Alpha Serial System Controller User Manual
Serial System Controller
© 2001
Operation and Maintenance Manual
Effective: January, 2001
®
TM
018-332-C0-002 Rev. B
2
© 2001
TM
®
Serial System
Controller
Operation and Maintenance Manual
018-332-C0-002, Rev. B
January, 2001
© 2001 Alpha Technologies
Overview: The purpose of the Serial System Controller
Operation and Maintenance Manual is to detail
system features, installation, operation, and
maintenance procedures. It is written primarily
for the system operator.
NOTE: Alpha Technologies products are subject to change through
continual improvement processes. Therefore, specifications
and/or design layouts may vary slightly from descriptions
included in this manual. Updates to the manual will be issued
when changes affect form, fit or function.
Keep these instructions for future reference.
© 2001
TM
3 018-332-C0-002 Rev. B
Serial System Controller
Product Safety ................................................................. 6
Important Safety Instructions Contained in this Manual .............................. 6
Safety Precautions ............................................................................... 7
Battery Safety Notes ............................................................................ 7
Contact Alpha .................................................................. 8
1. System Overview
1.1 Theory of Operation ...................................................................... 9
1.1.1 Battery Charging............................................................... 9
1.1.2 System Self-Test .............................................................10
1.1.3 Low battery Shutdown of Inverters ....................................11
1.1.4 Enclosure Monitoring ........................................................11
Table of Contents
1.2 Indicators & Connections.............................................................. 12
1.2.1 Front Panel Layout, Serial System Controller (SSC) .............. 12
1.2.2 Diagram: The SSC in a Power System ................................ 13
1.2.3 LED Indicators ................................................................ 14
1.2.4 Reset Switch.................................................................. 14
1.2.5 Serial Communications Interfaces ...................................... 15
1.2.5.1 Internal RS-485 ....................................................... 15
1.2.5.2 External RS-485 ...................................................... 15
1.2.5.3 External RS-232 ...................................................... 15
1.2.5.4 ECM Port................................................................ 16
1.2.6 SSC/Power Supply Interconnection .................................... 17
1.2.7 Data I/O Port ................................................................. 18
1.2.8 Battery Connection Port................................................... 20
1.2.9 Tamper .......................................................................... 21
1.3 Dip Switch: Switch 1 ................................................................... 22
2. Installation
2.1 Module Conversion....................................................................... 23
2.2 SSC Installation .......................................................................... 25
2.3 System Configuration ................................................................... 26
018-332-C0-002 Rev. B
2.4 Smart Display Setup Menu ............................................................ 27
3. Alarms
3.1 Alarm LEDs ................................................................................. 28
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© 2001
TM
Serial System Controller
Table of Figures
Figure 1-1; Alpha Technologies Serial System Controller (SSC) ................ 12
Figure 1-2; Basic Diagram: SSC Shown in Power System......................... 13
Figure 1-3; LED Block, Reset Switch .................................................... 14
Figure 1-4; RS-232 and Alpha/HMS Bus RS-485 Connectors .................... 15
Figure 1-5; ECM Port on SSC.............................................................. 16
Figure 1-6; ECM COMM Port ............................................................... 16
Figure 1-7; Configuration for Multiple Power Supplies ............................. 17
Figure 1-8; Data I/O Connector .......................................................... 18
Figure 1-9; Battery Connector ............................................................ 20
Figure 1-10; Battery Schematic ........................................................... 20
Figure 1-11; Tamper Switch Pin Arrangement.......................................... 21
Figure 1-12; Switch 1 - Configuration Switch......................................... 22
Figure 2-1; Location of Communications Module in XM2 Power Supply ....... 23
Figure 2-2; Preparing Inverter Module to Receive SSC ............................ 24
Figure 2-3; Inverter Module with SSC Installed ..................................... 25
List of Tables
Table 1-1; Digital Inputs and Outputs ................................................. 18
Table 3-1; Alarm LEDs ...................................................................... 28
© 2001
TM
5 018-332-C0-002 Rev. B
Product Safety
Safety Symbols Used in this Manual
Caution
Hazardous Condition
To reduce the risk of electrical shock, injury or death caused by
explosion of fuel or moving parts, and to ensure the safe operation of
this unit, the following symbols have been placed throughout the
manual. Where these symbols appear, servicing must be performed
only by qualified personnel.
Dangerous Voltage
This symbol indicates a dangerous voltage exists in this area
of the product. Use caution whenever working in the area to
prevent electrical shock.
Attention
This symbol indicates important installation, operation or
maintenance instructions. Always follow these instructions
closely.
018-332-C0-002 Rev. B
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© 2001
TM
Product Safety
Safety Precautions
The Serial System Controller (SSC) must be serviced only by
qualified personnel.
Remove all rings, watches and other jewelry before servicing
batteries or installing the SSC.
Verify the voltage requirements of the equipment to be protected
(load), the AC input voltage to the power supply (line), and the
output voltage of the system prior to installation.
The utility service panel must be equipped with a properly rated
circuit breaker for use with this power supply.
When connecting the load, DO NOT exceed the output rating of
the system.
Always use proper lifting techniques whenever handling units,
modules or batteries.
Battery Safety Notes
Chemical Hazards
Any gelled or liquid emissions from a Valve-Regulated Lead-Acid (VRLA) battery
is electrolyte which contains dilute sulfuric acid which is harmful to the skin
and eyes; is electrically conductive; and is corrosive. If electrolyte contacts
the skin, wash immediately and thoroughly with water. If electrolyte enters
the eyes, wash thoroughly for 10 minutes with clean water or a special
neutralizing eye wash solution and seek immediate medical attention.
Neutralize any spilled electrolyte with the special solutions contained in a spill
kit or with a solution of 1 lb. Bicarbonate of soda to 1 gallon of water.
Fire, Explosion, and Heat Hazards
Lead acid batteries can contain an explosive mixture of hydrogen gas which
can vent under overcharging conditions. Do not smoke or introduce sparks in
the vicinity of the battery. Prior to handling the batteries, touch a grounded
metal object, such as the rack, to dissipate any static charge that may have
developed in your body. Do not charge batteries in a sealed container. The
individual batteries should have 0.5 inches of space between them to allow for
convection cooling. If contained, assure the container or cabinet and room
have adequate ventilation to prevent an accumulation of potentially dangerous
gas.
© 2001
TM
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018-332-C0-002 Rev. B
Contact Alpha
Contact Information
General product information
and customer service
7:00 AM to 5:00 PM Pacific Time
1-800-863-3930
To obtain complete technical support
7:00 AM to 5:00 PM Pacific Time
or
For after-hours emergency support
7 days per week, 24 hours a day
1-800-863-3364
Instructions for Returns
Returns for Repair
For units that must be returned for repair, Alpha requires a Return Material Authorization
(RMA). An RMA can be obtained from Alpha Customer Service, using either method listed
below:
Download the necessary forms directly from Alpha's Web site, under "Customer
Service": www.alpha.com
Or call (800) 322-5742 for assistance.
Clearly mark the RMA on the units original shipping container. If the original container is not
available, make sure the unit is packed with at least three inches of shock absorbing
material to prevent shipping damage.
NOTE: Do not use popcorn-type material. Alpha Technologies is not responsible
for damage caused by improper packing on returned units.
In addition to the returned unit, please include a copy of the power supply maintenance log
and any information relevant to the power supply failure.
Returns for Credit
For returns for credit, call (800) 322-5742.
© 2001
TM
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017-900-B0-001 Rev. A
1. System Overview
1.1 Theory of Operation
The Serial System Controller (SSC) manages and provides status monitoring for powering
systems that contain single or multiple (up to six) power supplies, and a generator. It
coordinates battery charging, individual battery monitoring, and self-testing for individual
components in the system. Using a serial interface, Alphas Engine Control Module (ECM)
communicates with the SSC to manage generator operation.
The SSC coordinates the following control functions of the power supply system:
Battery charging
System self-test
Low battery shutdown of inverters
Initiation of low battery disconnect
Monitoring of system configuration
Battery temperature monitoring
Acquisition and maintenance of data from all units in the system
Response to queries from a digital transponder
Monitoring of individual battery voltage
Maintenance of critical parameters in nonvolatile memory
Four user-defined discrete outputs, one input
SSC to serial transponder communication supports: HMS022 for individual power supplies;
HMS022 for the generator system; Alpha power system status; Alpha individual power supply
and extended status; and Alpha generator configuration and extended status.
NOTE: XM2 power supplies must have firmware 3.01 or higher for SSC to
operate.
1.1.1 Battery Charging
Each XM2 has a battery charger capable of delivering a maximum current to the
battery string. XM2s in a system configuration typically share a single string of
batteries, and each provides its maximum charging current to the string after a major
discharge event. Since this may damage the batteries, the SSC determines the
number of power supplies in the system, and limits the individual power supply
chargers so that the maximum charging current is never exceeded. The maximum
charging current for a battery string can be calculated by using the following formula:
Maximum Charging Current <= (Battery Capacity / 5)
For example, total charger current of 100 Amp Hour batteries cannot exceed 20
Amps. If a system contains five power supplies, each will be limited to 4 Amps
maximum.
© 2001
The SSC waits for a unit in the system to transition into FLOAT mode, then watches
system charging current drop below a threshold, based on the number of power
supplies in the system. It then forces all of the XM2 power supplies into FLOAT mode
to complete the battery charge.
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018-332-C0-002 Rev. B
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