Novus FXM 2000 User manual

Operator’s Manual
017-201-B0 Rev. E5
Effective: January 2006
Alpha Technologies
Novus FXM 500/1100/1500/2000
Uninterruptible Power Supply

Power
Alpha Technologies
®

Uninterruptible Power Supplies
From Alpha Technologies
017-201-B0 Rev. E5 1/ 06
Operator’s Manual
Novus FXM 500/1100/1500/2000

Novus FXM 500/1100/1500/2000 Operator’s Manual
Save This Manual: It contains important installation and operating instructions. Keep it in a safe place.
Table of Contents
The emergency shutdown procedure is on the inside rear cover
1. Introduction....................................... 1
1.1 Safety Checklists .................................................. 2
1.1.1 UPS Safety Checklist...................................................... 2
1.1.2 Battery Safety Checklist.................................................. 3
1.2 Unpacking and Inspection Checklist..................... 4
1.3 The Novus FXM Front Panel ................................ 5
1.3.1 FXM 1100, 1500, 2000.................................................... 6
1.3.2 FXM 500 .......................................................................10
2. Installation....................................... 11
2.1 Site Preparation Checklist .................................. 12
2.2 Mounting the UPS............................................... 13
2.3 Wiring the External Batteries .............................. 14
2.4 Wiring the UPS ................................................... 16
3. Operation......................................... 17
3.1 Operating the Control Panel ............................... 18
3.2 Turning the UPS On and Off............................... 20
3.2.1 Turn On.........................................................................20
3.2.2 Turn Off.........................................................................21
3.3 Battery Replacement .......................................... 22
3.4 Operating the UPS.............................................. 23
3.5 Making Measurements ....................................... 25
3.6 Troubleshooting .................................................. 27
3.7 Last Event Log.................................................... 29
4. Communication............................... 30
4.1 Wiring the RS-232 Port....................................... 31
4.2 Using the Main Menu.......................................... 32
4.2.1 Main Menu Screen........................................................32
4.2.2 RS-232 Menu Tree........................................................33
4.2.3 Line Status....................................................................34
4.2.4 Output Status................................................................34
4.2.5 Fault and Alarm Displays ..............................................35
4.3 Operating the UPS.............................................. 36
4.4 Programming the Dry Contacts and the Clock ... 37
4.4.1 Programming the Dry Contacts ....................................37
4.4.2 Setting the Timer Contact .............................................38
4.4.3 Setting the Date and Time ............................................38
4.5 Accessing the 100-Event Log ............................. 39
4.6 Novus FXM Graphical User Interface................. 41
4.6.1 Introduction ...................................................................41
4.6.2 Installation and Set Up..................................................41
4.6.3 Operation ......................................................................42
5. Maintenance.................................... 45
5.1 Updating the Software ........................................ 46
Specications ...................................... 47
Index ..................................................... 49
Warranty ............................................... 54
DANGER
Risk of Electrical Shock
To reduce the risk of electrical shock and to ensure the safe operation of the Novus FXM, the symbols
below are used throughout this manual. Where they appear, only qualied personnel should carry out
these instructions.
A dangerous voltage exists in this area. Use extreme caution at all times.
Attention: Important operating instructions. Follow them exactly.

1
Introduction
This Section Introduces the Novus FXM Uninterruptible Power Supply (UPS)
Safety Instructions (Section 1.1)
Unpacking and Inspection Instructions (Section 1.2)
A Description of the FXM 500 and FXM 1100/1500/2000 Front Panels (Section 1.3)
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•
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1

2
Introduction
1.1.1 UPS Safety Checklist
This Uninterruptible Power Supply (UPS) is to be installed by people trained in
the safe use of high-energy power supplies and their batteries. Also assumed is
knowledge of the local electrical code(s) and their safe application.
DANGER: NEVER let water from rain, a hose, tap or a sprinkler’s output, road
splash or other water sources enter the UPS to prevent accidental shorts,
shocks or electrocutions.
Do not work alone under hazardous conditions.
Read this manual. If you have any questions about safe installation, operation or
maintenance, contact Alpha Technologies’s customer service department.
Carefully unpack the components. Report any shipping or other damage at once.
Always assume electrical connections or conductors are live. Turn off all circuit breakers
and double-check with a voltmeter before performing installation or maintenance.
Before installation, verify the input voltage and current requirements of the load are met by
the UPS’s output (See specications). Verify the line voltage and current meet the UPS’s
input requirements.
Place a warning label on the utility panel to tell emergency personnel a UPS is installed.
Use proper lifting techniques when lifting or moving the UPS or its components.
This UPS has more than one live circuit. AC power may be present at the outputs even if
the UPS is disconnected from line or battery power.
This UPS can be operated to a maximum operating temperature of 55°C. Also see the
specications section for temperature ratings.
At high ambient temperature conditions, the UPS’s surface can be very hot to the touch.
There is a Lithium battery inside the UPS. There is a danger of an explosion if it is
incorrectly replaced. Replace it only with the same type or an equivalent battery as
recommended by the manufacturer. Dispose of the old battery as instructed by the
manufacturer.
1.1 Safety Checklists

3
Introduction
1.1.2 Battery Safety Checklist
Battery Emergency 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
(3.9 L) of water.
Battery installation and servicing should be done or supervised by personnel
knowledgeable about batteries and their safety procedures.
Never open or damage the batteries. The electrolyte is harmful to the skin and eyes and
may be toxic as well as being an environmental hazard.
Never let live battery wires touch the UPS, the enclosure or any other metal objects. This
can cause a re or explosion. Never put metal tools on top of the batteries or on their
connectors.
Lead-acid batteries can release Hydrogen gas. Never expose the UPS or enclosure to
open ames or sparks to prevent a re or explosion.
Inspect the batteries once a year for signs of cracks, leaks or swells. Replace as needed.
If you have batteries in storage, charge them at least once every three months for optimum
performance and to extend their lifetime.
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.
Before connecting the batteries to the UPS, determine if they are accidentally grounded
and unground the batteries if they are.
Always use insulated tools to prevent accidental shocks. Wear rubber gloves and boots.
Remove all rings, watches, jewellery or other metal items before working inside the
enclosure or doing maintenance on the UPS to prevent accidental shocks.
Follow the manufacturer’s instructions for battery disposal. Recycling is the best method.
Never burn batteries to dispose of them. They may explode. Follow the manufacturer’s
directions for safe battery disposal.
1.1 Safety Checklists (Continued)

4
Introduction
If items are missing or damaged, contact Alpha Technologies and the shipping
company at once. Most shippers have a short claim period.
Carefully remove the UPS from the shipping container. Inspect the contents and make sure the
following items are included:
1 Novus FXM UPS.
1 Novus FXM Operator’s Manual.
8 terminal blocks and labels for the dry contacts.
1 temperature sensor cable.
Any ordered options.
If ordered from Alpha, the batteries are shipped separately.
Save The Shipping Container
To return the Novus FXM for servicing, pack it in the shipping
container. Alpha Technologies is not responsible for damage
caused by improper packaging of returned units.
Read This Manual
Before installation become familiar with the Novus FXM by
reviewing the procedures and drawings in this manual. If you have
any questions about the safe installation, operation or maintenance
of this UPS, contact Alpha’s customer service department (go to
www.alpha.com).
1.2 Unpacking and Inspection Checklist

5
Introduction
1.3 The FXM Front Panel
The FXM 500 and the FXM 1100/1500/2000 series look different, but all of the front panel
connectors and circuit breakers are the same. All units operate in the same way unless
otherwise stated in this manual. The FXM 500 is a 24VDC unit while the others are
48VDC. Some of the FXM 500’s dry contacts will output 24VDC instead of 48VDC. See the
specications section for more details.
Figure 1.3.1
Novus FXM 500 Front Panel
Figure 1.3.2
Novus FXM 1100/1500/2000 Front Panel

6
Introduction
1.3 The FXM Front Panel (Continued)
1.3.1 FXM 1100, 1500, 2000
1Battery Circuit Breaker
This circuit breaker provides overcurrent protection and is an on/off switch for battery
power. It must be on for proper UPS operation.
2Battery Connector
This connects the external batteries to the UPS.
3Internal Fan
This microprocessor-controlled fan regulates the UPS’s internal temperature for optimum
performance. It must not be blocked. If the fan fails, an Alarm is generated (See Section
3.6, “Troubleshooting”).
4Ethernet
This optional, factory-installed RJ-45 connector is the UPS’s Ethernet connector.
1
2
3
4

7
Introduction
1.3 The FXM Front Panel (Continued)
5LCD Control Panel
This panel and the cancel, scroll and select buttons below it let you monitor and control the
UPS. More information is given in Section 3, “Operation.”
6Battery Voltage Test Points
These let you measure the battery voltage. They accept 2mm diameter test probe tips. The
battery circuit breaker must be on to measure the voltage. NOTE: It is not a power outlet.
7RS-232 Port
This DB-9 connector allows you to use a standard computer cable to connect the UPS
to a computer for remote control and monitoring. More information is given in Section 4,
“Communiction.”
8Battery Temperature Sensor
This connector attaches the battery temperature probe to the UPS so the UPS can monitor
the battery temperature. The charging voltage is temperature dependant and the UPS’s
microprocessor adjusts it for optimum charging.
The probe MUST be attached to the UPS for normal operation. Firmly attach the sensor
end to the centre battery’s case with high-strength ameproof tape (such as duct tape)
as shown in Section 2.3, “Wiring the External Batteries.” If it isn’t, a “Temperature Probe
Unplugged” alarm will appear on the LCD. See Section 3.6, “Troubleshooting,” “Temp
Probe Unplug.”
9Dry Contacts
Contacts C1 to C5 allow you to connect the UPS to an external monitoring panel or to
trafc control equipment. The factory default settings are as given on the next page, but
you can program them to meet your requirements (See Section 4.4). To learn how the
contacts are congured, see Section 4.4.1, “Programming the Dry Contacts” or Section
4.6, “FXM Monitor Graphical User Interface.”
Contact C6’s default factory conguration for the FXM 1100/1500/2000 is as a +48VDC
output (the FXM 500 is +24VDC), but it can be factory congured as a dry contact.
Continued on the Next Page
5
6
7
89

8
Introduction
Figure 1.3.3A shows the dry contact’s layout while Figure 1.3.3B shows the +48VDC or
+24VDC terminal block layout. Figure 1.3.4 shows one way of connecting an external
terminal block to these contacts.
C1: This contact is energized when line power is unqualied and the UPS 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 preprogrammed level to match the batteries used and the actual operating
conditions. See Section 4.3, “Controlling the UPS,” “#35 Low Battery Warning Voltage.”
C4: This contact is energized after the UPS has been in Inverter mode for 2 hours. It can be called
the “Timer” contact.
You can change the preprogrammed 2 hours to match your operating conditions. See Section 4.4.2,
“Programming the Dry Contacts and the Clock,” “Setting the Timer Contact.”
C5: This contact is energized when the UPS has a malfunction. It can be called the “Alarm” contact.
C6: The factory default layout for this contact is a relay that is energized when the UPS is in Line
or Inverter modes and is de-energized when it is in Standby mode. It provides 48VDC (500mA) or
24VDC (500mA) from the external batteries to an external fan or other equipment. C6 can be factory-
congured as a dry contact.
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•
1.3 The FXM Front Panel (Continued)
Microprocessor
UPS
Interior
Normally
Closed (NC)
Normally
Open (NO)
Common (C)
LED
Dry Contact
+VB
Figure 1.3.3A
Dry Contact Layout
(Standard for C1 to C5, Factory Option for C6)
Figure 1.3.3B
48VDC/24VDC Contact Layout
(De-energized Shown, Factory Default for C6)
Figure 1.3.4
External Monitoring Panel Wiring
The contacts have
a maximum rating
of 1A at 250V.
+48VDC, 500mA (FXM
1100/1500/2000) or
+24VDC (FXM 500)
from the external
batteries.
Microprocessor
18
16 17
+
Contact
C6

9
Introduction
1.3 The FXM Front Panel (Continued)
10 User Input
These optically isolated inputs let you attach an external switch panel for remote control of
the UPS or have the UPS control Alpha Technologies’s optional Automatic Transfer Switch
(ATS).
User I/P (C7): This relay has 3 contacts to control the UPS (Figure 1.3.5A). They are:
19 (S1): Shorting this contact starts the UPS’s self test. Also see Section 3.4, “Battery Test.”
20 (S2): Shorting this contact activates an alarm. Also see Section 3.6, “User Input Alarm.”
21 (S3): Shorting this contact shuts off the UPS.
22 (C): Isolated return for contacts S1, S2 and S3.
ATS (C8): When the UPS is in Inverter mode, this normally open relay closes (Figure 1.3.5B),
sending 48VDC (FXM 1100/1500/2000) or 24VDC (FXM 500) from the external batteries to this dry
contact. If the optional Alpha Technologies’s Automatic Transfer Switch (ATS) is connected, this
causes the ATS to switch the load from line power to the UPS’s battery backup power.
11 Status and Alarm LEDs
Status: When this green LED is on, the UPS is in Line mode and line power is provided to the load.
When it is ashing, it is in Inverter mode and backup battery power is provided to the load.
Alarm: When this red LED is on, the UPS has a fault. When it is ashing, it has an alarm (See
Section 3.6, “Troubleshooting”).
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•
10
11
UPS Contact C7
19
(S1:Self Test)
20
(S2:Alarm)
21
(S3:Shutdown)
22
(Common)
Microprocessor
+
Figure 1.3.5A
User I/P Layout
Figure 1.3.5B
ATS Contact
48VDC or 24VDC from
the external batteries

10
Introduction
12 Input Circuit Breaker
This circuit breaker is an on/off switch for line power into the UPS and provides input
protection. It must be on for proper UPS operation.
13 Input
This terminal block is the UPS’s power input.
14 Output
This terminal block is the UPS’s power output.
1.3.2 FXM 500
The layout of the front panel is shown in Figure 1.3.6. The functions of the various connectors
and circuit breakers are the same as described in Section 1.3.1, “FXM 1100, 1500, 2000.”
The FXM 500 is a 24VDC unit, so contacts C6 and the ATS output 24VDC from the batteries
(Figures 1.3.3B and 1.3.5B).
1.3 The FXM Front Panel (Continued)
12
13 14
Figure 1.3.6
FXM 500 Front Panel
Battery
Connector
Ethernet
(Optional)
Battery Voltage
Test Points
Status & Alarm
LEDs Input
Input Circuit
Breaker
Battery
Circuit
Breaker
Internal Fan RS-232 Port Battery
Temperature
Sensor
Dry Contacts Output
LCD Control Panel

11
Installation
This Section Tells You How to Install and Wire the Novus FXM UPS
Site Preparation Instructions (Section 2.1)
How to Mount the UPS (Section 2.2)
How to Wire the Battery String (Section 2.3)
How to Wire the UPS to the Line and the Load (Section 2.4)
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2

12
Installation
2.1 Site Preparation Checklist
Grounding
The UPS MUST be correctly grounded for proper operation.
Older facilities may have inadequate electrical grounding. A qualied electrician
should inspect it before installation to see it meets the local electrical code.
Branch Circuit Breaker Protection
To provide branch circuit protection, the utility line attached to the UPS’s input
MUST be protected by a circuit breaker certied for this use as per the local elec-
trical code.
The breaker’s minimum size is calculated by the following formula:
Minimum Breaker Size= UPS’s maximum input current / 0.8
The UPS’s maximum input current is read off of the UPS’s nameplate. For exam-
ple, if the nameplate gives the maximum input current as 20A, the circuit breaker
should be rated at least 25A.
For the FXM 1100, to reduce the risk of re, connect a minimum of a 20A circuit
breaker (for 120VAC units) or a 10A (for 230VAC units).
Disconnects
The input and output lines to and from the UPS MUST have disconnect devices
attached.
Site Requirements
Install the UPS and batteries on a surface that supports the total weight. The input wires
must reach a suitably grounded power outlet and the load’s wires must reach the UPS’s
output terminal blocks.
Backup Generator (If Used)
In Generator Mode, the UPS’s range of acceptable input frequency and voltage is expand-
ed to accept the uctuations created by a generator (See Section 3.4, “Programming the
UPS,” “Sense Type”).
Use a generator with electronic speed and voltage controls which produces less than 10%
voltage Total Harmonic Distortion (THD). Mechanical governors can force the UPS to run
continuously in Battery mode.
Before installation, make sure the generator’s output voltage is compatible with the UPS’s
input voltage requirements. To make sure the system runs smoothly, use a generator that
supplies twice as much power as drawn by the total load.

13
Installation
2.2 Mounting the UPS
The UPS can be placed on a shelf with no other parts needed. Any version of the FXM can be
rack or wall mounted or secured to a shelf, such as on an outdoor enclosure’s shelf, with the
optional mounting brackets as shown in Figure 2.2.1. The brackets and the screws to attach
them to the UPS’s case are available from Alpha Technologies (part number 740-697-21).
Terminal block covers MUST be used and are available from Alpha Technologies
(part number 740-698-21). If the UPS end application is mounted inside an
enclosure or in an area restricted to authorized personnel, then the covers may
or may not be needed.
For the FXM 1100/1500/2000 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.
Do not damage or pull out the
wires or the ribbon cables when
rotating the panels.
Figure 2.2.1
UPS Mounting
Mounting brackets position for shelf
mounting (both sides)
Mounting brackets position for rack mounting (rotate to t either 19-inch or 23-inch racks)

14
Installation
2.3 Wiring the External Batteries
DANGER: Before starting, make sure you have read the instructions on battery
safety in Section 1.1 of this manual.
Tools and Materials Required
• DC Voltmeter.
• Labels or masking tape and marker.
• Torque wrench.
• High strength, ame-proof tape (such as duct tape).
• Battery terminal corrosion inhibitor (such as NOCO Company’s NCP-2 or Sanchem Inc.’s
No-Ox ID Grease “A”).
Battery Checklist
Use new batteries when installing a new unit. Verify they are all the same battery type with
identical date codes.
Before attaching the batteries to the UPS, make sure the polarity is correct.
If you are making your own battery wiring harness, use at least 10 AWG (for FXM 1100) or
8 AWG (FXM 1500/2000).
If 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 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.
Continued on the next page

15
Installation
2.3 Wiring the External Batteries (Continued)
Procedure
1. Number the batteries from 1 to 4 with labels or tape as shown in Figure 2.3.1.
2. Coat the battery terminals with battery corrosion inhibitor.
3. Wire the batteries as shown in Figure 2.3.1. If used, install the in-line fuse between
batteries #2 and #3.
Torque the battery terminals according to the manufacturer’s specications as
given on the name plate or data sheet.
4. Verify battery connector polarity and DC voltage with a voltmeter. If correct, attach it to the
UPS’s external battery connector. If not, perform troubleshooting before connecting it to
the UPS.
5. Route the sensor end of the battery temperature cable to the batteries. Tape it to the side
of battery #2 or #3 as shown in Figure 2.3.1.
6. If a second battery string is used, repeat steps 1 to 4.
Battery Wiring Finished
Figure 2.3.1
External Battery Wiring
– +
Battery #1
– +
Battery #2
– +
Battery #3
– +
Battery #4
Tape the battery temperature sensor to the side of either battery #2 or battery #3.
Optional In-Line Fuse
To negative (-) terminal To positive (+) terminal

16
Installation
2.4 Wiring the UPS
DANGER: Before starting, make sure line power is turned off and that the UPS’s
battery and input circuit breakers are turned off.
If stranded wires are used for the input and output terminal blocks, ferules MUST
be used.
Tools and Materials Required
• Slot head screwdriver to t the terminal blocks.
• Maximum 12 AWG copper wire rated to at least 90°C for the input and output power
terminal blocks (or as specied by the local electrical code).
Procedure
1. Connect the battery temperature sensor
to the UPS. Attach the sensor end of the
cable to the side of the centre battery as
shown in Figure 2.3.1.
2. If used, connect:
• The Ethernet port.
• The RS-232 port.
• The dry contacts.
• The user inputs.
3. Connect the load line to the UPS’s output
terminal block.
4. Connect the line power line to the UPS’s
input terminal block.
DANGER: Before proceeding,
verify 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. Connect the external battery.
Wiring Finished