Alpha Technologies CXPS-48-500-IWM User manual

Your Power Solutions Partner
CXPS-48-500-IWM
48 Vdc Pos Ground Power System
Installation & Operation Manual
Part # 0540033-J0
Effective: 07/2013
member of The Group™

CXPS-48-500-IWM
48 Vdc Pos Ground Power Systems
0540033-J0
The following documents and drawings are included in this manual:
• Schematic: 0380018-05
• Outline drawing: 0540033-00

CXPS-48-500-IWM
48 Vdc Pos Ground Power Systems
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: [phone]
Email: [email protected]
Copyright
Copyright © 2013 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo-
gies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or trans-
mitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or other-
wise without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the propri-
etary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technolo-
gies assumes no liability resulting from errors or omissions in this document, or from the use of the information
contained herein. Alpha Technologies reserves the right to make changes in the product design without reserva-
tion and without notification to its users.
Alpha shall not be held liable for any damage or injury involving its enclosures, power
supplies, generators, batteries, or other hardware if used or operated in any manner or
subject to any condition inconsistent with its intended purpose, or if installed or oper-
ated in an unapproved manner, or improperly maintained.
Photographs contained in this manual are for illustrative purposes only. These photo-
graphs may not match your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe operation of this powering
system, contact Alpha Technologies or your nearest Alpha representative.
NOTE:
NOTE:

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Table of Contents
1. Safety....................................................................................................................................3
1.1 Safety Symbols .......................................................................................................................... 3
1.2 General Warning and Cautions.................................................................................................. 3
1.3 Battery Safety ............................................................................................................................ 4
2. Overview...............................................................................................................................5
2.1 Product Overview....................................................................................................................... 5
3. Site Evaluation and Pre-Installation......................................................................................6
3.1 Packing Materials....................................................................................................................... 6
3.2 Check for Damage ..................................................................................................................... 6
3.3 General Receipt of Shipment..................................................................................................... 6
3.4 Pre-Installation Requirements.................................................................................................... 6
4. Installation.............................................................................................................................7
4.1 Safety Precautions..................................................................................................................... 7
4.2 Installing the AC Line Cord ........................................................................................................ 7
4.3 Wall Mounting the Enclosure ..................................................................................................... 7
4.4 Battery Installation ..................................................................................................................... 9
4.5 System Startup .........................................................................................................................11
4.6 Customer Signal Interface ....................................................................................................... 12
4.7 Padlocking the Enclosure ........................................................................................................ 12
5. Maintenance .......................................................................................................................13
6. Warranty and Service Information ......................................................................................14
6.1 Technical Support .................................................................................................................... 14
6.2 Warranty................................................................................................................................... 14
6.3 Battery Warranty ...................................................................................................................... 14
6.4 Return of Material ................................................................................................................... 14
6.5 Service Centers ....................................................................................................................... 14
7. Acronyms and Denitions ...................................................................................................15
8. Certication.........................................................................................................................16

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1. Safety
SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that
must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Re-
view the drawings and illustrations contained in this manual before proceeding. If there are any questions regard-
ing the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representa-
tive.
1.1 Safety Symbols
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
The use of ATTENTION indicates specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
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.
WARNING!
You must read and understand the following warnings before installing the enclosure
and its component. Failure to do so could result in personal injury or death.
CAUTION!
CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment. Cautions are designated with a yellow warning triangle, the word CAUTION,
and a rule beneath which the information appears.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure.
Notes are designated with a checkmark, the word NOTE, and a rule beneath which the
information appears
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or
user.
1.2 General Warning and Cautions
• Before using the product, read all instructions and cautionary markings on the product and any equip-
ment connected to the product.
• Do not expose the product to rain or snow; install only in a clean, dry environment.
• Use proper lifting techniques whenever handling equipment, parts, or batteries.

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CAUTION!
Unless otherwise noted, use of an attachment not recommended or sold by the product
manufacturer may result in a risk of re, electric shock, or injury to persons.
CAUTION!
Do not operate the product if it has received a sharp blow, it has been dropped, or oth-
erwise damaged in any way – return it to a qualied service center for repair.
CAUTION!
Do not disassemble the product – call our qualied service centers for servicing. Incor-
rect reassembling may result in a risk of electrical shock or re.
1.3 Battery Safety
• Never transport the enclosure with batteries installed. Batteries must ONLY be installed after the enclo-
sure has been securely set in place at its permanent installation location. Transporting the unit with bat-
teries installed may cause a short circuit, fire, explosion, and/or damage to the battery pack, enclosure
and installed equipment.
• Servicing and connection of batteries must be performed by, or under the direct supervision of, person-
nel knowledgeable of batteries and the required safety precautions.
• 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 ame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can ex-
plode.
CAUTION!
Risk of explosion if a battery is replaced by an incorrect type.
CAUTION!
Batteries are hazardous to the environment and should be disposed at a recycling facil-
ity. Consult the battery manufacturer for recommended local authorized recyclers.

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2. Overview
2.1 Product Overview
• Wall mountable enclosure
• Equipped with 2 Cordex CXRC 48-650W rectifiers (010-570-20-041) in a 19" shelf (030-728-20-237),
including a CXCI controller.
• AC input rated 120 Vac, 50/60Hz, 4.9 A, cord-connected
• DC input (Internal Batteries): two 48 Vdc battery strings using 12 V, 12.7 Ah batteries (customer-sup-
plied)
• DC Output rated: 48Vdc, 500W max
• Exterior dimensions: 24"W x 15"D x 14"H (see drawing 0540033-00 at the end of the manual)
• Weight: 18.8 kg (41.4 lbs), excluding batteries
Figure 1 — System W/O door showing rectifier shelf and customer connections
650W Rectier Shelf
CAUTION!
Do not installed any additional ancillary equipment inside the cabinet other than Alpha’s
rectier shelf and batteries.
Customer supplied connection
to the load.
NOTE:
Breakers CB3 and CB4 are not to be used. The two rectier position lled with blanking
plates are not to be used.
Customer signal interface - 3
dry contacts and 2 user inputs.

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3. Site Evaluation and Pre-Installation
3.1 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 International Safe
Transit Association standards.
Rectifiers are packaged separately according to the 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 that the product is packed with at
least three inches of shock-absorbing material to prevent shipping damage.
Alpha Technologies is not responsible for damage caused by improper packaging of returned products.
3.2 Check for Damage
Before 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, inform the carrier and
contact Alpha Technologies for advice on the impact of any damage.
3.3 General Receipt of Shipment
The inventory included with your shipment depends on the options you have ordered. The options are clearly
marked on the shipping container labels and bill of materials.
Call Alpha Technologies if you have any questions before you proceed: 1 888 462-7487
3.4 Pre-Installation Requirements
CAUTION!
For use in a controlled environment. Maximum ambient temperature should not exceed
40°C (104°F), with humidity 30 to 90% non-condensing. Refer to the Cordex 48-650W 19"
Integrated Shelf System (part number 030-806-B2) manual for specic component speci-
cations.
1. Select a location for mounting the enclosure that is within 3 m of a power outlet.
2. Provide adequate clearance for accessing the unit from the front.
3. Allow adequate space on either side of the enclosure for unrestricted cooling airflow—30" is recommended.
4. Bolts and washers for mounting are customer-supplied:
• Plywood mounting board: Quantity 4 of 5/16" x 4" lag bolts or screws with 5/16" flat washer and one 5/16"
spring lock washer per lag bolt/ screw.
• Enclosure: Quantity 4 of 5/16" x 1" lag bolts/ screws with 5/16" flat washer and one 5/16" spring lock
washer per lag bolt/ screw.
5. Batteries are not part of the system and must be supplied by the customer.

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4. Installation
This chapter is provided for qualified personnel to install the CXPS-48-500, which shall be mounted in a clean
and dry environment. Maximum ambient temperature should not exceed 40°C.
4.1 Safety Precautions
WARNING!
Hazardous voltages are present at the input of power systems. The DC output from the
rectiers is classied as hazardous voltage and 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 at all times during installation.
Metallic tools must be insulated.
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.
4.2 Installing the AC Line Cord
CAUTION!
The power supply cord is used as the main disconnect device. Ensure the socket-outlet
is located/installed near the equipment and is easily accessible.
The enclosure has several knockouts for routing the cord from inside the enclosure to a wall socket— refer to
drawing 0540033-00 at the end of this manual.
1. Select a knockout and route the cord through the knockout to the wall socket.
2. Screw the supplied mounting plate to the enclosure with the 10-32x3/4" screws.
4.3 Wall Mounting the Enclosure
CAUTION!
The enclosure weighs 18.8 kg (41.4 lbs). Use proper lifting techniques.
Prepare the enclosure for wall mounting by removing the front cover as follows:
1. Loosen the Phillips screw securing the cover.
2. Grasp the cover by the sides and lift up slightly.
3. Swing the bottom of the cover out and away from the unit.

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1. Install a 3/4" plywood backing plate measuring at least 28" wide by 14"
long on stud centers using four lag bolts or screws (Figure 2). Use one
customer-supplied 5/16" flat washer and one 5/16" spring lock washer
per lag bolt/ screw.
2. Use the supplied template ((7400182-H1) to mark the location of the
enclosure mounting bolts/ screws on the plywood.
3. Screw the top two 1" bolts/screws into the plywood leaving enough
room to mount the cabinet (see the keyhole mounting holes in Figure
3. Use one customer-supplied 5/16" flat washer and one 5/16" spring
lock washer per lag bolt/screw.
4. Hang the enclosure on these two bolts/ screws. Figure 3 shows the
enclosure probably seated on an upper mounting bolt/screw.
5. Install the bottom two bolts/screws—see Figure 4. Use customer-
supplied 5/16" x 1" lag bolts, with one 5/16" flat washer and one 5/16"
spring lock washer per lag bolt/screw.
6. Ensure that all four bolts/screws are securely fastened to the plywood.
Figure 2 — Mounting holes on the back of the enclosure
Figure 3 — Upper mounting bolt
Figure 4 — Lower mounting bolt hole
Lag bolt/screw
Spring lock washer
Flat washer
CAUTION!
Do not to cover or put anything on the top surface of the enclosure.
3/4" plywood backing plate
wall stud
This process requires 4 customer-supplied 5/16" x 1" lag bolts or screws, and 4 customer-supplied 5/16" x 4" lag
bolts or screws with one 5/16" flat washer and one 5/16" spring lock washer per lag bolt/screw

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4.4 Battery Installation
This system is designed for two 48 Vdc battery strings using 12 V 12.7 Ah batteries. The enclosure is equipped
with a battery harness for connecting two strings of batteries (Figure 5).
4.4.1 Preparation
WARNING!
This information is provided as a guideline. Follow the battery manufacturer’s safety
recommendations when working around battery systems and review the safety instruc-
tions provided in this manual.
Use new batteries when installing a new unit. Verify that all batteries are the same type with identical date codes.
1. Make sure the enclosure is properly mounted and secured before starting the battery installation.
2. Clean the batteries cells according to the battery manufacturer's recommendations. First neutralize any acid
with a baking soda and water solution, rinse the batteries with clean water, and then wipe them dry.
Figure 5 — Battery shelf
Battery harness
Battery shelf

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4.4.2 Procedure
WARNING!
Verify that all DC circuit breakers on the distribution panel are either in the OFF position
or removed.
WARNING!
Use OSHA approved INSULATED hand tools
1. Number the batteries from 1 to 8 with labels or tape as shown in Figure 6 .
2. Coat the battery terminals with the corrosion inhibitor.
3. Place the four batteries for the first string into the enclosure and install the inter-battery connectors as shown
in Figure 6.
4. Repeat for the second string of four batteries.
5. When the batteries are wired, measure the voltage at the battery connection terminals. It should measure 42-
54 V.
6. Note the polarity and ensure it is correct.
DO NOT CONNECT THE BATTERIES TO THE BATTERY HARNESS AT THIS TIME.
Battery #4 Battery #3 Battery #2 Battery #1
To positive terminal To negative terminal
Figure 6 — Battery string wiring
Battery #8 Battery #7 Battery #6 Battery #5
To positive terminal To negative terminal
STRING #1
STRING #2

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4.5 System Startup
After completing the enclosure installation and battery interconnection wiring, perform the following startup and
test procedure to ensure proper operation. Refer to the Cordex 48-650W 19" Integrated Shelf System (part num-
ber 030-806-B2) manual for more detail on the following steps.
4.5.1 Check System Connections
1. Ensure AC is off, battery is disconnected, and all power modules are removed from the shelf.
2. Triple check the polarity of all connections.
4.5.2 Verify AC and Power the Shelf
1. Install one power module.
2. Verify AC input voltage is correct and turn on the
corresponding AC input feeder breaker.
3. The power module OK LED should illuminate after a
preset start delay.
4. Using the CXCI, test functionality of various module
alarms and controls.
4.5.3 Check Battery Polarity and Connect
WARNING!
Disconnect rectier DC and check battery polarity before connection.
1. Remove the power module installed in the previous section.
2. Verify correct battery polarity of both battery strings using a voltmeter (ensuring no cells or batteries are
reversed).
3. Connect one string of batteries to the battery harness.
4. Verify the CXCI starts up.
5. Connect the second string of batteries to the battery harness.
6. Install both power modules.
7. In the adjustments menu of the CXCI (web browser), set Float and Equalize voltage to the levels specified by
the battery manufacturer. (Refer to the current version of the CXC software manual for detailed instructions.)
8. Using the CXCI, test functionality of various module alarms and controls.
9. Perform a load test with the system using a resistive load box as needed.
Figure 7 — Rectifier OK LED

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4.6 Customer Signal Interface
Refer to the Cordex 48-650W 19" Integrated Shelf System (part number 030-806-B2) manual to wire and config-
ure the 3 dry contacts and 2 user inputs (see Figure 1).
4.7 Padlocking the Enclosure
When the installation is complete, insert a padlock through the hole provided in the front cover (Figure 8).
Figure 8 — Front cover padlock location

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5. Maintenance
Although very little maintenance is required with Alpha systems, routine checks and adjustments are recom-
mended to ensure optimum system performance. Qualified service personnel should do the repairs.
The following table lists a few maintenance procedures for this system. These procedures should be performed
at least once a year.
Use extreme care when working inside the unit while the system is energized. Do not
make contact with live components or parts.
Circuit cards, including RAM chips, can be damaged by static electricity. Always wear a
grounded wrist strap when handling or installing circuit cards.
Ensure redundant modules or batteries are used to eliminate the threat of service inter-
ruptions while performing maintenance on the system’s alarms and control settings.
WARNING!
Table A — Sample maintenance log
Procedure Date Completed
Clean ventilation openings.
Inspect all system connections. Re-torque if necessary.
Verify alarm/control settings.
Verify alarm relay operation.

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6. Warranty and Service Information
6.1 Technical Support
Free Technical Support 24/7/365 is part of the Alpha customer satisfaction commitment. The phone numbers
below can also be used to access a wide range of service solutions both at your premise and at the Alpha facility
nearest you.
In Canada and the USA, call toll free 1-888-462-7487 24 hours a day, seven days a week.
Customers outside Canada and the USA, call [phone].
6.2 Warranty
Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for
a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing
or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to
the factory or other authorized location during the warranty period. There are limitations to this warranty cover-
age. The warranty does not provide to the customer or other parties any remedies other than the above. It does
not provide coverage for any loss of profits, loss of use, costs for removal or installation of defective equipment,
damages or consequential damages based upon equipment failure during or after the warranty period. No other
obligations are expressed or implied. Warranty also does not cover damage or equipment failure due to cause(s)
external to the unit including, but not limited to, environmental conditions, water damage, power surges or any
other external influence.
6.3 Battery Warranty
Note that battery warranty terms and conditions vary by battery and by intended use. The most common battery
warranty provided by Alpha is a two year full replacement warranty with a pro-rated warranty for the following
three years. Pro rated warranty provides a credit applicable toward the purchase of new batteries from Alpha. The
credit is calculated as the purchase price multiplied by the percentage of the battery life that was not available (in
months). Battery warranty coverage is lost where the battery charge is not maintained for 6 months. Contact your
Alpha sales representative or the Technical Support team at the above number to understand your entitlements
under Battery Warranty.
6.4 Return of Material
Please contact Technical Support at the number above to obtain a Service Repair Order (or Return Material
Authorization) number BEFORE sending material back. This will ensure that your service needs are handled
promptly and efficiently.
6.5 Service Centers
For a list of service centers, refer to the Alpha website:
http://www.alpha.ca/web2/services-and-support/service-and-repair.html.

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7. Acronyms and Definitions
AC Alternating current
ANSI American National Standards Institute
AWG American Wire Gauge
BTU British thermal unit
CAN Controller area network
CEC Canadian Electrical Code
CSA Canadian Standards Association
CX Cordex™ series; e.g., CXC for Cordex System Controller
DC Direct current
DHCP Dynamic Host Conguration Protocol
EIA Electronic Industries Alliance
EMC Electromagnetic compatibility
EMI Electromagnetic interference
ERM Electromagnetic Compatibility and Radio Spectrum Matters
ESD Electrostatic Discharge
FCC Federal Communications Commission (for the USA)
GSM Group Speciale Mobile (global system for mobile communications)
HVSD High voltage shutdown
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IP Internet Protocol
LED Light emitting diode
LVD Low voltage disconnect
MIL One thousandth of an inch; used in expressing wire cross sectional area
MOV Metal oxide varistor
MTBF Mean time between failures
NC Normally closed
NEC National Electrical Code (for the USA)
NO Normally open
OSHA Occupational Safety & Health Administration
OVP Over voltage protection
RAM Random access memory
RU Rack unit (1.75”)
TCP/IP Transmission Control Protocol / Internet Protocol
THD Total harmonic distortion
UL Underwriters Laboratories
VRLA Valve regulated lead acid

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8. Certification
About CSA and NRTL
CSA (Canadian Standards Association also known as CSA International) was established
in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an
NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety
and Health Administration) in the United States of America (Docket No. NRTL-2-92). This was
expanded and renewed in 1997, 1999, and 2001. The specific notifications were posted on
OSHA’s official website as follows:
• Federal Register #: 59:40602 - 40609 [08/09/1994]
• Federal Register #: 64:60240 - 60241 [11/04/1999]
• Federal Register #: 66:35271 - 35278 [07/03/2001]
When these marks appear with the indicator “C and US” or “NRTL/C” it means that the
product is certified for both the US and Canadian markets, to the applicable US and Cana-
dian standards. (1)
Alpha rectifier and power system products, bearing the aforementioned CSA marks, are cer-
tified to CSA C22.2 No. 950 and UL 1950, or CSA/UL 60950. Alpha UPS products, bearing
the aforementioned CSA marks, are certified to CSA C22.2 No. 107.3 and UL 1778.
As part of the reciprocal, US/Canada agreement regarding testing laboratories, the Stan-
dards Council of Canada (Canada’s national accreditation body) granted Underwriters Labo-
ratories (UL) authority to certify products for sale in Canada. (2)
Only Underwriters Laboratories may grant a licence for the use of this mark, which indicates
compliance with both Canadian and US requirements. (3)
NRTLs capabilities
NRTLs are third party organizations recognized by OSHA, US Depart-
ment of Labor, under the NRTL program.
The testing and certifications are based on product safety standards
developed by US based standards developing organizations and are
often issued by the American National Standards Institute (ANSI). (4)
The NRTL determines that a product meets the requirements of an
appropriate consensus-based product safety standard either by
successfully testing the product itself, or by verifying that a contract
laboratory has done so, and the NRTL certifies that the product meets
the requirements of the product safety standard. (4)
Governance of NRTL
The NRTL Program is both national and international in scope with
foreign labs permitted.
(1) www.csa-international.org
(2) www.scc.ca
(3) www.ulc.ca
(4) www.osha.gov