Alpha Technologies CXPS-E3 19 Quick start guide

Technical Guide: 9400016-J0
Effective: 05/2019
CXPS-E3 200A - 400A
Power System
Alpha Technologies Ltd.

CXPS-E3 Power System
For technical support, contact Alpha Technologies:
Canada and USA: 1-888-462-7487
International: [phone]
Copyright
Copyright © 2019 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 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:

39400016-J0 Rev D
Table of Contents
1. Safety....................................................................................................................................6
1.1 Safety Symbols .......................................................................................................................... 6
1.2 General Warning and Cautions.................................................................................................. 6
1.3 Electrical Safety ......................................................................................................................... 7
1.4 Battery Safety ............................................................................................................................ 7
2. Introduction ...........................................................................................................................8
2.1 Scope of the Manual .................................................................................................................. 8
2.2 Product Overview....................................................................................................................... 8
2.3 System Congurations............................................................................................................... 9
3. Specications......................................................................................................................11
4. Features..............................................................................................................................12
4.1 Seismic Racks ......................................................................................................................... 12
4.2 Distribution Centers ................................................................................................................. 12
4.3 Front Panel with a CXC HP Controller..................................................................................... 14
4.4 L-ADIO ..................................................................................................................................... 15
4.5 2.4kW Rectier......................................................................................................................... 17
4.6 4.0kW Rectier......................................................................................................................... 17
4.7 LVD Override ........................................................................................................................... 18
4.8 Integrated Battery Trays........................................................................................................... 20
4.9 Battery Landing Busbar Kit ...................................................................................................... 20
5. Inspection............................................................................................................................21
5.1 Packing Materials..................................................................................................................... 21
5.2 Check for Damage ................................................................................................................... 21
5.3 General Receipt of Shipment................................................................................................... 21
6. Installation...........................................................................................................................22
6.1 Safety Precautions................................................................................................................... 22
6.2 Tools Required ......................................................................................................................... 22
6.3 Installation of External Batteries .............................................................................................. 22
6.4 Battery Maintenance Report .................................................................................................... 24

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6.5 Power System Assembly and Mounting................................................................................... 25
6.6 Breaker Installation .................................................................................................................. 27
7. Wiring..................................................................................................................................28
7.1 Installation Notes ..................................................................................................................... 28
7.2 Grounding ................................................................................................................................ 29
7.3 AC Wiring ................................................................................................................................. 32
7.4 DC Wiring................................................................................................................................. 33
7.5 Distribution Cabling.................................................................................................................. 34
7.6 Alarm and Signal Connection................................................................................................... 35
7.7 Network and Remote Communication ..................................................................................... 36
7.8 Connecting Battery Temperature Probes................................................................................. 36
7.9 High Capacity Breaker Alarm and Shunt Wiring ...................................................................... 37
7.10 Signal Wiring.......................................................................................................................... 37
8. System Startup ...................................................................................................................38
9. Maintenance .......................................................................................................................40
9.1 LVD Override Operation........................................................................................................... 41
10. Acronyms and Denitions .................................................................................................42
11. Warranty and Service Information.....................................................................................43
11.1 Technical Support................................................................................................................... 43
11.2 Warranty Statement ............................................................................................................... 43
11.3 Limited Hardware Warranty.................................................................................................... 43
11.4 Battery Warranty .................................................................................................................... 43
11.5 Warranty Claims..................................................................................................................... 43
11.6 Service Centers...................................................................................................................... 43
12. Certication.......................................................................................................................44

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List of Figures
Figure 1 — CXPS-E3 System........................................................................................................... 8
Figure 2 — 19" CXPS-E3 with 48-2.4kW Rectiers.......................................................................... 9
Figure 3 — 23" CXPS-E3 with 48-2.4kW Rectiers.......................................................................... 9
Figure 4 — 19" CXPS-E3 with 48-4.0kW Rectiers........................................................................ 10
Figure 5 — 23" CXPS-E3 with 48-4.0kW Rectiers........................................................................ 10
Figure 6 — Front Panel w/ L-ADIO and CXC HP Controller........................................................... 14
Figure 7 — CXC HP Controller ....................................................................................................... 14
Figure 8 — CXC HP Controller Touchscreen Display..................................................................... 15
Figure 9 — L-ADIO I/O Peripheral .................................................................................................. 16
Figure 10 — Cordex HP 2.4k Rectier Front Panel LEDs .............................................................. 17
Figure 11 — Cordex HP 4.0k Rectier Front Panel LEDs............................................................... 17
Figure 12 — LVD Override.............................................................................................................. 18
Figure 13 — LVD Override Interface............................................................................................... 18
Figure 14 — LVD Override Connections......................................................................................... 19
Figure 15 — Integrated Battery Tray............................................................................................... 20
Figure 16 — Battery Landing Busbar Kit ........................................................................................ 20
Figure 17 — Rack Mounting Details (top view), Welded Rack ....................................................... 25
Figure 18 — Rack Mounting Details (top view), Bolted Rack ......................................................... 26
Figure 19 — Breaker Installation .................................................................................................... 27
Figure 20 — Connecting the Frame Ground to the CXPS-E3 ........................................................ 30
Figure 21 — Connecting the Frame Ground to Overhead Trays .................................................... 30
Figure 22 — AC Input and Ground for 23" Shelf............................................................................. 32
Figure 23 — Shelf AC Connection (3-phase, 3-wire shown with rear cover removed)................... 33
Figure 24 — Alarm (Relay) Connections ........................................................................................ 35
Figure 25 — Digital Input Connection Method ................................................................................ 35
Figure 26 — Battery Temperature Probes ...................................................................................... 36
Figure 27 — Battery Temperature Probes—Battery Bay ................................................................ 36
Figure 28 — Relay Connections, Not Energized State................................................................... 37
Figure 29 — Alarm Relay Pinouts................................................................................................... 37

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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. 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.
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.
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
» Read and follow all instructions included in this manual.
» Only trained personnel are qualified to install or replace this equipment and its components.
» Use proper lifting techniques whenever handling equipment, parts, or batteries.

79400016-J0 Rev D
1.3 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.
1.4 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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2. Introduction
2.1 Scope of the Manual
This manual covers the features, options, installation and startup of Alpha Technologies CXPS-E3 power system.
Images contained in this document are for illustrative purposes only and may not exactly match your installation. To
assist with installation reference may be made to the drawings at the rear of this manual.
In addition to this manual, the following documents may be included in the documentation package that ships with
the CXPS-E3:
• Cordex HP Controller (CXC HP) Software manual: 0350058-J0
• Cordex HP Controller and I/O Peripherals Hardware manual: 0180036-J0
• Cordex 48-2.4 kW Rectifier and Shelf manual: 0300040-J0
• Cordex 48-4 kW Rectifier and Shelf manual: 9400000-J0
2.2 Product Overview
The CXPS-E3 uses high-density rectifiers, a front access distribution center and the advanced CXC HP controller.
The E3 is the ideal solution for small to medium-sized 48Vdc applications, providing up to 400 Amps of output cur-
rent. With universal 19/23" mounting, high temperature operation and high power density, it is the perfect solution
for a wide variety of installation scenarios including those in harsh, outdoor environments. The distribution center
provides up to 26 load breaker positions, integrated shunt and LVD. All distribution connections and controller I/O
contacts are front accessible.
The CXC-HP controller includes a touch screen GUI for simple and convenient local setup. A built-in web server
provides alternate setup via local or remote IP access, using a standard internet browser. The E3 can be easily
integrated into customer-provided relay racks or enclosures, or can be ordered factory installed into various Alpha relay
rack configurations, including systems with pre-wired battery trays.
• Integrated 48V, 400A power system with front access distribution
• Industry leading power system density
• 400A, 26 distribution positions in 5RU
• Advanced CXC-HP controller with touch screen display for full local control
• High temperature rated design for harsh outdoor applications
• Wide range AC input for flexible worldwide deployment
Figure 1 — CXPS-E3 System

99400016-J0 Rev D
2.3 System Configurations
The following four configurations are currently available for the CXPS-E3 power system. For more ordering informa-
tion, refer to the CXPS-E3 Ordering Guide on the Alpha website.
Table A — CXPS-E3 Conguration
Rack Size Controller Expanded
I/O
Current
Rating
Rectier
Capacity
Load
Breakers
Battery
Breakers
Shunt LVD
(Optional)
Height
19" CXC HP L-ADIO 400A 8x 2.4kW
(2 shelves)
21 0 Load No 5 RU
16 5 Battery LVBD 5 RU
23" CXC HP L-ADIO 400A 10x 2.4kW
(2 shelves)
26 0 Load No 5 RU
21 5 Battery LVBD 5 RU
19" CXC HP L-ADIO 400A 5x 4kW
(1 Shelf)
21 0 Load No 7 RU
16 5 Battery LVBD 7 RU
23" CXC HP L-ADIO 400A 6x 4kW
(1 Shelf)
26 0 Load No 7 RU
21 5 Battery LVBD 7 RU
2.3.1 CXPS-E3 19" Systems with 48-2.4kW Rectifiers
• Rated for 400A with two 2.4kW shelves
• 5RU with two 2.4kW shelves
• 21 load breakers with load shunt or 16 load and 5 battery breakers with battery shunt
• CXC-HP controller
• L-ADIO module with extensive I/O capability
• Option for LVBD for battery breaker configuration
2.3.2 CXPS-E3 23" Systems with 48-2.4kW Rectifiers
• Rated for 400A with two 2.4kW shelves
• 5RU with two 2.4kW shelves
• 26 load breakers with load shunt or 21 load and 5 battery breakers with battery shunt
• CXC-HP controller
• L-ADIO module with extensive I/O capability
• Option for LVBD for battery breaker configuration
Figure 3 — 23" CXPS-E3 with 48-2.4kW Rectifiers
Figure 2 — 19" CXPS-E3 with 48-2.4kW Rectifiers