Alpha technologies Cordex 030-728 User manual

Your Power Solutions Partner

Cordex 48-650W Integrated Shelf System

Installation & Operation Manual

Part #CXS-650W-J0

Effective: 06/2017

member of The Group™

Cordex 48-650W Integrated Shelf System Manual

NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs 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: 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 operated in an unapproved manner, or improp-

erly maintained.

trademark 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, 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

proprietary, 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 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 without notification to its users.

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TABLE OF CONTENTS

1SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Wording/Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General Warning and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

EATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rectifier Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

True Module Fail Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Over Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . 8

Wide AC Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

AC Inrush/Transient Suppression . . . . . . . . . . . . . . . . . . . . . . 8

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Current Limit/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . 9

Power Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

High Voltage Shutdown (HVSD) . . . . . . . . . . . . . . . . . . . . . . . 9

Battery Eliminator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview of the CXCI HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

In-Shelf Display: Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

In-Shelf Controller Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Overview of the CXCI+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Reset (CXCI+ only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Controller Input and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Ethernet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Analog Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Digital Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Alarm and Control Output Relays . . . . . . . . . . . . . . . . . . . . . . 14

Network Connection and Remote Communication . . . . . . . . . . . . . 15

Controller Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

NSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Check for Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Returns for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

NSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shelf Preparation/Mounting . . . . . . . . . . . . . . . . . . . . . . . . . 19

Module Insertion/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Removing a CXRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Removing the CXCI HP . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

IRING AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power System Chassis Ground and DC Ground . . . . . . . . . . . . . . . . 23

AC Feeder Protection/Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . 23

AC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Calculating Output Wire Size Requirements . . . . . . . . . . . . . . . . . . 24

DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Circuit Breaker Distribution . . . . . . . . . . . . . . . . . . . . . . . . . 25

CAN Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Network Connection and Remote Communications via CXC . . . . . . . . . . 25

Ethernet Port for Network Connection . . . . . . . . . . . . . . . . . . . . 25

Ethernet Port for Local Connection . . . . . . . . . . . . . . . . . . . . . 26

Signal Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Alarm Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

LVD Control (Load Disconnect or Battery Disconnect) . . . . . . . . . . . 28

LVD Control Alternative . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

PERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Main Rectifier States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Soft Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Turning Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Main Rectifier Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Output Voltage Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Output Current/Power Modes . . . . . . . . . . . . . . . . . . . . . . . . 32

Can Bus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Factory Ranges and Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . 33

iii

8SYSTEM STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Check System Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Verify AC and Power The Shelf . . . . . . . . . . . . . . . . . . . . . . . . . 35

Check Battery Polarity and Connect . . . . . . . . . . . . . . . . . . . . . . 35

Controller Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Soft Reset (CXCI+ only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

IP Address Reset (CXCI+ only) . . . . . . . . . . . . . . . . . . . . . . . 36

Hard Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

AINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Replacing a CXCI HP Controller . . . . . . . . . . . . . . . . . . . . . . . . 37

Replacing a CXCI+ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 38

10 WARRANTY AND SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . 41

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Battery Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Warranty Claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

11 CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

12 GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

13 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2RU, 48-650W, 19”, 4-Module System . . . . . . . . . . . . . . . . . . . . . 47

2RU, 48-650W, 19”, 5 Module System . . . . . . . . . . . . . . . . . . . . . 48

Cordex 48-650W Switched Mode Rectifier . . . . . . . . . . . . . . . . . . . 49

CXCI HP Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

CXCI+ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

LIST OF FIGURES

Figure 1: Four Module, 030-728 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2: Five Module, 030-782. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3: Rectifier Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 4: CXCI HP Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Figure 5: In-Shelf Controller Dashboard Screens. . . . . . . . . . . . . . . . . . . .11

Figure 6: In-Shelf Controller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Figure 7: In-Shelf Controller Buttons . . . . . . . . . . . . . . . . . . . . . . . . . .12

Figure 8: Cordex CXCI+ model system controller front panel . . . . . . . . . . . . .13

Figure 9: Packing Materials and Environmental Codes . . . . . . . . . . . . . . . .17

Figure 10: Removing a Rectifier from the Shelf . . . . . . . . . . . . . . . . . . . . .20

Figure 11: Removing the CXCI HP . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Figure 12: Digital Input Connection Method . . . . . . . . . . . . . . . . . . . . . . .27

Figure 13: Relay Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Figure 14: Removing the CXCI HP. . . . . . . . . . . . . . . . . . . . . . . . . . . .37

LIST OF TABLES

Table 1: In-Shelf Controller Full Menu . . . . . . . . . . . . . . . . . . . . . . . . .11

Table 2: Recommended AC Supply Configuration. . . . . . . . . . . . . . . . . . .24

Table 3: Wiring Connections for the CXCI Series of Controllers. . . . . . . . . . . .26

Table 4: Voltage Level Definitions for Digital Inputs . . . . . . . . . . . . . . . . . .28

Table 5: Output Voltage Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Table 6: Output Current/Power Modes. . . . . . . . . . . . . . . . . . . . . . . . .32

Table 7: Factory Ranges and Defaults. . . . . . . . . . . . . . . . . . . . . . . . .33

Table 8: Sample Maintenance Log. . . . . . . . . . . . . . . . . . . . . . . . . . .37

Table 9: Specifications: 48-650W 19”, 4 Module System . . . . . . . . . . . . . . .47

Table 10: Specifications: 48-650W 19”, 5 Module System . . . . . . . . . . . . . . .48

Table 11: Specifications: Cordex 48-650W, Switched Mode Rectifier . . . . . . . . .49

Table 12: Specifications: CXCI HP Controller . . . . . . . . . . . . . . . . . . . . . .52

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