Alpha CFR 3000, CFR 3000RM User Manual
CFR
3000 and 3000RM
Uninterruptible Power Supplies
From Alpha Technologies
!!
! Operator ’s Manual
!!
!!
!
!!
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!
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Operator’s Manual
CFR 3000 and 3000RM
Uninterruptible Power Supplies
LINE PRESENT
LINE FAILURE
SERVICE
LOW BATTERY
WARNING
LOW BATTERY
SHUTDO WN
TEST
ALARM
OFF
MANUAL
START
OUTPUT LOAD
OVERLO AD
100%
75%
50%
25%
CFR 3000 and 3000RM
Save This Manual
It contains important installation and operating instructions.
Keep it in a safe place.
CAUTION
Risk Of Electrical Shock
T o reduce the risk of electrical shock and to ensure the safe operation of the CFR 3000 and
3000RM, these symbols are used throughout this manual. Where they appear only qualified
personnel should carry out the instructions.
A DANGEROUS VOLTAGE exists in this area. Use extreme caution.
ATTENTION: Important operating instructions. Follow them exactly.
NOTICE:
The CFR 3000 and 3000RM generates, uses and can radiate radio frequencies if not installed and
tested in accordance with the instructions contained in this manual. It has been tested and found to
comply with the limits established for a Class A computing device pursuant to part 15 of FCC rules
when it is operated alone. It also complies with the radio interference regulations of DOC which are
designed to provide reasonable protection against such interference when this type of equipment is
used in a commercial environment. If there is interference to radio or TV reception, which is determined by switching it on and off, relocate the equipment or use an electrical circuit other than the
one used by the CFR 3000 and 3000RM.
i
Safety Checklists
DANGER: Do not expose the unit to rain or moisture.
DANGER: Sealed lead-acid batteries with high energy and chemical hazards are
used. This manual contains important operation and safety instructions. Only qualified
personnel should service the CFR 3000 and 3000RM.
CFR 3000 and 3000RM Safety Checklist
Carefully unpack the unit. Report any shipping damage at once.
CFR 3000 and 3000RM
Read this manual. If you have any questions about the safe installation, operation or maintenance of the unit, contact Alpha Technologies’ customer service department.
Before installation, confirm the voltage and current input requirements of the load(s) is
compatible with the unit’s output. Also see the line voltage and current is compatible with
the unit’s input requirements.
The unit should be installed on a dedicated circuit.
Wiring should be done to meet local electrical codes.
Place a warning label on the electrical panel to tell emergency personnel an
Uninterruptible Power Supply (UPS) is installed.
Use proper lifting techniques when lifting or moving the unit.
The unit has more than one live circuit. AC power may be present at the outputs even if the
unit is disconnected from line power.
Battery Safety Checklist
Always switch the unit’s battery circuit breaker off before connecting or disconnecting an
external battery back. This reduces the chance of a spark.
There are dangerous voltages inside the unit. Only qualified personnel should perform
installation and maintenance.
ii
CFR 3000 and 3000RM
Safety Checklists (Continued)
Live battery wires must not touch the unit’s chassis or any other metal objects. This can
cause a fire or explosion.
Inspect the batteries once a year for signs of cracks, leaks or swelling. Replace as required.
When batteries are 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 type and rating. Never install old or un-
tested batteries.
Use insulated tools during servicing.
Remove all rings, watches, jewelry or other conductive items before working inside the
enclosure.
Follow local regulations for the disposal of batteries. Recycling is the best method.
Never burn batteries to dispose of them. They may explode.
Do not open the batteries. The contents are toxic.
iii
CFR 3000 and 3000RM
Table of Contents
The emergency shutdown procedure is on the inside rear cover
1. Introduction .........................................1
1.1 The CFR Advantage.................................. 2
1.2 Unpacking and Inspection Checklist......... 3
1.3 The Alpha CFR 3000 and 3000RM............ 5
2. Installation ..........................................10
2.1 Pre–Installation Checklist....................... 11
2.2 Installing the Unit ................................... 13
2.3 Connecting the Unit................................ 15
2.4 Connecting the External Battery Packs.. 18
2.5 Connecting the External Alarm Port ....... 20
2.6 Connecting the LAN Port........................ 21
2.7 Connecting the RS–232 Port .................. 22
2.8 Transformer Output Load Sharing ...........23
3. Operation ............................................26
3.1 Turning On the Unit ................................27
3.2 Turning Off the Unit ................................ 29
3.3 Testing the Unit ...................................... 30
3.4 Troubleshooting with the SID .................. 31
3.5 Controlling the Unit with the Standard
Interface Device ..................................... 32
4. Communication ............................. 35
4.1 RS–232 Set-Up ...................................... 36
4.2 Using the Opening Menu........................38
4.3 Menu Tree..............................................41
4.4 System, Input, Output & Battery Param-
eters ......................................................42
4.5 User Parameters ....................................45
4.6 Maintenance Parameters ....................... 49
4.7 Installing and Using the External Modem 50
5. Maintenance ....................................58
5.1 Testing the Battery Run Time ................. 59
5.2 Troubleshooting......................................60
5.3 Returning the CFR to Alpha for Repairs .. 62
5.4 Replacing the Internal Batteries.............. 62
5.5 Configuring the Input/Output Voltage ......67
5.6 Battery Run Times .................................70
5.7 Specifications.........................................72
Index ............................................ 73
Warranty ...................................... 78
iv
1
Section 1
Introduction
This section introduces you to the Alpha
CFR 3000 and 3000RM UPS’s:
• The CFR advantage (Section 1.1).
• An unpacking and inspection checklist (Section
1.2).
• A tour of the unit, it’s connectors, switches and
control panels (Section 1.3).
1 Introduction
2
1.1 The CFR Advantage
! Advanced Power Protection Technology
Alpha’s CFR Uninterruptible Power Supply (UPS) provides continuous and conditioned
computer-grade AC power for computer systems, point of sale terminals, process controls,
telecommunications, cable TV headend, broadband LAN, manufacturing control systems,
hospital critical care and lab equipment.
!
Rack or Tower Mounting
The unit comes in a rack mount case which can be fitted into any standard rack or a tower
case for mounting on the floor. The two units operate identically .
!
Regulation
The unit maintains ±1% output regulation without using the batteries. Even with input voltage
fluctuations as great as +10% or –20%, the output is constant regardless of the load’s size.
!
Isolation
The output is totally isolated from the input to protect the loads from spikes, surges and line
noise. The ferro resonant transformer provides nondegradable spike and surge protection.
! Extended Backup Cap ability
Alpha's EBP Series external battery packs extends backup time during power outages.
Installing the battery pack is as simple as plugging it in.
! Self Test Function
The built-in self test checks all critical areas, including the batteries, to ensure optimum performance.
! Load and Overload Information
The display panel shows the loading and tells you when the unit is overloaded.
! Generator Ready
The unit has frequency sense and constant slew frequency synchronization circuits for
trouble-free operation with most standby generators.
! Advanced Communications Capabilities
The RS–232 communications port is SNMP and modem compatible.
! Safety
Alpha designed the CFR to meet or exceed the UL, CSA or VDE safety standards. Our
commitment to safety makes Alpha T echnologies a leader in the power industry .
3 1 Introduction
1.2 Unpacking and Inspection Checklist
TIP: If items are missing or damaged, contact Alpha and the shipping company at
once. Most shippers have a short claim period.
Carefully remove the unit from its shipping container . Inspect it for damage and make sure the
following items are included:
One CFR series UPS.
One operator’s manual.
Any ordered options.
Save The Original Shipping Container
If you should have to return the unit for servicing, pack it in the original
shipping container. Alpha is not responsible for damage caused by the
improper packaging of returned units.
Read This Manual
Before installation, become familiar with your unit by reviewing the procedures and drawings in this manual. If you have any questions about safe
installation, operation or maintenance, contact Alpha’s customer service
department.
Transportation And Site Planning
The weight of the unit and optional battery packs can be as much as
several hundred lbs/kg. A safe means of transportation to the site, lifting
the cabinet into position and proper floor support must be devised.
1 Introduction
4
1.2 Unpacking and Inspection Checklist (Continued)
Complete the following for your records
Serial # __________________________________
Options __________________________________
Purchase Date ____________________________
This CFR was purchased from
Dealer ___________________________________
City _____________________________________
State/Province_____________________________
Zip/Postal Code ___________________________
Country __________________________________
T elephone #_______________________________
Fax #____________________________________
E Mail ___________________________________
T o order parts or for technical information, cont act Alpha T echnologies customer service department directly at:
:setatSdetinU:setatSdetinU
:adanaC6741-034)406(
:setatSdetinU:setatSdetinU0632-746)063(
:setatSdetinU
:modgniKdetinU011224-9721-44+
:ynamreG:ynamreG
:ynamreG:ynamreG0-98897-2219-94+
:ynamreG
:ailartsuA0233-2279-2-16+
:tsaEelddiM57657-352-753+
For emergency technical support 7 days a week / 24 hours a day call:
USA: 1–800–863–3364
CANADA: 1–800–667–8743
5 1 Introduction
1.3 The Alpha CFR 3000 and 3000RM
1.3.1 Front Panel
TIP: Unless otherwise shown in this manual, the 3000 and 3000RM are identical and
operate the same way .
The major difference is the 3000RM does not have internal batteries. An Alpha Exter-
nal Battery Pack (EBP) must be connected (Section 2.4).
3000 Tower Mount
Display Panel
This is either the St andard Interface Display (SID)
(Section 3.5) or the optional Intelligent Interface
Device (IID) (manual #018–029–B0–001).
Cover
The cover can be removed to allow access to the
unit’s interior in order to change the batteries,
perform maintenance, etc. (Section 5.4).
Front Panel
The front panel can be removed to allow access
to the unit’s interior in order to change the batteries, perform maintenance, etc. (Section 5.4).
Seismic Brackets
These secure the unit to the floor if required by the
local codes. They are removable (Section 2.2).
Casters
These let you move the unit.
Feet
If you don’t secure the unit with the seismic
brackets, you can stop the unit from moving by
screwing these down.
1 Introduction
6
1.3 The Alpha CFR 3000 and 3000RM (Continued)
3000 Rack Mount (RM)
Display Panel
This is either the St andard Interface Display (SID) (Section 3.5) or the
optional Intelligent Interface Device (IID) (manual #018–029–B0–001).
ALARM
OFF
MANUAL
START
LINE PRESENT
LINE FAILURE
SERVICE
LOW BATTERY
WARNING
LOW BATTERY
SHUTDOWN
TEST
OUTPUT LOAD
OVERLOAD
100%
75%
50%
25%
Fans
These two fans cool the unit. They must not be blocked.
7 1 Introduction
1.3 The Alpha CFR 3000 and 3000RM (Continued)
1.3.2 Rear Panel
3000RM
3000
Figure 1.1
Rear Panels
Fan (3000 Only)
This fan cools the unit. It must not be
blocked.
Output Receptacles
This is the unit’s output power connector . It
is factory configured to your specifica-
tions. See Section 2.3 for wiring informa-
tion.
Output Circuit Breaker
This resettable breaker provides addi-
tional protection to the load.
1 Introduction
8
1.3 The Alpha CFR 3000 and 3000RM (Continued)
Input Circuit Breaker
This provides protection for the unit. It can
be used as an input power on/off switch.
AC Line Cord
This is a standard, grounded line cord.
Battery Circuit Breaker
This protects the unit’s inverter and DC
circuits and can be used as a battery
power on/off switch.
TIP: It should be switched off
whenever the unit is turned off for
more than a few hours or is being
serviced. Having this breaker on
can drain the battery .
External Ground Lug
This provides a single point ground
connection. Always follow your local
electrical code for correct grounding.
This connector grounds the external EBP
battery packs to the unit.
External Battery Connector
It accepts a standard plug from either
Alpha's EBP series battery pack or a
custom battery source (Section 2.4).
9 1 Introduction
1.3 The Alpha CFR 3000 and 3000RM (Continued)
RS-232 Connector
This DB–9 port is the RS–232 connection
(Section 2.6).
LAN Interface Connector
This DB–9 port provides dry contact
status monitoring and output shutdown
capability via LAN communication (Sec-
tion 2.7).
External I2D
An external IID plugs into this connector
for remote control and monitoring.
External Alarm Connector
This RJ–45 connector provides line
failure and low battery warning informa-
tion and allows the connection of an
emergency shutdown switch with Form–
C contacts (Section 2.5).
10
Section 2
Installation
This section shows you how to install
and connect the Alpha CFR 3000 and
3000RM UPS’s:
• A pre-installation checklist (Section 2.1).
• How to unpack and install the unit (Section 2.2).
• How to connect the unit to the loads, the batteries and the line (Section 2.3).
• How to connect the external battery packs (Section 2.4).
• How to connect the external alarm port (Section
2.5).
• How to connect the RS–232 communications port
(Section 2.6)
• How to connect the LAN port (Section 2.7).
• How to prevent the UPS from being overloaded
(Section 2.8)
11 2 Installation
2.1 Pre–Installation Checklist
2.1.1 Site Preparation
Install the unit upright in a dry, well-ventilated, dust free environment. There must be at least
6 inches (152 mm) between the unit and the wall(s) for cooling and access to the front and
rear panels. Do not place the unit next to air conditioning or heating thermostats.
Do not connect the unit to line conditioning equipment. This can cause improper operation
of both the unit and the equipment.
Do not connect equipment that produces electrical noise such as motors, relay control
circuits, copiers or laser printers to the same circuit as quieter or more sensitive devices.
The unit cannot fully protect this type of equipment when noisy devices are connected.
Electrically noisy equipment should be connected to a dedicated unit.
Place a warning label on the electrical panel so emergency personnel know a UPS is in the
building. Label the service panel(s) to identify the circuit(s) supplying and being supplied by
the unit.
2.1.2 Grounding & Utility Line
All wiring should be done only by qualified personnel and comply with the local electrical
code.
The unit’s input and output voltage is factory configured to your specifications. If you need to
change either one or both, see Section 5.5, “Configuring the Input/Output Voltage.”
If required, install a hardwired ground. Since many older facilities have improper grounding,
a qualified electrician should inspect both the wiring and the grounding before installation.
Measure the line voltage at the main electrical panel. Compare that reading with the input
rating of the unit as listed on the nameplate label on the back panel:
• 240 VAC units: the voltage must be between 216 VAC and 252 VAC.
• 230 VAC units: the voltage must be between 207 VAC and 242 VAC.
• 208 VAC units: the voltage must be between 188 VAC and 216 VAC.
• 120 VAC units: the voltage must be between 110 VAC and 125 VAC.
Also see Section 2.8, “Transformer Output Load Sharing.” For information about
reconfiguring the unit’s input or output voltage , see Section 5.5, “Configuring the Input/
Output Voltage.”
2 Installation 12
2.1 Pre–Installation Checklist (Continued)
The unit should be wired to dedicated circuit equipped with a properly sized circuit breaker.
The breaker’s size is the unit’s maximum input current (as given in the specifications) plus
25%.
For example if the unit draws 32.0 Amps of current at 208 VAC, adding 25% the input
current becomes 40.0 Amps. A 40 Amp circuit breaker would be OK. Always follow the
local electrical code when installing or sizing circuit breakers.
2.1.3 Standby Generator
The unit has frequency sense circuits for operation with most standby generators. Use a
generator equipped with electronic speed and voltage controls since the unstable frequencies created by a mechanical governor can make the unit run continuously in line failure
mode, draining the batteries.
Before installation see that the generator’s output voltage meets the unit’s input voltage
requirements as shown on both nameplates. A 240 VAC unit must be attached to a 240
VAC generator.
13 2 Installation
2.2 Installing the Unit
2.2.1: CFR 3000
TIP: The seismic brackets can be removed if they are not required by the local code or
you are not in an earthquake zone (See
Tools and Materials Required:
• Fork lift or other means of transporting heavy objects (up to 288 lbs./131 kg).
• Screwdriver or power screwdriver with a Philips bit.
•15/16 inch socket wrench.
5
).
Procedure:
The unit is shipped attached to a pallet. Use a forklift to transport the unit and pallet to the
1
installation site.
Remove the packing from around the unit. Unbolt the unit from the pallet.
2
Slide the unit off the pallet as per the included instruction sheet (017–098–C3). Move the
3
unit to its final position.
If the seismic brackets are used:
4
The drawing below looks down unto the brackets and the floor:
0.562 inch diameter for mounting 0.5 inch anchor bolts.
0.781 inch diameter for mounting heavy duty anchor bolts
(Hilti #665927 (HSL M12/25)).
Mark the position on the floor where the unit will be secured by using the bracket as a template. Drill holes and secure using the appropriate anchor bolts.
2 Installation 14
2.2 Installing the Unit (Continued)
If the brackets are not needed, remove the cover and the front panel as described in Sec-
5
tion 5.4, Step 1, “Remove the Front Panel and the Cover .”
DANGER:
1) There are dangerous voltages inside the unit when the cover is removed.
2) When removing or attaching the cover , do not let it touch the battery terminals, battery
wires or other internal components.
Remove the seismic brackets by unbolting the four
6
bolts attaching them to the unit.
Reattach the cover and the front panel.
7
T o stop the unit from moving, screw down the feet until they are solid against the floor .
8
Installation finished
2.2.2: CFR 3000RM
Tip: The unit is shipped so that it will fit in a 19 inch rack. To fit in a 23 inch rack, reverse the
position of the mounting brackets.
Procedure:
The unit is shipped attached to a pallet. Use a forklift to transport the unit and pallet to the
1
installation site.
Remove the packing from around the unit. Unbolt the unit from the pallet.
2
Move the unit to the rack.
3
Mount it in the rack. The mounting screws are not provided by Alpha. Use the screws speci-
4
fied for your rack.
Mount an Alpha external battery pack (Section 2.4).
5
Installation finished
15 2 Installation
2.3 Connecting the Unit
2.3.1: Plug and Connector
Danger: All wiring must meet the local electrical code. Mark all circuit breakers supply-
ing power to the unit. Connect a dedicated ground wire to the external ground lug if the
building ground is inadequate.
Procedure:
Switch off the utility circuit breaker supplying power to the unit.
1
Plug the unit’s AC line cord into the receptacle.
2
If used, plug in an external battery pack (Section 2.4).
3
TIP: The rackmount unit has no internal batteries. It uses an external battery pack.
Switch on the utility circuit breaker supplying power to the unit. St art and test the unit with no
4
loads connected (Section 3.3).
• If it passes go to the next step.
• If it doesn’t do troubleshooting (Sections 3.4, 5.2).
Turn of f the unit (Section 3.2).
5
Connect the loads. The loads must be turned off before connection.
6
Connection Finished
6
6
3
2
Figure 2.1
Connecting the Unit (Plug and Connector)
3
2
2 Installation 16
2.3 Connecting the Unit (Continued)
2.3.2: Terminal Block
Danger: All wiring must meet the local electrical code. Mark all circuit breakers supply-
ing power to the unit. Connect a dedicated ground wire to the external ground lug if the
building ground is inadequate.
Procedure:
Switch off the utility circuit breaker supplying power to the unit.
1
Connect the line to the terminal block as given in Figure 2.3.
2
• For 120 VAC units use 12 AWG (3.3 mm2).
• For 208/230/240 VAC units use 14 AWG (2.0 mm2).
• Torque to 35 Inch–Pounds (4.0 Nm).
• Switch on the utility circuit breaker supplying power to the unit. Make sure the unit has
been wired correctly by measuring the voltages at the terminal block. Switch off the circuit
breaker.
If used, plug in an external battery pack (Section 2.4).
3
TIP: The rackmount unit has no internal batteries. It uses an external battery pack.
Switch on the utility circuit breaker supplying power to the unit. St art and test the unit with no
4
loads connected (Section 3.3).
• If it passes go to the next step.
• If it doesn’t do troubleshooting (Sections 3.4, 5.2).
Switch off the unit (Section 3.2).
5
Connect the loads to the terminal block as shown in Figure 2.4. See 2 for the recom-
6
mended wire gauges and torques.
Connection Finished
17 2 Installation
2.3 Connecting the Unit (Continued)
6
2
Connecting the Unit (T erminal Block)
3
Figure 2.2
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ycneuqerF
zH06zH06
zH06zH06
zH06
zH05zH05
zH05zH05
zH05
*egatloV*egatloV
*egatloV
021021
021021
021
LLLLLNNNNN
CAV
802802
802802
802
CAV
042042
042042
042
CAV
032032
032032
032
CAV
1L1L1L1L1L2L2L2L2L2L
LLLLLNNNNN
6
2
3
* Caution: Refer to the voltage and frequency ratings for the unit as shown on the nameplate.
Figure 2.3
Input T erminal Block Wiring
TIP: Over current protection for the AC output circuit must be provided when the unit is
installed.
ycneuqerFycneuqerF
ycneuqerFycneuqerF *egatloV*egatloV
ycneuqerF
zH06zH06
zH06zH06
zH06
zH05zH05
zH05zH05CAV032CAV032
zH05
* Caution: Refer to the voltage and frequency ratings for the unit as shown on the nameplate.
*egatloV*egatloV
*egatloV
802/021802/021
802/021802/021
802/021
CAV
042/021042/021
042/021042/021
042/021
CAV
CAV032CAV032
CAV032
1L1L1L1L1LNNNNN2L2L2L2L2L
toNtoN
toNtoN
toN
NNNNNLLLLL
desU
Figure 2.4
Output Terminal Block Wiring
2 Installation 18
2.4 Connecting the External Battery Pack
DANGER: There are hazardous voltages inside the battery packs. Use extreme cau-
tion. For more information on battery handling, see the safety instructions in the front of
this manual.
CAUTION:
1) Verify the p ack’s polarity and voltage at the connector before attaching the cable to
the unit.
2) When a pack or batteries have been in storage for more than 6 months, they should
be recharged for at least 24 hours and then thoroughly tested with a load before installation. If after charging, a battery’s voltage varies more than 0.3 VDC from the others, do
not use it.
Tools and Materials Required:
• DC voltmeter.
• Phillips screwdriver.
Procedure:
Verify the battery circuit breaker is switched of f. Keep it off until after the unit has been
1
started with line power .
Loosen the cover plate and slide it up to expose the connector (Figures 2.5, 2.6)
2
Verify the correct DC volt age and polarity at the battery pack’s connector . It should be
3
between 48 to 53 VDC.
TIP: Wrong voltages or polarities could damage the unit or the battery pack.
Connect the pack’s ground wire to the unit’s ground connection.
4
Connect the pack’s connector to the unit’s battery connector .
5
.
Battery Pack Connection Finished
19 2 Installation
2.4 Connecting the External Battery Pack (Continued)
2
4
Figure 2.5
Connecting an External Battery Pack to the 3000RM
5
4
Figure 2.6
Connecting an External Battery Pack to the 3000
2
5
2 Installation 20
2.5 Connecting the External Alarm Port
An external alarm panel can be connected to the external alarm port (Figure 2.7). The port’s
contacts are rated at 30 VDC at 1 Amp.
An Emergency Power Off (EPO) switch is created by wiring a switch to Pins 7 and 8. This feature must be ordered from the factory so the unit can be configured to operate with this switch.
• The switch must be a SPST, N.O. type and be electrically isolated (up to 1500 VAC
isolation is recommended). The connecting cable can be twisted or shielded wire not
more than 100 ft. long.
• The contacts must be shorted for at least 1.5 seconds with unit shutdown about 2 seconds
after the shorting starts.
CAUTION: The EPO switch does not disconnect the utility line. Switch off the circuit
breaker providing line power to the unit.
RJ-45
Connector
(8-Pin Type)
N.O. Low
Battery W arn in g
N.C.
Battery OK
EPO
Circuit
18
87654321
Optional
N.O. EPO Switch
Figure 2.7
Wiring the External Alarm Port
N.O. Line
Failure
N.C. Line
Present
UPS Internal
UPS External
Contact Rating:
30 VDC @ 1 Amp
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