Alpha Technologies Cordex User manual

Your Power Solutions Partner
Cordex PSU, 24V/400W or 48V/650W
Web Enabled, DIN Rail/Wall Mount Power Supply
Installation & Operation Manual
Part # 0100011-J0
Effective: 09/2013
member of The Group™

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

i
TABLE OF CONTENTS
1INTRODUCTION ............................................................................................................................................................. 1
1.1 Product Overview.......................................................................................................................................... 1
1.2 Specifications ................................................................................................................................................ 2
2FEATURES ................................................................................................................................................................... 3
2.1 Cordex Integrated System Controller (CXCI+) ............................................................................................. 3
2.2 Analog Input Channels.................................................................................................................................. 4
2.3 Digital Input Channels ................................................................................................................................... 4
2.4 Alarm and Control Output Relays ................................................................................................................. 4
2.5 Network Connection and Remote Communications ..................................................................................... 4
2.6 Rectifiers ....................................................................................................................................................... 5
2.7 True Module Fail Alarm................................................................................................................................. 6
2.8 Heat Dissipation ............................................................................................................................................ 6
2.9 Over Temperature Protection ....................................................................................................................... 6
2.10 Wide AC Range ............................................................................................................................................ 6
2.11 AC Inrush/Transient Suppression ................................................................................................................. 6
2.12 Soft Start ....................................................................................................................................................... 6
2.13 Current Limit/Short Circuit Protection ........................................................................................................... 6
2.14 High Voltage Shutdown (HVSD) ................................................................................................................... 7
2.15 Battery Eliminator Operation......................................................................................................................... 7
2.16 CAN bus........................................................................................................................................................ 7
3INSPECTION.................................................................................................................................................................. 8
3.1 Packing Materials.......................................................................................................................................... 8
3.2 Check for Damage ........................................................................................................................................ 8
4INSTALLATION .............................................................................................................................................................. 9
4.1 Safety Precautions ........................................................................................................................................ 9
4.2 PSU Preparation/Mounting ........................................................................................................................... 9
5WIRING AND CONNECTIONS ........................................................................................................................................ 11
5.1 Tools Required............................................................................................................................................ 11
5.2 Power System Chassis Ground and DC Ground Reference ...................................................................... 11
5.3 AC Feeder Protection/Sizing....................................................................................................................... 11
5.4 AC Input ...................................................................................................................................................... 11
5.5 Wiring Schematic ........................................................................................................................................ 12
5.6 Calculating Output Wire Size Requirements............................................................................................... 12
5.7 DC Output ................................................................................................................................................... 12
5.8 Network Connection and Remote Communications via CXCI+.................................................................. 13
5.9 Signal Wiring Connections .......................................................................................................................... 13
6OPERATION................................................................................................................................................................ 17
6.1 Main Rectifier States ................................................................................................................................... 17
6.2 Main Rectifier Modes .................................................................................................................................. 18
6.3 400W Rectifier Factory Ranges and Defaults............................................................................................. 19
6.4 650W Rectifier Factory Ranges and Defaults............................................................................................. 19
7SYSTEM STARTUP ...................................................................................................................................................... 20
7.1 CXC Reset .................................................................................................................................................. 20
8MAINTENANCE ........................................................................................................................................................... 22

ii
8.1 MOV Replacement...................................................................................................................................... 22
9WARRANTY AND SERVICE INFORMATION..................................................................................................................... 24
9.1 Technical Support ....................................................................................................................................... 24
9.2 Warranty...................................................................................................................................................... 24
9.3 Battery Warranty ......................................................................................................................................... 24
9.4 Return of Material........................................................................................................................................ 24
10 ACRONYMS AND DEFINITIONS ..................................................................................................................................... 25

0100011-J0 Rev D Page 1 of 25
1 Introduction
1.1 Product Overview
•Clean and reliable DC power supply for critical loads available in two options: 24V/400W or 48V/650W
•Internet ready and remotely accessible for complete and cost effective system and site monitoring
•Advanced battery charging, monitoring and testing to ensure sufficient reserve power availability and
prolonged battery life
•Configurable platform with I/Os for site monitoring, user-definable alarms, data logging and control
•Extended temperature range for installation in harsh outdoor environments
•Wide AC input operating range for worldwide installation requirements
Figure 1– Cordex PSU, 24V/400W or 48V/650W shelf system with integrated CXCI+ controller
Rectifier module
(650W shown)
CXCI+ controller

0100011-J0 Rev D Page 2 of 25
1.2 Specifications
The product is available under the following part numbers:
•24V-400W model, DIN Rail mount: #0100011-002
•48V-650W model, DIN Rail mount: #0100012-002
Electrical
>48V/650W
>24V/400W
Input voltage:
Operating:
120/208/240Vac
120/208/240Vac
Extended:
Low: 90 to 120Vac (de-rated power)
Input frequency:
45 to 65Hz
45 to 65Hz
Current:
5.0A max
4.9A max
Power:
650W max
400W max
Power factor:
>0.99%
>0.99%
THD:
<5%
<5%
Efficiency:
>90%
>88%
Output voltage:
42 to 58Vdc
20 to 30Vdc (24V Nominal)
Output current:
13.5A max
14A max
Load regulation:
Static <±0.5%
Static <±0.5%
Dynamic <±2% for 50 to 100% load step
Dynamic <±5% for 50 to 100% load step
2ms recovery time
2ms recovery time
Load regulation:
Static <±0.1%
Static <±0.1%
Dynamic ±1% for any change within rated
Dynamic ±1% for any change within rated
Noise:
Voice band:
<32dBrnC
<32dBrnC
Wide band:
<10mV RMS (to 10MHz)
<10mV RMS (to 10MHz)
<150mV pk to pk (to 100MHz)
<100mV pk to pk (to 100MHz)
Psophometric:.
<1mV RMS
<1mV RMS
Mechanical
Dimensions (HxWxD):
117mm x 281mm x 101mm (4.6in x 11.1in x 3.98in)
Weight:
3kg (6.6lbs)
Mounting:
Panel
DIN rail (standard TS-35/7.5 or 15 Mounting Rail)
Connections:
AC, Load & Battery:
Screw terminal 4mm2(#12AWG)
Alarms & I/Os:
Screw terminals 2.5mm2to (#14AWG)
Environmental
Temperature:
Operation:
- 40 to 50˚C (-40 to 122˚F)
Extended:
51 to 70˚C (123 to 158˚F)
Storage:
- 40 to 85˚C (-40 to 185˚F)
Humidity
0 to 95% RH non-condensing
Altitude:
-500 to 3000m (-1640 to 9840ft)
Heat Dissipation:
<110 BTU per hour
Other
MTBF: 369,000 hrs @30°C ambient; test model Telecordia SR-332, Issue 2
Agency Compliance
Safety:
CSA C22.2 No 60950-1-07 (2nd Ed) / UL 60950-1 (2nd Ed) cCSAus Marked
IEC 60950-1:2005 (2nd Ed) / EN60950-1:2006 CE Marked
EMC:
ETSI 300 386-2
Emissions:
CFR47 (FCC) Part 15 - Class A Device
EN 61000-3-2
EN 61000-3-3
Immunity:
EN 61000-4-2, EN 61000-4-3
EN 61000-4-4, EN 61000-4-5
EN 61000-4-6, EN 61000-4-11
ANSI / IEEE C62.41 CatB3
The above information is valid at the time of publication. Consult factory for up-to-date ordering information.

0100011-J0 Rev D Page 3 of 25
2 Features
Alpha’s Cordex PSU is an integrated, fully-featured DC power system in a compact form factor. It is designed to
provide power to critical loads while enabling remote site monitoring and delivering critical information on demand.
The PSU supplies reliable and low output ripple current along with short circuit, over voltage, over temperature
and over load protection. It also features advanced battery charging, monitoring and testing functionality. Two
temperature, two digital and one analog inputs can be used for monitoring system alarms such as intrusion
detection or equipment malfunction.
2.1 Cordex Integrated System Controller (CXCI+)
The integrated CXCI+ controller offers comprehensive local and remote control and monitoring, including a web
server, providing easy set up using a standard Windows Internet Explorer browser. SMTP features “enable alarm”
condition settings and multiple automatic notification options by e-mail to a computer, server or smartphone.
Sites without internet access can use the integrated CXCI+ controller as an advanced standalone data logging
system, allowing the capture of data from multiple inputs such as AC/DC voltages, load/battery current, and cell
voltage/temperature.
The CXCI+ captures and retains 90 days of statistical data and 500 alarm events, ready for download to a laptop
for site history file and analysis of system performance, power system details, thermal performance of outdoor
enclosures and failure conditions.
NOTE: Customer settings for the CXCI+ are provided in a separate software manual:included in the PSU documentation
package.
Figure 2 Cordex CXCI+ controller front panel
2.1.1 Front panel user interface
Display:
4-digit display for monitoring system voltage (V) and current (A). A pushbutton switch
toggles the display.
GUI:
Embedded web based GUI accessed via Ethernet using internet browser
LEDs:
Alarm indication:
•AC mains OK — Green
•Minor alarm — Yellow
•Major alarm — Red
Progress and Status Indication:
•Self-test: LEDs all on at the same time
•File transfer: red LED on when recovering from invalid firmware application
Ethernet port
Display pushbutton
toggle switch (V/A)
Soft reset
(push once)
[Hold for 3 seconds
to reset IP address]
System status
LEDs
LCD screen (V/A)
Hard reset (push
once)

0100011-J0 Rev D Page 4 of 25
Audio speaker:
Sounds an intermittent tone during active alarms
Reset:
Soft reset button: push once to reset controller; push hold for 3 sec to reset IP address
Hard reset button: use to reset controller when controller is hung up and not responding
Ethernet Port (RJ-
45 jack)
10/100 Base-T for TCIP/SNMP/Email features (standard network cable)
Local access, e.g., laptop computer (crossover cable)
2.2 Analog Input Channels
Voltage Inputs:
Two voltage input channels, V1 and V2, provide monitoring of discharge and charge
voltage. The CXCI+ software is pre-configured to monitor V2 for load and battery voltage.
V2 is used as the system reference for rectifier float voltage, low voltage disconnect (B),
system high voltage alarm, and system low voltage alarm. V1 is available for additional
voltage measurements.
Current Inputs:
The CXCI+ software is pre-configured to monitor I1 for load current wired internally to the
system current shunt.
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.
2.3 Digital Input Channels
The CXCI+ can accommodate up to two channels and can monitor digital alarm/control signals from sensors such
as a door alarm and other types of site monitoring equipment.
2.4 Alarm and Control Output Relays
The CXCI+ contains four Form C digital alarm output relays to extend alarms and control external apparatus.
Each internally generated alarm or control signal can be mapped to any one of relays K2-K4, or, several signals
can be mapped to just one relay or none at all. Relay K1 is mapped to the LVBD (see Section 5.9.4 on page 16).
2.5 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.