Related Manuals for Alpha Technologies CXPS-HX 48–2500
Summary of Contents for Alpha Technologies CXPS-HX 48–2500
- Page 1 CXPS-HX 48–2500 Distributed Power System Installation & Operation Manual Part # 0913000-J0 Effective: 03/2016 Your Power Solutions Partner member of The Group ™...
- Page 3 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Copyright Copyright © 2016 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies Ltd. No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmit- ted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies.
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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 ............... 7 2.1 Product Overview 2.2 Part Numbers and List Options ....................7 3. ... - Page 5 7. Installation - AC, DC and Grounding Cables...............31 7.1 Installation Notes ........................31 7.2 Connecting the Frame and Reference Grounds ..............33 7.3 AC Supply for the Rectifiers ..................... 34 7.4 Distribution ..........................36 7.5 DC Connections ........................37 8. System Startup ........................42 8.1 Check System Connections ..................... 42 8.2 ...
- Page 6 List of Figures Figure 1 — CXPS-HX Distributed Power System ................7 Figure 3 — 4.0kW Rectifier Front panel LEDs ................12 Figure 2 — 12kW/480 (3-phase) Rectifier front panel LEDs ............12 Figure 4 — Example of distribution panels ..................13 Figure 5 — Distribution shunts ......................14 Figure 6 — CXCP controller mounted in the power section ............15 Figure 7 —...
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Page 7: Safety
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 refer- ence. -
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
2. Introduction 2.1 Product Overview The CXPS-HX System (Figure 1) provides high capacity DC power for large communication network applications. This system combines the capabilities of tiered distribution, advanced microprocessor based supervision, and modular rectifiers in a single integrated bay. Two bays can easily be linked together and share a central controller to double the system capacity. -
Page 10: Specifications
3. Specifications Table A — Specifications for CXPS-HX 48–2000/2500 Power System Electrical AC Input Voltage Nominal Recommended Connection Recommended Knockout of AC Voltage Breaker (A) Type Wire Size (AWG) Dimension (in) Feeds (Vac) CXPS-HX-48-2000 (4kW, 4 rectifier shelves) with AC distribution panel 3W + PE 2.0 (1.5 KO) 277/480... - Page 11 Table B — Distribution Panels Panel Type Quantity/Rating Capacity Max Rating per Panel Output Termination TPL Fuses 2 hole 1/2" dia. on 1 3/4" centers or 2 hole 3/8" dia. on 1" centers Allows for dual cable landing back to back TPS/TLS/AM 2 hole 1/4"...
- Page 12 Table C — Specifications for Related Components Remote return bar Mounting 2" Auxiliary framing (customer supplied) With 4 kits: Termination 266 sets of 1/2-13 holes on 1-3/4" centers OR 266 sets of 3/8-16 holes on 1" centers Unit capacity per base kit 2500A per kit Ultimate capacity 4 kit limit (10,000A)
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Page 13: Product Description
4. Product Description The CXPS-HX is a high capacity power system that combines both power and distribution efficiently into a single standard box bay configuration. Basic power system • Each 2500A bay combines rectifiers, battery termination and distribution • Up to five single phase or three phase rectifier shelves for AC input, 208 to 240Vac or 480Vac •... -
Page 14: Figure 3 - 4.0Kw Rectifier Front Panel Leds
4.1.3 Cordex Rectifier Shelves A 2500 A power distribution bay has 5 rectifier shelves and a 2000A power distribution bay has 4 rectifier shelves. Each rectifier shelf can hold up to six Cordex 4 kW rectifier modules or two 12kW/480 rectifier modules. A Cordex 4.0kW rectifier supplies a nominal output of 74A at 54Vdc and the 12kW/480 rectifier supplies 222A at 54Vdc nominal. -
Page 15: Distribution Section
4.2.1 Rectifier Alarms and LEDs Rectifier status, such as Mains OK, Minor and Major alarms, display on the rectifier front panel. See the Cordex rec- tifier shelf manual included with the system documentation package for detailed information. A rectifier Major alarm indicates the module has shut down due to a critical fault. A rectifier Minor alarm indicates the module has a noncritical alarm, but it has not shut down. -
Page 16: Figure 5 - Distribution Shunts
4.2.4 Distribution Panel Alarms Fuse/Breaker alarms occur when one or more fuse or breaker has opened. The alarm for each fuse or breaker is daisy-chained back to the main system controller. Indication is provided by a red lamp on each distribution panel (Figure 4). When a secondary bay is installed, the alarm is wired to the controller on the primary bay. -
Page 17: Cordex System Controller
4.3 Cordex System Controller A Cordex system controller, mounted in the primary power section, provides easy access to controls and display status. The CXC provides comprehensive setup, control, monitoring and communication for Alpha DC power sys- tems. Serial port Reset button LEDs Figure 6 —... -
Page 18: Ethernet Port
4.3.4 Network Connection and Remote Communications The Cordex system can be set up, monitored, and tested via an Ethernet 10/100 Base-T serial data connection. The controller includes a web server that provides easy set up and monitoring over an Internet connection to a web browser. -
Page 19: Cordex Hp Controller (Cxc Hp)
4.4 Cordex HP Controller (CXC HP) The Cordex™ HP (CXC HP) controller provides centralized setup, control and monitoring of power systems. This ranges from simple monitoring and threshold alarms for temperature, voltage and current, to advanced battery charging and diagnostic features. The controller supports dual Ethernet ports and a 4.3”... -
Page 20: External Peripherals
• USB: dual ports on both the front and rear of the controller for upgrades and file management via a standard USB flash drive. • CAN: dual independent CAN bus ports for communication with the Alpha Cordex™ and AMPS family of products, which allows for a greater number of devices. -
Page 21: Figure 10 - 6I-Adio Power Module
Digital Inputs The L-ADIO can accommodate up to eight digital input channels, D1 – D8. Each channel responds to a zero or system voltage potential at the input to activate or deactivate the appropriate condition. These channels can monitor digital alarm/control signals from rectifiers, converters and many other types of equipment. -
Page 22: Redundant Input Power Module
4.6 Redundant Input Power Module The redundant input power module (RIPM) provides multiple power inputs to power the CXC HP controller and any I/O peripherals such as the L-ADIO. The unit enables users to wire system power into the control devices from multiple locations (e.g., on battery and load side of LVD’s or A and B power system(s)) and provides Diode-or protection between power inputs. -
Page 23: Pre-Installation Preparation
5. Pre-Installation Preparation NOTE: This power system is suitable for installation in Network Telecommunication facilities and locations where the NEC applies. 5.1 Site Selection The power system must be mounted in a clean and dry environment. Consider both the floor loading and the physical space required for the CXPS-HX power system and the batteries: •... -
Page 24: Tools And Test Equipment
5.1.2 Installation component requirements Supplied • Internal DC cables Not Supplied • Concrete mounting hardware • AC electrical conduit, cable and fittings • External DC conduit, cable and fittings • Auxilary frame (2" x 9/16") for optional external battery return busbar kit or optional external hot return busbar kit 5.2 Tools and Test Equipment Insulated tools are essential for a DC power system installation. -
Page 25: Unpacking The Equipment
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 26: Frame Installation
6. Frame Installation NOTE: No rectifiers should be installed at this time. Do not install rectifiers until told to do so later in the installation procedure. The power system must be mounted in a clean and dry environment. Provide sufficient free space at the front and rear of the power system to meet the cooling requirements of the rectifiers in the power system and to allow easy access to the power system components. -
Page 27: Placing And Securing The Bay
6.1.2 Setting the Anchors First, review manufacturer's instructions before setting the anchor. 1. Drop the anchor into the drilled hole. 2. Insert the anchor setting tool and hit it with a hammer to expand the anchor until the collar of the setting tool rests against the shoulder of the anchor. -
Page 28: Figure 15 - Battery Disconnect (Purchased Separately) Connections
6.2.2 LVBDs (purchased separately) If battery disconnect contactors are used: 1. Connect a secondary power source to the CXC. 2. Connect battery disconnect panels to the CXC battery fuse alarm input and LVBD control. Figure 15 — Battery disconnect (purchased separately) connections 0913000-J0 Rev D... -
Page 29: Tandem System Busbar Installation
THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF 0.040 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE Figure 16 — Tandem system busbar installation, bay shown with panels removed X.XX 0.020 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XXX... -
Page 30: Battery Installation
6.4 Battery Installation This information is provided as a guideline and is not meant to imply that batteries are part of this power system. WARNING! Follow battery manufacturer’s safety recommendations when working around battery systems and review the safety instructions provided in this manual. Figure 17 —... -
Page 31: Figure 18 - Battery Temperature Probes
6.4.3 Temperature Probe for Monitoring Battery Temperature 1. Locate the battery temperature probes coiled up in the power section of the bay. 2. Connect CXC temperature probes from CXC to battery termination post negative. 3. Pick a location at mid-height on one or more battery strings, which will provide a good average temperature reading;... - Page 32 After assembly, number the batteries and take “as received” readings, including specific gravity, cell voltage, and temperature. Designate one cell as the pilot cell. This is usually the cell with either the lowest specific gravity or volt- age. Refer to the manufacturer's literature for guidelines. See the following table for typical maintenance report: Company: _____________________________________________________ Date: _____________________ Address: _________________________________________________________________________________ Battery location and/or number:_______________________________________________________________...
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Page 33: Installation - Ac, Dc And Grounding Cables
7. Installation - AC, DC and Grounding Cables This section provides cabling details and notes on cable sizing for DC applications with respect to the Alpha CXPS- HX 48V high capacity distributed power system. • Only qualified personnel should install and connect the power components within the Alpha power system. •... - Page 34 Table F — Cable size equivalents (AWG to Metric) Cable size (see notes 1 Circular mils Square millimeters Equivalent metric cable and 2) 20 AWG 1020 0.519 18 AWG 1624 0.8232 16 AWG 2583 1.309 14 AWG 4107 2.081 12 AWG 6530 3.309 10 AWG...
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Page 35: Connecting The Frame And Reference Grounds
7.2 Connecting the Frame and Reference Grounds CAUTION! The grounding methods described in this section are generic. Follow local requirements and electrical code. NOTE: 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). -
Page 36: Ac Supply For The Rectifiers
7.3 AC Supply for the Rectifiers Rectifiers can be wired through an optional AC distribution panel, which is internally wired to the individual rectifier shelves, or directly to each rectifier shelf. For both options refer to the AC Input specification in Section 3 on page 8. NOTE: The recommendations for input breakers and wire sizes in Table A are for reference only. -
Page 37: Figure 20 - Ac Panel 5-Feed, 3-Wire 208Vac Shown
7.3.1 Wiring the AC Distribution Panel WARNING! Verify no rectifiers are installed in the power bay at this time. NOTE: Wire one side at a time with only one door open. Working with both doors open may make it difficult to close both doors when the wiring is complete. Knockouts Figure 20 —... -
Page 38: Distribution
7.4 Distribution 7.4.1 External Battery Return Bar Wiring Connect the external battery return bar(s) to the associated power bay positive return detail as shown in Figure 22 5x 750MCM (min) 2000/2500A Power bay External battery return bar To Master Ground Bus Figure 22 —... -
Page 39: Dc Connections
7.5 DC Connections 7.5.1 DC Landing Hot and Battery Landing without Top AC Termination Panel There are a total of 6 positions (12 cables back-to-back) to land the battery 'hot' cables. The dimensions for the holes are 1/2" on 1.75" centers and 3/8" on 1" centers. NOTE: Start at the front-most corner and move towards the back as shown in Figure 23. -
Page 40: Figure 25 - Dc Connection With Ac Panel Option
7.5.2 DC Landing Return and Battery Landing with Top AC Termination Panel There are a 5 total positions (10 cables back-to-back) to land the battery 'hot' cables when the AC panel is used. When an AC panel is installed, the left most holes do not go all the way through and only the back 4 are accessible. See the figure below. -
Page 41: Figure 27 - Internal Return Bar
7.5.3 Internal Return Bar The internal return bar eliminates the need to mount external bars to land the DC return cables. These are 30x 1/4" holes on 5/8" centers, 40x 3/8" holes on 1" centers and 10x 1/2" holes on 1.75" centers. Start landing the DC return cables on the vertical riser first. -
Page 42: Figure 28 - External Hot Bar (2 Kits Shown)
7.5.5 Mounting the External Remote Hot Bar The external remote hot bar kit option provides a central location to land all the 'hot' cables from the power plant and the batteries. The CXPS-HX Remote Hot Bar Kit, Base (0380213-001) has a capacity of 5000A per kit. An adder kit can be in- stalled on the existing base kit which increases the total system capacity to 10,000A. -
Page 43: Figure 29 - Landing The Cables
7.5.6 Landing Cables on External Return and External Hot Bar When landing cables on the bus bar for both optional external return bar and for the external hot bar follow the instructions in Figure 28. For full details refer to drawings included with the kit. 7.5.7 Return/Hot Bar to Loads Wiring Always start system and load wiring from the same side. -
Page 44: System Startup
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. -
Page 45: Shelf Id Connection
8.5 Shelf ID Connection The shelf/bay ID/ comes factory installed. If shelves are installed in more than one bay, then set the Bay ID se- quentially on each Shelf ID board. Rack-mounted Shelf ID Example of a single bay with two rectifier shelves. Bay ID 1 (manually set) J2 J3 J4 J5 J6 J7 J8 J9... -
Page 46: Test And Commissioning Overview
9. Test and Commissioning Overview 9.1 System All Alpha power system components undergo thorough factory testing. All levels/alarms are set to predetermined values as detailed in their individual component manuals except where custom levels are specified. Good installation practice is to check the operation of all features and alarms and to set the power system levels in accordance with the specific requirements of your system. -
Page 47: Maintenance
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. -
Page 48: Acronyms And Definitions
11. Acronyms and Definitions Alternating current ANSI American National Standards Institute American Wire Gauge Battery return bus British thermal unit Controller area network Canadian Electrical Code Canadian Standards Association Cordex™ series; e.g., CXC for Cordex System Controller Direct current DHCP Dynamic Host Configuration Protocol Electronic Industries Alliance Electromagnetic compatibility... -
Page 49: Warranty And Service Information
12. Warranty 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 Limited Hardware 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, unless otherwise specified in the product manual, in which case, the terms of the manual will take precedence... -
Page 50: Certification
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 56 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 © 2016 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.
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