Alpha Technologies CXPS-HX 48-2500 User manual

Your Power Solutions Partner
CXPS-HX 48–2500 Distributed Power System
Installation & Operation Manual
Part # 0913000-J0
Effective: 03/2016
member of The Group™

CXPS-HX 48–2500
Distributed Power System
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: [phone]
Copyright
Copyright © 2016 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies
Ltd.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmit-
ted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise
without prior explicit written permission from Alpha Technologies.
This document, the software it describes, and the information and know-how they contain constitute the proprietary,
confidential and valuable trade secret information of Alpha Technologies, and may not be used for any unauthorized
purpose, or disclosed to others without the prior written permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without notice. While
reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technologies
assumes no liability resulting from errors or omissions in this document, or from the use of the information contained
herein. Alpha Technologies reserves the right to make changes in the product design without reservation and with-
out notification to its users.
Alpha shall not be held liable for any damage or injury involving its enclosures, power
supplies, generators, batteries, or other hardware if used or operated in any manner or
subject to any condition inconsistent with its intended purpose, or if installed or oper-
ated in an unapproved manner, or improperly maintained.
Photographs contained in this manual are for illustrative purposes only. These photo-
graphs may not match your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual
before proceeding. If there are questions regarding the safe operation of this powering
system, contact Alpha Technologies or your nearest Alpha representative.
NOTE:
NOTE:

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Table of Contents
1. Safety....................................................................................................................................5
1.1 Safety Symbols .......................................................................................................................... 5
1.2 General Safety ........................................................................................................................... 5
1.3 Mechanical Safety...................................................................................................................... 5
1.4 Electrical Safety ......................................................................................................................... 6
1.5 Battery Safety ............................................................................................................................ 6
2. Introduction ...........................................................................................................................7
2.1 Product Overview ............................................................... 7
2.2 Part Numbers and List Options.................................................................................................. 7
3. Specications........................................................................................................................8
4. Product Description.............................................................................................................11
4.1 Power Section...........................................................................................................................11
4.2 Distribution Section .................................................................................................................. 13
4.3 Cordex System Controller........................................................................................................ 15
4.4 Cordex HP Controller (CXC HP).............................................................................................. 17
4.5 External Peripherals................................................................................................................. 18
4.6 Redundant Input Power Module .............................................................................................. 20
4.7 Shelf /Bay ID ............................................................................................................................ 20
5. Pre-Installation Preparation ................................................................................................21
5.1 Site Selection ........................................................................................................................... 21
5.2 Tools and Test Equipment ........................................................................................................ 22
5.3 Floor Loading ........................................................................................................................... 22
5.4 Unpacking the Equipment........................................................................................................ 23
5.5 Check for Damage ................................................................................................................... 23
5.6 General Receipt of Shipment................................................................................................... 23
6. Frame Installation ...............................................................................................................24
6.1 Floor Drilling for Standard Anchoring ....................................................................................... 24
6.2 Placing and Securing the Bay.................................................................................................. 25
6.3 Tandem System Busbar Installation......................................................................................... 27
6.4 Battery Installation ................................................................................................................... 28

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0913000-J0 Rev D
7. Installation - AC, DC and Grounding Cables.......................................................................31
7.1 Installation Notes ..................................................................................................................... 31
7.2 Connecting the Frame and Reference Grounds ...................................................................... 33
7.3 AC Supply for the Rectiers ..................................................................................................... 34
7.4 Distribution ............................................................................................................................... 36
7.5 DC Connections....................................................................................................................... 37
8. System Startup ...................................................................................................................42
8.1 Check System Connections..................................................................................................... 42
8.2 Verify AC and Power the Rectier Shelf................................................................................... 42
8.3 Check Battery Polarity and Connect ....................................................................................... 42
8.4 Final Conguration and Test .................................................................................................... 42
8.5 Shelf ID Connection ................................................................................................................. 43
9. Test and Commissioning Overview.....................................................................................44
9.1 System ..................................................................................................................................... 44
9.2 Battery...................................................................................................................................... 44
9.3 Documentation......................................................................................................................... 44
10. Maintenance .....................................................................................................................45
10.1 Rectiers ................................................................................................................................ 45
10.2 Batteries................................................................................................................................. 45
10.3 Controller Lithium Battery Replacement ................................................................................ 45
11. Acronyms and Denitions..................................................................................................46
12. Warranty and Service Information ....................................................................................47
12.1 Technical Support .................................................................................................................. 47
12.2 Warranty Statement ............................................................................................................... 47
12.3 Limited Hardware Warranty ................................................................................................... 47
12.4 Battery Warranty .................................................................................................................... 47
12.5 Warranty Claims..................................................................................................................... 47
12.6 Service Centers ..................................................................................................................... 47
13. Certication.......................................................................................................................48

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List of Figures
Figure 1 — CXPS-HX Distributed Power System............................................................................. 7
Figure 3 — 4.0kW Rectier Front panel LEDs................................................................................ 12
Figure 2 — 12kW/480 (3-phase) Rectier front panel LEDs........................................................... 12
Figure 4 — Example of distribution panels ..................................................................................... 13
Figure 5 — Distribution shunts........................................................................................................ 14
Figure 6 — CXCP controller mounted in the power section ........................................................... 15
Figure 7 — Cordex CXC HP Controller........................................................................................... 17
Figure 8 — LCD Color Touchscreen Display .................................................................................. 18
Figure 9 — L-ADIO I/O Peripheral .................................................................................................. 18
Figure 10 — 6I-ADIO Power Module .............................................................................................. 19
Figure 12 — Redundant input power module ................................................................................. 20
Figure 11 — Shelf/Bay ID................................................................................................................ 20
Figure 13 — Base dimensions and mounting holes (single bay).................................................... 24
Figure 14 — Securing power system bay to concrete oor ............................................................ 25
Figure 15 — Battery disconnect (purchased separately) connections............................................ 26
Figure 16 — Tandem system busbar installation, bay shown with panels removed....................... 27
Figure 17 — Battery installation...................................................................................................... 28
Figure 18 — Battery temperature probes ....................................................................................... 29
Figure 19 — Battery return busbars, frame ground and battery return reference........................... 33
Figure 20 — AC panel 5-feed, 3-wire 208Vac shown ..................................................................... 35
Figure 21 — Terminal blocks for 5-feed, 3-wire 208Vac input......................................................... 35
Figure 22 — External battery return bar wiring ............................................................................... 36
Figure 23 — Customer connections spacing .................................................................................. 36
Figure 24 — DC connection without AC panel option..................................................................... 37
Figure 25 — DC connection with AC panel option.......................................................................... 38
Figure 27 — Internal return bar....................................................................................................... 39
Figure 26 — External battery return bar kit (1 kit shown) ............................................................... 39
Figure 28 — External hot bar (2 kits shown)................................................................................... 40
Figure 29 — Landing the cables ..................................................................................................... 41

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0913000-J0 Rev D
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. Review the drawings and illustrations
contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of
this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future refer-
ence.
1.1 Safety Symbols
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following sym-
bols 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.
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 Safety
WARNING!
This system is designed to be installed in a restricted access location that is inacces-
sible to the general public.
1.3 Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.

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1.4 Electrical Safety
WARNING!
WARNING!
WARNING!
• Before working with any live battery or power system, follow these precautions:
a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
b. Wear safety glasses with side shields at all times during the installation.
c. Use OSHA approved insulated hand tools.
Lethal voltages are present within the power system. Always assume that an electrical
connection or conductor is energized. Check the circuit with a voltmeter with respect to
the grounded portion of the enclosure (both AC and DC) before performing any installa-
tion or removal procedure.
• Do not work alone under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment. Input voltages can range up to 480 Vac.
Ensure that the utility power is disconnected and locked out before performing any installation or removal proce-
dure.
• 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.
Follow battery manufacturer’s safety recommendations when working around battery
systems. Do not smoke or introduce an open ame when batteries (especially vented
batteries) are charging. When charging, batteries vent hydrogen gas, which can ex-
plode.
• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery
manufacturer for recommended local authorized recyclers.
Hazardous voltages are present at the input of power systems. The DC output from rec-
tiers and batteries, though not dangerous in voltage, has a high short-circuit current
capacity that may cause severe burns and electrical arcing.
WARNING!
High leakage current, earth connection essential before connecting the supply.
1.5 Battery Safety
• Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel knowl-
edgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metal-
lic 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 bat-
teries.

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0913000-J0 Rev D
2. Introduction
2.1 Product Overview
The CXPS-HX System (Figure 1) provides high capacity DC power for large communication network applications.
This system combines the capabilities of tiered distribution, advanced microprocessor based supervision, and
modular rectifiers in a single integrated bay. Two bays can easily be linked together and share a central controller to
double the system capacity.
Figure 1 — CXPS-HX Distributed Power System
The Cordex Distributed Power System is cost effective
due to the internal copper buswork, and is delivered
ready to assemble with factory tested components. No
overhead bus work is required. An optional external return
bus is available. Cable access is from the top and load
connections are terminated from the side or rear of the
bay. Hot swappable Cordex power modules provide safe
and easy installation and maintenance.
Unlike other midsize power plants, the CXPS-HX can
accept both three phase and single phase rectifiers in
combination with a variety of distribution configurations,
making it ideal for deployment in new small switching
center, data center or office expansion applications.
2.2 Part Numbers and List Options
The system offers several advanced features with add-
on list options. These list options can be included by
the customer at time of ordering or can be added in the
future; e.g., additional Cordex rectifiers. For more informa-
tion, see the ordering guide on the Alpha website.

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3. Specifications
Table A — Specications for CXPS-HX 48–2000/2500 Power System
Electrical
AC Input Voltage
No.
of AC
Feeds
Nominal
Voltage
(Vac)
Recommended
Breaker (A)
Connection
Type
Recommended
Wire Size (AWG)
Knockout
Dimension (in)
CXPS-HX-48-2000 (4kW, 4 rectier shelves) with AC distribution panel
4208 100 3W + PE 2 2.0 (1.5 KO)
277/480 50 3W + N + PE 6 1.5 (1.25 KO)
8208 50 3W + PE 6 1.5 (1.25 KO)
277/480 30 3W + N + PE 8 1.5 (1.25 KO)
CXPS-HX-48-2500 (4kW, 5 rectier shelves) with AC distribution panel
5208 100 3W + PE 2 2.0 (1.5 KO)
277/480 50 3W + N + PE 6 1.5 (1.25 KO)
10 208 50 3W + PE 6 1.5 (1.25 KO)
277/480 30 3W + N + PE 8 1.5 (1.25 KO)
CXPS-HX-48-2500 (4kW, 5 rectier shelves) with direct feed to rectiers and no AC distribution panel
10 (3Ø) 208 50 3W + PE 6 N/A
277/480 30 3W + N + PE 8 N/A
30 (1Ø) 208-277 30 60Hz, (1Ø) 8 N/A
CXPS-HX-48-2000 (12kW/480, 4 rectier shelves) with AC distribution panel
4480 50 3W + N + PE 6 1.5 (1.25 KO)
8 480 30 3W + N + PE 8 1.5 (1.25 KO)
CXPS-HX-48-2500 (12kW/480, 5 rectier shelves) with AC distribution panel
5 480 50 3W + PE 6 1.5 (1.25 KO)
10 480 30 3W + N + PE 8 1.5 (1.25 KO)
CXPS-HX-48-2500 (12kW/480, 5 rectier shelves) with direct feed to rectiers and no AC distribution panel
10 (3Ø) 480 30 3W+PE 8 1.5(1.25KO)
Table B — Distribution Panels
Panel Type Quantity/Rating Capacity Max Rating per Panel
TPL Fuses 61 to 800A Up to 4 positions/ panel 2000A
TPS/TLS
fuses
Up to 125A, 18 per panel Up to 18 positions/ panel 600A
Bolt-in high
capacity
breakers
1 pole up to 250A
2 pole 275 to 400A
3 pole 450 to 700A
4 pole 650 to 800A
5 pole 850 to 1000A
6 pole 1050 to 1200A
Up to 12 poles/ panel 2000A
Plug-in bullet
breakers
1 pole up to 125A
2 pole 150 to 200A
3 pole 225 to 300A
Up to 18 positions/ panel 600A