Alpha Technologies 030-706-J0 Installation & Operation Manual Download

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Your Power Solutions Partner

Cordex 48-1kW

19" Shelf For Systems Up To 6000W

Installation & Operation Manual

Part # 030-706-J0

Effective: 02/2014

member of The Group

™

Summary of Contents for 030-706-J0

Page 1: ...Your Power Solutions Partner Cordex 48 1kW 19 Shelf For Systems Up To 6000W Installation Operation Manual Part 030 706 J0 Effective 02 2014 member of The Group ...

Page 2: ......

Page 3: ...t the placement of equipment and or installation procedures NOTE A NOTE provides additional information to help complete a specific task or procedure CAUTION CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment Cautions are designated with a shock hazard icon the word CAUTION and a rule beneath which the information appears WARNING WARNING presents safety inform...

Page 4: ...allation 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 Battery Safety Servicing and connection of batteries must be performed by or under the direct supervision of personnel knowledgeable of batteries and the requir...

Page 5: ... NOTE provee información adicional para ayudar a completar una tarea o un procedimiento específico CUIDADO CUIDADO CAUTION indica información de seguridad con el propósito de PREVENIR DAÑOS al material o al equipo Los avisos de cuidado están designados con un icono de peligro de choque la palabra CUIDADO y una línea debajo de la cual aparece la información ADVERTENCIA Una ADVERTENCIA WARNING prese...

Page 6: ... de instalación o remoción Asegúrese de que ningún líquido ni ropa húmeda en contacto con los componentes internos Las partes eléctricamente activas peligrosas dentro de esta unidad están energizadas por las baterías incluso cuando se desconecta la alimentación de entrada de CA Seguridad de la Batería Externa El mantenimiento y la conexión de las baterías debe ser realizado por o bajo la supervisi...

Page 7: ...rocédure spécifique PRUDENCE Le symbole PRUDENCE CAUTION indique une information de sécurité destinée à ÉVITER DES DOMMAGES au matériel ou à l équipement Ce symbole est représenté par une icône de danger de décharge électrique le terme PRUDENCE et une ligne en dessous de laquelle l information est affichée AVERTISSEMENT Le symbole AVERTISSEMENT WARNING donne des informations sur la sécurité permet...

Page 8: ... n entre en contact avec les composants internes Les pièces électriques dangereuses à l intérieur de cette unité sont alimentées par les batteries même lorsque l alimentation CA en entrée est débranchée Sécurité de la Batterie L entretien et la connexion des batteries doivent être effectués par un spécialiste des batteries ou sous la supervision directe d un tel spécialiste en prenant les précauti...

Page 9: ...mte Aufgabe zu lösen bzw ein bestimmtes Verfahren durchzuführen Hinweise sind mit einem Häkchen dem Wort HINWEIS und einem Strich unter dem die Informationen aufgeführt sind gekennzeichnet ACHTUNG ACHTUNG CAUTION kennzeichnet Sicherheitsinformationen die darauf abzielen SCHÄDEN an Materialien oder Geräten ZU VERHINDERN Diese Warnhinweise sind mit einem gelben Warndreieck dem Wort ACHTUNG und einem...

Page 10: ...e Kleidungsstücke mit innenliegenden Komponenten in Berührung kommen Gefährliche stromführende Teile innerhalb dieses Geräts werden auch bei Trennung der Netzverbindung noch über die Batterien versorgt Batteriesicherheit Die Wartung und der Anschluss von Batterien muss von Mitarbeitern durchgeführt bzw direkt beaufsichtigt werden die über Kenntnisse über Batterien und die erforderlichen Sicherheit...

Page 11: ...y information re quired for installation operation and fault diagnosis of the unit Specifications 19 Shelf 030 706 B1 Specifications Rectifier 010 606 B1 010 566 20 non RoHS Schematic 030 706 05 Outline Drawing 19 Shelf 030 706 06 Customer Connections 030 706 08 Schematic 030 707 05 Outline Drawing 19 Shelf Flush Mounting 030 707 06 Customer Connections 030 707 08 ...

Page 12: ...tal Input Channels 8 3 4 Alarm and Control Output Relays 8 3 5 System Fail Alarm Relay 8 3 6 Network Connection and Remote Communications 8 4 INSPECTION 9 4 1 Packing Materials 9 4 2 Check for Damage 9 5 INSTALLATION 10 5 1 Safety Precautions 10 5 2 Shelf Preparation Mounting 10 5 3 Module Insertion Removal 10 6 WIRING AND CONNECTIONS 11 6 1 Safety Precautions 11 6 2 Tools Required 11 6 3 Power Sy...

Page 13: ...tory Ranges and Defaults 22 8 SYSTEM STARTUP 23 8 1 Check System Connections 23 8 2 Verify AC and Power the Shelf 23 8 3 Check Battery Polarity and Connect 23 8 4 CXC Reset 23 9 MAINTENANCE 24 10 WARRANTY 25 11 ACRONYMS AND DEFINITIONS 26 ...

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Page 15: ...40 50 60 Hz electrical service Rectifier power modules are hot swappable meaning 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 and rectifier system is designed to operate with the Apha Cordex System Controlle...

Page 16: ... centers List 85 Power module blank plate List 50 90 Cordex 48 1kW 19 Shelf for Systems up to 6000W flush mounting only 030 707 20 equipped to receive one CXCM controller and up to five CXRC 48 1kW rectifiers Figure 1 List 0 208 220 240Vac input List 6 Temperature sensor 1 4 lug 12 ft List 72 Temperature sensor 3 8 lug 12 ft List 75 Six 1kW rectifier module positions dual feed ac input no CXCM Fig...

Page 17: ...s within valid range The LED will flash 2Hz when AC is outside the nominal range AC voltage is invalid if the AC Mains Low or AC Mains High alarm is active The LED turns off when AC has failed 2 1 1 2 DC ON The middle LED green is on when the rectifier is delivering power to the load The LED will flash when communication is lost The LED turns off when the rectifier is off e g when commanded via th...

Page 18: ...5 of the rated output a low output current condition is detected and the Module Fail detection circuit is activated This circuit momentarily ramps up the output voltage to determine if the module will source current If no increase in current is detected the Module Fail alarm is activated The module will test once every 60 seconds for the condition until current is detected Output voltage ramping w...

Page 19: ... determines the maximum output current limit of the module regardless of output voltage or power Maximum output current is limited to a constant value down to short circuit condition Current limiting can be used to mate the rectifier output current ampacity to the needs of the load and parallel battery to minimize excessive battery recharge current The rectifier will sustain a short circuit at the...

Page 20: ...andard Windows Internet Explorer browser The data logging feature allows the user to capture data from multiple inputs for AC DC voltages load battery current cell voltages temperatures automatically for up to 16 user defined logs Typical applications of the CXCM logging include power system details thermal performance of outdoor enclosures battery cell specifics or mains variations captured by an...

Page 21: ...is designed for CXCM connection to a user supplied network TCP IP secured by user via a rear panel 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 crossover cable 3 1 5 RS 232 Serial Craft Port Local access to the CXCM is possible through a front panel RS 232 serial port using a null modem cable Th...

Page 22: ... control and distribution alarm card This provides a safety measure to protect against load disconnect during CXCM reset or replacement e g when the controller is off line Operators may also perform test and maintenance procedures on the CXCM without disturbing the load 3 5 System Fail Alarm Relay The CXCM system fail alarm K0 activates because of a major internal failure During such a condition t...

Page 23: ...be packaged in its original shipping container 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 Apha Technologies is not responsible for damage caused by the improper packaging of returned products 4 2 Check for Damage Prior to unpacking the product note any damage to the shipping contain...

Page 24: ...ck See drawing 030 706 06 For 030 707 20 the shelf has been designed for flush mounting only in a standard EIA 19 rack See drawing 030 707 06 NOTE The shelf shall be mounted in a clean and dry environment Allow at least 1 75 of free space above and below the unit for unrestricted convection cooling airflow Mounting brackets accommodate either 1 or 1 3 4 rack spacing The shelf should be mounted to ...

Page 25: ...r for additional safety precautions 6 2 Tools Required Various tools are essential for product installation Use this list as a guide Slot head screwdrivers blade sizes 1 4 1 8 1 16 Philips head screwdriver 2 tip size 3 16 Digital voltmeter equipped with test leads Adjustable 48Vdc load optional Cutters and wire strippers Crimping tool optional for large gauge wire Socket and rachet set Imperial me...

Page 26: ...r away as possible from the DC power wires to minimize EMI disturbances Remove the metal cover from the rear of the shelf to expose the wireway for input terminal blocks The wireway is designed for two customer supplied 1 conduit fittings for AC supply located on the left side of the shelf and two 3 4 conduit fittings on the rear Attach the conduit retainers to the wireway hole s and route the AC ...

Page 27: ...h they were shipped from the factory Tighten the bolts as per Customer Connections drawing at the rear of this manual The common output leg of the rectifier system should be connected to ground This is typically done at the load common termination point Replace rear cover once all connections have been completed 6 8 CAN Serial Ports Connect Cordex equipment and set jumpers as shown Figure 6 CAN po...

Page 28: ...cated on the backplane Daisy chain from shelf to shelf as necessary and ensure that the last shelf is terminated with the jumper below System equipped with CXCP or CXCR has one CAN OUT port List 81 shelf equipped for six rectifiers and no CXCM has one CAN IN port and one CAN OUT port The jumper P1 allows setting of the CAN OUT to be open to next shelf or TERMINATED if last shelf on CAN bus as show...

Page 29: ...rk Connection Standard Network Cable The Ethernet port is designed for CXC connection to a user supplied network TCP IP secured by user via a rear panel RJ 45 jack Connect to the Cordex shelf using a standard network cable 6 9 2 Ethernet Port for Local Connection Crossover Cable Local access e g laptop computer is also possible from the Ethernet port connection using a standard network crossover c...

Page 30: ...se Alarm Pos or Neg 0 60Vdc P5 3 P6 1 D2 Distribution CB Alarm Pos or Neg 0 60Vdc P6 2 3 D3 Battery CB Alarm Pos or Neg 0 60Vdc Analog Inputs and System Signals E1 Battery 48V Neg 20 60Vdc J3 Ethernet port N A N A P1 2 1 K1 LVD1 Pos Neg 0 60Vdc 1A P7 2 1 V1 Load Voltage Pos Neg 0 100Vdc P8 2 1 I1 Load Current Pos Neg 50mV for List 120 add the following 1 2 T1 GP1 Temp Probe 1 Pos Neg 0 20Vdc with ...

Page 31: ...ctly from the assigned output pins and to an external LVD contactor or panel See Controls Menu Defaults in the CXC Software manual Redundant LVD Control Circuit The shelf backplane2 provides circuitry to override the LVD Control function This is a safety measure to protect against accidental load disconnect should the CXCM be removed from the shelf This protection is also necessary during CXCM res...

Page 32: ... common of the system through a relay dry contact usually located on the equipment requiring monitoring This method see Figure 10 allows the digital input to receive or not receive a Ground signal on an alarm Figure 10 Showing connection method 6 10 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 presen...

Page 33: ...ections to an optional secondary voltage input For example this can be terminated to the load side of an LVD contactor to monitor load voltage Voltage Input 2 charge voltage per CXC software is wired internally to the rectifier output voltage of the shelf This is used as the reference for system alarming such as high voltage and control such as low voltage disconnect 6 10 4 2 Current Current Input...

Page 34: ...e next state When in this state the CXC continues to monitor its inputs After the Start Delay state the rectifier will transition to the Soft Start state NOTE Soft start or current walk in gradually increases the voltage and current output of the rectifier upon startup This is done to reduce the instantaneous load on the AC source 7 1 3 Soft Start State When the Soft Start state is entered the rec...

Page 35: ...le lists the four Output Current Power Modes and a description of when they are active Output Current Power Mode Active when Temperature foldback mode Output current and power limit have been reduced due to high temperature of the heatsink or internal ambient temperature sensor AC foldback mode Output current and power limit have been reduced due to low AC input voltage Note this will reduce the r...

Page 36: ...rrent 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 Voltage Alarm HVA 52 63V 55 5V EQ Timeout 1 2399h 30h BT Timeout 1 250h 8h Softstart Ramp rate Normal Fast Normal CL PL Alarm Enable Disable Enable Remote Shutdown Enable Disable Enable Ramp Test Enable Disable Enable Table F Cordex 48 1kW rectifier fac...

Page 37: ...nality of various module alarms and controls 8 3 Check Battery Polarity and Connect Verify correct battery polarity using a voltmeter ensuring no cells or batteries are reversed Connect battery as required to the output of the system or turn on battery breaker Install remaining power modules In the adjustments menu of the CXC set Float and Equalize voltage to the levels specified by the battery ma...

Page 38: ...e a year WARNING HIGH VOLTAGE AND SHOCK HAZARD Use extreme care when working inside the shelf while the system is energized Do not make contact with live components or parts Circuit cards including RAM chips can be damaged by static electricity Always wear a grounded wrist strap when handling or installing circuit cards Procedure Date Completed Clean ventilation openings Inspect all system connect...

Page 39: ...s any remedies other than the above It does not provide coverage for any loss of profits loss of use costs for removal or installation of defective equipment damages or consequential 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 s external to the unit inclu...

Page 40: ...ion CX Cordex series e g CXC for Cordex System Controller DC Direct current EIA Electronic Industries Alliance HVSD High voltage shutdown LED Light emitting diode LVD Low voltage disconnect NC Normally closed NEC National Electrical Code for the USA NO Normally open OSHA Occupational Safety Health Administration OVP Over voltage protection RAM Random access memory UL Underwriters Laboratories ...

Page 41: ...Dimensions 177 3mm H x 444 5mm W x 303 4mm D rectifier front panel 18 8mm D 6 98 H x 17 50 W x 11 95 D rectifier front panel 0 74 D Mounting 19 or 23 mid mount 23 flush Weight 7 5 kg 16 5 lb Connections AC Input 6 32 screw terminal blocks Chassis ground 1 4 20 stud Communications CAN bus in and out RJ 12 offset Ethernet RJ 45 DC Output 1 4 20 x 5 8 studs Signal wiring Terminal blocks 0 75 to 0 14m...

Page 42: ...n against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radi...

Page 43: ...m Controller Fail Red Audio Built in speaker for alarm and popup message tones Dimensions 177mm H x 74mm W x 255mm D 6 9 H x 2 9 W x 10 D Weight 2 2 kg 5 lb Mounting Modular on Cordex 4RU series 1kW shelves Relay Outputs Eight 8 Form C 60Vdc 1A maximum Digital Inputs Three 3 0 to 60Vdc Analog Inputs and System Signals standard for List 120 Two 2 DC voltage LVD1 K1 Form C relay 60Vdc 1A maximum Loa...

Page 44: ...ur modules EMI The unit meets requirements of EN55022 see Standards for more EMC In accordance with FCC requirements we provide the following statement as specified in the FCC guidelines for conformance to Part 15 Class B NOTE This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide rea...

Page 45: ...tate current of the rectifier within rated limits Start up Ready Time 5 seconds excluding soft start to complete inrush limit routine and ac measurement for OK signal Start up Delay Programmable up to 120 seconds to enable stagger start of multiple rectifiers and to minimize the effect on a supply source Soft Start User adjustable to at least 5 seconds not including start up delay time and is dete...

Page 46: ...y EN 61000 4 3 Radiated Electromagnetic Immunity EN 61000 4 4 Electrical Fast Transient Burst Immunity EN 61000 4 5 Power Line Surge Immunity EN 61000 4 6 Conducted Electromagnetic Immunity EN 61000 4 11 Voltage Dips Short Interruptions and Variations ETS 300 019 1 1 Environmental Conditions Storage ETS 300 019 1 2 Environmental Conditions Transportation ETS 300 132 2 Power Supply Interface at the...

Page 47: ...03070605B__ sch 1 Fri Mar 04 14 39 15 2005 ...

Page 48: ...03070605B__ sch 2 Fri Mar 04 14 39 49 2005 ...

Page 49: ...CCEPTS 1 CONDUIT SIZE DWG NO TYPE B SHEET TITLE ISSUE DATE OF TOLERANCES SCALE APPROVED CHECKED DRAWN DESIGN MATERIAL FINISH FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF REVISIONS LTR DESCRIPTION APPD DATE REV X X 0 04 X XX 0 02 X XXX 0 01 X 1mm X X 0 5mm X XX 0 25mm 030 706 06 OUTLINE 19 23 CN...

Page 50: ...ETRIC mm IN BRACKETS INCHES mm J K 2004 05 W E S 2004 05 NTS REV BY B SPECIFIED RECTIFIERS FED BY TB1 TB2 M P 2005 11 C UPDATED AC I P TERMINAL BLOCK FROM LINE 2 TO L2 N M P 2007 09 WES TB1 L1 L2 N 6 32 SCREWS TYPICAL AC INPUT TERMNINAL BLOCK TB1 SHOWN TB1 FEEDS RECTIFIERS 1 3 5 TB2 FEEDS RECTIFIERS 2 4 C J3 P1 P1 J3 E2 COMMON E1 LIVE AC INPUT KNOCKOUT PLATE REVERSIBLE AC INPUTS 1 125 KO ACCEPTS 3...

Page 51: ...TECHNOLOGIES O C DIMENSIONS ARE IN INCHES WITH METRIC mm IN BRACKETS INCHES mm J K 2004 05 W E S 2004 05 NTS REV BY AC INPUT KNOCKOUT PLATE REVERSIBLE AC INPUTS 1 125 KO ACCEPTS 3 4 FITTING CONDUIT 875 KO ACCEPTS 1 2 FITTING CONDUIT 1 4 20 CHASSIS GROUND DC OUTPUT USES 1 4 20 x 5 8 OUTPUT LUGS TIGHTEN TO 8 FT LB TB1 TB2 1 GND 2 CAN H 3 CAN L 4 CAN L 5 CAN H 6 NOT CONNECTED CAN IN RJ12 OFFSET PIN O...

Page 52: ...ES mm J K 2004 05 W E S 2004 05 NTS REV BY SYSTEM FAIL OUTPUT DIGITAL INPUTS D1 D2 D3 P5 P6 1 1 JP2 JP3 JP4 JP5 JP6 JP7 JP8 CURRENT INPUT 1 VOLTAGE INPUT 1 V1 V1 I1 I1 P8 P7 1 1 P1 1 LVD CONTROL LIST 0 5 MDL W CXC TOP VIEW CXC BACKPLANE 707 340 20 SOME DETAILS OMITTED J3 NC C NO 25 24 23 E1 BATTERY 48v 0 CONNECT TO BATTERY ONLY WHEN USING BATTERY DISCONNECT DEVICE 2 22 21 19 20 3 17 18 4 15 16 5 1...

Page 53: ...03070705B__ sch 1 Fri Mar 04 14 43 46 2005 ...

Page 54: ...03070705B__ sch 2 Fri Mar 04 14 44 27 2005 ...

Page 55: ...03070705B__ sch 3 Fri Mar 04 14 44 54 2005 ...

Page 56: ...LE ISSUE DATE OF TOLERANCES SCALE APPROVED CHECKED DRAWN DESIGN MATERIAL FINISH FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF REVISIONS LTR DESCRIPTION APPD DATE REV X X 0 04 X XX 0 02 X XXX 0 01 X 1mm X X 0 5mm X XX 0 25mm 030 707 06 OUTLINE 19 FLUSH MOUNT CABINET 5 MDL w CXCM SUP OR 6 MDL 48 1...

Page 57: ...MINAL BLOCK TB1 SHOWN TB1 FEEDS RECTIFIERS 1 3 5 L2 N P1 J3 P1 J3 2004 12 SIZE DWG NO TYPE B SHEET TITLE ISSUE DATE OF TOLERANCES SCALE APPROVED CHECKED DRAWN DESIGN MATERIAL FINISH FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF REVISIONS LTR DESCRIPTION APPD DATE REV B SDW DGW REV BY UPDATED AC ...

Page 58: ...ITTEN CONSENT ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF REV 030 707 08 C D2 48 1kW CXRC 19 FLUSH MNT 2 4 CUSTOMER CONNECTION 6 MOD OR 5 MOD w CXC SUP NTS TB1 TB2 J3 J4 P1 REVERSIBLE AC INPUT KNOCKOUT PLATE AC INPUTS ACCEPTS 3 4 FITTING CONDUIT 1 125 KO ACCEPTS 1 2 FITTING CONDUIT 1 4 20 CHASSIS GROUND 0 875 KO DC OUTPUT TIGHTEN TO 8 FT ...

Page 59: ...C SUP NTS TB1 TB2 P1 J3 TB3 REVERSIBLE AC INPUT KNOCKOUT PLATE AC INPUTS ACCEPTS 3 4 FITTING CONDUIT 1 125 KO ACCEPTS 1 2 FITTING CONDUIT 1 4 20 CHASSIS GROUND 0 875 KO DC OUTPUT E2 COMMON LIST 0 9 82 6 MODULE THREE FEEDS TIGHTEN TO 8 FT LB J4 USES 1 4 20 x 5 8 OUTPUT LUGS E1 LIVE 6 32 SCREWS L2 N TB3 FEEDS RECTIFIERS 5 6 TB2 TYPICAL AC INPUT TERMINAL BLOCK TB2 SHOWN TB1 FEEDS RECITIFIERS 1 2 TB2 ...

Page 60: ...6 JP7 JP8 DIGITAL INPUT 1 CURRENT INPUT 1 V1 V1 I1 I1 P8 P7 1 1 P1 1 VOLTAGE CONTROL LVD SYSTEM LIST 0 5 MDL e w CXC BATTERY SOME DETAILS OMITTED J3 NC C NO 25 24 23 E1 707 340 20 48v 0 TOP VIEW CXC BACKPLANE CONNECT TO BATTERY ONLY WHEN USING ALARM 2 22 21 19 20 3 17 18 4 15 16 5 13 14 6 11 12 7 9 10 8 OUTPUTS JUMPER SETTINGS FOR JP2 8 CLOSED NORMALLY OPEN 1 8 6 RX NORMALLY 7 COM2 PINOUT J3 ETHER...

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Page 64: ...2 79889 0 Fax 49 9122 79889 21 Alpha Technologies S A 131 Boulevard de l Europe 1301 Wavre Belgium Tel 32 10 438 510 Fax 32 10 438 213 Alpha Technologies Europe Ltd Twyford House Thorley Bishop s Stortford Hertfordshire CM22 7PA United Kingdom Tel 44 1279 501110 Fax 44 1279 659870 Alphatec Ltd 339 St Andrews St Suite 101 Andrea Chambers P O Box 56468 3307 Limassol Cyprus Tel 357 25 375 675 Fax 357...

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