Alpha Cordex 48-1.2kW User Manual
Cordex 48-1.2kW 19" Front Access Shelf System
Installation & Operation Manual
Part #030-834-J0
Effective: 06/2011
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Cordex 48-1.2kW
19” Front Access Shelf System
030-834-J0
In addition to these installation and operation instructions, the following documents and drawings are
included in this manual to provide the necessary information required for installation, operation and fault
diagnosis of the unit:
• Specifications, Shelf: 030-834-B1
• Specifications, Shelf w/CXCM1: 030-835-B1
• Specifications, Shelf, Bulk Power: 030-845-B1
• Specifications, Shelf w/CXCM1 & GMT Distribution Modules: 030-851-B1
• Specifications, Rectifier: 010-619-B1
• Specifications, CXCM1: 018-598-B1
• CSA/ NRTL Equivalence: 048-554-10
• Schematic: 030-834-05
• Outline Drawing, Shelf: 030-834-06
• Customer Connections: 030-834-08
• Schematic: 030-835-05
• Outline Drawing, Shelf: 030-835-06
• Customer Connections: 030-835-08
• Schematic: 030-845-05
• Outline Drawing, Shelf: 030-845-06
• Customer Connections: 030-845-08
• Outline Drawing, Shelf: 030-851-06
• Customer Connections: 030-851-08
IMPORTANT SAFETY INSTRUCTIONS
Save These Instructions
This section contains important instructions that must be followed during the installation and maintenance of the
equipment and batteries. Read all of the instructions before operating the equipment, and save this manual for future
reference.
The following safety symbol is found throughout this manual:
Carefully read all information and abide by the instructions.
The following warning levels are used in conjunction with the symbol:
DANGER: You WILL be KILLED or SERIOUSLY INJURED if instructions are not followed closely.
WARNING: You CAN be KILLED or SERIOUSLY INJURED if instructions are not followed closely.
CAUTION: You CAN be INJURED or equipment can be DAMAGED if instructions are not followed closely.
Before using the product, read all instructions and cautionary markings on the product and any equipment
connected to the product.
Do not expose the product to rain or snow; install only in a clean, dry environment.
CAUTION: Unless otherwise noted, use of an attachment not recommended or sold by the product
manufacturer may result in a risk of fire, electric shock, or injury to persons.
CAUTION: Do not operate the product if it has received a sharp blow, it has been dropped, or otherwise
damaged in any way – return it to a qualified service center for repair.
CAUTION: Do not disassemble the product – call our qualified service centers for servicing. Incorrect
reassembling may result in a risk of electrical shock or fire.
CAUTION: Double pole / Neutral fusing.
WARNING: High leakage current – Earth connection essential before connecting supply.
TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................................................. 1
1.1 Scope of the Manual ..................................................................................................................................... 1
1.2 Product Overview ......................................................................................................................................... 1
1.3 Part Numbers and List Options ..................................................................................................................... 3
EATURES ......................................................................................................................................................... 7
2 F
2.1 Rectifier modules .......................................................................................................................................... 7
2.2 Distribution Module ...................................................................................................................................... 9
2.3 Controller module ....................................................................................................................................... 10
NSPECTION .................................................................................................................................................... 14
3 I
3.1 Packing Materials ........................................................................................................................................ 14
3.2 Check for Damage ....................................................................................................................................... 14
NSTALLATION ................................................................................................................................................. 15
4 I
4.1 Safety Precautions ...................................................................................................................................... 15
4.2 Shelf Preparation/Mounting ....................................................................................................................... 15
4.3 Module Insertion/Removal ......................................................................................................................... 16
IRING AND CONNECTIONS ............................................................................................................................... 17
5 W
5.1 Safety Precautions ...................................................................................................................................... 17
5.2 Tools Required ............................................................................................................................................ 17
5.3 AC Feeder Protection/Sizing ....................................................................................................................... 17
5.4 AC Input ...................................................................................................................................................... 18
5.5 Calculating Output Wire Size Requirements............................................................................................... 18
5.6 DC Output for Model 030-851-20 (maximum 3600kW) ............................................................................. 19
5.7 DC Output for Model 030-834-20 (maximum 4800kw) .............................................................................. 21
5.8 DC Output for Model 030-835-20/ 030-845-20 (bulk distribution) ............................................................ 23
5.9 CAN Ports .................................................................................................................................................... 23
5.10 Network Connection and Remote Communications via CXCM1 ................................................................ 23
5.11 Signal Wiring Connections .......................................................................................................................... 24
PERATION .................................................................................................................................................... 27
6 O
6.1 Main Rectifier States ................................................................................................................................... 27
6.2 Main Rectifier Modes.................................................................................................................................. 28
6.3 Can Bus Communications ........................................................................................................................... 28
6.4 Factory Ranges and Defaults ...................................................................................................................... 29
YSTEM STARTUP ............................................................................................................................................. 30
7 S
7.1 Check System Connections ......................................................................................................................... 30
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7.2 Verify AC and Power the Shelf .................................................................................................................... 30
7.3 Check Battery Polarity and Connect ........................................................................................................... 30
7.4 CXC Reset .................................................................................................................................................... 30
AINTENANCE ................................................................................................................................................ 32
8 M
8.1 Fan Replacement ........................................................................................................................................ 32
ARRANTY AND SERVICE INFORMATION ............................................................................................................... 33
9 W
9.1 Technical Support ....................................................................................................................................... 33
9.2 Warranty ..................................................................................................................................................... 33
9.3 Battery Warranty ........................................................................................................................................ 33
9.4 Return of Material ...................................................................................................................................... 33
9.5 Service Centers ........................................................................................................................................... 33
CRONYMS AND DEFINITIONS ............................................................................................................................. 34
10 A
TABLE OF FIGURES
Figure 1–Cordex CXRF-HP 48-1.2 kW 1RU 19" shelf system, shown with 3 rectifier modules up to 3600W output
power, CXCM1 Controller and GMT fuse distribution ............................................................................................. 2
Figure 2–Cordex CXRF-HP 48-1.2 kW 1RU 19" shelf system, shown with (a) 4 rectifier modules up to 4800W output
power and CXCM1 controller (top shelf) and (b) 5 rectifier modules up to 6000W output power (lower shelf) .. 2
Figure 3–Cordex CXRF-HP 48-1.2kW 2 RU 19" shelf system, shown with 4 rectifier modules up to 4800W output
power, CXCM1 controller and GMT fuse distribution .............................................................................................. 2
Figure 4–Cordex CXRF-HP 48-1.2kW rectifier front panel ............................................................................................... 7
Figure 5–Cordex 48-1.2kW (4800W system) showing breakers and fuses .................................................................... 10
Figure 6–Cordex 48-1.2kW (4800W system) showing breakers and fuses .................................................................... 10
Figure 6–Cordex CXCM1 model system controller front panel ...................................................................................... 11
Figure 7–Cordex 48-1.2kW (4800W system) AC input, CAN, and signal connections ................................................... 18
Figure 8–DC output connections .................................................................................................................................... 21
Figure 9–Breaker ground connections ........................................................................................................................... 22
Figure 10–Front view of distribution module (cover removed) ..................................................................................... 23
Figure 11–Signal Wiring Terminal Blocks ....................................................................................................................... 24
Figure 12–Showing digital input connection method .................................................................................................... 25
Figure 13–Showing relay connections ............................................................................................................................ 26
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