Alpha AMPS80 HP User Manual

AMPS80 HP Power System

Installation & Operation Manual

Part #026-069-B0

Effective 8/2012

member of The Group

™

Your Power Solutions Partner

Installation & Operation Manual

NOTE:

Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation.

NOTE:

Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If there are questions regarding the safe operation of this powering system, contact Alpha Technologies or your nearest Alpha representative.

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:

Canada and USA: 1-888-462-7487

International: +1-604-436-5547

Email: support@alpha.ca

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.

Doc. #: 026-069-B0 Rev F

Table of Contents

1. Safety ..............................................................................................................................6

1.1 Safety Symbols ............................................................................................................................. 6

1.2 General Safety .............................................................................................................................. 7

1.3 External Battery Safety ................................................................................................................. 8

1.4 Utility Power Connection ............................................................................................................... 8

1.5 Equipment Grounding ................................................................................................................... 9

2. Product Description....................................................................................................... 10

2.1 Theory of Operation .................................................................................................................... 10

2.2 System Components ................................................................................................................... 12

2.3 Rear Components ....................................................................................................................... 13

2.4 Module Location Relative to System Wiring ............................................................................... 14

3. AC and DC Power Congurations.................................................................................18

3.1 Power System Conguration Terminology .................................................................................. 18

3.2 3-Phase Systems – Recommended AC and DC Breakers .........................................................19

3.3 120V/240V Split Phase or 120/208V 2-Pole Systems ................................................................ 22

3.4 DC Fuse/Breaker ....................................................................................................................... 25

3.5 AMPS80 DC Feed Options .........................................................................................................26

3.6 How to Congure Inverters in AC Input Groups, AC Output Groups and DC Input Groups ....... 27

4. System Pre-Installation ................................................................................................. 29

4.1 Site Selection .............................................................................................................................. 29

4.2 Recommended Installation Layout .............................................................................................. 30

4.3 Wiring for Generator and/or External MBS ................................................................................. 31

4.4 Transporting the Cabinet .............................................................................................................32

4.5 Unpacking Instructions ................................................................................................................ 33

4.6 Anchoring the Cabinet .................................................................................................................34

5. System Installation ........................................................................................................ 39

5.1 Input/Output Cabling Overview ................................................................................................... 41

5.2 AC Connections ..........................................................................................................................42

5.3 DC Connections .......................................................................................................................... 43

5.4 Commissioning the System for the First Time ............................................................................47

Doc. #: 026-069-B0 Rev F

6. System Operation ......................................................................................................... 55

6.1 Inverter Module Indicators .......................................................................................................... 55

6.2 T2S Inverter Control Card ........................................................................................................... 57

6.3 Using the CXC Unied System Controller .................................................................................. 58

6.4 Rectier Features ........................................................................................................................ 72

6.5 Synchronization with a Maintenance Bypass Switch (MBS) ....................................................... 76

7. Maintenance .................................................................................................................77

7.1 Preventive Maintenance ............................................................................................................. 77

7.2 Recommended maintenance schedule ....................................................................................... 77

7.3 Tools, Spare Parts and Equipment .............................................................................................77

7.4 Replacing the T2S Inverter Control Card .................................................................................... 79

7.5 Inverter or Rectier Fan Replacement ........................................................................................ 80

7.6 Replacement of AIM2500/1500 Inverter Modules ......................................................................81

7.7 Surge Suppression Replacement ............................................................................................... 82

7.8 Fuse Replacement ...................................................................................................................... 84

7.9 Synchronization After Maintenance or Repair .............................................................................85

8. Troubleshooting ............................................................................................................86

8.1 Non Recoverable Error ............................................................................................................... 86

8.2 Recoverable Error ....................................................................................................................... 86

8.3 Alarm Codes ...............................................................................................................................87

9. System Specications ................................................................................................... 96

9.1 Specications for 48/120 Inverter Module ................................................................................... 98

9.2 Specications for 48-1.8 kW Rectier ......................................................................................... 99

10. Conguration Parameters .........................................................................................100

10.1 Transferring Inverter Settings to Another System ................................................................... 100

10.2 Examples of Modications to Conguration Parameters ........................................................ 100

10.3 Global Settings (ID 1 – 50) ...................................................................................................... 102

10.4 Inverter Parameters (ID 51 – 550) .......................................................................................... 103

10.5 Alarm Settings (ID 551-950) ....................................................................................................109

11. Certication ................................................................................................................111

12. Warranty ....................................................................................................................112

Doc. #: 026-069-B0 Rev F

List of Figures

Figure 1 — Controller breakers on top of the AMPS80 ...................................................................... 13

Figure 2 — 20 kVA split-phase or 120/208V 2-pole system ...............................................................14

Figure 3 — 40 kVA, split-phase or 120/208V 2-pole system ............................................................. 15

Figure 4 — 75 kVA, 3-phase systems ................................................................................................ 16

Figure 5 — 30 kVA, 3-phase system ................................................................................................. 17

Figure 6 — Split Phase from a Single phase supply ......................................................................... 18

Figure 7 — 2-Pole from a 3-phase supply ......................................................................................... 18

Figure 8 — Monitotring AC Input Groups, AC Output Groups and DC Input Groups ........................ 27

Figure 9 — Inverter mapping for AC and DC Groups ........................................................................ 28

Figure 10 — Installation layout and clearances ................................................................................. 30

Figure 11 — System Schematic with Generator and MBS ................................................................ 31

Figure 12 — Arrangement of lifting eyes on top of cabinet ................................................................ 32

Figure 13 — Mounting hole pattern ................................................................................................... 34

Figure 14 — Single AC feed .............................................................................................................. 35

Figure 15 — Dual AC Feed ................................................................................................................ 35

Figure 16 — Rectier terminal block .................................................................................................. 36

Figure 17 — Representative system wiring for AMPS inverter or hybrid system with MBS with single

AC input feed. ......................................................................................................................... 38

Figure 18 — Representative system wiring for AMPS inverter system with independent AC input feed

for MBS ................................................................................................................................... 38

Figure 19 — Battery and power connections ..................................................................................... 40

Figure 20 — Top view of AMPS80 showing AC and DC connection partitions .................................. 41

Figure 21 — AC Connections ............................................................................................................ 42

Figure 22 — DC connections - top view ............................................................................................ 43

Figure 23 — Cabling and hardware arrangement .............................................................................. 43

Figure 24 — DC connection dimensions – front view ........................................................................ 44

Figure 25 — DC tie bar for single battery string ................................................................................. 45

Figure 26 — DC tie bar for two battery strings ................................................................................... 46

Figure 27 — Controller default home screen ..................................................................................... 48

Figure 28 — Seed modules shown for 40 kVA, split-phase systems ................................................. 49

Figure 29 — Inverter module showing AC input LED ........................................................................ 49

Doc. #: 026-069-B0 Rev F

Figure 30 — Unlocking and locking an inverter module for removal or insertion ............................... 50

Figure 31 — Inserting and removing an inverter module ................................................................... 50

Figure 32 — Inverters > View Live Status.......................................................................................... 51

Figure 33 — Matching AC Input Groups to AC Output Groups .........................................................52

Figure 34 — Inserting blanks in open slots ........................................................................................ 54

Figure 35 — Fig. 4.1 Inverter module status, power LEDs ............................................................... 55

Figure 36 — Output power indicator LEDs ........................................................................................ 56

Figure 37 — T2S front panel .............................................................................................................. 57

Figure 38 — CXC system controller .................................................................................................. 58

Figure 39 — LCD active areas ........................................................................................................... 60

Figure 40 — Password entry pop-up window .................................................................................... 60

Figure 41 — Navigation screen ......................................................................................................... 61

Figure 42 — Illustration of web interface window (sample home page) ............................................ 62

Figure 43 — View live status page .................................................................................................... 63

Figure 44 — View live status — inverters page ................................................................................. 63

Figure 45 — View group status window — inverters page ................................................................ 64

Figure 46 — Group mapping window ................................................................................................ 65

Figure 47 — Set input window .......................................................................................................... 66

Figure 48 — Set Output window ....................................................................................................... 67

Figure 49 — General settings window .............................................................................................. 68

Figure 50 — Manage Cong File window ......................................................................................... 68

Figure 51 — Congure alarms window ............................................................................................. 69

Figure 52 — T2S alarms in event logs ............................................................................................... 70

Figure 53 — Retrieve inverter alarm history le ................................................................................. 70

Figure 54 — Signals (inverters) window ........................................................................................... 71

Figure 55 — Cordex CXRF 48 V rectier ........................................................................................... 72

Figure 56 — T2S LED sequence during initialization ........................................................................ 79

Figure 57 — Update Inventory steps ................................................................................................. 80

Figure 58 — Rectier fuse locations .................................................................................................. 84

Figure 59 — Manage Cong File window ........................................................................................ 100

Doc. #: 026-069-B0 Rev F

1. Safety

SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that

must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.

1.1 Safety Symbols

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

The use of ATTENTION indicates specic regulatory/code requirements that may affect the

placement of equipment and /or installation procedures.

NOTE:

A NOTE provides additional information to help complete a specic 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.

Doc. #: 026-069-B0 Rev F

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.

Doc. #: 026-069-B0 Rev F

• 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.

Doc. #: 026-069-B0 Rev F

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.

Doc. #: 026-069-B0 Rev F

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.

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

Doc. #: 026-069-B0 Rev F

Boost

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.

Doc. #: 026-069-B0 Rev F

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

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. DC Input Breakers (optional): Provide SELV DC

power to each Inverter module.

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

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.

Doc. #: 026-069-B0 Rev F

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

Doc. #: 026-069-B0 Rev F

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

Rectier output to DC1

Rectier output to DC4

Figure 2 — 20 kVA split-phase or 120/208V 2-pole system

Doc. #: 026-069-B0 Rev F

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

Rectier output to DC1

Rectier output to DC4

Figure 3 — 40 kVA, split-phase or 120/208V 2-pole system

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)

Rectier output to DC1

Rectier output to DC4

Figure 4 — 75 kVA, 3-phase systems

Doc. #: 026-069-B0 Rev F

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

Rectier output to DC1

Rectier output to DC4

Figure 5 — 30 kVA, 3-phase system

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

Figure 6 — Split Phase from a Single phase supply

120V

240V

208V

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

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.

Doc. #: 026-069-B0 Rev F

208V

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

input

MBS

AMPS80-3-75

AC input voltage 120/208 V 120/208 V 120/208 V 120/208 V

Full load AC input current per phase 177 A 227 A 223 A 273 A

AC input poles & wiring 4 w + G 4 w + G 4 w + G 4 w + G

Wiring

Recommended

AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

NEC 30ºC #3/0 250 kcmil 250 kcmil 350 kcmil CEC 30ºC #4/0 300 kcmil 300 kcmil See dual feed

NEC 40ºC #4/0 300 kcmil 300 kcmil See dual feed CEC 40ºC 250 kcmil 350 kcmil 350 kcmil See dual feed

3Ф Wye 3Ф Wye 3Ф Wye 3Ф Wye

225 A 300 A 300 A 350 A

Without MBS

Without rectiers

AMPS80-3-75-H2

Without MBS

With rectiers

AMPS80-3-75,

With MBS

Without rectiers

MBS

With rectiers

AMPS80-3-75-H2,

With MBS

Total maximum AC output 75 kVA, 60 kW 75 kVA, 60 kW 75 kVA, 60 kW 75 kVA, 60 kW

AC output poles & wiring 4 w + G 4 w + G 4 w + G 4 w + G

output

AC input & output

connection terminals

Note 1

Note 2

AC output current per phase 208 A 208 A 208 A 208 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 signicant non-linear (ie rectied 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 voltage 120/208 V 120/208 V 120/208 V 120/208 V

Wiring

NEC 30ºC #4/0 #4/0 #4/0 #4/0 CEC 30ºC 250 kcmil 250 kcmil 250 kcmil 250 kcmil

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 250 kcmil 250 kcmil 250 kcmil 250 kcmil CEC 40ºC 300 kcmil 300 kcmil 300 kcmil 300 kcmil

3Ф Wye 3Ф Wye 3Ф Wye 3Ф Wye

250 A 250 A 250 A 250 A

Doc. #: 026-069-B0 Rev F

NOTE:

The recommendations in Table B are for reference only. A registered professional engineer must review and approve or modify these recommendations in compliance with applicable national and local electrical and building codes.

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

rectiers

AMPS80-3-75-H2

AMPS80-3-75-H2,

MBS

input

output

AC feed Inverter feed

AC input voltage 120/208 V 208 V 120/208 V 208 V

Full load AC input current per phase 177 A 50 A 223 A 50 A

AC input poles & wiring 4 w + G 4 w + G 4 w + G 4 w + G

Wiring

Recommended

AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

Total maximum AC output 75 kVA, 60 kW 75 kVA, 60 kW

AC output poles & wiring 4 w + G 4 w + G

AC output current per phase 208 A 208 A

Installed inverter input

& output circuit breaker

Recommended

AC output wire size

90ºC copper

AC output voltage 120/208 V 120/208 V

Wiring

NEC 30ºC #3/0 #6 250 kcmil #6 CEC 30ºC #4/0 #4 300 kcmil #4 NEC 40ºC #4/0 #6 300 kcmil #6 CEC 40ºC 250 kcmil #4 350 kcmil #4

NEC 30ºC #4/0 #4/0 CEC 30ºC 250 kcmil 250 kcmil NEC 40ºC 250 kcmil 250 kcmil CEC 40ºC 300 kcmil 300 kcmil

3Ф Wye 3Ф Wye 3Ф Wye 3Ф Wye

225 A 70 A 300 A 70 A

Rectier feed

3Ф Wye 3Ф Wye

250 A 250 A

Inverter/MBS

feed

Rectier feed

AC input & output

connection terminals

Rectier connection

Note 1

Note 2

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

for 3Ф systems with signicant non-linear (ie rectied 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)

Doc. #: 026-069-B0 Rev F

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

input

output

AMPS80-3-30

Feed Single Single Single Single

AC input voltage 120/208 V 120/208 V 120/208 V 120/208 V

Full load AC input current per phase 71 A 121 A 88 A 138 A

AC input poles & wiring 4 w + G 4 w + G 4 w + G 4 w + G

Wiring

Recommended

AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

Total maximum AC output 30 kVA, 24 kW 30 kVA, 24 kW 30 kVA, 24 kW 30 kVA, 24 kW

AC output poles & wiring

AC output current per phase 83 A 83 A 83 A 83 A

Installed inverter input

& output circuit breaker

AC output voltage

Wiring 3Ф Wye 3Ф Wye 3Ф Wye 3Ф Wye

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 Wye 3Ф Wye 3Ф Wye 3Ф Wye

90 A 150 A 125 A 175 A

120/208 V 120/208 V 120/208 V 120/208 V

4 w + G 4 w + G 4 w + G 4 w + G

125 A 125 A 125 A 125 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.

kA short circuit current. Double neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with signicant non-linear (ie rectied 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

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

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

input

output

Model

AMPS80-2-40

Feed Single Single Single Single

AC input voltage

Full load AC input current per phase 148 A 225 A 179 A 256 A

AC input poles & wiring 3 w + G 3 w + G 3 w + G 3 w + G

Wiring 2-pole 2-pole 2-pole 2-pole

Recommended

AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

Total maximum AC output 40 kVA, 32 kW 40 kVA, 32 kW 40 kVA, 32 kW 40 kVA, 32 kW

AC output poles & wiring 3 w + G 3 w + G 3 w + G 3 w + G

AC output current per phase 167 A 167 A 167 A 167 A

Installed inverter input

& output circuit breaker

Recommended

AC output wire size

90ºC copper

AC output voltage

Wiring

NEC 30ºC #2/0 250 kcmil #3/0 350 kcmil CEC 30ºC #3/0 300 kcmil #4/0 See dual feed

NEC 40ºC #3/0 250 kcmil #3/0 See dual feed CEC 40ºC #3/0l 300 kcmil #4/0 See dual feed

NEC 30ºC #4/0 #4/0 #4/0 #4/0 CEC 30ºC 250 kcmil 250 kcmil 250 kcmil 250 kcmil NEC 40ºC 250 kcmil 250 kcmil 250 kcmil 250 kcmil CEC 40ºC 300 kcmil 300 kcmil 300 kcmil 300 kcmil

120/208 V

or 120/240 V

200 A 300 A 225 A 350 A

120/208 V

or 120/240 V

2-pole 2-pole 2-pole 2-pole

250 A 250 A 250 A 250 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

connection

terminals

Double neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with signicant nonlinear (ie rectied 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

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

rectiers

AMPS80-2-40-H2

AMPS80-2-40-H2,

MBS

input

output

AC feed Inverter feed

AC input voltage

Full load AC input current per phase 148 A 77 A 179 A 77 A

AC input poles & wiring 3 w + G 3 w + G 3 w + G 3 w + G

Wiring 2-pole 2-pole 2-pole 2-pole

Recommended AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

Total maximum AC output 40 kVA, 32 kW 40 kVA, 32 kW

AC output poles & wiring 3 w + G 3 w + G

AC output current per phase 167 A 167 A

Installed inverter input

& output circuit breaker

Recommended

AC output wire size

90ºC copper

AC output voltage 120/208 V or 120/240 V 20/208 V or 120/240 V

Wiring

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 30ºC 250 kcmil 250 kcmil NEC 40ºC 250 kcmil 250 kcmil CEC 40ºC 300 kcmil 300 kcmil

120/208 V

or 120/240 V

200 A 100 A 225 A 100 A

Rectier feed

208 V or 240 V

2-pole 2-pole

250 A 250 A

Inverter/MBS feed

120/208 V

or 120/240 V

Rectier feed

208 V

or 240 V

AC input & output

connection terminals

Rectier connection

Note 1

Note 2

terminals

circuit current. Double neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with signicant non-linear (ie rectied 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)

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

input

output

Model

AMPS80-2-20

Feed Single Single Single Single

AC input voltage

Full load AC input current per phase 71 A 148 A 89 A 166 A

AC input poles & wiring 3 w + G 3 w + G 3 w + G 3 w + G

Wiring 2-pole 2-pole 2-pole 2-pole

Recommended

AC input breaker/fuse

Recommended

AC input wire size

90ºC copper

Total maximum AC output 20 kVA, 16 kW 20 kVA, 16 kW 20 kVA, 16 kW 20 kVA, 16 kW

AC output poles & wiring 3 w + G 3 w + G 3 w + G 3 w + G

AC output current per phase 83 A 83 A 83 A 83 A

Installed inverter input

& output circuit breaker

AC output voltage

Wiring

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 A 200 A 125 A 225 A

120/208 V

or 120/240 V

2-pole 2-pole 2-pole 2-pole

125 A 125 A 125 A 125 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

NEC 30ºC #2 #2 #2 #2

Recommended

AC output wire size

90ºC copper

short circuit current. Double neutral is strongly recommended for AC output wiring (and AC input wiring to the MBS) for 3Ф systems with signicant non-linear (ie rectied 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.

CEC 30ºC #2 #2 #2 #2 NEC 40ºC #1 #1 #1 #1

CEC 40ºC #1 #1 #1 #1

Doc. #: 026-069-B0 Rev F

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

input

AMPS80-3-75

AMPS80-3-75-H2

Maximum DC Input wattage 67 kW 27 kW 36 kW 18 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 A 563 A 750 A 375 A

1843 A 743 A 990 A 495 A

2000 A 800 A 1000 A 500 A

1200 A 400 A 500 A 250 A

600 A 200 A 250 A 125 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

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

Two 5. Dual Feed N+N 37.5kVA 30kW 20kV 16kW 15kVA 12kW

Four 7. Quad Feed N+1,

DC Breaker option

3. Dual Feed N+N 37.5kVA 30kW 20kV 16kW 15kVA 12kW

4. Quad Feed N+2

6. Quad Feed N+2

N+0, N+1, N+2 N+3 N+N

N+3

N+3 N+N

N+2 N+3 52.5kVA 42kW

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

30kVA 24kW

32kW 28kW 24kW 20kW 16kW

24kW 20kW

24kW 20kW 16kW

30kVA

22.5kVA 15kVA

7.5kVA 15kVA

15kVA

7.5kVA

15kVA

7.5kVA 15kVA

22.5kVA 18kW

24kW 18kW 12kW

6 kW

12kW

6 kW

12kW

6 kW

12kW

Doc. #: 026-069-B0 Rev F

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 congure

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

3.6.2 DC Input Groups

The conﬁguration of the DC input to the inverters provides several different ways to monitor DC input power and input current. The number of DC Input Groups (maximum eight) is set in the Inverters > Group Mapping screen and monitored as a unit in the View Group Status screen. The following table gives examples of possible conﬁgurations.

Monitoring DC Source

Bulk Assign all inverters to DC Input Group 1. 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 Input For 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.

Figure 9 — Inverter mapping for AC and DC Groups

Doc. #: 026-069-B0 Rev F

+ 86 hidden pages

Alpha AMPS80 HP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual