ABB CPS3200U User manual

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© 2021 ABB. All rights reserved.
PRODUCT MANUAL

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© 2021 ABB. All rights reserved.
Table of Contents
Table of Contents ································································································································ 2
Table of Figures···································································································································· 4
Table of Tables····································································································································· 6
1. Introduction···································································································································· 7
Reference Documents ·······························································································································7
Customer Service Contacts····················································································································· 8
On-Line Power Systems Product Manuals and Software··································································· 8
2. Product Description······················································································································· 9
Operation ··················································································································································· 9
Configurations··········································································································································· 9
Specifications ·········································································································································· 10
3. Ordering·········································································································································13
Ordering Codes ········································································································································13
Lugs ·························································································································································· 14
4. Safety ·············································································································································15
Safety Statements ···································································································································15
Warning Statements and Safety Symbols ·························································································· 18
Precautions ···············································································································································19
5. Pre-Installation······························································································································21
Purpose······················································································································································21
Audience ····················································································································································21
Precautions ···············································································································································21
Safety ·························································································································································21
Installation Tools······································································································································21
System Identification ······························································································································21
6. Installing the Shelf Level Upstream Product·············································································· 23
Unpacking Shelf Level Upstream Product ·························································································· 23
Installing and Powering the CP3200U Converter Shelf ···································································· 23
Ground the Shelf······································································································································ 25
Attach the Load Wiring ·························································································································· 25
Set Shelf ID and Attach Alarm Wiring ···································································································27

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Installing the Baffle··································································································································29
Installing the Fan Shelf··························································································································· 30
Installing the Filter Bracket and Filter··································································································33
7. Inspect the Network - Check and Mark Wiring Compliance ······················································35
8. Final Installation ···························································································································37
Installing the Converters ························································································································37
Apply DC Power······································································································································· 38
Recognizing Normal States··················································································································· 38
QS982A LED Information Map·············································································································· 39
Confirm Operation of Alarm Wiring····································································································· 40
Installing the QS941A Ethernet Module ······························································································ 40
Installing the Office Alarm Connector································································································· 44
9. Reference Information················································································································· 45
QS982A Converter LED Information Map ··························································································· 45
QS982A LED Information Map (visual)································································································ 46
Alarm Card Information ·························································································································47
QS912A Converter Shelf ························································································································ 48
QS930A Fan Shelf··································································································································· 50
10. Maintenance ·································································································································51
Filter Cleaning··········································································································································51
11. Product Warranty ·························································································································53
Appendix A: Operating Temperature Measurement and Vertical Spacing·································· 55
Operating Temperature························································································································ 55
Baffles and Fan Trays ···························································································································· 55
Appendix B: Alarm Reference Table·····································································································57
Appendix C: Operation without a Controller - Alarm Wiring ·························································· 59
CPS3200U Shelf Alarm Card State Table ··························································································· 60
Alarm Card Logical Operation of LEDs and Alarm Relays································································61
12. Revision ········································································································································63

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Table of Figures
Figure 1 Block Diagram -48V Fed CPS3200U Shelf ············································································ 9
Figure 2 Capacitance Safety Limits···································································································17
Figure 3 QS912A Converter Shelf ······································································································ 23
Figure 4 Mounting the Converter Shelf···························································································· 23
Figure 5 Preparing to Make DC Connections to Converter Shelf ··················································· 24
Figure 6 Making DC Connections to Converter Shelf······································································ 24
Figure 7 Grounding Converter Shelf ································································································· 25
Figure 8 Output Wiring for Converter Shelves ················································································ 27
Figure 9 Accessing Alarm Cards········································································································ 27
Figure 10 Removing Alarm Card········································································································ 28
Figure 11 Setting Shelf ID ·················································································································· 28
Figure 12 Signal Wiring between Converter Shelves ······································································· 29
Figure 13 Installing a Baffle··············································································································· 29
Figure 14 Mounting the Fan Shelf ····································································································· 30
Figure 15 Inserting Fan Trays············································································································ 30
Figure 16 Open the Wiring Region of the Fan Shelf········································································· 30
Figure 17 Alarm Wiring for Fan Shelf ·································································································31
Figure 18 DC Cabling Fan Trays in CPS3200U Systems····································································31
Figure 19 Cover the Wiring Region of the Fan Shelf ········································································ 32
Figure 20 Fan Tray LEDs ···················································································································· 32
Figure 21 Mounting the Filter Bracket······························································································ 33
Figure 22 Filter Retention Bracket···································································································· 33
Figure 23 Install Filter ························································································································ 34
Figure 24 Secure Filter Retention Bracket ······················································································· 34
Figure 25 Shelf Level ESD Jack ···········································································································37
Figure 26 Installing Converters··········································································································37
Figure 27 QS982A Faceplate and LEDs ····························································································· 38
Figure 28 Fan Shelf Right Hand Cover ······························································································40
Figure 29 Fan Shelf Controller Jumper ·····························································································40
Figure 30 Preparing a Fan Shelf for a CPS Controller······································································ 41

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Figure 31 Installing the Controller ·····································································································41
Figure 32 Controller Wiring ··············································································································· 42
Figure 33 Fan Shelf RS-485 Jacks ······································································································43
Figure 34 Signal Cables - System·······································································································43
Figure 35 Office Alarm Cable Pinout ································································································ 44
Figure 36 QS982 LEDs and Test Points ···························································································· 45
Figure 37 Alarm Card Faceplate·········································································································47
Figure 38 Shelf ID Rotary Switches····································································································47
Figure 39 QS912A Dimensions ·········································································································· 48
Figure 40 Output Connectors··········································································································· 49
Figure 41 QS930 Fan Shelf Dimensions···························································································· 50
Figure 42 QS930 Fan Shelf Connections and Fuses ········································································ 50
Figure 43 Converter Shelf with Slot Fillers ······················································································ 56
Figure 44 Alarm Card Office Alarm Pinout and Shelf ID·································································· 59
Figure 45 Alarm Card Office Alarm Cables ······················································································ 59

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Table of Tables
Table 1 Specifications·····························································································································10
Table 2 Ordering Codes ·························································································································· 13
Table 3 Output Connector Pinout··········································································································26
Table 4 QS982A LED Information Map ··································································································39
Table 5 QS982A Converter LED Information Map················································································ 45
Table 6 QS982A Converter LED Information Map (visual) ·································································· 46
Table 7 Output Connector Pinout········································································································· 49
Table 8 Alarm Reference·························································································································57
Table 9 Shelf Alarm Card State ············································································································· 60

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1. Introduction
Overview
The CPS3200U is the premier upstream dc/dc converter for line powering FTTN networks. The 3200U
contains 16 dc/dc converter/limiter cards in a dense 2 RU shelf. Each card contains a pair of
independent -48 Vdc input to ±190 Vdc output converters with each output safety limited to 100VA. In
addition, each output terminal is safety Ground Fault protected. The cards are fully connectorized and
insulator shielded, inrush current protected and completely hot swappable, making card addition to in
-service shelves in the field an easy, one step process. The converter card shelf is completely front
access, with all -48V input and RJ21 output connections made on connectors in front of the mid-
mount shelf brackets. The alarm and communications connections are also on the front of the shelf.
The CPS3200U converter shelf meets the applicable requirements of these North American product
standards: UL60950-21, UL60950-1, Telcordia GR-3108-CORE, GR-1089-CORE, GR-487-CORE (converter
shelf), and GR-063-CORE.
Summary
The CPS3200U Upstream System delivers power over telephone lines. The primary application is
enabling the delivery of video bandwidth data rates to residences over twisted pairs by allowing
placement of powered electronics at an acceptable distance from the residence.
48 Vdc Input, ±190 Vdc Output Converter/Limiter System distributes battery backed up power from
existing -48V battery backed up sites like Central Offices and Remote terminals to reliably power
electronics near the home. It does this by converting the -48V to a UL60950-21 safety approved + and
– 190V current limited and ground fault protected source. Each front access shelf provides 32
channels.
Reference Documents
Documents Title
CC848836981 Galaxy Pulsar Edge Product Manual
CC848853457 CPS3200U Technical Support Guide
Line Power Product Line Brochure – Specifications and Ordering Guide

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Customer Service Contacts
Customer Service, Customer Training, Technical Support, Product Repair and Return, and Warranty
Service
Services provided include initiating the spare parts procurement process, ordering documents, prod-
uct warranty administration, and providing other product and service information.
ABB Energy phones are staffed from 7:00 am to 5:00 pm USA Central Time Zone (GMT -6), Monday
through Friday, on normal business days. At other times, this number is still available, but for emer-
gencies only.
Calling from
• United States, Canada, Puerto Rico, and the US Virgin Islands
• All other countries
Or
Contact your local field support center or your sales representative to discuss your specific needs.
On-Line Power Systems Product Manuals and Software
Product manuals, technical support guides, product line brochures, and software are available on-
line. Software includes Easy View and SNMP MIB.
abbpowerconversion.com
1. The USA direct country code for the country where the call is originating
[phone] ( US )
[phone] ( Int’l )

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2. Product Description
Figure 1 Block Diagram -48V Fed CPS3200U Shelf
Basic block diagram of single converter shelf System
Operation
Power comes in as -48V and is distributed in an A and B redundant fashion to each of the converter
cards and the alarm card. There are two +/-190V circuits on each converter card. The circuits both
boost the voltage and limit the current as prescribed by UL60950-21 and GR-1089-CORE.
Warning: Ground faults or short circuits on the output do not permanently disconnect the output. The
converter circuit tests the line every 4 seconds and will re-energize if the wiring fault is cleared.
A serial communication bus links each converter to an alarm card at the end of each shelf.
The alarm card provides major and minor form C contacts, manages the converters and relays
information to a ABB Power CPS6000 family controller using Galaxy Protocol over an RS485 bus. Up to
24 shelves can be controlled and monitored by one CPS6000 family controller. The CPS6000 controller
is WEB and SNMP capable.
Configurations
32 circuit, front access +/-190V shelves come in two configurations - airflow from bottom to top and
airflow from top to bottom. A single IP drop can be used to manage up to 24 shelves or 768 circuits.

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Specifications
Electrical
Parameter Symbol Min Typical Max2Unit
Input Voltage
40 -52.8 Operating Continuous
Non-operating, No Damage
VI -60
-40
Vdc
Transient (@ duration =)
5 Seconds
10 ms (rise and fall rate of 10V/ms)
10 µs
1 µs
Vtr
Vtr
Vtr
tr
-65
-75
-100
-200
Vdc
Input Current - (per half shelf at 97.7W on all circuits)
VIN = 54.4V
VIN = 52.1V
VIN = 42.6V
VIN = 40.0V
IIN
IIN
IIN
IIN
34.7
36.2
44.3
47.2
Adc
Adc
Adc
Adc
Temperature
Normal Operating Ambient
Temperature at 150 lfm airflow
Operating Ambient Temperature
at higher (TBD) airflow
Cold Start Temperature
Storage Temperature
TA
TA
TA
Tstg
-40
-40
-40
-55
50 °C
75 °C
°C
85 °C
Power – per C/L Card
21
Input Power at -42.6 Vdc input Pin 2403W
Power Dissipation Pdiss 40* W
Output Power Pout 200 W
Output
378
95.0
251
Voltage – line to line VO380 382 Vdc
Power – per C/L circuit PO97.7 100 W
Current – per C/L circuit IOUT 257 262 mA
Isolation
1500 Vdc
Input to Output Voltage
Physical
Height
Width Depth Weight
lb (kg)
23-Inch Shelf 3.5 (88.9) 21.4 (543.6) 12 (304) 30 (13.6)
Fan Shelf 3.5 (88.9) 21.4 (543.6) 12 (304) 20 (9.0)
1U Baffle 1.75 (44.4) 21.4 (543.6) 12 (304) 4 (1.8)
2Max = Absolute Maximum Rating
3These are maximum situations with each circuit loaded to 100W. No actual or engineered application would load every circuit to this level. In the absence of
detailed information about the network we would recommend using the typical dissipation value of 21 Watts for most applications with 30W per card for highly
loaded networks.