cordex controller panel/rack mount 125/220vdc

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Cordex Controller Panel/Rack Mount 125/220Vdc

Installation & Operation ManualPart # 018-570-B2Effective: 07/2016

member of The Group™

Cordex Controller Panel/Rack Mount125/220Vdc

For technical support, contact Alpha Technologies:

Canada and USA: 1-888-462-7487International: +1-604-436-5547

CopyrightCopyright © 2016 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.

Alpha 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.

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 Technologies or your nearest Alpha representative.

NOTE:

NOTE:

9400010-J1 Rev A

Important Safety Instructions

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.

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 specific regulatory/code requirements that may affect the placement of equipment and /or installation procedures.

NOTE: A NOTE provides additional information to help complete a specific task or procedure.

CAUTION! CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. Cautions are designated with a shock hazard icon, the word CAUTION, and a rule beneath which the information appears.

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. HOT! The use of HOT presents safety information to PREVENT BURNS to the technician or user.

General Safety

WARNING! This system is designed to be installed in a restricted access location that is inaccessible to the general public.

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.

9400010-J1 Rev A

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 the installation. • Use OSHA approved insulated hand tools.

WARNING!

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 installation 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.

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.

WARNING!

Follow battery manufacturer’s safety recommendations when working around battery systems. Do not smoke or introduce an open flame when batteries (especially vented batteries) are charging. When charging, batteries vent hydrogen gas, which can explode.

• Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery

manufacturer for recommended local authorized recyclers.

#9400011-J1 Rev A

Seguridad

GUARDE ESTAS INSTRUCCIONES: Este manual contiene instrucciones de seguridad importantes que deben seguirse durante la instalación, reparación y mantenimiento del producto. Manténgalas en un lugar seguro. Inspeccione los dibujos y las ilustraciones contenidas en este manual antes de continuar. Si existe cualquier pregunta relacionada con la instalación u operación segura de este producto, póngase en contacto con Alpha Technologies o con su representante de Alpha más cercano. Guarde este documento para referencia futura.

Símbolos de Seguridad Para reducir el riesgo de lesión o muerte y para asegurar la operación continua segura de este producto, se han colocado los siguientes símbolos a lo largo de este manual. En las partes donde aparecen estos símbolos, preste atención y cuidado adicional.

Atención: El uso de ATENCIÓN indica requisitos de código o regulatorios específicos que pueden afectar la ubicación del equipo y/o los procedimientos de instalación.

NOTA: Una NOTA (NOTE)provee información adicional para ayudar a completar una tarea o un procedimiento específico. ¡CUIDADO! CUIDADO (CAUTION) indica información de seguridad con el propósito de PREVENIR DAÑOS al material o al equipo. Los avisos de cuidado están designados con un icono de peligro de choque, la palabra CUIDADO y una línea debajo de la cual aparece la información. ¡ADVERTENCIA! Una ADVERTENCIA (WARNING) presenta información de seguridad para PREVENIR LESIÓN O MUERTE al personal. Las advertencias se indican con un icono de peligro de choque, la palabra ADVERTENCIA y una línea debajo de la cual aparece la información

¡CALIENTE! El uso de CALIENTE (HOT) presenta información de seguridad para PREVENIR QUEMADURAS al técnico o al usuario.

Seguridad General ¡ADVERTENCIA! Este sistema está diseñado para instalarse en una ubicación con acceso restringido que no sea accesible para el público general.

Seguridad Mecánica

• Mantenga las manos y las herramientas alejadas de los ventiladores. Los ventiladores están controlados de forma termostática y se encienden automáticamente.

• Las fuentes de alimentación pueden alcanzar temperaturas extremas bajo carga. • Tenga cuidado cerca de bordes filosos y componentes de chapa.

#9400011-J1 Rev A

Seguridad Eléctrica

¡ADVERTENCIA! Hay voltajes peligrosos en la entrada de los sistemas de alimentación. La salida de CC de rectificadores y baterías, si bien no es peligrosa en cuanto al voltaje, cuenta con una alta capacidad de conducción de cortocircuito que puede causar quemaduras graves y arcos eléctricos.

Antes de trabajar con una batería activa o un sistema de alimentación, siga estas precauciones:

• Quítese toda joyería metálica, como relojes, anillos, anteojos con montura de metal o collares. • Use antiparras de seguridad con protecciones laterales en todo momento durante la instalación. • Use herramientas manuales aisladas aprobadas por OSHA.

¡ADVERTENCIA! El sistema de alimentación presenta voltajes mortales en su interior. Suponga siempre que las conexiones o los conductores eléctricos están energizados. Revise el circuito con un voltímetro con respecto de la porción a tierra del cerramiento (tanto CA como CC) antes de realizar cualquier procedimiento de instalación o remoción. • No trabaje solo en condiciones peligrosas. • Se requiere que un electricista matriculado se ocupe de instalar equipos con conexión permanente. Los

voltajes de entrada pueden llegar a los 240 VCA. Asegúrese de que la fuente de alimentación eléctrica del servicio esté desconectada y bloqueada antes de realizar un procedimiento de instalación o remoción.

• Asegúrese de que ningún líquido ni ropa húmeda en contacto con los componentes internos. • Las partes eléctricamente activas peligrosas dentro de esta unidad están energizadas por las baterías incluso

cuando se desconecta la alimentación de entrada de CA.

Seguridad de la Batería Externa • El mantenimiento y la conexión de las baterías debe ser realizado por, o bajo la supervisión directa de,

personal experto en baterías y tomando las precauciones de seguridad requeridas. • Siempre que trabaje con baterías utilice protección para los ojos, guantes de goma y un chaleco protector.

Quítese todos los objetos metálicos de las manos y el cuello. • Use herramientas manuales aisladas aprobadas por OSHA. No apoye las herramientas sobre las baterías. • Las baterías contienen o emiten elementos químicos que causan cáncer y defectos de nacimiento u otros

problemas reproductivos. • Los terminales de batería y accesorios similares contienen plomo y compuestos del plomo. Lávese las manos

después de manipular baterías.

¡ADVERTENCIA! Siga las recomendaciones del fabricante de las baterías cuando trabaje cerca de sistemas de baterías. No fume ni introduzca una llama abierta cuando las baterías (en especial las baterías ventiladas) se están cargando. Mientras se cargan, las baterías ventilan gas hidrógeno que puede explotar.

• Las baterías son peligrosas para el medioambiente y deben desecharse en un centro de reciclado. Consulte al

fabricante de las baterías acerca de centros de reciclado autorizados locales recomendados.

9400012-J1 Rev A

Sécurité

CONSERVEZ CES INSTRUCTIONS: Le présent manuel contient des consignes de sécurité importantes

à suivre pendant l'installation, l'entretien et la maintenance du produit. Rangez-le dans un endroit sûr. Examinez les schémas et illustrations contenus dans ce manuel avant de poursuivre. En cas de questions sur l'installation ou le fonctionnement en toute sécurité de ce produit, contactez Alpha Technologies ou le représentant d'Alpha le plus près. Conservez ce document pour référence future.

Symboles de Sécurité Pour réduire le risque de blessures ou d'accident mortel et assurer le maintien de conditions d'exploitation sécuritaires de ce produit, les symboles ci-après ont été utilisés systématiquement dans ce manuel. Lorsque ces symboles sont utilisés, prenez des précautions supplémentaires.

L'utilisation du symbole « ATTENTION » indique l'existence d'exigences réglementaires ou normatives qui peuvent affecter l'emplacement de l'équipement ou les procédures d'installation.

REMARQUE: Une REMARQUE (NOTE) fournit des informations supplémentaires destinées à aider à la réalisation d'une tâche ou d'une procédure spécifique.

PRUDENCE !

Le symbole PRUDENCE (CAUTION) indique une information de sécurité destinée à ÉVITER DES DOMMAGES au matériel ou à l'équipement. Ce symbole est représenté par une icône de danger de décharge électrique, le terme PRUDENCE et une ligne en dessous de laquelle l'information est affichée.

AVERTISSEMENT!

Le symbole AVERTISSEMENT (WARNING) donne des informations sur la sécurité permettant au personnel d'ÉVITER DES BLESSURES OU DES ACCIDENTS MORTELS. Les avertissements sont identifiés par une icône de danger de décharge électrique, le terme AVERTISSEMENT et une ligne en dessous de laquelle l'information est affichée.

CHAUD! Le symbole CHAUD (HOT) est associé à des informations de sécurité destinées à ÉVITER DES BRÛLURES au technicien ou à l'utilisateur.

Avertissements et Mises en Garde D'ordre Général AVERTISSEMENT !

Ce système est conçu pour être installé dans un endroit restreint inaccessible au public. Sécurité Mécanique

• Gardez les mains et les outils à l’écart des ventilateurs. Les ventilateurs sont thermostatés et s’allument automatiquement.

• Les blocs d’alimentation peuvent atteindre des températures extrêmes lorsqu’ils sont sous tension. • Procédez avec prudence autour des composants en tôle et des bords tranchants.

9400012-J1 Rev A

Sécurité Electrique AVERTISSEMENT !

Des tensions dangereuses sont présentes à l’entrée des systèmes électriques. La sortie CC des redresseurs et des batteries, bien que non dangereuse en termes de tension, a une capacité de courant de court-circuit élevée qui peut causer de graves brûlures et des arcs électriques. Avant de travailler sur une batterie ou un système électrique alimenté(e), suivez ces précautions :

• Retirez tout bijou métallique, tel qu’une montre, une alliance, des montures métalliques ou un collier. • Portez des lunettes de sécurité avec des écrans latéraux de protection à tout moment durant l’installation. • Utilisez des outils à mains isolés et approuvés par OSHA.

AVERTISSEMENT !

Des tensions mortelles sont présentes dans le système électrique. Considérez toujours une connexion électrique ou un conducteur comme étant sous tension. Vérifiez le circuit avec un voltmètre au niveau de la partie mise à la terre du boîtier (CA et CC) avant de lancer une procédure d’installation ou de retrait.

• Ne travaillez pas seul lorsque les conditions sont dangereuses. • Un électricien agréé est requis pour installer un équipement câblé de façon permanente. Les tensions d’entrée

peuvent atteindre • 240 V CA. Assurez-vous que l’électricité de service est débranchée et verrouillée avant de lancer une procédure

d’installation ou de retrait. • Assurez-vous qu’aucun liquide ou vêtement mouillé n’entre en contact avec les composants internes. • Les pièces électriques dangereuses à l’intérieur de cette unité sont alimentées par les batteries même lorsque

l’alimentation CA en entrée est débranchée.

Sécurité de la Batterie • L'entretien et la connexion des batteries doivent être effectués par un spécialiste des batteries ou sous la

supervision directe d'un tel spécialiste, en prenant les précautions de sécurité requises. • Portez toujours une protection pour les yeux, des gants en caoutchouc et un gilet de protection lorsque vous

travaillez à proximité de batteries. Retirez tous les objets métalliques de vos mains et de votre coup. • Utilisez des outils à main isolés et approuvés par OSHA. Ne déposez pas les outils sur les batteries. • Les batteries contiennent ou émettent des produits chimiques identifiés comme cause de cancer et de

malformations congénitales ou d'autres troubles de l'appareil reproducteur. Les bornes des batteries et leurs accessoires contiennent du plomb et des composés de plomb. Lavez-vous les mains après avoir manipulé des batteries.

AVERTISSEMENT !

Observez les recommandations de sécurité du fabricant quand vous travaillez avec des systèmes de batteries. Ne fumez pas, ou n'introduisez pas de flamme nue quand les batteries (surtout les batteries ouvertes) sont en cours de charge. En cours de charge, les batteries dégagent de l'hydrogène gazeux susceptible d'exploser.

• Les batteries sont néfastes pour l'environnement et doivent être mises au rebut dans un centre de recyclage.

Consultez le fabricant de la batterie pour connaître les centres de recyclages agréés locaux.

9400013-J1 Rev A

Wichtige Sicherheitshinweise BEWAHREN SIE DIESE ANWEISUNGEN AUF: Dieses Handbuch enthält wichtige Sicherheitshinweise, die bei der Installation, Wartung und Instandhaltung des Produkts beachtet werden müssen. Bewahren Sie es an einem sicheren Ort auf. Sehen Sie sich die Zeichnungen und Illustrationen in diesem Handbuch genau an, bevor Sie fortfahren. Sollten Sie Fragen zur sicheren Installation oder zum Betrieb dieses Produkts haben, wenden Sie sich bitte an Alpha Technologies oder den nächstgelegenen Alpha-Vertreter. Bewahren Sie dieses Dokument für den zukünftigen Gebrauch auf.

Sicherheitssymbole Um das Risiko von Verletzungen oder Todesfällen zu reduzieren und den weiteren sicheren Betrieb dieses Produkts zu gewährleisten, wurden in diesem Handbuch die folgenden Symbole verwendet. Seien Sie besonders vorsichtig und aufmerksam, wenn diese Symbole abgebildet sind.

Das Symbol VORSICHT (ATTENTION) deutet auf spezifische Anforderungen von aufsichtsrechtlichen Vorschriften oder Normen hin, welche Einfluss auf die Platzierung von Geräten und/oder Installationsverfahren haben können. HINWEIS: Ein HINWEIS (NOTE) liefert zusätzliche Informationen, die Ihnen helfen, eine bestimmte Aufgabe zu lösen bzw. ein bestimmtes Verfahren durchzuführen. Hinweise sind mit einem Häkchen, dem Wort HINWEIS und einem Strich, unter dem die Informationen aufgeführt sind, gekennzeichnet.

ACHTUNG!

ACHTUNG (CAUTION) kennzeichnet Sicherheitsinformationen, die darauf abzielen, SCHÄDEN an Materialien oder Geräten ZU VERHINDERN. Diese Warnhinweise sind mit einem gelben Warndreieck, dem Wort ACHTUNG und einem Strich, unter dem die Informationen aufgeführt sind, gekennzeichnet.

WARNUNG!

Eine WARNUNG (WARNING) enthält Sicherheitsinformationen zur VERHINDERUNG VON VERLETZUNGEN ODER TODESFÄLLEN bei Mitarbeitern. Diese Warnhinweise sind mit einem Stromschlagsymbol, dem Wort WARNUNG und einem Strich, unter dem die Informationen aufgeführt sind, gekennzeichnet.

HEISS!

Die Warnung HEISS! (HOT) liefert Sicherheitsinformationen, die dazu dienen, VERBRENNUNGEN des Technikers oder Benutzers zu VERHINDERN.

Allgemeine Sicherheit WARNUNG!

Dieses System wurde für eine Aufstellung an einem Standort mit Zugangsbeschränkung entworfen, der für die allgemeine Öffentlichkeit nicht zugänglich ist.

Mechanische Sicherheit • Achten Sie darauf, dass Hände und Werkzeuge nicht mit den Lüftern in Berührung kommen. Die Lüfter werden

thermostatisch kontrolliert und schalten sich automatisch ein. • Die Netzteile können unter Last Extremtemperaturen erreichen. • Gehen Sie in der Nähe von Blechteilen und scharfen Kanten vorsichtig vor.

9400013-J1 Rev A

Elektrische Sicherheit WARNUNG!

Am Punkt der Stromeinspeisung liegen gefährliche Spannungen vor. Der Gleichstromausgang von Gleichrichtern und Batterien weist zwar keine gefährliche Spannung auf, die Kurzschlussstrom-Kapazität ist jedoch sehr hoch, was zu ernsthaften Verbrennungen und Lichtbögen führen kann. Befolgen Sie die folgenden Vorsichtsmaßnahmen, bevor Sie mit einer spannungsführenden Batterie oder einem Stromversorgungssystem arbeiten: • Legen Sie sämtlichen Schmuck aus Metall wie z.B. Armbanduhren, Ringe, Brillen mit Metallrahmen oder

Halsketten ab. • Tragen Sie während der Installationsarbeiten jederzeit Schutzbrillen mit Seitenschutz. • Verwenden Sie nur geprüftes isoliertes Werkzeug.

WARNUNG! Innerhalb des Stromversorgungssystems herrschen lebensgefährliche Spannungen vor. Gehen Sie jederzeit davon aus, dass eine elektrische Verbindung oder ein Leiter Strom führt. Überprüfen Sie den Stromkreis mit einem Spannungsmesser bezüglich des geerdeten Teils des Gehäuses (sowohl Wechsel- als auch Gleichstrom), bevor Sie eine Installation oder Demontage durchführen.

• Arbeiten Sie unter gefährlichen Bedingungen niemals alleine. • Die Installation festverdrahteter Geräte muss durch einen zugelassenen Elektriker vorgenommen werden. Die

Eingangsspannungen können bis zu 240 VAC betragen. Stellen Sie sicher, dass die Verbindung zum Netzstrom getrennt und gegen Wiedereinschalten gesichert ist, bevor Sie eine Installation oder Demontage durchführen.

• Stellen Sie sicher, dass keine Flüssigkeiten oder nasse Kleidungsstücke mit innenliegenden Komponenten in Berührung kommen.

• Gefährliche stromführende Teile innerhalb dieses Geräts werden auch bei Trennung der Netzverbindung noch über die Batterien versorgt.

Batteriesicherheit • Die Wartung und der Anschluss von Batterien muss von Mitarbeitern durchgeführt bzw. direkt beaufsichtigt

werden, die über Kenntnisse über Batterien und die erforderlichen Sicherheitsmaßnahmen verfügen. • Tragen Sie jederzeit Augenschutz, Gummihandschuhe und eine Schutzweste, wenn Sie in der Nähe von

Batterien arbeiten. Entfernen Sie sämtliche Metallgegenstände von Ihren Händen und Ihrem Hals. • Verwenden Sie von der OSHA genehmigte isolierte Handwerkzeuge. Legen Sie Werkzeuge nicht auf Batterien

ab. • Verwenden Sie nur geprüftes isoliertes Werkzeug. Legen Sie Werkzeug niemals auf Batterien ab. • •Batterien enthalten Chemikalien bzw. setzen Chemikalien frei, von denen bekannt ist, dass sie Krebs oder

Geburtsfehler verursachen oder die Fortpflanzungsfähigkeit anderweitig schädigen. • Batterieanschlüsse und entsprechendes Zubehör enthalten Blei und Bleiverbindungen. Waschen Sie nach

dem Umgang mit Batterien Ihre Hände. • verursachen oder die Fortpflanzungsfähigkeit anderweitig schädigen.

WARNUNG!

Befolgen Sie die Sicherheitsempfehlungen von Batterieherstellern, wenn Sie mit Batteriesystemen arbeiten. Während Batterien (insbesondere geschlossene Batterien) aufgeladen werden, darf weder geraucht noch offenes Feuer verwendet werden. Beim Aufladen setzen Batterien Wasserstoffgas frei, das explodieren kann.

• Batterien sind schädlich für die Umwelt und sollten im Sondermüll entsorgt werden. Wenden Sie sich an den

Batteriehersteller, um sich über empfohlene zugelassene örtliche Recyclingstellen zu informieren.

ii

TABLE OF CONTENTS 1 INTRODUCTION ............................................................................................................................................................. 1

1.1 Scope of the Manual ..................................................................................................................................... 1 1.2 Product Overview .......................................................................................................................................... 1

2 SPECIFICATIONS ........................................................................................................................................................... 2 2.1 Basic Unit ...................................................................................................................................................... 2 2.2 Environmental ............................................................................................................................................... 2 2.3 Hardware Specifications ............................................................................................................................... 3 2.4 Recommended Connection Wire Sizes (as per UL/CSA) ............................................................................. 3 2.5 Part Numbers and List Options ..................................................................................................................... 4

3 HARDWARE FEATURES ................................................................................................................................................. 5 3.1 Operator Interface Devices ........................................................................................................................... 5 3.2 Serial Ports .................................................................................................................................................... 6 3.3 Real Time Clock ............................................................................................................................................ 6 3.4 Lithium Battery Backup ................................................................................................................................. 6 3.5 Analog Input Channels .................................................................................................................................. 6 3.6 Digital Input Channels ................................................................................................................................... 7 3.7 Alarm and Control Output Relays ................................................................................................................. 7 3.8 CXC System Fail Alarm/Relay ...................................................................................................................... 7

4 INSPECTION.................................................................................................................................................................. 8 4.1 Packing Materials .......................................................................................................................................... 8 4.2 Check for Damage ........................................................................................................................................ 8 4.3 General receipt of Shipment ......................................................................................................................... 8

5 INSTALLATION .............................................................................................................................................................. 9 5.1 Safety Precautions ........................................................................................................................................ 9 5.2 Shelf Preparation/Mounting .......................................................................................................................... 9

6 WIRING AND CONNECTIONS ........................................................................................................................................ 10 6.1 Safety Precautions ...................................................................................................................................... 10 6.2 Front Access ............................................................................................................................................... 10 6.3 Tools Required ............................................................................................................................................ 10 6.4 Power System Chassis Ground and DC Ground Reference ...................................................................... 10 6.5 Power Inputs ............................................................................................................................................... 10 6.6 Analog Inputs .............................................................................................................................................. 11 6.7 Digital Inputs ............................................................................................................................................... 11 6.8 Relay Outputs ............................................................................................................................................. 13 6.9 Rectifier Connections .................................................................................................................................. 13 6.10 Network Connection and Remote Communications ................................................................................... 14

7 MAINTENANCE ........................................................................................................................................................... 16 7.1 Lithium Battery Replacement ...................................................................................................................... 16

8 ALPHA CONVENTIONS ................................................................................................................................................ 17 8.1 Numbering System ...................................................................................................................................... 17 8.2 Acronyms and Definitions ........................................................................................................................... 17

9 WARRANTY AND SERVICE INFORMATION ..................................................................................................................... 18 9.1 Technical Support ....................................................................................................................................... 18 9.2 Warranty Statement .................................................................................................................................... 18 9.3 Product Warranty ........................................................................................................................................ 18

iii

9.4 Battery Warranty ......................................................................................................................................... 18 9.5 Warranty Claims .......................................................................................................................................... 18 9.6 Service Information ..................................................................................................................................... 18

018-570-B2 Rev D Page 1

1 Introduction

1.1 Scope of the Manual This instruction manual explains the installation and interconnection of the Cordex System Controller (CXC) 125/220Vdc rack (CXCR) model from AlphaTechnologies.

NOTE: To aid the user with installation, frequent reference is made to drawings located at the rear of this manual.

1.2 Product Overview The CXC 125/220Vdc is an advanced system controller designed by Alpha for operation with 125/220Vdc power systems.

The CXC HV controller provides four digital and nine analog inputs that may be used to monitor a wide range of power system components.

The CXC HV controllers allow the user to configure, monitor and control the entire DC power system from a touch screen display similar to that used in a Personal Digital Assistant (PDA). Other features include temperature compensation, auto equalization, remote access, dial out on alarm, battery diagnostics, as well as Web server and SNMP support for configuration and monitoring.

NOTE: Separate documentation will be provided detailing the CXC software features, setup and operation.

The CXC offers additional advanced features via add-on “list options.” The customer should include these list options at the time of ordering.

Refer to the specifications section for part numbers and ordering options.

Figure 1–Front view of Cordex controller 19” rack model CXCR

Touch Screen

Reset Button RS-232 (Craft Port)

Latch (2PL)

LEDs

018-570-B2 Rev D Page 2

2 Specifications

2.1 Basic Unit Input Voltage: 90 to 300Vdc within rated limits MTBF: 472,000 @ 25°C (77°F)

EMC: The unit meets requirements of:

ICES-003 Class A EN 55022 Class A (CISPR 22) EN 61000-4-2 ESD EN 61000-4-3 Radiated Immunity EN 61000-4-4 EFT /Burst EN 61000-4-6 Conducted Immunity FCC Part 15 Class A, FCC Part 68

Ground Fault Detection: 0 – 10mA In accordance with FCC requirements, we provide the following statement as specified in the FCC guidelines for conformance to Part 15, Class A:

NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Any changes or modifications to this equipment not expressly described in this manual could void the FCC compliance.

2.2 Environmental Operating Temperature: 0 to 65°C standard @ 3000m derate to 55°C @ 4000m

(32 to 149°F derate to 131°F @ 13124ft) [Optional -40°C]

Storage Temperature: -20 to 70°C standard

(-4 to 158°F) -40 to 80°C optional

(-40 to 176°F) Humidity: 0 to 95% non-condensing Elevation: -500 to +4000m

(-1640 to 13124 ft)

018-570-B2 Rev D Page 3

2.3 Hardware Specifications CPU: Coldfire RAM: 8MB Flash: 4MB standard, 4MB optional Display: 160 x 160 pixel grayscale LCD Front Panel Controls: Reset button and touch panel (display and input device) LED’s: System OK (Green)

Power System Minor Alarm (Yellow) Power System Major Alarm / Controller Fail (Red)

Internal Battery: 3V Lithium CR1616 [Alpha part number #185-005-10] Audio: Built-in speaker for alarm and popup message tones Mounting: Integrated with power system/distribution panel [List 80]

19" and 23" flush rack mounting, 3RU [Default List 81] Rack Mount Dimensions: 131mm H x 425mm W x 100mm D

(5.1” x H x 16.7” W x 3.9” D) Weight: 6.2 kg typical [Default List 81]

(13.8 lb.) Analog Inputs: 1 DC voltage, 1 DC current, 2 temperature, 4 bi-voltage

[sample configuration – other options available] Ground Fault Detect Alarms: 1 Digital Inputs: 4 Relay Outputs: 8 Form C, 220VDC 0.4A maximum;

8 optional Form C, 60VDC 1A maximum Communication Ports: Ethernet Port, 2 x CAN (bus), RS-485, 2 x RS-232,

TNV-1 Telephone Port (with communication expansion board)

2.4 Recommended Connection Wire Sizes (as per UL/CSA) Minimum Wire Size: 0.823 to 0.0507mm2

(#18 to #30 AWG) Temperature Range: 0 to 50°C

(32 to 122°F) CAUTION – TO REDUCE RISK OF FIRE, USE ONLY 0.129mm2 (#26 AWG) OR LARGER WIRE.

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2.5 Part Numbers and List Options This product is available to order under the following part numbers and list options: Description Part Number/List Option Cordex Controller ....................................................................................................................................... 018-570-20 Basic unit ............................................................................................................................................................ *List 0 125V system software configuration .................................................................................................................... List 3 220V system software configuration .................................................................................................................. *List 4 19” rack, flush mounting brackets .................................................................................................................... *List 21 Door mounting brackets .....................................................................................................................................List 22 23” rack, flush mounting brackets ......................................................................................................................List 25 Standard temperature (0 to 65°C) ......................................................................................................................List 40 Extended temperature (-40 to 65°C) ..................................................................................................................List 42 Gray finish with blue silkscreen ..........................................................................................................................List 50 Charcoal finish with white (contrasting) silkscreen ............................................................................................List 56 Temp sensor assembly:

1/4” lug, 6’ cable ....................................................................................................................................List 71 1/4” lug, 12’ cable ..................................................................................................................................List 72 1/4” lug, 24’ cable ..................................................................................................................................List 73 3/8” lug, 6’ cable ....................................................................................................................................List 74 3/8” lug, 12’ cable ..................................................................................................................................List 75 3/8” lug, 24’ cable ..................................................................................................................................List 76 3/8” lug, 50’ cable ..................................................................................................................................List 77 1/4” lug, 50’ cable ..................................................................................................................................List 78

CAN bus port (required for Cordex rectifier communications interface) ............................................................List 90 Auxiliary CAN bus port .......................................................................................................................................List 91 RS-485 port (required for Pathfinder rectifier communications interface) .........................................................List 92 Ethernet port ......................................................................................................................................................List 93 Expansion board, communication (Lists 90-93 must be ordered separately) ....................................................List 95 Expansion board, output relay, 8 x 1A Form C, internal ....................................................................................List 96 Internal modem, global (includes List 95) ........................................................................................................List 101 Expanded Flash memory .................................................................................................................................List 110 Analog input configuration: add one current shunt input .................................................................................List 128 * Default options Cable, 9-pin null modem ............................................................................................................................ 877-482-20 Cable, RJ-12 to RJ-12; sorted by length:

1’ .................................................................................................................................................... 877-176-26 1.5’ ................................................................................................................................................. 877-176-21 19” ................................................................................................................................................. 877-176-27 2’ .................................................................................................................................................... 877-176-22 6’ .................................................................................................................................................... 877-176-23 12’ .................................................................................................................................................. 877-176-24 25’ .................................................................................................................................................. 877-176-25

The above information is valid at the time of publication. Consult factory for up-to-date ordering information. Specifications are subject to change without notice.

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3 Hardware Features Behind the CXC’s front panel lies the main controller motherboard, which contains a microprocessor, memory, removable lithium battery, as well as numerous other electronic components. The input/output (I/O) board houses a series of terminal connections. Space is also available to add optional output relays or an internal modem. Connections are oriented for front access.

3.1 Operator Interface Devices The user interfaces with the CXC by one or more of the following methods:

• Graphical input device, front panel LEDs and audio speaker. • RS-232 serial port (local “craft” port w/ null modem cable). • Optional Ethernet connection.

3.1.1 Basic Audio Speaker

A built-in audio speaker confirms activity with short tones; that is, for successful selection of an item or selecting outside the bounds of a window prompt. The speaker also sounds an intermittent tone during active alarms.

3.1.2 Front Panel Descriptions

The front panel contains a touch screen, a local RS-232 serial (Craft) port, a reset button and LEDs. A brief description of each is provided below:

3.1.3 Touch Screen

Located on the front panel is a 160 x 160-pixel graphical LCD with touch screen similar to those used in PDAs. This graphical user interface (GUI) allows the operator to interact with screen selectable items using a fingertip.

Figure 2–Sample screen of CXC graphical user interface

3.1.4 RS-232 Serial (Craft) Port

Local access to the CXC is possible through a front panel RS-232 serial port; using a null modem cable. The communication protocol supports a web interface (via Microsoft® Internet Explorer 6 or greater). The remote screen display is an enhanced version of the CXC’s front panel display.

3.1.5 Reset Button

A reset button is located on the front panel for restarting the CXC’s microprocessor. It takes approximately 15 seconds before the display reappears after pressing the reset button.

NOTE: Refer also to the software manual – always select the reset menu item, on the pop-up window of the touch screen, and follow the prompts before pressing the reset button.

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3.1.6 Front Panel LEDs

The CXC has three LEDs located on the front panel. These are used to display the alarm status of the power system, CXC progress and status during startup, file transfers and lamp tests.

3.1.6.1 Alarm Conditions

The CXC illuminates the LED that corresponds to the system alarm status. The following show the corresponding alarm status for each LED color:

• Green – No alarms present • Yellow – Minor alarm is present (no major alarms) • Red – Major alarm is present.

Only one LED is illuminated at a time during alarm conditions.

3.1.6.2 Progress and Status Indication

The LEDs are also used in the following situations:

• Base unit validation – all three LEDs are on at the same time. • File transfer – when recovering from invalid firmware application – the red LED is illuminated. • Lamp Test – all three LEDs flash on and off at the same time for 2 seconds.

3.2 Serial Ports

3.2.1 CAN (Option)

Two CAN Serial ports, for communications with Alpha’ Cordex rectifiers and other CAN-enabled equipment, are located next to the RS-485 port on the CXC.

3.2.2 Ethernet (Option)

One 10/100 Base T Ethernet port is provided for CXC communications with a local area network (LAN), e.g. the Internet.

3.3 Real Time Clock The CXC contains a real time clock (Y2K compliant), which allows time stamps to be placed on alarm, and statistical events contained in the historical data files.

3.4 Lithium Battery Backup A removable lithium battery (see Specifications) is included in the system to retain time and date settings upon power loss or reset.

3.5 Analog Input Channels The CXCR each have up to nine analog channels, including up to five voltage inputs, two current inputs, and two temperature inputs.

3.5.1 Voltage Inputs Voltage-input channel V2 provides monitoring of the charge (battery) voltage. The CXC software is pre-configured to monitor V2 for battery voltage. V2 is used as the system reference for rectifier float voltage, low voltage disconnect (LVD), system high voltage alarm, and system low voltage alarm.

3.5.2 Ground Fault Detect (GFD) V2 is also used for GFD (internally connected circuit). Ground fault is detected when either terminal of V2 (system voltage that is normally connected to the battery string) shorts to earth ground either directly or through some conductive means. The GFD circuit will detect a fault current range of ±10mA. The resolution is 1mA.

The GFD will trip an alarm if the fault current exceeds the user configurable Trip Value under Configuration menu of Alarms/Configure Alarms/Miscellaneous Alarms/GFD. The default setting is ±5mA.

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As with any analog input, the GFD can also be calibrated as required. See Analog Calibration menu in the CXC software manual.

3.5.3 Current Inputs Up to two current-input channels (I1 and I2) provide monitoring of current; e.g., discharge (load) and charge (battery). The CXC software is pre-configured to monitor I1 for load current using an external DC current transformer. The second optional current input is factory configured to monitor an external 50mV current shunt.

3.5.4 Temperature Inputs Two dedicated temperature probe inputs (T1 and T2) provide monitoring of battery temperature or room/ambient temperature. They may also be used for temperature compensation (temp comp). A voltage is supplied to these terminals to power the temperature sensors.

3.5.5 General-Purpose Inputs The general-purpose (GP) input channels monitor various analog signals depending on how the channels are configured. The configuration determines whether the signals allowed are to be bipolar (may vary in either polarity from zero, e.g. +/-150Vdc), unipolar (may vary positive from zero, e.g. 0 to +300Vdc), or temperature.

All four GP inputs are factory configured as unipolar voltage inputs.

3.6 Digital Input Channels The CXC can accommodate up to four digital input channels.

NOTE: Each channel may be set by closing (shorting) or opening the inputs with a voltage free contact to achieve the appropriate condition. This is differs from the digital inputs on other Cordex controllers which require a zero or system voltage potential at the input to activate or deactivate the appropriate condition.

These channels can monitor digital alarm/control signals from rectifiers, converters and many other types of equipment. Some of these channels are pre-assigned to monitor specific signals. See the Software manual for more information.

3.7 Alarm and Control Output Relays Each CXCR contains eight standard and eight optional Form C alarm output relays to extend alarms and control external apparatus. Each internally generated alarm or control signal may be mapped to any one of the 16 relays, or, several signals may be mapped to just one relay or none at all.

3.8 CXC System Fail Alarm/Relay The CXC system fail alarm activates because of a major internal failure. During such a condition, the unit will attempt to reset, but if this fails, an alarm condition will be extended to a relay and the red LED on the front panel will illuminate. This is a fail-safe signal to the remote monitoring equipment; i.e. alarm will be extended even if power to the unit is interrupted.

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4 Inspection

4.1 Packing Materials Alpha is committed to providing products and services that meet our customers’ needs and expectations in a sustainable manner, while complying with all relevant regulatory requirements. As such Alpha strives to follow our quality and environmental objectives from product supply and development through to the packaging for our products.

Packaging assemblies and methods are tested to International Safe Transit Association standards.

Rectifiers and batteries are shipped on individual pallets and are packaged according to the manufacturer’s guidelines.

Almost all of Alpha’s packaging material is from sustainable resources and or is recyclable.

4.1.1 Returns for Service

Save the original shipping container. If the product needs to be returned for service, it should be packaged in its original shipping container. If the original container is unavailable, make sure that the product is packed with at least three inches of shock-absorbing material to prevent shipping damage.

Alpha Technologies is not responsible for damage caused by improper packaging of returned products.

4.2 Check for Damage Before unpacking the product, note any damage to the shipping container. Unpack the product and inspect the exterior for damage. If any damage is observed, contact the carrier immediately.

Continue the inspection for any internal damage. In the unlikely event of internal damage, inform the carrier and contact Alpha Technologies for advice on the impact of any damage.

WARNING To prevent possible ESD damage, all models of CXC controllers require that when the unit is open the users not touch the circuitry without a wrist strap properly worn and connected.

4.3 General receipt of Shipment The inventory included with your shipment depends on the options you have ordered. The options are clearly marked on the shipping container labels and bill of materials.

Call Alpha Technologies if you have any questions before you proceed: 1 888 462-7487.

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5 Installation This chapter is provided for qualified personnel to install the product, which shall be mounted in a clean and dry environment.

NOTE: To aid the user with installation, frequent reference is made to foldout drawings located at the rear of the manual.

5.1 Safety Precautions WARNING Hazardous voltages are present at both the input and the output of power systems. The DC output from the rectifiers and the battery system is at a lethal potential and has a high short circuit current capacity that may cause electrocution, severe burns and electrical arcing.

Before working with any live battery or power system/distribution center, follow these precautions:

• Remove all metallic jewelry; e.g., watches, rings, metal rimmed glasses, necklaces. • Wear safety glasses with side shields (and prescription lenses if necessary) at all times during installation.

The installer should follow all applicable local rules and regulations for electrical and battery installations; e.g., CSA, UL, CEC, NEC, OSHA, and local fire codes.

Use OSHA approved insulated hand tools.

5.2 Shelf Preparation/Mounting NOTE: The CXC must be mounted in a clean and dry environment.

5.2.1 Rack Mount

The CXCR rack mount model fits horizontally in a 19” or 23” rack. The CXCR should be mounted to the rack using two #12 – 24 x 1/2” screws in each bracket. Philips-type screws and screwdriver should be used to eliminate the possibility of slippage and scratching of the unit’s exterior. Washers (such as internal tooth) or special screws that are designed to cut through the painted surface should be used to ensure a good chassis ground.

Consult the drawings located at the rear of this manual and proceed to the next section for wiring connections.

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6 Wiring and Connections This chapter provides cabling details and notes on cable sizing for DC applications with respect to the product.

NOTE: Refer also to foldout drawings located at the rear of the manual.

6.1 Safety Precautions WARNING Hazardous voltages are present at both the input and the output of power systems. Ensure that input power and output power is removed before attempting work on the CXC’s connections. Use a voltmeter to verify the absence of voltage. Clearly mark the correct polarity of the battery leads before commencing work on DC connections.

Refer to the previous (Installation) chapter for additional safety precautions.

6.2 Front Access All wiring connections are accessible from the front of the panel and rack models. For example, to gain access to the terminal block connectors for the rack model: 1. Turn the two front panel latches (spring-loaded) counter-clockwise. 2. Tilt the front panel forward and down. 3. Loosen the CXC’s rear screws and remove its rear plate.

Terminal blocks can accommodate wire sizes per the specifications section near the front of this manual. All cables should be routed through the access holes, bundled together with clips and clamped directly into applicable terminal blocks.

NOTE: Connections to the CXC should comply with all local electrical codes and ordinances.

6.3 Tools Required Various insulated tools are essential for product installation. Use this list as a guide:

• Slot head screwdrivers (blade sizes: 1/4”, 1/8”, 1/16”) • Philips head screwdriver, #2 (tip size 3/16”) • Digital voltmeter equipped with test leads • Adjustable 125/220Vdc load (optional) • Anti-static wrist strap • Computer (laptop) with Microsoft Internet Explorer 6 or greater • Crossover cable RJ-45 (for access using the Ethernet port) • Null modem cable (for access using the RS-232 port) • Cutters and wire strippers.

6.4 Power System Chassis Ground and DC Ground Reference WARNING For safety reasons, ensure the system is properly bonded to the building’s ground grid. 125/220Vdc systems are typically floating; i.e., not connected to earth ground.

Connect the CXC chassis ground to the site ground to ensure correct operation of the CXC and to prevent drifting floating analog (especially current) readings. The Ground Fault Detect circuit will not function properly if the CXC chassis is not connected to the site ground.

6.5 Power Inputs The system can operate from 125/220Vdc input with no configuration required.

NOTE: The CXC cannot function without DC power to the motherboard.

Power must be connected as follows: 1. Connect system (+) power bus lead to (+) terminals 56 (primary input) and/or 54 (secondary input). 2. Connect system (-) power bus lead to (-) terminals 57 (primary input) and/or 55 (secondary input).

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6.6 Analog Inputs WARNING Ensure 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, which accommodate various types of analog signals.

Bundle the input cables together and route through the entry holes.

NOTE: Default configurations and terminal numbers described below have been summarized in Table A (next page). Refer also to foldout drawings located at the rear of this manual. Custom configurations may be detailed within the Alpha power system documentation package.

6.6.1 Voltage Input 2 (V2)

CAUTION If the V2 sense leads are disconnected from the CXC, the following will occur:

• The CXC registers the absence of DC as an invalid condition. • The LVD will not be de-activated. • The rectifier voltage may increase slightly, typically 1.8V (5.5V maximum).

6.6.2 Midpoint Monitoring (connection example)

An analog signal configured (at the factory) for voltage can be used for mid-point monitoring. Channel V1 is used in the example below but any of the available voltage channels can be used.

NOTE: See CXC Software manual for detailed instruction on programming.

Connect as shown ensuring correct polarity:

Figure 3–Connection example for mid-point monitoring

6.7 Digital Inputs The digital input channels are used to monitor various alarm and control signals. Shorting an input with a voltage-free relay contact will activate the channel.

Figure 4–Showing connection method

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CAUTION: to reduce risk of fire, use only 0.129mm2 (#26 AWG) or larger wire.

Terminal Description Default Name Signal Range 1 and 2; V2 Voltage Input 2 Charge Voltage Pos (+)/Neg (-) 0-300Vdc 3 and 4; GP1* General Input 1 GP1 Pos (+)/Neg (-) 0-300Vdc 5 and 6; GP2* General Input 2 GP2 Pos (+)/Neg (-) 0-300Vdc 7 and 8; GP3* General Input 3 GP3 Pos (+)/Neg (-) 0-300Vdc 9 and 10; GP4* General Input 4 GP4 Pos (+)/Neg (-) 0-300Vdc 11 and 12; T1 Temp Input 1 T1 Pos (+)/Neg (-) 0-20Vdc 13 and 14; T2 Temp Input 2 T2 Pos (+)/Neg (-) 0-20Vdc 15 and 16; I2 Current Input 2 I2 Pos (+)/Neg (-) ±50mV 19 and 20; D1** Digital Input 1 Distribution Fuse (Alarm) N/A Short or open 21 and 22; D2** Digital Input 2 Distribution CB (Alarm) N/A Short or open 23 and 24; D3** Digital Input 3 Battery CB (Alarm) N/A Short or open 25 and 26; D4** Digital Input 4 Battery CB (Alarm) N/A Short or open 27, 28 and 29; K1*** Alarm Output 1 LVD1 NC/COM/NO 220Vdc, 0.4A 30, 31 and 32; K2*** Alarm Output 2 LVD2 NC/COM/NO 220Vdc, 0.4A 33, 34 and 35; K3*** Alarm Output 3 LVD3 NC/COM/NO 220Vdc, 0.4A 36, 37 and 38; K4*** Alarm Output 4 System Minor NC/COM/NO 220Vdc, 0.4A 39, 40 and 41; K5*** Alarm Output 5 System Major NC/COM/NO 220Vdc, 0.4A 42, 43 and 44; K6*** Alarm Output 6 AC Mains Hi-Low NC/COM/NO 220Vdc, 0.4A 45, 46 and 47; K7*** Alarm Output 7 Not assigned NC/COM/NO 220Vdc, 0.4A 48, 49 and 50; K8*** Alarm Output 8 Not assigned NC/COM/NO 220Vdc, 0.4A 51, 52 and 53; K0**** Alarm Output 0 System Fail Output NC/COM/NO 220Vdc, 0.4A 54 and 55; B PWR Secondary Power Secondary Power Pos (+)/Neg (-) 90-300Vdc 56 and 57; A PWR Power Power Pos (+)/Neg (-) 90-300Vdc DCCT input; P3 Current Input 1 I1 Pos (+)/Neg (-);

Pwr (+)/Pwr (-) ±15Vdc, 100mA max.

Table A–Wiring connections * Bipolar (Voltage Input) is ±150Vdc, Unipolar Voltage (Input) is 0—300Vdc, Temp Probe is 0—20Vdc with power source. ** See Table B for definitions of impedance levels. *** Can be configured to de-energize on alarm (DOA) or energize on alarm (EOA). **** System Fail output relay is fail-safe and will de-energize during an alarm condition.

NOTE: DCCT power output is protected against short circuits and is able to power four DCCTs.

To aid the user with installation, frequent reference is made to drawings located at the rear of this manual. Custom configurations may be detailed within the Alpha power system documentation package.

6.7.1 Programming the Digital Input

The digital input channels (terminals 19 through 26) can be programmed for “active high” or “active low.” Active high indicates “alarm on the presence of a short circuit” and active low indicates “alarm on the removal of the short circuit.”

NOTE: See CXC Software manual for detailed instruction on programming.

Impedance Level (Ohms)

Considered As “0” (Off) Impedance Level (Ohms) Considered As “1” (On)

> 1M < 1

Table B–Digital input impedance level definitions

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6.8 Relay Outputs WARNING Relays are rated at 220Vdc 0.4A. Exceeding these limits may damage the relay and other circuitry in the CXC.

Terminals 27 to 50 provide 8 Form C contacts (NO, COM and NC) for extending various alarm or control signals. Each relay output can be wired for NO and/or NC operation during an alarm or control condition. See Figure 6.

Figure 5–Showing relay connections in the de-energized state

Relays can be programmed to energize or de-energize during an alarm condition (see Software manual). When the CXC reset button is pressed or power is lost, all relays de-energize.

Relay contacts 1-8 are high capacity and intended to be used for controlling LVD contactors.

6.8.1 System Fail Relay

Terminals 51 to 53 provide connections for a system (supervisory) fail relay. This fail-safe relay (i.e. it is de-energized during an alarm condition) can be wired for NO or NC operation.

6.8.2 LVD Control

The LVD control functions can be hardwired directly from the assigned relay output pins to the LVD contactor panel. See Controls Menu Defaults in the Software manual.

6.8.3 CEMF Cell Control

The CEMF control function can be hardwired directly from the assigned channel in to the CEMF cell controller panel. See Controls Menu Defaults in the Software manual.

6.8.4 Optional Relays and Outputs

Eight relays and outputs may be added to the CXC (panel and rack models) with the purchase of an optional expansion board (see List Options at the front of this manual).

6.9 Rectifier Connections

6.9.1 CAN Out Serial Port

A single CAN Out serial port, for communications with Alpha’ Cordex rectifiers and other CAN-enabled equipment (nodes) on the same system, is located next to the rear Ethernet port.

Daisy-chain from node to node (CAN OUT of one node to CAN IN of another) as necessary and ensure that only the last node is terminated.

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6.10 Network Connection and Remote Communications The Cordex system can be set up, monitored and tested via ETHERNET 10/100 Base-T or with a RS-232 serial data connection, or over a phone line using a modem.

NOTE: Pinouts are shown in the customer connections drawing.

The communication protocol supports a web interface. The remote screen display is an enhanced version of the CXC’s front panel display.

Some standard scenarios are described below:

6.10.1 Ethernet Port for Network Connection (Standard Network Cable)

The Ethernet port is designed for CXC connection to a user supplied network (TCP/IP secured by user) via a front panel RJ-45 jack. Connect to the Cordex controller using a standard network cable.

On the jack of the CXCP and CXCR only are two LEDs used to provide indication of status. The green LED illuminates when disconnected and flashes when there is activity on the line. The amber or yellow LED is off when disconnected and illuminates when a successful (data) connection is present.

6.10.2 Ethernet Port for Local Connection (Crossover Cable)

Local access (e.g. laptop computer) is also possible from the Ethernet port connection using a standard network crossover cable.

6.10.3 RS-232 Serial (Craft) Port for Local Connection (Null Modem Cable)

Local access to the CXC is possible through the front panel RS-232 serial port using a null modem cable. See Figure 7 below:

Figure 6–NULL modem pinouts

6.10.4 Communication Expansion Board (Modem Straight Through Cable)

The CXC may be equipped with a communication expansion board, which includes a rear RS-232 serial port to allow the use of an external modem. Connect the modem to the Cordex controller with a straight through cable.

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See Figure 8 below for a rendering of CXC connections for power system communications:

SNMP Server Remote Monitor

Technician's PC

Modem

Modem

PSTN

Cordex Controller (CXC)

LCD

Ethernet RS-232 RS-485 CAN CAN Analog + Digital I/O

System I/O

I/O Expansion

Battery Cells

3 Phase Mains

System I/O

Rectifiers

Intranet Internet

RS-232

Expansion Bus

Rectifier Bus, RS-485 or CAN

Technician's PC

Mains Monitor

Battery Cell

Monitor

Technician's PC

or

Crossover Cable

Null Modem Cable

Standard Network Cable

Straight Through Cable

Figure 7–Communications connections

See also Remote Communications in the Software manual for more details on local and remote communications.

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7 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 repairs.

The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year.

WARNING: HIGH VOLTAGE AND SHOCK HAZARD.

Use extreme care when working inside the shelf while the system is energized. Do not make contact with live components or parts.

Circuit cards, including RAM chips, can be damaged by static electricity. Always wear a grounded wrist strap when handling or installing circuit cards.

Procedure Date Completed Clean ventilation openings Inspect all system connections (re-torque as necessary) Verify alarm/control settings Verify alarm relay operation

Table C–Sample maintenance log

Refer to the specification section at the front of this manual for replacement parts.

7.1 Lithium Battery Replacement A removable lithium battery is located near the back and to the right of the motherboard. The battery life is rated up to three years, but should be replaced if the panel does not maintain date and time during power interruption. It is also recommended to replace when the lithium battery voltage is less than 2.6Vdc.

WARNING Exercise extreme caution and do not touch any connected equipment.

To replace the lithium battery, shut down the CXC, remove the rear cover, and pull battery out carefully. Ensure that the new battery is the same as the one being replaced.

NOTE: Replace the battery within 30 seconds to prevent loss of date and time.

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8 Alpha Conventions

8.1 Numbering System Alpha Technologies uses an eight-digit drawing number system, which is broken into three blocks. The first three digits describe the category of the product; e.g., rectifier or fuse panel. The next three digits indicate the sequence in which the product number was allocated in a particular category. The last two digits indicate the type of drawing, for example:

“-06” Outline Drawing “-08” Customer Connections “-20” Main Assembly

Alpha uses an eight-digit part numbering system for all components and sub assemblies. Each part is covered by its own unique number. Due to the quantity, categories will not be listed within this manual.

8.2 Acronyms and Definitions AC Alternating current AWG American wire gauge CAN Controller Area Network CEC Canadian Electrical Code CEMF Counter electro-motive force COM Common CPU Central processing unit CSA Canadian Standards Association CX Cordex series; e.g., CXC for Cordex™ System Controller DC Direct current DCCT Direct-current current transformer EMC Electromagnetic compatibility FCC Federal Communications Commission (USA) GUI Graphical user interface LAN Local area network LCD Liquid crystal display LED Light emitting diode LVD Low voltage disconnect NC Normally closed NEC National Electrical Code (USA) NO Normally open OSHA Occupational Safety & Health Administration PDA Personal digital assistant PSTN Public switched telephone network RAM Random access memory RU Rack unit (1.75”) SNMP Simple network management protocol TCP/IP Transmission control protocol / internet protocol UL Underwriters Laboratories

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9 Warranty and Service Information

9.1 Technical Support

In Canada and the USA, call toll free 1-888-462-7487. Customers outside Canada and the USA, call +1-604-436-5547.

9.2 Warranty Statement For full information details review Alpha's online Warranty Statement at www.alpha.ca.

9.3 Product Warranty Alpha warrants that for a period of two (2) years from the date of shipment its products shall be free from defects under normal authorized use consistent with the product specifications and Alpha’s instructions, the terms of the manual will take precedence.

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. The warranty does not provide to the customer or other parties any remedies other than the above. It does not provide coverage for any loss of profits, loss of use, costs for removal or installation of defective equipment, damages or consequential damages based upon equipment failure during or after the warranty period. No other obligations are expressed or implied. Warranty also does not cover damage or equipment failure due to cause(s) external to the unit including, but not limited to, environmental conditions, water damage, power surges or any other external influence.

The customer is responsible for all shipping and handling charges. Where products are covered under warranty Alpha will pay the cost of shipping the repaired or replacement unit back to the customer.

9.4 Battery Warranty Note that battery warranty terms and conditions vary by battery and by intended use. Contact your Alpha sales representative or the Technical Support team at the above number to understand your entitlements under Battery Warranty.

9.5 Warranty Claims Any claim under this Limited Warranty must be made in writing to Alpha BEFORE sending material back. Alpha will provide Product return instructions upon approval of return request. A Service Repair Order (SRO) and / or Return Authorization (RA) number will be issued ensuring that your service needs are handled promptly and efficiently.

Claims must be made online at: www.alpa.ca/support.

9.6 Service Information For a list of international service centers, refer to the Alpha website: www.alpha.ca

http://www.alpha.ca/

http://www.alpa.ca/support

Acronyms and DefinitionsAC Alternating current

ANSI American National Standards InstituteAWG American Wire GaugeBTU British thermal unitCAN Controller area networkCEC Canadian Electrical CodeCSA Canadian Standards AssociationCX Cordex™ series; e.g., CXC for Cordex System ControllerDC Direct current

DHCP Dynamic Host Configuration ProtocolEIA Electronic Industries Alliance

EMC Electromagnetic compatibilityEMI Electromagnetic interferenceERM Electromagnetic Compatibility and Radio Spectrum MattersESD Electrostatic DischargeFCC Federal Communications Commission (for the USA)GSM Group Speciale Mobile (global system for mobile communications)HVSD High voltage shutdownIEC International Electrotechnical Commission

IEEE Institute of Electrical and Electronics EngineersIP Internet Protocol

LED Light emitting diodeLVD Low voltage disconnectMIL One thousandth of an inch; used in expressing wire cross sectional area

MOV Metal oxide varistorMTBF Mean time between failures

NC Normally closedNEC National Electrical Code (for the USA)NO Normally open

OSHA Occupational Safety & Health AdministrationOVP Over voltage protectionRAM Random access memoryRU Rack unit (1.75”)

TCP/IP Transmission Control Protocol / Internet ProtocolTHD Total harmonic distortionUL Underwriters Laboratories

VRLA Valve regulated lead acid

CertificationAbout CSA and NRTL

CSA (Canadian Standards Association also known as CSA International) was established in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health Administration) in the United States of America (Docket No. NRTL-2-92). This was expanded and renewed in 1997, 1999, and 2001. The specific notifications were posted on OSHA’s official website as follows:

• Federal Register #: 59:40602 - 40609 [08/09/1994]



When these marks appear with the indicator “C and US” or “NRTL/C” it means that the product is certified for both the US and Canadian markets, to the applicable US and Cana-dian standards. (1)

Alpha rectifier and power system products, bearing the aforementioned CSA marks, are certified to CSA C22.2 No. 60950-01 and UL 60950-01. Alpha UPS products, bearing the aforementioned CSA marks, are certified to CSA C22.2 No. 107.3 and UL 1778.

As part of the reciprocal, US/Canada agreement regarding testing laboratories, the Stan-dards Council of Canada (Canada’s national accreditation body) granted Underwriters Labo-ratories (UL) authority to certify products for sale in Canada. (2)

Only Underwriters Laboratories may grant a licence for the use of this mark, which indicates compliance with both Canadian and US requirements. (3)

NRTLs capabilities

NRTLs are third party organizations recognized by OSHA, US Depart-ment of Labor, under the NRTL program.

The testing and certifications are based on product safety standards developed by US based standards developing organizations and are often issued by the American National Standards Institute (ANSI). (4)

The NRTL determines that a product meets the requirements of an appropriate consensus-based product safety standard either by successfully testing the product itself, or by verifying that a contract laboratory has done so, and the NRTL certifies that the product meets the requirements of the product safety standard. (4)

Governance of NRTL

The NRTL Program is both national and international in scope with foreign labs permitted.

(1)www.csagroup.org(2) www.scc.ca(3) www.ulc.ca(4) www.osha.gov

REAR ISOMETRIC VIEW-OPENING DETAIL

SIZE DWG NO.TYPE

B

SHEET

TITLE

I SSUE

D A T E OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH

FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT.

ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED

THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF

LTR

FINISHED HOLE LEGEND

QTYDESCRIPTION

REVISIONS

LTR DESCRIPTION APPDDATE

REV

X.X 0.04"X.XX 0.02"X.XXX 0.01"

[X] 1mm[X.X] 0.5mm[X.XX] 0.25mm

018-570-06

OUTLINE DRAWINGCXC 125/220VDC

...

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1:2

PER P.O. andDoc. 070-024-83

1 3

EOF

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D2

c 2003 ARGUS TECHNOLOGIESO

A

131 5.16

425.5 16.75

171 6.73155 6.10

175.3 6.90 175.3 6.9037.5 1.48

8 .31

FRONT VIEW

TOP VIEW

99.1 3.90

SIDE VIEW

FRONT ISOMETRIC VIEW

SIZE DWG NO.TYPE

B

SHEET

TITLE

I SSUE

D A T E OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH




LTR

FINISHED HOLE LEGEND

QTYDESCRIPTION

REVISIONS


REV

X.X 0.04"X.XX 0.02"X.XXX 0.01"

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018-570-06


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ADIMENSIONS ARE IN INCHES WITH METRIC [mm] IN BRACKETS: INCHES [mm]

584.3 23.00

425.5 16.75

22.2 .88

57.2 2.25

101.6 4.00

132.6 5.22

566.7 22.31

FRONT VIEW - 23" MOUNTING

482.7 19.00

425.5 16.75

132.5 5.22

101.6 4.00

57.2 2.25

22.2 .88

465.1 18.31

FRONT VIEW - 19" MOUNTING

SIZE DWG NO.TYPE

B

SHEET

TITLE

I SSUE

D A T E OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH




REVISIONS


REV

X.X 0.04"X.XX 0.02"X.XXX 0.01"

[X] 1mm[X.X] 0.5mm[X.XX] 0.25mm

018-570-06


...

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3 3

EOF

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A

DIMENSIONS ARE IN INCHES WITH METRIC [mm] IN BRACKETS: INCHES [mm]

REV BY

© 2009 ARGUS TECHNOLOGIES

JK2009/10WH MEUPDATED TO REV C PCBCFL2005/01JU RDUPDATED TO REV B PCBB

REVISIONSDESCRIPTIONLTR APPDDATEDWN CHKD

SYSTEM GROUND CONNECTION

(19" RACK MOUNTOPEN POSITION SHOWN)

SUGGESTED WIRE ROUTING

FRONT ISO VIEWCOVER REMOVED

PCB DETAIL OMITTEDLIST 21

TIME CLOCKBACKUP BATTERY CR1616ARGUS P/N 185-005-10

LIST 22 - PANEL MOUNTPCB DETAIL OMITTED

SYSTEM GROUND CONNECTION

REAR ISO VIEWCOVER REMOVED



2004/08

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F.L

R.D 2004/08

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B

SHEET

TITLE

ISSUEDATE OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

....J.U.

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EF/RD/JK

1 4CXC 125/220VDC

Doc. 070-024-83

X.XXX

2004/08

0.01"0.02"X.XX

FINISH

0.25mm

....

FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT.ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USED

0.04"


REV

CUSTOMER CONNECTION

X.X [X] 1mm[X.X] 0.5mm[X.XX]

PER P.O. and

1:2


1:2

SIZE DWG NO.TYPE

B

SHEET

TITLE

ISSUEDATE OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH

FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT.ARGUS TECHNOLOGIES AND SHALL NOT BE COPIED OR USEDTHESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF

REVISIONS


REV

D2

2004/08 R.D

2004/08

2004/08 F.L

2003/06

C

0.01"

0.04"

X.XXX 0.02"

X.X X.XX

0.25mm

018-570-08

CXC 125/220VDCCUSTOMER CONNECTION

....

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EF/RD/JK

J.U.

[X] 1mm[X.X] 0.5mm[X.XX]

PER P.O. and

REV BY

RELAY#7

RELAY#8

DETAIL A

19 20D1

21 22D2

23 24D3

25 26D4

27 28 29NC C NO

30 31 32NC C NO

33 34 35NC C NO

36 37 38NC C NO

39 40 41NC C NO

42 43 44NC C NO

45 46 47NC C NO

48 49 50NC C NO

51 52 53NC C NO

54 55+B PWR -

56 57+A PWR -

RELAY#1

RELAY#3

RELAY#2

RELAY#4

RELAY#5

RELAY#6

RELAY#0

SYSTEM FAIL

DCCT

TEMP

3 DCCT SENSE +2 +15V DCCT POWER

DETAIL B

T2

4 -15V DCCT POWER

1 2V2+ V2-

3 4GP1+ GP1-

5 6GP2+ GP2-

7 8GP3+ GP4+

GP4-

11 12T1+ T1-

13 14T2+ T2-

GP3-

9 10 15 16I2+ I2-

V2

CHARGEVOLTAGE

GP1

VOLTAGE#3

GP2

VOLTAGE#4

GP3

VOLTAGE#5

GP4

VOLTAGE#6

#1

1

I1

DCCTINPUT

T1

TEMPPROBE

I1

P3

P3

3 4

2

#2PROBE

1 DCCT SENSE -

I2

CURRENT#2

SOME DETAILS OMMITED

A

TOP VIEW - I/O BOARD (707-360-20)

B


1

4. NC

1 8

RJ45

3. CANL4. CANL5. CANH

1 6

6. NC

8. COM27. COM26. RX-5. COM14. COM13. RX+

1. TX+2. TX-

1. GND2. CANH

1. NC2. RING3. TIP

4

RS485

CAN2

CAN1

ETHERNET

J8

P1

J2

J3

J4

J5

J1

LIST 95 - EXPANSION BOARD, COMMUNICATION

MODEM

TOP VIEW - COMMUNICATION BOARD (707-329-20)

U1

TELCO

CAN1

BATTERY

J8

RS485

P6

P2

LIST 92 LIST 90 LIST 93

ETHERNET

SOME DETAILS OMMITED

CAN 2TELCO RS485 CAN 1

To I/O Board

TOP VIEW-MOTHER BOARD (707-314-20)

To Front PanelETHERNET

RJ12OFFSET

1:2

SIZE DWG NO.TYPE

B

SHEET

TITLE

ISSUEDATE OF

TOLERANCES

SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH


REVISIONS


REV

D2

2004/08 R.D

2004/08

2004/08 F.L

2003/06

C

0.01"

0.04"

X.XXX 0.02"

X.X X.XX

0.25mm

018-570-08


....

....

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EF/RD/JK

J.U.


PER P.O. and

REV BY

6

RJ11

1

1. GND2. RS485+3. RS485-4. RS485-5. RS485+6. SCI EN

RJ12OFFSET


1:2

SIZE DWG NO.TYPE

B

SHEET

TITLE

ISSUEDATE OF

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SCALE

APPROVED

CHECKED

DRAWN

DESIGN MATERIAL

FINISH


REVISIONS


REV

D2

2004/08 R.D

2004/08

2004/08 F.L

2003/06

C

0.01"

0.04"

X.XXX 0.02"

X.X X.XX

0.25mm

018-570-08


....

....

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EF/RD/JK

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PER P.O. and

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TOP VIEW-EXPANSION BOARD(707-179-20)LIST 96-EXPANSION BOARD, OUTPUT RELAY, 8 X 1A FORM C, INTERNAL

C

DETAIL WITH EXPANSION BOARD MOUNTED ON

1

1

REAR VIEW


DETAIL RIBBON CABLE NOT SHOWN

161

NC C8 N0

#15

SCALE 2 : 1

138

139

140

TB6 TB7 TB8 TB9

160

DETAIL C

NC C1 N0

RELAY#10

NC C2 N0

142

143

141

144

145

146

#9RELAY

NC C3 N0

RELAY#12

NC C4 N0

149

148

147

150

151

152

#11RELAY

NC C5 N0

RELAY#14

NC C6 N0

155

154

153

156

157

158

#13RELAY

NC C7 N0

RELAY#16

RELAY

159

Visit us at www.alpha.ca

Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. Copyright © 2016 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

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cordex controller panel/rack mount 125/220vdc

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