Alpha Technologies CXDF 48-24/2kW User manual

Your Power Solutions Partner
Cordex DC/DC Converter
CXDF 48-24/2kW, 48V In – 24V Out
Installation & Operation Manual
Part # 012-527-B2
Effective: 12/2013
member of The Group™

9400010-J1 Rev A
Important Safety Instructions
SAVE THESEINSTRUCTIONS: 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. Review the
drawings and illustrations contained in this manual before proceeding. If there are any questions re
g ar d ing the safe
installation or operation of this product, contact Alpha Technologies or the nearest Alpha
representa tive. Save this
document for future referen
c e.
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 specific regulatory/code requirements that may affect the
placement 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 PREVENT DAMAGE to material or
equipment. Cautions are designated with a shock hazard icon, the word CAUTION,
and a rule beneath which the information appears.
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.
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician
or user.
General Safety
WARNING!
This system is designed to be installed in a restricted access location that is
inaccessible to the general public.
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.

9400010-J1 Rev A
Electrical Safety
WARNING!
Hazardous voltages are present at the input of power systems. The DC output from
rectifiers and batteries, 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, follow these precautions:
•Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or ne
c kla c es
•Wear safety glasses with side shields at all times during the installation.
•Use OSHA approved insulated hand tools.
WARNING!
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
installation 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
•240 Vac. Ensure that the utility power is disconnected and locked out before performing any installation or
removal
pr ocedur e.
•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.
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 pr ecautions.
•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.
WARNING!
Follow battery manufacturer’s safety recommendations when working around battery
systems. Do not smoke or introduce an open flame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can
explode.
•Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the bat tery
manufacturer for recommended local authorized r
ecyclers.

#9400011-J1 Rev A
Seguridad
GUARDE ESTAS INSTRUCCIONES: Este manual contiene instrucciones de seguridad
importantes que deben seguirse durante la instalación, reparación y mantenimiento del producto. Manténgalas
en un lugar seguro. Inspeccione los dibujos y las ilustraciones contenidas en este manual antes de continuar. Si
existe cualquier pregunta relacionada con la instalación u operación segura de este producto, póngase en
contacto con Alpha Technologies o con su representante de Alpha más cercano. Guarde este documento para
referencia futura.
Símbolos de Seguridad
Para reducir el riesgo de lesión o muerte y para asegurar la operación continua segura de este producto, se han
colocado los siguientes símbolos a lo largo de este manual. En las partes donde aparecen estos símbolos, preste
atención y cuidado adicional.
Atención:
El uso de ATENCIÓN indica requisitos de código o regulatorios específicos que pueden
afectar la ubicación del equipo y/o los procedimientos de instalación.
NOTA:
Una NOTA (NOTE)provee información adicional para ayudar a completar una tarea o un
procedimiento específico.
¡CUIDADO!
CUIDADO (CAUTION) indica información de seguridad con el propósito de PREVENIR
DAÑOS al material o al equipo. Los avisos de cuidado están designados con un icono de
peligro de choque, la palabra CUIDADO y una línea debajo de la cual aparece la
información.
¡ADVERTENCIA!
Una ADVERTENCIA (WARNING) presenta información de seguridad para PREVENIR LESIÓN O
MUERTE al personal. Las advertencias se indican con un icono de peligro de choque, la palabra
ADVERTENCIA y una línea debajo de la cual aparece la información
¡CALIENTE!
El uso de CALIENTE (HOT) presenta información de seguridad para PREVENIR
QUEMADURAS al técnico o al usuario.
Seguridad General
¡ADVERTENCIA!
Este sistema está diseñado para instalarse en una ubicación con acceso restringido
que no sea accesible para el público general.
Seguridad Mecánica
•Mantenga las manos y las herramientas alejadas de los ventiladores. Los ventiladores están controlados de forma
termostática y se encienden automáticamente.
•Las fuentes de alimentación pueden alcanzar temperaturas extremas bajo carga.
•Tenga cuidado cerca de bordes filosos y componentes de chapa
.

#9400011-J1 Rev A
Seguridad Eléctrica
¡ADVERTENCIA!
Hay voltajes peligrosos en la entrada de los sistemas de alimentación. La salida de CC de
rectificadores y baterías, si bien no es peligrosa en cuanto al voltaje, cuenta con una alta
capacidad de conducción de cortocircuito que puede causar quemaduras graves y arcos
eléctricos.
Antes de trabajar con una batería activa o un sistema de alimentación, siga estas precauciones
:
•Quítese toda joyería metálica, como relojes, anillos, anteojos con montura de metal o collares.
•Use antiparras de seguridad con protecciones laterales en todo momento durante la instalación.
•Use herramientas manuales aisladas aprobadas por OSHA.
¡ADVERTENCIA!
El sistema de alimentación presenta voltajes mortales en su interior. Suponga
siempre que las conexiones o los conductores eléctricos están energizados. Revise el
circuito con un voltímetro con respecto de la porción a tierra del cerramiento (tanto
CA como CC) antes de realizar cualquier procedimiento de instalación o remoción.
•No trabaje solo en condiciones peligrosas .
•Se requiere que un electricista matriculado se ocupe de instalar equipos con conexión permanente. Los
voltajes de entrada pueden llegar a los 240 VCA. Asegúrese de que la fuente de alimentación eléctrica del
servicio esté desconectada y bloqueada antes de realizar un procedimiento de instalación o remoción.
•Asegúrese de que ningún líquido ni ropa húmeda en contacto con los componentes internos
.
•Las partes eléctricamente activas peligrosas dentro de esta unidad están energizadas por las baterías incluso
cuando se desconecta la alimentación de entrada de CA
.
Seguridad de la Batería Externa
•El mantenimiento y la conexión de las baterías debe ser realizado por, o bajo la supervisión directa de,
personal experto en baterías y tomando las precauciones de seguridad requeridas
.
•Siempre que trabaje con baterías utilice protección para los ojos, guantes de goma y un chaleco protector.
Quítese todos los objetos metálicos de las manos y el cuello
.
•Use herramientas manuales aisladas aprobadas por OSHA. No apoye las herramientas sobre las baterías
.
•Las baterías contienen o emiten elementos químicos que causan cáncer y defectos de nacimiento u otros
problemas reproductivos.
•Los terminales de batería y accesorios similares contienen plomo y compuestos del plomo. Lávese las manos
después de manipular baterías
.
¡ADVERTENCIA!
Siga las recomendaciones del fabricante de las baterías cuando trabaje cerca de
sistemas de baterías. No fume ni introduzca una llama abierta cuando las baterías
(en especial las baterías ventiladas) se están cargando. Mientras se cargan, las
baterías ventilan gas hidrógeno que puede explotar.
•Las baterías son peligrosas para el medioambiente y deben desecharse en un centro de reciclado. Consulte al
fabricante de las baterías acerca de centros de reciclado autorizados locales recomendados
.

9400012-J1 Rev A
Sécurité
CONSERVEZ CES INSTRUCTIONS:
Le présent manuel contient des consignes de sécurité importantes
à suivre pendant l'installation, l'entretien et la maintenance du produit. Rangez-le dans un endroit sûr. Examinez les schémas et illustrations
contenus dans ce manuel avant de poursuivre. En cas de questions sur l'installation ou le fonctionnement en toute sécurité de ce produit,
contactez Alpha Technologies ou le représentant d'Alpha le plus près. Conservez ce document pour référence future.
Symboles de Sécurité
Pour réduire le risque de blessures ou d'accident mortel et assurer le maintien de conditions d'exploitation sécuritaires de ce produit,
les symboles ci-après ont été utilisés systématiquement dans ce manuel. Lorsque ces symboles sont utilisés, prenez des précautions
supplémentaires.
L'utilisation du symbole « ATTENTION » indique l'existence d'exigences réglementaires ou normatives qui
peuvent affecter l'emplacement de l'équipement ou les procédures d'installation.
REMARQUE:
Une REMARQUE (NOTE) fournit des informations supplémentaires destinées à aider à la réalisation
d'une tâche ou d'une procédure spécifique.
PRUDENCE !
Le symbole PRUDENCE (CAUTION) indique une information de sécurité destinée à ÉVITER DES
DOMMAGES au matériel ou à l'équipement. Ce symbole est représenté par une icône de danger
de décharge électrique, le terme PRUDENCE et une ligne en dessous de laquelle l'information est
affichée.
AVERTISSEMENT!
Le symbole AVERTISSEMENT (WARNING) donne des informations sur la sécurité permettant au personnel d'ÉVITER
DES BLESSURES OU DES ACCIDENTS MORTELS. Les avertissements sont identifiés par une icône de danger de
décharge électrique, le terme AVERTISSEMENT et une ligne en dessous de laquelle l'information est affichée.
CHAUD!
Le symbole CHAUD (HOT) est associé à des informations de sécurité destinées à ÉVITER
DES BRÛLURES au technicien ou à l'utilisateur.
Avertissements et Mises en Garde D'ordre Général
AVERTISSEMENT !
Ce système est conçu pour être installé dans un endroit restreint inaccessible au
public.
Sécurité Mécanique
•Gardez les mains et les outils à l’écart des ventilateurs. Les ventilateurs sont thermostatés et s’allument
automatiquement.
•Les blocs d’alimentation peuvent atteindre des températures extrêmes lorsqu’ils sont sous tension.
•Procédez avec prudence autour des composants en tôle et des bords tranchants.

9400012-J1 Rev A
Sécurité Electrique
AVERTISSEMENT !
Des tensions dangereuses sont présentes à l’entrée des systèmes électriques. La
sortie CC des redresseurs et des batteries, bien que non dangereuse en termes de
tension, a une capacité de courant de court-circuit élevée qui peut causer de graves
brûlures et des arcs électriques.
Avant de travailler sur une batterie ou un système électrique alimenté(e), suivez ces précautions :
•Retirez tout bijou métallique, tel qu’une montre, une alliance, des montures métalliques ou un collier.
•Portez des lunettes de sécurité avec des écrans latéraux de protection à tout moment durant l’installation.
•Utilisez des outils à mains isolés et approuvés par OSHA.
AVERTISSEMENT !
Des tensions mortelles sont présentes dans le système électrique. Considérez
toujours une connexion électrique ou un conducteur comme étant sous tension.
Vérifiez le circuit avec un voltmètre au niveau de la partie mise à la terre du boîtier (CA
et CC) avant de lancer une procédure d’installation ou de retrait.
•Ne travaillez pas seul lorsque les conditions sont dangereuses .
•Un électricien agréé est requis pour installer un équipement câblé de façon permanente. Les tensions d’entrée
peuvent atteindre
•240 V CA. Assurez-vous que l’électricité de service est débranchée et verrouillée avant de lancer une procédure
d’installation ou de retrait.
•Assurez-vous qu’aucun liquide ou vêtement mouillé n’entre en contact avec les composants internes.
•Les pièces électriques dangereuses à l’intérieur de cette unité sont alimentées par les batteries même lorsque
l’alimentation CA en entrée est débranchée
.
Sécurité de la Batterie
•L'entretien et la connexion des batteries doivent être effectués par un spécialiste des batteries ou sous la
supervision directe d'un tel spécialiste, en prenant les précautions de sécurité requises.
•Portez toujours une protection pour les yeux, des gants en caoutchouc et un gilet de protection lorsque vous
travaillez à proximité de batteries. Retirez tous les objets métalliques de vos mains et de votre coup.
•Utilisez des outils à main isolés et approuvés par OSHA. Ne déposez pas les outils sur les batteries.
•Les batteries contiennent ou émettent des produits chimiques identifiés comme cause de cancer et de
malformations congénitales ou d'autres troubles de l'appareil reproducteur. Les bornes des batteries et leurs
accessoires contiennent du plomb et des composés de plomb. Lavez-vous les mains après avoir manipulé des
batteries.
AVERTISSEMENT !
Observez les recommandations de sécurité du fabricant quand vous travaillez avec
des systèmes de batteries. Ne fumez pas, ou n'introduisez pas de flamme nue quand
les batteries (surtout les batteries ouvertes) sont en cours de charge. En cours de
charge, les batteries dégagent de l'hydrogène gazeux susceptible d'exploser.
•Les batteries sont néfastes pour l'environnement et doivent être mises au rebut dans un centre de recyclage.
Consultez le fabricant de la batterie pour connaître les centres de recyclages agréés locaux
.

9400013-J1 Rev A
Wichtige Sicherheitshinweise
BEWAHREN SIE DIESE ANWEISUNGEN AUF:
Dieses Handbuch enthält
wichtige Sicherheitshinweise, die bei der Installation, Wartung und Instandhaltung des Produkts beachtet werden
müssen. Bewahren Sie es an einem sicheren Ort auf. Sehen Sie sich die Zeichnungen und Illustrationen in diesem
Handbuch genau an, bevor Sie fortfahren. Sollten Sie Fragen zur sicheren Installation oder zum Betrieb dieses
Produkts haben, wenden Sie sich bitte an Alpha Technologies oder den nächstgelegenen Alpha-Vertreter.
Bewahren Sie dieses Dokument für den zukünftigen Gebrauch auf.
Sicherheitssymbole
Um das Risiko von Verletzungen oder Todesfällen zu reduzieren und den weiteren sicheren Betrieb dieses
Produkts zu gewährleisten, wurden in diesem Handbuch die folgenden Symbole verwendet. Seien Sie besonders
vorsichtig und aufmerksam, wenn diese Symbole abgebildet sind.
Das Symbol VORSICHT (ATTENTION) deutet auf spezifische Anforderungen von
aufsichtsrechtlichen Vorschriften oder Normen hin, welche Einfluss auf die Platzierung von
Geräten und/oder Installationsverfahren haben können.
HINWEIS:
Ein HINWEIS (NOTE) liefert zusätzliche Informationen, die Ihnen helfen, eine bestimmte
Aufgabe zu lösen bzw. ein bestimmtes Verfahren durchzuführen. Hinweise sind mit einem
Häkchen, dem Wort HINWEIS und einem Strich, unter dem die Informationen aufgeführt sind,
gekennzeichnet.
ACHTUNG!
ACHTUNG (CAUTION) kennzeichnet Sicherheitsinformationen, die darauf abzielen, SCHÄDEN an
Materialien oder Geräten ZU VERHINDERN. Diese Warnhinweise sind mit einem gelben
Warndreieck, dem Wort ACHTUNG und einem Strich, unter dem die Informationen aufgeführt
sind, gekennzeichnet.
WARNUNG!
Eine WARNUNG (WARNING) enthält Sicherheitsinformationen zur VERHINDERUNG VON
VERLETZUNGEN ODER TODESFÄLLEN bei Mitarbeitern. Diese Warnhinweise sind mit einem
Stromschlagsymbol, dem Wort WARNUNG und einem Strich, unter dem die Informationen
aufgeführt sind, gekennzeichnet.
HEISS!
Die Warnung HEISS! (HOT) liefert Sicherheitsinformationen, die dazu dienen,
VERBRENNUNGEN des Technikers oder Benutzers zu VERHINDERN.
Allgemeine Sicherheit
WARNUNG!
Dieses System wurde für eine Aufstellung an einem Standort mit Zugangsbeschränkung
entworfen, der für die allgemeine Öffentlichkeit nicht zugänglich ist.
Mechanische Sicherheit
•Achten Sie darauf, dass Hände und Werkzeuge nicht mit den Lüftern in Berührung kommen. Die Lüfter werden
thermostatisch kontrolliert und schalten sich automatisch ein.
•Die Netzteile können unter Last Extremtemperaturen erreichen.
•Gehen Sie in der Nähe von Blechteilen und scharfen Kanten vorsichtig vor.

9400013-J1 Rev A
Elektrische Sicherheit
WARNUNG!
Am Punkt der Stromeinspeisung liegen gefährliche Spannungen vor. Der Gleichstromausgang
von Gleichrichtern und Batterien weist zwar keine gefährliche Spannung auf, die
Kurzschlussstrom-Kapazität ist jedoch sehr hoch, was zu ernsthaften Verbrennungen und
Lichtbögen führen kann.
Befolgen Sie die folgenden Vorsichtsmaßnahmen, bevor Sie mit einer spannungsführenden Batterie oder einem
Stromversorgungssystem arbeiten:
•Legen Sie sämtlichen Schmuck aus Metall wie z.B. Armbanduhren, Ringe, Brillen mit Metallrahmen oder
Halsketten ab.
•Tragen Sie während der Installationsarbeiten jederzeit Schutzbrillen mit Seitenschutz.
•Verwenden Sie nur geprüftes isoliertes Werkzeug.
WARNUNG!
Innerhalb des Stromversorgungssystems herrschen lebensgefährliche Spannungen vor.
Gehen Sie jederzeit davon aus, dass eine elektrische Verbindung oder ein Leiter Strom führt.
Überprüfen Sie den Stromkreis mit einem Spannungsmesser bezüglich des geerdeten Teils
des Gehäuses (sowohl Wechsel- als auch Gleichstrom), bevor Sie eine Installation oder
Demontage durchführen.
•Arbeiten Sie unter gefährlichen Bedingungen niemals alleine.
•Die Installation festverdrahteter Geräte muss durch einen zugelassenen Elektriker vorgenommen werden. Die
Eingangsspannungen können bis zu 240 VAC betragen. Stellen Sie sicher, dass die Verbindung zum
Netzstrom getrennt und gegen Wiedereinschalten gesichert ist, bevor Sie eine Installation oder Demontage
durchführen.
•Stellen Sie sicher, dass keine Flüssigkeiten oder nasse Kleidungsstücke mit innenliegenden Komponenten in
Berührung kommen.
•Gefährliche stromführende Teile innerhalb dieses Geräts werden auch bei Trennung der Netzverbindung noch
über die Batterien versorgt.
Batteriesicherheit
•Die Wartung und der Anschluss von Batterien muss von Mitarbeitern durchgeführt bzw. direkt beaufsichtigt
werden, die über Kenntnisse über Batterien und die erforderlichen Sicherheitsmaßnahmen verfügen.
•Tragen Sie jederzeit Augenschutz, Gummihandschuhe und eine Schutzweste, wenn Sie in der Nähe von
Batterien arbeiten. Entfernen Sie sämtliche Metallgegenstände von Ihren Händen und Ihrem Hals.
•Verwenden Sie von der OSHA genehmigte isolierte Handwerkzeuge. Legen Sie Werkzeuge nicht auf Batterien
ab.
•Verwenden Sie nur geprüftes isoliertes Werkzeug. Legen Sie Werkzeug niemals auf Batterien ab.
••Batterien enthalten Chemikalien bzw. setzen Chemikalien frei, von denen bekannt ist, dass sie Krebs oder
Geburtsfehler verursachen oder die Fortpflanzungsfähigkeit anderweitig schädigen.
•Batterieanschlüsse und entsprechendes Zubehör enthalten Blei und Bleiverbindungen. Waschen Sie nach
dem Umgang mit Batterien Ihre Hände.
•verursachen oder die Fortpflanzungsfähigkeit anderweitig schädigen.
WARNUNG!
Befolgen Sie die Sicherheitsempfehlungen von Batterieherstellern, wenn Sie mit
Batteriesystemen arbeiten. Während Batterien (insbesondere geschlossene Batterien)
aufgeladen werden, darf weder geraucht noch offenes Feuer verwendet werden. Beim
Aufladen setzen Batterien Wasserstoffgas frei, das explodieren kann.
•Batterien sind schädlich für die Umwelt und sollten im Sondermüll entsorgt werden. Wenden Sie sich an den
Batteriehersteller, um sich über empfohlene zugelassene örtliche Recyclingstellen zu informieren.

ii
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
2FEATURES ................................................................................................................................................................... 3
2.1 Converter Module.......................................................................................................................................... 3
2.2 Cordex Integrated System Controller (CXCI/CXCI+) Option ........................................................................ 4
2.3 System Controller Front Panel...................................................................................................................... 4
2.4 Analog Input Channels.................................................................................................................................. 6
2.5 Digital Input Channels................................................................................................................................... 6
2.6 Alarm and Control Output Relays ................................................................................................................. 6
2.7 Network Connection and Remote Communications ..................................................................................... 6
3INSPECTION.................................................................................................................................................................. 7
3.1 Packing Materials.......................................................................................................................................... 7
3.2 Check for Damage ........................................................................................................................................ 7
4INSTALLATION .............................................................................................................................................................. 8
4.1 Safety Precautions ........................................................................................................................................ 8
4.2 Tools Required.............................................................................................................................................. 8
4.3 Shelf Preparation/Mounting .......................................................................................................................... 8
4.4 Converter Module Insertion/Removal ........................................................................................................... 8
4.5 CXCI/CXCI+ Installation................................................................................................................................ 9
5WIRING AND CONNECTIONS ........................................................................................................................................ 12
5.1 Safety Precautions ...................................................................................................................................... 12
5.2 Calculating Wire Size Requirements .......................................................................................................... 12
5.3 Input/Output Connections ........................................................................................................................... 12
5.4 CAN Serial Ports ......................................................................................................................................... 13
5.5 Network Connection and Remote Communications via CXCI/CXCI+........................................................ 13
5.6 Signal Wiring Connections for CXCI/CXCI+ ............................................................................................... 14
6SYSTEM STARTUP ...................................................................................................................................................... 16
6.1 Check System Connections........................................................................................................................ 16
6.2 Power the Converter Shelf.......................................................................................................................... 16
6.3 Converter Operation and Programming via the CXC ................................................................................. 16
6.4 CXC Reset .................................................................................................................................................. 17
7MAINTENANCE ........................................................................................................................................................... 18
7.1 Fan Replacement........................................................................................................................................ 18
7.2 CXCI/CXCI+ Replacement Procedure........................................................................................................ 19
8WARRANTY ................................................................................................................................................................ 23
8.1 Warranty...................................................................................................................................................... 23
8.2 Battery Warranty ......................................................................................................................................... 23
9ACRONYMS AND DEFINITIONS ..................................................................................................................................... 24

iii
TABLE OF FIGURES
Figure 1–Perspective view of CXDF 48-24/2kW converter module ................................................................................. 1
Figure 2–CXCI model system controller front panel......................................................................................................... 4
Figure 3–Cordex CXCI+ model system controller front panel.......................................................................................... 5
Figure 4–Showing CXCI/CXCI+ blank plate removal....................................................................................................... 9
Figure 5–Showing CXCI+ controller module installation ................................................................................................ 10
Figure 6–Baffle and pem removal .................................................................................................................................. 10
Figure 7—Showing CXCI Module Preparation............................................................................................................... 11
Figure 8–Showing CXCI module installation .................................................................................................................. 11
Figure 9–Showing relay connections.............................................................................................................................. 14
Figure 10–Showing digital input connection method...................................................................................................... 14
Figure 11–Location of LVD bypass jumper .................................................................................................................... 19
Figure 12–Showing CXCI (original design) replacement detail...................................................................................... 20
Figure 13–Cordex CXCI+ controller module .................................................................................................................. 21

012-527-B2 Rev FPage 1 of 24
1 Introduction
1.1 Scope of the Manual
This instruction manual explains the installation and interconnection of the Alpha CXDF 48-24/2kW. Both the
converter modules and the shelves, which the modules are plugged into, are covered in this manual.
The following documents and drawings are included in this manual to provide the necessary information required
for installation, routine operation and fault diagnosis of the unit:
•Specifications, Converter and Shelf: 012-527-B1
•Specifications, CXCI+: 7400233-S0
•Outline, Shelf 19": 030-840-06
•Customer Connection, Shelf 19": 030-840-08
•Outline, Shelf 23": 030-901-06
•Customer Connection, Shelf 23" 030-901-08
•Outline, Controller I/O Terminal Block: 036-201-06
•Customer Connection, Controller I/O Terminal Block: 036-201-08
•Schematic: 012-527-05
1.2 Product Overview
The CXDF 48-24/2kW isolated DC-DC converter employs a high frequency switched mode conversion technique
to provide a fully regulated and isolated +24 Volt DC output from a -48 Volt DC input.
Each module is a stand-alone converter element, which plugs into a common shelf. The shelf provides external
connections for input, output, and alarm interfaces. Additional converter modules can increase the current
capacity and redundancy of the converter system.
Figure 1–Perspective view of CXDF 48-24/2kW converter module
The converter system consists of at least one shelf with one or more modules installed in each shelf. Additional
modules can be added to the shelf at time of ordering or at a later time after the system has been installed.
The shelf converter system is designed to operate with the Alpha Cordex System Controller (CXC).
All models of the CXC allow the user to set up, control and monitor the entire power system and ancillary
components from one central, easy-to-use source: your web browser. Other features of the controller include
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 provided in the current version software manual.

012-527-B2 Rev FPage 2 of 24
There are two external CXC models that can communicate with the converter shelf via offset RJ-12 shelf
connectors. The CXCR is mounted in a rack and the CXCP is (factory) mounted in a panel. Each of these models
has a touch screen display, similar to that used in a Personal Digital Assistant (PDA).
See manual #018-587-B2 (non-RoHS #018-557-B2).
The optional shelf-mounted integrated model (CXCI/CXCI+) does not have a touch screen; therefore, system
setup and management is performed exclusively with the web interface.
Details for installation and wiring are provided in the respective chapters of this documentation package.
1.3 Part Numbers and List Options
This product is available to order under the following part numbers and list options:
Description Part Number/List Option
Cordex DC/DC 2kW converter, -48V In to +24V Out.................................................................................012-527-20
Basic module...................................................................................................................................................... *List 0
Charcoal finish with white (contrasting) silkscreen .......................................................................................... *List 56
Cordex DC/DC 2kW converter, -48V In to +24V Out, 19" (flush mounting) 2RU shelf..............................030-840-20
[may be equipped with one CXCI/CXCI+ controller and up to four CXDF 48-24/2kW converters] .............. *List 0
19" rack, 6" offset mounting ...............................................................................................................................List 19
23" rack, 6" offset mounting ...............................................................................................................................List 24
Charcoal finish with white (contrasting) silkscreen .......................................................................................... *List 56
Positive I/P ground, negative O/P ground........................................................................................................ *List 80
Positive I/P ground, positive O/P ground ...........................................................................................................List 81
Output adapters (DC cable), right angle .......................................................................................................... *List 82
Module blank plate .............................................................................................................................................List 90
CXCI/CXCI+ blank plate .................................................................................................................................. *List 91
Rear cover, Kydex..............................................................................................................................................List 92
Cordex DC/DC 2kW converter, -48V In to +24V Out, 23" (flush mounting) 2RU shelf..............................030-901-20
[may be equipped with one CXCI/CXCI+ controller and up to five CXDF 48-24/2kW converters]............... *List 0
23" rack, 6" offset mounting ...............................................................................................................................List 24
Charcoal finish with white (contrasting) silkscreen .......................................................................................... *List 56
Module blank plate .............................................................................................................................................List 90
CXCI/CXCI+ blank plate .................................................................................................................................. *List 91
CXCI+ controller............................................................................................................................................... *List 98
Rear cover kit, CXDF 19" shelf, Kydex ......................................................................................................747-587-20
Replacement CXDF fan assembly.............................................................................................................747-362-20
Replacement CXCI+ controller ...............................................................................................................7400232-001
I/O terminal block kit (for external connections)......................................................................................**036-201-20
Cordex DC Modem (complete with Alpha cable).......................................................................................018-585-20
* Default option
** See drawings at the rear of this manual.
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.

012-527-B2 Rev FPage 3 of 24
2 Features
2.1 Converter Module
The Cordex converter modules plug into the Cordex converter shelf. The modules can be installed or removed
from a system without disturbing the system provided sufficient current capacity remains. This is often referred to
as “Hot Swap.”
The total output current capacity of the converter system is equal to the sum of the individual current capacities of
the converter modules.
2.1.1 Alarms
Converter Module Fail alarms consist of a group of (major) alarm conditions that are considered “serious” or an
immediate threat to service:
•Converter failure
•Output fuse failure
•Converter off
•Thermal shutdown
•Input Voltage is out of range
•Output OVP level has been exceeded
Converter Minor alarms consist of a group of alarm conditions that are not an immediate threat to service:
•Fan fail
•Current limit
2.1.2 Indicators
LED indicators are provided on the front panel of the converter module to display the operational status of the
module (see Table 1).
Indicator Color
Associated Condition
Green (I/P)
DC INPUT OK
Green (O/P)
Converter Module Power ON
Red (FAIL)
Converter Module FAIL
Red (FAIL flashing)
Converter Minor Alarm
Table 1 Module indicators and conditions
2.1.3 Regulation and Paralleling
Cordex modular converters use “output slope” or “regulation offset” to accomplish load sharing. When the
converters are run in parallel (as is the case when more than one converter module is installed in the shelf) it is
necessary to adjust the output voltage of the individual converter modules such that the output current is shared
equally between the individual modules. At that point, the modules will track each other and share the load over
the output current range of the units. The output slope value is fixed at 1.0% (1V / full current range).
2.1.4 Reverse Polarity Protection
The converter design has incorporated reverse polarity protection from the connection to a battery on the input
and to a power source on the output. This prevents damage to the converter circuitry if a reverse connection is
made. Return of module to the factory to replace fuses will be required.

012-527-B2 Rev FPage 4 of 24
2.2 Cordex Integrated System Controller (CXCI/CXCI+) Option
The controller is mounted in the converter system shelf and brings advanced monitoring technology to the Cordex
series of converters. This compact system controller is designed for seamless operation and set up of Alpha
power systems and is equipped with the complete range of Cordex software features, including the following:
•Designed to communicate directly with Cordex converters
•Provides local and remote communications
•User definable alarms
•Daily logging of power system events and system statistics.
Behind the CXCI/CXCI+’s front panel lies the main controller motherboard, which contains a microprocessor,
memory, as well as numerous other electronic components.
The CXCI/CXCI+ includes a web server providing easy set up and monitoring using an Internet connection with
Windows Explorer.
NOTE: Details of controller operation are provided in the current version software manual.
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
CXCI/CXCI+ 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.
2.3 System Controller Front Panel
The CXCI (Figure 2) and the CXCI+ (Figure 3) controllers have a 4-digit display, for monitoring system voltage (V)
and current (A). A pushbutton toggle switch allows the user to alternate the display reading.
Figure 2–CXCI model system controller front panel
Hard reset
(push once)
Soft reset
(push once)
[Hold for 3 seconds
to reset IP address]
Ethernet port
LCD screen (V/A)
Display pushbutton
toggle switch (V/A)
Port for Alpha DC
modem (e/w cable)
only
System status
LEDs
Details of controller operation
are provided in the current
version software manual.

012-527-B2 Rev FPage 5 of 24
Figure 3–Cordex CXCI+ model system controller front panel
2.3.1 LEDs
The CXC has three LEDs located on the front panel. These are used to display the alarm status of the power
system, CXC progress and status during startup, and file transfers.
2.3.1.1 Alarm Conditions
The CXCI/CXCI+ 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.
2.3.1.2 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.
2.3.2 Reset
A reset button is located on the front panel for restarting the CXCI/CXCI+ microprocessor.
Refer also to the software manual – always select the Reset menu item before pressing the reset button.
2.3.3 Modem Port (not available on the CXCI+, list 98)
The Modem port (front panel DB-9 connector, Figure 2) is designed for connection to Alpha Technologies’ Cordex
DC Modem #018-585-20.
CAUTION
Connect only Alpha-supplied modem and cable; otherwise, equipment damage can result.
2.3.4 Ethernet Port
The Ethernet port is designed for CXCI/CXCI+ connection to a user supplied network (TCP/IP secured by user)
via a front panel RJ-45 jack (Figure 2) 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.
Hard reset
(push once)
Ethernet port
System status
LEDs
LCD screen (V/A)
Display pushbutton
toggle switch (V/A)
Soft reset
(push once)
[Hold for 3 seconds
to re
set IP address]

012-527-B2 Rev FPage 6 of 24
2.4 Analog Input Channels
2.4.1 Voltage Inputs
Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage. The CXCI/CXCI+
software is pre-configured to monitor V2 for load and for 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.
2.4.2 Current Input
The CXCI/CXCI+ software is pre-configured to monitor I1 for load current using an external 100A/50mV current
shunt in the negative lead.
2.4.3 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.
2.5 Digital Input Channels
The CXCI/CXCI+ can accommodate up to two channels and can monitor digital alarm/control signals from
converters, rectifiers, and many other types of equipment.
2.6 Alarm and Control Output Relays
The CXCI/CXCI+ contains four (4) 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.
2.7 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 converters is accomplished
with a CXC via a CAN bus.

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3 Inspection
3.1 Packing Materials
All Alpha products are shipped in rugged cardboard boxes and suspended via solid inserts to minimize shock that
may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit
Association standards.
NOTE: Converters and batteries are shipped on individual pallets and are packaged per manufacturer’s guidelines.
3.1.1 Returns for Service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is unavailable, make sure the product 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 products.
3.2 Check for Damage
Prior to unpacking the product, note any damage to the shipping container. Unpack the product 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 proper assembly.

012-527-B2 Rev FPage 8 of 24
4 Installation
This chapter is provided for qualified personnel to install the product, which shall be mounted in a clean and dry
environment.
NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.
4.1 Safety Precautions
WARNING
Hazardous voltages are present at the input of converter/rectifier systems. The DC output, from
the converters/rectifiers and the battery system, 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, follow these precautions:
•Remove all metallic jewelry; e.g., watches, rings, metal rimmed glasses, necklaces.
•Wear safety glasses with side shields (and prescription lenses if necessary) at all times during installation.
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.
Use OSHA approved insulated hand tools.
4.2 Tools Required
Various insulated tools are essential for product installation. Use this list as a guide:
•Philips head screwdriver, #2 (tip size ¼")
•Slot head screwdriver (¼" x #6)
•Slot head screwdriver (blade size 0.09" x 0.02") or “tweaker”
•Digital voltmeter equipped with test leads
•Cutters and wire strippers
•Crimping tool (optional for large gauge wire)
•Socket and ratchet set (Imperial measure).
4.3 Shelf Preparation/Mounting
WARNING!
This system is designed to be installed in a restricted access location that is inaccessible to the
general public.
The 030-840-20 shelf has been designed for flush mounting in a 19" relay rack. The 030-901-20 shelf has been
designed for flush mounting in a 23" relay rack.
Both shelves have an option for 6" offset mounting. See outline drawings at the end of this manual.
Mount the shelf in a clean and dry environment. Allow at least 1.75" of free space in front of and behind the unit
for unrestricted cooling airflow.
Mounting brackets accommodate either 1" or 1¾" rack spacing. Mount the shelf to the rack using at least two
#12 – 24 x ½" screws in each bracket. Use Philips-type screws and screwdriver to eliminate the possibility of
slippage and scratching of the unit’s exterior. Use washers (such as internal tooth) or special screws that are
designed to cut through the painted surface to ensure a good chassis ground.
4.4 Converter Module Insertion/Removal
Insert by placing the converter module on the shelf bottom and sliding the module into the rear connector (inside
of the shelf). Apply pressure on the module handle to engage the rear connector in the shelf receptacle.
Insert the first converter module into the front leftmost position using the side of the shelf-mounted controller as a
guide. Insert the next module using the previous module as a guide.