402093 OM iUPS200 Installation And Operating Manual 1-2
Contents
1. 20 ATEX IDE Us apa es ye es re dit ae chem ye eae 21 10 EC Declaration Of Conformity lt 4 0 0 kc ave eal avenue 22 lt ashe hele 24 1 Introduction The iUPS200 Zone 2 UPS Enclosure is designed to supply an uninterruptible power supply for critical equipment located in hazardous areas The unit is designed to be either wall or pole mounted next to the equipment to power The system includes advanced battery charge controls including built in temperature compensation feedback to ensure the correct charging of the internal lead acid battery Optional features include UPS status indication via enclosure mounted lamps power output disable via an enclosure mounted button active logic outputs for connection to a DCS or other equipment plus the option of plug and socket cable entry instead of cable glands Mounting solutions and brackets are available on request 2 Safety Information and Notes 2 1 Storage of this Manual Keep this user manual safe and in the vicinity of the device All persons who have to work on or with the device should be advised on where the manual is stored 2 2 Special Conditions Of Safe Use 2 2 1 ATEX There are no special conditions of safe use 2 3 List Of Notes The notes supplied in this chapter provide information on the following e Danger Warning o Possible hazard to life or health2. 3 1 6 Fusing 24V System 90 264VAC 50 60 2 input fuse F1 20mm x 5 2 24VDC output fuse F2 20mm x 5 T3 15A Battery protection fuse F3 20mm x 5 T5A Warning All cables should be connected to the iUPS200 via the correct cable gland and fitted by a competent person Warning Changes in the design and modifications to the equipment are not permitted If any changes are performed on the enclosure the ATEX certification will become void Warning The installer MUST ensure that that all cables have adequate mechanical protection to avoid damage to the wires 3 1 7 Setting to work Once all cables are connected correctly and inspected refit the enclosure lid using the four screws previously removed Use a torque screwdriver set to 2 5 Nm Do not over tighten screws Important Ensure the lid is secure correct cable glands are fitted and the unit device correctly wired and earthed for the particular application before applying power Important iUPS200 is supplied fitted with anti seize grease on the lid screws Ensure that this is not removed during installation See section 6 5 1 for maintenance details Important that the lid gasket is clean and undamaged before fitting the lid Take care not to trap the lid earth cable in the gasket when closing the lid 12 4 Operation 4 1 1 Power On Off When AC power is applied to the unit the 12 24V output will power on and the various indica
3. atmospheres ATEX Provisions of the directive fulfilled by the equipment II 3G Ex nA II T4 Tamb 20 C to 55 C Notified Body for EC Type Examination Intertek 0359 Leatherhead UK EC Type Examination Certificate 5094 46416 latest supplement 509 46416 1 dated 26 September 2011 Notified Body for Production SIRA 0518 Chester UK Harmonised Standards used None Other Standards and Specifications used Electrical Apparatus for potentially explosive atmospheres General Requirements A review against EN 60079 0 2009 which is harmonised shows no significant changes relevant to this equipment so EN 60079 0 2006 continues to represent State of the Art Electrical apparatus for explosive gas atmospheres Construction test amp marking of type n A review against 60079 15 2010 which is harmonized shows no significant changes relevant to this ipment so EN 60079 15 2010 continues to represent State of the Art EN 60079 0 2006 EN60079 15 2005 Page of 2 402088 1 0 www extronics com Extronics Ltd 1 Dalton Midpoint 18 Middlewich OHU Tel 44 0 845 277 5000 Fax 44 0 845 277 4000 E mail info extronics com W rated in Engiand and Wal 22 Operating Manual Hazardous Area Specialists Directive 2004 108 EC Electromagnetic Compatibility Directive EMC Harmonised Standards used A1 2007 I
4. BTS revised d of c updated information on greasing threads and coating 1 1 5 1 2 Added warranty statement 20 12 13 BTS 24
5. are fully charged With the AC Power OFF Indicator Battery Logic Output Status Condition Descnpuon Charging OFF No charging when AC OFF When 15 battery energy left early Batt High OFF lt 11 3V 22 6V warning Input OK OFF lt 12 8V 25 6V Unit AC OFF DC Input goes down Load disconnected to protect battery from DC Output OFF lt 10 6V 20 9V deep discharging 4 1 5 Output OFF Pushbutton When the unit is in back up mode AC power OFF the DC output can be turned off by pressing the pushbutton as per diagram 4 1 2 or closing the contact as per diagram 4 1 3 Note When using this option please keep the iUPS200 loaded If not the iUPS200 will take 10 20 seconds for the DC output to turn off due to the internal circuits discharging during this time keep the pushbutton or contact closed 14 5 Testing and Commissioning 7 8 9 This manual should be fully read amp the iUPS200 unit should be fully inspected prior to powering on Check all fuses for their correct ratings see section 3 1 5 or 3 1 6 depending on system output voltage Connect any required test lamps pushbutton etc to the logic outputs if optional pushbuttons and indicators are not fitted see section 4 1 3 Connect a suitably rated load to terminals F2 amp see section 3 1 4 12V system 2 140 max 5 6A 24V system 9 230 max 2 6A Apply 90 264VAC 50 60Hz mains power to
6. iUPS200 devices must be so transported and stored that they are not subjected to any excessive mechanical stresses 6 2 Authorized Persons Only persons trained for the purpose are authorized to handle the iUPS200 they must be familiar with the unit and must be aware of the regulation and provisions required for correct installation as well as the relevant accident prevention regulations 6 3 Cleaning and Maintenance The iUPS200 and all its components require no maintenance are self monitoring All work on the iUPS200 by personnel who not expressly qualified for such activities will cause the guarantee to become void 6 3 1 Lead Acid Batteries The rechargeable sealed lead acid batteries contained within the iUPS200 have operational life of approximately 3 5 years dependant on charge discharge cycles After this period it is recommended to replace them please contact Extronics for battery sales and advice These batteries may be changed in the field by the customer under safe area conditions Please note that is essential that this work is carried out by a competent person and care must be taken not to short the terminals of the batteries Please contact Extronics for advice before performing this work 16 6 4 Safety Precautions Important For the installation maintenance and cleaning of the units it is absolutely necessary to observe the applicable regulations and provisions concerned with explosion protect
7. iUPS200 shall be operated as intended and only in an undamaged condition Never operate the iUPS200 unit outside its rated voltage current amp power as indicated in the specification or the safety of the unit may be impaired This assembly may weigh up to 15Kg depending on requirements therefore ensure the assembly is mounted using suitable fixtures Never exceed the maximum loading of the iUPS200 as stated in the specifications The iUPS200 is supplied fitted with anti seize grease on the lid screws Ensure that this is not removed during installation See section 6 5 1 for maintenance details The iUPS200 is supplied with a protective coating to prevent tea staining of the stainless steel enclosure Take care to avoid damage to this coating during handling and installation Do not use abrasive substances to clean the enclosure See section 6 5 2 for maintenance details rating Manual 3 Installation and Setting to Work 3 1 Installation iUPS200 is simple to install and can be secured directly to suitable surface using the mounting holes on the Enclosure The iUPS200 enclosure can be installed either horizontally or vertically but never upside down Correct Vertical Installation Correct Horizontal Installation Sany e o 3 1 1 Removing the cover Unscrew the four screws and remove the enclosure lid If required the lid earth connection may be removed but ENSURE it is re connected w
8. terminals F1 N amp see section 3 1 4 Check nominally 12 24V at terminals F2 amp voltage will vary dependant on load and charging voltage Ensure battery is fully charged amp then turn off the mains power supply Check 12 24V is still present at terminals F2 amp Check the lamps operate as per section 4 1 4 10 Leave the mains power off for approx 120 minutes or until the 12 24V turns off 11 Check the lamps operate as per section 4 1 4 12 Re apply the mains power to reset 13 Check 12 24V is still present at terminals F2 amp 14 Turn off the mains power amp press the output off pushbutton to turn the unit off 15 6 Intended Purpose Usage Important Before setting the units to work read the technical documentation carefully Important latest version of the technical documentation or the corresponding technical supplements is valid in each case The iUPS200 is built using modern components and is extremely reliable in operation however it must only be used for its intended purpose Please note that the intended purpose also includes compliance with the instructions issued by the manufacturer for installation setting up and service Any other use is regarded as conflicting with the intended purpose The manufacturer is not liable for any subsequent damage resulting from such inadmissible use The user bears the sole risk in such cases 6 1 Transportation and Storage All
9. tightening may cause damage 4 Ensure all connections are tight and then push the terminal insulating boot over the battery terminals 5 Fit the T10A fuse supplied into the screw in fuse holder amp then insert into the battery fuse FS3 see section 3 1 4 3 2 2 2 24V Unit Batteries The unit is supplied with a plastic bag attached inside the unit that contains the required parts for re connecting the batteries Contents 3 off battery terminal insulating boot 1 off battery link wire 1 off T5A fuse 1 off fuse holder cap AT ALL TIMES TAKE GREAT CARE NOT TO SHORT THE LEAD ACID BATTERY TERMINALS AGAINST THE METAL ENCLOSURE OR BRACKETS 6 Remove and loosen the brackets within the iUPS200 unit amp fit the 2 off 9020002 lead acid batteries Re fit and tighten all brackets 7 Fit the 3 off terminal insulating boots over the terminal wire amp also the battery link wire 8 Re connect the wire crimps to the outer terminals the battery link wire and also the temperature sensor crimp to the terminal as shown Take great care with these connections as over tightening may cause damage 9 Ensure all connections are tight and then push the terminal insulating boot over the battery terminals 10 Fit the T5A fuse supplied into the screw in fuse holder amp then insert into the battery fuse FS3 see section 3 1 4 3 1 3 Fitting the Cables The iUPS200 unit should be powered via an external site circui
10. E XTRONICS Installation amp Operating Manual x iUPS200 This page is intentionally left blank Warranty For full details of the Extronics warranty policy please go to the Company section of the website and download Terms and Conditions Document Number 402093 See Last Page for Revision Details 2013 Extronics Limited This document is Copyright Extronics limited Extronics reserve the right to change this manual and its contents without notice the latest version applies Contents OI lait iii 4 2 Safety Information and Notes 5 2 1 Storage of this Manual ashes 5 2 2 Special Conditions Of Safe Use 5 Aug 5 23 E E ee ea es 5 3 Installation and Setting to Work 7 Aa ath a GA ct 7 3 1 1 REMOVING 8 Sila2 Fitting the Batters iiin lie eee 9 2 1232 Fitting the amp ainarra ar aE ei 11 35134 11 3 5 Fusng A12V SYVSI6Msssseses nda 12 3 1 6 Fusing 24V ionici 12 3 1 7 Setting to 12 CE E RR NRE Ee en 13 Power On Off ei al
11. e Caution o Possible damage to property e Important o Possible damage to enclosure device or associated equipment e Information o Notes on the optimum use of the device Warning Installation to be by skilled electricians and instructed personnel in accordance with national legislation including the relevant standards and where applicable in accordance with IEC 79 17 on electrical apparatus for explosive atmospheres Warning For the installation maintenance and cleaning of the units it is absolutely necessary to observe the applicable regulations and provisions concerned with explosion protection EN60079 0 2006 EN 60079 14 2008 as well as the Accident Prevention Regulations Warning The iUPS200 must only be operated in ATEX Gas Zone 2 hazardous areas or in safe areas Refer to the ATEX certificate for further information Warning The iUPS200 must not be stored or operated outside of its rated temperature range as stated on the ATEX certificate Warning The technical data indicated on the iUPS200 ATEX rating plate this manual and the ATEX certificate must be observed at all times Warning Warning Warning Warning Caution Important Important Important The ATEX rating plate must be fitted at all times if damaged it must be replaced immediately the iUPS200 must be removed from service and the hazardous area Changes in the design and modifications to the equipment are not permitted The
12. ee e a IR 13 4212 Stalus Indicatofs lead 13 4 1 3 Logic Outputs dina ii lina i 13 4 1 4 Status Indicators Logic Outputs Operation 14 42125 14 5 Testing Commissioning alal lillo 15 6 Intended Purpose ara 16 6 1 dia 16 6 2 A thorized Persons 16 6 3 Cleaning and 16 6 3 1 Lead Acid 16 6 4 Eh 17 6 5 Cleaning and Maintenance Intervals 17 6 5 1 Screw 22 6 17 Bi gt UM ACE eee ROSI acted 17 6 6 Aggressive substances and environments n 17 6 7 Exposure to external 222 244 17 iPecnnical Dale ille 18 7 1 ea 18 7 2 Enclosure DIMENSIONS lille 19 Br gt 0
13. hen the lid the re fitted Top of Enclosure Lid screws Vent Valve Certification Label Optional Input OK Lamp Optional Output Off Button Optional Battery Charging Lamp Optional Power Supply Optional Logic DC Output Power Battery Cable Entry Outputs Cable Cable Entry High Lamp Entry Diagram 3 1 1 3 1 2 Fitting the Batteries The iUPS200 unit is delivered to the customer with the lead acid batteries removed to avoid any damage in transit The batteries need to be installed and re connected as per the diagrams below before the unit can be powered up 3 2 2 1 12V Unit Battery AT ALL TIMES TAKE GREAT CARE NOT TO SHORT THE LEAD ACID BATTERY TERMINALS AGAINST THE METAL ENCLOSURE OR BRACKETS The unit is supplied with a plastic bag attached inside the unit that contains the required parts for re connecting the batteries Contents 1 off battery terminal insulating boot 1 off T10A fuse 1 off fuse holder cap AT ALL TIMES TAKE GREAT CARE NOT TO SHORT THE LEAD ACID BATTERY TERMINALS AGAINST THE METAL ENCLOSURE OR BRACKETS 1 Remove and loosen the brackets within the iUPS200 unit amp fit the 1 off 9020001 lead acid batteries Re fit and tighten all brackets 2 Fit the 1 off terminal insulating boots over the terminal wire 3 Re connect the wire crimps to the outer terminals and also the temperature sensor crimp to the terminal as shown Take great care with these connections as over
14. impact Additional protection is required to protect against these external stresses The iUPS200 will require additional protection if it is installed in a location where it may be subjected to damage 17 Operating Manual 7 Technical Data 7 1 Specification Maximum Power Output 67 2W 5 6A 12V or 62 4W 2 6A 24V depending on battery power output voltage ordered Enclosure Material 316L Stainless Steel Weight Approximately 15 Kg Environmental Operating temperature 20 C to 55 C Storage temperature 20 C to 85 C Relative humidity 0 to 95 non condensing Output Connections 12 24VDC fused screw terminals via M20 cable gland See cable gland option 6 Logic Outputs Battery charging logic signal at battery voltage Battery being charged Optional when status indicators not used Battery high logic signal at battery voltage Battery voltage OK gt 11 3V 22 6V Input OK logic signal at battery voltage Unit supplied by AC gt 13 1V 26 2V Output off opto isolated input Connect to to turn off output voltage remove and re apply mains to reset 7 2 Enclosure Dimensions 8 Codes iUPS200 Zone 2 UPS Enclosure Specify option 1 Battery Power Output Voltage 12V DC 24V DC Specify option 2 Battery Charging Indicator No Battery Charging Indicator Fitted Enclosure Indicator Fitted Specify option 3 Battery High Indicator No battery High Indicator Fit
15. ion EN 60079 0 2006 EN 60079 14 2008 as well as the Accident Prevention Regulations 6 5 Cleaning and Maintenance Intervals The cleaning intervals depend on the environment where the system is installed 6 5 1 Screw Thread Lubrication The threads of the lid screws and inserts have been coated with a thin layer of Rocol 251 stainless steel anti seize grease It is recommended that this grease should be periodically renewed if the lid is opened frequently to prevent the stainless threads from binding Warning Use only Rocol 251 or Loctite 771 as thread lubricants as other materials may damage the gasket and invalidate the IP rating of the enclosure 6 5 2 Surface Coating The iWAP200 enclosure has been coated with a material to prevent tea staining of the stainless steel by build up of salt deposits in marine environments Avoid damage of the surface of the enclosure during handling However if tea staining does occur it is purely cosmetic and does not affect the performance of the enclosure If the coating is damaged it can easily be re applied in the field Contact Extronics for details 6 6 Aggressive substances and environments The iUPS200 is not designed to come into contact with aggressive substances or environments please be aware that additional protection may be required 6 7 Exposure to external stresses The iUPS200 is not designed to be subjected to excessive stresses e g vibration heat
16. nformation technology equipment es Radio disturbance characteristics Limits and methods of measurement Other Standards and Specifications used A2 2003 Information technology equipment Immunity characteristics Limits and methods of measurement review against 55024 2010 which is harmonized shows no significant changes relevant to F this equipment so EN 55024 1998 continues to represent State of the Art EN55024 1998 Other Standards and Specifications used Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements A review against EN61010 1 2010 which is harmonized shows no significant changes relevant to this equipment so EN 61010 1 2001 continues to represent State On behalf of Extronics Ltd I declare that on the date the equipment accompanied by this declaration is placed on the market the equipment conforms with all technical and regulatory requirements of the above listed directives David Crump Technical Manager Date 19 11 2013 Page 2 of 2 402088 1 0 Extronics Ltd 1 Dalton Way Midpoint 18 Middlewich CW10 OHU Tel 44 0 845 277 5000 Fax 44 0 845 277 4000 E mail info extronics com Web www extronics com in England and Wales Registration N 23 11 Manual Revision Revision Description Date By 1 0 Initial Release replaces 325722 08 Added 19 12 13
17. t breaker fuse switch to allow disconnection of the power This circuit breaker fuse switch should be located close to the unit and be suitably marked to identify it as the isolating device for the iUPS200 unit The connections for AC power in and DC out will need to be terminated into the enclosure via the correct cable entries shown in Diagram 3 1 1 The user wiring to connect the AC power in and DC out to the unit are connected via screw terminals and must conform to the following specification All wires to be rated 90 C or greater operating temperature and be capable of carrying a current of at least 10A All wires should be stripped and if stranded cable is used should be crimped using 2 5mm bootlace ferrules The stripped crimped wires should then be placed into the corresponding screw terminal and securely screwed in place If using solid core cable Minimum cross section of cable 0 2mm Maximum cross section of cable 2 5mm If using crimped stranded core cable Minimum cross section of cable 0 25mm Maximum cross section of cable 1 5mm 3 1 4 Terminals Input Output Terminals Battery Fuse Terminal F2 1 lt To colle WM E 11 DC Output AC Input 3 1 5 Fusing 12V System 90 264VAC 50 60 2 input fuse F1 20mm x 5 2 12VDC output fuse F2 20mm x 5 T6 3A Battery protection fuse F3 20mm x 5 T10A
18. ted Enclosure Battery High Indicator Fitted Specify option 4 Input OK Indicator No Input OK Indicator Fitted Enclosure Input OK Indicator Fitted Specify option 5 Output Off Pushbutton No Output Off Pushbutton Required Enclosure Output Off Pushbutton Fitted Specify option 6 Enclosure Cable Entry Cable Glands Fitted No Cable Glands Fitted M20 gland holes drilled iUPS200 1 2 3 4 5 6 7 12 24 Specify option 7 Logic Outputs only available when status indicators are not used gland not fitted if option 6N selected No Logic Outputs Required Logic Outputs Fitted 20 9 ATEX Label a iUPS200 EXTRONICS Serial ITSO9 ATE 46416 GExnA Il T4 20 C lt lt 55 Vin Max Vout Max Aout Max DO NOT OPEN WHILE ENERGIZED DO NOT OPEN W HEN AN EXPLOSIVE GAS ATMOSPHERE IS PRESENT ENSURE GASKET IS FITTED BETWEEN BODY AND COVER TO MAINTAIN IP RATING Extronics Ltd Meridian House Roe Street Congleton CW12 1PG Tel 44 0 1260 297274 Fax 44 0 1260 297280 E mail nfo extronics com W eb www extronics com 2 21 iting Manual 10 EC Declaration Of Conformity Hazardous Area Specialists EC Declaration of Conformity Extronics Ltd 1 Dalton Way Midpoint 18 Middlewich Cheshire CW10 OHU UK Equipment Type iUPS200 Directive 94 9 EC Equipment and protective systems intended for use in potentially explosive
19. tors or logic outputs will energise If the AC power is removed the unit will then go into backup mode amp supply the load with 12 24V for an amount of time dependant on load amp conditions See section 5 for instructions on testing and commissioning the iUPS200 4 1 2 Status Indicators Option If the status indicator option is fitted the enclosure will have a number of indicators and or a pushbutton as per the diagram 4 1 2 below Output Off Input OK Button Lamp Battery Battery Charging High Lamp Lamp Diagram 4 1 2 4 1 3 Logic Outputs Option If the logic output option is fitted a multi core cable can be installed via the optional M20 cable gland and the connections can be made directly into the A26000x module as per diagram 4 1 3 below The logic outputs are active signals switched at the output DC voltage 12 24V BuiBueyd Rea v yodu 9 neg 8 peg 6 13 Diagram 4 1 3 4 1 4 Status Indicators Logic Outputs Operation With the AC Power ON Indicator Battery Logic Output Sras Condition Charging ON gt 0 08A 0 05A Charging battery Batt High ON gt 11 3V 22 6V Battery voltage OK early warning Input OK ON gt 13 1V 26 2V Unit supplied by AC DC Output ON gt 10 4V 20 9V Output connected to battery PSU active Charging indicator logic output will go OFF when batteries
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