Alpha Technologies Cordex HP 48 1.2kW, Technical Manual

Page 1: ...Technical Guide 010 619 J0 Effective 10 2018 Cordex 48 1 2kW Rectifier Shelf System Alpha Technologies Ltd...

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Page 3: ...ark of Alpha Technologies No part of this documentation shall be reproduced stored in a retrieval system translated transcribed or transmitted in any form or by any means manual electric electronic el...

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Page 5: ...rush Transient Suppression 9 Soft Start 9 Start Delay 9 Current Limit Short Circuit Protection 9 Power Limiting 9 High Voltage Shutdown HVSD 9 Battery Eliminator Operation 9 Distribution 10 4 8kW Syst...

Page 6: ...ief 26 Calculating Output Wire Size Requirements 27 DC Output 27 DC Output for Model 030 851 20 maximum 3600W 27 DC Output for Model 0300165 maximum 4800W 29 DC Output for Model 030 835 20 030 845 20...

Page 7: ...er Reset 41 Soft Reset CXCM1 only 41 IP Address Reset CXCM1 only 41 Hard Reset 42 Accessing the LVD Jumper 42 9 MAINTENANCE 43 Rectifier Fan Replacement 43 10 WARRANTY AND SERVICE INFORMATION 45 Techn...

Page 8: ...nmental Codes 19 Figure 14 Removing a Rectifier from the Shelf 22 Figure 15 Removing a CXRF or CXCM1 or CXCM1 23 Figure 16 Removing the CXCM1 HP 24 Figure 17 AC input CAN and signal connections 4800W...

Page 9: ...nitions for Digital Inputs 34 Table 4 Output Voltage Modes 38 Table 5 Output Current Power Modes 38 Table 6 Factory Ranges and Defaults 39 Table 7 Sample Maintenance Log 43 Table 8 Specifications Cord...

Page 10: ...vi...

Page 11: ...gs present safety information to PREVENT INJURY OR DEATH to personnel NOTE HOT The use of Hot presents safety information to PREVENT BURNS to the technician or user 1 2 General Warning and Cautions WA...

Page 12: ...bassembly are suitable for connection to intra building or unexposed wiring or cabling only The intra building ports of the equipment or subassembly MUST NOT be metallically connected to interfaces th...

Page 13: ...010 619 J0 Rev B Page 3 Batteries are hazardous to the environment and should be disposed at a recycling facility Consult the battery manufacturer for recommended local authorized recyclers...

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Page 15: ...to the system at the time of ordering or after the shelf has been installed The shelves are designed for horizontal mounting in a 19 or 23 center mount flush mount for 1RU shelves installation via un...

Page 16: ...010 619 J0 Rev B Page 6 Figure 1 Single Shelf Figure 2 Dual Shelf Figure 3 2RU Shelf...

Page 17: ...igure 4 Rectifier Front Panel 3 1 2 LEDs The front panel LEDs provide rectifier status summary and help to locate a specific module with the controller AC The top LED green is on when AC is within val...

Page 18: ...icate a failed module or a failed load NOTE For Cordex rectifier systems without batteries or with a very light load below 2 5 of rated output it is recommended that the ramp test be disabled to avoid...

Page 19: ...condition Current limiting can be used to mate the rectifier output current ampacity to the needs of the load and parallel battery to minimize excessive battery recharge current The rectifier will sus...

Page 20: ...in a compact space See Wiring and Connections chapter of this manual for more details Figure 5 4 8kW System Distribution Module 3 2 2 3 6kW System Distribution Module 030 851 20 Cordex CXRF HP 48 1 2...

Page 21: ...press any of the three navigation buttons to re activate the screen and enter dashboard mode Figure 7 CXCM1 HP Controller 3 3 1 Display In dashboard mode the in shelf display shows the key operating p...

Page 22: ...enu screen The following table provides a full list of menus available via the in shelf display Figure 9 In Shelf Controller Menu A C 1 2 0 1 2 0 1 V 7 8 7 2 V A 8 0 2 3 V A 7 9 0 2 V A D C 4 8 5 4 0...

Page 23: ...Restore Restore the controller application and configuration from a file on a USB device Upgra Upgrade the controller application from a file on a USB device OS Upg Upgrade the controller s operating...

Page 24: ...Cordex controller includes a web server that provides easy set up and monitoring using an Internet connection with the standard web browser The data logging feature allows the user to capture data fr...

Page 25: ...minated at a time during alarm conditions Green OK no alarms present Yellow Minor alarm is present no major alarms Red Major alarm is present Progress and Status Indication The LEDs are also used in t...

Page 26: ...battery to monitor battery voltage or change battery setting from V1 to V2 in Signals Configure Signals Current Inputs The controller software is pre configured to monitor I1 for battery current wired...

Page 27: ...nications with your controller is available via the Alpha website http www alpha ca downloads 3 4 10 Controller Connections Next to the CXCM1 on the left side of the shelf are terminal block connectio...

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Page 29: ...quirements As such Alpha strives to follow our quality and environmental objectives from product supply and development through to the packaging for our products Rectifiers and batteries are shipped o...

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Page 31: ...nd battery installa tions e g CSA UL CEC NEC OSHA and local fire codes 5 2 Shelf Preparation Mounting NOTE The shelf is designed for horizontal mounting in a clean and dry environment Allow at least 1...

Page 32: ...f 2 Place the new rectifier module on the shelf bottom and slide the module into the rear connector inside the shelf 3 Apply pressure to the module front panel to engage the rear connector in the shel...

Page 33: ...oving the controller 2 Pull from the location noted in the following image to remove the controller CAUTION When removing the controller in a live system that has an LVD ensure that the LVD override j...

Page 34: ...010 619 J0 Rev B Page 24 Figure 16 Removing the CXCM1 HP 1 Push up here and hold to release latch while removing the controller from the shelf 2 Pull here to remove the controller from the shelf...

Page 35: ...size 3 16 Digital voltmeter equipped with test leads Adjustable 24 48Vdc load optional Cutters and wire strippers Crimping tool optional for large gauge wire Socket and ratchet set Imperial measure A...

Page 36: ...to customer connection drawings at the rear of this manual NOTE The shelf incorporates IEC plug connections requiring line cords with C19R type receptacles Figure 17 AC input CAN and signal connection...

Page 37: ...etc for guidelines If required increase the size of the cable to meet the code 6 6 DC Output 6 6 1 DC Output for Model 030 851 20 maximum 3600W Chassis and Site Ground Connections WARNING For safety...

Page 38: ...ect a DC output cable use needle nose pliers to pull out the appropriate plug in connector Apply gentle clamping force to the pliers to avoid breaking the connector 2 After the plug in connector has b...

Page 39: ...RW90 Type Double check the battery polarity and then connect the positive cable to the top side of the output bar and negative cable to bottom side Figure 20 DC Output to Batteries 6 6 2 DC Output fo...

Page 40: ...floating analog especially current readings The chassis ground connection is located on the center mount rack bracket Connect to the 10 32 stud using single hole lug and hardware as provided The syste...

Page 41: ...Hot Connections Connect to the four load breaker hot termination pairs using 1 4 on 5 8 center lugs Connection method is similar for breaker distributions in a 2 load 2 battery CB configuration Refer...

Page 42: ...rmination OUT default 6 8 6 8 1 6 8 2 6 9 NOTE This system has a limit of twelve Cordex 1 2kW rectifiers due to available power from CAN Bus They do not have self powered CAN Bus nodes Network Connect...

Page 43: ...r redundant power feed to the CXCM1 series controller when a battery disconnect device is used It is critical to controller opera tion as it ensures an auxiliary source of power to the controller shou...

Page 44: ...elay Outputs Terminals provide contacts for extending various alarm or control signals Each relay output K2 K3 K4 can be wired for NO or NC operation during an alarm or control condition Figure 26 Rel...

Page 45: ...ee the customer connections drawings If the LVD is controlled on NC contacts factory default for LVD option then JP2 pins 1 and 2 must be shorted together to maintain LVD operation If the LVD is contr...

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Page 47: ...ting for a given amount of time before transitioning to the next state The controller continues to monitor its inputs After the Start Delay state the rectifier transitions to the Soft Start state NOTE...

Page 48: ...2 Output Current Power Modes These four output current power modes directly affect the output current and power Table 4 Output Voltage Modes Output Voltage Modes Active when Float Output voltage is se...

Page 49: ...5 Output Current Power Modes Continued Sheet 2 of 2 Output Current Power Mode Output current and power limit have been reduced due to Table 6 Factory Ranges and Defaults Sheet 1 of 2 Setting Range mi...

Page 50: ...BT voltage setting or the safe mode voltage of 51 4V Current Limit Power Limit Alarm Enable Disable Enable Remote Shutdown Enable Disable Enable Ramp Test Enable Disable Enable Table 6 Factory Ranges...

Page 51: ...ing for low AC voltage alarming is 180Vac For nominal 120Vac operation it is recommended to reset this value to 100Vac Using the controller test the functionality of various module alarms and controls...

Page 52: ...D control jumper to the override position before unplugging the controller The load and batteries are still connected Use of hard reset may cause loss of data 8 5 Accessing the LVD Jumper To change th...

Page 53: ...HIGH VOLTAGE AND SHOCK HAZARD Use extreme care when working inside the shelf while the system is energized Do not make contact with live components or parts IMPORTANT Circuit cards can be damaged by...

Page 54: ...ischarge 2 Remove the bottom screw that secures the front panel to the module chassis 3 Slide the front panel out 4 Disconnect the fan power lead wires from the module 5 Note the direction of airflow...

Page 55: ...es or consequential damages based upon equipment failure during or after the warranty period No other obligations are expressed or implied Warranty also does not cover damage or equipment failure due...

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Page 57: ...d to CSA C22 2 No 107 3 and UL 1778 As part of the reciprocal US Canada agreement regarding testing laboratories the Standards Council of Canada Canada s national accreditation body granted Underwrite...

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Page 59: ...troller CXC Cordex Controller CXC HP Cordex Controller High Performance CXD Cordex DC DC Converter CXR Cordex Rectifier DC Direct current DCCT Direct Current Current Transducer DHCP Dynamic Host Confi...

Page 60: ...MOV Metal Oxide Varistor MUX Multiplexer NEBS Network Equipment Building System a set of safety spatial and environmental guidelines for telecom OLED Organic LED in shelf controller display RFC Reque...

Page 61: ...e within rated limits Static Line Regulation Better than 0 1 for any change in input voltage within rated limits Dynamic Line Regulation Better than 1 for any change in input voltage within rated limi...

Page 62: ...nt 7 5A maximum 176 to 300Vac 6A maximum 90 to 176Vac Power Factor 0 99 at nominal conditions and 50 100 load Protection 10kA interrupting capacity fuses in active and neutral lines Efficiency 94 peak...

Page 63: ...D Weight 1 23 kg 2 72 lb Compliance EN 55022 CISPR 22 Information Technology Equipment Radio Disturbance Characteristics Limits and Methods of Measurement Class A and Class B EN 61000 3 2 Harmonic Cur...

Page 64: ...1089 CORE Electromagnetic Compatibility and Electrical Safety In accordance with FCC requirements we provide the following statement as specified in the FCC guidelines for conformance to Part 15 Class...

Page 65: ...H x 88mm W x 318mm D 1 73 H x 3 5 W x 12 5 D Weight 0 62 kg 1 36 lb Mounting Modular on Cordex CXRF 48 1 2kW series shelves Relay Outputs Four 4 Form C 60Vdc 1A maximum Digital Inputs Two 2 60Vdc Anal...

Page 66: ...ifications Basic Unit CXCM1 Input Voltage 17 to 60Vdc within rated limits Current 100mA 48Vdc 200mA 24Vdc MTBF 472 000 hours 25 C 77 F EMC The unit meets requirements of Emissions EN 55022 Class A CIS...

Page 67: ...ase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radi...

Page 68: ...20Vdc with power source Communication Ports Ethernet RJ 45 CAN see shelf specifications Recommended Signal Wire Sizes Wire Size Range 16 to 26 AWG 1 5 to 0 14mm2 Temperature Rating 90 C 194 F CAUTION...

Page 69: ...OM CANH CANL CAN_ 5V AC_L1 AC_L2 POWER CANL J2 1 2 3 4 CAN AC IN AC_L1 AC_L2 CANL AC_L1 AC_L2 AC_L1 AC_L2 CAN_COM CANH CAN_ 5V POWER POWER CAN_COM CANH CAN_ 5V J2 1 2 3 4 CAN AC IN AC_L1 AC_L2 CANL PO...

Page 70: ...CTIFIER O P BATTERY CB OUTPUTS LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG 7050233 001 OR 7050259 001 10 POS N GMT FUSE BOARD GRN YEL 12 AWG BUS...

Page 71: ...O P BATTERY CB OUTPUTS LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG BUSBARS 7050238 001 ALARM STRIP BACKPLANE BOARD FROM CXCM1 BACKPLANE BOARD T...

Page 72: ...LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG BUSBARS 707 588 20 ALARM STRIP BACKPLANE BOARD FROM CXCM1 BACKPLANE BOARD TO CXCM1 BACKPLANE BOARD...

Page 73: ...AC_L1 AC_L2 AC_L1 AC_L2 7 5 6 8 BLK 2 X 18 AWG BLK 2 X 18 AWG GRN YEL 2 X 18 AWG AC FEED 2 MDLS 3 4 L1 L2 N PE BLK 2 X 18 AWG BLK 2 X 18 AWG GRN YEL 2 X 18 AWG 1 1 2 2 3 3 4 4 IEC RECEPTACLE AC_L1 AC...

Page 74: ...DATE APPROVALS VB Feb 20 14 Feb 20 14 SL THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED DIM ARE IN MM INTERPRET DIM AND TOL PER ASME Y14 5M 1994 X X X X XX ANGULAR 1 3 0 5 0 25 REAR RIGHT ISOMETRI...

Page 75: ...06 OUTLINE DRAWING CXRF 48 1 2kw 19 SHELF 8 0 439 5 0 304 4 12 5 123 2 10 32 GROUND STUD TYP BOTH SIDES 88 2 10 92 6 35 76 20 31 75 12 7 482 6 583 6 465 0 566 0 19 RACK MOUNTING 23 RACK MOUNTING DO N...

Page 76: ...HERWISE SPECIFIED A B CB4 CB3 CB2 CB1 CHASSIS GROUND 10 32 STUD HARDWARE AC IN MODULE 1 2 AC IN MODULE 3 4 SYSTEM STATUS LEDS LCD SCREEN DISPLAY PUSH BUTTON TOGGLE SWITCH A V HARD RESET BUTTON RESET B...

Page 77: ...LOAD RETURNS NOTE SITE GROUND TERMINALS ARE NOT VISIBLE IN THIS VIEW SEE 2 LOAD DISTRIBUTION CONFIG FOR TYPICAL DETAIL BATTERY OUTPUT BATTERY OUTPUT 19 30 15 875 1 4 20 TYP PAIRED HARDWARE 15 875 2 L...

Page 78: ...F A AA AB AC AD CORDEX CXCM1 HP SYSTEM CONTROLLER DETAIL A DETAIL AA SCALE 3 1 RESET STATUS DISPLAY DETAIL AB SCALE 3 1 MENU SELECT BUTTON C MENU CONTROL ALARM STATUS DETAIL AC SCALE 3 1 USB 2 0 PORT...

Page 79: ...POWER POWER POWER POWER K1_C K1_NC K2_C K2_NO K2_NC K3_C K3_NO K3_NC K4_C K4_NO K4_NC D1_1 D1_2 D2_1 D2_2 V1_ V1_ T1_ T1_ T2_ T2_ I1_ I1_ BATT_HOT CAN_L CAN_L CAN_H CAN_H CAN_ 5V CAN_ 5V CAN_COM CAN_C...

Page 80: ...4 5M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 PRODUCT TO BE FABRICATED ACCORDING TO ATL PRODUCTION STANDARD 0700001 1 NOTES UNLESS OTHERWISE SPECIFIED 010 619 20 MODULE 4x 0180054 001 or 018 598 20 0 12 0...

Page 81: ...ARGUS DC MODEM USE ONLY PIN 1 2 3 4 5 6 7 8 9 DTR DCD TX RI COM CTS RX FUNCTION DSR RTS DETAIL C 5 9 6 1 K3 NC 12 10 11 I1 T2 T1 D1 1 K4 COM FUNCTION K1 NC D2 1 K3 NO V1 K2 COM K1 COM 9 8 7 6 5 4 3 2...

Page 82: ...WER POWER CAN_COM CANH CAN_ 5V L1_3 L2_3 N CANL DC OUT POWER POWER CAN_COM CANH CAN_ 5V E10 E9 E11 E12 BUSBARS BUSBARS 7050471 001 BACKPLANE RECTIFIER MDL 2 RECTIFIER MDL 3 RECTIFIER MDL 4 P1 J5 37 CA...

Page 83: ...M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 0 152 4 6 00 303 7 11 96 325 0 12 80 341 0 13 43 12 0 0 47 17 0 0 67 0 105 4 4 15 130 8 5 15 308 6 12 15 334 0 13 15 439 4 17 30 6 OFFSET RACK MOUNT 18 0 0 71 37...

Page 84: ...N UNLESS OTHERWISE SPECIFIED DIM ARE IN MM INTERPRET DIM AND TOL PER ASME Y14 5M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 CAN IN RJ12 OFFSET PIN 1 2 3 4 5 6 CAN L CAN COM NOT CONNECTED NOT CONNECTED CAN H...

Page 85: ...815 20 PCB ASSY 8 GMT 1 2 3 4 5 6 7 8 9 10 E3 A1 A2 11 12 13 14 15 16 E4 E5 E6 E7 E8 JP1 JP4 JP5 JP6 JP7 JP8 JP3 LOAD LVD LIST 86 LOAD LVD LIST 86 BATTERY LVD LIST 87 BATTERY LVD LIST 87 JP9 NC K1 LV...

Page 86: ...22 05 SY 439 5 17 30 583 6 22 98 465 0 18 31 566 0 22 28 482 6 19 00 0 37 9 1 49 6 1 0 24 44 0 1 73 LIST 23 6 OFFSET FOR 23 RACK SCALE 1 3 LIST 19 6 OFFSET FOR 19 RACK 0 321 7 12 67 332 0 13 07 0 29 8...

Page 87: ...D TX RX NOT CONNECTED NOT CONNECTED TX FUNCTION RX NOT CONNECTED DETAIL B 1 8 CAUTION USE ONLY ALPHA DC MODEM SEE MANUAL FOR INSTRUCTIONS PIN 1 2 3 4 5 6 7 8 9 DTR DCD TX RI COM CTS RX FUNCTION DSR RT...

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