CFR 5000 & 5000RM Uninterruptible Power Supplies From Alpha Technologies ! Operator’s Manual
! Operator’s Manual ! CFR 5000 & CFR 5000RM Uninterruptible Power Supplies Alpha Technologies
CFR 5000 & CFR 5000RM Save This Manual It contains important installation and operating instructions. Keep it in a safe place. CAUTION Risk Of Electrical Shock To reduce the risk of electrical shock and to ensure the safe operation of the CFR 5000 and CFR 5000RM, these symbols are used throughout this manual. Where they appear only qualified personnel should carry out the instructions. A DANGEROUS VOLTAGE exists in this area. Use extreme caution. ATTENTION: Important operating instructions.
CFR 5000 & CFR 5000RM Safety Checklists DANGER: Do not expose the unit to rain or moisture. DANGER: Sealed lead-acid batteries with high energy and chemical hazards are used. This manual contains important operation and safety instructions. Only qualified personnel should service the CFR 5000 and CFR 5000RM. CFR 5000 and CFR 5000RM Safety Checklist Carefully unpack the unit. Report any shipping damage at once. Read this manual.
CFR 5000 & CFR 5000RM Safety Checklists (Continued) There are dangerous voltages inside the unit. Only qualified personnel should perform installation and maintenance. Live battery wires must not touch the unit’s chassis or any other metal objects. This can cause a fire or explosion. Inspect the batteries once a year for signs of cracks, leaks or swelling. Replace as required. When batteries are in storage, charge them at least once every three months for optimum performance and to extend their lifetime.
CFR 5000 & CFR 5000RM Table of Contents The emergency shutdown procedure is on the inside rear cover 1. Introduction ......................................... 1 1.1 The CFR Advantage .................................. 1.2 Unpacking and Inspection Checklist ......... 1.3 The Alpha CFR 5000 and CFR 5000RM .... 4. Communication .................... 35 2 3 5 Setting Up RS–232 Communications ..... 36 Using the Opening Menu ........................ 38 Menu Tree ..............................................
1 Section 1 Introduction This section introduces you to the CFR 5000 and CFR 5000RM UPS’s: • The CFR series many advantages (Section 1.1). • An unpacking and inspection checklist (Section 1.2). • An tour of the units, their connectors, switches and control panels (Section 1.3).
1 Introduction 1.1 ! 2 The CFR Advantage Advanced Power Protection Technology Alpha’s CFR Uninterruptible Power Supply (UPS) provides continuous and conditioned computer-grade AC power for computer systems, point of sale terminals, process controls, telecommunications, cable TV headend, broadband LAN, manufacturing control systems, hospital critical care and lab equipment. ! Regulation The unit maintains ±1% output regulation without using the batteries.
3 1.2 1 Introduction Unpacking and Inspection Checklist TIP: If items are missing or damaged, contact Alpha and the shipping company at once. Most shippers have a short claim period. Carefully remove the unit from its shipping container. Inspect it for damage and make sure the following items are included: One CFR series UPS. One operator’s manual. Any ordered options. Save The Original Shipping Container If you need to return the unit for servicing, pack it in the original shipping container.
1 Introduction 1.
5 1.3 1 Introduction The Alpha CFR 5000 and CFR 5000RM TIP: Unless otherwise shown in this manual, the CFR 5000 and CFR 5000RM are identical and work the same way. The major difference is the CFR 5000RM does not have internal batteries. An Alpha External Battery Pack (EBP) must be connected (Section 2.4). 1.3.1 Front Panel CFR 5000 Tower Mount Display Panel This is either the Standard Interface Display (SID) (Section 3.
1 6 Introduction 1.3 The Alpha CFR 5000 and CFR 5000RM (Continued) Feet 1.2 The Alpha CFR 5000 and 5000RM (Continued) If you don’t secure the unit with the seismic brackets, you can stop the unit from moving by screwing these down. CFR 5000 Rack Mount (RM) Display Panel This is either the Standard Interface Display (SID) (Section 3.5) or the optional Intelligent Interface Device (IID) (Alpha manual #018–029–B0–001).
7 1.3 1 Introduction The Alpha CFR 5000 and CFR 5000RM (Continued) 1.3.2 Rear Panel CFR 5000 CFR 5000RM Figure 1.1 Rear Panels Fans These fans cool the unit. They must not be blocked. Output Connector These plates are the unit’s output power connector. It is factory configured to your specifications. See Section 2.3 for wiring information. Output Circuit Breaker This resettable breaker provides additional protection to the loads.
1 Introduction 1.3 8 The Alpha CFR 5000 and CFR 5000RM (Continued) Input Line Cord or Terminal Block This is the unit’s line connector. It can either be a standard, grounded line cord or be factory configured to your specifications. Input Circuit Breaker This provides protection for the unit. It can be used as an input power on/off switch. External Ground Lug This provides a single point ground connection. Always follow your local electrical code for correct grounding.
9 1.3 1 Introduction The Alpha CFR 5000 and CFR 5000RM (Continued) RS–232 Connector This DB–9 port provides RS–232 communication (Section 2.6). LAN Interface Connector This DB–9 port provides dry contact status monitoring and output shutdown capability via LAN communication (Section 2.7). External IID An external IID plugs into this connector for remote control and monitoring.
10 Section 2 Installation This section shows you how to install and connect the CFR 5000 and CFR 5000RM UPS’s: • A pre-installation checklist (Section 2.1). • How to unpack and install the unit (Section 2.2). • How to connect the unit to the loads and the line (Section 2.3). • How to connect the external battery packs (Section 2.4). • How to connect the external alarm port (Section 2.5). • How to connect the RS–232 communications port (Section 2.6). • How to connect the LAN port (Section 2.7).
11 2.1 2 Installation Pre–Installation Checklist 2.1.1 Site Preparation Install the unit upright in a dry, well-ventilated, dust free environment. There must be at least 6 inches (152 mm) between the unit and the wall(s) for cooling and access to the front and rear panels. Do not place the unit next to air conditioning or heating thermostats. Do not connect the unit to line conditioning equipment. This can cause improper operation of both the unit and the equipment.
2 Installation 2.1 12 Pre–Installation Checklist (Continued) The unit should be wired to dedicated circuit equipped with a properly sized circuit breaker. The breaker’s size is the unit’s maximum input current (as given in the specifications) plus 25%. For example if the unit draws 32.0 Amps of current at 208 VAC, adding 25% the input current becomes 40.0 Amps. A 40 Amp circuit breaker would be OK. Always follow the local electrical code when installing or sizing circuit breakers. 2.1.
13 2.2 2 Installation Installing the Unit 2.2.1: CFR 5000 TIP: The seismic brackets can be removed if they are not required by the local code or you are not in an earthquake zone (See 5 ). Tools and Materials Required: • Fork lift or other means of transporting heavy objects (up to 381 lbs./173kg). • Screwdriver or power screwdriver with a Philips bit. • 5/8 inch socket wrench. Procedure: 1 The unit is shipped attached to a pallet.
2 Installation 2.2 14 Installing the Unit (Continued) 5 If the brackets are not used, remove the cover and the front panel as described in Section 5.4, Step 1, “Remove the Front Panel and the Cover.” DANGER: 1) There are dangerous voltages inside the unit when the cover is removed. 2) When removing or attaching the cover, do not let it touch the battery terminals, battery wires or other internal components. 6 Remove the bracket by unscrewing the 3 phillips screws attaching the bracket to the chassis.
15 2.2 2 Installation Installing the Unit (Continued) 2.2.2: CFR 5000RM Tip: The unit is shipped so that it will fit in a 19 inch rack. To fit in a 23 inch rack, reverse the position of the mounting brackets. Tools and Materials Required: • Fork lift or other means of transporting heavy objects (up to 225 lbs./102 kg). • Screwdriver or power screwdriver with a Philips bit. Procedure: 1 The unit is shipped attached to a pallet. Use a forklift to transport the unit and pallet to the installation site.
2 Installation 2.3 16 Connecting the Unit 2.3.1: Plug and Connector Danger: All wiring must meet the local electrical code. Mark all circuit breakers supplying power to the unit. Connect a dedicated ground wire to the external ground lug if the building ground is inadequate. Procedure: 1 Switch off the utility circuit breaker supplying power to the unit. 2 Plug the unit’s AC line cord into the receptacle (Figure 2.1). 3 If used, plug in an external battery pack (Section 2.4).
17 2.3 2 Installation Connecting the Unit (Continued) 2.3.2: Terminal Block Danger: All wiring must meet the local electrical code. Mark all circuit breakers supplying power to the unit. Connect a dedicated ground wire to the external ground lug if the building ground is inadequate. Procedure: 1 Switch off the utility circuit breaker supplying power to the unit. 2 Connect the line to the terminal block as given in Figures 2.2 and 2.3. • For 120 VAC units use 8 AWG (8.
2 Installation 2.3 18 Connecting the Unit (Continued) 6 2 3 Figure 2.2 Connecting the Unit (Terminal Block) F r eq u en c y Vo lt ag e* 120 VAC 60 H z 208 VAC 240 VAC 50 H z 230 VAC L N L1 L1 L2 L2 L N * Caution: Refer to the voltage and frequency ratings for the unit as shown on the nameplate. Figure 2.3 Input Terminal Block Wiring TIP: Over current protection for the AC output circuit must be provided when the unit is installed.
19 2 Installation 2.4 Connecting the External Battery Pack DANGER: There are hazardous voltages inside the battery packs. Use extreme caution. For more information on battery handling, see the safety instructions in the front of this manual. CAUTION: 1) Verify the pack’s polarity and voltage at the connector before attaching the cable to the unit.
2 Installation 2.4 20 Connecting the External Battery Pack (Continued) 4 5 Figure 2.5 Connecting an External Battery Pack to the 5000RM 4 2 5 Figure 2.
21 2 Installation 2.5 Connecting the External Alarm Port An external alarm panel can be connected to the external alarm port (Figure 2.7). The port’s contacts are rated at 30 VDC at 1 Amp. An Emergency Power Off (EPO) switch is created by wiring a switch to Pins 7 and 8. • The switch must be a SPST, N.O. type and be electrically isolated (up to 1500 VAC isolation is recommended). The connecting cable can be twisted or shielded wire not more than 100 ft. long. • The contacts must be shorted for at least 1.
2 Installation 2.6 22 Connecting the RS–232 Port The unit can be remotely setup, monitored, and tested by connecting the unit’s DB–9 connector to a computer’s serial port (Figure 2.8) or communication via a LAN with an optional SNMP agent. Windows HyperTerminal or any other terminal emulation program is used to communicate with the unit. Section 4 gives more information.
23 2.7 2 Installation Connecting the LAN Port The unit can be remotely monitored and shutdown with the unit’s DB–9 LAN port (Figure 2.9). Two dry contacts provide line failure and low battery information. A connection to the unit’s microprocessor shuts down the unit’s output. The shutdown delay, duration and recovery is controlled via RS–232 commands (Section 4.5).
2 Installation 2.8 24 Transformer Output Load Sharing 2.8.1: Transformer Output The units have a single phase output. They do NOT have three phase characteristics. Figure 2.10 shows the voltages between L1, L2 and N for 120/208/240 units and between L and N for 230 VAC units 60 Hz Units FERRO TRANSFORMER 50 Hz Units 240 VAC FERRO TRANSFORMER 32 VAC L 208 VAC 120 VAC L2 120 or 88 VAC 88 VAC NEUTRAL 120 VAC L1 240 or 208 VAC 230 VAC 120 VAC NEUTRAL Figure 2.10 Transformer Output 2.8.
25 2.8 2 Installation Transformer Output Load Sharing (Continued) 2.8.2.1: Measuring the Output Current This uses a clip-on current probe (Figure 2.12 for 240 VAC, Figure 2.13 for 208 VAC and Figure 2.14 for 230 VAC). For 120/208/240 VAC units the total current drawn from Winding 1 is the sum of the currents A, B and C where: • A is the total current drawn by all of the 120V loads connected to the receptacle. • B is the total current drawn by all of the 240V loads connected to the receptacle.
2 Installation 2.8 26 Transformer Output Load Sharing (Continued) The total output current for 230 VAC units is measured at A. A L 230 VAC Receptacle 230 VAC N Output Terminal Block Figure 2.14 230 VAC Current Measurement Point 2.8.2.2: Displaying the Output Current TIP: When using the display panels, you must calculate L1’s current as described below. Using the SID Display Panel: The current is displayed via RS–232 as Output Current 1 and Output Current 2 (Section 4.4.3).
27 Section 3 Operation This section shows you how to operate the CFR 5000 and CFR 5000RM UPS’s: • How to turn the unit on and off (Sections 3.1, 3.2). • How to start the unit’s self test (Section 3.3). • How to troubleshoot the unit with the SID (Section 3.4). • How to use the Standard Interface Device (SID) (Section 3.5).
3 28 Operation 3.1 Turning On the Unit WARNINGS: 1) This unit runs warm to the touch. During the first few weeks of operation, a brand new unit may give off an odor caused by the burning of the transformer’s lacquer finishing. This is normal and is not toxic. 2) The unit generates electromagnetic radiation. Keep all sensitive magnetic media such as floppy disks, recording tape, key cards, bank and credit cards away from it. Procedure: 1 Switch off: • All loads connected to the unit.
29 3.1 3 Operation Turning On the Unit (Continued) Cold Start Procedure This starts the unit with battery power when line power is unavailable or unqualified. Backup battery power is provided to the loads. 1 Switch on the battery circuit breaker. 2 For units with the: • SID display panel, press the Manual Start button. The unit’s alarm beeps every 20 seconds, indicating it is running on battery power. • IID display panel, press the Test button. Cold Start Finished 3.
3 Operation 30 3.3 Testing the Unit The self test confirms the unit can switch from line power to backup battery power and back without interrupting power to the loads. It takes about one minute to run. Before starting: • For the CFR 5000RM, the external battery pack must be connected. • The battery circuit breaker must be on. • The control panel’s Line Present LED must be on. Procedure: 1 Press the Manual Start button down for 5 seconds.
31 3 Operation 3.4 Troubleshooting With the SID The SID’s Output Load LEDs have two functions: • When the unit is operating normally, it serves to show the unit’s output loading. • When the Service LED is on, the load LEDs are turned into a fault indicator for as long as the Alarm Off button is pushed and held down. TIP: See Section 5.2 for more troubleshooting information. Procedure: 1 When the Service LED is on, press and ALARM OFF MANUAL START hold down the Alarm Off button.
3 32 Operation 3.5 Controlling the Unit With the Standard Interface Device (SID) The Standard Interface Device (SID) display panel (Figure 3.2) shows vital operating parameters and starts the self test. It has two push buttons, five LEDs showing the power drawn by the loads and six LEDs showing the unit’s operating status. ALARM OFF MANUAL START OUTPUT LOAD LINE PRESENT LOW BATTERY WARNING LINE FAILURE LOW BATTERY SHUTDOWN 100% SERVICE TEST 50% OVERLOAD 75% 25% Figure 3.
33 3 Operation 3.5 Controlling the Unit With the Standard Interface Device (SID) (Continued) Low Battery Shutdown This red LED turns on when the battery voltage is 12% below nominal. The unit automatically shuts itself down and no longer provides power to the loads to prevent overdischarge damage to the batteries. Test This yellow LED shows the unit is in self test mode (Section 3.3). If it fails the test, the Service LED is on and the unit defaults to Line Present operation.
3 Operation 34 3.5 Controlling the Unit With the Standard Interface Device (SID) (Continued) Output Load These five green LED's show the unit’s loading as a percentage of its maximum output. The Overload LED is on if: • The output exceeds the unit’s maximum rating. • The output exceeds either of the transformer output winding ratings (Section 2.8). WARNING: Do not run the unit when it is overloaded. Damage to the unit, the inverter or the batteries can result.
35 Section 4 Communication This section shows you how to control the CFR 5000 and CFR 5000RM UPS’s with RS–232 computer commands: • How to setup communications with Windows© HyperTerminal (Section 4.1). • How to understand and use the opening menu (Section 4.2). • A description of the menu tree (Section 4.3). • Descriptions of the system, input and output and battery parameters menus (Section 4.4). • Descriptions of the user and maintenance parameters (Sections 4.5 and 4.6).
4 Communication 36 4.1 Setting Up RS–232 Communications Wire the DB–9 connector as shown in Section 2.6, “Connecting the RS–232 Port.” Windows HyperTerminal Connection For this tutorial, Com 1 is used and the unit is called CFR. Procedure 1 The path is Start/Programs/Accessories/Communications/HyperTerminal. 2 Click on the Hypertrm.exe icon. The Connection Description screen appears (Figure 4.1). Enter a name and choose an icon for your unit. Click OK. Figure 4.
37 4 Communication 4.1 Setting Up RS–232 Communications (Continued) 4 The Com 1 Properties screen appears (Figure 4.3). Fill out the fields as shown. 5 Click OK. Figure 4.3 COM 1 Properties Screen 6 The CFR Screen appears. 7 Press Enter to go to the Opening Menu (Figure 4.4). The Opening Menu (Figure 4.5) appears.
4 Communication 4.2 38 Using the Opening Menu The opening menu (Figure 4.5, also see Figure 4.4) is the top-level menu. It shows the line’s status, displays if any alarms are present and gives access to the main menus. It is reached from anywhere in the menu tree by pressing Enter. The entire menu tree is given in Section 4.3. Tables describing the main and sub menus are given in Sections 4.4 to 4.7. Procedure: To access a particular main or sub menu, type in the number and press Enter.
39 4.2 4 Communication Using the Opening Menu (Continued) Figures 4.6 to 4.9 list the alarms, how they appear on the screen and what they mean. In p u t Alar m s N am e S h o w s o n S c r een F r eq u en c y L o w FREQ_L O The input frequency is low. F r eq u en c y H i FREQ_HI The input frequency is high. Glit c h GL ITCH The unit detects a glitch. Sp i k e SPIK E The unit detects a spike.
4 40 Communication 4.2 Using the Opening Menu (Continued) Ou t p u t Alar m s N am e S h o w s o n S c r een Ou t p u t Vo lt ag e Low VOLT_L O C au s e The unit is over loaded or there is a unit fault. Reduce the number of loads connected to the unit. This can be caused by: Ou t p u t Vo lt ag e Hig h --A piece of equipment that draws power at irregular intervals. Disconnect the suspect equipment and see if the alarm repeats. VOLT_HI --The unit is defective. Have it serviced by Alpha.
41 4 Communication 4.3 Menu Tree • To reach any main or sub menu from the opening menu, type its number and press Enter. • Detailed descriptions of each menu is given in Sections 4.4 to 4.7.
4 42 Communication 4.4 System, Input, Output & Battery Parameters Main menus #1 to #4 are read only menus which display important operating parameters. 4.4.1 Main Menu #1: System Parameters This displays the battery temperature (°C) and starts and stops the self test. • Sub menu 11 starts the self test. The test’s default duration is 60 seconds. • Sub menu 12 lets you stop the test before it has finished. 4.4.2 Main Menu #2: Input Parameters This displays selected input parameters.
43 4 Communication 4.4 System, Input, Output & Battery Parameters (Continued) 4.4.3 Main Menu #3: Output Parameters This displays selected output parameters. See Figure 4.12 for 120/208/240 VAC, 60 Hz units to see where the voltages and currents are measured. See Figure 4.13 for 230 VAC, 50 Hz units. TIP: If the unit has dual outputs, you have the option of displaying the voltage and current of each output individually.
4 44 Communication 4.4 System, Input, Output & Battery Parameters (Continued) L 230 VAC Receptacle Output Voltage 1 N Output Current 1 Output Terminal Block Figure 4.13 Output Voltage and Current Measurement Points (230 VAC, 50 Hz Units) 4.4.4 Main Menu #4: Battery Parameters This displays the battery voltage, the charger current and the charger’s status. Item #40 is disabled in this model. B at t er y P ar am et er s This is the DC voltage of the battery string.
45 4 Communication 4.5 User Parameters Main menu #5, user parameters, lets you set up the automatic self test, remotely shut down the unit, change the password and set up RS–232 communications with or without an external modem. To access most of these functions, you need to enter a password. The factory set password is 1111. If you change it (Items #58 and #59), make sure you keep a copy of it in a safe and easily accessible place or you will not be able to access the unit. 4.5.
4 Communication 46 4.5 User Parameters (Continued) Us er Par am et er s (Co n t in u ed ) 56 56 Tr an s m it U n s o l i c i t ed A l ar m s This allows you to start or stop the transmission of unsolicited alarms. This menu's use is explained in Section 4.5.3, "Sub Menu #56: Transmit Unsolicited Alarms." This lets you change the password. 58 58 S et U s er S ec u r i t y C o d e The factory set password is 1111. If you change it, make sure you keep the new code in a safe, secure place.
47 4 Communication 4.5 User Parameters (Continued) Set Ou t p u t Sh u t d o w n Par am et er s (Co n t in u ed ) This starts the shutdown. The 6 Power LEDs on the display panel flash in sequence to show the unit is alive, but the output is turned off.
4 48 Communication 4.5 User Parameters (Continued) 4.5.3 Sub Menu #56: Transmit Unsolicited Alarms These menus allow you to prevent or delay the continuous transmission of alarms in areas with unstable line power. Tr an s m it Un s o lic it ed Alar m s 509 D i s ab l e Tr an s m is s io n o f U n s o l i c i t ed A l ar m s Setting this to "Active" stops the transmission of all unsolicited alarm messages. "509 None (xxxx)" where xxxx= "Active" or blank. Active is default.
49 4 Communication 4.6 Maintenance Parameters Main menu #7, maintenance parameters, allows you to adjust the unit’s detection and warning parameters to suit your local line conditions. Usually these factory settings never have to be changed. CAUTION: Improper settings can damage the unit. If you have any questions, contact Alpha Technologies before changing them.
4 Communication 50 4.7 Installing and Using the External Modem Uses of the External Modem Where a network is not available, you can connect an external modem to the CFR’s RS–232 port. The modem lets you: • Program the CFR to send an alarm message to a remote host via the telephone line when a power event takes place. • Dial up the CFR for remote monitoring or control. Once connected, all RS–232 menus are accessible.
51 4 Communication 4.7 Installing and Using the External Modem (Continued) Step 1: Enable the CFR’s Modem Feature The CFR is shipped with the modem feature disabled. To enable it: 1 Connect a computer to the CFR’s RS–232 port (Sections 2.6, 4.1). 2 Go to Menu Item #52 (Figure 4.19). (For explanations of each item see “Modem Setup and Control: Sub Menu #52” in this section.
4 52 Communication 4.7 Installing and Using the External Modem (Continued) Step 2: Connect and Configure the Modem Use a shielded, null-modem serial cable, DB–25 male to DB–9 male, to connect the modem to the CFR. 1 The most common ways to connect the cable are: • A null-modem cable with DB–25 male to DB–-9 male ends (Figure 4.20). • A null-modem cable with DB–25 male to DB–25 male ends and a 9–25 adapter. • A standard straight-through cable with DB–9 male to DB–25 female and a nullmodem adapter.
53 4 Communication 4.7 Installing and Using the External Modem (Continued) 3 The initialization string (Item #527) is a set of commands the CFR sends to the modem to initialize it. For a US Robotics modem, the string is: • ATX4Q0V1&H0&R1&I0&B1 Where: • X4: Extended set of result codes. • Q0: Result codes are displayed. • V1: Display verbal (words not numbers) result codes. • &H0: Disable transmit data flow control (neither hardware “CTS” nor software “Xon/Xoff” flow control).
4 Communication 54 4.7 Installing and Using the External Modem (Continued) Step 3: Initalize the Modem To initalize the modem start a CFR self test (Section 3.3). The CFR must initialize the modem. If a remote host calls before initialization, the CFR/ modem combination will not answer the call. TIP: If the modem is set for auto answer and a call is answered before the CFR initalizes it, the modem uses its own baud rate which may not be the 1200 baud used by the CFR.
55 4 Communication 4.7 Installing and Using the External Modem (Continued) How the CFR Sends Alarms To send an alarm, the CFR sends the dial command to the modem and waits up to 60 seconds for a “connect.” If this fails, it will try the same dial command two minutes later if the modem responds back to the CFR with a “No Carrier,” “No Dial Tone” or “Busy” messages. If the modem does not respond (it is disconnected, not powered or is inoperable), the CFR tries to initalize the modem.
4 56 Communication 4.7 Installing and Using the External Modem (Continued) Ex t er n al Mo d em Set u p Men u s 520 E n ab l e A u t o m at i c A l ar m s Enable this feature near the end of the configuration session since the CFR will try to communicate with the modem two minutes after this feature is activated. When set to "Yes," this causes the modem to dial out and report a problem when it occurs (see Item #522). The default value is No.
57 4 Communication 4.7 Installing and Using the External Modem (Continued) Ex t er n al Mo d em Men u Set u p Men u s (Co n t in u ed ) 523 Set In v er t er A l ar m D el ay Setting this delays the transmission of "UPS003-Inverter on" messages for 1 to 5 minutes to prevent short interruptions in the line from being displayed. Setting it to 0 causes the immediate sending of the message.
58 Section 5 Maintenance This section describes how to maintain the CFR 5000 and CFR 5000RM UPS’s: • How to measure the battery backup time (Section 5.1). • How to troubleshoot the unit (Section 5.2). • How to return the unit to Alpha for repair (Section 5.3). • How to replace the CFR 5000’s internal batteries (Section 5.4). • How to change the unit’s input and output voltages (Section 5.5). • Typical battery run times (Section 5.6). • Specifications (Section 5.7).
59 5 Maintenance 5.1 Testing the Battery Backup Time This test measures how long the batteries can provide backup power by having them power the loads until they are discharged. Tips: • This test should be done once a year when the batteries are new. When the batteries are three years old or older, it should be done once every six months. • This test should be done when new loads are connected to the unit.
5 60 Maintenance 5.2 Troubleshooting Most problems involve: • Are the input, battery and output circuit breakers switched on? • Is the input voltage correct? • Are the batteries expired? If the unit fails to perform a specific function, Figure 5.1 lists typical symptoms, causes and solutions, starting with the most obvious and working systematically. If you cannot resolve a problem, contact Alpha’s customer service department. The unit’s electronics require no maintenance.
5 61 5.2 Maintenance Troubleshooting (Continued) Sy m p t o m C au s e No output. The Line Present and Line Failure LEDs are off or the Line Present is flashing. Line power absent or out of tolerance and the batteries are not connected. R em ed y Check the input voltage. Check the battery connections. Input circuit breaker off. and Battery circuit breaker off. Check to see both breakers are on. No output. Line Present LED or Line Failure LED is on. The output circuit breaker is off. Turn it on.
5 62 Maintenance 5.3 Returning the CFR to Alpha for Repairs If you need to return a unit for repair, obtain a Return Material Authorization (RMA) number from Alpha Technologies’ customer service department. Clearly write it on the original shipping container. If you do not have the container, pack the replacement with at least three inches of shock-absorbing material, but do not use popcorn type packaging. Returns should be prepaid and insured (COD and freight collect cannot be accepted).
63 5.4 5 Maintenance Replacing the Internal Batteries (Continued) Tools and Materials Required: • Phillips Screwdriver. • 7/16 and 3/8 inch wrenches for the battery connectors. • DC Voltmeter. Step 1: Remove the Front Panel and the Cover Procedure: 1 Switch off the Input and Battery circuit breakers. 2 Do not disconnect the unit from line power (See Step 2, “Charger Voltage Test”). 3 Disconnect all loads.
5 64 Maintenance 5.4 Replacing the Internal Batteries (Continued) Step 2: Charger Voltage Test This tests the unit’s charger so the new batteries will not damaged by a faulty charger. Do this before removing the batteries. Procedure: 1 Make sure: • The Battery circuit breaker is switched off. • The Input circuit breaker is switched on. • The utility line is connected. 2 Measure the DC voltage by: RED WIRES 2) CONNECT NEGATIVE (-) TO THE UPS’S CHASSIS.
5 65 5.4 Maintenance Replacing the Internal Batteries (Continued) Step 3: Battery Replacement Procedure: WARNING: Always remove the copper straps first and attach them last to reduce the chance of sparking. 1 Disconnect: 1) The copper straps. 2) The battery connection wires. 3) The in-line fuse.
5 Maintenance 5.4 66 Replacing the Internal Batteries (Continued) 2 Unscrew the battery retaining bars and remove them. Remove the top batteries first, then the bottom two batteries. 3 Starting at the bottom, install the new batteries. Battery Retaining Bars Battery Retaining Bars 4 Reinstall the battery retaining bars 5 Rewire the batteries. 6 Reattach the cover, the front panel, the loads and the line. 7 Restart and test the unit as given in Section 3.1.
5 67 5.5 Maintenance Configuring the Input/Output Voltage The unit is factory configured to your input/output voltage specifications. • Units configured for 230 VAC, 50 Hz input/output cannot be re-configured. • Units configured for 120, 208 or 240 VAC input/output voltage can be re-configured to 120, 208, 240 VAC input/output voltage. DANGER: Lethal levels of voltages and currents are inside the unit when it is connected to line and battery power.
5 68 Maintenance 5.5 Configuring the Input/Output Voltage (Continued) 4 Reconfigure the DIP switches and the jumpers on the main board according to the table printed on it (see diagram below). Main Board Reconfiguration Finished. Go to Step 2. Step 2: Reconfigure the Input Terminal Block 1 Find the input terminal block, which is on the right hand side of the unit when you are facing the batteries.
69 5.5 5 Maintenance Configuring the Input/Output Voltage (Continued) Input Terminal Block Reconfiguration Finished. Go to Step 3. Step 3: Reconfigure the Output Connectors 1 On the inside rear panel are four standoffs with the neutral and the 120/208/240 connectors as shown in the diagram below. 240 VAC 208 VAC Neutral 120 VAC Ground Stud 2 Wire the output connector(s) to the output voltage you need. 3 Reattach the cover and the front panel. 4 Turn on the unit (Section 3.1).
5 Maintenance 5.5 70 Configuring the Input/Output Voltage (Continued) 5.5.2: CFR 5000RM Procedure: Step 1: Reconfigure the Main Board 1 Turn off all loads. Make sure the Input and Battery circuit breakers on the rear panel are switched off. 2 Remove the top panel. 3 Find the main board, labeled as 700–255–xx, on the top right hand side of the interior when you are facing the rear panel.
5 71 5.5 Maintenance Configuring the Input/Output Voltage (Continued) Step 2: Reconfigure the Input Terminal Block 1 Find the input terminal block, which is mounted in front of the main board as you are facing the rear panel. Input Terminal Block Re a r Pa nel 2 If needed, configure the terminal block to the input voltage you are using as shown below.
5 72 Maintenance 5.5 Configuring the Input/Output Voltage (Continued) Step 3: Reconfigure the Output Terminal Block 1 Find the output terminal block, which is mounted on the bottom panel between the transformer and the rear panel. Output Terminal Block 2 If needed, configure the output terminal block to the output voltage you are using as shown below.
5 73 Maintenance 5.6 Battery Run Times The times in these charts are to be used in conjunction with the battery run time you measured in Section 5.1, “Testing the Battery Backup Time.” Tips: • Your run time can vary by ± 15%. Battery run time is affected by temperature, battery age and condition and the size and type of the loads. • End of battery life is defined when the battery capacity falls below 80% of rated capacity. • Times shown are averaged over a batch. • All battery voltages are 48VDC.
5 74 Maintenance 5.7 Specifications C o m m o n S p ec i f i c at i o n s Mec h an ic al Sp ec if ic at io n s 5000 5000R M 12.0 x 22.4 x 29.4 (305 x 569 x 747) 17 x 12.25 x 17 (432 x 311 x 432) 375 (170) 381 (173) 225 (102) 231 (105) In p u t Fr eq u en c y (Hz ) 50 ± 3, 60 ± 3 In p u t Vo lt ag e Var iat io n -20% to +10% VAC Ou t p u t Fr eq u en c y (Hz ) In v er t er m o d e ± 0.
75 A Adjusting Unit to Local Line Conditions ............... 49 Alpha, Returning Unit to for Repair ...................... 62 Alarm Off Button on SID Panel .............................. 33 Alarms On Display Panel ........................................... 32–34 RS–232 ......................................................... 39–40 Starting/Stopping of RS–232 Transmission ......... 48 Alarms, Turning Off Audible Alarm ....................... 33 Alarm Port, use of and Wiring ...............................
Index Computer Also See RS–232 Communications Communications Parameters ........................ 22, 37 Connecting to a Computer .................................. 22 Controlling Unit With ...................................... 35–57 External Modem Connection .......................... 50–57 Isolation, RS–232 Signal .................................... 22 With Windows HyperTerminal ........................ 36–37 76 External Alarm Panel, use of ................................
77 Internal Battery Replacement .......................... 62–66 Isolation, Signal, RS–232 ....................................... 22 Items Damaged in Shipping .................................... 3 L LAN, connection ..................................................... 23 LEDs Flashing .................................................... 32–34 LEDs On Display Panel ...................................... 32–34 Index Mounting to Floor ..............................................
Index RS–232 .........................................................35–57 Remote IID ........................................................... 9 78 SID Display Panel ................................................... 32 Removing Cover ..................................................... 63 Specifications ......................................................... 74 Battery Run times ............................................... 73 Removing Seismic Brackets .............................
79 Index V Voltage Adjusting Unit to Local Line Voltages ................. 49 Changing Voltage, Input/Output ..................... 67–72 Battery Charger Voltage Test .............................. 64 Battery String Voltage Measurement ................... 44 Line, Acceptable Ranges .................................... 11 Input/Output Measuring via RS–232 ........................ ................................ See RS–232 Communications W Warnings Labels, on Utility Panel, Placing ........................
Warranty 80 LIMITED 24-MONTH WARRANTY AC PRODUCTS Alpha Technologies warrants its equipment to be free of manufacturing defects in material and workmanship for a period of 24 months from the date of manufacture. The liability of Alpha Technologies under this warranty is solely limited to repairing, replacing, or issuing credit for such equipment (at the discretion of Alpha Technologies), provided that: 1.
Emergency Shutdown Procedure The unit has more than one live circuit. During an emergency, line power may be disconnected at the unit’s input but power can still be present at the output. Turn OFF the: 1 Input Circuit Breaker 2 Battery Circuit Breaker ALTERNATE PROCEDURE: 1 If used, press down the Emergency Power Off (EPO) Switch for 3 to 5 seconds. Emergency Power Off Switch (mounted on wall) 2 Turn off the Input Circuit Breaker.
Alpha Technologies 3767 Alpha Way Bellingham, WA, USA 98226 Tel: (360) 647–2360 Fax: (360) 671–4936 Alpha Technologies 4084 McConnell Court Burnaby, BC, Canada V5A 3N7 Tel: (604) 430–1476 Fax: (604) 430–8908 Alpha Technologies Cartel Business Estate Edinburgh Way Harlow, Essex CM20 2TT, UK Tel: +44–1279–422110 Fax: +44–1279–423355 Alpha Technologies GmbH Hansastrasse 8 D-91126 Schwabach, Germany Tel: +49–9122–79889–0 Fax: +49–9122–79889–21 MTI Technologies P.O.
