Alpha Technologies Cordex HP User manual

Your Power Solutions Partner
Cordex HP 2.4kW Switched Mode Rectifier System
Shelf Models: 19" 1RU universal mount 9600W
23" 1RU universal mount 12000W
Installation and Operation Manual
Part # 0100003-J0
Effective 11/2015
member of The Group™

Cordex HP Modular Switched Mode Rectier System
Shelf Models: 19" 1RU universal mount 9600W
23" 1RU universal mount 12000W
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: [phone]
Copyright
Copyright © 2015 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo-
gies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or trans-
mitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or other-
wise without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the propri-
etary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.
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 its accuracy, Alpha Technolo-
gies 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 reserva-
tion and without notification to its users.
Alpha shall not be held liable for any damage or injury involving its enclosures, power
supplies, generators, batteries, or other hardware if used or operated in any manner or
subject to any condition inconsistent with its intended purpose, or if installed or oper-
ated in an unapproved manner, or improperly maintained.
Photographs contained in this manual are for illustrative purposes only. These photo-
graphs may not match your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe operation of this powering
system, contact Alpha Technologies or your nearest Alpha representative.
NOTE:
NOTE:

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Table of Contents
1. Safety ....................................................................................................................................5
1.1 Safety Symbols .......................................................................................................................... 5
1.2 General Safety ........................................................................................................................... 5
1.3 Mechanical Safety ...................................................................................................................... 5
1.4 Electrical Safety ......................................................................................................................... 6
1.5 Battery Safety ............................................................................................................................ 6
2. Introduction ...........................................................................................................................7
2.1 Scope of the Manual .................................................................................................................. 7
2.2 Product Overview ....................................................................................................................... 7
2.3 Part Numbers and List Options .................................................................................................. 8
2.4 Specications ............................................................................................................................. 9
3. Product Features ................................................................................................................11
3.1 Rectier .....................................................................................................................................11
3.2 Distribution ............................................................................................................................... 14
3.3 Controller ................................................................................................................................. 15
4. Inspection............................................................................................................................16
4.1 Packing Materials ..................................................................................................................... 16
4.2 Check for Damage ................................................................................................................... 16
4.3 General Receipt of Shipment ................................................................................................... 16
5. Installation ...........................................................................................................................17
5.1 Safety Precautions ................................................................................................................... 17
5.2 Tools Required ......................................................................................................................... 17
5.3 Power System Assembly and Mounting ................................................................................... 18
6. Wiring ..................................................................................................................................19
6.1 Grounding ................................................................................................................................ 19
6.2 CAN Serial Ports (Rectier Shelf) ............................................................................................ 20
6.3 AC Wiring 23" Shelf .................................................................................................................. 21
6.4 AC Wiring 19" Shelf .................................................................................................................. 22
6.5 DC Output Connections - Bulk Distribution .............................................................................. 23
6.6 DC Output Connections - Single Component Distribution ....................................................... 24

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7. System Startup ...................................................................................................................25
7.1 Check System Connections ..................................................................................................... 25
7.2 Verify AC and Power the Rectier Shelf ................................................................................... 25
7.3 Check Battery Polarity and Connections ................................................................................. 25
8. Rectier Modes and Factory Defaults .................................................................................26
8.1 Rectier Modes ........................................................................................................................ 26
8.2 Factory Ranges and Defaults .................................................................................................. 27
9. Maintenance .......................................................................................................................28
9.2 Replacing a Rectier Module ................................................................................................... 28
9.3 Replacing a Rectier Module via the CXC HP Controller ........................................................ 29
9.4 Fan Replacement ..................................................................................................................... 30
10. Troubleshooting ................................................................................................................32
11. Acronyms and Denitions ..................................................................................................33
12. Warranty Statement and Service Information ...................................................................34
12.1 Technical Support .................................................................................................................. 34
12.2 Warranty Statement ............................................................................................................... 34
12.3 Product Warranty ................................................................................................................... 34
12.4 Battery Warranty .................................................................................................................... 34
12.5 Warranty Claims ..................................................................................................................... 34
12.6 Service Information ................................................................................................................ 34

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List of Figures
Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectier Shelf, (b) Typical 48V Power Systems with
2.4kW Rectiers ...................................................................................................................... 7
Figure 2 — Rectier Front Panel LEDs ............................................................................................11
Figure 3 — Locking Handle Disengaged/Engaged ......................................................................... 13
Figure 4 — 23" or 19" Shelf with Bulk Distribution Busbars ............................................................ 14
Figure 5 — 19" Shelf with Single Component Distribution .............................................................. 14
Figure 6 — 2.4kW Shelf with CXDM-E3 Distribution and CXC HP Controller ................................ 15
Figure 7 — Chassis Ground ........................................................................................................... 18
Figure 8 — CAN Bus Cabling ......................................................................................................... 20
Figure 9 — AC Input and Ground for 23" Shelf ............................................................................... 21
Figure 10 — 19" Shelf in with Single Component Distribution ........................................................ 24
Figure 11 — Rectier Bottom View ................................................................................................. 30
Figure 12 — Removing Front Panel from Rectier ......................................................................... 30
Figure 13 — 2.4kW Rectier Fan Assembly ................................................................................... 31
Figure 14 — Reattaching the Front Panel ...................................................................................... 31
Figure 15 — Locking the Front Panel in Place ............................................................................... 31

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WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to personnel.
Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath
which the information appears.
CAUTION!
CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment. Cautions are designated with a yellow warning triangle, the word CAUTION,
and a rule beneath which the information appears.
1. Safety
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that
must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Re-
view the drawings and illustrations contained in this manual before proceeding. If there are any questions regard-
ing the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representa-
tive. Save this 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
symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
The use of ATTENTION indicates specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure.
Notes are designated with a check mark, the word NOTE, and a rule beneath which the
information appears
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or
user.
1.2 General Safety
WARNING!
This system is designed to be installed in a restricted access location that is inacces-
sible to the general public.
1.3 Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.

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1.4 Electrical Safety
WARNING!
WARNING!
WARNING!
• Before working with any live battery or power system, follow these precautions:
a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
b. Wear safety glasses with side shields at all times during the installation.
c. Use OSHA approved insulated hand tools.
Lethal voltages are present within the power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to
the grounded portion of the enclosure (both AC and DC) before performing any installa-
tion or removal procedure.
• Do not work alone under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment. Input voltages can range up to
277Vac nominal. Ensure that the utility power is disconnected and locked out before performing any installa-
tion 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.
1.5 Battery Safety
• Servicing and connection of batteries must 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 approved insulated hand tools. Do not rest tools on top of batteries.
• Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm.
Battery post terminals and related accessories contain lead and lead compounds. Wash your hands after
handling batteries.
Follow battery manufacturer’s safety recommendations when working around battery
systems. Do not smoke or introduce an open ame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can ex-
plode.
• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the bat-
tery manufacturer for recommended local authorized recyclers.
Hazardous voltages are present at the input of power systems. The DC output from rec-
tiers and batteries, though not dangerous in voltage, has a high short-circuit current
capacity that may cause severe burns and electrical arcing.

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2. Introduction
2.1 Scope of the Manual
This manual explains the installation, interconnection, and operation of the Cordex HP 48-2.4kW rectifier systems.
2.2 Product Overview
A complete rectifier system consists of one or more power modules in a common shelf enclosure. The shelf
has connections for AC inputs, DC output, and system communications. The wide AC input operating range for
global installations and wide operating temperature ranges for installation in uncontrolled environments along with
high efficiency (>96%) reduces the carbon footprint and the operating expenses.
Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated
and isolated DC output from the AC mains. Multiple 48V configurations are available up to 250A in a compact
1RU shelf system. Industry leading power density (28W/in3) yields more space for revenue generating equipment.
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 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 Alpha 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, auto equalization, remote access, dial out on alarm, battery diagnostics, as
well as Web server and SNMP support for configuration and monitoring. Details of controller operation are pro-
vided in the current version of the related software manual.
External CXC models of the system controller communicate with the shelf via RJ-12 shelf connectors. The CXCR
is mounted in a rack and the CXCP is (factory) mounted in a panel. In a power system, up to five (5) rectifier
shelves may be stacked and connected to the same controller. The latest CXC-HP controller, featuring touch
screen, color LCD display with front Ethernet and USB connectors, is available as a panel mount controller or as
part of the CXPS-E3 system.
Figure 1 — (a) Cordex HP 19" 48Vdc-2.4kW Rectifier Shelf, (b) Typical 48V Power Systems with 2.4kW Rectifiers
(b)
CXPS-E3 Modular
Distribution
(a)

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2.3 Part Numbers and List Options
The product, options, and accessories can be ordered by using the part numbers in the following table.
Description List Option
23in 1RU universal mount 12000W shelf*
– bulk power for external distribution
– up to ve Cordex HP 2.4kW rectiers
0300057-001
19in 1RU universal mount 9600W shelf*
– bulk power for external distribution
– up to four Cordex HP 2.4kW rectiers
0300040-001
19in 1RU universal mount 9600W shelf*
– separate feed In/Out,
– up to four Cordex HP 2.4kW rectiers
0300040-002
Cordex HP 2.4kW rectier 0100003-001
Fan assembly replacement 7400374-001
Module blank 7400424-001
Rear DC Output 19" shelf cover 0370250-001
Rear DC Output 23" shelf cover 0370250-002
*Note: Standard DC bus bars available up to a maximum of ve shelves per
system.