alpha cxps 48 1.8 i, 48v pos gnd

8/9/2019 Alpha Cxps 48 1.8 i, 48v Pos Gnd

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Power System ManualCXPS 48-1.8-i, 48V Pos Gnd

053-990-B0


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Arg us Technologi es L td. Visit www.argus.ca

Burnaby, British Columbia. Telephone: 604 436 5900 Fax: 604 436 1233Argus Technologies reserves the right to make changes to the products and information contained in this document without notice.Copyright 2008 Argus Technologies Ltd. Argus

is a registered trademark of Argus Technologies Ltd. All Rights Reserved.

Printed in Canada.

This page intentionally left blank.


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Power System Manual

CXPS 48-1.8-i, 48V Pos Gnd Power System

053-990-B0

Drawing List:

The following drawings are included in this manual to provide the necessary

information required for routine operation and fault diagnosis of the system.

System Specifications 053-990-B1

CXCI Specifications 707-492-B1

Safety and Installation Instructions

053-990-C0 Outline Drawing 053-990-06

Schematic, Power System 053-990-05

Customer Connections 053-990-08

Warranty and Service 048-700-10

Service Centers 048-693-10

Manuals to be included with this package are as follows:

Cordex Controller Software (Current Version) CXC SOFT

Copyright 2008-06-26Argus Technologies Ltd 053-990-B0 Rev B

Printed in Canada. Argus is a registered Trademark. All rights reserved.


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Specifications for Argus CXPS 48-1.8-i 48Vdc Power System

Argus Technologies Lt d. 053-990-B1 Rev A WCPrinted in Canada. 2008 Argus Technologies Ltd. ARGUS and CORDEX are trademarks of Argus Technologies Ltd. All Rights Reserved. Page 1 of

Output

Voltage: 42 to 58Vdc within rated limits

Current: System: 150A maximum @ nominal input~96A @ 115Vac input

Rectifier Module: 37.5A maximum @ 48Vdc (nominal input)~24A @ 48Vdc (115Vac input)

Power: System: 7200W maximum @ nominal input~4600W @ 115Vac input

Rectifier Module: 1800W maximum @ nominal input~1150W @ 115Vac input (de-rated linearly to 900W @ 90Vac)

Heat Dissipation (per rectifier):


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Specifications for Argus Technologies CXPS 48-1.8-i 48Vdc Power System Continued


Connections

Load Connections: AM breakers (1-pole): 1/4 holes on 5/8 centersAM breakers (multiple pole): 3/8 holes on 1 centers (with adapter)

Battery Terminations: AM breakers (1-pole): 1/4 holes on 5/8 centers

AM breakers (multiple pole): 3/8 holes on 1 centers (with adapter)

Alarm/Signal Connections: 0.081mm2to 0.55mm

2(#28 to #20 AWG)

AC Input: Terminal blocks 2.5mm2to 6mm

2(#14 to #10 AWG),

individual feeds for four modules

Cable Access: Front and top

Environmental

Operating Temperature: -40 to +65C, power derated to 75C (167F)(-40 to 149F)

Storage Temperature: -40 to +85C(-40 to 185F)

Humidity: 0 to 95% non-condensing

Elevation: -500m to 2800m; to 4000m with temperature derated to 40C(-1640 feet to 9186 feet; to 13124 feet with temperature derated to 104F)

Miscellaneous

Number of Rectifiers: Up to four (4) Cordex 48-1.8kW modules;Argus #010-602-20 (pre-RoHS #010-580-20)

Distribution Capacity:

Load: 14x 1-pole positions, plug-in type (bullet terminals), AM-style, 5 to 250A

Battery: 4x 1-pole positions, plug-in type (bullet terminals), AM-style, 5 to 250A

Dimensions: 438mm W x 222mm H x 310mm D(17.24 W x 8.75 H x 12.2 D)[-000 configuration excludes mounting brackets, rear cover, and modulehandles. For additional options see outline drawings at the rear of this manual.]

MTBF (rectifier module): >400,000 hours ground benign @ 30C (86F)


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Specifications for Argus Technologies CXPS 48-1.8-i 48Vdc Power System Continued


Safety

NOTE: Safety certifications performed at rectifier level only.

EN 60950: Rectifier output shall be rated SELV suitable for connection to TNV-1 circuits

UL: 60950

CSA: C22.2 No. 60950

CE: EN 60950, CB Scheme73/23/EEC Low Voltage Directive with amendment 93/68/EEC

Telcordia (Bellcore): GR-1089-CORE (requirements applicable to rectifier)

Other Referenced Standards

EN 300 386-2: EMC and ERM; Telecommunication Network Equipment

EN 55022 (CISPR 22): Information Technology Equipment Radio Disturbance Characteristics Limitsand Methods of Measurement

EN 61000-3-2: Harmonic Current Emissions

EN 61000-3-3: Voltage Fluctuations and Flicker

EN 61000-4-2: ESD Immunity

EN 61000-4-3: Radiated Electromagnetic Immunity

EN 61000-4-4: Electrical Fast Transient/Burst Immunity

EN 61000-4-5: Power Line Surge Immunity

EN 61000-4-6: Conducted Electromagnetic Immunity

EN 61000-4-11: Voltage Dips, Short Interruptions and Variations

ETS 300 019-1-1: Environmental Conditions; Storage

ETS 300 019-1-2: Environmental Conditions; Transportation

ETS 300 132-2: Power Supply Interface at the Input to Telecommunications Equipment;Operated by Direct Current (DC)

ETS 300 753: Acoustic Noise Emissions

IEC 60950: Safety of Information Technology Equipment, Including Electrical BusinessEquipment (UL/CSA 60950)

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


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Specifications for Argus CXCI Cordex Controller Integrated Model

Argus Technologies Lt d. 707-492-B1 Rev B WCPrinted in Canada. 2007 Argus Technologies Ltd. ARGUS and CORDEX are trademarks of Argus Technologies Ltd. All Rights Reserved. Page 1 of 2

Basic Unit, CXCI

Input Voltage: 17 to 65Vdc within rated limits[9 to 65Vdc for shelf systems with 12V rectifiers (List 3)]

Current:


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Specifications for Argus CXCI Cordex Controller Integrated Model Continued

Argus Technologies Lt d. 707-492-B1 Rev B WCPrinted in Canada. 2007 Argus Technologies Ltd. ARGUS and CORDEX are trademarks of Argus Technologies Ltd. All Rights Reserved. Page 2 of 2

Hardware Specif ications, CXCI

CPU: Coldfire

RAM: 8MB

Flash: 4MB standard

Display: 4 digit LCD

Front Panel Controls: Display pushbutton toggle switch for voltage (V) or current (A)CXCI reset switch (soft reset button; hold for 3 seconds to reset IP)

LEDs: System OK (Green)Power System Minor Alarm (Yellow)Power System Major Alarm / Controller Fail (Red)

Audio: Built-in speaker for alarm and popup message tones

Dimensions: 88mm H x 26mm W x 280mm D

(3.5 H x 1 W x 11 D)

Weight: 0.34 kg (0.75 lb.)

Mounting: Integrated on Cordex 2RU series 19 and 23 shelves

Relay Outputs: Four (4) Form C, 60Vdc 1A maximum

Digital Inputs: Two (2), 0 to 60Vdc

Analog Inputs: One (1) DC voltage, 0 to 60VdcOne (1) DC current, 50mVTwo (2) temperature, 0 to 20Vdc with power source

Communication Ports: Ethernet RJ-45, Argus Modem DB-9, CAN [see shelf specifications]

Recommended Signal Wire Sizes (as per UL/CSA)

Wire Size Range: 0.14 to 1.50mm2

(#26 to #16 AWG)

Temperature Range: 0 to 50C(32 to 122F)

CAUTION TO REDUCE RISK OF FIRE, USE ONLY 0.14mm2(#26 AWG) OR LARGER WIRE.

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


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IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This section contains important instructions that should be followed during the installation and maintenance ofequipment and batteries. Please read all of the instruc tions before operating the equipment, and save thismanual for future reference.

A licensed electrician MUST perform connections to the branch circuit of service feed. Installation of the powersupply and batteries must be performed by, or under the direct supervision of service personnel knowledgeable ofthe required electrical and battery safety precautions.

If instructions in this manual conflict with local electrical codes, those instructions shall be superseded by the localcode.

The following safety symbols will be found throughout this manual, carefully read all information and abide by theinstructions:

DANGEROUS VOLTAGEThis symbol indicates a dangerous vol tage

exists in thi s area of the product.

GAS HAZARDThis symbol indicates a gas hazard

exists i n the area of vented batteries.

NO MATCHES OR OPEN FLAMESThis symbol indicates a fire or explosive hazard

exists in the area of the product.

The following levels of warning will be used with the above symbols:

DANGER: You WILL be KILLED or SERIOUSLY INJURED if instructions are not followed closely.

WARNING: You CAN be KILLED or SERIOUSLY INJURED if instructions are not followed closely.

CAUTION: You CAN be INJURED or equipment can be DAMAGED if instructions are not followed closely.

Mechanical Safety

Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically.

Power supplies can reach extreme temperatures under load.

Use caution around sheet metal components and sharp edges.


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Electrical Safety

WARNINGHazardous voltages are present at the input of a power system. The DC output from rectifiers andbatteries, though not dangerous in voltage, has a high short-circuit current capacity that maycause severe burns and electrical arcing.

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

Remove all metallic jewelry; e.g., watches, rings, metal rimmed glasses, necklaces.

Wear safety glasses with side shields (and prescription lenses if necessary) at all times during installation.

Use OSHA approved insulated hand tools.

Lethal voltages are present within a power system. Never assume that an electrical connection or conductor is noenergized. Check the circuit with a voltmeter with respect to the grounded portion of the enclosure (both AC andDC) prior to any installation or removal procedure.

Do not work alone under hazardous conditions.

A l icensed elect rician is requ ired to instal l permanently wired equipment. Input voltages can rangeup to 240Vac. Ensure that util ity power is disabled before beginning installation or removal.

Ensure no liquids or wet clothes contact internal components.

Hazardous electrically live parts inside this unit are energized from batteries even when the AC input power isdisconnected.

Battery Safety

Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnelknowledgeable of batteries and the required safety precautions.

Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove allmetallic objects from hands and neck.

Use OSHA approved insulated hand tools. Do not rest tools on top of batteries.

Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or otherreproductive harm. Battery post terminals and related accessories contain lead and lead compounds; wash handsafter handling (California Proposition 65).

WARNINGFollow battery manufacturers safety recommendations when work ing around battery systems.

WARNINGDo not smoke or present an open flame when batteries (especially vented batteries) are oncharge. Batteries vent hydrogen gas when on charge, which creates an explosion hazard.

Batteries are hazardous to the environment and should be disposed of safely at a recycling facility. Consult thebattery manufacturer for recommended local authorized recyclers.


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i

TABLE OF CONTENTS

1

INTRODUCTION ............................................................................................................................................................. 1

1.1 Scope of the Manual ..................................................................................................................................... 1

1.2 Product Overview.......................................................................................................................................... 1

1.3 System Configurations.................................................................................................................................. 2

1.4

Part Numbers and List Options..................................................................................................................... 2

2

FEATURES ................................................................................................................................................................... 3

2.1 System Overview .......................................................................................................................................... 3

2.2 Distribution Center ........................................................................................................................................3

2.3

Cordex Integrated System Controller (CXCI) ............................................................................................... 6

2.4

Cordex 48-1.8kW Rectifier............................................................................................................................ 8

3 INSPECTION................................................................................................................................................................ 12

3.1

Packing Materials........................................................................................................................................12

3.2

Check for Damage ...................................................................................................................................... 12

3.3 General Receipt of Shipment...................................................................................................................... 12

4 INSTALLATION ............................................................................................................................................................ 13

4.1

Safety Precautions...................................................................................................................................... 13

4.2

Tools Required............................................................................................................................................ 13

4.3

Power System Assembly and Mounting ..................................................................................................... 14

4.4 Rectifier Module Insertion/Removal............................................................................................................ 14

4.5 Breaker Installation ..................................................................................................................................... 14

4.6 Breaker Removal ........................................................................................................................................14

4.7

Battery Installation....................................................................................................................................... 15

5 WIRING...................................................................................................................................................................... 17

5.1 Grounding ................................................................................................................................................... 17

5.2 AC Feeder Protection/Sizing....................................................................................................................... 17

5.3

AC Input Connections ................................................................................................................................. 17

5.4

Calculating Output Wire Size Requirements............................................................................................... 18

5.5

DC Output Connections .............................................................................................................................. 18

5.6

System and Battery Connections................................................................................................................18

5.7 Alarm Connections...................................................................................................................................... 20

5.8 CAN Serial Ports .........................................................................................................................................20

5.9

Network Connection and Remote Communications via CXCI....................................................................21

5.10

Signal Wiring Connections for CXCI........................................................................................................... 21

6 SYSTEM STARTUP ...................................................................................................................................................... 24

6.1 Check System Connections........................................................................................................................24

6.2

Verify AC and Power the Rectifier Shelf ..................................................................................................... 24

6.3

Check Battery Polarity and Connect........................................................................................................... 24

6.4

CXCI Reset .................................................................................................................................................25

6.5

LVD Control................................................................................................................................................. 25

7 OPERATION................................................................................................................................................................ 26

7.1 Main Rectifier States................................................................................................................................... 26

7.2

Main Rectifier Modes .................................................................................................................................. 26

7.3

Factory Ranges and Defaults ..................................................................................................................... 27

8 MAINTENANCE ........................................................................................................................................................... 28


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ii

8.1 Fan Replacement........................................................................................................................................ 28

8.2 MOV Replacement...................................................................................................................................... 28

8.3 CXCI Replacement (as used with 1.8kW shelf) .......................................................................................... 29

9

ARGUS CONVENTIONS................................................................................................................................................ 30

9.1 Numbering System...................................................................................................................................... 30

9.2 Acronyms and Definitions ........................................................................................................................... 30

FIGURESFigure 1Front view of the 053-990-20-000 rail mount CXPS 48-1.8-i configuration ...................................................... 1

Figure 2DCP03 configured for 4 battery and 14 load breakers...................................................................................... 3

Figure 3Internal alarm card ............................................................................................................................................ 4

Figure 4Internal alarm card and CXCI I/O terminal block............................................................................................... 4

Figure 54R/8D ADIO option............................................................................................................................................ 5

Figure 6Cordex CXCI model system controller front panel............................................................................................6

Figure 7Cordex 48-1.8kW modular switched mode rectifier .......................................................................................... 8

Figure 8CXRF 48-1.8kW module performance............................................................................................................ 10

Figure 9Example of an insulated tool kit.......................................................................................................................13Figure 10Rear view of DCP03 distribution panel ......................................................................................................... 19

Figure 11Battery, load, and return connection locations.............................................................................................. 19

Figure 12DCP03 wire routing example.........................................................................................................................20

Figure 13Showing relay connections............................................................................................................................ 21

Figure 14Showing digital input connection method...................................................................................................... 22

Figure 15Showing CXCI replacement .......................................................................................................................... 29


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Argus Technologies Lt d. 053-990-C0 Rev A WCPrinted in Canada. 2008 Argus Technologies Ltd. ARGUS and CORDEX are trademarks of Argus Technologies Ltd. All Rights Reserved. Page 1 of 30

1 Introduction

1.1 Scope of the Manual

This instruction manual covers the features and installation of Argus Technologies CXPS 48-1.8-i 48V 150APower System.

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

1.2 Product Overview

The CXPS 48-1.8-i is a complete integrated 48Vdc power system with 150A capacity. The system utilizes theadvanced Cordex CXCI controller and 48V 1.8kW rectifier modules. The DCP03 300A distribution center providesfront access for DC distribution, site controller, and battery connections.

Cordex rectifier modules use a high frequency, switched mode conversion technique to provide a fully regulatedand isolated DC output from the AC mains. The rectifier input is wide range to allow use on120/208/220/230/240/277Vac 50/60Hz electrical service. NOTE: System has de-rated output below 176VACinput, see specifications at the front of this manual.

Rectifier power modules are hot swappable meaning they can be inserted or removed from the shelf without

cutting power to or from the system or the load.

NOTE: Rectifier modules are not included with the base system, but may be purchased along with the system at the timeof ordering or added after the shelf has been installed.

The shelf rectifier system is designed to operate with the Argus Cordex System Controller (CXC).

This system uses the CXCI integrated version of the controller, which is factory installed on the Cordex rectifiersystem shelf.

The CXC allows the user to configure, monitor and control the entire DC power system locally or remotely via aweb browser such as Internet Explorer. Features of the unit include temperature compensation, auto equalization,remote access, e-mail alarm notification, battery diagnostics, as well as web server and SNMP support forconfiguration and monitoring.Details of controller operation are provided in the current version software manual.

Figure 1Front view of the 053-990-20-000 rail mount CXPS 48-1.8-i configuration


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1.3 System Configurations

The system is available to order in the following configurations:

Description Part NumbeCXPS 48-1.8-i, Cordex base 48V 150A power system, 19/23 rail mount ........................................ 053-990-20-000CXPS 48-1.8-i system installed in 7foot Z4 23 rack with 2x battery trays ........................................ 053-990-20-040CXPS 48-1.8-i system installed in 7foot Z4 19 rack with 3x battery trays ........................................ 053-990-20-031

1.4 Part Numbers and List Options

This product is available to order with the following options and accessories:

Description Part NumbeCordex 48-1.8kW rectifier power module (pre-RoHS 010-580-20).................................................... 010-602-20-040

Breaker, AM-type mid-trip plug-in, 1A........................................................................................................470-300-10Breaker, AM-type mid-trip plug-in, 3A........................................................................................................470-301-10Breaker, AM-type mid-trip plug-in, 5A........................................................................................................470-302-10Breaker, AM-type mid-trip plug-in, 10A......................................................................................................470-303-10Breaker, AM-type mid-trip plug-in, 15A......................................................................................................470-304-10Breaker, AM-type mid-trip plug-in, 20A......................................................................................................470-305-10Breaker, AM-type mid-trip plug-in, 25A......................................................................................................470-306-10

Breaker, AM-type mid-trip plug-in, 30A......................................................................................................470-307-10Breaker, AM-type mid-trip plug-in, 35A......................................................................................................470-308-10Breaker, AM-type mid-trip plug-in, 40A......................................................................................................470-309-10Breaker, AM-type mid-trip plug-in, 45A......................................................................................................470-310-10Breaker, AM-type mid-trip plug-in, 50A......................................................................................................470-311-10Breaker, AM-type mid-trip plug-in, 60A......................................................................................................470-312-10Breaker, AM-type mid-trip plug-in, 70A......................................................................................................470-313-10Breaker, AM-type mid-trip plug-in, 80A......................................................................................................470-314-10Breaker, AM-type mid-trip plug-in, 90A......................................................................................................470-315-10Breaker, AM-type mid-trip plug-in, 100A....................................................................................................470-316-10

Load breaker kit, AM-type mid-trip plug-in, 125A (2-pole) .........................................................................747-523-20Load breaker kit, AM-type mid-trip plug-in, 150A (2-pole) .........................................................................747-524-20

Load breaker kit, AM-type mid-trip plug-in, 175A (3-pole) .........................................................................747-525-20Load breaker kit, AM-type mid-trip plug-in, 200A (3-pole) .........................................................................747-526-20Load breaker kit, AM-type mid-trip plug-in, 250A (3-pole) .........................................................................747-527-20

Battery breaker, AM-type series-trip plug-in, 100A....................................................................................470-347-10Battery breaker kit, AM-type series-trip plug-in, 150A (2-pole)..................................................................747-503-20Battery breaker kit, AM-type series-trip plug-in, 250A (3-pole)..................................................................747-504-20

Fan assembly, (spare for Cordex 48-1.8kW).............................................................................................747-272-20

MOV assembly, (spare for Cordex 48-1.8kW)...........................................................................................707-436-20

Replacement CXCI controller.....................................................................................................................747-427-20

23 battery tray expansion kit (for use with 040 configuration) ................................................................058-156-20

19 battery tray expansion kit (for use with 031 configuration) ................................................................058-157-20

Cordex DC Modem ....................................................................................................................................018-585-20(complete with Argus cable)

Cordex Smart Peripheral Kit, 4 O/P Relays, 8 Digital I/P ..........................................................................747-521-20

The above information is valid at the time of publication. Consult factory for up-to-date ordering information.


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2 Features

2.1 System Overview

The basic system configuration is called out by Argus part number 053-990-20-000; which includes:

300A DCP03 distribution center

Cordex Integrated System Controller (CXCI)

One (1) Cordex 48-1.8kW 4-module rectifier shelf Kydex rear cover

19 rack mount rails (center and flush mount)

19 to 23 rack mount adaptors

System integration cabling and bus work

Two (2) battery temperature compensation probes (12 each).

Optional system configurations are available as:

053-990-20-031: basic configuration factory installed into a 7 foot 19 zone 4 relay rack and three (3) batterytrays with cabling and 100A battery disconnects for up to three (3) 48V VRLA strings.

053-990-20-040: basic configuration factory installed into a 7 foot 23 zone 4 relay rack and two (2) battery trayswith cabling and 100A battery disconnects for up to two (2) 48V VRLA strings.

2.2 Distribut ion Center

2.2.1 Distribution Configurations

The DCP03 contains 18 total AM-type plug-in breaker positions with two-hole connection points for both breakeroutput and the ground return bus. The breaker distribution, for the CXPS 48-1.8-i, is configured for 4 batterybreaker and 14 load breaker positions as shown below:

Figure 2DCP03 configured for 4 battery and 14 load breakers

Battery breakerconnections

Load breakerconnections

NOTE: Load breakers require mid-trip AM plug-in breakers, and battery breakers require series-trip AM plug-in breakers.

NOTE: When there is no power on the rectifiers and there is only one battery circuit breaker, there will be no alarm if thecircuit breaker trips.

2.2.2 Low Voltage Battery Disconnect (LVBD)

A 400A LVD is included for the CXPS 48-1.8-i system configuration. The LVD is installed in series with thebatteries (LVBD).


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2.2.3 Shunt

A 400A shunt is included, in the CXPS 48-1.8-i system, for system current measurement. The shunt is installed inseries with the batteries and the system controller automatically calculates load current.

2.2.4 Internal Alarm Card

The DCP03 includes a standard alarm card providing a common interface point to internal system I/Oconnections, an LVD override switch, and LED indication of breaker trip.

The alarm card provides terminal block access to internal signals such as binary alarms for breaker trip & LVDopen, alarm relay for driving LVD, and analog inputs for current (shunt) and voltage measurements. The terminalblocks provide a single point of access to these signals for connecting to an external system controller. Refer tothe customer connections (08) drawing at the rear of this manual for details on terminal block assignments.

The LVD override switch provides the user with the ability to inhibit or override LVD contactor operation as asafeguard during controller maintenance. A green LED signals when the LVD is in normal operation mode and ayellow LED signals when the switch has been placed into the override position.

Figure 3Internal alarm card

2.2.5 CXCI I/O Terminal Block

A CXCI I/O terminal block kit is installed in the UDC front door for front access to controller signals and interfaces

to the CXCI controller, on the rectifier shelf, via a 25-pin D-sub wire harness.

The internal signals from the distribution center are wired to the CXCI I/O board direct from the internal alarmboard. The remaining relay outputs, digital inputs, and analog inputs are available on the board via terminalblocks for customer connection of external signals. Refer to the customer connections (08) drawing at the rearof this manual for details on terminal block assignments.

Figure 4Internal alarm card and CXCI I/O terminal b lock

I/O customer connection points

D-sub wire harnessesto 1.8kW shelf

LVD override switch

CXCI I/O terminalblock assembly


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2.2.6 4R/8D ADIO (Option)

The 4R/8D ADIO Cordex peripheral may also be optionally installed on the front door of the DCP03 expanding theI/O capability of an existing Cordex controller by adding an additional 4 relays outputs and 8 digital inputs.

The 4R/8D ADIO installs on the right side on the front door. The ADIO is connected to the Cordex system viaCAN communications using RJ-12 offset communications cables.

All I/O connections are made via screw terminal blocks. Refer to the customer connections (08) drawing at therear of this manual for details on terminal block assignments.

NOTE: The 4R/8D ADIO board does not come with the CXPS 48-1.8-i system and is purchased separately. Consultfactory for options.

Customer I/Oconnections viaterminal blocks

ADIO power supplyconnection

CAN in/out

Figure 54R/8D ADIO option


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2.3 Cordex Integrated System Controller (CXCI)

The controller is mounted in the rectifier system shelf and brings advanced monitoring technology to the Cordexseries of rectifiers. This compact system controller is designed for seamless operation and set up of Argus powersystems and is equipped with the complete range of Cordex software features, including the following:

Designed to communicate directly with Cordex rectifiers

Includes battery temperature compensation charging

Battery performance diagnostics

Provides local and remote communications User definable alarms

Daily logging of power system events and system statistics.

Behind the CXCIs front panel lies the main controller motherboard, which contains a microprocessor, memory, aswell as numerous other electronic components.

The CXCI includes a web server providing easy set up and monitoring using an Internet connection with thestandard Windows Internet Explorer browser.

NOTE: Details of controller operation are provided in the current version software manual.

The data-logging feature allows the user to capture data from multiple inputs, for AC/DC voltages, load/batterycurrent, cell voltages & temperatures (automatically for up to 16 user defined logs). Typical applications of theCXCI logging include power system details, thermal performance of outdoor enclosures, battery cell specifics, or

mains variations captured by an AC voltage watchdog.

A built-in audio speaker sounds an intermittent tone during active alarms.

2.3.1 System Contro ller Front Panel

The CXCI model has a 4-digit display for monitoring system voltage (V) and current (A). A pushbutton toggleswitch allows the user to alternate the display reading.

Figure 6Cordex CXCI model system controller front panel

LCD screen (V/A)

Display pushbuttontoggle switch (V/A) Hard reset

(push once)

Port for Argus DCmodem (e/w cable)only

System statusLEDs

Soft reset(push once)[Hold for 3 secondsto reset IP address]

Details of controller operationare provided in the currentversion software manual.

Ethernet port


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2.3.2 LEDs

The CXCI has three LEDs located on the front panel. These are used to display the alarm status of the powersystem, CXCI progress and status during startup, and file transfers.

2.3.2.1 Alarm Condit ions

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

Green OK, no alarms presentYellow Minor alarm is present (no major alarms)Red Major alarm is present.

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

2.3.2.2 Progress and Status Indication

The LEDs are also used in the following situations:

Base unit validation all three LEDs are on at the same time.File transfer when recovering from invalid firmware application the red LED is il luminated.

2.3.3 Reset

A reset button is located on the front panel for restarting the CXCIs microprocessor.

NOTE: Refer also to the software manual always select the Reset menu item before pressing the reset button.

2.3.4 Modem Port

The Modem port (front panel DB-9 connector, Figure 6)is designed for CXCI connection to Argus TechnologiesCordex DC Modem #018-585-20 (complete with Argus cable).

CAUTIONConnect only Argus-supplied modem and cable; otherwise, equipment damage can result.

2.3.5 Ethernet Port

The Ethernet port is designed for CXCI connection to a user supplied network (TCP/IP secured by user) via afront panel RJ-45 jack (Figure 6)and a standard network cable.

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

2.3.6 Analog Input Channels

The CXCI has analog input channels for voltage, current, and temperature.

2.3.6.1 Voltage Inputs

Two voltage input channels, V1 and V2, provide monitoring of discharge and charge voltage.The CXCI software is pre-configured to monitor V2 for load and for battery voltage. V2 is used

as the system reference for rectifier float voltage, low voltage disconnect (LVD), system highvoltage alarm, and system low voltage alarm. V1 is available for additional measurements.

2.3.6.2 Current Inputs

The CXCI software is pre-configured to monitor I1 for load current using an external 50mVcurrent shunt.

2.3.6.3 Temperature Inputs

Two temperature input channels, T1 and T2, provide monitoring of battery temperature andtemperature compensation (temp comp) or room/ambient temperature. A voltage is supplied tothese terminals to power the temperature sensors.


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2.3.7 Digital Input Channels

The CXCI has digital input channels to monitor alarm/control signals from rectifiers, converters and many othertypes of equipment.

2.3.8 Alarm and Contro l Output Relays

The CXCI contains Form C digital alarm output relays to extend alarms and control external apparatus. Eachinternally generated alarm or control signal may be mapped to any one of the relays, or, several signals may be

mapped to just one relay or none at all.

2.3.9 Network Connection and Remote Communications

The Cordex system can be set up, monitored and tested via Ethernet 10/100 Base-T serial data connection. Thecommunication protocol supports a web interface. All alarming and control of Cordex rectifiers is accomplishedwith a CXCI via a CAN bus.

A step-by-step connection wizard (Windows 2000 operating system) provided to establish remotecommunications with your CXCI is available via the Argus website (www.argusdcpower.com).

2.4 Cordex 48-1.8kW Rectifier

Figure 7Cordex 48-1.8kW modular switched mode rectifier

2.4.1 LEDs

The front panel LEDs provide:

Rectifier status summary,

Rectifier software upgrade in progress indication,

Locate module pattern.

Rectifier status summary will show the rectifier alarm status, communication fail status and rectifier on/off status.

2.4.1.1 AC

The top LED (green) is on when AC is within valid range.AC vo ltage is invalid i f the ACMains Low or AC Mains High alarm is active. The LED turns off when AC has failed.

2.4.1.2 DC

The middle LED (green) is on when the rectifier is delivering power to the load. The LED willflash when communication is lost. The LED turns off when the rectifier is off; e.g., whencommanded via the CXC.


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2.4.1.3 ALARM

The bottom LED (red) is on continuously, in the event of an active Module Fail alarm, if themodule is unable to source power as a result of any of the following conditions:

Output fuse blown AC Mains Input Fail Module fail (ramp test fail)High voltage (OVP) shutdown Thermal shutdown Local shutdownUPF fail No output power Fan fail.

The LED will flash (~2Hz), when a minor alarm is detected, if the modules output capability hasbeen reduced or a minor component failure is detected during the following conditions:

VAC meter fail AC foldback Remote equalizeFan fail Low output voltage High output voltageCurrent limit (programmable option) Power limit (programmable option) High temperature foldbackTemperature sense fail Soft start operation Communications lost.

The LED remains off in the absence of an alarm. If the unit output is not connected to a batteryor parallel rectifier, the LED will extinguish if no AC power is present.

2.4.1.4 LED Activity During Software Upload

When a rectifier software upload is in progress, the LEDs will behave in a distinctly different wayto indicate new rectifier software is being transferred from the CXC.

When a rectifier data transfer is in progress, all three LEDs will flash in a sequence lasting 1.5

seconds. When the last LED is lit, the sequence is repeated beginning at the first LED.

2.4.1.5 LED Activity During Locate Module Command from CXC

When the locate module command has been received from the CXC, the LEDs will behave inanother distinct fashion so that the rectifier is easier to visually identify among adjacentrectifiers.

This state is entered when commanded via the CXC. The LEDs will flash in a ping-pong patternrepeating every 2 seconds.

The ping-pong pattern lights each LED sequentially. After the last LED is lit, each LED is lit inreverse sequence. When the first LED is lit, the pattern repeats. The effect makes it appear as ifthe light is bouncing between the first and last LED.

2.4.2 Mechanical

A thumbscrew (1/4-turn) latch is provided to secure the rectifier into the shelf. During normal operation the rectifiershall be locked into position. A handle (or grip) is incorporated into the front panel to facilitate the removal of therectifier from the shelf. No special tools are required.

2.4.3 Rear Panel

Located on the rear panel of the rectifier are connections for shelf power and communications.

2.4.4 True Module Fail Alarm

The power modules have a true fail alarm. This provides a true indication of the power modules ability to source

current. When the modules output current drops below 2.5% of the rated output a low output current condition isdetected and the Module Fail detection circuit is activated. This circuit momentarily ramps up the output voltage todetermine if the module will source current. If no increase in current is detected, the Module Fail alarm isactivated. The module will test once every 60 seconds for the condition until current is detected. Output voltageramping will cease upon detection of current

1.A minimum 2.5% load is required to avoid the Ramp Test Fail

alarm; this can typically be provided with the parallel system battery. Activation of this alarm could indicate a failedmodule or a failed load.

NOTE: For Cordex rectifier systems without batteries (or with a very light load; below 2.5% of rated output) it isrecommended that the ramp test be disabled to avoid nuisance alarms. The Ramp Test feature isenabled/disabled via the CXCI menu item: Rectifiers, Configure Settings.

1Under normal conditions, a battery connected to the output of the rectifier will draw current when the voltage ramp occurs. Therefore the rectifier fail

alarm will not be generated with a battery connected.


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2.4.5 Heat Dissipation

Cooling of the module is front-to-rear with the exhaust air exiting at the back. The fan is variable speed; which isdetermined by heatsink temperature and load.

2.4.6 Over Temperature Protection

Each rectifier module is protected in the event of an excessive increase in temperature due to component failureor cooling airflow blockage. During over temperature conditions, the rectifier limits the output power as well as the

output current. If temperature continues to increase, a shutdown of the rectifier is initiated. The rectifier shallrestart automatically if the temperature has returned to a safe level.

2.4.7 Wide AC Range

For voltages above specifications, power factor and total harmonic distortion may be derated. For voltagesbetween 312 and 320Vac, the rectifier may not be operational but shall not suffer any damage.

Output power is derated below 176Vac. The module output power derates linearly to 900W @ 90Vac. Themodule provides approximately 1150W @ 115Vac input.

0

200

400

600

800

1000

1200

1400

1600

1800

2000

85 90 100 110 120 130 140 150 160 170 176 208 240 312

Input Vol tage (Vac)

OutputPower(W)

Figure 8CXRF 48-1.8kW module performance

1800W @ 176Vac

~1150W @ 115Vac

900W @ 90Vac

2.4.8 AC Inrush/Transient Suppress ion

The inrush current of the rectifier module is limited to the full load steady state line current to prevent surge on theAC line. Modules are also protected from input lightning and transient surges in accordance with IEEE/ANSIC62.41 Category B3.

2.4.9 Soft Start

To eliminate an instantaneous demand on the AC source, a soft start feature is employed. Soft Start, sometimesreferred to as current walk-in, works by gradually (up to five seconds) ramping the current limit up from zero tothe actual or defined customer setting. The rectifier output voltage is ramped up from the minimum voltage to thefloat voltage.

2.4.10 Start Delay

The rectifier modules are equipped with a delay timer in order to stagger start a series of modules to preventexcessive loading of generators upon start up. The built-in timer delays the turn on of the module depending onthe value selected (up to 120 seconds) via the CXC. A minimum one-second delay is preset to allow charging ofthe input capacitors.


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2.4.11 Current Limi t/Short Circuit Protection

The current limit function determines the maximum output current limit of the rectifier module, regardless of outputvoltage or power. Maximum output current is limited to a constant value down to short circuit condition. Currentlimiting can be used to mate the rectifier output current ampacity to the needs of the load and parallel battery tominimize excessive battery recharge current.

The rectifier will sustain a short circuit at the output terminals indefinitely. The maximum short circuit current shallnot exceed 105% of the rated full load current.

2.4.12 Power Limi ting

Each rectifier module is designed to limit power output to the module specification. This enables more current tobe supplied at lower output voltages, and allows matching of output to the demand of constant power loads,normally seen with telecom equipment.

This feature may also be used for a faster recharge of flooded batteries paralleled with the load.

NOTE: Current limiting overrides the power-limiting feature.

2.4.13 High Voltage Shutdown (HVSD)

This feature provides protection to the load from over voltage conditions originating from the rectifiers. It operatesby shutting down the offending rectifier module when a high output voltage condition occurs. Indication is throughthe red Alarm (Module Fail) LED. Modules will restart automatically; however, if more than three over voltageconditions occur in one minute, the module will latch off and remain shut down until it is reset via the CXC.

2.4.14 Battery Eliminator Operation

Rectifier modules maintain all specifications (except where indicated) with or without a battery attached in parallelto the output; however, if a battery or another module supplying DC voltage in parallel is not present, there will beno monitoring or control activity if there is an AC power failure or input fuse failure.


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3 Inspection

3.1 Packing Materials

All Argus products are shipped in rugged, double walled boxes and suspended via solid inserts to minimize shockthat may occur during transportation. Packaging assemblies and methods are tested to International Safe Transit

Association standards. Power systems are custom packaged in heavy-duty plywood crates.

Products are also packaged with Cortex. This plastic wrap contains a corrosive-inhibitor that protects the productfrom corrosion for up to two years.

NOTE: Rectifiers and batteries are shipped on individual pallets and are packaged per manufacturers guidelines.

3.1.1 Returns for Service

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

NOTE:Argus Technologies is not responsible for damage caused by the improper packaging of returned products.

3.2 Check for Damage

Prior to unpacking the product, note any damage to the shipping container. Unpack the product and inspect theexterior 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 thecarrier and contact Argus Technologies for advice on the impact of any damage.

3.3 General Receipt of Shipment

NOTE: The inventory included with your shipment is dependant upon the options you have ordered.

3.3.1 Racks

Consult the packing slip to verify that you have the correct number of racks per your order.

3.3.2 Rectifiers (Purchased Separately)

Consult the packing slip to verify that you have the correct number of rectifiers per your order.

3.3.3 Miscellaneous Small Parts

Review the packing slip to determine the part number of the configuration kits included with your system; e.g.,053-990-20-040 for CXPS 48-1.8-i system installed in 7foot Z4 23 rack with 2x battery trays.

3.3.4 Batteries (Purchased Separately)Verify that you have the correct number of batteries (if applicable). Refer to packing list.

Verify that you have all the necessary parts per your order for proper assembly.Call Argus Technologies if you have any questions before you proceed: 1 (888) 462-7487


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4 Installation

This chapter is provided for qualified personnel to install and interconnect the power components within the Arguspower system. Regarding battery installation, refer primarily to the manufacturers guidelines for more specificinformation.

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

4.1 Safety Precautions

Refer to the Important Safety Instructions near the front of this manual.

4.2 Tools Required

Various insulated tools are essential for DC power system installation. Use this list as a guide:

Battery lifting apparatus (as required)

Electric drill with hammer action, 1/2" capacity

Various crimping tools and dies, to match lugs used in installation

Load bank of sufficient capacity to load largest rectifier into current limit

Digital voltmeter equipped with test leads

Cable cutters

Torque wrench: 1/4 drive, 0-150 in./lb.

Torque wrench: 3/8 drive, 0-100 ft./lb.

Insulating canvases as required (2 x 2, 1 x 1, 3 x 3, etc.)

Various insulated hand tools (see Figure 9)including:-Combination wrenches -Ratchet and socket set-Various screwdrivers -Electricians knife

Battery safety spill kit (required for wet cells only) including:-Protective clothing -Face shields-Gloves -Baking soda-Eye wash equipment

Cutters and wire strippers 0.08 to 6mm2(#28 to #10 AWG).

Figure 9Example of an insulated tool kit


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4.3 Power System Assembly and Mounting

The power system must be mounted in a clean and dry environment. Sufficient free space must be provided atthe front and rear of the power system. This is to meet the cooling requirements of the rectifiers utilized in thepower system and to allow easy access to the power system components.

NOTE: The DCP03 requires at least 1RU (1.75) of space above the unit for tooling access to the load breaker groundconnections. Ensure that at least 1RU of space is open in the relay rack above the DCP03.

4.3.1 Rack Mounted Systems

Attach the power system to the customer-provided relay rack using mounting screws and star washers to ensurean electrical bond between system chassis and relay rack.

The system may be mounted into a 19 rack in either a flush or center mount position. 23 rack mounting (flush orcenter) is accomplished via the included 19 to 23 rack adaptors.

4.3.2 Floor Mounted Systems

Secure the system to a concrete floor utilizing either heavy duty anchors (1/2 x 2-1/2) or, for wooden floors,heavy-duty lag screws (5/8 x 2-1/2). Use appropriately sized flat washers.

Use isolating kits if required to isolate system from the floor.

It is recommended that the relay rack be secured to the overhead cable tray. Argus does not supply themechanical details necessary for overhead support.

4.4 Recti fier Module Insertion/Removal

Insert by placing the rectifier module on the shelf bottom and sliding the module into the rear connector (inside ofthe shelf). Apply pressure on the module handle to engage the rear connector in the shelf receptacle.

NOTE: It is recommended that the first module be inserted into the front leftmost position using the side of the shelf (orthe optional shelf-mounted controller) as a guide. Subsequent modules may be inserted using the previousmodule as a guide.

Tighten the thumbscrew (1/4-turn) latch on the bottom of the faceplate to secure the module to the shelf.

NOTE: Do not force a module into position if it does not seat properly. All modules are keyed to ensure that the correctmodule (voltage/polarity) type is used.

To remove a module, loosen the thumbscrew (1/4-turn) latch on the bottom of the faceplate. Grasp handle andpull out, sliding the module away from the rear connector and out of the shelf.

4.5 Breaker Installation

1. Ensure mid-trip breakers are used for load and series-trip breakers are used for battery connections.2. Turn breaker off.3. Ensure that the breaker is right side up.4. Align the breaker terminals with the correct holes.5. Carefully push the breaker into position.

4.6 Breaker Removal

1. Turn breaker off.2. Carefully pull the breaker out of position.


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4.7 Battery Installation

This information is provided as a guideline and is not meant to imply that batteries are part of this power system.

WARNINGFollow battery manufacturers safety recommendations when working around battery systemsand review the safety instructions provided in this manual.

4.7.1 Preparation/Mounting

Batteries should be located in a temperature-controlled environment. The temperature should be regulated atapprox. 25C (77F). Significantly lower temperatures reduce performance and higher temperatures decrease lifeexpectancy.

Provide adequate ventilation. VRLA batteries, though not requiring the special ventilation requirements of aflooded battery, should not be installed in an airtight enclosure. Hydrogen gas may be vented in a fault condition;i.e., failed battery.

Before assembly, clean cells (where applicable) as per the battery manufacturer's recommendations.First neutralize any acid with a baking soda and water solution. Then wipe the cells with clean water.

4.7.2 Installation of Batteries

Verify that all battery breakers, DC circuit breakers, and fuses on the d istribut ion panels are eitherin the OFF position or removed.

Use a corrosion-inhibiting agent, such as NO-OX-ID A, on all battery terminal connections.

1. Assemble battery rack (if required) and the cells or mono-blocks as per theinstallation instructions supplied with the batteries.

2. Ensure that the battery output cabling will reach the [+] and [] terminals of the seriesbattery string and that the batteries are oriented correctly for easy installation of theinter-unit series connectors.

3. Remove any NO-OX-ID Agrease from battery terminals.

4. Burnish terminal posts with a non-metallic brush, polishing pad or 3M Scotch Britescouring pad.

5. Apply a light coating of NO-OX-ID Agrease to the terminal posts.

6. If lead plated inter-unit connectors are used, they should also be burnished and NO-

OX-ID Agrease applied as above. Install the inter-unit connectors.

7. After all battery connections are completed, torque per battery specifications(typically 100 in-lbs).

NOTE: See system startup procedure before connecting batteries online.


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After assembly, batteries should be numbered and as received readings taken, including specific gravity, cellvoltage and temperature. One cell will be designated as the pilot cell; this is usually the cell with either the lowestspecific gravity or voltage. Refer to manufacturer's literature for guidelines.See following table for typicalmaintenance report:

Company: ________________________________________________ Date: ____________________

Address:____________________________________________________________________________

Battery location and/or number:__________________________________________________________

No. of cells: _______________ Type: __________________________ Date new: ________________

Date installed: _____________ Float voltage: ____________________ Ambient temp.: ____________

Cell Readings

Cell # Serial # Voltage SpecificGravity

Ohms Mhos Observations

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

Remarks and recommendations:_________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

Readings taken by: _________________________________________

Table ATypical VRLA battery maintenance report


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5 Wiring

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

WARNINGEnsure that power is removed by turning off rectifiers and removing battery line fuse orconnection before attempting work on the wiring connections. Use a voltmeter to verify theabsence of voltage. Clearly mark the correct polarity of the battery leads before commencing workon DC connections.

Refer to the previous (Installation) chapter for safety precautions and tools required.

5.1 Grounding

The isolated power system battery return bus (BRB) should be connected to the building master ground bus(MGB) or floor ground bus (FGB) in a larger building. This acts as a system reference and as a low impedancepath to ground for surges, transients, noise, etc. The MGB or FGB should have a direct low impedance path tothe building grounding system. The cable from the power system to the MGB or FGB should be sized to providesufficient ampacity to clear the largest fuse or breaker on the power system, excluding the battery protection fuseor circuit breaker. This is the minimum requirement; other factors including length of cable and special groundingrequirements of the load should also be factored in. The insulated cable should be equipped with two-hole crimptype lugs and should not have any tight bends or kinks.

Power System Ampacity Ground Reference Conductor Size

< 30A #10

30 100A #6-2

100 400A 0000

400 800A 350 MCM

> 800A 750 MCM

Table BTypical ground reference conductor selection

The power system frame must also be connected to the MGB or FGB. This is done for personnel safety and tomeet many Telco grounding requirements. Each bay should have its own frame or site ground connection. Referalso to the Customer Connections drawing at the rear of this manual.

5.1.1 Frame Ground

The DCP03 is grounded utilizing screws/bonding washers to the relay rack then to the main grounding bus using35mm

2(#2 AWG) insulated cable.

5.2 AC Feeder Protect ion/Sizing

To maximize system reliability, each power module should be fed from a dedicated protection feeder breakerlocated at the AC distribution panel. The feeder breaker can also act as the disconnect device for the connectedmodule. Refer to the specifications at the front of this manual for Argus recommendations.

5.3 AC Input Connections

CAUTION: AC input wires should be routed in flexible or rigid conduit as far away as possiblefrom the DC power wires to minimize EMI disturbances.

Ensure all modules are removed from the shelf. Refer to customer connections drawing.

For the terminal blocks, each terminal pair (L1 and L2) relates to a feed or individual module as marked.

Secure the wires to the AC input and chassis ground terminals as required. Use cable ties with the mountprovided for wire management.


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5.4 Calculating Output Wire Size Requirements

Wire size is calculated by first determining the appropriate maximum voltage drop requirement. Using the formulabelow calculate the CMA wire size requirement. Determine the size and number of conductors required to satisfythe CMA requirement.

CMA = (A x LF x K) / AVD, where:

CMA = Cross section of wire in circular MIL areaA = Ultimate drain in amps

LF = Conductor loop feetK = 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. Consultlocal electrical codes (NEC, CEC, etc.) for guidelines. If required, increase the size of the cable to meet the code.

5.5 DC Output Connections

WARNINGLeave cables or bus bars disconnected at battery and verify output polarity using a voltmeter.Make battery connections only after all other wiring is completed.

DC output wire shall be UL approved XHHW or RHH/RHW (for Canadian users, RW90 Type). Control and sensewires shall be UL approved Style 1015 (for Canadian users, TEW type).

Terminate cable leads with appropriate crimp lugs.

Secure the positive and negative to the shelf output post of the correct polarity; i.e., +Vcable to +Vpost. Ensurethe washers are on the bolts in the same order in which they were shipped from the factory.

The common output leg of the rectifier system should be connected to ground. This is typically done at the loadcommon termination point.

5.6 System and Battery Connections

WARNING

Ensure the correct polarity is used for all cable terminations.

Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a 0.5V loopdrop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker.

Battery cables should be sized for a 0.25V drop from battery to the power system at full load including anticipatedgrowth. The cables should also meet ampacity requirements. Cables terminating directly on battery posts orconnection details should be secured so that there is no stress on the battery posts. Lead plated lugs and leadplated or stainless steel hardware should be used on all terminations at vented batteries to reduce corrosion.

Prepare, route and connect cables from power system to battery termination details. Terminating points should be

burnished and a corrosion-inhibiting agent, such as NO-OX-ID A, should be applied to all battery terminalconnections.

NOTE: Final connection to battery live should not be made. Switch battery contactors off or remove the battery fuses (if

used). See system startup procedure before connecting batteries online.

5.6.1 DC Input to Panel

The DCP03 contains bus bar input for hot and return connections. The CXPS 48-1.8-i system is configured withvertical bus bars for rectifier shelf integration.

NOTE: Bus bar inputs are fixed for hot and return placement.


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DCP03 input bar (hot) DCP03 input bar (return)

Figure 10Rear view of DCP03 distr ibut ion panel

5.6.2 Distribution Cabling

Refer to guidelines supplied with the load equipment. Typically distribution cables are sized to provide a 0.5V loopdrop at full load as well as meeting ampacity requirements of the protection fuse or circuit breaker.

Distribution cabling must be terminated with 1/45/8C lugs for connecting to DCP03.

5.6.3 Breaker Output (Hot) Connections

Connect breaker (hot) output connections before connecting the breaker returns. Secure two hole lugs to the 1/4studs (on 5/8 centers) using the supplied hardware with the DCP03. Cables should run directly out the rear of thedistribution center. Refer to Figure 11.

5.6.4 Breaker Return (Ground) Connections

Connect breaker (ground) output connections to the DCP03 ground bar. Secure two hole lugs to the 1/4 holes(on 5/8 centers) using the supplied hardware with the DCP03. Cables should run directly out the rear of the

distribution center above the breaker (hot) output cables. Refer to Figure 11.

5.6.5 Battery Breaker Connections

Connect battery breaker (hot) connections first using the same guidelines as the load cable installation. Connectbattery ground connections using the same guidelines as load returns. Cables should run directly out the rear ofthe distribution center above the breaker (hot) output cables. Refer to Figure 11.

Figure 11Battery, load, and return connection locations

Battery (hot) connection Load breaker (hot) connection

System return (ground) bar


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5.7 Alarm Connections

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

For terminal block connections, the recommended wire sizes are 0.14 to 1.50mm2(#26 to #16 AWG) for the

temperature range of 0 to 50 deg. C (as per UL/CSA).

CAUTION: to reduce risk of fi re, use only 0.14mm2(#26 AWG) or larger w ire.

Route via wire-ways and use existing cable clamps to secure to existing (factory) wire harness along withcustomer run signal wires. Ensure signal wires are routed along hinge point of front door so door opening andclosing wont require excess wire slack. Refer to Figure 12 for wire routing example.

Terminal block connections for the internal alarm card or CXCI I/O should be routed along the left side of theDCP03 (looking at unit from front). Connections to the 4R/8D should be routed along the right hand side of theDCP03. Refer to the customer connections (08) drawing at the rear of this manual for details on terminal blockassignments.

4R/8D ADIO wire routing

Cable clamp

System internal andCXCI wire routing

4R/8D ADIO CAN ports

Figure 12DCP03 wire rout ing example

(Photo is for reference only subject to install ation requirements)

5.8 CAN Serial Ports

Two CAN Serial ports (modular jacks with offset latches), for communications with Argus Cordex rectifiers andother CAN-enabled equipment (nodes) on the same system, are located on the side of the rectifier shelf. CAN

ports may also be found on the optional 4R/8D ADIO Cordex peripheral (Figure 12).

Daisy-chain from node to node (CAN OUT of one shelf to CAN IN of another) as necessary and ensure that onlythe last shelf is terminated as follows:

5.8.1 CAN Termination

A CAN termination jumper is located beside the rightmost rectifier connector on the front of the shelf backplane.See the customer connections drawing for your shelf.

The CAN bus may be OPEN to the next node in the system or TERMINATED on the final node on the CAN bus.


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5.9 Network Connection and Remote Communications via CXCI

The Cordex system can be set up, monitored and tested via Ethernet 10/100 Base-T serial data connection. Thecommunication protocol supports a web interface.

NOTE: Pinouts are shown in customer connections drawing.

Some standard scenarios are described below:

5.9.1 Ethernet Port for Network Connection (Standard Network Cable)The Ethernet port is designed for CXCI connection to a user supplied network (TCP/IP secured by user) via afront panel RJ-45 jack.

Connect using a standard network cable.

5.9.2 Ethernet Port for Local Connection (Crossover Cable)

Local access (e.g. laptop computer) is also possible from the Ethernet port connection.

Connect using a standard network crossover cable.

5.9.3 CXCI Modem Port (Argus Cable)

The Modem port (front panel DB-9 connector, Figure 6)is designed for CXCI connection to Argus TechnologiesCordex DC Modem #018-585-20.

Connect using the Argus-supplied cable.

CAUTIONConnect only Argus-supplied modem and cable; otherwise, equipment damage can result.

5.10 Signal Wiring Connections for CXCI

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

For terminal block connections, the recommended wire sizes are 0.14 to 1.50mm2(#26 to #16 AWG) for the

temperature range of 0 to 50 deg. C (as per UL/CSA).

CAUTION: to reduce risk of fi re, use only 0.14mm2(#26 AWG) or larger w ire.

5.10.1 Alarm (Relay) Outputs

Terminals provide contacts for extending various alarm or control signals. Each relay output can be wired for NOor NC operation during an alarm or control condition. See Figure 13.

Figure 13Showing relay connections

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


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5.10.2 Digital Inputs for CXCI

The digital input channels (factory-installed) are used to monitor various alarm and control signals. All inputchannels are voltage activated and accept a bipolar (i.e. negative or positive) DC signal directly.

For the CXCI option, only D1 and D2 are available.

5.10.2.1 Connection Method

Typical Argus 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.,negative input for -48V systems. The other input terminal is wired to the Ground (common) ofthe system through a relay (dry contact usually located on the equipment requiringmonitoring). This method (see Figure 14)allows the digital input to receive (or not receive) aGround signal on an alarm.

Figure 14Showing digital input connection method

5.10.2.2 Programming the Digital Input

The digital input channels can be programmed for active high or active low. Active highindicates alarm on the presence of a ground signal and active low indicates alarm on theremoval of a ground signal. See CXC Software manual for detailed instruction onprogramming.

Voltage Range (VDC)Voltage Level (VDC)Considered As 0 (Off)

Voltage Level (VDC)Considered As 1 (On)

060(system voltage setting)

03 1860

Table CVoltage level definitions for d igital inputs

5.10.3 Analog Inputs

CAUTION: Ensure the correct polarity i s used for all input cable terminations.

The analog input channels are used to monitor various types of electrical signals. Some of the analog channelsare reserved for specific signals, while others are designated as general-purpose inputs, which accommodatevarious types of analog signals.

For the CXCI option, Battery Hot input on the I/O board is factory wired to the battery system voltage terminal forCXCI reference when a battery disconnect device is used. It is crit ical to CXCI operation as it ensures a

source of power to the CXCI should the disconnect device open the circui t.

5.10.3.1 Voltage

Voltage Input #1 (load voltage per CXC software) terminals (V1) on the shelf provideconnections to an optional secondary voltage input. For example, this can be terminated to theload side of an LVD contactor to monitor load voltage.

Voltage Input #2 (battery voltage per CXC software) is wired internally (V2) to the rectifier outputvoltage of the shelf. This is used as the reference for system alarming (such as high voltage)and control (such as low voltage disconnect).


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5.10.3.2 Temperature Sensor

Temperature Probe input channels (T1 and T2) provide connections for temperature sensors. Avoltage is supplied to these terminals for sensor measurements.

5.10.3.3 Current

Current Input #1 (discharge or load current per CXC software) terminals (I1) is factory wired tothe battery shunt in this system.


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6.4 CXCI Reset

CAUTIONBefore removing a CXCI from a live system, or performing controller maintenance, an externalLVD inhibit (or override) is required to avoid a disruption of service. See Section 6.5.

6.4.1 Soft Reset

The reset button, located on the front panel of the optional CXCI, is for restarting the microprocessor. When

pressed momentarily, the unit beeps twice then resets. The front-panel LEDs will illuminate temporarily, but willextinguish after the system has finished its 15-second self-test.

6.4.2 CXCI IP Address Reset

To reset the IP address, press and hold the front panel reset button for three seconds. The CXCI unit will beepthree times, IP will be reset (to 10.10.10.201) and DHCP will be disabled. The settings will be saved and the unitwill then reset.

This will allow local access; e.g., with a laptop and a standard network crossover cable. See current versionsoftware manual for details.

6.4.3 CXCI Hard Reset

There is a second reset button located to the right of the front panel on the side of the CXCI. This may be used torestart the microprocessor in the event that the front panel (soft) reset button fails to operate as described above.

CAUTION: Use of hard reset may cause loss of data.

To access the hard reset button, remove the rectifier module adjacent to the CXCI.

6.4.4 Time Settings

The CXCI, upon startup*, will set the time based on the following:

Attempt to synchcronize with the NTP server (see www.NTP.org).

Retrieve the last time stamp from the Event Log.

Retrieve the last time stamp from the Statistics Log.

Set the time to 2005-01-01 midnight.* Whenever the unit is reset or power is completely removed from the CXCI.

6.5 LVD Control

CAUTIONBefore removing a CXCI from a live system, or performing controller maintenance, an externalLVD inhibit (or override) is required to avoid a disruption o f service.

The LVD Control functions are hardwired directly from the assigned relay output to an optional front panel LVDoverride control.

Place the LVD Control switch to the INHIBIT position to keep the LVD contactor engaged.

CAUTIONDo not leave the switch in the INHIBIT position. Doing so may result in a complete discharge ofthe batteries during a power failure situation.

To allow the CXCI to resume automatic control of the LVD contactor, check that the AUTO IN (green) LED is li tconfirm ing that the CXCI will keep the LVD contactor engaged. Then you may return the LVD Control switchto the AUTO IN position.

Canada and USA to ll f ree 24-hour emergency technical suppor t: +1 888 GO ARGUS (462 7487).


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7 Operation

7.1 Main Recti fier States

Rectifier operation can be broken up into five main states:

1. Off,

2. Start delay,3. Soft start,4. Normal operation,5. Turning off.

Each state is characterized as being distinct and necessary for the operation of the rectifier. These states arebriefly described below.

7.1.1 Off State

The rectifier will be in the Off state immediately after power is applied to the rectifier or after a rectifier shutdown.The shutdown source may be remote or local shutdown, AC shutdown, OVP or thermal shutdown.

When the rectifier is in this state the DC-DC converter is turned off and the CXC will be monitoring its inputs forthe proper conditions to begin the start up sequence.

When the conditions have been met for the rectifier to start up, it will transition to the Start Delay state.

7.1.2 Start Delay State

When the rectifier is in the Start Delay state, the DC-DC converter is held off and still not sourcing power and iswaiting for a given amount of time before transitioning to the next state.

When in this state, the CXC continues to monitor its inputs.

After the Start Delay state the rectifier will transition to the Soft Start state.

NOTE: Soft start, or current walk-in, gradually increases the voltage and current output of the rectifier upon startup. Thisis done to reduce the instantaneous load on the AC source.

7.1.3 Soft Start StateWhen the Soft Start state is entered, the rectifier will be turned on and the output voltage and output current willbe gradually increased. If a load is present, the rectifier will begin to source power.

When the voltage and current limit ramps have finished, the rectifier will transition to the Normal Operation state.

7.1.4 Normal Operation State

The Normal Operation state is the state that the rectifier will be in performing all of the rectifier functions andfeatures specified herein.

From this state, the only valid transition is to the Turning Off state. This transition will happen if the rectifier isrequired to shut down.

7.1.5 Turning Off StateThe Turning Off state is entered because a short delay is required before the rectifier actually turns off to takecare of any initialization requirements.

When this short delay has elapsed, a transition to the Off state is made.

7.2 Main Recti fier Modes

In addition to Main Rectifier States, there is a set of Main Rectifier Modes. These modes can be divided into twocategories as follows:


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7.2.1 Output Voltage Modes

Voltage modes can be thought of as modes that, under software control, can directly adjust the output voltage.The qualification of under software control is made because there are processes that occur in the rectifier thatcan change the output voltage that do not adjust the output voltage directly (such as the rectifier being in currentlimit).

The following table lists the four Output Voltage Modes and a description of when they are active:

Output Voltage Modes Active when

Float Output voltage is set to the float voltage setting.Equalize Output voltage is set to the equalize voltage setting.

Battery Test Output voltage is set to the battery test voltage setting.

Safe Output voltage is set to the safe mode voltage setting.

Table DOutput voltage modes

7.2.2 Output Current/Power Modes

These modes directly affect the output current and power.

The following tabl

alpha cxps 48 1.8 i, 48v pos gnd

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