n Operator s Manual n Redundant Control Unit FOR CFR UNINTERRUPTIBLE POWER SUPPLIES FROM ALPHA TECHNOLOGIES

Transcription

1 n Operator s Manual n Redundant Control Unit FOR CFR UNINTERRUPTIBLE POWER SUPPLIES FROM ALPHA TECHNOLOGIES

2 TABLE OF CONTENTS 1. Introduction The Alpha Redundant Control Unit (RCU) A Tour of the RCU Front Panel RCU Interior Rear Panel Installation Unpacking and Inspection Checklist Rack Mount Installation Wall Mount Installation Operation RCU Start Up and Test Procedure RCU Voltage Configuration Maintenance Internal Fuse Replacement Troubleshooting RCU Wiring Diagrams Return Instructions Specifications Warranty... 20

3 1 Introduction 1.1 The Alpha Redundant Control Unit (RCU) Purpose: Describes the operation of Alpha s Redundant Control Unit (Figure 1.1) Alpha s Redundant Control Unit (RCU) provides a dual redundant configuration, ensuring power is always supplied to the critical load. Both input voltages are monitored, so if power is lost at input 1, the RCU transfers to input 2. Input 1 is the primary source of power so the RCU automatically returns to it when power is restored. Before transferring, it waits about 1 minute to allow input voltage and frequency to stabilize. The RCU has two contactors, one for each power source. They both cannot be on at the same time. If there is a failure in either contactor or the control logic, the Type C alarm contact on the rear panel is activated and the Red Alert LED turns on. Alarm conditions are: logic failure; Contactor 1 or 2 fails to open; Contactor 1 or 2 fails to close or open internal fuses. The front panel LEDs shows the RCU s status. Inputs Primary Secondary Contactor 1 Contactor 2 Output Logic Figure 1.1 RCU Operating Diagram 1

4 1 Introduction 1.2 A Tour of the RCU Purpose: Describes the RCU s controls, displays and terminal blocks (Figures 1.2, 1.3, 1.4, 1.5) Front Panel (Figure 1.2) 1 Input 1 LED: Shows the presence of AC power at Input 1. 2 Input 2 LED: Shows the presence of AC power at Input 2. 3 Contactor 1 LED: Shows Contactor 1 is closed, providing primary power to the output Contactor 2 LED: Shows Contactor 2 is closed, providing secondary power to the output. Output LED: Shows there is power at the output. Manual Transfer LED: Shows both primary and secondary power sources are in phase and that a manual transfer can be done with the make before break manual bypass switch. Red Alert LED: Shows that one of the contactors or the control logic has failed. Input 1 Circuit Breaker: Provides circuit breaker protection to the primary input and acts as an ON/OFF switch. Input 2 Circuit Breaker: Provides circuit breaker protection to the secondary input and acts as an ON/OFF switch Select 1 Switch: Opens the secondary contactor before closing the primary to provide Input 1 power to the output. Select 2 Switch: Opens the primary contactor before closing the secondary to provide Input 2 power to the output. 2

5 1 Introduction A Tour of the RCU (Continued) Front Panel (Continued) 14 Alarm Reset Switch: Shuts off the audible Red Alert alarm. Attachment Screws: These two screws secure the front panel to the RCU. Front Panel: This hinged panel opens downward to access the interior for voltage configuration, fuse changing or troubleshooting Figure 1.2 RCU Front Panel 3

6 1 Introduction 1.2 A Tour of the RCU RCU Interior (Figure 1.3) 1 2 Front Panel: This hinged panel opens downward to allow the operator access to the RCU interior to configure the input/output voltage, replace fuses or for troubleshooting. Two, 3.15 Amp fuses are located here. Contactors: The primary and secondary contactors. 3 Sliding Panel: This panel slides back and forth for access to the RCU s input, output and alarm terminal blocks Input 1 Terminal Block: This terminal block is the primary power input. Input 2 Terminal Block: This terminal block is the secondary power input. Output Terminal Block: This terminal block is the RCU s output. Alarm Terminal Block: This terminal block is the RCU s alarm connection. 8 Power Board: The RCU is configured here for 120, 208 or 240 VAC operation. Two, 500 ma fuses are located on this board. 4

7 1 Introduction 1.2 A Tour of the RCU RCU Interior (Continued) Figure 1.3 RCU Interior (Cutaway View) 6 7 Wiring: The wiring diagram for the terminal blocks is shown in Figure 1.4. Both Inputs share a common ground. The alarm terminal block has Type C contacts to provide Contactor and Alarm status to the monitoring system. Contactor K1 is normally closed. Contactor K2 is normally open. Red Alert Alarm is open when the system is operating normally. 5

8 1 Introduction 1.2 A Tour of the RCU L1 N L2 GND L1 N L2 GND L1 N L2 Legend: COM: Common, N/C: Normally Closed, N/O: Normally Open Figure 1.4 RCU Wiring Diagram Rear Panel (Figure 1.5) To access the terminal blocks, unscrew the five attachment screws then remove the panel. SOURCE 1 SOURCE 2 OUTPUT ALARMS Attachment Screws Figure 1.5 RCU Rear Panel 6

9 2 Installation 2.1 Unpacking and Inspection Checklist Carefully inspect the contents. If items appear damaged or missing, contact Alpha Technologies and the shipping company immediately. Most shipping companies have only a short claim period. Make sure the following have been included: Redundancy Control Unit and mounting kit. Operator s Manual Any other ordered options SAVE THE ORIGINAL SHIPPING CONTAINER If the RCU is returned for servicing, pack it in its original shipping container. Alpha Technologies is not responsible for damage caused by improper packaging of returned units. READ THE OPERATOR S MANUAL Become familiar with the RCU by reviewing the procedures and drawings in this manual before installation. If you have questions contact Alpha Technologies. COMPLETE THE FOLLOWING FOR YOUR RECORDS: Model Serial Number Options Purchase Date This Unit was purchased from: Dealer Name City State/Province ZIP/Postal Code Country Telephone/ Fax Number E Mail 7

10 2 Installation 2.2 Rack Mount Installation NOTES: 1) The RCU can be mounted in either a 19 or 23 inch rack by adjusting the configuration of the rack mount brackets. 2) Use #4 AWG for connecting the input and output terminal blocks and #18 22 AWG solid wire for connecting the communication terminal block. 3) DANGER: Before installation, make sure the Input 1 and 2 circuit breakers are OFF. 4 Wire the load(s) to the output terminal block with #4 AWG Attach the RCU to the rack 2 Mid Mount Attachment Points 1 Attach the rack mount brackets to the RCU in either the front or mid mount position 3 Wire the communication lines to the communication terminal block with #18 22 gauge solid wire 5 Wire the inputs to the input terminal block with #4 AWG Figure 2.1 RCU Rack Mounting 8

11 2 Installation 2.3 Wall Mount Installation NOTES: 1) Use #4 AWG for connecting the input and output terminal blocks and #18 22 AWG solid wire for connecting the communication terminal block. 2) DANGER: Before installation, make sure the Input 1 and 2 circuit breakers are OFF. Attach the RCU to the wall 2 3 Wire the communication lines to the communication terminal block with #18 22 AWG solid wire Attach the rack mount brackets to the RCU 1 Wire the load(s) to the output terminal block with #4 AWG 4 Figure 2.2 RCU Wall Mounting 5 Wire the inputs to the input terminal block with #4 AWG 9

12 3 Operation 3.1 RCU Start Up and Test Procedure WARNING: Before starting, turn OFF the Input 1 and 2 Circuit Breakers and the Load(s). NOTE: If there is any type of logic or contact failure during the system start-up, test or operation, the Red Alert LED turns ON. STEP 1: RCU Power Up Press the Select 1 contactor switch. 2 1 Switch ON both circuit breakers. Figure 3.1 RCU Power Up STEP 2: Test Primary Power 1 Switch the Input 1 circuit breaker OFF. The Input 1 LED on the front panel will go out, showing the loss of primary power. As the RCU transfers to the secondary power source the Contactor 2 LED turns ON. NOTE: There will be a five second delay between the transfer from Input 1 to Input 2. This conforms to the automatic transfer switch safety code. Input 1 LED Contactor 2 LED Turn OFF Input 1 circuit breaker Figure 3.2 Testing Primary Power 10

13 3 Operation 3.1 RCU Start Up and Test Procedure STEP 3: Restore Primary Power 1 Switch the Input 1 circuit breaker ON. The Input 1 LED lights, showing the return of primary power. The RCU transfers back to Input 1 after about 30 seconds, after the voltage and frequency stabilizes. When done, the Contactor 1 LED turns ON. Turn ON Input 1 LED Contactor 1 LED Input 1 circuit breaker Figure 3.3 Return Primary Power STEP 4: Test Secondary Power 1 Switch the Input 2 circuit breaker OFF. The Input 2 LED on the front panel turns OFF, indicating the loss of secondary power. There should be no transfer or any other change in the status of the RCU. 2 Switch the Input 2 circuit breaker ON to return to normal status. Input 2 LED Turn OFF Input 2 circuit breaker Figure 3.4 Test Secondary Power 11

14 3 Operation 3.1 RCU Start Up and Test Procedure STEP 5: Test Secondary Contactor 1 2 If the RCU s Contactor 1 LED is ON: Press the Select 2 switch. As the RCU transfers to the Secondary power source the Contactor 2 LED turns ON. Press the Select 1 switch to return to primary power. Select 2 Switch Contactor 1 LED Contactor 2 LED Red Alert LED Figure 3.5 Test Secondary Contactor STEP 6: Turn On The Loads If the Manual Transfer LED is ON, turn on the load(s). 12

15 3 Operation 3.2 RCU Voltage Configuration DANGER: This procedure should be done only by qualified personnel. DANGER: Verify the power is OFF before opening the front panel. NOTE: The Input 1 and 2 voltages must be configured identically. The RCU is designed so it is voltage configurable for 120/208/240 VAC. PROCEDURE: 1 Switch the Input 1 and 2 circuit breakers OFF. 2 Remove the two Phillips screws on the sides of the front panel. 3 Carefully lower the panel 45 degrees. 4 Locate the Input 1 and 2 pin jumpers on the power board. Input 1 Pin Jumpers Input 2 Pin Jumpers J 1 F 1 J 2 F R 3 R V R V R 2 R 5 or 120 V R 8 R 1 R V R 7 R 10 R 11 R V or 240 V J Figure 3.6 Input 1 and 2 Pin Jumpers on the Power Board 13

16 3 Operation 3.2 RCU Configuration Procedure 5 Position jumpers or 0 Ohm resistors according to the following chart. Require equired Voltages Jumper Placement Input 1* Jumper Placement Input 2* 1 20 VAC R1, R2, R3 R7, R8, R VAC R4, R5, R6 R10, R11, R VAC R4, R5, R6 R10, R11, R12 * NOTE: Input 1 and Input 2 must always be configured for the same voltage Figure 3.7 Input 1 and 2 Jumper Configuration Verify the Input 1 and 2 voltages are configured identically. Close the front panel. Test it for proper operation (Section 3.1) and required voltages. 14

17 4 Maintenance 4.1 Internal Fuse Replacement DANGER: Fuse replacement should be done only by qualified personnel. DANGER: Make sure the power is OFF before opening the front panel. The RCU has four internal fuses that are accessible from the front panel. To lower the front panel: 1 Switch OFF the Input 1 and 2 circuit breakers. 2 Remove the two Phillips screws on the RCU front panel. 3 Carefully lower the front panel forward 45 degrees. Two fuses are located on the power board: Input 1: F1 and Input 2: F2 (both are 500 ma). Input 1 Fuse (500 ma) Input 2 Fuse (500 ma) J 1 F 1 J 2 F R 3 R V R V R 2 R 5 or 120 V R 8 R 1 R V R 7 R 10 R 11 R V or 240 V J Figure 4.1 Power Board Fuse Location Two fuses are located on the logic board: Contactor 1: F1 and Contactor 2: F2 (both are 3.15 Amps). Logic Board K1 K3 F Amp F Amp Figure 4.2 Logic Board Fuse Location 15

18 4 Maintenance 4.2 Troubleshooting The most common problems, symptoms and causes are listed in Figure 4.3. It starts off with the simplest problems, working to the most complex. If the operator can t resolve the problem, contact Alpha Technologies. Maintenance and troubleshooting should be done only by qualified personnel. S YMPTOM M RCU will not transfer r from on Input to the other P ROBABLE CAUS E Circuit breaker tripped SOLUTIO N Reset Breaker Voltage too low *Check voltage Open fuse on logic board *Replace Fuse Contactor fused or open *Replace RCU Problem with control logic *Replace RCU " "Manual Bypass OK" on RCU will not turn on Circuit breaker tripped Reset Breaker Input 1 and Input 2 out of phase *Check phasing and correct as necessary * These Items are to be performed only by a qualified technician Figure 4.3 Troubleshooting Chart 16

19 Input CB Panel Bypass Input W1 W5 Static Switch Input Breaker Battery Breaker Battery Charger Battery CFR UPS Inverter Normally OFF Isolation/Output Waveform Control Output Breaker W 4 W 2 Input 1 Input 2 Figure 4.4 RCU Wiring Diagram RCU Logic W 3 Optional Manual Bypass Option XFMR Bypass Line UPS RCU W 8 (W 9) Output 4.3 RCU Wiring Diagrams 17 CB Panel W1 Bypass Input Input W5 Static Switch Input Breaker Battery Charger CFR UPS Inverter Normally OFF Output Breaker W 4 W 2 RCU Input 1 Input 2 W 3 Output Battery Breaker Battery Isolation/Output Waveform Control Figure 4.5 RCU Wiring Diagram (Without Manual Bypass Switch) Logic 4 Maintenance

20 4 Maintenance 4.4 Return Instructions Before returning an RCU to Alpha Technologies for repair, obtain a Return Material Authorization (RMA) number from Alpha s customer service department. Clearly write it on the original shipping container. If you do not have it, pack the substitute container with at least three inches of shock absorbing material. Do not use popcorn type material. Returns should be prepaid and insured (COD and freight collect cannot be accepted). NOTE: Alpha Technologies does not assume responsibility for damage caused by improper packaging of returned units. For parts and service, contact the Alpha Technologies Customer Service Department at: United States (360) Canada (604) United Kingdom Germany Middle East Australia +61 (0) To obtain complete technical support (7 days a week, 24 hours a day) call: USA CANADA

21 4 Maintenance 4.6 Specifications General Specifications 5 0 Amps 100 Amp s Input Voltage, VAC* 120 or 208/240 Input Frequency, Hz Input Current, Amps Input Breaker, Amps Typical (msec) Transfer Time, Operating Temperature ( O C) 0 to +40 Width (Inches/mm) 17/432 Height (Inches/mm) 5.25/133 Depth (Inches/mm) 15/381 Weight (lbs/kg) 35/16 * Primary and secondary power source must have the same nominal voltage. 19

22 4 Maintenance 4.6 Warranty LIMITED 24-MONTH WARRANTY AC PRODUCTS Alpha Technologies warrants its equipment to be free of manufacturing defects in material and workmanship for a period of 24 months from the date of manufacture. The liability of Alpha Technologies under this warranty is solely limited to repairing, replacing, or issuing credit for such equipment (at the discretion of Alpha Technologies), provided that: 1. Alpha Technologies Customer Service Department is promptly notified, by facsimile or telephone, that a failure or defect has occurred. 2. Alpha Technologies Customer Service Department issues a Return Materials Authorization (RMA) number, and designates the service location. The RMA must be clearly marked on the outside of the shipping container. 3. Purchaser is responsible for all in-bound shipping and handling charges (COD and freight collect will not be accepted without prior approval from Alpha Technologies); Alpha Technologies will pay out-bound surface shipping charges for return of repaired equipment. 4. A satisfactory examination of the returned unit by Alpha Technologies Service personnel shall disclose that defects have not been caused by misuse, neglect, improper installation, repair, alteration, or accident, or failure to follow instructions furnished by Alpha Technologies. If Alpha Technologies Service personnel determine that the unit has been damaged due to one of these causes, or if the unit is free of defects, a handling or repair fee may be assessed prior to returning the unit. WITH RESPECT TO BATTERIES, PERIPHERAL DEVICES, ATTACHMENTS OR APPARATUS NOT MANUFACTURED BY ALPHA TECHNOLOGIES, ALPHA WILL ASSIGN TO THE PURCHASER ITS RIGHTS UNDER THE ORIGINAL MANUFACTURER S WARRANTY OF SUCH BATTERIES, PERIPHERAL DEVICES, ATTACHMENTS OR APPARATUS, BUT OFFERS NO ADDITIONAL WARRANTIES IN CONNECTION THEREWITH. THIS LIMITED 24-MONTH WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO CASE SHALL ALPHA TECHNOLOGIES BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING WITHOUT LIMITATION ANY CLAIM FOR LOST PROFITS OR REVENUES, EVEN IF ALPHA TECHNOLOGIES HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH, FOR BREACH OF THIS OR ANY OTHER WARRANTY, EXPRESS OR IMPLIED. Any action for breach of this limited 24-month warranty must be brought within a period of 24 months from date of manufacture. This limited 24-month warranty does not extend to any unit that has been repaired or altered by any party other than Alpha Technologies or its Authorized Service Center. Alpha Technologies reserves the right to discontinue particular models and to make modifications in design and/or function at any time, without notice and without incurring obligations to modify previously purchased units. 8/96 20

23 USA, LATIN AMERICA & ASIA PACIFIC Alpha Technologies 3767 Alpha Way Bellingham, WA Tel: (360) Fax: (360) CANADA Alpha Technologies 7033 Antrim Ave., Burnaby BC V5J 4M5 Tel: (604) Fax: (604) UNITED KINGDOM, EUROPE & AFRICA Alpha Technologies Cartel Business Estate Edinburgh Way Harlow, Essex CM20 2DU Tel: Fax: GERMANY Alpha Technologies Hansastrasse 8 D Schwabach Tel: Fax: MIDDLE EAST Alphatec P.O. Box Limassol, Cyprus Tel: Fax: AUSTRALIA/SOUTH PACIFIC Alpha Technologies 8 Anella Ave., Unit 6 Castle Hill, NSW 2154 Tel: Fax: Alpha sales and service offices located throughout the world Printed In Canada B / Alpha Technologies