Modular High Capacity Distributed Power System Models: Cordex CXPS-D 48-2000/4000A Cordex CXPS-D 48-2500/5000A Installation & Operation Manual Part # 9400003-J0 Effective: 11/2011 member of The Group™ Your Power Solutions Partner
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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.
1.3 Electrical Safety :$51,1* +D]DUGRXV YROWDJHV DUH SUHVHQW DW WKH LQSXW RI SRZHU V\VWHPV 7KH '& RXWSXW IURP UHF WL¿HUV DQG EDWWHULHV WKRXJK QRW GDQJHURXV LQ YROWDJH KDV D KLJK VKRUW FLUFXLW FXUUHQW FDSDFLW\ WKDW PD\ FDXVH VHYHUH EXUQV DQG HOHFWULFDO DUFLQJ • 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.
2. Introduction 2.1 Scope of the Manual This instruction manual explains the features, installation, interconnection and startup of both the Alpha CXPS-D 48-2000/4000 Cordex system and the Alpha CXPS-D 48-2500/5000 Cordex system. Images contained in this document are for illustrative purposes only and may not exactly match your installation. In addition to this manual, the following documentation is part of the documentation package that ships with the Alpha CXPS: • Cordex Controller (CXC) v2.
3. Product Description Figure 1 shows a single bay 2500 A system.
3.1 Cordex Rectifier Shelves Each bay can contain up to five Cordex shelves that hold up to six individual rectifier modules. 3.1.1 AC Termination Wiring The individual Cordex rectifier shelves are wired to the customer-provided AC termination panel. The AC input is routed through a 1" knockout for direct connection to the rectifier shelf with appropriately sized wire according to the local electrical codes. Each shelf requires two AC input circuits.
3.1.4 DC Charge Buses Each rectifier bay has two vertical charge bars—one that connects all of the positive terminals and one that connects all of the negative terminals of the rectifier shelves (Figure 2). These bus bars are rated for the maximum current supplied by the rectifier shelves. The return charge bar connects to the battery return bar located at the top of the bay. The -48V vertical charge bar connects to the live battery bus bar located at the top of the bay. 3.1.
3.2 Distribution and Termination 3.2.1 Distribution Modules The fuse/circuit breaker distribution modules feature high capacity, modularity, and simplified installation. These features provide effective secondary load distribution and protection for multiple -48V DC feeds up to 600 amps.
3.2.2 Safety Features Insulating shield Each distribution bay has a insulating shield to the front of the bus bars. This shield prevents casual touching of the bus bars with cable lugs and tools while working inside the distribution module. It also maintains separation between the cables and the bus bars.
3.3 DC Inter-bay Copper The inter-bay bus bar is available in 2500 A nominal sizing. All inter-bay bus work is contained within the system racks. Hot Bay Expansion An additional bay can be added to the system while online without shutting down the DC plant. Review Section "1. Safety" on page 7 before undertaking this procedure. 3.3.
3.4.1 Remote Battery Return Bar (Optional) A remote battery return bar is required to facilitate termination of a high quantity of large cables. The kit contains all parts shown in Figure 7 and mounts to a customer supplied auxiliary frame (2 " x 9/16"). Lug Spacing 1.28 See Figure 8 for exact dimensions. Small: 72 sets 1/4" on 5/8" ctrs 0.27 1.28 Large: 24 sets 3/8" on 1" ctrs or 24 sets 1/2" on 1 ¾" ctrs 0.63 0.63 0.27 1.75 1.06 0.56 0.44 2.00 Dual bars can be stacked or installed separately.
3.5 Distribution Shunts Each TPL fuse or breaker bank can be connected to the distribution bus through an optional 800 A / 25 mV shunt. See Figure 8 and Figure 9. The individual shunt currents can be viewed on the CXC to monitor load/ battery balance. If the system has more than four shunts, then installation of the shunt multiplexer panel option is required to increase the number of observable shunt currents at the CXC to 16. Shunts and TPL fuses may be used for battery protection (programming required).
3.6 Low Voltage Load Disconnect The Low Voltage Load Disconnect (LVLD or LVD) feature controls a high capacity contactor that disconnects the load during extremely low voltage conditions. The system loads are automatically reconnected once AC is restored and battery voltage has risen above a preset value. The parameters for LVD activation and control are set in the Controls > Configure Controls menu in the CXC controller. Refer to the section titled "Controls" in the controller software manual.
3.7 Distribution Panel Alarms Fuse and breaker alarms occur when one or more fuse or breaker has opened. Breaker alarms are paralleled from each breaker bank to a single alarm which is displayed on the inside panel of the distribution module. The TPL fuse fail alarms, also paralleled, display as a single alarm. Each breaker/fuse panel is equipped with one alarm which is wired to the system controller.
3.8 External Low Voltage Battery Disconnect (purchased separately) The LVBD contactors, installed in the external battery disconnect panels, are placed in series with the batteries. This product provides automatic disconnect of the system batteries after a prolonged power failure when the batteries have been fully discharged. The batteries are automatically reconnected once AC is restored. Control is performed by the CXC and is triggered by the battery voltage. Cordex System Controller 3.
3.9.1 Control Cards The control cards are mounted inside the door of the controller distribution module (Figure 14). The CXCP can accommodate up to eight digital input channels. These channels can monitor digital alarm/control signals from rectifiers, converters and other types of equipment. Some of these channels are pre-assigned to monitor specific signals. See the Software manual for more information.
3.9.2 Front Panel LEDs Three LEDs are located on the front panel: one green, one yellow, and one red. These LEDs are used to display the alarm status of the power system, controller progress and status during startup, and file transfers. Alarm conditions Only one LED light is illuminated at a time during alarm conditions. Each LED light corresponds to a specific alarm. A built-in audio speaker sounds an intermittent tone during active alarms. ,OOXPLQDWHG /(' $ODUP *UHHQ 2.
4. Pre-Installation Preparation 4.1 Site Selection The power system must be mounted in a clean and dry environment. Consider both the floor loading and the physical space required for a single bay CXPS power system and the batteries: • Dimensions for one bay (refer to drawing #0250005-06): » mm.........2133H x 660W x 482D » Inches....84H x 26W x 19D • Avoid areas that may be subjected to hot air exhaust from nearby equipment.
4.1.1 Floor Plan Layout Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the rectifiers in the power system and to allow easy access to the power system components.
4.1.2 Installation component requirements Supplied • Internal DC cables Not Supplied • Concrete and metal grating mounting hardware • AC electrical conduit, cable and fittings • External DC conduit, cable and fittings • Auxilary frame (2" x 9/16") for external battery return busbar kit 4.2 Tools and Test Equipment Insulated tools are essential for a DC power system installation.
4.4 Unpacking the Equipment Product is shipped upright bolted to a pallet or horizontally in a wooden crate. Packaging assemblies and methods are tested to International Safe Transit Association standards. Rectifiers and batteries are shipped on individual pallets. Check For Damage Prior to unpacking the batteries, power system or components, perform a visual inspection and note any damage. Unpack the equipment and inspect the exterior for damage. If any damage is observed contact the carrier immediately.
5. Installation The power system must be mounted in a clean and dry environment. Provide sufficient free space at the front and rear of the power system to meet the cooling requirements of the rectifiers in the power system and to allow easy access to the power system components. 5.1 Floor drilling for standard anchoring The anchoring kit and procedures in this section are for a sesimic installation, but apply equally well to a nonseismic installation. 5.1.1 1.
5.1.2 Setting the Anchors First, review manufacturer's instructions before setting the anchor. 1. Drop the anchor into the drilled hole. 2. Insert the anchor setting tool and hit it with a hammer to expand the anchor until the collar of the setting tool rests against the shoulder of the anchor. 5.2 Placing and Securing the Bays 5.2.
5.3 Securing Adjacent Bays Bolt each pair of bays together with the rack joining kits, included in your shipment. Use one kit at the top and one at the bottom.
5.4 Installing the Inter-bay DC Bus Work and Cabling The inter-bay DC bus work ships as a kit that is sized according to the number of rectifiers and current demand of the load.
Install inter-bay bus bars top to bottom Two people are required to perform this procedure. 127( %H DZDUH WKHUH LV D FRSSHU SLHFH VDQGZLFKHG EHWZHHQ WKH YHUWLFDO EXV EDUV DQG KHOG LQ SODFH ZLWK WKH VDPH EROWV \RX DUH DERXW WR UHPRYH 1. Start with the top -48V bar in the primary bay. 2. Remove 2 bolts. 3. Remove the metal sandwiched between the two vertical bus bars along with the last 2 bolts. 4. Repeat the preceding steps on the extension bay. 5.
5.4.2 Installing the Inter-bay Cables A new expansion bay arrives with the CAN bus and signal cables ready for connection to the existing bay. 6LJQDO FDEOHV DQG FRQQHFWRU &$1 EXV FDEOH DQG FRQQHFWRU )LJXUH ² ,QWHU ED\ FDEOHV Inter-Bay Signal Cables 1. Locate the connector ends of the wiring harnesses in the existing bay and the expansion bay. 2. Join the two connectors together. 3. Tie-wrap the connector cable to the shelf as shown in Figure 21.
Inter-bay CAN Bus Cable The CAN bus provides a communication path between the controller and rectifiers. In a single bay, the CAN bus cabling is daisy-chained from the shunt mux, if installed, to the bottom rectifier shelf. The cable is then daisy-chained from the bottom shelf, to higher shelves, in sequence. At the last shelf, termination is enabled—see Figure 18.
5.4.3 Cutting and reinstalling rear Kydex covers Before reinstalling the covers, trim the sides to clear the inter-bay bus bars: 1. Use wire cutters to cut through the second row of holes on the adjacent sides of the Kydex covers. 2. Replace the covers and attach them to the cover support brackets (see Figure 19). 3. Join the covers together with the plastic pins and the Kydex strip shown in Figure 25. &XW WKURXJK VHFRQG VHW RI KROHV )LJXUH ² 5H LQVWDOODWLRQ RI UHDU .
5.5 Mounting the External Battery Return Bus Bar 127( 73/ IXVHV UHTXLUH DQ H[WHUQDO UHWXUQ EXV EDU An expandable external battery return bus bar kit (part number 7400250-001) is provided with each power system to make the battery return connections for the loads and to serve as the common connecting points for the positive side of the bays and the batteries. Each bar has a 2500A capacity. 1.
5.6 Battery Installation This information is provided as a guideline and is not meant to imply that batteries are part of this power system. :$51,1* )ROORZ EDWWHU\ PDQXIDFWXUHU¶V VDIHW\ UHFRPPHQGDWLRQV ZKHQ ZRUNLQJ DURXQG EDWWHU\ V\VWHPV DQG UHYLHZ WKH VDIHW\ LQVWUXFWLRQV SURYLGHG LQ WKLV PDQXDO )LJXUH ² %DWWHU\ LQVWDOODWLRQ 5.6.1 Preparation/Mounting Batteries should be located in a temperature-controlled environment. The temperature should be regulated at approx. 25°C (77°F).
5.6.3 Temperature Probe for Monitoring Battery Temperature 1. Connect CXC temperature probes from CXC to battery termination post negative, if applicable. Pick a good location at mid-height on one or more battery string that will provide a good average temperature reading; i.e., away from heating or cooling sources.
After assembly, number the batteries and take “as received” readings, including specific gravity, cell voltage, and temperature. Designate one cell as the pilot cell. This is usually the cell with either the lowest specific gravity or voltage. Refer to the manufacturer's literature for guidelines.
6. Installation - AC, DC and Grounding Cables This section provides cabling details and notes on cable sizing for DC applications with respect to the Alpha CXPS-D 48 Power System. • Only qualified personnel should install and connect the power components within the Alpha power system. • All wiring must be in accordance with applicable electrical codes. • A low voltage disconnect (LVBD) should be provided with the battery system.
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6.2 AC Supply for the Rectifiers To ease future access issues, connect the AC circuits to all rectifier shelves at the time of initial installation. 127( 9HULI\ 12 UHFWL¿HUV DUH LQVWDOOHG LQ WKH UHFWL¿HU ED\V DW WKLV WLPH 6.2.1 Standard AC Refer to Table A on page 11 for AC input options. Terminate flex conduit at rectifier shelves—one connection each side.
6.3 Connecting the Frame and Reference Grounds &$87,21 7KH JURXQGLQJ PHWKRGV GHVFULEHG LQ WKLV VHFWLRQ DUH JHQHULF )ROORZ ORFDO UHTXLUHPHQWV DQG HOHFWULFDO FRGH NOTE: This power system is suitable for installation as part of a Common Bonding Network (CBN) and is intended to be used in a DC-C configuration (common DC return). A true single point ground system means that everything is referenced to a single point that is tied to the external earth ground system.
6.3.2 Connecting the power plant frame ground The power plant frame must also be connected to the MGB or FGB—see Figure 30. This is done for personnel safety and to meet many telco-grounding requirements. Cable should be #6 AWG (16mm) for small to medium size power plants and #2/0 for large plants (> 800A).
6.4 External Battery Return Bar Wiring (Optional) Connect the external battery return bar(s) to the associated bay's battery return bus as shown in Figure 32.
6.5 Battery Connections Battery cables should be sized for a 0.25 V drop from battery to the power system at full load including anticipated growth. The cables should also meet ampacity requirements. 6.5.1 Battery Return Connections Procedure: 1.
6.6 Connecting DC Load Cables to Breaker Circuitry Refer to guidelines supplied with the load equipment. Distribution cables are typically sized to provide a 0.5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker. 6.6.1 1. Before You Begin: Cut cables to length and terminate with a two-hole lug: » TPL fuse connection—3/8" diameter on 1" center » AM breaker— 1/4" diameter on 5/8" center 2.
&LUFXLW EUHDNHU JXDUG 3URWHFWLYH QHJDWLYH WHUPLQDO FRYHU &DEOH WLH EDU )LJXUH ² %UHDNHU GLVWULEXWLRQ PRGXOH EHIRUH ORDG FDEOHV DUH LQVWDOOHG 4. Connect the load return cables to the (+) side of the bottom breaker (Figure 37) or to the external battery return bus bar (Figure 33). 5. Connect the -48V load cables to the circuit breaker bank starting with the bottom position. 6. Tie cables to the cable tie bars at the back of the power system (Figure 36 shows the location). 7.
6.7 Connecting Load Cables to TPL Circuitry High Capacity Connect TPL fuse holders to the load and the external return bus bar with up to 2x 750 MCM wire. Low Capacity Connect TPL fuse holders to the load and the external return bus bar with up to 350 MCM wire. )LJXUH ² +LJK FDSDFLW\ 73/ IXVH ZLULQJ VKRZQ ZLWK 2x 750 MCM wire) 6.7.
6.8 6.8.1 Final installation steps Tie Wraps Neatly group cables with tie wraps as shown in Figure 39.
6.8.3 Top Cover(s) Cut between the holes with side cutters to make a large enough entryway for the required cables. Figure 41 shows a small hole cut in the cover. Make a straight cut to the back edge of the cover, so the cover can be fitted around the cables when replacing it at the end of the installation. )LJXUH ² 7RS .\GH[ FRYHU ZLWK FXWV IRU FDEOH HQWU\ Reinstall the top cover. 6.8.
STEP 2 Repeat on the right busbar and cables. )LJXUH ² ,QVXODWLRQ FRYHUV LQ SODFH STEP 3 Secure the covers to the top of the bay with the plastic screws as shown in Figure 43.
6.9 External Alarm Wiring If using the alarm outputs from the CXCP relays, route the signal cable as shown in Figure 44 ,exiting through the knockout in the top distribution module. Refer to the controller software manual to set up the alarms.
7. System Startup Visually inspect the installation thoroughly. After completing the system installation and power system wiring, perform the following startup and test procedure to ensure proper operation: 7.1 1. Check System Connections Make sure that the AC input power is switched off, the batteries are disconnected, and all the power modules are removed from the shelf. 2. Triple-check the polarity of all connections. 7.2 1. Verify AC and Power the Rectifier Shelf Install one power module. 2.
8. Test and Commissioning Overview 8.1 System All Alpha power system components undergo thorough factory testing. All levels/alarms are set to predetermined values as detailed in their individual component manuals except where custom levels are specified. Good installation practice is to check the operation of all features and alarms and to set the power system levels in accordance with the specific requirements of your system.
9. Maintenance Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualified service personnel should do the repairs. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year.
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11. Warranty Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized location during the warranty period. There are limitations to this warranty coverage.
Alpha Technologies Ltd. 7700 Riverfront Gate Burnaby, BC V5J 5M4 Canada Tel: +1 604 436 5900 Fax: +1 604 436 1233 Toll Free: +1 800 667 8743 Alpha Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 Alpha Industrial Power Inc.
