n Operator’s n Manual Redundant Control Unit FOR CFR UNINTERRUPTIBLE POWER SUPPLIES FROM ALPHA TECHNOLOGIES
TABLE OF CONTENTS 1. Introduction.......................................................................................................1 1.1 The Alpha Redundant Control Unit (RCU) ................................................................... 1 1.2 A Tour of the RCU ........................................................................................................ 2 1.2.1 Front Panel......................................................................................................... 2 1.2.
1 Introduction 1.1 The Alpha Redundant Control Unit (RCU) Purpose: Describes the operation of Alpha’s Redundant Control Unit (Figure 1.1) Alpha’s Redundant Control Unit (RCU) provides a dual–redundant configuration, ensuring power is always supplied to the critical load. Both input voltages are monitored, so if power is lost at input 1, the RCU transfers to input 2. Input 1 is the primary source of power so the RCU automatically returns to it when power is restored.
1 Introduction 1.2 A Tour of the RCU Purpose: Describes the RCU’s controls, displays and terminal blocks (Figures 1.2, 1.3, 1.4, 1.5). 1.2.1 Front Panel (Figure 1.2) 1 Input 1 LED: Shows the presence of AC power at Input 1. 2 Input 2 LED: Shows the presence of AC power at Input 2. 3 Contactor 1 LED: Shows Contactor 1 is closed, providing primary power to the output. 4 Contactor 2 LED: Shows Contactor 2 is closed, providing secondary power to the output. 5 Output LED: Shows there is power at the output.
1 Introduction 1.2 A Tour of the RCU (Continued) 1.2.1 Front Panel (Continued) 12 Alarm Reset Switch: Shuts off the audible Red Alert alarm. 13 Attachment Screws: These two screws secure the front panel to the RCU. 14 Front Panel: This hinged panel opens downward to access the interior for voltage configuration, fuse changing or troubleshooting. 13 1 10 3 2 11 4 5 13 6 7 12 Figure 1.
1 Introduction 1.2 A Tour of the RCU 1.2.2 RCU Interior (Figure 1.3) 1 Front Panel: This hinged panel opens downward to allow the operator access to the RCU interior to configure the input/output voltage, replace fuses or for troubleshooting. Two, 3.15 Amp fuses are located here. 2 Contactors: The primary and secondary contactors. 3 Sliding Panel: This panel slides back and forth for access to the RCU’s input, output and alarm terminal blocks.
1 Introduction 1.2 A Tour of the RCU 1.2.2 RCU Interior (Continued) 1 8 2 3 4 5 6 7 Figure 1.3 RCU Interior (Cutaway View) Wiring: The wiring diagram for the terminal blocks is shown in Figure 1.4. Both Inputs share a common ground. The alarm terminal block has Type C contacts to provide Contactor and Alarm status to the monitoring system. • • • Contactor K1 is normally closed. Contactor K2 is normally open. Red Alert Alarm is open when the system is operating normally.
1 Introduction 1.2 A Tour of the RCU L1 N L2 GND L1 N L2 GND L1 N L2 Legend: COM: Common, N/C: Normally Closed, N/O: Normally Open Figure 1.4 RCU Wiring Diagram 1.2.3 Rear Panel (Figure 1.5) To access the terminal blocks, unscrew the five attachment screws then remove the panel. SOURCE 1 SOURCE 2 OUTPUT Attachment Screws Figure 1.
2 Installation 2.1 Unpacking and Inspection Checklist Carefully inspect the contents. If items appear damaged or missing, contact Alpha Technologies and the shipping company immediately. Most shipping companies have only a short claim period. Make sure the following have been included: Redundancy Control Unit and mounting kit. Operator’s Manual Any other ordered options SAVE THE ORIGINAL SHIPPING CONTAINER If the RCU is returned for servicing, pack it in its original shipping container.
2 Installation 2.2 Rack Mount Installation NOTES: 1) The RCU can be mounted in either a 19 or 23 inch rack by adjusting the configuration of the rack mount brackets. 2) Use #4 AWG for connecting the input and output terminal blocks and #18–22 AWG solid wire for connecting the communication terminal block. 3) DANGER: Before installation, make sure the Input 1 and 2 circuit breakers are OFF.
2 Installation 2.3 Wall Mount Installation NOTES: 1) Use #4 AWG for connecting the input and output terminal blocks and #18–22 AWG solid wire for connecting the communication terminal block. 2) DANGER: Before installation, make sure the Input 1 and 2 circuit breakers are OFF.
3 Operation 3.1 RCU Start–Up and Test Procedure WARNING: Before starting, turn OFF the Input 1 and 2 Circuit Breakers and the Load(s). NOTE: If there is any type of logic or contact failure during the system start-up, test or operation, the Red Alert LED turns ON. STEP 1: RCU Power Up Press the Select 1 2 contactor switch. 1 Switch ON both circuit breakers. Figure 3.1 RCU Power Up STEP 2: Test Primary Power 1 Switch the Input 1 circuit breaker OFF.
3 Operation 3.1 RCU Start–Up and Test Procedure STEP 3: Restore Primary Power 1 Switch the Input 1 circuit breaker ON. The Input 1 LED lights, showing the return of primary power. The RCU transfers back to Input 1 after about 30 seconds, after the voltage and frequency stabilizes. When done, the Contactor 1 LED turns ON. Input 1 LED Contactor 1 LED Turn ON Input 1 circuit breaker Figure 3.3 Return Primary Power STEP 4: Test Secondary Power 1 Switch the Input 2 circuit breaker OFF.
3 Operation 3.1 RCU Start–Up and Test Procedure STEP 5: Test Secondary Contactor 1 If the RCU’s Contactor 1 LED is ON: Press the Select 2 switch. As the RCU transfers to the Secondary power source the Contactor 2 LED turns ON. 2 Press the Select 1 switch to return to primary power. Select 2 Switch Contactor 1 LED Contactor 2 LED Red Alert LED Figure 3.5 Test Secondary Contactor STEP 6: Turn On The Loads If the Manual Transfer LED is ON, turn on the load(s).
3 Operation 3.2 RCU Voltage Configuration DANGER: This procedure should be done only by qualified personnel. DANGER: Verify the power is OFF before opening the front panel. NOTE: The Input 1 and 2 voltages must be configured identically. The RCU is designed so it is voltage configurable for 120/208/240 VAC. PROCEDURE: 1 Switch the Input 1 and 2 circuit breakers OFF. 2 Remove the two Phillips screws on the sides of the front panel. 3 Carefully lower the panel 45 degrees.
3 Operation 3.2 RCU Configuration Procedure 5 Position jumpers or 0 Ohm resistors according to the following chart. Req u i r ed Vo l t ag es Ju mp er Pl ac emen t Ju mp er Pl ac emen t In p u t 1* In p u t 2* 120 VAC R1, R2, R3 R7, R8, R9 208 VAC R4, R5, R6 R10, R11, R12 240 VAC R4, R5, R6 R10, R11, R12 * NOTE: Input 1 and Input 2 must always be configured for the same voltage Figure 3.7 Input 1 and 2 Jumper Configuration 6 Verify the Input 1 and 2 voltages are configured identically.
4 Maintenance 4.1 Internal Fuse Replacement DANGER: Fuse replacement should be done only by qualified personnel. DANGER: Make sure the power is OFF before opening the front panel. The RCU has four internal fuses that are accessible from the front panel. To lower the front panel: 1 Switch OFF the Input 1 and 2 circuit breakers. 2 Remove the two Phillips screws on the RCU front panel. 3 Carefully lower the front panel forward 45 degrees.
4 Maintenance 4.2 Troubleshooting The most common problems, symptoms and causes are listed in Figure 4.3. It starts off with the simplest problems, working to the most complex. If the operator can’t resolve the problem, contact Alpha Technologies. Maintenance and troubleshooting should be done only by qualified personnel.
4.3 O ptional Ma nual Bypass CB P an el O ption XF M R B ypa s s Line W 8 (W 9) B ypa s s UPS W 2 CFR U PS W5 In put Input Input B reaker W 4 S tatic S w itc h W 3 O utput B reaker B atter y C h arge r RCU RCU Input 1 Inv erte r N o rm a lly OFF Input 2 Log ic Isolation/O utput W a veform C on trol B atter y B reaker Figure 4.
4 Maintenance 4.4 Return Instructions Before returning an RCU to Alpha Technologies for repair, obtain a Return Material Authorization (RMA) number from Alpha’s customer service department. Clearly write it on the original shipping container. If you do not have it, pack the substitute container with at least three inches of shock–absorbing material. Do not use popcorn–type material. Returns should be prepaid and insured (COD and freight collect cannot be accepted).
4 Maintenance 4.6 Specifications Gen er al Sp ec i f i c at i o n s 50 A mp s 100 A mp s Input Voltage, VAC* 120 or 208/240 Input Frequency, Hz 47-63 Input Current, Amps 50 100 Input Breaker, Amps 50 100 Typical Transfer Time, (msec) 40-60 Operating Temperature (OC) 0 to +40 Width (Inches/mm) 17/432 Height (Inches/mm) 5.25/133 Depth (Inches/mm) 15/381 Weight (lbs/kg) 35/16 * Primary and secondary power source must have the same nominal voltage.
4 Maintenance 4.6 Warranty 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.
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