Summary of Contents for Alpha Technologies Cordex HP
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Cordex HP 48-12kW/480 Modular Switched Mode Three-Phase Rectifier Installation and Operation Manual Part #0100020-J0 Effective 08/2017 Your Power Solutions Partner member of The Group ™...
4.8 Start Delay ..........................14 4.9 Current Limit/Short Circuit Protection ..................15 4.10 Power Limiting ........................15 4.11 High Voltage Shutdown (HVSD) .................... 15 5. Cordex HP Controller (CXC HP) ..................16 5.1 Controller Features ........................16 5.2 External Peripherals ......................... 17 0100020-J0...
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6. Inspection..........................19 6.1 Packing Materials ........................19 6.2 Check for Damage ........................19 6.3 General Receipt of Shipment ....................19 7. Installation ...........................20 7.1 Safety Precautions ........................20 7.2 Tools Required ......................... 20 7.3 Power System Assembly and Mounting ................... 21 8.
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List of Figures Figure 1 — Cordex 48-12kW/480 ....................7 Figure 2 — Power Derating vs Ambient Temperature ..............11 Figure 3 — Power Derating vs Ambient Temperature ..............11 Figure 4 — 12kW Rectifier front panel LEDs .................. 12 Figure 5 — Cordex CXC HP Controller (left and right side views) ..........16 Figure 6 —...
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.
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. •...
The Cordex HP 48-12kW/480 is a perfect solution for various 48Vdc high capacity applications including Central Office, MTSOs and Data Centers. Cordex HP 48-12kW/480 is a true three-phase, three wire, 480 VAC input rectifier which meets the critical require- ments of current high density telecommunications environments. It combines the latest DSP controlled power conversion technology, to provide a flexible, efficient, and very highly reliable DC power source.
2.3 Part Numbers The product, options, and accessories can be ordered by using the following part numbers: Description Part Number Cordex 48-12kW rectifier power module 0100020-001 Fan, spare for Cordex 48-12kW/480 7400564-001 MOV replacement assembly 7050308-001 0300167-XXX Cordex 48-12kW/480V, 3 phase 23" shelf, flush or mid-mounting Module blank 5900550-002 Cordex CXC HP Controller (CXC HP)
3. Specifications Electrical Power Module Output Voltage: 42 to 58 Vdc within rated limits Maximum current: 220 A Maximum power: 12kW continuous(@ 54.5V), 10.56kW continuous (@ 48V) Static load regulation: Better than ±0.5% for any load within rated limits, under control of Cordex Controller Better than ±4%, 40 - 90% load step Dynamic load regulation: (output shall recover to static limits within 30 ms)
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Environmental Temperature: -10° to 65°C Operation: 0° to 40°C full nominal power output, see "Figure 2 — Power Derating vs Ambient Temperature" on page 11. Storage: -40° to 70°C (-40 to 158°F) Humidity: 0 to 90% RH non-condensing Elevation: -100 m to 2000 m (-330 feet to 6500 feet) 3.3.1 Cordex 48-12kW Rectifier Shelves 23 in 4RU universal mount 24,000W shelf P/N 0300167-001 Number of Rectifiers:...
3.1 Power Derating vs Ambient Temperature For ongoing reliability of the rectifier, the output power is reduced when the ambient temperature is very high or very low, see Figure 2. Figure 2 — Power Derating vs Ambient Temperature 3.2 Power Derating vs Input Voltage The output power is reduced when the input voltage drops below 430Vac, see Figure 3.
4. Rectifier Features 4.1 Front Panel 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.
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ALARM (3) The red LED is illuminated when a major alarm is detected and the module is unable to source power because of any of the following conditions: Output fuse open AC Input voltage high Over voltage protection (OVP) shutdown AC Input voltage low UPF/Converter failure Sense Leads -interlock...
4.2 Rectifier Rear Panel The 12kW rectifier has three connectors for shelf power and communications on the rear panel. These three con- nectors align with corresponding connectors in the shelf when the rectifier is installed. 4.3 True Module Fail Alarm The power modules have a “true”...
4.9 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. 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.
5. 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.
• 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.
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. An additional digital input, “EXT”...
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.
7. 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. 7.1 Safety Precautions Refer to the Safety section near the front of this manual before beginning this installation.
7.3 Power System Assembly and Mounting 7.3.1 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 airflow. Sufficient free space must be provided at the front and rear of the power system.
8. Wiring This chapter provides cabling details and notes on cable sizing for DC applications using the Cordex 48-12kW, 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 switched off. Remove battery line fuses or connections before attempting work on the wiring.
CAUTION! To minimize EMI disturbances, route the AC input wires in flexible 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.
8.5 CAN Serial Ports (Rectifier Shelf) Each module communicates with the CXC HP controller using CAN protocol. The modules report alarms, rectifier output voltages, and the location of the module within a cabinet. 8.5.1 Making CAN Bus Connections Figure 9 shows an example of a controller and three shelves. 1.
Bay ID 1 (manually set) J2 J3 J4 J5 J6 J7 J8 J9 Bay ID 1 Bay ID 1 Shelf ID 1 Shelf ID 2 Cordex HP CAN driver 2 x 12kW 2 x 12kW Bay ID 1 Bay ID 1 Rectifier...
8.7 Signal Wiring Connections to L-ADIO Board 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 fire, use only 0.129 mm² (#26 AWG) or larger wire. 8.7.1 Relay Outputs Terminals provide contacts for extending various alarm or control signals.
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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 HP Software manual for detailed instruction on programming.
9. 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: 9.1 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.
9.5 Rectifier Modes There are two main rectifier modes: output voltage mode and the output current/power mode. 9.5.1 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” 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 cur- rent limit.
9.6 Factory Ranges and Defaults Table D shows the rectifier settings/ranges/defaults. Changes are made through the CXC HP interface Table D — Rectifier 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 –...
10. 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.
10.3 Replacing a Rectifier Module NOTE: When a rectifier fails and or is permanently removed, the system generates a Rectifier Comms Lost alarm. The alarm is cleared by removing the rectifier from the system inventory. Replacing a Rectifier To remove the rectifier from the system inventory do the following: 1.
10.4 Fan Replacement WARNING! Do not work inside the rectifier module while it is energized. If working on the system with battery connected, use insulated tools to prevent accidental contact and arc flash A recommended replacement period of six years is suggested for preventative maintenance. 1.
10.5 MOV Replacement WARNING! Do not work inside the rectifier module while it is energized. If working on the system with battery connected, use insulated tools to prevent accidental contact and arc flash Lethal voltage persists inside the unit for several minutes after removal from the shelf. Allow 10 minutes before removing fan grill.
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5. Pull the MOV Insulator flap out of the chassis so that MOV board is exposed and remove the 5 of screws from module. 6. Carefully remove MOV board from the rectifier. Place MOV PCB into location by inserting it through the bottom of the chassis and secure to module using 5 screws.
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9. Place the MOV board cover into the chassis. 10. Install the screw on the MOV board cover to the chassis and torque the 1 of screw to 5in.lb. 0100020-J0 Rev C...
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 DHCP Dynamic Host Configuration Protocol Electronic Industries Alliance Electromagnetic compatibility Electromagnetic interference...
12. Warranty and Service Information 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. Warranty Statement For full information details review Alpha's online Warranty Statement at http://www.alpha.ca/warranty. 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...
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.
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