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i

 

T

ABLE OF 

C

ONTENTS

 

1

   

I

NTRODUCTION

 ............................................................................................................................................................ 1

   

1.1

   

Scope of the Manual ........................................................................................................................................ 1

   

1.2

   

Product Overview ............................................................................................................................................ 1

   

1.3

   

System Configurations .................................................................................................................................... 2

   

1.4

   

Accessories ..................................................................................................................................................... 2

   

2

   

F

EATURES

 .................................................................................................................................................................. 3

   

2.1

   

System Overview ............................................................................................................................................. 3

   

2.2

   

Distribution Center ........................................................................................................................................... 3

   

2.3

   

Cordex Integrated System Controller (CXCI/CXCI+) ....................................................................................... 5

   

2.4

   

Cordex 24-48/2kW Converter .......................................................................................................................... 7

   

3

   

I

NSPECTION

 ................................................................................................................................................................ 9

   

3.1

   

Packing Materials ............................................................................................................................................ 9

   

3.2

   

Check for Damage ........................................................................................................................................... 9

   

3.3

   

General Receipt of Shipment ........................................................................................................................... 9

   

4

   

I

NSTALLATION

 ........................................................................................................................................................... 10

   

4.1

   

Safety Precautions ........................................................................................................................................ 10

   

4.2

   

Tools Required .............................................................................................................................................. 10

   

4.3

   

Power System Assembly and Mounting ........................................................................................................ 11

   

4.4

   

Converter Module Insertion/Removal ............................................................................................................ 11

   

4.5

   

Breaker Installation ........................................................................................................................................ 11

   

4.6

   

Breaker Removal ........................................................................................................................................... 11

   

5

   

W

IRING

 ..................................................................................................................................................................... 12

   

5.1

   

Grounding ...................................................................................................................................................... 12

   

5.2

   

Calculating Wire Size Requirements ............................................................................................................. 12

   

5.3

   

Input/Output Connections .............................................................................................................................. 13

   

5.4

   

Alarm Connections ........................................................................................................................................ 14

   

5.5

   

CAN Serial Ports ........................................................................................................................................... 15

   

5.6

   

Network Connection and Remote Communications via CXCI/CXCI+ ........................................................... 15

   

5.7

   

Signal Wiring Connections for CXCI/CXCI+ .................................................................................................. 16

   

6

   

S

YSTEM 

S

TARTUP

 ..................................................................................................................................................... 18

   

6.1

   

Check System Connections .......................................................................................................................... 18

   

6.2

   

Power the Converter Shelf ............................................................................................................................. 18

   

6.3

   

Converter Operation and Programming via the CXCI/CXCI+ ........................................................................ 18

   

6.4

   

CXCI/CXCI+ Reset ........................................................................................................................................ 19

   

7

   

M

AINTENANCE

 .......................................................................................................................................................... 20

   

7.1

   

Fan Replacement .......................................................................................................................................... 20

   

7.2

   

CXCI/CXCI+ Replacement Procedure ........................................................................................................... 21

   

8

   

W

ARRANTY

 ............................................................................................................................................................... 25

   

8.1

   

Warranty ........................................................................................................................................................ 25

   

9

   

A

CRONYMS AND 

D

EFINITIONS

 .................................................................................................................................... 26

   

 
 

 

Содержание CXPS 24-48-i

Страница 1: ...Your Power Solutions Partner CXPS 24 48 i 8kW DC DC Converter System Installation Operation Manual Part 053 996 B0 Effective 11 2013 member of The Group...

Страница 2: ......

Страница 3: ...cement 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 PR...

Страница 4: ...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...

Страница 5: ...d une proc dure sp cifique PRUDENCE Le symbole PRUDENCE CAUTION indique une information de s curit destin e VITER DES DOMMAGES au mat riel ou l quipement Ce symbole est repr sent par une ic ne de dan...

Страница 6: ...tact avec les composants internes Les pi ces lectriques dangereuses l int rieur de cette unit sont aliment es par les batteries m me lorsque l alimentation CA en entr e est d branch e S curit de la Ba...

Страница 7: ...ovee informaci n adicional para ayudar a completar una tarea o un procedimiento espec fico CUIDADO CUIDADO CAUTION indica informaci n de seguridad con el prop sito de PREVENIR DA OS al material o al e...

Страница 8: ...aci n o remoci n Aseg rese de que ning n l quido ni ropa h meda en contacto con los componentes internos Las partes el ctricamente activas peligrosas dentro de esta unidad est n energizadas por las ba...

Страница 9: ...gabe zu l sen bzw ein bestimmtes Verfahren durchzuf hren Hinweise sind mit einem H kchen dem Wort HINWEIS und einem Strich unter dem die Informationen aufgef hrt sind gekennzeichnet ACHTUNG ACHTUNG CA...

Страница 10: ...ungsst cke mit innenliegenden Komponenten in Ber hrung kommen Gef hrliche stromf hrende Teile innerhalb dieses Ger ts werden auch bei Trennung der Netzverbindung noch ber die Batterien versorgt Batter...

Страница 11: ...ting 11 4 4 Converter Module Insertion Removal 11 4 5 Breaker Installation 11 4 6 Breaker Removal 11 5 WIRING 12 5 1 Grounding 12 5 2 Calculating Wire Size Requirements 12 5 3 Input Output Connections...

Страница 12: ...5 Figure 7 Cordex CXCI model system controller front panel 6 Figure 8 CXDF 24 48 2kW modular switched mode converter 7 Figure 9 Example of an insulated tool kit 10 Figure 10 Rear view of CXPS 24 48 i...

Страница 13: ...version technique to provide a fully regulated and isolated 48 Volt DC output from a 24 Volt DC input The system can accommodate up to four CXDF 24 48 2kW DC DC converter modules Converter power modul...

Страница 14: ...Breaker AM type mid trip plug in 40A 470 309 10 Breaker AM type mid trip plug in 45A 470 310 10 Breaker AM type mid trip plug in 50A 470 311 10 Breaker AM type mid trip plug in 60A 470 312 10 Breaker...

Страница 15: ...t and the ground return bus The breaker distribution for the CXPS 24 48 i is configured for 18 load breaker positions Figure 2 DCP03 configured for 18 load breakers 2 2 2 Internal Alarm Card The DCP03...

Страница 16: ...erminal block 2 2 4 4R 8D ADIO Option The 4R 8D ADIO Cordex peripheral may also be optionally installed on the front door of the DCP03 expanding the I O capability of an existing Cordex controller by...

Страница 17: ...ta 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 applicat...

Страница 18: ...plication the red LED is illuminated 2 3 3 Reset A reset button is located on the front panel for restarting the CXCI CXCI s microprocessor NOTE Refer also to the software manual always select the Res...

Страница 19: ...ut channels to monitor alarm control signals from converters rectifiers and many other types of equipment 2 3 8 Alarm and Control Output Relays The CXCI CXCI contains Form C digital alarm output relay...

Страница 20: ...Red FAIL flashing Converter Minor Alarm Table 1 Module indicators and conditions 2 4 3 Regulation and Paralleling Cordex modular converters use output slope or regulation offset to accomplish load sh...

Страница 21: ...d 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 please inform the c...

Страница 22: ...ist as a guide Battery lifting apparatus as required Electric drill with hammer action 1 2 capacity Various crimping tools and dies to match lugs used in installation Load bank of sufficient capacity...

Страница 23: ...isolate system from the floor It is recommended that the relay rack be secured to the overhead cable tray Alpha does not supply the mechanical details necessary for overhead support 4 4 Converter Modu...

Страница 24: ...also be factored in The insulated cable should be equipped with two hole crimp type lugs and should not have any tight bends or kinks Power System Ampacity Ground Reference Conductor Size 30A 10 30 1...

Страница 25: ...XPS 24 48 i system is configured for wiring with respect to converter shelf output integration to the distribution panel Refer to Figure 10 below 24Vdc input is connected to the converter shelf The ne...

Страница 26: ...ire sizes are 0 14 to 1 50mm 2 26 to 16 AWG for the temperature range of 0 to 50 deg C as per UL CSA CAUTION to reduce risk of fire use only 0 14mm 2 26 AWG or larger wire Route via wire ways and use...

Страница 27: ...connector on the front of the shelf backplane See the customer connections drawing for your shelf The CAN bus may be OPEN to the next node in the system or TERMINATED on the final node on the CAN bus...

Страница 28: ...age For terminal block connections the recommended wire sizes are 0 14 to 0 75mm 2 26 to 18 AWG for the temperature range of 0 to 50 deg C as per UL CSA CAUTION to reduce risk of fire use only 0 14mm...

Страница 29: ...correct polarity is used for all input cable terminations The analog input channels are used to monitor various types of electrical signals Some of the analog channels are reserved for specific signal...

Страница 30: ...er System For proper operation of Charge Current Control and Power Save the system load current must include the current drawn from the rectifiers used to power the converters Depending on the locatio...

Страница 31: ...el reset button for three seconds The CXCI CXCI beeps three times IP will be reset to 10 10 10 201 and DHCP will be disabled The settings are saved and the unit resets This will allow local access e g...

Страница 32: ...connections re torque as necessary Verify alarm control settings Verify alarm relay operation Table 4 Sample maintenance log NOTE Consult factory for replacement parts To order more breakers refer to...

Страница 33: ...f CXCI system shelf Figure 15 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 controlled o...

Страница 34: ...cing a CXCI Controller 1 Write down the CXC communication information dynamic or static IP IP address and gateway 2 Connect a laptop to CXC per software manual standard network crossover cable to Ethe...

Страница 35: ...Controller 1 Write down the CXC communication information dynamic or static IP IP address and gateway 2 Connect a laptop to CXC per software manual standard network crossover cable to Ethernet port 3...

Страница 36: ...s Make sure the site information is checked to save it and click Accept 11 Go to Logs and Files Manage Editable Text Files Upload Dynamic Text File and select the saved tfg file You do not need to sub...

Страница 37: ...rranty coverage The warranty does not provide to the customer or other parties any remedies other than the above It does not provide coverage for any loss of profits loss of use costs for removal or i...

Страница 38: ...I Electromagnetic interference ESD Electrostatic Discharge FCC Federal Communications Commission for the USA IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronics...

Страница 39: ...erter module Static Regulation 0 1 line 1 0 0 1 load Dynamic Regulation 1 deviation for 50 100 load step settling to 0 1 in 2ms Electrical Noise 38dBrnC voice band 10mVrms 10kHz to 10MHz wideband 150m...

Страница 40: ...ee outline drawings at the rear of this manual Connections Load Connections AM breakers 1 pole 1 4 holes on 5 8 centers AM breakers multiple pole 3 8 holes on 1 centers with adapter Battery Terminatio...

Страница 41: ...erter Other Referenced Standards This product is designed to meet or exceed the following FCC 47 CFR part 15 Class A radiated and conducted EMI EN 55022 CISPR 22 Class A radiated and conducted EMI ENV...

Страница 42: ...Susceptibility 10 Vrms EN61000 4 11 Voltage Dips and Interruptions In accordance with FCC requirements we provide the following statement as specified in the FCC guidelines for conformance to Part 15...

Страница 43: ...correct the interference at his own expense Any changes or modifications to this equipment not expressly described in this manual could void the FCC compliance Environmental Temperature 40 to 65 C st...

Страница 44: ...oftware Specifications CXCI CXCI CXCI Software version All CXCI Software version 2 10 minimum Recommended Signal Wire Sizes as per UL CSA Wire Size Range 0 14 to 1 50mm 2 26 to 16 AWG Temperature Rang...

Страница 45: ......

Страница 46: ......

Страница 47: ...ARE IN INCHES INTERPRET DIM AND TOL PER ASME Y14 5 1994 0 040 1 0 020 0 010 CONVERTER SHELF 030 905 20 UDC ASSEMBLY 020 702 20 CXDF 24 48 2kW CONVERTER MODULE 012 526 20 4 MAX CXCI SYSTEM CONTROLLER...

Страница 48: ...20 030 905 20 BREAKER OUTPUTS 1 4 20 HARDWARE ON 5 8 CENTERS LVD OVERRIDE ALARM AND SYSTEM INPUT OUTPUT BOARDS SEE SHEET 4 FOR CONNECTIONS CXDF 24 48 2kW CONVERTER 012 526 20 CXCI CXCI SYSTEM CONTROL...

Страница 49: ...ECTIONS 1 4 20 TAPPED HOLES ON 5 8 CENTERS 2 PLACES HARDWARE SUPPLIED DISTRIBUTION 48V HOT OUTPUT BUSBAR FACTORY CONNECTION NOTE REFER TO 053 996 05 WIRING SCHEMATIC FOR MORE INFORMATION CXCI CXCI SYS...

Страница 50: ...996 08 CONNECTION CXPS 24 48 i CONVERTER SYSTEM CHASSIS GROUND 10 32 STUD 18X BREAKER RETURN COM TERMINATIONS 1 4 20 TAPPED HOLES ON 5 8 CENTERS CHASSIS GROUND 10 32 STUD TOP VIEW DOOR OPEN 18X BREAKE...

Страница 51: ...FOR INTERNAL SYSTEM WIRING RESERVED FOR INTERNAL SYSTEM WIRING DISTRIBUTION LVD OVERRIDE ALARM PCB 020 702 20 CONNECTION DETAILS SYSTEM ASSIGNED RESERVED FORM C RELAY ALARM OUTPUT CONNECTIONS K2 SYSTE...

Страница 52: ......

Страница 53: ......

Страница 54: ......

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Страница 56: ...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 Stort...

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