Alpha Cordex 48-1kW 19 6000W Installation
Cordex 48-1kW
19" Shelf For Systems Up To 6000W
Installation & Operation Manual
Part # 030-706-B2
Effective: 08/2012
member of The Group
™
Your Power Solutions Partner
Cordex 48-1kW
19" Shelf For Systems Up To 6000W
030-706-B2 Rev B
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:
• Specications, 19” Shelf: 030-706-B1
• Specications, Rectier: 010-606-B1 (010-566-20 non-RoHS)
• CSA/NRTL Equivalence: 048-554-10
• Schematic: 030-706-05
• Outline Drawing, 19” Shelf: 030-706-06
• Customer Connections: 030-706-08
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 saf ety, follow the sequences as outlined.
2. This manual provides warnings and special notes f or 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 se rvice 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.
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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 Communi cat i ons ..................................................................................... 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 Communi cat ions via CXC ..................................................................... 15
6.10 Alarm and Signal Wiring Connections for CXCM ....................................................................................... 16
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OPERATION ................................................................................................................................................................ 20
7
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 WARRANTY ................................................................................................................................................................ 25
10.1 Warranty ...................................................................................................................................................... 25
11 ACRONYMS AND DEFINITIONS ..................................................................................................................................... 26
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1 Introduction
1.1 Scope of the Manual
This instruction manual explains the installation and interconnection of Apha Technol ogies’ Cordex 48-1kW 19"
Shelf for Systems up to 6000W.
NOTE: To aid the user with instal lation, frequent reference is made to drawings lo cat ed 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 co m m on 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 t o 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 syst em or the load. Additional power modules can b e i ncluded with
the system at the time of ordering or added after the shelf has been installed.
The shelf (and rectifier system) is designed to ope rate with the Apha Cordex System Controller (CXC); in
particular, the optional CXCM (modular version of the CXC controller) plugs directly into the rectifier system shelf.
See Figure 1 below.
Details for installation and wiring are provided in the respective chapters of this docum enta tion p ackage.
There are also rack (CXCR) and panel (CXCP ) m ount 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 comp onents 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
030-706-B2 Rev B Page 1 of 26
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
Cordex 48-1kW 19" Shelf for Systems up to 6000W ................................................................................. 030-706-20
[equipped to receive one CXCM controller and up t o five CXRC 48-1kW rectifiers (Figure 1)] ................... *List 0
208/220/240Vac input .......................................................................................................................................... List 6
19” rack, mid-mounting ...................................................................................................................................... List 19
23” rack, mid-mounting ...................................................................................................................................... List 23
23” rack, flush mounting ..................................................................................................................................... List 25
Temperature sensor, 1/4" lug, 12 ft. ................................................................................................................... List 72
Temperature sensor, 3/8" lug, 12 ft. ................................................................................................................... List 75
Six 1kW rectifier module positions, dual feed ac input, no CXCM (Figure 2) .................................................. *List 81
DC output adapters, dual 2-position, 5/8” centers ............................................................................................. List 85
Power module blank plate ............................................................................................................................ List 50,90
Cordex 48-1kW 19" Shelf for Systems up to 6000W, flush mounting only ................................................ 030-707-20
[equipped to receive one CXCM controller and up to five CXRC 48-1kW rectifiers (Figure 1)] ................... *List 0
208/220/240Vac input .......................................................................................................................................... List 6
Temperature sensor, 1/4" lug, 12 ft. ................................................................................................................... List 72
Temperature sensor, 3/8" lug, 12 ft. ................................................................................................................... List 75
Six 1kW rectifier module positions, dual feed ac input, no CXCM (Figure 2) .................................................. *List 81
Six 1kW rectifier module positions, three feed ac input, no CXCM (Figure 2) ................................................... List 82
DC output adapters, dual 2-position, 5/8” centers ............................................................................................. List 85
Power module blank plate ............................................................................................................................ List 50,90
Cordex 48-1kW rectifier power module ...................................................................................................... 010-566-20
Basic module ...................................................................................................................................................... *List 0
Gray finish with blue silkscreen ........................................................................................................................ *List 50
* Default option
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.
Figure 2–Cordex 6000W system (no CXCM)
030-706-B2 Rev B Page 2 of 26
2 Rectifier Features
2.1 Front Panel
2.1.1 LEDs
The front panel LEDs provide:
Rectifier status summary will show the re ct ifier alarm status, communication fail status and rectifier on/off status.
2.1.1.1 AC ON
2.1.1.2 DC ON
2.1.1.3 ALARM
Figure 3–Cordex 48-1kW rectifier
• Rectifier status summary,
• Rectifier software upgrade in progress indication,
• Locate module pattern.
The top LED (green) is on when AC is within valid range. The LED will flash (~2Hz) when AC is
outside the nominal range – AC voltage is invalid i f the AC Mains Low or AC Mai ns Hi gh
alarm is active. The LED turns off when AC has failed.
The middle LED (green) is on when the rectifier is delivering power to the load. The LED will
flash when communication is lost. The LED turns off when the rectifier is off; e.g., when
commanded via the CXC.
The bottom LED (red) is on continuously in the event of an active Module Fail alarm. The LED
will flash (~2Hz) when a minor alarm is detected. The LED remains off in the absence of an
alarm.
030-706-B2 Rev B Page 3 of 26
2.1.1.4 LED Activity During Software Upload
When a rectifier software upload is in progr ess, the LEDs will behave in a distinctly different way
to indicate new rectifier software is being transferred from the CXC.
When a rectifier data transfer is in progress, al l three LEDs will flash in a sequence lasting 1.5
seconds. When the last LED is lit, the sequence is repeated beginning at the first LED.
2.1.1.5 LED Activity During ‘Locate Module’ Command from CXC
When the ‘locate module’ command has been re ceived from the CXC, the LEDs will behave in
another distinct fashion so that the rectifier is easier to visually identify among adjacent
rectifiers.
This state is entered when commanded via the CXC. The LEDs will flash in a ping-pong pattern
repeating every 2 seconds.
The ping-pong pattern lights each LED sequent i all y. After the last LED is lit, each LED is lit in
reverse sequence. When the first LED is lit , the pattern repeats. The effect makes it appear a s if
the light is bouncing between the first and last LED.
2.1.2 Mechanical
A thumbscrew is provided to secure the rectifier into the shelf. During normal operation the rectifier shall be
locked into position. A handle (or grip) is incorporated into the front panel to facilitate the removal of the rectifier
from the shelf. No special tools are required.
2.2 Rear Panel
Located on the rear panel of the rectifier are connectors for shelf power and communications.
2.3 True Module Fail Alarm
The power modules have a “true” fail alarm. This provides a true indication of the power modul e’s ability to source
current. When the module’s output curre nt drops below 2.5% of the rated output a low outp ut current condition is
detected and the Module Fail detection circuit is activated. This circuit momentarily ramps up the output voltage to
determine if the module will source curre nt. If no increase in current is detected, the Module Fail alarm is
activated. The module will test once eve ry 60 seconds for the condition until current is detected. Output voltage
ramping will cease upon detection of current
1
. A minimum 2.5% load is required to avoid the Ramp T est F ail
alarm; this can typically be provided with t he paral lel system battery. Activation of thi s alarm could indicate a failed
module or a failed load.
NOTE: For Cordex rectifier sy st ems without batteries (or with a very light load; below 2.5% of rated output) it is
recommended that the ramp test be disabl ed to avoid nuisance alarms. The Ramp Test featu re i s
enabled/disabled via the CXC menu item: Rect ifiers, Configure Settings.
2.4 Heat Dissipation
Heat dissipation is achieved through natural (bottom to top) convection cooling.
NOTE: Some rectifier shelves i ncorporate fan aided cooling to increase th e temperature rating of the module. See shelf
manual supplied with your system.
2.5 Over Temperature Protection
Each module is protected in the event of an exce ssi ve increase in temperature due to component fai l ure or
cooling airflow blockage. During over t em perature conditions, the rectifier limits the output power as well as the
output current. At 65ºC output power and current limit are reduced to 70%. If t em perat ure continues to
increase, a shutdown of the rectifier is init i ated. The rectifier shall restart automatically if the temperature has
returned to a safe level.
1
A battery connected to the output of the rectifier will draw current when the voltage ramp occurs. Therefore the rectifier fail alarm will not be generated
with a battery connected.
030-706-B2 Rev B Page 4 of 26
2.6 Wide AC Range
A minor alarm is generated when the AC input voltage drops below 180Vac. Output power is re duced linearly
below 150Vac to 40% of the rated output power. At a lower voltage the module will shut down and will not restart
until the AC is greater than or equal to 150Vac.
For voltages above 276Vac, power factor an d total harmonic distortion may be derated. For voltages between
277Vac and 320Vac, the rectifier may not be operational but shall not suffer any damage.
2.7 AC Inrush/Transient Suppression
The modules’ inrush current is limited to l ess than one times the nominal peak line current to prevent surge on the
AC line. Modules are also protected from input lightning and transient surges in accordance with IEEE/ANSI
C62.41 Category B3.
2.8 Soft Start
To eliminate an instantaneous demand on the A C source, a soft start feature is employed. Soft Start, sometimes
referred to as “current walk-in”, works by grad ual ly (up to five seconds) ramping the current lim i t up from zero to
the actual or defined customer setting. The output voltage is ramped up from the minimum v oltage to the float
voltage.
2.9 Start Delay
The modules are equipped with a delay timer in order to stagger start a series of modules to prevent excessive
loading of generators upon start up. The built-in t i m er delays the turn on of the module depending o n the value
selected (up to 120 seconds) via the CXC. A m ini m um one-second delay is preset to allow charging of the input
capacitors.
2.10 Current Limit/Shor t Circuit Protection
The current limit function determines the maximum output current limit of the modul e, regardless of output voltage
or power. Maximum output current is lim i ted to a constant value down to short circuit con di tion. Current limiting
can be used to mate the rectifier output current am pacity to the needs of the load and parallel batt ery t o m inimize
excessive battery recharge current.
The rectifier will sustain a short circuit at the output terminals indefinitely. The maximum short circuit current shall
not exceed 105% of the rated full load current .
2.11 Power Limiting
Each module is designed to limit power output t o the module specification. This enables more current to be
supplied at lower output voltages, and al l ows matching of output to the demand of constant power loads, normally
seen with telecom equipment.
This feature may also be used for a faster recha rge of flooded batteries paralleled with the load.
NOTE: Current limiting over rides the power-limiting feature.
2.12 High Voltage Shutdown (HVSD)
This feature provides protection to the lo ad from over voltage conditions originating from the rectifiers. It operates
by shutting down the offending rectifier module when a high output voltage condition occurs. Indication is through
the red Alarm (Module Fail) LED. Modules will rest art automatically; however, if more than three over voltage
conditions occur in one minute, the module will latch off and remain shut down until it is reset via t he CXC.
2.13 Battery Eliminator Operation
Modules maintain all specifications (except where indicated) with or without a battery attached in parallel to the
output; however, if a battery or another module supplying DC voltage in parallel is not present, there will be no
monitoring or control activity if there is a n AC po wer failure or input fuse failure.
030-706-B2 Rev B Page 5 of 26
RS-232 (craft port)
Touch screen
Reset (RST) button
System status LEDs
3 CXCM Features
The optional CXCM (Cordex Controller, M odul ar) can be mounted in the rectifier system shelf and brings
advanced monitoring technology to the Cordex series of rectifiers. This compact 4RU s ystem controller is
designed for seamless operation and s et up of Apha power systems and is equipped with the complete range of
Cordex software features, including the following:
• Designed to communicate directly with Cordex rectifiers
• Includes battery temperature compensation charging
• Battery performance diagnostics
• Provides local and remote communications
• User definable alarms
• Daily logging of power system events and system statistics.
Behind the CXCM’s front panel lies the main c ontroller motherboard, which contains a micropro cessor, memory,
as well as numerous other electronic compon ents.
The CXCM includes a web server providing easy set up and monitoring using an Internet con nection with the
standard Windows® Internet Explorer br owser.
The data logging feature allows the user to capture data from multiple inputs, for AC/DC voltages, load/battery
current, cell voltages & temperatures (au tomatically for up to 16 user defined logs). T ypical applications of the
CXCM logging include power system details, thermal performance of outdoor enclosures, battery cell specifics, or
mains variations captured by an AC voltage w atchdog.
A built-in audio speaker sounds an intermittent tone during active alarms.
The input/output (I/O) board houses a serie s of terminal connections; located at the back of the system shelf.
3.1 Front Panel
3.1.1 Display
Located on the front panel is a 160 x 160-pixel graphical LCD with touch screen similar to those used in PDAs.
This graphical user interface (GUI) allo ws the operator to interact with screen selectable items using a fingertip.
030-706-B2 Rev B Page 6 of 26
Figure 4–Cordex CXCM model system controller front panel
3.1.2 LEDs
The CXCM has three LEDs located on the front panel. These are used to display the alarm stat us of the power
system, CXCM progress and status during startup, and file transfers.
3.1.2.1 Alarm Conditions
3.1.2.2 Progress and Status Indication
3.1.3 Reset
A reset button is located on the front panel for restarting the CXCM’s microprocessor. It takes approximately 15
seconds before the display reappears after pressing the reset button.
The CXCM illuminates the LED that corresponds to the system alarm status. The following
show the corresponding alarm status for each LED color:
Green – OK, no alarms present
Yellow – Minor alarm is present (no major alarms)
Red – Major alarm is present.
Only one LED is illuminated at a time during alarm conditions.
The LEDs are also used in the following situation s:
Base unit validation – all three LEDs are on at the same time.
File transfer – when recovering from invalid fi rmware application – the red LED is illuminated.
NOTE: Refer also to the softwa re manual – always select the shutdown menu item bef ore pressing the reset button.
3.1.4 Ethernet Port
The Ethernet port is designed for CXCM con nection to a user supplied network (TCP/IP secu red by user) via a
rear panel RJ-45 jack and a standard network c abl e.
Local access (e.g. laptop computer) is al so possible from the Ethernet port connection using a standard network
crossover cable.
3.1.5 RS-232 Serial (Craft) Port
Local access to the CXCM is possible through a front panel RS-232 serial port; using a null modem cable. The
communication protocol supports a web i nterface (via Microsoft® Internet Explorer 6 or greater). The remote
screen display is an enhanced version of the CXC’s front panel display.
3.2 Analog Input Channels
The CXCM has analog input channels for volt age, current, and temperature.
3.2.1 Voltage Inputs
Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCM software
is pre-configured to monitor V2 for both load and battery voltage. V2 is used as the system reference for rectifier
float voltage, low voltage disconnect (LVD), system high voltage alarm, and system low voltage alarm. V1 is
available for additional voltage measurement s.
3.2.2 Current Inputs
The CXCM software is pre-configured to monit or I1 for load current using an external 50mV current shunt.
3.2.3 General-Purpose
A set of terminals are provided to monitor a bi-voltage signal that may vary in either polarity fr om zero;
e.g., +/-60Vdc.
030-706-B2 Rev B Page 7 of 26
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