Alpha XM2, XM2-HV, XM2-HP User Manual

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Page 1

Intelligent CableUPS

Technical Manual

XM2, XM2-HV, XM2-HP

Effective: January 2013

Page 2

Alpha Technologies

Power

Page 3

Intelligent CableUPS® Technical Manual

017-805-B0-010, Rev K2

Effective Date: January 2013

Alpha Technologies, Inc.

NOTE:

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

NOTE:

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

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.

Notice of FCC Compliance

Per FCC 47 CFR 15.21:

Changes or modications not expressly approved by the party responsible for compliance could void the user’s

authority to operate the equipment.

Per FCC 47 CFR 15.105:

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause

harmful interference in which case the user will be required to correct the interference at their own expense.

Contacting Alpha T echnologies: www.alpha.com

For general product information and customer service (7 AM to 5 PM, Pacic Time), call

1-800-863-3930

For complete technical support, call

1-800-863-3364

7 AM to 5 PM, Pacic Time or 24/7 emergency support

017-805-B0-010 Rev. K2

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Table of Contents

Safety Notes .....................................................................................................................8

Safety Precautions ...........................................................................................................8

Battery Safety Notes.........................................................................................................9

Utility Power Connection Notes ......................................................................................10

Grounding and Earth Connection Notes.........................................................................13

1.0 Introduction ..........................................................................................................14

1.1 Theory of Operation ..................................................................................15

1.1.1 AC (Line) Operation .......................................................................15

1.1.2 Standby Operation .........................................................................16

1.1.3 Charger Operation .........................................................................17

1.2 Intelligent CableUPS Layout .....................................................................18

1.2.1 Transformer Module Overview .......................................................18

1.2.2 Inverter Module Overview ..............................................................19

1.2.3 Optional Status Monitoring Modules .............................................22

1.3 Recommended Enclosure System Options ..............................................23

2.0 Installation............................................................................................................25

2.1 Installation Procedure ...............................................................................25

2.2 Installing the Optional Indicator Lamps .....................................................26

2.2.1 AC Indicator Lamp .........................................................................26

2.2.2 Local/Remote Indicator ..................................................................27

2.3 Initial Turn Up ............................................................................................29

2.4 Inverter Module Removal and Installation.................................................30

2.5 Protective Interface Module (PIM) ............................................................31

2.6 Installing the PIM ......................................................................................32

2.7 Programming the PIM ...............................................................................35

2.7.1 The Setup Menu.............................................................................36

2.8 N+1 Congurations ...................................................................................37

2.9 Service Power Inserter (SPI) ....................................................................39

3.0 Conguration .......................................................................................................41

3.1 Power Distribution Board (PDB) Setup .....................................................41

3.1.1 Replacing the Metal Oxide Varistors (MOVs) .................................44

3.1.2. Replacing the Line Isolation Relay .................................................45

3.2 AC Input Voltage Reconguration .............................................................46

3.2.1 Reconguration from 120 to 240Vac ..............................................46

3.2.2 Reconguration from 240 to 120Vac ..............................................48

3.3 AC Output Voltage Reconguration ..........................................................50

3.3.1 Output Voltage Switch (SW1) Settings...........................................51

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Contents, continued

4.0 Operation .............................................................................................................53

4.1 Start-up and Test .......................................................................................53

4.1.1 AC Line Operation..........................................................................53

4.1.2 Self Test Operation .........................................................................54

4.1.3 Standby Operation ........................................................................55

4.2 Using the Smart Display ...........................................................................56

4.3 Smart Display Modes ................................................................................58

4.3.1 Operation Normal ...........................................................................58

4.3.2 Comms Information Display (with DSM2 or later) ..........................59

4.3.3 Setup Menu ....................................................................................60

4.3.4 Menu Structure/Navigation (from Operation Normal screen) .........63

4.3.5 Menu Structure/Navigation (from Active Alarms screen)................64

4.4 Alarm Indications ......................................................................................65

4.5 Smart Display LEDs ..................................................................................71

4.6 Smart Display Glossary ............................................................................72

4.7 Automatic Performance Test .....................................................................74

4.8 Providing Power via Portable Generator or Inverter .................................75

4.8.1 DC Powering ..................................................................................75

4.8.2 AC Powering ..................................................................................75

4.8.3 Using a Truck-mounted Inverter or Generator ...............................76

4.9 Resumption of Utility Power ......................................................................77

5.0 Intelligent CableUPS Maintenance ......................................................................78

5.1 System Information ...................................................................................78

5.2 Battery Charger Voltage............................................................................79

5.3 Battery Terminals and Connecting Wires ..................................................79

5.4 Output Voltage ..........................................................................................79

5.5 Output Current ..........................................................................................79

5.6 Check Output Connections .......................................................................79

5.6.1 Visual Inspection ............................................................................79

5.7 Inverter Module Maintenance ...................................................................80

5.8 Maintenance Log ......................................................................................81

5.9 Repair Record ...........................................................................................82

6.0 Specications.......................................................................................................83

6.1 Intelligent CableUPS North American Models ..........................................83

6.2 Intelligent CableUPS International Models ...............................................84

6.3 Safety and EMC Compliance ....................................................................85

7.0 Return and Repair Information ............................................................................86

7.1 Emergency Shutdown ...............................................................................87

017-805-B0-010 Rev. K2

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Figures and Tables

Fig. 1-1, XM2-HP Power Supply ..........................................................................................................15

Fig. 1-2, Standard XM2 Power Supply .................................................................................................15

Fig. 1-3, Simplied Block Diagram .......................................................................................................16

Fig. 1-4, Charger Modes ......................................................................................................................17

Fig. 1-5, Transformer Module Connections ..........................................................................................18

Fig. 1-6, Inverter Module Voltage Rating Labels ..................................................................................19

Fig. 1-7, Inverter Module Connections .................................................................................................20

Fig. 1-8, Placement of Remote Temperature Sensor (RTS) on battery ...............................................21

Fig. 1-9, Placement of Battery Spacer Clips on 36V and 48V battery strings ......................................21

Fig. 1-10, DSM3x .................................................................................................................................22

Fig. 1-11, IDH3 .....................................................................................................................................22

Fig. 1-12, Standard AlphaGuard ..........................................................................................................24

Fig. 1-13, Potted AlphaGuard ..............................................................................................................24

Fig. 2-1, AC Indicator Lamp .................................................................................................................26

Fig. 2-2, Wire/Housing Assembly .........................................................................................................26

Fig. 2-3, Local/Remote Indicator Lamp ................................................................................................27

Fig. 2-4, Wire/Housing Assembly .........................................................................................................27

Fig. 2-5, ACI/LRI Connection ...............................................................................................................28

Fig. 2-6, Inverter Module Ribbon Cable ...............................................................................................30

Fig. 2-7, Detail of Locking Mechanism .................................................................................................30

Fig. 2-8, PDB Connections ..................................................................................................................32

Fig. 2-9, J6 and J4 connection as seen from rear of Power Distribution Board ...................................33

Fig. 2-10, Location of JP1 on PIM ........................................................................................................34

Fig. 2-11, Jumper in 15A position .........................................................................................................34

Fig. 2-12, Jumper in 22A position ........................................................................................................34

Fig. 2-13, PIM (Protective Interface Module) and PDB (Power Distribution Board) .............................34

Fig. 2-14, N+1 Conguration ................................................................................................................37

Fig. 2-15, Dual Redundancy (N+1) Conguration ................................................................................38

Fig. 2-16, SPI Cover Removal .............................................................................................................39

Fig. 2-17, Coaxial Cable Insertion and Securing .................................................................................39

Fig. 2-18, Cover Replaced, SPI Switched On ......................................................................................40

Fig. 2-19, SPI Grounding Lug ..............................................................................................................40

017-805-B0-010 Rev. K2

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Figures and Tables, continued

Fig. 2-20, Enclosure Ground Bar .........................................................................................................40

Fig. 3-1, Locations of JP1, JP2 and SW1, SW2 on the Power Distribution Board (PDB) ....................42

Fig. 3-2, MOV Replacement ................................................................................................................44

Fig. 3-3, Typical NEMA Receptacles and Plugs ...................................................................................46

Fig. 3-4, Transformer Module Input Jumpers, PDB Jumpers ...............................................................47

Fig. 3-5, SW2 Settings .........................................................................................................................47

Fig. 3-7, Transformer Module Input Jumpers, PDB Jumpers ...............................................................48

Fig. 3-6, Typical NEMA Receptacles and Plugs ...................................................................................48

Fig. 3-8, SW2 Settings .........................................................................................................................49

Fig. 3-9, XM2-615A Transformer Output Tap Connector shown in default setting (63Vac) ..................50

Fig. 3-10, Transformer Output Tap Connector for other XM Series 2 Power Supplies ........................50

Fig. 4-1, Conguration Screen .............................................................................................................53

Fig. 4-2, Smart Display Navigation ......................................................................................................56

Fig. 4-3, Smart Display Panel ..............................................................................................................57

Fig. 4-4, Operation Normal Display ......................................................................................................58

Fig. 4-5, Comms Information Display ...................................................................................................59

Fig. 4-6, Setup Menu Display ..............................................................................................................62

Fig. 4-7, Output and Alarm LEDs .........................................................................................................71

Fig. 7-1 Emergency Shutdown .............................................................................................................87

Table 3-1, Power Distribution Board Setup ..........................................................................................43

Table 3-2, Output Voltage switch settings per Power Supply ...............................................................51

Table 3-3, Output Voltage switch settings for XM2-918HP, XM2-924HP .............................................52

Table 4-1, AC Output ............................................................................................................................54

Table 6-1 Specications for North American Models ...........................................................................83

Table 6-2 Specications for International Models ................................................................................84

Table 6-3, Product Certications ..........................................................................................................85

017-805-B0-010 Rev. K2

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Safety Notes

Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference.

To reduce the risk of injury or death and to ensure the continued safe operation of this product, the following

symbols have been placed throughout this manual. Where these symbols appear, use extra care and

attention.

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.

CAUTION! The use of CAUTION indicates safety information intended to PREVENT DAMAGE to

material or equipment.

WARNING!

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

Safety Precautions

• Only qualied personnel may service the Intelligent CableUPS.

• 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.

• Equip the utility service panel with a properly rated circuit breaker for use with this power supply.

• When connecting the load, DO NOT exceed the output rating of the power supply.

• Always use proper lifting techniques whenever handling units, modules or batteries.

• The power supply contains more than one live circuit! Even though AC voltage is not present at the input,

voltage may still be present at the output.

• If batteries are being stored prior to installation, recharge per manufacturer’s specications to ensure optimum performance and maximum battery service life.

• Reduce the chance of spark and wear on the connectors; always switch the inverter’s battery circuit

breaker off before connecting or disconnecting the battery pack

• The battery pack, which provides backup power, contains dangerous voltages. Only qualied personnel

should inspect or replace batteries.

• In the event of a short-circuit, batteries present a risk of electrical shock and burns from high current. Observe proper safety precautions.

• Always wear protective clothing, insulated gloves and eye protection (i.e. safety glasses or a face shield)

whenever working with batteries.

• Always carry a supply of water, such as a water jug, to wash the eyes or skin in the event of exposure to

battery electrolyte.

017-805-B0-010 Rev. K2

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Safety Precautions, continued

• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can result in a re

or possible explosion.

• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.

• Avoid using uninsulated tools or other conductive materials when handling batteries or working inside the

enclosure.

• Remove all rings, watches and other jewelry before servicing batteries.

• Spent or damaged batteries are environmentally unsafe. Always recycle used batteries. Refer to local

codes for proper disposition of batteries

• The Intelligent CableUPS has been investigated by regulatory authorities for use in various Alpha

enclosures. If you are using a non-Alpha enclosure, it is your responsibility to ensure your combination conforms to your local regulatory requirements and the power supply remains within its environmental

specications.

Battery Safety Notes

• Always refer to the battery manufacturer’s recommendation for selecting correct “FLOAT” and “ACCEPT”

charge voltages. Failure to do so can damage the batteries.

• Verify the power supply’s battery charger “FLOAT” and “ACCEPT” charger voltage settings.

• 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 compensate for changes in temperature, the battery charger used in the power supply is temperature compensating. Refer to Section 1.2.2 for

instructions on connecting the Remote Temperature Sensor (RTS).

• If the batteries appear to be overcharged or undercharged, rst check for defective batteries and then

verify the correct charger voltage settings.

• To ensure optimum performance, inspect batteries every three to six months for signs of cracking, leaking

or unusual swelling (note that some swelling is normal).

• Check battery terminals and connecting wires. Clean battery terminal connectors periodically and

retighten to approximately 110 inch-pounds (or to manufacturer’s specications if not AlphaCells). Spray

the terminals with an approved battery terminal coating such as NCP-2.

NOTE:

If installed, disconnect the AlphaGuard prior to measuring battery voltage.

NOTE:

Even with a AG-CMT present in the system, any battery which fails the 0.3V load test must be replaced

with an identical type of battery.

• Check battery voltages UNDER LOAD. Use a load tester if available. Differences between any battery in the set should not be greater than 0.3Vdc.

• Refer to the battery manufacturer’s recommendation for correct charger voltages and the power

supply operation manual for corresponding charger settings.

• Number the batteries (1, 2, 3, etc.) inside the enclosure for easy identication (refer to the appropriate enclosure installation guide).

• Establish and maintain a battery maintenance log.

NOTE:

Always verify proper polarity of cables before connecting the batteries to the power module. The batteries are clearly marked for polarity. If the cables become interchanged at the batteries the battery breaker will trip.

017-805-B0-010 Rev. K2

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Utility Power Connection Notes

ATTENTION:

Connecting to the utility should be performed only by qualied service personnel and in compliance with local

electrical codes. Connection to utility power must be approved by the local utility before installing the power supply.

UL and NEC require that a service disconnect switch (UL listed) be provided by the installer and be connected

between the power source and the ALPHA power supply. Connection to the power supply must include an appropriate service entrance weather head.

NOTE:

In order to accommodate the high-inrush currents normally associated with the start-up of ferroresonant

transformers (400 Amp, no-trip, rst-half cycle), either a “high-magnetic” or an HACR (Heating, Air Conditioning, Refrigeration) trip breaker must be used. Do not replace these breakers with a

conventional service entrance breaker. Alpha recommends ONLY Square D breakers because of the increased reliability required in this powering application. High-magnetic Square D circuit breakers and

a BBX option (UL Listed service entrance) are available from Alpha Technologies.

Description Alpha Part Number Square D Part Number

240V Installation - HACR (15A) 470-224-10 QO215

120V Installation - High-magnetic (20A) 470-017-10 QO120HM

BBX - External Service Disconnect 020-085-10 QO2 -4L70RB BBX - External Service Disconnect 020-141-10 QO8-16L100RB

ATTENTION:

In most cases, the following congurations qualify for service entrance use when wiring a duplex receptacle

to a service disconnect. Other codes may also apply. Always contact your local utility to verify the wiring conforms to applicable codes.

XM2 Connections

Proper 120Vac 20A service requires the installation site be:

• Equipped with a 120Vac duplex receptacle which provides power to the power supply and

peripheral equipment.

• Have a NEMA 5-20R receptacle protected by a single-pole, 20 Amp High Magnetic (HM) circuit

breaker inside the service entrance.

• Checked to NEC CODE to verify proper wire AWG (suggested wire gauge is 12AWG).

• Equipped with a grounding clamp on the enclosure to facilitate dedicated grounding.

NOTE:

When bonding the box to a neutral plate is required, use the long green bonding screw provided (Alpha P/N 523-011-10, Square D P/N 40283-371-50).

017-805-B0-010 Rev. K2

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Utility Power Connection Notes, continued

LI Black

Copper Ground Wire

#8 AWG (Minimum)

Grounding Point Made

to Enclosure Wall

Breaker

LI Black

Typical 120Vac Service Entrance Wiring

To Utility

Neutral (White)

Neutral Bus

To Enclosure Receptacle

(Black)

Neutral

(White)

Typical 120 Vac 20A Receptacle Wiring, 5-20R

(P/N 531-006-10)

Ground

(Green)

017-805-B0-010 Rev. K2

Page 12

Utility Power Connection Notes, continued

Proper 240Vac 20A service requires the installation site be:

• Equipped with a 240Vac duplex receptacle to provide power to the power supply and peripheral

equipment.

• Have aNEMA 6-15R receptacle is protected by a single, 2-pole, common trip 15A circuit breaker inside the service entrance.

• Checked to NEC CODE to verify proper wire AWG (suggested wire gauge is 14AWG).

• Equipped with a grounding clamp on the enclosure to facilitate dedicated grounding.

NOTE:

When bonding the box to a neutral plate is required, use the long green bonding screw provided (Alpha P/N 523-011-10, Square D P/N 40283-371-50).

LI (Black)

L2 (Red)

Copper Ground Wire

#8 AWG (Minimum)

Breaker

Grounding Point Made

to Enclosure Wall

To Utility

Neutral (White)

Neutral Bus

Typical 240Vac Service Entrance Wiring

017-805-B0-010 Rev. K2

Page 13

Grounding and Earth Connection Notes

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

Lightning strikes, grid switching or other aberrations on the power line and/or communications cable have the potential to cause high-energy transients that can damage the powering or communications systems. The most viable method available to protect the system from damage is to divert these unwanted high-energy transients along a lowimpedance path to Earth. A low-impedance path to Earth prevents these currents from reaching high voltage levels and posing a threat to equipment.

The key to the success of lightning protection is single-point grounding so the components of the grounding system appear as a single point of uniform impedance. Two places recommended by Alpha for single-point grounding are connections in the enclosure and connections to Earth. Single-point grounding in the enclosure is achieved by bonding all electrical connections to the enclosure, including the connection to Earth, as close together on the enclosure as

possible. Single-point grounding for the connection to Earth is achieved, for example by the proper bonding of the

ground rods.

Safety Ground and Earth Connection

The safety ground and Earth is a two-part system, comprised of the utility service and the Alpha system.

1. First, utility service; As a minimum requirement for the protection of Alpha equipment, the local utility service must provide a low-

impedance path for fault current return. In addition, there must be a low impedance bonded path between the Alpha Power Supply power plug Ground Pin and the Enclosure.

2. Second, the Alpha grounding system; The Alpha grounding system consists of a low-impedance connection between the enclosure and an Earth Ground

(located at least 6’ away from the Utility Earth connection).

This impedance between the enclosure and Earth must be 25 Ohms or less at 60 Hertz as measured by AMPROBE

Model DGC-1000 or equivalent. The measurement should be made on the wire or ground rod after it exits the

enclosure.

Local soil conditions will determine the complexity of the grounding system required to meet the 25 Ohm (maximum) resistance specied above. For example, a single 8’ ground rod may be sufcient to meet the requirement. In

some cases, a more elaborate system may be required such as multiple ground rods connected by a #6AWG solid

copper cable buried 8-12” below the surface. Where this is not possible, contact a local grounding system expert for alternate methods that will meet the 25 Ohm (maximum) specication.

All ground rod connections must be made by means of a listed grounding clamp suitable for direct burial or exothermic welding.

Power Output Return

For proper operation, the Service Power Inserter (SPI) must be securely bonded to the enclosure.

Communications Grounding

For an external status monitoring transponder, the transponder chassis is typically bonded via a separate ground wire

to the enclosure. For systems using an embedded transponder, the grounding connection is typically made either through a separate chassis ground block bonded to the enclosure or by means of the internal mounting hardware which bonds the transponder through the CableUPS. Please refer to the appropriate communications product manual for installation procedures.

Alpha strongly recommends on communication cables the use of a surge arresting device electrically bonded to the Alpha Enclosure.

WARNING!

Low impedance grounding is mandatory for personnel safety and critical for the proper operation of the cable system.

017-805-B0-010 Rev. K2

Page 14

1.0 Introduction

The Intelligent CableUPS powers signal processing equipment in cable television and broadband LAN distribution systems. The transformer module provides a critical load with current-limited regulated, AC power that is free of spikes, surges, sags and noise.

During AC line operation, AC power entering the power supply is converted into a quasi square wave and is regulated by a ferroresonant transformer at the required output voltage. The regulated voltage is connected to the load via the output connectors and some power is directed to the battery charger

to maintain a oat charge on the batteries.

When the incoming AC line voltage signicantly deviates from normal, the inverter module

automatically switches to standby operation and maintains power to the load. During the switch to

standby operation, energy in the module’s ferroresonant transformer continues to supply power to the

load. In standby mode, the Intelligent CableUPS powers the load until the battery voltage reaches a low-battery cutoff point.

When utility power returns, the transformer module waits a short time (approximately 20 to 40 seconds) for the utility voltage and frequency to stabilize and then initiates a smooth, in phase transfer

back to AC line power. Once the transfer is complete, the battery charger recharges the batteries in

preparation for the next event.

NOTE:

The duration of battery-backed standby operation depends upon the type and number of batteries and the load on the power supply.

The Intelligent CableUPS contains an impressive list of features, including:

• Smart Display

• Built-in self test

• Battery test

• An optional factory-installed Protective Interface Module (PIM)

Also available is the High Performance Intelligent CableUPS which features:

• A high efciency transformer

• Improved Status menus

• Communications menu with DOCSIS® parameters

• An optional factory-installed Protective Interface Module (PIM)

Via the Smart Display, the operator can view all of the power supply’s operating parameters. Automatic scrolling (AUTO-SCROLL) is always active so there is no need to press any buttons to view the power supply’s status or system parameters. In place of operating parameters, active alarms

automatically indicate in the Smart Display so the operator can immediately see what fault is being detected. Troubleshooting tips automatically display in the Alarm menu screen.

Built-in metering circuits measure voltage and current, without the need for external test equipment. In legacy models (manufactured prior to July 2006) front panel test points provide access for manual

measurements if desired.

The factory-installed Protective Interface Module (PIM) option allows the Intelligent CableUPS to

function in an N+1 redundant supply system and also provides programmable current limits for two output channels.

CAUTION!

To minimize the possibility of the transformer becoming unstable, a minimum load of at least 1A is required to be connected to the output (for the XM2-906G6 and XM2-906HP, minimum

load is 0.5A). Unstable transformers will self-correct as soon as a load of 1A or greater is

connected to the power supply. DO NOT operate unloaded.

017-805-B0-010 Rev. K2

Page 15

1.1 Theory of Operation

The Intelligent CableUPS is comprised of the:

• Transformer module, which acts as a stand-alone line conditioner. The transformer module contains a ferroresonant transformer, resonant capacitor, transfer isolation relay,

Power Distribution Board and the optional Protective Interface Module (PIM) board.

• Inverter module, which is required for standby operations and contains circuitry needed

for the three-stage temperature-compensated battery charger, DC to AC converter

(inverter), AC line detectors and Smart Display.

• Optional communications module, used to provide external status monitoring and

communications.

High Efciency

Transformer Module

Fig. 1-1, XM2-HP Power Supply

1.1.1 AC (Line) Operation

Communications

Intelligent Inverter

Module

DOCSIS

Module

Transformer Module Intelligent Inverter

Module

DOCSIS

Communications

Module

Fig. 1-2, Standard XM2 Power Supply

During AC Line operation, utility power is routed into the primary winding of the ferroresonant transformer through the contacts of the transfer isolation relay.

Simultaneously, in the inverter, power is directed to the rectier circuitry providing

power for the control circuitry. The bidirectional inverter also serves as a battery charger during line operation. The ferroresonant transformer and an AC capacitor

form the resonant tank circuit, which provides excellent noise and spike attenuation,

output short circuit current limiting and output voltage regulation. The ferroresonant transformer produces a quasi square wave output which resembles a rounded square wave.

NOTE:

When measuring the output voltage of ferroresonant transformers, use only a true RMS AC voltmeter. Non-RMS reading meters are calibrated to respond to pure sine waves and do not provide an accurate reading when measuring quasi square wave output.

017-805-B0-010 Rev. K2

Page 16

1.1 Theory of Operation, continued

Transformer

RV1

RV3

RV2

63 Vac

75 Vac

(+) (-)

AC1 AC2

Power Distribution Board

Inverter Module Assembly

Inverter

Relay Control

AC Line Detector

and Control Logic

Circuits

Transponder

Optional

Communications

Card

Batteries

Black

Red

Black

AC Output

Connectors

120Vac Jumper 240Vac Jumper

Input Select

Black

White Red

Battery Circuit

Breaker

Control Bus

Output 1A

Output 1B

Isolation Relay

Optional Surge Protector -

Replaceable Primary Power Supply

Overvoltage protection

(plugged into upper receptacle

of parallel-wired outlet)

RemoteTemperature Sensor

Littlefuse V320LA40BP Varistors

Secondary Power Supply Overvoltage protection

Coaxial surge protector (Gas Filled)

Transponder Overvoltage protection

(Alpha p/n 162-028-10)

Surge Protector

Earth Ground (Enclosure)

Black White

Coaxial Cable Power Inserter

(Alpha’s SPI)

Coaxial Network

87/89 Vac

Black

48 Vac

63 Vac

BlackRed

Blue

Transformer AC Output

Output tap connector (shown in default 63Vac position)

Factory-set output tap connector

(settings for 48V/63V models shown below)

XM Series 2 Power Supply Chassis

Status Monitoring

Network

1.1.2 Standby Operation

When the incoming AC line voltage drops or rises signicantly or a complete power outage occurs, the control logic’s line monitor activates standby operation. During the

transfer from AC line to standby operation, the battery powered inverter comes online as the isolation relay switches to prevent AC power from back-feeding to the utility. The energy contained in the ferroresonant transformer continues to supply power to

the load. The following changes also occur within the power supply:

• The isolation relay opens to disconnect the AC line from the primary winding of

the ferroresonant transformer.

• The control logic drives the inverter FETs on and off at line frequency. This

switching action converts the DC battery current into AC current in the inverter windings of the ferroresonant transformer, providing regulated power to the load.

• The control logic, which includes a microprocessor and other circuits to protect

the inverter FETs from overcurrent damage, monitors the condition of the batteries and the inverter during standby operation. Since a prolonged AC line outage would severely discharge the batteries, resulting in permanent damage,

the control logic disables the inverter when the batteries drop to approximately

10.5Vdc per battery (31.5Vdc in a three-battery set or 42.0Vdc in a four-battery

set).

When acceptable AC line voltage returns, the power supply returns to AC line operation after a 20 to 40 second lag. This delay lets the AC line voltage and

frequency stabilize before the control logic phase-locks the inverter’s output to the

utility input. The control logic then de-energizes the isolation relay, reconnects the

AC line to the primary of the ferroresonant transformer and disables (turns off) the

inverter. This results in a smooth, in-phase transfer back to utility power without interruption of service to the load. The battery charging circuit then activates to

recharge the batteries in preparation for the next power outage.

NOTE:

The output fuse has been removed from models of the XM2 Power Supply manufactured after July

2006.

Fig. 1-3, Simplied Block Diagram

017-805-B0-010 Rev. K2

Page 17

1.1 Theory of Operation, continued

2.15

2.25

2.05

2.40

1.1.3 Charger Operation

The Intelligent CableUPS uses a three-stage, temperature-compensated battery charger. During AC line operation, the inverter winding on the ferroresonant transformer feeds the charger circuit which provides BULK, ACCEPT and FLOAT charge voltages to the batteries.

Charger Modes

BULK charge is a “Constant Current” charge. The maximum current is 10A. As the

charge is returned to the batteries, their voltage increases to a specic threshold (2.27Vdc per cell). The charger then switches to ACCEPT mode. The BULK charger

mode generally returns the battery charge state to 80 percent of rated battery capacity.

ACCEPT charge is a “Constant Voltage” charge. This voltage, 2.40Vdc (adjustable)

per cell, is temperature-compensated to ensure longer battery life and proper completion of the charge cycle. This cycle is complete when the charging current into

the batteries becomes less than 0.5A or approximately six hours elapses from the

time ACCEPT mode was entered. When the batteries are fully recharged the charger switches to the FLOAT mode of operation.

FLOAT charge is a temperature-compensated “pulsed voltage” charge, averaging

about 2.27Vdc (adjustable) per cell. During FLOAT mode, the batteries are

fully charged and ready to provide backup power. The charger provides a small maintenance charge to overcome the batteries self-discharge characteristics and

other minor DC loads within the power supply. As the battery voltage reaches the “full charge” level the time delay between pulses increases.

017-805-B0-010 Rev. K2

During ACCEPT and FLOAT modes, the cell voltage is temperature-compensated

at -0.005Vdc per cell per degree C (adjustable) to ensure a safe battery cell voltage and to maximize battery life.

NOTE:

On HP models, when Alpha Cell is the selected battery type, ACCEPT and FLOAT are pre-set and are not manually selectable.

Volts Per Cell

Charger Current

Bulk Accept Float

Fig. 1-4, Charger Modes

(dashed lines indicate HV models)

Page 18

1.2 Intelligent CableUPS Layout

1.2.1 Transformer Module Overview

AC Output Fuse (legacy models only): Legacy XM2 power supplies use either a

20A slow blow or 30A slow blow fuse. To provide increased durability, an integrated fuse guard protects the fuse.

Output N L (legacy models only): Use the output test point (output N L) to check

the AC output. Use a true RMS AC voltmeter equipped with the proper test probes; other meters may give false or inaccurate readings.

N+1 (Optional): Use the N+1 ports in redundant system congurations where multiple power supplies are housed in a single enclosure. If a power supply fails, a

redundant power supply automatically switches into service (8ms delay). This feature

is part of the PIM option. LRI (Local/Remote Indicator): The LRI lamp option is used in conjunction with

the automatic performance feature and plugs directly into the LRI connector. The LRI circuit is rated at 12Vdc, 250mA. This option duplicates the function of the red

ALARM LED by illuminating an externally mounted red lamp for standby operation.

Output 1A (White = Neutral, Black = Line): The AC output connector is clearly

marked and color-coded for easy identication. The service power inserter (SPI)

connects directly into the Output 1A connector. Output 1B (White = Neutral, Black = Line): This output is wired in parallel to Output

1A (Output 1A +1B = Output 1) and is often used for auxiliary loads.

NOTE:

The Smart Display only displays Output 1, which is the sum of Output 1A and Output 1B.

Output 2 (Optional) [White = Neutral, Black = Line]: The AC output connector is

clearly marked and color-coded for easy identication. The SPI, which couples power

to the load, connects directly into the Output 2 connector. This feature is part of the PIM option.

N+1 Ports

Output 2

LRI

Output 1B

Output 1A

Fig. 1-5, Transformer Module Connections

017-805-B0-010 Rev. K2

Page 19

1.2 Intelligent CableUPS Layout, continued

48VOLT

48V

1.2.2 Inverter Module Overview

The removable inverter module provides uninterrupted power to the ferroresonant

transformer (via the batteries) during line failures. During line operation, the inverter

charges the batteries using a three-stage (BULK, ACCEPT and FLOAT) charger. Each inverter module and transformer module is labeled to indicate its voltage and

current rating. The power supply also carries a voltage and current rating label. It is very important the inverter module is installed only in a power supply with the same voltage and current rating. If the labels do not match, do not install the inverter

module. Each unit will bear a label (examples shown below) on the inverter module and on the inside chassis oor.

Current 36V Inverter Modules bear this yellow label. This

label and the label located on the interior chassis oor must

36V

953-527-10-002 F

match. However, inverter modules carrying this yellow label are backward compatible with 36V power supplies manufactured prior to September 2006, which bear yellow labels. Do not install the inverter module if the voltages do not match.

953-527-12-002 F

1350VA

953-527-11-002 F

Current 48V inverter modules bear this two-color label. This label

and the label located on the interior chassis oor must match.

However, inverter modules carrying this blue/green label are backward compatible with all 48V power supplies manufactured prior to September 2006, which bear green labels.

Obsolete-style label for the 1350VA 48V inverter modules. The current 1350VA 48V inverter module (manufactured after

September 2006) carries a green label. If your legacy power

supply carries this green voltage and current rating label, it is compatible with the latest blue/green labeled inverter module.

Fig. 1-6, Inverter Module Voltage Rating Labels

017-805-B0-010 Rev. K2

Page 20

1.2 Intelligent CableUPS Layout, continued

1.2.2 Inverter Module Overview, continued

Escape

Smart Display

Battery Breaker

Inverter Cooling Fan

Temperature Probe Connector

Battery Input Connector

Fig. 1-7, Inverter Module Connections

Smart Display: All operational functions, system testing, setup items and alarms are available via the Smart Display panel on the front of the power supply (the Smart Display is covered in detail in Section 4.2). Display functions are accessible by pressing any of the four keys: ESCAPE, UP, DOWN or ENTER. Backlighting is activated when any of the four keys are pressed and stays lit for a period of one hour. There are four levels of menu items for the standard unit: Operation Normal, Additional Information, Setup and Alarms. For units

equipped with DSM2 (or newer) Communications Modules the four levels are: Operation

Normal, Communication Information, Setup and Alarms. Pressing ENTER will sequence the display one level lower and pressing ESCAPE will sequence the display one level higher.

Down

Enter

Battery Breaker: The battery breaker disconnects the batteries from the inverter module’s

DC circuit. With the battery breaker turned off, the power supply does not transfer to standby mode, the inverter is disabled and the battery charger cannot charge the batteries. The breaker trips when an overcurrent is detected in the DC circuitry or the battery polarity is accidently reversed.

Battery Input Connector: The battery cable connector plugs directly into the inverter

module’s battery input connector. The connector is polarized and ts in one direction only.

NOTE:

Always verify proper polarity of cables before connecting the batteries to the power module. Reversing the battery polarity can cause permanent damage to the power supply. Polarity is

clearly marked for easy identication.

017-805-B0-010 Rev. K2

Page 21

1.2 Intelligent CableUPS Layout, continued

1.2.2 Inverter Module Overview, continued

Inverter Cooling Fan: The inverter module is equipped with a cooling fan that operates

during standby operation when the inverter heatsink temperature reaches 85°C. The fan stays on until the temperature drops below 75°C. The fan also operates whenever a self-test is in progress.

Temp Probe Connector: The Remote Temperature Sensor (RTS) plugs directly into the

temperature probe (RJ-11C type) connector.

Batt Volt (Battery Test Point) [legacy models only]: With the battery breaker on and

battery string(s) connected, DC Output can easily be checked using the inverter module’s

battery test point. Use a DC voltmeter whenever checking the output. The Remote Temperature Sensor is held in place on the AlphaCell 165, 195, 210 and 220

series batteries by a Battery Spacer Clip. To install, ex the clip and hook the retaining tabs

over the top of the battery and slide the sensor into place in the clip as shown below. For domestic applications, use one battery clip per 36V battery string and two clips per 48V battery string for optimal spacing. For International applications use two clips per 36V battery string and four per 48V battery string. As an option to the Battery Spacer Clip, an RTS with

ring lug can be used (p/n 746-254-XX).

Fig. 1-8, Placement of Remote Temperature Sensor (RTS) on battery

Battery Spacer Clips (Domestic applications)

RTS Ring Lug option placement

3 2 1 24 13

36V battery string

RTS Ring Lug option placement

48V battery string

Battery Spacer Clips (International applications)

RTS Ring Lug option placement

3 2 1 24

RTS Ring Lug option placement

Fig. 1-9, Placement of Battery Spacer Clips on 36V and 48V battery strings

(Note: actual placement determined by battery arrangement)

017-805-B0-010 Rev. K2

Page 22

1.2 Intelligent CableUPS Layout, continued

1.2.3 Optional Status Monitoring Modules

The power supply supports a number of Alpha Technologies communication modules

which may be ordered factory-installed or as a user-installed eld upgrade.

NOTE:

If communications options are installed, Alpha highly recommends adding the coaxial surge arrestor for the transponder (See Section 1.3, Recommended Enclosure System Options).

CAUTION!

Handle these modules with extreme care. Circuit boards and logic upgrades are

static-sensitive and susceptible to damage.

DOCSIS

The AlphaNet DSM3x Embedded

DOCSIS Transponder allows monitoring of Alpha power supplies

through existing cable network

infrastructure. Multiple power supplies, batteries and a generator can be monitored using a single transponder. Advanced networking services provide quick reporting and access to critical powering information.

The DSM3x utilizes Simple

Network Management

Protocol (SNMP) and standard

Management Information Bases

(MIBs) to provide network status

monitoring and diagnostics. A Web interface enables authorized personnel direct access to advanced diagnostics using a common Web browser. No custom software is required.

Status Module 3x

DOCSIS The IDH3 Digital Embedded

DOCSIS Transponder enables cable operators to manage their network powering through

the existing cable modem

infrastructure. Multiple power supplies, batteries and a generator can be monitored using a single transponder. Data is transmitted to a management

system over the network’s

DOCSIS cable modem channels

through the existing CMTS.

Bandwidth utilization is minimized by using standard SNMP (Simple Network Management

Protocol) communications.

Status monitoring information is compatible with ANSI/SCTE HMS standards.

IDH3

Fig. 1-10, DSM3x Fig. 1-11, IDH3

017-805-B0-010 Rev. K2

Page 23

1.3 Recommended Enclosure System Options

These options can be factory installed or upgraded in the eld by the user:

Protective Interface Module (PIM)

The PIM protects system components by shutting down the load during overcurrent and short

circuit conditions. The PIM has an operator programmable overcurrent threshold (3A-24A) and a programmable overcurrent tolerance period, which species the time (1-10 seconds)

an overcurrent condition is permitted before the output shuts down.

Using the programmable retry limit, the operator can select how many times (0-40) after a programmable delay (5-301 seconds) the PIM will attempt to reconnect an output that has

been shut down. Once the limit is reached, the power supply automatically retries once every 30 minutes until the fault clears. The PIM also provides N+1 redundancy in system

congurations with programmable dual outputs.

Local and Remote Indicator (LRI)

The LRI (red) lamp is located on the outside of pole-mount enclosures. Using this simple

form of status monitoring operators can check the operational status of the power supply without having to climb the pole and open the enclosure. During normal AC line operation, the LRI remains off. The LRI comes on only when the power supply is running in standby

mode. Whenever a fault is detected during self-test, the LRI ashes to indicate that service is

required.

AC Indicator (ACI)

The AC Indicator (green lamp) is located next to the LRI on the outside of pole-mount

enclosures and also acts as a simple form of status monitoring so cable technicians can check the output status of the power supply without having to climb the pole and open the enclosure. As long as there is voltage present at the output, the ACI remains on. To provide

much longer life than the original light bulb design, use the ACI-LL (long life LED). Models for

60V and 90V are available. Do not use ACIs for ground mount enclosures.

LA-P+, LA-P-120T 120V, 240V (Lightning Arrestor)

The LA-P+ plugs directly into the enclosure’s convenience outlet and provides additional

protection from voltage spikes caused by lightning and other power disturbances. It eliminates the need for hard-wired MOVs. No additional wiring is necessary.

LA-P+ With Status Monitoring

Incorporates the same features as the LA-P+, with the additional benet of Status Monitoring

capability.

Co-axial Surge Arrestor

Alpha recommends using coaxial surge suppression for enclosure protection. The Coax Surge Protector (Alpha P/N 162-028-10) includes 75 ohm surge suppressor and mounting

hardware.

APP90S /APP9022S (Service Power Supply)

The APP90S/APP9022S is a portable, non-standby power supply that provides conditioned AC power to the load when the main power module is out of service. An internal tap lets the APP90S/APP9022S be set for 90/75/60Vac applications. Use a 15A or 25A SPI (Service

Power Inserter) to transfer power from the APP9015S/APP9022S to the load.

017-805-B0-010 Rev. K2

Page 24

1.3 Recommended Enclosure System Options, continued

AlphaGuard™ Battery Charge Management System

The AlphaGuard

Battery Charge Management System extends battery life by providing the precise voltage required for each battery. 36V (3 battery) and 48V (4 battery) versions are available. The AlphaGuard performs electrical compensation for differences in individual batteries in the string. You can congure the unit to pass

measurements from the battery string to a status monitoring device, such as the EDSM card or DOCSIS transponder, using an interface cable. See the AlphaGuard System Installation Instructions, (P/N 012-306-C0), for detailed information (www.

alpha.com).

Fig. 1-12, Standard AlphaGuard Fig. 1-13, Potted AlphaGuard

017-805-B0-010 Rev. K2

Page 25

2.0 Installation

2.1 Installation Procedure

The Intelligent CableUPS can be shelf-mounted within a variety of Alpha enclosures. Complete the pre-installation instructions in Section 2.0 and the preliminary inspection and self-test procedure before you install the power supply.

CAUTION!

Read the Safety Precautions, Utility Power Connection Notes and Grounding Connection

Notes (pages 8-13) before you install the power supply.

Pre-installation Inspection

1. Remove the power supply from the shipping container. Conrm the power supply, including the Remote Temperature Sensor and all other ordered options are included.

2. During shipping, components might shift. Carefully inspect the power supply and other contents for possible shipping-related failures, such as loosened or damaged connectors. If any items are damaged or missing, contact Alpha Technologies or the shipping company immediately. Most shipping companies have a short claim period.

3. Do not attempt to install a damaged power supply without rst passing a complete pre-installation inspection and start-up test.

NOTE:

See the “Preliminary Inspection/Pre-Service Checklist” (Alpha P/N 017-805-B5) that accompanies

each power supply. SAVE THE ORIGINAL SHIPPING CONTAINER.

Use the original shipping container if the power supply needs to be returned for service. If the original container is not available, make sure the unit is well packed with at least three inches of shockabsorbing material to prevent shipping damage.

CAUTION! Do not use popcorn-type material. Alpha Technologies is not responsible for damage caused

by improper packaging of returned units.

017-805-B0-010 Rev. K2

Page 26

2.2 Installing the Optional Indicator Lamps

2.2.1 AC Indicator Lamp

The AC indicator (green lamp) is located on the outside of the enclosure. When lit,

it indicates AC power is available at the power supply output and enables service personnel to determine the status of the power supply without having to climb the pole.

Installation Procedure:

1. Remove the rear-most knockout (see Fig. 2-5).

2. Feed ACI wires through the hole.

3. Slide locking nut over the wires and thread onto lamp body (see Fig. 2-1).

4. Insert the crimped contacts into the plastic connectors. The BLACK wire must always go into the BLACK housing. Insert the remaining wire (this may be white,

yellow or blue) into the WHITE housing (see Fig. 2-2).

5. Connect the shorter BLACK/WHITE set of wires to the BLACK/WHITE wires leading from the SPI. The remaining set of longer wires connects to the Output

1A connector on the front of the power supply (Fig. 2-5).

To SPI

To Output 1A

Fig. 2-1, AC Indicator Lamp

CAUTION!

Secure the contact. If you do not properly position the contact, overheating and cable assembly failure can result.

NOTE:

To remove the wire from the plastic housing, use a small screwdriver to depress the metal retainer and slide out the wire.

Top View

White Housing

Black Housing

White, Yellow or Blue Wire

Black Wire

Verify contact snaps over metal retainer

Fig. 2-2, Wire/Housing Assembly

Side View

017-805-B0-010 Rev. K2

Page 27

2.2 Installing the Optional Indicator Lamps, continued

2.2.2 Local/Remote Indicator

The Local/Remote indicator (Red lamp) is located on the outside of the enclosure.

During normal AC operation, the lamp remains OFF. The lamp comes ON only when the power supply is running in Standby Mode. In the event a major alarm is detected,

the lamp ashes to indicate service is required. The LRI is a simple form of status monitoring which allows the operational status of the power supply to be veried from

the ground.

Installation Procedure:

1. Remove the front-most knockout (see Fig. 2-5).

2. Feed LRI wires through the hole.

3. Slide locking nut over the wires and thread onto lamp body (see Fig. 2-3).

4. Insert the crimped contacts into the plastic connectors. The BLACK wire must

always go into the BLACK housing and the RED wire into the RED housing (see

Fig. 2-4).

5. Connect the wire harness into the LRI connector on the front panel of the power

supply.

Fig. 2-3, Local/Remote Indicator Lamp

CAUTION!

Secure the contact. If you do not properly position the contact, overheating and cable assembly failure can result.

NOTE:

To remove the wire from the plastic housing, use a small screwdriver to depress the metal retainer and slide out the wire.

Top View

Black Housing

Red Housing

Verify contact snaps over metal retainer

Fig. 2-4, Wire/Housing Assembly

Black Wire

Red Wire

Side View

017-805-B0-010 Rev. K2

Page 28

LRI

Output 1A

LRI

ACI

SPI

2.2 Installing the Optional Indicator Lamps, continued

Installation is complete. Go to Start-up Test (Section 4.1, Start-up and Test).

ATTENTION:

See Section 5.6, Check Output Connections, for inspection guidelines.

Fig. 2-5, ACI/LRI Connection

017-805-B0-010 Rev. K2

Page 29

2.3 Initial Turn Up

NOTE:

Alpha enclosures are engineered to properly vent the power supply. The power supplies have been investigated by regulatory authorities for use in various Alpha enclosures. If you are using a nonAlpha enclosure, it is your responsibility to ensure your combination conforms to your local regulatory

requirements and the power supply remains within its environmental specications.

CAUTION!

Batteries are an important part of the power supply. Properly install and test all batteries, battery connections and battery cables before you connect them to the power supply.

1. Verify the Inverter Module’s battery breaker is OFF.

2. Connect battery cables to battery input connector.

3. Insert temperature probe cable.

4. Insert Local/Remote Indicator (LRI) cable. (Optional)

5. Connect status monitoring connectors, including tamper switch (if installed).

6. Verify SPI switch is in “ALT” position.

7. Connect the SPI (network load) to the Output 1A connector.

8. Connect an auxiliary load (i.e. fan) to the Output 1B connector (If optional

factory installed PIM has been installed).

9. Turn on AC breaker (located on enclosure) and verify correct (per unit’s

nameplate voltage) utility voltage at outlet; if correct, plug in XM2 line cord

to the utility outlet.

10. Switch the Inverter Module’s battery breaker ON.

11. Verify no alarms are present (it may take up to 60 seconds for alarms to

clear).

12. Perform self-test. Initiate the self-test by simultaneously pressing the DOWN arrow key and ENTER key. Wait for Self-test completion before proceeding.

13. Perform this live inverter test procedure:

a.) Turn AC input breaker OFF.

b.) Verify power supply transfers to “Inverter” mode. c.) Turn AC input breaker ON.

d.) Verify power supply transfers back to utility.

14. Verify Service Power Inserter (SPI) toggle switch in ON position (not ALT).

NOTE:

Output 2 is available only if the optional PIM is installed.

Use Output 1B to power auxiliary loads, such as cooling fans.

017-805-B0-010 Rev. K2

Page 30

2.4 Inverter Module Removal and Installation

The Intelligent CableUPS comes with a eld-replaceable inverter module assembly containing

the inverter and control logic. The inverter module accepts optional communications modules to facilitate remote status monitoring. The removable module is located on the front, righthand side of the unit.

CAUTION! ALWAYS switch the battery breaker off before removing or installing the inverter module

assembly.

Handle the inverter module with extreme care. Circuit boards and logic upgrades are static-

sensitive and susceptible to damage.

NOTE:

You can remove the inverter module assembly while the power supply is running on line power. The power supply will continue to operate as a non-voltage regulated power supply.

Removal Procedure:

1. Turn off the battery breaker.

2. Disconnect the battery input and temp probe cables from the inverter module and the TMPR and XPDR cables from the communication module.

3. Loosen the thumbscrews.

4. Grasp the handle on the right side of the inverter

module. Pull rmly to release the module from the

inverter connector. Gently slide the module assembly straight out until the inverter module ribbon cable connector is accessible. Move the retaining clips apart and the ribbon cable will come free from the connector.

Installation Procedure:

1. Reconnect the inverter module ribbon cable to the Inverter Module circuit board by seating the cable into the connector (the locking tabs

will automatically engage). Engage the sheet

metal in the upper and lower guides and slide the inverter module back onto the connector. It is important the sheet metal is properly seated in the card guides and fully inserted into the housing.

Disconnect here

Fig. 2-6, Inverter Module Ribbon Cable

2. Tighten the thumbscrews.

3. Verify the battery breaker is off. Reconnect the battery input, temp probe cables, TMPR and XPDR cables. Turn the battery breaker on.

Fig. 2-7, Detail of Locking Mechanism

017-805-B0-010 Rev. K2

Page 31

2.5 Protective Interface Module (PIM)

The optional (PIM) adds a second isolated output so the Intelligent CableUPS can function

as an N+1 redundant supply system. It provides programmable current limits for two output channels and protects system components by shutting down the load during overcurrent and short circuit conditions.

The PIM has a programmable overcurrent threshold (3A-24A) and overcurrent tolerance period that species the time (1-10 secs) an overcurrent condition is permitted before shutting

down.

You can use the programmable retry limit to select how many times (0-40) after a programmable delay (5-301 seconds) the PIM will attempt to reconnect an output once it has

been shut down. When the limit is reached, the XM2 power supply automatically retries once every 30 minutes until the fault clears. The PIM also provides N+1 redundancy in system

congurations and programmable dual outputs.

Adding the PIM to the Intelligent CableUPS provides these advantages:

• A second isolated output: The main purpose of the PIM is to limit the impact of a fault condition in one output channel. If a fault condition occurs in an Intelligent CableUPS

(without the optional PIM installed) the entire customer network can be affected. The PIM option affords protection to one output should a fault condition exist on the other. This gives you exibility to isolate Output 1A and 1B from Output 2.

• A current for critical loads: With the PIM option, you can designate one output as the primary connection and the other output as the secondary connection. Commonly, critical loads are connected to Output 1A as the primary feeder. Using the overcurrent limit settings, you can ensure the primary output always provides the necessary power. For

example, on a 15 Amp power supply, if a customer needs 10 Amps available on Output

1A, the overcurrent limit for Output 2 is set at 5 Amps, so regardless of Output 2, 10 Amps will remain available for the primary Output 1.

• Additional current protection: The standard power supply current limit protection is

provided by the fold-back characteristics of the transformer (180% of rated output). The 180% current limit may exceed the ratings of active devices in the cable network and cause failures. You can lower the maximum current provided at each output by lowering

the overcurrent limit of each respective output. Therefore, to minimize failures due to

excess current supply, set the overcurrent limit to a value below the maximum current the

active components can tolerate.

Power Supply Load Permitted Duration of Load

>150% 10 seconds

125% to 150% 10 minutes

115% to 125% 30 minutes

<115% Many months

For example, on a 15A power supply, where both outputs are programmed to 10A maximum and both outputs are supplying 9A, neither output is “in violation” but the total system at 18A is operating at 120% of its rated output. In this example, after 30 minutes, the power supply will begin a “load shedding” algorithm. The rst action is to disconnect Output 2. If this does not correct the system overload, the next action is to disconnect Output 1A and Output 1B (if used).

017-805-B0-010 Rev. K2

Page 32

2.6 Installing the PIM

NOTE:

Only qualied personnel should install the PIM. To install the PIM you must completely shut down

the power supply. To maintain output to the load, consider using either the APP9015S or APP9022S Service Power Supply during installation.

WARNING!

To avoid exposing the technician to potentially lethal voltages, before you proceed

you must remove all power from the power supply; unplug the power supply from the

AC power source, remove all front panel connections (such as N+1) and disconnect

the battery connector.

Tools Required:

• 90° Torque driver with #2 Phillips-head bit (set to 14 inch-pounds)

• 9/32” Nut driver

To install the PIM

1. Completely shut down the Intelligent CableUPS, verify all power is removed. Ensure

utility power is off and battery power is safely secured (or not installed) in the enclosure

assembly. All connections and cables must be removed from the power supply. To maintain output to the load, consider using the APP9015S or APP9022S Service Power Supply when installing the PIM.

2. To remove the transformer module’s front panel, remove the ve front panel screws. Lift the front panel up and away from the chassis. The front handle remains in place.

3. For Legacy models: Use a right-angled (90°) Phillips-head screwdriver to remove the

fuse wire (A). This wire may be connected to the power distribution board (PDB) by either a standoff (Fig. 2-8) or “Fast-On” connector.

4. Remove the transformer wire (B). This wire may be connected to the PDB by either a

standoff (Fig. 2-8) or “Fast-On” connector.

5. Remove the factory-installed bus bar (E) between standoffs P13 (D) and P16 (C).

A CD E

(may be yellow with

black trace on older models)

Fig. 2-8, PDB Connections

017-805-B0-010 Rev. K2

Page 33

2.6 Installing the PIM, continued

6. Install the PDB header in the J4 connector of the PIM circuit board.

7. Align the PIM circuit board holes labeled P3, P5 and P4 with the standoffs (P13, P15

and P16) on the PDB. Place the PIM circuit board on the standoffs, making the J6/J4

connection. Verify the J6 pins are aligned correctly and completely seated in J4.

8. Using the provided 6-32 hardware, re-attach the:

• Fuse/ output voltage selection block wire at P5 (on PIM board in legacy units)

• 0-Volt wire from the transformer to P4*

9. Torque the three 6-32 screws (P3, P5 and P4) fastening the PIM circuit board to the

power distribution circuit board to 14 inch-pounds (P13, P15 and P16).

10. Replace the front panel.

11. Program the PIM. See Section 2.6 for instructions.

* For installation assistance, call Alpha Technologies technical support, 1-800-863-3364

CAUTION!

Torque the 6-32 fastening hardware (with or without standoff) to 14 inch-pounds to avoid arcing or board failure.

NOTE:

The PIM header (Alpha P/N 545-739-10) is shipped uninstalled. Locate the header and install it

between J6 on the PDB board and J4 on the PIM board.

PIM to PDB Header

Connection

Fig. 2-9, J6 and J4 connection as seen from rear of Power Distribution Board

017-805-B0-010 Rev. K2

Page 34

2.6 Installing the Optional PIM, continued

NOTE:

The output current limit for the PIM is set by the position of the jumper on JP1. Congure JP1 to the

proper current setting; either 15A or 22A.* For the 918HP and 924HP Cable UPS models, set this jumper to the 22A position

* For additional conguration assistance, call Alpha Technologies Technical Support, 1-800-863-3364

Fig. 2-10, Location of JP1 on PIM

Line Isolation Relay

Fig. 2-11, Jumper in 15A position Fig. 2-12, Jumper in 22A position

15/22A Jumper

Replaceable

(Front of Power Supply)

Fig. 2-13, PIM (Protective Interface Module) and PDB (Power Distribution Board)

017-805-B0-010 Rev. K2

Page 35

2.7 Programming the PIM

Programmable parameters (with PIM installed) are:

Channel 1 Overcurrent Limit: The RMS current level that causes the Output 1 protection

relay to trip after a specied delay (overcurrent tolerance period).

Channel 2 Overcurrent Limit: The RMS current level that causes the Output 2 protection

relay to trip after a specied delay (overcurrent tolerance period).

Retry Delay: The time between each attempt to restart an output in the event of an overcurrent event.

Retry Limit: The number of times the CableUPS attempts to restart an output connection.

Once the RETRY LIMIT is exceeded, standard models attempt to restart the output

connection every 30 minutes (HV models do not attempt to restart after the retry limit is

exceeded). Set this parameter to “zero” to disable the “automatic retry” function.

Overcurrent Tolerance Period (1-10 seconds): In the event of an overcurrent episode, the amount of time an output overcurrent condition is permitted on either output connection.

Once this time expires, the output protection relay disables its output feeder.

Reset Output 1/Reset Output 2: Once fault condition has been corrected, this manually resets tripped output.

NOTE:

Programming any of the above parameters will reset the “trip/retry” counters.

N+1 (optional): The N+1 ports are used in redundant system congurations where multiple

power supplies are housed in a single enclosure. With the installation of the optional

Protective Interface Modules (PIM) on the power distribution board, a second output

connection becomes available and allows the CableUPS to function as an N+1 redundant power supply system. In the event of a power supply failure, a redundant power supply (with

an optional PIM board installed) is automatically switched into service with approximately a

8ms delay. This feature is part of the PIM option. This provision also protects system components by shutting down the load during overcurrent

and short circuit conditions. Adding a PIM in the secondary power supply enables both power

supplies to be connected in a “dual redundant” conguration so the system can protect two

critical loads.

NOTE:

If the optional PIM is not installed, the values shown on the “PIM PARAMETERS” line of the Smart Display are “read only”.

017-805-B0-010 Rev. K2

Page 36

2.7 Programming the PIM, continued

2.7.1 The Setup Menu

Press the Enter key to access the Setup Menu. Use the Setup menu to view or change the programmable operating parameters

of the power supply or the optional PIM. Navigation is similar to the Operation Normal menu. Press UP or DOWN to access the Single Step mode where you can individually select sub-menu items.

To select and change a value in the Setup Menu:

1. Press either UP or DOWN to put the display in the Manual Scroll Mode.

2. Continue pressing UP or DOWN until the desired item is displayed.

3. Press ENTER to select the item to edit.

4. Press UP to increase the displayed value or DOWN to decrease the value. To change the displayed values more rapidly, in Edit mode, press either UP or DOWN and hold for more than two seconds.

5. Press ENTER when the desired value is displayed. Press ENTER again to accept and save the new value. To leave programming mode without saving the new value, press ESCAPE.

If an incorrect value is accidently entered, repeat the above process and enter the proper value or select the SET DEFAULTS menu selection of the Setup Menu and press ENTER twice to reset all parameters to their factory default values.

6. To return to the Operation Normal menu, press ESCAPE three times.

You can also access ON or OFF and YES or NO selections as described above. The CODE VER, XM_CLASS VER and Total Run Time selections are for informational display only and cannot be edited.

NOTE:

The SET DEFAULTS menu selection does not reset STANDBY TIME, STANDBY EVENTS or DEVICE ADDRESS. Manually reset these options.

017-805-B0-010 Rev. K2

Page 37

OUTPUT 1A

OUTPUT 1B

LRI

OUTPUT 2N+1 N+1

RST

ALM/ RDY

REG

DS ACT

LNK

C/D

A/B

COM

Rx/Tx PWR

ENV

TPR

ETH

GRN = OK BLUE = WARN RED = OUT

OUTPUT 1A

OUTPUT 1B

LRI

OUTPUT 2N+1 N+1

RST

ALM/ RDY

REG

DS ACT

LNK

C/D

A/B

COM

Rx/Tx PWR

ENV

TPR

ETH

GRN = OK BLUE = WARN RED = OUT

SPI #1

90V

75V

60V

2.8 N+1Congurations

Because the PIM option provides a second output, the Intelligent CableUPS can function as an N+1 redundant supply system. The PIM also provides programmable current limits for two output channels, which protects system components by shutting down the load during overcurrent and short circuit conditions. Adding a PIM to a secondary power supply enables

both power supplies to be connected in a “dual redundancy” conguration to protect two

critical loads.

Enclosure Cooling Fan

Redundant N+1 Power Supply

(with optional PIM installed)

Fan Kit (Alpha P/N: 874-553-20)

Wire kit, N+1 Cable (Alpha P/N: 874-647-20)

Fig. 2-14, N+1 Conguration

Primary Power Supply

(with optional PIM installed)

017-805-B0-010 Rev. K2

Page 38

OUTPUT 1A

OUTPUT 1B

LRI

OUTPUT 2N+1 N+1

RST

ALM/ RDY

REG

DS ACT

LNK

C/D

A/B

COM

Rx/Tx PWR

ENV

TPR

ETH

GRN = OK BLUE = WARN RED = OUT

OUTPUT 1A

OUTPUT 1B

LRI

OUTPUT 2N+1 N+1

RST

ALM/ RDY

REG

DS ACT

LNK

C/D

A/B

COM

Rx/Tx PWR

ENV

TPR

ETH

GRN = OK BLUE = WARN RED = OUT

SPI #2

SPI #1

90V

75V

60V

2.8 N+1Congurations,continued

NOTE:

The N+1 unit and the primary unit cannot be loaded over 50% of rated capacity when congured as

shown below.

Enclosure Cooling Fan

Redundant N+1 Power Supply

(with optional PIM installed)

Fig. 2-15, Dual Redundancy (N+1) Conguration

Fan Kit (Alpha P/N: 874-553-20)

2 ea., Wire kit, N+1 Cable(Alpha P/N: 874-647-20)

(with optional PIM installed)

Primary Power Supply

017-805-B0-010 Rev. K2

Page 39

2.9 Service Power Inserter (SPI)

To connect the coaxial cable

1. Before you remove the cover, unplug the SPI from the power supply.

2. Remove the two screws holding the cover to the SPI chassis.

3. Remove the SPI cover to expose the circuit board and seizure screw assembly.

4. Insert the coaxial termination into the output port on the bottom of the SPI.

5. Tighten the seizure screw to 35 inch-pounds.This will prevent arcing within the SPI due to an improperly seated cable or loose connection.

Seizure Screw

Assembly

CAUTION!

Fig. 2-16, SPI Cover Removal

Fig. 2-17, Coaxial Cable Insertion and Securing

017-805-B0-010 Rev. K2

To prevent arcing, make certain the center conductor (stinger) of the coaxial termination is fully seated inside the seizure screw assembly (5) and tightened to 35 inch-pounds.

Page 40

2.9 Service Power Inserter (SPI), continued

ALT ON

6. Replace the SPI cover and reinstall the screws.

7. Reconnect the SPI to the power supply.

8. Using the switch on the top of the SPI, turn the unit ON to select the standby power supply as the power source to the cable plant.

9. The switch should only be in the ALT position when the standby power supply is connected to the cable. When in ALT, the standby power supply is bypassed for service or removal and provides power for status monitoring options.

10. Verify the SPI is properly grounded. Typically, grounding is accomplished by one of two methods:

a. If the SPI has been installed with a

mounting bracket, ground connection is made with paint-cutting star washers

(Fig. 2-18) used in conjunction with SPI

grounding wire.

b. If the SPI doesn’t use the mounting bracket,

the ground connection is made via a #8 AWG wire connected to the cover of the SPI

(Fig. 2-19) and terminated at the ground bar of the cabinet (Fig. 2-20).

Enclosure Wall

Paint-cutting

Star Washers

Fig. 2-18, Cover Replaced, SPI

Switched On

Fig. 2-19, SPI Grounding Lug

Fig. 2-20, Enclosure Ground Bar

017-805-B0-010 Rev. K2

Page 41

3.0 Conguration

3.1 Power Distribution Board (PDB) Setup

The PDB must be congured to correctly match actual power supply features and specications. Adjustable parameters are shown in Table 3-1.

There are conguration setting features on the PDB that cannot be changed. These congurations are included in the PDB setup instructions as an aid to troubleshooting and as a reference to verify conguration. Only qualied technicians should congure the PDB.

Output Switches

Frequency (SW1-8): Factory set to match the ferroresonant transformer operating

frequency of either 60Hz or 50Hz. Changing this setting does not change the operating frequency of the XM2. Do not change this setting.

Battery Voltage (SW1-7 and SW1-6): Factory set to match the ferroresonant transformer and inverter module battery operating voltage of either 36Vdc or 48Vdc. Changing this setting does not change the battery voltage of the XM2. Do not change this setting.

Power Rating (SW1-5 and SW1-4): Factory set to order. Change this setting as needed

during output voltage reconguration. The power rating must match both the model and

output voltage of the power supply. Only qualied technicians should change the power

rating setting.

Output Voltage (SW1-3 and SW1-2): Factory set to order. Change this setting as needed

during output voltage reconguration. Output voltage must match both the model and

output voltage of the power supply. Only qualied technicians should change the output

voltage setting.

Output Current (SW1-1): Factory set to order. May require changing as part of output

voltage reconguration. Output current must match both the model and output voltage of

the power supply. Only qualied technicians should change the output current setting.

Input Switches

Input Voltage (SW2-6, SW2-5, SW2-4, JP1 and JP2): Factory set to order, but can be

changed as needed when conguring the input voltage (120Vac to 240Vac or 240Vac to 120Vac). All input voltage elements, three switches and two jumpers, must be set to match input voltage conguration. Reconguration should only be performed by a qualied

technician.

Input Tolerance (SW2-7): Factory set to match the power supply transformer. Changing this setting can result in damage to the transformer. This setting should never be changed on standard models.

SW2-1, SW2-2, SW2-3, SW2-8 — Unused: These switches are unused and should never be changed.

017-805-B0-010 Rev. K2

Page 42

3.1 Power Distribution Board (PDB) Setup, continued

The jumpers (JP-1 and JP-2) and switches (SW-1, SW-2) are located on the Power Distribution Board (PDB) as shown below.

SW 1(Output)

SW 2 (Input)

JP 1

JP 2

Fig. 3-1, Locations of JP1, JP2 and SW1, SW2 on the Power Distribution Board (PDB)

Some models of the PDB’s JP1 and JP2 are two-pin jumpers, while other models have threepin jumpers. The voltages are congured as shown below.

Two-pin jumper

JP1 JP2

When congured for 120Vac Operation, the pins on

both JP1 and JP2 will be OPEN.

JP1 JP2

When congured for 240Vac Operation, the pins on

both JP1 and JP2 will be SHORTED.

120

When congured for 120Vac Operation, on both JP1 and JP2 the pin marked “120” and the center pin will

120

When congured for 120Vac Operation, on both JP1 and JP2 the pin marked “240” and the center pin will

Three-pin jumper

120

240

JP1 JP2

be shorted as shown.

240

120

JP1 JP2

be shorted as shown.

240

017-805-B0-010 Rev. K2

Page 43

3.1 Power Distribution Board (PDB) Setup, continued

The table below shows the respective Jumper and

OFF

Switch settings for the parameters applicable to the model of CableUPS in your system.

SW1 (Output)

SW1-3, SW1-4 ON

Setting for standard XM2-915, 120Vac, 60Hz and 36Vdc

Frequency 60 Hz 50Hz

SW1-8 OFF ON

Battery Voltage 36Vdc 48Vdc

SW1-7 OFF OFF SW1-6 OFF ON

Power Rating 480VA / 525VA1/ 600VA 720VA2/ 900VA 1350VA 1620VA6 / 2000VA / 2160VA

SW1-5 ON OFF OFF ON SW1-4 ON OFF ON OFF

Output Voltage 48Vac 63Vac 75Vac 87Vac

SW1-3 ON OFF OFF ON SW1-2 ON OFF ON OFF

Output Current <17A >17A

SW1-1 OFF ON

SW2 (Input) All OFF (120Vac)

Input Voltage 100Vac 110Vac 120Vac3127Vac 200Vac 220Vac 230Vac 240Vac

SW2-6 OFF ON OFF ON OFF OFF ON ON SW2-5 OFF ON OFF ON ON ON OFF OFF SW2-4 ON OFF OFF ON OFF ON OFF ON

JP1 & JP2

Input

Tolerance

OPEN

or 120V

Standard and HP models HV

SW2-7

525VA applies only to the XM2-906G6 and the XM2-906HP. SW1-5 and SW1-4 must be ON.

The output power rating of the XM2-615A when congured for 48V.

The XM2-906G5 will display an Input

OPEN

or 120V

OPEN

or 120V

OPEN

or 120V

+15% /–20% +15% /–30%

OFF

50Hz or 60Hz

Voltage of 115Vac when these switches are congured for

60Hz onlyON50Hz only

SHORT or 240V

CFR

+20%

SHORT

or 240V

SHORT or 240V

120Vac.

For HV units, SW2-7 must be changed from OFF to ON when upgrading the inverter module from

rmware v4.00.1 (or lower) to v4.0.1.0. See Alpha Tech Note 017-805-C0 for more information.

The XM2-906G6 and XM2-906HP use HV setting and the input tolerance is +20% / –30%.

Power rating for the XM2-918HP; supported by Code Version 7.08 and higher.

Power rating for the XM2-924 HP; SW1-7 and SW1-6 are both set to ON. Supported by Code

version7.08 and higher.

017-805-B0-010 Rev. K2

Table 3-1, Power Distribution Board Setup

Page 44

3.1 Power Distribution Board Setup (PDB), continued

3.1.1 Replacing the Metal Oxide Varistors (MOVs)

The PDB employs three MOVs that are mounted in sockets for easy replacement. MOVs must be replaced by those with comparable energy and voltage ratings.

Replacement MOV P/N 160-017-19, Metal Oxide Varistor, 320Vac 420Vdc.

Tools Required:

• #2 Phillips screwdriver

• Needlenose pliers (optional)

WARNING!

Before proceeding, remove all power from the power supply by unplugging the power supply from the AC power source, removing all front panel connections (i.e.,

N+1) and disconnecting the battery connector. Failure to do so could expose the

technician to potentially lethal voltages.

Replacement procedure:

1. Terminate all power to unit. Turn off battery breaker and unplug battery connector. Unplug line cord and remove all front panel connectors.

2. Remove the ve screws securing the transformer module front panel. Set the panel and screws aside in a safe location.

3. Remove the damaged MOVs using needlenose pliers. See Fig. 3-2.

4. Insert the new MOVs rmly into the sockets. The new MOVs must have comparable energy and voltage ratings as those you are replacing.

5. Replace front cover.

Fig. 3-2, MOV Replacement

017-805-B0-010 Rev. K2

Page 45

3.1 Power Distribution Board Setup (PDB), continued

3.1.2. Replacing the Line Isolation Relay

WARNING!

Before proceeding, remove all power from the power supply by unplugging the power supply from the AC power source, removing all front panel connections (i.e.,

N+1) and disconnecting the battery connector. Failure to do so could expose the

technician to potentially lethal voltages.

Tools Required:

• #2 Phillips screwdriver

• Flathead Screwdriver

Replacement procedure:

1. Verify the power supply is powered off and remove AC and DC power sources from XM2. Remove the leftmost front panel using a #2 Phillips head

screwdriver (screws circled at right).

2. Carefully loosen the relay circuit board with the

athead screwdriver and lift from the xture.

3. When lowering the new relay circuit board onto the tabs, verify all tabs align with the sockets on the relay circuit board. Failure to do so will result in damage to the tabs or the sockets.

4. Verify the relay circuit board is pushed rmly into

place before replacing the front panel of the power supply.

017-805-B0-010 Rev. K2

Page 46

NEMA 5-20P

(P/N 874-540-20)

NEMA 5-20R (P/N 531-006-10)

NEMA 6-15P

(P/N 874-540-22

NEMA6-15R (P/N 531-004-10)

3.2 ACInputVoltageReconguration

The input voltage on many models (XM2-915, XM2-918HP, XM2-910, XM2-906HP and XM2-

1350) can be recongured from 120 to 240Vac utility input or from 240 to 120Vac utility input,

depending upon utility input powering requirements.

WARNING!

To avoid exposing the technician to potentially lethal voltages, remove all power from

the power supply; unplug the power supply from the AC power source, remove all

front panel connections (i.e., N+1) and disconnect the battery connector.

ATTENTION:

Only qualied personnel should recongure the input voltage. Before modifying the power supply,

always consult local electrical codes for proper wiring procedures.

NOTE:

When the AC input voltage reconguration is complete the voltage rating of both the high-magnetic

breaker and enclosure receptacle must match the input voltage.

3.2.1 Recongurationfrom120to240Vac

Tools Required:

• #2 Phillips head screwdriver

• Flat-blade screwdriver

Supplies Required:

240Vac 15A line cord (NEMA 6-15P, P/N 874-540-22)

240Vac jumper (744-281-21).

Procedure (120 Input to 240Vac Input):

1. Completely shut down the XM2 power supply. Remove all utility and battery power. All connections and cables must also be removed from the XM2 power supply.

2. Verify the enclosure system wiring before

proceeding with power supply modication.

Refer to the appropriate enclosure installation instructions.

3. Replace the 120Vac 20A line cord (NEMA 5-20P) on the XM2 power supply input line cord with

a 240Vac 15A line cord (NEMA 6-15P). Verify

proper wiring and ground on the new plug.

120V, 20A Plug and Receptacle

240V, 15A Plug and Receptacle

Fig. 3-3, Typical NEMA Receptacles and Plugs

017-805-B0-010 Rev. K2

Page 47

3.2 ACInputVoltageReconguration, continued

3.2.1 Recongurationfrom120to240Vac,continued

4. Locate the transformer module’s input jumper in the transformer compartment.

Replace the currently installed 120Vac jumper (744-281-20) with a 240Vac jumper (744-281-21).

120

JP1 & JP2

120Vac

Input Select Jumper

(P/N 744-281-20)

240

120

JP1 & JP2

240Vac

Input Select Jumper

(P/N 744-281-21)

Fig. 3-4, Transformer Module Input Jumpers, PDB Jumpers

5. Remove the ve front panel screws. Lift the transformer module front panel up

and away from the chassis. The front handle and output fuse remain in place.

6. Recongure the PDB to 240Vac input, according to Table 3-2.

• Change Switch 2-4 (SW2-4) to ON, Switch 2-5 (SW2-5) to OFF

• Change Switch 2-6 (SW2-6) to ON, Jumper 1 (JP1) to Short (240) and Jumper 2 (JP2) to Short (240).

NOTE:

Only adjust positions SW2 -4, -5, -6. Do not adjust the other switch positions.

240

017-805-B0-010 Rev. K2

Legend

OFF ON

4 5 6

240Vac120Vac

4 5 6

Fig. 3-5, SW2 Settings

7. Replace the front panel.

8. Install the power supply into the enclosure as outlined in Section 2.1 (Installation

Procedure).

Page 48

3.2 ACInputVoltageReconguration, continued

NEMA 5-20P

(P/N 874-540-20)

NEMA 5-20R (P/N 531-006-10)

NEMA 6-15P

(P/N 874-540-22)

NEMA6-15R (P/N 531-004-10)

3.2.2 Recongurationfrom240to120Vac

Tools Required:

• #2 Phillips head screwdriver

• Flat-blade screwdriver

Supplies Required:

120Vac 20A line cord (NEMA 5-20P, P/N 874-540-20)

120Vac Input Select Jumper (P/N 744-281-20)

Contact your Alpha Technologies representative for Wire Set part numbers.

Procedure (240Vac Input to 120Vac Input):

1. Completely shut down the XM2 power supply. Remove all utility and battery power. Remove all connections and cables from the XM2 power supply.

2. Verify the enclosure system wiring before proceeding with power supply

modication. Refer to the appropriate enclosure installation instructions.

3. Replace the 240Vac 15A line cord (NEMA 6-15P) on the XM2 power supply with

a 120Vac 20A line cord (NEMA 5-20P). Verify proper wiring and ground on the

new plug.

240V,15A Plug and Receptacle

120V, 20A Plug and Receptacle

Fig. 3-6, Typical NEMA Receptacles and Plugs

4. Locate the transformer module input jumpers in the transformer compartment.

Replace the currently installed 240Vac jumper (744-281-21) with a 120Vac jumper (744-281-20) and recongure JP1 and JP2 as shown below.

120

JP1 & JP2

240

120

JP1 & JP2

240

240Vac Input Select Jumper

(P/N 744-281-21)

120Vac Input Select Jumper

(P/N 744-281-20)

Fig. 3-7, Transformer Module Input Jumpers, PDB Jumpers

017-805-B0-010 Rev. K2

Page 49

3.2 ACInputVoltageReconguration, continued

3.2.2 Recongurationfrom240Vacto120Vac,continued

5. Remove the ve front panel screws. Lift the transformer module front panel up and away from the chassis. The front handle and output fuse remain in place.

6. Recongure the PDB to 120Vac input, according to Table 3-2.

• Change Switch 2-4 (SW2-4) to OFF, Switch 2-5 (SW2-5) to OFF

• Change Switch 2-6 (SW2-6) to OFF, Jumper 1 (JP1) to Open (120) and

Jumper 2 (JP2) to Open (120).

NOTE:

Positions of SW2 (-4, -5, -6) are shown for clarity. Do not adjust the other switch positions

during this procedure.

Legend

OFF ON

240Vac

4 5 6

120Vac

4 5 6

Fig. 3-8, SW2 Settings

7. Replace the front panel.

8. Install the power supply into the enclosure as outlined in Section 2.1, Installation Procedure.

017-805-B0-010 Rev. K2

Page 50

3.3 ACOutputVoltageReconguration

The output voltage on many Intelligent CableUPS models (-906HP*, -910, -915, -918HP,

-918HP, -922, -922HP, -924HP, -1350) can be easily recongured to provide an output voltage

of 87, 75 or 63Vac, by moving a conveniently located OUTPUT TAP jumper and readjusting the DIP Switches on the PDB.

*63V or 87V only for the 906HP model.

NOTE:

For the XM2-615A power supply, the OUTPUT TAP jumper enables the output voltage to be changed

from 63Vac (default) to 48Vac only.

ATTENTION:

Only authorized personnel should recongure output voltage on the XM2 power supplies.

WARNING!

Before proceeding, remove all power from the power supply. Unplug the power

supply from the AC power source, remove all front panel connections (i.e., N+1) and disconnect the battery connector. Failure to do so can expose the technician to

potentially lethal voltages.

Tools Required:

• #2 Phillips head screwdriver • Small at-blade screwdriver

OutputVoltageRecongurationProcedure:

1. Shut down the power supply, verify all power is removed and utility power is off and

battery power is safely secured (or not installed) in the enclosure assembly. Remove all

connections and cables from the power supply.

2. Remove the ve front panel screws and lift the front panel up and away from the chassis. The front handle and output fuse remain in place.

3. Locate the transformer module’s output connectors above the Power Distribution Board. Move the single black connector to the desired output voltage connector. Connectors are

both labeled and color coded for easy identication (see Figs. 3-9, 3-10): Blue = 48Vac,

Black = 87Vac (89Vac for HV model); White = 75Vac; and Red = 63Vac.

NOTE:

You must change the auto transformer fan input when the output voltage changes. In some cases the power rating and the output current settings may also need to be changed.

4. Recongure the PDB as required. Set the Output Voltage switches (SW1-2 and SW1-3)

to reect the same rating as the currently selected voltage on the Output Tap connector. Set the power rating switches (SW1-4 and SW1-5) and the output current switch (SW1-1)

to the required setting.

5. Replace the front panel.

6. Install the unit into the enclosure as outlined in Section 2.1 (Installation Procedure).

63 Vac 48 Vac

Blue

BlackRed

To front panel AC output connectors

87/89 Vac 75 Vac 63 Vac

Black White Red

Black

To front panel AC output connectors

Fig. 3-9, XM2-615A Transformer Output

Tap Connector shown in

default setting (63Vac)

Fig. 3-10, Transformer Output Tap Connector for

other CableUPS models

017-805-B0-010 Rev. K2

Page 51

3.3 ACOutputVoltageReconguration,continued

3.3.1 Output Voltage Switch (SW1) Settings

Reconguration is a two-step process done while the power supply is switched OFF. Adjust the output tap connector, as well as the output voltage switch (SW1), and

cycle the unit ON for the changes to be effective.

NOTE:

For purposes of clarity, only the adjustable positions of SW1 (-1, -2, -3, -4, -5) are highlighted.

Do not adjust the other switch positions during this procedure.

Legend

Power Supply Output tap connector settings

48Vac 63Vac

63 Vac 48 Vac

ON OFF

Model Output Voltage Switch Setting

XM2-615A

12345

1 234 5

Legend Power Supply Output tap connector settings

63Vac 75Vac

87/89 Vac 75 Vac 63 Vac

ON OFF

Model Output Voltage Switch Setting

XM2-906G6,

XM2-906HP

12345

N/A

XM2-910

12345

87/89Vac

87/89 Vac 75 Vac 63 Vac

12345

017-805-B0-010 Rev. K2

XM2-915,

915-E, M, P, XM2-915HV

XM2-922,

XM2-922HV

(240Vac only),

XM2-924HP

(240Vac only)

12345

XM2-1350

(36Vdc)

12345

XM2-1350

(48Vdc)

12345

Table 3-2, Output Voltage switch settings per Power Supply

12345

Page 52

3.3.1 Output Voltage Switch (SW1) Settings, continued

Reconguration is a two-step process done while the power supply is switched OFF. Adjust the output tap connector, as well as the output voltage switch (SW1), and

cycle the unit ON for the changes to be effective.

Legend Power Supply Output tap connector settings

63Vac 75Vac

ON OFF

87/89 Vac 75 Vac 63 Vac

Model Output Voltage Switch Setting

87/89Vac

87/89 Vac 75 Vac 63 Vac

XM2-918HP

1 2 3 4 5 6 7 8

XM2-924HP

1 2 3 4 5 6 7 8

Table 3-3, Output Voltage switch settings for XM2-918HP, XM2-924HP

1 2 3 4 5 6 7 8

017-805-B0-010 Rev. K2

Page 53

4.0 Operation

4.1 Start-up and Test

4.1.1 AC Line Operation

1. Before making power supply connections, verify the correct voltage and

2. Verify the AC circuit breaker (on the customer supplied service disconnect) and

3. Plug the power cord into the convenience outlet and the battery cable into the

4. Switch the AC (service disconnect) circuit breaker on to start initial power

frequency are available from the AC utility power source and voltage and polarity from the DC battery system.

the battery breaker on the power supply are off.

inverter module. Plug the RTS into the temp probe connection and attach it to the center battery. Refer to Fig. 1-9. At this time, if an LRI is installed, connect it to the front panel connector labeled LRI.

up. During this stage the power supply performs a “display test” and veries conguration for the power supply. After the initial display test, a “No Batteries”

alarm message appears in the Smart Display because the battery breaker is

off. The green output LED remains off and the red alarm LED continues to ash

while in this alarm state.

i2M OUT FREQ BAT IN 90V 15A 60Hz 36V 120

Fig. 4-1, Conguration Screen

NOTE:

Access the conguration screen any time by simultaneously pressing UP and ENTER.

017-805-B0-010 Rev. K2

Page 54

4.1 Start-up and Test, continued

4.1.1 AC Line Operation, continued

5. Use the Smart Display to verify XM2 power supply operations. If desired, the No

Battery alarm can be disabled by changing Battery Capacity to “0” in the setup

menu.

6. Use the Smart Display to verify AC output (±5%).

Setting Low (-5%) High (+5%)

89Vac (HV) 85.4Vac 92.5Vac

87Vac 82.65Vac 91.35Vac 75Vac 71.25Vac 78.75Vac 63Vac 59.85Vac 66.15Vac 48Vac 45.6Vac 50.40Vac

7. Switch on the battery breaker. Within one minute the ashing red alarm LED turns off, the green output LED turns on, the No Battery alarm clears and the power supply resumes Operation Normals. Use the Smart Display to verify operations and setup as needed.

Table 4-1, AC Output

4.1.2 Self Test Operation

1. The power supply should be operating correctly with no alarms present. Use the Smart Display to verify Normal and Communication Information. Verify test duration in the Setup Menu as needed.

2. Press and hold DOWN and ENTER simultaneously to start Self Test. The test will

run for a preset time (5-180 minutes, set in the Setup Menu). Self Test can also

be entered by setting Self Test to ON in the Setup Menu.

3. While in self test mode, use the Smart Display or a true RMS voltmeter to

verify output at the module’s AC Output test point (legacy models only). Output

voltages should appear within ±5% of: 89Vac for HV models, 87Vac for 90V units, 75Vac for 75V units and 63Vac for 60V units, at nominal line input voltage. In the case of an XM2-615A that has been set for 48Vac output, the measured output voltage should be ±5% of 48Vac. See Table 4-1.

4. To cancel a self test in progress, push and hold DOWN and ENTER a second time or change Self Test to OFF in the Setup Menu.

017-805-B0-010 Rev. K2

Page 55

4.1 Start-up and Test, continued

4.1.3 Standby Operation

Perform the following procedure after successful completion of a self test with the CableUPS operating normally in AC line mode.

1. Momentarily fail the AC utility input power by switching the AC (service

disconnect) circuit breaker to OFF.

2. The power supply starts operating in the inverter mode. Use the Smart Display or

a true RMS voltmeter to verify output. Output voltages should appear within ±5% of: 89Vac for HV models, 87Vac for 90V units, 75Vac for 75V units and 63Vac for 60V units, at nominal line input voltage. In the case of an XM2-615A that has been set for 48Vac output, the measured output voltage should be ±5% of 48Vac. See Table 4-1.

3. Return the power supply to AC Line mode by switching the AC (service

disconnect) circuit breaker to ON. The transfer back to utility power may take 10 to 50 seconds for the utility voltage and frequency to stabilize, and the module’s phase-lock circuitry to activate. The module then synchronizes the inverter’s

waveforms before initiating a smooth, in-phase transfer back to utility power. Once the transfer is complete, the Smart Display reports: OPER MODE = LINE.

The CableUPS is now fully operational.

017-805-B0-010 Rev. K2

Page 56

4.2 Using the Smart Display

All operational functions, system testing, setup menus and alarms are available via the illuminated display panel on the front of the CableUPS. Display functions are accessible by pressing any of the four keys: ESCAPE, UP, DOWN and ENTER.

Descriptions of the key functions areas follows:

Icon Function

Move up one level in the menu tree. Move up one level in the menu tree.

Press to leave the EDIT mode without saving the changes made to the selected menu Leave the EDIT mode without saving the changes made to the selected menu item.

Escape

Down

item.

Scroll up in a branch of the menu tree.

Scroll up in a branch of the menu tree. Increase a parameter (or value) while in the EDIT mode.

Increase a parameter (or value) while in the EDIT mode.

Scroll down in a branch of the menu tree.

Scroll down in a branch of the menu tree. Decrease a parameter (or value) while in the EDIT mode.

Decrease a parameter (or value) while in the EDIT mode.

ENTER

Self-test

Displays the next lower level in the menu tree.

Displays the next lower level in the menu tree. In the EDIT mode, ENTER accepts the new value into memory.

In the EDIT mode, ENTER accepts the new value into memory. Pressing ENTER for two seconds or longer initiates Display Test mode. Display Test mode

Pressing ENTER for two seconds or longer initiates Display Test mode. Display Test mode switches all LED and LCD pixels (dots) on for several seconds.

switches all LED and LCD pixels (dots) on for several seconds. The XM2 power supply can manually be placed in a self test mode by pressing DOWN

and RETURN together:

Press DOWN and ENTER simultaneously to manually enter self test mode. A self test will Press DOWN and ENTER simultaneously. A self test will be initiated and run between

be initiated and run between 5-180 minutes (set in the setup menu). 5-180 minutes (set in the setup menu).

To cancel a self test in progress, simultaneously press DOWN and ENTER. To cancel a self test in progress, simultaneously press DOWN and ENTER.

The operator can view the Conguration screen by pressing UP and ENTER together.

OPERATION NORMAL

OUTPUT VOLTAGE 90V

Escape

Fig. 4-2, Smart Display Navigation

Down

Enter

017-805-B0-010 Rev. K2

Page 57

4.2 Using the Smart Display, continued

Display Backlighting

The display is normally unlit. Press any key once to activate backlighting and illuminate the display without deactivating Auto Scroll.

Auto Scroll

The display is normally in Auto Scroll mode, continually cycling through the sub-menu items at a two-second interval. In Auto Scroll mode you can quickly view menu items without the need to press any keys.

Single Step

Pressing either arrow key activates Single Step mode in which you can step through individual menu items one at a time. Each press of the arrow key steps up or down through the sub-menu items. Press ESC to return to Auto Scroll mode.

(provides additional instructions)

Top Line in Display

Second Line in Display

(scrolls through system information)

Direction Indicator Symbols

The rightmost character of the display (may appear on either line) indicates the proper

key function when manually scrolling. Where more than one choice is available multiple

characters display. Possible characters or text are:

Access more menu items by pressing either the UP or DOWN arrow keys.

Use the ENTER key to select this function.

Use the ESCAPE key to leave the selected function without altering any values or to go to back to the previous menu in the display.

OPERATION NORMAL

OUTPUT VOLTAGE 90V

Fig. 4-3, Smart Display Panel

Direction Indicator Symbols

(manual scroll mode)

017-805-B0-010 Rev. K2

Press UP or DOWN arrows to change a display value or mode.

Press ESCAPE to leave this menu item without making any changes (and go back to the

previous menu).

Press ENTER to save the change into memory. This type of multiple display choice is normally available in the programming mode.

Page 58

4.3 Smart Display Modes

4.3.1 Operation Normal

If no alarms are present, the power supply operates in Operation Normal display mode. In this mode you can view the primary operating parameters of the power supply while the display auto scrolls through the available menu items at two-second intervals.

In Operation Normal mode the displayed items are all “metered” items and are for informational purposes only (not programmable) with respect to the operational status of

the power supply. The Operation Normal menu contains the following items:

OPERATION NORMAL OPER MODE = LINE

INPUT VOLTAGE 120V INPUT FREqUENCy 60hz OUTPUT VOLTAGE 89V OUTPUT 1 CURRENT 12.2A OUTPUT 2 CURRENT 12.2A OUTPUT WATTS 900W OUTPUT VA 1060 PERCENT LOAD 80% ChARGER MODE = FLOAT BATTERy VOLTS 40.5V BATTERy TEMP 37C ChARGER CURRENT 8.2A 12 EVENTS 65 MIN

Only visible in single-step mode

Fig. 4-4, Operation Normal Display

(Examples are given for values in the display)

Top Line Second line

The top line indicates the current screen and provides additional instructions. Use the arrows to manually scroll.

The second line cycles through the parameters listed above.

017-805-B0-010 Rev. K2

Page 59

4.3 Smart Display Modes, continued

4.3.2 Comms Information Display (with DSM2 or later)

Pressing ENTER while in the Operation Normal screen will open the Comms Information display (only displayed when paired with suitable communications

module, otherwise display will read “NO DATA”). This mode operates in a similar fashion as the Operation Normal display. When you rst access the information

display, information displays in Auto Scroll mode. Press UP or DOWN to access information one step at a time. Press ENTER to access the Setup Menu (discussed

in Section 4.3.3, Setup Menu). Press ESCAPE to reactivate Auto Scroll mode. Press ESCAPE a second time to reactivate Operation Normal mode (up one level).

The Comms Information display contains the following items:

COMMS INFO

Top Line Second line

CM 00:90:EA:00:30:54

CM 192.168.1.151 CM Rx PWR -6.7dBMv CM Tx PWR 41.0dBMv DN FREq 369.000Mhz UP FREq 15.000Mhz MODEL DSM3x SW 4.5.9.0_00.77CO-N BATT A1 = 13.1 A2=14.0 BATT A3 = 13.5 B1 = 13.1 BATT B2 = 14.0 B3 = 13.5

Fig. 4-5, Comms Information Display

(Examples are given for values in the display)

The top line provides additional instructions. Use the arrows to manually scroll.

017-805-B0-010 Rev. K2

The second line cycles through the parameters listed above.

Page 60

4.3 Smart Display Modes, continued

4.3.3 Setup Menu

Pressing ENTER while in the Comms Status display opens the Setup Menu, one level below the Comms Status display. Using the Setup menu you can view and change the programmable operating parameters of the power supply or the optional PIM. Setup Menu navigation is similar to the Operation Normal menu. Press UP or DOWN to access the Single Step mode where sub-menu items are individually selected.

To select and change a value in the Setup Menu:

1. Press either UP or DOWN to put the display in the Manual Scroll mode.

2. Continue to press UP or DOWN until the desired item is displayed.

3. Press ENTER to select the item for editing.

4. Use UP to increase the displayed value or DOWN to decrease the value. To change the displayed value more rapidly, press and hold either UP or DOWN for more than two seconds while in edit mode.

NOTE:

When in EDIT mode, press the ENTER key twice for the change in the parameter to take effect.

5. Press ENTER when the desired value displays. This accesses an additional display where you can either ESCAPE from programming mode and not save the new value or press ENTER to accept and save the new value.

6. After the value is saved, the display returns to the Setup Menu. You may now check and view the new value or select additional parameters to modify.

If an incorrect value is entered, repeat the above process and enter the proper value; or select the Set Defaults menu selection on the Setup Menu and press ENTER twice to reset all parameters to their factory default values.

In addition to using UP and DOWN to increase or decrease numerical values, you can select ON or OFF and YES or NO in the same manner as described. The CODE VER, XM_CLASS VER and Total Run Time selections are for informational display

only and cannot be edited. To return to the “Operation Normal” menu from the Setup

Menu, press ESCAPE three times.

NOTE:

The Set Defaults menu selection does not reset Standby Time, Standby Events or Device Address; you must manually reset these settings.

017-805-B0-010 Rev. K2

Page 61

4.3 Smart Display Modes, continued

4.3.3 Setup Menu, continued

The Setup Menu contains the following items:

Top Line (provides additional information)

• SET UP MENU

TO MANUAL SCROLL

•

• <ESC> TO COMMS INFO

Second Line (cycles through the following parameters):

Default Minimum Maximum

Other Battery Types Other Float V/C 2.27 V/C 2.10 V/C 2.35 V/C

Accept V/C 2.40 V/C 2.20 V/C 2.45 V/C Temp Comp 5.0 mV 0.0 mV 5.0 mV Batt. Capacity* 100 AH 0 1000 AH Standby Time 0 0 65335 Standby Events 0 0 65335 Total Runtime 0 0 65335 Self Test Off Off Yes Test Inhibit — 7 Days 7 Days Test Interval 30 Days 0 Days 360 Days Test Duration 10 Min 5 Min 180 Min Test Countdown 0 0 365 Days Freq. Range 3.0Hz 1.0Hz 6.0Hz Tap Switch** No No Yes PIM Option Yes No Yes Reset Output 1 — No Yes Reset Output 2 — No Yes Over Curr1 — 3.0 A 24 A Over Curr2 — 3.0 A 24 A Retry Delay 60 Sec 5 Sec 301 Sec Retry Limit 20 0 40 Over Curr Tol 3000ms 20ms 9000ms N+1 Valid No No Yes Set Defaults — No Yes Language English Spanish/French/Portuguese/German

If AlphaCell™ is selected then user

selects between a range of Alpha cells

These items appear in the setup menu only if battery type Other is selected. They are preset

(but not displayed)

if AlphaCell™ is selected.

These items appear in the setup menu only if the optional PIM is installed.

* 100Ah = 1 battery string, 200Ah = 2 battery strings, 300Ah = 3 battery strings * * Feature not available in US

NOTE:

See Section 4.6 Smart Display Glossary for descriptions of setup menu parameters.

017-805-B0-010 Rev. K2

Page 62

4.3 Smart Display Modes, continued

4.3.3 Setup Menu, continued

SETUP MENU CODE VER 7.01.0

DEVICE ADDRESS 1 ALPhACELL OThER FLOAT V/C 2.27 ACCEPT V/C 2.40 TEMP COMP 5mV BATT CAPACITy 100Ah STANDBy TIME 65 M STANDBy EVENTS 12 TOTAL RUN TIME 365D SELF TEST OFF TEST INhIBIT — TEST DURATION 10 M FREq RANGE 3.0hz TAP SW NO PIM OPTION yES RESET OUTPUT 1 — RESET OUTPUT 2 — OVER CURR 1 15.0A OVER CURR 2 15.0A RETRy DELAy 60S RETRy LIMIT 20 OVER CURR TOL 3000ms N+1 VALID NO SET DEFAULTS NO SELECT LANGUAGE

Top Line Second line

ALPhACELL 195GXL NO. BATT STRIN 1

If battery type OTHER is selected, the menu will appear as indicated left. If ALPHACELL is selected, the section of the menu indicated in white will be replaced by the options pictured above (FLOAT, ACCEPT, TEMP COMP and BATT CAPACITY are hidden and preset according to the AlphaCell selected). Once the battery data has been accepted, the operator will be prompted to select the number of battery strings in the system.

This line item appears only in Auto-scroll mode

These items appear in the setup menu only if the optional PIM is installed and selection = YES.

Fig. 4-6, Setup Menu Display

(Examples are given for values in the display)

017-805-B0-010 Rev. K2

Page 63

4.3 Smart Display Modes, continued

automatically selected and not

number of battery strings used

4.3.4 Menu Structure/Navigation (from Operation Normal screen)

OPERATION NORMAL

(Auto-Scroll ) OPER MODE = LINE INPUT VOLTAGE 120V OUTPUT VOLTAGE 89V OUTPUT 1 CURRENT 12.2A OUTPUT 2 CURRENT 12.0A CHARGER MODE = FLOAT BATT VOLTAGE 40.5V BATTERY TEMP 37°C CHARGER CURRENT 8.2A 12 EVENTS 65 MIN

To Self-test

TEST: 10 MIN

BATT VOLTAGE

Self-test OFF

Back to Operation Normal

To Single-step

Back to Auto-Scroll

To COMMS INFO

To Operation Normal

37.3 V

OPERATION NORMAL

OPER MODE = LINE INPUT VOLTAGE 120V INPUT FREQUENCY 60Hz OUTPUT VOLTAGE 89V OUTPUT 1 CURRENT 12.2A OUTPUT 2 CURRENT 12.0A OUTPUT WATTS (W) OUTPUT VA 1060 PERCENT LOAD 80% CHARGER MODE = FLOAT BATT VOLTAGE 40.5V BATTERY TEMP 37°C CHARGER CURRENT 8.2A 12 EVENTS 65 MIN

CM = 00:90:EA:00:30:54 CM192.168.1.151 CMRx PWR -6.8dBMv CMTx PWR 41.0dBMv DN FREQ = 300.000 MHz UP FREQ = 15.000 MHz SW 4.5.9.0_00.77CO-N BATT A1=13.1 A2=14.0 BATT A3=13.5 B1=13.1 BATT B2=14.0 A2=13.5

(Single-step)

COMMS INFO

(Auto-Scroll )

Back to

Auto-Scroll

Only visible in single-step mode

To Single-step

Back to Auto-Scroll

COMMS INFO

(Single-step)

Displayed when

AlphaCell = Other selected.

Appears only in Auto-scroll mode

Displayed only when

optional PIM is installed.

LEGEND

Description Control panel

DOWN

ENTER

ESCAPE <ESC>

Key

Smart Display

Symbol

SETUP MENU

(Auto-scroll)

CODE VER = 7.01.0 DEVICE ADDRESS= 1 ALPHACELL = OTHER FLOAT V/C=2.27 ACCEPT V/C=2.40 TEMP COMP=5mV BATT CAPACITY=100Ah STANDBY TIME=65M STANDBY EVENTS=12 TOTAL RUN TIME = 365D SELF TEST = OFF TEST INTERVAL TEST INHIBIT TEST DURATION = 10M TEST COUNTDOWN FREQ. RANGE = 3.0Hz TAP SWITCH PIM OPTION = YES RESET OUT 1 RESET OUT 2 OVERCURRENT 1 = 15.0A OVERCURRENT 2 = 15.0A RETRY DELAY = 60s RETRY LIMIT = 20 OVER CURR TOL = 3000 N+1 VALID = NO SET DEFAULTS = NO SELECT LANGUAGE

To Accept New Data

Edit using

To Single-step

Displayed when

AlphaCell = Other

selected.

Back Auto-Scroll

Displayed only

when optional

PIM is installed.

Float V/C = 2.27 V

To Accept New Data

To Abort

SETUP MENU

(Single-step)

CODE VER = 7.01.0 DEVICE ADDRESS= 1 ALPHACELL = OTHER FLOAT V/C=2.27 ACCEPT V/C=2.40 TEMP COMP=5mV BATT CAPACITY=100Ah STANDBY TIME=65M STANDBY EVENTS=12 TOTAL RUN TIME = 365D SELF TEST = OFF TEST INHIBIT TEST INTERVAL TEST DURATION = 10M TEST COUNTDOWN FREQ RANGE = 3.0Hz PIM OPTION = YES RESET OUT 1 RESET OUT 2 OVERCURRENT 1 = 15.0A OVERCURRENT 2 = 15.0A RETRY DELAY = 60s RETRY LIMIT = 20 OVER CURR TOL = 3000 N+1 VALID = NO SET DEFAULTS = NO SELECT LANGUAGE

Back to Single-step Setup Menu

To Program Mode

220GOLD 220HPL-FT 220GXL 210GXL 195GXL 195GOLD 180GXL 165GXL 115HPL-FT 85GXL 70HPL-FT

LANGUAGE =

ENGLISH SPANISH FRENCH

PORTUGUESE

GERMAN

Back to Single-step Setup Menu

When an AlphaCell battery is selected, the values for Float, Accept, Temp Comp and Battery Capacity are

shown in the Smart Diaplay. Once the battery data has been updated, the operator will be prompted to select the

in the system.

017-805-B0-010 Rev. K2

Page 64

4.3 Smart Display Modes, continued

4.3.5 Menu Structure/Navigation (from Active Alarms screen)

***ACTIVE ALARMS***

Auto-Scroll Information

(Auto-scroll Information)

SELF TEST FAIL LOW BATT VOLTS HIGH BATT VOLTS NO BATTERIES BATT TEMP PROBE LINE ISOLATION OUTPUT FAILURE OUTPUT OVERLOAD OUTPUT 1 TRIPPED OUTPUT 2 TRIPPED CHARGER FAILURE INPUT FAILURE INV DISCONNECTED INVERTER TEMP TAP FUSE FAIL CONFIG ERROR N+1 IN USE N+1 FAULT

Single-step

Auto-Scroll

***ACTIVE ALARMS***

(Single-step Information)

To Help screens

for selected alarm

Sample Active

Alarm

To Single-step

Help Screens

Sample Active

Alarm

Output Overload

(Auto-scroll Information)

1. OUTPUT SHORT CKT?

2. TOO MUCH LOAD

3. CHK OUTPUT CURRENT

Output Overload

Single-step Information

1. OUTPUT SHORT CKT?

2. TOO MUCH LOAD

3. CHK OUTPUT CURRENT

Back to

Auto-scroll

Back to Auto-scroll

Help Screens

LEGEND

Description Control panel

Key

DOWN

ENTER

ESCAPE <ESC>

Smart Display

Symbol

To Operation Normal

To Active Alarms

Back to

OPERATION NORMAL

(Auto-scroll Information)

OPER MODE = LINE INPUT VOLTAGE 120V OUTPUT VOLTAGE 89V OUTPUT 1 CURRENT 12.2A OUTPUT 2 CURRENT 12.0A CHARGER MODE = FLOAT BATT VOLTAGE 40.5V BATTERY TEMP 37°C CHARGER CURRENT 8.2A 12 EVENTS 65 MIN

COMMS Info

COMMS INFO

(Auto-scroll Information) CM = 00:90:EA:00:30:54 CM192.168.1.151 CMRx PWR -6.8dBMv CMTx PWR 41.0dBMv DN FREQ = 300.000 MHz UP FREQ = 15.000 MHz SW 4.5.9.0_00.77CO-N BATT A1=13.1 A2=14.0 BATT A3=13.5 B1=13.1 BATT B2=14.0 A2=13.5

To Setup Menu

SETUP MENU

(Auto-scroll Information)

TEST DURATION = 10M TEST COUNTDOWN FREQ. RANGE = 3.0Hz TAP SWITCH PIM OPTION = YES RESET OUT 1 RESET OUT 2 OVERCURRENT 1 = 15.0A OVERCURRENT 2 = 15.0A RETRY DELAY = 60s RETRY LIMIT = 20 OVER CURR TOL = 3000 N+1 VALID = NO SET DEFAULTS = NO SELECT LANGUAGE

Visible when AlphaCell = Other

Visible only on Auto-scroll screen

Visible when PIM option = Yes

***

Operation Normal

COMMS Info

***

To Accept New Data

Edit using

Float V/C = 2.27 V

Back to

Single-step

Back to

To Single-step

Back to Auto-Scroll

Back to

Auto-scroll

To Single-step

Back Auto-scroll

To Accept New Data

OPERATION NORMAL

(Single-step Information)

Visible only on Single-step screen

COMMS INFO

(Single-step Information)

SETUP MENU

(Single-step Information)

CODE VER = 7.01.0 DEVICE ADDRESS= 1 ALPHACELL = OTHER FLOAT V/C=2.27 ACCEPT V/C=2.40 TEMP COMP=5mV BATT CAPACITY=100Ah STANDBY TIME=65M STANDBY EVENTS=12 TOTAL RUN TIME = 365D SELF TEST = OFF TEST INHIBIT TEST INTERVAL TEST DURATION = 10M TEST COUNTDOWN FREQ RANGE = 3.0Hz PIM OPTION = YES RESET OUT 1 RESET OUT 2 OVERCURRENT 1 = 15.0A OVERCURRENT 2 = 15.0A RETRY DELAY = 60s RETRY LIMIT = 20 OVER CURR TOL = 3000 N+1 VALID = NO SET DEFAULTS = NO SELECT LANGUAGE

To Abort

Back to Single-step Setup Menu

***

To Program Mode

Back to Single-step Setup Menu

220GOLD

220HPL-FT

220GXL 210GXL 195GXL

195GOLD

180GXL 165GXL

115HPL-FT

85GXL

70HPL-FT

LANGUAGE =

ENGLISH SPANISH FRENCH

PORTUGUESE

GERMAN

When an AlphaCell battery is selected, the values for Float, Accept, Temp Comp and Battery Capacity are automatically selected and not shown in the Smart Diaplay. Once the battery data has been updated, the operator will be prompted to select the number of battery strings used in the system.

017-805-B0-010 Rev. K2

Page 65

4.4 Alarm Indications

In the event of a failure, the Active Alarm displays which alarms are active and how to

correct the alarm condition. Major alarms cause the red LED to ash.

• Press UP or DOWN to stop Auto Scroll. Arrows on the right-hand side of the

display text indicate which keys to press to display the next menu item.

• Press UP or DOWN to select the alarm of interest.

• Press ENTER to select the alarm and display diagnostic information. Press

ESCAPE to return to the alarm list.

NOTE:

If only one alarm is active, the alarm list is bypassed and diagnostic information for the single active alarm displays.

A Help sub-menu provides possible remedies relating to the active alarm. To access the Active Alarm Help sub-menu, scroll to the alarm of interest and press ENTER. The diagnostic information initially auto scrolls. To enter manual scroll mode, press either UP or DOWN. Press DOWN to scroll through the list of remedies.

Alarms are classied in two categories:

MAJOR Alarms are indications of a serious failure within the CableUPS, such as a loss of output voltage or a failed battery charger. Any situation that causes output failure is considered a Major Alarm. Major alarms require immediate action to correct the failure. To correct major alarms, follow the Smart Display on-screen instructions.

MINOR Alarms indicate a less serious failure, such as defective RTS or loss of utility power. Corrective action can be delayed for a short time. To correct, follow the Smart Display on-screen instructions.

The alarm matrices on the following pages indicate the MAJOR/MINOR active alarms, the probable cause and troubleshooting items to check to correct the alarm condition.

017-805-B0-010 Rev. K2

Page 66

4.4 Alarm Indications, continued

Active Alarm or

Abnormal Condition

Self Test Fail

(see Note 1 below)

Cong Error

Tap Fuse Fail

Probable Causes Corrective Action

36 Volt battery string below 33.0 Vdc

48 Volt battery string below 44.0 Vdc

Alarm during a Self-Test Inverter failure has

occurred Line Isolation Alarm

Conguration Switch Settings Incorrect

Power Distribution Board failure (see Note 2 below)

Open A TS fuse (see Note 3 below)

ATS damage Power Distribution Board

damage (see Note 2

below)

1. Check/correct other alarms.

2. Check that correct AC Input Voltage is present

3. Check Battery Circuit Breaker

4. Check Battery Fuse, if installed

5. Check Battery condition and voltage

6. In the event that a Self Test Alarm condition was already present, re-run the Self Test to clear the alarm.

7. Change Inverter Module

8. Replace Power Supply

1. Check the conguration switch & jumper

settings on the Power Distribution Board match those required for the power supply.

2. Verify the conguration settings on display

(press UP and Enter simultaneously) match the application and conguration switch

settings on the Power Distribution Board.

3. Check transformer Output Tap setting to

verify the Inverter Module voltage matches the Transformer Module voltage and voltage shown on the label of the Inverter Module matches the voltage of Transformer Module.

4. Check for corrosion on the Power Distribution

Board.

5. Verify Power Distribution Board to Inverter

Module Ribbon Cable and Connectors are properly connected.

6. Turn all power off, wait 10 seconds, turn all

power back on.

7. Change Inverter Module

8. Replace power supply.

1. Check/replace fuse on ATS

2. Check for damaged contacts on the ATS

board relay.

3. Check the conguration switch settings on

the Power Distribution Board match those required for the power supply.

4. Check that conguration settings on display

(press UP and Enter simultaneously) match the conguration switch settings on the Power

Distribution Board.

5. Turn all power off, wait 10 seconds, turn all

power back on.

6. Replace power supply

NOTE:

Note 1: To clear a Latched Self-Test Fail Alarm, initiate and complete a successful self-test. Note 2: Remove and replace power supply. Do not try to clear alarm or replace relay while in service.

Note 3: The Automatic Tap Switch (ATS) option is not available in units sold in North America or

Europe.

017-805-B0-010 Rev. K2

Page 67

4.4 Alarm Indications, continued

Active Alarm or

Abnormal Condition

Output Overvoltage

Reading

Line Isolation

Alarm

Probable Causes Corrective Action

1. Check output voltage and compare to display reading:

2. Check the conguration switch settings on the

Conguration error

Failure of metering circuit on Power Distribution Board

Failure of Transformer

Failure of input relay

Power Distribution Board match those required for the power supply.

3. Check that conguration settings on display (press UP and Enter simultaneously) match the

conguration switch settings on the Power Distri-

bution Board.

4. Check Output Taps from Transformer.

5. Change inverter module

6. Replace power supply

1. Open the Battery Circuit Breaker

2. Pull out and re-seat Inverter Module

3. Turn the Battery Circuit Breaker back on.

4. Run Self Test (press Down and Enter

simultaneously).

5. If Alarm…..Replace power supply

Output Failure

Alarm

Battery Temp Probe

Alarm

Battery End of Discharge during Line Input Fail

Conguration Settings incorrect

Output overloaded Output in short circuit

Temperature Sensor Failure or Inverter Board Failure

1. Check for AC Input Voltage present

2. Check Output current on the display. If Output Current is > 100% of rating, correct overload conditions.

3. Measure the output voltage and compare to the display output voltage

4. Check Output Taps from Transformer.

5. Check the conguration switch settings on the

Power Distribution Board match those required for the power supply.

6. Check that conguration settings on display (press UP and Enter simultaneously) match the

conguration switch settings on the Power Distri-

bution Board.

7. Open the Battery Circuit Breaker and

8. Pull out and re-seat Inverter Module

9. Turn the Battery Circuit Breaker back on.

10. Replace power supply

1. Inspect RTS sensor, wire and connector to see if there is an intermittent connection

2. Replace with known good sensor

3. Check Battery Temperature Display Reading

4. Check for Alarm

5. Replace Inverter Module

017-805-B0-010 Rev. K2

Page 68

4.4 Alarm Indications, continued

Active Alarm or

Abnormal Condition

Low Batt Volts

High Batt Volts

Probable Causes of Alarm Corrective Action

1. Check Battery Voltage and compare to Displayed Battery Voltage

2. Check for correct battery capacity on Set-up Menu.

Bad Batteries or 36 Volt battery string below 33.0 Vdc or 48 Volt battery string below 44.0 Vdc, Inverter Module not seated or AC Input Fail or Inverter Module Failure

36 Volt battery string above 45.0Vdc or, 48V battery string above 60.0Vdc

3. Check for AC Input Voltage present

4. Open the Battery Circuit Breaker and

5. Pull out the Inverter Module

6. Verify Inverter Module securely connected.

7. Re-seat the Inverter Module

8. Turn the Battery Circuit Breaker back on.

9. Replace Inverter Module

1. Check Charger settings.

No Batteries

Active Alarm or

Abnormal Condition

Output Overload

(XM2)

Detected the absence of batteries (alarm inactive when battery

capacity set to 0)

Alarm States Corrective Action

Overload Indication

Alarm, no shutdown 110 to 115%

Alarm, shutdown in 30m 115 to 125%

Alarm, shutdown in 10m 125 to 150%

Alarm, shutdown in 30s >150%

Alarm, shutdown in <15s Short circuit

Current Range

(approx. %)

1. Check Battery breaker

2. Check Connections

3. Check battery Fuse

1. Check Output current on the display. If Output Current is > 100% of rating, correct overload conditions.

2. Check the conguration switch

settings on the Power Distribution Board match those required for the power supply.

3. Turn all power off, wait 10 seconds, turn all power back on.

4. Check that conguration settings

on display (press UP and Enter

simultaneously) match the conguration switch settings on

the Power Distribution Board.

5. If PIM option installed, check PIM limits on display

6. Replace Inverter Module

7. Replace power supply

017-805-B0-010 Rev. K2

Page 69

4.4 Alarm Indications, continued

Active Alarm or

Abnormal Condition

Output Overload

(XM2-918 HP, XM2-924HP)

Alarm States Corrective Action

Overload Indication

Alarm, no shutdown 105 to 107.5%

Alarm, shutdown in 30m

Alarm, shutdown in 10m

Alarm, shutdown in 30s

Alarm, shutdown in <15

Current Range

(approx. %)

107.5 to 112.5%

112.5 to 125%

>125%

Short circuit

1. Check Output current on the display. If Output Current is > 100% of rating, correct overload conditions.

2. Check the conguration

switch settings on the Power Distribution Board match those required for the power supply.

3. Turn all power off, wait 10 seconds, turn all power back on.

4. Check that conguration

settings on display (press UP and Enter

simultaneously) match the conguration switch

settings on the Power Distribution Board.

5. If PIM option installed, check PIM limits on display

6. Replace Inverter Module

7. Replace power supply

Active Alarm or

Abnormal Condition

Batt Temp Probe

Input Failure

N+1 In Use

Preliminary

N+1 Fault

017-805-B0-010 Rev. K2

Corrective Action Probable Cause of Alarm

1. Check Connection

2. Check Sensor

1. Utility Failure

2. Circuit breaker input

3. Input Connections

4. Check 120/240 Jumpers

1. Check Output Fuse

2. Check Output Connections

1. Verify wiring

2. Check N+1 output

Remote Temp Sensor (RTS) failed or

is not connected

Utility AC Input has failed

Output of CableUPS has failed. Load has been transferred to N+1 unit

Input voltage was expected on N+1

unit; none detected.

Page 70

4.4 Alarm Indications, continued

Active Alarm or

Abnormal Condition

Output 1 Tripped

Charger Failure Alarm

Inverter Disconnected

Inverter Temperature

Probable Causes Corrective Action

Output 1 hardware protection mode engaged (only active with optional PIM

installed)

Output 1 hardware protection mode engaged (only active with optional PIM

installed)

Bad batteries Inverter Module not seated Inverter Module failure?

The Inverter Module is not properly connected

Inverter heatsink has exceeded set

temperature (Standby operations suspended until temperature drops

to safe level).

1. Over Current

2. Check Settings

1. Over Current

2. Check Settings

1. Open the Battery Circuit Breaker,

2. Verify the Display is still on.

3. If Display drops out….

4. Pull out the Inverter Module

5. Inspect the Inverter Module and rear Anderson connectors.

6. Re-seat the Inverter Module

7. Turn the Battery Circuit Breaker back on.

8. Check charging current on display.

9. Run Self Test (press Down and Enter

simultaneously).

10. Check Battery Voltage.

11. Check Battery physical condition.

12. Wait a minimum of three hours.

13. Check Battery Voltage again.

14. Verify Battery Voltage has increased

(Battery charging) and Alarm has not

returned.

15. Replace Inverter Module

1. Reseat Inverter Module

2. Check Ribbon Cable

1. Check Fan

2. Check Filter (legacy models)

017-805-B0-010 Rev. K2

Page 71

4.5 Smart Display LEDs

Two LEDs on the Smart Display indicate the condition and status of the Intelligent CableUPS.

The green Output LED, when lit, indicates the power supply is functioning normally

and supplying output AC to the load. A ashing output LED indicates that a minor

alarm has been detected. If the Output LED is off, a major alarm has been detected.

The red Alarm LED ashes to indicate a major alarm has been detected. This state

clears when the alarm is no longer present. Under typical operating situations, the red Alarm LED is off. This indicates normal power supply operation.

OUTPUT LED (green)

SOLID = Operation Normal FLASHING = Minor Alarm OFF = Major Alarm

i2M OUT FREQ BAT IN 90V 15A 60Hz 36V 120

ALARM LED (red)

FLASHING = Major Alarm OFF = Minor Alarm

OFF = Operation Normal

Fig. 4-7, Output and Alarm LEDs

017-805-B0-010 Rev. K2

Page 72

4.6 Smart Display Glossary

Battery Capacity: The capacity of the battery strings attached to a particular Intelligent

CableUPS. When batteries are not attached, the setting must be programmed to “0.” This disables

standby operations, including test mode and disables the No Batteries Alarm. If batteries are attached, then this setting should be programmed to the total rating of all the battery strings. This setting can be programmed to higher values to accommodate multiple battery strings (i.e., 1 battery string = 100 AH, 2 battery strings = 200 AH, 3 battery strings = 300 AH. 4 battery

strings = 400AH).

NOTE:

If the power supply is used in a non-standby application, this variable must be programmed to “0” to

disable the battery maintenance cycle portion of a self test.

Charger Accept Voltage: Battery Accept charge voltage control in volts per cell. This voltage,

2.40Vdc (adjustable) per cell, is temperature compensated to ensure longer battery life. It properly completes the charge cycle and is factory set for AlphaCell batteries. If another manufacturer’s

batteries are used, consult the battery manufacturer for Accept voltage levels. Charger Float Voltage: Battery Float charge voltage control in volts per cell. The average is

approximately 2.27Vdc (adjustable) per cell. It is factory set for AlphaCell batteries. If another manufacturer’s batteries are used, consult the battery manufacturer for Float voltage levels.

Charger Temperature Compensation: Battery charger temperature compensation control.

Programming this parameter to “0.0” disables temperature compensation. It is factory set for AlphaCell batteries (5mV/cell). If another manufacturer’s batteries are used, consult the battery

manufacturer for Charger Temperature compensation ranges. Device Address: The power supply must have a unique address to communicate with a system

controller. The system controller uses the address as an identier to query the power supply for information. Each power supply on the same communications bus must be identied with a value

between 1 and 7.

NOTE:

The device address does not reset to 1 when factory defaults are reset.

End of Battery Discharge (EOD): The point at which the batteries are fully discharged (default

1.75V/C * 18 cells for 36V inverter) and the power supply shuts off, preventing permanent damage

to the batteries. Frequency Range Limit (may be used when powering with AC Generator): AC input voltage

frequency range limit. This limit establishes the acceptable input frequency range outside of which standby operation is initiated.

Output 1 Overcurrent Trip level — Primary leg: Value of RMS current that causes an overcurrent

trip on the Output 1A + Output 1B protection relay after a specied delay. This limit is linked to

counter data item Overcurrent Tolerance Period. This parameter is only visible when the Protective

Interface Module (PIM) is attached.

Output 2 Overcurrent Trip level — Secondary leg: Value of RMS current that causes an

overcurrent trip on the Output 2 protection relay after a specied delay. This limit is linked to

counter data item Overcurrent Tolerances Period. This parameter is only visible when the optional PIM is attached.

Battery Type: (HP models only) The AlphaCell battery type can be specied in the smart display

(if not AlphaCell, leave as default battery type, Other). If AlphaCell is selected, Accept, Float,

Temp, Comp and Battery Capacity is automatically selected. If Other, these parameters will need

to be manually set to the manufacturer’s recommended rating.

NOTE:

If AlphaCell is selected, Accept, Float, Temperature Compensation and Battery Capacity are not displayed.

017-805-B0-010 Rev. K2

Page 73

4. 0 Operation, continued

4.6 Smart Display Glossary, continued

Overcurrent Tolerance Period: An output overcurrent condition is tolerated on either of

the PIM outputs for this amount of time. When this delay expires, the output protection relay

disables the output. This parameter is only visible when a PIM is installed. Reset Output 1, Reset Output 2: Programming this feature resets the corresponding output

in the event one or both outputs are tripped. Upon clearing the alarm, either manually or via

an automatic retry, the output(s) remain on. This parameter is only visible when a PIM is

installed. Retry Delay: PIM option output fault retry interval timer. This is the period of time between

each attempt to restart an output connection. A value greater than 600 seconds disables the automatic retry function. This parameter is only visible when a PIM is installed.

Retry Limit: PIM fault retry count limit. This is the number of times the unit will attempt to

restart an output connection at the frequency specied by Retry Delay. Once the retry limit is exceeded, attempts to restart the feeder occur indenitely, once every 30 minutes. This

parameter is only visible when a PIM is installed.

Set Defaults: When programmed to YES, all the programmable data levels (except DEVICE

ADDRESS) are reset to the original factory settings.

Self Test: When programmed to YES, the CableUPS automatically starts a self test. Standby Events: A standby events counter. This does not include self test events. Use the

Setup Menu to reset Standby Events to zero. Standby Time: The total amount of time the power supply has operated in standby mode.

This does not include self test time and represents the sum total number of minutes of AC line failure since the last time the counter was reset. Use the Setup Menu to reset Standby Time to zero.

NOTE:

Resetting factory defaults does not clear Standby Events or Standby Time.

Test Countdown: The number of days remaining before the next scheduled automatic

self-test initiates. This variable is programmable and you can select the day the autotest sequence will begin. This counter has no effect if test interval is set to 0.

Test Duration: Automatic self test duration timer. This sets the number of minutes of a battery maintenance cycle test. This timer applies to automatically or manually initiated tests.

Test Inhibit: Becomes active when programmed by the operator (or when the unit runs in

inverter mode for more than 5 minutes). The power supply delays the start of a scheduled

self test for seven days if the test countdown is less than seven days (See Section 4.4,

Automatic Performance Test for complete details).

Test Interval: Automatic self test control timer. The number of days between battery maintenance cycle tests. Set this value to zero to disable automatic self test.

Total Run Time: The amount of time (in days) the power supply has functioned in any mode

of operation. This is not a resetable value.

017-805-B0-010 Rev. K2

Page 74

4.7 Automatic Performance Test

Automatic Self-Test: An automatic self test can be periodically performed to verify the

state of the batteries and the inverter circuitry. The automatic test feature has several programmable parameters that determine the frequency and duration of automatic tests. In addition to automatic testing, the operator can manually initiate a self-test by pressing ENTER and DOWN simultaneously. A running test may be halted manually by pressing ENTER and DOWN a second time.

The test sequence process:

• Begins with a check to verify the batteries are attached and the battery circuit breaker is closed. If the batteries are discharged or not connected, the power supply does not attempt to operate in inverter mode, preventing a drop of the load.

• Next, the power supply switches to standby mode for a pre-programmed period.

Successful completion of a test sequence indicates the unit is operating normally in standby mode, the battery voltage did not drop below a preset threshold and the output was stable throughout the test. Failure of test is indicated by a Self-Test Fail alarm, which can be cleared by subsequently running a successful test for at least one minute.

Test Control: Initiate a manual test (or a running test may be halted) at any time by pressing

ENTER and DOWN simultaneously or by changing the Self-Test switch via the front panel interface or status communications. A self-test may also be initiated via the status monitoring card.

To prevent an automatic test scheduled to occur in the next week, issue a Test Inhibit

command. This command is useful if periodic maintenance of the power supply is scheduled

close to the next scheduled automatic test.

This control feature may also be used when inclement weather is expected that might cause

a utility failure. The Test Inhibit command only affects an automatic test scheduled to run

in the next seven days. Multiple issues of the Test Inhibit command result in the deferral of the next automatic test until at least seven days after the last request. This command has no affect if an automatic test is not scheduled to take place in the next week. Starting a test

manually overrides the Test Inhibit command. The automatic test feature is on by default. To turn auto-test off, change Test Interval to 0

days in the Setup Menu. Auto-test may be enabled at any time by changing the test interval

to any numerical value (excluding “0”). The default test interval is 30 days.

Test Countdown: Indicates a pending automatic test. Test Duration: The Test Duration is adjustable to meet customer requirements. Exercise

caution when increasing the parameter because long self tests compromise the standby capability during and shortly after, the test.

Standby Time and Standby Events: Counters that are not incremented during self-tests.

017-805-B0-010 Rev. K2

Page 75

4.8 Providing Power via Portable Generator or Inverter

In the event of an extended utility failure, an external AC or DC power supply can provide

backup power to the system. This backup power enables the power supply to continue charging the batteries ensuring interrupted service to the network. Follow the documentation and connection procedures listed below.

4.8.1 DC Powering

The AlphaGen Portable Generator provides a convenient method of providing

backup DC power. Upon the loss of commercial AC power, the existing battery

strings immediately supply voltage to the inverter module. After some point of battery discharge, a portable generator can be deployed to the site to supply power to the DC bus. For complete connection and operation information of the AlphaGen

Portable Generator, refer its operator’s manual (Alpha P/N 041-028-B0).

4.8.2 AC Powering

Should it become necessary to power the CATV system with a portable AC generator, truck-mounted AC generator or truck-mounted inverter, follow the procedures below for the protection of service personnel and powering system equipment.

Connection Procedure:

1. Read the Smart Display to determine if there is output power to the system. If there is still power to the system, check the battery voltage on the Smart Display:

• If the battery voltage is greater than 34.5Vdc (3-battery system) or 46.0Vdc

(4-battery system) then approximately one hour remains to complete the

changeover to generator power before the cable system loses power to its customers.

• If the battery voltage is less than the previous numbers, move rapidly as

there is not much time until the system fails. However, exercise caution as

there are dangerous voltages in the system that can shock you or damage

the cable ampliers.

2. Verify the AC Input breaker from the utility powering system is in the OFF

position. This ensures that if power returns suddenly, you will not experience a

surge in power. This also ensures when the generator is connected it will not put AC voltage back onto the power lines.

3. Properly ground the generator by connecting a #6 AWG wire from the grounding lug on the output panel of the generator to either a driven ground rod or the strand ground on the pole to which the power supply is mounted. If working with a ground-mounted power supply, locate the grounding point inside the enclosure and clamp on to that point.

CAUTION!

Grounding the generator is mandatory for safety and for proper operation of the power supply.

017-805-B0-010 Rev. K2

Page 76

4.9 Providing Power via Portable Generator or Inverter, continued

4.8.2 AC Powering, continued

4. After the generator is properly grounded, unplug the power supply from the convenience outlet inside the enclosure and plug the power supply input cable

into the generator output. Use an NEC or UL approved extension cord.

5. Start and operate the generator according to the generator operation manual.

6. If the generator kilowatt rating is twice the kilowatts used by the power supply indicated on the Smart Display, leave the battery breaker on and the generator will charge the batteries. If the generator fails, the power supply will continue to

provide battery backup. If the generator output is not approximately twice the

kilowatt rating indicated on the Smart Display, switch the battery breaker off to reduce the load on the generator if battery backup of the system is unavailable.

7. In either case, after the power from the generator is applied to the power supply, use the Smart Display to increase the Frequency Input Tolerance to ±6Hz from the normal ±3Hz, inhibiting the power supply from switching to battery backup if the generator occasionally does not operate on the proper frequency. It is not

uncommon for smaller (4 kilowatt or less) sized generators to get “off frequency”

due to the step loading of the power supply.

WARNING!

Ground the vehicle before operating a truck inverter or truck-mounted generator. Failure to do so places service personnel at risk for electric shock.

4.8.3 Using a Truck-mounted Inverter or Generator

To use a truck-mounted inverter or generator follow the steps listed in Section

4.8.2 with the additional step of grounding the truck. Run the ground wire from an unpainted point on the truck chassis to either a driven ground rod or strand ground to complete the grounding circuit. The rubber tires on the truck insulate it from being

grounded in all but the most exceptional circumstances.

017-805-B0-010 Rev. K2

Page 77

4.9 Resumption of Utility Power

WARNING!

Use caution when disconnecting and reconnecting a generator to utility power. Dangerous voltages are present.

CAUTION!

Exercise care to ensure that both powering systems are not connected at the same time or damage to the power supply and the generator may result.

1. Before turning on the AC voltage input breaker, use a voltmeter to verify the input voltage

is within specications.

2. When the proper voltage is present, verify the battery voltage indicated on the Smart

Display is greater than 31.5Vdc or 42.0Vdc (3 or 4 battery systems respectively).

Disconnect the power supply from the generator output and plug the power supply input cord into the convenience outlet within the enclosure. The power supply operates on

battery backup for this short period of time, but exercise caution during this changeover

as the grounding circuit to the power supply is broken. If the batteries are at or below the low voltage cutoff, then the power supply will NOT

transfer to battery back up and there will be a momentary power outage to the cable system while you make this changeover.

3. Turn on the AC input power.

4. Shut down the generator and remove the grounding system.

017-805-B0-010 Rev. K2

Page 78

5.0 Intelligent CableUPS Maintenance

A routine maintenance program, performed every three to six months, ensures the Intelligent

CableUPS will provide years of trouble-free operation.

Good battery care is the rst step in any power supply maintenance program. In addition to voltage

checks, visually inspect the batteries for signs of cracking, leaking or swelling.

To aid in quick identication and tracking of voltages in the maintenance log, number the batteries

inside the enclosure using labels or masking tape. Batteries are temperature sensitive and susceptible to overcharging and undercharging. Since batteries behave differently in the winter than

in the summer, Alpha’s battery chargers automatically compensate for changes in temperature by adjusting oat and accept charge voltages.

CAUTION!

• The power supply must be serviced by qualied personnel.

• Use heavy gloves when handling a unit that has recently been taken out of service. The

ferroresonant transformer generates heat that may cause burns if handled with bare hands.

• Alpha Technologies is not responsible for battery damage due to improper charger voltage settings. Consult the battery manufacturer for correct charger voltage requirements.

• When removing batteries, ALWAYS switch the battery breaker off before unplugging the battery connector.

• Always wear safety glasses when working with batteries.

5.1 System Information

Observe and record the following system information from the Operation Normal and Comms Status Menus in the maintenance log in Section 5.8.

Operation Normal:

Comms Status/Menu:

The DSM3x can monitor up to 4 x

48V battery strings.

Input Voltage Output Voltage (if PIM installed) Output 1 Voltage Output 2 Current (if PIM installed) Output 1 Current Standby Events Battery Voltage Charger Mode Total Standby Time Operation Mode Battery Temperature Charger Current Input Frequency Output Watts Output VA Percent Load

CM (Address)

CM MAC CM Version CMRX CMTX

DN FREQ UP FREQ MODEL SW

BATT (Str A) A1 A2 A3 A4 BATT (Str B) B1 B2 B3 B4 BATT (Str C) C1 C2 C3 C4 BATT (Str D) D1 D2 D3 D4

017-805-B0-010 Rev. K2

Page 79

5.2 Battery Charger Voltage

The advanced three-stage charging features of the Intelligent CableUPS are completely self-

monitoring. During normal power supply operations, the power supply continuously veries

the operating condition of the battery charger. If, for any reason, the battery charger fails, a Charger Fail alarm displays on the Smart Display. No operator voltage checks are required.

5.3 Battery Terminals and Connecting Wires

• Check each battery terminal and connection.

• Verify the hardware is clean and the crimped connectors are tight. Terminal connectors

should be torqued and re-torqued to the battery manufacturer’s recommended specications.

• If there is an “in-line” fuse in the battery cable, check the fuse holder and fuse.

• Verify the terminals are properly protected with an approved battery terminal corrosion

inhibitor such as NCP-2.

• Record date of maintenance in the maintenance log.

NOTE:

Whenever the battery breaker is turned off or the batteries are not connected, the CableUPS automatically reports a No Batteries alarm. This is a built in safety feature. The unit does not attempt inverter operations, either standby or test, during a No Battery alarm.

5.4 Output Voltage

Observe Output voltages using the Smart Display. Record the voltages in the maintenance log.

5.5 Output Current

With the power supply in normal operating mode observe the Smart Display Output Current. The value of output current is dependent on the total amount of load connected to the power supply. Record the current in the maintenance log.

5.6 Check Output Connections

Inspect the output connectors to prevent problems that may be caused by improper connector engagements.

5.6.1 Visual Inspection

1. Unplug and inspect the output connections, using the Service Power Supply to safely bypass the power supply.

2. Remove the AC and DC power sources from the power supply.

3. Carefully inspect the separated halves of each connector for signs of abnormal heating, such as a deformed housing or other damage.

017-805-B0-010 Rev. K2

4. If necessary, replace the PDB and SPI harness connector.

Page 80

5.7 Inverter Module Maintenance

1. Carefully remove the inverter module assembly (see Section 2.3, Inverter Module

Removal and Installation).

2. Inspect the inverter module for signs of dust or corrosion.

CAUTION!

Circuit boards are static-sensitive and must be handled with care.

3. On legacy models: Remove the inverter module’s cooling fan shroud and clean the fan’s

foam lter. Verify the fan rotates easily and is free of obstructions. Replace the lter and fan shroud (lter and fan shroud depend on unit model and version).

WARNING!

Do not remove the fan shroud (Legacy models only) if the inverter module is

installed into the transformer module. The fan can start without warning, possibly placing the service technician in danger from moving parts.

4. Reinstall the inverter module (see Section 2.3 Inverter Module Removal and Installation) and test the power supply for proper operation (see Section 4.1, Start-up and Test).

NOTE:

When DIP switches SW1 and SW2 on PDB are recongured, all items in the setup menu are reset to

the original factory defaults.

CAUTION!

If the CableUPS fails the following test, there will be a loss of power to the load. Do not

perform the next test step if the power supply or batteries are suspect or the load is at a

critical stage.

5. If the power supply passes all previous tests (e.g. Battery Load Test, Self Test):

a. Turn off the utility input breaker to remove input power. The power supply goes into

standby operation.

ATTENTION:

In the event of a low battery warning alarm, immediately reapply utility power and resolve alarm condition. Once the cause of the alarm has been resolved, perform Step 5.

b. Verify there is no interruption to the output.

c. After ve minutes reapply utility power. The power supply then transfers back to

Operation Normal, clears any alarms and starts the battery charger (BULK mode, if

needed). This test adds standby events and time to the event counter.

017-805-B0-010 Rev. K2

Page 81

5.8 Maintenance Log

Battery Maintenance

Battery Number A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 Battery Manufacturer Date Code/Lot Number Terminal Check

Voltage (Unloaded)

Voltage (Loaded)

Power Supply Maintenance

Model Number Serial Number

Operation Normal

Operation Mode Input Voltage Input Frequency * Output Voltage Output 1 Current Output 2 Current Output Watts * Output VA * Percent Load * Charger Mode Battery Voltage Battery Temperature

Charger Current Standby Events Standby Time

* Viewed in single-step mode

Communications Status

CM CM Mac Address

CM Rx PWR

CM Tx PWR

DN Freq (MHz)

UP Freq (MHz)

Model SW Battery Voltage A1 A2 A3 A4

The DSM3x can monitor up to

4 x 48V battery strings.

Commissioning

Service Technician Date Serviced

017-805-B0-010 Rev. K2

B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4

Page 82

5.9 Repair Record

Use this form to note the specics of required service for the power supply and as a reference

for use in the event the power supply requires service at an Alpha repair facility.

RMA Number

Date/Time (local)

Site No. / Address / Location

Power Supply Serial Number

Inverter Module Serial Number

Alarm

Corrective Action T aken

017-805-B0-010 Rev. K2

Page 83

6.0 Specications

6.1 Intelligent CableUPS North American Models

The following table shows the electrical, mechanical and physical specications for the North

American models of the Intelligent CableUPS.

Models: XM2-906HP XM2-910 XM2-1350-48 XM2-915 XM2-915HV XM2-922 XM2-922HV XM2-918HP XM2-924HP

Electrical

Input Voltage (Vac): 120/240 120/240 120/240 120/240 120/240 208/240 240 120/240 208/240

Input Voltage Window: -30 to +20% -20 to +15% -20 to +15% -20 to +15% -30 to +15% -20 to +15% -30 to +15% -20 to +15% -20 to +15%

Input Frequency: 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz 60Hz

Input Frequency Window: ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz

Output Voltage (Vac): 63/87 63/75/87 63/75/87 63/75/87 63/75/89 63/75/87 63/75/89 63/75/87 63/75/87

Output Current (A): 8/6 10/10/10 22/15/15 15/15/15 20/17.5/15 22/22/22 22/22/22 22/18/18 22/22/24

Max Output Power (VA): 540 900 1350 1350 1350 2025 2025 1620 2160

Output Waveform: Quasi-square wave

Voltage Regulation

Output Frequency Stability:

Short Circuit Protection: <150% of maximum current rating

Transfer Characteristics: Uninterrupted output

Battery Voltage (Vdc): 36 36 48 36 36 48 48 36 48

Efﬁciency (Typical Load Range)

Line Mode: 80-87% 86-90% 90-92%

Standby Mode: 79-84% 82-85% 84-86%

Battery Charger

Temperature Compensation: Programmable (0 to 5mV/Cell/°C)

Charger Current: 10A at 80% load and nominal input (bulk charge mode)

Three Stage: Bulk, Accept, Float

Mechanical

Status Display: 2 x 20 Blue LCD with backlight

Dimensions H x W x D (in/mm):

Approx. Weight (lb/kg): 53/24 62/28.1 70/31.8 70/31.8 72/32.7 92/41.7 96/43.5 72/32.7 95/42.9

Finish: Black, epoxy powdercoat

Environment

Operating Temperature: -40 to 55°C / -40 to 131°F

Relative Humidity: 0 to 95% non-condensing

Agency Compliance: FCC Part 15 Class A, UL1778, UL1012, CSA 22.2 No. 107.1

Optional Features

Standard Protective Interface Module (PIM/N+1): Provides two programmable outputs from a single XM2 CableUPS power supply for redundancy in critical applications. The PIM protects system components and provides isolation between distribution legs by shutting down the individual load during over-current conditions.

Note: Voltage regulation is maintained over both line and load ranges.

: ±5% ±5% ±5% ±5% ±5% ±5% ±5% ±5% ±5%

Line Mode 60Hz Nominal

Inverter Mode 60Hz, ±0.05%

8.8 x 15 x 13 / 222 x 381 x 330

017-805-B0-010 Rev. K2

Table 6-1 Specications for North American Models

Page 84

6.2 Intelligent CableUPS International Models

The following table shows the electrical, mechanical and physical specications for the

International models of the Intelligent CableUPS.

XM2 Models: 906HP 906G5 608G5 910 915E 915M 915P 622CE 615CE HP 918HP

Electrical

Input Voltage (Vac): 120/240 115/230 115/230 120/240 190/220/247 100/112/127 190/220/253 230 230 120/240 Input Voltage Window: -30 to +20% -30 to +20% -30 to +20% -20 to +15% -20 to +15% -20 to +15% -20 to +15% -20 to +15% -20 to +15% -20 to +15% Input Voltage Window w/ATS: n/a n/a n/a n/a -30 to +25% -30 to +25% -30 to +25% n/a n/a n/a Input Frequency: 60Hz 50Hz 50Hz 60Hz 50Hz 60Hz 60Hz 50Hz 50Hz 60Hz Input Frequency Window: ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz ±3Hz Output Voltage (Vac): 63/87 63/87 63 63/75/87 63/75/87 63/75/87 63/75/87 63/48 63/48 63/75/87 Output Current (A): 8/6 8/6 8 10/10/10 15/15/15 15/15/15 15/15/15 22/22 15/15 22/18/18 Max Output Power (VA): 540 540 540 900 1350 1350 1350 1350 900 1620 Output Waveform: Quasi-square wave Voltage Regulation Output

Frequency Stability:

Short Circuit Protection: <150% of maximum current rating Transfer Characteristics: Uninterrupted output Battery Voltage (Vdc): 36 36 36 36 36 36 36 48 36 36

Efciency

(Typical Load Range)

Line Mode: 80-87% 86-90% 88-92% Standby Mode: 79-84% 82-85% 84-86%

Battery Charger

Temperature Compensation: Programmable (0 to 5mV/Cell/°C) Charger Current: 10A at 80% load and nominal input (bulk charge mode) Three Stage: Bulk, Accept, Float

Mechanical

Status Display: 2 x 20 Blue LCD with backlight Dimensions H x W x D (in/mm): 8.8 x 15 x 13 / 222 x 381 x 330 Approx. Weight (lb/kg): 53/24 62/28.1 62/28.1 62/28.1 82/37.2 70/31.8 70/31.8 82/37.2 70/31.8 72/32.7 Finish: Black, epoxy powdercoat

Environment

Operating Temperature: -40 to 55°C / -40 to 131°F Relative Humidity: 0 to 95% non-condensing

Agency Compliance

FCC Part 15 Class A, UL1778, UL1012, CSA 22.2 No. 107.1:

CE, EN50083-2, EN62040-2, EN60950-1, EN62040-1:

CB Scheme, IEC 60950-1, EMC to CISPR22 Class A:

Optional Features

Five Output Protective Interface Module (PIM): Provides four programmable outputs from a single XM2 CableUPS power supply for protection in centralized powering applications. The PIM protects system components and provides isolation between distribution legs by shutting down the individual load during over-current conditions. An Optical Network Unit (ONU) output is tied to Output 2.

Automatic Tap Switch (ATS): The ATS extends the input AC operating voltage range as indicated above. The ATS is used when a broader input operating range is needed due to utility voltage uctuations and is currently

available in XM2-915 E/P/M models. Not used in the United States or Canada.

: ±5% ±5% ±5% ±5% ±5% ±5% ±5% ±5% ±5% ±5% Line Mode 60Hz Nominal 50Hz Nominal 60Hz Nominal 50Hz Nominal 60Hz Nominal 50Hz Nominal 60Hz Nominal Inverter Mode 60Hz, ±0.05% 50Hz, ±0.05% 60Hz, ±0.05% 50Hz, ±0.05% 60Hz, ±0.05% 50Hz, ±0.05% 60Hz, ±0.05%

Yes - - Yes - - - - - Yes

- - Yes - - - - Yes Yes -

- Yes Yes - Yes

Yes Yes

- - -

Note: Voltage regulation is maintained over both line and load ranges.

Note: Certied to CB Scheme and IEC 60950-1.

Note: Available only for XM2-915P-CB models.

Table 6-2 Specications for International Models

017-805-B0-010 Rev. K2

Page 85

6.3 Safety and EMC Compliance

North American Product Compliance (60hz Models)

Safety (NRTL/C)

Electromagnetic Compatibility (EMC):

European Union Product Compliance (50hz Models)

Safety (CE)

Low Voltage Directive 2006/95/EC Technical Standards EN 62040-1-2

Electromagnetic Compatibility (EMC)

EMC Directive 2004/108/EC Technical Standards EN 62040-2 Category 2

UL1778 and CSA C22.2 No.107.1, CSA C22.2 No. 107.3 UL/CSA 60950-1

FCC Part 15, sub-part B, Class A

EN 60950-1 EN 50083-1

Table 6-3, Product Certications

017-805-B0-010 Rev. K2

Page 86

7.0 Return and Repair Information

In the event you need to return the Intelligent CableUPS.to Alpha Technologies for service, a Return

Material Authorization (RMA) form must accompany the unit. The form can be found at Alpha’s Web site (www.alpha.com/rma). Follow the instructions contained in the form to obtain an RMA. Once an

RMA number has been issued, pack the unit per instructions and return to the service center assigned

by Alpha Technologies. Or, if preferred, contact Alpha Technologies at (800) 322-5742 for assistance.

NOTE:

Any information pertaining to the nature of the power supply failure or problem, along with a copy of

the power supply’s maintenance log, should be included with the returned power supply.

017-805-B0-010 Rev. K2

Page 87

7.1 Emergency Shutdown

The Intelligent CableUPS contains more than one live circuit. During an emergency, utility power can be disconnected at the service entrance or main electrical panel to protect emergency personnel. However, power is still present at the output. To prevent the possibility of injury to service or emergency personnel, always follow this procedure to safely shutdown the power supply.

Emergency Shutdown Procedure:

• STEP 1: Turn the battery breaker to OFF.

• STEP 2: Unplug the AC Input Line Cord from the service entrance.

• STEP 3: Unplug both the Output 1 and Output 2 connections.

• STEP 4: If applicable, unplug the N+1 connections.

Fig. 7-1 Emergency Shutdown

017-805-B0-010 Rev. K2

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Visit us at www.alpha.com

Due to continuing product development, Alpha Technologies reserves the right to change specications without notice. Copyright © 2013 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

017-805-B0-010 Rev. K2 (1/2013)