Alpha CFR 5000, CFR 5000RM User Manual
CFR
5000 & 5000RM
Uninterruptible Power Supplies
From Alpha Technologies
!!
! Operator’s Manual
!!
!!
!
!!
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!
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Operator’s Manual
CFR 5000 & CFR 5000RM
Uninterruptible Power Supplies
Alpha Technologies
CFR 5000 & CFR 5000RM
Save This Manual
It contains important installation and operating instructions.
Keep it in a safe place.
CAUTION
Risk Of Electrical Shock
To reduce the risk of electrical shock and to ensure the safe operation of the CFR 5000 and
CFR 5000RM, 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 5000 and CFR 5000RM 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 5000 and CFR 5000RM.
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 5000 and CFR 5000RM.
CFR 5000 and CFR 5000RM Safety Checklist
CFR 5000 & CFR 5000RM
Carefully unpack the unit. Report any shipping damage at once.
Read this manual. If you have any questions about the safe installation, operation or maintenance of this 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 utility panel to tell emergency personnel an Uninterruptible
Power Supply (UPS) is in the building.
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 pack. This greatly reduces the chance of a spark.
ii
CFR 5000 & CFR 5000RM
Safety Checklists (Continued)
There are dangerous voltages inside the unit. Only qualified personnel should perform
installation and maintenance.
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.
Never open the batteries. The contents are toxic.
iii
CFR 5000 & CFR 5000RM
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 5000 and CFR 5000RM .... 5
2. Installation .......................................... 10
2.1 Pre–Installation Checklist ....................... 11
2.2 Installing the Unit ................................... 13
2.3 Connecting the Unit ................................ 16
2.4 Connecting the External Battery Pack ... 19
2.5 Connecting the External Alarm Port ....... 21
2.6 Connecting the RS–232 Port .................. 22
2.7 Connecting the LAN Port ........................ 23
2.8 Transformer Output Load Sharing ........... 24
3. Operation ............................................ 27
3.1 Turning On the Unit ................................ 28
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 (SID) ............................. 32
4. Communication .................... 35
4.1 Setting Up RS–232 Communications ..... 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 Backup 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 ................................. 73
5.7 Specifications......................................... 74
Index ............................................ 75
Warranty ...................................... 80
iv
1
Section 1
Introduction
This section introduces you to the CFR
5000 and CFR 5000RM UPS’s:
• The CFR series many advantages (Section 1.1).
• An unpacking and inspection checklist
(Section 1.2).
• An tour of the units, their 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.
!
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 non-degradable spike and surge protection.
!
Extended Backup Capability
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 UL, CSA or VDE safety standards. This commitment to safety makes Alpha Technologies a leader in the power industry.
Alpha Technologies
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 need 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 greater than 381
lbs (173 kg). A safe means of transportation to the site, lifting the cabinet
into position and proper floor support must be devised.
Alpha Technologies
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 __________________________________
Telephone # _______________________________
Fax # ____________________________________
E Mail ___________________________________
For technical support contact Alpha Technologies 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
Alpha Technologies
5 1 Introduction
1.3 The Alpha CFR 5000 and CFR 5000RM
TIP: Unless otherwise shown in this manual, the CFR 5000 and CFR 5000RM are
identical and work the same way.
The major difference is the CFR 5000RM does not have internal batteries. An Alpha
External Battery Pack (EBP) must be connected (Section 2.4).
1.3.1 Front Panel
CFR 5000 Tower Mount
Display Panel
This is either the Standard Interface Display (SID) (Section 3.5) or the optional
Intelligent Interface Device (IID) (Alpha
manual #018–029–B0–001).
Cover
The cover can be removed to allow access
to the unit’s interior in order to perform
maintenance, reconfigure the input and
output voltage, 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).
Alpha Technologies
1 Introduction
6
1.3 The Alpha CFR 5000 and CFR 5000RM (Continued)
Feet
1.2 The Alpha CFR 5000 and 5000RM (Continued)
If you don’t secure the unit with the seismic
brackets, you can stop the unit from moving
by screwing these down.
CFR 5000 Rack Mount (RM)
Display Panel
This is either the Standard Interface Display (SID) (Section 3.5) or the optional
Intelligent Interface Device (IID) (Alpha manual #018–029–B0–001).
ALARM
OFF
MANUAL
START
LINE P RESEN T
LINE FAILURE
SERVICE
LOW BATTERY
WARNIN G
LOW BATTERY
SHUTD OWN
TEST
OUTPUT LOAD
OVERL OAD
100%
75%
50%
25%
Mounting
Brackets
These brackets
allow rack mounting. They are
factory configured to fit in a 19
inch rack. To fit in
a 23 inch rack,
remove and then
reverse them.
Alpha Technologies
Fans
These four fans cool the unit. They must not be blocked.
7 1 Introduction
1.3 The Alpha CFR 5000 and CFR 5000RM (Continued)
1.3.2 Rear Panel
CFR 5000
CFR 5000RM
Figure 1.1
Rear Panels
Fans
These fans cool the unit. They must not be
blocked.
Output Connector
These plates are the unit’s output power connector. It is factory configured to your specifications. See Section 2.3 for wiring information.
Output Circuit Breaker
This resettable breaker provides additional
protection to the loads.
Alpha Technologies
1 Introduction
8
1.3 The Alpha CFR 5000 and CFR 5000RM (Continued)
Input Line Cord or Terminal Block
This is the unit’s line connector. It can either be
a standard, grounded line cord or be factory
configured to your specifications.
Input Circuit Breaker
This provides protection for the unit. It can be
used as an input power on/off switch.
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
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 turned off whenever
the unit is turned off for more than a
few hours or is being serviced. The
battery can be drained if this breaker
is left on.
External Battery Connector
It accepts a Blue Fast Disconnect plug from
either Alpha's EBP series battery pack or a
custom battery source (Section 2.4).
Alpha Technologies
9 1 Introduction
1.3 The Alpha CFR 5000 and CFR 5000RM (Continued)
RS–232 Connector
This DB–9 port provides RS–232 communication (Section 2.6).
LAN Interface Connector
This DB–9 port provides dry contact status
monitoring and output shutdown capability via
LAN communication (Section 2.7).
External IID
An external IID plugs into this connector for
remote control and monitoring.
External Alarm Connector
This RJ–45 connector allows the connection of
an external alarm panel or an emergency
shutdown switch (Section 2.5).
Phone
This connector is not used in the CFR 5000.
Alpha Technologies
10
Section 2
Installation
This section shows you how to install
and connect the CFR 5000 and CFR
5000RM 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 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 communica-
tions port (Section 2.6).
• How to connect the LAN port (Section 2.7).
• How to prevent the UPS from being over-
loaded (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.”
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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.
Alpha Technologies
13 2 Installation
2.2 Installing the Unit
2.2.1: CFR 5000
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 381 lbs./173kg).
• Screwdriver or power screwdriver with a Philips bit.
5
•
/8 inch socket wrench.
Procedure:
The unit is shipped attached to a pallet. Use a forklift or pallet jack to transport the unit and
1
pallet to the installation site.
5
).
Remove the packing from around the unit. Unbolt the unit from the pallet.
2
CFR 5000
attached to
pallet with 5/8
inch bolts.
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, mark the position on the floor where the unit will be se-
4
cured by using the bracket as a template. Drill holes and secure using the appropriate
anchor bolts.
Alpha Technologies
2 Installation 14
2.2 Installing the Unit (Continued)
If the brackets are not used, remove the cover and the front panel as described in Section
5
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 bracket by unscrewing the 3 phillips
6
screws attaching the bracket to the chassis.
Reattach the cover and the front panel.
7
To stop the unit from moving, screw down the feet until they are solid against the floor.
8
Installation finished
Alpha Technologies
15 2 Installation
2.2 Installing the Unit (Continued)
2.2.2: CFR 5000RM
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.
Tools and Materials Required:
• Fork lift or other means of transporting heavy objects (up to 225 lbs./102 kg).
• Screwdriver or power screwdriver with a Philips bit.
Procedure:
The unit is shipped attached to a pallet. Use a forklift to transport the unit and pallet to the
1
installation site.
Unscrew the box attached to 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
Alpha Technologies
2 Installation 16
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 (Figure 2.1).
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. Start 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 off the unit (Section 3.2).
5
Connect the loads. The loads must be turned off before connection.
6
Connection Finished
6
Alpha Technologies
3
2
Figure 2.1
Connecting the Unit (Plug and Connector)
17 2 Installation
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 Figures 2.2 and 2.3.
2
• For 120 VAC units use 8 AWG (8.4 mm2) and torque to 25 Inch–Pounds (2.8 Nm).
• For 208/230/240 VAC units use 10 AWG (5.3 mm2) and torque to 20 Inch–Pounds
(2.3 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. Start 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
Alpha Technologies
2 Installation 18
2.3 Connecting the Unit (Continued)
6
2
3
Figure 2.2
Connecting the Unit (Terminal Block)
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zH06zH06
zH06zH06
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zH05zH05
zH05zH05
zH05
* Caution: Refer to the voltage and frequency ratings for the unit as shown on the nameplate.
*egatloV*egatloV
*egatloV
021021
021021
021
LLLLLNNNNN
CAV
802802
802802
802
CAV
042042
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042
CAV
032032
032032
032
CAV
1L1L1L1L1L2L2L2L2L2L
LLLLLNNNNN
Figure 2.3
Input Terminal Block Wiring
TIP: Over current protection for the AC output circuit must be provided when the unit is
installed.
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ycneuqerFycneuqerF *egatloV*egatloV
ycneuqerF
zH06zH06
zH06zH06
zH06
*egatloV*egatloV
*egatloV
802/021802/021
802/021802/021
802/021
CAV
042/021042/021
042/021042/021
042/021
CAV
1L1L1L1L1LNNNNN2L2L2L2L2L
Alpha Technologies
toNtoN
toNtoN
zH05zH05
zH05zH05CAV032CAV032
zH05
* Caution: Refer to the voltage and frequency ratings for the unit as shown on the nameplate.
CAV032CAV032
CAV032
toN
desU
NNNNNLLLLL
Figure 2.4
Output Terminal Block Wiring
19 2 Installation
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 pack’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 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 off. Keep it off until after the unit has been
1
started with line power.
For the CFR 5000, loosen the cover plate and slide it up to expose the connector (Figure
2
.
2.6)
Verify the correct DC voltage 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 (Figures 2.5 and 2.6).
4
Connect the pack’s connector to the unit’s battery connector (Figures 2.5 and 2.6).
5
Battery Pack Connection Finished
Alpha Technologies
2 Installation 20
2.4 Connecting the External Battery Pack (Continued)
4
5
Figure 2.5
Connecting an External Battery Pack to the 5000RM
4
2
Alpha Technologies
5
Figure 2.6
Connecting an External Battery Pack to the 5000
21 2 Installation
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.
• 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 Warning
N.C.
Battery OK
1
8
EPO
Circuit
N.O. Line
Failure
N.C. Line
Present
UPS Internal
87654321
UPS External
Contact Rating:
Optional
N.O. EPO Switch
30 VDC @ 1 Amp
Figure 2.7
Wiring the External Alarm Port
Alpha Technologies
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