Intelligent CableUPS® Technical Manual XM2, XM2-HV, XM2-HP Effective: November 2010
Power Alpha Technologies ®
Intelligent CableUPS® Technical Manual 017-805-B0-010, Rev K Effective Date: November 2010 Copyright © 2010 Alpha Technologies, Inc. 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.
Table of Contents Safety Notes......................................................................................................................8 Safety Precautions............................................................................................................8 Battery Safety Notes.........................................................................................................9 Utility Power Connection Notes.............................................................................
Contents, continued 4.0 Operation..............................................................................................................53 4.1 5.0 Start-up and Test........................................................................................53 4.1.1 AC Line Operation..........................................................................53 4.1.2 Self Test Operation..........................................................................54 4.1.3 Standby Operation .....................
Figures and Tables Fig. 1-1, XM2-HP Power Supply........................................................................................................... 15 Fig. 1-2, Standard XM2 Power Supply.................................................................................................. 15 Fig. 1-3, Simplified Block Diagram........................................................................................................ 16 Fig. 1-4, Charger Modes...................................................
Figures and Tables, continued Fig. 2-20, Enclosure Ground Bar.......................................................................................................... 40 Fig. 3-1, Locations of JP1, JP2 and SW1, SW2 on the Power Distribution Board (PDB)..................... 42 Fig. 3-2, MOV Replacement................................................................................................................. 44 Fig. 3-3, Typical NEMA Receptacles and Plugs................................................
Safety Notes Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. 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.
Safety Precautions, continued • Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a fire or possible explosion. • Always replace batteries with those of an identical type and rating. Never install old or untested batteries. • Avoid using uninsulated tools or other conductive materials when handling batteries or working inside the enclosure. • Remove all rings, watches and other jewelry before servicing batteries.
Utility Power Connection Notes ATTENTION: Connecting to the utility should be performed only by qualified service personnel and in compliance with local electrical codes. Connection to utility power must be approved by the local utility before installing the power supply. UL and NEC require that a service disconnect switch (UL listed) be provided by the installer and be connected between the power source and the ALPHA power supply.
Utility Power Connection Notes, continued To Utility LI Black Copper Ground Wire #8 AWG (Minimum) Neutral (White) Breaker Neutral Bus Grounding Point Made to Enclosure Wall To Enclosure Receptacle LI Black Typical 120Vac Service Entrance Wiring LI (Black) Neutral (White) Ground (Green) Typical 120 Vac 20A Receptacle Wiring, 5-20R (P/N 531-006-10) 017-805-B0-010 Rev.
Utility Power Connection Notes, continued Proper 240Vac 20A service requires the installation site be: • Equipped with a 240Vac duplex receptacle to provide power to the power supply and peripheral equipment. • Have aNEMA 6-15R receptacle is protected by a single, 2-pole, common trip 15A circuit breaker inside the service entrance. • Checked to NEC CODE to verify proper wire AWG (suggested wire gauge is 14AWG). • Equipped with a grounding clamp on the enclosure to facilitate dedicated grounding.
Grounding and Earth Connection Notes In order to provide a ready, reliable source of backup power it is necessary to connect the power supply to an effective grounding and Earthing system that not only provides for the safety of the service personnel responsible for its operation and maintenance, but also facilitates the proper operation and protection of the equipment within the network.
1.0 Introduction The Intelligent CableUPS powers signal processing equipment in cable television and broadband LAN distribution systems. The transformer module provides a critical load with current-limited regulated, AC power that is free of spikes, surges, sags and noise. During AC line operation, AC power entering the power supply is converted into a quasi square wave and is regulated by a ferroresonant transformer at the required output voltage.
1.1 Theory of Operation The Intelligent CableUPS is comprised of the: • Transformer module, which acts as a stand-alone line conditioner. The transformer module contains a ferroresonant transformer, resonant capacitor, transfer isolation relay, Power Distribution Board and the optional Protective Interface Module (PIM) board.
1.1 Theory of Operation, continued 1.1.2 Standby Operation When the incoming AC line voltage drops or rises significantly or a complete power outage occurs, the control logic’s line monitor activates standby operation. During the transfer from AC line to standby operation, the battery powered inverter comes online as the isolation relay switches to prevent AC power from back-feeding to the utility. The energy contained in the ferroresonant transformer continues to supply power to the load.
1.1 Theory of Operation, continued 1.1.3 Charger Operation The Intelligent CableUPS uses a three-stage, temperature-compensated battery charger. During AC line operation, the inverter winding on the ferroresonant transformer feeds the charger circuit which provides BULK, ACCEPT and FLOAT charge voltages to the batteries. Charger Modes BULK charge is a “Constant Current” charge. The maximum current is 10A. As the charge is returned to the batteries, their voltage increases to a specific threshold (2.
1.2 Intelligent CableUPS Layout 1.2.1 Transformer Module Overview AC Output Fuse (legacy models only): Legacy XM2 power supplies use either a 20A slow blow or 30A slow blow fuse. To provide increased durability, an integrated fuse guard protects the fuse. Output N L (legacy models only): Use the output test point (output N L) to check the AC output. Use a true RMS AC voltmeter equipped with the proper test probes; other meters may give false or inaccurate readings.
1.2 Intelligent CableUPS Layout, continued 1.2.2 Inverter Module Overview The removable inverter module provides uninterrupted power to the ferroresonant transformer (via the batteries) during line failures. During line operation, the inverter charges the batteries using a three-stage (Bulk, Accept and Float) charger. Each inverter module and transformer module is labeled to indicate its voltage and current rating. The power supply also carries a voltage and current rating label.
1.2 Intelligent CableUPS Layout, continued 1.2.2 Inverter Module Overview, continued Escape Up Smart Display Down Enter Battery Breaker Inverter Cooling Fan Temperature Probe Connector Battery Input Connector Fig. 1-7, Inverter Module Connections Smart Display: All operational functions, system testing, setup items and alarms are available via the Smart Display panel on the front of the power supply (the Smart Display is covered in detail in Section 4.2).
1.2 Intelligent CableUPS Layout, continued 1.2.2 Inverter Module Overview, continued Inverter Cooling Fan: The inverter module is equipped with a cooling fan that operates during standby operation when the inverter heatsink temperature reaches 85°C. The fan stays on until the temperature drops below 75°C. The fan also operates whenever a self-test is in progress. Temp Probe Connector: The Remote Temperature Sensor (RTS) plugs directly into the temperature probe (RJ-11C type) connector.
1.2 Intelligent CableUPS Layout, continued 1.2.3 Optional Status Monitoring Modules The power supply supports a number of Alpha Technologies communication modules which may be ordered factory-installed or as a user-installed field upgrade. NOTE: If communications options are installed, Alpha highly recommends adding the coaxial surge arrestor for the transponder (See Section 1.3, Recommended Enclosure System Options). CAUTION! Handle these modules with extreme care.
1.3 Recommended Enclosure System Options These options can be factory installed or upgraded in the field by the user: Protective Interface Module (PIM) The PIM protects system components by shutting down the load during overcurrent and short circuit conditions. The PIM has an operator programmable overcurrent threshold (3A-24A) and a programmable overcurrent tolerance period, which specifies the time (1-10 seconds) an overcurrent condition is permitted before the output shuts down.
1.3 Recommended Enclosure System Options, continued AlphaGuard™ Battery Charge Management System The AlphaGuard Battery Charge Management System extends battery life by providing the precise voltage required for each battery. 36V (3 battery) and 48V (4 battery) versions are available. The AlphaGuard performs electrical compensation for differences in individual batteries in the string.
2.0 Installation 2.1 Installation Procedure The Intelligent CableUPS can be shelf-mounted within a variety of Alpha enclosures. Complete the pre-installation instructions in Section 2.0 and the preliminary inspection and self-test procedure before you install the power supply. CAUTION! Read the Safety Precautions, Utility Power Connection Notes and Grounding Connection Notes (pages 8-13) before you install the power supply. Pre-installation Inspection 1.
2.2 Installing the Optional Indicator Lamps 2.2.1 AC Indicator Lamp The AC indicator (green lamp) is located on the outside of the enclosure. When lit, it indicates AC power is available at the power supply output and enables service personnel to determine the status of the power supply without having to climb the pole. Installation Procedure: 1. Remove the rear-most knockout (see Fig. 2-5). 2. Feed ACI wires through the hole. 3. Slide locking nut over the wires and thread onto lamp body (see Fig. 2-1). 4.
2.2 Installing the Optional Indicator Lamps, continued 2.2.2 Local/Remote Indicator The Local/Remote indicator (Red lamp) is located on the outside of the enclosure. During normal AC operation, the lamp remains OFF. The lamp comes ON only when the power supply is running in Standby Mode. In the event a major alarm is detected, the lamp flashes to indicate service is required.
2.2 Installing the Optional Indicator Lamps, continued Installation is complete. Go to Start-up Test (Section 4.1, Start-up and Test). ATTENTION: See Section 5.6, Check Output Connections, for inspection guidelines. LRI ACI SPI LRI Output 1A Fig. 2-5, ACI/LRI Connection 28 017-805-B0-010 Rev.
2.3 Initial Turn Up NOTE: Alpha enclosures are engineered to properly vent the power supply. The power supplies have been investigated by regulatory authorities for use in various Alpha enclosures. If you are using a nonAlpha enclosure, it is your responsibility to ensure your combination conforms to your local regulatory requirements and the power supply remains within its environmental specifications. CAUTION! Batteries are an important part of the power supply.
2.4 Inverter Module Removal and Installation The Intelligent CableUPS comes with a field-replaceable inverter module assembly containing the inverter and control logic. The inverter module accepts optional communications modules to facilitate remote status monitoring. The removable module is located on the front, righthand side of the unit. CAUTION! ALWAYS switch the battery breaker off before removing or installing the inverter module assembly. Handle the inverter module with extreme care.
2.5 Protective Interface Module (PIM) The optional (PIM) adds a second isolated output so the Intelligent CableUPS can function as an N+1 redundant supply system. It provides programmable current limits for two output channels and protects system components by shutting down the load during overcurrent and short circuit conditions.
2.6 Installing the PIM NOTE: Only qualified personnel should install the PIM. To install the PIM you must completely shut down the power supply. To maintain output to the load, consider using either the APP9015S or APP9022S Service Power Supply during installation.
2.6 Installing the PIM, continued 6. Install the PDB header in the J4 connector of the PIM circuit board. 7. Align the PIM circuit board holes labeled P3, P5 and P4 with the standoffs (P13, P15 and P16) on the PDB. Place the PIM circuit board on the standoffs, making the J6/J4 connection. Verify the J6 pins are aligned correctly and completely seated in J4. 8.
2.6 Installing the Optional PIM, continued NOTE: The output current limit for the PIM is set by the position of the jumper on JP1. Configure JP1 to the proper current setting; either 15A or 22A.* For the 918HP and 924HP Cable UPS models, set this jumper to the 22A position * For additional configuration assistance, call Alpha Technologies Technical Support, 1-800-863-3364 Fig. 2-10, Location of JP1 on PIM Fig. 2-11, Jumper in 15A position P3 P4 P5 Fig.
2.7 Programming the PIM Programmable parameters (with PIM installed) are: Channel 1 Overcurrent Limit: The RMS current level that causes the Output 1 protection relay to trip after a specified delay (overcurrent tolerance period). Channel 2 Overcurrent Limit: The RMS current level that causes the Output 2 protection relay to trip after a specified delay (overcurrent tolerance period). Retry Delay: The time between each attempt to restart an output in the event of an overcurrent event.
2.7 Programming the PIM, continued 2.7.1 The Setup Menu Press the Enter key to access the Setup Menu. Use the Setup menu to view or change the programmable operating parameters of the power supply or the optional PIM. Navigation is similar to the Operation Normal menu. Press UP or DOWN to access the Single Step mode where you can individually select sub-menu items. To select and change a value in the Setup Menu: 1. Press either UP or DOWN to put the display in the Manual Scroll Mode. 2.
2.8 N+1 Configurations Because the PIM option provides a second output, the Intelligent CableUPS can function as an N+1 redundant supply system. The PIM also provides programmable current limits for two output channels, which protects system components by shutting down the load during overcurrent and short circuit conditions. Adding a PIM to a secondary power supply enables both power supplies to be connected in a “dual redundancy” configuration to protect two critical loads.
2.8 N+1 Configurations, continued NOTE: The N+1 unit and the primary unit cannot be loaded over 50% of rated capacity when configured as shown below.
2.9 Service Power Inserter (SPI) To connect the coaxial cable 1. Before you remove the cover, unplug the SPI from the power supply. 2. Remove the two screws holding the cover to the SPI chassis. 3. Remove the SPI cover to expose the circuit board and seizure screw assembly. 4. Insert the coaxial termination into the output port on the bottom of the SPI. 5. Tighten the seizure screw to 35 inch-pounds.This will prevent arcing within the SPI due to an improperly seated cable or loose connection.
2.9 Service Power Inserter (SPI), continued 6. Replace the SPI cover and reinstall the screws. 7. Reconnect the SPI to the power supply. 8. Using the switch on the top of the SPI, turn the unit ON to select the standby power supply as the power source to the cable plant. Enclosure Wall 9. The switch should only be in the ALT position when the standby power supply is connected to the cable.
3.0 Configuration 3.1 Power Distribution Board (PDB) Setup The PDB must be configured to correctly match actual power supply features and specifications. Adjustable parameters are shown in Table 3-1. There are configuration setting features on the PDB that cannot be changed. These configurations are included in the PDB setup instructions as an aid to troubleshooting and as a reference to verify configuration. Only qualified technicians should configure the PDB.
3.1 Power Distribution Board (PDB) Setup, continued The jumpers (JP-1 and JP-2) and switches (SW-1, SW-2) are located on the Power Distribution Board (PDB) as shown below. SW 1(Output) SW 2 (Input) JP 2 JP 1 Fig. 3-1, Locations of JP1, JP2 and SW1, SW2 on the Power Distribution Board (PDB) Some models of the PDB’s JP1 and JP2 are two-pin jumpers, while other models have threepin jumpers. The voltages are configured as shown below.
3.1 Power Distribution Board (PDB) Setup, continued The table below shows the respective Jumper and Switch settings for the parameters applicable to the model of CableUPS in your system.
3.1 Power Distribution Board Setup (PDB), continued 3.1.1 Replacing the Metal Oxide Varistors (MOVs) The PDB employs three MOVs that are mounted in sockets for easy replacement. MOVs must be replaced by those with comparable energy and voltage ratings. Replacement MOV P/N 160-017-19, Metal Oxide Varistor, 320Vac 420Vdc.
3.1 Power Distribution Board Setup (PDB), continued 3.1.2. Replacing the Line Isolation Relay WARNING! Before proceeding, remove all power from the power supply by unplugging the power supply from the AC power source, removing all front panel connections (i.e., N+1) and disconnecting the battery connector. Failure to do so could expose the technician to potentially lethal voltages. Tools Required: • #2 Phillips screwdriver • Flathead Screwdriver Replacement procedure: 1.
3.2 AC Input Voltage Reconfiguration The input voltage on many models (XM2-915, XM2-918HP, XM2-910, XM2-906HP and XM21350) can be reconfigured from 120 to 240Vac utility input or from 240 to 120Vac utility input, depending upon utility input powering requirements. WARNING! To avoid exposing the technician to potentially lethal voltages, remove all power from the power supply; unplug the power supply from the AC power source, remove all front panel connections (i.e.
3.2 AC Input Voltage Reconfiguration, continued 3.2.1 Reconfiguration from 120 to 240Vac, continued 4. Locate the transformer module’s input jumper in the transformer compartment. Replace the currently installed 120Vac jumper (744-281-20) with a 240Vac jumper (744-281-21). 120 240 240 120 JP1 & JP2 JP1 & JP2 120Vac Input Select Jumper (P/N 744-281-20) 240Vac Input Select Jumper (P/N 744-281-21) Fig. 3-4, Transformer Module Input Jumpers, PDB Jumpers 5. Remove the five front panel screws.
3.2 AC Input Voltage Reconfiguration, continued 3.2.2 Reconfiguration from 240 to 120Vac Tools Required: • #2 Phillips head screwdriver • Wire cutters and strippers • Flat-blade screwdriver Supplies Required: 120Vac 20A plug (NEMA 5-20P, P/N 874-540-20) 120Vac Input Select Jumper (P/N 744-281-20) Contact your Alpha Technologies representative for Wire Set part numbers. Procedure (240Vac Input to 120Vac Input): 1. Completely shut down the XM2 power supply. Remove all utility and battery power.
3.2 AC Input Voltage Reconfiguration, continued 3.2.2 Reconfiguration from 240Vac to 120Vac, continued 5. Remove the five front panel screws. Lift the transformer module front panel up and away from the chassis. The front handle and output fuse remain in place. 6. Reconfigure the PDB to 120Vac input, according to Table 3-2. • Change Switch 2-4 (SW2-4) to OFF, Switch 2-5 (SW2-5) to OFF • Change Switch 2-6 (SW2-6) to OFF, Jumper 1 (JP1) to Open (120) and Jumper 2 (JP2) to Open (120).
3.3 AC Output Voltage Reconfiguration The output voltage on many Intelligent CableUPS models (-906HP*, -910, -915, -918HP, -918HP, -922, -922HP, -924HP, -1350) can be easily reconfigured to provide an output voltage of 87, 75 or 63Vac, by moving a conveniently located OUTPUT TAP jumper and readjusting the DIP Switches on the PDB. *63V or 87V only for the 906HP model. NOTE: For the XM2-615A power supply, the OUTPUT TAP jumper enables the output voltage to be changed from 63Vac (default) to 48Vac only.
3.3 AC Output Voltage Reconfiguration, continued 3.3.1 Output Voltage Switch (SW1) Settings Reconfiguration is a two-step process done while the power supply is switched OFF. Adjust the output tap connector, as well as the output voltage switch (SW1), and cycle the unit ON for the changes to be effective. NOTE: For purposes of clarity, only the adjustable positions of SW1 (-1, -2, -3, -4, -5) are highlighted. Do not adjust the other switch positions during this procedure.
3.3.1 Output Voltage Switch (SW1) Settings, continued Reconfiguration is a two-step process done while the power supply is switched OFF. Adjust the output tap connector, as well as the output voltage switch (SW1), and cycle the unit ON for the changes to be effective.
4.0 Operation 4.1 Start-up and Test 4.1.1 AC Line Operation 1. Before making power supply connections, verify the correct voltage and frequency are available from the AC utility power source and voltage and polarity from the DC battery system. 2. Verify the AC circuit breaker (on the customer supplied service disconnect) and the battery breaker on the power supply are off. 3. Plug the power cord into the convenience outlet and the battery cable into the inverter module.
4.1 Start-up and Test, continued 4.1.1 AC Line Operation, continued 5. Use the Smart Display to verify XM2 power supply operations. If desired, the No Battery alarm can be disabled by changing Battery Capacity to “0” in the setup menu. 6. Use the Smart Display to verify AC output (±5%). Setting Low (-5%) High (+5%) 89Vac (HV) 85.4Vac 92.5Vac 87Vac 82.65Vac 91.35Vac 75Vac 71.25Vac 78.75Vac 63Vac 59.85Vac 66.15Vac 48Vac 45.6Vac 50.40Vac Table 4-1, AC Output 7.
4.1 Start-up and Test, continued 4.1.3 Standby Operation Perform the following procedure after successful completion of a self test with the CableUPS operating normally in AC line mode. 1. Momentarily fail the AC utility input power by switching the AC (service disconnect) circuit breaker to OFF. 2. The power supply starts operating in the inverter mode. Use the Smart Display or a true RMS voltmeter to verify output.
4.2 Using the Smart Display All operational functions, system testing, setup menus and alarms are available via the illuminated display panel on the front of the CableUPS. Display functions are accessible by pressing any of the four keys: ESCAPE, UP, DOWN and ENTER. Descriptions of the key functions areas follows: Icon Escape Up Down ENTER + Self-test + Function Move up one level in the menu tree. Move up one level in the menu tree.
4.2 Using the Smart Display, continued Display Backlighting The display is normally unlit. Press any key once to activate backlighting and illuminate the display without deactivating Auto Scroll. Auto Scroll The display is normally in Auto Scroll mode, continually cycling through the sub-menu items at a two-second interval. In Auto Scroll mode you can quickly view menu items without the need to press any keys.
4.3 Smart Display Modes 4.3.1 Operation Normal If no alarms are present, the power supply operates in Operation Normal display mode. In this mode you can view the primary operating parameters of the power supply while the display auto scrolls through the available menu items at two-second intervals. In Operation Normal mode the displayed items are all “metered” items and are for informational purposes only (not programmable) with respect to the operational status of the power supply.
4.3 Smart Display Modes, continued 4.3.2 Comms Information Display (with DSM2 or later) Pressing ENTER while in the Operation Normal screen will open the Comms Information display (only displayed when paired with suitable communications module, otherwise display will read “NO DATA”). This mode operates in a similar fashion as the Operation Normal display. When you first access the information display, information displays in Auto Scroll mode. Press UP or DOWN to access information one step at a time.
4.3 Smart Display Modes, continued 4.3.3 Setup Menu Pressing ENTER while in the Comms Status display opens the Setup Menu, one level below the Comms Status display. Using the Setup menu you can view and change the programmable operating parameters of the power supply or the optional PIM. Setup Menu navigation is similar to the Operation Normal menu. Press UP or DOWN to access the Single Step mode where sub-menu items are individually selected. To select and change a value in the Setup Menu: 1.
4.3 Smart Display Modes, continued 4.3.3 Setup Menu, continued The Setup Menu contains the following items: Top Line (provides additional information) • • • SET UP MENU TO MANUAL SCROLL TO COMMS INFO Second Line (cycles through the following parameters): Default Other Battery Types Other Minimum Maximum If AlphaCell™ is selected then user selects between a range of Alpha cells Float V/C 2.27 V/C 2.10 V/C 2.35 V/C Accept V/C 2.40 V/C 2.20 V/C 2.45 V/C Temp Comp 5.0 mV 0.0 mV 5.
4.3 Smart Display Modes, continued 4.3.3 Setup Menu, continued SETUP MENU CODE VER Top Line 7.01.0 DEVICE ADDRESS 1 ALPHACELL OTHER FLOAT V/C 2.27 ACCEPT V/C 2.40 TEMP COMP 5mV BATT CAPACITY 100Ah STANDBY TIME 65 M STANDBY EVENTS 12 TOTAL RUN TIME 365D SELF TEST OFF TEST INHIBIT — TEST DURATION 10 M FREQ RANGE 3.0HZ TAP SW NO PIM OPTION YES RESET OUTPUT 1 — RESET OUTPUT 2 — OVER CURR 1 15.0A OVER CURR 2 15.
4.3 Smart Display Modes, continued 4.3.4 Menu Structure/Navigation (from Operation Normal screen) To Single-step Back to Auto-Scroll To Self-test + To COMMS INFO To Operation Normal OPERATION NORMAL (Auto-Scroll ) OPER MODE = LINE INPUT VOLTAGE 120V OUTPUT VOLTAGE 89V OUTPUT 1 CURRENT 12.2A OUTPUT 2 CURRENT 12.0A CHARGER MODE = FLOAT BATT VOLTAGE 40.5V BATTERY TEMP 37°C CHARGER CURRENT 8.2A 12 EVENTS 65 MIN TEST: 10 MIN BATT VOLTAGE 37.
4.3 Smart Display Modes, continued 4.3.
4.4 Alarm Indications In the event of a failure, the Active Alarm displays which alarms are active and how to correct the alarm condition. Major alarms cause the red LED to flash. • Press UP or DOWN to stop Auto Scroll. Arrows on the right-hand side of the display text indicate which keys to press to display the next menu item. • Press UP or DOWN to select the alarm of interest. • Press ENTER to select the alarm and display diagnostic information. Press ESCAPE to return to the alarm list.
4.4 Alarm Indications, continued Active Alarm or Abnormal Condition Probable Causes 36 Volt battery string below 33.0 Vdc Self Test Fail (see Note 1 below) 48 Volt battery string below 44.0 Vdc Alarm during a Self-Test Inverter failure has occurred Corrective Action 1. Check/correct other alarms. 2. Check that correct AC Input Voltage is present 3. Check Battery Circuit Breaker 4. Check Battery Fuse, if installed 5. Check Battery condition and voltage 6.
4.4 Alarm Indications, continued Active Alarm or Abnormal Condition Probable Causes Configuration error Output Overvoltage Reading Failure of metering circuit on Power Distribution Board Failure of Transformer Line Isolation Alarm Failure of input relay Battery End of Discharge during Line Input Fail Output Failure Alarm Configuration Settings incorrect Output overloaded Output in short circuit Battery Temp Probe Alarm 017-805-B0-010 Rev.
4.4 Alarm Indications, continued Active Alarm or Abnormal Condition Probable Causes of Alarm Corrective Action Low Batt Volts Bad Batteries or 36 Volt battery string below 33.0 Vdc or 48 Volt battery string below 44.0 Vdc, Inverter Module not seated or AC Input Fail or Inverter Module Failure 1. Check Battery Voltage and compare to Displayed Battery Voltage 2. Check for correct battery capacity on Set-up Menu. 3. Check for AC Input Voltage present 4. Open the Battery Circuit Breaker and 5.
4.4 Alarm Indications, continued Active Alarm or Abnormal Condition Output Overload (XM2-918 HP, XM2-924HP) Active Alarm or Abnormal Condition Batt Temp Probe Input Failure Alarm States Corrective Action Overload Indication Current Range (approx. %) Alarm, no shutdown 105 to 107.5% Alarm, shutdown in 30m 107.5 to 112.5% Alarm, shutdown in 10m 112.5 to 125% Alarm, shutdown in 30s >125% Alarm, shutdown in <15 Short circuit Corrective Action 1. Check Output current on the display.
4.4 Alarm Indications, continued Active Alarm or Abnormal Condition Probable Causes Output 1 Tripped Output 1 hardware protection mode engaged (only active with optional PIM installed) 1. Over Current 2. Check Settings Output 1 Tripped Output 1 hardware protection mode engaged (only active with optional PIM installed) 1. Over Current 2.
4.5 Smart Display LEDs Two LEDs on the Smart Display indicate the condition and status of the Intelligent CableUPS. The green Output LED, when lit, indicates the power supply is functioning normally and supplying output AC to the load. A flashing output LED indicates that a minor alarm has been detected. If the Output LED is off, a major alarm has been detected. The red Alarm LED flashes to indicate a major alarm has been detected. This state clears when the alarm is no longer present.
4.6 Smart Display Glossary Battery Capacity: The capacity of the battery strings attached to a particular Intelligent CableUPS. When batteries are not attached, the setting must be programmed to “0.” This disables standby operations, including test mode and disables the No Batteries Alarm. If batteries are attached, then this setting should be programmed to the total rating of all the battery strings. This setting can be programmed to higher values to accommodate multiple battery strings (i.e.
4. 0 Operation, continued 4.6 Smart Display Glossary, continued Overcurrent Tolerance Period: An output overcurrent condition is tolerated on either of the PIM outputs for this amount of time. When this delay expires, the output protection relay disables the output. This parameter is only visible when a PIM is installed. Reset Output 1, Reset Output 2: Programming this feature resets the corresponding output in the event one or both outputs are tripped.
4.7 Automatic Performance Test Automatic Self-Test: An automatic self test can be periodically performed to verify the state of the batteries and the inverter circuitry. The automatic test feature has several programmable parameters that determine the frequency and duration of automatic tests. In addition to automatic testing, the operator can manually initiate a self-test by pressing ENTER and DOWN simultaneously. A running test may be halted manually by pressing ENTER and DOWN a second time.
4.8 Providing Power via Portable Generator or Inverter In the event of an extended utility failure, an external AC or DC power supply can provide backup power to the system. This backup power enables the power supply to continue charging the batteries ensuring interrupted service to the network. Follow the documentation and connection procedures listed below. 4.8.1 DC Powering The AlphaGen Portable Generator provides a convenient method of providing backup DC power.
4.9 Providing Power via Portable Generator or Inverter, continued 4.8.2 AC Powering, continued 4. After the generator is properly grounded, unplug the power supply from the convenience outlet inside the enclosure and plug the power supply input cable into the generator output. Use an NEC or UL approved extension cord. 5. Start and operate the generator according to the generator operation manual. 6.
4.9 Resumption of Utility Power WARNING! Use caution when disconnecting and reconnecting a generator to utility power. Dangerous voltages are present. CAUTION! Exercise care to ensure that both powering systems are not connected at the same time or damage to the power supply and the generator may result. 1. Before turning on the AC voltage input breaker, use a voltmeter to verify the input voltage is within specifications. 2.
5.0 Intelligent CableUPS Maintenance A routine maintenance program, performed every three to six months, ensures the Intelligent CableUPS will provide years of trouble-free operation. Good battery care is the first step in any power supply maintenance program. In addition to voltage checks, visually inspect the batteries for signs of cracking, leaking or swelling.
5.2 Battery Charger Voltage The advanced three-stage charging features of the Intelligent CableUPS are completely selfmonitoring. During normal power supply operations, the power supply continuously verifies the operating condition of the battery charger. If, for any reason, the battery charger fails, a Charger Fail alarm displays on the Smart Display. No operator voltage checks are required. 5.3 Battery Terminals and Connecting Wires • Check each battery terminal and connection.
5.7 Inverter Module Maintenance 1. Carefully remove the inverter module assembly (see Section 2.3, Inverter Module Removal and Installation). 2. Inspect the inverter module for signs of dust or corrosion. CAUTION! Circuit boards are static-sensitive and must be handled with care. 3. On legacy models: Remove the inverter module’s cooling fan shroud and clean the fan’s foam filter. Verify the fan rotates easily and is free of obstructions.
5.
5.9 Repair Record Use this form to note the specifics of required service for the power supply and as a reference for use in the event the power supply requires service at an Alpha repair facility. RMA Number Date/Time (local) Site No. / Address / Location Power Supply Serial Number Inverter Module Serial Number Alarm Corrective Action Taken 82 017-805-B0-010 Rev.
6.0 Specifications 6.1 Intelligent CableUPS North American Models The following table shows the electrical, mechanical and physical specifications for the North American models of the Intelligent CableUPS.
6.2 Intelligent CableUPS International Models The following table shows the electrical, mechanical and physical specifications for the International models of the Intelligent CableUPS.
6.3 Safety and EMC Compliance North American Product Compliance (60Hz Models) Safety (NRTL/C) UL1778 and CSA C22.2 No.107.1, CSA C22.2 No. 107.
7.0 Return and Repair Information In the event you need to return the Intelligent CableUPS.to Alpha Technologies for service, a Return Material Authorization (RMA) form must accompany the unit. The form can be found at Alpha’s Web site (www.alpha.com/rma). Follow the instructions contained in the form to obtain an RMA. Once an RMA number has been issued, pack the unit per instructions and return to the service center assigned by Alpha Technologies.
7.1 Emergency Shutdown The Intelligent CableUPS contains more than one live circuit. During an emergency, utility power can be disconnected at the service entrance or main electrical panel to protect emergency personnel. However, power is still present at the output. To prevent the possibility of injury to service or emergency personnel, always follow this procedure to safely shutdown the power supply. Emergency Shutdown Procedure: • STEP 1: Turn the battery breaker to OFF.
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Alpha Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 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 Industrial Power Inc.
