Alpha ACS HP User Manual

ACS HP Series Battery Charger

Quick Start Guide

Effective: December 2011

PowerAlpha Technologies ®

ACS HP Series Battery Charger

Quick Start Guide

Effective Date: December, 2011

© 2011Alpha Industrial Power

1075 Satellite Blvd, Suite 400, Suwanee, GA 30024

Tel: [phone] Fax: [phone]

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, please contact Alpha Technologies or your nearest Alpha representative.

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NOTE:

Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators, batteries or other hardware if used or operated in any manner or subject to any condition not consistent with its intended purpose or is installed or operated in an unapproved manner or improperly maintained.

Contacting Alpha Industrial Power: www.alpha.com

For service information, (7 AM to 5 PM, Eastern Time):

Tel: [phone]

Fax: [phone]

AIP900-0012-B0-001 Rev. A (01/2012)

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Figures&

Contents

		Contents
SAFETY NOTES....................................................................................................................			5
IMPORTANT SAFETY INSTRUCTIONS...............................................................................			5
GENERAL SAFETY PRECAUTIONS....................................................................................			6
1.0	Introduction..................................................................................................................		8
	What This Manual Covers...........................................................................................		8
	Who Should Read This Manual...................................................................................		8
	How to Use This Manual.............................................................................................		8
	1.1	Product Overview.............................................................................................	8
	1.2	Theory of Operation .........................................................................................	9
	1.3	System Components.......................................................................................	11
	1.4	Specifications.................................................................................................	12
2.0	System Installation....................................................................................................		13
	2.1	Installation Notes............................................................................................	13
	2.2	Recommended Installation Layout.................................................................	14
	2.3	Electrical Connection and Wiring....................................................................	15
	2.4	Installing the Rectifier Modules.......................................................................	16
3.0	Operation...................................................................................................................		17
	3.1	Placing the System into Service.....................................................................	17
		3.1.1 Initial Turn-Up......................................................................................	17
	3.2	Rectifier Operational Status............................................................................	18
	3.3	CXC Controller Operational Status.................................................................	19
		3.3.1 Startup and Reset Procedure .............................................................	19
		3.3.2 Normal Operation ...............................................................................	20
		3.3.3 Menu Navigation and Sample Programming.......................................	20

Figures

Fig. 1-1, Simplified Block Diagram.......................................................................................	10
Fig. 1-2, Configured Charger System..................................................................................	11
Fig. 2-1, Cabinet Footprint with Dimensions........................................................................	14
Fig. 2-2, Rectifier Module.....................................................................................................	16
Fig. 3-1, Rectifier LEDs........................................................................................................	18
Fig. 3-2, Cordex Controller Front Panel...............................................................................	19
Fig. 3-3, Normal Operating Mode “Home Page”..................................................................	20
Fig. 3-4, Navigation Screen..................................................................................................	20

AIP900-0012-B0-001 Rev. A (01/2012)

SAFETY NOTATION

Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Industrial Power, Tel: [phone] Fax: [phone] or the nearest Alpha representative. Save this document for future reference.

To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.

NOTE:

A NOTE provides additional information to help complete a specific task or procedure.

ATTENTION:

The use of ATTENTION indicates specific regulatory/code requirements that may affect the placement of equipment and /or installation procedures.

CAUTION!

use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment.

WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to the	5
technician or user.

Safety Notation

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SafetyGeneral

GENERAL SAFETY PRECAUTIONS:

This unit and its associated hardware must be serviced only by qualified, authorized personnel. Unit must remain locked at all times, except when authorized service personnel are present.

Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors, wiring, or batteries.

Read and follow all installation, equipment grounding, usage, and service instructions included in this manual. Use proper lifting techniques whenever handling enclosure, equipment, parts, or batteries.

Batteries contain dangerous voltages, currents and corrosive material.

Battery installation, maintenance, service and replacement must be performed by authorized personnel only.

Never use un-insulated tools or other conductive materials when installing, maintaining, servicing or replacing batteries.

Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable or an unconnected battery cable can result in arcing, a fire, or possible explosion.

A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized personnel using a battery of identical type and rating.

Avoid any contact with gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery. Emissions contain dilute sulfuric acid which is harmful to the skin and eyes. Emissions are electrolytic, which are electrically conductive and are corrosive. Follow the Chemical Hazards notes if contact occurs.

Do not smoke or introduce sparks in the vicinity of a battery.

Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is explosive. Proper venting of the enclosure is required.

Follow the battery manufacturer’s approved transportation and storage instructions.

Never charge a frozen battery.

Never energize a physically damaged charger.

Prior to installation, verify that the AC input voltage to the unit and its equipment match with respect to voltage and frequency.

Prior to installation, verify that the output voltage from the unit or its equipment match the voltage requirements of the connected equipment (load).

Prior to installation, verify that the unit’s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside. Refer to manufacturer’s recommendations.

Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the enclosure is changed.

Prior to installation, contact local utilities, local building maintenance departments, and cable/piping locator services to ensure that installation does not interfere with existing utility or building cables/piping.

Before performing any maintenance on this, make sure that the battery and the AC Power are disconnected.

Note that both AC and DC current are present in this unit even with indicators and breakers set to the “OFF” position. Do not exceed the output rating of equipment. Verify load requirements prior and during connection process.

Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed in your body.

The charger contains electrostatically-sensitive equipment. Use proper electrostatic discharge (ESD) procedures to prevent any severe damage to the electronic components.

AIP900-0012-B0-001 Rev. A (01/2012)

Utility Power Connection Notes

Connecting to the utility should be performed only by qualified service personnel and in compliance with local electrical codes. Connection to utility power must be approved by the local utility before installing the system.

Equipment Grounding Connection Notes

In order to provide a ready, reliable source of backup power it is necessary to connect the system to an effective grounding and Earthing system that not only provides for the safety of the service personnel responsible for its operation and maintenance, but also facilitates the proper operation and protection of the equipment within the network. Such a grounding system provides protection with respect to operator safety, system communication, and equipment protection.

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.

SAFETY GROUND

The safety ground is a two-part system, comprised of the utility service and the ACS HP Series Battery Charging system.

1. Utility service

As a minimum requirement for the protection of equipment, the local utility service must provide a lowimpedance path for fault current return to Earth. This must meet or exceed the requirements of the US National Electrical Code or the Canadian Electrical Code. The connection between the system and the utility must also meet or exceed the requirements of the US National Electrical Code or the Canadian Electrical Code.

2. The grounding system

The grounding system consists of a low-impedance connection between the enclosure and an Earth Ground (located at least 6’ away from the Utility Earth connection).

This impedance between the system and Earth must not exceed 0.1 Ohms.

Lightning Strike Ground

Lightning strikes, grid switching, or other aberrations on the power line and/or communications cable have the potential to cause high-energy transients which can damage the powering or communications systems. Without a low-impedance path to ground, the current, when traveling through wires of varying impedance, produce damaging high voltage. The most viable method available to protect the system from damage is to divert these unwanted high-energy transients along a low-impedance path to ground. A lowimpedance path to ground prevents these currents from reaching high voltage levels and posing a threat to equipment. The single-point grounding system provides a low-impedance path to ground, and the

key to its success is the proper bonding of the ground rods, so the components of the grounding system appear as a single point of uniform impedance. We recommend the use of a surge arresting device electrically bonded to the ACS HP Charger Ground System.

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Power Connection

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Introduction1.0

What This Manual Covers

This user’s manual contains important technical instructions to be followed by qualified personnel for the installation, start-up, and maintenance of this unit. It is recommended that this manual be read closely to ensure and reliable operation of this equipment.

Who Should Read This Manual

The Product Safety Information chapter and the Operation chapter are intended for anyone who will be operating the ACS HP Series Battery Charger. The Installation and Maintenance chapters are intended for qualified installers, trained electricians or technicians who are fully educated on the hazards of installing electrical equipment such as uninterruptible power supplies and their

associated batteries and accessories.

How to Use This Manual

Before you begin installing or operating the system, please ensure that you are familiar with all the warnings and cautions described in this manual (see Product Safety Information). Once you are aware of all the safety issues, then you can start to plan the installation per Section 2.0, Installation. After you have completed the installation, you can start learning how to operate the system to meet the needs of your application.

1.1Product Overview

The ACS HP Series Battery Charger is a modular, switched mode AC-DC conversion design, consisting of one or more Cordex rectifier modules coupled with a Cordex CXC microprocessor controller. This charging system possesses a unity power factor with efficiency greater than

93%, a negligible THD input level, and clean output power, providing reliable, quality DC power for many years.

The 4RU shelf of the unit accommodates up to five, hot swappable Cordex 4.4 kW rectifiers, which allows for N+1 or N+N redundancy capability, as well as expansion capability up to

175A output capacity. The hot swappable design of the rectifiers allows them to be inserted or removed from the shelf without requiring the power to be cut to or from the system or the load.

Configuration, monitoring, and control of the charging system is provided by the Cordex CXC controller, either locally via the CXC touch screen display or remotely via an ethernet or RS232 connection and an internet browser (DNP3 Level 2 communication is also available as an optional feature). Battery management, data logging, and temperature compensation are just some of the standard features supplied by the CXC controller.

Other standard features of the ACS HP series battery charger include high interrupting current input and output circuit breakers, AC and DC surge protection, common Form C alarm relay contacts, and high voltage shutdown.

For full component technical and operational details of the ACS HP series battery charger, please refer to the following manual sections pertaining to the Cordex 125-4.4kW modular switched mode rectifiers, the Cordex CXC controller, and the Cordex CXC controller software .

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