Alpha Cordex HP CXRF 48-2.4kW Manual Download

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Cordex HP 2.4kW / 3.0kW

Switched Mode Rectifier System

dels:

Cordex

HP CXRF 48-3.0kW

Cordex

HP CXRF 48-2.4kW

User Guide ID:

0100037-J0

Effective:

05/2021

Read this manual carefully.

Learn how to protect your equipment from damage and fully understand its functions.

Summary of Contents for Cordex HP CXRF 48-2.4kW

Page 1: ...d Mode Rectifier System Models Cordex HP CXRF 48 3 0kW Cordex HP CXRF 48 2 4kW User Guide ID 0100037 J0 Effective 05 2021 Read this manual carefully Learn how to protect your equipment from damage and fully understand its functions ...

Page 2: ...rmation 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...

Page 3: ...x HP 2 4kW rectifier 11 4 Features 13 4 1 Cordex HP 3 0kW rectifier 13 4 2 Cordex HP 2 4kW rectifier 18 5 Inspection 22 5 1 Packing materials 22 5 2 Check for damage 22 5 3 General receipt of shipment 22 6 Installation 23 6 1 Installation overview 23 6 2 Safety precautions 23 6 3 Installation tools 23 6 4 Assembly and mounting 24 6 5 DC output connections bulk distribution 25 6 6 AC wiring 23 inch...

Page 4: ...tenance 38 9 1 Replacing a rectifier module via the Cordex HP controller 38 9 2 Replacing a rectifier module via Cordex controller 39 9 3 Fan replacement 39 10 Troubleshooting 41 11 Acronyms and definitions 42 12 Warranty statement and service information 43 12 1 Technical support 43 12 2 Warranty statement 43 12 3 Product warranty 43 12 4 Battery warranty 43 12 5 Warranty claims 43 12 6 Service i...

Page 5: ...ment 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 specific regulatory code requirements that may affect the placement of equipment or installation procedures N...

Page 6: ...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 or international equivalent approved insulated hand tools Do not rest tools on top of batteries Batteries contain or emit c...

Page 7: ... 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 a...

Page 8: ...helf cover 0370250 001 Rear DC output 23 inch shelf cover 0370250 002 Note Standard DC busbars available up to a maximum of five shelves per system 2 3 2 Cordex HP 2 4kW rectifier Description Part number 23 inch 1RU universal mount 12000 15000W shelf bulk power for external distribution up to five Cordex HP 2 4kW 3 0kW rectifiers 0300057 001 19 inch 1RU universal mount 9600 12000W shelf bulk power...

Page 9: ...o 120 seconds Soft start User adjustable to at least 5 seconds Protection 10kA interrupting in L and N wires THD current 5 at nominal input 100 load Input leakage current 3 5mA at 265Vac with 2 rectifiers Output specifications Output voltage 42 to 58Vdc Maximum power 3000W Output current 55 5A at 54Vdc Maximum output current 62 5A at 48Vdc Holdup time 5ms at 100 Load Characteristics Efficiency 96 ...

Page 10: ... lbs Environmental Temperature Operating full power 40 C to 55 C 40 F to 131 F Extended 55 C to 75 C 131 F to 167 F derate to 600W Storage 40 C to 85 C 40 F to 185 F Characteristics Relative humidity 0 to 95 non condensing Heat dissipation 500 BTU per hour 146 5W worst case 100 load at 187 Vac Elevation 500m to 3000m 1640ft to 9842ft 3 1 1 Cordex 48 3 0kW rectifier shelves 23 inch 1RU universal mo...

Page 11: ...14 UL 60950 1 2014 IEC EN 60950 1 2006 A11 2009 A1 2010 A12 2011 A2 2013 CAN CSA C22 2 No 62368 1 14 ANSI UL 62368 1 2nd Ed IEC 62368 1 2014 Second Edition EN 62368 1 2014 A11 2017 EMC FCC Section 15B ICES 003 Class A Digital Device IEC EN 55024 2010 ITE Equipment Immunity Characteristics IEC EN 55032 CISPR 32 Class A 2012 AC 2013 IEC EN 61000 3 2 2014 Harmonic Current Emission IEC EN 61000 3 3 20...

Page 12: ...Vac input Load regulation 0 7 static Line regulation 0 1 static Transient response 3 for 40 to 90 load step Noise Voice band 38dBrnC Wide band 20mV RMS 10kHz to 10MHz 150mV peak to peak 10kHz to 100MHz Psophometric noise 2mV RMS Acoustic 60dBa at 1m 3ft 30 C Reliability MTBF 627 000 hours per Telcordia SR 332 Issue 3 2011 Mechanical Dimensions H W D 41mm 104mm 333mm 1 6in 4 1in 13 1in Weight 1 76k...

Page 13: ...als 19 inch 1RU universal mount 9 600 12 000W shelf P N 0300040 001 002 Number of rectifiers Four Cordex HP 48 2 4kW 3 0kW rectifiers Nominal AC input current one module per feed 120Vac 11 5A per feed 50 60Hz 208 to 277Vac 12 5 to 9 5A per feed 50 60Hz Recommended input feeder breakers four feeds for shelf 20A per feed for nominal 120 208 240 277 Vac Recommended AC input wire size 12 AWG line 14 A...

Page 14: ...D remains illuminated 4 1 2 True module fail alarm The power modules have a true fail alarm that provides a true indication of the power module s ability to source current When the module s output current drops below 2 5 percent 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 d...

Page 15: ...ine the inrush current of a rectifier module is limited to the full load steady state line current Modules are also protected from input lightning and transient surges in accordance with ANSI IEEE C62 41 Category B3 standards 4 1 7 Soft start A soft start feature is used to eliminate an instantaneous demand on the AC power source A soft start sometimes referred to as a current walk in works by gra...

Page 16: ...als The maximum short circuit current will not exceed 62 5A per module 4 1 10 Power limiting Each rectifier module is designed to limit the power output to the module specification This enables more current to be supplied at lower output voltages and allows matching the output power to the demands of constant power loads often seen in telecom equipment This feature can also be used for a faster re...

Page 17: ...040 001 2 4kW compatible 0300228 001 shelf ID support 4 1 16 Controller The 3 0kW rectifier shelf is designed to operate with the Cordex HP controller A controller adds the following capabilities to the rectifiers Local and remote communications and monitoring User definable alarms Daily logging of events and system statistics Load sharing Power save NOTE The 3 0kW rectifier requires AC input powe...

Page 18: ...50228 001 in last position 4 1 17 Internal CAN bus A CAN bus is used to transmit all alarm and control functions between the controller and rectifier shelves Two CAN serial ports modular jacks are located on the left side of the rectifier shelf as viewed from the front The CAN bus can be daisy chained from shelf to shelf CAN 1 of one shelf to CAN 2 of another The last shelf is terminated using a C...

Page 19: ...f this manual for shelf power and communications connections compatible with 2 4kW and 3 0kW rectifiers 0300057 08 0300040 08 4 2 3 True module fail alarm The power modules have a true fail alarm that provides a true indication of the power module s ability to source current When the module s output current drops below 2 5 percent of the rated output a low output current condition is detected and ...

Page 20: ...ong with Start Delay prevents any instantaneous surge demand from the utility 4 2 9 Start delay The rectifier modules are equipped with a delay timer to stagger start a series of modules When multiple modules and multiple shelves part of a larger system are used in conjunction with a controller a start delay prevents all rectifiers from starting at the same time and causing an inrush on the utilit...

Page 21: ...ut down until it is reset by restarting the rectifier via the controller 4 2 13 Battery eliminator operation Rectifier modules maintain all specifications except where indicated with or without a battery or a DC source attached in parallel to the output Under these conditions there will be no monitoring or control activity if AC power failure occurs 4 2 14 Distribution Bulk 23 inch 1RU universal m...

Page 22: ...e without a Cordex controller however load balancing among the rectifiers won t be as efficient particularly at lower input voltages 4 2 16 Internal CAN bus A CAN bus is used to transmit all alarm and control functions between the controller and rectifier shelves Two CAN serial ports modular jacks are located on the left side of the rectifier shelf as viewed from the front The CAN bus can be daisy...

Page 23: ...es 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 Unpack the product and inspect the exterior for damage If any damage is observed contact the carrier immediately Continue the inspection for any internal damage In the unlikely event of internal damage inform the carrier and ...

Page 24: ...cifier shelf 7 Check battery polarity and connections 8 Final tests 6 2 Safety precautions Refer to Safety on page 4 before beginning this installation 6 3 Installation tools Various insulated 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 used in in...

Page 25: ...driver to eliminate the possibility of slippage and scratching of the unit s exterior 2 Connect the shelf chassis ground to the rack The primary option is using the intended chassis ground location located on the back of the rectifier shelf using a 2 hole lug 1 4 on 5 8 center The secondary option is to use rack the shelf is installed into for grounding through the mounting ears Ensure to be using...

Page 26: ...n users TEW type for European users must be EN or IEC approved wire If the systems is operating in a floating output then no reference or common ground is required to be connected to the power system If the system is intended to operate in a common bond network than the common output leg must be connected to ground Typical locations for connecting reference ground 1 Battery termination bar 2 Commo...

Page 27: ... on 1 centers 1 Remove the bolts and washers at both positive and negative output bars Bolts are 3 8 16 1 2 Use fasteners removed from the previous step to secure the positive and negative cables to the shelf output bars Install all fasteners finger tight 3 Use a Tongue and Groove or similar pliers to hold and stabilize the output bar torque each bolt to 27 12Nm 20 ft lbf CUSTOMERS VERTICAL BUS BA...

Page 28: ...tion Use the fasteners removed from the previous step to secure the positive and negative cables to the shelf output bars Install all fasteners finger tight Use a Tongue and Groove or similar pliers to hold and stabilize the output bar torque each bolt to 10 85Nm 8 ft lbf The shelf is intended to operate as four independent outputs Ensure that the controller connected has all load balancing and po...

Page 29: ...emove screw and flip the cover down two places to access the AC input terminal blocks each terminal pair corresponds to either two rectifiers or a single rectifier 3 The wire way is designed for two customer supplied 3 4 trade size conduit fittings for the AC supplies located on each side of the shelf Attach the conduit retainers to the wire way holes and route the AC cables through them 4 Secure ...

Page 30: ...NG Use care when removing or replacing the covers for the AC input connections Never assume that an electrical connection or conductor is not energized 1 Ensure that all rectifier modules are removed from the shelf 2 At the rear of the shelf remove the screw and flip the cover down two places to access the AC input terminal blocks Each terminal pair corresponds to an individual rectifier as marked...

Page 31: ...tional 6 8 1 CAN serial ports rectifier shelf Two CAN serial ports modular jacks are provided for communications with Cordex controllers and other CAN enabled equipment These are located on the left side of the rectifier shelf as viewed from the front 1 Daisy chain from shelf to shelf CAN 1 of one shelf to CAN 2 of another 2 Insert a CAN terminator P N 5450228 001 in the last CAN bus position at t...

Page 32: ...Slot IDs 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 transmits bay ID shelf ID and rectifier slot IDs to Cordex HP controller Rack mounted Shelf ID PCB Bay ID 1 manually set Shelf ID board RJ12 connection located on right side of shelf Bay ID display Up button Reset button Dow...

Page 33: ...rgize during an alarm condition see the Cordex HP Controller Software Manual When the controller reset button is pressed or power is lost all relays de energize 6 8 5 Digital inputs The digital input channels are used to monitor various alarm and control signals All input channels are voltage activated and accept a bipolar negative or positive DC signal directly Connection method Typical systems u...

Page 34: ...ge the rear connector in the shelf receptacle c Place the handle in the down position 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 illuminates after a preset start delay See the Product Features on page 12 for a description of the LEDs 3 Use the controller if installed to test the functiona...

Page 35: ...n amps LF Conductor loop feet K 11 1 constant factor for commercial TW type copper wire AVD Allowable voltage drop Check again that the ampacity rating of the cable meets the requirement for the installation application Consult local electrical codes for example NEC or CEC for guidelines If required increase the size of the cable to meet the code The following table provides cable size equivalents...

Page 36: ...n DC return Connect the isolated power system battery return bus BRB to the building master ground bus MGB or floor ground bus FGB in a larger building This acts as a system reference and as a low impedance path to the ground for surges transients or noise The MGB or FGB must have a direct low impedance path to the building grounding system The cable from the power system to the MGB or FGB must be...

Page 37: ...roller the rectifiers will switch to safe mode 51 4V default after five minutes 8 1 2 Output current power modes These modes directly affect the output current and power Table G lists the output current power modes and a description of when they are active Table G Output current power modes Output current modes Active when Temperature foldback mode Output current and power limit have been reduced ...

Page 38: ...V 55V Battery Test BT Voltage 44V to 52V 46V Over Voltage Protection OVP 63V 63V Current Limit CL 20 to 100 100 Power Limit PL 0 to 100 100 Module Start Delay 0s to 250s 1s System Start Delay 0s to 600s 0s Low Voltage Alarm LVA 42V to 52V 44V High Voltage Alarm HVA 52V to 63V 55 5V EQ Timeout 1h to 2399h 30h BT Timeout 1h to 250h 8h Softstart Ramp rate Normal Fast Normal CL PL Alarm Enable Disable...

Page 39: ... and control settings 9 1 Replacing a rectifier module via the Cordex HP controller When a rectifier is permanently removed the system generates a Rectifier Comms Lost alarm That alarm is cleared by removing the rectifier from the system inventory To remove the rectifier from the system inventory do the following 1 Remove the defective rectifier from the shelf 2 To remove a module flip the handle ...

Page 40: ... window appears with a progress bar showing the number of modules acquired during the update 3 Place the new rectifier module on the shelf bottom Lift the handle and slide the module into the rear connector inside the shelf Apply pressure to the module front panel to engage the rear connector in the shelf receptacle 4 Flip the handle down to lock the module in place 9 3 Fan replacement The fan on ...

Page 41: ... proper polarity and that the wires stay clear of the fan blade 7 Slide the front panel into the rectifier body 8 Ensure the metal tabs of the rectifier body aligned with the screw holes of the front panel 9 Ensure the plastic tabs of the front panel are protruding through the metal cutouts in the rectifier body 10 Secure the front cover by hand tightening the bottom screws ...

Page 42: ...lt states AC DC Alarm fault Rectifier state Possible causes Solutions Green Green Off Normal operation Green Off Off Unit has no DC output Unit is in Power Save mode Unit will automatically resume power delivery power when load is increased or when the Remote restart is enabled Off Off Off Unit may not be plugged in or system is off or unit has failed Plug in unit completely check AC and DC wiring...

Page 43: ...and Radio Spectrum Matters ESD Electrostatic Discharge FCC Federal Communications Commission for the US FGB Floor ground bus HVSD High voltage shutdown IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics Engineers IP Internet Protocol LVD Low voltage disconnect MGB Master ground bus MIL One thousandth of an inch used in expressing wire cross sectional area MO...

Page 44: ...on 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 causes external to the unit including but not limited to environmental conditions water damage power surges or any other external influence The customer is responsibl...

Page 45: ... the aforementioned CSA marks are certified to CSA C22 2 No 107 3 and UL 1778 As part of the reciprocal US Canada agreement regarding testing laboratories the Standards Council of Canada Canada s national accreditation body granted Underwriters Laboratories UL authority to certify products for sale in Canada 2 Only Underwriters Laboratories may grant a licence for the use of this mark which indica...

Page 46: ...UT TERMINAL 3 8 16 FOR TERMINAL CONNECTION ON 1 CENTERS RJ12 CAN 1 RJ12 CAN 2 AC WIREWAY BOTH SIDES 1 02 HOLE FOR CUSTOMER SUPPLIED 3 4 TRADE SIZE CONDUIT FITTING A DETAIL A SCALE 1 2 L1 L2 N L1 L2 N DETAIL B SCALE 1 2 L1 L2 N L1 L2 N AC FEED FOR RECTIFIER SLOT 4 AC FEED FOR RECTIFIER SLOT 3 NOTE DAISYCHAIN CAN BUS FROM ONE SHELF TO THE NEXT INSERT TERMINATOR P N 5450228 001 IN LAST POSITION AC FE...

Page 47: ...IT FITTING NOTE DAISYCHAIN CAN BUS FROM ONE SHELF TO THE NEXT INSERT TERMINATOR P N 5450228 001 IN LAST POSITION PROTECTIVE EARTH TERMINAL 2 PLACES CHASSIS GROUND 2 HOLE LUG 1 4 ON 5 8 CENTERS POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL 3 8 16 FOR TERMINAL CONNECTION ON 1 CENTERS DETAIL A SCALE 1 2 L1 L2 N L1 L2 N DETAIL B SCALE 1 2 L1 L2 N AC FEED FOR RECTIFIER SLOT 3 4 AC FEED FOR RECTIFIE...

Page 48: ...HAIN CAN BUS FROM ONE SHELF TO THE NEXT INSERT TERMINATOR P N 5450228 001 IN LAST POSITION PROTECTIVE EARTH TERMINAL 2 PLACES CHASSIS GROUND 2 HOLE LUG 1 4 ON 5 8 CENTERS POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL 3 8 16 FOR TERMINAL CONNECTION ON 1 CENTERS DETAIL A SCALE 1 2 L1 L2 N L1 L2 N DETAIL B SCALE 1 2 L1 L2 N AC FEED FOR RECTIFIER SLOT 3 4 AC FEED FOR RECTIFIER SLOT 5 AC FEED FOR R...

Page 49: ...ECTION ON 1 CENTERS RJ12 CAN 1 RJ12 CAN 2 AC WIREWAY BOTH SIDES 1 11 HOLE FOR CUSTOMER SUPPLIED 3 4 TRADE SIZE CONDUIT FITTING A RJ22 SHELF ID DETAIL A SCALE 1 2 L1 L2 N L1 L2 N DETAIL B SCALE 1 2 L1 L2 N L1 L2 N AC FEED FOR RECTIFIER SLOT 4 AC FEED FOR RECTIFIER SLOT 3 NOTE DAISYCHAIN CAN BUS FROM ONE SHELF TO THE NEXT INSERT TERMINATOR P N 5450228 001 IN LAST POSITION AC FEED FOR RECTIFIER SLOT ...

Page 50: ...ATIC 7050007 05 L1 L2 N SLOT 2 INPUT TB2 TB1 TB2 PCBA AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 SLOT 3 4 INPUT SLOT 5 INPUT L2 N L1 L2 N L1 SLOT 4 SLOT 3 SLOT 2 SLOT 1 SHELF ID J3 L1 L2 N SLOT 1 INPUT TB1 OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID OU...

Page 51: ...L2 N SLOT 1 2 INPUT TB2 TB1 TB2 PCBA AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 SLOT 3 4 INPUT SLOT 5 INPUT L2 N L1 L2 N L1 SLOT 5 SLOT 4 SLOT 3 SLOT 2 SLOT 1 OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID J3 SHELF ID OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 SHELF ID OUTPUT OUTPUT INTERLOCK CAN INTERFACE...

Page 52: ...PUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 L1 L2 N L1 L2 N SLOT 3 INPUT SLOT 4 INPUT PCBA AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 TB2 TB1 PCBA AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 L1 L2 N L1 L2 N SLOT 1 INPUT SLOT 2 INPUT TB2 TB1 BUSBAR DC OUTPU...

Page 53: ...AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 SLOT 4 INPUT SLOT 3 INPUT L2 N L1 L2 N L1 L1 L2 N CAN INTERFACE INTERLOCK OUTPUT OUTPUT L1 L2 N CAN INTERFACE INTERLOCK OUTPUT OUTPUT L1 L2 N CAN INTERFACE INTERLOCK OUTPUT OUTPUT OUTPUT OUTPUT INTERLOCK CAN INTERFACE SLOT 4 SLOT 3 SLOT 2 SLOT 1 L2 N L1 EARTH J1 CAN IN PCBA Bkpl Comm O P 19 Shlf CX HP 2 4kW P N 7050011 001 SCHEM...

Page 54: ...07 001 SCHEMATIC 7050007 05 L1 L2 N SLOT 1 2 INPUT TB2 TB1 TB2 PCBA AC Intrfc 4 Terminal CX HP 2 4kW P N 7050007 001 SCHEMATIC 7050007 05 SLOT 3 4 INPUT SLOT 5 INPUT L2 N L1 L2 N L1 SLOT 5 SLOT 4 SLOT 3 SLOT 2 L1 L2 N SLOT 1 CAN INTERFACE INTERLOCK OUTPUT OUTPUT OUTPUT OUTPUT INTERLOCK CAN INTERFACE L2 N L1 L1 L2 N CAN INTERFACE INTERLOCK OUTPUT OUTPUT L1 L2 N CAN INTERFACE INTERLOCK OUTPUT OUTPUT...

Page 55: ......

Page 56: ...0 667 8743 Outside North America 1 604 436 5547 Technical Support 1 888 462 7487 For more information visit our website at www alpha com 2021 Alpha Technologies Ltd All Rights Reserved Trademarks and logos are the property of Alpha Technologies Ltd and its affiliates unless otherwise noted Subject to revisions without prior notice E O E ...

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