Alpha DCX Series User manual

DCX™Series
Top Terminal Battery Disconnect System
Installation and Operation Manual
Effective: January 2021

2C048-699-30 R03, Rev. B (01/2021)
The following sections contain important safety information that must be followed during the installation and maintenance
of the equipment and batteries. Read all of the instructions before installing or operating the equipment, and save this
manual for future reference.
There may be multiple warnings associated with the call out. Example:
ATTENTION provides specic regulatory/code requirements that may a󰀨ect the placement of equipment and /or
installation procedures.
ATTENTION:
NOTICE provides additional information to help complete a specic task or procedure.
NOTICE:
ELECTRICAL HAZARD WARNING provides electrical safety information to PREVENT INJURY OR DEATH
to the technician or user.
WARNING! ELECTRICAL HAZARD
FUMES HAZARD WARNING provides fumes safety information to PREVENT INJURY OR DEATH to the
technician or user.
WARNING! FUMES HAZARD
FIRE HAZARD WARNING provides ammability safety information to PREVENT INJURY OR DEATH to the
technician or user.
WARNING! FIRE HAZARD
This WARNING provides safety information for both Electrical AND Fire Hazards
WARNING! ELECTRICAL & FIRE HAZARD
CAUTION provides safety information intended to PREVENT DAMAGE to material or equipment.
CAUTION!
GENERAL HAZARD WARNING provides safety information to PREVENT INJURY OR DEATH to the
technician or user.
WARNING! GENERAL HAZARD
Safety Notes
Alpha Technologies Services, Inc. considers customer safety and satisfaction its most important priority. To reduce the
risk of injury or death and to ensure continual safe operation of this product, certain information is presented di󰀨erently in
this manual. Alpha®tries to adhere to ANSI Z535 and encourages special attention and care to information presented in
the following manner:

3C048-699-30 R03, Rev. B (01/2021)
DCX™ Series
Top Terminal Battery Disconnect System
Installation and Operation Manual
C048-699-30 R03, Rev. B
E󰀨ective: January 2021
© 2021 by Alpha Technologies Services, Inc.
Disclaimer
Images contained in this manual are for illustrative purposes only. These images may not match your installation.
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, please contact Alpha Technologies Services, Inc. or your
nearest Alpha representative.
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 not consistent with its intended purpose or is
installed or operated in an unapproved manner or improperly maintained.
Contact Information
Sales information and customer service in USA
(7AM to 5PM, Pacic Time): 1 800 322 5742
Complete Technical Support in USA
(7AM to 5PM, Pacic Time or 24/7 emergency support): 1 800 863 3364
Sales information and Technical Support in Canada: 1 888 462 7487
Website: www.alpha.com

4C048-699-30 R03, Rev. B (01/2021)
Contents
1.0 Purpose and Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Product Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Circuit Breaker Trip Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Mounting Congurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Monitoring Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Installation Kit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Installation Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.1 Elevated Operating Ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.2 Reduced Air Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.3 Mechanical Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.4 Circuit Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.5 Reliable Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2.6 Disconnect Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Battery Top Terminal Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.1 Termination Bus Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3.2 Battery Top Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Chassis Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Battery Positive Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 EPO Emergency Power O󰀨 Switch Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.7 Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.8 Auxiliary Power Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.9 Electrical Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.10 Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.11 Safety Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.12 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.0 Product Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6.0 Models and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Appendix A: Mechanical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A.1 DCX Battery Disconnect Isometric View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A.2 DCX Battery Disconnect Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A.3 DCX Chassis Ground Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5C048-699-30 R03, Rev. B (01/2021)
1.01.0 Purpose and ApplicabilityPurpose and Applicability
This document covers the installation and operation of the DCX™Series top terminal battery disconnect system.
1.11.1 Product ModelProduct Model
This document applies to Alpha products in the following model congurations:
Table 1. DCX Model Congurations - Switch Only Versions (No Current Limiting)
DESCRIPTION PART NUMBER
400A DCX Battery Disconnect; -48VDC; w/shunt C016 -1001-10
600A DCX Battery Disconnect; -48VDC; w/shunt C016 -1003-10
800A DCX Battery Disconnect; -48VDC; w/shunt C016-1005-10
1000A DCX Battery Disconnect; -48VDC; w/shunt C016 -1007-10
1200A DCX Battery Disconnect; -48VDC; w/shunt C016 -1009 -10
Table 2. DCX Model Congurations - Magnetic Trip Versions
DESCRIPTION PART NUMBER
400A DCX Battery Disconnect; -48VDC; w/shunt C016 -198-10
600A DCX Battery Disconnect; -48VDC; w/shunt C016 -195-10
800A DCX Battery Disconnect; -48VDC; w/shunt C016-199-10
1000A DCX Battery Disconnect; -48VDC; w/shunt C016 -196 -10
1200A DCX Battery Disconnect; -48VDC; w/shunt C016-207-10
For a list of mounting kit and accessory part numbers, refer to Section 6 on Page 17.
2.02.0 Theory of OperationTheory of Operation
The DCX disconnect product family includes multiple amperage ratings and installation mounting schemes to provide a
DC or Battery source disconnect device for use in Telecom +24 or -48VDC systems as well as solar-alternate energy
or other DC applications. The primary application for the DCX system is to provide over-current protection for battery
sourced equipment and wiring. The secondary function is to provide a service disconnect in order to maintain batteries or
to shut down the battery source connection in an emergency.
2.12.1 Circuit Breaker Trip RatingsCircuit Breaker Trip Ratings
The DCX product family includes circuit breaker trip ratings of 400, 600, 800, 1000, and 1200A. The electrical
conguration allows for both positive and negative connected systems as factory congured options. The DCX system
includes a circuit breaker or switch, an internal input and output copper bus structure, a steel inner housing, a circuit
board, and a ame retardant plastic outer housing.
2.22.2 Mounting CongurationsMounting Congurations
Several di󰀨erent mounting bracket option kits provide battery top terminal mounting congurations for numerous battery
manufacturer's cell congurations.

6C048-699-30 R03, Rev. B (01/2021)
2.32.3 Monitoring OptionsMonitoring Options
The DCX battery disconnect system includes monitoring features
for local and remote status indication:
LED indicators “ON-LINE”, “OFF-LINE”, “ALARM/FAULT”, “EPO
TRIPPED” (see Figure 1). Alarm contacts: Form-C relay contacts
to provide breaker trip status.
yON-LINE: The battery string is connected – circuit
breaker/switch is ON.
yOFF-LINE: The battery string is disconnected – circuit
breaker/switch is OFF.
yALARM/FAULT or OPTION STATUS – provides
information for any installed option, such as the TRD
VRLA Battery Thermal Runaway Detection System
NO LIGHT: No option is installed
GREEN LIGHT: Option is installed and working normally
RED LIGHT: Option is in alarm (for more information,
refer to the installed option's manual)
yEPO TRIPPED – Emergency Power O󰀨 input is active.
This indicator is not persistent.
Figure 1. LED Indicators
3.03.0 Unpacking and InspectionUnpacking and Inspection
The DCX battery disconnect system is shipped in a box that includes protective inserts for the main DCX housing as well
as the mounting bracket component set and related hardware.
Inspect the outer box immediately after receipt as well as the contents to conrm that there is no shipping damage. Most
shipping carriers require notication within 24 hours of delivery of any shipping damage in order to cover the cost of the
damage via repair or replacement. It is the responsibility of the recipient to inspect the shipment immediately upon receipt.
Remove the DCX unit and related brackets and hardware and conrm that the components are present. Refer to the
mounting kit instruction sheet that comes with the shipment and is specic to the mounting kit option that was ordered to
conrm that all parts are present for installation.
The plastic ip-up front panel and the plastic housing of the DCX unit are not designed as structural components so be
careful to lay the unit on it’s side or back temporarily until it is mounted to the mounting bracket set to avoid damage.
Arrange the mounting bracket kit including hardware for preparation for installation at the install location.
3.13.1 Package ContentsPackage Contents
yDCX™ Series top terminal battery disconnect unit (Figure 2, A.)
yBattery mounting kit with hardware (ordered separately)
yMounting bracket(s) (Figure 2, B.)
yCopper battery termination bus (Figure 2, C)
4.04.0 InstallationInstallation
4.14.1 Installation Kit OptionsInstallation Kit Options
Refer to Section 6 on Page 15 for ordering information.
Battery top terminal mount installation kits for the DCX battery
disconnect system are available for the following battery manufacturers:
yEnerSys®
yC&D Technologies®
yGNB®
yEast Penn Manufacturing
Figure 2. Package Contents
A.
B.
C.

7C048-699-30 R03, Rev. B (01/2021)
4.24.2 Installation PreparationInstallation Preparation
THIS PRODUCT MUST BE INSTALLED WITHIN A RESTRICTED ACCESS LOCATION WHERE ACCESS
IS THROUGH THE USE OF A TOOL, LOCK AND KEY, OR OTHER MEANS OF SECURITY, AND IS
CONTROLLED BY THE AUTHORITY RESPONSIBLE FOR THE LOCATION. THIS PRODUCT MUST BE
INSTALLED AND MAINTAINED ONLY BY QUALIFIED TECHNICIANS.
NOTICE:
4.2.14.2.1 Elevated Operating AmbientElevated Operating Ambient
If you install the unit in a closed or multi-unit rack assembly, the operating ambient temperature of the rack environment
may be greater than room ambient. Therefore, take care to install the equipment in an environment compatible with the
maximum ambient temperature (TMA).
4.2.24.2.2 Reduced Air FlowReduced Air Flow
Installation of the equipment in a rack should be such that the amount of air ow required for safe operation of the
equipment is not compromised.
4.2.34.2.3 Mechanical LoadingMechanical Loading
Mounting of the equipment in the rack should be such that a hazardous condition is not achieved due to uneven
mechanical loading.
4.2.44.2.4 Circuit OverloadingCircuit Overloading
Give consideration to the connection of the equipment to the supply circuit and the e󰀨ect that overloading of the circuits
might have on overcurrent protection and supply wiring. Use appropriate consideration for equipment nameplate ratings
when addressing this concern.
4.2.54.2.5 Reliable EarthingReliable Earthing
Maintain reliable earthing of rack-mounted equipment. Pay particular attention to supply connections other than direct
connections to the branch circuit (e.g., use of power strips).
4.2.64.2.6 Disconnect DeviceDisconnect Device
A readily accessible disconnect device must be incorporated into the building installation wiring.

8C048-699-30 R03, Rev. B (01/2021)
4.34.3 Battery Top Terminal MountBattery Top Terminal Mount
4.3.14.3.1 Termination Bus AssemblyTermination Bus Assembly
ENSURE BATTERY STRING IS NOT COMPLETELY
CONNECTED IN SERIES PRIOR TO THE
INSTALLATION OF THE DCX UNIT FOR SAFETY
PURPOSES. DISCONNECT SEVERAL SERIES BUS
CONNECTIONS OF THE STRING TO ENSURE THE
TOP NEGATIVE TERMINAL IS NOT CONNECTED
TO THE REST OF THE STRING SO THAT THE
INSTALLATION WORK CAN BE DONE SAFELY
WITHOUT VOLTAGE PRESENT. ENSURE THAT
ALL THE PLASTIC CELL TERMINAL COVERS ARE
INSTALLED TO PREVENT ACCIDENTAL CONTACT OR
SHORT CIRCUIT OF THE STRING TERMINALS WITH
TOOLS ETC. DURING THIS INSTALLATION PROCESS.
CAUTION!
The DCX unit ships without the battery termination bus installed and
will require assembly. The termination bus hardware comes pre-
installed on the DCX and requires removal before terminal plate can
be installed. Follow the steps below for termination bus installation
instructions.
Step 1. Flip up the front hinged lid, then remove the lexan breaker
cover by removing the phillips-head screws as shown in Fig.
3.
Step 2. Remove the 3/8 in. socket head cap hardware from the
bottom of the circuit breaker as shown in Fig. 4.
Step 3. Remove the three pre-installed phillips-head screws from the
glastic isolators as shown in Fig. 5.
Step 4. Insert the termination plate into the slot located on the
bottom of the DCX battery disconnect chassis as shown in
Fig. 6.
Step 5. Reinstall the three phillips-head screws into the glastic
isolators from Step 3.
Step 6. Reinstall the 3/8 in. socket head cap hardware into bottom of
the circuit breaker from Step 2 (recommended torque value:
225 in-lbs). Ensure the ring terminal (blue wire) on the
furthest breaker pole to the right is secured between the 3/8
in. socket head cap screw hardware and the DCX
termination plate as shown in Figure 7.
Table 3. Termination Plate Torque Specications
TERMINATION
TYPE
HOLE/
STUD SIZE
RECOMMENDED TORQUE
VALUE
Threaded Insert 3/8 in. 18.75 ft·lbs
Step 7. Reinstall the lexan breaker cover from Step 1 by reinstalling
the phillips-head screws.
Step 8. Close the hinged lid.
Figure 3. Lexan breaker cover
Figure 4. 3/8 in. socket head hardware
Figure 5. Phillips head screws
Figure 6. Termination Bus
Figure 7. Reinstall socket head hardware

9C048-699-30 R03, Rev. B (01/2021)
4.3.24.3.2 Battery Top Mounting BracketsBattery Top Mounting Brackets
WARNING! ELECTRICAL HAZARD
MULTIPLE POWER SOURCES ARE PRESENT. ENSURE ALL INPUT POWER FEEDS ARE NOT
ENERGIZED BEFORE INSTALLING THEM. ELECTRICAL INSTALLATION SHOULD ONLY BE
PERFORMED BY QUALIFIED PERSONNEL WITH PROPER TOOLS AND PROTECTIVE SAFETY
EQUIPMENT.
MULTIPLE DCX MOUNTING KIT CONFIGURATIONS EXIST. THE ILLUSTRATIONS AND INSTRUCTIONS
DEPICTED MAY NOT ACCURATELY REFLECT YOUR SELECTED CONFIGURATION.
NOTICE:
DO NOT DRILL MOUNTING HOLES DIRECTLY ABOVE EACH BATTERY CELL – THE CELL WILL BE
PUNCTURED.
CAUTION!
The DCX Series chassis includes mounting provisions for mounting brackets to secure into place on top of the battery
stack. Note that the mounting location and terminal plate are congured for the -48VDC output terminals located on the
top battery of the battery string.
For C&D Technologies®, GNB®, and East Penn Manufacturing batteries, ensure that the battery bus bar kit included with
the battery is congured for the -48V output to be the center top battery for direct bolted connection to the DCX.
For EnerSys® batteries, ensure that the battery bus bar kit included with the battery is congured for the -48V output to
be the center top battery (3x8 stack congurations) or the rightmost top battery (4x6 stack congurations).
The DCX mounting brackets will require nger tight installation onto the DCX to properly allow marking for self-tapping
screw locations (EnerSys/C&D/GNB mounting bracket kits) or for 1/4 in. X 20 threaded insert locations found on the front
of mounting brackets (East Penn mounting bracket kits). Brackets will then require removal from the DCX so that they can
be secured into place onto the battery stack frame followed by reinstallation of the DCX.
Figure 8. DCX mounting bracket slots
Figure 9. DCX mounting bracket
NOTE: the mounting brackets for East Penn Manufacturing
batteries each have a 1/4 in. x 20 threaded insert installed
where the bracket seats inside of the cell module U-channel
that runs left to right on top of the cell module.
Step 1. Use the 3/8 in. bolts and washers included in the
hardware kit to install the left and right mounting
brackets via the slots in the underside of the DCX unit.
Tighten the two bolts per side nger tight for alignment
later. Refer to Figure 8 and 9.
Step 2. Position the DCX unit on top of the cell module over the
-48VDC battery terminals on the top battery of the
battery string. Carefully bolt the negative terminal posts
to the holes in the DCX termination plate nger tight
with the 1/4 in. x 20 bolts provided with the battery pack.
Adjust the 3/8 in. bolts on the DCX mounting brackets
to allow the DCX unit to adjust vertically via the bolt
slots in the brackets. Adjust the DCX unit up and down
to ensure that it is perpendicular to the battery module
and that the termination plate seats on the battery
terminals properly.

10 C048-699-30 R03, Rev. B (01/2021)
Step 3. Once the DCX unit is in it's nal position, mark the DCX
mounting bracket hole locations onto the battery stack frame top
rails (see Figure 10).
Step 4. Uninstall the termination plate from the battery terminals, then
uninstall the DCX mounting brackets from the DCX unit.
Step 5. Align the DCX mounting brackets with the marked locations from
Step 3 and secure into place by tightening the included self-
tapping screws (EnerSys/C&D/GNB battery kits, Figure 11) or by
tightening the included 1/4 in. hardware into the threaded inserts
of the mounting brackets (East Penn Manufacturing kits).
Step 6. Reinstall the DCX unit into position again as described in Step 2,
then tighten all hardware. See Table 4 for DCX mounting
bracket to DCX chassis torque specications.
NOTE: REFER TO BATTERY MANUFACTURER TORQUE
SPECIFICATIONS FOR TIGHTENING BATTERY
TERMINATION PLATE TO BATTERY TERMINAL POSTS
(FIGURE 12).
NOTICE:
Table 4. Mounting Bracket to DCX Chassis Torque Specications
TERMINATION
TYPE
HOLE/STUD
SIZE
RECOMMENDED
TORQUE VALUE
Threaded Insert 3/8 in. 50 in·lbs
Step 7. After mechanical mounting of DCX unit has been completed,
snap the two black plastic hole plugs into the access holes that
cover the 3/8 in. mounting bolts (see Figure 13)
4.44.4 Chassis GroundChassis Ground
DO NOT ENERGIZE THE DCX BATTERY
DISCONNECT SWITCH BEFORE CHASSIS GROUND
IS CONNECTED.
CAUTION!
Two chassis ground landings are located on the inside of the DCX
chassis (see Figure 14). Refer to mechanical drawing found in
Appendix A.3 for greater detail regarding grounding locations. A
minimum of #6 AWG chassis ground cable is required. IMPORTANT:
Grounding hardware not included. A properly-sized grounding
conductor must be installed per NEC (250.122).
Table 5. Chassis Ground Specications
TERMINATION
TYPE
HOLE/
STUD
SIZE
CENTER TO
CENTER
RECOMMENDED
TORQUE VALUE
Threaded Stud 1/4 in. 5/8 in. 5.83 ft·lbs
Step 1. Select the desired grounding location and break away the
associated knock-out points found on the clear plastic covers.
Step 2. Connect the ground cable with 1/4 in. hardware. Ensure heat
shrink and no-oxide compound are applied appropriately prior to
termination. Torque the fasteners to 5.83 ft·lbs (see Table 5).
Figure 10. Mark bracket locations
Figure 11. Secure brackets
Figure 12. Secure to cell terminals
Figure 13. Insert hole plugs
Figure 14. Chassis ground