TOWER MAXI T SINGLE CONVERSION ON LINE UPS SYSTEMS

INSTRUCTION MANUAL TOWER MAXI T SINGLE CONVERSION ON LINE UPS SYSTEMS September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 1

1. INTRODUCTION T A B L E O F C O N T E N T S 1.1 General Description... 3 1.2 Features... 3 1.3 Inspection... 3 1.4 Storage... 3 1.5 Installation Precautions... 4 2. INSTALLATION 2.1 General... 4 2.2 Cable and Circuit Breaker Ratings... 4 2.3 Wiring Layout and Connections... 4 2.4 Battery Requirements and Precautions... 6 2.5 Battery Connection... 7 3. OPERATING PROCEDURES 3.1 Initial Startup... 8 3.2 Transfer Load to Inverter.... 8 3.3 Transfer Load to Reserve.... 8 3.4 Manual Bypass Mode... 8 3.5 Isolate Load... 8 4. TROUBLE SHOOTING 4.1 General Problems... 9 4.2 Alarms Status... 9 4.3 Description of Alarms... 9 5. MAINTENANCE 5.1 Preventative Maintenance... 10 5.2 Battery Maintenance... 10 6. SPECIFICATIONS 11 7. UPS SERVICE HISTORY 12 September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 2

1 I N T R O D U C T I O N 1.1 GENERAL DESCRIPTION The Tower Series of Uninterruptible Power Supplies, UPS, provide low noise, reliable and continuous power to an external load. The load is protected against input transients, i.e. sudden voltage or current fluctuations, and the output frequency is controlled to within specified parameters. In the event of a power failure the UPS will continue to maintain the load demands for a period which is dependent on the degree of loading and the size of the installed reservoir battery. In the event of UPS failure, the load will be automatically transferred to the reserve mains supply. The unit can then be connected into Manual Bypass mode for repairs to the unit if required. Provided that the mains supply is reliable, the load will thus never be without a source of power. The Double Conversion UPS units are also available from Tower, the manufacturers, however these will not be featured as only the Single conversion-on-line units are covered in this manual. 1.2 FEATURES. UPS Systems Power Range Display Alarm card Serial Ports 3KVA, 5KVA, 8KVA, 10KVA, 15KVA, or 20KVA. 230V, 50Hz single phase output. Liquid crystal type (LCD). Remote alarms monitoring. Interface to Server / PC for automatic shutdown and monitoring of units parameters. See note. Advanced power switching and digital diagnostics. Ergonomic, low noise and compact design. Note: The remote alarms and interface to a computer server is an optional extra. Should the latter be desired, an interface card and a RS232 cable together with the software would have to be installed at a nominal fee. 1.3 INSPECTION Inspect the unit on arrival for any damages that may have occurred during transit. If so, report these immediately to the supplier and retain the packaging for inspection by the supplier and Transport Company. Note: The unit has undergone thorough factory testing and inspections. 1.4 STORAGE If the unit is not to be installed immediately it would be advisable to keep it stored in the original packing materials, in normal temperatures, i.e. between -10 C and 50 C and protected from any moisture whatsoever. If the unit is not to be utilised for a long period it would be advisable to contact the battery supplier concerning battery shelf life periods. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 3

1.5 INSTALLATION PRECAUTIONS The following factors should be considered to determine a suitable location for your unit: Protection against excessive temperature and humidity. Protection against moisture. Ease of access. Its position relative to the critical load for ease of electrical reticulation. Adequate ventilation clearance. A close proximity of the Battery Cabinet to the UPS unit where applicable. Potential expansion, e.g. additional battery cabinet. 2 I N S T A L L A T I O N 2.1 GENERAL The following information concerning the required circuit breakers and cable cross sectional area should be adhered to. Table 1 outlines these ratings as laid down by the electrical wireman s code. 2.2 CABLE AND CIRCUIT BREAKER RATINGS. The recommended input circuit breaker and input and output cable sizes are listed in Table 1. The input circuit breaker must have a D curve response and should be mounted in the existing distribution board. The UPS must not be connected via an EARTH LEAKAGE breaker on the input supply. All cable sizes are rated for a maximum distance of 50 meters. Table 1. UPS Rating KVA Input Amps Recommend Circuit Breaker Input cable Cross sec.area Output Amps Output cable Cross sec.area 3KVA 11A 20A 1 pole 2.5mm 2 13A 2,5mm 2 5KVA 18A 25A 1 pole 4mm 2 22A 4mm 2 8KVA 28A 40A 1 pole 6mm 2 35A 6mm 2 10KVA 36A 50A 1 pole 10mm 2 43A 10mm 2 15KVA 53A 80A 1 pole 16mm 2 65A 16mm 2 20KVA 71A 100A 1 pole 25mm 2 87A 25mm 2 NOTE: The input and output cables should have two cores plus an earth respectively. 2.3 WIRING LAYOUT AND CONNECTIONS The wiring details are shown in Figure 1. Ensure that all cables are secure and the length adequate to allow sufficient movement of the unit for access when servicing. Figure 1 Terminal block wiring layout. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 4

1 2 3 4 5 6 7 Figure 2 Key Description 1 Rotary Switch 3 5 KVA units only * 2 Battery Fuses 3 CB1 AC Input 4 Terminal Block 5 Alarms Relay Card 6 Input & Output Cables 7 Chassis Earth Point * 8 20 KVA units use OUTPUT & BYPASS Isolators. INVERTER STATUS MESSAGE ALARM OFF ON INPUT OUTPUT VOLTAGE OUTPUT AMPS FREQ. Hz BATTERY VOLTAGE CANCEL Inverter ON/OFF switch LCD Display Alarms Cancel Button Figure 3 September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 5

2.4 BATTERY REQUIREMENTS AND PRECAUTIONS. The four battery trays were designed to house a maximum of 2 parallel banks of 32, 12V @7A/H batteries. A minimum of 32 batteries are required for normal operation of your unit. Each tray houses 16, 7A/H batteries. An additional external battery cabinet can house 3 parallel banks of 32, 7A/H batteries. This would allow for extended time during a power failure. Other available battery options include using 32, 12A/H batteries or 2 parallel banks of 32, 12A/H batteries if an external cabinet is employed. Battery links and interconnecting cables are supplied with your unit.! Care should be exercised when installing the batteries. The following should be considered: Do not short out the battery terminals. Do not drop the batteries. Ensure the polarity connections are correct. Ensure that the battery interconnections are connected securely. Ensure that the interconnecting cables are not pinched underneath trays. High DC voltage is dangerous and is potentially lethal. Batteries should only be installed by qualified personel. Battery life expectancy is reduced when exposed to temperatures above 28 C September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 6

2.5 BATTERY CONNECTION. 12 13 F1 F2 F3 Fuses Top Tray Back of UPS unit Bottom tray Figure 4: 2. The batteries should be connected as shown above. CB1 F1 + F2 - F3 AC INPUT hager TRANSFER BYPASS NORMAL ISOLATE LOAD Figure 5: CB1 (AC Input) Battery Fuses Rotary Switch 3 & 5 KVA units only September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 7

3 O P E R A T I N G P R O C E D U R E S 3.1 INITIAL STARTUP: (Refer to figure 2 and figure 3) Ensure the INVERTER KEY Switch is in the OFF position and the Battery Fuses are OPEN. For the 3-5KVA units, place the Rotary Switch in the TEST position. For the 8-20KVA units, close the BYPASS Switch (SW2) and open the OUTPUT ISOLATE Switch (SW1). Close the AC input circuit breaker. Depress ALARM Cancel button to reset the hooter. The LCD will activate and after a brief period analog values and status alarms will be displayed. Turn the INVERTER KEY Switch to the ON position. The unit will start up when synchronized to the reserve (mains) in approximately 20 seconds. The sound of a closing relay contact will be heard and the fan will commence spinning. The DC voltage on LCD will rise to 432V and the UPS output voltage will indicate 230V with a frequency of 50Hz. Above these values the NO ACTIVE ALARMS message should appear. Check for correct polarity at the top of the fuses before closing. Close the DC input fuses (Battery fuses, F1, F2 & F3). 3.2 TRANSFER LOAD TO INVERTER: Turn the INVERTER KEY Switch to the OFF position and confirm INVERTER IN STANDBY / LOAD ON BYPASS is displayed on the LCD. For 3-5KVA units, place the Rotary Switch to the NORMAL position. For 8-20KVA units, Close the OUTPUT ISOLATE Switch (SW1) and open the BYPASS Switch (SW2) Turn INVERTER KEY Switch to the ON position. After approximately 20 seconds depress ALARM CANCEL button to silence hooter if required. The display should now read NO ACTIVE ALARMS together with the units input and output parameter values. The unit is now operating in the normal mode. 3.3 TRANSFER LOAD TO RESERVE: Ensure that the status, NO ACTIVE ALARMS is displayed. If LOSS OF PHASE LOCK alarm is displayed the load will loose power if the next step is performed. Do not proceed. Turn the INVERTER KEY Switch to the OFF position. The LCD will display the status INVERTER IN STANDBY LOAD ON BYPASS. For 3-5KVA units, place the Rotary Switch in the BYPASS position. For 8-20KVA units, close the BYPASS switch (SW2) and open the OUTPUT ISOLATE switch (SW1). The load is presently fed from the detour supply, i.e. raw mains. Open the DC fuses (F1, F2 & F3). Open the input circuit breaker (CB1). After approximately 1 minute the internal capacitors will discharge completely and the display will switch off. The unit may now be serviced or cleaned in this state. To switch the unit on again, refer to the INITIAL STARTUP procedures. 3.4 MANUAL BYPASS MODE: Perform the TRANSFER LOAD TO RESERVE procedure. The unit is placed in this state if a fault has occurred within the unit or the load conditions have changed. Depress the ALARMS CANCEL button to confirm an actual fault condition or otherwise. 3.5 ISOLATE LOAD: (3 & 5 KVA Units Only) This is a position on the Rotary Switch on the 3-5KVA units. The load will loose its source of power in this state. This position should be evaded unless a fault condition developes in the load,e.g. short circuit. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 8

4 T R O U B L E S H O O T I N G 4.1 GENERAL PROBLEMS The Tower range has been designed for maximum efficiency and reliability. This will be realized as long as the unit is operated within the specifications listed on the last page. The temperature is a major factor affecting the tolerances of the electronic components and also influences the lifespan of the batteries. It is important then that the units internal fan is always in working order. In the unlikely event of a failure occurring, it would not be wise to close circuit breakers that had tripped. Investigate the alarm status on the LCD, check for obvious causes and contact your service centre for advice. 4.2 ALARMS STATUS The LCD indicates the current alarm status of the UPS. 4.3 DESCRIPTION OF ALARMS A L A R M HIGH DC SHUTDOWN BATTERY DISCHARGING DC CRITICAL LOW DC SHUTDOWN INVERTER IN STANDBY INV. VOLTS OUT OF LIMITS INVERTER OVERLOAD OVER CURRENT STOP INVERTER LOCKOUT E X P L A N A T I O N DC voltage exceeded trip point (+20% of normal battery voltage).the over-voltage condition was present for longer than 15 seconds. The DC voltage has dropped below the float of 432V DC value. This indicates that the Inverter is drawing from the batteries and not from the charger. The DC voltage has decreased to a value approaching the Inverter switch-off point. The DC voltage has dropped below the low DC trip point. The Inverter is off. It will restart automatically when the condition that caused it to switch off e.g.low DC SHUTDOWN returns to normal. The Inverter output voltage is out of tolerance.( +10% or 10% ) The load demands on the Inverter exceeded 120% of its capacity. The condition was prevalent for longer than 15 seconds. The Inverter switched off due to excessive load current demands. ( Load current exceeded 300% for a period greater than 40ms ). After 5 unsuccessful attempts to start the Inverter within a time frame of 250 seconds, the LOCK OUT mode is reached. The Inverter will remain off and the load will source to the mains supply via the Static Switch. (Static bypass mode ). INPUT OUT OF LIMITS The MAINS source voltage is out of tolerance.( +/- 15% ) LOAD ON BYPASS ON OFF/DETOUR SWITCH OFF The Critical Load is fed from the reserve source via the Static Switch. The Inverter Key Switch is in the OFF position. FREQ OUT LIMITS The frequency of the reserve source is out of tolerance. ( +/- 2% ). LOSS OF PHASELOCK SINE ERROR CHARGER FAIL OVER TEMPERATURE SUPERVISION STOP The inverter is not able to lock in phase with the reserve source. The instantaneous value of the Inverter output voltage deviated from the limits by more than 15%. The load will be switched to the reserve source if it is present. The charger source has been interrupted. The unit has shut down due to excessive internal temperatures. The Inverter has switched off due to an excessive current demand detected in the IGBT Bridge. A fault condition has occurred and the Inverter will not restart. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 9

NO ACTIVE ALARMS No alarm conditions exist, the unit is functioning normally. 5 M A I N T E N A N C E 5.1 PREVENTATIVE MAINTENANCE To ensure continuous reliable operation of and to protect your unit from potential component failure and premature battery incapacity, it is advisable to have the unit serviced. This should be done at least anually but preferably every six months. The following checks may be carried out on a monthly basis : 1. Switch the unit OFF. ( See Operating Procedures ). 2. Ensure that ventilation slots and openings are not blocked.( Avoid placing the unit in confined spaces unless there is adequate ventilation ). 3. Check that the unit is not covered in excessive dust. If necessary remove the covers and blow the unit out. 4. Ensure that the unit remains free of moisture. 5. Check all cables to ensure that they are secure and in good condition. 6. Switch the unit ON. ( See Operating Procedures ) 7. Switch off the input mains supply by opening CB1. 8. Check that the UPS continues to supply the load and the NO ACTIVE ALARMS status is being displayed. (See battery maintenance below if the unit fails at this point.) 9. The unit is now operating on batteries. No additional alarms should be encountered. 10. Reset CB1 after a period of approximately 5 minutes. Depress the ALARMS CANCEL to clear the hooter if required. 11. Check the LCD for the following parameters: Input voltage : 200-253V (Rms value) Output voltage : Frequency : 50Hz Output current : 230V Rms (Inverter voltage) Within the specified limit.e.g. < 23A for the 5KVA unit. Battery voltage : 432V DC. ( All Single conversion On Line units ) 5.2 BATTERY MAINTENANCE It is crucial that the units battery back up is monitored and kept maintained. Steps 7 and 8 above will give an indication of the state of charge of the batteries. If the Inverter switches off during this test it indicates that either an individual battery has failed or the entire bank may be due for replacement, or an open circuit condition exists. The following may be checked quarterly: 1. Isolate the batteries from the UPS by opening the fuses F1, F2 and F3. 2. Remove the cabinet side panels and blow out the trays with a blower. 3. Check and ensure that all battery interconnections are tightly secured, and free of corrosion. 4. Check the main battery cable connections to the UPS. 5. Replace and secure all cabinet side panels. The anticipated life of the batteries is between 3 to 5 years depending on the number of discharges and the ambient temperatures. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 10

6 S P E C I F I C A T I O N S INPUT 3KVA 5KVA 8KVA 10KVA 15KVA 20KVA Voltage 230V±15% 230V±15% 230V±15% 230V±15% 230V±15% 230V±15% Frequency 50Hz±4% 50Hz±4% 50Hz±4% 50Hz±4% 50Hz±4% 50Hz±4% Current 11A 18A 28A 36A 54A 68A Power 2.22KW 3.7KW 5.92KW 7.4KW 11.1KW 14.8KW OUTPUT Voltage 230V rms 230V rms 230V rms 230V rms 230V rms 230V rms Voltage stability static 1% 1% 1% 1% 1% 1% Voltage stability dynamic <3% <3% <3% <3% <3% <3% Frequency 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz Waveform Sine Sine Sine Sine Sine Sine Harmonic distortion(linear loads) 3% 3% 3% 3% 3% 3% Inverter overload 200% 15sec 200% 15sec 200% 15sec 200% 15sec 200% 15sec 200% 15sec Bypass overload 1000% 0.1s 1000% 0.1s 1000% 0.1s 1000% 0.1s 1000% 0.1s 1000% 0.1s Efficiency (input-output) 95% 95% 95% 95% 95% 95% Current @ 0.7 pf 13A 22A 35A 43A 64A 87A BATTERY N o of 12V blocks 32 x 7A/H 32 x 7A/H 32 x 7A/H 32 x 7A/H 32 x 7A/H 32 x 7A/H Max N o of banks in cabinet 2 2 2 2 2 2 Float voltage 432V 432V 432V 432V 432V 432V Battery discharging 384V 384V 384V 384V 384V 384V Shutdown imminent 345V 345V 345V 345V 345V 345V Low DC off 335V 335V 335V 335V 335V 335V Autonomy 100% @ 0.7 pf (2 banks) 50min 30 min 20 min 12 min 8min 4min GENERAL Weight of UPS with 1 set of batteries 120kg 150kg 165kg 180kg 215kg 230kg Dimensions of UPS units and extended battery cabinets. L - 660mm H - 850mm W - 370mm Weight of battery cabinet with 3 sets of batteries Ambient temperature Noise level PROTECTION (ALL RANGES ) Input AC circuit breaker 300kg. 0-40 C 90% maximum humidity 50dBA @ 1 meter Input DC circuit breaker / fuses. Electronic overload. Electronic over current. Electronic Transistor supervision. A l l u n i t s c a r r y a o n e y e a r f a c t o r y w a r r a n t y. September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 11

7 S E R V I C E H I S T O R Y Commissioned By : Commissioned Date: Service Date Serviced By Next Service Date Notes: September 2000 TOWER UPS DISTRIBUTION (PTY) LTD 12