TN31 Series 10-20kVA user manual V2,1
Contents
1. 5 232 DB 9 INVERTER SWITCH MANUAL s BYPASS SWITCH LOCATED BEHIND PLATE eco eee OUTPUT TET TERMINAL i BLOCK ottLu rz cz 4 5 A Way S 0 n i UPS Systems Inc Input Output and External Battery Connection The UPS is supplied with an input output and battery terminal block assembly located on the rear of the UPS system The cable sizes and distribution methods used during installation are subject to the local and national electrical codes of practice therefore are not detailed here Permanent wiring must be routed to the terminal block using appropriate materials as required by local and national codes External battery bank connections are described later in this manual Ensure UPS is provided with an adequate ground earth 9 9 INPUT BAT OUTPUT OJO O OI O 120 240 Figure 4 5 1 Rear view of the TN31 10 kVA amp 15 12 A Way S 0 n i UPS Systems Inc 5 Start up Shutdown Once the UPS is installed make sure it is located on a sturdy well ventilated surface and that the exhaust fans and ventilation grills are not obstructed 5 1 Turn On From Shutdown Procedure 1 Switch the BATTERY Breaker to the position Wait 10 seconds 2 Switch the INPUT Breaker to the ON position Control Panel LED Display will light up fans will start etc Wait 25 second2. 14 TROUBLESHOOTING NOTE Please check the following fundamental items if the UPS does not function before calling your authorized service center 1 15 the UPS connected to the power source 2 Is the input voltage and frequency within operating parameters NOTE When you contact Always On for service please provide the following information 1 UPS model name and serial number 2 Date the problem occurred 3 Complete description of the problem Table 14 1 is a troubleshooting chart for diagnosing abnormal and unusual situations It includes some possible problems and solutions occurring under daily operation TROUBLESHOOTING CHART Possible Reasons Input power source failure Check power source Breaker switch on rear panel has been Press breaker switch to On UPS will not operate opened position ornolights or warning Time of pressing On button is too Press On button longer than 1 sounds appear after short second pressing On Off Turn off UPS remove all load to switches test for internal short circuit Output short circuit or UPS overload dies Press On button longer than 1 second Indicates no utility and No power source input Check power source input rns 5 1 aa SENGES UPS Input Breaker switch has opened Turn breaker switch to the On seconds position Fault light ON and UPS has failed Contact dealer or service center buzzer keeps beeping for help Buzze
3. This function allows electrical removal of the UPS from the load Thus maintenance may be performed on the UPS without disturbing the load This is an important feature for mission critical load applications On the 10 amp 15 kVA UPS systems the switch is located under a removable cover plate to prevent accidental operation On the 20 system the switch is located behind the front door MANUAL BYPASS SWITCH TT wasay LOCATED 55 BEHIND PLATE k REMOVE COVER PLATE Figure 8 1 Figure 8 2 20 kVA Manual Bypass Switch Location 10 amp 15 Manual Bypass Switch Location During normal operation the Inverter Switch is the position and the Maintenance Switch 15 the OFF position WARNING Utility power will be fed directly into the inverter output if both the Inverter and the Maintenance Switches are ON during normal operation This may damage the UPS 8 1 To put the UPS into Manual Bypass mode a Push OFF button green one on front display panel and the BYPASS LED will light if using manual bypass mode b Open the metal cover of the MANUAL BYPASS SWITCH CB3 Switch on the MANUAL BYPASS SWITCH CB3 c Switch off CB2 d Turn off the input circuit breaker The UPS electronics are now shut down and you may begin maintenance work 19 A Way S 0 n 3 UPS Systems Inc 8 2 res
4. A battery can present a risk of electrical shock and high short circuit current The following precautions should be observed when working on batteries Remove watches rings and 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 whether the battery is grounded If grounded remove the source of the ground connection Contact with any part of a grounded battery can result in electrical shock The likelihood of such a shock is reduced if grounding is removed during installation and maintenance This is applicable to a UPS with a remote battery supply not having a grounded supply circuit 23 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 24 A Way S 0 n i UPS Systems Inc 12 Standard Software 12 1 About the Software UPSilon 2000 offers powerful features such as the ability to monitor local UPS s as well as remote units by TCP IP from your central location Also UPSilon 2000 can notify you of any problems automatically by sending email or dialing your pager through a modem when an event occurs such as a power outage UPSilon 2000 can also broadcast messages to remote computers and even send them commands to shutdown with the included software package ClientMate The UPSilon 2000 GUI is a real time graphica
5. AVAILABLE CONSULT BANKS OUTPUT SHORT PROTECTION NOISE PROTECTION COMMON amp NORMAL NOISE SUPPRESSION COMMUNICATION Rs232 DRY CONTACT OPTIONAL SNMP OR 5400 INTERFACE DISPLAY LED INDICATOR STATUS PANEL AUDIBLE ALARMS ON BATTERY LOW BATTERY OVERLOAD FAULT OPERATING 0 40 ENVIRONMENT HUMIDITY 0 90 NON CONDENSING AUDIBLENOISE 255 dBA AT 1 METER FROM UNIT SAFETY ULI778 CSA C222 SAFETY APPROVAL FCC CLASS A SURGE TRANSIENT IEEE C6241 CAT A 340x640x980 340x760x1160 340 760 1160 PHYSICAL w n gt gt 2 a gt 2 gt lt ES 3 gt Q m lt d n T o lt z n m m a E 2 n 25 B du Za gt m 2 m 5 m gt g m gt a o g 5 E EZ JB E 3 2 an 2 gt E m z n m 35 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 36 16 A Way S 0 n i UPS Systems Inc CONTACT INFORMATION 16 1 Additional Purchases or Upgrades Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada 758 Phone 250 491 9777 Ext 451 Fax 250 491 9775 Email sales alwaysonups com Website www alwaysonups com 16 2 QA Warranty Questions Always On UPS Syst
6. Also make sure the UPS and the load equipment are grounded to a common point to prevent ground current loops 1 Battery Cabinet s should be installed as close as possible to the UPS system The cable from the Battery Cabinet to the UPS should be as short as possible WARNING Choose the correct battery pack voltage according to the UPS rated capacity Do not connect too few or too many batteries as this could cause electrical shock damage or death 2 The DC Voltage of the Battery Cabinet must be the same as the DC Voltage of the UPS system Battery Bank Voltage is 240VDC nominal 3 Before connecting the Battery Cabinet to the UPS i You Must Power down the UPS and remove input AC supply ii Battery Breaker MUST BE in the Off position on the UPS system and Battery Bank 4 The battery cable that is supplied shall be hardwired to the Battery Cabinet and the UPS without connectors WARNING Ensure correct battery bank voltage and polarity before connecting Ensure UPS is OFF and battery breakers are OFF Do not connect the wires to the UPS first electrical shock will occur 5 If multiple battery banks have been purchased connect all batteries banks together in a parallel fashion Refer to figure 13 1 1 for a parallel connection Ensure batteries are connected with the proper polarities before connecting the battery cable to the UPS It is also recommended to test the cable voltage with a Digital Voltmeter an
7. Provides protection to UPS and equipment from power surges such as lighting and phase to phase faults Input EMI RFI Filter This filter attenuates the electrical noise associated with the polluted utility power to the UPS or noise THD generated by the UPS Rectifier Incoming AC power is converted to DC by the rectifier The rectifier supplies DC power to the inverter Internal Charger Charges the included battery pack A quick charge is approximately 6hrs duration and a slow charge is approximately 10 hrs duration Float operation is also included Batteries Sizes will vary in series and series parallel configurations Batteries are sealed lead acid valve regulated gel cells Extra External Battery Cabinets may be added in parallel to provide extra runtime Inverter The inverter is the solid state equipment and controls used to convert DC from the rectifier or batteries to AC power for the load The inverter will produce 50 or 60Hz auto selectable using Insulated Gate Bipolar Transistors IGBT s that switch at 18kHz This is above the audible frequency range and does not generate low frequency magnetic components The inverter uses pulse width modulation PWM to generate and regulate the AC output with a very small tolerance 4299 CPU Control Panel Communications The CPU controller monitors and maintains all systems within the UPS while permitting communication between the UPS user and peripheral devices Static Bypass A
8. Always On UPS Systems Inc GES TN31 Series 3Phase Input Single Phase Output I 9 GES 103TN31 GESI53TN31 GES203TN31 On Line 10 15 20kVA Operators Manual Version 2 1 THIS PAGE ISINTENTIONALLY BLANK A Way S 0 n i UPS Systems Inc Note The instructions contained in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred directly to Always On UPS Systems Inc Any electrical or mechanical modifications to this equipment without prior written consent of Always On UPS Systems Inc will void all warranties and may void UL cUL listing Unauthorized modifications also can result in personal injury death or destruction or the equipment Uninterruptible Power Supply Please complete the Warranty Card supplied with this UPS and return it by mail to Always On UPS Systems Inc This activates the warranty If additional information or technical assistance is required call Always On UPS Systems Inc Sales and Technical Support Line Toll free at 1 877 259 2976 Ext 451 or 250 491 9777 Ext 451 or Fax 250 491 9775 Or E mail at sales alwaysonups comor visit our we
9. E THAT THE WALL OUTLET IS ALSO WIRED TO THESE SPECIFICATIONS e THE UPS CONTAINS ITS OWN ENERGY SOURCE BATTERY THE OUTPUT RECEPTACLES MAY BE LIVE EVEN WHEN THE UPS IS NOT CONNECTED TO AN AC SUPPLY e ONCE YOU HAVE CONNECTED THE BATTERY CONNECTORS DO ATTEMPT TO LIFT THE CABINETS DO NOT CONNECT OR DISCONNECT BATTERY CABINETS WHILE THE UPS IS OPERATING FROM BATTERY SYMBOLS Protective grounding terminal a terminal which must be connected to ground prior to making any other connection to the equipment A terminal to which or from which an alternating sine wave current or voltage may be applied or supplied A terminal to which or from which a direct current or voltage may be applied or supplied This symbol indicates the word phase May be used in lieu of the wording caution risk of electric shock for any cautionary marking iv 10 11 12 13 14 15 16 A Way S 0 n UPS Systems Inc Table of Contents INTRODUCTION 1 PRODUCT DESCRIPTION 2 1 BLOCK DIAGRAM OF THE TN31 2 2 THEORY OF OPERATION 2 3 DESCRIPTION OF SIGNIFICANT BLOCKS HANDLING 3 1 DELIVERY 3 2 INITIAL INSPECTION 3 3 STORAGE TNS TAL LATION 7 4 1 LOCATIONS ceteros 4 2 ELECTRICAL CONSIDERATIONS 4 3 DIAGRAM OF FRONT COVER OPEN FOR 20 KVA 4 4 DIAGRAM
10. Each output contact provides status information of the UPS operation These statuses enable the UPS to notify an unattended computer or automation device being supported by the UPS of a power anomaly The connected device may then be programmed to recognize these signals and initiate a shutdown sequence The UPS reads the input signals through a photo coupled diode transistor pair so your control equipnent remains electrically isolated Maximum conduction levels are 40VDC at 40mA __Operation Explanation vO Maintain pulse 5VDC to 12VDC for 500ms to Remote Shutdown shutdown the UPS of UPS Available When System is in Battery Mode Reference Ground Reference GND for Pin 6 INPUT Table 12 4 1 Pin Assignment Figure 12 4 1 Photo Coupled Transistor 27 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 28 A Way S 0 n i UPS Systems Inc 13 Optional Extras 13 1 Installation Procedure for Optional Extended Battery Cabinets WARNING It is important to follow the correct procedures for connecting the battery packs If the procedures are not followed properly it will increase the chance of electrical shock damage or death Follow the procedure to avoid any possible danger WARNING Observe the appropriate federal and local electrical regulations at all times Using cables of improper size may damage your equipment and cause fire hazards
11. IBED TO INSURE SAFE RELIABLE OPERATION OF THE UPS SAVE THESE INSTRUCTIONS iii A Way S 0 n UPS Systems Inc MORE SAFETY INSTRUCTIONS DO NOT USE THIS EQUIPMENT FOR ANY PURPOSE OTHER THAN THE INTENDED USE e EXAMINE THE PACKAGING CONTAINER FOR DAMAGE NOTIFY THE CARRIER IMMEDIATELY IF DAMAGE IS PRESENT DISASSEMBLE THE UPS OPERATE OR LOCATE NEAR WATER OR EXCESSIVE HUMIDITY DO NOT USE OTHER MANUFACTURERS ACCESSORIES MAY CAUSE DAMAGE OR UNSAFE CONDITIONS KEEP LIQUID AND FOREIGN OBJECTS FROM GETTING INSIDE THE UPS DO NOT BLOCK AIR VENTS IN THE FRONT OF THE UPS OR AIR EXHAUSTS IN THE BACK NOT PLACE OR OPERATE CLOSE TO GAS HEATERS OR FIRE DONOT LET POWER CORDS CONTACT HOT SURFACES e PLUG APPLIANCES SUCH AS HALF BRIDGE RECTIFIED LOADS INTO THE UPS e USE CAUTION WHEN SERVICING BATTERIES BATTERY ACID CAN CAUSE BURNS TO SKIN AND EYES IF ACID IS SPILLED ON SKIN OR IN EYES FLUSH ACID WITH FRESH WATER AND CONTACT A PHYSICIAN IMMEDIATELY e DO OPERATE IF THE UNIT IS LEAKING LIQUID OR IF A WHITE POWDERY RESIDUE IS PRESENT e BATTERIES MAY CONTAIN METALS AND OTHER CHEMICAL HAZARDOUS WASTE FOR PROPER DISPOSAL CONSULT YOUR LOCAL STATE AND FEDERAL EPA AND OTHER ENVIRONMENTAL LAWS AND REGULATIONS e USE ONLY THE POWER SUPPLY CORD PROVIDED WITH THIS UNIT THE POWER CORD FOR UPS IS WIRED IN ACCORDANCE WITH NATIONAL ELECTRICAL CODE NEC SPECIFICATIONS BE SUR
12. IONALLY BLANK 14 A Way S 0 n 3 UPS Systems Inc 6 Front Control Panel 6 1 CONTROL PANEL OPERATION D E 872 7 H Figure 6 1 1 Front Control Panel FRONT CONTROL PANEL FUNCTIONS FUNCTION PROPERTIES LINE UTILITY ON MIMIC DIAGRAM INDICATES UTILITY IS ON MIMIC DIAGRAM INDICATES INVERTER IS INVERTER ON OPERATING BYPASS MIMIC DIAGRAM INDICATES UPS IS IN BYPASS C MODE FAULT INDICATES SELF DIAGNOSTICS HAS FOUND A PROBLEM IN THE UPS OR BATTERIES E LOAD LEVEL BAR GRAPH INDICATION OFLOAD LEVEL FROM 0 TO 15096 BATTERY CHARGE BAR GRAPH INDICATION OF BATTERY CHARGE LEVEL LEVEL FROM 0 TO 10096 ON BUTTON TO TURN UPS ON TO DUAL UPS ON BUTTON CONVERSION OR INVERTER MODE H UPS OFF BUTTON TO TURN UPS OFF DUAL CONVERSION OR BYPASS MODE INVERTER MODE PUTS INTO BYPASS MODE Figure 6 1 2 Front Control Panel Functions List 15 A Way S 0 n UPS Systems Inc 6 2 Control Panel Indication Truth Table LED STATUS LINE INVERTER BYPASS FAULT ALARM STATUS A mee mur ALARM UTILITY POWER FAILURE MAIN POWER SWITCH OFF CONTINUOUS ALARM OVERLOAD BEEP EVERY 4 SECONDS RAPID BEEPING EVERY 0 5 SECONDS continuous BATTERY DEAD ABEBING amp UTILITY FAILURE ON OFF CONTINUOUS MAIN POWER DELAYED DELAYED ALARM SWITCH ON INVERTER OFF ON CONTINUOUS FAULT OR BEEPING OVERLOAD EVERY 4 Figure 6 2 1 Contr
13. OF REAR VIEW FOR 10 amp 15 4 5 INPUT OUTPUT AND EXTERNAL BATTERY CONNECTION 5 1 TURN ON PROCEDURE 5 2 TURN OFF SHUTDOWN PROCEDURE FRONT CONTROL PANEL 6 1 CONTROL PANEL OPERATION 6 2 CONTROL P ANEL INDICATION TRUTH TABLE AUDIBLE ALARM 17 7 1 BACKUP MODE 7 2 Low BATTERY ds SS MJ ipd N MAINTENANCE BYPASS OPERATION 8 1 To PUT THE UPS INTO MANUAL BYPASS 8 2 TO RESTORE THE UPS TO NORMAL OPERATION ENVIRONMENTAL PROTECTION 21 BATTERY REPLACEMENT STANDARD SOFTWARE 12 1 ABOUT THE SOFTWARE 12 2 INSTALLATION OF THE SOFTWARE 12 3 RS 232 INTERFACE 12 4 DRY CONTACT OPTIONAL EXTRAS 13 1 INSTALLATION PROCEDURE FOR OPTIONAL EXTENDED BATTERY CABINETS 13 2 AS 400 AND DRY CONTACT OPTIONAL 13 3 SNMP WEB ACCESSIBLE MONITORING DAPTER CONTACT INFORMATION 16 1 ADDITIONAL PURCHASES OR UPGRADES 16 2 QA WARRANTY QUESTIONS 16 3 SOFTWARE QUESTIONS A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK A Way S 0 n UPS Systems Inc Introduction Congratulations on your choice of the Always On TN31 Series On Line Uninterruptible Power System UPS The TN31 Series features the very latest top of the line microproces
14. S shuts down immediately when these 2 pins are connected together 22 amp 23 Function Fault On Battery Battery Low On Bypass On Inverter 1 2 amp 3 4 5 amp 6 7 amp 8 9 amp 10 11 amp 12 Allow for easy connection of wires if 25pin connector is not available Table 13 2 1 Pin Assignments E Figure 3 2 1 Line Drawing 5 400 Communications Interface Output Truth Table State Pin1 2 Pin Pin Pin 5 6 Pin 7 8 Pin Pin Noma Open Closed Open Closed Open Open Closed Open 1 Closed Low Oninverer Open Coa 1 Open Closed 1 Inactive State may be open or closed condition Table 13 2 2 Output Truth Table 31 A Way S 0 n UPS Systems Inc 13 3 SNMP Web Accessible Monitoring Adapter The Always On Simple Network Management Protocol SNMP adapter is a web based management product that uses multiple open standards such as Telnet HTTP and SNMP to provide full management of supported devices The SNMP Adapter is designed to connect directly to the network and allow for network broadcasting of UPS conditions Also the SNMP Adapter empowers you to have remote access to the UPS system to monitor parameters and displays For set up instructions view the READ ME file provided with the set up disk 32 A Way S 0 n i UPS Systems Inc
15. THE UNIT S POWER SWITCH IS WHETHER OR NOT THE UNIT AC SUPPLY IS PRESENT QUALIFIED PERSONNEL SHOULD CONSULTED WHEN 1 THE POWER CABLE HAS BEEN DAMAGED 2 LIQUID HAS BEEN SPILLED INTO THE UNIT 3 THE UNIT DOES NOT OPERATE NORMALLY EVEN THOUGH THE OPERATING INSTRUCTIONS HAVE BEEN FOLLOWED DO NOT PLACE MAGNETIC STORAGE MEDIA ON TOP OF THE UNIT AS THIS CAN RESULT IN DATA CORRUPTION THIS UPS WAS DESIGNED POWER ALL MODERN COMPUTER LOADS AND ASSOCIATED PERIPHERAL DEVICES SUCH AS MONITORS MODEMS CARTRIDGE TAPE DRIVES EXTERNAL FLOPPY DRIVES ETC DO NOT USE IT FOR PURE INDUCTIVE OR CAPACITIVE LOADS IT IS NOT RATED TO POWER LIFE SUPPORT EQUIPMENT WARNING ALL RECORDED MEDIA SUCH AS DISKETTES TAPES AND CARTRIDGES SHOULD BE KEPT A MINIMUM OF 60CM FROM THE UPS THE MAGNETIC FIELD CREATED BY OPERATION OF THE UPS MAY ERASE DATA ON THOSE DEVICES WARNING INSTALL THE ON LINE UPS IN A WELL VENTILATED AREA AWAY FROM FLAMMABLE LIQUIDS GASES OR EXPLOSIVES DO NOT LET THE UNIT COME INTO CONTACT WITH WATER POTENTIALLY LETHAL VOLTAGES EXIST WITHIN THIS UNIT AS LONG AS THE BATTERIES ARE CONNECTED DO NOT TOUCH ELECTRICAL CIRCUITS WHEN POWER IS CONNECTED TO THE UPS TURN THE UPS OFF AND DISCONNECT THE UNIT FROM THE POWER SOURCE BEFORE REMOVING THE COVER PLATES ALL REPAIRS SHOULD BE PERFORMED BY A QUALIFIED SERVICE PERSONNEL READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR USING THE UNIT FOLLOW ALL PROCEDURES AS DESCR
16. b site at www alwaysonups com Or write to Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC 758 Please complete the following information for your records to remain within this equipment manual Model Number Serial Number Date of Installation Inspected By A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK A Way S 0 n i UPS Systems Inc SAFETY INSTRUCTIONS THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS THAT SHOULD BE FOLLOWED DURING INSTALLATION AND MAINTENANCE OF THE UPS AND BATTERIES THE UPS SYSTEM IS NOT INTENDED FOR EXTERNAL USE UNLESS SPECIFICALLY DESIGNED FOR IT ALL SERVICING MUST DONE BY QUALIFIED PERSONNEL DO ATTEMPT TO SERVICE THIS EQUIPMENT YOURSELF OPENING OR REMOVING COVERS WILL RISK EXPOSURE TO DANGEROUS VOLTAGES DO NOT LOCATE UPS IN AN AREA WHERE UNAUTORIZED PERSONNEL HAVE ACCESS THE POWER SUPPLY FOR THIS UNIT MUST BE SINGLE PHASE RATED IN ACCORDANCE WITH THE EQUIPMENT DATA PLATE IT MUST BE SUITABLY GROUNDED DO NOT STAND BEVERAGE CONTAINERS ON THE UNIT EXTERNAL LOUVRES AND OPENINGS IN THE CABINET ARE PROVIDED FOR VENTILATION TO ENSURE RELIABLE OPERATION OF THE PRODUCT AND TO PROTECT FROM OVERHEATING THESE OPENINGS MUST NOT BE BLOCKED OR COVERED OBJECTS MUST NEVER BE INSERTED INTO VENTILATION HOLES OR OPENINGS THE POWER OUTLET THE UPS DISTRIBUTION PANEL WILL LIVE WHEN
17. d compare with the battery voltage in Table 11 1 before connecting the batteries to the UPS 29 A 5 0 i UPS Systems Inc 6 Connect the battery leads to the UPS terminal block with the proper polarities The positive battery cable connects to B and the negative battery cable connects to B 7 The minimum tightening torque shall be no lessthan 35 ft Ib in 8 Additional Battery Cabinets for the TN31 series UPS require a 208VAC to 240V AC two wire supply to power the additional charger that is provided with the Battery Cabinet Refer to Figure 13 1 1 The cable is not supplied for the additional charger Start up Procedure 1 Install the UPS system and Battery Cabinets s as per recommendations in above procedure 2 Once all connections are secure turn all the Battery Breaker s starting from farthest away from the UPS 3 Perform the Turn Start up Procedure for the UPS Section 5 1 EXTRA BATTERY BANK BATTERY BANK Figure 13 1 1 Battery Bank and UPS Connections 30 A Way S 0 n i UPS Systems Inc 13 2 AS 400 and Dry Contact Optional An AS 400 25 Pin Connector is located on the rear panel of the UPS This provides status information through relay contacts and control by photo coupled inputs Input Signal Pin Assignment Function Explanation Remote Emergency Shutdown Mode Shutdown Vpin23 by 5 to 12 VDC Output Signal Pin Assignment UP
18. ems Inc Bldg 1 150 Campion Road Kelowna BC Canada 758 Phone 250 491 9777 Ext 209 Fax 250 491 9775 Email ga alwaysonups com Website www alwaysonups com 16 3 Software Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada 758 Phone 250 491 9777 Ext 204 Fax 250 491 9775 Email webmaster alwaysonups com Website www alwaysonups com 37
19. g shipment If there is damage or anything is mssing contact the dealer from whom you purchased the unit and save the packaging for future shipment When the unit has passed the initialinspection record the Installation date on the back panel of the unit and in the space provided towards the front of this manual Included with UPS System 1 User manual 2 Communication cable 3 Software package 4 AS400 cable when optional AS400 included Storage 1 If the on line UPS is to be stored prior to installation it should be placed in a dry well ventilated area where it will not be exposed to dirt moisture or other contaminants 2 Extreme storage temperatures are i 30 C to 602 C without battery ii 209 C to 45 C with battery for a short period 3 Maximum storage period for battery is 6 months at 20 C or 3 months at 30 C IMPORTANT When the UPS and or battery banks are to stored for longer than 3 months it is recommended the batteries are recharged every 3 months Do not stack these units Once the unit is taken out of storage for a long period it is recommended that the batteries be charged before putting the UPS into full service Refer to start up procedure 5 1 and follow the steps for turning the UPS on Leave the unit running for at least 8 hours preferably unloaded so that the batteries may charge A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 4 A Way S 0
20. igned to operate as a continuously on line dual conversion system in the following modes Normal The critical AC load is continuously supplied by the UPS Inverter The input Rectifier derives power from a utility AC source and supplies power to the Inverter while simultaneously float charging the batteries Emergency Upon failure of AC utility the Inverter obtains power from the batteries without interruption There are no interruptions in power to the critical load upon failure or restoration of the AC utility source Recharge Upon restoration of AC utility the Rectifier will automatically restart and supply DC power to the inverter and battery charger Automatic Restart Upon restoration of AC utility after an extended utility and complete battery discharge the UPS will automatically restart and resume supplying power to the critical load Also the battery charger will automatically start and recharge the batteries This feature is enabled in the factory and is capable of being disabled consult factory Static Bypass The bypass will provide an alternate path for power to the critical load that is capable of operating in the following manner Automatic In the event of the inverter overload capacity be exceeded or should an internal failure occur the UPS will perform an automatic transfer of the critical AC load from the inverter to the bypass source Manual Should the UPS need to be taken out of service for limited maintenance or
21. l display of UPS status including input output voltage frequency load temperature and capacity It also has a data logging feature For battery management UPSilon 2000 will shutdown the system in a safe fashion before the batteries run out NOTE The UPS can run without the software Installation of the Software Install Software package included with the UPS and follow software instruction included with CD Connect the UPS to the computer via the RS 232 cable included with the software package Start software NOTE Use the connecting cord supplied by the manufacturer or the monitoring software will not work Follow the read me file on the disk to run the setup 25 A Way S 0 n UPS Systems Inc 12 3 RS 232 Interface A 9 pin male SUB D connector is located on the UPS rear panel to provide a communications link between the UPS and the computer The software package and interface allows the user to monitor the operating status of the UPS system UPS Port Computer Port Transmit Data TXD Receive Data RXD ES Signal Ground GND Table 12 3 1 Battery Types and Quantities gt C N O Figure 12 3 1 Pin Configuration of RS 232 port on the UPS 26 A Way S 0 n 3 UPS Systems Inc 12 4 Dry Contact Dry Contact outputs and Photo Diode Coupled inputs are provided through the RS 232 port located at the back of the UPS
22. n UPS Systems Inc Installation 4 1 Location The TN31 Series UPS is intended for installation in a controlled indoor environment where temperature and humidity levels are maintained free of conductive contaminants with unrestricted airflow Ambient temperature must not exceed 40 C 1042 P IMPORTANT Maximum battery life is obtained by placing the battery in a room at an ambient temperature of 15 C to 25 Battery life decreases by half for every 10 C above 25 C The unit is fitted with castor wheels for moving it over a short distance Figure 4 1 1 Front View 20 kVA A Way S 0 n UPS Systems Inc Figure 4 1 2 Front View 10 amp 15 A Way S 0 n i UPS Systems Inc Air vents are located on the rear and sides of the UPS system Do not position the UPS in an enclosed area with restricted airflow Allow a minimum of 100mm 4 inches around the UPS with a minimum of 300mm 12 inches at the rear for easy operator access to the connections and the rear panel mounted input output battery maintenance breakers Figure 4 1 2 Maintenance Servicing of the TN31 Series requires access to all side of the UPS system and battery banks Provide the necessary free space and flexible wiring to allow complete access to the UPS View UPS I stallatan Wall OPTICNAL Extended Bg k 100 rm 100 mrr Figure 4 1 3 Top View 4 2 Elec
23. n The UPS incorporates sealed maintenance free lead acid batteries When replacing the batteries the defective batteries must be disposed of carefully to prevent any risk of environmental pollution by the harmful products they contain lead and acid Please refer to local and regional environmental codes when disposing of the batteries 21 A Way S 0 n UPS Systems Inc THIS PAGEIS INTENTIONALLY BLANK 22 A Way S 0 n i UPS Systems Inc 11 Battery Replacement When replacing batteries use the same number and following types of batteries UPS Rating Number of Batteries Type of Batteries Combined Voltage 10 16 12 7 192VDC o 16 15kVA 16 12VDC 26Ah 192VDC 20kVA 12VDC 26Ah 360VDC Table 11 1 Battery Types and Quantities WARNING Potentially lethal voltage exists within this unit as long as the battery supply is connected During any service work the battery should be disconnected from the UPS by turning off the battery breaker The battery cabinet assembly is heavy Use suitable lifting equipment WARNING Servicing of the batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from the batteries Do not dispose of batteries in a fire They may explode Do not open or mutilate the battery or batteries Released electrolyte is harmful to the skin and eyes It may be toxic
24. ol Panel amp Alarm Indication Truth Table UM ra E ON FF ON ON FF ON ON ON ON FF FF FF FF FF FF FF N FF A Way S 0 n i UPS Systems Inc 7 Audible Alarm Please refer to Control Panel Indication Truth Table for Alarm Status and Indication 7 1 Backup mode The UPS will beep once every four 4 seconds when the unit is in back up mode beep beep beep Slow beep NOTE The UPS incorporates a mute function When the UPS is beeping press the ON button on the front display to mute Press the button again to reactivate 7 2 Low Battery The UPS will beep at 2 Hz or every 0 5seconds when the batteries are almost depleted beep beep beep Fast beep NOTE When a low battery condition occurs the Audible Alarm cannot be reset and silenced 7 3 Fault The UPS will sound a continuous beep and the fault light indicator will illuminate beeeeep Continuous beep 7 4 Silencing the Audible Alarm To silence the audible alarm in battery backup mode push the alarm reset button located on the front panel 17 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 18 A Way S 0 n UPS Systems Inc Maintenance Dypass Operation Qualified Technicians or Service Personnel Only The purpose of the Maintenance Bypass Switch and Inverter Switch is to provide a Manual Bypass function
25. r keeps beeping Remove some of the load Save digital data and shutdown Utility indicatinglight Voltage of utility is exceeding UPS Refer to the application program is flashing input range to ensure utility is not within UPS range Keep UPS On for over 8 hours to recharge the batteries Check the load and remove any non critical equipment The charger has failed Contact dealer or service center for help Check that UPS batteries are well connected Replace any damaged battery packs immediately Batteries have not been charged UPS overload Batteries are aged and Battery backup time cannot be charged fully too short The battery light is flashing when utility is Battery voltage is too low or batteries supplying power to the have not been connected UPS Table 14 1 Troubleshooting Chart 33 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK 34 A Way S 0 n 3 UPS Systems Inc 15 TECHNICAL DATA Standard Models Isolation XFM Included TN31 SERIES MODEL NO GES 103TN11 GES 153TN11 GES 203TN11 CAPACITY 10 8 15kVA I2KW 20kVA 16kW FREQUENCY 3 0 4 Wire GND 50 60Hz 120 120 208 120 240 110 220 3 WIRE 50Hz 60Hz_ 0 5 lt 3 LINEAR LOAD lt 5 RECTIFIED LOAD OUTPUT 1Hz SECOND 4 10095 LOAD CHANGE 105 150 FOR 20 SECONDS 3 SEALED LEAD ACID MAINTENANCE FREE 5 8HOURS RECOVERY 90 TYPICAL dis RUN
26. repair manual activation of the bypass will cause an immediate transfer of the critical AC load from the inverter to the bypass source The input rectifier inverter and battery charging operations will be inhibited until the user transfers the UPS back to normal operation Maintenance Bypass TN Series units include provisions to allow for maintenance of the unit or replacement of batteries without interruption of power to the load This will be done with the manually operated bypass switch included A Way S 0 n UPS Systems Inc THIS PAGE ISINTENTIONALLY BLANK A 5 0 n 4 UPS Systems Inc 2 Product Description 2 1 Block Diagram of the TN31 Figure 2 1 1 Block Diagram of TN Series 2 2 2 3 A Way S 0 n UPS Systems Inc Theory of Operation The UPS Uninterruptible Power Supply is designed for installation between the utility commercial supplied power and your load It is designed to protect your load from experiencing any power fluctuations like blackouts brownouts and over voltage conditions The UPS supplies sufficient amounts of steady constant AC power during these power fluctuations Thus you are empowered to shut down your load properly preventing possible damage to both hardware and software Description of Significant Blocks Input Breaker Prevents the main distribution panel breaker from tripping when a UPS fault or over current condition occurs Surge Protection
27. s Refer to Figure 6 1 1 INVERTER indicator on the mimic diagram will light up The BYPASS indicator will turn off after 25 seconds The UPS inverter will automatically produce a voltage at the output once the bypass indicator turns off WARNING If there is utility voltage present at the input of the UPS during startup there will be a voltage at the output immediately after the input breaker is turned on This is because the unit is temporarily in BYPASS mode for 25 seconds prior to the UPS inverter taking over 5 2 Turn Off Shutdown Procedure 1 Press and hold the Front Panel OFF button for one 1 second The UPS is now in Bypass Mode and the UPS inverter is shut down The BYPASS indicator will turn on The unit can be turned on again from this point by pressing and holding the ON button for one 1 second WARNING If there is utility voltage present at the input of the UPS and the input breaker is on there will still be a voltage at the output after the OFF switch is pushed This is because the unit is in BYPASS mode 2 Switch the INPUT Breaker to the OFF position The UPS will do a Power Down sequence Front Panel Display LEDs will not be on Fans will stop Wait 10 seconds 3 Switch the BATTERY Breaker to the OFF position 4 The UPS is now fully shut down 13 A Way S 0 n UPS Systems Inc THIS PAGE ISINTENT
28. sor technology and IGBT transistors for clean highly regulated PWM Pulse Width Modulated power Also included within our high quality engineering is an output isolation transformer to provide the final touch to complete power conditioning and noise attenuation even during bypass operation Powerful standard features such as the ability to operate on wide input voltages allow use with generators offers reduced discharges of the batteries and higher reliability of the UPS For ease of use the TN31 Series utilizes a simple to read LED display to indicate load percentage battery capacity and the mode of operation at a glance The TN31 series micro processing technology operates self diagnostic algorithms and provides a fault indicator to aid in troubleshooting The On and Off Bypass selection buttons are conveniently located with the display The TN31 Series incorporates an interface port for communications between the UPS and a LAN server or other computer system with various operating systems installed This port provides detailed operating information including voltages currents and alarm status to the host system when used in conjunction with the shutdown software Also available are the optional SNMP Adapter to permit remote monitoring and notification of UPS conditions via a network or the Internet and an AS 400 interface to allow for relay communications in PLC or contact environments 1 4 Modes of Operation The TN Series UPS is des
29. static transfer switch and bypass circuit is integrated into the UPS This provides an automatic bypass of the UPS if there is a problem The CPU controller controls the automatic bypass by sensing the status of the inverter logic signals operating and alarm conditions This control circuit will provide an uninterrupted transfer of the load to a normal input source or alternate bypass source Transfers are made when an overload or malfunction occurs within the UPS without exceeding the transient limits specified herein Maintenance Bypass Allows for power wrap around from input directly to output while still utilizing the output isolation transformer This provides a convenient way to permit maintenance of the UPS system Transformer An output isolation transformer is included The output transformer is factory installed inside the UPS module cabinet The transformer features tap selection to serve any input and output voltage configurations in the UPS module 9 Way S 0 n i UPS Systems Inc Handling 3 1 3 2 3 3 Delivery Check condition of equipment on delivery Contact the carrier and supplier immediately if the packaging or unit is damaged Initial Inspection Unpack the UPS carefully notice the packing method and retain the box and packing material If you must return the UPS at any time you must repack it the way it was originally shipped Visually inspect the UPS for damage that may have occurred durin
30. tore the UPS to normal operation a Turnon the input circuit breaker b Switch on and push the OFF button on the control panel The BYPASS indicator on the control panel should light up c Switch on CB2 d Switch off MANUAL BYPASS SWITCH CB3 e Push ON button on the control panel The INVERTER indicator on the control panel should light The BYPASS indicator turns off after a delay of 25 seconds and the UPS inverter shall be supplying power to the load f Replace the metal cover over the MANUAL BYPASS SWITCH 20 10 A Way S 0 n UPS Systems Inc Battery Maintenance initial start up it is recommended the batteries have minimum eight 8 hours charging to ensure proper operation During normal operation of the UPS the charge level of the batteries will be maintained automatically The typical recharge time to 90 from 0 charge level is 6 8 hours Under normal operating conditions the supplied batteries are expected to last approximately five 5 years 200 discharges from date of receipt Refer to the purchase date you recorded in this manual if you suspect that the batteries have been exhausted If the UPS is to remain in storage for an extended period of time it is strongly recommended that the UPS be powered up every three 3 months for a period of twenty four 24 hours to recharge the batteries and prevent premature failure Environmental Protectio
31. trical Considerations WARNING The UPS shall be installed by a qualified technician and wired in accordance with local and national electrical codes The following information is for recommendation only Input The commercial supply input cable shall be connected to the UPS via a dedicated 3 pole circuit breaker rated for operation and protection of the UPS branch circuit The breaker is to be mounted within two meters six feet of the UPS and be readily accessible to the operator Output Provide adequately sized cabling distribution panel and circuit breakers to supply the critical loads with the power available Optional Battery Bank AC Supply If battery banks have been purchased ensure a separate double pole breaker is available to connect to the battery bank chargers One 15A double pole breaker will power three battery bank chargers A Way S 0 n UPS Systems Inc 4 3 Diagram of Front Cover Open For 20 The 20 kVA unit has the terminations and switches behind the front door INVERTER BATTERY BREAKER SWITCH MAIN POWER MANUAL Switch BYPASS TERMINA BLOCK Figure 4 3 1 Front View 20 kVA With Door Open 10 A 5 0 UPS Systems Inc 44 Diaeram of Rear View For 10 amp 15 BATTERY BREAKER MAIN POWER SWITCH Figure 4 4 1 Rear view of the TN31 10 amp 15 FANS 8
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