Amax Load 100Amax LOAD (+)RETURN(GND) Figure 22. Output Cable Connection( CONNECTIONS) CPRS-1400,1400D INSTALLATION MANUAL...
-
Page 34: Battery Cable Connection & Fuse Location
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 Table 4. Output Cable Connection Bolts & Nuts LOAD GND (RETURN) 45mm, 2HOLE LUG 45mm, 2HOLE LUG BOLT : M8, hexa BOLT, 25mm BOLT : M8, hexa BOLT, 25mm 22mm, 2HOLE LUG 22mm, 2HOLE LUG OLT : M8. - Page 35 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 BATT(-) BUS-BAR M12 X 40mm M12 NUT TERMINAL BATTERY (-) SIDE BUSBAR BOLT SIZE : M12, 30mm Figure 23 Battery Connection Figure 24. Battery Fuse Layout and Installation(CPRS-1400DD) CPRS-1400,1400D INSTALLATION MANUAL...
-
Page 36: Bat Fuse Alarm
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 TPHCS FUSE HOLDER BASE & PULLOUT TPH TYPE FUSE(800A) Figure 25. Battery Fuse Type 3.3.14 BAT 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... -
Page 37: Installation Of Output Nfb
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.4 Installation 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 100Amax Load 300Amax Load 200Amax S/W가... - Page 38 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 BULLET Nose TYPE 2POLE 150A DC CIRCUIT PROTECTOR (CARLINGSWITCH) BULLET Nose TYPE 1POLE CIRCUIT PROTECTOR (CARLINGSWITCH) Figure 28. Installation Direction & NFB Type CPRS-1400,1400D INSTALLATION MANUAL 38 /47...
-
Page 39: Check Settings
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 3.5 Check Settings 3.5.1 Rectifier Module ID Setting The order of installing the rectifier module and setting ID are as listed below: * When shipped, the ID setting DIP switch at the rectifier rear has been set. -
Page 40: Initialization & Check Points
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 4 Initialization & Check Points Once all of the cabling and installation procedures are finished, initialize the system and carry out the function test in the following order. Check carefully if there are any service failure or alarm in the middle of the test. -
Page 41: Rectifier Module Insertion & Deletion
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 4.2 Rectifier Module Insertion & Deletion Caution : Before deleting a module make sure that the NFB and switch of each unit is turned off. 4.2.1 Rectifier Module Installation Each rectifier module should be inserted to the rack from the top. Then, insert each module until it reaches the contact. -
Page 42: Normal Operation
Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 4.3 Normal Operation Default setting of the rectifier is FLOAT mode. NORMAL LED and AC LED at the control panel will be turned on. The LCD window shows various information of the rectifier (See the Figure). - Page 43 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ① Voltage/Current Display Make choice of input voltage or output voltage Make choice of currrnt, input currrent, output currrent, battery currrent. ② Alarm Display STATUS Make choice of audio alarm switch.
- Page 44 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ① Press F2 in the following display: OPERATING V 1. 0 Temp : OFF 880Amax MANUAL - FL MODE 54.5Vadj DISPLAY EDIT ENTER DOWN ALARM ② Default password is ‘000000’. Press F3.
- Page 45 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 ⑤ Press F5 to confirm. Then, the EQ charge (default : 56.0V) will be started. OPERATING V 1. 0 Temp : OFF 880Amax AUTO - EQ MODE 56.0Vadj DISPLAY EDIT ENTER...
- Page 46 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 This page intentionally left blank CPRS-1400,1400D INSTALLATION MANUAL 46 /47...
- Page 47 Issue : 2004.07 CPRS-1400,1400D INSTALLATION MANUAL ED : 0 CPRS-400,800 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.
Need help?
Do you have a question about the CPRS-1400 and is the answer not in the manual?
Questions and answers