EnerSys alpha Cordex CXRF 48-3.6kW Technical Manual Download Page 34 | Manualshive

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9400000-J0 Rev E

32

4. Disconnect the fan cables from the module by

pulling out the fan cable connector.

5. Remove the two screws that secure the fan to

the front panel.

6. Note the direction of the airflow and remove the

fan from the front panel.

7. Install the replacement fan following the preceding steps in reverse order.

Fan screws

Figure 10 — 4kW/4.6kW Rectifier Fan Removal

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Summary of Contents for alpha Cordex CXRF 48-3.6kW

Page 1: ...Alpha Modular Switched Mode Rectifier System Models Cordex CXRF 48 3 6kW Cordex HP CXRF 48 4kW 48 4 6kW 48 12kW Technical Guide 9400000 J0 Effective 06 2020...

Page 2: ......

Page 3: ...ologies 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 it...

Page 4: ...4 1 Rectifier 11 4 2 Cordex HP Controller CXC HP 15 5 Inspection 17 5 1 Packing Materials 17 5 2 Check for Damage 17 5 3 General Receipt of Shipment 17 6 Installation 18 6 1 Safety Precautions 18 6 2...

Page 5: ...s 27 9 2 Main Rectifier Modes 27 9 3 Factory Ranges and Defaults 29 10 Maintenance 30 10 1 Replacing a Rectifier Module 30 10 2 Fan and Fan Filter Replacement 31 10 3 MOV Replacement 35 11 Acronyms an...

Page 6: ...11 Figure 5 Cordex HP Controller left and right side views 15 Figure 6 LCD Color Touchscreen Display 16 Figure 7 CAN Port Connections 22 Figure 8 Relay Connections in the De energized State 24 Figure...

Page 7: ...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 th...

Page 8: ...ower 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 prec...

Page 9: ...electrical service 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 incl...

Page 10: ...5 seconds excluding soft start Start up Delay 120 second programmable 120 second programmable 120 second programmable 120 second programmable Soft Start 10 seconds use adjustable not including start...

Page 11: ...19 Shelf 12 7kg 28lb Module 12kg 27lb 23 Shelf 14 5kg 32lb 19 Shelf 12 7kg 28lb Environmental Temperature Operation 40 to 75 C 40 to 167 F 40 to 75 C 40 to 167 F 40 to 75 C 40 to 167 F 40 to 75 C 40 t...

Page 12: ...Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment genera...

Page 13: ...s 4 1 Rectifier The three LEDs on the rectifier front panel indicate status AC ON 1 DC ON 2 Alarm 3 Figure 4 Rectifier Front Panel LEDs 1 2 3 LEDs Thumbscrew 4 0 4 6kW 3 6kW LEDs 1 2 3 Thumbscrews LED...

Page 14: ...alarm is detected if the modules output capability has been reduced or a mi nor component failure is detected The LED remains extinguished in the absence of an alarm LED Activity During Firmware Uploa...

Page 15: ...excessive increase in temperature During over temperature conditions the rectifier limits the output power and the output current If the temperature continues to increase the rectifier is shutdown The...

Page 16: ...e used to mate the rectifier output current ampacity to the needs of the load and parallel battery to minimize excessive battery recharge currents The rectifier will sustain a short circuit at the out...

Page 17: ...only used ADIO peripheral is the L ADIO for low voltage systems which includes 8 digital inputs 4 voltage sensors 4 temperature sensors 4 current sensors 12 Form C relay outputs Figure 5 Cordex HP Con...

Page 18: ...drive CAN dual independent CAN bus ports for communication with the Cordex and AMPS family of products which allows for a greater number of devices Real time clock with field replaceable lithium batte...

Page 19: ...unpacking the product note any damage to the shipping container Unpack the product and inspect the exterior for damage If any damage is observed contact the carrier immediately Continue the inspection...

Page 20: ...tools are essential for the installation Use this list as a guide Battery lifting apparatus if required Electric drill with hammer action 1 2 capacity Various crimping tools and dies to match lugs use...

Page 21: ...the possibility of slippage and scratching of the unit s exterior An electrical conducting path must exist between the shelf chassis and the metalwork of the enclosure in which it is mounted or a gro...

Page 22: ...conductor selection Power system ampacity Ground reference conductor size 30A 10 30 100A 6 2 100 400A 0000 400 800A 350 MCM 800A 750 MCM The power system frame must also be connected to the MGB or FG...

Page 23: ...the load common termination point 7 4 1 Terminating Cable Leads Terminate cable leads with appropriate crimp lugs for 3 8 holes on 1 centers Secure the positive and negative to the shelf output post o...

Page 24: ...7 shows an example of a controller and three shelves 1 Daisy chain the CAN bus cables from the controller to shelf 1 shelf 2 and then to the last shelf 3 2 Insert the CAN terminator in the last shelf...

Page 25: ...kW Rectifier Slot IDs 2 x 12kW Rectifier Slot IDs Bay ID 1 Shelf ID 1 Bay ID 1 Shelf ID 1 Bay ID 1 Shelf ID 2 Bay ID 1 Shelf ID 2 CAN driver Cordex HP J1 J12 J11 J10 J2 J3 J4 J5 J6 J7 J8 J9 CAN bus tr...

Page 26: ...power is lost all relays de energize 7 7 2 Digital Inputs The digital input channels are used to monitor various alarm and control signals All input channels are voltage acti vated and accept a bipol...

Page 27: ...ry system voltage terminal for CXC HP reference when a battery disconnect device is used It is critical to CXC HP operation as it ensures a source of power to the CXC HP should the disconnect device o...

Page 28: ...ghten the screw on the bottom of the faceplate to secure the module to the shelf 2 Verify that the AC input voltage is correct and switch on the corresponding feeder breaker The power module AC ON LED...

Page 29: ...adually increases the voltage and current output of the rectifier upon startup This is done to reduce the instantaneous load on the AC source 9 1 3 Soft Start When the Soft Start state is entered the...

Page 30: ...t to the safe mode voltage setting Manual Test Output voltage can be manually adjusted outside of the standard adjustment ranges 9 2 2 Output Current Power Modes These modes directly affect the output...

Page 31: ...44 52V 46V Over Voltage Protection OVP 63V 57V Current Limit CL 23 100 100 Power Limit PL 0 100 100 Module Start Delay 0 250s 1s System Start Delay 0 600s 0s Low Voltage Alarm LVA 42 52V 44V High Volt...

Page 32: ...eat of service inter ruptions while performing maintenance on the system s alarms and control settings Table F Sample maintenance log Procedure Date Completed Clean ventilation openings Inspect all sy...

Page 33: ...ws 2 Front panel 1 Switch off the unit and unscrew the front fastener that secures the power module to the shelf 2 Slide the module 10cm 4 out of the shelf and wait ten minutes for the module capacito...

Page 34: ...cable connector 5 Remove the two screws that secure the fan to the front panel 6 Note the direction of the airflow and remove the fan from the front panel 7 Install the replacement fan following the...

Page 35: ...wn in Figure 11 Side screw 1 Bottom screws 3 Figure 11 Fan Assembly Screw Removal 3 Disconnect the fan cables and remove the fan assembly from the rectifier 4 Remove the two screws that secure the fai...

Page 36: ...citors to discharge 3 Remove the four screws two each side that secure the front panel to the module chassis 4 Slide the front panel out 5 Disconnect the fan power lead wires one set per fan and front...

Page 37: ...rikes High capacity surges may permanently damage MOVs but they are easily replaced in the field using the following procedure 1 Shut off the unit and unscrew the front fastener that secures the power...

Page 38: ...cure the MOV PCB to the module MOV PCB screws Insulating mat 6 Remove the MOV PCB 7 Decontaminate the area and unit with a flux remover or similar cleaning compound This is done to remove any metallic...

Page 39: ...power module to the shelf 2 Slide the module out of the shelf and wait ten minutes for the module capacitors to discharge 3 Remove the six screws that secure the back panel to the module 4 Slide the b...

Page 40: ...o the shelf 2 Slide the module 10 cm 4 out of the shelf and wait two minutes for module capacitors to discharge 3 Turn the module around to face the back of the unit and remove the one screw module bo...

Page 41: ...munications Commission for the USA GSM Group Speciale Mobile global system for mobile communications HVSD High voltage shutdown IEC International Electrotechnical Commission IEEE Institute of Electric...

Page 42: ...nsequential damages based upon equipment failure during or after the warranty period No other obligations are expressed or implied Warranty also does not cover damage or equipment failure due to cause...

Page 43: ...for sale in Canada 2 Only Underwriters Laboratories may grant a licence for the use of this mark which indi cates compliance with both Canadian and US requirements 3 NRTLs Capabilities NRTLs are third...

Page 44: ...23 25 DC COM AC IN LIVE OUT 2 LINE 2 LINE 1 4 J4 MODULE 4 8 7 8 9 10 CAN RET CAN CAN CAN 20 22 24 21 23 25 DC COM AC IN LIVE OUT 2 LINE 2 LINE 1 4 J5 MODULE 5 10 9 8 9 10 CAN RET CAN CAN CAN 20 22 24...

Page 45: ...E 1 4 J4 MODULE 4 8 7 8 9 10 CAN RET CAN CAN CAN 20 22 24 21 23 25 DC COM AC IN LIVE OUT 2 LINE 2 LINE 1 4 J5 MODULE 5 10 9 8 9 10 CAN RET CAN CAN CAN 20 22 24 21 23 25 DC COM AC IN LIVE OUT 2 LINE 2...

Page 46: ...MODULE 4 8 7 8 9 10 CAN RET CAN CAN CAN 20 22 24 21 23 25 DC COM AC IN LIVE OUT 2 LINE 2 LINE 1 4 J5 MODULE 5 10 9 8 9 10 CAN RET CAN CAN CAN 20 22 24 21 23 25 DC COM AC IN LIVE OUT 2 LINE 2 LINE 1 4...

Page 47: ...INCORPORATED EOs A1 A9 C 12 10 JL SY REVISED FOR SOLIDWORKS INTEGRATION F 05 10 MP WES CORRECTED VIEWS DESCRIPTION E 584 2 23 00 529 3 20 84 566 7 22 31 0 6 0 0 24 37 7 1 49 50 4 1 99 82 2 3 24 94 9 3...

Page 48: ...6 92 188 5 7 42 340 9 13 42 353 6 13 92 379 0 14 92 404 4 15 92 REAR VIEW LIST 81 OUTPUT BARS 0 152 4 6 00 388 2 15 28 511 4 20 13 LIST 25 23 FLUSH MOUNT LIST 23 23 MID MOUNT TOP VIEW LIST 81 OUTPUT B...

Page 49: ...N UNTERMINATED J8 J7 CAN OUT RJ12 OFFSET PIN OUT J8 CAN IN RJ12 OFFSET PIN OUT J7 GND 1 CAN H 2 NOT CONNECTED 3 CAN L 4 NOT CONNECTED 5 NOT CONNECTED 6 GND 1 CAN H 2 NOT CONNECTED 3 CAN L 4 NOT CONNEC...

Page 50: ...TALLATION NEGATIVE BUS BAR CUSTOMER SUPPLIED POSITIVE BUS BAR CUSTOMER SUPPLIED NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL 3 8 FLAT WASHER 3 8 LOCK WASHER 3 8 20 x 1 HEX BOLT CUSTOMER SUPPLIED...

Page 51: ......

Page 52: ...00 667 8743 Outside North America 1 604 436 5547 Technical Support 1 888 462 7487 For more information visit our website at www alpha com 2020 Alpha Technologies Ltd All Rights Reserved Trademarks and...

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