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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
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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
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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.
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•
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.
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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.
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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
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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)
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•
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)
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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.
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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.
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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
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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.
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2.7
Mechanical Overview
2.7.1 Dimensions
Figure 10 : Front view
Figure 11 : Top view
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2.8
Electrical Overview
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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.
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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.
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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.
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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.
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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
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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
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0V signal
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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.
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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
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+
-
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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
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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).
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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
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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
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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
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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)
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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.
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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.
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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
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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.
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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Hansastrasse 8
D-91126
Schwabach, Germany
Tel: +49 9122 79889 0
Fax: +49 9122 79889 21
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131 Boulevard de l’Europe
1301 Wavre
Belgium
Tel: +32 10 438 510
Fax: +32 10 438 213
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Twyford House Thorley
Bishop’s Stortford
Hertfordshire, CM22 7PA
United Kingdom
Tel: +44 1279 501110
Fax: +44 1279 659870
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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
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Stroenie 1, Office 403
Moscow, 109028
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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
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Rua Manuel Augusto
de Alvarenga, 155
São Paulo, SP - Brasil
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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
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