Alpha Technologies ALPHA OUTBACK ENERGY Cordex 48-1kW User manual

Your Power Solutions Partner
Cordex 48-1kW
23" Shelf for Systems up to 4000W
with Distribution
Installation & Operation Manual
Part # 030-704-B2
Effective: 07/2020
member of The Group™

Cordex 48-1kW
23" Shelf For Systems Up To 4000W
With Distribution
030-704-B2 Rev C
The following documents and drawings are included in this manual to provide the necessary information
required for installation, operation and fault diagnosis of the unit:
• Specications, Rectier: 010-606-B1 (010-566-20 non-RoHS)
• CSA/NRTL Equivalence: 048-554-10
• Outline Drawing, 23” Shelf: 030-704-06
• Customer Connections: 030-704-08

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety and installation instructions
for Alpha’s Modular Switched Mode Rectifier System Cordex™ 48-1kW.
1. Please read this manual prior to use to become familiar with the system’s numerous features and
operating procedures. To obtain a maximum degree of safety, follow the sequences as outlined.
2. This manual provides warnings and special notes for the user:
a. Points that are vital to the proper operation of the system or the safety of the operator
are indicated by the heading: WARNING.
b. A notation that is in Bold Italic typeface covers points that are important to the
performance or ease of use of the system.
3. Before using the system, read all instructions and cautionary markings on the system and any
equipment connected to the system.
4. Do not expose the system to rain or snow.
5. CAUTION – Unless otherwise noted, use of an attachment not recommended or sold by the system
manufacturer may result in a risk of fire, electric shock, or injury to persons.
6. CAUTION – Do not operate the system if it has received a sharp blow, it has been dropped, or
otherwise damaged in any way – return it to a qualified service center for repair.
7. CAUTION – Do not disassemble the system – call our qualified service centers for servicing. Incorrect
reassembling may result in a risk of electrical shock or fire.

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TABLE OF CONTENTS
1INTRODUCTION..............................................................................................................................................1
1.1 Scope of the Manual.........................................................................................................................1
1.2 Product Overview .............................................................................................................................1
1.3 Part Numbers and List Options ........................................................................................................2
2RECTIFIER FEATURES ...................................................................................................................................3
2.1 Front Panel .......................................................................................................................................3
2.2 Rear Panel........................................................................................................................................4
2.3 True Module Fail Alarm ....................................................................................................................4
2.4 Heat Dissipation................................................................................................................................4
2.5 Over Temperature Protection ...........................................................................................................4
2.6 Wide AC Range ................................................................................................................................5
2.7 AC Inrush/Transient Suppression.....................................................................................................5
2.8 Soft Start...........................................................................................................................................5
2.9 Start Delay ........................................................................................................................................5
2.10 Current Limit/Short Circuit Protection ...............................................................................................5
2.11 Power Limiting ..................................................................................................................................5
2.12 High Voltage Shutdown (HVSD).......................................................................................................5
2.13 Battery Eliminator Operation ............................................................................................................6
3CXCM FEATURES.........................................................................................................................................7
3.1 Front Panel .......................................................................................................................................7
3.2 Analog Input Channels .....................................................................................................................8
3.3 Digital Input Channels ......................................................................................................................9
3.4 Alarm and Control Output Relays.....................................................................................................9
3.5 System Fail Alarm/Relay ..................................................................................................................9
3.6 Network Connection and Remote Communications.........................................................................9
4INSPECTION ................................................................................................................................................10
4.1 Packing Materials ...........................................................................................................................10
4.2 Check for Damage..........................................................................................................................10
5INSTALLATION.............................................................................................................................................11
5.1 Safety Precautions..........................................................................................................................11
5.2 Shelf Preparation/Mounting ............................................................................................................11
5.3 Module Insertion/Removal..............................................................................................................11
6WIRING AND CONNECTIONS.........................................................................................................................12
6.1 Safety Precautions..........................................................................................................................12
6.2 Tools Required ...............................................................................................................................12
6.3 Power System Chassis Ground......................................................................................................12
6.4 AC Feeder Protection/Sizing ..........................................................................................................12
6.5 AC Input Connections.....................................................................................................................13
6.6 Calculating Output Wire Size Requirements ..................................................................................13
6.7 DC Output Connections..................................................................................................................13
6.8 CAN Serial Port ..............................................................................................................................14
6.9 Ethernet Side Access (List Option 93)............................................................................................14
6.10 Network Connection and Remote Communications via CXCM .....................................................14
6.11 CXCM Battery –48V Connection ....................................................................................................15

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6.12 Alarm and Signal Wiring Connections for CXCM ...........................................................................15
6.13 Analog Inputs for CXCM.................................................................................................................16
6.14 Digital Inputs for CXCM ..................................................................................................................17
6.15 Alarm (Relay) Outputs for CXCM ...................................................................................................18
7OPERATION ................................................................................................................................................19
7.1 Main Rectifier States ......................................................................................................................19
7.2 Main Rectifier Modes ......................................................................................................................20
7.3 Thermal Management ....................................................................................................................20
7.4 Factory Ranges and Defaults .........................................................................................................21
8SYSTEM STARTUP .......................................................................................................................................22
8.1 CXCM Reset...................................................................................................................................22
9MAINTENANCE ............................................................................................................................................23
10 WARRANTY ................................................................................................................................................24
11 ACRONYMS AND DEFINITIONS......................................................................................................................25

030-704-B2 REV C PAGE 1OF 25
1 Introduction
1.1 Scope of the Manual
This instruction manual explains the installation and interconnection of Alpha Technologies’ Cordex 48-
1kW 23” Integrated Shelf System with up to 4000W Output Power and Distribution.
Note: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.
For systems ordered with the Cordex CXCM System Controller option, separate documentation
will be provided detailing the software features, setup and operationProduct Overview.
1.2 Product Overview
A complete Cordex rectifier system consists of a CXCM with one or more power modules in a common
shelf enclosure. The shelf can be mid-mounted in a 23” rack and has connections for AC inputs, DC
output, and system communications.
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 input is wide range to allow use on
208/220/240 50/60 Hz electrical services. Rectifier power modules are “hot swappable” meaning 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. See documents #010-606-B1 in this documentation package.
The integrated shelf rectifier system is designed to operate with the Alpha Cordex CXCM (modular
version of the CXC controller); which plugs directly into the rectifier system shelf. See Figure 1 below.
Details for installation and wiring are provided in the respective chapters of this documentation
package.
The CXCM allows 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 distribution component features up to six AM-style bullet-type breakers with a capacity of 100A. A low
voltage disconnect (LVD) is optional and has a capacity of 125A. Also available is a separate battery
breaker with a capacity of 100A.
A fuse distribution option is available to provide up to ten GMT fuse positions in two feeds rated at 10A
maximum per feed.
Figure 1–Cordex 4000W system with plug-in controller and distribution

030-704-B2 REV C PAGE 2OF 25
1.3 Part Numbers and List Options
The shelf is available to order under the following part numbers and list options:
Description Part Number/List Option
Cordex 48-1kW 23" Shelf for Systems up to 4000W with Distribution ......................................... 030-704-20
[equipped to receive one CXCM controller and four CXRC 48-1kW rectifiers (Figure 1)] ...............*List 0
208/220/240Vac input (dual feeds)........................................................................................................*List 6
Gray finish ............................................................................................................................................*List 50
Cordex 48-1kW rectifier power module. ....................................................................................... 010-566-20
Basic module.. ...................................................................................................................................... *List 0
Gray finish with blue silkscreen. ..........................................................................................................*List 50
Temperature sensor, 1/4” lug, 12 ft. ..................................................................................................... List 72
Temperature sensor, 3/8” lug, 12 ft. ..................................................................................................... List 75
Circuit breaker distribution, AM-style, bullet-type, six load positions................................................. **List 80
Circuit breaker distribution, AM-style, bullet-type, two load positions, four battery positions............ **List 82
Circuit breaker distribution, AM-style, bullet-type, four load positions, two battery positions............ **List 84
DC output adapters, dual 2-position, 5/8” centers ................................................................................ List 85
Load LVD .............................................................................................................................................. List 86
Battery LVD........................................................................................................................................... List 87
Fuse distribution, ten-position GMT...................................................................................................... List 88
Power module blank plate (includes List 50) ........................................................................................ List 90
Side access (RJ-45) communications jack ........................................................................................... List 93
Breaker, mid-trip, 5A ........................................................................................................................... List 100
Breaker, mid-trip, 10A ......................................................................................................................... List 101
Breaker, mid-trip, 20A ......................................................................................................................... List 102
Breaker, mid-trip, 30A ......................................................................................................................... List 103
Breaker, mid-trip, 40A ......................................................................................................................... List 104
Breaker, mid-trip, 50A ......................................................................................................................... List 105
Breaker, mid-trip, 60A ......................................................................................................................... List 106
Breaker, mid-trip, 70A ......................................................................................................................... List 107
Breaker, mid-trip, 80A ......................................................................................................................... List 108
Breaker, mid-trip, 90A ......................................................................................................................... List 109
Breaker, mid-trip, 100A ....................................................................................................................... List 110
Breaker, series-trip, 60A .................................................................................................................***List 156
Breaker, series-trip, 100A ...............................................................................................................***List 160
* Default option ** Must order one of List 80, 82, or 84 *** Recommended for battery breaker
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.

030-704-B2 REV C PAGE 3OF 25
2 Rectifier Features
2.1 Front Panel
Figure 2–Cordex 48-1kW rectifier
2.1.1 LEDs
The front panel LEDs provide:
•Rectifier status summary,
•Rectifier software upgrade in progress indication,
•Locate module pattern.
Rectifier status summary will show the rectifier alarm status, communication fail status and rectifier on/off
status.
2.1.1.1 AC ON
The top LED (green) is on when AC is within valid range. The LED will flash (~2Hz) when AC is
outside the nominal range – AC voltage is invalid if the AC Mains Low or AC Mains High
alarm is active. The LED turns off when AC has failed.
2.1.1.2 DC ON
The middle LED (green) is on when the rectifier is delivering power to the load. The LED will flash
when communication is lost. The LED turns off when the rectifier is off; e.g., when commanded
via the CXC.
2.1.1.3 ALARM
The bottom LED (red) is on continuously in the event of an active Module Fail alarm. The LED will
flash (~2Hz) when a minor alarm is detected. The LED remains off in the absence of an alarm.

030-704-B2 REV C PAGE 4OF 25
2.1.1.4 LED Activity During Software Upload
When a rectifier software upload is in progress, the LEDs will behave in a distinctly different way
to indicate new rectifier software is being transferred from the CXC.
When a rectifier data transfer is in progress, all three LEDs will flash in a sequence lasting 1.5
seconds. When the last LED is lit, the sequence is repeated beginning at the first LED.
2.1.1.5 LED Activity During ‘Locate Module’ Command from CXC
When the ‘locate module’ command has been received from the CXC, the LEDs will behave in
another distinct fashion so that the rectifier is easier to visually identify among adjacent rectifiers.
This state is entered when commanded via the CXC. The LEDs will flash in a ping-pong pattern
repeating every 2 seconds.
The ping-pong pattern lights each LED sequentially. After the last LED is lit, each LED is lit in
reverse sequence. When the first LED is lit, the pattern repeats. The effect makes it appear as if
the light is bouncing between the first and last LED.
2.1.2 Mechanical
A thumbscrew is provided to secure the rectifier into the shelf. During normal operation the rectifier shall
be locked into position. A handle (or grip) is incorporated into the front panel to facilitate the removal of
the rectifier from the shelf. No special tools are required.
2.2 Rear Panel
Located on the rear panel of the rectifier are connectors for shelf power and communications.
2.3 True Module Fail Alarm
The power modules have a “true” fail alarm. This provides a true indication of the power module’s ability
to source current. When the module’s output current drops below 2.5% 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 determine if the module will source current. If no increase in current is
detected, the Module Fail alarm is activated. The module will test once every 60 seconds for the condition
until current is detected. Output voltage ramping will cease upon detection of current1. A minimum 2.5%
load is required to avoid the Ramp Test Fail alarm; this can typically be provided with the parallel system
battery. Activation of this alarm could indicate 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 nuisance alarms. The Ramp Test feature is
enabled/disabled via the CXC menu item: Rectifiers, Configure Settings.
2.4 Heat Dissipation
Heat dissipation is achieved through natural (bottom to top) convection cooling.
NOTE: Some rectifier shelves incorporate fan aided cooling to increase the temperature rating of the module.
See shelf manual supplied with your system.
2.5 Over Temperature Protection
Each module is protected in the event of an excessive increase in temperature due to component failure
or cooling airflow blockage. During over temperature conditions, the rectifier limits the output power as
well as the output current. At 65ºC output power and current limit are reduced to 70%. If temperature
continues to increase, a shutdown of the rectifier is initiated. The rectifier shall restart automatically if the
temperature has returned to a safe level.
1A battery connected to the output of the rectifier will draw current when the voltage ramp occurs. Therefore the
rectifier fail alarm will not be generated with a battery connected.

030-704-B2 REV C PAGE 5OF 25
2.6 Wide AC Range
A minor alarm is generated when the AC input voltage drops below 180Vac. Output power is reduced
linearly below 150Vac to 40% of the rated output power. At a lower voltage the module will shut down and
will not restart until the AC is greater than or equal to 150Vac.
For voltages above 276Vac, power factor and total harmonic distortion may be derated. For voltages
between 277Vac and 320Vac, the rectifier may not be operational but shall not suffer any damage.
2.7 AC Inrush/Transient Suppression
The modules’ inrush current is limited to less than one times the nominal peak line current to prevent
surge on the AC line. Modules are also protected from input lightning and transient surges in accordance
with IEEE/ANSI C62.41 Category B3.
2.8 Soft Start
To eliminate an instantaneous demand on the AC source, a soft start feature is employed. Soft Start,
sometimes referred to as “current walk-in”, works by gradually (up to five seconds) ramping the current
limit up from zero to the actual or defined customer setting. The output voltage is ramped up from the
minimum voltage to the float voltage.
2.9 Start Delay
The modules are equipped with a delay timer in order to stagger start a series of modules to prevent
excessive loading of generators upon start up. The built-in timer delays the turn on of the module
depending on the value selected (up to 120 seconds) via the CXC. A minimum one-second delay is
preset to allow charging of the input capacitors.
2.10 Current Limit/Short Circuit Protection
The current limit function determines the maximum output current limit of the module, regardless of output
voltage or power. Maximum output current is limited to a constant value down to short circuit 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 sustain a short circuit at the output terminals indefinitely. The maximum short circuit
current shall not exceed 105% of the rated full load current.
2.11 Power Limiting
Each module is designed to limit power output to the module specification. This enables more current to
be supplied at lower output voltages, and allows matching of output to the demand of constant power
loads, normally seen with telecom equipment.
This feature may also be used for a faster recharge of flooded batteries paralleled with the load.
NOTE: Current limiting overrides the power-limiting feature.
2.12 High Voltage Shutdown (HVSD)
This feature provides protection to the load from over voltage conditions originating from the rectifiers. It
operates by shutting down the offending rectifier module when a high output voltage condition occurs.
Indication is through the red Alarm (Module Fail) LED. Modules will restart automatically; however, if more
than three over voltage conditions occur in one minute, the module will latch off and remain shut down
until it is reset via the CXC.

030-704-B2 REV C PAGE 6OF 25
2.13 Battery Eliminator Operation
Modules maintain all specifications (except where indicated) with or without a battery attached in parallel
to the output; however, if a battery or another module supplying DC voltage in parallel is not present,
there will be no monitoring or control activity if there is an AC power failure or input fuse failure.

030-704-B2 REV C PAGE 7OF 25
3 CXCM Features
The optional CXCM (Cordex Controller, Modular) can be mounted in the rectifier system shelf and brings
advanced monitoring technology to the Cordex series of rectifiers. This compact 4RU system controller is
designed for seamless operation and set up of Apha power systems and is equipped with the complete
range of Cordex software features, including the following:
•Designed to communicate directly with Cordex rectifiers
•Includes battery temperature compensation charging
•Battery performance diagnostics
•Provides local and remote communications
•User definable alarms
•Daily logging of power system events and system statistics.
Behind the CXCM’s front panel lies the main controller motherboard, which contains a microprocessor,
memory, as well as numerous other electronic components.
The CXCM includes a web server providing easy set up and monitoring using an Internet connection with
the standard Windows® Internet Explorer browser.
The data 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
applications of the CXCM logging include power system details, thermal performance of outdoor
enclosures, battery cell specifics, or mains variations captured by an AC voltage watchdog.
A built-in audio speaker sounds an intermittent tone during active alarms.
The input/output (I/O) board houses a series of terminal connections; located at the back of the system
shelf.
3.1 Front Panel
3.1.1 Display
Located on the front panel is a 160 x 160-pixel graphical LCD with touch screen similar to those used in
PDAs. This graphical user interface (GUI) allows the operator to interact with screen selectable items
using a fingertip.
Figure 3–Cordex CXCM model system controller front panel
RS-232
(craft port)
Touch screen
Reset (RST)
button
System status
LEDs

030-704-B2 REV C PAGE 8OF 25
3.1.2 LEDs
The CXCM has three LEDs located on the front panel. These are used to display the alarm status of the
power system, CXCM progress and status during startup, and file transfers.
3.1.2.1 Alarm Conditions
The CXCM illuminates the LED that corresponds to the system alarm status. The following show
the corresponding alarm status for each LED color:
Green – OK, no alarms present
Yellow – Minor alarm is present (no major alarms)
Red – Major alarm is present.
Only one LED is illuminated at a time during alarm conditions.
3.1.2.2 Progress and Status Indication
The LEDs are also used in the following situations:
Base unit validation – all three LEDs are on at the same time.
File transfer – when recovering from invalid firmware application – the red LED is illuminated.
3.1.3 Reset
A reset button is located on the front panel for restarting the CXCM’s microprocessor. It takes
approximately 15 seconds before the display reappears after pressing the reset button.
NOTE: Refer also to the software manual – always select the shutdown menu item before pressing the reset
button.
3.1.4 Ethernet Port
The Ethernet port is designed for CXCM connection to a user supplied network (TCP/IP secured by user)
via a rear panel RJ-45 jack and a standard network cable.
Local access (e.g. laptop computer) is also possible from the Ethernet port connection using a standard
network crossover cable.
3.1.5 RS-232 Serial (Craft) Port
Local access to the CXCM is possible through a front panel RS-232 serial port; using a null modem cable.
The communication protocol supports a web interface (via Microsoft® Internet Explorer 6 or greater). The
remote screen display is an enhanced version of the CXC’s front panel display.
3.2 Analog Input Channels
The CXCM has analog input channels for voltage, current, and temperature.
3.2.1 Voltage Inputs
Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCM
software is pre-configured to monitor V2 for both load and battery voltage. V2 is used as the system
reference for rectifier float voltage, low voltage disconnect (LVD), system high voltage alarm, and system
low voltage alarm. V1 is available for additional voltage measurements.
3.2.2 Current Inputs
The CXCM software is pre-configured to monitor I1 for load current using an external 50mV current shunt.

030-704-B2 REV C PAGE 9OF 25
3.2.3 General-Purpose
A set of terminals are provided to monitor a bi-voltage signal that may vary in either polarity from zero;
e.g., +/-60Vdc.
3.2.4 Temperature Inputs
Two temperature input channels, T1 and T2, provide monitoring of battery temperature and temperature
compensation (temp comp) or room/ambient temperature. A voltage is supplied to these terminals to
power the temperature sensors.
3.3 Digital Input Channels
The CXCM can accommodate up to three channels and can monitor digital alarm/control signals from
rectifiers, converters and many other types of equipment.
3.4 Alarm and Control Output Relays
The CXCM contains eight Form C digital alarm output relays to extend alarms and control external
apparatus. Each internally generated alarm or control signal may be mapped to any one of the relays, or,
several signals may be mapped to just one relay or none at all.
3.4.1 LVD Control (External Option)
The LVD Control functions can be hardwired directly from the assigned relay output to an optional LVD
override control and distribution alarm card. This provides a safety measure to protect against load
disconnect during CXCM reset or replacement; e.g. when the controller is off-line. Operators may also
perform test and maintenance procedures on the CXCM without disturbing the load.
3.5 System Fail Alarm/Relay
The CXCM system fail alarm (K0) activates because of a major internal failure. During such a condition,
the unit will attempt to reset, but if this fails, an alarm condition will be extended to a relay and the red
LED on the front panel will illuminate. This is a fail-safe signal to the remote monitoring equipment; i.e.
alarm will be extended even if power to the unit is interrupted.
3.6 Network Connection and Remote Communications
The Cordex system can be set up, monitored and tested via Ethernet 10/100 Base-T serial data
connection. The communication protocol supports a web interface. All alarming and control of Cordex
rectifiers is accomplished with a CXC via a CAN bus.
A step-by-step connection wizard – provided to establish remote communications with your CXC – is
available via the Apha website (www.alph.ca).

030-704-B2 REV C PAGE 10 OF 25
4 Inspection
4.1 Packing Materials
All Alpha products are shipped in rugged, double walled boxes and suspended via solid inserts to
minimize shock that may occur during transportation. Packaging assemblies and methods are tested to
National Safe Transit Association standards.
4.1.1 Returns for Service
Save the original shipping container. If the unit needs to be returned for service, it should be packaged in
its original shipping container. If the original container is unavailable, make sure the unit is packed with at
least three inches of shock-absorbing material to prevent shipping damage.
Note: Alpha Technologies is not responsible for damage caused by the improper packaging of returned units.
4.2 Check for Damage
Prior to unpacking the equipment, note any damage to the shipping container. Unpack the equipment 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, please inform
the carrier and contact Alpha Technologies for advice on the impact of any damage.
Verify that you have all the necessary parts per your order for the proper assembly of your
system.

030-704-B2 REV C PAGE 11 OF 25
5 Installation
This chapter is provided for qualified personnel to install the shelf.
Note: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.
5.1 Safety Precautions
WARNING
Hazardous voltages are present at the input of power systems. The DC output from the
rectifiers and the battery system though not dangerous in voltage has a high short circuit
current capacity that may cause severe burns and electrical arcing.
Before working with any live battery or power system/distribution center, the following precautions should
be followed:
•Remove all metallic jewelry; e.g., watches, rings, eyeglasses, necklaces.
•Wear safety glasses with side shields at all times during installation.
Insulated metallic tools shall be used.
The installer should follow all applicable local rules and regulations for electrical and battery installations;
e.g., CSA, UL, CEC, NEC, OSHA, and local fire codes.
5.2 Shelf Preparation/Mounting
The shelf has been designed for mounting in a standard 23” relay rack. Mounting brackets accommodate
either 1” or 1-3/4” rack spacing. The shelf should be mounted to the rack using at least two #12 – 24 x
1/2” screws in each bracket. Philips-type screws and screwdriver should be used to eliminate the
possibility of slippage and scratching of the unit's exterior. Washers (such as internal tooth) or special
screws that are designed to cut through the painted surface should be used to ensure a good chassis
ground.
Note: The shelf shall be mounted in a clean and dry environment. Allow at least 1.75” of free space around the
unit for unrestricted convection cooling airflow.
5.3 Module Insertion/Removal
Insert by placing the module on the shelf bottom and sliding the module into the rear connectors (inside of
the shelf). Apply pressure on the handles to engage the rear connector in the shelf receptacle. Tighten
the screw on the bottom of the faceplate to secure the module to the shelf.
Note: Do not force a module into position if it does not seat properly. All modules are keyed to ensure
that the correct module type is used.
To remove modules, loosen the screw on the bottom of the faceplate. Grasp handle and pull out, sliding
the module away from the rear connectors and out of the shelf.

030-704-B2 REV C PAGE 12 OF 25
6 Wiring and Connections
This chapter provides cabling details and notes on cable sizing for DC applications with respect to the
shelf.
Note: Refer also to drawings at the rear of this manual.
6.1 Safety Precautions
WARNING
Hazardous AC voltages may be present. Ensure power at the AC service panel is off
before attempting work on the AC connections. Use a voltmeter to verify the absence of
voltage. Clearly mark the correct polarity of the battery leads before commencing work on
DC connections.
Refer to the previous (Installation) chapter for additional safety precautions.
6.2 Tools Required
Various tools are essential for product installation. Use this list as a guide:
•Slot head screwdrivers (blade sizes: 1/4”, 1/8”, 1/16”)
•Philips head screwdriver, #2 (tip 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 rachet set (Imperial measure)
•Anti-static wrist strap
•Computer (laptop) with MicrosoftInternet Explorer 6 or up
•Crossover cable RJ-45 (for access using the Ethernet port)
•Null modem cable (for access using the RS-232 port).
6.3 Power System Chassis Ground
WARNING
For safety reasons, ensure the system is properly bonded to the building’s ground grid.
Both the shelf chassis ground (via power system chassis ground) and common return shall be connected
to the site ground to ensure correct operation of the system and to prevent drifting floating analog
(especially current) readings.
6.4 AC Feeder Protection/Sizing
To maximize system reliability, a dual AC feed divides the rectifiers into two groups to be supplied by two
separate feeds. It is recommended for each feed to use a dedicated protection feeder breaker located at
the AC distribution panel. The feeder breaker can also act as the disconnect device for the connected
modules.
Note: The recommended AC supply configuration for up to two rectifiers on AC feed is a 20A breaker with #12
AWG (90 deg. C) wire at 30 deg. C ambient.