Argus Technologies reserves the right to make changes to the products and information contained in this document without notice.
Copyright 2008 Argus Technologies Ltd. Argus
Printed in Canada.
®
is a registered trademark of Argus Technologies Ltd. All Rights Reserved.
Power System Manual
CXPS 48-1T 48V Pos Gnd Power System
053-392-B0
Drawing List:
The following drawings are included in this manual to provide the necessary
information required for routine operation and fault diagnosis of the system.
Specifications 053-392-B1
Safety and Installation Instructions 053-392-C0
Outline Drawing 053-392-06
Schematic, Power System 053-392-05
Customer Connections 053-392-08
Warranty and Service 048-700-10
Service Centers 048-693-10
Manuals to be included with this package are as follows:
Copyright 2008-04-09 Argus Technologies Ltd053-392-B0 Rev D
Printed in Canada. Argus is a registered Trademark. All rights reserved.
This page intentionally left blank.
Specifications for Argus’ CXPS 48-1T 48Vdc Power System
Output
Voltage: 42 to 60Vdc within rated limits
Current: System: up to 375A standard configuration,
(expandable to 600A via additional rectifier shelf)
Rectifier: 67A @ 48Vdc nominal (75A max.)
Power: System: up to 18,000W standard configuration,
(expandable to 28,800W via additional rectifier shelf)
Rectifier: 3600W maximum
Heat Dissipation (per rectifier): <1415 BTU per hour
Static Load Regulation: Better than ±0.1% for any load change within rated limits
Dynamic Load Regulation: Better than ±2% for 40% - 90% load step
(output shall recover to static limits within 30ms)
Static Line Regulation: Better than ±0.1% for any change in input voltage within rated limits
Electrical Noise: <32dBrnC (voice band)
Voltage: 208, 220, 230, 240, 277Vac nominal
Operational Range: 176 to 320Vac
Extended Operation: Low: 176 to 90Vac (derate d power)
Frequency: 45 to 66Hz
Current: 16.8A @ 240Vac
19.4A @ 208Vac
22.8A @ 176Vac (maximum)
Recommended Feeder Breaker
Single Phase: 30A, #10 AWG (for a single rectifier module)
Three Phase: 50A, #6 AWG delta connection (for three rectifier modules)
30A, #10 AWG wye connection (for three rectifier modules)
Power Factor: >0.99 at nominal conditions and 50-100% load
Protection: 10kA-interrupting capacity fuses in active and neutral lines
Efficiency: >90% at nominal conditions and 50-100% load
Specifications for Argus Technologies’ CXPS 48-1T 48Vdc Power System Continued
Safety
NOTE: Safety certifications performed at rectifier level only.
EN 60950 Rectifier output shall be rated SELV suitable for connection to TNV-1 circuits
UL 60950
CSA C22.2 No. 60950
CE EN 60950, CB Scheme
73/23/EEC Low Voltage Directive with amendment 93/68/EEC
Telcordia (Bellcore) GR-1089-CORE (requirements applicable to rectifier)
Other Referenced Standards
EN 300 386-2 EMC and ERM; Telecommunication Network Equipment
EN 55022 (CISPR 22) Information Technology Equipment – Radio Disturbance Characteristics – Limits
and Methods of Measurement
EN 61000-3-2 Harmonic Current Emissions
EN 61000-3-3 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.
This section contains important instructions that should be followed during the installation and maintenance of
equipment and batteries. Please read all of the instructions before operating the equipment, and save this manual for future reference.
A licensed electrician MUST perform connections to the branch circuit of service feed. 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 precautions.
If instructions in this manual conflict with local electrical codes, those instructions shall be superseded by the local
code.
The following safety symbols will be 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 levels of warning will be used with the above 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 will turn on a utomatically.
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 a power system. 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; e.g., watches, rings, metal rimmed glasses, necklaces.
• Wear safety glasses with side shields (and prescription lenses if necessary) at all times during installation.
• Use OSHA approved insulated hand tools.
Lethal voltages are present within a power system. Never assume that an electrical connection or conductor is not
energized. Check the circuit with a voltmeter with respect to the grounded portion of the enclosure (both AC and
DC) prior to 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 240Vac. Ensure that utility power is disabled before beginning installation or removal.
Ensure no liquids or wet clothes contact internal components.
Hazardous electrically live parts inside this unit are energized from batteries eve n when the AC input power is
disconnected.
Battery Safety
Servicing and connection of batteries shall 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 hands and neck.
Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.
Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or other
reproductive harm. Battery post terminals and related accessories contain lead and lead compounds; wash hands
after handling (California Proposition 65).
WARNING
Follow battery manufacturer’s safety recommendations when working around battery systems.
WARNING
Do not smoke or present an open flame when batteries (especially vented batteries) are on
charge. Batteries vent hydrogen gas when on charge, 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.
1.1 Scope of the Manual..................................................................................................................................... 1
1.3 System Configurations..................................................................................................................................2
1.4 Part Numbers and List Options.....................................................................................................................2
2 FEATURES ................................................................................................................................................................... 3
2.1 System Overview..........................................................................................................................................3
2.2 Tiered Distribution Features..........................................................................................................................3
2.3 Cordex System Controller (CXC)..................................................................................................................4
3.2 Check for Damage......................................................................................................................................11
3.3 General Receipt of Shipment......................................................................................................................11
5.2 AC Feeder Protection/Sizing....................................................................................................................... 16
5.3 AC Input Connections................................................................................................................................. 16
5.4 DC Output Connections.............................................................................................................................. 17
5.7 Network Connection and Remote Communications via CXC.....................................................................25
6 SYSTEM STARTUP......................................................................................................................................................26
6.1 Check System Connections........................................................................................................................26
6.2 Verify AC and Power the Rectifier Shelf..................................................................................................... 26
6.3 Check Battery Polarity and Connect...........................................................................................................26
7.1 Main Rectifier States...................................................................................................................................27
7.2 Main Rectifier Modes .................................................................................................................................. 27
7.3 Factory Ranges and Defaults .....................................................................................................................28
8.1 Fan Replacement........................................................................................................................................ 29
9.2 Acronyms and Definitions ........................................................................................................................... 31
i
1 Introduction
1.1 Scope of the Manual
This instruction manual covers the features and installation of Argus Technologies’ CXPS 48-1T 48V 375A Power
System.
For advanced detail on the system components used in the CXPS 48-1T, please refer to the following manuals:
• Cordex 48-3.6kW Rectifier Module: 010-600-B2
[This manual also provides CXCM4 (controller) installation details.]
(010-567-20 pre-RoHS)
• Cordex Controller (CXC) Software: 034-109-B2 or latest revision of software.
NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.
1.2 Product Overview
The CXPS 48-1T is a complete integrated 48Vdc power system with 375A initial capacity; expandable up to 600A.
The system utilizes the advanced Cordex controller and 48V 3.6kW rectifier modules. The one-tier (Vista II series)
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
208/220/230/240/277Vac 50/60Hz electrical service.
Rectifier power modules are “hot swappable” meaning they can be inserted or removed fro m the shelf without
cutting power to or from the system or the load.
NOTE: 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
Argus Cordex System Controller (CXC).
This system uses the CXCM4 modular version of the
controller, which plugs directly into the Cordex rectifier
system shelf. The rectifier/shelf manual provides CXCM4
installation details.
The CXC allows the user to configure, monitor and control
the entire DC power system from its touch screen display
similar to that used in a personal digital assistant (PDA).
Other 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 controller operation are provided in the
current version software manual.
The basic system configuration is called out by Argus part number 053-392-2 0-000; which includes:
• 600A One-Tier Distribution Center (Vista II One-Tier UDC)
• Cordex System Modular Controller 4RU (CXCM4)
• One (1) Cordex 48-3.6kW 6-module rectifier shelf
• Kydex rear cover
• 23” rack mount rails
• System integration cabling and bus work.
Optional system configurations are available as:
053-392-20-010: basic configuration factory installed into a 22RU battery mount 23” relay rack.
053-392-20-020: basic configuration factory installed into a 7 foot 23” zone 4 relay rack.
053-392-20-030: basic configuration factory installed into a 7 foot 23” zone 4 relay rack and three (3) battery
trays with cabling and 100A battery disconnects for up to three (3) 48V VRLA strings.
2.2 Tiered Distribution Features
2.2.1 Overview (Vista II One-Tier)
The 600A One Tier Distribution Center is a modular, front access system that provides DC distribution, rectifier
and battery connections. Coupled with Argus Cordex system controller, rectifiers and converters, it provides a
complete solution in a compact integrated package.
The distribution center in the CXPS 48-1T is configured at the factory with:
• 48V, 18-position split-breaker tier with 600A LVD (can also be configured for split 48V/24V voltage
applications)
• 48V, 10-position, 30A GMT fuse assembly
• Load shunt for current measurement.
The modular distribution center allows customization of integrated power systems; perfect for space-restricted
installs. The system provides front access to controller interface and I/O connections, load breakers & fuses, and
battery connections.
Figure 2–Example of distribution center in the CXPS 48-1T
The distribution tier in the CXPS 48-1T has support for eighteen (18) AM-type plug-in breaker
positions with an 800A shunt and 600A LVD. This option is a split-tier design – factory
configured – with a jumper to support eighteen (18) 48Vdc breaker positions.
The jumper is removable for future system installation / upgrade of 48V-24V converters.
Removing the jumper will change the tier capacity to eight (8) 48Vdc brea ker positions and ten
(10) 24Vdc breaker positions.
NOTE:
When implementing the 48/24V split distribution configuration, the LVD will only be in series with the 48V distribution
side. LVD for the 24V loads will be performed via the 48V input to the converter or via software at the converter level.
For split voltage modification of Tier 1, please reference the installation section of this manual.
2.2.2.2 GMT Fuse Block
A 10-position GMT fuse block is also factory installed and is configured for additional primary
voltage (48V) distribution. The GMT fuse block has a total capacity of 30A.
2.3 Cordex System Controller (CXC)
2.3.1 CXCM4 Overview
The CXCM4 (Cordex Controller, Modular, 4RU) is mounted in the rectifier system shelf and brings advanced
monitoring technology to the Cordex series of rectifiers. This compact system controlle r is designed for seamless
operation and set up of Argus 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 CXCM4’s front panel lies the main controller motherboard, which contains a microprocessor, memory,
as well as numerous other electronic components.
The CXCM4 includes a web server providing easy set up and monitoring using an Internet connection with the
standard Windows Internet Explorer browser.
The data logging feature allows the user to capture data from multiple inputs, for AC/DC voltages, load/battery
current, cell voltages & temperatures (automatically for up to 16 user defined logs). Typical applications of the
CXCM4 logging include power system details, thermal performance of outdoor enclosures, ba ttery cell specifics,
or mains variations captured by an AC voltage watchdog.
A built-in audio speaker sounds an intermittent tone during active alarms.
The input/output (I/O) board houses a series of terminal connections.
2.3.2 Front Panel
2.3.2.1 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) allows the operator to interact with screen
selectable items using a fingertip.
The CXCM4 has three LEDs located on the front panel. These are used to displ ay the alarm
status of the power system, CXCM4 progress and status during startup, and file transfers.
Alarm Conditions
The CXCM4 illuminates the LED that corresponds to the system alarm statu s. T he 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.
Progress and Status Indication
The LEDs are also used in the following situations:
Base unit validation – all three LEDs are on at the same time.
File transfer – when recovering from invalid firmware application – the red LED is
illuminated.
Reset (RST) button
Ethernet port
System status LEDs
Figure 3–Cordex CXCM4 model system controller front panel
2.3.2.3 Reset
A reset button is located on the front panel for restarting the CXCM4’s microprocessor. It takes
approximately 15 seconds before the display reappears after pressing the reset button.
NOTE: Refer also to the software manual – always select the shutdown menu item before pressin g the reset
button.
2.3.2.4 Ethernet Port
The Ethernet port is designed for CXCM4 connection to a user supplied network (TCP/IP
secured by user) via a front panel RJ-45 jack and a standard network cable.
Local access (e.g. laptop computer) is also possible from the Ethernet port connection using a
standard network crossover cable.
2.3.2.5 RS-232 Serial (Craft) Port
Local access to the CXCM4 is possible through a front panel RS-232 serial port; using a null
modem cable. The communication protocol supports a web interface (via Microsoft® Internet
Explorer 6 or greater). The remote screen display is an enhanced version of the CXC’s front
panel display.
The CXCM4 has analog input channels for voltage, current, and temperature.
2.3.3.1 Voltage Inputs
Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage.
The CXCM4 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
measurements.
2.3.3.2 Current Inputs
The CXCM4 software is pre-configured to monitor for load current using an external 50mV
current shunt.
2.3.3.3 Temperature Inputs
Two temperature input channels, T1 and T2, provide monitoring of battery temperature and
temperature compensation (temp comp) or room/ambient temperature. A voltage is supplied by
the CXC to these terminals to power the temperature sensors.
2.3.4 Digital Input Channels
The CXCM4 can accommodate up to four channels and can monitor digital alarm/control signals from rectifiers,
converters and many other types of equipment.
2.3.5 Alarm and Control Output Relays
The CXCM4 contains eight Form C digital alarm output relays to extend alarms and control ex ternal apparatus.
Each internally generated alarm or control signal may be mapped to any one of the relays, or, several signals may
be mapped to just one relay or none at all.
2.3.5.1 LVD Control (External Option)
The LVD Control functions can be hardwired directly from the assigned relay output to an
optional LVD override control and distribution alarm card. This provides a safety measure to
protect against load disconnect during CXCM4 reset or replacement; e.g. when the controller is
off-line. Operators may also perform test and maintenance procedures on the CXCM4 without
disturbing the load.
2.3.6 System Fail Alarm/Relay
The CXCM4 system fail alarm (K0) activates because of a major internal failure. Durin g such a condition, the unit
will attempt to reset, but if this fails, an alarm condition will be extended to a relay and the red LED on the front
panel will illuminate. This is a fail-safe signal to the remote monitoring equipment; i.e. alarm will be extended even
if power to the unit is interrupted.
2.3.7 Network Connection and Remote Communications
The Cordex system can be set up, monitored and tested via ETHERNET 10/100 Base-T serial data connec tion.
The communication protocol supports a web interface. All alarming and control of Cordex rectifiers is
accomplished with a CXC via a CAN bus.
A step-by-step connection wizard – provided to establish remote communications with your CXC – is available via
the Argus website (www.argusdcpower.com).