Alpha AMP24 HP User Manual
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.
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.
For technical support, contact Alpha Technologies:
Copyright
Copyright © 2012 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of
Alpha Technologies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated,
transcribed, or transmitted in any form or by any means manual, electric, electronic,
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Alpha Technologies.
This documentation, the software it describes, and the information and know-how they contain
constitute the proprietary, confidential and valuable trade secret information of Alpha Technologies,
and may not be used for any unauthorized purpose, or disclosed to others without the prior written
permission of Alpha Technologies.
The material contained in this document is for information only and is subject to change without
notice. While reasonable efforts have been made in the preparation of this document to assure
its accuracy, Alpha Technologies assumes no liability resulting from errors or omissions in this
document, or from the use of the information contained herein. Alpha Technologies reserves the right
to make changes in the product design without reservation and without notification to its users.
Canada and USA: 1-888-462-7487
International: +1-604-436-5547
Email: support@alpha.ca
Table of Contents
1. Safety .............................................................................................................................. 6
1.1 Safety Symbols ............................................................................................................................. 6
1.2 General Safety .............................................................................................................................. 7
1.3 External Battery Safety ................................................................................................................. 8
1.4 Utility Power Connection ............................................................................................................... 8
1.5 Equipment Grounding ................................................................................................................... 9
2. Product Description....................................................................................................... 10
2.1 Theory of Operation .................................................................................................................... 10
2.2 System Components ................................................................................................................... 12
2.3 Rear Components ....................................................................................................................... 13
2.4 Low Voltage Battery Disconnect (Optional) ................................................................................ 15
2.5 Battery Temperature Probes ....................................................................................................... 16
2.6 Network Requirements ............................................................................................................... 17
3. Power Congurations.................................................................................................... 19
3.1 Power System Conguration Terminology .................................................................................. 19
3.2 4i Shelf Systems (No Battery Charger) ....................................................................................... 20
3.3 3i+1R Shelf Systems (Integrated Battery Charger) .................................................................... 20
3.4 System Spares ............................................................................................................................ 20
3.5 120V Single Phase Systems ....................................................................................................... 21
3.6 120V/240V Split Phase or 120/208V 2-Pole Systems ................................................................ 24
3.7 120V/208V 3-Phase Systems ..................................................................................................... 27
3.8 AMPS24 HP - Recommended DC Breaker and Wire Sizes ....................................................... 29
3.9 How to Congure Inverters in AC Input Groups, AC Output Groups and DC Input Groups ....... 30
4. System Pre-Installation ................................................................................................. 32
4.1 Site Selection .............................................................................................................................. 32
4.2 Recommended Installation Layout .............................................................................................. 32
4.3 Transporting the Cabinet ............................................................................................................. 33
4.4 Unpacking Instructions ................................................................................................................ 34
5. Installation ..................................................................................................................... 35
5.1 Input/Output Cabling ................................................................................................................... 35
5.2 AC Wiring .................................................................................................................................... 37
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5.3 DC Battery and Ground Cabling ................................................................................................. 38
5.4 DC Ground .................................................................................................................................. 41
5.5 AMPS24 HP with External Maintenance Bypass Switch ............................................................ 42
5.6 Generator Automatic Transfer Switch ......................................................................................... 42
5.7 Commissioning the System for the First Time ............................................................................ 43
6. System Operation ......................................................................................................... 52
6.1 CXCU Controller Operation ........................................................................................................ 52
6.2 Inverter monitoring and control ................................................................................................... 55
6.3 Inverter Module Indicators .......................................................................................................... 62
6.4 Rectier Module .......................................................................................................................... 63
7. Preventive Maintenance ............................................................................................... 67
7.1 Recommended maintenance schedule ....................................................................................... 67
7.2 Tools and Equipment .................................................................................................................. 67
7.3 Spare Parts ................................................................................................................................. 68
7.4 Replacing a Rectier ................................................................................................................... 69
7.5 Replacing a Defective Fan—Inverter or Rectier ........................................................................ 69
7.6 Removing the CXCU Controller .................................................................................................. 69
7.7 Replacing the Surge Suppression Module .................................................................................. 70
7.8 Fuse Replacement ...................................................................................................................... 71
7.9 Synchronization with a Maintenance Bypass Switch (MBS) ....................................................... 73
8. Troubleshooting ............................................................................................................ 74
8.1 Non Recoverable Error ............................................................................................................... 74
8.2 Recoverable Error ....................................................................................................................... 74
9. System Specications ................................................................................................... 84
9.1 Power De-rating Due To Altitude ................................................................................................. 84
9.2 Power De-rating Due To Temperature ........................................................................................ 84
9.3 System Specications ................................................................................................................. 85
9.4 Specications for AIM 1500 Module ............................................................................................ 86
9.5 Specications for 48-1.8 kW Rectier (P/N 010-621-20-040) ..................................................... 87
10. Conguration Parameters ........................................................................................... 88
10.1 Transferring Inverter Settings to Another System ..................................................................... 88
10.2 Examples of Modications to Conguration Parameters .......................................................... 88
10.3 Global Settings (ID 1 – 50) ........................................................................................................ 90
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10.4 Inverter Parameters (ID 51 – 550) ............................................................................................ 91
10.5 Alarm Settings (ID 551-950) ...................................................................................................... 97
11. Warranty ...................................................................................................................... 99
11.1 Battery Warranty ....................................................................................................................... 99
12. Certication ............................................................................................................... 100
List of Figures
Figure 1 — AMPS24 HP System Components .................................................................................. 13
Figure 2 — Surge Suppression Modules ........................................................................................... 14
Figure 3 — AMPS24 HP rear view (with protective covers removed) ................................................ 14
Figure 4 — Eight-pin terminal strip and 40-pin connector pin locations ............................................. 15
Figure 5 — LVD wiring ....................................................................................................................... 16
Figure 7 — Batteries > Congure Batteries ....................................................................................... 17
Figure 6 — Battery temperature probes ............................................................................................ 17
Figure 8 — Cable connection to CXCU for graphic display ............................................................... 18
Figure 9 — Single network connection to CXCU ............................................................................... 18
Figure 10 — Multiple network connections to the CXCU ................................................................... 19
Figure 11 — Split Phase from a Single phase supply ........................................................................ 20
Figure 12 — 2-Pole from a 3-phase supply ...................................................................................... 20
Figure 13 — Monitoring AC Input Groups, AC Output Groups and DC Input Groups ....................... 31
Figure 14 — DC input breakers ......................................................................................................... 32
Figure 15 — Shipping dimensions (in inches) ................................................................................... 34
Figure 16 — AMPS24 Power and Battery Connections ..................................................................... 37
Figure 17 — AC Wiring connections diagram .................................................................................... 38
Figure 18 — AC Wiring (shown for 3-phase) ..................................................................................... 38
Figure 19 — Single feed, parallel battery strings ............................................................................... 39
Figure 20 — Dual feed, two battery strings in parallel ....................................................................... 40
Figure 21 — DC battery wiring with independent dual A/B feed ........................................................ 41
Figure 22 — DC ground, inverter only systems ................................................................................. 42
Figure 23 — Representative system wiring for AMPS24 HP system with MBS ................................ 43
Figure 24 — Controller ....................................................................................................................... 45
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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 and removing an inverter module ................................................................... 47
Figure 30 — Inverters > View Live Status.......................................................................................... 48
Figure 31 — Matching AC Input Groups to AC Output Groups ......................................................... 49
Figure 32 — Set Output (Split Phase System) .................................................................................. 50
Figure 33 — Inserting blanks in open slots ........................................................................................ 51
Figure 34 — CXCU system controller home screen .......................................................................... 53
Figure 35 — CXCU controller ............................................................................................................ 54
Figure 36 — Editing the user interface text. ....................................................................................... 55
Figure 37 — Inverters > View Live Status interface ........................................................................... 56
Figure 38 — Set Output window ........................................................................................................ 57
Figure 39 — Group Mapping window (shown for a two phase system) ............................................. 58
Figure 40 — Group Status window .................................................................................................... 58
Figure 41 — Set Input window .......................................................................................................... 59
Figure 42 — General Settings window .............................................................................................. 59
Figure 43 — Congure alarms window ............................................................................................. 60
Figure 44 — T2S alarms in event logs ............................................................................................... 61
Figure 45 — Retrieve alarm history le .............................................................................................. 61
Figure 46 — Signals (inverters) window ........................................................................................... 62
Figure 47 — Auto DC Priority ............................................................................................................. 62
Figure 48 — Inverter module status, power LEDs ............................................................................. 63
Figure 49 — Output power indicator LEDs ........................................................................................ 63
Figure 50 — Cordex 48-1.8kW .......................................................................................................... 64
Figure 51 — Surge Suppression Modules ......................................................................................... 71
Figure 52 — Rectier fuses (behind back top panel) ......................................................................... 72
Figure 53 — Fuse location for LCD touch screen .............................................................................. 73
Figure 54 — Maintenance Bypass Switch ......................................................................................... 74
Figure 55 — Manage Cong File window .......................................................................................... 89
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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 ................................................. 24
Table E — 21kVA, 18kVA, & 9.0kVA 120/240V Split Phase or 120/208 2-Pole 3i+1R Shelf ............. 26
Table F — 24kVA & 12KVA 120/240V Split Phase or 120/208 2-Pole 4i shelf Systems .................... 27
Table G — 18kVA and 13.5kVA, 120V/208V 3-Phase Systems ........................................................ 29
Table H — DC Input Groups .............................................................................................................. 32
Table I — Tools .................................................................................................................................. 68
Table J — Spare Parts ....................................................................................................................... 69
Table K — Inverter Alarm Codes ........................................................................................................ 78
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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 Safety Symbols
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.
The use of ATTENTION indicates specic regulatory/code requirements that may affect the
placement of equipment and /or installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure. Notes
are designated with a checkmark, the word NOTE, and a rule beneath which the information
appears.
CAUTION!
CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. Cautions are designated with a yellow warning triangle, the word CAUTION, and a rule
beneath which the information appears.
WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to personnel. Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath which the
information appears.
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or user.
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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.
• 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.
• Before installation, verify that the input voltage and current requirements of the load are within
the specifications of the power system. Refer to the product nameplate label.
• Keep tools away from walk areas to prevent personnel from tripping over the tools.
• Wear safety glasses when working under any conditions that may be hazardous to your eyes.
• Do not work on the power system, or connect or disconnect cables, during atmospheric lightning
activity.
• Do not let water enter the enclosure as this can cause electrical shorts, shocks, or electrocutions.
• Do not remove the covers of electrical components as this can cause electrical shorts, shocks or
electrocutions. There are no user serviceable parts inside.
• The power system is certified for use in restricted access locations only.
• All operators must be trained to perform the emergency shutdown procedure.
• For 3i+1R shelf models containing rectifiers, see section 7.8 to replace internal fuses.
• The power system must be connected only to a dedicated branch circuit.
• Equip the utility service panel with a circuit breaker of appropriate rating.
• Do not exceed the output rating of the system when connecting the load.
• External metal surface temperatures on the rear of the AMPS24 HP system can exceed 70°C.
Use caution when working around the equipment while it is in operation.
• Always use proper lifting techniques when handling units, modules, or batteries.
• The power system contains more than one live circuit. Voltage may still be present at the output
even when the input voltage is disconnected.
• Minimize the risk of sparks and wear on the connectors. Always switch off the inverter’s battery
circuit breaker before connecting or disconnecting the battery pack.
• In the event of a short-circuit, batteries present a risk of electrical shock and burns from high
currents. Observe proper safety precautions.
• Always wear protective clothing, such as insulated gloves, and safety glasses or a face shield
when working with batteries.
• Carry a supply of water, such as a water jug, to wash eyes or skin in case of exposure to battery
electrolyte.
• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result
in a fire or possible explosion.
• Replace batteries with those of an identical type and rating. Never install old or untested batteries.
• 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.
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• 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.
1.3 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.
• If the batteries are stored for extended periods before the installation, charge the batteries at
least once every three months to ensure optimum performance and maximum battery service
life.
• Refer to the battery manufacturer’s recommendation to select the correct float and equalize
charge voltage settings. Failure to do so can damage the batteries. Verify that the battery charger’s float and equalize settings are correct.
• The batteries are temperature sensitive. During extremely cold conditions, a battery’s charge
acceptance is reduced and requires a higher charge voltage. During extremely hot conditions,
a battery’s charge acceptance is increased and requires a lower charge voltage. To allow for
changes in temperature, the battery charger must be equipped with a temperature compensating system. For 3i+1R shelf systems, refer to the rectifier manual for information about temperature compensation.
• If the batteries appear to be overcharged or undercharged, first check for defective batteries
and then verify that the charger voltage settings are correct.
• To ensure optimal performance, inspect the batteries according to the battery manufacturers
recommendations. Check for signs of cracking, leaking, or unusual swelling. Some swelling is
normal.
• Check the battery terminals and connecting wires. Periodically clean the battery terminal con-
nectors and retighten them to the battery manufacturer's torque specifications. Spray the terminals with an approved battery terminal coating such as NCP-2 or No-Ox.
• Verify that the polarity of the cables are correct before connecting the batteries to the power
module. The polarity is clearly marked on the batteries. The battery breaker will trip and the rectifiers may be damaged if the cables are connected with the wrong polarity.
1.4 Utility Power Connection
Connecting to the utility must be performed by qualified service personnel only and must comply
with local electrical codes. The utility power connection must be approved by the local utility before
the installation.
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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.
1.5.1 Safety Ground
The safety ground is a two-part system – the utility service ground and the power system ground.
Utility Service Ground
As a minimum requirement for the protection of equipment, the local utility service must provide a
low-impedance 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.
Power System Ground
The power system ground consists of a low-impedance connection between the enclosure and an
Earth Ground, which must be located at least six feet away from the utility earth connection.
1.5.2 Lightning Strike Ground
Lightning strikes, grid switching, or other power surges on the power line and/or communications
cable can cause high-energy transients that can damage the power or communications systems.
Without a low-impedance path to the ground, the current will travel through wires of varying
impedance, which can produce damaging high voltages. The best method to protect the system
from damage is to divert these unwanted high-energy transients along a low-impedance path to the
ground.
See section "2.2 System Components" on page 13 for a description of the surge suppression modules
installed in the AMPS24 HP.
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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. A smart, unified controller with an integrated
Ethernet/SNMP monitors and manages both AC power modules and rectifier modules through
a remote web-based GUI. The AMPS24 HP is designed for installation in a climate-controlled
environment where ambient temperatures are between 0°C to 50°C (32 to 122°F).
2.1 Theory of Operation
AMPS modules feature a revolutionary high performance technology that combines the high reliability
of a telecom-grade inverter system with the high efficiency of a UPS.
Each AMPS module includes a reliable 48VDC-to-120VAC inverter as well as an AC-to-DC rectifier.
When AC Mains is available, AC power is converted to a high voltage DC bus, which is then
converted back to AC. In this high performance (HP) mode, AMPS delivers fully conditioned, lineregulated telecom-grade AC power with 93% system efficiency.
AC
Mains
DC In
CAN bus external
communication
When AC Mains is unavailable, DC battery power is converted to AC with zero transfer time. An
intelligent high voltage DC bus decides when to draw power, and how much power to draw, from AC
or DC source. During AC input brownout condition, output power is supplemented by battery power.
In case of a fault, advanced DSP controls allow the AMPS module to isolate itself, while the rest of the
system continues to power the load (with reduced output).
DSP
Dual redundant
communication and
synchronization
between modules
Telecom Grade
AC Output
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11
Boost
AC
Mains
DC In
CAN bus external
communication
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. If AC commercial power is available, this power is
filtered twice and passed to the AC output. If the AC commercial power fails, the DC converter
simply takes over and supplies the power from the batteries.
DSP
400 Vdc
Telecom Grade
AC Output
Dual redundant
communication and
synchronization
between modules
12
If DC priority is chosen, AMPS24 HP acts more like an Inverter with AC bypass function.
Normally, power is drawn from the batteries. If DC power fails, the AC-DC converter takes over,
still providing regulated and filtered power to the load.
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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
10
4
11
5
6
3
2
12
13
7
8
9
Figure 1 — AMPS24 HP System Components
1. Inverter AC Input Breaker: Main disconnect for AC input
2. Internal Maintenance B ypass Switch (MBS) (optional): Can be used to route power directly
from the AC input to the AC output, bypassing the inverter modules.
3. Inverter AC Output Breaker: Serves as the main disconnect for the inverter AC outputs.
4. Graphic display touch screen: Connected to the CXCU controller by cable (see figure)
5. RJ45 cable connector: Front panel connection for cable from the CXCU to the Graphic display
6. CXCU Unified System Controller with integrated Ethernet / SNMP: Monitors and manages
both inverter and rectifier modules through a web-based GUI (only 1 per unit).
7. DC Input Breakers: Individual DC input breakers for each shelf.
8. 4i or 3i+1R shelves: Up to four shelves for installing up to four hot-swappable AIM 1500
modules OR three AIM 1500 modules plus one 1800W rectifier per shelf.
9. AIM 1500 Modules: Up to 4 AIM 1500 per 4i (4 x inverter modules) shelf or up to 3 AIM 1500
per 3i+1R (3 x inverter modules and 1 x rectifier module) shelf.
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13
10. Rectifier Modules (opt ional): 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. The surge suppression modules,
shown in Figure 2, short to ground any unwanted
voltages above a safe threshold.
2.3 Rear Components
AC and DC wiring are accessed from the rear of the unit. See Chapter 5 for details.
A 3i+1R shelf system (one rectifier and three AIM1500 modules) has AC rectifier fuses that protect
the system from a wiring fault. Remove the back cover of the AC Wiring panel to access the fuses.
Figure 2 — Surge Suppression Modules
Remove grey cover to
change rectier fuses
Figure 3 — AMPS24 HP rear view (with protective covers removed)
AC distribution
panel
DC distribution
panel
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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
19
21
39
1
2
10
20
22
To install wires
in the 40-pin
connector, use
needle-nose pliers
to remove the ter-
minal blocks in the
40-pin connector.
40 pin
connector
40
Figure 4 — Eight-pin terminal strip and 40-pin connector pin locations
Table A — Eight-pin Terminal Strip from AMPS 24
1 TVSS2 alarm
2 Input circuit breaker (CB6) alarm
Factory installed
wiring
Customer
Doc. #: 0260011-J0 Rev B
3 Maintenance bypass switch alarm
4 Output circuit breaker (CB5) alarm
7 Fused DC-: 3A, CXCU LCD, V- to controller (fuse location shown in Figure 1)
8 DC+: CXCU LCD, V+ to controller
5 Fused DC-: up to 2A load, (fuse location shown in Figure 1)
6 DC+
15
Table B — Pinouts for 40 Pin Connector Interface to CXCR
1 DIN1 2 DIN2 Output circuit breaker CB5
3 D_COM Fused DC- 4 DIN3 MBS
5 DIN4 6 DIN5 Input circuit breaker CB6
7 D_COM Fused DC- 8 DIN6 TVSS
Not Used
9 N/A 10 N/A
11 N/A 12 N/A
Analog Inputs
13 V1+ 14 T1+
15 V1- 16 T1-
17 I1+ 18 T2+
19 I1- 20 T2-
Relay Contacts (rated at 60VDC or 42V AC, 0.5A)
From the factory, the Cordex controller is congured with the relay assignments shown below. The relays can
be unassigned from their factory conguration and remapped. For example Relay 2, K2, can be unassigned
from LVD #2 then remapped as an alarm relay. Refer to the Cordex controller manual for details.
21 K1_NO
LVD #1
25 K1_COM 26 K2_COM
27 K3_NO
LVD #3
31 K3_COM 32 K4_COM
33 Not installed 34 Not installed
35 K5_NO
Power System
Major alarm
39 K5_COM 40 K6_COM
22 K2_NO
28 K4_NO
36 K6_NO
Battery temperature probe
(Figure 6)
Battery temperature probe
(Figure 6)
LVD #223 K1_NC 24 K2_NC
Power System Minor alarm29 K3_NC 30 K4_NC
AC Mains High/Low alarm37 K5_NC 38 K6_NC
2.4 Low Voltage Battery Disconnect (Optional)
A built-in AMPS24 shutdown cuts off the load
during a lengthy power outage.
Installing an LVD (Alpha part number 020615-20), between the AMPS24 HP and the
batteries, disconnects the AMPS24 HP from
the batteries to prevent further drain of the
batteries during a lengthy power outage.
The controller is configured with a relay
assigned to LVD #1. Figure 5 shows how to
wire the normally closed contacts of the LVD
#1 relay to activate the LVD. The activation
value is set in the Controls >LVD Control
menu—see the controller software manual.
16
Pinouts available at the AMPS24 40 pin connector
– see Figure 4 and (Table B.
LVD#1
K1 Relay
-48V@Pin 3
AMPS24 HP
Pin 21
Pin 25
LVD
Pin 23
Batteries
Figure 5 — LVD wiring
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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. Figure 6 shows the connection of two
battery probes where pins #14 and #16 are used for
the second probe.
Connection Procedure
1. Use needle nose pliers to remove the terminal
block.
2. Connect the battery temperature probes,
3. To calibrate the temperature probes, refer to
Analog Signal Calibration in the CXCU manual or
to the alpha website (www.alpha.ca): Technical
Documentation > Method of Procedures
> Cordex > Controller > Calibration –
Temperature (web interface).
4. Complete the Batteries > Battery Properties
parameters to enable the Temperature
Compensation feature. The Battery Properties window contains information provided by the
battery manufacturer.
Figure 6 — Battery temperature probes
5. Set up temperature compensation in Batteries > Configure Batteries—see Figure 7.
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Figure 7 — Batteries > Configure Batteries
17
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
Figure 8 — Cable connection to CXCU for graphic display
CXCU RJ45
connection
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.
To use a laptop to configure the
system, disconnect the graphic
display cable from the RJ45
jack on the CXCU (Figure 8).
Connect the laptop to the RJ45
jack with an Ethernet crossover
cable.
CXCU installed
in AMPS24 HP shelf
Ethernet
connector
Ethernet
connector
Figure 9 — Single network connection to CXCU
OR
Graphic Display
http://10.10.10.201/
Obtain an IP Address Using DHCP
Use the following IP Address
IP Address:
10. 10. 10. 202
Subnet Mask:
255. 255. 255. 0
Default Gateway:
PC running IE8.0
or Firefox
Application SettingsCXC Connection SettingsIP Protocol SettingsConnection Status
Cancel Apply
18
Doc. #: 0260011-J0 Rev B
2.6.2 Multiple Connections
Since the CXCU controller only has one port, a switch must be used for the following requirements:
• Simultaneous display at the graphic display and a local laptop
• Local display at the graphic display and remote Simple Network Management Protocol (SNMP) /
Ethernet functionality
Alpha Technologies has tested the Netgear JFS516 network switch, but network switches with the following
functionality will work:
• Network Interface: RJ-45 connector for 10BASE-T or 100BASE-TX Ethernet interface
• Meets IEEE 802.3i 10BASE-T Ethernet, IEEE 802.3u,100BASE-TX Fast Ethernet
• Meets IEEE 802.3x Flow Control; compatible with Windows®
Graphic Display
http://10.10.10.201/
Obtain an IP Address Using DHCP
Use the following IP Address
IP Address:
10. 10. 10. 202
Subnet Mask:
255. 255. 255. 0
Default Gateway:
Application SettingsCXC Connection SettingsIP Protocol SettingsConnection Status
Cancel Apply
CXCU
Ethernet
connector
Remote Network
Access
PC running
IE7.0 or greater
or Firefox
Router or switch
Ethernet
Ethernet
PC running IE8.0
or Firefox
Figure 10 — Multiple network connections to the CXCU
Doc. #: 0260011-J0 Rev B
19
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).
3.1.3 120/240Vac 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.
3.1.2 120/208Vac 2-Pole
The term 120/208 2-POLE is used
throughout this manual to identify
the “2-pole from a 3-phase supply”
configuration such as L2 to L3 shown
in Figure 12.
120V /0°
N
120V /180°
Figure 11 — Split Phase from a Single phase supply
120V
120V
L1
240V
L2
L1
208V
L2
3.1.4 120/208Vac 3-Phase
Each phase conductor is 120 degrees out of phase with the other, as shown in Figure 12. All three
phases (3-pole) plus the neutral are used.
20
N
208V
Figure 12 — 2-Pole from a 3-phase supply
120V
208V
L3
Doc. #: 0260011-J0 Rev B
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
0260012-201 6kVA 4.8 kW
0260012-203 12kVA 9.6 kW 2 8
0260012-202
(no LCD)
0260012-204 12kVA 9.6 kW 120/208 V 2-phase
0260012-206 24kVA 19.2 kW 4 16
0260012-205 18kVA 14.4 kW 120/208 V 3-phase 3 12 Section 3.7
Max AC
output VA
" " " " " "
Max AC
output power
AC Input and
Output voltage
120 V single phase
or
120/240 V split phase
# of 4
Inverter
shelves
1 4
2 8
Max # of
AIM1500
modules
3.3 3i+1R Shelf Systems (Integrated Battery Charger)
3i+1R Shelf Systems have 1 rectifier per shelf and up to 3 inverters per shelf.
System Part
Number
0260011-101 4.5kVA 3.6 kW
0260011-102 9kVA 7.2 kW 2 x 3i+1R shelves 6
0260011-104
0260011-103
0260011-106 18kVA 14.4 kW 4 x 3i+1R shelves 12
0260011-107
0260011-105 13.5kVA 10.8 kW 120/208 V 3-phase 3 x 3i+1R shelves 9 Section 3.7
Max AC
output VA
10.5kVA 8.4 kW 1 x 3i+1R shelf
9kVA 7.2 kW
21kVA 16.8 kW 2 x 3i+1R shelf
Max AC
output power
AC Input and
Output voltage
120 V single phase
120/208 V 2-pole
or
120/240 V split
phase
# of 3i+1R
shelves
1 x 3i+1R shelf 3
plus 1 x 4i shelf
2 x 3i+1R shelves 6
plus 2 x 4i shelf
Max # of
AIM1500
modules
14
Reference
Section 3.5
Section 3.6
Reference
Section 3.5
7
Section 3.6
3.4 System Spares
See "Table J — Spare Parts" on page 69.
Doc. #: 0260011-J0 Rev B
21
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
Configurations for Two Shelves
• two 4i shelves
• two 3i+1R shelves
• one 3i+1R shelf and one 4i shelf
DC 1
DC 2
Phase 1
Phase 1
22
Doc. #: 0260011-J0 Rev B
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
Models
AC Input Voltage 120V 120V 120V
Full Load AC Input Current
(per phase)
AC Input poles & wiring 2w +G 2w + G 2w + G
Wiring 1 pole 1 pole 1 pole
SCCR 2100A 2100A 1600A
Recommended
AC Input
AC input Breaker/fuse
(Note: 2)
Recommended
AC Input Wire size,
90ºC copper (Note 1)
Total AC Output (Max)
AC Output Voltage 120V 120V 120V
AC Output poles & wiring 2w +G 2w +G 2w +G
Wiring 1 pole 1 pole 1 pole
AC Output Current (per Phase) 87.5A 75A 37.5A
NEC
50ºC
CEC
50ºC
AMPS24-1-10.5-H1-i1
#0260011-104
108A 108A 54A
125A 120A 70A
1 1/0 6
1/0 1/0 4
10.5kVA/
8.4kW
AMPS24-1-9-H2
#0260011-102
9kVA/7.2kW 4.5kVA/3.6kW
AMPS24-1-4.5-H1
#0260011-101
Installed Inverter Output
Circuit Breaker 100% rated
AC Output
Recommended
AC Input Wire size,
90ºC copper (Note 1)
AC Input & Output
connection terminals
Doc. #: 0260011-J0 Rev B
100A 100A 70A
NEC
50ºC
CEC
50ºC
Box lugs are rated for both Aluminum and Copper wire, #2/0 to #6 AWG. Fasten
clamping screw to 120 in-lbs (14 N-m)
1 1 6
1/0 1/0 4
23
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.
Table D — 12kVA and 6kVA, 120V Single Phase, 4i Shelf
Systems
Models
AMPS24-2-12-i2
#0260012-203/202
AC Input Voltage 120V 120V
Full Load AC Input Current
(per phase)
AC Input poles & wiring 2w +G 2w +G
Wiring 1 pole 1 pole
SCCR 2100A 1600A
Recommended
AC Input
AC input Breaker/fuse
(Note: 2)
Recommended
AC Input Wire size,
90ºC copper (Note 1)
Total AC Output (Max)
AC Output Voltage 120V 120V
AC Output poles & wiring 2w +G 2w +G
Wiring 1 pole 1 pole
AC Output Current (per Phase) 100A 50A
NEC 50ºC
CEC 50ºC
106A 53A
150A 70A
1 6
1/0 4
12kVA/
9.6kW
AMPS24-1-6-i1
#0260012-201
6kVA/
4.8kW
24
Installed Inverter Output
Circuit Breaker 100% rated
AC Output
Recommended
AC Input Wire size,
90ºC copper (Note 1)
AC Input & Output
connection terminals
Note 1:
Note 2:
Inverter AC Input & AC Output connections: Calculations based on full load and charging current, 0.8
derating with 5 current carrying conductors, (L1,L2,L3,2xN) due to possible high harmonic content load.
Temperature correction factor for 50C applied.
Maximum AC Utility Service protection feeding the AMPS24 is 150A. Actual supply circuit breaker must
be sized appropriately for the supply wire used. Consult your local and national electrical codes. Double
neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with
signicant non-linear (ie rectied capacitive) loads. Since the AC input to systems without MBS is power
factor corrected, AC wiring to systems without MBS does not require double neutral wiring.
100A 70A
NEC 50ºC
CEC 50ºC
Box lugs are rated for both Aluminum and Copper wire, #2/0 to #6
AWG. Fasten clamping screw to 120 in-lbs (14 N-m)
1 6
1/0 4
Doc. #: 0260011-J0 Rev B
3.6 120V/240V Split Phase or 120/208V 2-Pole Systems
For facility planning data sheets, see
• "Table E — 21kVA, 18kVA, & 9.0kVA 120/240V Split Phase or 120/208 2-Pole 3i+1R Shelf Systems" on page
26 and
• "Table F — 24kVA & 12KVA 120/240V Split Phase or 120/208 2-Pole 4i shelf Systems" on page 27
Configurations for Two Shelves
• two 4i shelves (AMPS24-2-12-i2)
• two 3i+1R shelves (AMPS24-2-9-H2)
DC 1
DC 2
Configurations for Four Shelves
• four 4i shelves (AMPS24-2-24-i4)
• four 3i+1R shelves (AMPS24-2-18-H4)
• two 3i+1R shelves and two 4i shelves (AMPS24-2-21-H2-i2)
DC 1
Phase 1
Phase 2
Phase 1
DC2
DC 3
DC 4
Doc. #: 0260011-J0 Rev B
Phase 2
25
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, & 9.0kVA 120/240V Split Phase or 120/208
2-Pole 3i+1R Shelf Systems
Models
AC Input Voltage 120/208V or 120/240V 120/208V or 120/240V 120/208V or 120/240V
Full Load AC Input Current
(per phase)
AC Input poles & wiring 3w + G 3w + G 3w + G
Wiring 2 pole 2 pole 1 pole
SCCR 2100A 2100A 1600A
Recommended
AC Input
AC input Breaker/fuse
(Note: 2)
Recommended
AC Input Wire size,
90ºC copper (Note 1)
Total AC Output (Max)
AC Output Voltage 120/208V or 120/240V 120/208V or 120/240V 120/208V or 120/240V
NEC 50ºC
CEC 50ºC
AMPS24-2-21-H2-i2
0260011-107
118A 121A 61A
150A 150A 80A
2/0 2/0 3
2/0 2/0 3
21kVA/
16.8kW
AMPS24-2-18-H4
0260011-106
18kVA/
14.4kW
AMPS24-2-9-H2
0260011-103
9kVA/
7.2kW
26
AC Output poles & wiring 3w + G 3w + G 3w + G
Wiring 2 pole 2 pole 1 pole
AC Output Current (per Phase) 87.5A 75A 37.5A
Installed Inverter Output
Circuit Breaker 100% rated
AC Output
Recommended
AC Input Wire size,
90ºC copper (Note 1)
AC Input & Output
connection terminals
NEC 50ºC
CEC 50ºC
Box lugs are rated for both Aluminum or Copper wire, #2/0 to
#6 AWG. Fasten clamping screw to 120 in-lbs (14 N-m)
100A 100A 70A
2/0 2/0 3
2/0 2/0 3
Doc. #: 0260011-J0 Rev B
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.
Table F — 24kVA & 12KVA 120/240V Split Phase or 120/208
2-Pole 4i shelf Systems
Models
AC Input Voltage 120/208V or 120/240V 120/208V or 120/240V
Full Load AC Input Current
(per phase)
AC Input poles & wiring 3w + G 3w + G
Wiring 2 pole 2 pole
SCCR 2100A 1600A
Recommended
AC Input
AC input Breaker/fuse
(Note: 2)
Recommended
AC Input Wire size,
90ºC copper (Note 1)
Total AC Output (Max) 24kVA/19.2kW 12kVA/9.6kW
AC Output Voltage 120/208V or 120/240V 120/208V or 120/240V
AC Output poles & wiring 3w + G 3w + G
Wiring 2 pole 2 pole
AC Output Current (per Phase) 100A 50A
NEC 50ºC
CEC 50ºC
AMPS24-2-24-i4
0260012-206
106A 53A
150A 70A
2/0 4
2/0 4
AMPS24-2-12-i2
0260012-204
Installed Inverter Output
Circuit Breaker 100% rated
AC Output
Recommended
AC Input Wire size,
90ºC copper (Note 1)
AC Input & Output
connection terminals
Note 1:
Note 2:
Doc. #: 0260011-J0 Rev B
Inverter AC Input & AC Output connections: Calculations based on full load and charging current, 0.8
derating with 5 current carrying conductors, (L1,L2,L3,2XN) due to possible high harmonic content load.
Temperature correction factor for 50C applied.
Maximum AC Utility Service protection feeding the AMPS24 is 150A. Actual supply circuit breaker must
be sized appropriately for the supply wire used. Consult your local and national electrical codes. Double
neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with
signicant non-linear (ie rectied capacitive) loads. Since the AC input to systems without MBS is power
factor corrected, AC wiring to systems without MBS does not require double neutral wiring.
100A 70A
NEC 50ºC
CEC 50ºC
Box lugs are rated for both Aluminum and Copper wire, #2/0 to #6
AWG. Fasten clamping screw to 120 in-lbs (14 N-m)
2/0 4
2/0 4
27
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
• three 4i shelves (AMPS24-3-18-i3)
• three 3i+1R shelves (AMPS24-3-13.5-H3)
DC 1
DC 2
DC 3
Phase 1
Phase 2
Phase 3
28
Doc. #: 0260011-J0 Rev B
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