GES-NX-Series Three Phase Input, Three Phase Output

Transcription

1 GES-NX-Series Three Phase Input, Three Phase Output GES-103NX33 GES-1603NX33 Operators Manual Version 1.10

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3 Dear Customer, We Thank You for selecting our NX Series UPS system as your power quality solution, and we are pleased to include you as one of our valued customers at Always "On" UPS Systems Inc. We are confident that this Always On NX Series Uninterruptible Power Supply system, developed and manufactured in our ISO 9001 Certified facilities will provide the quality and satisfaction you demand. Please read the Operators Manual carefully as it contains the necessary information required to extend the life of this UPS to its fullest and this manual will also inform you as to how to use this UPS. Thank you for choosing us. We Are Always "On"!

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5 Preface Congratulations on your choice of NX Series Uninterruptible Power Supply (UPS). This system will protect your valuable equipment from the electrical noise, spikes, surges and other power aberrations found in today s power grids. This manual describes how to prepare the installation site and procedures for moving, installing and connecting the UPS, with detailed information of maintenance procedures suggested to allow for maximum reliability. It will also explain the function of the UPS module, the purpose and location of the switches, the meaning of system events identified on the front LCD panel and provides procedures for starting and stopping the UPS. While every care has been taken to ensure the completeness and accuracy of this manual, Always "On" UPS Systems Inc assume no responsibility or liability for any losses or damages resulting from the use of the information contained in this document. WARNING! Installation restrictions or additional measures may be needed to prevent specific disturbances. Ensure all local and national electrical codes are followed during installation and connection. The information contained in this manual is to be used as a guideline and recommendation only We recommend that this manual be kept with the UPS (Holder provided inside the front door) for future reference. If any problems are encountered with the procedures contained in this manual, please contact our Service Center before proceeding. This document shall not be copied or reproduced without the explicit written permission of Always "On" UPS Systems Inc. Due to technical advancements and improvements, some of the information contained in this manual may be changed or modified without prior notice. Safety Instructions Read the safety instructions contained on the following pages carefully before the installation, start-up of the UPS its options and batteries. Also refer to this manual before any maintenance procedures are undertaken Please pay particular attention to the text in the rectangular boxes as below: They contain important information or warnings concerning electrical connections and personnel safety.

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7 TABLE OF CONTENTS 1 IMPORTANT SAFETY INSTRUCTIONS INTRODUCTION System Description Definitions THEORY OF OPERATION General Topology Normal Operation Mode Back-Up Mode: Reserve Mode: Maintenance Bypass Mode: Features and Advantages Rectifier Inverter Static Switch Maintenance Bypass Switch INTER-PCB DIAGRAM DIMENSIONS & DRAWINGS INSTALLATION Transport Delivery Storage STORAGE OF THE UPS...20 STORAGE OF BATTERY Site & Environment Consideration Unpacking Cable Selection CURRENT RATING FOR INPUT CABLE SIZE FOR INPUT & OUTPUT FUSE RATING & CABLE SIZE FOR BATTERY BANKS Terminal Connection FRONT PANEL OPERATION Switch On Procedure (Authorized personnel ONLY) Shutdown Procedure From Inverter To Manual Bypass Procedure From Manual Bypass To Inverter Procedure THE LCD DISPLAY Menu 0 Main Menu Menu 1 Select Menu...42

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9 9.3 Menu 2 Status Warning Menu Menu 3 Real Time Data Menu Menu 4 Historical Event Menu Menu 5 Parameter Setting Menu Menu 6 Rectifier Data Menu Menu 7 Reserve Data Menu Menu 8 Output Data Menu Menu 9 Other Data Menu Menu 10 Boost Charge Setting Menu Menu 11 Data Time Setting Menu Menu 12 Other Setting Menu INTERFACE CONNECTIONS Dry Contacts Software for PC Monitoring Emergency Power Off Connection DB9 Connectors OPTIONS Battery Cabinet Battery Runtime Charts Emergency Stop Switch Remote Display Panel Isolated Parallel Redundant Operation (IPRO) Web Monitoring Module (SNMP Module) Pulse Rectifier th Harmonic Filter External Wrap Around Bypass TECHNICAL SPECIFICATION NX Series 10kVA to 60kVA UPS 3Ø Input - 3Ø Output NX Series 80kVA To 160kVA UPS 3Ø Input 3Ø Output NX Series 200kVA To 320kVA UPS 3Ø Input 3 Ø Output PREVENTATIVE MAINTENANCE FORM Maintenance Measurement Form Initial Start Up (no load connected) Maintenance Measurement Form cont Normal Service Measurements (normal loads connected and operating) Front Panel Status Report Log Front Panel Readings Battery Maintenance Form CONTACT INFORMATION...84

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11 1 IMPORTANT SAFETY INSTRUCTIONS Save These Instructions. This manual contains important safety instructions that should be followed during installation and maintenance of the NX Series UPS system and optional packages. Before the installation process begins, we recommend that the installer read through the safety precautions, operators manual and the option installation instructions, taking all necessary safety precautions to protect themselves and the equipment being installed. GENERAL Move the UPS in an upright position, in its original packaging, to its final destination. To lift the cabinets, use a forklift or lifting belts with spreader bars. - Check for sufficient floor and elevator loading capacity. - Check the integrity of the UPS equipment carefully. If visible damage is evident, do not attempt to install or start the UPS. Contact the transport delivery company, immediately file a claim with the transport company and inform Always On directly. - WARNING! RISK OF ELECTRICAL SHOCK: use extreme caution when removing covers. - All maintenance and service work should be performed by qualified and trained service personnel. The UPS contains its own energy source, (batteries) which can be dangerous to the untrained person. This UPS contains potentially hazardous voltages - The field-wiring terminals may be electrically live, even when the UPS is not connected to the utility. - Dangerous voltages may be present during battery operation. The batteries must be disconnected during maintenance or service work. (Open battery breaker of fuses) - Be aware that the inverter can restart automatically after the utility voltage is restored. INSTALLATION This UPS is intended for use in a controlled indoor environment free of conductive contaminants and protected against any type of intrusion. Do not install the UPS in an excessively humid environment or near water. Avoid spilling liquids and/or dropping any foreign object(s) onto the UPS. The unit must be placed in a sufficiently ventilated area; the ambient temperature should not exceed 35 C (95 F). Optimal battery life is obtained if the ambient temperature does not exceed 25 C (77 F). HIGH GROUND LEAKAGE CURRENT: ground connection completed before connecting the AC voltage wires on the input! Switching OFF the UPS does not isolate the UPS from the utility as the utility supply is still HOT at the input terminal strip. Supply breaker needs to be opened. It is important that air can move freely around and through the unit. Do not block the air vents. Avoid locations in direct sunlight or near heat sources. STORAGE - Store the UPS in a dry location free of contaminants; - Storage temperature must be within -25 C (-13 F) to 55 C (131 F). - If the unit is stored for a period exceeding 3 months, the batteries must be recharged periodically (time depending on storage temperature). 1

12 WARNING! LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS APPARENTLY NOT OPERATING. OBSERVE ALL CAUTIONS AND WARNINGS IN THIS MANUAL. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH. REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED. NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY QUALIFIED TO DO SO. AN INSTALLER SHOULD NEVER WORK ALONE. WARNING! WHEN REMOVING POWER FROM THE UPS, ALLOW FIVE MINUTES FOR CAPACITORS TO DISCHARGE BEFORE WORKING ON THE EQUIPMENT. CAUTION! This equipment complies with the requirements in Part 15 of FCC rules for a Class A computing device. Operation of this equipment in a residential area may cause interference to radio and TV reception, requiring the operator to take whatever steps necessary to correct the interference. CAUTION! Do not put option control wiring in the same conduit as the UPS input or output power cables. 2

13 2 INTRODUCTION 2.1 System Description The NX Series (UPS) continually monitors and provides conditioning to the incoming electrical power removing surges, spikes, sags, over-voltages, and other irregularities that are inherent in commercial utility power. This UPS system supplies clean, consistent power at the rated voltage with low wave distortion to your sensitive electronic equipment. Blackouts, brownouts and other power interruptions regardless of duration can be protected against with additional optional battery cabinets to provide the necessary emergency power to safeguard your operation. Always On UPS Systems Inc. believes that product reliability is first and foremost in acquiring the confidence of the industry. Our Quality Control Standards ensures that testing at the component level, board level, function level and completed stage level as specified by our ISO9001 Certification allows us to gain this confidence and sets us apart as one of the leading UPS manufacturers in this industry. Always On maintains reliability by incorporating conservatively rated components minimizing transfers to bypass, which eliminates over working many components. Always On provides a truly isolated output (no common neutral from input to output) to eliminate all types of power aberrations as well as Common and Normal Mode noise increasing the reliability and life of the loads connected. 2.2 Definitions UPS Module: That portion of the UPS system which contains the rectifier/charger, inverter, static bypass switch, maintenance bypass switch, controls, monitoring, and indicators. Rectifier/Charger: That portion of the UPS module, which converts the normal source AC input power to DC power for the inverter input and for charging the battery. Inverter: That portion of the UPS module, which converts DC bus power to regulated and filter AC power that is then supplied to the critical loads. Static Bypass Switch: That portion of the UPS module which automatically transfers the critical loads, without interruption, from the inverter output to the bypass AC power source in the event of an overload or degradation of the inverter s performance. Maintenance Bypass Switch: That portion of the UPS module which is used to connect the bypass AC power source to the critical loads while electrically isolating the static bypass switch, rectifier/charger and inverter for maintenance purposes. Battery: The battery system provides DC power to the inverter input when the normal AC input power to the UPS fails or in the event that the rectifier/charger failure. Critical Loads: These are loads that require clean, regulated and continuous AC power and which are connected to the output of the UPS module. 3

14 Key features: 0.9 power factor, the Always On NX Series delivers more real power than other manufactured UPS s. With today s trend toward power factor corrected loads, the NX Series can support more total load than any other UPS, of similar size, allowing you to support a greater number of today s Power Factor Corrected (PFC) equipment. Isolated Parallel Redundancy Operation (IPRO) is exclusive Always On technology. With IPRO the NX Series UPS s are controlled in a true peer-to-peer configuration where all critical elements and functions (including bypass) being redundant. The NX Series is designed to be the most reliable power protection system available on the market today. IGBT technology and new triggering technology allows the NX Series to offer efficiencies up to 94%. Digital Signal Processor (DSP), Flash memory and user compatibility are the technology corner stones of our New Age of power quality and reliability. Custom made power protection and tailored to meet your individual requirements, the NX Series offers user selectable options. I.e. Input harmonic filters, comprehensive shutdown software suite for mission control and data protection needed to facilitate all your needs. 4

15 3 THEORY OF OPERATION 3.1 General Topology Figure General Block Diagram UPS Module Components: The UPS module consists of the following major components: - Input, Reserve and Bypass circuit breakers - Rectifier / Charger - Inverter - Microprocessor controlled logic and control panel with alarm indicators and digital metering display - External battery connection - Static bypass - Full maintenance bypass - Emergency power off (EPO) connection - Communications interface - Input power walk-in - Front cable connections - Output isolation transformer - Optional Features: - 5 th harmonic filter to reduce input harmonic content. - SNMP Adapter for network communications and monitoring - Additional battery modules for extended runtime - Top cable entry - Remote display panel - Emergency power off switch - External maintenance bypass cabinet - Isolated parallel redundant operation (IPRO) Generally, there are four modes of operation for a UPS system, NORMAL MODE, BACK-UP (BATTERY) MODE, RESERVE MODE and MAINTENANCE BYPASS MODE. 5

16 3.2 Normal Operation Mode The rectifier/charger converts the supplied AC power into DC (bus) power, which is then supplied to the inverter and the battery charger. The DC to AC inverter then supplies continuous, noise free AC power to the critical loads. The inverter output is synchronized with the bypass AC power source provided that the bypass AC power source is within the specified frequency range. 3.3 Back-Up Mode: Figure Normal Mode Operation Figure Back-up Mode Operation As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus, the AC power will remain constant and continuous without interruption to the loads when the AC fails or falls out side of the operating parameters. Upon return of the supplied AC input power the UPS the rectifier will automatically assume the DC load (charger, inverter) from the batteries. The UPS will simultaneously supply power to the inverter and the battery charger to replenish the batteries. 6

17 3.4 Reserve Mode: If the inverter is placed into an abnormal condition, such as over temperature, short circuit, abnormal output voltage or is overloaded for a period which exceeds the inverter s limits, the inverter will automatically shutdown in order to protect itself. If the AC utility power is within the normal parameters, the static switch will automatically transfer the load to the reserve (utility) source without interruption of the AC output. 3.5 Maintenance Bypass Mode: Figure Reserve Mode Operation Figure Maintenance (Manual) Bypass Mode Operation During UPS maintenance procedures or battery replacement, the loads cannot be interrupted, and as such the technician needs to turn off the inverter switch, close the bypass breaker and then open the rectifier and reserve (utility) breakers. The UPS is now running in Maintenance By-pass mode supplying utility AC to the loads. The AC output will not be interrupted during the manual bypass transfer procedure because the maintenance bypass switch is designed to supply continuous power to the loads. 7

18 3.6 Features and Advantages a. Reliable input protection: Circuit breakers are in each input loop to ensure power can continue through the other loops in the event of a breaker trip caused by abnormal conditions in either the rectifier or the load. b. Input surge protection: Input surge protection is added at the input to provide enhanced protection to both the UPS and the load and also protects against lightning effects and/or surges caused by large cycling loads or those that are being turned on and/or off. c. EMI suppression: An EMI filter is added to meet the international EMC limits to ensure that No noise will effect or interfere with other equipment connected to the same AC source. d. Ruggedness: The rectifier employs phase control technology to regulate the DC bus voltage allowing the batteries to be charged while supplying DC power to the inverter. This has been proven to be the most efficient method to control and regulate the charge on the batteries. The SCR technology and PFC circuit also assist in maintaining the input waveform. e. High frequency design: The inverter design incorporates high frequency, highly efficiency Insulated Gate Bi-polar Transistors (IGBT). A PWM wave, synchronized to the bypass input, triggers the IGBT s, which invert the DC into AC power required by the loads. This design decreases the number of required components, increases reliability and performance while decreasing acoustic noise, size and weight. f. True galvanic isolation: The isolation transformer addresses ground differentials between the input and output, and prevents ground leakage current problems, common mode and normal mode noise. This transformer is located on the output side of the UPS system providing isolation under every mode of operation. g. PNP modular design: The circuit boards are designed into several modules, which are plugged into slots in the UPS. These plug-able modules allow for easy replacement in the field when necessary and eliminate field diagnostics. h. Cold start function: The UPS can be started without the utility AC supply being activated. Or present at the input terminal strip because our designed system is designed with current limiting circuitry, which allows Startup of the UPS on battery DC power. i. Multi-CPU design: Several CPU s are designed into the control circuit. These critical functions are designed with multi-level redundancy increasing reliability and up-times by eliminating field problems. j. Protection against possible operator error: The UPS is designed with breaker on/off sensors and power supply sensors. These sensors prevent potential operational mistakes from interfering with the start up operation causing possible damage. k. Wide input range: The components are overrated by designed to handle high input voltages and currents without harm to the system, ensuring that Always On UPS s remain one of the most reliable UPS Systems available in today s market. 8

19 l. Harsh environment: Each component of the UPS is chosen with the highest degree of safety margins allowing for wider environmental parameters and specifications related to temperature, humidity, altitude, surge or noise. m. Intelligent charger: The UPS will automatically recharge (boost charge) the batteries when the battery voltage level decreases to approximately 2V/Cell or to a user specified level. To prevent the over-charging of the battery, the boost charge will stop when batteries achieve a 90% charged level or the ambient temperature reaches 35 o C (95 o F) at which point the float charging begins. n. Intelligent battery test: The batteries are tested after every boost charge whether the charge has been initiated by a battery discharge state (2V/Cell) or by the regular battery test preformed by the UPS (monthly test). When an abnormal condition (low charge rating, or bad battery) is found the user will be informed immediately through alarms on the UPS system. o. Charging rate: The charging rate is selectable (L/M/H) according to Ah ratings of the batteries. The charger is designed to charge the larger battery banks without adding an additional charger (up to 8hr. back-up). p. MTBF of cooling fans: Long cycling fans will operate at variable speeds necessary which is dependent on the ambient temperature of the UPS system increasing the life expectancy of the fan motors. q. Redundant power supply: Redundant power supplies have been installed to allow for worry free operation of the system. r. Intelligent interface: One remote control panel (or one PC) can monitor and control up to ninety-nine UPS s. The communication allows for N+1 redundancy, whereby if one system encounters an emergency or fault condition, it will warn the user immediately and the load is automatically transferred to the other UPS systems. The UPS status, data or commands are transmitted to external modules through four RS-485 ports. s. Data log capability: All abnormal conditions will be stored within the UPS control interface board for further reference by the user. Each abnormal condition is time and date stamped (realtime clock) as the event occurs. This history is stored and cannot be removed even if or when the UPS is turned off for servicing. t. Convenient front panel design: The LCD display and control switches are accessible through the up, down, and enter switches below the front panel window. All the viewable parameters can be read without opening the front door. The inverter on/off switch is protected from accidental operation by being located behind the locked front door although the inverter can still be switched on and off via the control switches on the front panel but this feature is password protected. u. Emergency stop: In the event of an emergency the UPS can be shutdown (no AC at the output) either through a switch (optional) or through a smoke detector signal (optional). 9

20 3.7 Rectifier The main function of a rectifier is to convert the AC input power to DC power. The DC power is then used to charge the batteries, supply the DC bus, which in turn supplies the inverter. The rectifier design used in the 10kVA to 60kVA UPS s include a 6-pulse full controlled rectifier. Power Factor Correction (PFC) has been added to maintain a high input power factor, independent of the load power factor. This 6 pulse rectifier smoothes the current waveform and reduces the harmonic content reflected back to the utility. The control circuit regulates the DC bus to within 1% of the nominal voltage. Soft walk-in circuitry (approximately 20 seconds) and current limiting circuitry are used to prevent over current or surge currents from affecting any part of the UPS system. Additionally, over and under-voltage protection is added to improve reliability and to shutdown the rectifier in the event of abnormal conditions. The DC bus is adjustable to allow for different types and capacities of batteries. The power components used within the rectifier are specially designed and selected to handle extreme ranges of high voltage and high current ( 25% to +25%). In order to further improve the power factor and reduce harmonic current drawn by the rectifier, Always On UPS s above 80kVA incorporate a 12-pulse full controlled rectifier (also available as an option on the 10 to 60kVA UPS s) to reduce the total harmonic current to less than 12%. A phase shift transformer is added with input inductors to achieve this higher level of performance while maintaining our high input power factor. An optional 5 th harmonic filter can be added to further reduce the total harmonic distortion current to less than 9%. The total harmonic current can be decreased to less than 7% with the inclusion of the 18-pulse full controlled rectifier. This option is recommended for the larger (80kVA and up) UPS systems. 10

21 3.8 Inverter Figure Inverter Layout The inverter is composed of IGBT s, inductors, capacitors, highly efficient filters, control circuitry and protection circuitry. This inverter inverts the DC power received on the DC bus to isolated, noise-free AC power, which is then supplied to the critical loads. Our PWM wave generator is switching at a higher frequency well above the human audible range. The Voltage regulating circuitry limits the output voltage variation to within 1% of the nominal voltage and special compensation circuitry has been added to eliminate output distortion. Every component is oversized to accept a wide DC input range (from 285 to 420VDC), allowing the output waveform to remain sinusoidal throughout the entire range. With the aid of dynamic feedback loop circuits the inverter maintains a true sine wave output, even if non-linear loads are connected. The system is designed and incorporates an independent inverter per phase. These inverters are totally independent of each other preventing the possibility of cascading failures while allowing the user to connect loads to adjacent inverters without affecting the other inverters. This connectivity provides high-end voltage regulation under a 100% unbalanced load situation. The IGBT is operated in its optimal condition to obtain maximum efficiency, keeping electrical costs to a minimum. Usually, most UPS failures are a result of inverter failures. To prevent this occurrence, Always On has included redundant protection circuitry to protect the inverter and increase its reliability. To enhance this protection we have also added a high efficiency filter designed to suppress the spikes and noise that can be reflected from the attached loads back into the UPS system. Specifying oversized and high quality components, additional semi-conductor fuses and allowing for good ventilation systems within further increase reliability. 11

22 3.9 Static Switch Figure Static Bypass The static switch is composed of two pairs of back to back naturally commutated SCR s, which moves the load from inverter to reserve (utility) or from reserve to inverter without interruption of power to the load. Detection circuitry is included in the control circuit to achieve 0 dead time transfer. Additional detection is employed to control the static switch transfer. Dead Short: If a dead short circuit was to occur under normal mode operation, the UPS would detect the short circuit and immediately stop the inverter until the problem has been rectified. Due to the large amount of current a dead short requires, the static switch will not transfer to reserve preventing the tripping of the reserve breaker. Overload condition: The UPS will transfer the load to reserve (utility) path. The static switch is designed to handle 110% of the capacity of the system but will switch to the reserve path if the overload continues for any length of time. The load will still be operational, but the load system will not be protected from a utility failure, as it has no battery capability until the overload is removed. The static switch will only be activated if the input levels are within parameters to ensure the load is only supplied with acceptable power to protect against damage that may be caused to the critical load. The system performs numerous checks on the transfer from inverter to bypass and visa versa to ensure the exchange is smooth Maintenance Bypass Switch The maintenance bypass switch is a function of Always On UPS s, which is open under normal operation, and closed for maintenance service. All power supplied to the UPS should be disconnected before service begins. The maintenance bypass is switched seamlessly to supply utility AC power to the loads during UPS maintenance and servicing. If the bypass breaker is closed (by mistake) under normal operations, the inverter will stop and the load will be transferred to reserve (utility) power. The inverter cannot be turned on when the maintenance bypass breaker is in the closed position. (The operation of the maintenance bypass breaker is explained later in this manual) 12

23 4 INTER-PCB DIAGRAM 12 Pulse Rectifier Rectifier Driver Rectifier Control Power Supply SS Drive Rectifier Driver Rectifier Control Batt Relay R Phase Inverter Driver 6 Pulse Rectifier Controller S Phase Inverter Driver LCD Call Service Remote Control Panel T Phase Inverter Driver Switch LED Display PC Communications SNMP (Web) Monitoring Dry Contact Battery Monitoring Optional Communication Features Figure 4.1 Block Diagram For Component And Feature Layout 13

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25 5 DIMENSIONS & DRAWINGS 92mm (3.6in) 1,600mm (63.0in) 550mm (21.7in) 800mm (31.5in) Figure kVA to 60kVA Dimensional Drawing 15

26 FROM INVERTER TO BYPASS PROCEDURE: Always On UPS Systems Inc Figure kVA to 60kVA Interior Layout Table 5.1 Weight, Dimensions and Loading of the 10 to 60kVA UPS systems. UPS Rating Dimensions Weight (kva) W (Width) D (Depth) H (Height) UPS Floor Loading mm (20.0") 800mm (32.0") 1,600mm (64.0") 250kg (550lbs) 625kg/sq.m (124lbs/sq.ft.) mm (20.0") 800mm (32.0") 1,600mm (64.0") 300kg (660lbs) 750kg/sq.m (149lbs/sq.ft) mm (20.0") 800mm (32.0") 1,600mm (64.0") 400kg (880lbs) 1,000kg/sq.m (198lbs/sq.ft.) mm (20.0") 800mm (32.0") 1,600mm (64.0") 480kg (1,056lbs) 1,200kg/sq.m (238lbs/sq.ft.) mm (20.0") 800mm (32.0") 1,600mm (64.0") 550kg (1,210lbs) 1,375kg/sq.m (273lbs/sq.ft) mm (20.0") 800mm (32.0") 1,600mm (64.0") 680kg (1,496lbs) 1,700kg/sq.m (337lbs/sq.ft.) 16

27 Figure kVA to 160kVA Dimensional Drawing 17

28 INVERTER ON INVERTER SS SHORT CIRCUIT FUSE/OVER TEMP SD INVERTER FAIL S H U T D O W N BYPASS ON S H U T D O W N HIGH DC S H U T D O W N OVERLOAD S H U T D O W N 7 0 % LOAD % LOAD % LOAD % LOAD RESERVE AC FAIL RESERVE FREQ FAIL BATTERY LOW B A T T E R Y L O W S H U T D O W N RECT AC FAIL ROTATION ERROR RECTIFIER S H U T D O W N HIGH DC BOOST CHARGE B A T T E R Y T E S T EMERGENT STOP DATA LINE START / PROCEDURE: 1. CLOSE THE RESERVE BREAKER. 2. CLOSE THE RECTIFIER BREAKER. SHUTDOWN PROCEDURE: 1. PUSH THE INVERTER OFF SWITCH (RIGHT & MIDDLE OF INVERTER 3. WAIT 30sec FOR DC VOLTAGE RISE UP. SWITCH). 4. CLOSE THE BATTERY BREAKER. 2. OPEN THE BATTERY BREAKER. 5. PUSH INVERTER ON SWITCH (LEFT & 3. OPEN THE RECTIFIER BREAKER. MIDDLE OF INVERTER SWITCH). 4. WAIT 5min FOR DC CAPACITOR INSIDE 6. THE LOAD WILL TRANSFER TO TO DISCHARGE. INVERTER OUTPUT AFTER 7sec. 5. OPEN THE RESERVE BREAKER. 7. L O C K T H E D O O R. 6. L O C K T H E D O O R. FROM BYPASS TO INVERTER PROCEDURE: 1. CLOSE THE RESERVE BREAKER. 2. OPEN THE BYPASS BREAKER. F R O M INVERTER TO BYPASS PROCEDURE: 1. PUSH THE INVERTER OFF SWITCH (RIGHT & MIDDLE OF INVERTER SWITCH). 2. OPEN THE BATTERY BREAKER. 3. OPEN THE RECTIFIER BREAKER. 3. CLOSE THE RECTIFIER BREAKER. 4. WAIT 30sec FOR DC VOLTAGE RISE UP. 5. CLOSE THE BATTERY BREAKER. 6. PUSH INVERTER ON SWITCH (LEFT & 4. WAIT 5min FOR DC CAPACITOR INSIDE MIDDLE OF INVERTER SWITCH). TO DISCHARGE. 7. THE LOAD WILL TRANSFER TO 5. CLOSE THE BYPASS BREAKER. INVERTER OUTPUT AFTER 7sec. 6. OPEN THE RESERVE BREAKER. 8. L O C K T H E D O O R. 7. L O C K T H E D O O R. RECT AC FAIL RESERVE FAIL FUSE / TEMP OVERLOAD ON INVERTER L C D BAT LOW B A T L O W S T O P O F F F A U L T Always On UPS Systems Inc WARNING ~ ~ ~ ~ ~ / ~ ~ TRUE GALVANIC ISOLATED UPS UP D O W N ENTER Figure kVA to 160kVA Interior Layout Table 5.2 Weight, Dimensions and Loading of the 80 to 160kVA UPS systems UPS Rating Dimensions Weight (kva) W (Width) D (Depth) H (Height) UPS Floor Loading 80 1,100mm (44.0") 800mm (32.0") 1,600mm (64.0") 820kg (1,804lbs) 932kg/sq.m (185lbs.sq.ft.) 100 1,100mm (44.0") 800mm (32.0") 1,600mm (64.0") 950kg (2,090lbs) 1,080kg/sq.m (214lbs/sq.ft.) 120 1,100mm (44.0") 800mm (32.0") 1,600mm (64.0") 1,180kg (2,596lbs) 1,340kg/sq.m (266lbs/sq.ft.) 160 1,100mm (44.0") 800mm (32.0") 1,600mm (64.0") 1,450kg (3,190lbs) 1,648kg/sq.m (327lbs/sq.ft.) 18

29 6 INSTALLATION 6.1 Transport The UPS is packaged on a pallet, suitable for handling with a forklift. Pay strict attention to the center of gravity. The UPS must be moved in upright position. Do not tilt cabinets more than +/- 10 during handling. Move the UPS in its original package to the final destination site. Do not stack other packages on top. If the UPS must be lifted by crane, use suitable lifting straps and spreader bars. 6.2 Delivery Upon receiving the UPS system, inspect the packaging integrity and the physical condition of the cabinets carefully. In the event that physical damage is visible, the carrier must be informed immediately and a claim filed with them. Inform Always On as soon as the claim has been filed and a copy of claim should be faxed to Always On at (250) A detailed report of the damage is necessary for carrier insurance claim. WARNING A damaged UPS system must never be installed or connected to the utility or batteries without written instruction from Always On Engineering. 19

30 6.3 Storage STORAGE OF THE UPS The UPS is carefully packed for transport and storage. Never leave a UPS outside the building exposed to the elements and do not place other packages on the top of the UPS. Storing: It is recommended to store the UPS in its original package in a dry, dust-free room, away from chemical substances, and with a temperature range of -25 C (- 13 F) to 55 C (131 F). Exceeding this temperature range may cause damage. Important functions of the UPS, are defined by parameters stored in a RAM memory. The RAM is supplied by a small backup battery located on the Controller board. If the storage time of the UPS exceeds 1 year, these functions should be verified by an Always On Service Center before putting the UPS into operation STORAGE OF BATTERY Although this system includes maintenance free batteries, keep in mind that they are subject to self-discharge and therefore must be recharged. The storage time without battery recharge depends on the temperature of the storage site. The optimal temperature for battery storage is 20 C (68 F) to 25 C (77 F). Recharge of the stored maintenance free battery every: 6 months when the ambient storage temperature is 20 C (68 F) 3 months when the ambient storage temperature is 30 C (86 F) 2 months when the ambient storage temperature is 35 C (95 F) 20

31 6.4 Site & Environment Consideration The designed function of the UPS is to provide a safe, clean and independent electrical supply free from random variations, disturbances or interruptions of the utility mains. The UPS will provide a constant power source, which is regulated in both voltage and frequency. When the utility mains are not available, the UPS will provide optimal back-up time depending on the capacity connected battery bank. Usually the life expectancy of the UPS is 8 to 10 years. The optimal life expectancy of the UPS can be achieved by careful consideration of the site and environment. The following precautions and recommendations should be checked when considering the site and environment for the UPS: a. The UPS should be located in a place with adequate ventilation (refer to the specification of the heat dissipation of the UPS). Should the UPS be installed in a sealed room, care must be taken to ensure adequate heat evacuation is provided. b. Void space is not required on all sides of the UPS system, but adequate space, a minimum of 1m (3 ), should be allowed for the door to open. Adequate space, a minimum of 60cm (2 ) [recommended 1m (3 )], should also be allowed at the top of the UPS system to allow for proper heat dissipation and ventilated through the top openings (optional ventilation booth is available upon request). c. The battery banks require access to front and both sides. A minimum of 60cm (2 ) [recommended 1m (3 )] should be allowed at the front and both sides to allow for the door to open and removal of the side panels for operation or maintenance purposes. Figure Minimum Spacing Requirements 21

32 d. Do not place any objects on the top of the UPS that might obscure the ventilation. Do not place the UPS near any heat source, or machinery, which may produce metallic particles, dust or powder. Do not place the UPS near equipment that will produce corrosive substances or vapor. e. Do not place the UPS below the shower of a fire extinguishing system (optional drip shield available). Abnormal conditions of the UPS should be protected by a cutoff from the power supply. e. The user is required to guarantee the temperature and humidity values of the site into which the UPS will be installed meet the required and published manufacturer specifications. The UPS should be installed within the range allowed by these specifications. The UPS is capable of continuous normal operation within a temperature range of 0 C (32 F) to 40 C (104 F). For optimal performance and reliability the recommended environment temperature is best at 25 C, with humidity < 80% non-condensing. f. The floor loading capacity should be sufficient to endure the weight of the UPS. Four rightangled steel feet attached restrainers are included with the UPS system, which should be inserted into the floor for securing the UPS system, when the location has the potential to experience vibrations. (e.g.: earthquake, moving vehicles, or tanker.) The locations and layout of the restrainers are shown below. Figure Layout Of Securing Tab Locations h. Walls, ceilings, floors or anything near to the UPS should be constructed of noncombustible materials. A portable fire extinguisher should be accessible nearby. i. Avoid accumulating litter or trash of any sort in or around the UPS system. The floor area surrounding the UPS should be kept clean, free from metallic powder and/or filings. 22

33 j. Access to the UPS room should be limited to operation and maintenance personnel. The doors should be kept locked and the keys should be available only to authorized personnel. k. Personnel who operate or maintain the UPS system should be proficient in normal and emergency operational procedures. New personnel should be trained and qualified prior to operation of the equipment. l. Although the UPS has passed the international EMC tests, it is not recommended to install the UPS near to any equipment that is susceptible to electro-magnetic interference, such as computer systems, monitors, radios etc. 6.5 Unpacking Carefully remove all the packaging material of the UPS, then carefully place the UPS at the final destination site. This UPS system has passed all stages of production testing and final stage QC testing prior to shipment from the factory (report enclosed). The UPS should be in full operating condition upon receipt. Upon receiving visually check the UPS for any physical damage that may have occurred during transport. If damage is notice file a damage report immediately with the transport company and inform Always On. Also check to ensure all of the accessories/options ordered are received. DOOR KEY OPERATOR S MANUAL BATTERY FUSE (FOR BATTERY CABINET ONLY) Check and verify the specifications of the UPS are identical to the specifications of the system ordered. The key items in the specifications you must check are: RATED POWER OF THE UPS INPUT VOLTAGE & FREQUENCY OUTPUT VOLTAGE & FREQUENCY BATTERY RUNTIME Check that the necessary documentation located inside the front door of the UPS, is included: OPERATORS MANUAL TEST AND WARRANTY INFORMATION SERVICE MANUAL (If purchased) 23

34 6.6 Cable Selection The cabling of the UPS system has to be sized according to the UPS power rating. Sizing of circuit breakers, fuses and cables for input utility, output load and battery must meet the requirements of local and national electrical codes. The following tables list the information between kva of the UPS and the current requirements of the systems. WARNING Inadequate cable size and over sized breakers can increase the risk of fire or damage connection cables and internal components. The following tables can be used to determine the input circuit breaker rating and the size of cable for input, output and battery connections. This data is for reference only as final installation must meet the requirements of local and national electrical codes CURRENT RATING FOR INPUT Table Maximum Input current ratings Imax(A) KVA Minimum 120/208VAC Rating Breaker/Fuse 3Ø Imax(A) 277/480VAC 3Ø Minimum Breaker/Fuse Imax(A) 347/600VAC 3Ø Minimum Breaker/Fuse When choosing a non-fused breaker (NFB) for the UPS, always choose the NFB that is closest, but not below the maximum rated input current CABLE SIZE FOR INPUT & OUTPUT NEC SECTION (a) Table (next page) shows the allowable amperage of insulated conductors rated 0 through 2000 Volts, 60 C through 90 C (140 F through 194 F) not more than three current-carrying conductors in a raceway, cable, or earth (directly buried), based on ambient temperature of 30 C (86 F). 24

35 Table 2 (See rules 4-004, 8-104, , , , , , and and Tables 5A, 5C, 19, and D3) Allowable Ampacities for Not More Than 3 Copper Conductors in Raceway or Cable Based on Ambient Temperature of 30 C Allowable Ampacity 60 C C Size AWG kcmil Types TW Types RW75 TW75 Types R90, RW90 T90 NYLON Paper Mineral-Insulated Cable** See Note (1) See Note (1) See Note (1) COPPER Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7 CORRECTION FACTORS Ambient Temp. For ambient temperatures other than 30 C (86 F), multiply the allowable amperage shown above by the ( C) appropriate factor below

36 Table 4 (See rules 4-004, 8-104, , , , , and and Tables 5A, 5C, and D3) Allowable Ampacities for Not More Than 3 Aluminum Conductors in Raceway or Cable Based on Ambient Temperature of 30 C Allowable Ampacity 60 C C Size AWG kcmil Types TW Types RW75 TW75 Types R90,RW90 T90 NYLON Paper COPPER See Note See Note Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7 See Note 26

37 Table 5A (See rules 4-004(8), , and Tables 1,2,3,4,57,58, and D3) Correction Factors Applying to Tables 1,2,3, and 4 Ampacity Correction Factors for Ambient Temperatures Above 30 C (These correction factors apply, column for column, to Tables 1,2,3, and 4. The correction factors in column 2 also apply to Table 57.) Correction Factor 60 C C Ambient Temperature C 60 C Types TW 75 C Types RW75 TW C Types R90,RW90 T90 NYLON Paper 110 C See Note(2) 125 C See Note(2) 200 C See Note(2) Col.1 Col.2 Col.3 Col.4 Col.5 Col.6 Col.7 NOTES: (1) The ampacity of a given conductor type at these higher ambient temperatures is obtained by multiplying the appropriate value from Table 1,2,3, or 4 by the correction factor for that higher temperature. (2) These ampacities are only applicable under special circumstances where the use of insulated conductors having this temperature rating are acceptable. 27

38 6.6.3 FUSE RATING & CABLE SIZE FOR BATTERY BANKS Table Recommended Fuse and Cable Size for the Battery Banks KVA Rating Imax(A) FUSE(A) CABLE(mm²) CABLE (AWG) # # # # # *2 38*2 # *2 50* *2 80* *2 80* *4 80* *4 80*4 00 *THE BATTERY VOLTAGE IS V **LEAD ACID BATTERY 174 CELLS 28

39 6.7 Terminal Connection Different models of UPS s may have different cable connection terminals. UPS connection terminal configurations fall into one of the following types: RR RS RT IN IR IS IT OR OS OT ON B+ B- RESERVE INPUT RECTIFIER INPUT UPS OUTPUT 3 PHASE INPUT / 3 PHASE OUTPUT TERMINAL WITH TWO SOURCE BATTERY INPUT IN IR IS IT OR OS OT ON B+ B- RECTIFIER & RESERVE INPUT UPS OUTPUT 3 PHASE INPUT / 3 PHASE OUTPUT TERMINAL WITH SINGLE SOURCE BATTERY INPUT Figure Terminal Strip Layout for Dual in Single input UPS systems 29

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41 7 FRONT PANEL A B C R Q P D E F G H I J K L M N O Figure 7.1 Front Panel Display 31

42 The front panel is located behind the glass window on the front of the UPS system. It displays the real time information and status of the UPS and battery system. It also provides for user interface for controlling and setting the UPS operating status. This panel also allows the user to operate and monitor the system with ease. The panel is explained below: A: LCD display- Real time status, data and historical events are displayed on the LCD. The UPS parameters, real time clock, inverter, and buzzer can also be set through this LCD. The LCD is back lit by LED s for a sharper display, but in order to lengthen the LED s life time, the LED will automatically shut off 3 minutes after a key has been pressed, and will light up again when one of the up/down/enter keys are pushed. B: Warning LED s-when an abnormal condition occurs, these LED s will illuminate allowing the user to identify the fault. This will also allow the service personnel the ability to troubleshoot the system. These LED s are described below: RECT AC FAIL when the supply to the rectifier is outside of the operating parameters. This not only applies to voltage range but also when phase rotation is incorrect or the rectifier has been shutdown (refer to C: Status LED s). RESERVE FAIL supply to the reserve is outside of the operating parameters. Supply voltage or frequency out of range (refer to C: Status LED s). FUSE/TEMP inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters. OVERLOAD an overload condition has occurred on the output. HIGH DC this LED will be lit as long as the DC voltage exceeds 430VDC. BAT LOW this LED will be lit as long as the DC voltage is lower than 320VDC. BAT LOW STOP the LED will be lit as long as the DC voltage is lower than 295VDC. The inverter will not activate until the DC voltage is above this level. FAULT the inverter has shutdown because an abnormal condition has occurred. Possible conditions include overload, short circuit, high DC shutdown, fuse/over temperature, bypass breaker on or emergency stop (refer to C: Status LED s). C: Status LED s- 24 LED s represent the real-time information regarding the status of the UPS system. These LED s will aid in diagnosing and trouble shooting abnormal conditions. The 24 LED s represent the following: INVERTER ON inverter is running. INVERTER SS inverter static switch is active. SHORT CIRCUIT UPS output is in a short circuit state. FUSE/OVER TEMP SD inverter has shutdown due to inverter fuse open or heat sink temperature above operating parameters. 32

43 INVERTER FAIL SHUTDOWN inverter has shutdown due to inverter output voltage below tolerances. BYPASS ON SHUTDOWN inverter has shutdown because the bypass breaker has been activated while the inverter is supplying power to the load. HIGH DC SHUTDOWN inverter has shutdown because the DC Bus voltage is outside of operating parameters while the inverter is operating. OVERLOAD SHUTDOWN inverter has shutdown because an overload condition has been detected on the output. The inverter will automatically restart after the condition has been removed for a period of seven seconds. 70% LOAD load connected to the output is over 70% of the UPS rating. 110% LOAD - load connected to the output is over 110% of the UPS rating. 125% LOAD - load connected to the output is over 125% of the UPS rating. 150% LOAD - load connected to the output is over 150% of the UPS rating. RESERVE AC FAIL supply voltage to the Reserve is outside of operating window. RESERVE FREQ FAIL supply frequency to the Reserve is outside of operating window. BATTERY LOW the DC bus (or battery) voltage is lower than 320VDC. Low battery shutdown is approaching. BATTERY LOW SHUTDOWN the inverter has shutdown because the DC bus (or battery) voltage is below operating level (lower than 295VDC). RECT AC FAIL supply to rectifier is outside of operating window. ROTATION ERROR supply phase rotation is outside of operating window. RECTIFIER SHUTDOWN the rectifier has shutdown because the DC bus voltage has exceeded maximum operating level (over 445VDC). The rectifier will automatically restart 30 seconds this abnormal condition has been cleared. HIGH DC the DC voltage has exceeded maximum operating level (over 430VDC). The bus voltage is limited to this voltage. BOOST CHARGE the batteries are being boost charged by the rectifier. BATTERY TEST batteries are being tested. EMERGENCY STOP the inverter has shutdown because the emergency stop switch has been activated. DATA LINE blinks when data is being transmitted or received via the communication port. 33

44 D: Buzzer outlet: There is a buzzer located behind the LCD Display. The buzzer will allow for audile notification during an abnormal condition. The buzzer will be activated under one of the following conditions: (The frequency of the buzzer is also described for your reference.) INVERTER IS OVERLOADED >110%, beep once / 3 seconds >125%, beep once / second >150%, beep twice / second BACK-UP >320VDC, beep once/ 3 seconds <320VDC, beep twice / second <295VDC, no beeping INVERTER IS SHORT CIRCUITED beep continuously FUSE BROKEN beep continuously HEAT SINK OVER TEMPERATURE beep continuously HIGH DC SHUTDOWN beep continuously BYPASS ON STOP beep continuously EMERGENCY STOP beep continuously The buzzer will beep once every time the inverter is switched on or off. This will allow for the user to be sure the operation was preformed correctly. E. Bypass LED: This LED is lit when the maintenance bypass breaker is closed leaving the inverter in the off mode. If the inverter is active when the bypass breaker is closed the inverter will shutdown immediately. F. Reserve LED: This LED is lit when the reserve breaker is closed, and the supply is within operating parameters. G. Rectifier LED: This LED is lit when the rectifier is operating, the supply is within operating parameters, the rectifier breaker is closed and the DC bus voltage is within operating parameters. H. Back-up LED: This LED is lit while the UPS is in back-up mode. This LED also indicates the results of battery test. If the battery pack does not pass the test, this LED will flash prompting the user to change the battery pack. I. Inverter LED: This LED is lit when the inverter is supplying power to the load. J. Inverter SS LED: This LED is lit when the inverter static switch is operating and the reserve static switch is turned off. When this LED is on, the load is supplied from the inverter. Usually this LED will stay lit for 7sec. after the inverter is switched on. K. Reserve SS LED: This LED is lit when the reserve static switch is operating and the inverter static switch is turned off. When this LED is on, the load is being supplied by the reserve. Since the reserve static switch and inverter static switch will never operate simultaneously, the Inverter SS LED and the Reserve SS LED will never be lit at the same time. 34

45 L. Output LED: This LED is lit when there is AC power present at the output terminals. M. Up key: This is an LCD control key. It moves the cursor one field upward when items are being selected or changes the number/character forward when data or parameters of the UPS are being set. N. Down key: This is an LCD control key. It moves the cursor one field downward when items are being selected or changes the number/character backward when data or parameters of the UPS are being set. O. Enter key: This is an LCD control key. It returns to the previous page, and also confirms the number/character/item selected. P. Inverter On switch: This is an inverter control switch. When this switch is pushed simultaneously with the control key, the inverter will switch on. Q. Inverter Control switch: This is an inverter control switch. When this switch is pushed in conjunction with the inverter On switch the inverter will activate. Similarly, when this switch is pushed with the inverter Off switch the inverter will shutdown. This switch acts as a safety switch to prevent accidental operation of the inverter. R. Inverter Off switch: This is an inverter control switch. When this switch is pushed simultaneously with the control switch the inverter will be turned off. 35

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47 8 OPERATION After all the cables have been connected and power is present at the input terminal, the UPS is ready to operate. Before initial start-up, re-check the following: a. Make certain there is no foreign material left on, inside or around the UPS b. Ensure all breakers and the battery disconnect switches are opened c. Ensure all loads are switched off. d. Check that the input frequency matches the UPS s rated input frequency e. Check that the input voltage matches the UPS s rated input voltage 8.1 Switch On Procedure (Authorized Trained Personnel ONLY) These start-up procedures can be preformed with the AC utility source connected to or with only the batteries connected. a. Close the reserve breaker The reserve and output LED on the status panel will light up, indicating the reserve static switch loop is energized and there is power on the output terminals. The power supplies within the UPS will energize and the internal fans will rotate. b. Close the rectifier breaker - The rectifier will automatically start if the AC utility power connected is within operating parameters. The DC voltage will slowly rise (15 30 sec.) until the designated voltage is reached. The DC voltage is now ready for the inverter and battery bank. c. Close the battery fuse holder - A fuse holder between the battery to the DC bus is used for safety purposes. The batteries will start charging once the fuse door or breaker is closed. This fuse holder can be located within the UPS system or within the battery cabinets depending on rating. d. Push inverter on switch To turn on the inverter simultaneously press the inverter on switch (?) and the control switch (?? ). The inverter will begin to function with inverter output within 4 sec. The load will automatically transfer to the inverter 3 sec. later. The UPS is now operating in normal mode. e. Check the status panel for correctness as shown in the diagram on the next page. All warning LED s on the right hand side are off, two LED s: INVERTER ON and INVERTER SS on the left hand side should be lit, and the LED s circle should also be lit. If the load is over 70%, the 70% LOAD LED will also be lit. 37

48 8.2 Shutdown Procedure Figure Status Panel Display Under Normal Operation Circles represent LED s that are on. To completely shutdown the UPS, please follow the following steps. a. Switch off the inverter The inverter can be switched off by simultaneously pressing the inverter off switch (O) and the inverter control switch (?? ). The load will be automatically transferred to reserve without interruption. b. Open the battery fuse holder This will disconnect the batteries from the DC bus and the UPS no longer has back up available. This fuse holder can be located within the UPS system or within the battery cabinets. c. Open the rectifier breaker Opening the rectifier breaker will remove the power source from the DC bus. The DC bus will start to drop slowly until it reaches a save level of approximately 20VDC. WARNING! Completing the next step will turn off the power to the loads. Make sure all loads have been turned off before proceeding or the external wrap-around bypass has been initiated. d. Open the reserve breaker Before opening the reserve breaker you must make sure there is no critical load connected to the UPS that requires power. NO OUTPUT POWER WILL BE SUPPLIED FROM THE UPS ONCE THE RESERVE (UTILITY) BREAKER IS OPENED. e. Now that all power has been cut off within the UPS system. All LED s, displays and fans should be off. CAUTION! Terminal strip and breakers may still be energized if the main input breaker feeding the UPS system is not turned off or open. 38