User Manual
Contents
1. amom m m oh 1 205 988 u u Generic Wiring Diagram Example M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 18 Emo E PRSE Breaker Status Port The Breaker Status Port is a set of DB25 connectors which use the Normally Closed contact on the breakers e g when the breaker is off it is a closed circuit when the breaker is on it is an open circuit See below for the pin number corresponding to each breaker DB25 Pin Number Assignment NOTE When connecting ensure that the connector is secured to the port by attaching the connector s screws to the port standoffs M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 BREAKER STATUS PORT SCHEDULE Left Column Right Column U 3 Breaker Port Breaker Port N 4 1 OA JOO OO 2 2 PO PO O IO Po IN IND R IN IN IM M IN IN ID IDP Generic Breaker Status Port Example M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 20 7 Breaker Reset Procedures Reset a Tripped Circuit Breaker or Turn On Breake2. Do not use this equipment for other than intended use INSTALLATION This Breaker Cabinet is intended for use in a controlled indoor environment free of conductive contaminants and protected against any type of intrusion Do not install the Breaker Cabinet in an excessively humid environment or near water Avoid spilling liquids and or dropping any foreign object s onto the Breaker Cabinet The unit must be placed in a sufficiently ventilated area the ambient temperature should not exceed 40 C 104 F HIGH GROUND LEAKAGE CURRENT ground connection completed before connecting the AC voltage wires on the input Avoid locations in direct sunlight or near heat sources gas or electric heaters STORAGE Store the Genie Breaker Cabinet in a dry location free of contaminants Storage temperature must be within 25 C 13 F to 55 C 131 F M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 WARNING LETHAL VOLTAGES MAY BE PRESENT WITHIN THIS UNIT EVEN WHEN IT IS APPARENTLY NOT OPERATING OBSERVE ALL CAUTIONS AND WARNINGS IN THIS MANUAL FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH REFER UNIT TO QUALIFIED SERVICE PERSONNEL IF MAINTENANCE IS REQUIRED NO ONE SHOULD WORK ON THIS EQUIPMENT UNLESS THEY ARE FULLY QUALIFIED TO DO SO AN INSTALLER SHOULD NEVER WORK ALONE THIS SAFETY NOTICE IS ADDRESSED TO THE ALWAYS ON CUSTOMER ENGINEERS WHO PERFORM MAINTENANCE OF THE GENIE BREAKER CABINET Electrical Safety Mainte
3. The UPS system is configured to switch to bypass after three cycles Report Prepared by AA JA M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 Short Circuit Inverter Mode Test 1 Tested with a MDL 15A Fuse Note UPS stayed in Inverter Mode fuse opened 0 5 cycle Figure 4 Current and Voltage waveform short circuit MDL 15A Fuse M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 12 Short Circuit Inverter Mode Test 2 Tested with a Federal Pioneer 15A breaker Note Breaker tripped in 5 cycles UPS system went to bypass and waited until breaker cleared Figure 5 Current and Voltage waveform short circuit Federal Pioneer 15A breaker M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 Short Circuit Inverter Mode Test 3 Tested with a 15A SDB Specially Designed Breaker Note UPS stayed in on line mode Inverter Mode SDB opened within of a cycle dui IM It L wil Figure 6 Current and Voltage waveform short circuit 15A SDB M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 14 Conclusion As the above test results show the Specifically Designed Breakers SDB is easily resettable like a standard breaker It also incorporates the best attributes of a fuse The SDB reacts and clears the fault within one cycle providing the fast reaction time of a fuse and can be reset the same way as a breaker after the fault has been cleared Because of the fast reaction of the SDB the UPS system sup
4. of the breakers can be monitored electronically M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 4 Unpacking Transport Genie Breaker Cabinet is packaged on a pallet suitable for handling with a forklift Pay strict attention to the center of gravity The cabinet must be moved in upright position Do not tilt cabinets more than 10 during handling Move the cabinet in its original package to the final destination site Do not stack other packages on top If the cabinet must be lifted by crane use suitable lifting straps and spreader bars Delivery Upon receiving the Genie Breaker Cabinet inspect the packaging integrity and the physical condition of the container carefully Inthe event that physical damage is visible the carrier must be informed immediately and a claim filed with them Inform Always On as soon as the claim has been filed and a copy of claim should be faxed to Always On at 250 491 9775 A detailed report of the damage is necessary for carrier insurance claim WARNING A damaged Genie Breaker Cabinet must never be installed or connected to the utility without written instruction from Always On Engineering Storage Genie Breaker Cabinet is carefully packed for transport and storage Never leave a Genie Breaker Cabinet outside the building exposed to the elements and do not place other packages on the top of the Genie Breaker Cabinet Storing It is recommended to s
5. Always On Genie Smart Cabinet ups Powered Distribution Unit User Manual Always On M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 Table of Contents 1 CAUTION 2 IMPORTANT SAFETY INSTRUCTIONS 3 INTRODUCTION 4 UNPACKING 5 GENIE BREAKER PANEL THEORY 6 INSTALLATION 7 BREAKER RESET PROCEDURES 8 BREAKER REMOVAL REPLACEMENT PROCEDURES 9 CONTACT ALWAYS ON M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 16 21 22 23 1 Caution This user manual is for installation and operation purposes only Do not attempt to apply power to the input terminals of the Genie Cabinet system until factory authorized personnel check connections Factory authorized personnel shall inspect installation prior to start up and commissioning to validate warranty Failure to follow this directive will void the warranty NOTE The instructions contained in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred directly to Always On UPS Systems Any electrical or mechanical modifications to this equipment without prior written consent of Always On UPS Syst
6. and negative wave cycle as well as the energy content over that cycle This allows the SDB to detect a symmetrical waveform from the inverter current see Figure 4 during a short circuit The SDB allows the problem circuit to trip within 1 to 1 cycles The majority of power supplies are designed and required to comply with the ITI CBEMA standard which states that the power supply must be able to withstand a short duration of loss of power Therefore in the event of a short circuit the additional systems connected to the Always On GENIE distribution cabinet will be protected to the maximum level Current Voltage Figure 4 Voltage and Current Waveform of a 15A SDB M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 10 Short Circuit Testing 30kVA Here are the results of a comparison test preformed in our Kelowna factory The tests were performed on a 30kVA 3 phase UPS system with various types of protection devices System Information Model GES 303NX33 Capacity of UPS 30kVA 120 208 120 208 VAC S N 04049050 Testing Date 04 10 19 Equipment used Tektronix TDS 3012 100MHz 1 25 GS s Current Probe Fluke 80i 500s AC 1A to 500A AC RMS Analyzing Software WaveStar for Oscilloscopes Method Line to Neutral short circuit was introduced to the UPS Inverter output Response between fuse standard breaker and the GENIE Breaker were observed Note Tests performed with a 30kVA 3 phase UPS system
7. e Genie Breaker Cabinet has to be sized according to the bypass system power rating Sizing of circuit breakers fuses and cables for input utility output load must meet the requirements of local and national electrical codes WARNING Inadequate cable size and over sized breakers can increase the risk of fire or damage connection cables and internal components CAUTION Do not apply utility power before an Always On representative has confirmed connections L u n ae 1 0 tr 2 a poon 4 x m m PARE e er gt a lt 7 Moon 2 4 ao m T Wo 12 ADI c m 4 ZSZ f 11 t mov w 52 40 I I 1 m rn gt 2 SADZ oup m m gt e m m Pr cess oa z a cin 1 5 I 2 amom k ium ob m o ARK 0704 MMM p cA 53 gt of fel k m om E N 365 ADI c m a4 cp castra a 9m 46 92 Ies cm C E A rete ey i APOS 11 5 I 44 13 45 HD gt ES ae p IL 46 TP v AD m bro a w 49 so 9 m m 485 HIR OE o 51 gt 1 mov m gt 1 m ME m m Us UD i mn s m s 0 4 1 I 5 I s ar et qos ps 2 4 I I 1 T m m
8. ed The key items in the specifications you must check are e CIRCUIT BREAKERS INSTALLED e VOLTAGE e CURRENT RATINGS M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 5 Genie Breaker Cabinet Theory Short Circuit Comparison Study Thermal Breaker vs GENIE Breaker Short circuits within a system will cause the voltage to drop to OV and the current will spike well above the nominal range 1000 and greater until the short circuit condition has been removed see Figure 1 Figure 1 15A Federal Pioneer Breaker on 100 feet of 14AWG wire Current Voltage Figure 1 Voltage and Current Waveforms during a typical Short Circuit As Figure 1 demonstrates the voltage drops below operating capacity and the current is well above nominal until the breaker trips and clears the fault If the load was connected with no disconnect protection the voltage in Figure 1 would drop to OV and the current could rise to thousands of amps until a means of disconnect somewhere in the stream tripped or the equipment burned out When an Always On UPS system has been added to the circuit the UPS has customized operational features that limit the current to a 3 1 crest factor in accordance with Always On specifications M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 7 The crest factor is the maximum current that the inverter will supply over a short duration approximately 2 12 cycles A crest factor of 3 1 means that the inverter ca
9. ems will void all warranties and may void CSA listing Unauthorized modifications may also result in personal injury death and damage to the equipment M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 2 Important Safety Instructions READ AND FOLLOW ALL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during installation and maintenance of the Genie Breaker Cabinet system and optional packages Before the installation process begins we recommend that the installer read through the safety precautions and the instructions taking all necessary safety precautions to protect themselves and the equipment being installed GENERAL Move the Genie Breaker Cabinet in an upright position in its original packaging to its final destination To lift the cabinet use a forklift or lifting belts with spreader bars Check the integrity of the Genie Cabinet equipment carefully If visible damage is evident do not attempt to install or start the Genie Breaker Cabinet Contact the transport delivery company immediately file a claim with the transport company and inform Always On directly Do not use outdoors The use of accessory equipment not recommended by Always On may cause an unsafe condition WARNING RISK OF ELECTRICAL SHOCK use extreme caution when removing covers All maintenance and service work should be performed by qualified and trained service personnel
10. n supply times the RMS current rating of the inverter i e a 2kVA inverter produces a 16A maximum output so the maximum peak current is 48A Figure 2 Typical UPS Output Short Circuit Waveform with UPS on bypass The figures above presume the load is connected to a standard thermal breaker that typically takes 5 to 22 cycles to clear depending on the manufacturer and model The inverter is rated to the current limit for 2 v2 cycles before inverter shutdown Then depending on the configuration the system will either turn off or switch to bypass mode See Figure 2 for switched to bypass and Figure 3 for system shutdown In the event that the system is configured to switch to bypass mode the load is essentially connected directly to the utility and power will be provided until a means of disconnect is tripped or the equipment burned out This migrates the short circuit to the rest of the power system that affects the other loads M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 Figure 3 Typical UPS Output Short Circuit Waveform with UPS on inverter only Both these scenarios will cause any additional loads connected to the distribution cabinet to shut down due to lack of voltage simulated blackout M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 Always On has designed and patented a new specifically designed breaker SDB The SDB incorporates technology to monitor the waveform and compare the symmetry of the positive
11. nance work to be preformed by a factory trained customer engineers or qualified personnel Extreme caution must be used This manual is designed as an aid tool in diagnosing problems that may arise Always On does not assume responsibility if information causes injuries Apart from the front door do not open any other part of the Breaker Cabinet without consulting the factory first READ AND FOLLOW ALL SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 3 Introduction Congratulations on your choice of the Always n UPS Systems Genie Smart Cabinet Power Distribution Unit This breaker cabinet features the latest top of the line breaker technology which provides effective protection for all loads behind a UPS Overview This Cabinet is designed for installation between your UPS and your critical loads It distributes the power provided through the UPS to your equipment at all times while protecting your equipment from any short circuits Features This Genie Smart Cabinet uses Genie Breakers which operate with the benefits of fuse like shutdown capacity and the reset abilities of a normal breaker In addition the system has been designed with technology to allow the breakers to be swapped in and out while still powered Another feature that may be included is Breaker Status Ports which make use of the Normally Closed and Common Dry Contacts on the Breakers so that the status
12. plying the cabinet remains on line The other loads connected to the distribution cabinet with the SDB s does not detect the short circuit on the problematic branch Note based on ITI CBEMA standard mentioned earlier These advantages make the SDB in combination with the GENIE cabinet the most reliable means of distribution for any type of critical environment based on sensitivity or demand i e hospitals server rooms control centres air traffic towers etc M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 6 Installation WARNING The Genie Breaker Cabinet should be installed by a qualified technician or personnel and wired in accordance with local and national electrical codes Be sure the polarities and voltage match the rating of the unit Check that the loads being protected are within the capacity of the system Ensure no power has been applied to the systems and nothing has been turned on before proceeding FOR PROJECT SPECIFIC DRAWINGS AND INFORMATION PLEASE REFER TO MANUAL ADDENDUM Physical Layout LO OL TIE LOU MOD MMO LE N ODM M2102_Genie_Breaker_Cabine
13. r Unlock and open door on the front of breaker cabinet Find circuit breaker that is tripped or in the OFF position Push circuit breaker handle to the ON position Turn Off a Circuit Breaker Unlock and open door on the front of breaker cabinet Locate appropriate circuit breaker that is to be turned off Push circuit breaker handle to the OFF position TV z r 1 see x r M W Seat o LE CHTETITNI J EN KUR tt r S gt EIE M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 8 Breaker Removal Replacement Procedures WARNING SHOCK HAZARD ONLY QUALIFIED PERSONNEL SHOULD CONDUCT BREAKER REPLACEMENT PROCEDURES A circuit breaker may be replaced or added to the cabinet for upgrading or maintenance purposes BREAKER MALE FEMALE CONNECTOR CONNECTOR TO LOAD To Remove a Circuit Breaker Unlock and open front access door Locate and remove the two self tapping screws to release the breaker from the breaker frame Pull the breaker out of the mounting frame until the connector is exposed Cut the plastic tie strap that secures the connector disconnect the connectors and remove the breaker To Add a New Circuit Breaker Unlock and open front access door Find an available circuit breaker bay A cable lead is provided to quickly connect the special Genie circuit b
14. reaker Remove the two self tapping screws that secure the bay cover Disconnect the lead from the bay cover Connect the available cable lead to the circuit breaker lead Ensure a bracket is attached to the breaker before inserting Push the leads into the circuit breaker mounting frame and mount the new circuit breaker into the circuit breaker frame with self tapping screws Test the circuit breaker and circuit for correct operation NOTE Only use breaker doors if absolutely necessary M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 22 9 Contact Always On Mailing Address Always UPS Systems Inc 100 150 Campion Rd Kelowna BC V1X 788 Canada Guality Assurance and Warranty Support P 250 491 9777 Ext 209 F 250 491 9775 qa alwayson com www alwayson com Additional Purchases or Upgrades P 250 491 9777 Ext 451 F 250 491 9775 sales alwayson com www alwayson com M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 M2102_Genie_Breaker_Cabinet_Manual V1 0 2012 06 12 24 Always On M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 25
15. t_Manual V1 0 2012 06 12 16 Wiring Connect appropriate load wires through the gland plate to the corresponding terminal block number Ensure wire is securely held in place by terminal block screw Similarly for Isolated Neutral Ground or Isolated Ground wires ensure that they are securely held and associated with the proper set of wires Connect main power through rear gland plate to the appropriate connections Line wires will go directly to the main breaker while Neutral and Ground will be attached to the marked distribution blocks to be sent to the appropriate Buss bars xr zr zr A to BRE E pep I N 5 alej 1 JE p Internal Layout Example M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 17 Cable Selection The cabling of th
16. tore the Genie Breaker Cabinet in its original package in a dry dust free room away from chemical substances and with a temperature range of 25 C 13 F to 55 C 131 F Exceeding this temperature range may cause damage Site and Environment Consideration The following precautions and recommendations should be checked when considering the site and environment for the Genie Breaker Cabinet Void space is not required on all sides of the Genie Breaker Cabinet but adequate space a minimum of 1m 3 should be allowed for the doors to open Avoid accumulating litter or trash of any sort in or around the Genie Breaker Cabinet system The floor area surrounding the Genie should be kept clean free from metallic powder and or filings The system when installed in a sprinkler equipped room must have a sprinkler guard installed Do not place the Genie Breaker Cabinet near any heat source or machinery which may produce metallic particles dust or powder Do not place the Genie Breaker Cabinet near equipment that will produce corrosive substances or vapor M2102 Genie Breaker Cabinet Manual V1 0 2012 06 12 Do not place the Genie Breaker Cabinet below the shower of a fire extinguishing system The user is required to guarantee the temperature and humidity values of the site into which the Genie Breaker Cabinet will be installed meet the required and published manufacturer specifications The Genie Breaker Cabinet should be installed
17. within the range allowed by these specifications The Genie Breaker Cabinet is capable of continuous normal operation within a temperature range of 0 C 32 F to 40 C 104 F For optimal performance and reliability the recommended environment temperature is best at 25 C with humidity lt 80 non condensing Access to the Genie Breaker Cabinet should be limited to operation and maintenance personnel The Cabinet should be kept locked and secure Personnel who operate or maintain the Genie Breaker Cabinet should be proficient in normal and emergency operational procedures New personnel should be trained and qualified prior to operation of the equipment Unpacking Carefully remove all the packaging material of the Genie Breaker Cabinet and then carefully place the Genie Breaker Cabinet at the final resting site This Genie Breaker Cabinet has passed all stages of production testing and final stage QC testing prior to shipment from the factory report enclosed The Genie Breaker Cabinet should be in full operating condition upon receipt Upon receiving visually check the Genie Breaker Cabinet for any physical damage that may have occurred during transport If damage is noticed file a damage report immediately with the transport company and inform Always On Check to ensure all of the accessories options ordered are received Check and verify the specifications of the Genie Breaker Cabinet are identical to the specifications of the system order
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