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User Manual Power Wave 1

1. 192 Volt Nominal Online Power 6002 1405 REV M C 5 Typical 1 Strings of 20 Battery system 2 STRING 3 STRING 4 STRING 1 2 1 2 240 VDC 4 3 2 1 7 8 9 10 14 13 12 11 5 6 15 17 18 19 20 16 BATT C B UPS ELECTRONICS Maximum 4 Strings of 20 Battery system Depend upon Battery Run Time requirement batteries can be in UPS cabinet or separate maximum of 3 Cabinets Consult Factory for detail 240 Volt Nominal Online Power 6002 1405 REV M D 1 APPENDIX D LCD DISPLAY MENU AND TROUBLESHOOTING GUIDE Two screens A B are updated continuously for units without optional output transformer Three screens A B C are updated continuously for units with optional output transformer Start up Screen When input power is applied for the unit LCD panel lights up and displays If LCD display panel is not lit the unit has problem Contact the factory service at 1 800 PWR SRVC 800 797 7782 Screen A The first default screen appears as below The display may say Line 1 UPS NORMAL 15 KVA 5 KVA indicates the KVA rating STAND BY or NORMAL indicating normal operating modes STAND BY ALARM FAILURE indicates UPS alarm condition and FAILURE indicates unit failed or had persistent alarm condition This will require system reset by cycling power Shut if off and wait till LCD is dark Restart the unit Line 2 INPUT OK CHG ON INPUT OK Inp
2. Wear rubber insulating gloves and boots Do not lay tools or metal parts on top of batteries Disconnect charging source prior to connecting or disconnecting battery terminals Verify that batteries are properly grounded Lead acid batteries can present a risk of fire because they generate hydrogen 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 When replacing batteries use with the same number of batteries and same manufacturer type and model that was supplied with the unit To avoid system failure replace all batteries if one or more batteries fail to perform to specifications Caution Caution Caution Caution Caution Danger DO NOT GROUND BATTERY POSITIVE OR NEGATIVE Online Power 6002 1405 REV M 5 6 5 4 4 Battery Cabinets Although the individual batteries are sealed and require minimal maintenance 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 batte
3. 20 1 Input Breaker CB2 21 1 Battery Breaker CB1 22 1 Output Breaker CB3 23 1 Output Distribution Breaker CB4 and Up 24 8 10 16 20 Maintenance Free Lead Acid Battery s B1 and Up Online Power 6002 1405 REV M 4 1 SECTION 4 SYSTEM OPTIONS This section describes options available with the Power Wave 1 phase The following are available Part Number Options 3000 044 thru 056 External Manual Bypass Switch 9100 1359 01 thru 04 Internal Manual Bypass Switch 9100 1363 01 Audio Alarms with Silence Switch 9100 1020 06 Remote UNIT Status Display 9100 1362 01 Form C N O Contacts for Alarms 9100 1401 02 12 13 TVSS Transient Voltage Surge Suppressor 9100 1343 01 thru 16 Normally ON OFF Output Aux Circuit Breakers 9100 1439 01 thru 03 External Output Aux Circuit Breakers in Panel Board 9100 1429 xx Stackable Rack 1 rack per 2 cabinets N A System Input CB Standard Higher KAIC N A System Output CB Standard Higher KAIC 9100 1434 31 thru 86 Higher KAIC Norm ON OFF Output Circuit Breaker Molded case 208 240 9100 1435 01 26 61 86 Higher KAIC Norm ON OFF Output Circuit Breaker 1 Phase Din rail 277V 9100 1317 02 Seismic Mounting Bracket Left and Right set per cabinet 9100 1493 01 Power Flow Mimic GMS Global Monitoring System 9800 005 xx Local on PC via RS232 9800 006 01 Local on PC via RS485 9800 007 01 Basic NetAgent SNMP 9800 0
4. 277V Output connection ILLUSTRATION 2 15 277V Output Customer Connections w Output XFMR The output aux CB can be 2 pole CB wire neutral T1 14 to second pole of CB TB2 277V GND 2 1 4 3 CB3 9 8 11 12 14 13 Output XFMR T1 Output CB Option Aux output CB 1P CB Option Customer connects load to these aux CB 3 wires CB H N and G Load 1 2 3 4 5 6 7 N G N H Online Power 6002 1405 REV M 6 17 3 continued E 120 240V Dual Output connection ILLUSTRATION 2 16 120 240V Dual Output Customer Connections 1 2 3 4 5 6 7 TB2 240V GND 2 1 4 3 CB3 9 8 157V 120V 88V 11 OV 12 OV 14 120V 13 Output XFMR T1 Output CB Option Aux output CB for 120V output Directly connect load to each CB 3 wires CB N and G Load 120V N G A B qty up to A 3 120V If qty is more than 3 use for balance loading B H N H Online Power 6002 1405 REV M 6 18 3 continued F 120V 208V Dual Output connections ILLUSTRATION 2 17 120 208V Dual Output Customer Connections 1 2 3 4 5 6 7 TB2 208V GND 2 1 4 3 CB3 9 8 157V 120V 88V 11 OV 12 OV 14 120V 13 Output XFMR T1 Output CB Option Aux output CB for 120V output Connect load directly to each aux CB Load N G A 120V NOTE For 120V and 208V dual ou
5. 4 mounting locations 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 to equipment This concludes the mechanical installation 6 3 2 Electrical Connection Arrangements Danger VERIFY THAT ALL CUSTOMER SUPPLIED WIRING IS DE ENERGIZED BEFORE PERFORMING ANY ELECTRICAL WORK FAILURE TO DO SO COULD RESULT IN ELECTROCUTION INJURY OR DAMAGE TO EQUIPMENT Danger EVEN WHEN THE POWER WAVE 1 IS OFF THERE ARE POTENTIALLY DANGEROUS VOLTAGES WITHIN THE POWER WAVE 1 UNIT DUE TO THE BATTERIES EXTREME CARE MUST BE TAKEN WHEN WORKING WITHIN THE POWER WAVE 1 ENCLOSURE TO AVOID THE POSSIBILITY OF ELECTROCUTION INJURY OR DAMAGE TO THE EQUIPMENT Online Power 6002 1405 REV M 6 7 6 3 3 Customer Connections A Input Power Connection by Customer Connect input Hot at TB 1 Connect input Hot Neutral at TB1 2 Connect input ground at TB1 3 1 2 INPUT TB1 To Customer s Load OUTPUT TB2 CONNECTION TB3 3 HOT HOT N GND 1 2 3 GND 1 2 3 4 5 6 7 GND BATTERY ILLUSTRATION 6 5 POWER WAVE 1 CUSTOMER S CONNECTION INPUT TERMINAL BLOCK INPUT POWER VOLT TERMINAL 1 2 3 120 H N GND 208 H H GND 240 H H GND 277 H N GND B Output Load Connection by Customer Connect the critical load to one output terminal TB2 as shown in the voltage connection
6. Molded case Higher KAIC Norm ON OFF Output Circuit Breaker 1 Phase Din rail Seismic Mounting Bracket Left and Right set per cabinet Power Flow Mimic GMS Global Monitoring System Local via PC with RS232 Local via PC with RS485 Basic NetAgent SNMP Basic NetAgent SNMP with WIFI HUB application Advanced NetAgent SNMP Advanced NetAgent SNMP with WIFI HUB Advanced NetAgent SNMP with GPRS mobile modem Advanced NetAgent SNMP with dial up modem ECC Emergency Circuit Converter ECM Emergency Control Module Online Power 6002 1405 REV M 3 1 SECTION 3 OPERATION 3 1 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 1 for maintenance
7. 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 USRGE WITHSTANDABILITY ANSI C62 41 1980 Categories A amp 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 SIZE H x W x D in cm 70 x 39 x 20 177 8 x 99 1 x 50 8 WEIGHT lbs kg with batteries 896 408 1191 533 1666 758 2042 929 3572 1625 3132 1425 4732 2153 CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door and Full Length Door Hinge ENCLOSURE Designed for Inside Installations COLOR Natural finish ACCESSIBILITY Front All Servicing is Through the Front No Side or Rear Access is Required CABLE ENTRY Bottom or sides MOUNTING Four 4 Holes Provided to Anchor Enclosure to Pedestal Supplied by Others Online Power 6002 1405 REV M A 3 SPECIFICATIONS FOR KW 1 0PF UNITS POWER RATING KW 3 3 5 5 7 5 7 5 10 10 12 5 12 5 15 15 17 INPUT VOLTAGE VAC Single Phase 120 208 240 277 VAC Single Phase 208 240 277 VAC MAXIMUM CURRENT 40 23 20 17 60 35 30 26 51 41 36 64 56 48 79 69 59 95 83 71 107 94 80 TOLERANCE 15 to 15 FREQUENCY Hz 60 3 POWER F
8. on the battery bank The charger is fully automatic with a current limiting feature so that battery damage will be prevented in case of a charger malfunction The charger is sized such that the batteries will be maintained at full charge even when the input voltage is at the low line limit for indefinite periods of time 2 4 6 Battery The battery bank shall consist of 8 10 16 20 or 32 12 Volt batteries providing the reserve energy to sustain the load when suitable AC input power is not present The batteries are sealed maintenance free VRLA Valve Regulated Lead Acid construction 2 4 7 DC Choke The DC choke helps boost battery voltage to a higher internal DC bus voltage while it reduces high frequency noise 2 4 8 Output Transformer used only for multiple output voltage units 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 2 4 9 Inverter Test Switch The SW 2 test momentary switch is a push button switch for testing the Power Wave 1 and the batteries for proper operation When the Power Wave 1 is running and Switch SW 2 is pushed and held in the Power Wave 1 will automatically tra
9. 1 Verify all power connections are tight 2 Verify all control wire terminations are tight 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 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 Online Power 6002 1405 REV M 4 4 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 in mounted in a box which is field installed on the unit cabinet This box includes a rotary switch to provide a single control for transferring to and from maintenance bypass For ratings wiring diagram enclosure dimensions and installation refer to drawings 6001 032 31 The operator control switch for external manual bypass switch can be accessed by opening the cabinet front door The single control simplifies the operation of the external manual bypass switch however operating instructions must be carefully observed before using the bypass switch The THREE Manual Bypass Switch Po
10. 1020 06 revision A attached at the end of System Options Section Online Power 6002 1405 REV M 4 6 4 5 OPTIONAL FORM C CONTACTS FOR ALARMS P N 9100 1362 01 4 5 1 Installation Terminal strip TB is provided on the optional alarm relay board for user connection to the individual alarm contacts 4 5 2 Operation The Remote Contact Board includes isolated Form C contacts for the following alarm signals TB 1 LOW BATTERY TB 2 ON BYPASS TB 3 SUMMARY ALARM TB 4 NOT USED TB 5 INPUT FAIL TB 6 COMMON 4 6 OPTIONAL TVSS P N 9100 1440 02 4 6 1 Operation 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 is 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 Online Power 6002 1405 REV M 4 7 4 7 OPTIONAL NORMALLY ON NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS P N 9100 1343 01 THRU 16 These circuit breakers are 1 pole 20A devices for protection of customer s circuits Normally ON C B Option Normally OFF C B Option Normally OFF Delay C B Option NORM ON OFF OUTPUT AUX CBS STANDARD KAIC CB Refer t
11. BATTERY CONNECTIONS For the actual battery connection diagram for your system refer to the diagram on each unit The drawings below are shown for electrical connection only and do not necessarily match the actual battery layout in your unit The arrangement may be different from drawings 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 2 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 the damage if possible and contact Online Power at 800 PWR SRVC 800 797 7782 3 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 If battery is dropped or makes hard contact with any abject inspect it again 5 Batteries are heavy so exercise care when lifting them to the shelves of a battery cabinet 6 If at any tim
12. Connection w Output XFMR 208V 6 14 Illustration 6 14 Customer Connections Output Connection w Output XFMR 240V 6 15 Illustration 6 15 Customer Connections Output Connection w Output XFMR 277V 6 16 Illustration 6 16 Customer Connections Dual Output Connection w Output XFMR 120 240V 6 17 Illustration 6 17 Customer Connections Dual Output Connection w Output XFMR 120 208V 6 18 Illustration 6 18 Customer Connections Dual Output Connection w Output XFMR 120 277V 6 19 Illustration 6 19 Customer Connections Battery Connections 6 20 6 4 REMOTE SIGNALLING CONNECTIONS OPTIONAL 6 20 6 5 BATTERY STORAGE 6 21 Online Power 6002 1405 REV M c 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 2009 Online Power Inc All rights reserved Online Power 6002 1405 REV M d Congratulations on selecting one of the fine products from On
13. Input Voltage Battery Charger UPS Output On Battery Low Battery Summary Alarm INDICATORS LCD Display Panel RELAY INTERFACE Dry Contacts for UPS On N C On Inverter 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 USRGE WITHSTANDABILITY ANSI C62 41 1980 Categories A amp 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 SIZE HxWxD in cm 70 x 39 x 20 177 8 x 99 1 x 50 8 WEIGHT lbs kg with batteries 1066 485 1284 584 2350 1069 2870 1306 3777 1719 4512 2053 4512 2053 CONSTRUCTION Painted Steel Enclosure with 3 Point Double Locking Front Door and Full Length Door Hinge ENCLOSURE Designed for Inside Installations COLOR Natural finish ACCESSIBILITY Front All Servicing is Through the Front No Side or Rear Access is Required CABLE ENTRY Bottom or sides MOUNTING Four 4 Holes Provided to Anchor Enclosure to Pedestal Supplied by Others Online Power 6002 1405 REV M B 1 APPENDIX B OPTIONAL MAIN INPUT amp MAIN OUTPUT BREAKERS FOR VARIOUS MODELS Online Power 6002 1405 REV M B 2 Online Power 6002 1405 REV M C 1 Caution APPENDIX C
14. OnLine PWM 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 1 is designed to fit the needs of virtually all power conditioning and unit applications It has been designed to power all forms of modern data processing communication and process control equipment The Power Wave 1 does not require any de rating as other products may when powering 100 electronic loads including switching mode power supplies The Power Wave 1protects sensitive electrical equipment such as computer servers telecommunication networks LANs multi user and instrumentation systems from electrical interference including problems associated with poor quality AC power sags and complete power outages Online Power 6002 1405 REV M 2 3 2 3 PRODUCT FEATURES The following describes the major blocks within the Power Wave 1 Please refer to Illustration 2 2 System Component Layout to find specific items 2 3 1 Input Contactor K1 Illustration 2 2 Item 12 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 outage 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 whe
15. User Manual Power Wave 1 Central Lighting Inverter 3 20 KVA 2 1 17KW Document No 6002 1405 Revision M Installation and Operation Due to continuous product improvement this document is subject to change without prior notice Online Power 6002 1405 REV M a TABLE OF CONTENTS SECTION PAGE REVISION HISTORY c PROPRIETARY d SECTION 1 SAFETY 1 1 SECTION 2 OVERVIEW 2 1 2 1 INTRODUCTION 2 1 Illustration 2 1 Power Wave 1 2 1 2 2 BENEFITS 2 2 2 3 PRODUCT FEATURES 2 3 Illustration 2 2 Unit Component Layout 2 4 2 4 FUNCTIONAL DESCRIPTIONS 2 5 Illustration 2 3 Functional Block Diagram 2 7 2 5 THEORY OF OPERATION 2 8 2 6 OUTPUT LOADS 2 9 2 7 OPTIONS See more detail on Section 4 2 9 SECTION 3 OPERATION 3 1 3 1 START UP PROCEDURES 3 1 3 2 OPERATION 3 3 3 3 FIELD REPLACEABLE UNITS 3 3 Illustration 3 1 Heat Sink Assembly FRU 3 4 3 4 RENEWAL PARTS 3 5 SECTION 4 SYSTEM OPTIONS 4 1 4 1 OPTIONAL EXTERNAL MANUAL BYPASS SWITCH 4 2 Illustration 4 1 Manual Bypass Switch 4 2 Illustration 4 2 Manual Bypass Switch Diagram 4 3 4 2 OPTIONAL INTERNAL MANUAL BYPASS SWITCH 4 4 4 3 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH 4 4 4 4 OPTIONAL REMOTE UNIT STATUS PANEL P N 9100 1020 06 4 5 Illustration 4 3 Remote Status Panel 4 5 4 5 OPTIONAL FORM C CONTACTS FOR ALARMS P N 9100 1362 01 4 6 4 6 OPTIONAL TVSS P N 9100 1440 02 4 6 4 7 OPTIONAL NORMALLY O
16. 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 3 1 1 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 all cable connections are firmly secured If during the start up procedures anything unusual occurs immediately turn off the input circuit breaker and contact Online Power at 800 797 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 same time when dual input power sources are used 3 1 3 Apply input power to the Power Wave 1 Input Circuit Breaker remains open Verify that the voltage measured on the input circuit breaker is 120 208 240 or 277 VAC and is the same as nameplate voltage rating If the voltage is not the same as on nameplate within 15 to 10 tolerance do not proceed any further Contact Online Power at 800 797 7782 for technical assistance 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 1runs through its internal diagnostic routines Hear
17. 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 electrically noisy equipment Whether the electrical disturbances are generated outside or within the facility the following power problems can occur Complete power outages Brown outs including momentary sags Voltage surges Transients including common mode and transverse mode noise Frequency shifts and fluctuations Sensitive equipment needs protection from power problems Without power protection users of sensitive equipment may experience Loss of data Database corruption Rebuilding of files Equipment and component deterioration Premature equipment failures Unexpected equipment malfunctions Missed deadlines especially during batch processing Loss of real time transaction processing Loss of employee productivity The Power Wave 1 is a self contained unit a 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 It offers significant advantages over other alternatives For example just one Power Wave 1 Central Lighting Inverter can replace 70 bug eyes to make service and maintenance much quicker and easier The convection cooled
18. test so it will not deplete the batteries 3 1 10 The Power Wave 1 is now fully functional providing clean sine wave power to the load with battery back up in case of an input power failure This concludes the start up procedures UPS NORMAL XX kVA INPUT OK CHRG ON BATTERY OK DC OK ON INVERTER OUT OK Line 1 Line 2 Line 3 Line 4 Caution Online Power 6002 1405 REV M 3 3 3 2 OPERATION 3 2 1 Turning On the Power Wave 1 1 Apply input power 2 With input power available turn on the main input circuit breaker 3 Wait until you hear the input contactor closing and fan running 4 Close the battery circuit breaker only after the LCD display is lit and displays screens per Appendix D 5 Verify that all parameters on the LCD display panel are proper See Appendix D for display details 6 Close the output circuit breaker 7 Turn On the auxiliary output circuit breakers 3 2 2 Turning Off the Power Wave 1 Turn off the Output Breaker s Battery Breaker and Input Breaker 3 3 FIELD REPLACEABLE UNITS FRUS Refer to Table 3 1 for ordering the 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 factory Call Toll Free 800 PWR SRVC in North America Replacement parts must be replaced by qualified factory trained service personne
19. the sound of contactor closing See the fan s running See the LCD display screen showing UPS Normal message Caution Caution Online Power 6002 1405 REV M 3 2 Verify that the LCD display panel indicates all correct parameters see Appendix D for details Verify that the output voltage is 120 208 240 277 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 1 should be providing AC line power If the Power Wave 1 is not operating in the normal mode turn off the input circuit breaker Contact Online Power at 800 797 7782 for technical assistance 3 1 8 Recheck that the output voltage is 120 208 240 or 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 To place the Power Wave 1 in battery operation simulate loss of input power press and hold yellow Inverter Test Push Button With Push Button in the hold position the Power Wave 1 should be running on its internal batteries Verify that the LCD panel displays is as below where xx is the kVA of this unit UPS ALARM XX kVA INPUT BAD CHRGR OFF BATTERY OK DC OK ON INVERTER OUT OK Line 1 Line 2 Line 3 Line 4 Release the yellow Inverter Push Button and Verify that the LCD PANEL displays INPUT OK CHRGR ON Be sure to release the Push Button after the
20. to a sensing circuit During a power interruption this circuit causes contact X to drop into a N C position Please review wiring schematics 4 17 3 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 A N 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 x 1 25 D overall Color Black Weight 8 oz ILLUSTRATION 4 11 ECM EMERGENCY CONTROL MODULE 4 18 OFF Line Inverter operation 4 18 1 Slow transfer unit P N 9100 1473 01 4 18 2 Fast transfer unit P N 9100 1634 01 thru 14 Online Power 6002 1405 REV M 5 1 SECTION 5 MAINTENANCE 5 1 SAFETY PRECAUTIONS 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 CAN CONSIST OF EXCESSIVE DUST IN AND AROUND THE UNIT AS THE COOLING FANS IN THE UNIT WILL PULL THIS DUST INTO T
21. to be continuously charged The on line DC AC inverter converts the DC voltage to a pulse width modulation PWM waveform This waveform is filtered and reconstructed back to a desired AC output 2 5 3 Response To Input Power Failure If the system controller senses a change in input frequency of more than 3 Hz or an out of range input voltage it will consider it an input failure and will immediately open the input contactor isolating the unit from the facility 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 UPS ALARM message When the facility power returns stabilizes and is in phase with the backup power the system controller closes the input contactor and the system returns to NORMAL If the battery voltage drops below 16 of its nominal value and the facility power remains off then the system will assume a ALERT mode 2 5 4 UPS ALERT The System controller will issue a ALERT message on the LCD screen if any of the following conditions happen Internal failure System overheats Battery bank undervoltage During a ALERT the system stops its backup operation inverter SCRs are switched OFF and bypass SCRs are switched ON A summary alarm 5V signal is sent to the hardwired interface The system remains in this mode until power is cycled or system has been repaired when ne
22. 0 V 2 TO 5 120 V TB2 2 TB2 3 208 H H GND 208 1 TO 4 7 240 H H GND 240 1 TO 5 7 277 H N GND 277 1 TO 6 TB2 1 TB2 1 120 1 TO 2 TB2 1 TB2 1 1 2 INPUT TB1 To Customer s Load OUTPUT TB2 From External Battery Cabinet CONNECTION TB3 3 HOT HOT N GND 1 2 3 GND 1 2 3 4 5 6 7 0V 120V 0V 88V 120V 157V GND BATTERY ILLUSTRATION 2 7 CUSTOMER S CONNECTION OUTPUT TERMINAL BLOCK 120 208 240 277V If there are no requirements for remote signaling section 2 4 may be skipped Online Power 6002 1405 REV M 6 9 2 Same input voltage and output voltage unit A 120V Unit 1 2 3 4 5 6 7 N G 1 2 3 INPUT CB OPTIONAL INPUT 120V 120VAC OUTPUT GND TB1 TB2 H H N N H N CB3 1 3 2 4 G OUTPUT CB OPTIONAL Jumper from TB2 1 to TB2 7 for 120V In Out unit Aux Output CBs option Customer connect load to the Aux CB and Neutral for Aux CB option ILLUSTRATION 2 8 120V UNIT Online Power 6002 1405 REV M 6 10 2 continued B 208V Unit ILLUSTRATION 2 9 208V UNIT H H H Online Power 6002 1405 REV M 6 11 2 continued C 240V Unit 1 2 3 4 5 6 7 1 2 3 INPUT CB OPTIONAL INPUT CONNECTION 240V OUTPUT CONNECTION 240VAC GND GND TB1 TB2 H H N N H N CB3 1 3 2 4 G OUTPUT CB OPTIONAL 2P Aux Output CBs opt
23. 07 02 Basic NetAgent SNMP with WIFI HUB 9800 008 01 Advanced NetAgent SNMP 9800 008 02 Advanced NetAgent SNMP with WIFI HUB 9800 008 03 Advanced NetAgent SNMP with mobile GPRS modem 9800 008 04 Advanced NetAgent SNMP with Dial up modem 9100 1501 ECC EMERGENCY CIRCUIT CONVERTER 9100 1502 ECM EMERGENCY CONTROL MODULE Online Power 6002 1405 REV M 4 2 4 1 Optional External Maintenance Bypass Switch P N 3000 044 thru 056 PART NO AMP ENCLOSURE SIZE INCH W H D W1 H1 3000 044 55 AMP 14 16 8 12 16 75 3000 045 110 AMP 14 16 10 12 16 75 ENCLOSURE DIM S SELECTION CHART FOR SINGLE PHASE UPS KW KVA 3 KW KVA 5 KW KVA 7 5 KW KVA 10 KW KVA 15 KVA KW 20 17 FOR WIRING DIAGRAM SEE DWG 3000 045 3000 044 3000 044 3000 045 3000 045 3000 045 6001 032 31S ILLUSTRATION 4 1 EXTERNAL MAINTENANCE BYPASS SWITCH Online Power 6002 1405 REV M 4 3 ILLUSTRATION 4 2 MAINTENANCE BYPASS SWITCH WIRING DIAGRAM 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 Refer to Section 3 1 Site Planning and Preparation Verify the following connections have been made per wiring diagrams 6001 032 31 S Wiring Inspection
24. ACTOR 0 98 to 1 0 Typical OVERCURRENT PROTECTION Electronic Circuit Breaker NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block OUTPUT RATING KVA KW 3 3 5 5 7 5 7 5 10 10 12 5 12 5 15 15 17 17 VOLTAGE VAC Single Phase 120 208 240 277 VAC VOLTAGE REGULATION 3 No Load to Full Load 3 High Line to Low Line FREQUENCY Hz 60 Hz 0 25 Hz When on Inverter WAVESHAPE Sine Wave HARMONIC DISTORTION lt 5 THD lt 3 Single Harmonic CREST FACTOR Up to 3 to 1 POWER FACTOR 0 65 Lagging or Leading to Unity STEADY STATE CURRENT Normal Mode Emergency Mode 25 14 13 11 42 24 21 18 63 36 31 27 83 48 42 36 104 60 52 45 125 72 63 54 142 82 91 61 OVERLOAD 125 for One 1 minutes surge 150 PROTECTION Electronic Circuit Breaker NOISE REJECTION 120 dB Common Mode 60 dB Normal Mode NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block Online Power 6002 1405 REV M A 4 POWER RATING KW 3 3 5 5 7 5 7 5 10 10 12 5 12 5 15 15 17 BATTERY RUN TIME 90 Minutes Minimum BATTERY TYPE Sealed Maintenance Free AGM VRLA type NOMINAL DC VOLTAGE 96 VDC 120 VDC 120 VDC 192 VDC 192 VDC 240 VDC 240VDC OVERCURRENT PROTECTION Circuit Breaker PACKAGING Batteries Housed in Same Enclosure and or additional battery cabinet See Table 2 2 MONITORING AND COMMUNICATIONS LCD SCREEN
25. CB1 24 Output Breaker CB3 25 Output Distribution Breakers CB4 and on 26 Maintenance Free Lead Acit Battery s 27 Inverter Test Switch S2 28 Rectifier Block BR1 ILLUSTRATION 2 2 COMPONENT LAYOUT Online Power 6002 1405 REV M 2 5 2 4 FUNCTIONAL DESCRIPTION Illustrations 2 3 depict FUNCTIONAL block diagrams of the Power Wave 1 These diagrams provide an excellent tool for identifying the major building blocks within the Power Wave 1 2 4 1 Main input circuit breaker optional The main input circuit breaker provides Power Wave 1 with incoming power isolation and input overcurrent protection 2 4 2 Input Contactor Input contactor controls power applied to the unit The microprocessor control circuit verifies that the unit is in normal and not at a fault condition and that the input voltage and frequency are within an acceptable range Only then it energizes the contactor closing coil via control transformer and fuse 2 4 3 Input Inductors The input inductors are a single phase input filter 2 4 4 Inverter When the AC input power is not available to power the load the inverter converts the energy stored in the battery bank to AC power to supply power to the load The pulse width modulated PWM inverter utilizes high speed high efficiency IGBT s for fast response sinusoidal power 2 4 5 Battery charger The battery charger converts AC power into regulated DC power to re charge and to maintain the charge
26. D ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION FIRE EQUIPMENT FAILURE OR ELECTROCUTION Online Power 6002 1405 REV M 1 3 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 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 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 FAILURES 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 Danger IN CASE OF FIRE INVOLVING ELECTRICAL EQUIPMENT ONLY CARBON DIOXIDE FIRE EXTINGUISHERS OR THOSE APPROVED FOR USE ON ELECTRICAL EQUIPMENT SHOULD BE USED USE OF WATER ON FIRES INVOLVING LIVE HIGH VOLTAGE ELECTRICAL CIRCUITS COULD PRESENT AN ELECTROCUTION HAZARD Danger SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO CHASSIS GROUND ANY CONTACT BETWEEN FLOATING CIRCUITS AND T
27. ETY 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 FAILURE OR ELECTROCUTION 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 CAPACITOR BANKS ALWAYS OBSERVE BATTERY PRECAUTIONS WHEN OPERATING NEAR ANY BATTERIES FAILURE TO OBSERVE THESE PRECAUTIONS COULD RESULT IN DEATH INJURY OR DAMAGE TO EQUIPMENT Online Power 6002 1405 REV M 5 3 5 2 WHEN TO CALL Call for service if you encounter any of the following conditions 1 Repeated start up attempts are unsuccessful 2 A UPS fault occurs which cannot be cleared 3 Normal operation of the critical load rep
28. H BATTERY Online Power 6002 1405 REV M 6 5 Each model of the Power Wave 1 is designed to supply a maximum load which is determined by its kVA 1000 s of volt amperes and kW rating It is very important that the load is within the rating of this Power Wave 1 to ensure that the connected loads will be properly supported Each electrical device to be powered by the Power Wave 1 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 nameplate should also list the electrical requirements of the device The total load to be powered by the Power Wave 1 must not exceed its kVA rating If the total load is exceeded the Power Wave 1 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 1 consists of one electronics and one or more battery cabinets 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 UNPACK
29. HE CHASSIS IS A LETHAL SHOCK HAZARD Online Power 6002 1405 REV M 1 4 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 SHOULD BE RECYCLED RATHER THAN DISCARDED 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 1 REMOVE WATCHES RINGS OR OTHER METAL OBJECTS 2 USE TOOLS WITH INSULATED HANDLES 3 WEAR RUBBER GLOVES AND BOOTS 4 DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES 5 DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR DISCONNECTING BATTERY TERMINALS 6 DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED IF SO REMOVE THE SOURCE OF THE GROUND CONTACT WITH ANY PART OF A GROUNDED BATTERY CAN RESULT IN ELECTRICAL SHOCK THE LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS ARE REMOVED DURING INSTALLATION AND MAINTENANCE 7 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 NOT CAUSE FLAME OR SPARK
30. HE UNIT 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 FAILURE 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 Online Power 6002 1405 REV M 5 2 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 FAILURES 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 Danger OBSERVE ALL BATTERY SAF
31. IN BATTERY AREA 8 DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE 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 Online Power 6002 1405 REV M 2 1 SECTION 2 OVERVIEW 2 1 INTRODUCTION The Power Wave 1 Central Lighting Inverters are manufactured to provide critical power for lighting during a power outage The Power Wave 1 meets or exceeds the life safety codes of UL924 and UL1778 These codes were established to allow the emergency lighting inverters to provide critical power to the lighting circuits during a power failure The emergency lighting inverter will then provide power for 90 minutes that will allow safe and orderly evacuation from the facility When input power to the Power Wave 1 is lost during a power outage the system will automatically draw power from its internal battery supply without any interruption The critical load will receive only clean sine wave power The optional output transformer allows multiple output voltages as well as input voltages that are different than output voltages The internal VRLA valve regu
32. ING Remove the equipment from the shipping carton Since the Power Wave 1 is designed for pad mounting installations there are no casters It is suggested that a forklift be used to remove the Power Wave 1 from its shipping pallet See Illustration 6 4 for the location of forklift slot ILLUSTRATION 6 4 FORKLIFTING Caution Online Power 6002 1405 REV M 6 6 6 3 UNIT INSTALLATION 6 3 1 Mechanical Installation Preparing to Install Unit 1 Before placing the Power Wave 1 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 6 2 and 6 3 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 will be happy in assisting you in locating the conduit to maintain unit reliability 2 Determine 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 1 to the mounting pad at the four
33. LE ACID NEUTRALIZING AGENT ONE COMMON PRACTICE IS TO USE A SOLUTION OF APPROXIMATELY ONE POUND 450 GRAMS OF BICARBONATE OF SODA TO APPROXIMATELY ONE GALLON 4 LITERS OF WATER THE BICARBONATE OF SODA SOLUTION SHOULD BE APPLIED TO THE SPILL UNTIL EVIDENCE OF CHEMICAL REACTION FOAMING HAS CEASED THE RESULTING LIQUID SHOULD BE FLUSHED WITH WATER AND THE AREA DRIED Danger DO NOT DISPOSE OF A BATTERY OR BATTERIES IN A FIRE THE BATTERIES MAY EXPLODE CAUSING DEATH OR SERIOUS INJURY Online Power 6002 1405 REV M 5 5 Do not substitute batteries from other manufacturers without the express approval of Online Power Customer Service personnel Power Battery PRC 12xxx is one battery manufacturer used by Online Power with xxx representing the amp hour size of the battery Universal Battery UB12xxx is another battery manufacturer authorized by Online Power the xxx is the amp hour size of battery Lead acid batteries contain hazardous materials and must be handled transported and recycled or scrapped in accordance with federal state and local regulations Since lead is a toxic substance lead acid batteries should be recycled rather than scrapped A battery can present a risk of electrical short and high short circuit current The following precautions should be observed when working on or around batteries Remove watches rings necklaces or other metal objects Use only tools with insulated handles
34. N NORMALLY OFF OUTPUT AUX CIRCUIT BREAKERS P N 9100 1343 01 THRU 16 4 7 4 8 OPTIONAL EXTERNAL OUTPUT AUX CB S IN PANEL BOARD P N 9100 1439 01 THRU 03 4 7 4 9 OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CB 4 7 4 10 OPTIONAL INPUT CB STANDARD HIGHER KAIC 4 7 4 11 OPTIONAL OUTPUT CB STANDARD HIGHER KAIC 4 8 4 12 OPTIONAL SEISMIC MOUNTING BRACKET P N 9100 1317 02 4 8 4 13 OPTIONAL STACKABLE CABINET RACK P N9100 1429 XX 4 8 4 14 OPTIONAL POWER FLOW MIMIC P N 9100 1493 01 4 8 Illustration 4 4 Power Flow Mimic 4 8 4 15 OPTIONAL GLOBAL MONITORING SYSTEM Local on UPS 4 9 Online Power 6002 1405 REV M b SECTION PAGE 4 15 1 Local On UPS Event Log P N 9100 1466 01 9100 1538 XX 4 9 Illustration 4 5 Logged Events 4 9 Illustration 4 6 Status Screen 4 9 Illustration 4 7 System Info 4 10 4 15 2 Local On UPS AUX CBs Trip Monitor with Event Log P N 9100 1453 01 4 10 Illustration 4 8 Auxiliary CB Trip 4 10 4 15 3 Local on PC via RS 232 4 11 Illustration 4 9 Sample PC Screen 4 11 4 15 4 Local on PC via RS 485 4 11 4 16 OPTIONAL ECC Emergency Circuit Converter 4 12 Illustration 4 10 ECC Emergency Circuit Converter 4 12 4 17 OPTIONAL ECM Emergency Control Module 4 13 Illustration 4 11 ECM Emergency Control Module 4 13 SECTION 5 MAINTENANCE 5 1 5 1 SAFETY PRECAUTIONS 5 1 5 2 WHEN TO CALL 5 3 5 3 STEPS TO TAKE 5 3 5 4 PREVENTIVE MAINTENANCE 5 3 5 5 ONLI
35. NE POWER CUSTOMER SERVICE AND SUPPORT 5 7 APPENDICES APPENDIX A SPECIFICATIONS A 1 APPENDIX B OPTIONAL MAIN INPUT OUTPUT BREAKERS FOR VARIOUS MODELS B 1 APPENDIX C BATTERY CONNECTIONS C 1 APPENDIX D LCD DISPLAY MENU amp TROUBLESHOOTING GUIDE D 1 APPENDIX E DRAWINGS amp TABLES REQUEST FOR TURN ON E 1 APPENDIX F CONNECTION DIAGRAM FOR EXISTING 3 POLE PANELBOARD F 1 SECTION 6 INSTALLATION 6 1 6 1 SITE PLANNING AND PREPARATION 6 1 Illustration 6 1 48 Cabinet Cable Access and Mounting 6 2 Illustration 6 2 68 Cabinet Cable Access and Mounting 6 3 Illustration 6 3 Oversize Cabinet Cable Access and Mounting 6 4 6 2 EQUIPMENT UNPACKING 6 5 Illustration 6 4 Fork lifting 6 5 6 3 UNIT INSTALLATION 6 6 Illustration 6 5 Power Wave 1 Customer s Connection Input Terminal Block 6 7 Illustration 6 6 Customer s Connection Terminal Block for 120 208 240 277V Output 6 8 Illustration 6 7 Customer s Connection Terminal Block for 208 240 277V Output 6 8 Illustration 6 8 Customer Connections Same Input Output Voltage 120V Unit 6 9 Illustration 6 9 Customer Connections Same Input Output Voltage 208V Unit 6 10 Illustration 6 10 Customer Connections Same Input Output Voltage 240V Unit 6 11 Illustration 6 11 Customer Connections Same Input Output Voltage 277V Unit 6 12 Illustration 6 12 Customer Connections Output Connection w Output XFMR 120V 6 13 Illustration 6 13 Customer Connections Output
36. al Code 3 Connection Type Wire Size Range 4 Torque Specifications Unless Otherwise Labeled 5 Unit Installation Data 6 Specifications OnLine Power 6002 1405 REV M F1 APPENDIX F Connection Diagram using existing 3 pole panel board for dual output voltages 7 6 5 4 3 2 1 TB G OUTPUT XFMR UPS OUTPUT 120V 88V HI N H2 208V PNL BD HI H2 208V H2 N 120V HI N NOT USE 88V A 7 6 5 4 3 2 1 TB G 120V 157V HI N H2 120V 277V PNL BD HI H2 277V H2 N 120V HI N NOT USE 157V B 7 6 5 4 3 2 1 TB G HI N H2 120V 240V PNL BD HI H2 240V H2 N 120V HI N 120V C 120V 11 12 13 14 OUTPUT CB2 T1 OUTPUT CB2 OUTPUT XFMR UPS OUTPUT T B 8 12 13 14 T1 157V 120V OUTPUT CB2 OUTPUT XFMR UPS OUTPUT T B 9 12 13 14 T1 120V 88V 120V Online Power 6002 1405 REV M 6 1 SECTION 6 INSTALLATION 6 1 SITE PLANNING AND PREPARATION The Power Wave 1 is designed for installation indoors and meets NEMA specifications for operating temperature humidity and utility voltage These cabinets are rugged and corrosion resistant The footprint of the Power Wave 1 is less than 6 square feet Listed below are the environmental specifications for the Power Wave 1 Adequate clearance in the front of the equipmen
37. ates L N output voltage 2 Line 3 Indicates L N output voltage 3 Line 4 Indicates L N output voltage 4 OUTPUT _____V ______ W INPUT _____V ______ A DC BUS _____V NA A BATT _______V _____ W OUTPUT 120 V OUTPUT 208 V OUTPUT 277 V OUTPUT 480 V OnLine Power 6002 1405 REV M E1 APPENDIX E DRAWINGS FOR SINGLE PHASE UNIT All drawings are downloadable from Website www onlinepower com 1 Unit amp Battery Cabinet Installations 1 Phase UPS with 90 Min Battery Backup 3 5 7 5 10 12 5 15 17and 20 kVA 2 1 3 3 5 5 5 25 7 7 5 8 8 5 10 10 5 14 15 17 kW 6001 033 01 2 UPS amp Barttery Cabinet Layout 1 Phase UPS with 90 Min Battery Backup 3 5 7 5 10 12 5 15 and 20 kVA 2 1 3 3 5 5 5 25 7 7 5 8 8 5 10 10 5 14 15 17 kW 6001 033 02 3 1 Phase UPS Functional Block Diagram Single Line Diagram Dwg 6001 033 03 4 UPS amp Battery Cabinet Seismic Certification Drawing Dwg 6002 1658 09 0319 A 5 Single Phase UPS with Load Center Dwg 6001 032 19 6 Single Phase External Wrap around by pass Panel 3KVA TO 20 KVA and 17 kw Dwg 6001 032 31 amp 6001 032 31S TABLES 1 Single Phase Unit Chart for recommended output input protective device rating BTU HR and Floor Loading Table XXX 1 and XXX 2 2 Allowable Ampacities of Insulated Conductors Rated 0 2000 V 60 to 90 deg C 140 194 deg F Table 310 16 of National Electric
38. ating 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 Danger symbol indicate that there is a high risk of personal injury or death if instructions are not followed Warnings labeled with the symbol indicate that there is a high probability of equipment failure damage or destruction if instructions are not followed If you require assistance call 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 Rating Input Voltage Output Voltage Manufacturer Date Danger READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING THE INSTALLATION START UP OPERATION OR MAINTENANCE OF THE UNIT Uninterruptible Power System OR BATTERY SYSTEMS FAILURE TO DO SO COULD RESULT IN ELECTROCUTION FIRE EXPLOSION OR EQUIPMENT FAILURE 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 FAILURE Verify the O
39. attery Breaker Off except when set on 3 Turn on battery CB for Normal operation UPS position Manual Bypass Switch 4 3 OPTIONAL AUDIO ALARM WITH SILENCE SWITCH P N 9100 1363 01 Caution Online Power 6002 1405 REV M 4 5 4 4 OPTIONAL REMOTE UNIT STATUS PANEL P N 9100 1020 06 4 4 1 Installation The Remote Unit Status Panel is available in a console mount style box in black finish It can also be wall mounted and comes with a 10 foot long DB connector signal cable or optional length cable that can be up to 1000 feet long 4 4 2 Operation Remote Status Panel comes with 10ft long cable SILENCE LED HORN test switches and includes following status LED s INPUT OK Input power is within acceptable range INVERTER ON Inverter is On ON BYPASS Unit is on bypass mode ON BATT Unit is running from Battery LOW BATT Battery voltage is at low voltage before shutdown SUM ALARM Unit is on critical alarm such as Over Temperature DC OV UV HORN Audible warning for alarm condition SILENCE SWITCH Silences the audible warning LED TEST Tests the LED s by push in Side Mount Provision Back Mount Provision Use Bumpers for console install T o UPS P100 T erminal Block See installation instruction shipped with the assembly ILLUSTRATION 4 3 REMOTE STATUS PANEL 4 4 3 Specifications Unit Remote Status Panel Installation Drawing 9100
40. bView software translates data protocol coming to COM port 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 ILLUSTRATION 4 9 SAMPLE PC SCREEN 4 15 3 3 Specification Description Local On PC Via RS 232 Part Number 9800 005 XX PC system requirements 98 and higher Windows OS serial port Viewing software Lab View included RS232 cable 25 thru 15 ft as specified included 4 15 4 Local On PC Via RS 485 P N 9800 006 01 Installation Operation Specification as above except RS 485 cable Online Power 6002 1405 REV M 4 12 4 16 OPTIONAL ECC EMERGENCY CIRCUIT CONVERTER P N 9100 1501 4 16 1 Installation Indoor use only Simple and fast installation in ceiling or wall mounted standard single gang E box Installation must be performed by a qualified electrician per Installation Operation and Maintenance Instructions provided with the ECC 4 16 2 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 failure The device will 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 fa
41. ble window voltage range There are two versions one is fast transferring with a quarter of cycle 2 5 milli second another is slow transferring with 25 cycles 400 milli second second to 1second Fast transferring time is required when the loads are sensitive to voltages such as HID lights and other that any voltage disturbance effects their operation One must consider that higher efficiency of unit is only requirement and output voltage regulation is not critical as much Option part numbers refer to 4 18 options AC off line inverter operation with 2 version of transferring time Caution STOPPING ROTATION OF THE MAINTENANCE BYPASS SWITCH BETWEEN POSITIONS WILL RESULT IN THE REMOVAL OF OUTPUT VOLTAGE Online Power 6002 1405 REV M 2 7 ILLUSTRATION 2 3 FUNCTIONAL BLOCK DIAGRAM Online Power 6002 1405 REV M 2 8 2 5 THEORY OF OPERATION 2 5 1 Standby Mode After power is applied the system is placed in STANDBY mode and a self check starts During this period the start subroutine checks for the input voltage and proper operation of the inverter and bypass SCR s After the routine is completed and check confirmed OK the system goes into the NORMAL mode 2 5 2 Normal Mode The input contactor K1 receives a closing signal connecting input power to the DC supply transformer The DC rectifier supplies the battery charger Control Board and the DC AC inverter circuit The battery charger is then activated allowing the batteries
42. 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 20 NM M8 BM 195 231 277 266 IN LB 30 NM M10 NOTE For annual re torque reduce 5 IN LB from recommended torque value 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 Caution Online Power 6002 1405 REV M 5 7 5 4 6 Battery Terminals 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 OnLine Power Customer Service personnel must approve use of non standard batteries Please call at 1 800 PWR SRVC 800 797 7782 5 5 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 e
43. cility at all times The automatic Diagnostic feature will confirm the emergency system is ready to provide back up power 4 16 3 Specification Description ECC EMERGENCY CIRCUIT CONVERTER OPTION Part Number 9100 1501 01 120 VAC 9100 1501 02 277 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 ILLUSTRATION 4 10 ECC EMERGENCY CIRCUIT CONVERTER Online Power 6002 1405 REV M 4 13 4 17 OPTIONAL ECM EMERGENCY CONTROL MODULE P N 9100 1502 4 17 1 INSTALLATION Indoor use only gt ECM is a universal mount unit simple and fast installation in ceiling or wall mounted standard single gang E box recommended box size 4 Installation must be performed by a qualified electrician per Installation Operation and dMaintenance Instructions provided with the EMC 4 17 2 Operation The emergency power is provided from a central lighting inverter that is automatically switched over to 24 hour emergency power distribution panel 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
44. diagram with the main output circuit breaker Refer to Section 6 However when any aux output CBs are used follow the instructions below 1 No main output CB but only aux output CBs are used Connect critical loads to aux CBs directly not TB2 Do Not Use 2 Both main output CB and aux output CBs are used Connect the main load to TB2 as shown in the voltage connection diagram and connect other aux load directly to aux output CBs Locate the aux output CBs Neutral and grounding terminals are provided Online Power 6002 1405 REV M 6 8 For 120 208 240 277V output verify jumper between TB2 2 and TB2 3 120V output is connected at TB2 1 Neutral TB2 2 120VAC Hot 208V output is connected at TB2 1 Hot TB2 4 208VAC Hot 240V output is connected at TB2 1 Hot TB2 5 240VAC Hot 277V output is connected at TB2 1 Neutral TB2 6 277VAC Hot 1 2 INPUT TB1 To Customer s Load OUTPUT TB2 From External Battery Cabinet CONNECTION TB3 3 HOT HOT N GND 1 2 3 GND 1 2 3 4 5 6 7 0V 120V JUMPER 208V 240V 277V 0V 88V 120V 157V GND FOR 208V 240V 277V OUTPUT BATTERY ILLUSTRATION 2 6 CUSTOMER S CONNECTION OUTPUT TERMINAL BLOCK 120 208 240 277V For 208V 240 277V output INPUT POWER OUTPUT POWER VOLT TERMINAL VOLT TB2 TERMINAL NO NEUTRAL BUS MOVE TO GND BUS MOVE TO 1 2 3 120 H N GND 120 240 1 TO 2 12
45. e fans s with taps to match unit output voltages Fuse F2 protects fans amp transformer 2 4 14 Efficiency Optimizer Function OFF Line Inverter Mode When Input Power is available the batteries shall be charged and AC output from inverter thru inverter static switch supports to the critical load In this Normal Mode Operation the inverter static switch is closed and bypass static switch is opened The bypass static switch is closed only upon inverter faults or upon manual operation and then output power thru bypass static switch supports critical load This is normal operation for true double convention UPS However there is demand for higher efficiency UPS in industry to reduce cost of electricity and want to use as off line inverter which means that normal operating mode is reversed such that bypass static switch is closed normally as long as input voltage and input frequency are within 10 permissible windows of normal voltage and 3hz of normal frequencies and inverter static switch is opened The inverter static switch is only closed upon the failure of input power or upon out of voltage and frequency normal ranges This is called the off line inverter mode and system efficiency is higher as 98 and reduces the total power loss The output AC voltage in the mode of operation follows proportionally to the input line voltage In another words there is no output voltage regulation within 10 window voltage range or 15 selecta
46. e 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 Online Power 6002 1405 REV M C 2 4 3 2 1 5 6 7 8 96 VDC BUSS UPS ELECTRONICS BATT C B 1 2 1 2 Typical 1 Strings of 8 Battery system 96 Volt Nominal Maximum 4 Strings of 8 Battery system are available in maximum 2 Cabinets depend upon Battery Run Time requirement Consult Factory for detail 2 STRING 3 STRING 4 STRING Online Power 6002 1405 REV M C 3 4 3 2 1 7 8 9 10 120 VDC BUSS UPS ELECTRONICS 5 6 BATT C B 1 2 1 2 Typical 1 Strings of 10 Battery system Maximum 4 Strings of 10 Battery system Depend upon Battery Run Time requirement batteries can be in UPS cabinet or separate maximum of 2 Cabinets Consult Factory for detail 2 STRING 3 STRING 4 STRING 120 Volt Nominal Online Power 6002 1405 REV M C 4 4 3 2 1 7 8 9 10 14 13 12 11 Typical 1 Strings of 16 Battery system 2 STRING 3 STRING 4 STRING 5 6 15 16 BATT C B 1 2 1 2 192 VDC UPS ELECTRONICS Maximum 4 Strings of 16 Battery system Depend upon Battery Run Time requirement batteries can be in UPS cabinet or separate maximum of 3 Cabinets Consult Factory for detail
47. eatedly 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 unit failure Momentary overload conditions will be handled within the parameters of the Unit but sustained overloads will cause the Unit to fail 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 5 4 PREVENTATIVE MAINTENANCE Unit Operator Maintenance consists of the basic tasks listed in this section Other maintenance functions require Online Power Service personnel 5 4 1 Maintaining an Operator s Log Careful record keeping will ensure proper maintenance of the Unit and assist in the correction of any abnormal conditions The operator s log should contain the following information Date of system start up Dates that battery maintenance was performed Dates that input output and battery status readings were checked and the values displayed for these readings Dates and summaries of all communications with Online Powe
48. eded 2 5 5 UPS ALARM The System controller will issue a UPS ALARM message on the LCD screen if any of the following conditions occur Input power failure Output overload During a ALARM mode inverter IGBs remain on and an alarm signal may be sent to the signal interface The system will reset itself as soon as the problems disappear Online Power 6002 1405 REV M 2 9 2 6 OUTPUT LOADS The Power Wave 1 is designed to power any fluorescent or incandescent and HID lighting There are however certain types of loads that exhibit an excessive inrush current when first turned on or at other times during operation The capacity of the Power Wave 1 may need to be greater than what would be estimated based on the nameplate requirements of loads previously discussed Contact your Online Power dealer or the factory directly if you have any questions about powering unusual loads from your Power Wave 1 2 7 OPTIONS See Section 4 for details The following options are available with the Power Wave 1 Internal External Manual Bypass Switch Audio Alarms with Silence Switch Remote UPS Status Display 1 phase Monitor Form C N O Contacts for Alarms TVSS Transient Voltage Surge Suppressor Normally ON OFF Output Aux Circuit Breakers External Output Aux Circuit Breakers in Panel Board Stackable Cabinet Rack System Input CB Standard Higher KAIC System Output CB Standard Higher KAIC Higher KAIC Norm ON OFF Output Circuit Breaker
49. fore disconnecting 5 Loosen 3 Phillips head screws at front holding heat sink bracket Pull the complete assembly forward and up Remove it from tray gently making sure that no cables or wires are catching See illustration 3 1 6 Install 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 7 Reinstall all the cables and connectors in the reverse order Verify per illustration 3 1 8 Verify connections prior to starting up the unit ILLUSTRATION 3 1 HEAT SINK ASSEMBLY FRU Online Power 6002 1405 REV M 3 5 3 4 RENEWAL PARTS Table 3 1 System Parts ITEM QTY DESCRIPTION DESIGN 1 1 Power Board A1 2 1 Bypass Static Switch PB2 3 1 Output Static Switch PB1 4 1 Input Output Battery Terminal Block for customer s use TB1 TB2 TB3 5 1 Input Choke L1 L3 6 1 Output Choke L2 7 1 DC Choke L4 8 1 The Frequency Noise Filter Capacitors for output Power C1 C2 C3 9 1 Control Board A2 10 1 LCD Display Board A5 11 1 Input Contactor K1 12 1 Terminal Block to remove heat sink assembly TB4 13 1 Fan Transformer T3 14 1 Control Power Transformer T2 15 1 Control Transformer Fuse F1 16 1 Fan Fuse F2 17 1 Heat Sink Assembly HS1 18 1 Fan s B1 thru B5 19 1 Optional Output Isolation Transformer T1
50. 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 including SNMP options 2 3 5 Output Static Switch Illustration 2 2 Item 3 This SCR solid state switch connects the output of the inverter UPS to the load It is connected on the primary side of the optional output isolation transformer This switch shuts off in case of a problem or failure within the unit and transfers the load directly to the utility input via the bypass static switch It maintains it s status opposite to that of bypass switch 2 3 6 LCD Display Panel Illustration 2 2 Item 11 The LCD Liquid Crystal Display panel provides all the input output battery metering and alarm data and UPS status for customer use on a constantly scrolling set of 2 default screens with continuous update Online Power 6002 1405 REV M 2 4 1 2 3 1 2 3 1 2 3 4 5 6 7 9 C1 C2 C3 19 5 6 4 20 26 7 8 14 1 15 3 27 11 2 18 24 25 23 22 28 17 16 19 10 13 12 21 2 3 7 Optional Output Isolation Transformer Illustration 2 2 Item 20 The output isolation transformer provides isolation between the inverte
51. ion Customer connect loads to these Aux Output CB When both main output CB and Aux output CB option are used notice these jumpers Customer can turn on off each CB individually This is factory standard T o locate all Aux Output CBs after the main output CB move these jumpers to CB3 2 and CB3 4 ILLUSTRATION 2 10 240V UNIT H H H Online Power 6002 1405 REV M 6 12 2 continued D 277V Unit 1 2 3 4 5 6 7 1 2 3 INPUT CB OPTIONAL INPUT CONNECTION 277V OUTPUT CONNECTION 277VAC GND GND TB1 TB2 H N H N G When both main output CB and Aux Output CB option are used notice these jumpers Customer can turn on off each CB individually This is factory standard N G H N CB3 1 3 2 4 OUTPUT CB OPTIONAL Neutral and Gnd are tied Jumper from TB2 7 and TB2 1 for 277V unit 1P Aux Output CB If 1P Aux CB option is called out neutral is brought out as shown here ILLUSTRATION 2 11 277V UNIT Online Power 6002 1405 REV M 6 13 3 Customer Connection Output connection with output transformer The following Illustrations 2 12 to 2 18 are standard Aux CB Output CB s connections Note When desire to locate all Aux Output CBs after the main output CB move Aux CB wiring to CB3 2 amp CB3 4 For multiple output unit and different input output voltage application There is an output transformer Input power connections are sa
52. l only 3 3 1 Control Board This 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 Reconnect all plugs and connections maintain 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 Online Power 6002 1405 REV M 3 4 PB1 2 P6 P4 P7 Phase C Q3 Q4 TB4 Phase A Q1 Q2 Phase B Q5 Q6 E1 C2 Q7 Q8 E2 Q7 Q8 P1 A3 P1 RED A4 P1 RED A3 P1 WHITE A4 P1 WHITE PB1 1 PB2 1 PB2 2 J6 1 2 3 4 J4 1 2 BLK RED J7 1 2 BLK RED 3 3 3 Heat Sink Assembly Replacement Procedure 1 Disconnect and isolate all sources of power 2 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 3 Disconnect connectors P7 P6 P4 P1 from the PCB A1 which is mounted horizontally on the big black heat sink 4 Disconnect 5 power cables at TB4 1 through TB4 5 using flat screw driver Verify and install label ID for each cable be
53. lated lead acid maintenance free batteries provide 90 minutes of backup power Upon restoration of input power the Power Wave 1 automatically resumes normal operation and immediately begins to recharge the batteries The Power Wave 1 has an internal bypass circuit which maintains the power to the load in case of internal unit failure The Power Wave 1 provides comprehensive monitoring capabilities In addition to the LCD display it provides five dry relay contacts for remote monitoring capabilities Power Wave 1 contains as standard features an AS 400 RS 232 protocol interface RS485 data transmission ports and many other communication options The Power Wave 1 is an on line single phase PWM inverter available in output rating of 3 5 7 5 12 5 15 20 kVA and 3 5 7 5 12 5 15 17 KW The Power Wave 1 is listed for compliance to UL1778 UL924 UL924A and CSA107 1 standards The Power Wave 1 is available with an input or output voltages of 120 208 240 or 277 VAC single 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 1 specifications ILLUSTRATION 2 1 POWER WAVE 1 48 High Cabinet 68 High Cabinet Online Power 6002 1405 REV M 2 2 2 2 BENEFITS Electrical disturbances can come from practically anywhere from the incoming power lines and even from within a building Outside electrical disturbances
54. line 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 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 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 Online Power 6002 1405 REV M 1 1 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS SECTION 1 SAFETY Following safety precautions is important when oper
55. lock OUTPUT RATING KVA KW 3 2 1 5 3 5 7 5 5 25 10 7 12 5 8 75 15 10 5 20 14 VOLTAGE VAC Single Phase 120 208 240 277 VAC VOLTAGE REGULATION 3 No Load to Full Load 3 High Line to Low Line FREQUENCY Hz 60 Hz 0 25 Hz When on Inverter WAVESHAPE Sine Wave HARMONIC DISTORTION lt 5 THD lt 3 Single Harmonic CREST FACTOR Up to 3 to 1 POWER FACTOR 0 65 Lagging or Leading to Unity STEADY STATE CURRENT 18 10 9 8 29 17 15 13 44 25 22 19 58 34 29 25 73 4236 32 88 50 44 38 96 83 72 OVERLOAD 125 for One 1 minutes surge 150 PROTECTION Electronic Circuit Breaker NOISE REJECTION 120 dB Common Mode 60 dB Normal Mode NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal Block Online Power 6002 1405 REV M A 2 POWER RATING KVA 3 2 1 5 3 5 7 5 5 25 10 7 12 5 8 75 15 10 5 20 15 BATTBATTERY BATTERY RUN TIME 90 Minutes Minimum BATTERY TYPE Sealed Maintenance Free AGM VRLA type NOMINAL DC VOLTAGE 96 VDC 120 VDC 120 VDC 192 VDC 192 VDC 240 VDC OVERCURRENT PROTECTION Circuit Breaker PACKAGING Batteries Housed in Same Enclosure and or additional battery cabinet See Table 2 1 MONITORING AND COMMUNICATIONS LCD SCREEN Input Voltage Battery Charger UPS Output On Battery Low Battery Summary Alarm INDICATORS LCD Display Panel RELAY INTERFACE Dry Contacts for UPS On N C On Inverter
56. ludes the installation procedures Please proceed to Section 3 1 Start Up 6 5 BATTERY STORAGE The Power Wave 1 System can be placed in storage while not in use Provide a protected environment which meets the environmental parameters listed below AMBIENT TEMPERATURE 20 to 70 C 4 to 158 F RELATIVE HUMIDITY 0 to 95 non condensing If the Power Wave 1 will be stored for three months or longer it should be serviced by charging the batteries for 24 hours at regular three month intervals While in storage service the unit using the procedures in this section 6 5 1 Battery Maintenance During long term storage the batteries are subject to aging and deterioration After visual inspection if the batteries need to be replaced contact your Online Power dealer or the Online Power factory directly to purchase new batteries Batteries matching sequence numbers used should be purchased to set up a string If the unit is stored in its original packaging unpack unit using unpacking procedures outlined in Equipment Unpacking Section 6 2 If the unit is not connected to a source of power first connect the unit to an appropriate power source using the procedures in Unit Installation Section 6 3 Then recharge 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 UPS Normal is dis
57. me as I refer to each voltage I A B C D A 120V Output connection ILLUSTRATION 2 12 120V Output Customer Connections w Output XFMR 1 2 3 4 5 6 7 TB2 H N 120V Load GND 2 1 4 3 CB3 9 8 157V 120V 88V 11 OV 12 OV 14 120V 13 Output XFMR T1 Output CB Option Output CB3 is sometimes 1P CB not 2P for low current unit amp 120VAC unit N G Aux Output CB Aux output CBs Customer Connections 3 wires each 1P CB for L N G H N Online Power 6002 1405 REV M 6 14 3 continued B 208V Output connection ILLUSTRATION 2 13 208V Output Customer Connections w Output XFMR 1 2 3 4 5 6 7 TB2 H H 208V GND 2 1 4 3 CB3 9 8 157V 120V 88V 11 OV 12 OV 14 120V 13 Output XFMR T1 Output CB Option Aux output CB Customer Connections 2P CB Load Online Power 6002 1405 REV M 6 15 3 continued C 240V Output connection ILLUSTRATION 2 14 240V Output Customer Connections w Output XFMR 1 2 3 4 5 6 7 TB2 H H 240V GND 2 1 4 3 CB3 9 8 11 12 14 13 Output XFMR T1 Output CB Option Aux output CB Customer Connection 2P CB if 1P CB is used one side of 240V is connected without disconnecting mean Load 1P CB is not recommended for 240V output Online Power 6002 1405 REV M 6 16 3 continued D
58. n power to the unit is restored after a complete battery discharge 2 3 2 Battery Charger The battery charger maintains the batteries at full charge After a battery discharge the charger will automatically recharge the batteries upon restoration of input power This circuit is on the Power Board 2 3 3 Power Board Assembly with IGBT s Illustration 2 2 Item 1 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 technology for a smooth AC sine wave In case of a catastrophic failure the complete Heat Sink Assembly is easily replaceable using only a screwdriver The Power Board also contains the housekeeping 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 currents 2 3 4 Control Board Illustration 2 2 Item 10 The 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
59. nd Time stamped events The default setting is a scroll of monitoring and alarm screens When the log is full the first oldest events is erased from the register System events are in Appendix B Key pad functions and resulting screens are presented below LOG Press one time to activate the event log display After approximately 5 seconds the screen will show the event log All stored events will be continuously scrolled on display Press Log once again to return to the main menu 10 04 06 16 10 04 06 16 10 04 06 08 10 04 06 14 OVERTEMP INP UV INP UV INP UV LOG FREEZE INFO ESC RESET SILENCE ILLUSTRATION 4 5 LOGGED EVENTS FREEZE Press one time The display will freeze the default monitoring and alarms screen Press the Freeze key again to return the display to the initial menu with scrolling operation UPS NORMAL INPUT OK BATTERY OK ON INVERTER 20 KVA CHRG ON DC OK OUT OK LOG FREEZE INFO ESC RESET SILENCE ILLUSTRATION 4 6 STATUS SCREEN INFO Press the key one time System data appears on the screen after few seconds Pressing the key once again returns the display to default screen Online Power 6002 1405 REV M 4 10 MINUTE ON BATT SYSTEMS HOUR BATT EVENT TEMPERATURE 00072 00256 00019 32 C LOG FREEZE INFO ESC RESET SILENCE ILLUSTRATION 4 7 SYSTEM INFO RESET Pressing the Reset and Info key
60. nline Power 6002 1405 REV M 1 2 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 EQUIPMENTS 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 Danger EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL CABINETS WEIGH SEVERAL HUNDRED POUNDS 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 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 AN
61. nsfer to battery operation The Power Wave 1 will continue to run on batteries until the switch is released When the switch is released the Power Wave 1 returns to normal operation provided input power is present Online Power 6002 1405 REV M 2 6 2 4 10 Power Supply Transformer This transformer with fuse F1 provides internal housekeeping DC power supply The primary of this transformer has taps to match with the input voltage 2 4 11 Control Transformer T2 Transformer with 120 VAC secondary for control of the K1 contactor coil from the A1 control board 2 4 12 Maintenance Bypass Switch This Maintenance Bypass Switch MBS allows the Power Wave 1 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 2 4 13 Fan Transformer The Fan transformer provides 120 VAC to th
62. o the table for details in the separate attachment 10 KAIC 120 240 VOLT 6 KAIC 277 VOLT 4 8 OPTIONAL EXTERNAL OUTPUT AUX CIRCUIT BREAKERS IN PANEL BOARD P N 9100 1439 01 THRU 03 4 8 1 Description A matching external panel board with 1P 20A QO Square D circuit breakers is provided for power distribution from the unit output to critical loads The panel board accommodates up to 42 breakers A main circuit breaker is provided with each panel board See drawing 6001 03 15 for panel mounting arrangement 4 8 2 Specification Part Number Description 9100 1439 01 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD 1PH CB UP TO 24 QO BREAKER 125AMP 9100 1439 02 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD 1PH CB UP TO 30 QO BREAKER 200AMP 9100 1439 03 EXTERNAL OUTPUT AUX CBS OPTION IN A PANEL BOARD 1PH CB UP TO 42 QO BREAKER 225AMP 2025 125 10KAIC 240V 120 240V APPLICATION CB 1PH 20AMP QO BREAKER FOR 9100 1439 xx 4 9 OPTIONAL HIGHER KAIC NORM ON OFF OUTPUT CIRCUIT BREAKER HIGHER KAIC NORMALLY ON NORMALLY OFF OUTPUT AUX CBs OPTION 1 PHASE 20AMP Part Number Description 9100 1434 31 56 42 KAIC 120 240V Din Rail 9100 1434 61 86 65 KAIC 208 240V ONLY Din Rail 9100 1435 01 26 14 KAIC 277V ONLY Molded Case C B 9100 1435 61 86 65 KAIC 277V ONLY Molded Case C B 4 10 OPTIONAL INPUT CB STANDARD HIGHER KAIC INPUT CIRCUIT BREAKER OPTION STANDARD AND HIGHER KAIC Refer
63. oses upon loss of input power LOW BATTERY N O contact that closes when the unit is on battery operation and the batteries approach inadmissible 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 Failure System Overheat Battery Undervoltage WARNING USE BATTERY CONNECTION DIAGRAM FROM THE ACTUAL UNIT EACH BATTERY CABINET SHOULD HAVE A COPY OF THE CONECCTION DIAGRAM EACH UNIT CABINET SHOULD HAVE A COPY OF CONNECTION DIAGRAM MAKE SURE THE BATTERY CONNECTION DIAGRAM NUMBER IN THE NAMEPLATE OF EACH UNIT MATCHS THE BATTERY CONNECTION DIAGRAM IN THE BATTERY CABINET Online Power 6002 1405 REV M 6 21 6 4 1 Dry relay contacts for remote signaling are provided via connector P2 on Control Board A2 located on the inside of the right door of the enclosure See illustration 2 2 for location of Control PCB 6 4 2 Dry relay contacts have the following maximum ratings 125 volts AC or DC maximum 1 25 amperes maximum 30 watts 50 VA maximum It is imperative that the relay contact ratings are not exceeded Otherwise damage to the relays within the Power Wave 1 will occur 6 4 3 Determine which signals will be used Connect wires customer supplied to the connector 6 4 4 See illustration 2 2 for location of dry C contacts terminal This conc
64. played on screen 5 The unit automatically recharges batteries The LCD panel will indicate the battery voltage and charging current 6 Allow unit to run for 24 hours to fully charge batteries 7 When batteries have reached partial charge 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
65. r Service Personnel 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 ELECTROCUITION BY REFERRING SERVICE TO QUALIFIED PERSONNEL ONLY Online Power 6002 1405 REV M 5 4 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 Danger BATTERY CIRCUIT BREAKER OPERATES AT THE RATED BATTERY VOLTAGES AT ALL TIMES TRIPPED BATTERY CIRCUIT BREAKER INDICATES A SERIOUS PROBLEM THAT MAY RESULT IN SERIOUS INJURY OR DAMAGE TO THE EQUIPMENT IF CLOSE THE CIRCUIT BREAKER WITHOUT KNOWING WHY IT FAILED CHECK SHORT IN BATTERY OR CALL ONLINE POWER CUSTOMER SERVICE AND SUPPORT FOR ASSISTANCE AT 1 800 PWR SRVC 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 BE WASHED DOWN WITH A SUITAB
66. r and protected output The power to the primary of this transformer is received from unit and is transformed to required output voltage levels It will also add another screen to the main menu 2 3 8 Optional Maintenance Bypass Switch Illustration 2 2 Item 2 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 9 Battery Bank Illustration 2 2 Item 26 The battery bank consists of sealed maintenance free batteries The batteries provide emergency power during power outages The battery bank includes a breaker for over current protection and DC disconnect 2 3 10 System Component Layout 1 Power Board A1 2 Bypass Static Switch PB1 3 Output Static Switch PB2 4 Input Output Battery Terminal Block for customer s use TB1 TB2 TB3 5 Input Choke L2 6 Output Choke L3 7 DC Choke L4 8 Input Choke L1 9 High Frequency Noise Filter Capacitors for Input C1 Output C2 and Battery C3 Power 10 Control Board A2 11 LCD Display Board 12 Input Contactor K1 13 Terminal Block to remove heat sink assembly TB4 14 Fan Transformer T3 15 Control Power Transformer T2 16 Control Transformer Fuse F1 17 Fan Fuse F2 18 Heat Sink 19 Fan s 20 Optional Output Isolation Transformer T1 21 Breaker Panel 22 Input Breaker CB2 23 Battery Breaker
67. ry voltages individual cells terminal torque measurements and dates of maintenance 5 4 5 Power Connections Check for corrosion and connection integrity Visually inspect wiring for discolored or cracked insulation Clean and or re torque as required All Battery terminal connections must be tighten with proper torque value set in accordance with the table or instructions provided by battery manufacturer 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 PRC 12150 C 150AH 120 IN LB 13 6 NM 115 IN LB 13 6 NM Copper Insert Terminal 20 UNC Bol t UB 12750 88 5 IN LB 10 NM 84 IN LB 9 5 NM Z1 Z post type terminal 1 to 1 25 long bolt w 14mm head 14mm nut 8mm washer amp lock washer 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 above 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 GSLF 12012 120 IN LB 13 6 NM 115 IN LB 13 0 NM Copper Insert Type N Nickel Cad battery only nickel plated copper
68. s together clears 4 15 1 2 Specification Description Local On UPS Event Log Part Number 9100 1466 01 9100 1538 XX Components Monitoring PCBA P N 1625 344 01 Power Supply P N 1625 339 5 12 VDC 25W Com Cable P N 7060 1187 01 Keypad Overlay P N 1250 070 4 15 2 Local On UPS Aux CB s Trip Monitor P N 9100 1453 01 4 15 2 1 Operation Trip signals coming from the breakers are displayed on the circuit breaker trip screen The circuit breaker is a part of default monitoring and alarm display that scrolls continuously when the unit is in operation Below is an illustration of a typical circuit breaker trip screen AUX CB TRIP LOG FREEZE INFO ESC RESET SILENCE ILLUSTRATION 4 8 AUXILLIARY CB TRIP 4 15 2 2 Specification Description Local On UPS Aux CB S Trip Monitor With Event Log Part Number 9100 1453 01 Components Event Log Option P N 9100 1466 01 Trip monitoring modules ABB S2C S H 6R DIN rail mount Monitored CBs only ABB MCB series Online Power 6002 1405 REV M 4 11 4 15 3 Local On PC Via RS 232 P N 9800 01 25 THRU 150 25 150ft 4 15 3 1 Description This option requires a PC and LabView monitoring software The software is provided on a disc that is easily installed on any 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 selected for COM port 1 4 15 3 2 Operation La
69. sitions are 1 UPS Connects the critical load to the output of the Inverter and establishes normal operation 2 SBS Connects power to the critical load through Static Bypass Switch For 0 Phase angle synch 3 BYPASS Connects power to the critical load through the Bypass switch to bypass the Inverter 4 1 3 Specification Optional External Manual Bypass Switch Part Number Description 3000 044 EXTERNAL MANUAL BYPASS SWITCH MAKE BEFORE BREAK 55AMP 3 POLES LINE ONLY 14 W x 8 00 D x 16 00 H USE FOR 3 5 and 7 5 KVA UNITS 3000 045 EXTERNAL MANUAL BYPASS SWITCH MAKE BEFORE BREAK 110AMP 3 POLES LINE ONLY 14 W x 8 00 D x 16 00 H USE FOR 10 15 20 KVA AND 17 KW UNITS 4 2 OPTIONAL INTERNAL MANUAL BYPASS SWITCH P N 9100 1359 01 THRU 04 4 2 1 Specifications Part Number Description 9100 1359 01 FOR 3 5 and 7 5 KVA UNITS SAME IN OUT VOLT UNIT 9100 1359 02 FOR 3 5 and 7 5 KVA UNITS DIFFERENT IN OUT VOLT UNIT 9100 1359 03 FOR 10 15 15 KVA UNITS AND 17 KW SAME IN OUT VOLT UNIT 9100 1359 04 FOR 10 15 15 KVA UNITS AND 17 KW DIFFERENT IN OUT VOLT UNIT 4 2 2 Instruction for Internal Maintenance Bypass Switch UPS to BYPASS BYPASS to UPS 1 Turn Battery Breaker Off 1 Turn Battery Breaker Off 2 Switch Manual Bypass switch to BYPASS position 2 Switch Manual Bypass switch to UPS position Note Leave B
70. t MUST be provided for service access 6 1 1 Operating Environment AMBIENT TEMPERATURE 0 to 40 C 32 to 104 F 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 RELATIVE HUMIDITY 0 to 95 non condensing Operating the Power Wave 1 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 6 1 2 Storage Environment Provide a storage environment which meets the following conditions AMBIENT TEMPERATURE 20 C to 68 C 4 to 154 F RELATIVE HUMIDITY 0 to 95 non condensing NOTE System should be stored in its original packaging Online Power 6002 1405 REV M 6 2 6 1 3 Location Considerations ILLUSTRATION 6 1 48 CABINET CABLE ACCESS AND MOUNTING 3 KW 6 1 4 Cable Access Blocking vents may cause equipment malfunction and failure The Power Wave 1 Cabinet Installation Diagrams for 3 20 KVA and 17kw models provide cable conduit openings on the top and sides of the cabinet Refer to Illustration 6 1 6 2 and 6 3 Caution Online Power 6002 1405 REV M 6 3 ILLUSTRATION 6 2 68 CABINET CABLE ACCESS AND MOUNTING Online Power 6002 1405 REV M 6 4 ILLUSTRATION 6 3 OVERSIZE CABINET CABLE ACCESS AND MOUNTING 7 5 17 KW WIT
71. to the separate table in Appendix B Online Power 6002 1405 REV M 4 8 4 11 OPTIONAL OUTPUT CB STANDARD HIGHER KAIC OUTPUT CIRCUIT BREAKER OPTION STANDARD AND HIGHER KAIC Refer to the separate table in Appendix B 4 12 OPTIONAL SEISMIC MOUNTING BRACKET P N 9100 1317 02 Left Right seismic floor mounting bracket 1 set per cabinet 4 13 OPTIONAL STACKABLE RACK P N 9100 1429 XX Drawings 6001 033 02 One rack per 2 cabinets 4 14 OPTIONAL POWER FLOW MIMIC P N 9100 1493 02 illustration 6 3 4 14 1 Operation Power Flow Mimic allows unit power status verification at a glance It has 6 LED s indicating the following conditions GREEN Input OK GREEN Inverter On YELLOW On Battery YELLOW On Bypass RED Low Battery RED Summary Alarm The LED s are located on the pictogram below for quick status assessment ILLUSTRATION 4 4 MIMIC PAD 4 14 2 Specification Description POWER FLOW MIMIC OPTION 1 PHASE Part Number 9100 1493 02 Color Blue with black lettering Dimensions 4 25 x 4 Mounting Self adhesive Scotch pad LED s Water clear lens 20 mA View Angle 140 Nicom ZU55W 05 Connectors Nicomatic 8 Pin Black Online Power 6002 1405 REV M 4 9 4 15 OPTIONAL GMS GLOBAL MONITORING SYSTEM LOCAL ON UPS 4 15 1 Local On UPS EVENT LOG 4 15 1 1 Operation Control and Monitoring PCB acquires event data and displays up to 100 most recent Date a
72. tput case TB2 1 or T1 14 can be treated as a neutral point and can be tied together neutral and ground If neutral and ground isolation is needed disconnect jumper A H N H Online Power 6002 1405 REV M 6 19 3 continued G 120V 277V Dual Output connections ILLUSTRATION 2 18 120 2277V Dual Output Customer Connections C Battery Connections For battery connections please refer to the battery connection diagram for each sales order There are various configurations due to battery run time and battery bus voltages Appendix C 2 C 3 C 4 and C 5 show the maximum strings of each battery system as reference only 1 2 3 4 5 6 7 TB2 277V GND 2 1 4 3 CB3 9 8 157V 120V 88V 11 OV 12 OV 14 120V 13 Output XFMR T1 Output CB Option Aux output CB 120V output Connect load directly to each aux CB and N Load N G Aux output CB 277V output 120V output and 277V output CBs can be combined as shown NOTE Neutral and Ground is tied together 120V N H H Online Power 6002 1405 REV M 6 20 Verify the following items 1 thru 7 against the nameplate information on front of the unit ILLUSTRATION 6 19 6 4 REMOTE SIGNALING CONNECTIONS OPTION The Power Wave 1 includes the feature of providing dry relay contacts for remote signaling capabilities Signals available for remote annunciation are INPUT FAILURE N O contact that cl
73. ut within an acceptable range INPUT BAD Input out of range CHRG ON Charger on CHRG OFF The charger is off This will happen if the input capacitor is open or the system is in a failure mode UPS ALARM Line 3 BATTERY OK DC OK BATTERY OK Battery voltage within an acceptable range BATTERY OV Battery voltage high This is normal when the battery is charging BATTERY LOW Battery voltage low Recharge battery DC OK DC bus voltage within an acceptable range Online Power UNIT UNIT NORMAL XX KVA INPUT OK CHRG ON BATTERY OK DC OK ON INVERTER OUT OK Online Power 6002 1405 REV M D 2 DC OV DC bus voltage too high UPS ALARM DC UV DC bus voltage too low UPS ALARM NOTE The typical DC buss voltage should be higher than the battery voltage SCREEN B The second default screen appears as below Line 1 Indicates output voltage and power in watts when an output transformer is not used It indicates primary voltage of the output transformer T1 208 VAC typically when T1 is used Line 2 Indicates input volts and Amps Line 3 Indicates internal DC bus condition for factory use Line 4 Indicates battery voltage The current in Amps indicates charging Amps while indicates discharging Amps SCREEN C When an optional output transformer is installed the multiple output voltages are displayed as follows Line 1 Indicates L N output voltage 1 Line 2 Indic
74. very 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 5 5 1 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 5 5 2 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 5 5 3 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 Online Power 6002 1405 REV M A 1 APPENDIX A SPECIFICATIONS SPECIFICATIONS FOR KVA 0 7PF UNITS POWER RATING KVA KW 3 2 1 5 3 5 7 5 5 25 10 7 12 5 8 75 15 10 5 20 14 INPUT VOLTAGE VAC Single Phase 120 208 240 277 VAC Single Phase 208 240 277 VAC MAXIMUM CURRENT 29 17 15 13 44 25 22 19 36 30 26 74 40 35 57 49 43 68 59 51 89 77 66 TOLERANCE 15 to 15 FREQUENCY Hz 60 3 POWER FACTOR 0 98 to 1 0 Typical OVERCURRENT PROTECTION Electronic Circuit Breaker NUMBER OF WIRES 2 Wires plus Ground POWER CONNECTION Hard Wired Terminal B

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