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
• 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
    • 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
    • 9.5 Spares
  • 10. Acronyms and Definitions
  • 11. Warranty
    • 11.1 Battery 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