AFP 10 Series UPS Manual_Eng
Contents
1. Figure 3 1 6 BATTERY CONNECTION The UPS back up battery bank may be a 48VDC external battery set VRLA or flooded battery type with a battery back up time of greater than 15 minutes or an internal 100AH A8VDC max battery bank VRLA battery type only installed on a battery tray located on the bottom floor of the UPS see figure 4 below For any battery banks used with the UPS please follow the battery manual provided by the battery manufacturer to insure proper installation and maintenance of the battery bank Figure 4 member of The eiiim Group 13 Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com Note The stand by battery maximum operating back up time 1600AH VRLA battery is 10 5 hours with a battery re charge time within 48 hours This figure is based on the AFP10 UPS with a full load of 7 Cordex rectifier modules Please refer to the battery manufacturer s manual for detailed battery specifications Please refer to the AFP10 UPS electrical drawing see Section 5 for battery connection to the UPS Note Only a qualified battery installer should be used for installation of the battery bank and should use only correctly sized battery connecting cables as defined by the load current requested for the AFP 10 UPS unit To obtain the battery life indicated by the battery manufacturer the operating temperature must remain between 0 and 25 C However although2. in factory workmanship and materials such warranty being conditional upon the product having been installed commissioned operated and maintained by qualified personnel and according to manufacturer instructions A I P liability is limited to repairing or replacing without charge at its factory any product or component which is proven to the satisfaction of A I P to have been defective at the time it was sold which at user s expense has been returned to or authorized service center within 1 year from date of commissioning or 18 months from date of shipment whichever occurs first A I P repair or replacement of any defective product shall constitute fulfillment of his obligations This Warranty applies to the manufactured products which are shown by the purchaser to have been originally defective and shall not apply to products which must be repaired or replaced due to normal wear misuse negligence wreckage accident any ACT OF GOD or to products which have been repaired or altered outside of seller s factory or one of its authorized service centers unless authorized solely by A I P Alpha Industrial Power shall not be liable for loss damage or expense consequential or otherwise from the use of its products or from any other cause THIS WARRANTY SUPERSEDES AND IS GIVEN IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED OR CONDITIONS WHETHER STATUTORY OR OTHERWISE AS TO QUALITY AND FITNESS FOR ANY PURPOSE FOR WHICH THE PRODUCTS ARE SUPPL
3. model and serial number as well as a brief description of the problem prior to issuing the RMA number An RMA number may also be requested at www alpha com RMA All material must be pre authorized before being returned Product received without an RMA number will be refused repairs will not be processed and credit will not be issued Moving and Storage Units must be suitably packed in the original shipping container or equivalent prior to re shipping The box should be completely enclosed and constructed of wood or double wall corrugated cardboard At least 3 of foam or shock absorbing packing material must surround the unit Factory Service Centers USA Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 USA Toll Free 800 996 6104 Phone 678 475 3995 Fax 678 584 9259 Email alpha alpha com Alpha Technologies Services 10393 Brockwood Road Dallas TX 75238 USA Toll Free 877 623 5227 Phone 214 217 6300 Fax 214 217 6313 Alpha Technologies Services 3767 Alpha Way Bellingham WA 98225 USA Phone 360 756 4904 Fax 360 647 0498 Alpha Technologies Services 2329 W Mescal St 306 Phoenix AZ 85029 USA Phone 602 710 1382 Alpha Technologies Services 5055 Central Hwy Pennsauken NJ 08109 USA Toll Free 800 681 8324 Phone 856 317 9410 Fax 856 317 9411 CANADA Alpha Technologies Ltd 4084 McConnell Court Burnaby BC V5A 3N7 Canada EUROPE Alpha Technologies Ltd Europ
4. panel E POWER CONDITIONING MODE Should the batteries be removed from the UPS the UPS continues to function and provides protection against spikes common normal mode noise load steps and frequency shifts without battery back up capability 3 0 SYSTEM SPECIFICATIONS A UPS Input 1 Input Voltage 120VAC Supervised 2 Input Voltage Requirement 1 Phase 2 Wire Ground 3 Input Current 12AMax 90 135VAC per each rectifier module 20 8A 120VAC Nominal per each inverter module 4 Rated Frequency 50 60 Hz 5 Nominal Battery Voltage 48VDC 6 Maximum Charge Current 220A 7 Maximum Battery Capacity 1600Ah Supervised Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com B UPS Output 1 Rated Voltage 120VAC 2 Output Voltage Requirements 1 Phase 2 Wire Ground 3 Output Capacity 5 7 5 10 kVA 4 Rated Load Power Factor 0 75 lagging 5 Frequency 50 60Hz 6 Programmable Relays 60VDC 1A Resistive Supplemental use C Environmental 1 Operating Temperature UPS 32 to 120 F 0 to 49 C Battery 68 to 77 F 20 to 25 2 Storage Temperature UPS 4 to 1 40 F 20 to 60 C Battery prolonged storage above 104 40 causes rapid battery degradation 3 Relative Humidity 90 non condensing IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS 1 Please read this manual prior to use to become familiar with the product s numerous fe
5. stored in a temperature controlled dry and dust free sheltered room 1 3 HANDLING AND LOCATING OF THE AFP 10 UPS For handling of the UPS prior to installation it is recommended that the UPS remain attached to its shipping pallet to reduce risk of over turning Immediately prior to the UPS installation the UPS should be removed from the shipping pallet The UPS should then be placed into the final installation position by use of a forklift The UPS must be installed in a clean dust free dry room If the UPS includes an internal VRLA battery bank the room must be properly ventilated in order to reduce heat and provide for optimum system performance It is strongly recommended that the UPS be installed in a temperature controlled room in order to maximize the life of the battery bank 1 4 AC INPUT OUTPUT CONNECTION The electrical connections are a part of the installation that must be provided by a qualified trained UPS installer and must meet all standards per local electrical code The manufacturer of the AFP 10 UPS is not responsible for the electrical connection The following information is provided to serve only as a guideline for the qualified installer However the AFP 10 UPS manufacturer recommends that the installer use correct cable sizes and circuit breakers as shown below membe Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com There are 4 x 32A Circuit Breakers CB1 to CB4 us
6. AND SHALL NOT BE COPIED OR USED FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT ossen 2 01 10 customer PROVECT DRAN 2 01 10 CHECKED D Q 12 01 10 APPROVED Customer TOLERANCES UNLESS OTHERWISE NOTED CUSTOMER PO 8 Iu 222 ZO a Uem UU UU CAN OUT LAdNI 2VAOcCI T a SCALE N A E TITLE AFP10 050 211 pce RC E DATE 12 01 10 DWG NO AFP10 050 2 1 DWG lig ee 60 Enclosure fan REMSIONS DESCRIPTION DATE APPD e 6 LTR DESCRIPTION FINISHED HOLE LEGEND iN ALPHA INDUSTRIAL POWER NS SS Sy THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF 5 AIP AND SHALL NOT BE COPIED OR USED aS WA aS Sy FOR MANUFACTURING WITHOUT ITS WRITTEN CONSENT P oS aS DESIGN Lan D 5 11 09 CUSTOMER PROJECT SNQ EEEN CNN EE INQ APPROVED ustomer GUSTOWER POF P TOLERANCES UNLESS OTHERWISE NOTED TITLE ISSUE 05 13 09 DWG NO PF 48 5000 120 PN4 CAB This page intentionally left blank Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com ELECTRONIC ELECTRICAL PRODUCT WARRANTY Alpha Industrial Power A I P warrants to the original user that its rectifying equipment load banks DC DC converters chargers and UPS systems are free from defects
7. Alpha Industrial Power member of The alpha Group Indoor Fire Protection UPS System AFP 10 Series AIP900 0012 BO0 001 Rev F 2 2011 Alpha Industrial Power member of the Alpha Group Visit www alpha com Suwanee GA USA Telephone 1 800 996 6104 Fax 678 584 9259 Alpha Technologies reserves the right to make changes to the products and information contained in this document without notice Copyright 201 Alpha Technologies Inc All Rights Reserved Alpha Industrial Power Indoor Fire Protection UPS System AFP 10 Series Rev F 2 2011 Table of Contents 1 Introduction Page 4 8 2 Safety Instructions Page 9 3 Installation Instructions Pages 10 14 4 Component Manual Reference Information Page 15 5 UPS system drawings Pages 16 18 6 Alpha Industrial Power Product Warranty Page 20 d Alpha Industrial Power Factory Service Information Page 21 Alpha Industrial Power member of the Alpha Group Visit www alpha com Suwanee GA USA Telephone 1 800 996 6104 Fax 678 584 9259 Alpha Technologies reserves the right to make changes to the products and information contained in this document without notice Copyright 201 Alpha Technologies Inc All Rights Reserved Alpha Industrial Power Inc ui 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com TECHNICAL MANUAL UPS 1 0 SCOPE 1 1 System This manual describes a continuous duty single phase on line solid state uninterruptible power supply system her
8. IED No person agent or dealer is authorized to give any warranty on behalf of manufacturer or to assume for seller any other liability in connection with any of its products unless made in writing and signed by an officer of Alpha Industrial Power Inc ALPHA INDUSTRIAL POWER INC 1075 Satellite Blvd Suite 400 Suwanee GA 30024 or to their local authorized representative FACTORY SERVICE INFORMATION Technical Support Technical support staff are available for answering general questions related to installation operation and maintenance of Alpha products In the USA call Alpha toll free 8 00 am to 5 00 pm Eastern Standard Time at 1 800 996 6104 For emergencies call 1 800 996 6104 24 hours a day seven days a week Training Alpha Industrial Power offers various levels of product and technical training These workshops provide a mix of theory and hands on application for qualified customers Please consult your sales representative for course schedules locations and costs or visit our website at www alpha com Factory Repair and Servicing All service beyond initial adjustments should be carried out by qualified factory service personnel For these procedures please contact Alpha Industrial Power at the locations listed to the right Product Returns Before returning any product for service please obtain a Return Material Authorization RMA number from an Alpha factory service representative The representative will require the
9. alpha com Suwanee GA USA Telephone 1 800 996 6104 Fax 678 584 9259 Alpha Technologies reserves the right to make changes to the products and information contained in this document without notice Copyright 201 Alpha Technologies Inc All Rights Reserved EE UR DESCRIPTION DATE APPD N E 1 all AC cables are AWG 2 cables except indicated ios 2 all DC cables are AWG 6 cables except indicated 5 i Neg 3 3 DB 25 wires AWG 22 20 4 Customer is to connect battery to the UPS with suitable E E BATTERY CABINET vi T TRAY 9 1 Wire SIZES AS per lines o Jd Wr A ing m nm a mm 5 1 4121212121515151212121 gt COOCOCOUOCCA MI M NOLLO3NNOO amp JWOLSO Q 8181 eia E LEGEND bar 2 2 Rec Shelf 1 3 2 _ e zS za BS zal s 3 Shelff2 S E FP 070 4 4 Inverter U 0 7 E C E 120VAC OUTPUT lelf side 5 5 O Panel CB7 yd 100A 6 6 Manual Bypass Sw 2 7 IN OUT Terminal LTR DESCRIPTION FINISHED HOLE LEGEND ALPHA INDUSTRIAL POWER THESE DESIGNS AND SPECIFICATIONS ARE THE PROPERTY OF AIP
10. atures and operating procedures To obtain a maximum degree of safety follow the sequences as outlined 2 his manual provides warnings and special notes for the user a Points that are vital to the proper operation of the product or the safety of the operator are indicated by the heading WARNING or SECURITY amp SAFETY SECURITY amp SAFETY The symbols listed above also alert the user to warnings b A notation that is in Bold or Italic typeface covers points that are important to the performance or ease of use of the product 3 Before using the product read all instructions and cautionary markings on the product and any equipment connected to the product 4 Only qualified personnel should install operate and service the product and its components 5 Observe all applicable national and local electrical codes when installing the product 6 Always assume electrical connections or conductors are live 7 Do not expose the product to rain or snow install only a clean dry environment 8 CAUTION Unless otherwise noted use of an attachment not recommended or sold by the product manufacturer may result in a risk of fire electric shock or injury to persons 9 CAUTION Do not operate the product if it has received a sharp blow it has been dropped or otherwise damaged in any way return it to a qualified service center for repair 10 CAUTION Do not disassemble the product call our qualified service c
11. e Twyford House Thorley Bishop s Stortford Hertfordshire CM22 7PA United Kingdom ASIA Alpha Technologies Unit 504 5 F Fourseas Building No 208 212 Nathan Road Kowloon Hong Kong
12. eafter referred to as the AFP 10 series modular UPS 2 0 SYSTEM DESCRIPTION 2 1 Applicable Standards The AFP UPS is compliant with the current revisions of the following standards e ANSI C62 41 IEEE 587 Guide on Surge Voltages in AC Power Circuits up to 600V UL 1481 Standard for Safety Power Supplies for Fire Protective Signaling Systems e National Electrical Code NFPA 70 NEMA PE 1 2003 Uninterruptible Power Systems UPS Specification and Performance Verification e OSHA 2 2 Components The AFP 10 UPS consists of the following components A Cordex switched mode charger rectifier B Cordex System Controller CXC Software Version 2 0 C Pulse Width Modulated PWM modular Inverter with built in modular static switch D Manual Make Before Break MBB bypass switch E Input Circuit Breaker amp Output Breaker Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com 2 3 AFP 10 Series UPS Model Number Explanation AFP10 XXX X 1 Series System Input Output Voltage 1 120 Indoor Power Rating 050 5kVA 075 7 5kVA 100 10kVA Quantity of Rectifiers 1 7 Example AFP 10 Series Modular UPS 5 KVA Power Rating Quantity of Rectifier Modules 5 Indoor 120VAC System Input Output Voltage AFP10 050 5 1 Series Input Output Voltage 12120VAC Indoor Power Rating 050 5kVA 075 7 5kVA 100 10kVA Quantity of Rectifier
13. ed for AC inputs to all rectifiers installed on two rectifier shelves CB5 is the main AC input and is the AC output of the unit NUMBER OF RECTIFIERS ON me nce AC EEn HO set nn ae an a e 1 98 ea mo _ 2 0 Na B NA NA N A na wa cm The Input and Output terminals are located at the right side of the AFP 10 UPS and can easily be accessed from the front of the UPS see figure 1 below All GND wires must be properly connected to GND TBs with the same gauge sizes of AC L amp N wires 120VAC OUTPUT TBs 120VAC BYPASS INPUT TBs 120VAC MAIN INPUT TBs 4 x rectifier AC input TBs Figure 1 ror ine nr GOroup Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com Please refer to the AFP 10 UPS electrical drawing see Section 5 UPS System Drawings for inputs and output connection For alarm relay contacts for remote monitoring access the alarm contact terminals by removing the communication terminal cover see figure 2 below Figure 2 NOTE All intermediate communication devices router SCADA etc required for remote monitoring communications must be located within the same room in which the AFP 10 UPS unit is installed All alarm free voltage relay contacts are programmable via the Cordex controller software Please ref
14. enters for servicing Incorrect reassembling may result in a risk of electrical shock or fire 11 CAUTION The TSI inverter rack is not supplied with internal disconnect devices and is dual input power supply system For proper installation system access and safety instructions including proper grounding please refer to Chapter 3 of the TSI Inverter Installation manual Alpha Industrial Power Inc x 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com INSTALLATION 1 1 RECEIVING THE AFP 10 UPS When the UPS is received please attend immediately to its unpacking carefully removing all shipping material and packaging Carry out an accurate visual inspection to ensure that the equipment has not been damaged during transport Make sure to save all packaging and shipping materials until it has been determined that no shipping damage has occurred IMPORTANT If any damage is discovered upon delivery of the UPS make sure to notate damages on all copies of the delivering carrier s delivery receipt prior to signature If damage is discovered after the delivery immediately notify the delivering carrier and request an inspection The manufacturer assumes no liability for damages during transportation and handling 1 2 STORING THE AFP 10 UPS Should the UPS need to be stored prior to installation it should be stored in its original shipping packaging in an upright position as indicated on the packaging The UPS should only be
15. er to the Cordex controller software section see Section 3B and alarm contact identifications as illustrated in the drawing below e VES LO DB15 PIN OUT FRONT VIEW DB9 PIN OUT 1 K6 NO H 2 NC 2 K1 NO 3 K5 COM 3 K1 NC K4 NO D6 K4 5 D5 6 K3 COM H K2 7 K1 COM 8 K2 NC 8 D6 9 K6 COM 9 D5 10 K5 NO 11 K5 NC 12 K4 COM 13 K3 NO DB25 PIN OUT 14 K3 NC 18 K2 COM eat 3 GP1 16 GP1 4 GP2 17 GP2 5 18 P3 JUMPER SETTINGS FOR LVD CONTROL INHIBIT FUNCTION 6 GPa 1e SHORT PINS 1 AND 2 IF LVD IS CONTROLLED ON 8 T1 21 T1 K1 NC CONTACTS TO MAINTAIN OPERATION SEDE SIGNAL WIRES 9 D1 22 D1 SHORT PINS2 AND 3 IF LVD IS CONTROLLED ON i K1 NO CONTACTS TO MAINTAIN OPERATION TOP VIEW WITH COVER REMOVED 15 PIN CABLE P N 877 498 10 REMOVE SCREW nm SLIDE COVER OFF 25 PIN CABLE EE ISOMETRIC VIEWS P N 877 499 10 CUST CONN CTRLR I O TERM 9 PIN CABLE BLOCK 1 8kW SHELF CXCM2 P N 877 497 10 pres neer 1 1 US 036 200 08 member of The 11151 Group 12 Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com 1 5 CHARGING CURRENT amp BATTERY VOLTAGE MEASUREMENT TERMINALS There are charging current and battery voltage measurement terminals located between CB5 amp CB7 of the unit see figure 3 below
16. rives power from the battery bank and continues to feed the load with clean regulated AC power There is no interruption to the critical load upon failure or restoration of commercial power Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com C RECHARGE Upon restoration of the commercial AC source the switched mode rectifier charger powers the inverter while simultaneously recharging the battery bank The AFP 10 UPS has the following recharge process a a constant level of current is used to recharge the batteries the process utilizes a current limit function to prevent overcharging batteries thus extending the life of the batteries b as the batteries reach the normal charge level a constant voltage control begins which causes the battery recharge current to gradually decrease c under normal operation the UPS battery bank floats at the 2 25 2 27 volts per cell DC level to stay fully charged and ready for the next discharge D BYPASS MODE Upon detection of an internal inverter fault the UPS automatically switches from inverter power to an AC input source via the built in static switch Transfer occurs within 1 millisecond causing no interruption to the critical load Return from the bypass mode is an automatic function without interruption to the critical load Transfer to Bypass may also be performed as a manual operation via the UPS manual bypass switch located in the front
17. s 1 7 UPS Input AFP10 050 Xl1 AFP10 075 Xl1 AFP10 100 XI1 120 VAC 1 Phase 50 60 Hz 12A max per rectifier module 20 8 max per inverter module Supervised UPS Output AFP10 050 XI1 120 VAC regulated 1 Phase 50 60 Hz 5 kVA 0 75pf AFP10 075 XI1 120 VAC regulated 1 Phase 50 60 Hz 7 5 kVA 0 75pf AFP10 100 XI1 120 VAC regulated 1 Phase 50 60 Hz 10 kVA 0 75pf Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com 2 System Operation The AFP 10 UPS operates as an on line double conversion fully automatic system in the following modes please note the AFP 10 UPS system s block diagram below BOOST 1 K N N y Not S ANS 400VDC Bus o L s 120VAC 1 phase Pe 120VAC 1 phase 60HZ input EMI 60HZ 120 2 5KA INVERTER V y LS 120 320VAC 1Phase 60HZ input Ng A NORMAL Incoming power is boosted using a switching circuit and converted into DC power to power the inverter module The inverter then converts DC power to regulated AC power which feeds the load Additionally the AC input source provides power to the Cordex rectifier to either charge a battery bank or to operate at float charging mode to maintain a battery bank B EMERGENCY Upon failure of commercial AC power the UPS de
18. the battery can operate in temperatures up to 40 C a significant reduction of the battery life will occur Further to avoid the formation of potentially explosive gasses suitable ventilation must be provided at the location of the battery per NFPA 70 PE requirements Warning CORRECT BATTERY POLARITY CONNECTIONS MUST BE FOLLOWED TO AVOID SERIOUS DAMAGE TO THE AFP 10 UPS UNIT Note Limited to same room battery bank installations Non power limited wiring required Battery connection must be in an area of limited access Must be approved by AHJ Alpha Industrial Power Inc 1075 Satellite Blvd Suite 400 Suwanee GA 30024 www alpha com Component Manual Reference Information For detailed information specifications features configuration etc concerning the Cordex 48VDC Modular Switched Mode Rectifier system please refer to Manual 030 809 B2 Rev B CXRF 48 1 8kW 2008 For detailed information concerning the Cordex Controller Software Version 2 0 please refer to Manual 034 136 B2 Rev B Cordex Controller Software Version 2 0 2009 For detailed information specifications features configuration etc concerning the Bravo TSI 120VAC Inverter System please refer to Manual TSI BRAVO 120VAC User Manual V3 3 3 2 2009 Alpha Industrial Power j 71 m num member of he all dip Group Fire Protection UPS System Technical Drawings Alpha Industrial Power member of the Alpha Group Visit www
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