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Alpha Modular Switched Mode Rectifier System Rectifier model: Cordex CXCRF 48-300W Installation & Operation Manual Part # 0300072-J0 Effective: 10/2012 member of The Group™ Your Power Solutions Partner Alpha Modular Switched Mode Rectifier System Rectifier Model: Cordex CXCRF 48-300W NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs 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: 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 operated in an unapproved manner, or improperly maintained. For technical support, contact Alpha Technologies: Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Email: [email protected] Copyright Copyright © 2012 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technologies. No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or transmitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or otherwise without prior explicit written permission from Alpha Technologies. This document, the software it describes, and the information and know-how they contain constitute the proprietary, 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 Technologies 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 reservation and without notification to its users. IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 1. Please read this manual prior to use to become familiar with the product’s numerous features and operating procedures. To obtain a maximum degree of safety, follow the sequences as outlined. 2. This manual provides warnings and special notes for the user: a. Points that are vital to the proper operation of the product or the safety of the operator are indicated by the heading: WARNING. b. A notation that is in Bold Italic typeface covers points that are important to the performance or ease of use of the product. 3. Before using the product, read all instructions and cautionary markings on the product and any equipment connected to the product. 4. Do not expose the product to rain or snow; install only in a clean, dry environment. 5. CAUTION – Unless otherwise noted, use of an attachment not recommended or sold by the product manufacturer may result in a risk of fire, electric shock, or injury to persons. 6. CAUTION – Do not operate the product if it has received a sharp blow, it has been dropped, or otherwise damaged in any way – return it to a qualified service center for repair. 7. CAUTION – Do not disassemble the product – call our qualified service centers for servicing. Incorrect reassembling may result in a risk of electrical shock or fire. TABLE OF CONTENTS 1 Safety Instructions ..................................................................................... 4 1.1 Safety Symbols .............................................................................................................. 4 1.2 General Warnings and Cautions .................................................................................... 4 2 Product Overview ....................................................................................... 6 2.1 General Overview .......................................................................................................... 6 2.2 Part Numbers and List Options ...................................................................................... 6 2.3 Stand-alone Energy System .......................................................................................... 6 2.4 IEC Input Voltage ........................................................................................................... 7 2.5 Overview of Control Unit Configurations ........................................................................ 8 2.6 Features ......................................................................................................................... 8 2.7 Mechanical Overview ................................................................................................... 14 2.8 Electrical Overview....................................................................................................... 15 2.4.1 2.5.1 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.7.1 3 IEC...........................................................................................................................................................7 Basic units ...............................................................................................................................................8 System controller (low profile MCU without LCD screen) .......................................................................8 Front signal connection card ...................................................................................................................9 System controller (MCU with LCD screen) .......................................................................................... 10 Distribution Unit (only for stand-alone systems)................................................................................... 11 Cordex Rectifier CXRF 48-300W ......................................................................................................... 13 Dimensions ........................................................................................................................................... 14 Installation ................................................................................................ 16 3.1 Site Planning ................................................................................................................ 16 3.2 Safety Markings ........................................................................................................... 17 3.3 Installation .................................................................................................................... 18 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 Safety Precautions ............................................................................................................................... 18 Tools and Equipment Required for Installation .................................................................................... 18 Mounting the Shelf ............................................................................................................................... 18 Ventilation ............................................................................................................................................. 19 Wiring Procedure .................................................................................................................................. 19 Summary .............................................................................................................................................. 27 0300072-J0 RevA Page 2 of 46 4 Operating the 48-300W Modular Switched Mode Rectifier System ....... 28 4.1 Switching ON and OFF ................................................................................................ 28 4.2 Rectifiers 300 W: CXRF 48-300W................................................................................ 28 4.3 Comp@s Settings ........................................................................................................ 29 4.4 Alarm Monitoring .......................................................................................................... 36 4.1.1 4.1.2 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4.1 4.4.2 4.4.3 5 Switching ON ........................................................................................................................................ 28 Switching OFF ...................................................................................................................................... 28 Licence Overview ................................................................................................................................. 29 Factory Preset Settings Overview ........................................................................................................ 30 54 Vdc Bus Voltage .............................................................................................................................. 31 Battery Setup ........................................................................................................................................ 32 LVD Trip Level ...................................................................................................................................... 33 Rectifier Settings .................................................................................................................................. 33 Save the Configuration ......................................................................................................................... 35 Factory Preset Alarm Table.................................................................................................................. 36 Type of Alarm ....................................................................................................................................... 37 Battery Test .......................................................................................................................................... 38 Maintenance .............................................................................................. 41 5.1 Battery Replacement.................................................................................................... 41 5.2 Troubleshooting ........................................................................................................... 42 6 Specifications ........................................................................................... 43 7 Warranty .................................................................................................... 45 7.1 8 Warranty ...................................................................................................................... 45 Abbreviations............................................................................................ 46 0300072-J0 RevA Page 3 of 46 1 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. 1.1 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. Notes are designated with a checkmark, the word NOTE and a ruled line beneath which the relevant information appears. CAUTION CAUTION! Indicates safety information intended to PREVENT DAMAGE to material and equipment. Cautions are designated with a yellow warning triangle, the word CAUTION and a ruled line beneath which the relevant 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 ruled line beneath which the information appear. 1.2 General Warnings and Cautions You must read and understand the following warnings before installing the 48-300W Modular Switched Mode Rectifier System and its components. Failure to do so could result in personal injury or death. • Please read this manual before using the system, in order to become familiar with the numerous features of the product and the relevant operating procedures. To ensure the maximum degree of safety, follow the sequences as outlined. • Before using the product, read all instructions and cautionary markings on the product and any equipment connected to the product. • Only qualified personnel are allowed to install, operate and service this system and its components. • Do not work alone under hazardous conditions. • Use proper lifting techniques whenever handling equipment, parts or batteries. • Always assume electrical connections or conductors are live. Turn off all circuit breakers and doublecheck with a voltmeter before performing installation or maintenance. 0300072-J0 RevA Page 4 of 46 • The 48-300W Modular Switched Mode Rectifier System uses more than one live circuit. DC power may be present at the outputs even if the system is disconnected from the mains supply. • In high ambient temperature conditions, the surface of the shelf can be very hot to the touch. • Battery installation and servicing should be done or supervised by personnel knowledgeable about batteries and their safety procedures. • Be extra cautious when connecting or adjusting battery cabling. An improperly connected battery cable or an unconnected battery cable can result in arcing, fire or possible explosion. • Use new batteries when installing a new unit. Verify that they are all the same battery type with identical date codes. • Always replace batteries with ones of identical number, type and rating. Never install old or untested batteries. One sealed lead-acid battery is rated to a maximum voltage of 12Vdc. • A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized personnel using a battery of identical type and rating. • Keep the chassis area clear and dust-free during and after installation. • Keep walkways free of tools to ensure that others cannot fall over them. • Do not work on the unit or connect or disconnect cables during periods of lightning activity. • A battery can present a risk of electrical shock and high short-circuit current. The following precautions should be observed when working on batteries: Remove watches, rings, or other metal objects. Use tools with insulated handles. Wear rubber gloves and boots. Do not lay tools or metal parts on top of batteries. Disconnect charging source prior to connecting or disconnecting battery terminals. Determine if the battery is inadvertently grounded, remove source from ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such a shock can be reduced if such grounds are removed during installation and maintenance (applicable to equipment and remote battery supplies not having a grounded supply circuit). • Never let live battery wires touch the 48-300W Modular Switched Mode Rectifier System, the enclosure or any other metal objects. This can cause a fire or explosion. • Never dispose of batteries in a fire or furnace. The batteries may explode. Follow the manufacturer’s directions and check with your local jurisdictions for safe battery disposal. • Before plugging the batteries to the 48-300W Modular Switched Mode Rectifier System, make sure the polarity is correct. • If the batteries have been in storage for more than 3 months, recharge them for at least 24 hours then test them with a load before installation. 0300072-J0 RevA Page 5 of 46 2 PRODUCT OVERVIEW 2.1 General Overview The user manual explains the installation, interconnections and operation of Alpha Technologies 48-300W Modular Switched Mode Rectifier System. Listed below are the possible product configurations: 2.2 Part Numbers and List Options Description: Cordex HP 48-300W rectifier power module 0100010 Cordex 48-300W 19in 1RU shelf system, front/back access with controller and DC distribution 0300072 Comp@s supervisory communication card 7400325 Dummy module for empty rectifier slot 0100010-001 AC power cord C15 18AWG, right angle 8700551 2.3 Stand-alone Energy System Figure 1: Stand-alone energy system including controller with LCD This stand-alone energy system includes a controller board on the left and a modular distribution unit with 4 outlets protected by alarm-indicating fuses, a battery circuit breaker and an internal LVD. The distribution unit allows the user to connect the loads, the battery and the battery temperature sensor directly on the front of the system. The controller board can be one of two types: 1. Controller board with LCD screen – 1RU high (see Figure 1) 2. Controller board without LCD screen – 0.5RU high. A communication card for can be added on top of the controller (see Figure 2). The controller board can be equipped with a Comp@s card. This allows the user to configure, monitor and control the entire power system and auxiliary components from a computer. 0300072-J0 RevA Page 6 of 46 NOTE Details of controller operations are provided in the latest version of the Comp@s software manual. Figure 2 : Stand-alone energy system including controller with front access communication board Mains input options for the stand-alone energy system: 2.4 IEC Input Voltage Europe: 190 – 250V ̴ nom. USA/Canada: 100 – 250V ̴ nom. Max. input voltage is -10% / +6% of nominal input voltage range 2.4.1 IEC • An IEC C16 inlet connector is attached to the rear of the energy system (as on Figure 2) • All 3 rectifier slots are powered via the single IEC C16 connector • Max. 900W output power with up to 3 rectifiers High temperature socket Figure 3: IEC C16 inlet 0300072-J0 RevA Page 7 of 46 NOTE: IEC C16 is a high temperature inlet which requires IEC C15 plug IEC input voltage limitations are shown in section 2.4 2.5 Overview of Control Unit Configurations 2.5.1 Basic units MCU0348M4: Monitoring and control unit with LCD display. Unit features USB and Ethernet port connectors for the communication card. Display indications: output voltage, rectifiers and battery current. Comp@s: Remote communication card with basic package. OR MCU0348M4LP: Monitoring and control unit for the energy system without LCD display. Unit features USB and Ethernet port connectors for the communication card. Front signal connection card (optional): Front access communication I/O card for digital inputs, alarm signals, temperature sensor and CAN Bus. Comp@s: Remote communication card with basic package. 2.6 Features 2.6.1 System controller (low profile MCU without LCD screen) Figure 4 : System controller LED’s 2.6.1.1 LEDS The monitoring unit has six LEDs located on the front panel. These are used to display the status of the controller, LVD, system and battery: • Controller status Green LED indicates MCU and Comp@s functions are OK. Green LED is blinking if no Comp@s is present. • LVD OK Green LED indicates LVD (low voltage disconnection) is closed. The green LED blinks during a battery test. If the LED remains OFF, it means the LVD is open. • 1 Major alarm Red LED indicates a major alarm in the system (defined in the alarm table) • 2 Minor alarm Red LED indicates a minor alarm in the system (defined in the alarm table) 0300072-J0 RevA Page 8 of 46 • 3 Battery alarm Red LED indicates a battery failure • 4 AC fail alarm Red LED indicates a mains failure 2.6.1.2 USB PORT The USB port is designed for connecting a computer to the system controller via a standard USB cable (type A/B), with direct access to the Comp@s software (Comp@s card required). 2.6.1.3 ETHERNET PORT The Ethernet port is designed for connecting the controller to a user supplied network (TCP/IP secured by the user) via an RJ-45 jack and a standard network cable. 2.6.1.4 BATTERY TEST SAVE This button can be used for starting a battery test (see section 4.4.3 for more information). 2.6.2 Front signal connection card Figure 5 : Front signal connection card The front signal connection card (optional) is located just above the low profile MCU. It provides a front access point for communication of different signals: 2.6.2.1 CAN PORT This CAN port enables the connection of the CDM Comp@s display module (RJ-45 inverted 8P8C). 2.6.2.2 TEMPERATURE SENSOR CONNECTION (ENVIRONMENTAL) The system enables the monitoring of the cabinet temperature via this connection point. 2.6.2.3 SIGNALS IN/OUT The Sub-D 26-pole connector allows the user to monitor the system via the potential free alarm relays. In addition the user has four digital inputs, which can be monitored by the MCU. • 4 digital inputs (e.g., door contact open) • 4 alarm outputs (relay contacts can be programmed individually with single alarm or a combination of alarms) 0300072-J0 RevA Page 9 of 46 2.6.3 System controller (MCU with LCD screen) Figure 6 : System controller This controller board offers the same functions as the low profile MCU. Connectors for digital inputs and alarms (signals IN/OUT) are located at the back of the shelf. 2.6.3.1 LCD SCREEN The LCD screen displays the values of: • DC bus voltage [V] • Total rectifier output current [A] • Battery current [A] + = Charging – = Discharging 2.6.3.2 LED MODE INDICATORS The LEDs indicate the mode of the three possible measurements. • V for DC bus voltage • Ir for total rectifier output current • Ib for battery current 2.6.3.3 MODE PUSH BUTTON By pressing the push button, the user can scroll to the three different measurement modes. 2.6.3.4 LVD DISCONNECTED This button has no function in the 48-300W Modular Switched Mode Rectifier System energy system. 0300072-J0 RevA Page 10 of 46 Figure 7 : LVD Disconnected 2.6.3.5 LEDS The monitoring module has six LEDs located on the front panel. These are used to display the status of the controller, LVD, system and battery: • Controller status Green LED indicates MCU and Comp@s functions are OK. Green LED is blinking if no Comp@s is present. • LVD OK Green LED indicates the LVD (low voltage disconnection) is closed. If the LED remains OFF, it means the LVD is open. The Green LED blinks during a battery test • 1 Major alarm Red LED indicates a major alarm in the system (defined in the alarm table). • 2 Minor alarm Red LED indicates a minor alarm in the system (defined in the alarm table). • 3 Battery alarm Red LED indicates a battery failure. • 4 AC failure alarm Red LED indicates a mains failure. 2.6.3.6 USB PORT The USB port is designed for connecting a computer to the system controller via a standard USB cable (type A/B), with direct access to the Comp@s software (Comp@s card required). 2.6.3.7 ETHERNET PORT The Ethernet port is designed for connecting the controller to a user network (TCP/IP secured by user) via a front panel RJ-45 jack and a standard network cable. 2.6.3.8 BATTERY TEST SAVE This button can be used for starting a battery test (see section 4.4.3 for more information). 2.6.4 Distribution Unit (only for stand-alone systems) Figure 8 : Distribution unit Adding the modular distribution unit creates a stand-alone energy system. In combination with the low profile MCU and the front signal connection card, the resulting system provides full front access installation. The distribution unit includes an internal LVD (low voltage disconnection) in order to protect the battery from a deep discharge. The LVD will stay open if the polarity of the battery does not match the polarity of the system DC bus or if the battery voltage is out of range. 0300072-J0 RevA Page 11 of 46 2.6.4.1 TEMPERATURE SENSOR (BATTERY) Temperature probe input for battery temperature compensation. 2.6.4.2 54V DC OUTPUT WITH ALARM-INDICATING FUSES 4 outputs are available on the distribution unit, protected by alarm-indicating fuses. The available fuse ratings are 2A, 5A and 10A and these can be ordered from Alpha Technologies. When a fuse is blown, a coloured dot indicates the circuit is open. The fuses are numbered from 1 to 4, fuse 1 corresponding to the most left DC output and so on from left to right. 2.6.4.3 BATTERY CIRCUIT BREAKER If the battery is correctly connected, the user can set (close) the LVD by pushing the button of the battery circuit breaker. When the LVD is active (closed), the green “LVD OK” LED on the front of the distribution unit and the green “LVD OK” LED on the front of the controller illuminate. By pulling the button of the battery circuit breaker, the LVD will open and the battery is disconnected from the system. Both green LEDs will then extinguish. The status of the battery circuit breaker is monitored by the controller and can be used as an alarm source. CAUTION CAUTION! Before plugging and unplugging the battery connector, the user should pull the battery circuit breaker and check whether the LVD is non-active (open) to avoid damaging the battery connector contacts. 2.6.4.4 54V DC OUTPUT TERMINAL BLOCK The four DC outputs are located below the alarm-indicating fuses. Each output is protected by a single pole alarm-indicating fuse (see section 2.6.4.2). Please observe the polarity of the DC output connector: Out 1 Out 2 + - + Out 3 - + Out 4 - + - Please observe the following wiring specifications: • Stripping length: 10 mm • Minimum conductor cross section: 0.2 mm² stranded • Maximum conductor cross section: 2.5 mm² stranded 2.6.4.5 BATTERY CONNECTOR Please observe the polarity of the battery. The battery connector polarity is indicated on the front plate: + Battery - The battery connector is a 2-pole Phoenix contact PC 4/2-G-7,62 (18 04 79 7) The battery mating connector reference is Phoenix contact PC 4/ 2-ST-7,62 (18 04 90 4) The battery capacity is limited by the interrupting capacity of the 20A battery circuit breaker and should not exceed 62Ah. CAUTION CAUTION! Before plugging and unplugging the battery connector, the user should pull the battery circuit breaker and check whether the LVD is non-active (open) to avoid damaging the battery connector contacts 0300072-J0 RevA Page 12 of 46 2.6.4.6 LED When the green LED is on, the LVD is active (closed). When the LED is off, the LVD is not active (open). 2.6.5 Cordex Rectifier CXRF 48-300W Figure 9 : Cordex Rectfier 2.6.5.1 LED RECTIFIER STATUS INDICATOR The LED indicates the status of the rectifier: • Green LED Normal conditions • Orange LED Stand-by (remote on/off) • Red LED Low output voltage • Red blinking LED Failure (mains, temperature, output short circuit) 2.6.5.2 54V DC AUXILIARY OUTPUT This auxiliary 54V output allows the user to start with a basic bulk shelf without any controller or distribution unit. Thanks to the modular architecture the user can upgrade the system when the application requires battery backup, system monitoring or redundancy. The output power is limited to 300W. Auxiliary Output GND + - • Maximum conductor cross section: 2.0 mm² stranded (14AWG), maximum 8A current • The auxiliary output connector on the front is a 3-pole Phoenix contact MC 1,5/ 3-GF-3,81. The mating connector must be a 3.81mm (0.150”) pitch, 3 positions. It can be ordered from Alpha Technologies. 0300072-J0 RevA Page 13 of 46 2.7 Mechanical Overview 2.7.1 Dimensions Figure 10 : Front view Figure 11 : Top view 0300072-J0 RevA Page 14 of 46 2.8 Electrical Overview 0300072-J0 RevA Page 15 of 46 3 INSTALLATION 3.1 Site Planning CAUTION Restricted Access: the 48-300W Modular Switched Mode Rectifier System must be installed in a restricted area accessible by qualified service personnel only. CAUTION Grounding: the 48-300W Modular Switched Mode Rectifier System must be correctly grounded for proper operation. Older facilities may have inadequate electrical grounding. Inspection must be performed by a qualified electrician before installation to ensure that grounding meets the local electrical standards. CAUTION Branch Circuit Protection: the utility line attached to the 48-300W Modular Switched Mode Rectifier System input must be protected by a circuit breaker certified for this use in accordance with the local electrical standards. CAUTION Disconnect: the input and output lines of the 48-300W Modular Switched Mode Rectifier System are to be equipped with a disconnect device. Observe the following safety precautions when setting up the 48-300W Modular Switched Mode Rectifier System: • Install the 48-300W Modular Switched Mode Rectifier System on a surface that can bear its weight. See specifications. • The input wiring must reach a suitably grounded power outlet and the load wiring must reach the 48300W Modular Switched Mode Rectifier System output terminal blocks. • The 48-300W Modular Switched Mode Rectifier System should be installed in a suitably conditioned building or inside a weather-proof enclosure to protect electronics from water, dust and other possible contaminations (Pollution degree 2 according to IEC 60950-1). Once the installation location has been planned and prepared, you are ready to install the 48-300W Modular Switched Mode Rectifier System. NOTE: Alpha Technologies offers a large range of indoor and outdoor enclosed systems. See our website at www.alpha.ca or call our customer service for more information. 0300072-J0 RevA Page 16 of 46 3.2 Safety Markings This equipment is a Class 1 appliance. Applicable standards: CE marking for Low Voltage Directive 73/23/EEC. • • EN 60950-1, CEBEC approval pending. Leakage current Earth connection essential before connecting supply Mains cables DOUBLE INSULATION REQUIRED BETWEEN PRIMARY AND SECONDARY SUPPLEMENTARY SLEEVING MUST BE PLACED ON MAINS WIRES IF THE PROTECTIVE REAR COVER (OPTIONAL) IS NOT FITTED Supply sources WARNING EQUIPMENT WITH MULTIPLE SUPPLY SOURCES ENERGY ON AC INPUTS & DC BATTERY TERMINALS DISCONNECT BOTH BEFORE ANY INTERVENTION DC outputs WARNING High Energy Hazard External batteries Warning to be placed by the final user on the complete system or close to the batteries: WARNING High Energy Hazard Each external battery string MUST be protected according to the system power and the installed cross-section of the cable. The fuse or disconnect device must be capable of interrupting the current in the event of a short-circuit. The short-circuit current of the batteries is specified by the manufacturer. 0300072-J0 RevA Page 17 of 46 3.3 Installation This part is provided for the guidance of qualified personnel to install the product, which shall be mounted in a clean and dry environment. 3.3.1 Safety Precautions WARNING! Hazardous voltages are present at the input of power systems. The DC output from the rectifiers and battery system, though not dangerous in voltage, has a high short circuit current capacity that may cause severe burns and electrical arcing. 3.3.2 Tools and Equipment Required for Installation • DC voltmeter • Labels or masking tape and marker • Torque wrench (for earth) • Slot head screwdriver to fit the terminal blocks • Up to 4mm² insulated copper wire for connecting the battery (colour according to local standards) • Up to 2.5mm² insulated copper wire for connecting the loads (colour according to local standards) • Up to 1.5mm² insulated white cable for digital in and outputs • 2.5mm² (recommended) insulated green/yellow cable for EMC ground connection • Battery temperature sensor kit • High strength, flame-proof tape (such as duct tape) 3.3.3 Mounting the Shelf All versions of the 48-300W modular switched mode rectifier system are intended for rack-mount installation only, as shown in Figure 12. The shelf can be fixed with 19” or ETSI brackets. The brackets delivered together with the shelf can be used for both 19” and ETSI mounting. Remove and rotate the bracket to convert from 19” to ETSI or vice-versa. 1. Before installation, clean all fixing points on the 48-300W Modular Switched Mode Rectifier System shelf and mounting brackets. Bring them to a bright finish. Then coat them with an anti-oxidant (such as Sanchem Inc. No-Ox ID “A-Special Electrical Grade” or equivalent). 2. Attach the mounting brackets with the self-tapping screws and the paint piercing washers provided with the brackets to ensure adequate grounding between the 48-300W Modular Switched Mode Rectifier System shelf and the chassis of the enclosure. 3. Two chassis supports (not delivered) must be mounted under the shelf, as shown on Figure 12. WARNING! Do not operate the 48-300W rectifier system on a table on any other surface. 0300072-J0 RevA Page 18 of 46 Chassis support Figure 12 : Mounting the shelf 3.3.4 Ventilation The CXRF 48-300W features a forced air cooling. The air flow goes from front to rear. It is necessary to keep a minimum free space in front and behind the shelf. This space must be at least 15mm. Front 15mm 15mm Figure 13 : Ventilation of the shelf 3.3.5 Wiring Procedure WARNING! Make sure the line power is off. Turn off all input and output circuits on the 48-300W Modular Switched Mode Rectifier System before making any electrical connections. WARNING! If stranded wires are used to connect the input and output blocks, ferrules or equivalent crimping terminals must be used. CAUTION! The 48-300W Modular Switched Mode Rectifier System is sensitive to electrostatic discharges. Wear an electrostatic wrist strap connected to grounded metal before making the dry contact. Failure to do so may result in the unit temporally shutting down. 0300072-J0 RevA Page 19 of 46 Signals If used, make the Ethernet connection via the port on the front of the controller (Figure 14) and signal connectors at the rear of the shelf (Figure 15) Figure 14 : Front ethernet port Figure 15 : Rear signal connectors Optionally, a set of mating connectors can be provided with the system. Figure 16 : Signal connector pinning The following table lists all the pin assignments for the signal connectors: X110 Name Remarks 1 -- 2 -- 3 0 V signal 0V signal for Temp. sensor and the four digital inputs 4 Tenv. sensor Thermal sensor (NTC 10kΩ) with 0V signal 5 DIG_IN1 External digital input 1 – used with 0V signal 6 DIG_IN2 External digital input 2 – used with 0V signal 7 CANH 8 CANL X111 DO NOT CONNECT CAN bus Name Remarks 1 DIG_IN3 External digital input 3 – used with 0V signal 2 DIG_IN4 External digital input 4 – used with 0V signal 3 Dig_Out1_common Common point of potential free alarm 1 4 Dig_Out1_n_open Normally open contact of potential free alarm 1 5 Dig_Out1_n_closed Normally closed contact of potential free alarm 1 6 Dig_Out2_common Common point of potential free alarm 2 7 Dig_Out2_n_open Normally open contact of potential free alarm 2 0300072-J0 RevA Page 20 of 46 8 Dig_Out2_n_closed X112 Normally closed contact of potential free alarm 2 Name Remarks 1 Dig_Out3_common Common point of potential free alarm 3 2 Dig_Out3_n_open Normally open contact of potential free alarm 3 3 Dig_Out3_n_closed Normally closed contact of potential free alarm 3 4 Dig_Out4_common Common point of potential free alarm 4 5 Dig_Out4_n_open Normally open contact of potential free alarm 4 6 Dig_Out4_n_closed Normally closed contact of potential free alarm 4 7 -- 8 -- DO NOT CONNECT Table 1 : Signal connector pin assignments Signal connections can be brought back to the front of the shelf via the front signal connection card (Figure 17). Figure 17 : Front signal connectors Figure 18 : Sub-D 26 poles pin layout The following table lists all of the pin assignments for the Sub-D26 signal connector: X104 Name Remarks 1 DIG_IN4 External digital input 4 – used with 0V signal 2 DIG_IN3 External digital input 3 – used with 0V signal 3 DIG_IN2 External digital input 2 – used with 0V signal 4 DIG_IN1 External digital input 1 – used with 0V signal 5 -- DO NOT CONNECT 6 Dig_Out4_n_open Normally open contact of potential free alarm 4 7 Dig_Out3_n_open Normally open contact of potential free alarm 3 8 9 Dig_Out2_n_open Normally open contact of potential free alarm 2 Dig_Out1_n_open Normally open contact of potential free alarm 1 10 0 V signal 11 0 V signal 12 0 V signal 13 0 V signal 14 -- DO NOT CONNECT 15 Dig_Out4_common Common point of potential free alarm 4 16 Dig_Out3_common Common point of potential free alarm 3 0300072-J0 RevA 0V signal Page 21 of 46 X104 Name Remarks 17 Dig_Out2_common Common point of potential free alarm 2 18 Dig_Out1_common Common point of potential free alarm 1 19 -- 20 -- 21 -- 22 -- 23 Dig_Out4_n_closed Normally closed contact of potential free alarm 4 24 Dig_Out3_n_closed Normally closed contact of potential free alarm 3 25 Dig_Out2_n_closed Normally closed contact of potential free alarm 2 26 Dig_Out1_n_closed Normally closed contact of potential free alarm 1 DO NOT CONNECT Table 2 : Sub-D26 signal connector pin assignments DC Output There are 3 different load connection options with the 48-300W Modular Switched Mode Rectifier System: 1. Output terminal block of the distribution unit (only for stand-alone systems) (Figure 19) 2. DC bus at rear of the shelf (Figure 20) 3. Auxiliary DC output (300W max.) on the front of each rectifier (Figure 21) 1. Terminal block with four protected DC outputs: The rectifiers are connected in parallel: • If the fuse box is empty, insert a alarm-indicating fuse (2A or 5A or 10A) in the fuse holder of the distribution unit. • Insert wires (stripping length 10mm) in the associated position in the spring cage terminal block. A flat screwdriver can be used to assist in the insertion or removal of these wires. Alarm indicating fuse Figure 19 : Front terminal block DC outputs Out 1 Out 2 Out 3 Out 4 + + + + - - - - 2. DC Bus at rear side: A load can be connected directly to the DC bus by making connections to the screw-type connector (M5 inserts), as shown in Figure 20. 0300072-J0 RevA Page 22 of 46 Figure 20 : Rear DC bus connector DC Bus + - NOTE: On delivery, the “+” pole of the DC bus is FLOATING (i.e. NOT connected to earth). In order to comply with the SELV (Safety Extra Low Voltage) rules, the “+” DC bus must be connected to earth. 3. Auxiliary DC output: Each rectifier has a front panel mounted DC output. The polarity is indicated on the front plate. Insert the wires in the mating connector and secure them by tightening the screws located on top of the connector. The mating connector can be ordered from Alpha Technologies. Figure 21 : Front Auxiliary DC output Auxiliary Output GND 0300072-J0 RevA + - Page 23 of 46 Mains input Connect the mains to the 48-300W Modular Switched Mode Rectifier System AC input according the shelf configuration. Please observe the following recommendations: • Pigtail (1.5m cable): first connect the yellow/green protective earth cable to the protective earth of the mains before connecting the neutral and line. • IEC: Insert a 3-pole IEC C15 plug only (see Figure 22) • Dual IEC: Insert two 3-pole IEC C15 plugs (see Figure 22) A complete mains cord kit can be purchased from Alpha Technologies. Each mains connection has to be protected by a 16A circuit breaker. For internal protection please refer to the specification sheet of the corresponding rectifier module. Protective earth Figure 22 : IEC mains inlet WARNING! Type of detachable mains cord: Cord used must be in compliance with table NAE.4 of CSA 60950-1/UL 60950-1, Bi-National standard, with the following characteristics: UL/CSA approved and rated 300V/90°C/1.5mm² crosssection. EMC ground If necessary for the end user system and for better EMC performance connect a ground cable to the common ground of the shelf (M4 thread at the rear side). It is also possible to use this M4 thread to ground the positive pole of the 54Vdc output. This ground is not a protective earth. Protective earth is provided by the 3-pole mains cable. Figure 23 : EMC ground 0300072-J0 RevA Page 24 of 46 Battery (only for stand-alone systems) WARNING! The batteries must be installed by qualified personnel trained in the safe use of high-energy power supplies and batteries. Refer to product safety information. WARNING! The external battery MUST be protected according to the system power and the installed cross-section of the cables. The fuse or disconnecting device must be capable of interrupting the current in the event of a short-circuit. The short-circuit current of the batteries is specified by the manufacturer. Shock hazard: all metal parts of batteries are live and so there is a danger of injury from electric shock and of accidental short circuit. Touch the battery on the insulated part only. Be careful with non-insulated tools, bracelets, watches and rings. Explosion hazard: regardless of service conditions, hydrogen gas can escape from the pressure relief valves. Installation in hermetically sealed enclosure is therefore prohibited. CAUTION! The short circuit current of the batteries must be lower than 1500A. It is recommended to place a fuse or disconnect device close to the batteries. This device must be capable of interrupting the current in the event of a short-circuit. CAUTION CAUTION! Before plugging and unplugging the battery connector, the user should pull the battery circuit breaker and check whether the LVD is non-active (open) to avoid damaging the battery connector contacts. Please also note the following: 1. Use new batteries when installing a new rectifier system. Verify they are all the same battery type with identical date codes. 2. The battery string must be 48Vdc nominal. 3. If you are making your own battery wiring harness, use up to 4mm² cables. 4. The maximum capacity of the battery is limited to 62Ah (or 1500A short-circuit current). Please observe the following procedure: 1. Number the batteries from 1 to 4 with labels or tape. 2. Coat the battery terminals with battery corrosion inhibitor. 3. Wire the batteries as shown in Figure 25. If used, install the in-line fuse. 4. Pull (open) the battery circuit breaker at the distribution unit and ensure that the LVD is open and the “LVD OK” indicator is off (Figure 25). 0300072-J0 RevA Page 25 of 46 5. Verify the battery connector polarity and DC voltage with a DC voltmeter. If correct, plug it into the battery connector at the front of the distribution unit (Figure 25). 6. Route the sensor end of the battery temperature cable to the batteries. Tape it to the side of the centre of the batteries string. As the cable terminal is voltage free, the sensor can even be placed directly on one of the copper bar inter-cell links. Insert the temperature sensor connector into the battery temperature probe socket at the front of the distribution unit (Figure 24 & Figure 25). 7. To activate the battery, push (close) the battery circuit breaker at the distribution unit and ensure that the LVD is closed (“LVD OK” LED is on) (see Figure 25). As batteries can be charged and discharged by the 48-300W Modular Switched Mode Rectifier System, the DC bus voltage and the charging current have to be defined by the MCU. The factory voltage has been set to -54.0 V at +25°C and the charging current has no limitation. When the temperature sensor is connected and activated, the temperature compensation is -3mV/K/cell. The battery disconnection voltage is fixed at 43.2V (1.8V per cell). Figure 24 : Battery temperature sensor NTC @10kΩ at +25°C (NTC 10K B=3977K) Figure 25 : Battery connections 0300072-J0 RevA Page 26 of 46 3.3.6 Summary Mode Push Button Battery Temperature Sensor Connector LCD Display Fuses 1234 1 2 3 4 DC Outputs USB +‒ Status & Alarm LEDs Ethernet Battery Test Push Button IEC C16 Mains Inlet Rectifier Status LED Battery Circuit Breaker LVD OK Status LED Auxiliary DC Outputs GND +‒ Battery connector Protective Earth EMC Ground DC Bus Output +‒ Signal connectors X110 X111 X112 Figure 26 : Connection overview 0300072-J0 RevA Page 27 of 46 4 OPERATING THE 48-300W MODULAR SWITCHED MODE RECTIFIER SYSTEM 4.1 Switching ON and OFF 4.1.1 Switching ON After powering up the 48-300W Modular Switched Mode Rectifier System, please verify that the following: • The mains is ON. • The rectifiers correctly report mains present. (Green LEDs on each rectifier should illuminate). • If the system is fitted with a Comp@s board, after 30 seconds the leftmost LED should be permanently ON Note: LED continues to flash if no Comp@s is present. If it is present, verify the display: V =~54.0 V • Close the breaker for the battery (if present). The system is then operational. Some alarms may be ON, depending of the settings on the MCU. 4.1.2 Switching OFF In order to switch off the complete system, use the external mains disconnect device. If the shelf has a battery back-up, pull the battery breaker button (the LVD will open) too. NOTE: The mains disconnect device and the battery breaker must always be easily accessible to facilitate system shut down in an emergency. In this case, the battery is disconnected from the system as the LVD is open and the load is no longer supplied by the DC Bus. 4.2 Rectifiers 300 W: CXRF 48-300W There is an LED on the rectifier front panel which illuminates in green, orange or red depending upon the status of that unit. When in fault condition, the rectifier sends an alarm signal and the LED flashes. This signal is detected by the MCU. LED Figure 27 : CXRF 48-300W 0300072-J0 RevA Page 28 of 46 Colour Pulse freq. State (Hz) Green Permanent OK Orange Permanent REMOTE_OFF Red Permanent DC_NOT_OK Red Flashing (2) MAJOR_FAULT Description Normal conditions : Uout within specifications Normal conditions: in standby = OFF DC voltage is below minimum rated voltage (36 V) The power supply is interrupted by one of the following causes: • AC voltage out of range ≥ 285 V • Internal temperature too high • Output short-circuit longer than 10 sec Table 3 : Rectifier LED indication 4.3 Comp@s Settings The following features are available with the Comp@s card only. 4.3.1 Licence Overview The following 4 different Comp@s software licenses are available: • Basic license • Battery license • Asset management license • Modbus (in combination with Asset management license) 0300072-J0 RevA Page 29 of 46 Table 4 summarises the features of each license (for more details refer to the Comp@s manual). Description License 1. Basic 2. Battery 3. Asset 4. Modbus Float voltage, TC, LVD Boost functions DC Bus alarms Battery continuity Battery temperature Battery max. charging current Battery Test Alarm settings: outputs , input PLC functions Serial Nr, Manufacturing date, ID Users (user name, PW) SNMP, XML Data records Modbus RTU over TCP protocol Table 4: Short-form license overview 4.3.2 Factory Preset Settings Overview Table 5 lists all the default settings of the MCU. Table General Config.Table Item Value Licence 1 2 Comment 3 URL address 192.168.45.2 x User (as administrator ) admin x Case sensitive Password compas x Case sensitive DC Bus Float 54.0 Vdc x At +25°C ; 2.25 Vdc/cell DC Bus Voltage Extra Low 45.0 Vdc x 1.88Vdc/ cell DC Bus Voltage Low 48.0 Vdc x 2.00Vdc/cell DC Bus Voltage High 56.5 Vdc x 2.35Vdc/cell DC Bus Voltage Extra High 58.0 Vdc x 2.42Vdc/cell LVD Disconnect Voltage 43.2 Vdc x 1.80Vdc/cell LVD Disconnect Delay 0 x Temp. Comp. slope -72 mVdc x Minimum nr. of Present Rectifiers 0 x Battery Charge Current Limit / x Battery String Capacity 62 Ah x Bat. Temp. Low 0°C x Bat. Temp. High +40°C x 0300072-J0 RevA Only applied when system is in float -3 mVdc/K/cell No battery charging current limitation Page 30 of 46 Min. Current for Discharge Alarm -2 Amps x Boost Automatic False x Boost Activation Low Voltage 46.0 Vdc x Boost Termination Voltage 56.4 Vdc x When reached ; back to Float Boost Termination Current 2 Amps x When reached ; back to Float Boost Termination Time 120 minutes x When reached ; back to Float Battery Test (BT) End Voltage 46.0Vdc x BT Discharge Ratio 0% x Editable with Battery licence BT Interval 0 day x No automatic test, manual start only BT Discharge Current 1000 Amps x BT Min. Discharge Current 2 Amps x BT Time Out 10 minutes Digital input 1 Name Digital input 1 x Digital input 2 Name Digital input 2 x Digital input 3 Name Digital input 3 x Digital input 4 Name Digital input 4 x Read Access Users 1, 2, 3, 4, 5 x Write Access Users 0 x x Table 5 : Overview factory settings MCU 4.3.3 54 Vdc Bus Voltage The float voltage at +25°C can be adjusted. In the edit mode, go to the DC System tab and click on “Configuration”. Figure 28 below shows the Bus voltage screen through which setting changes can be made by entering a new value and clicking on “Modify”. It is important to note that these values will be used as references for alarms. 0300072-J0 RevA Page 31 of 46 Figure 28: Bs voltage 4.3.4 Battery Setup The battery and related alarms can be configured individually. Temperature compensation The bus voltage (and hence the battery charging voltage) can be automatically adjusted proportionate to the ambient temperature around the batteries. The value of this compensation is given by the battery manufacturer. Note that the compensation is usually given per 2V cell. As the DC Bus is 48Vdc, this value must be multiplied by 24 to obtain the figure to be set in the dedicated field of the Comp@s menu (see Figure 29 below). Figure 29 : Temperature compensation Battery String Capacity The “Battery String Capacity” is the Ah value of the installed battery blocks (see Figure 30). NOTE: You should not install a battery with a capacity greater than 62Ah. Therefore the “battery string capacity” is limited to 62Ah. Battery Charge Current Limit The maximum charging current is defined by the user. Usually the maximum charging current in Amps is one tenth of the battery capacity in Ah. Refer to the specifications of the battery and the recommendations given by the battery manufacturer. NOTE: The maximum battery current is calculated as the difference between the available rectifier current (up to 7 Amps per rectifier at 43Vdc) and the load current. The “Battery Charge Current” limit is factory pre-set to 1000 Amps. This means the batteries are not subject to a current limitation. The maximum charging current can be automatically limited by changing the setting in Comp@s. Battery Temperature The same sensor is used both to monitor battery temperature and to provide the temperature compensation reference. The battery temperature function is always active and a battery alarm is given by the MCU LED and the corresponding relay. An alarm is generated when the battery temperature reaches one of the trip levels (low or high limit). A “Battery Temperature Sensor Fail” alarm is indicated when the temperature sensor is out of range: i.e. open circuit, not connected or in short circuit. 0300072-J0 RevA Page 32 of 46 Figure 30: Battery setup Battery pre-alarms Alarms are generated when the DC Bus voltage reaches one of the pre-set alarm levels. In this case, no action is initiated other than an alarm (major, minor or battery) being generated on the MCU LEDs and the corresponding relay. 4.3.5 LVD Trip Level During a battery discharge the internal LVD opens when the battery low voltage trip level is reached. The factory settings for this are the following: Description Factory setting trip level MCU settings 43.2Vdc Factory setting delay 0 second LVD when MCU removed CLOSED Comments LVD opens when the value is reached after the time given in seconds opens at typ. 42Vdc Table 6: LVD Trip level NOTE: When the MCU is removed from the shelf (e.g. for adjustment or replacement), the LVD remains CLOSED and when the mains is absent (shelf working on the battery) the LVD will open at approximately 42 V. The LVD will re-close automatically when the mains is restored. 4.3.6 Rectifier Settings It is recommended that the minimum quantity of rectifiers needed in the system is defined in the MCU in order to generate an alarm, if one or more rectifiers are missing. Select the Edit Mode and go to the configuration tab of the DC System, change the number of rectifiers, click on “Modify” and save the new settings. The default setting is “0”. Figure 31: Remote off – Rectifiers menu 0300072-J0 RevA Page 33 of 46 If more than one rectifier is installed in the system and the load is significantly less that the full rated capacity of the installed rectifiers (e.g. load is on stand-by) the Smart Energy function can be activated in order to limit the power consumption and increase the system efficiency. The Smart Energy function turns off unused rectifiers, depending on the load activity. If a rectifier is in standby, an orange LED on its front panel will be illuminated. It is recommended that this mode of operation should only be deployed when batteries are connected to the system. To activate this function, it is necessary to change the Boolean condition in the same menu (Edit Mode – DC system – Configuration as shown in Figure 32). To avoid an unplanned activation of this function, it is recommend that a PLC should be applied relating to the battery LVD (e.g. “@(alarm17)==false”). For more details, please see the Comp@s user manual. Figure 32 : Smart Energy Boolean condition NOTE: It is important to note there is a delay of 10 seconds on the rectifier remote shut-down function. This hysteresis time is necessary in the event that the load fluctuates around a critical value. CAUTION! Please note that changes in configuration settings are only possible if the system is fitted with a Comp@s Communication Card is present in the MCU. 0300072-J0 RevA Page 34 of 46 4.3.7 Save the Configuration Once the configuration has been modified, it needs to be saved. If not, the new settings will be lost once the MCU is switched off (no DC supply). The settings are temporarily saved in the Comp@s Card until you save the data into the MCU. There are two ways to save the settings as illustrated on the screenshot: First option Second option Figure 33 : Configuration - save 0300072-J0 RevA Page 35 of 46 4.4 Alarm Monitoring 4.4.1 Factory Preset Alarm Table Table 7 contains the default alarms in the MCU. ID Description 1. DC Bus Extra Low 2. DC Bus Low X 3. DC Bus High X 4. DC Bus Extra High X 5. DC Bus Voltage Sense Failure X 6. Mains Failure X 7. Mains Partial Failure X 8. Mains Low X 9. Not used 10. One rectifier Failure 11. More than One Rectifier Failure X 12. Missing Rectifier (with Comp@s) X 13. Battery Last Test Failed X 14. Battery on discharge X 15. Not used 16. Not used 17. Battery LVD relay Open X 18. Bat. Temperature too High X 19. Bat. Temperature too Low X 20. Bat. Temperature Sensor Fail X 21. Ambient temperature too high 22. Ambient temperature too low 23. Ambient temperature sensor fail 24. Not used 25. Output fuse blown 26. Battery breaker open 27. Digital input 3 28. Digital input 4 29. Digital input 5 30. Digital input 6 1 X 2 Relay 3 4 X X X Table 7: Overview Alarm settings 0300072-J0 RevA Page 36 of 46 4.4.2 Type of Alarm There are 5 different alarm types: • Warning • Minor • Major • Critical • Disabled For each type of alarm, a severity level between 0 and 9 can be assigned (fully user configurable). Each alarm can also be associated to a relay. Each relay controls one LED. There are four possibilities. Here are some examples of factory preset configurations: Alarm Out Type Alarm Common NO 26 Urgent 1 or Major 9 25 Non Urgent or minor 8 24 Battery LED 3 23 4 AC fail LED 4 9 18 26 Off or Alarm R1 9 18 26 Normal R2 8 17 25 Off or Alarm R2 8 17 25 Normal R3 7 16 24 Off or Alarm R3 7 16 24 Normal R4 6 15 23 Off or Alarm R4 6 15 23 16 7 15 6 Condition R1 17 LED 2 3 Schematic 18 LED 1 2 NC Normal Table 8: Types of alarms (Front Signal Connection Card X104) A delay can also be programmed into the trigger point of each alarm. Relays and alarms can be associated to external signals. 0300072-J0 RevA Page 37 of 46 Figure 34 below illustrates some alarm and relay associations: Figure 34: Alarms 4.4.3 Battery Test Depending on the Comp@s license procured with the system, there are two different battery tests. 4.4.3.1 BATTERY CONTINUITY CHECK This check is part of the Basic License. When the test is manually started, the output of all installed rectifiers is set to deliver a low output voltage (lower than the battery voltage). The batteries are discharged by the load current. All settings are fixed and cannot be changed. The test time and the end test voltage are fixed at 10 minutes and 46Vdc but the battery current is determined by the load. The table below lists all the actions for conducting this type of battery test: Status Start Continuity Test Stop Continuity Test Reset Alarm Conditions End voltage reached Test time reached Actions Battery Test pressed >10” Automatic Comments Manual start Test time of 10 minutes not reached Automatic Manual Manual Indications Battery Alarm No Alarm Battery Test pressed >5” Perform a short Battery Test and cancel it No Alarm Table 9: Battery Continuity Test 0300072-J0 RevA Page 38 of 46 4.4.3.2 BATTERY TEST NOTE: The Battery License is required to perform a full battery test. The battery test starts when: • the time period between two automatic tests is reached (see Comp@s user manual for more details) OR • the “BATT TEST” button is pressed for a period of more than 5 seconds. During the test, the green “LVD ON” LED flashes. The battery test cannot start when: • an alarm is present • the batteries are charging or discharging • the mains is absent NOTE: The delay between two tests is set as 180 days. It starts: • after an automatic test • after each manual test • after stopping a manual test • when the MCU is inserted into the shelf • each time the whole system, including the MCU, is switched ON When the test is started (manually or automatically after 180 days), all installed rectifiers are set to deliver a low output voltage (lower than the battery voltage). The batteries are discharged at a fixed current which can be set by the user. The difference between the load current and the battery current is supplied by the rectifiers (the rectifiers keep the battery discharge current stable in case of load variations during the test). The discharge current and the battery voltage are measured and integrated. As the battery discharging current is always the same, the discharge curves from different discharge tests can easily be compared. The battery test terminates when: • the programmed power (30% to 50% of the nominal battery Ah value) is extracted before the end voltage (44V or 46V) • the end voltage is reached OR • the “BATT TEST” button is pressed. The batteries are discharged until 30% (user settable) of their nominal capacity has been extracted. The nominal capacity of the batteries is a variable set by the user via Comp@s. The battery test settings can be modified via the dedicated Comp@s page, as shown in Figure 35 . 0300072-J0 RevA Page 39 of 46 Figure 35: Comp@s - Battery test Table 10 lists the actions for conducting a battery test: Status Conditions Start Battery Test Actions Test Time Interval reached Battery test button pressed more than 5sec. Manual test started from Comp@s (Control tab) Stop Battery Test Discharge power limit reached End voltage reached Test Time Out reached Automatic Automatic Automatic Manual Via Comp@s Reset Alarm Manual Via Comp@s Comment Automatic test when Battery Test Interval > 0 days Manual start Start (Force) Battery Test End Voltage AND Battery Test Time Out are not reached Preset Discharge power not reached Preset Discharge Ratio not reached Batt. Test button pressed more than 5 sec. Back to Float Perform a short Battery Test Reset Last Battery Test State Indication Status MCU flashing (1Hz) during test Status MCU flashing (1Hz) during test Status MCU flashing (1Hz) during test No Alarm Battery Alarm Battery Alarm No Alarm No Alarm Table 10: Battery test 0300072-J0 RevA Page 40 of 46 5 MAINTENANCE 5.1 Battery Replacement WARNING! Use insulated tools when working with batteries. WARNING! Ensure that the system is connected to the mains. The following procedure should be followed to change the batteries when the system is connected to an AC supply: 1. Check that the rectifiers are delivering power and that the output voltage is 54Vdc (+/- 0.5Vdc). 2. Open the system battery breaker. 3. Open the external battery disconnect device (if present) 4. Remove one of the links between the battery blocks. 5. Remove the battery connector from the shelf. 6. Replace the batteries, install all except one of the links between the blocks 7. Connect the cables to the batteries. 8. Install the last inter-cell link. 9. Measure the total battery voltage: 48 V (+/- 2 V). 10. Close the external battery disconnect device (if present). 11. Insert the battery connector in the shelf 12. Close the system battery breaker 13. The green “LVD OK“ LED will illuminate if the batteries have been connected in the correct polarity. 14. Perform a battery continuity check 0300072-J0 RevA Page 41 of 46 5.2 Troubleshooting If any red LEDs on the front panel of the MCU are illuminated this indicates that a fault has developed in the 48300W Modular Switched Mode Rectifier System. Table 11 provides a summary of system alarms: Alarm submenus Alarm Description of problem What to do Battery temperature high The battery temperature is above the specified limits Ensure that the battery cooling system (if used) is working. Battery temperature low The battery temperature is below the specified limits Use optional battery heating system. Contact Alpha Technologies Technical Support for product information. Battery low voltage The batteries are almost discharged. Ensure that batteries are charging and run a battery test. If the charging voltage is low, the battery may need to be replaced. Temperature probe unplugged The temperature probe is unplugged or faulty Reconnect probe to the 48-300W Modular Switched Mode Rectifier System or replace if if faulty Battery LVD relay open The battery relay is open Ensure the battery relay is working by switching the battery breaker on and off (the batteries have to be connected) Rectifier failure One or more rectifier failed Contact Alpha Technologies Technical Support DC bus low The voltage of DC bus is too low The load is faulty or unsuitable for powering via the 48-300W rectifier system or one or more rectifiers may be faulty DC bus high The voltage of DC bus is too high The load is unsuitable for powering via the 48-300W rectifier system Table 11: Troubleshooting 0300072-J0 RevA Page 42 of 46 6 SPECIFICATIONS Power Module Output Voltage 40 to 58 Vdc within rated limits Power 300 W Maximum Operating voltage without damage 300 Vac Current 5.6A @ -54Vdc 6.7A @ -45V Hold-up Time >10ms Electrical noise <10mVrms (wideband) <2nV (psophometric) Acoustic noise 49 dBA Power Module Input Voltage Operating Range 90 to 265 Vac Maximum operating voltage without damage 300 Vac Frequency 47 to 63.6 Hz Current 1.40A @ 230Vac 3A @ 110Vac 3.7A @ 90Vac Efficiency 95% Environmental Operating Temperature -40 to +70°C (-40 to 158°F) Storage Temperature -40 to +85°C (-40 to 185°F) Humidity 20 to 80% non-condensing Elevation 3000m (9843 feet) max Maximum Output 20.1A @ 45Vdc Power IEC C15 16AWG plug connector with retention cable at the rear Earth M6 male stud on the rear of the shelf Shelf Mechanical 0300072-J0 RevA Page 43 of 46 Shelf dimensions 43mm H x 439mm W x 237 D (with rectifier 250mm D 1.7” H x 17.3” W x 9” D (with rectifier 9.84”D) Mounting 19” or ETSI Earth M6 male stud on the rear of the shelf Shelf weight (including controller and DC distribution) 2.8 KG (6.2 lb) Rectifier power module weight 0.57 Kg (1.2 lb) Agency Compliance Safety CSA C22.2 No. 60950-1-07 UL 60950-1 2 nd edition IEC/EN 60950-1 CE marked Emissions CFR47 (FCC) Part 15 Class B EN550022 Class B EN 61000-3-2 EN 61000-3-3 Immunity EN 61000-4-2 EN 61000-4-3 EN 61000-4-4 EN 61000-4-5 EN 61000-4-6 EN 61000-4-11 NEBS Designed to meet, consult factory for certification status: GR-1089-CORE GR-63-CORE GR-3108-CORE 0300072-J0 RevA Page 44 of 46 7 WARRANTY Visit http://www.alpha.ca/web2/services-and-support/warranty.html for full warranty information. 7.1 Warranty Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. 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. 0300072-J0 RevA Page 45 of 46 8 ABBREVIATIONS NOTE: This table does not contain all standard abbreviations. Abbreviation Symbol Complete name Explanation Bonding Connection with the common Ground 19’’ 19 inches Standardised dimension for shelves A xx Unit XX BAT BATtery BT Battery Test C Common (for NO & NC) The common part from relay contact is floating Communication with the MCU controller (hard- and Software ) Comp@s ETSI European Telecommunications Standards Institute Fxx Fuse or breaker XX I/O Input / Output L&N Life and Neutral Related to the Mains LVD Low Voltage Disconnect Protection against deep discharge of batteries MCB Magnetic Circuit Breaker Disconnect device MCU Monitoring and Control Unit The MCU allows communication with the system NC Normally Closed Related to relay contacts NO Normally Open Related to relay contacts NTC Negative Temperature Coefficient Specification of the component to measure a temperature PE Protective Earth Related to the Mains PLC Programmable Logic Controller Function available with Comp@s asset license to create a Boolean relation between inputs and outputs PLD Partial Load Disconnect RFID Radio Frequency Identification RH Relative Humidity SELV Safety Extra Low Voltage Safety norm (max 60 Vdc) U Unit for measuring shelf height 1U = 44.45mm / 1.75 inch Table 12: Abbreviations 0300072-J0 RevA Page 46 of 46 Alpha Technologies Ltd. 7700 Riverfront Gate Burnaby, BC V5J 5M4 Canada Tel: +1 604 436 5900 Fax: +1 604 436 1233 Toll Free: +1 800 667 8743 Alpha Energy, Alpha Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 Alpha Industrial Power Inc. 1075 Satellite Blvd NW, Suite 400 Suwanee, GA 30024 United States Tel: +1 678 475 3995 Fax: +1 678 584 9259 Outback Power 5917 195th St NE, Arlington, WA 98223 United States Tel: +1 360 435 6030 Fax: +1 360 435 6019 Alpha Technologies GmbH Hansastrasse 8 D-91126 Schwabach, Germany Tel: +49 9122 79889 0 Fax: +49 9122 79889 21 Alpha Technologies S.A. 131 Boulevard de l’Europe 1301 Wavre Belgium Tel: +32 10 438 510 Fax: +32 10 438 213 Alpha Technologies Europe Ltd. Twyford House Thorley Bishop’s Stortford Hertfordshire, CM22 7PA United Kingdom Tel: +44 1279 501110 Fax: +44 1279 659870 Alphatec Ltd. 339 St. Andrews St. Suite 101 Andrea Chambers P.O. Box 56468 3307 Limassol, Cyprus Tel: +357 25 375 675 Fax: +357 25 359 595 Alpha TEK ooo Khokhlovskiy Pereulok 16 Stroenie 1, Office 403 Moscow, 109028 Russia Tel: +7 495 916 1854 Fax: +7 495 916 1349 Alpha Technologies Suite 1903, 191F., Tower 1, 33 Canton Rd. Tsim Sha Tsui China, Hong Kong City, Kowloon, Hong Kong Tel: +852 2736 8663 Fax: +852 2199 7988 Alpha Innovations Brasil Rua Manuel Augusto de Alvarenga, 155 São Paulo, SP - Brasil Tel: +55 11 2476 0150 Fax: +55 11 2476 0150 Alphatec Baltic S. Konarskio Street 49-201 Vilnius, LT-03123 Lithuania Tel: +370 5 210 5291 Fax: +370 5 210 5292 For technical support, contact Alpha Technologies: Canada and USA: 1-888-462-7487 International: +1-604-436-5547 Visit us at www.alpha.ca ue to continuing product development, Alpha Technologies reserves the right to change specifications without notice. D Copyright © 2012 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.