Alpha Outback Energy FXM 350 Series User manual

Alpha FXM Series 350
USER MANUAL

Table of Contents
1. Safety ........................................................................................................................................................................5
1.1 Safety Symbols........................................................................................................................................ 5
1.2 General Warnings.................................................................................................................................... 6
1.3 Battery Safety .......................................................................................................................................... 6
1.4 Work Environment Safety........................................................................................................................ 7
1.5 Certifications and Compliances............................................................................................................... 8
2. General Description...............................................................................................................................................9
2.1 Alpha FXM350.........................................................................................................................................9
2.2 Micro350/ Alpha FXM350 .........................................................................................................................9
2.3 FXM350 Front Panel.............................................................................................................................. 11
2.4 Micro350 Top Panel............................................................................................................................... 14
3. Site Planning ..........................................................................................................................................................15
3.1 Safety Precautions.................................................................................................................................15
3.2 Electromagnetic Compatibility (EMC) Requirements ............................................................................. 16
3.3 Mounting Options for the Micro350 (XL and XL3)................................................................................. 16
3.4 Options for Communicating with the FXM............................................................................................. 21
4. Unpacking the Equipment.....................................................................................................................................22
4.1 Alpha FXM350/Micro350 Configuration.................................................................................................22
4.2 Unpacking.............................................................................................................................................. 22
4.3 Optional Items........................................................................................................................................ 22
5. Installation...........................................................................................................................................................23
5.1 Installation of the Micro350.................................................................................................................... 23
5.2 Mounting and wiring the FXM350 as a standalone device.................................................................... 30
5.3 Wiring the External Batteries and Optional Battery Heater Mats .......................................................... 32
5.4 Start-Up.................................................................................................................................................. 34
6. Theory of Operation...............................................................................................................................................34
6.1 Block Diagram ....................................................................................................................................... 34
6.2 Modes of Operation............................................................................................................................... 35
7. Operating the FXM350...........................................................................................................................................38
7.1 Switching the Alpha FXM On and Off.................................................................................................... 38
7.2 Operating from the Control Panel Interface........................................................................................... 40
7.3 Operating via the FXM Communication Module (Intranet or Internet) .................................................. 49
7.4 The Alpha UPS Monitor Interface.......................................................................................................... 73
7.5 HyperTerminal Interface ......................................................................................................................... 75
8. Maintenance ...........................................................................................................................................................88
8.1 Updating the Software........................................................................................................................... 88
8.2 Testing and Replacing the Batteries...................................................................................................... 91
8.3 Preventive Maintenance........................................................................................................................ 94
9. Troubleshooting.....................................................................................................................................................95
9.1 Procedure .............................................................................................................................................. 95
10. Specifications.........................................................................................................................................................97
11. Warranty................................................................................................................................................................100
12. Emergency Shutdown Procedure ......................................................................................................................101
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List of Figures
Figure 1 — Micro350 cabinets....................................................................................................................................9
Figure 2 —FXM350 mounted in a standard Micro350 cabinet................................................................................10
Figure 3 —FXM 350 front panel description ...........................................................................................................11
Figure 4 —User input layout ...................................................................................................................................12
Figure 5 —Contact Layout (Standard for C1 and C2) ............................................................................................13
Figure 6 —Micro350 Top Panel ..............................................................................................................................14
Figure 7 —Mounting the Micro350 ..........................................................................................................................16
Figure 8 —Mounting on optional pedestal...............................................................................................................17
Figure 9 —FXM350 Mounting Dimensions..............................................................................................................18
Figure 10 —Rack-mount options...............................................................................................................................19
Figure 11 —FXM350 with ears for rack mounting.....................................................................................................20
Figure 12 —Alpha FXM Communication Options ......................................................................................................21
Figure 13 —Mounting to a wooden pole....................................................................................................................24
Figure 14 —Securing the enclosure to the mounting bracket ...................................................................................24
Figure 15 —Attaching the mounting bracket to the wall studs ..................................................................................26
Figure 16 —AC Power distribution terminal blocks ...................................................................................................27
Figure 17—Wiring the Micro350................................................................................................................................28
Figure 18—Terminal block wiring ............................................................................................................................28
Figure 19 —Ferrite ring installed on RJ45 network cable..........................................................................................29
Figure 20 —FXM350 with rack-mount ears and signal assembly option (wiring box not shown) ............................30
Figure 21 —FXM350 Electrical Connections.............................................................................................................31
Figure 22 —External Battery Wiring (for 48 VDC string (top) and 24 VDC string)....................................................32
Figure 23 —Securing the batteries with the optional restraining bar.........................................................................33
Figure 24 —FXM 350 block diagram.........................................................................................................................34
Figure 25 —Battery charging in line mode ................................................................................................................36
Figure 26 —Back up power from batteries................................................................................................................36
Figure 27 —LCD Control Panel Logo Screen............................................................................................................40
Figure 28 —LCD Menu Tree......................................................................................................................................42
Figure 29 —Web GUI (UPS Specification Screen shown)........................................................................................49
Figure 30 —Alpha UPS Monitor: UPS Communications screen...............................................................................50
Figure 31 —Web GUI: UPS Specification screen .....................................................................................................51
Figure 32 —Web GUI: Input & Output screen...........................................................................................................52
Figure 33 —Web GUI: Battery & Inverter screen ......................................................................................................52
Figure 34—Web GUI: Relay & Load Shed screen....................................................................................................53
Figure 35— Web GUI: User Input Status screen ..........................................................................................................53
Figure 36 —UPS Maintenance: Unit Configuration screen .......................................................................................54
Figure 37 —Restore all default commands ...............................................................................................................54
Figure 38 —UPS Maintenance: Battery screen.........................................................................................................56
Figure 39 —UPS Maintenance: Inverter screen........................................................................................................57
Figure 40 —UPS Maintenance: Relay & Load Shed screen.....................................................................................58
Figure 41 —Programmable Timer Operation ............................................................................................................59
Figure 42 —Time Of Day Action Operation...............................................................................................................59
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Figure 43 —Time Of Day Configuration ....................................................................................................................60
Figure 44 —Time Of Day Action Status.....................................................................................................................60
Figure 45 —Assigning the Temperature trigger function to a dry contact –Alpha UPS Monitor..............................61
Figure 46 —Setting the Temperature trigger value ...................................................................................................61
Figure 47 —UPS Maintenance: Time & Date screen................................................................................................62
Figure 48 —UPS Maintenance: Password screen ....................................................................................................62
Figure 49 —User Input Configuration: Setting the Trigger Type...............................................................................63
Figure 50 —User Input Configuration: Setting the Logic Level .................................................................................63
Figure 51 —User Input Configuration: Setting an Action...........................................................................................64
Figure 52 —User Input Current Status......................................................................................................................64
Figure 53 —User Input Current Status......................................................................................................................64
Figure 54 —Alarms & Faults screen..........................................................................................................................65
Figure 55 —Event History screen..............................................................................................................................65
Figure 56 —Event Log Monitor screen......................................................................................................................66
Figure 57 —Event Log Monitor, Open Event File window.........................................................................................67
Figure 58 —Alpha UPS Monitor: Upgrade Firmware ................................................................................................67
Figure 59 —Upgrade Communication Module ..........................................................................................................68
Figure 60 —Alpha UPS Monitor: Configure Site Information ....................................................................................68
Figure 61 —Configure SNMP screen ........................................................................................................................69
Figure 62 —Email Notification screen .......................................................................................................................69
Figure 63 —Test email feature ..................................................................................................................................70
Figure 64 —Alpha UPS Monitor (UPS Specification Screen shown)........................................................................73
Figure 65 —Add or Remove Programs Window........................................................................................................74
Figure 66 —HyperTerminal communication parameters...........................................................................................75
Figure 67 —Main Menu Screen.................................................................................................................................76
Figure 68 —Menu Tree .............................................................................................................................................77
Figure 69 —Temperature trigger function via HyperTerminal...................................................................................83
Figure 70 —Typical Discharge Characteristics for Lead Acid Batteries....................................................................91
Figure 71 —Battery string example .........................................................................................................................103
Figure 72 —Edge Trigger ........................................................................................................................................105
Figure 73 —Level Trigger........................................................................................................................................105
Figure 74 — Level Alternative...................................................................................................................................106
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List of Tables
Table A —UPS Operating Modes .............................................................................................................................41
Table B —Control Menu ...........................................................................................................................................43
Table C —System Status Menu ................................................................................................................................46
Table D —List of Parameters ....................................................................................................................................55
Table E —Line Status (see Figure 67) ......................................................................................................................78
Table F —Output Status (see Figure 67)..................................................................................................................78
Table G —Faults (see Figure 67) ..............................................................................................................................79
Table H —Alarms (see Figure 67).............................................................................................................................79
Table I —Maintenance Submenu.............................................................................................................................80
Table J —Dry Contact Configuration Settings..........................................................................................................81
Table K —Setting the Timer Contact.........................................................................................................................82
Table L —Setting the Date and Time........................................................................................................................84
Table M —Event Codes ............................................................................................................................................87
Table N —Battery Temperature Compensation Values ............................................................................................92
Table O —Alarm Submenu........................................................................................................................................95
Table P —Fault Submenu .........................................................................................................................................96
Table Q —Problems Not Reported by System..........................................................................................................96
Table R —Mechanical Specifications ........................................................................................................................97
Table S —Electrical Specifications............................................................................................................................98
Table T —Boost/Buck/Line Transfer Thresholds ......................................................................................................99
Table U —Regulatory ................................................................................................................................................99
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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.
1.1 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 atten- tion.
The use of ATTENTION indicates specific regulatory/code requirements that may affect the placement of
equipment and /or installation procedures.
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.
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.
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.
HOT!
The use of HOT presents safety information to PREVENT BURNS to the technician or user.
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1.2 General Warnings
You must read and understand the following warnings before installing the product. Failure to do so could result in
personal injury or death.
Read and follow all instructions included in this manual.
Only qualified personnel are allowed to install, operate and service this system and its components.
CAUTION!
Risk of Electric Shock. See Installation Instruction before connecting to the supply.
The FXM350/ Micro350 is only intended for restricted access locations
The UPS shall be connected only to a dedicated branch circuit.
CAUTION!
To reduce the risk of fire, connect only to a maximum branch circuit overcurrent protection in accordance
with the National Electrical Code, ANSI/NFPA 70.
Always assume electrical connections or conductors are live. Switch all circuit breakers and double check
connections with a voltmeter before performing installation or maintenance.
A disconnect switch shall be provided by others for the AC input and AC output circuits.
The branch circuit overcurrent protection for the AC input and AC output circuit shall be provided in the end
installation.
Place warning label(s) on the utility panel to tell emergency personnel that a UPS is installed.
Use only proper lifting techniques whenever handling equipment, parts, or batteries.
Ferules or the equivalent must be used when stranded wire is used on the AC input and output terminal
blocks.
WARNING!
The Alpha FXM350/ Micro350 have more than one live input circuit. AC power may be present at the
outputs even if the system is disconnected from line or battery power.
CAUTION!
The Alpha FXM350/ Micro350 metal surfaces can be very hot to the touch.
1.3 Battery Safety
Battery Installation and servicing should be performed or supervised by personnel knowledgeable about
batteries and the required precautions performed.
Be extra cautious when connecting or adjusting battery cabling. An improperly connected battery cable or an
unconnected battery cable can result in arching, fire or explosion.
Before attaching the batteries to the Alpha FXM350/ Micro350, make sure that the polarity is correct.
Use new batteries when installing a new unit. Verify that all batteries are the same type with identical date
codes.
When replacing batteries, use sealed lead acid batteries, rated 12 V. Never install old or untested batteries.
Batteries that show signs of cracking, leaking or swelling must be replaced immediately by authorized
personnel using a battery of identical type and rating.
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CAUTION!
Never open, damage or mutilate batteries. Released Electrolyte is harmful to the skin and eyes. It may be
toxic and hazardous to the environment.
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.
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 special neutralizing eye wash
solution. Seek medical attention at once.
Neutralize spilled electrolyte with special neutralizing solution and a “spill kit” or solution of 1 lbs (0.45KG)
of baking soda (bicarbonate of soda) in 1 gallon (3.8 L) of water.
CAUTION!
A battery can present a risk of electrical shock and high short-circuit current. The fol- lowing 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). Never let live battery wires
touch the Alpha FXM350/ Micro350, the enclosure or any other metal objects. This can cause a fire or
explosion.
Do not smoke or introduce sparks in the vicinity of a battery.
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 AlphaCellTM battery has a date code found on the warning label which must be recorded in the
maintenance log. If non-Alpha batteries are used, see the manufacturer’s documentation for date code type
and placement.
1.4 Work Environment Safety
Do not work alone under hazardous conditions.
Keep the chassis area clear and dust-free during and after the 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.
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1.5 Certifications and Compliances
The Alpha FXM350 and Micro350, 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 reason-
able 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
accordance 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 conformé la norme NMB-003 du Canada.
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2. General Description
2.1 Alpha FXM350
The Alpha FXM350 is available in 24Vdc and 48Vdc models. It provides up to 350W of regulated AC Power to the
load, when utility power is available, and provides back up power from the batteries in case of a utility power failure.
Noteworthy features include:
Local or remote monitoring and control via USB and SNMP communication
Small footprint for wall, rack or enclosure mounting
Dependable operation in extreme operating environments (-40 to 74°C or -40 to 165°F)
Powerful firmware with enhanced features such as battery run-time information
2.2 Micro350/ Alpha FXM350
The Micro350 contains a standard FXM350 along with batteries—Figure 1 shows three options for the enclosure.
These enclosures are designed with a NEMA 3R rating for outdoor applications.
Figure 2 shows the FXM350 installed in a standard-sized Micro350 cabinet. Power is distributed through terminal
blocks mounted on a DIN rail.
(a) Standard Micro350
(1 battery tray)
(b) Micro350 XL
(2 battery trays)
(c) Micro350 XL3
(4 battery trays)
Figure 1 — Micro350 cabinets
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