Alpha Technologies Cordex HP 48-12kW/480 User manual

Technical Guide: 0100020-J0
Effective:03/2019
Cordex HP 48-12kW/480
Modular Switched Mode
Three-Phase Rectifier
Alpha Technologies Ltd.

Cordex HP 48-12kW/480
Modular Switched Mode Three-Phase Rectier
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 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:

0100020-J0 Rev D2
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 Part Numbers and List Options.................................................................................................. 8
3. Specications........................................................................................................................9
3.1 Power Derating vs Ambient Temperature .................................................................................11
3.2 Power Derating vs Input Voltage...............................................................................................11
4. Rectier Features................................................................................................................12
4.1 Front Panel LEDs..................................................................................................................... 12
4.2 Rectier Rear Panel................................................................................................................. 14
4.3 True Module Fail Alarm ............................................................................................................ 14
4.4 Heat Dissipation....................................................................................................................... 14
4.5 Over Temperature Protection................................................................................................... 14
4.6 AC Inrush/Transient Suppression ............................................................................................ 14
4.7 Soft Start .................................................................................................................................. 14
4.8 Start Delay ............................................................................................................................... 14
4.9 Current Limit/Short Circuit Protection ...................................................................................... 15
4.10 Power Limiting ....................................................................................................................... 15
4.11 Over Voltage Protection (OVP) .............................................................................................. 15
5. Cordex HP Controller (CXC HP).........................................................................................16
5.1 Controller Features .................................................................................................................. 16
5.2 External Peripherals................................................................................................................. 17
6. Inspection............................................................................................................................19

30100020-J0 Rev D
6.1 Packing Materials..................................................................................................................... 19
6.2 Check for Damage ................................................................................................................... 19
6.3 General Receipt of Shipment................................................................................................... 19
7. Installation...........................................................................................................................20
7.1 Safety Precautions................................................................................................................... 20
7.2 Tools Required ......................................................................................................................... 20
7.3 Power System Assembly and Mounting................................................................................... 21
8. Wiring..................................................................................................................................22
8.1 Grounding ................................................................................................................................ 22
8.2 AC Feeder Protection/Sizing.................................................................................................... 22
8.3 AC Input Connections .............................................................................................................. 23
8.4 DC Output Connections ........................................................................................................... 23
8.5 CAN Serial Ports (Rectier Shelf) ............................................................................................ 24
8.6 Shelf ID Connection ................................................................................................................. 25
8.7 Signal Wiring Connections to L-ADIO Board ........................................................................... 26
9. System Startup ...................................................................................................................28
9.1 Check System Connections..................................................................................................... 28
9.2 Verify AC and Power the Rectier Shelf................................................................................... 28
9.3 Triple Check Battery Polarity and Connections........................................................................ 28
9.4 CXC HP Reset ......................................................................................................................... 28
9.5 Rectier Modes ........................................................................................................................ 29
9.6 Factory Ranges and Defaults .................................................................................................. 30
10. Maintenance .....................................................................................................................31
10.2 Spares.................................................................................................................................... 31
10.3 Replacing a Rectier Module ................................................................................................. 32
10.4 Fan Replacement................................................................................................................... 33
10.5 MOV Replacement................................................................................................................. 34
11. Acronyms and Denitions..................................................................................................36
12. Warranty and Service Information ....................................................................................37
13. Certication.......................................................................................................................38

0100020-J0 Rev D4
List of Figures
Figure 1 — Cordex 48-12kW/480 .................................................................................................... 7
Figure 2 — Power Derating vs Ambient Temperature......................................................................11
Figure 3 — Power Derating vs Input Voltage...................................................................................11
Figure 4 — 12kW Rectier Front Panel LEDs ................................................................................ 12
Figure 5 — Cordex CXC HP Controller........................................................................................... 16
Figure 6 — LCD Color Touchscreen Display .................................................................................. 17
Figure 7 — L-ADIO I/O Peripheral .................................................................................................. 17
Figure 8 — Shelf/Bay ID ................................................................................................................. 18
Figure 9 — CAN Port Connections ................................................................................................. 24
Figure 10 — Relay Connections in the De-energized State ........................................................... 26
Figure 11 — Digital Input Connection Method ................................................................................ 26

50100020-J0 Rev D
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.
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. 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
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 a󰀨ect the
placement of equipment and /or installation procedures.
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.

0100020-J0 Rev D6
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
480Vac. Ensure that the utility power is disconnected and locked out before performing any installation or
removal procedure.
• 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.
1.5 Battery Safety
• Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all
metallic 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 batteries.
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 bat-
tery 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.

70100020-J0 Rev D
2. Introduction
2.1 Scope of the Manual
This instruction manual explains the installation, interconnection, and operation of the Alpha Cordex HP 48-
12kW/480 modular switched mode rectifier systems.
2.2 Product Overview
Cordex High-Performance rectifiers make a proven, reliable platform even better, with significant advancements
in efficiency and performance. In a compact, fan-cooled design, Alpha's HP rectifiers open the possibility for
immediate OPEX/CAPEX savings, reducing total cost of ownership and impact on the environment, and are
usable under a wider range of applications.
The Cordex HP 48-12kW/480 is a perfect solution for various 48Vdc high capacity applications including Central
Office, MTSOs and Data Centers.
Cordex HP 48-12kW/480 is a true three-phase, three wire, 480 VAC input rectifier which meets the critical require-
ments of current high density telecommunications environments. It combines the latest DSP controlled power
conversion technology, to provide a flexible, efficient, and very highly reliable DC power source.
Local and remote setup, adjustment and control is a simple single-step process with CXC HP controllers. By
utilizing TCP/IP technology, complete configuration and monitoring of power equipment is possible through a
network web browser.
The CXC HP controller allows the user to configure, monitor and control the entire DC power system from its
touch screen display including temperature compensation, auto equalization, remote access, dial out on alarm,
battery diagnostics, as well as Web server and SNMP support for configuration and monitoring. Details of CXC
HP controller operation are provided in the current version software manual.
Figure 1 — Cordex 48-12kW/480

0100020-J0 Rev D8
2.3 Part Numbers and List Options
The product, options, and accessories can be ordered by using the part numbers in the following table.
Description List Option
Cordex 48-12kW rectier power module 0100020-001
Fan, spare for Cordex 48-12kW/480 5000064
MOV replacement assembly 7050308-001
Cordex 48-12kW/480V, 3 phase 23" shelf, ush or mid-
mounting
0300167-XXX
Module blank 5900550-002