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Alpha Technologies Cordex HP Installation And Operation Manual

2.4kw switched mode rectifier system, shelf models: 19" / 23" 1ru universal mount 9600w / 12000w
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Download this manual See also: Operation & Installation Manual
Cordex HP 2.4kW Switched Mode Rectifier Sys tem
Shelf Models: 19" 1RU universal mount 9600W
23" 1RU universal mount 12000W
Installation and Operation Manual
Part # 0100003-J0
Effective 11/2015
Your Power Solutions Partner
member of The
Group
™

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Summary of Contents for Alpha Technologies Cordex HP

  • Page 1 Cordex HP 2.4kW Switched Mode Rectifier Sys tem Shelf Models: 19" 1RU universal mount 9600W 23" 1RU universal mount 12000W Installation and Operation Manual Part # 0100003-J0 Effective 11/2015 Your Power Solutions Partner member of The Group ™...
  • Page 3 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Copyright Copyright © 2015 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo- gies. No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or trans- mitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or other- wise without prior explicit written permission from Alpha Technologies.

  • Page 4: Table Of Contents

    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 ........................
  • Page 5 7. System Startup ........................25 7.1 Check System Connections ..................... 25 7.2 Verify AC and Power the Rectifier Shelf ................... 25 7.3 Check Battery Polarity and Connections ................. 25 8. Rectifier Modes and Factory Defaults .................26 8.1 Rectifier Modes ........................26 8.2 Factory Ranges and Defaults ....................
  • Page 6 List of Figures Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectifier Shelf, (b) Typical 48V Power Systems with 2.4kW Rectifiers ........................7 Figure 2 — Rectifier Front Panel LEDs ....................11 Figure 3 — Locking Handle Disengaged/Engaged ................. 13 Figure 4 — 23" or 19" Shelf with Bulk Distribution Busbars ............14 Figure 5 —...

  • Page 7: Safety

    If there are any questions regard- ing the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representa- tive. Save this document for future reference.

  • Page 8: Electrical Safety

    1.4 Electrical Safety WARNING! Hazardous voltages are present at the input of power systems. The DC output from rec- tifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing. •...

  • Page 9: Introduction

    LCD display with front Ethernet and USB connectors, is available as a panel mount controller or as part of the CXPS-E3 system. CXPS-E3 Modular Distribution Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectifier Shelf, (b) Typical 48V Power Systems with 2.4kW Rectifiers 0100003-J0 Rev B...

  • Page 10: Part Numbers And List Options

    List Option 23in 1RU universal mount 12000W shelf* 0300057-001 – bulk power for external distribution – up to five Cordex HP 2.4kW rectifiers 19in 1RU universal mount 9600W shelf* 0300040-001 – bulk power for external distribution – up to four Cordex HP 2.4kW rectifiers...

  • Page 11: Specifications

    2.4 Specifications 2.4.1 2.4kW Rectifier Electrical Input voltage: Nominal: 120 to 277Vac Operating: 90 to 310Vac Extended: 90 to 187Vac (de-rated power) Input frequency: 44 to 66Hz Power: 2400W continuous (1200W output @ 120Vac Input) Power Factor: >0.99 (50 to 100% load) THD: <5% Efficiency:...
  • Page 12 2.4.2 Cordex 48-2.4kW Rectifier Shelves 23in 1RU universal mount 12,000W shelf P/N 0300057-001 Number of Rectifiers: 5 x CXRF HP 48-2.4kW Nominal AC input current (two 120VAC/23A (per feed), 50/60Hz modules per feed): 208-277VAC/25A (per feed), 50/60Hz Recommended input feeder breakers 40A per feed for nominal 120, 208, 240, 277 Vac (three feeds per shelf): 40A per feed for extended 90 to 108 Vac...

  • Page 13: Product Features

    3. Product Features 3.1 Rectifier 3.1.1 Front Panel LEDs The front panel LEDs indicate the rectifier status summary and patterned response to Locate Module command. LEDs Figure 2 — Rectifier Front Panel LEDs ALARM / FAULT (1) The red LED is on during an active Module Fail alarm if the module is unable to source power due to a fault con- dition.
  • Page 14 3.1.2 Rectifier Rear Panel Refer to drawings 0300057-08 and 0300040-08 at the end of this manual for shelf power and communications connections. 3.1.3 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.

  • Page 15: Figure 3 - Locking Handle Disengaged/Engaged

    3.1.9 Start Delay The rectifier modules are equipped with a delay timer to stagger-start a series of modules. When multiple mod- ules and multiple shelves, part of a larger system are used in conjunction with a controller, a start delay prevents all rectifiers from starting at the same time and causing an inrush on the utility.

  • Page 16: Distribution

    3.2 Distribution 3.2.1 Bulk • 23in 1RU universal mount 12,000W P/N 0300057-001 • 19in 1RU universal mount 9,600W P/N 0300040-001 Figure 4 — 23" or 19" Shelf with Bulk Distribution Busbars 3.2.2 Separate feed In/ Out • 19in 1RU universal mount 9,600W P/N 0300040-002 Figure 5 —...

  • Page 17: Controller

    3.3 Controller The 2.4kW rectifier shelf is designed to operate with the CXCR/CXCP controller (panel/rack) or the CXC HP con- troller. A controller adds the following capabilities to the rectifiers: • Local and remote communications and monitoring • User definable alarms •...

  • Page 18: Inspection

    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.

  • Page 19: Installation

    5. 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 inacces- sible 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.

  • Page 20: Power System Assembly And Mounting

    5.3 Power System Assembly and Mounting 5.3.1 Mounting and Grounding a Rectifier Shelf 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 airflow. Sufficient free space must be provided at the front and rear of the power system.

  • Page 21: Wiring

    6. Wiring This chapter provides cabling details and notes on cable sizing for DC applications using the Cordex HP 2.4kW 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 switched off. Remove battery in line fuses or connections before attempting work on the wiring.

  • Page 22: Can Serial Ports (Rectifier Shelf)

    6.2 CAN Serial Ports (Rectifier Shelf) Two CAN Serial ports (modular jacks), are provided for communications with Alpha Cordex controllers and other CAN-enabled equipment. These are located on the left side of the rectifier shelf as viewed from the front. 1.

  • Page 23: Ac Wiring 23" Shelf

    6.3 AC Wiring 23" Shelf 6.3.1 AC Feeder Protection/Sizing To maximize system reliability, each feed should have a dedicated protection feeder breaker located at the AC distribution panel. The feeder breaker can also act as the disconnect device for the connected modules. Refer to section "2.4.2 Cordex 48-2.4kW Rectifier Shelves"...

  • Page 24: Ac Wiring 19" Shelf

    6.4 AC Wiring 19" Shelf For the 19" shelf, AC wiring is fed separately to each of the four rectifiers. 6.4.1 AC Feeder Protection/Sizing To maximize system reliability it is recommended that, each power module be fed from a dedicated protection feeder breaker located at the AC distribution panel.

  • Page 25: Dc Output Connections - Bulk Distribution

    6.5 DC Output Connections - Bulk Distribution WARNING! 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. 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).

  • Page 26: Dc Output Connections - Single Component Distribution

    6.6 DC Output Connections - Single Component Distribution WARNING! 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. 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).

  • Page 27: System Startup

    7. System Startup Visually inspect the installation thoroughly. After completing the system installation and power system wiring, perform the following startup and test proce- dure to ensure proper operation: 7.1 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.

  • Page 28: Rectifier Modes And Factory Defaults

    8. Rectifier Modes and Factory Defaults 8.1 Rectifier Modes There are two main rectifier modes: output voltage mode and the output current/power mode. 8.1.1 Output Voltage Modes Voltage modes are under software control, and can be used to directly adjust the output voltage. The qualifica- tion of “under software control”...

  • Page 29: Factory Ranges And Defaults

    8.2 Factory Ranges and Defaults Table D shows the rectifier settings/ranges/defaults. Changes are made through the CXC interface. Table D — Rectifier factory ranges and defaults (TBD) Setting Range (minimum to maximum) Default Float (FL) Voltage 47.5 – 58.2 V 54 V Equalize (EQ) Voltage 49.8 –...

  • Page 30: Maintenance

    9. Maintenance Although very little maintenance is required with Alpha systems, routine checks and adjustments are recom- mended 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.

  • Page 31: Replacing A Rectifier Module Via The Cxc Hp Controller

    9.3 Replacing a Rectifier Module via the CXC HP Controller When a rectifier is permanently removed, the system generates a Rectifier Comms Lost alarm. That alarm is cleared by removing the rectifier from the system inventory. To remove the rectifier from the system inventory do the following: 1.

  • Page 32: Fan Replacement

    9.4 Fan Replacement The fan assembly part number is 7400374-001. The Fan on the individual rectifiers is designed for very high reli- ability and long life. During year 6 of the life of the product the manufacturer recommends replacement of the fan assembly.

  • Page 33: Figure 13 - 2.4Kw Rectifier Fan Assembly

    4. Disconnect the fan cables from the module by pulling out the fan cable connector. 5. Discard the old fan assembly and unpack the new replacement assembly. Fan cable Figure 13 — 2.4kW Rectifier Fan Assembly 6. Reconnect the fan cable. Insert the connector into the fan connector in the module. Ensure proper polarity and that the wires stay clear of the fan blade.

  • Page 34: Troubleshooting

    10. Troubleshooting The rectifiers and the shelves are designed for simple installation and reliable, trouble-free operation for several years. In most cases the rectifiers will recover from minor alarms and faults automatically. However under certain condi- tions the rectifiers may need remote control. And under very rare cases the rectifier may need a manual reset (unplug and reinsert the rectifier).

  • Page 35: Acronyms And Definitions

    11. Acronyms and Definitions Alternating current ANSI American National Standards Institute American Wire Gauge British thermal unit Controller area network Canadian Electrical Code Canadian Standards Association Cordex™ series; e.g., CXC for Cordex System Controller Direct current Electronic Industries Alliance Electromagnetic compatibility Electromagnetic interference Electromagnetic Compatibility and Radio Spectrum Matters Electrostatic Discharge...

  • Page 36: Warranty Statement And Service Information

    12. Warranty Statement and Service Information 12.1 Technical Support In Canada and the USA, call toll free 1-888-462-7487 Customers outside Canada and the USA, call +1-604-436-5547. 12.2 Warranty Statement For full information details review Alpha's online Warranty Statement at http://www.alpha.ca/warranty. 12.3 Product Warranty Alpha warrants that for a period of two (2) years from the date of shipment its products shall be free from defects under normal authorized use consistent with the product specifications and Alpha’s instructions, the terms of the...
  • Page 37 13. Certification About CSA and NRTL CSA (Canadian Standards Association also known as CSA International) was established in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health Administration) in the United States of America (Docket No.
  • Page 38 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF SCALE: 1 : 2 0.040 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE X.XX 0.020 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XXX 0.010...
  • Page 39 6.10 536.70 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE 565.38 DIM ARE IN MM CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE 0.20 COPIED OR USED WITHOUT ITS WRITTEN CONSENT 584.43 X.XX 0.10 APPROVALS DATE...
  • Page 40 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DETAIL B DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF 0.040 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE SCALE: 1 : 2 X.XX 0.020 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XXX 0.010...
  • Page 41 DO NOT SCALE DRAWING SLOT 4 SLOT 3 SLOT 2 SLOT 1 PROTECTIVE EARTH TERMINAL 2 PLACES. CHASSIS GROUND 2-HOLE LUG 1/4" ON 5/8" CENTERS. NEGATIVE (-) OUTPUT TERMINAL POSITIVE (+) OUTPUT TERMINAL NEGATIVE (-) OUTPUT TERMINAL RJ12, CAN 1 POSITIVE (+) OUTPUT TERMINAL RJ12, CAN 2 NEGATIVE (-) OUTPUT TERMINAL...
  • Page 42 37.85 6.10 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN MM CONFIDENTIAL, REMAIN THE PROPERTY OF 435.10 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE 0.20 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XX 0.10 APPROVALS DATE ANGULAR:...
  • Page 43 43.94 37.85 6.10 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE X.XX 0.20 COPIED OR USED WITHOUT ITS WRITTEN CONSENT 435.10 X.XXX 0.10 ANGULAR:...
  • Page 45 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Visit us at www.alpha.ca Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. Copyright © 2015 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

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