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010-619-J0 Rev B

Page 5

2

Introduction

2.1

Scope of the Manual

This manual explains the installation, interconnection, and operation of the Alpha Cordex CXRF-HP
48-1.2 kW 48Vdc power and distribution systems that contain the CXCM1 series of controllers (includes
CXCM1+ and CXCM1 HP).

2.2

Product Overview

These 48Vdc power and distribution systems incorporate the high performance (HP) series of 48V
1.2kW Cordex rectifier modules and are specifically designed for restricted space installation. Cordex
rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated
and isolated DC output from the AC mains. The rectifier module input is universal to allow use on
120/208/220/240Vac 50/60Hz electrical service. The front access design, allows for all customer
connections in front of the rack channel.

•

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 added to the system at the time of ordering or after the shelf
has been installed.

•

The shelves are designed for horizontal mounting in a 19" or 23" center mount (flush mount for
1RU shelves) installation via universal mounting brackets (EIA rack spacing) and utilize dual
IEC-type connectors for multiple AC line cord solutions.

•

The Alpha CXCM1 HP was designed as a modular, high performance controller for the rectifier
series.

•

All controllers models allow the user to set up, control and monitor the entire power system and
ancillary components from one central, easy-to-use source. Details of controller operation are
provided in the current version software manual.

•

The equipment is suitable for installation in network telecommunication facilities.

The following figures are examples of:

1. CXRF-HP 48-1.2 kW 1RU 19" shelf system, with 3 rectifier modules up to 3.6kW output power,

controller and GMT fuse distribution

2. CXRF-HP 48-1.2 kW 2RU 19" shelf system, with (a) 4 rectifier modules up to 4.8kW output power

and controller (top shelf) and (b) 5 rectifier modules up to 6.0kW output power (lower shelf)

3. CXRF-HP 48-1.2kW 2RU 19" shelf system, with 4 rectifier modules up to 4.8kW output power,

controller and breaker/GMT fuse distribution

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Содержание Cordex HP 48 1.2kW

Страница 1: ...Technical Guide 010 619 J0 Effective 10 2018 Cordex 48 1 2kW Rectifier Shelf System Alpha Technologies Ltd...

Страница 2: ......

Страница 3: ...ark of Alpha Technologies No part of this documentation shall be reproduced stored in a retrieval system translated transcribed or transmitted in any form or by any means manual electric electronic el...

Страница 4: ......

Страница 5: ...rush Transient Suppression 9 Soft Start 9 Start Delay 9 Current Limit Short Circuit Protection 9 Power Limiting 9 High Voltage Shutdown HVSD 9 Battery Eliminator Operation 9 Distribution 10 4 8kW Syst...

Страница 6: ...ief 26 Calculating Output Wire Size Requirements 27 DC Output 27 DC Output for Model 030 851 20 maximum 3600W 27 DC Output for Model 0300165 maximum 4800W 29 DC Output for Model 030 835 20 030 845 20...

Страница 7: ...er Reset 41 Soft Reset CXCM1 only 41 IP Address Reset CXCM1 only 41 Hard Reset 42 Accessing the LVD Jumper 42 9 MAINTENANCE 43 Rectifier Fan Replacement 43 10 WARRANTY AND SERVICE INFORMATION 45 Techn...

Страница 8: ...nmental Codes 19 Figure 14 Removing a Rectifier from the Shelf 22 Figure 15 Removing a CXRF or CXCM1 or CXCM1 23 Figure 16 Removing the CXCM1 HP 24 Figure 17 AC input CAN and signal connections 4800W...

Страница 9: ...nitions for Digital Inputs 34 Table 4 Output Voltage Modes 38 Table 5 Output Current Power Modes 38 Table 6 Factory Ranges and Defaults 39 Table 7 Sample Maintenance Log 43 Table 8 Specifications Cord...

Страница 10: ...vi...

Страница 11: ...gs present safety information to PREVENT INJURY OR DEATH to personnel NOTE HOT The use of Hot presents safety information to PREVENT BURNS to the technician or user 1 2 General Warning and Cautions WA...

Страница 12: ...bassembly are suitable for connection to intra building or unexposed wiring or cabling only The intra building ports of the equipment or subassembly MUST NOT be metallically connected to interfaces th...

Страница 13: ...010 619 J0 Rev B Page 3 Batteries are hazardous to the environment and should be disposed at a recycling facility Consult the battery manufacturer for recommended local authorized recyclers...

Страница 14: ...010 619 J0 Rev B Page 4...

Страница 15: ...to the system at the time of ordering or after the shelf has been installed The shelves are designed for horizontal mounting in a 19 or 23 center mount flush mount for 1RU shelves installation via un...

Страница 16: ...010 619 J0 Rev B Page 6 Figure 1 Single Shelf Figure 2 Dual Shelf Figure 3 2RU Shelf...

Страница 17: ...igure 4 Rectifier Front Panel 3 1 2 LEDs The front panel LEDs provide rectifier status summary and help to locate a specific module with the controller AC The top LED green is on when AC is within val...

Страница 18: ...icate a failed module or a failed load NOTE For Cordex rectifier systems without batteries or with a very light load below 2 5 of rated output it is recommended that the ramp test be disabled to avoid...

Страница 19: ...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 sus...

Страница 20: ...in a compact space See Wiring and Connections chapter of this manual for more details Figure 5 4 8kW System Distribution Module 3 2 2 3 6kW System Distribution Module 030 851 20 Cordex CXRF HP 48 1 2...

Страница 21: ...press any of the three navigation buttons to re activate the screen and enter dashboard mode Figure 7 CXCM1 HP Controller 3 3 1 Display In dashboard mode the in shelf display shows the key operating p...

Страница 22: ...enu screen The following table provides a full list of menus available via the in shelf display Figure 9 In Shelf Controller Menu A C 1 2 0 1 2 0 1 V 7 8 7 2 V A 8 0 2 3 V A 7 9 0 2 V A D C 4 8 5 4 0...

Страница 23: ...Restore Restore the controller application and configuration from a file on a USB device Upgra Upgrade the controller application from a file on a USB device OS Upg Upgrade the controller s operating...

Страница 24: ...Cordex controller includes a web server that provides easy set up and monitoring using an Internet connection with the standard web browser The data logging feature allows the user to capture data fr...

Страница 25: ...minated at a time during alarm conditions Green OK no alarms present Yellow Minor alarm is present no major alarms Red Major alarm is present Progress and Status Indication The LEDs are also used in t...

Страница 26: ...battery to monitor battery voltage or change battery setting from V1 to V2 in Signals Configure Signals Current Inputs The controller software is pre configured to monitor I1 for battery current wired...

Страница 27: ...nications with your controller is available via the Alpha website http www alpha ca downloads 3 4 10 Controller Connections Next to the CXCM1 on the left side of the shelf are terminal block connectio...

Страница 28: ...010 619 J0 Rev B Page 18...

Страница 29: ...quirements As such Alpha strives to follow our quality and environmental objectives from product supply and development through to the packaging for our products Rectifiers and batteries are shipped o...

Страница 30: ...010 619 J0 Rev B Page 20...

Страница 31: ...nd battery installa tions e g CSA UL CEC NEC OSHA and local fire codes 5 2 Shelf Preparation Mounting NOTE The shelf is designed for horizontal mounting in a clean and dry environment Allow at least 1...

Страница 32: ...f 2 Place the new rectifier module on the shelf bottom and slide the module into the rear connector inside the shelf 3 Apply pressure to the module front panel to engage the rear connector in the shel...

Страница 33: ...oving the controller 2 Pull from the location noted in the following image to remove the controller CAUTION When removing the controller in a live system that has an LVD ensure that the LVD override j...

Страница 34: ...010 619 J0 Rev B Page 24 Figure 16 Removing the CXCM1 HP 1 Push up here and hold to release latch while removing the controller from the shelf 2 Pull here to remove the controller from the shelf...

Страница 35: ...size 3 16 Digital voltmeter equipped with test leads Adjustable 24 48Vdc load optional Cutters and wire strippers Crimping tool optional for large gauge wire Socket and ratchet set Imperial measure A...

Страница 36: ...to customer connection drawings at the rear of this manual NOTE The shelf incorporates IEC plug connections requiring line cords with C19R type receptacles Figure 17 AC input CAN and signal connection...

Страница 37: ...etc for guidelines If required increase the size of the cable to meet the code 6 6 DC Output 6 6 1 DC Output for Model 030 851 20 maximum 3600W Chassis and Site Ground Connections WARNING For safety...

Страница 38: ...ect a DC output cable use needle nose pliers to pull out the appropriate plug in connector Apply gentle clamping force to the pliers to avoid breaking the connector 2 After the plug in connector has b...

Страница 39: ...RW90 Type Double check the battery polarity and then connect the positive cable to the top side of the output bar and negative cable to bottom side Figure 20 DC Output to Batteries 6 6 2 DC Output fo...

Страница 40: ...floating analog especially current readings The chassis ground connection is located on the center mount rack bracket Connect to the 10 32 stud using single hole lug and hardware as provided The syste...

Страница 41: ...Hot Connections Connect to the four load breaker hot termination pairs using 1 4 on 5 8 center lugs Connection method is similar for breaker distributions in a 2 load 2 battery CB configuration Refer...

Страница 42: ...rmination OUT default 6 8 6 8 1 6 8 2 6 9 NOTE This system has a limit of twelve Cordex 1 2kW rectifiers due to available power from CAN Bus They do not have self powered CAN Bus nodes Network Connect...

Страница 43: ...r redundant power feed to the CXCM1 series controller when a battery disconnect device is used It is critical to controller opera tion as it ensures an auxiliary source of power to the controller shou...

Страница 44: ...elay Outputs Terminals provide contacts for extending various alarm or control signals Each relay output K2 K3 K4 can be wired for NO or NC operation during an alarm or control condition Figure 26 Rel...

Страница 45: ...ee the customer connections drawings If the LVD is controlled on NC contacts factory default for LVD option then JP2 pins 1 and 2 must be shorted together to maintain LVD operation If the LVD is contr...

Страница 46: ...010 619 J0 Rev B Page 36...

Страница 47: ...ting for a given amount of time before transitioning to the next state The controller continues to monitor its inputs After the Start Delay state the rectifier transitions to the Soft Start state NOTE...

Страница 48: ...2 Output Current Power Modes These four output current power modes directly affect the output current and power Table 4 Output Voltage Modes Output Voltage Modes Active when Float Output voltage is se...

Страница 49: ...5 Output Current Power Modes Continued Sheet 2 of 2 Output Current Power Mode Output current and power limit have been reduced due to Table 6 Factory Ranges and Defaults Sheet 1 of 2 Setting Range mi...

Страница 50: ...BT voltage setting or the safe mode voltage of 51 4V Current Limit Power Limit Alarm Enable Disable Enable Remote Shutdown Enable Disable Enable Ramp Test Enable Disable Enable Table 6 Factory Ranges...

Страница 51: ...ing for low AC voltage alarming is 180Vac For nominal 120Vac operation it is recommended to reset this value to 100Vac Using the controller test the functionality of various module alarms and controls...

Страница 52: ...D control jumper to the override position before unplugging the controller The load and batteries are still connected Use of hard reset may cause loss of data 8 5 Accessing the LVD Jumper To change th...

Страница 53: ...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 IMPORTANT Circuit cards can be damaged by...

Страница 54: ...ischarge 2 Remove the bottom screw that secures the front panel to the module chassis 3 Slide the front panel out 4 Disconnect the fan power lead wires from the module 5 Note the direction of airflow...

Страница 55: ...es 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...

Страница 56: ...010 619 J0 Rev B Page 46...

Страница 57: ...d 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 Underwrite...

Страница 58: ...010 619 J0 Rev B Page 48...

Страница 59: ...troller CXC Cordex Controller CXC HP Cordex Controller High Performance CXD Cordex DC DC Converter CXR Cordex Rectifier DC Direct current DCCT Direct Current Current Transducer DHCP Dynamic Host Confi...

Страница 60: ...MOV Metal Oxide Varistor MUX Multiplexer NEBS Network Equipment Building System a set of safety spatial and environmental guidelines for telecom OLED Organic LED in shelf controller display RFC Reque...

Страница 61: ...e within rated limits Static Line Regulation Better than 0 1 for any change in input voltage within rated limits Dynamic Line Regulation Better than 1 for any change in input voltage within rated limi...

Страница 62: ...nt 7 5A maximum 176 to 300Vac 6A maximum 90 to 176Vac Power Factor 0 99 at nominal conditions and 50 100 load Protection 10kA interrupting capacity fuses in active and neutral lines Efficiency 94 peak...

Страница 63: ...D Weight 1 23 kg 2 72 lb Compliance EN 55022 CISPR 22 Information Technology Equipment Radio Disturbance Characteristics Limits and Methods of Measurement Class A and Class B EN 61000 3 2 Harmonic Cur...

Страница 64: ...1089 CORE Electromagnetic Compatibility and Electrical Safety In accordance with FCC requirements we provide the following statement as specified in the FCC guidelines for conformance to Part 15 Class...

Страница 65: ...H x 88mm W x 318mm D 1 73 H x 3 5 W x 12 5 D Weight 0 62 kg 1 36 lb Mounting Modular on Cordex CXRF 48 1 2kW series shelves Relay Outputs Four 4 Form C 60Vdc 1A maximum Digital Inputs Two 2 60Vdc Anal...

Страница 66: ...ifications Basic Unit CXCM1 Input Voltage 17 to 60Vdc within rated limits Current 100mA 48Vdc 200mA 24Vdc MTBF 472 000 hours 25 C 77 F EMC The unit meets requirements of Emissions EN 55022 Class A CIS...

Страница 67: ...ase the separation between the equipment and receiver Connect the equipment into an outlet on a circuit different from that to which the receiver is connected Consult the dealer or an experienced radi...

Страница 68: ...20Vdc with power source Communication Ports Ethernet RJ 45 CAN see shelf specifications Recommended Signal Wire Sizes Wire Size Range 16 to 26 AWG 1 5 to 0 14mm2 Temperature Rating 90 C 194 F CAUTION...

Страница 69: ...OM CANH CANL CAN_ 5V AC_L1 AC_L2 POWER CANL J2 1 2 3 4 CAN AC IN AC_L1 AC_L2 CANL AC_L1 AC_L2 AC_L1 AC_L2 CAN_COM CANH CAN_ 5V POWER POWER CAN_COM CANH CAN_ 5V J2 1 2 3 4 CAN AC IN AC_L1 AC_L2 CANL PO...

Страница 70: ...CTIFIER O P BATTERY CB OUTPUTS LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG 7050233 001 OR 7050259 001 10 POS N GMT FUSE BOARD GRN YEL 12 AWG BUS...

Страница 71: ...O P BATTERY CB OUTPUTS LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG BUSBARS 7050238 001 ALARM STRIP BACKPLANE BOARD FROM CXCM1 BACKPLANE BOARD T...

Страница 72: ...LOAD CB OUTPUTS LOAD BATTERY SITE GROUND RETURNS CB_ALM FU_ALM 2 3 4 5 6 7 LVD K1 NC 4 5 BLK 22 AWG BUSBARS 707 588 20 ALARM STRIP BACKPLANE BOARD FROM CXCM1 BACKPLANE BOARD TO CXCM1 BACKPLANE BOARD...

Страница 73: ...AC_L1 AC_L2 AC_L1 AC_L2 7 5 6 8 BLK 2 X 18 AWG BLK 2 X 18 AWG GRN YEL 2 X 18 AWG AC FEED 2 MDLS 3 4 L1 L2 N PE BLK 2 X 18 AWG BLK 2 X 18 AWG GRN YEL 2 X 18 AWG 1 1 2 2 3 3 4 4 IEC RECEPTACLE AC_L1 AC...

Страница 74: ...DATE APPROVALS VB Feb 20 14 Feb 20 14 SL THIRD ANGLE PROJECTION UNLESS OTHERWISE SPECIFIED DIM ARE IN MM INTERPRET DIM AND TOL PER ASME Y14 5M 1994 X X X X XX ANGULAR 1 3 0 5 0 25 REAR RIGHT ISOMETRI...

Страница 75: ...06 OUTLINE DRAWING CXRF 48 1 2kw 19 SHELF 8 0 439 5 0 304 4 12 5 123 2 10 32 GROUND STUD TYP BOTH SIDES 88 2 10 92 6 35 76 20 31 75 12 7 482 6 583 6 465 0 566 0 19 RACK MOUNTING 23 RACK MOUNTING DO N...

Страница 76: ...HERWISE SPECIFIED A B CB4 CB3 CB2 CB1 CHASSIS GROUND 10 32 STUD HARDWARE AC IN MODULE 1 2 AC IN MODULE 3 4 SYSTEM STATUS LEDS LCD SCREEN DISPLAY PUSH BUTTON TOGGLE SWITCH A V HARD RESET BUTTON RESET B...

Страница 77: ...LOAD RETURNS NOTE SITE GROUND TERMINALS ARE NOT VISIBLE IN THIS VIEW SEE 2 LOAD DISTRIBUTION CONFIG FOR TYPICAL DETAIL BATTERY OUTPUT BATTERY OUTPUT 19 30 15 875 1 4 20 TYP PAIRED HARDWARE 15 875 2 L...

Страница 78: ...F A AA AB AC AD CORDEX CXCM1 HP SYSTEM CONTROLLER DETAIL A DETAIL AA SCALE 3 1 RESET STATUS DISPLAY DETAIL AB SCALE 3 1 MENU SELECT BUTTON C MENU CONTROL ALARM STATUS DETAIL AC SCALE 3 1 USB 2 0 PORT...

Страница 79: ...POWER POWER POWER POWER K1_C K1_NC K2_C K2_NO K2_NC K3_C K3_NO K3_NC K4_C K4_NO K4_NC D1_1 D1_2 D2_1 D2_2 V1_ V1_ T1_ T1_ T2_ T2_ I1_ I1_ BATT_HOT CAN_L CAN_L CAN_H CAN_H CAN_ 5V CAN_ 5V CAN_COM CAN_C...

Страница 80: ...4 5M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 PRODUCT TO BE FABRICATED ACCORDING TO ATL PRODUCTION STANDARD 0700001 1 NOTES UNLESS OTHERWISE SPECIFIED 010 619 20 MODULE 4x 0180054 001 or 018 598 20 0 12 0...

Страница 81: ...ARGUS DC MODEM USE ONLY PIN 1 2 3 4 5 6 7 8 9 DTR DCD TX RI COM CTS RX FUNCTION DSR RTS DETAIL C 5 9 6 1 K3 NC 12 10 11 I1 T2 T1 D1 1 K4 COM FUNCTION K1 NC D2 1 K3 NO V1 K2 COM K1 COM 9 8 7 6 5 4 3 2...

Страница 82: ...WER POWER CAN_COM CANH CAN_ 5V L1_3 L2_3 N CANL DC OUT POWER POWER CAN_COM CANH CAN_ 5V E10 E9 E11 E12 BUSBARS BUSBARS 7050471 001 BACKPLANE RECTIFIER MDL 2 RECTIFIER MDL 3 RECTIFIER MDL 4 P1 J5 37 CA...

Страница 83: ...M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 0 152 4 6 00 303 7 11 96 325 0 12 80 341 0 13 43 12 0 0 47 17 0 0 67 0 105 4 4 15 130 8 5 15 308 6 12 15 334 0 13 15 439 4 17 30 6 OFFSET RACK MOUNT 18 0 0 71 37...

Страница 84: ...N UNLESS OTHERWISE SPECIFIED DIM ARE IN MM INTERPRET DIM AND TOL PER ASME Y14 5M 1994 X X X X XX ANGULAR 1 1 0 5 0 25 CAN IN RJ12 OFFSET PIN 1 2 3 4 5 6 CAN L CAN COM NOT CONNECTED NOT CONNECTED CAN H...

Страница 85: ...815 20 PCB ASSY 8 GMT 1 2 3 4 5 6 7 8 9 10 E3 A1 A2 11 12 13 14 15 16 E4 E5 E6 E7 E8 JP1 JP4 JP5 JP6 JP7 JP8 JP3 LOAD LVD LIST 86 LOAD LVD LIST 86 BATTERY LVD LIST 87 BATTERY LVD LIST 87 JP9 NC K1 LV...

Страница 86: ...22 05 SY 439 5 17 30 583 6 22 98 465 0 18 31 566 0 22 28 482 6 19 00 0 37 9 1 49 6 1 0 24 44 0 1 73 LIST 23 6 OFFSET FOR 23 RACK SCALE 1 3 LIST 19 6 OFFSET FOR 19 RACK 0 321 7 12 67 332 0 13 07 0 29 8...

Страница 87: ...D TX RX NOT CONNECTED NOT CONNECTED TX FUNCTION RX NOT CONNECTED DETAIL B 1 8 CAUTION USE ONLY ALPHA DC MODEM SEE MANUAL FOR INSTRUCTIONS PIN 1 2 3 4 5 6 7 8 9 DTR DCD TX RI COM CTS RX FUNCTION DSR RT...

Страница 88: ...lvares Cabral N 338 Diadema SP 09981 030 Brazil Tel 55 1 1 2476 0150 www alphainnovations com br Alpha Innovations S A 1 Avenue Alexander Fleming B 1348 Ottignies Louvain la Neuve Belgium Tel 32 10 43...

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