Alpha CXRF 48-12kW User Manual

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Alpha Modular Switched Mode Rectiﬁer System

Rectiﬁer Models: Cordex CXRF 48-3.6kW

Cordex HP CXRF 48-4kW

Cordex HP CXRF 48-12kW

Installation and Operation Manual

Part #9400000-J0

Effective 12/2012

member of The Group

™

Your Power Solutions Partner

Modular Switched Mode Rectier System

Models: Cordex CXRF HP 48-12kW

Cordex CXRF HP 48-4.0kW

Cordex CXRF 48-3.6kW

NOTE: Photographs contained in this manual are for illustrative purposes only. These photo-

graphs 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

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.

Table of Contents

1. Safety ....................................................................................................................................5

1.1 Safety Symbols .......................................................................................................................... 5

1.2 General Safety ........................................................................................................................... 5

1.3 Mechanical Safety ...................................................................................................................... 5

1.4 Electrical Safety ......................................................................................................................... 6

1.5 Battery Safety ............................................................................................................................ 6

2. Introduction ...........................................................................................................................7

2.1 Scope of the Manual .................................................................................................................. 7

2.2 Product Overview ....................................................................................................................... 7

2.3 Part Numbers and List Options .................................................................................................. 8

3. Rectier Features................................................................................................................10

3.1 Front Panel .............................................................................................................................. 10

3.2 Rectier Rear Panel ................................................................................................................. 12

3.3 True Module Fail Alarm ............................................................................................................ 12

3.4 Heat Dissipation ....................................................................................................................... 12

3.5 Over Temperature Protection ................................................................................................... 12

3.6 Wide AC Range ....................................................................................................................... 12

3.7 AC Inrush/Transient Suppression ............................................................................................ 13

3.8 Soft Start .................................................................................................................................. 13

3.9 Start Delay ............................................................................................................................... 13

3.10 Current Limit/Short Circuit Protection .................................................................................... 13

3.11 Power Limiting ........................................................................................................................ 13

3.12 High Voltage Shutdown (HVSD) ............................................................................................ 13

3.13 Battery Eliminator Operation .................................................................................................. 13

4. Cordex System Controller (CXC) ........................................................................................14

4.1 CXCM4 Features ..................................................................................................................... 14

4.2 Controller Front Panel .............................................................................................................. 14

4.3 Rectier Report from Controller Display .................................................................................. 16

4.4 Analog Input Channels ............................................................................................................. 16

4.5 Digital Input Channels .............................................................................................................. 17

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4.6 Alarm and Control Output Relays ............................................................................................ 17

4.7 System Fail Alarm/Relay .......................................................................................................... 17

5. Inspection............................................................................................................................18

5.1 Packing Materials ..................................................................................................................... 18

5.2 Check for Damage ................................................................................................................... 18

5.3 General Receipt of Shipment ................................................................................................... 18

6. Installation ...........................................................................................................................19

6.1 Safety Precautions ................................................................................................................... 19

6.2 Tools Required ......................................................................................................................... 19

6.3 Power System Assembly and Mounting ................................................................................... 20

7. Wiring ..................................................................................................................................21

7.1 Grounding ................................................................................................................................ 21

7.2 AC Feeder Protection/Sizing .................................................................................................... 21

7.4 DC Output Connections ........................................................................................................... 22

7.3 AC Input Connections .............................................................................................................. 22

7.5 CAN Serial Ports (Rectier Shelf) ............................................................................................ 23

7.6 Inserting the CXCM4 Module ................................................................................................... 24

7.7 Signal Wiring Connections for CXCM4 .................................................................................... 24

7.8 Network Connection and Remote Communications via CXC .................................................. 26

8. System Startup ...................................................................................................................27

8.1 Check System Connections ..................................................................................................... 27

8.2 Verify AC and Power the Rectier Shelf ................................................................................... 27

8.3 Triple Check Battery Polarity and Connections ........................................................................ 27

8.4 CXC Reset ............................................................................................................................... 27

9. Rectier States, Modes and Factory Defaults.....................................................................28

9.1 Main Rectier States ................................................................................................................ 28

9.2 Main Rectier Modes ............................................................................................................... 29

9.3 Factory Ranges and Defaults .................................................................................................. 30

10. Maintenance .....................................................................................................................31

10.2 Replacing a Rectier Module ................................................................................................. 31

10.3 Replacing the CXCM4 Module ............................................................................................... 32

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10.4 Fan and Fan Filter Replacement ........................................................................................... 33

10.5 MOV Replacement ................................................................................................................. 37

11. Acronyms and Denitions ..................................................................................................41

12. Warranty and Service Information ....................................................................................42

12.1 Technical Support .................................................................................................................. 42

12.2 Warranty ................................................................................................................................. 42

12.3 Battery Warranty .................................................................................................................... 42

12.4 Return of Material .................................................................................................................. 42

List of Figures

Figure 1 — (a) Cordex 48-3.6kW (b)Cordex 48-4kW (c) Cordex 48-12kW switched mode rectier 7

Figure 2 — Rectier front panel LEDs ............................................................................................ 10

Figure 3 — Cordex CXCM4 model system controller front panel ................................................... 14

Figure 4 — Rectier (or Converter) report screen .......................................................................... 16

Figure 5 — CAN termination selection and serial ports .................................................................. 23

Figure 6 — Relay connections in the de-energized state ............................................................... 24

Figure 7 — Digital input connection method ................................................................................... 25

Figure 8 — LVD override control and distribution alarm card ......................................................... 32

Figure 9 — 4kW rectier fan removal ............................................................................................. 34

Figure 10 — 4kW rectier fan lter removal .................................................................................... 34

Figure 11 — Fan assembly - screw removal ................................................................................... 35

Figure 12 — Fan assembly ............................................................................................................. 35

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1. Safety

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 specic regulatory/code requirements that may affect the placement of equipment and /or installation procedures.

NOTE:

A NOTE provides additional information to help complete a specic task or procedure.

Notes are designated with a checkmark, the word NOTE, and a rule beneath which the information appears

CAUTION!

CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. Cautions are designated with a yellow warning triangle, the word CAUTION, and a rule beneath which the information appears.

WARNING!

WARNING presents safety information to PREVENT INJURY OR DEATH to personnel. Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath which the information appears.

HOT!

The use of HOT presents safety information to PREVENT BURNS to the technician or user.

1.2 General Safety

WARNING!

This system is designed to be installed in a restricted access location that is inaccessible to the general public.

1.3 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.

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1.4 Electrical Safety

WARNING! Hazardous voltages are present at the input of power systems. The DC output from rec-

tiers 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:

a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.

b. Wear safety glasses with side shields at all times during the installation.

c. Use OSHA approved insulated hand tools.

WARNING! Lethal voltages are present within the 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 before 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.

1.5 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. Do not smoke or introduce an open ame when batteries (especially vented

batteries) are charging. When charging, batteries vent hydrogen gas, which can explode.

• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery manufacturer for recommended local authorized recyclers.

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2. Introduction

2.1 Scope of the Manual

This instruction manual explains the installation, interconnection, and operation of the Alpha Cordex 48-3.6kW, 48-4.0kW and 48-12kW modular switched mode rectiﬁer systems.

2.2 Product Overview

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

Cordex rectiﬁer modules use a high frequency, switched mode conversion technique to provide a fully regulated and isolated DC output from the AC mains. The rectiﬁer input is wide range to allow use on 208/220/240 Vac 50/60 Hz electrical service.

Rectiﬁer power modules are “hot swappable”—they can be inserted or removed from the shelf without cutting power to or from the system or the load.

Additional power modules can be included with the system at the time of ordering or added after the shelf has been installed.

The shelf rectiﬁer system is designed to operate with the Alpha Cordex System Controller (CXC). The CXC controller allows the user to conﬁgure, monitor and control the entire DC power system from its touch screen display including temperature compensation, auto equalization, remote access, dial out on alarm, 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.

There are two options for the Alpha CXC

• External CXC models of the system controller communicate with the shelf via offset RJ-12 shelf connec-

tors. The CXCR is mounted in a rack and the CXCP is (factory) mounted in a panel.

• The CXCM4, a 4 RU model designed for integrated use with the rectiﬁer shelf, requires a connection

interface (adapter) for modular installation and uses the shelf space of the leftmost rectiﬁer position (as viewed from the front). This CXC model also has a touch screen display.

(a)

Figure 1 — (a) Cordex 48-3.6kW (b)Cordex 48-4kW (c) Cordex 48-12kW switched mode rectifier

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(b)

(c)

2.3 Part Numbers and List Options

The product, options, and accessories can be ordered by using the following part numbers:

Description List Option

Cordex 48-12kW rectier power module 0100002-002

Basic module *List 0

Fan, spare for Cordex 48-12kW 747-679-20

Fan lter, spare for Cordex 48-12kW 747-652-20-060

MOV assembly, spare for Cordex 48-12kWt 707-813-20

Cordex 48-3.6kW rectier power module (pre-RoHS # 010-567-20) 010-600-20

Basic module *List 0

Gray nish with blue silkscreen *List 50

1 x 420Vac and 2 x 660Vac MOVs List 81

Fan assembly, (spare for Cordex 48-3.6kW) (pre-RoHS # 747-212-20) 747-359-20

MOV assembly, (spare for Cordex 48-3.6kW) 707-374-20

Cordex 48-4kW rectier power module 010-623-20

Basic module *List 0

Gray nish with blue silkscreen List 50

Black nish with gray silkscreen *List 58

Fan assembly, spare for Cordex 48-4kW 747-679-20

Fan lter, spare for Cordex 48-12kW 747-652-20-060

MOV assembly, spare for Cordex 48-4kW 707-813-20

Cordex 48-3.6/4.0/12kW 23" shelf, ush or mid-mounting (pre-RoHS # 030-716-20)

Basic shelf, can be equipped with up to six Cordex 48-3.6kW or 48-4kW modules** *List 0

Mid-mounting *List 23

Flush mounting List 25

DC output, bus bar adapters, 20" deep

DC output, bus bar adapters, 16" deep

AC input, dual three phase (no neutral required) List 83

AC input, dual three phase (neutral required, Wye source) List 84

AC input, single phase *List 85

Kydex rear cover List 89

Module blank List 90

Cordex 48-3.6/4.0/12kW 19" shelf, ush mounting, AC input, single phase (pre-RoHS # 030-717-20)

Basic shelf, may be equipped with up to ve Cordex 48-3.6kW or 48-4kW modules** *List 0

Mid-mounting, 19" rack

Mid-mounting, 23" rack

DC output, bus bar adapters, 16" deep

030-801-20

List 81

List 82

030-802-20

List 19

List 23

List 82

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Description List Option

Kydex rear cover List 89

Module blank List 90

CXCM4 Cordex Controller, Modular, 4RU, takes the space of one rectier (pre-RoHS # 018-574-20) 018-586-20

Basic unit *List 0

48 V system [requires a connection interface (747-271-20) for modular installation] List 2

Standard temperature (0 to 65ºC) List 40

Extended temperature (-40 to 65ºC) *List 42

Gray nish with blue silkscreen *List 50

Charcoal nish with gray silkscreen List 56

Expanded Flash memory List 110

Analog input conguration: two voltage, four temperature, two current, no bi-voltage List 121

Analog input conguration: two voltage, two temperature, four current, two bi-voltage *List 125

CXCM4 connection interface, CXRF 48V, necessary for CXCM4 installation in the shelf 747-271-20

LVD override control and distribution alarm card 707-307-20

* Default option

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3. Rectifier Features

3.1 Front Panel

The three LEDs on the rectiﬁer front panel indicate status:

• AC ON (1)

• DC ON (2)

• Alarm (3)

LEDs

1 2 3

3.6kW

1 2 3

LEDs

Thumbscrew

LEDs

1 2 3

4kW

LEDs

1 2 3

Thumbscrews

Figure 2 — Rectifier front panel LEDs

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3.1.1 Rectiﬁer LEDs

The front panel LEDs indicate:

• Rectiﬁer status summary

• Rectiﬁer software upgrade in progress

• Patterned response to Locate Module command

The rectiﬁer status summary shows the rectiﬁer alarm status, communication fail status, and rectiﬁer on/off status.

AC ON (1)

The green LED is illuminated when the AC input voltage is within its allowable range. The LED ﬂashes (~2Hz) when input voltage is outside the allowable range. The AC input voltage is invalid if the AC Mains Low or AC Mains High alarm is active. This LED extinguishes if the AC input fails.

DC ON (2)

The green LED is illuminated when the rectiﬁer is delivering power to the load. The LED ﬂashes when communication is lost. The LED extinguishes when the rectiﬁer is off, e.g., when commanded via the CXC.

ALARM (3)

The red LED is illuminated during an active Module Fail alarm if the module is unable to source power because of the following conditions:

Output fuse blown AC mains input fail Module fail (ramp test fail)

High voltage (Over voltage protection (OVP)) shutdown

UPF fail No output power Fan (1 and 2) fail

Thermal shutdown

Local shutdown

The LED ﬂashes (~2Hz) when a minor alarm is detected if the modules output capability has been reduced or a minor component failure is detected during the following conditions:

VAC meter fail AC foldback Remote equalize

Fan fail Low output voltage High output voltage

Current limit (programmable option) Power limit (programmable option) High temperature foldback

Temperature sense fail Soft start operation Communications lost

The LED remains extinguished in the absence of an alarm.

LED Activity During Software Upload

When a rectiﬁer software upload is in progress, the LEDs ﬂash in a distinct pattern to indicate new rectiﬁer software is being transferred from the CXC. All three LEDs ﬂash in a sequence lasting 1.5 seconds. When the last LED is lit, the sequence is repeated beginning at the ﬁrst LED.

LED Activity During the ‘Locate Module’ Command from CXC

The ‘Locate Module’ command from the CXC, causes the target rectiﬁer LEDs to ﬂash in a ping-pong pattern that repeats every 2 seconds. Each LED illuminates sequentially and after the last LED illuminates, the sequence is reversed. When the ﬁrst LED is illuminated, the pattern repeats. This effect makes it appear that the light bounces between the ﬁrst and last LED.

Mechanical

A thumbscrew is provided to secure the rectiﬁer into the shelf. During normal operation, the rectiﬁer must be locked into position. A handle or grip on the front panel helps to remove the rectiﬁer from the shelf. No special tools are required.

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3.2 Rectiﬁer Rear Panel

A single connector for shelf power and communications is located on the rear panel of each rectiﬁer. The 12kW rectiﬁer has three connectors.

3.3 True Module Fail Alarm

The power modules have a “true” fail alarm that provides a true indication of the power module’s ability to source current. When the module’s output current drops below 2.5% of the rated output, a low output 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 current. If no increase in current is detected, the Module Fail alarm is activated. The module will test once every 60 seconds for the condition until a current is detected. The output voltage ramping ceases upon detection of Current1. A minimum 2.5% load is required to avoid the Ramp Test Fail alarm. This can be provided with the parallel system battery. Activation of this alarm could indicate a failed module or a failed load.

For Cordex rectiﬁer systems without batteries, or with a very light load below 2.5% of the rated output, the ramp test should be disabled to avoid nuisance alarms. The Ramp Test feature is enabled/disabled from the CXC menu: Rectiﬁers > Conﬁgure Settings.

3.4 Heat Dissipation

Each rectiﬁer module is equipped with at least one front-mounted fan. The fan runs when temperatures are above 0ºC (32ºF). The air ﬂow is front-to-rear with the exhaust air exiting at the back. The fan is a variable speed fan; the speed is determined by the heatsink temperature and the load.

3.5 Over Temperature Protection

Component failure or a cooling airﬂow blockage can result in an excessive increase in temperature. During overtemperature conditions, the rectiﬁer limits the output power and the output current. If the temperature continues to increase, the rectiﬁer is shutdown. The rectiﬁer restarts automatically when the temperature returns to a safe level.

3.6 Wide AC Range

A minor alarm is generated when the AC input voltage drops below its allowable limit.

3.6.1 4.0kW and 12kW

The rectiﬁer output power is reduced linearly between 187 Vac and 150 Vac to 67% of the rated output power. The unit delivers derated output power down to 90 Vac.

At 90 Vac, the module shuts down and does not restart until the AC voltage is greater than or equal to 150 Vac. The restart voltage depends on the load current. A reduced load current may allow a restart input voltage as low as 100 Vac.

For voltages above 277 Vac, the power factor and total harmonic distortion may be derated. Up to 320 Vac, the rectiﬁer will be operational and will not suffer any damage.

3.6.2 3.6kW

Rectiﬁer output power is reduced linearly between 176Vac and 150Vac to 75% of the rated output power (the unit will deliver derated output power down to 80Vac).

For voltages above 277 Vac, the power factor and total harmonic distortion may be derated. Up to 320 Vac, the rectiﬁer will be operational and will not suffer any damage.

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3.7 AC Inrush/Transient Suppression

To prevent a surge on the AC inout line, the inrush current of a rectiﬁer module is limited to the full load steady state line current. Modules are also protected from input lightning and transient surges in accordance with IEEE/ ANSI C62.41 Category B3 standards.

3.8 Soft Start

A soft start feature is used to eliminate an instantaneous demand on the AC power source. A soft start, sometimes referred to as a “current walk-in”, works by gradually (up to ﬁve seconds) ramping up the current limit from zero to the actual or deﬁned customer setting. The rectiﬁer output voltage is ramped from the minimum voltage to the ﬂoat voltage.

3.9 Start Delay

The rectiﬁer modules are equipped with a delay timer to stagger-start a series of modules to prevent excessive loading of generators upon start up. The built-in timer delays the switching on of the module by an interval (up to 120 seconds), which is set in the CXC. A minimum one-second delay is preset to allow the input capacitors to charge.

3.10 Current Limit/Short Circuit Protection

The current limit function determines the maximum output current limit of the rectiﬁer module, regardless of the output voltage or power. The maximum output current is limited to a constant value down to a short circuit condition. Current limiting can be used to mate the rectiﬁer output current ampacity to the needs of the load and parallel battery to minimize excessive battery recharge currents.

The rectiﬁer will sustain a short circuit at the output terminals indeﬁnitely. The maximum short circuit current will not exceed 105% of the rated full load current.

3.11 Power Limiting

Each rectiﬁer module is designed to limit the power output to the module speciﬁcation. This enables more current to be supplied at lower output voltages, and allows matching the output power to the demands of constant-power loads often seen in telecom equipment.

This feature may also be used for a faster recharge of ﬂooded batteries paralleled with the load.

NOTE:

The current limiting feature overrides the power-limiting feature.

3.12 High Voltage Shutdown (HVSD)

This feature protects the load from over-voltages originating in the rectiﬁers. The offending rectiﬁer module is shut down when a high output voltage condition occurs. The red Alarm (Module Fail) LED will illuminate. The module will restart automatically. However, if more than three over-voltage conditions occur within one minute, the module will latch off and remain shut down until it is reset by restarting the rectiﬁer via the CXC.

3.13 Battery Eliminator Operation

Rectiﬁer 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 during an AC power failure or input fuse failure.

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4. Cordex System Controller (CXC)

4.1 CXCM4 Features

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 controller is designed for seamless operation and set up for Alpha power systems. It is equipped with a complete range of Cordex software features:

• Designed to communicate directly with the Cordex rectiﬁers

• Battery temperature compensation charging

• Battery performance diagnostics

• Provision for local and remote communications

• User deﬁnable alarms

• Daily logging of power system events and system statistics

The main controller motherboard, behind the CXCM4 front panel, contains a microprocessor, memory, and other electronic components.

The CXCM4 includes a web server that provides easy set up and monitoring via an Internet connection that uses a 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 and temperatures (automatically for up to 16 user deﬁned logs). Typical applications for CXCM4 logging include power system details, thermal performance of outdoor enclosures, battery 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.

4.2 Controller Front Panel

Display

Located on the front panel is a 160 x 160-pixel graphical LCD with a touch screen similar to those used in PDAs. This graphical user interface (GUI) allows the operator to interact with screen selectable items using a stylus.

Touch screen

RS-232 (craft port)

Reset (RST) button

System status LEDs

Ethernet port

Figure 3 — Cordex CXCM4 model system controller front panel

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LEDs

The three LEDs, located on the CXCM4 front panel, display 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 status. Each LED color corresponds to a speciﬁc alarm status (only one LED is illuminated at a time during alarm conditions.)

Green OK, no alarms present. Yellow Minor alarm is present, no major alarms. Red Major alarm is present.

Progress and Status Indications

Base unit validation All three LEDs are illuminated at the same time. File transfer The red LED is illuminated when recovering from an invalid rmware application.

Reset Button

A reset button is located on the front panel to restart the CXCM4 microprocessor. The display reappears approximately 15 seconds after pressing the reset button. Refer to the software manual for more information.

NOTE:

Always select the shutdown menu item on the LCD before pressing the reset button.

Ethernet Port

The RJ-45 jack and a standard network cable can be used to connect the CXCM4 to a user supplied network (TCP/IP secured by user) .

Local access (e.g. with a laptop computer) is also possible from the Ethernet port using a standard network crossover cable.

RS-232 Serial (Craft) Port

Local access to the CXCM4 is possible through the front panel RS-232 serial port with a null modem cable. The communication protocol also supports a web interface (Microsoft Internet Explorer 7 or greater). The remote screen display is an enhanced version of the CXC front panel display.

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4.3 Rectiﬁer Report from Controller Display

To display the installed rectiﬁers and their status, logon through the controller interface. From the Main Menu, select Rectiﬁers > Rectiﬁer Report to generate the report screen for all acquired modules in

the system (Figure 4). Tapping on a rectiﬁer in the screen generates a Rectiﬁer Locate command that causes the rectiﬁer's LEDs to ﬂash brieﬂy.

Serial numbers of the modules

Select a module and then tap

Details to produce a new window

with pull-down menus showing all of the alarms and settings that are out of tolerance

View

Figure 4 — Rectifier (or Converter) report screen

FL + TC

54.00V

250A

Report headings for serial number, current display (% or A), number of alarms and settings out of tolerance

A value of ‘---‘ indicates Comms Lost

Return to previous screen

4.3.1 Rectiﬁer Report for 12kW Rectiﬁers

The 12kW rectiﬁer report contains three separate serial numbers. These serial numbers are derived from the top

level serial number located on the rectiﬁer label. For example, if the label serial number is N300020/1210, then the rectiﬁer report screen displays three serial numbers 300021/1210, N300022/1210, and N300023/1210.

4.4 Analog Input Channels

The CXCM4 is equipped with analog input channels for voltage, current, and temperature.

Voltage Inputs

Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCM4 software is pre-conﬁgured to monitor V1 for load voltage and V2 for 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.

Current Inputs

The CXCM4 software is pre-conﬁgured to monitor load current using an external 50 mV current shunt.

Temperature Inputs

Two temperature input channels, T1 and T2, monitor the battery temperature, and the room/ambient temperature, and provide temperature compensation (temp comp). A voltage is supplied to these terminals to power the temperature sensors.

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4.5 Digital Input Channels

The CXCM4 can accommodate up to four channels and can monitor digital alarm/control signals from rectiﬁers, converters, and other types of equipment.

4.6 Alarm and Control Output Relays

The CXCM4 contains eight Form-C digital alarm output relays that are used to extend alarms and to control external apparatus. Each internally generated alarm or control signal can be mapped to any one of the relays, or several signals can be mapped to just one relay or none at all.

4.6.1 LVD Control (External Option)

The LVD control functions can be hard-wired directly from the assigned relay output to an optional LVD override control and distribution alarm card. This protects against a load disconnect during a CXCM4 reset or replacement; when the controller is off-line for example. Operators can perform test and maintenance procedures on the CXCM4 without disturbing the load.

4.7 System Fail Alarm/Relay

The CXCM4 system fail alarm activates during a major internal failure. During 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, which means that the alarm will be extended even if the power to the unit is interrupted.

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5. Inspection

5.1 Packing Materials

All Alpha products are shipped in rugged, double walled boxes and suspended via solid inserts to minimize shock that may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit Association standards.

Rectiﬁers and batteries are shipped on individual pallets and are packaged according to the manufacturer’s guidelines.

5.1.1 Returns for Service

Save the original shipping container. If the product needs to be returned for service, it should be packaged in its original shipping container. If the original container is unavailable, make sure that the product is packed with at least three inches of shock-absorbing material to prevent shipping damage.

NOTE:

Alpha Technologies is not responsible for damage caused by improper packaging of returned products.

5.2 Check for Damage

Before unpacking the product, note any damage to the shipping container. Unpack the product and inspect the exterior for damage. If any damage is observed, contact the carrier immediately.

Continue the inspection for any internal damage. In the unlikely event of internal damage, inform the carrier and contact Alpha Technologies for advice on the impact of any damage.

5.3 General Receipt of Shipment

The inventory included with your shipment depends on the options you have ordered. The options are clearly marked on the shipping container labels and bill of materials.

5.3.1 Shelves

Consult the packing slip and power system bill of materials to verify that you have the correct number of shelves per your order.

5.3.2 Rectiﬁers (Purchased Separately)

Consult the packing slip to verify that you have received the correct number of rectiﬁers per your order.

5.3.3 Miscellaneous Small Parts

Review the packing slip and bill of materials to determine the part number of the “conﬁguration kits” included with your system.

Review the bill of materials to verify that all the small parts are included.

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6. Installation

The equipment is suitable for installation in Network Telecommunication Facilities.

WARNING!

This system is designed to be installed in a restricted access location that is inaccessible to the general public.

The following procedure is written for qualiﬁed personnel to install this product in a clean and dry environment. For the battery installation, refer primarily to the manufacturer’s manual.

6.1 Safety Precautions

Refer to the Safety section near the front of this manual before beginning this installation.

6.2 Tools Required

Various insulated tools are essential for the installation. Use this list as a guide:

• Battery lifting apparatus if required

• Electric drill with hammer action, 1/2" capacity

• Various crimping tools and dies to match lugs used in installation

• Load bank of sufﬁcient capacity to load largest rectiﬁer to its current limit

• Digital voltmeter equipped with test leads

• Cable cutters

• Torque wrench: 1/4" drive, 0 - 150 in-lb

• Torque wrench: 3/8" drive, 0 - 100 ft-lb

• Insulating canvases as required (2' x 2', 1' x 1', 3' x 3', etc.)

• Various insulated hand tools including:

- Combination wrenches - Ratchet and socket set

- Various screwdrivers. - Electricians knife

• Battery safety spill kit required for wet cells only:

- Protective clothing - Face shields

- Gloves - Baking soda

- Eye wash equipment

• Cutters and wire strippers (#14 to #22 AWG) [2.5 to 0.34 mm²]

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6.3 Power System Assembly and Mounting

6.3.1 Shelf Preparation/Mounting

NOTE:

Mount the shelf in a clean and dry environment. Allow at least 1.75” of free space in

front of the unit for unrestricted cooling airow. Sufcient free space must be provided

at the front and rear of the power system. This is to meet the cooling requirements of

the rectiers and to allow easy access to the power system components.

The 19” shelf has been designed for ﬂush mounting in a standard EIA relay rack. Options for mid-mounting in a 19” or 23” rack are also available. The 23” shelf can be ﬂush or mid-mounted in a 23” relay rack.

Mounting brackets accommodate either 1" or 1-3/4" rack spacing. Mount the shelf to the rack using at least two #12 – 24 x 1/2" screws in each bracket. Use Philips-type screws and screwdriver to eliminate the possibility of slippage and scratching of the unit’s exterior.

An electrical conducting path must exist between the shelf chassis and the metalwork of the enclosure in which it is mounted or a grounding conductor. This electrical continuity requirement can be met by the use of threadforming type unit mounting screws and star washers that remove any paint or non-conductive coatings and establish metal-to-metal contact.

6.3.2 Rack Mounted Systems

Attach the power system to the customer-provided relay rack using the mounting screws and star washers. Ensure a proper electrical bond between the system chassis and the relay rack.

6.3.3 Floor Mounted Systems

Secure the system to a concrete ﬂoor using either heavy duty anchors (½" x 2½"), or for wooden ﬂoors, heavyduty lag screws (5/8" x 2½"). Use appropriately sized ﬂat washers.

If required, use isolating kits to isolate system from the ﬂoor.

Secure the relay rack to the overhead cable tray. Alpha does not supply the mechanical details necessary for overhead support.

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7. Wiring

This chapter provides cabling details and notes on cable sizing for DC applications using the Cordex 48-3.6kW,

4.0kW and 12kW modular switched mode rectiﬁer systems.

Refer to the Safety section on page 5 for safety precautions.

WARNING!

Ensure that the power at the AC service panel is off is switched off. Remove battery line fuses or connections before attempting work on the wiring. Use a voltmeter to verify the absence of a voltage. Clearly mark the correct polarity of the battery leads before starting work on DC connections.

7.1 Grounding

This power system is suitable for installation as part of a Common Bonding Network (CBN) and is intended to be used in a DC-C conﬁguration (common DC return).

Connect the isolated power system battery return bus (BRB) to the building master ground bus (MGB), or ﬂoor ground bus (FGB) in a larger building. This acts as a system reference and as a low impedance path to the ground for surges, transients, noise, etc. The MGB or FGB must have a direct low impedance path to the building grounding system.

The cable from the power system to the MGB or FGB must be sized to provide sufﬁcient ampacity to clear the largest fuse or breaker on the power system, excluding the battery protection fuse or circuit breaker. 750 MCM is recommended. This is the minimum requirement. Other factors including the length of the cable and special grounding requirements of the load must also be factored in. The insulated cable must be equipped with twohole crimp type lugs and must not have any tight bends or kinks.

T able A — Typical ground reference conductor selection

Power system ampacity Ground reference conductor size

< 30A #10

30 – 100A #6-2

100 – 400A 0000

400 – 800A 350 MCM

> 800A 750 MCM

The power system frame must also be connected to the MGB or FGB. This is done for personnel safety and to meet many telecom grounding requirements. Each bay must have its own frame or site ground connection. Refer also to the customer connections drawing at the rear of the manual.

7.2 AC Feeder Protection/Sizing

To maximize system reliability, each power module should be fed from a dedicated protection feeder breaker located at the AC distribution panel. The feeder breaker can also act as the disconnect device for the connected module. Refer to the speciﬁcations for Alpha recommendations.

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7.3 AC Input Connections

CAUTION!

To minimize EMI disturbances, route the AC input wires in exible or rigid conduit and

located as far away as possible from the DC power wires.

WARNING!

Use care when removing or replacing the covers for the AC input connections. Never assume that an electrical connection or conductor is not energized.

1. Ensure that all modules are removed from the shelf.

2. Remove the covers (two places) from the rear of the shelf to expose the AC input terminal blocks, L1 and L2 for each rectiﬁer. (Refer to the customer connections drawing towards the end of the manual for AC terminal block location.) Each terminal pair corresponds to an individual power module as marked.

3. The wire way is designed for two customer-supplied, 1" conduit ﬁttings for the AC supplies located on each side of the shelf. Attach the conduit retainers to the wire way hole(s) and route the AC cables through them.

4. Secure the wires to the AC input and chassis ground terminals.

5. Tighten the cable connector to the AC cable (conduit similar).

6. Replace rear cover(s) once all connections have been completed.

7.4 DC Output Connections

WARNING!

Leave cables or bus bars disconnected at the battery and verify the output polarity using a voltmeter. Make battery connections only after all other wiring is completed.

The DC output wires must be UL approved XHHW or RHH/RHW (RW90 type for Canadian users). Control and sense wires must be UL approved Style 1015 (TEW type for Canadian users).

The common output leg of the rectiﬁer system must be connected to the ground. This is typically done at the load common termination point.

7.4.1 Cable

Terminate cable leads with appropriate crimp lugs for 3/8" holes on 1" centers.

Secure the positive and negative to the shelf output post of the correct polarity; i.e., +Vcable to +Vpost. Ensure the washers are on the bolts in the same order in which they were shipped from the factory. Tighten the bolts as per Customer Connections drawing at the rear of this manual.

7.4.2 Bus Bar

Do not complete the ﬁnal live connections to the battery. Leave open and insulate the ﬁnal connections or remove the battery fuses. Switch off the battery contacts if used. Refer to the system startup procedure before connecting the batteries online.

Bus bar adapters may be factory-installed, for the option selected, to easily accommodate direct connections to customers’ vertical bus bars.

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7.5 CAN Serial Ports (Rectiﬁer Shelf)

Two CAN Serial ports (modular jacks with offset latches), are provided for communications with Alpha’ Cordex rectiﬁers and other CAN-enabled equipment. These are located on the left side of the rectiﬁer shelf as viewed from the front.

Daisy-chain from shelf to shelf (CAN OUT of one shelf to CAN IN of another) and ensure that only the last shelf is terminated.

7.5.1 CAN Termination

A jumper, or switch depending on your conﬁguration, allows setting the CAN OUT to be open to the next shelf in the system or terminated. Termination must be enabled in ﬁnal shelf on the CAN bus only. Access the termination selection inside the shelf by removing the left most rectiﬁer #1 (MDL 1).

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Figure 5 — CAN termination selection and serial ports

7.6 Inserting the CXCM4 Module

NOTE:

Do not force a module into position if it does not seat properly. All modules are keyed to ensure that the correct module (voltage/polarity) type is used.

1. Insert by placing the controller on the shelf bottom and sliding the module into the CXCM4 connection interface (inside of the shelf, see drawing 747-271-08).

2. Apply pressure on the metal faceplate to engage the rear connectors.

3. Tighten the screw on the bottom of the faceplate to secure the module to the shelf.

7.7 Signal Wiring Connections for CXCM4

The CXCM4 (speciﬁcations 018-586-B1) requires an adapter for modular installation (drawing 747-271-08).

For terminal block connections, the recommended wire sizes are 0.823 to 0.129mm2 (#18 to #26 AWG) for the temperature range of 0 to 50 deg. C (as per UL/CSA).

CAUTION!

To reduce risk of re, use only 0.129 mm² (#26 AWG) or larger wire.

7.7.1 Relay Outputs

Terminals provide contacts for extending various alarm or control signals. Each relay output can be wired for NO or NC operation during an alarm or control condition (Figure 12).

Figure 6 — Relay connections in the de-energized state

Relays can be programmed to energize or de-energize during an alarm condition (see CXC Software manual). When the CXC reset button is pressed or power is lost, all relays de-energize.

System Fail Relay

The System Fail output relay (K0) is fail-safe and will de-energize during an alarm condition.

Low Voltage Disconnect (LVD) Control

The LVD control functions can be hard wired directly from the assigned relay output to an optional LVD override control and distribution alarm card. This safety measure protects against load disconnect during CXCM4 reset or replacement (see Section 10.3), e.g. when the controller is off-line. Operators can also perform test and maintenance procedures on the CXCM4 without disturbing the load. See the Controls Menu defaults in the CXC Software manual.

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7.7.2 Digital Inputs

The digital input channels are used to monitor various alarm and control signals. All input channels are voltage activated and accept a bipolar (negative or positive) DC signal directly.

Connection Method

Typical Alpha systems use the “reset with Hot and trigger with Ground” connection. The digital input is wired in such a way that the Hot is wired directly into one of the input terminals. For example, the positive input for +24 V systems. The other input terminal is wired to the Ground (common) of the system through a dry contact relay usually located on the equipment requiring monitoring. This method allows the digital input to receive or not receive a Ground signal on an alarm.

Figure 7 — Digital input connection method

Voltage level deﬁnitions for digital inputs

The digital input channels can be programmed for “active high” or “active low.” Active high indicates “alarm on the presence of a ground signal” and active low indicates “alarm on the removal of a ground signal.” See CXC Software manual for detailed instruction on programming.

Voltage Range (Vdc)

0 - 60

(system voltage setting)

Voltage Level (Vdc)

Considered As “0” (Off)

0 - 3 18 - 60

Voltage Level (Vdc)

Considered As “1” (On)

7.7.3 Analog Inputs

CAUTION!

Ensure the correct polarity is used for all input cable terminations.

The analog input channels are used to monitor various types of electrical signals. Some of the analog channels are reserved for speciﬁc signals, while others are designated as general-purpose inputs, which accommodate various types of analog signals.

The Battery -48V should be connected at the battery system voltage terminal for CXC reference when a battery disconnect device is used. It is critical to CXC operation as it ensures a source of power to the CXC should the disconnect device open the circuit.

Voltage

Voltage Input #1 (load voltage per CXC software) terminals (V1) on the shelf provide connections to an optional secondary voltage input. For example, this can be terminated to the load side of an LVD contactor to monitor load voltage.

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Voltage Input #2 (battery voltage per CXC software) is wired internally (V2) to the rectiﬁer output voltage of the shelf. This is used as the reference for system alarming (such as high voltage) and control (such as low voltage disconnect).

Temperature Sensing

Temperature Probe input channels provide connections for temperature sensors. A voltage is supplied to these terminals for sensor measurements.

Current

Current Input #1 (discharge or load current per CXC software) terminals (I1) are available for customer connection as required.

Current Input #2 (charge or battery current per CXC software) terminals (I2) are available for customer connection as required.

7.8 Network Connection and Remote Communications via CXC

The Cordex system can be set up, monitored and tested via an Ethernet 10/100 Base-T serial data connection. The communication protocol supports a web interface.

Some standard scenarios are described below:

7.8.1 Ethernet Port for Network Connection (Standard Network Cable)

The Ethernet port is designed for CXC connection to a user supplied network (TCP/IP secured by user) via a front panel RJ-45 jack. Connect to the Cordex shelf using a standard network cable.

7.8.2 Ethernet Port for Local Connection (Crossover Cable)

Local access (e.g. with a laptop computer) is available from the Ethernet port connection using a standard network crossover cable.

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8. System Startup

Visually inspect the installation thoroughly.

After completing the system installation and power system wiring, perform the following startup and test procedure to ensure proper operation:

8.1 Check System Connections

1. Make sure that the AC input power is switched off, the batteries are disconnected, and all the power modules are removed from the shelf.

2. Triple-check the polarity of all connections.

8.2 Verify AC and Power the Rectiﬁer Shelf

NOTE:

Insert the rst module into the front left most position using the side of the shelf (or the

optional shelf-mounted controller) as a guide. Subsequent modules can be inserted using the previous module as a guide.

Do not force a module into position if it does not seat properly. All modules are keyed to ensure that the correct module (voltage/polarity) type is used.

1. Install one power module.

a. Place the rectiﬁer module on the shelf bottom and slide the module into the rear connector (inside the

shelf).

b. Apply pressure on the module handle to engage the rear connector in the shelf receptacle.

c. Tighten the screw on the bottom of the faceplate to secure the module to the shelf.

2. Verify that the AC input voltage is correct and switch on the corresponding feeder breaker. The power module

3. Using the CXC, test the functionality of various module alarms and controls.

AC ON LED illuminates after a preset start delay. (See 3 .1.1 for a description of the LEDs.)

8.3 Triple Check Battery Polarity and Connections

1. Use a voltmeter to verify that the battery polarity is correct. Ensure that no cells or batteries are reversed.

2. Connect the batteries to the output of the system.

3. Install the remaining power modules.

4. In the adjustments menu of the CXC, set the ﬂoat and equalize voltages to the levels speciﬁed by the battery manufacturer.

5. Using the CXC, test the functionality of the various module alarms and controls. Perform a load test with the system using a resistive load box.

6. Enable the temperature compensation (temp comp) feature in the batteries menu. Program the settings for slope and breakpoints (upper and lower) according to the speciﬁc batteries used.

8.4 CXC Reset

The reset button located on the front panel of the optional CXC is used to restart the microprocessor. When pressed momentarily, the unit beeps twice then resets. The front-panel LEDs illuminate temporarily but extinguish after the system has ﬁnished its 15-second self-test.

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9. Rectifier States, Modes and Factory Defaults

9.1 Main Rectiﬁer States

The rectiﬁer operation can be broken up into ﬁve main states:

1. Off.

2. Start delay.

3. Soft start.

4. Normal operation.

5. Switching off.

Each state is characterized as being distinct and necessary for the operation of the rectiﬁer. These states are brieﬂy described below.

9.1.1 Off State

The rectiﬁer is in the Off state immediately after power is applied to the rectiﬁer or after a rectiﬁer shutdown. The shutdown source may be a remote or local shutdown, an AC shutdown, an OVP shutdown, or a thermal shutdown.

When the rectiﬁer is in the Off state, the DC-DC converter is switched off and the CXC is monitoring its inputs for the proper conditions to begin the start up sequence.

When the conditions have been met for start up, the rectiﬁer transitions to the Start Delay state.

9.1.2 Start Delay State

When the rectiﬁer is in the Start Delay state, the DC-DC converter is held off and not sourcing power. The rectiﬁer is waiting for a set time before transitioning to the next state.

When the rectiﬁer is in the Start Delay state, the CXC continues to monitor its inputs.

After the Start Delay state, the rectiﬁer transitions to the Soft Start state.

9.1.3 Soft Start State

When the rectiﬁer is in the Soft Start state, it is switched on. The output voltage and output current are gradually increased. If a load is present, the rectiﬁer begins to source power. This gradual increase reduces the instantaneous load on the AC source.

When the voltage and current limit ramp ups have ﬁnished, the rectiﬁer transitions to the Normal Operation state.

9.1.4 Normal Operation State

During the Normal Operation state, the rectiﬁer performs all of the rectiﬁer functions and features.

From the Normal Operation state, the only valid transition is to the Switching Off state. This transition happens if the rectiﬁer is required to shut down.

9.1.5 Switching Off State

The Switching Off state is entered because a short delay is required before the rectiﬁer actually switches off. The short delay takes care of any initialization requirements.

When this short delay has elapsed, the rectiﬁer transitions to the Off state.

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9.2 Main Rectiﬁer Modes

In addition to the main rectiﬁer states, there is a set of main rectiﬁer modes. These modes can be divided into two categories, the output voltage mode and the output current/power mode.

9.2.1 Output Voltage Modes

Voltage modes can be thought of as modes that, under software control, can directly adjust the output voltage. The qualiﬁcation of “under software control” is made because there are processes that occur in the rectiﬁer that can change the output voltage that do not adjust the output voltage directly, for example, if the rectiﬁer has reached the current limit.

Table B lists four output voltage modes and a description of when they are active.

Table B — Output voltage modes

Output Voltage Modes Active when…

Float Output voltage is set to the oat voltage setting.

Equalize Output voltage is set to the equalize voltage setting.

Battery Test Output voltage is set to the battery test voltage setting.

Safe Output voltage is set to the safe mode voltage setting.

9.2.2 Output Current/Power Modes

These modes directly affect the output current and power. Table C lists the four output current/power modes and a description of when they are active.

Table C — Output current/power modes

Output Voltage Modes Active when…

Temperature foldback mode

AC foldback mode

Short circuit foldback mode Output current limit has been reduced due to a short circuit at the output.

Internal fault foldback mode Output current limit has been reduced due to an internal fault.

Output current and power limit have been reduced because a high temperature has been detected on the heatsink or internal ambient temperature sensor.

Output current and power limits have been reduced because the AC input voltage is low. This will reduce the risk of tripping an AC breaker due to increased AC current draw as the AC voltage decreases.

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9.3 Factory Ranges and Defaults

Table D shows the rectiﬁer settings/ranges/defaults. Changes are made through the CXC interface.

Table D — Rectier factory ranges and defaults

Setting Range (minimum to maximum) Default

Float (FL) Voltage 47.5 – 58.2 V 54 V

Equalize (EQ) Voltage 49.8 – 60.2 V 55 V

Battery Test (BT) Voltage 44 – 52 V 46 V

Over Voltage Protection (OVP)* 63 V 57 V

Current Limit (CL) 23 – 100% 100%

Power Limit (PL) 0 – 100% 100%

Module Start Delay 0 – 250 s 1 s

System Start Delay 0 – 600 s 0 s

Low Voltage Alarm (LVA) 42 – 52 V 44 V

High Voltage Alarm (HVA) 52 – 63 V 55.5 V

EQ Timeout 1 – 2399 h 30 h

BT Timeout 1 – 250 h 8 h

Softstart Ramp-rate Normal/Fast Normal

CL/PL Alarm Enable/Disable Enable

Remote Shutdown Enable/Disable Enable

Ramp Test Enable/Disable Enable

*The OVP cannot be set below the present system/FL/EQ/BT voltage setting or the safe mode voltage of 51.0 V.

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10. Maintenance

Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualiﬁed service personnel should do the repairs.

The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year.

WARNING!

Use extreme care when working inside the unit while the system is energized. Do not make contact with live components or parts.

Circuit cards, including RAM chips, can be damaged by static electricity. Always wear a grounded wrist strap when handling or installing circuit cards.

Ensure redundant modules or batteries are used to eliminate the threat of service interruptions while performing maintenance on the system’s alarms and control settings.

Table E — Sample maintenance log

Procedure Date Completed

Clean ventilation openings.

Inspect all system connections. Re-torque if necessary.

Verify alarm/control settings.

Verify alarm relay operation.

10.2 Replacing a Rectiﬁer Module

The Cordex Converter (CXD) Rectiﬁer (CXR) series modules are plug and play. When a rectiﬁer module is added to the system, the CXC will detect and update the inventory automatically. Replacing an installed rectiﬁer requires a manual Inventory Update at the controller to clear the removed rectiﬁer from its current list of rectiﬁers.

1. To remove a module, loosen the screw on the bottom of the faceplate. Grasp the handle and pull it out, sliding the module away from the rear connector and out of the shelf.

2. At the controller LCD initiate an Inventory Update as follows (or Main Menu > Rectiﬁers > Inventory Update for the web interface):

Tap the Rectier icon on the controller home page.

Tap Inventory Update.

A pop-up window appears with a progress bar showing the number of modules acquired during the update.

FL + TC

Inventory Update

Rectier Report

Converter Report

54.00V

250A

nventory Update clears the current list of rectiers and re-acquires all connected modules.

3. Place the new rectiﬁer module on the shelf bottom and slide the module into the rear connector (inside the shelf). Apply pressure on the module handle to engage the rear connector in the shelf receptacle.

4. Tighten the screw on the bottom of the faceplate to secure the module to the shelf.

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10.3 Replacing the CXCM4 Module

WARNING!

Before removing a CXCM4 from a live system, an external LVD override is required to avoid a disruption of service.

Figure 8 — LVD override control and distribution alarm card

The LVD Control functions can be hardwired directly from the assigned relay output to an optional LVD override control and distribution alarm card (707-307-20).

1. Place the LVD Control switch to the OVERRIDE IN position to keep the LVD contactor engaged.

2. To remove a module, loosen the screw on the bottom of the faceplate. Slide the module away from the rear connectors and out of the shelf.

3. Place the new controller on the shelf bottom and slide the module into the CXCM4 connection interface (inside of the shelf, see drawing 747-271-08). Do not force the module into position if it does not seat properly. All modules are keyed to ensure that the correct module (voltage/polarity) type is used.

4. Apply pressure on the metal faceplate to engage the rear connectors.

5. Tighten the screw on the bottom of the faceplate to secure the module to the shelf.

WARNING! Do not leave the switch in the OVERRIDE IN position. Doing so may result in a complete

discharge of the batteries during a power failure.

6. To allow the CXC to resume automatic control of the LVD contactor, check that the green AUTO IN LED is

illuminated conﬁrming that the CXC will keep the LVD contactor engaged.

7. Switch the LVD control switch back to the AUTO IN position.

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10.4 Fan and Fan Filter Replacement

10.4.1 4.0kW Rectiﬁer Fan and Filter Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement fan assembly and ﬁlter.

Top screw (1)

Front panel

Side screws (2)

1. Switch off the unit and unscrew the front fastener that secures the power module to the shelf.

2. Slide the module 10 cm (4") out of the shelf and wait ten minutes for the module capacitors to discharge.

3. Remove the three screws that secure the front panel to the module chassis. Slide the front panel out.

Fan cables

Fan cable connector

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4. Disconnect the fan cables from the module by pulling out the fan cable connector.

5. Remove the two screws that secure the fan to the front panel.

6. Note the direction of the airﬂow and remove the fan from the front panel.

7. Inspect the fan ﬁlter and replace if necessary.

Fan screws

Figure 9 — 4kW rectifier fan removal

Figure 10 — 4kW rectifier fan filter removal

8. Install the replacement fan following the preceding steps in reverse order.

Filter

Screen

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10.4.2 12kW Rectiﬁer Fan Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement fan.

1. Switch off the unit and unscrew the front fastener that secures the power module to the shelf.

2. Remove the eight screws shown in Fig u re 11

Bottom screws (3)

Top screws (3)

Side screw (1)

Figure 11 — Fan assembly - screw removal

3. Disconnect the fan cables and remove the fan assembly from the rectiﬁer.

Side screw (1)

Figure 12 — Fan assembly

4. Remove the two screws that secure the failed fan to the panel.

5. Note the direction of the airﬂow and remove the fan.

6. Inspect the fan ﬁlter and replace if necessary.- see Figure 10

7. Install the replacement fans following the preceding steps in reverse order.

9400000-J0 Rev C

10.4.3 3.6kW Rectiﬁer Fan or Filter Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement fan.

1. Shut off the unit and unscrew the front fastener that secures the power module to the shelf.

2. Slide the module 10 cm (4") out of the shelf and wait two minutes for module capacitors to discharge.

3. Remove the four screws (two each side) that secure the front panel to the module chassis.

4. Slide the front panel out.

5. Disconnect the fan power lead wires (one set per fan) and front panel ribbon cable from the module.

6. Remove the screws that secure the fans to the front panel.

7. Note the direction of airﬂow and remove the fans (or ﬁlters) from the front panel.

8. Install the replacement fans (or ﬁlters) following the preceding steps in reverse order.

9400000-J0 Rev C

10.5 MOV Replacement

10.5.1 4.0kW Rectiﬁer MOV Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement MOV.

The MOVs (metal oxide varistor) are used to protect the power modules from power line surges and surges caused by lightning strikes. High capacity surges may permanently damage MOVs but they are easily replaced in the ﬁeld using the following procedure:

1. Shut off the unit and unscrew the front fastener that secures the power module to the shelf.

2. Slide the module 10 cm (4") out of the shelf and wait ten minutes for the module capacitors to discharge.

Back panel screws

Back panel

3. Remove the two screws that secure the back panel to the module.

MOVs

MOV PCB

9400000-J0 Rev C

4. Remove the cover and ﬁnd the MOV printed circuit board (PCB).

Insulating mat

MOV PCB screws

5. Fold the insulating mat out of the way and remove the three screws that secure the MOV PCB to the module.

MOV PCB

6. Remove the MOV PCB.

7. Decontaminate the area and unit with a ﬂux remover or similar cleaning compound. This is done to remove any metallic particles or carbon that may have been deposited when the MOV failed.

8. Install the replacement MOV PCB following the preceding steps in reverse order.

9400000-J0 Rev C

10.5.2 12kW Rectiﬁer MOV Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement MOV.

1. Shut off the unit and unscrew the front fastener that secures the 12kW power module to the shelf.

2. Slide the module out of the shelf and wait ten minutes for the module capacitors to discharge.

3. Remove the six screws that secure the back panel to the module.

4. Slide the back panel downwards to release it from the top of the chassis.

1 screw

5. Unscrew and remove the defective MOV board.

1 screw

4 screws

MOV PCBs

6. Decontaminate the area and unit with a ﬂux remover or similar cleaning compound. This is done to remove any metallic particles or carbon that may have been deposited when the MOV failed.

7. Install the replacement MOV PCB following the preceding steps in reverse order.

9400000-J0 Rev C

10.5.3 3.6kW Rectiﬁer MOV Replacement

Refer to "2.3 Part Numbers and List Options" on page 8 for the part number of the replacement MOV.

The MOVs (metal oxide varistor) are used to protect the power modules from power line surges and the surges caused by lightning strikes. High capacity surges may permanently damage MOVs but they are easily replaced in the ﬁeld using the following procedure:

1. Shut off the unit and unscrew the front fastener that secures the power module to the shelf.

2. Slide the module 10 cm (4") out of the shelf and wait two minutes for module capacitors to discharge.

3. Turn the module around to face the back of the unit and remove the one screw (module bottom toward the rear) securing the MOV cover.

4. Remove the cover and locate the MOV printed circuit board (PCB).

5. Remove the three screws that secure the MOV PCB.

6. Decontaminate the area and unit with ﬂux remover or a similar cleaning compound. This is to remove any metallic particles or carbon, which may have been deposited when the MOV failed.

7. Install the replacement MOV PCB following the preceding steps in reverse order.

9400000-J0 Rev C

11. Acronyms and Definitions

AC Alternating current ANSI American National Standards Institute AWG American Wire Gauge

BTU British thermal unit CAN Controller area network CEC Canadian Electrical Code

CSA Canadian Standards Association

CX Cordex™ series; e.g., CXC for Cordex System Controller DC Direct current

DHCP Dynamic Host Conguration Protocol

EIA Electronic Industries Alliance

EMC Electromagnetic compatibility

EMI Electromagnetic interference

ERM Electromagnetic Compatibility and Radio Spectrum Matters

ESD Electrostatic Discharge FCC Federal Communications Commission (for the USA) GSM Group Speciale Mobile (global system for mobile communications)

HVSD High voltage shutdown

IEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics Engineers

IP Internet Protocol LED Light emitting diode LVD Low voltage disconnect

MIL One thousandth of an inch; used in expressing wire cross sectional area

MOV Metal oxide varistor

MTBF Mean time between failures

NC Normally closed

NEC National Electrical Code (for the USA)

NO Normally open

OSHA Occupational Safety & Health Administration

OVP Over voltage protection RAM Random access memory

RU Rack unit (1.75”)

TCP/IP Transmission Control Protocol / Internet Protocol

THD Total harmonic distortion

UL Underwriters Laboratories

VRLA Valve regulated lead acid

9400000-J0 Rev C

12. Warranty and Service Information

12.1 Technical Support

Free Technical Support 24/7/365 is part of the Alpha customer satisfaction commitment. The phone numbers below can also be used to access a wide range of service solutions both at your premise and at the Alpha facility nearest you.

In Canada and the USA, call toll free 1-888-462-7487 24 hours a day, seven days a week. Customers outside Canada and the USA, call +1-604-436-5547.

12.2 Warranty

Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized location during the warranty period. There are limitations to this warranty coverage. The warranty does not provide to the customer or other parties any remedies other than the above. It does not provide coverage for any loss of proﬁts, loss of use, costs for removal or installation of defective equipment, damages or consequential damages based upon equipment failure during or after the warranty period. No other obligations are expressed or implied. Warranty also does not cover damage or equipment failure due to cause(s) external to the unit including, but not limited to, environmental conditions, water damage, power surges or any other external inﬂuence.

The customer is responsible for all shipping and handling charges. Where products are covered under warranty Alpha will pay the cost of shipping the repaired or replacement unit back to the customer.

12.3 Battery Warranty

Note that battery warranty terms and conditions vary by battery and by intended use. The most common battery warranty provided by Alpha is a two year full replacement warranty with a pro-rated warranty for the following three years. Pro rated warranty provides a credit applicable toward the purchase of new batteries from Alpha. The credit is calculated as the purchase price multiplied by the percentage of the battery life that was not available (in months). Battery warranty coverage is lost where the battery charge is not maintained for 6 months. Contact your Alpha sales representative or the Technical Support team at the above number to understand your entitlements under Battery Warranty.

12.4 Return of Material

Please contact Technical Support at the number above to obtain a Service Repair Order (or Return Material Authorization) number BEFORE sending material back. This will ensure that your service needs are handled promptly and efﬁciently.

For more service and warranty information, visit the Alpha website:

http://www.alpha.ca

9400000-J0 Rev C

Specifications for Alpha Sw it c he d Mode Rect ifier Cordex 48-4kW

Power Module Output

Voltage: 44 to 60 Vdc within ra t ed li mits Current: 74 A @ 54 Vdc nominal (83 A maximum @ 48 V) Maximum Power: 4000 W continuous/module Static Load Regulation: Better than ±0.5% 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 10 ms) Static Line Regulation: Better than ±0.1% for any change in input voltage within rated limits Hold-up Time: >10 ms Time Stability: ≤ 0.5% per year Temperature Stability: < 300 ppm/°C over the operating range Heat Dissipation: < 1415 BTU per hour Electrical Noise: < 38 dBrnC (voice band)

< 20 mVrms 10 kHz to 10 MHz (wideband)

< 150 mVp-p 10 kHz to 100 MHz

< 2 mV (psophometric) Acoustic Noise: < 60 dBa @ 1 m (3 ft) @ 30°C (86°F) EMI: The unit meets requirements of EN55022 (see Standards for more EMC)

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

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

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

To comply with regulations in terms of radiated emissions, the CAN communication cable shall be wound in 3 loops around a ferrite p/n 417-401-10/19 (Fair-Rite p/n 0443167251), placed close to the socket in the shelf.

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

AlphaTechno logies Ltd. 010-623-B1 Rev E

Specifications for Alpha Switched Mode Rectifier Cordex 4kW

Power Module Input

Voltage: 208, 220, 230, 240, 277 Vac nominal Operational Range: 187 to 320 Vac Extended Operation: Low: 187 to 90 Vac (derated power) Frequency: 45 to 66 Hz Current: 17.5 A @ 240 Vac

21.5 A @ 208 Vac

23.5 A @ 176 Vac (maximum)

Recommended Feeder Breaker Single Phase: 30 A, #10 AWG Three Phase: 50 A, #6 AWG delta connection

30 A, #10 AWG wye connection Power Factor: > 0.99 at nominal conditions and 50-100% load Protection: 10 kA-interrupting capacit y fuses in active and neutral l ines Efficiency: > 94% at nominal conditions and 25-75% load

> 92.5% at nominal conditions and 100% load Inrush Current: ≤ full load steady state current Start-up Ready Time: < 5 seconds (excluding soft start) Start-up Delay: ≤ 120 seconds (programmable) Soft Start: ≤ 10 seconds (user adjustable, not including start-up)

Input Transient Suppression: Meets ANSI/IEEE C62.41 Category B3 Input Leakage Current: < 3.5 mA @ 265 Vac 60 Hz

Environmental

Operating Temperature: -40 to +75°C, power derated above 55°C (131°F)

(-40 to 167°F) Storage Temperature: -40 to +85°C

(-40 to 185°F) Humidity: 0 to 95% non-condensing Elevation: -500 m to 2800 m; to 4000 m with temperature derated to 40°C

(-1640 feet to 9186 feet; to 13124 feet with temperature derated to 104°F)

Miscellaneous

MTBF: > 479,000 hours ground benign @ 30°C (86°F) Dimensions (in) W3.4 x H6.3 x D13 (W3.4 x H7 x D13 including front panel)

Dimensions (mm) W87 x H160 x D330 (W87 x H177 x D331 including front panel)

Alpha Technol ogies Ltd. 010-623-B1 Rev E

Specifications for Alpha Switched Mode Rectifier Cordex 4kW

Weight: Module: 3.9 kg (8.6 lb)

23" Shelf: 14.5 kg (32 lb)

19" Shelf: 12.7 kg (28 lb)

Safety

EN 60950-1: 2006 Rectifier output shall be rated SELV suitable for connection to TNV-1 circuits UL 60950-1: 2

Ed. CSA C22.2 No. 60950-1-07 CE EN 60950-1: 2006 CB Scheme

2006/95/EC Low Voltage Directive

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 Suppl y Interfac e at the Input to Telec om munications Equipment; Operated

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

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.

Equipment (UL/CSA 60950)

Alpha Technol ogies Ltd. 010-623-B1 Rev E

Specifications for Alpha Sw it c he d Mode Rect ifier Cordex 48-12kW