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Summary of Contents for Alpha Technologies CXPS-E101
- Page 1 CXPS-E101 Power Systems Technical Guide: 0540569-J0 Effective: 08/2018 Alpha Technologies Ltd.
- Page 3 The material contained in this document is for information only and is subject to change without notice. While reason- able efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies assumes no liability resulting from errors or omissions in this document, or from the use of the information contained herein.
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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. Wiring ..........................26 7.1 Installation Notes ........................26 7.2 Ground Sizing .......................... 27 7.3 AC Feeder Protection/Sizing ....................27 7.4 AC Wiring ..........................27 7.5 DC Wiring ..........................28 7.6 System and Battery Connections ..................... 28 7.7 Chassis Ground and Return Bus Bar Connections ..............29 7.8 Distribution Cabling ........................
- Page 6 List of Figures Figure 1 — Front view of the CXPS-E101 48V 225A ................ 7 Figure 2 — CXPS-E101 100A Configuration ..................8 Figure 3 — CXPS-E101 225A Configuration ..................8 Figure 4 — CXPS-E101 225A (CXCM1 HP) Configuration .............. 8 Figure 5 — Front Panel Status Indicators ..................11 Figure 6 — CXDM-E1 Rear Output Connections ................11 Figure 7 —...
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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. Save this document for future reference. -
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 covers the features and installation of the Alpha Technologies CXPS-E101 series 100A and 225A 48Vdc power systems. In addition to this manual, the following documents may be included in the documentation package that ships with the CXPS-E101: •... -
Page 10: System Configurations
2.3 System Configurations The following configurations are currently available for the CXPS-E101 power system. For more ordering information, refer to the CXPS-E101 Ordering Guide on the Alpha website. Table A — Configuration CXPS-E101 Configuration Table Rack Size Controller Current Rectifier... -
Page 11: Specifications
3. Specifications Table B — CXPS-E101 Series - 48Vdc Power Systems Electrical Output Voltage: 48Vdc (nominal) CXPS-E101 225A CXPS-E101 100A 1.2 kW Rectifier Module: Capacity System: Capacity System: Current: 225A max @ 48Vdc 100A max @ 48Vdc 25A max @ 48Vdc... - Page 12 Table B — CXPS-E101 Series - 48Vdc Power Systems Mechanical CXPS-E101 100A CXPS-E101 225A Capacity Rectifier: Capacity System: System: 90 x 438 x 381mm (3.5 x 133 x 438 x 381mm (5.25 x Dimensions, H x W x D 17.24 x 14.35in) 17.24 x 14.35in)
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Page 13: Features
4. Features 4.1 CXDM-E1 Distribution Panel 4.1.1 Distribution Panel Status Indicators The LEDs, located on the front panel, indicate the following information: Table C — Status Indicators POWER (Green): Power to the shelf INHIBIT (Yellow): LVD switch in override ALARM (Red): Breaker tripped 4.1.2 Distribution Configurations POWER... -
Page 14: Figure 7 - Lvbd Override Switch (Front Cover Removed)
4.1.3 Low Voltage Battery Disconnect (LVBD) A 225A LVBD is installed in series with the batteries. The LVBD override switch is located behind the front panel, which can be removed by loosening the thumbscrews. The switch can then be used to override LVBD contactor operation as a safeguard during controller maintenance. -
Page 15: Overview Of The Cxcm1+ Controller
4.2 Overview of the CXCM1+ Controller 4.2.1 CXCM1+ Controller Front Panel System Status LEDs LCD Screen Display pushbutton toggle switch (V/A) Reset-Push once for soft reset Hold 3 seconds to reset IP address Ethernet Port Figure 8 — CXCM1+ Controller Front Panel 4.2.2 LCD Screen The controller front panel uses a 4-digit LCD screen to monitor the system voltage (V) and current (A). - Page 16 RJ-45 jack and a standard network cable. Local access (e.g. laptop computer) is also possible from the Ethernet port connection using a standard network cable. 4.2.6 Analog Input Channels The controller is provided with analog input channels for voltage, current, and temperature. Voltage Inputs Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage.
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Page 17: Overview Of The Cxcm1 Hp Controller
4.3 Overview of the CXCM1 HP Controller 4.3.1 CXCM1 HP Controller Front Panel LED Screen Forward and Back Buttons to scroll through Menus and Select button to Execute System Status LEDs USB Port Ethernet Port Figure 9 — CXCM1 HP Controller Front Panel 4.3.2 Display In dashboard mode, the in-shelf display shows the key operating parameters of a system. -
Page 18: Figure 11 - In-Shelf Controller Full Menu
4.3.3 In-Shelf Display: Menu From the OLED dashboard, use the Select button to enter a menu. From the menu, the OLED display lets you ex- ecute a set of commands much like the LCD screens on the CXC HP. When you enter a menu, the top item is highlighted. To go to another menu scroll through using the Forward and Back buttons. -
Page 19: Cordex Cxrf-Hp Rectifier
4.4 Cordex CXRF-HP Rectifier The Cordex CXRF-HP series of 48V 1.2kW rectifier modules employ high frequency, switch mode technology featur- ing high power conversion efficiency. All internal semiconductor devices operate under “soft-switching” conditions and exhibit very low power loss. The reduced power loss leads to lower thermal stress on the semiconductors and thus improves reliability. - Page 20 4.4.3 Mechanical A locking clip automatically secures the rectifier into the shelf. 4.4.4 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 21 4.4.10 Start Delay The rectifier modules are equipped with a delay timer in order to stagger start a series of modules to prevent exces- sive loading of generators upon start up. The built-in timer delays the turn on of the module depending on the value selected (up to 120 seconds) via the controller.
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Page 22: Inspection
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. 5.2 Check for Damage Before unpacking the product, note any damage to the shipping container. -
Page 23: Installation
6. Installation Only qualified personnel should install and connect the power components within the Alpha power system. For the battery installation, refer primarily to the manufacturer’s manual. 6.1 Safety Precautions Refer to the Safety section near the front of this manual. 6.2 Tools Required Various insulated tools are essential for the installation. -
Page 24: Rectifier Module Insertion/Removal
6.4 Rectifier Module Insertion/Removal 6.4.1 To Insert a Module 1. Place the module on the shelf bottom and slide it into the rear connector. 2. Apply pressure to the module to make it connects properly. 3. Use the locking clip to secure the rectifier into the shelf. Module locking clip at resting position... -
Page 25: Breaker Installation
6.5 Breaker Installation 6.5.1 To Install a Breaker 1. Ensure mid-trip breakers are used for load and series-trip breakers are used for battery connections. 2. Turn the breaker OFF. 3. Orient the breaker so that the actuator is pointing to the right, with the breaker in the OFF position. 4. -
Page 26: Battery Installation
6.6 Battery Installation This information is provided as a guideline and is not meant to imply that batteries are part of this power system. WARNING! Follow the battery manufacturer’s safety recommendations when working around bat- tery systems and review the safety instructions provided in this manual. 6.5.3 Preparation/Mounting The batteries should be located in a temperature-controlled environment. -
Page 27: Battery Maintenance Report
6.7 Battery Maintenance Report After assembly, number the batteries and take “as received” readings, including specific gravity, cell voltage, and tem- perature. Designate one cell as the pilot cell. This is usually the cell with either the lowest specific gravity or voltage. Refer to the manufacturer's literature for guidelines. -
Page 28: 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 29: Ground Sizing
Table G — Cable size equivalents (AWG to Metric) Cable size Circular mils Square millimeters Equivalent metric cable 313 MCM (or kcmil) 313600 150 or 185 350 MCM (or kcmil) 350000 177.36 373 MCM (or kcmil) 373700 185 or 240 500 MCM (or kcmil) 500000 253.36... -
Page 30: Dc Wiring
7.5 DC Wiring WARNING! Leave the cables or bus bars disconnected at the battery and verify the output polarity using a voltmeter. Make the battery connections only after all other wiring is complete. DC output wire 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 31: Chassis Ground And Return Bus Bar Connections
7.7 Chassis Ground and Return Bus Bar Connections The CXPS-E101 has two ground connections: one for chassis ground to the rack and the other to connect the return bus to the main grounding bus (MGB). The recommended wire size is #2 AWG (35mm²) insulated cable. -
Page 32: Distribution Cabling
Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a 0.5V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker. Terminate distribution cabling with 1/4"–5/8" center lugs for connecting to CXPS-E101. NOTE: Connect load breaker returns before hot connections. -
Page 33: Alarm And Signal Connections
7.9 Alarm and Signal Connections 1. Locate the terminal block on the rear of the CXPS-E101. Refer to Figure 20 and the schematic drawing at the end of this manual for details on terminal block assignments. 2. Connect these alarms and signals to the local alarm-sending unit. Use wire sizes #20 to #26 AWG (0.518 to 0.14mm²). -
Page 34: Figure 22 - Digital Input Connection Method
7.10.2 Digital Inputs The factory-installed digital input channels are used to monitor various alarm and control signals. All input channels are voltage activated and directly accept a bipolar (negative or positive) DC signal. D1 and D2 are available for customer connections Connection Method Typical Alpha systems use a “reset with Hot and trigger with Ground”... -
Page 35: Can Serial Ports
7.11 CAN Serial Ports The CAN serial port(s) are located on the sides of each rectifier shelf. CAN serial ports are modular jacks with offset latches that are used to communicate with the rectifiers and other CAN-enabled equipment (nodes) on the same system. -
Page 36: System Startup
8. System Startup 8.1 Check System Connections • Ensure that the AC input is switched off, the battery breaker is off, and all power modules are removed from the shelf. • Triple-check the polarity of all the connections. 8.2 Verify AC Input and Power Up Rectifier Shelf 1. -
Page 37: Lvd Control
8.4.2 Controller IP Address Reset To reset the IP address, press and hold the front panel reset button for three seconds. The controller unit will beep three times, the IP will be reset (to 10.10.10.201), and DHCP will be disabled. The settings will be saved and the unit will then reset. -
Page 38: 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, under software control, can directly adjust the output voltage. Situations, such as the rectifier being in current limit, can change the output voltage with no software control. -
Page 39: Factory Ranges And Defaults
9.2 Factory Ranges and Defaults The following table lists the rectifier settings/ranges/defaults; changes are made from the CXC: Table L — Rectifier factory ranges and defaults Setting Range (minimum to maximum) Default Float (FL) Voltage 48 – 58V Equalize (EQ) Voltage 50 – 58V Battery Test (BT) Voltage 44 – 52V Over Voltage Protection (OVP)*... -
Page 40: 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. WARNING! Use extreme care when working inside the unit while the system is energized. -
Page 41: Troubleshooting
10.3 Troubleshooting Table N — Troubleshooting Symptom Reason Solution Distribution is not communicating with DB 25 cable is not plugged in. Plug in DB 25 cable. the controller Distribution panel is turned off. Slide the POWER on/off switch to the ON (up) position on the logic board. No load/battery circuit breaker trip DB 25 cable is not plugged in. Plug in DB 25 cable. -
Page 42: Warranty Statement And Service Information
11. Warranty Statement and Service Information 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. Warranty Statement For full information details review Alpha's online Warranty Statement at www.alpha.ca/support. 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 manual will take precedence. -
Page 43: Acronyms And Definitions
12. Acronyms and Definitions Alternating current ANSI American National Standards Institute American Wire Gauge Battery return bus 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... -
Page 44: 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 52 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. 0540569-J0 (08/2018) Copyright © 2018 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.
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