EnerSys Alpha Cordex HP 3.0kW Technical Manual
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EnerSys Alpha Cordex HP 3.0kW Technical Manual

Switched mode rectifier system
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Cordex HP 3.0kW
Switched Mode Rectifier System
Technical Guide: 0100037-J0
Effective: 04/2020

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Summary of Contents for EnerSys Alpha Cordex HP 3.0kW

  • Page 1 Cordex HP 3.0kW Switched Mode Rectifier System Technical Guide: 0100037-J0 Effective: 04/2020...
  • Page 3 Cordex HP Modular Switched Mode Rectifier System Shelf Models: 19" 1RU universal mount 12000W 23" 1RU universal mount 15000W NOTE: Photographs contained in this manual are for illustrative purposes only. These photo- graphs may not match your installation. NOTE: Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding.

  • 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 2.1 Scope of the Manual ........................7 2.2 Product Overview ........................
  • Page 5 7.7 Shelf ID Connection (optional) ....................25 7.8 Signal Wiring Connections to L-ADIO Board (optional) ............26 8. System Startup ........................27 8.1 Check System Connections ..................... 27 8.2 Verify AC and Power the Rectifier Shelf ................... 27 8.3 Check Battery Polarity and Connections ................. 27 8.4 CXC HP Reset .........................
  • Page 6 List of Figures Figure 1 — Cordex HP 19" 48Vdc-3.0kW Rectifier Shelf ..............7 Figure 2 — Typical 48V Power System with 3.0kW Rectifiers ............7 Figure 3 — Rectifier Front Panel LEDs ....................11 Figure 4 — Locking Handle Disengaged/Engaged ................. 13 Figure 5 —...

  • Page 7: Safety

    1. Safety SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that must be followed during the installation, servicing, and maintenance of the product. 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.

  • 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 Scope of the Manual This manual explains the installation, interconnection, and operation of the Cordex HP 48-3.0kW rectifier systems. 2.2 Product Overview A complete rectifier system consists of one or more power modules in a common shelf enclosure. The shelf has connections for AC inputs, DC output, and system communications.

  • Page 10: Part Numbers And List Options

    2.3 Part Numbers and List Options The product, options, and accessories can be ordered by using the part numbers in the following table. Description List Option 23in 1RU universal mount 15000W shelf* 0300216-001 (shelf/slot ID supported) – bulk power for external distribution –...

  • Page 11: Specifications

    3. Specifications Table A — 3.0kW Rectifier Specifications Electrical Input voltage: Nominal: 208 to 277Vac Operating: 85 to 310Vac Extended: 85 to 187Vac (de-rated power) Input frequency: 45 to 65Hz Power: 3000W continuous Linear de-rating from 187Vac to 85Vac, 1200W @ 90Vac Power Factor: >0.98 (50 to 100% load, nominal voltages) THD:...
  • Page 12 3.3.1 Cordex 48-3.0kW Rectifier Shelves 23in 1RU universal mount 15,000W shelf P/N 0300216-001 (shelf/slot ID supported) Number of Rectifiers: 5 x CXRF HP 48-3.0kW Nominal AC input current (two 120VAC/29A (per feed), 50/60Hz modules per feed): 208-277VAC/31-24A (per feed), 50/60Hz Recommended input feeder breakers 40A per feed for nominal 120, 208, 240, 277 Vac (three feeds per shelf):...

  • Page 13: Features

    4. Features 4.1 3.0kW Rectifier 4.1.1 Front Panel LEDs The front panel LEDs indicate the rectifier status summary and patterned response to Locate Module command. ALARM / FAULT (1) LEDs Figure 3 — Rectifier Front Panel LEDs The red LED is on during an active Module Fail alarm if the module is unable to source power due to a fault condi- tion.
  • Page 14 4.1.2 Rectifier Rear Panel Refer to drawings at the end of this manual for shelf power and communications connections (compatible with 2.4kW recti- fiers): • 0300057-08 • 0300040-08 Refer to drawings at the end of this manual for the 3.0kW shelf ID version. •...

  • Page 15: Figure 4 - Locking Handle Disengaged/Engaged

    4.1.10 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 down to a short circuit condi- tion.

  • Page 16: Distribution

    4.2 Distribution 4.2.1 Bulk • 23" 1RU universal mount P/N 0300057-001 (2.4kW compatible), 0300216-001 (shelf ID support) • 19" 1RU universal mount P/N 0300040-001 (2.4kW compatible), 0300228-001 (shelf ID support) Figure 5 — 19" Shelf with Bulk Distribution Busbars 4.3 Controller The 3.0kW rectifier shelf is designed to operate with the CXC HP controller.

  • Page 17: Inspection

    5. Inspection 5.1 Packing Materials Alpha Technologies is committed to providing products and services that meet our customers’ needs and expecta- tions in a sustainable manner, while complying with all relevant regulatory requirements. As such Alpha Technolo- gies strives to follow our quality and environmental objectives from product supply and development through to the packaging for our products.

  • Page 18: Installation

    6. 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. For the battery installation, refer primarily to the manufacturer’s manual.

  • Page 19: Power System Assembly And Mounting

    6.3 Power System Assembly and Mounting 6.3.1 Mounting and Grounding a Rectifier Shelf 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.

  • Page 20: Wiring

    7. Wiring This chapter provides cabling details and notes on cable sizing for DC applications with respect to the product. WARNING! Ensure that the power is switched off by switching off rectifiers and removing battery line fuses, turn off battery breakers before attempting work on the wiring. Use a volt- meter to verify the absence of a voltage.

  • Page 21: Grounding

    Table B — Cable size equivalents (AWG to Metric) Cable size Circular mils Square millimeters Equivalent metric (see notes 1 and 2) cable 0000 AWG (or 4/0) 211600 107.2 313 MCM (or kcmil) 313600 150 or 185 350 MCM (or kcmil) 350000 177.36 373 MCM (or kcmil)

  • Page 22: Can Serial Ports (Rectifier Shelf)

    7.3 CAN Serial Ports (Rectifier Shelf) Two CAN Serial ports (modular jacks), are provided for communications with Cordex controllers and other CAN- enabled equipment. These are located on the left side of the rectifier shelf as viewed from the front. 1.

  • Page 23: Ac Wiring 23" Shelf

    7.4 AC Wiring 23" Shelf 7.4.1 AC Feeder Protection/Sizing To maximize system reliability, each feed should have a dedicated protection feeder breaker located at the AC distri- bution panel. The feeder breaker can also act as the disconnect device for the connected modules. Refer to section "3.3.1 Cordex 48-3.0kW Rectifier Shelves"...

  • Page 24: Ac Wiring 19" Shelf

    7.5 AC Wiring 19" Shelf For the 19" shelf, AC wiring is fed separately to each of the four rectifiers. 7.5.1 AC Feeder Protection/Sizing To maximize system reliability it is recommended that, each power module be fed from a dedicated protection feeder breaker located at the AC distribution panel.

  • Page 25: Dc Output Connections - Bulk Distribution

    7.6 DC Output Connections - Bulk Distribution WARNING! Do not complete the final live connections to the battery. Leave open and insulate the final connections or remove the battery fuses. Switch off the battery contacts if used. The DC output wires must be UL approved XHHW or RHH/RHW (RW90 type for Canadian users). Control and sense wires must be UL approved Style 1015 (TEW type for Canadian users).

  • Page 26: Figure 11 - Connecting Output Bars To Customer's Vertical Busbars

    7.6.1 Busbar Connection Multiple shelves can be connected directly to customers’ vertical busbar. 1. Remove the bolts and washers at both positive and negative output bars. Bolts are 3/8-16 x 1", and can accom- modate up to 1/4" thick busbar. 2.

  • Page 27: Shelf Id Connection (Optional)

    7.7 Shelf ID Connection (optional) The Shelf ID module can be used for loading individual rectifiers when multiple shelves are used in multiple bays. Rack-mounted Shelf ID Bay ID 1 (manually set) J2 J3 J4 J5 J6 J7 J8 J9 Bay ID 1 Bay ID 1 Shelf ID 1...

  • Page 28: Signal Wiring Connections To L-Adio Board (Optional)

    7.8 Signal Wiring Connections to L-ADIO Board (optional) For terminal block connections, the recommended wire sizes are 0.823 to 0.129mm (#18 to #26 AWG) for the tem- perature 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. 7.8.1 Relay Outputs Terminals provide contacts for extending various alarm or control signals.

  • Page 29: 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 30: Rectifier Modes And Factory Defaults

    9. Rectifier Modes and Factory Defaults 9.1 Rectifier Modes There are two main rectifier modes: output voltage mode and the output current/power mode. 9.1.1 Output Voltage Modes Voltage modes are under software control, and can be used to directly adjust the output voltage. The qualification of “under software control”...

  • Page 31: Factory Ranges And Defaults

    9.2 Factory Ranges and Defaults Table G shows the rectifier settings/ranges/defaults. Changes are made through the CXC interface. Table G — Rectifier factory ranges and defaults Setting Range (minimum to maximum) Default Float (FL) Voltage 47.5 – 58V Equalize (EQ) Voltage 49.8 –...

  • Page 32: 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 33: Fan Replacement

    10.2 Fan Replacement The fan assembly part number is 7400732-001. The Fan on the individual rectifiers is designed for very high reliability and long life. During year 6 of the life of the product the manufacturer recommends replacement of the fan assembly. 1.

  • Page 34: Figure 18 - 3.0Kw Rectifier Fan Assembly

    4. Disconnect the fan cables from the module by pulling out the fan cable connector. 5. Discard the old fan assembly and unpack the new replacement assembly. Fan cable Figure 18 — 3.0kW Rectifier Fan Assembly 6. Reconnect the fan cable. Insert the connector into the fan connector in the module. Ensure proper polarity and that the wires stay clear of the fan blade.

  • Page 35: Troubleshooting

    11. Troubleshooting The rectifiers and the shelves are designed for simple installation and reliable, trouble-free operation for several years. In most cases the rectifiers will recover from minor alarms and faults automatically. However under certain conditions the rectifiers may need remote control. And under very rare cases the rectifier may need a manual reset (unplug and reinsert the rectifier).

  • Page 36: 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 Electronic Industries Alliance Electromagnetic compatibility Electromagnetic interference Electromagnetic Compatibility and Radio Spectrum Matters Electrostatic Discharge...

  • Page 37: Warranty Statement And Service Information

    13. Warranty Statement and Service Information 13.1 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. 13.2 Warranty Statement For full information details review Alpha's online Warranty Statement at www.alpha.ca/support. 13.3 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: Certification

    14. 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 44 Alpha Technologies Ltd.| 7700 Riverfront Gate, Burnaby, BC V5J 5M4 CANADA Tel.: Toll Free North America: +1 800 667 8743 | Outside North America +1 604 436 5547 | Technical Support +1 888 462 7487 For more information visit our website at: www.alpha.com www.alpha.com ©...

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