Alpha CXCRF 48-300W User Manual
Alpha Modular Switched Mode Rectifier System
Rectifier model: Cordex CXCRF 48-300W
Installation & Operation Manual
Part # 0300072-J0
Effective: 10/2012
member of The Group
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Your Power Solutions Partner
Alpha Modular Switched Mode Rectier System
Rectier Model: Cordex CXCRF 48-300W
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe operation of this powering
system, contact Alpha Technologies or your nearest Alpha representative.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power
supplies, generators, batteries, or other hardware if used or operated in any manner or
subject to any condition inconsistent with its intended purpose, or if installed or operated in an unapproved manner, or improperly maintained.
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: +1-604-436-5547
Email: support@alpha.ca
Copyright
Copyright © 2012 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark 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, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the proprietary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies assumes no liability resulting from errors or omissions in this document, or from the use of the information
contained herein. Alpha Technologies reserves the right to make changes in the product design without reservation and without notification to its users.
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.
TABLE OF CONTENTS
1 Safety Instructions ..................................................................................... 4
1.1 Safety Symbols .............................................................................................................. 4
1.2 General Warnings and Cautions .................................................................................... 4
2 Product Overview ....................................................................................... 6
2.1 General Overview .......................................................................................................... 6
2.2 Part Numbers and List Options ...................................................................................... 6
2.3 Stand-alone Energy System .......................................................................................... 6
2.4 IEC Input Voltage ........................................................................................................... 7
2.4.1 IEC ...........................................................................................................................................................7
2.5 Overview of Control Unit Configurations ........................................................................ 8
2.5.1 Basic units ...............................................................................................................................................8
2.6 Features ......................................................................................................................... 8
2.6.1 System controller (low profile MCU without LCD screen) .......................................................................8
2.6.2 Front signal connection card ...................................................................................................................9
2.6.3 System controller (MCU with LCD screen) .......................................................................................... 10
2.6.4 Distribution Unit (only for stand-alone systems)................................................................................... 11
2.6.5 Cordex Rectifier CXRF 48-300W ......................................................................................................... 13
2.7 Mechanical Overview ................................................................................................... 14
2.7.1 Dimensions ........................................................................................................................................... 14
2.8 Electrical Overview ....................................................................................................... 15
3 Installation ................................................................................................ 16
3.1 Site Planning ................................................................................................................ 16
3.2 Safety Markings ........................................................................................................... 17
3.3 Installation .................................................................................................................... 18
3.3.1 Safety Precautions ............................................................................................................................... 18
3.3.2 Tools and Equipment Required for Installation .................................................................................... 18
3.3.3 Mounting the Shelf ............................................................................................................................... 18
3.3.4 Ventilation ............................................................................................................................................. 19
3.3.5 Wiring Procedure .................................................................................................................................. 19
3.3.6 Summary .............................................................................................................................................. 27
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4 Operating the 48-300W Modular Switched Mode Rectifier System ....... 28
4.1 Switching ON and OFF ................................................................................................ 28
4.1.1 Switching ON ........................................................................................................................................ 28
4.1.2 Switching OFF ...................................................................................................................................... 28
4.2 Rectifiers 300 W: CXRF 48-300W ................................................................................ 28
4.3 Comp@s Settings ........................................................................................................ 29
4.3.1 Licence Overview ................................................................................................................................. 29
4.3.2 Factory Preset Settings Overview ........................................................................................................ 30
4.3.3 54 Vdc Bus Voltage .............................................................................................................................. 31
4.3.4 Battery Setup ........................................................................................................................................ 32
4.3.5 LVD Trip Level ...................................................................................................................................... 33
4.3.6 Rectifier Settings .................................................................................................................................. 33
4.3.7 Save the Configuration ......................................................................................................................... 35
4.4 Alarm Monitoring .......................................................................................................... 36
4.4.1 Factory Preset Alarm Table.................................................................................................................. 36
4.4.2 Type of Alarm ....................................................................................................................................... 37
4.4.3 Battery Test .......................................................................................................................................... 38
5 Maintenance .............................................................................................. 41
5.1 Battery Replacement .................................................................................................... 41
5.2 Troubleshooting ........................................................................................................... 42
6 Specifications ........................................................................................... 43
7 Warranty .................................................................................................... 45
7.1 Warranty ...................................................................................................................... 45
8 Abbreviations ............................................................................................ 46
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NOTE
CAUTION
WARNING
to personnel.
1 SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety instructions that must be followed during the installation, servicing, and
maintenance of the product. Keep it in a safe place. Review the drawings and illustrations contained in this
manual before proceeding. If there are any questions regarding the safe installation or operation of this
product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future
reference.
1.1 Safety Symbols
To reduce the risk of injury or death and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
The use of ATTENTION indicates specific regulatory/code requirements that may affect the placement of
equipment and /or installation procedures.
A note provides additional information to help complete a specific task or procedure. Notes are
designated with a checkmark, the word NOTE and a ruled line beneath which the relevant
information appears.
CAUTION! Indicates safety information intended to PREVENT DAMAGE to material and
equipment. Cautions are designated with a yellow warning triangle, the word CAUTION and a
ruled line beneath which the relevant information appears.
WARNING! Presents safety information to PREVENT INJURY OR DEATH
Warnings are indicated by a shock hazard icon, the word WARNING and a ruled line beneath
which the information appear.
1.2 General Warnings and Cautions
You must read and understand the following warnings before installing the 48-300W Modular Switched Mode
Rectifier System and its components. Failure to do so could result in personal injury or death.
• Please read this manual before using the system, in order to become familiar with the numerous
features of the product and the relevant operating procedures. To ensure the maximum degree of safety,
follow the sequences as outlined.
• Before using the product, read all instructions and cautionary markings on the product and any
equipment connected to the product.
• Only qualified personnel are allowed to install, operate and service this system and its components.
• Do not work alone under hazardous conditions.
0300072-J0 RevA Page 4 of 46
• Use proper lifting techniques whenever handling equipment, parts or batteries.
• Always assume electrical connections or conductors are live. Turn off all circuit breakers and double-
check with a voltmeter before performing installation or maintenance.
• The 48-300W Modular Switched Mode Rectifier System uses more than one live circuit. DC power may
be present at the outputs even if the system is disconnected from the mains supply.
• In high ambient temperature conditions, the surface of the shelf can be very hot to the touch.
• Battery installation and servicing should be done or supervised by personnel knowledgeable about
batteries and their safety procedures.
• Be extra cautious when connecting or adjusting battery cabling. An improperly connected battery cable
or an unconnected battery cable can result in arcing, fire or possible explosion.
• Use new batteries when installing a new unit. Verify that they are all the same battery type with identical
date codes.
• Always replace batteries with ones of identical number, type and rating. Never install old or untested
batteries. One sealed lead-acid battery is rated to a maximum voltage of 12Vdc.
• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized
personnel using a battery of identical type and rating.
• Keep the chassis area clear and dust-free during and after installation.
• Keep walkways free of tools to ensure that others cannot fall over them.
• Do not work on the unit or connect or disconnect cables during periods of lightning activity.
• A battery can present a risk of electrical shock and high short-circuit current. The following precautions
should be observed when working on batteries:
Remove watches, rings, or other metal objects.
Use tools with insulated handles.
Wear rubber gloves and boots.
Do not lay tools or metal parts on top of batteries.
Disconnect charging source prior to connecting or disconnecting battery terminals.
Determine if the battery is inadvertently grounded, remove source from ground. Contact with any
part of a grounded battery can result in electrical shock. The likelihood of such a shock can be
reduced if such grounds are removed during installation and maintenance (applicable to equipment
and remote battery supplies not having a grounded supply circuit).
• Never let live battery wires touch the 48-300W Modular Switched Mode Rectifier System, the enclosure
or any other metal objects. This can cause a fire or explosion.
• Never dispose of batteries in a fire or furnace. The batteries may explode. Follow the manufacturer’s
directions and check with your local jurisdictions for safe battery disposal.
• Before plugging the batteries to the 48-300W Modular Switched Mode Rectifier System, make sure the
polarity is correct.
• If the batteries have been in storage for more than 3 months, recharge them for at least 24 hours then
test them with a load before installation.
0300072-J0 RevA Page 5 of 46
2 PRODUCT OVERVIEW
2.1 General Overview
The user manual explains the installation, interconnections and operation of Alpha Technologies 48-300W
Modular Switched Mode Rectifier System. Listed below are the possible product configurations:
2.2 Part Numbers and List Options
Description:
Cordex HP 48-300W rectifier power module 0100010
Cordex 48-300W 19in 1RU shelf system, front/back access
with controller and DC distribution 0300072
Comp@s supervisory communication card 7400325
Dummy module for empty rectifier slot 0100010-001
AC power cord C15 18AWG, right angle 8700551
2.3 Stand-alone Energy System
Figure 1: Stand-alone energy system including controller with LCD
This stand-alone energy system includes a controller board on the left and a modular distribution unit with 4
outlets protected by alarm-indicating fuses, a battery circuit breaker and an internal LVD. The distribution unit
allows the user to connect the loads, the battery and the battery temperature sensor directly on the front of the
system.
The controller board can be one of two types:
1. Controller board with LCD screen – 1RU high (see Figure 1)
2. Controller board without LCD screen – 0.5RU high. A communication card for can be added on top of
the controller (see Figure 2).
The controller board can be equipped with a Comp@s card. This allows the user to configure, monitor and
control the entire power system and auxiliary components from a computer.
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NOTE
Details of controller operations are provided in the latest version of the Comp@s software
manual.
Figure 2 : Stand-alone energy system including controller with front access communication board
Mains input options for the stand-alone energy system:
2.4 IEC Input Voltage
Europe: 190 – 250V nom.
USA/Canada: 100 – 250V nom.
Max. input voltage is -10% / +6% of nominal input voltage range
2.4.1 IEC
• An IEC C16 inlet connector is attached to the rear of the energy system (as on Figure 2)
• All 3 rectifier slots are powered via the single IEC C16 connector
• Max. 900W output power with up to 3 rectifiers
High temperature socket
Figure 3: IEC C16 inlet
0300072-J0 RevA Page 7 of 46
NOTE:
IEC C16 is a high temperature inlet which requires IEC C15 plug
IEC input voltage limitations are shown in section 2.4
2.5 Overview of Control Unit Configurations
2.5.1 Basic units
MCU0348M4: Monitoring and control unit with LCD display.
Unit features USB and Ethernet port connectors for the communication card.
Display indications: output voltage, rectifiers and battery current.
Comp@s: Remote communication card with basic package.
OR
MCU0348M4LP: Monitoring and control unit for the energy system without LCD display. Unit features USB and
Ethernet port connectors for the communication card.
Front signal connection card (optional): Front access communication I/O card for digital inputs, alarm signals,
temperature sensor and CAN Bus.
Comp@s: Remote communication card with basic package.
2.6 Features
2.6.1 System controller (low profile MCU without LCD screen)
Figure 4 : System controller LED’s
2.6.1.1 LEDS
The monitoring unit has six LEDs located on the front panel. These are used to display the status of the
controller, LVD, system and battery:
• Controller status Green LED indicates MCU and Comp@s functions are OK.
Green LED is blinking if no Comp@s is present.
• LVD OK Green LED indicates LVD (low voltage disconnection) is closed.
The green LED blinks during a battery test.
If the LED remains OFF, it means the LVD is open.
• 1 Major alarm Red LED indicates a major alarm in the system (defined in the alarm table)
• 2 Minor alarm Red LED indicates a minor alarm in the system (defined in the alarm table)
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• 3 Battery alarm Red LED indicates a battery failure
• 4 AC fail alarm Red LED indicates a mains failure
2.6.1.2 USB PORT
The USB port is designed for connecting a computer to the system controller via a standard USB cable (type
A/B), with direct access to the Comp@s software (Comp@s card required).
2.6.1.3 ETHERNET PORT
The Ethernet port is designed for connecting the controller to a user supplied network (TCP/IP secured by the
user) via an RJ-45 jack and a standard network cable.
2.6.1.4 BATTERY TEST SAVE
This button can be used for starting a battery test (see section 4.4.3 for more information).
2.6.2 Front signal connection card
Figure 5 : Front signal connection card
The front signal connection card (optional) is located just above the low profile MCU. It provides a front access
point for communication of different signals:
2.6.2.1 CAN PORT
This CAN port enables the connection of the CDM Comp@s display module (RJ-45 inverted 8P8C).
2.6.2.2 TEMPERATURE SENSOR CONNECTION (ENVIRONMENTAL)
The system enables the monitoring of the cabinet temperature via this connection point.
2.6.2.3 SIGNALS IN/OUT
The Sub-D 26-pole connector allows the user to monitor the system via the potential free alarm relays.
In addition the user has four digital inputs, which can be monitored by the MCU.
• 4 digital inputs (e.g., door contact open)
• 4 alarm outputs (relay contacts can be programmed individually with single alarm or a combination of
alarms)
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2.6.3 System controller (MCU with LCD screen)
Figure 6 : System controller
This controller board offers the same functions as the low profile MCU. Connectors for digital inputs and alarms
(signals IN/OUT) are located at the back of the shelf.
2.6.3.1 LCD SCREEN
The LCD screen displays the values of:
• DC bus voltage [V]
• Total rectifier output current [A]
• Battery current [A]
+ = Charging
– = Discharging
2.6.3.2 LED MODE INDICATORS
The LEDs indicate the mode of the three possible measurements.
• V for DC bus voltage
• Ir for total rectifier output current
• Ib for battery current
2.6.3.3 MODE PUSH BUTTON
By pressing the push button, the user can scroll to the three different measurement modes.
2.6.3.4 LVD DISCONNECTED
This button has no function in the 48-300W Modular Switched Mode Rectifier System energy system.
0300072-J0 RevA Page 10 of 46
Figure 7 : LVD Disconnected
2.6.3.5 LEDS
The monitoring module has six LEDs located on the front panel. These are used to display the status of the
controller, LVD, system and battery:
• Controller status Green LED indicates MCU and Comp@s functions are OK.
Green LED is blinking if no Comp@s is present.
• LVD OK Green LED indicates the LVD (low voltage disconnection) is closed.
If the LED remains OFF, it means the LVD is open.
The Green LED blinks during a battery test
• 1 Major alarm Red LED indicates a major alarm in the system (defined in the alarm table).
• 2 Minor alarm Red LED indicates a minor alarm in the system (defined in the alarm table).
• 3 Battery alarm Red LED indicates a battery failure.
• 4 AC failure alarm Red LED indicates a mains failure.
2.6.3.6 USB PORT
The USB port is designed for connecting a computer to the system controller via a standard USB cable (type
A/B), with direct access to the Comp@s software (Comp@s card required).
2.6.3.7 ETHERNET PORT
The Ethernet port is designed for connecting the controller to a user network (TCP/IP secured by user) via a
front panel RJ-45 jack and a standard network cable.
2.6.3.8 BATTERY TEST SAVE
This button can be used for starting a battery test (see section 4.4.3 for more information).
2.6.4 Distribution Unit (only for stand-alone systems)
Figure 8 : Distribution unit
Adding the modular distribution unit creates a stand-alone energy system. In combination with the low profile
MCU and the front signal connection card, the resulting system provides full front access installation.
The distribution unit includes an internal LVD (low voltage disconnection) in order to protect the battery from a
deep discharge. The LVD will stay open if the polarity of the battery does not match the polarity of the system
DC bus or if the battery voltage is out of range.
0300072-J0 RevA Page 11 of 46
CAUTION
Out 1
Out 2
Out 3
Out 4
+ - + - + - +
-
Battery
+
-
CAUTION
2.6.4.1 TEMPERATURE SENSOR (BATTERY)
Temperature probe input for battery temperature compensation.
2.6.4.2 54V DC OUTPUT WITH ALARM-INDICATING FUSES
4 outputs are available on the distribution unit, protected by alarm-indicating fuses. The available fuse ratings
are 2A, 5A and 10A and these can be ordered from Alpha Technologies.
When a fuse is blown, a coloured dot indicates the circuit is open. The fuses are numbered from 1 to 4, fuse 1
corresponding to the most left DC output and so on from left to right.
2.6.4.3 BATTERY CIRCUIT BREAKER
If the battery is correctly connected, the user can set (close) the LVD by pushing the button of the battery circuit
breaker. When the LVD is active (closed), the green “LVD OK” LED on the front of the distribution unit and the
green “LVD OK” LED on the front of the controller illuminate. By pulling the button of the battery circuit breaker,
the LVD will open and the battery is disconnected from the system. Both green LEDs will then extinguish.
The status of the battery circuit breaker is monitored by the controller and can be used as an alarm source.
CAUTION! Before plugging and unplugging the battery connector, the user should pull the
battery circuit breaker and check whether the LVD is non-active (open) to avoid damaging the
battery connector contacts.
2.6.4.4 54V DC OUTPUT TERMINAL BLOCK
The four DC outputs are located below the alarm-indicating fuses. Each output is protected by a single pole
alarm-indicating fuse (see section 2.6.4.2). Please observe the polarity of the DC output connector:
Please observe the following wiring specifications:
• Stripping length: 10 mm
• Minimum conductor cross section: 0.2 mm² stranded
• Maximum conductor cross section: 2.5 mm² stranded
2.6.4.5 BATTERY CONNECTOR
Please observe the polarity of the battery. The battery connector polarity is indicated on the front plate:
The battery connector is a 2-pole Phoenix contact PC 4/2-G-7,62 (18 04 79 7)
The battery mating connector reference is Phoenix contact PC 4/ 2-ST-7,62 (18 04 90 4)
The battery capacity is limited by the interrupting capacity of the 20A battery circuit breaker and should not
exceed 62Ah.
CAUTION! Before plugging and unplugging the battery connector, the user should pull the
0300072-J0 RevA Page 12 of 46
battery circuit breaker and check whether the LVD is non-active (open) to avoid damaging the
battery connector contacts
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