ABB CPS3200U User manual

Page 1
© 2021 ABB. All rights reserved.
PRODUCT MANUAL
CPS3200U
Technical Support Guide
Product Manual
Ordering code CC848853457
Issue 1
September 2008

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© 2021 ABB. All rights reserved.
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© 2021 ABB. All rights reserved.
CPS3200U Technical Support Guide
WEB
Front Panel
Hardware
Converter
Cards
Alarm Card
Slots
1-8
Slots
9-16
BDFB FED SHELF

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© 2021 ABB. All rights reserved.
PRODUCT MANUAL
This document is a compilation of class material aimed at people who provide technical support.
Information pulled from product manuals is marked with a reference indicator in brackets.
CPS3200U
Technical Support Guide
Table of Contents
1. Hardware ········································································································································5
Brief Hardware Orientation·····················································································································6
Always look first at the alarm card to establish valid A and B power feeds
to both sides of the shelf·························································································································7
This diagram can be used to diagnose powering faults as indicated by
the “A” and “B” LEDs ·································································································································7
Once both the “A” and the “B” input power LEDs are green, other LEDs
can be used to diagnose other faults ····································································································8
The Shelf ID rotary DIP switches are as shown here: ··········································································8
Converter LEDs look like this:··················································································································9
Alarm Reference Table····························································································································10
Locating Failed Fans······························································································································· 12
2. WEB ··············································································································································· 13
The web page reflects the physical configuration of each shelf ····················································14
To help find the FTTN relevant information on each tab, please use this guide ·························14
To interact with the QS941 Controller through the WEB interface it is
possible to connect a computer to the QS941A directly using server
mode or through a LAN using client mode ·························································································16
3. Front Panel····································································································································19
Most of the detail needed to interact with the front panel is in the
QS941A Controller User Interface document available from the
ABB website ············································································································································ 20

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© 2021 ABB. All rights reserved.
1. Hardware
.
WEB
Front Panel
Converter
Cards
Alarm Card
BDFED SHELF
Slots
1-8
Slots
9-16
Hardware

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© 2021 ABB. All rights reserved.
Brief Hardware Orientation
Figure 6-1: QS912A Converter Shelf
(Shown configured with 2 operational circuits and 14 slot fillers for airflow control)
[CPS3200U Page 21]
To distribute airflow across every card in the shelf make sure each slot is filled with either a converter
or an empty slot filler. Converter cards and slot fillers are inserted according to this diagram:
Figure 8-2: Installing Converters
[CPS3200U Page 40]
Please shift focus now to understanding the shelf schematic. This is key to recognizing and correcting
errors.
Converter Guide
Positions
Thumb-Latch

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© 2021 ABB. All rights reserved.
Always look first at the alarm card to establish valid A and B power feeds to both sides of the shelf.
[CPS3200U Page 7]
The orange and blue regions above indicates that there is an A and a B feed for the left hand side of
the shelf (slots 1-8) and an A and a B feed for the right hand side of the shelf (slots 9-16). The letters
“A” and “B” labeling the top two alarm card LEDs refer to these -48V input power feeds.
This diagram can be used to diagnose powering faults as indicated by the “A” and “B” LEDs.
[CPS3200U Page 55]
Energized (E) is the normal state. This makes any failures of power to the relay are alarmed:
-48 V INPUT BUS Vin LEDs STATUS LEDs ALARM RELAYs
A1-8B1-8A9-16 B9-16 A LED B LED OK LED ALM LED PMN PMJ
OK OK OK OK GRN GRN GRN OFF
LOW OK OK OK RED GRN OFF YEL
OK LOW OK OK GRN RED OFF YEL
OK OK LOW OK RED GRN OFF YEL
OK OK OK LOW GRN RED OFF YEL
LOW LOW OK OK RED RED OFF RED
LOW OK LOW OK RED GRN OFF RED
LOW OK OK LOW RED RED OFF RED
OK LOW LOW OK RED RED OFF RED
10 OK LOW OK LOW GRN RED OFF RED
11 OK OK LOW LOW RED RED OFF RED
12 LOW LOW LOW OK RED RED OFF RED
13 LOW LOW OK LOW RED RED OFF RED
14 LOW OK LOW LOW RED RED OFF RED
15 OK LOW LOW LOW RED RED OFF RED
16 LOW LOW LOW LOW OFF OFF OFF OFF
BDFB FED SHELF
Slots
1-8
Slots
9-16
Converter
Cards
Alarm Card
Alarm Relay: E – Energized relay in non-alarm state; D – De-energized relay in alarm state

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© 2021 ABB. All rights reserved.
Once both the “A” and the “B” input power LEDs are green, other LEDs can be used to diagnose
other faults.
One fault that may show as a red flashing ALM LED on the alarm card is communications fail. The
flashing red ALM light on the alarm card indicates that it is configured to expect a controller and is
not seeing one.
The Shelf ID rotary DIP switches are as shown here:
[CPS3200U Page 53]
If there is no controller present, the flashing red LED can be addressed by switching the Tens and
Units rotary switches to positions 0 using a small Phillips screwdriver. If a controller is present the
signal between the alarm card and the controller is likely broken. Please examine all wiring. Also note:
all shelves in a system must have different addresses to be recognized by the controller.
Shelf 6
Setting
Cards per
Shelf Tens Units
Shelf 3
Shelf 2
Shelf 1
Shelf 1
Setting
Shelf 6
Shelf 5
Shelf 4
Alarm Board

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© 2021 ABB. All rights reserved.
Converter LEDs look like this: [CPS3200U Page 52]
LED Display Conditions
(on b circuit) Action Required
All OK None
Circuit Placed in Standby
None depending on desired state of circuit b.
Standby state can be set using the QS941
controller or web browser.
Loss of comm. Check seating on Alarm card and converter card
Ground fault Check 5 pin protectors and faults to ground
Overcurrent or
under voltage Check output lines for shorts to each other
OV or internal failure Replace unit
Thermal Alarm Solve Thermal problem
card not powered or input
fuse failure Check source voltage

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© 2021 ABB. All rights reserved.
Converter LEDs look like this: [CPS3200U Page 52]
Alarm Reference Table
This Alarm Table shows how FTTN Alarms are categorized by the QS941 Controller. Many alarms are
best processed at the converter shelf alarm card and converter card level. In other words columns 4,
and 5, can be used to select the appropriate action from column 6.
[QS941 Controller Page 27]
LED Display Conditions
(on b circuit) Action Required
Lamps test requested from
controller
Observe Lamp Test
3. QS941 4.Alarm Card 5.Converter Card 6.Human Response
1.
Alarm
Display
2.
What it
means
LED
State Relay State
Alarm
LED
State
Relay
State
OK LED
State
Alarm LED
State Corrective Action
Circuit Fail Short + to - Yellow Min Yellow Min Green Flashing
Yellow
Make sure each
converter has an
independent isolated
send and return path.
Circuit Fail Short to
Ground Yellow Min Yellow Min Flashing Red
Flashing
Red
Make sure each
converter has an
independent isolated
send and return path.
Comm.
Fail
1 Card
Removed Yellow Min Yellow Min Green Off
Check to see that all
cards are seated.
Replace
non- functioning
cards.
Comm.
Fail
2 Cards
Removed Red Maj
Check to see that all
cards are seated.
Replace
non- functioning
cards.
Comm.
Fail
Comm.
Cable
Removed
Red Maj Flashing
Red Green Off
Check communication
path from alarm cards
to QS941 controller. If
no controller is
present, set alarm
card rotary switch to
position 0 for contact
closures only
communication.
Comm.
Fail
Alarm Card
Removed Red Maj Green Flashing Red Replace Alarm card.
None Standby Green Green Yellow
Remove unit from
standby if desired
using QS941 or
Ethernet interface

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© 2021 ABB. All rights reserved.
3. QS941 4.Alarm Card 5.Converter Card 6.Human Response
1.
Alarm
Display
2.
What it
means
LED
State
Relay
State
Alarm LED
State
Relay
State
OK LED
State
Alarm LED
State Corrective Action
Circuit Fail Open Fuse Yellow Min Yellow Min Green Flashing
Yellow
Replace unit. Note:
Restoring service to
one line will interrupt
service to the other
line served by that
card.
Circuit Fail Under
Voltage Yellow Min Yellow Min Flashing Yellow
Replace unit. Note:
Restoring service to
one line will interrupt
service to the other
line served by that
card.
Fan Fail 1 Fan Tray
Failed Yellow Min Yellow Min Green Off Replace fan tray.
Fan Fail
1 of 6 fans
Failed on
one Fan
Tray
Yellow Min Yellow Min Green Off Replace fan tray.
Fan Fail 2 Fan Trays
Failed Red Maj Red Maj Green Off Replace fan trays.
Input
Power
A1-8
Power Fail Yellow Min A Red Min Green Off
Reconnect DC input
power flowing to the
A1-8 input terminal.
Input
Power
B1-8
Power Fail Yellow Min B Red Min Green Off
Reconnect DC input
power flowing to the
B1-8 input terminal
Input
Power
A9-16
Power Fail Yellow Min A Red Min Green Off
Reconnect DC input
power flowing to the
A9-16 input terminal
Input
Power
B9-16
Power Fail Yellow Min B Red Min Green Off
Reconnect DC input
power flowing to the
B9-16 input terminal.
Input
Power Mul
Circuit Fail
A1-8 &
B1-8 Power
Fail
Red Maj A Red
B Red Maj Green Off
Reconnect DC input
power flowing to the
A1-8 input terminal
and Reconnect DC
input power flowing
to the B1- 8 input
terminal
Input
Power Mul
Circuit Fail
A9-16 &
B9-16
Power Fail
Red Maj A Red
B Red Maj Green Off
Reconnect DC input
power flowing to the
A9-16 input terminal.
Reconnect DC input
power flowing to the
B9-16 input terminal.

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© 2021 ABB. All rights reserved.
3. QS941 4.Alarm Card 5.Converter Card 6.Human Response
1.
Alarm
Display
2.
What it
means
LED
State
Relay
State
Alarm LED
State
Relay
State
OK LED
State
Alarm LED
State Corrective Action
Load Drop Load Drop Yellow Min A, B & OK
Green Green Off
Check the integrity of
the circuits going to
the load. Or Adjust
load drop threshold to
0 to disable this
feature.
Load Share
As set of
circuits
assigned to
one remote
destination
are not
sharing
current as
would be
expected .
Yellow Min A, B & OK
Green Green Off
Check the integrity of
the circuits going to
the load. Or Adjust
load share threshold
to disable this feature.
Line Test OK, Fail or
Aborted A, B & OK
Green Green Off
Estimated line
resistance has
increased since last
measurement.
Loss Of
Redundancy Yellow Min A, B & OK
Green Green Off
The loss of n
additional circuits will
cause customers to
lose service. Check
redundancy threshold
in the
configuration.
Locating Failed Fans
Fan failures within a tray can be found by correlating the number of LED flashes to this map:
1
Connectors
6

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© 2021 ABB. All rights reserved.
2. WEB
Front Panel
BDFB FED SHELF
Hardware
Slots
1-8
Slots
9-16
Converter
Cards Alarm Card
WEB

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© 2021 ABB. All rights reserved.
The web page reflects the physical configuration of each shelf.
The right hand side shows the 48V input current and alarm states for each of the DC inputs. Text
changes to yellow for power minor and red for power major. Fan tray status is also alarmed on the
right hand side of the figure. The output voltage and current of each circuit on each card is also
shown on the physical representation of the shelf. The ‘a’ circuit output is shown on the top and the
‘b’ circuit output is shown below. The left hand side of the WEB display shows how circuits are
grouped, including group name, number of circuits assigned, current draw, and current capacity.
[QS941A WEB Interface page 8]
Details about the WEB interface can be found in the QS941A Controller WEB Interface. This pdf
document can be found at the bottom of the CPS2300U page located at: abbpowerconversion.com
To help find the FTTN relevant information on each tab, please use this guide
(ovals show start links):
Home:>
Think of the FTTN
shelf as protected
power distribution
panel similar to a
circuit breaker
distribution.
Estimate of 48V
current is shown.
Reports:>
FTTN data is
under these
links

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© 2021 ABB. All rights reserved.
Please note: loop resistance measurements only work for a small subset of applications.
Installation:>
This is where one sets the
date and time.
Settings:>
Details of FTTN
setting can be
found here
On/Standby control is
available for FTTN starting
here, too.
Maintenance:>
Clear missing devices declares the
current state as good, retiring all
alarms.

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© 2021 ABB. All rights reserved.
Step Action
1. Press Menu or Accept key, .
2. Press down arrow, ▼, to Configuration.
3. Press the right arrow key, ▶ (or square “accept” key, ) to advance.
4. Press down arrow, ▼, to Communications Ports.
5. Press the right arrow key, ▶ (or square “accept” key, ) to advance.
6. Press down arrow, ▼, to Network Settings.
7. P Press the right arrow key, ▶ (or square “accept” key, ) to advance.
8. Press down arrow, ▼, to highlight DHCP.
9. Press the right arrow key, ▶ (or square “accept” key, ) to advance.
10. Press down arrow, ▼, to toggle to SERVER.
11. Press save, .
12. Press the Back Arrow, ,to return to the default screen.
13. Wait 2 minutes.
14. Activate changes by removing the QS941 controller circuit card from the backplane. Wait until the LEDs
extinguish.
15. Reapply power by reinserting the circuit card connection until seated.
16. Verify Server Mode by pressing Menu>Status>Network Settings>Port 1> to find 192.168.2.1 as the network
address.
To interact with the QS941 Controller through the WEB interface it is possible to connect a
computer to the QS941A directly using server mode or through a LAN using client mode.
This section details how to set up the controller as either a server or a Client.
Change LAN to Server Mode
To access the controller directly from a PC, you must first change LAN connection to server mode.
Warning: It is always safer to leave the controller in Client mode. This avoids LAN conflicts should
the controller ever be connected to a Local Area Network.

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© 2021 ABB. All rights reserved.
Restore the LAN Connection to Client Mode
As good policy, always leave the controller in Client mode.
Step Action
1. Press Menu or Accept key,
2. Press down arrow, ▼, to Configuration.
3. Press the right arrow key, ▶ (or square “accept” key, ) to advance.
4. Press down arrow, ▼, to Communications Ports.
5. Press the right arrow key, ▶ (or square “accept” key, ) to advance.
6. Press down arrow, ▼, to Network Settings.
7. P Press the right arrow key, ▶ (or square “accept” key, ) to advance.
8. Press down arrow, ▼, to highlight DHCP.
9. Press the right arrow key, (or square “accept” key, ) to advance.
10. Press down arrow, ▼, to toggle to CLIENT.
11. Press save, .
12. Press the Back Arrow, , to return to the default screen.
13. Wait 2 minutes.
14. Activate changes by removing the QS941 controller circuit card from the backplane. Wait until the LEDs extinguish.
15. Reapply power by reinserting the circuit card connection until seated.
16. Verify Client Mode by pressing Menu>Configuration>Communications Ports>Network Settings> to show Client
mode.

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© 2021 ABB. All rights reserved.
3. Front Panel
Hardware
WEB
Alarm Card
Slots
1-8
Slots
9-16
Converter
Cards
Front Panel

Page 20
© 2021 ABB. All rights reserved.
Most of the detail needed to interact with the front panel is in the QS941A Controller User Interface
document available from the website.
Key to getting started is understanding that the top row keys on the faceplate are soft keys. Text on
the lower edge of the display indicates key function.
The QS941A Controller User Interface manual is the best reference to use when discussing interacting
with the display with a customer. It can be found at this WEB address: abbpowerconversion.com