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Alpha Technologies Cordex 030-728 Installation & Operation Manual

48-650w integrated shelf system
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Cordex 48-650W Integrated Shelf System
Installation & Operation Manual
Part #CXS-650W-J0
Effective: 06/2017
Your Power Solutions Partner
member of The
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Summary of Contents for Alpha Technologies Cordex 030-728

  • Page 1 Cordex 48-650W Integrated Shelf System Installation & Operation Manual Part #CXS-650W-J0 Effective: 06/2017 Your Power Solutions Partner member of The Group ™...
  • Page 3 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...

  • Page 5: Table Of Contents

    ABLE OF ONTENTS ........1 AFETY Safety Wording/Symbols .
  • Page 6 Check for Damage ....... 17 Packing Materials ....... . 17 Returns for Service .
  • Page 7 ....... . 35 YSTEM TARTUP Check System Connections ......35 Verify AC and Power The Shelf .
  • Page 8 IST OF IGURES Figure 1: Four Module, 030-728 ......6 Figure 2: Five Module, 030-782......6 Figure 3: Rectifier Front Panel .
  • Page 9 IST OF ABLES Table 1: In-Shelf Controller Full Menu ......11 Table 2: Recommended AC Supply Configuration....24 Table 3: Wiring Connections for the CXCI Series of Controllers.

  • Page 11: Safety

    Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any ques- tions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative.

  • Page 12: Battery Safety

    : Lethal voltages are present within the power system. Always assume that an electrical WARNING 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. •...
  • Page 13 • Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery manufacturer for recommended local authorized recyclers. CXS-650W-J0 Rev A Page 3...
  • Page 14 CXS-650W-J0 Rev A Page 4...

  • Page 15: Introduction

    Cordex 48-650W integrated 19" 2RU shelf system with up to 3250W output power and distribu- tion. Product Overview A complete Alpha Technologies Cordex rectifier system consists of a controller with one or more power modules in a common shelf enclosure. The shelf has connections for AC inputs, DC output, and system communications.

  • Page 16: Figure 1: Four Module, 030-728

    Figure 1: Four Module, 030-728 Figure 2: Five Module, 030-782 CXS-650W-J0 Rev A Page 6...

  • Page 17: Features

    Features Rectifier The Cordex CXRC series of 48V 650W rectifier modules employ an advanced resonant power conver- sion technology featuring high power conversion efficiency. All internal semiconductor devices operate under “soft-switching” conditions and exhibit very low power loss. The reduced power loss leads to lower thermal stress on the semiconductors and thus improves reliability.

  • Page 18: Mechanical

    When a rectifier firmware upload is in progress, the LEDs behave in the same way as the locate module command described above. 3.1.3 Mechanical A thumbscrew is provided to secure the rectifier into the shelf. During normal operation the rectifier shall be locked into position.

  • Page 19: Soft Start

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

  • Page 20: Overview Of The Cxci Hp

    Overview of the CXCI HP The CXC HP in-shelf controllers have a small organic LED (OLED) display. This display shows 30 char- acters total (five lines high, six characters wide) and the controller has three navigation buttons and one reset button. The in-shelf display has three main operating modes: dashboard, menu and screen saver.

  • Page 21: In-Shelf Display: Menu

    Figure 5: In-Shelf Controller Dashboard Screens D C - - 4 8 5 4 . 0 9 V Output Voltage 1 0 3 . 1 A Output Current F l o a t Battery Mode Nominal System D C - - 2 4 Output Output Type Voltage...

  • Page 22: In-Shelf Controller Buttons

    Table 1: In-Shelf Controller Full Menu (Continued) (Sheet 2 of 2) Menu Label Description Backup Backup the controller application and configuration to a file on a USB device Restore Restore the controller application and configuration from a file on a USB device Upgra...

  • Page 23: Leds

    Figure 8: Cordex CXCI+ model system controller front panel System Status LEDs LCD Screen Display Mode: pushbutton toggle switch Soft Reset (push once) Hard Reset (push once) Hold for three seconds to reset IP address Ethernet Port 3.3.1 LEDs The controller has three LEDs to display the alarm status of the power system, controller progress and status during startup, files transfers and lamp tests.

  • Page 24: Reset (Cxci+ Only)

    3.3.2 Reset (CXCI+ only) A reset button is located on the front panel for restarting the controller. During reset, the controller may occasionally need to run a defragmentation cycle. This can be recognized by the LEDs cycling on the front panel. A full defragmentation may take up to 20 minutes to perform, do not power down the controller during this time.

  • Page 25: Network Connection And Remote Communication

    3.4.5 Network Connection and Remote Communication The Cordex system can be set up, monitored and tested via an Ethernet connection. The communica- tion protocol supports a web interface. All alarming and control of Cordex rectifiers is accomplished with a controller via a CAN bus. A step-by-step connection wizard –...
  • Page 26 CXS-650W-J0 Rev A Page 16...

  • Page 27: Inspection

    Alpha Technologies is not responsible for damage caused by improper packaging of returned products. If you have any questions before you proceed, call Alpha Technologies: 1 888 462-7487. CXS-650W-J0 Rev A...
  • Page 28 CXS-650W-J0 Rev A Page 18...

  • Page 29: Installation

    Installation Installation This chapter is provided for qualified personnel to install the product. Mount the unit horizontally in a clean and dry environment. : Drawings are located at the rear of the manual. NOTE : This system is designed to be installed in a restricted access location that is inaccessible to WARNING the general public.

  • Page 30: Removing A Cxrc

    Insert rectifiers by placing the module on the shelf bottom and sliding the module into the rear connector (inside of the shelf). Apply pressure on the front of the module to engage the rear connector in the shelf receptacle. A thumbscrew is provided to secure the rectifier into the shelf. : Do not force a module into position if it does not seat properly.

  • Page 31: Figure 11: Removing The Cxci Hp

    Figure 11: Removing the CXCI HP 1. Remove the screw from the front side controller. 2. Pull here to remove the controller from the shelf. CXS-650W-J0 Rev A Page 21...
  • Page 32 CXS-650W-J0 Rev A Page 22...

  • Page 33: Wiring And Connections

    Wiring and Connections Safety Precautions : Hazardous AC voltages may be present. Ensure power at the AC service panel is off before WARNING attempting work on the AC connections. Use a voltmeter to verify the absence of voltage. Clearly mark the correct polarity of the battery leads before commencing work on DC connections.

  • Page 34: Ac Input

    Table 2: Recommended AC Supply Configuration Number of Rectifiers on AC Circuit Breaker, Exact Value AC Input (Vac) Feed to Use (A) 120/240 120/240 An external surge protection device is not required. The rectifiers are protected by internal MOVs. AC Input : Route the AC input wires in flexible or rigid conduit as far away as possible from the DC power CAUTION wires to minimize EMI disturbances.

  • Page 35: Dc Output

    DC Output : Leave cables disconnected at battery and verify output polarity using a voltmeter. Make WARNING battery connections only after all other wiring is completed. DC output wire shall be UL approved XHHW or RHH/RHW (for Canadian users, RW90 Type). Control and sense wires shall be UL approved Style 1015 (for Canadian users, TEW type).

  • Page 36: Ethernet Port For Local Connection

    6.9.2 Ethernet Port for Local Connection Local access (e.g. laptop computer) is also possible from the Ethernet port connection using a standard network cable. : Older CXCI models must use a crossover Ethernet cable for direct connection to a computer. NOTE 6.10 Signal Wiring Connections...

  • Page 37: Analog Inputs

    Bundle the signal cables together and route them through the entry holes of the shelf. 6.10.1 Analog Inputs : Ensure the correct polarity is used for all input cable terminations. CAUTION The analog input channels are used to monitor various types of electrical signals. The Voltage Input is -60 to +60Vdc.

  • Page 38: Alarm Relay Outputs

    Programming the Digital Input 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 controller software manual for detailed instruction on programming. Table 4: Voltage Level Definitions for Digital Inputs Voltage Level (Vdc),...

  • Page 39: Lvd Control Alternative

    6.10.5 LVD Control Alternative The LVD Control functions can be hardwired directly from an alarm output relay to an external LVD contactor (or panel). See Controls Menu Defaults in the CXC Software manual. CXS-650W-J0 Rev A Page 29...
  • Page 40 CXS-650W-J0 Rev A Page 30...

  • Page 41: Operation

    Operation Main Rectifier States Rectifier operation has five main states; each state is distinct and necessary for the operation of the rectifier. • • Start Delay • Soft Start • Normal Operation • Turning Off 7.1.1 The rectifier is in the Off state immediately after power is applied to the rectifier or after a rectifier shut- down (remote or local shutdown, AC shutdown, OVP or thermal shutdown).

  • Page 42: Turning Off

    7.1.5 Turning Off The Turning Off state is entered because a short delay is required before the rectifier actually turns off to take care of any initialization requirements. When this short delay has elapsed, a transition to the Off state is made. Main Rectifier Modes In addition to main rectifier states, there is a set of main rectifier modes.

  • Page 43: Can Bus Communication

    Table 6: Output Current/Power Modes (Continued) (Sheet 2 of 2) Output Current/Power Mode Output current and power limit have been reduced due to: Short circuit foldback Short circuit at the output. mode Internal fault foldback Internal fault. mode Can Bus Communication The CAN bus is used for commands and data transfer between the rectifier and controller to configure the rectifier with system settings and to monitor rectifier status.

  • Page 44: Table 7: Factory Ranges And Defaults

    Table 7: Factory Ranges and Defaults (Continued) (Sheet 2 of 2) Setting Range (minimum to maximum) Default CL/PL Alarm Enable/Disable Enable Remote Shutdown Enable/Disable Enable Ramp Test Enable/Disable Enable : OVP cannot be set below the present system/FL/EQ/BT voltage setting or the safe mode voltage NOTE of 51.4V.

  • Page 45: System Startup

    System Startup Check System Connections • Ensure AC is off, battery is disconnected, and all power modules are removed from the shelf. • Triple-check the polarity of all connections. Verify AC and Power The Shelf • Install one power module. •...

  • Page 46: Ip Address Reset (Cxci+ Only)

    8.4.2 IP Address Reset (CXCI+ only) To reset the IP address, press and hold the front panel soft reset button for three seconds. The CXCI+ unit beeps three times, IP address resets to 10.10.10.201 and DHCP is disabled. The settings are saved and the unit then resets.

  • Page 47: Maintenance

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

  • Page 48: Replacing A Cxci+ Controller

    Replacing a CXCI+ Controller This procedure is for replacing a CXCI+ controller. Write down the controller communication information: dynamic or static IP, IP address, and gateway. 1. Connect a laptop to controller per software manual; standard network cable to the Ethernet port. 2.
  • Page 49 5. Place the new CXCI+ controller on the shelf bottom and slide into the rear connector at the back of the slot. 6. Log on to the controller and go to Logs and Files > Manage Configuration File > Upload Site Configuration and select the saved *.cfg file.
  • Page 50 CXS-650W-J0 Rev A Page 40...

  • Page 51: Warranty And Service Information

    Warranty and Service Information 10.1 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. 10.2 Warranty Statement For full information details review Alpha's online Warranty Statement at www.alpha.ca. 10.3 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 manual will take precedence.The warranty provides for repairing, replacing or issuing...
  • Page 52 CXS-650W-J0 Rev A Page 42...

  • Page 53: Certification

    Certification 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 54 CXS-650W-J0 Rev A Page 44...

  • Page 55: Glossary

    Glossary Alternating Current ACCT Alternating Current Current Transducer ADIO Analog-digital input-output ALCO Alarm cutoff Controller Area Network Current Transducer Cordex series; e.g. CXC for Cordex™ System Controller Cordex™ Controller CXC HP Cordex™ Controller High Performance Cordex™ DC-DC Converter Cordex™ Rectifier Direct current DCCT Direct Current Current Transducer...
  • Page 56 IPv4 Internet Protocol version 4 IPv6 Internet Protocol version 6 International Organization for Standardization Liquid Crystal Display Light Emitting Diode Low voltage disconnect LVBD Low voltage battery disconnect Media Access Control; e.g. MAC address Management Information Base; a database of entities most often associated with SNMP Metal Oxide Varistor Multiplexer NEBS...

  • Page 57: Specifications

    Specifications 13.1 2RU, 48-650W, 19”, 4-Module System Table 9: Specifications: 48-650W 19”, 4 Module System Specifications: 48-650W 19”, 4 Module System Basic Unit: Shelf Maximum Output: 54A, 60VDC Recommended 20A, #12 AWG per feed Feed Breaker, Single Phase: Mechanical Dimensions: 88mm H x 444mm W x 307mm D, rectifier front panel 18mm D (3.5"...

  • Page 58: 2Ru, 48-650W, 19", 5 Module System

    13.2 2RU, 48-650W, 19”, 5 Module System Table 10: Specifications: 48-650W 19”, 5 Module System Specifications: 48-650W 19”, 5Module System Basic Unit: Shelf Maximum Output: 67.5A, 60VDC Recommended 20A, #12 AWG per feed Feed Breaker, Single Phase: Mechanical Dimensions: 88mm H x 444mm W x 307mm D, rectifier front panel 18mm D (3.5" H x 17.5" W x 12.1"...

  • Page 59: Cordex 48-650W Switched Mode Rectifier

    13.3 Cordex 48-650W Switched Mode Rectifier Table 11: Specifications: Cordex 48-650W, Switched Mode Rectifier (Sheet 1 of 4) Specifications: Cordex 48-650W, Switched Mode Rectifier Power Module Output Voltage: 40.5 to 58Vdc within rated limits Power: 650W continuous/module @ 208-240Vac nominal 500W continuous/module @ 120Vac nominal Current: 12A @ 54Vdc, 13.5A maximum @ 48Vdc...
  • Page 60 Table 11: Specifications: Cordex 48-650W, Switched Mode Rectifier (Continued) (Sheet 2 of 4) Specifications: Cordex 48-650W, Switched Mode Rectifier : This equipment has been tested and found to comply with the limits for a Class B digital device, NOTE pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
  • Page 61 Table 11: Specifications: Cordex 48-650W, Switched Mode Rectifier (Continued) (Sheet 3 of 4) Specifications: Cordex 48-650W, Switched Mode Rectifier Input Transient Meets ANSI/IEEE C62.41 Category B3 Suppression: Input Leakage Current: <3.5mA @ 265Vac 60Hz for up to two rectifiers Environmental Operating -40 to +65°C (de-rated linearly to 70% output power for ambient Temperature:...

  • Page 62: Cxci Hp Controller

    Table 11: Specifications: Cordex 48-650W, Switched Mode Rectifier (Continued) (Sheet 4 of 4) Specifications: Cordex 48-650W, Switched Mode Rectifier 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 Supply Interface at the Input to Telecommunications Equipment;...
  • Page 63 Table 12: Specifications: CXCI HP Controller (Continued) (Sheet 2 of 3) Specifications: Basic Unit, CXCI HP EMC: The unit meets requirements of: • EN 300 386-2 EMC and EMR, Telecommunications Network Equipment Emissions: • EN 55022 Class A (CISPR 22) •...

  • Page 64: Cxci+ Controller

    Table 12: Specifications: CXCI HP Controller (Continued) (Sheet 3 of 3) Specifications: Basic Unit, CXCI HP Display: 5-line, LED matrix Front Panel Menu up and down, home and select buttons Controls: LED’s: System OK (Green) Power System Minor Alarm (Yellow) Power System Major Alarm / Controller Fail (Red) Audio: Built-in speaker for alarm and popup message tones 70dbl...
  • Page 65 Specifications: Basic Unit, CXCI+ <200mA @ 24Vdc MTBF: 1,500,000 hrs @30°C (86°F) ambient EMC: Radiated and Conducted Emissions :North America Regions • CFR 47, Part 15 Subpart B, Class B • ICES-003 Issue 2, Rev 1, Class European Regions • EN 55022 Class B •...
  • Page 66 Specifications: Basic Unit, CXCI+ Temperature: -40 to 65°C standard @ 3000m derate to 55°C @ 4000m (-40 to 149°F derate to 131°F @ 13124ft) Humidity: 5 to 95% non-condensing Elevation: -500 to +4000m (-1640 to 13124 ft) Hardware Specifications CPU: Coldfire Display: 4 digit LCD...
  • Page 80 CANCOM CANH CANL +5VCAN CANCOM CANH CANL +5VCAN CANL CANL CANH CANH +5VCAN +5VCAN CANCOM CAN COM POWER + V2 + POWER - V2 -...
  • Page 81 CANCOM CANH CANL +5VCAN CANCOM CANH CANL +5VCAN CANL CANL CANH CANH +5VCAN +5VCAN CANCOM CAN COM POWER + V2 + POWER - V2 -...
  • Page 82 CANCOM CANH CANL +5VCAN CANCOM CANH CANL +5VCAN CANL CANL CANH CANH +5VCAN +5VCAN CANCOM CAN COM POWER + V2 + POWER - V2 -...
  • Page 84 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 © 2017 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

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Cordex 030-782

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