Related Manuals for Alpha Technologies CXDF 48-24Vdc/2kW
Summary of Contents for Alpha Technologies CXDF 48-24Vdc/2kW
- Page 1 Cordex DC/DC Converter CXDF 48-24/2kW, 48V In – 24V Out Installation & Operation Manual Part # 012-527-B2 Effective: 07/2020 Your Power Solutions Partner...
- Page 3 Important Safety Instructions 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 and Outback Energy GmbH or the nearest AOE representative.
- Page 4 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 5 Seguridad GUARDE ESTAS INSTRUCCIONES: Este manual contiene instrucciones de seguridad importantes que deben seguirse durante la instalación, reparación y mantenimiento del producto. Manténgalas en un lugar seguro. 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 and Outback Energy GmbH o con su representante de AOE más cercano.
- Page 6 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 7 Sécurité CONSERVEZ CES INSTRUCTIONS: Le présent manuel contient des consignes de sécurité importantes à suivre pendant l'installation, l'entretien et la maintenance du produit. Rangez-le dans un endroit sûr. Examinez les schémas et illustrations contenus dans ce manuel avant de poursuivre. En cas de questions sur l'installation ou le fonctionnement en toute sécurité de ce produit, contactez Alpha and Outback Energy GmbH ou le représentant d'AOE le plus près.
- Page 8 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 9 Wichtige Sicherheitshinweise BEWAHREN SIE DIESE ANWEISUNGEN AUF: Dieses Handbuch enthält wichtige Sicherheitshinweise, die bei der Installation, Wartung und Instandhaltung des Produkts beachtet werden müssen. Bewahren Sie es an einem sicheren Ort auf. Sehen Sie sich die Zeichnungen und Illustrationen in diesem Handbuch genau an, bevor Sie fortfahren.
- Page 10 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: •...
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Page 11: Table Of Contents
ABLE OF ONTENTS ................................1 NTRODUCTION Scope of the Manual ............................. 1 Product Overview ............................1 Part Numbers and List Options ........................2 ................................... 3 EATURES Converter Module ............................3 Cordex Integrated System Controller (CXCI/CXCI+) Option ................ 4 System Controller Front Panel ........................4 Analog Input Channels .......................... - Page 12 ABLE OF IGURES Figure 1–Perspective view of CXDF 48-24/2kW converter module ................. 1 Figure 2–CXCI model system controller front panel ......................4 Figure 3–Cordex CXCI+ model system controller front panel ..................5 Figure 4–Showing CXCI/CXCI+ blank plate removal ....................... 9 Figure 5–Showing CXCI+ controller module installation ....................
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Page 13: Introduction
Introduction Scope of the Manual This instruction manual explains the installation and interconnection of the Alpha CXDF 48-24/2kW. Both the converter modules and the shelves, which the modules are plugged into, are covered in this manual. The following documents and drawings are included in this manual to provide the necessary information required for installation, routine operation and fault diagnosis of the unit: •... -
Page 14: Part Numbers And List Options
There are two external CXC models that can communicate with the converter shelf via offset RJ-12 shelf connectors. The CXCR is mounted in a rack and the CXCP is (factory) mounted in a panel. Each of these models has a touch screen display, similar to that used in a Personal Digital Assistant (PDA). See manual #018-587-B2 (non-RoHS #018-557-B2). -
Page 15: Features
Features Converter Module The Cordex converter modules plug into the Cordex converter shelf. The modules can be installed or removed from a system without disturbing the system provided sufficient current capacity remains. This is often referred to as “Hot Swap.” The total output current capacity of the converter system is equal to the sum of the individual current capacities of the converter modules. -
Page 16: Cordex Integrated System Controller (Cxci/Cxci+) Option
Cordex Integrated System Controller (CXCI/CXCI+) Option The controller is mounted in the converter system shelf and brings advanced monitoring technology to the Cordex series of converters. 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: •... -
Page 17: Figure 3-Cordex Cxci+ Model System Controller Front Panel
Refer also to the software manual – always select the Reset menu item before pressing the reset button. 2.3.3 Modem Port (not available on the CXCI+, list 98) The Modem port (front panel DB-9 connector, Figure 2) is designed for connection to Alpha Technologies’ Cordex DC Modem #018-585-20. CAUTION Connect only Alpha-supplied modem and cable;... -
Page 18: Analog Input Channels
Analog Input Channels 2.4.1 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 V2 for load and 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 19: 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 20: 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 this manual. Safety Precautions WARNING Hazardous voltages are present at the input of converter/rectifier systems. -
Page 21: Cxci/Cxci+ Installation
Tighten the thumbscrew (¼-turn) latch on the bottom of the faceplate to secure the module to the shelf. Do not force a module into position if it does not seat properly. All modules are keyed to ensure that the correct module (polarity/voltage) type is used. -
Page 22: Figure 5-Showing Cxci+ Controller Module Installation
3. Place the CXCI+ controller module on the bottom of the shelf and slide into the rear connector at the back of the slot. Figure 5–Showing CXCI+ controller module installation 4.5.2.2 Installing a CXCI Controller Module 1. Remove blank plate as described previously. 2. -
Page 23: Figure 7-Showing Cxci Module Preparation
Gently remove LCD circuit Remove two (2) side mounting screws to release the CXCI front panel Figure 7—Showing CXCI Module Preparation Install front mounting screw Install by placing the to secure body of CXCI module on the shelf CXCI module bottom and sliding the module into the rear connector (inside of the... -
Page 24: Wiring And Connections
Wiring and Connections This chapter provides cabling details and notes on cable sizing for DC applications. Refer also to foldout drawings located at the rear of the manual. Safety Precautions WARNING: Ensure that power is removed by turning off rectifiers (if equipped) and removing the battery line fuse circuit breaker or connection before attempting work on the converter wiring connections. -
Page 25: Can Serial Ports
5.5.1 Modem Port (not available on the CXCI+, list 98) The Modem port (front panel DB-9 connector, Figure 2) is designed for CXCI connection to Alpha Technologies’ Cordex DC Modem #018-585-20 (complete with Alpha cable). CAUTION: Connect only Alpha-supplied modem and cable; otherwise, equipment damage can result. -
Page 26: Signal Wiring Connections For Cxci/Cxci
Signal Wiring Connections for CXCI/CXCI+ To aid the user with installation, frequent reference is made to drawings located at the rear of this manual. Custom configurations may be detailed within the Alpha power system documentation package. For terminal block connections, the recommended wire sizes are 0.14 to 0.75mm (#26 to #18 AWG) for the temperature range of 0 to 50°C (as per UL/CSA). - Page 27 5.6.2.2 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.
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Page 28: 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 power is off, battery is disconnected, and all modules are removed from the shelves. • Triple check the polarity of all connections. -
Page 29: Cxc Reset
time, the present implementation turns off the converter before the programming. The programming time is added to the Start Delay to provide the total amount of time for which the converter will be off or out-of-service. Therefore, with one redundant converter in a system, the load will still receive power from the other converters while one of them is being programmed. -
Page 30: 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. Consult factory for replacement parts. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year. -
Page 31: Cxci/Cxci+ Replacement Procedure
CXCI/CXCI+ Replacement Procedure 7.2.1.1 Replacing a CXCI controller 1. Write down the CXC communication information: dynamic or static IP, IP address, and gateway. 2. Connect a laptop to CXC per software manual; standard network crossover cable to Ethernet port. 3. Save the CXC configuration file (see software manual Logs and Files > Manage Configuration File > Save Full Site Configuration). -
Page 32: Figure 12-Showing Cxci (Original Design) Replacement Detail
9. Remove four (4) mounting screws from the CXCI as shown below. The first two screws will release the front panel from the controller circuit board to expose the third screw that releases the LCD circuit board. Carefully remove the LCD board to expose the fourth and final screw to release the remains of the CXCI. Screw 3 and 4 Screw 1 and 2 (2PL) Figure 12–Showing CXCI (original design) replacement detail... -
Page 33: Figure 13-Cordex Cxci+ Controller Module
7.2.1.2 Replacing a CXCI+ Controller 1. Write down the CXC communication information: dynamic or static IP, IP address, and gateway. 2. Connect a laptop to CXC per software manual; standard network crossover cable to Ethernet port. 3. Save the CXC configuration file (see software manual Logs and Files > Manage Configuration File > Save Full Site Configuration). - Page 34 7.2.1.3 Replacing a CXCI Controller with a CXCI+ Controller 1. Write down the CXC communication information: dynamic or static IP, IP address, and gateway. 2. Connect a laptop to CXC per software manual; standard network crossover cable to Ethernet port. 3.
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Page 35: Warranty
Warranty For full warranty information, please contact us: Tel: +49 9122 79889 0 Mail: info@alpha-outback-energy.com Warranty Alpha and Outback Energy GmbH . 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 AOE’s discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized location during the warranty period. -
Page 36: Acronyms And Definitions
Acronyms and Definitions Alternating current ANSI American National Standards Institute American wire gauge Controller area network Canadian Electrical Code Circular mil area Canadian Standards Association Cordex™ series; e.g., CXC for Cordex System Controller Direct current DHCP Dynamic host configuration protocol Electromagnetic compatibility Electromagnetic interference Electrostatic discharge... - Page 37 Specifications for Alpha Technologies Cordex DC/DC Converter, 48V to 24V Module Input Voltage: -42 to -60 Vdc Efficiency: >88% @ 50 to 100% load Electrical Noise: <32 dBrnC (voice band) <10 mV 10 kHz to 10 MHz (wideband) <150 mVp-p 10 kHz to 100 MHz Current: <48 A @ 48 Vdc input, 55 A maximum...
- Page 38 Specifications for Alpha Technologies Cordex DC/DC Converter, 48V to 24V Continued Mechanical, 19" Shelf Size: 88.4 mm H x 438 mm W x 332 mm D overall, includes handle and rear terminal cover but does not include mounting brackets (3.48" H x 17.2" W x 13.1" D) Mounting: Flush (only for 19"...
- Page 39 Specifications for Alpha Technologies Cordex DC/DC Converter, 48V to 24V Continued Shelf Connections (rear access except where noted) Input, -48V, Feed A: 3/8" holes, 1” spacing (1 set) Input, -48V, Feed B: 3/8" holes, 1” spacing (1 set) Shelf Common Return: 3/8"...
- Page 40 Specifications for Alpha CXCI/CXCI+ Cordex Controller Integrated Model Basic Unit, CXCI/CXCI+ CXCI Input Voltage: 17 to 65Vdc within rated limits [9 to 65Vdc for shelf systems with 12V rectifiers (List 3)] CXCI+ Input Voltage: 10 to 65Vdc within rated limits Current: <100mA @ 48Vdc <200mA @ 24Vdc...
- Page 41 Specifications for Alpha CXCI/CXCI+ Cordex Controller Integrated Model Continued In Accordance with FCC requirements, we provide the following statement as specified in the FCC guidelines for conformance to Part 15, Class A: NOTE: The CXCI has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules.
- Page 42 Specifications for Alpha CXCI/CXCI+ Cordex Controller Integrated Model Continued Software Specifications, CXCI/CXCI+ CXCI Software version: All CXCI+ Software version: 2.10 minimum Recommended Signal Wire Sizes (as per UL/CSA) Wire Size Range: 0.14 to 1.50mm (#26 to #16 AWG) Temperature Range: 0 to 50°C (32 to 122°F) CAUTION –...
- Page 43 22.99 ITEM SHOWN WITH LIST 80 59.8 2.35 THESE DESIGNS AND SPECIFICATIONS ARE CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE COPIED OR USED WITHOUT ITS WRITTEN CONSENT. UNITS: mm [in] X [X.X] [ 0.040] X.X [X.XX] [ 0.020]...
- Page 44 NOT CONNECTED CAN L NOT CONNECTED NOT CONNECTED THESE DESIGNS AND SPECIFICATIONS ARE CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE COPIED OR USED WITHOUT ITS WRITTEN CONSENT. UNITS: mm [in] X [X.X] [ 0.040] X.X [X.XX] [ 0.020]...
- Page 45 59.5 2.34 11.9 0.47 UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF 0.05 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE X.XX 0.01 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XXX 0.005 APPROVALS...
- Page 46 ITEM FUNCTION UNLESS OTHERWISE SPECIFIED THESE DESIGNS AND SPECIFICATIONS ARE DIM ARE IN INCHES CONFIDENTIAL, REMAIN THE PROPERTY OF 0.05 ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE X.XX 0.01 COPIED OR USED WITHOUT ITS WRITTEN CONSENT X.XXX 0.005 NOT CONNECTED...
- Page 47 REVISION DESCRIPTION DATE APPD Chg'd PCB Numbers 09/06 Assy200 E100(+24V) E100(+24V) PCB,48V to 24V,Main,CXDF 2kW S500 E101(-24V) E101(-24V) P/N:707-687-20 LIST 0 E1(+54V) E1(+54V) SCHEMATIC:707-687-05 E4(-54V) E4(-54V) S501 P100 DC INPUT PCB,48V to 24V,Conn,CXDF 2kW PCB,48V to 24V,Collector,CXDF 2kW P/N: 707-688-20 LIST 0 42Vdc to 60Vdc P/N:707-689-20 LIST 0 SCHEMATIC: 707-688-05...
- Page 48 REVISIONS DESCRIPTION REV BY DATE APPD SECURED TO RACK WITH TWO #12-24 x 1/2" TAPPING SCREWS FRONT RACK VIEW (TYPICAL MOUNTING SHOWN) REAR RACK VIEW (TYPICAL MOUNTING SHOWN) 0.25 25 PIN DB CONNECTOR 1.25 32 3.5 88 0.5 13 1.25 32 THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT.
- Page 49 REVISIONS DESCRIPTION REV BY DATE APPD 1 2 3 1 NO NO 14 C 15 3 NC NC 16 4 NO NO 17 C 18 6 NC NC 19 + 20 - 21 FRONT VIEW + 22 DB25 PIN OUT - 23 11 + 14.
- Page 52 Worldwide Corporate Offices Headquarter Germany France and Benelux Russia Eastern Europe fbnl@alpha-outback-energy.com ee@alpha-outback-energy.com russia@alpha-outback-energy.com Hansastrasse 8 D-91126 Schwabach Tel: +49 9122 79889 0 Middle East Spain Africa Fax: +49 9122 79889 21 me@alpha-outback-energy.com spain@alpha-outback-energy.com Mail: info@alpha-outback-energy.com africa@alpha-outback-energy.com Alpha and Outback Energy GmbH reserves the right to make changes to the products and information contained in this document without notice. Copyright © 2020 Alpha and Outback Energy GmbH. All Rights reserved.
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