DONGAH ELECOMM CPRS-1400 User manual

208VAC 3Phase Input
-48VDC Output
1400Amps per Rack
200Amps per Module,
60Port per Rack
CPRS-1400,1400DD
INSTALLATION MANUAL

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- CONTENTS -
1. System Specifications 8
1.1 Electric Characteristics...................................... 8
1.1.1 Input Characteristics........................................ 8
1.1.2 Output Characteristics ...................................... 8
1.2 Safety Specifications ....................................... 9
1.2.1 Electro Magnetic Interference (EMI) .......................... 9
1.2.2 Surge Voltage of Power Cable ............................... 9
1.2.3 Leaked Current ............................................ 9
1.3 Environmental Characteristics ............................... 9
1.3.1 Operating Temperature & Humidity ........................... 9
1.3.2 Storage Temperature & Humidity............................. 9
1.4 Physical Specifications...................................... 9
1.4.1 Dimension ................................................ 9
1.4.2 Weight.................................................... 10
2 Package 10
2.1 Packing State.............................................. 10
2.2 Transportation ............................................. 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 Monitoring Module ....................... 22
3.3.7 BATT Cell Check Sensor Connection ......................... 23
3.3.8 Temperature Sensor Connection ............................. 25
3.3.9 Current Sensor per Battery Bank ............................. 25
3.3.10 Comm Cable Connection between Batt Cell Check Module &
Control Panel ......................................................... 25
3.3.11 Comm Cable and Alarm Cable Connection in Control Panel ..... 26
3.3.12 DC Output Connection ...................................... 32
3.3.13 Battery Cable Connection & Fuse Location .................... 34
3.3.14 BAT FUSE ALARM......................................... 36

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3.4 Installation of Output NFB ................................... 37
3.5 Check Settings ............................................ 39
3.5.1 Rectifier Module ID Setting .................................. 39
4 Initialization & Check Points 40
4.1 INSTALLATION 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 are descriptions on rectifier.

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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.
- This product has been manufactured under strict quality management. If there are any
potential damages to human life or assets, 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.
《Directions in Storage》
●Do not put this product package in a place where water or rain
drops, there are any harmful gas or liquids or direct lay of light
reaches.
●Do not store this product under high temperature and humidity
conditions.

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《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. (It may cause an electric burn or
fire.)
●Operate this system under the environmental conditions specified in
this manual. Take particular attention to voltage, frequency,
temperature, humidity and vibrations. (Violating the environmental
requirements may cause an electric shock or fire.)
●Before connecting the battery wire, load and gronding wire, pay
attention not to reverse the polarity of them. (Polarity reversal may
cause fire.)
●While the system is on, do not touch the battery wire, 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 be
driven. Pay close attention not to cause an electric shock or short
circuit.
●When the rectifier units are added, pay close attention as AC input
voltage is fed to the Connector in the rack side. (It may cause an
electric shock.)
●When you take apart or insert a rectifier unit from/to the rack, pay
close attention not to have a burn as the part has been heated. (It
may cause an injury.)
●Do not put your finger or other things to the ractifier unit fan. (It may
cause an injury.)
●When you extend units, pay close attention not to arise an accident
of short circuit. (It may cause an electric shock.)

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●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.
●Connect the battery wire, load and grounding wire while the load side
has been unloaded.
●External transmission 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 of the rectifier system.
●Tightly join the unit fixing screws, and then, turn on the input switch
of the rectifier unit.
●As AC input may be fed to turned on system while power is failed,
special care should be paid to check and maintain the AC input.

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《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. (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 work of the AC input.
《Disposal》
●This product should be disposed under the ordinary industrial
wastes disposition procedure.

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1. 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% ∼100% load)
6) Power factor : 96% or greater (at 25% ∼100% load)
1.1.2 Output Characteristics
1) Rated output voltage : -54.5V ±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 supply to BATT.BANK 1.
3 BATT.2 DC 800A×2EA -48V Power supply to BATT.BANK 2.
4 BATT.3 DC 800A×2EA -48V Power supply to BATT.BANK 3.
5 BATT.4 DC 800A×2EA -48V Power supply to BATT.BANK 4.
6 BATT.5 DC 800A×2EA -48V Power supply to BATT.BANK 5.
7 BATT.6 DC 800A×2EA -48V Power supply to BATT.BANK 6.

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•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 ∼
60V.
8)Battery over discharge protection : Suspend battery at 42.0V ±0.2V.
9)Output Ripple / Noise : - 250mV or less at peat point
1.2 Safety Specifications
1.2.1 Electro Magnetic Interference (EMI)
ÎFCC 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
ÎVoltage →6kV (1.2 ×50 ㎲), Current →3kA (8 ×20 ㎲)
1.2.3 Leaked Current
Î100mA or lower
1.3 Environmental Characteristics
1.3.1 Operating Temperature & Humidity
-20℃∼+50℃, 10% ∼90%
1.3.2 Storage Temperature & Humidity
-40℃∼+80℃, 5% ∼95%
1.4 Physical Specifications
1.4.1 Dimension
: 1800(H) X 750(W) X 700(D) ( mm )

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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.
2.2 Transportation
Special care should be paid to handle this power supply system as severe shock
or vibrations 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 computer equipped with a monitoring program.
2) 4-1/2 Digital voltmeter
3) PLUS(＋) screw driver
4) MINUS(－) screw driver
5) (－) screw driver for adjustment
6) (＋) screw driver for adjustment
7) Cutters, wire stripers(#10 to #22 AWG)

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●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.
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

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3 Installation & Cabling
3.1 Exterior View of Rectifier System
Figure 2. Exterior View of CPRS-1400

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Figure 3. Exterior View of CPRS-1400DD

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3.1.1 Front View
Figure 4. Front View of CPRS-1400

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Figure 5. Front View of CPRS-1400D

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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. 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
AA
CPRS-1400 CPRS-1400DD CPIS-3K/6K
M12 NUT M12 X 40mm
BUS-BAR
M6 X 20mm
M6 NUT
Figure 6. Fixing Racks Side by Side

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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

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3.3 Cabling
●Pay particular attention to keep safety in installing rectifiers.
●Before starting the operation check if AC/DC voltage has been
suspended using DVM.
●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.
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 connected either to
the right side of the input port or to the rack top.
CPRS-1400 CPRS-1400DD CPIS-3K/6K
Figure 9. Chassis GND Connection Point

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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

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3.3.3 Surge Observer Ground
Surge observer ground should be connected to the main ground busbar using a
green wire (14SQ) for safety.
R S T
RST
SR T
VAL-
MS
-32 0
VAL-
MS
-320
VAL-
MS
-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 hole lug should be used.
☞For cabling see above Figure 11.
SURGE Absorbor Ground