Alpha Technologies Cordex CXRF 48-3.6kW Bedienungsanleitung
Your Power Solutions Partner
Alpha Modular Switched Mode Rectifier System
Rectifier Models: Cordex CXRF 48-3.6kW
Cordex HP CXRF 48-4kW
Cordex HP CXRF 48-12kW
Installation and Operation Manual
Part #9400000-J0
Effective 07/2020
Modular Switched Mode Rectier System
Models: Cordex CXRF HP 48-12kW
Cordex CXRF HP 48-4.0kW
Cordex CXRF 48-3.6kW
Copyright
Copyright © 2017 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo-
gies.
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.
NOTE:
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 and Outback Energy GmbH or your nearest AOE representative.
NOTE:
AOE 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.
For technical support, contact Alpha and Outback Energy
GmbH:
Tel: +49 9122 79889 0
Mail: [email protected]
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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. Rectier Features................................................................................................................10
3.1 Front Panel .............................................................................................................................. 10
3.2 Rectier Rear Panel ................................................................................................................. 12
3.3 True Module Fail Alarm ............................................................................................................ 12
3.4 Heat Dissipation ....................................................................................................................... 12
3.5 Over Temperature Protection ................................................................................................... 12
3.6 Wide AC Range ....................................................................................................................... 12
3.7 AC Inrush/Transient Suppression ............................................................................................ 13
3.8 Soft Start .................................................................................................................................. 13
3.9 Start Delay ............................................................................................................................... 13
3.10 Current Limit/Short Circuit Protection .................................................................................... 13
3.11 Power Limiting ........................................................................................................................ 13
3.12 High Voltage Shutdown (HVSD) ............................................................................................ 13
3.13 Battery Eliminator Operation .................................................................................................. 13
4. Cordex System Controller (CXC) ........................................................................................14
4.1 CXCM4 Features ..................................................................................................................... 14
4.2 Controller Front Panel .............................................................................................................. 14
4.3 Rectier Report from Controller Display .................................................................................. 16
4.4 Analog Input Channels ............................................................................................................. 16
4.5 Digital Input Channels .............................................................................................................. 17
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4.6 Alarm and Control Output Relays ............................................................................................ 17
4.7 System Fail Alarm/Relay .......................................................................................................... 17
5. Inspection............................................................................................................................18
5.1 Packing Materials ..................................................................................................................... 18
5.2 Check for Damage ................................................................................................................... 18
5.3 General Receipt of Shipment ................................................................................................... 18
6. Installation ...........................................................................................................................19
6.1 Safety Precautions ................................................................................................................... 19
6.2 Tools Required ......................................................................................................................... 19
6.3 Power System Assembly and Mounting ................................................................................... 20
7. Wiring ..................................................................................................................................21
7.1 Grounding ................................................................................................................................ 21
7.2 AC Feeder Protection/Sizing .................................................................................................... 21
7.4 DC Output Connections ........................................................................................................... 22
7.3 AC Input Connections .............................................................................................................. 22
7.5 CAN Serial Ports (Rectier Shelf) ............................................................................................ 23
7.6 Inserting the CXCM4 Module ................................................................................................... 24
7.7 Signal Wiring Connections for CXCM4 .................................................................................... 24
7.8 Network Connection and Remote Communications via CXC .................................................. 26
8. System Startup ...................................................................................................................27
8.1 Check System Connections ..................................................................................................... 27
8.2 Verify AC and Power the Rectier Shelf ................................................................................... 27
8.3 Triple Check Battery Polarity and Connections ........................................................................ 27
8.4 CXC Reset ............................................................................................................................... 27
9. Rectier States, Modes and Factory Defaults.....................................................................28
9.1 Main Rectier States ................................................................................................................ 28
9.2 Main Rectier Modes ............................................................................................................... 29
9.3 Factory Ranges and Defaults .................................................................................................. 30
10. Maintenance .....................................................................................................................31
10.2 Replacing a Rectier Module ................................................................................................. 31
10.3 Replacing the CXCM4 Module ............................................................................................... 32
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10.4 Fan and Fan Filter Replacement ........................................................................................... 33
10.5 MOV Replacement ................................................................................................................. 37
11. Acronyms and Denitions ..................................................................................................41
12. Warranty and Service Information ....................................................................................42
12.1 Technical Support .................................................................................................................. 42
12.2 Warranty Statement ............................................................................................................... 42
12.3 Product Warranty ................................................................................................................... 42
12.4 Battery Warranty .................................................................................................................... 42
12.5 Warranty Claims ..................................................................................................................... 42
12.6 Service Information ................................................................................................................ 42
13. Certication .......................................................................................................................43
List of Figures
Figure 1 — (a) Cordex 48-3.6kW (b)Cordex 48-4kW (c) Cordex 48-12kW switched mode rectier 7
Figure 2 — Rectier front panel LEDs ............................................................................................ 10
Figure 3 — Cordex CXCM4 model system controller front panel ................................................... 14
Figure 4 — Rectier (or Converter) report screen .......................................................................... 16
Figure 5 — CAN termination selection and serial ports .................................................................. 23
Figure 6 — Relay connections in the de-energized state ............................................................... 24
Figure 7 — Digital input connection method ................................................................................... 25
Figure 8 — LVD override control and distribution alarm card ......................................................... 32
Figure 9 — 4kW rectier fan removal ............................................................................................. 34
Figure 10 — 4kW rectier fan lter removal .................................................................................... 34
Figure 11 — Fan assembly - screw removal ................................................................................... 35
Figure 12 — Fan assembly ............................................................................................................. 35
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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 specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic 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.
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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
240 Vac. 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-
tiers and batteries, though not dangerous in voltage, has a high short-circuit current
capacity that may cause severe burns and electrical arcing.
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2. Introduction
2.1 Scope of the Manual
This instruction manual explains the installation, interconnection, and operation of the Alpha Cordex 48-3.6kW,
48-4.0kW and 48-12kW modular switched mode rectifier systems.
2.2 Product Overview
A complete Cordex rectifier system consists of one or more power modules in a common shelf enclosure. The
shelf has connections for AC inputs, DC output, and system communications.
Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulated
and isolated DC output from the AC mains. The rectifier input is wide range to allow use on 208/220/240 Vac
50/60 Hz electrical service.
Rectifier power modules are “hot swappable”—they can be inserted or removed from the shelf without cutting
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.
The shelf rectifier system is designed to operate with the Alpha Cordex System Controller (CXC). The CXC con-
troller 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 controller operation are
provided in the current version software manual.
There are two options for the Alpha CXC
• External CXC models of the system controller communicate with the shelf via offset RJ-12 shelf connec-
tors. The CXCR is mounted in a rack and the CXCP is (factory) mounted in a panel.
• The CXCM4, a 4 RU model designed for integrated use with the rectifier shelf, requires a connection
interface (adapter) for modular installation and uses the shelf space of the leftmost rectifier position (as
viewed from the front). This CXC model also has a touch screen display.
Figure 1 — (a) Cordex 48-3.6kW (b)Cordex 48-4kW (c) Cordex 48-12kW switched mode rectifier
(a) (b) (c)
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2.3 Part Numbers and List Options
The product, options, and accessories can be ordered by using the following part numbers:
Description List Option
Cordex 48-12kW rectier power module 0100002-002
Basic module *List 0
Fan, spare for Cordex 48-12kW 747-679-20
Fan lter, spare for Cordex 48-12kW 747-652-20-060
MOV assembly, spare for Cordex 48-12kWt 707-813-20
Cordex 48-3.6kW rectier power module (pre-RoHS # 010-567-20) 010-600-20
Basic module *List 0
Gray nish with blue silkscreen *List 50
1 x 420Vac and 2 x 660Vac MOVs List 81
Fan assembly, (spare for Cordex 48-3.6kW) (pre-RoHS # 747-212-20) 747-359-20
MOV assembly, (spare for Cordex 48-3.6kW) 707-374-20
Cordex 48-4kW rectier power module 010-623-20
Basic module *List 0
Gray nish with blue silkscreen List 50
Black nish with gray silkscreen *List 58
Fan assembly, spare for Cordex 48-4kW 747-679-20
Fan lter, spare for Cordex 48-12kW 747-652-20-060
MOV assembly, spare for Cordex 48-4kW 707-813-20
Cordex 48-3.6/4.0/12kW 23" shelf, ush or mid-mounting (pre-RoHS # 030-716-20) 030-801-20
Basic shelf, can be equipped with up to six Cordex 48-3.6kW or 48-4kW modules** *List 0
Mid-mounting *List 23
Flush mounting List 25
DC output, bus bar adapters, 20" deep List 81
DC output, bus bar adapters, 16" deep List 82
AC input, dual three phase (no neutral required) List 83
AC input, dual three phase (neutral required, Wye source) List 84
AC input, single phase *List 85
Kydex rear cover List 89
Module blank List 90
Cordex 48-3.6/4.0/12kW 19" shelf, ush mounting, AC input, single phase (pre-RoHS # 030-717-20) 030-802-20
Basic shelf, may be equipped with up to ve Cordex 48-3.6kW or 48-4kW modules** *List 0
Mid-mounting, 19" rack List 19
Mid-mounting, 23" rack List 23
DC output, bus bar adapters, 16" deep List 82
Dieses Handbuch passt für folgende Modelle
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