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Summary of Contents for Alpha Technologies CXPS-FR3
- Page 1 CXPS-FR3 Power System Technical Guide: 9400018-J0 Effective: 01/2019 Alpha Technologies Ltd.
- Page 3 Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Copyright Copyright © 2019 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 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 5: Table Of Contents
5.5 General Receipt of Shipment ....................19 5.6 Rectifiers (Purchased Separately) ................... 19 5.7 Miscellaneous Small Parts ....................... 19 6. Installation ...........................20 6.1 CXPS-FR3 Lorain Replacement Installation ................20 6.2 CXPS-FR3 PECO II Replacement Installation ................. 21 6.3 CXPS-FR3 Supplemental Bay Installation ................21 9400018-J0 Rev D... - Page 6 7. Wiring ..........................22 7.1 Accessing AC and DC Connections ..................23 7.2 Recommended Torque Values ....................24 7.3 Frame Ground .......................... 24 7.4 AC Connections ........................25 7.5 DC Connections ........................26 7.6 Signal Wire Routing ......................... 27 7.7 Signal Wiring ..........................28 7.8 Inter-bay CAN Communications ....................
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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. 1.1 Safety Symbols To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following sym- bols have been placed throughout this manual. -
Page 8: Electrical Safety
1.3 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. Before working with any live battery or power system, follow these precautions: a. -
Page 9: Introduction
2. Introduction The Alpha Technologies CXPS-FR3 is a standalone rectifier bay that can be used to upgrade inefficient and aging Ferroresonant rectifiers. As a drop-in replacement for RL400 and PECO II 400 rectifiers, the FR3 repurposes existing AC and DC cabling which minimizes installation time and avoids costly replacements. -
Page 10: Specifications
3. Specifications Table A — CXPS-FR3 Specifications Electrical Single 800A B2B & S2S 1200A B2B & S2S 208Vac 3 Phase 208Vac 3 Phase AC Voltage 480Vac 3 Phase 480Vac 3 Phase 480Vac 3 Phase 208Vac: 1x 100A Breaker 208Vac: 2x 100A Breaker... -
Page 11: Features
4. Features The CXPS-FR3 power system is available in various configurations. Refer to ordering guide for a complete list of configurations and accessories. Figure 2 — CXPS-FR3 Lorain replacement Figure 3 — CXPS-FR3 PECO II replacement 9400018-J0 Rev D... -
Page 12: Cxps-Fr3 400A Single Configuration
4.1 CXPS-FR3 400A Single Configuration 1. Replaces one 400A Lorain or PECO II rectifier. 2. One System AC input terminal block, rated 600V / 175A, accepts #2/0 – #14 AWG cable. • 480Vac system: Recommend 50A 480Vac 3-pole feeder breaker, #6 AWG wire. -
Page 13: Cxps-Fr3 800A Back To Back And Side By Side Configuration
4.2 CXPS-FR3 800A Back to Back And Side by Side Configuration 1. Replaces two 400A Lorain or PECO II rectifiers. 2. Two system AC input terminal blocks, rated 600V / 175A that accept #2/0 – #14 AWG cable. • 480Vac system: Recommend 50A 480Vac 3-pole feeder breaker per input, #6 AWG wire. -
Page 14: Cxps-Fr3 1200A Back To Back And Side By Side Configuration
4.3 CXPS-FR3 1200A Back to Back And Side by Side Configuration 1. Replaces three 400A Lorain or PECO II rectifiers 2. Two system AC input terminal blocks, rated 600V / 175A that accept #2/0 – #14 AWG cable. • Recommend 60A 480Vac 3-pole feeder breaker per input, #6 AWG wire. -
Page 15: Cxps-Fr3 System Expansion
4.4 CXPS-FR3 System Expansion Supplemental CXPS-FR3 bays available in the same configurations as the primary bay can be added to further increase system ampacity. A supplemental bay contains the same components as a primary bay except the system controller. Inter-bay communication cables connect the rectifiers in supplemental bays to the primary bay controller. -
Page 16: L-Adio
• Ethernet: dual ports 10/100 BaseT Ethernet connection on both the front and rear of the controller for remote or local communication. • USB: dual ports on both the front and rear of the controller for upgrades and file management via a standard USB flash drive. - Page 17 4.6.1 Analog Inputs Four voltage inputs, V1 – V4, are provided for a variety of voltage monitoring requirements. The input channels can measure a signal between -60Vdc to +60Vdc. Four current input channels, I1 – I4, provide monitoring of current; e.g., discharge (load) and charge (battery). The CXC HP is capable of monitoring standard shunts of 25, 50 and 100mV as well as application specifications of up to 250mV.
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Page 18: Cordex Hp 4.0Kw Rectifiers
4.6.2 6I-ADIO (Optional) The 6I-ADIO is an analog input peripheral providing six isolated shunt inputs. The 6I-ADIO communicates on CAN bus to the CXC HP controller and provides access to shunt inputs via the controller. Figure 10 — 6I-ADIO Power Module 4.7 Cordex HP 4.0kW Rectifiers 4.7.1 Rectifier Features •... -
Page 19: Cordex Hp 12Kw Rectifiers
4.7.2 LED status The three LEDs on the rectifier front panel indicate status (see Figure 11): • AC Input Voltage present (1) • DC Output Voltage present (2) • Rectifier Alarm (3) 4.8 Cordex HP 12kW Rectifiers 4.8.1 Rectifier Features •... -
Page 20: Site Evaluation And Pre-Installation
5. Site Evaluation and Pre-Installation The Alpha CXPS-FR3 power system is designed to use the existing floor mounting hardware and AC input and DC output cables for Lorain or PECO II 400A rectifiers. Alpha recommends to check the integrity of the mounting sur- face/hardware and cabling before proceeding. -
Page 21: Check For Damage
If the original container is unavailable, make sure that the product is packed with at least three inches of shock-absorbing material to prevent shipping damage. Alpha Technologies is not responsible for damage caused by improper packaging of returned products. 5.4 Check for Damage Before unpacking the product, note any damage to the shipping container. -
Page 22: Installation
6. Installation The CXPS-FR3 must be mounted in a clean and dry environment. Provide sufficient free space at the front of the system to allow for unrestricted air flow to the rectifier intakes and provide easy access. No clearance is required for the sides or back of the system for cooling. -
Page 23: Cxps-Fr3 Peco Ii Replacement Installation
1. Remove the existing PECO II rectifier(s). 2. Inspect and replace the anchoring hardware if necessary. 3. Use a 5/16th nut driver to remove the lower front panel of the CXPS-FR3 to access the mounting holes in the base of the frame. See Figure 18. -
Page 24: Wiring
7. Wiring The CXPS-FR3 is designed to use the existing Ferro AC input and DC output wiring. Alpha recommends to inspect the integrity of the existing cables and replace if necessary with agency approved equivalent. WARNING! Before starting, read the safety section of this manual. Verify AC power is OFF and AC panel feeder breakers are locked out and tagged. -
Page 25: Accessing Ac And Dc Connections
7.1 Accessing AC and DC Connections 1. Remove the four panel retaining screws of the front breaker cover using a 5/16" nut driver to remove the panel. 2. Set the front panel and hardware aside. Remove panel Figure 21 — Main Bay Front Breaker Panel Removal 3. -
Page 26: Recommended Torque Values
7.2 Recommended Torque Values Table B lists the recommended torque values for connection to the power system with the following hardware: • Clear hole connections (nut and bolt) • PEM studs • PEM threaded inserts • Thread formed connections (in copper busbar) Grade 5 rated hardware is required for these torque values. -
Page 27: Ac Connections
7.4 AC Connections 1. Loosen but do not remove the AC cover screws on either side of the AC input connection terminal block then slide the cover up to remove. 2. Use a 3/16” Allen wrench to loosen the exposed AC input terminal block connection screws. 3. -
Page 28: Dc Connections
7.5 DC Connections NOTE: For 1200A systems, additional cabling, or upsize in cable gauge, may be required to cover the additional ampacity from each section of the bay. Ensure all cables are the same gauge. It is also important to note, the captive nuts are added only to the ½" on 1 ¾"... -
Page 29: Signal Wire Routing
NOTE: If the overhead bus is energized by the batteries, the system controller will power on and alarms will be present as soon as the initial DC (-) cable is connected. Disregard alarms during this period. 8. For 1200A systems, either upsize the wire gauge or connect additional cables to the third landing on each of the system output busbars. -
Page 30: Signal Wiring
7.7 Signal Wiring 1. Use the Form C relay contacts on the L-ADIO to extend various alarm or control signals to an external site monitor. 2. Use 0.129 mm² (#26 AWG) or larger wire. 3. Bundle signal wires together and route through the conduit to the top of the bay. Figure 27 —... - Page 31 7.7.2 Analog Inputs WARNING! Ensure that the correct polarity is used for all input cable terminations. The analog input channels are used to monitor various types of electrical signals. Some of the analog channels are reserved for specific signals, while others are designated as general-purpose inputs, which accommodate various types of analog signals.
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Page 32: Inter-Bay Can Communications
7.8 Inter-bay CAN Communications NOTE: This section applies only to systems with supplemental bays. The CAN bus provides a communication path between the controller and rectifiers. In a primary bay, the CAN bus cabling is internally daisy-chained from the controller sequentially down from the top to the bottom rectifier shelf. From the last shelf, a CAN cable is extended back up to a CAN OUT jack located at the top of the primary bay. -
Page 33: System Startup
6. Verify that the AC input voltage is correct. Switch the main feeder breaker in the external AC utility panel ON. If installed, switch the feeder breaker in the CXPS-FR3 system corresponding to the installed rectifier module 8. The power module green LED will illuminate after a preset start delay. -
Page 34: Accessory Installation
8.1 Shunt Input Module Kit (18 Shunt) A CXPS-FR3 primary bay includes a standard ADIO module capable of monitoring up to four shunts. Installation of the Shunt Input Module kit expands this monitoring capability to include an additional 18 shunts. Shunt Input Module kits are installed in either the rear or side of primary or supplemental bays. - Page 35 3. Connect the kit green/yellow ground wire to the wall stud. Place the supplied internal/external tooth washer on the stud followed by the wire terminal and supplied nut. Ground wire wall stud Figure 33 — Shunt Input Module Mounting 4. Connect the kit red (+) and black (-) power wires to the extension DC output bars #10-32 tapped holes using the supplied screws.
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Page 36: 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. -
Page 37: Warranty Statement And Service Information
11. Warranty Statement and Service Information 11.1 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. 11.2 Warranty Statement For full information details review Alpha's online Warranty Statement at www.alpha.ca/support. 11.3 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 38: Acronyms And Definitions
12. 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 Electromagnetic Compatibility and Radio Spectrum Matters Electrostatic Discharge Federal Communications Commission (for the USA) Group Speciale Mobile (global system for mobile communications) -
Page 39: 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 84 Fax: +90 216 370 23 68 www.alphapower.mx www.alpha.com.tr Alpha Technologies Ltd. Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. 9400018-J0 (01/2019) Copyright © 2019 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.
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