Alpha_FXM1100_Manual.pdf

Your Power Solutions Partner

Alpha FXM 650, 1100, 2000 UPS

Installation & Operation Manual Part # 017-230-B4 Effective: 07/2013 member of The Group™

Alpha FXM 650, 1100, 2000 UPS Installation and Operation Manual

For technical support, contact Alpha Technologies:

Canada and USA: 1-888-462-7487 International: +1-604-436-5547

Copyright Copyright © 2013 Alpha Technologies Ltd. All rights reserved. Alpha is a registered trademark of Alpha Technolo-gies.

No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed, or trans-mitted in any form or by any means manual, electric, electronic, electromechanical, chemical, optical, or other-wise without prior explicit written permission from Alpha Technologies.

This document, the software it describes, and the information and know-how they contain constitute the propri-etary, confidential and valuable trade secret information of Alpha Technologies, and may not be used for any unauthorized purpose, or disclosed to others without the prior written permission of Alpha Technologies.

The material contained in this document is for information only and is subject to change without notice. While reasonable efforts have been made in the preparation of this document to assure its accuracy, Alpha Technolo-gies assumes no liability resulting from errors or omissions in this document, or from the use of the information contained herein. Alpha Technologies reserves the right to make changes in the product design without reserva-tion and without notification to its users.

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 inconsistent with its intended purpose, or if installed or oper-ated in an unapproved manner, or improperly maintained.

Photographs contained in this manual are for illustrative purposes only. These photo-graphs 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.

NOTE:

017-230-B4 Rev B2

Table of Contents

1. Safety�������������������������������������������������������������������������������������������������������������������������������������4

1.1 Safety Symbols��������������������������������������������������������������������������������������������������������������������� 4

1.2 General Warnings and Cautions������������������������������������������������������������������������������������������� 5

1.3 Certifications and Compliances��������������������������������������������������������������������������������������������� 6

2. General Description���������������������������������������������������������������������������������������������������������������7

2.1 Overview������������������������������������������������������������������������������������������������������������������������������� 7

2.2 Front Panel���������������������������������������������������������������������������������������������������������������������������� 7

3. Site Planning������������������������������������������������������������������������������������������������������������������������11

3.1 Safety Precautions���������������������������������������������������������������������������������������������������������������11

3.2 Communicating with the Alpha FXM����������������������������������������������������������������������������������� 12

3.3 Electromagnetic Compatibility (EMC) Requirements���������������������������������������������������������� 13

4. Unpacking Alpha FXM���������������������������������������������������������������������������������������������������������14

5. Installation����������������������������������������������������������������������������������������������������������������������������15

5.1 Tools and Equipment Required for Installation�������������������������������������������������������������������� 15

5.2 Mounting the Alpha FXM����������������������������������������������������������������������������������������������������� 16

5.3 Wiring the External Batteries����������������������������������������������������������������������������������������������� 17

5.4 UATS and (UGTS) Option��������������������������������������������������������������������������������������������������� 19

6. Operating the Alpha FXM����������������������������������������������������������������������������������������������������20

6.1 Switching the Alpha FXM On and Off���������������������������������������������������������������������������������� 20

6.2 Operating from the Control Panel Interface������������������������������������������������������������������������ 21

6.3 Operating via the FXM Communication Module (Intranet or Internet)�������������������������������� 30

6.4 The Alpha UPS Monitor Interface���������������������������������������������������������������������������������������� 56

6.5 HyperTerminal Interface������������������������������������������������������������������������������������������������������ 60

7. Maintenance������������������������������������������������������������������������������������������������������������������������72

7.1 Upgrading the FXM Firmware��������������������������������������������������������������������������������������������� 72

7.2 Testing and Replacing the Batteries������������������������������������������������������������������������������������ 74

7.3 Preventative Maintenance��������������������������������������������������������������������������������������������������� 77

8. Troubleshooting�������������������������������������������������������������������������������������������������������������������78

8.1 Procedure���������������������������������������������������������������������������������������������������������������������������� 78

3017-230-B4 Rev B

9. Specifications�����������������������������������������������������������������������������������������������������������������������80

10. Warranty����������������������������������������������������������������������������������������������������������������������������83

11. Emergency Shutdown Procedure��������������������������������������������������������������������������������������84

Appendix A - Peukert Number and Battery Capacity

A.1 Introduction

A.2 Determining the Peukert’s Number and Peukert’s Capacity

A.3 Determining Peukert’s Capacity for Series Parallel Combinations

A.4 Example

A.5 Using the Spreadsheet

Appendix B - Types of Triggers

B.1 Edge trigger

B.2 Level Toggle

017-230-B4 Rev B4

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. Re-view the drawings and illustrations contained in this manual before proceeding. If there are any questions regard-ing the safe installation or operation of this product, contact Alpha Technologies or the nearest Alpha representa-tive. Save this document for future reference.

1.1 Safety Symbols

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.

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

WARNING!

WARNING presents safety information to PREVENT INJURY OR DEATH to personnel.

Warnings are indicated by a shock hazard icon, the word WARNING, and a rule beneath which the information appears.

CAUTION!

CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment. Cautions are designated with a yellow warning triangle, the word CAUTION, and a rule beneath which the information appears.

NOTE:

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

Notes are designated with a checkmark, the word NOTE, and a rule beneath which the information appears.

HOT!

The use of HOT presents safety information to PREVENT BURNS to the technician or user.

5017-230-B4 Rev B

1.2 General Warnings and Cautions

You must read and understand the following warnings before installing the Alpha FXM and its components. Fail-ure 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.

• Always assume electrical connections or conductors are live. Switch off all circuit breakers and double-check connections with a voltmeter before performing installation or maintenance.

• Place warning label(s) on the utility panel to tell emergency personnel a UPS is installed.

• The Alpha FXM uses more than one live circuit. AC power may be present at the outputs even if the system is disconnected from line or battery power.

• The Alpha FXM surface can be very hot to the touch.

• Battery installation and servicing should be done or supervised by personnel knowledgeable about batteries and their safety procedures.

• If electrolyte splashes on your skin, immediately wash the affected area with water. If electrolyte gets into your eyes, wash them for at least 10 minutes with clean running water or a special neutralizing eye wash solution. Seek medical attention at once.

• Neutralize spilled electrolyte with special neutralizing solutions in a “spill kit” or a solution of 1 lb. (0.45 kg) of baking soda (bicarbonate of soda) in 1 gallon (3.8 L) of water.

• Be extra cautious when connecting or adjusting battery cabling. An improperly connected battery cable or an unconnected battery cable can result in arcing, fire, or explosion.

• Use new batteries when installing a new unit. Verify that all batteries are the same type with identical date codes.

• Always replace batteries with ones of identical number, type and rating. Never install old or untested batter-ies. One sealed lead-acid battery is rated to a maximum voltage of 12 Vdc.

• A battery that shows signs of cracking, leaking or swelling must be replaced immediately by authorized per-sonnel using a battery of identical type and rating.

• Keep the chassis area clear and dust-free during and after installation.

• Keep tools away from walk areas where you or others could fall over them.

• Wear safety glasses when working under any conditions that might be hazardous to your eyes.

• Do not work on the unit or connect or disconnect cables during periods of lightning activity.

• Do not smoke or introduce sparks in the vicinity of a battery.

• Never open or damage the batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic and hazardous to the environment.

• A battery can present a risk of electrical shock and high short-circuit current. The following precautions should be observed when working on batteries:

a. Remove watches, rings, or other metal objects.

b. Use tools with insulated handles.

c. Wear rubber gloves and boots.

d. Do not lay tools or metal parts on top of batteries.

e. Disconnect the charging source before connecting or disconnecting battery terminals.

f. Determine if the battery is inadvertently grounded. If inadvertently grounded, remove the source from the ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock can be reduced if the grounds are removed during installation and maintenance (applicable to equipment and remote battery supplies not having a grounded supply circuit).

017-230-B4 Rev B6

• 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.

• If the batteries have been in storage for more than 3 months, recharge them for at least 24 hours and then test them with a load before installation.

• Each AlphaCell™ battery has a date code, found on the warning label, which must be recorded in the main-tenance log. If non-Alpha batteries are used, see the manufacturer’s documentation for date code type and placement.

1.3 Certifications and Compliances

The Alpha FXM has been designed, manufactured, and tested to the requirements of the following national and international safety standards:

• CAN/CSA-C22.2 No. 107.3-05 – Uninterruptible Power Systems; additional requirements (RD): CAN/CSA- C22.2 No. 60950-1-03 - Information Technology Equipment - Safety.

• UL 1778 (Edition 4) – Uninterruptible Power Systems; additional requirements (RD): UL 60950-1 (Edition 1) - Information Technology Equipment - Safety.

• FCC CFR47 Part 15 Class A – This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in ac-cordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

• Industry Canada - This Class A digital device apparatus complies with Canadian ICES-003.

• Industry Canada - Cet appareil numrique de la Classe A est conforme la norme NMB-003 du Canada.

7017-230-B4 Rev B

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. How-ever the circuit breakers for each unit have different ratings. See Chapter "9. 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.

• FXM 650-48Vdc – with a 48 Vdc battery string voltage.

• FXM 1100-48Vdc – with a 48 Vdc battery string voltage.

• FXM 2000-48Vdc – with a 48 Vdc battery string voltage.

2.2 Front Panel

Figure 1 shows the front panel connectors and circuit breakers, which are described in detail in the following sections.

2 3

4 56

8 12

13 149 11

Figure 1 — FXM 650 (top) and FXM 1100/2000 front panel description

92 5

108 C6 13

14 12

017-230-B4 Rev B8 Figure 2 — Contact Layout (Standard for C1 to C5, Factory Option for C6)

Battery breaker

This circuit breaker provides over-current protection and is used 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 Replaceable fan assembly

This microprocessor-controlled fan turns on at a programmable temperature to lower the Alpha FXM internal tem-perature. It must not be blocked. An Alarm is generated if the fan fails; a failed fan can be replaced in the field.

4 RJ45 communication module connector

The RJ-45 connector is the Alpha FXM Ethernet connector.

5 LCD control panel and menu navigation buttons

The LCD control panel together with the cancel, scroll and select buttons are used to monitor and control the Alpha FXM.

6 Battery voltage test points

These test points accept 2 mm diameter test probe tips. The battery circuit breaker must be on to measure the voltage.

The battery voltage test points are not to be used as a power outlet.

7 RS-232

This DE-9 connector allows a straight-through DE-9 to DE-9 connector cable to be used to connect the Alpha FXM to a computer for remote control and monitoring.

8 Battery temperature sensor connector

The battery charging voltage is temperature dependant when compensation is not set to 0 mV/°C/cell. A battery temperature sensor connects to the Alpha FXM so the Alpha FXM microprocessor can adjust the charging volt-age for optimum charging. Refer to "UPS Maintenance > Battery" on page 38.

The sensor MUST be attached to the Alpha FXM for normal operation. If the sensor is not attached, a “Tempera-ture Probe Unplugged” alarm appears on the LCD.

9 Contacts C1 to C6

Contacts C1 to C5 allow the Alpha FXM to be connected to an external monitoring panel or to traffic control equipment.

The factory default settings can be reprogrammed to meet your requirements. Each contact can only be pro-grammed for one function at a time and cannot show multiple conditions. See "UPS Maintenance > Relay & Load Shed" on page 41 and section 6.5.7 on page 66 for the HyperTerminal interface.

For Contact C6, the default factory configuration is +48 Vdc output (FXM 650-24 is +24 Vdc), but it can be fac-tory configured as a dry contact. Figure 2 shows the contact’s layout while Figure 3 shows the +48 Vdc or +24 Vdc terminal block layout.

The contacts have a maximum rating of 1A at 250V.

Microprocessor

UPS

Interior

Normally Closed (NC)

Normally Open (NO)

Common (C)

9017-230-B4 Rev B

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 used to generate an “On Battery” contact.

C2, C3: These contacts are energized when the battery drops below a pre-set voltage level. They can be used to generate a Low Battery alarm. To change the pre-programmed level to match the batteries used and the actual operating conditions, see Low Battery Warning in "UPS Maintenance > Battery" on page 38.

C4: This contact is energized after the Alpha FXM has been in Inverter mode for 2 hours.

To change the pre-programmed 2 hours to match your operating conditions, see Load Shed Timer Configura-tion in "UPS Maintenance > Relay & Load Shed" on page 41.

C5: The C5 contact is energized when any alarm is generated—see "Table P — Alarm Submenu" on page 78.

C6: The factory default layout for the C6 contact is a relay that is energized when the Alpha FXM is in Line or Inverter modes and is de-energized when in Standby mode. It provides 48 Vdc (500 mA) from the external bat-teries to an external fan or other equipment. C6 can be factory-configured as a dry contact.

Figure 3 — 48 Vdc Contact Layout (De-energized Shown, Factory Default for C6)

Figure 4 — User Input Layout

Optically isolated user inputs C7 and contacts C8

The optically isolated user inputs are used to attach an external switch panel for remote control of the Alpha FXM or to allow the Alpha FXM to control optional Alpha Off-Line Automatic Transfer Switch (ATS).

User Input (C7): This relay has three contacts that are used to control the Alpha FXM:

19 (S1): Shorting this contact starts the Alpha FXM self test. See "UPS Maintenance > Battery" on page 38.

20 (S2): Shorting this contact activates an alarm. See "UPS Maintenance > User Input" on page 46.

21 (S3): Shorting this contact disables the AC output. There is no AC output power, but the Alpha FXM is still energized. A manual restart is required to put the Alpha FXM back to normal operation.

22 (C): Isolated return for contacts S1, S2 and S3.

S1:Self Test

S2:Alarm

S3:Shutdown

Common

+48Vdc, 500mA

(FXM 1100/2000, 650-

48) or +24Vdc (FXM 650-24) from the external batteries.

Microprocessor

1816 17

Contact C6

017-230-B4 Rev B10

ATS (C8): When the Alpha FXM is in the Inverter mode, this normally open relay closes sending 48 Vdc (FXM 650-48, 1100, 2000) or 24 Vdc (FXM 650-24) from the external batteries to this dry contact (Figure 5). If the op-tional Alpha Off-Line Automatic Transfer Switch (ATS) is connected, it will cause the ATS to switch the load from line power to the Alpha FXM battery backup power.

48Vdc from the external batteries

Contact C8

Microprocessor

23 24

11 Status and Alarm LEDs

Status:

Green LED solidly illuminated: the Alpha FXM is in Line mode and line power is provided to the load.

Green LED flashing: the unit is in Inverter mode and backup battery power is provided to the load.

Alarm:

Red LED solidly illuminated: fault in the Alpha FXM. (See "Table Q — Fault Submenu" on page 79.)

Red LED flashing indicates an alarm. (See "Table P — Alarm Submenu" on page 78.)

12 AC Input Circuit Breaker

This circuit breaker is an on/off switch for the line power into the Alpha FXM that also provides input protection. It must be switched on for proper Alpha FXM operation.

13 Input Terminal Block

This terminal block is the Alpha FXM AC line power input.

14 Output Terminal Block

This terminal block is the Alpha FXM AC power output.

Figure 5 — ATS Layout

11017-230-B4 Rev B

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 elec-trician before installation to ensure that grounding meets the local electrical code.

The utility line attached to the Alpha FXM input MUST be protected by a circuit breaker certified for this use in accordance with the local electrical code. The UPS must be con-nected only to a dedicated branch circuit.

The UPS equipment that is powered by this service panel requires the neutral to be per-manently bonded to the ground. Always disconnect the batteries before servicing the circuit breaker panel.

The input and output lines to and from the Alpha FXM MUST have disconnect devices attached.

The Alpha FXM is suitable for installations in Network Telecommunication Facilities and locations where the National Electrical Code applies.

Grounding: The Alpha FXM is suitable both for installation as part of a common bonding network and an iso-lated bonding network.

For installations above 1400 m (4500 ft) elevation, additional cooling may be needed to reduce the operating temperature of the Alpha FXM. The maximum allowable operating temperature must be reduced by 2°C (3.5 °F) for every 300 m (1000 ft) above 1400 m (4500 ft).

3.1 Safety Precautions

• Install the Alpha FXM on a surface that can support its weight. See Chapter "9. Specifications".

• The input wiring must reach a suitably grounded power outlet and the load wiring must reach the Alpha FXM output terminal blocks.

• Place the Alpha FXM in a properly sheltered location or inside a weather-proof enclosure to protect the electronics from water, dust and other possible contamination.

• Alpha Technologies offers a wide range of outdoor enclosure systems. Visit our website at www.alpha.ca, or call customer service for more information.

• Backup Generator (If used) Use Generator mode so that noise tolerance is increased to accept the fluctuations created by a genera-tor. See Sense Type in Table B on page 24 .

Use a generator with electronic speed and voltage controls which produces less than 10% voltage to-tal harmonic distortion (THD). Mechanical governors can force the Alpha FXM to run continuously in the Inverter mode.

Before installation, make sure the generator’s output voltage is compatible with the Alpha FXM input volt-age requirements. To make sure the system runs smoothly, use a generator that supplies twice as much power as drawn by the total load.

http://www.alpha.com

017-230-B4 Rev B12

3.2 Communicating with the Alpha FXM

There are several ways you can communicate with the Alpha FXM UPS:

1. Using the control panel.

2. Using an RS-232 interface, you can access the UPS command line system with Windows HyperTerminal or other terminal emulation program.

3. Using an 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. Using the optional factory-installed FXM communication module, you can communicate with the Alpha FXM over a company intranet or the internet using a web browser or with SNMP communications.

Figure 6 — Alpha FXM Communication Options

Option 4 Option 4

Option 4 Options 2 & 3

On-Site Ethernet Connection

FXM

Communication

Module

Ethernet Port Note: FXM Communication Module is a factory-installed option

CANCEL SCROLL SELECT

Alpha

FXM 2000

120/60/N

LINE

Option 1:

Control PanelRS-232 Port

(Using HyperTerminal or Alpha UPS Monitor available at www.alpha.ca)

(Using Web browser for Ethernet connection to on-site computer)

13017-230-B4 Rev B

3.3 Electromagnetic Compatibility (EMC) Requirements

Observe the following EMC requirements when setting up the Alpha FXM and its internal equipment:

• All AC mains and external supply conductors must be enclosed in a metal conduit or raceway when speci-fied by local, national, and/or other applicable government codes and regulations.

• The customer facilities must provide suitable surge protection.

017-230-B4 Rev B14

4. Unpacking 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.

Follow these guidelines for unpacking the Alpha FXM.

1. Select a suitable area for unpacking.

2. Store all the packing material and boxes for possible equipment returns.

3. Compare the packing slip and the list of parts with the items you received: make sure the standard items as well as purchased options are included:

Standard items 1 Alpha FXM

1 Alpha FXM operator manual

8 Terminal blocks and labels for the dry contacts

1 Temperature sensor cable

Purchased options

4. If the list of parts on your packing slip does not match the items you received, or any items appear damaged, immediately notify your carrier agent and the supplier who prepared your shipment.

15017-230-B4 Rev B

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 ser-vice 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. Wiring the Alpha FXM

5.1 Tools and Equipment Required for Installation

• DC voltmeter.

• Labels or masking tape and marker.

• Torque wrench for input/output terminal blocks.

• Slot head screwdriver to fit the terminal blocks.

• Minimum #10 AWG copper wire for input/output terminal blocks.

• High strength, flame-proof tape such as duct tape.

• Battery terminal corrosion inhibitor such as NOCO Company NCP-2 or Sanchem Inc. No-Ox ID Grease “A”.

017-230-B4 Rev B16

5.2 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 shelf, with the optional mounting brackets as shown in the figure below The brackets and the screws to attach them to the Alpha FXM case are available from Alpha Technologies (part number 740-697-21).

CAUTION!

Terminal block covers and the battery harness restraining bracket MUST be used and are available from Alpha Technologies (part number 740-698-21). If the Alpha FXM end application is mounted inside an enclosure or in an area restricted to authorized per-sonnel, then the covers and bracket may or may not be needed.

To meet NEBS Level 1 specifications when you are installing this unit in a rack or frame, do the following:

1. Before installation, clean all attachment points on the Alpha FXM, rack and mounting brackets and bring them to a bright finish. Then coat them with an anti-oxidant such as Sanchem Inc. No-Ox ID “A-Special Electrical Grade” or equivalent.

2. Attach the mounting brackets with the thread forming screws and the paint piercing washers provided with the brackets to insure adequate grounding between the Alpha FXM chassis and the rack.

Figure 7 — Mounting the Alpha FXM Mounting brackets position for rack mounting. Rotate to fit either 19" or 23" racks.

For the FXM 1100/2000 units only, the control panel and the power connection panel can be rotated to suit your needs. To rotate either one, unscrew the screws in each corner, remove the panel, rotate it and reinstall the screws.

CAUTION!

Use care to avoid damaging or pulling out the wires or the ribbon cables when rotating the panels.

17017-230-B4 Rev B

5.3 Wiring the External Batteries

WARNING!

The batteries must be installed by qualified personnel trained in the safe use of high-energy 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.

• If you are making your own battery wiring harness, use at least 10 AWG (for FXM 650/1100) or 8 AWG (FXM 2000) wires.

• The battery return connection is to be treated as an Isolated DC return (DC-I) as defined in GR-1089-CORE.

5.3.1 Procedure

NOTE: The optional in-line fuse option shown in Figure 8 on page 18, is available as part number SPB98-645- 1, Kit, FuseUpgrade, 100A.

1. For FXM 650-48/1100/2000 (48 V battery string), number the batteries from 1 to 4 with labels or tape. For FXM 650-24 (24 V battery string), number the batteries from 1 to 2 with labels or tape.

2. Coat the battery terminals with the corrosion inhibitor.

3. Connect the batteries as shown in Figure 8 on page 18. If used, install the in-line fuse as shown.

4. Connect the black battery cable to the negative terminal of the battery string, and the red battery cable to the positive terminal of the battery string.

5. When the batteries are wired, measure the voltage at the battery connection terminals. It should read between 42 and 54V for the FXM 650-48/1100/2000 or 21 and 27V for the FXM 650-24.

6. Note the polarity and ensure it is correct.

7. Ensure that the DC breaker if OFF.

8. Connect the external batteries to the Battery connector—location 2 in Figure 1.

9. Route the sensor end of the battery temperature cable to the batteries.

10. Attach the battery temperature sensor to the body of the battery, about 2 to 3" (5 to 7.5 cm) from the base of the battery.

11. If multiple battery strings are used, repeat steps 1 to 4 as required.

017-230-B4 Rev B18

5.3.2 Wiring the Alpha FXM

WARNING!

Make sure the line power is off. Switch off all 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.

Figure 8 — External Battery Wiring (for 48 Vdc string (top) and 24 Vdc string)

CAUTION!

Torque the battery terminals according to the manufacturer’s specifications on the battery name plate or data sheet.

Battery #4 Battery #3 Battery #2 Battery #1

To positive terminal To negative terminal Optional in-line fuse

Battery #2 Battery #1

To positive terminal To negative terminal Optional in-line fuse

19017-230-B4 Rev B

5.3.3 Procedure

1. If used, connect the following ports (see Figure 1 on page 7 for location of numbered elements):

• Ethernet port 4 .

• RS-232 port 7 .

• Dry contacts 9 .

• User inputs 10 .

2. Connect the load to the Alpha FXM Output terminal block 14 . Torque to 1.4 N-m (12 lb-in).

3. Connect the line power to the Alpha FXM AC Input terminal block 13 . Torque to 1.4 N-m (12 lb-in).

4. If needed, attach the terminal block covers and battery harness restraining bracket.

WARNING!

Before proceeding, verify that the line wire is attached to the line terminal block, the ground wire is attached to the ground terminal block, and the neutral wire is attached to the neutral terminal block to prevent accidental shocks or electrocutions.

5.4 UATS and (UGTS) Option

The Universal Automatic Transfer Switch (UATS) and Universal Generator Transfer Switch (UGTS) are the next generation of Automatic Transfer Switch (ATS) and Generator Transfer Switch (GTS) products. They are optional add-on switching units specifically designed for the FXM UPS family (FXM 650, 1100 and 2000), the Micro UPS family (Micro 300 and 1000) and the Alpha FXM350/ Micro350 UPS. These switching units provide power and/or bypass capacity (automatic or manual) so that the operator may safely disconnect the UPS from line or generator power for easy removal and servicing. In bypass mode, the loads are directly connected to the line or generator power without any conditioning. Depending on the use of one and/or the other, the UATS/UGTS allows the use of up to 3 different back-up sources (line, batteries and generator). Refer to the UATS/UGTS Installation Manual (Alpha P/N 020-165-B0) for details.

WARNING!

Make sure you have read and understood the instructions given in the UATS/UGTS In-stallation Manual before making any connection to the supply.

017-230-B4 Rev B20

6. Operating the Alpha FXM

6.1 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.

6.1.1 Switch Off Procedure

1. Switch off the AC input circuit breaker.

2. Switch off the battery circuit breaker.

The status LED turns off and the LCD panel goes blank. The Alpha FXM is now switched off and no backup power is supplied to the load.

6.1.2 Switch On Procedure (LINE mode)

Before you put the Alpha FXM back into commission, make sure that the line is qualified and the batteries are fully charged.

1. Switch on the battery circuit breaker. The LCD displays STANDBY and the fan turns on for about a minute. If the temperature is below –15ºC, the LCD display may not function. See Chapter "8. Troubleshooting".

2. Switch on the AC input circuit breaker. The Alpha FXM qualifies the line power. The LCD displays RETRAN, then shows LINE, BUCK or BOOST. The status LED illuminates.

3. If there is no line power, the Alpha FXM remains in the STANDBY mode until the line power is qualified. To provide backup battery power to the load, perform a manual start by using the Inverter command: From the Control Menu, scroll till the LCD displays Inverter, press Select and select ON. (See Figure 11 on page 23).

The Alpha FXM uses auto-frequency detection. When it is first switched on, it senses the line frequency and ad-justs its output frequency to match that of the input. The load should be receiving power, If not, perform trouble-shooting.

6.1.3 Switching the Alpha FXM from Line mode to Inverter mode You can force the Alpha FXM to operate in the Inverter mode by manually switching off the input circuit breaker.

Doing so will effectively disconnect any line power to the Alpha FXM, simulating a power outage which triggers the Alpha FXM to switch to the inverter mode of operation.

Procedure

1. Switch off the input circuit breaker. The LCD shows INVERTER, the status LED starts flashing to show that the Alpha FXM is running on backup battery power. Confirm that the load is receiving power.

6.1.4 Switching the Alpha FXM from Inverter mode to Line mode The Alpha FXM remains in the Inverter mode for as long as the input circuit breaker is switched off. Backup pow-er is provided to the load until the batteries are drained to a preset level which triggers the Alpha FXM to shut-down automatically. If it is not necessary to operate the Alpha FXM in the Inverter mode, switch the Alpha FXM back to the Line mode as soon as possible.

Procedure

1. Switch on the input circuit breaker. The Alpha FXM qualifies the line power. The LCD displays RETRAN, then shows LINE, BUCK or BOOST. The status LED illuminates.

If the Alpha FXM constantly switches between Inverter and Line modes because of a noisy line, broaden the input parameter tolerances from Normal to Generator. See Sense Type in Table B on page 24.

21017-230-B4 Rev B

Figure 9 — LCD Control Panel Logo Screen

6.2 Operating from the Control Panel Interface

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 of the LCD interface is shown in Figure 9.

The Alpha FXM is monitored and controlled with a series of menus and submenus.

D

A

B

C

CANCEL SCROLL SELECT

Alpha 120/60/N

LINEFXM 2000

A Alpha FXM model name

B Alpha FXM voltage configuration - 120 Vac or 230 Vac Alpha FXM Frequency - 50 Hz or 60 Hz Sense Type setting - Normal (N) or Generator (G); see Sense Type in Table B

C Present operating mode - (LINE mode shown) See Figure 10.

D

Control buttons:

SELECT - Pressing SELECT moves you down 1 level in the menu tree (Table C) or accepts a change when programming.

SCROLL - Pressing SCROLL moves you through the submenus (Table C) or toggles between choices when programming.

CANCEL - Pressing CANCEL moves you up one level in the menu tree (Table C).

The Alpha FXM operating mode automatically changes as a result of changes in the line or the Alpha FXM op-erating mode. (The LCD panel automatically updates to reflect the new mode. See Table A and also "Table V — Boost/Buck/Line Transfer Thresholds" on page 82.

Table A — UPS Operating Modes LCD display Description

SHUTDOWN The Alpha FXM inverter is switched off. Line power is disconnected from the load.

LINE The Alpha FXM is switched on. Line power is provided to the load.

BOOST1 OR BOOST2 The Alpha FXM transformer is raising line voltage without using the batteries. AVR is enabled.

BUCK1 OR BUCK2 The Alpha FXM transformer is lowering line voltage without using the batteries. AVR is enabled.

INVERTER The Alpha FXM is providing backup battery power to the load.

RETRAN The Alpha FXM is transferring from INVERTER mode to Line mode.

STANDBY

The Alpha FXM is switched on and waiting for the line power to qualify or the user to clear some faults.

CAUTION: Do not touch the AC output terminals, which may still be energized.

BYPASS

This mode is manually set with the Control Menu. See Figure 11, “Control Menu, BYPASS”.

This locks the unit into line mode and turns off the battery charger so the unit can work with a manual break-before-make bypass switch.

017-230-B4 Rev B22

Logo Screen (Figure 9)

System Status Menu (Table C)

Control Menu (Table B)

Alarm and Fault Menus (If Active)

(Table P and Table Q) Event Status Menu

CANCEL

SCROLL

SELECT

SCROLL SCROLL

CANCEL SELECT

SCROLL

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.

Press the SELECT button to enter the submenu.

Then press the SCROLL button to cycle through the submenu items. The SCROLL button moves only in one direction, so if you overshoot, you have to go all the way around the submenu again.

Figure 10 — LCD Menu Structure

23017-230-B4 Rev B

The CONTROL MENU (Table B) lets you control, program and adjust the Alpha FXM for connection to traffic intersection equipment or other applications.

You can control the:

• INVERTER Enable/

Disable

Enable/Disable

• INVERTER CUTOFF

(voltage)

The SYSTEM STATUS menu (Table C) lets you measure various inputs, outputs and other values. The available measurements are:

OR 3

The ALARM and FAULT menus in the Trouble-shooting section are invisible and disabled until the Alpha FXM has a malfunction.

When the front panel alarm LED is on or flashing, press SELECT.

One of the malfunctions listed in Table R and Table S will appear on the LCD. Press the SCROLL button to see if more than one malfunction is present.

Fix the malfunction.

Press the SELECT button to clear the malfunction from the screen.

If the malfunction is fixed, the malfunction is cleared from the LCD. If it isn’t fixed, it will reappear on the screen.

The EVENT STATUS menu displays the last 200 Alpha FXM events on the LCD.

Press the SELECT button to access the menu. Press SELECT and then the SCROLL button to scroll through the events. To see what a specific event was, press the SELECT but-ton. Press the SCROLL button to see what malfunction triggered the event.

Figure 11 — LCD Menu Tree

017-230-B4 Rev B24

6.2.1 The LCD Control Menu

The control menu (Table B) lets you operate the Alpha FXM or program it to suit your operating conditions.

Procedure

1. From the Logo screen go to the Control menu.

2. Press the SELECT button to enter the submenu (Table B).

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. The item chosen is blinking.

5. To toggle between the choices, press the SCROLL button. Stop when you reach the choice you want.

6. To make the change, press the SELECT button. The blinking stops.

Table B — Control Menu LCD display Meaning Description

INVERTER

Inverter (Enabled/ Disabled)

When Disable is selected and AC is lost, the FXM will be in Standby mode. The inverter cannot be started through the Inverter On/Off menu, When Enable is selected and AC is lost, the FXM will be in Inverter mode. Turning inverter on/off manually will work.

INVERTER Inverter (On/ Off)

When inverter mode is set to ON, the Alpha FXM provides backup battery power to the load. This mode of operation is normally activated automatically when line power becomes unavailable, or the line power is not qualified. You can also put the Alpha FXM into this mode during initial startup in the absence of line power or because of unqualified line power.

LVD DSCNNCT Battery voltage value at which the LVD configured relay should open

LVD CONNECT Battery voltage value at which the LVD configured relay should close

BYPASS Inverter Bypass

This function can only be switched on when the Alpha FXM is in Line mode. When switched on, it locks the Alpha FXM into the Line mode, switches off the battery charger and makes the output voltage equal to the input voltage.

Used when:

• Replacing the batteries.

OR:

• To allow the use of a break-before-make manual bypass switch so the

Alpha FXM can be shut off for maintenance or replacement without interrupting power to the load.

BATT TEST Battery Test

Available when CHARGER on the Control Menu is set to Standard method.

Starts the battery test, which uses depth-of-discharge setting, the battery capacity, Peukert number, and open-circuit voltage. This setting can be adjusted using BT TS DOD menu. A battery test is also performed during the self test.

BT TS DOD

Battery Test Depth-of- Discharge

Available when CHARGER on the Control Menu is set to Standard method.

Sets the desired battery test depth-of-discharge to a value between 0 and 100%.

Make sure that the set time duration is shorter than the max back up time of your battery bank. Otherwise, you will drain the battery and trigger a fault – Batt Volt Low.

The default value is set to 20% DoD.

AUTO TEST Automatic Test Available when CHARGER on the Control Menu is set to Standard method.

If the GUI periodic self test is enabled, this starts the test when it is scheduled to take place.

SHUTDOWN

Shutdown AC and DC (On/ Off)

When this function is switched On, the Alpha FXM inverter is shut off. Neither Line nor Inverter power is supplied to the load. If a dry contact was used as a LVD, the LVD will open.

SHUTDOWN AC Shutdown AC (On/Off)

When this function is switched On, the Alpha FXM inverter is shut off. Neither Line nor Inverter power is supplied to the load.

SHUTDOWN DC Shutdown DC (On/Off)

When this function is switched On, the LVD configured relay will be de-energized.

Applies when ANY programmable dry contact is programmed to be the Low Voltage Disconnect indicator. See "UPS Maintenance > Relay & Load Shed" on page 41.

When the function is switched from On to Off, a 10 second delay occurs before the LVD configured relay is re-energized.

25017-230-B4 Rev B

Table B — Control Menu LCD display Meaning Description

SENSE TYPE Sense Type

This function can only be used when the Alpha FXM is in Standby or Shutdown mode (Table A).

Normal: The Alpha FXM can operate successfully with most line conditions.

OR:

Generator: This setting increases noise tolerance so the fluctuations created by a generator are acceptable. (A noisy line can cause the Alpha FXM to constantly switch between inverter and line modes.)

FUNC MODE Functional Mode

The Functional mode can be changed when the Alpha FXM is in any mode (Table C and "Table V — Boost/Buck/Line Transfer Thresholds" on page 82).

Automatic Voltage Regulation (AVR): Buck and boost modes are active.

OR:

Quality: Buck and boost modes are switched off; the input voltage is the Alpha FXM output voltage.

VOLTAGE Voltage Sets the Alpha FXM output voltage setting to one of the voltages specified in "Specifications" on page 80. Changing the voltage setting from factory default should be done by a qualified technician acting under the instructions of Alpha Technical Support (1 888 462 7487). Failure to contact Alpha Technologies before performing this procedure could void your warranty.

AUTO FREQ Automatic Frequency Detection

Enable (default) allows the unit to detect and automatically configure the AC input frequency (50Hz or 60Hz).

In cases where the AC input frequency can be out of range for long periods, Disable prevents the unit from switching back and forth between 50Hz and 60Hz.

FREQUENCY Frequency The frequency can only be changed when the Alpha FXM is in Standby mode—to 50 Hz or 60 Hz. This change should ONLY be done by a qualified technician acting under the instructions of Alpha Technical Support (1 888 462 7487). Failure to contact Alpha Technologies before doing this procedure could void your warranty.

QUAL TIME Line qualify time

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. The factory default setting is 3 seconds. User adjustable in increments of 1 sec until 1 minute, and then in increments of 1 minute to 15 minutes max.

INV CUTOFF

Inverter Cutoff (Enabled/ Disabled)

When Disable is selected the default FXM inverter cutoff threshold is used.

When Enable is selected the user configured inverter cutoff threshold voltage is used.

INV CUTOFF

Inverter Cutoff Threshold (Voltage)

Defines the point where the unit will switch from Inverter to Standby when the battery is considered to be low or in order to preserve the battery. See "UPS Maintenance > Inverter" on page 40.

CHARGER

Battery charging options

When Standard charger is selected, set BATT FLOAT to AUTO or Constant.

When Bulk charger is selected, set MAX VOLT and FLOAT VOLT. See section 6.2.2

BATT FLOAT

Battery charging float options

When BATT FLOAT is set to Constant, the default max charge voltage is 54.6V and float is 54.2V, both at 25°C. Temperature compensation will be active

When BATT FLOAT is set to AUTO, the float voltage is set to 1.8V below the max charge voltage. The default max charge voltage is 54.6V and default float is 52.8V, both at 25°C

BATT COMP

Battery temperature compensation

Sets the battery temperature compensation to match the batteries you are using. It can be set from 0 to -6 mV/°C/Cell in increments of 0.5. The factory default setting is -5 mV/°C/Cell.

DATE FRMT Date Format Selection

Toggles the Alpha FXM date format between YY-MM-DD, MM-DD-YY, DD-MM-YY

YYYY-MM-DD, MM-DD-YYYY, DD-MM-YYYY, YY-TXT-DD, TXT-DD-YY, DD-TXT-

YY, YYYY-TXT-DD, TXT-DD-YYYY, DD-TXT-YYYY, YYYY-DD-TXT, YY-DD-TXT,

YYYY-DD-MM, YY-DD-MM. The factory default setting is MM-DD-YY.

CLOCK FRMT Clock display format option

Format to display time information: in 24 hour clock format or 12 hour clock (AM/

PM).

INV RECORD Inverter record clear Clears the inverter counter and timer from the LCD system status menu.

CHGR CUR Charger current

Charging current can be set to 0A or any value between 2 and maximum in increments of 1A, where maximum = 15A for FXM1100/FXM2000 and 10A for FXM650. (Charging current cannot be set to 1A).

When charging current is set to 0A, the charger will stop charging.

017-230-B4 Rev B26

6.2.2 Battery Charging Options

CAUTION!

The adjustments to the charge algorithm must be made only by qualified personnel, who understand the different charging modes and their suitability to the battery chemistry.

CANCEL SCROLL SELECT

Alpha 120/60/N

FXM2000 STANDBY

Standard Battery Charging For more information on standard battery charging, refer to the web GUI description "UPS Maintenance > Battery" on page 38.

1. Put the unit in STANDBY mode before starting this procedure.

2. Use a combination of the SCROLL and SELECT keys on the control panel interface to select CHARGER in the Control menu.

3. Select Standard to charge the batteries in AUTO or Constant mode.

120/60/NCONTROL

MENUS STANDBY

CHARGER

Standard

120/60/N

STANDBY

BATT FLOAT

AUTO

120/60/N

STANDBY

BATT FLOAT

Constant

120/60/N

STANDBY

When BATT FLOAT is set to AUTO, the float voltage is set to 1.8V below the max charge voltage.