DCP03 300A Distribution Center Installation & Operation Manual XXX-XX
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DCP03 300A Distribution Center 020-702-B2 The following documents and drawings are included in this manual: • Specifications: 020-702-B1 • Installation and Operation Instructions 020-702-C0 • Customer connection drawing: 020-702-08 • Outline drawing: 020-702-06 • Schematic 020-702-05 Alpha Technologies Ltd. Printed in Canada. © 2010 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved.
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 1. Please read this manual prior to use to become familiar with the product’s numerous features and operating procedures. To obtain a maximum degree of safety, follow the sequences as outlined. 2. This manual provides warnings and special notes for the user: a. Points that are vital to the proper operation of the product or the safety of the operator are indicated by the heading: WARNING. b.
TABLE OF CONTENTS 1 INTRODUCTION ............................................................................................................................................................. 1 1.1 1.2 1.3 2 DISTRIBUTION CENTER FEATURES ................................................................................................................................ 3 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 Safety Precautions ...........................................................................................
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1 Introduction 1.1 Scope of the Manual This instruction manual covers the features and installation of Alpha Technologies DCP03 300A Distribution Center. NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual. 1.2 Product Overview The DCP03 300A Distribution Center is an integrated DC system distribution package designed for small to midsized power applications. The compact unit installs in three rack units of space.
1.3 Part Numbers and List Options This product is available to order under the following part numbers and list options: Description Part Number/List Option DCP03 300A Distribution Center (18-position) ............................................................................................................. 020-702-20 Basic unit .............................................................................................................................................................................
2 Distribution Center Features 2.1 Distribution Configurations The DCP03 contains 18 total AM-type plug-in breaker positions with two-hole connection points for both breaker output and the ground return bus. The breaker distribution can be configured one of two ways: 1. List 87 configuration provides for all 18 positions to be dedicated to load distribution. In this configuration, both rectifier and battery connections must be made on the rear bus bar input or external to the distribution center. 2.
2.4 Internal Alarm Card The DCP03 includes a standard alarm card providing a common interface point to internal system I/O connections, an LVD override switch, and LED indication of breaker trip. The alarm card provides terminal block access to internal signals such as binary alarms for breaker trip & LVD open, alarm relay for driving LVD, and analog inputs for current (shunt) and voltage measurements.
Figure 4–Internal alarm card and CXCI I/O terminal block option 2.6 CXCM2 I/O Terminal Block (Option) When using the DCP03 as a distribution solution for use with a 1.8kW rectifier shelf with a modular CXCM2 controller, an I/O terminal block can be installed in the UDC front door for front access to controller signals. The CXCM2 terminal block kit comes with 25-pin, 15-pin, and 9-pin D-sub wire harnesses for connection to the back of the 1.8kW rectifier shelf using the CXCM2 controller.
Customer I/O connections via terminal blocks ADIO power supply connection CAN in/out Figure 6–4R/8D ADIO option Customer I/O connections via terminal blocks 8DIO power supply connection CAN in/out Figure 7–8R/8D 8DIO option 020-702-C0 Rev C WC Page 6 of 16
3 Inspection 3.1 Packing Materials All Alpha products are shipped in rugged, double walled boxes and suspended via solid inserts to minimize shock that can occur during transportation. Packaging assemblies and methods are tested to International Safe Transit Association standards. Products are also packaged with Cortex. This plastic wrap contains a corrosive-inhibitor that protects the product from corrosion for up to two years. 3.1.1 Returns for Service Save the original shipping container.
4 Installation This chapter is provided for qualified personnel to install the product, which shall be mounted in a clean and dry environment. For battery installation refer to the manufacturer’s guidelines for more specific information. NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual. 4.1 Safety Precautions DANGER Hazardous voltages are present at both the input and the output of power systems.
4.4 Breaker Installation 1. 2. 3. 4. 5. 4.5 Ensure mid-trip breakers are used for load and series-trip breakers are used for battery connections. Turn breaker off. Ensure that the breaker is right side up. Align the breaker terminals with the correct holes. Carefully push the breaker into position. Breaker Removal 1. Turn breaker off. 2. Carefully pull the breaker out of position.
5 Wiring This chapter provides cabling details and notes on cable sizing for DC applications with respect to the product. WARNING Ensure that power is removed by turning off rectifiers and removing battery line fuse or connection before attempting work on the wiring connections. Use a voltmeter to verify the absence of voltage. Clearly mark the correct polarity of the battery leads before commencing work on DC connections.
NOTE: Bus bar inputs are fixed for hot and return placement. Labels indicating polarity will be reversed when configured for 48Vdc positive ground versus 24Vdc negative ground. DCP03 input bar (hot) DCP03 input bar (return) Figure 8–Rear view of DCP03 bus bar input 5.2.2 Distribution Cabling Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a 0.
5.3 Alarm Connections Terminal blocks can accommodate wire sizes #16 to #26 AWG (1.5 to 0.14mm²). Route via wire-ways and use existing cable clamps to secure to existing (factory) wire harness along with customer run signal wires. Ensure signal wires are routed along hinge point of front door so door opening and closing won’t require excess wire slack. Refer to Figure 10 for wire routing example.
5.5 CAN Serial Ports (4R/8D ADIO or 8R/8D 8ADIO Option) Two CAN Serial ports (modular jacks with offset latches), for communications with Alpha’ Cordex rectifiers and other CAN-enabled equipment (nodes) on the same system, are located on the optional 4R/8D ADIO or 8R/8D 8ADIO Cordex peripherals (Figure 10). Daisy-chain from node to node (CAN OUT of one shelf to CAN IN of another) as necessary and ensure that only the last shelf is terminated as follows: 5.5.
6 System Startup Visually inspect the installation thoroughly. After completing the system installation and power system wiring, perform the following startup and test procedure to ensure proper operation: 6.1 Check System Connections • • 6.2 Verify AC and Power the Rectifier Shelf • • • • 6.3 Install one power module. Verify AC input voltage is correct and turn on the corresponding feeder breaker. The power module OK LED should illuminate after a preset start delay.
7 Maintenance Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualified service personnel should do repairs. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year. WARNING: HIGH VOLTAGE AND SHOCK HAZARD. Use extreme care when working inside the unit while the system is energized. Do not make contact with live components or parts.
8 Acronyms and Definitions AC Alternating current AWG American wire gauge CEC Canadian Electrical Code CMA Circular mil area CSA Canadian Standards Association CX Cordex series; e.g.
Specifications for Alpha Technologies DCP03 300A Distribution Center System Output Voltage: 24 or 48Vdc Current: ≤300A (dc) m axim um Distribution Breaker Ratings: 18-position, plug-in type (bullet terminals), AM-style, 5 to 100A Connections Load Connections: 18x sets 1/4”-20 studs on 5/8” centers (List 87) 14x sets 1/4”-20 studs on 5/8” centers (List 88) [multiple pole breaker adapter: 3/8” holes on 1” centers] Battery Terminations: 4x sets 1/4”-20 studs on 5/8” centers (List 88) [multiple pole br
REVISIONS 17.25 438.1 LTR REV BY DESCRIPTION DATE APPD 16.8 426.7 12.52 317.9 TYP 11.3 287.0 TYP LIST 21 - 19" FLUSH MOUNTING TOP VIEW 0 0.48 12.2 TYP 5.23 132.8 4.99 126.7 3.74 95.0 1.49 37.8 0.24 6.1 0 18.31 465.1 DESIGN RP 2007/09 DRAWN RP 2007/09 CHECKED RP 2007/09 APPROVED JK 2007/09 TOLERANCES X.X 0.04" 0.02" X.XX X.XXX 0.01" [X] 1mm 0.5mm [X.X] [X.XX] 0.25mm TITLE 19.0 482.
12.52 317.9 TYP REVISIONS LTR DESCRIPTION REV BY DATE APPD 11.3 287.0 TYP LIST 19 - 19" MOUNTING LIST 23 - 23" MOUNTING 6.0 152.4 TYP 0 0.48 12.2 TYP 16.80 426.7 17.25 438.1 LIST 19/23 - CENTER MOUNTING TOP VIEW 5.23 132.8 4.99 126.7 3.74 95.0 1.49 37.8 0.24 6.1 0 THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. NTS SCALE TITLE 22.31 566.7 23.00 584.
REVISIONS LTR B REV BY DESCRIPTION ADDED LIST 80, 8R/8D 8DIO JLM APPD 12/10 12/10 JK BREAKER RETURNS 1/4-20 HARDWARE ON 5/8" CENTERS BREAKER OUTPUTS 1/4-20 HARDWARE ON 5/8" CENTERS BATTERY BREAKERS (FOUR POSITIONS) WHEN LIST 88 SPECIFIED UDC INPUT BUS (RECTIFIER HOT) TOP VIEW UDC RETURN BUS (RECTIFIER RETURN) CHASSIS GROUND (10-32 STUD) CHASSIS GROUND (10-32 STUD) THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT I
REVISIONS LTR REV BY DESCRIPTION DATE APPD USED INTERNALLY WHEN LIST 71 OR 72 EQUIPPED USED INTERNALLY WHEN LIST 74 OR 75 EQUIPPED USED INTERNALLY WHEN LIST 84 EQUIPPED USED INTERNALLY WHEN LIST 74 OR 75 EQUIPPED LIST 75 - CXCM2 INTERFACE PCB LVD OVERRIDE SWTICH USED INTERNALLY WHEN LIST 74 OR 75 EQUIPPED GREEN LVD AUTO CONTROL LED YELLOW LVD OVERRIDE LED USED INTERNALLY WHEN LIST 74 OR 75 EQUIPPED LIST 1,4 OR 2 - LVD OVERRIDE / DISTRIBUTION ALARM PCB USED INTERNALLY WHEN LIST 71 OR 72 BATTER
REVISIONS LTR DESCRIPTION REV BY DATE APPD LIST 79 - 4 RELAY / 8 DIGITAL ADIO PCB OUT IN DIGITAL INPUTS JUMPER SETTINGS FOR CAN TERMINATION P10 OUT IN RELAY OUTPUTS CAN IN RJ12 OFFSET PIN OUT (J2) 1. GND 2. CAN H 3. NOT CONNECTED 4. CAN L 5. NOT CONNECTED 6. NOT CONNECTED CAN + - POWER CAN OUT RJ12 OFFSET PIN OUT (J1) 1. GND 2. CAN H 3. NOT CONNECTED 4. CAN L 5. NOT CONNECTED NOT CONNECTED 6.
REVISIONS LTR DESCRIPTION REV BY DATE APPD LIST 80 - 8 RELAY / 8 DIGITAL 8DIO PCB P10 K1 IN 1 TB1 IN 2 TB2 IN 3 TB3 IN 4 TB4 K2 IN 5 TB5 IN 6 TB6 IN 7 K5 K3 K4 IN 8 NC K1 NO NC K2 NO NC K3 NO TB9 TB10 TB11 TB7 TB8 NC K4 TB12 K7 K6 NO NC K5 NO TB13 K8 NC K6 NO NC K7 NO NC K8 NO TB14 TB15 TB16 CAN PWR DS2 J2 J1 TB17 DS1 2 1 IN OUT CAN DIGITAL INPUTS RELAY OUTPUTS JUMPER SETTINGS FOR CAN TERMINATION P10 OUT IN CAN IN RJ12 OFFSET PIN OUT (J2) 1. GND 2. CAN H 3.
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Alpha Technologies Ltd. 7700 Riverfront Gate Burnaby, BC V5J 5M4 Canada Tel: +1 604 436 5900 Fax: +1 604 436 1233 Toll Free: +1 800 667 8743 Alpha Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 Alpha Industrial Power Inc.
