Vectra Charger

Switched Mode Battery Charger

Installation and Operation Manual

145VDC Industrial Charging System

Effective: June, 2005

®
Alpha Technologies
 Alpha Technologies ®

Power
 Vectra 145VDC Industrial Charging System
Installation and Operation Manual

031-186-B0-001, Rev. A

Effective Date: June, 2005

Copyright© 2005
Alpha Technologies, Inc.
A Member of the Alpha Group

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

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

NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.

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, PST, or 24/7 emergency support)
 Table of Contents
Safety Notes .......................................................................................................................... 6

1.0 Specifications ........................................................................................................... 10

2.0 Introduction to the Vectra Charger .............................................................................11

2.1 AZ328 Monitoring Control Module (MCM) ..................................................... 12
2.2 AZ435 Rectifiers ............................................................................................ 13
2.3 AC Input Distribution Module ......................................................................... 14
2.4 DC Distribution Module .................................................................................. 15
2.5 DC Main Load Disconnect ............................................................................. 16
2.6 DC Current Transducer (DCCT) .................................................................... 17
2.7 AC Monitoring Module ................................................................................... 18
2.8 DC Monitoring Module ................................................................................... 18
2.9 28VDC Power Supplies ................................................................................. 19
2.10 DC Voltage Transducer .................................................................................. 19
2.11 AZ329A High Voltage Interface Unit .............................................................. 20
2.12 Alarm Relay Module ...................................................................................... 21

3.0 Installation ............................................................................................................... 22

3.1 Unpacking and Placement ............................................................................. 22
3.2 Optional Wall-mounting Procedure ................................................................ 23
3.3 Wiring the Battery Strings .............................................................................. 24
3.4 Wiring the Service Entrance .......................................................................... 26
3.5 Installing and Removing the Rectifiers .......................................................... 27
3.6 Wiring the DC Load Terminal Block ............................................................... 28
3.7 Wiring the Alarm Relay Module ..................................................................... 29

4.0 System Startup ......................................................................................................... 30

4.1 Initial Startup .................................................................................................. 30
4.2 Startup ........................................................................................................... 32

4 031-186-B0-001, Rev. A
 List of Figures
Fig. 2-1, Vectra Charger Overview .......................................................................................11

Fig. 2-2, AZ328 Monitoring and Control Module .................................................................. 12

Fig. 2-3, AZ435 Rectifiers .................................................................................................... 13

Fig. 2-4, AC Input Breakers ................................................................................................. 14

Fig. 2-5, DC Distribution Module ......................................................................................... 15

Fig. 2-6, DC Main Load Disconnect .................................................................................... 16

Fig. 2-7, DC Current Transducer (DCCT) ............................................................................ 17

Fig. 2-8, AC Monitoring Module ........................................................................................... 18

Fig. 2-9, DC Monitoring Module .......................................................................................... 18

Fig. 2-10, 28VDC Power Supplies ....................................................................................... 19

Fig. 2-11, Optional DC Voltage Transducer ......................................................................... 19

Fig. 2-12, High Voltage Interface Unit ................................................................................. 20

Fig. 2-13, Alarm Relay Module ............................................................................................ 21

Fig. 3-1, Shroud Screw Location ......................................................................................... 22

Fig. 3-2, Vectra Charger Minimum Spacing Requirements ................................................. 22

Fig. 3-3, Wall-mount Hardware ............................................................................................ 23

Fig. 3-4, Rectifier Switch Locations ..................................................................................... 27

Fig. 3-5, Standard DC Load Terminal Block Wiring ............................................................. 28

Fig. 3-6, Optional DC Load Terminal Load Block Wiring ..................................................... 28

Fig. 3-7, Alarm Relay Module .............................................................................................. 29

031-186-B0-001, Rev. A 5
 Safety Notes
Review the drawings and illustrations contained in this manual before proceeding. If there are any questions
regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and
attention.

ATTENTION!
The use of ATTENTION indicates specific regulatory/code requirements that may affect the placement of
equipment and installation procedures.

NOTE:
A NOTE provides additional information to help complete a specific task or procedure.

CAUTION!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment.

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

6 031-186-B0-001, Rev. A
 General Safety Precautions
To avoid injury:
• This enclosure and its associated hardware must be serviced only by authorized personnel.
• Enclosure must remain locked at all times, except when authorized service personnel are present.
• Remove all conductive jewelry or personal equipment prior to servicing equipment, parts,
connectors, wiring, or batteries.
• Read and follow all installation, equipment grounding, usage, and service instructions included in this
manual.
• Use proper lifting techniques whenever handling enclosure, equipment, parts, or batteries.
• Batteries contain dangerous voltages, currents and corrosive material. Battery installation,
maintenance, service and replacement must be performed by authorized personnel only.
• Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or
replacing batteries.
• Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable
or an unconnected battery cable can result in arcing, a fire, or possible explosion.
• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized
personnel using a battery of identical type and rating.
• Avoid any contact with gelled or liquid emissions from nickel-cadmium or lead-acid batteries.
Emissions contain electrolyte that is harmful to the skin and eyes. Emissions are electrically conductive
and corrosive. Follow the Chemical Hazards notes if contact occurs.
• Do not smoke or introduce sparks in the vicinity of a battery.
• Under certain overcharging conditions, lead-acid batteries can vent a mixture of hydrogen gas that is
explosive. Proper venting of the enclosure is required.
• Follow the battery manufacturer’s approved transportation and storage instructions.

CAUTION!
Enclosure, equipment or parts may be damaged or cause damage if used or installed improperly.

To avoid damage:
• Prior to installation, verify that the AC input voltage to the enclosure and its equipment match with respect
to voltage and frequency.
• Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage
requirements of the connected equipment (load).
• Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly rated circuit
breaker for use with the equipment inside. Refer to manufacturer’s recommendations.
• Review and upgrade utility service panel circuit breaker requirements whenever the equipment within the
enclosure is changed.
• Prior to installation, contact local utilities, local building maintenance departments, and cable/ piping
locator services to ensure that installation does not interfere with existing utility or building cables/piping.
• Do not exceed the output rating of equipment. Verify load requirements prior and during connection
process.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may
have developed in your body.

031-186-B0-001, Rev. A 7
 Battery Safety Notes
WARNING!

Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery
installation, maintenance, service and replacement must be performed only by authorized
personnel.

Chemical Hazards
Any gelled or liquid emissions from nickel-cadmium or lead-acid batteries are caustic and harmful to the skin
and eyes. Emissions are electrolytic, electrically conductive, and corrosive.

To avoid injury:
• Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove
all metallic objects from hands and neck.
• Batteries produce explosive gases. Keep all open flames and sparks away from batteries.
• Use tools with insulated handles, do not rest any tools on top of batteries.
• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects
or other reproductive harm. Battery post terminals and related accessories contain lead and lead
compounds. Wash hands after handling (California Proposition 65).
• Wear protective clothing (insulated gloves, eye protection, etc.) whenever installing, maintaining,
servicing, or replacing batteries.
• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your
company’s approved chemical exposure procedures.
• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with
a solution of one pound Bicarbonate of soda to one gallon of water. Report chemical spill using your
company’s spill reporting structure and seek medical attention if necessary.
• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.
• Do not charge batteries in a sealed container. Each individual battery should have at least 0.5
inches of space between it and all surrounding surfaces to allow for convection cooling.
• All battery compartments must have adequate ventilation to prevent an accumulation of potentially
dangerous gas.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
developed on your body.
• Never use uninsulated tools or other conductive materials when installing, maintaining, servicing or
replacing batteries.
• Use special caution when connecting or adjusting battery cabling. An improperly connected battery cable
or an unconnected battery cable can make contact with an unintended surface that can result in arcing,
fire, or possible explosion.
• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by Authorized
Personnel using a battery of identical type and rating.

8 031-186-B0-001, Rev. A
 Battery Maintenance Guidelines
The battery maintenance instructions listed below are for reference only. Battery manufacturer’s instructions
for transportation, installation, storage or maintenance take precedence over these instructions.

• To prevent damage, inspect batteries every 3 months for:

Signs of battery cracking, leaking or swelling. The battery should be replaced immediately by
authorized personnel using a battery of the identical type and rating.
Signs of battery cable damage. Battery cable should be replaced immediately by Authorized Personnel
using replacement parts specified by vendor.
Loose battery connection hardware. Refer to battery manufacturer’s documentation for the correct
torque and connection hardware for the application.
• Apply battery manufacturer’s specified antioxidant compound on all exposed connections.
• Verify battery terminals and/or exposed connection hardware is not within 2 inches of a conductive
surface. Reposition batteries as necessary to maintain adequate clearance.
• Clean up any electrolyte (battery emission) in accordance with all federal, state, and local regulations or
codes.
• Proper venting of the enclosure is recommended. Follow the Battery Manufacturer’s approved
transportation and storage instructions.
• Always replace batteries with those of an identical type and rating. Never install old or untested batteries.
• Do not charge batteries in a sealed container. Each individual battery should have at least 0.5
inches of space between it and all surrounding surfaces to allow for convection cooling.
• All battery compartments must have adequate ventilation to prevent an accumulation of potentially
dangerous gas.

Recycling and Disposal Instructions

Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose
of the batteries in accordance with all federal, state and local regulations.

Electrical Safety
• Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical
connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded
portion of the enclosure (both AC and DC) prior to any installation or removal procedure.
• Always use the buddy system when working under hazardous conditions.
• A licensed electrician is required to install permanently wired equipment.
• Input voltages can range up to 250VAC. Ensure that utility power is disabled before beginning installation
or removal.
• Ensure no liquids or wet clothes contact internal components.
• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input
power is disconnected.

Mechanical Safety
• Keep hands and tools clear of fans. Fans are thermostatically controlled and will turn on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components and sharp edges.

031-186-B0-001, Rev. A 9
 1.0 Specifications
Electrical Features
Input Voltage 208/240VAC (nominal) LCD Metered Display
Phase 1 DC Voltage
Frequency 45/66Hz Output Current
Input Current 16A per module Alarms: AC Fail, Charger Fail, Distribution Breaker
Fail, LVA, HVA, Earth Fault
Power Factor >99% (Vin 230VAC, Pout 1500W)
Input/Output Protection
Efficiency >90% (Pout 1500W)
Current Limit
Output Voltage 95-145VDC
Soft Start
Output Current 20A per module, up to 4 modules per shelf
Surge Suppression
AC Ripple Level <4mV RMS Polarity Reverse
(Psophometric weighted) 100mV p-p
Control
Load Regulation < 0.5% (minimum)
Float Charging Adjustable Auto/Manual
Mechanical Equalize Charging Adjustable Auto/Manual
Charger Enclosure Standard Temperature Compensating
Dimensions 34"w x 30"d x 24"h (864 x 762 x 610mm) Current Limit Adjustable
Weight 180 lbs / 81.7kg High Voltage Adjustable
Enclosure NEMA 1 Low Voltage Adjustable
Gray ANSI 61 Low Voltage Disconnect (Optional)
Seismic Zone 4 High Voltage Shutdown (Optional)
Floor Mount Relay Contacts (for all alarms except Current Limit)
Wall Mount (optional equip. enclosure only) Contact Rated up to 3A @ 240V
Forced Ventilation (rectifier) Form C
Battery Enclosure Optional Common Form C Relay collection of any of the
Dimensions 34"w x 30"d x 30"h (864 x 762 x 762mm) above alarms for remote indication
Weight (empty) 390 lbs. / 177kg DC Distribution
Enclosure NEMA 1 Up to 12 two-pole, 5-40A distribution breakers
Gray ANSI 61 (10KAIC) , or 20 two-pole, 5-40A distribution
breakers using optional expansion DC breaker
Environmental box, with alarm monitoring.
Temperature Range 32-122ºF (0-50ºC) System DC output breaker two-pole, (10KAIC)
battery disconnect (breaker or fuse).
Humidity 0-90% Non-condensing
Main Load Disconnect (Optional)
Audible Noise <55dB at 1.5m
Standards AC Input (not a service entrance)
Maximum 4X two-pole 10KAIC (65KAIC option),
Safety: CSA (UL1012)
one per rectifier module position, 220/240 VAC
ANSI/IEEE 450, 484 single phase, 50/60Hz
ANSI/NEMA ICS-1, ICS-6, PE-5

Output current vs Input voltage (per rectifier module)

25

20
Output Current (Adc)

15

10

0
140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310

Input Voltage (VAC)

10 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger
The Vectra Charger is a switched-mode battery charger designed for a wide variety of batteries used
in utility, petrochemical, and industrial applications. This modular system accommodates up to four
20A rectifiers for a combined maximum output of 80A. Using four rectifiers at 60A load provides N+1
redundancy in the system. With and input range of 95V-145V, the unit charges a variety of batteries,
including nickel-cadmium, sealed lead-acid, and flooded lead-acid types. The Vectra charges up to
ten front-access batteries per optional enclosure. Two enclosures can be stacked on top of each other
to minimize the charger’s footprint.

AC Input Breakers

DC Output Breakers
(up to 12)
Optional Expansion
DC Breaker Box
(up to 20) AZ328 Monitoring
Control Module

Rectifiers
Optional DC Load (up to 4)
Main Disconnect

Battery String
Optional Battery
Breakers
Enclosure

Fig. 2-1, Vectra Charger Overview

031-186-B0-001, Rev. A 11
 2.0 Introduction to the Vectra Charger, continued

2.1 AZ328 Monitoring Control Module (MCM)

The AZ328 is the versatile, compact monitoring module used with the Vectra Charger. The
AZ328’s features include:

• Monitoring system voltages and currents, e.g. load voltage, battery voltage, and load
current

• Monitoring battery temperatures

• Review of alarm status

• Review of alarm history and system statistics

• Starting or stopping battery charging cycles

• Starting or stopping battery test cycles

• Unlatching battery test warning or failure alarms

• System reset

• Connection or disconnection of batteries from the system

• Modification of system parameters

For complete operation and maintenance instructions, see the AZ328 Monitoring and Control
Manual.

Fig. 2-2, AZ328 Monitoring and Control Module

12 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger, continued

2.2 AZ435 Rectifiers

The AZ435 Rectifier is a 125V, 20A, switched-mode rectifier. The Vectra Charger can
be configured with up to four AZ435s. The AZ435 offers fully regulated DC output from
a power factor corrected AC input.
Features include:

• Continuous 2500W output at 50°C

• Flexibility of control, monitoring, and adjustments

• Compact

• High efficiency and reliability

• Fan-cooled

• Active current share facilities for use with the AZ328 Monitoring Control Module
(MCM)

• All connections made via a single connector at the rear of the unit
For complete operation and maintenance instructions, see the AZ435 125V 20A
Product Manual.

Fig. 2-3, AZ435 Rectifiers

031-186-B0-001, Rev. A 13
 2.0 Introduction to the Vectra Charger, continued

2.3 AC Input Distribution Module

Current protection to the AZ435 rectifiers is provided by up to four (one per rectifier) 20A two-
pole circuit breakers located on the front of the Vectra Charger. The AC Distribution Module
provides AC power distribution to up to four rectifiers. Up to four Siemens CQD220 (65kA)
breakers or four AS168XCB2G200 (10kA) breakers can be fitted for rectifier input protection.

Fig. 2-4, AC Input Breakers

14 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger, continued

2.4 DC Distribution Module

The DC distribution module is designed for DC power distribution of up to 120A in
telecommunications and industrial applications. The module can accommodate up to 12 two-
pole circuit breakers, or up to 20 two-pole circuit breakers using the optional expanded DC
output breaker box. Auxiliary contacts associated with each breaker allows for individual DC
circuit breaker monitoring.

Electrical Specifications:

• Voltage 125V (nominal)

• 200A DC Bus Bar Rating

• Up to 12 (or optional 20) two-pole circuit breakers type S282UC

• Live Load Connections, 24-way (or optional 40-way) made directly to DC output
terminals. Bare wire ends: #10AWG for breakers up to 25A; #8 AWG for breakers above
25A

DC
Distribution
Optional Expansion Module
DC Output Breaker
Box

Fig. 2-5, DC Distribution Module

031-186-B0-001, Rev. A 15
 2.0 Introduction to the Vectra Charger, continued

2.5 DC Main Load Disconnect

The DC Main Disconnect disconnects power to all DC loads.

DC Main Load
Disconnect

Fig. 2-6, DC Main Load Disconnect

16 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger, continued

2.6 DC Current Transducer (DCCT)

The DC Current Transducer (DCCT) employs the Hall Effect to passively measure DC
current. Galvanic isolation is provided between the primary (measured) and analog output
(control) signal. The DCCT measures load current (IR)in the Vectra Charger. The monitoring
and control module reads the total rectifier current (IR) directly from the rectifiers, and then
calculates the remaining battery charging current (IB = IR – IL).
The load cables are routed through the DCCT. The size of the DCCT allows a maximum of
two #4AWG cables to pass through the unit.

Fig. 2-7, DC Current Transducer (DCCT)

031-186-B0-001, Rev. A 17
 2.0 Introduction to the Vectra Charger, continued

2.7 AC Monitoring Module

The AC Monitoring Module monitors the AC mains. If the AC mains fails, an alarm signal is
sent to the AZ328 for reporting.

Fig. 2-8, AC Monitoring Module

2.8 DC Monitoring Module

The DC Monitoring Module monitors the DC bus voltage. If the DC bus voltage fails the
module sends an alarm signal to the AZ328 for reporting. The module is located on the inner
main door in the standard configuration, or, optionally, in the expanded DC breaker box.

DC Monitoring Module

Door Mounted Breaker Box Mounted

Fig. 2-9, DC Monitoring Module

18 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger, continued

2.9 28VDC Power Supplies

The Vectra Charger uses two 28VDC power supplies to deliver power to the AZ328 and HV
Interface Board.

Fig. 2-10, 28VDC Power Supplies

NOTE:
If equipped, a third 28VDC power supply is used with an output voltage transducer.

2.10 DC Voltage Transducer

The optional DC voltage/current transducer measures bus voltage and converts it to a current
equivalent. The output can be measured with an appropriate monitoring device by connecting
at the spare transducer outlet, located in the expansion DC breaker box.

Fig. 2-11, Optional DC Current Transducer

031-186-B0-001, Rev. A 19
 2.0 Introduction to the Vectra Charger, continued

2.11 AZ329A High Voltage Interface Unit

The AZ329A High Voltage Interface Unit allows the AZ328 Monitoring Control Module (MCM)
to operate in the Vectra Charger. The AZ329A is installed in between the MCM and the rest
of the system. It provides a suitable voltage to power the MCM. It scales the system voltages
down to a level suitable for the MCM and protects inputs and outputs (except for the current
shunts and temperature probe) from faults that could cause the AZ328 to be connected to a
potential of greater than Single-ended Loop Testing (SELV) limits. The high voltage interface
unit has no serviceable parts.
For complete operating instructions, and specifications, refer to the AZ329A High Voltage
Interface Unit Product Manual.

Fig. 2-12, AZ329A High Voltage Interface Unit

Power Input 95-142VDC

Output 55VDC ±5%, 0-350mA
Voltage Inputs (Vi) 80-150VDC, > 200kΩ
Outputs Vi/3 ±0.2%, <15mA DC
CMRR >53dB, 0 – 150VDC
Alarm Inputs Suitable for AZ328 MCM
Alarm Outputs Form C, 2A @ 30VDC, 400mA @ 150VDC (resistive)
Earth Leakage Detector Range < 3mA, ³ 10 mA (see AZ329 Manual for details)
Accuracy ± 10%
Hysteresis ± 360mA
COMS Ports Suitable for AZ328 MCM and Com10 Rectifiers

20 031-186-B0-001, Rev. A
 2.0 Introduction to the Vectra Charger, continued

2.12 Alarm Relay Module

The Alarm Relay Module receives alarm data from the AZ328 Monitoring Control Module.
When an alarm is tripped the message is routed to a customer-supplied signalling device.
Monitored alarms are:

• Current limit (display only)

• AC fail

• Rectifier fail

• Low voltage

• High voltage

• Ground Fault (- or +)

• Battery fuse or breaker fail

Fig. 2-13, Alarm Relay Module

031-186-B0-001, Rev. A 21
 3.0 Installation
3.1 Unpacking and Placement
Tools Required:

• 15/16" socket or wrench

• Tin snips
• Box knife
• #2 Phillips screwdriver

1. Move the Vectra Charger to a level location.

2. Unband and remove protective covering.

WARNING!
Metal bands can cause injury. Wear protective eyewear when cutting bands.
3. Remove the left and front shroud from the bottom battery enclosure. The front shroud is
secured with nine Phillips screws. The left shroud is secured with three Phillips screws
(see below).

4. Unbolt the Vectra Charger from the pallet. The charger is secured with four 15/16" bolts
at the corners.

4. Move the Vectra Charger to its installation location with a forklift. See Fig. 3-2 for spacing
requirements.
WARNING!
The Vectra Charger must only be moved by a certified forklift operator. Use securing straps
on the load to prevent a tip-over hazard. Center of Gravity is below the midpoint in the
pictured configuration.

18"
(46cm)

36" 36"
(91cm) (91cm)

Front

48"
(122cm)

Fig. 3-2, Vectra Charger Minimum Spacing Requirements

(top view)
Fig. 3-1, Shroud Screw Location
22 031-186-B0-001, Rev. A
 3.0 Installation, continued

3.2 Optional Wall-mounting Procedure

Tools Required:

• Torque wrench with 7/16" socket

• Socket or wrench for selected 1/2" mounting hardware

The Vectra Charger equipment section can be wall-mounted using optional wall-mount
bracket kit (Alpha P/N 745-395-20). The Vectra Charger weighs approximately 300 lbs fully
configured. Alpha recommends mounting to a load bearing wall capable of supporting 1200
lbs. Mount the left and right brackets to the sides of the enclosure with the included 1/4-20
hardware (8). Torque to 72 in-lbs. The enclosure is now ready for wall-mounting. Prepare
the desired wall, and position the unit using a forklift. Secure the enclosure with customer-
supplied 1/2" hardware (6).

Included
1/4-20 Hardware
(4 each side) Customer Supplied
1/2" Mounting Hardware
(3 each side)

Fig. 3-3, Wall-mount Hardware

031-186-B0-001, Rev. A 23
 3.0 Installation, continued

3.3 Wiring the Battery Strings

Tools Required:

• #2 Phillips screwdriver
• Flat-head screwdriver
• 1/2" socket or wrench
• 6mm Allen wrench

1. Remove the left and front shrouds from the second battery enclosure.

2. Remove the battery brackets.

Battery Bracket

3. Place five batteries per shelf with the terminal facing the front of the unit.

4. Verify the battery breakers are in the OFF position.

5. Wire the battery strings according to the diagram below.

- + - + - + - + - +

- + - + - + - + - +

24 031-186-B0-001, Rev. A
 3.0 Installation, continued

3.3 Wiring the Battery Strings, continued

6. Verify the voltage and polarity of each battery string at the red and black SMH
connectors.

SMH Connector

7. Connect the battery string SMH connector to the Vectra Charger SMH connector for each
battery string. Leave the battery breakers in the OFF position.

031-186-B0-001, Rev. A 25
 3.0 Installation, continued

3.4 Wiring the Service Entrance

Tools Required:

• Ball-peen hammer
• #1 flat-head screwdriver
• 7/16" socket or wrench

1. Select and remove one of the two-inch knockouts along the left or right sides of the
enclosure. Using a left side knockout is recommended.

Location of Knockouts

2. Run the customer-supplied cabling and conduit into enclosure. Hook up the Line and
Neutral wires to the terminal block. The block is labelled “L” and “N.”

Standard Block Optional Block

3. Install the ground wire.

Ground Wire Lug

26 031-186-B0-001, Rev. A
 3.0 Installation, continued

3.5 Installing and Removing the Rectifiers

To Install:

1. Unpack and inspect the AZ435 rectifiers for shipping damage.

2. Verify the rectifier switch is in the “O” position.

3. Slide the first rectifier into place and lock to the “I” position.

4. Repeat until all the rectifiers are installed.

Open Position

Locked Position

Fig. 3-4, Rectifier Switch Locations

NOTE:
The AZ238 default is 48V. The unit will detect and set the working bus voltage only when the unit has been
powered up with an AZ435 rectifier. If the unit is powered up with battery power only, it may display the battery
voltage incorrectly until the unit has been initialized with a 125V rectifier and rebooted.

To Remove:
The AZ435 Rectifier is hot-swappable. There is no need to power the Vectra Charger down
when replacing the rectifiers. To remove an AZ435 move the locking switch to the “O” (open)
position and slide the rectifier partially out of the rack. Support the back half of the rectifier
with your other hand and remove the rectifier from the shelf.

031-186-B0-001, Rev. A 27
 3.0 Installation, continued

3.6 Wiring the DC Load Terminal Block

Tools Required:

• #1 Phillips screwdriver

• Wire cutter/stripper

The DC load terminal block is located inside the enclosure or, optionally, in the expansion DC
breaker box. Customer DC loads hook up to the lower row on the terminal block. The upper
terminal block comes prewired. Strip wires 1/2".
CAUTION!
Avoid shorting hazard by verifying no errant wire strands are left after wiring.

Connect customer load

to bottom row

Fig. 3-5, Standard DC Load Terminal Block Wiring

Connect customer load

to bottom row

Fig. 3-6, Optional DC Load Terminal Load Block Wiring

28 031-186-B0-001, Rev. A
 3.0 Installation, continued

3.7 Wiring the Alarm Relay Module

Tools Required:

• Flat-head jeweler’s screwdriver

• Wire cutter/stripper

The Alarm Relay Module comes prewired with alarm signals routed from the AZ328.
Customer alarms are installed in the “NO” (normally open) and “COM” (common) terminals
for each alarm along the alarm relay terminal block.

“NO” terminal
“COM” terminal

Fig. 3-6, Alarm Relay Module

NOTE:
The board labels “NO” and “NC” refer to the state of the contacts when the relay is energized.

031-186-B0-001, Rev. A 29
 4.0 System Startup
4.1 Initial Startup
Before starting the unit for the first time, perform the following procedures and tests:

1. The DC Monitoring Module relay jumpers are shipped in the DISABLE position. The
relay jumper must be moved to the ENABLE position to report an alarm. Use a pair of
needle nose pliers or your fingers to move each jumper you intend to use to the ENABLE
position.

Move jumpers to ENABLE position ENABLE Position

2. Test the AC input voltages at the AC terminal blocks. Voltage should be between 208-
240VAC.

Test Points

30 031-186-B0-001, Rev. A
 4.0 System Startup, continued

4.1 Initial Startup, continued

3. Test the DC bus voltage at each battery breaker, the DC main disconnect, and the DC
load terminal blocks. Voltage should be between 95-145VDC.

4. Verify the 28VDC power supply 4ADC breaker is in the ON position.

031-186-B0-001, Rev. A 31
 4.0 System Startup, continued

4.2 Startup
1. Turn the AC input breaker to the ON position. This will trigger an alarm in the AZ328.

2. Turn the battery breaker(s) to the ON position.

3. Turn the DC main disconnect to the ON position (if installed)

4. Turn the DC output breakers to the ON position.

5. Verify that no alarms are present on the AZ435 rectifiers.

6. Verify:

• No alarms are present on the AZ328

• The voltage display reads between 95-145V

• The amps display reads between 0-80

No Alarms Present

7. The unit is now in service. Refer to the AZ328 manual for instructions on customizing
your monitoring settings.

32 031-186-B0-001, Rev. A
 Alpha Technologies ®

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Due to continuing product improvements, Alpha reserves the right to change specifications without notice.
Copyright © 2005 Alpha Technologies, Inc. All rights reserved. Alpha is a registered trademark of Alpha Technologies. 031-186-B0--001, Rev A.