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TM
Uninterruptible Power Supplies
Technical Manual
XM Series 2 60VAC Models
XM Series 2 90VAC Models
Effective: July, 2002
®
Alpha Technologies
Power
Alpha Technologies.
2
Protecting The Power in Communications.
017-805-B0-005 Rev. D
™
Uninterruptible Power Supplies 60VAC / 90VAC Models
017-805-B0-005, Rev. D — © 2002 Alpha Technologies
Important Technical Note
To minimize the possibility of the transformer becoming unstable, the XM Series 2
Uninterruptible Power Supply requires a minimum load of at least 1.0 Ampere connected to
the output. Unstable transformers will self correct as soon as any load is connected to the
power supply.
For further information, contact Alpha Technologies or your nearest Alpha representative.
Notice of FCC Compliance
Per FCC 47 CFR 15.21:
Changes or modifications 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:
NOTE: 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 Technologies:
For general product information and customer service
1-800-863-3930
(7:00 AM to 5:00 PM Pacific Time )
For complete technical support
1-800-863-3364
(7:00 AM to 5:00 PM Pacific Time, or 24/7 emergency support)
Emergency Shutdown Procedure on Page 80.
017-805-B0-005 Rev. D
3
Preface
Table of Contents
Preface ................................................................................................................. 4
Important Safety Instructions ............................................................................... 7
Safety Precautions ............................................................................................... 8
Battery Notes ....................................................................................................... 9
Utility Power Connection Notes .......................................................................... 10
Grounding Connection Notes ............................................................................. 13
1. Introduction ........................................................................... 14
1.1 The XM Series 2 Power Supply ............................................................................... 14
1.2 Theory of Operation ................................................................................................. 15
1.2.1 AC (LINE) Operation ................................................................................... 15
1.2.2 Standby Operation ...................................................................................... 16
1.2.3 Charger Operation ....................................................................................... 17
1.3 XM Series 2 Power Supply Layout ........................................................................... 18
1.3.1 Transformer Module .................................................................................... 18
1.3.2 Inverter Module ........................................................................................... 19
1.3.3 Optional Status Monitoring Modules ........................................................... 22
1.4 Optional Features ..................................................................................................... 24
2. Installation ............................................................................ 26
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Installation—General ................................................................................................ 26
XM Series 2 Power Supply Installation .................................................................... 27
Installing the optional AC Indicator Lamp ................................................................. 28
Inverter Module Removal and Installation ................................................................ 30
Protective Interface Module (optional) ..................................................................... 31
Installing the PIM ...................................................................................................... 32
Programming the PIM .............................................................................................. 36
N+1 Front Panel Configurations ............................................................................... 38
Service Power Inserter (SPI) .................................................................................... 40
3. Configuration ........................................................................ 42
3.1 Power Distribution Board Setup ............................................................................... 42
3.2 AC Input Voltage Reconfiguration ............................................................................ 44
3.2.1 Reconfiguration from 120VAC to 240VAC ................................................... 44
3.2.2 Reconfiguration from 240VAC to 120VAC ................................................... 46
3.3 AC Output Voltage Reconfiguration.......................................................................... 48
3.3.1 Output Voltage Switch (SW1) settings ......................................................... 49
4
017-805-B0-005 Rev. D
Preface
Contents
4. Operation .............................................................................. 50
4.1 Start-up and Test ...................................................................................................... 50
4.1.1 AC Line Operation ....................................................................................... 50
4.1.2 Self Test Operation ...................................................................................... 51
4.1.3 Standby Operation ...................................................................................... 51
4.2 Smart Display ........................................................................................................... 52
4.2.1 Operation Normal ........................................................................................ 54
4.2.2 Additional Information Display ..................................................................... 55
4.2.3 Setup Menu ................................................................................................. 56
4.2.4 Alarm Indications ......................................................................................... 59
4.2.5 Control Panel LEDs ..................................................................................... 62
4.2.6 Detailed Menu Structure and Navigation .................................................... 63
4.3 Smart Display Glossary ........................................................................................... 65
4.4 Automatic Performance Test ..................................................................................... 67
4.5 Providing Power via External Source ....................................................................... 68
4.5.1 DC Powering ............................................................................................... 68
4.5.2 AC Powering ................................................................................................ 68
4.5.3 Using a truck-mounted inverter or truck-mounted generator ...................... 69
4.6 Resumption of Utility Power ..................................................................................... 70
5. Maintenance ......................................................................... 71
5.1 XM Series 2 Power Supply Maintenance ................................................................. 71
5.1.1 Check Battery Open Circuit Voltage ............................................................ 71
5.1.2 System Information ..................................................................................... 72
5.1.3 Check Battery Voltage Under Load ............................................................. 72
5.1.4 Check Battery Charger Voltage ................................................................... 73
5.1.5 Check Battery Terminals and Connecting Wires ......................................... 73
5.1.6 Check Output Voltage .................................................................................. 73
5.1.7 Check Output Current ................................................................................. 73
5.1.8 Inverter Module Maintenance ...................................................................... 74
5.2 Maintenance Log ...................................................................................................... 75
6. Specifications ....................................................................... 76
6.1 Specifications, XM Series 2 power supplies ............................................................ 76
6.2 Electrical Specifications, 60V, 90V models .............................................................. 77
6.3 Safety and EMC Compliance ................................................................................... 78
7. Product Support ................................................................... 79
7.1
7.2
7.3
7.4
7.5
Troubleshooting ........................................................................................................ 79
Return/Repair Information ........................................................................................ 79
Parts Ordering Instructions ...................................................................................... 79
Contacting Alpha Technologies ................................................................................ 79
Emergency Shutdown .............................................................................................. 80
017-805-B0-005 Rev. D
5
Preface
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1-1
1-2
1-3
1-4
1-5
1-6
1-7(a)
1-7(b)
1-8
1-9
1-10
1-11
1-12
1-13
1-14
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
4-1
4-2
4-3
4-4
4-5
4-6
7-1
XM Series 2 Power Supply ...............................................................................................
Simplified Block Diagram ..................................................................................................
Charger Modes .................................................................................................................
Transformer Module Connections .....................................................................................
Inverter Module Voltage Rating Labels .............................................................................
Smart Display ...................................................................................................................
Inverter Module Connections ............................................................................................
Inverter Module Connections ............................................................................................
Location of Temperature Probe ........................................................................................
USM 2 Communication Module ........................................................................................
USM 2.5 Communication Module .....................................................................................
USM 2.5 Communication Module with Embedded Transponder ......................................
XM Series 2 Power Supply Web Status Monitoring Module (Statusphere) ......................
Digital Status Monitor (DSM) ............................................................................................
Serial System Controller (SSC) ........................................................................................
Exploded view, AC Indicator lamp ....................................................................................
Wire/connector assembly .................................................................................................
ACI connection .................................................................................................................
Inverter Module Ribbon Cable ..........................................................................................
Detail of Locking Mechanism ............................................................................................
Transformer/PDB Connection with Standoff .....................................................................
Transformer Wire, Output Fuse Wire PDB Connection via "Fast-On" Connectors ...........
J6 and J4 Connection as seen from rear of Power Supply ..............................................
Location of JP1 on PIM ....................................................................................................
Shunt in 15A position ........................................................................................................
Shunt in 22A position ........................................................................................................
Completed assembly, PIM and PDB .................................................................................
Front Panel Configuration .................................................................................................
Dual Redundancy Configuration .......................................................................................
SPI Cover Removal ...........................................................................................................
Coaxial Cable insertion and Securing ..............................................................................
Cover Replaced, SPI Switched ON ..................................................................................
SPI Grounding Lug ...........................................................................................................
Enclosure Ground Bar ......................................................................................................
Power Distribution Board ..................................................................................................
Typical NEMA Receptacles and Plugs .............................................................................
Transformer Module Input Jumpers, PDB Jumpers ..........................................................
SW2 Settings ....................................................................................................................
Typical NEMA Receptacles and Plugs .............................................................................
Transformer Module Input Jumpers, PDB Jumpers ..........................................................
SW2 Settings ....................................................................................................................
Output Tap Connector .......................................................................................................
Configuration Screen ........................................................................................................
Smart Display ...................................................................................................................
Operation Normal Display .................................................................................................
Additional Info Display ......................................................................................................
Setup Menu Display ..........................................................................................................
Control Panel LEDs ..........................................................................................................
Emergency Shutdown .......................................................................................................
15
16
17
18
19
19
20
21
21
22
22
22
23
23
23
28
28
29
30
30
33
33
34
35
35
35
35
38
39
40
40
41
41
41
42
44
45
45
46
47
47
48
50
53
54
55
58
62
80
Tables
Table 3-1
Table 3-2
Table 4-1
Table 4-2
Table 6-1
Table 6-2
6
Power Distribution Board Setup ........................................................................................
Output Voltage Reconfiguration ........................................................................................
Major Alarms .....................................................................................................................
Minor Alarms .....................................................................................................................
Series Specifications ........................................................................................................
Electrical Specifications ....................................................................................................
43
48
60
61
76
77
017-805-B0-005 Rev. D
Preface
Important Safety Instructions
Contained In This Manual
Read This Manual Before Proceeding!
Become familiar with the power supply’s front panel. Review the drawings and illustrations contained in
this manual before proceeding. If there are any questions regarding the safe installation or operation of the
XM Series 2 Uninterruptible Power Supply, contact Alpha Technologies or the nearest Alpha representative.
Save this document for future reference.
To reduce the risk of injury or death caused by electrical shock, explosion of fuel or moving parts; 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.
DANGEROUS VOLTAGE
This symbol indicates a “dangerous voltage” may exist in this area of the product. Use caution
whenever working in the area to prevent electrical shock.
INHALATION HAZARD - DON’T BREATHE VAPORS
This symbol indicates an “inhalation hazard” may exist in this area of the product. Use caution
whenever working in the area to prevent possible inhalation of harmful (fuel or exhaust) vapors.
NO MATCHES OR OPEN FLAMES
This symbol indicates a “fire or explosive hazard” may exist in this area of the product. Use
caution whenever working in the area to prevent possible combustion of fuel vapors.
MECHANICAL OR MOVING PARTS HAZARD
These symbols indicate a “mechanical or moving parts hazard” may exist in this area of the
product. Use caution whenever working in the area to prevent possible injury to the operator or
service personnel.
LEAK HAZARD
This symbol indicates a “leak hazard” may exist in this area of the product. Use caution whenever
working in this area to prevent and correct any leaks detected.
ATTENTION
This symbol indicates important installation, operation or maintenance instructions. Always
follow these instructions closely.
NOTE: Alpha Technologies’ products are subject to change through continual
improvement processes. Therefore, specifications and/or design layouts
may vary slightly from descriptions included in this manual. Updates to
the manual will be issued when changes affect form, fit or function.
017-805-B0-005 Rev. D
7
Preface
Safety Precautions
• The XM Series 2 Power Supply must be serviced only by qualified personnel.
• Verify the voltage requirements of the equipment to be protected (load), the AC input voltage
to the power supply (line), and the output voltage of the system prior to installation.
• The utility service panel must be equipped with a properly rated circuit breaker for use with
this power supply.
• When connecting the load, DO NOT exceed the output rating of the power supply.
• Always use proper lifting techniques whenever handling units, modules or batteries.
• The XM Series 2 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, they should be charged at least once every
three months 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, used to provide backup power, contains dangerous voltages. Battery
inspection and replacement must be performed by qualified personnel.
• Batteries present a risk of electrical shock and burns from high current in the event of a
short-circuit. Observe proper safety precaurtions.
• 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.
• Do not allow live battery wires to contact the enclosure chassis. Shorting battery wires can
result in a fire 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 considered environmentally unsafe. Always recycle used
batteries. Refer to local codes for proper disposition of batteries
8
017-805-B0-005 Rev. D
Preface
Battery 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. Please refer to Section 1.3.2, XM Series 2 Power Supply Inverter
Module (step 5) for instructions regarding the connection of the Remote Temperature Sensor
(RTS).
• If the batteries appear to be overcharged or undercharged, first check for defective batteries
and then verify the correct charger voltage settings.
• Batteries must be inspected every three to six months for signs of cracking, leaking, or unusual
swelling (Note: some swelling is normal) to ensure optimum performance.
• Check battery terminals and connecting wires. Battery terminal connectors should be cleaned
periodically and retightened to approximately 50 inch-pounds. Spray the terminals with an
approved battery terminal coating such as NCP-2.
NOTE: If installed, disconnect the Battery Box–Charge Management Technology Card
(BB–CMT) prior to measuring battery voltage.
NOTE: Even with a BB–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 identification (refer to the
Enclosure Installation Guide).
• Establish and maintain a battery maintenance log.
017-805-B0-005 Rev. D
9
Preface
Utility Power Connection Notes
CAUTION:
The following should be performed ONLY by qualified 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.
NOTE:
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.
IMPORTANT NOTE
In order to accommodate the high-inrush currents normally
associated with the start-up of ferroresonant transformers (400 Amp,
no-trip, first-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 ONLY recommends Square D breakers because of
increased reliability in this powering application.
High-magnetic Square D circuit breakers are available from Alpha Technologies, as well as a BBX option
which is a UL Listed service entrance.
Description
Alpha P/N
Square D P/N
240V Installation —
Heating, Air Conditioning, Refrigeration (15A)
470-224-10
Q0215
120V Installation —
High Magnetic (20A)
470-017-10
Q0120HM
120V Installation —
High Magnetic (15A)
470-013-10
QO115HM
BBX — Ext. Service Disconnect
020-085-10
Q02-4L70RB
Wiring: (from duplex receptacle to service disconnect)
In most cases, the following configurations (see next page) qualify for service entrance use, however,
other codes may apply. Always contact your local utility to verify that the wiring conforms to applicable
codes.
10
017-805-B0-005 Rev. D
Preface
Utility Power Connection Notes
120VAC 15A service (XM Series 2 615):
These configurations are equipped with a 120VAC duplex receptacle which provides power to the
power supply and peripheral equipment. The receptacle, NEMA 5-15R, is protected by a single-pole,
15 Amp High Magnetic (HM) circuit breaker located inside the service entrance. Wiring is typical
14AWG per NEC code, and a grounding clamp, located on the enclosure, facilitates dedicated
grounding.
120VAC 20A service (XM Series 2 915-120):
These configurations are equipped with a 120VAC duplex receptacle which provides power to the
power supply and peripheral equipment. The receptacle, NEMA 5-20R, is protected by a single-pole,
20 Amp High Magnetic (HM) circuit breaker located inside the service entrance. Wiring is typical
12AWG per NEC code, and a grounding clamp, located on the enclosure, facilitates dedicated
grounding.
NOTE: When it is required to bond box to neutral plate, use the long green bonding
screw that is provided (Alpha p/n 523-011-10, Square D p/n 40283-371-50).
to utility
L1 (black)
neutral (white)
Copper ground wire
#8 awg (minimum)
breaker
neutral bus
grounding point made
to enclosure wall
L1 (black)
to enclosure
receptacle
Typical 120VAC Service Entrance Wiring
15 Amp Receptacle -- 5-15R
20 Amp Receptacle -- 5-20R
(P/N 531-003-10)
(P/N 531-006-10)
L1
L1
(black)
(black)
neutral
neutral
(white)
ground
(green)
Typical 120VAC 15A
Receptacle Wiring
017-805-B0-005 Rev. D
(white)
ground
(green)
Typical 120VAC 20A
Receptacle Wiring
11
Preface
Utility Power Connection Notes
240VAC service (XM Series 2-915-240, XM Series 2-922-240):
These configurations are equipped with a 240VAC duplex receptacle to provide power to the power
supply and peripheral equipment. The receptacle, NEMA 6-15R, is protected by a single, 2-pole,
common trip 15 Amp circuit breaker located inside the service entrance. Wiring is typical 14AWG per
NEC code, and a grounding clamp, located on the enclosure, facilitates dedicated grounding.
NOTE: When it is required to bond box to neutral plate, use the long green bonding
screw that is provided (Alpha p/n 523-011-10, Square D p/n 40283-371-50).
to utility
L1 (black)
L2 (red)
Copper ground wire
#8AWG (minimum)
breaker
neutral (white)
neutral bus
Grounding point made
to enclosure wall
L1
to enclosure
receptacle
L2
Typical 240VAC Service Entrance Wiring
L1
(black)
L2
(red)
ground
(green)
Typical 240VAC 15A Receptacle Wiring
6-15R
12
(P/N 531-004-10)
017-805-B0-005 Rev. D
Preface
Grounding Connection Notes
In order to provide a ready, reliable source of backup power it is necessary to establish a grounding
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 will provide protection with respect to operator safety, system
communication, and equipment protection.
Safety Ground
The safety ground is a two-part system. The first part is a return path for stray current back to the
input breaker, and the second is a return path from the Alpha enclosure to a second ground rod.
Typically, the safety, or utility ground, provides a return path to the input breaker or fuse panel by
means of a connection to an appropriate driven ground rod at the base of the power pole. This path
must meet National Electric Code (NEC) as well as local codes to ensure the breaker will open,
preventing unwanted current flow from posing a hazard to service personnel.
The second part of the safety ground arrangement is the ground path between the Alpha enclosure
and a second ground rod located at least 6 feet away from the driven ground rod at the power pole.
The second ground rod and enclosure are connected via an AWG #6 solid copper wire buried at a
depth of 8-12 inches. The wire is connected to the cabinet by means of a ground lug on the back of
the cabinet (for pole-mounted enclosures), or to a ground lug inside the cabinet (for ground-mounted
enclosures), and connected to the ground rod by means of a listed grounding clamp suitable for
direct burial, or exothermic weld. Normally it is specified that the impedance of this ground can be no
greater than 25 ohms at 60 Hertz. If, however, dual ground rods are installed approximately eight feet
apart, it is not necessary to measure the impedance of the ground rods to meet the maximum 25
ohms specification—it is assumed that the impedance specification is met.
Signal Ground
For proper operation, the Service Power Inserter must be securely grounded to the enclosure
chassis. This is of particular importance in systems utilizing an external status monitoring
transponder. The transponder chassis is grounded via a separate ground wire to the SPI case. For
systems utilizing an embedded transponder, the ground connection is made either through a
separate chassis ground block, or by means of the internal mounting hardware which then grounds
the transponder through the XM Series 2 Power Supply.
Strike (Lightning) Ground
Lightning strikes, grid switching, or other aberrations on the power line all have the potential to cause
“fast rise-time currents” which can cause damage to the powering system. Without a low-impedance
path to ground, the current, while traveling through wires of varying impedance, can produce high
voltages which will damage the powering equipment. The most viable method available to protect the
system from damage is to divert these unwanted “fast rise-time currents” along a low-impedance
path to ground. A low-impedance path to ground will prevent these currents from reaching high
voltage levels and posing a threat to equipment. The single-point grounding system provides a lowimpedance path to ground, and the key to its success is the proper bonding of the ground rods, so
the components of the grounding system appear as a single point of uniform impedance.
Low impedance grounding is not only critical for the proper operation of the cable system, but
also is mandatory for personnel safety.
017-805-B0-005 Rev. D
13
1. Introduction
1.1 The XM Series 2 Power Supply
The Alpha XM Series 2 Power Supply family of Uninterruptible Power Supplies (UPS) is designed for powering
signal processing equipment in Cable Television and Broadband LAN distribution systems. The power supply,
which consists of an XM Series 2 Power Supply power module, provides the critical load with current-limited,
regulated AC power that is free from disturbances such as spikes, surges, sags, noise, brownouts or blackouts.
During AC line operation, AC power enters the power supply and is converted to a “quasi” square wave and
regulated (at the required output voltage) by the ferroresonant transformer. This regulated, “quasi” square
wave voltage is connected to the load via the Output Connector. At the same time, some power is directed to
the battery charger to maintain a float charge on the batteries.
When the incoming AC line voltage significantly deviates from normal, or a utility power outage occurs, the
XM Series 2 Power Supply Inverter Module automatically switches to standby (inverter) operation in order to
maintain power to the load. During the switch to standby operation, energy contained in the module’s
ferroresonant transformer continues to supply power to the output. Standby power will continue to power the
load until the battery voltage reaches a low-battery voltage. When utility line power returns, the XM Series 2
Power Supply power module waits a short time (approximately 10 to 20 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 quickly recharges the batteries in preparation for the next utility power
outage.
NOTE: The duration of battery-backed standby operation depends upon the type and
number of batteries used and the load on the power supply.
The XM Series 2 Uninterruptible Power Supply contains an impressive list of features which includes a builtin self test, battery test, and a Smart Display. The Smart Display allows the operator to 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. Any active alarm that may be
present is automatically indicated in the display in place of the operating parameters. This conveniently
allows the operator to immediately see what fault has been detected. Troubleshooting tips to remedy the
problem are automatically displayed in the Alarm menu screen. Voltage and current measurements are
easily accomplished via the built in metering circuits, without the need for external test equipment. Front
panel test points are provided in the event that the operator needs (or wants) to perform manual measurements.
The Protective Interface Module (PIM) option allows the XM Series 2 Uninterruptible Power Supply to function
in an N+1 redundant supply system and also provides programmable current limits for two output channels.
14
017-805-B0-005 Rev. D
1. Introduction
1.2 Theory of Operation
The modular XM Series 2 Power Supply is comprised of the Transformer Module, which can act as a standalone line conditioner; the Inverter Module, required for inverter operations; and the optional Communications
Module, used to provide external status monitoring and communications. The ferroresonant (or optional
CFR, Controlled Ferroresonant) transformer, resonant capacitor, transfer isolation relay are all part of the
Transformer Module. The Inverter Module has all the necessary circuitry needed for the three-stage
temperature-compensated battery charger, DC to AC converter (inverter), AC line detectors, and the Smart
Display.
Transformer
Module
Inverter
Module
Communications
Module
Figure 1-1 XM Series 2 Power Supply
1.2.1 AC (LINE) Operation
During AC Line operation, utility power is routed into the primary winding of the ferroresonant
transformer through the contacts of the transfer isolation relay. At the same time, power is directed to
the rectifier circuitry in the inverter which provides 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 will not provide an accurate reading when measuring a
“quasi” square wave output.
017-805-B0-005 Rev. D
15
1. Introduction
1.2 Theory of Operation, continued
1.2.2
Standby Operation
When the incoming AC line voltage drops or rises significantly, 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 on-line as the isolation relay switches to
prevent AC power from back-feeding to the utility. Also, the energy contained in the ferroresonant
transformer continues to supply power to the load. Additionally, the following changes occur within the
XM Series 2 Power Supply: the isolation relay opens to disconnect the AC line from the primary
winding of 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 which provides 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 AC line voltage returns, the power supply transfers back to AC line operation within 10 to 20
seconds. This delay allows the AC line voltage and frequency to 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 is then activated to recharge the batteries in
preparation for the next power outage.
Transponder
,QYHUWHU0RGXOH$VVHPEO\
Power Distribution Board
Optional
Communications
Card
AC1
AC Line Detector and
Control Logic
Circuits
AC2
Control Bus
5HOD\
&RQWURO
Remote
Temperature
Sensor
Battery
Circuit Breaker
K1
RED
RED
BLK
BLK
(+)
,QYHUWHU
RV2
(-)
RV1
RV3
&
Batteries
2XWSXW6HOHFW
90VAC
75VAC
60VAC
%/.
:+7
5('
2XWSXW)XVH
%/.
:+7
%/.
$&2XWSXW
120VAC
Jumper
240VAC
Jumper
Transformer
,QSXW6HOHFW
$&2XWSXW
$&2XWSXW
$&2XWSXW
3,02SWLRQ
Figure 1-2 Simplified Block Diagram
16
017-805-B0-005 Rev. D
1. Introduction
1.2 Theory of Operation, continued
1.2.3
Charger Operation
The XM Series 2 Uninterruptible Power Supply 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. This current is the maximum which the charger is
capable of delivering; 10A for 615, 915, and 922 models, 5A for 608 and 610 models. As the charge
is returned to the batteries, their voltage increases and, when a specific threshold is reached,
2.25VDC per cell, the charger switches to ACCEPT mode. The BULK charger mode generally returns
the battery charge state to 80 percent of rated battery capacity. BULK charge is not a temperature
compensated battery charge.
ACCEPT charge is a "Constant Voltage" charge. This voltage, 2.35VDC (adjustable) per cell, is
temperature compensated to ensure longer battery life and properly completes the charge cycle. This
cycle is complete when the charging current into the batteries becomes less than 0.5A, or 6 hours
elapses from the time ACCEPT mode was entered. At this time, the batteries are fully recharged and
the charger switches to the FLOAT mode of operation.
FLOAT charge is a temperature compensated, "Pulsed Current" charge, averaging about 2.25VDC
(adjustable) per cell. During FLOAT mode, the batteries are fully charged and ready to provide
backup power. The charger provides the small maintenance charge pulse 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.
During ACCEPT and FLOAT modes, the cell voltage is temperature compensated at -0.003VDC per
cell per degree C (adjustable) to ensure a safe battery cell voltage and maximize battery life.
2.35
2.25
2.15
Volts Per Cell
2.05
10
9
Charger Current
8
7
6
5
4
3
2
1
Bulk
Accept
Float
Time
Figure 1-3 Charger Modes
017-805-B0-005 Rev. D
17
1. Introduction
1.3 XM Series 2 Power Supply Layout
1.3.1
Transformer Module
1.
AC Output Fuse — A 30A Slow Blow fuse is used in all XM Series 2 Power Supply (Buss Fuse
Model BKMDA 30 — Alpha p/n 460-179-10, or Littlefuse model 326-030). For increased durability,
the fuse is protected by an integrated fuse guard (see inset below).
2.
OUTPUT N L (Test Point) —The XM Series 2 Power Supply’s AC Output can easily be checked
by using the Transformer Module’s OUTPUT test point. Only use a true RMS AC Voltmeter
equipped with the proper test probes, whenever checking the output, other meters may give
false or inaccurate readings.
3.
N+1 (Optional) —The N+1 ports are used in redundant system configurations where multiple
power supplies are housed in a single enclosure. If a power supply fails, a redundant power
supply is automatically switched into service with approximately an 8mS delay. This feature is
part of the PIM option.
4.
OUTPUT 1 — White = Neutral; Black = Line. The AC output connector is clearly marked and
color-coded for easy identification. The Service Power Inserter (SPI), which couples power to
the load connects directly into the OUTPUT 1 connector.
5.
OUTPUT 2 (Optional) — White = Neutral; Black = Line. The AC output connector is clearly
marked and color-coded for easy identification. The Service Power Inserter (SPI), which couples
power to the load connects directly into the OUTPUT 2 connector. This feature is part of the
PIM option.
6.
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, and flashing the lamp when a major alarm is detected,
indicating service is required.
7.
SSR - Standby Status Relay —The SSR connector is used to supply a dry “form C” contact for
systems requiring remote alarms. The white connector is common. The red connector is normally
configured “Normally Open” (contacts close
when alarm is present), but can be configured
“Normally Closed” (contacts open when
alarm is present) by moving the JP3 jumper,
located on the Power Distribution Board, from
the “NO” position to the “NC” position.
1
NOTE:
Effective late-2002, the
SSR feature will be
removed from the XM
Series 2 Power Supply.
3
5
2
7
4
6
Figure 1-4 Transformer Module Connections
18
017-805-B0-005 Rev. D
1. Introduction
1.3 XM Series 2 Power Supply Layout, continued
1.3.2
Inverter Module
The removable Inverter Module serves to provide 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.
IMPORTANT NOTE
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 that 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 IM and on the inside chassis floor.
Yellow
Green
Blue
36VOLT
48VOLT
48VOLT
1350VA
2000VA
953-527-11-001
953-527-12-001
953-527-10-001
Figure 1-5 Inverter Module Voltage Rating Labels
1.
Smart Display — All operational functions, system testing, setup items, and alarms are available
via the illuminated display panel on the front of the XM Series 2 Power Supply. Display functions
are accessible by pressing any of the four keys: ESCAPE, UP arrow, DOWN arrow, and ENTER.
Backlighting on the display illuminates when any of the four keys are pressed and stays
illuminated for a period of one hour. There are four (4) levels of menu items; Normal operation,
Additional Information, Setup, and Alarms. Pressing the ENTER key will sequence the display
one level lower, pressing the ESCAPE key will sequence the display one level higher. The
Smart display is covered in detail in section 4.2.
1
Figure 1-6 Smart Display
017-805-B0-005 Rev. D
19
1. Introduction
1.3 XM Series 2 Power Supply Layout, continued
1.3.2
Inverter Module, continued
2.
BATTERY BREAKER — The BATTERY (Circuit) BREAKER is used to disconnect the batteries
from the Inverter Module’s DC circuit. With the BATTERY BREAKER turned OFF, the XM Series
2 Power Supply will not transfer to standby mode, the inverter is disabled, and the battery
charger is unable to charge the batteries. If over current is detected in the DC circuitry, or
battery polarity is accidently reversed, the breaker will trip.
3.
BATTERY INPUT Connector — Red = Positive; Black = Negative. The batteries plug directly
into the Inverter Module’s battery connector. The connector is color-coded and fits in one direction
only.
NOTE:
4.
Always verify proper polarity of cables before connecting the batteries
to the power module. Polarity is clearly marked for easy identification. If,
for some reason, the cables become interchanged at the batteries, the
BATTERY BREAKER will trip.
BATT VOLT, Battery Test Point —With the Battery Breaker ON, and battery string(s) connected,
the XM Series 2’s DC Output can easily be checked by using the Inverter Module’s battery test
point. Use a DC Voltmeter whenever checking the output.
Integrated Circuit
Breaker Guard
2
3
4
Figure 1-7 (a) Inverter Module Connections
20
017-805-B0-005 Rev. D
1. Introduction
1.3 XM Series 2 Power Supply Layout, continued
1.3.2
5.
6.
Inverter Module, continued
TEMP PROBE, Temperature Probe
Connector — The Remote Temperature
Sensor (RTS) plugs directly into the
temperature probe, “RJ-11C” type connector.
The sensor end of the RTS is routed into the
battery compartment and taped directly to
the side of the center battery (Figure 1-8
below) . This provides precise battery
temperature measurements in order to
accurately adjust the battery charge voltage
with changes in battery temperature. If the
remote temperature sensor is not connected
or defective, a temperature sensor in the
Inverter Module adjusts the battery charge
voltage with changes in ambient temperature
within the power supply.
6
Inverter Cooling Fan — The Inverter Module
is equipped with a cooling fan that will
operate during standby operation if the
inverter heatsink temperature is above 85°C
and stay on until the temperature has
dropped below 75°C. The fan will also
operate any time a self-test is in progress.
5
Figure 1-7 (b) Inverter Module Connections
5
Figure 1-8 Location of Temperature Probe
017-805-B0-005 Rev. D
21
1. Introduction
1.3 XM Series 2 Power Supply Layout, continued
1.3.3
Optional Status Monitoring Modules
The XM Series 2 Power Supply supports a number of Alpha Technologies communications modules.
The modules may be ordered factory-installed or as user-installed field upgrades.
Handle these modules with extreme care. Circuit boards and logic upgrades are staticsensitive and susceptible to damage.
Figure 1-9
USM 2 Communication Module
The USM2 card is a field-replaceable,
user-configured logic card that allows
the XM Series 2 Power Supply to be
configured for existing status
monitoring systems and is configured
for parallel applications. The USM2
facilitates use with all common
monitoring systems (specify vendor).
Figure 1-10
USM 2.5 Communication Module
The USM2.5 card is a fieldreplaceable, user-configured logic
card that allows the XM Series 2
Power Supply to be configured for
existing status monitoring systems
and is configured for parallel
applications. The USM2.5 facilitates
use with all common monitoring
systems (specify vendor). Additionally,
the USM2.5 has the ability to monitor
Utility line voltage.
Figure 1-11
USM 2.5 Communication Module
with Embedded Transponder
The Embedded Transponder allows for an
internal or “embedded” transponder to be
collocated in the communications slot of the
XM Series 2 Power Supply.
22
017-805-B0-005 Rev. D
1. Introduction
1.3 XM Series 2 Power Supply Layout, continued
1.3.3 Optional Status Monitoring Modules, continued
Handle these modules with extreme care. Circuit boards and logic upgrades are staticsensitive and susceptible to damage.
Figure 1-12
XM Series 2 Power Supply Web
Status Monitoring Module (Statusphere)
Alpha’s Web-based power
management enables
communication service
providers to manage the power
node via the use of a standard
Web browser. In addition to
managing communications and
environmental elements, the
Statusphere product allows the
user to view and change the
setpoints of the various XM
Series 2 Power Supply
components not only via an
RS-232 Serial
Communications port, but also
by means of a unit-specific
status monitoring Website.
Figure 1-13
Digital Status Monitor (DSM)
The all-digital interface from the
power supply to the transponder
utilizes a simple serial interface
cable. It eliminates the complex
parallel wire harness normally
used as well as the analog errors
characteristic of traditional
monitoring methods. Individual
battery voltages and enclosure
tamper are monitored from the
HMS. SCTE HMS022 compliant.
Figure 1-14
Serial System Controller (SSC)
In multiple XM Series 2 Power
Supply installations, the SSC
provides status monitoring functions
combined with coordinated battery
charging, as well as individual
battery charging, and self test for
individual components. The SSC
provides field technicians local
interface for programming system
parameters and system maintenance
data. SCTE HMS022 compliant.
017-805-B0-005 Rev. D
23
1. Introduction
1.4 Optional Features
The following options can be factory installed, or upgraded in the field by the user.
Universal Status Monitor 2 (USM2)
The USM2 is a field replaceable, plug-in logic card that allows the XM Series 2 Power Supply to be field or
factory configured for status monitoring systems and is configured for parallel applications. The USM2
facilitates use with common amplifier monitoring systems such as Scientific Atlanta “6585” (SA), Magnavox
“6DSS” (M) and “Lifeline” (LL), AM Communications “TMC-8061” (AM), Texscan “Vital Signs” (T), Tollgrade
(TG), C-COR “Quick Alert” (C), and Superior Electronics “Cheetah” (SEG). (Refer to the USM2 technical
manual — p/n 704-587-B0 for detailed information)
Universal Status Monitor 2.5 (USM 2.5) — USM 2.5 with Embedded Transponder
The USM2.5 is a field replaceable, plug-in logic card that allows the XM Series 2 Power Supply to be field
or factory configured for status monitoring systems and is configured for parallel applications as well as
line sense and embedded transponder capability. The USM2.5 facilitates use with common amplifier
monitoring systems such as Scientific Atlanta “6585” (SA), Magnavox “6DSS” (M) and “Lifeline” (LL), AM
Communications “TMC-8061” (AM), Texscan “Vital Signs” (T), Tollgrade (TG), C-COR “Quick Alert” (C),
and Superior Electronics “Cheetah” (SEG) The Embedded Transponder decreases the complexity of and
increases the reliability of interface/battery wiring, and is capable of directly monitoring four 36-volt battery
strings, or three 48-volt battery strings. It is also capable of Alpha Generator monitoring via a discrete
signal interface. (Refer to the USM2.5 technical manual — p/n 704-683-B0 for detailed information, or
the Addendum to USM2.5 Status Monitor technical manual — p/n 018-041-C0 for detailed information
regarding the Embedded Transponder).
Web Status Monitoring Module (Statusphere)
Alpha’s Web-based power management enables communication service providers to manage the power
node via the use of a standard Web browser. In addition to managing communications and environmental
elements, the Statusphere product allows the user to view and change the setpoints of the various Power
Supply components not only via an RS-232 Serial Communications port, but also by means of a unitspecific status monitoring Website. (Refer to the XM2 Web technical manual — p/n 018-327-C0 for
detailed information)
Serial System Controller (SSC)
The Serial System Controller (SSC) manages and provides status monitoring for powering systems that
contain single or multiple (up to six) power supplies and a generator. The module coordinates battery
charging, individual battery monitoring and self-testing for individual components of the system. By means
of a serial interface, an Engine Control Module (ECM) communicates with the SSC to manage generator
operation. (Refer to the SSC technical manual — p/n 018-332-C0 for detailed information)
Digital Status Module (DSM)
Alpha’s advanced Digital Status Module (DSM) is a status monitoring interface to the XM Series 2 Power
Supply, and is designed to monitor a single power supply and batteries via a standard Serial interface
(SCTE-HMS). Conveniently located inside of the XM Series 2 Power Supply, the DSM continuously gathers
enclosure, battery, and power supply data. This data is then transferred to an industry standard digital
transponder (DT) using a new serial interface specified by the HMS022 standard. The DT will quickly
assemble and prepare the data before sending it back to the head-end equipment and network monitoring
software. The software will graphically display the power supply health via a user-friendly interface. (Refer
to the DSM technical manual — p/n 018-331-B0 for detailed information)
24
017-805-B0-005 Rev. D
1. Introduction
1.4 Optional Features, continued
Protective Interface Module (PIM)
The PIM serves to protect system components by shutting down the load during over-current and short
circuit conditions. The PIM has an operator programmable over-current threshold (3A-24A) and a
programmable over-current tolerance period which specifies the time in seconds (1-10) that an overcurrent condition will be allowed on the XM Series 2 Power Supply output before the output is shut down.
A programmable retry limit allows the operator to select how many times (0-40) after a programmable
delay (5-301 seconds) the PIM will attempt to reconnect an output which has been shut down. Once the
limit is reached the XM Series 2 Power Supply will automatically retry once every 30 minutes until the fault
is cleared. The PIM also provides N+1 redundancy in system configurations and programmable dual outputs.
Local and Remote Indicator (LRI)
The LRI lamp (red) is located on the outside of pole-mount enclosures. During normal AC line operation,
the lamp remains OFF. The lamp comes ON only when the power supply is running in Standby Mode.
Whenever a fault is detected during self-test, the lamp flashes to indicate that service is required. The LRI
is a simple form of status monitoring by allowing operators to check the operational status of the power
supply without having to climb the pole and open the enclosure.
SSR - Standby Status Relay
The SSR connector is used to supply a dry “form C” contact for systems requiring remote alarms. The
white connector is common. The red connector is normally configured “Normally Open” (contacts close
when alarm is present), but can be configured “Normally Closed” (contacts open when alarm is present)
by moving the JP3 jumper, located on the Power Distribution Board, from the “NO” position to the “NC”
position.
NOTE:
Effective late-2002, the SSR feature will be removed.
AC Indicator (ACI)
The AC Indicator (green lamp) is located next to the LRI lamp on the outside of pole-mount enclosures. As
long as there is voltage present at the output, the ACI lamp remains ON. As with the LRI, this acts as a
simple form of status monitoring by allowing cable technicians to check the output status of the power
supply without having to climb the pole and open the enclosure. The ACI-LL, long life LED is recommended,
since it provides much longer life than the original light bulb design. Models for 60V and 90V are available.
ACIs are NOT recommended for ground mount enclosures.
LA-P+ — 120V, 240V (Lightning Arrestor)
The LA-P+ plugs directly into the enclosure’s convenience outlet, to provide additional protection from
voltage spikes caused by lightning and other power disturbances, eliminating the need for hard-wired
MOVs, no additional wiring is necessary. However, the Utility safety ground must meet NEC standards.
APP90S /APP9022S (Service Power Supply)
The APP90S/APP9022S is a portable, non-standby power supply used to provide conditioned AC power
to the load when the main power module is out of service. An internal tap allows the APP90S/APP9022S
to be set for 90/75/60VAC applications. Used in conjunction with the “Jones” connector and the “ALT/ON”
switch located on the enclosure’s 20Amp SPI (Service Power Inserter), power can be transferred from the
main power module to the XM90S without interrupting the connected load.
NOTE:
017-805-B0-005 Rev. D
The 25 Amp SPI is configured with an “AMP” connector.
25
2. Installation
2.1 Installation—General
To ensure operator safety:
• Power supplies must be installed only by qualified personnel and in accordance with applicable
electrical codes.
• Use eye protection whenever working with batteries.
• Use only sealed, lead-acid type batteries with a minimum rating of 55Ah (gelled-electrolyte
or equivalent).
Unpacking and Inspection:
Remove the XM Series 2 Power Supply from the shipping container. Verify that the power supply (including
Remote Temperature Sensor), and any other ordered options have been included.
• XM Series 2 Power Supply (including RTS).
• Any other ordered options.
Carefully inspect the contents of the shipping container. If any items are damaged or missing, contact
Alpha Technologies or the shipping company immediately. Most shipping companies have only a short
claim period.
Preinstallation Inspection:
1.
During shipping, movement of components may occur. Inspect the power supply for possible
shipping related failures, such as loosened or damaged connectors.
2.
Before installing the power supply, inspect the exterior for signs of damaged or loose components.
If needed, inspect the interior for loose or damaged connectors. Correct any discrepancies
before proceeding with the power supply installation.
3.
Do NOT attempt to install a damaged power supply without first passing a complete
Preinstallation Inspection and Start-up Test. Please refer to the “Preliminary Inspection/
Turn Up Checklist” (Alpha p/n 017-805-B5) which accompanies each power supply.
SAVE THE ORIGINAL SHIPPING CONTAINER:
Use the original shipping container if the XM Series 2 Power Supply needs to be returned for service. If the
original container is not available, make sure the unit is packed with at least three inches of shock-absorbing
material to prevent shipping damage.
NOTE: Do not use popcorn-type material. Alpha Technologies is not responsible for
damage caused by improper packaging on returned units.
26
017-805-B0-005 Rev. D
2. Installation
2.2 XM Series 2 Power Supply Installation
XM Series 2 Power Supply has been specially designed for shelf mounting within a variety of Alpha Enclosure
Systems.
INSTALLATION PROCEDURE
1.
Before installing the power supply, inspect for damage, loose connectors, or other potential
failures. Correct discrepancies before proceeding.
2.
Place the XM Series 2 Power Supply on the appropriate enclosure mounting shelf. The unit is
placed in the lower-right compartment of PME enclosures, the upper compartment of PWE,
UPE, UPE/M Enclosures, and on the equipment trays of PN Series enclosures.
3.
Switch OFF the BATTERY BREAKER. This will prevent the inverter from starting when the
batteries are first connected to the XM Series 2 Power Supply.
4.
Batteries are an important part of the XM Series 2 Power Supply. It is mandatory to properly
install and test all batteries, battery connections, and battery cables before connecting to the
power supply.
5.
After the batteries, battery connections, and battery cables have been tested, plug the quick
connects from the battery cable into the Inverter Module’s BATTERY INPUT connector. The
connector is keyed and color-coded to fit in one direction only.
6.
Plug the Remote Temperature Sensor into the TEMP PROBE connector located on the Inverter
Module assembly. Route the sensor end of the cable into the battery compartment, and attach
it to the side of the center battery (please refer to page 21 for illustration).
7.
If remote alarms are included in the installation, the cable will be plugged into the module’s
SSR connector.
NOTE:
Effective late-2002, the SSR feature will be removed from the XM Series
2 Power Supply.
8.
If the optional LRI lamp (Local / Remote Indicator) is included, plug the LRI cable into the LRI
connector.
9.
If USM2, or USM 2.5 status monitoring is used, plug in the tamper switch into the 2 pin TMPR
connector and plug the transponder cable into the 13 pin XPDR connection on the USM2, or
USM 2.5.
10. Plug the connector from the SPI(s) into the module's “OUTPUT 1 and (optional) OUTPUT 2
connector(s). Verify the SPI’s “ALT/ON” switch is in the ON position.
NOTE:
017-805-B0-005 Rev. D
OUTPUT 2 is only available if the optional PIM (Protective Interface
Option) is installed.
27
2. Installation
2.3 Installing the optional AC Indicator Lamp
NOTE: If the system configuration includes an ACI lamp option, install per the following
instructions.
ACI Option — The AC indicator (green lamp) is located on the outside of the enclosure. When the lamp is
ON, it indicates AC power is available at the power supply output. This enables service personnel to determine
the status of the power supply without having to climb the pole.
Tools required:
Assorted hand tools
INSTALLATION PROCEDURE:
1.
Remove rear-most knockout.
2.
Feed ACI wires through hole.
3.
Slide locking nut over wires, and thread onto lamp body (Figure 2-1).
E n c lo s u re W a ll
Figure 2-1 Exploded view, AC Indicator lamp
4.
Insert the crimped contacts into the plastic connectors. The BLACK wire must always go into
the BLACK connector. Insert the remaining wire (may be white, yellow, or blue in color) into the
WHITE connector (Figure 2-2).
NOTE: Failure to properly position contact will result in overheating, and cable
assembly failure.
NOTE: To remove a wire from a plastic connector, depress the metal retainer with a
small screwdriver, and slide the wire out.
Top View
White or Yellow or Blue Wire
White Connector
Black Connector
Verify contact snaps
over metal retainer.
Black Wire
Side View
Figure 2-2 Wire/connector assembly
28
017-805-B0-005 Rev. D
2. Installation
2.3 Installing the optional AC Indicator Lamp, continued
5.
The shorter BLACK/WHITE set of wires should be connected to the BLACK/WHITE wires leading
from the SPI. The remaining longer set of wires should go to the OUTPUT connector on the
front of the XM Series 2 power supply (Figure 2-3).
LRI
ACI
SPI
LRI
Output 1
Figure 2-3 ACI connection
Installation is complete. DO NOT switch ON the Inverter Module’s BATTERY BREAKER, or
apply AC power to the power supply. Go to Start-up Test (Section 4.1, Start-up and Test).
017-805-B0-005 Rev. D
29
2. Installation
2.4 Inverter Module Removal and Installation
The XM Series 2 Power Supply power module comes with a field-replaceable Inverter Module assembly
containing the inverter and control logic. The Inverter Module is designed to accept optional communications
modules to facilitate remote status monitoring. The removable module is located on the front, right-hand side
of the XM Series 2 Power Supply.
CAUTION:
ALWAYS switch the Battery Breaker OFF prior to removing or installing
the Inverter Module assembly.
NOTE:
The Inverter Module assembly can be removed while the power supply is
running on line power. The XM Series 2 Power Supply will continue to operate
as a non-standby power supply.
NOTE:
When reinstalling the Inverter Module, verify the metal shield is properly seated
in the card guides and fully inserted into the housing.
Handle the Inverter Module with extreme care. Circuit boards and logic upgrades are
static-sensitive and susceptible to damage.
REMOVAL PROCEDURE:
1.
Turn OFF the BATTERY BREAKER. Disconnect the
BATTERY INPUT, and the TEMP PROBE cables from
the Inverter Module. Disconnect the TMPR and XPDR
cables from the Communication Module.
2.
Loosen the thumbscrews.
3.
To remove the Inverter Module assembly, grasp the
handle on the right side of the Inverter Module. Pull
firmly to release the module from the inverter
connector. Gently slide the module assembly straight
out until the Inverter Module ribbon cable connector
is accessible. Unlock the retaining clips on the ribbon
cable and disconnect the Inverter Module ribbon
cable. The Inverter Module has been designed to be
removed while the power supply is operating on AC
line power.
Disconnect
Disconnecthere
here
Figure 2-4
Inverter Module Ribbon Cable
INSTALLATION PROCEDURE:
1.
30
To reseat the Inverter Module assembly, align the
metal shield in the card-guides; reconnect the Inverter
Module ribbon cable and slide the Inverter Module
back onto the connector. The thumbscrews are not
intended to aid in making this connection, but to
secure the Inverter Module to the chassis.
2.
Retighten the thumbscrews.
3.
Verify that the BATTERY BREAKER is still OFF,
reconnect the BATTERY INPUT, the TEMP PROBE
cables, the TMPR and XPDR cables, and then finally
turn the BATTERY BREAKER ON.
UNLOCK
Figure 2-5
Detail of Locking Mechanism
017-805-B0-005 Rev. D
2. Installation
2.5 Protective Interface Module (optional)
The optional Protective Interface Module (PIM) option adds a second output and allows the XM Series 2
Uninterruptible Power Supply to function in an N+1 redundant supply system and also provides programmable
current limits for two output channels.
It also protects system components by shutting down the load during over-current and short circuit conditions.
The PIM has an operator-programmable over-current threshold (3A-24A) and a programmable over-current
tolerance period which specifies the time in seconds (1-10) that an over-current condition will be allowed on
the output before the output is shut down. A programmable retry limit allows the operator to select how many
times (0-40) after a programmable delay (5-301seconds) the PIM will attempt to reconnect an output which
has been shut down. Once the limit is reached the XM Series 2 Power Supply will automatically retry once
every 30 minutes until the fault is cleared. The PIM also provides N+1 redundancy in system configurations
and programmable dual outputs. There are three distinct benefits for adding the PIM to the XM Series 2
Power Supply:
1.
Provide a second, isolated output — The main purpose of the PIM is to limit the impact of a
fault condition to one output channel. If a fault condition were to occur on a standard XM Series
2 Power Supply (without the optional PIM installed), the entire network of customers would be
affected. The PIM option affords protection to one output should a fault condition exist on the
other. This gives the user flexibility to isolate Output #1 from Output #2. Consideration must be
given to the case of a reconnecting load. During a reconnect, the XM Series 2 Power Supply is
unable to distinguish between a fault and normal inrush current. As a result, it is possible that
the “good” channel may be temporarily affected during the Over-Current Tolerance Period created
by reconnecting the load. To minimize this impact, the Over-Current Tolerance Period should
be reduced.
2.
Ensure current for critical loads — The PIM enables the user to designate one output as the
primary connection, and the other output as the secondary connection. Commonly, critical
loads are connected to output #1 as the primary feeder. Via the Over-Current Limit settings, the
user can ensure that the primary output always provides the necessary power. For example, on
a 15 Amp power supply, if the customer needs 10 Amps available on output #1, the OverCurrent Limit for output #2 would be set at 5 Amps. This example demonstrates that regardless
of output #2, 10 Amps will remain available for the primary output, #1.
3.
Additional current protection — The standard XM Series 2 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. The user can lower the maximum current provided at each output by lowering
the Over-Current Limit of each respective output, #1 or #2. Therefore, to minimize failures due
to excess current supply, set the Over-Current Limit to a value below the maximum current the
active components can tolerate.
XM2 load
Allowed duration of load
> 150%
125% to 150%
115% to 125%
115%
10 seconds
10 minutes
30 minutes
Many months
For example, on a 15 Amp 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 first action is to disconnect Output 2. If this does not correct the system overload, then the next action is
to disconnect Output 1.
017-805-B0-005 Rev. D
31
2. Installation
2.6 Installing the PIM
NOTE: Installation of the optional Protective Interface Module must ONLY be performed
by qualified personnel.
WARNING:
Before proceeding, make certain ALL power has been removed 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 Philips head screwdriver (offset or “stubby”).
9/32” Nut driver
Supplies Required:
Qty.
Description (Part number)
1
Protective Interface Module assembly (p/n 744-799-20)
INSTALLATION PROCEDURE (Refer to figures on following page):
1. Completely shut down the XM2 power supply, verify ALL power is removed. 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 XM2 power supply.
2. Remove the Transformer Module’s front panel by removing the five front panel screws.
Lift the front panel up and away from the chassis, the front handle and output fuse
remain in place.
3. Use a right-angled (90°) Philips-head screwdriver to remove the Output Fuse Wire
(A). This wire may be connected to the PDB either by a standoff (Figure 2-6) or "FastOn" connector (Figure 2-7).
4. Remove the transformer wire (B) . This wire may be connected to the PDB either by a
standoff (Figure 2-6) or "Fast-On" connector (Figure 2-7).
5. At this time, remove the factory-installed bus bar (E) between the standoffs marked
P13 (D), and P16 (C).
32
017-805-B0-005 Rev. D
2. Installation
2.6 Installing the PIM, continued
A
E
D
C
B
Figure 2-6 Transformer/PDB Connection with Standoff
B
A
Figure 2-7 Transformer Wire, Output Fuse Wire PDB Connection via "Fast-On" Connectors
NOTE: The transformer wire on earlier units may be yellow with a black trace.
017-805-B0-005 Rev. D
33
2. Installation
2.6 Installing the PIM, continued
6.
Align the holes in the PIM circuit board labeled P3, P5, and P4 with the standoffs (P13, P15,
and P16) on the Power Distribution board. Place PIM circuit board on the standoffs, and
make the J6/J4 connection. Verify the pins of J6 are correctly aligned and completely seated in
J4.
7.
Using provided 6-23 hardware, reattach output fuse wire at P5 (on PIM board).
8.
Using provided 6-23 hardware, reattach the 0-Volt wire from the transformer to P4 (XMS21350/-922 models only).
9.
Securely tighten the three 6-32 screws (P3, P5, and P4) which fasten the Protective Interface
Module circuit board to the Power Distribution circuit board (P13, P15, and P16).
NOTE: The screws must be tight because high current passes through the standoffs, and
to reduce the possibility of arcing which could lead to a failure on the board. The
6-32 fastening hardware (with or without standoff) is tightened to a torque
specification of 14 inch-pounds.
P5 (Output fuse wire)
P4 (0-Volt wire)
P3
J4
J6
P16
P13
Figure 2-8 J6 and J4 Connection as seen from rear of Power Supply (P15 not shown)
34
017-805-B0-005 Rev. D
2. Installation
2.6 Installing the PIM, continued
NOTE: The output current limit for the PIM is set by the position of the shunt on JP1. Verify
JP1 is configured to the proper current setting; either 15A or 22A.
Figure 2-9 Location of JP1 on PIM
Figure 2-10 Shunt in 15A position
P4
Figure 2-11 Shunt in 22A position
P5
J4
P3
(Front of Power Supply)
Figure 2-12 Completed assembly, PIM (Protective Interface Module) and PDB (Power Distribution Board)
10. Replace the front panel.
11. Using approved methods, as outlined in Section 2.2, install the XM Series 2 power supply into
the enclosure.
12. Go to the Smart Display SETUP menu to program the PIM.
017-805-B0-005 Rev. D
35
2. Installation
2.7 Programming the PIM
Programmable Parameters (when PIM is installed)
Channel 1 Over-current limit — The RMS current level that causes, after a specified delay,
the Output 1 protection relay to trip. [RETRY DELAY]
Channel 2 Over-current limit — The RMS current level that causes, after a specified delay,
the Output 2 protection relay to trip. [RETRY DELAY]
Retry Delay — In the event of an over-current event, this is the time between each attempt to
restart an output.
Retry Limit — The number of times the XM Series 2 Power Supply will attempt to restart an
output connection at the frequency specified by RETRY DELAY. Once RETRY LIMIT is
exceeded, attempts to restart the output connection will occur once every thirty (30) minutes
for an indefinite period of time. Setting this parameter to "zero" disables the "automatic
retry" function.
Over-current Tolerance Period (1-10 seconds) — In the event of an over-current episode, the
amount of time an output over-current condition is allowed 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.
Installation of the PIM will require complete power supply shut down. Appropriate measures to maintain
output to the load, such as the use of either the APP9015S Service Power Supply or the APP9022S
Service Power Supply, must be considered when installing the PIM.
N+1 (Optional)
The N+1 ports are used in redundant system configurations 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 XM Series 2
Uninterruptible Power Supply to function as an N+1 redundant 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 over-current and short
circuit conditions. Adding a PIM in the secondary power supply will enable both power supplies to be
connected in a “dual redundant” configuration which would allow the system to protect two critical loads.
36
017-805-B0-005 Rev. D
2. Installation
2.7 Programming the PIM, continued
NOTE: If the optional PIM is not installed, the values shown on the “PIM
PARAMETERS” line of the Smart display will be “read only”.
The Setup Menu is one level below the Additional Information display and is reached by pressing the
ENTER key. This menu allows the operator to view and/or change the programmable operating parameters
of the power supply or the optional PIM. When the Setup Menu is accessed, navigation is similar to the
Normal Operation menu. Pressing the UP or DOWN arrow keys will access the Single Step mode where
sub-menu items can be individually selected.
To select and change a value in the Setup Menu:
1.
Press either the UP or DOWN arrow keys to put the display in the Manual Scroll Mode.
2.
Continue pressing the UP or DOWN keys until the desired item is displayed.
3.
Press the ENTER key to select the item for editing.
4.
Use the UP arrow key to increase the displayed value or the DOWN arrow key to decrease the
value. Pressing and holding either the UP or DOWN arrow keys for more than two seconds
while in edit mode will cause the displayed value to change more rapidly.
NOTE: The actual parameter being modified in EDIT mode doesn’t change until the
new data is saved by pressing the ENTER key twice.
5.
Press the ENTER key when the desired value is displayed. This will access an additional display,
giving the operator a chance to back out of the programming mode (ESCAPE) and not save the
new value, or to accept and save the new value in to memory by pressing the ENTER key.
6.
Once the value is entered into memory, the display will return to the Setup Menu, where you
can check and view the new value, or select additional parameters to modify.
If an incorrect value was 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.
NOTE: The SET DEFAULTS menu selection will not reset STANDBY TIME, STANDBY
EVENTS, or DEVICE ADDRESS; the operator must manually reset these
settings.
In addition to incrementing or decrementing numerical values using the UP and DOWN arrow keys, the
operator will also have selections such as ON or OFF and YES or NO. These are selected and entered
exactly the same as described above. The CODE VER, XM_CLASS VER, and Total Run Time selections
are for informational display only and cannot be edited.
To return to the Normal Operation menu from the Setup Menu, press the ESCAPE key three times.
017-805-B0-005 Rev. D
37
2. Installation
2.8 N+1 Front Panel Configurations
The addition of optional Protective Interface Modules (PIM) provides a second output and allows the XM
Series 2 Uninterruptible Power Supply to function as an N+1 redundant supply system and also provides
programmable current limits for two output channels. This provision also protects system components by
shutting down the load during over-current and short circuit conditions. Adding a PIM in the secondary
power supply will enable both power supplies to be connected in a “dual redundant” configuration which
would allow the system to protect two critical loads.
Redundant (N+1) Power Supply
(With Optional PIM Installed)
Enclosure Cooling Fan
Battery
Breaker
N+1
N+1 Output 2
SSR
LRI
Battery
Input
Output 1
Temp
Probe
60V
75V
90V
Fan kit
Alpha p/n: 874-553-20
Wire kit, N+1 Cable
Alpha p/n: 874-647-20
Battery
Breaker
N+1
N+1 Output 2
Battery
Input
SSR
LRI
Output 1
Temp
Probe
SPI #1
Primary Power Supply
(With Optional PIM Installed)
Figure 2-13 Front Panel Configuration
38
017-805-B0-005 Rev. D
2. Installation
2.8 N+1 Front Panel Configurations, continued
IMPORTANT NOTE:
When configured in the manner shown below, the N+1 unit and
the primary unit cannot be loaded over 50% of rated capacity.
Fan kit
Alpha p/n: 874-553-20
Redundant (N+1) Power Supply
(With Optional PIM Installed)
Enclosure Cooling Fan
Battery
Breaker
60V
75V
90V
N+1
N+1 Output 2
SSR
LRI
Battery
Input
Output 1
Temp
Probe
SPI #2
Battery
Breaker
2 ea., Wire kit, N+1 Cable
Alpha p/n: 874-647-20
N+1
N+1 Output 2
SSR
LRI
Battery
Input
Output 1
Temp
Probe
SPI #1
Primary Power Supply
(With Optional PIM Installed)
Figure 2-14 Dual Redundancy Configuration
017-805-B0-005 Rev. D
39
2. Installation
2.9 Service Power Inserter (SPI)
COAXIAL CABLE CONNECTION PROCEDURE:
1.
2.
3.
Ensure SPI is not plugged into the power supply prior to removing cover.
Remove the two screws holding the cover onto the SPI’s chassis.
Remove the SPI’s cover, exposing the circuit board and seizure screw assembly.
1
Seizure
Screw
Assembly
2
3
Figure 2-15 SPI Cover Removal
4.
5.
Insert the Coaxial Termination into the Output Port on the bottom of the SPI.
Tighten the Seizure Screw to 35 Inch-Pounds.
5
4
Figure 2-16 Coaxial Cable insertion and Securing
NOTE:
40
To prevent arcing, and failure of the unit, the center conductor (stinger) of
the coaxial termination must go fully inside the seizure screw assembly.
017-805-B0-005 Rev. D
2. Installation
2.9 Service Power Inserter (SPI), continued
6.
7.
8.
Replace the SPI’s cover and reinstall the screws.
enclosure wall
Verify the switch on the top of the SPI is in the ON position.
The switch in the ON position selects the standby power
supply as the power source to the cable plant. The switch
should only be in the ALT position when a service power
supply is connected to the cable. At this time, the standby
power supply is bypassed for service or removal; also paint-cutting
provides power for status monitoring options.
star washer
7
6
ALT
ON
Verify the SPI is properly grounded. Typically, grounding
is accomplished by one of two methods:
If the SPI has been installed with a mounting bracket,
ground connection is made with paint-cutting star washers
(Figure 2-17) used in conjunction with SPI grounding wire.
6
If the SPI doesn’t utilize the mounting bracket, the ground
connection is made via a #8 AWG wire connected to the
cover of the SPI (Figure 2-18) and terminated at the ground
bar of the cabinet (Figure 2-19).
Figure 2-17 Cover Replaced,
SPI Switched ON
Figure 2-18 SPI Grounding Lug
017-805-B0-005 Rev. D
Figure 2-19 Enclosure Ground Bar
41
3. Configuration
3.1 Power Distribution Board Setup
The Power Distribution Board (PDB) must be correctly configured to match actual power supply features
and specifications. Some models (XM Series 2-922, XM Series 2-915, XM Series 2-910 and XM Series
2-1350) allow for operator adjustment of the output voltage, and some models (XM Series 2-915, XM
Series 2-910 and XM Series 2-1350) allow for operator adjustment of the input voltage. Other features on
the PDB are needed for configuration settings but will never need to be changed after initial factory setup.
A detailed listing and complete PDB setup are included in this manual ONLY as an aid to troubleshooting
and a reference to be used to verify configuration. ONLY qualified technicians should ever attempt
reconfiguration and only if following all the steps including, Power Supply jumpers, input plugs and Power
Distribution Board setup.
Frequency (SW1-8): Factory set to match the ferroresonant transformer operating frequency, either 60Hz
or 50Hz operation. Changing this setting will NOT change the operating frequency of the XM2, this setting
should never be changed.
NOTE: DO NOT CHANGE THE FREQUENCY (SW1-8) SETTING!
Battery Voltage (SW1-7 and SW1-6): Factory set to match the ferroresonant transformer and Inverter
Module battery operating voltage, either 36VDC, 48VDC, or 96VDC. Changing this setting will not change
the battery voltage of the XM2, this setting should never be changed.
NOTE: DO NOT CHANGE THE BATTERY VOLTAGE (SW1-7 AND SW1-6) SETTING!
Power Rating (SW1-5 and SW1-4): Factory set to order, can be changed as needed during Output Voltage
reconfiguration. Power Rating must be set to match both the model and output voltage of the power supply.
Only qualified technicians should change the Power Rating setting.
Output Voltage (SW1-3 and SW1-2): Factory set to order, can be changed as needed during Output
Voltage reconfiguration. Output Voltage must be set to match both the model and output voltage of the
power supply. Only qualified technicians should change the Output Voltage setting.
Output Current (SW1-1): Factory set to order, may require changing as part of Output Voltage
reconfiguration. Output Current must be set to match both the model and output voltage of the power
supply. Only qualified technicians should change the Output Current setting.
SW1
SW2
JP2
JP1
Figure 3-1 Power Distribution Board
42
017-805-B0-005 Rev. D
3. Configuration
3.1 Power Distribution Board Setup, continued
Input Voltage (SW2-6, SW2-5, SW2-4, JP1, and JP2): Factory set to order, can be changed as needed
during Input Voltage reconfiguration. All Input Voltage elements, three switches and two jumpers, must be
set to match input voltage configuration. Except for input voltage reconfiguration (120VAC to 240VAC or
240VAC to 120VAC), this setting should never be changed. Only qualified technicians should change the
Input Voltage setting.
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.
NOTE: DO NOT CHANGE THE INPUT TOLERANCE (SW2-7) SETTING!
SW2-1, SW2-2, SW2-3, SW2-8 — Unused: These switches are unused and should never be changed.
SW2 -- Input Switch
Frequency
60 Hz
50 Hz
SW1-8
OFF
ON
Battery
Voltage
36 VDC
48 VDC
96 VDC
SW1-7
OFF
OFF
ON
SW1-6
OFF
ON
OFF
Power
Rating
400VA
600VA
900VA
1350VA
2000VA
SW1-5
ON
OFF
OFF
ON
SW1-4
ON
OFF
ON
OFF
Output
Voltage
63 VAC
75 VAC
87 VAC
SW1-3
OFF
OFF
ON
SW1-2
OFF
ON
OFF
Output
Current
<17 A
>17 A
SW1-1
OFF
ON
Input
Tolerance
+/- 15%
+/- 20%
SW2-7
OFF
ON
Input
Voltage
100 VAC
110 VAC
120 VAC
127 VAC
200 VAC
220 VAC
230 VAC
240 VAC
SW2-6
OFF
ON
OFF
ON
OFF
OFF
ON
ON
SW2-5
OFF
ON
OFF
ON
ON
ON
OFF
OFF
OFF
1 2 3 4 5 6 7 8
ON
SW1 -- Output Switch
ON
ON
Legend
1 2 3 4 5 6 7 8
Front of power supply
Rear of power supply
JP1 & JP2
Open
JP1 & JP2
Short (closed)
NOTE:
On some revisions of the PDB, JP1 & JP2 are two pin
jumpers (shown above), and other revisions of the PDB
have 3 pin jumpers (shown below).
120
240
120
240
JP1 & JP2
JP1 & JP2
(set for 120V)
(set for 240V)
SW2-4
ON
OFF
OFF
ON
OFF
ON
OFF
ON
JP1 & JP2
OPEN
or 120
OPEN
or 120
OPEN
or 120
OPEN
or 120
SHORT
or 240
SHORT
or 240
SHORT
or 240
SHORT
or 240
Unused
SW2-8
N/A
SW2-3
N/A
Table Legend:
SW2-2
N/A
Selectable Setting: Must be set to match configuration!
SW2-1
N/A
Factory Setting: DO NOT CHANGE!
Table 3-1 Power Distribution Board Setup
017-805-B0-005 Rev. D
43
3. Configuration
3.2 AC Input Voltage Reconfiguration
The input voltage on many models (XM Series 2-915, XM Series 2-910 and XM Series 2-1350) can be
reconfigured from 120VAC to 240VAC utility input, or from 240VAC to 120VAC utility input, depending upon
utility input powering requirements.
NOTE:
Input voltage reconfiguration must ONLY be performed by qualified
personnel.
WARNING:
Before modifying the power supply, always consult local electrical codes for
proper wiring procedures.
WARNING:
Before proceeding, verify ALL power has been removed 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.
NOTE:
Upon completion of AC Input voltage reconfiguration, the voltage rating of
both the high-magnetic breaker and enclosure receptacle must match the
input voltage.
3.2.1 Reconfiguration from 120VAC to 240VAC
Tools Required:
Supplies Required:
#2 Philips head screwdriver, Wire Cutters and Strippers
Flat-blade screwdriver.
240VAC 15Amp plug (NEMA 6-15P — p/n 874-540-22)
RECONFIGURATION PROCEDURE (from 120VAC Input to 240VAC Input):
1.
Completely shut down the XM Series 2 power supply, verify ALL power is removed. Verify AC
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 XM Series 2 power supply.
2.
Verify the enclosure system wiring before proceeding with power supply modification. Refer to
the appropriate enclosure installation instructions.
3.
Replace the 120VAC 20Amp plug (NEMA 5-20P) on the XM Series 2 power supply input line
cord with a 240VAC 15Amp plug (NEMA 6-15P). Verify proper wiring and ground on the new
plug.
120V, 20Amp Plug and Receptacle
240V,15Amp Plug and Receptacle
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)
Figure 3-2 Typical NEMA Receptacles and Plugs
44
017-805-B0-005 Rev. D
3. Configuration
3.2 AC Input Voltage Reconfiguration, continued
3.2.1
4.
Reconfiguration from 120VAC to 240VAC, continued
Locate the Transformer Module’s input jumpers (located in the transformer compartment).
Replace the currently-installed 120VAC Jumper (744-281-20) with the supplied 240VAC jumper
(744-281-21).
120
240
JP1 & JP2
120
Becomes
120 VAC
Input Select Jumper
(p/n 744-281-20)
240
JP1 & JP2
240 VAC
Input Select Jumper
(p/n 744-281-21)
Figure 3-3 Transformer Module Input Jumpers, PDB Jumpers
5.
Remove the Transformer Module’s front panel by removing the five front panel screws. Lift the
front panel up and away from the chassis, the front handle and output fuse remain in place.
6.
Reconfigure the Power Distribution Board to 240VAC input, according to Table 3-2. Switch 2-4,
2-5, and 2-6; and Jumpers 1 and 2 will need to be changed. Change SW2-4 to ON, SW2-5 to
OFF, SW2-6 to ON, JP1 to Short 9 (240), and JP2 to Short (240). Refer to Section 3.1, Power
Distribution Board Reconfiguration for further details.
NOTE: In this procedure, only adjust positions SW2 -4, -5, -6. Do not adjust the other
switch positions.
240VAC
120VAC
ON
ON
Becomes
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW2
SW2
Figure 3-4 SW2 Settings
7.
Replace the front panel.
8.
Using approved methods, as outlined in Section 2.2 (XM Series 2 Installation), install the power
supply into the enclosure.
017-805-B0-005 Rev. D
45
3. Configuration
3.2 AC Input Voltage Reconfiguration, continued
3.2.2
Reconfiguration from 240VAC to 120VAC
Tools Required:
#2 Philips head screwdriver, Wire Cutters and Strippers
Flat-blade screwdriver
Supplies Required:
120VAC 20Amp plug (NEMA 5-20P — 874-540-20)
RECONFIGURATION PROCEDURE (from 240VAC Input to 120VAC Input):
1.
Completely shut down the XM Series 2 power supply, verify ALL power is removed. Verify AC
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 XM2 power supply.
2.
Verify the enclosure system wiring before proceeding with power supply modification. Refer to
the appropriate enclosure installation instructions.
3.
Replace the 240VAC 15Amp plug (NEMA 6-15P) on the XM Series 2 power supply input line
cord with a 120VAC 20Amp plug (NEMA 5-20P). Verify proper wiring and ground on the new
plug.
240V,15Amp Plug and Receptacle
120V, 20Amp Plug and Receptacle
NEMA 6-15P
(p/n 874-540-22
NEMA6-15R
(p/n 531-004-10)
NEMA 5-20P
(p/n 874-540-20)
NEMA 5-20R
(p/n 531-006-10)
Figure 3-5 Typical NEMA Receptacles and Plugs
46
017-805-B0-005 Rev. D
3. Configuration
3.2 AC Input Voltage Reconfiguration, continued
3.2.2
4.
Reconfiguration from 240VAC to 120VAC, continued
Locate the Transformer Module’s input jumpers (located in the transformer compartment).
Replace the currently installed 240VAC jumper (744-281-21) with the supplied 120VAC Jumper
(744-281-20).
120
120
240
JP1 & JP2
Becomes
240
JP1 & JP2
120 VAC Input Select Jumper
(p/n 744-281-20)
240 VAC Input Select Jumper
(p/n 744-281-21)
Figure 3-6 Transformer Module Input Jumpers, PDB Jumpers
5.
Remove the Transformer Module’s front panel by removing the five front panel screws. Lift the
front panel up and away from the chassis, the front handle and output fuse remain in place.
6.
Reconfigure the Power Distribution Board to 120VAC input, according to Table 3-2. Switch 2-4,
2-5, and 2-6; and Jumpers 1 and 2 will need to be changed. Change SW2-4 to OFF, SW2-5 to
OFF, SW2-6 to OFF, JP1 to Open (120), and JP2 to Open (120). Refer to Section 3.1, Power
Distribution Board Reconfiguration for further details.
NOTE: For clarity, only the positions of SW2 (-4, -5, -6) that are to be adjusted are
shown. Do not adjust the other switch positions during this procedure.
240VAC
120VAC
ON
ON
Becomes
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW2
SW2
Figure 3-7 SW2 Settings
7.
Replace the front panel.
8.
Using approved methods, as outlined in Section 2.2 (XM Series 2 Installation), install the XM
Series 2 power supply into the enclosure.
017-805-B0-005 Rev. D
47
3. Configuration
3.3 AC Output Voltage Reconfiguration
The output voltage on many XM Series 2 Power Supply models (-910, -915, -922, -1350) can be easily
reconfigured 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 Power Distribution Board.
NOTE:
Output voltage reconfiguration must ONLY be performed by qualified personnel.
WARNING:
Before proceeding, make certain ALL power has been removed 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 Philips head screwdriver, Small Flat-blade screwdriver
OUTPUT VOLTAGE RECONFIGURATION PROCEDURE:
1.
Completely shut down the XM Series 2 Power Supply, verify ALL power is removed. 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 XM Series 2 Power Supply power supply.
2.
Locate the Transformer Module’s output tap connectors (located in the transformer compartment).
Move the single black connector to the desired output voltage connector. Connectors (refer to
Figure 3-8 below) are both labeled and color coded for easy identification: Black = 87VAC;
White = 75VAC; and Red = 63VAC.
3.
Remove the Transformer Module’s front panel by removing the five front panel screws. Lift the
front panel up and away from the chassis, the front handle and output fuse remain in place.
4.
Reconfigure the Power Distribution Board as required. Set the Output Voltage switches (SW12 and SW1-3) to reflect the same rating as the currently selected voltage on the Output Tap
connector. In some cases when changing the Output Voltage selection, the Power Rating and
the Output Current settings may also need to be changed, consult Table 3-1 for proper Power
Rating and Output Current settings
for specific models and Output
63VAC
75VAC
87VAC
Voltages. Set the Power Rating
switches (SW1-4 and SW1-5), and
S W 1-2 SW 1-3
SW 1-2 SW 1-3
SW 1-2 SW 1-3
OFF
OFF
ON
OFF
OFF
ON
the Output Current switch (SW1-1)
Output
Output
Output
to the required setting.
Pow er Rating Current Pow er Rating Current Pow er Rating Current
5.
Replace the front panel.
480/600V A
<17A
900V A
<17A
900VA
<17A
XM2-910
6.
Using approved methods, as
outlined in Section 2.2 (XM Series 2
Power Supply Installation), install the
unit into the enclosure.
900V A
S W 1-4
OFF
<17A
SW 1-4
OFF
SW 1-5
OFF
1350VA
S W 1-1
OFF
<17A
SW 1-4
OFF
SW 1-5
OFF
1350V A
SW 1-1
OFF
<17A
SW 1-5
OFF
SW 1-1
OFF
>17A
SW 1-4
ON
SW 1-5
OFF
2000VA
S W 1-1
OFF
>17A
SW 1-4
ON
SW 1-5
OFF
2000V A
S W 1-1
OFF
>17A
XM2-922
S W 1-4
ON
SW 1-5
OFF
SW 1-1
ON
SW 1-4
OFF
SW 1-5
ON
S W 1-1
ON
SW 1-4
OFF
SW 1-5
ON
S W 1-1
ON
BLK
RED
1350VA
Figure 3-8 Output Tap Connector
>17A
1350VA
>17A
1350V A
<17A
XM2-1350
S W 1-4
ON
48
SW 1-1
OFF
XM2-915
BLK
WHT
SW 1-5
ON
1350VA
Output Select
87VAC
75VAC
63VAC
S W 1-4
ON
SW 1-5
OFF
SW 1-1
ON
SW 1-4
ON
SW 1-5
OFF
S W 1-1
ON
SW 1-4
ON
SW 1-5
OFF
S W 1-1
OFF
Table 3-2 Output Voltage Reconfiguration
017-805-B0-005 Rev. D
3. Configuration
3.3 AC Output Voltage Reconfiguration, continued
3.3.1
Output Voltage Switch (SW1) settings
NOTE: For clarity, only the positions of SW1 (-1, -2, -3, -4, -5) that are to be adjusted
are highlighted. Do not adjust the other switch positions (-6, -7, -8) during this
procedure.
NOTE: Reconfiguration is a 2-step process. The output tap connector as well as the
output voltage switch (SW1) must be adjusted for the changes to be effective.
DESIRED OUTPUT VOLTAGE
75VAC
RED
BLK
9$&
9$&
9$&
Model
BLK
WHT
BLK
RED
ON
ON
9$&
9$&
9$&
+
BLK
WHT
+
9$&
9$&
9$&
87VAC
BLK
BLK
WHT
RED
+
63VAC
ON
XM2-910
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW1
SW1
SW1
ON
1 2 3 4 5 6 7 8
ON
ON
XM2-915
915-E, M, & P
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW1
SW1
SW1
ON
ON
ON
XM2-922
(240VAC only)
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW1
ON
XM2-1350
(36VDC)
ON
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
SW1
SW1
SW1
ON
1 2 3 4 5 6 7 8
SW1
017-805-B0-005 Rev. D
SW1
SW1
ON
ON
XM2-1350
(48VDC)
1 2 3 4 5 6 7 8
ON
1 2 3 4 5 6 7 8
SW1
1 2 3 4 5 6 7 8
SW1
49
4. Operation
4.1 Start-up and Test
4.1.1
AC Line Operation
1.
Before making any power supply connections, verify the correct voltage, polarity, and frequency
are available from both the AC utility power source and the DC battery system.
2.
Verify both the AC circuit breaker (located on customer supplied service disconnect) is OFF,
and the BATTERY BREAKER on the XM Series 2 Power Supply is OFF.
3.
Plug the XM Series 2 Power Supply power cord into the convenience outlet, the battery cable
into the Inverter Module, the RTS into the TEMP PROBE Connection and attach it to the side of
the center battery (please refer to p. 21 for illustration). Also, if applicable, connect the SSR and
LRI cables into the front panel.
4.
Switch the AC (service disconnect) circuit breaker ON to start initial power up. During this stage
the power supply performs a “display self test”, and verifies the configuration for the power
supply. The configuration screen will look similar to the figure below. After the initial display self
test, a NO BATTERIES alarm message will appear in the Smart Display as the BATTERY
BREAKER is still OFF. The green OUTPUT LED will remain OFF, and the red ALARM LED will
continue to FLASH. Because the BATTERY BREAKER is still OFF, this is correct.
OUTPUT FREQ BAT IN
90V 15A 60HZ 36V 240
Figure 4-1 Configuration Screen
NOTE: The Configuration Screen can be accessed any time by simultaneously pressing
the UP arrow and the ENTER keys.
5.
Use the Smart Display to verify XM Series 2 Power Supply operations; press the ENTER key to
view Normal Information. Press the ENTER key again to view Additional Information. Press the
ENTER key a third time to view the Setup Menu. (If desired, the NO BATTERY alarm can be
disabled by changing the battery capacity to “0”.)
6.
Use the Smart Display or a true RMS voltmeter to verify AC output (±5%) at the module’s AC
OUTPUT Test Point. If a non-RMS voltmeter is used, the output reading can vary by as much as
10% due to the “quasi” square wave output of the ferroresonant transformer.
7.
50
SETTING
LOW (-5%)
HIGH (+5%)
87VAC
75VAC
63VAC
82.65VAC
71.25VAC
59.85VAC
91.35VAC
78.75VAC
66.15VAC
Switch ON the BATTERY BREAKER. Within one minute the FLASHING red ALARM LED will
turn OFF, the green OUTPUT LED will turn ON, the NO BATTERIES alarm will clear, and the
power supply will resume normal operations. Use the Smart Display to verify operations and
Setup as needed.
017-805-B0-005 Rev. D
4. Operation
4.1 Start-up and Test, continued
4.1.2
Self Test Operation
1.
The XM Series 2 Power Supply must be operating correctly with NO alarms present. Use the
Smart Display to verify Normal and Additional Information. Verify Test Duration in the Setup
Menu as needed.
2.
Press and hold the DOWN arrow and ENTER key simultaneously to start a Self Test. The test
will run for a preset time (5-180 minutes as 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. Output voltages should appear within ±5% of: 87VAC for 90V
units; 75VAC for 75V units; and 63VAC for 60V units, at nominal line input voltage.
4.
SETTING
LOW (-5%)
HIGH (+5%)
87VAC
75VAC
63VAC
82.65VAC
71.25VAC
59.85VAC
91.35VAC
78.75VAC
66.15VAC
To cancel a Self Test in progress, Push and hold the DOWN arrow and the ENTER key a
second time, or change Self Test to OFF in the Setup Menu.
4.1.3
Standby Operation
1.
ONLY after a successful completion of a Self Test, with the XM Series 2 Power Supply operating
normally in AC line mode; momentarily fail the AC utility input power by switching the AC (service
disconnect) circuit breaker to OFF.
2.
The XM Series 2 Power Supply will start operating in the inverter mode. Use the Smart Display
or a true RMS voltmeter to verify output at the module’s AC output test point. Output voltages
should appear within ±5% of: 87VAC for 90V units; 75VAC for 75V units; and 63VAC for 60V
units, at nominal line input voltage.
SETTING
LOW (-5%)
HIGH (+5%)
87VAC
75VAC
63VAC
82.65VAC
71.25VAC
59.85VAC
91.35VAC
78.75VAC
66.15VAC
3.
Return the XM Series 2 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. This delay
allows the utility voltage and frequency to stabilize before the module’s phase-lock circuitry is
activated. The module then synchronizes the inverter’s waveform to the utility’s before initiating
a smooth, inphase transfer back to utility power. Once the transfer is complete, the smart display
will report: OPER MODE = LINE.
4.
The XM Series 2 Power Supply is now fully operational.
017-805-B0-005 Rev. D
51
4. Operation
4.2 Smart Display
All operational functions, system testing, setup menus, and alarms are available via the illuminated display
panel on the front of the XM Series 2 Power Supply. Display functions are accessible by pressing any of the
four keys: ESCAPE, UP arrow, DOWN arrow, and ENTER. Description of the key functions is as follows:
ESCAPE Key:
The ESCAPE key offers the following features:
• Move up one level in the menu tree.
• Allow the operator to leave the EDIT mode without saving (ignoring) the changes made to
the selected menu item.
UP Arrow:
The UP arrow serves two primary functions:
• To scroll up in a branch of the menu tree.
• To increase a parameter (or value) while in the EDIT mode.
• When the TOP menu item is reached, a DOWN arrow ( ) will appear in the display,
indicating to use the DOWN arrow to navigate through the menu items.
DOWN Arrow:
The DOWN arrow serves two primary functions:
• To scroll down in a branch of the menu tree.
• To decrease a parameter (or value) while in the EDIT mode.
• When the BOTTOM menu item is reached an UP arrow ( ) will appear in the display,
indicating to use the UP arrow to navigate through the menu items.
ENTER Key:
The ENTER key provides the following functions:
• Displays the next lower level in the menu tree.
• In the EDIT mode, the ENTER accepts the new value into memory.
• Depressing the ENTER key for two seconds or longer initiates the DISPLAY TEST mode.
The DISPLAY TEST mode switches all LED and LCD pixels (dots) ON for several seconds.
SELF TEST Function: +
The XM Series 2 Power Supply can manually be placed in a self test mode by pressing the DOWN
arrow and ENTER keys together:
• Press the DOWN arrow and ENTER keys simultaneously. A self test will be initiated and run
for a preset time (5 - 180 minutes, period is set in the setup menu).
• To cancel a self test in progress, press the DOWN arrow and ENTER keys simultaneously.
Display Backlighting
The display will normally be “dark”. Press any key, once, to activate backlighting. This will illuminate the
display without deactivating the AUTO SCROLL mode.
Auto Scroll
The display will normally be in the AUTO SCROLL mode, continually cycling through the sub-menu items
at a two second interval. In this mode the operator can quickly view all operating parameters without the
need to press any keys.
Single Step
Pressing either arrow key will activate SINGLE STEP, allowing the operator to “step” through the individual
menu items. Each press of the arrow key will step up or down through the sub-menu items. Pressing the
ESCAPE key will return to auto-scroll.
52
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
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 will appear. The following
characters or text may appear:
The top of the menu has been reached. To view more menu items, use the DOWN arrow.
The bottom of the menu has been reached. To view additional menu items, use the UP arrow.
Access more menu items by pressing either the UP or DOWN arrow keys.
Use the ENTER key to select this function.
<ESC> Use the ESCAPE keys to leave the selected function without altering any values or to go
to back to the previous menu in the display.
<ESC>
Use the UP or DOWN arrows to change a display value or mode; ESCAPE to leave this menu item
without making any changes (and go back to the previous menu); ENTER to save the change into
memory. These types of multiple display choices are normally available in the programming mode.
Top Line in Display
(provides additional instructions)
Direction Indicator Symbols
(manual scroll mode)
OPERATION NORMAL
OUTPUT VOLTAGE
60V
Second Line in Display
(scrolls through system
information)
ENTER Key
ESCAPE Key
UP Arrow
DOWN Arrow
Figure 4-2 Smart Display
017-805-B0-005 Rev. D
53
4. Operation
4.2 Smart Display, continued
4.2.1
Operation Normal
If no Alarms are present, the XM Series 2 Power Supply will be operating in the Operation Normal
display mode. This mode allows the operator to view the primary operating parameters of the power
supply. In this mode, the display will AUTO-SCROLL through the available menu items at a two
second interval. In the “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:
Top Line (Provides additional instructions):
•
OPERATION NORMAL
TO MANUAL SCROLL
•
•
FOR ADDIT’L INFO
Second Line (cycles through the following parameters):
•
INPUT VOLTAGE xxxV
•
OUTPUT VOLTAGE xxV
•
OUTPUT CURRENT xx.xA
•
BATT VOLTS xx.xV
•
xx EVENTS xxx MIN
•
CHARGER MODE = float
•
OPER MODE = line
NOTE: Lower case italicized items indicate variables which will change according to the
operating mode, setup, and/or measured values. These items will appear as
normal UPPER CASE text in the actual display (see below).
OPERATION NORMAL
INPUT VOLTAGE
OUTPUT VOLTAGE
OUTPUT CURRENT
BATTERY VOLTS
12 EVENTS
CHARGER MODE =
OPER MODE =
240V
87V
12.2A
40.5V
65 MIN
FLOAT
LINE
Figure 4-3 Operation Normal Display
(Examples are given for values in the display)
54
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
4.2.2
Additional Information Display
Press the ENTER key to activate the Additional Information display which is an extension of the
Operation Normal mode and displays information of secondary importance to the operator. This
mode operates in a similar fashion as the normal operation display described. When the Additional
Information display is first accessed, the displayed information will be in the AUTO SCROLL mode,
cycling through the menu items at a two second interval. Pressing the UP or DOWN arrow keys will
allow the information to be accessed one step at a time. Pressing the ENTER key will access the
Setup Menu (discussed in Section 4.2.3, Setup Menu) and pressing the ESCAPE key will reactivate
the AUTO SCROLL mode. Pressing the ESCAPE key a second time will reactivate the Operation
Normal display (up one level).
The Additional Information display contains the following items:
Top Line (Provides additional instructions):
• ADDITIONAL INFO
TO MANUAL SCROLL
•
TO SETUP MENU
•
• <ESC> TO SYSTEM INFO
Second Line (cycles through the following parameters):
• BATTERY TEMP xx°C
• CHARGER CURR xx.x A
• INPUT FREQ xx.x HZ
• OUTPUT WATTS xxx W
• OUTPUT VA xxx
• PERCENT LOAD xx%
NOTE: Lower case italicized items indicate variables which will change according to the
operating mode, setup, and/or measured values. These items will appear as
normal UPPER CASE text in the actual display.
NOTE: INPUT FREQ is not valid during inverter operation.
ADDITIONAL INFO
BATTERY TEMP
CHARGER CURR
INPUT FREQ
OUTPUT WATTS
OUTPUT VA
PERCENT LOAD
37°C
8.2A
60HZ
900W
1060
80%
Figure 4-4 Additional Info Display
(Examples are given for values in the display)
017-805-B0-005 Rev. D
55
4. Operation
4.2 Smart Display, continued
4.2.3
Setup Menu
The Setup Menu is one level below the Additional Information display and is reached by pressing
the ENTER key. This menu allows the operator to view and/or change the programmable operating
parameters of the power supply or the optional PIM. When the Setup Menu is accessed, navigation
is similar to the Operation Normal menu. Pressing the UP or DOWN arrow keys will access the
Single Step mode where sub-menu items can be individually selected.
NOTE: When initializing the XM Series 2 Power Supply, all settings are reset to factory
defaults (i.e., if the Inverter Module is removed and restarted).
To select and change a value in the Setup Menu:
1.
Press either the UP or DOWN arrow keys to put the display in the Manual Scroll Mode.
2.
Continue pressing the UP or DOWN keys until the desired item is displayed.
3.
Press the ENTER key to select the item for editing.
4.
Use the UP arrow key to increase the displayed value or the DOWN arrow key to decrease the
value. Pressing and holding either the UP or DOWN arrow keys for more than two seconds
while in edit mode will cause the displayed value to change more rapidly.
NOTE: The actual parameter being modified in EDIT mode doesn’t change until the new
data is saved by pressing the ENTER key twice.
5.
Press the ENTER key when the desired value is displayed. This will access an additional
display, giving the operator a chance to back out of the programming mode (ESCAPE) and not
save the new value, or to accept and save the new value in to memory by pressing the ENTER
key.
6.
Once the value is entered into memory, the display will return to the Setup Menu, where you
can check and view the new value, or select additional parameters to modify.
If an incorrect value was 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 the their factory default values.
NOTE: The SET DEFAULTS menu selection will not reset STANDBY TIME, STANDBY
EVENTS, or DEVICE ADDRESS; the operator must manually reset these settings.
In addition to incrementing or decrementing numerical values using the UP and DOWN arrow keys,
the operator will also have selections such as ON or OFF and YES or NO. These are selected and
entered exactly the same as described above. The CODE VER, XM_CLASS VER, and Total Run
Time selections are informational display only items and cannot be edited.
To return to the “Operation Normal” menu from the Setup Menu, press the ESCAPE key three
times.
56
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
4.2.3 Setup Menu, continued
The Setup Menu contains the following items:
Top Line (provides additional information)
•
•
•
SET UP MENU
TO MANUAL SCROLL
<ESC> TO ADD’L INFO
Second Line (cycles through the following parameters):
3DUDPHWHU
'HIDXOW
)ORDW9&
$FFHSW9&
7HPS&RPS
%DWW&DSDFLW\ 6HOI7HVW
7HVW,QKLELW
7HVW,QWHUYDO
7HVW&RXQWGRZQ
7HVW'XUDWLRQ
)UHT5DQJH
7DS6ZLWFK 3,02SWLRQ
5HVHW2XWSXW
5HVHW2XWSXW
2XWSXW
2XWSXW
2YHU&XUU
2YHU&XUU
5HWU\'HOD\
5HWU\/LPLW
2YHU&XUU7RO
19DOLG
6WDQGE\7LPH
6WDQGE\(YHQWV
6HW'HIDXOWV
&RGH9HU
;0B&ODVV9HU
'HYLFH$GGUHVV
7RWDO5XQWLPH
6HOHFW/DQJXDJH
P9&HOOƒ&
$K
2))
²
GD\V
GD\V
PLQXWHV
+]
12
<(6
²
²
21
21
$
$
VHFRQGV
VHFRQGV
12
PLQXWHV
HYHQWV
12
(QJOLVK
5DQJH
0LQLPXP
0D[LPXP
9&HOO
9&HOO
9&HOO
9&HOO
P9&HOOƒ&
P9&HOOƒ&
$K
$K
21
2))
GD\V
GD\V
GD\V
GD\V
GD\V
GD\V
PLQXWHV
PLQXWHV
+]
+]
12
<(6
12
<(6
12
<(6
12
<(6
21
2))
21
2))
$
$
$
$
VHFRQGV
VHFRQGV
VHFRQG
VHFRQGV
12
<(6
PLQXWHV
PLQXWHV
HYHQWV
HYHQWV
12
<(6
These items will
appear in the
setup menu only
if the optional
PIM is installed.
GD\V
GD\V
)UHQFK6SDQLVK3RUWXJXHVH
* 100Ah = 1 battery string, 200Ah = 2 battery strings, 300Ah = 3 battery strings
* * Feature not available in US.
Refer to Section 4.3 Smart Display Glossary, for descriptions of the Setup Menu Parameters.
017-805-B0-005 Rev. D
57
4. Operation
4.2 Smart Display, continued
4.2.3
Setup Menu, continued
SETUP MENU
FLOAT V/C
ACCEPT V/C
TEMP COMP
BATT CAPACITY
SELF TEST
TEST INHIBIT
TEST INTERVAL
TEST COUNTDOWN
TEST DURATION
FREQ RANGE
TAP SWITCH
PIM OPTION
RESET OUTPUT 1
RESET OUTPUT 2
OUTPUT 1
OUTPUT 2
OVER CURR 1
OVER CURR 2
RETRY DELAY
RETRY LIMIT
OVER CURR TOL
N+1 VALID
STANDBY TIME
STANDBY EVENTS
SET DEFAULTS
CODE VER
XM_CLASS VER
DEVICE ADDRESS
TOTAL RUN TIME
SELECT LANGUAGE
2.25
2.35
3mV
100Ah
OFF
—
30 D
3D
10 M
3.0HZ
NO
YES
—
—
ON
ON
15.0A
15.0A
60S
20
3S
NO
65 M
12
NO
3.03.0
3
0
XXXD
These items will appear in
the setup menu only if the
optional PIM is installed.
Figure 4-5 Setup Menu Display
(Examples are given for values in the display)
58
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
4.2.4
Alarm Indications
In the event of a failure, the Active Alarm display will show which alarms have been detected and
items to check to correct the alarm condition. Major alarms will also cause the red LED to flash.
Press either the UP or DOWN arrow keys to stop automatic scrolling. The arrows appearing at the
right-hand side of the display text indicate which keys to press to show the next item in the menu.
Use the UP and DOWN arrow keys to select the alarm of interest. Press ENTER to select the alarm
and display diagnostic information. Press the ESCAPE key to return to the alarm list.
NOTE: If only one alarm is active, the alarm list is bypassed and the display will
show diagnostic information for the single active alarm.
To assist the operator in troubleshooting an Active Alarm condition, a HELP sub-menu offers possible
remedies relating to the displayed alarm. To access the Active Alarm Help sub-menu, scroll to the
alarm of interest and press the ENTER key. The diagnostic information will auto scroll initially. Enter
manual scroll mode by pressing either the UP or DOWN arrow key. Press the DOWN arrow to scroll
through the list of remedies.
Alarms are classified in two categories:
MAJOR Alarms are indications of a serious failure within the XM Series 2 Power Supply power
supply, such as a loss of output voltage or a failed battery charger. Any situation that causes the
output to be OFF can be considered a Major Alarm. Any Major Alarm, when encountered, requires
immediate action to be taken by the operator to correct the failure. To correct, simply, 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, simply, 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-B0-005 Rev. D
59
4. Operation
4.2 Smart Display, continued
Major Alarms
Active Alarm
Corrective Action
Probable cause of alarm
1. CHECK BATTERIES
2. CHECK INVERTER
36 Volt battery string below 33.3 VDC or,
48 Volt battery string below 44.4 VDC or,
Inverter failure has occurred or,
batteries will not sustain load.
LOW BATT VOLTS
1. SHUTDOWN IMMINENT
2. CHECK AC INPUT
3. CONNECT GENERATOR
36 Volt battery string below 31.5 VDC or,
48 Volt battery string below 42.0 VDC
HIGH BATT VOLTS
1. CHECK CHGR SETTINGS
36 Volt battery string above 45.0 VDC or,
48 Volt battery string above 60.0 VDC
NO BATTERIES
1. CHECK BATTERY BRKR.
2. CHECK CONNECTIONS
3. CHECK BATTERY FUSE
Detected the absence of batteries
(alarm inactive when battery capacity set to 0)
1. REPLACE POWER SUPPLY
Line isolation has failed
All inverter operations are suspended
OUTPUT FAIL
1. CHECK CONFIG. SWITCHES
2. CHECK OUTPUT FUSE
3. OUTPUT OVERLOADED?
The AC output has failed (check configuration)
OUTPUT OVERLOAD
1. CHECK CONFIG. SWITCHES
2. OUTPUT SHORT CIRCUIT?
3. TOO MUCH LOAD
4. CHECK OUTPUT CURRENT
The XM Series 2 output is overloaded
OUTPUT 1 TRIPPED
1. OVER CURRENT
2. CHECK SETTINGS
Output 1 hardware protection mode engaged
(only active with PIM option installed)
OUTPUT 2 TRIPPED
1. OVER CURRENT
2. CHECK SETTINGS
Output 2 hardware protection mode engaged
(only active with PIM option installed)
CHARGER FAILURE
1. RESEAT INVERTER
2. PERFORM SELF TEST
Charger has failed or shutdown, possible battery overtemperature
INV DISCONNECTED
1. RESEAT INVERTER
2. CHECK RIBBON CABLE
The inverter module is not properly connected
1. CHECK FAN
2. CHECK FILTER
Inverter heatsink has exceeded set temperature
(Stand-by operations suspended until temp drops to
safe level)
1. CHECK TAP FUSES
2. CHECK TAP RELAYS
One or both of the fuses in the Automatic Tap Switch
option have failed
1. CHECK CONFIG SWITCHES
2. CHECK INV MODULE
The XM Series 2 is improperly configured
Operation is suspended until error is corrected
SELF TEST FAIL
LINE ISOLATION
INVERTER TEMP
TAP FUSE FAIL
CONFIG ERROR
Table 4-1 Major Alarms
NOTE: The TAP fuse is not available in units sold in North America
60
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
Minor Alarms
Active Alarm
BATT TEMP PROBE
INPUT FAILURE
Corrective Action
1. CHECK CONNECTION
2. CHECK SENSOR
1. UTILITY FAILURE
2. CIRCUIT BREAKER INPUT
3. INPUT CONNECTIONS
4. CHECK 120/240 JUMPERS
Probable Cause of Alarm
REMOTE TEMP SENSOR (RTS)
FAILED, OR IS NOT CONNECTED
UTILITY AC INPUT
HAS FAILED
N+1 IN USE
1. CHECK OUTPUT FUSE
2. CHECK CONNECTIONS
OUTPUT OF XM SERIES 2 HAS FAILED, LOAD
HAS BEEN TRANSFERRED TO N+1 UNIT
N+1 FAULT
1. VERIFY WIRING
2. CHECK N+1 OUTPUT
INPUT VOLTAGE WAS EXPECTED ON N+1 UNIT,
BUT NONE DETECTED
Table 4-2 Minor Alarms
017-805-B0-005 Rev. D
61
4. Operation
4.2 Smart Display, continued
4.2.5
Control Panel LEDs
Two front panel LEDs indicate the condition and status of the XM Series 2 Power Supply. The green
OUTPUT LED, when illuminated, indicates the power supply is functioning normally and supplying
output AC to the load. A FLASHING 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 either flashes or is OFF depending on the operating state of the power supply. A
flashing ALARM LED indicates that a major alarm has been detected. This state will clear when the
alarm is no longer present. Normally, the red ALARM LED will be OFF indicating normal power supply
operation.
OUTPUT LED (green)
SOLID = Normal Operation
FLASHING = Minor Alarm
OFF = Major Alarm
ALARM LED (red)
FLASHING = Major Alarm
OFF = Minor Alarm
OFF = Normal Operation
Figure 4-6 Control Panel LEDs
Major Alarms are indications of a serious failure within the XM Series 2 Power Supply, such as a loss
of output voltage or a failed battery charger. Any situation that causes the output to be OFF can be
considered a Major Alarm. Any Major Alarm, when encountered, requires immediate action to be
taken by the operator to correct the failure. To correct, simply, 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, simply, follow the Smart Display on-screen
instructions.
62
017-805-B0-005 Rev. D
4. Operation
4.2 Smart Display, continued
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017-805-B0-005 Rev. D
4. Operation
4.3 Smart Display Glossary
Battery Capacity
Capacity of the battery strings that are attached to this XM Series 2 Power Supply. When batteries are
not attached, the setting must be programmed to “0.” This will disable all standby operations, including
test mode, and disable the NO BATTERIES Alarm. If batteries are attached, then this setting should
be programmed to the total rating of all 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).
NOTE: If an XM Series 2 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, 2.35VDC (adjustable) per cell, is
temperature compensated to assure longer battery life and properly completes the charge cycle and
is factory set for Alpha Cell batteries, if other 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 — averaging about 2.25VDC (adjustable) per cell.
Factory set for Alpha Cell batteries, if other 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” will disable
temperature compensation. Factory set for Alpha Cell batteries (3mV/cell). If other manufacturer’s
batteries are used, consult the battery manufacturer for Charger Temperature compensation ranges.
Device Address
The XM Series 2 Power Supply must have a unique address to communicate with a system controller.
The system controller uses the address as an identifier to query the XM Series 2 Power Supply for
information. All XM Series 2 Power Supplies on the same communications bus must be uniquely
identified by setting this address, in each XM Series 2 Power Supply, to a unique value between 1
and 7.
NOTE: This parameter is not reset to 0 when factory defaults are reset. Device addresses
8 through 15 are not implemented, and device address 0 should not be used with
a system controller.
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 Over-Current Trip level — Primary leg
Value of RMS current that causes an over-current trip on the output #1 protection relay after a
specified delay. This limit is linked to counter data item Over Current Tolerance Period. This parameter
is only effective when the Protective Interface Module is attached.
Output 2 Over-Current Trip level — Secondary leg
Value of RMS current that causes an over current trip on the output #2 protection relay after a
specified delay. This limit is linked to counter data item Over Current Tolerances Period. This
parameter is only effective when the optional Protective Interface Module is attached.
017-805-B0-005 Rev. D
65
4. Operation
4.3 Smart Display Glossary, continued
Over-Current Tolerance Period
An output over-current condition will be tolerated on either of the PIM outputs for this amount of time.
When this delay expires, the output protection relay disables the output. This counter is only used
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) will remain
on. This feature is available with the optional PIM.
Retry Delay
Protective Interface Module 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 timer is only used if the PIM is installed.
Retry Limit
Protective Interface Module fault retry count limit. This is the number of times the XM Series 2 Power
Supply will attempt to restart an output connection at the frequency specified by RETRY DELAY. Once
RETRY LIMIT is exceeded, attempts to restart the feeder will occur once every 30 minutes
indefinitely. This counter is only used if the PIM is installed.
Set Defaults
When programed by the operator to “YES,” all the programmable data levels (except DEVICE
ADDRESS) are reset to the original factory settings.
Self Test
When programed by the operator to “YES,” the XM Series 2 Power Supply will start a SELF TEST.
Standby Events
XM Series 2 Power Supply 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 XM Series 2 Power Supply has operated in standby mode. This does not
include self test time and thus represents the sum total number of minutes of AC line failure since the
last time this 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 autotest is initiated. This variable is
programmable and allows the operator to select the day that the autotest sequence will begin. This
counter has no affect if Autotest Interval is set to 0.
Test Duration
Automatic self test duration timer. The number of minutes the XM Series 2 Power Supply performs
battery maintenance cycle test. This timer applies to tests initiated automatically or manually.
Test Inhibit
When programed by the operator (or an inverter run time of 5 minutes or longer) to “+7DAYS,” the XM
Series 2 Power Supply will delay 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.
Setting this value to zero will 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
resettable value.
66
017-805-B0-005 Rev. D
4. Operation
4.4 Automatic Performance Test
Automatic Self-Test
The XM Series 2 Power Supply can periodically perform an automatic self test to verify the state of
the batteries and the inverter circuitry. The automatic test feature has several programmable
parameters that affect the frequency and duration of automatic tests. In addition to automatic testing,
the XM Series 2 Power Supply can manually be put into test mode by pressing the ENTER and the
DOWN arrow keys simultaneously. A running test may be halted manually by pressing the ENTER
and the DOWN arrow keys a second time.
The test sequence starts with a check to verify that batteries are attached and the battery circuit
breaker is closed. If the batteries are discharged or not connected, the XM Series 2 Power Supply will
NOT attempt to operate in inverter test mode, and thus NOT drop the load if the inverter does not
have sufficient batteries to operate. Next, the XM Series 2 Power Supply switches to standby mode
for a pre-programmed period. Successful completion of a test sequence means that the XM Series 2
Power Supply operated normally in standby mode, the battery voltage didn’t drop below a preset
threshold and the output was stable throughout the test. Failure of test will be indicated by a SELF
TEST FAIL alarm which can be cleared by subsequently running a successful test for at least one
minute.
Test Control
A manual test may be initiated (or a running test may be halted) at any time by pressing the ENTER
and the Down arrow keys simultaneously or by changing the SELF TEST switch via the front panel
interface or status communications. A self test may also be started via the USM2 or USM2.5 card.
Prevention of an automatic test that is scheduled to occur in the next week can be accomplished by
issuing a TEST INHIBIT command. This command is useful if periodic maintenance is scheduled to
occur on the power supply near the time that the next automatic test is to start. This control feature
may also be used when inclement weather is expected that may cause a utility failure. The TEST
INHIBIT command only affects an automatic test scheduled to run in the next 7 days. Multiple issues
of the TEST INHIBIT command will result in the deferral of the next automatic test until at least 7 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, but may be turned OFF. To turn auto-test OFF, change the
TEST INTERVAL to 0 days in the SET UP menu. Auto-test may be enabled at any time by changing
the TEST INTERVAL to any nonzero value. The default TEST INTERVAL is 30 days.
TEST COUNTDOWN has two purposes: To inform the operator of a pending automatic test, or to
allow the operator to schedule the next automatic test.
TEST DURATION can be adjusted to meet the customer’s needs. Caution must be exercised when
increasing the parameter because long self tests compromise the standby capability during and
shortly after the test.
The STANDBY TIME and STANDBY EVENTS counters are not incremented during XM Series 2
Power Supply self tests.
017-805-B0-005 Rev. D
67
4. Operation
4.5 Providing Power via External Source
In the event of an extended utility failure, backup power to the system can be provided either by an
external DC supply, or external AC supply. The backup power enables the power supply to continue
charging the batteries ensuring uninterrupted service to the network. Follow the procedures as
outlined in the documentation and/or connection procedures listed below.
4.5.1 DC Powering
A convenient method of providing backup DC power is via Alpha Technologies’ AlphaGen Portable
Generator. Upon the loss of commercial AC power, the existing battery string(s) will immediately
supply voltage to the Inverter Module. After some interval of battery discharge, an operator can
deploy the portable generator to the site to supply power to the dc bus. For complete connection and
operation information of the AlphaGen Portable Generator unit, refer its technical manual (Alpha p/n
041-024-C0).
4.5.2 AC Powering
Should it become necessary to power the CATV system with a portable AC generator, a truck
mounted AC generator or a truck mounted inverter, the procedures below must be followed for the
protection of service personnel and powering system equipment.
CONNECTION PROCEDURE:
1.
Determine if there is output power to the system by reading the SMART DISPLAY. If there is
still power to the system then check the battery voltage on the SMART DISPLAY. If the battery
voltage is greater than 34.5 VDC (3-battery system) or 46.0 VDC (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 will fail but do NOT be hasty
as there are dangerous voltages in the system that can shock you or damage the cable amplifiers.
2.
Verify the AC INPUT breaker from the utility powering system is in the OFF position. That will
ensure that were the power to return suddenly, both you and the system will NOT experience a
surge in power. And when you connect the generator, it will not put AC voltage back onto the
power lines.
3.
Properly GROUND the generator. This is accomplished 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.
NOTE: GROUNDING OF THE GENERATOR IS ABSOLUTELY MANDATORY FOR
SAFETY AND FOR PROPER OPERATION OF THE POWER SUPPLY.
Without reestablishment of this ground, the power supply loses its isolation from powering events,
surges, spikes, transients and other aberrations that may damage its sensitive electronic components.
Additionally, these power transients may find another path to ground which will, most likely, be
through the cable grounding system thus sending such damaging events into the very system that the
power supply was designed to protect.
NOTE: PROPER GROUNDING PROTECTS OPERATION AND SERVICE PERSONNEL
FROM ELECTRICAL SHOCK.
68
017-805-B0-005 Rev. D
4. Operation
4.5 Providing Power via External Source, continued
4.5.2 AC Powering, continued
4.
After properly grounding the generator, then and only then, unplug the power supply from the
convenience outlet inside the enclosure and plug the power supply input cable into the output
of the generator. An extension cord which meets the safety standards of the NEC and UL may
be used.
5.
Start and operate the generator according to the generator operator manual.
6.
If the generator kilowatt rating is twice that of the kilowatts being used by the power supply as
indicated on the ADDITIONAL INFORMATION Menu, (value shown in Watts), leave the
BATTERY BREAKER ON and the generator will charge the batteries so that were the generator
to fail for whatever reason, the power supply will continue to provide battery backup. However,
if the generator is NOT approximately twice the kilowatt rating indicated on the ADDITIONAL
INFORMATION Menu, then switch the battery breaker OFF.
NOTE: At this point, the load on the generator will be reduced, however, there will be
no battery backup available for the system.
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 ±6 Hz from the normal
±3 Hz. This will limit 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.
4.5.3 Using a Truck-Mounted Inverter or a Truck-Mounted Generator
NOTE: As a safety precaution, it is important to properly ground the vehicle before
operating the truck inverter or truck-mounted generator. Failure to do so will place
service personnel at risk for electric shock.
The same steps must be followed; however, grounding of the truck becomes necessary as normally
the truck-mounted inverter or truck-mounted generator is grounded to the truck chassis. It becomes a
simple matter to run the ground wire from an unpainted point on the truck chassis to either a driven
ground rod or strand ground as done before to complete the grounding circuit. The rubber tires on the
truck insulate it from grounding in all but the most exceptional circumstances.
017-805-B0-005 Rev. D
69
4. Operation
4.6 Resumption of Utility Power
DANGEROUS VOLTAGE!
USE EXTREME CAUTION WHEN DISCONNECTING A
GENERATOR AND RECONNECTING THE UTILITY POWER.
Care must be exercised to ensure that both powering systems are NOT connected at the same time
or damage to the power supply and/or the generator may result.
1.
Use a voltmeter to verify the input voltage is within specifications before turning on the AC
voltage input breaker.
2.
Once the proper voltage is present, verify the BATTERY VOLTAGE as indicated on the Smart
Display is greater than 31.5 or 42.0 (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 will operate 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 while you are in the act of unplugging and reconnecting the power
supply.
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.
70
3.
Turn on the AC input power.
4.
Shut down the generator and remove the grounding system that you established.
017-805-B0-005 Rev. D
5. Maintenance
5.1 XM Series 2 Power Supply Maintenance
Maintenance must be performed every three to six months. By establishing a routine maintenance
program and following the guidelines contained in this manual, the XM Series 2 Power Supply will
continue to provide years of trouble-free operation.
Care of the batteries is the first 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
identification and tracking of voltages in the maintenance log, number the batteries inside the
enclosure using labels or masking tape, etc. Batteries are temperature sensitive and susceptible to
over- and under-charging. Since batteries behave differently in the winter than in the summer, Alpha’s
battery chargers automatically compensate for changes in temperature by adjusting float and accept
charge voltages.
SAFETY PRECAUTIONS
• The XM Series 2 Power Supply must be serviced ONLY by qualified personnel.
• Use heavy gloves when handling an XM Series 2 Power Supply module that has just been
taken out of service. The ferroresonant transformer generates heat and 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 OFF the BATTERY BREAKER before
unplugging the battery connector.
• ALWAYS wear safety glasses whenever working with batteries.
IMPORTANT NOTE
PERFORM THIS CHECK FIRST AS A SAFETY PRECAUTION !
5.1.1
Check Battery Open Circuit Voltage
Prior to testing, record the batteries’ manufacturer, Date Code and lot number, and the power supply’s
Model Number and Serial Number.
Inspect all battery posts, verify that all connections are clean and tight. Reapply corrosion inhibitor.
Switch the front panel BATTERY BREAKER of the XM Series 2 Power Supply Inverter Module to
OFF. Disconnect the battery connector from the Inverter Module and measure the individual voltage
across each battery. The difference between any battery in the string should not be greater than 0.3
VDC. Defective or marginal batteries should be replaced with an identical type of battery. Record the
unloaded battery voltages in the maintenance log.
017-805-B0-005 Rev. D
71
5. Maintenance
5.1 XM Series 2 Power Supply Maintenance, continued
5.1.2 System Information
Observe and record the following system information from the “Operation Normal”, and “Additional
Information” menus in the Maintenance log in Section 5.2.
Operation Normal:
Input Voltage
Output 1 Voltage
Output 1 Current
Battery Voltage
Total Standby Time
Operation Mode
Output 2 Voltage (if PIM is installed)
Output 2 Current (if PIM is installed)
Standby Events
Charger Mode
Additional Information:
Battery Temperature
Input Frequency
Output VA
Charger Current
Output Watts
Percent Load
5.1.3
Check Battery Voltage Under Load
An unloaded battery test will not give a true indication of a battery’s health. In order to completely
verify a battery’s ability to supply load, the battery must be tested while under a load. This is the most
accurate method to determine the condition of the batteries. If available, use a battery load tester and
follow the manufacturer’s instructions to test the individual batteries. If a battery load tester is not
available, use the following procedure.
NOTE: If installed, disconnect the Battery Box–Charge Management Technology Card
(BB–CMT) prior to measuring battery voltage.
NOTE: Even with a BB–CMT present in the system, any battery which fails the 0.3V
load test must be replaced with an identical type of battery.
CAUTION:
Weak or severely discharged batteries can explode when put under load.
As an added safety precaution, place the enclosure’s door between the
operator and batteries before attempting standby operation.
Test Procedure:
1.
If the batteries appear functional (i.e., if they have passed “Check Battery Open Circuit Voltage”
test), reconnect the BATTERY INPUT connector to the Inverter Module, switch ON the BATTERY
BREAKER, WAIT for the NO BATTERIES alarm to reset.
2.
Simultaneously press the ENTER and the DOWN arrow keys on the Smart Display, to manually
start an inverter self-test.
NOTE: The XM Series 2 Power Supply will NOT go to self-test if the batteries are defective
or disconnected. Initially the battery voltage will appear to drop quickly (this is just
the “surface” charge on the batteries), after a short time in standby the battery
voltage will stabilize.
72
3.
When the battery voltage appears to stabilize (approximately 8-10 minutes), use a multimeter
to measure individual battery voltages under load.
4.
The difference between any of the batteries should not be greater than 0.3 VDC. Replace
defective or marginal batteries with an identical type of battery.
5.
Record the loaded battery voltages in the maintenance log.
017-805-B0-005 Rev. D
5. Maintenance
5.1 XM Series 2 Power Supply Maintenance, continued
5.1.4
Check Battery Charger Voltage
The advanced three-stage charging features of the XM Series 2 Power Supply are completely self
monitoring. During normal power supply operations the power supply will continuously verify the
operating condition of the battery charger. If, for any reason, the battery charger fails, a CHARGER
FAIL alarm will immediately be displayed on the Smart Display. Because of the operation of the
battery charger there are NO operator voltage checks required.
5.1.5
Check Battery Terminals and Connecting Wires
Check each battery terminal and connection. Verify the posts are clean and the crimped connectors
are tight. Terminal connectors should be torqued to 75 inch/pounds at installation and then re-torqued
to 50 inch/pounds during routine maintenance. If there is an “in-line” fuse in the battery cable, check
the fuse holder and fuse. Verify the terminals are properly greased 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 XM Series 2 Power Supply will automatically report a NO
BATTERIES alarm. This is normal for this condition and is part of the built in
safety features, the unit will NOT attempt any inverter operations, either standby
or test, during a NO BATTERY alarm.
5.1.6
Check Output Voltage
Measure the AC output voltage at the XM Series 2 Power Supply Transformer Module’s OUTPUT test
points using a true RMS AC voltmeter. Only use a True RMS meter, as other meters may not give a
correct reading.
Output voltages should appear within ±5% of rated output at a nominal line input.
SETTING
LOW (-5%)
HIGH (+5%)
87VAC
75VAC
63VAC
82.65VAC
71.25VAC
59.85VAC
91.35VAC
78.75VAC
66.15VAC
Record the voltages in the maintenance log. Output voltages can also be observed by using the
Smart Display.
5.1.7
Check Output Current
With the XM Series 2 Power Supply in normal operating mode observe the Smart Display OUTPUT
CURRENT. The value of output current will be dependant on the total amount of load connected to
the power supply. Record the current in the maintenance log.
017-805-B0-005 Rev. D
73
5. Maintenance
5.1 XM Series 2 Power Supply Maintenance, continued
5.1.8
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. Clean with a damp rag or soft,
nonmetallic brush if necessary and allow to dry completely.
NOTE: Circuit boards are static-sensitive and must be handled with care.
3.
Carefully inspect the Inverter Module for signs of burned or damaged components.
4.
Remove the Inverter Module’s cooling fan shroud and clean the fan’s foam filter. Verify that the
fan rotates easily and is free of obstructions. Replace the filter and then the fan shroud.
WARNING: DO NOT remove the fan shroud if the Inverter Module is installed into
the Transformer Module, the fan can start up without warning placing
the service technician in possible danger from moving parts.
5.
Reinstall the Inverter Module (see Section 2.3 Inverter Module Removal and Installation) and
test the XM Series 2 Power Supply for proper operation (see Section 4.1 Start-up and Test).
NOTE: When DIP switches SW1 and SW2 on PDB are reconfigured, all items in the
setup menu are reset to the original factory defaults.
WARNING: If the XM Series 2 Power Supply 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.
6.
74
If the XM Series 2 Power Supply has passed ALL previous tests (e.g. Battery Load Test, Self
Test), remove input power by turning OFF the utility input breaker. The XM Series 2 Power
Supply will go into standby operation, verify that there is no interruption to the output. Observe
the battery voltage as reported on the Smart Display. If battery voltage drops below 34.0VDC,
reapply utility power immediately. After five (5) minutes reapply utility power. The power supply
will then transfer back to normal operation, clear any alarms, and start the battery charger
(BULK mode, if needed). This test will add standby events and time to the event counter.
017-805-B0-005 Rev. D
5. Maintenance
5.2 Maintenance Log
BATTERY MAINTENANCE
Battery Number
1
2
Battery Manufacture
Date code/Lot number
Terminal check
Voltage (Unloaded)
Voltage (Loaded)
3
4
5
6
7
8
XM2 MAINTENANCE
Model Number
Serial Number
NORMAL OPERATION
Input Voltage
Output (1) Voltage
Output (2) Voltage
Output (1) Current
Output (2) Current
Battery Voltage
Standby Events
Standby Time
Charger Mode
Operation Mode
Additional Information
Battery Temperature
Charger Current
Input Frequency
Output Watts
Output VA
Percent Load
COMMISSIONING
Service Technician
Date Serviced
017-805-B0-005 Rev. D
75
6. Specifications
6.1 Specifications, XM Series 2 Power Supplies
The following tables show the electrical, mechanical, and physical specifications for the various models of
the XM Series 2 Power Supply.
ELECTRICAL INPUT
615 Models
915 Models
922 Models
1350 Models
+/- 15% of Nominal
+/- 15% of Nominal
+/- 15% of Nominal
+/- 15% of Nominal
60Hz +/- 3%
50Hz +/- 3%
60Hz +/- 3%
50Hz +/- 3%
60Hz+/- 3%
60Hz +/- 3%
0.9
0.9
0.9
0.9
Output Power
900W
1350W
2000W
1350W
Output Voltage
63VAC
63, 75, 87VAC
63, 75, 87VAC
63, 75, 87VAC
Output Current
15A
15A
22A
22.5, 15, 15A
Output Voltage
Regulation`
Inverter Output
Frequency
+/- 5%
+/- 5%
+/- 5%
+/- 5%
+/- 0.1%
+/- 0.1%
+/- 0.1%
+/- 0.1%
150% of max.
output rating
Uninterrupted
Output
90+% Line Mode
85% Inverter Mode
150% of max.
output rating
Uninterrupted
Output
90+% Line Mode
85% Inverter Mode
150% of max.
output rating
Uninterrupted
Output
90+% Line Mode
85% Inverter Mode
150% of max.
output rating
Uninterrupted
Output
90+% Line Mode
85% Inverter Mode
Input Voltage
Input Frequency
Input Power Factor
at Nominal
Output
Output Current Limit
Inverter Transfer time
Efficiency
Pim Option
Qty 2 @ 3 - 30A
Qty 2 @ 3 - 30A
Qty 2 @ 3 - 30A
Qty 2 @ 3 - 30A
Smart Display
Std 2X20 Backlit
LCD
Std 2X20 Backlit
LCD
Std 2X20 Backlit
LCD
Std 2X20 Backlit
LCD
36VDC
36VDC
48VDC
36VDC / 48VDC
31.5 VDC
31.5VDC
42VDC
31.5 / 42VDC
Float Voltage
39 - 41.4VDC
39 - 41.4VDC
52 - 55.2VDC
Equalize Voltage
39 - 44.1VDC
39 - 44.1VDC
52 - 58.8VDC
39 - 41.4VDC
52 - 55.2VDC
39 - 44.1VDC
52 - 58.8VDC
Temp Compensation
0.0 - 0.005 VDC/C
0.0 - 0.005 VDC/C
0.0 - 0.005 VDC/C
0.0 - 0.005 VDC/C
Current Charger (Max)
10 Amps
10 Amps
10 Amps
10 Amps
Typical Recharge Time
12 Hours w/ 100Ah
Battery
12 Hours w/ 100Ah
Battery
12 Hours w/ 100Ah
Battery
12 Hours w/ 100Ah
Battery
Battery
Battery Voltage
Low Voltage Cutout
Mechanical
Chassis Dimensions
15"W X 8.75"H X 14.3"D
15"W X 8.75"H X 14.3"D
15"W X 8.75"H X 14.3"D
15"W X 8.75"H X 14.3"D
381mm X 223mm X 318mm
381mm X 223mm X 318mm
381mm X 223mm X 318mm
381mm X 223mm X 318mm
Shipping Weight
60 Lbs. (27.8 kg)
80 Lbs. (36.4 kg)
100 Lbs. ( 45.5 kg)
80 Lbs. (36.4 kg)
Inverter and
Connections
Front Panel Access
Front Panel Access
Front Panel Access
Front Panel Access
Operating Temperature
-40C to +55C
-40C to +55C
-40C to +55C
-40C to +55C
Humidity
0 to 90%
Non-Condensing
0 to 90%
Non-Condensing
0 to 90%
Non-Condensing
0 to 90%
Non-Condensing
Environment
Table 6-1 Series Specifications
76
017-805-B0-005 Rev. D
6. Specifications
6.2 Electrical specifications, 60V, 90V models
60 VAC Models
Input Line
Voltage
Low Line
Voltage
High Line
Voltage
Input
Current
(max)
Input
Freq
+/-3%
Output
Voltage
+/-5%
Output
Current
Batt
Volts
XM2 622E-CE
230
184
265
15
50
63 / 48
22
48
XM2 615P
190/220/253
161/187/215
218/253/290
10
60
63
15
36
XM2 615M
100/112/127
85/95/108
115/129/146
15
60
63
15
36
XM2 615J5
100
85
115
15
50
63
15
36
XM2 615 E-CE
230
184
265
10
50
63 / 48
15
48
XM2 615E
190/220/247
161/187/210
218/253/284
10
50
63
15
36
XM2 615
120
102
138
15
60
63
15
36
XM2 610
120
102
138
8
60
63
10
36
XM2 608E-CE
230
184
265
6
50
63 / 48
8
48
XM2 615P-CB
220
187
253
10
60
63
15
36
Input Line
Voltage
Low Line
Voltage
High Line
Voltage
Input
Current
(max)
Input
Freq
+/-3%
Output
Voltage
+/-5%
Output
Current
Batt
Volts
XM2 922
200 / 240
170 / 204
230 / 276
15
60
87/75/63
22
48
XM2 915P-CB
220
187
253
10
60
87/75/63
15
36
XM2 915P
190/220/253
161/187/204
218/253/290
10
60
87/75/63
15
36
XM2 915M
100/112/127
85/95/108
115/129/146
15
60
87/75/63
15
36
XM2 915E
190/220/247
161/187/204
218/253/284
10
50
87/75/63
15
36
XM2 915
120 / 240
102 / 204
138 / 276
15 / 8
60
87/75/63
15
36
XM2 910
120 / 240
102 / 204
138 / 276
15 / 10
60
87/75/63
10
36
XM2 1350-48
120 / 240
102 / 204
138 / 276
15 / 8
60
87/75/63
15/18/22
48
XM2 1350
120 / 240
102 / 204
138 / 276
15 / 8
60
87/75/63
15/18/22
36
90 VAC Models
Table 6-2 Electrical Specifications, 60 VAC, 90 VAC Models
017-805-B0-005 Rev. D
77
6. Specifications
6.3 Safety and EMC Compliance
North American Product Compliance
•
Safety (NRTL/C):
UL1778 and CSA C22.2 No.107.1-M95
•
Electromagnetic Compatibility (EMC):
FCC Part 15, sub-part B, Class A
European Union Product Compliance
•
Safety (CE):
Low Voltage Directive:
Technical Standards:
•
Electromagnetic Compatibility (EMC):
EMC Directive:
Technical Standards:
NOTE:
78
72/23/EEC, 93/68/EEC
EN 50091-1:1993, EN 60950:1992
89/336/EEC, 92/31/EEC, 93/68/EEC
EN 50091-2:1996
A separate PRODUCT SPECIFICATION document can be supplied for models
not covered by this specification.
017-805-B0-005 Rev. D
7. Product Support
7.1 Troubleshooting
The Smart Display troubleshooting guide is designed to display typical symptoms, causes and
solutions, starting with the most obvious and working systematically through the XM Series 2 Power
Supply. Alpha Technologies recommends that the power supply’s maintenance log accompany units
brought in for bench service to aid the operator in troubleshooting the problem.
7.2 Return/Repair Information
In the event the Power Supply must be returned to Alpha Technologies for service, a Return Material
Authorization (RMA) form must accompany the unit. The form can be found at Alpha’s website
(www.alpha.com/support). 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 power supply’s maintenance log, should be included with
the returned XM Series 2 Power Supply.
7.3 Parts Ordering Instructions
When ordering parts from Alpha Technologies, contact the Customer Service Department directly:
Asia Pacific
Canada
Latin America
United Kingdom
(360) 647-2360
(604) 430-1476
(360) 647-2360
+44-1279-422110
Australia
Germany
Middle East
United States
+61-2-9722-3320
+49-9122-79889-0
+357-25-375675
(360) 647-2360
7.4 Contacting Alpha Technologies
• For general product information and customer service
7:00 AM to 5:00 PM Pacific Time, call:
1-800-863-3930
• To obtain complete technical support
7:00 AM to 5:00 PM Pacific Time, or for after-hours emergency support, call:
1-800-863-3364
(7 days per week, 24 hours a day)
017-805-B0-005 Rev. D
79
7. Product Support
7.5 Emergency Shutdown
The XM Series 2 Power Supply contains more than one live circuit. During an emergency, utility power may
be disconnected at the service entrance or main electrical panel to protect emergency personnel. But
power will still be 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. If applicable, unplug the
N+1 connections at this time.
1. Turn Battery Breaker OFF
3. Disconnect OUTPUT 1 and OUTPUT 2
2. Unplug AC Line Cord
Figure 7-1 Emergency Shutdown
80
017-805-B0-005 Rev. D
Power
www.alpha.com
Protecting The Power in Communications.
Corporate
Alpha Technologies
3767 Alpha Way
Bellingham, WA 98226
USA
Tel: (360) 647-2360
Fax: (360) 671-4936
Web: www.alpha.com
Alpha Technologies Ltd.
4084 McConnell Court
Burnaby, BC, V5A 3N7
CANADA
Tel: (604) 430-1476
Fax: (604) 430-8908
Alpha Technologies
Europe Ltd.
Cartel Business Estate
Edinburgh Way
Harlow, Essex CM20 2TT
UNITED KINGDOM
Tel: +44-1279-422110
Fax: +44-1279-423355
Alpha Technologies
Hansastrasse 8
D-91126 Schwabach
GERMANY
Tel: +49-9122-79889-0
Fax: +49-9122-79889-21
Alphatec
339 St. Andrews Street
Suite 101
Andrea Chambers
Limassol, Cyprus
CYPRUS
Tel: +357-25-375675
Fax: +357-25-359595
Alpha Technologies
Unit R5-R7 Regents Park Estate
Corner Park Rd and Prince’s Rd East
Regents Park, NSW 2143
AUSTRALIA
Tel: +61-2-9722-3320
Fax: +61-2-9722-3321
Due to continuing product improvements, Alpha reserves the right to change specifications without notice.
Copyright © 2002 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 017-805-B0-005 Rev. D.