Alpha Cordex HP CXRF 48-3.0kW User manual

Cordex HP 2.4kW / 3.0kW
Switched Mode Rectier System
Models:
Cordex®HP CXRF 48-3.0kW
Cordex®HP CXRF 48-2.4kW
User Guide ID: 0100037-J0
E󰀨ective:05/2021
Read this manual carefully.
Learn how to protect your equipment from damage and fully understand its functions.

Cordex® HP 3.0kW switched mode rectier system
Shelf models: 19 inch 1RU universal mount 12,000W
23 inch 1RU universal mount 15,000W
Cordex® HP 2.4kW switched mode rectier system
Shelf models: 19 inch 1RU universal mount 9,600/12,000W
23 inch 1RU universal mount 12,000/15,000W
Copyright
Copyright © 2021 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 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 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 operated in an unapproved
manner, or improperly maintained.
Photographs contained in this manual are for illustrative purposes only. These photographs
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
For technical support, contact Alpha Technologies:
Canada and US: 1.888.462.7487
International: +1.604.436.5547
Email: [email protected]

Contents
1. Safety..............................................................................................4
1.1 Safety symbols........................................................................................................................... 4
1.2 General safety............................................................................................................................ 4
1.3 Mechanical safety...................................................................................................................... 5
1.4 Electrical safety.......................................................................................................................... 5
1.5 Battery safety............................................................................................................................. 5
2. Introduction.....................................................................................6
2.1 Scope of the manual.................................................................................................................. 6
2.2 Product overview ....................................................................................................................... 6
2.3 Part numbers ............................................................................................................................. 7
 ..................................................................................8
 .......................................................................................................... 8
 .........................................................................................................11
4. Features........................................................................................13
 ........................................................................................................ 13
 ........................................................................................................ 18
5. Inspection......................................................................................22
5.1 Packing materials..................................................................................................................... 22
5.2 Check for damage.................................................................................................................... 22
5.3 General receipt of shipment..................................................................................................... 22
6. Installation.....................................................................................23
6.1 Installation overview................................................................................................................. 23
6.2 Safety precautions................................................................................................................... 23
6.3 Installation tools....................................................................................................................... 23
6.4 Assembly and mounting........................................................................................................... 24
6.5 DC output connections - bulk distribution ................................................................................ 25
6.6 AC wiring 23 inch shelf............................................................................................................. 28
6.7 AC wiring 19 inch shelf............................................................................................................. 29
6.8 Communication cabling (optional)............................................................................................ 30

6.9 System startup......................................................................................................................... 33
7. Wiring............................................................................................34
7.1 Installation notes...................................................................................................................... 34
7.2 Calculating output wire size requirements............................................................................... 34
7.3 Grounding................................................................................................................................ 35
 .............................................36
  ........................................................................................................................ 36
8.2 Factory ranges and defaults .................................................................................................... 37
9. Maintenance .................................................................................38
  ...................................................... 38
  .................................................................. 39
9.3 Fan replacement...................................................................................................................... 39
10. Troubleshooting ..........................................................................41
  ............................................................42
12. Warranty statement and service information ..............................43
12.1 Technical support................................................................................................................... 43
12.2 Warranty statement................................................................................................................ 43
12.3 Product warranty.................................................................................................................... 43
12.4 Battery warranty..................................................................................................................... 43
12.5 Warranty claims ..................................................................................................................... 43
12.6 Service information................................................................................................................ 43
 .................................................................................44

0100037-J0 Rev D
4
User GuideCordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
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. 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
symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
󰀨
equipment or installation procedures.
NOTE
A NOTE provides additional information to help complete a specic task or procedure. Notes
are designated with a check mark, 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 inaccessible to the
general public.
Ce système est conçu pour être installé dans un endroit à accès restreint inaccessible au grand
public.
WARNING!
This equipment is not suitable for use in locations where children are likely to be present.
Cet équipement ne convient pas pour une utilisation dans des lieux ou des enfants sont
susceptibles d’être présents.

50100037-J0 Rev D
User Guide Cordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
1.4 Electrical safety
WARNING!
WARNING!
WARNING!
Before working with any live battery or power system, follow these precautions:
• Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces.
• Wear safety glasses with side shields at all times during the installation.
• Use OSHA (or international equivalent) 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 installation 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 277Vac nominal. 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 (or international equivalent) 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 explode.
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 rectiers
and batteries, though not dangerous in voltage, has a high short-circuit current capacity that
may cause severe burns and electrical arcing.
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.

0100037-J0 Rev D
6
User GuideCordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
2. Introduction
2.1 Scope of the manual
This manual explains the installation, interconnection, and operation of:
• 
• 
2.2 Product overview

connections for AC inputs, DC output, and system communications. The wide AC input operating range for global
installations and wide operating temperature ranges for installation in uncontrolled environments along with high
󰀩


1RU shelf system. Industry leading power density (35W/in3) yields more space for revenue generating equipment.

power to or from the system or the load. Additional power modules can be included with the system at the time of
ordering or added after the shelf has been installed.


includes temperature compensation, auto equalization, remote access, dial out on alarm, battery diagnostics,

provided in the current version of the related software manual.
External system controller models communicate with the shelf via RJ12 shelf connectors. In a power system, up

featuring touch screen, color LCD display with front Ethernet and USB connectors, is available as a panel mount

Shelf ID location technology is built into the Cordex HP 3.0kW rectier. This feature is capable of remotely

service interruption or when a unit has failed.
  Cordex HP 19 inch rectifier shelf

70100037-J0 Rev D
User Guide Cordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
2.3 Part numbers
The product, options, and accessories can be ordered by using the part numbers in the following tables.
2.3.1 
Description Part numbers
23 inch 1RU universal mount 15000W shelf*
• bulk power for external distribution
• 
0300216-001 (shelf/slot ID supported)
19 inch 1RU universal mount 12000W shelf*
• bulk power for external distribution
• 
0300228-001 (shelf/slot ID supported)
 0100037-001
Fan assembly replacement 7400732-001
Module blank 7400424-001
Rear DC output 19 inch shelf cover 0370250-001
Rear DC output 23 inch shelf cover 0370250-002

2.3.2 
Description Part number
23 inch 1RU universal mount 12000/15000W shelf*
• bulk power for external distribution
• 
0300057-001
19 inch 1RU universal mount 9600/12000W shelf*
• bulk power for external distribution
• 
0300040-001
19 inch 1RU universal mount, 4 × 2.4kW/3.0kW outputs
• 
• 
0300040-002
 0100003-001
Fan assembly replacement 7400374-001
Module blank 7400424-001
Rear DC output 19 inch shelf cover 0370250-001
Rear DC output 23 inch shelf cover 0370250-002


0100037-J0 Rev D
8
User GuideCordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
3. Specifications
3.1 
Table A — Cordex 3.0kW rectier specications
Electrical
Input specications
Nominal input 208 to 277Vac
Full power 187 to 300Vac
Input operational 90 to 300Vac
Input extended high 277 to 300Vac reduced input PF
Input extended low 90 to187Vac derate linearly to 1200W
Input frequency 45 to 65Hz
Input nominal 15.5A at 208 to 277Vac
Input maximum 16.5A at 185Vac
Power factor 
Inrush current 
Start-up ready times <5 seconds
Start-up delay Programmable up to 120 seconds
Soft start User adjustable to at least 5 seconds
Protection 10kA interrupting in L and N wires
THD current 
Input leakage current 
Output specications
Output voltage 42 to 58Vdc
Maximum power 3000W
Output current 55.5A at 54Vdc
Maximum output current 62.5A at 48Vdc
Holdup time 
Characteristics
E󰀩ciency 

Acoustic noise <55dBa at 1m (3ft) 30°C (86°F)
Static load regulation 
Dynamic load regulation
(40%-90%, 90%-40%)

Static line regulation 
Temperature stability 
Time stability 
Electrical noise (nominal voltages)
Voice band <53dBrnc
Wide band 10kHz to 10MHz <260mVrms

90100037-J0 Rev D
User Guide Cordex HP 2.4kW / 3.0kW Modular Switched Mode Rectier
Wide band 10kHz to 100MHz <180mVpk-pk
Reliability
MTBF 623,860 hours
Telcordia SR-332 Issue 3
Method 1 Case 3, Parts Count Method, Quality Level II

(Remarks)
• 
stress. However, the operating point and temperature of selected critical components
was measured and included in the model for improved accuracy.
• All components are assumed to be necessary for operation of the product.
• Failures are expected to have an exponential distribution during the useful life period of
the product.
• The MTBF calculation does not include batteries, software, or mechanical parts.
Mechanical
Dimensions H × W × D 41mm × 104mm × 333mm (1.6in × 4.1in × 13.1in)
Weight 1.76 kg (3.9 lbs)
Environmental
Temperature
Operating full power –40°C to 55°C (–40°F to 131°F)
Extended 55°C to 75°C (131°F to 167°F) derate to 600W
Storage –40°C to 85°C (–40°F to 185°F)
Characteristics
Relative humidity 
Heat dissipation 
Elevation –500m to 3000m (–1640ft to 9842ft)
3.1.1 
23 inch 1RU universal mount 15,000W shelf P/N 0300216-001 (shelf/slot ID supported)
Number of rectiers 
Nominal AC input current
(two modules per feed) 120Vac; 29A (per feed); 50/60Hz
208 to 277Vac; 31-24A (per feed); 50/60Hz
Recommended input feeder breakers
(three feeds per shelf)


Recommended AC input wire size 40A: 8 AWG line; 10 AWG protective earth
20A: 12 AWG line; 14 AWG protective earth
Shelf output power 15kW maximum
Distribution Bulk power for external distribution
Dimensions H × W × D 44mm × 537mm × 420mm (1.75in × 21.1in × 16.5in)
Weight 5.7kg (12.6lbs)