Alpha CXPS 48-1.2-225 48 Vdc User Manual
CXPS 48-1.2-225 48 Vdc Power System
Installation & Operation Manual
053-691-B1
Effective: 09/2012
member of The Group
™
Your Power Solutions Partner
CXPS 48 – 1.2-225 48Vdc Power System
053-691-B1
The following drawings are included in this manual:
• Schematic Drawing, CXPS 48-1.2-225_A 053-691-05
• Layout Drawing, CXPS 48-1.2-225_A 053-691-06
• Customer Connection, CXPS 48-1.2-225_A 053-691-08
Manuals to be included in this package:
• DCP03 300 A Distribution Center: 020-702-B2
• Cordex 48-1.2kW 19” 1 RU Shelf System 030-835-B2
• Cordex Controller Software (current version) CXC SOFT
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.
All electrical connections must be performed by licensed electricians only. Installation of the power supply and
batteries must be performed by, or under the direct supervision of, service personnel knowledgeable of the
required electrical and battery safety procedures.
If instructions in this manual conflict with the local electrical codes, follow the local codes.
The following safety symbols are found throughout this manual. Carefully read all information and abide by the
instructions:
DANGEROUS VOLTAGE
This symbol indicates a dangerous voltage
exists in this area of the product.
GAS HAZARD
This symbol indicates a gas hazard
exists in the area of vented batteries.
NO MATCHES OR OPEN FLAMES
This symbol indicates a fire or explosive hazard
exists in the area of the product.
The following warning levels are used in conjunction with the symbols:
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.
Mechanical safety
Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
Power supplies can reach extreme temperatures under load.
Use caution around sheet metal components and sharp edges.
Electrical safety
WARNING: Hazardous voltages are present at the input of power systems. The DC output from
rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that
may cause severe burns and electrical arcing.
Before working with any live battery or power system, follow these precautions:
• Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
• Wear safety glasses with side shields at all times during installation.
• Use OSHA approved insulated hand tools.
DANGER: Lethal voltages are present within a power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to the grounded
portion of the enclosure (both AC and DC) before performing any installation or removal procedure.
Do not work alone under hazardous conditions.
A licensed electrician is required to install permanently wired equipment. Input voltages can range up
to 240 Vac. Ensure that the utility power is disconnected and locked out performing any installation or
removal procedure.
Ensure that no liquids or wet clothes come into contact with internal components.
Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input power is
disconnected.
Battery safety
Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and the required safety precautions.
Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all
metallic objects from your hands and neck.
Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.
Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm. Battery
post terminals and related accessories contain lead and lead compounds. Wash your hands after handling
batteries.
WARNING: Follow battery manufacturer’s safety recommendations when working around battery
systems.
WARNING: Do not smoke or introduce an open flame when batteries (especially vented batteries) are
charging. Batteries vent hydrogen gas when charging, which creates an explosion hazard.
Batteries are hazardous to the environment and should be disposed of safely at a recycling facility. Consult the
battery manufacturer for recommended local authorized recyclers.
Post installation weather proofing
After installing the conduits and removing any knockouts to accommodate conduit locations, ensure that any gaps
between the conduit fittings and the shroud are sealed. Apply a weatherproof caulking to gaps to prevent wind
driven rain from reaching the electrical equipment.
TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................................................. 1
1.1 Manual scope ................................................................................................................................................ 1
1.2 Product overview .......................................................................................................................................... 1
1.3 Available system configurations ................................................................................................................... 2
1.4 Part numbers including options .................................................................................................................... 2
EATURES ......................................................................................................................................................... 4
2 F
2.1 System overview ........................................................................................................................................... 4
2.2 Distribution center ........................................................................................................................................ 4
2.3 CXCM1 Controller ......................................................................................................................................... 7
2.4 Rectifiers ..................................................................................................................................................... 10
2.5 Rectifier front panel .................................................................................................................................... 10
NSPECTION .................................................................................................................................................... 13
3 I
3.1 Packing materials ........................................................................................................................................ 13
3.2 Check for damage ....................................................................................................................................... 13
3.3 General receipt of shipment ....................................................................................................................... 13
NSTALLATION ................................................................................................................................................. 14
4 I
4.1 Safety precautions ...................................................................................................................................... 14
4.2 Tools required ............................................................................................................................................. 14
4.3 Power system assembly and mounting ...................................................................................................... 15
4.4 Rectifier module insertion/removal ........................................................................................................... 16
4.5 Breaker installation ..................................................................................................................................... 16
4.6 Breaker removal .......................................................................................................................................... 16
4.7 Battery installation ...................................................................................................................................... 17
IRING ......................................................................................................................................................... 19
5 W
5.1 Grounding ................................................................................................................................................... 19
5.2 AC feeder protection/sizing ........................................................................................................................ 19
5.3 AC input connections .................................................................................................................................. 19
5.4 Calculating output wire size requirements ................................................................................................. 20
5.5 DC output connections ............................................................................................................................... 20
5.6 System and battery connections ................................................................................................................ 20
5.7 Alarm connections ...................................................................................................................................... 22
5.8 CAN serial ports .......................................................................................................................................... 22
5.9 Network connection and remote communications via controller ............................................................. 23
5.10 Signal wiring connections for controller ..................................................................................................... 23
YSTEM STARTUP ............................................................................................................................................. 26
6 S
053-691-B1 Rev E Page i of ii
6.1 Check system connections .......................................................................................................................... 26
6.2 Verify AC input and power up rectifier shelf .............................................................................................. 26
6.3 Check battery polarity and connect the batteries ...................................................................................... 26
6.4 Controller Reset .......................................................................................................................................... 27
6.5 LVD control ................................................................................................................................................. 27
PERATION .................................................................................................................................................... 28
7 O
7.1 Main rectifier states .................................................................................................................................... 28
7.2 Main rectifier modes................................................................................................................................... 29
7.3 Factory ranges and defaults ........................................................................................................................ 29
AINTENANCE ................................................................................................................................................ 31
8 M
8.1 General maintenance schedule .................................................................................................................. 31
8.2 Fan replacement ......................................................................................................................................... 31
ARRANTY .................................................................................................................................................... 32
9 W
9.1 Warranty ..................................................................................................................................................... 32
LPHA CONVENTIONS ....................................................................................................................................... 33
10 A
10.1 Acronyms .................................................................................................................................................... 33
FIGURES
Figure 1–Front view of the 053-691-20-000 rail mount CXPS 48-1.2-225 configuration ................................................. 1
Figure 2–Distribution center configured for 4 battery and 14 load breakers .................................................................. 4
Figure 3–Internal alarm card ............................................................................................................................................ 5
Figure 4–Internal alarm card and controller I/O terminal block ...................................................................................... 6
Figure 5–4R/8D ADIO option ............................................................................................................................................ 6
Figure 6–Controller front panel ........................................................................................................................................ 7
Figure 7–Rectifier front panel ........................................................................................................................................ 10
Figure 8–Example of an insulated tool kit ...................................................................................................................... 14
Figure 9–Rear view of distribution panel ....................................................................................................................... 21
Figure 10–Battery, load, and return connection locations ............................................................................................ 21
Figure 11–DCP03 wire routing example ......................................................................................................................... 22
Figure 12–Showing relay connections ............................................................................................................................ 23
Figure 13–Showing digital input connection method .................................................................................................... 24
053-691-B1 Rev E Page ii of ii
1 Introduction
1.1 Manual scope
This manual covers the features and installation of the Alpha Technologies CXPS 48-1.2-225 48V 225A Power
System.
1.2 Product overview
The CXPS 48-1.2-225 is a complete integrated 48 Vdc power system with 225 A capacity. The system uses the
advanced Cordex CXCM1 controller and HP 48 V 1.2 kW rectifier modules. The DCP03 300A distribution center
provides front access for DC distribution, site controller, and battery connections.
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
120/208/220/230/240/277 Vac 50/60 Hz electrical input. The system has de-rated output below 176 VAC input.
See specifications at the front of this manual.
The 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. Rectifier modules are not included with the base system, but may
be purchased along with the system at the time of ordering, or added after the shelf has been installed. The shelf
rectifier system is designed to operate with the Alpha Cordex CXCM1 controller.
This system uses the controller integrated version of the controller, which is factory installed on the Cordex
rectifier system shelf.
The CXC allows the user to configure, monitor and control the entire DC power system locally or remotely via a
web browser. Features of the unit include temperature compensation, auto equalization, remote access, e-mail
alarm notification, battery diagnostics, as well as web server and SNMP support for configuration and monitoring.
Details of the controller operation are provided in the software manual.
Figure 1–Front view of the 053-691-20-000 rail mount CXPS 48-1.2-225 configuration
053-691-B1 Rev E Page 1 of 33
Description
Part Number
CXPS 48-1.2-225, Cordex base 48V 225A power system, 19/23" rail mount
053-691-20-000
CXPS 48-1.2-225 system installed in 7foot Z4 23" rack with 2x battery trays
053-691-20-040
CXPS 48-1.2-225 system installed in 7foot Z4 19" rack with 3x battery trays
053-691-20-031
Description
Part Number
Cordex HP 48-1.2kW rectifier power module
010-619-20-040
Breaker, AM-type mid-trip plug-in, 1 A
470-300-10
Breaker, AM-type mid-trip plug-in, 3 A
470-301-10
Breaker, AM-type mid-trip plug-in, 5 A
470-302-10
Breaker, AM-type mid-trip plug-in, 10 A
470-303-10
Breaker, AM-type mid-trip plug-in, 15 A
470-304-10
Breaker, AM-type mid-trip plug-in, 20 A
470-305-10
Breaker, AM-type mid-trip plug-in, 25 A
470-306-10
Breaker, AM-type mid-trip plug-in, 30 A
470-307-10
Breaker, AM-type mid-trip plug-in, 35 A
470-308-10
Breaker, AM-type mid-trip plug-in, 40 A
470-309-10
Breaker, AM-type mid-trip plug-in, 45 A
470-310-10
Breaker, AM-type mid-trip plug-in, 50 A
470-311-10
Breaker, AM-type mid-trip plug-in, 60 A
470-312-10
Breaker, AM-type mid-trip plug-in, 70 A
470-313-10
Breaker, AM-type mid-trip plug-in, 80 A
470-314-10
Breaker, AM-type mid-trip plug-in, 90 A
470-315-10
Breaker, AM-type mid-trip plug-in, 100 A
470-316-10
Load breaker kit, AM-type mid-trip plug-in, 125 A (2-pole)
747-523-20
Load breaker kit, AM-type mid-trip plug-in, 150 A (2-pole)
747-524-20
Load breaker kit, AM-type mid-trip plug-in, 175 A (3-pole)
747-525-20
Load breaker kit, AM-type mid-trip plug-in, 200 A (3-pole)
747-526-20
Load breaker kit, AM-type mid-trip plug-in, 250 A (3-pole)
747-527-20
Battery breaker, AM-type series-trip plug-in, 100 A
470-347-10
Battery breaker kit, AM-type series-trip plug-in, 150 A (2-pole)
747-503-20
Battery breaker kit, AM-type series-trip plug-in, 250 A (3-pole)
747-504-20
One universal AC line cord, C19R – flying leads, 3.5 m, feeds 2 modules
877-671-19
One 120Vac line cord, L5-15P plugs, 2.5 m, feeds 2 modules
877-690-19
Replacement rectifier blank plate
747-622-20-000
Replacement controller (basic module, 1RU horizontal mount)
018-598-20
23" battery tray expansion kit (for use with –040 configuration)
058-156-20
1.3 Available system configurations
The system is available to order in the following configurations:
1.4 Part numbers including options
This product is available to order with the following options and accessories:
053-691-B1 Rev E Page 2 of 33
19" battery tray expansion kit (for use with –031 configuration)
058-157-20
Cordex DC Modem (complete with Alpha cable)
018-585-20
4R/8D ADIO expansion assembly
747-521-20
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.
053-691-B1 Rev E Page 3 of 33
Load breaker
positions
Battery breaker
positions
2 Features
2.1 System overview
Basic configuration included in Alpha part number 053-691-20-000:
• 300A DCP03 distribution center
• Cordex modular system controller (CXCM1)
• Two (2) Cordex HP 48-1.2kW rectifier shelves (nine positions total)
• Kydex rear covers
• 19" rack mount rails with center and flush mount
• 19" to 23" rack mount adaptors
• System integration cabling and bus work
• Two (2) battery temperature compensation probes (12' each)
Rectifier modules, DC distribution breakers, and AC input cables are not included in the basic configuration. See
section 1.4 to order these optional components.
Optional configurations:
053-691-20-031: Basic configuration factory installed into a 7' x 19" Zone 4-relay rack and three (3) battery trays
with cabling and 100A battery disconnects for up to three (3) 48 V VRLA strings.
053-691-20-040: Basic configuration factory installed into a 7' x 23" Zone 4-relay rack and two (2) battery trays
with cabling and 100 A battery disconnects for up to two (2) 48 V VRLA strings.
2.2 Distribution center
2.2.1 Distribution configurations
The distribution center contains 18 AM-type plug-in breaker positions. Each breaker position has two-hole
connection points, one for the breaker output and another one for the ground return bus. The breaker distribution
system has 4 breaker positions for the batteries and 14 breaker positions for the loads.
053-691-B1 Rev E Page 4 of 33
Figure 2–Distribution center configured for 4 battery and 14 load breakers
Load breakers require mid-trip AM plug-in breakers while battery breakers require series-trip AM plug-in breakers.
If there is no power to the rectifiers and only one battery circuit breaker, there will be no alarm when the circuit
breaker trips.
LVD override switch
I/O customer connection points
2.2.2 Low voltage battery disconnect (LVBD)
A low voltage disconnect (LVD) is installed in series with the batteries. This is called a low voltage battery
disconnect (LVBD).
2.2.3 Shunt
A shunt is installed in series with the batteries for current measurements. The controller automatically calculates
the load current.
2.2.4 Internal alarm card
The distribution center includes an alarm card, a low voltage disconnect override switch, and a breaker trip LED
indicator.
The alarm card provides terminal block access to internal signals such as binary alarms for breaker trips and
LVDs, alarm relays for driving the LVDs, and analog inputs for current (shunt) and voltage measurements. The
terminal block provides a single access point between these signals and an external system controller. Refer to
the customer connections (“–08”) drawing at the rear of this manual for details on terminal block assignments.
The LVD override switch allows the user to override the LVD during controller maintenance. A green LED
illuminates when the LVD is operating normally. A yellow LED illuminates when the LVD is in the override
position.
053-691-B1 Rev E Page 5 of 33
Figure 3–Internal alarm card
Controller I/O terminal
block assembly
D-sub wire harnesses to
1.8k W shelf
CAN in/out
8DIO power supply
Customer I/O
connections via
terminal blocks
2.2.5 Controller I/O terminal block
A controller I/O terminal block is installed in the distribution center front door to allow controller access to signals
and interfaces. A 25-pin D-sub wire harness is used to connect the terminal block to the controller.
The internal signals from the distribution center are wired to the controller I/O board directly from the internal
alarm board. The remaining relay outputs, digital inputs, and analog inputs can be accessed via terminal blocks to
customer connections. Refer to the customer connections (“–08”) drawing at the rear of this manual for details on
terminal block assignments.
2.2.6 8R/8D 8DIO (Option)
The 8R/8D 8DIO Cordex peripheral can be installed on the front door of the DCP03. The 8R/8D 8DIO option
expands the I/O capability of an existing Cordex controller by adding additional 8 relays outputs and 8 digital
inputs.
The 8R/8D 8DIO installs on the right side on the front door. The 8R/8D 8DIO is connected to the Cordex system
via CAN ports and RJ-12 offset communications cables.
All I/O connections are made via screw terminal blocks. Refer to the customer connections (“–08”) drawing at the
rear of this manual for details on terminal block assignments.
connection
Figure 4–Internal alarm card and controller I/O terminal block
053-691-B1 Rev E Page 6 of 33
Figure 5–8R/8D 8DIO option
System status LEDs
Ethernet port
Push once for soft reset
Hold for 3 seconds
LCD screen (V/A)
Display pushbutton
toggle switch (V/A)
Modem port. Do not
connects to anything
other than an Alpha
modem and cable
2.3 CXCM1 Controller
Details of the controller operation are provided in the software manual.
The controller is mounted in the rectifier system shelf and controls the rectifiers. The controller includes software
that does the following:
• Direct communication with the rectifiers.
• Battery temperature compensation charging.
• Battery performance diagnostics.
• Local and remote communications.
• User definable alarms.
• Daily logging of power system events and system statistics.
The motherboard is located behind the controller’s front panel. The motherboard contains a microprocessor,
memory chips, and many other electronic components.
The controller includes a web server that provides easy set up and monitoring over an Internet connection to a
web browser.
The data-logging feature allows the user to automatically collect data from multiple sources. The collected data
can be AC/DC voltages, load/battery currents, cell voltages, and temperatures. Up to 16 user-defined logs are
available. Typical applications for the collected data include power system details, thermal performance of
outdoor enclosures, battery cell specifics, or power input variations captured by an AC voltage watchdog.
A built-in audio speaker sounds an intermittent tone during active alarms.
2.3.1 Controller front panel
2.3.2 LCD screen
The controller front panel uses a 4-digit LCD screen to monitor the system voltage (V) and current (A). A pushbutton toggle switch allows the user to alternate the display reading.
Figure 6–Controller front panel
053-691-B1 Rev E Page 7 of 33
Illuminated
Green
OK, no alarms
Yellow
Minor alarm, no major alarms
Red
Major alarm
Illuminated
All three
Base unit validation
Red
File transfer
2.3.3 LED lights
Three LED lights are located on the front panel, one green, one yellow, and one red. The lights are used to
display the alarm status of the power system, controller progress and status during startup, and file transfers.
Alarm conditions
Only one LED light is illuminated at a time during alarm conditions. Each LED light corresponds to a specific
alarm.
Progress and status indication
The LED lights are also used in the following situations:
Alarm
LED
LED
2.3.4 Reset button
A reset button is located on the front panel for restarting the controller’s microprocessor. Select the reset menu
item before pressing the reset button. Refer to the software manual.
2.3.5 Modem port
A modem port is located on the front panel. It is designed to be used in conjunction with an Alpha DB-9 connector
and an Alpha Cordex DC Modem #018-585-20.
CAUTION: Connect the modem port with an Alpha-supplied modem and cable only. Otherwise,
equipment damage may result.
2.3.6 Ethernet port
An Ethernet port is located on the front panel. This port is designed to connect the controller to a user supplied
TCP/IP network. Use a standard RJ-45 jack with a standard network cable.
The Ethernet port can be used for local access, for example to a laptop computer. Use a standard network
crossover cable for the connection.
Situation
053-691-B1 Rev E Page 8 of 33
Loading...