EnerSys Alpha Cordex HP 3.0kW Guida rapida

Cordex HP 3.0kW

Switched Mode Rectiﬁer System

Technical Guide: 0100037-J0

Effective: 04/2020

Cordex HP Modular Switched Mode Rectier System

Shelf Models: 19" 1RU universal mount 12000W

23" 1RU universal mount 15000W

For technical support, contact Alpha Technologies:

Canada and USA: 1-888-462-7487

International: +1-604-436-5547

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

ted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise

without prior explicit written permission from Alpha Technologies.

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

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 Technologies

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 reservation and with-

out 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:

0100037-J0 Rev C

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

3. Specications ........................................................................................................................9

4. Features ..............................................................................................................................11

4.1 3.0kW Rectier ..........................................................................................................................11

4.2 Distribution ............................................................................................................................... 14

4.3 Controller ................................................................................................................................. 14

5. Inspection............................................................................................................................15

5.1 Packing Materials ..................................................................................................................... 15

5.2 Check for Damage ................................................................................................................... 15

5.3 General Receipt of Shipment ................................................................................................... 15

6. Installation ...........................................................................................................................16

6.1 Safety Precautions ................................................................................................................... 16

6.2 Tools Required ......................................................................................................................... 16

6.3 Power System Assembly and Mounting ................................................................................... 17

7. Wiring ..................................................................................................................................18

7.1 Installation Notes ..................................................................................................................... 18

7.2 Grounding ................................................................................................................................ 19

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

7.4 AC Wiring 23" Shelf .................................................................................................................. 21

7.5 AC Wiring 19" Shelf .................................................................................................................. 22

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

30100037-J0 Rev C

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 Rectier Shelf ................................................................................... 27

8.3 Check Battery Polarity and Connections ................................................................................. 27

8.4 CXC HP Reset ......................................................................................................................... 27

9. Rectier Modes and Factory Defaults .................................................................................28

9.1 Rectier Modes ........................................................................................................................ 28

9.2 Factory Ranges and Defaults .................................................................................................. 29

10. Maintenance .....................................................................................................................30

10.1 Replacing a Rectier Module via the CXC HP Controller ...................................................... 30

10.2 Fan Replacement ................................................................................................................... 31

11. Troubleshooting .................................................................................................................33

12. Acronyms and Denitions .................................................................................................34

13. Warranty Statement and Service Information ...................................................................35

13.1 Technical Support .................................................................................................................. 35

13.2 Warranty Statement ............................................................................................................... 35

13.3 Product Warranty ................................................................................................................... 35

13.4 Battery Warranty .................................................................................................................... 35

13.5 Warranty Claims ..................................................................................................................... 35

13.6 Service Information ................................................................................................................ 35

14. Certication .......................................................................................................................36

0100037-J0 Rev C

List of Figures

Figure 1 — Cordex HP 19" 48Vdc-3.0kW Rectier Shelf ................................................................. 7

Figure 2 — Typical 48V Power System with 3.0kW Rectiers .......................................................... 7

Figure 3 — Rectier Front Panel LEDs ............................................................................................11

Figure 4 — Locking Handle Disengaged/Engaged ......................................................................... 13

Figure 5 — 19" Shelf with Bulk Distribution Busbars ...................................................................... 14

Figure 6 — CXPS-E3 System Containing 3.0kW Shelf and CXC HP Controller ............................ 14

Figure 7 — Chassis Ground ........................................................................................................... 17

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

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

Figure 10 — Positive and Negative Output Bars on 23" and 19" Bulk Distribution Models ............ 23

Figure 11 — Connecting Output Bars to Customer's Vertical Busbars ........................................... 24

Figure 12 — Connecting Output Bars Directly to Cables ................................................................ 24

Figure 13 — Example of a Single Bay with Two Rectier Shelves. ................................................ 25

Figure 14 — Relay Connections in the De-energized State ........................................................... 26

Figure 15 — Digital Input Connection Method ................................................................................ 26

Figure 16 — Rectier Bottom View ................................................................................................. 31

Figure 17 — Removing Front Panel from Rectier ......................................................................... 31

Figure 18 — 3.0kW Rectier Fan Assembly ................................................................................... 32

Figure 19 — Reattaching the Front Panel ...................................................................................... 32

Figure 20 — Locking the Front Panel in Place ............................................................................... 32

50100037-J0 Rev C

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. 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.

1.1 Safety Symbols

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

bols 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 a󰀨ect 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.

0100037-J0 Rev C

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 installation or re-

moval 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 knowl-

edgeable of batteries and the required safety precautions.

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

lic 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 bat-

teries.

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 battery

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.

70100037-J0 Rev C

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. The wide AC input operating range for global

installations and wide operating temperature ranges for installation in uncontrolled environments along with high ef-

ﬁciency (>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 312.5A in a compact 1RU shelf

system. Industry leading power density (35W/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 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 provided 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. 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.

Shelf ID location technology is built into the 3.0kW rectiﬁer. This feature is capable of remotely locating the exact posi-

tion of a rectiﬁer within a large system. This can be useful for quickly locating a unit during a service interruption or

when a unit has failed.

Figure 1 — Cordex HP 19" 48Vdc-3.0kW Rectifier Shelf

Figure 2 — Typical 48V Power System with 3.0kW Rectifiers

0100037-J0 Rev C

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*

– bulk power for external distribution

– up to ve Cordex HP 3.0kW rectiers

0300216-001 (shelf/slot ID supported)

19in 1RU universal mount 12000W shelf*

– bulk power for external distribution

– up to four Cordex HP 3.0kW rectiers

0300228-001 (shelf/slot ID supported)

Cordex HP 3.0kW rectier 0100037-001

Fan assembly replacement 7400732-001

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.

Indice

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