Alpha Modular Power System 24 HP Installation & Operation Manual Part # 0260011-J0 Effective: 03/2012 member of The Group™ Your Power Solutions Partner
Alpha Modular Power System 24 HP Installation & Operation Manual NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation. NOTE: Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If there are questions regarding the safe operation of this powering system, contact Alpha Technologies or your nearest Alpha representative.
Table of Contents 1. 2. Safety ������������������������������������������������������������������������������������������������������������������������������ 6 1.1 Safety Symbols ����������������������������������������������������������������������������������������������������������������������������� 6 1.2 General Safety ������������������������������������������������������������������������������������������������������������������������������ 7 1.
.3 DC Battery and Ground Cabling ������������������������������������������������������������������������������������������������� 38 5.4 DC Ground ���������������������������������������������������������������������������������������������������������������������������������� 41 5.5 AMPS24 HP with External Maintenance Bypass Switch ������������������������������������������������������������ 42 6. 7. 5.
10.4 Inverter Parameters (ID 51 – 550) �������������������������������������������������������������������������������������������� 91 10.5 Alarm Settings (ID 551-950) ������������������������������������������������������������������������������������������������������ 97 11. Warranty ���������������������������������������������������������������������������������������������������������������������� 99 11.
Figure 25 — Controller default home screen ������������������������������������������������������������������������������������� 45 Figure 26 — Placement of initial inverters (shown for split phase system) ���������������������������������������� 46 Figure 27 — Inverter module showing AC input LED ������������������������������������������������������������������������ 46 Figure 28 — Unlocking and locking an inverter module for removal or insertion ������������������������������� 47 Figure 29 — Inserting an
List of Tables Table A — Eight-pin Terminal Strip from AMPS 24............................................................................. 15 Table B — Pinouts for 40 Pin Connector Interface to CXCR.............................................................. 16 Table C — 10.5kVA, 9kVA and 4.5kVA, 120V Single Phase 3i+1R Shelf Systems............................ 23 Table D — 12kVA and 6kVA, 120V Single Phase, 4i Shelf Systems..................................................
1. Safety SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. 1.
1.2 8 General Safety • Only qualified personnel shall install, operate, and service the power system and components. • Observe all applicable national and local electrical and building codes during installation. • Mount the AMPS24 HP system in a rack that is securely bolted to the floor. • Always assume electrical connections and/or conductors are live. • Turn off all circuit breakers and double-check potentially charged components with a voltmeter before performing installation or maintenance.
1.3 1.4 • A disconnect switch shall be provided by others for the AC input and AC output circuits. • Risk of Electric Shock and Fire Hazard: replace fuse with the same type and rating. External Battery Safety • The power system requires an over-current protection device for the external batteries. The maximum allowable current is typically 450A but can be less depending on the model. Follow the local electrical codes. • Ensure that the external battery connection is equipped with a disconnect.
1.5 Equipment Grounding To provide a ready, reliable source of backup power, the power system must be connected to an effective grounding and earthing system. The grounding system must be designed to protect both personnel and equipment. WARNING! Low impedance grounding is mandatory for personnel safety, critical for the proper operation of the system, and must be in place and connected to the system before the supply cables are connected. 1.5.
2. Product Description The Alpha Modular Power System 24 HP (AMPS24 HP) is a unique, high performance AC power system that is designed to provide highly reliable back-up power to cable headend, telecom or server room facilities. The AMPS24 HP features hot swappable 1.5 kVA/1.2 kW AC power modules and optional 1.8 kW rectifier modules that are the building blocks of a highly reliable power system with 99.999% availability, 93% efficiency, and high power density.
Boost AC Mains 400 Vdc DC In CAN bus external communication DSP Telecom Grade AC Output Dual redundant communication and synchronization between modules AMPS modules also have a ‘Boost’ over-current feature with 10 times the rated current capacity for 20ms, allowing it to trip breakers downstream, thus protecting the load. 2.1.1 AC or DC input priority The user can choose either AC or DC input priority. If AC priority is chosen, the AMPS24 HP acts more like an on-line, double conversion UPS.
2.2 System Components The AMPS24 HP is made up of a number of individual subsystems designed to work together to provide highly reliable, filtered power in support of the load. A typical system contains the following: 1 4 3 2 12 11 13 5 7 10 6 8 9 Figure 1 — AMPS24 HP System Components 1. Inverter AC Input Breaker: Main disconnect for AC input 2.
10. Rectifier Modules (optional): Up to one rectifier per shelf. The rectifiers are used as the charging component of a 3i+1R shelf system. 11. Fuse for the graphic display for the CXCU, and V+/ V- to the controller 12. Fuse for customer use 2A load, pins #5 and #6 on 8-pin terminal strip—see section 2.3.1 on page 15. 13. Surge Suppression Modules (behind removable panel) built into the power distribution panel to protect equipment from damage caused by surges and high transient voltages.
2.3.1 User Interface On the side of the unit are two connectors. The eight-pin terminal strip is an interface to the AMPS24 with the pinouts listed in Table A. The 40-pin connector is an interface to the CXCR controller with the pinouts listed in Table B. Some pins are available for customer use. 8-pin terminal strip 8 1 2 10 19 20 21 22 39 40 To install wires in the 40-pin connector, use needle-nose pliers to remove the terminal blocks in the 40-pin connector.
Table B — Pinouts for 40 Pin Connector Interface to CXCR 1 DIN1 3 D_COM 5 DIN4 7 D_COM Fused DCFused DC- 2 DIN2 Output circuit breaker CB5 4 DIN3 MBS 6 DIN5 Input circuit breaker CB6 8 DIN6 TVSS Not Used 9 N/A 10 N/A 11 N/A 12 N/A 13 V1+ 14 T1+ 15 V1- 16 T1- 17 I1+ 18 T2+ 19 I1- 20 T2- Analog Inputs Battery temperature probe (Figure 6) Battery temperature probe (Figure 6) Relay Contacts (rated at 60VDC or 42V AC, 0.
2.5 Battery Temperature Probes Adjusting the battery’s float or equalize voltage to correspond with temperature fluctuations ensures maximum battery performance and life expectancy. The CXC’s built-in automatic temperature compensation function adjusts the system every ten minutes as the temperature changes and changes the voltage by a maximum of 0.1 V during this interval. A battery probe from a single string can be connected to pins #18 and #20 of the AMPS24 HP 40-pin connector.
2.6 Network Requirements The CXCU has a single Ethernet port on its front panel for communication with either the graphic display or a laptop. Cable that connects the CXCU to the graphic display CXCU RJ45 connection Figure 8 — Cable connection to CXCU for graphic display 2.6.1 Single Connection The graphic display, which uses a browser to launch CXC web pages, is installed in the DC distribution shelf (see Figure 1). This display connects to the Ethernet port on the front of the CXCU.
2.6.
3. Power Configurations This section lists the power configurations available with the AMPS24 system and defines the terminology used throughout this manual. 3.1 Power System Configuration Terminology 3.1.1 120Vac Single Phase A single phase system is 120Vac from L1 to N (neutral). 3.1.3 L1 120/240Vac Split Phase The term 120/240Vac SPLIT PHASE is used throughout this manual to identify the “3-wire/ 2 legs from a single phase supply” configuration shown in Figure 11.
3.2 4i Shelf Systems (No Battery Charger) The 4i systems, with up to 4 AIM1500 modules per shelf, do not have an integrated 48V charger. The following table shows available configurations: refer to the section in the last column for more details. System Part Number 3.3 Max AC output VA Max AC output power 0260012-201 6kVA 4.8 kW 0260012-203 12kVA 9.6 kW 0260012-202 (no LCD) " " 0260012-204 12kVA 9.
3.5 120V Single Phase Systems See the facility planning data sheets for the two configurations shown below: • "Table C — 10.5kVA, 9kVA and 4.5kVA, 120V Single Phase 3i+1R Shelf Systems" on page 23 • "Table D — 12kVA and 6kVA, 120V Single Phase, 4i Shelf Systems" on page 24 Configurations for a Single Shelf • 4i shelf • 3i+1R shelf DC 1 Phase 1 Configurations for Two Shelves • two 4i shelves • two 3i+1R shelves • one 3i+1R shelf and one 4i shelf DC 1 Phase 1 DC 2 22 Doc.
NOTE: The recommendations in Table C are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes. Table C — 10.5kVA, 9kVA and 4.5kVA, 120V Single Phase 3i+1R Shelf Systems AC Input Models AMPS24-1-10.
NOTE: The recommendations in Table D are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes.
3.6 120V/240V Split Phase or 120/208V 2-Pole Systems For facility planning data sheets, see • "Table E — 21kVA, 18kVA, & 9.
NOTE: The recommendations in Table E are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes. Table E — 21kVA, 18kVA, & 9.
NOTE: The recommendations in Table F are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes.
3.7 120V/208V 3-Phase Systems For facility planning data sheet, see "Table G — 18kVA and 13.5kVA, 120V/208V 3-Phase Systems" on page 29. Configurations for 3-Phase Three Shelf 28 • three 4i shelves (AMPS24-3-18-i3) • three 3i+1R shelves (AMPS24-3-13.5-H3) DC 1 Phase 1 DC 2 Phase 2 DC 3 Phase 3 Doc.
NOTE: The recommendations in Table G are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes. Table G — 18kVA and 13.5kVA, 120V/208V 3-Phase Systems AMPS24-3-18-i3 (4i Shelf) AMPS24-3-13.5-H3 (3i+1R Shelf) 120/208V 120/208V 56A 59A AC Input poles & wiring 4w+G 4w+G Wiring 3Ф Wye 3Ф Wye SCCR 1600A 1600A 80A 80A NEC 50ºC 4 4 CEC 50ºC 3 3 18 kVA/ 14.
3.8 AMPS24 HP - Recommended DC Breaker and Wire Sizes NOTE: The recommendations in this table are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes. Maximum wire gauge size is 350 kcmil; 4/0 or smaller is recommended, 90°C or better copper only.
3.9 How to Configure Inverters in AC Input Groups, AC Output Groups and DC Input Groups The following sections show how to distribute the inverters among the phases and also suggests how to distribute the DC input to the inverters. NOTE: The groups in the software settings generally correspond to the AC phases or DC inputs. 3.9.1 AC Input Groups/ AC Output Groups The CXCU System Controller provides an interface to assign inverters to phases (Inverters > Group Mapping).
3.9.2 DC Input Groups DC feed from the batteries to the inverters is protected by input breakers. The numbering of each DC input breaker corresponds to the shelf it protects: DC3 input breaker, for example, protects shelf 3. shows a four shelf, split phase system with the breakers and corresponding shelves labeled.
4. System Pre-Installation 4.1 Site Selection The power system must be mounted in a clean and dry environment. Consider both the floor loading and the physical space required for the AMPS24 HP power system and the batteries. 4.1.1 Floor Plan Layout Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the power system and to allow easy access to the power system components.
4.3 Transporting the Cabinet The cabinet is shipped upright on a 99 cm x 99 cm (39" x 39") pallet. The height of the rack, including pallet and shipping material is 31" (78.7 cm). The maximum weight of the AMPS24 rack is 123 kg/ 270 lb (4-shelf fully loaded AMPS24 modules included). Figure 15 — Shipping dimensions (in inches) 34 Doc.
4.4 Unpacking Instructions 1. Remove 4 front screws. 2. Remove the screws that are holding the AMPS24 against the inner frame of the packaging (the # of screws varies depending on the size of the AMPS24 unit, i.e. 1 shelf vs. 4 shelves). 3. Remove the 6 nails that hold the entire packaging down on the skid (3 nails on each side of the box). 4. Remove entire wooden box up and over the AMPS24. Doc.
5. Installation The AMPS24 is designed for installation in a controlled environment, sheltered from rain, excessive moisture, dust and other contaminants. Mount the AMPS24 HP system in 19" or 23" rack – front or mid-mount – that is securely bolted to the floor. The system arrives pre-wired, and the installer is responsible for connecting the following: 5.
Carefully review the following schematic and notes 1 through 7 before beginning the AC input and output, and DC wiring. Figure 16 — AMPS24 Power and Battery Connections Notes 1. All wiring must be in accordance with applicable electrical codes. 2. A low voltage battery disconnect (LVBD) should be provided with the battery system. 3. Inverter main input must always include a neutral connection. 4. Power and control cables must be in separate conduits. 5.
5.2 AC Wiring The two figures below provide both a representation of the AC wiring connections (Figure 17) as well as an actual unit wired for 3-phase AC power (Figure 18). N out N in L1 out L1 in L2 out L3 out GND out GND in L3 in L2 in Figure 17 — AC Wiring connections diagram Customer connections Figure 18 — AC Wiring (shown for 3-phase) 38 Doc.
5.3 5.3.1 DC Battery and Ground Cabling Hardware and Torque Specifications The DC wiring is attached with 3/8” hardware (1” bolt, washer, spring washer) and 8 are provided with each AMPS24 system (2 per each of the 4 bolting locations). However, the crimp or lug is not provided. The crimp/lug can either be on 1” centers with 3/8” or ½” holes, or 1.75” centers with ½” holes only.
5.3.3 DC Wiring Dual Feed – with Tie Bar The following figure shows a unit wired for dual feed with two battery strings in parallel. Tie Bar DC minus Feed 1 DC minus Feed 2 DC plus Feed 1 NOTE: the wire lugs shown are for illustration only. They are not supplied with the equipment. DC plus Feed 2 Ground To MGB + + AC – – AMPS24 HP Figure 20 — Dual feed, two battery strings in parallel 40 Doc.
5.3.4 DC Battery Wiring with Independent Dual A/B Feed CAUTION! Dual feed provides capacity sharing, but NO REDUNDANCY. The loss of one battery string will result in the loss of half the inverters. DC minus Feed 2 DC minus Feed 1 DC plus Feed 2 GND To MGB GND DC plus Feed 1 + + AC – – AMPS24 HP Figure 21 — DC battery wiring with independent dual A/B feed Doc.
5.4 5.4.1 DC Ground Inverter Only Systems Ground reference is at the DC source, as shown in Figure 22 AC – – + + DC Plant AC AMPS24 HP MGB Figure 22 — DC ground, inverter only systems 5.4.2 Inverter plus Rectifier System Refer to Figure 19 and Figure 20. 42 Doc.
5.5 AMPS24 HP with External Maintenance Bypass Switch An external MBS switch allows the entire AMPS24HP system to be taken offline for maintenance. Figure 23 shows the logical interconnections. It is not a detailed representation of the actual system wiring. AC 24 Figure 23 — Representative system wiring for AMPS24 HP system with MBS 5.5.1 External MBS Installation Install and test the MBS before beginning installation of the AMPS24 HP system. 1.
5.
Starting-up the system 11. Switch on the AC mains/utility power. 12. Refer to illustration "AC Wiring" on page 38 and verify the AC input voltages at the AC wiring terminals: System ALL 3 phase 2-pole Split Phase Voltage Neutral to Earth Ground Value ~0V L1 to L2, L2 to L3, L3 to L1 ~208V Neutral to L1 / L2 / L3 ~120V L1 to L2 ~208V Neutral to L1 / L2 ~120V L1 to L2 ~240V Neutral to L1 / L2 ~120V 13. Check that the battery polarity is correct. 14.
Connecting a laptop 17. If you prefer to use a laptop to connect to the CXCU controller, refer to section 2.6.1 in this manual and “Establishing a Network Connection via a Crossover Cable” section in the Cordex Controller Software manual. Installing One Seed Module per Phase You are now going to configure the system with just one inverter per phase. Position each inverter in the same shelf position per phase. Install ONLY ONE INVERTER PER PHASE.
Insertion/ Removal instructions for Inverter Modules See below for detailed module insertion/removal instructions. You may not want to close/lock the grill at this time because the module may have to be removed at a later stage. CAUTION! Improper installation or removal of modules can break latching components. Unlock Lock Insert a flat head screw driver into the center flap Leave the module plastic front grill in the open/unnotch and pry open the center flap.
21. Use the CXCU GUI as follows to verify that the modules are recognized and the voltages and currents of the modules are displayed. (Ignore any alarms at this point. The current readings at no load are not very precise.) a. Select Inverters > View Live Status. b. In the Inverter Report screen, locate the module for AC phase 1 by clicking each row until the LEDs of the inverter, in the first phase 1 shelf, flash for a few seconds. c.
22. Now that the inverter modules in each shelf have a number, use the controller to place one module in each of the AC input and output groups: a. Select Main Menu > Inverters > Group Mapping. b. Turn the inverter modules OFF by clicking the power icon Turn All Modules Off. The green power icons turn black in a few seconds. c. Match AC Input Groups to AC Output Groups by configuring the modules to the groups as shown in Figure 31. d. DO NOT TURN THE INVERTERS BACK ON. PROCEED WITH THE NEXT STEP.
23. Select Inverters -> Set Output to set the number of inverters in each phase of your system. Match the AC input phase to the corresponding AC output phase. a. Number of Modules: Enter the total number of inverter modules that will be installed for that phase. b. Redundancy: Enter the number of inverter modules that will provide redundant power for that phase (used to provide system warnings). Figure 32 — Set Output (Split Phase System) c.
WARNING! Use blanks to cover any open module slots. Do not leave any module slots open. Safe solution. Blanks must be used to cover any open module slots. Unsafe solution. Do not leave any module slots open. Figure 33 — Inserting blanks in open slots Installing remaining inverters and rectifiers 30. Install the remaining inverters. The newly installed inverter modules will clone themselves to be identical to the initial modules that were installed and set up. 31.
Final configuration and test 34. Using the CXCU controller web interface, configure any other parameters as required. Typical changes could include battery and charging values for the rectifiers in a 3i+1R shelf AMPS24 HP system or changing the low and high voltage AC and DC warning and cutout limits. 35. At this point there should be no alarms present. Investigate and correct any alarm issues. a.
6. System Operation 6.1 CXCU Controller Operation The CXCU software controls the DC + AC power system. The following sections provides a brief overview of the controller with respect to operation of the AMPS24 HP; in-depth information can be found in the current operations manual for the Cordex Controller Software. 6.1.1 Human Interface The graphical user interface (GUI) is available through a remote web interface or directly at the unit if a graphic display is installed. Refer to section 2.
6.1.3 Menu Navigation Clicking any of the Home Screen icons results in a login screen. Login with your own name. Anyone denied access will know you’re logged on. The time you spent logged in will also show up in the events log. Use one of the default passwords shown to the right. Refer to the software user manual for permissions associated with each password. 6.1.
6.1.5 Customizing the User Interface To customize alarm, signal and relay labels for your specific application, select Logs and Files > Manage Editable Text Files to change the text strings. The following example shows how to revise a text string on the Home page; in this example, the string Load Current is changed to Inverter DC Input Current. 1 Choose the label category from the drop-down menu. 3 2 Locate the text string on the left and edit it in the box on the right.
6.2 Inverter monitoring and control The Inverter menu category consists of inverter alarms, signals and settings. Parameters can be accessed such as the number of acquired inverters, output voltage/power, and source position. Other features include: input source, inventory update,inverter locate, group assignment, inverter firmware upgrade, major and minor alarms. 6.1.6 View Live Status inverter report The menu category View Live Status generates a report of all acquired inverters in the system.
6.2.1 Set Output Verify that the Phase Shift is set correctly before mapping inverters in the new groups and turning them on. Figure 38 — Set Output window CAUTION! The value entered in the Nominal Output Voltage field can change the actual AC output voltage of the inverters. Setting this value to anything other than 120 V will render the UL/ CSA approval invalid. Number of modules: The value is the number to be acquired by the CXCU.
6.2.3 Group Mapping Ensure phases are configured correctly in the Set Output menu before mapping inverters into groups and turning them on. All inverters must be turned OFF to enable the AC Output Groups radio buttons. Power Buttons – Use with caution.
6.2.4 Set Inputs Figure 41 shows the default configuration input parameters Figure 41 — Set Input window 6.2.5 General Settings This submenu of the inverter category provides setting for the following parameters: Figure 42 — General Settings window Doc.
6.2.6 Manage Config File The inverter settings have their own configuration and are not part of the full site configuration file. Refer to Chapter 10 for a list of the configuration file parameters and steps to save the file and upload it to another system. 6.2.
Alarms reported by T2S are reported in the event logs. Figure 44 — T2S alarms in event logs 6.2.8 Retrieve Inverter History File A new submenu Retrieve History File under Inverters opens a page with a Save Inverter History File button to download the inverter alarm history file to local disc. These history files can be used by service people to troubleshoot inverter alarms. Figure 45 — Retrieve alarm history file Doc.
6.2.9 Signals The Inverter Signals category (under Main Menu > Signal > View Live Status) displays inverter signals for all of the acquired inverters in the system. These signals can be used for logging and equation building. Figure 46 — Signals (inverters) window 6.2.10 Auto DC Priority The inverters can be configured to switch to DC Priority mode when a custom alarm is tripped.
6.3 Inverter Module Indicators AC output DC input AC input Output power indicator LEDs Status LEDs Figure 48 — Inverter module status, power LEDs 6.3.
6.4 Rectifier Module Figure 50 shows the Cordex 48-1.8kW can be used in the AMS24 HP systems to provide battery charging thumbscrew latch that secures the rectifier into the shelf. During normal operation the rectifier is locked into position. A handle (or grip) is incorporated into the front panel to facilitate the removal of the rectifier from the shelf. No special tools are required. LEDs Handle Thumbscrew Latch Figure 50 — Cordex 48-1.8kW 6.4.
The LED flashes (~2Hz) when a minor alarm is detected if the module's output capability has been reduced or a minor component failure is detected during the following conditions: VAC meter fail AC foldback Remote equalize Fan fail Low output voltage High output voltage Current limit (programmable option) Power limit High temperature foldback (programmable option) Temperature sense fail Soft start operation Communications lost The LED remains extinguished in the absence of an alarm.
6.4.4 Over Temperature Protection Each rectifier module is protected against an excessive increase in temperature caused by a component failure or a cooling airflow blockage. During over-temperature conditions, the rectifier limits the output power and the output current. If the temperature continues to increase, a shutdown of the rectifier is initiated. The rectifier restarts automatically when the temperature returns to a safe level. 6.4.
6.4.10 Power Limiting Each rectifier module is designed to limit the power output to the module specification. This enables more current to be supplied at lower output voltages, and allows matching the output power to the demands of constant-power loads often seen in telecom equipment. This feature may also be used for a faster recharge of flooded batteries paralleled with the load. NOTE: The current limiting feature overrides the power-limiting feature. 6.4.
7. Preventive Maintenance This equipment requires regular maintenance. Maintenance must be performed by qualified service personnel only. Contact Alpha Technologies at 1-888-462-7487 for any assistance with maintenance. WARNING! WARNING: HIGH VOLTAGE AND SHOCK HAZARD Use extreme care when working inside the enclosure/shelf while the system is energized. Do not make contact with live components or parts. Static electricity may damage circuit boards, including RAM chips.
Table I — Tools Required Service /Maintenance Commissioning 7/16" ratchet socket X 7/16" ratchet socket extended neck X 9/16" ratchet socket X 9/16" ratchet socket extended neck X 5/8" ratchet socket X 5/8" ratchet socket extended neck X 10 mm combo wrench X 10 mm flat gear ratchet X 3/8" Allen key on a 3/8" ratchet socket X X 3/16" Allen key on a 3/8" ratchet socket X X Flash light or trouble light X X Crossover Ethernet cable X X Straight through Ethernet cable X X Compu
Table J — Spare Parts P/N Part Description 162-601-19 Surge suppression replacement module, green stripe, Neutral-Ground, 40kA rating 0190017 Netgear JFS516 network switch 7.4 Replacing a Rectifier The Cordex Converter (CXD) Rectifier (CXR) series modules are plug and play. When a rectifier module is added to the system, the CXC will detect and update the inventory automatically.
7.7 Replacing the Surge Suppression Module WARNING! There may still be live parts inside the system and shock hazards may be present throughout this procedure. At the AMPS24 front panel, 1. Turn off the Inverter AC Input breaker. 2. Remove the wiring access panel. 3. Pull out the surge suppression module. 4. Replace the module with one of the same type.
7.8 Fuse Replacement CAUTION! Risk of Electric Shock and Fire Hazard: replace fuse with the same type and rating. 7.8.1 Rectifier Fuse Replacement WARNING! Remove all input AC and DC power to the AMPS24 HP before starting this procedure: set an external bypass switch to BYPASS mode or turn off the AC mains. Disconnect battery feeds. Refer to "Table J — Spare Parts" on page 69 for the part number of the fuse.
7.8.2 Replacing the Fuse for the LCD touch screen (for the CXCU) Refer to "Table J — Spare Parts" on page 69 for the part number of the fuse. The fuse for the LCD touch screen is located on the front of the DC distribution panel (see Figure 53. 1. Push and turn simultaneously to release the fuse. 2. Replace with fuse listed in Table J on page 69. Fuse Figure 53 — Fuse location for LCD touch screen Doc.
7.9 7.9.1 Synchronization with a Maintenance Bypass Switch (MBS) Internal Maintenance Bypass Switch Implement the following sequence before switching the unit from bypass mode to inverter mode. Switching from Bypass Mode to Inverter (On-line) 1. Switch on the Inverter AC Input breaker. 2. Wait for the inverters to synchronize to the line—all status LEDs on the inverters will turn green. 3. Switch on the Inverter AC Output breaker. 4.
8. 8.1 Troubleshooting Non Recoverable Error Inverter status LEDs Output power status LEDs 8.1.1 Inverter The status LEDs illuminate solid red when a non recoverable error occurs. As a result of its double input port, the AMPS24 HP inverter module will stop when either the output stage is non-recoverable or when both input stages are faulty. 8.2 • Attempt to clear fault condition by removing and reinserting the module • Download CXCU inverter alarm logs (see section 10.
All alarm codes are listed in Table K including the following codes. They are listed here to provide further information. No Ethernet Communication For a direct connection to the CXCU, verify the following: • A cross-over cable is installed • Wireless connection is turned off Verify the settings of the local area network connection as follows: 1. In Windows®, select the Start menu, Control Panel, and then select Network Connections. 2.
Manually Off (83) The Manually Off alarm occurs when one or more inverters have been turned off in the Group Mapping screen. Black indicates the inverter is off. Doc.
Table K — Inverter Alarm Codes Alarm Type Description Cause Solution Error Not Recoverable 78 0 NO ERROR No error present on the system N/A N/A 1 FAN FAILURE Failed fan or speed inappropriate Dust on FAN or FAN failure Replace fan or clean it 2 TEMP TOO LOW Measured temperature inside the module is below -20°C The temperature sensor Replace the module.
Table K — Inverter Alarm Codes Alarm Type Description Cause Solution 13 Vout INVERSE Error in the self-test during the starting process This error happens if the module is not configured on the correct output phase Verify the phase configuration of the modules. Then, reset the module and try again. If the problems still happens, replace the module 14 OVRLOAD TOO LONG Output voltage too low due overload for a long time Load too higher for the inverter quantity operational on system.
Table K — Inverter Alarm Codes Alarm Type 80 Description Cause Solution 44 BACKFEED ERROR ACin is supplied by the ACout of the module Grid is not present and there is a short circuit between ACin and ACout 45 Vint TOO HIGH Same as error 10 but recoverable 65 TSI COM BUS FAIL The inverter doesn't see itself on the bus TSI Communication problem Hardware problem. Replace inverter 66 T2S COM BUS FAIL The inverter doesn't see itself on the bus T2S Communication problem Hardware problem.
Table K — Inverter Alarm Codes Alarm Type Description Cause AC in below 100V - reduce power from the AC input and pull power from the DC input Solution 80 BROWNOUT DERATING The nominal power is not available from the AC Grid. The inverter could compensate from DC source.
Table K — Inverter Alarm Codes Alarm Type Description Cause Solution 178 STATUS 178 179 Vac_in TOO LOW The input grid is below the preset range Check AC In configuration and live value Check AC grid and configuration 180 Vac_in TOO HIGH The input grid is above the preset range Check AC In configuration and live value Check AC grid and configuration 181 Fac_in TOO LOW Input frequency is lower than the preset value Check AC In configuration and live value Check AC grid and configuration 1
Table K — Inverter Alarm Codes Alarm Type Description Cause Solution 229 REDUNDANCY LOST 229 and text "Redundancy Lost" when the condition is true Lost of inverter redundancy Replace defective inverter or adapt configuration 230 REDUND + 1 LOST Generate alarm code 230 and text "Redundancy + 1 Lost" when the condition is true Lost of inverter redundancy + 1 inverter Replace defective inverter(s) or adapt configuration 231 SYS SATURATED Generate alarm code 231 and text "Sys Saturated" when the
Table K — Inverter Alarm Codes Alarm Type 243 84 T2S FLASH ERROR Description Flash of T2S is corrupt and has failed Cause T2S failure Solution Hardware problem. Replace T2S Doc.
9. System Specifications 9.1 Power De-rating Due To Altitude The AMPS24 HP runs at full power up to an altitude of 1500 m, then derates by 8% for every 1000 m of elevation increase. The AMPS24 HP is not designed to operate at elevations above 5000 m. 9.2 Power De-rating Due To Temperature Derating alarm triggered Actual system derating occurs 120 % VA Load 100 80 60 DC mode Derating 40 20 0 25 30 35 40 45 50 55 60 Ambient Temperature (C) Doc.
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9.5 Specifications for 48-1.8 kW Rectifier (P/N 010-621-20-040) Rectifier Module Input Voltage, Output Current, Power AC Input Voltage 3i+1R shelves Max # of Rectifier Modules Max DC output 120 4 4 150 Adc 120/240 Vac 4 4 150 Adc Current (Adc) Power Module Output Voltage 42 to 60 Vdc within rated limits Current 37.
10. Configuration Parameters The inverter settings have their own configuration file which is not part of the full site configuration file. The default configuration settings, described in the following sections, are presented in a logical manner, but in reality they are one contiguous file. All available parameters are described in this section, though not all are used in a basic installation.
10.2.2 Changing the Synchronization Tracking Speed Operation This parameter sets the speed with which the module tries to synchronize ACout. 1. Save the inverter configuration file to a local disk (Main Menu > Inverters > Manage Config File). 2. Open the file with a text editor. 3. Scroll down to Synchronization Tracking Speed ;100; ;Synchronization Tracking Speed; ;0; ;; 4. Change the default to one of the values from the following table: Value Tracking speed, Hz/sec -2 2 -1 1 0 0.5 +1 0.
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;80; ;81; ;82; ;Short Circuit Voltage Threshold; ;91; ;92; ;100; ;V; xx Minimum Voltage Threshold where module considers that outlet is in short circuit xx Adjustable from 20 to 100 Vac, default: 80 Vac ;Short Circuit Hold Time; ;60.0; ; sec; xx Time Duration when the module tries to eliminate the short-circuit existing on the outlet xx When this time expires and the voltage is less than the value on line 80, the module stops. xx Adjustable from 0.
;101; ;102; ;Remote OFF disable ACin Power; xx 0 –> Normal mode, default xx 1 –> ACin power is de-activated ;Negative Power (0 : OFF, 1 : ON); xx ;103; ;0; ;; ;1; ;; ;0; ;; 1 –> ON, default ;External clock (0 : OFF, 1 : ON); xx 0 no in service protection xx 1 in service protection ;160; ;OUT 1 : phase shift (-180 to 360, default 0); ;0; ;deg; ;161; ;OUT 1 : Nominal Output Voltage (100 to 140); ;120; ;V; xx Record of the phase shift and nominal Outlet voltage.
;261; ;262; ;263; ;264; ;265; ;DC 1 : Vdc_in Low Transfer; ;42; ;V; xx Low DC Voltage – a lower value transfers the load from DC/AC to AC/AC converter. xx Range: 39 to 61, default: 42 V ;DC 1 : Vdc_in Low Stop; ;42; ;V; xx Low DC Voltage – a lower value causes the DC/AC converter to stop.
;290; ;DC 4 : Vdc_in Low Start; ;49; ;V; ;291; ;DC 4 : Vdc_in Low Transfer; ;42; ;V; ;292; ;DC 4 : Vdc_in Low Stop; ;42; ;V; ;293; ;DC 4 : Vdc_in High Start; ;58; ;V; ;294; ;DC 4 : Vdc_in High Transfer; ;61; ;V; ;295; ;DC 4 : Vdc_in High Stop; ;61; ;V; xx The same as Group DC 1 ;300; ;DC 5 : Vdc_in Low Start; ;49; ;V; ;301; ;DC 5 : Vdc_in Low Transfer; ;42; ;V; ;302; ;DC 5 : Vdc_in Low Stop; ;42; ;V; ;303; ;DC 5 : Vdc_in High Start; ;58; ;V; ;304; ;DC 5 : Vdc_in Hi
;381; ;382; ;383; ;AC 1 : Vac_in Low Transfer; ACin Voltage where a lower value transfers the load from the AC/AC converter to the DC/ AC converter xx Range: 80 to 143, default: 81.5 V ;AC 1 : Vac_in Low Stop; ; 81.5; ;V; xx ACin Voltage where a lower value causes the AC/AC converter to stop xx It is possible to step down to 150 Vac. In this case, the AC/DC converter runs at a lower power.
10.5 Alarm Settings (ID 551-950) Global Parameters (ID: 551-600) ;551; ;553;; ;Alarm on prog. relay (255 is NU); Replace 255 by the Alarm Code you wish for programming the relay user selectable 3 xx See previous codes for the T2S and Enclosed list for the TSI.
;829; ;228.DIG INP2 FAILURE; xx ;830; ;831; ;832; ;833; ;834; ;835; ;; ;1; ;2; xx Type of alarm when Main source is lost xx In AIM2500 mode : Main source is ACin = Network xx In ON LINE mode : Main source is DCin = battery ;233.SEC SOURCE LOST; ;; ;1; ;; ;; xx Activates when Secondary source is lost xx In AC/AC mode : Secondary Source is DCin = battery xx In ON LINE mode : Secondary Source is ACin = Network ;234.T2S BUS FAIL; Doc.
11. Warranty Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized location during the warranty period. There are limitations to this warranty coverage.
12. Certification About CSA and NRTL CSA (Canadian Standards Association also known as CSA International) was established in 1919 as an independent testing laboratory in Canada. CSA received its recognition as an NRTL (Nationally Recognized Testing Laboratory) in 1992 from OSHA (Occupational Safety and Health Administration) in the United States of America (Docket No. NRTL-2-92). This was expanded and renewed in 1997, 1999, and 2001.
Index self-test at startup 52 user interface 54 A AC Configuration AC Input Groups 30 AC Output Groups 30 AC wiring AC input breaker 12 AC output breaker 12 connections diagram 37 pre-configured from the factory 35 torque setting 43 Alarms AC Mains Lost (232) 75 AC Secondary Source Lost (233) 75 inverter custom 59 standard 59 inverter alarm codes 77 saturation level alarm 88 System Saturated (231) 75 Auto DC Priority 61 B Customer Connections 40 pin connector pinouts 15 eight-pin terminal strip 14 D DC
transfer config file 88 specifications 86 L Login 53 Logs and files editing text files 54 generating an inverter report 55 saving inverter config file 88 Low voltage battery disconnect wiring to 40 pin connector 15 LVD LVD #1 relay contacts 15 M part number 68 replacing 71 Rectifiers 1.
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 Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 Alpha Industrial Power Inc.
