Electric Fail-Safe Device
Installation, Operation &
Maintenance Manual
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TCAYWOOD@INDELAC.COM
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Electric Fail-Safe Device Installation, Operation & Maintenance Manual
INTRODUCTION:
Thank you for selecting Indelac Controls, Inc. (ICI) for your valve or damper automation requirement. We at ICI
are proud of our products and feel confident they will meet or exceed your expectations of quality and reliability.
Every precaution has been taken to insure that your equipment will arrive undamaged; however, accidents do
occur. Therefore, the first thing you must do upon receipt of your package is to inspect it for damage. If the box
is damaged there is a possibility that the equipment inside the box may be damaged as well. If this is the case
YOU MUST FILE A CLAIM with the delivering CARRIER. All shipments are F.O.B. our factory and it is YOUR
RESPONSIBILITY to file a claim for damages.
NOTE: ICI’S ELECTRIC FAILSAFE DEVICE CAN BE USED WITH OTHER BRANDS OF ELECTRIC ACTUATORS ACTUATOR TERMINAL CONNECTIONS WILL NOT BE THE SAME.
STORAGE:
If the actuators are scheduled for installation at a later date:
1.
Store off the floor protect with unsealed cover allowing for side and bottom ventilation. In the
event that the unit is going to be stored where there is insufficient temperature control internal
heaters must be installed and energized to protect the unit from condensation and extreme
temperature variations.
2.
Store in a climate controlled building.
3.
Store in a clean and dry area.
FOR FUTURE REFERENCE RECORD:
1.
Fail-Safe model number
2.
Fail-Safe enclosure type NEMA 4 , NEMA 4X , NEMA 7
, NEMA 4 & 7
3.
Fail-Safe output Voltage
4.
Motor characteristics, Voltage
Hertz
Phase
5.
Fail-Safe serial number
6.
Date of installation
Put into operation
Page 2
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
INSTALLATION:
1. Check Label for Voltage, Current and correct Model Number.
2. Check supply voltage to be sure the model being used is correct for the application.
3. Mount Fail-Safe remote or local of the Actuator (for best result mount as close to the actuator as
possible). CAUTION: MUST BE INSTALLED BY A LICENSED ELECTRICIAN.
4. Disconnect main power before wiring to Fail-Safe using appropriate lock out procedures.
5. Loosen cover screws and open enclosure. Cover is hinged for your convenience.
6. To wire the Fail-Safe device see typical Wiring Diagram below. CAUTION: WIRING MUST
CONFORM TO ALL STATE AND LOCAL SPECIFICATIONS.
7. Be sure relay is secure in socket. Turn on the power switch to the inverter. CAUTION: OUTPUT
PINS WILL BE ENERGIZED WHEN INVERTER IS ON.
Close cover and secure cover screws.
8. Turn the front cover power switch “ON”.
NOTE: (2) CONDUIT OPENINGS HAVE BEEN SUPPLIED, (1) FOR SUPPLY POWER & (1) FOR
POWER TO ACTUATOR.
WIRE SIZE AND LENGTH:
Wire Gage Size
Fail-Safe
Actuator
Watts
Model
12
10
8
6
4
Approximate Distance in Feet From Fail-Safe
100
R
S, SD, MS & MR
SX & SDX
25
20
15
50
40
35
60
50
45
75
65
60
100
85
75
150
ML & MH
15
35
45
60
75
500
LA
LX & 5K
-
-
20
15
35
30
50
45
700
7K
-
-
10
25
40
1000
12K & 14K
-
-
10
25
40
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Electric Fail-Safe Device Installation, Operation & Maintenance Manual
WIRING DIAGRAM 3 & 5 AMP BATTERY BACKUP UNIT
The 3 & 5 AMP Fail-safe device is equipped with a Tripp-Lite PowerVerter. Output voltage regulation:
LINE POWER (AC): Maintains 120V nominal sine wave output from line power source.
INVERTER POWER (AC): Maintains PWM sine wave output voltage of 120 VAC (+/-5%).
The actuator in the below wiring diagram can be wired to fail close or fail open upon loss of supply power.
To wire the fail safe unit to the actuator, connect terminal #9 of the fail-safe device to the OPEN or
CLOSE input of the electric actuator.
When the incoming AC power fails, the inverter will automatically turn on and deliver 120 VAC to the
actuator through terminals #9 & #10. When the incoming power is restored, the fail safe will
automatically switch back to incoming AC power, turn off the inverter and re-charge the battery.
BLK
BLK
BLK
4
1
RED
SWITCH VIEW, REAR
RELAY 40A
SMOOTH
6
BATTERY
RED
INVERTER
120V OUTPUT
AC OUT
PLUG
RED
RED
4
3
RIDGE
+
5
RED
- +
BATTERY
CHARGER
+
-
2
1
RED
PLUG/CORD CUT
FROM CHARGER
BLK
Y
A
4
NO
B
3PDT,
120VAC
COIL
1
5
NC
NO
9
2
8
NO
6
3
WHT
BLK
LINE
GRN
LINE
POWER
FILTER
250V
BLK
BLK
1
WHT
HEATER
THERMOSTAT
WHT
WHT
POWER
INDICATOR
2
BLK
R
2
3
WHT
BLK
LOAD
WHT
WHT
BLK
4
G
WHT
GRN
1
FUSE
BLK
BLK
WHT
BLK
BATTERY
INDICATOR
NC
NC
7
OPTIONAL
BLK
CR1MP WIRE
NUTS (2)
WHT
BLK
BLK
RLY 1
POWER 3
SWITCH 5
4
6
7
CHERRY
#KDH3ALA2RBB
GRN
9
8
10
11
12
GROUND
SCREW
BLK
HOT NEU. GND
OPERATION:
NEU. HOT
FAIL
GND
120V OUT
120V IN
NOTES: THE NEMA 7 ENCLOSURE POWER SWITCH IS A SPST AND IS WIRIED
FROM TERMINALS 3 AND 5. A JUMPER IS ADDED FROM 4 TO 6.
THE FAIIL SAFE BOX HAS BEEN SHIPPED IN THE "DISABLED" MODE.
WIRING FOR 3.0A AND 5.0A ARE IDENTICAL. THE DIFFERENCE IS IN
THE BATTERY AHr SIZE AND INVERTER OUTPUT FOR EACH.
COMPLETE ALL WIRING CONNECTIONS PRIOR TO "ENABLING" THE FAIL SAFE BOX.
WIRE THE INCOMING POWER TO TERMINAL #'S 5, 6 & 7. WIRE THE OUTGOING POWER FROM TERMINAL #'S 9, 10, 11 & 12 TO THE ACTUATOR.
ENABLE THE FAIL SAFE BY TURNING THE INVERTER POWER SWITCH TO "ON". THIS IS FOUND ON THE SIDE OF THE INVERTER. CLOSE THE FAIL
SAFE BOX AND TURN THE FRONT MOUNTED AC POWER SWITCH TO "ON". VERIFY THAT THE RED & GREEN DOOR LAMPS ARE ILLUMINATED.
WHEN THE POWER SWITCH IS TURNED "OFF", ONLY THE YELLOW DOOR LAMP WILL BE ILLUMINATED.
A MODIFIED RELAY TERM #'S & REMOVED FAIL SWITCH
REV
DESCRIPTION
Page 4
POWER CORDS - RIDGE CONDUCTOR IS NEG (-) OR NEU.
SMOOTH CONDUCTOR IS POS (+) OR HOT.
FAIL SAFE UNIT, 120VAC SUPPLY,
120VAC OUTPUT - 3.0A & 5.0A, FAIL
MODE
31DEC13 WJR
DATE
BY
IC
I
Indelac Controls, Inc. WJR
19MAR13
W130319
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
WIRING DIAGRAM 7 & 10 AMP BATTERY BACKUP UNIT
The 7 & 10 AMP Fail-safe device is equipped with a Tripp-Lite PowerVerter. Output voltage regulation:
LINE POWER (AC): Maintains 120V nominal sine wave output from line power source.
INVERTER POWER (AC): Maintains PWM sine wave output voltage of 120 VAC (+/-5%).
The actuator in the below wiring diagram can be wired to fail close or fail open upon loss of supply power.
To wire the fail safe unit to the actuator, connect terminal #7 of the fail-safe device to the OPEN or
CLOSE input of the electric actuator.
When the incoming AC power fails, the inverter will automatically turn on and deliver 120 VAC to the
actuator through terminals #5 & #7. When the incoming power is restored, the fail safe will automatically
switch back to incoming AC power, turn off the inverter and re-charge the battery.
ELECTRIC FAIL-SAFE DEVICE
NOTES:
ACTUATORS SHOWN TO FAIL TO CLOSE POSITION.
AUTO/
REMOTE
CHARGE
ONLY
BACKUP POWER IS SQUARE SINE WAVE.
DC
OFF
RED 4 GAGE
USE PLUG CUT FROM
POWER INPUT CABLE
+
AC OUT
+
BATTERY
INVERTER
WHT
BLK 4 GAGE
-
BLK
-
AC IN
GRN
B
L
K
FUSE,
8.0A
OPERATION:
B
L
K
W
H
T
POWER SWITCH TO "ON" ILLUMINATES RED LAMP
TO INDICATE INCOMING POWER PRESENT.
GREEN LAMP WILL ILLUMINATE INDICATING
POWER OUTPUT PRESENT AND FUSE IS GOOD.
WHEN INPUT POWER FAILS, RED LAMP AND GREEN
LAMP WILL TURN OFF AND YELLOW LAMP WILL
TURN ON INDICATING BATTERY POWER AND FUSE
IS GOOD.
WHEN INCOMING POWER RESETS, BATTERY WILL
TURN OFF AND RED AND GREEN LAMPS WILL
ILLUMINATE.
GRN
BLK
FILTER
T
H
E
R
M
O
GRN
B
L
K
W
H
T
HEATER
GROUND
SCREWS
INVERTER 3 POSITION SWITCH ON REAR PANEL OF
INVERTER IS SET TO "DC OFF" FOR SHIPMENT.
AFTER ALL CONNECTIONS ARE MADE, MOVE THIS 3
POSITION SWITCH LEFT TO THE "AUTO/REMOTE"
POSITION TO OPERATE FAIL SAFE (SEE DETAIL).
ALL OTHER SWITCHES ARE PRESET AT THE
FACTORY. FOR FURTHER DESCRIPTION OF THESE
SETTINGS AND LED INDICATORS, SEE THE
OPERATORS MANUAL FOR THE INVERTER.
W
H
T
BLK
7
A
G
R
N
RELAY 1
POWER
SWITCH
1
G
R
N
NC
NO
4
NO
1
5
1
2
3
4
NO
NC
6
2
B
L
K
B
L
K
SWITCH VIEW, REAR
G
Y
WHT
GRN
B
L
K
2
NC
3
B
L
K
B
L
K
R
W
H
T
RELAY 1
B
L
K
W
H
T
9
8
B
2
1
3
3
4
4
5
6
7
8
9
10
11
12
FIELD WIRING
OPTIONAL
SPDT CONTROL
SWITCH SHOWN FOR
ILLUSTRATION ONLY
FIELD
WIRING
N
A
NO.
HOT GND
120VAC
SUPPLY
G
N
D
1
2
3
N
E
U
O
P
E
N
C
L
O
S
E
MODIFIED FOR NEW INVERTER AND RELAY
REVISION
I
C
I
WIRING DIAGRAM ,ELECTRIC
FAIL-SAFE , 7 AMP, 120VAC-1PH
SUPPLY POWER
ACTUATOR 1
Page 5
12-10-13 WJR
DATE
BY
Indelac Controls, Inc.
Florence, Ky. 41042
WJR
06NOV13
W080321
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
WIRING DIAGRAM 24 VDC, 10 AMP BATTERY BACKUP UNIT
The 24 VDC, 10 AMP Fail-safe device is equipped with a Power Inverter and 2 – 12 VDC Batteries.
Output voltage regulation:
- LINE POWER (DC): Maintains 24V from line power source.
- INVERTER POWER (DC): Maintains 24V from internal Battery Source.
The actuator in the below wiring diagram can be wired to fail close or fail open upon loss of supply power.
To wire the fail safe unit to the actuator, connect terminal #4 of the fail-safe device to the OPEN or
CLOSE input of the electric actuator.
When the incoming DC power fails, the inverter will automatically turn on and deliver 24 VDC to the
actuator through terminals #4 & #5. When the incoming power is restored, the fail safe will automatically
switch back to incoming DC power, turn off the inverter and re-charge the batteries.
RED 10 GAGE
"DC OK "
CONTACT
RED
INVERTER
RLH-UPS-24
G
-
-
+
BATT.
+
INPUT
+
BATTERY
12VDC
R
E
D
+
BATTERY
12VDC
BLK 10GAGE
RED
T
H
E
R
M
O
-
C
RELAY 1
HEATER
B
L
K
B
L
K
R
E
D
INVERTER POWER SWITCH ON FRONT
PANEL OF INVERTER IS TURNED OFF FOR
SHIPMENT. AFTER ALL CONNECTIONS
ARE MADE, UNIT NEEDS TO BE TURNED
ON (PRESS BUTTON) TO OPERATE FAIL
SAFE.
NC
R
E
D
R
E
L
A
Y
1
ON/OFF
SWITCH
NOTES:
ACTUATOR SHOWN TO FAIL TO CLOSE
POSITION.
NO
B
L
K
R
R
E
D
R
E
D
1
2
3
4
6
5
ELECTRIC
FAIL-SAFE
DEVICE
SPDT CONTROL SWITCH SHOWN
FOR ILLUSTRATION ONLY
24VDC
SUPPLY
FIELD WIRING
OPTIONAL
FIELD
WIRING
-
+
1
2
3
N
E
G
O
P
E
N
C
L
O
S
E
I
ACTUATOR
Page 6
C
I
Indelac Controls, Inc.
Florence, Ky. 41042
WIRING DIAGRAM FOR ELECTRIC
FAIL-SAFE DEVICE 10 AMP, 24VDC
SUPPLY POWER
30APR13
WJR
W130430C
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
WIRING DIAGRAM FAIL SAFE DEVICE CONNECTIONS TO
AN INDELAC MODULATING ACTUATOR
Other Actuators will differ in their connections.
Page 7
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
TEST OPERATION:
For your convenience the on/off switch is also a test switch which can be used to test the operation of
the failsafe device. With the supply power ON, the red & green light will be illuminated and the actuator
can be positioned as required to control system requirements. To check the fail-safe device flip the
power switch to the OFF position, the yellow light will illuminate and the actuator will begin to travel to
the designated fail position. By setting the power switch to the ON position the actuator will automatically
return to the position designated by the control switch. If the actuator fails to travel to the designated
position, check the green light for power output. Also, check that the actuator is wired correctly. If the
green light is off, the fuse is blown and will need to be replaced. Check system for the failure that caused
the fuse to blow. If actuator is wired correctly the battery may have low voltage, allow battery to charge
overnight and try again. In the future the operation can be tested as often as desired.
MAINTENANCE:
After proper installation, ICI’s electric fail-safe device requires no actual maintenance. However, we do
recommend a periodic battery check to assure that the battery is retaining a charge. This can be
accomplished by checking the battery % indicator on the charger. Normal battery life is four to five years
or between 299 to 1000 charge/discharge cycles depending upon the depth of discharge.
THE FOLLOWING CHART HAS BEEN PROVIDED FOR YOUR RECORD
KEEPING:
Date
Time By
OK
Date
Time By
OK
IMPORTANT:
Alarms and automatic shutdown are normal safety functions of the inverter supplied with this unit,
indicating either outlet overload or low battery voltage. If the alarm sounds or the inverter shuts down
and will not turn on:
•
Check the inverter connections
•
Reduce the wattage load (be sure the unit was sized correctly)
•
Turn on supply power so battery can recharge
•
Toggle inverter on/off switch on and off 3 to 4 time ending in the on (I) position.
Page 8
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
Page 9
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
- >>>
TROUBLE SHOOTING
<<< -
SYMPTOM
PROBLEM
SOLUTION
GREEN LIGHT DOES NOT ILLUMINATE.
POWER NOT ON.
RELAY NOT IN SOCKET.
BLOWN FUSE
TURN ON POWER.
INSTALL RELAY.
REPLACE FUSE
- 5X20MM, 4MA
250VOLT SLO-BLO
VALVE DOES NOT RESPOND TO
CONTROL SIGNAL.
POWER NOT ON.
W RONG VOLTAGE.
W IRED INCORRECTLY.
VALVE TORQUE EXCEEDS ACTUATOR TORQUE.
TURN ON POWER.
CONNECT CORRECT VOLTAGE.
CHECK WIRING.
CHECK SIZING.
VALVE DOES NOT TRAVEL FULL STROKE.
CAM/SWITCH ADJUSTMENT SET INCORRECT.
LOW BATTERY VOLTAGE.
ADJUST CAM.
CHARGE BATTERY.
YELLOW LIGHT DIM
BATTERY LOW VOLTAGE
A. DUE TO LONG STORAGE.
B. DUE TO EXCESSIVE DISCHARGE/CHARGE
CYCLES.
C. BATTERY LIFE NEARING EXPECTANCY
RECHARGE BATTERY.
RECHARGE BATTERY.
REPLACE BATTERY.
- CHECK THE STATUS
INDICATOR IN CHARGE MODE
ON THE BATTERY CHARGER.
THE ERROR LED INDICATES
BATTERY NEEDS TO BE
REPLACED.
YELLOW LIGHT OFF
POWER SWITCH DOES NOT
ILLUMINATE “RED”.
BATTERY IS DISCONNECTED
INVERTER IS BAD OR POWER OVERLOAD
HAS OCCURRED.
RECONNECT BATTERY
CHANGE THE SIZE OF THE
INVERTER FUSE BLOWN
ACTUATOR LOAD OR SERVICE
REPLACE FUSE
- AUTOMOTIVE 40A
INCOMING POWER DISCONNECTED
RECONNECT POWER
Page 10
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
NOTES
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Page 11
Electric Fail-Safe Device Installation, Operation & Maintenance Manual
Contact Information
Debbie Voges
Matt Robinson
Talbot Caywood
dvoges@indelac.com
mrobinson@indelac.com
tcaywood@indelac.com
859-727-7890 ext. 100
859-727-7890 ext. 109
859-727-7890 ext. 110
For News & Updates, Check Out Our Blog: www.blog.indelac.com
Page 12