CXPS 48-1.
CXPS 48 – 1.2-225 48Vdc Power System 053-691-B1 The following drawings are included in this manual: • Schematic Drawing, CXPS 48-1.2-225_A 053-691-05 • Layout Drawing, CXPS 48-1.2-225_A 053-691-06 • Customer Connection, CXPS 48-1.2-225_A 053-691-08 Manuals to be included in this package: • DCP03 300 A Distribution Center: 020-702-B2 • Cordex 48-1.
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This section contains important instructions that must be followed during the installation and maintenance of the equipment and batteries. Read all of the instructions before operating the equipment, and save this manual for future reference. All electrical connections must be performed by licensed electricians only.
Electrical safety WARNING: Hazardous voltages are present at the input of power systems. The DC output from rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing. 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 installation.
TABLE OF CONTENTS 1 2 3 4 5 6 INTRODUCTION..................................................................................................................................................1 1.1 Manual scope ................................................................................................................................................ 1 1.2 Product overview ................................................................................................................................
7 8 9 6.1 Check system connections .......................................................................................................................... 26 6.2 Verify AC input and power up rectifier shelf .............................................................................................. 26 6.3 Check battery polarity and connect the batteries ...................................................................................... 26 6.4 Controller Reset ..............................
1 Introduction 1.1 Manual scope This manual covers the features and installation of the Alpha Technologies CXPS 48-1.2-225 48V 225A Power System. 1.2 Product overview The CXPS 48-1.2-225 is a complete integrated 48 Vdc power system with 225 A capacity. The system uses the advanced Cordex CXCM1 controller and HP 48 V 1.2 kW rectifier modules. The DCP03 300A distribution center provides front access for DC distribution, site controller, and battery connections.
1.3 Available system configurations The system is available to order in the following configurations: 1.4 Description Part Number CXPS 48-1.2-225, Cordex base 48V 225A power system, 19/23" rail mount CXPS 48-1.2-225 system installed in 7foot Z4 23" rack with 2x battery trays CXPS 48-1.
19" battery tray expansion kit (for use with –031 configuration) 058-157-20 Cordex DC Modem (complete with Alpha cable) 4R/8D ADIO expansion assembly 018-585-20 747-521-20 The above information is valid at the time of publication. Consult factory for up-to-date ordering information.
2 Features 2.1 System overview Basic configuration included in Alpha part number 053-691-20-000: • • • • • • • • 300A DCP03 distribution center Cordex modular system controller (CXCM1) Two (2) Cordex HP 48-1.
2.2.2 Low voltage battery disconnect (LVBD) A low voltage disconnect (LVD) is installed in series with the batteries. This is called a low voltage battery disconnect (LVBD). 2.2.3 Shunt A shunt is installed in series with the batteries for current measurements. The controller automatically calculates the load current. 2.2.4 Internal alarm card The distribution center includes an alarm card, a low voltage disconnect override switch, and a breaker trip LED indicator.
2.2.5 Controller I/O terminal block A controller I/O terminal block is installed in the distribution center front door to allow controller access to signals and interfaces. A 25-pin D-sub wire harness is used to connect the terminal block to the controller. The internal signals from the distribution center are wired to the controller I/O board directly from the internal alarm board. The remaining relay outputs, digital inputs, and analog inputs can be accessed via terminal blocks to customer connections.
2.3 CXCM1 Controller Details of the controller operation are provided in the software manual. The controller is mounted in the rectifier system shelf and controls the rectifiers. The controller includes software that does the following: • • • • • • Direct communication with the rectifiers. Battery temperature compensation charging. Battery performance diagnostics. Local and remote communications. User definable alarms. Daily logging of power system events and system statistics.
2.3.3 LED lights Three LED lights are located on the front panel, one green, one yellow, and one red. The lights 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.
2.3.7 Analog input channels The controller is supplied with analog input channels for voltage, current, and temperature. Voltage inputs Two voltage input channels, V1 and V2, are used to monitor the discharge and charge voltage. The controller software is pre-configured to monitor V1 for load voltage and V2 for battery voltage. V2, which is wired internally, is used as a system reference for the rectifier float voltage, low voltage disconnect (LVD), system high voltage alarm, and system low voltage alarm.
2.4 Rectifiers The rectifier modules employ an advanced resonant power conversion technology with high power conversion efficiency. All internal semiconductor devices operate under “soft-switching” conditions and exhibit very low power loss. The reduced power loss leads to lower thermal stresses on the semiconductors and thus improves reliability.
2.5.4 True module fail alarm The rectifier modules use a “true” fail alarm. This provides a true indication of the module’s ability to source current. When a module’s output current drops below 2.5% of the rated output, a low output current condition is detected and the Module Fail detection circuit is activated. This circuit momentarily ramps up the output voltage in an attempt to increase the output current. If no increase in current is detected, the Module Fail alarm is activated.
2.5.9 Soft start A soft start feature, sometimes referred to as a “current walk-in”, is used to eliminate an instantaneous demand on the AC input source. The soft start gradually ramps up the current limit from zero to the pre-determined setting over a time interval of up to five seconds. The rectifier output voltage is ramped up from the minimum voltage to the float voltage. 2.5.
3 Inspection 3.1 Packing materials All Alpha products are shipped in rugged, double-walled boxes and are suspended via solid inserts to minimize shock that may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit Association standards. Power systems are custom packaged in heavy-duty plywood crates. Products are also packaged with a plastic wrap that contains a corrosive-inhibitor that protects the product from corrosion for up to two years.
4 Installation Only qualified personnel should install and connect the power components within the Alpha power system. For battery installation, refer primarily to the manufacturer’s manual. Refer to the drawings located at the rear of this manual. 4.1 Safety precautions Refer to the important safety instructions near the front of this manual. 4.2 Tools required Appropriate insulated tools are essential for the installation. Use this list as a guide: • • • • • • • • • • Battery lifting apparatus.
4.3 Power system assembly and mounting The power system must be mounted in a clean and dry environment. Sufficient free space must be provided at the front and rear of the power system. This is to meet the cooling requirements of the rectifiers and to allow easy access to the power system components. NOTE: The distribution center requires at least 1RU (1¾") of space above the unit to access to the load breaker ground connections.
4.4 Rectifier module insertion/removal Insert a rectifier module by placing the module on the bottom of the shelf and then sliding the module into the rear connector inside of the shelf. Apply pressure on the front of the module to engage the rear connector in the shelf receptacle. Use the enclosed locking clip to secure the rectifier into the shelf. Insert the first module into the front leftmost position. Use the side of the shelf or the optional shelf-mounted controller as a guide.
4.7 Battery installation The battery installation procedure in this manual is a guideline only. The batteries are purchased separately from the power system and have their own manuals. WARNING Follow battery manufacturer’s safety recommendations when working around battery systems and review the safety instructions provided in this manual. 4.7.1 Preparation/mounting Batteries should be located in a temperature-controlled environment. Regulate the temperature to approximately 25°C (77°F).
After assembly, number the batteries and take “as received” readings that include: 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 manufacturer's manual.
5 Wiring This chapter provides cabling details and notes on cable sizing for DC applications. WARNING Ensure that the power is removed by turning off rectifiers and removing battery line fuses or connections before attempting work on the wiring connections. Use a voltmeter to verify the absence of voltages. Clearly mark the correct polarity of the battery leads before working on DC connections. Refer to the Installation chapter for safety precautions and tools required. 5.
5.4 Calculating output wire size requirements To calculate wire sizes, first determine the appropriate maximum voltage drop requirement. Use the formula below to calculate the CMA wire size requirement. Determine the size and number of conductors needed to satisfy the CMA requirement. CMA = (A x LF x K) / AVD, where: CMA = Cross section of wire in circular MIL area A = Ultimate drain in amps LF = Conductor loop feet K = 11.
5.6.1 DC input to panel The distribution center contains a bus bar input for hot and return connections. The power system is configured with vertical bus bars for rectifier shelf integration purposes. The bus bar inputs are fixed for hot and return placement. Distribution center input (hot) bar Distribution center input (return) bar Figure 9–Rear view of distribution panel 5.6.2 Distribution cabling Refer to the guidelines supplied with the load equipment.
5.7 Alarm connections Frequent reference is made to drawings located at the rear of this manual. Custom configurations are detailed within the Alpha power system documentation package. 2 For terminal block connections, the recommended wire sizes are 0.14 - 1.50 mm (#26 to #16 AWG) for a temperature range of 0 - 50ºC (UL/CSA). CAUTION: to reduce risk of fire, use only 0.14 mm2 (#26 AWG) or larger wire.
5.9 Network connection and remote communications via controller The Cordex system can be set up, monitored and tested via an Ethernet 10/100 Base-T serial data connection. The communication protocol supports a web interface. Pin-outs are shown in the customer connections drawing. Some standard scenarios are described below: 5.9.
5.10.2 Digital inputs for controller The factory-installed digital input channels are used to monitor various alarm and control signals. All input channels are voltage activated and directly accept a bipolar (negative or positive) DC signal. D1 and D2 are available for customer connections. Connection method Typical Alpha systems use a “reset with Hot and trigger with Ground” connection. The digital input is wired so that Hot is wired directly into one of the input terminals; e.g.
5.10.3 Analog inputs CAUTION: Ensure that the correct polarity is used for all input cable terminations. The analog input channels are used to monitor various types of electrical signals. Some of the analog channels are reserved for specific signals, while others are designated as general-purpose inputs that accommodate various types of analog signals. The Battery Hot input terminal on the I/O board is factory wired to the battery system terminal.
6 System startup After completing the system installation and power system wiring, perform the following: 6.1 Check system connections • • 6.2 Verify AC input and power up rectifier shelf • • • • 6.3 Install one rectifier module. Verify that the AC input voltage is correct and switch on the corresponding feeder breaker. The controller OK LED light should illuminate continuously after a preset start delay. Using the controller, test the functionality of all module alarms and controls.
6.4 Controller Reset CAUTION: Before removing a controller from a live system or performing controller maintenance, an external LVD inhibit or override is required to prevent a service disruption. 6.4.1 Soft reset Use the reset button on the front panel of the optional controller is to restart the microprocessor. When pressed momentarily, the unit beeps twice and then resets. The front-panel LED lights will illuminate temporarily and then extinguish after the system has finished its 15-second self-test.
7 Operation 7.1 Main rectifier states Rectifier operation can be broken up into five main states: 1. Off 2. Start Delay 3. Soft Start 4. Normal Operation 5. Turning Off Each state is distinct and necessary for the operation of the rectifier. These states are briefly described below. 7.1.1 Off state The rectifier is in the Off state immediately after power is applied to the rectifier or after a rectifier shutdown.
7.2 Main rectifier modes In addition to Main Rectifier States, there is a set of Main Rectifier Modes. These modes can be divided into two categories as follows: 7.2.1 Output voltage modes Voltage modes can be thought of as modes that, under software control, can directly adjust the output voltage. There are processes that occur in the rectifier that can change the output voltage without software control, for example when the rectifier is at the current limit.
Setting Range (minimum to maximum) Default EQ timeout 1 – 2399 h 30 h BT timeout 1 – 250 h 8h Soft start ramp-rate Normal/Fast Normal CL/PL alarm Enable/Disable Enable Remote shutdown Enable/Disable Enable Ramp test Enable/Disable Enable Table F–CXPS 48-1.
8 Maintenance This equipment requires regular maintenance. The maintenance must be done by qualified service personnel only. WARNING: HIGH VOLTAGE AND SHOCK HAZARD Use extreme care when working inside the enclosure/shelf while the system is energized. Do not make contact with live components or parts. Static electricity may damage circuit boards, including RAM chips. Always wear a grounded wrist strap when handling or installing circuit boards.
9 Warranty Visit http://www.alpha.ca/web2/services-and-support/warranty.html for full warranty information. 9.1 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.
10 Alpha Conventions 10.1 Acronyms Acronym AC ANSI AWG BTU CAN CEC CMA CSA CX DC DCP EMC EMI ERM ESD FCC HVSD IEC IEEE IP LED LVD LVBD LVLD MIL MOV MTBF NC NEC NO OSHA OVP RAM RU TCP/IP UL VRLA 053-691-B1 Rev E Definition Alternating current American National Standards Institute American wire gauge British thermal unit Controller area network Canadian Electrical Code Circular mil area Canadian Standards Association Cordex™ series; e.g.
REVISIONS REV.
USED INTERNALLY 020-702-20 PCB DETAILS EXTERNAL VOLTAGE SIGNAL INPUT (3) FORM C RELAY ALARM CUSTOMER CONNECTIONS (NOTE: ALL OTHER INPUTS USED INTERNALLY) LVD OVERRIDE SWTICH GREEN LVD AUTO CONTROL LED USED INTERNALLY YELLOW LVD OVERRIDE LED LIST 74 - CXCI / CXCM1 INTERFACE PCB LIST 2 - LVD OVERRIDE / DISTRIBUTION ALARM PCB CAN TERMINATION SETTINGS CAN TERMINATION CLOSE CAN TERMINATION OPEN CAN TERMINATION OPEN UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES [mm]. 0.040 [ 1] X.X [X] X.XX [X.X] 0.
REVISIONS REV. DESCRIPTION DATE DRWN CHKED APPR'D A CORRECT POLARITY LABELS; SWAP RECTIFIER SHELVES; UPDATE TEMPLATE; REFER TO ECO-10718 3/22/2011 HW ME ME 589.8 23.22 482.6 19.00 221.7 8.73 215.6 8.49 183.9 7.24 171.2 6.74 139.4 5.49 126.7 4.99 95.0 3.74 82.3 3.24 50.5 1.99 37.8 1.49 6.1 0.24 0 16.8 0.66 465.0 18.31 19" RACK 566.7 22.31 23" RACK 126.7 5.0 CENTER MOUNT 376.4 14.
235.2 9.26 FOR 5 RU 457.2 18.00 304.8 12.00 2133.6 84.00 304.8 12.00 457.2 18.00 355.6 14.00 8RU TYP 304.8 12.00 467.2 18.39 547.7 21.56 400.6 15.77 23.8 0.94 TYP 286.3 11.27 CXPS 48-1.2-225_A SYSTEM INSTALLED IN 19", 7ft Z4 RACK WITH 3 x BATTERY TRAYS (PRE-WIRED FOR 3 x 48V VRLA STRINGS) 053-691-20-031 SHOWN 203.2 8.00 317.5 12.50 UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES [mm]. 0.040 [ 1] X.X [X] X.XX [X.X] 0.020 [ 0.5] X.XXX [X.XX] 0.010 [ 0.
235.2 9.26 FOR 5 RU 2133.6 84.00 400.1 15.75 9 RU TYP 649.3 25.56 585.9 23.07 502.2 19.77 23.8 0.94 TYP 286.3 11.27 203.2 8.00 419.1 16.50 CXPS 48-1.2-225_A SYSTEM INSTALLED IN 23", 7ft Z4 RACK WITH 2 x BATTERY TRAYS (PRE-WIRED FOR 2 x 48V VRLA STRINGS) 053-691-20-040 SHOWN UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES [mm]. 0.040 [ 1] X.X [X] X.XX [X.X] 0.020 [ 0.5] X.XXX [X.XX] 0.010 [ 0.25] ANGULAR: 1 INTERPRET DIM AND TOL PER ASME Y14.
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 Energy, 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.
