Alpha Technologies Cordex CXPS-M 48_24-1200_600A User Manual
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Table of contents
Document Outline
- 9400004-J0_B_body.pdf
- 1. Safety
- 1.1 Safety Symbols
- 1.2 General Safety
- 1.3 Mechanical Safety
- 1.4 Electrical Safety
- 1.5 Battery Safety
- 2. Introduction
- 2.1 Scope of the Manual
- 2.2 Options and Additional Alpha Products
- 3. Product Description
- 3.1 Specifications
- 3.2 Cordex 4kW Rectifier Shelves
- 3.3 Cordex 2kW Rectifier Shelves
- 3.4 Cordex 1.2kW Rectifier Shelves
- 3.5 Cordex Converter Shelves (dual voltage systems)
- 3.6 Distribution and Termination
- 3.7 Battery Terminations
- 3.8 Distribution Shunts
- 3.9 Low Voltage Load Disconnect
- 3.10 Distribution Panel Alarms
- 3.11 External Low Voltage Battery Disconnect (purchased separately)
- 3.12 Cordex System Controller
- 4. Pre-Installation Preparation
- 4.1 Site Selection
- 4.2 Tools and Test Equipment
- 4.3 Floor Loading
- 4.4 Unpacking the Equipment
- 5. Installation
- 5.1 Floor drilling for standard anchoring
- 5.2 Placing and Securing the Bay
- 5.3 Mounting the External Battery Return Bus Bar (Optional)
- 5.4 Battery Installation
- 6. Installation - AC, DC and Grounding Cables
- 6.1 Installation Notes
- 6.2 AC Supply for the Rectifiers
- 6.3 Connecting the Frame and Reference Grounds
- 6.4 External Battery Return Bar Wiring (Optional)
- 6.5 Battery Connections
- 6.6 Connecting DC Load Cables to Breaker/Fuse Circuitry
- 6.7 Connecting Load Cables to TPL Circuitry
- 6.8 Final installation steps
- 6.9 External Alarm Wiring
- 7. System Startup
- 7.1 Check System Connections
- 7.2 Verify AC and Power the Rectifier Shelf
- 7.3 Check Battery Polarity and Connect
- 7.4 Final Configuration and Test
- 8. Test and Commissioning Overview
- 8.1 System
- 8.2 Battery
- 8.3 Documentation
- 9. Maintenance
- 9.1 Rectifiers
- 9.2 Controller Lithium Battery Replacement
- 9.3 Batteries
- 9.4 Adding Rectifier Shelves
- 10. Acronyms and Definitions
- 11. Warranty
- 11.1 Battery Warranty
- Figure 1 — Example of a 1200 A system , dual voltage
- Figure 2 — CXDF 24-48/2kW converter module
- Figure 3 — Rear view showing DC charge buses (covers removed)
- Figure 4 — 1200A dual voltage system
- Figure 5 — DC distribution modules
- Figure 6 — Dual Voltage distribution modules
- Figure 7 — Distribution module installation shield
- Figure 8 — Battery termination (front view)
- Figure 9 — Remote battery return bar: customer connections (single bar shown)
- Figure 10 — TPL shunts
- Figure 11 — Breaker bank shunt (one per bank)
- Figure 12 — Shunt mux panel mounted on the inside door of the top distribution module
- Figure 13 — LVD circuits
- Figure 14 — CB/fuse alarm LEDs and LVD control
- Figure 15 — CXCP controller mounted in a distribution module
- Figure 16 — Control cards
- Figure 17 — Battery terminations shown with protective covers
- Figure 18 — Template for anchoring bolts
- Figure 19 — External battery return bus bar kit (2 bars shown)
- Figure 20 — Battery shelf in the bay
- Figure 21 — Temperature probe
- Figure 22 — Shelf AC connection (208Vac, 3 phase, 3-wire shown with rear cover removed)
- Figure 23 — Frame and reference returns (front view)
- Figure 24 — Frame reference ground (top of bay)
- Figure 25 — Remote battery return bar wiring
- Figure 26 — External battery return bus bar (dual level shown)
- Figure 27 — Battery terminations (front view)
- Figure 28 — Preparation for 2-pole and 3-pole breakers
- Figure 29 — Breaker distribution module before load cables are installed
- Figure 30 — Breaker load cable and return connections
- Figure 31 — High capacity TPL fuse wiring (shown with 2x 750 MCM wire)
- Figure 32 — Final load cable arrangement (shown with protective covers removed)
- Figure 34 — Insulation cover (rear view)
- Figure 33 — Top Kydex cover with cuts for cable entry
- Figure 35 — Insulation covers in place
- Figure 36 — Securing Insulation covers to bay
- Figure 37 — Route of external signal wiring
- Figure 38 — CAN bus termination
- Figure 39 — CAN OUT connection
- Table A — Specifications for Mid Capacity Power Systems
- Table B — Mid Capacity Power Systems Output Configurations
- Table C — Modular distribution components and termination
- Table D — Typical VRLA battery maintenance report
- Table E — Cable size equivalents (AWG to Metric)
- Table F — Recommended torque values
- Table G — Typical Ground Reference Conductor Selection
- Table H — Sample maintenance log
- 1. Safety
- 9400004-J0_B_body_May11.pdf
- Table A — Specifications for Mid Capacity Power Systems
- Table B — Mid Capacity Power Systems Output Configurations
- Table C — Modular distribution components and termination
- Table D — Typical VRLA battery maintenance report
- Table E — Cable size equivalents (AWG to Metric)
- Table F — Recommended torque values
- Table G — Typical Ground Reference Conductor Selection
- Table H — Sample maintenance log
- 1. Safety
- 2. Introduction
- 3. Product Description
- 3.1 Specifications
- 3.2 Cordex 4kW Rectifier Shelves
- 3.3 Cordex 2kW Rectifier Shelves
- 3.4 Cordex 1.2kW Rectifier Shelves
- 3.5 Cordex Converter Shelves (dual voltage systems)
- 3.6 Distribution and Termination
- 3.7 Battery Terminations
- 3.8 Distribution Shunts
- 3.9 Low Voltage Load Disconnect
- 3.10 Distribution Panel Alarms
- 3.11 External Low Voltage Battery Disconnect (purchased separately)
- 3.12 Cordex System Controller
- 4. Pre-Installation Preparation
- 5. Installation
- 6. Installation - AC, DC and Grounding Cables
- 6.1 Installation Notes
- 6.2 AC Supply for the Rectifiers
- 6.3 Connecting the Frame and Reference Grounds
- 6.4 External Battery Return Bar Wiring (Optional)
- 6.5 Battery Connections
- 6.6 Connecting DC Load Cables to Breaker/Fuse Circuitry
- 6.7 Connecting Load Cables to TPL Circuitry
- 6.8 Final installation steps
- 6.9 External Alarm Wiring
- 7. System Startup
- 8. Test and Commissioning Overview
- 9. Maintenance
- 10. Acronyms and Definitions
- 11. Warranty
- Figure 1 — Example of a CXPS-M 1200 A power system with dual voltage
- Figure 2 — CXDF 24-48/2kW converter module
- Figure 3 — Rear view showing DC charge buses (covers removed)
- Figure 4 — 1200A dual voltage system
- Figure 5 — DC distribution modules
- Figure 6 — Dual Voltage distribution modules
- Figure 7 — Distribution module installation shield
- Figure 8 — Battery termination (front view)
- Figure 9 — Remote battery return bar: customer connections (single bar shown)
- Figure 10 — TPL shunts
- Figure 11 — Breaker bank shunt (one per bank)
- Figure 12 — Shunt mux panel mounted on the inside door of the top distribution module
- Figure 13 — LVD circuits
- Figure 14 — CB/fuse alarm LEDs and LVD control
- Figure 15 — CXCP controller mounted in a distribution module
- Figure 16 — Control cards
- Figure 17 — Battery terminations shown with protective covers
- Figure 18 — Template for anchoring bolts
- Figure 19 — External battery return bus bar kit (2 bars shown)
- Figure 20 — Battery shelf in the bay
- Figure 21 — Temperature probe
- Figure 22 — Shelf AC connection (208Vac, 3 phase, 3-wire shown with rear cover removed)
- Figure 23 — Frame and reference returns (front view)
- Figure 24 — Frame reference ground (top of bay)
- Figure 25 — Remote battery return bar wiring
- Figure 26 — External battery return bus bar (dual level shown)
- Figure 27 — Battery terminations (front view)
- Figure 28 — Preparation for 2-pole and 3-pole breakers
- Figure 29 — Breaker distribution module before load cables are installed
- Figure 30 — Breaker load cable and return connections
- Figure 31 — High capacity TPL fuse wiring (shown with 2x 750 MCM wire)
- Figure 32 — Final load cable arrangement (shown with protective covers removed)
- Figure 34 — Insulation cover (rear view)
- Figure 33 — Top Kydex cover with cuts for cable entry
- Figure 35 — Insulation covers in place
- Figure 36 — Securing Insulation covers to bay
- Figure 37 — Route of external signal wiring
- Figure 38 — CAN bus termination
- Figure 39 — CAN OUT connection