Related Manuals for Alpha Technologies CXDF 24-48/2kW
Summary of Contents for Alpha Technologies CXDF 24-48/2kW
- Page 1 Cordex DC/DC Converter CXDF 24-48/2kW, 24V In – 48V Out Installation & Operation Manual Part # 012-526-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 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 e plus près.
- Page 6 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 7 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 8 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 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: Legen Sie sämtlichen Schmuck aus Metall wie z.B.
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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 ........................3 .................................. 4 EATURES Converter Module ............................4 Cordex Integrated System Controller (CXCI/CXCI+) Option ................5 System Controller Front Panel ......................... - Page 12 IGURES Figure 1–Perspective view of CXDF 24-48/2kW converter module ................1 Figure 2–Cordex CXCI model system controller front panel ................... 5 Figure 3–Cordex CXCI+ model system controller front panel ..................6 Figure 4–Showing CXCI/CXCI+ blank plate removal ....................10 Figure 5–Showing CXCI+ controller module installation ....................11 Figure 6–Baffle and pem removal ..........................
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Page 13: Introduction
• Product Overview The CXDF 24-48/2kW isolated DC-DC converter employs a high frequency switched mode conversion technique to provide a fully regulated and isolated -48 Volt DC output from a +24 Volt DC input. Each module is a stand-alone converter element, which plugs into a common shelf. The shelf provides external connections for input, output, and alarm interfaces. - Page 14 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 (pre-RoHS #018-557-B2).
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Page 15: Part Numbers And List Options
Cordex DC/DC 2kW converter, 24V In – 48V Out, 23” (flush mounting) 2RU shelf ........030-900-20 [may be equipped with one CXCI/CXCI+ controller and up to five CXDF 24-48/2kW converters] ....*List 0 23” rack, 6” offset mounting ..........................List 24 Charcoal finish with white (contrasting) silkscreen .................. -
Page 16: 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 17: Cordex Integrated System Controller (Cxci/Cxci+) Option
Cordex Integrated System Controller (CXCI/CXCI+) Option The CXCI/CXCI+ option 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: Designed to communicate directly with Cordex converters... -
Page 18: Figure 3-Cordex Cxci+ Model System Controller Front Panel
NOTE: 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. 2.3.4... -
Page 19: 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 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 converter/rectifier systems. -
Page 22: Installing A Cxci/Cxci
Tighten the thumbscrew (1/4-turn) latch on the bottom of the faceplate to secure the module to the shelf. NOTE: 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 23: 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 4.5.3 CXCI Module Installation 1. Remove blank plate as described previously. 2. -
Page 24: Figure 7-Showing Cxci Module Preparation
Remove two (2) side mounting screws to release the CXCI front panel Gently remove LCD Figure 7–Showing CXCI module preparation Install by placing the CXCI module on the shelf bottom Install front and sliding the mounting screw to module into the rear secure body of connector (inside of CXCI module... -
Page 25: Wiring And Connections
Wiring and Connections This chapter provides cabling details and notes on cable sizing for DC applications. NOTE: 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 26: Can Serial Ports
5.5.1 Modem Port (not available on the CXCI+) The Modem port is designed for CXCI connection to the Alpha Technologies’ Cordex DC Modem (#018-585-20) via a front panel DB-9 connector. Connect to the CXCI from the modem with the Alpha-supplied DB-9 cable. -
Page 27: Signal Wiring Connections For Cxci/Cxci
Signal Wiring Connections for CXCI/CXCI+ NOTE: 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 deg. - Page 28 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. Voltage Level (VDC) Voltage Level (VDC) Voltage Range (VDC)
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Page 29: 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 30: Cxc Reset
CXC Reset 6.4.1 Soft Reset The reset button located on the front panel of the CXC is for restarting the microprocessor. When pressed momentarily, the unit beeps twice then resets. The front-panel LED’s will illuminate temporarily, but will extinguish after the system has finished its 15-second self-test. CAUTION: During rest, the controller may need to run a defragmentation cycle. -
Page 31: 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. NOTE: 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 32: 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 33: Figure 12-Showing Cxci (Original Design) Replacement Detail
Screw 3 and 4 Screw 1 and 2 (2PL) Figure 12–Showing CXCI (original design) replacement detail 10. Replace CXCI following steps 7 and 8 in reverse order. CAUTION - Do not push on the LCD. To replace original design with the latest CXCI/CXCI+ design, refer to the Installation chapter (remove the pem, etc.), and then continue with the next steps regarding the CXC/CXCI+ configuration. -
Page 34: 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 35 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 36: Warranty
8 Warranty For full warranty information, please contact us: Tel: +49 9122 79889 0 Mail: info@alpha-outback-energy.com 8.1 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 37: 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 38 High current terminals, hot-swappable Cooling: Forced air, front-to-back I/O Protection: Internal fusing Alpha Technologies Ltd. 012-526-B2 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 39 Vibration and Shock Bellcore GR-1089-CORE: Electromagnetic Compatibility and Electrical Safety Alpha Technologies Ltd. 012-526-B2 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 40 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. 012-526-B2 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 41 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 42 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 43 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 45 SCALE: ANGULAR: CUSTOMER CONNECTION TITLE: SHELF 23",5MDL,CXDF 2kW NOT CONNECTED NAME DATE NOT CONNECTED DESIGN 2007/12 ISSUE SHEET NOT CONNECTED DATE DRAWN 2007/12 NOT CONNECTED CXCI+ SIZE TYPE DWG NO. 030-900-08 CHECKED 2007/12 APPROVED 2007/12 2013 ALPHA TECHNOLOGIES © ©...
- Page 46 REVISIONS DESCRIPTION DWN DATE APPD A1 DIM ADDED 08/06 332.0 13.07 324.0 12.76 List 19 6" OFFSET FOR 19" RACK 152.4 6.00 20.0 0.79 List 24 6" OFFSET FOR 23" RACK 18.0 0.71 012-526-20 MODULE 305.2 12.02 88.4 3.48 82.3 3.24 56.9 2.24 50.6...
- Page 47 CAN L NOT CONNECTED NOT CONNECTED ETHERNET RJ45 FUNCTION THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF ALPHA TECHNOLOGIES AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT. UNITS: mm [in] X [X.X] [ 0.040] NOT CONNECTED X.X [X.XX]...
- Page 48 18.94 584.1 22.99 ITEM 59.4 2.34 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] X.XX [X.XXX]...
- Page 49 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] ETHERNET RJ45 DB9 (FOR CXCI ALPHA DC X [X.X]...
- 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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