Alpha Novus FXM 650 User manual

Uninterruptible Power Supplies
Operator’s Manual
Rev 0408
Power
Novus FXM 650, 1100, 2000
Total Power Solutions by Alpha Technologies

Notice
Rev 0408
Doc# 017-201-B0
Copyright © 2007-2008 Alpha Technologies Ltd. All rights reserved. Alpha®is a registered trademark of
Alpha Technologies.
No part of this documentation shall be reproduced, stored in a retrieval system, translated, transcribed,
or transmitted in any form or by any means – manual, electric, electronic, electromechanical, chemical,
optical, or otherwise – without prior explicit written permission from Alpha Technologies.
This documentation, the software it describes, and the information and know-how they contain consti-
tute the proprietary, 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 Technologies 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 reservation and without notification to its users.
About Us
The Alpha Group represents an alliance of independent companies who share a common philosophy –
to create world class powering solutions. Collectively, Alpha Group members develop and manufacture
AC and DC power conversion, protection and standby products. Applications for these products
include broadband, telecom, AC/UPS, commercial, industrial, and distributed generation for a
worldwide customer base. In addition, our companies provide a range of installation and maintenance
services.

Contents
Notice ............................................................... ii
1. ProductSafetyInformation...........................................5
General warnings and cautions ........................................5
Certication and compliances .........................................7
2. Introduction........................................................9
What this manual covers .............................................9
Who should read this manual ........................................ 10
How to use this manual ............................................. 10
Symbols used in this manual ......................................... 10
Symbols used on the product ........................................ 11
Related documents ................................................ 11
3. Overview......................................................... 13
Introduction ...................................................... 13
Frontpaneldescription ............................................. 14
4. Site Planning ...................................................... 21
Safety precautions................................................. 21
Electromagnetic compatibility (EMC) requirements ........................22
5. UnpackingtheNovusFXM ..........................................23
Openingthepackage ..............................................23
Checking the package contents.......................................23
6. Installation........................................................25
Tools and equipment required for installation ............................25
MountingtheNovusFXM ...........................................26
Wiringtheexternalbatteries.........................................28
Wiring the Novus FXM..............................................30
ATS/GTS option................................................... 31
7. Operation .........................................................33
Operating the control panel ..........................................34
TurningtheNovusFXMonandoff .................................... 37
Replacingthebatteries .............................................39
Operating the Novus FXM ...........................................40
Making measurements ............................................. 42
Viewing the 25-event log ............................................43
Communicating with the RS-232 interface ..............................44
Wiring the RS-232 port ..........................................45
Using the main menu ...........................................46
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Adjusting and controlling the Novus FXM ............................50
Programming the dry contacts and the clock ......................... 51
100-Event Log ................................................54
Novus User Software ...........................................56
8. Maintenance ......................................................79
Updatingthesoftware..............................................79
Testingandreplacingthebatteries ....................................82
Preventative maintenance ...........................................85
Service and technical support ........................................86
9. Troubleshooting ...................................................87
Appendix A: Specications ............................................89
Index ...............................................................93
Warranty ............................................................95
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1. Product Safety Information
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS: This manual contains important safety in-
structions that must be followed during the installation, servicing and maintenance of the prod-
uct. Keep it in a safe place.
General Warnings and Cautions
WARNING
You must read and understand the following warnings before
installing the Novus 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 ser-■
vice this system and its components.
Use proper lifting techniques whenever handling equipment,■
parts, or batteries.
Always assume electrical connections or conductors are live.■
Turn off all circuit breakers and double-check with a voltmeter
before performing installation or maintenance.
Place a warning label on the utility panel to tell emergency per-■
sonnel a is installed.
The FXM has more than one live circuit. AC power may be pres-■
ent at the outputs even if the system is disconnected from line
or battery power.
At high ambient temperature conditions, the FXM’s 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 affect-■
ed area with water. If electrolyte gets into your eyes, wash them
for at least 10 minutes with clean running water or a special neu-
tralizing eye wash solution. Seek medical attention at once.
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Neutralize spilled electrolyte with special neutralizing solutions in■
a “spill kit” or a solution of 1 lb. (0.45 kg) of baking soda (bicar-
bonate of soda) in 1 gallon (3.9 L) of water.
Use special caution when connecting or adjusting battery■
cabling. An improperly connected battery cable or an uncon-
nected battery cable can result in arcing, a fire, or possible
explosion.
Use new batteries when installing a new unit. Verify that they are■
all the same battery type with identical date codes.
Always replace batteries with ones of identical number, type■
and rating. Never install old or untested batteries. One sealed
lead-acid battery is rated to a maximum voltage of 12VDC.
A battery that shows signs of cracking, leaking or swelling must■
be replaced immediately by authorized personnel using a bat-
tery 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 system 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:
Remove watches, rings, or other metal objects.•
Use tools with insulated handles.•
Wear rubber gloves and boots.•
Do not lay tools or metal parts on top of batteries.•
Disconnect charging source prior to connecting or disconnect-•
ing battery terminals.
Determine if the battery is inadvertently grounded. If inadver-•
tently grounded, remove source from ground. Contact with any
part of a grounded battery can result in electrical shock. The
likelihood of such shock can be reduced if such 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 FXM, the enclosure or any■
other metal objects. This can cause a fire or explosion.
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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.
Caution: You must read and understand the following cautions
before installing the Novus FXM and its components. Failure to do so
could result in equipment damage.
Before attaching the batteries to the FXM, make sure the polar-■
ity is correct.
If the batteries have been in storage for more than 3 months,■
recharge them for at least 24 hours then test them with a load
before installation.
Each AlphaCell™ battery has a date code, found on the warn-■
ing label, which must be recorded in the maintenance log. If
non-Alpha batteries are used, see the manufacturer’s documen-
tation for date code type and placement.
Certifications and Compliances
The Novus 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 – Uninterruptible Power Systems
;UL 1778 (Edition 4) – Uninterruptible Power Systems
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 radi-
ate 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 equip-
ment in a residential area is likely to cause harmful interfer-
ence in which case the user will be required to correct the
interference at his own expense..
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2. Introduction
What This Manual Covers
This manual provides full procedures for the safe and proper installa-
tion, operation, maintenance, and troubleshooting of the Novus FXM.
It contains the following chapters and appendices:
“Product Safety Information”■on page 5: Draws your attention to
product safety and encourages you to think “Safety First!”
“Introduction”■on this page: Provides information about the
manual and explains the meaning of each safety symbol that
appears throughout the manual and on the labels of the device.
“Overview”■on page 13: Provides a detailed description of the
front panel of the Novus FXM.
“Site Planning”■on page 21: Presents the safety requirements
and EMC considerations before you install the Novus FXM.
“Unpacking the Novus FXM”■on page 23: Describes the ship-
ping contents of the Novus FXM.
“Installation”■on page 25: Describes how to mount and wire up
the FXM and the tools you need for the job.
“Operation”■on page 33 : Describes how to use the control
panel and RS-232 interface to control, program, measure and
monitor the Novus FXM.
“Maintenance”■on page 79: Describes how to update the FXM’s
firmware.
“Troubleshooting”■on page 87: Explains various alarms and
faults displays and provides other troubleshooting tips.
Appendix A: “Specifications”■on page 89: Contains detailed
specifications (mechanical and electrical) of the Novus FXM.
“Warranty”■on page 95: Provides a detailed description of the
terms of the product warranty.
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Who Should Read This Manual
This manual is intended for qualified installers – trained electricians
or technicians who are fully educated on the hazards of installing
electrical equipment such as uninterruptible power supplies and their
associated batteries.
How to Use This Manual
Before you begin installing the Novus FXM, please ensure that you
are familiar with all the warnings and cautions described in this
manual (see “Product Safety Information” on page 5). Once you are
aware of all the safety issues, then you can start to plan the installa-
tion according to “Installing the Novus FXM” on page 25. After you
have completed the installation, you can start learning how to oper-
ate and program the system to meet the needs of your application.
Symbols Used in This Manual
This section explains the warning, caution and information symbols
used in this manual.
WARNING
Warnings draw special attention to anything that could injure or kill
you (the operator) or somebody else, and explain how to avoid these
situations. They are placed before the step in the procedure to which
they apply. Warnings display the “attention” icon, followed by the
word “WARNING” (in bold uppercase) highlighted in gray as shown
in this example.
Caution
Cautions draw special attention to anything that could damage
equipment or cause the loss of data, and provide information on
how to avoid these situations. They are placed before the step in the
procedure to which they apply. Cautions display the “attention” icon,
followed by the word “Caution” in bold title case as shown in this
example.
Note
Notes contain information or options you should remember for future
use – something that may seem minor or inconsequential but will be
important in the future. Notes display the “push pin” icon, followed by
the word “Note” in title case as shown in this example.
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Symbols Used on The Product
The following symbol appears on various internal components of the
Novus FXM:
Risk of electric shock.
Related Documents
None■
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3. Overview
Introduction
The Novus 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” on page 89 for details. All units operate
in the same way unless stated otherwise in this manual.
The FXM 650 is available in the following two version:
FXM 650-24VDC – with a 24 VDC battery string voltage■
FXM 650-48VDC – with a 48 VDC battery string voltage■
The FXM 1100 is available in the following version:
FXM 1100-48VDC – with a 48 VDC battery string voltage■
The FXM 2000 is available in the following version:
FXM 2000-48VDC – with a 48 VDC battery string voltage.■
Figure 3 .1- FXM 650 Front Panel
Figure 3.2- FXM 1100/2000 Front Panel
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Front Panel Description
1
2
3
4
1
24
Figure 3.3 - Front Panel Description
1Battery Breaker
This circuit breaker provides overcurrent protection and is
an on/off switch for battery power. It must be on for proper
FXM operation.
2Battery Connector
This connects the external batteries to the FXM.
3Internal Fan
This microprocessor-controlled fan regulates the FXM’s
internal temperature for optimum performance. It must not
be blocked. If the fan fails, an Alarm is generated (See
“Troubleshooting” on page 87).
4LAN
This optional RJ-45 connector is the FXM’s Ethernet
connector.
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5LCD Control Panel
This panel and the cancel, scroll and select buttons below
it let you monitor and control the FXM. More information is
given in “Operation” on page 33.
6Battery Voltage Test Points
These let you measure the battery voltage. They accept 2
mm diameter test probe tips. The battery circuit breaker
must be on to measure the voltage.
Note: The battery voltage test points are not and should not be used
as a power outlet.
7RS-232
This DE-9 connector allows you to use a straight-through
DE-9 to DE-9 connector cable to connect the FXM to
a computer for remote control and monitoring. See
“Communicating with the RS-232 Interface” on page 44.
8Battery Temp
This connector attaches the battery temperature sensor
6
78
FXM650
10
C6 11
9
5
FXM1100/2000
5
6
7
89
11
10
Figure 3.4 - Front Panel Description (cont’d)
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to the FXM for it to monitor the battery temperature. The
charging voltage is temperature dependant and the FXM’s
microprocessor adjusts it for optimum charging.
• ThesensorMUSTbeattachedtotheFXMfornormal
operation. Firmly attach the sensor end to the centre
battery’s case with high-strength flameproof tape (such
as duct tape) as shown in “Wiring the External Batteries”
on page 28. If it isn’t, a “Temperature Probe Unplugged”
alarm will appear on the LCD. See “Troubleshooting”,
Temp Probe Unplugged on page 87.
9Contacts C1 to C6
Contacts C1 to C5 allow you to connect the FXM to an
external monitoring panel or to traffic control equipment.
The factory default settings are as given below, but
you can program them to meet your requirements (See
“Programming the Dry Contacts and the Clock” on page
51). See also “Novus User Software, Operations, Relay and
Load Shed” on page 63.
For Contact C6, the default factory configuration for the
FXM 650-48, FXM 1100 and FXM 2000 is +48VDC output
(FXM 650-24 is +24VDC), but it can be factory configured
as a dry contact.
Figure 3.5 shows the contact’s layout while Figure 3.6
shows the +48VDC or +24VDC terminal block layout.
The contacts have
a maximum rating
of 1A at 250V.
Microprocessor
UPS
Interior
Normally
Closed (NC)
Normally
Open (NO)
Common(C)
Figure 3.5 - Contact Layout
(Standard for C1 to C5, Factory Option for C6)
• C1: This contact is energized when line power is unquali-
fied and the 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. They can be called
the “Low Battery” contacts.
You can change the pre-programmed level to match the
batteries used and the actual operating conditions. See
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“Operating the Novus FXM “#35 Low Battery Warning
Voltage.” on page 40.
• C4: This contact is energized after the FXM has been in
Inverter mode for 2 hours. It can be called the “Timer”
contact.
You can change the pre-programmed 2 hours to match
your operating conditions. See “Programming the Dry
Contacts and the Clock, Setting the Timer Contact.” on
page 52.
• C5: This contact is energized when the FXM is operating
close to the specified limits. It can be called the “Alarm”
contact.
• C6: The factory default layout for this contact is a relay
that is energized when the FXM is in Line or Inverter
modes and is de-energized when it is in Standby mode.
It provides 48VDC (500 mA) or 24VDC (500 mA) from
the external batteries to an external fan or other equip-
ment. C6 can be factory-configured as a dry contact.
+48VDC, 500mA
(FXM 1100/2000, 650-
48) or +24VDC (FXM
650-24) from the
external batteries.
Microprocessor
18
16 17
+
Contact
C6
Figure 3.6- 48VDC/24VDC Contact Layout
(De-energized Shown, Factory Default for C6)
10 Contacts C7 and C8
These optically isolated inputs let you attach an external
switch panel for remote control of the FXM or have the FXM
control Alpha Technologies’s optional Automatic Transfer
Switch (ATS).
• User Input (C7): This relay has 3 contacts to control the
FXM (Figure 3.7). They are:
19 (S1): Shorting this contact starts the FXM’s self test. Also
see “Operating the FXM, Self Test.” on page 40.
20 (S2): Shorting this contact activates an alarm. Also see
“Troubleshooting”, User Input Alarm on page 87.
21 (S3): Shorting this contact disables the AC output. There
is no AC output power, the LCD display shows “SHUTDOWN”
(Model 1000 only), but the FXM is still energized. A manual
restart is required to put the FXM back to normal operation.
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22 (C): Isolated return for contacts S1, S2 and S3. It is locat-
ed on contact C8 (#22).
Contact C7 Contact C8
19
S1:Self Test
20
S2:Alarm
21
S3:Shutdown
22
Common
Figure 3.7- User Input Layout
• ATS (C8): When the FXM is in Inverter mode, this nor-
mally open relay closes (Figure 3.8), sending 48 VDC
(FXM 650-48, 1100, 2000) or 24 VDC (FXM 650-24)
from the external batteries to this dry contact. If the
optional Alpha Technologies’s Automatic Transfer Switch
(ATS) is connected, it will cause the ATS to switch the
load from line power to the FXM’s battery backup power.
48VDC or 24VDC from
the external batteries
Contact C8
Microprocessor
23 24
+
Figure 3.8 ATS Layout
11 Status and Alarm LEDs
• Status: When this green LED is on, the FXM is in Line
mode and line power is provided to the load. When it is
flashing, it is in Inverter mode and backup battery power
is provided to the load.
• Alarm: When this red LED is on, the FXM has a fault.
When it is flashing, it has an alarm (See “Troubleshoot-
ing” on page 87).
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12 Input Circuit Breaker
This circuit breaker is an on/off switch for line power into
the FXM and provides input protection. It must be on for
proper FXM operation.
13 Input Terminal Block
This terminal block is the FXM’s AC line power input.
14 Output Terminal Block
This terminal block is the FXM’s AC power output.
12
14
13
13 14
12
Figure 3.9 - Front Panel Description (cont’d)
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