Serial System Controller Operation and Maintenance Manual Effective: January, 2001 ® © 2001 TM
018-332-C0-002 Rev.
® Serial System Controller Operation and Maintenance Manual 018-332-C0-002, Re v. B January, 2001 © 2001 Alpha Technologies Overview: NOTE: The purpose of the Serial System Controller Operation and Maintenance Manual is to detail system features, installation, operation, and maintenance procedures. It is written primarily for the system operator. Alpha Technologies products are subject to change through continual improvement processes.
Serial System Controller Table of Contents Product Safety ................................................................. 6 Important Safety Instructions Contained in this Manual .............................. 6 Safety Precautions ............................................................................... 7 Battery Safety Notes ............................................................................ 7 Contact Alpha .................................................................. 8 1.
Serial System Controller Table of Figures Figure 1-1; Figure 1-2; Figure 1-3; Figure 1-4; Figure 1-5; Figure 1-6; Figure 1-7; Figure 1-8; Figure 1-9; Figure 1-10; Figure 1-11; Figure 1-12; Figure 2-1; Figure 2-2; Figure 2-3; Alpha Technologies Serial System Controller (SSC) ................ Basic Diagram: SSC Shown in Power System ......................... LED Block, Reset Switch .................................................... RS-232 and Alpha/HMS Bus RS-485 Connectors ....................
Product Safety Safety Symbols Used in this Manual Caution Hazardous Condition To reduce the risk of electrical shock, injury or death caused by explosion of fuel or moving parts, and to ensure the safe operation of this unit, the following symbols have been placed throughout the manual. Where these symbols appear, servicing must be performed only by qualified personnel. Dangerous Voltage This symbol indicates a dangerous voltage exists in this area of the product.
Product Safety Safety Precautions The Serial System Controller (SSC) must be serviced only by qualified personnel. Remove all rings, watches and other jewelry before servicing batteries or installing the SSC. Verify the voltage requirements of the equipment to be protected (load), the AC input voltage to the power supply (line), and the output voltage of the system prior to installation.
Contact Alpha Contact Information General product information and customer service 7:00 AM to 5:00 PM Pacific Time 1-800-863-3930 To obtain complete technical support 7:00 AM to 5:00 PM Pacific Time or For after-hours emergency support 7 days per week, 24 hours a day 1-800-863-3364 Instructions for Returns Returns for Repair For units that must be returned for repair, Alpha requires a Return Material Authorization (RMA).
1. System Overview 1.1 Theory of Operation The Serial System Controller (SSC) manages and provides status monitoring for powering systems that contain single or multiple (up to six) power supplies, and a generator. It coordinates battery charging, individual battery monitoring, and self-testing for individual components in the system. Using a serial interface, Alphas Engine Control Module (ECM) communicates with the SSC to manage generator operation.
1. System Overview 1.1 Theory of Operation, continued 1.1.2 System Self-Test System self-test is either initiated by expiration of the Auto Test Countdown timer, or by asserting the Self-Test switch via the digital transponder interface.
1. System Overview 1.1 Theory of Operation, continued 1.1.3 Low battery Shutdown of Inverters Each XM2 attempts to protect the batteries in a system from deep discharge that can permanently damage them. The XM2 will disable its inverter when the battery voltage drops below a threshold referred to as End of Discharge (EOD). The SSC will monitor each XM2 for an EOD flag. If and when it receives an EOD indication, the SSC will disable all inverters in the system simultaneously.
1. System Overview 1.2 Indicators & Connections 1.2.1 Front Panel Layout, Serial System Controller (SSC) LED Indicator Block Reset Button RS-232 Connection RS-485 Connection (Alpha Bus) RS-485 Connection (HMS) DATA I/O Connection Port Battery Connection Port ECM Port Tamper Switch Alarm Connection Port Figure 1-1; Alpha Technologies Serial System Controller (SSC) 018-332-C0-002 Rev.
1. System Overview 1.2.2 Diagram: The SSC in a Power System 3RZHU 6XSSO\ (QFORVXUH *HQHUDWRU (QFORVXUH 7DPSHU 6ZLWFK &200 3RUW 7DPSHU 3RUW ,17 56 3RUW %DWWHU\ 3RUW (&0 3RUW 7DPSHU 3RUW ;0 3RZHU 6XSSO\ (&0 66& &200 3RUW ;0 3RZHU 6XSSO\ % % 860 7, % % *HQHUDWRU $38 %DWWHULHV Figure 1-2; SSC Shown in Basic Power System © 2001 TM 13 018-332-C0-002 Rev.
1. System Overview 1.2 Indicators & Connections, continued 1.2.3 LED Indicators The SSC Alarm LED reflects system level alarms. When a system level alarm is active, all LEDs will periodically (every ten seconds) turn off, and an alarm code will be displayed. (See section entitled Alarm LEDs for more information.) The Ready LED flashes at a rate of 1 Hz to indicate that the SSC software is running normally. Generally, this LED is only turned off while alarm codes are being displayed.
1. System Overview 1.2 Indicators & Connections, continued 1.2.5 Serial Communications Interfaces The SSC has four serial communications interfaces: the internal RS-485; the external RS-485; the external RS-232; and the ECM port. 1.2.5.1 Internal RS-485 This interface connects the SSC to each XM2 power supply in the system. The SSC coordinates all system activity and status through the interface. An offset modular cable is connected from this interface to an XM2 in the system.
1. System Overview 1.2 Indicators & Connections, continued 1.2.5 Serial Communications Interfaces, continued 1.2.5.4 ECM Port This interface connects the SSC to the Engine Control Module (ECM) in an AlphaGen generator system. The SSC coordinates all generator activity and status monitoring through this interface.
1. System Overview 1.2 Indicators & Connections, continued 1.2.6 SSC/Power Supply Interconnection The SSC can communicate with up to six additional power supplies by means of a connection between the RS-485 Internal connector and the COMM connector of the next Communications Module, as shown below. Each succeeding power supply may be linked via a connection from the SYS connector to the COMM connector.
1. System Overview 1.2 Indicators & Connections, continued 1.2.7 Data I/O Port The Data I/O port consists of a 10-pin user-definable set of contact closures. It contains one discrete input, and four discrete outputs, both read by the external communication ports. The output signals are contact closure to its return pin on activation. The input signal is activated by a short between pins 6 and 7. The location and function of each pin is illustrated in the figures below.
1. System Overview 1.2 Indicators & Connections, continued 1.2.7 DATA I/O port, continued Notes from table 1-1: Note 1 This mode is selected by turning SSC configuration switch #1 ON. Note 2 Minor alarms* indicate: Battery system fault Enclosure intrusion (tamper) Communication fault System configuration fault System self-test failure Note 3 A short between pins 6 and 7 will initiate a system self-test. The test will run until it is complete, or until the pins become open.
1. System Overview 1.2 Indicators & Connections, continued 1.2.8 Battery Connection Port The BATT connection (8-pin Mini Mate-n-Lok) is a battery monitoring interface capable of measuring two sets of 36V or 48V battery strings. Pin 1 is always the lowest potential of the battery string.
1. System Overview 1.2 Indicators & Connections, continued 1.2.9 Tamper The SSC monitors cabinet intrusion sensors, and will report an alarm via the digital transponder interface when a door opens. The Tamper port (2-pin header) is specifically designed to be compatible with the existing magnetic or mechanical tamper switches in Alpha Technologies' products. To disable the tamper switch intrusion alarm, press the Reset switch three times within the first thirty seconds of alarm activation.
1. System Overview 1.3 Dip Switch: Switch 1 Switch 1 is used to identify user-configurable options of the SSC. The ON position of the switch indicates that the generator is in the system. Position Use 1 Activates the parallel status monitoring option that is described, in detail, in the manual. 2 Not currently used. 3 Defines whether or not the APU (if present) is included in the self-test sequence. 4-8 Not currently used.
2. Installation 2.1 Module Conversion Note: If the XM2 system already has a Serial System Controller (SSC) module installed, proceed to section 2.3, Smart Display Setup Menu. Note: During this procedure, backup capability may be temporarily lost. Module Conversion Procedure: 1. Disconnect any status monitoring cables/harnesses connected to the front panel of the existing module. (Module shown for illustrative purposes only.) 2. Verify that the battery breakers are OFF. 3.
2. Installation 2.1 Module Conversion, continued Module Conversion Procedure, continued 5. Slide the Inverter Module (IM) out from the chassis. 6. Remove the existing COMM module (Universal Status Monitor) housing from the IM. 7. The unit is now ready to receive the Serial System Controller. 6 5 Figure 2-2; Preparing Inverter Module to Receive SSC 018-332-C0-002 Rev.
2. Installation 2.2 SSC Installation SSC Installation Procedure: 1. Carefully align the 2x9 header plastic standoffs of the SSC card to the IM, and position the board over the two nylon standoffs. 2. Reattach with the 2 screws from the existing COMM module. 3. Slide the IM into the chassis. 4. Plug the Tamper, ECM, BATT, DATA I/O, and RS-485 (internal/ external), cables into their respective connectors. 5. Plug in the XM2 Battery Connector and turn ON the Battery Breaker. 6.
2. Installation 2.3 System Configuration Communication between the SSC, ECM and XM2s takes place through the RS-485 Alpha Bus. To set power supply addresses (Refer to section 2.4, Smart Display Setup Menu for more information): 1. Beginning at the Normal Operations menu of the LCD on the power supply, press the ENTER key twice. This brings the user into an Auto-Scroll Setup menu. 2. Look for the Parameter named DEVICE ADDRESS. 3. Press the ENTER key to select the item for editing. 4.
2. Installation 2.
3. Alarms 3.1 Alarm LEDs Specific alarms will be displayed as a count of flashes on the Alarm LED, as shown on the table below. Note that major alarms are labeled; all others are minor alarms.
© 2001 TM 29 018-332-C0-002 Rev.
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