ACS HP Series Battery Charger Quick Start Guide Effective: December 2011
Power Alpha Technologies ®
ACS HP Series Battery Charger Quick Start Guide Effective Date: December, 2011 © 2011- Alpha Industrial Power 1075 Satellite Blvd, Suite 400, Suwanee, GA 30024 Tel: 1-800-996-6104 Fax: 1-678-584-9259 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.
Contents SAFETY NOTES.................................................................................................................... 5 IMPORTANT SAFETY INSTRUCTIONS................................................................................ 5 GENERAL SAFETY PRECAUTIONS.................................................................................... 6 1.0 Introduction..................................................................................................................
SAFETY NOTATION Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Industrial Power, Tel: 1-800-996-6104 Fax: 1-678-584-9259 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.
GENERAL SAFETY PRECAUTIONS: This unit and its associated hardware must be serviced only by qualified, authorized personnel. Unit must remain locked at all times, except when authorized service personnel are present. Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors, wiring, or batteries. Read and follow all installation, equipment grounding, usage, and service instructions included in this manual.
Utility Power Connection Notes 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 system.
What This Manual Covers This user’s manual contains important technical instructions to be followed by qualified personnel for the installation, start-up, and maintenance of this unit. It is recommended that this manual be read closely to ensure and reliable operation of this equipment. Who Should Read This Manual The Product Safety Information chapter and the Operation chapter are intended for anyone who will be operating the ACS HP Series Battery Charger.
1.2 Theory of operation Please refer to the power circuit block diagram on the following page for a theory of operation of the ACS HP switched mode AC-DC conversion system. The 187-312 VAC, 50/60 Hz input is fed through a circuit breaker into a full wave rectifier, which in turn provides a 120 Hz (340V peak) pulse train to an input filter circuit. The input filter provides a nominal 290 VDC "raw supply", with approximately 30 VP-P 120 Hz ripple, to the transistor switching circuit.
1.2 Theory of operation, continued 1.0 Introduction 10 Fig.1-1, Simplified Block Diagram AIP900-0012-B0-001 Rev.
1.3 System Components The ACS HP Series Battery Charger is comprised of a number of individual subsystems designed to work together to provide highly reliable, filtered power in support of the load. A typical system will contain the following: 1. Blank equipment panel. 2 3 4 3. Cordex Controller CXCR: Controls the entire AC and DC power system.
1.4 Specifications Specifications Standard Features (continued) Electrical Control Functions Input: Phase: 1 or 3 Automatic, scheduled, or manual float charging (adjustable) Automatic, scheduled, or manual equalize charging (adjustable) High/Low voltage alarm setting (adjustable) Charge current limit (adjustable) Automatic or manual battery testing Battery capacity and runtime prediction Temperature compensation Frequency: 45 to 70Hz Daily Statistics: Current: 23A/module-nom.
2.1 Installation Notes • The ACS HP Series Battery Charger is designed to be installed in a controlled environment, sheltered from rain, excessive dust and other contaminants. • The system arrives pre-wired, and the installer is responsible for connecting the utility input to the system, the battery strings, and the system to the load. • All wiring must be in accordance with applicable electrical codes. • Access to connection points is provided from the front of the system rack.
2.2 Recommended Installation Layout Verify input (supply) wiring has been run to site in accordance with applicable local and national electrical codes. The ACS Series system is heavy equipment. To prevent personal injury or equipment damage, use lifts and extreme care when handling. Ventilation and Cooling: The rectifier/charger is rated to better perform within 18°F (–10°C) and 122°F (+50°C) temperature range.
2.3 Electrical Connection and Wiring Always refer to the ACS system electrical schematic diagram for proper installation. Before connecting the ACS Series Battery Charger insure that: The battery is disconnected (if applicable) The circuit breakers are “OFF” The relays, fuses and circuit boards are installed The unit is wired in accordance with the instructions (refer to the wiring connections and electrical diagram) Wire size is very important.
2.4 Installing the Rectifier Modules Before installation, verify all upstream and downstream circuit breakers are in the OFF (open) position. NOTE: The Rectifier shelves are factory-installed and pre-wired. In the event a shelf requires removal or replacement, contact Alpha Industrial Power service at 1-800-996-6104. 2.0 Installation 16 Fig. 2-2, Rectifier Module Rectifier Module Installation Procedure: 1. Load the first module in the leftmost position on the shelf.
3.1 Placing the System into Service CAUTION! This procedure must be performed by a qualified service technician. WARNING! To meet North American safety standards, do not change the output voltage and frequency settings. NOTE: Perform each step and verify no alarm conditions exist upon completion of the step. If an alarm condition exists, determine the cause of the alarm and correct before proceeding to the next step. 3.1.1 Initial Start-Up Before applying input power, verify the following: 1.
3.2 Rectifier Operational Status 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. NOTE: For detailed installation, operation and fault diagnosis information, refer to the Cordex 1254.4kW Modular Switched Mode Rectifier technical manual (p/n 010-589-B2). 1 2 3 3.0 Operation 18 Fig.
3.3 CXC Controller Operational Status The Charging system is shipped with the Cordex CXC Controller pre-installed. Detailed information regarding installation, operation and fault diagnosis can be found in the Cordex Controller technical manual (018-570-B2). Fig. 3-2, Cordex Controller Front panel 3.3.1 Startup and Reset Procedure When the CXC is powered-up or reset, it will first perform a 15-second self-test before displaying the Cordex logo and various identification messages.
3.3 CXC Controller Opeational Status, continued 3.3.2 Normal Operation This is the default-operating mode or “home page.” The GUI displays system status information and monitors all input channels. Active areas to tap and activate are noted below: Analog Signals Display Mode Status Rectifiers Information Converter treport may also be accessed via this area Alarm Condition Icon Alarm Indication Priority Icon Date and Time Software Version Home Page Icon, tap to login 20 Fig.
Emergency Shutdown Procedure CAUTION! WARNING! In an emergency, Line power may be disconnected at the service entrance or main electrical panel to protect emergency personnel, but there can still be AC power present at the UPS output. You must always turn OFF the battery circuit breaker. 1. Turn OFF the battery Circuit Breaker of the UPS. 2. Turn OFF the Generator (if connected). 3. Turn OFF the input Circuit Breaker of the UPS. 4. Disconnect the AC input power to the UPS. 5.
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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.
