Alpha Technologies Cordex HP Manuale utente

Your Power Solutions Partner

Cordex HP 2.4kW Switched Mode Rectiﬁer System

Shelf Models: 19" 1RU universal mount 9600W

23" 1RU universal mount 12000W

Installation and Operation Manual

Part # 0100003-J0

Effective 11/2015

member of The Group™

Cordex HP Modular Switched Mode Rectier System

Shelf Models: 19" 1RU universal mount 9600W

23" 1RU universal mount 12000W

For technical support, contact Alpha Technologies:

Canada and USA: 1-888-462-7487

International: +1-604-436-5547

gies.

No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or trans-

mitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or other-

wise without prior explicit written permission from Alpha Technologies.

This document, the software it describes, and the information and know-how they contain constitute the propri-

etary, conﬁdential and valuable trade secret information of Alpha Technologies, and may not be used for any

unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.

The material contained in this document is for information only and is subject to change without notice. While

reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technolo-

gies assumes no liability resulting from errors or omissions in this document, or from the use of the information

contained herein. Alpha Technologies reserves the right to make changes in the product design without reserva-

tion and without notiﬁcation to its users.

Alpha shall not be held liable for any damage or injury involving its enclosures, power

supplies, generators, batteries, or other hardware if used or operated in any manner or

subject to any condition inconsistent with its intended purpose, or if installed or oper-

ated in an unapproved manner, or improperly maintained.

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. If there are questions regarding the safe operation of this powering

system, contact Alpha Technologies or your nearest Alpha representative.

NOTE:

0100003-J0 Rev B

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 ....................................................................................................................... 7

2.3 Part Numbers and List Options .................................................................................................. 8

2.4 Specications ............................................................................................................................. 9

3. Product Features ................................................................................................................11

3.1 Rectier .....................................................................................................................................11

3.2 Distribution ............................................................................................................................... 14

3.3 Controller ................................................................................................................................. 15

4. Inspection............................................................................................................................16

4.1 Packing Materials ..................................................................................................................... 16

4.2 Check for Damage ................................................................................................................... 16

4.3 General Receipt of Shipment ................................................................................................... 16

5. Installation ...........................................................................................................................17

5.1 Safety Precautions ................................................................................................................... 17

5.2 Tools Required ......................................................................................................................... 17

5.3 Power System Assembly and Mounting ................................................................................... 18

6. Wiring ..................................................................................................................................19

6.1 Grounding ................................................................................................................................ 19

6.2 CAN Serial Ports (Rectier Shelf) ............................................................................................ 20

6.3 AC Wiring 23" Shelf .................................................................................................................. 21

6.4 AC Wiring 19" Shelf .................................................................................................................. 22

6.5 DC Output Connections - Bulk Distribution .............................................................................. 23

6.6 DC Output Connections - Single Component Distribution ....................................................... 24

0100003-J0 Rev B

7. System Startup ...................................................................................................................25

7.1 Check System Connections ..................................................................................................... 25

7.2 Verify AC and Power the Rectier Shelf ................................................................................... 25

7.3 Check Battery Polarity and Connections ................................................................................. 25

8. Rectier Modes and Factory Defaults .................................................................................26

8.1 Rectier Modes ........................................................................................................................ 26

8.2 Factory Ranges and Defaults .................................................................................................. 27

9. Maintenance .......................................................................................................................28

9.2 Replacing a Rectier Module ................................................................................................... 28

9.3 Replacing a Rectier Module via the CXC HP Controller ........................................................ 29

9.4 Fan Replacement ..................................................................................................................... 30

10. Troubleshooting ................................................................................................................32

11. Acronyms and Denitions ..................................................................................................33

12. Warranty Statement and Service Information ...................................................................34

12.1 Technical Support .................................................................................................................. 34

12.2 Warranty Statement ............................................................................................................... 34

12.3 Product Warranty ................................................................................................................... 34

12.4 Battery Warranty .................................................................................................................... 34

12.5 Warranty Claims ..................................................................................................................... 34

12.6 Service Information ................................................................................................................ 34

0100003-J0 Rev B

List of Figures

Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectier Shelf, (b) Typical 48V Power Systems with

2.4kW Rectiers ...................................................................................................................... 7

Figure 2 — Rectier Front Panel LEDs ............................................................................................11

Figure 3 — Locking Handle Disengaged/Engaged ......................................................................... 13

Figure 4 — 23" or 19" Shelf with Bulk Distribution Busbars ............................................................ 14

Figure 5 — 19" Shelf with Single Component Distribution .............................................................. 14

Figure 6 — 2.4kW Shelf with CXDM-E3 Distribution and CXC HP Controller ................................ 15

Figure 7 — Chassis Ground ........................................................................................................... 18

Figure 8 — CAN Bus Cabling ......................................................................................................... 20

Figure 9 — AC Input and Ground for 23" Shelf ............................................................................... 21

Figure 10 — 19" Shelf in with Single Component Distribution ........................................................ 24

Figure 11 — Rectier Bottom View ................................................................................................. 30

Figure 12 — Removing Front Panel from Rectier ......................................................................... 30

Figure 13 — 2.4kW Rectier Fan Assembly ................................................................................... 31

Figure 14 — Reattaching the Front Panel ...................................................................................... 31

Figure 15 — Locking the Front Panel in Place ............................................................................... 31

0100003-J0 Rev B

WARNING!

WARNING presents safety information to PREVENT INJURY OR DEATH to personnel.

Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath

which the information appears.

CAUTION!

CAUTION indicates safety information intended to PREVENT DAMAGE to material or

equipment. Cautions are designated with a yellow warning triangle, the word CAUTION,

and a rule beneath which the information appears.

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. Re-

view the drawings and illustrations contained in this manual before proceeding. If there are any questions regard-

ing the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representa-

tive. Save this document for future reference.

1.1 Safety Symbols

To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following

symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.

The use of ATTENTION indicates specic regulatory/code requirements that may affect the

placement of equipment and /or installation procedures.

NOTE:

A NOTE provides additional information to help complete a specic task or procedure.

Notes are designated with a check mark, the word NOTE, and a rule beneath which the

information appears

HOT!

The use of HOT presents safety information to PREVENT BURNS to the technician or

user.

1.2 General Safety

WARNING!

This system is designed to be installed in a restricted access location that is inacces-

sible to the general public.

1.3 Mechanical Safety

• Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.

• Power supplies can reach extreme temperatures under load.

• Use caution around sheet metal components and sharp edges.

0100003-J0 Rev B

1.4 Electrical Safety

WARNING!

• Before working with any live battery or power system, follow these precautions:

a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.

b. Wear safety glasses with side shields at all times during the installation.

c. Use OSHA approved insulated hand tools.

Lethal voltages are present within the power system. Always assume that an electrical

connection or conductor is energized. Check the circuit with a voltmeter with respect to

the grounded portion of the enclosure (both AC and DC) before performing any installa-

tion or removal procedure.

• Do not work alone under hazardous conditions.

• A licensed electrician is required to install permanently wired equipment. Input voltages can range up to

277Vac nominal. Ensure that the utility power is disconnected and locked out before performing any installa-

tion or removal procedure.

• Ensure that no liquids or wet clothes come into contact with internal components.

• Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input

power is disconnected.

1.5 Battery Safety

• Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel

knowledgeable of batteries and the required safety precautions.

• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all

metallic objects from your hands and neck.

• Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.

• Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm.

Battery post terminals and related accessories contain lead and lead compounds. Wash your hands after

handling batteries.

Follow battery manufacturer’s safety recommendations when working around battery

systems. Do not smoke or introduce an open ame when batteries (especially vented

batteries) are charging. When charging, batteries vent hydrogen gas, which can ex-

plode.

• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the bat-

tery manufacturer for recommended local authorized recyclers.

Hazardous voltages are present at the input of power systems. The DC output from rec-

tiers and batteries, though not dangerous in voltage, has a high short-circuit current

capacity that may cause severe burns and electrical arcing.

0100003-J0 Rev B

2. Introduction

2.1 Scope of the Manual

This manual explains the installation, interconnection, and operation of the Cordex HP 48-2.4kW 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. The wide AC input operating range for

global installations and wide operating temperature ranges for installation in uncontrolled environments along with

high efﬁciency (>96%) reduces the carbon footprint and the operating expenses.

Cordex rectiﬁer modules use a high frequency, switched mode conversion technique to provide a fully regulated

and isolated DC output from the AC mains. Multiple 48V conﬁgurations are available up to 250A in a compact

1RU shelf system. Industry leading power density (28W/in3) yields more space for revenue generating equipment.

Rectiﬁer power modules are “hot swappable”—they can be inserted or removed from the shelf without cutting

power to or from the system or the load. Additional power modules can be included with the system at the time of

ordering or added after the shelf has been installed.

The shelf rectiﬁer system is designed to operate with the Alpha Cordex System Controller (CXC). This controller

allows the user to conﬁgure, monitor and control the entire DC power system from its touch screen display which

includes temperature compensation, auto equalization, remote access, dial out on alarm, battery diagnostics, as

well as Web server and SNMP support for conﬁguration and monitoring. Details of controller operation are pro-

vided in the current version of the related software manual.

External CXC models of the system controller communicate with the shelf via RJ-12 shelf connectors. The CXCR

is mounted in a rack and the CXCP is (factory) mounted in a panel. In a power system, up to ﬁve (5) rectiﬁer

shelves may be stacked and connected to the same controller. The latest CXC-HP controller, featuring touch

screen, color LCD display with front Ethernet and USB connectors, is available as a panel mount controller or as

part of the CXPS-E3 system.

Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectifier Shelf, (b) Typical 48V Power Systems with 2.4kW Rectifiers

(b)

CXPS-E3 Modular

Distribution

(a)

0100003-J0 Rev B

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 12000W shelf*

– bulk power for external distribution

– up to ve Cordex HP 2.4kW rectiers

0300057-001

19in 1RU universal mount 9600W shelf*

– bulk power for external distribution

– up to four Cordex HP 2.4kW rectiers

0300040-001

19in 1RU universal mount 9600W shelf*

– separate feed In/Out,

– up to four Cordex HP 2.4kW rectiers

0300040-002

Cordex HP 2.4kW rectier 0100003-001

Fan assembly replacement 7400374-001

Module blank 7400424-001

Rear DC Output 19" shelf cover 0370250-001

Rear DC Output 23" shelf cover 0370250-002

*Note: Standard DC bus bars available up to a maximum of ve shelves per

system.

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