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User Manual - OnLine Power, Inc.

1. INVERTER re 10 ma R ON BATTERY dud CIRCUIT 19 93 OG BREAKER OPTIONAL AUX OUTPUT CBs BATTERY CABINET Batt Batt Batt Batt Batt Cab1 Cab2 Cab3 Cab4 Cab5 ILLUSTRATION 2 5 FUNCTIONAL BLOCK DIAGRAM FOR DUAL DELTA INPUT POWER OnLine Power A Internal or External Cabinet RESERVE A A INPUT eB 2 POWER plus Gnd B GN RESERVE BYPASS POWER From Internal CONTACTOR Transformer A OUTPUT CIRCUIT BREAKER om 0 0 MAINT BYPASS SWITCH INPUT CIRCUIT INPUT TB10 oA H BREAKER CONTACTOR MAIN ay le OUTPUT INPUT 2 0 r 93 POWER DELTA c 1610 INVERTER STATIC SWITCH 1ER BATTERY 1 CIRCUIT 2 93 OPTIONAL AUX OUTPUT CBs BATTERY CABINET A Optional External A WYE XFMR when the reserve is 3 wire Delta input A Output CB can be after MBS for special arrangement Batt Batt Batt Cab1 Cab2 Cab3 Cab4 Cab5 ILLUSTRATION 2 6 FUNCTIONAL BLOCK DIAGRAM FOR DUAL WYE INPUT POWER 6002 1443 Rev M 2 10 OnLine Power 2 5 2 5 1 2 5 2 2 5 3 2 5 4 THEORY OF OPERATION The Power Wave 3 utilizes on board microprocessor that continuously monitor control and display all functions measurement alarm alert and system status in real time by utilizing high frequency digital signal processing a reliable and user friendly battery back up system Standby Mode Aft
2. Ip OUTPUT CIRCUIT BREAKER m oA STATIC SWITCH INPUT J gt 10 cIRCUIT __ INPUT IBREAKER CONTACTOR nr af OUTPUT I ro 1 031 POWER ec 9193 u 4 INVERTER ree STATIC I 03 INPUT SWITCH 18791 POWER 3 PHASE CIRCUIT 22203 BREAKER OPTIONAL AUX OUTPUT CBs BATTERY CET Optional CABINET A Line removed when External Reserve Input Power is in use A Use for different Input and Output Voltage unit A Reserve input voltage must be same as UPS output voltage NOTE Optional External Wrap around Bypass Switch is available Batt Batt Batt Batt Cab1 Cab2 Cab3 Cab4 Cab5 ILLUSTRATION 2 4 FUNCTIONAL BLOCK DIAGRAM FOR SINGLE INPUT POWER 6002 1443 Rev M 2 8 OnLine Power A RESERVE INPUT POWER SOURCE 1 gt Z s Re uim o m m a 9B 21 RN 52 S ap CONTACTOR TVSS fom EJ INPUT TB10 REUS INPUT 1 BREAKER Bl L POWER 3 PHASE Optional A Line removed when External Reserve Input Power is in use A Use for different Input and Output Voltage unit A Reserve input voltage must be same as UPS output voltage NOTE Optional External Wrap around Bypass Switch is available 6002 1443 Rev M OUTPUT CIRCUIT STATIC BREAKER t SWITCH 5 B 5 r 1 OUTPUT 515 1 POWER 9 93 3PHASE
3. Congratulations on selecting one of the fine products from OnLine Power the leader in power protection technology Our wide product offering includes UPS Uninterruptible Power Systems power conditioners automatic voltage regulators and specialty transformers e g computer grade medical grade Since our founding in 1972 OnLine Power has shipped many of these fine products to discerning customers around the world for use on sensitive equipment and in critical applications One of our goals is to make our manuals both comprehensive and easy to use The new format of our user manual is the result of ideas and inputs from customers like you who have taken an active interest in our continued success We invite and appreciate your feedback on our products and documentation via e mail fax mail or telephone 6002 1443 Rev M SALES Phone 800 227 8899 FAX No 323 721 3929 E mail sales onlinepower com Office Hours are 7 00 AM to 5 00 PM PST WARRANTY REGISTRATION AND WARRANTY CERTIFICATE REQUEST www 800pwrsrvc com SERVICE If you require assistance please call our 24 hour toll free hot line 800 PWR SRVC 800 797 7782 or email to info 800pwrsrvc com Please have the following information from your unit s nameplate available to speed assistance Serial Number KVA Power Rating Input Voltage Output Voltage Manufacturer Date Due to continuous product improvement this document is subject to change without prior notice
4. OnLine Power SECTION 1 SAFETY Following safety precautions are important when operating or servicing electrical equipment The symbols shown are used extensively throughout this manual Always heed these precautions since they are essential to the safe operation and servicing of this product Boxes labeled with the A Danger symbol indicate that there is a high risk of personal injury or death if instructions are not followed Warnings labeled with the Caution symbol indicate that there is a high probability of equipment malfunction damage or destruction if instructions are not followed A Danger ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START UP PROBLEMS HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT S AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT MALFUNCTION A Danger READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING INSTALLATION START UP OPERATION AND MAINTENANCE OF THE UNIT OR BATTERY SYSTEMS FAILURE TO DO SO COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT MALFUNCTION If you require assistance calls toll free 800 PWR SRVC 800 797 7782 Please have the following information from your unit s nameplate available to speed assistance Serial Number KVA Power Rat
5. 6002 1443 Rev M 6 1 SITE PLANNING AND PREPARATION Table 6 A Site Planning Specifications Illustration 6 1 Cable Access and Mounting Illustration 6 2 UPS Cabinet Center of Gravity Illustration 6 3 Battery Cabinet Center of Gravity 6 2 EQUIPMENT UNPACKING Illustration 6 4 Fork lifting 6 3 UNIT INSTALLATION Illustration 6 5 Power Wave Customer s Connection 6 4 REMOTE SIGNALLING CONNECTIONS FORM C DRY CONTACT OPTIONAL 65 BATTERY STORAGE PAGE 4 10 4 10 4 10 4 11 4 11 4 11 4 11 4 12 4 12 4 12 4 19 4 20 5 1 5 8 A 1 B 1 D 1 6 1 6 1 6 1 6 2 6 3 6 4 6 5 6 5 6 6 6 7 6 9 OnLine Power OnLine Power Inc Reproduction or Distribution forbidden NOTICE THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION This document contains proprietary and confidential information of OnLine Power Inc OnLine Power In consideration of the receipt of this document the recipient agrees not to copy any of its contents nor to disclose them to or allow them to be used by any person not currently an OnLine Power employee or an employee of the recipient having a need to know without the express written consent of OnLine Power and further agrees to surrender this document to OnLine Power when the reason for its receipt has terminated Due to continuous product improvement this document is subject to change without prior notice 2009 OnLine Power Inc All rights reserved 6002 1443 Rev M OnLine Power
6. Caution If during the start up procedures anything unusual occurs immediately turn off the input circuit breaker and contact OnLine Power at 800 797 Ao o 7782 for technical assistance Also use this number for any other questions or additional information The main input power and reserve input power should be available at the Caution same time when dual input power sources are used 4 1 3 Apply input power to the Power Wave e Input Circuit Breaker remains open e Verify that the voltage measured on the input circuit breaker is 208V or 480 VAC and is the same as the nameplate voltage rating If the voltage is not the same as on nameplate within 10 to 1596 tolerance do not proceed any further Contact OnLine Power at 800 797 7782 for technical assistance e Verify that there are no voltages measured on the output terminal block 3 1 4 Turn on the main input circuit breaker 3 1 5 After turning on the system wait one 1 minute while the Power Wave runs through its internal diagnostic sub routine Hear the sound of contactor closing Observe the fan s running Observe the LCD display screen showing unit normal message 6002 1443 Rev M 3 1 OnLine Power Line 1 UPS NORMAL 15 kVA Line 2 INPUT OK CHRG ON Line 3 BATTERY OK DC OK Line 4 ON INVERTER OUT OK e Verify that the LCD display panel indicates all correct parameters see Appendix D for details Verif
7. Input is within an acceptable range Input is out of range Charger on The charger is off This will happen if the input capacitor is open or the system is ina malfunction mode Unit ALARM OnLine Line 3 Power BATTERY OK DC OK BATTERY OK Battery voltage is within an acceptable range BATTERY OV Battery voltage is high This is normal when the battery is charging BATTERY LOW Battery voltage is low Recharge the battery DC OK DC OV DC UV NOTE DC bus voltage is within an acceptable range DC bus voltage is too high UNIT ALARM DC bus voltage too low UNIT ALARM The typical DC buss voltage should be higher than the battery voltage SCREEN B The second default screen appears as below Line 1 Line 2 Line 3 Line 4 6002 1443 Rev M Indicates the output voltage and power in watts Indicates the input volts and amps Indicates the internal DC bus condition for factory use Indicates the battery voltage The current in Amps indicates charging amps while indicates discharging Amps C 2 OnLine Power 10 11 APPENDIX D Drawings All drawings can be downloadable from our Website www onlinepower com Three Phase unit Installation Installation Dwg 6001 032 03 Unit and Battery Cabinet Configuration layout Battery Cabinet Layout Dwg 6001 032 05 Unit and Battery Cabinet Installations Battery Cabinet Layout Dwg 6001 032 06 Unit and Battery Cabinet Inst
8. User Manual Power Wave 3 Emergency Lighting Inverter 10 KVA 50 KW Document No 6002 1443 Revision Installation and Operation Due to continuous product improvements this document is subject to change without notice OnLine Power SECTION TABLE OF CONTENTS PROPRIETARY NOTICE SECTION 1 SAFETY SECTION 2 OVERVIEW 2 1 2 2 2 3 2 4 2 5 2 6 INTRODUCTION Illustration 2 1 Power Wave 3 BENEFITS PRODUCT FEATURES Illustration 2 2 Component Layout Illustration 2 3 Sub Assembly Component Location FUNCTIONAL DESCRIPTIONS Illustration 2 4 Functional Block Diagram for Single Input Power System Illustration 2 5 Functional Block Diagram for Dual Delta Input Power System Illustration 2 6 Functional Block Diagram for Dual Wye Input Power System THEORY OF OPERATION OUTPUT LOADS SECTION 3 OPERATION 3 1 3 2 3 3 3 4 START UP PROCEDURES OPERATION FIELD REPLACEABLE UNITS Illustration 3 1 40KVA and lower Heat Sink Assembly FRU Illustration 3 2 50 KVA and up Heat Sink Assembly FRU REPLACEABLE PARTS LIST SECTION 4 SYSTEM OPTIONS 4 1 4 1 3 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 6002 1443 Rev M MAINTENANCE BYPASS SWITCH Illustration 4 1 External Maintenance Bypass Switch Diagram Illustration 4 2 Maintenance Bypass Switch External Manual Bypass Switch AUDIO ALARM WITH SILENCE SWITCH REMOTE UPS STATUS PANEL Illustration 4 2 1 Remote St
9. VOLTAGE I O TYPE 208 208 3000 050 480 480 3000 050 480 208 3000 050 208 480 3000 050 3000 050 3000 050 3000 050 3000 050 3000 055 3000 050 3000 055 3000 050 3000 055 3000 050 3000 055 3000 050 3000 056 3000 050 3000 056 3000 050 3000 056 3000 050 3000 056 3000 050 3000 057 3000 055 3000 057 3000 055 3000 057 3000 055 3000 057 3000 055 For load disconnect option add B suffix to the part no 3000 044 B Unit with different input output voltage require step up or down transformer W1 D c a H1 95 MAINT i xu EO ise H CB2 Y MOUNTING FT PST DIM LJ T durs sl ae OG GINE Oe OPTIONAL LOAD DISCONNET DIM S INCH SWITCH Part No RATING W H D w H1 55 AMP 3000 044 044 B 050 050 B 14 16 8 12 16 75 110 AMP 3000 045 045 B 055 055 B 14 16 10 12 16 75 175 AMP 3000 046 046 B 056 056 B 20 20 10 18 50 18 50 240 AMP 3000 047 047 B 057 057 B 24 24 10 22 50 22 50 ENCLOSURE DIM S 6002 1443 Rev M 4 5 OnLine Power 42 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH P N 9100 1363 02 43 OPTIONAL REMOTE UPS STATUS PANEL P N 9100 1020 07 4 3 1 Installation The Remote UPS Status Panel is available in a wall mount or console style box in black finish Up to 500 feet long cable option 4 3 2 Opera
10. 4 STRING ILLUSTRATION B 1 6002 1443 Rev M B 2 OnLine Power 288 Volt Nominal Typical Typical 1 Strings of 24 Battery system A system with a maximum of four strings of 24 C CL CL CE T SD JD JD JD batteries is available utilizing a maximum of four e e cabinets depending battery run time 24 23 22 21 requirements Consultthe factory for details ES MEN DIE p H BATT C B lt gt 16 17 18 19 20 O O 288 vDC INVERTER CABINET z BUSS Q TO 09 09 CIN NL Q 9 O OO a o P1 ui 2 4 288 VDC 2 STRING MB A as QD Hk sO ac 3 STRING 4 STRING ILLUSTRATION B 2 6002 1443 Rev M B 3 OnLine Power 312 Volts Nominal Typical Typical 1 Strings of 26 Battery system A system with a maximum of five strings of BATT C B 26 batteries is available utilizing a maximum of seven cabinets depending on battery run time requirements Consult the factory for details INVERTER CABINET 312 VDC 2 STRING 3 STRING 4 STRING 5 STRING ILLUSTRATION B 3 6002 1443 Rev M B 4 OnLine Power 552 Volts Nominal Typical Typical 1 Strings of 46 Battery system o Ta E 2 2 E 3 E x G E z gt o lt of 26 batteries is available utilizing a maximum of seven cabinets depending on battery run
11. 4 pole make before break 2 When the switch is in UPS position the critical load is being powered through the inverter with battery backup available 3 When the switch is in MAINT position the critical load is being powered through the input utility or input transformer for different voltage with no battery backup available 4 The wrap around By pass SW switch should be used with the same input output voltage 5 For different input output voltages the switch should be used with an external transformer 6 The wrap around By pass SW switch cannot be used with any built in distribution secondary auxiliary circuit Breakers 4 1 1 Installation Allow front access to the MBS box at all times for maintenance and servicing Electrical codes require that the MBS box be installed with no less than 3 feet at the front of the cabinet Side and rear panels do not require service clearance however side vents must not be blocked A Danger ALL POWER CONNECTIONS MUST BE MADE BY LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES IMPROPER WIRING MAY CAUSE DEATH INJURY EXPLOSION FIRE OR DAMAGE TO THE EQUIPMENT VERIFY THAT ALL INCOMING HIGH AND LOW VOLTAGE POWER CIRCUITS ARE DE ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS Refer to Section 6 1 Site Planning and Prepa
12. DC Choke L4 9 High Frequency Noise Filter Capacitors Output and Battery Power 10 Control Board A2 11 LCD Display Board 12 Output High Frequency Filter C5 C6 C7 13 Terminal Block to remove heat sink assembly TB4 14 Control Power 40 kva and lower Transformer T2A 15 Fan Fuse F3 F6 16 IGBT Heat Sink Assembly 17 Control Fuses F2 F1 18 Heat Sink Bypass SCR 19 Fan s B1 B6 20 Input Contactor K1 21 Ground Terminal Option w item 25 22 Input Breaker CB1 23 Battery Breaker CB2 24 Output Breaker CB3 25 Output Distribution Breakers Optional 26 Neutral Bus Option w item 25 27 Customer Input Output Connection Terminal Blocks 28 Maintenance Bypass Switch SW1 29 SCRs and Snubbers 30 Contactor Coil Transformer T5 31 Fan Transformer T4 32 Inverter Test Switch 33 RS232 RS485 Option 34 TVSS Option 35 Ground Lug 36 5 Form C Alarm Terminal Option 37 MBS S 1 Toggle Switch or maintenance bypass switch with 3 positions ILLUSTRATION 2 3 6002 1443 Rev M K REN Eee wes e E ELECTRONIC TRAY 40 KVA amp LOWER ELECTRONIC TRAY 50 KVA amp UP SUB ASSEMBLY COMPONENT LOCATION 2 5 OnLine Power 2 4 2 4 1 2 4 2 2 4 3 2 4 4 2 4 5 2 4 6 2 4 7 2 4 8 2 4 9 FUNCTIONAL DESCRIPTION Illustrations 2 2 thru 2 6 depict functional block diagrams of the Power
13. OPTIONAL STACKABLE RACK Drawings 6001 032 07 Refer to Appendix D 6002 1443 Rev M 4 10 OnLine Power 4 17 4 17 1 4 17 1 1 Description 4 17 1 2 Operation Ups_mainvi C Ups_main vi File G Operate Windows Help Global Monitoring System GMS Local On PC Via RS 232 P N 9800 003 25 THRU 150 25 150ft This option requires a PC and LabView monitoring software The software is provided on a CD ROM that is easily installed on any Microsoft Windows platform An attached cable of a specified length plugs into a PC serial port and connector J6 on the Control PCB 1625 296 LabView software must be selected for COM port 1 LabView software translates data protocol coming to COM port 1 from an active unit via the RS232 RS485 interface and displays the parameters and active alarms on a PC monitor in the appropriate form Below is a sample of a PC screen with measured parameters and actual unit status ONLINE POWER 3PHASE Output Power W Output QA Volts p 00 Output QB Volts p 00 Output QC Volts p 00 Inverter Output OK UPS Status NORMAL Static Switch ON INVERTER Battery Voltage V Battery Current A STOP Battery Charger ON Battery Status Charger Current Battery OK po Input QA Volts p 00 Input QB Volts p 06 Input QC Volts p 00 Input Status Input OK Input Current A 4 17 1 3 Specification 4 17 2 6002 1443 Rev M Description Loca
14. 2000 s Event Log the unit s Event Logger must first be downloading to your PC You must be online with the unit to download the Event Log Choose Functions from the main menu and then select View Events You can also access the Event Logger from the toolbar button labeled Events The following event log form will appear 04 08 1997 06 25 23PM Event Log Viewer Viewing the Event Logger Once the Event Logger has been downloaded it can be viewed on the form called Event Viewer Below is a list of programming parameters for viewing the Event Logger Event Viewer GMS 2000 Event Logger Query Informs Plant 1 Oak amp Pin Datalogger Download 4 8 97 6 25 05 PM Plant 1 Oak amp Pin Datalogger Reset p 4 8 97 6 25 02 PM Plant 1 Oak Pini Datalogger Reset Event Viewer form 4 18 OnLine Power 4 18 OPTIONAL ECC EMERGENCY CIRCUIT CONVERTER P N 9100 1501 4 18 1 Installation 4 18 2 4 18 3 Indoor use only Simple and fast installation in ceiling or wall mounted standard single gang E box ECCA qualified electrician must perform the installation per the Installation Operation and Maintenance Instructions provided with the ECC Operation When used with an inverter system the ECC is designed to allow you the ability to turn off all of the lighting in a given area via the local switch and still provide emergency lighting during a power disruption The device will
15. 3 5 OnLine Power 3 4 REPLACEABLE PARTS LIST T s e 11 1 Fanis B1 9 6002 1443 Rev M 3 6 OnLine Power SECTION 4 SYSTEM OPTIONS This section describes options available for the Power Wave 3 phase The following options are available Part Number Options 3000 044 thru 048 and External Manual Bypass Switch 055 thru 057 9100 1363 02 9100 1020 04 9100 1362 02 9100 1440 01 TVSS Transient Voltage Surge Suppressor 208V 9100 1440 01 1 TVSS Transient Voltage Surge Suppressor 480V 9100 1343 01 thru 26 Normally ON OFF Output Aux Circuit Breakers 9100 1439 01 thru 03 External Output Aux Circuit Breakers in Panel Board 11 thru 13 9100 1372 01 03 9100 1373 01 04 See page 4 9 Audio Alarms with Silence Switch Remote unit Status Display 3 Phase Monitor Form C N O Contacts for Alarms 1096 Input Current Harmonic Filter 596 Input Current Harmonic Filter Higher KAIC Norm ON OFF Output Circuit Breaker 3 Phase 9100 1445 01 thru 05 EMI Filters 9100 1446 01 thru 03 Dual Input System WYE WYE 9100 1446 04 thru 06 Dual Input System DELTA WYE Dual Input System DELTA DELTA Seismic Mounting Bracket Left and Right set per cabinet GMS Global Monitoring System 9800 003 25 thru 150 Local on PC via RS232 9800 004 150 thru 1000 Local on PC via RS485 9100 1468 02 See page 4 10 9100 1317 02 Remo
16. and charging current 6 Allow unit to run for 24 hours minumun to charge batteries fully 7 When batteries have reached partial charge level the battery charging current will be under 1 Amp on LCD panel 8 Open CB2 Battery Breaker 9 Turn OFF input power to the unit 10 Close and lock front door or use an external charger to charge each individual battery 6002 1443 Rev M 6 9
17. modem destinations 6002 1443 Rev M 4 16 OnLine Power 4 17 3 5 DATA LOGGING The GMS 2000 s built in data logger can log and store information in eight 8 universal inputs AC power and backup battery voltage You must be on line with the unit to program Data logging You can also access the Data Log programming from the toolbar button labeled Data Log Note Whenever you change any parameters on the data log form the data logger in the GMS 2000 will be reset If you need to make changes to your programming be sure to Retrieve Data first Viewing the Data Logger on line Once the Data Logger has been downloaded it can be viewed in the Data Logger Form Click the View Database button on the Data Log Programming form The following will appear Date 04 08 1997 Data Log Viewer Viewing the Data Logger off line To view a unit s downloaded Data Logger off line follow the instructions for Offline Communication Below is a list of programming parameters for viewing the Data Logger 6002 1443 Rev M 4 17 OnLine Power 4 17 3 6 6002 1443 Rev M EVENT LOGGER The GMS 2000 keeps track of important system events with its built in Event Logger Each GMS 2000 unit stores the last 500 system events System events include alarms incoming and outgoing phone calls and alarm acknowledgments Once the Event Log is full the oldest record is overwritten by the newest Downloading the Event Logger To view GMS
18. power supplies and drivers for the IGBTs The entire assembly provides the landing place for all internal input output DC cables and metering devices for control and monitoring of the unit input and output parameters Control Board Illustration 2 2 Item 10 The on board microprocessor with unit specific firmware and control circuitry is located on the Control Board The Control Board is mounted on the cabinet door and communicates with the Power Board A2 via a ribbon cable It monitors the input and output voltages and generates the command to close or open the input contactor and to sense and change the status of the bypass static switch The Control Board sends data to the LCD panel located on the door where actual status and parameters are displayed It additionally has AS400 RS232 and RS485 output capabilities and supports various communication options Static Bypass Switch Illustration 2 2 Item 18 The Static Bypass Switch is a fully rated solid state device capable of switching the critical load between the inverter output and the normal AC by pass line In the event of a system output overload of 12596 or more of the unit full load current rating a make before break both directions transfers power to the bypass source via a static switch LCD Display Panel Illustration 2 2 Item 11 The unit display via a 4 by 20 backlit character display provides all the input output battery metering alarm data and unit status for custo
19. provide single phase power from the emergency source to the designated emergency fixtures regardless of their current status on or off thereby insuring safe egress from the facility The automatic diagnostic feature will confirm the emergency system is ready to provide back up power Specifications Description ECC EMERGENCY CIRCUIT CONVERTER OPTION Part Number 9100 1501 01 120 VAC 9100 1501 01 277 VAC Rating 120 VAC 20 A Ballast load 1000 W Tungsten Lamp load 20 A 1 HP 277 VAC 20 A Ballast load 1800 W Tungsten Lamp load 20 A 1 5 HP Operating Temperature 20 to 150 F Flame rating UL 94V O Size 2 75 W x 4 75 H x 1 75 D overall Low profile recessed portion is only 1 5 deep Color White Weight 8 oz EMERGENCY POWER e TEST SWITCH e UTILITY POWER ILLUSTRATION 4 12 ECC EMERGENCY CIRCUIT CONVERTER 6002 1443 Rev M 4 19 OnLine Power 4 19 OPTIONAL ECM EMERGENCY CONTROL MODULE P N 9100 1502 4 19 1 4 19 2 4 19 3 Installation Indoor use only ECM is a universal mount unit that allows simple and fast installation in the ceiling or a wall mounted standard single gang e box recommended box size 4 ECCA qualified electrician must perform the installation per the Installation Operation and Maintenance Instructions provided with the ECC Operation Emergency power is provided from a central lighting inverter that is automatically switched to a 24 hour emergency power distribution p
20. record of each battery with evidence that the terminal connections have been torque checked Preventive Maintenance List Description Check Room Temperature Removal of dust from all electronics Verification of all electrical connection Check all Batteries post and connection for corrosion Check for batteries deformations Record all batteries Nominal Voltages 5 4 1 Maintenance Log Carefully record keeping will ensure proper maintenance of the unit and assist in the correction of any abnormal conditions At a minimum the Maintenance log should contain the following information 6002 1443 Rev M Date of system start up Dates that battery maintenance was performed Dates input output and battery status readings were checked and the values displayed for these readings Date of load changes Dates and summaries of all communications with OnLine Power service personnel Every six 6 months or at least annual individual battery voltage amp torque check 5 4 OnLine Power 5 4 2 Periodic Testing of unit The unit should be manually exercised on a periodic basis once every three months for example This forces the unit to transfer to the battery and return to main power This process activates self diagnostic testing which may reveal conditions that require attention 5 4 3 Maintaining the Batteries A Danger THE BATTERY CIRCUIT BREAKER OPERATES AT THE RATED BATTERY VOLTAGES AT ALL TIMES A TRIPPED BATTE
21. 00 Clear 40emps Okey NoAlam 00 158 ear Open Off No Alam Open Okay Alarm Bl degF Okey Outstanding 317 858 Clear Open Okay Alarm Open Ott Outstanding On No Alam 0 0 Volts Very Low 0 0 00 Clear 6 125 i kstort A SG gt Document 2000 4 Manager 2000 Event Log Viewer Everk Viewer manes Time Monto SC QBS SAAS sem ILLUSTRATION 4 10 2000 SCREEN 6002 1443 Rev 4 12 OnLine Power 4 17 3 2 4 17 3 3 6002 1443 Rev M Operation The dial up Monitor 2000 measures and monitors the following set of parameters and status contacts Input Volts Output Volts Output AMPS Battery run Low battery Cabinet temperature F On by pass Summary alarm ONO P gt The user can monitor all inputs in real time graphical form and can access real time input monitoring from the tool bar button labeled monitors The details are given in the GMS 2000 user s Manual 6002 1770 Alarms When an alarm occurs the unit will dial out and send a message to all programmed destinations GMS 2000 will call up to 32 telephone numbers or email addresses both referred to as destinations to report alarm conditions or send reports Destinations can be voice calls fax machines computers with modems running GMS 2000 software e mail addresses numeric pagers or alphanumeric pagers You must be on line with the unit to program the destination parame
22. 08Y 120 or 480Y 277 VAC 20 to 15 OUTPUT VOLTAGE VAC Three Phase 4 Wire plus Ground 208Y 120 or 480Y 277 VAC OUTPUT FREQUENCY Hz 60 Hz 0 5 Hz VOLTAGE REGULATION 3 Regulated within CBEMA curve OUTPUT WAVE FORM Sine Wave lt 5 THD EFFICIENCY Greater than 90 Typical CREST FACTOR 3 to 1 Typical SURGE PROTECTION The unit will protect itself and the load against surges as defined in ANSI IEEE C62 41 Categories A and B ISOLATION Complete from line Output neutral bonded to ground NOISE ISOLATION 120 dB Common Mode 60 kB Transverse Mode BATTERY Sealed maintenance free AGM battery RECHARGE CURRENT Comforts to UL Standards EXTERNAL BATTERY Provisions for hardwire connection of optional external battery cabinets or DC source BATTERY BATTERY RUN TIME BATTERY TYPE NOMINAL BATTERY VOLTAGE OVERCURRENT PROTECTION PACKAGING 90 minutes consult Online Power for other runtimes Sealed Maintenance Free AGM VRLA type standard Consult factory for other type 192 VDC 192 VDC 192 VDC 288 VDC 288 VDC 312 VDC 552 VDC 552 VDC Circuit Breaker Batteries not housed in Same Enclosure as electronic Batteries are shipped directly from the battery manufacturer separately to insure freshness 6002 1443 Rev M A 1 OnLine Power Specifications for KVA 0 8pf Units Continued MONITORING AND COM
23. 2 365 5239 480Y 277 208Y 120 27 34 42 56 30 38 92 112 6066 679 344 2 1780 2 365 5239 25kva 20kw 208 120 208Y 120 77 76 120 69 86 08 288 85 7582 679 344 2 2284 2 469 6247 480Y 277 480Y 277 35 44 55 30 38 48 288 85 7582 679 344 2 224 2 469 6247 480Y 277 208Y 120 35 44 55 69 86 08 288 85 7582 679 344 2 224 2 469 6247 30kva 25kw 208 120 208Y 120 93 16 145 83 104 30 288 102 9098 719 353 2 2284 2 469 6287 480Y 277 480Y 277 41 51 64 36 45 56 288 102 9098 719 353 2 2284 2 469 6287 480Y 277 208Y 120 41 51 64 83 104 30 288 102 9098 719 353 2 2284 2 469 6287 40kva 32kw 208Y 120 208Y 120 123 154 192 11 139 74 312 169 2131 2066 424 3 2288 3 592 8930 480Y 277 480 277 64 68 84 48 60 75 312 169 2131 2066 424 3 2288 3 592 8930 480Y 277 208Y 120 128 54 192 11 139 74 312 169 2131 2066 424 3 2288 3 592 8930 50kva 40kw 208Y 120 208Y 120 155 194 242 39474 217 552 20 5164 2463 505 i 1244 en 11263 480Y 277 480Y 277 67 84 105 60 75 94 552 20 5164 2463 505 3 doin 11263 480Y 277 208Y 120 155 194 242 39474 217 552 20 5164 2463 505 1 2284 1 400 11263 50kw 208Y 120 208Y 120 194 243 303 74 218 272 552 150 8000 2565 526 6 2184 6 448 15669 480Y 277 480Y 277 84 105 131 75 94 117 552 150 8000 2565 526 6 9184 6 448 15669 480Y 277 208Y 120 194 243 303 74218 272 552 150 8000 25
24. 2300 Note If your pager service is answered by a voice promted message you will need to enter additional pro gramming See the special dialing codes section iht the GMS 2000 Manual packed with the unit Alphanumeric Pagers The GMS 2000 can dial alphanumeric pagers to send alarm messages The GMS 2000 will send the unit description tele phone number input name and input value To program an alphanumeric pager destination enter the phone followed by the letter A and then the pager indentification number Example 1 610 555 4593 A 0504099 E mail The GMS 2000 can send alarm messages and reports via email To use this function you must designate an e mail host You can use your own computer as an email host Dial Type This is used to specify the type of call GMS 2000 will make to a particular destination The available dialout types are Fax voice e mail pager alpha pager and modem Fax This instructs GMS 2000 to send a fax transmission to either a fax machine or a PC with the ability to receive a fax directly Email This instructs the GMS 2000 to deliver a message to the E mail address programmed in the destination field Note For e mail dial types only e mail addresses may be programmed in the destination field NOT telephone numbers The GMS 2000 will contact an e mail host as designated on the system screen Numeric Pager This instructs GMS 2000 to dial a numeric pager and leave the unit s Indentification nu
25. 34 01 26 22 KAIC 120 240V Din Rail 9100 1434 31 56 42 KAIC 120 240V Din Rail 9100 1434 61 86 65 KAIC 120 240V ONLY Din Rail 9100 1435 01 26 14 KAIC 277V ONLY Molded Case 9100 1435 31 56 25 KAIC 277V Only 9100 1435 61 86 65 KAIC 277V ONLY Molded Case C B 9100 1343 01 26 22 KAIC 120 240V 10 KAIC 277V Din Rail Standard 9100 1343 41 66 30 KAIC 120 277V Din Rail 6002 1443 Rev M 4 9 OnLine Power 4 12 4 13 4 14 4 14 1 4 15 4 16 OPTIONAL DUAL INPUT SYSTEM WYE WYE SAME INPUT OUTPUT VOLTAGE P N Voltage 9100 1446 01 208V IN OUT 10 15 20 kVA 480V IN OUT 10 50 kVA 9100 1446 02 208V IN OUT 25 30 40 kVA 9100 1446 03 208V IN OUT 50 kVA OPTIONAL DUAL INPUT SYSTEM DELTA WYE SAME INPUT OUTPUT VOLTAGE P N Voltage 9100 1446 04 208V IN OUT 10 15 20 kVA 480V IN OUT 10 50 kVA 9100 1446 05 208V IN OUT 25 30 40 kVA 9100 1446 06 208V IN OUT 50 kVA OPTIONAL DUAL INPUT SYSTEM DELTA DELTA DIFFERENT INPUT OUTPUT VOLTAGE Delta Input System 208V IN 480V OUT Wye Wye Use 6 13 and 6 12 Dual Input System and separate Iso Care Transformer to match the output voltages Consult factory for proper KVA and model number OPTIONAL SEISMIC MOUNTING BRACKET P N 9100 1317 02 Consult factory for certification P N 5088 025 Left Right seismic floor mounting bracket
26. 65 526 6 2184 6 448 15669 Note 3 Phase Power Wave 3 electronic is in one cabinet and the batteries are in a separate cabinet For more information please contact your Sales Engineer Battery cabinet can be reduced to 5 using larger 150AH batteries 4 2670 Ibs floor loading 548 lbs and 1 2270 lbs floor loading 466 Ibs 5 Depend on options added 6002 1443 Rev M A 3 OnLine Power APPENDIX B BATTERY CONNECTIONS FOr the actual battery connection diagram for your system refer to the Caution diagram on each unit The drawings below are shown for electrical eeeeeeeeee Connection only and do not necessarily match the actual battery layout in your unit The arrangement may be different from drawings A Danger The use of a physically damaged battery can cause a catastrophic system failure and can even result in a fire or explosion that could endanger life and property Before accepting a battery shipment from the carrier please read and follow these instructions 1 Thoroughly inspect each battery for any signs of damage If there is any damage reject the shipment and notify the manufacturer at 800 PWR SRVC 800 797 7782 If possible photograph the damage for future reference As you unpack the pallet or container check each battery box for damage on all sides the top and bottom If there is any sign of damage photograph
27. Call Mode are Disabled Until A Acknowledged and Inform Disabled Destinations programmed with Alarm Call Mode Disabled will never be called This is simply a way to disable dialing to this destination if necessary Until Acknowledged Destinations programmed with Alarm Call Mode Until Acknowledged will continue to be called until one of them acknowledges the alarm Once acknowledged the remaining destinations will not be called NOTE Fax e mail and modem destinations cannot be programmed as Until Acknowledged call modes Inform Destinations programmed with Alarm Call Mode Inform will be called until the alarm message has been successfully delivered one time regardless of acknowledgment If a transmission to an Inform destination was successful that destination will not be contacted again GMS 2000 will only make additional attempts to contact an Alarm Call Mode Inform destination if that destination hasn not successfully received its transmission for example due to a no answer busy signal or no carrier response If a transmission fails to reach a destination after the last calling round is completed the malfunction is recorded in event Log Calls to priority Inform destinations are useful for providing records of alarm events Important Destinations programmed as Alarm Call Mode Inform cannot acknowledge alarms 4 15 OnLine Power 4 17 3 4 GRAPH Once the data log records have been displayed they may b
28. D ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION FIRE EQUIPMENT MALFUNCTION OR ELECTROCUTION 6002 1443 Rev M 1 2 OnLine Power A Danger ALL POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT FAILURE TO DO SO COULD RESULT IN ELECTROCUTION A Danger IN A FIRE INVOLVING ELECTRICAL EQUIPMENT ONLY USE CARBON DIOXIDE FIRE EXTINGUISHERS OR THOSE APPROVED FOR USE ON ELECTRICAL EQUIPMENT USE OF WATER ON FIRES INVOLVING HIGH VOLTAGE ELECTRICAL CIRCUITS COULD RESULT IN ELECTROCUTION A Danger EXTREME CAUTION IS REQUIRED WHEN PERFORMING MAINTENANCE LETHAL VOLTAGES EXIST WITHIN THE EQUIPMENT DURING OPERATION OBSERVE ALL WARNINGS AND CAUTIONS IN THIS MANUAL FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH OBTAIN QUALIFIED SERVICE FOR THIS EQUIPMENT AS INSTRUCTED A Danger BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES WITH INPUT POWER OFF AND THE BATTERY DISCONNECTED HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS HOWEVER POWER CIRCUIT MALFUNCTIONS CAN OCCUR SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT A Danger SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO CHASSIS GROUND ANY CONTACT BETWEEN FLOATING CIRCUITS AND THE CHASSIS IS A LETHAL S
29. HOCK HAZARD 6002 1443 Rev M 1 3 OnLine Power A Danger INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER PRIOR TO MOVING THIS UNIT THIS UNIT CONTAINS NON SPILLABLE BATTERIES KEEP THE UNIT UPRIGHT DO NOT STACK DO NOT TIP ALWAYS FOLLOW THE BATTERY MANUFACTURER S SAFETY INFORMATION LOCATED IN A POCKET ATTACHED TO THE INSIDE OF THE LEFT DOOR OF YOUR UNIT TO PREVENT AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH A Danger LEAD ACID BATTERIES CONTAIN HAZARDOUS MATERIALS BATTERIES MUST BE HANDLED TRANSPORTED AND RECYCLED OR DISCARDED IN ACCORDANCE WITH FEDERAL STATE AND LOCAL REGULATIONS BECAUSE LEAD IS A TOXIC SUBSTANCE LEAD ACID BATTERIES MUST BE RECYCLED OR DISCARDED AS HAZADEROUS WAIST DO NOT DISPOSE OF BATTERIES IN A FIRE THE BATTERIES MAY EXPLODE DO NOT OPEN OR MUTILATE THE BATTERIES RELEASED ELECTROLYTE IS HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC A BATTERY CAN HAVE A HIGH SHORT CIRCUIT CURRENT AND PRESENT A RISK OF ELECTRICAL SHOCK THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED WHEN WORKING ON BATTERIES REMOVE WATCHES RINGS OR OTHER METAL OBJECTS USE TOOLS WITH INSULATED HANDLES WEAR RUBBER GLOVES AND BOOTS DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR DISCONNECTING BATTERY TERMINALS DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED SO REMOVE THE SOURCE OF THE GROUND CONTACT WITH ANY PART OF A GROUNDED BATTERY CA
30. MUNICATIONS INDICATORS LCD Display Panel RELAY INTERFACE Dry Contacts for Sum Alarm N C Bypass On N O Loss of Input Power N O Low Battery N O CONTACT RATING 125 Volts AC or DC Maximum 1 25 Amperes Maximum 30 Watts 50 VA Maximum INTERFACE CONNECTION Hard Wired Terminal Block ENVIRONMENTAL SURGE WITHSTANDABILITY ANSI C62 41 1980 Categories A and B OPERATING TEMPERATURE Meets NEMA Requirements OPERATING RELATIVE HUMIDITY 0 to 95 Non Condensing ALTITUDE Up to 6 000 Feet 1 829 Meters with No De Rating COOLING Air Cooled Forced Fan PHYSICAL KVA KW 10 8 15 12 20 16 25 20 30 24 40 32 50 40 50KW SIZE HxWxD in cm 70 x 39 x 20 177 8 x 99 1 x 50 8 WEIGHT Ibs kg Electronic only see battery 1083 1446 1679 1679 1719 2066 2463 2565 weight for total weight CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door and Full length Door Hinge ENCLOSURE Designed for Inside Installations COLOR Black ACCESSIBILITY Front All Servicing is Through the Front No Side or Rear Access is Required CABLE ENTRY Top or sides MOUNTING Four 4 Holes Provided to Anchor Enclosure to Pedestal Supplied by Others Note This is Electronic cabinet only refer to battery cabinet based on each KVA for 90 min NOTE This is the basic weight s Actual unit weight s may vary depending on the option s added approximat
31. N RESULT IN ELECTRICAL SHOCK THE LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS ARE REMOVED DURING INSTALLATION AND MAINTENANCE LEAD ACID BATTERIES CAN PRESENT A RISK OF FIRE BECAUSE THEY GENERATE HYDROGEN GAS THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED 1 DO NOT SMOKE WHEN NEAR BATTERIES 2 DO CAUSE FLAME OR SPARK IN BATTERY AREA DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE 6002 1443 Rev M 1 4 OnLine Power 2 1 SECTION 2 OVERVIEW INTRODUCTION Power Wave 3 Central Lighting Inverters are manufactured to provide critical power for lighting during a power outage The Power Wave 3 meets or exceeds life safety codes of UL924 UL924A as an option for shorter than 90 minutes use in conjunction with a generator UL1778 and NFPA101 These codes were established to allow emergency lighting inverters to provide critical power to lighting circuits during a power malfunction The emergency lighting inverter will provide power for 90 minutes to allow safe and orderly evacuation from the facility When input power to the Power Wave 3 is lost during a power outage the system will automatically draw power from its battery bank supply without any interruption and with zero transfer time The critical load will receive only clean sine wave power The output transformer provides multiple output voltages as well as input voltages that are different than the outp
32. NE 1 800 295 5510 3 3 1 Control Board Circuit boards and IGBTs contain ESDS ElectroStatic Discharge Susceptable components Handle and package ESDS devices in accordance with JEDEC standard JESD625 A Use a grounded ESD wrist strap when handling the devices and circuit boards Always package components and circuit boards in static dissipative plastic bags before transporting even if a device has failed Fauilure to do so could result in further damage complicating repair and malfunction analysis The Control Board is located on the inside right door at the top and mounted at 4 corners with screws and washers Verify that all connectors are matches with their designations and pins 1 2 etc Unplug P1 through P15 install the new board and reconnect all plugs and connections maintaining them with their original orientations 3 3 2 All Other Parts Verify that the cables are marked before disconnecting Replace the defective part with the new part Reconnect wiring the same way as it was disconnected 6002 1443 Rev M 3 3 OnLine Power 3 3 3 Heat Sink Assembly Replacement Procedure 40 KVA and lower 1 2 Disconnect and isolate all sources of power The Heat Sink Assembly is located on the right side of the top electronic shelf inside the unit cabinet Illustration 3 1 Verify that all cables and connectors have labels and are identified as shown This is important for reinstalling the assembly Disconnect connectors P7
33. P6 P4 and P1 from the PCB A1 which is mounted horizontally on the heat sink Disconnect 11 power cables at TB4 1 through TB4 7B using a slot blade screw driver Verify and install identificaton labels for each cable before disconnecting Loosen 3 Phillips head screws at the front thant hold the heat sink bracket Pull the complete assembly forward and up removeing gentlyfrom the tray while making sure that no cables or wires are catching See illustration 3 1 Install the new assembly in the reverse order Note that the rear bracket attached to the heat sink slides under the bracket secured on to the back panel Slide the assembly back and reinstall 3 Phillips Screws Reinstall all the cables and connectors in the reverse order Verify per illustration 3 1 Verify connections prior to starting up the unit 10 40 kVA Item Terminal Phase C 03 04 Phase A Q1 Q2 Phase B Q5 Q6 D E2 Q7 Q8 gt lt E1 C2 Q9 Q10 TB1 TB2 1828 384858 1Bj2B 3B TA 2A 5 1 2 ILLUSTRATION 3 1 40 KVA AND LOWER HEAT SINK ASSEMBLY FRU 6002 1443 Rev M 3 4 OnLine Power 3 3 4 Heat Sink Assembly Replacement Procedure 50 KVA and up 1 2 Disconnect and isolate all sources of power The Heat Sink Assembly is located on the right side of the top electronic shelf inside the unit cabinet Illustration 3 2 Verify that al
34. R OF GRAVITY LEFT VIEW FRONT VIEW RIGHT VIEW KVA KW WT NOTES UNLESS OTHERWISE SPECIFIED 50 KW 2565 50 40 2463 1 DIMENTIONS SHOWN ARE APPROXIMATE 40 32 2066 2 CONSTRUCTION INDOOR NEMA 1 30 25 1719 3 CENTER OF GRAVITY IS SHOWN AS TYPICAL AND MAY VARY PER 25 20 1679 KVA AND OPTION 20 16 1679 15 12 1446 10 8 1083 ILLUSTRATION 6 2 6002 1443 Rev M 6 3 OnLine Power 34 37 TYP 8X 3 4 1 31 87 TYP CONDUIT gt in 10X 1 1 5 2 CONDUIT TOP CTR OF GRAVITY 4 5 69 4X NOTES UNLESS OTHERWISE SPECIFIED 1 DIMENSIONS SHOWN ARE APPROXIMATE 2 CONSTRUCTION INDOOR NEMA 1 BOTTOM BATTERY CABINET CENTER OF GRAVITY ILLUSTRATION 6 3 6002 1443 Rev M 6 4 OnLine Power Caution Each model of the Power Wave 3 is designed to supply a maximum load which is determined by its kVA 1000 s of volt amperes and KW rating Since the power factor is 8 calculate the maximum load using the formula kVA x 8 KW It is very important that the load is within the rating of the Power Wave 3 to ensure that the connected loads will be properly supported Each electrical device to be powered by the Power Wave 3 should have a specification sheet attached to it which specifies the amount of power it requires In addition this information should be listed in the manual supplied with each piece of equipment The device s namepla
35. RY CIRCUIT BREAKER INDICATES A SERIOUS PROBLEM THAT MAY RESULT IN SERIOUS INJURY OR DAMAGE TO THE EQUIPMENT DO NOT CLOSE THE CIRCUIT BREAKER WITHOUT KNOWING WHY IT FAILED CHECK FOR A SHORT IN BATTERY OR CONNECTIONS CALL ONLINE POWER CUSTOMER SERVICE AND SUPPORT FOR ASSISTANCE AT 1 800 PWR SRVC A Danger THE BATTERY ELECTROLYTE IS A DILUTED SULFURIC ACID THAT IS HARMFUL TO THE SKIN AND EYES IT IS ELECTRICALLY CONDUCTIVE AND CORROSIVE WEAR FULL EYE AND HAND PROTECTION ALONG WITH PROTECTIVE CLOTHING IF THE ELECTROLYTE CONTACTS THE SKIN WASH IT OFF IMMEDIATELY WITH WATER IF ELECTROLYE CONTACTS THE EYES FLUSH THOROUGHLY AND IMMEDIATELY WITH WATER SEEK IMMEDIATE MEDICAL ATTENTION SPILLED ELECTROLYTE SHOULD ADDRESSED PER APPROPRITE HARADIDEROUS SPILL CLEANUP PROCEDURES A Danger DO NOT DISPOSE OF A BATTERY OR BATTERIES IN A FIRE THE BATTERIES MAY EXPLODE CAUSING DEATH OR SERIOUS INJURY 6002 1443 Rev M 5 5 OnLine Power Cautions Do not substitute batteries from other manufacturers without the express Seeececeeeee approval of OnLine Power Customer Service personnel e The use of any battery other than Online Power may cause damage to the inverter and voids your Online Power warranty 58 esse Lead acid batteries contain hazardous materials and must be handled Caution transported and recycled or scrapped in accordance with federal state and local T regulations Since lead is a toxic substance lead acid b
36. S FILTER USE FOR 25KVA 9100 1372 03 10 INPUT CURRENT HARMONICS FILTER USE FOR 30 40 KVA 4 9 OPTIONAL 5 INPUT CURRENT HARMONICS FILTER P N 9100 1373 01 04 add approximately 400 Ibs to system weight Part Number Description 9100 1373 01 5 INPUT CURRENT HARMONICS FILTER USE FOR 10 15 20KVA 9100 1373 02 5 INPUT CURRENT HARMONICS FILTER USE FOR 25KVA 9100 1373 03 5 INPUT CURRENT HARMONICS FILTER USE FOR 30 40KVA 9100 1373 04 5 INPUT CURRENT HARMONICS FILTER USE FOR 50KVA 4 10 OPTIONAL EMI FILTER P N 9100 1445 1 THRU 05 EMI FILTER EN55022 1998 CLASS B RADIATED EMISSION EN55022 1998 CLASS B CONDUCTED EMISSION FCC PART 15 CLASS B RADIATED EMISSION FCC PART 15 CLASS B CONDUCTED EMISSION Part Number Description D EMI FILTER ASSY 60AMP 3 PHASE UNIT FOR 10KVA 15KVA 20KVA 25KVA 30KVA 480Y 277V ENE EMI FILTER ASSY 100AMP 3 PHASE UNIT FOR 20KVA 25KVA 208Y 120V 40KVA S0KVA 50KW 480Y 277V EMI FILTER ASSY 150AMP 3 PHASE UNIT bolas ca FOR 30KVA 40KVA 208Y 120V EMI FILTER ASSY 200AMP 3 PHASE UNIT 9100 1425 04 FOR 50KVA 208Y 120V EMI FILTER ASSY 200AMP 3 PHASE UNIT 9100 1445 05 FOR 50 KW 208Y 120V 4 11 OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CIRCUIT BREAKER 4 11 1 Specifications HIGHER KAIC NORMALLY ON NORMALLY OFF OUTPUT AUX CBs OPTION 3 PHASE 20AMP Part Number Description 9100 14
37. SISTING OF EXCESSIVE DUST IN AND AROUND THE UNIT WILL BE PULLED INTO THE UNIT BY THE COOLING FANS A Danger ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START UP PROBLEMS SERVICE PERSONNEL SHOULD WEAR INSULATING SHOES FOR ISOLATION FROM DIRECT CONTACT WITH THE FLOOR EARTH GROUND AND SHOULD MAKE USE OF RUBBER MATS WHEN PERFORMING MAINTENANCE ON ANY PORTION OF THE UNIT WHILE IT IS UNDER POWER HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT S AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT MALFUNCTION A Danger SPECIAL SAFETY PRECAUTIONS AND LOCKOUT TAGOUT PROCEDURES ARE REQUIRED FOR ALL OPERATIONS INVOLVING THE HANDLING INSTALLATION OR MAINTENANCE OF THE UNIT SYSTEM AND ANY ASSOCIATED BATTERY CABINETS FAILURE TO FOLLOW SAFETY PROCEDURES COULD RESULT IN DEATH INJURY OR DAMAGE TO EQUIPMENT 6002 1443 Rev M 5 1 OnLine Power A Danger THIS EQUIPMENT CONTAINS CIRCUITS THAT ARE ENERGIZED WITH HIGH VOLTAGES ONLY TEST EQUIPMENT DESIGNED FOR TROUBLESHOOTING HIGH VOLTAGES SHOULD BE USED PARTICULARLY FOR OSCILLOSCOPES AND PROBES ALWAYS CHECK WITH AN AC AND DC VOLTMETER TO ENSURE SAFETY BEFORE INITIATING CONTACT OR USING TOOLS EVEN WHEN THE POWER IS OFF DANGEROUSLY HIGH POTENTIAL VOLTAGES MAY EXIST AT CAPACI
38. Site Planning Specifications Refer to details in A 3 Table KVA INPUT OUTPUT VOLTAGE MODEL NUMBER 0 8 Power Factor Electronic BATTERY W X H X D VOLTAGE mevem mewum ewoosvstetsva me EIE ee esse m s asvan ewonssostetsva ve lt EE mum mevm mewm Pwoaososunts va Rm ete _ mevm mewm ewososostersva me EE at oe C ADI DN aswa asv Pwososostrts va lm ee e D DD asvan Pwosesostrts va Mee men men 6002 1443 Rev M 6 1 OnLine Power 6 1 4 Cable Access Blocking air vents will cause equipment over heating and malfunction For best performance the air around the unit must be clean dust free and free of chemical or other contaminantion Do not place the system or batteries in a sealed container or room Caution The Power Wave 3 Cabinet Installation Diagrams for 10 50 KVA and 50 KW models provide cable conduit openings on the top and sides of the cabinet Refer to Illustration 6 1 CABLE ENTRY 3 4 1 CONDUIT CABLE ENTRY 1 5 2 CONDUIT TOP VIEW CABLE ENTRY CABLE ENTRY TRIPLE K O TRIPLE K O 1 1 5 2 1 1 5 2 RIGHT VIEW LEFT VIEW 69 4X MTG HOLES 2d L s BOTTOM VIEW ILLUSTRATION 6 1 CABLE ACCESS AND MOUNTING 6002 1443 Rev M 6 2 OnLine Power 1 CT
39. TOR BANKS ALWAYS OBSERVE BATTERY PRECAUTIONS WHEN OPERATING NEAR ANY BATTERIES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DEATH INJURY OR DAMAGE TO EQUIPMENT A Danger OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE OFF POSITION THE DANGER OF ELECTROCUTION MAY STILL BE PRESENT THE BATTERY POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT THE BATTERY MANUFACTURER S SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT FAILURE TO FOLLOW THOSE INSTRUCTIONS AND THE INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION FIRE EQUIPMENT MALFUCTION OR ELECTROCUTION A Danger BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES WITH INPUT POWER OFF AND THE BATTERY DISCONNECTED HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS HOWEVER POWER CIRCUIT MALFUNCTIONS CAN OCCUR SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT 6002 1443 Rev M 5 2 OnLine Power 5 2 WHEN TO CALL 1 800 PWR SRVC 1 800 797 7782 Call for service if you encounter any of the following conditions 1 Repeated start up attempts a
40. This concludes the start up procedures Please be sure the load as balance as possible on each phase 6002 1443 Rev M 3 2 OnLine Power 3 2 OPERATION 3 2 4 Turning On the Power Wave 3 1 Apply input power 2 With input power available turn on the main input circuit breaker 3 Wait untill you hear the input contactor closing and fan running 4 Close the battery circuit breaker only after the LCD display is lit and display screen is per Appendix C 5 Verify that all parameters on the LCD display panel are correct See Appendix C for display details 6 Close the output circuit breaker 7 Turn On the auxilery output circuit breakers 8 Verify that the load is as balanced as posiible on all 3 phases Check to be sure you are not overloading any phase see max current on the name plate 3 2 2 Turning Off the Power Wave 3 Turn off the Output Breaker s Battery Breaker and Input Breaker 3 3 FIELD REPLACEABLE UNITS FRUS Refer to Table 3 1 for ordering replacement parts from the factory Supply the information from the unit s nameplate including the serial number model number kVA P F input output battery voltages and date of manufacture when ordering parts from the factory Call Toll Free 800 PWR SRVC in North America Replacement parts must be replaced by qualified factory trained service personnel only ATTENTION OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES S 2245 ULI
41. Wave 3 These diagrams provide an excellent tool for identifying the major building blocks within the Power Wave Main input circuit breaker optional The main input circuit breaker provides Power Wave 3 with incoming power isolation as a well as means of disconnect and input over current protection Input Contactor The Input contactor controls power applied to the unit The microprocessor control circuit verifies that the unit is in normal condition and that the input voltage and frequency are within an acceptable range When the unit transfers to the battery it disconnects the source so the batteries do not feed back to the utility Input Inductors The input inductors are a three phase input filter Inverter The inverter provides continuous power to the load When the AC input power is not available the inverter converts the energy stored in the battery bank to AC power to supply the load The PWM Pulse Width Modulation inverter utilizes high frequency digital signal processing with high efficiency IGBTs for fast accurate measurement and response Battery charger The constant power battery chargers supply DC power to re charge and to maintain the charge on the battery bank The charger is fully automatic with a current tapering feature so that battery damage will be prevented in case of a charger malfunction or increased battery temperature The charger is sized to maintain a full charge even when the input voltage at is the lo
42. aintenance only the batteries should be given a periodic inspection and electrical check every six months Battery Service Agreements are available through OnLine Power Customer Service and Support at 1 800 PWR SRVC 800 797 7782 In order to qualify for battery warranty replacement you will need to show records of the battery maintenance history including battery numbers battery voltages individual cells terminal torque measurements and dates of maintenance 5 4 5 Power Connections e Check for corrosion and connection integrity Visually inspect wiring for discolored or cracked insulation Clean and or re torque as required e All Battery terminal connections must be tighten with proper torque value set in accordance with the table or instructions provided by battery manufacturer e Use the correct torque tool to tighten the terminal bolts as indicated in table below and use all hardware s provided with batteries Type Standard VRLA Battery Battery part number Initial torque in LBS Annual re torque in LBS Terminal Type Hardware 120 IN LB 13 6 115 IN LB 13 6NM Copper Insert V4 20 UNC Bolt 150AH Terminal Z1 Z post 1 to 1 25 long bolt UB 12750 88 5 IN LB 10 NM 84 IN LB 9 5 NM pos w 14mm head 14mm nut type terminal 8mm washer amp lockwasher UB12900 88 5 IN LB 10 NM 84 IN LB 9 5 NM Same as above Same as above UB12110 88 5 IN LB 10 NM 84 IN LB 9 5 NM Same as a
43. allations with Stackable Rack Dwg 6001 032 07 3 Phase unit Functional Block Diagram Single Line Diagram Single Input Dwg 6001 032 11 3 Phase unit Functional Block Diagram Single Line Diagram Dual Input Wye Wye Dwg 6001 032 04 3 Phase unit Functional Block Diagram Single Line Diagram Dual Input Delta Delta Dwg 6001 032 10 Unit and Battery Cabinet Seismic Certification Drawing Dwg 6002 1658 09 0319 A 3 Ph External Wrap Around by pass panel 3 4 Pole By Pass Panel 55 A 350 A same I O Dwg 6001 032 27 and 6001 032 275 3 Ph External Wrap Around 3 4 Pole By Pass Panel 55 A 350 Dwg with same I O optional load disconnect 6001 032 28 and 6001 032 28S 3 Ph External Wrap Around 3 4 Pole By Pass Panel 55 A 350 A Dwg with different I O DWR 6001 032 295 TABLES Allowable Ampacities of Insulated Conductors Rated 0 2000 V 60 to 90 deg C 140 194 deg F Table 310 16 of National Electrical Code 2 National Electrical Rating of the Wire 3 Connection Type Wire Size Range 4 Torque Specifications Unless Otherwise Labeled 5 Specifications Due to continuous product improvement this specification is subject to change without prior notice 6002 1443 Rev M D 1 OnLine Power 6 1 6 1 2 6 1 3 SECTION 6 INSTALLATION SITE PLANNING AND PREPARATION The Power Wave 3 is designed for installation indoors and meets NEMA specifications for operating temperature h
44. anel The room switch turns on and off both regular and emergency lights simultaneously This is accomplished by having the room switch leg power activate the Emergency Control Module Wire input 1 is connected internally to a sensing circuit During a power interruption this circuit causes contact X to drop into an N C position Please review the wiring schematics Specification Description ECM EMERGENCY CONTROL MODULE Part Number 9100 1502 01 120 VAC 9100 1502 02 277 VAC Rating Maximum Ballast load 1500 W 120 and 277 VAC 20 AN C UL contact rating High Voltage surge protectors Approvals UL 924 NFPA 1104 2 4 1 OSHA NEC 700 thru 700 26 701 717 702 709 705 750 Operating Temperature 210 to 150 F Size 2 75 W x 1 5 H 1 25 D overall Color Black Weight 8 oz ILLUSTRATION 4 13 ECM EMERGENCY CONTROL MODULE 6002 1443 Rev M 4 20 OnLine Power SECTION 5 MAINTENANCE 5 1 SAFETY PRECAUTIONS The Power Wave 3 requires regularly schedule periodic maintenance A Danger READ AND UNDERSTAND THIS SECTION THOROUGHLY BEFORE PERFORMING ANY MAINTENANCE WORK ON OR AROUND THE UNIT READ THE BATTERY MANUFACTURER S MANUAL AND MATERIAL SAFETY DATA SHEETS BEFORE WORKING ON OR NEAR THE BATTERIES ONLY NORMAL SAFETY PRECAUTIONS ARE REQUIRED WHEN THE UNIT IS OPERATING WITH ALL CABINET DOORS CLOSED HOWEVER THE UNIT AND BATTERY CABINETS MUST BE KEPT FREE OF STANDING PUDDLES OF WATER EXCESS MOISTURE OR DEBRIS DEBRIS CON
45. atteries should be recycled rather than scrapped 4 A battery can present a risk of electrical short and high short circuit current The Caution following precautions should be observed when working on or around batteries e Remove watches rings necklaces or other metal objects e Useonly tools with insulated handles e Wear rubber insulating gloves and boots e Do not lay tools or metal parts on top of batteries e Disconnect charging source prior to connecting or disconnecting battery terminals e Verify that battery cabinets are properly grounded A Danger DO NOT GROUND BATTERY POSITIVE OR NEGATIVE 04 Lead acid batteries can present a risk of fire because they generate hydrogen e Caution gas The following safety procedures must be followed DO NOT SMOKE when near batteries DO NOT cause flame or sparks in battery areas Discharge static electricity from your body before touching batteries by first touching a grounded metal surface Caution When replacing batteries use the same number of batteries of the same manufacturer type and model that was supplied with the unit To avoid system malfunction replace all batteries in each string if one or more batteries fail to perform to specifications Please record all individual cell voltages on the chart 6002 1443 Rev M 5 6 OnLine Power 5 4 4 Battery Cabinets Although the individual batteries are sealed and require minimal m
46. atus Panel FORM C CONTACTS FOR ALARMS Optional TVSS NORMALLY ON NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS EXTERNAL OUTPUT AUX CIRCUIT BREAKERS Illustration 4 3 UPS with External Load Center 10 INPUT CURRENT HARMONIC FILTER 5 INPUT CURRENT HARMONICS FILTER EMI FILTER OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CIRCUIT BREAKERS DUAL INPUT SYSTEM WYE WYE DUAL INPUT SYSTEM DELTA WYE PAGE 1 1 2 1 2 1 2 1 2 2 2 3 2 4 2 5 2 6 2 9 2 10 2 11 2 12 3 1 3 1 3 3 3 3 3 4 3 6 4 1 4 2 4 4 4 5 4 6 4 6 4 7 4 7 4 7 4 8 4 9 4 9 4 9 4 9 4 10 4 10 OnLine Power SECTION 4 14 DUAL INPUT SYSTEM DELTA DELTA 4 15 SEISMIC MOUNTING BRACKET 4 16 STACKABLE RACK 4 17 Global Monitoring System GMS 4 17 1 Local on PC via RS 232 Illustration 4 8 Sample PC Screen 4 17 2 Local on PC via RS 485 4 17 3 Remote Dial Up Data Voice Fax Pager PC E mail Event Log and Stats Illustration 4 9 Monitoring 2000 Front View Illustration 4 10 Manager 2000 Screen 4 18 ECC EMERGENCY CIRCUIT CONVERTER 4 19 ECM EMERGENCY CONTROL MODULE SECTION 5 MAINTENANCE 5 1 SAFETY PRECAUTIONS 5 2 WHEN TO CALL 5 3 STEPS TO TAKE 5 4 PREVENTIVE MAINTENANCE 5 5 ONLINE POWER CUSTOMER SERVICE AND SUPPORT APPENDICES APPENDIX A SPECIFICATIONS APPENDIX B BATTERY CONNECTIONS APPENDIX C LCD DISPLAY MENU AND TROUBLE SHOOTING GUIDE APPENDIX D DRAWINGS amp TABLES SECTION 6 INSTALLATION
47. bove Same as above Type G Longer warranty battery Battery part number Initial torque in LBS Annual re torque in LBS Terminal Type Hardware GSLF 10512 120 IN LB 13 6 NM 115 IN LB 13 0 NM Copper Insert 14 GSLF 12012 120 IN LB 13 6 NM 115 IN LB 13 0 NM Copper Insert 4 N Nickel Cad battery only nickel plated copper cable lugs should be used Ni Cad P N Recommended Torque Bolt Diameter BM 112 138 66 IN LB 7 5 NM M5 BM 148 184 177 IN LB 20NM M8 BM 195 231 277 266 IN LB 30 NM M10 NOTE For annual re torque reduce 5 IN LB from recommended torque value CAUTION Torque all connections in accordance with the above tables unless provided from battery manufacturer Failure to do so may create an unsafe condition or fire hazard 6002 1443 Rev M 5 7 OnLine Power 5 4 6 5 5 5 5 1 5 5 2 5 5 3 Battery Terminals e Check for discoloration corrosion and connection integrity Clean and tighten as necessary To access battery terminals remove the top strapping material located at the lower front of the battery shelf Pull the battery forward to access the battery connections Disconnect the cables connected to the battery Once disconnected insulate the cables to prevent accidental shorts Use a protective boot or electrical tape Before replacing the battery connections clean and re torque the connection hardware e OnLin
48. e Power Customer Service personnel must approve use of non standard batteries Please call at 1 800 PWR SRVC 800 797 7782 ONLINE POWER CUSTOMER SERVICE AND SUPPORT Start up unit maintenance battery maintenance and preventative maintenance programs are available through your OnLine Power sales representative or through OnLine Power Customer Service and Support A program of periodic maintenance is recommended once every six months but is mandatory once every twelve months since heat and cold will effect the compression of the electrical connections and lack of maintenance will shorten the product s life expectancy possibly causing unsafe operating condition Start Up Services Various start up services are available See your sales representative or telephone OnLine Power Customer Service at 1 800 PWR SRVC 800 797 7782 Maintenance Agreements Standard Full Service 24 7 Full Service and Extended On or OFF Site Maintenance agreements are available See your sales representative or telephone OnLine Power Customer Service at 1 800 PWR SRVC 800 797 7782 Warranties Contact OnLine Power Customer Service and Support at 1 800 PWR SRVC 800 797 7782 if you have any questions regarding the warranty on your unit system or batteries 6002 1443 Rev M 5 8 OnLine Power APPENDIX A SPECIFICATIONS EFFECIENCY GREATER THAN 90 Specifications for KVA 0 8pf Units INPUT and OUTPUT INPUT VOLTAGE VAC Three Phase 4 Wire plus Ground 2
49. e occurs so that there is no back feeding of power into the power line Finally the contactor allows for automatic unit operation upon a complete discharge of the batteries No operator intervention is required when power to the unit is restored after a complete battery discharge Input Transformer T3 Illustration 2 2 Item 2 The input transformer adjusts the input voltage for proper rectifier DC voltage depending on the unit rated power and back up capacity Battery Charger Illustration 2 3 Electronics Tray The constant power battery charger maintains the batteries at full charge while utility power is available After a battery discharge the charger will automatically recharge the batteries upon restoration of input power This circuit is on the Power Board Power Board Assembly with IGBT s Illustration 2 3 Item 3 The Power Board is bolted onto the IGBT Insulated Gate Bipolar Transistor blocks that are mounted on a heat sink The complete Heat Sink Assembly with IGBTs and Power Board is replaceable as a single part This FRU Field Replaceable Assembly converts all the power i e input AC power converted to DC bus battery power boosted to DC bus and finally DC bus power converted to output AC power using PWM with digital signal processing technology for a smooth AC sine wave In case of a malfunction the complete Heat Sink Assembly is easily replaceable using only a screwdriver The Power Board also contains the housekeeping
50. e proceed to Section 3 Start Up 6002 1443 Rev M 6 8 OnLine Power 6 5 6 5 1 BATTERY STORAGE The Power Wave 3 can be placed in storage while not in use Provide a protected environment which meets the environmental parameters listed below AMBIENT TEMPERATURE 20 C to 70 C 4 F to 158 F e RELATIVE HUMIDITY 0 to 95 non condensing If the Power Wave 3 batteries will be stored for three months or longer batteries should be charged for 24 hours every three months to avoid permanent damage to the batteries Battery Maintenance and Recharge During long term storage the batteries are subject to aging and deterioration After visual inspection if the batteries need to be replaced contact OnLine Power Services 1 800 PWR SERV 1 800 797 7782 Matching battery type and manufacture is required If the unit is stored in its original packaging unpack the unit using the unpacking procedures outlined in Equipment Unpacking Section 6 2 If the unit is not connected to a source of power first connect it to an appropriate power source using the procedures in unit Installation Section 6 3 Then recharge the batteries as follows 1 Unlock and open front doors 2 Set AC input power source to ON 3 Close input circuit breaker and wait for 1 minute 4 Close battery circuit breaker only when unit Normal is displayed on screen 5 The unit automatically recharges batteries The LCD panel will indicate the battery voltage
51. e viewed in graph form by clicking the Graph button The graph will show all inputs selected in the query If too many samples are selected for graphing the software gives you the option to average values Oherwise you will have to perform a smaller query to avoid averaging The graph has many features that allow to display the data graphically including line graphs bar charts and three dimensional views Experimentation is the best way to larn about all of the available options A sample graph follows 13 01 I 04 06 25 07 04 08 1997 i 05 06 25 08 04 08 1997 i 06 06 25 09 04 08 1997 i 07 06 25 10PM 04 08 1997 i 08 06 25 11 04 08M 997 1 03 06 25 12PM 04 08 1997 i 10 06 25 13PM 04 08 1997 13 06 25 14PM 04 08 1997 12 06 25 15PM 04 08 1997 1 13 06 25 18PM 04 08 1997 i 14 06 25 17PM 04 08 1997 i 15 06 25 18 04 08 1997 16 06 25 19 04 08 1997 7 06 25 20 04 08 1997 Sample Graph PRINT Once the Data Log records have been displayed clicking this button may print them EXPORT Once the data log records have been displayed the displayed information may be saved as a comma delimited file This file can then be used in a spreadsheet programs such as Lotus 123 or Microsoft Excel Send Report The GMS 2000 can be programmed to automatically send reports to selected destinations Check this box to include this destination when sending reports Note Reports may only be sending to fax e mail or
52. ely 200 lbs variance Due to continuous product improvement this specification is subject to change without prior notice 6002 1443 Rev M A 2 OnLine Power Recommended Input Output Protective Device Ratings BTU HR and Floor Loading 5 Pu Max Full Electronic er Each Re Total Input utput Input utput Batt Batt Load Cab No of Loading System MSG Sgt Volt Current Current current Current Volt Disch BTU HR Weight LB SQFT Battery Battery LB SQFT weight protect protect Protect AMP M Only electronic Cabinet Batt cab 9t AMP AMP Pap a Cab abinet weight Norm Max Norm Max Hokva skw 208Y i20 208 120 31 38 48 28 35 44 92 56 3032 083 222 1 1392 286 2475 480 Y277 480Y 277 14 18 23 12 15 18 92 56 3032 083 222 1 1392 286 2475 480Y 277 208Y 120 14 18 23 28 35 44 92 56 3032 083 222 1 1392 286 2475 15 kva t2kw 208Y 120 208Y 120 47 59 74 42 53 66 92 84 4549 446 297 2 1612 2 331 4670 480Y 277 480Y 277 21 26 33 18 23 29 92 84 4549 446 297 2 1612 2 331 4670 480Y 277 208Y 120 21 26 33 42 53 66 92 84 4549 446 297 2 1612 2 331 4670 20kva l6kw 208 120 208Y 120 62 78 97 56 70 88 92 112 6066 679 344 2 1780 2 365 5239 480Y 277 480Y277 27 34 42 24 30 38 92 112 6066 679 344 2 1780
53. er power is applied the system is placed in the STANDBY mode and a self check starts During this period the start up subroutine program checks for input voltage and proper operation of the inverter and bypass SCR s After the sub routine is completed and the system is confirmed OK the system goes into the NORMAL mode Normal Mode The input contactor K1 receives a closing signal connecting input power to the input transformer The rectifier supplies DC power to the battery charger Control Board and the DC AC inverter circuit The battery charger is then activated allowing the batteries to be continuously charged The on line DC AC inverter converts the DC voltage to a PWM Pulse Width Modulation waveform This waveform is filtered and reconstructed to a desired AC output by using high frequency digital signal processing Response To Input Power Abnormal Condition If the system controller senses an input frequency change of more than 3 Hz or an out of range input voltage it will consider it an input malfunction and immediately open the input contactor isolating the unit from the facility power At the same time the charger is turned off and the battery bank becomes a DC supply source to the inverter circuit maintaining an uninterrupted AC supply to the protected load The LCD screen will display a UNIT PROBLEM ALARM message When the facility power returns stabilizes and is in phase with the backup power the system controller closes the
54. hown on illustration 6 1 6 Anchor the conduits to the conduit knockouts If equipment is not ready for normal operation it must be protected from dust to prevent damage This concludes the mechanical installation 6 3 2 Electrical Connection A Danger VERIFY THAT ALL CUSTOMER SUPPLIED WIRING IS DE ENERGIZED BEFORE PERFORMING ANY ELECTRICAL WORK FUILURE TO DO SO COULD RESULT IN ELECTROCUTION INJURY OR DAMAGE TO EQUIPMENT A Danger EVEN WHEN THE UNIT IS OFF THERE ARE POTENTIALLY DANGEROUS VOLTAGES WITHIN THE UNIT DUE TO THE BATTERIES EXTREME CARE MUST BE TAKEN WHEN WORKING WITHIN THE POWER WAVE ENCLOSURE TO AVOID THE POSSIBILITY OF ELECTROCUTION INJURY OR DAMAGE TO THE EQUIPMENT Caution VOLTAGES ON INPUT TERMINAL BLOCK TB10 MUST HAVE CORRECT PHASE ROTATION AND PROPER VOLTAGE CLOCKWISE A B C 6002 1443 Rev M 6 6 OnLine Power 6 3 3 Customer Connections Input and Output 1 Verify that the main input circuit breaker battery circuit breaker and output circuit breaker s if provided are in the OFF position See ILLUSTRATION 6 5 for the location of the circuit breakers 2 Run the wires through the space between shelf and cabinet using provided knockouts by following the NEC standard based on the local code and type of wires being used See ILLUSTRATION 6 1 for knockouts location 3 Connect the input wires to the input terminal block TB10 Five 5 wires total Phase A Phase B Phase C ne
55. ing Input Voltage Output Voltage Manufacturer Date 6002 1443 Rev M 1 1 OnLine Power A Danger ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES IMPROPER WIRING MAY CAUSE DAMAGE TO THE EQUIPMENT INJURY OR DEATH OF PERSONNEL VERIFY THAT ALL HIGH AND LOW VOLTAGE INPUT POWER CIRCUITS ARE DE ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS A Danger EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL CABINETS WEIGH SEVERAL HUNDRED POUNDS A Danger TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COMPLETELY UNDERNEATH THE UNIT A Danger OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE OFF POSITION THE DANGER OF ELECTROCUTION MAY STILL BE PRESENT THE BATTERY POWER TO THE UNIT MUST BE LOCKED AND TAGGED OFF BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT THE BATTERY MANUFACTURER S SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT FAILURE TO FOLLOW INSTRUCTION LISTE
56. input contactor and the system returns to normal If the battery voltage drops below useable voltage and the facility power remains off the system will assume a standby mode and will only resume normal operation upon restoration utility power UNIT MESSAGES The System controller will issue a Failure Alert message on the LCD screen if any of the following conditions happen during the power outage e Internal malfunction e System overheats e DC bus Overvoltage Undervoltage During a malfunction the system stops its backup operation inverter SCRs are switched OFF and bypass SCRs are switched ON without any interruption to the load A summary alarm 5 volt signal is sent to the hardwired interface The system remains in this mode until power is cycled or the system has been repaired if needed 6002 1443 Rev M 2 11 OnLine Power 2 5 5 Unit Problem Alarm Message The System controller will issue a unit problem alarm message on the LCD screen if any of the following conditions occur e Input power abnormality e Battery bank under voltage e Charger OFF e Output overload During a Problem Alarm mode inverter IGBTs remain on and an alarm signal may be sent to the signal interface The system will reset itself as soon as the problem alarm has been cleared 2 6 OUTPUT LOADS The Power Wave 3 is designed to power any fluorescent or incandescent HID lighting There are however certain types of loads that exhibit an excessive inrush c
57. l On PC Via RS 232 Part Number 9800 03 25 thru 150 PC system requirements Windows 98 or higher operating system and a serial port Viewing software LabView included RS232 cable 25 to 150ft as specified included 4 11 Buss Voltage V Dc Buss Status DC Buss OK ILLUSTRATION 4 8 SAMPLE PC SCREEN Local On PC Via RS 485 P N 9800 004 150 thru 1000 150 1000 ft Installation Operation Specification as above except RS 485 cable OnLine Power 4 17 3 GMS Remote Dial UP Monitor 2000 p n 9100 1468 02 Remote Dial Up Data Voice Fax Pager PC E mail Event Log Stats For details of all fuctions and operation refer to User s Manual 6002 1770 4 17 3 1 Description Monitor 2000 requires a phone line for remote operation It comes with an interface PCB that provides monitor inputs with isolated signals from the unit The option comes wired and fully functional For local PC communication you must connect your computer serial port to the 2000 RS232 data communication port ILLUSTRATION 4 9 MONITOR 2000 FRONT VIEW The Manager 2000 Windows Setup Program makes installation quick and easy Pictured below is an actual Manager 2000 screen Manager 2000 HEO138 Inputs for HEO138 File Edk Configuration Programming Functions Poling Window xl puts 1 INPLIT VOLTS 127 1 volts Okay 00 133 4 Clear 2 DUTPUT VOLTS 1248 volts Okay Alam 62 1 13
58. l cables and connectors have labels and are identified as shown This is important for reinstalling the assembly Disconnect connectors P7 P6 P4 and P1 from the PCB A1 which is mounted horizontally on the heat sink Disconnect 11 power cables at TB4 2 through TB4 4 TB5 1 TB5 2 and TB3 2 using a slot blade screw driver Verify and install identificaton labels for each cable before disconnecting Loosen 3 Phillips head screws at the front thant hold the heat sink bracket Pull the complete assembly forward and up removeing gentlyfrom the tray while making sure that no cables or wires are catching See illustration 3 2 Install the new assembly in the reverse order Note that the rear bracket attached to the heat sink slides under the bracket secured on to the back panel Slide the assembly back and reinstall 3 Phillips Screws Reinstall all the cables and connectors in the reverse order Verify per illustration 3 2 Verify connections prior to starting up the unit 1 178428 6 res 7 ms s TB 9 Te Phase C Q3 Q4 Phase 01 02 Phase B Q5 Q6 DA 7 2 07 08 TB5 1B lt Heen 7 4 TB3 TB5 1B 2B 3B 4B 1B 2B 3B 4B 5B 18 2B 3B 1B 2B 3B 1B 2B 1 2 4 2 4A SA 2 3A 2A 3A 1A 2A ILLUSTRATION 3 2 50 KVA AND UP HEAT SINK ASSEMBLY FRU 6002 1443 Rev M
59. mber and alarm input numbers on the display This will happen automatically just by entering the pager s telephone number in the destination field If you want to change the information that is identifies your pager or you are having trouble receiving the page you may use the special dialing codes to customize the signal to your pager Alpha Pager This instructs GMS 2000 to deliver a text message to an alphanumeric pager 6002 1443 Rev M 4 14 OnLine Power Modem This instructs GMS 2000 to call a modem attached to a computer running Manager 2000 software The sofhware must be in Answer Mode When the Manager 2000 software receives the alarm call it will download the unit s event log execute an alarm query and display the result on the screen You may also have the computer print a copy of the alarm event as well as play a recorded message when an alarm is received Important The unit description on your computer must match the unit description stored in your GMS 2000 for Alarm and Report call in features to work properly Intercall Delay The intercall delay is the amount of time the MGS 2000 will wait after completing a call before calling the next destination The delay is in seconds with a default of 30 Note A 30 second delay is too short to allow a call back if a pager is being called Increase the delay time enough to accommodate your pager Alarm Call Mode 6002 1443 Rev M The three selections for destination Alarm
60. mer use on a constantly scrolling set of two monitor measurement default screens with continuous update at a very high frequency 6002 1443 Rev M 2 3 OnLine Power 2 3 8 Output Isolation Transformer Illustration 2 2 Item 1 The output isolation transformer provides isolation between the inverter and critical load The power to the primary of this transformer is received form the unit and is transformed to required output voltage levels 2 3 9 Maintenance Bypass Switch Illustration 2 2 Item 28 The MBS Maintenance Bypass Switch removes the critical load from the backup power and providing utility input directly to the load in case of a malfunction of the unit or during system maintenance 2 3 10 Battery Bank located in External Battery Cabinet s The battery bank consists of sealed maintenance free valve regulated VRLA Type batteries as standard The batteries provide emergency power during power outages The battery bank includes a breaker for over current protection and DC disconnect for each cabinet or string to allow the servicing of the battery 2 3 11 System Component Layout ELECTRONIC TRAY ILLUSTRATION 2 2 COMPONENT LAYOUT 6002 1443 Rev M 2 4 OnLine Power Output Transformer T1 Input Transformer T3 Power Board Assembly A1 Interconnect Terminal Block Input T4B Output TB1 Battery TB3 DC B5 Output Inductor L2 Diode Bridge Pre charge PONS own 7
61. nit needs to be de energized for maintenance purposes 2 UPS Connects the critical load to the output of the unit and establishes normal operation NOTE 1 The middle position of the switch when present is not designed for operating the unit If the switch is left in the middle position there will be no output power when the invert is off 2 Switch contacts are 3 phase L L Line to Line 3 pole amp optional L N Line to Neutral 4 pole make before break 3 The wrap around by pass switch should be used with the same input output voltage 4 For different input output should be used with external transformer 5 Wrap around by pass switch should not be used with any built in distribution secondary auxilary circuit breakers 6002 1443 Rev M 4 4 OnLine Power 4 1 3 Specification Optional External Manual Bypass Switch Three phase 3 and 4 pole Make Before Break External Wrap Around By Pass Switch PART NO SELECTION CHART VOLTAGE I O PART VOLTAGE I O PART NO VOLTAGE I O PART NO VOLTAGE I O TYPE 208 208 3000 044 480 480 3000 044 480 208 3000 044 208 480 3000 044 3000 044 3000 044 3000 044 3000 044 3000 045 3000 044 3000 045 3000 044 3000 045 3000 044 3000 045 3000 044 3000 046 3000 044 3000 046 3000 044 3000 046 3000 044 3000 046 3000 044 3000 047 3000 045 3000 047 3000 045 3000 047 3000 045 3000 047 3000 045 VOLTAGE I O PART VOLTAGE I O PART NO VOLTAGE PART NO
62. nsfer to battery operation manually The unit will continue to run on batteries until the switch is released Upon release the Power Wave 3 transfers back to utility from the battery and resumes normal operation Input Transformer The Input Transformer conditions the voltage ahead of the DC rectifier and supplies power to the inverter and battery charger Maintenance Bypass Switch MBS This Maintenance Bypass Switch MBS allows the Power Wave 3 to be switched off line for maintenance or troubleshooting when the inverter malfunctions or PM Periodic Maintenance is required The MBS transfers the input power directly to critical load without any break or power disruption Before switching the MBS to the maintenance position turn on toggle switch S1 if unit is so equipped and then rotate the maintenance bypass switch to the maintenance MAN position Refer to the operation label on the unit After repair or periodic maintenance the MBS must be switched to UPS position in cases where the toggle switch has been incorporated with the switch be sure not to leave the switch in the middle position as this will not provide any output power when the unit is off Caution STOPPING ROTATION OF THE MAINTENANCE BYPASS SWITCH BETWEEN POSITIONS WILL RESULT IN THE REMOVAL OF OUTPUT VOLTAGE 6002 1443 Rev M 2 7 OnLine Power A RESERVE INPUT POWER SOURCE 12 i uL 1 IR 1 Q 1 131 CONTACTOR I
63. o 42 breakers See drawing below for panel mounting arrangement 4 7 2 Specification et DIM LOAD CENTER Part Number Description w E Hs 9100 1439 01 Load center QO Breaker 208Y 120 24 16 5 45 34 14 5 4 21 9100 1439 02 Load center QO Breaker 208Y 120 30 165 45 38 14 5 4 30 9100 1439 03 Load center QO Breaker 208Y 120 42 165 45 43 145 4 38 9100 1439 1 Load center EDB Breaker 480Y 120 18 20 46 36 20 525 26 9100 1439 12 Load center EDB Breaker 480Y 120 30 20 46 39 20 525 32 9100 1439 13 Load center EDB Breaker 480Y 120 42 20 46 56 20 5 25 44 pore 21 39 A jaunes DP 68 HT Ea ILLUSTRATION 4 3 UPS WITH EXTERNAL LOAD CENTER NOTE Customer to specify single pole or three pole QO or EDB type SQ D breaker with appropriate ampacity to maximum pole position of the load center When utilizing secondary auxiliary breakers be assure that each phase is loaded no more than 33 of unit capacity Load balancing within 10 is recommended 6002 1443 Rev M 4 8 OnLine Power 4 8 OPTIONAL 10 INPUT CURRENT HARMONIC FILTER P N 9100 1372 01 03 add approximately 300 Ibs to system weight Part Number Description 9100 1372 01 10 INPUT CURRENT HARMONICS FILTER USE FOR 10 15 25KVA 9100 1372 02 10 INPUT CURRENT HARMONIC
64. ration Verify the following connections have been made per wiring diagrams 6002 1443 Rev M 4 3 OnLine Power Wiring Inspection 1 Verify all power connections are tight 2 Verify all control wire terminations are tight 3 Verify all power wires and connections have proper spacing between exposed surfaces phase to phase and phase to ground 4 Verify that all control wires are run in individual separate steel conduit 4 1 2 Operation The external maintenance bypass switch is mounted in a box which is field installed on adjacent wall or on the side of the unit cabinet be sure not to block airflow This box includes a rotary switch to provide a single control for transferring to and from the utility The operator control switch for external manual bypass can be accessed by opening the cabinet s front door A single control simplifies the operation of the external manual bypass Caution switch however operating instructions must be carefully observed before using the bypass switch Using the improper sequence in operation of the bypass switch SW 1 and toggle switch S 1 when present could result in unwanted results AC INPUT rie CRITICAL EXTERNAL MAINTENANCE BYPASS LINE LOAD UPS MODULE BATTERY CABINET ILLUSTRATION 4 2 MAINTENANCE BYPASS SWITCH The Switch Positions are 1 MAINT Connects power to the critical load through the external maintenance bypass line The u
65. re unsuccessful 2 Aunit fault occurs which cannot be cleared 3 Normal operation of the critical load repeatedly causes an overload condition This is not a unit fault but a qualified person must analyze the total load connected to the unit to prevent malfunction Momentary overload conditions will be handled within the parameters of the unit but sustained overloads will cause failure 4 Any indicators or alarms operate abnormally or continuously 5 Any other abnormal function of the system occurs 6 If any abnormal battery condition is detected 7 When you are unsure of what action to take 5 3 STEPS TO TAKE If any of the above occur 1 Consult Appendix C LCD Display Menu and Troubleshooting Guide Record information on the LCD Display to relay to OnLine Power Customer Service and Support 2 Call OnLine Power Customer Support at 1 800 797 7782 or 1 800 PWR SRVC A Danger LETHAL VOLTAGES ARE PRESENT INSIDE THE EQUIPMENT EVEN WHEN THERE APPEARS TO BE NO INPUT POWER TO THE UNIT PROTECT YOURSELF FROM THE RISK OF ELECTROCUTION BY REFERRING SERVICE TO QUALIFIED PERSONNEL ONLY 6002 1443 Rev M 5 3 OnLine Power 5 4 PREVENTATIVE MAINTENANCE The unit maintenance consists of the basic tasks listed in this section Other maintenance functions require OnLine Power factory trained service personnel In order to comply with the terms of the prorated battery warranty you must maintain at least an annual individual voltage
66. remote signaling section 3 4 may be skipped REMOTE SIGNALING CONNECTION FORM C DRY CONTACT OPTION The Power Wave 3 includes the feature of providing dry relay contacts for remote signaling capabilities Signals available for remote annunciation are INPUT MALFUNCTION N O contact that closes upon loss of input power LOW BATTERY N O contact that closes when the unit is on battery operation and the batteries approach low limit discharge status BYPASS ON N O contact that closes when the unit transfers the load to static by pass SUMMARY ALARM N O contact that closes when the unit has any one of the following alarm conditions Internal malfunction system overheating input frequency out of tolerance low battery DC bus OV UV battery charger malfunction unit on bypass overload and battery under voltage Dry relay contacts for remote signaling are provided through the connector located on the inside panel remove distribution panel See illustration 6 5 Dry relay contacts have the following maximum ratings e 125 volts AC or DC maximum e 1 25 amperes maximum e 30 watts 50 VA maximum e Itis important that contact ratings are observed to prevent damage to the relays and the Control Board 6 4 2 Determine which signals will be used Connect wires customer supplied to the connector 6 4 3 See illustration 6 5 for location of dry C contacts terminal This concludes the installation procedure Pleas
67. rklift be used to remove the Power Wave from its shipping pallet See illustration 6 4 for the location of forklift slots ILLUSTRATION 6 4 FORKLIFTING 6 5 OnLine Power 6 3 UNIT INSTALLATION 6 3 1 Mechanical Installation Preparing to install unit 1 Before placing the Power Wave 3 onto the mounting bolts where it will be installed the conduit knockouts need to be removed The conduit knockouts are located on the sides and top of the cabinet See illustration 6 1 NOTE If site restrictions prevent routing of conduit to the locations where conduit knockouts are located do not drill holes in the cabinet without first consulting OnLine Power at 800 PWR SRVC 800 797 7782 The conduit knockouts provided are positioned to prevent airflow disruptions that could cause the unit to overheat Our engineers are available to assist you in locating the conduit to maintain unit reliability 2 All external cables to and from to unit and battery cabinet must be provided by the installing contractor based on the National Electrical Code for types of wire and distances It is important to pre determent which knockouts will be used to bring cables into and out of the unit Only remove the conduit knockouts that are to be used 3 Measure the locations for the conduits on the conduit knockouts 4 Punch holes in the conduit knockouts for the conduits 5 Anchor the Power Wave 3 to the mounting pad at the four 4 mounting locations s
68. rom the input or inverter power Secondly it provides voltage transformation and tight regulation of the output voltage while the Power Wave is operating from its internal inverter and it can be utilize to provide a different voltage than input source voltage ILLUSTRATION 2 1 POWER WAVE 3 6002 1443 Rev M 2 1 OnLine Power 2 2 BENEFITS Power Wave 3 is a self contained simple solution for back up power for any fluorescent or incandescent lighting source such as overhead fixtures exit signs etc It has been specifically designed to maintain 90 minutes of lighting power and ensure a safe building evacuation In addition since electrical disturbances can come from practically anywhere e g from the incoming power lines from within a building outside electrical disturbances include lightning strikes utility switching brown outs and accidents Electrical disturbances in a facility can be caused by load cycling elevators HVAC systems etc fault conditions welders and other electrical noisy equipment Whether the electrically disturbances are generated outside or within the facility the following power problems can occur e Complete power outages e Brown outs including momentary sags e Voltage surges e Transients including common mode and transverse mode noise e Frequency shifts and fluctuations The Power Wave 3 offers significant advantages over other alternatives For example just one of the smalles
69. s still operational due to redundant circuits After the second spike the device will show and alarm condition indicating replacement is mandatory Remote indication contacts TS allows remote control of the protection status 4 5 2 Specifications Part Number Description 9100 1440 01 IEC61643 1 EN61643 11 TVSS OPTION 208V 3 PHASE 40KVA 8 20U REPLACEABLE DIN RAIL ALARM INDICATOR AND INTERNAL DISCONNECTOR ANSI IEEE C62 41 011449 Second Edition Feb 2007 CULUS UL94 V2 3 PHASE PLUS NEUTRAL 9100 1440 11 IEC61643 1 EN61643 11 TVSS OPTION 480V 3 PHASE REPLACEABLE DIN RAIL ALARM INDICATOR AND INTERNAL DISCONNECTOR ANSI IEEE C62 41 011449 Second Edition Feb 2007 CULUS UL94 V2 3 PHASE PLUS NEUTRAL 4 6 OPTIONAL NORMALLY ON NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS P N 9100 1343 01 THRU 16 26 These circuit breakers are 1 pole 20 amp devices for protection of customer s circuits Normally ON C B Option Normally OFF C B Option Normally OFF Delay C B Option 6002 1443 Rev M 4 7 OnLine Power 4 7 EXTERNAL OUTPUT AUX CIRCUIT BREAKER LOAD CENTER WITH LOCKABLE ENCLOSURE 4 7 1 Description A lockable unique external interior load center with single pole of three pole auxiliary circuit breaker is provided for power distribution from the unit output to critical loads The panel board 24 30 or 42 pole can be used for customer selected ampacity QO breaker s up t
70. t Power Wave 3 Central Lighting Inverters can replace over 70 bug eyes to make service and maintenance in a centralize place much quicker and easier The air cooled OnLine PWM zero transfer inverter system is virtually silent and can be installed anywhere On line PWM technology provides switchover from utility to battery power without any interruption The Power Wave 3 is designed to fit the needs of virtually all power conditioning and emergency lighting backup applications It has been designed to power all forms of lighting fixture including HID incandescent fluorescent light communication and process control equipment The Power Wave 3 does not require any de rating as other products may when powering 100 lighting fixture including switching mode power supplies and or HID incandescent fluorescent lights 6002 1443 Rev M 2 2 OnLine Power 2 3 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 2 3 7 PRODUCT FEATURES The Power Wave 3 is designed in module concept for ease of maintenance and repair all electronic are centralize in two assembly module The following describes the major blocks within the Power Wave 3 Please refer to Illustration 2 2 Subassembly Component Location to find specific items Input Contactor K1 Illustration 2 3 Item 20 The input contactor is multifunctional First it provides connections for the input power to the unit Secondly the contactor disconnects the input line when an outag
71. te Dial Up with WEB data logger 9100 1501 ECC EMERGENCY CIRCUIT CONVERTER 9100 1502 ECM EMERGENCY CONTROL MODULE 6002 1443 Rev M 4 1 OnLine Power 4 1 Optional External Maintenance Bypass Switch P N 3000 044 thru 056 Typical THREE PHASE 3 POLE MAKE BEFORE BREAK EXTERNAL WRAP AROUND BY PASS SWITCH OPTIONAL LOAD DISCONNECT OPTIONAL 4 POLE OPTIONAL TRANSFORMER FOR DIFFERENT INPUT OUTPUT VOLTAGE FACILITY FEEDER CIRCUIT BREAKER SIZE CB FOR PROPER APPLICATION 3 PHASE MAIN INPUT POWER OPTIONAL ET LS LOPTIONALI OPTIONAL FOR STEP UP OR STEP DOWN LOAD DISCONNECT TRANSFORMER CIRCUIT BREAKER SEE INSIDE MBBS BOX ON LINE POWER ISO CARE PRODUCTS OPTIONAL THREE PHASE 3 4 POLE MAKE BEFORE BREAK EXTERNAL WRAP AROUND BY PASS SWITCH DIFFERENT INPUT OUTPUT VOLTAGE DUAL INPUT TO BY PASS 3 PHASE MAIN i INPUT POWER OBI 1 1 1 CUSTOMER IPOWER 480 208Y120 STEP DOWN SOURCE TO TRANSFORMER AND CUSTOMER POWER MBS BOX SUPPLY ng nor fed Je ol go ee ILLUSTRATION 4 1 EXTERNAL MAINTENANCE BYPASS SWITCH DIAGRAM 6002 1443 Rev M 4 2 OnLine Power Notes for Illustration 4 1 1 Switch contacts are 3 phase L L Line to Line 3 pole and optional L N Line to Neutral
72. te should also list the electrical requirements of the device The total load to be powered by the Power Wave 3 must not exceed its kVA rating If the total load is exceeded the Power Wave monitoring will sense an overload condition and a summary alarm will occur 6 1 5 Pre Installation All customer connections are brought through knockouts located on the top or on the sides of the unit The Power Wave 3 consists of one electronics and one or more battery cabinets depending on the unit size Before unpacking the equipment inspect the exterior the shipping container and the equipment itself for damage that may have occurred during transit If the shipping container or equipment itself shows evidence of damage note the damage on the receiving document before signing for receipt of the equipment Damage claims should be filed directly with the carrier 6 2 EQUIPMENT UNPACKING A Danger EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL CABINETS WEIGH SEVERAL HUNDRED POUNDS TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COMPLETELY UNDERNEATH THE UNIT Forklift Forks 6002 1443 Rev M Remove the equipment from the shipping carton Since the Power Wave is designed for pad mounting installations there are no casters It is suggested that a fo
73. ters Once you are online choose Program from the main menu then select Destinations You can also access the destination programming from the toolbar button labeled Destinations s Dialout Destinations for Plant 1 Oak amp Pine St News D Bestnation 1 2 3 4 m Mode ae a us Er Next Page Page 1 DD Dialout Destinations Form The Dialout Destinations form allows you to program information for up to 32 destinations The parameters and their options are listed below 4 13 OnLine Power Name This field allows you to program a description 16 characters maximum for each destination The name will appear on faxes and e mail transmissions whenever an alarm or report is send to a destination If you are entering a fax destination be sure to use the name of person who you intend to receive the fax Destination The destination is the actual telephone number or e mail address the GMS 2000 dials to deliver its report or alarm message The destination field can be up to 64 characters long for e mail addresses and 32 digits for all other dial types and may consist of numbers letters and special dialing codes Numeric Pagers The GMS 2000 can send alarm messages to numeric pagers It will automatically send its telephone number and the alarm input number when dialing to a numeric pager All you have to do is enter the telephone number of your pager Example 301 565
74. the damage if possible and contact Online Power at 800 PWR SRVC 800 797 7782 Before you install each battery in the cabinet remove it from its carton and thoroughly inspect it again on every side the top and bottom for any signs of physical damage including but not limited to cracks chips leaks bulges and so forth 4 f battery is dropped or makes hard contact with any abject inspect it again Batteries are heavy so exercise care when lifting them to the shelves of a battery cabinet If at any time you have any questions regarding the condition of a battery set it aside and notify the manufacturer at 800 PWR SRVC 800 797 7782 Do not use a questionable battery under any circumstances even temporarily The following diagrams show various battery connection configurations in the battery cabinets that are shipped with the unit Referto Table A 1 tor typical nominal battery voltage information Depending on your back up time you may have more than one string of batteries to meet your requirement 6002 1443 Rev M B 1 OnLine Power 192 Volt Nominal Typical i i A system with a maximum of four strings of 16 Typical 1 Strings of 16 Battery system batteries is available utilizing a maximum of four cabinets depending on battery run time requirements Consult the factory for details BATT C B O 192 VDC buss O O INVERTER CABINET E Z O10 p I AN E gt o 5 4 3 2 1 im 3 STRING
75. time requirements Consult the factory for details INVERTER CABINET C T 552 VDC 2 STRING 3 STRING 4 STRING ILLUSTRATION B 4 B 5 6002 1443 Rev M OnLine Power APPENDIX C LCD DISPLAY MENU AND TROUBLESHOOTING GUIDE The Power Wave 3 utilizes an on board microprocessor that continuously monitors and displays all functions measurement alarm alert and system status in real time by utilizing high frequency digital signal processing for a reliable and user friendly battery back up system Two screens A B are updated continuously Start up Screen When input power is applied to the unit LCD panel lights up and displays OnLine Power UPS If the LCD display panel is not lit a problem exists Contact OnLine Power Services at 1 800 PWR SRVC 800 797 7782 Screen A The first default screen appears as below UPS NORMAL XX KVA INPUT OK CHRG ON BATTERY OK DC OK ON INVERTER OUT OK The display may say Line 1 UPS NORMAL XX KVA XX KVA indicates the KVA rating STAND BY or NORMAL indicating normal operating modes STAND BY ALARM MALFUNCTION indicates unit alarm condition and MALFUNCTION indicates that the unit failed or had a persistent alarm condition This will require a system reset by cycling power Shut the unit off and wait until LCD is dark Restart the unit Line 2 INPUT OK CHG ON INPUT OK INPUT BAD CHRG ON CHRG OFF 6002 1443 Rev M
76. tion The Remote Status Panel may come with 5 LED s HORN TEST SWITCH and SILENCE SWITCH Status LED s are as follow e INVERTER ON e LOW BATT e INPUT FAIL ON BYPASS SUMMARY ALARM Note In some units it might require 120VAC Power Side Mount Provision f are ar REMOTE STATUS PANEL Back Mount i Provision ON BYPASS 3 o ON INPUT OUTPUT n 6 edle O ANA ON BATT Batt reer HORN To UPS P100 Terminal Block See installation instruction shipped with the assembly Use Bumpers for console install ILLUSTRATION 4 2 1 REMOTE STATUS PANEL 6002 1443 Rev M 4 6 OnLine Power 4 4 OPTIONAL FORM C CONTACTS FOR ALARMS P N 9100 1362 02 4 4 1 Installation Terminal strip TB is provided on the optional alarm relay board for user connection to the individual alarm contacts 4 4 2 Operation The Remote Contact Board includes isolated Form C contacts for the following alarm signals TB 1 TB 2 TB 3 TB 4 TB 5 TB 6 LOW BATTERY ON BYPASS SUMMARY ALARM NOT USED INPUT FAIL COMMON 4 5 OPTIONAL TVSS P N 9100 1440 01 4 5 1 Operation The TVSS contains energy absorbing components designed for specific line configurations The device has two stage protection When protection components are damaged by absorbed transients the device will show a reserve flag indicating a need for replacement At this time the device i
77. umidity and utility voltage The cabinets is rugged and corrosion resistant and the footprint of the Power Wave 3 is less than 6 square feet Listed below are the environmental specifications for the Power Wave Adequate clearance in the front of the equipment MUST be provided for service access Operating Environment e AMBIENT TEMPERATURE 0 C to 40 C 32 F to 104 F e OPERATING ALTITUDE 1 829 M 6 000 FT DERATE 10 FOR EACH ADDITIONAL 305 M 1 000 FT UP TO 2 744 m 9 000 FT e RELATIVE HUMIDITY 0 to 95 non condensing Operating the Power Wave and batteries at either extreme of the temperature range may affect the long term reliability of the system This is especially true of the sealed maintenance free batteries Sealed maintenance free batteries are designed to operate at normal room temperatures 72 to 77 F 22 2 C to 25 c Storage Environment Provide a storage environment which meets the following conditions e AMBIENT TEMPERATURE 20 C to 70 C 4 F to 158 F e RELATIVE HUMIDITY 0 to 95 non condensing e NOTE System should be stored in its original packaging e Batteries must be recharged after 90 days if they are not put into service otherwise the batteries will be permanently damage e Batteries have longer shelf life if they are stored below 25 C 77 F Keep stored batteries fully charged Recharge the batteries every 90 days Location Considerations Illustration 6 1 See Technical drawings
78. urrent when first turned on or at other times during operation Please check load requirements for proper sizing of the system 6002 1443 Rev M 2 12 OnLine Power 3 1 3 1 1 SECTION OPERATION START UP PROCEDURES The unit s batteries are shipped directly from battery the manufacturer to insure brand new batteries and allow an opportunity for the installing contractor to schedule their arrival when they are ready to commission the system The battery cabinet and the interconnect cables are shipped with the electronics section of the inverter in a cardboard box located inside each battery cabinet OnLine Power service personnel must perform initial start up or a factory trained authorized representative To request start up fax a completed Request Turn On form 6002 1545 to 323 721 3929 or e mail it to info 800pwrsrvc com Form is now available in the web at www 800pwrsrvc com The start up procedure described in this manual is a reference only to a start up of the Power Wave 3 for maintenance and shutdown Please be sure not to start up the unit without the assistance of a factory trained authorize personal as failure to do so may damage the unit and void the unit warrantee Verify that the main input circuit breaker battery breaker and output circuit breaker s are in the OFF or down positions Refer to illustration 2 2 for the location of the circuit breakers 3 1 2 Check that all cable connections are firmly secured
79. ut voltages The standard VRLA Valve Regulated Lead acid maintenance free batteries provide 90 minutes of backup power as standard Upon restoration of input power the Power Wave 3 automatically resumes normal operation and immediately begins to recharge the batteries for the next power outage The Power Wave 3 has an internal bypass circuit which maintains the power to the load in case of internal system or component malfunction The Power Wave 3 provides comprehensive monitoring capabilities In addition to the LCD display it provides four dry relay contacts for remote monitoring capabilities The Power Wave 3 contains as standard features AS 400 RS 232 RS485 data transmission ports with optional soft ware and many other communication options The Power Wave 3 is an on line three phase PWM high frequency digital signal processing true double conversion inverter system available in output ratings of 10 15 20 25 30 40 50 KVA and 50 KW The Power Wave 3 is listed for compliance to UL1778 UL924 UL924A and CSA107 1 standards The Power Wave 3 is available with an input or output voltages of 480Y 277 or 208Y 120 VAC three phase This information is provided on the nameplate located on the inside front door of the unit See Appendix A for a complete listing of the Power Wave 3 specifications The Output transformer performs two critical functions First it provides excellent common mode and normal mode noise isolation of the load f
80. utral and ground to the terminal shown on the Ground Lug located on the based of the cabinet From 1 Phase A e Connect Phase A B C Utility 2 Phase Power 3 Phase C Input Power 4 Neutral e Please refer to the functional diagram for Dual Input Power System Illustration 2 5 and 2 6 4 Connect the output wires to the output terminal block TB12 Five 4 wires total Phase A Phase B Phase C neutral and ground To tighten connections use torque value on terminal block 2 0 6 awg 120in Ibs 14NM To 1 Phase A Critical 2 Phase B Load 3 Phase C Output Power 4 Neutral 5 Connect TB6 the battery terminal block inside the unit three 3 wires for ground based on local code wire type and distance to external battery cabinet circuit breaker These cables are not provided Do not apply power the Power Wave 3 at this time Refer to battery connection diagram MAINTENANCE BYPASS SWITCH E 4 FORM C ALARM TERM L BATTERY CB INPUT T B INPUT CB OUTPUT T B OUTPUT CB BATTERY T B NEUTRAL BUS GROUND T B AUX OUTPUT BREAKERS GROUND LUG ILLUSTRATION 6 5 POWER WAVE 3 CUSTOMER CONNECTION 6002 1443 Rev M 6 7 OnLine Power 6 4 6 4 1 CONNECT OUTPUT POWER TO OUTPUT POWER TB11 Phase A Phase B Phase C Neutral as shown above This concludes the electrical connections If there are no requirements for
81. w line limit for indefinite periods of time meets and exceeds the UL 924 requirement Battery The battery bank consist of 16 24 26 or 46 12 volt batteries depending on the unit s specified capacity providing the reserve energy to sustain the load when suitable AC input power is not present The batteries are designed and tested to meet UL 924 requirements The standard VRLA Valve Regulated Lead Acid batteries are sealed and maintenance free DC Choke The DC choke helps boost battery voltage to a higher internal DC bus voltage while it reduces high frequency noise Output AC Inductor The Output AC Inductor acts as a filter circuit component to reduce high frequency noise to the output transformer Output Transformer The Output transformer performs two critical functions First it provides excellent common mode and normal mode noise isolation of the load from the input or inverter power Secondly it provides voltage transformation and tight regulation of the output voltage while the Power Wave is operating from its internal inverter and it can be utilize to provide a different voltage than input source voltage 6002 1443 Rev M 2 6 OnLine Power 2 4 10 2 4 11 2 4 12 Inverter Test Switch The Inverter Test Switch is a momentary push button for manually testing the Power Wave 3 and its batteries for proper operation With Power Wave 3 in operation the test switch is pushed and held the unit will automatically tra
82. y that the output voltage is 120 208 277 480 VAC per the nameplate 3 1 6 Close battery breaker in the unit cabinet and in battery cabinet s 3 1 7 At this time the Power Wave should be providing AC line power If the Power Wave is not operating in the normal mode turn off the input circuit breaker s including the battery circuit breaker s Contact OnLine Power at 800 797 7782 for technical assistance 3 1 8 Recheck that the output voltage is 208Y 120 or 480Y 277 VAC If the output voltage is approximately the same as the nameplate turn on the loads 3 1 9 Verify battery operation and the inverter test switch e To place the Power Wave in battery operation simulate loss of input power press and hold the yellow Inverter Test Pushbutton With the pushbutton in the hold position the Power Wave should be running on its internal batteries e Verify that the LCD panel displays is as below where xx is the kVA of this unit Line 1 UPS NORMAL 0 xx kVA Line 2 INPUT BAD CHRGR ON Line 3 BATTERY OK DC OK Line 4 ONINVERTER OUT OK e Release the yellow Inverter pushbutton and Verify that the LCD PANEL displays INPUT OK CHRGR OFF Caution Be sure to release the Push button after the test so it will not deplete the batteries 3 1 10 The Power Wave is now lully functional providing clean sine wave power to the load with battery back up in case of an input power malfunction

User Manual - OnLine Power, Inc.

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