Alpha Technologies CXPS-E101 User manual

Technical Guide: 0540569-J0
Effective: 08/2018
CXPS-E101 Power Systems
Alpha Technologies Ltd.

CXPS-E101
100A and 225A -48Vdc Power Systems
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: [phone]
Copyright
Copyright © 2018 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmitted
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 reason-
able 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 without notifi-
cation 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:

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 Scope of the Manual .................................................................................................................. 7
2.2 Product Overview....................................................................................................................... 7
2.3 System Congurations............................................................................................................... 8
3. Specications........................................................................................................................9
4. Features..............................................................................................................................11
4.1 CXDM-E1 Distribution Panel.....................................................................................................11
4.2 Overview of the CXCM1+ Controller........................................................................................ 13
4.3 Overview of the CXCM1 HP Controller.................................................................................... 15
4.4 Cordex CXRF-HP Rectier ...................................................................................................... 17
5. Inspection............................................................................................................................20
5.1 Packing Materials..................................................................................................................... 20
5.2 Check for Damage ................................................................................................................... 20
5.3 General Receipt of Shipment................................................................................................... 20
6. Installation...........................................................................................................................21
6.1 Safety Precautions................................................................................................................... 21
6.2 Tools Required ......................................................................................................................... 21
6.3 Power System Assembly and Mounting................................................................................... 21
6.4 Rectier Module Insertion/Removal ......................................................................................... 22
6.5 Breaker Installation .................................................................................................................. 23
6.6 Battery Installation ................................................................................................................... 24
6.7 Battery Maintenance Report .................................................................................................... 25

7. Wiring..................................................................................................................................26
7.1 Installation Notes ..................................................................................................................... 26
7.2 Ground Sizing .......................................................................................................................... 27
7.3 AC Feeder Protection/Sizing.................................................................................................... 27
7.4 AC Wiring ................................................................................................................................. 27
7.5 DC Wiring................................................................................................................................. 28
7.6 System and Battery Connections............................................................................................. 28
7.7 Chassis Ground and Return Bus Bar Connections.................................................................. 29
7.8 Distribution Cabling.................................................................................................................. 30
7.9 Alarm and Signal Connections................................................................................................. 31
7.10 Signal Wiring Connections for Controller ............................................................................... 31
7.11 CAN Serial Ports .................................................................................................................... 33
7.12 Network Connection and Remote Communications via Controller ........................................ 33
8. System Startup ...................................................................................................................34
8.1 Check System Connections..................................................................................................... 34
8.2 Verify AC Input and Power Up Rectier Shelf .......................................................................... 34
8.3 Check Battery Polarity and Connect the Batteries................................................................... 34
8.4 Controller Reset ....................................................................................................................... 34
8.5 LVD Control.............................................................................................................................. 35
9. Rectier Modes and Factory Defaults.................................................................................36
9.1 Rectier Modes ........................................................................................................................ 36
9.2 Factory Ranges and Defaults .................................................................................................. 37
10. Maintenance .....................................................................................................................38
10.1 Rectiers ................................................................................................................................ 38
10.2 Batteries................................................................................................................................. 38
10.3 Troubleshooting ..................................................................................................................... 39
11. Warranty Statement and Service Information ...................................................................40
12. Acronyms and Denitions .................................................................................................41
13. Certication.......................................................................................................................42

List of Figures
Figure 1 — Front view of the CXPS-E101 48V 225A........................................................................ 7
Figure 2 — CXPS-E101 100A Conguration .................................................................................... 8
Figure 3 — CXPS-E101 225A Conguration .................................................................................... 8
Figure 4 — CXPS-E101 225A (CXCM1 HP) Conguration .............................................................. 8
Figure 5 — Front Panel Status Indicators........................................................................................11
Figure 6 — CXDM-E1 Rear Output Connections ............................................................................11
Figure 7 — LVBD Override Switch (front cover removed) .............................................................. 12
Figure 8 — CXCM1+ Controller Front Panel .................................................................................. 13
Figure 9 — CXCM1 HP Controller Front Panel .............................................................................. 15
Figure 10 — In-Shelf Controller Dashboard Screens ..................................................................... 15
Figure 11 — In-Shelf Controller Full Menu...................................................................................... 16
Figure 12 — In-Shelf Controller Buttons: Vertical Mount ................................................................ 16
Figure 13 — In-Shelf Controller Buttons: Horizontal Mount............................................................ 16
Figure 14 — Rectier Front Panel .................................................................................................. 17
Figure 15 — Breaker Installation .................................................................................................... 23
Figure 16 — Breaker Removal Tools .............................................................................................. 23
Figure 17 — Ground and Return Busbar Connections ................................................................... 29
Figure 18 — Battery / Rectier Bus Bar Connections..................................................................... 29
Figure 19 — Battery, Load, and Return Connection Locations....................................................... 30
Figure 20 — Alarm and Signal Connections ................................................................................... 31
Figure 21 — Relay Connections ..................................................................................................... 31
Figure 22 — Digital Input Connection Method ................................................................................ 32
Figure 23 — LVD LED Status Indicators......................................................................................... 35

50540569-J0 Rev F
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 reference.
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 a󰀨ect 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
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.
WARNING!
This system is designed to be installed in a restricted access location that is inacces-
sible to the general public.

0540569-J0 Rev F
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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.

70540569-J0 Rev F
2. Introduction
2.1 Scope of the Manual
This manual covers the features and installation of the Alpha Technologies CXPS-E101 series 100A and 225A 48Vdc
power systems.
In addition to this manual, the following documents may be included in the documentation package that ships with
the CXPS-E101:
• 0350058-J0 Cordex HP Controller Software Manual
2.2 Product Overview
The CXPS-E101 series power systems are complete integrated 48Vdc power systems available in either 100A or
225A capacities. Each system uses the advanced Cordex CXCM1 controller and HP 48V 1.2kW rectifier modules.
The CXDM-E1 1RU 225A distribution panel provides front access for DC distribution circuit breakers.
Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated and
isolated DC output from the AC mains. The rectifier input accepts a wide range of input voltages, allowing the flex-
ibility to connect to supply mains rated 120/208/220/230/240/277 Vac, 50/60 Hz. The system has de-rated output
below 176Vac input. See specifications in the next section.
The rectifier power modules are “hot swappable” meaning they can be inserted or removed from the shelf without
cutting power to or from the system or the load. Rectifier modules are not included with the base system, but may be
purchased along with the system at the time of ordering, or added after the shelf has been installed. The shelf rectifier
system includes the Alpha Cordex CXCM1 modular controller.
This system uses the controller modular version, which is factory installed on the Cordex rectifier system shelf.
The CXCM1 controller allows the user to configure, monitor and control the entire DC power system locally or re-
motely via a web browser. Features of the unit include temperature compensation, auto equalization, remote access,
e-mail alarm notification, battery diagnostics, as well as web server and SNMP support for configuration and monitor-
ing.
Details of the controller operation are provided in the software manual.
Figure 1 — Front view of the CXPS-E101 48V 225A

0540569-J0 Rev F
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2.3 System Configurations
The following configurations are currently available for the CXPS-E101 power system. For more ordering information,
refer to the CXPS-E101 Ordering Guide on the Alpha website.
Table A — Conguration
CXPS-E101 Conguration Table
Rack Size Controller Current
Rating
Rectier
Capacity
Load
Breakers
Battery
Breakers
Shunt LVBD Height
19"/ 23" CXCM1+ 100A 4x 1.2kW
(1 shelves)
10 2 250A 225A 2 RU
19"/ 23" CXCM1+ 225A 9x 1.2kW
(2 shelves)
10 2 250A 225A 3 RU
19"/ 23" CXCM1 HP 225A 9x 1.2kW
(2 shelves)
10 2 200A 225A 3 RU
Rectier modules, DC distribution breakers, temperature probes and AC input cables are not included in the basic conguration.
• CXDM-E1 high density 1U 225A
distribution center
• Cordex modular system controller
(CXCM1+)
• One Cordex HP 48-1.2kW rectifier
shelf (four positions total)
• Kydex rear cover
• User switchable 19" rack mount
bracket for center mount
• 19" to 23" rack mount adaptors
2.3.1 100A Configuration - with CXCM1+ Controller (0540569-001)
• CXDM-E1 high density 1U 225A
distribution center
• Cordex modular system controller
(CXCM1+)
• Two (2) Cordex HP 48-1.2kW rectifier
shelves (nine positions total)
• Kydex rear cover
• User switchable 19" rack mount
bracket for center mount
• 19" to 23" rack mount adaptors
2.3.2 225A Configuration - with CXCM1+ Controller (0540570-001)
• CXDM-E1 high density 1U 225A
distribution center
• Cordex modular system controller
(CXCM1 HP)
• Two (2) Cordex HP 48-1.2kW rectifier
shelves (nine positions total)
• Kydex rear cover
• User switchable 19" rack mount
bracket for center mount
• 19" to 23" rack mount adaptors
2.3.3 225A Configuration - with CXCM1 HP Controller (0540570-401)
Figure 2 — CXPS-E101 100A Configuration
Figure 3 — CXPS-E101 225A Configuration
Figure 4 — CXPS-E101 225A (CXCM1 HP) Configuration