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Cordex Modular Distribution System Models: CXDS-M 1200/1200-23" CXDS-M 600/600-19" CXDS-M 1200/1200-19" CXDS-M 600/600-19" CXDS-M Micro CXDS-M Mini Installation & Operation Manual Part # 9400002-J0 Effective: 04/2013 member of The Group™ Your Power Solutions Partner Cordex Modular Distribution System Models: CXDS-M 1200/1200-23" CXDS-M 600/600-23" CXDS-M 1200/1200-19" CXDS-M 600/600-19" CXDS-M Micro CXDS-M Mini 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. Table of Contents 1. Safety������������������������������������������������������������������������������������������������������������������������������������5 1.1 Safety Symbols�������������������������������������������������������������������������������������������������������������������������� 5 1.2 General Safety��������������������������������������������������������������������������������������������������������������������������� 5 1.3 Mechanical Safety���������������������������������������������������������������������������������������������������������������������� 5 1.4 Electrical Safety������������������������������������������������������������������������������������������������������������������������� 6 1.5 Battery Safety���������������������������������������������������������������������������������������������������������������������������� 6 2. Introduction���������������������������������������������������������������������������������������������������������������������������7 2.1 Scope of the Manual������������������������������������������������������������������������������������������������������������������ 7 2.2 Terminology�������������������������������������������������������������������������������������������������������������������������������� 7 2.3 Product Specifications��������������������������������������������������������������������������������������������������������������� 9 2.4 Theory of Operations��������������������������������������������������������������������������������������������������������������� 10 3. Product Description������������������������������������������������������������������������������������������������������������12 3.1 Distribution and Termination���������������������������������������������������������������������������������������������������� 12 3.2 Cordex System Controller�������������������������������������������������������������������������������������������������������� 15 4. Pre-Installation Preparation������������������������������������������������������������������������������������������������20 4.1 Site Selection��������������������������������������������������������������������������������������������������������������������������� 20 4.2 Tools and Test Equipment�������������������������������������������������������������������������������������������������������� 21 4.3 Unpacking the Equipment�������������������������������������������������������������������������������������������������������� 21 5. Installation���������������������������������������������������������������������������������������������������������������������������22 5.1 Rack Mounting������������������������������������������������������������������������������������������������������������������������� 22 5.2 External Cable Tie Bar Option������������������������������������������������������������������������������������������������� 22 6. Installation - DC and Grounding Cables�����������������������������������������������������������������������������23 6.1 Installation Notes��������������������������������������������������������������������������������������������������������������������� 23 6.2 Connecting the Frame and Reference Grounds���������������������������������������������������������������������� 25 6.3 DC Input����������������������������������������������������������������������������������������������������������������������������������� 26 6.4 Connecting DC Load Cables to Breaker/Fuse Circuitry����������������������������������������������������������� 27 6.5 External Alarm Wiring�������������������������������������������������������������������������������������������������������������� 30 6.6 Top Cover(s)���������������������������������������������������������������������������������������������������������������������������� 31 7. System Startup�������������������������������������������������������������������������������������������������������������������32 8. Test and Commissioning Overview�������������������������������������������������������������������������������������33 2 9400002-J0 Rev C 8.1 System������������������������������������������������������������������������������������������������������������������������������������� 33 8.2 Documentation������������������������������������������������������������������������������������������������������������������������� 33 9. Adding an Expansion module���������������������������������������������������������������������������������������������34 10. Maintenance���������������������������������������������������������������������������������������������������������������������38 10.1 Controller Lithium Battery Replacement�������������������������������������������������������������������������������� 38 10.2 Spare Parts���������������������������������������������������������������������������������������������������������������������������� 39 11. Acronyms and Definitions��������������������������������������������������������������������������������������������������40 12. Warranty���������������������������������������������������������������������������������������������������������������������������41 12.1 Battery Warranty�������������������������������������������������������������������������������������������������������������������� 41 13. Ordering Options and Accessories�����������������������������������������������������������������������������������42 13.1 CXDS-M 1200/1200-23" Systems (0906xxx-001)������������������������������������������������������������������ 42 13.2 CXDS-M 1200/1200-19" Systems (0907xxx-001)������������������������������������������������������������������ 42 13.3 CXDS-M 600/600-23" Systems (0908xxx-001)���������������������������������������������������������������������� 42 13.4 CXDS-M 600/600-19" Systems (0908xxx-001)���������������������������������������������������������������������� 42 13.5 Accessories���������������������������������������������������������������������������������������������������������������������������� 43 List of Figures Figure 1 — Single module, dual feed with isolated returns��������������������������������������������������������������� 7 Figure 2 — Example of a distribution system with two modules������������������������������������������������������� 8 Figure 3 — CXDS-M 1200/1200 with common return - normal limits��������������������������������������������� 10 Figure 4 — CXDS-M 1200/1200 with common return - abnormal limits����������������������������������������� 10 Figure 5 — CXDS-M 600/600 with split return���������������������������������������������������������������������������������11 Figure 6 — Breaker bank shunt (left bank shown)�������������������������������������������������������������������������� 12 Figure 7 — Shunt mux panel mounted on the inside door of the top module��������������������������������� 13 Figure 8 — Fuse/breaker alarm LEDs and shunt multiplexer reset button������������������������������������� 14 Figure 9 — CXC controller mounted in a distribution BDFB����������������������������������������������������������� 15 Figure 10 — Controller communication ports��������������������������������������������������������������������������������� 16 Figure 11 — Connection method for digital inputs (shown for +24V input)������������������������������������� 17 Figure 13 — Relay connections in the de-energized state������������������������������������������������������������� 18 Figure 12 — BDFB installation shield��������������������������������������������������������������������������������������������� 18 9400002-J0 Rev C 3 Figure 14 — Circuit breaker guard�������������������������������������������������������������������������������������������������� 19 Figure 16 — Center mount brackets����������������������������������������������������������������������������������������������� 22 Figure 17 — Locations for optional cable tie bar���������������������������������������������������������������������������� 22 Figure 18 — Battery return reference��������������������������������������������������������������������������������������������� 25 Figure 19 — DC input bus bars������������������������������������������������������������������������������������������������������ 26 Figure 21 — Load cable connection to BDFB��������������������������������������������������������������������������������� 27 Figure 20 — Preparation for 2-pole and 3-pole breakers��������������������������������������������������������������� 27 Figure 22 — Load cables exiting the bottom���������������������������������������������������������������������������������� 28 Figure 23 — Final load cable arrrangement (4 module BDFB shown)������������������������������������������� 28 Figure 24 — Left hand bank����������������������������������������������������������������������������������������������������������� 29 Figure 25 — Right hand bank��������������������������������������������������������������������������������������������������������� 29 Figure 26 — Route of external signal wiring����������������������������������������������������������������������������������� 30 Figure 27 — Top Kydex cover with cuts for cable entry������������������������������������������������������������������ 31 Figure 28 — Cable tie bar and insulation shield����������������������������������������������������������������������������� 34 Figure 29 — BDFB bottom covers�������������������������������������������������������������������������������������������������� 34 Figure 30 — Alignment of filler plates and bus bar connectors������������������������������������������������������� 35 Figure 32 — I/O and Alarm Interface board������������������������������������������������������������������������������������ 36 Figure 31 — BDFB back cover installation������������������������������������������������������������������������������������� 36 Figure 33 — Joining the two doors������������������������������������������������������������������������������������������������� 37 Figure 34 — Shunt mux and control boards����������������������������������������������������������������������������������� 39 4 9400002-J0 Rev C 1. Safety 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 rule beneath which the information appears CAUTION! CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. Cautions are designated with a yellow warning triangle, the word CAUTION, and a rule beneath which the information appears. WARNING! WARNING presents safety information to PREVENT INJURY OR DEATH to personnel. Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath which the information appears. HOT! The use of HOT presents safety information to PREVENT BURNS to the technician or user. 1.2 General Safety WARNING! This system is designed to be installed in a restricted access location that is inaccessible to the general public. 1.3 Mechanical Safety • Keep hands and tools clear of fans. Fans are thermostatically controlled and switch on automatically. • Power supplies can reach extreme temperatures under load. • Use caution around sheet metal components and sharp edges. 9400002-J0 Rev C 5 1.4 Electrical Safety WARNING! Hazardous voltages are present at the input of power systems. The DC output from rectifiers and batteries, though not dangerous in voltage, has a high short-circuit current capacity that may cause severe burns and electrical arcing. • Before working with any live battery or power system, follow these precautions: a. Remove all metallic jewelry, such as watches, rings, metal rimmed glasses, or necklaces. b. Wear safety glasses with side shields at all times during the installation. c. Use OSHA approved insulated hand tools. WARNING! Lethal voltages are present within the power system. Always assume that an electrical connection or conductor is energized. Check the circuit with a voltmeter with respect to the grounded portion of the enclosure (both AC and DC) before performing any installation or removal procedure. • Do not work alone under hazardous conditions. • A licensed electrician is required to install permanently wired equipment. Input voltages can range up to 240 Vac. Ensure that the utility power is disconnected and locked out before performing any installation or removal procedure. • Ensure that no liquids or wet clothes come into contact with internal components. • Hazardous electrically live parts inside this unit are energized from the batteries even when the AC input power is disconnected. 1.5 Battery Safety • Servicing and connection of batteries must be performed by, or under the direct supervision of, personnel knowledgeable of batteries and the required safety precautions. • Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic objects from your hands and neck. • Use OSHA approved insulated hand tools. Do not rest tools on top of batteries. • Batteries contain or emit chemicals known to cause cancer and birth defects or other reproductive harm. Battery post terminals and related accessories contain lead and lead compounds. Wash your hands after handling batteries. WARNING! Follow battery manufacturer’s safety recommendations when working around battery systems. Do not smoke or introduce an open flame when batteries (especially vented batteries) are charging. When charging, batteries vent hydrogen gas, which can explode. • 6 Batteries are hazardous to the environment and should be disposed at a recycling facility. Consult the battery manufacturer for recommended local authorized recyclers. 9400002-J0 Rev C 2. Introduction 2.1 Scope of the Manual This instruction manual explains the features, installation, interconnection and startup of the Alpha CXDS-M Cordex modular distribution system. Images contained in this document are for illustrative purposes only and may not exactly match your installation. 2.2 Terminology Throughout this document the following terminology is used: • One tier systems (Figure 1) are referred to as CXDS-M Micro distribution systems. • Two tier systems (Figure 2 are referred to as CXDS-M Mini distribution systems. • CXDS-M Modular Distribution Systems are commonly referred to as BDFBs (Battery Distribution Fuse Board) or BDCBBs (Battery Distribution Circuit Breaker Board). Product Overview Alpha modular distribution solution provides a remote power distribution solution for large communications applications that utilize large centralized power systems such as the Alpha CXPS-C series—central offices, mobile switching centers, data center and cable headend facilities. The CXDS-M 1200/1200 and CXDS-M 600/600 series are designed to be fed from a ±24Vdc or -48Vdc power system to bring power closer to the connected equipment and increase the number of load distribution points. These systems have many benefits: • Dual feed with a maximum rating of 1200A for common return and 600A for split return • Compact front access design that reduces floor and rack space footprint • Flexible circuit breaker and TPS fuse options • Cordex Controller (optional) to configure, monitor and control the distribution system from its local graphics display or remotely via a web browser. Other controller features include: event data storage, alarm generation and e-mail alarm notification. • Rack mount up to four modules in a 23" rack or two modules in a 19" Feed A Return Feed B Figure 1 — Single module, dual feed with isolated returns 9400002-J0 Rev C 7 Controller Figure 2 — Example of a distribution system with two modules Table A — Configurations 23" Rack Mount 19" Rack Mount Model CXDS-M 1200/1200 CXDS-M 600/600 CXDS-M 1200/1200-19 CXDS-M 600/600-19 Part Number 0906xxx-xxx 0908xxx-xxx 0907xxx-xxx 0909xxx-xxx 1200/1200A Common return 600/600A Split return 1200/1200A Common return 600/600A Split return Description System Voltage: System Current: -24V, +24V and -48V • Dual feed, split return, 600A max • Dual feed, common return, 1200A max 8 9400002-J0 Rev C 2.3 Product Specifications Electrical System voltage: Single input: Dual input: -24V, +24V and -48V 1200A max 600A x2 max Mechanical Dimensions 23" (HxWxD): 19" (HxWxD): Weight: 263mm x 660mm x 482mm (10.5in x 26in x 19in) 263mm x 550mm x 482mm (10.5in x 22in x 19in) 27.2kg (60lbs) approx Mounting: Standard flush or center mount 19" or 23" relay rack Temperature: Humidity Altitude: Heat Dissipation: 0 to 50˚C (32 to 122˚F) 0 to 95% RH non-condensing -500 to 2800m (-1640 to 9186ft) <110 BTU per hour Safety: CSA C22.2 No 60950-1-07 (2nd Ed) / UL 60950-1 (2nd Ed) Environmental Agency Compliance 9400002-J0 Rev C 9 2.4 Theory of Operations The CXDS-M 1200/1200 and CXDS-M 600/600 series are compact, high capacity distribution systems designed to be fed from a +/-24Vdc or -48Vdc power system to bring power closer to the connected equipment and increase the number of load distribution points. FEED A Max 600A x 12 1200A Customer Load 1200A Max 600A x 12 FEED B Return Return Max 1200A CXDS-M POWER PLANT Figure 3 — CXDS-M 1200/1200 with common return - normal limits FEED A Max 1200A x 12 1200A 0A Customer Load x 12 FEED B Return Return Max 1200A POWER PLANT CXDS-M Figure 4 — CXDS-M 1200/1200 with common return - abnormal limits 10 9400002-J0 Rev C Plant A Max 600A x 12 800A MGB Customer Equipment EQ Plant B Max 600A x 12 800A Max 600A Return Return Max 600A POWER PLANT CXDS-M Figure 5 — CXDS-M 600/600 with split return 9400002-J0 Rev C 11 3. Product Description 3.1 Distribution and Termination A CXDS-M Modular Distribution System features high capacity, front access, modularity, and simplified installation. These features provide effective secondary load distribution and protection for high capacity loads. Each BDFB can contain 2 banks of 12 plug-in bullet positions that can accommodate either plug-in bullet breakers or TLS/TPS plug-in fuse holders. Table B lists the full complement of fuses/breakers for different configurations. Table B — Fuses and Breakers Configurations Type Fuses Breakers BDFB with 4x 23" modules GMT CXDS-M Mini CXDS-M Micro 10 positions, up to 10A (max) TLS/TPS plug-in bullet 96 positions (max) 48 positions (max) 24 positions (max) AM plug-in bullet 96 positions (max) 48 positions (max) 24 positions (max) Table C — Termination Type Connection Fuses GMT 0.34 to 2.5 mm2 (14 to 22AWG) TLS/TPS plug-in bullet 1 pole and 2 pole are 1/4" diameter on 5/8" centers 3 pole are 3/8" diameter on 1" centers Breakers AM plug-in bullet 1 pole and 2 pole are 1/4" diameter on 5/8" centers 3 pole are 3/8" diameter on 1" centers 3.1.1 Distribution Shunts Each bank of breakers is connected to the distribution bus through an 800 A / 25 mV shunt and the individual distribution shunt current can be viewed on the CXC. Refer to the electrical schematic that ships with your system. Figure 6 — Breaker bank shunt (left bank shown) 12 9400002-J0 Rev C 3.1.2 Shunt Multiplexer Panel The Cordex controller can monitor up to four load current shunts. A shunt mux PCB is used for configurations with more than 4 current shunts. Shunt mux PCB Figure 7 — Shunt mux panel mounted on the inside door of the top module 9400002-J0 Rev C 13 3.1.3 Fuse/Breaker Alarms The blowing of a fuse and/or opening of a breaker in a BDFB generates an alarm in the system controller. See section 3.2.2 for a description of the Controller alarm LEDs. LEDs on the panel inside the front door indicate whether the blown fuse or open breaker is in the left or right bank (Figure 8). CB/Fuse Alarm LEDs #1 Left Bank Alarm #2 Right Bank Alarm #3 Secondary Voltage Alarm #3 #2 #1 Module with Controller #1 #2 #3 CB/Fuse Alarm LEDs Shunt Multiplexer Reset Button #1 Left Bank Alarm #2 Right Bank Alarm #3 Secondary Voltage Alarm Module without Controller Figure 8 — Fuse/breaker alarm LEDs and shunt multiplexer reset button 14 9400002-J0 Rev C 3.2 Cordex System Controller A Cordex system controller (CXC), mounted in one of the modules, provides easy access to controls and display status. The CXC provides comprehensive setup, control, monitoring and communication for Alpha DC power systems. The CXC features include the following: • Local and remote communications • User definable alarms • Daily logging of events and system statistics See the CXC Software Manual shipped with your order for detailed information. LCD screen System status LEDs Reset button Craft port Figure 9 — CXC controller mounted in a distribution BDFB 3.2.2 Front Panel LEDs Three LEDs are located on the front panel: one green, one yellow, and one red. These LEDs display the alarm status of the system, controller progress and status during startup, as well as file transfers. Alarm conditions Only one LED is illuminated at a time during alarm conditions. Each LED corresponds to a specific alarm condition. A built-in audio speaker sounds an intermittent tone during active alarms. Illuminated LED Alarm Green OK, no alarms Yellow Minor alarm, no major alarms Red Major alarm Progress and status indication The LED lights are also used in the following situations: • Base unit validation—all three LEDs illuminate • File transfer—red LED illuminates 3.2.1 Front Panel Reset Button If it is necessary to reset the controller (before a power-down for example), use the LCD to select the reset menu item. Resetting from the LCD initiates a soft reset with no loss of data. The reset button (Figure 9) on the front panel initiates a hard reset of the CXC microprocessor. No data is saved and should be used only If the controller is hung up. It takes approximately 15 seconds before the display reappears after pressing the reset button. 9400002-J0 Rev C 15 3.2.3 Network connection and remote communications The Cordex system can be set up, monitored, and tested over an Ethernet 10/100 Base-T serial data connection. The controller includes a web server that provides easy set up and monitoring over an Internet connection to a web browser. Craft port A DB9 COM port on the front panel provides computer to CXC communication over an RS-232 serial data connection (PPP) using a null modem cable connected to the Craft port (front panel RS-232). Ethernet port An Ethernet port is located inside the front panel. This port is designed to connect the controller to a user supplied TCP/IP network. Use a standard RJ-45 jack with a standard network cable. The Ethernet port can be used for local access, for example to a laptop computer. Use a standard network crossover cable for the connection. Internal CAN Bus A CAN bus provides a communication path between the shunt mux and the controller. The CAN serial port is located inside the front panel next to the Ethernet port. Ethernet port CAN port Figure 10 — Controller communication ports 16 9400002-J0 Rev C 3.2.4 Analog Inputs Temperature inputs Two temperature input channels, T1 and T2, can be used to monitor battery or room/ambient temperature. Voltage is supplied to these terminals to power the temperature sensors. Voltage inputs Two voltage input channels, V1 and V2, are used to monitor the system voltage. The controller software is preconfigured to monitor V1 for load voltage A and V2 for load voltage B. Current inputs The controller software is pre-configured to monitor I1 for load current A and I2 for load current B. It is wired internally to the system current shunt. 3.2.5 Digital Input Channels Eight digital input channels (terminals 21 through 36) are available to monitor various alarm and control signals. Some of these channels are pre-assigned to monitor specific signals. Refer to the software manual and drawing #0380033-05 at the end of this manual. All input channels are voltage activated and accept a bipolar (i.e. negative or positive) DC signal directly. Typical Alpha systems use the “reset with Hot and trigger with Ground” connection. The digital input is wired in such a way that the Hot is wired directly into one of the input terminals; e.g., positive input for +24V or negative input for –48V systems. The other input terminal is wired to the Ground (common) of the system through a relay (dry contact – usually located on the equipment requiring monitoring). This method (see Figure 11) allows the digital input to receive (or not receive) a Ground signal on an alarm. The digital input channels can then be programmed for “active high” or “active low.” Active high indicates “alarm on the presence of a ground signal” and active low indicates “alarm on the removal of a ground signal.” Voltage level definitions for digital inputs Voltage Range (Vdc) Voltage Level (Vdc) Considered As “0” (Off) Voltage Level (Vdc) Considered As “1” (On) 0—60 (system voltage setting) 0—3 18—60 Figure 11 — Connection method for digital inputs (shown for +24V input) CAUTION! to reduce risk of fire, use only #26 AWG (0.14mm²) or larger wire. 9400002-J0 Rev C 17 3.2.6 Alarm and Control Output Relays Terminals 37 to 60 provide 8 Form C contacts (NO, COM and NC) for extending various alarm or control signals. Each relay output can be wired for NO and/or NC operation during an alarm or control condition (Figure 13). Relays can be programmed to energize or de-energize during an alarm condition (see Software manual). When the CXC reset button is pressed or power is lost, all relays de-energize. Relay contacts 1-8 are high capacity and can be used for controlling LVD contactors. Figure 13 — Relay connections in the de-energized state Fail-safe relay Terminals 61 to 63 provide connections for a system (supervisory) fail relay. This fail-safe relay (i.e. it is de-energized during an alarm condition) can be wired for NO or NC operation 3.2.7 Safety Features Insulating shield Each BDFB has an insulating shield in front of the bus bars. This shield prevents casual touching of the bus bars with cable lugs and tools while working inside the BDFB. It also maintains separation between the cables and the bus bars. Insulation shield Figure 12 — BDFB installation shield 18 9400002-J0 Rev C Circuit Breaker Guard The pivoting circuit breaker guard, with a circuit designation strip, prevents accidental tripping of a breaker. Circuit breaker guard Figure 14 — Circuit breaker guard 9400002-J0 Rev C 19 4. Pre-Installation Preparation 4.1 Site Selection NOTE: This BDFB is suitable for installation in Network Telecommunication facilities and locations where the CEC/NEC applies. See specifications in Section 2.3 on page 9 for dimensions and environmental conditions. • Avoid areas that may be subjected to hot air exhaust from nearby equipment. • Provide adequate space for safe access for installation and maintenance personnel. (Post installation, only front access is required for maintenance.) xx Rear: 3ft (1m) xx Front: 3ft (1m) xx Top and bottom: clearance required for load cable entry 4.1.1 Floor Plan Layout Sufficient free space must be provided at the front of the BDFB to allow easy access to the controller and load connections. Consider the following before selecting a location for the CXDS-M 1200 BDFB. • Structure of building able to support the additional weight • Enough space to meet requirements for access • Adequate space to do the install • Check and record distances to the load; minimize input cable length where possible • Understand the full load on the DC system • Window for working hours and other similar restrictions • How much and what kind of prep work can be done in advance xx Reinforce floors xx Install cable racks xx Run wiring xx Minimize cable lengths (cost) xx Minimize cable flow and congestion 4.1.2 Installation Component Requirements Supplied • Internal DC cables Not Supplied 20 • Rack mounting hardware • External DC conduit, cable and fittings 9400002-J0 Rev C 4.2 Tools and Test Equipment Insulated tools are essential for a DC power system installation. Use the following list as a guide: • Slot head screwdrivers (blade sizes: 1/4", 1/8", 1/16") • Phillips head screwdriver, #2 (tip size 3/16") • Digital voltmeter equipped with test leads • Adjustable 24/48Vdc load (optional) • Anti-static wrist strap • Computer (laptop) with Microsoft® Internet Explorer 7 or greater • Crossover cable RJ-45 (to connect a laptop to the Ethernet port) • Null modem cable (for access using the RS-232 port) • Cutters and wire strippers (#14 to #22 AWG) [2.5 – 34 mm2] 4.3 Unpacking the Equipment Packaging assemblies and methods are tested to International Safe Transit Association standards. Check For Damage Prior to unpacking the BDFB, perform a visual inspection and note any damage. Unpack the equipment and inspect the exterior for damage. If any damage is observed contact the carrier immediately. Continue the inspection for any internal damage. In the unlikely event of internal damage, please inform the carrier and contact Alpha Technologies for advice on the consequence of any damage. General Receipt of Shipment Consult the packing slip and power plant bill of materials to verify that you have the correct number of BDFBs per your order. The inventory included with your shipment is dependant upon the options you have ordered. The options are clearly marked on the labels on the shipping containers. Miscellaneous Small Parts Review the packing slip and bill of material to determine the part numbers of the “configuration kits” included with your BDFB. Review the bill of materials for each configuration kits to verify all the small parts are included. Verify that you have all the necessary parts per your order for proper assembly. Call Alpha Technologies if you have any questions before you proceed: 1-888-462-7487 9400002-J0 Rev C 21 5. Installation The CXDS-M must be mounted in a clean and dry environment. Provide sufficient free space at the front and rear of the distribution system to allow easy access to the system components. 5.1 Rack Mounting The CXDS-M is designed for a standard flush or center mount in a 19" or 23" rack. A 19" system includes adapters to mount the module in a 23" relay rack 1. Mechanically secure the rack to the floor or other suitable structure. 2. Mount the BDFB(s) to the rack using four #12 – 24 x 1/2" screws in each bracket. 3. Use Phillips-type screws and screwdriver to prevent slippage and scratching of the unit’s exterior. 4. Washers (such as internal tooth) or special screws that are designed to cut through the painted surface should be used to ensure a good chassis ground. Mounting brackets can be moved for flush or center mounting. Figure 16 — Center mount brackets 5.2 External Cable Tie Bar Option Before beginning the installation, an external tie bar can be installed to provide additional cable support. The tie bar can be located at the top of the module, as shown in Figure 17, or below the module for cables exiting through the bottom. Two locations for mounting above the module Two locations for mounting below the module Figure 17 — Locations for optional cable tie bar 22 9400002-J0 Rev C 6. Installation - DC and Grounding Cables This section provides cabling details and notes on cable sizing for DC applications with respect to the Alpha CXDS-M -48/24 V modular distribution. • Only qualified personnel should install and connect the power components within the Alpha power system. • All wiring must be in accordance with applicable electrical codes. • Electrical codes require that conductors carrying AC current be installed separately from conductors carrying DC current and signals. 6.1 Installation Notes 6.1.1 Installer Responsibility The system arrives pre-wired, and the installer is responsible for connecting the following: • DC input to the system • System to the load • Chassis ground • Alarms 6.1.2 Calculating Output Wire Size Requirements Although DC power wiring and cabling in telecommunication applications tend to exceed electrical code requirements, mostly due to the voltage drop requirements, all applicable electrical code(s) take precedence over the guidelines and procedures in the present chapter, wherever applicable. Wire size is calculated by first determining the appropriate maximum voltage drop requirement. Use the formula below to calculate the circular mil area (CMA) wire size requirement. Determine the size and number of conductors required to satisfy the CMA requirement. CMA = (A x LF x K) / AVD A = Ultimate drain in amps LF = Conductor loop feet K = 11.1 constant factor for commercial (TW type) copper wire AVD = Allowable voltage drop Check again that the ampacity rating of the cable meets the requirement for the installation application. Consult local electrical codes (NEC, CEC, etc.) for guidelines. If required, increase the size of the cable to meet the code. Refer to Table D for cable size equivalents. Table D — Cable size equivalents (AWG to Metric) Cable size (see notes 1 and 2) Circular mils Square millimeters Equivalent metric cable 20 AWG 1020 0.519 1 18 AWG 1624 0.8232 1 16 AWG 2583 1.309 1.5 14 AWG 4107 2.081 2.5 12 AWG 6530 3.309 4 10 AWG 10380 5.261 6 8 AWG 16510 8.368 10 9400002-J0 Rev C 23 Table D — Cable size equivalents (AWG to Metric) Cable size (see notes 1 and 2) Circular mils Square millimeters Equivalent metric cable 6 AWG 26250 13.30 16 4 AWG 41740 21.15 25 2 AWG 66370 33.63 35 0 AWG (or 1/0) 105600 53.48 50 or 70 00 AWG (or 2/0) 133100 67.42 70 0000 AWG (or 4/0) 211600 107.2 120 313 MCM (or kcmil) 313600 159 150 or 185 350 MCM (or kcmil) 350000 177.36 185 373 MCM (or kcmil) 373700 189 185 or 240 500 MCM (or kcmil) 500000 253.36 300 535 MCM (or kcmil) 535300 271 300 750 MCM (or kcmil) 750000 380.00 400 777 MCM (or kcmil) 777700 394 400 6.1.3 Recommended Torque Values Recommended torque values for connection to the power system: xx Clear hole connections (nut and bolt) xx PEM studs xx PEM threaded inserts xx Thread formed connections (in copper bus bar) Table E — Recommended torque values 1/4" 8.8 ft-lbs (105 in-lb) 3/8" 32.5 ft-lbs (390 in-lb) 1/2" 73 ft-lbs (880 in-lb) SAE Grade 5 hardware is required for these torque values. 6.1.4 Cabling Layout The cabling at the time of installation is very straightforward. xx The DC input cables connect to the bus bars at the top of BDFB at the rear. xx The load cables from the BDFB fuse/breaker can exit the unit through the top or bottom. Open the front door of the BDFB to access fuse/breaker connections. xx All signaling wires (for example, alarms from the CXC Controller) interfacing with the outside world exit the BDFB through the top or bottom. 6.1.5 Alarms All applicable alarms should be connected to the local alarm-sending unit from the power system. The CXC system controller provides form “C” relay contacts for interconnection. See section 3.2.6 on page 18. 24 9400002-J0 Rev C 6.2 Connecting the Frame and Reference Grounds CAUTION! The grounding methods described in this section are generic. Follow local requirements and electrical code. NOTE: This power system is suitable for installation as part of a Common Bonding Network (CBN) and is intended to be used in a DC-C configuration (common DC return) A true single point ground system means that everything is referenced to a single point that is tied to the external earth ground system. In reality each component and external source is effectively bonded to a single point, which is then effectively bonded to the facility or site external ground system. 6.2.1 Frame Grounding Securely ground the rack, containing the BDFB(s), to the building grounding system. 6.2.2 Battery Return Reference The return reference is obtained from the DC source. -48V Power Plant Source CXDS-M Return Master Ground Bus (MGB) Figure 18 — Battery return reference 9400002-J0 Rev C 25 6.3 DC Input • Dual feed, split return, 600A max • Dual feed, common return, 1200A max 6.3.1 DC Cables from the DC Plant Source Input cables should be sized for a 0.25 V drop from power system to the CXDS-M at full load including anticipated growth. The cables should also meet ampacity requirements of the protective device. DC Plant Cables Connect the DC plant return cables to the return bus bars (shown in Figure 19). The return bus bars are designed for a connection of 3/8" holes on 1" centers. Live DC Plant Cables Connect directly to the live bus bar. Protect input feeds with a high capacity fuse or circuit breaker. Maximum allowable is an 800A fuse with maximum anticipated load of 600A. Returns Live secondary Live primary Figure 19 — DC input bus bars 26 9400002-J0 Rev C 6.4 Connecting DC Load Cables to Breaker/Fuse Circuitry Refer to guidelines supplied with the load equipment. Distribution cables are typically sized to provide a 0.5 V loop drop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker. 6.4.1 Before You Begin: 1. Cut cables to length and terminate with a two-hole lug: xx 3-pole AM breaker—3/8" diameter on 1" center xx 1-pole, 2-pole AM breaker or TLS/TPS fuse holder— 1/4" diameter on 5/8" center 2. Identify each cable with a label that indicates its location within the BDFB. 3. Remove the top Kydex cover. 6.4.2 Load Cables to Breakers 1. Route the load cables through the top or bottom of the BDFB. 2. Remove the protective live terminal cover. 3. If using 2-pole or 3-pole breakers, remove the Insulating materials between adjacent breaker connections (Figure 20). 4. Connect the cables to the BDFB as shown in Figure 21. 5. Use the internal cable tie bars for strain relief. 6. Neatly group cables with tie wraps or lacing as shown in Figure 22 and Figure 23. Insulating material Figure 20 — Preparation for 2-pole and 3-pole breakers Load (-) Load (+) Figure 21 — Load cable connection to BDFB 9400002-J0 Rev C 27 Figure 22 — Load cables exiting the bottom Figure 23 — Final load cable arrrangement (4 module BDFB shown) 28 9400002-J0 Rev C 6.4.3 Installing Breakers 1. Unscrew and pivot breaker guard out of the way. Circuit breaker guard 2. Turn breakers off and orient as shown in Figure 24 for the left hand bank or Figure 25 for a right hand bank. Align the breaker terminals with the correct holes and carefully push the breaker into position. Figure 24 — Left hand bank Figure 25 — Right hand bank 3. When all breakers are installed, pivot the breaker guard back into position and secure with screws. 9400002-J0 Rev C 29 6.5 External Alarm Wiring See section 3.2.6 for description of available alarm relays on the control card. Route the signal cable as shown in Figure 26 ,exiting through the knockout in the top BDFB. Refer to the controller software manual to set up the alarms. Figure 26 — Route of external signal wiring 30 9400002-J0 Rev C 6.6 Top Cover(s) Cut between the holes with side cutters to make a large enough entryway for the required cables. Figure 27 shows a small hole cut in the cover. Make a straight cut to the back edge of the cover, so the cover can be fitted around the cables when replacing it at the end of the installation. Figure 27 — Top Kydex cover with cuts for cable entry Reinstall the top cover. WARNING! To prevent electrical hazards such as short circuits, ensure that the system is free of debris such as metal filings, screws, etc., after the installation is complete. 9400002-J0 Rev C 31 7. System Startup Visually inspect the installation thoroughly. After completing the system installation and power system wiring, perform the following startup and test procedure to ensure proper operation: CAUTION! Make sure that the input source is disconnected or fuses are removed. 1. Use a voltmeter to verify that the input polarity is correct. 2. Connect the input (or insert the input fuses/breakers) to the output of the system. 3. Verify startup of the Cordex controller. 4. At the CXC controller LCD verify/ set the following network IP parameters and logout. xx IP address: 10.10.10.201 (factory default) xx Subnet mask:255.255.255.0 5. Connect a laptop to the CXC controller with a network crossover cable. 6. Laptop IP Network settings (Start > Control Panel) xx IP address: 10.10.10.202 xx Subnet mask:255.255.255.0 7. Enter 10.10.10.201 in the laptop web address bar and log-in to the controller: xx Username: your company name and your initials xx Password: 1234 8. Configure other system parameters as required—changing the high current alarms, for example. 9. At this point there should be no alarms present. Investigate and correct any alarm issues. 10. Test the functionality of various alarms and controls as follows: Alarm Minor alarm Major alarm Supervisory Fail Test Refer to the Alarms>Configure Alarms menu and replicate a condition that causes each of these alarms. At the controller, tap the Home icon at the lower left of the “home” page and select Reset from the pop-up menu. NOTE: A Load Current High alarm will be triggered if the BDFB amperage capacity is exceeded. 32 9400002-J0 Rev C 8. Test and Commissioning Overview 8.1 System All Alpha power system components undergo thorough factory testing. All levels/alarms are set to predetermined values as detailed in their individual component manuals except where custom levels are specified. Good installation practice is to check the operation of all features and alarms and to set the power system levels in accordance with the specific requirements of your system. The individual system component manuals detail the methodology for testing and calibration of all components. 8.2 Documentation Complete all necessary documentation; i.e., battery reports, DC wiring lists, AC distribution tables, floor plans, etc. Tag wires, fill out identification strips, and identify circuit breakers. 9400002-J0 Rev C 33 9. Adding an Expansion module This section describes the installation of an additional module to an existing rack-mounted BDFB system. The installation kit that ships with the expansion module includes the following parts: xx Copper bus bars connectors xx Filler plates xx Miscellaneous hardware Preparation STEP 1 • Remove the cable tie bar and insulation shield in the add-on module. • Set aside for later re-installation in Step 5. Remove internal cable tie bar Remove insulation shield Figure 28 — Cable tie bar and insulation shield STEP 2 • Remove the bottom covers from the bottom module in the rack. • Reinstall them on the bottom of the add-on module. Figure 29 — BDFB bottom covers 34 9400002-J0 Rev C Installing the Bus Bar Connectors, Filler Plates and Covers STEP 3 • Use bolts in the BOTTOM row of the bus bar connectors (Figure 30) to attach them to the add-on module. • Fasten the bolts FINGER TIGHT to allow for later alignment of the bus bars. Filler Plates Fasten bus bar connectors in the bottom row finger tight. Figure 30 — Alignment of filler plates and bus bar connectors STEP 4 • Install the add-on module in the rack below the existing BDFB. • Place the filler plates as shown in Figure 30. • Adjust the position of the add-on module until the filler plates align with both upper and lower modules and the bus bars also align. • Join modules through the filler plates with the supplied hardware. 9400002-J0 Rev C Required torque values 1/4" 8.8 ft-lbs 3/8" 32.5 ft-lbs 1/2" 73 ft-lbs 35 STEP 5 • Re-install the cable tie bar and insulation shield in the add-on module (see Figure 28). • Install the back cover (Figure 31) on the add-on module (cover ships loose in the kit). Figure 31 — BDFB back cover installation Signal Wiring STEP 6 • Open the front door of the add-on module and locate the inter-module signal cable. • Open the front door of the module with the controller and remove the inner cover. • Connect the inter-module cable to the terminal block of the I/O and Alarm Interface board (Figure 32). • Replace the inner cover. Relays Analog/ Digital Inputs I/O and Alarm Interface board Cordex Controller board LCD Display board Figure 32 — I/O and Alarm Interface board 36 9400002-J0 Rev C Joining the Doors Together STEP 7 • Align the two doors and join with the hardware provided in the kit (2 places). See Figure 33 for location of the two screws. Upper unit door, left Upper unit door, right Lower unit door, left Lower unit door, right Figure 33 — Joining the two doors 9400002-J0 Rev C 37 10. Maintenance Although very little maintenance is required with Alpha systems, routine checks and adjustments are recommended to ensure optimum system performance. Qualified service personnel should do the repairs. The following table lists a few maintenance procedures for this system. These procedures should be performed at least once a year. WARNING! Use extreme care when working inside the unit while the system is energized. Do not make contact with live components or parts. Circuit cards, including RAM chips, can be damaged by static electricity. Always wear a grounded wrist strap when handling or installing circuit cards. Ensure redundant BDFBs are used to eliminate the threat of service interruptions while performing maintenance on the system alarms and control settings. Table F — Sample maintenance log Procedure Date Completed Clean ventilation openings. Inspect all system connections. Re-torque if necessary. Verify alarm/control settings. Verify alarm relay operation. 10.1 Controller Lithium Battery Replacement NOTE: Replace the battery within 30 seconds to prevent loss of date and time. A removable lithium battery is located near the back and to the right of the motherboard. The battery life is rated up to three years, but replace earlier if the panel does not maintain date and time during power interruption. WARNING! Exercise extreme caution and do not touch any connected equipment. To replace the lithium battery, shut down the CXC, remove the rear cover, and pull battery out carefully. Ensure that the new battery is the same as the one being replaced. 38 9400002-J0 Rev C 10.2 Spare Parts Description Part # Alarm interface board 7050132-001 Slam latch 6470008 Controller 018-587-20 Shunt Mux board 707-404-20 10.2.2 Replacing the latch 1. Loosen and remove the hex nut on the inside of the door. 2. Slide the latch out the front side of the door. 10.2.3 Replacing Control Boards Shunt Mux Board Typically, the shunt mux panel is mounted on the inside door of the top distribution module. 1. Remove the cover on the inside of the door. Shunt mux. 2. Disconnect the CAN BUS IN and CAN BUS OUT cables. Alarm Interface board 3. Label and disconnect the shunt input cables. 4. Disconnect the power input cable. 5. Remove the 4 screws holding the board to the door. 6. Reverse steps 1 through 4 to install the new board. Alarm Interface Boards Call technical service @ 1-888-462-7487 for assistance with the replacement of this board. Controller Call technical service @ 1-888-462-7487 for assistance. Controller Figure 34 — Shunt mux and control boards 9400002-J0 Rev C 39 11. Acronyms and Definitions AC ANSI AWG BDFB BDCBB BRB BTU CAN CEC CSA CX DC EIA EMC EMI ERM ESD FCC HVSD IEC IEEE IP LED LVLD LVBD MIL MOV MTBF NC NEC NO OSHA OVP RAM RU TCP/IP THD UL VRLA 40 Alternating current American National Standards Institute American Wire Gauge Battery Distribution Fuse Board Battery Distribution Circuit Breaker Board Battery return bus British thermal unit Controller area network Canadian Electrical Code Canadian Standards Association Cordex™ series; e.g., CXC for Cordex System Controller Direct current Electronic Industries Alliance Electromagnetic compatibility Electromagnetic interference Electromagnetic Compatibility and Radio Spectrum Matters Electrostatic Discharge Federal Communications Commission (for the USA) High voltage shutdown International Electrotechnical Commission Institute of Electrical and Electronics Engineers Internet Protocol Light emitting diode Low voltage load disconnect Low Voltage Battery Disconnect One thousandth of an inch; used in expressing wire cross sectional area Metal oxide varistor Mean time between failures Normally closed National Electrical Code (for the USA) Normally open Occupational Safety & Health Administration Over voltage protection Random access memory Rack unit (1.75”) Transmission Control Protocol / Internet Protocol Total harmonic distortion Underwriters Laboratories Valve regulated lead acid 9400002-J0 Rev C 12. 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. 12.1 Battery Warranty Note that battery warranty terms and conditions vary by battery and by intended use. The most common battery warranty provided by Alpha is a two year full replacement warranty with a pro-rated warranty for the following three years. Pro rated warranty provides a credit applicable toward the purchase of new batteries from Alpha. The credit is calculated as the purchase price multiplied by the percentage of the battery life that was not available (in months). Battery warranty coverage is lost where the battery charge is not maintained for 6 months. Contact your Alpha sales representative or the Technical Support team at the above number to understand your entitlements under Battery Warranty. 9400002-J0 Rev C 41 13. Ordering Options and Accessories 13.1 CXDS-M 1200/1200-23" Systems (0906xxx-001) Table G — CXDS-M 1200/1200-23" Systems Options List -48V +24V CB Left CB Right CXC 005 x x x x x 006 x x x x 007 x x x x 008 x x x x 009 x x x 010 x x x 011 x x x 012 x x x 013 x x x 014 x x x 015 x x x 016 x x x 029 x x x x 030 x x x x 031 x x x x 032 x x x x 033 x x x 034 x x x 035 x x x 036 x x x 037 x x x 038 x x x 039 x x x 040 x x x 098 x x x x 100 x x x x x AM return LVLD CB sytems > 4 shunts Ganged Tiers x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 13.2 CXDS-M 1200/1200-19" Systems (0907xxx-001) See options 005 through 012, 033, 034, 035, 036, 098 and 100 (14 configurations) in Table G. 13.3 CXDS-M 600/600-23" Systems (0908xxx-001) See options 005 through 016, 033, 034, 035, 036, 037, 038, 039, 040, 098 and 100 (14 configurations) in Table G. 13.4 CXDS-M 600/600-19" Systems (0908xxx-001) See options 005 through 012, 033, 034, 035, 036, 098 and 100 (14 configurations) in Table G. 42 9400002-J0 Rev C 13.5 Accessories Part Number Description 0380061-001 External Cable Tie Bar, 23" 0380061-101 External Cable Tie Bar, 19" 0370110-001 Breaker kit, 2-Pole, 110A, 80VDC, Bullet, Mid-trip 0370111-001 Breaker kit, 2-Pole, 125A, 80VDC, Bullet, Mid-trip 0370112-001 Breaker kit, 2-Pole, 150A, 80VDC, Bullet, Mid-trip 0370113-001 Breaker kit, 3-Pole, 175A, 80VDC, Bullet, Mid-trip 0370114-001 Breaker kit, 3-Pole, 200A, 80VDC, Bullet, Mid-trip 0370115-001 Breaker kit, 3-Pole, 225A, 80VDC, Bullet, Mid-trip 0370116-001 Breaker kit, 3-Pole, 250A, 80VDC, Bullet, Mid-trip 9400002-J0 Rev C 43 REVISIONS BUS BAR CONFIGURATION VARIES PER PART NUMBER FAMILY LTR DESCRIPTION DWN DATE CHK A INITIAL RELEASE KLAU Feb-15-13 JK 4.84 122.9 8.53 216.7 17.54 445.5 6.00 152.4 0.80 20.3 9.75 247.7 15.38 390.6 2.25 57.2 10.47 265.9 2.25 57.2 3.00 76.2 22.33 567.1 21.27 540.3 23.00 584.2 CORDEX DISTRIBUTION MODULE TYPICAL CONFIGURATION SHOWN WITH TOP COVER AND LATCH INSTALLED MAIN BUS BAR CONFIGURATIONS (SEE SHEET 3 & 4) OF MAIN APPLICABLE PART NUMBER #BUS BAR 0200039-XXX 2 BUS BAR SIZE RATED CURRENT (A) APPLICATION APPLICABLE POWER SYSTEM 1/4" X 5" X 2 LAYER 2500 SINGLE VOLTAGE (HOT + GROUND) 0901XXX-XXX 1200 SINGLE VOLTAGE (HOT + GROUND) 0903XXX-XXX 1200/600 DUAL VOLTAGE (PRIMARY 1200A + GROUND + SECONDARY 600A) 0904XXX-XXX UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES 0.040 X.X 0.020 X.XX X.XXX 0.010 ANGULAR: 1 600/600 SINGLE VOLTAGE A-B FEED WITH COMMON GROUND 0906XXX-XXX INTERPRET DIM AND TOL PER ASME Y14.5 -1994 600/600 SINGLE VOLTAGE A-B FEED WITH SPLIT GROUND 0908XXX-XXX 0200040-XXX 0200041-XXX 0200042-XXX 0200044-XXX 0200046-XXX RESERVED 2 3 1/4" X 4" X 1 LAYER 1/4" X 4" X 1 LAYER 3 1/4" X 4" X 1 LAYER 4 1/4" X 4" X 1 LAYER (HOT) 1/4" X 2" X 1 LAYER (GROUND) THIRD ANGLE PROJECTION THESE DESIGNS AND SPECIFICATIONS ARE CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE COPIED OR USED WITHOUT ITS WRITTEN CONSENT APPROVALS DRAWN CHECKED DATE K.LAU OCT-05-11 JK OCT-05-11 TITLE: OUTLINE, 23" CORDEX DISTRIBUTION MODULE SIZE DWG NO. B © ALPHA TECHNOLOGIES LTD SCALE: REV 0200038-06 A 1 OF 4 1:6 SHEET 17.54 445.5 6.00 152.4 1.55 39.4 2.25 57.2 10.47 3.00 265.9 76.2 2.25 57.2 21.27 540.3 22.33 567.1 23.00 584.2 CORDEX DISTRIBUTION MODULE WITH CXC CONTROLLER TYPICAL CONFIGURATION SHOWN WITH TOP COVER AND LATCH INSTALLED UNLESS OTHERWISE SPECIFIED DIM ARE IN INCHES 0.040 X.X 0.020 X.XX X.XXX 0.010 ANGULAR: 1 INTERPRET DIM AND TOL PER ASME Y14.5 -1994 THIRD ANGLE PROJECTION THESE DESIGNS AND SPECIFICATIONS ARE CONFIDENTIAL, REMAIN THE PROPERTY OF ALPHA TECHNOLOGIES LTD., AND SHALL NOT BE COPIED OR USED WITHOUT ITS WRITTEN CONSENT APPROVALS DRAWN CHECKED DATE K.LAU OCT-05-11 JK OCT-05-11 TITLE: OUTLINE, 23" CORDEX DISTRIBUTION MODULE SIZE DWG NO. B © ALPHA TECHNOLOGIES LTD SCALE: REV 0200038-06 A 2 OF 4 1:6 SHEET 0200039-XXX 0200040-XXX TITLE: OUTLINE, 23" CORDEX DISTRIBUTION MODULE SIZE DWG NO. B SCALE: REV 0200038-06 A 3 OF 4 1:6 SHEET 0200042-XXX OR 0200044-XXX TITLE: 0200046-XXX OUTLINE, 23" CORDEX DISTRIBUTION MODULE SIZE DWG NO. B SCALE: REV 0200038-06 A 4 OF 4 1:6 SHEET 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. 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