Alpha Cordex 48-1kW 19 6000W User Manual

Cordex 48-1kW 19" Shelf, Flush Mounting For Systems Up To 6000W

030-828-B2 (030-707-20 pre-RoHS)

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Argus Technologies Ltd. Visit www.argus.ca Burnaby, British Columbia. Telephone: 604 436 5900 Fax: 604 436 1233

Cordex 48-1kW 19” Shelf, Flush Mounting For Systems Up To 6000W

030-828-B2 (030-707-20 pre-RoHS)

The following documents and drawings are included in this manual to provide the necessa ry information required for installation, operation and fault diagnosis of the unit:

• Specifications, 19” Shelf, Flush Mounting: 030-828-B1

• Specifications, Rectifier: 010-606-B1 (010-566-20 pre-RoHS)

• CSA/NRTL Equivalence: 048-554-10

• Installation and Operation Instructions: 030-827-C0

• Schematic: 030-707-05 (RoHS: 030-828-20)

• Outline Drawing, 19” Shelf, Flush Mounting: 030-707-06 (RoHS: 030-828-20)

• Customer Connections: 030-707-08 (RoHS: 030-828-20)

• Warranty and Service Information: 048-700-10

• Service Centers: 048-693-10

Argus Technologies Ltd. 030-828-B2 Rev A WC

Specifications for Argus’ Cordex 48-1kW 19" Shelf, Flush Mounting, System

Basic Unit, Shelf

Output: 111A @ 54Vdc nominal (124.8A maximum @ 48V) Recommended Feeder Breaker

Single Phase: 15A, #12AWG, 90 deg.C wire at 30 deg. C ambient (per rectifier)

[refer also to AC Feeder Protection/Sizing section of the manual]

Mechanical

Dimensions*: 177.3mm H x 444.5mm W x 303.4mm D (rectifier front panel 18.8mm D)

[6.98" H x 17.50" W x 11.95" D (rectifier front panel 0.74” D)] Mounting*: 19” flush Weight: 7.5 kg (16.5 lb.)

Connections*

AC Input: #6-32 screw terminal blocks Chassis ground: 1/4-20 stud Communications: CAN (bus), in and out, RJ-12 offset; Ethernet RJ-45 DC Output: 1/4-20 x 5/8” studs Signal wiring: Terminal blocks

0.75 to 0.14mm

Safety

CSA C22.2 No. 60950-1 UL 60950-1 CE EN 60950, CB Scheme

73/23/EEC Low Voltage Directive with amendment 93/68/EEC EN 60950 Rectifier output shall be rated SELV suitable for connection to TNV-1 circuits

* See drawings at the rear of this manual.

(#18 to #26 AWG)

Argus Technologies Ltd. 030-828-B1 Rev A WC

Specifications for Argus’ Cordex 48-1kW 19" Shelf, Flush Mounting, System Continued

Basic Unit, CXCM

Input Voltage: 17 to 65Vdc within rated limits Current: <100mA @ 48Vdc

<200mA @ 24Vdc MTBF: >430,000 hours @ 30°C (86°F) EMC: The unit meets requirements of:

ICES-003 Class B

EN 55022 Class B (CISPR 22)

EN 61000-4-2 ESD

EN 61000-4-3 Radiated Immunity

EN 61000-4-4 EFT /Burst

EN 61000-4-6 Conducted Immunity

FCC Part 15 Class B, FCC Part 68

In accordance with FCC requirements, we provide the following statement as specified in the FCC guidelines for conformance to Part 15, Class B:

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or televisi on reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase 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 radio/TV technician for help.

Any changes or modifications to this equipment not expressly described in this manual could void the FCC compliance.

Environmental

Temperature: -40 to 65°C standard @ 3000m derate to 55°C @ 4000m

(-40 to 149°F derate to 131°F @ 13124ft) Humidity: 0 to 95% non-condensing Elevation: -500 to +4000m

(-1640 to 13124 ft)

Argus Technologies Ltd. 030-828-B1 Rev A WC

Specifications for Argus’ Cordex 48-1kW 19" Shelf, Flush Mounting, System Continued

Hardware Specifications, CXCM

CPU: Coldfire RAM: 8MB Flash: 4MB standard, 8MB optional Display: 160 x 160 pixel grayscale LCD Front Panel Controls: Reset button and touch panel (display and input device) LED’s: System OK (Green)

Power System Minor Alarm (Yellow)

Power System Major Alarm / Controller Fail (Red) Audio: Built-in speaker for alarm and popup message tones Dimensions: 177mm H x 74mm W x 255mm D

(6.9” H x 2.9” W x 10“ D) Weight: 2.2 kg (5 lb.) Mounting*: Modular on Cordex 4RU series 1kW shelves Relay Outputs*: Eight (8) Form C, 60Vdc 1A maximum Digital Inputs*: Three (3), 0 to 60Vdc Analog Inputs and System Signals*:

[standard for List 120] Two (2) DC voltage

-LVD1 (K1), Form C relay, 60Vdc 1A maximum

-Load Voltage (V1), 0 to 100Vdc

One (1) current, ±50mV

Two (2) temperature, 0 to 20Vdc with power source

One (1) bi-voltage

* See drawings at the rear of this manual.

The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice.

Argus Technologies Ltd. 030-828-B1 Rev A WC

Specifications for Argus’ Switched Mode Rectifier Cordex 48-1kW

Power Module Output

Voltage: 40.5 to 58Vdc within rated limits Current: 18.5A @ 54Vdc nominal (20.8A maximum @ 48V) Maximum Power: 1000W continuous/module Static Load Regulation: Better than ±0.5% for any load change within rated limits Dynamic Load Regulation: Better than ±2% for 10% - 90% load step

(output shall recover to static limits within 2ms) 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 limits

(output voltage shall recover to static limits within 2ms) Hold-up Time: 10ms Time Stability: ≤0.2% per year Temperature Stability: ≤100ppm/°C over the operating range Heat Dissipation: <340BTU per hour (per rectifier module) Electrical Noise: <26dBrnC (voice band) without battery

≤22dBrnC (voice band) with battery

<5mVrms to 100MHz (wideband)

<100mVp-p to 100MHz

<2mV (psophometric) Acoustic Noise: <55dBa @ 1m (3ft.) @ 30°C (86°F) [individual module]

<55dBa @ 1m (3ft.) @ 30°C (86°F) [four modules] EMI: The unit meets requirements of EN55022 (see Standards for more EMC)

In accordance with FCC requirements, we provide the following statement as specified in the FCC guidelines for conformance to Part 15, Class B:

NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipm ent generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase 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 radio/TV technician for help.

Any changes or modifications to this equipment not expressly described in this manual could void the FCC compliance.

Argus Technologies Ltd. 010-606-B1 Rev A WC

Specifications for Argus’ Switched Mode Rectifier Cordex 48-1kW Continued

Power Module Input

Voltage: 208 to 240Vac nominal Extended Operation: Low: 150 to 90Vac (power de-rated linearly to 40% output)

High: 176 to 320Vac (de-rated power factor above 265Vac) Frequency: 50/60Hz nominal (45 to 66Hz) Current: 5.3 to 4.6A (nominal Vac)

7.4A maximum @150Vac

Power Factor: >0.99 at nominal conditions and 50-100% load;

>0.98 at nominal conditions and 30-100% load Protection: 10kA-interrupting capacity fuses in active and neutral lines Efficiency: >91% at nominal conditions and 50-100% load Inrush Current: ≤ full load steady state current of the rectifier within rated limits Start-up Ready Time: <5 seconds (excluding soft start) to complete inrush limit routine

and ac measurement (for OK signal) Start-up Delay: Programmable up to 120 seconds to enable stagge r-start of multiple rectifiers

and to minimize the effect on a supply source Soft Start: User adjustable to at least 5 seconds (not including start-up delay time) and is

determined by output current limit ramp-up T.H.D. (Current): <5% at 100% load Input Transient Suppression: Meets ANSI/IEEE C62.41 Category B3 Input Leakage Current: <3.5mA @ 265Vac 60Hz

Miscellaneous

MTBF: >400,000 hours Dimensions: 177mm H x 71mm W x 250mm D (excluding connector)

[6.9" H x 2.8" W x 9.8" D] Weight: 2.9 kg (6.4 lb.)

Environmental

Temperature Operating: -40 to +50°C (-40 to 122°F)

Extended: 400W @ +65°C (149°F) Storage: -50 to +85°C (-58 to 185°F) Humidity: 0 to 95% non-condensing Elevation: -500 to +4000m; derate @ -4°C/1000m above sea level

(-1640 feet to 13124 feet; derate @ -7.2°F/3281 feet above sea level)

Argus Technologies Ltd. 010-606-B1 Rev A WC

Specifications for Argus’ Switched Mode Rectifier Cordex 48-1kW Continued

Referenced Standards

EN 300 386-2 EMC and ERM; Telecommunication Network Equipment EN 55022 (CISPR 22): 1998 Information Technology Equipment – Radio Disturbance Characteristics – Limits

and Methods of Measurement EN 61000-3-2:2000 Harmonic Current Emissions EN 61000-3-3:1995 Voltage Fluctuations and Flicker EN 61000-4-2 ESD Immunity EN 61000-4-3 Radiated Electromagnetic Immunity EN 61000-4-4 Electrical Fast Transient/Burst Immunity EN 61000-4-5 Power Line Surge Immunity EN 61000-4-6 Conducted Electromagnetic Immunity EN 61000-4-11 Voltage Dips, Short Interruptions and Variations ETS 300 019-1-1 Environmental Conditions; Storage ETS 300 019-1-2 Environmental Conditions; Transportation ETS 300 132-2 Power Supply Interface at the Input to Telecommunications Equipment;

Operated by Direct Current (DC) ETS 300 753 Acoustic Noise Emissions IEC 60950 Safety of Information Technology Equipment, Including Electrical Business

Equipment (UL/CSA 60950)

The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice.

Argus Technologies Ltd. 010-606-B1 Rev A WC

CSA/NRTL — MARKS — BACKGROUND

What are the CSA and NRTL?

CSA (Canadian Standards Association also known as CSA International) was established in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health Administration) in the United States of America (Docket No. NRTL-2-92). This was expanded and renewed in 1997, 1999, and 2001. The specic notications were posted on OSHA’s ofcial website as follows:

Federal Register #: 59:40602 - 40609 [08/09/1994] Federal Register #: 64:60240 - 60241 [11/04/1999] Federal Register #: 66:35271 - 35278 [07/03/2001]

When these marks appear with the indicator “C and US” or “NRTL/C” it means that the product is certied for both the US and Canadian markets, to the applicable US and Canadian standards. (1)

Argus rectier and power system products, bearing the aforementioned CSA marks, are certied to CSA C22.2 No. 950 and UL 1950, or CSA/UL 60950.

As part of the reciprocal, US/Canada agreement regarding testing laboratories, the Standards Council of Canada (Canada’s national accreditation body) granted Underwriters Laboratories (UL) authority to certify products for sale in Canada. (2)

Only Underwriters Laboratories may grant a licence for the use of this mark, which indicates compliance with both Canadian and US requirements. (3)

What are NRTLs and what do they do?

NRTLs are third party organizations recognized by OSHA, US Department of Labor, under the NRTL program.

The testing and certications are based on product safety standards developed by US based standards developing organizations and are often issued by the American National Standards Institute (ANSI). (4)

The NRTL determines that a product meets the requirements of an appropriate consensus-based product safety standard either by successfully testing the product itself, or by verifying that a contract laboratory has done so, and the NRTL certies that the product meets the requirements of the product safety standard. (4)

The product on which either of these marks appear has been certied by CSA as meeting applicable Canada/US standards.

The product on which this mark appears has been certied by UL as meeting applicable Canada/US standards.

When was the NRTL started and who governs it?

In 1983, in a suit brought on by an independent testing laboratory, OSHA was court ordered to remove specic references to UL (Underwriters Laboratories) and FMRC (Factory Mutual Research Corporation) from its regulations.

In 1988, OSHA revised its regulations to remove those references and the NRTL program was established.

The NRTL Program is both national and international in scope with foreign labs permitted.

References:

Information in this document has been developed from the ofcial websites of the respective organizations. (1) www.csa-international.org (2) www.scc.ca (3) www.ulc.ca (4) www.osha.gov

argusdcpower.com

048-554-10-I1 Rev C (2004/02)

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. A notation that is in Bold Italic typeface covers points that are important to the performance

or ease of use of the product.

3. Before using the product, read all instructions and cautionary markings on the product and any equipment connected to the product.

4. Do not expose the product to rain or snow; install only in a clean, dry environment.

5. 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.

6. 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.

7. 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.

i ii

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.....................................................................................................................2

2 RECTIFIER FEATURES...................................................................................................................................................3

2.1 Front Panel....................................................................................................................................................3

2.2 Rear Panel....................................................................................................................................................4

2.3 True Module Fail Alarm................................................................................................................................. 4

2.4 Heat Dissipation............................................................................................................................................4

2.5 Over Temperature Protection ....................................................................................................................... 4

2.6 Wide AC Range ............................................................................................................................................ 5

2.7 AC Inrush/Transient Suppression.................................................................................................................5

2.8 Soft Start .......................................................................................................................................................5

2.9 Start Delay .................................................................................................................................................... 5

2.10 Current Limit/Short Circuit Protection ...........................................................................................................5

2.11 Power Limiting...............................................................................................................................................5

2.12 High Voltage Shutdown (HVSD)................................................................................................................... 5

2.13 Battery Eliminator Operation.........................................................................................................................5

3 CXCM FEATURES........................................................................................................................................................6

3.1 Front Panel....................................................................................................................................................6

3.2 Analog Input Channels.................................................................................................................................. 7

3.3 Digital Input Channels...................................................................................................................................8

3.4 Alarm and Control Output Relays.................................................................................................................8

3.5 System Fail Alarm/Relay............................................................................................................................... 8

3.6 Network Connection and Remote Communications.....................................................................................8

4 INSPECTION..................................................................................................................................................................9

4.1 Packing Materials..........................................................................................................................................9

4.2 Check for Damage........................................................................................................................................ 9

5 INSTALLATION............................................................................................................................................................10

5.1 Safety Precautions......................................................................................................................................10

5.2 Shelf Preparation/Mounting ........................................................................................................................10

5.3 Module Insertion/Removal..........................................................................................................................10

6 WIRING AND CONNECTIONS ........................................................................................................................................ 11

6.1 Safety Precautions......................................................................................................................................11

6.2 Tools Required............................................................................................................................................11

6.3 Power System Chassis Ground..................................................................................................................12

6.4 AC Feeder Protection/Sizing....................................................................................................................... 12

6.5 AC Input Connections................................................................................................................................. 12

6.6 Calculating Output Wire Size Requirements...............................................................................................12

6.7 DC Output Connections.............................................................................................................................. 13

6.8 CAN Serial Ports.........................................................................................................................................13

6.9 Network Connection and Remote Communications via CXC.....................................................................15

6.10 Alarm and Signal Wiring Connections for CXCM .......................................................................................16

7 OPERATION................................................................................................................................................................20

7.1

Main Rectifier States...................................................................................................................................20

7.2 Main Rectifier Modes ..................................................................................................................................21

7.3 Can Bus Communications...........................................................................................................................21

7.4 Factory Ranges and Defaults .....................................................................................................................22

8 SYSTEM STARTUP......................................................................................................................................................23

8.1 Check System Connections........................................................................................................................23

8.2 Verify AC and Power the Shelf ................................................................................................................... 23

8.3 Check Battery Polarity and Connect...........................................................................................................23

8.4 CXC Reset..................................................................................................................................................23

9 MAINTENANCE ...........................................................................................................................................................24

10 ARGUS CONVENTIONS................................................................................................................................................25

10.1 Numbering System......................................................................................................................................25

10.2 Acronyms and Definitions ...........................................................................................................................25

iii

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1 Introduction

1.1 Scope of the Manual

This instruction manual explains the installation and interconnection of Argus Technologies’ Cordex 48-1kW 19" Shelf for Systems up to 6000W.

NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.

For systems ordered with the Cordex CXC System Controller option, separate documentation will be provided detailing the software features, setup and operation.

1.2 Product Overview

A complete Cordex rectifier system consists of a CXC and one or more power modules in a common shelf enclosure. The shelf has connections for AC inputs, DC output, and system communications.

Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated and isolated DC output from the AC mains. The rectifier input is wide range to allow use on 208/220/240 50/60 Hz electrical service. Rectifier power modules are “hot swappable” meaning they can be inserted or removed from the shelf without cutting power to or from the system or the load. Additional power modules can be included with the system at the time of ordering or added after the shelf has been installed.

The shelf (and rectifier system) is designed to operate with the Argus Cordex System Controller (CXC); in particular, the optional CXCM (modular version of the CXC controller) plugs dire ctly into the rectifier system shelf. See Figure 1 below. Details for installation and wiring are provided in the respective chapters of this documentation package.

There are also rack (CXCR) and panel (CXCP) mount versions of the system controller that communicate with the shelf via offset RJ-12 shelf connectors.

See manual #018-587-B2 (pre-RoHS #018-557-B2).

The CXC allows the user to set up, control and monitor the entire power system and ancillary components from one central, easy-to-use source. Details of controller operation are provided in the current version software manual.

Figure 1–Cordex 5000W system with CXCM

Argus Technologies Ltd. 030-827-C0 Rev A WC

+ 35 hidden pages

Alpha Cordex 48-1kW 19 6000W User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Basic Unit, Shelf

Mechanical

Connections*

Safety

Basic Unit, CXCM

Environmental

Hardware Specifications, CXCM

Power Module Output

Power Module Input

Miscellaneous

Environmental

Referenced Standards

IMPORTANT SAFETY INSTRUCTIONS

1.1 Scope of the Manual