AMPS80 HP Power System Installation & Operation Manual Part #026-069-B0 Effective 8/2012 member of The Group™ Your Power Solutions Partner
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.
6. System Operation ��������������������������������������������������������������������������������������������������������� 55 6.1 Inverter Module Indicators ���������������������������������������������������������������������������������������������������������� 55 6.2 T2S Inverter Control Card ����������������������������������������������������������������������������������������������������������� 57 7. 6.
List of Figures Figure 1 — Controller breakers on top of the AMPS80 ���������������������������������������������������������������������� 13 Figure 2 — 20 kVA split-phase or 120/208V 2-pole system ��������������������������������������������������������������� 14 Figure 3 — 40 kVA, split-phase or 120/208V 2-pole system ������������������������������������������������������������� 15 Figure 4 — 75 kVA, 3-phase systems ������������������������������������������������������������������������������������������
Figure 30 — Unlocking and locking an inverter module for removal or insertion ������������������������������� 50 Figure 31 — Inserting and removing an inverter module ������������������������������������������������������������������� 50 Figure 32 — Inverters > View Live Status ����������������������������������������������������������������������������������������� 51 Figure 33 — Matching AC Input Groups to AC Output Groups ��������������������������������������������������������� 52 Figure 34 — Inserting
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 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. • Maintain the security of all SELV Circuits in the AMPS80 when connecting to other equipment like signaling/alarm circuits, emergency power off (EPO) circuits, relay contacts, Ethernet or CANBUS. The other equipment must be the same circuit type.
• Only use insulated tools when handling batteries or working inside the enclosure. • Remove all rings, watches and other jewelry before servicing batteries. • Recycle used batteries. Spent or damaged batteries are environmentally unsafe. Refer to local codes for the proper disposal of batteries. • 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. 1.
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 80HP (AMPS80 HP) is a unique, high performance AC and hybrid AC/ DC power system that is ideally suited to provide highly reliable back-up power to cable headend, telecom or server room facilities. The AMPS80 HP features hot swappable 2.5 kVA/2.0 kW inverter modules and optional 1.8 kW rectifier modules that are the building blocks of a highly reliable power system.
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 AMPS80 HP acts more like an on-line, double conversion UPS.
2.2 System Components The AMPS80 HP consists 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. 1 Main Wiring Access Panel: AC input and output as well as Safety Extra-Low Voltage (SELV) DC battery connections are accessed through the front panel and fed through the opening at the top of the rack. 2.
2.3 Rear Components Two breakers are mounted at the rear, upper corners of the cabinet – one is a breaker for DC1 to the CXCR controller and the other for the signal wiring and DC4 to the CXCR controller. (DC4 is provides backup power for the controller if DC1 fails.) Breaker for DC1 to the controller Breaker for signal wiring and DC4 to the controller Front Figure 1 — Controller breakers on top of the AMPS80 Doc.
2.4 Module Location Relative to System Wiring 2.4.1 Split-phase or 120/208V 2-Pole systems Refer to section 3 for an explanation of the "split-phase" and "2-pole" terminology.
DC 1 Optional DC breaker inputs DC 3 DC 2 DC 4 DC feeds for inverters Inverters for AC phase 1 (L1) Inverters for AC phase 2 (L2) Blank panels Rectifier output to DC1 Rectifier output to DC4 Figure 3 — 40 kVA, split-phase or 120/208V 2-pole system Doc.
2.4.2 3-phase systems Optional DC breaker inputs DC 1 DC 3 DC 2 DC feeds for inverters DC 4 Inverters for AC phase 1 (L1) Inverters for AC phase 2 (L2) Inverters for AC phase 3 (L3) Rectifier output to DC1 Rectifier output to DC4 Figure 4 — 75 kVA, 3-phase systems 16 Doc.
DC 1 Optional DC breaker inputs DC 3 DC 2 DC feeds for inverters DC 4 Blank panel Inverters for AC phase 1 (L1) Inverters for AC phase 2 (L2) Inverters for AC phase 3 (L3) Blank panels Rectifier output to DC1 Rectifier output to DC4 Figure 5 — 30 kVA, 3-phase system Doc.
3. AC and DC Power Configurations This section lists the power configurations available with the AMPS80 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). 3.1.4 L1 120/240Vac Split Phase 120V 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 6.
3.2 3-Phase Systems – Recommended AC and DC Breakers NOTE: The recommendations in Table A 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.
NOTE: The recommendations in Table B 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.
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.
3.3 120V/240V Split Phase or 120/208V 2-Pole Systems 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.
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.
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.
3.4 DC Fuse/Breaker Alpha recommends using fuses instead of breakers because they provide better fault protection. 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.
3.5 AMPS80 DC Feed Options One Two Four AMPS80-2-40 Max Load Power AMPS80-2-40 Redundancy Power AMPS80-3-30 Max Load Power AMPS80-3-30 Redundancy Power 1. Single feed – no DCB AMPS80-3-75 Redundancy Power Feed Option N+0, 75kVA 60kW 40kVA 32kW 30kVA 24kW N+1, 67.5kVA 54kW 35kVA 28kW 22.
3.6 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. 3.6.1 AC Input Groups/ AC Output Groups The CXC controller provides an interface to assign inverters to phases (Inverters > Group Mapping).
3.6.2 DC Input Groups The configuration of the DC input to the inverters provides several different ways to monitor DC input power and input current. The number of DC Input Groups (maximum eight) is set in the Inverters > Group Mapping screen and monitored as a unit in the View Group Status screen. The following table gives examples of possible configurations. Monitoring DC Source Bulk Assign all inverters to DC Input Group 1.
4. System Pre-Installation 4.1 Site Selection The AMPS80 HP is designed to be installed in a controlled environment, sheltered from rain, excessive dust and other contaminants. Consider both the floor loading and the physical space required for the AMPS80 HP power system and the batteries. 4.1.
4.2 Recommended Installation Layout NOTE: In the unlikely event that internal components need repair, 1 m access around the unit is recommended. Minimum required clearances around the cabinet: • Rear: 18" (46 cm) • Sides: no clearance required.
4.3 Wiring for Generator and/or External MBS Refer to Figure 11 for schematic of a system with a generator and/or external MBS. Figure 11 — System Schematic with Generator and MBS Doc.
4.4 Transporting the Cabinet The cabinet is shipped upright on a 122 cm x 122 cm (48" x 48") pallet and can be transported to the installation site either by forklift or overhead crane. The empty cabinet weighs approximately 270 kg (595 lb). The height of the rack, including pallet and shipping material is 234 cm (92"). When tilting the rack to fit through doors, tilt the rack toward the back and ensure that it is not subjected to sudden shock.
4.5 Unpacking Instructions WARNING! The AMPS80 HP rack weighs 270 kg / 595 lb. Care must be taken to ensure that it does not topple over. 1. Remove 6 screws from top panel to access AMPS80 HP lifting eyes. Use Phillips head tool to remove 2. Remove 4 screws from each top 2 x 4 and 6 screws from each wooden side piece to gain access to removal of the front and rear wooden frames. Lifting eyes Use Phillips head tool to remove 3. Remove 3 screws from the front and rear wooden frames. 4.
4.6 Anchoring the Cabinet The cabinet must be fixed in place by means of anchor bolts. In areas prone to seismic events, use anchors rated for the appropriate Seismic zone. 185.0mm [7.28in] 647.2mm [25.48 in] 277.2mm [10.91in] 12.7mm x4 [0.50in] 185.0mm [7.28in] 25.4mm [1.00in] [21.51in] 546.4mm 597.2mm [23.51in] 25.4mm [1.00in] Figure 13 — Mounting hole pattern 34 Doc.
4.6.1 Optional Conversion from Single to Dual AC Feed The AMPS80 HP system is preconfigured from the factory for a single AC feed per phase for inverters and rectifiers if present.
Procedure to remove the internal rectifier powering wiring: Have the following tools on hand: • Phillips screw driver • 3/8” wrench or socket • 3/16” hex key WARNING! Before removing the wiring access panel, make sure all power to the unit is switched off, tagged and locked. STEP 1: Remove the wiring access panel. STEP 2: Locate the rectifier terminal block Figure 16 — Rectifier terminal block 36 Doc.
STEP 3: Remove the internal rectifier powering wires before installing the separate rectifier feed Disconnect with a 3/16" hex key Disconnect the 10-32 nut with a 3/8" wrench or socket Once the internal rectifier powering wires have been removed, install the external rectifier powering wires into the rectifier terminal block—see Figure 16. Doc.
4.6.2 AMPS80 HP with External Maintenance Bypass Switch These diagrams show the logical internal connections. They are not a detailed representation of the actual internal system wiring.
5. System Installation The AMPS80 HP system is pre-configured from the factory for a single AC feed per phase for inverters, a maintenance bypass switch, and rectifiers if present. The installer is responsible for connecting the following: • Utility input to the system (120 V line to neutral) • Battery strings • System to the load • Chassis and battery return to the reference ground Reference Notes: • If the AC input neutral is connected, remove the neutral to ground bonding wire.
Carefully review the following schematic and installation notes before proceeding with the installation. 5 6 8 Figure 19 — Battery and power connections Installation notes: 1. All wiring must be in accordance with applicable electrical codes. 2. All external wiring by others. 3. Inverter main input must always include a neutral connection. 4. Power and control cables must be in separate conduits. 5. N-G shorting jumper is factory-installed for inverter-only systems.
5.1 Input/Output Cabling Overview Connection points are accessed from the top of the unit. A protective panel partitions the AC and DC connections. DC1 DC2 DC3 DC4 DC connections Protective panel between AC & DC connections AC output ground AC connections AC input ground Ground bus Frame ground Figure 20 — Top view of AMPS80 showing AC and DC connection partitions 5.1.
5.2 AC Connections • Access to connection points is provided from the front of the system rack. • AC wires enter the cabinet through the top. • AC input and AC output wires are connected to box lugs rated for 350 kcmil to #6 AWG. AC input lugs L1 left L2 middle L3 right AC input ground Industrial grade surge suppression modules.
5.3 DC Connections • Access to connection points is provided from the front of the system rack. • DC wires enter the cabinet either through the top or the bottom of the cabinet. • A low voltage disconnect should be provided with the battery system. DC+ bus: DC1, DC2, DC3, DC4 input connectors shown with one 4DC tie bar DC- bus: DC1, DC2, DC3, DC4 Figure 22 — DC connections - top view 5.3.
5.3.2 DC Connection Configurations CAUTION! A tie bar is only recommended for single feed installations. The use of a tie bar in a two feed installation can cause current loops.
Single battery string Two 4DC joining plates are supplied with the dimensions shown in Figure 25. DC+ Row DC– Row .6in [16mm] 14 x 1/2in bolt clearance hole 7 x 3/8in bolt clearance hole .9in [24mm] 1.75in [44mm] .6in [16mm] .9in [24mm] .9in [24mm] 1.5in [38mm] 1.5in [38mm] 1.5in [38mm] 1.5in [38mm] 1.8in [46mm] 1.8in [46mm] Figure 25 — DC tie bar for single battery string Doc.
Two battery strings Four 2DC joining plates are supplied with the dimensions shown in Figure 26. DC+ Row DC– Row .6in [16mm] 6 X1/2" bolt clearance hole .9in [24mm] 3 X3/8" bolt clearance hole 3.0in [76mm] 1.75in [44mm] .9in [24mm] .6in [16mm] 1.5in [38mm] 1.5in [38mm] .9in [24mm] Figure 26 — DC tie bar for two battery strings 46 Doc.
5.4 5.4.
8. Verify that all breakers at the external load distribution box are switched OFF. 9. Refer to and verify that the following breakers are OFF • Rectifier AC input circuit breakers (if option installed) • inverter AC input circuit breaker • Inverter AC output circuit breaker • DC input breakers (if option installed) 10. If equipped with a maintenance bypass switch (MBS), place this switch in the INVERTER mode. 11.
Connecting a laptop 17. Connect a computer to the CXCR controller with a crossover cable. Installing One Seed Module per Phase You are now going to configure the system with just one inverter per phase. 18. Install only one inverter "seed module" per phase according to the instructions in Figure 30 and Figure 31. Position each inverter in the same shelf position per phase. Install ONLY ONE INVERTER PER PHASE in the right most position of the top shelf for each phase.
WARNING! Do not install all inverter modules at once but load one inverter module into an open slot for each AC phase. This allow the initial set-up of the AC phases. All remaining modules will automatically take on the configurations of these “seed” modules. See diagrams under Section 8.1: Module Location Relative to System Wiring for AC phase locations. See below for detailed module insertion/removal instructions.
precise.) a. Select Inverters > View Live Status> Inverter Report. b. In the Inverter Report screen, locate the module for AC phase 1: click each row until the LEDs of the inverter in the first phase 1 shelf flash for a few seconds. c. Using the pull down box in the Module Number column, set the module number to 1 to correspond to AC phase 1. d. Locate the module for AC phase 2: click each row until the LEDs of the inverter in the first phase 2 shelf flash for a few seconds. e.
a. Select Main Menu > Inverters > Group Mapping. b. Turn the inverter modules OFF by clicking the green power icon at the end of the row. 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 33. 22. DO NOT TURN THE INVERTERS BACK ON. PROCEED WITH THE NEXT STEP.
25. Select Main Menu > Inverters > Group Mapping. 26. Turn the inverters on by clicking the black power icon at the right end of the row. 27. Switch on the Inverter AC Output breaker on the front panel of the AMPS80 HP. 28. Check the actual Inverter AC Output by measuring voltages on the AMPS80 HP AC output terminal block in the wiring compartment (Figure 21): a. The voltage from Neutral to L1 / L2 / L3 is approximately 124 V. At no load, the inverter output voltage is slightly higher than nominal. b.
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 34 — Inserting blanks in open slots 33. Using the CXC controller web interface, configure any other parameters as required. Typical changes could include battery and charging values for the rectifiers, if installed, or changing the low and high voltage AC and DC warning and cutout limits. 34.
6. System Operation 6.1 Inverter Module Indicators AC output DC input AC input Status LEDs Figure 35 — Fig. 4.1 Inverter module status, power LEDs 6.1.
Output Power (redundancy not counted) The output power LEDs (located on the right side of the module’s front panel indicate the amount of power (percentage of rated power) provided by the module. The number of bars that are illuminated combined with whether or not they are on steady or flashing indicate the output power level or overload condition as shown in the figure below.
6.2 T2S Inverter Control Card The CXC unified system controller monitors and manages inverter modules by communicating with the T2S inverter control card. The T2S may be useful in troubleshooting inverter alarms. LEDs 1 through 3 on the front panel of the T2S indicate the following alarm conditions: • Major Alarm LED • Minor Alarm LED Major alarm LED Minor alarm LED USB port Figure 37 — T2S front panel Doc.
6.3 Using the CXC Unified System Controller The CXC controls the AMPS80 HP system and allows the user to set wide variety of parameters regarding the alarms and operational functionality of the rectifier and inverter modules. The following guide provides a brief overview of the controller; in-depth information can be found in the Technical Manual for the Cordex Controller Software. 6.3.
6.3.2 Communication and Control Connections Remove two screws and fold the controller front panel down to access the communication and control connectors. NOTE: The breakers located at the top of the AMPS80 (see Figure 1) protect the wiring to the CXC and alarm contacts of the different auxiliary contacts on the AC inverter input and output breaker, the TVSS and the MBS. Input and output signal connections 6.3.3 1.
6.3.4 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. The three front-panel LEDs illuminate temporarily, and then extinguish after the system has finished its self-test. The GUI then displays the power system parameters during Normal operating mode. 6.3.5 Normal Operation This is the default-operating mode or “home page.” The GUI displays system status information and monitors all input channels.
6.3.6 Menu Navigation and Sample Programming Menu Navigation The sample screen shown below is presented upon login. From here, the user may navigate (e.g. browse – as on a personal computer) to each of the CXC menu items, including alarms, controls and configuration items. Battery volts and load current display Mode + temp comp. display The folders can be expanded (indicated by the plus sign shown here) if there are files inside. Tap on the folder icon or label to expand.
6.3.7 Web-accessed Features This section describes the additional web page features for Inverter system. See the CXC Software manual for a complete description of the Cordex functionality. These instructions explain the interconnection and operation of the Cordex Controller with Inverter Support. The CXC has Ethernet capability that supports a web interface and SNMP for customer access to the equipment it is monitoring.
6.3.8 View live status inverter report This submenu of Inverters will enable the user to view, in a list report, all of the acquired inverters in the system. The first column lists the module numbers (ID) of the inverters; which may be re-assigned. The report then displays the unique serial number and module version, followed by the corresponding AC In, DC In, and AC Out group mapping values. The input frequency and temperature of each inverter completes the top portion of the report table.
6.3.9 View Group Status This submenu of Inverters displays the grouping of input sources and inverter output that share the unique operating parameters that were set in the Group Mapping menu. This screen can display 4 Inverter DC Input Groups and 3 AC Input Groups and 3 AC Output Groups. Three groups support a threephase input. Up to four groups for DC input sources. Figure 45 — View group status window — inverters page 64 Doc.
6.3.10 Group Mapping A matrix of buttons allows the supervisor to map (enable/disable) the inverter's assignment per group for all of the acquired inverters in the system. Ensure phases are configured correctly before mapping inverters in the new groups and turning them on. "Power Buttons" Click these buttons to switch the inverter ON/OFF. Use with caution.
6.3.11 Set Inputs This submenu of Inverters enables the supervisor to set the parameters shown below: See general settings. For inverters, changes apply on a page by page basis; select Submit. Select Cancel to discard all changes made (including invalid settings). Figure 47 — Set input window 66 Doc.
6.3.12 Set Output This submenu of Inverters will enable the supervisor to modify the following parameters: 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 Total number of inverter modules installed for that phase.
6.3.13 General Settings This submenu of Inverters enables the supervisor to set the parameters shown below: Value 0 or 100 only. For inverters, changes apply on a page by page basis; select Submit. Select Cancel to discard all changes made (including invalid settings). Figure 49 — General settings window The Free Running Frequency min/max setting is determined by the General Settings value. If AC input is present, AC output will synchronize; however an irregular AC voltage could damage the inverters.
6.3.
Alarms reported by T2S are reported in the event logs. Figure 52 — T2S alarms in event logs 6.3.16 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. This functionality is similar to downloading the inverter configuration file (see section 10.1. Figure 53 — Retrieve inverter alarm history file 70 Doc.
6.3.17 Signals The Signals submenu displays inverter signals for all acquired inverters in the system. The following signals can be used for logging and equation building. Figure 54 — Signals (inverters) window Doc.
6.4 6.4.1 Rectifier Features Rectifier Front Panel Lights Refer to the Cordex CXRF 48-1.8 kW manual for further details. AC LED light AC LED light The top LED (green) is on when AC is within valid range. AC voltage is invalid if the AC Mains Low or AC Mains High alarm is active. The LED turns off when AC has failed. DC LED light Alarm LED light DC LED light The middle LED (green) is on when the rectifier is delivering power to the load. The LED will flash when communication is lost.
6.4.2 LED Activity During Rectifier Software Upload When a rectifier software upload is in progress, the LEDs will behave in a distinctly different way to 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. 6.4.
6.4.5 1. Mapping Alarms to Relays Connect a computer to the controller. Refer to the controller software manual. The 48 V DC power must be switched on before the controller can operate. Provide either DC power on the main DC1 or DC4 connections or switch on at least one rectifier. 2. Navigate to Alarms > Configure Alarms. 3. Select Digital Inputs. Select Digital Alarms 4. Select the desired relay. In this example K7 and K8 are available.
5. After changes have been made, press Submit Changes. 6. Accept changes. Press Accept 7. Hook up control wires to the selected relay. Relays Doc.
6.5 6.5.1 Synchronization with a Maintenance Bypass Switch (MBS) Internal Maintenance Bypass Switch If an internal MBS is present, 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.
7. Maintenance 7.1 Preventive Maintenance This equipment requires regular maintenance. The maintenance must be done 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 3/8" ratchet socket X 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 Computer with Ethernet port a
7.4 Replacing the T2S Inverter Control Card CAUTION! Perform this procedure with the system in bypass mode and/or during a scheduled maintenance window. Step 1: Removal To release the T2S from the shelf, insert a small flat screwdriver in the square hole under the USB port and lift up the lock pin. Then pull out the module. Step 2: Replacement and Initialization Insert the new T2S into the system.
Step 3: Inventory Update When the initialization sequence is complete (top two LEDs solid green and the bottom LED flashing green), use the CXC touch display to perform an inventory update. The CXC memory is cleared of the original T2S and updated to the latest installed T2S. Allow up to five minutes upon completion of the inventory update for the CXC to display the inverter information. Tap on the number of rectifiers (will be 0 if no rectifiers in the system.
7.6 Replacement of AIM2500/1500 Inverter Modules Removing a module from a working system generates an alarm, which will not clear until the module is replaced or the number of modules in that phase is reduced by the number of modules removed. CAUTION! Improper installation or removal of modules can break latching components. Insert a flat head screw driver into the center flap notch and pry open the center flap. Then pull out the module by pulling on the center flap with both hands.
7.7 Surge Suppression Replacement WARNING! There may still be live parts inside the system and shock hazards may be present throughout this procedure. 1. Turn off the inverter input breaker. Replaceable parts Alpha part number Description 2. Remove the wiring access panel. 162-600-19 3. Pull out the surge suppression module. Surge suppression replacement module, red stripe, Line-Ground, 40 kA rating 162-601-19 Surge suppression replacement module, green stripe, Neutral-Ground, 40 kA rating 4.
Side Access Replacement This is the preferred replacement procedure. 1. Turn off the inverter input breaker. 2. Remove the side access panel. 3. With the proper tools, reach in and remove the screws holding the surge suppression assembly. 4. Replace the module with an Alpha service entrance grade surge suppression assembly. Bolts holding surge suppression assembly Front Access Replacement 1. Turn off the inverter input breaker. 2. Remove the screw securing the CXCR unit. 3.
7.8 Fuse Replacement For hybrid systems equipped with rectifiers, there are two fuses located behind the DC input breakers shelf (see Figure 58). These fuses are sized to blow only if there is a wiring fault in the system. These fuses must be replaced by a qualified service person. 1. Turn the rectifier breakers off. 2. Disconnect the battery feeds to the AMPS unit. WARNING! There may still be live parts inside the system and shock hazards may be present throughout this procedure. 3.
7.9 Synchronization After Maintenance or Repair Implement the following sequence before switching the unit from bypass mode to inverter mode. 1. Switch on the inverter input breaker. Wait for the inverters to synchronize to the line, and for all status LEDs to turn green. 2. Switch on the inverter output breaker. 3. If present, switch the internal bypass switch to AMPS80 HP system. If present, switch the external bypass switch to AMPS80 HP system. Doc.
8. Troubleshooting 8.1 Non Recoverable Error Inverter status LEDs Output power status LEDs The status LEDs illuminate permanently red when a non recoverable error occurs. Thanks to its double input port, the AMPS80 HP inverter module will actually stop when either the output stage is non recoverable or when both input stages are faulty. Generally, a non-recoverable error cannot be erased and the module must be returned for repair. 8.
8.3 Alarm Codes All alarm codes are listed in Table K. The following alarm codes are included here as well to provide more information. 8.3.1 No Ethernet Communication For a direct connection to the CXCR, verify that you are using a cross over cable, that your wireless connection is turned off, and that your local area network connection is set up as shown below. Reset the CXCR by using the LCD touch screen as shown below: 252W 2% Press Reset Press Press the “reset now” pop up when it appears.
8.3.2 System Saturated The system saturated alarm defaults to 80% load on the non redundant inverters. To remove this alarm, add more inverters or reduce the amount of redundant units. 8.3.3 AC Secondary Source Lost The AC Secondary alarm happens when the DC is removed from the system and when settings in the group mapping screen are incorrect. Click to remove 88 Click to add Doc.
8.3.4 AC Mains Lost The AC Mains Lost alarm happens when the AC input does not meet the correct voltage, phase, or frequency. When AC mains is lost the UPS goes into Inverter Mode. This alarm is sometimes accompanied by other alarms. Both the T2S and CXC software give inverter alarm AC Mains Source Lost when a column is not used (or accidentally added) in the AC Input Group in the Inverters>Group Mapping screen. 8.3.
Table K — Alarm Codes Alarm Type Description Cause Solution Error Not Recoverable 90 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 3 FLASH FAILURE Internal software is corrupted Replace the module 4 Vref FAILURE Internal voltage reference is out of range Replace the modul
Table K — 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 — Alarm Codes Alarm Type 92 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 — 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 — 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 182 Fac_i
Table K — Alarm Codes Alarm Type Description Cause Solution 230 REDUND + 1 LOST Generate alarm code 230 and text "Redundancy + 1 Lost" when 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 condition is true Load of system is greater than the preset value Reduce load, or add inverter to the system or reduce the number of redundant units in Inverters > Set Out
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Inverter Module AC Input Nominal Voltage (AC) Voltage Range Input Power Factor Frequency Synchronization Range 120 V 90-140 (user adjustable) >99% 60 Hz 57-63 Hz Inverter Module DC Input Nominal Voltage Voltage Range (max) Max DC input current @ 48 Vdc Max DC input current @ 40 Vdc Voltage Ripple 48 Vdc 40-60 Vdc (user adjustable) 1400 A / 560 A / 750 A / 375 A 1700 A / 680 A / 900 A / 450 A <2 mV / <38 dbrnc Unified System Controller with SNMP Control & Monitoring Display Communication Ports Configur
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9.2 Specifications for 48-1.8 kW Rectifier Rectifier Module Input Voltage, Output Current, Power AC Input Voltage Rectifier shelves Max # of Rectifier Modules Max DC output VA 120 2 8 192 Adc 120/240 Vac 2 8 300 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; 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; ;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; ;V; 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; 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.
11. 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.
12. Warranty Alpha Technologies Limited (ATL) warrants its products to be free from defects in material and workmanship for a period of two (2) years from the date of purchase. ATL obligation under this warranty is limited to the repair or replacement, at its sole discretion, at the ATL factory or ATL Authorized Service Center, of any defective product. This warranty does not cover any failure of the unit caused in whole or in part by any cause or causes external to the unit.
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.
