Alpha CPH-144 User manual

CPH-144
Central Power Hub
User Guide ID: 0570257-J0
Eective:03/2022
Read this manual carefully.
Learn how to protect your equipment from damage and fully understand its functions.

CPH-144
Central Power Hub
Copyright notice
© 2022 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its aliates unless
otherwise noted. Subject to revisions without prior notice. E. & O.E.
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 EnerSys.
This document, the software it describes, and the information and know-how they contain constitute the
proprietary, confidential and valuable trade secret information of EnerSys, and may not be used for any
unauthorized purpose, or disclosed to others without the prior written permission of EnerSys.
The material contained in this document is for information only and is subject to change without notice. While
reasonable eorts have been made in the preparation of this document to assure its accuracy, EnerSys assumes
no liability resulting from errors or omissions in this document, or from the use of the information contained
herein. EnerSys reserves the right to make changes in the product design without reservation and without
notification to its users.
NOTICE
For the latest version of software, firmware, and product documentation, visit the Alpha®
website, www.alpha.com or www.alpha.ca.
NOTICE
Photographs contained in this document are for illustrative purposes only. These photographs
may not match your installation.
NOTICE
Operator is cautioned to review the drawings and illustrations contained in this document before
proceeding. If there are questions regarding the safe operation of this powering system, contact
Alpha Technologies Ltd. or your nearest Alpha® representative.
NOTICE
EnerSys 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.

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Contents
1. Safety......................................................................................................................... 5
1.1 Safety symbols..................................................................................................................................................................5
1.2 General warning and cautions..........................................................................................................................................5
1.3 Mechanical safety.............................................................................................................................................................6
1.4 Electrical safety.................................................................................................................................................................6
2. Overview.................................................................................................................... 7
3. Specifications ............................................................................................................ 8
4. Features..................................................................................................................... 9
4.1 Cordex® CXPS-E3 400A power system ............................................................................................................................9
4.2 Cordex® HP LPS36 up-converter......................................................................................................................................10
4.3 Cordex® CXC HP system controller .................................................................................................................................11
4.4 High voltage 50-pair protector panels ............................................................................................................................12
4.5 External AC loadcenter ...................................................................................................................................................12
4.6 48 Vdc heat exchanger....................................................................................................................................................13
5. Inspection ................................................................................................................ 14
5.1 Packing materials............................................................................................................................................................14
5.2 Returns for service ..........................................................................................................................................................14
5.3 Check for damage ...........................................................................................................................................................14
5.4 General receipt of shipment ...........................................................................................................................................14
5.5 Miscellaneous small parts..............................................................................................................................................14
6. Installation............................................................................................................... 15
6.1 Safety precautions ..........................................................................................................................................................15
6.2 Installation tools .............................................................................................................................................................15
6.3 Site selection ..................................................................................................................................................................15
6.4 Lifting ..............................................................................................................................................................................15
6.5 Mounting the enclosure..................................................................................................................................................16
7. Wiring...................................................................................................................... 18
7.1 Grounding the enclosure.................................................................................................................................................18
7.2 Internal wiring configurations of enclosure master ground bar .....................................................................................20

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7.3 Grounding system location .............................................................................................................................................21
7.4 Bonding OSP cable shield to the master ground bar......................................................................................................22
7.5 AC input wiring to the loadcenter...................................................................................................................................24
7.6 Wiring the HV DC output ................................................................................................................................................24
8. System startup ........................................................................................................ 28
8.1 Software..........................................................................................................................................................................29
9. Maintenance............................................................................................................ 30
9.1 Heat exchanger fan test procedure ................................................................................................................................31
9.2 Heat exchanger fan replacement procedure ..................................................................................................................32
10. Acronyms and definitions...................................................................................... 35

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Figures
Figure 1: CPH-144 interior ........................................................................................................................................................7
Figure 2: Cordex® CXPS-E3 400A power system.......................................................................................................................9
Figure 3: Cordex® HP LPS36 up-converter...............................................................................................................................10
Figure 4: Cordex® CXC HP system controller...........................................................................................................................11
Figure 5: High voltage 50-pair protector panels .....................................................................................................................12
Figure 6: External AC loadcenter.............................................................................................................................................12
Figure 7: 48 Vdc heat exchanger.............................................................................................................................................13
Figure 8: Pole mounting detail ................................................................................................................................................16
Figure 9: Ground mounting detail............................................................................................................................................17
Figure 10: CPH-144 combination meter and loadcenter grounding diagram..........................................................................18
Figure 11: CPH-144 with remote disconnect (<4 feet) grounding diagram.............................................................................19
Figure 12: CPH-144 with remote disconnect (>4 feet) grounding diagram.............................................................................20
Figure 13: Enclosure MGB with site ground ...........................................................................................................................21
Figure 14: Internal AC loadcenter utility connection ..............................................................................................................24
Figure 15: 3M Company MS2pair GBM connector pinout......................................................................................................24
Figure 16: 50-pair protector panel...........................................................................................................................................26
Figure 17: Enclosure alarm block wiring .................................................................................................................................27

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1. Safety
Save these instructions
This document 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 document before proceeding. If there are any questions regarding the safe installation or operation of this
product, contact Alpha Technologies Ltd. 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
symbols have been placed throughout this document. Where these symbols appear, use extra care and attention.
1.2 General warning and cautions
• Read and follow all instructions included in this document.
• Only trained personnel are qualified to install or replace this equipment and its components.
• Use proper lifting techniques whenever handling equipment, parts, or batteries.
CAUTION
Cautions indicate the potential for injury to personnel.
CAUTION
Risk of burns
A device in operation can reach temperature levels which could cause burns.
WARNING
Risk of serious injury or death
Equipment in operation poses a potential electrical hazard which could result in serious injury or
death to personnel. This hazard may continue even when power is disconnected.
WARNING
This system is designed to be installed in a restricted access location which is inaccessible to the
general public.
ATTENTION
The use of attention indicates specific regulatory or code requirements that may aect the
placement of equipment or installation procedures. Follow the prescribed procedures to avoid
equipment damage or service interruption.
GROUNDING
This symbol indicates the location or terminal intended for the connection to protective earth. An
enclosure that is not properly connected to protective earth presents an electrical hazard. Only a
licensed electrician can connect AC power and protective earth to the enclosure.
NOTICE
A notice provides additional information to help complete a specific task or procedure or general
information about the product.

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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 approved insulated hand tools. Do not rest tools on top of batteries.
• Do not work alone under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment. Input voltages can range
up to 240Vac.
• 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.
• The enclosure which contains the DC or AC power system along with customer installed radios must
remain locked at all times, except when authorized service personnel are present.
• Always assume electrical connections or conductors are live. Turn o all circuit breakers and double-
check with a voltmeter before performing installation or maintenance.
• Place a warning label on the utility panel to warn emergency personnel that a reserve battery source
is present which will power the loads in a power outage condition or if the AC disconnect breaker is
turned o.
• At high ambient temperature conditions, the internal temperature can be hot so use caution when
touching the equipment.
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.
1.4 Electrical safety
WARNING
Hazardous voltages are present at the input of power systems. The DC output from rectifiers,
though not dangerous in voltage, has a high short-circuit current capacity that can cause severe
burns and electrical arcing.
The DC output from converters is a potentially hazardous voltage. Do not touch the output connections
when under power. Ensure that power has been removed from the outputs before working on them.
WARNING
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.

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2. Overview
The Central Power Hub (CPH) is based on an SE41-2722 enclosure with a Cordex® CXPS-E3 400A power
system and a Cordex® HP LPS36 shelf to provide ±190 Vdc line powering channels from an AC utility
source. To better communicate the function and application of the system, marketing material (user guide,
data sheet, and website) will refer to the SE41-2722 enclosure as the CPH-144.
The CPH-144 is a Type 3R outdoor central power hub enclosure providing up to 144 ±190 Vdc line powering
channels from an AC utility power source. The CPH-144 utilizes remote line powering equipment as a method of
energizing remote devices using power delivered from a central source over copper cable.
The CPH-144 is configured as follows:
• SE41-2722 enclosure with heat exchanger AC loadcenter with main breaker and TVSS.
• Cordex® CXPS-E3 400A power system with Cordex® HP 2.4/3.0 kW rectifier shelves.
• Cordex® HP LPS36 up-converter shelves.
• Cordex® CXC HP system controller.
• High-voltage 50-pair protector panel.
Figure 1: CPH-144 interior
Thermal
management
System alarm
wiring block
Cordex® HP LPS36
up-converter
Fan tray
50-pair protector
panel
Bae
Cordex® CXPS-E3 power
system
48 Vdc heat exchanger
Enclosure master
ground bar
Four inch plinth (optional)

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3. Specifications
Electrical
Input voltage Nominal: 187 to 277 Vac
Operating: 187 to 310 Vac
Extended: 90 to 187 Vac (de-rated power)
187 to 277 Vac (single phase)
Input frequency 45 to 66 Hz
Power factor >98% (50 to 100% load)
THD <8% (50 to 100% load)
Eciency 90%
Output voltage ±190 Vdc
Output power 10.8 kW
Features
Protection • Pad-lockable door handle
• 40 kA surge suppression
• 50-pair protector panel for gas discharge tube modules
Mechanical
Dimensions H × W × D Footprint: 1041 mm × 686 mm × 559 mm (41 in. × 27 in. × 22 in.)
Enclosure: 1041 mm × 803 mm × 767 mm (41 in. × 31.6 in. × 30.2 in.)
Weight 193 kg (425 lb)
Mounting • Pole
• Ground (optional plinth)
Cooling 50 W/°C heat exchanger
Enclosure Aluminum, 5052-H32
Environmental
Temperature Operating: –40 to 46°C (–40 to 115°F)
Storage: –40 to 85°C (–40 to 185°F)
Relative humidity 0 to 95% non-condensing
Elevation –100 to 3000 m (–330 to 9840 ft)
Cabinet rating Type 3R
Acoustic noise < 65 dBA
Agency compliance
Safety¹ • CSA/UL 60950-1
• CSA/UL 60950-21
• CSA/UL 60950-22
¹ Only 0570228-101, 0570228-102, and 0570228-103 system part numbers are CSA/UL certified systems.
ATTENTION
Only use accessories (such as grommets or fittings) with the proper Type 3R rating or better
during field installation.

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4. Features
4.1 Cordex® CXPS-E3 400A power system
For more information, refer to the CXPS-E3 400A power system documentation.
The Cordex® CXPS-E3 400A power system uses high-density rectifier shelves, a front access distribution panel,
and the advanced Cordex® CXC HP system controller. The CXPS-E3 power system is the ideal solution for small
to medium-sized 48 Vdc applications, providing up to 400 amps of output current. With universal 19-/23-inch
mounting, high temperature operation, and high power density, it is the perfect solution for a wide variety of
installation applications including those in harsh outdoor environments. The distribution panel provides up to
21 load breaker positions and five battery breaker positions, integrated shunt, and battery LVD. All distribution
connections and controller I/O contacts are front accessible.
The Cordex® CXC HP system controller includes a touchscreen display 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.
• Integrated 48 V, 400 A power system with front access distribution.
• Industry leading power system density.
• 26 distribution positions in 5RU form factor.
• Advanced Cordex® CXC HP system controller with touchscreen LCD for full local control.
• High temperature rated design for harsh outdoor applications.
• Wide range AC input for flexible worldwide deployment.
Figure 2: Cordex® CXPS-E3 400A power system

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4.2 Cordex® HP LPS36 up-converter
For more information, refer to the Cordex® HP LPS36 documentation.
The Cordex® HP LPS36 is a modular DC to DC up-converter system designed for distributed power applications
using ±190 Vdc over existing or new copper cabling.
Using switched mode technology, the LPS36 quad output converter module provides outstanding eciency in a
compact design. Applications include powering sealed DSLAMs, Distribution Point Units (DPU) as well as Optical
Network Terminals (ONT) in Fiber to the Home Networks (FTTH). Each LPS36 converter module contains four
isolated DC to DC converters, up to 100 watt maximum. Converter modules are ordered separately at time of
ordering or later after the converter system has been installed. Blank plates can be ordered separately for empty
slots.
• High eciency >92% for reduced operating expenses (OPEX) and carbon footprint.
• High temperature tolerance for installation in Central Oce (CO) or harsh outside plant (OSP) cabinet
environments.
• Industry leading power density enabling up to 48 channels in a compact 2RU form factor.
Figure 3: Cordex® HP LPS36 up-converter

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4.3 Cordex® CXC HP system controller
For more information, refer to the Cordex® CXC HP controller documentation.
The Cordex® CXC HP system controller provides a high performance control and monitoring option for all Cordex®
products. The controller brings a refreshed look, increased horsepower, and advanced configurability to the
proven Cordex® controller family.
The controller includes multiple communication ports including two Ethernet connections to permit simultaneous
local craft access as well as permanent LAN/WAN connectivity. Dual USB ports provide advanced file
management capabilities including firmware upgrades and system configuration management. Use a USB
storage device to quickly backup and restore site configuration settings and data logs.
The web-based user interface provides detailed inventory management allowing integration of advanced energy
systems incorporating multiple power elements. Systems with various energy generation and storage elements
can be configured and monitored with ease. Users can create custom inventory such as shunts, battery LVDs,
battery systems, and loads to eectively manage all aspects of their energy system. The controller ensures
eortless operation and management to satisfy the most demanding and advanced energy system applications.
• Advanced next-generation control and monitoring platform for the Cordex® product family.
• High-resolution color touchscreen LCD with advanced local UI.
• Integrated USB host for local firmware upgrades, configuration updates, and system backup and restore.
• Comprehensive user interface for advanced system configuration.
• Seamless integration of multiple energy systems allowing comprehensive management, monitoring, and
control.
• External ADIO smart peripherals for customizing unique I/O configurations.
• Compact flexible mounting options to reduce space requirements.
Ethernet
(rear
USB (rear)
USB (front)
Ethernet (front)
Status LEDsLCD screen
Home
Reset
Figure 4: Cordex® CXC HP system controller

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4.4 High voltage 50-pair protector panels
Each panel provides overvoltage protection for up to 50 copper circuit pairs. The panel accepts five-pin gas
discharge tube (GDT) modules (part number: 1620018).
• Output uses 3M Company MS² 4005 Gel Bridge Module (GBM) connectors.
• Each loaded circuit requires one GDT module.
4.5 External AC loadcenter
The CPH-144 includes a 208/240 Vac loadcenter, with a 100 amp main breaker, that is pre-wired for the DC power
system and other AC electrical connections.
Refer to the 0570257-05 drawing at the end of this document for the loadcenter wiring schematic.
Figure 5: High voltage 50-pair protector panels
Figure 6: External AC loadcenter

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4.6 48 Vdc heat exchanger
The heat exchanger consists of a core, internal loop recirculation fans, and external loop fans for circulating
outside ambient air across the core.
The heat exchanger features adjustable thermostat control and a heat exchanger fan fail alarm output that is wired
to the enclosure alarm block. The heat exchanger fans shut o automatically when the enclosure door is opened.
Refer to the 0570257-05 drawing at the end of this document for the heat exchanger wiring schematic.
Figure 7: 48 Vdc heat exchanger
Enclosure air return
Enclosure air supply

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5. Inspection
5.1 Packing materials
EnerSys® is committed to providing products and services that meet our customers’ needs and expectations in a
sustainable manner, while complying with all relevant regulatory requirements. As such EnerSys strives to follow
our quality and environmental objectives from product supply and development through to the packaging for our
products.
Rectifiers and batteries are shipped on individual pallets and are packaged according to the manufacturer’s
guidelines.
Almost all EnerSys packaging material is from sustainable resources and is recyclable.
5.2 Returns for service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is unavailable, make sure that the product is packed with at
least 7.6 cm (3 in.) of shock-absorbing material to prevent shipping damage.
5.3 Check for damage
Before unpacking the product, note any damage to the shipping container. Unpack the product and inspect the
exterior for damage. If any damage is observed, contact the carrier immediately. Continue the inspection for any
internal damage. In the unlikely event of internal damage, inform the carrier and contact Alpha Technologies Ltd.
for advice on the impact of any damage.
5.4 General receipt of shipment
The inventory included with your shipment depends on the options you have ordered. The options are clearly
marked on the shipping container labels and bill of materials.
5.5 Miscellaneous small parts
Review the packing slip and bill of materials to determine the part number of the “configuration kits” included
with your system. Review the bill of materials to verify that all the small parts are included. Contact Alpha
Technologies Ltd. if you have any questions before you proceed.
NOTICE
EnerSys is not responsible for damage caused by improper packaging of returned products.

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6. Installation
Only qualified personnel should install and connect the power components within the Alpha® power system. For
the battery installation, refer primarily to the manufacturer’s documentation.
6.1 Safety precautions
Refer to the "Safety" section near the beginning of this document.
6.2 Installation tools
Various insulated tools are essential for the installation. Use this list as a guide:
• Battery lifting apparatus (if required)
• Electric drill with hammer action, 1/2 inch capacity
• Various crimping tools and dies to match lugs used in installation
• Load bank of sucient capacity to load largest rectifier to its current limit
• Digital voltmeter equipped with test leads
• Cable cutters
• MS² splicing tool
• Cutters and wire strippers 0.34 mm² to 2.5 mm² (22 AWG to 14 AWG)
• Torque wrench: 1/4 inch drive, 0 to 17 Nm (0 to 150 in-lb)
• Torque wrench: 3/8 inch drive, 0 to 135 Nm (0 to 100 ft-lb)
• Insulating canvases as required
• Various insulated hand tools including:
- Combination wrenches. - Ratchet and socket set.
- Various screwdrivers. - Electricians knife.
• Battery safety spill kit (required for wet cells only)
6.3 Site selection
Consider the following before selecting a mounting site:
• The CPH-144 is designed for pole or ground mounting.
• Avoid areas that could be subjected to hot air exhaust from nearby equipment or buildings.
• Avoid mounting in areas of extreme heat such as exposure to direct sunlight.
• Find out if your intended area is subjected to architectural controls or environmental restrictions.
6.4 Lifting
1. Before lifting the enclosure, make sure the lifting eyes have not come loose during shipping and are securely
fastened.
2. Ensure that the clevises are correctly installed and that the enclosure is approximately level during the lift.
This will simplify the enclosure positioning.
CAUTION
Follow all local safety practices and guidelines while lifting the enclosure. All personnel involved
with lifting and positioning the enclosure must wear head and eye protection, and gloves. Only
properly trained and certified personnel should operate the crane. Only properly trained and
certified personnel should operate the forklift.

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3. Close and latch the enclosure front door.
4. If included, place the enclosed rubber mat onto the slab or platform. Orient the mat so that the mounting
holes line up. If the rubber mat is “ribbed” the ribs should be against the concrete slab.
6.5 Mounting the enclosure
The CPH-144 is designed for pole or ground mounting.
Concrete pad installation requiring seismic compliance requires approval by the appropriate engineering discipline,
for example, civil or structural. Cast-in-place or pre-cast concrete slabs can be used.
Use the template in Figure 9 to place the anchor bolts. Follow the specific recommendations from the fastener
manufacturer to ensure that the securing device achieves its full structural capacity. Refer to drawings at the end
of this document for further details.
6.5.1 Pole mounting
7.1
4.1
2 × 1.00
2 × 22.6
50.00
3 × 2.75
3 × 0.75
3 × 1.00
Figure 8: Pole mounting detail

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2
18
2 23
22
27
4.5 18
3
16
4 ×
0.625 MOUNTING HOLES
4 × 2" TRADE SIZE KNOCKOUT
Figure 9: Ground mounting detail
6.5.2 Ground mounting

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7. Wiring
Only qualified personnel should install and connect the power components within the Alpha® power system.
7.1 Grounding the enclosure
There are three dierent configurations of the CPH-144 enclosure, the following content describes grounding
for these dierent scenarios. The grounding specifications and diagrams depicted in this document are based on
recommended industry best practices. However, site grounding design and construction shall always adhere to
local electrical codes and the internal standards of the company that is responsible for ownership and operation of
equipment.
7.1.1 Configuration 1: Grounding the CPH-144 with a combination meter and
loadcenter
1. Install a 35 mm² (2 AWG) tinned solid copper site ground wire (grounding electrode conductor) originating at
the closest driven ground electrode and connect it to the loadcenter AC Equipment Ground (ACEG) bus.
2. Route a length of 35 mm² (2 AWG) tinned solid copper conductor from a junction point on the grounding
electrode conductor (GEC) and connect to the Enclosure Master Ground Bar (MGB) using an appropriate
compression two-hole lug.
Figure 10: CPH-144 combination meter and loadcenter grounding diagram
WARNING
• Only qualified personnel should install and connect the power components within the Alpha®
system.
• An enclosure that is not properly grounded presents an electrical hazard and will likely result
in premature equipment failure.
• A proper grounding system (ground electrode system) that meets or exceeds the
specifications of the equipment must be designed and installed prior to or in conjunction
with the installation. The ground system must be bonded to the enclosure to ensure a
common or single-point ground.
GROUNDING
It is recommended that all buried grounding connectors are 30.1 cm (12 in.) below finished
grade line or below the frost line. For below grade connections, use crimp or mechanical
connectors instead of an exothermic weld provided they are listed for direct burial applications.