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:
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, electromechanical, chemical, optical, or
otherwise without prior explicit written permission from 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.
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 equip-
ment. 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.
6
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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.
• Maintain the security of all SELV Circuits in the AMPS80 when connecting to other equipment like signal-
ing/alarm circuits, emergency power off (EPO) circuits, relay contacts, Ethernet or CANBUS. The other
equipment must be the same circuit type.
• Bolt the AMPS80 HP system securely 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 electro-
cutions. 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 Hybrid UPS configurations, see section 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 AMPS80 HP system can exceed 70°C. Use cau-
tion 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.
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• 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.
1.3 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 Hybrid UPS
configurations, 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 connectors
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 lowimpedance 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 7.7 for a description of the surge suppression modules installed in the AMPS80 HP.
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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. A smart, unified controller with an integrated Ethernet/SNMP monitors and manages both inverter and rectifier modules through a web based GUI and
a local LCD touch screen. The AMPS80 HP is designed to be installed in a climate-controlled environment
where ambient temperatures are between -20°C to 40°C.
2.1 Theory of Operation
Each AMPS module includes a reliable 48 VDC to 120 VAC 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, line-regulated telecom-grade AC
power with 94% 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.
AC to DC input transfer can also be automatically triggered via the system controller to enable advanced
operation such as utility peak shaving.
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
10
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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.
DSP
400 Vdc
Dual redundant
communication and
synchronization
between modules
Telecom Grade
AC Output
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. 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.
If DC priority is chosen, the AMPS80 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 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. 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
1
2
3
4
5
6
fed through the opening at the top of the rack.
2. Rectifier AC Input Breakers (optional): Provide a
means to switch off the rectifiers independently of the
inverters.
3. Inverter AC Input Breaker: Serves as the main
disconnect for the inverter AC input.
4. Maintenance Bypass Switch (MBS) (optional): Can
be used to route power directly from the AC input to
the AC output, bypassing the inverter modules.
5. Inverter AC Output Breaker: Serves as the main
disconnect for the inverter AC outputs.
6. CXC Unified System Controller with integrated
Ethernet/ SNMP: Monitors and manages both
inverter and rectifier modules through a web-based
GUI and local LCD touch screen. This is a SELV
controller.
7
7. DC Input Breakers (optional): Provide SELV DC
power to each Inverter module.
8
8. T2S Inverter Control Card: Communicates with the
CXC Unified controller. This is a SELV Controller.
9. Inverter Modules and shelves: Up to 9 shelves
containing 4 hot-swappable 2500 VA / 2000 W inverter
modules on each shelf.
10. Rectifier Modules and shelves (optional): Tw o
shelves contain up to four hot-swappable 1800 W
9
rectifier modules on each shelf. The rectifiers are used
as the SELV DC battery charging component of a
hybrid system.
Each rectifier shelf is only connected to one of the DCbattery feeds: the top shelf to DC1, and the bottom
rectifier shelf is connected to DC4. In a system with
four independent battery feeds, two of these battery
banks will not be charged from the AMPS80 HP
rectifiers.
10
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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
Front
Breaker for signal
wiring and DC4 to
the controller
Figure 1 — Controller breakers on top of the AMPS80
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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.
• 20 kVA, see Table F on page 24
• 40 kVA, see Table E on page 23
Optional DC
breaker inputs
DC 1
DC 2
DC 3
DC feeds for inverters
DC 4
Blank panel
Inverters for AC phase 1 (L1)
Inverters for AC phase 2 (L2)
Blank panels
14
Rectier output to DC1
Rectier output to DC4
Figure 2 — 20 kVA split-phase or 120/208V 2-pole system
Doc. #: 026-069-B0 Rev F
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Optional DC
breaker inputs
DC 1
DC 2
DC 3
DC feeds for inverters
DC 4
Inverters for AC phase 1 (L1)
Inverters for AC phase 2 (L2)
Blank panels
Doc. #: 026-069-B0 Rev F
Rectier output to DC1
Rectier output to DC4
Figure 3 — 40 kVA, split-phase or 120/208V 2-pole system
15
Page 18
2.4.2 3-phase systems
Optional DC
breaker inputs
DC 1
DC 2
DC 3
DC feeds for inverters
DC 4
Inverters for AC phase 1 (L1)
Inverters for AC phase 2 (L2)
Inverters for AC phase 3 (L3)
16
Rectier output to DC1
Rectier output to DC4
Figure 4 — 75 kVA, 3-phase systems
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Page 19
Optional DC
breaker inputs
DC 1
DC 2
DC 3
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
Doc. #: 026-069-B0 Rev F
Rectier output to DC1
Rectier output to DC4
Figure 5 — 30 kVA, 3-phase system
17
Page 20
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).
3.1.4 120/240Vac 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 6.
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 7.
120V120V
N
Figure 6 — Split Phase from a Single phase supply
120V
120V
L1
240V
L2
L1
208V
L2
3.1.3 3-Phase
Each phase conductor carries the same
current, 120 degrees out of phase with each
other as shown in Figure 7.
208V
Figure 7 — 2-Pole from a 3-phase supply
120V
N
3.1.5 120/208Vac 3-Phase
Each phase conductor is 120 degrees out of phase with the other, as shown in Figure 7. All three phases (3pole) plus the neutral are in use.
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Doc. #: 026-069-B0 Rev F
208V
L3
Page 21
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.
T able A — 75 kVA, 3-phase systems (AMPS80-3-75 series), single AC feed
Model
AC
input
MBS
AMPS80-3-75
AC input voltage120/208 V120/208 V120/208 V120/208 V
Full load AC input current per phase177 A227 A223 A273 A
AC input poles & wiring4 w + G4 w + G4 w + G4 w + G
Total maximum AC output75 kVA, 60 kW75 kVA, 60 kW75 kVA, 60 kW75 kVA, 60 kW
AC output poles & wiring4 w + G4 w + G4 w + G4 w + G
AC
output
AC input & output
connection terminals
Note 1
Note 2
AC output current per phase208 A208 A208 A208 A
Installed inverter input
& output circuit breaker
Recommended
AC output wire size
90ºC copper
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
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized
appropriately for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to
18 kA short circuit current. 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. Because the AC input to the inverters is power
factor corrected, AC wiring solely to the inverters does not require double neutral wiring.
AC output voltage120/208 V120/208 V120/208 V120/208 V
Wiring
NEC 30ºC#4/0#4/0#4/0#4/0
CEC 30ºC250 kcmil250 kcmil250 kcmil250 kcmil
1
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw to
42 N-m (375 in-lbs) for #1 A WG to 350 kcmil wire or 23 N-m (200 in-lbs) for #6 to #2 AWG wire.
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.
Table B — 75 kVA, 3-phase systems (AMPS80-3-75 series), dual AC feeds
Model
Dual feed with separate AC
feed for inverters/MBS and
rectiers
AMPS80-3-75-H2
AMPS80-3-75-H2,
MBS
AC
input
AC
output
AC feedInverter feed
AC input voltage120/208 V208 V120/208 V208 V
Full load AC input current per phase177 A50 A223 A50 A
AC input poles & wiring4 w + G4 w + G4 w + G4 w + G
Wiring
Recommended
AC input breaker/fuse
Recommended
AC input wire size
90ºC copper
Total maximum AC output75 kVA, 60 kW75 kVA, 60 kW
AC output poles & wiring4 w + G4 w + G
AC output current per phase208 A208 A
Installed inverter input
& output circuit breaker
Recommended
AC output wire size
90ºC copper
1
AC output voltage120/208 V120/208 V
Wiring
1
2
NEC 30ºC#3/0#6250 kcmil#6
CEC 30ºC#4/0#4300 kcmil#4
NEC 40ºC#4/0#6300 kcmil#6
CEC 40ºC250 kcmil#4350 kcmil#4
NEC 30ºC#4/0#4/0
CEC 30ºC250 kcmil250 kcmil
NEC 40ºC250 kcmil250 kcmil
CEC 40ºC300 kcmil300 kcmil
3Ф Wye3Ф Wye3Ф Wye3Ф Wye
225 A70 A300 A70 A
Rectier feed
3Ф Wye3Ф Wye
250 A250 A
Inverter/MBS
feed
Rectier feed
AC input & output
connection terminals
Rectier connection
Note 1
Note 2
20
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw to
42 N-m (375 in-lbs) for #1 A WG to 350 kcmil wire or 23 N-m (200 in-lbs) for #6 to #2 AWG wire.
terminals
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
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized
appropriately for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to
18 kA short circuit current. 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. Because the AC input to the inverters is power
factor corrected, AC wiring solely to the inverters does not require double neutral wiring.
Box lugs are rated for either Aluminum or Copper wire, #2/0 to #6 AWG. Fasten clamping screw to 14
N-m (120 in-lbs)
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Page 23
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 — 30 kVA, 3-phase systems (AMPS80-3-30...), single AC feed
Model
MBS
MBS
AC
input
AC
output
AMPS80-3-30
FeedSingleSingleSingleSingle
AC input voltage120/208 V120/208 V120/208 V120/208 V
Full load AC input current per phase71 A121 A88 A138 A
AC input poles & wiring4 w + G4 w + G4 w + G4 w + G
Wiring
Recommended
AC input breaker/fuse
Recommended
AC input wire size
90ºC copper
Total maximum AC output30 kVA, 24 kW30 kVA, 24 kW30 kVA, 24 kW30 kVA, 24 kW
AC output poles & wiring
AC output current per phase83 A83 A83 A83 A
Installed inverter input
& output circuit breaker
1
AC output voltage
Wiring3Ф Wye3Ф Wye3Ф Wye3Ф Wye
2
NEC 30ºC#4#1#2#1/0
CEC 30ºC#3#1/0#2#2/0
NEC 40ºC#3#1/0#2#2/0
CEC 40ºC#3#2/0#2#2/0
3Ф Wye3Ф Wye3Ф Wye3Ф Wye
90 A150 A125 A175 A
120/208 V120/208 V120/208 V120/208 V
4 w + G4 w + G4 w + G4 w + G
125 A125 A125 A125 A
AMPS80-3-30-H2
AMPS80-3-30,
AMPS80-3-30-H2,
Recommended
AC output wire size
90ºC copper
AC input & output
connection terminals
Inverter AC Input & AC Output connections: Calculations based on full load and charging current, 0.8 derating with 5
Note 1
Note 2
current carrying conductors, (L1,L2,L3,2XN) due to possible high harmonic content load. Temperature correction factor
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized
appropriately for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to 18
kA short circuit current. 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. Because the AC input to the inverters is power factor corrected,
AC wiring solely to the inverters does not require double neutral wiring.
Doc. #: 026-069-B0 Rev F
NEC 30ºC#2#2#2#2
CEC 30ºC#2#2#2#2
1
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw
to 42 N-m (375 in-lbs) for #1 A WG to 350 kcmil wire or 23 N-m (200 in-lbs) for #6 to #2 AWG wire.
NEC 40ºC#1#1#1#1
CEC 40ºC#1#1#1#1
21
Page 24
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.
Table D — 40 kVA, split-phase, 2-pole systems (AMPS80-2-40 series), single AC feed
AC
input
AC
output
Model
AMPS80-2-40
FeedSingleSingleSingleSingle
AC input voltage
Full load AC input current per phase148 A225 A179 A256 A
AC input poles & wiring3 w + G3 w + G3 w + G3 w + G
Wiring2-pole2-pole2-pole2-pole
Recommended
AC input breaker/fuse
Recommended
AC input wire size
90ºC copper
Total maximum AC output40 kVA, 32 kW40 kVA, 32 kW40 kVA, 32 kW40 kVA, 32 kW
AC output poles & wiring3 w + G3 w + G3 w + G3 w + G
AC output current per phase167 A167 A167 A167 A
Installed inverter input
& output circuit breaker
Recommended
AC output wire size
90ºC copper
1
AC output voltage
Wiring
1
2
NEC 30ºC#2/0250 kcmil#3/0350 kcmil
CEC 30ºC#3/0300 kcmil#4/0See dual feed
NEC 40ºC#3/0250 kcmil#3/0See dual feed
CEC 40ºC#3/0l300 kcmil#4/0See dual feed
NEC 30ºC#4/0#4/0#4/0#4/0
CEC 30ºC250 kcmil250 kcmil250 kcmil250 kcmil
NEC 40ºC250 kcmil250 kcmil250 kcmil250 kcmil
CEC 40ºC300 kcmil300 kcmil300 kcmil300 kcmil
120/208 V
or 120/240 V
200 A300 A225 A350 A
120/208 V
or 120/240 V
2-pole2-pole2-pole2-pole
250 A250 A250 A250 A
AMPS80-2-
40-H2
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AMPS80-2-40,
MBS
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AMPS80-2-
40-H2, MBS
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AC input & output
Note 1
Note 2
22
connection
terminals
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
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized appropriately
for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to 18 kA short circuit current.
Double neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with signicant nonlinear (ie rectied capacitive) loads. Because the AC input to the inverters is power factor corrected, AC wiring solely to the inverters
does not require double neutral wiring.
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw to
42 N-m (375 in-lbs) for #1 A WG to 350 kcmil wire or 23 N-m (200 in-lbs) for #6 to #2 AWG wire.
Doc. #: 026-069-B0 Rev F
Page 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 — 40 kVA, split-phase, 2-pole systems (AMPS80-2-40 series), dual AC feeds
Model
Dual feed with separate AC
feed for inverters/MBS and
rectiers
AMPS80-2-40-H2
AMPS80-2-40-H2,
MBS
AC
input
AC
output
AC feedInverter feed
AC input voltage
Full load AC input current per phase148 A77 A179 A77 A
AC input poles & wiring3 w + G3 w + G3 w + G3 w + G
Wiring2-pole2-pole2-pole2-pole
Recommended AC
input breaker/fuse
Recommended
AC input wire size
90ºC copper
Total maximum AC output40 kVA, 32 kW40 kVA, 32 kW
AC output poles & wiring3 w + G3 w + G
AC output current per phase167 A167 A
Installed inverter input
& output circuit breaker
Recommended
AC output wire size
90ºC copper
1
AC output voltage120/208 V or 120/240 V20/208 V or 120/240 V
Wiring
1
2
NEC 30ºC#2/0#3#3/0#3
CEC 30ºC#3/0#3#4/0#3
NEC 40ºC#2/0#3#3/0#3
CEC 40ºC#2/0#3#4/0#3
NEC 30ºC#4/0#4/0
CEC 30ºC250 kcmil250 kcmil
NEC 40ºC250 kcmil250 kcmil
CEC 40ºC300 kcmil300 kcmil
120/208 V
or 120/240 V
200 A100 A225 A100 A
Rectier feed
208 V or 240 V
2-pole2-pole
250 A250 A
Inverter/MBS feed
120/208 V
or 120/240 V
Rectier feed
208 V
or 240 V
AC input & output
connection terminals
Rectier connection
Note 1
Note 2
terminals
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
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized
appropriately for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to 18 kA short
circuit current. 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. Because the AC input to the inverters is power factor corrected, AC wiring solely
to the inverters does not require double neutral wiring.
Doc. #: 026-069-B0 Rev F
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw to
375 in-lbs (42 N-m) for #1 A WG to 350 kcmil wire or 200 in-lbs (23 N-m) for #6 to #2 AWG wire.
Box lugs are rated for either Aluminum or Copper wire, #2/0 to #6 AWG. Fasten clamping screw to 14
N-m (120 in-lbs)
23
Page 26
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 — 20 kVA, split-phase, 2-pole systems (AMPS80-2-20 series),
single AC feed
AC
input
AC
output
Model
AMPS80-2-20
FeedSingleSingleSingleSingle
AC input voltage
Full load AC input current per phase71 A148 A89 A166 A
AC input poles & wiring3 w + G3 w + G3 w + G3 w + G
Wiring2-pole2-pole2-pole2-pole
Recommended
AC input breaker/fuse
Recommended
AC input wire size
90ºC copper
Total maximum AC output20 kVA, 16 kW20 kVA, 16 kW20 kVA, 16 kW20 kVA, 16 kW
AC output poles & wiring3 w + G3 w + G3 w + G3 w + G
AC output current per phase83 A83 A83 A83 A
Installed inverter input
& output circuit breaker
1
AC output voltage
Wiring
2
NEC 30ºC#4#2/0#2#3/0
CEC 30ºC#3#3/0#2#4/0
NEC 40ºC#4#2/0#2#3/0
CEC 40ºC#3#3/0#2#4/0
120/208 V
or 120/240 V
90 A200 A125 A225 A
120/208 V
or 120/240 V
2-pole2-pole2-pole2-pole
125 A125 A125 A125 A
AMPS80-2-
20-H2
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AMPS80-2-
20, MBS
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AMPS80-2-
20-H2, MBS
120/208 V
or 120/240 V
120/208 V
or 120/240 V
AC input & output
connection terminals
Note 1
Note 2
24
NEC 30ºC#2#2#2#2
Recommended
AC output wire size
90ºC copper
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
applied when needed.
Maximum AC utility service protection feeding the AMPS80 HP is 400 A. The actual supply circuit breaker must be sized
appropriately for the supply wire used. Consult your local and national electrical codes. The AC source must be limited to 18 kA
short circuit current. 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. Because the AC input to the inverters is power factor corrected, AC wiring
solely to the inverters does not require double neutral wiring.
1
Box lugs are rated for either Aluminum or Copper wire, 350 kcmil to #6 AWG. Fasten clamping screw
to 42 N-m (375 in-lbs) for #1 A WG to 350 kcmil wire or 23 N-m (200 in-lbs) for #6 to #2 AWG wire.
CEC 30ºC#2#2#2#2
NEC 40ºC#1#1#1#1
CEC 40ºC#1#1#1#1
Doc. #: 026-069-B0 Rev F
Page 27
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.
Table G — Recommended DC fuse/breaker
Model
DC
input
AMPS80-3-75
AMPS80-3-75-H2
Maximum DC Input wattage 67 kW27 kW36 kW18 kW
Maximum DC Input Current
@ 48 Vdc, full load
DC input current @ 40 V
110% load
Maximum DC input breaker
Single DC
Recommended
minimum DC fuse/
breaker rating
(100% rated, per
feed)
feed
Dual DC
feed
Quad DC
feed
1396 A563 A750 A375 A
1843 A743 A990 A495 A
2000 A800 A1000 A500 A
1200 A400 A500 A250 A
600 A200 A250 A125 A
AMPS80-3-30
AMPS80-3-30-H2
2500 A, maximum 50 kA SCC
AMPS80-2-40
AMPS80-2-40-H2
AMPS80-2-20
AMPS80-2-20-H2
Doc. #: 026-069-B0 Rev F
25
Page 28
3.5 AMPS80 DC Feed Options
Table H — DC Feed Option – Max Load Power and Redundancy Power
# of
Independent
DC Sources
Feed Option
Redundancy
Possible Output
AMPS80-3-75
Max Load Power
AMPS80-3-75
Redundancy Power
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
2. Single Feed with
One
Two5. Dual FeedN+N37.5kVA30kW20kV16kW15kVA12kW
Four7. Quad FeedN+1,
DC Breaker option
3. Dual FeedN+N37.5kVA30kW20kV16kW15kVA12kW
4. Quad FeedN+2
6. Quad FeedN+2
N+0,
N+1,
N+2
N+3
N+N
N+3
N+3
N+N
N+2
N+352.5kVA42kW
75kVA
67.5kVA
60kVA
52.5kVA
37.5kVA
60kVA
52.5kVA
60kVA
52.5kVA
37.5kVA
60kW
54kW
48kW
42kW
30kW
48kW
42kW
48kW
42kW
30kW
40kVA
35kVA
30kVA
25kVA
20kVA
30kVA
25kVA
30kVA
25kVA
20kVA
30kVA24kW
32kW
28kW
24kW
20kW
16kW
24kW
20kW
24kW
20kW
16kW
30kVA
22.5kVA
15kVA
7.5kVA
15kVA
15kVA
7.5kVA
15kVA
7.5kVA
15kVA
22.5kVA18kW
24kW
18kW
12kW
6 kW
12kW
12kW
6 kW
12kW
6 kW
12kW
26
Doc. #: 026-069-B0 Rev F
Page 29
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).
The logical approach is to match the configuration of inverters in the AC Input Group to the configuration of
inverters in the AC Output Group as shown. See Figure 9 also for three Input Groups.
These groups of inverters can then be monitored as a unit in the
Turn off the inverters to congure
AC Output Groups by clicking the
green power icon.
View Group Status screen.
Figure 8 — Monitotring AC Input Groups, AC Output Groups and DC Input Groups
Doc. #: 026-069-B0 Rev F
27
Page 30
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.
MonitoringDC Source
BulkAssign all inverters to DC Input Group 1.
Dual Input For example:
Assign all the inverters in column 1 & 2 to DC Input Group 1.
Assign all the inverters in shelves 3 & 4 to DC Input Group 2.
Quad InputFor example:
Assign all the inverters in column 1 to DC Input Group 1.
Assign all the inverters in shelves 2 to DC Input Group 2.
Assign all the inverters in column 3 to DC Input Group 3.
Assign all the inverters in shelves 4 to DC Input Group 4.
28
Figure 9 — Inverter mapping for AC and DC Groups
Doc. #: 026-069-B0 Rev F
Page 31
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.
4.1.1 Floor Plan Layout
Sufficient free space must be provided at the front and rear of the power system to meet the cooling requirements of the inverters and rectifiers(if installed) in the power system and to allow easy access to the power
system components.
Consider the following before selecting a location for the AMPS80 HP power system
• Structure of building able to support the additional weight
• Enough space to meet requirements for access
• Enough space to meet cooling requirements of the rectifiers
• Adequate space to do the install
• Route that equipment will take through the building to reach the site
• Check and record distances to load
• Check and record distances to AC power source
• Check and record distances to batteries/DC power source
• Understand the full load on the DC system
• Window for working hours and other similar restrictions
• How much and what kind of prep work can be done in advance
xReinforce floors
xInstall distribution panels
xInstall cable racks
xRun wiring
xMinimize cable lengths (cost)
xMinimize cable flow and congestion
Doc. #: 026-069-B0 Rev F
29
Page 32
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.
However for 75 kVA hybrid systems and systems with TVSS option, 36" (100 cm) clearance to the left
side of the cabinet is strongly recommended for ease of service
• Top: 12" (30 cm)
• Front: 36" (100 cm)
OTHER EQUIPMENT OR WALL
OTHER EQUIPMENT
OR WALL
[1 m]
3 Feet
The 1m recommended
clearance only applies to 75kVA
hybrid systems with TVSS
option (for ease of service).
Minimum distance
for service
[1 m]
3 Feet
18in
[46cm]
Rear
Front
[15cm]
6.0in
Minimum distance
for ventilation
Minimum distance
for ventilation
OTHER EQUIPMENT
OR WALL
30
Figure 10 — Installation layout and clearances
Doc. #: 026-069-B0 Rev F
Page 33
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.
Doc. #: 026-069-B0 Rev F
Figure 11 — System Schematic with Generator and MBS
31
Page 34
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.
Use the supplied lifting eyes to lift the cabinet from the top. The lifting eyes are accessible by removing the
top sheet of wood from the shipping crate.
Figure 12 — Arrangement of lifting eyes on top of cabinet
32
Doc. #: 026-069-B0 Rev F
Page 35
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
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.
3. Remove 3 screws from the front
and rear wooden frames.
4. Remove AMPS80 HP metal side panels to gain
access to 4 interior lag bolts. Remove 4 lag bolts to
allow removal of the AMPS80 HP from the pallet.
Use Phillips head
tool to remove
A
Use 9/16" wrench or
socket to remove
Doc. #: 026-069-B0 Rev F
33
Page 36
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]
185.0mm
[7.28in]
25.4mm
[1.00in]
[21.51in]
546.4mm
597.2mm
[23.51in]
Figure 13 — Mounting hole pattern
12.7mm
[0.50in]
25.4mm
[1.00in]
x 4
34
Doc. #: 026-069-B0 Rev F
Page 37
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. You have the option to convert to dual feed—see (Figure 14 and Figure 15
AMPS80 HP
AC Input
Inverter AC Input
Rectifier
(optional)
Inverters
DC breakers
(optional)
Figure 14 — Single AC feed
AMPS80 HP
Inverters
AC Output
Make before break
manual bypass
switch (optional)
Battery
Connection
AC Output
Rectifier AC Input
Doc. #: 026-069-B0 Rev F
Rectifier
(optional)
Make before break
manual bypass
switch (optional)
Battery
Connection
Figure 15 — Dual AC Feed
35
Page 38
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
rectier terminal block
36
Figure 16 — Rectifier terminal block
Doc. #: 026-069-B0 Rev F
Page 39
STEP 3: Remove the internal rectier powering wires before installing the separate recti-
er feed
Disconnect with a 3/16" hex key
Once the internal rectifier powering wires have been removed, install the external rectifier powering wires into
the rectifier terminal block—see Figure 16.
Doc. #: 026-069-B0 Rev F
Disconnect the 10-32 nut with a 3/8"
wrench or socket
37
Page 40
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.
AMPS80 HP Installation Diagram for
Generator
Automatic
Transfer
Switch Break
Before Make
Utility
MAIN
Distribution
Panel
single AC input feed for the
Inverter/MBS and Rectifiers
AC Input
AMPS80 HP
Rectifier
(optional)
Inverters
DC breakers
(optional)
Battery
Connection
Make before break
manual bypass
switch (optional)
AC Output
External
Maintenance
Bypass
Switch
UPS
BYPASS
Dedicated
UPS
Distribution
Panel
Critical
Systems
Power
Figure 17 — Representative system wiring for AMPS inverter or hybrid system with MBS with single AC input feed.
AMPS80 HP Installation Diagram for
Generator
Automatic
Transfer
Switch
MAIN
Distribution
Panel
separate AC input feeds for the
Inverter/MBS and Rectifiers
Inverter AC Input
Rectifier AC Input
AMPS80 HP
Rectifier
(optional)
Inverters
DC breakers
(optional)
Battery
Connection
Make before break
manual bypass
switch (optional)
AC Output
External
Maintenance
Bypass
Switch
UPS
BYPASS
Dedicated
UPS
Distribution
Panel
Critical
Systems
Power
38
400A for AMPS80-3-75
AMPS80-2-40
Utility
200A for AMPS80-3-30
AMPS80-2-20
Figure 18 — Representative system wiring for AMPS inverter system with independent AC input feed for MBS
Doc. #: 026-069-B0 Rev F
Page 41
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. The neutral to ground
wire is provided for systems without AC Input connections in which case the inverter output is considered a separately derived source and the AC output neutral must be connected to earth ground.
• In a 3-phase system equipped with an internal maintenance bypass switch and a load with a significant
distortion power factor, it is strongly recommended to provide the AC input and AC output connection
with a double neutral feed. Non-power factor corrected IT power supplies with rectified-capacitive loads
can contain high levels of 3rd harmonics that are created in such 3-phase systems. The current in the
neutral line can easily be twice the current in the line currents.
• DC tie bars are supplied to allow dual A/B battery feed (DC1 tied to DC2 and DC3 tied to DC4) or single
battery feed (DC1 - 4 are tied)
• If the system is equipped with the optional rectifiers, each rectifier shelf in a hybrid system is only connected to one of the DC- battery feeds: the top shelf to DC1, and the bottom rectifier shelf is connected
to DC4. In a system with four independent battery feeds, two of these battery banks will not be charged
from the AMPS80 HP rectifiers. When using two independent A/B feeds, DC1 should be tied to DC2 and
DC3 tied to DC4 at the AMPS80 HP DC connection points. Tie bars are provided.
* Connections and components relating to L3 are only present for 120/208 V, 3-phase systems.
** Connections and components relating to L2 are only present for 120/240 V split phase and 120/208 V
3-phase systems.
Doc. #: 026-069-B0 Rev F
39
Page 42
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. Remove if AC input ground is
connected (#5 on Figure 19).
6. Where rectifier is fed separately from AC (#6 on Figure 19), remove these wires during installation—see
section 4.6.1.
7. L3 is only used with 3-phase systems.
8. Four independent battery strings can be connected. Shorting jumpers are provided for single or dual DC
feed ((#8 on Figure 19).
WARNING!
To maintain the security of all SELV Circuits in the AMPS80, connect to other equipment of
the same circuit type: signaling/alarm circuits, emergency power off (EPO) circuits, relay
contacts, Ethernet or CANBUS.
40
Doc. #: 026-069-B0 Rev F
Page 43
5.1 Input/Output Cabling Overview
Connection points are accessed from the top of the unit. A protective panel partitions the AC and DC con-
nections
Protective panel between
.
DC connections
AC & DC connections
DC1
DC2DC3DC4
Ground
bus
AC connections
Figure 20 — Top view of AMPS80 showing AC and DC connection partitions
AC output ground
AC input ground
Frame ground
5.1.1 Wiring Gauge
The required gauge of the AC input, DC+/DC- input and AC output cabling is determined by the current rating, circuit breaker rating, typical ambient temperatures and the applicable local electrical codes. Typically
the AC input and standard AC output is 6 wires (L1, L2, and L3, N, N, G) up to 350 kcmil THHW or RW90
type cable that connects to the AMPS80 HP system with trade size up to 2.5" conduit.
5.1.2 Grounding
Refer to Figure 20 for connection points for frame ground, AC input ground and AC output ground.
Doc. #: 026-069-B0 Rev F
41
Page 44
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
Industrial grade
surge suppression modules.
Rectier terminal
block (see Figure
16 for details
Optional rectier
AC input breakers
AC input
ground
Figure 21 — AC Connections
AC neutral
connection
points
AC output
ground
AC output lugs
L1 left
L2 middle
L3 right
Earth ground bus
5.1.3 Grounding
N-G shorting jumper is factory-installed for inverter-only systems.
Remove if AC input ground is connected (#5 on Figure 19).
42
Doc. #: 026-069-B0 Rev F
Page 45
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
5.3.1 DC Battery Cabling
DC battery cable terminations are designed for two-hole spade lugs crimped to
the cabling, then attached to the bus bars.
Depending upon the gauge of the input
wiring used, the connections may be made
either singly or with two back-to-back lugs
per mounting hole.
Each bar (DC+, DC-) can accept seven
2-hole ½" mounting lugs on 1-3/4" centers
or seven 2-hole 3/8" lugs on 1" centers.
Torque specifications for DC wiring (3/8"
bolts that attach the DC lugs at the back
of the DC distribution box) are 190 – 240
inch/lbs (21.5 – 27.1 N-m).
Input cabling
3/8" or 1/2" hardware
Tie bar
Bus bar
Doc. #: 026-069-B0 Rev F
Figure 23 — Cabling and hardware arrangement
43
Page 46
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.
If the system is equipped with optional rectifiers, each rectifier shelf in a hybrid system is only connected to
one of the DC- battery feeds:
• Top rectifier shelf to DC1
• Bottom rectifier shelf to DC4
In a system with four independent battery feeds, two of these battery banks will not be charged from the
AMPS80 HP rectifiers. When using two independent A/B feeds, DC1 should be tied to DC2 and DC3 tied to
DC4 at the AMPS80 HP DC connection points. Tie bars are provided.
8.9in
[227mm]
[76mm]
3.0in
[76mm]
Outside of left side
of AMPS system
5.5
[141]
3.0in
8.3in3.0in
[211mm]
7.4in
[187mm]
[76mm]
3.0in
[76mm]
3.6in
[92mm]
3.6in [92mm]
[76mm]
3.0in
[76mm]
3.0in
Outside of right side
of AMPS system
5.4in
[137mm]
Top of
AMPS system
DC+ ROW
DC- ROW
6.3in
[161mm]
44
Figure 24 — DC connection dimensions – front view
Doc. #: 026-069-B0 Rev F
Page 47
Single battery string
Two 4DC joining plates are supplied with the dimensions shown in Figure 25.
DC+
Row
DC–
Row
14 x 1/2in bolt
clearance hole
7 x 3/8in bolt
clearance hole
.9in [24mm]
1.5in [38mm]
1.5in [38mm]
.6in [16mm]
.9in [24mm]
1.75in [44mm]
.6in [16mm]
.9in [24mm]
1.5in [38mm]
1.5in [38mm]
1.8in [46mm]1.8in [46mm]
Figure 25 — DC tie bar for single battery string
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Two battery strings
Four 2DC joining plates are supplied with the dimensions shown in Figure 26.
DC+
Row
6 X1/2" bolt
clearance hole
3 X3/8" bolt
clearance hole
.
9in [24mm]
1.5in [38mm]
.
9in [24mm]
1.75in [44mm]
.
6in [16mm]
DC–
Row
.
6in [16mm]
3.0in [76mm]
46
1.5in [38mm]
Figure 26 — DC tie bar for two battery strings
.
9in [24mm]
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5.4 Commissioning the System for the First Time
5.4.1 Tools Required
The following tools are required to commission the AMPS80 HP system for the first time:
• Medium flat screwdriver with approximately 3/8" (5 mm) blade width
• True RMS digital multimeter
• Computer with Ethernet port and Internet Explorer 7 or later
• Crossover Ethernet cable if a computer is directly connected to the CXC controller
• Straight through Ethernet cable if the network connections are made through a router or hub
• Torque wrench
• 3/8" hex driver
CXCR Ethernet port
5.4.2 Before you begin:
WARNING!
The AMPS80 HP must have no power (utility breaker OFF and locked out) and no modules
installed prior to start-up.
1. Verify that the AMPS80 HP system is mechanically secured to the floor or other structure.
2. Verify that the contoller breakers on top of the unit are set to ON. See Figure 1
3. Verify that the clearances around the AMPS80 HP system meet the minimum requirements (see Figure
10).
4. Ohm-test the AC and DC bus bars to check for any shorts caused by cut wires, loose bolts, washers and
other conductive material. If possible do Megger testing.
5. Verify that the AMPS80 HP system is correctly and securely grounded to the building grounding system.
6. Verify that the AMPS80 HP system is correctly and securely connected to the utility and batteries:
a. For the battery connections, follow the manufacturer's recommendations and record the torques.
b. For the AC connections, torque #1 AWG - 350 kcmil wire to 375 in-lbs (42 N-m), and #6 - #2 AWG
wire to 200 in-lbs (23 N-m).
c. If rectifier wiring is installed, torque the connections to 120 in-lbs (14 N-m).
7. If this system includes rectifiers for charging, verify that all rectifier modules are removed from the rectifier
shelves.
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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. If a Generator is installed, verify that the transfer switch has a minimum 1 second switching delay or that
the transfer is always in phase (+/- 30 deg).
Starting-up the system
12. Switch on the AC mains/utility power.
13. Verify the AMPS80 HP system AC input voltages at the AC wiring terminals (Figure 21):
SystemVoltageValue
ALLNeutral to Earth Ground~0V
3 phaseL1 to L2, L2 to L3, L3 to L1~208V
Neutral to L1 / L2 / L3 120V
2-poleL1 to L2~208V
Neutral to L1 / L2 120V
Split PhaseL1 to L2~240V
Neutral to L1 / L2 120V
14. Check that the battery polarity is correct and then switch on the external battery breakers or complete the
fuse circuit.
15. Turn on the AMPS80 DC Input Breakers (if installed).
16. Verify that the system starts up and that the controller switches on: the controller display initializes with
three LEDs blinking while a self-test runs for 15 seconds. Ignore any alarm conditions indicated by the
amber and red LEDs.
AC Output Power
252W
% ratio of the Output
2%
Power VA or Watts
whichever is higher
48
Figure 27 — Controller default home screen
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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
Inverters for AC phase 1 (L1)
Inverters for AC phase 2 (L2)
Blank panels
PER PHASE in the right most
position of the top shelf for
each phase.
Figure 28 — Seed modules shown for 40 kVA, split-phase systems
19. Switch on the inverter AC input breaker on the AMPS80 HP front panel. Verify that the AC input LEDs turn
on for each module. The LEDs may flash in different colors but this behavior is not a cause for concern.
20. Use the CXC GUI as follows to verify that the modules are recognized and the voltages and currents of
the modules are displayed. (Ignore any alarms at this point. The current readings at no load are not very
AC input LED
Figure 29 — Inverter module showing AC input LED
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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 congurations 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. You may not want to close/lock the grill at
this time because the module may have to be removed at a later stage.
CAUTION!
Improper installation or removal of modules can break latching components.
Unlock
Insert a at head screw driver into the center ap
notch and pry open the center ap. Then pull out the
module by pulling on the center ap with both hands.
Figure 30 — Unlocking and locking an inverter module for removal or insertion
1. Place module into shelf.
Figure 31 — Inserting and removing an inverter module
2. Press module into place and
ensure connection is engaged.
Lock
Leave the module plastic front grill in the open/unlocked position, then slide/push the module all the
way into the module slot, and then close the ap.
3. Close cover and snap module
into place. If cover does not close
easily, repeat Step 2.
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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. Use the pull down box to set the module number to 2 to correspond to AC phase 2 (for split phase,
2-pole and 3 phase systems).
f. Repeat for a third module (select 3 to correspond to AC phase 3) if the system is 3 phase.
21. Now that the inverter modules in each shelf have a number, place one module in each of the AC input
and output groups as follows:
Select a row to send a
Module number
pull down box
Locate command; the inverter module LEDs will
ash for a few seconds.
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Figure 32 — Inverters > View Live Status
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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.
For a 3-phase 120/208V system,
click on heading button 3
For a split phase 120/240V system,
click on heading button 2
Figure 33 — Matching AC Input Groups to AC Output Groups
23. Select Inverters -> Set Outputto set the number of inverters in each phase of your system. Match the AC
input phase to the corresponding AC output phase.
a. Number of Modules: Enter the total number of inverter modules that will be installed for that phase.
b. Redundancy: Enter the number of inverter modules that will provide redundant power for that phase.
This information is used to provide system warnings.
c. Phase Shift: Enter the phase shift for output group in your system configuration
d. Nominal Output Voltage: Enter 120 for all phases.
e. Press Submit.
CAUTION!
The value entered in the Nominal Output Voltage eld 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.
24. Check for alarms (Inverters > View Live Status): alarm code (41) PHASE NOT READY indicates that the
phase rotation of the AC Input is not correct. (The inverters will not start until the phase and rotation are
correct.)
If necessary, return to Inverters -> Set Output and correct the phases as shown:
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. The voltage from L1 to L2 is approximately 240 V for a split phase system, 208 V for 2-pole, or the
voltage from L1 to L2, L2 to L3, and L3 to L1 is approximately 208 V for a 3 phase system.
c. The voltage from AC Input L1 to AC Output L1 is less than 30 V. Similarly, the voltage between L2
input and output and L3 input and output should be less than 30 V.
Installing remaining inverters and rectifiers
29. Install the remaining inverters. The newly installed inverter modules will clone themselves to be identical
to the initial modules that were installed and set up.
30. Select: Inverters > View Live Status at the CXC GUI, and verify that all inverters are recognized as
follows:
a. At this point the inverter module numbers are likely random. Note that the largest possible inverter
number is 32, corresponding to the total number of inverter slots. Renumber the inverter modules in
some logical pattern, such as from the bottom shelf up, using Inverters > View Live Status to locate
and number each module (see Figure 32).
9101112
5678
1234
b. We recommend that you mark each physical inverter model with its corresponding inverter number.
To help identify a specific Inverter, click on the inverter row in the View Live Status screen and the
LEDs of that inverter will flash for a few seconds.
c. Select: Inverters > Group Mapping and verify that all inverters are mapped to the correct AC Input
Group and AC Output Group. If necessary, match the AC Input Group to the AC Output Group, as
shown in Figure 33.
d. Map inverters to DC Input Groups as discussed in section 3.6.2.
31. If the system includes the rectifier option:
a. Install one rectifier module per shelf according to the instructions in the rectifier shelf manual that
ships with the unit.
b. Select: Rectifiers > View Live Status and verify that all rectifiers are recognized.
32. Use blank housings to fill slots without modules. See Figure 34.
Final configuration and test
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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.
Figure 34 — Inserting blanks in open slots
Unsafe solution. Do not leave any module slots open.
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. At this point there should be no alarms present. Investigate and correct any alarm issues.
a. You will see a “communication” alarm if the number of installed inverters do not match the number of
modules set in the Inverters > Set Output menu.
b. Refer to the Troubleshooting Chapter 8 for other alarms.
35. Test the functionality of various module alarms and controls as follows:
TestExpected result
Turn the bypass switch to BYPASS.
Turn off the Inverter AC Input breaker.
Turn off the Inverter AC Output breaker.
Verify the number of modules is correct
in Inverters -> Set Output.
Pull out one inverter module.
Bypass Mode Active alarm
Inverter AC Input Breaker alarm and no change in AC output
voltage
Inverter AC Output Breaker Off alarm and power to loads is off
Inverter Comms Lost alarm
37. Perform a system load test. Power up the equipment, one at a time. If possible, add heater or light bulb
loads to increase the load temporarily.
38. Turn off the inverter AC input breaker to perform a full load test from DC power.
39. Test operation of Generator and external Maintenance Bypass Switch, if installed.
WARNING!
To prevent electrical hazards such as short circuits, ensure that the system is free of debris
such as metal lings, screws, etc. after the installation is complete.
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6. System Operation
6.1 Inverter Module Indicators
AC output
DC input
AC input
Output power
Status LEDs
Figure 35 — Fig. 4.1 Inverter module status, power LEDs
6.1.1 Status LEDs
Inverter Status LED Description Remedial action
OFF No input power or forced stopCheck AC input
Permanent green AC Intput OK, normal operationNone required
Flashing green Inverter OK but conditions are not
within normal parameters
Flashing green/orange alternatingRecovery mode after boost
(10 In short circuit condition)
Permanent orange Starting-up mode Wait
Flashing orange Modules cannot startInsert CXC
Flashing redRecoverable faultWait or attempt to clear fault condition by
Permanent red Non recoverable fault
Check upstream and surrounding equipment
Wait for a while
removing and reinserting the module
• Attempt to clear fault condition by
removing and reinserting the module
• Download CXC inverter alarm logs
• Record the alarm(s)
• Send module back for repair
indicator LEDs
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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.
100% Overload
< 5%
5% to 40%
40% to 70%
80% to 95%
100%
Flashing
On steady
On steady
Figure 36 — Output power indicator LEDs
On steady
On steady
Flashing
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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
Figure 37 — T2S front panel
Major alarm LED
Minor alarm LED
NOTE: USB port functionality is disabled
as of T2S software version 2.91. The
USB port
Access to locking latch. To remove T2S
from Inverter shelf, insert a small at
screwdriver and gently press up on the
latch, then pull out the T2S.
T2S can be accessed from the CXC with
current software versions.
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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.
6.3.1 Software Overview
The CXC software enables control of an entire DC + AC power system via the CXC central touch screen user
interface or web based monitoring and control interface. The software also allows the user to control temperature compensation, auto equalization, remote access, and battery diagnostics.
Figure 38 — CXC system controller
User interface
Located on the front panel of each model is a 160-x-160-pixel touch screen liquid crystal display. This graphical user interface (GUI) enables a person to interact with screen selectable items.
LED lights
Each CXC has three LEDs located on the front panel. These are used to display the alarm status of the power
system, CXC progress and status during startup, and file transfers.
Alarm conditions
The CXC illuminates the LED that corresponds to the system alarm status. The following show the corresponding alarm status for each LED color:
• Green – OK, no alarms present.
• Yellow – Minor alarm is present (no major alarms).
• Red – Major alarm is present.
• Only one LED is illuminated at a time during alarm conditions.
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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
Controller Ethernet port
6.3.3 Quick Start
1. To initiate a startup routine, switch on the power to the controller by closing the battery breaker. The
controller performs a short self-test as it boots up. Alarm alerts are normal. The LEDs perform a scrolling
pattern to indicate there is activity. Wait for the startup routine to finish.
2. Check and adjust alarms and control levels in the CXC submenus.
3. Check and adjust group settings in the INVERTERS and RECTIFIERS submenus; e.g. float, equalize
voltage, etc.
4. Verify COMMUNICATIONS settings as needed.
5. Program the CXC TEMP COMP and AUTO EQUALIZE settings as needed.
6. Test relay OUTPUT ALARM\CONTROLS as needed; e.g. Major Alarm, CEMF, etc.
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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. The Analog Signals Display on the home page show two lines of text for system voltage
and current by default.
Each active area is touch sensitive and responds best to a stylus suited for this purpose.
Mode status
AC Output Power
252W
Rectier information
(Converter report if applicable)
2%
Alarm condition icon
Priority icon
Software version
Home page icon, tap to login
Figure 39 — LCD active areas
Login
1. Tap the Home icon (Figure 39) and select Login from the menu prompt. A pop-up window for password
entry appears.
2. Enter 1234 for Supervisor access, 5678 (or nothing) for User access. In User access mode, the user
cannot make changes to parameters but can navigate through menus.
% ratio of the Output
Power VA or Watts
whichever is higher
Alarm indication
Date and time
60
Figure 40 — Password entry pop-up window
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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.
Mode + temp comp. display
The folders can be expanded
(indicated by the plus sign shown
here) if there are les inside.
Folders that can be collapsed will
be shown with a minus sign.
Buttons display here for addi-
tional functions, such as logout,
programming, or save changes.
Figure 41 — Navigation screen
Option to Logout Via the Option button, a pop-up window enables the user to logout of the menu navigation
screen and return to the home page. Follow the on-screen prompts to log out
Option to save Saving in menu navigation (Supervisor only) will result in a prompt (pop-up window) to
appear; e.g., “Save Complete” when the settings are downloaded. Follow the on-screen
prompts to save or discard changes.
Auto-logout time out After 20 minutes of inactivity (no user input), the CXC will automatically logoff the user.
The CXC will discard any unsaved changes made by the user while logged in the system
and return to Normal Operation mode.
Backlight time out After one minute of inactivity (no user input), the CXC will automatically turn off the LCD
backlight.
ResetSee below.
Battery volts and
load current display
Tap on the folder icon
or label to expand.
Sliders and scroll
bars are used for
navigation
38335W
Press
Doc. #: 026-069-B0 Rev F
38335W
77%
Press Reset
Press the “reset now” pop up when it appears.
77%
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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.
The CXC also has a CAN bus for communication with the Cordex rectifiers and other peripheral equipment.
Refer to the Cordex Software manual for details.
Inverter monitoring and control
The Inverter menu category consists of inverter alarms, signals and settings. Parameters can be accessed
such as the number of acquired inverters, output voltage/power, and source position.
Other features include: Input source, Inventory update,Inverter locate, Group assignment, Inverter firmware
upgrade, major and minor alarms.
62
Figure 42 — Illustration of web interface window (sample home page)
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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. The bottom portion of the report lists all the currently active inverter module specific
and system alarms.
Figure 43 — View live status page
A pull down menu allows the user to reassign the inverter module number in the
report to correspond with its physical location on the shelf, for example.
Selecting a module number that is already
used will swap the two modules.
Select a row to send a
locate command. The
inverter module's LEDs
will blink momentarily
Doc. #: 026-069-B0 Rev F
Figure 44 — View live status — inverters page
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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
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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 congured
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.
Green = inverter is ON
Black = inverter is OFF
Amber/Red = inverter ALARM
Figure 46 — Group mapping window
Power buttons – Green indicates an inverter is turned ON. An amber/orange/yellow color indicates the
inverter is in a recoverable error. The user can attempt to turn on the unit. The red color indicates the inverter
is in an irrecoverable error and there is nothing the user can do to turn on the unit. Black indicates an inverter
is manually OFF. Adding/removing groups (columns) may take a few seconds to incorporate the change.
Changing the radio style buttons (rows) will also take time to apply changes; for example, approximately two
seconds for one inverter and up to ten seconds for the maximum number of inverters (32).
If there are inverters mapped to a column, disabling a column is prevented and a warning message is displayed.
All inverters must be turned OFF to enable the AC Output Groups column buttons. The AC Output Groups of
an inverter in the ON state cannot be changed. The radio buttons for that inverter AC output group will remain
disabled until the inverter is turned OFF.
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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
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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 eld 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
Redundancy
Phase shift
Nominal Output Voltage
Ensure that the Phase Shift is set correctly before mapping inverters in the new groups and turning them on.
For inverters,changes
apply on a page by
page basis; select
Submit.
Select Cancel to
discard all changes
made (including
invalid settings).
Total number of inverter modules installed for that phase. Setting this number to
something different from the actual number of installed modules results in the
alarm condition Inverter Comms Lost.
Defines the number of inverter modules that will provide redundant power for that
phase (used to provide system warnings).
Assigns a phase shift (in degrees) to the AC output group.
Enter 120 for all phases.
An invalid setting (for any
congurable parameter)
will be indicated with a
red exclamation mark.
!
Hovering the mouse on
the exclamation mark reveals the error message.
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Figure 48 — Set Output window
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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 pres-
ent, AC output will synchronize; however an irregular AC voltage could damage the inverters.
6.3.14 Manage Config File
The inverter settings have their own configuration and are not part of the full site configuration file. Refer to
Chapter 10 for a list of the configuration file parameters and steps to save the file and upload it to another
system.
Figure 50 — Manage Config File window
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6.3.15 Alarms
Standard Inverter Alarms
Alarms for the following conditions can be configured from the Alarms > Configure Alarms menu category
(refer to the controller software manual for more details on alarm configuration):
Alarm NameAlarm Condition
Inverter Major Fail Count
Inverter Minor Fail CountNumber of failed Inverters equals or exceeds a user congurable
Inverter Comms LostController loses communications with any one inverter. The number of
Inverter AC Input FailMain AC input of the inverter is lost
Inverter AlarmAny individual or system alarm is detected
Number of failed Inverters equals or exceeds a user congured threshold
threshold
inverters must be correctly identied in the Inverters > Set Output menu.
Figure 51 — Configure alarms window
Custom Inverter Alarms—Mapping Alarms to Relays
Custom inverter alarms can be mapped through the digital inputs to available relays. Refer to the latest version of the CXCU Controller software manual.
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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 le to local disc. This functionality is similar to downloading the inverter
conguration le (see section 10.1.
Figure 53 — Retrieve inverter alarm history file
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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
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6.4 Rectifier Features
6.4.1 Rectifier Front Panel Lights
Refer to the Cordex CXRF 48-1.8 kW manual for further details.
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
The middle LED (green) is on when
the rectifier is delivering power to
the load. The LED will flash when
communication is lost. The LED
turns off when the rectifier is off;
e.g., when commanded via the
controller.
Alarm (ALM) LED light
The bottom LED (red) is on continuously
in the event of an active Module Fail
alarm; if the module is unable to source
power as a result of any of the following
conditions:
• Output fuse blown
• AC Mains Input Fail
• Module fail (ramp test fail)
• High voltage (OVP) shutdown
• Thermal shutdown
• Local shutdown
• UPF fail
• No output power
• Fan fail.
AC LED light
DC LED light
Alarm LED light
Figure 55 — Cordex CXRF 48 V rectifier
The LED will flash (~2Hz) when a minor alarm is detected; if the modules output capability has been reduced
or a minor component failure is detected during the
following conditions:
• VAC meter fail
• AC foldback
• Remote equalize
• Fan fail
• Low output voltage
• High output voltage
• Current limit (programmable option)
• Power limit (programmable option)
• High temperature foldback
• Temperature sense fail
72
• Soft start operation
• Communications lost.
The LED remains off in the absence of an alarm. If the
unit output is not connected to a battery or parallel rectifier, the LED will extinguish if no AC power is present.
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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.
6.4.3 LED Activity During Rectifier ‘Locate Module’ Command from
Controller
When the ‘locate module’ command has been received from the CXC, the LEDs will behave in another distinct fashion so that the rectifier is easier to visually identify among adjacent rectifiers.
This state is entered when commanded via the CXC. The LEDs will flash in a ping-pong pattern repeating
every 2 seconds.
The ping-pong pattern lights each LED sequentially. After the last LED is lit, each LED is lit in reverse sequence. When the first LED is lit, the pattern repeats. The effect makes it appear as if the light is bouncing
between the first and last LED.
6.4.4 True Rectifier Module Fail Alarm
The power modules have a “true” fail alarm. This provides a true indication of the power module’s ability to
source current. When the module’s output current drops below 2.5% of the rated output a low output current
condition is detected and the Module Fail detection circuit is activated. This circuit momentarily ramps up the
output voltage to determine if the module will source current. If no increase in current is detected, the Module
Fail alarm is activated. The module will test once every 60 seconds for the condition until current is detected.
Output voltage ramping will cease upon detection of Current1. A minimum 2.5% load is required to avoid the
Ramp Test Fail alarm; this can typically be provided with the parallel system battery. Activation of this alarm
could indicate a failed module or a failed load.
For Cordex rectifier systems without batteries (or with a very light load; below 2.5% of rated output) it is
recommended that the ramp test be disabled to avoid nuisance alarms. The Ramp Test feature is enabled/
disabled via the CXC menu item: Rectifiers, Configure Settings.
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6.4.5 Mapping Alarms to Relays
1. 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.
Select desired relay
If this popup appears
select another relay
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5. After changes have been made, press Submit Changes.
6. Accept changes.
7. Hook up control wires
to the selected relay.
Press Accept
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Relays
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6.5 Synchronization with a Maintenance Bypass Switch (MBS)
6.5.1 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. Smoothly rotate the maintenance bypass switch in a clockwise rotation from BYPASS to INVERTER.
6.5.2 External Maintenance Bypass Switch
Before switching an external MBS from UTILITY mode to UPS mode:
1. Switch on the AMPS80 Inverter AC Input breaker. Wait for the inverters to synchronize to the line, and for
all status LEDs to turn green.
2. Switch on the AMPS80 Inverter AC Output breaker.
3. Follow the steps in the external MBS user manual to switch the external MBS bypass switch to UPS.
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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. Always
wear a grounded wrist strap when handling or installing circuit boards. Ensure redundant
modules or batteries are used to eliminate the threat of service interruptions while performing maintenance on the system’s alarms and control settings.
7.2 Recommended maintenance schedule
Task: Interval
Clean ventilation openings1-6 month
Inspect all cable connections, re-torque if necessary1 year
Verify alarm/control settings1 year
Verify alarm relay operation1 year
Verify circuit breaker operation1 year
7.3 Tools, Spare Parts and Equipment
Table I — Tools
RequiredService /Maintenance Commissioning
Torque wrenchXX
#2 Philips screw driverXX
#2 at head screw driver (3/16") width headX
#1 at head screw driver (1/8") width headX
Small at head screw driver (1/16") width headXX
3/8" ratchet socketX
7/16" ratchet socketX
7/16" ratchet socket extended neckX
9/16" ratchet socketX
9/16" ratchet socket extended neckX
5/8" ratchet socketX
5/8" ratchet socket extended neckX
10 mm combo wrenchX
10 mm at gear ratchetX
3/8" Allen key on a 3/8" ratchet socketXX
3/16" Allen key on a 3/8" ratchet socketXX
Flash light or trouble lightXX
Crossover Ethernet cableXX
Straight through Ethernet cableXX
Computer with Ethernet port and Internet ExplorerXX
True RMS digital multimeterXX
Other Recommended Tools Service /Maintenance Commissioning
Needle nose pliersX
Side cuttersX
Wire stripper 10 AWG to 20 AWGX
Exacto knifeX
Measuring tape with inches and cmX
ScissorsX
Rubber mallet 1-1/4" diameterX
Table J — Spare Parts
P/NPart Description
014-201-20AIM2500 inverter module, 2.5 kVA, 2.0 kW
571-005-10Inverter black plastic front assembly
7400026Inverter fan
010-580-20-040
747-272-20-000Rectier fan (hybrid option only)
460-421-19Rectier Fuse, 200A, In-line (hybrid option only)
741-032-21Blanking module for inverter or rectier slot
018-557-20-342CXCR controller
543-027-19CanBus connector cable
545-596-10CAT5 Ethernet connector cable
5450196Connector, Male, 3.81mm pitch, 8 pin, spring loaded, screw terminals (rear DC wiring panel)
162-600-19Surge suppression replacement module, red stripe, Line-Ground, 40kA rating
162-601-19Surge suppression replacement module, green stripe, Neutral-Ground, 40kA rating
741-021-31AMPS80, TVSS 3-ph, 140kA rating per phase (TVSS option only)
741-021-21AMPS80, TVSS 2-ph, 140kA rating per phase (TVSS option only)
741-021-41AMPS80, TVSS 1-ph, 140kA rating (TVSS option only)
78
1.8kW rectier module for AMPS80 shelf (de-rated to 1150kW for single phase)
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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. Once inserted, it will take about 10
minutes (or longer with fully loaded systems) for the T2S to initialize with
the inverter modules.
CAUTION!
Ignore error/alarm conditions displayed during initialization. Do not remove any system
components during the initialization sequence. Interruptions to the initialization sequence
can result in software corruption and reduced functionality.
When the T2S is initially
inserted, all LEDS are off
for a few seconds.
Initialization is in progress:
Top 2 LEDs: solid green
Bottom LED: off
DO NOT INTERRUPT
Initialization complete:
Top 2 LEDs : solid green
Bottom LED: ashing green
Doc. #: 026-069-B0 Rev F
Figure 56 — T2S LED sequence during initialization
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Step 3: Inventory Update
When the initialization sequence is complete (top two LEDs solid green and the bottom LED ashing 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 recti-
ers (will be 0 if
no rectiers in
the system.)
Figure 57 — Update Inventory steps
If the system remains in alarm or the inverter information does not appear after five minutes, call Alpha Technologies Technical Support at 1-888-462-7487 for assistance. A laptop and crossover cable is required for
troubleshooting activities.
Tap on
Inventory
Update
7.5 Inverter or Rectifier Fan Replacement
To replace a rectifier fan, refer to the manual that shipped with your system.
To replace an inverter fan, refer to Section 7.6 to remove and replace the inverter.
1. Slide the module out of the shelf and wait two minutes for the module capacitors to discharge.
2. Disconnect the fan power wires from the module.
3. Note the direction of the airflow and remove the fan from the front panel.
4. Install the replacement fan with the airflow in the same direction.
5. Reconnect the fan power wires to the module.
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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 at head screw driver into the center ap
notch and pry open the center ap. Then pull out the
module by pulling on the center ap with both hands.
With the module plastic front grill in the open/unlocked
position, slide the module all the way into the slot
Press the module into place and ensure connection is
engaged. Close the ap.
Unlock
A new module can take between 5 and 10 minutes
to synchronize with the T2S controller and clear any
alarms. Do not interact with the system during the
initialization process.
When the initialization sequence is complete, the
three LEDs on the left hand side of the inverter module turn a solid green.
Use the touch display or a web connection to confirm that the # of modules versus actual installed are
equal. (Inverters > AC Output Groups on the web
interface).
If the system remains in alarm or the inverter information does not appear after five minutes please call Alpha
Technologies Technical Support at 1-888-462-7487 for assistance. A laptop and crossover cable is required
for troubleshooting activities.
Doc. #: 026-069-B0 Rev F
AC output
DC input
AC input
all green
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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.
2. Remove the wiring access panel.
3. Pull out the surge suppression
module.
4. Replace the module with one of the
same type.
Surge suppression
Red stripe = L-G
Green stripe = N-G
Replaceable parts
Alpha part numberDescription
162-600-19
162-601-19
Surge suppression replacement module,
red stripe, Line-Ground, 40 kA rating
Surge suppression replacement module,
green stripe, Neutral-Ground, 40 kA rating
7.7.1 Service Entrance Grade Surge Suppression Replacement
Front and left side access may be required to properly service the service entrance grade TVSS located
behind the CXCR control panel.
WARNING!
There may still be live parts inside the system and shock hazards may be present throughout this procedure.
the screws holding the surge suppression
assembly.
4. Replace the module with an Alpha service
entrance grade surge suppression
assembly.
Front Access Replacement
Bolts holding surge
suppression assembly
1. Turn off the inverter input breaker.
2. Remove the screw securing the CXCR unit.
3. Remove the 4 mounting screws that hold
the CXCR to the chassis.
4. Pull the CXCR out and to the left. Do not
remove any of the wires from the CXCR.
5. Dangle CXCR unit gently.
6. With the proper tools, reach in and remove
the bolts holding the surge suppression
assembly.
7. Replace the module with an Alphaservice
entrance grade surge suppression
assembly.
Bolts holding surge
suppression assembly
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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. Remove the left side panel.
4. Remove the ¼-20 nut holding the fuse to the fuse holder/bracket (594-110-13). Use a 7/16 socket or
wrench.
5. Remove the ¼-20 screw and ¼-20 nut holding the wire to the fuse. Use a 7/16 socket or wrench.
6. Replace the fuse with a fuse of the same rating and type:
Replaceable parts
Alpha part numberDescription
460-421-19Fuse, 200A, In-line
84
Fuses
Figure 58 — Rectifier fuse locations
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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.
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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.
8.2 Recoverable Error
A recoverable error is a kind of protection that acts when, some parameters exit temporarily from their proper
limit range. Stopping the module or removing it from its slot and plugging it back in may solve the problem.
For more detailed diagnostics, use the Ethernet port of the CXCR to view the alarm description. See Alarm
descriptions below. The inverter alarms can be found in Inverters > View Live Status.
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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:
Press
Press the “reset now” pop up when it appears.
To reset the T2S, remove it from the system, then hook it back up.
Doc. #: 026-069-B0 Rev F
Press Reset
252W
2%
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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 removeClick to add
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8.3.4 AC Mains Lost
The AC Mains Lost alarm happens when the AC input does not meet the correct voltage, phase, or frequen-
cy. 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.
8.3.5 Manual Off
The Manual Off alarm happens when one or more inverters have been turned off in the group mapping
screen.
8.3.6 Phase Not Ready
Phase not ready alarm happens when the inverter thinks it should be in a certain phase and the input to it is
another phase. This can be correct either by changing the input wiring to the AMPS80 HP or by changing the
phase in the group mapping settings screen.
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Table K — Alarm Codes
Alarm TypeDescriptionCauseSolution
Error Not Recoverable
0NO ERROR No error present on the
system
1FAN FAILURE Failed fan or speed
inappropriate
2 TEMP TOO LOW Measured temperature
inside the module is below
-20°C
3 FLASH FAILURE Internal software is
corrupted
4 Vref FAILUREInternal voltage reference is
out of range
5 ALIM AUX1 FAIL Internal 15V supply is out of
range
6 ALIM AUX2 FAIL Internal -15V supply is out
of range
7 TOO MANY
STARTS
8 OVERCURRENT
OUT
9 Vint TOO LOWIntermediate voltage has
10 Vint TOO HIGHIntermediate voltage has
11 Vout PI2 ERROR Error in the self-test during
12 Vout MPI2
ERROR
Too many starts in 1 minute
( 10 times in 1 minute)
The AC output current has
been too high for too long
been too low
been too high
the starting process
Error in the self-test during
the starting process
N/AN/A
Dust on FAN or FAN failureReplace fan or clean it
The temperature sensor Replace the module
Replace the module
Replace the module
Replace the module
Replace the module
This problem usually
happens when the input
source is not powerful
enough to supply the load.
The inverter has a correct
DC voltage and starts. After it
has started, the power taken
on the input source is too
important and the DC voltage
falls under the minimum and
the inverter stops. After 10
attempts to start, the inverter
stops. The aim of this error is
to avoid a situation in which
the inverter keeps starting
and stopping.
Problem with IGBTs or
current sensor or output
stage. This can also
happen in very harsh surge
conditions.
Many causesReset the module and try again.
The most likely cause is that
energy has been reinjected
into the module (by the load,
if the Acout has been shortcircuited with the grid…)
This can be caused by a
problem on the IGBTs
This can be caused by a
problem on the IGBTs
Correct the problem : increase
the input power, reduce the
load, increase the voltage
hysteresis… Then, turn the
module OFF to clear the error
and back ON (or, if you have
no access to the supervision,
unplug and replug the module)
Reset the module and try again.
If the problem persists, replace
the module
If the problem persists, replace
the module.
Check if there is a problem
around the module which could
explain the error. Then, reset
the module and try again. If the
problem persists, replace the
module.
Reset the module and try again.
If the problem persists, replace
the module..
Reset the module and try again.
If the problem persists, replace
the module.
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Table K — Alarm Codes
Alarm TypeDescriptionCauseSolution
13 V
14 OVRLOAD TOO
15 OUT FUSE
16 V
18 VoutPout TOO
19 RAM FAILUREValues in the RAM are
33OUT OF SYNC Inverter is not synchronised
34TEMP T OO
35COM BUS
36COM BUS
37NO POWER
38COM BUS
39PARAM QUERYInverter is updating his
40PARAM
41PHASE NOT
42STATUS 42
43INV MISMATCH Inverter incompatible with
INVERSEError in the self-test during
out
LONG
FAILURE
TOO
outIout
LOW
LOW
HIGH
FAILURE
CONFLICT
SOURCE
FAILURE
MISMATCH
READY
the starting process
Output voltage too low due
overload for a long time
Module is delivering no
power to the load while the
other module on the same
phase does.
Output voltage is too low
while the output current is in
an acceptable range
Output voltage is too low
while the output power is in
an acceptable range
corrupt
with other inverters
Temperature on heat sink
too high
The inverter doesn't see
itself on the bus
2 TSI have same ADX Will self repair
No input AC and DC
available on inverter
TSI must have a T2S to
start
parameters
Conguration le
incompatible with TSI
inverter
The phase inverter is not
congured for this phase (
multiple phase system)
inverter installed in system
This error happens if the
module is not congured on
the correct output phase
Load too higher for the
inverter quantity operational
on system.
Output fuse open / problem
in the connection of AC
Problem inside the module.Reset the module and try again.
Problem inside the module.Reset the module and try again.
Error recoverable
Problem on the
communication bus
Problem inside the moduleReplace the module
Temperature too high in the
room, cooling insufcient, or
inverter component defective
Problem on bus or internal
problem
No supply voltageCheck AC input voltage at AC
Circuit Breaker openCheck Circuit breakers
Wiring faultCheck input voltage at
No T2S in the systemAdd a T2S
Part of starting processNothing to do
Problem with parametersCheck conguration le and
AC not present, or phase not
congured
Inverter for pack solution.
Limitation to 6 inverter on the
same BUS
out
Verify the phase conguration
of the modules. Then, reset
the module and try again. If the
problems still happens, replace
the module
Reduce load or add inverter on
the system.
Check if the problem can be
caused by something external
to the module. If not, replace the
module
ACinput Current is too highSurge / hardware problem on
range
Input DC voltage lower than
the preset value.
Input DC voltage higher
than the preset value.
Input DC voltage lower than
the preset value.
Input DC voltage lower than
the preset value.
Input DC voltage higher
than the preset value.
Input DC voltage lower than
the preset value.
Input DC voltage higher
than the preset value.
Check AC In conguration
and live value
Check AC In conguration
and live value
Check AC In conguration
and live value
Check AC In conguration
and live value
Inverter not congured on the
phase
ACinput stage
10 Iin on short circuits) has a
problem
Status DC on Inverter
Check VDC parameter and
live value
Check VDC parameter and
live value
Check VDC parameter and
live value
Check VDC parameter and
live value
Check VDC parameter and
live value
Check VDC parameter and
live value
Check VDC parameter and
live value
Check AC grid and conguration
Check AC grid and conguration
Check AC grid and conguration
Check AC grid and conguration
Reconnect AC IN, congure the
inverter phase
Retry / replace module if the
problem still happens
Replace inverter
Nothing to do
Check DC from battery and
conguration
Check DC from battery and
conguration
Check DC from battery and
conguration
Check DC from battery and
conguration
Check DC from battery and
conguration
Check DC from battery and
conguration
Check DC from battery and
conguration
226 NO
TRANSMISSION
227 DIG INP1
FAILURE
228 DIG INP2
FAILURE
229 REDUNDANCY
LOST
94
Write "No Transmission"
event in log le when the
inverter is no longer seen by
the T2S.
Generate alarm code 227
and appropriate text when
digital input 1 changes state
Generate alarm code 228
and appropriate text when
digital input 2 changes state
229 and text "Redundancy
Lost" when condition is true
T2S Event
Alarm from the T2S - does
not see any TSI- all modules
- system alarm or when the
T2S does not see one of the
modules
Digital input has changed
status
Digital input has changed
status
Lost of inverter redundancyReplace defective inverter or
Replace defective inverter or
adapt conguration
Check device connected on
input digital
Check device connected on
input digital
adapt conguration
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Table K — Alarm Codes
Alarm TypeDescriptionCauseSolution
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 conguration
231 SYS
SATURATED
232 MAIN SOURCE
LOST
233 SEC SOURCE
LOST
234 T2S BUS FAIL Generate alarm code 234
235 T2S FAILURE Generate alarm code 235
236 T2S STARTED Write event "T2S Started" in
237 LOG CLEARED Write event "Log Cleared"
238 CONFIG
MODIFIED
239 NEW MOD
DETECTED
240 DATE & TIME
MOD
241 CFG READ IN
MOD
242 LOG
NEARLY FULL
243 T2S FLASH
ERROR
Generate alarm code 231
and text "Sys Saturated"
when the condition is true
Generate alarm code 232
and text "Mains source lost"
when the condition is true
Generate alarm code 233
and "Sec Source Lost"
when the condition is true
and "T2S Bus Fail" when
the condition is true
and text "T2S Failure" when
the condition is true
log le when T2S is started
(powered up)
in log le when the log is
cleared
Write event "Cong
Modied" in log le when
conguration is modied.
Write event "New Mod
Detected" in log le when
new module is seen by T2S
Write event "Date & Time
Mod" in log le when date
and/or time are modied
Write event "Cfg Read In
Mod" in log le when T2S
had read the conguration
le from TSI inverter.
Tipically after insterting new
T2S on live system.
Generate alarm code 242
and text "Log Nearly full"
when the condition is true
Flash of T2S is corrupt and
has failed
Load of system is greater
than the preset value
Priority source lost (depends
on the conguration AC/AC
or Online)
Secondary source
lost (depends on the
conguration AC/AC or
Online)
The communication bus to
T2S has failed
T2S has failedHardware problem. Replace T2S
T2S has started
T2S has cleared the log
Conguration is modied
One more module is plugged
Date and time are modied
T2S has read the CFG
This item will be set as, No
alarm, Minor or major alarm.
(see conguration le)
T2S failureHardware problem. Replace T2S
Reduce load, or add inverter to
the system or reduce the number
of redundant units in Inverters >
Set Output, or change the alarm
level trigger.
1) In AC/AC conguration:
Reconnect AC IN or check
conguration or check live
value. 2) In Online conguration:
Reconnect DC or check
conguration or check level
voltage
1) In ONLINE conguration:
reconnect AC IN or check
conguration or check live value.
2) In AC/AC conguration:
reconnect DC or check
conguration or check level
voltage
Hardware problem. Replace T2S
Clear log le
Doc. #: 026-069-B0 Rev F
95
Page 98
9. System Specifications
ModelAMPS80-3-75AMPS80-3-30AMPS80-2-40AMPS80-2-20
Input & Output Phase120/208 V 3-ph120/208 V 3-ph
Nominal Output Power (max)7,500 to 75,000 VA 7,500 to 30,000 VA5,000 to 40,000 VA5,000 to 20,000 VA
Output Power (resistive load)6,000 to 60,000 W6,000 to 24,000 W4,000 to 32,000 W4,000 to 16,000 W
TechnologyTwin Sine Inverter (TSI); each module has DC input & AC input
Static SwitchNot required; each module has own static switch
Efciency94% AC-to-AC; 90% DC-to-AC (from 50% to 100% full load resistive)
WaveformPure sine wave
Output Power Factor0.8
Transfer time0 ms
Warranty2 years
3012168
3322
120/240 V or
120/208 V 2-pole
120/240 V or
120/208 V 2-pole
Inverter Module AC Output
Nominal Voltage (AC)120 V
Voltage Accuracy
Frequency
Inverter frequency accuracy
THD (resistive load)
Transient load recovery time
Soft start time20 s
Max. crest factor at nominal
power
Short circuit overload capacity10 x In for 20 msec in EPC mode (AC input)
Short term overload capacity150% for 5 seconds
Permanent overload capacity110%
60 Hz, Same as input frequency
± 2%
0.03%
<1.5%
0.4 ms
3.5
96
Doc. #: 026-069-B0 Rev F
Page 99
Inverter Module AC Input
Nominal Voltage (AC)120 V
Voltage Range90-140 (user adjustable)
Input Power Factor>99%
Frequency60 Hz
Synchronization Range57-63 Hz
Inverter Module DC Input
Nominal Voltage48 Vdc
Voltage Range (max)40-60 Vdc (user adjustable)
Max DC input current @ 48 Vdc1400 A / 560 A / 750 A / 375 A
Max DC input current @ 40 Vdc1700 A / 680 A / 900 A / 450 A
Voltage Ripple<2 mV / <38 dbrnc
Unied System Controller with SNMP
Control & MonitoringCongure, control and monitor Inverter & Rectier modules via Internet
Explorer 7 and onwards
DisplayLCD Touchscreen display (160 x 160 pixels)
OK / Major / Minor 3-color LED display
Web-based GUI via Ethernet
Communication PortsRJ45 Ethernet Port
RS232 Craft Port
RS232 Modem Port (optional)
Controller I/O
Voltage Inputs
Temperature Inputs
Current Inputs
Bivoltage Inputs
Digital Inputs
Relay Outputs
2
2
4
2
8
8
Environmental Specications
Operating Temperature (full load)-20° to 40°C (-4° to 104°F)
Storage Temperature-40° to 70°C (-40° to 158°F)
Relative HumidityUp to 95%, non-condensing
Operating AltitudeUp to 1,500 m (4,900 ft) above sea level
Thermal Dissipation Per Module437 BTU/hr in AC-to-AC mode & 758 BTU/hr in DC-to-AC mode
Mechanical Specications
System Dimensions
D x W x H (mm/in)
System Weight -- without modules
(kg/lb)
Total Weight with modules
(kg/lb)
Inverter Module Dimensions
D x W x H (mm/in)
Inverter Module Weight (kg/lb)5 kg / 11 lb
680 mm x 600 mm x 2134 mm (26.75" x 23.6" x 84")
270 kg/595 lb
420 kg/925 lb
435 mm x 102 mm x 88.9 mm (17.13" x 4" x 3.5")
Agency Compliance
CSA
UL
C22.2 107.3-05
UL1778; Issue 4
(shelves and modules)
Doc. #: 026-069-B0 Rev F
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Page 100
9.1 Specifications for 48/120 Inverter Module
General specications:
EMC (immunity)EN 61000-4
EMC (emission)EN55022 (Class A), FCC 47 VFR Part 15, class A
SafetyIEC 60950, UL 1778 Issue 4
CoolingForced Air
MTBF240000 hrs
Efciency (typical)
Enhanced Power Conversion94%
On Line89%
AC Output Power
Nominal2500 VA
Resistive Load2000 W
Overload Capacity (short)150% @ 5 s
Overload Capacity (permanent)110%
Nominal48 V
Range (V dc)40 to 60 V
Nominal Current (@40 Vdc)56 A
Max input current (5 s)84 A
Voltage Ripple2 mV
AC Input Specications
Nominal voltage (AC)120 Vac
Voltage range (AC)90 to 140 Vac (adjustable)
Power factor> 99%
Frequency range (selectable)60 Hz
Frequency Tolerance± 3 Hz (Adjustable)
AC Output
Nominal (AC)*120 Vac Accuracy 2%
Frequency60 Hz (Same as input frequency in EPC mode)
Frequency accuracy0.03%
Transient load recovery time0.4 ms
Transfer Performance
Maximum Voltage interruption0 s
Total Transient voltage duration0 s
Environmental
Operating Temperature: -20 to +40°C
Storage Temperature: -40 to +70°C
Humidity:Up to 95% non-condensing
Elevation:<1500M
Miscellaneous
Dimensions: 2 RU H x 102 mm W x 435 mm D
Weight: 5 kg (11 lb.)
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Doc. #: 026-069-B0 Rev F
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