T100 Series 2-15kVA User Manual
Contents
1. WARNING DO NOT LIFT THE BATTERY RACK OR CABINET AFTER THE BATTERIES HAVE BEEN INSTALLED CL300 Series UPS User Manual Figure 2 1 Installation Diagram 2 4 Connecting the UPS Power Cables WARNING separate power line should be used to supply the UPS AC input Never use the same line to supply another electrical device Do not use any additional cable to increase the length of the UPS s input cable It is advised to use an MCCB suitable for the input current on the UPS s input line The connection of the electrical panel should be supplied by a grounded outlet Otherwise the UPS and the load connected to the output will be left ungrounded The grounding system must be checked and must be strengthen if required Potential difference between ground and neutral must be less than 3V AC Descriptions of the UPS input output cable connection terminals are shown in figure 2 1 Recommended input line cable and fuse ratings are given in the table below Recommended cable size External AC Input AC Battery AC INPUT Bypass INPUT Battery Output Cable Terminals AC OUTPUT INPUT Terminals U V W N amp 100 50 50 50 8 bolt 8 bolt 120 50 50 70 8 bolt 8 bolt 160 70 70 70 8 bolt 8 bolt 200 90 90 90 8 bolt 8 bolt 250 120 120 120 M10 bolt M10 bolt 300 150 150 150 M10 bolt M10 bolt CL300 Series UPS User Manual NOTES The neutral conductor should2. 28 CL300 Series UPS User Manual 5 2 3 Switching into Maintenance Bypass Mode 1 Use DOWN button to choose COMMAND MENU and press ENTER Use DOWN button again to reach ENTER BYPASS message Press ENTER the UPS will switch into bypass mode MANUAL BYPASS and A52 MANUA BYPASS messages will appear on the screen 2 Remove the padlock on S3 Maintenance Bypass Switch and turn it on into 1 position 3 Turn off S7 S5 1 S2 and S4 Now there is bypass voltage directly on the load note that there is no AC or DC power in the UPS for maintenance and servicing purposes 5 2 4 Switching From Maintenance Bypass Into Normal Operation 1 Turn on S1 AC Input 2 Turn on S2 Bypass 3 Turn on S4 AC Output 4 Turn on S7 ON OFF Switch LCD panel will start running RECTIFIER START message will appear on the front panel After the rectifier is started the inverter will not start and the message MAINT SW ON will be seen on the panel instead of INVERTER START 5 Turn off S3 Maintenance Bypass Switch and lock again The inverter will start automatically 6 Turn on S5 Battery Now the UPS is ready for normal operation 5 3 OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPSs 5 3 1 Procedure For Turning on the UPS First Installation With all the switches 1 2 S3 4 and S5 in OFF 0 position and with S6 static bypass switch in NORMAL position Note S6 i
3. esses 28 5 2 23 sped uii 28 5 2 3 Switching into Maintenance Bypass 29 5 2 4 Switching From Maintenance Bypass Into Normal Operation 29 5 3 OPERATING INSTRUCTIONS FOR PARALLEL CONNECTED UPSs 29 5 3 1 Procedure For Turning on the UPS First Installation 29 53 2 POWOer e y nd e doge aie iad oe Lv 30 5 3 3 Switching the Parallel UPS System into Maintenance Bypass Mode uninterrupted transfer 30 5 3 4 Switching the Parallel UPS system into Normal Operation 30 From a Maintenance Bypass Power down Condition uninterrupted transfer 30 MAINTENANGE 22 2 E seat 31 6 1 Scheduled snnt 31 6 2 Daily checks ces cix erp uve ctc dote rug cpi p d ee Ee n 31 6 3 Weekly checks creen ceci e ae rc saute uu cec Y n de e a 31 6 4 Annual maintenance naseiani ei eai EEE aa nannten nnn nens 32 6 5 UPS Storage and transportation sess 32 FAULTS AND TROUBLESHOOTING 33 7 1 General Procedure for Fault Checking And 33 UPS REMOTE MONITORIN
4. P24 DUBL UPS NR Same UPS number is used in parallel system Change from OPTIONS MENU P25 NO CLOCK During power up the synchron clock signal is lost by slave UPS 22 CL300 Series UPS User Manual IV PARALLEL OPERATION 4 1 Introduction Two or more identical CL 300P series UPSs can be interconnected for parallel operation The main purposes for parallel use of CL 300P series UPSs are Redundancy for Increased Reliability Power Increase Although recent UPS designs are perfect and have high MTBF figures a second or more UPS can be used in parallel with the first one for supplying the critical load in case of any possible failure of the first UPS In such an application the faulty UPS is isolated automatically from the parallel system and the other UPS or UPSs continues to supply the critical load Use of Redundant UPSs in parallel therefore provides increased reliability for the critical load connected to the parallel system output If power demand increases in a certain UPS appliction exceeding the power rating of an already installed stand alone UPS a second or more UPS of the same model and power rating can be added in parallel to the existing UPS to increase the output power capacity Schematic diagram of parallel connection of two CL 300P series UPS units is shown in Figure 4 1 Maintenance Bypass Switch S2 F4 F5 F6 connected if Static 1 52 not used Bypass 1
5. 160 200 250 300 Output kW Output Power Factor INPUT Number of Phases 3 Phase Neutral Input Voltage 220 380 Vac 230 400Vac or 240 415Vac 3phase N Input Voltage Tolerance 20 25 15 30 for 240 415 Vac Input Power Factor PF 0 99 at full load Input THDI lt 5 at full load Input Frequency 50Hz 5 By pass Voltage 220 380 Vac 230 400Vac or 240 415Vac 3phase N By pass Frequency 50Hz By pass Frequency Tolerance 2 RFI Level EN50091 Split By pass Connection OUTPUT Number of phases Available 3 Phase Neutral Output Voltage 220 380 Vac 230 400Vac or 240 415Vac 3phase N Output Voltage Tolerance 1 Output Frequency 50 Hz Output Freq Tolerance line synchron amp 2 96 Output Frequency Tolerance free running 0 2 96 Efficiency at full linear load up to 94 96 Load Crest Factor 3 1 Output Voltage THD Overload BATTERY Total Number 12596 Load 10min 15096 Load 1min 60 2x30 pieces 12V Float Charge Voltage 25 C 405 Vdc End of Discharge Voltage 300 Vdc Battery Cabinet External Battery Test Automatic and Manual Boost Charge INTERFACE RS 232 Comm Port Available Standard Optional port multiplexer available RS 485 Comm Port Optional Remote Monitoring Panel Optio
6. nnne tnnt 16 3 2 4 ADJUST Menu ltems eene nennen nnns innen nnne 17 3 2 5 OPTIONS Menu Items 17 3 2 6 COMMAND Menu nennen nennen 18 3 2 7 TIME MENU LEMS orta rima ERE e Roni Lena ee EA cgay TRA Ru UR TRE Re DEDE RE eR uS 19 3 2 8 SERVICE Menu ltems sss nennen nnns nnne 19 3 9 STATUS MESSAGES i Cua PEE 19 3 4 Shutdown 14 sene tenni nter nen 20 3 5 Fault Messages and Quick Troubleshooting ssseeeeenne 20 IV PARALLEL OPERATION riz oco sacs ez cua a aon cu nu iacu Deo Diae Cer 23 A T Introduction 2 oe M 23 4 2 Parallel Operation Modes of CL 300P Series UPSS 24 4 24 PARALLEL mode nee pe doeet dade ed genou ctv eua dana 24 4 2 2 REDUNDANT 1 24 4 2 3 N 1 REDUNDANT T MOHE ieai ia a ia 25 VI VII VII OPERATING 28 5b INTRODBUGTIQN 28 5 2 OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT ONLINE OPERATION 28 5 2 1 Procedure For Turning On The UPS To Supply The Load From A Complete Power Off Condition
7. Batteries are completely discharged wait for restoration of electric power A5 BATT AUT END input This message occurs only at the end of a battery operation during line failure A6 CHARGER FAULT Rectifier could not produce DC bus voltage A7 BATTERY LOW Battery voltage is low either positive or negative Possible Causes 1 UPS operation for long time when line out 2 Charger system failure Inverter output voltage is higher than the max tolerated value OUTPUT HIGH Inverter is stopped Possible Causes 1 Inverter failure 20 CL300 Series UPS User Manual ALARM DESCRIPTION A9 OVERLOAD UPS loaded more than 100 of nominal power rating This state is may be continous or temporary When this alarm is continous Possible Causes check the loads connected to the UPS output A10 LINE FAILURE Line failure Possible Causes 1 Mains may be off 2 Check all three input phases 3 Check UPS input fuses 11 HIGH TEMPER Overtemperature 1 Overload for inverter 2 Excessive ambient temperature 3 Fan failure or dirty air inlets 4 Bad UPS location not enough ventilation A12 OVERCURRENT Inverter output system failure 1 Internal overcurrent 2 Output short circuit 3 UPS failure Call the service A13 OUTPUT LOW Inverter output voltage is lower than the min tolerated value Inverter is stopped A14 BATTERY HIGH Battery voltage is higher than max tolerated value for batteries
8. SNMP adapter Optional CL300 Series UPS User Manual Remote monitoring Panel Optional RS232 port multiplexer Optional MODBUS adapter Optional Diagnostic and adjustment via PC Input and or output isolation transformers optional 1 2 Design Concept Maintenance Bypass Switch Static Bypass S2 F4 F5 F6 i connected if S2 not used 3 PHASE 3 PHASE MAINS I P S1 K2 S4 AC Output F1 F2 F3 Rectifier F7 F8 F9 i I Charger S5 F10 F11 F12 I 1 l Battery Dual Polarity gg ee Ee ee Figure 1 1 Block Diagram Of The UPS 1 F1 F2 F3 Rectifier Input Switch Fuses S2 F4 F5 F6 Bypass Input Switch OPTIONAL 3 Maintenance Bypass Switch S4 F7 F8 F9 Output Switch S5 F10 F11 F12 Battery Switch OPTIONAL Fuses K1 Rectifier Input Contactor K2 Inverter Output Contactor DESCRIPTION OF BLOCKS RECTIFIER In CL 300P Series UPSs a PWM controlled IGBT rectifier is used to increase input power factor PFC and to decrease input current harmonics THDI The IGBT rectifier accepts 3 phase AC input and produces a dual polarity DC voltage for both supplying the inverter and charging the batteries BATTERIES Batteries are used as reserve DC power supply for the Inverter in case of mains failure In CL 300P Series batteries are connected in series with a center tap output to obtain a dual polarity DC supply Batteries
9. 12 7 SET YEAR 2006 and adjust year 2000 2099 8 9 ENTER lt gt Enter 4 exit from submenu Go to STATUS MENU 3 2 8 SERVICE Menu Items Submenu item Function HOURMTR 00027 Total operation time of the UPS MAX LOAD 095 Recorded max load TO B TEST 008Hr Time until next automatic battery test ENTER lt gt Enter 1 Exit from submenu Go to STATUS MENU 3 3 STATUS Messages This message group simply shows the UPS STATUS on the upper line of LCD PANEL RECTIFIER START INVERTER START MAINT SWITCH ON MANUEL BYPASS STATUS ALARM STATUS NORMAL EMERGENCY STOP WAITING SYNC STATUS FAULT STATUS WARNING CLOSE BATT CB UPS started the rectifier UPS started the inverter Maintenance bypass switch is on Load is transferred to mains manually Alarm status UPS is operating normally External emergency signal is detected Inverter started and waiting for synchronization Fault status Warning message is valid on LCD panel UPS is waiting for battery CB to be closed INV OUT FAILURE The UPS gave four successive INV BALANCE error RECTIFIER START At start up the UPS controller board checks for input voltage frequency battery voltage for starting if these parameters are normal it starts up INVERTER START If the inverter stops by any reason controller board tries
10. 5 on the LCD panel of one of the UPS units and you will see REDUNDT MODE SL on the LCD panels of all the other UPS units connected in the parallel system As explained above higher degree of reliability for supplying a critical load can be obtained by choosing REDUNDANT mode for parallel operation and using as many as possible parallel connected UPSs 4 2 3 N 1 REDUNDANT mode This mode is used for operation of at least three 2 1 configuration UPS units connected in parallel for increased reliability If this mode is selected the load is shared equally by each UPS available in the parallel system N 1 numbers of UPS units during normal operation In case of a failure of any one of the UPS units the faulty UPS is isolated from the parallel system and the critical load is supplied by the remaining N number of UPSs If any one of those UPS units fails too then the critical load is transferred to bypass supply via the static bypass switches of the parallel connected UPSs If the faulty UPS returns to normal operation it joins the parallel system again and starts sharing the load In N 1 REDUNDANT parallel mode the total VA rating of the parallel system is equal to the VA rating of a single UPS multiplied by N If this mode is active you will see N 1 REDUNDANT MS on the LCD panel of one of the UPS units and you will see N 1 REDUNDANT SL on the LCD panels of all the other UPS units connected in the parallel system Mo
11. Bypass Switches of all the UPSs 5 3 4 Switching the Parallel UPS system into Normal Operation From a Maintenance Bypass Power Down Condition uninterrupted transfer With the S6 switches static bypass of at least one of the UPSs in STATIC BYPASS position turn on all the units as follows Turn on S1 AC Input switches into 1 position Turn on S2 Bypass switches into 1 position Turn on S4 AC Output switches into 1 position Turn on S7 ON OFF switches into 1 position When MAINT SWITCH ON message appears on LCD turn off S3 Maintenance bypass switches of all UPSs Turn on S5 Battery into 1 position 7 Bring S6 static bypass switches of all UPS units back to NORMAL position Or mo NU 30 CL300 Series UPS User Manual VI MAINTENANCE WARNING DO NOT OPEN the covers of the UPS because there are no user serviceable parts inside DO NOT TOUCH battery leads There is high voltage even if the UPS is off Therefore no one should open the covers of the UPS except authorized service personnel Otherwise serious injuries may occur 6 1 Scheduled Maintenance Some semiconductor devices inside the UPS do not require any maintenance Cooling fans are the only moving parts If the environment is clean and cool enough the scheduled maintenance requirements will be at minimum level On the other hand periodic checks and maintenance based on well prepared documents will increase the pe
12. K1 S4 F1 F2 F3 Rectifier Inverter F7 F8 F9 Charger S5 F10 F11 F12 Battery Dual Polarity 3 PHASE 3 PHASE bu rre dr er Pier reuersi oer rers MAINS I P Maintenance Bypass Switch S2 F4 F5 F6 connected if S2 not used oe Bypass 1 K1 S4 F1 F2 F3 Rectifier Inverter F7 F8 F9 Charger S5 10 11 12 Battery Dual Polarity Ha 8 1 Figure 4 1 Parallel Connection of two UPSs 23 CL300 Series UPS User Manual The AC inputs of all UPSs in the parallel system are connected to the same mains and all the AC outputs are connected to each other Each UPS has its own battery group The critical load is connected to the common output of the parallel system There are also some signal cable connections between the UPS units necessary for parallel operation and will be described later 4 2 Parallel Operation Modes of CL 300P Series UPSs NOTE Parallel operation hardware parallel controller boards and some other accessories are not installed in a standard CL 300P series UPS but parallel operation option is available and can easily be added to all UPSs Parallel operation is possible in one of the three modes 1 PARALLEL operation power increase 2 REDUNDANT parallel operation 3 N 1 REDUNDANT parallel
13. are discharged by the inverter during mains failure The discharged batteries are re charged by the IGBT Rectifier on a constant current constant voltage basis if AC mains power is available INVERTER It is manufactured by using the latest IGBT technology and Pulse width Modulation PWM technique The Inverter converts the DC BUS voltage supplied by the IGBT Rectifier and or the batteries into a well regulated 3 phase AC voltage with fixed voltage and frequency The output of the inverter is used to supply the critical loads connected to the UPS output CL300 Series UPS User Manual STATIC TRANSFER SWITCH STATIC BYPASS This is an electronically controlled transfer switch which enables the critical load to be connected either to inverter output or to a by pass power source During normal operation the load is supplied by the inverter output but in case of an overload it is automatically transferred to the bypass source without any interruption MAINTENANCE BYPASS SWITCH MBS This is a manually controlled mechanical switch which is used to supply the critical load using the bypass source when the UPS is shut down for maintenance or troubleshooting purposes The load is unprotected against mains supply disturbances and black outs when it is connected to either static or maintenance bypass supply BATTERY SWITCH OPTIONAL It is connected on the battery inputs of the UPS This switch is connected after the Battery Input Fuses a
14. are listed below Switch to BYPASS Switch to INVERTER SOUND on off Adjust UPS time and date Start SIMULATION mode Quick BATTERY TEST BATTERY TEST until battery low alarm CANCEL battery test Turn off UPS output voltage immediately SHUTDOWN Turn off UPS output voltage after delay WAITING SHUTDOWN Turn off UPS output voltage SHUTDOWN and turn on UPS output voltage WAITING RESTART CANCEL SHUTDOWN RENAME UPS UPS will give response to these commands only if the REMOTE ENABLE option is selected from OPTIONS MENU Apply your local distributor for information on available software for monitoring and controlling the UPS RS232 Communication Port DB9 Female Communication Routing DIP Switch Figure 8 8 1 1 Communication Routing Switch RS232 Communication of the UPS can be routed either to an internal e g ML100 port multiplexer MD1 MODBUS adapter SNMP unit etc or to an external device There are two sets of DIP switch positions 1 2 3 4 INTERNAL e g SNMP ON OFF ON OFF RS232 EXTERNAL OFF ON OFF ON 34 CL300 Series UPS User Manual In RS232 position of DIP switches RS232 communication with an external device is performed through the standard DB9 socket shown above If DIP switches are in INTERNAL position communication through the standard socket is turned off and routed to an internally connected device For example if an ML100 Port Multiplexer has
15. be sized for 1 5 times the output bypass phase current These recommendations are for guideline purposes only and are superceded by local regulations and codes of practice WARNING THERE ARE NO INTERNAL FUSES ON THE BYPASS INPUT AND ON THE AC OUTPUT OF THE UPS THEREFORE IT IS RECOMMENDED THE USE EXTERNAL FUSES OR MCCBS OF SUITABLE RATINGS BOTH ON THE AC INPUT AND OUTPUT OF THE UPS 2 4 1 Safety Earth The safety earth cable must be connected to the earth BUSBAR and bonded to each cabinets in the system and also the earthing and neutral bonding arrangements must be in accordance with the local laws ATTENTION Failure to follow adequate earthing procedures can result in electric shock hazard to personnel or the risk of fire 2 4 2 Cable connection procedure WARNING All connections of the UPS must be done by qualified service personnel After positioning the UPS the cables must be connected as described below 1 Verify all switches in front of the UPS are at 0 position OFF 2 Connect the 3 phase AC input coming from the mains distribution panel to the AC input terminals as shown on the label Figure 2 2 ATTENTION ENSURE CORRECT PHASE SEQUENCE If there is a phase sequence error UPS doesn t transfer the load to INVERTER output If you can t see SYNC OK in the INFORMATION MENU on LCD then change the input phase sequence 3 Connect the output of the UPS to the load distribution panel 4 Connect the batter
16. been installed in the UPS standard DB9 socket is not used for RS232 communication instead the two ports COM1 and COM2 on the ML100 can be used for external communication simultaneously 8 2 Serial Communication Cable The maximum length for RS232 communication cable should be 25 meters Cable connector pin configuration is as follows UPS side PC side 9 Tx 2 Rx 7 Gnd 5 Gnd 6 Rx 3 Tx For remote panel and UPS connection the same pin configuration is valid 8 3 Modem Connection A CL 300P Series UPS can be controlled through a normal telephone line by means of a remote operator connected through a PC with modem device who performs a phone call to the UPS connected number So the operator can see all parameters and control the UPS if permitted from OPTIONS MENU 8 3 1 Hardware Configuration All requirements for modem connection are as follows e PC with modem e WINDOWS 98 e Available UPS control software T MON e NULL modem which is connected to UPS In order to perform this function a PC with UPS control software and an external or internal modem device connected to telephone line are needed A NULL modem device configured according to NULL and auto answer modes when installed in the UPS and once programmed following a telephone call of the PC embedded modem will connect the UPS to the telephone line 8 3 2 Functioning Principle The remote operator by means of a PC and a modem device and using
17. event Date time hh mm On the second line of LCD PANEL you can see al recorded alarms Use PLUS and MINUS keys for moving on events 3 ENTER CLEAR LOG Enter 4 clear log event records After you cleared events you see EMPTY LOG message PARR ERR NR 017 Parallel control board fault number if the parallel board is installed 0 means that there is no error on parallel board ENTER lt gt Enter 4 exit from submenu Go to STATUS MENU 3 2 3 INFORMATION Menu Items This menu gives information about the UPS Submenu item Function 1 SYNC OK COMM OK If the UPS is operating in syncron to mains SYNC OK if not syncron SYNC If communication is active COMM OK if not active COMM 2 POWER 120000 VA The maximum power rating of the UPS 3 VERSION B12 Shows the UPS control software version 4 FREQUENCY PLL Frequency generation mode PLL phase locked loop is generating the frequency SLAVE in parallel system master is generating the frequency NOM FRQ 50 Hertz Nominal output frequency MODEL CL310 Model name of the UPS ENTER lt gt Enter 1 exit from submenu Go to STATUS MENU 16 CL300 Series UPS User Manual 3 2 4 ADJUST Menu Items Only service personnel can use this menu the incorrect use of this menu can cause damage to the UPS Submenu
18. item Function Service password input key 100 UP key 10 key 1 changes PASSWORD after you write the password on screen press ENTER key if the password is wrong the is no action If the password is okay a beep sounds and you see ADJUST MODE at the second line 2 ENTER EXIT Enter 4 exit from submenu Go to STATUS MENU 3 2 5 OPTIONS Menu Items In this menu the user can set some important parameters for UPS operation Submenu item Function By using and keys you can move on 5 different operation modes ONLINE stand alone mode PARALLEL 2 UPS in symmetric parallel operation 1 MODE ONLINE N 1 REDUNDANT 2 or more UPS in N 1 redundant parallel mode REDUNDANT 2 UPS in redundant parallel mode ECONO Off line mode press ENTER for seconds and the selection is valid By using PLUS and MINUS keys you can change number 0 to 3 In parallel operation select different number for each UPS If you select the same number DUBL UPS NUMBER message tells the fault press ENTER for 3 seconds and the selection is valid 2 UPS No 001 By using PLUS and MINUS keys you can change enable and disable options Enable remote battery test shutdown and bypass functions are enabled disable these functions are disabled press ENTER for 3 seconds and the selection is valid 3 REMOTE ENABLE By using PLUS and MINUS keys you can change on a
19. may be in one of the following operating conditions A Normal Operation If Mains supply is available All fuses and power switches are closed except the Maintenance Bypass Switch and the load is supplied by the Inverter Output During normal operation the Rectifier supplies DC power to the Inverter and charges the Batteries at the same time B Battery Operation The Batteries are connected to the Rectifier output In case of a mains failure mains power outage or AC input voltage out of tolerance the Rectifier stops operating and the DC voltage necessary for the inverter operation is supplied by the batteries Therefore the AC voltage output supplying the critical load is not interrupted until the batteries are fully discharged At the end of the discharging time the Inverter is turned off and it start again automatically together with the Rectifier when the mains power is restored and the UPS returns o normal operation The Rectifier is also turned off and Inverter operates on batteries during automatic or manual battery test procedure C By Pass Operation If the Inverter output is overloaded or in case of a problem in the UPS the static switch transfers the load to the bypass supply without any interruption provided that the bypass supply is available and within the tolerated limits At the end of the overloading period if the fault condition is restored static switch transfers the critical load again to the inverter o
20. number is 10 boost charge stops If you press ENTER key before this time boost charge stops immediately Boost charge starting and boost charge end times are recorded in log event menu If boost is active UPS beeps every 15 seconds 6 SIMULATION OFF The purpose of this submenu is to check dry contact connections Normally to check line failure contact you must turn off mains power This is not necessary with this utility 3 options are available SIMULATION OFF simulation mode is off SIM LINE FAILURE if you press ENTER key for 3 seconds the line failure relay on the interface board is energized SIM LIN F BT LOW if you press enter key for 3 seconds line failure and battery low relays are energized SIM BYPASS if you press ENTER key for 3 seconds bypass relay is energized This way you can check dry contact connections 7 ENTER lt gt Enter 4 exit from submenu Go to STATUS MENU 18 3 2 7 TIME MENU ITEMS CL300 Series UPS User Manual You can see date and time of RTC real time clock on UPS And you can adjust date and time ENTER lt UPDATE gt Enter update new date and time Submenu item Function 1 TIME 23 15 time 2 DATE 11 10 2006 date 3 SET HOURS 11 and adjust hours 0 23 4 SET MINS 38 and adjust minutes 0 59 5 SET DAY 21 and adjust day 1 31 6 SET MONTH 06 and adjust month 1
21. operating mode but different UPS numbers 9 Turn on S4 AC Output switches of all UPSs one by one Now the parallel UPS system is ready to supply the critical load 5 3 2 Power Off After turning off all the loads connected to the Parallel UPS System output apply the following procedure to all the UPS units in the parallel system 1 Turn off S4 AC Output into 0 position 2 Turn off S7 ON OFF Switch into 0 position 3 Turn off S5 Battery into 0 position 4 Turn off S2 Bypass into O position 5 Turn off 1 AC Input into 0 position This is a complete power off condition and both RECTIFIER and INVERTER are not operating in this case 5 3 3 Switching the Parallel UPS System into Maintenance Bypass Mode uninterrupted transfer 1 Switch S6 static bypass switch for parallel UPSs of either one of the UPS units into STATIC BYPASS position 2 See that the red coloured by pass LEDs L4 on the front panels of all UPSs are turned on Static Bypass Operation Turn on S3 switches maintenance bypass of all UPSs in the parallel system Turn off S4 switches AC Output of all UPS units Turn off S1 AC Input and S2 Bypass switches of all UPSs Turn off S5 Battery switches off all the UPS units in the parallel system Aa Oo Now all the UPS units which are connected in parallel are completely turned off and the load is supplied by the common Bypass supply via the Maintenance
22. operation NOTES 1 The preferred mode for parallel operation can be selected using OPTIONS MENU 2 For parallel operation each UPS must be assigned a unique UPS No again using OPTIONS MENU 4 2 1 PARALLEL mode This mode should be selected for increasing the available UPS power capacity If this mode is selected for parallel UPS operation the total VA rating of the parallel system is the sum of the VA ratings of all the UPSs connected in parallel The output load is equally shared by each UPS in the parallel system Mains power is used as the spare energy supply BYPASS In case of a failure in one of the UPSs the Static Bypass Switches of all UPSs are turned on and the load is transferred totally to the spare energy supply usually mains voltage without any interruption If the fault is cleared and if everything returns to normal operating conditions the Inverters of all UPSs in the parallel system resume the load together at the same time The output load of the parallel system is shared equally by each UPS both during Inverter or Bypass operation If this mode is active you will see PARALLEL MODE MS on the LCD panel of one of the UPSs and you will see PARALLEL MODE SL on the LCD panels of all the other UPSs connected in the parallel system MS meaning Master and SL meaning Slave In PARALLEL mode the Static Bypass Switches of all the UPSs in the parallel system act turns on or off simultaneously During normal PARAL
23. send commands to UPS from operating system by using some softwares UPS takes these commands and produces some messages listed below WAITING SHUTDOWN Shutdown command is performed by the operating system and UPS is waiting for a certain delay for shutdown UPS SHUTDOWN UPS is in shutdown status WAITING RESTART UPS is shutdown but it is waiting for a certain delay for restart PAR SHUTDOWN n parallel systems the other UPS sends shutdown command and UPS is in shutdown status CANCEL SHUTDOWN Shutdown command is cancelled Only operating system or a PC computer can send these commands If the shutdown command is performed during line failure UPS shutdowns and if the mains is okay UPS starts again automatically 3 5 Fault Messages and Quick Troubleshooting All alarms contained in CL 300P UPS control software are listed in the following table ALARM DESCRIPTION A1 BYPASS FAILURE Bypass system failure Possible Causes Bypass components may be faulty call service A2 INVERTER FAILURE Inverter digital start system is failed Possible Causes Internal failure Call service A3 3 OVERTEMP Overtemperature in UPS repeated 3 times in the last 30 mins Possible Causes 1 Check for UPS air inlets and outlets for any blocking by dust etc 2 Fan failure 3 Bad UPS location 4 Check for Overload A4 OUT FAILURE UPS output voltage is out of tolerance for 3 times in the last 30 mins Internal failure Call service
24. the parameter values without any reason please immediately call the qualified service personnel 31 CL300 Series UPS User Manual 6 4 Annual maintenance To get reliable and efficient performance from the UPS please call the qualified service personal at least once a year 6 5 UPS Storage and transportation 1 Check the batteries charge by performing manual battery test before storage If the charge is not enough then charge the batteries at least for 12 hours 2 Qualified service personal should disconnect the electrical connections 3 Batteries should be charged every six months during storage period 4 Keep the UPS and batteries in dry and cool place UPS ideal storage temp 0 C 40 C max Battery ideal storage temp 10 C 35 C max 5 The UPS must be placed on a suitable palette for transportation purposes 32 CL300 Series UPS User Manual Vil FAULTS AND TROUBLESHOOTING 7 1 General Procedure For Fault Checking And Troubleshooting UPS contains complicated electronic control circuits In order to locate any fault occurring circuits an advanced knowledge about the circuitry and its operation principles must be known The aim of this section is to give the knowledge required at the first intervention There is no practical way to locate any possible fault Most of the faults do not occur as a performance decrement Generally the UPS operates normally or switches into by pass mode But in order to determin
25. the remote connection function of the control software calls the UPS through the number to which this is connected The NULL modem device connected to the UPS will answer the call and convert the data coming from UPS s serial port on to the telephone line This way all measurements and controls allowed by the RS232 serial port can be carried out 35 CL300 Series UPS User Manual 8 3 3 Modem programming procedure Smart modem SM is the one connected to PC and NULL Modem NM is the one connected to the UPS Standard Hayes AT programming language is the suitable language for modems In usual applications a modem which uses AT command set should be selected 8 3 3 1 SMART Modem Programming PC modem The connected modem to PC smart modem will be programmed from UPS control software T Mon automatically BO E1 F1 M1 0 V1 BAUD 2400 PARITY WORDLEN 8 DIAL TONE which can be programmed amp amp B1 amp C1 amp DO amp H1 amp 10 amp K1 amp 4 amp NO amp R2 850 amp T5 amp Y1 8 3 4 Modem UPS Connection Cable The connection cable between NULL modem and UPS is configured as follows UPS MODEM DB9 female DB25 male 6 3 7 7 9 2 8 4 Dry Contact Interface Connections Some important events of the UPS can be monitored or controlled by these connections There is a relay for each event which is located on the interface board The NC C NO contacts of each Relay are
26. to restart the inverter Each time the inverter is started this message appears on the first line of LCD PANEL MAINT SWITCH ON Maintenance bypass switch is connected from bypass input to the output of UPS directly the maintenance bypass switch is on 1 position controller stops the inverter against any accidental short circuits between mains voltage and inverter output If the user turns off the maintenance bypass switch inverter starts again EMERGENCY STOP If an external EPO switch is installed to system connected to interface board it is possible to stop all UPS parts rectifier static bypass inverter etc After pressing EPO switch the rectifier and inverter are turned off and the power to the critical load is turned off To start again turn off the ON OFF switch and turn it on again FAULT STATUS 19 CL300 Series UPS User Manual In some cases controller checks events but can not find solutions in this case controller decide to stop the system For restarting the user must turn off the ON OFF switch and turn it on again WARNING STATUS Some events recorded to log event file stays on LCD PANEL but UPS continues to work these messages named as warning messages user can clear this messages by pressing ENTER key for 3 seconds These are e 20 Boost charge alert e A6 Charge fault e A18 Batt capacity low 3 4 Shutdown messages CL 300P series UPS can operate interactive with the operating system You can
27. AIN AC INPUT M nono MA _ REN BYPASS A INPUT Seto he pu eed habeas ie 4 t H e 4 H Waser rads Tone ik dx st aad Flor ee EDU d Po eee eee ce m qr PAE E x x oax mix nemi Ca E ccc E E i E a T X cece UPSS lt E BATTERIES BATTERIES TPUT3 AC OUTPUT2 BATTERIES rat Gai E U Vi wi Ni FUSES OUTPUT LOAD BRAKE SWITCH AC DISTRIBUTION BOARD rc CES ds 4 UVWN LOAD Figure 4 3 CL300P Series Parallel UPS Power Connections Note Asseenin the figure the outputs of parallel UPS units should be connected to each other using an AC distribution board ATTENTION The cables from each UPS output to the distribution board must be of the same size and length for proper load sharing during parallel operation 27 CL300 Series UPS User Manual V OPERATING INSTRUCTIONS 5 1 INTRODUCTION After completing the installation of the unit and connecting all the power cables with all switches and fuses in OFF position 1 Check the battery polarities K1 V 360V Nominal 405V under float charge K2 K2 NEUTRAL BUSBAR 0 Volts connected to the midpoint of the 60 blocks battery string K3 V 860V Nominal 405V under float charge 2 Check the 3 phase AC input and neutral connections Phase sequence is importa
28. G AND CONTROL 34 He mn ote E 34 8 1 1 Communication Routing Switch essent 34 8 2 Serial Communication Cable 4 35 8 3 Modem Connection o tees re Be d t eue ca b rs et 35 8 3 1 Hardware Configuration aan eaa raaa a eaaa 35 8 3 2 Functioning Prinelple ett dd i Dove ter eue ug 35 8 3 3 Modem programming procedure 36 8 3 3 1 SMART Modem Programming PC 36 8 3 4 Modem UPS Connection Cable 36 8 4 Dry Contact Interface nennen 36 8 5 Remote Monitoring nnne nennen nnns 37 SAFETY IMPORTANT NOTICES Read instructions carefully before installing and starting the UPS All warnings in the manual should be adhered to All operating instructions should be followed The unit should be supplied by a grounded outlet Do not operate the unit without a ground source Power cord of the UPS should be routed carefully so that they are not to be walked on Please save this manual Please save or recycle the packaging mat
29. L1 lf lamp is lit mains is okay L2 If lamp is lit the rectifier is operating L3 If lamp is lit UPS is operating on batteries L4 If lamp is lit static bypass is active and load is supplied by the bypass source L5 is lit mechanical bypass switch is on L6 If lamp is lit inverter supplies the load L7 is lit the output switch is ON There are 5 function keys on front panel These are ENTER 1 UP t DOWN PLUS and MINUS UP and DOWN keys help moving on menus PLUS and MINUS keys select options ENTER key means the selected option or menu is valid 3 2 Front Panel Menu Descriptions By using the buttons on the front panel you can move on main menu functions You can enter the submenus of the item seen on the LCD panel MEASURES ALARMS INFORMATION etc and navigate within it by using 1 and ENTER keys The Main Menu items are listed below You can choose any requested menu using 1 and keys By pressing ENTER key you can choose that menu and you can reach all submenu items using 1 and keys again At the end of submenus of each MENU an ENTER EXIT message is seen and if you press ENTER you exit from the selected menu and go back to the beginning of the Main Menu Main Menu items Function STATUS MENU The status message which shows the UPS status MEASURES MENU Enter go to Meausures submenu ALARMS MENU Enter to Alarm
30. LEL operation the load is shared equally by the inverter outputs of each UPS provided that the output switches of all UPS units are turned on In case of a failure in one of the UPS units or if the output switch of one of the units is turned off the static bypass switches of all the parallel units are turned on simultaneously and the critical load is transferred to the bypass supply without any interruption In other words during operation in PARALLEL mode the parallel UPS system behaves like a single stand alone UPS with a higher power rating 4 2 2 REDUNDANT mode This mode is used for operation of two or more UPS units connected in parallel for increased reliability If this mode is selected the load is shared equally by each UPS available in the parallel system during normal operation In case of failure of one or more of the UPSs the faulty UPS is isolated from the parallel system and the critical load is still supplied by the remaining UPSs If the faulty UPS returns to normal operation it joins the parallel system again and starts sharing the load In REDUNDANT parallel mode the total VA rating of the parallel system is equal to the VA rating of a single UPS used in the system Only after all the UPS units in the system fail and are isolated from the System the critical load is transferred to Bypass supply without interruption 24 CL300 Series UPS User Manual If this mode is active you will see REDUNDT
31. ODE FAILURE In parallel system the operation mode of the UPS is different from the others A24 P FAILURE 17 Parallel controller board failure A25 P FAILURE 18 Parallel controller board failure A26 P FAILURE 19 Parallel controller board failure A27 P FAILURE 20 Parallel controller board failure 21 CL300 Series UPS User Manual ALARM DESCRIPTION A28 P FAILURE 21 Parallel controller board failure A29 P TEST MODE Parallel controller is in test mode A30 P FAILURE 23 Parallel controller board failure A31 DUBL UPS NR Same UPS number is used for two UPS in the parallel system Possible Causes 1 Change number s in OPTIONS Menu A39 PSP FAILURE1 Control Power supply fault One of parallel modes is selected but there is no parallel control board A40 CANT FIND PR on UPS Change mode from OPTIONS Menu A41 P BAL FAILURE In parallel operation current sharing is not okay A42 BATTERY TEST Performing battery test A43 P SYNC FAIL In parallel system SLAVE UPS is not synchronized to MASTER UPS A44 BT OPERATION UPS is operating on batteries Possible Causes 1 AC line voltage is not available or out of tolerated voltage limits 2 Distribution problems or blown fuse s After mains failure mains voltage restored again This message AIT MAINS OK appears on screen for 15 seconds after mains restoration A46 BOOST CH END Boost charging period has been completed normal float charging conditions are v
32. PS In CL 300P Series UPS 60 blocks of batteries are connected in series in such a way that they form two strings of batteries with opposite polarity with a center tap connection to the NEUTRAL N1 N2 internally NOTE THAT SEPARATE CABLES FROM EACH BATTERY GROUP SHOULD BE CONNECTED TO K2 TERMINALS ON THE NEUTRAL BUSBAR TO FORM THE MIDPOINT CONNECTION WARNING NEVER TURN ON THE BATTERY CB ON THE BATTERY CABINET OR S5 IF EXISTS WITHOUT CENTER POINT CONNECTION TO NEUTRAL BUSBAR NEUTRAL BUSBAR BATTERY BATTERY K1 K3 pum Battery CB on the battery 4 j cabinet 36ov 0 30x12V Batts t H 30x12V Batts H H oe Figure 2 3 Battery Connections 60x12V 13 CL300 Series UPS User Manual NEUTRAL BUSBAR N Battery CB on the battery 7 p cabinet 30x12V BATTS 30x12V BATTS Figure 2 4 CL300P 100 120 160 200 250 300 KVA Battery Connections 14 CL300 Series UPS User Manual Ill FRONT PANEL 3 1 Introduction The front panel of UPS consisting of a 2 lines alphanumeric display 7 status lamps plus 5 function keys allows the complete monitoring of the UPS status The mimic flow diagram helps to comprehend the operating status of the UPS By using the function keys operator can moves on menus and change some parameters Figure 3 Operator control and indicator panel
33. Y CABINET OR THE BATTERY SWITCH S5 BEFORE STARTING THE UPS AFTER COMPLETING AND CHECKING ALL THE POWER CONNECTIONS The battery racks used for the UPS units should be sited and assembled in accordance with the battery manufacturer s recommendations In general batteries require a well ventilated clean and dry environment at reasonable temperatures to obtain efficient battery operation In general a minimum space of 10 mm must be left on all vertical sides of the battery block A minimum clearance of 20 mm should be allowed between the cell surface and any walls All metal racks and cabinets must be earthed 1 Unpack each battery and check its terminal voltage Any battery with terminal voltage less than 10 5V must be charged before installation Please check the battery connecting hardware and documents cables trays connection diagrams Please locate suitable number of batteries on each rack according to the battery installation and connection diagram given with the unit 4 Start locating the batteries from top to the bottom on the racks 12 CL300 Series UPS User Manual 5 careful about the connection between the racks and polarities 6 After interconnecting the batteries as shown in Figure 2 3 connect O and leads of the batteries to the battery input terminals on the UPS Be careful to connect the batteries correctly and do not turn on S5 before checking all connections and before starting the U
34. alid A47 CANNOT START Inverter can not start because of an internal fault A52 MANUA BYPASS Load transferred to bypass supply from COMMAND MENU A64 INV BALANCE DC balance problem at the Inverter output Call service A65 MAINS HIGH AC Input Voltage above the tolerated value Additional Alarm codes for Parallel Operation Optional ALARM DESCRIPTION P05 P SYNC ALARM In parallel system SLAVE UPS is not synchronized to MASTER UPS P07 P BAL ALARM In parallel operation current sharing is not okay temporary P10 P CLK ALARM There is an interruption or false status on parallel synchron signal between 2 UPS temporary P16 MODE FAILURE SLAVE ups search for the same operating mode with MASTER ups if they are different this message is seen on LCD panel Change the operation mode of SLAVE ups from OPTIONS MENU Don t forget to press ENTER key for 3 seconds Turn off the SLAVE ups and turn on again P17 RS485 ALARM There is an interruption or false status in parallel communication between the UPSs P19 DATA CABLE Data connection cable between parallel UPS is not OK bad connection or cable mismatch P20 ONLY ONLINE There is an online UPS in parallel system please change the operation mode P21 PLUG IN DIG The digital connection cable between parallel UPSs is unplugged P23 PSP FAILURE 2 Parallel controller board isolated power supply is out
35. available at the Interface Board output terminals These events are LINE FAILURE BATTERY LOW LOAD ON BYPASS BATTERY CB input BATTERY CB output EMERGENCY STOP input ATTENTION Max 42VAC or 60VDC voltage should be applied to the dry contact outputs 36 CL300 Series UPS User Manual BATT CB a LINE BATT AUX NO C NC NO NC NO C NC Battery Circuit Emergency Stop Line Failure Battery Low Relay By Pass Breaker Input Relay Relay eee 2 4 IC cae A Pie tat AM BAS 202 CN3 CN4 NOTE Emergency stop terminals 4 and 5 should be short circuited by an external EPO switch to apply an EMERGENCY POWER OFF to the UPS No output voltage Line Failure Battery Low and Bypass relays are normally de energized and they are energized only in case of an alarm The behavior of these relays can be reversed by the user i e all relays are energized normally and de energized in case of alarm 8 5 Remote Monitoring Panel Remote monitoring panel can be extended to 400 meters away from UPS Up to 25 meters there is no need for extra hardware and RS232 communication is okay But if the distance is longer than 25 meters additional RS485 hardware is needed Up to 5 remote monitoring panels can be used in the system 37 AGKK7045 08 2011
36. e any change in load or the system the parameters must be recorded regularly as mentioned previously Generally the output voltage can deviate 2 from the predefined values If values differ more than this percentage then reasons must be investigated The following general structure must be systematically followed while trying to indicate the error Fault determination First step is to record the messages indicator panel LEDs operating parameter values and last status of switches This must be done before Fixing interventions After recording all indications check the meaning of the fault and alarm messages using The operator control indicator panel If anything related follow the related procedure Reporting the fault Service personal must clearly report the work done Hence if any other error occurs there will be enough information to fix it 33 CL300 Series UPS User Manual Vill UPS REMOTE MONITORING AND CONTROL Following external connections are available for CL 300P series UPSs e Communication by serial port connection e Dry contact interface board connections e Remote monitoring panel 8 1 Using Serial Port A standard Serial RS232 communication port is installed to all CL 300P series UPS By using this port user can get all information about the UPS All measured parameters and alarms can be monitored via this port This port is interactive and some commands for UPS operation are available These commands
37. eec The British Power Conversion Company CL 300 SERIES UPS 100 120 160 200 250 300 kVA 3 Phase Input 3 Phase Output USER MANUAL CL300 Series UPS User Manual CONTENTS Ie GENERAL DESCRIPTION riter Irure 1 1 1 2 Design GO cepto e e tbe best P o eee sieves 2 1 2 1 OPERATING MODES OF UPS nnne 3 1 3 Technical nennen nnne nens 6 Il UPS INSTALLATION cerco rrr Dean 7 221 IMTROQUCTION Eae T 2 2 Unpacking 2 E AT T E E 7 2 9 Equipment Positioning i segerea aceite ieee eee phi 7 2 4 Connecting the UPS Power Cables 8 241 Satety cect cian ate ht UHR rc dente funebre ee 9 2 4 2 Cable connection procedure ssssssssssseeee eene nennen 9 2 4 8 UPS Power Cable Connection Terminals sss 10 2 4 4 Battery nennen nnnm nennen nennen nnn 12 diim lude 15 Sols Introductions noo rie Hb eie HERI 15 3 2 Front Panel Menu 15 3 2 1 MEASURES Menu ltems sss enne nennen nnne 16 3 2 2 ALARMS Menu Items sen nnne 16 3 2 8 INFORMATION Menu ltems
38. either positive or negative battery groups A15 FUSE FAILURE Blown fuse s not used in this power range During transfer to bypass Voltage or frequency value of bypass source is incorrect and the UPS turns off the load power During normal inverter operation some times you can see this message A16 BYP INPUT BAD due to fluctuations in bypass supply During bypass if the bypass protection option is and if the bypass source is out of tolerance UPS switches off the static bypass for load protection Battery circuit breaker is off batteries are not connected to UPS At start up If the mains is okay you can start operation having this message A17 BATT CB OPEN active At start up during line failure UPS waits for the battery CB to be turned on and then starts If the battery charge level is low this message indicates that charge period is not completed yet If mains failure occurs during this message battery A18 BATT CAPA LOW M operation time may be unexpectedly short UPS gives beep sound every 15 sec Battery test aborted And batteries are not OKAY A19 BATT FAULT UPS gives beep sound every 15 sec You can clear this message by pressing the ENTER key for 3 seconds Possible Causes 1 Rectifier fault 2 Damaged battery cells 3 Poor battery connections Boost charge is active At the end of the boost charging time UPS stops the A20 BOOST CHARGE boost charge UPS gives beep sound every 15 sec A23 M
39. erials WARNING e Do not insert any object into ventilation holes or other openings e Toreduce the risk of fire or electric shock install in temperature and humidity controlled indoor area free of conductive contaminants e Toreduce the risk of fire replace fuses with the same type and rating when necessary CAUTION e Only qualified personnel should install or service UPS batieries e Risk of electric shock do not remove covers No user serviceable parts inside refer servicing to qualified service personnel e The output may be energized when the unit is not connected to a mains supply e Risk of electric shock Hazardous live parts inside This unit is energized from the battery supply even when the input AC power is disconnected e Toreduce the risk of electric shock disconnect the UPS from the mains supply before installing a computer interface signal cable Reconnect the power cord only after signaling interconnections have been made CAUTION Units are designed to operate on the concrete floor ABOUT THE BATTERIES CAUTION RISK OF ELECTRIC SHOCK The battery circuit is not isolated from the mains voltage Hazardous voltages may occur between the battery terminals and the ground e battery can present a risk of electric shock or burn from high short circuit currents The following precautions should be taken when working on batteries Remove watches rings or other metal objec
40. lue on the right indicates the battery voltage during battery test Starting time of battery test is recorded to log event menu If the test is performed successfully you can see only BATTERY TEST message on log records If the test is unsuccessful a BATT FAULT message will also be recorded On the bottom line of LCD BAT FAULT message will stay and the user will be warned audibly every 15 seconds until this message is cleared by pressing the ENTER key for 3 seconds 3 ENTER lt BYPASS gt If you press ENTER key for 3 the load is transferred to bypass If the load is on bypass in this submenu you see ENTER lt INVERTER gt message at this position If you press ENTER key for 3 seconds UPS transfers the load on inverter this time In parallel modes this function is disabled and you see BYP FUNC DISABLE message on this submenu item 4 ENTER MODEM INIT If you press ENTER key the connected modem of RS232 port is installed UPS sends AT command set to modem for installation If the function is completed you must hear a beep sound At the and of this function modem is ready to answer dial up connection 5 ENTER lt BOOST gt If you press ENTER key for 3 seconds boost charge starts The given time for boost charge is 10 hours At the end of this time UPS stops boost charging If the boost charge is active this submenu item changes to STOP BOOST gt 005H message 005H indicating that boost charge has lasted for 5 hours If the
41. nal SNMP Adapter Optional Modbus Adapter Optional Alarm Relay Contacts 3x Dry Relay Contacts Line failure battery low bypass EPO Input ENVIRONMENT Operating Temperature Standard 0 40 C Operating Humidity lt 90 Non Condensing Acoustic Noise 70dB 72dB 75dB Dimensions HxWxD mm 1900x780x890 1900x1 150x890 Protection Class IP20 Weight w O Batteries approx kgs 375 425 CL300 Series UPS User Manual UPS INSTALLATION 2 1 Introduction WARNING e Do not apply electrical power to the UPS equipment before the arrival of authorized service personnel e The UPS equipment should be installed only by qualified service personnel e The connection of the batteries and the maintenance should be done by qualified service personnel e Do not make any short circuit to the battery poles Because of high voltage and high short circuit current there is risk of electrical shock or burn e Eye protection should be worn to prevent injury from accidental electrical arcs Remove rings watches and all metal objects Only use tools with insulated handles Wear rubber gloves This chapter contains location installation information of the UPS and the batteries All the establishments have their own specialties and needs So in this part the installation procedure is not being explained step by step Instead general procedure and the applications are e
42. ncy regulating circuits which ensure that its output to the critical load is maintained within close tolerances independent of voltage and frequency variations on the mains power lines e Increased noise rejection By rectifying the input AC power to DC power and then converting it back to AC Double Conversion any electrical noise present on the input mains supply line is effectively isolated from the UPS output Therefore the critical load is supplied with only clean and uninterrupted AC power Basic Features Microprocessor Controlled Double Conversion on line UPS IGBT Rectifier PWM High Input PF Low THDI IGBT Inverter PWM Sinusoidal output Waveform Low output Voltage THD High Nonlinear Load capacity CF 3 1 High Unbalanced loading capability Efficiency Up to 9496 Overload and short circuit Protection Overtemperature protection Static Bypass Switch Maintenance Bypass Switch Separate bypass input facility split Bypass Parallel Operation Optional LCD Display Alarm History Up to 128 Alarms Real time clock date and time Emergency Power off EPO Cold start feature Dual Polarity Batteries Internal and or external Automatic and manual Battery Test Automatic and manual Boost Charge Battery current limit adjust Deep discharge protection Remaining battery time indication AC input filter AC output filter Alarm relay contacts Standard RS232 communication port Standard RS485 interface Optional
43. nd off options ON during mains failure at the and of battery discharge UPS shutdowns and after mains is restored UPS starts again battery trip out is on every time OFF after mains restoration UPS doesn t start by itself again You must turn off and then turn on the UPS battery trip out is off press ENTER for 3 seconds and then the selection is valid 4 RESTART ON OFF RELAY BATT LOW By using key the function of the RL3 Relay on the interface board can be 3 COMMON selected between Battery Low or Common Alarm 6 BATTERY By using PLUS and MINUS keys you can change on and off options Used to TEST ON OFF enable or disable automatic battery test 7 ENTER EXIT Enter 4 exit from submenu Go to STATUS MENU 17 CL300 Series UPS User Manual 3 2 6 COMMAND Menu Items This menu is used to give various commands to the UPS or to perform some tests on it Submenu items Function 1 SOUND ON OFF Used for turning on off the audible alarm If you press ENTER key the option will change push ON push OFF If the OFF option is selected audible alarm is turned off but in case of a new alarm UPS changes the option to ON state 2 ENTER B TEST gt 405 If you press enter for 3 seconds battery test starts and lasts for 15 seconds If battery test fails A6 BATT FAULT message is shown on panel and this message stays until you press ENTER key for 3 seconds The va
44. nd used for turning on or off the battery inputs to the UPS ATTENTION IF A BATTERY SWITCH IS NOT AVAILABLE ON THE UPS A SEPARATE BATTERY CIRCUIT BREAKER MUST BE USED ON THE BATTERY CABINET 1 2 1 OPERATING MODES OF UPS CL300P series UPSs are capable of operating in various different modes for maximum application flexibility These modes are ONLINE mode This is the normal operation mode for a single UPS As long as the mains supply is available and in required tolerances the load is supplied by the well regulated inverter output and the batteries are charged at the same time In case of mains failure the inverter keeps supplying the load using the energy stored in the batteries ECONO mode This is the off line operation mode for a single UPS As long as the mains supply is available and in required tolerances the load is supplied by the mains supply bypass supply via the Static Bypass Switch of the UPS and the batteries are charged at the same time During that time inverter keeps running under no load conditions and takes over the load in case of a mains supply bypass supply failure without any interruption After restoration of the mains supply the load is transferred back to bypass supply again PARALLEL REDUNDANT and N 1 REDUNDANT modes are used for parallel operation of two or more UPS units and will be explained in parallel operation section later in this manual When operating in one of the above operating modes UPS
45. ns S5 and S2 are not available 11 CL300 Series UPS User Manual NOTES e As shown on the power cable connection diagram of the UPS U1 V1 and W1 phase of the incoming 3 phase supply are used as the bypass inputs under normal conditions if there is not a separate bypass supply split bypass U1 V1 W1 and U2 V2 W2 are the same in this case e lf there is a separate 3 phase AC supply for bypass Split Bypass IF BYPASS SWITCH S2 AVAILABLE a Remove the links from AC Inputs to Bypass Inputs b Connect the phases of the bypass source U2 V2 and W2 to the indicated terminals for Bypass Inputs c Connect the Neutral N2 of the Bypass source to K11 Neutral Busbar IF BYPASS SWITCH S2 IS NOT AVAILABLE a Remove the links from AC Inputs to Maintenance Bypass Inputs I b Remove the AC Links to Static Bypass Inputs II c Connect Maintenance Bypass and Static Bypass Inputs to each other as shown by the dashed lines in Figure 2 2 b d Connect the phases of the bypass source U2 V2 and W2 to the indicated terminals K5 K7 K9 e Connect the Neutral N2 of the Bypass Sorce to K11 Neutral Busbar Note that the Neutral of the 3 phase input supply N1 and the Neutral of the 3 phase bypass supply N2 must always be connected together to form the Neutral of the AC output 2 4 4 Battery Installation WARNING Be careful while connecting batteries ATTENTION NEVER TURN ON THE BATTERY CB ON THE BATTER
46. nt NOTE THAT SEPARATE CABLES FROM EACH BATTERY GROUP SHOULD BE CONNECTED TO K2 TERMINALS ON THE NEUTRAL BUSBAR TO FORM THE MIDPOINT CONNECTION WARNING The UPS must never be turned on without input neutral connection 3 Check the output load connections 5 2 OPERATING INSTRUCTIONS FOR A SINGLE UPS UNIT ONLINE OPERATION 5 2 1 Procedure For Turning On The UPS To Supply The Load From A Complete Power Off Condition 1 Turn on S1 AC Input 2 Turn on S2 Bypass 3 Turn on S4 AC Output ATTENTION AS SOON AS YOU TURN ON ON OFF SWITCH S7 BYPASS VOLTAGE WILL APPEAR THE OUTPUT TERMINALS 4 Turn on S7 ON OFF Switch LCD panel will start running RECTIFIER START message will appear on the front panel 5 When INVERTER START appears on the front panel turn on S5 Battery into 1 position After a few seconds the BYPASS led L4 red will turn off and the INVERTER led L6 green will turn on The UPS is ready for uninterrupted operation when STATUS NORMAL ONLINE MODE message appears on the front panel 5 2 2 Power Off After turning off all the loads connected to UPS output Turn off S4 AC Output into 0 position Turn off 57 ON OFF Switch into 0 position Turn off S5 Battery into 0 position Turn off S2 Bypass into 0 position Turn off 1 AC Input into 0 position This is a complete power off condition and both RECTIFIER and INVERTER are not operating in this case
47. re detailed diagrams for two or more CL 300P series UPSs connected in parallel are given in Figures 4 2 and 4 3 Figure 4 2 CL300P Series Parallel UPS Signal Cable Connections Parallel Parallel Parallel Parallel Port1 Port2 Port1 Port2 OOO OOO OOO OOO Figure 4 2 a 2 units in parallel 25 CL300 Series UPS User Manual Parallel Parallel Parallel Parallel Parallel Parallel Port 1 Port 2 Port 1 Port 2 Port 1 Port 2 OOO OOO f OOO OOO OOO OOO Figure 4 2 b 3 units in parallel Note One purpose built signal cable DB25 is provided for each UPS unit in the parallel system Parallel signal cables are interconnected between the UPS units to form a loop as shown in figure 4 2 for having higher reliability against any possible signal cable failures After completing the parallel connection of all the UPS units as shown in Figures 4 2 and 4 3 turn on each UPS unit one by one and select the operation mode and assign a UPS No using OPTIONS MENU All the units must be set for the same operation mode and must have a different UPS number CAUTION You must never set the operation modes of parallel connected UPS units to ONLINE otherwise serious damage may occur in UPSs 26 CL300 Series UPS User Manual ui M
48. rformance of the UPS and prevent some unimportant faults to become serious ones The equipment has been designed to require minimum maintenance effort The user should follow the instructions below 6 2 Daily checks Check the UPS everyday and be careful about the following 1 Check the operator control panel Verify that all LEDs and parameter measurements are normal and there is no alarm message on the indicator panel 2 Check if the device is overheated 3 Check the cooling fans operations 4 Check if there is any sensible change in the noise level of the equipment 5 Check if there is any stoppage on the ventilation path If so clean the dust using a vacuum cleaner 6 Make sure that there is nothing placed on the UPS 6 3 Weekly checks 1 Record the results on the indicator panel 2 Measure and record voltages on each phase 3 Measure and record currents on the output of the UPS 4 aes batteries status by performing a manual battery test Use a dry humid gland to clean the cover of the Record the observations if possible Check if there is any difference with the previous records observations If the last recorded values are significantly different from previous records please check If the load has been changed and if so please record the type size and position of this load These information will be very valuable in helping the service personal in determining any possible errors If there is significant change in
49. s submenu INFORMATION MENU Enter go to Information submenu ADJUST MENU Enter go to adjust submenu OPTIONS MENU gt Enter go to options submenu COMMAND MENU Enter go to Command submenu TIME MENU Enter go to Time and date submenu SERVICE MENU Enter go to service submenu Go to STATUS MENU 15 CL300 Series UPS User Manual 3 21 MEASURES Menu Items In this menu you can see all measured values Use 1 and keys for moving on submenu items Submenu item Function LD 060 074 080 Output load percentage OPV 220 221 220 Output voltages FREQU 50 0 Hz Output frequency IPV 240 235 220 Input voltages BYP 230 232 231 Bypass source voltages IPI 022 010 030 Input currents amperes BATT 405 V 000 A Battery voltage and charge discharge current BATT 405 V 000A Battery voltage and charge discharge current TEMP 030 c Cabinet inside temperature BATT CAPACI 068 Battery charge level 5 joo 5o2a ENTER lt gt Enter 1 exit from menu Go to STATUS MENU 3 2 2 ALARMS Menu Items In this menu you can see recorded log events and valid alarms Submenu item Function 1 UPS STATUS Alarm status at that instant 2 000311201 23 15 Monitoring past alarms The first 3 digit number indicates the event number 000 numbered event is the last
50. s the Manual Bypass Switch used in parallel connected UPSs In parallel UPSs the ENTER lt BYPASS gt item in the COMMAND menu is disabled and static bypass function is controlled by S6 Turn on the parallel connected UPS units as follows 1 Make sure that all signal and power connections have been completed properly according to the diagrams and instructions given before 2 Turn on S1 AC Input 3 Turn on S2 Bypass ATTENTION NEVER TURN ON S4 AC Output BEFORE COMPLETING MODE SELECTION PROCEDURE FOR ALL UPS UNITS 4 Turn on S7 ON OFF switch LCD panel starts running and following messages appears on the panel RECTIFIER START INVERTER START 5 Using UP DOWN keys on the front panel select OPTIONS MENU on LCD and press ENTER When you see MODE display select one of the following parallel operation modes suitable for your application using and keys PARALLEL N 1 REDUNDANT REDUNDANT After selecting one of the parallel modes press ENTER 6 Again using UP DOWN and keys in the OPTIONS MENU enter a number 0 to 3 for each UPS 29 CL300 Series UPS User Manual 7 Turn off S7 ON OFF and after a few seconds turn it on again UPS wilt start running again 8 When INVERTER START message appears on the front panel turn on S5 Battery into 1 Perform the same procedure given above for all UPS units Make sure that all the units have the same
51. ts Use tools with insulated handles e The batteries in this UPS are recyclable Batteries must be disposed of according to local environmental laws The batteries contain lead and pose a hazard to the environment and human health if not disposed of properly e Do not dispose of batteries in a fire The batteries may explode Do not open or mutilate the batteries They contain an electrolyte which is toxic and harmful to the skin and eyes If electrolyte comes into contact with the skin the affected area should be washed immediately e The internal energy source the battery cannot be de energized by the user e When changing batteries install the same number and same type of batteries CL300 Series UPS User Manual GENERAL DESCRIPTION 1 1 Introduction CL 300P Series Uninterruptible Power Supplies are double conversion on line UPS s manufactured with the latest IGBT and PWM technology to produce an uninterruptible microprocessor controlled pure sine wave output to critical loads CL 300P Series units are 3 phase in 3 phase out devices and they are installed between a three phase critical load and a 3 phase N mains supply The advantages of using CL 300P UPS e Power blackout protection If the mains power fails the UPS continues to supply the critical load using the energy stored in its batteries keeping the load immune from power disturbances e Increased power quality The UPS has its own internal voltage and freque
52. utput Note that during operation from the bypass supply the critical load may be effected by any possible disturbances or power failure in the bypass supply CL300 Series UPS User Manual BATT CB EM LINE BATT AUX ejejeeie jojojojojojojojojo Communication NO C NC NO NO C Select Switch Battery Emergency Line Failure Battery Low Bypass OPTIONAL CB Input Stop Relay Relay Relay Wie a es a ee RS232 Dry Rel ny Belay Communication Port Parallel DB9 Female Communication Sockets OPTIONAL S6 Manual Bypass Switch OPTIONAL S7 ON OFF Switch S4 AC Output Switch S3 Maintenance Bypass Switch S2 Static Bypass Switch OPTIONAL 1 Input Switch S5 Battery Input Switch OPTIONAL Figure 1 2 100 120 160 200 kVA Switch Configuration 4 CL300 Series UPS User Manual RS232 SNMP RS232 Communication Communication Select Switch Port Relay Dry Optional DB9 Female Contact Outputs Parallel Communication Sockets Optional S6 Manual Bypass Switch Optional S7 ON OFF Switch S4 AC Output S3 Maintenance Bypass 52 Static Bypass Optional S1 AC Input S5 Battery Inpu Optional Figure 1 3b 250 300 kVA Switch Configuration CL300 Series UPS User Manual 1 3 Technical Specifications MODEL CL 3100P CL 3120P CL 3160P CL 3200P CL 3250P CL 3300P Output kVA
53. xplained for the technical personnel 2 2 Unpacking The UPS is packed and enclosed in a structural cardboard carton to protect it from damage 1 Inspect for damage that may have occurred during the shipment If any damage is noted call the shipper immediately and retain the shipping carton and the UPS 2 Carefully open the carton and take the UPS out 3 Retain the carton and packing material for future use Unit package contents 1 Auser manual and Guarantee certificate 2 Battery cabinet and or shelf Optional 3 Battery connection cables 2 3 Equipment Positioning ATTENTION Units are designed to operate on the concrete floor The equipments installation place must be an easy serving place Install the UPS in a protected area with adequate air flow and free of excessive dust You must therefore allow for a minimum gap of 800 mm behind the unit to allow adequate air flow Select a suitable place temperature between 0 C and 40 C and the relative humidity 90 max It is recommended to place the equipment in an air conditioned the room 24 C Temperature is a major factor in determining the battery life and capacity Keep batteries away from main heat sources or main air inlets etc In case of an operating the UPS in a dusty place clean the air with a suitable air filtration system Keep out of your equipment from explosive and flammable items Avoid direct sunlight rain and high humidity
54. y groups Refer to battery installation section WARNING CHECK BOTH OF THE BATTERY GROUPS FOR CORRECT POLARITY AND VOLTAGE DO NOT TURN ON THE BATTERY CB ON THE BATTERY CABINET OR THE BATTERY SWITCH S5 IF EXISTS BEFORE STARTING THE UPS 5 Connect the copper earth bus to the safety earth of the mains distribution panel NOTE The earth and the neutral connections must be in accordance with the local rules WARNING NEVER TURN ON THE UNIT WITHOUT AN INPUT NEUTRAL CONNECTION N1 CL300 Series UPS User Manual 2 4 3 UPS Power Cable Connection Terminals U AC OUTPUTS SPLIT BYPASS INPUTS STATIC AND MAINTENANCE BYPASS OPTIONAL BYPASS SWITCH AC LINKS TO u1 BYPASS INPUT Vi AC INPUTS N1 AC INPUT OPTIONAL N2 BATTERY SWITCH BYPASS AND OUTPUT NEUTRAL K10 K11 BATTER BATTER 0 0 BATTERY INPUTS Figure 2 2 a 100 120 160 200 250 300 kVA Power Cable Connections 10 CL300 Series UPS User Manual V AC OUTPUTS MAINTENANCE BYPASS INPUTS Connected for only split bypass STATIC BYPASS INPUTS AC LINKS TO MAINTENANCE BYPASS INPUTS 1 Ui AC INPUTS W1 AC LINKS TO STATIC BYPASS INPUTS AC INPUT FUSES N1 AC INPUT NEUTRAL N2 BYPASS AND OUTPUT NEUTRAL B FUSES NEUTRAL 5 BUSBAR K2 K2 A K10 K11 2 BATTERY BATTERY BATTERY INPUTS 0 0 Figure 2 2 6 100 120 160 200 250 300 kVA Power Cable Connectio
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