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Alpha FXM 650, 1100, 2000 UPS

Installation and Operation Manual

Summary of content (88 pages)

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Alpha FXM 650, 1100, 2000 UPS Installation and Operation Manual member of The Group™ Your Power Solutions Partner
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Alpha FXM 650, 1100, 2000 UPS Installation and Operation Manual 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, contact Alpha Technologies or your nearest Alpha representative.
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Table of Contents 1. Safety ��4 1.1 Safety Symbols �� 4 1.2 General Warnings and Cautions �� 5 1.
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7. Maintenance ��68 7.1 Updating the Software �� 68 7.2 Testing and Replacing the Batteries �� 71 7.
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1. Safety SAVE THESE INSTRUCTIONS: This manual contains important safety instructions that must be followed during the installation, servicing, and maintenance of the product. Keep it in a safe place. Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. 1.
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1.2 General Warnings and Cautions You must read and understand the following warnings before installing the Alpha FXM and its components. Failure to do so could result in personal injury or death. • Read and follow all instructions included in this manual. • Do not work alone under hazardous conditions. • Only qualified personnel are allowed to install, operate and service this system and its components. • Use proper lifting techniques whenever handling equipment, parts, or batteries.
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• Never let live battery wires touch the Alpha FXM, the enclosure or any other metal objects. This can cause a fire or explosion. • Never dispose of batteries in a fire. The batteries may explode. Follow the manufacturer’s directions and check with your local jurisdictions for safe battery disposal. • Before attaching the batteries to the Alpha FXM, make sure that the polarity is correct.
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2. General Description 2.1 Overview The Alpha FXM is available in 3 models – FXM 650, FXM 1100 and FXM 2000. The FXM 650 and the FXM 1100/2000 look different, but all of the front panel connectors and circuit breakers operate in the same way. However the circuit breakers for each unit have different ratings. See “Specifications” for details. All units operate in the same way unless stated otherwise in this manual. • FXM 650-24VDC – with a 24 VDC battery string voltage.
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Battery Breaker 1 This circuit breaker provides over-current protection and is uses as an on/off switch for the battery power. It must be switched on for proper Alpha FXM operation. 2 Battery Connector The battery connector connects the external batteries to the Alpha FXM. 3 Internal Fan This microprocessor-controlled fan regulates the Alpha FXM’s internal temperature for optimum performance. It must not be blocked. If the fan fails, an Alarm is generated.
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Microprocessor UPS Interior The contacts have a maximum rating of 1A at 250V. Normally Closed (NC) Normally Open (NO) Common (C) Figure 3 — Contact Layout (Standard for C1 to C5, Factory Option for C6) C1: The C1 contact is energized when line power is unqualified and the Alpha FXM provides backup battery power to the load(s). It can be called the “On Battery” contact. C2, C3: These contacts are energized when the battery drops below a pre-set voltage level.
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Contacts C7 and C8 10 These optically isolated inputs are used to attach an external switch panel for remote control of the Alpha FXM or to allow the Alpha FXM to control Alpha Technologies’s optional Automatic Transfer Switch (ATS). User Input (C7): This relay has three contacts that are used to control the Alpha FXM (Figure 5). They are: 19 (S1): Shorting this contact starts the Alpha FXM’s battery test. See “Operating the Alpha FXM, Battery Test”.
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3. Site Planning WARNING! Restricted Access: The Alpha FXM must be installed in a restricted area accessible only by qualified service personnel. The Alpha FXM is intended for permanent AC connection only. The only exception is the FXM650(U) model. The Alpha FXM must be correctly grounded for proper operation. Older facilities may have inadequate electrical grounding. Inspection must be performed by a qualified electrician before installation to ensure that grounding meets the local electrical code.
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• In the Generator mode, the Alpha FXM’s range of acceptable input frequency and voltage is expanded to accept the fluctuations created by a generator. See “Operating the Alpha FXM, Sense Type”. Use a generator with electronic speed and voltage controls which produces less than 10% voltage total harmonic distortion (THD). Mechanical governors can force the Alpha FXM to run continuously in the Battery mode.
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4. Unpacking Alpha FXM Follow these guidelines for unpacking the Alpha FXM. WARNING! The Alpha FXM. is heavy, up to 16 kg (35 lb). Use proper lifting techniques. The lifting and moving should be done by at least two people to avoid injury. 1. Select a suitable area for unpacking. 2. Store all the packing material and boxes for possible equipment returns. 3. Check the contents in your product package. See “Checking the Package Contents” on this page. 4.
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5. Installation WARNING! The Alpha FXM module MUST be correctly grounded for proper operation. The input and output lines to and from the Alpha FXM. MUST have disconnect devices attached. The Alpha FXM must be installed in a restricted area accessible only by qualified service personnel. Once the installation location has been planned and prepared, you are ready to install the Alpha FXM. There are three steps to setting up the Alpha FXM: 1. Mounting the Alpha FXM. 2. Wiring the external batteries. 3.
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5.1.1 Mounting the Alpha FXM The Alpha FXM can be placed on a shelf with no other parts needed. Any version of the FXM can be rack or wall mounted or secured to a shelf, such as on an outdoor enclosure’s shelf, with the optional mounting brackets as shown in the figure below The brackets and the screws to attach them to the Alpha FXM’s case are available from Alpha Technologies (part number 740-697-21).
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5.2 Wiring the External Batteries WARNING! The batteries must be installed by qualified personnel trained in the safe use of highenergy power supplies and their batteries. Refer to the safety section in this manual. • Use new batteries when installing a new unit. Verify that all batteries are the same type with identical date codes. • For the FXM 650-24, the battery string is 24 VDC. For the FXM 650-48/1100/2000, the battery string is 48 VDC.
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2. Wire the batteries as shown in Figure 8. If used, install the in-line fuse as shown. CAUTION! Torque the battery terminals according to the manufacturer’s specifications as given on the name plate or data sheet. 3. Verify the battery connector polarity and the DC voltage with a DC voltmeter. If correct, attach it to the Alpha FXM’s external battery connector. Otherwise, perform troubleshooting before connecting it to the Alpha FXM. 4.
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5.2.2 Wiring the Alpha FXM WARNING! Make sure the line power is off. Switch off all input and output circuit breakers on the Alpha FXM before making any electrical connections. If stranded wires are used to connect the input and output terminal blocks, ferules or equivalent crimping terminals must be used. 5.2.3 1. Procedure Connect the temperature sensor to the Alpha FXM (Batt Temp connector 8 ). Attach the end of the battery temperature sensor to the side of the centre battery. 2.
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6. Operation The following subsections describe the operation of the Alpha FXM: • Communicating with the Alpha FXM. • Operating the control panel. • Switching the Alpha FXM on and off. • Operating the Alpha FXM. • Making measurements. • Viewing the 100-event log. • Communicating with the RS-232 interface. • Communicating via the intranet or internet.
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6.1 Communicating with the Alpha FXM There are several ways you can communicate with the Alpha FXM UPS: 1. Using the control panel. 2. Using a RS-232 interface, you can access the UPS’s command line system with Window’s HyperTerminal or other terminal emulation program. 3. Using a RS-232 serial connection via the Alpha UPS Monitor installed on your computer. The Alpha UPS Monitor software can be downloaded from www.alpha.ca./downloads/. 4.
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6.2 Operating the Control Panel The LCD control panel provides “at a glance” monitoring. This panel, when used along with the CANCEL, SCROLL and SELECT buttons, allows you to program, make measurements, and troubleshoot the Alpha FXM. The layout is shown in the figure below. The Alpha FXM is monitored and controlled with a series of menus and submenus. The Menu Tree is shown in Figure 11. For a tutorial on how to use this panel, see “Replacing the Batteries”.
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Table C — UPS Operating Modes LCD display Description SHUTDOWN LINE BOOST1 OR BOOST2 BUCK1 OR BUCK2 INVERTER RETRAN TRAN STANDBY BYPASS The Alpha FXM’s inverter is switched off. Line power is disconnected from the load. The Alpha FXM is switched on. Line power is provided to the load. The Alpha FXM’s transformer is raising line voltage without using the batteries. AVR is enabled. The Alpha FXM’s transformer is lowering line voltage without using the batteries. AVR is enabled.
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Logo Screen (Figure 7.2) CANCEL   Starting at the Logo Screen, press the SELECT button to go down one level. Press the SCROLL button to move between the menus. The SCROLL button moves only in one direction, so if you overshoot, you have to go all the way around the menu tree again. SELECT Control Menu (Table D) SCROLL System Status Menu (Table E) CANCEL SCROLL Alarm and Fault Menus (If Active) (Table R and S) SCROLL Event Status Menu SELECT  Press the SELECT button to enter the submenu.
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6.3 Switching the Alpha FXM On and Off Under normal operation, the Alpha FXM is always powered ON to supply uninterruptible power to the load. Switching off the Alpha FXM will disconnect the power supply to the load. If for any reason you need to switch off the Alpha FXM while maintaining power to your critical load, make sure that you have a plan that provides an alternate source of power. 6.3.1 1. Switch Off Procedure Switch off the AC input circuit breaker. 2.
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6.4 Operating the Alpha FXM The control menu (Table D) lets you operate the Alpha FXM or program it to suit your operating conditions. You can also use the Alpha UPS Monitor to make these adjustments. See “Alpha UPS Monitor”. 6.4.1 Procedure 1. From the Logo screen go to the Control menu. 2. Press the SELECT button to enter the submenu (Table D). 3. Press the SCROLL button to move between items in the submenu. 4. When you have reached the item you want to change, press the SELECT button.
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Table D — Control Menu LCD display Meaning QUAL TIME Line qualify time Lets you set how long it takes for the Alpha FXM to return to Line mode after the line has become requalified to make sure the line is stable. It can be set to 3, 10, 20, 30, 40 or 50 seconds. The factory default setting is 3 seconds. Also See “Adjusting and Controlling the Alpha FXM, #34: Line Qualify Time”.
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6.5 Making Measurements The System Status menu lets you make measurements of various Alpha FXM inputs, outputs, temperatures and other values. You can also use the Alpha UPS Monitor to make these measurements. See “Alpha UPS Monitor”. 6.5.1 Procedure 1. From the Logo screen go to the System Status menu. 2. Press the SELECT button to enter the submenu (Table E). 3. Press the SCROLL button to move between items in the submenu. When you reach the item you want to measure, stop pressing the button.
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6.6 Viewing the 100-Event Log Using the LCD display, RS-232 or web interface, you can view up to the last 100 events the Alpha FXM went through and the malfunctions that triggered each of them. If more than 100 events occurred, the oldest is overwritten. To clear this log, see “Operating the Alpha FXM, INV RECORD.” To view the events on the LCD display, refer to the following procedure.
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6.7 Communicating with the RS-232 interface The following subsections describe the operation of the Alpha FXM via the RS-232 interface. • Wiring the RS-232 port. • Using the Main menu. • Adjusting and controlling the Alpha FXM. • Programming the dry contacts and the clock. • 100-event log. • Communicating with the "Alpha UPS Monitor".
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6.7.1 Wiring the RS-232 port The Alpha FXM’s front panel has a DE-9 female connector. When connected to a PC with Windows HyperTerminal or other terminal emulation software, the Alpha FXM can be remotely monitored and controlled with it’s command-line system. The Alpha UPS Monitor provides a Windows or web browser type of control. Procedure 1. Connect a 9-pin, fully shielded, straight-through DE-9 to DE-9 connector cable between the computer’s port and the Alpha FXM’s port.
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6.8 Using the Main Menu The Alpha FXM’s main menu screen runs on a command line system. This program does not recognize the backspace or delete keys even if it appears that way on the monitor. If you make a mistake and press Enter, the Alpha FXM echoes the command back exactly as you typed it. Press Enter and retype the command again. If you choose not to use the command line system, you can use the Alpha UPS Monitor to control and monitor the Alpha FXM. 6.8.
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6.9 RS-232 Menu Tree Submenus #1, 2 and 4 are read-only screens for monitoring the Alpha FXM. To control the Alpha FXM, use submenu #3, the Maintenance submenu.
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6.9.1 Line Status Line status tells you the line’s condition. For an updated value, press Enter. Table G — Line Status Normal The line is within specifications. See specifications, “Boost/Buck/Line Transfer Thresholds”. The Alpha FXM is operating in Line mode. Boost Line voltage is out of tolerance. The Alpha FXM is operating in Boost mode. Boost2 Line voltage is out of tolerance. The Alpha FXM is operating in Boost 2 mode. Buck Line voltage is out of tolerance. The Alpha FXM is operating in Buck mode.
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6.9.3 Fault and Alarm Displays Fault and alarm displays any malfunctions the Alpha FXM has encountered. Also see "Troubleshooting". Table I — Faults Short_Circuit The load has a short. Vout_Hi The output voltage is above specifications. Batt_Hi The batteries cannot be charged. Batt_Lo The batteries are almost discharged. Vout_Lo The output voltage is below specifications. Overload The Alpha FXM is overloaded. Remove excess loads.
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6.9.4 Adjusting and Controlling the Alpha FXM The Maintenance submenu lets you control the Alpha FXM and change selected items to meet your operational needs. Procedure From the Main menu, type 3 and press Enter. Table K — Maintenance Submenu 30 Battery Test Options This starts the battery test and sets how long the test will run. The default setting for the test duration is 2 minutes, but this can be adjusted in 1 minute intervals. See "Operating the Alpha FXM, BATT TEST”.
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6.9.5 Programming the Dry Contacts and the Clock The Alpha FXM’s front panel contacts (C1 to C6) can be programmed to meet your specifications with RS–232 communications. You can also adjust the Alpha FXM’s date and time. Programming the Dry Contacts The functions of dry contacts C1 to C5 (and if factory configured, dry contact C6) can be changed with RS-232 communications. For example, to change contact C1: 1. To see how it is currently programmed, type c1 (all lower case) and press Enter. 2.
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6.9.6 Setting the Timer Contact The front panel’s timer contact can be programmed to suit your application. See "Contacts C1 to C6” and "Programming the Dry Contacts and the Clock". The table below explains how.
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6.9.7 Setting the Date and Time Table N — Setting the Date and Time Enter command UPS display clock and press Enter *clock=12/31/07 22:00:00 clock=010107  120000 and press Enter *clock=01/01/07 12:00:00 Description Returns the current date and time. † Sets the date and time to Jan 01, 2007, 12:00 pm. Notes: 1. Time is displayed in the 24 hours clock format. 2. Changing the mm/dd/yy format with DATE SEL on the LCD Control menu does not change the RS-232 mm/dd/yy format. 3.
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6.9.8 Viewing the Serial Number To display the serial number of the Alpha FXM UPS, type "∗QY0" at the command line and press "Enter". 6.9.9 Setting the Peukert Number and Capacity You can set the Peukert Number and Capacity using the RS-232 interface or the web interface. To display the current Peukert Number, type "∗QY6" at the command line and press "Enter". To change the Peukert Number to 1.1345, type "∗ST6:1.1345" at the command line and press "Enter".
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6.9.10 100-Event Log Up to 100 events are stored in the Alpha FXM’s log. If more than 100 events occur, the oldest is over-written. Procedure 1. To see the log, type event (all lower case) and press Enter.
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6.9.11 Communicating with the Alpha UPS Monitor Introduction The Alpha UPS Monitor graphical user interface (GUI) provides web or Windows© like computer communications with the Alpha FXM. The screen and its features are shown below. It is used to monitor, control and set various parameters like the date and time, determine when to perform the weekly self test, change the relay configurations, etc. The Fault or Alarm indicators show if the Alpha FXM has experienced a malfunction and the cause.
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6.9.12 Checking Your Windows Computer for the .NET Framework 1. Click on the Start button. 2. Go to and click on Settings. 3. Click on Control Panel. 4. Double-click on the Add or Remove Programs icon. 5. When the window shown in the figure below appears, scroll through the list of applications. If you see Microsoft .NET Framework listed, the Framework is already installed and you can install the Alpha UPS Monitor.
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6.9.13 Installation and Set Up The following tools and materials are required: • Alpha UPS Monitor, available for download from www.alpha.ca./downloads/. • Windows 98 or later with Microsoft’s .NET framework installed. • DE–9 serial straight-through computer cable. Procedure 1. Install the Alpha UPS Monitor onto your computer. Restart the computer. If you install the Alpha UPS Monitor on a version of Windows without the .
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6.10 Operation The various screens are described on the following pages and operate like Web or Windows-type screens. Point and click to change the various functions or fields. The on line indicator shows if you are connected to the Alpha FXM. The Alpha UPS Monitor automatically polls the Alpha FXM to obtain its status. The default setting is polling once every 3 seconds, but you can change this in the UPS Maintenance-Unit Configuration screen in the “Status Refresh Time” menu.
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6.10.2 UPS Monitoring These read-only screens show the Alpha FXM’s current input and output values and other measurements. Input & Output Shows the current line input and Alpha FXM output values and the Alpha FXM’s present operating mode. Figure 18 — UPS Monitoring: Input & Output screen Battery & Inverter Shows the battery string’s status and how many times and for how long the inverter has been active.
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Relay & Load Shed Shows how the front panel dry contacts are configured. If any relays are used for load shedding, the time setting is shown. Figure 20 — UPS Monitoring: Relay & Load Shed screen User Input Status Shows the current status of the user programmable inputs 1 to 3.
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6.10.3 UPS Maintenance The UPS Maintenance screens are used to configure and adjust the Alpha FXM to meet your operating needs. To change parameters, either click on the On/Off buttons or choose an item from a drop down menu. To execute the changes, click on the Update Settings button. If you do not click this button, the changes will not happen. Unit Configuration Is used to set the name, input, output and how often the GUI polls the Alpha FXM.
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An accurate battery runtime estimation requires the following parameter to be adjusted: • Peukert Number: Refer to the appendix for information about how to calculate the Peukert number to be entered here. • Battery Capacity: This is the rated capacity (Ah) of the battery shown on the battery data sheet. Do not confuse the battery capacity with the Peukert capacity. • Battery Open Circuit Voltage: This number is obtained from the battery data sheet.
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Relay & Load Shed Is used to configure the front panel’s dry contact to provide a signal for turning off the load. Figure 25 — UPS Maintenance: Relay & Load Shed screen Controlling the external fan by temperature triggered dry contact The Alpha FXM has up to 6 dry contacts (C1 to C6) on the front panel which can be configured by the user to open or close based on the specific trigger conditions. Dry contact functions currently available include: Alarm, Fault, Timer, Low Battery, On Battery, etc.
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Dry contact functions are not programmable through the LCD. Use the RS-232 GUI or the HyperTerminal instead. 2. RS-232 GUI – Figure 26a shows the Relay Configuration window under the UPS Maintenance > Relay & Load Shed screen. As an example, to assign C1 as the Temperature trigger, select Temperature from the drop down menu. Click Update Configuration and the current status will update momentarily. In the example shown below, the fan on temperature threshold is set at 55°C.
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3. RS-232 HyperTerminal – the Temperature trigger function can be assigned to any available dry contacts as described in "Programming the Dry Contacts" (e.g. c1=11, where 11 is the assigned index for the Temperature trigger function.) After establishing an RS-232 connection with the Alpha FXM at the HyperTerminal screen prompt, type Temp and press Enter to display the current temperature setting (Alpha FXM returns *temp=20). To change the value to +35°C, type temp=35 and press Enter.
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A typical application of this timer controlled dry contact function is to control a traffic light. When the grid power fails, the Alpha FXM goes into the Inverter mode and continues supplying backup power to the traffic light. Since the batteries supplying the backup power have limited capacity, a timer controlled dry contact is usually configured to switch the traffic light into the flashing amber or flashing red mode after a user-defined period to conserve battery power.
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Figure 31 — Time Of Day Action Status Once the Time of Day Action is configured, the Alpha FXM will automatically disable the timers during the Inverter mode at the defined peak periods. You can switch off the Time of Day Action by setting one or both time period(s) to OFF. The dry contact will be activated by the timer regardless of the peak period settings. Time & Date Is used to set the Alpha FXM’s date and time.
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Password Is used to set the Alpha FXM’s password. The factory set password is 1111. Figure 33 — UPS Maintenance: Password screen The password is limited to 4 alphanumeric characters. The software will not accept more than 4 characters. User Input Three programmable User Inputs exist. Their functions are similar to the Dry Contact relays. Supported functions include: (a) Shutdown, (b) User Alarm and (c) Self Test.
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Procedure 1. Select UPS Maintenance > User Input to display the User Input Configuration window. Figure 35 — User Input Configuration: Setting the Trigger Type 2. In the Input 1 column, select the Type down arrow to display the 3 types of available triggers: Edge Trigger, Level Toggle, and Level Alternative. For more information on how triggers work, see "Types of Trigger". 3. Select Edge Trigger. 4. Select Low from the Level drop down menu.
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7. Check the User Input Current Status at the UPS Monitoring > User Input Status page. Figure 38 — User Input Current Status Perform a quick test by shorting the User Input 1 dry contact pin (Pin 19 of C6) to ground (Pin 22 of C6) with a short length of PVC insulated electronic wire. This will trigger the Alpha FXM to issue a User Input Alarm as shown below. Figure 39 — User Input Current Status Hovering the cursor over the amber indicator will display the corresponding context sensitive message.
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Operation Many of the screens used for Ethernet communications look and function the same and contain the same information as the Alpha UPS Monitor screens. There are additional screens only available with Ethernet communications which are detailed below. Configure Site Information This screen is used to enter site location information into the UPS’s memory. Figure 40 — Alpha UPS Monitor: Configure Site Information Communications • Configure TCP/IP is used to set the UPS’s IP or TCP address.
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Restoring All Parameters to Default Values The purpose of this command is to reset the Alpha FXM to the factory default state. See Table P for a list of parameters that will be restored to their default values. CAUTION! This command resets all parameters that are user-configurable. All previously programmed operation will be lost. Implement a backup plan for mission critical operations. This command is password protected.
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Table P — List of Parameters Maximum battery charging current Temperature compensation of battery charging Maximum allowable duration of output short circuit before shutdown Property settings of programmable user input #1 Action #1 setting of programmable user input #1 Action #2 setting of programmable user input #1 Property settings of programmable user input #2 Action #1 setting of programmable user input #2 Action #2 setting of programmable user input #2 Property settings of programmable user input #3 Ac
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Alarms & Faults This read-only screen shows the operating status of the Alpha FXM. When the fault or alarm indicators on the horizontal bar are illuminated, place the mouse cursor over the light to display the context sensitive message. Figure 44 — Alpha UPS Monitor: UPS Alarms & Faults screen Event History This screen shows the last 100 events recorded by the Alpha FXM.
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To view all the events, click on the View All button to open the Event Log Monitor window. Clicking on the Clear History button clears the log. This action cannot be undone. Figure 45 — Alpha UPS Monitor: Event Log Monitor screen In the Event Log Monitor window, the events are displayed by date and time. Scroll up and down the list to select the events you want to see. To download the latest events from the Alpha FXM, click on the Get Events button. This process may take a few minutes.
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Upgrade Files This feature is available only on Alpha FXM UPS equipped with the network interface card factory option. To upgrade the Alpha UPS Monitor firmware, browse to the .bin file and click OK to start the upload. This may take a few minutes to complete. Figure 47 — Alpha UPS Monitor: Upgrade Firmware To upgrade the Communication module, browse to the .ezip file and click OK to start the upload. This may take a few minutes to complete.
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Keep Alive The Keep Alive feature can be used to reset power when a communication failure is detected. The purpose of the reset is to temporarily remove power and reset the local communications equipment powered by this unit.
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Keep Alive status/manual control: a. The Status field allows the user to enable or disable the Keep Alive function. When disabled the alarm is cleared. b. The Delay to Startup field allows the user to set the time to the first ping from the enable ping or UPS restart after a ping failure. Minimum = 5 s, Maximum = 3600 s. Keep Alive Method to detect communication failure: a. The Protocol field allows Ping as the only option. b. The IP Address field is used to enter the IP address to be pinged. c.
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6.11 Communicating Via The Intranet or Internet If the Alpha FXM is equipped with the optional, factory-installed FXM communication module, then the internet or a company intranet can be used to communicate with the Alpha FXM. In addition, the Alpha FXM can be monitored and controlled via a web browser or with SNMP protocols. 6.11.1 Installation and Set Up The following tools and materials are needed: • Computer with network card and web browser. • Cross over cable or hub.
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6.11.3 Types of Trigger There are 3 types of trigger: Edge trigger When the user input changes from one state to the other, the Alpha FXM is triggered to perform Action #1. If the level is set to High, the action will be triggered by a Low to High edge (leading edge). If the level is set to Low, the action will be triggered by the High to Low edge (falling edge).
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Level Alternative When the level is set to High, the Alpha FXM is triggered to perform the next action when the user input changes from Low to High. If the input then changes from High to Low, no action will be triggered because the level is set to High. In other words, only a Low to High user input level triggers an action when Level is set to High. Similarly, when Level is set to Low, the Alpha FXM will trigger an action only with a High to Low user input.
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7. Maintenance 7.1 Updating the Software The Alpha FXM’s firmware can be reinstalled or updated to the latest version with this procedure. If your Alpha FXM is provided with the factory-installed FXM communication module, the firmware upgrade can be done via an intranet or internet connection. You will need the following items: • RS-232 connection cable to the Alpha FXM. • uBug12 software must be installed. It is available for download at www.alpha.ca\downloads. • Alpha’s firmware must be installed.
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6. In the uBug12 screen, type (all lower case) fbulk and press ENTER. The erase pop-up appears. It disappears when the Alpha FXM’s memory is erased. If an error message appears, send the fbulk command again. 2: Erase pop-up appears. 1: Type fbulk. 7. In the uBug12 screen, type (all lower case) fload(1 space);b and press ENTER. A pop-up appears asking you to locate the new firmware. Look for a “sx record” (*.sx). Select this new firmware. The fload pop-up appears. 2: Look for a .sx file.
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8. When the software has finished loading into the Alpha FXM, the pop-up shows “Loaded OK in (xx) seconds.” If an error message appears, switch off the Alpha FXM and start over again. It should not take more than one or two restarts to load the software. If problem persists, contact Alpha technical support. Firmware is loaded. 9. Type (all lower case) exit and press ENTER. The uBug12 screen disappears. 10. Switch of the battery breaker. 11.
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7.2 7.2.1 Testing and Replacing the Batteries Battery life Batteries lose their ability to store power as they age. Regularly test the batteries to ensure that they can continue providing reliable service. Battery life is reduced by three major factors: • Temperature – higher ambient temperatures, especially above 25°C, will reduce battery life. For example, an average operating temperature of 27°C will likely reduce the life of the battery by 25%.
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7.2.3 Battery Maintenance The batteries supplied with this unit are sealed and maintenance free. Regularly ensure that all connectors are tight and free of corrosion. The presence of corrosion, swelling of the battery case, or distortion in the shape of the case suggests that the batteries need to be replaced. 7.2.4 1. Battery Conductance Test (Optional) Place the conductance meter probes across Battery #1. 2. Record the voltage and Siemens values in a log book. 3. Repeat for batteries #2, #3 and #4.
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WARNING! Read and understand the battery safety instructions in “Product Safety Information”. CAUTION! Make sure all the replacement batteries are of the same type and rating. Failure to do so could result in improper charging and damage to the batteries. The Alpha FXM cannot provide backup battery power while the batteries are being replaced. If the line becomes unqualified while the batteries are being replaced, the Alpha FXM shuts down and no power is provided to the load. Procedure 1.
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7.3 Preventative Maintenance Perform preventative maintenance on the Alpha FXM module every 6 to 12 months. For mission critical applications such as backup traffic intersections, more frequent maintenance should be done. Proper implementation of the following procedure will insure that your system continues to provide reliable backup power in the event of a utility power failure. 7.3.1 Tools and Materials Required • Wrench set. • Labels and marker to number batteries.
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8. Troubleshooting When the front panel alarm LED is illuminated or flashing, the Alpha FXM has a malfunction. The alarm and fault submenus describe the malfunction. The Alpha UPS Monitor can also be used for troubleshooting. 8.1 1. Procedure Press the SELECT button. 2. The LCD may display one or more conditions in the following table. 3. Press the SCROLL button to see if more than one malfunction is present. 4. To clear the malfunction from the screen, press and hold the SELECT button for 5 seconds.
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Table S — Fault Submenu LCD Shows Problem Description Overload Fault Short Circuit Intl Temp Fault Output Over Voltage Output Voltage Low Battery Fail What To Do The load draws more power than the Alpha FXM can provide. This can lead to an automatic Alpha FXM shutdown. Remove excess loads. The load has a short. Check the output. Remove the faulty load if necessary. The Alpha FXM’s internal temperature is too high and could cause an automatic Alpha FXM shutdown.
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9. Specifications Table U — Mechanical Specifications Parameter Value Dimensions H x W x D mm (in) Weight without batteries kg (lb) Color FXM 1100-2000: 5.22 x 15.5 x 8.75 (133 x 394 x 222) FXM 650: 3.47 x 17 x 9 (89 x 432 x 229) FXM 650: 25 (11.3) FXM 1100-2000: 35 (15.9) Black Mounting Shelf, rack or wall; horizontal or vertical mount. Humidity Operating (non-condensing): Up to 95% Storage: Up to 95% Cooling Method of cooling: forced convection (fan cooled) Maximum heat release: see table below.
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Table U — Mechanical Specifications Parameter Value User inputs Three optically-isolated and powered inputs are located on the front panel. When they are shorted, their functions are: S1: Starts the self test. S2: Activates an alarm. S3: Unit shutdown. User interface 6 2 x 20 backlit alpha-numeric LCD screen. Three control buttons located below. 1. 2. 3. 4. 5. 6. Capable of operating at 73% of rated full load for up to 2 hours at 74°C. Above 55°C ambient, derate output power by 1.
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Table V — Electrical Specifications Parameter Value Battery Charger Current, Amps FXM 650-48/1100/2000: 48 VDC. Battery Charger Temperature Compensation 8 -5 mV/°C/Cell (factory default), user adjustable to -2.5, -4, -5 or -6 mV/°C/Cell. Battery type Anderson Power mating part SB50 or equivalent. 7. 8. Efficiency is measured at an ambient temperature of 25°C, full resistive condition and nominal Line and Battery voltage. With external battery temperature probe assembly.
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10. Puekert Number and Battery Capacity 10.1 Introduction The Alpha FXM series UPS units run on batteries when the AC utility power fails. In this mode, the user may want to estimate the remaining time that UPS batteries can supply power to the loads. The battery run time remaining is calculated based on the Peukert equation. Two critical parameters are required for the equation: • Peukert number. • Peukert capacity. The Peukert number and Peukert capacity depend on the battery characteristics.
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10.4 Example The following example shows how to calculate Peukert’s number and capacity from a configured battery string. Consider four Alpha 180GXL batteries connected and configured as shown in the figure below. Two of the four batteries are connected in series, and the two series strings are connected in parallel to the 24 V DC output.
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10.5 Using the Spreadsheet Download the spreadsheet “Peukert’s Parameters Calculator.xls” from www.alpha.ca website.
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11. Warranty Alpha Technologies Ltd. warrants all equipment manufactured by it to be free from defects in parts and labor, for a period of two years from the date of shipment from the factory. The warranty provides for repairing, replacing or issuing credit (at Alpha’s discretion) for any equipment manufactured by it and returned by the customer to the factory or other authorized location during the warranty period. There are limitations to this warranty coverage.
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12. Emergency Shutdown Procedure The Alpha FXM UPS contains more than one live circuit. In an emergency, line power may be disconnected at the UPS’s input, but AC power can still be present at the output. 1. Switch OFF the input circuit breaker. 2. Switch OFF the battery circuit breaker. 3. Disconnect the AC input power. 4. Disconnect the battery string.
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Alpha Technologies Ltd. 7700 Riverfront Gate Burnaby, BC V5J 5M4 Canada Tel: +1 604 436 5900 Fax: +1 604 436 1233 Toll Free: +1 800 667 8743 Alpha Technologies Inc. 3767 Alpha Way Bellingham, WA 98226 United States Tel: +1 360 647 2360 Fax: +1 360 671 4936 Alpha Industrial Power Inc.