Valcom 1620ES-24VDC Series User manual

Valcom Failsafe Unit
1620ES-24VDC SERIES
Operation and Maintenance Manual

Table of Contents
Section Title Page
1. - Introduction…………………………………………………..
2. - Unpacking the Failsafe unit………………………………….
3. - Installation……………………………………………………
3.1 - Auto / Timed UPS Shut Down………………………………
4. - Failsafe Operation……………………………………………
5. - Maintenance………………………………………………….
5.1. - Testing the Batteries………………………..…………………
5.2. - UPS RESET………………………………………………
6. - Electrical Drawings…………………………………………..
7. - Specifications………………………………………………….
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Valcom Failsafe Unit
1. - Introduction
Congratulations on the purchase of the Valcom Failsafe unit, Series1620E-24VDC this unit
was designed specifically for your System. Please follow the instructions outlined on these next
few pages to put your system on line.
In general a UPS (Uninterrupted Power Supply) or Failsafe unit delivers emergency power in the
event of regular source power failure or interruption. This Failsafe unit was designed to open or
close one or more actuators after a power failure, if more than one actuator is to be controlled by
this system the unit will remain ON until the last controlled actuator has reached the failsafe
position.
Your Failsafe unit is housed in a NEMA Enclosure, and is shipped with two complete sets of
drawings one set has been attached to the inside door and an extra set is supplied for your files.
Your Fail-safe unit features sophisticated electronic circuitry. It provides high peak power output
to start and run devices requiring high current for short duration. This high current is referred to
as locked rotor amperage. Once interfaced with your system, the unit will operate
automatically during power failure.
2. - Unpacking the Failsafe unit
Upon receiving your Failsafe unit, you should check the contents of your package. First inspect
the shipping container for any indications of mishandling. If there is any evidence of damage to
the container you should report it to your carrier, a representative of Valcom, or to Valcom
directly. Next inspect the control cabinet and the internal controls and if anything appears to be
abnormal or damaged report it at once.
This Failsafe unit was manufactured by:
Valcom div. of Tooling Research Inc.
81 Diamond St.
Walpole, MA 02081
Phone # [phone]
Fax # [phone]

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3. - Installation Caution !!!
The installation maintenance and operation of this unit should be
performed BY QUALIFIED PERSONNEL ONLY.Valcom, it’s
representatives or affiliates accepts no responsibility for damages
or injuries resulting from the improper installation, maintenance
or operation of its equipment. Personnel responsible for the
installation and operation of this unit must read and understand
this manual fully before proceeding. If you do not understand the installation or operation
procedures of this unit completely STOP, and contact either Valcom or an affiliate for
further instructions. Technicians are available to answer your questions.
Use extreme caution when working inside the Failsafe unit. Insure that all electrical
power has been turned OFF before attempting installation, or maintenance of this
unit.
Never short or bridge the two DC terminals at the Battery, or the DC input
terminals at the Inverter.
DO NOT allow anything to come in contact with these terminals during Failsafe
operation, or during service or installation. You must insulate these terminals to
help protect against accidental short circuits.
Failure to properly ground the Failsafe to earth ground may result in a lethal
electrical shock hazard.
Serious injury to personnel and / or property can result from failure to follow
correct procedures.
Before you proceed with the installation of this Fail-safe unit, ensure that the fuses located inside
the Failsafe unit are OUT; this will prevent an accidental activation of the unit during
installation.
Disconnect all power to the equipment to be controlled by the Failsafe unit, and read the
instructions and connection drawings provided by the actuator manufacturer before proceeding
with the installation.
All the connections between the Failsafe unit and field equipment are provided for by the
customer, unless a specific agreement has been reached with Valcom or its affiliates to provide
such installation.
The Failsafe enclosure may be punched or drilled for conduit attachments on any of the four
sides of the enclosure however the conduit entry point must be at least 3” from the internal back

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panel to allow room for wires to clear all internal components. Do not make connections
through the back of the control box. All connections and conduit hubs must be of the type
which will maintain the correct NEMA rating of your unit.
All connections are to be made directly to the terminal block located inside the Failsafe unit;
these terminals are clearly marked and assigned on the electrical drawings attached to the door.
Make all the connections between the actuators and the Failsafe unit. When connecting the limit
switches be sure that you have selected a set of contacts that will close when the actuator has
reached a FULLY OPENED or FULLY CLOSED position after power failure. Failure to
select the correct set of contacts will prevent the Failsafe unit from automatically disconnecting
after the actuators have reached the failsafe position.
3.1. – AUTO / TIMED UPS shut down
The 1620ES-24VDC series includes an option that allows the system to
be shut down in AUTO or TIMED mode.
AUTO MODE requires that a Limit Switch from the valve actuator be
connected to the controller for the system to shut down automatically
after power failure.
TIMED MODE should be used only when the valve actuator does not
have an available limit switch.
To enable this option, jumpers J1 and J2 must be moved from pins 1-2
to pins 2-3. Once enabled, the time available for a shut down after a
power failure is selected with the potentiometer P3, the minimum time
is factory set at 4.5 minutes (P3 set fully to the left) and the maximum
possible time to select is of 12.5 minutes (P3 set fully to the right).
Longer times are available and should be requested when ordering.
Regardless of the mode selected, this controller has an LED above P3 that will be ON when the
failsafe has been shut down after a power failure, and it will remain ON until normal power is
restored.
The battery included with this Failsafe unit was sized to operate a specific system for a specific
amount of time. If it is not disconnected from the valve it will fully discharge the battery after
activation.
Ensure that all the electrical connections are made according to the drawings and schematics
provided by the actuator manufacturer. If more than one actuator is to be controlled by the
Failsafe, each one should be connected to the assigned terminal block inside the Failsafe unit.

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CAUTION!!!! Never connect two actuators to the same terminal block.
No external controls are provided with standard Failsafe units. All manual switch/controls are to
be provided by the customer, and should be connected according to the electrical drawing, or
drawings provided with the Failsafe unit and the switch/control manufacturer. Wiring must
comply with all Federal, State, and local codes.
If your Fail-safe unit is controlling a modulating actuator (4/20 ma signal ), regardless of the
source of the signal, the Failsafe unit will cut the (4/20 ma signal) to the actuator and drive it
down to zero (0 ma ). This will force the actuator to move to its failsafe position. For this type
of operation the signal wires should be connected as follows:
1. - Connect the negative (-) wire from the 4 /20 ma source to the terminal labeled signal (-) at
the actuator.
2. - Connect the positive (+) wire from the 4 / 20 ma source to one of the terminals labeled MOD
in the Failsafe unit.
3. - Connect the other terminal labeled MOD at the Failsafe unit, to the terminal labeled signal
(+) in the actuator.
4. - Connect the normally open Limit Switch wires from the Actuator to the terminals labeled
ALS in the Failsafe unit
5. - Connect the motor from the Actuator to the Failsafe according to the drawings supplied with
the unit.
6. - Connect Power to the unit, make sure you connect a solid ground to the Failsafe
7. - Install the Fuses; (they were shipped separately for security reasons.)
WARNING !
Valcom does not recommend the use of any of its Failsafe units in life support systems or in
any life threatening applications where a malfunction or failure of the unit could cause
failure of these applications.

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4. - Failsafe Operation
This Failsafe unit was designed to perform automatically upon power failure.
During normal operation the Failsafe will be in STAND-BY mode, the battery charger is trickle
charging the batteries.
During power failure the battery charger will stop charging, and the Failsafe will be
automatically switched to the battery. The Failsafe will be turned ON. Once all of the actuators
are in the failsafe position the unit will cut power and disconnect the battery from the system to
maintain maximum battery charge.
The Failsafe will remain off until normal power is restored to the system, Re-establishment of
normal power will restart the Failsafe unit in the STAND-BY mode and the battery charger will
be activated again.
If the actuator is the modulating type, after power failure it will go to the failsafe position. This
will be OPENED or CLOSED depending on customer needs. Once normal power is restored to
the unit, the actuator will return to its original position and resume normal operation.
If an OPEN-CLOSE switch has been interfaced between the Failsafe unit and the actuator,
ensure that the actuator will go to the failsafe mode (open or close) regardless of the position of
the switch. Follow the wiring diagram provided with the failsafe.
The Electronic Control Board has two timers that control how fast the Failsafe reacts upon
power failure and power return. These timers are controlled by two potentiometers, P1=UPS
Power and P2=Normal Power. Turning the potentiometer to the left, decreases the time delay,
turning the potentiometer to the right increases the time delay for the transfer. If instant transfer
is required turn the potentiometers fully to the left.
P1 controls the time required for the Inverter to supply emergency power to the actuator after a
Power Failure.
P2 controls the time required to RESET the Failsafe system to normal working condition.
These potentiometers provide the customer with extra buffer time between transfers, preventing
unnecessary activation of the Failsafe if loss of power is less than a few seconds. In some cases
Emergency Generators are expected to get online after a Power Failure, if this is your case, you

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may set the potentiometers somewhere in the middle to get extra time before activating the
Failsafe. If the generator goes online before the timer times out the Failsafe will return to
“Normal Condition”. If the Generator fails to go online the Failsafe will transfer to Emergency
Power sending the Actuator to its Failsafe position.
The Controller incorporates LED lights that show the type of power that the actuator is
receiving; these lights will be ON only when either Power has been applied to the actuator
terminal block.
Green NORMAL POWER LED = When lit actuator is receiving Normal Power.
Red UPS POWER LED = When lit actuator is receiving UPS power.
Green POWER LED = When lit Normal Power is present.
Clear UPS SHUT DOWN LED = When lit Failsafe has completed emergency cycle.
5. - Maintenance
The Failsafe unit requires minimum maintenance but should be kept dry and clean at all times,
periodically check all cable connections to the battery, clean and tighten these as necessary.
At least once a month test the system to make sure that the unit is in good condition and to
exercise the batteries.
Caution: blown fuses are an indication of a fault in the system or its connections. Such as short
circuits, overloads etc.. Locate the source of the problem before replacing the fuse.
The Failsafe unit operates at high efficiency and generates minimal heat during use. To ensure
that you will always get the maximum output from the Failsafe unit, periodically verify that the
battery is fully charged.
5.1 Testing the Batteries
Test the Failsafe unit once a month, cut the power supply to the Failsafe unit or use a Remote
test switch. Allow the actuator or actuators to move to there failsafe position, once they are in
failsafe mode reconnect power to the unit and check that all the relays are working properly, this
is also a good time to verify that the battery charger is working, the charging light should remain
ON (Yellow) until the battery reaches a fully charged condition.
You may check the condition of the battery with an Industrial sealed battery load tester, when
testing follow the instructions supplied with the battery load tester unit.
A quick test may be perform to check the condition of the battery, connect a volt-meter to the
battery terminals, disconnect power to the Failsafe unit and allowed the actuator to go to the
failsafe position, during all this time check the reading of the volt-meter, if the voltage do not

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drop bellow 11 Vdc. the battery is holding charge as expected, if the voltage drops bellow 11
Vdc. you need to perform a test with a battery load tester.
5.2 UPS RESET
You may connect a momentary switch to the UPS RESET (TB3) terminal block; this will
restore additional time of emergency power to the valve. This feature is enabled only when
normal power is not present, and after the Failsafe has completed the first emergency cycle.