Alpha CXRF 48-12kW User Manual
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 Rectier 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
Copyright
Copyright © 2012 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the proprietary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies assumes no liability resulting from errors or omissions in this document, or from the use of the information
contained herein. Alpha Technologies reserves the right to make changes in the product design without reservation and without notification to its users.
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. Rectier Features................................................................................................................10
3.1 Front Panel .............................................................................................................................. 10
3.2 Rectier 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 Rectier Report from Controller Display .................................................................................. 16
4.4 Analog Input Channels ............................................................................................................. 16
4.5 Digital Input Channels .............................................................................................................. 17
2
9400000-J0 Rev C
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 (Rectier 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 Rectier Shelf ................................................................................... 27
8.3 Triple Check Battery Polarity and Connections ........................................................................ 27
8.4 CXC Reset ............................................................................................................................... 27
9. Rectier States, Modes and Factory Defaults.....................................................................28
9.1 Main Rectier States ................................................................................................................ 28
9.2 Main Rectier Modes ............................................................................................................... 29
9.3 Factory Ranges and Defaults .................................................................................................. 30
10. Maintenance .....................................................................................................................31
10.2 Replacing a Rectier Module ................................................................................................. 31
10.3 Replacing the CXCM4 Module ............................................................................................... 32
9400000-J0 Rev C
3
10.4 Fan and Fan Filter Replacement ........................................................................................... 33
10.5 MOV Replacement ................................................................................................................. 37
11. Acronyms and Denitions ..................................................................................................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 rectier 7
Figure 2 — Rectier front panel LEDs ............................................................................................ 10
Figure 3 — Cordex CXCM4 model system controller front panel ................................................... 14
Figure 4 — Rectier (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 rectier fan removal ............................................................................................. 34
Figure 10 — 4kW rectier fan lter removal .................................................................................... 34
Figure 11 — Fan assembly - screw removal ................................................................................... 35
Figure 12 — Fan assembly ............................................................................................................. 35
4
9400000-J0 Rev C
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 specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic 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.
9400000-J0 Rev C
5
1.4 Electrical Safety
WARNING!
Hazardous voltages are present at the input of power systems. The DC output from rec-
tiers 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.
6
9400000-J0 Rev C
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
9400000-J0 Rev C
(b)
(c)
7
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 rectier 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 rectier 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 rectier 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
8
9400000-J0 Rev C
Description List Option
Kydex rear cover List 89
Module blank List 90
CXCM4 Cordex Controller, Modular, 4RU, takes the space of one rectier (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 conguration: two voltage, four temperature, two current, no bi-voltage List 121
Analog input conguration: 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
9400000-J0 Rev C
9
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
LEDs
1 2 3
3.6kW
1 2 3
LEDs
Thumbscrew
LEDs
1 2 3
4kW
LEDs
1 2 3
10
Thumbscrews
Figure 2 — Rectifier front panel LEDs
9400000-J0 Rev C
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.
9400000-J0 Rev C
11
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.
12
9400000-J0 Rev C
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.
9400000-J0 Rev C
13
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
14
Figure 3 — Cordex CXCM4 model system controller front panel
9400000-J0 Rev C
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.
9400000-J0 Rev C
15
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.
16
9400000-J0 Rev C
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.
9400000-J0 Rev C
17
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.
18
9400000-J0 Rev C
Loading...