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Alpha Technologies Cordex 48-650W Installation & Operation Manual

19" integrated shelf system, up to 2600w with cxci/cxci+ and distribution
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Cordex 48-650W 19" Integrated Shelf System
Up to 2600W with CXCI/CXCI+ and Distribution
Installation & Operation Manual
Part # 030-728-20 (030-806-B2 RoHS)
Effective: 12/2013
Your Power Solutions Partner
member of The
Group
™

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Summary of Contents for Alpha Technologies Cordex 48-650W

  • Page 1 Cordex 48-650W 19" Integrated Shelf System Up to 2600W with CXCI/CXCI+ and Distribution Installation & Operation Manual Part # 030-728-20 (030-806-B2 RoHS) Effective: 12/2013 Your Power Solutions Partner member of The Group ™...
  • Page 2 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.
  • Page 3 Electrical Safety WARNING! Hazardous voltages are present at the input of power systems. The DC output from rectifiers 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: •...
  • Page 4 Inspeccione los dibujos y las ilustraciones contenidas en este manual antes de continuar. Si existe cualquier pregunta relacionada con la instalación u operación segura de este producto, póngase en contacto con Alpha Technologies o con su representante de Alpha más cercano. Guarde este documento para referencia futura.
  • Page 5 Seguridad Eléctrica ¡ADVERTENCIA ! Hay voltajes peligrosos en la entrada de los sistemas de alimentación. La salida de CC de rectificadores y baterías, si bien no es peligrosa en cuanto al voltaje, cuenta con una alta capacidad de conducción de cortocircuito que puede causar quemaduras graves y arcos eléctricos.
  • Page 6 En cas de questions sur l'installation ou le fonctionnement en toute sécurité de ce produit, contactez Alpha Technologies ou le représentant d'Alpha le plus près. Conservez ce document pour référence future. Symboles de Sécurité...
  • Page 7 Sécurité Electrique AVERTISSEMENT ! Des tensions dangereuses sont présentes à l’entrée des systèmes électriques. La sortie CC des redresseurs et des batteries, bien que non dangereuse en termes de tension, a une capacité de courant de court-circuit élevée qui peut causer de graves brûlures et des arcs électriques.
  • Page 8 Bewahren Sie es an einem sicheren Ort auf. Sehen Sie sich die Zeichnungen und Illustrationen in diesem Handbuch genau an, bevor Sie fortfahren. Sollten Sie Fragen zur sicheren Installation oder zum Betrieb dieses Produkts haben, wenden Sie sich bitte an Alpha Technologies oder den nächstgelegenen Alpha-Vertreter. Bewahren Sie dieses Dokument für den zukünftigen Gebrauch auf.
  • Page 9 Elektrische Sicherheit WARNUNG! Am Punkt der Stromeinspeisung liegen gefährliche Spannungen vor. Der Gleichstromausgang von Gleichrichtern und Batterien weist zwar keine gefährliche Spannung auf, die Kurzschlussstrom-Kapazität ist jedoch sehr hoch, was zu ernsthaften Verbrennungen und Lichtbögen führen kann. Befolgen Sie die folgenden Vorsichtsmaßnahmen, bevor Sie mit einer spannungsführenden Batterie oder einem Stromversorgungssystem arbeiten: •...

  • Page 10: Table Of Contents

    ABLE OF ONTENTS     ................................1 NTRODUCTION     Scope of the Manual ............................1     Product Overview ............................1     Part Numbers and List Options ........................2     .................................. 3 EATURES     Cordex Integrated System Controller (CXCI/CXCI+) ..................3  ...
  • Page 11     Can Bus Communications ..........................17     Factory Ranges and Defaults ........................18     ..............................19 YSTEM TARTUP     Check System Connections .......................... 19     Verify AC and Power the Shelf ........................19     Check Battery Polarity and Connect ......................

  • Page 12: Introduction

    Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated and isolated DC output from the AC mains. There are two Cordex 48-650W rectifier models from which to choose, the input of model #010-570-20 is universal to allow use on 120/208/220/240Vac 50/60Hz electrical service.

  • Page 13: Part Numbers And List Options

    This product is available to order under the following part numbers and list options: Description Part Number/List Option Cordex 48-650W 19" (flush mounting) 2RU shelf for systems up to 2600W ..........030-728-20 [equipped to receive one CXCI/CXCI+ controller and four CXRC 48-650W rectifiers] ........ *List 0 48Vdc output ..............................*List 2 120Vac input ...............................

  • Page 14: Features

    Features Cordex Integrated System Controller (CXCI/CXCI+) The Cordex CXCI/CXCI+ integrated system controller 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 of Alpha power systems and is equipped with the complete range of Cordex software features, including the following: Designed to communicate directly with Cordex rectifiers •...
  • Page 15 LCD screen (V/A) System status LEDs Display pushbutton toggle switch (V/A) Soft reset Hard reset (push once) (push once) [Hold for 3 seconds to reset IP address] Ethernet port Figure 3–Cordex CXCI+ model system controller front panel 2.2.1 LEDs The CXCI/CXCI+ has three LEDs located on the front panel. These are used to display the alarm status of the power system, CXCI/CXCI+ progress and status during startup, file transfers and lamp tests.

  • Page 16: Analog Input Channels

    Analog Input Channels The CXCI/CXCI+ has four analog input channels: one voltage, one current, and two temperature. See Section 5.10.1. 2.3.1 Voltage Inputs Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCI/CXCI+ 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.

  • Page 17: Rectifier Front Panel

    Rectifier Front Panel Figure 4–Cordex 48-650W rectifier front panel 2.8.1 LEDs The front panel LEDs provide rectifier status summary and help to locate a specific module under CXC control. 2.8.1.1 The top LED (green) is on when AC is within valid range and the rectifier is delivering power to the load.

  • Page 18: True Module Fail Alarm

    True Module Fail Alarm The power modules have a “true” fail alarm. This 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.

  • Page 19: Soft Start

    2.14 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.

  • Page 20: Inspection

    If the original container is unavailable, make sure 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 the improper packaging of returned products. Check for Damage Prior to unpacking the product, note any damage to the shipping container.

  • Page 21: Installation

    Installation This chapter is provided for qualified personnel to install the product, which shall be mounted in a clean and dry environment. NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of the manual. Safety Precautions WARNING Hazardous voltages are present at the input of power systems.

  • Page 22: Wiring And Connections

    Wiring and Connections This chapter provides cabling details and notes on cable sizing for DC applications with respect to the shelf. NOTE: Refer also to foldout drawings located at the rear of the manual. Safety Precautions WARNING Hazardous AC voltages may be present. Ensure power at the AC service panel is off before attempting work on the AC connections.

  • Page 23: Ac Input Connections

    AC Input Connections CAUTION: AC input wires should be routed in flexible or rigid conduit as far away as possible from the DC power wires to minimize EMI disturbances. If the shelf is factory-equipped with a line cord, proceed to the next section. Refer to customer connections drawing 030-728-08 (rear view –...

  • Page 24: Can Out Port

    CAN Out Port A single CAN Out port, for communications with CAN-enabled equipment (nodes), is located on the shelf backplane. Daisy-chain from node to node (CAN OUT of one node to CAN IN of another) as necessary and ensure that only the last node is terminated.
  • Page 25 5.10.1 Analog Inputs CAUTION: Ensure the correct polarity is used for all input cable terminations. The analog input channels are used to monitor various types of electrical signals. 5.10.1.1 Voltage Voltage Input #1 (load voltage per CXC software) terminals on the shelf (V1 on TB12) provide connections to an optional secondary voltage input.
  • Page 26 5.10.2.2 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 CXC Software manual for detailed instruction on programming. Voltage Level (VDC) Voltage Level (VDC) Voltage Range (VDC)

  • Page 27: Operation

    Operation Main Rectifier States Rectifier operation can be broken up into five main states: 1. Off, 2. Start delay, 3. Soft start, 4. Normal operation, 5. Turning off. Each state is characterized as being distinct and necessary for the operation of the rectifier. These states are briefly described below.

  • Page 28: Main Rectifier Modes

    Main Rectifier Modes In addition to Main Rectifier States, there is a set of Main Rectifier Modes. These modes can be divided into two categories as follows: 6.2.1 Output Voltage Modes Voltage modes can be thought of as modes that, under software control, can directly adjust the output voltage. The qualification of ‘under software control’...

  • Page 29: Factory Ranges And Defaults

    Remote Shutdown Enable/Disable Enable Ramp Test Enable/Disable Enable Table 6 Cordex 48-650W factory ranges and defaults NOTE: OVP cannot be set below the present system/FL/EQ/BT voltage setting or the safe mode voltage of 51.4V. 030-728-B2 Rev C Page 18 of 23...

  • Page 30: System Startup

    System Startup After completing the shelf wiring and installation, perform the following startup and test procedure to ensure proper operation: 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.
  • Page 31 This will allow local access; e.g., with a laptop and a standard network crossover cable. See current version software manual for details. 7.4.3 Hard Reset Refer to Figure 2 and Figure 3 for the location of the hard reset button on the CXCI/ CXCI+. This can be used to restart the microprocessor in the event that the front panel (soft) reset button fails to operate as described above.

  • Page 32: 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 33: Warranty

    9.1 Warranty Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to the...

  • Page 34: Acronyms And Definitions

    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...
  • Page 35 CSA/NRTL — MARKS — BACKGROUND What are the 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 36 The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice. Alpha Technologies Ltd. 030-728-B1 Rev B Printed in Canada. © 2012 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 1 of 1...
  • Page 37 Any changes or modifications to this equipment not expressly described in this manual could void the FCC compliance. Alpha Technologies Ltd. 010-604-B1 Rev C Printed in Canada. © 2012 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 1 of 3...
  • Page 38 (-1640 feet to 13124 feet; derate @ -7.2°F/3281 feet above sea level) Alpha Technologies Ltd. 010-604-B1 Rev C Printed in Canada. © 2012 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 2 of 3...
  • Page 39 The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice. Alpha Technologies Ltd. 010-604-B1 Rev C Printed in Canada. © 2012 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 3 of 3...
  • Page 40 Consult the dealer or an experienced radio/TV technician for help. • Alpha Technologies Ltd. 7400233-S0 Rev C Printed in Canada. © 2013 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 1 of 3...
  • Page 41 Ethernet RJ-45, Alpha Modem DB-9, CAN [see shelf specifications] CXCI+ Communication Ports: Ethernet RJ-45, CAN [see shelf specifications] Alpha Technologies Ltd. 7400233-S0 Rev C Printed in Canada. © 2013 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 2 of 3...
  • Page 42 The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice. Alpha Technologies Ltd. 7400233-S0 Rev C Printed in Canada. © 2013 Alpha Technologies Ltd. ALPHA and CORDEX are trademarks of Alpha Technologies Ltd. All Rights Reserved. Page 3 of 3...
  • Page 46 REVISIONS REV BY DATE APPD ADDED LIST OPTIONS 2005/05 UPDATED TO REV C ASSEMBLY 2006/02 UPDATED CXCI CONTROLLER LIST 22 - 5" OFFSET LIST 99 CXCI-CONTROLLER LIST 19 - 6" OFFSET 010-570-20 CXRC POWER MODULE LIST 90 MODULE BLANK LIST 80, 83, OR 84 DISTRIBUTION LIST 21 - FLUSH MOUNT 19"...
  • Page 47 LIST 19 - 6" OFFSET LIST 22 - 5" OFFSET LIST 26 - 5" OFFSET LIST 23 - 6" OFFSET 12.1 12.1 6.0 152 6.0 152 0.7 18 0.7 18 LIST 21 - FLUSH MOUNT LIST 25 - FLUSH MOUNT 3.5 88 3.2 82 18.3 465...
  • Page 48 7. RTS 8. CTS 9. R1 ETHERNET RJ45 1. TX THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ALPHA TECHNOLOGIES AND SHALL NOT BE COPIED OR USED 2. TX FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. MATERIAL DESIGN 2005/04 3. RX...
  • Page 49 NOT CONNECTED CAN L NOT CONNECTED +5 V CAN CAN UNTERMINATED THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ALPHA TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. SCALE TITLE CUSTOMER CONNECTION, 2RU,4 MDL,CXC,DISTRN,650W...
  • Page 50 REFER TO MANUAL FOR JUMPER SETTINGS FOR JP2 1 2 3 4 TB13 THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ALPHA TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. SCALE TITLE CUSTOMER CONNECTION,...

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